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TM 9-2320-277-14&P

TECHNICAL MANUAL

OPERATOR'S ORGANIZATIONALDIRECT SUPPORT AND GENERAL

SUPPORTMAINTENANCE MANUAL

(INCLUDING REPAIR PARTS LIST)

FORTRUCK, TRACTOR, YARD TYPEDIESEL ENGINE DRIVEN, 4 X 2,

OTTAWA MODEL 50ARMY MODEL M878

NSN 2320-01-044-8376

OPERATION PROCEDURES

OPERATOR PMCS

VEHICLE PROCEDURES

ORGANIZATIONAL PMCS

REPAIR PARTS

APPENDIX A/REFERENCES

APPENDIX B/MAINTENANCEALLOCATION CHART

APPENDIX C/MAINTENANCE ANDOPERATING SUPPLY LIST

INDEX

HEADQUARTERS, DEPARTMENT OF THE ARMYJUNE 1984

TM 9-2320-277-14&P

SAFETY PRECAUTIONS

BEFORE OPERATIONWhen servicing batteries, do not smoke or use flame invicinity. Batteries generate hydrogen, a highly explosivegas.

When filling the fuel tank, provide a metal-to-metalcontact between the fuel container and fuel tank. Do notfill fuel tank when engine is running.

Correct or report any faulty condition that may result indamage to the tractor or cause injury to personnel.

DURING OPERATIONAlways fasten seat belt when operating vehicle.

Be alert for personnel in the area to make sure they arenot in the way of the moving trailer or tractor.

Be sure there is sufficient clearance overhead and toeach side of the vehicle.

Avoid sudden starting and stopping of the tractor. Uselow and medium speed ranges when working andreduce speed when making a turn.

Do not operate the engine in an enclosed area for alengthy interval unless the exhaust is piped to an openarea.

AFTER OPERATIONWhen parking on an incline, block at least two wheels toprevent the vehicle from rolling in case the parking brakefalls.

Do not remove the radiator cap from a hot radiator; stopthe engine and allow it to cool before removing cap.This will avoid injury by scalding.

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WARNING

Carbon Monoxide (Exhaust Gas) Can Kill You. Carbon monoxide is without coloror smell, but can kill you. Breathing air with carbon monoxide producessymptoms of headache, dizziness, loss of muscular control, a sleepy feeling, andcoma. Brain damage or death can result from heavy exposure. Carbon monoxideoccurs in the exhaust fumes of fuel burning heaters and internal combustionengines. Carbon monoxide can become dangerously concentrated underconditions of no air movement. Precautions must be followed to ensure crewsafety when the personnel heater, main or auxiliary engine of any vehicle isoperated for any purpose.

WARNING

If you sustain any injuries, no matter how slight, follow the first aid proceduresoutlined in FM 21-11.

WARNING

Compressed air used for cleaning purposes will not exceed 30 PSI. Use only witheffective chip guarding and personal protective equipment (goggles/shield, gloves,etc.)

WARNING

Do not remove the radiator cap from a hot engine; stop the engine and allow it tocool before removing cap.

WARNING

Do not smoke or employ any open flame near the batteries, as an explosive gas isproduced by the batteries during the operation.

WARNING

To reduce the possibility of bodily injury, personnel required to operate the tractormust become thoroughly familiar with all controls and must also becomeacquainted with the specific handling and operating characteristics of this vehicle.

WARNING

Always fasten seat belts when operating tractor.

WARNING

Do not operate engine for prolonged periods in an unventilated area. Internalcombustion engines produce poisonous carbon monoxide gas which is extremelythick if allowed to accumulate in a closed area.

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WARNING

Place gear shift in neutral (N) position, set tractor brakes, and block front wheels.Do not allow personnel to stand at front or rear of tractor.

WARNING

Do not allow personnel to stand at front or rear of vehicle.

WARNING

Wear safety goggles, and keep clear of injector spray to prevent fuel frompenetrating the skin.

WARNING

Remove all traces of lubricating oil and cleaning solvent before welding.

WARNING

When inspecting the blower on an engine, with the engine running, keep fingersand Clothing away from moving parts of the blower and run the engine at lowspeed only.

WARNING

Do not allow smoking or open flame within 50 feet of tractor. Keep fuel spillagecleaned up at all times.

WARNING

Purge fuel tank prior to welding.

WARNING

Either is highly volatile. Do not allow smoking or open flame in vicinity of tractor.

WARNING

Do not bypass key switch when reconnecting wiring to ether pushbutton.Connection through key switch prevents operation unless starter is engaged.Allowing operation with engine stopped could overload engine air intake with etherand result in a minor explosion.

WARNING

Be extremely careful when removing the radiator filler cap of a hot engine. Releaseof pressure may cause violent boiling and serious injury to personnel.

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WARNING

Use cleaning solvent or alkaline solution only in a well ventilated area. Avoidinhaling of fumes or contact with skin. Do not use near open flame.

WARNING

Use trichlorethane in a well ventilated area only.

WARNING

Battery box lid is heavy. Keep hands on outside of battery box lid to prevent injuryshould lid fall closed.

WARNING

Do not weld in the vicinity of batteries. Batteries release hydrogen, an explosivegas, during normal operation.

WARNING

Do not smoke or allow open flame near batteries. Batteries release hydrogen, anexplosive gas, during normal operation.

WARNING

Do not permit anyone to stand in front of tractor during pressure tests.

WARNING

Relieve all pressure from tractor air system before proceeding.

WARNING

Before handling transmission after removal from vehicle, attach 6837993 converterretaining strap to front of housing with two screws and nuts as shown to preventtorque converter from sliding off front support assembly, with possible bodilyinjury and damage to converter resulting.

WARNING

Before moving transmission from vertical position, install shipping bracket acrossfront end of transmission housing to prevent torque converter from sliding out ofhousing.

WARNING

During disassembly, do not strike hardened steel parts such as arms, draw keys,and knuckle pins directly with a hammer. Parts may shatter, causing personalinjury. Always use a brass or bronze drift.

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WARNINGDo not attempt to remove release stud from spring chamber assembly. Springinside spring chamber assembly is under extreme tension. Serious bodily injurycould result if spring is released.

WARNINGBe sure release stud has been installed in brake chamber as described inparagraph 11-4 steps 1 through 4 before proceeding.

WARNINGBe sure the tire is deflated, and the valve core removed, before proceeding withdismounting.

WARNINGPull operator's 5TH WHEEL control lever back to lower fifth wheel and relievehydraulic pressure before proceeding.

WARNINGUse adequate hand and eye protection when removing glass. Remove and handlebroken glass carefully to prevent injury. Do not break glass out of frame orweather seal.

WARNINGKeep clear of deck when cab is raised or lowered.

WARNINGDry cleaning solvent, used to clean parts is potentially dangerous to personnel andproperty. Do not use near open flame or excessive heat. Flash point of solvent is= 138°F.

WARNINGWhen filling the fuel tank, provide a metal-to-metal contact between the fuelcontainer and fuel tank. Do not fill fuel tank when engine is running.

WARNING

Be sure there is sufficient clearance overhead and to each side of the vehicle.

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WARNING

FIRE HAZARD

Diesel fuel and combustible materials are used in operation and maintenance ofthis equipment.

DEATHor severe bums may result if personnel fail to observe safety precautions

WARNINGHIGH PRESSURE AIR AND FLUID HAZARD

2000 PSIG HYDRAULIC FLUID PRESSURE AND 120 PSIG AIR PRESSURE are usedin the operation and maintenance of this equipment. Fuel injectors produce highpressure diesel fuel spray.

DEATHor severe injury may result if personnel fail to observe safety precautions

WARNINGDANGEROUS CHEMICALS

are used in the maintenance of this equipment.DEATH

or severe injury may result if personnel fail to observe safety precautions whenhandling battery electrolyte, or when using cleaning solvent or alkaline solution

WARNINGELECTRICAL SHOCK HAZARD

Always disconnect battery ground cable when working on electrical componentsof this equipment


WARNINGFALLING EQUIPMENT HAZARD

Never crawl under equipment when performing maintenance unless equipment isblocked securely. Keep clear of deck when cab is raised or lowered. Do not allowheavy components to swing while suspended by lifting device. Exercise extremecaution when working near a cable or chain under tension. Keep hands clearwhen opening and closing battery box lid.


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How To Use This Manual

In this manual (TM 9-2320-277-14&P), paragraphs are numbered specifically for the Operator's and Maintenance section.Each of the three sections has it's own Table of Contents, List of Illustrations, and List of Tables. Thus, if a table isneeded in the Maintenance Section, turn to the List of Tables in the Maintenance Section to find the table number andpage number. An Alphabetical Index can be found at the back of the book.

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This manual contains copyright materialPublished with permission of Gulf & Western Manufacturing Company, Ottawa, Truck Division

Southfield, Michigan 48037TM 9-2320-277-14&P

Technical Manual HEADQUARTERSDEPARTMENT OF THE ARMY

No. 9-2320-277-14&P WASHINGTON, DC22 June 1984

OPERATOR'S, ORGANIZATIONAL, DIRECT SUPPORTAND GENERAL SUPPORT MAINTENANCE MANUAL

(INCLUDING REPAIR PARTS LISTS)

FOR

TRUCK, TRACTOR, YARD TYPEDIESEL ENGINE DRIVEN, 4 X 2

OTTAWA MODEL 50ARMY MODEL M878

(NSN 2320-01-044-8376)

REPORTING OF ERRORSYou can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures,please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms),or DA Form 2028-2 located in the back of this manual direct to: Commander, US Army Tank-AutomotiveCommand, ATTN: DRSTA-MB, Warren, MI 48090. A reply will be furnished direct to you.

SECTION I - OPERATION PROCEDURESSECTION II - VEHICLE PROCEDURESSECTION III - REPAIR PARTS

APPENDIXESINDEX

NOTEThis manual is published for the purpose of identifying an authorized commercialmanual for the use of the personnel to whom this Yard Truck Tractor is issued.

Manufactured by:

Gulf & Western Manufacturing CompanyOttawa Truck DivisionOttawa, Kansas, 66067Procured under Contract No. DAAE07-78-C-6799

This technical manual is an authentication of the manufacturers commercial literature and does not conform withthe format and content specified in AR 310-3, Military Publications. This technical manual does, however,contain available information that is essential to the operation and maintenance of the equipment.

i/(ii Blank)

TM 9-2320-277-14&P

SECTION IOPERATION PROCEDURES

TRUCK, TRACTOR, YARD TYPEDIESEL ENGINE DRIVEN

4 X 2, OTTAWA MODEL 50ARMY MODEL M878

NSN 2320-01-044-8376

TM 9-2320-277-14&P

TABLE OF CONTENTS

ChapterSection

Paragraph Page

LIST OF ILLUSTRATIONS ............................ ii

LIST OF TABLES ....................................... iii

1. INTRODUCTION AND DESCRIPTION........ 1-1I. INTRODUCTION ................................ 1-1

1-1. Scope ............................................... 1-11-2. Maintenance Forms, Records

and Reports ....................................... 1-11-3. Destruction of Army Materiel

to Prevent Enemy Use......................... 1-11-4. Administrative Storage ....................... 1-11-5. Reporting of Errors ............................. 1-11-6. Destruction to Deny Enemy Use ......... 1-11-7. Common Tools and Equipment ........... 1-11-8. Repair Parts ....................................... 1-1

II. DESCRIPTION1-9. General Description ........................... 1-31-10. Detailed Description ......................... 1-31-11. Warranty ......................................... 1-9

2. PREPARATION FOR USE ANDRESHIPMENT ........................................... 2-1

I.. PREPARATION FOR USE ................. 2-12-1. General ............................................. 2-12-2. Preliminary Inspection ........................ 2-12-3. Under Hood Check ............................. 2-12-4. Switches, Gages, and Lights .............. 2-12-5. Operational Check ............................. 2-22-6. Lubrication ......................................... 2-2

II. PREPARATION FORRESHIPMENT ........................................... 2-22-7. General ............................................. 2-22-8. Preservation and Packaging ............... 2-22-9. Packing ............................................. 2-22-10. Shipping........................................... 2-3

3. OPERATING INSTRUCTIONS ................... 3-1I. INTRODUCTION ................................ 3-1

3-1. Scope ............................................... 3-13-2. Controls and Instruments .................... 3-1

II. OPERATING INSTRUCTIONS ........... 3-13-3. Starting the Engine ............................ 3-1

ChapterSection

Paragraph Page

3-4. Mobile Operation ............................... 3-63-5. Coupling to Trailer .............................. 3-63-6. Trailer Towing Operations .................. 3-73-7. Stopping the Tractor ........................... 3-73-8. Uncoupling from Trailer ...................... 3-8

III. OPERATION in EXTREME COLD ....... 3-83-9. General ............................................. 3-83-10. Shelter ............................................ 3-83-11. Cooling System ................................ 3-83-12. Electrical System ............................. 3-83-13. Fuel System .................................... 3-83-14. Transmission ................................... 3-83-15. Brake System .................................. 3-8

IV. TOWING THE TRACTOR.................... 3-84. PERIODIC INSPECTION AND

LUBRICATION .......................................... 4-1I. PERIODIC INSPECTION REQUIRE-

MENTS AND PROCEDURES.............. 4-14-1. Introduction ....................................... 4-14-2. Periodic Inspection Schedule............... 4-1

II. PERIODIC LUBRICATIONAND SERVICES ................................ 4-1

4-3. Lubrication and Service Chart .............. 4-14-4. Lubrication and

Service Frequency ............................. 4-1III. FUEL, LUBRICANTS, AND

COOLANT SPECIFICATIONS ............. 4-14-5. Diesel Fuel ........................................ 4-14-6. Engine Oil ......................................... 4-94-7. Transmission Oil .............................. 4-104-8. Power Steering Fluid ........................ 4-104-9. Hydraulic Oil .................................... 4-104-10. Differential Gear Oil ........................ 4-114-11. Engine Coolant .............................. 4-11

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LIST OF ILLUSTRATIONS

FigureNumber Title Page

1-1. XM878 Yard tractor .................................... 1-01-2. Yard Tractor Dimensions ................................ 1-2.11-3. Yard Tractor Major Components ................. 1-41-4. Engine Assembly ....................................... 1-51-5. Tractor Air System ..................................... 1-61-6. Steering System ........................................ 1-71-7. Typical Cooling System .............................. 1-81-8. Typical Fuel System.................................... 1-8

FigureNumber Title Page

1-9. Fifth Wheel Hydraulic System...................... 1-91-10. Warranty Statement .................................... 1-92-1. Tractor Tie down Locations ......................... 2-33-1. Tractor Controls and Instruments ................ 3-23-2. Proper Fifth Wheel Coupling Height ............ 3-74-1. Lubrication and Services (6 Sheets)............. 4-44-2. Recommended Antifreeze Concentration...... 4-11

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LIST OF TABLES

Number Title Page

1-1. Specifications.........................................1-22-1. Antifreeze Specifications ........................2-24-1. Preventive Maintenance Inspection .........4-24-2. Diesel Fuel Properties ...........................4-94-3. Diesel Fuel Selection Chart ....................4-9

Number Title Page

4-4. Recommended Oil Performance Levels......4-104-5. Additional Oil Performance Levels .............4-104-6. Oils Not Recommended ............................4-104-7. Hydraulic Oil Selection Chart .....................4-104-8. Gear Oil Selection Chart ...........................4-11

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Figure 1-1. XM878 Yard Tractor

1-0

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CHAPTER 1

INTRODUCTION AND DESCRIPTION

CHAPTER OVERVIEWThe purpose of this chapter is to give you standard data required in all manuals, to familiarize you with the purpose andcapabilities of the Yard Type Tractor and to give you a brief description of the different systems and components.

Section I. INTRODUCTION

1-1. SCOPEa. Type of Manual. Operator's Organizational

Direct Support, and General Support MaintenanceRepair Parts List.

b. Model Number and Equipment Name. M878Truck Tractor, Yard Type, Diesel Engine Driven,manufactured by the Ottawa Truck Division, Ottawa,Kansas 66067.

c. Purpose of Equipment. The tractor is a primemover unit specifically designed for moving truck trailersaround a terminal yard. It is not designed for highwayuse. An hydraulically operated, adjustable fifth wheel isprovided at the rear of the tractor for the attachment ofthe trailer. General characteristics and performancespecifications are given in Table 1-1 and Figure 1-2.

1-2. MAINTENANCE FORMS, RECORDS, ANDREPORTS

Department of the Army forms and procedures used forequipment maintenance will be those prescribed byTM 38-750, The Army Maintenance ManagementSystem.

1-3. DESTRUCTION OF ARMY MATERIEL TOPREVENT ENEMY USE

Refer to TM 750-244-6.

1-4. ADMINISTRATIVE STORAGE

Refer to TM 740-90-1.

1-5. REPORTING OF ERRORS

You can improve this publication by calling attention toerrors, recommending improvements, and by statingyour reasons for the recommendations. Your letter orDA Form 2028 (Recommended Changes to Publicationsand Forms) should be mailed directly to Commander,US Army Tank Automotive Command, ATTN: DRSTA-MBS, Warren, MI 48090. A reply will be furnisheddirectly to you.

1-6. DESTRUCTION TO DENY ENEMY USE

Refer to TM 750-244-3 for instructions governingdestruction of equipment to prevent enemy use.

1-7. COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment refer to theModified Table of Organization and Equipment (MTOE)applicable to your unit.

1-8. REPAIR PARTS

Repair parts are listed and illustrated in the repair partsand special tools list located in Section III of this manual.

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Table 1-1. Specifications

GENERALVehicle model ..................................... Commando 50Serial numbers ...............................51748 thru 51763Vehicle weight ......................................... 16,280 lbs.

Front ..................................................... 9,800 lbs.Rear ..................................................... 6,480 lbs.

ENGINEMake ..................................... Detroit Diesel IndustrialModel .......................................................5067-5040Design .....................................................6V-53RANType .................................Overhead 4-Valve, 2 cycleNo. of Cylinders ......................................................6Displacement ......................................... 318 cubic in.Bore ............................................................ 3.875 in.Stroke..............................................................4.5 in.Compression ..................................................... 21:1Brake horsepower .....................210 HP @ 2800 RPMTorque .................................. 440 ft/lbs @ 1800 RPMGoverned speed (full load) ......................... 2800 RPMGoverned speed (no load) ......................... 3040 RPMIdle speed ..................................................550 RPMFiring order ................................. 1L-3R-3L-2R-2L-1ROil capacity (incl. 2 qts. required

for oil filter replacement) ..............................16 qts.Oil pressure, hot ......................................40 to 60 psi

ELECTRICALSystem type .......................... 12 volt-negative groundBatteries ..................................Four 12 volt, lead-acidAlternator ......................................... 12 volt, 80 amp.Starter type ...................................Overrunning clutch

TRANSMISSIONMake ......................................... Detroit Diesel AllisonModel ............................................................ MT653Speeds ...................................... 5 forward, 1 reverseGoverner pressure ..............54 to 58 psi @ 1500 RPMMain fluid pressure ......................125 psi @ 600 RPMFluid temperature ...................................160 to 220°FDry Weight ......................................................540 lb.Gear ratios (mechanical) ........................ First 8.04:01

Second 3.58:1Third 2.09:1

Fourth 1.39:1Fifth 1.00:1

Reverse 5.67:1

FRONT AXLEMake ............................................ Rockwell StandardModel ..............................................FF931-RDAX-4ECapacity ................................................... 12,000 lbsSuspension ............................... Semi-elliptical springBrakes ........................................................ 15 x 5 inTires ............................................. 12:00 x 20, 16 plyInflation pressure ........................................... 105 psi

REAR AXLEMake ............................................ Rockwell StandardModel ............................................................PX 132Type ...............................................................U-240Load rating ............................................... 32,914 lbsSuspension .........................................Rubber MountReduction ratio ..............................................11.36:1Brakes ................................................. 16-1/2 x 7 in.Tires (dual mounted) ...................... 12:00 x 20, 16 plyInflation pressure .............................................95 psi

FIFTH WHEEL

Hydraulic cylinders .........................Two Double-ActingUnlatch ................................ Cab Control (pneumatic]Relatch ......................................................AutomaticLift frame ............................................. No OscillationCapacity .................................................. 70,000 lbs.Lift ...................................................................16 in.

GENERAL CAPACITIESCooling system (incl. engine, radiator,

and heaters) ...............................................56 qts.Engine crankcase ...........................................14 qts.Transmission (with new filter) ...........................16 qts.Fuel tank ........................................................50 gal.Power steering system ..................................... 4 qts.Hydraulic system ........................................9-1/2 gal.Differential .....................................................38 pint.

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Figure 1-2. Yard Tractor Dimensions

1-3 (1-4 Blank)

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Section II. DESCRIPTION

1-9. GENERAL DESCRIPTION.

a. The tractor is designed for ease of use interminal yard operations. The vehicle is built inaccordance with conventional design for automotive typevehicles, and is equipped with a diesel engine, fivespeed automatic transmission, air brake system, andhydraulically powered fifth wheel, steering, and cab tiltsystems. See Figure 1-3 for identification of majorcomponents.

b. The tractor is driven by the six cylinder dieselengine, which provides power to the rear axle through atorque converter and five speed automatic transmission.The rear axle is equipped with dual mounted tires.

c. The operator's cab is outfitted with a cushioned,adjustable seat. All controls and instruments necessaryfor tractor operation are conveniently arranged in thecab, and are generally similar to the controls for anyconventional piece of automotive equipment. A handoperated hydraulic pump tilts the cab 45 degreesforward to provide access for maintenance.

NOTERight hand and left hand aredetermined from the operator's seatfacing toward the front of the tractor.

1-10. DETAILED DESCRIPTION.

a. Frame. The vehicle frame consists of two heavyduty flange beams extending the length of the tractor.Sufficient cross members are added for rigidity andstrength, to carry all the anticipated stresses of thepower train and towed trailers. The frame providesmounting facilities for the engine, transmission, front andrear axles, operator's tilt cab, and the fifth wheel boom.

b. Engine. The diesel engine is a V-6 overheadvalve type of 318 cubic inch displacement size. Thebasic engine is equipped with a 12-volt electrical systemwhich includes a starting system and a battery chargingsystem of the alternator type. Fuel is supplied to theinlet side of the fuel injectors by a mechanical typespeed-limiting engine governor. The basic engine hasbeen adapted for the tractor with additions of air cleaner,power steering pump, fan and viscous fan drive, andradiator. See Figure 1-4 for engine and transmissionassembly.

c. Transmission. The transmission is a fivespeed automatic unit with a torque converter andplanetary gear train. The transmission provides fiveforward speeds, neutral, and reverse. A power takeoff(PTO) is mounted on the right side of the transmission todrive the fifth wheel hydraulic pump. Control of thetransmission and PTO is accomplished through flexiblecables attached to the gear shift lever and PTO controlat the right of the operator's console. A mechanical lockout prevents shifting to or from reverse unless the brake

treadle is depressed.

d. Rear Axle. The rear axle is a heavy duty doublereduction drive unit which employs a spiral bevel for thefirst reduction and wide-faced helical spur pinion andgear for the second reduction. Both gear sets aremounted on tapered roller bearings. The axle has semi-floating type axle shafts, and is mounted to the tractorframe through rubber pads.

e. Front Axle. The front axle is a non-driving, I-beam type steerable axle. Ackerman type steering isused, the steering spindles being mounted on king pinsat the ends of the axle with a tie rod connecting the twospindles. The axle is suspended from the frame bysemi-elliptical leaf springs. The leaf springs are attachedto shackles on the frame, and the front axle is affixed tothe bottom of the springs by means of spring pads andbolts. Shock absorbers are provided.

f. Brakes. All tractor brakes are the drum type.The service brakes are actuated by pressure from thetractor air system. The rear axle brake air chambers areof the fail-safe type, where loss of air pressure in thetractor air system allows a large spring built into thechamber to apply the parking brake automatically. Arelease bolt built into the chamber provides a means forretracting the spring if the air system cannot bepressurized. The operating controls of the parking brakeare independent of the operating controls of the servicebrakes. The service brakes are controlled by a footoperated treadle valve mounted on the cab compartmentfloor. Movement of a foot pedal on the valve controls theamount of air pressure delivered to or released from theservice brake air chambers which, in turn, determinesthe braking force. Air pressure to the front brakechambers is applied through a ratio reducing valve,which automatically reduces application pressure to thefront brakes under normal conditions. During severebrake applications, the valve allows full braking pressureto be delivered. Flexible hoses and quick-disconnectcouplings from the hose tender couple the tractor brakesystems to the towed trailer. A tractor protection valve(not shown) protects the tractor air system under severeleakage conditions or trailer breakaway by automaticallyclosing the trailer air lines.

g. Air System. The three tank air systemmaintains a supply of compressed air, directs andcontrols the flow of the compressed air, and transfers theenergy of the compressed air into mechanical motionnecessary to apply the tractor service brakes. Airsystem pressure also operates the windshield wiper androof mounted air horn, and unlatches the fifth wheeljaws. Figure 1-5 illustrates the major components of thetractor air system. Suction developed by an aircompressor draws outside air through

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Figure 1-3. Yard Tractor Major Components

1-6

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Figure 1-4. Engine Assembly

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Figure 1-5. Tractor Air System

an evaporator, which distributes alcohol vaporthroughout the entire air system to increase brakingefficiency at low temperatures. The air compressor,located on the right side of the engine, compresses air toa pressure approximating 120 psi and applies the air to asupply tank. A governor on the compressor sensespressure in the system and cuts out compressoroperation when normal operating air pressure isreached, and starts compressor operation wheneversystem pressure falls below a predetermined level. inaddition, a warning buzzer and light will actuatewhenever air pressure falls to a point where the brakescannot be operated safely. Air in the supply tank isallowed to cool and water is condensed; then dry air isrouted to a service tank. All air operated componentsnormally operate from the air supply in the service tank.in the event of a loss of air in the service tank, anemergency tank provides enough air for approximatelythree service brake applications. Air from theemergency tank may also be used to release the rearaxle fail-safe brake chambers.

h. Steering System. See Figure 1-6 foridentification of major steering system components. Thesteering system consists of a conventional steering

wheel and column, which is connected at the cab floor toa power assisted integral type steering gear. A flexiblesteering joint provides coupling between the, steeringcolumn and steering gear. A hydraulic pump andreservoir assembly mounted at the top front of theengine provides the fluid pressure for power assist. Anexternal filter in the return line removes contaminantsfrom the hydraulic fluid. Movement of the steering wheelin either direction, when the engine is running, actuatesinternal valving at the steering gear, admitting hydraulicfluid under pressure to assist the operator's steeringeffort. From the steering gear, the motion is transmittedto the front wheels by a drag link and conventionalsteering knuckle and tie rod linkage. In case of hydraulicpressure failure, the system remains completelyoperable, although steering effort will be considerablyincreased.

i. Electrical System. The electrical systemoperates at 12 volts, supplied by four 12 voltwet-cell batteries connected in parallel. A12 volt engine driven alternator supplies the currentto maintain the battery charge. Current fromthe 80 ampere alternator is rectified and

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Figure 1-6. Steering System

controlled internally, according to the systemrequirements. Electrically operated components andaccessories include headlights, taillights, directionalsignals, flood lights, cab lights, engine starting motor,instrument gages and senders, and heater motors. Asolid state converter enables the 12 volt tractor systemto power the turn signal, brake, and running lights on 24volt trailers. All accessory circuits are protected againstoverloads by circuit breakers located in the front of thecab.

j. Cooling System. The diesel engine is cooledby circulating the engine coolant through the radiator,cylinder block, and cylinder head (see Figure 1-7).Coolant is drawn from the bottom of the radiator by thewater pump and circulated through the engine block andcylinder head. During the engine warm-up period, whencoolant temperature is below normal, the coolant isrestricted at the thermostats. A bypass tube connectedbetween the thermostat housings and the water pumpprovides circulation within the engine. As the coolanttemperature rises above 170°F, the thermostat valvesopen, restricting the bypass system and circulatingcoolant through the radiator. Cooling air is drawn

through the tube-and-fin type radiator by action of thefan, which is belt driven from the engine crankshaftpulley. A coolant recovery reservoir prevents loss ofcoolant and also provides a convenient fill and checkpoint. The transmission fluid is cooled by circulating thehot fluid through the oil cooler built into the bottom tankof the radiator. An external transmission filter is installedin the cooler to-transmission circuit to filter debris out ofthe fluid stream.

k. Fuel System. See Figure 1-8 for the fuelsystem diagram. The engine fuel system consists of thefuel tank of 50 gallons capacity, mounted to the left sideof the frame, a mechanical, gear pump driven off theengine, an in line fuel filter, the fuel injectors, plus thenecessary tubing and fittings to complete the circuits.The fuel tank provides a drain for the removal ofcondensation and sediment from the system. Fuel isdrawn from the supply tank through the fuel filterand enters the fuel pump at the inlet side. Uponleaving the pump under pressure, the fuel is forcedinto the fuel inlet manifold where it passes throughfuel pipes into the inlet side of each fuel injector.The fuel is filtered through elements in

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Figure 1-7. Typical Cooling System

Figure 1-8. Typical Fuel System

the injectors and atomized through small spray tiporifices into the combustion chamber. Surplus fuel,returning from the injectors, passes through the fuelreturn manifold and connecting fuel lines back to the fueltank. A restricted fitting is located in the left-bankcylinder head fuel return manifold outlet to maintainpressure within the fuel system.

l. Exhaust System. Engine exhaust gases areexpelled from the engine through the exhaust valves andthe exhaust manifolds. An exhaust tee and pipesconnect the manifolds to the vertical muffler and exhauststack mounted on the right side of the tractor. A rain capis installed on top of the hinged exhaust stack.

m. Fifth Wheel Hydraulic System. Figure 1-9illustrates the major components of the fifth wheelhydraulic system. Hydraulic fluid is supplied by areservoir bolted to the chassis directly behind the fueltank. The reservoir consists of a cubical tank, fillerbreather cap, and a magnetic drain plug. The drain plugprevents metallic particles from recirculating through the

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Figure 1-9. Fifth Wheel Hydraulic System

hydraulic system. Oil for operation of the fifth wheelboom is delivered to the hydraulic valve by a pump. Thehydraulic pump is driven by the power takeoff on theside of the transmission. Control of the hydraulic valveis accomplished through a flexible cable attached to thefifth wheel control lever at the right of the operator'sconsole. Once the hydraulic fluid has been circulatedthrough the pump, valve, hoses, and double acting liftcylinders, it is returned to the reservoir through a filterBleed down valves, located at the front of the fifth wheelboom, provide a convenient point for purging thehydraulic system. Return the fluid to reservoir.

1-11. WARRANTY.

The manufacturer's warranty is provided as Figure 1-10.

OTTAWA TRUCK DIVISION, INC, a Gulf + Western ManufacturingCompany, warrants each new Ottawa Commando to be free fromdefects in material or workmanship under normal use and service, for aperiod not to exceed 15 months from date of acceptance at the OttawaManufacturing facility, or 1500 hours, whichever shall first occur.

The obligation of OTTAWA TRUCK DIVISION, INC, under thiswarranty is limited to repairing or replacing, as the company may elect.any part or parts which are returned to us transportation prepaid, andwhich, upon examination, are determined by us to be detective inmaterial or workmanship.

The provisions of this warranty do not apply to the prime product orany component part thereof, which has been subject to misuse, ordamaged through negligence or accident, or has been repaired oraltered by anyone other than OTTAWA TRUCK DIVISION, INC., or itsauthorized parts and service distributors Further excluded are suchparts as filters, belts, or other operative Items, which are a part ofnormal maintenance service replacements.

The repair or replacement of defective parts or workmanship under theterms of this warranty will be made by OTTAWA TRUCK DIVISION,INC., or Its authorized Parts and Service Center, without charge forparts or labor, If the prepaid returned parts are judged by the companyto be faulty or defective. OTTAWA TRUCK DIVISION, INC., will nothonor Invoices or PARTS PURCHASED FROM OUTSIDE SOURCES,unless written authorization is first given by OTTAWA TRUCKDIVISION, INC, Service Department. Further OTTAWA TRUCKDIVISION, INC, will not honor Invoices for labor charges, unless therate per hour charged and the number of hours Involved, are firstauthorized by OTTAWA TRUCK DIVISION, INC.

THIS WARRANTY is in LIEU OF ALL OTHER WARRANTIES.EXPRESS OR IMPLIED. OF ANY KIND OR NATURE Whatsoever

90002405Figure 1-10. Warranty Statement

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CHAPTER 2

PREPARATION FOR USE AND RESHIPMENT

Section I. PREPARATION FOR USE

2-1. GENERAL.

When a new or reconditioned tractor is first received bythe using organization, it is necessary to determine thatthe tractor is in satisfactory condition and will operateproperly when first placed into service. For this reason,follow closely the service procedures outlined in thefollowing paragraphs.

2-2. PRELIMINARY INSPECTION.

Visually inspect the vehicle upon receipt for obviousshipping damage, such as broken, cracked, dented ormissing parts, or chafing where tie down chains wereused. Report any damage, errors or discrepancies onthe appropriate forms.

2-3. UNDER HOOD CHECK.

Open the engine hood and check the following for properquantity:

NOTERefer to Chapter 4 for fuel, oil andcoolant specifications.

a. Engine Coolant Level Check to see that coolantlevel reaches the full mark, or approximately 2 to 4inches below the top of the filler neck on the overflowrecovery reservoir.

WARNING

Do not remove the radiator cap froma hot engine; stop the engine andallow it to cool before removing cap.

Remove radiator filler cap. Check that coolant levelreaches the radiator filler neck. Also check that coolantcontains rust inhibiter or permanent-type antifreeze (30%minimum).

CAUTIONIf ambient temperature is expected tofall below 32°F, also check level of

antifreeze protection by testingcoolant with a hydrometer.

b. Fuel Level Remove filler cap from fuel tank, andcheck instrument panel gage reading with key switch setat ON.

c. Engine Oil Level Remove the dipstick oil gage,and check oil level on dipstick to ensure that it is at, orclose to, the FULL mark.

d. Transmission Fluid Level Transmission fluidlevel should be checked with the transmission warm, inneutral range, and the engine idling. The transmissiondipstick gage is located in the engine compartment onthe right side.

e. Hydraulic Fluid Levels -

(1) Remove hydraulic reservoir cap andcheck that fluid level is approximately 3 inches below thetop of the reservoir.

(2) Remove power steering pump cap andcheck that fluid level reaches the full mark.

f Battery Water Level -

WARNING

Do not smoke or employ any openflame near the batteries, as anexplosive gas is produced by thebatteries during their operation.

Remove filler caps on the batteries and check thatelectrolyte reaches 3/8 inches above the plates.

2-4. SWITCHES, GAGES, AND LIGHTS.

Check the following for proper operation:

a. Check operation of neutral start switch byplacing gear shift lever in forward or reverse position andturning ignition switch key clockwise to START position.Starter must not engage until gear shift lever is returnedto neutral position.

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b. Start engine and check hour meter, temperaturegage, pressure gages, ammeter, voltmeter, tachometer,and fuel level gage for proper operation.

c. Pull HEADLIGHT switch out to second detentand check to see that headlights, instrument panel lights,clearance lights, side marker lights, front and rear parklights, and tail light are operable. Depress dimmerswitch to check low beam and high beam headlightoperation. Check operation of left and right turn signallights by operating the turn signal lever and the hazardwarning switch.

2-5. OPERATIONAL CHECK.

Refer to operating instructions in Chapter 3 and checkoperation of engine, transmission, fifth wheel andbrakes. Check that parking (spring) brake will preventtruck motion with transmission in gear.

2-6. LUBRICATION.

Check tractor record or service tags for indication of lastperiodic maintenance performance. If necessary, referto Chapter 4 and service the vehicle.

Section II. PREPARATION FOR RESHIPMENT

2-7. GENERAL.

The instructions below are the minimum requirementsacceptable for interim protection of tractors duringshipment.

2-8. PRESERVATION AND PACKAGING.

a. Cooling System. Check the system to assurethat it is filled to the proper level with a clean solution ofethylene glycol compound conforming to MIL-A-46153A.Always ensure that cooling system contains antifreezecapable of providing protection as outlined in Table 2-1.

b. Lubrication System. Check the level andcondition of lubricant. If low add lubricant, conforming tospecifications of Chapter 4 for the anticipated ambienttemperature range expected, to bring lubricant tooperating level. Operate the engine until the lubricanthas been circulated through the system. Do not drain oil

from crankcase.

c. Openings. Seal openings that will permit directentry of water with pressure-sensitive tape conforming toPPP-T-60, type IV. Bridge large openings withwaterproof barrier material conforming to PPP-B-1055,and secure the edges of the barrier material to adjacentsurfaces with pressure-sensitive tape.

d. Fuel Tank. Draining of fuel tank is not required.If fuel tank is empty, no preservation is required.

e. Hydraulic System. Retract the pistons as faras the linkage will permit and secure in retractedposition. Coat exposed portions of the hydraulic pistonram shafts with type P-6 preservative (CL) conforming toMIL-C-11796, class 3. Grease, automotive and artillery,conforming to MIL-G-10924 may be used if type P-6preservative is unavailable. Wrap the coated shafts withtype 1, class 2, grade A, greaseproof barrier materialconforming to MIL-B-121.

f. Exterior Surfaces. Coat exposed machinedferrous metal surfaces with type P-6 preservative (CL)conforming to MIL-C-11796, class 3. GAA grease maybe substituted if type P-6 preservative is not available.

g. Keys. Remove, package and place keys in thetool box to prevent pilferage.

h. Batteries and Cables. Ensure that batteriesare filled and fully charged and secured in the batterycompartment. Disconnect cable terminals and secure tothe battery support with tape to prevent grounding.

i. Pneumatic Tires. Inflate tires to their normalrequired operating pressures.

j. Disassembly. Remove components and partsthat are subject to pilferage or damage.

2-9. PACKING.

Pack removed parts in the tool box, if possible. If thetool box will not accommodate the removed componentsand parts, pack in suitable containers and secure to theequipment to prevent loss or pilferage.

Table 2-1. Antifreeze Specifications

Lowest Estimated AntifreezeTemperature In Antifreeze Mixture SpecificationGeographic Area Percent By Volume Requirement

+20° F. to -30° F. 50% Ethylene Glycol & 50% Water MIL-A-46153A-30° F. to -55° F. 60% Ethylene Glycol & 40% Water MIL-A-46153A

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2-10. SHIPPING.

a. Rail Shipment. Block and secure equipment toor in the railway car in accordance with the Associationof American Railroads, "Rules Governing the Loading ofCommodities on Open Top Cars".

b. Highway Shipment. Load, block, and bracevehicle and equipment for haul-away or tow-away inaccordance with the applicable motor carrier tariff.

c. Tractor Tie Down. Refer to Figure 2-1 fortractor tie down locations.

LIFTING AND TIEDOWNACTUAL WEIGHT - 16,440 POUNDS

LIFTING-Use cables, chains, or straps of sufficientcapacity to lift unit as shown. Spreader barshould be used to prevent damage to cab andbumper guard. TIE DOWN-Use cables, chains, orstraps of sufficient capacity, and tie down asshown. Chock blocks should also be used asshown.

Figure 2-1. Tractor Tie Down Locations

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TM 9-2320-277-14&PCHAPTER 3

OPERATING INSTRUCTIONS


3-1. SCOPE.

This chapter provides information and instructionsconcerning the proper operation and use of the tractor.Operating and maintenance personnel must becomethoroughly familiar with the tractor, and theseinstructions, before attempting any operation or serviceprocedure.

3-2. CONTROLS AND INSTRUMENTS.Refer to Figure 3-1 for an illustration of all controls andinstruments. The legend accompanying the illustrationexplains the function of each control and gives thenormal reading for each gage.

Section II. OPERATING INSTRUCTIONS

WARNINGTo reduce the possibility of bodilyinjury, personnel required to operatethis tractor must become thoroughlyfamiliar with all controls andinstruments, and must also becomeacquainted with the specific handlingand operating characteristics of thisvehicle.

3-3. STARTING THE ENGINE.

WARNINGAlways fasten seat belt whenoperating tractor.

WARNINGDo not operate engine for prolongedperiods in an unventilated area.Internal combustion engines producepoisonous carbon monoxide gaswhich is extremely toxic if allowed toaccumulate in a closed area.

a. Refer to Chapter 4 and perform the dailyservices listed in Table 4-1.

b. Push parking brake valve in to make certain

tractor, will remain stationary while engine is beingstarted.

c. Make certain the gear shift lever is in neutralposition.

d. Press down on accelerator pedal approximatelyone-fourth the distance from its normal position.

CAUTIONDo not operate the starter motorcontinuously for more than 20seconds. If the engine fails to startafter 20 seconds, allow the startermotor to cool for at least two minutesbefore attempting to start the engineagain.

e. Insert key into switch and turn clockwise to theSTART position to crank the engine. As the enginestarts, release key switch and accelerator pedal.

f. Immediately observe engine oil pressure gagefor normal reading (18 psi minimum within 10 to 15seconds).

g. If the engine does not start due to low ambienttemperature (less than 40°F) proceed as follows:

(1) Turn key switch key clockwise to theSTART position.

(2) Depress and hold the ether switch for oneto three seconds, then release to discharge ether toengine.

(3) Release key switch as engine starts.Repeat the procedure if engine does not start on the firstattempt.

NOTEThe greatest percentage of wearoccurs when a cold engine is started.After the engine is stopped andallowed to cool, oil drains off movingparts and into the oil pan. If theengine is started and operated athigh speeds before oil is circulated toall moving parts, wear on these partsis greatly increased.

h. Warm engine until it will idle smoothly, and avoidfull throttle operation until water temperature gageindicates at least 140°F. Report any malfunctions to theproper authority.

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Figure 3-1. Tractor Controls and Instrument

3-2

TM 9-2320-277-14&PLEGEND FOR FIGURE 3-1

INDEXNO. NOMENCLATURE NORMAL USE OR READING

1 Tachometer Indicates engine speed in RPM. Normally 550 to 2800 RPM.

2 Warning Bell Bell sounds, and LOW WATER warning lamp illuminates, to alert operator to lowengine oil pressure and/or high engine coolant temperature.

3 Ammeter Indicates rate of battery charge or discharge. With engine running, shouldindicate slightly to the plus (+) side of zero.

4 Voltmeter Expanded scale meter indicates electrical system voltage.

5 Speedometer/ Speedometer indicates vehicle speed in MPH and KPH (normally less thanOdometer 30 MPH). Odometer indicates total vehicle mileage.

6 HIGH BEAM Light Indicates red when headlights are on high beam.

7 TRAILER AUX If trailer electrical cable is connected, pull out to illuminate trailer interior lights.LIGHT CIRCUIT Push in to extinguish lights.Switch

8 Fuel Level Gage Indicates quantity of fuel remaining in fuel tank. E=empty, F=full (tank capacityis 50 gallons).

9 LOW AIR Indicates red, and buzzer (not shown) sounds, when air system pressure is lessPRESSURE Light than 60 PSI.

10 Restriction Indicator Indicates red band when engine air filter service is-required. After air filterservice, depress reset button on top of indicator to release red signal from view.

11 Air Pressure Gage Indicates system air pressure in PSI. Normally 100 to 120 PSI.

12 TRANS OIL TEMP Indicates red when automatic transmission fluid is too hot for normal operation.Warning Light

13 Emergency Brake Normally out. Push and hold to release parking (spring) brake after emergencyRelease Valve (automatic) application. When released, brakes will apply automatically. May be

used for approximately three applications.

14 Parking Brake Valve Pull out to apply rear wheel parking (spring) brake. Push in to release parkingbrake.

15 Tractor Protection After connecting trailer brake hoses, push in to release trailer brakes. WhenValve dropping a trailer, before removing either trailer brake hose, pull up to apply

the trailer brakes. If a brake line fails, pull up for emergency trailer brakeapplication.

16 DOMELIGHT Pull out to illuminate cab dome light. Push in to extinguish light.Switch

17 HEADLIGHT Pull out to first detent to illuminate clearance, dash, side marker, and frontSwitch and rear parking lights. Pull out to second detent to also illuminate head lights.

Push in to extinguish all lights. Switch controls corresponding trailer lights if trailerelectrical cable is connected.

18 WASHER Button Push in to apply two streams of washing solvent to windshield, and clean solventfrom windshield with wipers. Release button to stop solvent flow.

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LEGEND FOR FIGURE 3-1 (Continued)

INDEXNO. NOMENCLATURE NORMAL USE OR READING19 WIPER Control Turn counterclockwise to RUN to operate windshield wiper blade. Turn further

counterclockwise to increase wiper speed. Turn clockwise to PARK to returnblade to park position.

20 Hour Meter Indicates total engine operating time in hours and tenths.

21 Ether Switch Depress and hold for three seconds to fill ether starting aid valve. Release todischarge ether to engine.

22 Engine STOP Push in to stop engine. Release when engine stops.Button

23 BLOWER Switch Turn clockwise to turn heater fans on low or high speed. Turn counterclockwise tostop heater fans.

24 Key Switch When turned clockwise to ON, energizes instrument, accessory, and engine startercircuits. Turning further clockwise engages engine starter. Turn counterclockwiseto OFF to deenergize all electrical systems. Turning further counterclockwise toACC energizes accessory circuit only.

25 DEFROSTER Switch Pull out to energize defroster vent fan. Push in to stop defroster fan.

26 Oil Pressure Gage Indicates engine lubricating oil pressure in PSI. Normally 40 to 60 PSI (18 PSIminimum at 1200 RPM).

27 FRESH AIR Control Use to regulate air flow to heater. Push in to recirculate cab air throughheater. Pull out to circulate outside fresh air through heater.

28 OIL PRESSURE Indicates red with loss of engine lubricating oil pressure.Warning Light

29 HEATER TEMP Regulates amount of hot water to heater. Push in for minimum heat. Pull out forControl maximum heat.

30 LOW WATER Indicates red with drop in engine coolant level. Indicates red, and warningWarning Light bell sounds, if engine oil pressure is low and/or coolant temperature is high.

31 WATER TEMP Indicates red with overheating of engine coolant.Warning Light

32 Water Temperature Indicates temperature of engine coolant in degrees Fahrenheit. Normally 175Gage to 195°F.

33 Converter Switch Slide toggle switch to illuminate converter light and operate 24 volt trailers.Slide switch back to extinguish converter light and operate 12 volt trailers.

34 Turn Signal Lever Push forward to signal right turn. Pull back to signal left turn. Lever willreturn to neutral when turn is completed.

35 Turn Signal Light Flashes to indicate that left turn, right turn, or warning flasher lights are operating.

36 Horn Button Depress to sound electric horn.

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INDEXNO. NOMENCLATURE NORMAL USE OR READING37 Hazard Warning Slide to flash all turn signal lights simultaneously. Slide back to extinguish

Switch lights.

38 Hand Brake Control Used to apply trailer brakes without applying tractor brakes. With emergencyand service air hoses connected to trailer, gradually pull down to apply trailerbrakes. Push lever up to release trailer brakes. Do not tow trailer with leverpartially down, and do not use as a parking brake.

39 Horn Lanyard Pull down to sound roof-mounted air horn.

40 Gear Shift Lever Selects the transmission gear ranges for tractor operation. Service brake treadlemust be depressed when shifting to or from reverse.R (reverse) - Bring tractor to complete stop, idle engine, and select for

backing the tractor.N (neutral) - Idle engine and select for operation of fifth wheel. Also used

for starting engine.D (drive) - Idle engine and select for normal operation. Transmission

automatically shifts from 2nd through 5th gears.3 (intermediate range) - Restricts automatic shifting to 4th gear. Used for engine

braking or heavy pulling.2 (intermediate range) - Restricts automatic shifting to 3rd gear. Used for

greater engine braking or puling power.1 (creeper) - Select for 1st gear. Used for ascending steep grade with heavy

load, or for pulling through mud or snow.

41 5th WHEEL Lever With power take-off engaged, pull back to lower fifth wheel. Push forward toraise fifth wheel.

42 Fifth Wheel Unlatch With service brakes applied, depress and hold until fifth wheel jaws lock open,Valve then release. Used to unhook from a trailer.

43 PTO Control Pull up to engage power takeoff. Push down to release PTO. CAUTION: Placegear shift lever in any drive position to eliminate gear clash and possibledamage to PTO.

44 Accelerator Pedal Depress to increase engine speed.

45 Service Brake Treadle Depress to apply service brakes.

46 Back Angle While leaning forward in seat, pull cam out and turn to select desired backAdjustment Cam cushion angle.

47 Tilt Handle Shift weight to rear of seat; then grasp tilt handle to select one of three bottomcushion positions.

48 Release Lever Depress with right heel to disengage and reset automatic shock absorber. Shockabsorber will automatically engage on the next rough, bumpy stretch of road.

49 Weight Adjustment Operate to adjust seat torsion spring to driver's weight. Turn clockwise to putHandle more preload on the tension spring. Turn counterclockwise for a softer ride.

50 Height Adjustment Turn handle to raise or lower seat and adjust for leg length.Handle

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INDEXNO. NOMENCLATURE NORMAL USE OR READING51 Position Lever Pull lever forward to slide seat forward or back. Push down to lock adjustment.

52 Isolator Lever Pull lever out and back to engage fore and aft isolator. To lock out, push liverforward and in.

53 Dimmer Switch Depress with left foot to select headlight high beam or low beam. Used withHEADLIGHT switch.

54 Cab Vent When open, directs fresh air at operator. Vehicle speed determines air flow.

55 Converter Light Illuminates to indicate converter is applying 24 volt power to trailer lights.Extinguishes when converter is turned off to indicate trailer light operation from12 volt power.

56 LEFT ROOF Push up to illuminate left flood light. Pull down to extinguish flood light.FLOOD LIGHTSwitch

57 RIGHT ROOF Push up to illuminate right flood light. Pull down to extinguish flood light.FLOOD LIGHTSwitch

58 CAB REAR Push up to illuminate rear flood light. Pull down to extinguish flood light.FLOOD LIGHTSwitch

3-4. MOBILE OPERATION.

Operation of this vehicle is essentially the same as thatfor any automotive-type equipment; all controls andinstruments are positioned conveniently for operator'suse, and in approximately the same location orrelationship as that used in an ordinary truck orpassenger car. Operators should familiarize themselveswith the steering and performance characteristics of thevehicle before attempting to perform any actual towingoperations. Sudden starts, stops, and turns are to beavoided except in cases of emergency.

CAUTIONDisengage power takeoff if tractor isto be driven at high speeds or inexcess of 1/2 mile.

3-5. COUPLING TO TRAILER.

a. Back the tractor up to the front of the trailer sothat the trailer kingpin is in line with the fifth wheel jawson the tractor.

b. Engage hydraulic pump power takeoff asfollows:

(1) Stop tractor, idle engine, and placegearshift lever in any drive position.

(2) Pull PTO control up to engage powertakeoff.

(3) Place gear shift lever in neutral position.

c. Momentarily apply service brakes and depressfifth wheel unlatch valve to unlock the fifth wheel jaws.

CAUTIONMake certain the gear shift lever is inneutral position.

d. Operate the 5th WHEEL lever to obtain theproper coupling height as shown in Figure 3-2.

CAUTIONPosition chock blocks under trailerwheels to prevent movement andlanding gear damage.

e. Slowly back tractor under the trailer until the fifthwheel jaws engage the trailer kingpin and lockautomatically

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Figure 3-2. Proper Fifth Wheel Coupling Height

f. To couple to a low trailer:

(1) Pull 5th WHEEL lever back to lower fifthwheel.

(2) Slowly back tractor under the trailer untilthe fifth wheel plate is just covered by nose of trailer.

(3) Push 5th WHEEL lever forward to raisefifth wheel approximately five inches.

(4) Slowly finish backing tractor under thetrailer until fifth wheel jaws engage the trailer kingpin andlock automatically.

g. Shift transmission into a forward gear to testcoupling, then return gear shift lever to neutral position.

h. Push the 5th WHEEL lever forward to lift thetrailer to maximum height.

NOTETrailer lifting speed may beincreased by accelerating the tractorengine. The fifth wheel boom willnot lift unless the PTO is engagedand the transmission is in neutral.

i. Connect the emergency and service air hosesand electrical system cables to trailer, and retract trailerlanding gear. Remove chock blocks from under trailerwheels.

j. Depress tractor protection valve to release trailerbrakes.

k. To disengage hydraulic pump power takeoff(required only if tractor is to be driven at or nearmaximum speed or in excess of 1/2 mile) :

(1) Stop tractor, idle engine, and place gearshift lever in any drive position.

(2) Push PTO control down to disengagepower takeoff.

(3) Place gear shift lever in neutral position.

l. Shift transmission into desired gear and driveaway with trailer.

3-6. TRAILER TOWING OPERATIONS.During towing operations, keep transmission in a gearrange that will provide adequate torque for ascendinggrades. Vehicle speed must be kept low enough that thetractor and trailer can be safely stopped, within anassured clear distance.

a. When negotiating turns or operating in areaswhere clearances are restricted, always take intoconsideration the physical size and steeringcharacteristics of the trailer being towed.

b. When towing loads at or near maximumcapacity, closely monitor the TRANS OIL TEMP warninglight. If warning light indicates red, stop tractor, shift toneutral range and run engine at 1200 to 1500 rpm untilthe TRANS OIL TEMP warning light extinguishes.

c. When tractor is to be driven in excess of 1/2mile, or at high speeds, disengage hydraulic pumppower takeoff.

3-7. STOPPING THE TRACTOR.a. Remove foot from accelerator pedal.

b. Apply foot pressure to the service brake treadleto bring tractor to a stop. Avoid sudden application of fullbraking effort except in cases of emergency.

NOTEA smooth stop results when footpressure is gradually released as thetractor speed decreases. Applyingthe brakes lightly at first and thenharder as the speed decreasesresults in a rough stop. The enginemay be used to assist the brakes instopping the tractor if the enginegoverned speed of 2800 rpm is notexceeded.

c. Place the gear shift lever in neutral position.

d. Push parking brake valve in to set tractorparking brake.

CAUTIONDo not shut engine down while gearshift lever is in reverse position.

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NOTEIf the engine has been operating at,or near, full load, it should be allowedto run at 800 to 1200 rpm for severalminutes after the load is removedbefore being stopped. This allowsinternal engine temperatures toequalize.

e. Depress and hold engine STOP button untilengine stops; then release. Turn key switch keycounterclockwise to the OFF position, and remove key toprevent unauthorized use of vehicle.

3-8. UNCOUPLING FROM TRAILER.

a. Make certain the gear shift lever is in neutralposition.

b. Pull tractor protection valve up to set the trailerbrakes.

c. Extend the trailer landing gear, and disconnectthe brake air hoses and electrical system cables fromthe trailer.

d. Pull the 5th WHEEL lever back until trailerlanding gear is on the ground.

CAUTIONUse chock blocks to secure trailerand protect landing gear againstdamage.

e. Momentarily apply service brakes and depressfifth wheel unlatch valve until fifth wheel jaws lock in theopen position.

f. Shift into forward gear and drive away fromtrailer.

Section III. OPERATION IN EXTREME COLD

3-9. GENERAL.Extensive preparation of mechanical equipment isrequired when cold weather is anticipated. Extreme coldgenerally causes lubricants to thicken or congeal,presents a risk of freezing batteries and diminishes theirefficiency, and prevents fuel from vaporizing readily toform a combustible mixture necessary for enginestarting. The following paragraphs provide specialrecommendations for operation in extreme cold.

3-10. SHELTER.The tractor should be sheltered in a closed building withsome heat, if possible. If this is not possible, cover witha tarpaulin or similar kind of material.

3-11. COOLING SYSTEM.

Add proper amount of ethylene glycol antifreeze tocooling system. A solution of 29 quarts ethylene glycoland 27 quarts of water will afford protection to -35°F. Ifantifreeze is not available, drain radiator and cylinderblock when ambient temperature is expected to dropbelow 32° F. Never add water to the cooling systemwithout subsequently checking the antifreeze solution foradequate strength and adding antifreeze if necessary.

3-12. ELECTRICAL SYSTEM.a. Test the specific gravity of the electrolyte in the

batteries, using a hydrometer. Specific gravity readingshould be between 1.270 and 1.290 at 80°F.

b. Electrolyte level of batteries must be maintainedat 3/8 inch above plates. Do not add water to a batterywhich has been exposed to low temperature exceptwhen engine is to be operated immediately.

c. Remove batteries and store in a warm placewhen shelter for truck is not available. The efficiency ofa battery decreases at lower temperatures, and acompletely discharged battery will freeze at 20°F.

d. Be sure that battery cables are in good conditionand that all connections are clean, dry, and secure.

3-13. FUEL SYSTEM.Fill fuel tank at end of day to prevent condensation fromcontaminating the fuel. Use prescribed winter grade ofdiesel fuel, and use the ether starting aid when ambienttemperature is less than 40°F.

3-14. TRANSMISSION.Use auxiliary preheat or a heated shelter to raisetemperature whenever ambient temperature drops below-10°F.

3-15. BRAKE SYSTEM.For maximum braking efficiency maintain proper alcoholevaporator level. Drain water from air tanks at the endof each day's operation.

Section IV. TOWING THE TRACTOR3-16. Before towing or pushing a disabled vehicle,disconnect the driveline or hoist the drive wheels off theroad.

CAUTIONTowing the tractor for more than 15miles with the drive wheels on theground will overheat thetransmission and may causepermanent damage. Do not tow over20 miles per hour.

NOTEIt is not possible to start a disabledvehicle by pushing or towing.

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CHAPTER 4PERIODIC INSPECTION AND LUBRICATION

Section I. PERIODIC INSPECTIONREQUIREMENTS AND PROCEDURES

4-1. INTRODUCTION.

This chapter presents specific periodic maintenanceprocedures to be followed on a regularly scheduledbasis. Manufacturer's recommended lubrication andinspection schedules are included.

4-2. PERIODIC INSPECTION SCHEDULE.

Establish and maintain a periodic inspection schedule inaccordance with the information provided in Table 4-1.The frequency (except daily) of inspection is based onnormal operating conditions and tractor usage with oneshift operation. Adjust inspection intervals accordingly ifextreme climatic or operating conditions exist for anyextended period of tractor operation.

Another factor that determines frequency of inspection ismultiple shift operation combined with hours of use.Roughly, single shift preventive maintenance items arebased on 200 hours or 6000 miles of operation permonth, with weekly maintenance set at 50 hours or 1500miles of operation.

NOTEThe operator is normally responsiblefor performing the daily checks only -the remaining checks are listed forready reference by maintenancepersonnel. For detailed serviceinformation on these checks, refer tothe applicable topics in the separatemaintenance manual.

Section II. PERIODIC LUBRICATION AND SERVICES

4-3. LUBRICATION AND SERVICE CHART.Refer to Figure 4-1 for the lubrication and service chart,which indicates proper lubricants to be used in servicingthe tractor, the points of application, and the maximumintervals for performance of lubrication services.

4-4. LUBRICATION AND SERVICE FREQUENCY.

The frequency of lubrication and services shown inFigure 4-1 is based on normal operating conditions andtractor usage with one shift operation (50 hours or 1500miles per week, and 200 hours or 6000 miles permonth). Adjust frequency of lubrication and services toshorter periods if extreme climatic conditions or severityof service require more frequent attention to lubrication.Periodic lubrication and services may be omitted whilethe tractor is in dead storage.

Section III. FUEL, LUBRICANTS, ANDCOOLANT SPECIFICATIONS

4-5. DIESEL FUEL.a. The quality of fuel used for diesel engine

operation is a very important factor in obtainingsatisfactory engine performance, long engine life, andacceptable exhaust emission levels. The diesel engineis designed to operate on fuels classified by the ASTMas Designation D-975 (grades 1-D and 2-D). Thesegrades are very similar to grades DF-A, DF-1 and DF-2of Federal Specification VV-F-800B, as shown in(Table 4-2).

NOTEThe use of drained lubricating oil as adiesel fuel is not recommended.

b. All diesel fuel contains a certain amount ofsulfur. Too high a sulfur content results in excessivecylinder wear due to acid build-up in the lubricating oil.For most satisfactory engine life, fuels containing lessthan 0.5% sulfur should be used.

c. Residual fuels and furnace oils, generally, arenot considered satisfactory. In some regions, however,fuel suppliers may distribute one fuel that is marked aseither diesel fuel (ASTM D-975) or domestic heating fuel(ASTM D-396) sometimes identified as furnace oil. Inthis case, the fuel should be investigated to determinewhether the properties conform with those shown in(Table 4-3). The Diesel Fuel Selection Chart also willserve as a guide in the selection of the proper fuel forvarious applications.

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Table 4-1. Preventive Maintenance Inspection.

Inspection Interval

Daily, Weekly Monthly 500 hours Twicewhen or 15,000 yearlyused miles,

whichevercomes first

AXLES

Check and tighten wheel mounting nuts. XCheck and tighten differential Xhousing bolts.Check security of axle mounting to Xframe. XCheck differential for oil leaks.

BRAKES

Drain air tanks of condensed water. X(Note 1)Check air compressor filter. XCheck service and parking brake foraction and adequate reserve. XCheck stoplight switch operation. XCheck air brake slack adjustment. X (Note 2)Check cut-out, cut-in pressures of compressor X (Note 3)governor.Inspect brake linings for wear X (Note 2)and adjustment.

CAB AND CHASSIS

Check that tilt cab latch hooks are secure. XRe-torque chassis and mounting bolts. XCheck door drain holes. X

COOLING SYSTEM

Check system for coolant leaks. XClean radiator fins with compressed air. XCheck antifreeze protection. XCheck thermostat operation. X

ELECTRICAL

Check ammeter and voltmeter for Xproper alternator operation.Check operation of all lights. XClean exterior of lights. XWith engine running, check fornormal indications of instruments. XCheck for chafed or broken wires.

X

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Table 4-1. Preventive Maintenance Inspection (Continued)

Inspection Interval

Daily, Weekly Monthly 500 hours Twicewhen or 15,000 yearlyused miles,

whichevercomes first

ENGINE FUEL SYSTEM

Visually check fuel tank for leaks. XDrain fuel tank to remove waterand sediment. XCheck security of fuel lines. X

ENGINE - GENERAL

Check engine and mounting bolts forproper torque. XCheck and adjust V-belts X (Note 2)Check governor with tachometer. XCheck exhaust system for leaks. XPerform engine tune up. X

ENGINE OIL SYSTEM

Check ground below tractor for oil leaks. X

FIFTH WHEEL

Check operation of fifth wheel lever and cable. XCheck fifth wheel jaws for wear. X

HYDRAULIC SYSTEM

Check fifth wheel circuit for proper pressure(2000 psig) X (Note 2)

STEERING

Check steering wheel for excessive play. XCheck steering system for looseness. XCheck and adjust steering stop. X (Note 2)Check and adjust alignment. X (Note 2)Check tie rod ends. X (Note 4)

TRANSMISSION

Check ground below tractor for fluid leaks. XCheck freedom of gear shift lever. XCheck and adjust cable and controls. X (Note 2)Check mounting bolts for proper torque. X

WHEELS AND TIRESCheck tires for cuts or foreign objects. XCheck tires for proper inflation. XCheck hub bolt nuts. XCheck front wheel bearings for looseness. X

INSPECTION NOTES1. On hot days, several drainings daily may be necessary.2. Adjust as required.3. Compressor governor should cut-out between 118 and 120 psig and cut-in between 100 and 102 psig.4. Inspect tie rod ends at 3000 hours or one year, whichever comes first.

4-3

(Figure 4-1 Sheet 1 of 6)(Figure 4-1 Sheet 2 of 6)(Figure 4-1 Sheet 3 of 6)(Figure 4-1 Sheet 4 of 6)(Figure 4-1 Sheet 5 of 6)(Figure 4-1 Sheet 6 of 6)

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Figure 4-1. Lubrication and Services Chart (Sheet 1 of 6)

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LUBRICATION NOTES1. Replace at first 100 hours on new vehicles, and

at normal 300 hour interval thereafter.

2. The frequency of repacking depends upon theindividual operating conditions, speed and loads.Change, whenever seals are replaced, when brakes arerelined, or at 30,000 miles. If yearly mileage is less than30,000 miles, repack twice a year (spring and fall).

3. Replace at first 5000 miles on new vehicles, andat normal oil change intervals thereafter.

4. Maintain electrolyte level with distilled water.Flush dirty battery tops with solution of baking soda andwater, and clean cables and terminals.

5. Service air cleaner when restriction indicator redband is in full view. Clean primary element withcompressed air. Every third service, replace primaryand safety elements.

6. Do not raise wheel end off ground for lubrication.

7. The lubricant key is provided for reference only.For exact fuel, oil, and coolant specifications refer toapplicable portions of Chapter 4 text.

LUBRICANT KEY

Symbol Type of SpecificationLubricant

AF Permanent Ethylene glycol MIL-A-46153Aantifreeze and water

ATF Automatic Dextron® IItransmissionfluid

DF Diesel Low sulfur Fed Spec VV-F-800Bfuel fuel or ASTM

Designation D-975GAA Grease, General MIL-G-10924C or

automotive purpose NATO G-403and artillery grease

GO Gear oil GL-5 hypoid MIL-L-2105Cgear oil, SAE140 or 85W/ 140

OHO Hydraulic oil MS-DG SAE MIL-H-5606D or20W or SAE NATO H-51510W

OE Oil, engine API CC/SC or MIL-L-2104C/1964lubricating CB, SAE 30 or MS Supplement 1

SAE 40


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Lube/ Part Daily, Weekly Monthly 500 hours Twice Type Lube Number ofService when or 15,000 yearly of Key places or

Point used miles, Service (Note 7) amountNo. whichever needed

comes firstFUEL SYSTEM

1 Fuel filter(Note 1)

C(300 hours)

Replaceelement

DF 1

X Fill as needed DF 50 gal.2 Fuel

tank X Drain andrefill

DF 50 gal.

DRIVE AXLE

3Drive shaft X Pressure

fittingGAA 3

4Axle bearings

(Note 2)X Clean and

repackGAA 4

X Fill as needed GO AR5

DifferentialC and clean

breatherDrain andrefill

GO 38 pints

TRANSMISSIONX Maintain to

dipstick FULLmark

ATF AR6

Transmission

C(800 hours)

Replaceelement, refill,and cleanbreather

ATF 16 qts.

7External filter

(Note 3)C

(800 hours)Replaceelement ATF 1

Governor8 oil filter

C(800 hours)

Replaceelement

ATF

BATTERIES

9Batteries(Note 4) X

Maintain 3/8"above plates

Distilledwater

AR

COOLING SYSTEM

10Overflowreservoir

X Maintain level AF AR

11Radiator C Flush engine

and radiatorand refill

AF 56 qts.

11AWaterfilter

C(800 hours)

Replaceelement

AF 1


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comes firstENGINE

Air cleaner Clean primary 1(Note 5) element with

12

compressed airCrankcase X Maintain to OE AR

dipstick FULL13

markC14 Oil filters Drain

crankcase,replaceelementsand refill

OE 16 qts.

HYDRAULIC SYSTEMOHO ARX Maintain to 3"

below top1X Clean breather

capC Drain and refill OHO 9-1/2 gal.

and clean

15 Hydraulicreservoir

magnetic plugHydraulic Replace16filter

Celement

OHO 1

WINDSHIELD WASHERReservoir X Maintain level Isopropyl 1 gal.

alcohol17

and waterSTEERING AND FRONT AXLE

18 Powersteering

X Maintain level ATF 4 qts.

19 reservoirAxle knucklepins(Note 6)

X Pressure fitting GAA 4

Drag link ballsockets

20

(Note 6)


21 SteeringshaftU-joint


22 Wheelbearings

X Clean andrepack

GAA 4


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comes firstSTEERING AND FRONT AXLE (Continued)

Spring X Pressure fitting GAA 623 shackles

Power C Replace ATF24 steering filter element

BRAKESAlcohol X Fill as needed Methanol AR

25 evaporator alcoholSlack adjuster X Pressure fitting GAA 2

26 pivotBrake X Hand lubricate OE 2

27 chamber clevisTreadle hinge X Hand lubricate OE 2

28 and rollerFIFTH WHEEL

Fifth wheel X Hand lubricate GAA AR29 plate

Pivot points X Pressure fitting GAA 430

31 Lift cylinders X Pressure fitting GAA 4Boom pivot X Pressure fitting GAA 2

32 pinUnlatch X Hand lubricate OE 1

cylinder clevis33pin

34 Jaw pin X Hand lubricate OE 2CAB AND CHASSIS

35 Vent hinge X Hand lubricate OE 136 Door handle X Hand lubricate OE 137 Door hinge X Hand lubricate OE 1

Engine hood X Hand lubricate OE 3hinge and38

latchesSpeedometer X Hand lubricate Speedom- 1

cable eter cable39lubricant


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comes firstCAB AND CHASSIS (Continued)

Tiedown X Hand lubricate OE 440 shackle41 Seat X Pressure fitting GAA 9

Accelerator X Hand lubricate OE 3pedal hinge42and rollerCab pivot X Pressure fitting GAA 2

43 pinsKEY

X= Inspect and service.C= Change.


Table 4-2. Diesel Fuel Properties

Specification or VV-F- ASTM VV-F- ASTM VV-F-Classification 800B D-975 800B D-975 800B

Grade DF-1 1-D DF-2 2-D DF-AFlash Point, min. 100°F 100°F 122°F 125°F 100°FCarbon Residue 0.10 0.15 0.35 0.35 0.10(10% residuum),% max.

Water & 0.01 trace 0.01 0.05 0.01Sediment, % byvol., max.

Ash, % by wt., 0.01 0.01 0.01 0.01 0.01max.

DistillationTemperature,90% by vol.recovery, min. — — — 540°F 550°F

max. 550°F 550°F 640°F 640°FEnd Point, max. 626°F — 700°F — 572°FViscosity 100°FKinematic, cs.

min. 1.4 1.4 2.0 2.0 1.2Kinematic, cs.

max. 3.0 2.5 4.3 4.3 1.5Sulfur, % by wt.,max. 0.50 0.50 0.50 0.50 0.25

Cetane No. 40 40 45 40 40

Table 4-3. Diesel Fuel Selection Chart

Application General Fuel Final Cetane Sulfur Temp.Classification Boiling No. Content Ambient

PointWinter No. 2-D 675°F 45 0.50% –25°F to 160

Summer No. 2-D 675°F 40 0.50% –25°F to 160Winter No. 1-D 675°F 45 0.50% –25°F To

–65°FWinter No. DF-1 675°F 45 0.50% –25°F To

–65°FArctic DF-A 572°F 40 min. 0.25% Arctic

NOTEWhere minimum exhaust smoke isrequired or when prolonged idlingperiods or cold weather conditionsbelow 32°F are encountered, the useof lighter distillate (more volatile)fuels may be more practical.

d. During cold weather engine operation, the cloudpoint (the temperature at which wax crystals begin toform in diesel fuel) should be 10°F below the lowestexpected fuel temperature to prevent clogging of the fuelfilter by wax crystals.

4-6. ENGINE OIL

a. All diesel engines require heavy-duty lubricatingoils. The basic requirements for engine lubricating oilsare:

(1) Maintain pistons, rings, and other movingparts in a carbon free, varnish free, and clean condition.

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(2) Maintain enough film thickness to satisfactorilylubricate the moving parts at maximum oil temperatures.

(3) Prevent bearing corrosion, and counteractcorrosive products of combustion or contaminants in thefuel.

(4) Promote general cleanliness within the engine.

b. For optimum engine performance and longestservice life, use oil conforming to the performance levelsof Table 4-3 and the following ash and zinc limits:

(1) Ash Limit The sulfated ash limit (ASTM D-874)of the lubricants shall not exceed 1.000% byweight, except lubricants that contain onlybarium detergent-dispersant salts where 1.500%by weight is allowed. The majority of lubricantsmarketed under the performance levels shownin Table 4-4 have a sulfated ash contentbetween 0.55 to 0.85% by weight.

(2) Zinc Content The zinc content, as zincdiorganodithiophosphate, shall be a minimum of0.07% by weight.

Table 4-4. Recommended Oil Performance Levels

Military API SAE GradeIdentification Letter Code (See

Service Note 1)Classification

MIL-L-2104C/1964 MS CC/SC 30 or 40Supplement 1 CB 30 or 40

NOTE 1 - SAE 40 grade oil has performedsatisfactorily and is recommended. Onlywhen the ambient temperatures andengine cranking capabilities result indifficult starting should SAE 30 grade oilbe used.

c. Lubricating oils listed in Table 4-5 may besatisfactory for use if they conform to the preceding ashand zinc limits, although the engine manufacturer doesnot have sufficient experience with these oils torecommend their use. The oils listed in Table 4-6 arenot recommended due to a history of poor performance.

4-7. TRANSMISSION OIL.

Since the transmission oil cools, lubricates and transmitspower, it is important that the proper oil type and level bemaintained at all times. Only Dexron® II automatictransmission fluid is recommended.

Table 4-5. Additional Oil Performance Levels

Military API Letter Comment onIdentification Code Service Application

Classification and PerformanceMIL-L-2104C CD/SC Supersedes

MIL-L-45199B(Series 3) intendedfor diesel service.

MIL-L-46152 CS/SE Supersedesand QPL MIL-L-2104B

intended forgasoline enginepassenger cars.

Table 4-6. Oils Not Recommended

Military or API Letter CommentCommercial Code Service onIdentification Classification Performance.

MIL-L-2104B/1968 MS CC/SD Excessive ashdeposits formed.

MIL-L-45199B, CD Excessive ashSeries 3 (Cancelled) deposits formed.Multigrade oils Numerous History of poor

performance inmost heavy-dutydiesel engines.

4-8. POWER STEERING FLUID.

Automatic transmission fluid type A, suffix A containinganti-wear additives is recommended.

4-9. HYDRAULIC OIL.

For maximum service life, use a heavy duty MS (mostsevere) hydraulic fluid conforming to MIL-H-5606D orNATO H-515. Table 4-7 may be used as a guide inselecting the proper fluid grade for various applications.

NOTE

Do not mix brands or SAE grades ofoil. Do not use a foaming oil, as itwill not provide adequate lubricationfor continuous pump operation.

Table 4-7. Hydraulic Oil Selection Chart

Application API Letter Code SAE GradeService Classification

Summer MS-DG 20WWinter MS-DG 10W

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4-10. DIFFERENTIAL GEAR OIL.

Table 4-8 lists the recommended hypoid gear oils (MIL-L-2105C).

Table 4-8. Gear Oil Selection Chart

Ambient API Service SAE GradeTemperature Classification(Minimum)

+40°F GL-5 140+10°F GL-5 85W/140-10°F GL-5 80W/90

4-11. ENGINE COOLANT.

a. When freeze protection is required, an ethyleneglycol base permanent antifreeze conforming to MIL-A-46153A is recommended. An inhibitor system isincluded in this type of antifreeze and no additionalinhibitors are required on initial fill if a minimumantifreeze concentration of 30% volume is used.Solutions of less than 30% concentration do not providesufficient corrosion protection. Concentrations over 67%adversely affect freeze protection and heat transferrates. (See Figure 4-2).

b. The inhibitors in permanent antifreeze should bereplenished at approximately 500 hour or 20,000 mileintervals with a non-chromate inhibitor system.Commercially available inhibitor systems may be used toreinhibit antifreeze solutions. When permanentantifreeze is not used, a non-chromate inhibitor systemmust be used to provide corrosion protection.

c. Several brands of permanent antifreeze areavailable with sealer additives. The specific type ofsealer varies with the manufacturer. Antifreeze withsealer additives is not recommended due to possibleplugging throughout various areas of the cooling system.

Figure 4-2. Recommended Antifreeze Concentration

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SECTION IIVEHICLE PROCEDURES

TRUCK, TRACTOR, YARD TYPE,DIESEL ENGINE DRIVEN,


NSN 2320-01-044-8376

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TABLE OF CONTENTS

ChapterSection

Paragraph Page

LIST OF ILLUSTRATIONS............................vii

LIST OF TABLES ..........................................xii

1. INTRODUCTION, DESCRIPTIONAND DATA ....................................................1-1

I. INTRODUCTION ..........................................1-11-1. Scope and Related Publications .....1-11-2. Introduction ........................................1-11-3. General Information .........................1-1

II. DESCRIPTION AND DATA.............1-11-4. Description .........................................1-11-5. Data .....................................................1-1

2. ENGINE ..........................................................2-1I. INTRODUCTION,

DESCRIPTION AND DATA.............2-12-1. Introduction .......................................2-12-2. General Description .........................2-12-3. Specifications and Data ..................2-2

II. ENGINE TUNE UP ANDADJUSTMENTS ...............................2-2

2-4. Description ........................................2-22-5. Exhaust Valve Clearance

Adjustment ........................................2-22-6. Fuel Injector Timing .........................2-32-7. Governor Adjustments .....................2-4

III. ENGINE REMOVAL,CLEANING, INSPECTIONAND INSTALLATION .......................2-7

2-8. Removal and Cleaning ....................2-72-9. Inspection and Installation ..............2-9

IV. AIR INLET HOUSING ANDEXHAUST MANIFOLDS .................2-9

2-10. Air Inlet Housing ...............................2-92-11. Exhaust Manifolds ......................... 2-10

V. FUEL PUMP ANDCROSSOVER LINES .................... 2-12

2-12. Fuel Crossover Lines .................... 2-122-13. Fuel Pump ...................................... 2-12

VI. FUEL INJECTOR .......................... 2-152-14. General ........................................... 2-152-15. Fuel Injector Removal ................... 2-162-16. Fuel Injector Tests ........................ 2-162-17. Disassembly and Cleaning .......... 2-212-18. Inspection and Repair .................. 2-242-19. Fuel Injector Reassembly ............. 2-252-20. Fuel Injector Installation ............... 2-26

VII. ROCKER ARMS, PUSHRODS AND CAM FOLLOWER .... 2-27

2-21. General ........................................... 2-27

ChapterSection

Paragraph Page

2-22. Removal and Disassembly....... 2-282-23. Cleaning, Inspection and

Repair........................................... 2-292-24. Reassembly and Installation .... 2-33

VIII. CYLINDER HEADS ................... 2-352-25. General ........................................ 2-352-26. On-Vehicle Tests ....................... 2-352-27. Removal and Disassembly....... 2-362-28. Cleaning, Inspection and

Repair........................................... 2-392-29. Reassembly and Installation .... 2-41

IX. GOVERNOR AND DRIVESUPPORT . ................................. 2-47

2-30. General . ...................................... 2-472-31. Removal ...................................... 2-472-32. Disassembly and Cleaning ...... 2-502-33. Inspection and Repair .............. 2-502-34. Reassembly and Installation .... 2-50

X. LUBRICATION SYSTEM........... 2-542-35. General ........................................ 2-542-36. Changing Oil and Filters .......... 2-542-37. Oil Pan ......................................... 2-562-38. Oil Inlet Tube and Strainer ....... 2-582-39. Dipstick ........................................ 2-58

XI. FRONT TRUNNIONMOUNT, LOWER FRONTCOVER AND OIL PUMP .......... 2-60

2-40. Front Trunnion Mount ............... 2-602-41. Lower Front Cover .................... 2-602-42. Oil Pump...................................... 2-62

XII. FLYWHEEL ANDFLYWHEEL HOUSING ............. 2-63

2-43. Description ................................. 2-632-44. Flywheel Removal and

Disassembly ............................... 2-632-45. Flywheel Cleaning, Inspection

and Repair................................... 2-642-46. Flywheel Reassembly and

Installation ................................... 2-642-47. Flywheel Housing Removal

and Disassembly ....................... 2-652-48. Flywheel Housing Cleaning,

Inspection and Repair .............. 2-662-49. Flywheel Housing Reassembly

and Installation .......................... 2-66XIII. PISTONS AND

CONNECTING RODS .............. 2-682-50. Description ................................. 2-682-51. Removal and Disassembly ...... 2-692-52. Cleaning, Inspection and

Repair .......................................... 2-702-53. Reassembly and Installation ... 2-73

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TABLE OF CONTENTS (Continued)

ChapterSection

Paragraph Page

XIV. CAMSHAFTS, TIMINGGEARS AND IDLER GEAR.......... 2-75

2-54. Description ..................................... 2-752-55. Camshaft and Timing Gear

Removal and Disassembly .......... 2-752-56. Idler Gear Removal and

Disassembly ................................... 2-772-57. Cleaning, Inspection and

Repair .............................................. 2-772-58. Idler Gear Reassembly and

Installation ....................................... 2-812-59. Camshaft and Timing Gear

Reassembly and Installation ....... 2-81XV. CRANKSHAFT AND MAIN

BEARINGS ..................................... 2-822-60. Description ..................................... 2-822-61. Removal and Disassembly .......... 2-832-62. Cleaning, Inspection and

Repair .............................................. 2-852-63. Reassembly and Installation ....... 2-89

XVI. CYLINDER LINERS ...................... 2-912-64. Description and Removal ............. 2-912-65. Cleaning, Inspection and

Repair .............................................. 2-912-66. Installation ...................................... 2-92

XVII. CYLINDER BLOCK ....................... 2-942-67. Description and Removal ............. 2-942-68. Pressure Test and


Repair............................................... 2-952-70. Reassembly and Installation ....... 2-96

XVIII. BLOWER ASSEMBLY .................. 2-972-71. Description ..................................... 2-972-72. Inspection, Removal and



XIX. ENGINE TROUBLESHOOTINGCHART...........................................2-102

2-75. General .........................................2-1022-76. Engine Troubleshooting Chart ...2-102

3. FUEL SYSTEM ..................................3-1I. AIR CLEANER AND

INDICATOR ........................................3-13-1. Restriction Indicator .........................3-13-2. Air Cleaner .........................................3-2

II. FUEL TANK, FILTER ANDSTARTING AID ..................................3-5

3-3. Fuel Tank ...........................................3-53-4. Fuel Filter ...........................................3-53-5. Ether Starting Ad ..............................3-7

ChapterSection

Paragraph Page

III. ACCELERATOR LINKAGEAND PEDAL ......................................3-9

3-6. Accelerator Cable andEngine Linkage .................................3-9

3-7. Accelerator Pedal .............................3-94. EXHAUST SYSTEM .........................4-1

I. EXHAUST PIPE AND TEE ..............4-14-1. Removal and Cleaning ....................4-14-2. Inspection, Repair and

Installation ..........................................4-1II. MUFFLER AND EXHAUST

STACK ................................................4-24-3. Removal and Cleaning .....................4-24-4. Inspection, Repair and

Installation .........................................4-25. COOLING SYSTEM .........................5-1

I. FAN, HOSES ANDRADIATOR ........................................5-1

5-1. Flushing the Cooling System ..........5-15-2. Fan and Fan Drive ............................5-25-3. Coolant Hoses and Fittings ............5-35-4. Radiator and Fan Shroud ...............5-45-5. Overflow Recovery System .............5-6

II. THERMOSTATS, WATERPUMP, OIL COOLERAND FILTER ......................................5-9

5-6. Thermostats and CoolantPiping .................................................5-9

5-7. Water Pump.................................... 5-115-8. 011 Cooler ...................................... 5-135-9. Coolant Filter................................... 5-15

6. ELECTRICAL GROUP ....................6-1I. ALTERNATOR ..................................6-1

6-1. Description ........................................6-16-2. On-Vehicle Tests ...............................6-16-3. Removal and Disassembly..............6-26-4. Cleaning, Inspection and

Repair .................................................6-26-5. Reassembly and Installation ..........6-6

II. STARTER, SOLENOID AND70 AMP CIRCUIT BREAKER..........6-7

6-6. Solenoid and 70 AmpCircuit Breaker...................................6-7

6-7. Starter Motor ......................................6-8III. WARNING KITS.............................. 6-12

6-8. Engine Alarm and ShutdownKit...................................................... 6-12

6-9. Water Level Warning Kit .............. 6-14IV. INSTRUMENT PANEL AND

GAUGES.......................................... 6-166-10. Instrument Panel ........................... 6-16

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ChapterSection

Paragraph Page

6-11. Speedometer .................................. 6-176-12. Tachometer..................................... 6-18

V. EXTERIOR LIGHTS ...................... 6-196-13. Location ........................................... 6-196-14. Head Lights ..................................... 6-196-15. Clearance Lights ........................... 6-216-16. Front Turn and Stop Lights........... 6-216-17. Back Up and Tail Lights ............... 6-226-18. Side Marker Lights ........................ 6-236-19. License Plate Light ........................ 6-236-20. Flood Lights ..................................... 6-23

VI. ELECTRIC HORN ANDRELAY.............................................. 6-24

6-21. Introduction and Description......... 6-246-22. Horn Relay....................................... 6-246-23. Electric Horn ................................... 6-25

VII. TRAILER LIGHT CIRCUITS......... 6-266-24. Trailer Cable and Converter. ........ 6-266-25. Separate Lighting Cable .............. 6-27

VIII. BATTERY BOX ANDBATTERIES .................................... 6-28

6-26. Battery Box ..................................... 6-286-27. Batteries .......................................... 6-29

7. AUTOMATIC TRANSMISSION ..................7-1I. PREVENTIVE MAINTENANCE ......7-1

7-1. Oil Level .............................................7-17-2. Changing Oil and Filters .................7-17-3. Transmission Vent Assembly..........7-3

II. TROUBLESHOOTING .....................7-47-4. General ..............................................7-47-5. Troubleshooting Chart .....................7-5

III. ADJUSTMENTS ...............................7-57-6. Shift Speed Adjustments .................7-57-7. Gear Shift Adjustments ...................7-8

IV. TRANSMISSION REPAIR ..............7-97-8. Removal, Disassembly and

Cleaning..............................................7-97-9. Repair, Reassembly and

Installation ..........................................7-9V. EXTERNAL OIL FILTER .............. 7-10

7-10. Removal, Disassembly andCleaning .......................................... 7-10

7-11. Inspection, Repair, Reassemblyand Installation .............................. 7-11

VI. SHIFT LOCK .................................. 7-117-12. Removal and Disassembly ........... 7-117-13. Cleaning, Inspection and

Repair .............................................. 7-127-14. Reassembly and Installation ......... 7-13

VII. GEAR SHIFT................................... 7-137-15. Removal and Disassembly ........... 7-13

ChapterSection

Paragraph Page

7-16. Cleaning, Inspection andRepair .............................................. 7-15

7-17. Reassembly and Installation ........ 7-158. TRANSMISSION OVERHAUL ...................8-1

I. INTRODUCTION,DESCRIPTION AND DATA.............8-1

8-1. Introduction .......................................8-18-2. General Description .........................8-18-3. Specifications and Data ..................8-1

II. TROUBLESHOOTING ANDADJUSTMENTS ...............................8-1

8-4. Troubleshooting ................................8-18-5. Shift Speed Adjustments .................8-3

III. REMOVAL ANDDISASSEMBLY OFEXTERNAL PARTS ANDMAJOR PARTS GROUPS ..............8-4

8-6. Removal of External Partsand Major Parts Groups ..................8-4

8-7. Disassembly of Major PartsGroups ............................................ 8-15

IV. CLEANING, INSPECTIONAND REPAIR .................................. 8-28

8-8. Cleaning .......................................... 8-288-9. Inspection and Repair .................. 8-28

V. REASSEMBLING ANDINSTALLING MAJORPARTS GROUPS ANDEXTERNAL PARTS ...................... 8-35

8-10. Reassembling Major PartsGroups ............................................. 8-35

8-11. Installing Major Parts Groupsand External Parts ........................ 8-52

9. DRIVE SHAFT ...............................................9-1I. DESCRIPTION .................................9-1

9-1. Description ........................................9-1II. REPAIR ..............................................9-1

9-2. Removal and Disassembly .............9-19-3. Cleaning, Inspection and

Repair .................................................9-29-4. Reassembly and Installation ..........9-2

10. FRONT AXLE ............................................ 10-1I. INTRODUCTION,

DESCRIPTION AND DAT A.......... 10-110-1. Introduction .................................... 10-110-2. General Description ...................... 10-110-3. Specifications and Data ................ 10-1

II. OVERHAUL PROCEDURES....... 10-110-4. Removal and Disassembly .......... 10-110-5. Parts Cleaning ............................... 10-5

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10-6. Inspecting, Repairing andReplacing Parts ............................. 10-5

10-7. Reassembly and Installation ....... 10-511. REAR (DRIVE) AXLE ............................... 11-1

I. INTRODUCTION,DESCRIPTION, AND DATA......... 11-1

11-1. Introduction .................................... 11-111-2. General Description ...................... 11-111-3. Specifications and Data ............... 11-2

II. OVERHAUL PROCEDURES....... 11-211-4. Disassembly ................................... 11-211-5. Parts Cleaning ............................... 11-711-6. Inspecting, Repairing, and

Replacing Parts ............................. 11-811-7. Reassembly .................................... 11-9

12. AIR SYSTEM ............................................. 12-1I. INTRODUCTION,

DESCRIPTION AND DATA.......... 12-112-1. Introduction .................................... 12-112-2. General Description ...................... 12-112-3. Specifications and Data ............... 12-6

II. AIR COMPRESSOR ANDCOMPONENTS ............................. 12-7

12-4. Air Strainer....................................... 12-712-5. Alcohol Evaporator ........................ 12-912-6. Air Compressor .............................. 12-912-7. Air Compressor Governor ..........12-13

III. AIR TANKS ANDAUTOMATIC DRAIN VALVE

12-8. Air Tanks .......................................12-1412-9. Automatic Drain Valve ................12-15

IV. CHECK VALVES .........................12-1612-10.Check Valve .................................12-1612-11.Double Check Valve ....................12-17

V. BRAKE TREADLE ANDQUICK RELEASE VALVES........12-19

12-12.Brake Treadle Valve ....................12-1912-13.Quick Release Valves ................12-20

VI. BRAKE CONTROL PANELAND TRAILER HANDBRAKE CONTROL ......................12-21

12-14.Brake Control Panel ....................12-1412-15.Trailer Hand Brake

Control Valve.................................12-24VII. FIFTH WHEEL UNLATCH

CYLINDER AND VALVE ............12-2412-16.Fifth Wheel Unlatch Cylinder......12-2412-17.Fifth Wheel Unlatch Valve ..........12-25

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VIII. AIR HORN ....................................12-2612-18.Removal and Disassembly ........12-2612-19.Cleaning, Inspection and

Repair ............................................12-2612-20.Reassembly, Installation and

Adjustment ...................................12-2613. WHEELS AND TIRES .............................. 13-1

I. DESCRIPTION .............................. 13-113-1. Description ..................................... 13-1

II. REPAIR ........................................... 13-113-2. Removal and Dismounting .......... 13-113-3. Cleaning, Inspection and

Repair .............................................. 13-113-4. Mounting and Installation ............. 13-2

14. STEERING GROUP .................................. 14-1I. STEERING COLUMN .................... 14-1

14-1. Description ..................................... 14-114-2. Removal and Disassembly .......... 14-114-3. Cleaning, Inspection and


II. STEERING UNIVERSALJOINT ASSEMBLY......................... 14-3

14-5. Removal and Disassembly .......... 14-314-6. Cleaning, Inspection and


III. STEERING GEAR ......................... 14-414-8. Removal and Disassembly .......... 14-414-9. Cleaning, Inspection and

Repair .............................................. 14-614-10.Reassembly and Installation ....... 14-6

IV. POWER STEERING PUMP.......... 14-714-11.Description ..................................... 14-714-12.Removal and Disassembly .......... 14-714-13.Cleaning, Inspection and


V. FILTER ASSEMBLY ...................14-1014-15.Removal and Disassembly ........14-1014-16.Cleaning, Inspection and

Repair ............................................14-1014-17.Reassembly and Installation ......14-10

VI. BALL SOCKETS...........................14-1114-18.Description, Removal and

Disassembly..................................14-1114-19.Cleaning, Inspection, Repair,

Reassembly and Installation ......14-11

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15. FRAME AND DECK .................................. 15-1I. MAIN FRAME, BUMPER

AND GRILLE GUARD ................... 15-115-1. Description ...................................... 15-115-2. Removal and Disassembly .......... 15-115-3. Cleaning, Inspection and


II. REAR PLATFORM ANDCROSS TIE ASSEMBLY............... 15-4



III. DECK, ENGINE HOOD,SIDE STEP AND MIRROR ........... 15-7

15-8. Description ..................................... 15-715-9. Removal and Disassembly .......... 15-715-10.Cleaning, Inspection and


IV. SPARE TIRE CARRIERAND MUD FLAP ............................ 15-9

15-12.Removal and Disassembly .......... 15-915-13.Cleaning, Inspection and

Repair ............................................15-1015-14.Reassembly and Installation ......15-10

16. FIFTH WHEEL AND BOOM..................... 16-1I. INTRODUCTION,

DESCRIPTION AND DATA.......... 16-116-1. Introduction .................................... 16-116-2. General Description ...................... 16-116-3. Specifications and Data ............... 16-2

II. FIFTH WHEEL............................................ 16-216-4. Removal and Disassembly .......... 16-216-5. Cleaning, Inspection and


III. FIFTH WHEEL BOOMAND PLATFORM............................ 16-4



17. FIFTH WHEEL HYDRAULICS ................ 17-1I. DESCRIPTION .............................. 17-1

17-1. Description ..................................... 17-1

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II. HYDRAULIC FILTER,RESERVOIR AND PUMP ............ 17-2

17-2. Hydraulic Filter................................ 17-217-3. Hydraulic Reservoir ....................... 17-317-4. Hydraulic Pump.............................. 17-4

III. POWER TAKE-OFF,HYDRAULIC CYLINDERAND CONTROL VALVE ............... 17-6

17-5. Power Take-off .............................. 17-617-6. Hydraulic Cylinder ......................... 17-817-7. Hydraulic Control Valve ................ 17-9

18. OPERATOR'S CAB .................................. 18-1I. INTRODUCTION,

DESCRIPTION AND DATA.......... 18-118-1. Introduction ..................................... 18-118-2. Description ...................................... 18-118-3. Specifications and Data ................ 18-2

II. CAB DOOR AND SEAT ............... 18-218-4. Cab Door ......................................... 18-218-5. Seat .................................................. 18-4

III. REAR WINDOW SCREEN,SIDE MIRROR ANDSUN VISOR ...................................18-10

18-6. Rear Window Screen ..................18-1018-7. Side Mirror......................................18-1118-8. Sun Visor........................................18-12

IV. WINDSHIELD, WINDOWSAND UPHOLSTERY....................18-12

18-9. Windshield and Windows ...........18-1218-10.Headliner, Floor Mat and

Upholstery .....................................18-15V. WINDSHIELD WASHER

AND WIPER .................................18-1618-11. Windshield Washer ...................18-1618-12. Windshield Wiper .......................18-18

VI. DEFROSTER, HEATERSAND VENT.....................................18-19

18-13.Defroster and Heater ..................18-1918-14.Auxiliary Heater ...........................18-2118-15.Cab Vent .......................................18-24

19. CAB TILT HYDRAULICS ........................ 19-1I. DESCRIPTION .............................. 19-1

19-1. Description ...................................... 19-1II. HYDRAULIC LATCHES ............... 19-1

19-2. Removal and Cleaning .................. 19-119-3. Inspection, Repair and

Installation ...................................... 19-1III. HYDRAULIC PUMP ....................... 19-1

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IV. HYDRAULIC CYLINDER ............. 19-3

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LIST OF ILLUSTRATIONS

Number Title Page Number Title Page2-1. Engine Assembly ..................................... 2-1 2-48. Seating of Exhaust Valve Bridge2-2. Rocker Arm Cover Removal ..................... 2-3 on Valve Stems................................... 2-352-3. Exhaust Valve Clearance Adjustment ........ 2-3 2-49. Reading Manometer Scale......................... 2-362-4. Fuel Injector Timing Adjustment ................ 2-4 2-50. Cylinder Head Removal ............................ 2-372-5. Governor Adjustment Points ..................... 2-5 2-51. Cam Follower Removal.............................. 2-372-6. Positioning Injector Rack Control Levers .... 2-6 2-52. Injector Control Tube Disassembly ............ 2-382-7. Governor Stop Lever Adjustment .............. 2-7 2-53. Exhaust Valve Spring Removal .................. 2-382-8. Engine Oil Drain Plug Location ................. 2-8 2-54. Fuel Injector Tube Removal ....................... 2-382-9. Engine Lifter Brackets .............................. 2-8 2-55. Exhaust Valve Guide Removal ................... 2-392-10. Engine Mounts and Hardware ................... 2-8 2-56. Exhaust Valve Seat Insert Removal ........... 2-392-11. Engine Belt Sets ...................................... 2-8 2-57. Cylinder Head Disassembly ....................... 2-402-12. Engine Dipstick ........................................ 2-9 2-58. Cylinder Head Prepared for Leak Test ........ 2-412-13. Air Inlet Housing Removal ........................ 2-10 2-59. Checking Bottom of Cylinder Head2-14. Exhaust Manifold Removal ....................... 2-10 for Warpage ....................................... 2-412-15. Fuel Crossover Lines ............................... 2-12 2-60. Minimum Distance Between Top and2-16. Fuel Pump Pressure Test ......................... 2-12 Bottom Faces of Cylinder Head ........... 2-412-17. Fuel Pump Flow Test ............................... 2-13 2-61. Alignment of Water Nozzles in2-18. Fuel Pump and Mounting Plate Removal ... 2-13 Cylinder Head .................................... 2-412-19. Fuel Pump and Gear Adapter Removal ..... 2-13 2-62. Installing Exhaust Valve Seat Insert ........... 2-422-20. Fuel Pump Disassembly ........................... 2-14 2-63. Installing Exhaust Valve Guide .................. 2-422-21. Removing Fuel Pump Oil Seals ................ 2-14 2-64. Exhaust Valve and Valve Seat2-22. Fuel Pump Inner Oil Seal Installation ......... 2-15 Insert Grinding Dimensions ................. 2-432-23. Fuel Pump Outer Oil Seal Installation ........ 2-15 2-65. Checking Valve Seat Insert Concentricity.... 2-432-24. Fuel Injector Component Identification ....... 2-15 2-66. Fuel Injector Tube Installation .................... 2-442-25. Fuel Injector Metering ............................... 2-16 2-67. Flaring Lower End of Fuel Injector Tube ..... 2-442-26. Rocket Arm Bolts and................................ 2-68 Reaming Fuel Injector Tube for

Injector Clamp Removal ....................... 2-17 Injector Body and Spray Tip ................ 2-442-27. Fuel Injector Removal .............................. 2-17 2-69. Checking Location of Fuel Injector2-28. Checking Rack and Plunger Freeness ....... 2-17 Spray Tip ........................................... 2-452-29. Fuel Injector Mounted in Test Stand .......... 2-18 2-70. Reaming Fuel Injector Tube for2-30. Injector Follower Stop Pin Removal ........... 2-19 Injector Nut ........................................ 2-452-31. Checking Needle Valve Lift ....................... 2-20 2-71. Checking Cam Follower-to-Guide Clearance 2-452-32. Position of Fuel Flow Pipes ....................... 2-20 2-72. Positioning Cam Follower Guides .............. 2-462-33. Placing Fuel Injector 2-73. Installing Seal Rings and

in Typical Comparator .......................... 2-21 Compression Gaskets .............................. 2-462-34. Fuel Injector Disassembly ......................... 2-22 2-74. Cylinder Head Bolt Tightening Sequence ... 2-472-35. Removing Spray Tip from Injector Nut ....... 2-22 2-75. Governor and Drive Support Removal ........ 2-482-36. Cleaning Injector Spray Tip ....................... 2-33 2-76. Governor Control Link Removal ................. 2-482-37. Cleaning Injector Spray Tip Orifices .......... 2-23 2-77. Governor Removal ................................... 2-492-38. Cleaning Injector Body Ring ...................... 2-23 2-78. Governor Disassembly (2 sheets) .............. 2-512-39. Cleaning Injector Nut Spray Tip Seat ......... 2-23 2-79. Removing Governor Cover Needle Bearings 2-532-40. Cleaning Injector Nut Lower End ............... 2-24 2-80. Removing Governor Operating Fork .......... 2-532-41. Sealing Surfaces Which May Require Lapping 2-25 2-81. Removing Governor Control Link Bearings . 2-532-42. Injector Rack, Gear, Spray Tip 2-82. Removing Governor Weight Shaft from

and Valve Reassembly ........................ 2-26 Weight Carrier .................................... 2-532-43. Checking Fuel Injector Spray Tip 2-83. Installing Weight Carrier on Shaft .............. 2-54

for Concentricity .................................. 2-27 2-84. Installing Drive Support Gear ..................... 2-542-44. Rocker Arm, Shaft and Push Rod Removal 2-28 2-85. Checking Clearance Between Drive Support2-45. Rocker Arm, Push Rod and Gear and Governor Weights ................ 2-54

Cam Follower Disassembly .................. 2-29 2-86. Engine Oil Filter ........................................ 2-552-46. Cam Roller Wear and Clearance ............... 2-33 2-87. Engine Oil Filter Adapters ......................... 2-562-47. Cam Follower Roller Pin Removal 2-88. External Oil Filter ...................................... 2-57

and Installation .................................... 2-34 2-89. External Oil Filter Hoses and Mounting ...... 2-57

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TM 9-2320-277-14&PLIST OF ILLUSTRATIONS (Continued)

Number Title Page Number Title Page

2-90. Oil Pan Removal....................................... 2-58 2-137. Crankshaft Timing Gear Removal .............. 2-852-91. Oil Inlet Tube and Strainer Removal .......... 2-59 2-138. Oil Pump Drive Gear Removal ................... 2-852-92. Dipstick Removal ...................................... 2-60 2-139. Crankshaft Inspection Details .................... 2-862-93. Crankshaft Pulley and Trunnion................. 2-140. Main Bearing Shell Measurement Diagram.. 2-88

Mount Removal...................................... 2-60 2-141. Measuring Main Bearing Shell Thickness ... 2-892-94. Lower Front Cover Removal ...................... 2-61 2-142. Crankshaft Timing Gear Installation ........... 2-892-95. Lower Front Cover Disassembly ................ 2-61 2-143. Checking Crankshaft End Play .................. 2-902-96. Installing Lower Front Cover...................... 2-62 2-144. Cylinder Liner Removal ............................. 2-912-97. Oil Pump Removal and Disassembly ......... 2-62 2-145. Cylinder Liner Measurement Diagram ........ 2-922-98. Inspecting Oil Pump Rotor......................... 2-63 2-146. Checking Cylinder Liner Bore .................... 2-922-99. Installing Oil Pump Drive Gear ................... 2-63 2-147. Clamping Cylinder Liner min Bore .............. 2-922-100. Scuff Plate Removal ................................. 2-64 2-148. Installing Piston and Connecting Rod in2-101. Flywheel Removal..................................... 2-64 Cylinder Liner ..................................... 2-932-102. Flywheel and Flywheel Housing Removal .. 2-65 2-149. Installing Piston, Connecting Rod and2-103. Checking Flywheel to Flywheel .................. Cylinder Liner Assembly ..................... 2-94

Housing Runout .................................... 2-65 2-150. Cylinder Block Prepared for2-104. Installing Oil Seal in Flywheel Housing ...... 2-66 Pressure Test .................................... 2-942-105. Positioning Oil Seal on Grooved Crankshaft 2-67 2-151. Cylinder Block Disassembly ...................... 2-952-106. Flywheel Housing Installation..................... 2-67 2-152. Cylinder Block Measurement Diagram ....... 2-962-107. Flywheel Housing Bolt Tightening Sequence 2-68 2-153. Blower Removal ....................................... 2-972-108. Checking Flywheel to Flywheel .................. 2-154. Lifting Blower from Engine ........................ 2-98

Housing Concentricity ............................ 2-68 2-155. Removing Governor from Blower ............... 2-982-109. Piston and Connecting Rod Removal ........ 2-69 2-156. Blower Disassembly .................................. 2-992-110. Piston Ring Removal................................. 2-70 2-157. Blower Gear Removal ............................... 2-1002-111. Piston and Connecting Rod Disassembly .. 2-70 2-158. Blower Rotor Timing and Clearance2-112. Piston Pin Removal................................... 2-71 Diagram.............................................. 2-1002-113. Measuring Piston to Cylinder..................... 2-159. Measuring Rotor Lobe-to-Housing Clearance 2-101

Liner Clearance .................................... 2-71 2-160. Measuring Rotor Lobe-to-End2-114. Measuring Piston Ring Gap ....................... 2-72 Plate Clearance .................................. 2-1012-115. Measuring Piston Ring Side Clearance ...... 2-72 2-161. Inserting Blower Drive Cam in Spring ......... 2-1012-116. Removing Piston Pin Bushing.................... 2-73 2-162. Blower and Governor Gasket and2-117. Spray Nozzle Removal.............................. 2-73 Seal Location ..................................... 2-1022-118. Installing Piston Pin Retainer..................... 2-73 3-1. Restriction Indicator Removal .................... 3-12-119. Piston Assembly Cutaway View ................. 2-74 3-2. Air Cleaner Operation ............................... 3-22-120. Tapered (Fire) Compression Ring ............. 2-74 3-3. Air Cleaner Removal ................................. 3-32-121. Removing Parts from Engine Upper 3-4. Air Cleaner Disassembly ........................... 3-4

Front Cover ........................................... 2-75 3-5. Air Cleaner Valve ..................................... 3-42-122. Camshaft Pulley Removal.......................... 2-76 3-6. Fuel Tank Removal .................................. 3-62-123. Engine Upper Front Cover Removal .......... 2-76 3-7. Fuel Filter Removal .................................. 3-72-124. Camshaft Front Oil Slinger and 3-8. Ether Cylinder Removal ............................ 3-8

Seals Removal ...................................... 2-76 3-9. Starting Aid Disassembly .......................... 3-82-125. Camshaft Timing Gear Removal ............... 2-77 3-10. Accelerator Cable and Engine Linkage ...... 3-102-126. Camshaft Gear Removal ........................... 2-78 3-11. Accelerator Pedal Disassembly ................. 3-112-127. Engine Upper Front Cover Exploded View.. 2-78 4-1. Exhaust Pipe and Tee Removal ................ 4-12-128. Idler Gear Removal and Disassembly ........ 2-78 4-2. Muffler and Exhaust Stack Removal .......... 4-22-129. Camshaft Bearing Removal ....................... 2-80 5-1. Engine Coolant Draincocks ....................... 5-12-130. Camshaft Bearing Installation .................... 2-80 5-2. Reverse Flow Radiator Flushing (typical) .... 5-12-131. Idler Gear Hub Installation ......................... 2-81 5-3. Reverse Flow Engine Flushing (typical) ...... 5-22-132. Gear Train Timing Mark Alignment ............ 2-81 5-4. Fan and Fan Drive Removal ...................... 5-22-133. Camshaft Timing Gear Installation ............ 2-82 5-5. Fan and Fan Drive Disassembly ................ 5-32-134. Removing Main Bearing Cap Stabilizers .... 2-83 5-6. Radiator Hoses and Fittings ...................... 5-42-135. Crankshaft Disassembly............................ 2-84 5-7. Radiator and Fan Shroud Removal ............ 5-52-136. Rear Main Bearing Cap and Bearing ......... 2-84 5-8. Radiator Disassembly ............................... 5-7

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LIST OF ILLUSTRATIONS (Continued)


5-9. Radiator Overflow Kit Removal .................. 5-8 7-1. Transmission Dipstick Location ................. 7-15-10. Thermostats and Coolant Piping, Removal . 7-2. Oil Pan Removal ...................................... 7-2

and Disassembly .................................. 5-10 7-3. Governor Oil Filter .................................... 7-25-11. Thermostat Test ...................................... 5-11 7-4. External Oil Filter ...................................... 7-35-12. Water Pump Removal ............................. 5-11 7-5. Transmission Vent Assembly .................... 7-45-13. Water Pump Disassembly ........................ 5-12 7-6. Oil Pressure Check Points ........................ 7-55-14. Oil Cooler Removal and Disassembly ........ 5-13 7-7. Shift Signal Valve Adjustments .................. 7-85-15. Oil Cooler Leak Test ................................ 5-14 7-8. Modulator Valve Adjustment ...................... 7-85-16. Coolant Filter Removal ............................. 5-15 7-9. Transmission Removal ............................. 7-106-1. Voltage Adjustment Cap ........................... 6-1 7-10. Transmission Sling and Retaining Strap ..... 7-116-2. Electrical Wiring Diagram ......................... 6-3 7-11. External Oil Filter Removal ........................ 7-116-3. Alternator and Brackets Removal .............. 6-4 7-12. Shift Lock Removal ................................... 7-126-4. Alternator Disassembly ............................. 6-4 7-13. Shift Lock Cylinder Location ....................... 7-136-5. Checking Rotor Windings for Shorts........... 7-14. Gear Shift Control, Removal and

and Opens ........................................... 6-5 Disassembly ...................................... 7-146-6. Checking Stator for Grounded.................... 8-1. Preparing Transmission for Disassembly ... 8-5

Field Windings ...................................... 6-5 8-2. Removing Torque Converter ..................... 8-56-7. Diode Trio Test ........................................ 6-5 8-3 Transmission Housing, Oil Filter and6-8. Rectifier Bridge Test ................................. 6-6 Oil Pan Group .................................... 8-66-9. Regulator Connector Body Test ................ 6-6 8-4. Control Valve Group ................................. 8-76-10. Slip Ring End Bearing and Seal Locations . 6-6 8-5. Oil Pump and Front Support Group............. 8-96-11. Drive End Bearing Assembly .................... 6-7 8-6. Removing Oil Pump and Front6-12. Solenoid and 70 Amp Circuit Breaker ........ 6-8 Support Assembly .............................. 8-96-13. Starter Motor Removal and Disassembly.... 6-9 8-7. Forward Clutch and Turbine Shaft Group .... 8-106-14. Starter Bench Test Circuit ......................... 6-10 8-8. Fourth Clutch Group ................................. 8-116-15. Checking Field Windings for Opens............ 8-9. Third Clutch, Center Support and

and Grounds ............................................ 6-11 Second Clutch Groups ........................ 8-126-16. Checking for Grounded Armature Windings 6-11 8-10. Removing Center Support Assembly ......... 8-136-17. Circuit for Checking Pinion Clearance ....... 6-12 8-11. Main Shaft and Gear Unit Group................. 8-146-18. Pinion Clearance Adjustment .................... 6-12 8-12. Removing Main Shaft and Gear Unit .......... 8-156-19. Engine Alarm and Shutdown Kit................. 6-13 8-13. First Clutch Group .................................... 8-166-20. Water Level Warning Kit ........................... 6-14 8-14. Governor and Rear Cover Group ............... 8-176-21. Water Level Sensor Disassembly .............. 6-15 8-15. Low Planetary, Low Clutch and Adapter6-22. Instrument Panel and Gauges .................. 6-16 Housing Group ................................... 8-186-23. Speedometer Removal ............................. 6-17 8-16. Checking Converter End Play Prior6-24. Tachometer Removal ............................... 6-18 to Disassembly ................................... 8-196-25. Wiring Harnesses and Lights .................... 6-19 8-17. Converter Cover and Torque6-26. Head Light Removal and Disassembly ...... 6-20 Converter Group.................................. 8-206-27. Head Light Aiming Pattern......................... 6-21 8-18. Modulated Lockup Valve ........................... 8-216-28. Clearance Light Removal and Disassembly 6-21 8-19. Low Shift Valve ........................................ 8-216-29. Front Turn and Stop Light Removal ........... 6-21 8-20. Removing Valve Retaining Snap Rings6-30. Back Up and Tail Light Removal ............... 6-22 from Front Support ................................... 8-236-31. Side Marker Light Removal ....................... 6-23 8-21. Removing Converter Pressure Regulator6-32. License Plate light Removal ...................... 6-23 Valve Guide Pin ................................. 8-236-33. Horn Circuit Schematic ............................. 6-24 8-22. Removing Forward Clutch Spring6-34. Horn Relay Removal ................................ 6-25 Retainer Snapring ..................................... 8-246-35. Electric Horn Removal .............................. 6-25 8-23. Removing Fourth Clutch Spring6-36. Horn Current Adjustment Circuit ................ 6-25 Retainer Snapring ..................................... 8-246-37. Trailer Cable and Converter ...................... 6-26 8-24. Removing Dust Shield and Oil Seal6-38. Separate Lighting Cable ........................... 6-27 from Rear Cover ................................. 8-266-39. Battery Box and Batteries ......................... 6-28 8-25. Removing Spring Retainer Snapring .......... 8-266-40. Specific Gravity Test ................................ 6-29 8-26. Removing Snapring and First Clutch6-41. Specific Gravity Correction Scale .............. 6-30 Spring Retainer .................................. 8-27

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8-27. Measuring Clutch Plate Cones .................. 8-32 11-4. Rear Axle Shafts, Hubs and Drums ........... 11-48-28. Pinion Pin Swaging (Staking) Pattern ........ 8-35 11-5. Differential Carrier Assembly ..................... 11-68-29. Governor Support Pin Location ................. 8-36 11-6. Checking Preload of Pinion Shaft Bearings 11-118-30. Drain Tube, Ball Bearing, Oil Seal, and....... 11-7. Checking Preload of Input Pinion Bearings.. 11-11

Dust Shield Installation ............................. 8-36 11-8. Setup for Checking Gear Backlash ............ 11-128-31. Installing Governor Filter ........................... 8-37 11-9. Worn Tooth Sections and Matching ........... 11-128-32. Installing Cup Plug in Output Shaft ............ 8-37 11-10. Pinion and Bevel Gear Tooth Contact ........ 11-148-33. Installing Needle Roller Bearing in.............. 12-1. Tractor Air System Components ................ 12-2

Output Shaft ............................................ 8-38 12-2. Air Compressor Operation ......................... 12-38-34. Installing Front Bushing in Sun................... 12-3. Air Compressor Governor Operation .......... 12-3

Gear Shaft ............................................... 8-38 12-4. Air Tanks, Hoses and Fittings .................... 12-48-35. Installing Rear Bushing in Sun................... 12-5. Automatic Drain Valve Operation ............... 12-4

Gear Shaft ............................................... 8-38 12-6. Trailer Hand Brake Control Operation ........ 12-58-36. Installing Self-Locking Retainer Ring ......... 8-42 12-7. Brake Treadle Valve Operation .................. 12-58-37. Measuring Fourth Clutch Clearance .......... 8-42 12-8. Air Strainer Removal and Disassembly ...... 12-78-38. Measuring Forward Clutch Running Clearance 8-43 12-9. Alcohol Evaporator Removal and8-39. Installing Oil Pump Body Oil Seal .............. 8-44 Disassembly ...................................... 12-88-40. Assembling Support on Oil Pump Body ..... 8-44 12-10. Air Compressor Removal .......................... 12-108-41. Installing Needle Bearing Assembly min ..... 12-11. Air Compressor Disassembly ..................... 12-11

Converter Ground Sleeve ...................... 8-46 12-12. Governor Disassembly .............................. 12-148-42. Installing Regulator Valve Guide in............. 12-13. Air Tank Removal ..................................... 12-15

Front Support ....................................... 8-46 12-14. Automatic Drain Valve Disassembly .......... 12-168-43. Control Valve Bore Locations .................... 8-47 12-15. Check Valve Disassembly ......................... 12-168-44. Installing Shift and Modulator Valves min.... 12-16. Double Check Valve Removal and

Control Valve Body ............................... 8-47 Disassembly ...................................... 12-178-45. Installing Low Shift Valve .......................... 8-48 12-17. Treadle Valve Disassembly ....................... 12-188-46. Installing Stator Needle Roller.................... 12-18. Treadle Valve Hoses and Fittings .............. 12-19

Bearing Assembly ................................. 8-49 12-19. Quick Release Valve Removal and8-47. Stator Needle Roller Bearing Installation..... 8-50 Disassembly ...................................... 12-208-48. Installing Freewheel Roller Race ............... 8-50 12-20. Brake Control Panel Removal ................... 12-218-49. Spring and Roller Installation min............... 12-21. Parking Brake and Emergency Release

Cam Pockets ........................................ 8-50 Valve Disassembly ............................. 12-228-50. Installing Bushing in Converter................... 12-22. Trailer Hand Brake Valve Disassembly ...... 12-23

Pump Cover ......................................... 8-51 12-23. Unlatch Cylinder Removal ......................... 12-248-51. Installing Selector Shaft Seal in.................. 12-24. Unlatch Cylinder Air Breather .................... 12-24

Transmission Housing ........................... 8-52 12-25. Unlatch Valve Removal and Disassembly .. 12-258-52. Compressing Center Support for Selection. 12-26. Air Horn Removal and Disassembly ........... 12-27

of Snap Ring ......................................... 8-53 13-1. Front Wheel and Tire Removal .................. 13-18-53. Checking Second Clutch Running Clearance 8-53 13-2. Tire Dismounting ...................................... 13-28-54. Determining Low Clutch Running Clearance 8-54 14-1. Steering Column Removal and Disassembly 14-28-55. Measuring First Clutch Running Clearance. 8-55 14-2. Steering Joint Disassembly ....................... 14-48-56. Measuring Third Clutch Running Clearance 8-56 14-3. Steering Gear Disassembly ....................... 14-58-57. Checking Torque Converter Seating Height 8-58 14-4. Power Steering Pump Operation ............... 14-79-1. Drive Shaft Removal and Disassembly ...... 9-1 14-5. Power Steering Hydraulics ........................ 14-810-1. Front Axle Hub and Drum ......................... 10-2 14-6. Power Steering Pump Disassembly ........... 14-910-2. Front Axle Assembly ................................ 10-3 14-7. Filter Disassembly .................................... 14-1110-3. Front Axle Brakes .................................... 10-4 14-8. Ball Sockets Removal and Disassembly...... 14-1210-4. Brake Air Chamber ................................... 10-4 15-1. Main Frame, Rear Cab Guard and10-5. Bushing Installation Tool ........................... 10-6 Radiator Grille .................................... 15-210-6. Bushing Reamers .................................... 10-6 15-2. Bumper and Grille Guard .......................... 15-310-7. Checking End Play of Knuckles ................ 10-7 15-3. Rear Platform Removal and Disassembly ... 15-411-1. Rear Axle Assembly ................................. 11-1 15-4. Transmission Sling Attachment ................. 15-511-2. Brake Chamber ........................................ 11-3 15-5. Cross Tie Removal and Disassembly ......... 15-611-3. Rear Axle Brakes ..................................... 11-4 15-6. Deck and Engine Hood ............................. 15-7x

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15-7. Side Step Removal ................................... 15-8 18-8. Removing Back Angle Adjustment15-8. Mirror Removal and Disassembly .............. 15-8 Mechanism ........................................ 18-715-9. Spare Tire Carrier .................................... 15-9 18-9. Shock Absorber Removal .......................... 18-815-10. Mud Flap Removal ................................... 15-9 18-10. Seat Suspension Disassembly .................. 18-916-1. Fifth Wheel Operation ............................... 16-1 18-11. Adjuster Stud Installation ........................... 18-1016-2. Fifth Wheel Dimensions ............................ 16-2 18-12. Rear Window Screen Removal16-3. Fifth Wheel Removal ................................ 16-2 and Disassembly ................................ 18-1116-4. Fifth Wheel Shaft and Brackets ................. 16-2 18-13 Side Mirror Removal and Disassembly ....... 18-1116-5. Fifth Wheel Disassembly ........................... 16-3 18-14. Sun Visor Removal and Disassembly ......... 18-1216-6. Fifth Wheel Boom and Platform.................. 16-4 18-15. Typical Glass Installation .......................... 18-1316-7. Fifth Wheel Boom Removal ...................... 16-5 18-16. Cab Windshield and Windows ................... 18-1317-1. Hydraulic Schematic ................................. 17-1 18-17. Right Side Window Removal and17-2. Filter Removal and Disassembly................ 17-2 Disassembly ...................................... 18-1417-3. Hydraulic Reservoir Removal .................... 17-3 18-18. Headliner, Floor Mat and17-4. Hydraulic Pump Removal ......................... 17-4 Acoustical Upholstery ......................... 18-1617-5. Hydraulic Pump Disassembly ................... 17-5 18-19. Windshield Washer Removal and Disassembly 18-1717-6. Power Take-Off Removal and Disassembly 17-7 18-20. Windshield Wiper Removal and Disassembly 18-1817-7. Hydraulic Cylinder Removal and Disassembly 17-9 18-21. Defroster and Heater Removal .................. 18-2017-8. Hydraulic Control Valve Removal .............. 17-10 18-22. Defroster Disassembly............................... 18-2117-9. Hydraulic Valve Disassembly .................... 17-11 18-23. Heater Disassembly .................................. 18-2218-1. Operator's Cab ........................................ 18-1 18-24. Auxiliary Heater Removal and Disassembly 18-2318-2. Door Stop Removal .................................. 18-2 18-25. Cab Vent Removal ................................... 18-2418-3. Cab Door Removal and Disassembly ......... 18-3 19-1. Cab Tilt Hydraulics ................................... 19-218-4. Seat and Seat Belt Removal ..................... 18-4 19-2. Hydraulic Latch Removal .......................... 19-318-5. Upper Seat Disassembly .......................... 18-5 19-3. Hydraulic Pump Disassembly .................... 19-418-6. Rear Bracket Assembly Shaft Location ...... 18-6 19-4. Hydraulic Cylinder Disassembly ................ 19-518-7. Seat Latch Bar Removal ........................... 18-6

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LIST OF TABLES


1-1. Standard Torque Data ............................... 1-2 8-4. Springs Data ............................................. 8-332-1. Engine Specifications and Data .................. 2-2 8-5. Transmission Assembly Torque Values ........ 8-452-2. Engine Assembly Torque Values ................. 2-11 8-6. Spacer Selection Chart ............................... 8-512-3. Engine Wear Limits, Fits and Tolerances ..... 2-30 8-7. Snap Ring Selection Chart........................... 8-532-4. Cylinder Compression Test Chart ................ 2-36 10-1. Front Axle Specifications and Data .............. 10-12-5. Crankshaft Journal Dimensions .................. 2-87 10-2. Torque Specifications for Screws and Nuts .... 10-82-6. Main Bearing Shell Thickness ..................... 2-88 11-1. Rear Axle Specifications and Data ............... 11-22-7. Crankshaft Thrust Washer Thickness .......... 2-89 11-2. Torque Specifications for Screws and Nuts .... 11-102-8. Engine Troubleshooting Chart .................... 2-103 11-3. Nut Torque Values and Press Loads6-1. Starter Bench Test Troubleshooting Chart .... 6-10 Required to Preload Input Pinion Bearings 11-126-2. Specific Gravity and Battery Charge ............ 6-29 12-1. Air System Specifications and Data .............. 12-67-1. Transmission Shift Speeds ......................... 7-4 12-2. Air Compressor Wear Limits, Fits7-2. Oil Pressure Specifications ......................... 7-5 and Tolerances .................................... 12-127-3. Transmission Troubleshooting Chart ........... 7-6 12-3. Air Compressor Assembly Torque Values ..... 12-138-1. Transmission Specifications and Data ......... 8-2 16-1. Fifth Wheel Specifications and Data ............. 16-28-2. Output Shaft Speeds at Shift Points.............. 8-4 18-1. Specifications and Data............................... 18-28-3. Transmission Wear Limits Data .................. 8-29

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CHAPTER 1

INTRODUCTION, DESCRIPTION AND DATA


1-1. SCOPE AND RELATED PUBLICATIONS.

a. Scope.

This Maintenance Manual includes repair and overhaulinstructions for the M878 Yard Type Tractor, ModelCommando Fifty, manufactured by the Ottawa TruckDivision of G + W, Ottawa, Kansas. Throughout thismanual, the Model Commando Fifty tractor will bereferred to as the vehicle or the tractor.

b. Related Publications.

Operation and periodic service of the tractor aredescribed in the separate Operator's Manual. Repairparts are listed and illustrated in the separate RepairParts Manual.

1-2. INTRODUCTION.

a. Manual Coverage.

Overhaul information and procedures which arestandard for heavy vehicle maintenance personnel mayor may not be covered in this manual in instances whereinformation or procedures have not been provided,maintenance shall be performed in a manner consistentwith good mechanical practice.

b. Procedures.

Where text describes procedures of a non-critical nature(improbability of danger to personnel or damage toequipment), it is intended as a guide. Workmanshipover and above that described is encouraged. Wherefrequency intervals, dimensional limits, tolerances, etc.are cited, deviations from the text are not permittedexcept in emergencies and with the approval ofsupervisory personnel.

1-3. GENERAL INFORMATION.

a. Format.

This manual is divided into nineteen separate chaptersas outlined in the Table of Contents. The introductoryparagraph, if applicable, of each chapter contains a briefsummary of the contents of the chapter.

b. Table of Contents.

The Table of Contents lists all chapter headings, sectionheadings and primary paragraph headings. Theseheadings are referenced, by chapter, section, orparagraph number and page number, to the areas in themanual where information covering the subject may belocated.

c. Illustrations and Tables.

Illustrations and tables are used in this manual to clarifyinformation contained in the text. in some cases,illustrations may provide all the instructions necessary toperform a given task and text is not required. Theillustrations and tables contained in this manual arelisted in the List of Illustrations and List of Tablesimmediately following the Table of Contents

d. Parts Kits.

Many repair parts for equipment covered in this manualare available in the form of kits. See the separateRepair Parts Manual for details. Whenever a kit isobtained for the repair of an equipment, all parts whichare removed in the process of disassembly should bereplaced with like parts contained in the kit.

e. Terms.

Unless otherwise specified, references to the right andleft side of the tractor are made facing the normaldirection of highway travel References to the right andleft sides of the engine are made facing the flywheel endof the engine.

Section II. DESCRIPTION AND DATA

1-4. DESCRIPTION.

a. General Description.

Refer to the separate Operator's Manual for an overalldescription of the tractor and its major components.

b. Detail Description.

Refer to the introductory paragraph, if applicable, ofeach chapter or section for a detail description of theapplicable tractor equipment.

1-5. DATA.

a. Identification and Data Plates.

Refer to the separate Repair Parts Manual foridentification and data plates and decals used on thetractor.

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b. Tabulated Data.

Overall specifications for the tractor are tabulated in theseparate Operator's Manual. If applicable, detailspecifications, wear limits, and torque data of individualtractor equipment (for example, transmission) areprovided in the appropriate chapters within this manual.

c. Standard Torque Data.

Table 1-1 lists the standard torque data for the tractor.Use the values listed in table 1-1 unless otherwisespecified. The recommended torque values for standardapplication nuts and bolts are applicable, provided that:

(1) Threads are not degreased and have a lightcoating of lubricant film.

(2) Joints are rigid and do not use gaskets orcompressible non-metallic materials.

(3) Grade 2 nuts are used with grade 5 bolts, andgrade 5 nuts with grade 8 bolts.

(4) The material for tapped holes is steel.

Table 1-1. Standard Torque Data

Bolt Size(Inches)

Grade 5Torque(lb-ft)

Grade 8Torque(lb-ft)

NC NF NC and NF1/4 9 - 10 10 - 12 12 - 145/16 19 - 21 19 - 24 27 - 303/8 33 - 37 35 - 40 45 - 507/16 50 - 55 55 - 60 70 - 801/2 80 - 90 90 - 95 115 - 1309/16 110 - 125 125 - 140 160 - 1805/8 160 - 180 180 - 200 220 - 2503/4 290 - 320 310 - 330 400 - 4507/8 420 - 470 470 - 490 650 - 7301 630 - 710 700 - 720 970 - 10901-1/8 850 - 950 950 - 1050 1380 - 15501-1/4 1200 - 1350 1300 - 1400 1940 - 2180

NOTE: Manufacturer's bolt markings may vary. Three-line markings on

the following heads, for example, all indicate SAE Grade 5:

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CHAPTER 2

ENGINE

Section I. INTRODUCTION,DESCRIPTION AND DATA

2-1. INTRODUCTION.

This chapter contains basic description of, specificationsand data for, and adjustment and overhaul proceduresfor the engine.


a. Arrangement.

The diesel engine (figure 2-1) is equipped with an oilcooler, oil filter, limiting speed-type governor, air inlethousing and exhaust manifolds. The engine alsoprovides mounting facilities for accessories such as thefan, air compressor, alternator and power steering pump.

Figure 2-1. Engine Assembly

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b. Description.

The diesel engine is an internal combustion power unit inwhich the heat of diesel fuel is converted into work in thecylinders of the engine. The engine has no carburetor orelectrical ignition system, and relies on the heat ofcompressed air alone to ignite the fuel. Fuel flow andengine speed are controlled by the engine governor andfuel injectors. Full pressure oil lubrication is supplied toall main bearings, connecting rod bearings, andcamshaft bearings in addition to other moving parts.

2-3. SPECIFICATIONS AND DATA.

Specifications and data for the engine are presented inTable 2-1.

Table 2-1. Engine Specifications and Data

Manufacturer Detroit DieselModel 5067-5040Design 6V-53RANType Overhead 4-Valve, 2 cycleNo. of Cylinders 6Displacement 318 cubic in.Bore 3.875 mn.Stroke 4.5 in.Compression 21:1Brake horsepower 210 HP @ 2800 RPMTorque 440 ft/lbs @ 1800 RPMGoverned speed (full load) 2800 RPMGoverned speed (no load) 3040 RPMIdle speed 550 RPMFiring order IL-3R-3L-2R-2L- 1ROil capacity (incl. 2 qts.

required for oil filterreplacement) 16 qts.

Oil pressure, hot 40 to 60 psi

Section II. ENGINE TUNE UPAND ADJUSTMENTS

2-4. DESCRIPTION.

Normally, when performing a tune up on an engine inservice, it is only necessary to check the variousadjustments for a possible change in the settings.However, If the cylinder head, governor or injectors havebeen replaced or overhauled, then certain preliminaryadjustments are required before the engine is started.The preliminary adjustments consist of the first fouritems in the following sequence. The remaining itemscomplete the list of engine adjustments to be performed.

CAUTION

Before starting an engine after anengine speed control adjustment orafter removal of the engine governorcover, verify that the injector racksmove to the no fuel position when thegovernor stop lever is placed in thestop position. Engine overspeed willresult if the injector racks cannot bepositioned at no fuel with thegovernor stop lever.

NOTE

Since the adjustments are normallymade while the engine is stopped, itmay be necessary to run the enginebetween adjustments to maintainnormal operating temperature.

a. Exhaust valve clearance adjustment(paragraph 2-5).

b. Fuel injector tuning (paragraph 2-6).

c. Governor gap adjustment (paragraph 2-7a).

d. Injector rack control levers adjustment(paragraph 2-7b).

e. Maximum no load engine speed adjustment(paragraph 2-7c).

f. Idle speed adjustment (paragraph 2-7d).

g. Buffer screw adjustment (paragraph 2-7e).

h. Governor stop lever adjustment (paragraph 2-7f).

2-5. EXHAUST VALVE CLEARANCEADJUSTMENT.

a. General.

The correct exhaust valve clearance at normal engineoperating temperature is important for smooth, efficientoperation of the engine. Insufficient valve clearance canresult in loss of compression, misfiring cylinders, andeventually burned valve seats and valve seat inserts.Excessive valve clearance will result in noisy operation,especially in the low speed range.

b. Cold Engine Adjustment Procedure.

(1) Remove rocker arm covers as instructed onfigure 2-2.

(2) Adjust the exhaust valve clearance as follows(see figure 2-3):

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Figure 2-2. Rocker Arm Cover Removal

Figure 2-3. Exhaust Valve Clearance Adjustment

NOTETo adjust valves on a hot enginemaintain a normal operatingtemperature of 160 to 185°F, andadjust the valves to 0.023 inchclearance.

(a) Place stop lever in no-fuel position.

NOTE

If a wrench is used on the crankshaftbolt, do not turn the engine in a left-hand direction of rotation or thecrankshaft bolt will be loosened.

(b) Rotate crankshaft until injector follower isfully depressed on cylinder to be adjusted.

(c) Loosen push rod nut.

(d) Place a 0.025 inch feeler gage J9708between end of valve stem and rocker arm bridge.

(e) Adjust push rod to obtain a smooth pull onfeeler gage.

(f) Remove feeler gage and tighten locknut.

(g) Recheck clearance. Adjustment is correctif a 0.024 inch feeler gage will pass between the valvestem and bridge and a 0.026 inch feeler gage will not.

(3) Proceed to remaining adjustments, or installrocker arm covers, using new gaskets, in reverse ofinstructions on figure 2-2.

c. Hot Engine Adjustment Procedure.


NOTE

Maintaining normal engine operatingtemperature is particularly importantwhen making the final valveclearance adjustment. If the engineis allowed to cool off before settingany of the valves, the clearance(when running at full load) maybecome insufficient.

(2) With the engine at normal operatingtemperature, recheck the exhaust valve clearance withfeeler gage J9708 (see figure 2-3). At this time, if thevalve clearance is correct, a 0.023 inch gage shouldpass freely between the end of one valve stem and therocker arm bridge and a 0.025 inch feeler gage shouldnot. Readjust the push rod, if necessary.

(3) Proceed to remaining adjustments, or Installrocker arm covers, using new gaskets, in reverse ofinstructions on figure 2-2.

2-6. FUEL INJECTOR TIMING.

a. General.

To time a fuel injector properly, the injector follower mustbe adjusted to a definite height (1.460 inches) in relationto the injector body. All of the injectors may be timed, infiring order sequence, during one full revolution of thecrankshaft.

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NOTE

If a wrench is used on the crankshaftbolt at the front of the engine, do notturn the crankshaft in a left-handdirection of rotation or the bolt will beloosened.

b. Fuel Injector Timing Adjustment.

(1) If necessary, remove rocker arm coversas instructed on figure 2-2.

(2) Place the governor speed control lever in theidle speed position.

(3) Secure the governor stop lever in the no fuelposition.

(4) Time the fuel injectors as follows (see figure 24):

(a) Rotate crankshaft until the exhaust valvesare fully closed on the cylinder being timed (b) Loosenthe push rod locknut.

(c) Place the small end of Injector timing gageJ1853 in the hole provided in the top of the injector body,with the flat of the gage toward the Injector follower.

(d) Adjust push rod until the extended part ofthe gage will just pass over the top of the injectorfollower.

(e) Hold push rod and tighten locknut.Recheck timing.

Figure 2-4. Fuel Injector Timing Adjustment

(5) Proceed to remaining adjustments, or installrocker arm covers, using new gaskets, in reverse ofinstructions on figure 2-2.

2-7. GOVERNOR ADJUSTMENTS.

a. Governor Gap Adjustment.

(1) With the engine stopped and at normaloperating temperatures, remove the spring housing(figure 2-5B).

CAUTION

Do not back the buffer screw outbeyond the limits listed below, or thecontrol link lever may disengage thedifferential lever.

(2) Back out the buffer screw until it extends 9/16 to5/8 Inch from the surface of the governor housing.

(3) Start the engine and loosen the idle speedadjusting lock nut. Then adjust the idle screw(figure 2-5B) to obtain desired engine idle speed (550rpm).

(4) Stop the engine and remove the governor cover.

(5) If necessary, remove rocker arm covers asinstructed on figure 2-2.

NOTE

The engine must be controlledmanually during the adjustmentprocedures, therefore care must beexercised to prevent overspeeding.

(6) Start and run the engine between 800 and 1000rpm by manual operation of the differential lever.

(7) Check the gap between the low speed springcap and the high speed spring plunger with 0.0015 inchfeeler gage J3172. If the gap setting is incorrect, resetthe gap adjusting screw. If the setting is correct, the0.0015 inch movement can be seen by placing a fewdrops of engine oil into the governor gap and pressing ascrewdriver against the gap adjusting screw. Movementof the cap toward the plunger will force the oil from thegap in the form of a small bead.

(8) Hold the gap adjusting screw and tighten locknut. Recheck the gap and readjust as necessary.

(9) Stop the engine and install the governor cover.

b. Injector Rack Control Levers Adjustment.

(1) Injector control rack positioning andidentification.

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Figure 2-5. Governor Adjustment Points

(a) The position of the injector control racksmust be correctly set in relation to the governor. Theirposition determines the amount of fuel injected into eachcylinder and ensures equal distribution of the load.

(b) The letters R or L indicate the injectorlocation in the right or left cylinder bank, viewed from therear of the engine. Cylinders are numbered starting atthe front of the engine on each cylinder bank. Adjust theNo. 3L injector rack control lever first to establish a guidefor adjusting the remaining levers.

(2) Loosen the lock nut and back out the bufferscrew (figure 2-5B) approximately 3/4 inch.

(3) If necessary, remove rocker arm covers asinstructed on figure 2-2.

(4) Remove the clevis pin from the fuel rod and theright cylinder bank injector control tube lever(figure 2-6A).

(5) Loosen all of the inner and outer injector rackcontrol lever adjusting screws (figure 2-6B) on bothinjector control tubes. Be sure all of the injector rackcontrol levers are free on the injector control tubes.

(6) Move the speed control lever to the maximumspeed position.

(7) Move the stop lever (figure 2-5A) to the "run"position and hold It in that position with finger pressure.Turn the inner adjusting screw of the No. 3L injector rackcontrol lever down (figure 2-6B) until a slight

movement of the control tube is observed, or a step upin effort to turn the screwdriver is noted. This will placethe No. 3L injector rack in the full fuel position. Turn theouter adjusting screw down until it bottoms lightly on theinjector control tube. Then, alternately tighten both theinner and outer adjusting screws.

(8) To be sure the control lever is properly adjusted,hold the stop lever in the "run" position and press downon the injector rack with a screwdriver (figure 2-6B) orfinger tip causing the rack to rotate slightly. The settingis sufficiently tight If the rack returns to its originalposition. If the rack does not return to its originalposition, it is too loose. To correct this condition, backoff the outer adjusting screw slightly and tighten theinner adjusting screw. The setting is too tight if, whenmoving the stop lever from the "stop" to the "run"position, the injector rack becomes tight before thegovernor stop lever reaches the end of its travel. Thiswill result in a step-up in effort required to move the stoplever to the "run" position and a deflection in the fuel rod(fuel rod deflection can be seen at the bend). If the rackis found to be too tight, back off the inner adjustingscrew slightly and tighten the outer adjusting screw.

(9) Remove the clevis pin from the fuel rod and theleft bank injector control tube lever.

(10) Insert the clevis pin in the fuel rod and the rightcylinder bank injector control tube lever and position theNo. 3R injector rack control lever as previously outlinedin Step 7 for the No. 3L control lever.

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Figure 2-6. Positioning Injector Rack Control Levers

(11) Insert the clevis pin in the fuel rod and the leftbank injector control tube lever. Repeat the check onthe 3L and 3R injector rack control levers as outlined inStep 8. Check for and eliminate any deflection whichmay occur at the bend in the fuel rod where it enters thecylinder head.

(12) Manually hold the No. 3L injector rack in the full-fuel position, with the lever on the Injector control tube,and turn the inner adjusting screw of the No. 2L injectorrack control lever down until the injector rack of No. 2Linjector has moved into the full-fuel position. Turn theouter adjusting screw down until It bottoms lightly on theinjector control tube. Then, alternately tighten both theinner and outer adjusting screws.

(13) Recheck the No. 3L injector rack to be sure thatit has remained snug on the ball end of the rack controllever while positioning the No. 2L injector rack. If therack of the No. 3L injector has become loose, back offthe inner adjusting screw slightly on No. 2L Injector rackcontrol lever and tighten the outer adjusting screw.When the settings are correct, the racks of both injectorsmust be snug on the ball end of their respective controllevers.

(14) Position the 1L injector rack control lever asoutlined in Steps 12 and 13.

(15) Position the No. 2R and IR injector rack controllevers as outlined above for the left cylinder bank inSteps 12 through 14.

c. Maximum No Load Engine SpeedAdjustment.

(1) Start the engine and operate until normaltemperature of 160 to 185°F is reached. Remove anyload which may have been applied to the engine andshut the engine down.

(2) Loosen the lock nut with a spanner wrench andback off the high speed spring retainer nut (figure 2-5B)several turns.

WARNING

Place gear shift lever in neutral (N)position, set tractor brakes, andblock front wheels Do not allowpersonnel to stand at front or rear oftractor.

NOTE

Use an accurate test tachometer todetermine tractor tachometer error.Correct tractor tachometer readingsas necessary during the followingsteps.

(3) Start the engine and slowly increase the speedwith the speed control lever. If the speed exceeds 304Crpm before the speed control lever reaches the end of itstravel, back off the spring retainer a few additional turns.

(4) With the engine operating at normal temperature(160 180°F) and no load, place the speed control lever inthe maximum speed position. Turn the high speedspring retainer in until the engine is operating at 3040rpm.

(5) Hold the spring retainer and tighten the lock nut.

d. Idle Speed Adjustment.

(1) Start the engine and, when normal operatingtemperature is maintained, back out the buffer screw toavoid contact with the differential lever. Loosen lock nutand turn the idle speed adjusting screw (figure 2-5B)until the engine Idles at 535 rpm.

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(2) Hold the idle screw and tighten the lock nut.

(3) Install the high speed spring retainer housingand tighten the two bolts.

e. Buffer Screw Adjustment.

(1) With the engine running at normal temperature,turn the buffer screw in so it contacts the differentiallever as lightly as possible and still eliminates the engineroll.

NOTE

Do not increase engine idle speedmore than 15 rpm with the bufferscrew.

(2) Recheck the maximum no load speed. If it hasincreased more than 25 rpm, back off the buffer screwuntil the increase is less than 25 rpm.

(3) Recheck for correct idle speed (550 rpm).

(4) Hold the buffer screw and tighten the lock nut.

f. Governor Stop Lever Adjustment.

(1) Refer to figure 2-7 and remove the boltconnecting the right angle clip to the governor stop lever.

Figure 2-7. Governor Stop Lever Adjustment

NOTE

The following step assures that thelinkage will travel as straight aspossible. The solenoid plunger travelis more than adequate to move theinjector control racks from the full-fuel to the complete no-fuel position,and shutdown will occur prior toattaining complete travel.

(2) Align and clamp the lever to the shutdown shaftin such a way that, at its mid-travel position, the lever isperpendicular to the solenoid plunger.

(3) Place the stop lever in the "run" position andadjust the right angle clip for minimum engagement onthe solenoid plunger when the connecting bolt isinstalled.

(4) Lock the bolt to the stop lever and adjust to aheight that will permit the right angle slip to floatvertically. The clearance above and below the clipshould be 1/32 inch as shown In figure 2-7.

Section III. ENGINE REMOVAL, CLEANING,INSPECTION AND INSTALLATION

2-8. REMOVAL AND CLEANING.

a. Removal.

NOTE

Remove engine only If necessary forrepair or replacement.

(1) Remove engine hood (see Chapter 15).

(2) Remove air inlet piping, air cleaner and bracket,ether starting aid and fuel lines (see Chapter 3) Sealhose ends and openings to prevent contamination.

(3) Disconnect accelerator and modulator cablesfrom engine governor (see Chapter 3).

(4) Remove fan, fan drive, fan shroud and allcoolant hoses (see Chapter 5).

(5) Tag all wires and remove tachometer, starter,alternator, shutdown solenoid, and sending unit wires;then remove wiring harness from engine (see Chapter6).

(6) Remove exhaust pipes (see Chapter 4).

(7) Disconnect hoses from air compressor (seeChapter 12). Seal hose ends and openings to preventcontamination.

(8) Remove transmission (see Chapter 7).

(9) Remove drain plug and gasket (figure 2-8) anddrain engine crankcase.

(10) If necessary, attach engine lifter brackets tocylinder heads using 3/8 inch hardware (see figure 2-9).

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Figure 2-8. Engine Oil Drain Plug Location

Figure 2-9. Engine Lifter Brackets

(11) Attach a suitable hoist and sling with a capacityof at least 2000 pounds to the engine lifter brackets.Operate hoist to remove slack from sling.

(12) Remove mounting hardware and engine mountsas illustrated in figure 2-10.

CAUTION

Do not allow engine to contactradiator, as damage to radiator finsand core may result.

(13) Hoist the engine assembly lightly while sliding ittoward the radiator until It clears the cross tie assembly.Remove the engine from the tractor.

(14) Remove the engine belt sets (see figure 2-11)and alternator, starter motor, air compressor and powersteering pump. Refer to Chapter 5 (water pump belts;fan and air compressor belts), Chapter 6 (alternator,starter, and belts), Chapter 12 (air compressor) andChapter 14 (power steering pump and belts).

1. Engine assembly 8. Engine mount (2)2. Bolt (2) 9. Bolt (2)3. Hex nut (2) 10. Lock washer (2)4. Rubber mount (2) 11. Ground strap5. Washer (4) 12. Right bank lifter bracket6. Snubbing washer (2)7. Lock washer (2)

Figure 2-10. Engine Mounts and Hardware

1. Fan and air compressor belts (2)2. Alternator belts (2)3. Water pump belts (2)4. Power steering pump belts (2)

Figure 2-11. Engine Belt Sets

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b. Cleaning.

(1) Protect all openings, electrical components, andparts made of rubber by shielding with grease-proofbarrier material or other suitable protection. Protectcomponents which could be damaged by steam cleaningby coating with waterproof banner material.

CAUTION

Do not allow cleaning solvent tocontact electrical leads, v-belts andother parts which may be damaged.

(2) Clean the exterior of the engine with cleaningsolvent, or steam clean. Dry thoroughly after cleaning.

2-9. INSPECTION AND INSTALLATION.

a. Inspection.

(1) Visually inspect the engine assembly forevidence of damage. Make notes of any suspecteddamage or malfunction which may aid during the repairof the engine assembly.

(2) Inspect engine belt sets, wires, coolant hoses,air inlet piping, and other items removed from engine forevidence of damage or excessive wear. Replace alldefective items during installation of engine.

b. Installation.

(1) Install engine in reverse of procedure outlined inparagraph 2-8a.

(2) Refill the cooling system (see Chapter 5).

(3) Check transmission for proper fluid level (seeChapter 7).

(4) Refill engine crankcase with lubricating oil asspecified in the separate Operator's Manual. Removecap from rocker arm cover (figure 2-2) and add oil tobring level to full mark on engine dipstick (figure 2-12).

Figure 2-12. Engine Dipstick

(5) Start engine and idle at 550 to 600 rpm withtransmission in neutral range. Immediately check oilpressure (18 psi minimum within 10 to 15 seconds).

(6) Allow engine to Idle for five minutes whilechecking for oil leaks, fuel leaks and coolant leaks. Stopengine, then check and tighten all external bolts.

WARNING

Do not allow personnel to stand atfront or rear of tractor.

(7) Start engine and, with brakes applied andtransmission in neutral range, accelerate engine to 1800rpm for ten minutes; then momentarily accelerate engineto 2800 rpm and check for 40 to 60 psi oil pressure.

(8) Idle engine to allow internal temperatures toequalize, and recheck for leaks, then stop engine andrecheck crankcase oil level.

Section IV. AIR INLET HOUSING AND EXHAUSTMANIFOLDS

2-10. AIR INLET HOUSING.

a. Removal.

(1) Disconnect air piping from air inlet elbow (seeChapter 3).

(2) Disconnect ether starting aid fluid tube andremove nozzle (1, figure 2-13) from inlet elbow (5).

(3) Remove air inlet housing in numerical sequenceillustrated in figure 2-13.

b. Cleaning, Inspection and Repair.

(1) Clean all parts thoroughly by washing withcleaning solvent. Dry parts with a clean cloth.

(2) Inspect mating surface of inlet elbow, air inletadapter and air inlet housing for nicks and rough spots.Polish rough spots smooth with a stone or crocus cloth.

(3) Inspect inlet elbow, air inlet adapter and air inlethousing for cracks, deformation and any damage whichwould cause leaks. Replace defective parts.

(4) Inspect hardware and threaded openings fordamaged threads. Chase damaged threads with thecorrect size tap. Replace damaged hardware.

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1. Ether nozzle 9. Flat washer (4)2. Screw (4) 10. Air inlet adapter3. Hex nut (4) 11. Bolt4. Lock washer (4) 12. Bolt (2)5. Inlet elbow 13. Bolt (3)6. Gasket (2) 14. Lock washer (6)7. Bolt (4) 15. Flat washer (6)8. Lock washer (4) 16. Air inlet housing

Figure 2-13. Air Inlet Housing Removal

c. Installation.

(1) Install air inlet housing with new gaskets inreverse of procedure outlined in paragraph 2-10a.

(2) Tighten air inlet housing bolts (11, 12 and 13,figure 2-13) to torque value specified in Table 2-2.

2-11. EXHAUST MANIFOLDS.

a. Removal.

(1) Remove exhaust pipes (see Chapter 4).

(2) If necessary to remove right hand exhaustmanifold, remove engine oil dipstick (paragraph 2-39a).

(3) Remove exhaust manifolds in numericalsequence illustrated in figure 2-14.

(4) If necessary for replacement, apply penetratingsolvent to studs (6, figure 2-14) and remove studs fromcylinder heads.

1. Hex nut (8) 4. Manifold (2)2. Dished lock washer (4) 5. Gasket (2)3. Bridge clamp (4) 6. Stud (8)

Figure 2-14. Exhaust Manifold Removal


(1) Scrape all gasket residue from mating surfacesof exhaust manifolds and engine heads.

(2) Clean all rust, carbon and oxidized material fromthe manifolds with a wire brush; then clean manifoldswith cleaning solvent and dry with a clean cloth.

(3) Inspect manifold mating surfaces for nicks andrough spots. Polish rough spots smooth with a stone orcrocus cloth.

(4) Inspect manifolds for cracks and evidence ofleaks. Replace a defective manifold.

(5) Inspect hardware and threaded openings fordamaged threads. Chase threaded openings with thecorrect size tap. Replace damaged hardware.

c. Installation.

Install exhaust manifolds in reverse of procedureoutlined in paragraph 2-11 a.

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Table 2-2. Engine Assembly Torque Values

Note: Items are listed in order of reassembly procedures.

Figure Index Size TorqueNo. No. Application (in.-thread) (b-ft)

2-13 11, 12, 13 Air inlet housing to engine 3/8-16 16 to 20

2-34 9 Injector nut (needle valve) 15/16-24 75 to 85

2-34 1 Injector filter caps 5/8-24 65 to 75

2-36 n/a Injector clamp bolt 3/8-16 20 to 25

2-45 1 Rocker arm bracket bolts 7/16-14 50 to 55

2-44 n/a Fuel pipe nuts 3/8-24 12 to 15

2-51 n/a Cam follower guide bolts 1/4-20 12 to 15

2-52 1 Injector control tube bracket bolts 1/4-20 10 to 12

2-57 19 Cylinder head bolts 5/8-11 170 to 180

2-77 15 Governor bolts 3/8-16 20 to 24

2-75C n/a Drive support bolts 3/8-16 20 to 25

2-75B n/a Drive support cover capscrews 3/8-16 20 to 24

2-86 9 Oil filter shoulder bolt 7 to 12

2-88 1 External oil filter stud 7 to 12

2-90 1 Oil pan drain plug 25 to 35

2-93 1 Crankshaft pulley bolt 3/4-16 290 to 300

2-94 1, 2, 3 Lower front cover bolts 3/8-16 30 to 35

2-102 1 Flywheel attaching bolts 1/2-20 110 to 120

2-107B 1-8, 15-26 Flywheel housing bolts 3/8-16 25 to 30

2-107B 9-12 Flywheel housing bolts 3/8-24 40 to 45

2-107B 13, 14 Flywheel housing bolts 5/16-18 19 to 23

2-111 1 Connecting rod nuts 3/8-24 45 to 50(lubricated)

50 to 55(dry)

2-128 4 Idler gear hub capscrew 3/8-16 40 to 45

2-125 4 Camshaft nuts 1-1/8-18 300 to 325

2-125 12 Camshaft thrust washer capscrews 3/8-16 30 to 35

2-135 4 Main bearing cap bolts 9/16-12 120 to 130

2-134 n/a Bearing cap stabilizer bolts 7/16-14 46 to 50

2-151 21 End plate capscrews 3/8-16 20 to 25

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Section V. FUEL PUMP ANDCROSSOVER LINES

2-12. FUEL CROSSOVER LINES.

a. Removal and Cleaning.

(1) Remove fuel crossover lines and fittings fromthe front of the engine assembly as illustrated in figure2-15.

(2) Clean all parts except hoses by washing withcleaning solvent. Clean hoses by wiping with a cleancloth.

1. Hose2. Straight fitting (2) 6. Pipe adapter (2)3. Hose fitting (2) 7. Hose4. Tube connector 8. Elbow5. Elbow 9 Hose clip (2)

Figure 2-15. Fuel Crossover Lines

b. Inspection, Repair and Installation.

(1) Inspect threaded openings and fittings fordamaged threads. Chase damaged threads with thecorrect size tap. Replace defective fittings.

(2) Inspect hoses for cracks, cuts and evidence ofleaks. Replace a defective hose.

(3) Install fuel crossover lines and fittings on thefront of the engine assembly as illustrated in figure 2-15.

(4) Start engine and check fuel lines for leaks. Stopengine and retighten fittings and hoses as necessary.

2-13. FUEL PUMP.

a. General.

The fuel pump is a positive displacement gear typewhich transfers the fuel from the supply tank to the fuelinjectors. The pump circulates an excess supply of fuelthrough the injectors which purges the air from thesystem and cools the injectors. The unused portion offuel returns to the fuel tank by means of a fuel manifoldand return line.

b. Fuel Pump Tests.

(1) Fuel pump pressure test.

(a) Remove left rocker arm cover asinstructed on figure 2-2.

(b) Use flexible fuel hoses to connect apressure gage as illustrated in figure 2-16.

Figure 2-16. Fuel Pump Pressure Test

(c) Start engine and, after a suitable warm-upperiod, accelerate engine to 2500 rpm.

(d) Observe indication on fuel pressure gage.Pressure must not be less than 35 psig. Nominal fuelpump pressure at 2500 rpm engine speed is 45 to 70psig.

(e) If pressure is less than 35 psig repair thefuel system.

(f) Stop engine, remove gage and flexiblehoses, and reinstall fuel pipe; then install rocker armcover with a new gasket in reverse of instructions onfigure 2-2.

(2) Fuel pump flow test.

(a) Disconnect the fuel manifold return linefrom the fuel tank.

(b) If necessary, connect a flexible tube to thefuel return line to reach the container (see figure 2-17).

(c) Start the engine and, after a suitablewarm-up period, accelerate engine to approximately1200 rpm.

(d) Collect the fuel from the return line for aperiod of one minute.

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Figure 2-17. Fuel Pump Flow Test

(e) Stop the engine and measure the volumeof diesel fuel collected. The amount of fuel collectedmust not be less than 1/2 gallon. If less than 1/2 gallonrepair the fuel system.

(f) Disconnect flexible hose and reconnectfuel return line to fuel tank.

c. Fuel Pump Removal.

(1) Disconnect fuel lines from the fuel pump.

(2) Remove fuel pump and mounting plate asinstructed on figure 2-18.

(3) Remove the pump mounting plate, drive fork,and drive gear adapter in numerical sequence shown onfigure 2-19.

d. Fuel Pump Disassembly.

(1) Disassemble the fuel pump in numericalsequence illustrated on figure 2-20.

(2) Remove the oil seals (8, figure 2-20) asillustrated in figure 2-21. Discard oil seals.

e. Cleaning, Inspection and Repair.

(1) Clean all parts by washing with cleaning solvent.Dry parts with a clean cloth.

Figure 2-18. Fuel Pump and Mounting Plate Removal

1. Fork2. Capscrew w/seal

washer (3)3. Plate4. Gasket5. Plug

6. Fuel pump7. Capscrew (2)8. Drive gear adapter

Figure 2-19. Fuel Pump and Gear Adapter Removal

(2) Inspect the pump gear teeth for scoring,chipping and excessive wear. Inspect the ball slot in thedrive gear for wear. If any of these conditions are found,replace the damaged or worn parts.

(3) Inspect the drive shaft and driven shaft forscoring and excessive wear. Replace as necessary.The driven shaft is serviced as gear and shaft assemblyonly.

(4) Inspect the mating surfaces of the pump bodyand the cover for scratches, nicks, burrs and otherdamage which may result in pressure leaks. The matingsurfaces must be flat and smooth and fit tightly together.Replace the cover or body as necessary.

(5) The relief valve must be free from score marksand burrs. If the relief valve is scored and cannot becleaned up with fine emery cloth or crocus cloth it mustbe replaced.

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1. Screw w/washer (8) 10. Gasket2. Cover 11. Spring3. Driven shaft 12. Pin4. Drive shaft assembly 13. Relief valve5. Drive gear 14. Dowel pin (2)6. Ball 15. Pump body7. Shaft8. Seal (2)9. Plug

Figure 2-20. Fuel Pump Disassembly

f. Fuel Pump Reassembly.

(1) Install inner oil seal in' pump body as shown infigure 2-22.

(2) Install outer oil seal in pump body as shown infigure 2-23.

(3) Reassemble the fuel pump in reverse ofnumerical sequence as illustrated in figure 2-20.

g. Fuel Pump Installation.

(1) Install gear adapter to the drive gear and pumpto mounting plate in reverse of numerical sequence asIllustrated in figure 2-19.

(2) Install the fuel pump and mounting plateassembly in reverse of removal instructions onfigure 2-18.

(3) Reconnect the fuel lines to the fuel pump.

(4) Start engine and observe fuel pump and lines forevidence of leaks. Stop engine and tighten connectionsas necessary.

Figure 2-21. Removing Fuel Pump Oil Seals

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Figure 2-22. Fuel Pump Inner Oil Seal Installation

Figure 2-23. Fuel Pump Outer Oil Seal Installation

Section VI. FUEL INJECTOR

2-14. GENERAL.

a. Description.

The fuel injector (figure 2-24) Is a light weight compactunit which permits the use of a simple open type engine

combustion chamber. The simplicity of design andoperation provides for simplified controls and easyadjustment. The fuel injector performs the following fourfunctions:

(1) Creates the high fuel pressure required forefficient operation.

(2) Meters fuel to the exact amount required tohandle the load.

(3) Atomizes the fuel for mixing with the air in thecombustion chamber.

(4) Injects metered fuel at the proper time.

Figure 2-24. Fuel Injector Component Identification

b. Fuel Metering.

Metering of fuel is accomplished by an upper and lowerhelix machined in the lower end of the injector plunger.Figure 2-25 illustrates the fuel metering from no load tofull load by rotation of the plunger in the plunger bushing.Rotation of the plunger, by changing the position of thehelix, retards or advances the closing of the ports andthe beginning and ending of the injector period. Thisaction increases or decreases the desired amount of

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Figure 2-25. Fuel Injector Metering

fuel which remains under the plunger for injection intothe engine cylinder. The diesel fuel is thereby meteredinto the supply chamber between the plunger bushingand spill deflector (figure 2-24). As the plunger operatesup and down in the plunger bushing, the fuel is injectedat the proper time through the spray tip into thecombustion chamber.

c. Continuous Fuel Flow.

The continuous fuel flow through the injector serves, inaddition to preventing air pockets in the fuel system, as acoolant for those injector parts subjected to highcombustion temperatures.

d. Injector Control.

Each fuel injector control rack (figure 2-24) is actuatedby a lever on the injector control tube which, in turn, isconnected to the governor by means of a fuel rod.These levers can be adjusted independently on thecontrol tube, thus permitting a uniform setting of allinjector racks.

2-15. FUEL INJECTOR REMOVAL.

a. Rocker Arm Cover Removal.

Remove the rocker arm covers as instructed onfigure 2-2.

b. Injector Removal.

(1) Remove the fuel supply and fuel return linesfrom the fuel injector and fuel connectors.

NOTE

Immediately after removal of the fuelpipes from the injectors, cover thefilter caps with shipping

caps to prevent dirt from entering theinjector. Also cover the fuel pipesand connectors to prevent entry ofdirt or foreign material.

(2) Crank the engine with the starter motor to bringthe push rod ends, outer ends of the injector and thevalve rocker arms in line horizontally.

(3) Remove the rocker arm shaft bracket bolts andfuel injector clamp as instructed on figure 2-26. Pivotrocker arms back as shown.

(4) Remove the injector as illustrated in figure 2-27.

2-16. FUEL INJECTOR TESTS.

If visual inspection does not reveal any external damage,perform the following series of tests to determine thecondition of the injector to avoid unnecessary repair. Aninjector that passes all the tests is consideredsatisfactory for service.

a. Control Rack and Plunger Movement Test.

(1) Place the fuel injector in a test fixture. with thedowel in the underside of the injector located in theproper slot or hole in the adapter plate Position thehandle support to proper height (figure 2-28).

CAUTION

When testing an injector justremoved from an engine, the flow offuel through the injector on the testfixture should be the same as on theengine. Connections on the testhead of the test fixture may bechanged to obtain the correctdirection of flow.

(2) Place handle on top of injector follower; thenclose inlet and outlet clamps to hold injector in testfixture. With injector control rack held in the no fuelposition, push handle down and depress follower tobottom of its stroke. Slowly release pressure on handlewhile moving control rack back and forth, as shown infigure 2-28, until follower reaches top of its travel. If therack does not move freely it indicates that internal partsof the injector are misaligned, damaged or dirty.

b. High Pressure Test.

(1) Install injector in test stand as shown infigure 2-29.

(2) Thoroughly dry the injector with clean, drycompressed air.

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Figure 2-26. Rocker Arm Bolts and Injector Clamp Removal

Figure 2-27. Fuel Injector Removal Figure 2-28. Checking Rack and Plunger Freeness

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Figure 2-29. Fuel Injector Mounted in Test Stand

(3) Check the fuel connections for leaks. If leakshave occurred, tighten the connections, dry the injectorand recheck.

WARNING

Wear safety goggles, and keep clearof injector spray to prevent fuel frompenetrating the skin.

CAUTION

Do not permit the pressure in theinjector tester to equal or exceed thecapacity of the pressure gage.

NOTE

It is normal for fuel to seep outaround the rack due to high pressurefuel being applied to a normally lowpressure area in the injectorassembly. However, fuel droplets atthe rack indicate excessive leakage.

(4) With the injector rack in the full fuel position andthe injector tester popping handle locked in position bymeans of the handle lock, operate the pump handle to

build up and maintain the pressure at 1600 to 2000 psigby actuating the pump handle. Then inspect for leaks atthe injector filter cap gaskets, body plugs and injector nutseal ring.

NOTE

If there is excessive clearancebetween the plunger and bushing,pressure beyond the normal valveopening pressure cannot beobtained. Replacement of theplunger and bushing assembly isthen required.

c. Injector Holding Pressure Test.

WARNING

Wear safety goggles, and keep clearof fuel leak (spray) to prevent fuelfrom penetrating the skin.

(1) Operate pump handle to bring pressure up toapproximately 450 psig (figure 2-29).

(2) Close fuel shut-off valve and note pressure drop.The time for a pressure drop from 450 psig to 250 psigshould be not less than 40 seconds.

(3) If Injector pressure drops from 450 psig to 250psig in less than 40 seconds, inspect injector for leaks asfollows:

(a) Thoroughly dry injector with clean, drycompressed air.

(b) Open tester fuel valve and operate thepump handle to maintain testing pressure (figure 2-29).

(c) Check for a leak at injector rack opening.A leak indicates a poor bushing-to-body fit.

(d) A leak around the spray tip or seal ringusually is caused by a loose injector nut, a damagedseal ring, or a brinnelled surface on injector nut or spraytip.

(e) A leak at filter cap indicates a loose filtercap or a damaged filter cap gasket.

(f) A "dribble" at spray tip orifices indicates aleaking valve assembly due to a damaged surface ordirt.

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d. Spray Pattern Test.

WARNING

Wear safety goggles, and keep clearof injector spray to prevent fuel frompenetrating the skin.

CAUTION

To prevent damage to pressure gage,do not exceed 100 psig during thistest.

(1) After completing injector holding pressure test,open fuel shut-off valve, then place injector rack in fullfuel position. Operate injector several times insuccession by operating tester popping handle atapproximately 40 strokes per minute as shown in (figure2-29). Observe the spray pattern to see that all sprayorifices are open and injecting evenly. The beginningand ending of injection should be sharp and the fuelinjected should be finely atomized.

(2) If all of the spray tip orifices are not open andinjecting evenly, clean them during injector overhaul.

e. Visual Inspection of Plunger.

(1) An injector which passes the previouslydescribed tests must have the plunger checked visually,under a magnifying glass, for excessive wear or for apossible chip in the bottom helix. There is a small areaon the bottom helix and lower portion of the upper helix,if chipped, that will not be indicated in any of the tests.

(2) Remove the plunger from the injector as follows:

(a) Support the injector, right side up, in aholding fixture (figure 2-30) or in injector vise jaws.

Figure 2-30. Injector Follower Stop Pin Removal

(b) Compress the follower spring; then, usinga screwdriver, raise the spring above the stop pin andremove the pin (figure 2-30). Release the springfollower gradually.

(c) Lift the follower and plunger from theinjector body as an assembly.

(d) Inspect the plunger for chipped edges. Ifplunger is chipped, replace the plunger and bushingassembly.

(e) If the plunger is in good condition, reinstallthe plunger and follower.

f. Needle Valve Test.

(1) Remove injector nut, and remove all the valveparts below the injector bushing as outlined indisassembly (paragraph 2-17a).

(2) Clean all the carbon off the spray tip seats in theinjector nut as outlined in paragraph 2-17b.

(3) If the spray pattern test indicated that tipcleaning is necessary, clean the carbon from the tipcavity below the needle valve and orifices as outlined inparagraph 2-17b.

(4) With the injector nut and spray tip cleaned,clamp the nonthreaded end of the body in a bench vise.Assemble the check valve, check valve cage, spring,spring seat, spring cage, needle valve and tip assemblyon top of the body. Carefully pilot the injector nut overthe spray tip and valve parts and thread it on the injectorbody. Tighten the injector nut to torque value specifiedin Table 2-2.

(5) Remove the body with the injector parts from thebench vise and install m the adapter in the injector testeras illustrated in figure 2-29.

WARNING

Wear safety goggles, and keep clearof injector spray to prevent fuel frompenetrating the skin. (6) Operate thepump handle until the spray tip valvehas opened several times to purgethe air from the system.

(7) Operate the pump handle with smooth evenstrokes (40 strokes per minute) and note the pressure atwhich the needle valve opens. The valve should openbetween 2300 and 3300 psig. The opening and closingaction should be sharp and produce a finely atomizedspray.

(8) If the valve opening pressure is less than 2300psig, or atomization is poor, replace the needle valveand tip assembly.

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(9) If the valve opening pressure is within 2300 to3300 psig, proceed to check for spray tip seat leakage.Pump up the injector tester and maintain a pressure of1500 psig for 15 seconds by actuating pump handle.Inspect the spray tip seat for leakage. There should beno fuel droplets, although a slight wetting of the end ofthe valve tip is permissible.

Figure 2-31. Checking Needle Valve Lift

(10) Check the needle valve lift (figure 2-31) asfollows:

(a) Place the bottom surface of the plungerassembly on a flat surface and zero the indicator dial.

(b) Place the spray tip and needle valveassembly tight against the bottom of the gage, with thequill of the needle valve in the hole in the plunger.

(c) While holding the spray tip and needlevalve assembly tight against the gage, read the needlevalve lift on the indicator. This lift should be 0.008 to0.018 inch; if it exceeds 0.018 inch, the tip assemblymust be replaced. If the lift is less than 0.008 inch,inspect for foreign material between the needle valveand tip seat.

(d) If the needle valve lift is within the abovelimits, install a new needle valve spring and recheck thevalve opening pressure and valve action. Low valveopening pressure or poor atomization with a new springindicates the spray tip and needle valve assembly isdefective and must be replaced.

(11) Reassemble the injector (paragraph 2-19).

g. Fuel Output Test.(1) When injectors are removed from an engine foroutput testing and, If satisfactory, reinstalled without

disassembly, extreme care must be taken to avoidreversing the fuel flow. Note the direction of fuel flowthrough the injector before removal from the engine.When the fuel flow is reversed, dirt trapped by the filterelement is back-flushed into the injector components.To avoid reversing the fuel flow when checking injectorfuel output on the comparator, use the appropriateadapter. The position of the fuel flow pipes illustrated infigure 2-32 depends on the adapter being used and thedirection of fuel flow through the injectors.

NOTE

The fuel passages in some adaptersare drilled straight through theadapters (figure 2-32B) while othersare cross drilled (figure 2-32A).

Figure 2-32. Position of Fuel Flow Pipes

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(2) Install and operate the injector in the comparatorand check the fuel output as follows:

(a) Place the injector in the comparator asillustrated in figure 2-33. Turn the wheel to clamp theinjector and adapter in position.

NOTE

Make sure the stroke counter(figure 2-33) on the comparator ispreset to 1,000 strokes. If this settinghas been altered, reset the counter to1,000 strokes by pulling the selectorwheel to be changed to the right androtating It to the proper position; thenrelease the wheel.

(b) Pull the injector rack out to the no fuelposition.

(c) Start the comparator by turning the off-onswitch to the on position.

Figure 2-33. Placing Fuel Injector in Typical Comparator

(d) After the comparator has started, push theinjector rack into the full fuel position, and allow theinjector to operate for approximately 30 seconds topurge the air that may be in the system.

(e) After purging, press fuel flow start button.This will start the flow into the vial. The comparator willautomatically stop the flow of fuel at the predeterminednumber of strokes (1,000).

(f) After the fuel stops flowing into the vial,pull the rack out to the no fuel position.

(g) Turn the comparator off and reset thecounter.

(h) Observe reading on vial of comparator.Injector fuel output must be within 18-24 cubicmillimeters. If volume of fuel in the vial does not fallwithin specified limits, disassemble injector and inspectspray tip and valve parts for damage (paragraph 2-18a)(3) The comparator may be used to check and select aset of injectors which will inject the same amount of fuelinto each cylinder at a given throttle setting, thusresulting in a smooth running engine.

(4) An injector which passes all the above tests canbe put back into service. However, an injector whichfails to pass one or more of the tests must be repaired orreplaced.

2-17. DISASSEMBLY AND CLEANING.

a. Disassembly.

(1) Support the injector upright in the injectorassembly fixture tool or in injector vise jaws.

(2) Remove the follower stop pin as shown infigure 2-30.

(3) Disassemble the injector follower, spring andplunger in numerical sequence as illustrated infigure 2-34.

(4) Reverse the fuel injector in the fixture anddisassemble the remaining injector components innumerical sequence as illustrated in figure 2-34.

(5) Lift the injector nut (9) straight up, being carefulnot to dislodge the spray tip and valve parts. Place allparts in a clean receptacle.

(6) When an injector has been in service for sometime the spray tip, even though clean on the outside,may not be pushed readily from the nut with the fingers.in this event, support the nut on a wood block and drivethe tip through the nut with a suitable drift as illustratedin figure 2-35.

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1. Injector cap (2)2. Gasket (2)3. Filter element (2)4. Stop pin

10. Injector valve11. Valve cage12. Valve spring

5. Injector follower 13. Spring seat6. Plunger-bushing 14. Spring cage

assembly 15. Tip assembly7. Guide pin 16. Deflector8. Plunger spring 17. Gear retainer9. Injector nut 18. Injector gear

19. Injector rack20. Preformed

packing21. Number tag22. Body23. Dowel pin

Figure 2-34. Fuel Injector Disassembly

Figure 2-35. Removing Spray Tip from Injector Nut

(7) Remove spill deflector (16, figure 2-34) andpreformed packing (20) from injector nut (9).

(8) Withdraw injector control rack (19) from injectorbody (22).

b. Cleaning.

(1) Carbon on inside of spray tip may be loosenedfor easy removal by soaking about 15 minutes incleaning solvent prior to external cleaning and buffingoperation. (Methyl Ethyl Ketone solvent isrecommended.)

CAUTION

Exercise care when inserting reamerin spray tip to avoid contactingneedle valve seat in the tip.

(2) Clean spray tip with J1243 reamer as shown infigure 2.36. Turn reamer in a clockwise direction toremove carbon deposits. Wash spray tip and dry withcompressed air.

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Figure 2-36. Cleaning Injector Spray Tip

(3) Clean the spray tip orifices with J8169 pin viseand proper diameter spray tip cleaning wire (0.005 or0.006 inch) as Illustrated in figure 2-37. Before usingwire, hone the end of the wire until it is smooth and freeof burrs, and taper end a distance of 1/16 inch, usingJ8170 stone. Allow the wire to extend 1/8 inch from thepin vise.

(4) Clean the exterior surface of the spray tip usinga brass wire buffing wheel. Place the tip over the drillend of the spray tip cleaner tool and hold the body of thetip against the buffing wheel. in this way, the spray tip isrotating while being buffed

(5) When the body of the spray tip is clean, lightlybuff the tip end in a similar manner. This cleans thespray tip orifice area and will not plug the orifices.

(6) Wash the spray tip in clean diesel fuel and drywith moisture free compressed air.

(7) Clean and brush passages in the injector body,using J8152 fuel hole cleaning brush and J8150 rackhole cleaning brush. Blow out the passages and drythem with compressed air.

(8) Carefully insert reamer in the injector body asillustrated in figure 2-38. Turn the reamer in a clockwisedirection a few turns; then remove the reamer and checkthe face of the body ring for reamer contact. Repeat thereaming procedure until the reamer makes contact overthe entire face of the ring. Clean the opposite side of thering in a similar manner.

(9) Carefully insert J4986-1 reamer in the injectornut as illustrated in figure 2-39. Turn the reaming tool ina clockwise direction to remove the carbon deposits fromspray tip seat. in the same manner. remove the carbon

Figure 2-37. Cleaning Injector Spray Tip Orifices

Figure 2-38. Cleaning Injector Body Ring

Figure 2-39. Cleaning Injector Nut Spray Tip Seat

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deposits from the lower end of the injector nut as shownin figure 2-40. Use care to avoid removing any metal orsetting up burrs on the spray tip seat.

(10) Wash Injector nut in clean diesel fuel and drywith compressed air. Carbon deposits on the spray tipseating surfaces of the injector nut will result in poorsealing and fuel leakage around the spray tip.

(11) When handling injector plunger, do not touch thefinished plunger surfaces. Wash plunger and bushingwith clean diesel fuel and dry with compressed air. Finalclean by wrapping tissue paper around J1291-01 cleanertool, and clean out bushing bore. Be sure the highpressure bleed hole in side of bushing is not plugged. Ifthis hole is plugged fuel leakage will occur at upper endof bushing where it will drain out of injector body ventand rack holes, during engine operation, causing aserious oil dilution problem. Keep plunger and bushingtogether as they are mated parts.

(12) After washing, submerge parts in a receptaclecontaining clean diesel fuel. Keep parts of each Injectorassembly together.

2-18. INSPECTION AND REPAIR.

a. Inspection.

(1) Inspect teeth on control rack and control rackgear for excessive wear or damage. Also check forexcessive wear in bore of gear, and replace damaged orworn parts.

Figure 2-40. Cleaning Injector Nut Lower End

(2) Inspect injector follower for wear. Inspect bothends of spill deflector for sharp edges or burrs whichcould create burrs on Injector body or injector nut andcause particles of metal to be introduced into the spraytip and valve parts. Remove burrs with a 500 grit stone.

(3) Inspect follower spring for defects and checkspring with a spring tester and a torque wrench. Theinjector follower spring (0.142 inch diameter wire) has afree length of approximately 1.504 inches and must bereplaced when a load of less than 70 pounds willcompress to 1.028 inches.

(4) Check seal ring area on injector body for burrsor scratches. Also check surface which contacts injectorbushing for scratches, scuff marks or other damage. Ifnecessary lap this surface. A faulty sealing surface atthis point will result in high fuel consumption andcontamination of the lubricating oil.

(5) Replace any loose injector body plugs or a loosedowel pin. Install proper number tag on a replacementinjector.

CAUTION

Injector plungers cannot be reworkedto change the output. Grinding willdestroy the hardened case at thehelix and result in chipping andseizure or scoring of plunger.

(6) Inspect injector plunger for scoring, erosion,chipping or wear. Check for sharp edges on that portionof the plunger which rides in the gear. Remove sharpedges with a 500 grit stone and wash plunger. Use theinjector bushing "Inspectalite" to check plunger bushingfor cracks or chipping. Check locating pin in bushing. Ifpin is damaged or sheared off, it must be replaced. Slipplunger in bushing and check for free movement. Badlyworn, chipped or scored plungers or bushings must bereplaced.

NOTE

Plungers and bushings are matedparts and must be replaced as anassembly.

(7) Examine spray tip seating surface of injector nutfor nicks, burrs, or brinelling. Reseat the surface orreplace nut If it is severely damaged.

(8) Inspect sealing surfaces of Injector partsindicated by arrows in figure 2-41. Examine the sealingsurfaces, with a magnifying glass. The slightestimperfections will prevent the injector from operatingproperly. Check for burrs, nicks, erosion, cracks,chipping and excessive wear. Check for enlargedorifices in spray tip. Replace damaged or excessivelyworn parts.

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Figure 2-41. Sealing Surfaces Which May Require Lapping

(9) Examine needle valve for wear, scoring ordamage to grill where it contacts the valve spring seat. Ifthe needle valve is scored or damaged, replace thespray tip assembly.

(10) Before installing used injector parts, lap allsealing surfaces. It is also good practice to lightly lapsealing surfaces of new injector parts which maybecome burred or nicked during handling.

b. Repair.

(1) Lap the sealing surfaces indicated in figure 2-41as follows

(a) Clean lapping blocks with compressed air.Do not use a cloth or any other material for this purpose.

(b) Spread a good quality 600 grit dry lappingpowder on one of the lapping blocks.

(c) Place part to be lapped flat on block and,using a figure eight motion, move part back and forthacross the block'. Do not press on the part, use justenough pressure to keep part flat on the block at alltimes.

(d) After each four or five passes, cleanlapping powder from part by drawing part across a cleanpiece of tissue placed on a flat surface and inspect thepart. Do not lap excessively.

(e) When the part is flat, wash with cleaningsolvent and dry with compressed air at approximately 40psig.

(f) Place dry part on the second lappingblock. After applying lapping powder, move part lightlyacross block in a figure eight motion several times togive it a smooth finish. Do not lap excessively. Againwash part in cleaning solvent and dry with compressedair.

(g) Place the dry part on a third lapping block.Do not use lapping powder on this block. Keep the partflat and move it across the block several times in a figureeight motion. Lapping the dry part in this manner gives itthe finish required for perfect sealing.

(2) Wash all of the lapped injector parts in cleandiesel fuel and dry with clean compressed air.

2-19. FUEL INJECTOR REASSEMBLY.

a. Filter Reassembly.

(1) Use new filter and gaskets, and reassemble thefilter assembly on the injector as illustrated infigure 2-34.

NOTEThe fuel filter has a dimple at oneend. Always install the filter with thedimple end down.

(2) Lubricate the injector cap (1) threads and tightento torque value specified in Table 2-2. Install cleanshipping caps on all openings to prevent any dirtparticles from entering injector

NOTEThe filter cap must be tightenedsecurely to compress the gasket andestablish a good seal with theinjector body. Also, the tightenedcap compresses the filter springwhich holds the filter securely inplace (so all fuel entering the injectoris properly filtered).

b. Rack and Gear Reassembly.

(1) Hold the injector body (10, figure 2-42), bottomend up, and slide the rack (8) through the hole in thebody. Look into the bore of the body for the gear teethon the rack, move rack so that the drill marks can beobserved, and hold the rack in this position.

NOTEThe rack can be placed in the body inonly one position and have the toothmarks show in the opening for thegear.

(2) Slide gear (9) into the injector body so that themarked tooth is engaged between the two marked teethon the rack as shown in figure 2-42.

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1. Nut 6. Check valve 11. Bushing2. Preformed packing 7. Gear retainer 12. Valve cage3. Spray tip 8. Rack 13. Spring seat4. Spring cage 9. Gear 14. Needle valve5. Spring 10. Body 15. Spill deflector

Figure 2-42. Injector Rack, Gear, Spray Tip and Valve Reassembly

(3) Place the gear retainer (7) on the gear (9).Next, align the locating pin in the bushing (11) with theslot in the injector body; then slide bushing into place.

c. Spray Tip, Spring Cage and Check ValveReassembly.

(1) Position a new preformed packing (2, figure 2-42)on the shoulder of the body (10). Slide the spilldeflector (15) over the installed bushing (11).

(2) Place check valve (6) centrally on the bushing(11). Place valve cage (12) over the check valve (6) andagainst bushing (11).

(3) Insert the spring seat (13) into spring (5). Insertthis assembly into spring cage (4), spring seat first.

(4) Place the assembled spring cage (4), springseat (13) and spring (5) on the check valve cage (12),spring end first.

(5) Insert needle valve (14), tapered end down,inside the spray tip (3). Place the spray tip with needlevalve on the spring cage (4), with the small end of theneedle valve in the hole in the spring cage.

(6) Lubricate the threads in the nut (1), and carefullythread the nut on the injector body (10) by hand. Rotatespray tip (3) with fingers while threading the nut on thebody. As the nut is being tightened by hand, the spraytip should become difficult to turn until eventually thespray tip will not turn. This insures the proper seating ofcomponents and nut.

NOTE

Do not use wrench to tighten nut atthis time..

d. Plunger and Follower Reassembly.

(1) Support injector body in the holding fixture,connector side up, and push the control rack all the wayin.

(2) Slide the head of the plunger into the followerand insert this assembly through the follower spring.

(3) Place the stop pin on the injector body so thatthe follower spring rests on the narrow flange of the stoppin (figure 2-30). Then align the slot in the follower withthe stop pin hole in the injector body. Align the flat sideof the plunger with the slot in the follower. Insert the freeend of the plunger in the injector body. Press down onthe follower and at the same time press the stop pin intoposition. When in place, the spring will hold the stop pinin position.

CAUTION

Do not exceed the specified injectornut torque. Excessive torque maystretch nut and cause impropersealing of the lapped surfaces in theinjector.

(4) Invert injector in the holding fixture, bottom endup, and tighten injector nut to torque value specified in(Table 2-2).

2-20. FUEL INJECTOR INSTALLATION.

a. Preliminary Checks.

(1) Perform all fuel injector tests as outlined inparagraph 2-16.

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(2) Before installing the fuel injector, wipe carbondeposits from the beveled seat in the injector tube. Usecare to prevent entry of foreign material into the engine.

(3) If carbon deposits are excessive and the injectortube requires reaming, refer to paragraph 2-29a, step11, and ream injector tube.

(4) Check spray tip concentricity as follows:

(a) Place the injector in J5119 concentricitygage as illustrated in figure 2-43 and adjust the dialindicator to zero.

(b) Rotate the injector 360° and note the totalrunout as indicated on the dial.

(c) If the total runout exceeds 0.008 inch,remove the injector from the gage. Loosen the injectornut, recenter the spray tip, tighten the injector nut (seeTable 2-2) and recheck the concentricity.

(d) If after several attempts the spray tipcannot be positioned satisfactorily, check thereassembly of the entire injector.

b. Installation.

(1) Fill the injector with clean diesel fuel at the inletfilter until fuel runs out of the outlet cap.

(2) Insert injector into injector tube with lockingdowel registering with locating hole in cylinder head, andwith pin on injector control tube lever registering withcontrol rack lever.

Figure 2-43. Checking Fuel Injector Spray Tip forConcentricity

(3) Install the injector clamp (figure 2-26) andtighten bolt to torque value specified in Table 2-2. Donot tighten injector clamp bolt with more than specifiedtorque, as this may cause the moving parts of theinjector to bind. After tightening, check the injector rackfor free movement.

(4) Check to make sure the rocker arm bridge ispositioned properly; then tighten the rocker arm bracketbolts to torque value specified in Table 2-2.

CAUTION

Do not bend the fuel pipes, and donot exceed the specified fuel pipe nuttorque. Excessive tightening willtwist or fracture the flared ends of thefuel pipes and result in leaks.

(5) Align the fuel pipes and connect them to theInjector and the fuel connectors. Use socket J8932-01and a torque wrench to tighten fuel pipe nuts to torquevalue specified in Table 2-2.

(6) Adjust the exhaust valve clearance (cold setting,paragraph 2-5).

(7) Time the fuel injector as outlined inparagraph 2-6.

NOTE

If all of the fuel injectors have beenreplaced, perform a complete tune upon the engine.

(8) Install rocker arm covers in reverse ofinstructions on figure 2-2.

Section VII. ROCKER ARMS,PUSH RODS AND CAM FOLLOWER

2-21. GENERAL.

a. Rocker Arms.

(1) Three rocker arms are provided for eachcylinder; the two outer arms operate the exhaust valvesand the center arm operates the fuel injector.

(2) Each set of three rocker arms pivots on aseparate shaft supported by two brackets. Bolts securethe brackets to the cylinder head.

b. Push Rods

The rocker arms are operated by a camshaft throughcam followers and short push rods extending through thecylinder head.

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c. Cam Followers.

Each cam follower operates in a bore in the cylinderhead. A guide for each set of three cam followers isattached to the bottom of the cylinder head to keep thefollower rollers in line with the cams.

2-22. REMOVAL AND DISASSEMBLY.

a. Removal.

(1) Rocker arms and shaft removal.

(a) Remove rocker arm covers as instructedon figure 2-2.

(b) Rotate the engine in the direction ofengine rotation to bring the push rod ends of fuel injectorand valve rocker arms in line horizontally.

CAUTION

Immediately after removing the fuelpipes, cover each injector openingwith a dust cap to prevent dirt orother foreign matter from enteringthe injector.

(c) Remove the rocker arm and shaft(figure 244).

(d) Repeat steps (b) and (c) for each of thesix rocker arm shafts.

(2) Cam follower and push rod removal (cylinderhead installed).

(a) Remove push rod lock nut (figure 2-44).Install push rod remover too] on push rod with flatwasher and reinstall lock nut, tightening the lock nut untilthe cam follower spring is compressed

Figure 2-44. Rocker Arm, Shaft and Push Rod Removal

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(b) Remove push rod retaining ring(figure 244).

(c) Pull the push rod and cam follower fromthe bore in the cylinder head.

(d) Remove the lock nut, tool and flat washerfrom the push rod.

b. Disassembly.

Disassemble the rocker arms, injector arm, push rod andcam follower in numerical sequence Illustrated onfigure 2-45.

2-23. CLEANING, INSPECTION AND REPAIR.

a. Cleaning.

Clean all parts with cleaning solvent and dry thoroughlyMake sure all oil passages in the rocker arms, rockerarm shafts and bracket bolts are open and clean.

b. Inspection and Repair.

(1) Inspect all parts for excessive wear or otherdamage. Parts subject to wear are listed in Table 2-3.in addition to the following inspections, inspect partssubject to wear according to the wear limits specified inthe table, and replace any parts that fail to meet therequirements.

Figure 2-45. Rocker Arm, Push Rod and Cam Follower Disassembly

19. Clevis (6)20. Bushing (6)21. Small bushing (6)22. Large bushing (6)23. Lock nut (18)24. Retaining ring (18)25. Upper seat (18)26. Spring (18)27. Lower seat (18)28. Push rod (18)29. Pin (18)30. Roller (18)31. Bushing (18)32. Cam follower (18)33. Valve locks (48)34. Spring cap (24)35. Spring (24)36. Valve (24)

1. Bolt (12)2. Rocker bracket (12)3. Rocker shaft (6)4. Plug5. LH exhaust valve arm (6)6 Bridge pin (6)7. Valve bridge (6)8. Clevis pin (6)9. Clevis (6)

10. Bushing (12)11. RH exhaust valve arm (6)12. Bridge pin (6)13. Valve bridge (6)14. Clevis pin (6)15. Clevis (6)16. Bushing (12)17. Injector arm (6)18. Clevis pin (6)

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Table 2-3. Engine Wear Limits, Fits and Tolerances

Note: Items are listed in order of inspection procedures.

Dimensions andTolerances (Inches)

Component Points of Measurement MIN. Max

MaximumAllowableWear andClearance(Inches)

ROCKER ARMS AND SHAFTSRocker arm shaft diameter 0.8735 0.8740Injector rocker arm bushing inside diameter 0.8750 0.8760Diameter of bore in exhaust valve rocker arm for rocker arm shaft 0.8753 0.8763Clearance - shaft-to-injector rocker arm bushing 0.0010 0.0025 0.0040Clearance - shaft-to-valve rocker arm bore 0.0013 0.0028 0.0040

CAM FOLLOWERSDiameter 1.0600 1.0610Clearance - follower-to-head 0.0016 0.0036 0.0060

CAM FOLLOWER ROLLERS AND PINSClearance - pin-to-bushing 0.0013 0.0021 0.010

Horiz.Side clearance - roller-in-follower 0.0150 0.0230 0.0230

CYLINDER HEADBottom surface flatness 0.004

Transverse 0.005Longitudinal

Cam follower bore 1.0626 1.0636Exhaust valve seat insert counterbore diameter 1.1590 1.1600

EXHAUST VALVESStem diameter 0.2480 0.2488Valve head-to-cylinder head Valve 0.0240 0.0390

flush recess max. belowwithhead

VALVE GUIDESDistance below top of head 0.0100 0.0400Diameter - inside 0.2505 0.2515Clearance - stem-to-guide 0.0017 0.0035 0.0050

VALVE SEAT INSERTS 1.1605 1.1615Outside diameter 3/64 5/64 5/64Seat width 0.0020 0.0020Valve seat runout

0.0030 0.0050 0.0070GOVERNOR DRIVE GEARBacklash

OIL PUMPRotor lobe clearance 0.0040 0.0110Body-to-rotor clearance 0.0010 0.00352-30

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Table 2-3. Engine Wear Limits, Fits and Tolerances (Continued)


Component Points of MeasurementMIN. Max

MaximumAllowableWear and

Clearance (Inches)FLYWHEEL AND FLYWHEEL HOUSINGRunout - flywheel-to-housing 0.0070Concentricity - flywheel-to-housing 0.0130

PISTON PINSDiameter 1.3746 1.3750 0.0100Clearance - pin-to-piston bushing 0.0025 0.0034 0.0100Clearance - pin-to-rod bushing 0.0010 0.0019

PISTONSDiameter (at skirt) 3.8699 3.8721Clearance - piston-to-liner 0.0031 0.0068 0.0100Out-of-round 0.0005Taper 0.0005Piston pin bushing - inside diameter 1.3775 1.3780

PISTON RINGSCompression rings

Gap 0.0200 0.0460 0.0600Clearance - ring-to-groove

Top (No. 1) 0.0030 0.00060 0.0120No. 2 0.0070 0.0100 0.0140No. 3 and 4 0.0045 0.0070 0.0120

Oil ringsGap 0.0100 0.0250 0.0440Clearance - ring-to-groove 0.0015 0.0055 0.0080

CONNECTING ROD BEARINGSBearing inside diameter (vertical axis) 2.7511 2.731Bearing thickness - 90 degrees from parting line 0.1247 0.1252 0.1230Clearance - bearing-to-crankshaft journal 0.0011 0.0041 0.0060

CONNECTING RODSLength - center to center 8.7990 8.8010Lower bore - diameter 2.7515 2.7525Bushing inside diameter 1.3760 1.3765Normal rod side clearance 0.0080 0.0160

IDLER GEARBacklash 0.0030 0.0050 0.0070Idler gear bearing inside diameter 2.1860 2.1870Idler gear hub outside diameter 2.1825 2.1835

Clearance - bearing-to-hub 0.0025 0.0045 0.0070Thrust washer thickness 0.1180 0.1200End play 0.0060 0.0130 0.0170

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Table 2-3. Engine Wear Limits, Fits and Tolerances (Continued)


Component Points of MeasurementMIN. Max

MaximumAllowableWear and

Clearance (Inches)CAMSHAFTShaft diameter at bearings 2.1820 2.1825Runout at center bearing (when mounted on end bearings) 0.002Thrust washer thickness 0.2080 0.2100Clearance - camshaft-to-thrust washer 0.0080 0.0150 0.0210

CAMSHAFT BEARINGSBearing inside diameter 2.1870 2.1880Clearance - bearings-to-shaft 0.0045 0.006 0.0080

CAMSHAFT TIMING GEARSBacklash 0.0030 0.0050 0.0070

CRANKSHAFT TIMING GEARBacklash 0.0030 0.0050 0.0070

CRANKSHAFTJournal diameter - connecting rod 2.7490 2.7500Journal out-of-round 0.00025Journal taper 0.0005 0.0030End play 0.0040 0.0110 0.0180

CYLINDER LINERSOutside diameter (upper seal ring surface) 4.4850 4.4860Outside diameter (lower seal ring surface) 4.3550 4.3560Inside diameter 3.8752 3.8767

Out-of-round 0.0020 0.0030Taper-liner 0.0010 0.0020

Depth of liner flange below block 0.0465 0.0500 0.0500

CYLINDER BLOCKBlock bores

Diameter (top) 4.5195 4.5215 4.5235Diameter (center) 4.4865 4.4880 4.4900Diameter (bottom) 4.3565 4.3575 4.3595Out-of-round 0.0015Taper 0.0015

Top surface flatnessTransverse (all) 0.0030Longitudinal 0.0060

Depth of counterbores (top surface)Cylinder head seal strip groove 0.0970. 0.1070Oil holes 0.0920 0.0980Water holes 0.1090 0.1150

Main bearing bore inside diameter (vertical axis) 3.7510 3.7520Cylinder liner counterbore

Diameter 4.8200 4.8350Depth 0.3000 0.3020

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(2) Measure the clearance between the rocker armshaft and the injector rocker arm bushing. Measure theclearance between the rocker arm shaft and the exhaustrocker arm (which has no bushing). The maximumclearance is 0.004 inch with used parts.

CAUTION

Do not attempt to straighten a bentpush rod.

(3) Inspect rounded end of push rods for excessivewear. Inspect push rods for bent condition. Replace adefective push rod.

(4) Inspect the push rod springs for damage. Checkthe push rod spring tension. Use a spring tester tocheck the push rod spring load. Replace the springwhen a load of less than 250 pounds will compress thespring to a length of 2-9/64 inches.

(5) Inspect the cam follower holes in the cylinderhead to make sure they are clean, smooth and free ofscore marks.

(6) Check the follower to cylinder head clearance.The clearance must not exceed 0.006 inch with usedparts. Inspect the cam follower roller to make sure itturns smoothly and freely on its pin, and that the roller isfree from flat spots or scuff marks If the roller isdamaged, then inspect the cam lobe on which itoperates.

CAUTION

Do not attempt to bore out the legs ofa standard cam follower for anoversize roller and pin set. Thiscannot be over emphasized becauseof the extremely close manufacturingtolerances.

NOTE

Cam follower assemblies with theletter "S" stamped on the end of theroller, pin and on the leg of the camfollower body are equipped withoversize roller and pin sets.

(7) Refer to figure 2-46 and check the clearancebetween the cam roller and follower, and the clearancebetween the roller bushing and pin. If the clearance isexcessive replace the cam follower or install a new rollerfollower set. When replacing a cam follower or installinga new roller set make sure the follower legs are beveled.

(8) Remove and install the cam follower roller andpin as follows:

(a) Clamp fixture securely in a vise asillustrated in figure 2-47A and place the cam follower inthe groove in the top of the fixture, with the follower pinresting on top of the corresponding plunger in the fixture.

Figure 2-46. Cam Roller Wear and Clearance

(b) Use a suitable drift and drive the pin fromthe roller. Exercise caution in removing the cam followerbody and roller from the fixture as the follower pin isseated on top of a spring loaded plunger in the fixturebody.

(c) Prior to installing a new pin, remove anyburrs on the surface of the cam follower at the pin holes.

(d) Position the follower body in the groove ofthe fixture with the proper size fixture plunger extendingthrough the roller pin hole in one of the legs of thefollower body.

(e) Coat the new roller bushing and pin withlightweight engine oil.

(f) Position roller in the cam follower body(figure 2-47). The small plunger in the fixture will alignthe roller with the pin holes in the follower body.

(g) Align the pin with the hole in the followerbody and carefully drive the pin into the body until theends of the pin are centered in the legs of the body.

(h) Refer to figure 2-46 and check the sideclearance.

2-24. REASSEMBLY AND INSTALLATION.

a. Cam Follower Installation (Cylinder HeadInstalled).

(1) Immerse the cam follower assemblies in a screentype basket and place the basket in a container oflightweight engine oil (heated to 100 to 125°F) for atleast one hour before installation. Rotate the camfollower roller during the soaking period to aid in purgingany air from the bushing-roller area.

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Figure 2-47. Cam Follower Roller Pin Removal and Installation

(2) Note the oil holes in the bottom of the camfollower (32, figure 2-45). With this hole pointing awayfrom the exhaust valves, slide the cam followerassembly into position.

(3) Install a serrated lower spring seat (27), spring(26) and upper spring seat (25) on each push rod (28).

(4) Install the assembled push rod into the propercam follower.

(5) Install flat washer and nut on the push rod, thenplace removal tool on the push rod between the washerand upper spring seat. Tighten nut on push rod until thespring is compressed far enough and install the push rodspring retainer (24, figure 2-45).

(6) Remove the nut, flat washer and tool from thepush rod. Reinstall the locknut (23, figure 2-45) on thepush rod.

b. Rocker Arm and Shaft Reassembly andInstallation.

(1) Reassemble injector and rocker arms in reverseof numerical sequence as illustrated in figure 2-45.

NOTEThe injector rocker arm (17, figure2-45) (center rocker arm) is slightlydifferent from the exhaust rockerarms (5 and 11) ; the boss for theshaft on the valve rocker arms islonger on one side of the arm thanthe other. The extended boss on thevalve rocker arms must face theinjector rocker arm.

(2) Screw each arm assembly clevis down onrespective push rods (figure 2-44) until the end of thepush rod is flush with the inner side of the clevis. Lockclevis to push rod with lock nuts.

CAUTIONThere is a possibility of damaging theexhaust valves if the exhaust valvebridges are not resting on the ends ofthe exhaust valves when tighteningthe rocker arm bracket bolts. Referto figure 2-48 for proper rocker armbridge position.

(3) Install rocker arm shaft, brackets and bolts inreverse of instructions on figure 2-44. Tighten rockerarm bracket bolts to torque value specified in Table 2-2.

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A. BRIDGE IMPROPERLY POSITIONED B. BRIDGE PROPERLY POSITIONED

Figure 2-48. Seating of Exhaust Valve Bridge on Valve Stems

CAUTION

Do not bend the fuel pipes, and donot exceed the specified fuel pipe nuttorque. Excessive tightening willtwist or fracture the flared ends of thefuel pipes and result in leaks.

(4) Remove dust caps, align the fuel pipes, andconnect them to the injectors and fuel connectors. Usesocket J8932-01 and a torque wrench to tighten fuel pipenuts to torque value specified in Table 2-2.


(6) Time the fuel injectors as outlined in paragraph2-6.


Section VIII. CYLINDER HEADS

2-25. GENERAL.The engine is equipped with two cylinder heads. Theexhaust valves, valve seat inserts, cam followers, rockerarms, and fuel injectors are mounted in the cylinderheads. To ensure efficient cooling the exhaustpassages, valve inserts and fuel injectors are completelysurrounded with coolant. Water nozzles are installedbetween each pair of cylinders in the water inlet portswhere coolant is directed at high velocity against thesections of the head injected to the greatest heat.Gaskets and seal rings are incorporated to seal theheads to the cylinder block.

2-26. ON-VEHICLE TESTS.The following tests should be performed to aid indetermining whether a cylinder head should be removed.If an engine fails either of these tests, the cylinder headsshould be removed to determine the cause of failure.

a. Cylinder Compression Test.

(1) Start engine and operate until normal operatingtemperature is reached.

(2) Stop engine and remove rocker arm covers asInstructed on figure 2-2.

(3) Remove fuel inlet and fuel outlet pipes from No.2L fuel injector and fuel connectors.

(4) Remove the No. 2L fuel injector(paragraph 2-15).

(5) Use one of the fuel pipes as a jumperconnection between the fuel inlet and return manifold topermit fuel to flow directly to the return manifold.

(6) Install the adapter and pressure gage fromJ9531-01 diagnosis kit in place of the No. 2L fuelinjector.

NOTEDo not crank the engine with thestarter motor when checkingcompression pressure.

(7) Start the engine and operate at 600 rpm.

(8) Observe and record compression pressureindicated on gage.

(9) Stop engine and remove pressure gage,adapter, and jumper connection.

(10) Install No. 2L fuel injector and fuel inlet andoutlet pipes.

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(11) Perform the preceding cylinder compressioncheck, steps 3 through 10, on each cylinder.

(12) The compression pressure in any one cylinder ata given altitude above sea level must not be less thanthe minimum listed in Table 2-4. in addition, thedifference between highest and lowest cylindercompression pressures must not be more than 25 psigat 600 rpm.

Table 2-4. Cylinder Compression Test Chart

Minimum Compression Altitude AbovePressure at 600 RPM Sea Level

(PSIG) (Feet)540 0500 2,500465 5,000430 7,500395 10,500

b. Crankcase Pressure Test.

The crankcase pressure indicates the amount of air thathas passed between the piston oil control rings and thecylinder liner into the crankcase. A slight pressure in thecrankcase is required to prevent the entrance of dust. Aloss of lubricating oil through the breather tube ordipstick hole m the cylinder block indicates excessivecrankcase pressure. The causes of high crankcasepressure may be traced to excessive blow-by due toworn piston rings, a hole or a crack in a piston crown,loose piston pin retainers, or defective cylinder head orend plate gaskets. Obstructions in the breather tubemay also cause the high crankcase pressure.

(1) Remove dipstick and dipstick tube from cylinderblock (paragraph 2-39a).

(2) Using an adapter and the manometer fromJ9531-01 diagnosis kit, install adapter in dipstick tubeopening of cylinder block and connect hose to adapterand to one manometer tube connector assembly.

(3) Mount manometer in a vertical position andadjust scale so that zero mark is opposite liquid level.

NOTEA mercury manometer is read bysighting horizontally between the topof the convex mercury surface (figure2-49) and the scale. A watermanometer is read by sightinghorizontally between the bottom ofthe concave water surface and thescale.

SURFACE OF FLUIDSCONVEX FOR MERCURY CONCAVE FOR WATER

Figure 2-49. Reading Manometer Scale

(4) Close manometer tube connector attached tohose.

(5) Start engine and operate at a speed of 2500rpm.

(6) Slowly open manometer tube connectorattached to hose while carefully observing liquid level inmanometer tube.

(7) When manometer tube connector has beenopened one full turn, measure crankcase pressureindicated on manometer scale. Pressure indication mustnot exceed 0.9 Inch of water (0.066 inch of mercury).

(8) Increase engine speed to 2800 rpm.(9) Measure crankcase pressure indicated on

manometer scale. Pressure indication must not exceed1.0 inch of water (0.074 inch of mercury).

(10) Disconnect hose from manometer and adapter,remove adapter, and install dipstick tube and dipstick(paragraph 2-39c).


a. Removal.

(1) Remove exhaust manifold (paragraph 2-11).(2) Drain coolant and remove thermostat and

coolant piping (Chapter 5, paragraph 5-6).(3) If necessary, remove rocker arm cover as

instructed on figure 2-2.(4) Remove eight cylinder head bolts, attach a

suitable lifting device with at least 200 pounds capacity,and remove the cylinder head as illustrated in figure2-50.

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Figure 2-50. Cylinder Head Removal

b. Disassembly.

CAUTIONWhen resting cylinder head assemblyon work bench, protect cam followerrollers and injector spray tips byresting valve side of head on woodenblocks at least 2 inches thick.

(1) Rest the cylinder head on its side and removethe cam followers as illustrated in figure 2-51.

(2) Remove the rocker arms and push rods asoutlined in paragraph 2-22a.

(3) Remove the fuel injectors as outlined inparagraph 2-15.

(4) Disassemble the fuel injector control tube innumerical sequence as illustrated in figure 2-52.

(5) Place a block of wood under the cylinder head tosupport the exhaust valves.

(6) Thread the spring compressing tool into one ofthe rocker arm bolt holes as illustrated in figure 2-53Compress the spring and remove the twelve two-piecevalve locks (33, figure 2-45).

Figure 2-51. Cam Follower Removal

(7) Remove twelve spring caps (34) and springs(35). Turn the cylinder head over, using care to keep thevalves from falling out of the head. Number the valves(36) so they can be installed in the same location andremove the valves.

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1. Capscrew (4) 5. Screw (6) 9. Lever2. Lock washer (4) 6. Lever (3) 10. Bracket3. Bracket 7. Pin 11. Tube4. Spring 8. Grooved pin

Figure 2-52. Injector Control Tube Disassembly

Figure 2-53. Exhaust Valve Spring Removal

NOTEFurther disassembly of the cylinderhead should be performed only ifinspection requires replacement ofvalve guides, injector tubes, valveseats, water nozzles, etc. If waterjacket is to be leak tested (paragraph2-28b), the injector tubes must not beremoved.

(8) Support the cylinder head with the top side upand screw the remover tool shown in figure 2-54 into theinjector tube.

Figure 2-54. Fuel Injector Tube Removal

(9) Invert the cylinder head and insert the drivingrod through the spray tip opening of the tube; thenthread the driving rod into the end of the remover tool,and remove the injector tube as illustrated in figure 2-54.

(10) Support the cylinder head, bottom side up, onwooden blocks which are at least 3 inches thick.Remove the exhaust valve guide as Illustrated in figure2-55.

(11) Place the cylinder head on its side and removethe exhaust valve seat insert as illustrated in figure 2-56.

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Figure 2-55. Exhaust Valve Guide Removal

Figure 2-56. Exhaust Valve Seat Insert Removal

(12) Disassemble the remaining cylinder headcomponents as illustrated in figure 2-57.


a. Cleaning.

(1) Clean the cylinder head by washing withcleaning solvent and dry thoroughly.

(2) Steam clean the cylinder head oil galleries.

b. Cylinder Head Leak Test.

(1) Prepare the cylinder head for leak test bysealing all water holes in the head with steel plates andrubber gaskets as illustrated in figure 2-58.

(2) Install dummy or scrap injectors to insureseating of the injector hole tubes, and tighten injectorclamp bolts to torque value specified in Table 2-2.

NOTE

The dummy injectors may be madeup with old injector nuts and bodies;the spray tip is not necessary.

(3) Drill and tap one of the end water hole covers foran air hose connection as illustrated in figure 2-58 andapply 80 to 100 psig air pressure.

(4) Immerse the head in a tank of water previouslyheated to 180 to 200°F for twenty minutes to thoroughlyheat the cylinder head. Observe water in tank forbubbles, which indicates a crack or leak.

(5) Release air pressure and remove the cylinderhead from the tank. Remove plates and dummyinjectors.

(6) Dry the head with compressed air.(7) Replace any leaking injector hole tubes.

Replace a cracked cylinder head.

c. Inspection and Repair.

(1) Use an accurate straight edge and feeler gageto check the cylinder head for warpage as illustrated infigure 2-59. Check the transverse warpage at each end(A and D) and between all cylinders (B and C). Alsocheck for longitudinal warpage in six places (1 through6) in the same manner. Reface the cylinder head ifwarpage exceeds the limits specified in Table 2-3.

(2) The maximum allowable warpage limits shouldbe used as a guide m determining the advisability ofreinstalling the head on the engine or of refacing it. Thenumber of times a cylinder head may be refaced will, ofcourse, depend upon the amount of stock removed fromthe head during previous reworking operations. Whenrefacing a cylinder head, the amount of stock removedshould be stamped on the face of the fire deck near theouter edge of the head, in an area not used as a sealingsurface. Not over 0.020 inch of metal should beremoved from the fire deck of any cylinder head. Thedistance from the top deck to the bottom (fire deck) ofthe cylinder head must not be less than 4.376 inches asshown in figure 2-60.

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1. Injector tube (3)2. Ring seal (3)3. Valve spring seat (12)4. Valve guide (12)5. Valve seat insert (12)6. Cup plug7. Water nozzle (4)8. Plug (4)9. Pipe plug (2)

10. Fuse plug

11. Pipe plug (6)12. Cup plug (3)13. Capscrew (4)14. Lock washer (4)15. Cover (2)16. Cover gasket (2)17. Cylinder head18. Stud (8)19. Cylinder head bolt (16)20. Cylinder head oil ring (2)21. Water hole end seal (8)22. Nonmetallic oil washer (4)23. Compression gasket (6)24. Water hole center seal (8)

Figure 2-57. Cylinder Head Disassembly

NOTE

If the cylinder head has been refaced,and new injector tubes have beeninstalled, perform the cylinder headleak test as outlined in paragraph 2-28b.

(3) Inspect cam follower bores in cylinder head forscoring or wear. Light score marks may be cleaned upwith crocus cloth dampened with diesel fuel. If bores areexcessively scored or worn so that cam follower-to-headclearance exceeds value specified in Table 2-3, replacethe cylinder head.

(4) Check valve seat inserts for cracks or burning.Also check valve guides for scoring.

(5) Check water nozzles for tightness in cylinderhead. Water nozzles are used only in the passagesbetween cylinders. To install or replace cylinder headwater nozzles:

(a) Be sure water inlet ports in bottom of headare clean and free of scale. Water holes may becleaned up with a 5/8 inch diameter drill. Break theedges of holes slightly.

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Figure 2-58. Cylinder Head Prepared for Leak Test

Figure 2-59. Checking Bottom of Cylinder Headfor Warpage

Figure 2-60. Minimum Distance Between Top andBottom Faces of Cylinder Head

(b) Check for press fit of nozzles in cylinder head. Ifwater holes in head have been enlarged by corrosion,use wooden plug or other suitable tool to expandnozzles, so that they will remain tight after installation.

(c) Press the nozzles into place with outlet holespositioned toward longitudinal centerline of cylinder headas shown in figure 2-61. The angle between the outletholes in the nozzles is 90°. Nozzles should be fromflush to 1/32 inch below bottom surface of cylinder head,otherwise interference with proper seating of the headon the cylinder block may be encountered.


a. Reassembly.NOTE

When installing the plugs in the fuelmanifold, apply a small amount ofsealant as a "dual purpose sealer" tothe threads of the plugs only. Workthe sealant into the threads and wipeoff excess sealant with a clean lint-free cloth so that the sealant will notbe washed into the fuel system andresult in serious damage to the fuelinjectors.

(1) Install all cylinder head plugs and studs ifremoved.

Figure 2-61. Alignment of Water Nozzles in CylinderHead

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(2) Clean the valve seat insert counterbores in thecylinder head and the valve seat inserts by washing withcleaning solvent. Dry thoroughly with compressed air atapproximately 40 psig.

(3) Inspect the counterbores for cleanliness,concentricity, flatness and cracks. Refer to Table 2-3 forvalve seat insert counterbore diameter.

(4) Immerse the cylinder head for at least 30minutes in water heated to 180 to 200°F.

(5) Rest the cylinder head, bottom side up, on awork bench and position the valve seat insert squarely inthe counterbore seat, face up. Install the insert in thecylinder while the head is still hot and the insert is atroom temperature. Drive the insert into place withreplacer tool as illustrated in figure 2-62.

Figure 2-62. Installing Exhaust Valve Seat Insert

NOTE

Installation may be difficult iftemperature of the two parts is nearlythe same. If necessary, repeat step 4to heat cylinder head.

(6) Turn the cylinder head right side up and installthe exhaust valve guides as follows:

(a) Install the threaded end of valve guide inthe proper guide replacer tool.

(b) Position the valve guide squarely in thebore of the cylinder head, tap the replacer tool gently,and drive the guide into the cylinder head as illustratedin figure 2-63.

Figure 2-63. Installing Exhaust Valve Guide

CAUTION

Do not use the installed valve guidesas a means of turning the cylinderhead over or handling the cylinderhead.

(7) An exhaust valve which is to be reused may berefaced, if necessary. To provide sufficient valvestrength and spring tension, the edge of the valve mustnot be less than 1/32 inch thick.

(a) Before either a new or used valve isinstalled, inspect the valve seat in the cylinder head forproper valve seating. The proper angle for the seatingface for both valve and seat insert is 30 degrees.

(b) When a new valve seat insert is installedor an old insert is reconditioned, the valve inserts mustbe ground.

(c) Refer to figure 2-64 and Table 2-3 forexhaust valve seat insert grinding specifications.

CAUTION

Do not allow the grinding wheel totouch the cylinder head whengrinding the inserts.

(d) Apply a 30 degree grinding wheel to thevalve seat insert.

(e) Grinding will reduce the thickness of thevalve seat insert and cause the valve to recede into thecylinder head. If after several grinding operations thevalve recedes beyond the limits shown in figure 2-64,replace the valve seat insert.

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NOTE: ALL DIMENSIONS IN INCHES.

Figure 2-64. Exhaust Valve and Valve Seat InsertGrinding Dimensions

(f) After grinding has been completed, cleanthe valve eat thoroughly with cleaning solvent and drywith clean compressed air.

(g) Set a dial indicator in position asIllustrated in figure 2-65, and rotate the dial indicator tocheck the concentricity of each valve seat relative to thevalve guide. If the runout exceeds that specified inTable 2-3, check for a bent valve guide beforeregrinnding the insert.

(h) After a valve seat insert runout within thedesired limits is obtained, determine the position of thecontact area between the valve and the valve seatinsert. Apply a light coat of Prussian Blue, or similarpaste, to the valve seat insert. Next, lower the stem ofthe valve m the valve guide and bounce, but do notrotate, the valve on the insert. This procedure willindicate the area of contact on the valve face. The mostdesirable area of contact is the center of the valve faceand is 3/64 inch to 5/64 inch wide (figure 2-64).

(i) The 30 degree valve seat insert face maybe adjusted, relative to center of valve face, by using 15and 60 degree grinding wheels to dress the insert top oropen the insert throat.

(j) After the valve seat inserts have beenground and checked, thoroughly clean the cylinder headbefore installing the valves.

(k) Apply a light coat of engine oil on thevalve stems (36, figure 2-45) and install the valves in thecylinder head. If reconditioned valves are used, installthem in the same ports from which they were removed.

(l) Hold the valves in place with masking tapeand turn the cylinder head right side up on the workbench. Place a board under the head to support thevalves.

Figure 2-65. Checking Valve Seat Insert Concentricity

(m) Install valve spring seat (3, figure 2-57),valve spring 35, figure 2-45), and spring cap (34).Thread the valve spring compressor adapter into therocker shaft bolt holes in the cylinder head as illustratedin figure 2-53. Depress the compressor tool and secureeach valve in position with two spring locks (33, figure2-45). Release tool and install the remaining exhaustvalves in a similar manner.

(n) Refer to figure 2-64 and check the positionof the exhaust valves after installation.

(8) Thoroughly clean the injector tube hole in thecylinder head; remove all dirt, burrs, and foreign materialthat may prevent the tube from seating at the lower endor sealing at the upper end.

(9) Install a new injector tube sealing ring in theinjector tube counterbore. Use the injector tube installertool and install the injector tube in the cylinder head asillustrated in figure 2-66.

(10) With the injector tube properly positioned in thecylinder head, flare the lower end of the tube as follows:

(a) Turn the cylinder head bottom side up.Remove the pilot tool and thread CSD1229-2 flaring toolinto the tapped end of the CSD1229-1 installer tool asillustrated in figure 2-67.

(b) Use a socket and torque wrench asillustrated in figure 2-67 and apply approximately 30 lbs.ft. torque to flare tube; then remove tools.

(11) After the injector tube has been installed in thecylinder head, it must be finished in three operations.First, hand reamed, to receive the injector body nut andspray tip; second, spot faced to remove excess stock atlower end of injector tube; and third, hand reamed toprovide a good seating surface for lower end of injectornut.

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Figure 2-66. Fuel Injector Tube Installation

Figure 2-67. Flaring Lower End of Fuel Injector Tube

(a) Ream the injector tube for injector nut andspray tip with the cylinder head right side up and theinjector free from dirt as illustrated in figure 2-68.Withdraw reamer frequently for removal of chips.

(b) With the cylinder head bottom side up,insert pilot cutting tool into small hole of injector tube.Then, use a socket and speed handle and removeexcess stock so that the lower end of the injector tube isflush to 0.005 inch below the finished surface of thecylinder head.

Figure 2-68. Reaming Fuel Injector Tube for InjectorBody and Spray Tip

(c) Install the injector assembly in the cylinderhead to determine the amount of stock that must beremoved from the bevel seat of the injector tube. Notethe relationship between the numbered surface of thespray tip to the fire deck of the cylinder head asillustrated in figure 2-69.

(d) With the first reaming operation completedand the injector tube spot faced, wash interior of injectortube with cleaning solvent and dry with compressed air.Then, perform the second reaming operation.

CAUTIONService replacement injector tubesare semi finished and have a narrowland machined at the beveled seat toreduce reaming time. Extreme caremust be exercised while reaming thebevel seat to prevent reamer fromcutting too deeply and possiblythrough the thin wall of the tube.

(e) Ream the injector tube for the injector nutas illustrated in figure 2-70. Make trial cut by turningreamer without applying downward force. Removereamer, blowout chips, and look at the bevel seat to seewhat portion of the seat has been cut.

(f) Proceed carefully with the reamingoperation, withdrawing the reamer occasionally toobserve progress.

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Figure 2-69. Checking Location of Fuel Injection SprayTip

Figure 2-70. Reaming Fuel Injector Tube forInjector Nut

(g) Remove chips from injector tube and,using an injector for a gage (figure 2-69), continue thereaming operation until the shoulder of the spray tip iseither flush or extends a maximum of 0.015 inch belowthe fire deck of cylinder head as illustrated in figure 2-69.

(12) Install the push rods and cam followers asfollows:

(a) Install nine push rod spring retainers (24,figure 2-45) in the cylinder head.

(b) Install lower spring seat (27), spring (26)and upper spring seat (25) on the push rod (28). Then,install the assembled push rod into the cylinder head inthe proper bore.

(c) Screw the push rod lock nut (23), on eachpush rod as far as possible; then screw the push rod intothe rocker arm clevis until the end of the rod is flush withor above the inner side of the clevis.

(d) Place the cam followers in a screen typebasket and immerse the basket m a container oflightweight engine oil (heated to 100 to 125°F) for atleast one hour before installation. Rotate the camfollower rollers during the soaking period to aid inpurging any air from the bushing roller area.

(e) Note the oil hole m the bottom of the camfollower. With this hole pointing away from the exhaustvalve guide, slide the cam followers into position incylinder head (figure 2-51).

(f) Install the cam follower guide as illustratedin figure 2-51. Tighten cam follower guide bolts totorque value specified in Table 2-2.

(g) Check to make sure there is at least 0.005inch clearance between the cam follower legs and thefollower guide as illustrated in figure 2-71.

(h) If the clearance is insufficient, loosenguide bolts slightly and tap each corner of the guide witha brass rod as shown in figure 2-72. Then, retightenbolts and recheck the clearance.

Figure 2-71. Checking Cam Follower-to-GuideClearance

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Figure 2-72. Positioning Cam Follower Guides

(13) Install the fuel injectors (paragraph 2-20).

(14) Install the rocker arms (paragraph 2-24).

(15) Reassemble the injector control tube in reverseof numerical sequence Illustrated in figure 2-52. Tightenbracket bolts (1, figure 2-52) to torque value specified in(Table 2-2).

(16) Install proper sized pipe plugs in cylinder headsif removed.

b. Installation.

(1) Check to make sure the tops of the pistons are clean and free from foreign material.

(2) Check to make sure that each push rod isthreaded into the clevis until the end of the push rodprojects through the clevis.

(3) To avoid damage to water and oil seals, checkmake sure that the grooves and the counterbores in thetop of the cylinder block are clean and smooth.

(4) Refer to figure 2-73 and install new seal ringsand compression gaskets as follows:

NOTE

Water seals, oil seals, andcompression gaskets should neverbe reused.

(a) Install new compression gasket on eachcylinder liner.

Figure 2-73. Installing Seal Rings and CompressionGaskets

(b) Place new seat rings in counterbores ofwater and oil holes in cylinder block.

(c) Install new oil ring in rectangular milledgroove near the outer edge of the area to be covered bythe cylinder head.

(5) Install two guide studs in each end of thecylinder block bolt holes to keep from disturbing gasketsand seals during cylinder head installation.

(6) Wipe bottom of cylinder head clean. Use asuitable lifting device and install the cylinder head asillustrated in figure 2-50.

(7) Lubricate head bolt threads and the underside ofeach bolt head with sealing compound (InternationalCompound No. 2 or equivalent) and install cylinder headbolts; then, beginning on camshaft side of head take uptension in follower springs by tightening bolts lightly.

(8) Tighten bolts in numerical sequence shown mfigure 2-74, about one-half turn at a time, until torquevalue specified in Table 2-2 is attained.

(9) Install the exhaust manifold (paragraph 2-11).

(10) Install thermostat and coolant piping (Chapter 5,paragraph 5-6).

(11) Refill cooling system with antifreeze solution(see Chapter 5).


(13) Time the fuel injectors as outlined in paragraph2-6.

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Figure 2-74. Cylinder Head Bolt Tightening Sequence

(14) Start engine and check for leaks. Operateengine until normal operating temperature is reached.

(15) Stop engine and retorque cylinder head bolts tovalue specified in Table 2-2.

(16) Install rocker arm covers with new gaskets inreverse of instructions on figure 2-2.

Section IX. GOVERNOR AND DRIVE SUPPORT

2-30. GENERAL.

a. Description.

The mechanical governor is mounted on the flywheelhousing of the engine, and driven by a gear that extendsthrough the end plate and meshes with the balance shaftgear. The governor controls the engine idle speed andlimits the maximum operating speed of the engine. Thegovernor is lubricated by oil splash from engine geartrain distributed by revolving weights. Excess oil isreturned to the gear train through holes in the governorbearing retainer.

b. Operation.

(1) The governor holds the injector racks in theadvanced fuel position for starting when the speedcontrol lever is in the idling position. Immediately afterstarting, the governor moves the fuel injector racks to theposition required for idling.

(2) The centrifugal force of the revolving low andhigh speed weights is converted into a linear motionwhich is transmitted through the riser and operating shaftto the operating shaft lever. Refer to figure 2-5. Oneend of the lever operates against the high and low speedsprings through the spring cap, while the other endprovides a moving fulcrum on which the differential leverpivots. When the centrifugal force of the revolvinggovernor

weights balances out the tension on the high or lowspeed spring (depending on the speed range), thegovernor stabilizes the engine speed for a given settingof the speed control lever.

(3) in low speed range, the centrifugal force of thelow-and-high-speed weights together operate againstthe low speed spring. As the engine speed increases,the centrifugal force of the low and high speed weighttogether compress the low speed spring until the lowspeed weights are against their stops, thus limiting theirtravel, at which time the low speed spring is fullycompressed.

(4) Throughout the intermediate speed range theoperator has complete control of the engine becauseboth low speed spring and low speed weights are notexerting enough force to overcome the high speedspring.

(5) As speed continues to increase, the centrifugalforce of the high speed weights increases until this forcecan overcome the high speed spring and the governoragain takes control of the engine, limiting the maximumengine speed.

2-31. REMOVAL.a. Governor Linkage and Drive Support Removal.

(1) Remove piping from air cleaner and air inletelbow (see Chapter 3).

(2) Remove accelerator cable, modulator cable, andbrackets from governor (see Chapter 3).

(3) Disconnect shutdown solenoid from governorstop lever (figure 2-75A) and remove shutdown solenoid.

(4) Remove governor cover, spring housing,clamps, and hose (figure 2-75A).


(6) Remove governor control links as instructed onfigure 2-76.

(7) Remove drive support from flywheel housing asinstructed on figure 2-75.

(8) Use a suitable punch to drive the dowel pin(figure 2-75D) through the flywheel housing into thegovernor housing.

b. Governor Removal.(1) Remove six bolts (15, figure 2-77) and lock

washers (16) and remove governor.(2) Remove and discard gaskets (19 and 22).

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Figure 2-75. Governor and Drive Support Removal

Figure 2-76. Governor Control Link Removal

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1. Bolt2. Lock washer3. Stop lever4. Bolt5. Lock washer6. Throttle arm7. Cotter pin (2)8. Clevis pin (2)9. Nut (2)

10. Lower control link (2)11. Upper control link (2)12. Hose clamp (4)13. Hose (2)14. Link housing15. Bolt (6)16. Lock washer (6)17. Governor18. End adapter (2)19. Gasket20. Ball bearing21. Expansion plug22. Gasket

Figure 2-77. Governor Removal

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2-32. DISASSEMBLY AND CLEANING.

a. Disassembly.

(1) Disassemble the governor in numericalsequence illustrated in figure 2-78.

NOTEIf necessary to remove weightretainer pins (3, figure 2-78), drivepins out of carrier (6) from retainingring (2) end. Punch mark carrier atretaining ring end of weight pins tofacilitate proper reinstallation of pins.

(2) Remove governor cover bearings as illustratedin figure 2-79.

(3) Remove governor operating fork as illustrated infigure 2-80.

(4) Remove control link lever bearings as illustratedin figure 2-81.

(5) Remove governor weight shaft from weightcarrier as illustrated in figure 2-82.

NOTEDo not remove thrust bearing (8,figure 2-78) from riser (7). Riser andthrust bearing are serviced as anassembly only.

b. Cleaning.(1) Clean all parts except bearings by washing with

cleaning solvent and dry thoroughly.

(2) Clean bearings by washing with volatile mineralspirits and dry with a clean cloth. Do not spin bearingswith compressed air.

2-33. INSPECTION AND REPAIR.a. Inspection.

(I) Inspect operating levers for cracks, bentcondition or other damage.

(2) Inspect upper and lower fuel rod links forevidence of excessive wear or damage.(3) Inspect bearings and weight pins for corrosion,flat spots and excessive wear.

(4) Inspect spring seat, plunger adjusting screws,lock nuts, and other parts of control housing for defects.

(5) Check backlash of governor drive gear (seeTable 2-3).

(6) Inspect hardware and threaded openings fordamaged threads or other evidence of damage.

b. Repair.

(1) Chase threaded openings with the correct sizetap. Replace damaged hardware, including buffer screwand all lock nuts.

(2) Replace all parts found defective duringinspection.


a. Reassembly.(1) Reassemble the governor with new gasket and

copper washers in reverse of numerical sequence listedin figure 2-78. Be sure to Install the weight retainer pins(3) in the same position from which they were removed.

NOTEThe low speed spring (37) isidentifiable by a narrow blue stripe;the high speed spring (42) isidentifiable by a white stripe.

(2) Install weight carrier on shaft as illustrated infigure 2-83.

(3) Install drive gear as illustrated in figure 2-84.

(4) Check the clearance between drive support gearand governor weights as illustrated in figure 2-85.

b. Installation.(1) Install governor with new gaskets and secure

with six bolts (15, figure 2-77) and lock washers (16).Tighten bolts to torque value specified in Table 2-2.

(2) Install governor control links in reverse ofremoval (figure 2-76).

(3) Install drive support in reverse of removal (figure2-75). Tighten drive support bolts and drive supportcover capscrews to torque values specified in Table 2-2.

(4) Install governor springs and connect governorlinkage in reverse of removal (figure 2-75A).

(5) Install shutdown solenoid and reconnectsolenoid to governor stop lever (figure 2-75A).

(6) Install air cleaner piping, accelerator cable,modulator cable and brackets (see Chapter 3).

(7) Adjust governor as outlined in paragraph 2-7.

(8) Install rocker arm covers in reverse of instructions onfigure 2-2.

2-50

(Figure 2-78 Sheet 1 of 2)(Figure 2-78 Sheet 2 of 2)

TM 9-2320-277-14&P

Figure 2-78. Governor Disassembly (Sheet 1 of 2)

1. Weight assembly2. Retaining ring (4)3. Weight pin (4)4. High speed weight (2)5. Low speed weight (2)6. Weight carrier7. Riser assembly8. Thrust bearing9. Carrier shaft

10. Gasket11. Machine screw12. Lock washer13. Screw w/lock washer (6)14. Cover assembly15. Retaining ring16. Flat washer (2)17 Back-up washer

18. Preformed packing19. Roll pin20. Shutdown shaft21. Retaining ring22. Flat washer (2)23. Back-up washer24. Preformed packing25. Shaft assembly26. Pipe plug27. Tapered pin28. Fulcrum pin29. Cover assembly30. Roller bearing (2)

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TM 9-2320-277-14&P

Figure 2-78. Governor Disassembly (Sheet 2 of 2)

31. Bolt (2)32. Copper washer (2)33. Housing34. Spring retainer35. Gasket36. Retainer cap37. Low speed spring38. Low speed spring seat39. Low speed adjusting screw40. Hex nut41. Lock nut42. High speed spring43. Shim44. Hex nut45. Low speed spring plunger46. Buffer screw47. Buffer spring48. Retaining clip49. Washer(2)50. Link pin (2)51. Lever assembly52. Needle bearing (2)53. Retaining clip54. Washer55. Lever assembly56. Shoulder pin57. Housing assembly58. Expansion plug59. Screw60. Bearing (2)61. Governor shaft fork

62. Shaft assembly63. Gap adjusting screw64. Hex nut65. Lever assembly66. Shoulder pin67. Ball bearing68. Shaft69. Special pin70. Dowel pin (2)71. Dowel pin72. Boot adapter (2)73. Expansion plug74. Lock washer75. Washer

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TM 9-2320-277-14&P

Figure 2-79. Removing Governor Cover NeedleBearings

Figure 2-80. Removing Governor Operating Fork

Figure 2-81. Removing Governor Control Link Bearings

Figure 2-82. Removing Governor Weight Shaft fromWeight Carrier

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TM 9-2320-277-14&P

Figure 2-83. Installing Weight Carrier on Shaft

Figure 2-84. Installing Drive Support Gear

Figure 2-85. Checking Clearance Between DriveSupport Gear and Governor Weights

Section X. LUBRICATION SYSTEM

2-35. GENERAL.

This section provides overhaul procedures for the engineoil filter, external oil filter, oil pan, dipstick, and oil inlettube and strainer. Refer to paragraph 2-42 for theengine oil pump.

2-36. CHANGING OIL AND FILTERS.

a. Engine Oil and Filter.

The crankcase oil and engine filter element should bechanged at the interval specified in the separateOperator's Manual. To change the oil and filter elementproceed as follows:

(1) Start engine and operate until normal operatingtemperature is reached; then stop engine.

(2) Remove oil pan drain plug (figure 2-8) and draincrankcase oil.

(3) Remove plug (12, figure 2-86) and drain oil fromengine oil filter located on left side of engine crankcase.

NOTEExamine the oil drained from oil panand engine oil filter for evidence ofdirt or metal particles.

(4) Loosen and remove shoulder bolt (9) and gasket(10) and discard gasket.

(5) Lower filter shell (11) from adapter assembly (1);then remove and discard gasket (3) and throw away typefilter element (2).

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1. Adapter assembly 7. Spacer ring2. Filter element 8. Compression spring3. Gasket 9. Shoulder bolt4. Hex nut 10. Gasket5. Retainer 11. Filter shell6. Preformed packing 12. Plug

Figure 2-86. Engine Oil Filter

(6) If necessary for replacement, remove hex nut (4)and disassemble remaining filter element parts innumerical sequence illustrated in figure 2-86.

(7) If necessary for repair, remove adapters fromengine as follows:

(a) Remove two plugs (3, figure 2-87), fourcapscrews (5), lock washers (6) and flat washers (1) ;then remove filter adapter (9) from mounting adapter (7).

(b) Remove four capscrews (4) and lockwashers (6) and remove mounting adapter (7) fromengine crankcase. Discard gaskets (2 and 8).

(c) Disassemble the filter bypass assembly byremoving screw (10), spring retainer (11), spring (12)and bypass valve (13).

(d) Clean adapters and all parts of bypassassembly by washing with cleaning solvent and drythoroughly.

(e) Inspect all parts for damage, and replacedefective parts.

(f) Install bypass assembly and adapters,with new gaskets (2 and 8), in reverse of steps a throughc above.

(8) Clean parts by washing with cleaning solventand dry thoroughly. Make sure all old gasket material isremoved from mating surface on adapter assembly.

(9) Inspect spring for broken coils, and inspect thefilter shell and adapter for cracks, breaks and otherdefects.

(10) Inspect plug, shoulder bolt-and threadedopenings for damaged threads.

(11) Replace all parts found defective duringinspection.

(12) If necessary, reassemble spring (8, figure 2-86),spacer ring (7), preformed packing (6), retainer (5) andhex nut (4).

(13) Lightly coat new gasket (3) with clean engine oil,install new filter element (2) and gasket (3), and secureto adapter (1) with shell (11), new gasket (10) andshoulder bolt (9) Tighten shoulder bolt to torque valuespecified in Table 2-2.

(14) Install plugs (figure 2-8 and 12, figure 2-86) ;then remove cap from rocker arm cover (figure 2-2) andfill engine crankcase with oil specified in the separateOperator's Manual.

CAUTION

Check for oil leaks after engine isstarted. Loss of lubricating oil maycause serious damage to engine.

(15) Start engine and immediately check forminimum oil pressure gage indication (18 psig within 10to 15 seconds). Check for oil leaks with engine idling;then stop engine and check crankcase oil level asIllustrated in figure 2-12. Add oil as necessary to bringdipstick level to the full mark.

b. External Oil Filter.

The external engine oil filter is mounted outside the righthand frame rail near the front of the tractor. The externaloil filter should be changed at the interval specified in theseparate Operator's Manual as follows:

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Figure 2-87. Engine Oil Filter Adapters

(1) Remove plug (3, figure 2-88) and gasket, anddrain engine oil from filter. Inspect oil for contamination,such as evidence of metal particles.

(2) Loosen and remove stud (1) and lower shell (2),element (5), and gasket (6) from filter base. Discard thethrow away type paper element (5) and gasket (6).

(3) Clean the filter base (10) by washing withcleaning solvent and dry thoroughly. Make sure all oldgasket material is removed from mating surface on base.

(4) Inspect the filter base and shell for cracks,breaks and loose connections, and inspect plug, studand threaded openings for damaged threads. Replaceall defective parts.

(5) If necessary for replacement, disconnect hosesand remove external oil filter in numerical sequenceillustrated in figure 2-89.

(6) Lightly coat new gasket (6) with clean engine oil,install new filter element (5) and gasket (6), and secureto base (10) with shell (2) and stud (1). Tighten stud totorque value specified in Table 2-2.

(7) Install plug (3) and gasket (4), start engine, andcheck for oil leaks.

(8) Stop engine and check crankcase oil level asillustrated in figure 2-12. If necessary, add engine oil

specified in the separate Operator's Manual to bring thedipstick level to the full mark.

2-37. OIL PAN.

a. General.

The engine oil pan is constructed of stamped andwelded steel, and sealed to the engine crankcase by aone piece gasket. The oil pan houses the lower enginecomponents and also contains lubricating oil for theengine. A drain plug is provided for draining engine oil,at oil change intervals or for oil pan removal.

b. Removal.

(1) Remove oil pan drain plug (figure 2-8) and drainthe engine oil.

(2) Disconnect air compressor return hose fromright side of oil pan.

(3) Remove the oil pan in numerical sequenceillustrated in figure 2-90.

c. Cleaning.

(1) Clean the oil pan, drain plug and bolts with'cleaning solvent and dry thoroughly.

(2) Clean all gasket material from oil pan andcrankcase mating surfaces.

1. Flat washer (4)2. Gasket3. Plug (2)4. Capscrew (4)5. Capscrew (5)6. Lock washer (8)7. Mounting adapter8. Gasket9. Filter adapter

10. Screw11. Spring retainer12. Spring13. Bypass valve

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Figure 2-88. External Oil filter

Figure 2-89. External Oil Filter Hoses and Mounting

1. Stud2. Shell3. Plug4. Gasket5. Filter element6. Gasket7. Retainer8. Spring9. Bypass valve

10. Base

2-57

1. Hose fitting (4) 5. Hex nut (4)2. Hose (2) 6. Lock washer (4)3. Elbow (2) 7. Capscrew (4)4. Reducing bushing (2) 8. External oil filter

TM 9-2320-277-14&P

1. Drain plug2. Gasket 4. Oil Pan3. Bolt and washer (22) 5. Gasket

Figure 2-90. Oil Pan Removal

d. Inspection and Repair.

WARNING

Remove all traces of lubricating oiland cleaning solvent before welding.

(1) Inspect the oil pan for dents or breaks in themetal, and for cracks and broken welds. Repair dentsby pounding out with a hammer and backing block.Repair cracks and broken welds by welding. Replace anoil pan beyond economical repair.

(2) Inspect the mounting flanges for misalignment orraised surfaces surrounding the bolt holes. Replace asrequired.


e. Installation.

(1) Position a new gasket (5, figure 2-90) on oil pan(4), and secure oil pan to engine with bolts and washers(3). Tighten the bolts evenly to prevent damage to thegasket or springing the oil pan.

(2) Install gasket (2) and drain plug (1). Tightendrain plug to torque value specified in Table 2-2.

(3) Connect air compressor return hose to right sideof oil pan.

(4) Remove cap from rocker arm cover (figure 2-2)and fill engine crankcase with oil specified in theseparate Operator's Manual.

CAUTIONCheck for oil leaks after engine isstarted. Loss of lubricating oil maycause serious damage to engine.

(5) Start engine and immediately check forminimum oil pressure gage indication (18 psig within 10to 15 seconds). Check for oil leaks with engine idling;then stop engine and check crankcase oil level asillustrated in figure 2-12. Add oil as necessary to bringdipstick level to the full mark.

2-38. OIL INLET TUBE AND STRAINER.

a. Removal.

(1) Remove engine oil pan as outlined in paragraph2-37b.

(2) Remove oil inlet tube and strainer in numerical sequence illustrated in figure 2-91.


(1) Clean all parts by washing with cleaning solventand dry thoroughly. Be sure to clean all traces of gasketmaterial from the inlet tube and front end cover.

(2) Inspect strainer for breaks or holes which wouldpermit the entry of foreign material in the inlet tubeassembly. Replace as necessary.

(3) Inspect the inlet tube assembly for dents oilbreaks which would cause improper operation.

(4) Inspect gasket for breaks or tears which wouldcause leakage. Replace damaged gasket.

(5) Inspect all mounting hardware for damagedthreads. Replace parts having damaged threads.

c. Installation.

(1) Install oil inlet tube and strainer in reverse ofnumerical sequence illustrated in figure 2-91.

(2) Install engine oil pan as outlined in paragraph2-37e.

2-39. DIPSTICK.

a. Removal.

(1) Pull dipstick (1, figure 2-92) from dipstick tube(2).

(2) Remove hex nut (5), lock washer (8), flat washer(7) and bolt (6) securing clip (4) to clip bracket (9).

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Figure 2-91. Oil Inlet Tube and Strainer Removal

(3) Remove the dipstick tube (2) by unthreadingfrom the adapter (3).

(4) Remove adapter (3) by unthreading from theengine block, then remove clip (4) from adapter.


(1) Clean all parts by washing with cleaning solventand dry thoroughly.

(2) Inspect parts for bends, breaks, dents anddamaged threads. Replace all damaged parts.

c. Installation.

(1) Position clip (4) on adapter (3), and threadadapter into engine block.

(2) Thread dipstick tube (2) into adapter (3).

(3) Secure clip (4) to clip bracket (9) with hardwareillustrated in figure 2-92.

(4) Insert dipstick (1) into dipstick tube (2).

2-59

1. Self-locking bolt (2)2. Flat washer (2)3. Strainer element4. Screw (4)5. Screw (2)6. Lock washer (2)7. Gasket8. Lock washer (4)9. Flat washer (4)

10. Hex nut (2)11. Flat washer (8)12. Screw (2)13. Bracket (2)14. Oil inlet tube

TM 9-2320-277-14&P

Figure 2-92. Dipstick Removal

Section XI. FRONT TRUNNIONMOUNT, LOWER FRONT COVER AND

OIL PUMP

2-40. FRONT TRUNNION MOUNT.

a. Removal.

(1) Remove engine from tractor as outlined inparagraph 2-8.

(2) Remove bolt (1, figure 2-93) and pulley retainer(2).

(3) Use a suitable puller and remove pulley (3) fromcrankshaft.

(4) Remove the front trunnion mount in numericalsequence Illustrated in figure 2-93.


(1) Clean all parts except the cushion ring (8) bywashing with cleaning solvent. Clean the cushion ringby wiping with a damp cloth.

Figure 2-93. Crankshaft Pulley and Trunnion MountRemoval

(2) Inspect the crankshaft pulley for cracks andworn grooves. Replace a defective pulley.

(3) Inspect the trunnion for cracks and breaks.Repair by replacement.

(4) Inspect the cushion ring for evidence ofdeterioration. Replace a defective cushion ring.

(5) Inspect hardware for damaged threads.Replace all parts having damaged threads.

c. Installation.

(1) Install the front trunnion mount in reverse ofnumerical sequence illustrated in figure 2-93.

(2) Install crankshaft pulley (3), pulley retainer (2) and bolt (1). Tighten bolt to torque value specified in(Table 2-2).

(3) Install engine as outlined m paragraph 2-9.

2-41. LOWER FRONT COVER.

a. Removal.

(1) Remove the front trunnion mount as outlined inparagraph 2-40a.

(2) Remove the engine oil pan as outlined inparagraph 2-37b.

(3) Remove the oil inlet tube and strainer(paragraph 2-38a).

1. Dipstick 6. Bolt2. Tube connector 7. Flat washer3. Adapter 8. Lock washer4. Clip 9. Clip bracket5. Hex nut

1. Bolt2. Pulley retainer3. Pulley4. Bolt (2)5. Lock washer (2)6. Top support

7. Bottom support8. Cushion ring9. Bolt (6)

10. Lock washer (6)11. Trunnion

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(4) Remove attaching hardware in numericalsequence illustrated in figure 2-94 and pull lower frontcover from engine.

1. Capscrew (4) 3. Capscrew (4)2. Capscrew (4) 4. Lower front cover

Figure 2-94. Lower Front Cover Removal

b. Disassembly and Cleaning.

(1) Disassemble lower front cover in numericalsequence illustrated in figure 2-95. Discard crankshaftseal (8) and gasket (1).

(2) Clean all traces of gasket material from the frontcover and engine.

(3) Clean all parts with cleaning solvent and drythoroughly.


(1) Inspect parts for damaged threads. Replace allparts having damaged threads.

(2) Inspect the lower front cover for cracks andbreaks. Replace a defective lower front cover.

(3) Inspect bypass valve springs (6) for distortion,loss of tension and broken coils. Replace a defectivespring.

(4) Inspect bypass valves (7) for sticking. Valvesmust move freely in their bores.

d. Reassembly and Installation.

NOTE

If necessary, remove, repair, andinstall oil pump prior to installinglower front cover (see paragraph2-42).

(1) Apply a thin coat of non-hardening sealant toouter circumference of new crankshaft oil seal (8).Position front cover (9) inner face down in an arborpress, and press crankshaft seal into cover until seal isflush with outer face of cover.

(2) Reassemble lower front cover in reverseofnumerical sequence in figure 2-95.

(3) Install the lower front cover with new gasket asillustrated in figure 2-96.

(4) Secure lower front cover to the engine in reverseof numerical sequence illustrated in figure 2-94.Remove guide studs from engine before installing lasttwo capscrews. Alternately tighten capscrews, one-halfturn at a time, to torque value specified in Table 2-2.

(5) Install oil inlet tube and strainer (paragraph2-38c).

(6) Install engine oil pan (paragraph 2-37e).

(7) Install the front trunnion mount as outlined inparagraph 2-40c.

1. Gasket2. Large plug3. Small plug4. Regulator plug (2) 7. Bypass valve (2)5. Washer (2) 8. Crankshaft oil seal6. Spring (2) 9. Lower front cover

Figure 2-95. Lower Front Cover Disassembly2-61

TM 9-2320-277-14&P

Figure 2-96. Installing Lower Front Cover

2-42. OIL PUMP.

a. General.

The lubricating oil pump is assembled to the inside of thelower front cover. The pump is the rotor type in whichthe inner rotor is driven by a gear pressed on the frontend of the crankshaft. The outer rotor is driven by theinner rotor. As the rotors revolve, a vacuum is formedon the inlet side of the pump and oil is drawn from thecrankcase, through the oil pump inlet pipe and apassage in the front cover, to the inlet port and then intothe rotor compartment of the pump. Oil drawn into thecavities between the inner and outer rotors on the inletside of the pump is then forced out under pressurethrough the discharge port into a passage in the frontcover which leads to the lubricating oil filter and cooler,and is then distributed throughout the engine.

b. Removal and Disassembly.(1) Remove lower front cover as outlined in

paragraph 2-41b.

(2) If necessary for replacement, use a suitablepuller and remove oil pump drive gear (6, figure 2-97).

(3) Remove six capscrews (1) and remove oil pumpfrom inside face of lower front cover.

(4) Disassemble oil pump in numerical sequenceIllustrated in figure 2-97.

Figure 2-97. Oil Pump Removal and Disassembly

c. Cleaning, Inspection and Repair.


(2) Inspect the lobes and faces of the rotors forscratches or burrs, and the surfaces of the pump bodyand cover plate for scoring. Scratches, burrs or scoremarks may be removed with a soft stone or crocus cloth.

(3) Measure the clearance between the inner andouter rotors at each lobe (figure 2-98A). Replace rotorsif clearance exceeds limits specified in Table 2-3.

NOTE

Rotors must be replaced as amatched set.

(4) Measure the clearance from the face of thepump body to the side of the inner and outer rotor (figure2-98B). Replace rotors if clearance exceeds limitsspecified in Table 2-3, and recheck clearance with newrotor set installed. If body-to-rotor clearance stillexceeds limits specified in Table 2-3, replace the oilpump assembly.

(5) Inspect the splines of the inner rotor and thedrive gear. Replace rotor set and drive gear if splinesare excessively worn.


(1) If the oil pump drive gear was removed, refer tofigure 2-99 and install the drive gear on the crankshaft.

(2) Reassemble oil pump in reverse of numericalsequence in figure 2-97.

(3) Secure oil pump to inside face of lower frontcover with six capscrews (1, figure 2-97).

(4) Install lower front cover as outlined in paragraph2-41d.

2-62

1. Capscrew (6)2. Drive screw (6)3. Pump cover

4. Rotor set5. Pump body6. Drive gear

TM 9-2320-277-14&P

A. MEASURING ROTOR LOBE CLEARANCE B. MEASURING BODY-TO-ROTOR CLEARANCE

Figure 2-98. Inspecting Oil Pump Rotor

Figure 2-99. Installing Oil Pump Drive Gear

Section XII. FLYWHEEL ANDFLYWHEEL HOUSING

2-43. DESCRIPTION.

a. Flywheel.

The flywheel is attached securely to the rear end of thecrankshaft with six capscrews The flywheel is machinedto permit a true alignment with a torque converter drive.A heat-treated steel ring gear is secured to the flywheelperiphery to engage with the starting motor drive forcranking purposes.

b. Flywheel Housing.

The flywheel housing is a one-piece casting mountedagainst the rear end of the cylinder block. The housingprovides protection for the gear train and flywheel. Thehousing also supports the starting motor andtransmission.

2-44. FLYWHEEL REMOVAL AND DISASSEMBLY.

a. Removal.

(1) Remove the engine from the tractor (paragraph2-8).

CAUTION

When removing or installingattaching bolts, hold flywheel firmlyagainst crankshaft by hand toprevent it from slipping off end ofcrankshaft. The flywheel is notdowelled to crankshaft.

(2) Remove flywheel attaching bolts and scuff platewhile holding flywheel in position by hand, thentemporarily reinstall one bolt (figure 2-100).

(3) Attach flywheel lifting hook to flywheel with two1/2 inch-20 bolts of suitable length; then attach hoist tolifting hook, move upper end of hook back and forth toloosen flywheel, and withdraw flywheel from crankshaftand flywheel housing (figure 2-101).

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Figure 2-100. Scuff Plate Removal

Figure 2-101. Flywheel Removal

b. Disassembly.

(1) in the event the ring gear (4, figure 2-102)requires replacement, support the flywheel, crankshaftside down, on a solid surface or hardwood block which isslightly less in diameter than the flywheel.

CAUTION

Do not heat the ring gear over 400°F.Excessive heating may destroyoriginal heat treatment and weakengear.

(2) Drive the ring gear off the flywheel using asuitable drift and hammer. The ring gear may be heatedwith a torch to facilitate removal. Work around thecircumference of the ring to avoid binding ring gear onthe flywheel.

2-45. FLYWHEEL CLEANING, INSPECTION ANDREPAIR.

a. Cleaning.

Clean all parts by washing with cleaning solvent and drythoroughly.


(1) Inspect the flywheel for cracks, damagedthreads, or evidence of overheating.

(2) Replace flywheel if cracked or if it has beenoverheated. Chase damaged threads with the correctsize tap, and replace damaged hardware.

2-46. FLYWHEEL REASSEMBLY ANDINSTALLATION.

a. Reassembly.

(1) Support the flywheel on a solid flat surface withring gear side of flywheel up.

CAUTIONDo not heat the ring gear over 400°F.Excessive heating may destroyoriginal heat treatment and weakengear.

(2) Rest the new ring gear on a metal or concretesurface and, using a blow torch or acetylene torch, heatring gear uniformly, keeping the torch moving around thecircumference of the ring gear to avoid hot spots.

(3) Pick the ring gear up with tongs and place inposition on flywheel.

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Figure 2-102. Flywheel and Flywheel Housing Removal

(4) Tap ring gear into place against shoulder onflywheel. If ring gear cannot be tapped into placereadily, remove ring gear and apply additional heat,heeding the above caution about overheating.

b. Installation.

(1) Mount flywheel, using lifting hook and hoist(figure 2-101), into position against rear end ofcrankshaft.

(2) While holding flywheel in place by hand, removeflywheel lifting hook and install scuff plate (2, figure 2-102)and attaching bolts (1). Tighten flywheel attaching boltsto torque value listed in Table 2-2.

(3) Check the runout of the flywheel to flywheelhousing as shown in figure 2-103. Maximum allowablerunout is 0.007 inch total indicator reading, throughoutone revolution of the flywheel.

2-47. FLYWHEEL HOUSING REMOVAL ANDDISASSEMBLY.

a. Removal.


Figure 2-103. Checking Flywheel to FlywheelHousing Runout

2-65

1. Selflock bolt (6)2. Scuff plate3. Flywheel4. Ring gear5. Hex nut (2)6. Bolt (2)7. Bolt (2)8. Bolt (8)9. Bolt (2)

10. Bolt (6)11. Bolt (2)12. Lock washer (20)

13. Selflock bolt (2)14. Selflock bolt (4)15. Flywheel housing16. Housing shim17. Gasket18. Bolt (8)

19. Plug20. Rear oil seal21. Dowel pin22. Gasket23. Copper washer (2)24. Lock washer (8)

25. Large hole cover26. Cover gasket27. Inspection hole

cover (2)28. Lock washer (4)29. Bolt (4)

TM 9-2320-277-14&P

(2) Remove the starting motor, tachometer driveand housing (see Chapter 6).

(3) Remove the flywheel (paragraph 2-44a).

(4) Remove the oil pan (paragraph 2-37b).

(5) Remove the fuel pump (paragraph 2-13).

(6) Remove the governor and drive support(paragraph 2-31).

(7) Attach a suitable sling to the flywheel housing,using eyebolts threaded into tapped holes in pads on topor sides of flywheel housing.

(8) Remove two nuts (5, figure 2-102), lock washers(12) and capscrews (7).

NOTE

When removing the flywheel housingbolts, note the location of the varioussize bolts and lock washers so theymay be reinstalled in their properlocation at reassembly.

(9) Remove eight capscrews (8) and lock washers(12).

(10) Remove two capscrews (9) and lock washers(12).

(11) Remove six capscrews (10) and lock washers(12).

(12) Remove two capscrews (11) and lock washers(12).

(13) Remove two selflock bolts (13) and four selflockbolts (14).

(14) Thread two pilot studs in the holes located aboutthe center of the crankshaft, from which capscrews (8)were removed.

(15) Make sure the flywheel housing is supportedadequately with a sling and hoist.

(16) Strike the front face of the flywheel housing (15)alternately on each side of the engine with a softhammer to loosen and work it off dowel pins.

(17) Remove shim (16), gasket (17) and gasket (22).

b. Disassembly.

(1) Remove plug (19, figure 2-102) from flywheelhousing (15).

(2) Drive rear oil seal (20) from the flywheel housing(15) with a suitable drift.

(3) Remove bolts (29), lock washers (28) andinspection hole cover (27).

(4) Remove bolts (6 and 18), copper washers (23),lock washers (24), large hole cover (25) and gasket (26).

2-48. FLYWHEEL HOUSING CLEANING,INSPECTION AND REPAIR.

a. Cleaning.


(2) Clean all traces of old gasket material from theflywheel housing, covers, and engine.


(1) Inspect the flywheel housing for cracks or otherdamage. Replace a damaged flywheel housing.

(2) Inspect all threaded parts for damaged threads. Replace parts that have damaged threads.

2-49. FLYWHEEL HOUSING REASSEMBLY ANDINSTALLATION.

a. Reassembly.

(1) Install new rear oil seal in the flywheel housingas shown in figure 2-104. Seal should be flush withouter face of housing bore.

(2) If the rear seal contact area on the crankshaft isgrooved from excessive wear, press the seal into theflywheel housing 1/8 Inch, or install an oversize oil sealand sleeve as shown in figure 2-105.

Figure 2-104. Installing Oil Seal in Flywheel Housing

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TM 9-2320-277-14&P

Figure 2-105. Positioning Oil Seal on GroovedCrankshaft

NOTE

An oversize oil seal is required whenthe oil seal sleeve is used.

(3) Install plug (19, figure 2-102) in flywheel housing(15).

(4) Install new gasket (26), large hole cover (25),lock washers (24), copper washers (23) and bolts (6 and18).

(5) Install inspection hole cover (27) with lockwashers (28) and bolts (29).

b. Installation.

(1) Lubricate the gear train teeth with clean engineoil.

(2) Install new gaskets (17 and 22, figure 2-102) onthe rear face of the cylinder block end plate.

(3) Install shim (16) on the left side of the engine. Use grease to hold the shim in place until the flywheelhousing is installed.

(4) Coat the hp of the crankshaft seal (20) lightlywith high temperature cup grease. Do not scratch ornick the sealing edge of the seal, and do not use hypoidgear lubricant.

(5) Use proper seal expander to aid in piloting theseal on the crankshaft (figure 2-106). Also, thread twoaligning guide studs into cylinder block to guide thehousing into place.

Figure 2-106. Flywheel Housing Installation

(6) With the housing suitably supported, position itover the crankshaft and up against the cylinder blockrear end plate (figure 2-106).

(7) Install the capscrews, lock washers and selflockbolts in the same locations they were removed from.Tighten finger-tight only.

(8) For the sequence of initial tightening, refer tofigure 2-107A. Starting at position no. 1, draw all of thehousing bolts up snug.

(9) For the final tightening sequence, refer to figure2-107B. Starting at position no. 1, tighten all of thehousing bolts (in the sequence shown) to the torquevalues listed in Table 2-2.

(10) Install the flywheel as outlined in paragraph2-46b.

(11) Check flywheel to flywheel housing concentricitywith a dual dial indicator on surfaces shown in (figure 2-108). Rotate the flywheel through one full revolution,taking readings at each 45 degree interval. Maximumtotal indicator reading must not exceed 0.013 inch. Ifreading exceeds 0.013 inch, loosen flywheel housingattaching bolts, tap housing, retighten bolts and recheck.It may be necessary to remove the flywheel housing andcheck for dirt or foreign material, such as old gasketmaterial between rear end plate and flywheel housing,which may result in warpage. The flywheel housingmust be replaced if above limit is unobtainable.

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TM 9-2320-277-14&P

A. FLYWHEEL HOUSING BOLT TIGHTENINGSEQUENCE (OPERATION 1)

B. FLYWHEEL HOUSING BOLT TIGHTENINGSEQUENCE (OPERATION 2)

Figure 2-107. Flywheel Housing Bolt TighteningSequence

Figure 2-108. Checking Flywheel to Flywheel HousingConcentricity

(12) Install governor and drive support (paragraph2-34).

(13) Install fuel pump (paragraph 2-13).

(14) Install engine oil pan (paragraph 2-37e).

(15) Install starter motor, tachometer drive andhousing (see Chapter 6).

(16) Install engine in the tractor (paragraph 2-9).

Section XIII. PISTONS ANDCONNECTING RODS

2-50. DESCRIPTION.

a. Pistons.(1) The malleable iron piston is plated with a

protective coating of tin which permits close fitting,reduces scuffing, and prolongs piston life. The top of thepiston forms the combustion chamber bowl and isdesigned to compress the air into proximity to the fuelspray.

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(2) The piston is cooled by a spray of lubricating oildirected at the underside of the piston head from anozzle in the top of the connecting rod, by fresh air fromthe air inlet housing to the top of the piston, andindirectly by the water jacket around the cylinder.

(3) Two bushings, with helical grooved oilpassages, are pressed into the piston to provide abearing for the hardened, floating piston pin. Each end ofthe piston pin is sealed with a piston pin retainer.

(4) Each piston is fitted with six piston rings. Fourcompression rings are installed above the piston pin,and two three-piece oil control rings are installed belowthe piston pin. Eight equally spaced holes are drilled justbelow each oil control ring to permit excess oil to returnto the crankcase.

b. Connecting Rods.

(1) Each connecting rod is made of forged steel.The rod is drilled to provide lubrication to the piston atthe upper end and is equipped with an oil spray nozzlefor cooling the piston.

(2) The connecting rod bearing shells are differentand not interchangeable.

(3) A helically-grooved bushing is pressed into eachside of the connecting rod at the upper end. A cavity ofapproximately 1/8 inch between the inner ends of thebushings, registering with the drilled oil passage in therod, forms a duct around the piston pin for lubrication.

(4) The connecting rod bearings are prevented frommovement by a tang at the parting line of each shell. Each connecting rod cap is numbered.


a. Removal.

(1) Remove cylinder heads (paragraph 2-27).

(2) Remove oil pan (paragraph 2-37b).

(3) Remove oil tube and strainer (paragraph 2-38a).

(4) Use a suitable reamer and remove carbon fromthe upper, inner surface of the cylinder liner.

NOTEMove the piston to the bottom of itstravel and place a cloth on the top ofthe piston to collect cuttings. Afterreaming is completed, turn thecrankshaft until the piston is at thetop of Its stroke and carefully removethe cloth with cuttings.

(5) Remove the piston and connecting assembliesas instructed on figure 2-109.

b. Disassembly.

(1) Position the connecting rod and piston assemblyin a bench vise with soft jaws and remove the pistonrings with a ring expander as illustrated in figure 2-110.

(2) Punch a hole through the center of piston pinretainer (7, figure 2-111) with a narrow chisel or punch topry the retainer from the piston (13).

(3) With one hand covering piston pin hole, placepiston on its side and allow piston pin (8) to fall frompiston (13) and rod (11).

NOTEIn some cases, piston pin may be asnug fit. If necessary, positionconnecting rod in a soft-jawed benchvise, repeat step 2 to removeremaining piston pin retainer, andgently drive piston pin from pistonand rod with a brass drift as shown infigure 2-112.

(4) Remove the piston (13, figure 2-111) from theconnecting rod (11). If necessary, use a brass drift andremove the remaining piston pin retainer (7) from thepiston.

(5) Do not remove piston or rod bushings (9 and 12)or the rod spray nozzle (10), unless inspection indicatesreplacement is required.

NOTEPUSH THE PISTON AND RODASSEMBLY OUT THROUGH THE TOPOF THE CYLINDER BLOCK.

Figure 2-109. Piston and Connecting Rod Removal

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Figure 2-110. Piston Ring Removal


a. Cleaning.

(1) Clean all parts by washing with cleaning solvent.Dry parts with compressed air at approximately 40 psig.

(2) Clean carbon from the top of the piston using awire brush.

(3) Use a suitable tool and clean the carbon fromthe piston ring grooves.

(4) Use a suitable size drill and clean the carbonfrom the eight oil control holes in the bottom of the pistonoil ring grooves.


(1) Inspect the pistons for scoring, overheating,cracks and damaged ring grooves. A piston with lightscore marks can be cleaned up and reused.

(2) Refer to Table 2-3 and inspect and measure thepiston pins and pin bushings.

(3) Replace the piston bushings as follows:

(a) Place the piston in a holding fixture anddrive the bushings from the piston.

(b) Place the fixture spacer in counterbore ofholding fixture, small end up. Place the piston on theholding fixture so that the spacer protrudes into thepiston pin bushing bore.

1. Nut (12) 8. Piston pin (6)2. Bolt (12) 9. Bushing (6)3. Cap (6) 10. Spray nozzle (6)4. Bearing shell set (6) 11. Connecting rod (6)5. Compression ring set (6) 12. Bushing (12)6. Oil control ring set (12) 13. Piston (6)7. Retainer (12)

Figure 2-111. Piston and Connecting Rod Disassembly

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Figure 2-112. Piston Pin Removal

(c) Locate the joint in the bushing toward thebottom of the piston, insert the installer handle and drivethe bushing in until it bottoms on the spacer.

(d) Install the opposite pin bushing in a similarmanner.

(4) Refer to Table 2-3 and ream the piston pinbushings to the value listed.

(5) Fit the pistons on the cylinder liners as follows:

(a) Refer to Table 2-3 and measure the pistonskirt diameter and cylinder liner bore. Take thesemeasurements with the piston and liner at normal roomtemperature (72°F).

(b) Refer to Table 2-3 and check the piston toliner clearance. Check this in four places, 90 degreesapart, while holding the piston upside down in thecylinder liner as illustrated in figure 2-113.

(c) The spring scale, attached to theappropriate feeler gage, is used to measure the force inpounds required to withdraw the feeler gage frombetween the piston and the liner. The clearance will be0.001 inch greater than the feeler gage used when it iswithdrawn at a pull of six pounds. The feeler gage usedmust be flat and free of nicks and bends.

(6) Fit the piston rings as follows:

NOTEUse new piston rings whenever apiston is removed for inspection orreplacement.

(a) Refer to Table 2-3 and measure the gapbetween the ends of the piston rings before installingrings on piston.

Figure 2-113. Measuring Piston to Cylinder LinerClearance

(b) Insert the piston rings into the cylinderliner, far enough in the bore to be on normal wiping areaof the ring. Measure the ring gap with a feeler gage asillustrated in figure 2-114. Make sure the ring is parallelwith the top of the liner.

(c) If the piston ring gap is less than theclearance specified in Table 2-3, file or stone the end ofthe piston ring. File or stone the ring in such a directionthat the file or stone will cut from the outside (chromeplated) surface of the ring toward the inside surface.This will prevent chipping or peeling of the chrome plate.The ends of the ring must remain square and thechamfer must be approximately 0.015 inch on the outeredge.

(7) Refer to Table 2-3, and check the ringclearances in the piston groove as illustrated in figure2-115.

(8) Inspect and open the holes in the spray nozzle. Blow dry compressed air through the drilled oil passagesin the rod and nozzle to make sure all passages areopen.

(9) Refer to Table 2-3 and inspect the connectingrod bushings for scoring, indications of overheating andother damage. Bushings that have overheated maybecome loose and creep together, thus blocking offlubricating oil to the piston pin bushing and spray nozzle.

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Figure 2-114. Measuring Piston Ring Gap

Figure 2-115. Measuring Piston Ring Side Clearance

(10) Replace the piston pin bushing and spray nozzleas follows:

(a) Remove the piston pin bushing asillustrated in figure 2-116.

(b) Remove the spray nozzle from theconnecting rod as Illustrated in figure 2-117.

NOTE

The orifice in the lower end of thedrilled passage in the connecting rodis not serviced separately, and It isnot necessary to remove it whenreplacing the spray nozzle.

(c) Install the new spray nozzle straight intothe counterbore in the top of the connecting rod.Support the connecting rod in an arbor press. Then,place a short 3/8 inch I.D. sleeve on top of the spraynozzle and press the spray nozzle in the connecting rod.

(d) Clamp the upper end of the connectingrod in the holder as shown in figure 2-116, so the bore ofthe bushing is aligned with the hole in the base of theinstallation tool.

(e) Press the bushing into the connecting rodbore as illustrated in figure 2-116.

NOTE

When installing a bushing in theconnecting rod, locate the joint of thebushing at the top of the connectingrod.

(f) Turn the connecting rod over in the holderand install the opposite bushing in the same manner.

(11) Refer to Table 2-3 for dimensions and ream thepiston pin bushing.

(12) Refer to Table 2-3 for dimensions and measurethe connecting rod bearings for excessive wear. Visuallyinspect the bearings for excessive wear to determine ifused bearings are satisfactory for further service. Theupper bearings, which carry the load, will normally showsigns of wear before the lower bearings do.

(13) Refer to Table 2-3 for dimensions and measurethe thickness of the bearing 90 degrees from the partingline using a micrometer with a ball attachment.

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Figure 2-116. Removing Piston Pin Bushing

Figure 2-117. Spray Nozzle Removal


a. Reassembly.(1) Apply clean engine oil to the piston pin and

cushing and rest the piston in a fixture as illustrated infigure 2-118.

(2) Install one piston pin retainer in the piston asillustrated in figure 2-118. Strike the retainer installertool just hard enough to deflect the retainer and seat itevenly.

Figure 2-118. Installing Piston Pin Retainer

CAUTION

Do not drive too hard on the pinretainer or the pin bushing may bemoved inward and result in reducedpin clearance.

(3) Slide the piston pin into the piston andconnecting rod and install the second piston pin retainer(step 2 above).

NOTEThe piston pin will slip readily intoposition without force, and must floatfreely after installation.

(4) Check the piston pin retainers for proper sealingas follows:

(a) Place the assembled piston and rod on abench upside down and fill the piston with clean dieselfuel to a level above the piston pin bosses.

(b) Dry the exterior surfaces of the piston inthe area around the retainers and allow the diesel fuel toset for about 15 minutes.

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(c) Check for seepage of diesel fuel aroundthe retainers. If fuel leaks at the retainers, install newretainers.

(d) Empty the fuel from the piston and drywith compressed air.

(5) Install the oil control rings by hand with thescraping edge of each ring down as follows:

(a) Install the expander in the upper ringgroove (figure 2-119) being careful not to overlap theends.

CAUTION

The oil control ring expander must becompletely seated in the oil ringgroove. If the ends of the expandershould overlap, the oil ring willprotrude slightly and be broken whenthe piston ring compressor isinstalled over the piston, or when thepiston and rod assembly is installedin the cylinder liner.

(b) Install the top oil ring, with the gap 180°from the ends of the expander. Install the bottom oilring, with the gap 45° from the top oil ring gap. Recheckto make sure the ends of the expanders are notoverlapped.

CAUTION

Do not cut off or grind the ends of theoil ring expander to prevent the endsfrom overlapping. This will decreasethe tension on the oil control ringsand result in high oil consumption.

(c) Install the second set of oil rings in thesame manner.

(6) Refer to figure 2-119 for proper ring location,and install the four compression rings on the pistonusing a ring expander as illustrated in figure 2-110.Stagger the ring gaps around the piston.

NOTEWhen installing the top compression(Fire) ring with the tapered face, besure to install the ring with the mark"TOP" toward the top of the piston(figure 2-120).

b. Installation.(1) Rotate the crankshaft until the connecting rod

journal is at the bottom of its travel. Wipe the journalclean and lubricate it with clean engine oil.

(2) Install the two connecting rod bolts(2, figure 2-111) and the upper bearing half (4) in theassembled connecting rod (11).

Figure 2-119. Piston Assembly Cutaway View

Figure 2-120. Tapered (Fire) Compression Ring

(3) Use a suitable ring compressor and apply cleanengine oil to the piston rings and the inside of the ringcompressor. Place ring compressor on a wood block,taper end up, and push piston straight down into ringcompressor until piston contacts wood block.

CAUTIONDo not force the piston into the liner.The expanders apply considerableforce on the oil ring; therefore, extracare must be taken duringinstallation to prevent ring breakage.

(4) Start the skirt of the piston into the cylinder blockand lightly tap the top of the piston into the block with thewooden handle of a hammer until it clears the ringcompressor. Pull the piston and rod assembly downuntil the upper bearing half seats firmly on the crankshaftjournal.

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(5) Place the lower bearing half (4, figure 2-111) inthe connecting rod cap (3) and lubricate the bearing withclean engine oil.

(6) Note the identifying marks on the bearing capand the rod, and assemble the cap to the rod asillustrated in figure 2-109. Tighten connecting rod nutsto torque value specified in Table 2-2.

(7) Install oil tube and strainer (paragraph 2-38c).

(8) Install the oil pan (paragraph 2-37e).

(9) Install the cylinder heads (paragraph 2-29).

Section XIV. CAMSHAFTS, TIMINGGEARS AND IDLER GEAR

2-54. DESCRIPTION.'

a. Camshafts and Timing Gears.

The engine is equipped with two camshafts which areidentical except for the camshaft gears. One gear is aright hand gear while the other is a left hand gear. Theshaft are supported by bearings (bushing type) pressedinto bores in the cylinder block. Lubrication is directedunder pressure through oil passages. The engine mustbe removed from the tractor to remove the camshafts.

b. Idler Gear.

The engine idler gear and bearing assembly, located atthe flywheel end of the engine, meshes with thecamshaft and crankshaft gears and rotates on astationary hub. The hub is secured directly to thecylinder block by a capscrew which passes through thehub and three capscrews which pass through theflywheel housing, hub, and end plate. Two timing marksare stamped on the idler gear diametrically oppositeeach other.

2-55. CAMSHAFT AND TIMING GEAR REMOVALAND DISASSEMBLY.

a. Removal.

(1) Drain the cooling system (see Chapter 5).


(3) Remove the cylinder heads (paragraph 2-27).

(4) Remove the flywheel housing(paragraph 2-47a).

(5) Remove power steering pump bracket from fanbracket (see Chapter 14) ; then remove remaining partsfrom engine upper front cover as instructed on (figure 2-121).

(6) Wedge a clean cloth between the camshaftgears, and use a suitable puller to remove camshaftpulleys as shown in figure 2-122.

Figure 2-121. Removing Parts from Engine Upper Front Cover2-75

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Figure 2-122. Camshaft Pulley Removal

NOTE

The engine upper front cover isattached to the cylinder block withattaching capscrews. The camshaftoil seals are pressed into the cover.

(7) Remove the engine upper front cover (figure2-123). Remove cover gasket from upper front cover orengine block.

(8) Remove the oil shingers, seal spacers and keysfrom the camshafts (figure 2-124).

(9) Remove the fuel pump drive adapter (8, figure2-19) from the left hand gear (9, figure 2-125).

(10) Remove the capscrews (2), lock washers (5)and nut retainers (3).

(11) Remove the capscrews (12) that secure thethrust washers (13) to the engine block.

(12) Wedge a cloth between the two gears andremove nuts (4).

(13) Withdraw the camshafts with gears from thecylinder block.

b. Disassembly.

(1) Press the timing gears from the camshafts(figure 2-126).

Figure 2-123. Engine Upper Front Cover Removal

Figure 2-124. Camshaft Front Oil Slinger and SealsRemoval

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Figure 2-125. Camshaft Timing Gear Removal

(2) Remove keys (10, figure 2-125), thrust washers(13) and spacers (14) from camshafts (6 and 15)

(3) Support the inner face of upper front cover(figure 2-127) on wood blocks at least one inch thick toprotect the dowel pins in the cover. Drive the right andleft camshaft oil seals out of the cover.

2-56. IDLER GEAR REMOVAL AND DISASSEMBLY.

a. Removal.

(1) Remove the rear idler thrust washer (1, figure2-128).

(2) Slide the idler gear assembly (2) off the hub (5).

(3) Remove capscrew (4) securing hub to thecylinder block.

(4) Remove the front thrust washer (6) and hub (5)as an assembly.

b. Disassembly.

(1) Separate the thrust washer (6) from the hub (5).

(2) Press sleeve bearing (3) from idler gear (2).


a. Cleaning.

(1) Soak the camshafts in cleaning solvent.

(2) Run a wire brush through the camshaft oilpassages to remove sludge or foreign material, and blowoil passages dry with compressed air.

(3) Clean remaining parts with cleaning solvent anddry thoroughly.

(4) Clean all gasket material from front cover andengine block.

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1. Pulley (2)2. Capscrew (4)3. Retainer (2)4. Hex nut (4)5. Lock washer (4)6. LH camshaft7. Bearing set (2)8. RH gear9. LH gear

10. Woodruff key (4)11. Oil slinger (2)12. Capscrew (4)13. Thrust washer (2)14. Spacer (2)15. RH camshaft

TM 9-2320-277-14&P

Figure 2-126. Camshaft Gear Removal

Figure 2-127. Engine Upper Front Cover Exploded View

1. Rear thrust washer 4. Capscrew2. Idler gear assembly 5. Idler hub3. Sleeve bearing 6. Front thrust washer

Figure 2-128. Idler Gear Removal and Disassembly


(1) Inspect idler gear teeth and bearing for scoring,pitting and other evidence of damage. Also inspect gearand bearing for wear, and replace if wear exceedsvalues listed in Table 2-3.

(2) Inspect idler gear thrust washers for wear, andreplace if wear exceeds values listed in Table 2-3.

(3) Inspect idler gear hub for scored, pitted or worncondition. Replace a defective idler gear hub.

(4) Inspect the camshaft cams and journals for wearor scoring. Replace as necessary.

(5) Check the runout at the intermediate bearingswith the camshaft mounted on the end bearing surfaces.Runout must not exceed the value listed in Table 2-3.

(6) Inspect both faces of each camshaft thrustwasher (13, figure 2-125). If either face is scored or ifthe thrust washers are worn beyond limits listed in Table2-3, replace the washers.

(7) Inspect the surfaces which the camshaft thrustwashers contact; if these surfaces are scratched but arenot severely scored, smooth them down with an oilstone. If the scores are too deep to be removed or ifparts are badly worn replace parts.

(8) Excessive clearance between the camshaftsand the camshaft bearings will cause low oil pressureand excessive back lash between-the gears. Replaceparts if worn beyond limits listed in Table 2-3.

(9) If necessary, remove camshaft bearings asfollows:

CAUTION

When removing camshaft bearings,note the position of the bearings inthe block bore with respect to thenotch in the bearing. Replacementbearings must be installed in thesame position.

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(a) The end bearings must be removed priorto removing the intermediate bearings. Insert smalldiameter of pilot (figure 2-129) into bore of an endbearing.

(b) Position the remover tool as shown in theopposite end bearing.

(c) Insert the unthreaded end of the shaftthrough the pilot and block bore until it snaps into theremover.

(d) Drive the end bearing from the cylinderblock by using a mallet on the threaded end of the shaft.

(e) Remove the next intermediate bearing inthe same manner.

(f) Remove the opposite end bearing andintermediate bearing in the same manner, working fromthe opposite end of the block and inserting the largediameter of the pilot into the block bore.

NOTE

Camshaft bearings must be installedin the following sequence: (1) Therear intermediate and rear endbearings, in that order, by pressingfrom the rear to the front of the block;(2) The front intermediate and frontend bearings, in that order, bypressing from the front to the rear ofthe block. To facilitate assembly,bearings are color coded on theends; brown for end bearings andorange for intermediate bearings.

CAUTION

All replacement bearings must beinstalled with the notch located at thesame position min bore as notedprior to removal of original bearings.

(10) Install rear intermediate bearings as follows:

(a) Insert large diameter of pilot min front bearingbore of block (figure 2-130A).

(b) Insert new intermediate bearing throughthe rear bore and position against intermediate bearingsupport with notch facing rear of block.

(c) Insert unthreaded end of shaft through thepilot and push through entire block bore.

(d) Slide the installer on the shaft as shown infigure 2-130A, with locating pin registering with notch inbearing.

(e) Install the installer/pilot, large diameterfirst, over the shaft and into rear bore of block.

(f) Install short spacer tool, a thrust washer,flat washer, and hex nut over threaded end of shaft.

(g) Align the shaft so a C-washer can beinserted in groove adjacent to installer as shown in figure2-130A.

(h) Place a C-washer in groove at end ofshaft.

(i) Position installer and bearing with notch inposition noted at removal and, using a suitable wrenchon the hex nut, draw the bearing into place until the endC-washer is up against the installer/pilot. The notchedend of the right rear intermediate bearing should now be5.54 inches from the rear face of the block. The left rearintermediate bearing will be 6.66 inches from the rearface of the block.

(11) Refer to figure 2-130B and install rear endbearing as follows:

(a) Insert large diameter of pilot in frontbearing bore of block.

(b) Insert the support ring in the rear bearingbore.

(c) Install the shaft, unthreaded end first,through the pilot and the support.

(d) Position new end bearing on installer/pilotand install the installer/pilot over the end of shaft asshown.

(e) Place a C-washer in end groove of shaft,and install short spacer tool, thrust washer, flat washer,and nut on threaded end of shaft.

(f) Align notch in bearing with locator pininstaller/ pilot and position, as noted at removal, againstend of bearing bore. Draw bearing into place in block byusing a wrench on the hex nut. End bearing is in properposition when shoulder on installer/pilot is againstmachined face of block.

(12) Install the front intermediate bearings in thesame manner as the rear intermediate bearings (step 10above), with tools inserted from opposite end of blockand inserting small diameter of pilot into bore of the rearbearing.

(a) The right front intermediate bearing will be6.66 inches from the front face of the block.

(b) The left front intermediate bearing will be5.54 inches from the front face of the block.

(13) Install the front end bearings in the samemanner as the rear end bearings (step 11 above), withtools inserted from opposite end of block and smalldiameter of pilot inserted into bore of the rear endbearings.

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Figure 2-129. Camshaft Bearing Removal

A. INTERMEDIATE BEARING INSTALLATION

B. END BEARING INSTALLATION

Figure 2-130. Camshaft Bearing Installation

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2-58. IDLER GEAR REASSEMBLY ANDINSTALLATION.

a. Reassembly.

(1) Lubricate the idler gear (2, figure 2-128) andsleeve bearing (3) with clean engine oil and press thebearing in the idler gear. If a new bearing is used it mustnot protrude beyond the gear face on either side.

(2) Position the inner thrust washer (6) on forwardend of the hub (5), with the flat in the inner diameter ofthe thrust washer over the flat on the end of the hub andwith the oil grooves in the thrust washer facing the idlergear.

b. Installation.

(1) Place the small protruding end of the gear hubthrough the end plate and into the counterbore in thecylinder block.

(2) Temporarily install two pilot bolts in the gear huband cylinder block to align the holes in the hub andcylinder block when the flywheel housing is installed asshown in figure 2-131.

(3) Install capscrew (4, figure 2-128) and tighten totorque value listed in Table 2-2. Remove the two pilotcapscrews previously installed in step 2.

(4) Position the crankshaft gear so the timing mark -will align with the timing mark on the idler gear (figure 2-132). With these marks in alignment, install the idlergear (2, figure 2-128) on the hub (5).

(5) Apply a thin film of high temperature cup greaseto inner face (face with the oil grooves) of the outerthrust washer (1). Place the thrust washer over the hubwith grooves toward the gear and the flat in the insidediameter of the thrust washer over the flat on the gearhub.

(6) Check the backlash between the mating gears.The crankshaft timing gear backlash should not exceedthe limits listed in Table 2-3.

2-59. CAMSHAFT AND TIMING GEAR REASSEMBLYAND INSTALLATION.

a. Reassembly.

(1) Both camshafts are reassembled in the samemanner. Make sure the correct gears are installed onthe respective camshafts (figure 2-125).

(2) Install spacer (14, figure 2-125), thrust washer(13) and key (10) on the camshaft. Align keyway andpress camshaft gear on camshaft as shown in (figure2-133).

Figure 2-131. Idler Gear Hub Installation

Figure 2-132. Gear Train Timing Mark Alignment

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Figure 2-133. Camshaft Timing Gear Installation

(3) Measure the clearance between the camshaftthrust washer and the camshaft. The clearance mustnot exceed limits listed in Table 2-3.

(4) Install the nuts on the camshafts finger-tightonly.

(5) Support the inner face of upper front cover(figure 2-127) on wood blocks at least one inch thick toprotect the dowel pins in the cover. Position new oilseals, lip facing down, in cover bores. Press seals intocover until seals are flush with inside face of bore.

b. Installation.

(1) Lubricate the shafts and bearings withlightweight engine oil.

(2) Refer to figure 2-125 and carefully install thecamshafts into the cylinder block, being careful not todamage the bearings, cam lobes or journals.

(3) Make sure the timing marks are in alignment asillustrated in figure 2-132.

(4) Install oil slingers on shafts (figure 2-124).

(5) Install the engine upper front cover with a newgasket (figure 2-123).

(6) Apply a light coat of high temperature cupgrease to outside diameter of seal spacers (figure 2-124)and slide on camshafts.

(7) Position keys (10, figure 2-125) in camshaftkeyways. Align keyway of pulleys (1) and install oncamshafts. It may be necessary to tap the pulleys toseat them properly; support the gear end of camshaftswhen tapping pulleys. Install pulley nuts (4).

(8) Secure thrust washers (13) in place withcapscrews (12). Tighten thrust washer capscrews (12)and camshaft nuts (4) to torque values listed in Table2-2.

(9) Recheck clearance between the thrust washers(13) and the camshaft gears (8 and 9).

(10) Install nut retainers (3) on camshaft gears (8 and9), securing with capscrews (2) and lock washers (5).

(11) Install the fuel pump drive adapter (8, figure2-19) on the left hand camshaft gear (9, figure 2-125).

(12) Check the backlash between the matingcrankshaft, camshaft, and idler gears. Backlash mustnot exceed the values listed in Table 2-3.

(13) Reinstall parts on engine upper front cover inreverse of instructions on figure 2-121; then install powersteering pump bracket (see Chapter 14).

(14) Install the flywheel housing (paragraph 2-49b).

(15) Install the cylinder heads (paragraph 2-29).

(16) Install the engine in the tractor (paragraph 2-9).

Section XV. CRANKSHAFT ANDMAIN BEARINGS

2-60. DESCRIPTION.

a. Crankshaft.

The crankshaft is a one-piece steel forging, heat-treatedto insure strength and durability. All main andconnecting rod bearing journal surfaces and oil sealsurfaces are induction hardened. Complete static anddynamic balance has been achieved by counterweights.

b. Main Bearings.

The main bearing shells are of the precision type andmay be readily replaced without machining. They areused at each crankshaft main journal and consist of anupper shell seated in the cylinder block main bearingsupport and a

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lower shell seated in the main bearing cap. Bearingshells are prevented from endwise or radial movementby a tang at the parting line at one end of each shell.The bearing caps are numbered 1, 2, 3 and 4, indicatingtheir respective position and, when removed, mustalways be reinstalled in their original positions. Mainbearing thrust washers absorb the crankshaft thrust ateach side of the rear main bearing. Each washer ismade up of two halves. The lower halves are doweledto the bearing cap. The upper and lower bearing shellsare not interchangeable; the upper bearing shells aregrooved, and the lower shells are not. If one bearingshell is to be replaced, all main bearings shells must bereplaced.


a. Removal of Main Bearings with CrankshaftInstalled.

(1) If removal of the crankshaft is not required, thebearing shells may be removed in the following manner.If removal of the crankshaft is required proceed toparagraph 2-61b.

NOTEWhen using the following method ofbearing removal, remove only onemain bearing cap at a time, completethe cap and bearing inspection, andreplace or reinstall the bearing shellsand cap before removal of the nextbearing cap and bearing.

(2) Remove the engine oil pan (paragraph 2-37b).

(3) Remove the oil inlet tube and strainer(paragraph 2-38a).

(4) Remove, one at a time, the main bearing capstabilizers (figure 2-134A) ; then reinstall main bearingcap bolts and washers using spacers the samethickness as bosses on stabilizers (figure 2-134B).

(5) Remove, one at a time, the front andintermediate bearing shells as follows:

(a) Remove main bearing cap (figure 2-134)and remove lower bearing shell (9, figure 2-135).

(b) Insert a special bolt (standard 1/4 inch x3/4 inch long, with head ground to a thickness of 1/16inch) into crankshaft journal oil hole so that the bolthead does not extend beyond the outer surface of theupper bearing shell. Rotate the crankshaft in aclockwise direction and roll the upper bearing shell (10)out of the bearing support.

(c) Clean, inspect, and install main bearings(paragraphs 2-62 and 2-63b).

Figure 2-134. Removing Main Bearing Cap Stabilizers

(d) Repeat steps a through c above for eachintermediate bearing.

(6) Remove the rear main bearing shells as follows:(a) Refer to figure 2-136 and remove rear

main bearing cap, and remove lower thrust washerhalves and lower bearing shell.

(b) Remove upper thrust washer halves bypushing on one side with a small rod, forcing washeraround and out on opposite side of the journal.

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1. Capscrew2. Pulley retainer3. Pulley4. Capscrew (8)5. Thrust washer (4)6. Dowel pin (4)7. Main bearing cap (4)8. Bearing set9. Lower bearing shell (4)

10. Upper bearing shell (4)11. Front oil seal12. Oil pump drive gear13. Rear oil seal14. Timing gear15. Woodruff key16. Crankshaft17. Washer (8)

Figure 2-135. Crankshaft Disassembly

Figure 2-136. Rear Main Bearing Cap and Bearing

(c) Remove the upper rear main bearing shellby driving on the edge of the shell with a small curvedrod, at the same time rotating the crankshaft. This willroll the bearing shell from its position.

b. Removal of Crankshaft and Main Bearings.(1) Remove engine from tractor (paragraph 2-8).


(3) Remove fuel pipes (paragraph 2-15) and installdust caps on injectors and fuel connectors to preventcontamination.

(4) Pivot the rocker arms away from the valve stems(paragraph 2-15). This step is necessary to preventdamage to valves and valve stems should a pistonassembly be dropped or pushed down on the valves.

(5) Remove the engine oil pan (paragraph 2-37b)and oil inlet tube and strainer (paragraph 2-38a).

(6) Remove lower front cover with oil pump(paragraph 2-41a).

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(7) Remove flywheel housing (paragraph 2-47a).

(8) Remove the connecting rod nuts (1, figure2-111) and bearing caps (3). Push the pistonassemblies toward the cylinder head until the connectingrod bolts (2) are clear of the crankshaft journals.

NOTE

It may be necessary to push one ofthe valves open to expel air from thecylinder chamber when pushingpiston toward cylinder head.

(9) Remove main bearing cap stabilizers, bearingcaps and lower bearing shells (figures 2-134 and 2-136).

(10) Attach a suitable sling to crankshaft, and removethe crankshaft from the cylinder block. Remove upperbearing shells (10, figure 2-135) from main bearingsupports.

c. Crankshaft Disassembly.(1) Remove the crankshaft timing gear with a

suitable gear puller (figure 2-137). Remove key (15,figure 2-135) from crankshaft keyway.

(2) If necessary for repair, install crankshaft pulleyretaining capscrew into end of crankshaft and removethe oil pump drive gear with a suitable gear puller asshown in figure 2-138.


a. Cleaning.(1) Clean all parts by washing with cleaning solvent.

(2) Clean crankshaft oil passages with cleaningsolvent and a stiff wire brush. Dry parts withcompressed air at approximately 40 psig.


(1) Inspect the keyways for evidence of cracks orwear. Replace the crankshaft, if necessary.

(2) If the crankshaft has been subjected toexcessive overheating, the heat treatment will bedestroyed and a new crankshaft should be installed.

(3) Used crankshafts will sometimes show a certainamount of ridging caused by the groove in the uppermain bearing shell or lower connecting rod bearing shell(figure 2-139A). Ridges exceeding 0.0002 inch must beremoved. If the ridges are not removed, localized highunit pressures on new bearing shells will result duringengine operation

Figure 2-137. Crankshaft Timing Gear Removal

Figure 2-138. Oil Pump Drive Gear Removal

(4) The ridges may be removed by working crocuscloth, wet with diesel fuel, around the circumference ofthe crankshaft journal.

(a) If the ridges are greater than 0.0005 inch,first use 120 grit emery cloth to clean up the ridge, 240grit emery cloth for finishing, and wet crocus cloth forpolishing. Use of a piece of rawhide or other suitablerope wrapped around the emery cloth or crocus clothand drawn back and forth will minimize the possibility ofan out-of-round condition developing (keep the strandsof rawhide apart to avoid bind).

(b) If rawhide or rope is not used, thecrankshaft should be rotated at intervals. If the ridgesare greater than 0.001 inch, the crankshaft may have tobe reground.

(5) Carefully inspect the front and rear end of thecrankshaft in the area of the oil seal contact surface forevidence of a rough or grooved condition. Anyimperfections of the oil seal contact surface will result inoil leakage at this point.

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NOTE: ALL DIMENSIONS IN INCHES

A. TYPICAL RIDGING OF CRANKSHAFT

C. DIMENSIONS OF CRANKSHAFT JOURNALS ANDCRANK PINS

B. CRANKSHAFT FATIGUE CRACKS

D. CRANKSHAFT JOURNAL FILLETS

E. DIMENSIONS AT REAR MAIN BEARING THRUST WASHERS

Figure 2-139. Crankshaft Inspection Details

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(6) Slight ridges on the crankshaft oil seal contactsurfaces may be cleaned up with emery cloth ad crocuscloth in the same manner as detailed for the crankshaftjournals. If the crankshaft cannot be cleaned upsatisfactorily, replace the crankshaft.

(7) Check the crankshaft thrust surfaces forexcessive wear or grooving. If only slightly worn, thesurfaces may be dressed with a stone. Otherwise, it willbe necessary to regrind the thrust surfaces.

(8) Check the crankshaft timing gear for worn orchipped teeth. Replace a defective timing gear.

(9) Support the crankshaft on its front and rearjournals on V-blocks or in a lathe and check thealignment at the adjacent intermediate main journalswith a dial indicator.

(a) The maximum run out on the intermediatejournals must not exceed 0.002 inch total indicatorreading.

(b) When the runout on the adjacent journalsis in opposite directions, the sum must not exceed 0.003inch total indicator reading. When the runout on theadjacent journals is in the same direction, the differencemust not exceed 0.003 inch total indicator reading.When high spots of runout on the adjacent journals areat right angles to each other, the sum must not exceed0.004 inch total indicator reading, or 0.002 inch on eachjournal. If the runout is greater than the limits givenabove, the crankshaft must be replaced.

(10) Measure all of the main and connecting rodbearing journals. Measure the journals at several placeson the circumference so that taper, out-of-round andbearing clearances can be determined. If the crankshaftis worn so that the maximum connecting rod journal-to-bearing shell clearance (with new shells) exceeds0.0041 inch, or the main bearing journal-to-bearing shellclearance (with new shells) exceeds 0.0040 inch, thecrankshaft must be reground. Also, if the journal taperor out-of-round is greater than 0.003 inch, the crankshaftmust be regound. Measurements of the crankshaftshould be accurate to the nearest 0.002 inch.

(11) Carefully check the crankshaft for cracks (figure2-139B) which start at an oil hole and follow the journalsurface at an angle of 45° to the axis. Any crankshaftwith such cracks must be rejected. Several methods ofdetermining the presence of minute cracks not visible tothe eye are outlined below.

(a) Magnetic Particle Method: The part ismagnetized and then covered with a fine magneticpowder or solution. Flaws, such as cracks, form a smalllocal magnet which causes the magnetic particles in thepowder or solution to gather there, effectively markingthe flaw. The crankshaft must be demagnetized afterthe test.

(b) Fluorescent Magnetic Particle Method:This method is similar to the magnetic particle method,but is more sensitive since it employs magnetic particleswhich are fluorescent and glow under "black light". Veryfine cracks that may be missed under the first method,especially on discolored or dark surfaces, will bedisclosed under the "black light".

(c) Fluorescent Penetrant Method: This is amethod which may be used on non-magnetic materialssuch as stainless steel, aluminum and plastics. A highlyfluorescent liquid penetrant is applied to the parts; then,the excess penetrant is wiped off and the part is dried. Adeveloping powder is then applied which helps to drawthe penetrant out of the flaws by capillary action.Inspection is carried out under "black light".

(12) A majority of indications revealed by theinspection methods of step II are normal and harmless,and only in a small percentage of cases is reliability ofthe part impaired when indications are found. Sinceinspection reveals the harmless indications with thesame intensity as the harmful ones, detection of theindications is but a first step in the procedure.Interpretation of the indications is the most Importantstep.

(13) If the crankshaft is to be reground, proceed asfollows:

(a) Compare the crankshaft journalmeasurements taken during inspection with thedimensions in Table 2-5 and figure 2-139C, anddetermine the size to which the journals are to bereground.

NOTEThe 0.002 inch undersize bearingsare used only to compensate forslight wear on crankshafts on whichreground is unnecessary.

Table 2-5. Crankshaft Journal Dimensions

Bearing Connecting Rod Main BearingSize Journal Diameter Journal Diameter(Inch) (Inches) (Inches)

Standard 2.750 3.5000.002 Undersize 2.750 3.5000.010 Undersize 2.740 3.4900.020 Undersize 2.730 3.4800.030 Undersize 2.720 3.470

(b) Measurement of the crankshaft journals,and comparison of these measurements to thediameters required for various undersize bearings shownin Table 2-5, will determine the size to which thecrankshaft journals must be reground.

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(c) If one or more main or connecting rodjournals require grinding, then grind all of the mainjournals or all of the connecting rod journals to the samerequired size.

(d) All journal fillets must have a 0.100 inch to0.130 inch radius between the crank cheek and thejournal, and must not have any sharp grind marks (figure2-139D). The fillet must blend smoothly into the journaland the crank cheek, and must be free of scratches.The radius may be checked with a fillet gage.

(e) Care must be taken to avoid localizedheating which often produces grinding cracks. Cool thecrankshaft while grinding, using coolant generously. Donot crowd the grinding wheel into the work.

(f) Polish the ground surfaces to an 8 to 12RMS finish. The reground journals will be 'subject toexcessive wear unless polished smooth.

(g) If the thrust surfaces of the crankshaft areworn or grooved excessively, they must be reground andpolished. Care must be taken to leave a 0.100 inch to0.130 inch radius between each thrust surface and thebearing journal (figure 2-139D).

(h) Stone the edge of all oil holes m thejournal surfaces smooth to provide a radius ofapproximately 3/32 inch.

(i) After grinding has been completed,inspect the crankshaft by the magnetic particle methodto determine whether cracks have originated due to thegrinding operation.

(j) Demagnetize the crankshaft.

(k) Clean the crankshaft and oil passagesthoroughly with clean diesel fuel. Dry the crankshaft withcompressed air.

(14) Inspect the bearing shells visually for scoring,pitting, flaking, cracking, loss of babbitt, or signs ofoverheating. If any of these defects are present, thebearings must be replaced. However, the babbitt platedbearings may develop minute cracks or small isolatedcavities on the bearing surface during engine operation. These are characteristics of, and are not detrimental to,this type of bearing. The bearings should not bereplaced for these minor surface imperfections sincefunctioning of the bearings is in no way impaired. Thelower bearing shells, which carry the load, will normallyshow signs of wear before the upper shells do.

(15) Inspect the backs of the bearing shells for brightspots which indicate they have been moving in the capor cylinder block. If such spots are present, discard theshells.

(16) Measure the thickness of the main bearingshells (point C, figure 2-140) with a micrometer and ballattachment as illustrated in figure 2-141.

(17) The minimum thickness of a worn standard mainbearing shell is 0.123 inch. If any of the shells arethinner than this dimension, replace all shells. Table 2-6lists the minimum bearing shell thickness for newstandard and undersize bearings, and the crankshaftmain bearing journal diameters corresponding to eachbearing size.

Table 2-6. Main Bearing Shell Thickness

Nominal Size ofBearing (Inch)

Minimum NewBearing Shell

Thickness (Inch)

Crankshaft MainBearing Journal

Diameter(Inches)

Standard 0.1240 3.499 to 3.5000.002 Undersize 0.1250 3.497 to 3.498

(18) Measure the clearance between main bearingsand crankshaft journals. If the crankshaft is in place,measure the clearance with a soft plastic measuring stripforced between the journal and bearing. If the clearanceis 0.006 inch or more, replace all bearing shells. Withnew shells, the clearance should be 0.0025 to 0.0057inch.

Figure 2-140. Main Bearing Shell MeasurementDiagram

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Figure 2-141. Measuring Main Bearing Shell Thickness

(19) If the crankshaft is removed, install the bearingshells in the block; then install bearing caps and torquebearing cap bolts to value specified in Table 2-2.Measure inside diameter of bearings and compare withcrankshaft main bearing journal diameters as listed in(Table 2-6). The tolerances specified in paragraph (18)above apply.

2-63. REASSEMBLY AND INSTALLATION.a. Reassembly.

(1) Install the oil pump drive gear on the crankshaft(figure 2-99).

(2) Position timing gear key (15, figure 2-135) inkeyway of crankshaft, and drive the timing gear (14) onthe crankshaft as shown in figure 2-142.

b. Installation of Crankshaft and Main Bearings.

(1) If a new crankshaft is to be installed, steamclean it to remove the rust preventive, and blow out theoil passages with compressed air. Install the crankshaftas follows:

CAUTIONMain bearing shells should not bereplaced separately. If bearing shellrequires replacement, a new upperand lower shell should be installed.If a new crankshaft is used, all newbearing shells should be installed.

Figure 2-142. Crankshaft Timing Gear Installation

(2) Install the upper grooved bearing shells in theblock. If the old bearing shells are to be used again,install them in the same locations from which they wereremoved.

(3) Apply clean engine oil to all crankshaft journals,and install the crankshaft in place so that the timingmarks on the crankshaft timing gear and the idler gearmatch (figure 2-132).

(4) Install the upper halves of the crankshaft thrustwashers on each side of the rear main bearing support,and the doweled lower halves on each side of the rearmain bearing cap. The grooved side of the thrustwashers must face toward the crankshaft thrust surfaces(figure 2-136).

NOTEIf the crankshaft thrust surfaces werereground, it may be necessary toinstall oversize thrust washers onone or both sides of the rear mainjournal. Refer to figure 2-139E and(Table 2-7).

Table 2-7. Crankshaft Thrust Washer Thickness

Thrust Washer Thickness(Inch)Nominal Size

(Inch)Min. Max.

Standard 0.1190 0.12200.005 Oversize 0.1255 0.12700.010 Oversize 0.1300 0.1320

(5) Install the lower bearing shells (no oil grooves)in the bearing caps. If the old bearing shells are to beused again, install them in the same bearing caps fromwhich they were removed. Lubricate the bolt threadsand bolt head contact surfaces with a small quantity ofInternational Compound No. 2, or equivalent. Install the

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bearing cap stabilizers and draw the bolts up snug(figure 2-134). Then, rap the caps sharply with a softhammer to seat them properly.

(6) Draw the main bearing cap bolts uniformly tight,starting with the center cap and working alternatelytoward both ends of the block, to torque value specifiedm Table 2-2. Tighten the stabilizer-to-cylinder blockbolts to torque value specified in Table 2-2. Rotate thecrankshaft to make sure that it rotates freely.

NOTEIf the bearings have been installedproperly, the crankshaft will turnfreely with all of the main bearing capbolts drawn to the specified torque.

(7) Check the crankshaft end play by moving thecrankshaft toward the dial indicator (figure 2-143) with apry bar or screwdriver. Keep a constant pressure on thepry bar and set the dial indicator to zero. Then, removeand insert the pry bar on the other side of the bearingcap. Force the crankshaft in the opposite direction andnote the amount of end play on the dial. The end playshould not exceed limits listed in Table 2-3. Insufficientend play can be the result of a misaligned rear mainbearing, or a burr or dirt on the inner face of one or moreof the thrust washers.

NOTEIf end play is excessive, new thrustwashers should be installed.

(8) Pull the piston and rod assemblies down untilthe upper bearing halves seat firmly on the crankshaftjournals; then place the lower bearing halves (4, figure2-111) in the connecting rod cap (3).

(9) Note the identifying marks on the bearing capand the connecting rod, and assemble the cap to the rodas illustrated in figure 2-109. Tighten connecting rodnuts to torque value specified in Table 2-2.

(10) Install rocker arms (paragraph 2-24b) and fuelpipes (paragraph 2-20).

(11) Install rocker arm covers with new gaskets inreverse of instructions on figure 2-2.

(12) Install flywheel housing (paragraph 2-49b).

(13) Install engine lower front cover with oil pump(paragraph 2-41d).

(14) Install oil inlet tube and strainer (paragraph2-38c) and engine oil pan (paragraph 2-37e).

(15) Install the engine (paragraph 2-9).

Figure 2-143. Checking Crankshaft End Play

c. Installation of Main Bearings with CrankshaftInstalled.

(1) Apply clean engine oil to all crankshaft journalsand install the main bearing shells (one at a time) inreverse of removal outlined in paragraph 2-61a.

CAUTION

One main bearing shell, alone,should not be replaced. If onebearing shell requires replacement, anew upper and lower shell must beinstalled.

(2) Install new or original upper bearing shells afterinspection by rolling into place in the bearing support.

NOTE

Start the end of shell having no tangaround the crankshaft journal first,so that when shell is in place the tangwill fit into groove in shell support.

(3) Install the upper thrust washers (figure 2-136).

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(4) Position the lower bearing shell and the lowerthrust washer halves (on rear bearing cap only) inbearing caps (figure 2-136) and install over crankshaftrear bearing journal.

(5) Position lower bearing shells in remainingbearing caps and position on crankshaft journals.

(6) Secure bearing caps with stabilizers asinstructed in steps 5 and 6 of paragraph 2-63b.

NOTE

If the main bearings have beeninstalled properly, the crankshaft willturn freely.

(7) Check crankshaft end play as outlined in step 7of paragraph 2-63b.

(8) Install the oil inlet tube and strainer (paragraph 2-38c).

(9) Install the engine oil pan (paragraph 2-37e).

Section XVI. CYLINDER LINERS

2-64. DESCRIPTION AND REMOVAL.

a. Description.The cylinder liners are of the replaceable wet type madeof hardened alloy cast Iron, and are a slip fit in thecylinder block. They are inserted in the cylinder boresfrom the top of the cylinder block. The flange of eachliner rests on a counterbore in the top of the block.

b. Removal.(1) Remove pistons and connecting rods as outlined

in paragraph 2-51a.

(2) Remove the cylinder liners as shown infigure 2-144.

(3) If the engine has been in service, it may benecessary to exert considerable effort to remove theliner with puller tool as follows:

(a) Slip the lower puller clamp up the pullerrod and off its tapered seat. Cock the clamp so it willslide through the liner. The clamp will drop back onto itsseat in a horizontal position after it clears the bottom ofthe liner.

(b) Slide the puller top clamp down againstthe top edge of the liner (figure 2-144).

Figure 2-144. Cylinder Liner Removal

(c) With the tool in place, strike the upsethead on the upper end of the puller rod a sharp blowwith puller weight, thus releasing the liner. Remove theliner.

(4) Remove the cylinder liner seal ring from thegroove in the cylinder block bore.


a. Cleaning.Clean cylinder liners by washing with cleaning solventand dry thoroughly.b. Inspection and Repair.

(1) Refer to figure 2-145 and thoroughly inspect thecylinder liner for out-of-round condition, excessive taper,cracks, scoring, flange irregularities and erosion.

(2) Refer to Table 2-3 for liner dimensions andmeasure the liner at points shown in figure 2-145. Tocheck these dimensions, use a dial bore gage which hasa dial indicator calibrated in 0.001 inch increments asillustrated in figure 2-146.

(3) If the taper is out-of-round and does not exceedthe limits hosted in Table 2-3, hone the liner to removeany step or ridge at the top of the ring travel and toremove the glaze caused by the rubbing action of thepiston rings.

(4) After the liner has been honed, clean the linerand the cylinder block thoroughly with cleaning solventand dry with clean compressed air.

(5) After honing, the liner must conform to the samelimits on taper and out-of-round as a new liner, and thepiston-to-liner clearance must be within specified limitslisted in Table 2-3. Replace a defective cylinder liner.

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Figure 2-145. Cylinder Liner Measurement Diagram

(6) Wipe the inside and outside of the cylinder linerclean. Make sure the block bore and counterbore areclean so the liner flange will seat properly.

2-66. INSTALLATION.

a. Fitting Lining in Bore.

(1) Slide the liner into the block until the flange onthe liner rests on the bottom of the counterbore in theblock.

CAUTIONDo not drop or slam the cylinder linerflange against the counterbore in theengine block.

(2) Tap the liner lightly with a soft hammer to makesure the liner seats in the bottom of the counterbore.

(3) Clamp the cylinder liner in place as illustrated infigure 2-147. Refer to Table 2-3 and measure thedistance from the top of the liner flange to top of theblock with a dial indicator.

Figure 2-146. Checking Cylinder Liner Bore

Figure 2-147. Clamping Cylinder Liner in Bore

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(4) Matchmark the liner and block with chalk orwhite paint, so the liner may be reinstalled in the sameposition and in the same bore. Place the matchmark onthe outer edge of the engine serial number side.

(5) Remove the hold-down clamp (figure 2-147) andcylinder liner from the engine block.

b. Installing Piston, Connecting Rod and Liner.

(1) With the piston assembled to the connecting rodand the piston rings m place (paragraph 2-53a) apply aclean coat of engine oil to the piston, rings and inside ofpiston ring compressor tool.

(2) Place the ring compressor on a wood block,tapered end up, as illustrated in figure 2-148.

(3) Stagger the piston ring gaps and make sure theoil control ring expanders are not overlapped (paragraph2-53a).

(4) Start the top of the piston straight into the ringcompressor; then, push the piston down until it contactsthe wood block (operation 1, figure 2-148).

(5) Note the position of the matchmark made on theliner and place the liner on a wood block.

(6) Place the ring compressor and the piston androd assembly on the liner, so the numbers on the rodand cap are aligned with the matchmark on the liner(operation 2, figure 2-148).

NOTEThe numbers, or number and letter,on the side of the connecting rod andcap identify the rod with the cap andindicate the particular cylinder inwhich they are used. If a newconnecting rod is to be installed, thesame identification number, ornumber and letter, must be stampedor etched in the same location as onthe connecting rod that was replaced.

(7) Push the piston and rod assembly down into theliner until the piston is out of the ring compressor.

CAUTIONDo not force the piston into the liner.The expanders apply considerableforce on the oil ring; therefore, extracare must be taken duringinstallation to prevent ring breakage.

Figure 2-148. Installing Piston and Connecting Rod inCylinder Liner

(8) Remove the connecting rod bearing cap andring compressor and push the piston down into the lineruntil the compression rings pass the liner ports.

(9) After the piston and connecting rod assembly isinstalled in the liner, install the piston and liner assemblyas follows:

(a) Make sure the seal ring groove in thecylinder block is clean, and install a new seal ring.

(b) Apply vegetable-type shortening, or apermanent-type antifreeze solution, to the inner surfaceof the seal ring.

(c) If any of the pistons and liners are alreadyin the engine, use hold-down clamps (figure 2-147) toretain the liners in place when the crankshaft is rotated.

(d) Hold the piston, rod, and liner in line withthe block bore (figure 2-149) so the identification numberon

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Figure 2-149. Installing Piston, Connecting Rod andCylinder Liner Assembly

the rod is facing the engine serial number side. Also,align the matchmarks on the liner and block. Slide theentire assembly into the block bore and seal ring, beingcareful not to damage the seal ring.

(e) Install the bearing shells and theconnecting rod caps as outlined in paragraph 2-53b.

(f) Remove the cylinder liner hold-downclamps (figure 2-147).

(10) Complete the installation of the pistons andconnecting rods as outlined in paragraph 2-53b.

Section XVII. CYLINDER BLOCK

2-67. DESCRIPTION AND REMOVAL.

a. Description.The cylinder block is a one piece casting which formsthe main structural part of the engine. Transverse websprovide rigidity and strength and insure alignment of theblock bores and bearings under load. The block is boredto receive replaceable wet-type cylinder liners.

b. Removal.

(1) Remove the engine from the tractor(paragraph 2-8).

(2) Remove all subassemblies and componentsfrom the cylinder block (paragraphs 2-10 through 2-64b).

2-68. PRESSURE TEST AND DISASSEMBLY.

a. Cylinder Block Pressure Test.

(1) To perform pressure test, It will be necessary tofabricate a steel plate from 1/2 inch stock to cover eachcylinder bank of block. Plates will adequately seal topsurface of block when used with cylinder linercompression gaskets and water hole seal rings. It willalso be necessary to use water hole cover plates andgaskets to seal water inlet openings in sides of block.One cover plate should be drilled and tapped to providea connection for an air line so the water jacket can bepressurized.

(2) Install new compression gaskets and water holeseal rings in counterbores in the top surface of block(figure 2-73).

(3) Place plates on top of block and tighten securelywith capscrews and flat washers (figure 2-150).

(4) If necessary, install water hole cover plates andgaskets on sides of the block.

(5) Immerse the block for twenty minutes in a tankof water which is heated to 180 to 200°F.

Figure 2-150. Cylinder Block Prepared for PressureTest

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(6) Attach air line to water hole cover plate andapply 80 to 100 psig air pressure to water jackets.Observe water in tank for bubbles which will indicatecracks or leaks.

(7) Remove block from water tank. Remove plates,seals, and gaskets and blow out all passages in blockwith compressed air.

b. Disassembly.(1) Remove cylinder liners as outlined in

paragraph 2-64b.

(2) Disassemble the cylinder block in numericalsequence illustrated in figure 2-151.


a. Cleaning.(1) Remove all traces of gasket material from the

block and end plate.

(2) Thoroughly clean cylinder and crankcase oilpassages using compressed air and brass wire probes.Flush cylinder and crankcase water jacket thoroughly.Clean block with live steam. Make sure oil galleries, airbox floor, and air box drain openings are thoroughlycleaned. Jets machined in camshaft bushing borespermit oil to be sprayed on cam followers; make surethey are not plugged. A 0.020 inch wire may be used toclean jets.

(3) Dry block with compressed air.

1. Draincock 10. Gasket (4) 19. Capscrew (2)2. Capscrew (2) 11. Clamp (4) 20. Washer (2)3. Lock washer (2) 12. Tube assembly (2) 21. Capscrew (12)4. Cover 13. Elbow (2) 22. Lock washer (12)5. Gasket 14. Selflock screw (8) 23. End plate6. Capscrew (4) 15. Washer(8) 24. Gasket7. Washer (4) 16. Bolt (8) 25. Washer (8)8. Gasket (4) 17. Stabilizer (4) 26. Plug nut (2)9. Cover (4) 18. Bearing cap (4) 27. Block

Figure 2-151. Cylinder Block Disassembly

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b. Inspection and Repair.(1) Check top machined surfaces of block for

flatness with an accurate straight edge and a feelergage. Top surface flatness must not vary more thanlimits specified in Table 2-3.

(2) Make sure seal ring grooves are thoroughlyclean. Inspect grooves and lands for evidence of pittingand erosion. If both grooves are eroded to extent thatsealing is affected, block must be replaced.(3)Measure each cylinder block cylinder bore, atpositions on axes 90 degrees apart (figure 2-152). Ifdiameter does not exceed 4.5235 inches at position "A",4.4900 inches at position "B" (and a sealing problem hasnot occurred), or 4.3595 inches at position "C" and "D",block may be reused. Taper and out-of-round must notexceed limits specified in Table 2-3.

(4) Lubricate threads and underside of each mainbearing cap bolt head with OE-30 engine oil. Install fourmain bearing caps, using main bearing cap bolts withtemporary spacers (figure 2-134B), and tighten bolts totorque value listed in Table 2-2.

(5) Measure main bearing bores (E, figure 2-152).Bearing bores must be 3.751 to 3.752 inches. If boresdo not fall within these limits, discard block.

(6) Check main bearing bores for alignment.Bearing bores are properly aligned with one another if acrankshaft with standard size journals can be rotatedfreely by hand, after new main bearing shells have beeninstalled and lubricated, and bearing caps have beensecured.

(7) Make sure cylinder liner counterbores in blockare clean. Check counterbore depth. Depth must befrom 0.300 inch to 0.302 inch and must not vary morethan 0.001 inch throughout entire circumference.Counterbored surfaces must be smooth and square withcylinder bore within 0.001 inch total indicator reading.

(8) Check all machined surfaces and threadedholes in block. Remove nicks and burrs from machinedsurfaces with a fine mill file. Chase damaged threads intapped holes with proper tap, or install helical threadinserts if threads cannot be restored with tap.

(9) Check the surfaces of the end plate for nicks,dents, scratches, or score marks; also check the endplate for flatness. Plug type nuts in the end plate shouldalso be checked for cracks and damaged threads. Ifnicks or scratches on the sealing surfaces of the endplate are too deep to be cleaned up, or the plug typenuts are damaged, the end plate or plug nuts should bereplaced.

(10) If a new service replacement block is used,stamp unit serial number and model number on top right-hand

Figure 2-152. Cylinder Block Measurement Diagram

corner of new block. Make sure bearing caps areproperly numbered.

(11) After inspection, if the cylinder block is not goingto be assembled for a temporary period of time, spraythe machined surfaces with OE-10 engine oil. If thecylinder block is not going to be assembled for anextended period of time, spray or dip the block in apolar-type rust preventive compound. Castings that arefree of grease and oil will rust immediately whenexposed to the atmosphere.


a. Reassembly.

(1) Reassemble the cylinder block in reverse ofnumerical sequence as illustrated in figure 2-151.

(2) Tighten twelve end plate capscrews (21, figure2-151) to torque value listed in Table 2-2.

b. Installation.(1) Install all subassemblies and components on the

cylinder block (paragraphs 2-10 through 2-66a).

(2) Install the engine in the tractor (paragraph 2-9).

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Section XVIII. BLOWER ASSEMBLY

2-71. DESCRIPTION.

a. The blower assembly, mounted on the top of theengine block, supplies fresh air required for combustionand scavenging. Two hollow double lobe rotors revolvein the rotor housing. The revolving motion of the rotorsprovides a continuous and uniform displacement of air.b. Gears located at the splined ends of the rotor shaftsassist in spacing the rotor lobes. Normal gear wear willhave some material effect on the rotor-to-rotorclearance. A combination of gear and rotor shaftbearing surface wear will result in a decrease of rotor tohousing clearance.c. Seals are incorporated in each end of the blowerrotors and serve a dual purpose; first to prevent airleakage past the blower rotor shaft bearing surfaces,and second, to prevent oil used for lubricating the blowergears and bearings from entering the rotor compartment.

2-72. INSPECTION, REMOVAL ANDDISASSEMBLY.

a. Inspection (Blower Installed).

(1) Remove air cleaner and air inlet housing(paragraph 2-10a).

(2) Inspect the rotors for scratches, chips or otherabrasions. If burrs cause interference between therotors or between rotors and housing, the blower mustbe removed and parts dressed down to eliminate theinterference or replaced.

WARNINGWhen inspecting the blower on anengine, with the engine running, keepfingers and Clothing away frommoving parts of the blower and runthe engine at low speed only.

(3) Start the engine and check for leaking oil seals.Leaky oil seals are indicated by presence of oil on theblower rotors or the inside surfaces of the housing. Runthe engine at low speed and direct a light into the rotorcompartment at the end plates and oil seals. A thin filmof oil radiating away from the seals indicates an oil leakis present.

(4) With the engine running, check blower drive. Aworn blower drive results in a loose, rattling sound withinthe blower which can be detected with the engine idlingat As approximately 550 rpm.

(5) Inspect the rotor for loose rotor shafts or wornbearings. Defective bearings will result in contactbetween the rotor lobes, rotors and end plates or rotorsand housing.

(6) Inspect the rotor lobes for excessive backlash.Excessive backlash between the blower timing gears willresult in the rotor lobes rubbing throughout their entirelength.

(7) Install the air inlet housing (paragraph 2-10c).

b. Removal.

(1) Remove air cleaner and air cleaner bracket(paragraph 3-2b).

(2) Remove governor linkage and drive support(paragraph 2-31a).

(3) Remove four blower mounting bolts (figure2-153).

(4) Use a suitable lifting hoist and remove blowerand governor assembly from engine (figure 2-154).

(5) Remove six capscrews and lock washers (figure2-155) and remove governor from blower.

Figure 2-153. Blower Removal

c. Disassembly.(1) Disassemble the blower as illustrated m figure

2-156.(2) Wedge a clean cloth between the blower rotors

to prevent their turning. Match mark the left hand gearso it can be installed m the same position. Remove thetwo rotor gear retaining bolts and pull the rotor gearswith pullers as illustrated in figure 2-157. Remove thetwo gears simultaneously.

2-73. CLEANING, INSPECTION AND REPAIR.a. Cleaning.Clean all parts by washing with cleaning solvent and astiff bristled brush. Dry parts with compressed air atapproximately 40 psig.

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Figure 2-154. Lifting Blower from Engine

Figure 2-155. Removing Governor from Blowerb. Inspection and Repair.

(1) Inspect the finished inside face of the endplates. Slight scoring may be cleaned with crocus cloth.If the surface is badly scored, replace the end plate.

(2) Inspect the surface of the rotors and the blowerhousing. Remove burrs and scratches with an oil stone.

(3) Inspect the rotor shaft, gear and drive couplingfor burred or worn condition. Remove burrs with crocuscloth. Replace parts that are worn.

(4) Inspect blower gears for excessive wear ordamage. Replace as necessary.

(5) Inspect the bearing and oil seal contact surfacesof the rotor shafts and end plates for scoring, wear ornicks. Replace-as necessary.

(6) Replace all gaskets and seals.

(7) Inspect threaded openings and hardware fordamaged threads. Chase damaged threads with thecorrect size tap or die. Replace all damaged hardware.


a. Reassembly.(1) Install new seals (30, figure 2-156) in front plate

(27) and rear plate (29) as follows:(a) Place the plate on the bed of an arbor

press.

(b) Lubricate the outside diameter of the sealand using a suitable installer tool, press the seal (lipfacing down) into the Counterbored hole until theshoulder on the installer tool contacts the plate.

NOTEThe seal must be positioned belowthe finished face of the plate within0.002 to 0.008 inch.

(2) Place front plate (27) on two wood blocks. Theninstall rotors (28), gear end up, on the plate.

(3) Install the blower housing (31) over the rotors.

NOTETo prevent inadequate lubrication orlow oil pressure, care must beexercised in the assembly of the frontand rear blower end plates to theblower housing. The rear end platedoes not have tapped holes for thethrust washer plates and is the onlycover that has the horizontal oilpassage drilled through into thepocket on the left side of the endplate for supplying oil to the blowerdrive gear support bearing.

(4) Place the rear plate (29) over the rotor shafts.Temporarily secure each end plate to the blower housingwith four plate cover capscrews (1) and plain washers.

(5) Attach two thrust washers (26) to the front endof rotor shafts with capscrews (25). Tighten capscrewswith 56 lbs. ft. torque.

(6) Attach the three spacers (24) and thrust plate(23) to the front plate (27) of the blower. Tightencapscrews (22) with 8 lbs. ft. torque. Check theclearance between the thrust plate (23) and the thrustwashers (26). The specified clearance is 0.001 to 0.1 13inch.

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1. Capscrew (6)2. Plate (2)3. Plate (2)4. Front cover 13. Drive plate5. Cover gasket 14. 12 Point bolt 22. Capscrew (3)6. Capscrew(4) 15. Pilot 23. Thrust plate7. Cam retainer 16. Bolt 24. Spacer (3)8. Drive cam 17. Pilot 25. Capscrew(2)9. Spring pack 18. Right hand gear 26. Thrust washer (2) 30. Seal (4)10. Spring support 19. Left hand gear 27. Front plate 31. Housing11. Capscrew 20. Shim (AR) 28. Rotor assembly (2) 32. Dowel pin (4)12. Spacer 21. Spacer(2) 29. Rear plate 33. Lock washer (6)

Figure 2-156. Blower Disassembly

(7) Position the rotors so that the missing serrationson the gear end of the rotor shafts are 90° apart. This isaccomplished by placing the rotors in a "T" shape withthe missing serration in the upper rotor facing to the leftand the missing serration in the lower rotor facing towardthe bottom (figure 2-158). Install the shims (20, figure2-156) and spacers (21) in their respective counterbores(these were marked during disassembly) in the rear faceof the rotor gears (18 and 19). Place gears on the endsof the shafts with the missing serrations in alignmentwith the missing serrations on the shafts.

(8) Tap the gears lightly with a soft (plastic) hammerto seat them on the shafts. Then rotate the gears untilthe punch marks on the face of the gears match. If themarks do not match re-position the gears.

(9) Wedge a clean cloth between the blower rotors.Use the gear retaining bolts (14 and 16) (the twelve pointbolt in the left hand rotor identified by gear (19) ), andplain washers to press the gears on the rotor shafts.Tighten the bolts uniformly until the gears are tightagainst the shoulders on the shafts.

(10) Remove the bolts (14 and 16) and the plainwashers.

(11) Place pilots (17 and 15) m the counterbore ofgears (18 and 19) respectively, and start the twelve pointbolt (14) in the left hand rotor shaft and start the hexhead bolt (16) in the right hand rotor shaft. Tighten thebolts with 28 lbs. ft. torque.

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Figure 2-157. Blower Gear Removal

Figure 2-158. Blower Rotor Timing and ClearanceDiagram

(12) Measure the backlash between the blowergears, using a suitable dial indicator. The specifiedbacklash is 0.0005 to 0.0025 inch with new gears or amaximum of 0.0035 inch with used gears.

(13) After the blower rotors and gears have beeninstalled, the blower rotors must be timed. Whenproperly positioned, the blower rotors run with a slightclearance between the rotor lobes and with a slightclearance between the lobes and the walls of thehousing.

(14) The clearance between the rotors may beestablished by moving one of the helical gears out or inon the shaft relative to the other gear by adding orremoving shims (20) between the gear hub and the rotorspacers.

(15) It is preferable to measure the clearance with afeeler gage comprised of two or more feelers, since acombination is more flexible that a single feeler gage.Take measurements from both the inlet and outlet sidesof the blower.

(16) Measure the clearance between the rotor lobesand the housing as shown m figure 2-159. Takemeasurements across the entire length of each rotorlobe to be certain that a minimum clearance of 0.004inch exists at the air outlet side (B, figure 2-158) and aclearance of 0.010 exists at the inlet side (A, figure2-158).

(17) Measure the clearance between the rotor lobes,across the length of the lobes. Rotate the gears until thelobes are at their closest relative position (C, figure2-158). The clearance between the lobes should be aminimum of 0.010 inch.

(18) Measure the clearance between the end of therotors and the front end plate as shown in figure 2-160.The clearance should be a minimum of 0.008 inch.

NOTE

Push and hold the rotor toward theend plate at which the clearance isbeing measured.

(19) Measure the clearance between the end of therotors and the rear end plate in the same manner. Theclearance should be a minimum of 0.012 inch.

(20) Remove the capscrews (1, figure 2-156) andwashers used to temporarily secure the front end plateto the housing. Install gasket (5), cover (4), reinforcingplates (3 and 2) and secure with six lock washers (33)and capscrews (1). Tighten capscrews with 23 lbs. ft.torque.

(21) Assemble the coupling assembly as follows:

(a) Place the spring support (10) on twoblocks of wood.

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Figure 2-159. Measuring Rotor Lobe-to-HousingClearance

Figure 2-160. Measuring Rotor Lobe-to-End PlateClearance

(b) Position the spring seats in the support,apply grease to the springs to hold the leaves together,then slide the two spring packs (fifteen leaves per pack)in place.

(c) Place the drive cam (8) over the end of aninstalling tool, insert tool between the spring packs andpress the cam in place (figure 2-161).

(22) Place spacer (12, figure 2-156) on gear (19) andposition coupling on spacer. Secure the couplingassembly with cam retainer (7) and capscrews (6).Tighten capscrews with 18 lbs. ft. torque.

(23) Install governor drive plate (13) on the right handgear (18) and secure with four capscrews (11). Tightencapscrews with 9 lbs. ft. torque.

b. Installation.

(1) Install governor on the blower in reverse ofremoval (figure 2-155).

(2) Position new blower and governor gaskets andblower seal as shown in figure 2-162.

(3) Install the blower on the engine in reverse ofremoval (figures 2-154 and 2-153).

(4) Install drive support and governor linkage(paragraph 2-34b).

(5) Install air cleaner and bracket (paragraph 3-2e).

(6) Adjust governor as outlined in paragraph 2-7.


Figure 2-161. Inserting Blower Drive Cam in Spring

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Figure 2-162. Blower and Governor Gasket and SealLocation

Section XIX. ENGINE TROUBLE- SHOOTING CHART

2-75. GENERAL.

a. This section contains troubleshooting information forlocating and correcting most of the trouble which maydevelop in the diesel engine. Each malfunction for anindividual component, unit, or system is followed by a listof tests or inspections which will help to determineprobable causes and corrective actions to take. Performthe tests/inspections and corrective actions in the orderlisted.

b. This manual cannot list all malfunctions that mayoccur, nor all test or inspections and corrective actions.If a malfunction is not listed or is not corrected by listedcorrective actions, notify your supervisor.

2-76. ENGINE TROUBLESHOOTING CHART.

The Engine Troubleshooting Chart, Table 2-8, outlinesthe possible causes of engine troubles and theirremedies. To use the chart, read down the SYMPTOMcolumn until the malfunction is located. Then readacross to the PROBABLE CAUSE column, and performthe recommended remedy in the CORRECTIVEACTION column.

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Table 2-8. Engine Troubleshooting ChartSymptom Probable Cause Corrective ActionEngine fails to crank 1. No electrical power at starter motor 1. Check key switch, neutral start

switch, and start pushbutton2. Starter motor or solenoid defective 2. Repair or replace starter or solenoid

(paragraph 6-6)3. Engine internally seized 3. Hand-crank engine one revolution. If

engine cannot be hand-cranked,disassemble and repair engine(paragraph 2-8)

4. Flywheel ring gear defective 4. Replace flywheel ring gear(paragraph 2-44)

Engine cranks but 1. Fuel pump defective 1. Repair or replace fuel pumpfails to start (paragraph 2-13)

2. Fuel lines obstructed 2. Clean or replace fuel lines(paragraph 2-12)

3. Governor linkage or injector rackimproperly adjusted

3. Adjust governor linkage or injectorrack (paragraph 2-7)

Engine is hard to start 1. Engine out of tune 1. Perform engine tune up(paragraph 2-4)

2. Blower inoperative 2. Repair or replace blower (paragraph2-72)

Engine emits black or grayexhaust smoke

1. Excessive back pressure in exhaustsystem

1. Replace muffler or exhaust system2. Clean air inlet elbow and housing

(paragraph 2-10)2. Air inlet restricted 3. Service air cleaner (paragraph 3-2)

4. Time fuel injectors (paragraph 2-6)3. Air cleaner restricted 5. Adjust injector rack control levers4. Fuel injectors improperly timed (paragraph 2-7b)5. Injector rack control levers improperly 6. Repair or replace fuel injectors

adjusted (paragraph 2-16)6. Fuel injectors defective 1. Repair or replace fuel injectors

(paragraph 2-16)Engine emits white 1. Fuel injectors defective 2. Perform compression test (paragraphexhaust smoke 2-26a). If compression is low, check

2. Low cylinder compression for worn or broken rings, sticking orburned exhaust valves, and leakycylinder head gaskets

1. Perform engine tune up(paragraph 2-4) and check gear train

Engine lacks power 1. Engine out of tune timing (paragraph 2-58)2. Governor-to-injector linkage binding or

improperly adjusted2. Correct binding, adjust linkage

(paragraph 2-7)3. Low cylinder compression 3 Perform compression test

(paragraph 2-26a). If compression islow, check for worn or brokencompression rings , sticking orburned exhaust valves, and leakycylinder head gaskets

4. Fuel pump defective 4. Perform fuel pump flow test(paragraph 2-13b) If pump fails test,and lines are obstructed, repair orreplace fuel pump (paragraph 2-13)

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Table 2-8. Engine Troubleshooting Chart (Continued)Symptom Probable Cause Corrective Action

Engine lacks power 5. Blower-to-cylinder block gasket 5. Replace gasket (paragraph 2-72)(Continued) defective

6. Blower oil seals defective 6. Replace oil seals (paragraph 2-73)7. Governor defective 7. Repair or replace governor

(paragraph 2-31)Excessive lubricating 1 Gaskets or seals leaking 1. Replace gaskets and sealsoil consumption (paragraph 2-41)

2. Cylinder head gasket leaking 2. Replace gasket (paragraph 2-27)3. Pistons, rings or liners worn or

broken3. Replace damaged pistons, rings or

liners (paragraph 2-51 and 2-64)4. Exhaust valve guides worn 4. Replace valve guides

(paragraph 2-27)Engine noisy 1. Valves defective 1. Repair or replace valves

(paragraph 2-27)2. Connecting rod or main bearings 2. Replace bearings (paragraph 2-51

defective and 2-61)3. Piston pins loose or broken 3. Replace piston pins

(paragraph 2-51)4. Flywheel loose or defective 4. Tighten or replace flywheel

(paragraph 2-44)Lubricating oil pressure NOTElow

Checks must be made withengine oil at normal operatingtemperature1. Pressure regulator valve dirty or

defective1. Clean or replace valve

(paragraph 2-41)2. Oil pump defective 2. Repair or replace oil pump

(paragraph 2-42)3. Connecting rod or main bearings

loose and or defective3. Replace bearings

(paragraph 2-51 and 2-61)4. Air leaks in oil pump inlet (suction)

tube4. Replace oil inlet tube

(paragraph 2-38)5. Fuel injector or line leaking (oil

dilution)5. Repair or replace fuel injector or

fuel line (paragraph 2-16)Engine overheats 1. Radiator defective 1. Clean, repair or replace radiator

(paragraph 5-1)2. Water pump defective 2. Repair or replace water pump

(paragraph 5-7)3. Thermostat defective 3 .Replace thermostat

(paragraph 5-6)4. Alarm and shutdown kit defective (no 4. Repair or replace alarm and

shutdown kit automatic shutdownof engine) (paragraph 6-8).

5. Cylinder head cracked 5. Replace cylinder head(paragraph 2-27)

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CHAPTER 3

FUEL SYSTEM

Section I. AIR CLEANER AND INDICATOR

3-1. RESTRICTION INDICATOR.

a. Description.

The restriction indicator, mounted at the top right of theinstrument panel, monitors the resistance to airflow(restriction) through the air cleaner system into theengine. Dirt particles trapped by the air cleanerelements gradually increase restriction, causing the redsignal within the indicator to appear. When the presetrestriction level is reached, the red signal locks in fullview, indicating filter element service is required. Afterfilter element service, the restriction indicator is reset bypressing the button at the top of the unit.

b. Removal.(1) Grasp indicator body (1, figure 3-1) and remove

from safety filter (2) by turning counterclockwise.

(2) Remove safety filter (2) and hose (4) withconnectors (3). Remove elbow (5).

(3) If necessary for replacement, remove twoscrews (7) and hex nuts (6), and lift mount (8) frominstrument panel.


(1) If indicator displays red signal and will not resetwhen button at top is depressed, the indicator isdefective.

(2) Inspect safety filter (2) for clogging or otherindication of restriction.

(3) Examine hose (4) and connectors (3) for cracks,tears, and damaged threads. Blow compressed airthrough hose to check for blockage.

(4) Replace damaged or defective components withnew parts.

Figure 3-1. Restriction Indicator Removal

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d. Installation.

(1) Position mount (8) on instrument panel andsecure with two machine screws (7) and hex nuts (6).

(2) Install elbow (5) at bottom of mount (8).(3) Install hose (4) with connectors (3).(4) Screw safety filter (2) into mount (8) with filter

end on top (toward restriction indicator).

CAUTIONDo not use thread sealant at indicatorconnection. Install indicator hand-tight only; do not overtighten or usetools to tighten.

(5) Install restriction indicator (1) on threadedconnection of safety filter (2).

3-2. AIR CLEANER.

a. Description.Figure 3-2 illustrates operation of the air cleaner,Contaminated air enters the air cleaner inlet from therain cap on the engine hood. Dust and dirt are forcedaround the baffle to the dust cup assembly by spinningprecleaner vanes. Suction within the air cleanerassembly keeps the rubber lips of the vacuator valveclosed whenever the engine is operating. When theengine stops, the vacuator valve opens and allows thedust and dirt to fall from the dust cup assembly. Theprecleaned air passes through two filter elements beforereaching the engine (the safety element protects theengine from contamination immediately followingservicing of the primary element).

b. Removal.NOTE

Removal is not required for filterelement servicing (see paragraph3-2c below).

(1) Disconnect restriction indicator hose (4, figure3-1) and connector (3) from air cleaner body.

(2) Loosen and remove two hose clamps (1, figure3-3) and rubber coupling (2).

(3) Loosen and remove two hose clamps (3) andrubber coupling (4), and remove air manifold (5) fromvehicle.

(4) Loosen and remove four hex nuts (11), lockwashers (12), hex head screws (13) securing mountingbands (10) to bracket (17).

(5) Lift air cleaner (9) and mounting bands (10)from tractor.

Figure 3-2. Air Cleaner Operation

(6) Remove hex nuts (6), lock washers (7) andscrews (8) and remove bands (10) from air cleaner (9).

(7) If necessary for repair, remove screws (13 and16), lock washers (12 and 15) and hex nuts (11 and 14)securing bracket (17) to cross tie assembly and front ofengine; then lift bracket from tractor.

c. Disassembly.(1) Pull vacuator valve (1, figure 3-4) from snorkel

on dust cup assembly (3).

(2) Loosen and remove clamp assembly (2), andremove dust cup assembly (3).

(3) Remove wingnut and baffle (5) from dust cupassembly (3).

(4) Loosen and remove wing nut (4) and slideprimary filter element (6) from body (9).

(5) If necessary for replacement, loosen andremove wing nut (4) and slide safety element (7) frombody (9).

d. Cleaning, Inspection and Repair.(1) Shake accumulated dust from dust cup

assembly (3). Do not clean body assembly (9) unless aircleaner has been removed from tractor.

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1. Hose clamp (2)2. Rubber coupling3. Hose clamp (2)4. Rubber coupling5. Air manifold6. Hex nut (2)7. Lock washer (2)8. Screw (2)9. Air cleaner

10. Mounting band (2)11. Hex nut (7)12. Lock washer (7)13. Screw (7)14. Hex nut (2)15. Lock washer (2)16. Screw (2)17. Bracket

Figure 3-3. Air Cleaner Removal

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Figure 3-4. Air Cleaner Disassembly

(2) Check vacuator valve (1) for clogging depositsof dust or dirt. Shake out deposits of dust or dirt. Lipseals of vacuator valve should be open, forming awedge-shaped cone (see figure 3-5). If valve lips areinverted, check for obstruction at air cleaner inlet.

Figure 3-5. Air Cleaner Valve

(3) Clean all metal parts by washing with cleaningsolvent.

(4) Inspect all metal parts for damage aftercleaning, and apply a light film of engine oil to exposedmetal parts to protect from rust.

(5 )Wipe rubber couplings (2 and 4, figure 3-3) witha clean, dry cloth and inspect for cuts, tears, or cracks.

(6) Inspect all other parts for damage, and replacedamaged parts.

(7) Direct compressed air not exceeding 100 psigthrough primary filter element (6, figure 3-4) from insidecavity outward (opposite direction to normal flow inservice). Cover entire element with air stream whilekeeping nozzle at least one inch from pleated paperelement. When cleaning is completed, inspect byplacing light within element cavity and visually inspectexterior of element for tears or ruptures. Replaceelement if defective, and at every third service interval.

(8) Do not clean safety element (7). Inspect exteriorof installed safety element for tears or ruptures. Replaceelement if defective, and at every third service interval ofprimary element.

(9) Inspect preformed packing (8) for cracks, tears,or cuts. Replace damaged preformed packing.

e. Reassembly and Installation.

(1) Reassemble air cleaner in reverse of procedureoutlined in paragraph 3-2c.

(2) Install air cleaner in reverse order of procedureoutlined in paragraph 3-2b. Check all connectionsbetween air cleaner and engine for leaks, and tightenconnections as necessary.

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Section II. FUEL TANK, FILTERAND STARTING AID

3-3. FUEL TANK.

WARNINGDo not allow smoking or open flamewithin 50 feet of tractor. Keep fuelspillage cleaned up at all times.

a. Removal.

(1) Dram fuel from tank by removing drain plug.

(2) Remove fuel tank in numerical sequence asillustrated on figure 3-6.

(3) If necessary for repair, remove fuel tankbrackets (16) and tank guard (22) in numerical sequenceas illustrated on figure 3-6.

(4) Remove filler cap and fuel gauge sending unitfrom fuel tank.


(1) Clean all metal parts by washing with cleaningsolvent, and dry with compressed air at approximately40 psig.

(2) Inspect tank guard (22), stiffeners (17), brackets(16) and platform (4) for broken welds or cracks. Repairby welding. Replace a tank guard, stiffener, bracket orplatform beyond economical repair.

(3) Clean rubber strips (11) and hoses (5 and 7) bywashing with a mild detergent solution, and rinse withclear water. Inspect rubber strips and hoses for cracks,tears and deterioration. Replace a defective rubber stripor hose.

(4) Inspect connectors, hardware and threadedopenings for damaged threads. Chase threadedopenings with the correct size tap or die. Replacedamaged hardware.

WARNINGPurge fuel tank prior to welding.

CAUTIONDo not use detergent, soap oralkalies for cleaning interior of fueltank.

(5) Inspect fuel tank for leaks or damage. Flushtank with clean water for 5 minutes; then purge tank withcommercial fuel tank purging solution per manufacturer'sinstructions. Flush tank with clear water, drain waterfrom tank, and repair by welding. Replace a defectivefuel tank beyond economical repair.

c. Installation.

(1) Install fuel tank in reverse of procedure outlinedin paragraph 3-3a.

(2) Refill tank with diesel fuel as specified in theseparate Operator's Manual.

3-4. FUEL FILTER.

WARNINGDo not allow smoking or open flamewithin 50 feet of tractor. Keep fuelspillage cleaned up at all times.

a. Removal.

(1) Remove filter element (15, figure 3-7) by turningcounterclockwise and lowering from filter cover (16).Discard filter element.

NOTERefer to the separate Operator'sManual for filter element replacementschedule.

(2) If necessary for repair, remove fuel filter cover,hoses and fittings in numerical sequence as shown infigure 3-7.


(1) Clean filter cover, fittings and hardware bywashing with cleaning solvent. Dry clean parts withcompressed air at approximately 40 psig.

(2) Clean exterior of hoses by washing with a milddetergent solution and rinsing with clear water. Cleaninterior of hoses with compressed air. Inspect hoses forcracks and evidence of leakage, and replace defectivehoses.

(3) Inspect hardware, fittings and threadedopenings for damaged threads. Chase threadedopenings with the correct size tap. Replace damagedfittings and hardware.

c. Installation.

(1) Install fuel filter cover, hoses and fittings mreverse of numerical sequence illustrated in figure 3-7.

(2) Fill a new filter element (15) approximately 2/3full with clean diesel fuel, and lightly coat the elementgasket with diesel fuel.

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TM 9-2320-277-14&P

1. Hex nut (4) 12. Fuel tank2. Lock washer (4) 13. Lock nut (12)3. Capscrew (4) 14. Screw (4)4. Platform 15. Screw (8)5. Return hose 16. Bracket (2)6. Connector 17. Stiffener(2)7. Supply hose 18. Hex nut (4)8. Connector 19. Lock washer (4)9. Hex nut (4) 20. Screw (2)10. Strap assembly (2) 21. Screw (2)11. Rubber strip (2) 22. Tank guard

Figure 3-6. Fuel Tank Removal3-6

TM 9-2320-277-14&P

1. Hose2. Connector (2)3. Connector4. Elbow (2)5. Hose6. Connector (2)7. Inlet elbow8. Hose9. Connector (2)10. Extension11. Connector12. Capscrew (4)

13. Lock washer (4)14. Bracket15. Filter element16. Filter cover17. Plug (2)

Figure 3-7. Fuel Filter Removal

CAUTIONDo not use tools to tighten filterelement. Hand-tighten only.

(3) Install filter element and turn clockwise untilgasket contacts filter cover (16) ; then hand-tighten anadditional 2/3 turn.

(4) Start the engine and check filter andconnections for leaks.

3-5. ETHER STARTING AID.

a. Description.

The starting aid is a pressurized system used to injecthighly volatile ether into the engine air intake system.This is to facilitate starting when ambient temperaturesare below 40 ° F. An electrically operated solenoid valveinjects a pre-measured shot (approximately 6 cubiccentimeters) whenever the starter is energized and theether

pushbutton is operated. The replaceable pressurizedcylinder contains sufficient ether for approximately 100engine starts.

b. Removal and Disassembly.

WARNINGEther is highly volatile. Do not allowsmoking or open flame in vicinity oftractor.

(1) Remove ether cylinder as instructed on (figure3-8). Gently shake cylinder to estimate quantity of etherremaining.

(2) Tag electrical leads, and disassemble startingaid components in numerical sequence as illustrated infigure 3-9.


(1) Clean metal parts, except ether valve, bywashing with cleaning solvent. Dry clean parts withcompressed air at approximately 40 psig.

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TM 9-2320-277-14&P

Figure 3-8. Ether Cylinder Removal

(2) Clean ether valve and tubing by wiping with aclean, dry cloth. Apply 10 psig compressed air throughtubing and atomizer to check for obstructions. Replacedefective tubing or atomizer.

(3) Inspect hardware and threaded openings fordamaged threads. Replace all damaged parts.

(4) Inspect wiring for frayed insulation and damagedconductors. Replace defective wiring.

(5) Test operation of ether pushbutton switch withan ohmmeter.

(6) Test operation of ether solenoid valve bymomentarily connecting to a 12 volt battery. If a clickingnoise is not heard, the valve is defective.


1. Screw (2)2. Lock washer (2)3. Hex nut (2)4. Tube clip5. Lock washer6. Hex nut7. Switch

8. Ether cylinder9. Decal10. Ether valve11. Clamp assembly (2)12. Nylon tubing13. Fitting14. Atomizer

Figure 3-9. Starting Aid Disassembly

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TM 9-2320-277-14&P

WARNINGDo not bypass key switch whenreconnecting wiring to etherpushbutton. Connection through keyswitch prevents operation unlessstarter is engaged. Allowingoperation with engine stopped couldoverload engine air intake with etherand result in a minor explosion.

(1) Reassemble starting aid components in reverseof numerical sequence illustrated in figure 3-9. Ensurethat all fittings are tight.

(2) Install ether cylinder in reverse of instructions onfigure 3-8. Tighten cylinder hand-tight only.

(3) Operate system as described in the separateOperator's Manual and check for proper operation andleaks (fogging).

Section III. ACCELERATORLINKAGE AND PEDAL

3-6. ACCELERATOR CABLE AND ENGINE LINKAGE.

a. Removal and Disassembly.

CAUTIONDo not start engine with acceleratorlinkage at any stage of disassembly.

(1) Disconnect spring (1, figure 3-10) from lever (2)and clip bracket (3).

(2) Loosen and remove hex nut (12), and lower balljoint (14) and cable from bracket (8).

(3) Mark position of ball joint lock nut on cable shaft;then loosen lock nut and unscrew ball joint (14) fromcable shaft.

(4) Loosen and remove two hex nuts (19), lockwashers (18), machine screws (20), two spacers (16)and clamp (17).

(5) Loosen and remove hex nut (6), lock washer (5),cable clamp (22), and capscrew (21).

(6) Loosen and remove two capscrews (21), hexnuts (6) and lock washers (5), and separate lever (2) andbracket (8) from throttle arm (7).

(7) Remove cable clamp (26) and pull acceleratorcable (24) through bracket (27).

NOTEMatch mark throttle arm (7) andgovernor shaft to aid in reassembly.

(8) Remove brackets (3, 23, and 27) and throttlearm (7) only if required for repair.


(1) Clean all parts except accelerator and modulatorcable by washing with cleaning solvent. Dry parts with aclean cloth, and apply a light film of engine oil toexposed metal parts to prevent corrosion.

(2) Clean exterior of accelerator and modulatorcable by washing with a mild detergent solution andrinse with clear water. Check for freedom of cablemovement within cable cover, and inspect cableassembly for kinks or other damage. Replace adefective cable.

(3) Inspect hardware and threaded openings fordamaged threads. Chase threaded openings with thecorrect size tap or die, and replace damaged hardware.

(4) Inspect springs (1 and 15) for broken coils orother damage. Replace a defective spring.

c. Reassembly and Installation.

(1) Reassemble and install cable and engine linkagein reverse of procedure outlined in paragraph 3-6a.

NOTEObserve match mark alignment wheninstalling throttle arm (7) on governorshaft and ball joint (14) on cableshaft.

(2) Adjust accelerator pedal stop as described inparagraph 3-7d.

(3) Lubricate cable as specified in the separateOperator's Manual.

3-7. ACCELERATOR PEDAL.


CAUTIONDo not start engine with acceleratorpedal at any stage of disassembly.

(1) Remove hex nut securing ball joint (19, figure 3-11)to accelerator lever (8), and remove ball joint from lever.

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TM 9-2320-277-14&P

Figure 3-10. Accelerator Cable and Engine Linkage

(2) Mark position of hex nut (18) on cable shaft,then loosen hex nut (18) and unscrew ball joint (19) fromcable shaft.

(3) Remove capscrew (5), hex nut (7) and lockwasher (6); then remove clamp (20) and acceleratorcable from accelerator bracket (1).

(4) Remove two capscrews (13) and lock nuts (14),and lift pedal assembly (2) from cab floor.

(5) Remove hex nut (10), lock washer (11),accelerator lever (8) and shaft bracket (12).

(6) Loosen hex nut (10); then unscrew and removecapscrew (9) and hex nut (10).

NOTEExposed threads on shoulder bolt(15) are staked to retain bolt. Cleanstaked threads with the correct sizedie or a small file prior to removal ofbolt.

(7) If necessary for repair, remove shoulderbolt (15) and roller (16) from shaft bracket (12).


(1) Clean all parts except accelerator cable androller (16) by washing with cleaning solvent. Dry partsby wiping with a clean rag.

(2) Clean roller and exterior of accelerator cablewith a mild detergent solution and rinse with clear water.Inspect roller for flat spots and damage. Inspect cablefor kinks and freedom of movement within the cablecover. Replace a defective roller or cable.

(3) Inspect pedal assembly (2) for freedom ofmovement and hinge damage. Replace a defectivepedal assembly.


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TM 9-2320-277-14&P

Figure 3-11. Accelerator Pedal Disassembly


NOTE

Observe alignment mark whensecuring ball joint (19) and hex nut(18) to cable shaft.

(1) Reassemble and install accelerator pedal inreverse of procedure outlined in paragraph 3-7a. Do nottighten hex nut (10) at this time.

(2) Stake threads of installed shoulder bolt (15) witha prick punch and hammer.

(3) Adjust the accelerator pedal stop as described inparagraph 3-7d below.

d. Pedal Stop Adjustment.

(1) Check that ball joints (14, figure 3-10 and 19,figure 3-11) engage cable shaft at least 1/4 inch. If not,readjust ball joints for minimum 1/4 inch engagement oncable shaft.

(2) Depress accelerator pedal until governor throttlearm (7, figure 3-10) is in the full open position.

(3) Rotate capscrew (9, figure 3-11)counterclockwise until bottom of depressed pedalcontacts top of capscrew (9). Tighten hex nut (10) tosecure adjustment.

(4) Recheck pedal and linkage operation.Adjustment is correct when accelerator pedal iscontacting accelerator pedal stop and governor throttlearm is in full throttle position.

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TM 9-2320-277-14&P

CHAPTER 4

EXHAUST SYSTEM

Section I. EXHAUST PIPE AND TEE


a. Removal.

Remove the exhaust pipes and tee in numericalsequence as illustrated in figure 4-1.

b. Cleaning.

Clean all metal pats with cleaning solvent and drythoroughly.

4-2. INSPECTION, REPAIR AND INSTALLATION.

a. Inspection And Repair.

(1) Inspect the flex pipe, exhaust pipes and exhausttee for holes and areas that may be rusted and wouldcause exhaust leaks. Replace defective parts.

(2) Inspect clamps and hardware for damage andreplace defective parts.

b. Installation.

Install the exhaust pipes and tee m reverse of numericalsequence illustrated in figure 4-1.

1. Hex nut (6) 7. RH Exhaust pipe 13. Exhaust tee2. Lock washer (6) 8. LH Exhaust pipe 14. Exhaust swivel3. Clamp (3) 9. Pipe (2) 15. Hex nut4. Flex pipe 10. Hex nut (2) 16. Lock washer5. Screw (2) 11. Lock washer (2) 17. Capscrew6. Marman clamp (2) 12. Clamp 18. Hanger

Figure 4-1. Exhaust Pipe and Tee Removal

4-1

TM 9-2320-277-14&P

Section II. MUFFLER AND EXHAUST STACK


a. Removal.

Remove the muffler and exhaust stack in numericalsequence as illustrated in figure 4-2.

b. Cleaning.

Clean all metal parts with cleaning solvent and drythoroughly.


a. Inspection and Repair.

Inspect the muffler and tailpipes for holes and areas thatmay be rusted and would cause exhaust leaks. Replacedefective parts. Inspect clamps and hardware fordamage and replace defective parts.

b. Installation.

Install the muffler and exhaust stack in reverse ofnumerical sequence illustrated in figure 4-2.

1. Hex nut (2) 6. Self lock nut (8) 11. Hex nut (4) 16. Lock nut (4)2. Capscrew (2) 7. Capscrew (8) 12. Lock washer (4) 17. Flat washer (4)3. Hex nut 8. Tailpipe (30") 13. Clamp (2) 18. Capscrew (4)4. Capscrew 9. Screw (4) 14. Muffler 19. Bracket5. Rain cap 10. Cage 15. Tallpipe (18")

Figure 4-2. Muffler and Exhaust Stack Removal4-2

TM 9-2320-277-14&P

CHAPTER 5

COOLING SYSTEM

Section I. FAN, HOSES AND RADIATOR

5-1. FLUSHING THE COOLING SYSTEM.

a. Flushing Radiator.

WARNING

Be extremely careful when removingthe radiator filler cap of a hot engine.Release of pressure may causeviolent boiling and serious injury topersonnel.

(1) Remove the radiator filler cap and drain thecooling system to below the thermostat housings byopening the cylinder block drain cocks (figure 5-1).

Figure 5-1. Engine Coolant Draincocks

(2) Disconnect radiator hoses from radiator inletsand outlets.

(3) Connect long adapter hoses and flushing gun toradiator connections as shown in figure 5-2.

CAUTION

Apply air pressure gradually toprevent damage to radiator. Do notuse air pressure greater than 30 psig.

Figure 5-2. Reverse Flow Radiator Flushing (Typical)

(4) Fill radiator with water. Shut off water supplyand blow water out of radiator with air. Repeat asrequired until flushing stream runs clear.

(5) Disconnect flushing gun and adapter hoses.

(6) Reconnect radiator inlet and outlet hoses.

(7) Refill cooling system with antifreeze solution(see Operator's Manual).

b. Flushing Engine.

(1) Drain the cooling system (step 1, paragraph 5-1a).

(2) Disconnect radiator hoses from engine.

(3) Remove thermostats and hoses at engine blockinlet elbows (13 and 14, figure 5-10).

(4) Remove water pump (figure 5-12).

(5) Attach a hose and flushing gun to one wateroutlet as shown in figure 5-3. Plug the opposite outletelbow.

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TM 9-2320-277-14&P

Figure 5-3. Reverse Flow Engine Flushing (Typical)

(6) Completely fill the engine water jacket withwater. Blow water out with short blasts of air, allowingjacket to fill with water between air blasts. Repeat asrequired until flushing stream runs clear.

(7) Disconnect flushing gun and adapter hose.

(8) Reinstall water pump, thermostats and hoses.


5-2. FAN AND FAN DRIVE.a. Description.

The engine cooling fan is driven by a matched set of V-drive belts from the crankshaft pulley. The eight-bladefan is mounted on a viscous fan drive, and acombination fan hub and pulley which rotates on twotapered roller bearings.b. Removal.

Remove the fan and viscous fan drive assembly asinstructed on figure 5-4.c. Disassembly.

Disassemble the fan and fan drive components innumerical sequence as Illustrated m figure 5-5.d. Cleaning.

(1) Clean all parts, except bearings and fan drive,by washing in cleaning solvent. Dry clean parts with

Figure 5-4. Fan and Fan Drive Removal

compressed air at approximately 40 psig. Apply a lightcoat of engine oil to metallic parts to prevent corrosion,and protect oiled parts from dust.

(2) Clean bearings and fan drive by washing withvolatile mineral spirits. Repack bearings immediatelyafter cleaning, and protect from dust by wrapping inpaper.

e. Inspection and Repair.

(1) Inspect the pulley for cracks or other visualdamage. Replace a defective pulley.

(2) Inspect the fan for loose blades, elongatedholes, cracks or other damage. Replace a defective fan.

(3) Inspect bearings for excessive wear. Replacebearings that are worn or rough after cleaning andrepacking.

(4) Inspect the fan drive for excessive wear andleakage of drive fluid. Replace a defective fan drive.

(5) Discard oil seal and fan hub cap.

5-2

TM 9-2320-277-14&P

1. Hex nut 10. Pulley 18. Cap 26. Spacer2. Lock washer 11. Flat washer 19. Selflock screw 27. Shim3. Hex nut 12. Capscrew 20. Washer 28. Shim4. Lock washer 13. Lock washer 21. Shaft assembly 29. Shim5. Fan drive 14. Adjusting bracket 22. Oil seal 30. Capscrew6. Fan 15. Capscrew 23. Rear bearing 31. Lock washer7. Spacer 16. Lock washer 24. Front bearing 32. Capscrew8. Stud 17. Flat washer 25. Grease retainer 33. Fan support9. Capscrew

Figure 5-5. Fan and Fan Drive Disassembly

f. Reassembly.

Reassemble the fan and fan drive with a new oil sealand fan hub cap in reverse of numerical sequence asillustrated in figure 5-5.

g. Installation.

Install the fan and fan drive assembly in reverse ofinstructions on figure 5-4.

5-3. COOLANT HOSES AND FITTINGS.

a. Removal.

(1) Remove the radiator filler cap and drain thecooling system by opening the cylinder block drain cocks(figure 5-1) and the radiator drain cock (9, figure 5-6).

(2) Disconnect coolant hoses and fittings fromradiator inlets and outlets as shown in figure 5-6.


(1) Thoroughly clean hose fittings and gasketsurfaces to remove old gasket material.

(2) Inspect fittings and surfaces for cracks or otherdamage. Inspect hoses for deterioration and cuts.Replace defective fittings and hoses.

c. Installation.

(1) Reinstall coolant hoses and fittings with newgaskets as shown in figure 5-6.

(2) Close cylinder block and radiator drain cocks,and refill cooling system with antifreeze solution (seeOperator's Manual).

5-3

TM 9-2320-277-14&P

1. Hose 9. Drain cock 16. Vent hose 23. Plug (2)2. Clamp (2) 10. Hose (2) 17. Clamp (2) 24. Flange3. Adapter tube 11. Clamp (4) 18. Fitting 25. Gasket4. Hose 12. Hose 19. Flange (2) 26. Capscrew(2)5. Clamp 13. Clamp (2) 20. Gasket (2) 27. Lock washer (2)6. Reducer(2) 14. Fitting 21. Capscrew (6) 28. Flange7. Adapter 15. Elbow 22. Lock washer (6) 29. Gasket8. Plug (2)

Figure 5-6. Radiator Hoses and Fittings

5-4. RADIATOR AND FAN SHROUD.a. Description.The radiator assembly includes a top tank, bottom tankand center core, which dissipates heat from the enginecoolant. The bottom tank has an integral coil which isused to cool the transmission fluid. To increase cooling

efficiency of the radiator, a fan shroud is positionedaround the fan.

b. Removal.(1) Remove radiator filler cap and drain the cooling

system by opening the cylinder block drain cocks (figure5-1) and the radiator drain cock (9, figure 5-6).

5-4

TM 9-2320-277-14&P

1. Locknut(2)2. Fat washer (413. Capscrew (2)4. Locknut (2)5. Capscrew (2)6. Special washer (4)7. Rubber isolator (2)8. Flat washer (2)9. Strut rod (2)

10. Capscrew (6)11. Lock washer (6)12. Locknut (4)13. Flat washer (2)14. Rubber biscuit (4)15. Upper bracket (2)16. Capscrew (2)17. Strap assembly (2)18. Locknut (2)19. Special washer (2)20. Radiator21. Flat washer (2)22. Rubber isolator (2)23. Capscrew (10)24. Lock washer (10)25. Flat washer (10)26. Fan shroud

Figure 5-7. Radiator and Fan Shroud Removal5-5

TM 9-2320-277-14&P

(2) Disconnect coolant hoses and fittings(paragraph 5-3a)

(3) Remove the radiator and fan shroud innumerical sequence as Illustrated in figure 5-7.

c. Cleaning.

WARNINGUse cleaning solvent or alkalinesolution only in a well ventilated area.Avoid inhaling of fumes or contactwith skin. Do not use near openflame. The radiator may be cleanedusing the alkaline immersion processwith cleaning compound P-C-436.After use of this process, thoroughlyrinse until free of alkaline solution.The radiator exterior and cooling finsmay also be cleaned with cleaningsolvent. After cleaning with solvent,dry with compressed air atapproximately 40 psig in the oppositedirection of the normal air flow.

d. Inspection.

(1) Inspect radiator cooling fins for bends.

(2) Inspect the radiator core and inside of radiatorfor scale deposits.

(3) Inspect fan shroud for cracks and corrosion.

e. Leak rest.

If a leak in the radiator cannot be located, proceed asfollows:

(1) Insert an air hose into one outlet pipe and plugopening.

(2) Plug the remaining outlet, inlet, filler andoverflow pipes.

CAUTIONDo not exceed 10 psig air pressure inthe following step, as It may damagethe radiator core.

(3) Submerge the radiator assembly in a vat ofwater and apply air pressure at approximately 3 to 5psig. Observe for air bubbles which indicate the radiatoris leaking. If leaks are indicated, mark the location tofacilitate repair.

f. Disassembly.

If necessary for repair, disassemble the radiator innumerical sequence as illustrated in figure 5-8.

g. Repair.

(1) Straighten bent cooling fins using care not todamage the radiator core.

(2) Repair small leaks by soldering the area whereleaking. Use minimum amount of solder to preventclogging of core tubes.

NOTEBecause of high pressure the bottomtank coil may be subjected to,soldering is not allowed for coilrepairs. All repairs must be silversoldered or brazed, or the bottomtank should be replaced.

(3) Repair extensive leaks by replacing defectivecore or tank.

(4) As soon as possible after cleaning, paint theradiator exterior and fan shroud with dull black radiatorpaint.

h. Reassembly.

Assemble the radiator, using new gaskets, in reverse ofnumerical sequence listed on figure 5-8.

i. Installation.

(1) Install the radiator and fan shroud in reverse ofnumerical sequence listed on figure 5-7.

(2) Connect coolant hoses and fittings, and refillcooling system (paragraph 5-3c).

5-5. OVERFLOW RECOVERY SYSTEM.

a. Description.

The overflow recovery system works as a continuation ofthe radiator pressure cap operation. Excessive pressurebuildup and coolant boll-over escapes past the pressurevalve in the radiator cap, out the overflow hose (2, figure5-9), to the overflow bottle (5) where it is collected forlater use. After engine shutdown, the low pressure thatoccurs in the cooling system allows atmosphericpressure (min the vented overflow bottle) to push coolantthrough the overflow tube hose and back into theradiator. A special radiator cap gasket (4) completelyseals the filler neck to form a closed system.

b. Removal.

Remove the radiator overflow components in numericalsequence as illustrated in figure 5-9.

5-6

TM 9-2320-277-14&P

1. Capscrew (27)2. Hex nut (38)3. Lock washer (46)4. Capscrew (2)5. Capscrew (3)6. Capscrew (11)7. Capscrew (3)8. Top tank9. Header (2)

10. Decal11. Bar (2)12. Hex nut (34)13. Lock washer (42)14. Capscrew (30)15. Capscrew (12)16. Bottom tank17. Core washer (4)18. Header(2)19. Left sidemember20. Right sidemember21. Core22. Sight glass (2)

Figure 5-8. Radiator Disassembly

5-7

TM 9-2320-277-14&P

1. Overflow bottle cap2. Overflow hose3. Vent hose4. Radiator cap gasket5. Overflow bottle6. Tapping screw (2)7. Bracket

Figure 5-9. Radiator Overflow Kit Removal


(1) Thoroughly clean hoses, overflow bottle andradiator cap.

(2) Inspect hoses and overflow bottle for cracks orother damage.

(3) Inspect radiator cap, rubber valve seat andspring for cracks or other defects. Check the valve forfreedom of movement.

NOTEIf a cooling system pressure tester isavailable, check for proper radiatorcap operation using the tester andappropriate adapter.

(4) Replace components found defective duringinspection.

d. Installation.

(1) Install the radiator overflow components inreverse of numerical sequence listed on figure 5-9.

(2) Refill the overflow bottle and radiator withcoolant.

(3) Purge air from the cooling system by alternatelyrunning the engine to operating temperature andreplenishing coolant level at the overflow bottle.

5-8

TM 9-2320-277-14&P

Section II. THERMOSTATS, WATERPUMP, OIL COOLER AND FILTER

5-6. THERMOSTATS AND COOLANT PIPING.

a. Description.

The thermostats aid quick engine warmup by retainingcoolant flow within the engine until increasedtemperature relaxes the thermostat spring and allowscoolant to flow through the radiator. The thermostatsopen at approximately 170°F, which is adequate for bothsummer and winter operation.



(2) Disconnect two radiator hoses (10, figure 5-6) atthe thermostat housing elbows (13 and 14, figure 5-10).

(3) Remove two hose clamps (1) and hose (2).

(4) Remove hose connector (4) from the waterpump.

(5) Remove two capscrews (5), lock washers (6),tube flange (7), preformed packing (8) and bypass tube(9) from the water pump side of the thermostat housing(27).

(6) Remove four capscrews (5), lock washers (6),two tube flanges (7), preformed packings (8) andcrossover tube (10) that connects between the twothermostat housings (24 and 27).

(7) Remove two capscrews (11), lock washers (12),left hand outlet elbow (13) and gasket (15) from thethermostat housing (27). Remove right hand outletelbow (24) in the same manner.

(8) Disconnect electrical lead and remove watertemperature sender (44) and two pipe plugs (16) locatedin thermostat housings (24 and 27).

(9) Disconnect electrical leads and remove watertemperature alarm sender (43), fitting (3) and pipe plug(17) located in the two housing bases (33).

(10) Remove two capscrews (18), lock washers (19),housing cover (20) and gasket (21) from the right handthermostat housing (24).

(11) Remove two capscrews (22), lock washers (23)and remove gasket (45) and thermostat housing (24)from housing base (33). Remove left hand thermostathousing (27) in the same manner.

(12) Remove thermostat seal (28), thermostat (29)and gasket (30) from the housing and housing base (33).Both thermostats are removed in the same manner.

(13) Remove capscrews (31), lock washers (32),housing base (33) and gasket (34) from the engine.Both housing bases are removed in the same manner.

(14) Remove hose clamps (35) and hose (36) fromthe oil cooler and elbow (41).

(15) Remove pipe plug (37), two capscrews (39),lock washers (40), elbow (41) and gasket (38) from theengine.

c. Cleaning.

(1) Clean the elbows and housing by washing incleaning solvent. Dry clean parts with compressed air atapproximately 40 psig.

(2) Scrape or otherwise remove all residue of oldgaskets and sealer in the housings and housing bases.


(1) Inspect the thermostats for an accumulation ofrust and corrosion. Replace defective thermostats.

(2) Inspect hoses for cracks or other evidence ofdeterioration. Replace hoses that are cracked orleaking.

(3) Inspect the castings for cracks or damagedmating surfaces. Replace damaged or defectivecastings.

e. Thermostat Test.

(1) Suspend thermostat and a thermometer in acontainer of hot water as shown in figure 5-11. Do notallow the thermostat or thermometer to touch the sidesor bottom of the container.

(2) Slowly heat the water while agitating to maintainan even temperature throughout the container.

(3) If thermostat starts to open before 170°F or doesnot open until 180°F, it is defective and must bereplaced. Thermostat should be fully open atapproximately 190 to 192°F.

f. Reassembly and Installation.

(1) Refer to figure 5-10. Using new gaskets andpreformed packings, reassemble and install the coolantpiping and thermostats in reverse of removal anddisassembly instructions (paragraph 5-6b).

5-9

TM 9-2320-277-14&P

1. Clamp (2) 13. Left elbow 24. Thermostat housing 35. Clamp (2)2. Hose 14. Right elbow 25. Capscrew (2) 36. Hose3. Fitting(2) 15. Gasket (2) 26. Lock washer 37. Pipe plug4. Connector 16. Pipe plug (2) 27. Thermostat housing 38. Gasket5. Capscrew (6) 17. Pipe plug 28. Seal (2) 39. Capscrew (2)6. Lock washer (6) 18. Capscrew (2) 29. Thermostat (2) 40. Lock washer (2)7. Flange (3) 19. Lock washer (2) 30. Gasket (2) 41. Elbow8. Preformed packing (3) 20. Plate 31. Capscrew (4) 42. Reducer bushing9. Bypass tube 21. Gasket 32. Lock washer (4) 43. Water temp. alarm sender

10. Crossover tube 22. Capscrew (2) 33. Housing base (2) 44. Water temp. sender11. Capscrew (4) 23. Lock washer (2) 34. Gasket (2) 45. Gasket12. Lock washer (4)

Figure 5-10. Thermostats and Coolant Piping, Removal and Disassembly

5-10

TM 9-2320-277-14&P

Figure 5-11. Thermostat Test

WARNINGSeat thermostat and seal (28, figure5-10) in housing so that thethermostat spring (or bellows) istoward the engine with unit bolted tohousing.

(2) Tighten capscrews (11, 22, 25 and 31) to 33 ft.Ibs. of torque.


5-7. WATER PUMP.

a. Description.

The centrifugal water pump is driven by a matched set ofV-drive belts from one of the engine camshafts. As thecamshaft turns, the pump vanes receive coolant from thepump inlet and force coolant to circulate into the blockand throughout the cooling system.

b. Removal.


(2) Remove the water pump as instructed onfigure 5-12.

Figure 5-12. Water Pump Removal

5-11

TM 9-2320-277-14&P

1. Pulley2. Screw with washer (7)3. Pump Cover4. Gasket5. Pump body6. Plug7. Impeller8. Seal9. Shaft and bearing

Figure 5-13. Water Pump Disassembly

c. Disassembly.

(1) Note the position of the pulley on the shaft sothe pulley can be reinstalled in the same position.

(2) Using a suitable puller remove pulley(1, figure 5-13) from the shaft and bearing.

(3) Disassemble the water pump in numericalsequence illustrated in figure 5-13.

(4) Press shaft and bearing (9) from impeller (7).

d. Cleaning.

(1) Clean the permanently sealed bearing and shaftwith a clean, dry cloth.

(2) Clean the remainder of the parts by washing incleaning solvent. Dry clean parts with compressed air atapproximately 40 psig. Be sure the water pump body isfree of old gasket material.


(1) Inspect the impeller for damage and excessivewear on the impeller face which contacts the seal.Replace the impeller if it is worn or damaged.

(2) Inspect the bearing and shaft assembly forroughness or excessive tightness. Replace bearing andshaft assembly if one of these conditions are found or ifthe bearing and shaft assembly is worn.

(3) Replace the seal and gasket with new parts.

(4) Inspect the pump body for cracks, breaks orother damage. Replace the pump assembly if any ofthese defects are found.

(5) Inspect the V-belts for cuts and deterioration. Ifa belt is defective replace both belts with a matched set.

f. Reassembly.

(1) Use suitable installer tool to apply pressure tothe outer race of the bearing and install the shaft andbearing (9) in the pump body (5). The bearing and shaftmust be installed through the pulley end of the body.Proper position of the assembly is when the bearing isflush with the outer face of the body.

(2) Lightly coat the outside diameter of the new seal(8) with sealing compound. With the face of the bodyand the bearing outer race supported, install the seal byapplying pressure on the seal outer flange only, until theflange contacts the body. Wipe the face of the seal witha chamois to remove all dirt and metal particles.

(3) Support the pulley end of the shaft on the bed ofan arbor press and press the impeller (7) on the shaftuntil the impeller is flush with the large end of the body(5).

(4) Place the pulley (1) on the bed of an arborpress. Place a suitable rod between the ram of thepress and the impeller end of the shaft, then press theshaft into the c.

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TM 9-2320-277-14&P

pulley until the pulley is in its original position which wasnoted during removal.

(5) Install the cover (3) with a new gasket (4) andsecure with seven capscrews (2). Tighten capscrews to7 lbs. ft. of torque.

(6) Install pipe plug (6) in pump body (5).

(7) Run pump dry at 1200 rpm for 30 seconds or asrequired to assure satisfactory seating of the seal.

g. Installation.

(1) Install the water pump with a new gasket inreverse of instructions on figure 5-12.

(2) Close radiator and cylinder block drain cocks,and refill cooling system with antifreeze solution (seeOperator's Manual).

(3) Adjust idler (figure 5-12) until the V-drive beltshave one-half inch deflection between the water pumppulley and camshaft pulley; then secure idler with twobolts.

5-8. OIL COOLER.

a. Description.

The engine oil cooler is mounted on the lower left side ofthe cylinder block. Engine oil flows from the oil filterthrough the oil cooler; then back into the front enginecover and cylinder block oil galleries for distribution tothe various engine bearings. Oil temperature is reducedby circulating coolant through the oil cooler and aroundthe oil cooler core.



(2) Drain the engine crankcase by removing the oilpan drain plug.

(3) Remove the water pump as instructed onfigure 5-12.

1. Pipe plug2. Capscrew (8)3. Lock washer (8)4. Gasket5. Cooler core6. Gasket7. Cooler housing8. Drain cock9. Hose fitting

Figure 5-14. Oil Cooler Removal and Disassembly

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(4) Loosen clamps and disconnect hoses from oilcooler inlet (1, figure 5-6), oil cooler outlet, and hosefitting (9, figure 5-14).

(5) Remove eight capscrews (2, figure 5-14) andlock washers (3) and remove the oil cooler.

(6) Disassemble the oil cooler in numerical.sequence as illustrated in figure 5-14.

c. Cleaning.

(1) Clean all parts by washing in cleaning solvent.Dry clean parts with compressed air at approximately 40psig.

WARNINGPerform the following cleaningoperations in a well ventilated area.Avoid breathing the fumes or directcontact of the chemicals with the skin.

NOTEDo not attempt to clean the oil coolercore when an engine failure hasoccurred in which metal particles fromworn or broken parts are released intothe lubricating oil. Replace the corewhen this condition exists.

(2) Clean the oil passages in the oil cooler core bycirculating a trichloroethane solution through thepassages with a force pump until all carbon and sludgedeposits are removed.

(3) Flush the core assembly with an alkalinesolution and then with clean hot water.

CAUTIONAvoid breathing fumes or contact ofthe oxalic and muriatic acid solutionwith the skin.

(4) Clean the water side of the core by immersing ina solution consisting of one half pound of oxalic acid toeach two and one half gallons of solution composed ofone third muriatic acid and two thirds water. Thecleaning is evidenced by bubbling and foaming.Observe the process carefully and when bubbling stops(after 30 to 60 seconds) remove the core assembly fromthe solution and flush thoroughly with clean hot water.After cleaning, dip the core in light oil.

d. Test and Repair.

(1) Test the core for leaks by making a suitablemetal plate and rubber gasket and attaching to the

Figure 5-15. Oil Cooler Core Leak Test

flanged side of the oil cooler (figure 5-15). Connect toan air source (approximately 75 psig) and immerse thecore in a vat of water. The presence of bubblesindicates a leaky core which must be replaced.

NOTEIf a leaking core is found, flush theengine lubricating system to removeall contaminated oil.

(2) Remove the plate and gasket from the core anddry core thoroughly.

e. Reassembly and Installation.

(1) Assemble the oil cooler, using new gaskets, inreverse of numerical sequence listed on figure 5-14.

(2) Secure the oil cooler to the cylinder block witheight capscrews (2, figure 5-14) and lock washers (3).

(3) Reconnect hoses to oil cooler inlet (1, figure 5-6),oil cooler outlet, and hose fitting (9, figure 5-14).

(4) Install the water pump with a new gasket inreverse of instructions on figure 5-12.

(5) Adjust idler (figure 5-12) until the V-drive beltshave one-half inch deflection between the water pumppulley and camshaft pulley; then secure idler with twobolts.

(6) Install the oil pan drain plug, and refill the enginecrankcase with lubricating oil (see Operator's Manual).

(7) Close radiator and cylinder block drain cocks,and refill cooling system with antifreeze solution (seeOperator's Manual).

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5-9. COOLANT FILTER.

a. Description.

The engine coolant filter is mounted on the outsideframe rail at the right front side of the tractor. Theborate-type filter element contains a combination ofchemical compounds which provide corrosion protection,pH control and water softening ability. The pH control isused to maintain an acid-free solution, while the watersoftening ability deters formation of mineral deposits.The throwaway type filter element should be changed atthe interval specified in the Operator's Manual.

b. Removal.

(1) Remove the radiator filler cap and drain thecooling system by opening the cylinder block drain cocks(figure 5-1) and the radiator drain cock (9, figure 5-6)

(2) Unscrew and discard the filter element(2, figure 5-16).

(3) Loosen and remove hose clamps (4), anddisconnect hoses (5 and 6).

(4) Remove hardware attaching filter housing toframe rail and remove filter housing.

(5) Remove fittings (3; 9, 10, 11, and 12) andclamps (8) only if necessary for repair.

c. Cleaning.

Clean all parts except hoses by washing in cleaningsolvent. Dry clean parts with compressed air atapproximately 40 psig. Clean hoses by wiping with acloth and mild detergent solution.


(1) Inspect hoses for cracks or other evidence ofdeterioration. Replace defective hoses.

1. Filter kit 5. Hose 9. Tee2. Filter element 6. Hose 10. Connector3. Connector(2) 7. Hex nut 11. Tee4. Clamp(6) 8. Clamp (2) 12. Nipple

Figure 5-16. Coolant Filter Removal

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(2) Inspect all hardware and threaded openings fordamaged threads. Chase damaged threads with thecorrect size tap or die, and replace damaged hardware.

(3) Inspect the filter housing for cracks, corrosion, ordamage to the sealing surface. Replace a defective filterhousing.

e. Installation.

(1) Install fittings (3, 9, 10, 11 and 12, figure 5-16)and clamps (8) if previously removed.

(2) Attach filter housing to frame rail and connecthoses (5 and 6) and hose clamps (4).

(3) Hand tighten new filter element (2) on filterhousing until filter contacts mating surface on housing;then tighten one-half additional turn.

(4) Close radiator and cylinder block drain cocks,and refill cooling system with antifreeze solutionspecified in Operator's Manual.

(5) Start engine and check filter and connections forleaks.

(6) Stop engine and refill recovery reservoir asnecessary to maintain proper level.

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TM 9-2320-277-14&P

CHAPTER 6

ELECTRICAL GROUP

Section I. ALTERNATOR

6-1. DESCRIPTION.

The 80 ampere alternator contains an integral electroniccharging system; only one wire connects the alternatorto the battery circuit, along with an adequate groundreturn. The voltage setting of the internal voltageregulator can be adjusted by repositioning an adjustmentcap located on the end frame.

6-2. ON-VEHICLE TESTS.

Conduct the following on-equipment tests to aid indetermining whether the alternator is defective'

a. Undercharging.

(1) Check alternator drive belts for correct tensionand adjust if necessary. Check all electrical connectionsbetween batteries and alternator, including battery posts.

(2) Test the batteries as outlined in paragraph 6-27band insure that they are fully charged.

(3) Connect a voltmeter from the alternator "BAT"terminal to ground. A zero reading indicates an opencircuit between the voltmeter connection and thebatteries. Trace wiring to locate open circuit and repair.

(4) Disconnect battery group ground cable.Connect an ammeter in series with the wire connected tothe alternator "BAT" terminal and reconnect batterygroup ground cable.

(5) Turn on accessories and connect a carbon pileacross the batteries.

(6) Operate engine at moderate speed to givealternator speed of 4000 rpm or more, and adjust carbonpile to obtain maximum current output.

(7) If ammeter reading is within 10 amperes of ratedoutput stamped on alternator frame, the integralcharging unit is not defective. Adjustment of voltagesetting may correct undercharging condition.

(8) Raise the voltage setting by removing thevoltage adjusting cap, rotating in increments of 90°, andreinserting cap into connector body as shown in (figure6-1). With position 2 aligned with the arrow, the setting ismedium low. Position LO is the lowest charging voltageand position HI is the highest regulator setting.

Figure 6-1. Voltage Adjustment Cap.

(9) After adjusting the charging voltage setting,check for improved battery charging after a reasonableservice period, such as one week.

CAUTIONField winding tab is within one inchof end frame. Do not forcescrewdriver deeper than one inchinto end frame.

(10) If ampere output in step 7 is not within 10amperes of rated output, insert thin-bladed screwdriverinto end frame hole below and to the right of the voltageadjustment cap. Insert screwdriver about 3/4 inch toground field winding.

(11) Operate engine as in step 6 above, and adjustcarbon pile to obtain maximum current output whilegrounding tab to end frame with screwdriver.

(12) If output is within 10 amperes of rated output,proceed with removal and disassembly steps, andreplace integral charging system regulator.

(13) If output is not within 10 amperes of ratedoutput, proceed with removal and disassembly steps,and carefully check all components as outlined.

(14) Turn off engine and accessories, and removeammeter and carbon pile.

b. Overcharging.


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(2) Connect a voltmeter from the alternator "BAT"terminal to ground. Start the engine and, with allaccessories off, increase engine speed to obtainmaximum voltage reading.

(3) If voltmeter reading exceeds 15 volts, proceedwith removal and disassembly steps and replace integralcharging system regulator.

(4) If voltmeter reading does not exceed 15 volts,adjust charging voltage to a lower value by removingvoltage adjustment cap, rotating to a lower setting, andreinserting (see figure 6-1). After adjusting the chargingvoltage setting, check for improvement of overchargingcondition after a reasonable service period, such as oneweek.


a. Removal.

(1) Disconnect alternator knife disconnect (refer toelectrical wiring diagram, figure 6-2) or battery groupground cable, and remove alternator "BAT" terminalwire.

(2) Loosen hex nut (4, figure 6-3) and bolt (7).Loosen bolt (1) on adjusting strap (11), and swingalternator towards engine to slacken belts. Removedrive belts from alternator pulley (8).

(3) Remove bolt (1), lock washer (2), and flat washer(3) securing alternator (9) to adjusting strap (11).

(4) Remove hex nut (4), lock washer (5), and flatwasher (6). Pull out bolt (7) and flat washer (6), andremove alternator from vehicle.

(5) Remove brackets (11, 17 and 19) from engineas shown on figure 6-3.

b. Disassembly.

(1) Remove four thru bolts (4, figure 6-4).

(2) Separate slip ring end frame (26) and statorassembly (6) from drive end frame (5) and rotorassembly (20).

(3) Remove hex nut (1) and felt washer (2).Remove pulley, fan (3), and outside collar (19) fromalternator shaft.

(4) Remove rotor (20) from drive end frame (5).

(5) Remove three machine screws (15), bearingretainer plate (16), and inside collar (17). Press bearing(18) from end frame.

(6) Remove three hex nuts (7) that attach the statorleads to the rectifier bridge (11), and separate stator (6) from the slip ring end frame (26).

(7) Examine grease supply in slip ring end framebearing (27). If contaminated with dirt or nearlyexhausted, remove seal (28) and bearing (27) bypressing out with a tube or drift that just fits inside theend frame bearing housing. Press bearing from outsidetowards inside of housing.

(8) Disassemble remaining components asnecessary for replacement (figure 6-4).


a. Cleaning and Inspection.

(1) Clean all metal parts by washing with cleaningsolvent and blow dry with clean, compressed air. Cleanstator windings with a dry bristle brush and compressedair. If stator windings are saturated with oil or grease,wipe lightly with a clean cloth saturated with cleaningsolvent and blow dry with compressed air. Do not allowcleaning solvent to contact brushes or slip ring endframe bearing (if still installed).

(2) Inspect stator windings and leads for cracks,breaks, or chipped insulation.

(3) Clean drive end bearing (18) by washing withcleaning solvent and Inspect for wear or roughness.Replace if defective.

(4) Examine brushes for excessive wear, chipping,or cracks; and brush springs (23) for misshapen coils ordiscoloration. Replace if defective.

(5) Inspect the two insulated screws (21) thatsecure the brush assembly (22) and regulator (25) to theend frame. Replace cracked, damaged, or missinginsulators.

(6) Inspect rotor for mechanical damage andbearing surfaces for wear. Check slip ring assembly fordamage or looseness. Replace a defective rotor or slipring assembly.

b. Repair and Electrical Tests.

(1) Refinish rotor slip rings (if not grooved) byspinning rotor in a lathe and polishing slip ring surfaceswith number 400 silicone carbide paper. Finish polishwith crocus cloth. If slip rings are grooved, or rough andpitted, machine in lathe to make rings smooth and round.Finish polish with crocus cloth and use clean,compressed air to blow away dust.

(2) Refer to figure 6-5 to test rotor for a grounded,shorted, or open winding. Check the rotor for agrounded winding by connecting the ohmmeter leads tothe slip rings and rotor shaft and note the reading. If theohmmeter reading is low, the winding is grounded.

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TM 9-2320-277-14&P

Figure 6-2. Electrical Wiring Diagram6-3

TM 9-2320-277-14&P

1. Bolt2. Lock washer3. Flat washer4. Hex nut5. Lock washer6. Flat washer (2)7. Bolt8. Pulley9. Alternator

10. Hex nut11. Adjusting strap12. Flat washer13. Lock washer14. Bolt15. Bolt (2)16. Lock washer (2)17. Adjusting strap bracket18. Bolt (3)19. Copper washer (3)20. Mounting bracket

Figure 6-3. Alternator and Brackets Removal

1. Hex nut2. Felt washer3. Fan4. Bolt (4)5. Drive end frame6. Stator7. Hex nut (3)8. Diode trio9. Screw (2)

10. Lock washer (2)11. Rectifier bridge12. Screw (2)13. Capacitor bracket14. Capacitor15. Screw (3)16. Bearing retainer17. Inside collar18. Ball bearing19. Outside collar20. Rotor21. Insulated screw (2)22. Brush assembly23. Spring brush (2)24. Grounding screw 28. Seal 32. Rubber boot25. Regulator 29. Battery terminal package 33. Screw26. Slip-ring end frame 30. Relay terminal package 34. Lock washer27. Bearing 31. Voltage adjustment cap 35. Bracket

Figure 6-4. Alternator Disassembly6-4

TM 9-2320-277-14&P

(CHECK FOR SHORTS AND OPENS)Figure 6-5. Checking Rotor Windings for Shorts and Opens

3) Check the rotor for a shorted winding byconnecting the ohmmeter leads to the slip rings and notethe reading. If the ohmmeter reading is below 0.2 ohms,the winding is shorted.

(4) Check the rotor for an open winding byconnecting ohmmeter leads to the slip rings and note thereading. A high (infinite) ohmmeter reading indicates anopen winding Replace rotor if ohmmeter readingsindicate grounded or open winding; replace rotor andregulator if ohmmeter reading indicates a shortedwinding.

(5) Refer to figure 6-6 to test stator field windings forgrounds. Check the field windings for grounds byconnecting ohmmeter leads to the laminated statorframe and winding leads, and note the readings. A lowohmmeter reading indicates that the windings aregrounded. Replace a stator that checks grounded. Thestator winding cannot be tested for opens or for shortcircuits without special test equipment. If all otherelectrical tests are normal and the alternator fails tosupply rated current, but will supply at least 10 amperesoutput, a shorted stator winding is indicated.

(6) Refer to figure 6-4 and remove the diode trio (8)for testing. Remove the attaching screw from the singleconnector tab (figure 6-7), slip the diode trio off of thethreaded posts of the rectifier bridge, and remove thediode trio from the end frame. Set ohmmeter to lowestrange, and connect ohmmeter leads to the singleconnector and to one tab of the three connector group.Note the reading, then reverse ohmmeter leads. A goodunit will display one high reading and one low reading.Repeat the same test between the single connector andthe other two connector tabs If both readings are thesame across the single connector tab and any tab of thethree connector group, the diode trio is defective andmust be replaced.

(CHECK FOR GROUNDS)Figure 6-6. Checking Stator for Grounded Field Windings

Figure 6-7. Diode Trio Test(7) Refer to figure 6-8 to test the rectifier bridge

assembly in the slip-ring end frame. Set ohmmeter tolowest range, and connect ohmmeter leads to thegrounded heat sink and to each of the flat metal clips atthe base of the three threaded posts. Press ohmmeterleads firmly and note the reading; then reverseohmmeter leads. A good unit will display one highreading and one low reading. Repeat the same testbetween the grounded heat sink and the other two flatmetal clips. Repeat the same test again between theinsulated heat sink and the three flat metal clips. Thismakes a total of six tests, with two readings taken foreach test. If both readings are the same at any of the sixtests, the rectifier bridge is defective and must bereplaced.

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Figure 6-8. Rectifier Bridge Test

(8) Refer to figure 6-4 and remove the regulatorconnector body for testing. Remove screw (33) and lockwasher (34), and pull-regulator connector body fromspade terminals on regulator (25).

(9) Refer to figure 6-9 to test regulator connectorbody. Set ohmmeter to middle range resistance scale,and connect ohmmeter leads to each adjacent pair ofterminals, making a total of four tests. If any one testindicates an open circuit (infinite reading), the connectorbody is defective and must be replaced. The regulator(25, figure 6-4) is sealed and cannot be tested. If anovercharging condition was present, or the rotor testedshorted, replace the regulator unit. If regulator isremoved, inspect and note the position of insulatedscrews (21) and grounding screw (24). Replace anyhardware with cracked or missing insulating spacers orwashers.

(10) Check brush assembly (22) for free movementof brushes, inspect brushes for wear or damage, andinspect brush springs for discoloration or lack of tension.Replace defective parts.


(1) If slip-ring end frame bearing (27, figure 6-4)was removed, install new bearing and seal as follows:

(a) Fill the plug with lubricant (Delco-Remypart no. 1948791) so that when pressed in flush with theend frame the grease reservoir will be half filled. Insurethat some of the lubricant will be contacting the bearingwhen the plug is assembled.

Figure 6-9. Regulator Connector Body Test

(b) Position a new seal on bearing opening onthe outside of the end frame with the seal lip facinginward, or toward the rotor. Press seal in to thedimension shown in figure 6-10. Coat the seal lip withthe lubricant to facilitate assembly of the rotor shaft intothe bearing.

(c) Position new bearing (27, figure 6-4) onoutside of end frame, and press bearing into housing witha tube or collar to the dimension shown in figure 6-10.

Figure 6-10. Slip Ring End Bearing and Seal Locations

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TM 9-2320-277-14&P

(2) Reassemble alternator in reverse of procedureoutlined in paragraph 6-3b. Repack drive end bearingwith lubricant (Delco-Remy part no. 1958791) or replacewith a new bearing. Fill grease cavity in drive end frameone-half full with same lubricant.

(3) Install bearing by pressing in with a tube orcollar that just fits over the outer race, with the bearingand slinger assembled into the end frame as shown infigure 6-11.

NOTEInstall a new retainer plate if the feltseal in the retainer plate is hardenedor excessively worn.

Figure 6-11. Drive End Bearing Assembly

(4) Before installing the slip-ring end frameassembly to the rotor and drive end frame, insert a pin orstiff wire through the holes in the brush assembly tokeep the brushes retracted. After assembly, remove thebrush retaining pin or wire through the slot in the endframe to allow the brushes to contact the slip rings.

(5) Install outside collar (19, figure 6-4), slinger, fan(3), pulley, felt washer (2) and hex nut (1). Tighten nutwith 70 to 80 ft. lbs. torque.

b. Installation.

(1) Install alternator on engine in reverse order ofprocedure outlined in paragraph 6-3a.

(2) Inspect drive belts for wear, cracks, or frayedcords. If worn, replace both drive belts as a matchedset.

(3) Adjust the belt set by loosening the adjustingstrap screw (1, figure 6-3) and lifting the alternator upuntil there is approximately 1/4 to 1/2 Inch deflection ofthe belt set midway between the camshaft and alternatorpulleys. Tighten the adjusting strap screw.

NOTEThe rotor normally retains magnetismto provide voltage build-up (self-excitation) when the engine isstarted. After repair, however, it maybe necessary to reestablishmagnetism in the rotor as describedin the following step.

(4) Momentarily connect a jumper lead from thebattery positive post to the alternator relay ("R") terminal(30, figure 6-4).

(5) Recheck alternator voltage, and adjust, ifnecessary, using voltage adjustment cap (figure 6-1).

Section II. STARTER, SOLENOID AND70 AMP CIRCUIT BREAKER

6-6. SOLENOID AND 70 AMP CIRCUIT BREAKER.a. Description.

The starter 70 amp circuit breaker and solenoid circuitallows the low current dashboard key switch to controlthe large current demand of the starter solenoid shift andstarter motor.

b.On-vehicle Testing.

(1) Refer to figure 6-12. Turning dashboard keyswitch to START position should energize solenoid (8),allowing current to pass through circuit breaker (10),solenoid, and to starter mounted solenoid shift switchassembly through the black wire (5). If starter mountedsolenoid shift switch assembly does not pull in, check forvoltage at solenoid control terminal (12 gage white wireto starter switch). If no voltage is present, trace wiringback to dashboard key switch.

(2) If voltage is present at solenoid switch controlterminal, check for voltage at 8 gage red wire connectionto breaker (13).

(3) If voltage is present at breaker (13), disconnectjumper wire (7) from breaker and connect a 12-volt testlamp from the jumper wire connection at the circuitbreaker to ground.

(4) Turn key switch to START position and observetest lamp. If lamp lights and stays on, circuit breakeroperation is normal.

(5) If lamp does not light, check wiring for opencircuit or poor contact at connections. If wiring andconnections are satisfactory, circuit breaker is defective.

(6) If lamp does not light immediately, but thenstarts to flicker, and a clicking noise can be heard, thecircuit breaker is defective.

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TM 9-2320-277-14&P

1. Hex nut (2)2. Lock washer (2)3. Hex nut (2)4. Lock washer (2)5. Black wire (8 gage)6. Red wire (8 gage)

7. Jumper wire8. Solenoid9. Brass screw (2)

10. Circuit breaker11. Machine screw (2'12. Bracket

Figure 6-12. Solenoid and 70 Amp Circuit Breaker

(7) If circuit breaker operation is normal, andsolenoid (8) does not energize, solenoid is defective.

c. Removal and Repair.

(1) Tag or otherwise label wire connectionsand disconnect wiring from terminals of defectivecomponents.

(2) Remove and replace defective parts.

d. Installation.

(1) Install new parts and reconnect wiring to correctterminals.

(2) Check for correct operation of starter mountedsolenoid shift and switch assembly after replacingbreaker or solenoid switch.

6-7. STARTER MOTOR.

a. Description.

The starting motor is a heavy duty, 12 volt, solenoidoperated, enclosed shift-type-lever engine starter witheight brushes retained in four brush holders. The driveclutch is a heavy duty overrunning type and the pinionclearance is adjustable. Repair is limited to replacementof brushes, solenoid assembly, drive clutch, seals, andsmall internal Darts.

b. On-Vehicle Testing.


(2) Connect the leads of a 15 Vdc voltmeterbetween the switch (S) terminal of the solenoid andground. Observe voltmeter reading while momentarilyturning key switch to START position.

(3) If the voltage is less than 7.7 volts, check forexcessive resistance in the solenoid control circuit.Inspect ring-tongue wire terminals (figure 6-12) for dirt orcorrosion and polish to brightness with fine sandpaper.Clean stud terminals and nuts to brightness with a wirebrush. Tighten all connections securely.

(4) If the voltage exceeds 7.7 volts, but the solenoiddoes not pull in, the solenoid or starter motor isdefective. Proceed with removal and disassembly.

(5) If the solenoid "chatters" but does not hold in,the solenoid is defective.

(6) If solenoid pulls in and starter gear engagesflywheel, but engine does not crank, or cranks slowly,check first for high resistance connections m batterycircuit. If connections are secure, starter motor isdefective.

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c. Removal.

(1) Disconnect battery group ground cable.

(2) Refer to figure 6-12. Tag and disconnect wiringharness and battery leads at circuit breaker and solenoidterminals that connect to starter motor and solenoid shift

assembly. Remove engine ground wire at starter motorterminal. Remove solenoid (8) from starter.

(3) Remove starter mounting bolts (44, figure 6-13)and lock washers (45) and disengage starter assemblyfrom flywheel housing. Remove starter from vehicle,and discard gasket (46).

23. Drive clutch assembly24. Inspection plug25. Gasket26. Plunger nut27. Retaining ring28. Retainer29. Return spring30. Retainer31. Plunger boot32. Flat washer33. Plunger34. Retaining ring35. Preformed packing

11. Brush assembly (8) 36. Preformed packing12. End plate assembly 37. Lever shaft13. Preformed packing 38. Hex nut

1. Hex nut 14. Thrust washer 39. Lock washer2. Lock washer 15. Capscrew (4) 40. Terminal connector3. Wire assembly 16. Capscrew (2) 41. Screw w/washer (4)4. Screw (4) 17. Drive housing 42. Solenoid switch5. Brush cover plate (2) 18. Gasket (5) assembly6. Gasket (2) 19. Capscrew (5) 43. Frame and7. Screw (4) 20. Lock washer armature assembly8. Lock washer (4) 21. Lever housing 44. Bolt (3)9. Screw (8) 22. Preformed packing 45. Lock washer (3)

10. Lock washer (8) 46. Gasket

Figure 6-13. Starter Motor Removal and Disassembly6-9

TM 9-2320-277-14&P

d. No-load Bench Test.With the starter motor removed from the tractor, thearmature should be checked for freedom of rotation. Ifthe armature does not turn freely, the motor should bedisassembled for repair. If the armature does operatefreely, the starter motor should be given the following no-load bench test before disassembly:

(1) Provide test hook-up to starter motor as shownin figure 6-14.

(2) Adjust carbon pile to provide a voltage indicationof 9 volts.

(3) Armature speed should be 3000 to 4500 rpm.

Current draw must be 120 amperes, minimum and 150amperes maximum. Refer to Table 6-1 if armaturespeed and current draw are not within the above limits.

e. Disassembly.

(1) Mark the position of the solenoid (42,figure 6-13), lever housing (21), drive housing (17), andbrush end plate (12) with a scribe or center-punch to aidin reassembly.

(2) Disconnect field coil connector from solenoidmotor (M) terminal.

Figure 6-14. Starter Bench Test Circuit(3) Remove four screws (4), two brush cover plates

(5), and gaskets (6).

(4) Remove eight brush lead screws (9) and lockwashers (10). This disconnects the field winding leadsfrom the brush holders.

Table 6-1. Starter Bench Test Troubleshooting Chart.

ArmatureSpeed

CurrentDraw

ProbableCause

InspectionData

Zero Zero Open field circuit. Check internal connections and field coils for opencondition.

Open armature coils. Inspect commutator for badly burned bars afterdisassembly.

Poor brush contact Check for broken brush springs, worn brushes, andhigh insulation between commutator bars.

Zero High Grounded terminals or fields. Disconnect field coil ground connections and checkfor grounded condition.

Frozen bearings. Rotate armature by prying pinion with a screwdriver.Low Low High internal resistance. Check for poor connections, defective leads, and

dirty commutator.Low High Excessive friction. Check for tight, dirty, or worn bearings, bent

armature shaft or loose pole shoes allowingarmature to drag.

Shorted armature. Check armature in a growler after disassembly.Grounded field coils or armature. Disconnect field coil ground connections and check

for grounded condition.High High Shorted field coils. Replace field coils and repeat bench test.

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TM 9-2320-277-14&P

(5) Remove four hex head screws (7) and lockwashers (8) and separate end plate assembly fromframe and armature assembly (43).

(6) Remove six capscrews (15 and 16), andseparate drive housing (17) from frame and armatureassembly (43).

(7) Remove internal parts (24 thru 32) from leverhousing (21); then remove four screws (41) andseparate solenoid (42) and plunger (33) from leverhousing (21).

(8) Remove four capscrews (19) and lock washers(20) and separate lever housing (21) from frame andarmature assembly (43).

f. Cleaning, Inspection and Repair.(1) The drive clutch assembly (23) and the frame

and armature assembly (43) should not be cleaned withgrease dissolving solvents as this would damage thelubricant in the drive clutch and damage the armatureand field coil insulation. Wipe these parts, the end plateassembly (12) and the brush holders and brushes with aclean dry cloth only.

(2) Clean all other metal parts with a clothmoistened with cleaning solvent.

(3) If the armature commutator is dirty, it may becleaned with fine sandpaper. Use low pressure, cleancompressed air to blow away dust after cleaning.

(4) Inspect drive clutch (23) pinion gear for brokenor worn teeth. Check inside diameter of drive clutchbushings; inside diameter must not be more than 0.6250inch. Replace drive clutch assembly if wear or damageis visible.

(5) Check brushes for wear, cracks, or chips; andbrush springs for tension and discoloration or damage.Replace defective brush parts or damaged brushholders.

(6) Refer to figure 6-15 and check the field windingfor grounds or opens. Connect ohmmeter leads to thehousing and to field winding terminal, and note thereading. If ohmmeter reading is low, the field winding isgrounded.

(7) Connect ohmmeter leads across brushterminals, and note the reading. If ohmmeter reading ishigh (infinite), the field winding is open. Replace frameand armature assembly if field winding is open orgrounded.

(8) Refer to figure 6-16 and check the armature fora grounded winding by connecting ohmmeter leads tothe commutator bars and to the shaft, and note readingwhile slowly rotating armature. If the ohmmeter readingis low on one or more of the commutator bars, thewinding is grounded.

Figure 6-15. Checking Field Windings for Opens andGrounds

Figure 6-16. Checking for Grounded Armature Windings

(9) Check the armature for a shorted winding byvisually inspecting the insulating spacers betweencommutator bars for metal chips or other material, andtest armature on a growler, if available. Check thearmature for opens by visually inspecting the wireconnections to the commutator bars. Replace frame andarmature assembly if armature is defective.

(10) Replace all preformed packings and gasketswith new parts.g. Reassembly.

(1) Reassemble starting motor in reverse order ofprocedure outlined in paragraph 6-7e. Be sure to alignmatch marks for correct assembly, and lightly coatarmature shaft and bushings with lubricant (Delco-Remypart No. 1960954).

(2) If new brushes are to be installed, coverarmature commutator with number 00 sandpaper(abrasive side out) and hold in place with masking tape.

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assemble armature, brushes, end frame and brushholder assembly in frame, and turn m brushes. Brushesmust be seated to point where contact is made 100%from leading to trailing edge of brush and at least 85% ofthe brush length. Disassemble, remove sandpaper, anduse low pressure compressed air to blow away carbondust and sandpaper grit.

(3) Tighten capscrews (15, 16, and 19, figure 6-13)to 13 ft. lbs. of torque.

(4) To check and adjust pinion clearance, connect avoltage source of about one-half rated voltage betweenthe terminals of the solenoid shift, and momentarilyconnect a heavy jumper lead between the solenoidmotor (M) terminal and ground to prevent the starterarmature from rotating (see figure 6-17). With thesolenoid shifted into cracking position, manually pushthe pinion gear back towards the commutator end of thestarter to take up any slack movement. Check andadjust clearance as shown in figure 6-18, after removinginspection plug (24, figure 6-12) and gasket (25) fromlever housing (21).

Figure 6-17. Circuit for Checking Pinion Clearance(5) If applicable, refill grease cups with lubricant

(Delco-Remy part no. 1960954) and turn down one turn.h. Installation.

(1) Install starter motor with a new gasket in reverseorder of procedure outlined in paragraph 6-7c.

(2) Tighten mounting bolts with 140 ft. lbs. torque.

Figure 6-18. Pinion Clearance Adjustment

Section III. WARNING KITS6-8. ENGINE ALARM AND SHUTDOWN KIT.a. Description.The engine alarm and shutdown kit (figure 6-19)constantly monitors the engine cooling and lubricationsystems. A drop in engine oil pressure or rise in coolanttemperature, beyond acceptable ranges, activates thewarning bell (11) and illuminates the LOW WATERWARNING LIGHT on the instrument panel. If eithercondition reaches a critical stage where engine damagecould occur (predetermined settings), automatic engineshutdown will take place. An automatic override featureallows the engine to be re-started and run for 30seconds in order to move the tractor off the road, andwill then shut down again.b. On-Vehicle Tests and Troubleshooting.

(1) To test the installed system, disconnect the wireat the common (C) terminal of the oil pressure sensor (9,figure 6-19) and start the engine. The engine should runfor 20 to 40 seconds and automatically shut down. If theengine does not shut down, check the automaticoverride module (7) and shutdown solenoid (10)connections.

(2) Reconnect the wire to the common (C) terminalof the oil pressure sensor, and place the key switch inthe ON position with the engine off. Refer to Chapter 5(43, figure 5-10) for location of the water temperaturesensor. The common (C) and normally closed (NC)terminals of the water temperature sensor (8, figure6-19) should both measure approximately 12 Vdc. If not,replace the water temperature sensor.

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1. Swivel fitting2. Hose3. Pipe fitting4. Adapter5. Pipe tee6. Bracket7. Automatic override module8. Water temperature sensor9. Oil pressure sensor

10. Shutdown solenoid11. Warning bell

Figure 6-19. Engine Alarm and Shutdown Kit

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(3) The common (C) and normally closed (NC)terminals of the oil pressure sensor (9) should alsomeasure approximately 12 Vdc (without oil pressure). Ifnot, replace the oil pressure sensor.

(4) The automatic override module (7) should havebattery voltage at the number 1 terminal only. Thenumber 2 terminal should have battery voltage onlywhen the starter motor is energized, and the number 3terminal should measure approximately 12 Vdc for 20 to40 seconds after the starter motor is energized. If not,the automatic override module (7) is defective and mustbe replaced.

(5) To check operation of warning bell (11) andshutdown solenoid (10), temporarily disconnect powerleads and use a jumper wire to momentarily connectbattery voltage to each point. Replace a defectivewarning bell or shutdown solenoid.c. Removal.

(1) Drain engine coolant below the level of thethermostats as described in Chapter 5.

(2) Disconnect electrical leads from oil pressuresensor (9, figure 6-19) and water temperature sensor(8).

(3) Position an adjustable wrench on the hex ring ofsensor body, and unscrew and remove sensors (8 and9).

(4) Disconnect wires from terminals of automaticoverride module (7); then remove two attaching screwsand lift override module from tractor.

(5) Disconnect wires from warning bell (11) andshutdown solenoid (10), remove attaching hardware,and remove warning bell and shutdown solenoid.d. Cleaning, Inspection and Repair.

(1) Inspect fittings for cracks or other damage.Inspect hose (2) for deterioration and cuts. Replacedefective fittings or hose.

(2) Inspect all hardware and threaded openings fordamaged threads. Chase threaded openings with thecorrect size tap or die, and replace damaged hardware.

(3) Inspect sensors (8 and 9) for evidence of leaksat electrical terminals. Replace a leaking sensor.

(4) Inspect all terminals and connectors forevidence of corrosion. Clean or replace corrodedterminals and connectors.e. Installation.

(1) Install components in reverse of procedureoutlined in paragraph 6-8c. Coat threads of sensors withhigh temperature thread sealant prior to installation.

(2) Refill cooling system with antifreeze solution(see Chapter 5).

(3) Test engine alarm and shutdown kit for properoperation as described in Step 1 of paragraph 6-8b.

6-9. WATER LEVEL WARNING KIT.a. Description.The water level sensor (13, figure 6-20) is a flow-sensingdevice that constantly monitors engine coolantcirculation. If a loss of coolant circulation occurs, thewater level sensor activates the buzzer (15) and LOWWATER WARNING LIGHT to alert the operator. Thewater level sensor will detect the following coolingsystem malfunctions: low coolant level, compressionleaks, broken or loose water pump belts, defective waterpump, air or vapor lock of water pump, defective (closed)thermostats, and broken or clogged hoses.

1. Clamp (6)2. Hose3. Hose4. Connector (3)5. Pipe tee6. Clip7. Hose8. Connector

9. Elbow10. Hex nut (2)11. Lock washer (2)12. Capscrew (2)13. Water level sensor14. Bracket15. Buzzer

Figure 6-20. Water Level Warning Kit

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b. On-Vehicle Tests and Troubleshooting.

(1) Check for correct coolant level in radiator andoverflow reservoir (see Chapter 5).

(2) Turn keyswitch to ON position but do not startengine. LOW WATER WARNING LIGHT and buzzershould be on, indicating warning condition.

(3) Start engine. Warning condition should clear ina few seconds.

(4) Operate engine at idle until warmed. Squeezeor clamp supply hose (7, figure 6-20) to block flow tosensor. LOW WATER WARNING LIGHT and buzzershould indicate warning condition within a few seconds.

(5) Perform drain-down test by operating engineand opening radiator drain cock. Remove only sufficientcoolant to drop level below sensor supply line at topradiator tank. Warning light and buzzer should indicatewarning condition within a few seconds. Stop engine.

(6) If warning device does not function properly inabove tests, perform the following test with the engineoff:

(a) Remove hex nut (14, figure 6-21) andcontact cover (15). Disconnect power lead (commonterminal) and tape wire terminal to prevent shorting.Remove warning device lead (normally closed terminal).

(b) Use an ohmmeter to check across thecommon and normally closed terminals for a closedcircuit (zero resistance). An open circuit indicates adefective sensor.

(7) Repeat Step 6 above with engine operating andcheck for open circuit across sensor terminals.

(8) If sensor operates properly in Steps 6 and 7,check wiring harness back to indicator light and buzzer.Check buzzer operation by temporarily disconnectingpower lead, and use a jumper wire to momentarilyconnect battery voltage to power terminal.

c. Removal.

(1) Drain cooling system (refer to Chapter 5) andremove hoses (7 and 3, figure 6-20) from connectors (8and 9).

(2) Loosen and remove two hex nuts (10), lockwashers (11), and capscrews (12).

(3) Remove sensor (13) and bracket (14) fromvehicle.

1. Screw2. Top cover3. Bottom cover4. Cylinder5. Piston6. Gasket

7. Ring 13. Spring holder8. Arm assembly 14. Lock nut9. Setscrew 15. Contact cover

10. Spring 16. Hex nut11. Pin 17. Wiring harness12. Leaf spring 18. Contact assembly

Figure 6-21. Water Level Sensor Disassembly

d. Disassembly, Repair and Reassembly.(1) Disassemble sensor by removing the 12

machine screws (1, figure 6-21), separate top andbottom covers (2 and 3), and remove internal parts innumerical sequence as shown in figure 6-21.

(2) Replace defective parts, and reassemble withnew gaskets (6) in reverse of numerical sequenceshown on figure 6-21.

e. Installation.(1) Attach sensor (13, figure 6-20) and bracket (14)

to cross tie assembly with two capscrews (12), lockwashers (11), and hex nuts (10).

(2) Attach hoses (7 and 3) to connectors on sensor.

(3) Attach wiring harness (17, figure 6-21) to sensorterminals. Install contact cover (15).

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(4) Fill cooling system (refer to Chapter 5) andoperate engine with radiator cap removed to bleed airfrom system. Replace radiator cap, and check systemfor leaks.

(5) Test sensor operation as outlined in Step 4 ofparagraph 6-9b.

Section IV. INSTRUMENT PANEL AND GAUGES

6-10. INSTRUMENT PANEL.

a. Introduction.

This section describes electrical repair of the tractorinstrument panel and gauges (see figure 6-22). Repairof the instrument panel is limited to replacement ofdefective gauges, switches, lights and controls. Refer toChapters 3 and 12 for repair of the restriction Indicator(11) and brake controls (14), respectively.

b. On-Vehicle Tests and Troubleshooting.

(1) Place key switch (24, figure 6-22) in the OFFposition.

(2) To troubleshoot electrical gauges with senderunits, connect two flashlight batteries in series andconnect (+) and (-) terminals across gauge terminalsusing jumper wires. If gauge pointer reads downscale,reverse jumper wires. If gauge pointer does not deflectto nearly full scale the gauge is defective.

(3) If gauge operates satisfactorily, check wiring byoperating engine, removing gauge wire at sending unit,and momentarily grounding wire to engine block or metalframe of tractor. If gauge pointer does not deflect, wiringis defective. Check wiring for open circuit. If gaugepointer deflects, the sender unit is defective. Replacesender unit.

1. Tachometer 8. Switch 15. Dome light switch 22. Engine stop switch2. Warning bell 9. Fuel gauge 16. Headlight switch 23. Heater switch3. Ammeter 10. Air pressure light 17. Washer control 24. Key switch4. Bracket 11. Indicator 18. Wiper control 25. Defroster switch5. Voltmeter 12. Air pressure gauge 19. Hour meter 26. Oil pressure gauge6. Speedometer 13. Xmsn temp. light 20. Instrument panel 27. Fresh air control7. High beam light 14. Brake controls 21. Ether switch 28. Oil pressure light

Figure 6-22. Instrument Panel and Gauges6-16

TM 9-2320-277-14&Pc. Removal, Inspection and Repair.

(1) Remove defective gauges by tagging anddisconnecting wires; then loosening and removing hexnuts and clamp at back of gauge.

(2) Check gauge lights and panel warning lights foropen filaments, corroded sockets, and opens in thewiring.

(3) Check electrical connections for tightness andwires for broken or cracked insulation. Replacedefective wiring. If necessary, refer to the electricalwiring diagram (figure 6-2) for correct wire connections.

(4) Remove dimmer switch (33) by disconnectingleads under cab floor; then remove attaching hardwareand lower dimmer switch from tractor.

(5) Remove turn signal flasher (34) by unpluggingfrom the connector behind the instrument panel.

(6) If necessary for replacement, remove instrumentpanel from tractor as follows.

(a) Disconnect ground cable from batterygroup, and relieve pressure from air tanks.

(b) Remove steering column as described inChapter 14.

(c) Tag and disconnect hoses and wires frominstrument panel.

(d) Remove ten bolts and flat washerssecuring instrument panel to cab, and removeinstrument panel from tractor.d. Installation.

(1) If necessary, install instrument panel in reverseof procedure outlined in paragraph 6-10c.

(2) Install new gauges from the front of theinstrument panel, slip clamping bracket over threadedstuds, and install and tighten hex nuts.

(3) Install dimmer switch and turn signal flasher inreverse of procedure outlined in paragraph 6-10c.

(4) Install wiring, and check gauge lights for properoperation.6-11. SPEEDOMETER.a. Removal.

(1) Refer to figure 6-23. Loosen and unscrewspeedometer cable nut (9) at back of speedometer head(5) and remove cable housing (3) from head.

(2) Loosen and remove the two hex nuts andclamping bracket that secure the speedometer head tothe instrument panel. Disconnect speedometer lightwiring, and remove speedometer head from vehicle.

1. Light socket2. Bulb3. Cable housing4. Grommet

5. Speedometer head6. Adapter7. Gear and sleeve assembly8. Cable9. Cable nut (2)

Figure 6-23. Speedometer Removal(3) Pull the speedometer cable (8) from the cable

housing (3). Check length and both ends for drivingflats. Occasionally a cable will break, leaving lower partin cable housing. To remove lower part of a brokencable, remove adapter (6) and pull lower part of cablefrom cable housing.b. Disassembly, Inspection and Repair.

(1) The speedometer head (5) is replaced as a unitand not serviced separately. Replace speedometerhead if pointer is broken or bent, or mechanism isbinding or frozen.

(2) Erratic pointer movement or scraping noise iscaused by a dry or kinked speedometer cable ordamaged cable housing. Inspect cable by placing on aflat surface and twisting one end with fingers. A goodcable will turn over smoothly over the entire length. Akinked cable will flop over after initial twisting motion,and should be replaced. Inspect cable housing fordents, sharp bends, and other signs of damage.Replace cable and housing if defective.

(3) Inspect adapter (6) by turning shaft andchecking for free movement. Replace if binding orfrozen.

(4) Inspect gear on assembly (7) for missing orcracked teeth. Rotate shaft and check for freemovement. Replace if binding or frozen.

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(5) Check bulb (2) for open filament and inspectsocket (1) for corrosion, broken wiring, or cracked orfrayed insulation. Replace defective parts.c. Reassembly and Installation.

(1) To install and lubricate cable, fill ferrule atinstrument panel end of cable housing with graphitelubricant and slowly insert cable in housing, rotating thecable continuously. Refill ferrule with lubricant asnecessary. If cable jams or binds during insertion, checkcable housing for sharp bends and straighten.

(2) Install gear assembly (7) and insure that gearmeshes properly with speedometer gear ontransmission.

(3) Install adapter (6), cable (8), cable housing (3),grommet (4), speedometer head (5), and connect lightsocket (1).

6-12. TACHOMETER.a. Removal.

(1) Unplug socket housing (5, figure 6-24) from pinhousing (7).

(2) Tag and remove wires and pin-type contacts (8)from pin housing (7).

(3) Remove two screws from either side ofmounting bracket (3) and lift tachometer head (1) frommounting bracket.

(4) Pull rubber boot from sender unit (2); then tagwires, remove two contact screws, and remove wiresfrom sender unit.

(5) Unscrew sender unit (2) from adapter (9); thenunscrew right-angle adapter (9) from adapter (13).

(6) Remove two hex nuts (15) and lock washers(14), and remove adapter (13), gasket (12), and driveshaft (10).

(7) If necessary for replacement, remove fivecapscrews and lock washers and remove coverassembly (11) and gasket.

(8) If necessary for replacement, remove twoscrews (16), hex nuts (18) and lock washers (17) and liftbracket (3) from instrument panel.

1. Tachometer head2. Sender unit3. Mounting bracket and screws4. Wire loom5. Socket housing6. Contact (2)7. Pin housing8. Contact (2)9. Adaptor

10. Drive shaft11. Cover assembly

12. Gasket13. Adaptor14. Lock washer (2)15. Hex nut (2)16. Screw (2)17. Lock washer (2)18. Hex nut (2)

Figure 6-24. Tachometer Removal

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(1) Examine contacts on sender unit (2) and cableharness (6 and 8). If dirty or discolored, polish tobrightness with fine sandpaper to insure good electricalcontact.

(2) Test tachometer head by momentarily touchingohmmeter leads to tachometer head wires. If pointerdeflects downward, reverse ohmmeter leads Pointershould deflect to approximately half scale. If tachometerpointer does not deflect, meter circuit in head is open.Replace tachometer head.

(3) Check drive shaft (10) for free rotation by turningshaft in adapter (13). If bound or frozen, remove adapter(13) and gasket (12) and free shaft (10) or replace withnew part.

(4) Check input and output shafts of adapter (9) forfree movement. Replace if shafts are binding or frozen.

c. Installation.

(1) Install tachometer and tachometer drive withnew gaskets in reverse of procedure outlined inparagraph 6-12a.

(2) Start engine and use an accurate testtachometer to determine accuracy of tractor tachometer.Tachometer error should be less than 5 percent (100rpm error at 2000 rpm engine speed). If error is morethan 5 percent, replace tachometer head or sender unit.

Section V. EXTERIOR LIGHTS

6-13. LOCATION.Refer to figure 6-25 for the location of tractor wiringharnesses and exterior lights.

6-14. HEAD LIGHTS.a. Removal and Disassembly.

(1) Remove screw (2, figure 6-26), moulding (1),and clip (4)

(2) Remove three screws (7) and retainer (6).

15. Dome light16. Terminal block

1. Panel harness 9. Head light (2) 17. Wire2. Firewall harness 10. Front turn light (2) 18. Fuel gauge sender3. Engine harness 11. Sid marker light(2) 19. Temperature sender, xmsn4. Headlamp harness 12. Stop light (2) 20. Temperature sender, water5. Rear cab harness 13. Stop light (2) 21. Backup light(2)6. Tail light harness 14. Air pressure sender 22. Tail light (2)7. Side flood light (2) 23. License plate light8. Neutral start switch harness 24. Rear flood light

Figure 6-25. Wiring Harnesses and Lights

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1. Moulding 6. Retainer2. Screw 7. Screw (3)3. Housing 8. Headlight4. Moulding clip 9. Lampholder5. Spring 10. Aiming screw (2)

11. Connector housing12. Electrical contact (3)13. Electrical connector (3)14. Insulator (2)15. Strain Relief

Figure 6-26. Head Light Removal and Disassembly

(3) Pull lamp (8) from lampholder (9) anddisconnect electrical connector (11).

(4) Remove lampholder (9), housing (3), connector(11) and strain relief (15) only if necessary forreplacement.

b. Cleaning, Inspection and Repair.(1) Clean metal parts by wiping with a cloth

moistened with cleaning solvent.

(2) Inspect lamp for burned-out filaments orcorroded terminals.

(3) Check for corroded terminals, broken wires, andcracked or frayed insulation at connector housing (11).

(4) Replace defective lamp (8) and other partsfound defective during inspection.

(5) Replace headlight assembly if lampholder (9),housing (3) or connector (11) is defective.c. Reassembly and Installation.

(1) Connect lamp (8) to electrical connector (11)and position in lampholder (9).

(2) Position retainer (6) over rim of lamp and installthe three attaching screws (7).

(3) Attach molding clip (4), moulding (1), and installand tighten screw (2).

(4) Use a mechanical aimer and adjust aimingscrews (10) to properly aim headlight beam. If amechanical aimer is not available, adjust the headlightbeam as follows:

(a) Position the tractor in a level areasquare with a screen or wall having a non-reflectingwhite surface, and with the front of the head lights 25feet from the screen.

(b) Mark the vertical center of the aimingscreen with tape after sighting down the centerline of thetractor; then measure the horizontal distance betweenhead light centers and place vertical tape strips on thescreen at the corresponding horizontal locations.

(c) Measure distance from the center ofeach head light to the surface on which the tractor rests,and mark the same distances on the screen with tape.

(d) Turn the head lights on low beam andcover one light.

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NOTETap the light lightly with the handafter making an adjustment of theaiming screws. This assures propertension against the screws to avoidany change in aiming due to roadbumps and vibrations.

(e) Turn vertical aiming screw (10) located attop position of lampholder (9) counterclockwise untilbeam has been considerably lowered; then turn screwclockwise until the top edge of the beam is even with thehorizontal line (see figure 6-27).

Figure 6-27. Head Light Aiming Pattern

(f) Turn the horizontal aiming screw (10,figure 6-26) located at the side of the lampholder (9)counterclockwise, then clockwise, until left edge of beamis 2 inches to the right of the head light centerline (seefigure 6-27).

(g) Cover head light that has been aimed andfollow same aiming procedure for the opposite headlight.

6-15. CLEARANCE LIGHTS.a. Removal and Disassembly.

(1) Remove two machine screws (4, figure 6-28)and separate the retainer (5) and lens (6) from themounting pad (2).

(2) Remove lamp (7). Do not remove mountingpad, lamp socket, or wiring unless damage or corrosionrequires complete replacement of lamp assembly.b. Cleaning, Inspection and Repair.

(1) Clean metal parts with a cloth moistened withcleaning solvent.

(2) Rinse lens in water and wipe dry. Inspect lampfor open filament and socket for corrosion.

(3) Check for broken wiring and cracked or frayedinsulation.

(4) Replace defective lamp and other parts founddefective during inspection.

1. Tapping screw (4)2. Pad3. Grommet

4. Machine screw (2)5. Retainer6. Lens7. Lamp

Figure 6-28. Clearance Light Removal and Disassembly


(1) Install lamp (7) min socket.

(2) Place retainer (5) over lens (6) and positiontogether against mounting pad (2). Install and tightenthe two screws (4).

6-16. FRONT TURN AND STOP LIGHTS.a. Removal.

(1) Pry grommet and lamp assembly from vehiclemounting opening.

(2) Unplug connector (4, figure 6-29) from sealedlamp unit (2).

1. Grommet 3. Tapping screw2. Sealed lamp unit 4. Connector

Figure 6-29. Front Turn and Stop Light Removal

(3) Separate grommet (1) from sealed lamp unit (2).

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b. Cleaning and Inspection.

(1) Wipe grommet (1) with a clean dry cloth andinspect for cracks or tears.

(2) Inspect lamp contacts and connector contactsfor corrosion.

(3) Check lamp filaments with an ohmmeter forcontinuity (low resistance circuit).

NOTERed lamp (stop light) is a threecontact, dual filament. Amber lamp(front turn light) is a double contact,single filament.

(4) Inspect grounding screw (3) and connector wirefor good electrical contact to tractor frame.

c. Repair.(1) Replace the sealed lamp unit if continuity check

indicates open circuit.

(2) Replace a defective grommet or connector.

(3) Tighten grounding screw (3) if necessary.


(1) Push grommet (1) over sealed lamp unit (2).

(2) Position lamp assembly adjacent to vehiclemounting opening, and push connector onto lampterminals.

(3) Coat rubber grommet (I) with detergent solutionto aid in installation, and snap grommet and lampassembly into vehicle mounting opening.

6-17. BACK UP AND TAIL LIGHTS.

a. Removal.

(1) Pry grommet and lamp assembly from vehiclemounting opening.

(2) Unplug connector (4, figure 6-30) from sealedlamp unit (2).

(3) Separate grommet (1) from sealed lamp unit (2).

1. Grommet 3. Tapping screw2. Sealed lamp unit 4. Connector

Figure 6-30. Back Up and Tall Light Removal

b. Cleaning and Inspection.

(1) Wipe grommet (1) with a clean dry cloth andinspect for cracks or tears.

(2) Inspect lamp contacts and connector contactsfor corrosion.

(3) Check lamp filaments with an ohmmeter forcontinuity (low resistance circuit).

NOTERed lamp (tall light) is a threecontact, dual filament. Clear lamp(back up light) is a double contact,single filament.

(4) Inspect grounding screw (3) and connector wirefor good electrical contact to tractor frame.

c. Repair.(1) Replace the sealed lamp unit if continuity check

indicates open circuit.

(2) Replace a defective grommet or connector.

(3) Tighten grounding screw (3) if necessary.

d. Reassembly and Installation.(1) Push grommet (1) over sealed lamp unit (2).

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(2) Position lamp assembly adjacent to vehiclemounting opening, and push connector onto lampterminals.

(3) Coat rubber grommet (1) with detergent solutionto aid in installation, and snap grommet and lampassembly into vehicle mounting opening.

6-18. SIDE MARKER LIGHTS.a. Removal.

(1) Refer to figure 6-31. Remove plug and socketassembly (1) by grasping plug and turning 1/4 turncounterclockwise.

1. Plug and socket assembly2. Bulb3. Screw (2)4. Lens and housing assembly5. Gasket

Figure 6-31. Side Marker Light Removal

(2) Pull plug from lens and housing assembly (4).

NOTELens and housing are a molded one-piece unit and do not separate.


(1) Remove bulb and check for open filament byvisual inspection. Replace if defective.

(2) Inspect socket contacts for corrosion and wiringfor broken or frayed insulation. Replace if defective.

(3) If lens and housing assembly (4) is damaged,remove two screws (3) and replace assembly andgasket (5) with new parts.c. Installation.

(1) Press wedge base bulb (2) firmly into socket.

(2) Position plug (1) into opening in lens andhousing assembly (4), and rotate clockwise 1/4 turn tolock in place.

6-19. LICENSE PLATE LIGHT.a. Removal and Inspection.

(1) Remove connector (1, figure 6-32) and inspectconnector socket and lamp unit terminal for corrosion

1. Connector2. Screw (2)3. Sealed lamp unit

Figure 6-32. License Plate Light Removal

(2) Check sealed lamp unit (3) with ohmmeter byconnecting leads to lamp terminal and mounting screw(2). If ohmmeter reads open circuit (infinite resistance),lamp unit is defective.

b. Repair and Installation.(1) If sealed lamp unit is defective, remove two

mounting screws (2) and replace sealed lamp unit withnew part.

(2) Install sealed lamp unit and press connector (1)firmly onto lamp terminal.

6-20. FLOOD LIGHTS.

a. Removal.(1) Refer to figure 6-25 for flood light locations, and

remove flood lights by tagging wires and removingattaching hardware.

(2) Remove flood light mounting brackets only ifnecessary for repair.

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(2) Clean flood light lenses by washing with a milddetergent solution and rinsing with clear water.

(3) Inspect metal parts for cracks and breaks.Replace damaged parts.

(4) Inspect lenses for breaks and chips. Replacedefective lenses.

(5) Inspect hardware for damaged threads, andreplace damaged hardware.

(6) Inspect wiring for frayed insulation and brokenconductors, and replace as necessary.c. Installation.

(1) Secure flood lights and mounting brackets totractor, and reconnect wiring.

(2) Adjust side flood lights vertically for correctbeam location; then tighten mounting hardware.

Section VI. ELECTRIC HORN AND RELAY

6-21. INTRODUCTION AND DESCRIPTION.a. Introduction.

This section contains a basic description of, and repairprocedures for, the electric horn and relay. For repair ofthe horn button and contact, refer to the steering columnprocedures contained in Chapter 14.

b. Description.The horn circuit (see figure 6-33) includes the horn, hornrelay, battery group, bush button and contact, and the 15ampere horn circuit breaker. The tractor framecompletes the ground path for the horn-to-battery circuit.The relay is used between the batteries and horn toreduce the current flow through the push button andcontact, and thereby supply a higher working voltage atthe horn. The push button and contact carry only relaycurrent, while the relay opens and closes the circuitbetween the horn and batteries. The horn relay consistsof an electromagnet and a set of contacts arranged sothat when the magnet is energized an armature isattracted and the contacts close. A spring keeps thecontacts open until the relay is energized by depressingthe push button located in the center of the steeringwheel.

Figure 6-33. Horn Circuit Schematic

6-22. HORN RELAY.

a. Troubleshooting.(1) Turn key switch to ON position with engine off.

(2) If horn falls to sound when push button isdepressed, measure voltage at terminal F of horn relaywith a voltmeter. If battery voltage is not present,remove the front access panel (see Chapter 15) andcheck for battery voltage at the horn circuit breaker.

(3) Connect a jumper between terminal G of hornrelay and tractor frame (battery ground). If horn sounds,repair the horn push button or steering column harness(see Chapter 14).

(4) With terminal G of the horn relay still grounded,measure voltage at the horn terminal of the relay (redwire). If less than 11 volts is present, horn relay isdefective.

(5) If the horn sounds continuously (horn pushbutton not depressed), check for a ground in the pushbutton, contact or steering column harness (see Chapter14).b. Removal and Repair.

(1) Tag three wires connected to horn relayterminals, and remove terminal screws (4, figure 6-34)and wires from horn relay (6).

(2) Remove hex nut (1), lock washer (2) andmachine screw (3); then remove horn relay (6) fromtractor.

(3) Repair a defective horn relay by installing a newunit.

(4) Check relay and wire terminals for corrosion,and check wiring for broken or frayed insulation.Replace if defective.

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1. Hex nut2. Lock washer3. Machine screw4. Terminal screw (3)5. Red wire6. Horn relay

Figure 6-34. Horn Relay Removal

c. Installation.(1) Install horn relay in reverse of procedure

outlined in paragraph 6-22b.

(2) Check operation of horn by turning key switch toON position and depressing horn push button.

6-23. ELECTRIC HORN.

a. Troubleshooting.

(1) Troubleshoot horn relay as described inparagraph 6-22a.

(2) If horn still fails to sound when horn push buttonis depressed, connect a jumper between the horn bodyand tractor frame (battery ground). If horn sounds,check for corrosion at horn and horn bracket attachmentpoints.

(3) If horn does not sound, check for voltage at hornpower terminal with a voltmeter or test light. If voltage ispresent, horn is defective. If voltage is not present,check red horn wire and terminals.

b. Removal, Inspection and Repair.(1) Unplug terminal (1, figure 6-35) from horn (5).

(2) Remove hex nut (4) and pull horn from bracket(6).

(3) If necessary for repair, remove hardwaresecuring bracket (6) to tractor and remove bracket.

(4) Repair a defective horn by installing a new unit.

1. Terminal2. Red wire3. Adjusting screw4. Hex nut5. Horn6. Bracket

Figure 6-35. Electric Horn Removal

(5) Check horn and wire terminals for corrosion, andcheck wiring for broken or frayed insulation. Replace ifdefective.

(6) Check horn and horn bracket attachment pointsfor corrosion. Clean as necessary to assure goodelectrical contact.

c. Adjustment and Installation.

(1) Connect horn to adjustment circuit as shown infigure 6-36. Adjust rheostat for 12.4 Vdc indication onvoltmeter.

Figure 6-36. Horn Current Adjustment Circuit

NOTEDo not stuff rags or other material inthe horn throat to muffle the soundwhile adjusting, as this changes thevibration frequency and results in afalse current setting.

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(2) Turn adjusting screw (3, figure 6-35) 1/10 of aturn at a time until ammeter (figure 6-36) indicates 4.5amperes. Turn adjusting screw counterclockwise toincrease the current, or clockwise to decrease thecurrent.

(3) Disconnect horn from test circuit and install inreverse of procedure outlined in paragraph 6-23b.

(4) Check for proper operation of horn by turningkey switch to ON position and depressing horn pushbutton.

Section VII. TRAILER LIGHT CIRCUITS

6-24. TRAILER CABLE AND CONVERTER.

a. Troubleshooting and Inspection.

(1) Inspect coiled cable assembly (2, figure 6-37) forbroken wires and frayed or damaged Insulation. Inspectplug body for cracks, chips, or other defects.

(2) Remove front access panel (see Chapter 15) togain access to circuit breakers (4).

(3) Inspect wiring at circuit breakers (4) for looseconnections and corrosion. Check ground lugconnection, and tighten connections as necessary.

(4) Test operation of TRAILER AUX LIGHTCIRCUIT switch (5) with a voltmeter or test lamp.

(5) Remove converter fuse from fuse holder (7), andcheck fuse for continuity with an ohmmeter.

(6) Test output of each circuit breaker (4) with testlamp, with appropriate tractor light circuits activated.

(7) Turn on converter switch, and check terminals 7,8, and 9 of 24 volt converter (6) with a voltmeter.Voltmeter should indicate approximately 24 volts at eachterminal when corresponding tractor light circuits (talllight and turn signals) are activated. If not, measurevoltage at terminals 4, 5, and 6 of converter. Voltmetershould indicate approximately 12 volts when appropriatetractor light circuits are activated. If 12 volt input toconverter is present, converter is defective.

b. Removal, Repair and Installation.

(1) Tag wiring connections, and remove and replaceall defective components.

NOTEConverter repair is limited toreplacement of a defective converterassembly.

(2) Install new parts where required, and check allelectrical connections for tightness.

NOTEDo not loosen the brass coloredscrews on the converter terminalstrip. Use the chrome screws for allconnections.

1. Clamp (2)2. Cable assembly3. Grommet (2)4. Circuit breaker (6)5. Switch6. Converter7. Fuse holder

Figure 6-37. Trailer Cable and Converter6-26

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6-25. SEPARATE LIGHTING CABLE.

a. Removal, Disassembly and Inspection.

(1) Unplug trailer connector plugs (2, figure 6-38)from plug holders (9) and remove cable from tractor.

(2) Tag wires at connector receptacle (8), andloosen screws at rear of receptacle to disconnect wires.

(3) Remove two hex nuts (4), lock washers (5) andcapscrews (6); then remove receptacle (8) from tractor.

(4) If necessary for replacement, remove hardwaresecuring plug holders (9) to tractor and remove plugholders.

(5) Use an ohmmeter to check continuity betweencorresponding terminals on the cable plugs (2). Ifnecessary for repair, slide rubber cover (7) back fromcable plug (2) and disconnect plug from cable.

b. Cleaning and Repair.

WARNINGUse trichlorethane in a well ventilatedarea only.

(1) Clean electrical connectors with a clothmoistened in trichloroethane.

(2) Clean cable and rubber cover by washing with amild detergent solution; then rinsing with clear water.


(4) Replace all parts found defective duringinspection.c. Reassembly and Installation.

(1) Reassemble and install lighting cablecomponents in reverse of procedure outlined inparagraph 6-25a.

(2) Connect one end of cable to the receptacle (8)and, using a voltmeter or test lamp, check for properlight circuit voltage at the open end of cable.

1. Cable 6. Capscrew (2)2. Connector plug (2) 7. Rubber cover3. Chain 8. Connector receptacle4. Hex nut (2) 9. Plug holder (2)5. Lock washer (2)

Figure 6-38. Separate Lighting Cable

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Section VIII. BATTERY BOXAND BATTERIES

6-26. BATTERY BOX.

a. Battery Removal.

(1) Remove lock, if installed, from hasp at lowercenter of battery box.

WARNINGBattery box lid is heavy. Keep handson outside of battery box lid toprevent injury should lid fall closed.

(2) Remove four screws (14, figure 6-39), lockwashers (15) and flat washers (16), and pull lid up togain access to batteries.

(3) Remove terminal nut and disconnect negativecable (6) from terminal lug (3).

CAUTIONDo not pry the terminal lugs loose byapplying a screwdriver bladebetween the lugs and battery cases,as damage to the batteries will result.

(4) Loosen terminal nuts and spread lugs (3 and 4)using a heavy screwdriver blade between terminal boltand battery post; then lift lugs (3 and 4) from batteries.

(5) Loosen and remove six hex nuts (13), lockwashers (12) and screws (11). Lift two hold-down links(2) and four hold-down brackets (9) from battery box.

(6) Carefully lift batteries from battery box.b. Disassembly.

(1) Lift two rubber pads (8) from battery box.

(2) If necessary for replacement, remove terminalnuts from lugs (3 and 4) and disconnect battery cables(5 and 7). Remove grommet (19).

(3) If battery box is to be removed from tractor,remove spare tire and tire carrier as outlined in Chapter15.

(4) Attach a suitable hoist to battery box andremove screws (17 and 18), hex nuts (21) and lockwashers (20); then lift battery box from tractor.

1. Battery box 11. Screw (6)2. Battery (4) 12. Lock washer (6)3. Negative lug (4) 13. Hex nut (6)4. Positive lug (4) 14. Screw (4)5. Battery cable (6) 15. Lock washer (4)6. Negative cable 16. Flat washer (4)7. Positive cable 17. Screw (3)8. Rubber pad (2) 18. Screw (4)9. Hold-down bracket (4) 19. Grommet

10. Hold-down link (2) 20. Lock washer (7)21. Hex nut (7)

Figure 6-39. Battery Box and Batteriesc. Cleaning, Inspection and Repair.

(1) If corrosion is evident, clean all parts with abaking soda and water paste and flush with clean water.When dry, apply a light film of engine oil to exposedmetal parts.

(2) Clean terminal lugs with a wire brush or steelwool, and inspect battery cables for frayed insulation anddamaged lugs. Replace a defective battery cable.

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WARNINGDo not weld in the vicinity ofbatteries. Batteries releasehydrogen, an explosive gas, duringnormal operation.

(4) Inspect battery box and hold-downs for brokenwelds or cracks. Repair by welding. Replace a batterybox or hold-down beyond economical repair.

(5) Inspect rubber pads for tears and damage fromcorrosion. Replace a defective rubber pad.


(1) Reassemble and install battery box andbatteries in reverse of procedures outlined in paragraphs6-26b and 6-26a.

(2) Tighten hex nuts (13) evenly with 60 to 80 Inchpounds torque. Do not overtighten, as damage to thebattery cases could result.

6-27. BATTERIES.a. Cleaning and Inspection.

WARNINGDo not smoke or allow open flamenear batteries. Batteries releasehydrogen, an explosive gas, duringnormal operation.

(1) Open battery box lid as outlined inparagraph 6-26a.

(2) Clean battery cases with a baking soda andwater paste, and flush with clear water. Exercise care toprevent baking soda from entering batteries.

(3) Clean battery posts with a wire brush or steelwool.

(4) Inspect battery case and cell covers for breaksand cracks.

(5) Remove battery cell covers and inspect ventholes for obstruction. If necessary, use a fine wire toclear vent holes.

(6) Inspect battery case and cell covers for cracksor breaks. Replace if defective.

(7) Check electrolyte level in each cell. Add distilledwater if less than 3/8 inch above plates.

b. Specific Gravity Test.

(1) Remove battery vent covers if installed.

(2) Check each cell of battery by drawing sufficientelectrolyte into hydrometer to allow float to besuspended freely (see figure 6-40) Note the reading ofthe float at the liquid level, and return electrolyte to thebattery cell by squeezing hydrometer bulb.

NOTE

For convenience, hydrometer scalemay be marked 1.270, 1.280, etc.,instead of 1.270, 1.280, etc.

Figure 6-40. Specific Gravity Test

(3) Correct hydrometer readings for temperatureaccording to the conversion scale shown in figure 6-41;then compare readings with those in Table 6-2. If thedifference between the highest and lowest cell reading ismore than 50 points (0.050), charge battery and repeatspecific gravity test. If the difference between individualcells is still more than 50 points, the battery is defective.

Table 6-2. Specific Gravity and Battery Charge

Specific Gravity Battery State1.270 to 1.290 Full charge1.200 to 1.215 1/2 charge1.125 to 1.140 Discharged

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Figure 6-41. Specific Gravity Correction Scale

c. Battery Charging.

WARNING

Do not smoke or allow open flamenear batteries. Batteries release-hydrogen, an explosive gas, duringcharging.

(1) Connect battery charger positive lead to thebattery positive post, and the charger negative lead tothe battery negative post.

(2) With battery cell covers m place, turn oncharger.

(3) Periodically remove cell covers and checkspecific gravity and electrolyte level. Add distilled waterto maintain level 3/8 inch above plates.

(4) Battery is considered fully charged when, over atwo-hour period, the specific gravity as measured withthe hydrometer does not change.

NOTEIf one or more cells of the battery hasa specific gravity less than 1.230 afterprolonged charging, the battery isdefective.

(5) Turn off charger and disconnect charger leadsfrom the battery posts.

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CHAPTER 7AUTOMATIC TRANSMISSION

Section I. PREVENTIVEMAINTENANCE

7-1. OIL LEVEL.

a. Importance of Proper Level.

The transmission oil is used to apply clutches andlubricate and cool the transmission components.Transmission performance will be affected unless theproper oil level is maintained.

(1) A low oil level (denoted on the dipstick) will notcompletely envelope the sump oil filter. Therefore oiland air are drawn by the input pump, and directed to theclutches and converter causing irregular shifting. Thisaeration of the oil also changes the viscosity and color toa thin milky liquid.

(2) At the normal oil level (between the ADD andFULL marks on the dipstick) the oil is slightly below theplanetary gear units. If additional oil is added bringingthe oil level above the FULL mark, the planetary unitswill run in the oil, foaming and aerating the oil.Overheating and irregular shift patterns can occur whenthe oil is aerated.

b. Oil Level Check Procedure.

(1) Operate the transmission until normal operatingtemperature is reached.

(2) Shift the transmission through all drive ranges tofill the clutch cavities and oil passages.

(3) With the tractor positioned on level ground, allowthe engine to idle at 550 to 600 rpm.

CAUTIONWhen checking oil level, dirt orforeign material must not be allowedto enter the fill pipe. Beforeremoving the dipstick, clean aroundthe end of the fill pipe.

(4) Remove the dipstick (figure 7-1) and check theoil level. The oil should register at the FULL mark underthe conditions stated above. The safe operating level isfrom the ADD mark to the FULL mark on the dipstick.

Figure 7-1. Transmission Dipstick Location

CAUTION

The oil level rises as sumptemperature increases. Therefore, donot fill above the ADD mark beforethe transmission has reached normaloperating temperature.

(5) Drain any excess oil to restore the proper level,or add oil as specified in the Operator's Manual until theoil registers at the FULL mark on the dipstick.

7-2. CHANGING OIL AND FILTERS.

a. Oil and Sump Filter.

The transmission oil and sump filter should be changedat the interval specified in the Operator's Manual. Tochange the oil and sump filter proceed as follows:

(1) Operate the transmission until normal operatingtemperature is reached.

(2) Place the gear shift lever in neutral (N) position.

(3) Drain the transmission oil and remove the oilpan as instructed on figure 7-2.

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NOTEExamine the oil which is drained forevidence of dirt, metal particles orengine coolant. Clean the oil panthoroughly, and remove anyaccumulation of sludge or soft dirt inthe sump. Metal particles or enginecoolant in the oil indicates probabledamage to the transmission(disassembly, inspection andcleaning of the transmission isrecommended).

(4) Remove the single screw that retains the sumpfilter.

(5) Separate the sump filter from the oil filter tube.Discard the filter element and retain the oil filter tube foruse with the new filter.

(6) Install a new seal ring onto the oil filter tube, andlubricate the seal ring with new transmission fluid.

(7) Install the suction tube into the new oil sumpfilter.

(8) Align end of oil filter tube in bore of transmissionhousing and oil filter on control valve. Secure oil filter tocontrol valve with a 5/16-18 x 5/8 inch washerheadscrew. Tighten screw to torque value specified inChapter 8, Table 8-5.

(9) Install two 5/16-18 by 3 inch headless bolts intwo of the oil pan screw holes in transmission housing.

CAUTIONDo not use any substance as agasket retainer. Do not use sealingcompounds or fibrous greases insidethe transmission or where they mightget washed into the transmission.

(10) Align oil pan gasket on transmission housing.Align oil pan on gasket, and secure with washer headscrews, removing headless bolts to install last twoscrews. Tighten screws (initially and finally after gasketsets) to torque value specified in Chapter 8, Table 8-5.

(11) Change the governor oil filter (paragraph 7-2bbelow).b. Governor Oil Filter.The governor oil filter should be changed at every oil andsump filter change interval. To change the governor oilfilter proceed as follows:

NOTEIf transmission oil has not beendrained, be sure to drain oil beforeproceeding (see figure 7-2, step 1).

Figure 7-2. Oil Pan Removal

(1) Refer to figure 7-3 and remove plug, O-ring sea)and governor filter.

(2) Insert the new filter into the rear cover, open-endfirst.

(3) Install the plug with new O-ring seal to retain thefilter.

Figure 7-3. Governor Oil Filter

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(4) Install drain plug, gasket, and filler tube in oilpan (figure 7-2).

(5) Pour approximately 15 US quarts oftransmission fluid into the transmission through the fillertube (refer to Operator's Manual for fluid specifications);then check the oil level as described in paragraph 7-1b.c. External Oil Filter.

After a transmission failure that introduces debris intothe oil system, complete clean-up of the system cannotbe assured. Repeated cleaning and flushing may notremove all debris from the radiator oil cooler tank. Toprevent a repeat failure, caused by eventual movementof trapped debris, an external oil filter is installedbetween the radiator cooler tank and transmission returnline. The external oil filter should be changed at everyoil and sump filter change interval as follows:

(1) Remove plug (3, figure 7-4) and gasket anddrain transmission fluid from filter. Inspect fluid forcontamination, such as evidence of metal particles orengine coolant.

(2) Loosen and remove stud (1) and lower shell (2),element (5), and gasket (6) from filter base. Discard thethrow away type paper element (5) and gasket (6).

(3) Clean the filter base (10) by washing withcleaning solvent and dry thoroughly. Make sure all oldgasket material is removed from mating surface on base.

(4) Inspect the filter base and shell for cracks,breaks and loose connections, and inspect plug, studand threaded openings for damaged threads. Replaceall defective parts.

(5) Lightly coat new gasket (6) with cleantransmission fluid, Install new filter element (5) andgasket (6), and secure to base (10) with shell (2) andstud (1). Tighten stud with 7 to 10 ft. lbs. of torque.

(6) Install plug (3) and gasket (4), start engine, andcheck for fluid leaks.

(7) Check the transmission fluid for proper level asdescribed in paragraph 7-1b.

7-3. TRANSMISSION VENT ASSEMBLY.

a. Description.

The transmission vent assembly is located at the top ofthe transmission housing as shown in figure 7-5. Thevent assembly serves to prevent pressure buildup withinthe transmission. The vent assembly must be kept cleanand the passage open.

1. Stud2. Shell3. Plug4. Gasket5. Filter element6. Gasket7. Retainer8. Spring9. Bypass valve

10. Base

Figure 7-4. External Oil Filter

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Figure 7-5. Transmission Vent Assembly

b. Cleaning.The transmission vent assembly should be cleaned atevery oil and sump filter change interval as follows:

NOTEClean the vent assembly morefrequently in extremely dustyconditions.

(1) Use an open end wrench to rotate the ventassembly counterclockwise and remove from thetransmission housing.

(2) Clean the vent assembly by washing withvolatile mineral spirits. Inspect the vent for damagedthreads or blocked passages, and replace a defectivevent assembly.

(3) Lightly coat the vent assembly threads withclean transmission fluid and install the vent in thetransmission housing. Tighten the vent assembly, usingcare not to distort or crush the breather stem.

Section II. TROUBLESHOOTING

7-4. GENERAL.

a. Inspection.

(1) Visually inspect all splitlines, plugs, hose andtube connections at the transmission and radiator oil

cooler for oil leakage. Leakage at splitlines may becaused by loose mounting bolts or defective gaskets.Tighten all bolts, plugs and connections where leakageis found.

(2) Check to ensure that the modulator control cableand linkage are free.

(3) Check the transmission fluid for proper level asdescribed in paragraph 7-1b.

(4) Check the gear shift cable linkage for properadjustment.

(5) Be sure the engine is properly tuned.

b. Road Test.

NOTEPrior to conducting the road test,check the engine full load governedspeed (see Chapter 2).

(1) Determine the tractor tachometer error with atest tachometer. Make corrections for error, as required,in the following steps.

(2) Operate the tractor in all positions of the gearshift lever to check for slipping and variations in shifting.Note whether the shifts are harsh or spongy.

(3) Observe closely for slipping or engine speedflareup. Slipping or flareup in any gear range usuallyindicates clutch or band problems.

(4) Place the gear shift lever in the drive (D) positionso that all automatic upshifts can occur. Drive the tractorat full throttle from a standing start until the 4-5 upshiftoccurs, and record the engine speed at which eachupshift occurs. Compare the upshift speeds with thoselisted in Table 7-1.

Table 7-1. Transmission Shift Speeds

Upshift Engine Speed(rpm)

1-2 28002-3 24003-4 28004-5 2800

c. Hydraulic Pressure Test.

Pressure testing is an important step in thetroubleshooting procedure. These tests usually revealthe cause of most transmission problems.

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(1) Refer to figure 7-6 for pressure check points,and use a tee fitting to connect a pressure gauge to theappropriate check point.

(2) Apply tractor service and parking brakes, andblock front wheels.

WARNINGDo not permit anyone to stand infront of tractor during pressure tests.

(3) Place the gear shift lever in the drive (D) positionand accelerate the engine to the speed listed in Table 7-2.Compare the measured oil pressure with the pressurelisted in Table 7-2.

(4) Repeat steps 1 through 3 above until desiredtests are completed.

(5) Place gear shift lever in the neutral (N) position,stop engine and disconnect tee fitting and pressuregauge.

7-5. TROUBLESHOOTING CHART.The Troubleshooting Chart, Table 7-3, outlines thepossible causes of transmission troubles and theirremedies. To use the chart, read down the SYMPTOMcolumn until the malfunction (as observed in paragraph7-4) is located. Then read across to the PROBABLECAUSE column, and perform the recommended remedyin the CORRECTIVE ACTION column.

Table 7-2. Oil Pressure Specifications

Test Engine Speed Pressure(rpm) (psig)

600 125 min.Main pressure tap

1200 165 to 190

Governor pressure 1500 54 to 58tap

Lubrication pressure 2000 23 to 30

Converter-out 2000 32 to 52pressure

Section III. ADJUSTMENTS

7-6. SHIFT SPEED ADJUSTMENTS.

a. Shift Signal Valve Adjustments.If an upshift speed in paragraph 7-4b does not reach thespecified value, the transmission shift point may beraised by increasing the spring force on the 1-2, 2-3, 3-4or 4-5 shift signal valve. If an upshift speed exceeds thespecified rpm, or if an upshift does not occur at all, thespring force must be reduced. Adjust the force on onlythe springs for valves that do not upshift at the properengine speed using adjusting ring tool J-24314. Seefigure 7-7.

Figure 7-6. Oil Pressure Check Points7-5

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Table 7-3. Transmission Troubleshooting Chart

Symptom Probable Cause Corrective Action

Automatic upshifts occur 1. Governor valve stuck 1. Clean or replace governor (Chapter 8)at too high speed 2. Valves sticking 2. Overhaul valve body assembly

(Chapter 8)3. Shift points not properly adjusted 3. Adjust shift speed (paragraph 7-6)

Automatic shifts occur 1. Governor valve stuck 1. Clean or replace governor (Chapter 8)at too low speed 2. Governor spring weak 2. Replace governor (Chapter 8)

3. Modulator valve stuck 3. Clean or replace modulator valve(Chapter 8)

4. Shift point not properly adjusted 4. Adjust shift speed (paragraph 7-6)

Low main pressure in 1. Low oil level 1. Add oil to proper level (paragraph 7-1b)all ranges 2. Sump oil filter clogged 2. Replace filter (paragraph 7-2a)

3. Sealring at oil intake pipe (filter 3. Replace sealring (paragraph 7-2a)output) leaking or missing

4. Main-pressure regulator valve spring 4. Replace spring (Chapter 8)weak

5. Control valve body leakage 5. Replace or rebuild valve bodyassembly (Chapter 8)

6. Valves stuck (trimmers, relays, and 6. Overhaul valve body assembly, main-main-pressure regulator) pressure regulator valve (Chapter 8)

7. Oil pump worn or damaged 7. Replace or rebuild oil pump (Chapter 8)

Low main pressure in 1. Leakage in clutch apply circuits for 1. Replace or rebuild valve body assemblyone operating range, specific range (Chapter 8)normal in other ranges 2. Excessive leakage at clutch piston 2. Overhaul transmission and replace piston

seals for specific range seals (Chapter 8)

Excessive creep in first 1. Idle throttle setting too high 1. Adjust engine idle setting (Chapter 2)and reverse gears

Low Lubrication 1. Oil level low 1. Add oil to proper level (paragraph 7-1b)pressure 2. Excessive internal oil leakage 2. Check the valve body mounting bolts

and lubrication valve seat and spring(Chapter 8)

3. Cooler lines restricted or leaking 3. Reroute or replace as necessary4. Lubrication valve spring weak 4. Replace valve spring (Chapter 8)5. External oil filter clogged 5. Replace filter (paragraph 7-2c)

Oil leaking into 1. Converter pump hub seal worn 1. Replace seal (Chapter 8)converter housing 2. Converter pump hub worn at 2. Replace pump hub (Chapter 8)

seal area3. Engine rear seal worn 3. Replace seal (Chapter 2)

Transmission overheating 1. Oil level low 1. Add oil to proper level (paragraph 7-1b)in all ranges 2. Oil level high 2. Drain oil to proper level (paragraph 7-1b)

3. Cooler restricted (oil or coolant side) 3. Remove restrictions

No response to shift 1. Range selector linkage disconnected 1. Connect linkage (paragraph 7-10)lever movement 2. Range selector linkage defective 2. Repair or replace linkage

or broken (paragraph 7-14)3. Main pressure low 3. See "Low main-pressure in all ranges"4. Range selector not engaged at 4. Install or replace internal parts involved

control valve (Chapter 8)

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Table 7-3. Transmission Troubleshooting Chart (Continued)

Symptom Probable Cause Corrective Action

Rough shifting 1. Manual selector linkage out of 1. Adjust linkage (paragraph 7-7)adjustment

2. Control valves sticking 2. Replace or rebuild control valveassembly

(Chapter 8)3. Modulator valve sticking; spring 3. Repair or replace valves; adjust spring

adjustment (Chapter 8)4. Modulator actuator cable kinked or 4. Replace or adjust actuator cable

out of adjustment (paragraph 7-10)

Dirty oil 1. Failure to change oil and filters at 1. Change oil, install new filtersproper interval (paragraphs 7-1 and 7-2)

2. Heat excessive 2. See "Transmission overheating in allranges"

3. Clutch failure 3. Overhaul transmission (Chapter 8)4. Damaged sump oil filter 4. Replace filter (paragraph 7-2a)

Oil leaking at output 1. Oil seal at output flange worn or 1. Replace seal (Chapter 8)shaft damaged

2. Flange worn at seal surface 2. Replace flange (Chapter 8)

Clutch slippage in all 1. Oil level low 1. Add oil to proper level (paragraph 7-1b)forward gears 2. Clutch (main) pressure low 2. See "Low main pressure in all ranges"

3. Forward clutch slipping 3. Rebuild forward clutch and replacepiston sealrings (Chapter 8)

4. Sealrings on front support hub 4. Replace sealrings (Chapter 8)worn or broken

Clutch slippage in first 1. First clutch slipping 1. Rebuild clutch and replace pistonand reverse only sealrings (Chapter 8)

Clutch slippage in third 1. Clutch for particular range slipping 1. Rebuild clutch and replace pistonor fourth only sealrings (Chapter 8)

Clutch slippage in fourth 1. Fourth clutch slipping 1. Rebuild clutch and replace pistonand reverse only sealrings (Chapter 8)

2. Sealrings on center support hub 2. Replace sealrings (Chapter 8)worn or broken

Clutch slippage in first 1. Low clutch slipping 1. Rebuild clutch and replace pistononly sealrings (Chapter 8)

Vehicle moves in 1. Range selector linkage out of 1. Adjust linkage (paragraph 7-7)neutral adjustment

Oil thrown from 1. Oil level too high 1. Drain oil to proper level (paragraph 7-1b)filler tube 2. Vent assembly clogged 2. Clean or replace vent assembly

(paragraph 7-3)3. Dipstick gasket worn 3. Replace gasket or dipstick (Chapter 8)

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Figure 7-7. Shift Signal Valve Adjustments

b. Modulator Valve Adjustment.

If more than one shift signal valve spring requiresadjustment, it may be necessary to adjust the springforce on the modulator valve (figure 7-8) one position inthe same direction as adjustment for signal valves. If allupshift points are either too high or too low, byapproximately the same amount, only the modulatorvalve should be adjusted.

7-7. GEAR SHIFT ADJUSTMENTS.

a. Gear Shift Linkage Adjustment.

Check the gear shift linkage at the interval specified inthe Operator's Manual. The gear shift lever shouldmove easily and give a crisp detent feel in each position.When the linkage is correctly adjusted, the trunnionswhich engage the levers at the transmission and shifttower can be moved freely in each range. If adjustmentis necessary, refer to paragraph 7-17.

b. Neutral Start Switch Adjustment.

The neutral start switch is adjusted to prevent

engagement of the engine starter unless the gear shiftlever is in the neutral (N) position. If the engine startercan be engaged with the gear shift lever in any otherposition, adjust the neutral start switch as described inparagraph 7-17.

Figure 7-8. Modulator Valve Adjustment

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Section IV. TRANSMISSION REPAIR

7-8. REMOVAL, DISASSEMBLY AND CLEANING.

a. Removal.(1) Position tractor over a suitable maintenance

bay.

NOTEThe transmission is normallyremoved by lowering from thevehicle. If a suitable maintenancebay is not available, remove the rearcab guard and other components asnecessary to allow removal of thetransmission from the top of thetractor.

(2) Remove the hydraulic pump and power take-off(PTO) as described in Chapter 17.

(3) Drain transmission fluid and remove dipstick andfill tube as instructed on figure 7-2.

(4) Remove drive shaft as described in Chapter 9.

NOTEMatch mark drive shaft andtransmission output flange foralignment during installation.

(5) Remove retainer nut and output flange fromtransmission output shaft. Discard retainer nut, as aused nut may have lost its self-locking ability.

(6) Refer to paragraph 7-14 and remove shift cableand lever from transmission.

(7) Disconnect modulator cable from modulator (1,figure 7-9).

(8) Disconnect speedometer cable (23) and removespeedometer drive adapter (24) and drive gear (25).

(9) Remove all hoses and fittings from transmission.

CAUTIONIn the following step, reroute thehoses above the transmission asnecessary to prevent the three-strandsling from damaging hoses as thetransmission is lowered from thetractor.

(10) Attach a three-strand sling and 1000 pound hoistto the transmission as shown in figure 7-10. Operate thehoist to take the slack out of the sling.

(11) Remove twelve capscrews (15, figure 7-9) andlock washers (16) securing transmission to flywheelhousing.

(12) Remove eight bolts (27), flat washers (28) andlock nuts (26) securing brackets (29) to cross tieassembly.

(13) Remove hardware securing converter flex plateto engine flywheel.

CAUTIONNothing retains the torque converterto the transmission. Install converterretaining strap prior to shipping orhandling of transmission.

(14) Using the hoist, move the transmission rearwardjust far enough to allow clearance for the converterretaining strap (figure 7-10). Install the converterretaining strap.

(15) Lower transmission from tractor and disconnecthoist from sling.

(16) Tow tractor from maintenance bay.

(17) Remove eight capscrews (30, figure 7-9) andlock washers (31) and remove brackets (29) fromtransmission.

(18) Reattach hoist to three-strand sling and removetransmission from maintenance bay.


Refer to Chapter 8 for transmission disassembly andcleaning.

7-9. REPAIR, REASSEMBLY AND INSTALLATION.

a. Repair and Reassembly.

Refer to Chapter 8 for transmission repair andreassembly.

b. Installation.(1) Install the transmission by reversing the

procedures outlined m paragraph 7-8a.(2) Secure the output flange to the transmission

output shaft with a new retainer nut. Tighten retainer nutwith 600 to 800 ft. lbs. torque.

(3) Check gear shift adjustments as described inparagraph 7-7.

(4) Fill transmission with clean, new fluid asspecified m Operator's Manual and check level asoutlined in paragraph 7-1b.

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1. Modulator2. Street elbow (2)3. Hose end (4)4. Hose5. Swivel adapter (2)6. O-Ring fitting (2)

17. Drain plug18. Dipstick19. Dipstick tube20. Bracket21. Transmission assembly22. Washer

7. Street tee 23. Speedmeter cable8. Reducer bushing 24. Drive adapter9. Temperature sender 25. Drive gear10. Nipple 26. Lock nut (8)11. Tee 27. Hex head bolt (8)12. Reducing bushing 28. Flat washer (8)13. Hose assembly 29. Bracket(2)14. Adapter 30. Capscrew (8)15. Capscrew (12) 31. Lock washer (8)16. Lock washer (12)

Figure 7-9. Transmission Removal

CAUTIONLubricate modulator cable withtransmission fluid only. Use of otherlubricants may contaminatetransmission fluid and damagetransmission.

(5) Lubricate modulator cable with clean, newtransmission fluid as specified m Operator's Manual, andreconnect cable to modulator (1, figure 7-9).

(6) Inspect transmission as outlined in paragraph7-4a.

(7) Test transmission for proper operation asdescribed in paragraph 7-4b.

Section V. EXTERNAL OIL FILTER

7-10. REMOVAL, DISASSEMBLY AND CLEANING.

a. Removal.

(1) Disconnect hoses (3, figure 7-11), elbow (5) andadapter (6).

(2) Remove four hex nuts (8), lock washers (9) andcapscrews (7); then remove oil filter (1) from bracket (2).

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Figure 7-10. Transmission Sling and Retaining Strap


Disassemble and clean oil filter as described inparagraph 7-2c.

1. Oil Filter2. Bracket3. Hose (2)4. Fitting (4)

5. Elbow6. Adapter7. Capscrew (4)8. Hex nut (4)9. Lock washer (4)

7-11. INSPECTION, REPAIR, REASSEMBLY ANDINSTALLATION.

a. Inspection, Repair and Reassembly.

Inspect, repair and reassemble the oil filter as outlined inparagraph 7-2c.

b. Installation.(1) Secure oil filter (1, figure 7-11) to bracket (2)

with four capscrews (7), lock washers (9) and hex nuts(8).

(2) Install elbow (5), adapter (6) and hoses (3).

(3) Check transmission oil level as describedparagraph 7-1b.

Section VI. SHIFT LOCK

7-12. REMOVAL AND DISASSEMBLY.a. Removal.

WARNINGRelieve all pressure from the tractorair system before proceeding.

(1) Disconnect tubing (4, figure 7-12), sleeve (3)and elbow (5) from air cylinder (9).

Figure 7-11. External Oil Filter Removal

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(2) Remove two hex nuts (16), pin (15), washer (17)and adapter (10).

(3) Remove two retainer rings (13) and rod block(12) from levers (14).

(4) Remove two capscrews (7) and lock washers(6), and remove air cylinder (9) from bracket (8).

b. Disassembly.

(1) Remove tube sleeves (2 and 3) and tee (1) fromrear brake supply lines.

(2) Remove retainer rings, pins and 7/16 inch O.D.bushings from levers (14) and remove levers from aircylinder (9).


a. Cleaning.

Cap the inlet of the air cylinder to prevent contamination;then clean all parts by washing with cleaning solvent.Dry clean parts with compressed air at approximately 40psig.


(1) Inspect hardware and threaded openings fordamaged threads. Chase damaged threads with thecorrect size tap or die. Replace damaged hardware.

(2) Inspect all metal parts for corrosion, cracks,burrs, breaks, distortion or other damage. Inspectcontact areas of pin and levers for scoring or wear.Replace all damaged parts.

1. Tee 7. Capscrew(2) 13. Retainer ring (2)2. Tube sleeve (2) 8. Bracket 14. Lever (2)3. Tube sleeve (2) 9. Air cylinder 15. Pin4. Tubing 10. Adapter 16. Hex nut (2)5. Elbow 11. Spacer 17. Flat washer6. Lock washer (2) 12. Rod block 18. Lever

Figure 7-12. Shift Lock Removal

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(3) Clean bushings by washing with volatile mineralspirits. Inspect bushings for evidence of extreme wearor damage. Check for looseness of bushings or roughbushing operation. If a bushing is damaged, replace theair cylinder assembly.

(4) Examine sealing surface on air cylinder shaft forexcessive wear and scratches or gouges. Replace adamaged air cylinder.


a. Reassembly.

(1) Remove retainer rings, pins and 7/16 inch O.D.bushings from lever supplied with replacement aircylinder. Install bushings into levers (14, figure 7-12).

(2) Reconnect levers (14) to air cylinder (9).(3) Install tube sleeves (2 and 3) and tee (1) into

rear brake supply lines.

b. Installation.

(1) Refer to figure 7-13 for proper air cylinderlocation, and install air cylinder on bracket (8, figure7-12) using two capscrews (7) and lock washers (6).

(2) Install rod block (12) and retainer rings (13) onlevers (14).

(3) Install adapter (10), washer (17), pin (15) andtwo hex nuts (16).

Figure 7-13. Shift Lock Cylinder Location

(4) Install elbow (5), sleeve (3) and tubing (4) on aircylinder (9).

(5) Start tractor engine and allow air compressor tocharge air system; then stop engine.

(6) Check extended and retracted positions of pin(15) by depressing brake treadle and referring to (figure7-12). If necessary, loosen hex nuts at pin and aircylinder shaft and adjust for proper extended andretracted position.

CAUTIONBe sure tractor is stationary beforeproceeding. Improper adjustmentmay allow gear shift to be placed inreverse position, and truck motionmay damage transmission.

(7) With foot off brake treadle, verify properadjustment by attempting to place gear shift lever inreverse position. Lever should be locked out, andtransmission should not be in reverse range. Depressbrake treadle, and observe that gear shift lever may beplaced into and out of reverse position.

Section VII. GEAR SHIFT


a. Removal.(1) Remove eight capscrews (37, figure 7-14) and

flat washers (38). Lift the shifter panel (36) as requiredfor access to components.

(2) Tag and disconnect electrical leads from neutralstart switch (32).

(3) Remove lock nut (7) and hex nuts, lock washersand clamp securing gear shift cable (11) to adapter plate(18); then lower gear shift cable from gear shift control.

(4) Remove two capscrews (25) securing gear shiftcontrol to fifth wheel control, and remove gear shiftcontrol from tractor.

(5) Remove cotter pin (24), hex nuts (16), lockwashers (4) and clamp (5); then remove gear shift cablefrom tractor.

NOTEDo not allow the transmission levershaft to move too far inside thetransmission housing. If the shaftloses index location with itscorresponding valve inside thetransmission housing, the oil panmust be removed to reposition theshaft. To avoid this possibility, thefollowing steps should be followedclosely.

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1. Reflector (2) 20. Shim2. Pigtail assembly 21. Screw (2)3. Shaft 22. Screw (4)4. Lock washer (2) 23. Screw5. Clamp 24. Cotter pin6. Knob assembly 25. Capscrew(2)7. Lock nut 26. Set screw (2)8. Trunnion (2) 27. Lock nut9. O-ring (2) 28. Hex nut (2)10. Selector lever 29. Bulb11. Gear shift cable 30. Actuator arm12. Light pipe 31. Support13. Gate plate 32. Neutral start switch14. Position strip 33. Capscrew (2)15. Bracket 34. Lock washer (2)16. Hex nut (2) 35. Lock nut (2)17. Housing 36. Shifter panel18. Adapter plate 37. Capscrew (8)19. Lever assembly 38. Flat washer (8)

Figure 7-14. Gear Shift Control, Removal and Disassembly

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(6) Move transmission selector lever (10) clockwiseto last detent position, then counterclockwise to thirddetent position.

CAUTIONDo not use the mechanical stopinside the transmission for removalof lock nut. The stop is used formaking a calibrated adjustment andcould be damaged or altered. Holdthe lever when removing the lock nut.

(7) Loosen the selector lever lock nut (27)approximately 1/8 inch and tap lightly with a plastichammer to loosen the selector lever (10).

(8) Remove the lock nut (27) and selector lever(10).

b. Disassembly.

(1) Remove two lock nuts (35, figure 7-14), O-rings(9) and actuator arm (30).

(2) Remove hex nut (28) and neutral start switch(32).

(3) Remove two capscrews (33) and lock washers(34); then remove support (31) from adapter plate (18).

(4) Remove two set screws (26), and remove knobassembly (6) from lever assembly (19).

(5) Remove six screws (21 and 22), light pipe (12),two reflectors (1) and gate plate (13).

(6) If necessary for replacement, remove screw (23)and shaft (3) from housing (17), then remove leverassembly (19).


a. Cleaning.

Clean all parts, except neutral start switch, by washingwith cleaning solvent. Dry clean parts with compressedair at approximately 40 psig. Clean neutral start switchby wiping with a clean cloth.


(1) Inspect all parts for wear, cracks or other visualdamage.

(2) Inspect gear shift cable for sharp bends orbroken condition. Replace as necessary.



a. Reassembly.

Reassemble gear shift control in reverse of proceduresoutlined in paragraph 7-15b.

b. Installation.

(1) Hold the transmission selector shaft with a pairof pliers. Be sure the jaws contact the flats of the shaftand not the threaded area.

(2) With the selector shaft in the third detentposition (paragraph 7-15a, step 6), slide the selectorlever (10) onto its shaft and start the lock nut (27).

NOTEBe careful not to cross-thread. Thiscan easily occur on a threaded shankwith flats.

(3) Grasp lever at the end and pull out (away fromtransmission). Keep tension on end of lever until locknut is fully installed. Holding lever in detent position,tighten the lock nut with 14 to 17 ft. lbs torque.

(4) Install the remaining gear shift controlcomponents in reverse of removal procedures outlined inparagraph 7-15a.

(5) Loosen hex nuts (28) and position neutral startswitch (32) on support (31) so that switch actuates inneutral (N) position; then tighten hex nuts (28). Operategear shift lever and check that neutral start switchactuates in neutral position only.

(6) Remove lock nut (7) and check that trunnion (8)moves freely in lever assembly (19) at each gear shiftlever position. If necessary, turn trunnion up or down ongear shift cable shaft; then install trunnion in correctlever assembly hole and secure with lock nut. Checkand adjust gear shift cable at transmission end in asimilar manner by removing cotter pin (24).

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CHAPTER 8

TRANSMISSION OVERHAUL


8-1. INTRODUCTION.

This chapter contains a basic description of theautomatic transmission as well as repair, adjustment andoverhaul procedures.


a. Speeds.

The transmission provides five forward speeds and onereverse speed. Shifting, within any of the forward driveranges selected by the operator, is fully automatic. Thetransmission provides the following speed ranges:NEUTRAL (N) No vehicle movement.

• DRIVE (D) - This range is the most commonly usedforward range. It includes four gears (2-3-4-5). Thevehicle will automatically start in second gear andthe transmission will automatically upshift atpredetermined speeds and throttle position throughthird, fourth and into fifth gear. Downshifts will alsooccur automatically in relation to vehicle speed andthrottle position.

• DRIVE 3 (D3) - This range includes three gears (2-3-4). The vehicle will automatically start in secondgear and the transmission will automatically upshiftat predetermined speed and throttle position throughthird gear and into fourth gear. Downshifts will alsooccur automatically from fourth through third, tosecond gear.

• DRIVE 2 (D2) - In this range, the vehicle will start insecond gear and the transmission will not upshiftinto a higher gear.

• DRIVE 1 (D1) - In this range, the transmission willoperate in first gear only.

• REVERSE (R) - This range provides one gear forreverse operation of the vehicle.

b. Torque Converter.

A simple three-element torque converter transmits powerfrom the engine crankshaft to the transmission gearing.

The torque converter serves both as a fluid coupling anda torque multiplier.

c. Lockup Clutch.

The lockup clutch located within the torque converterlocks the converter input and output elements togetherat a predetermined vehicle speed. When this speed isattained, hydraulic pressure automatically applies theclutch. Closed throttle downshifting will hold lockupengagement until shortly before the 3-2 shift. With thelockup clutch applied, the engine output is directed to thetransmission input at a 1:1 speed ratio.

d. Planetary Gearing.

The gearing provides ratios for five forward speedsthrough the use of four planetary gearing arrangements.The planetary gears are controlled by associatedhydraulically applied clutches. All gearing is in constantmesh.


Specifications and data for the transmission arepresented in Table 8-1.

NOTEUniform designations are used forclutches and planetary gear sets.The five clutches are designated(starting from the front end of thetransmission) as Forward, Fourth,Third, Second, First, and Low. Thefour planetary gear sets aredesignated (starting from the front ofthe transmission) as Front, Center,Rear, and Low.

Section II. TROUBLESHOOTING ANDADJUSTMENTS

8-4. TROUBLESHOOTING.

a. Troubleshooting Chart.

Refer to Chapter 7, Table 7-3, for the transmissiontroubleshooting chart.

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Table 8-1. Transmission Specifications and Data

Transmission Manufacturer Allison Division of General MotorsModel No. MT653

RatingInput Torque (foot pounds) 480Input Speed, Max. (rpm) 4000Input Horsepower (Actual installed, 250

SAE 500 ft., 85°F) (maximum)Drive (Input) FlexdiskRotation (Viewed from input)

Input ClockwiseOutput (in forward ranges) Clockwise

Torque ConverterType Single stage, polyphase, 3-elementModel TC370Torque Multiplication Ratio at Stall 2.4:1

Drive Ranges and Sequence (Forward)Drive 1 (D1) First Gear OnlyDrive 2 (D2) Second Gear OnlyDrive 3 (D3) Second-to-Third-to Fourth GearsDrive (D) Second-to-Third-to-Fourth-to-Fifth Gears

Shift Mechanism Hydraulic clutches controlled

Shift Modulation Mechanical

ClutchesCooling OilActuation Hydraulically Applied, Spring Released

Gearing Type Straight Cut Spur, Constant Mesh

Oil Requirements and DataCapacity (U.S. Gallons) 4 (Approximately)Type Dexron® II

Temperature (max)Converter out to cooler 300°FSump 250°F

Pressure (Main, in forward drive range, vehicle brakes applied)psig minimum at idle 600 rpm 125*psig at 1200 rpm 165-190

Lubrication Pressure (psig at 2000 rpm) 23-30Converter out pressure (psig at 2000 rpm) 32-52Governor (psig)

1500 rpm Output Shaft Speed2400 to 2600 Input Speed 74 to 822800 54 to 583000 54 to 58

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Table 8-1. Transmission Specifications and Data (Continued)

2200 rpm Output Shaft Speed3200 to 3400 Input Speed 82 to 913600 to 4000 Input Speed 59 to 65

Dry Weight (pounds) 540

Gear Ratios (Input: Output)First Gear 8.04:1Second Gear 3.58:1Third Gear 2.09:1Fourth Gear 1.39:1Fifth Gear 1.00:1Reverse Gear 5.67:1

Clutch Application (See Note above)

Neutral FirstFirst Gear Forward and LowSecond Gear Forward and FirstThird Gear Forward and SecondFourth Gear Forward and ThirdFifth Gear Forward and FourthReverse Fourth and First

®Dexron is a registered trademark of General Motors.*WARNING: Perform in-vehicle transmission tests in accordance with procedures outlined in Chapter 7.

b. Test Stand.When the cause of malfunction of a transmission is notdetermined by test, inspections, and the troubleshootingchart before removal of the transmission from the tractor,the transmission may be mounted in a test stand (Ifavailable) and checked.

8-5. SHIFT SPEED ADJUSTMENTS.

a. Introduction.

Shift speeds may be checked and adjusted using theroad test method described in Chapter 7. The shiftspeeds are adjusted by changing the position ofadjusting rings that determine the applied force ofsprings against their associated shift valves. Adjustingtool J24314 is used to depress and rotate the adjustingrings. Clockwise rotation increases spring force andraises the shift speed; counterclockwise rotation has theopposite effect.

b. Calibration by Test Stand Method.

NOTETransmission shift speeds cannot beadjusted properly unless the correctgovernor assembly is installed in thetransmission. Check the two-digitcode on the head of the governorwith the code shown in the separateRepair Parts Manual. If the letter "M"follows the two-digit code, thegovernor is a service replacementassembly. Absence of the "M"indicates an originally installedgovernor assembly.

(1) Shift speeds may be adjusted on a test standafter the transmission has been overhauled. Test standequipment may differ from one overhaul facility toanother. Some facilities may have a test stand on whichthe control valve and governor can be calibrated beforeinstallation in the transmission housing. If test standequipment is not available, shift speeds should beadjusted using the road test method described inChapter 7.

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(2) Table 8-2 provides detailed information requiredfor adjusting shift speeds using the test stand method.The actual adjustment procedures are the same asoutlined in Chapter 7 for calibration by the road testmethod; however, the base for checks and adjustmentsis output shaft speed instead of engine speed.

Section III. REMOVAL AND DISASSEMBLY OFEXTERNAL PARTS AND MAJOR PARTS GROUPS

WARNINGBefore handling transmission afterremoval from vehicle, attach 6837993converter retaining strap to front ofhousing with two screws and nuts asshown in figure 8-1 to prevent torqueconverter from sliding off frontsupport assembly, with possiblebodily injury and damage toconverter resulting.

NOTEBefore starting to disassembletransmission, plug all openings tothe interior and thoroughly steamclean all exterior surfaces.

NOTETo facilitate disassembly andreassembly of transmission, removepower take off cover, if used, fromright side of housing and attachJ23642 holding fixture and J24462-1holding plate to housing with 3/8-16

hex head bolts and 3/8 flat washersas shown in figure 8-1. Then using athree-strand sling and hoist to lifttransmission, insert shaft of holdingfixture into J3289-20 holding fixturebase -that has been securely boltedto top of a sturdy workbench. Use ofthe fixtures will facilitate positioningthe axis of transmission atconvenient angles for disassemblyand reassembly.

NOTEIf oil has not been drained, be sure todrain transmission before startingdisassembly procedure. To drain,remove plug from lower right comerof transmission oil pan. Dispose (donot reuse) oil drained fromtransmission. Replace plug in oil panafter draining.

8-6. REMOVAL OF EXTERNAL PARTS AND MAJORPARTS GROUPS.

a. Removing Torque Converter.

(1) Position transmission with axis vertical and input(torque converter) end upward.

(2) Remove converter shipping bracket (used onlyto restrain torque converter during handling, shipping,and storage).

Table 8-2. Output Shaft Speeds at Shift Points

Transmission Throttle Shift Output Shaft RPMRange Setting at Start of ShiftDrive 5 Full open 1-2 640- 700

(0" Hg) 3-4 1110-12504C4LU 1360-1615

4-5 1870-2010

Closed 5-4 700-1240(19-21" Hg) 4-3 525- 735

3-2 20- 245Drive 4 Full open 5-4 2095-2380

(0" Hg)

Drive 3 Full open 4-3 1445-1705(0" Hg)

Drive 2 Full open 3-2 745- 975(0" Hg)

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Figure 8-1. Preparing Transmission for Disassembly

(3) Attach J7695-01 converter assembly lifter to torqueconverter with two nuts as shown in figure 8-2.

(4) Use a hoist attached to ring in converter assemblylifter to lift torque converter straight upward out of transmissionhousing.

b. Removing Modulator Retainer.

Take out screw (33, figure 8-3) and withdraw modulatorretainer (34) from transmission housing (11).

c. Removing Oil Pan, Oil Filter, and Oil Tubes.

(1) Remove screws (30, figure 8-3), and withdraw oil pan(29) from transmission housing (11). Remove gasket (24) fromoil pan or from housing. Discard gasket.

(2) Remove screw (26), and withdraw oil filter (23) fromtransmission housing (11). Then remove tube (25) from filteror housing (11). Remove seal ring (22) from tube. Discardseal ring and oil filter.

(3) Remove bolts (17, 18, and 20), as required, securingoil tubes (79, 80, and 81, figure 8-4). Then carefully withdrawoil tubes from bodies of valves.

Figure 8-2. Removing Torque Converter

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1. Vent assembly2. Gasket3. Cover4. Bolt (6)5. Bolt (2)6. Adapter7. Gasket8. Seal ring9. Lube valve

10. Spring11. Housing12. Tube13. Plug14. Drive screw 19. Roller and spring assembly15. Nameplate 20. Bolt(18)16. Bolt(7) 21. Bolt (4)17. Bolt (2) 22. Seal ring18. Bolt 23. Oil filter

24. Gasket25. Tube26. Screw27. Plug28. Washer29. Oil pan

32. Nut 30. Screw(21)33. Bolt 31. Lever34. Retainer35. Bolt36. Washer37. Ball38. Pin39. Plug (2)40. Washer41. Plug42. Seal43. Shaft44. Nut45. Plug

Figure 8-3. Transmission Housing, Oil Filter and Oil Pan Group

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1. Pin2. Spring3. Valve4. Valve5. Spring6. Pin7. Washer8. Ring9. Valve

10. Pin11. Valve

55. Plug12. Valve 56. Spring13. Spring 57. Spring14. Stop 39. Valve 58. Stop15. Ring 40. Spring 59. Valve16. Pin 41. Washer 60. Plug17. Valve 42. Pin 61. Spring18. Valve 43. Ring 62. Spring19. Spring 44. Body 63. Stop20. Stop 45. Pin 64. Valve21. Ring 46. Plate 65. Plug22. Pin 47. Ball 66. Spring23. Valve 48. Body 67. Spring24. Valve 49. Valve 68. Stop25. Spring 50. Plug 69. Cover26. Stop 51. Spring 70. Bolt(8)27. Ring 52. Spring 71. Pin(2)28. Pin 53. Stop 71. Valve29. Valve 54. Valve 73. Spring30. Spring 74. Stop31. Stop 75. Valve32. Pin 76. Spring33. Valve 77. Spacer34. Spring 78. Tube(2)35. Stop 79. Tube36. Pin 80. Tube37. Bolt (3) 81. Tube38. Pin

Figure 8-4. Control Valve Group

39. Valve

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d. Removing Modulated Lockup Valve, Low ShiftValve, and Control Valve.

(1) Remove bolts (21, figure 8-3) that securemodulated lockup valve to control valve; then withdrawmodulated lockup valve.

(2) Remove bolts (16) that secure low shift valve tooil transfer plate; then withdraw low shift valve fromtransfer plate.

(3) Remove bolts (17) that secure oil transfer plateto transmission housing (11). Then carefully withdraw oiltransfer plate with two governor tubes (78, figure 84) asan assembly. Separate governor tubes from oil transferplate.

(4) Using a rubber band, secure range selectorvalve of the control valve to a pad on the control valvebody.

(5) Remove bolt (18) that secures detent roller andspring assembly (19) to control valve body, and withdrawdetent roller and spring assembly.

(6) Loosen two bolts (20) at the top of control valveassembly, leaving bolts in place to support control valve.

(7) Remove remaining bolts (20) that secure controlvalve to transmission housing (11).

(8) Hold control valve firmly, and remove two boltsloosened in Step 6 above. Then remove control valve ina downward and outward movement to clear actuator pin(38, figure 8-4) from bore in transmission housing (11,figure 8-3).

NOTEUse care to prevent loss of governorpressure check ball (37).

(9) Remove governor pressure check ball (37) fromrecess in transmission housing (11).

e. Removing Other Parts from TransmissionHousing.

(1) Unscrew breather (1, figure 8-3) with an openedwrench.

(2) Unscrew plugs (13, 39, and 41) fromtransmission housing to facilitate cleaning internalpassages, and remove washer (40) from plug (41).

(3) Remove bolts (5) that secure lubrication valveadapter (6) to transmission housing. Then withdrawlubrication valve adapter. Remove and discard gasket(7).

(4) Remove seal ring (8) from adapter (6). Discardseal rind.

(5) Remove lubrication valve (9) and spring (10)from bore in transmission housing (11).

(6) If necessary for replacement, pull valve guidetube (12) from housing.

(7) Remove shaft retainer pin (38) and nut (32) frommanual selector shaft (43). While holding inside detentlever (31) with one hand, carefully pull manual selectorshaft (43) out of transmission housing (11).

(8) Remove selector shaft seal (42) fromtransmission housing (11), using J26401 shift lever sealremover.

(9) Do not remove name plate (15) fromtransmission housing (11) unless replacement isrequired.

f. Removing Oil Pump and Front Support Assembly.

(1) Remove bolts (28, figure 8-5) and rubber coatedwashers (27) that secure oil pump body (3) and frontsupport (20) to transmission housing.

(2) Attach J24473 front lifter assembly ontoconverter ground sleeve as shown in figure 8-6. Be surefront support lifter assembly is secure before proceeding.

(3) Attach a hoist to front support lifter assembly.

CAUTIONThe oil pump body and front supportare fitted to the transmission housingwith very little clearance. Parts maybind in housing if housing is cold.Heat housing slightly, if necessary,using a sun lamp current of warm air.Do not use a torch or other sourceof' highly concentrated heat. If whenhoisting parts bind after starting toseparate, tap parts back In place andhoist again.

(4) Carefully hoist oil pump body, front support, andconverter ground sleeve with associated parts as anassembly from transmission housing.

(5) Remove gasket (26, figure 8-5) from frontsupport (20) or from transmission housing.

(6) Remove step joint seal rings (25), bearing race(24), and roller bearing assembly (23) from hub of frontsupport (20).

g. Removing Forward Clutch.

(1) Grasp the shaft of turbine shaft and clutchhousing assembly (3, figure 8-7) and lift the forwardclutch group (consisting of turbine, shaft and clutchhousing assembly (3), PTO drive gear (10), fourth clutchdriving hub (23) and associated internal and externalparts) as an assembly from transmission housing.

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TM 9-2320-277-14&P

1. Oil seal2. Seal ring3. Body4. Gear5. Gear6. Snap ring7. Stop8. Spring 15. Bolt (2) 22. Bearing assembly9. Valve 16. Guide 23. Bearing assembly10. Snap ring 17. Spring 24. Race11. Stop 18. Valve 25. Seal ring (2)12. Spring 19. Sleeve 26. Gasket13. Valve 20. Support 27. Washer(12)14. Bolt(2) 21. Plug 28. Bolt (12)

Figure 8-5. Oil Pump and Front Support Group

Figure 8-6. Removing Oil Pump and FrontSupport Assembly

(2) Remove bearing race (27), roller bearingassembly (26), and bearing race (25) from hub offorward clutch hub (20).

h. Removing Fourth Clutch.

(1) Insert fingers of both hands into fourth clutchhousing (12, figure 8-8) and grasp spring retainer (6);then lift fourth clutch housing with internal parts fromtransmission housing.

(2) Remove bearing race (15), bearing (14), andbearing race (13) from hub of fourth clutch housing.

i. Removing Third Clutch.

(1) Remove snap-ring (1, figure 8-9) from internalgroove in transmission housing.

(2) Lift third clutch backing plate (2) and third clutchplates (3 and 4) out of transmission housing.

j. Removing Center Support Group.

(1) Remove snap ring (5) from internal groove intransmission housing.

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TM 9-2320-277-14&P

15. Spring retainer16. Snap ring17-. Bearing race18. Bearing assembly19. Bearing race20. Clutch hub21. Clutch plate (5)22. Clutch plate (5)23. Driving hub24. Snap ring25. Bearing race26. Bearing assembly27. Bearing race

1. Seal ring2. Seal ring (2)3. Housing assembly4. Check ball (2)5. Pin6. Plug7. Spring8. Valve9. Snap ring10. PTO drive gear11. Seal ring12. Seal ring13. Piston14. Spring

Figure 8-7. Forward Clutch and Turbine Shaft Group

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TM 9-2320-277-14&P

1. Snap ring2. Backing plate 9. Seal ring3. Clutch plate (4) 10. Seal ring4. Clutch plate (4) 11. Check ball (4)5. Snap ring 12. Housing6. Spring retainer 13. Bearing race7. Spring 14. Bearing8. Piston 15. Bearing race

Figure 8-8. Fourth Clutch Group

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TM 9-2320-277-14&P

1. Snap ring2. Backing plate3. Clutch plate (3)4. Clutch plate (3)5. Snap ring6. Retainer ring (4)7. Retainer ring8. Spring (20)9. Piston

10. Seal ring11. Seal ring12. Ring (2)13. Bushing

14. Check ball15. Support16. Seal ring17. Seal ring18. Piston19. Spring (20)20. Retainer ring21. Retainer ring (4)22. Snap ring23. Clutch plate (3)24. Clutch plate (3)25. Backing plate

Figure 8-9. Third Clutch, Center Support and Second Clutch Groups

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TM 9-2320-277-14&P

(2) Remove center support bolt (35, figure 8-3) andwasher (36) from transmission housing (11).

(3) Attach J24455 center support lifter in recessbetween step joint rings on hub of center support (15,figure 8-9) as shown in figure 8-10.

Figure 8-10. Removing Center Support Assembly

CAUTIONCenter support is fitted totransmission housing with very littleclearance. Center support may bindduring removal if housing is cold.Heat housing slightly with a sun lampor current of warm air. Do not use atorch or other source of highlyconcentrated heat. If center supportbinds during withdrawal, tap it backinto place and lift again.

(4) Carefully withdraw center support with attachedparts from transmission housing.

k. Removing Gear Unit and Main Shaft Group,Second Clutch, and First Clutch Plates.

(1) Attach J24454 gear unit lifter to main shaft (29,figure 8-11) as shown in figure 8-12.

(2) Attach a hoist to gear unit lifter, and carefullywithdraw main shaft and gear unit from transmissionhousing.

(3) Remove rear thrust washer (40, figure 8-11)from gear unit or from transmission housing.

(4) Remove snap ring (22, figure 8-9) from internalgroove in transmission housing. Then remove secondclutch plates (23 and 24) and backing plate (25) fromtransmission housing.

(5) Remove first clutch ring gear (5, figure 8-13) andhub (6) from transmission housing. Remove snap ring(7) from internal groove in ring gear, and separate ringgear from hub.

(6) Remove snap ring (1) from internal groove intransmission housing. Then withdraw first clutchbacking plate (2) and clutch plates (3 and 4) fromtransmission housing.

l. Removing Governor Assembly.

(1) Rotate transmission housing 180 degrees sothat output shaft is extending upward.

(2) Remove bolts (32, figure 8-14) that securegovernor cover (31) to rear cover (11); then withdrawgovernor cover.

(3) Remove and discard gasket (30).

(4) Withdraw governor assembly (28) from recess inrear cover (11).

m. Removing Rear Cover and Output Shaft.

(1) Remove bolts (22, figure 8-14) and washers (21)securing rear cover (11) to transmission housing.

(2) Attach a lifting tool to output shaft (3).(3) Using a hoist, carefully separate rear cover (11)

with low clutch piston components from adapter housing,leaving adapter housing in place on transmissionhousing.

(4) Withdraw output shaft (3) with attached partsfrom rear cover (11), leaving bearing outer race (12) inrear cover.

(5) Remove gasket (10) from rear cover (11).(6) Remove spacer (8) and speedometer drive gear

(7) from output shaft (3).

n. Removing Low Planetary Components and LowClutch Components.

(1) Lift low clutch ring gear (18, figure 8-15) fromplanetary carrier (13).

(2) Remove thrust washer (15) from internal hub oflow clutch ring gear (18).

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TM 9-2320-277-14&P

1. Thrust washer2. Sun gear3. Thrust washer4. Pin (6)5. Thrust washer (12)6. Thrust washer (12)7. Pinion (set)8. Roller (120) 11. Thrust washer9. Flange and carrier assembly 12. Snap ring

10. Bushing 13 Ring gear14. Pin(4)15. Carrier16. Thrust washer (8)17. Thrust washer (8)18. Pinion (set)19. Roller (72)20. Spring pin (2)

21. Sleeve bushing (2) 35. Thrust washer (8)22. Shaft 36. Roller (72)23. Bearing assembly 27. Ring gear 31. Snap ring 37. Pinion (set)24. Bearing race 28. Plug 32. Bearing assembly 38. Carrier25. Drum 29. Shaft 33. Pin (4) 39. Snap ring26. Snap ring 30. Sun gear 34. Thrust washer (8) 40. Thrust washer

Figure 8-11. Main Shaft and Gear Unit Group

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TM 9-2320-277-14&P

Figure 8-12. Removing Main Shaft and Gear Unit

(3) Lift out low planetary carrier (13) with associatedparts, and remove thrust washer (7) from carrier or fromface of low sun gear (6).

(4) Lift out sun gear (6), and remove thrust washer(5) from sun gear or from recess in adapter housing (3).

(5) Remove clutch plates (16 and 17) from adapterhousing (3).

(6) Separate adapter housing (3) with first clutchpiston components from transmission housing.

(7) Remove gasket (1) from adapter housing (3) orfrom transmission housing.

(8) Remove thrust washer (2) from adapter housing(3).

8-7. DISASSEMBLY OF MAJOR PARTS GROUPS.

a. Checking Converter End Play.

(1) Support converter on the converter cover asshown in figure 8-16A. Place J24470 converter end playgauge assembly into converter pump hub. Hold centerscrew of gauge assembly and tighten until gaugeassembly is secure.

(2) Install a dial indicator as shown in figure 8-16B.Adjust the indicator bracket so stem of indicator is in firmcontact with top of center screw in converter end playgauge assembly. Set dial indicator to read zero.

(3) Using both hands, lift center screw of converterend play gauge assembly as far as possible and notedial indicator reading.

(4) If end play exceeds 0.025 inch, wear ofconverter components is indicated. Disassembleconverter, check parts for wear, and select a-new spacer(18, figure 8-17) as described in paragraph 8-7b below.

(5) If end play is less than 0.025 inch, disassembleconverter for inspection and cleaning of parts.Reassemble with same spacer (18, figure 8-17), exceptwhen major parts must be replaced.

(6) Remove converter end play gauge assemblyfrom converter.

b. Converter Disassembly.

NOTEBefore disassembling converter,check end play as described inparagraph 8-7a to determine wear ofparts.

(1) Place converter on a clean work bench withcover (5, figure 8-17) upward.

(2) Remove spacer retainers (2) and spacers (3)from studs of torque converter cover (5).

(3) Remove nuts (4) from cover (5), then separatecover with internal clutch parts as a unit from lockupclutch backing plate (13) and pump assembly (34).

(4) Place cover (5) with studs downward onworkbench.

(5) Remove bearing race (15) from center hub ofcover (5).

(6) Depress center of piston (9) and remove snapring (14) from groove in hub of cover (5).

(7) Turn cover over and bump on a wooden surfaceto remove piston (9).

(8) Remove seal ring retainer (7) and seal ring (8)from hub of cover (5).

NOTEDo not remove bushing (6) fromcover (5) unless replacement isrequired.

(9) Remove seal ring (10) from groove in piston (9).Discard seal ring.

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TM 9-2320-277-14&P

1. Snap ring2. Backing plate 8. Snap ring3. Clutch plate (6) 9. Spring retainer4. Clutch plate (6) 10. Spring (26)5. Ring gear 11. Piston6. Gear hub 12. Seal ring7. Snap ring 13. Seal ring

Figure 8-13. First Clutch Group

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TM 9-2320-277-14&P

1. Bearing2. Cup plug3. Shaft4. Spring pin5. Bearing6. Gear7. Gear8. Spacer9. Bearing assembly

10. Gasket11. Cover12. Bearing race13. Pin14. Plug15. Plug16. Filter17. O-ring seal18. Plug19. Drain tube20. Plug21. Washer (14)22. Bolt (14)23. Ball bearing24. Snap ring25. Oil seal26. Dust shield27. Nut28. Governor assembly29. Pin (2)30. Gasket31. Cover32. Bolt (4)

Figure 8-14. Governor and Rear Cover Group

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TM 9-2320-277-14&P

1. Gasket 7. Thrust washer2. Thrust washer 8. Pin (6)3. Adapter housing 9. Thrust washer (12)4. Plug 10. Thrust washer (12)5. Thrust washer 11. Pinion (set)6. Sun gear 12. Roller (114)

13. Carrier14. Bushing15. Thrust washer16. Clutch plate (6)17. Clutch plate (5) 21. Spring (26)18. Ring gear 22. Piston19. Snap ring 23. Seal ring20. Spring retainer 24. Seal ring

Figure 8-15. Low Planetary, Low Clutch and Adapter Housing Group

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TM 9-2320-277-14&P

B. CHECKING END PLAY

Figure 8-16. Checking Converter End PlayPrior to Disassembly

(10) Lift clutch plate (I 1) from splines of turbine (19),and remove clutch backing plate (13) from pumpassembly (34).

(11) Remove seal ring (12) from clutch backing plate(13). Discard seal ring.

(12) Remove roller bearing assembly (16), bearingrace (17), and spacer (18) from hub of turbine (19).

(13) Lift turbine (9) out of pump assembly (34).(14) Lift stator assembly (20) with needle roller

bearing assembly (21) and free wheel roller race (22) asa unit from pump assembly (34), placing the unit on workbench with race upward. Remove free wheel roller raceby rotating It clockwise while lifting it out of stator.

(15) Remove rollers (24) and springs (23) from stator(20).

(16) Wash and flush needle roller bearing assembly(21) with cleaning solvent or volatile mineral spirits.Thoroughly dry bearing assembly and lubricate it withtransmission oil. Replace free wheel roller race (22) instator (20) and rotate bearing assembly by pressingupon and rotating free wheel roller race. If no roughnessor binding is detected, bearing assembly need not beremoved from stator.

NOTEDo not mistake dirt or grit in or onparts or roughness or chatter markson free wheel roller race for damagedneedle roller bearing.

(17) If needle roller bearing assembly (21) requiresreplacement, remove it carefully to avoid nickingaluminum bore in stator (20).

(18) Remove needle roller bearing assembly (25)and bearing race (26) from converter pump hub (30).

(19) Remove seal ring (33) from pump assembly(34). Discard seal ring.

(20) Flatten corners of locking strips (29); thenremove bolts (28) securing converter pump hub (30) topump assembly (34), and remove converter pump hubfrom converter pump.

(21) Remove gasket (32) from converter pump hub(30) or from converter pump (34). Discard gasket.

c. Modulated Lockup Valve Disassembly.

(1) Mark spring adjusting ring (6, figure 8-18) toindicate its position in relation to pin (2).

(2) Depress spring adjusting ring (6) against force ofspring (4), and remove pin (2) from valve body (1).

(3) Remove spring adjusting ring (6), stop (5),spring (4), and valve (3) from valve body (1).

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TM 9-2320-277-14&P

1. Disk nut (6)2. Retainer (6)3. Spacer(6)4. Lock nut (24)5. Cover assembly6. Bushing7. Retainer8. Seal ring9. Piston

10. Seal ring11. Clutch plate12. Seal ring13. Backing plate14. Snap ring15. Bearing race16. Bearing assembly17. Bearing race18. Spacer19. Turbine20. Stator assembly21. Bearing assembly 29. Locking strip (4)22. Roller race 30. Pump hub23. Spring (10) 31. Shipping bracket24. Roller(10) 32. Gasket25. Bearing assembly 33. Seal ring26. Bearing race 34. Pump assembly27. Bolt (24)28. Bolt (8)

Figure 8-17. Converter Cover and Torque Converter Group

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TM 9-2320-277-14&P

1. Valve body2. Pin3. Valve4. Spring5. Stop6. Adjusting ring

Figure 8-18. Modulated Lockup valve

d. Low Shift Valve Disassembly.

(1) Mark location of spring adjusting ring (13, figure8-19) with respect to pin (5). Depress spring adjustingring against force of spring (10), and remove pin (5) fromvalve body (3).

(2) Remove washer (12), valve stop (11), spring(10), and low shift signal valve (9) from valve body (3).

(3) Depress valve stop (8) against force of spring(7), and remove pin (4) from valve body (3). Thenremove valve stop, spring, and low shift relay valve (6)from valve body.

e. Control Valve Disassembly.

CAUTIONThe control valve contains a numberof springs, some of which are similarin appearance and can be mistakenlyInterchanged. If springs are notreinstalled in the locations fromwhich they were removed, calibrationof the valve will be lost and the valvewill not function properly. Atremoval, tag each spring with theitem number shown in figure 8-4 tosimplify correct reinstallation.

(1) Place control valve assembly on work benchwith modulator valve (44, figure 8-4) upward.

1. Plate2. Plate3. Valve body4. Pin5. Pin6. Valve7. Spring

8. Valve stop9. Valve

10. Spring11. Stop12. Washer13. Ring

Figure 8-19. Low Shift Valve

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TM 9-2320-277-14&P

(2) Remove bolts (37) from modulator valve body(44), and withdraw modulator valve from separator plate(46).

NOTEDuring disassembly, mark thepositions of spring adjusting rings (8,15, 21, 27, and 43) with respect topins (10, 16, 22, 28, and 45) beforeremoving pins. If the valve isreassembled with same springs, andadjusting rings are installed inoriginal positions, original calibrationwill be maintained.

(3) Depress spring adjusting ring (43) against forceof spring (40), and withdraw pin (45) from modulatorvalve body (44). Then remove spring adjusting ring,valve stop pin (42), washer (41), spring (40), modulatorvalve (39), and actuator pin (38) from modulator valvebody.

(4) Remove separator plate (46) from control valvebody (48).

(5) Remove priority valve (3), spring (2), and stop (I)from control valve body (48).

(6) Carefully note location of check ball (47) incontrol valve body (48); then remove check ball.

(7) Turn control valve body over so that flat surfaceis resting on work bench.

NOTETrimmer valve cover (69) is springloaded and must be restrained whilebolts (70) are being removed.

(8) Remove bolts (70) securing trimmer valve cover(69) to control valve body (48). Then remove cover andtake out valve stops (53, 58, 63, and 68).

(9) Remove springs (51, 52, 56, 57, 61, 62, 66, and67) from bores in control valve body (48).

(10) Remove trimmer plugs (50, 55, 60, and 65) andthird clutch trimmer valve (49), first clutch trimmer valve(54), second clutch trimmer valve (59) and fourth clutchtrimmer valve (64) from respective bores in control valvebody (48).

(11) Depress valve stop (74) against force of spring(73); then withdraw associated retainer pin (71). Thenremove valve stop, spring (73), and 34 relay valve (72)from bore in control valve body (48).

(12) Depress spacer (77) against force of spring (76),and withdraw associated retainer pin (71) from controlvalve body (48). Then remove spacer, spring (76), and2-3 relay valve (75) from control valve body.

(13) Depress spring adjusting ring (8) against force ofspring (5) and withdraw retainer pin (10) from controlvalve body (48). Then remove spring adjusting ring (8),washer (7), valve stop pin (6), spring (5), and holdregulator valve (4) from bore of control valve body.

(14) Remove range selector valve (9) from controlvalve body (48).

(15) Successively compress spring adjusting rings(15, 21, and 27) against force of springs (13, 19, and 25)respectively; and remove retainer pins (16, 22, and 28)from valve body (48). Then remove spring adjustingrings, valve stop pins (14, 20, and 26); springs (13, 19,and 25); 1-2 modulator valve (12); 1-2 shift valve (11); 3-4 modulator valve (18); 34 shift valve (17); 4-5 modulatorvalve (24); and 4-5 shift valve (23) from control valvebody (48).

(16) Compress relay valve stop (31) against force ofspring (30), and remove retainer pin (32) from valvebody (48). Then remove relay valve stop, spring (30),and 4-5 relay valve (29) from control valve body.

(17) Depress trimmer regulator valve stop (35)against the force of spring (34), and remove retainer pin(36) from control valve body (48) Then remove valvestop, spring, and trimmer regulator valve (33) fromcontrol valve body.

f. Oil Pump and Front Support Disassembly.

(1) Place oil pump and front support assembly onwork bench with converter ground sleeve (19, figure 8-5)upward.

(2) If not previously removed, remove step joint sealrings (25), roller bearing assembly (23), and bearingrace (24) from hub of front support (20).

(3) Remove seal ring (2) from oil pump body (3).Discard seal ring.

(4) Remove needle bearing assembly (22) fromconverter ground sleeve (19) only if replacement isrequired.

(5) Attach J24459 main regulator and lockup valvespring compressor to front support as shown in figure 8-20. Tighten the compressor screws to remove all springforce from snap rings. Remove both snap rings (6 and10, figure 8-5).

NOTEMain pressure regulator valve spring(8) is under approximately 65 poundscompression.

(6) Carefully loosen screws in compressor untilcompressor can be removed from front support(figure 8-20).

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TM 9-2320-277-14&P

Figure 8-20. Removing Valve Retaining Snap Ringsfrom Front Support

(7) Remove valve stops (7 and 11, figure 8-5), valvesprings (8 and 12), main pressure regulator valve (9),and lockup valve (12) from bores in front support (20).

(8) Attach J24412-2 valve pin remover tool ontohead of converter pressure regulator valve guide pin (16)as shown in figure 8-21. Attach J6125-2 slide hammerassembly to valve pin remover tool, and remove guidepin. Also remove spring (17, figure 8-5) and converterpressure regulator valve (18) from bore in front support(20).

Figure 8-21. Removing Converter Pressure RegulatorValve Guide Pin

(9) Remove bolts (14 and 15) which secure frontsupport (20) to oil pump body (3) ; then separate frontsupport from oil pump body.

(10) Do not remove converter ground sleeve (19)from front support (20).

(11) Remove plug (21) from front support (20) only ifreplacement is required.

(12) Remove oil pump gears (4 and 5) from oil pumpbody (3).

(13) Remove oil seal (1) from oil pump body (3).Discard oil seal.

g. Forward Clutch and Turbine ShaftDisassembly.

(1) Remove hook-type seal rings (2, figure 8-7) fromhousing assembly (3).

(2) Compress snap ring (9) located inside PTOdrive gear (10), then slide PTO drive gear off of housingassembly (3).

NOTETo compress snap ring, first locatethe snap ring gap. At the cutoutnearest the gap, press snap ring intogroove in housing and insert a pieceof shim stock (3/32 X 0.020 X 3inches) between snap ring and PTOgear. 'Repeat the operation on theother side of the gap. Workingaround the gear, at each openingcompress the snap ring and insertpieces of shim stock atapproximately 3-inch intervals.

(3) Remove snap ring (9) from PTO drive gear (10).(4) Remove snap ring (24) from interval groove in

housing assembly (3) ; then remove fourth clutch hub(23) and forward clutch hub (20) from housing assembly(3).

(5) Remove bearing race (17), bearing assembly(18) and bearing race (19) from forward clutch hub (20)or from inside housing assembly (3).

(6) Remove clutch plates (21 and 22) from housingassembly (3).

(7) Place housing assembly (3) in a press withJ6438-01 forward and fourth clutch spring compressoras shown m figure 8-22. Depress spring retainer andremove snap ring (16, figure 8-7). Remove springcompressor, and remove housing assembly from press.

(8) Remove spring retainer (15), spring (14), andpiston (13) from housing assembly (3).

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TM 9-2320-277-14&P

Figure 8-22. Removing Forward Clutch Spring RetainerSnapring

(9) Remove seal ring (12) from piston (13), andremove seal ring (11) from housing assembly (3).Discard seal rings.

(10) Remove balls (4) from housing assembly (3)only if replacement is required. To remove balls, clearbores of staked metal, allowing balls to fall out.

(11) Remove pin (5) from housing assembly (3) ;then remove valve plug (6), valve spring (7), andcentrifugal valve (8) from bore in housing assembly (3).

h. Fourth Clutch Disassembly.

(1) Using J6438-01 forward and fourth clutch springcompressor and J24204-2 clutch spring compressorapplied to fourth clutch assembly as shown in figure 8-23, depress spring retainer (6, figure 8-8) and removesnap ring (5) from internal hub of clutch housing (12).

(2) Remove spring compressors; then removespring retainer (6) and spring (7) from clutch housing(12).

(3) Remove snap ring (1) from internal groove inclutch housing (12) ; then withdraw backing plate (2)from clutch housing (12).

(4) Remove clutch plates (3 and 4), and piston (8)from clutch housing (12).

(5) Remove seal ring (9) from piston (8), andremove seal ring (10) from clutch housing (12). Discardseal rings.

Figure 8-23. Removing Fourth Clutch Spring RetainerSnapring

(6) Remove balls (11) from clutch housing (12) onlyIf replacement is required. To remove balls, clear stakedmetal from bores in housing, allowing balls to fall out.

i. Center Support and Second ClutchDisassembly.

(1) Place center support vertically upright on workbench, and remove pistons (9 and 18, figure 8-9) withattached parts.

(2) Remove inner seal ring (10) and outer seal ring(11) from piston (9), and remove inner seal ring (17) andouter seal ring (16) from piston (18). Discard all sealrings.

(3) If parts replacement is necessary, cut self-locking retainer rings (6 and 21) from projections onpistons (9 and 18). Then remove spring retaining rings(7 and 20) and springs (8 and 19) from pistons (9 and18).

(4) Remove step joint seal rings (12) from hub ofcenter support (15). Discard seal rings.

(5) Do not remove bushing (13) from center support(15) unless replacement is required.

j. Gear Unit and Main Shaft Disassembly.

(1) Remove thrust washer (1, figure 8-11) from frontsun gear (2), and remove front sun gear from center sungear shaft (22). Remove thrust washer (3) from frontsun gear or from center sun gear shaft.

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TM 9-2320-277-14&P

(2) Lift front planetary flange and carrier assembly(9) from drum (25). Remove thrust washer (11) fromcenter planetary carrier (15).

NOTEIf front carrier assembly fails to meetinspection requirements specified inparagraph 8-9l, disassemble the unitas described in Steps 3 through 6below.

(3) Using a drill bit that is slightly smaller thandiameter of pinion pin (4), drill into swaged end of pins atone end only, being careful not to drill into flange andcarrier (9).

(4) Place J25587-1 press fixture in an hydraulicpress. Assemble J25587-16 pin remover into pressfixture shaft and tighten setscrew. Place flange andcarrier (9) on press fixture plate, flat side down.

(5) Apply sufficient force (approximately one ton) topress fixture shaft to push pinion pins (4) one at a timefrom flange and carrier (9).

(6) Remove pinions (7), thrust washers (5), pinionthrust washers (6), and rollers (8) from each pinionlocation.

(7) Remove center sun gear shaft (22) from centercarrier (15).

(8) Remove sleeve bushings (21) and spring pin(20) from center sun gear shaft (22) only if replacementis required.

(9) Remove bearing assembly (23) and bearingrace (24) from center sun gear shaft (22) or from rearcarrier (38).

(10) Remove snap ring (12) from internal groove indrum (25), then withdraw ring gear (13) from drum.

(11) Lift center planetary carrier (15) out of drum(25).

NOTEIf center carrier unit fails to meetinspection requirements specified inparagraph 8-9l, disassemble the unitas described in steps 12 through 15below.

(12) Using a drill bit that is slightly smaller thandiameter of pinion pins (14), drill into swaged end onpins (one end only required). Be careful not to drill intocarrier (15).

(13) Place J25587-1 press fixture in an hydraulicpress. Assemble J25587-16 pin remover into pressfixture shaft and tighten setscrew.

(14) Place carrier (15) flat side down on press fixtureplate, and apply sufficient force to each pinion pin (14) topress pin from carrier.

(15) Remove pinions (18), rollers (19), thrustwashers (16), and pinion thrust washers (17) from carrier(15).

(16) Remove main shaft (29) with center planetaryring gear (27) and rear planetary sun gear (30) fromdrum (25).

(17) Remove snap ring (31) from groove in mainshaft (29), and remove main shaft from sun gear (30)and center planetary ring gear (27)

(18) Remove lube orifice plug (28) from main shaft(29) only if replacement is required.

(19) Remove snap ring (26) from groove in sun gear(30), then separate sun gear from ring gear (27).

(20) Remove snap ring (39) from internal groove indrum (25) ; then withdraw rear planetary carrier (38)from drum.

NOTEIf rear planetary carrier falls to meetinspection requirements specified inparagraph 8-9l, disassemble the unitas described in steps 21 through 25below.

(21) Using a drill bit slightly smaller than the diameterof pinion pins (33), drill into swaged end of each pin atone end only. Be careful not to drill into carrier (38).

(22) Using J25587-2 adapter and J25587-6 spacer,place J25587-1 press fixture in an hydraulic press.Assemble J25587-16 pin remover into press fixture shaftand tighten setscrew.

(23) Place carrier (38) flat side downward on pressfixture plate.

(24) Apply sufficient force (approximately one ton) topress pinion pins (33), one at a time, from carrier (38).

(25) Remove pinions (37), rollers (36) thrust washers(34), and pinion thrust washers (35) from carrier (38).

k. Output Shaft Disassembly.

(1) Place output shaft (3, figure 8-13) in a press withsmall end of shaft upward.

(2) Install J22912-01 output shaft front bearing innerrace remover so that flat side of puller plates makescontact with forward edge of teeth on governor drivegear (6).

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TM 9-2320-277-14&P

(3) Force shaft (3) downward with press until springpin (4) clears slot and is free in "V" portion of governordrive gear (6) ; then remove spring pin and governordrive gear.

(4) Remove race remover, and remove output shaftfrom press.

(5) Remove roller bearing (5) from output shaft (3),using J22912-01 output shaft front bearing inner raceremover with press if bearing resists removal.

(6) Remove needle roller bearing (1) and cup plug(2) from output shaft (3) only if replacement is required.

l. Rear Cover Disassembly.

(1) Place rear cover (11, figure 8-14) on workbench, front side down.

(2) Using J24171 output shaft seal and dust shieldremover as shown in figure 8-24, remove dust shield(26, figure 8-14) and the oil seal (25) from rear cover(11).

Figure 8-24. Removing Dust Shield and Oil Seal fromRear Cover

(3) Remove snap ring (24) from internal groove inrear cover (11), then remove ball bearing (23) frombearing recess in rear cover.

(4) Turn rear cover (11) over (front side up).(5) Place J24452 spring compressor on spring

retainer (20, figure 8-15) as shown in figure 8-25 andinstall J24204-2 clutch spring compressor base.Compress spring retainer, and remove snap ring (19,figure 8-15) from groove in hub of rear cover (11, figure8-14).

Figure 8-25. Removing Spring Retainer Snapring

(6) Remove spring compressor and base from rearcover (11).

(7) Remove spring retainer (20, figure 8-15), springs(21), and piston (22) from rear cover (11, figure 8-14).

(8) Remove seal rings (23 and 24, figure8-15) from grooves in piston (22). Discard seal rings.

(9) Remove plugs (14 and 15, figure 8.14), plug(18), O-ring seal (17), filter (16), and plug (20) from rearcover (11).

(10) Remove outer bearing race (12) from hub of rearcover (11) only if replacement is required.

(11) Remove governor support pin (13), and draintube (19) only if replacement is required.

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TM 9-2320-277-14&P

m. Adapter Housing Disassembly.

(1) Place adapter housing (3, figure 8-15) withinternal parts on work bench with first clutch piston (11,figure 8-13) upward.

(2) Install J24452 spring compressor onto firstclutch piston and attach J24204-2 clutch springcompressor base as shown in figure 8-26. Tightenscrew, compressing springs (10, figure 8-13).

Figure 8-26. Removing Snapring and First Clutch SpringRetainer

(3) Remove snap ring (8) from groove in hub ofadapter housing (figure 8-26). Then disassemble baseand spring compressor from first clutch piston andadapter housing.

(4) Remove spring retainer (9, figure 8-13) andsprings (10) from adapter housing (3, figure 8-15).

(5) Remove seal rings (12 and 13, figure 8.13) fromgrooves in piston (11). Discard seal rings.

n. Low Planetary Gear Disassembly.

(1) Using a drill that is slightly smaller than thediameter of pinion pins (8, figure 8-15), drill into swagedend of each pin, being careful not to drill into carrier (13).

(2) Place J25587-1 removing, installing, andswaging fixture in an hydraulic press. AssembleJ25587-16 pin remover into fixture shaft and tightensetscrew.

(3) Place carrier (13) on fixture plate, flat side down.

(4) Press pins (8) one at a time out of carrier (13).

(5) Remove pinions (11), rollers (12), thrustwashers (9) and pinion thrust washers (10) from carrier(13).

(6) Remove bushing (14) from carrier (13) only ifreplacement is required.

o. Governor Disassembly.

(1) The governor assembly (28, figure 8-14) may bedisassembled for cleaning and inspection. Do notdisassemble governor unless kit consisting of two weightpins (29) and gasket (30) is available.

(2) Follow the instructions furnished with thegovernor kit to disassemble the governor assembly.

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TM 9-2320-277-14&P

Section IV. CLEANING, INSPECTIONAND REPAIR

8-8. CLEANING.

a. General.The importance of thorough cleaning of parts cannot beoveremphasized. Not only must parts be clean to insureproper reassembly, but parts must be kept clean aftercleaning and before reassembly.

CAUTIONHandle all parts carefully duringcleaning to avoid nicking, scratching,or burring close-fitting surfaces.

b. Metallic Parts Cleaning.Clean all metallic parts except bearings by washing involatile mineral spirits. Clean parts thoroughly tofacilitate inspection. Dry clean parts with compressed airat approximately 40 psig. Apply a light coat oftransmission oil to metallic parts to prevent corrosion,and protect oiled parts from dust. Clean all passages ifnecessary by passing a piece of soft wire through thepassages while flushing with mineral spirits. Dry thepassages with compressed air.

c. Cleaning Bearings.

Clean bearings (22 and 23, figure 8-5; 18 and 26, figure8-7; 14, figure 8-8; 23, figure 8-11; 9 and 23, figure 8-14;and 16, 21 and 25, figure 8-17) by washing in volatilemineral spirits. Dry bearings with soft lint-free cloth.Apply transmission oil to cleaned bearings and protectfrom dust by wrapping in paper.

8-9. INSPECTION AND REPAIR.

a. Parts Subject to Wear.Parts subject to wear are listed in Table 8-3. Inspectthese parts for the conditions specified in the table. Themethod for measuring the clutch plate cones isillustrated in figure 8-27. No repair of the parts subject towear is recommended. Replace any parts that fail tomeet the requirements of Table 8-3.

b. Springs.

Inspect springs for conformance to test data in (Table8-4). Additional information is presented in the table asan aid in identifying springs. Replace any spring that isdistorted, obviously damaged due to overheating,cracked, or that falls to comply with the test data.

c. Bearings.

Inspect bearings for roughness of rotation; scored,pitted, scratched, cracked, or chipped races, balls, orrollers. Replace any bearing that is defective in anyway.

d. Bearing Mountings.

Inspect bearing bores in housings and bearing mountingsurfaces on shafts or hubs for grooved, burred, or galledconditions that would indicate that bearing race hadbeen turning against mounting surface. Repair minordamage by polishing with crocus cloth. Replace anydamaged parts that cannot be made serviceable by thismeans.

e. Cast Parts.

Inspect bores for wear, scratches, grooves, or burrs.Correct minor defects by polishing with crocus cloth or asoft stone. Inspect tapped holes for thread damage.Repair minor thread damage using a worn (not new) tap.Replace any parts that cannot be made serviceable bythe above procedures. Replace any parts that arecracked or distorted.

f. Carriers.

Subject planetary carriers to magnetic particle inspectionusing approximately 8000 ampere turns (8 amperes in1000 turn coil) to determine if parts are fractured.Replace any carrier that is fractured or cracked.

g. Splines and Splined Parts.

Inspect splines and splined parts for stripped, twisted,chipped, or burred splines. Remove burrs with a softstone. Replace any part having damage that cannot becorrected by stoning.

NOTESpline wear is not considereddetrimental except where it affectstightness of fit of the splined parts.

h. Seal Ring Surfaces.Inspect seal ring surfaces, (bores and recesses inhousings, and grooves in shafts and pistons) for pitting,burrs, or other damage. These surfaces should have asmoothness of 50 micro inch or better. Polish partslightly to eliminate minor defects; otherwise, replacedefective parts.

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TM 9-2320-277-14&P

Table 8-3. Transmission Wear Limits Data

Figure Index RequirementsNo. No. Part Inspection Area For Acceptability8-5 3 Oil pump body Shaft bore No scoring

8-5 4 Oil pump Side clearance between 0.003 inchdriven gear body (3) and support (2) maximum

8-5 5 Oil pump Side clearance between 0.003 inchdrive gear body (3) and support (20) maximum

8-7 21 Forward Thickness 0.0955 inchclutch minimumexternal-tangedplates Cone (see figure 8-27) 0.010 inch

maximum

8-7 22 Forward Thickness 0.090 inchclutch minimuminternal-splinedplates Cone (see figure 8-27) 0.010 inch

maximum

Oil grooves depth 0.008 inchminimum

8-7 23 Fourth clutch Step wear at clutch 0.252 inchdriving hub plate contact area maximum

8-8 2 Fourth clutch Step wear at clutch 0.252 inchbacking plate plate contact area maximum

8-8 3 Fourth clutch Thickness 0.0955 inchinternal-splined minimumplates

Cone (see figure 8-27) 0.010 inchmaximum


8-8 4 Fourth clutch Thickness 0.090 inchexternal-tanged minimumplates


8-9 2 Third clutch Thickness 0.476 inchbacking plate minimum(IdentificationNo. 1)

8-9 2 Third clutch Thickness 0.450 inchbacking plate minimum(IdentificationNo. 2)

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Table 8-3. Transmission Wear Limits Data (Continued)

Figure Index RequirementsNo. No. Part Inspection Area For Acceptability8-9 3 Third clutch Thickness 0.117 inch

internal-splined minimumplates



8-9 4 Third clutch Thickness 0.0955 inchexternal-tanged minimumplates

8-9 13 Center support Clearance on center sun 0.0061 inchbushing gear shaft (22, figure 8-11) maximum

8-9 23 Second clutch Cone (see figure 8-27) 0.010 inchexternal-tanged maximumplates

8-9 24 Second clutch Cone (see figure 8-27) 0.010 inchinternal-splined maximumplates

Oil grooves depth 0 008 inchminimum

8-11 1 Thrust washer Thickness 0.092 inchminimum

8-11 10 Flange and Clearance on center sun 0.0049 inchcarrier bushings gear shaft (22) maximum

8-11 21 Center sun gear Clearance on main 0.0061 inchshaft bushings shaft (29) maximum

8-13 2 First clutch Thickness 0.702 inchbacking plate minimum(IdentificationNo. 1)

First clutch Thickness 0.671 inchbacking plate minimum(IdentificationNo. 2)

First clutch Thickness 0.640 inchplate minimum(IdentificationNo. 3)

8-13 3 First clutch Thickness 0.090 inchinternal-splined minimumplates

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TM 9-2320-277-14&P


Figure Index RequirementsNo. No. Part Inspection Area For Acceptability



8-13 4 First clutch Thickness 0.0955 inchexternal-tanged minimumplates


8-14 28 Governor Clearance in bore of 0.0035 inchassembly rear cover (11) maximum


8-15 14 Low clutch Clearance on hub of low 0.0049 inchcarrier bushing clutch ring gear (18) maximum


8-15 16 Low clutch Thickness 0.0955 inchexternal-tanged minimumplates


8-15 17 Low clutch Thickness 0.117 inchinternal-splined minimumplates



8-17 6 Bushing Inside diameter clearance on 0.0045 inchshaft of turbine and clutch maximumhousing assembly (3, figure 8-7

8-17 9 Piston Face wear No scoring

8-17 11 Lockup clutch Thickness 0.175 inchplate minimum

8-17 13 Clutch backing Face wear No scoringplate

8-17 20 Stator assembly Inside diameter of side plates 2.857 inchmaximum

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TM 9-2320-277-14&P


Figure Index RequirementsNo. No. Part Inspection Area For Acceptability8-17 20 Stator assembly Measure across thrust face and 0.435 inch

21 (20) and thrust needle bearing with bearing minimumbearing assembly installed(21)

8-17 22 Freewheel Face No chatterroller race marks or

roughness

Outside diameter No scoring

Figure 8-27. Measuring Clutch Plate Cones

i. Gear Teeth.

Inspect gear teeth (internal and external) on gears,pinions, and other parts for scuffed, nicked, chipped,burred, or broken teeth. Inspect teeth for wear that mayhave destroyed the original tooth shape. Inspect thethrust face of gears for scores, scratches, or burrs.Remove minor defects with soft stone or crocus cloth.Replace severely damaged parts.

j. Friction Faced Clutch Plates.

In addition to the requirements specified in Table 8-3,inspect friction faced (Internally-splined) clutch plates forburrs, imbedded metal particles, severely pittedsurfaces, cracks, distortion or damaged splines.Remove burrs with a soft stone. Replace plates thathave other defects.

k. Steel Clutch Plates.

In addition to the requirements specified in Table 8-3,inspect steel (externally-tanged) clutch plates for burrs,

scoring, distortion, galling, cracks, breaks, and damagedtangs. Remove burrs and minor surface defects with asoft stone. Replace plates which have other defects.

I. Swaged Interference-fit Parts.

Inspect for any evidence of looseness betweeninterference-fit parts. Replace or repair assemblies iflooseness is detected.

m. Bushings and Thrust Washers.

In addition to the requirements specified in Table 8-3,inspect bushings and thrust washers for burrs, scoring,sharp edges, galling, pitting, or evidence of overheating.Remove minor defects with crocus cloth. Replace anydefective part that cannot be made serviceable by thismethod.

n. Snap Rings and Snap Ring Grooves.

Inspect all snap rings for nicks or distortion. Replaceany defective snap rings. Inspect snap ring grooves inhousings, or hubs and in shafts, for burrs or otherdamage that would prevent good snap ring seating.Remove minor defects with soft stone.

o. Gaskets, Seal Rings and Pinions.

Replace all gaskets and seal rings with new parts ateach reassembly of the transmission. If any pinion ineither the front, center, rear, or low planetary requiresreplacement, replace all pinions in that planetary with anew matched set.

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TM 9-2320-277-14&P

Table 8.4. Springs Data.

Figure Index Spring Application Color Outside Free Test DataNo. No. Code Diameter Length Compressed

(inches) (inches) Height Load(inches) (Pounds)

8-3 10 Lubrication valve Solid 0.678 3.09 1.30 11.25 to 13.75spring white

8-4 2 Priority valve Solid 0.384 1.16 0.94 8.15 to 9.15spring white,

yellowstripe

8-4 5 Hold regulator Solid 0.400 2.00 1.15 6.22 to 6.48valve spring white

8-4 13 2-3 shift valve Solid 0.640 2.31 1.15 6.75 to 7.25spring yellow,

bluestripe

8-4 13 3-4 shift valve Solid 0.640 2.17 1.15 8.60 to 9.10spring blue

8-4 25 4-5 shift valve Solid 0.640 1.98 1.15 8.22 to 8.72spring yellow

8-4 30 4-5 relay valve Solid 0.690 2.18 1.20 16.20 to 19.80spring red

8-4 34 Trimmer regulator Solid 0.464 1.37 0.890 2.43 to 2.69valve spring yellow,

bluestripe

8-4 40 Modulator valve Solid 0.490 1.47 0.80 11.90 to 13.10spring white,

orangestripe

8-4 51 Third clutch Solid 0.940 2.181 1.94 6.20 to 7.40outer trimmer orangevalve spring

8-4 56 First clutch Solid 0.930 230 1.94 9.4 to 11.4trimmer valve bluespring

8-4 61 Second clutch Solid 0.940 2.328 1.20 37.8 to 41.8outer trimmer yellowvalve spring

8-4 66 Fourth clutch Solid 0.940 2.081 1.94 6.20 to 7.40outer trimmer orangevalve spring

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TM 9-2320-277-14&P

Table 8-4. Springs Data (Continued).

Figure Index Spring Application Color Outside Free Test DataNo. No. Code Diameter Length Compressed

(inches) (inches) Height Load(inches) (Pounds)

8-4 73 3-4 relay valve Solid 0.690 2.18 1.20 16.2 to 19.8spring red

8-4 76 2-3 relay valve Solid 0.680 1.52 1.10 7.20 to 8.80spring blue,

yellowstripe

8-5 8 Main pressure Solid 0.830 3.16 1.93 76.4 to 84.4regulator valve whitespring

8-5 12 Lockup valve Solid 0.690 2 84 1.46 26.1 to 28.9spring yellow

8-5 17 Converter pressure Solid 0.468 1.21 1.00 23.4 to 28.6regulator spring red

8-7 7 Centrifugal Solid 0.330 0.87 0.60 4.75 to 5.25valve spring white

8-7 14 Forward clutch None 4.072 3.22 1.280 158 to 178piston returnspring

8-8 7 Fourth clutch None 4.072 3.22 1.28 158 to 178piston returnspring

8-9 8 Third clutch Solid 0.385 1.29 0.815 4.3 to 5.7piston return greenspring

8-9 19 Second clutch Solid 0.385 1.29 0.815 4.3 to 5.7piston return greenspring

8-18 4 Modulated lockup Solid 0.640 2.720 1.385 11.74 to 12.46valve spring green,

whitestripe

8-19 10 Low shift signal Solid 0.501 1.112 0.690 2.83 to 3.47valve spring white,

orangestripe

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TM 9-2320-277-14&P

Section V. REASSEMBLING AND INSTALLINGMAJOR PARTS GROUPS AND EXTERNAL PARTS

8-10. REASSEMBLING MAJOR PARTS GROUPS.

a. Governor Assembly.

Assemble governor assembly as outlined in theinstructions supplied with the governor kit.

b. Low Planetary Gear Assembly.

(1) Using J25587-20 (5/8 inch) loading pins, installloading pins and rollers (12, figure 8-15) into the bore ofeach pinion (11).

(2) Place pinion thrust washer (10) followed by athrust washer (9) on each side of each pinion (11).

(3) Place each pinion assembly into carrier (13),aligning pinion assembly with pinion pin holes in carrier.

(4) Install J25587-49 guide pins (pin pilot-top side),pushing the loading pins from the carrier. The guidepins will centrally locate and retain the pinions (11) andthrust washers (9 and 10) in place.

(5) Install J25587-8 pin installer Into J25587-1installing and swaging fixture and tighten setscrew.

NOTEPin installer heads with flat side(s)are designed to clear bosses oncarrier. Position head to clearcarrier.

(6) Position carrier (13) on installing and swagingfixture mounting plate, and place pinion pin (8) into pilotof guide pin.

CAUTIONAny carrier contact made underpressure may seriously damagecarrier. Use care when pressingpinion pins into place.

(7) Using an hydraulic press, apply sufficient force(approximately 1000 pounds) to pinion pin (8) until pininstaller makes contact with carrier. This will assureproper depth of pinion pin in carrier.

NOTETest tightness of pinion pin (8) incarrier (13) by applying 350 poundtest load to pin. If this force causespinion pin to move, replace the pin.

(8) Repeat Steps 6 and 7 above for the remainingpinion pins and pinions.

(9) Remove pin installer from fixture shaft. InstallJ25587-17 bottom swaging tool holder in base of fixture.Install one J25587-25 swaging tool in swaging toolholder and one J25587-25 swaging tool in fixture shaftand tighten setscrews.

(10) Place carrier (13) on fixture base, using J25587-3 support block to maintain accurate carrier level.

NOTECarrier must be parallel to fixturebase and perpendicular to swagingtools, and pinion pins must becentrally located with the swagingtools to ensure a correct stakingpattern on pinion pins.

(11) Apply sufficient force (approximately two tons) toswag pinion pin (8) firmly against carrier (13), forming apattern as shown in figure 8-28. After swaging, thepinion (11) must rotate freely with an end play of 0.008to 0.031 inch.

Figure 8-28. Pinion Pin Swaging (Staking) Pattern

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TM 9-2320-277-14&P

NOTEThe amount of force required forstaking will vary with the condition ofswaging tools and press equipmentused.

(12) Carefully press bushing (14, figure 8-15) intobore of carrier (13) until flush with surrounding surface.

c. Adapter Housing and First Clutch PistonAssembly.

(1)Install plug (4, figure 8-15) in adapter housing (3).Tighten sufficiently to prevent oil leakage.

(2) Install hp-type seal (13, figure 8-13) in internalgroove of piston (11), being sure that hp of seal facestoward adapter housing (3, figure 8-15).

(3) Install seal (12, figure 8-13) in external groove ofpiston (11) with lip of seal facing in same direction as lipof seal (13).

(4) Coat lips of seals (12 and 13) with hightemperature grease, and insert piston (11) into adapterhousing (3, figure 8-15) with lug on piston aligned withcorresponding recess in housing.

(5) Insert piston release springs (10, figure 8-13)into pockets in piston (11) ; then place spring retainer(9), cupped side first, on top of springs.

(6) Place J24452 spring compressor on springretainer, and install J24204-2 clutch spring compressorbase on spring compressor as shown m figure 8-26.Tighten compressor base handle to depress springretainer; then install snap ring in groove of hub inadapter housing (3, figure 8-15) to retain spring retainer.Remove spring compressing tools.

d. Rear Cover Assembly.

(1) Press governor support pin (13, figure 8-14) intorear cover (11) to dimension shown in figure 8-29.Accuracy of location and concentricity between pin andbore of cover is Important for proper governor operation.

(2) Install drain tube (19, figure 8-14) in rear cover(11), pressing tube until it is 0.050 to 0.100 inch fromchamfer in cover as shown in figure 8-30.

(3) Install seal (23, figure 8-15) in external groove ofpiston (22) with lip of seal facing toward cavity in rearcover (11, figure 8-14).

(4) Install seal (24, figure 8-15) in internal groove ofpiston (22) with lip of seal facing same direction as lip ofseal (23).

(5) Lubricate lips of seals (23 and 24) withtransmission oil; then install piston (22) in rear cover (11,figure 8-14). Use extreme care to prevent lip of eitherseal from folding back over itself.

Figure 8-29. Governor Support Pin Location

(6) Place springs (21, figure 8-15) into pockets inpiston (22) ; then place spring retainer (20), cupped sidefirst, onto springs.

(7) Place J24452 low and first clutch springcompressor on spring retainer (20), and install J24204-2clutch spring compressor base on compressor as shownin figure 8-25. Tighten handle of compressor base todepress spring retainer, then install snap ring (19, figure8-15) into groove in hub of rear cover (11, figure 8-14) toretain spring retainer. Remove compressing tools.

(8) Place ball bearing (23, figure 8-14) into rearcover (11). Using J24447 rear bearing installer withJ242024 compressor base, press bearing until It bottomsin rear cover recess as shown in figure 8-30.

Figure 8-30. Drain Tube, Ball Bearing, Oil Seal, andDust Shield Installation

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TM 9-2320-277-14&P

(9) Install snap ring (24, figure 8-14) in internalgroove of rear cover (11) with beveled side outward toretain ball bearing (23). Be sure snap ring is fullyexpanded in groove.

(10) Coat outer circumference of rear oil seal (25)with a non-hardening type sealing compound. Placeseal onto J24620 output shaft oil seal installer, springloaded side of seal away from installer. Insert sealinstaller and seal into bore of rear cover and drive theseal in until installer seats. Rear face of seal should be1.03 to 1.07 inch below face of rear cover as shown infigure 8-30. Remove seal installer.

(11) Place dust shield (26, figure 8-14) on J24198dust shield installer, concave side first. Coat outer rim ofshield with a non-hardening sealing compound. Drivedust shield into rear cover until it is flush with rearsurface of cover as shown in figure 8-30.

(12) Install governor filter, O-ring seal, and plug intorear cover as shown in figure 8-31.

Figure 8-31. Installing Governor Filter

(13) Install plugs (14, 15, and 20, figure 8-14) inrespective holes in rear cover (11).

(14) Install bearing outer race (12) into rear cover(11), inner lip first, until front face of race is 0.080 to0.090 inch below surface of bore in cover.

e. Output Shaft Assembly.

(1) Place new cup plug (2, figure 8-14) on end ofJ24369 output shaft orifice installer. Install plug in outputshaft as shown in figure 8-32.

Figure 8-32. Installing Cup Plug in Output Shaft

(2) Place new needle roller bearing (1, figure 8-14)on J24451 output shaft bearing installer, with numberedend of bearing facing Installer (figure 8-33). AttachJ8092 driver handle to installer and install bearing inoutput shaft (3, figure 8-14).

NOTEIf tools in Step 2 above are notavailable, insert bearing (1, figure8-14) into output shaft (3). Press onnumbered end of bearing, locatingbearing 0.270 to 0.290 inch belowfront face of shaft.

(3) Place output shaft (3, figure 8-14) on press,small end downward.

(4) Place bearing roller (5), chamfered end first,onto shaft (3). Place a steel sleeve (2.375 ID X 2.875OD X 1.750 inches long) next to bearing roller. InstallJ24447 rear bearing installer and J242024 driver handleonto output shaft and press bearing roller (5) againstshoulder on shaft. Remove tools.

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TM 9-2320-277-14&P

Figure 8-33. Installing Needle Roller Bearing in OutputShaft

(5)Press spring pin (4) into hole in shaft until it protrudes0.150 to 0.170 inch above shaft surface.

(6) Place governor drive gear (6) on shaft (3) withgroove in gear precisely aligned with pin (4). PlaceJ24447 rear bearing installer and J24202-4 driver handle(in that sequence) on output shaft (3) and pressgovernor drive gear into place. Remove tools from shaft.

f. Gear Unit and Main Shaft Assembly.

(1) Press lube orifice plug (28, figure 8-11) into mainshaft (29), small orifice end first, using J24369 outputshaft orifice installer. Press plug into shaft until frontsurface of plug is recessed 0.140 to 0.180 inch belowfront face of shaft.

(2) Press spring pin (20) into shaft (22). Split in pinmust be directly toward either adjacent spline tooth.Press pin until outer end of pin is flush with, to 0.010inch below, top of adjacent spline teeth.

(3) Using J24468 sun gear shaft bearing installer,press bushings (21) into sun gear shaft (22) as shown infigures 8-34 and 8-35. Note that installer is designed to

position each bushing at a different depth: front bushing(figure 8-34) at 0.400 to 0.420 inch, and rear bushing(figure 8-35) at 0.650 to 0.670 inch. Be sure to use theproper step on installer. Hone or bore both bushings to1.5640 to 1.5655 inch diameter. After honing, insidediameter of bushings must be concentric with finishedoutside diameter of shaft within 0.002 inch.

Figure 8-34. Installing Front Bushing in Sun Gear Shaft

Figure 8-35. Installing Rear Bushing in Sun Gear Shaft

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TM 9-2320-277-14&P

(4) Install J25587-18 loading pins and rollers (36,figure 8-11) into the bores of rear planetary pinions (37).Place a pinion thrust washer (35) on each side of pinionand place a thrust washer (34) on each pinion thrustwasher.

(5) Place pinions (37) into rear planetary carrier(38), aligning the pinion bores with holes in carrier; andinstall J2558748 guide pins (pin pilot-top side), pushingloading pins from carrier. Guide pins will centrally locateand retain pinions and thrust washers in place.

(6) Install J25587-12 pin installer into J25587-1removing, installing and swaging fixture, and tightensetscrew.

NOTEInstaller heads with flat side(s) aredesigned to clear bosses on carrier.Position head, if required, to clearcarrier bosses.

(7) Position carrier (38) on fixture mounting plate.

CAUTIONExcessive contact made underpressure may seriously damagecarrier (38). Use care when applyingpressing force to avoid damage tocarrier.

(8) Place a pinion pin (33) onto pilot of guide pin.Apply sufficient force (approximately 1000 pounds) topress pinion pin into carrier (38) and pinion (37) until pininstaller makes contact with carrier. This will provideproper location of pinion pin in carrier.

NOTETest tightness of pinion pin (33) incarrier (38) by applying 350 poundforce to end of pin. Pinion pin mustnot move under this force. If pinmoves, fit its improper and pinion pinmust be removed and replaced.

(9) Install the remaining pinion pins (33) byrepeating Step 8 above.

(10) Remove pin installer from fixture; install J25587-17 bottom swaging tool holder in fixture plate base, andinstall one J25587-23 swaging tool in bottom swagingtool holder and install one J25587-23 swaging tool infixture shaft and tighten setscrew.

(11) Place carrier (38) on fixture base with J25587-3support block to maintain carrier at proper level. Carriermust be parallel to fixture surface, perpendicular to

swaging tools, and pinion pin must be centrally locatedwith swaging tools to assure accurate swaging (staking)of pinion pins.

(12) Apply sufficient force (approximately two tons) toswag the pinion pin firmly against carrier (38), formingthe swaging pattern shown in figure 8-28. After swaging,pinions (37) must rotate freely with side play of 0.008 to0.031 inch.

NOTEForce required for swaging will varydepending on the condition ofswaging tools and type of pressused.

(13) Repeat the above swaging procedure for theother three pinion pins (33).

(14) Install needle roller bearing assembly (32) inrecess of rear planetary carrier (38).

(15) Position planetary connecting drum (25) on workbench with front internal splines (long splines)downward. Assemble rear planetary carrier (38) intodrum, installing snap ring (39) into internal groove ofdrum to secure carrier.

(16) Install rear planetary sun gear (30) into centerplanetary ring gear (27), and install snap ring (26) ingroove of sun gear to secure it in position.

(17) Install main shaft (29) into rear planetary sungear (30) and secure by installing snap ring into groovein main shaft.

(18) Install main shaft (29) together with ring gear(27) and sun gear (30) into planetary connecting drum(25). When installed, rear face of sun gear (30) mustcontact needle roller bearing (32) installed min rearplanetary carrier (38).

(19) Using J25587-18 loading pins, install rollers (19)in bores of pinions (18) ; then place one pinion thrustwasher (17) followed by one thrust washer (16) on eachside of pinion.

(20) Place pinions (18) and thrust washers (16 and17) in center planetary carrier (15). Align bores ofpinions with holes in carrier, and install J25587-48 guidepins (pin pilot-top side), pushing loading pins fromcarrier. Guide pins will centrally locate and retainpinions and thrust washers.

NOTEInstaller heads with flat side(s) aredesigned to clear bosses on carrier.Position head, if required, to clearcarrier boss.

(21) Install J25587-11 pin installer into shaft ofJ25587-1 removing, installing and swaging fixture, andtighten setscrew.

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TM 9-2320-277-14&P

(22) Position carrier (15) on fixture mounting plate.

CAUTIONAny carrier contact made duringpressing may severely damagecarrier (15). Use care to preventcarrier damage during pin pressingoperation.

(23) Place a pinion pin (14) onto pilot of a guide pin.Apply sufficient force (approximately 1000 pounds) topivot pin until pin installer makes contact with carrier(15). This will provide proper depth of pinion pin incarrier.

NOTETest tightness of pin (14) in carrier(15) by applying 350 pound load topin. Pin must not move out ofposition under this load. If pinmoves, it must be removed andreplaced.

(24) Repeat Step 23 above to install the remainingthree pinion pins (14).

(25) Remove pin installer from shaft of fixture, andinstall one J25587-23 swaging tool in fixture shaft.Tighten setscrew.

(26) Install J25587-17 bottom swaging tool holderinto fixture plate base, and install one J25587-23swaging tool into swaging tool holder.

(27) Place carrier (15) on fixture base, using J255874support block to maintain proper carrier level.

NOTECarrier (15) must be parallel to fixturebase and perpendicular to swagingtools; and pinion shafts (14) must becentrally located with swaging toolsto ensure correct swaging operation.

(28) Apply sufficient force (approximately two tons) toswage pinion pin (14) firmly against carrier (15), formingthe swaging pattern shown in figure 8-28. After swaging,pinion (18) must rotate freely with 0.008 to 0.031 inchside play.

NOTEForce required for swaging may varydepending upon condition ofswaging tools and type of pressused.

(29) Repeat above procedure to swage theremaining three pinion pins (14, figure 8-11).

(30) Position planetary connecting drum so that hubof rear planetary carrier (38) is downward.

(31) Coat roller bearing race (24) with oil solublegrease, and install race with inner lip upward on frontface of rear planetary sun gear (30).

(32) Coat needle roller bearing assembly (23) with oilsoluble grease, and install roller bearing on bearing race(24).

(33) Install center planetary carrier (15) with installedpinions (18), (pinions first) into center planetary ring gear(27) and planetary connecting drum (25).

(34) Install front planetary ring gear (13) intoplanetary connecting drum (25), and secure by installingsnap ring (12) into internal groove in drum.

(35) Install center gear shaft (22) on main shaft (29)so that rear face of center sun gear shaft seats onneedle roller bearing (23).

(36) Using J25587-22 loading pins, install rollers (8)together with loading pins into pinions (7).

(37) Place one pinion thrust washer (6) followed byone thrust washer (5) on each face of each pinion (7).

(38) Align pinions (7) in carrier (9) with holes inpinions aligned with holes in carrier, and install J25587-50 guide pins (pin pilot-top side), pushing loading pinsfrom carrier and pinions. Guide pins will centrally locateand retain pinion and thrust washers.

(39) Install J25587-13 pin Installer into shaft ofJ25587-1 removing, installing and swaging fixture andtighten setscrew.

CAUTIONHeavy contact of pin installer withcarrier (9) while pressing in pinionpins (4) could severely damagecarrier. Use care to prevent damageto carrier during pressing operation.

(40) Position carrier (9) on fixture mounting plate,and place a pinion pin (4) onto pilot of one of -he guidepins. Apply sufficient force (approximately 1000 pounds)to press pinion pin into carrier until pin installer makescontact with carrier. This will ensure that pinion pin isinstalled to proper depth in carrier.

NOTETest tightness of pinion pin (4) incarrier (9) by applying 350 poundforce on pinion pin. If pin moves,interference fit between pin andcarrier is too loose. Remove pinionpin and replace with a new pin.

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(41) Repeat Step 40 above to install the remainingfive pinion pins (4).

(42) Remove pin installer from shaft of fixture, andinstall one J25587-27 swaging tool in fixture shaft andtighten setscrew. Also install J25587-17 bottom swagingtool holder into fixture base, and install one J25587-27swaging tool into bottom swaging tool holder.

(43) Using J25587-4 support block, place carrier onfixture base. Support block will maintain proper carrierlevel.

NOTECarrier must be parallel to fixturebase and perpendicular to swagingtools; and pinion pins must becentrally located with swaging toolsto ensure correct swaging pattern onpinion pins.

(44) Apply sufficient force (approximately two tons) toswage pinion pins (4) firmly against carrier (9) to formswaging pattern as shown in figure 8-28.

NOTEForce required for swaging will varydepending upon condition ofswaging tools and type of pressused.

NOTEAfter swaging, pinion (4, figure 8-11)must rotate freely with 0.008 to 0 013inch side play.

(45) Repeat procedure in Step 44 above to swagethe remaining five pinion pins (4, figure 8-11).

(46) Press bushing (10) into bore of carrier (9) untilface is flush with bore in carrier.

(47) Coat thrust washer (11) with oil-soluble grease,and install it on rear hub of carrier assembly (9).

(48) Coat thrust washer with oil soluble grease andinstall it on rear hub of front planetary gear (2).

(49) Install front planetary sun gear (2) on center sungear shaft (22) with gap in splines indexed with springpin (20) in shaft.

(50) Assemble front planetary carrier (9) onto shaft(22) so that pinions (7) mesh with sun gear (2) and withring gear (13).

g. Center Support Assembly.

(1) Place center support (15, figure 8-9) front sideupward on work bench.

(2) Align lug on third clutch piston (9) with recess incenter support (15), and temporarily insert piston intocenter support.

(3) Install springs (8) into pockets in piston (9).(4) Align spring retainer ring (7) on ejector pin

bosses of piston (9) ; then compress springs (8) byforcing ring into recess at outer edges of center support.

NOTEBe sure piston (9) is forced to thebottom of cavity in center supportwhile lock rings are being installed inStep S below.

(5) Using J24453 lock ring installer as shown infigure 8-36, install self-locking retainer rings (6, figure8-9) on ejector pins of piston (9).

(6) Remove third clutch piston (9) with ring (7) fromcenter support (15).

(7) Turn center support over.(8) Align lug on second clutch piston (18) with

recess in center support (15), and temporarily insertpiston into center support.

(9) Install springs (19) into pockets in piston (15).(10) Align spring retainer ring (20) on ejector pin

bosses of piston (18) ; then compress springs (19) byforcing ring into recess at outer edges of center support(15).

NOTEBe sure piston (18) is forced to thebottom of cavity in center support(15) while lock rings (21) are beinginstalled.

(11) Using J24453 lock ring installer as shown infigure 8-36, install new self-locking retainer rings (21,figure 8-9) onto ejector pins of piston (18).

(12) Remove piston (18) with ring (20) from centersupport (15).

(13) Place check ball (14) in hole of center support(15). Stake metal around hole lightly to retain ball.

(14) Press bushings (13) into center bore of centersupport (15) until bushings are centered in bore.

(15) Coat lip-type seal rings (10, 11, 16 and 17) withoil soluble grease and install in grooves of pistons (9 and18), being sure that lips of all seal rings face towardrespective cavities in center support (15).

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Figure 8-36. Installing Self-Locking Retainer Ring

(16) Install piston (18) m rear cavity of centersupport, being sure that lips of seal rings (16 and 17) donot fold back over themselves.

NOTEDo not install third clutch piston (9) incenter support (15) at this time.

h. Fourth Clutch Assembly.

(1) Place check balls (11, figure 8-8) in holes infourth clutch housing. Stake each hole at three equallyspaced locations to retain balls. Holes are properlystaked when balls have at least 0.020 inch axialmovement and when balls are retained by staking whena 30 pound force is applied against balls.

(2) Position fourth clutch housing (12), cavityupward, on work bench.(3)Lubricate lip-type seal ring (10) with transmission oiland install, lip facing downward, in groove of hub inhousing (12).

(4) Lubricate lip-type seal ring (9) with transmissionoil, and install it on piston (8) with lip facing towardpressure side of piston.

(5) Install piston (8) in housing (12), being careful toprevent lips of seal rings (9 and 10) from folding backover themselves.

(6) Alternately install clutch plates (4 and 3) inhousing (12), starting with an external-tanged plate (4).

(7) Install backing plate (2) in housing (12) on top oflast internal-splined clutch plate (3).

(8) Install snap ring (1) in internal groove of housing(12) to retain backing plate (2).

(9) Using J26917 fourth clutch clearance gauge,check clearance between backing plate (2) and adjacentclutch plate (3). When clearance is correct, smaller endof gauge (0.064) inch) will fit between backing plate andclutch plate; larger end (0.125 inch) will not. See (figure8-37).

Figure 8-37. Measuring Fourth Clutch Clearance

NOTEIf clearance exceeds 0.125 inch,replace thinner clutch plates (3 and 4,figure 8-8) with new parts. Ifclearance still exceeds 0.125 inch,replace piston (8) with a thickerpiston. If clearance is less than 0.064inch, replace piston (8) with a thinnerone. Refer to separate Repair PartsManual for available pistons.

(10) Place piston return spring (7, figure 8-8) onpiston and place spring retainer (6) on hub in housing(12) and against spring (7).

(11) Place J6438-01 forward and fourth clutch springcompressor on spring retainer (6) as shown in figure 8-23.Assemble J24204-2 clutch spring compressor onhousing and spring compressor. Tighten handle ofclutch spring compressor to depress spring retainer, andinstall snap ring (5, figure 8-8) in groove of hub inhousing (12) to retain spring retainer.

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(12) Remove spring compressors.

i. Forward Clutch and Turbine Shaft Assembly.

NOTEBefore assembling valve plug (6,figure 8-7), spring (7), and centrifugalvalve (8) in housing (3), ensure thatall three parts are color coded white.

(1) Place centrifugal valve (8) in valve bore ofhousing (3), place spring (7) in valve, and place plug (6)on spring. Depress plug and install pin (5) in housing toretain installed parts.

(2) Place balls (4) in holes of housing (3), and stakeeach hole at three equally spaced locations. Holes areproperly staked when the balls have at least 0.020 inchaxial movement and when balls are retained by stakingwhen a 30 pound force is applied against balls.

(3) Position housing assembly (3), shaft downward,on work bench.

(4) Lubricate lip-type seal rings (11 and 12) withtransmission oil, and install them on hub of housing (3)and in groove of piston (13), respectively, ensuring thatlips of seal rings face toward pressure side of piston.

(5) Install piston (13) in housing (3), being verycareful to ensure that lips of seal rings (11) and 12) donot fold back over themselves.

(6) Alternately install clutch plates (21 and 22) inhousing (3), starting with an external-tanged clutch plate(21) and ending with an internal-splined clutch plate (22).

(7) Install fourth clutch driving hub (23) in housing(3), and install snap ring (24) in internal groove ofhousing to retain hub.

(8) Using J26913 forward clutch gauge, checkrunning clearance by holding fourth clutch driving hub(23) firmly against snap ring, and inserting gaugebetween hub and adjacent internal-splined clutch plate(22) as shown in figure 8-38. When clearance is correct,smaller end of gauge (0.079 inch) will enter between huband clutch plate; larger end of gauge (0.130 inch) willnot.

NOTEIf clearance exceeds 0.130 inch, replacethinner clutch plates (21 and/or 22, figure8-7) with new plates, and/or replacefourth clutch driving hub (23) with newhub. If clearance still exceeds 0.130 inch,replace piston (13) with a thicker piston.If clearance is less than 0.079 inch,replace piston (13) with a thinner one.Refer to separate Repair Parts Manual forthickness of available pistons.

Figure 8-38. Measuring Forward Clutch RunningClearance

(9) Remove snap ring (24) and take out hub (23)and clutch plates (21 and 22). Be sure to retain parts asa set for reinstallation.

(10) Place piston return spring (14) on piston (13),and place spring retainer (15) over hub in housing (3)and on spring.

(11) Place J6438-01 forward and fourth clutch springcompressor on spring retainer (15) as shown in figure 8-22; and, using a press, depress spring retainer intohousing far enough to allow snap ring (16, figure 8-7) tobe installed in groove of hub in housing (3). Install snapring; and remove spring compressor.

(12) Coat bearing race (17) with oil-soluble greaseand place race, outer hp first, onto hub in housing (3).Use sufficient grease to hold race in place duringassembly.

(13) Coat bearing race (19) and roller bearingassembly (18) with oil-soluble grease; then place race,flat side first, onto hub in forward clutch hub (20) andplace roller bearing onto race. Be sure to use sufficientgrease to hold parts together while hub is assembledinto housing (3).

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(14) Place forward clutch hub (20), splined OD first,into housing (3).

(15) Reinstall clutch plates (21 and 22) alternately,starting with an external-tanged plate (21).

(16) Reinstall fourth clutch driving hub (23) inhousing (3), and secure by installing snap ring (24) intointernal groove in housing.

(17) Install snap ring (9) into external groove ofhousing (3). Place PTO drive gear (10), chamfered sidefirst, onto housing, sliding gear forward until snap ring,engages mating groove in gear.

(18) Invert housing (3) and install hook-type sealrings (2) near base of shaft, using oil-soluble grease tohold seal rings in place.

(19) Install seal ring (1) near front end of shaft.

j. Oil Pump and Front Support Assembly.

(1) Coat outside diameter of oil seal (1, figure 8-5)with non-hardening sealing compound. Place seal onJ2444D oil pump seal installer with spring-loaded lipaway from installer. Attach J24202-4 driver handle toinstaller. Drive seal into pump body (3) as shown infigure 8-39. Remove installer and coat inside diameterof seal with high temperature grease.

Figure 8-39. Installing Oil Pump Body Oil Seal

(2) Press plug (21, figure 8-5) into hole in support(20) until plug bottoms on shoulder.

(3) Place gears (4 and 5) in recess of valve body(3).

(4) Align support (20) on body (3) and start twobolts (14) 180° apart, engaging threads one or two turns.

(5) Install J24461 centering band around body (3)and support (20) as shown in figure 8-40, and install theremaining bolts (14 and 15, figure 8-5). Tighten bolts totorque values shown in Table 8-5.

Figure 8-40. Assembling Support on Oil Pump Body

(6) Remove centering band, and check that split linebetween pump body (3, figure 8-5) and support (20) isperfectly smooth. If it is not, centering band was notproperly installed. Loosen bolts (14 and 15), reinstallband, and retighten bolts. Remove centering band andrecheck.

(7) Place needle bearing assembly (22) in converterground sleeve (19) with numbered end of bearing cagefacing outward. Using J24457 front support bearinginstaller and J8092 driver handle as shown in figure 8-41, drive bearing into ground sleeve. Correct depthprovided by installer is 1.240 to 1.260 inch from face ofsupport hub.

(8) Remove installer. Apply 200 pound force onbearing (22, figure 8-5) and check that it does not movein sleeve bore. If bearing moves, remove it and install adifferent bearing.

(9) Install main pressure regulator valve (9) andlock-up valve (13) in respective bores of support (20) ;then install springs (8 and 12) and valve stops (7 and 11)in bores of support.

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Table 8-5. Transmission Assembly Torque Values

Note: Items are listed in order of reassembly procedure.

Figure Index No. Location Size TorqueNo. (in.-thread) (lb-ft)

8-5 14 Support to oil pump body 3/8-16 24 to 32

8-5 15 Support to oil pump body 5/16-18 17 to 208-4 70 Trimmer valve cover to valve body 1/4-20 9 to 118-4 37 Modulator valve body to control valve body 1/4-20 9 to 11

8-17 28 Converter pump hub to converter pump 1/4-20 9 to 11assembly

8-17 4 Converter cover assembly to pump assembly 5/16-24 19 to 23

8-3 5 Lubrication valve adapter to transmission 1/4-20 9 to 11housing

8-3 41 Neutral safety switch plug on transmission 3/4-16 50 to 60housing

8-3 32 Detent lever to selector shaft nut 3/8-24 15 to 208-14 22 Rear cover and adapter housing to 1/2-13 67 to 80

transmission housing8-14 32 Governor cover to rear cover 5/16-18 15 to 208-3 35 Center support anchor bolt 3/8-16 39 to 46

8-5 28 Oil pump and support to transmission 3/8-16 24 to 32housing

8-3 17 Oil transfer plate to transmission housing 1/4-20 9 to 11

8-3 18 Detent roller and spring assembly to control 1/4-20 8 to 12valve body

8-3 20 Control valve body to transmission housing 1/4-20 8 to 12

8-3 16 Low shift valve body to transmission housing 1/4-20 9 to 118-3 33 Modulated valve retainer to transmission 5/16-18 15 to 20

housing

8-3 21 Modulated lockup valve body to transmission 1/4-20 9 to 11housing

8-3 26 Oil filter to control valve body 5/16-18 10 to 15

8-3 30 Oil pan to transmission housing 5/16-18 10 to 13initially; 5aftergasket sets

8-3 4 PTO cover (if used) to transmission housing 3/8-16 17 to 20

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Figure 8-41. Installing Needle Bearing Assembly inConverter Ground Sleeve

(10) Place snap rings (6 and 10) on screws ofJ24459 main regulator and lockup valve springcompressor, and install compressor on front support asshown in figure 8-20. Tighten compressor screws todepress stops (7 and 11, figure 8-5), and install snaprings (6 and 10) into internal grooves in support.Remove spring compressor.

(11) Place regulator valve (18) into bore in support(20). Assemble spring (17) onto a new guide (16) and,using J24458 valve pin installer as shown infigure 8-42A, drive guide into support. When installedproperly, head of guide will extend 1.20 to 1.16 inchabove finished surface of support as shown in figure 8-42B.

(12) Lubricate seal ring (2, figure 8-5) withtransmission oil and install In groove of pump body (3),being sure that oil seal does not twist m groove.

k. Assembling Control Valve.

NOTEA cross sectional view of the controlvalve is shown in figure 8-43 as anaid in identifying the bores called outin the following steps.

(1) Install hold regulator valve (4, figure 8-4)into bore A of control valve body (48) ; then install spring(5), valve stop pin (6), washer (7), and spring adjusting

ring (8) into same bore. Depress adjusting ring, andinsert retainer pin (10) into body and through hole in stoppin (6), maintaining same position of ring with respect tostop pin as noted during disassembly.

Figure 8-42. Installing Regulator Valve Guide In FrontSupport

(2) Refer to figure 8-44 and insert 2-3 shift valve,shorter end first, into bore B of valve body; then insert 2-3 modulator valve, smaller end first, spring, valve stop,and spring adjusting ring into same bore. Depressadjusting ring into body and insert retainer pin (16, figure8-4) into body and through hole in valve stop,maintaining position of adjusting ring with respect toretainer pin as noted during disassembly.

(3) Insert 3-4 shift valve (figure 8-44), smaller endfirst, into bore C of body; then insert 34 modulator valve,spring, valve stop, and spring adjusting ring into samebore. Depress spring adjusting ring into bore and installretainer pin (22, figure 8-4) into body and through hole invalve stop, maintaining same position of spring adjustingring with respect to retainer pin as noted duringdisassembly.

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Figure 8-43. Control Valve Bore Locations

Figure 8-44. Installing Shift and Modulator Valves In Control Valve Body

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(4) Insert 4-5 shift valve (figure 8-44), smaller endfirst, into bore D of valve body; then insert 4-5 modulatorvalve, smaller end first, spring, valve stop, and springadjusting ring into same bore. Depress spring adjustingring into bore and Install retainer pin (28, figure 8-4) intobody and through hole in valve stop, being sure tomaintain same position of adjusting ring with respect toretainer pin as noted during disassembly.

(5) Insert 4-5 relay valve (29, figure 8-4) into bore Eof valve body (48) ; then insert spring (30) and valvestop (31) Into same bore. Depress valve stop into boreand insert retaining pin (32) into body.

(6) Install trimmer regulator valve (33) into bore F ofvalve body (48) ; then install spring (34) and valve stop(35) into same bore. Depress valve stop into body boreand install retainer pin (36) into body to retain valve stop.

(7) Insert third clutch trimmer valve (49), open endfirst, into bore G of valve body (48) ; then install trimmerplug (50), springs (51 and 52), and valve stop (53) intosame bore.

(8) Install first clutch trimmer valve (54), open endfirst, into bore H of valve body (48) ; then Install trimmerplug (55), springs (56 and 57), and valve stop (58) intosame bore.

(9) Insert second clutch trimmer valve (59), openend first, into bore I of body (48) ; then install trimmerplug (60), springs (61 and 62), and valve stop (63) intosame bore.

(10) Insert fourth clutch trimmer valve (64), open endfirst, into bore K of valve body (48) ; then install trimmerplug (65), springs (66 and 67) and valve stop (68) intosame bore.

(11) Place cover (69) on valve body (48),compressing valve stops (53, 58, 63, and 68) into bodybores. Secure cover with bolts (70). Tighten bolts totorque values shown in Table 8-5.

(12) Insert 3-4 relay valve (72) into bore L of valvebody (48) ; then insert spring (73), and valve stop (74)into same bore. Depress valve stop Into body and installretainer pin (71) in body to retain stop.

(13) Insert 2-3 relay valve (75) Into bore AM of valvebody (48) ; then install spring (76) and spacer (77) Intosame bore. Depress spacer into bore and install retainerpin (71) in body to retain spacer.

(14) Insert modulator valve actuator pin (38), smallend first into modulator valve body (44). Then insertmodulator valve (39), spring (40), washer (41), valve

stop pin (42) and spring adjusting ring (43) Intomodulator valve body. Depress spring adjusting ring intovalve body and install retainer pin in body and throughhole in valve stop pin to retain spring adjusting ring,being sure to maintain same position of ring with respectto pin as noted during disassembly.

(15) Place check ball (47) in cavity of body (48),using oil-soluble grease to retain ball.

(16) Install priority valve stop pin (1), spring (2) andpriority valve (3) in bore of body (48).

(17) Place separator plate (46) on valve body (48),with bolt holes in both parts aligned.

(18) Assemble modulator valve body (44) onseparator plate (46) and secure to valve body with bolts(37). Tighten bolts to torque value specified inTable 8-5.

(19) Insert range selector valve (9), drilled end first,into bore P of valve body (48). Secure valve temporarilywith a rubber band, piece of string, or short length of softwire.I. Assembling Low Shift Valve.

(1) Insert low shift relay valve (6, figure 8-19) intovalve body (3), then insert spring (7), and valve stop (8)into same bore. Depress valve stop into body, andinsert retainer pin (4) into body to retain valve stop.

(2) Refer to figure 8-45 and insert 1-2 shift signalvalve into valve body; then insert spring, valve stop,washer, and spring adjusting ring into same bore invalve body. Depress spring adjusting ring into body andinsert retainer pin (5, figure 8-19) into body and throughhole in valve stop, being sure to maintain same positionof spring adjusting ring with respect to retainer pin asnoted at disassembly.

Figure 8-45. Installing Low Shift Valve

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m. Assembling Modulated Lockup Valve.

(1) Insert modulated lockup valve (3, figure 8-18)into valve body (1) ; then insert spring (4), stop (5), andspring adjusting ring (6) into valve body.

(2) Depress spring adjusting ring (6) into valve body(1) and install pin (2) through body and hole in stop (5),being sure to maintain same position of spring adjustingring and pin as noted during disassembly.

n. Torque Converter Assembly.

(1) Install converter pump hub (30, figure 8-17) inpump assembly (34) with bolts (28) and locking strips(29), using a new gasket (32) between hub and pumpassembly. Tighten bolts to value specified in Table 8-5.Bend corners of locking strips against adjacent flats onheads of bolts.

(2) Install any required bolts (27) in rim of pumpassembly (34), making sure any weights are In theiroriginal positions.

(3) Install seal ring (33) in groove in outercircumference of pump assembly (34).

(4) Install bearing race (26) into converter pump hub(30).

(5) Install needle roller bearing assembly (25) intoconverter pump hub (30).

(6) Place needle roller bearing assembly (21) inbore of stator assembly (20). Then using J23549 statorthrust bearing installer and J8092 driver handle asshown in figure 8-46, drive bearing into stator untilinstaller bottoms on area of stator surrounding bearing.When properly installed, bearings will project abovesurrounding area of stator assembly 0.035 to 0.025 inchas shown in figure 8-47.

(7) Place stator assembly (20, figure 8-17) on workbench with bearing side downward.

(8) Coat bottoms of cam pockets with oil-solublegrease; then install J24218-1 stator roller retainer ringwith cord attached as shown in figure 8-48. Then installsprings (23, figure 8-17) and rollers (24) into pockets incam as shown In figures 8-48 and 8-49. Note that openends of springs touching rollers must be toward center ofstator cam, and rollers must be installed in shallow endsof cam pockets.

(9) Insert freewheel roller race (22, figure 8-17) intocam stator assembly (20) until race contacts rollers (24) ;then raise stator assembly and pull on cord to removecollapsible retainer ring.

Figure 8-46. Installing Stator Needle Roller BearingAssembly

(10) Continue rotating and pressing race (22) until itis fully seated against needle roller bearing assembly(21); then rotate race counterclockwise firmly to lock it instator.

(11) Place pump assembly (34), cavity upward, onworkbench

(12) Holding freewheel roller race (22) firmly in place,invert stator assembly and place it m pump assembly(34).

(13) Place turbine (19) into pump (34) and over statorassembly (20).

(14) Install bearing race (17), outer lip upward, intohub of turbine (19) without spacer (18)

(15) Coat bearing assembly (16) with oil-solublegrease and place it on race (17).

(16) Install seal ring (12) into groove of lockup clutchbacking plate (13).

(17) Install clutch backing plate (13) into pump (34),aligning balance mark on plate with balance mark onpump.

(18) Assemble lockup clutch plate (11) onto backingplate (13).

(19) Using J24648 converter pump cover bushinginstaller (figure 8-50), install bushing (6, figure 8-17) intoconverter cover assembly (5). After assembly, insidediameter of bushing must be 0.9990 to 1.0010 inch.

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Figure 8-47. Stator Needle Roller Bearing Installation

Figure 8-48. Installing Freewheel Roller Race Figure 8-49. Springs and Roller Installation in CamPockets

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Figure 8-50. Installing Bushing in Converter PumpCover

(20) Install seal ring retainer (7) onto groove In hub ofconverter cover assembly (5) ; larger diameter towardopen side of cover; then install seal ring (8) into seal ringretainer.

(21) Install seal ring (10) into groove in lockup clutchpiston (9).

(22) Insert piston (9) into cover assembly (5), withbalance marks on parts aligned, so that piston guidepins will enter nearest holes in piston.

NOTETo facilitate installation, place a pencilmark in line with pin nearest orifice inpiston when balance marks are aligned.Then, when inserting piston, use pencilmark as a guide for location of pinbeneath orifice. One recessed hole isconcentric with orifice. Rotate pistonslightly, if necessary, during insertion toensure that piston engages pins. Toensure that piston is seated, measuredistance from pump cover mountingsurface to piston. This distance Isapproximately 1-1/2 inches when pistonis seated.

NOTELockup clutch will not release if piston isnot engaged with pins.

(23) Using hand force only on center of piston (9),depress piston into cover assembly (5), and install snapring (14) into groove in hub of cover assembly to retainpiston.

(24) Coat bearing race (15) with oil-soluble greaseand Install race, Inner lip first, into hub of coverassembly (5).

(25) Install cover assembly (5) onto pump assembly(34) with balance marks on parts aligned. Secureconverter cover with nuts (4). Tighten nuts to torquevalue specified in Table 8-5.

(26) Install a spacer (3) and a spacer retainer (2)onto each stud on converter cover assembly (5).

(27) Support converter assembly on converter cover(5) with pump hub (30) upward, as shown In figure 8-16A. Place J24470 -converter end play gauge assemblyinto converter pump hub. Hold center screw of gaugeassembly and tighten until gauge assembly is secure.

(28) Install a dial indicator as shown In figure 8-16B.Adjust indicator bracket so stem of indicator is in firmcontact with top of center screw in converter end playgauge assembly. Set dial Indicator to read zero.

(29) Using both hands, lift center screw of gaugeassembly as far as possible and note dial indicatorreading.

(30) Refer to Table 8-6 and select proper spacer (18,figure 8-17) for use between bearing race (17) andturbine (19) Remove gauge assembly from converter.

Table 8-6. Spacer Selection Chart.

Thickness ofDial Indicator Spacer Required Color Code

Reading (inch) (inch) of SpacerLess than 0.0177 None required None0.0177 to 0.034 0.015 Gold0.034 to 0.049 0.030 Silver0.049 to 0.062 0.042 Plain0.062 to 0.079 0.060 Black0.079 to 0.093 0.075 Copper

(31) Remove nuts (4) from bolts (27) ; then removecover (5), piston (9) and related parts as a unit.

(32) Remove bearing assembly (16) and race (17)from hub of turbine (19)

(33) Place selected spacer (18) on hub of turbine(19) and reassemble converter. Recheck end play asdescribed above. Any end play within the range of 0.001to 0.025 inch is acceptable.

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o. Transmission Housing Reassembly.

(1) Install valve guide tube (12, figure 8-3) into borein housing (11), pressing tube until it is 0.56 to 0 60 inchbelow surface of adapter mounting boss.

(2) Install spring (10) and lubrication valve (9),convex side outward, into lubrication valve bore inhousing (11).

(3) Lubricate seal ring (8) with new transmission oil;then install it in groove of adapter (6).

(4) Using new gasket (7), install adapter (6) - inhousing with bolts (5). Tighten bolts to torque valuespecified in Table 8-5.

(5) Install plug (13) in housing (11) and tightensufficiently to prevent oil leakage.

(6) If nameplate (15) was removed, stamp newname-plate with all information on old nameplate, theninstall new nameplate on housing (11) with drive screws(14).

(7) Install plug (41) and washer (40) in housing, andtighten plug to torque value specified in Table 8-5.

(8) Install plugs (39) m housing (11). Tighten plugssufficiently to prevent oil leakage.

(9) Install vent assembly (1) In housing (11),tightening vent assembly sufficiently to prevent oilleakage without damaging vent assembly.

(10) Place selector shaft seal (42) onto J26282installer, with lip of seal away from installer. Apply anon-hardening type sealing compound to outercircumference of seal. Use installer to drive seal Intobore of housing (11) as shown in figure 8-51. Removeinstaller, and lubricate lip of seal with transmission oil.

(11) Guide selector shaft (43) through seal (42).Place detent lever (31) on selector shaft so that selectorvalve pin extends toward inside of housing (11),engaging slot in lever with flats on shaft. Secure lever toshaft with nut (32) and shaft retainer pin (38). Tightennut to torque value specified in Table 8-5.

8-11. INSTALLING MAJOR PARTS GROUPS ANDEXTERNAL PARTS.

a. Installing Center Support and Second Clutch.

(1) Position transmission housing (11, figure 8-3)with center axis vertical, converter end upward.

(2) Install second clutch backing plate (25, figure 8-9)into transmission housing. Then alternately installinternal-splined clutch plates (24) and external-tangedclutch plates (23), starting with an internal-splined plate.Install snap ring (22) into internal groove in housing toretain clutch plates.

Figure 8-51. Installing Selector Shaft Seal inTransmission Housing

(3) Attach J24455 center support lifter into recessbetween step joint rings on hub of center support asshown in figure 8-10. Align tapped hole in centersupport with center support anchor bolt hole in housing,and carefully lower center support into housing. Centersupport (15, figure 8-9) must rest securely against snapring (22).

(4) Install center support anchor bolt (35, figure 8-3)and washer (36) through housing (11) and into tappedhole in center support (15, figure 8-9). Tighten anchorbolt finger tight at this time.

(5) Install J24475-1 compressor base over hub ofcenter support as shown in figure 8-52. Then installJ24475-2 compressor bar and J23717-1 center bolt asshown in figure 8-52, using two 3/8-16 X 1-1/4 bolts tosecure compressor bar to transmission housing. Tightencenter bolt against compressor base with torque of 5 ft.lbs. This is equivalent to a 300 pound load on centersupport hub.

(6) Using J24208-4 snap ring gauge as shown infigure 8-52, measure clearance between top edge ofcenter support and top of snap ring groove in housing.Select the proper snap ring (5, figure 8-9) according to(Table 8-7).

(7) Install selected snap ring (5) in internal groove inhousing to retain center support.

(8) Remove gauge, center bolt, compressor bar,and compressor base from transmission housing andfrom center support.

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Figure 8-52. Compressing Center Support for Selectionof Snap Ring

Table 8-7. Snap Ring Selection Chart.

Measured Snap Ring Snap RingClearance Thickness Color

(inch) (inch)0.150 to 0.154 0.48 to 0.150 Blue0.154 to 0.157 0.152 to 0.154 Yellow0.157 to 0.160 0.155 to 0.157 Green0.160 to 0.164 0.158 to 0.160 Red

(9) Invert transmission housing, output end upward.(10) Using J26915 second clutch gauge as shown in

figure 8-53, check second clutch running clearance byinserting the gauge between second clutch backing plateand recess in transmission housing. When runningclearance is correct, smaller end of gauge (0.049 inch)will center; larger end (0.111 inch) will not. If clearanceis not within above limits, replace clutch plates (23 and24, figure 8-9) as necessary. If correct clearance cannotbe achieved by this method, replace backing plate (25)with a thicker or thinner one. Refer to the separateRepair Parts Manual for available thickness of backingplates.

b. Installing Low Clutch and Rear Cover.

(1) Place adapter housing (3, figure 8-15), with firstclutch piston installed, on work bench piston downward.

Figure 8-53. Checking Second Clutch RunningClearance

(2) Install internal-splined low clutch plates (17) andexternal-tanged low clutch plates (16) in adapter, startingand ending with an external-tanged plate.

(3) Place rear cover (11, figure 8-14), with lowclutch piston installed, on work bench, piston upward.

(4) Align gasket (10) on flange of rear cover (11).

(5) Using a depth micrometer as shown in figure8-54, determine and record dimension A (distance fromtop of adapter housing to top clutch plate) whilemaintaining firm hand force against plates at point ofmeasurement. Also determine and record dimension B(distance from top of low clutch piston to gasket).Subtract dimension B from dimension A to determine lowclutch running clearance. Clearance is acceptable ifwithin range of 0.081 to 0.139 inch; however, the closerthe clearance is to the lower value (0.081 inch), thelonger will be the expected life of the clutch pack.Replace worn clutch plates with new plates to obtainspecified running clearance.

NOTEIf adapter housing and/or rear coverwere replaced, it may be necessary toselect a low clutch piston with adifferent thickness to obtain thespecified running clearance. Refer tothe separate Repair Parts Manual forthicknesses of available pistons.

(6) Remove clutch plates (16 and 17, figure 8-15)from adapter housing (3). Retain clutch plates as aselected set for later installation.

(7) Align gasket (1) on rear end of transmissionhousing.

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Figure 8-54. Determining Low Clutch RunningClearance

(8) Install tanged thrust washer (5) in bore ofadapter housing (3).

(9) Install adapter housing (3), with first clutchpiston installed, on housing using 1/2-13 X 6 inch boltsto maintain gasket alignment during assembly.

(10) Install low planetary sun gear (6) in adapterhousing (3).

(11) Install thrust washer (7) into low clutch planetarycarrier (13) using oil-soluble grease to retain thrustwasher.

(12) Install low clutch planetary carrier (13), withpinions (11) installed, onto sun gear (6).

(13) Install thrust washer (15) onto hub of low clutchring gear (18), using oil-soluble grease to retain thrustwasher. Center thrust washer within planetary assemblyand install ring gear within planetary carrier (13).

(14) Reinstall low clutch plates (16 and 17), asselected In Step 5 above, into adapter housing (3).

NOTE

External-tanged clutch plates (16) areprovided with three sets of doubletangs. Be sure to position thesedouble tangs in the corresponding

double slots in adapter housing (3).If tangs are not positioned properly,movement of the plates will occurunder load.

c. Installing Output Shaft, Rear Cover and Governor.

(1) Insert end of output shaft (3, figure 8-14) into lowclutch ring gear (18, figure 8-15), engaging splines onshaft with splines in gear. Install speedometer drivegear (7, figure 8-14) and spacer (8) on output shaft (3).

(2) Remove bolts used to secure adapter housing(3, figure 8-15), without disturbing alignment of adapterhousing to transmission housing.

(3) Align gasket (10, figure 8-14) on adapterhousing (3, figure 8-15). Then install rear cover (11,figure 8-14) with previously installed parts onto adapterhousing. Secure with bolts (22) and washers (21).Tighten bolts to torque value shown in Table 8-5, asfollows: tighten two bolts that are 180° apart to 33 ft. lbs.,move approximately 90° around the bolt circle andrepeat the operation. Tighten remaining bolts at 180°increments to 33 ft. lbs. Repeat the process, tighteningall bolts to final torque value.

(4) Insert governor assembly (28, figure 8-14) intocavity in rear cover (11). Install governor cover (31) onrear cover with bolts (32), using a new gasket (30)between governor cover and rear cover. Tighten bolts totorque value specified in Table 8-5.

(5) Install nut (27) finger tight onto output shaft (3).

d. Installing First Clutch, Gear Unit and RelatedParts.

(1) Invert transmission housing, front end upward.(2) Remove center support anchor bolt (35, figure

8-3) and washer (36); then remove snap ring (5, figure8-9) from internal groove in transmission housing.

(3) Attach J24455 center support lifter to hub ofcenter support as shown in figure 8-10, and lift centersupport from transmission housing.

(4) Remove snap ring (22, figure 8-9) from internalgroove in transmission housing; then take out secondclutch plates (23 and 24) and second clutch backingplate (25).

NOTE

Since clutch plates (23 and 24) andbacking plate (25) have previouslybeen selected as a matched set,retain these parts as a group forreinstallation.

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(5) Install first clutch ring gear hub (6, figure 8-13)into ring gear (5), and install snap ring (7) into internalgroove of ring gear to retain hub.

(6) Install tanged thrust washer (2, figure 8-15) intohub of adapter housing (3).

(7) Install first clutch ring gear hub (6, figure 8-13)and ring gear (5) into transmission housing, so thatsplines on hub engage splines in low sun gear (6, figure8-15).

(8) Install external-tanged first clutch plates (4) andinternal-splined first clutch plates (3) alternately, startingwith an external-tanged plate.

(9) Install first clutch backing plate (2), and installsnap ring (1) in groove of transmission housing to retainbacking plate.

(10) Using J26914 first clutch gauge as shown infigure 8-55, check first clutch running clearance byinserting gauge between backing plate and snap ring.When running clearance is correct, smaller end (0.074inch) of gauge will enter; larger end (0.147 inch) will not.If clearance is not between these limits, remove andreplace clutch plates as necessary. If clearance is notcorrect when all worn plates have been replaced, installa different thickness of backing plate. Refer to theseparate Repair Parts Manual for thicknesses ofavailable backing plates.

Figure 8-55. Measuring First Clutch Running Clearance

(11) Install second clutch backing plate (25, figure8-9) and second clutch plates (23 and 24) (removed inStep 4 above) in transmission housing. Install snap ring(22) in internal groove in housing to retain clutch plates.

(12) Attach J24454 gear unit lifter to main shaft ofgear unit as shown in figure 8-12.

(13) Coat thrust washer (40, figure 8-11) with oilsoluble grease, and install it on rear hub of rearplanetary carrier (38).

(14) Using a hoist attached to gear unit lifter, lowergear unit into transmission housing, engaging internalsplines in rear planetary carrier hub with splines onoutput shaft (3, figure 8-14), and engaging pinions (37,figure 8-11) in rear planetary ring gear (5, figure 8-15).

(15) Place thrust washer (1, figure 8-11) on front sungear (2)

(16) Install third clutch piston (9, figure 8-9) intocenter support (15), aligning lug on piston with recess insupport. Use care to prevent lips of seal rings (10 and11) from folding back over themselves.

NOTE

When performing the following step,reposition gap in snap ring (22, figure8-9), if necessary, so that it will bebetween any two of the four tangs onspring retainer ring (20).

(17) Attach J24455 center support lifter to hub ofcenter support as shown in figure 8-10. Align tappedhole in center support with anchor bolt hole intransmission housing, and lower center support intohousing. Be sure center support seats on snap ring (22,figure 8-9). Remove lifter.

(18) Install a new center support anchor bolt (35,figure 8-3) and washer (36) through transmissionhousing (11) and into center support (15, figure 8-9).

(19) Install selected snap ring (5) into internal groovein transmission housing to retain center support (15),positioning gap in snap ring between any two tangs onspring retainer ring (7). Then tighten center supportanchor bolt (35, figure 8-3) to torque value specified inTable 8-5.

(20) Install bearing race (15, figure 8-8) and bearing(14) onto hub of center support (15, figure 8-9).

(21) Install teflon step-joint seal rings (12) onto hub ofcenter support (15), using oil-soluble grease to retainseal rings in place.

e. Installing Fourth and Third Clutch.

(1) Install bearing race (13, figure 8-8) on hub offourth clutch housing (12).

(2) Grasp the assembled fourth clutch by springretainer (6), and lower assembly onto hub of centersupport (15, figure 8-9).

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(3) Alternately install external-tanged third clutchplates (4, figure 8-9) and internal-splined clutch plates(3) into housing, starting with an external-tanged plate.Be sure that three sets of double tangs are positioned indouble slots in transmission housing, otherwisemovement of the plates will occur under load.

(4) Install third clutch backing plate (2) onto lastinternal-splined plate (3), and install snap ring (1) intointernal groove in transmission housing to retain plates.

(5) Using J26915 third clutch gauge as shown infigure 8-56, check third clutch running clearance.Clearance is correct if narrow end of gauge (0.050 inch)will enter gap between backing plate and snap ring, butwide end of gauge (0.114 inch) will not enter gap. Ifclearance is incorrect, remove and replace clutch plates(3 and/or 4, figure 8-9) until gap is within limits. Ifnecessary, replace backing plate (2) with one of adifferent thickness. Refer to separate Repair PartsManual for available thicknesses of backing plates.

Figure 8-56. Measuring Third Clutch Running Clearance

f. Installing Forward Clutch.

(1) Align splines of internal-splined fourth clutchplates (3, figure 8-8); then direct compressed air intofourth clutch apply port in transmission housing to applyclutch, preventing clutch plate movement.

(2) Install bearing race (25, figure 8-7) followed byroller bearing assembly (26) on hub of fourth clutch hub(20), using oil-soluble grease to retain race and bearingin place.

(3) Install bearing race (27) on hub of fourth clutchhousing (12, figure 8-8).

(4) Install turbine shaft and clutch housing assembly(3, figure 8-7) with internal and external associatedparts, including forward clutch plates (21 and 22), intotransmission housing. Splines on fourth clutch drivinghub (23) must engage splines in fourth clutch plates (3,figure 8-8). When forward clutch housing is properlyseated, front surface of housing assembly (3, figure 8-7)will be approximately 1/2 inch behind forward edge ofPTO opening in transmission housing.

NOTE

Check for proper seating of forwardclutch by applying short bursts ofcompressed air to fourth clutch applyport in transmission housing. Ifturbine shaft and clutch housingassembly (3) does not move, theassembly is properly seated.

g. Installing Oil Pump and Front Support.

(1) Align gasket (26, figure 8-5) with holes matchedon internal flange of transmission housing (11, figure8-3).

(2) Place bearing assembly (23, figure 8-5), racefirst, on hub of support (20). Use oil-soluble grease toretain race and rollers.

(3) Install bearing race (24) on hub of support (20),using oil-soluble grease to retain race.

(4) Install teflon step-joint seal rings (25) onto hub ofsupport (20), using oil-soluble grease to retain seal ringsin place.

(5) Lubricate seal ring (2) with new transmission oil.(6) Install two 3/8-16 X 6 inch headless guide bolts

into transmission housing.(7) Attach J24473 front support lifter assembly to

converter ground sleeve as shown in figure 8-6.(8) Using a hoist, lower oil pump and support onto

the headless guide bolts and into transmission housing,being sure that all holes in oil pump body are alignedwith corresponding bolt holes in transmission housing. Remove front support lifter.

(9) Install bolts (28, figure 8-5) and rubber coatedwashers (27) through oil pump body and support intotransmission housing, removing two guide bolts beforeinstalling the last two retaining bolts.

(10) Tighten any two bolts (28) 180° apart to 15 ft.lbs. torque. Move approximately 90° around the boltcircle and repeat the operation. Tighten remaining boltsat 180° increments. Repeat the above process,tightening all bolts to final torque value specified in Table8-5.

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h. Installing Control Valve, Low Shift Valve, andTubes.

(1) Place governor pressure check ball (37, figure8-3) into the deep pocket end of the governor pressurerecess in transmission housing (11).

(2) With range selector valve secured, positioncontrol valve assembly body (48, figure 8-4) so thatmodulator valve actuator pin (38) enters bore intransmission housing.

(3) Install bolts (20, figure 8-3) to secure controlvalve body (48, figure 8-4) to transmission housing (11,figure 8-3). Leave bolts loose at this time.

(4) Engage ends of governor tubes (78, figure 8-11)m holes of oil transfer plate (1, figure 8-19), align oiltransfer plate in transmission housing, using seven 1/4-20 X 2-1/2 inch bolts temporarily to align oil transferplate. Be sure to engage other ends of governor tubesinto holes of valve body (48, figure 8-4). Secure oiltransfer plate to transmission housing with bolts (17).Tighten bolts to torque specified in Table 8-5. Removeseven temporary aligning bolts.

(5) Engage groove in range selector valve (9, figure8-4) with pin on detent lever (31, figure 8-3); thenposition detent roller and spring assembly (19) toengage detent lever, and secure to control valve bodywith bolt (18). Tighten bolt to torque valve specified in(Table 8-5).

(6) Align oil transfer plate (1, figure 8-19), transferplate (2), and low shift valve body (3) with internal partsonto oil separator plate. Install bolts (16, figure 8-3) toretain low shift valve body; but do not tighten bolts at thistime.

(7) Install drive tube (81, figure 8-4), trimmer tube(79), and low clutch feed tube (80) in that sequence, byinserting ends of tubes into control valve body (48) andlow shift valve body (3, figure 8-19) after removing anybolts that will be used to retain the tubes. Then reinstallthe bolts through tube brackets but do not tighten at thistime.

(8) Working from the center outward, tighten controlvalve bolts (20, figure 8-3) and low shift valve bolts (16)to torque value specified in Table 8-5.

(9) Install modulator valve retainer (34, figure 8-3)on transmission housing with bolt (33). Tighten bolt totorque value specified in Table 8-5.

i. Installing Modulated Lockup Valve, Oil Filter, andOil Pan.

(1) Align modulated lockup valve body (1, figure8-18) on transmission housing (11, figure 8-3). Securemodulated valve body to transmission housing with bolts

(21). Tighten bolts to torque value specified in Table8-5.

(2) Insert end of oil filter tube (25, figure 8-3) into oilfilter (23). Install seal ring (22) on upper end of tube.Apply oil-soluble grease to seal ring and tocorresponding bore in transmission housing (11).

(3) Align end of oil filter tube (25) in bore oftransmission housing (11) and oil filter (23) on controlvalve. Secure oil filter to control valve with bolt (26).Tighten bolt to torque value specified in Table 8-5.

(4) Install two 5/16-18 by 3 inch headless bolts intwo of the oil pan screw holes in transmission housing(11, figure 8-3). Align gasket (24) on transmissionhousing. Align oil pan (29) on gasket, and secure withwasher-head screws (30), removing headless bolts toinstall last two screws Tighten screws (initially and finallyafter gasket sets) to torque value specified in Table 8-5.

(5) Install plug (27) and washer (28) in oil pan (29,figure 8-3).

j. Installing Torque Converter.

(1) Attach J6795-01 converter assembly lifter totorque converter as shown in figure 8-2.

(2) Using a hoist, lower torque converter intotransmission housing, being careful to avoid damage tooil seal (1, figure 8-5).

NOTEFlat sides of pump hub must engageflats in pump drive gear.

(3) To ensure that converter is properly seated,measure distance from housing mounting flange to nutbearing surface on converter surface as shown in (figure8-57). This distance must be approximately 9/16 inch. Ifmeasurement is not correct, lift, rotate, and recheckconverter.

WARNINGBefore moving transmission fromvertical position, install shippingbracket (31, figure 8-17) across frontend of transmission housing (11,figure 8-3) to prevent torqueconverter from sliding out ofhousing.

(4) After removing holding fixture and holding platefrom transmission, install gasket (2, figure 8-3) and PTOcover (3), if used, on transmission housing (11). Ifapplicable, secure PTO cover with screws (4), andtighten screws to torque value specified in Table 8-5.

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Figure 8-57. Checking Torque Converter Seating Height

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CHAPTER 9

DRIVE SHAFT

Section I. DESCRIPTION

9-1. DESCRIPTION.

The drive shaft consists of a telescoping tube with auniversal joint at each end. The telescoping tubeprovides length adjustment and the universal jointsprovide for misalignment between the transmissionoutput shaft and the differential input shaft.

Section II. REPAIR


a. Removal.

CAUTION

Do not allow bearings to fall off thedrive shaft spiders (12, figure 9-1) asthe shaft is removed from thetransmission and differential yokes.

1. Transmission yoke 7. Cork washer2. Capscrew (16) 8. Flat washer3. Sleeve tube 9. Differential yoke4. Lubrication fitting (3) 10. Lockstrap (8)5. Splined shaft 11. Retainer (8)6. Dust cap 12. Spider (2)

Figure 9-1. Drive Shaft Removal and Disassembly

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TM 9-2320-277-14&P

(1) Bend tabs on lockstraps (10, figure 9-1) andremove eight capscrews (2), four lockstraps (10) andfour retainers (11). Remove only two retainers fromeach yoke end so as to keep spiders (12) with driveshaft.

(2) Compress slip joint to shorten shaft length andlower drive shaft from tractor.

b. Disassembly.

(1) Remove remaining capscrews (2), lockstraps(10) and retainers (11) from both ends of drive shaft.

(2) Carefully remove two spiders (12) so as not tolose bearings.

(3) Remove lubrication fittings (4) only if necessaryfor replacement.

(4) Unscrew dust cap (6) and slide splined shaft (5)from sleeve tube (3).

(5) Remove flat washer (8) and cork washer (7).Discard cork washer.


a. Cleaning.

Clean all parts except spiders (12) and bearings bywashing with cleaning solvent. Use a stiff bristled brushto loosen heavy deposits of grime and grease. Cleanexterior of spiders by wiping with a cloth dampened incleaning solvent.


(1) Inspect the spiders and bearings for evidence ofextreme wear or damage. Check for looseness ofbearings or rough bearing operation. Replace a spiderassembly if any parts are worn or damaged.

(2) Inspect yokes (1 and 9) for signs ofmisalignment and breakage. Replace a damaged yoke.

(3) Inspect the sleeve tube (3) and splined shaft (5)for straightness and evidence of twisting. Inspect thesplines for wear or damage. Replace a damaged tubeor shaft.

(4) Inspect hardware and threaded openings fordamaged threads. Chase damaged threads with theproper size tap. Replace damaged hardware.


a. Reassembly.

(1) Install dust cap (6), flat washer (8) and new corkwasher (7) on splined shaft (5); then slide splined shaftinto sleeve tube (3) and tighten dust cap.

NOTE

Insure that arrows scribed on splinedshaft and slip tube are aligned.

(2) Reinstall lubrication fittings (4).

(3) Reassemble the spider assemblies (12) to thesplined drive shaft using four retainers (11), fourlockstraps (10) and eight capscrews (2). Bend tabs onlockstraps to secure capscrews.

b. Installation.

(1) Position spiders (12) in transmission yoke (1)and differential yoke (9) while expanding slip joint toincrease shaft length.

(2) Secure spider assemblies to the yokes usingfour retainers (11), four lockstraps (10) and eightcapscrews (2). Bend tabs on jockstraps to securecapscrews.

(3) Lubricate the drive shaft at all fittings using agrease gun and grease specified in the Operator'sManual.

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CHAPTER 10

FRONT AXLE

Section I. INTRODUCTION, DESCRIPTION ANDDATA

10-1. INTRODUCTION.

This chapter contains basic description of specificationsand data for, and overhaul procedures for the front axle.


a. Arrangement.

The front axle comprises an axle center member, twosteering knuckles, drum and shoe type brakes, wheelhubs, and steering compartments comprising a steeringarm, steering bull, two tie rod arms, and a cross tubeassembly.

b. Axle Center.

The axle center is of the I-beam type, having integralspring-mounting pads. The axle center is bored at theends for the steering knuckle pins which are held inplace by draw keys.

c. Steering Knuckles and Knuckle Pins.

The steering knuckles are bushed in the upper and lowerbosses so that they may rotate freely on the knucklepins. Core and plates equipped with lubrication fittingscover the ends of the knuckle pins. The knuckle pins areof the straight type and are held in the axle center endsby draw keys. The knuckles provide mounting for thebrake spiders and for the wheel hubs.

d. Brakes.

The brakes are of the double-activated drum and shoetype. Brakes are activated by four brake air chambers,each consisting of a pressure housing and a non-pressure housing separated by a diaphragm.Application of air pressure to the pressure housingsforces a wedge assembly between the plungersmounted in the brake spider which in turn force thebrake shoes outward against the brake drums. Releaseof air pressure allows tension springs to retract theshoes. The brake drums are mounted on the wheelhubs. The brakes are of the self-adjusting type.

e. Wheel Hubs.

The wheel hubs mount on the knuckle spindles on inner

and outer roller bearings. Seals are provided to retainbearing lubricant. The wheel hubs contain studs formounting the front wheels. The brake drums are alsosecured to the wheel hubs.

f. Steering Components.

The steering arm and cross tube arms are taper-fittedand keyed to the knuckles. A cross tube assembly(adjustable in length to allow wheel toe-in toe-outadjustment, and equipped with ball joint-type tie rodends) connects the two cross tube arms. The steeringarm is also equipped with a ball for connecting the lefthand knuckle to the vehicle steering gear.


Specifications and data for the front axle are shown intable 10-1.

Table 10-1. Front Axle Specifications and Data

Manufacturer Rockwell InternationalModel No FF931RDAX48Type I-beamBrakes

Type Shoe and Drum,Self-adjusting

Actuation DoubleSize 15 x 15 in.Operating Medium Air Pressure

Spring Pads IntegralCapacity 12,000 pounds

WARNING

During disassembly, do not strikehardened steel parts such as arms (4and 28, figure 10-2), draw keys (13),and knuckle pins (16) directly with ahammer. Parts may shatter, causingpersonal injury. Always use a brassor bronze drift.

Section II. OVERHAUL PROCEDURES


a. Removing Brake Drums and Wheel Hubs.

(1) Remove front wheels and tires (see Chapter 13).(2) Remove screws (17, figure 10-1) securing brake

drums (18) to wheel hubs from axle.10-1

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Figure 10-1. Front Axle Hub and Drum

(3) Remove screws (14) and washer (15) securingaxle seal sets (1) to wheel hubs (9), then withdraw axleseal sets and remove gaskets (2). Discard gaskets.

(4) Remove jam nuts (3), lock washers (4 and 5),and nuts (6) securing wheel hubs (9) to steeringknuckles (36, figure 10-2). Withdraw wheel hubs (9,figure 10-1) from axle, and remove bearing cases (7 and12).

(5) Do not remove studs (10) from wheel hubs (9)unless replacement is required.

(6) Remove oil seals (13) from wheel hubs (9), thenpull bearing cups (8 and 11) from wheel hubs. Discardoil seals (13).

b. Removing and Disassembling Brake AirChamber.

(1) Using a blunt drift and hammer, loosen colletnuts (3, figure 10-3) on external threads of brake airchambers (2).

(2) Unscrew brake air chambers (2) out of integralplunger housings on brake spider (6), and removewedge assemblies from bores in spiders.

(3) Remove nut (1, figure 10-4) and bolt (2)securing clamp ring (3) to housings (4 and 7). Spread

clamp ring, remove, and separate housings.

(4) Separate diaphragm (5), plate assembly (6) andguide (8) from housings (4 and 7).

c. Disassembling Brakes.

(1) Using brake spring pliers, unhook and removereturn springs (5, figure 10-3) from brake shoes (1).Disengage brake shoes from clips (14) and from slots inends of adjusting bolts (7) and plungers (13).

(2) Remove guide screws (11) and gaskets (12)from plunger housings on spider (6). Discard gaskets.

(3) Remove hollow screws (20), gaskets (12),springs (19), and pawls (18) from plunger housings onspider (6).

(4) Pry seal and retainers (8) out of plungerhousings on spider (6); then remove adjusting bolts (7),adjusting sleeve (10), and plungers (9 and 13) fromhousings.

(5) Remove bolts (15), lock washers (16), and nuts(17) securing clips (14) to spider (6), and withdraw clipsonly if replacement is necessary.

(6) Remove screws, nuts, and washers securingspiders (6) to steering knuckles (36, figure 10-2), andwithdraw spiders.

1. Axle seal set 10. Wheel stud2. Gasket 11. Bearing cup3. Jam nut 12. Bearing cone4. Lock washer 13. Oil seal5. Lock washer 14. Screw6. Nut 15. Washer7. Bearing cone 16. Nut8. Bearing cup 17. Screw9. Hub and cup assembly 18. Drum

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Figure 10-2. Front Axle Assembly

d. Removing Cross Tube Assembly and SteeringKnuckles.

(1) Remove cotter pin (21, figure 10-2) and nuts(22) from tie rod ends (27). Then using a drift andhammer, separate tie rod ends from arms (28).

(2) Loosen nuts (26) and bolts (23), and unscrew tierod ends (27) from cross tube assembly (24). Removeclamps (25) from cross tube assembly (24) only ifreplacement is required.

(3) Remove cotter pins (2, 19, and 38) and nuts (3and 37) from ball (39) steering arm (4) and arms (28).Then, using a drift and hammer, separate ball (39) fromsteering arm (4) and separate steering arm and arms(28) from knuckles (38) and remove keys (1 and 29).

(4) Remove screws (14 and 17) securing caps (5and 33) to knuckles (36), then remove caps and gaskets(6 and 34). Discard gaskets. Remove grease fittings(18 and 32) from caps (5 and 33) only if replacement isrequired.

(5) Remove nuts (12) from threaded ends of drawkeys (13); then using a drift and hammer, drive drawkeys out of axle center (20).

(6) Using a drift and hammer, drive knuckle pins(16) out of knuckles (36) and axle center (20); thenseparate knuckles from axle center and take out seals(8), shims (9), seals (10), and thrust bearings (11).

(7) Pull bushings (7 and 35) from knuckles (36).

1. Key2. Cotter pin3. Castle nut4. Steering arm5. Cap6. Gasket7. Bushing8. Seal9. Shim

10. Seal11. Thrust Bearing12. Hex nut13. Draw key14. Screw15. Washer16. Knuckle pin17. Capscrew18. Grease fitting19. Cotter pen20. Axle center

21. Cotter pin 31. Lock nut22. Nut 32. Grease fitting23. Bolt 33. Cap24. Cross tube assembly 34. Gasket25. Clamp 35. Bushing26. Nut 36. Knuckle27. Tie rod end 37. Nut28. Arm 38. Cotter pin29. Key 39. Ball30. Stop screw

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Figure 10-3. Front Axle Brakes

1. Hex nut 5. Diaphragm2. Bolt 6. Plate assembly3. Clamp ring 7. Housing4. Housing 8. Wedge guide

Figure 10-4. Brake Air Chamber

1. Brake shoe2. Air chamber3. Collet nut4. Wedge assembly5. Return spring6. Spider7. Adjusting bolt8. Seal and retainer9. Plunger

10. Adjusting sleeve11. Guide screw12. Gasket13. Plunger14. Clip15. Bolt16. Lockwasher17. Nut18. Pawl19. Spring20. Screw

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(8) Do not remove stop screws (30) and lock nuts(31) from knuckles unless replacement is required.

10-5. PARTS CLEANING.

a. General.

The importance of thorough cleaning of parts cannot beoveremphasized. Not only must parts be clean to insureproper inspection, but parts must be kept clean aftercleaning and before reassembly.

b. Cleaning Procedures.

CAUTION

Do not clean parts having groundand polished surfaces such asknuckle pins, knuckles, bearing cups,and bearing cones in a hot solutiontank with water and alkaline solutionssuch as sodium hydroxide,orthosilicates, or phosphates.

(1) Clean metallic parts by washing in solvent suchas kerosene or diesel fuel or by steam cleaning. Ifsteam cleaning is used, be sure to dry parts immediatelyand apply a thin coat of oil to ground and polishedsurfaces to prevent corrosion.

(2) Dry parts washed in solvent with compressed airat approximately 40 psig.

10-6. INSPECTING, REPAIRING AND REPLACINGPARTS.

a. Bearings.

Inspect bearing cups (8 and 11, figure 10-1), bearingcones (7 and 12), and thrust bearings (11, figure 10-2)for wear or pitting of roller surfaces, cup surfaces, orrace surfaces, for brinelling, for fatigue cracks, fordiscoloration as evidence of overheating, and for otherdefects or damage. Replace any bearings if damaged ordefective in any way.

b. Knuckles, Arms, Cross Tube, and Axle Center.

(1) Inspect knuckles (36, figure 10-2) for cracks,distortion, deformation or other structural damage.Inspect bearing mounting surfaces of scoring, pitting, orother damage that would prevent good bearing fitup.Replace knuckles if damaged in any way.

(2) Inspect arms (4, and 28) and ball (39) for cracks,distortion, and damage to threads. Replace any partsfound to be defective.

(3) Inspect cross tube assembly (24) and tie rodends (27) for distortion and for damage to threads.Replace any defective or damaged parts.

(4) Inspect axle center (20) for distortion, cracks, orother damage. Replace axle center if distorted orcracked.

c. Brake Drums and Wheel Hubs.

(1) Inspect brake drums (18, figure 10-1) for internalscoring, for warpage, and for other types of damage.Replace drums that are internally scored or warped.

(2) Inspect wheel hubs (9) for warpage, distortion,cracks and for pitting or galling in bearing bores thatwould prevent good bearing fitup. Repair minor damagein bearing bores by polishing with crocus cloth. Replacehubs if cracked, warped, or distorted.

d. Brake Parts.

(1) Inspect brake shoes (1, figure 10-3) for cracks,distortion, and for worn linings. Replace shoes ifcracked or distorted or if linings are worn to depth ofchamfer or groove at side of lining.

(2) Check that plungers (9 and 13) slide freely inrespective bores in spider (6). Replace parts that aregalled or pitted.

(3) Inspect springs (5) for distortion, cracks, or lossof tension. Replace springs that are defective in anyway.

(4) Inspect wedge assembly (4) for cracked ordistorted spring, bent plunger rod or roller cage, for looseor damaged rollers, and other defects. Replace wedgeassembly if damaged or defective.

e. Brake Air Chamber Parts.

(1) Inspect clamp ring (3, figure 10-4), pressurehousing (4), plate assembly (6), and non-pressurehousing (7) for cracks, distortion, stripped, crossed, orbattered threads, and other damage. Replace anydamaged parts.

(2) Inspect diaphragm (5) for tears, holes, anddeterioration. Replace diaphragm if damaged ordeteriorated.


a. Installing Steering Knuckles and Cross TubeAssembly.

(1) Install bushings (7 and 35, figure 10-2) insteering knuckles, using a stepped and piloted type toolthat will prevent collapse or distortion of bushings duringinstallation. See figure 10-5.

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NOTE: ALL DIMENSIONS SHOWN IN INCHES

Figure 10-5. Bushing Installation Tool

NOTE

Press bushings into knuckles inthree or more steps to allowbushings to align themselves in thebores. Be sure oil holes in bushingsare aligned with oil holes in knuckles.First press bushings into knucklesapproximately 1/8 inch; then relieveforce. Press bushings another 1/2inch and relieve force. Then pressbushings into knuckles until flushwith inner machine surfaces ofknuckles.

(2) Ream bushings (7 and 35, figure 10-2) with

reamers having dimensions shown in figure 10-6. Usereamer No. 1 first to ream upper bushing, then reamerNo. 2 to ream lower bushing.

(3) Place steering knuckles (36, figure 10-2) bottomside up in a vise equipped with self metal protectors,then place seal (8) over counterbore in knuckle withrubber lip facing up. Using a sleeve and bronze drift, tapseal into counterbore until it bottoms.

(4) While holding thrust bearings (11) chamferedside up, snap seals (10) or to thrust bearings.

(5) Position knuckles (36) on axle center (20) withknuckle pin holes aligned. Then insert thrust bearings(11) with seals (10) between lower knuckle bosses andlower face of axle center, being certain that bottom sideof thrust bearing are sealed on faces of lower knuckleyokes.

NOTE: ALL DIMENSIONS SHOWN IN INCHES

Figure 10-6. Bushing Reamers

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(6) Place a jack under lower side of yoke onknuckles and raise knuckles so that all clearance istaken up between lower yoke, thrust bearing (11) andlower face of axle center (20).

(7) Align flats on knuckle pins (16) with holes fordraw keys (13) in axle center (20); then tap pins intoplace with a drift and hammer.

(8) Install draw keys (13) at each end of axle center(20). At each end of axle center, be sure to install onedraw key from each side of axle center. Install nuts (12)on draw keys. Tighten nuts to torque specified in Table10-2.

(9) Remove jack from underneath steering knuckle(36); and place it underneath end of axle center (20) atspring mount.

(10) Attach a dial indicator to spindle of knuckle (36)as shown in figure 10-7, locating dial indicate plunger onexposed end of knuckle pin so that line of action isapproximately parallel to knuckle pin center line. Zerothe dial indicator.

Figure 10-7. Checking End Play of Knuckles(11) Set steering knuckle to extreme left turn

position; then, using a pinch bar, lift knuckle to highestpoint and note dial indicator reading as indication of totalclearance between knuckle yoke and axle center.Repeat the above procedure with knuckle set at straightahead and at extreme right turn position.

(12) Select shims (9, figure 10-2) that will limit endclearance to the range of 0.005 to 0.025 inch. Removenuts (12), draw keys (13), and knuckle pins (16); theninsert selected shims between upper yoke of knuckleand axle center. Reinstall knuckle pins, draw keys, andnuts.

(13) Place gaskets (6 and 34) on knuckles (36)followed by caps (5 and 33). Secure caps to knuckleswith screws (14 and 17) and washers (15). Tighten

screws to torque specified in table 10-2.

(14) Install grease fittings (18 and 32) in caps (5 and33). Apply lubricant as specified in Operator's Manual.

(15) Install steering arm (4) in knuckle (36) with key(1). Secure with nut (3). Tighten nut to torque valvespecified in table 10-2, and install cotter pin (19).

(16) Install ball (39) in steering arm (4) with nut (3).Tighten nut to torque specified in table 10-2, and installcotter pin (2).

(17) Install arms (28) in knuckles (36) with keys (29),and secure with nuts (37). Tighten nuts to torquespecified in table 10-2, and install cotter pins (38).

(18) Assemble clamps (25) on ends of cross tubeassembly (24) with screws (23) and nuts (26). Leavenuts loose.

(19) Set knuckles (36) at straight ahead position;then screw tie rod ends (27) into ends of cross tubeassembly (24) equal amounts until studs on tie rod endsalign with tapered holes in arms (28).

NOTE

After wheels have been installed,final toe-in-toe-out adjustment maybe required by turning cross tubeassembly as specified in axlereinstallation procedures.

(20) Install tie rod ends (27) in arms (28) and securewith nuts (22). Tighten nuts to torque specified in table10-2, and install cotter pins (21).

(21) Install stop screws (30) and lock nuts (31) inknuckles. Adjust standout of stop screws in accordancewith vehicle requirements. Then tighten lock nuts totorque specified in table 10-2.

b. Assembling and Installing Brakes.

(1) Install clips (14, figure 10-3) onto spiders (6) withnuts (17), bolts (15), and nuts (17).

(2) Mount spiders (6) onto knuckles (36, figure 10-2)with screws, nuts, and washers as required.

(3) Mask brake shoe web slots in ends of solidplungers (13, figure 10-3) with thin strip of masking tapeto prevent damage to seals (8). Apply film of grease toinside surfaces of seal and retainers (8), then carefullypush seal and retainers onto plungers, stretching outerseal lip over taped end of plunger, until inner lip isseated in second plunger groove and outer lip is seatedin first plunger groove. Remove masking tape.

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Table 10-2. Torque Specifications for Screws and Nuts

(Note: Listing is in order of reassembly instructions).

Torques apply to parts lightly coated with rust preventive type oil. For dry parts, increase torque values by 10%. For partsheavily coated with oil, decrease torque values by 10%.

Torque (Foot Pounds)Location Size

Min. Max.

Draw key nuts 3/8-24 20 307/16-20 30 40

Cap attaching screws 5/16-18 20 30

Steering arm nut* 7/8-14 250 (initial) 325 (initial)450 (final)

1-14 390 (initial) 525 (initial)725 (final)

1-1/8-12 650 (initial) 740 (initial)1025 (final)



Steering arm ball nut* 5/8-16 60 (initial) 80 (initial)115 (final)

5/8-18 60 (initial) 80 (initial)115 (final)



Cross tube arm nut* 1-14 390 (initial) 525 (initial)725 (final)



Tie rod end nut* 9/16-18 40 (initial) 55 (initial)75 (final)

5/8-16 60 (Initial) 80 (initial)115 (final)




1-14 250 (initial) 325 (initial)450 (final)

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Table 10-2. Torque Specifications for Screws and Nuts (Continued)


Min. Max.

Tie rod end nut 1-1/8-12 350 (initial) 475 (initial)(continued)* 650 (final)

Cross tube clamp nuts 5/16-24 7 93/8-24 18 247/16-20 35 501/2-20 40 555/8-18 50 65

Stop screw lock nut 1/2-13 50 65

Pawl cap screw - 15 25

*These nuts require installation of cotter pins. Tighten nuts within initial range shown. Then increase torque (if required)to install cotter pin. If torque shown as maximum final is exceeded, remove nut and reinstall.

NOTE

Install plungers (13) marked "L" inleft hand brake and plungers marked"R" in right hand brake.

(4) Coat plungers (13) with grease, and completelyfill cavities behind seal and retainers (8) with grease.

(5) Insert plungers (13) into bores of spider (6) withkeyways in plungers aligned with guide screw holes. Besure plungers go all the way into bores and seat onbosses at bottom of bores.

(6) Using a 1-3/4-inch wrench socket, carefully driveseal and retainers (8) on solid plungers (13) into bores ofspider (6).

(7) Install guide screws (11) with gaskets (12) intospiders (6). Ends of screws must locate in keyways ofplungers (13).

(8) Coat inside and outside surfaces of adjustingplungers (9) with grease, and insert plungers into boresof spider (6).

(9) Coat seal and retainers (8) and threads ofadjusting bolts (7) with grease and assemble seals andretainers on bolts. Coat adjusting sleeves (10) withgrease and thread onto adjusting bolts.

(10) Insert adjusting sleeves (10), bolts (7) and sealand retainers (8) into bores in spider (6).

NOTE

Adjusting sleeves (10) must bottomon shoulders of plungers (9). If bolts(7) are threaded too far into sleeves,bolts will bottom in plungers andautomatic adjusters will not function.

(11) Coat pawls (18) with grease, and assemblepawl, spring (19) and hollow cap screws (20) in spiders(6) with gaskets (12) Tighten cap screws to torquespecified in table 10-2.

(12) Using a 1-3/4-inch wrench socket, carefully driveseal and retainers (8) into bores of spider (6).

(13) Align brake shoes (1) in clips (14) with webs ofshoes engaged in slots of plungers (13) and adjustingbolts (7). Then, using brake spring pliers, install returnsprings (5) on brake shoes.

(14) Insert wedge assemblies (4) into spiders (6),being sure that rollers on wedge assemblies engageslots in ends of plungers (9 and 13).

c. Assembling and Installing Brake Air Chambers.

(1) Install wedge guide (8, figure 10-4) in housing(7).

(2) Assemble plate assembly (6) and diaphragm (5)in housing (7), and install housing (4) over diaphragm(5).

(3) Assemble clamp ring (3) over flanges ofhousings (4 and 7) and secure with bolt (2) and nut (1).Leave nut loose.

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(4) Thread collet nut (3, figure 10-3) onto housing ofbrake air chamber (2). Apply non-hardening sealer tofirst three threads of brake air chamber tube.

(5) Thread brake air chamber into tapped hole inspider (6), and tighten until bottomed with collet nut (3)loose.

(6) Rotate housing (4, figure 10-4) so that inlet portis aligned for vehicle installation requirements, thentighten nut (1).

(7) Temporarily place brake drums (18, figure 10-1)over brake shoes (1, figure 10-3); then apply 120 psig airpressure to brake air chamber port, and hold.

(8) Tighten collet nuts (3, figure 10-3) againstspiders (6), firmly by hand; then, using a drift andhammer, tighten collet nuts an additional 3/16 turn (or 1-1/2 teeth).

(9) Check for air leaks. Make any requiredcorrections if air leaks are detected.

(10) Release air pressure and remove brake drums.

d. Installing Wheel Hubs and Brake Drums.

(1) Drive or press wheel studs (10, figure 10-1) intohubs (9) until fully bottomed.

(2) Press bearing cups (8 and 11) into wheel hubs(9) until fully bottomed.

(3) Install oil seals (13) and bearing cones (12) onspindles of knuckles (36, figure 10-2).

(4) Pack bearing cones (7 and 12, figure 10-1) withlubricant specified In Operator's Manual.

(5) Place wheel hubs (9) on spindles of knuckles(36, figure 10-2) and place bearing cones (7) on spindlesand inside bearing cups (8). Then install wheel bearingadjusting nuts (6). Tighten adjusting nuts againstbearing cones (7) with 50 foot pounds torque whilerotating wheel hubs to ensure that all bearing surfacesare in contact.

(6) Back bearing adjusting nut (6) off 1/6 to 1/4 turn.

(7) Install lock washers (5 and 4) followed by jamnuts (3) on spindles of knuckles to lock bearingadjustment nut against rotation.

(8) Install axle seal sets (1) on wheel hubs (9) withscrews (14) and washers (15), using new gaskets (2).

(9) Install brake drums (18) on wheel hubs (9) withscrews (17).

(10) Install front wheels and tires (see Chapter 13).

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CHAPTER 11

REAR (DRIVE) AXLE

Section I. INTRODUCTION, DESCRIPTION, ANDDATA

11-1. INTRODUCTION.

This chapter contains basic description of, specificationsand data for, and overhaul procedures for the rear(drive) axle.


a. Arrangement.

The major parts of the rear axle comprise the axlehousing, axle shafts, wheel hubs, brake drums, brakes,and double-reduction drive unit consisting of pinion andbevel gear, reduction gears, and limited-slip differentialassembly. Refer to figure 11-1.

Figure 11-1. Rear Axle Assembly

1. Carrier assembly2. Axle housing3. Plug4. Filler plug5. Breather assembly6. Stud7. Heat indicator8. Plug9. Brake chamber

10. Clamp plate11. Torque link12. Screw13. Nut14. Screw

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b. Axle Housing.

The axle housing is of one piece construction. Itprovides mounting for the drive unit, brakes, wheel hubs,and axle shafts.

c. Axle Shafts.

The two axle shafts are rigidly attached to the two wheelhubs, and splines on the ends of the axle shafts engagesplines in the two side gears within the differential.

d. Wheel Hubs.

The two wheel hubs are roller-bearing mounted on theends of the axle housing and are driven by the axleshafts. The hubs contain studs for attachment of thebrake drums and rear wheels.

e. Brake Drums.

The two brake drums are rigidly mounted to the wheelhubs. The drums surround the brake shoes.

f. Brakes.

The brakes comprise the brake shoe and liningassemblies, spiders, cam shafts, brackets, and brake airchambers. The spiders are rigidly mounted at the endsof the axle housing and the shoe and lining assembliesare pivot mounted on the spiders. The shoe and liningassemblies are actuated by the cam shafts which in turnare controlled by the brake air chambers. The brakesare normally applied due to a heavy spring in the upperchamber in each brake air chamber. When this chamberis pressurized, the spring is caged and the brakesrelease. For service operation, the lower chambers arepressurized, rotating the camshafts to apply the brakes.For parking or emergency application, pressure in theupper chambers is exhausted, allowing the springs toapply the brakes. The brake air chambers are alsoequipped with special release studs which can be usedto cage the springs, thus releasing the brakes when airpressure is not available.

g. Drive Unit.

The drive unit incorporates a roller bearing input pinionshaft which drives a bevel gear. The bevel gear ismounted on a pinion shaft, the integral pinion of whichdrives a spur gear attached to the differential cage. Thedifferential is of the limited-slip type.


Specifications and data for the rear axle are presented intable 11-1.

Table 11-1. Rear Axle Specifications and Data

Manufacturer Rockwell InternationalModel PX132Type U240Load Rating 32,914 poundsSuspension Rubber MountBrakes

Type Spring, Drum & ShoeSize 16-1/2 x 7 inches

Reduction ratio 11.36:1

Section II. OVERHAUL PROCEDURES

NOTE

Before starting to disassemble rearaxle, plug all openings to the interiorof the housing and thoroughly steamclean all exterior surfaces.

11-4. DISASSEMBLY.

a. Removing Brake Chambers.

(1) Remove dust plug (1, figure 11-2) from cover ofspring chamber assembly (6).

(2) Remove release stud (2) from hole in adapter(7), and remove nut and washer from release stud.

(3) Insert cross pin end of release stud throughcover of spring chamber assembly (6) and engage inpressure plate. Turn release stud 1/4 turn clockwise tosecure pin in release stud in pressure plate.

(4) Install washer and nut on release stud (2).Tighten nut with a wrench to completely cage internalspring. While tightening nut, check that push rod (19) isretracting into housing assembly (15).

WARNING

Do not attempt to remove releasestud (2) from spring chamberassembly. Spring inside springchamber assembly is under extremetension. Serious bodily injury couldresult if spring is released.

(5) Remove cotter pins from pins in devises (14,figure 11-2) and disengage pins from clevises and slackadjusters (10, figure 11-3).

(6) Remove nuts (16, figure 11-2) and lock washers(17) securing brake chambers (7, figure 11-3) to brakechamber brackets (17); then withdraw brake chambersfrom brackets.

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1. Dust plug 8. Diaphragm (2) 15. Housing Assembly2. Release stud 9. Screw (2) 16. Nut (2)3. Nut (2) 10. Plate (2) 17. Lock washer (2)4. Bolt (2) 11. Spring 18. Nut5. Clamp half (2) 12. Push rod adapter 19. Push rod6. Spring chamber assembly 13. O-Ring 20. Spring7. Adapter 14. Clevis assembly 21. Dust boot assembly

Figure 11-2. Brake Chamber

b. Disassembling Brake Chambers.

WARNINGBe sure release stud has beeninstalled in brake chamber asdescribed in paragraph 11-4 steps 1through 4 before proceeding

(1) Remove nuts (3, figure 11-2) and bolts (4); thendisengage clamp halves (5) from adapter (7) and springchamber assembly (6) and separate adapter from springchamber assembly.

(2) Remove diaphragm (8) from spring chamberassembly (6). Discard diaphragm.

(3) Remove nuts (3) and bolts (4), then disengageclamp halves (5) from adapter (7) and housing assembly(15); then separate housing assembly from adapter.

(4) Remove diaphragm (8) from adapter (7).Discard diaphragm.

(5) Remove screws (9) securing plates (10) to endsof push rod adapter; and separate plates, spring (11)and push rod adapter from adapter (7).

(6) Remove O-ring (13) from recess in adapter (7)Discard O-ring.

(7) Unscrew clevis (14) and nut (18) from push rod(19), then remove dust boot assembly (21).

(8) Remove push rod (19) from housing assembly(15) and remove spring (20) from push rod.

c. Removing Axle Shafts, Brake Drums, and WheelHubs.

(1) Remove rear wheels and tires (see Chapter 13).

NOTEIf lubricant has not previouslydrained from axle housing, removeplug (3, figure 11-1) and allowlubricant to drain before proceeding.Reinstall plug.

(2) Remove nuts (1, figure 11-4) and lock washers(2) from studs (15).

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1. Return Spring (2) 11. Retainer (2) 21. Retainer (2)2. Retainer (8) 12. Washer (2) 22. Preformed packing (2)3. Retainer (8) 13. Washer (4) 23. Oil seal (2)4. Felt (8) 14. Bushing (2) 24. Bushing (2)5. Anchor pin (4) 15. Screw (8) 25. Nut (12)6. Brake and lining Assembly (4) 16. Lock washer (8) 26. Washer (12)7. Brake air chamber (2) 17. Bracket (2) 27. Screw (12)8. Retaining ring (2) 18. Gasket (2) 28. Spider (2)9. Retainer (2) 19. Camshaft (2) 29. Lock wire

10. Slack adjuster (2) 20. Washer (2) 30. Screw (4)

Figure 11-3. Rear Axle Brakes

Figure 11-4. Rear Axle Shafts, Hubs and Drums

1. Hex nut (16)2. Lock washer (16)3. Tapered sleeve (16)4. Axle shaft5. Gasket (4)6. Oil seal (2)7. Wiper(2)8. Nut(2)9. Lock washer (2)

10. Nut (2)11. Bearing cone (2) 12. Bearing cone (2)

13. Oil seal (2)14. Brake drum (2)15. Stud (8)16. Bearing cup (2)17. Bearing cup (2)18. Hub(2)19. Wheel stud (20)20. Nut (20)

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CAUTIONDo not strike studs (15) since thismay cause them to shatter orsplinter. Do not use chisel or wedgeto loosen axle shaft (4) or taperedsleeves (3) since this procedure willdamage wheel hub, shaft, and oilseal.

(3) Place a 1-1/2 inch diameter brass drift againstcenter of axle shaft (4), and strike drift sharply with a 5-to6-pound hammer or sledge to loosen tapered sleeves(3). Then remove tapered sleeves.

(4) Withdraw axle shafts (4) from the axle housing.Remove gaskets (5), outer oil seal (6), and seal wiper (7)from flange of axle shaft (4) and face of wheel hub (18).Discard gaskets, oil seal, and seal wiper.

(5) Remove nuts (21) from wheel studs (19), thenwithdraw brake drums (14) from wheel hubs (18).

(6) Remove nuts (8), lock washers (9), and nuts(10) from threaded ends of axle housing. Then,withdraw wheel hubs (18) from ends of axle housing andtake out bearing cones (11 and 12).

(7) Pull bearing cups (16 and 17) from recesses inwheel hubs (18)

(8) Remove oil seals (13) from ends of axlehousing. Discard oil seals.

(9) Do not remove wheel studs (19) from wheelhubs (18) unless replacement is required. Ifreplacement is required, drive studs out of hub flangewhile solidly supporting flanges to prevent distortion.

d. Removing and Disassembling Brakes.

(1) Unhook shoe return spring (1, figure 11-3) fromshoe and hiring assemblies (6).

(2) Remove retainers (2) from grooves in ends ofanchor pins (5). Then remove retainer (3) and felts (4).

(3) Remove lockwire from heads of cap screws(30). Then remove cap screws from spider (28).

(4) Disengage anchor pins (5) from spider (28) andshoe and lining assemblies (6). Then lift off shoe andhiring assemblies (6).

(5) Remove retaining rings (8) from grooves in endsof camshafts (19). Then remove retainer (9), slackadjusters (10), retainers (11) and washers (12 and 13)from camshafts.

(6) Withdraw camshafts (19) from spiders (28) andbrake chamber brackets (17); then remove specialwasher (20), retainer (21), preformed packing (22), andoil seal (23).

(7) Take out screws (15) and lock washers (16)securing brake chamber brackets (17) to spiders (28),arid withdraw brake chamber brackets. Remove gasket(18) from spider.

(8) Remove bushings (14) from brake chamberbrackets (17) only if replacement is required.

(9) Remove screws (27), nuts (25) and lockwashers (26) securing spiders (28) to flanges on axlehousing. Then, withdraw spiders from axle housing.

(10) Do not remove bushings (24) from spiders (28)unless replacement is required.

e. Removing Carrier Assembly.

NOTEAxle shafts must be at least partiallywithdrawn from axle housing beforecarrier assembly can be removed.

(1) Remove carrier assembly to axle housing studnuts and lock washers, leaving two top nuts on studs toprevent carrier assembly from falling.

(2) Break carrier assembly loose from axle housingby tapping with a rawhide mallet. Remove taper dowelsfrom studs.

(3) Remove two top nuts from studs and workcarrier assembly free, using puller screws in holesprovided.

NOTEA small pinch bar may be used tostraighten carrier assembly in axlehousing to facilitate removal. Do notuse any type of bar that will damagemounting flange on carrier assembly.

f. Disassembling Carrier Assembly.

(1) Mount carrier assembly in 3-11546 or similarrepair stand.

(2) Punch mark one leg of one bearing cap (4,figure 11-5) and corresponding leg of differential carrier(1) for identification at reassembly.

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34. Shim35. Shim36. Shim37. Oil seal38. Companion yoke assembly39. Plug40. Screw41. Screw

14. Cover 42. Screw15. Washer 43. Washer16. Screw 44. Cage assembly17. Bolt 45. Bearing cup18. Spur gear 46. Shim19. Bearing cone 47. Shim20. Bearing cup 48. Shim

1. Carrier and cap assembly 21. Screw 49. Screw2. Screw 22. Washer 50. Bearing retainer3. Washer 23. Gasket 51. Bearing cone4. Cap 24. Lock nut 52. Key5. Screw 25. Input pinion and bevel gear 53. Pinion shaft6. Washer 26. Shim 54. Cage assembly7. Nut 27. Shim 55. Bearing cup8. Screw 28. Shim 56. Shim9. Washer 29. Bearing cone 57. Shim

10. Nut 30. Bearing cone 58. Shim11. Limited-slip differential 31. Cage assembly 59. Screw12. Plug 32. Bearing cup 60. Lock washer13. Gasket 33. Bearing cup 61. Cover

Figure 11-5. Differential Carrier Assembly

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(3) Remove screws (2) and flat washers (3)securing bearing caps (4) to differential carrier (1), andwithdraw bearing caps and bearing adjusting nuts (7).Remove screws (5) and flat washers (nut locks) (6) fromdifferential bearing caps.

(4) Insert a strong wooden dowel through limitedslip differential assembly (11) to serve as handles; thenlift differential assembly with spur gear (18) and otherassociated parts from carrier and cap assembly (1).Separate bearing cups (20) from bearing cones (19).

(5) Using a bearing puller, remove bearing cones(19) from differential assembly (11).

(6) If spur gear (18) requires replacement, removebolts (17) securing spur gear to differential assembly,and press spur gear from differential (11).

(7) Do not disassemble differential (11). The limitedslip differential is serviced as an assembly only.

(8) Remove screws (21) and washers (22) securingpinion cage assembly (31) to carrier and cap assembly(1). Then withdraw cage assembly with associatedparts, using a brass drift applied to inner face of inputpinion (25) and hammer (if necessary) to tap cage free.

(9) Remove and retain shims (26, 27, and 28) as aset to facilitate adjustment at reassembly.

(10) Align cage assembly (31) on carrier and capassembly (1), and attach with three screws (21). Lockinput pinion against rotation by attaching a torque arm tocompanion yoke assembly (38), and remove lock nut(24) from input pinion.

(11) Remove torque arm from companion yokeassembly (38), and remove cage assembly (31) fromcarrier and cap assembly (1).

(12) Place cage assembly (31) flange side downwardon bed of an arbor press and carefully press input pinion(25) out of companion yoke assembly (38) and cageassembly (31).

(13) Remove and retain shims (34, 35, and 36) as aset to facilitate adjustment at reassembly.

(14) Remove oil seal (37), bearing cone (30) andbearing cups (32 and 33) from cage assembly, and pullbearing cone (29) from input pinion (25).

(15) Do not remove plug (39) from cage assembly(31) unless replacement is required.

(16) Remove screws (41, 42, and 43) and washers(43) securing cage assembly (44) to carrier and capassembly (1).

(17) Insert a pinch bar between bevel gear (25) andcarrier and cap assembly (1), and pry gear and shaft(53) toward cage assembly (44), forcing cage assemblyout of bore in carrier and cap assembly.

(18) Remove and retain shims (46, 47, and 48) as aset to facilitate adjustment when reassembling.

(19) Tilt pinion shaft (53) and withdraw it with bevelgear (25) and bearing cones (51) from carrier and capassembly (1).

(20) Remove screws (49) and bearing retainer (50)from end of pinion shaft (53). Then place pinion shaft inan arbor press and carefully press shaft out of bevelgear (15) and bearing cone (51), being careful not toloose key (52).

(21) Pull bearing cone (51) from pinion shaft (53).

(22) Remove screws (41) and washers (43) securingcage assembly (54) to carrier and cap assembly (1);then remove cage assembly.

(23) Retain shims (56, 57, and 58) as a set tofacilitate adjustment at reassembly.

(24) Pull bearing cups (45 and 55) from cageassemblies (44 and 54, respectively).

(25) Remove screws (59) and lock washers (60)holding cover (61) on carrier and cap assembly (1); thenremove cover and gasket (23).

(26) Remove screws (16) and washers (15) securingcover (14) to carrier and cap assembly (1); then removecover and gasket (13).

(27) Do not remove plug (12) from carrier and capassembly (1) unless replacement is required.

11-5. PARTS CLEANING.

a. General.

The importance of thorough cleaning of parts cannot beoveremphasized. Not only must parts be clean to insureproper inspection, but parts must be kept clean aftercleaning and before reassembly.

b. Cleaning Procedures.

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CAUTIONSteam cleaning of internalsubassemblies is not recommendedsince moisture may be trappedbetween close fitting parts. This canlead to corrosion (rusting) of criticalparts and the possibility ofcirculating rust particles in thelubricant after axle is in use.

CAUTIONDo not clean parts having groundand polished surfaces such as gears,shafts, and bearings in a hot solutiontank or with water and alkalinesolutions such as sodium hydroxide,orthosilicates, or phosphates.

NOTECompletely assembled axle may besteam cleaned on the outside only, tofacilitate disassembly, provided allopenings to interior are tightly sealedto prevent entrance of moisture.

(1) Wash metallic parts having ground or polishedsurfaces such as camshaft (19, figure 11-3); bearingcups (16 and 17, figure 11-4; 20, 32, 33, 45 and 55,figure 11-5); hubs (18, figure 11-4); brake drums (14),exterior of differential assembly (11, figure 11-5); spurgear (18); input pinion and bevel gear (25), cageassemblies (31, 44, and 54), and pinion shaft (53) min asolvent such as kerosene or diesel fuel. Use a stiffbrush with solvent, if required, to remove foreign matter.If solvent becomes heavily contaminated, rinse parts minclean solvent. Thoroughly dry washed parts withcompressed air (at approximately 40 psig) or with softclean lintless absorbent paper towels or wiping cloths.Do not dry bearing cones by spinning with compressedair.

(2) Clean other metallic parts such as axle housing(2, figure 11-1); spring chamber assemblies (6, figure11-2); clamp halves (5), housing assemblies (15),adapters (7); brackets (17, figure 11-3); shoe and liningassemblies (6); spiders (28), slack adjusters (10); andattaching parts and shims in hot solution tank with mildalkali solution. Leave parts in solution long enough to beheated through. This will aid in evaporation of rinsewater. Thoroughly rinse cleaned parts with hot water toremove all traces of alkali.

11-6. INSPECTING, REPAIRING, AND REPLACINGPARTS.

a. Bearings.

Inspect bearing cups (16 and 17, figure 11-4; and 20, 32,33, 45 and 55, figure 11-5) and bearing cones (11 and

12, figure 11-4; and 19, 29, 30, and 51) for wear orpitting of roller and cup surfaces, for brinelling, for fatiguecracks, for discoloration as evidence of overheating, andfor other defects or damage. Replace bearing cups andcones as a set if damaged or defective in any way.

b. Gears and Pinions.

Inspect teeth on spur gear (18, figure 11-5), input pinionand bevel gear (25), and pinion shaft (53), for worn,ridged, pitted, or scored condition. Replace if defectivein any way. If replacement of either the input pinion orbevel gear (25) is required, replace both items with anew set.

c. Differential.

(1) Inspect bearing mounting surfaces on differential(11, figure 11-5) for any damage that would preventgood bearing fitup. Inspect differential case for cracks.Replace differential as an assembly if defective in anyway.

(2) Inspect bearing mounting surfaces on pinionshafts (25 and 53) for damage or defects that wouldprevent good fitup of bearing cones. Repair minerdamage or defects by polishing with crocus cloth.Replace severely damaged parts.

(3) Inspect cages (31, 44, and 54) for cracks,distortion, or damage to recesses that receive bearingcups. Replace any defective parts.

(4) Inspect carrier and cap assembly (1) for cracks,distortion or damaged threads. Repair minor threaddamage with a worn (not new) tap of same size asoriginal thread. Replace carrier and cap assembly ifcracked or distorted.

d. Axle Shafts, Brake Drums, and Wheel Hubs.

(1) Inspect axle shafts (4, figure 11-4) for distortion,cracks, and damage to splines and bearing mountingsurfaces. Repair minor defects on bearing mountingsurfaces with crocus cloth. Replace axle shafts ifdistorted, cracked, or damaged.

(2) Inspect brake drums (14) for cracks, distortion,and for grooving in brake lining contact area. Replacebrake drums that are defective in any way.

NOTEReboring of brake drums is notrecommended due to reducedstrength as a result of reboring.

(3) Inspect wheel hubs (18) for cracks, distortionand damage in recesses that receive bearing cups.Repair minor surface defects in bearing recesses bypolishing with crocus cloth or soft stone. Replacecracked or distorted wheel hubs.

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e. Brake Parts.

(1) Inspect anchor pins (5, figure 11-3) for groovingor other damage. Replace pins if defective in any way.

(2) Inspect shoe and lining assemblies for distortionand for cracked or worn linings. Replace shoe and liningassemblies if distorted or worn.

(3) Inspect return spring (1) for distortion and loss oftension. Replace spring if defective.

(4) Inspect slack adjusters (10) for distortion,damaged splines, elongation of clevis pin holes, androtation of splined section as adjusting stud is rotated.Replace slack adjusters if defective.

(5) Inspect bushings (14 and 24) for wear resultingin loose fit on camshaft (19). Replace bushings if worn.

(6) Inspect brackets (17) for cracks and distortion.Replace brackets if defective.

(7) Inspect camshafts (19) for distortion, cracks, anddamage to splines. Replace camshafts if defective.

(8) Inspect spider (28) for cracks or distortion, andfor damaged threads in tapped holes. Repair minorthread damage with a worn (not new) tap. Replacespiders if cracked or distorted.

(9) Inspect clamp halves (4, figure 11-2), housing ofspring chamber assembly (6), adapter (7), housingassembly (15) and push rod (19) for cracks, distortion, ordeformation. Replace any defective parts.

(10) Inspect springs (11 and 20) for deformation,cracks, collapsed coils, or loss of tension. Replacesprings found to be defective.

NOTE

Since disassembly of spring chamberassembly (6) is not practicable, noinspection of internal parts ispossible. Replace entire assembly iffaulty operation is suspected.

11-7. REASSEMBLY.

a. Installing Pinion Shaft and Bevel Gear.

(1) Insert key (52, figure 11-5) into keyway in pinionshaft (53); align keyway in bevel gear (25) with key andpress pinion shaft into gear until hub of gear is firmlyagainst shoulder on shaft.

NOTE

To facilitate installation, bevel gearmay be heated in oil at 200 to 250°F.

(2) Press bearing cones (51) onto ends of pinionshaft (53) until races are firmly seated against shoulderson shaft.

(3) Install bearing retainer (50) on bevel gear end ofpinion shaft (53) with screws (49). Tighten screws totorque specified in table 11-2. Lock wire heads ofscrews with soft iron wire.

(4) Carefully press bearing cups (45 and 55) intocage assemblies (44 and 54, respectively) until cups arefirmly seated.

(5) Place pinion shaft (53) into carrier and capassembly (1); and install cage assembly (54) on carrierwith screws (41) and washers (43), being sure to includeshims (56, 57, and/or 58) between cage assembly andcarrier. Tighten screws to torque specified in table 11-2.

(6) Install cage assembly (44) on carrier and capassembly (1) with screws (40, 41, and 42) and washers(43). Tighten screws to torque specified in table 11-2.

(7) Rotate pinion shaft several revolutions to assurefull bearing contact.

(8) Wrap a length of soft iron wire around teeth ofpinion shaft (53) and attach a spring scale as shown infigure 11-6. Pull wire tangent to pinion shaft and notetorque required to maintain rotation. Disregard torquerequired to start rotation. Torque must be 5 to 15 inchpounds.

Example: Assuming that diameter over teeth is 4 inches,the radius would be two inches. Five pounds pull onscale would equal 10 inch pounds torque.

To increase bearing preload (hence increasing requiredtorque), add one or more shims (46, 47, or 48). Todecrease bearing preload (hence reducing requiredtorque), remove one or more shims (46, 47, or 48). Besure to retighten screws (40, 41, and 42) beforerechecking torque.

b. Assembling and Installing Input Pinion andCage.

(1) Press bearing cone (29) onto input pinion (25),using a sleeve to apply force to bearing cone race. Besure bearing cone makes firm contact with shoulder onpinion shaft.

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Table 11-2. Torque Specifications for Screws and Nuts

(Note: Listing is in order of reassembly instructions.)


Min. Max.

Pinion shaft bearing 7/16-14 42 54retainer screws 9/16-12 94 120

Pinion shaft cage 1/2-13 81 104assembly mounting 1/2-20 81 104screws 9/16-12 116 149

9/16-18 116 1495/8-11 160 205

Yoke assembly nut 1-20 300 4001-1/4-18 700 9001-1/2-12 800 11001-1/2-18 800 11001-3/4-12 800 1100

Input pinion cage 3/8-16 33 34attaching screws 7/16-14 53 67

7/16-20 53 671/2-13 81 1041/2-20 81 1049/16-12 116 1499/16-18 116 1495/8-11 160 205

Case assembly 3/8-16 33 34screws and nuts 7/16-14 53 67

1/2-20 92 1189/16-18 130 1675/8-18 185 2353/4-16 320 415

Carrier and cap 5/8-11 160 205assembly cap 5/8-18 160 205attaching screws or 3/4-10 290 370stud nuts 3/4-16 290 370

7/8-9 470 5957/8-14 470 5951-14 580 745

Nut lock attaching 5/16-18 16 20screws

Inspection cover 3/8-16 27 35attaching screws

Shift unit cover screws 3/8-16 27 35or stud nuts

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Table 11-2. Torque Specifications for Screws and Nuts (Continued)


Min. Max.

Carrier assembly 7/16-14 53 67to axle housing 7/16-20 53 67stud nuts 1/2-13 81 104

1/2-20 81 1045/8-11 160 2055/8-18 160 205

Figure 11-6. Checking Preload of Pinion Shaft Bearings

(2) Press bearing cups (33 and 32) squarely intofront and rear recesses in cage assembly (31) until cupsare firmly seated.

(3) Lubricate bearing cones (29 and 30) andbearing cups (32 and 33) with light machine oil.

(4) Insert pinion shaft (25) into cage assembly (31)and place shim(s) (34, 35 and/or 36) on pinion shaft.

(5) Press bearing cone (30) on input pinion shaft(25), using a sleeve to apply force to bearing cone race.Be sure bearing cone seats firmly against shims (34, 35,36).

(6) Rotate cage assembly (31) several revolutionsto assure normal bearing contact.

(7) While pinion shaft (25) and cage assembly (31)are still in press, check bearing preload torque asfollows:

NOTE

If a suitable press is not available,preload may be checked withcompanion yoke assembly (38) andlock nut (24) installed on input pinionshaft (25) and with nut tightened totorque shown in table 11-3.

(a) Wrap a length of soft iron wire severalturns around cage assembly (31) and attach a springscale to wire as shown in figure 11-7.

(b) Apply force as shown in table 11-3 withpress to preload bearings.

(c) Start cage assembly rotating and checkforce required to maintain rotation by pulling on wire.Convert force to torque. Torque must be 5 to 15 inchpounds.

Example. If cage assembly diameter is 6 inches, theradius would be 3 inches. Four pounds pull on scalewould equal 4 x 3 or 12 inch pounds torque.

Figure 11-7. Checking Preload of Input Pinion Bearings

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If torque is not within the range of 5 to 15 inch pounds,add one or more shims (34, 35, 36) to increase bearingpreload (thus increasing torque) or remove one or moreshims to decrease preload (thus reducing torque).

Table 11-3. Nut Torque Values and Press LoadsRequired to Preload Input Pinion Bearings

Input Pinion Nut Torque Press ForceShaft Thread Required to Required to

Size Obtain Correct Obtain CorrectBearing Preload Bearing Preload(Foot Pounds) (Tons)

1-20 300 to 400 61-1/4-18 700 to 900 111-1/2-12 800 to 1100 141-1/2-18 800 to 1100 141-3/4-12 800 to 1100 14

(8) Coat outer edge of oil seal (37) with non-hardening sealing compound, and press seal firmlyagainst shoulder in cage assembly (31).

(9) Attach cage assembly (31) to carrier and capassembly (1) temporarily with three screws (21); theninstall companion yoke assembly (38) on input pinionshaft (25), and secure with lock nut (24). Tighten nut totorque value shown in Table 11-2. Remove cageassembly from carrier and cap assembly.

(10) Align shims (26, 27, and 28) on carrier and capassembly (1), being sure that screw holes and oilpassages are all matched.

(11) Mount cage assembly (31) with installed inputpinion shaft (25) on carrier and cap assembly (1) withscrews (21) and washers (22). Tighten screws to torquespecified in Table 11-2.

c. Checking and Adjusting Backlash In Used GearSets.

Generally if original gears are being reinstalled, red-leading of teeth will not indicate the same contact asnew gears and can be misleading. Gears that havebeen in service for long periods form running contactsdue to wear of teeth. Therefore, increase the thicknessof the original shim pack by approximately 0.015 inch,then check backlash using a dial indicator set up asshown in figure 11-8. Backlash must be within the rangeof 0.020 to 0.026 inch. In the event the backlash is inexcess of 0.026 inch, reduce backlash (by reducingthickness of shim pack) only in the amount that will avoidoverlap of the worn tooth section (figure 11-9).Backlash, however, may be reduced only to the point of

maintaining smooth rotation of pinion and gear. Checkfor smoothness by rotating bevel gear. If slight overlapis present (figure 11-9B), rotation will be rough.Generally, with the original gear and pinion tone will besatisfactory.

Figure 11-8. Setup for Checking Gear Backlash

A. NO OVERLAP B. OVERLAP

Figure 11-9. Worn Tooth Sections and Matching

d. Checking and Adjusting Tooth Contact andBacklash In New Gear and Pinion Sets.

(1) Using a dial indicator setup as shown in figure11-8, check and adjust bevel gear backlash toapproximately 0.010 inch by varying thickness of shimpack (26, 27, 28, figure 11-5).

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(2) Apply oiled red lead to about 12 to 15 teeth ofbevel gear (25), and rotate pinion. Figure 11-10 showsvarious contact patterns and the direction bevel gearand/or pinion must be shifted to obtain correct pattern.To shift bevel gear away from pinion, transpose shim(s)(56, 57, 58) from under cage assembly (54) to undercage assembly (44). To shift bevel gear toward pinion,transpose shim(s) (46, 47, 48) from under cageassembly (44) to under cage assembly (54) Combinationof shims (46, 47, 48, 56, 57 and 58) must always equalthickness previously selected to maintain bearingpreload. To shift input pinion, add or remove shims (26,27, and 28) between cage assembly (31) and carrier andcap assembly (1).

NOTEThe pattern on the coast side of teethwill appear the same width as on thedrive side, however, the overalllength will be centered between thetoe and heel of gear tooth.

NOTEAfter shifting position of bevel gearor pinion, always readjust backlashto 0.010 inch before proceeding.

(3) After obtaining correct tooth contact, readjustbacklash within the range of 0.020 to 0.026 inch.

e. Assembling and Installing Differential.

NOTEHeat spur gear (18) for about 10minutes in water at 160 to 180degrees F before assembly.

(1) Assemble spur gear (18) on differentialassembly (11) and secure with bolts (17).

(2) Press bearing cones (19) on hubs of differentialassembly (11) until races are firmly seated againstshoulders on differential assembly.

(3) Temporarily install bearing cups (20) in bores ofcarrier and cap assembly (1). Tighten screws (2) totorque specified in table 11-2, and check that bearingcups are hand push fit in bores. If bearing cups bind inbores, use a scraper or emery cloth on bores to providea hand push fit. When proper fit has been obtained,remove screws, caps, and bearing cups.

NOTEUse a blued bearing cup as a gaugeand check the fit as work progresses

(4) Lubricate bearing cones (19) and bearing cups(20) with axle lubricant, place bearing cups on bearingcones, and insert differential into carrier and capassembly (1).

(5) Place bearing adjusting nuts (7) in carrier andcap assembly and tighten hand tight against bearingcups (20)

(6) Place caps of carrier and cap assembly (1) overbearing cups (20) and adjusting nuts (7), and tap lightlyinto position.

CAUTIONIf bearing caps do not seat properly,adjusting nuts are cross threaded.Remove caps and reposition theadjusting nuts. Forcing caps intoposition will result in irreparabledamage to parts.

(7) Install screws (2) and washers (3) to securecaps Tighten screws to torque specified in table 11-2,and lock wire heads of screws.

(8) Turn adjusting nuts (7) to align spur gear (18)with gear teeth on pinion shaft (53), then adjust the nutsto obtain 0.000 inch end play in differential.

(9) Make final adjustment by tightening eachadjusting nut (7) an additional notch to preload bearings.

(10) Install washers (nut locks) (6) on caps of carrierand cap assembly (1) with screws (5). Tighten screws totorque specified In table 11-2. Lock wire heads ofscrews.

(11) Install covers (61 and 14), using new gaskets(23 and 13), with screws (59 and 16) and washers (60and 15). Tighten screws to torque specified in table 11-2.

f. Installing Carrier Assembly In Axle Housing.(1) Place new gasket on studs of axle housing (2,

figure 11-1).

(2) Align flange of carrier assembly (1) on studs maxle housing so that studs project through flangeapproximately 1/4 inch.

(3) Install lock washers and nuts on any studslocated underneath offsets in housing of carrierassembly (1).

(4) Install flat washers and nuts on four other studsequally spaced around flange of carrier assembly (1).

(5) Tighten nuts evenly to draw carrier assembly (1)squarely into axle housing (2).

(6) Remove nuts over flat washers, and install taperdowels, lock washers and nuts on studs. Tighten allnuts to torque specified in table 11-2.

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Figure 11-10. Pinion and Bevel Gear Tooth Contact

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g. Reassembling Brakes.

(1) Press bushings (14 and 24, figure 11-3) intobrackets (17) and spiders (28) respectively; and installoil seals (23), preformed packings (22), and retainers(21) in spiders.

(2) Assemble spiders (28) onto axle housing withscrews (27), washers (26) and nuts (25).

(3) Mount brackets (17) on spiders (28) with screws(15) and lock washers (16), using new gaskets (18)between brackets and spiders.

(4) Place washers (20) on camshafts (19), theninsert camshafts through spiders (28) and brackets (17).Place washers (13), washers (12), retainers (11), slackadjusters (10), and retainers (9) on camshafts andsecure In place by installing retaining rings (8) ingrooves of ends of camshafts.

(5) Assemble brake shoe and lining assemblies (6)to spiders (28) with anchor pins (5). Center anchor pinswith respect to shoe and lining assemblies, and lock inplace with screws (30). Lockwire screws with soft ironwire.

(6) Assemble felts (4), retainers (3), and retainers(2) on ends of anchor pins (5).

(7) Connect return spring (1) to brake shoe andlining assemblies (6).

h. Assembling and Installing Brake Chambers.

WARNINGDo not remove nut from release stud(2, figure 11-2) before spring chamberassembly (6) has been securelyclamped to adapter (7), since springinside chamber is under extremetension and could cause seriousbodily injury If uncaged.

(1) Place spring (20, figure 11-2) on push rod (19);then insert push rod through housing assembly (15), andinstall dust boot assembly (21), nut (18), and clevis (14)on end of push rod.

(2) Install O-ring (13) In adapter (7).

(3) Insert push rod adapter (12) through adapter (7)and assemble spring (11) and plates (10) don push rodadapter. Secure plates to push rod adapter with screws(9).

(4) Place diaphragm (8) on housing assembly (15)and align adapter (7) on diaghragm. Secure adapter tohousing assembly with clamp halves (5), using bolts (4)and nuts (3) to secure clamp halves.

(5) Place diaphragm (8) on adapter (7); then alignhousing of spring chamber assembly (6) with diaphragm

and adapter. Secure spring chamber assembly toadapter with clamp halves (5), using bolts (4) and nuts(3) to secure clamp halves.

(6) Align assembled brake chambers (7, figure 11-3) on brackets (17) and secure with nuts (16, figure 10-2) and lock washers (17).

(7) Attach devises (14) to arms of slack adjusters(10, figure 11-4) with clevis pins supplied with clevises.

(8) Slowly remove hex nut and washer fromthreaded stem of release stud (1), then depress releasestud and turn slightly to unlock pinned end of releasestud from pressure plate inside spring chamberassembly (6). Withdraw release stud and reassemble inspecial pocket provided in adapter (7).

(9) Reinstall dust plug (I) in cover of spring chamberassembly (6).

i. Installing Wheel Hubs, Axle Shafts, and BrakeDrums.

(1) Drive wheel studs (19, figure 11-4) into holes inwheel hubs (18), providing support underneath flange ofwheel hub to prevent distortion. Install nuts (20) onwheel studs (2) Press bearing cups (16 and 17) intobores of wheel hubs (18) until firmly bottomed.

(3) Install inner oil seals (13) and bearing cones(12) on ends of axle housing.

(4) Install studs (15) min wheel hubs (18)

(5) Place wheel hubs (18) on ends of axle housing,and install bearing cones (11) into bearing cups (16) andsecure parts with nuts (10), lock washers (9) and nuts(8). Tighten nuts (10) first to 50 foot pounds torque whilerotating wheel hubs to ensure complete bearing contactThen back nuts off 1/6 to 1/4 turn and hold securelywhile tightening nuts (8) to lock both nuts againstrotation.

(6) Install outer seal wipers (7).

(7) Place gaskets (5), outer oil seals (6) andgaskets (5) on studs (15).

(8) Carefully insert axle shafts (4) through oil seal(6) and align flange on studs (15).

(9) Secure axle shafts (4) to wheel hubs (18) withtapered sleeves (3), lock washers (2), and nuts (1).

(10) Install brake drums (14) on wheel studs (19),and secure with nuts (21).

(11) Install rear wheels and tires (see Chapter 13).NOTE

Lubricate axle in accordance withOperator's Manual before placingaxle in service.

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CHAPTER 12

AIR SYSTEM


12-1. INTRODUCTION.

This chapter contains basic description of, specificationsand data for, and overhaul procedures for the tractor airsystem. For repair of the tractor brake chambers, referto Chapter 10 (front axle) or Chapter 11 (rear axle). Forrepair of the windshield wiper and control refer toChapter 18.


a. Arrangement.

(1) The major components of the air system (figure12-1) are an air compressor, governor, alcoholevaporator, air reservoirs, air gauge, service braketreadle valve, trailer hand brake control, stop light switch(7), quick release valves, brake air chambers, ratioreducing valve, tractor protection valve, brake controlpanel (15), fifth wheel unlatch cylinder and valve, andvarious fittings and interconnecting hoses.

(2) The air system provides a means of controllingthe brakes through the medium of compressed air. Theair system equipment installed on the tractor is used tomaintain a supply of compressed air, direct and controlthe flow of the compressed air, and transfer the energyof the compressed air into mechanical force and motionnecessary to apply the tractor and trailer brakes.Compressed air is also used to 'operate the roofmounted air horn, windshield wiper motor, and fifthwheel unlatch cylinder.

b. Air Compressor.(1) The air compressor (figure 12-2) is a liquid

cooled, single acting, two cylinder in-line type, which iscooled and lubricated with engine coolant and lubricatingoil supplied through lines that tap directly into the enginecooling and lubrication systems. The major componentsof the air compressor are a governor, inlet valves,discharge valves, unloader valves, cylinder head,pistons, connecting rods, crankshaft, and integralcylinder block and crankcase.

(2) The cylinder head has an inlet and outlet portmachined into its face above each piston. Inlet andoutlet valves consist of spring loaded discs. The inletvalve is pulled open by cylinder vacuum duringdownstroke. The outlet valve is pushed open by cylindercompression during upstroke. The unloader valves eachconsist of a push rod, a piston, and a spring loadingmechanism shared by both unloading pistons consistingof a spring and a saddle that transmits spring force toboth unloader pistons. The unloader valves hold thecylinder inlet valves open, preventing compression,when the desired pressure exists in the air system. Theunloader valves are activated by introducing airpressure, transmitted by the governor, into the cavitybelow the unloader piston. The unloader valves willretract whenever the system pressure drops below thegovernor setting.

(3) Each piston is made of cast iron and is equippedwith three compression rings and two oil rings. The wristpins are held in place by a press fit and a lock wire.

(4) The connecting rods contain sleeve bearings forthe wrist pins and crank pins. Both bearings arelubricated by a full pressure feed via passages throughthe crankshaft and connecting rods.

(5) The crankshaft has machined journals for themain bearings and connecting rod bearings, and issupported in the crankcase by a ball bearing at the frontand a sleeve bearing at the rear. The front bearing ispressed into the crankcase and is self-lubricated. Therear bearing is pressed Into the rear crankcase coverand is lubricated by a full pressure feed through thecover. An oil seal is provided for the crankshaft in thefront crankcase cover.

(6) The cylinder block and crankcase is a one-pieceiron casting. The cylinder block, in addition to thecylinder bores, also contains the primary air intakeopening through which air is drawn into the cylinderhead and cylinders. The crankcase provides support forthe crankshaft and cylinder block and is open at thebottom, with the air compressor mounting plate providingthe closure.

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Figure 12-1. Tractor Air System Components

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LEGEND FOR FIGURE 12-1:

1. Connector (16) 7. Stop light switch (2) 13. Cross 19. Drain cock(2)2. Elbow (25) 8. Check valve (2) 14. Low pressure switch 20. Automatic drain valve3. Reducing bushing (6) 9. Close nipple (3) 15. Brake control panel 21. Discharge fitting4. Bulkhead fitting (12) 10. Horn valve 16. Street elbow (6) 22. Emergency coupling5. Service tee (2) 11. Double check valve 17. Tee (3) 23. Service coupling6. Pipe plug (5) 12. Straight adapter 18. Safety valve

Figure 12-2. Air Compressor Operation

b. Air Compressor Governor.

(1) The governor (figure 12-3) consists of acylindrical body with one inlet port, connected to the airsystem pressure, one outlet port, connected to theunloader valve, and one exhaust port. Alternate portsare plugged. The body houses a spring loaded, hollowpiston. An inner cavity of the piston is open to theoutside of the piston, between two piston rings, which Isopen to the outlet port. On the bottom of this piston islocated an inlet/ exhaust valve disc. Contact betweenthe piston and disc forms an inlet seal. Contact betweenthe disc and a hollow tube forms an exhaust seal. Theupper end of the hollow tube, or exhaust stem, ridesagainst the bottom, flared end of an adjusting screw.The flared end retains a three-piece spring seat for thepiston spring. The top end threads through a cover,retained in the end of the housing by a snap ring. Arubber cap covers the end of the housing.

(2) The governor operates by opening the outletport to either the inlet port or the exhaust port as thesystem Figure 12-3. Air Compressor Governor Operation

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requires. When reservoir pressure reaches 118 to 120psig, the governor piston is subjected to sufficient airpressure to overcome the spring loading, allowing theinlet/exhaust valve to move up, permitting the exhauststem to close the exhaust valve and to open the inletvalve. Reservoir pressure then passes through thegovernor to operate the compressor unloadingmechanism, stopping further compression of air by thecompressor. When reservoir pressure is reduced to 100to 102 psig, the spring loading within the governorovercomes the developed force of the air pressure underthe piston. The valve mechanism is actuated, closingthe inlet valve and opening the exhaust valve, therebyshutting off and exhausting the air from the compressorunloading mechanism, and compression is resumed.

Figure 12-4. Air Tanks, Hoses and Fittings

c. Air Tanks.

(1) The tractor air system uses three air tanks(figure 12-4). The tanks are constructed from stampedand rolled steel sheets with all seams electricallywelded. All connections to the tanks are made throughthreaded pipe fittings. The service and supply reservoirshave a capacity of 1760 cubic inches each. Capacity ofthe emergency reservoir is 830 cubic inches.

(2) The two main air tanks are connected in series,air entering the supply reservoir ("wet tank") first, thenpassing into the service reservoir ("dry tank"). Thesupply reservoir provides a place where the air, heatedduring compression, may cool and cause the watervapor to condense. An automatic drain valve is installedon the "wet tank" to eject the moisture. A tee on thesupply reservoir provides dry air to the compressorgovernor and emergency reservoir. A safety valve onthe emergency reservoir protects the air system byopening to exhaust excessive air pressure. Air isapplied to the emergency and service reservoirs throughcheck valves, which prevent loss of service andemergency air if a leak develops in the supply lines orsupply reservoir.

d. Automatic Drain Valve.

(1) The automatic sump drain valve (figure 12-5)ejects moisture and other contaminants from the supplytank. The valve has a two-piece cast aluminum body,housing a diaphragm-like rubber valve plunger, a springtension valve guide, and a threaded adapter whichcontains a wire mesh filter screen.

Figure 12-5. Automatic Drain Valve Operation

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(2) Rising pressure allows contaminants to drainpast the diaphragm into the bottom sump of the valvehousing. Spring pressure from the valve guide closesthe valve when the pressure is stable. A pressure dropof approximately 2 psig will cause the bottom side of thediaphragm to exhaust the collected contaminants fromthe air tank. The length of time the exhaust valveremains open, and the amount of contaminants ejected,depends upon the sump pressure and the reservoirpressure drop that occurs each time air is used from thesystem. Manual draining is accomplished by moving thewire in the exhaust port upward, holding it in untildraining is completed.

e. Brake Control Panel.The brake control panel (15, figure 12-1) contains threeganged-valves used to control the parking and trailerbrakes. A dual spring brake unit combines the parkingbrake valve and emergency brake release valve into oneunit. The tractor protection valve provides for bothautomatic and manual application of the trailer brakes.

f. Trailer Hand Brake Control.(1) The trailer hand brake control (figure 12-6)

consists of a cylindrical body, secured to the steeringwheel column, and a valve head and handle. The bodyhouses a cam, cam follower, and a spring loaded, hollowpiston. An inner cavity of the piston Is open to theoutside of 'the piston, which is open to the delivery port.

Figure 12-6. Trailer Hand Brake Control Operation

(2) The valve operates by opening the delivery portto either the supply port or the exhaust port, as requiredto apply or release the trailer brakes. The valve allowsgraduated application of the trailer brakes withoutapplying the tractor service brakes.

g. Service Brake Treadle-Valve.

(1) The tractor service brakes are controlled by afoot operated air valve (figure 12-7) mounted on theoperator's cab floor. Movement of a foot pedal on thevalve controls the amount of air pressure delivered to orreleased from the service brakes air chambers.

Figure 12-7. Brake Treadle Valve Operation

(2) The valve consists of a cylindrical body attachedto the bottom of a circular mounting plate. The footpedal, supported on the top of the mounting plate, has aroller on its underside. The roller rides on top of aplunger installed in a hole in the center of the mountingplate. The bottom of the plunger bears against the top ofa spring loaded piston installed in the upper part of thevalve body. The bottom of the piston bears against avalve plunger that is free to move vertically, under spring

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tension, in a cylindrical housing installed in the lower partof the valve body. The bottom surface of the piston, thetop surface of the valve plunger, and a seat machined ona surface in the upper interior of the valve body form aninlet seal. The valve plunger and its housing form a"quick-repair" assembly that contains most of the partsnormally replaced to put a valve back in service. Thisassembly is installed in the valve body by a retainingring, enabling the assembly to be removed and replacedwithout disconnecting any hoses or removing any otherparts.

h. Quick Release Valve.

(1) The quick release valves (figure 12-1), installedon the tractor frame close to the rear brake airchambers, reduce the time required to release the rearbrakes by

hastening the exhaust of air pressure from the brake airchambers.

(2) The quick release valves consist of a circularhousing and lower body containing a diaphragm. Thetop surface of the diaphragm and a seat machined on asurface in the interior of the housing form an inlet seal,and the bottom surface of the diaphragm and a sealmachined on the top surface of the lower body form theexhaust seal.


Specifications and data for major components of thetractor air system are presented in Table 12-1.

Table 12-1. Air System Specifications and Data

Air Compressor Alcohol EvaporatorManufacturer Bendix-Westinghouse Manufacturer Bendix-WestinghouseModel Tu-Flo 501 Type AE-1Part No. 285924 Part No. 284641Type Single-acting Capacity 1 pintDelivery 12-1/2 cfm @ 1250 rpm Brake Treadle ValveNo. of cylinders 2 Manufacturer Bendix-WestinghouseCylinder arrangement In-line Type E-3Operating cycle 2 Part No. 278352Cylinder head cooling Liquid (from engine) Pedal angle 34 degreesBlock cooling Air Ratio Reducing ValveLubrication 011 (from engine) Manufacturer Bendix-WestinghouseCrankshaft speed Type LQ-3

(max.) 3000 rpm Part No. 287276Discharge temperature Hold-off pressure 10 psig

(max.) 400° F Equalizing pressure 65 psigAir Compressor Governor Stop Light Pressure Switch

Manufacturer Bendix-Westinghouse Manufacturer Bendix-WestinghouseType D-2 Type SL-5Part No. 276336 Part No. 286392Cut-in pressure 100 to 102 psig Pressure setting 4 psigCut-out pressure 118 to 120 psig Contact arrangement Normally-open

Emergency Air Tank Trailer Hand Brake ControlManufacturer Bendix-Westinghouse Manufacturer Bendix-WestinghousePart No. 226911 Type TC-2Diameter 7 inches Part No. 229666Volume 830 cu. in. Graduated pressure range 5 to 80 psig

Service and Supply Air Tanks Quick Release ValveManufacturer Bendix-Westinghouse Manufacturer Bendix-WestinghousePart No. 220521 Type QR-1Diameter 9-1/2 inches Part No. 229844Volume 1760 cu. in. Differential pressure 1 psig

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Section II. AIR COMPRESSOR ANDCOMPONENTS

12-4. AIR STRAINER.

a. Filter Element Service.

The air compressor filter element should be inspected atthe interval specified in the separate Operator's Manualand, if necessary, serviced as follows:

(1) Remove two screws (3, figure 12-8) securingcover (4) to strainer body (11). Lift cover (4), top baffle'(5) and filter element (6) from strainer body.

(2) Inspect filter element and top baffle for evidenceof dust and dirt. Clean parts by washing with a milddetergent solution and rinsing with clear water. Allowfilter element to air dry.

(3) Inspect filter element for tears and deterioration.

Replace a damaged filter element.

(4) Insert dry filter element (6) and top baffle (5) instrainer body (11), and secure cover (4) to body withscrews (3).


(1) Remove two screws (3, figure 12-8) securingcover (4) to strainer body (11). Lift cover (4), top baffle(5) and filter element (6) from strainer body.

(2) Remove six screws (7), base plate (8), gasket(9) and lower baffle (10).

(3) If necessary for repair, remove screws (1) andlock washers (2) securing strainer body (11) and gasketto intake adapter on air compressor.


(1) Inspect and service filter element as outlined inparagraph 12-4a.

(2) Clean all metal parts by washing with cleaningsolvent and dry thoroughly.

(3) Inspect hardware and threaded openings fordamaged threads. Replace defective parts.

(4) Inspect mating surfaces of body, base plate andcover for gouges, scratches and pitting. Replacedefective parts.

1. Screw(2)2. Lock washer (2)3. Screw with washer (2)4. Cover5. Baffle6. Filter element7. Screw with washer (6)8. Base plate9. Gasket

10. Baffle11. Body

Figure 12-8. Air Strainer Removal and Disassembly

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(5) Inspect strainer body, baffles, base plate andcover for cracks, breaks, dents and other damage.Replace defective parts.

(6) Be sure all gasket residue is removed fromstrainer body, base plate and air compressor intakeadapter.


(1) Install lower baffle (10), and install base plate (8)on strainer body (11) with new gasket (9) and six screws(7).

(2) Insert filter element (6) and top baffle (5) instrainer body (11).

1. Reservoir2. Gasket3. Evaporator tube4. Preformed packing5. Filter6. Welch plug7. Body8. Filler plug9. Tube connector

10. Tube connector11. Tubing12. Elbow13. Close nipple14. Intake adapter15. Loom16. Hex nut (3)17. Lock washer (3)18. Capscrew(3)19. Reservoir decal

Figure 12-9. Alcohol Evaporator Removal and Disassembly

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(3) Secure cover (4) to body with two screws (3).

(4) Install air strainer assembly on air compressorintake adapter, using new gasket, with two screws (1)and lock washers (2).

12-5. ALCOHOL EVAPORATOR.

a. Removal.(1) Unscrew reservoir (1, figure 12-9) and lower

from body (7).

(2) Disconnect and remove tube connectors (9 and10) and tubing (11).

(3) If necessary for repair, remove intake adapter(14) as follows:

(a) Remove air strainer assembly as outlined inparagraph 12-4b.

(b) Pull intake adapter (14) and gasket from aircompressor.

(4) Remove three capscrews (18), hex nuts (16)and lock washers (17) securing body (7) to side memberof engine radiator, and remove alcohol evaporatorassembly.

b. Disassembly.

(1) Unscrew and remove filler plug (8).

(2) Unscrew evaporator tube (3) and removegaskets (2 and 4).

(3) Remove retaining ring and filter (5).

(4) Remove fittings (9, 10, 12 and 13) and welchplug (6) only if necessary for replacement.

c. Cleaning, Inspection and Repair.(1) Clean all parts except gaskets (2 and 4) and

filter (5) by washing with cleaning solvent. Dry parts withcompressed air at approximately 40 psig.

(2) Clean all gasket residue from intake adapter(14) and air compressor.

(3) Inspect mating surfaces of intake adapter andair compressor for gouges, scratches and pitting.Smooth surfaces with crocus cloth or a fine stone.Replace a Defective intake adapter.

(4) Inspect intake adapter, reservoir and body forcracks, breaks and other damage. Replace defectiveparts.


(6) Inspect tubing (11) for cuts, kinks and evidenceof leakage. Replace defective tubing.d. Reassembly and Installation.

(1) Reassemble alcohol evaporator, using newgaskets (2 and 4) and filter (5), in reverse of procedureoutlined in paragraph 12-5b.

(2) Install alcohol evaporator, using new intakeadapter gaskets, in reverse of procedure outlined inparagraph 12-5a.

(3) Remove filler plug (8), fill reservoir withmethanol alcohol, and reinstall filler plug.

12-6. AIR COMPRESSOR.

a. Removal.(1) Exhaust air pressure from air tanks, and remove

air lines from air compressor and governor.

(2) Remove air strainer as outlined m paragraph12-4b.

(3) Remove intake adapter (14, figure 12-9) andgaskets.

(4) Drain engine cooling system (see Chapter 5).

(5) Remove cotter pin (1, figure 12-10) and castlenut (27); then, using a suitable pulley puller, removepulley (2) from air compressor crankshaft.

(6) Disconnect and remove coolant hoses (4) andlubricating oil hoses (6). Remove fittings (3, 5, 7, 8 and9) only if necessary for repair.

(7) Remove hardware (10, 11, 12 and 26) attachingsupport (25) to bracket (24) and head of air compressor(15).

(8) Remove six bolts (17), hex nuts (13) and lockwashers (14) securing air compressor (15) to enginesupport (20).

NOTEAir compressor weighsapproximately 40 pounds.

(9) Lift air compressor (15) from engine support (20)and remove from tractor.

(10) Remove support (20) and bracket (24) fromengine only if necessary for repair.

(11) Remove and discard gasket (16).

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1. Cotter pin2. Pulley3. Elbow4. Coolant hose (2)5. Connector 1/26. Oil hose (2)7. Connector8. Pipe adapter9. Elbow

10. Hex nut (2)11. Lock washer (2)12. Bolt (2)13. Hex nut (6)14. Lock washer (6)15. Air compressor16. Gasket17. Bolt (6)18. Bolt (4)19. Lock washer (4)20. Support21. Bolt (2)22. Lock washer (2)23. Flat washer (2)24. Bracket25. Support26. Head bolt (2)27. Castle nut

Figure 12-10. Air Compressor Removal

b. Disassembly.(1) Remove two bolts (24, figure 12-11) and lock

washers (25), and pull governor (26) and gasket (27)from crankcase. Discard gasket.

(2) Remove key (49) from crankshaft (29).

(3) Remove screws (52), discharge fitting (51) andgasket (7) from cylinder head. Discard gasket.

(4) If intake adapter gasket remained on crankcase,remove and discard gasket. Pull unloader spring (18),spring seat (17) and spring saddle (16) out the side ofthe block.

(5) Remove two plugs (28), valve seats (3),discharge valves (5) and valve springs (6).

(6) Remove screws (2) and lift cylinder head (55) offof crankcase (10). If necessary, tap cylinder head with arawhide hammer to unseat head gasket seal. Removeand discard gasket (8).

(7) Remove inlet valve spring seats (4) fromunderside of cylinder head.

(8) Pull valve springs (19), valve guides (20), valves(21), valve seats (9), unloader plungers (14), pistons(11), back-up rings (12) and grommets (13) from ports ofcrankcase. Separate plungers (14) from guides (15).

(9) Remove six capscrews (1) and base adapter(43). Remove and discard gasket (48).

(10) Disassemble the pistons and connecting rods asfollows.

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1. Capscrew(6) 15. Plunger guide (2) 29. Crankshaft 43. Base adapter2. Screw (6) 16. Spring saddle 30. Ball bearing 44. Wrist pin (2)3. Discharge valve seat (2) 17. Spring seat 31. Thrust washer 45. Piston (2)4. Inlet valve spring seat (2) 18. Unloader spring 32. Preformed packing 46. Wrist pin plug5. Discharge valve (2) 19. Compression spring (2) 33. Rear end cover 47. Piston ring set6. Discharge valve spring (2) 20. Inlet valve guide (2) 34. Screw (4) 48. Gasket7. Gasket 21. Inlet valve (2) 35. Lock washer (8) 49. Crankshaft key8. Gasket head 22. Strainer gasket (2) 36. Gasket 50. Rod cap (2)9. Inlet valve seat (2) 23. Air strainer assembly 37. Front end cover 51. Discharge fitting

10. Crankcase 24. Bolt (2) 38. Screw (4) 52. Screw (2)11. Unloader piston (2) 25. Lock washer (2) 39. Oil seal 53. Connecting rod (2)12. Back-up ring (2) 26. Governor assembly 40. Connecting rod bearing (2) 54. Bearing (2)13. Grommet (2) 27. Gasket 41. Bolt (4) 55. Cylinder head14. Unloader plunger (2) 28. Pipe plug (2) 42. Lock strap (4)

Figure 12-11. Air Compressor Disassembly

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NOTEIdentify the positions of the parts asthey are removed from the aircompressor. If these parts are to bereused, it will be necessary to installthe parts in their original positions.

(a) Rotate crankshaft (29) until one connectingrod cap (50) is at its lowest point. Remove rod bolts (41)and lock straps (42).

(b) Pull cap (50) off of connecting rod (53) andremove lower bearing shell (40).

(c) Push piston (45) and connecting rod (53) outthrough top of crankcase. Insure that upper bearingshell (40) is not lost.

(d) Remove plugs (46) and, using a brass drift,gently drive wrist pin (44) out of piston (45). Pullconnecting rod (53) out of piston and press sleevebearing (54) out of rod.

(e) Using a suitable ring expander, remove pistonrings (47) from piston (45).

(f) Repeat steps a through e for the remainingpiston and connecting rod.

(11) Remove four screws (34) and lock washers (35)and remove rear cover (33) and thrust washer (31)Remove and discard preformed packing (32).

(12) Remove four screws (38) and lock washers (35)and remove front end cover (37). Remove and discardgasket (36).

(13) Press oil seal (39) out of bore in front end cover(37).

(14) Rotate crankshaft (29) so that front crankpin is inalignment with cut-out in bearing bore in crankcase (10).Using a rawhide hammer, tap on rear end of crankshaftuntil bearing (30) is forced out of its bore in crankcase.

NOTEDo not attempt to remove thecrankshaft rear main bearing. Therear main bearing is not servicedseparately, and can only be replacedby installing a new rear end cover(33).

c. Cleaning, Inspection and Repair.(1) Clean carbon deposits from pistons and cylinder

head with a wire brush.

(2) Remove accumulations of rust, mineral depositsand foreign matter from water passages in cylinderhead.

(3) Clean bearings (30 and 40) by washing withvolatile mineral spirits. Do not spin ball bearing (30) withcompressed air.

(4) Clean remaining parts by washing with cleaningsolvent and a stiff bristled brush.

(5) Inspect sealing surfaces on valves (5 and 21)and seats (3 and 9) for scratches, gouges and pitting.Replace defective parts.

(6) Inspect stems on plungers (14) for excessivewear, scoring, and straightness, and inspect ends ofplungers for excessive wear. Replace defectiveplungers.

(7) Inspect springs (6, 18 and 19) for weak, bentand broken coils. Replace defective springs.

Table 12-2. Air Compressor Wear Limits, Fits and Tolerances

Component Points of MeasurementPISTON RINGS

Dimensions and Tolerances(Inches)

Clearance - ring-to-groove Min. Max.Top (No. 1) 0.0015 0.0035No. 2 0.0010 0.0030No. 3 0.0010 0.0035

GapTop (No. 1) 0.0050 0.0100No. 2 0.0050 0.0100No. 3 0.0060 0.0150

WRIST PINRunning clearance - pin-to-bearing 0.0002 0.0005CONNECTING RODSEnd play - rod-to-crankshaft cheek 0.0030 0.0060Running clearance - bearing-to-crankshaft journal 0.0005 0.0020CRANKSHAFT REAR BEARINGRunning clearance - bearing-to-crankshaft journal 0.0008 0.0028

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(8) Inspect bearing shells (40) and bearings (54) forexcessive wear and scoring, and check bearingclearance as listed in Table 12-2. Replace damaged orexcessively worn bearings.

(9) Examine bearing in rear end cover (33) forexcessive wear and scoring. Replace rear end cover ifbearing is defective.

(10) Inspect connecting rods for straightness, andinspect connecting rods and caps for corrosion anddamage. Replace a damaged rod and cap assembly.

(11) Inspect crankshaft journals and wrist pins forexcessive wear and scoring. Replace defective parts.

(12) Check dimensions of remaining parts as listed inTable 12-2, and replace excessively worn parts.

d. Reassembly and Installation.NOTE

Stagger ring gaps when installingrings on pistons.

(1) Pack bearing (30) with high temperature cupgrease, and reassemble air compressor with newgaskets in reverse of procedure outlined in paragraph12-6b. Tighten hardware to torque values specified in(Table 12-3).

Table 12-3. Air Compressor Assembly Torque Values

Figure

No.

IndexNo. Application

Torque(Ib-ft)

12-11 2 Cylinder head bolts 12 to 1712-11 41 Connecting rod cap

bolts 8 to 1012-10 27 Crankshaft pulley nut 38 to 42

(2) Install air compressor with new gasket in reverseof procedure outlined in paragraph 12-6a. Tighten pulleynut (27, figure 12-10) to torque value specified in Table12-3.

12-7. AIR COMPRESSOR GOVERNOR.

a. Removal and Disassembly.(1) Remove governor (26, figure 12-11) as outlined

in paragraph 12-6b.

(2) Disassemble governor as illustrated in figure12-12.

b.Cleaning, Inspection and Repair.


(2) Inspect springs (5, 11 and 17) for weak, bentand broken coils. Replace a defective spring.

(3) Inspect sealing surface in body bore for cracks,pitting and other damage. Hone a slightly pitted bodybore. If body is beyond repair, replace governorassembly.

(4) Examine remaining parts for damage andexcessive wear. Replace all defective parts.c. Reassembly and Installation.

(1) Reassemble air compressor governor, usingnew preformed packings, as illustrated in figure 12-12.Do not install cover (1) at this time.

(2) Install governor with new gasket in reverse ofprocedure outlined in paragraph 12-6b.d. Governor Adjustment.

NOTECheck accuracy of tractor airpressure gauge with a test gaugebefore making adjustments.

(1) Start engine and build up 118 to 120 psig airpressure in air system; then stop engine.

NOTEIf the governor cuts out (aircompressor stops pumping) before118 to 120 psig air pressure can bedelivered to the air tanks, turn theadjusting screw (9, figure 12-12)clockwise (one complete turn at atime) until specified pressure can bedelivered to the air tanks.

(2) Start engine and slowly exhaust air pressurefrom tanks until governor cuts in (air compressor startspumping). Air pressure gauge should indicate 100 to102 psig.

(3) Continue running engine until governor cuts out,and recheck for 118 to 120 psig air pressure. Readjustscrew (9, figure 12-12) as necessary for 118 to 120 psigcut-out pressure.

NOTEAir compressor governor has a non-adjustable range between cut-in andcut-out pressures. With cut-outpressure set at 118 to 120 psig, cut-inpressure must be 100 to 102 psig. Ifnot, governor is defective and shouldbe replaced.

(4) Stop engine and install cover (1, figure 12-12).

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1. Cover2. Retaining ring3. Hex nut4. Upper spring seat5. Spring6. Lower spring seat7. Spring guide8. Lower spring seat9. Adjusting screw

10. Exhaust stem11. Spring12. Washer13. Grommet14. Preformed packing (2)15. Piston16. Valve17. Valve spring18. Filter (2)19. Body

Figure 12-12. Governor Disassembly

Section III. AIR TANKS AND AUTOMATICDRAIN VALVE

12-8. AIR TANKS.

a. Removal.

(1) Open drain cocks to exhaust air pressure fromtanks.

(2) Disconnect air lines (see figure 12-4), andremove drain cocks, auto drain valve, check valve, plug,tee, elbow and safety valve as applicable.

(3) Support tank and remove hardware securingbrackets (1 or 10, figure 12-13) to air tank and tractor.

(4) Remove cross bar (5) only if necessary forrepair.


(1) Clean air tanks, drain cocks, tee, elbows andplugs by washing with cleaning solvent and a stiffbristled brush. Dry parts with compressed air atapproximately 40 psig.

(2) Clean hoses, check valves and safety valve bywiping exterior with a clean, dry cloth.

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1. Bracket (6) 8. Hex nut (4)2. Capscrew (4) 9. Bar (2)3. Lockwasher (14) 10. Bracket (4)4. Hex nut (14) 11. Capscrew (9)5. Cross bar (2) 12. Capscrew (2)6. Capscrew(4) 13. Flat washer (2)7. Lock washer (4) 14. Lock nut (2)

Figure 12-13. Air Tank Removal

(3) Inspect interior of air tank for accumulations ofrust, corrosion and foreign matter. Flush interior of tankas necessary to remove all foreign matter. Replace anexcessively corroded tank.

(4) Inspect exterior of air tank for cracks and brokenwelds. Repair by welding. Replace an air tank beyondeconomical repair.


(6) Inspect hoses for cracks and deterioration.Replace defective hoses.

c. Installation.

NOTERepair automatic drain valve, ifnecessary, prior to installing onsupply reservoir. See paragraph12-19.

(1) Install air tanks and components in reverse ofprocedure outlined in paragraph 12-8a.

(2) Start engine to build up pressure in air tanks;then stop engine and observe air pressure gauge. If airpressure drops more than 3 psig per minute with brakesreleased, check for leakage using a soapy water solutionat connections and fittings. Presence of bubblesindicates leakage.

12-9. AUTOMATIC DRAIN VALVE.


(1) Push up on wire of valve (7, figure 12-14) toexhaust air pressure from supply reservoir.

(2) Unscrew automatic drain valve and lower fromsupply reservoir.

(3) Disassemble automatic sump drain valve asillustrated in figure 12-14. Discard preformed packing(5).

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1. Body2. Cover3. Washer4. Screw5. Preformed packing6. Valve guide7. Valve8. Plug9. Adapter

Figure 12-14. Automatic Drain Valve Disassembly


(1) Clean all parts by washing with cleaning solventand a stiff bristled brush. Dry with compressed air atapproximately 40 psig.

(2) Inspect valve (7) for scratches and gouges.Replace a defective valve.

(3) Inspect body and cover for cracks and breaks. Replace damaged parts.


(5) Inspect filter in adapter (9) for dirt andobstructions. Replace adapter if unable to thoroughlyclean filter.


(1) Reassemble automatic sump drain valve, withnew preformed packing, as illustrated in figure 12-14.

(2) Screw automatic drain valve into supplyreservoir, and start engine to build up air pressure insupply tank. Check for leaks and proper automaticoperation of drain valve; then stop engine.

Section IV. CHECK VALVES

12-10. CHECK VALVE.



(2) Disconnect air line from check valve(figure 12-4) and unscrew check valve from air reservoir.

(3) Disassemble check valve in numerical sequenceas illustrated in figure 12-15. Discard preformed packing(3).

1. Body2. Valve seat3. Preformed packing4. Valve disc5. Compression spring6. Screw cap

Figure 12-15. Check Valve Disassembly


(1) Clean parts by washing with cleaning solventand a stiff bristled brush. Dry parts with compressed airat approximately 40 psig.

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TM 9-2320-277-14&P

(2) Inspect spring (5) for weak, bent and brokencoils. Replace a defective spring.

(3) Inspect sealing surfaces on seat (2) and disc (4) for scratches, gouges and pitting. Replace defectiveparts.


(1) Reassemble check valve, with new preformedpacking (3), in reverse of numerical sequence illustratedin figure 12-15.

(2) Check for proper valve operation usingcompressed air at approximately 35 psig. Valve shouldallow air flow in direction of arrow, and should block airflow in opposite direction. If not, valve assembly isdefective and must be replaced.

(3) Install check valve on reservoir (figure 124) andreconnect air line to valve.

(4) Start engine to build up pressure in air tanks;then stop engine and check for leakage.

12-11. DOUBLE CHECK VALVE.



(2) Tag and disconnect air lines (1 and 3, figure12-16) from double check valve.

(3) Unscrew double check valve from brake treadlevalve and remove from tractor.

(4) Disassemble double check valve in numericalsequence illustrated in figure 12-16. Discard preformedpacking (9).



(2) Inspect sealing surfaces of shuttle (10), shuttleguide (11) and bore in valve body (12) for scratches,gouges and pitting. Replace damaged parts.


(4) Inspect air lines (1 and 3) for cracks anddeterioration. Replace defective air lines.


(1) Reassemble double check valve, with newpreformed packing (9), in reverse of numerical sequenceillustrated in figure 12-16.

1. Nylon tube2. Tube fitting3. Nylon tube4. Tube fitting5. Pipe plug6. Capscrew (2)7. Flat washer (2)8. Valve cap9. Preformed packing

10. Shuttle assembly11. Shuttle guide12. Valve body

Figure 12-16. Double Check Valve Removal and Disassembly

12-17

TM 9-2320-277-14&P

(2) Check for proper valve operation usingcompressed air at approximately 35 psig. Valve shouldallow air flow from brake treadle valve or trailer handbrake control, and should block air flow in oppositedirection. If not, valve assembly is defective and mustbe replaced.

(3) Install double check valve on brake treadle valveand reconnect air lines.

(4) Start engine to build up pressure in air tanks;then stop engine. Check for leaks while an assistantoperates the brake treadle valve and trailer hand brakecontrol.

1. Capscrew (3)2. Lock washer (3)3. Hex nut (3)4. Spring pin5. Fulcrum pin6. Cotter pin7. Straight pin8. Roller9. Control pedal

10. Rubber bumper11. Dust boot12. Valve plunger13. Mounting plate14. Capscrew (3)15. Lock washer (3)16. Piston retainer17. Preformed packing18. Screw19. Flat washer20. Shouldered washer21. Rubber spring22. Piston23. Valve spring24. Valve body25. Valve plunger26. Preformed packing27. Spring seat28. Compression spring29. Preformed packing30. Plunger retainer31. Exhaust baffle retainer32. Nonmetallic valve disk33. Disk retainer34. Tapping screw35. Snap ring36. Pipe plug

Figure 12-17. Treadle Valve Disassembly

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TM 9-2320-277-14&P

Section V. BRAKE TREADLE AND QUICKRELEASE VALVES

12-12. BRAKE TREADLE VALVE.

a. Removal.

(1) Remove the "quick-repair" insert from thetreadle valve as follows:

(a) Open drain cocks to exhaust air pressurefrom tanks.

(b) Remove snap ring (35, figure 12-17) and"quick-repair" insert from brake treadle valve.

NOTE

The "quick-repair" insert consists ofitems 25 through 34 as illustrated infigure 12-17.

(2) If necessary for repair, remove the brake treadlevalve from the tractor as follows:

(a) Open drain cocks to exhaust air pressure fromtanks.

(b) Tag and disconnect air lines (figure 12-18)from brake treadle valve.

(c) Unscrew and remove double check valve frombrake treadle valve.

(d) Remove three capscrews (1, figure 12-17),hex nuts (3) and lock washers (2), and lift brake treadlevalve from top of cab floor.

1. Hose assembly (24") 6. Elbow (3) 11. Hose assembly (34")2. Hose assembly (14") 7. Adapter (2) 12. Bulkhead fitting (9)3. Hose assembly (45-1/2") 8. Hose assembly (61") 13. Street elbow (3)4. Hose assembly (40") 9. Hose assembly (29") 14. Elbow5. Hose assembly (37") 10. Hose assembly (63-1/2")

Figure 12-18. Treadle Valve Hoses and Fittings

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TM 9-2320-277-14&P

b. Disassembly.

(1) Remove pins (4 through 7) and roller (8), and liftpedal (9) from mounting plate (13).

(2) Remove boot (11) and pull valve plunger (12)from the treadle valve assembly.

(3) Remove three capscrews (14) and lock washers(15), and separate the mounting plate (13) from thevalve body (24). Remove piston retainer (16).

(4) Disassemble remaining parts as illustrated infigure 12-17. Discard preformed packings (17, 26 and29).


(1) Clean all parts except bumper (10), boot (11)and rubber spring (21) by washing with cleaning solventand a stiff bristled brush. Dry clean parts withcompressed air at approximately 40 psig.

(2) Inspect sealing surfaces on plunger retainer(30), piston (22) and bore in valve body (24) forscratches, gouges and pitting. Replace a defectiveplunger or piston. If valve body is defective, replacebrake treadle valve assembly.

(3) Inspect bumper (10), boot (11) and rubberspring (21) for cracks and evidence of deterioration.Replace defective parts.

(4) Inspect springs (23 and 28) for weak, bent orbroken coils. Replace defective springs.

(5) Inspect pins (5 and 7), roller (8) and pedal (9) forexcessive wear. Replace excessively worn parts.


(1) Reassemble brake treadle valve, with newpreformed packings, in reverse of procedure outlined inparagraph 12-12b.

NOTEProngs on piston retainer (16) mustsnap under flange on valve body (24).

(2) Install brake treadle valve in reverse ofprocedure outlined in paragraph 12-12a.

(3) Start engine to build up pressure in air tanks anddepress brake pedal. Observe air pressure gauge andtime for two minutes. If air pressure drops more than 4psig per minute with brake treadle applied, brake treadlevalve is defective or there is leakage. Check for leaks byusing a soapy water solution with brake treadle applied.Bubbles indicate leakage. Brake treadle valve must bereplaced if defective.

12-13. QUICK RELEASE VALVES.

a. Removal and Disassembly.(1) Tag and disconnect air lines from valve body,

and unscrew valve from nipple (1, figure 12-19).

1. Pipe nipple2. Housing3. Diaphragm4. Screw (4)5. Body6. Gasket

Figure 12-19. Quick Release Valve Removal andDisassembly

(2) Disassemble quick release valve as illustrated infigure 12-19. Discard gasket (6).

(3) If necessary for replacement, remove closenipple (1) from bulkhead fitting on tractor frame.

b. Cleaning, Inspection and Repair.(1) Clean all parts except diaphragm (3) by washing

with cleaning solvent and dry thoroughly.

(2) Clean diaphragm (3) by wiping with a clean, dry,lint-free cloth.

(3) Inspect mating surfaces of body (5) and housing(2) for scratches, nicks, gouges and pitting. Repairminor damage by using crocus cloth or a fine stone.Replace a defective body or housing.

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TM 9-2320-277-14&P

(4) Inspect diaphragm (3) for cuts, tears andevidence of deterioration. Replace a defectivediaphragm.

(5) Inspect screws (4), nipple (1) and threadedopenings in housing (2) for damaged threads. Chasethreaded openings with the correct size tap. Replace adamaged screw or close nipple.


(1) Reassemble and install quick release valve, withnew gasket (6), in reverse of procedure outlined inparagraph 12-13a.

(2) Apply tractor brakes and check for proper valveoperation (exhaust when brakes are released) andleakage.

Section VI. BRAKE CONTROL PANEL AND TRAILERHAND BRAKE CONTROL

12-14. BRAKE CONTROL PANEL.

a. Removal.


(2) Tag and remove air lines and fittings fromcontrol panel body located behind instrument panel.

(3) Remove screws (1 through 3, figure 12-20)securing knobs (4 through 6) to brake control panel, andpull knobs from valve stems.

1. Screw2 Screw

3. Screw4. Red knob5. Yellow knob6. Green knob7. Machine screw (3)8. Bolt (2)9. End manifold

10. Tractor protection valve11. Supply manifold12. Parking brake and emergency release valve

Figure 12-20. Brake Control Panel Removal

12-21

TM 9-2320-277-14&P

(4) Remove machine screws (7) securing brakecontrol panel to instrument panel, and lower brakecontrol panel from behind instrument panel.

b. Disassembly.(1) Remove two bolts (8) and separate end manifold

(9), tractor protection valve (10), supply manifold (11)and parking brake and emergency release valve (12).

(6) Pull valve stem (21) from valve. Removeretaining ring (22), spring (23) and preformed packings(24 and 26) from valve body (25). Discard preformedpackings.

(7) Disassemble tractor protection valve accordingto instructions provided in valve repair kit.

1. Yellow knob2. Screw3. Green knob4. Screw5. End cover6. Screw7. Screen8. Spring9. Poppet

10. Valve spool11. Preformed packing12. Preformed packing13. Spring14. Valve stem15. Preformed packing.16. Retaining ring17. Preformed packing18. Bushing19. Poppet20. Screw21. Valve stem22. Retaining ring23. Spring24. Preformed packing25. Valve body26. Preformed packing

Figure 12-21. Parking Brake and Emergency Release Valve Disassembly

(2) Remove screws (6, figure 12-21) and pull endcover (5) from valve. Remove screens (7).

(3) Remove spring (8), poppet (9) and valve spool(10). Remove and discard preformed packings (11 and12).

(4) Remove spring (13), valve stem (14) andpreformed packing (15). Remove retaining ring (16).Discard preformed packing.

(5) Remove and discard preformed packing (17).Pull bushing (18) from valve stem. Remove poppet (19)by removing screw (20).




(3) Inspect sealing surfaces of end cover (5), valvespool (10), valve stems (14 and 21), poppets (9 and 19)and valve body (25) for scratches, nicks, gouges andpitting. Replace defective parts.

(4) Inspect springs (8, 13 and 23) for bent, brokenand weak coils. Replace defective springs.

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TM 9-2320-277-14&P

(5) Inspect remaining parts and air lines forexcessive wear, damage and general condition.Replace defective parts.

d. Reassembly.(1) Install new preformed packings (26 and 24) into

valve body (25).

(2) Insert spring (23), retaining ring (22) and valvestem (21).

(3) Install poppet (19) and secure with screw (20).Install bushing (18) over valve stem.

(4) Install preformed packings (17 and 15), retainingring (16) and valve stem (14). Insert spring (13) andpreformed packings (12 and 11).

(5) Install preformed packings (17 and 15), retainingring (16) and valve stem (14). Insert spring (13) andpreformed packings (12 and 11).

(6) Install valve spool (10), poppet (9), and spring(8).

(7) Insert screens (7) into ports of end cover (5).

Place end cover (5) over valve body and securewith screws (6).

(8) Reassemble tractor protection valve accordingto instructions provided in valve repair kit.

(9) Reassemble parking brake and emergencyrelease valve (12, figure 12-20), supply manifold (11),tractor protection valve (10); and end manifold (9) usingbolts (8).

e. Installation.(1) Position brake control panel behind instrument

panel and secure with machine screws (7).

(2) Install knobs (4 through 6) and secure withscrews (1 through 3).

(3) Attach fittings and air lines to brake controlpanel.

(4) Start engine to build up pressure in air tanks andapply soap solution around air line connections; thenstop engine and check for air leaks while operatingbrake control panel valves.

(5) Release parking brakes, slowly exhaust airpressure from tanks, and observe air pressure gaugewhen parking (spring) brakes are automatically applied.Pressure should be between 20 and 35 psig. If not,parking brake valve (12. figure 12-20) is defective andmust be replaced.

1. Knob 7. Lock washer (2) 13. Spring 19. Cover 25. Return spring2. Handle 8. Clamp 14. Inlet valve seat 20. Adjusting ring 26. Grommet3. Spirol pin 9. Body 15. Stem 21. Lock washer 27. Machine screw (2)4. Grommet 10. Piston 16. Compression spring 22. Grommet 28. Lock washer (2)5. Head 11. Cam follower 17. Valve guide 23. Gasket 29. Machine screw (2)6. Screw(2) 12. Cam 18. Valve (2) 24. Grommet

Figure 12-22. Trailer Hand Brake Valve Disassembly

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TM 9-2320-277-14&P

12-15. TRAILER HAND BRAKE CONTROL VALVE.



(2) Tag and remove air lines and fittings from trailerhand brake control valve.

(3) Support valve assembly, remove screws (6,figure 12-22), lock washers (7) and clamp (8) securingtrailer hand brake valve assembly to steering wheelcolumn, and remove valve assembly from tractor.

(4) Disassemble trailer hand brake control valve asillustrated in figure 12-22. Discard grommets (4, 22, 24and 26).


(1) Clean all parts by washing with cleaning solventand a stiff bristled brush. Dry clean parts withcompressed air at approximately 40 psig.

(2) Inspect hardware and threaded openings fordamaged threads. Replace all parts having damagedthreads.

(3) Inspect springs (13, 16 and 25) for bent, brokenand weak coils. Replace defective springs.

(4) Inspect mating surfaces of head (5), body (9),piston (10), cam and follower (11 and 12), valve seat(14) and valves (18) for scratches, gouges, nicks andpitting. Replace defective parts.

(5) Inspect air lines for cuts and evidence ofdeterioration. Replace defective air lines.


(1) Reassemble trailer hand brake control valve,with new grommets (4, 22, 24 and 26), as illustrated infigure 12-22.

(2) Position valve assembly on steering wheelcolumn and secure with clamp (8), lock washers (7) andscrews (6).

(3) Attach fittings and air lines to valve assembly.

(4) Start engine to build up pressure in air tanks andapply soap solution around air line connections; thenstop engine and check for air leaks while operatingtrailer hand brake control valve.

Section VII. FIFTH WHEEL UNLATCH CYLINDERAND VALVE

12-16. FIFTH WHEEL UNLATCH CYLINDER.


(1) Remove unlatch cylinder as instructed on figure12-23.

(2) Unscrew air breather from cylinder(figure 12-24).


(1) Clear air breather and exterior of unlatch cylinder bywashing with cleaning solvent and dry thoroughly.(2) Inspect air breather for obstructions and damage.Replace a defective breather.

Figure 12-24. Unlatch Cylinder Air Breather

Figure 12-23. Unlatch Cylinder removal

12-24

TM 9-2320-277-14&P

(3) Inspect unlatch cylinder piston rod and seal fordamage and evidence of leakage, inspect extended rodfor straightness, and examine exterior of cylinder bodyfor dents, cracks, broken welds and other damage.Replace a defective cylinder assembly.

(4) Inspect air hose for cuts and evidence ofdeterioration. Replace a defective air hose.

(5) Inspect hardware, clevis pin and cotter pin fordamage. Replace defective parts.


(1) Reassemble and install unlatch cylinder inreverse of procedure outlined in paragraph 12-16a.

(2) With fifth wheel jaws closed, depress brakepedal and push fifth Wheel unlatch control whileobserving operation of unlatch cylinder. Cylinder shouldopen fifth wheel jaws without evidence of binding orsticking.

12-17. FIFTH WHEEL UNLATCH VALVE.

a. Removal.

(1) Loosen nut (2, figure 12-25); then unscrew andremove button (1) and nut (2).

(2) Tag and remove air lines and fittings from valve.

(3) Support valve from behind mounting surface.Remove screws (3) and dial plate (13), and pull valvefrom mounting surface.

b. Disassembly.

(1) Pull pin (8) from body (12). Pull plunger (9) andspring (10) from body.

(2) Remove preformed packing (11) from plunger(9). Discard preformed packing.

1. Push button2. Lock nut3. Machine screw (2)4. Cap nut5. Gasket6. Valve spring7. Disc valve8. Retaining pin9. Valve plunger

10. Return spring11. Preformed packing12. Valve body13. Dial plate

Figure 12-25. Unlatch Valve Removal and Disassembly

12-25

TM 9-2320-277-14&P

(3) Unscrew nut (4) and remove gasket (5), spring(6) and valve (7). Discard gasket.


(1) Inspect sealing surfaces of plunger (9) and body(12) for scratches, gouges, nicks and pitting. Insertplunger into body and check to see that the stem ofplunger moves freely inside body. Replace a defectiveplunger or valve body.

(2) Inspect springs (6 and 10) for broken, bent orweak coils. Replace a defective spring.

(3) Inspect hardware and threaded openings fordamaged threads. Replace all defective parts.

(4) Inspect hoses for cuts and deterioration.Replace a defective hose.

(5) Visually inspect remaining parts for wear,damage and general condition. Replace all defectiveparts.


(1) Reassemble unlatch valve, with new gasket (5)and preformed packing (11), in reverse of procedureoutlined in paragraph 12-17b.

(2) Position unlatch valve and dial plate onmounting surface and secure with screws (3).

(3) Attach fittings and air lines to unlatch valve.

(4) Install nut (2) and push button (1), and securebutton by tightening nut.

(5) Depress brake pedal, push unlatch valve andcheck for leakage and proper operation.

Section VIII. AIR HORN


a. Removal.(1) Open drain cocks to exhaust air pressure from

tanks and remove air line (17, figure 12-26).

(2) Disconnect chain (14) from lever on air valve(12), and unscrew and remove air valve.

(3) Remove nuts (1 and 4), lock washers (2 and 5),flat washer (6), screw (3), air horn assembly, and gasket(7).

b. Disassembly.

(1) Pry screens (8) from the horn bells (9 and 10).

(2) Unscrew and remove bells (9 and 10) from airhorn assembly.


a. Cleaning.

(1) Clean air line (17), air valve (12) and exterior ofair horn assembly by wiping with a clean, dry, lint-freecloth.

(2) Clean hardware, fittings, horn bells and screensby washing with cleaning solvent and dry thoroughly.


(1) Inspect air line for cuts and evidence ofdeterioration. Replace a defective air line.

(2) Inspect hardware and threaded openings fordamaged threads. Replace defective parts.

(3) Visually inspect remaining parts for wear,damage and general conditions. Replace all defectiveparts.

12-20. REASSEMBLY, INSTALLATION ANDADJUSTMENT.

a. Reassembly and Installation.

(1) Reassemble air horn in reverse of procedureoutlined in paragraph 12-18b.

(2) Install air horn, with new gasket (7), in reverse ofprocedure outlined in paragraph 12-18a.

b. Adjustment.

(1) Start engine to build up pressure in air tanks,and loosen hex nuts (11).

(2) Pull chain (14) to sound horn and adjust screwsto obtain maximum volume; then secure adjustment bytightening nuts (11).

12-26

TM 9-2320-277-14&P

1. Hex nut 10. Short bell2. Lock washer 11. Hex nut (2)3. Screw 12. Air valve4. Hex nut 13. Repair link5. Lock washer 14. Chain6. Flat washer 15. Tubing connector7. Gasket 16. Pipe tee8. Screen (2) 17. Air line9. Long bell 18. Elbow connector

Figure 12-26. Air Horn Removal and Disassembly

12-27

TM 9-2320-277-14&P

CHAPTER 13

WHEELS AND TIRES


13-1. DESCRIPTION.

The tractor uses 12:00 x 20, 16 ply rating, non-directional tread tires. All tires and wheels are the samesize. A spare tire is mounted on the right side of thetractor below the battery box. Refer to Chapter 15 for adescription of the spare tire carrier.

Section II. REPAIR

13-2. REMOVAL AND DISMOUNTING.

a. Removal.

(1) Apply the tractor parking brake and chock thefront or rear wheels.

(2) Raise the front or rear of the tractor, blockingunder the frame for support.

(3) Remove the wheel and tire as instructed onfigure 13-1.

Figure 13-1. Front Wheel and Tire Removal

NOTEFigure 13-1 illustrates removal of thefront wheels and tires. Removal ofthe dual-mounted rear wheels andtires is similar, except that both tiresmust be removed to replace the innerwheel and tire.

b. Dismounting.

WARNINGBe sure the tire is deflated, and thevalve core removed, beforeproceeding with dismounting.

(1) Insert the end of any flat pointed tool at safetybulge on rim (1, figure 13-2), and pry rim out of groove inwheel base.

(2) Break top bead loose from wheel flange; thenturn assembly over and break opposite bead loose fromwheel.

(3) Place valve cap on valve, and push valve downthrough valve hole using a blunt tool.

(4) Withdraw wheel evenly out of tire, and removeflap and tube.


a. Cleaning.

Clean rim, wheel, lug nuts and threads on studs bywashing with cleaning solvent. Dry clean parts withcompressed air at approximately 40 psig. Clean rubberparts (tire, flap and valve core) by washing with a milddetergent solution, then rinsing with clear water.


(1) Inspect studs and lug nuts for damaged threads,and replace damaged hardware. If tractor has operatedwith one or more broken studs, replace all studs onaffected side of tractor.

(2) Inspect tube and tire for cuts, breaks or otherdamage. Replace or repair a leaking tire or tube.

(3) Inspect wheel mounting surfaces and bolt holesfor wear or damage. If bolt holes are elongated due tooperation with loose lug nuts. replace wheel.

13-1

TM 9-2320-277-14&P

1. Rim2. Wheel3. Tube4. Tire5. Flap

Figure 13-2. Tire Dismounting

(4) Inspect rim for excessive corrosion, sprungcondition or other damage. Rim must properly mate withwheel in remounting. Replace a defective rim.

13-4. MOUNTING AND INSTALLATION.

a. Mounting.

(1) Insert tube (3, figure 13-2) and flap (5) into tire(4), and lubricate tire beads and flap with soapy watersolution or commercial lubricant.

(2) Start wheel into tire evenly and insert valvethrough valve hole in wheel.

(3) Push wheel evenly into tire, and place on blocksto hold wheel up into the tire.

(4) Place rim (1) on wheel (2) evenly and walk riminto position.

(5) Inflate mounted tire to approximately 30 psig;then lift assembly upright and check to see if the beadsare positioned properly.

(6) Inflate tire to pressure specified in Operator'sManual.

b. Installation.

(1) Install wheel and tire in reverse of instructionson figure 13-1.

(2) Lower tractor, remove the wheel chocks andrelease tractor parking brake.

13-2

TM 9-2320-277-14&P

CHAPTER 14

STEERING GROUP

Section I. STEERING COLUMN

14-1. DESCRIPTION.

The steering column connects the steering wheel to thesteering universal joint assembly, which drives thesteering gear and pitman arm connected to the drag linkand steering linkage of the vehicle.


a. Removal.

(1) Park the vehicle with the wheels pointed straightahead, that is, with the wheels in the center of theturning limits.

(2) Mark position of steering wheel spokes by chalkor masking tape strips to the steering column.

(3) Remove trailer hand brake control from steeringcolumn (see Chapter 12).

(4) Disconnect electrical connector (11, figure 14-1).

(5) Remove two upper steering column brackets(33).

(6) Loosen lower steering column clamp (35).

(7) Loosen pinch bolt locknut (39) and cap screw(38) on upper yoke of steering universal joint assembly(37).

(8) Grasp steering wheel and pull column upward,releasing steering shaft splines from upper universaljoint yoke.

NOTEPosition steering column in soft-jawed vise to prevent damage ordistortion.

b. Disassembly.

(1) Press on button (3) and rotate counterclockwiseuntil button unlocks.

(2) Remove button (3), spring seat (4), and spring(5).

(3) Remove screw (7), retainer (6), and wheel nut(14).

(4) Remove steering wheel (1).(5) Remove horn button electrical contact (8) and

screw (9).(6) Unscrew turn signal lever (10) and remove

signal switch assembly (16 thru 19).(7) Remove spacer (20), spring seat (21) and upper

bearing assembly (22).(8) Remove pilot light assembly (24 thru 28) and

pull out wiring harness.(9) Pull steering shaft (32) from tube and jacket

assembly (23), and remove lower bearing assembly (29)spring seat (21) spring (30), and dust cap (31).


a. Cleaning.

(1) Clean all metal parts by wiping with a clothmoistened with cleaning solvent. Wipe steering wheelwith a dry lint-free cloth. Protect non-painted metal partsfrom corrosion and rust by applying a light film of engineoil, and store away from dust.

(2) Clean steering column bearings by washing withvolatile mineral spirits. Let dry, repack with grease, andwrap in paper to protect from dust and dirt.


(1) Inspect steering shaft and tube and jacketassembly visually for cracks or other signs of damage.Replace steering shaft or tube and jacket assembly ifdefective.

(2) Examine other metal parts for signs of wear ordamage. Replace any defective parts.

(3) Inspect steering shaft bearings for excessivewear. Replace defective bearings.

(4) Discard dust cap (31).

14-1

TM 9-2320-277-14&P

1. Steering wheel 15. Signal switch assembly 29. Lower bearing assembly 43. Lock washer2. Horn button kit 16. Pan head screw (2) 30. Spring 44. Nut3. Push button 17. Hex nut 31. Dust cap 45. Pitman arm4. Spring seat 18. Pan head screw (2) 32. Steering shaft 46. Drag link5. Compression spring 19. Roller contact assembly 33. Upper steering bracket (2) 47. Ball socket6. Retainer 20. Spacer 34. Grommet 48. Dust cover7. Screw(2) 21. Spring seat (2) 35. Clamp 49. Ball socket8. Electrical contact 22. Upper bearing assembly 36. Bracket 50. Dust cover9. Screw (2) 23. Tube and jacket assembly 37. Steering joint assembly 51. Capscrew 3/4-10

10. Turn signal lever 24. Pilot light housing 38. Capscrew (2) 52. Hex head screw (2)11. Connector housing 25. Pan head screw (2) 39. Lock nut (2) 53. Hex head screw12. Connector pin (8) 26. Socket assembly 40. Rubber boot 54. Lock washer (4)13. Steering column 27. Bulb 41. Lock ring14. Wheel nut 28. Cover 42. Steering gear assembly

Figure 14-1. Steering Column Removal and Disassembly

14-2

TM 9-2320-277-14&P


a. Reassembly.

Reassemble steering column with new dust cap (31) inreverse order of procedures in paragraph 14-2b.

b. Installation.

Reverse the removal procedure outlined in paragraph14-2a. Be sure steering wheel is positioned as beforeremoval. If overhaul of the steering universal jointassembly and steering gear will follow, do not connectsteering shaft to upper yoke of the universal joint.

Section II. STEERING UNIVERSAL JOINTASSEMBLY


a. Removal.

(1) Remove joint access panel from deck (seeChapter 15).

(2) Loosen pinch bolt locknut (39, figure 14-1) andcap screw (1;) on lower yoke of steering universal jointassembly.

(3) Remove lockring (41) and rubber boot (40).

(4) Pull lower yoke off of the splined steering gearshaft, and remove the steering universal joint assemblyfrom vehicle.

b. Disassembly.

(1) Clamp sleeve tube (14, figure 14-2) in a soft-jawed vise. Match mark the sleeve tube (14) andsplined shaft (9) to aid in proper reassembly.

(2) Remove retaining rings (1).(3) Use a brass or aluminum punch rod, or tube of

approximately the same diameter as -',bushing, (5) o)the center cross (2), and drive bushing (3) out of theyoke.

(4) Repeat step 3 for the other yoke.(5) Bend tabs of dust cap (12) outward and ,,

splined shaft (9) out of sleeve tube (14) and remove feltwasher (13).

(6) If necessary for replacement, remove lubricationfittings (5 and 11) from crosses and sleeve tube (14).Discard crosses (2), bushings (3), and washers (4).


a. Cleaning.

Clean all parts by wiping with a cloth moistened withcleaning solvent. Use a wire brush, if necessary, toremove heavy deposits of dirt and grease. Protect non-painted metal parts from corrosion and rust by applyinga light film of engine oil, and store away from dust.


Inspect sleeve yoke, splined shaft, and the internalsplines of the yokes for cracks or other signs of damage.Replace any parts that are defective.


a. Reassembly.

(1) Install new washers (4) on opposite ends of thenew crosses (2'.

(2) Position the new crosses in yokes.(3) Center the new bushings (3) in holes of yokes

from the outside.(4) Center opposite ends of the cross and yoke

assembly between the jaws of a sturdy bench vise orbench press and press bushings (3) into place. Use ashort rod or discarded bushing to depress bushingsbelow retaining ring grooves. Repeat for the other endsof the cross.

(5) Repeat step 4 for the other cross and yokeassembly.

(6) Install all retaining rings (1).(7) Install new dust cap (12) and new felt washer

(13) over splines on shaft (9).(8) Insert splined shaft (9) into sleeve tube (14) so

that the alignment arrows match.(9) Slide felt washer (13) into position and bend

tabs of dust cap (12) into grooves in sleeve tube (14).(10) Install lubrication fittings (5 and 11).

Installation.

Reverse the removal procedure outlined inparagraph 14-5a. If overhaul of the steering gear willfollow, do not connect the lower splined yoke to the inputshaft of the steering gear.

(2) Use a grease gun to lubricate fittings at center ofcrosses (5, figure 14-2) and at the sleeve yoke (11).Refer to Operator's Manual for lubrication specifications.

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1. Retaining ring (8) 8. Capscrew (2)2. Center cross (2) 9. Splined shaft3. Cross bushing (8) 10. Lock nut (2)4. Cork washer (8) 11. Lubrication fitting5. Lubrication fitting (2) 12. Dust cap6. Yoke 13. Felt washer7. Yoke 14. Sleeve tube

Figure 14-2. Steering Joint Disassembly

Section III. STEERING GEAR


a. Removal.

(1) Park vehicle straight ahead, with the wheels inthe center of the turning limits.

(2) Remove front access panel from deck (seeChapter 15).

(3) Relieve hydraulic pressure and disconnecthydraulic lines (3 and 16, figure 14-4). Cap hydrauliclines to prevent entry of dirt into the hydraulic system.

(4) Loosen pinch bolt locknut (10, figure 14-2) andcapscrew (8) on bottom yoke (6) of steering universaljoint assembly if the steering universal joint assemblywas not removed for servicing.

(5) Remove pitman arm nut (44, figure 4-1) and lockwasher (43). Mark position of pitman arm (45) to pitmanshaft, and remove pitman arm from shaft.

(6) Remove four steering gear to frame bolts (51, 52and 53) and lock washers (54).

(7) Remove steering gear from vehicle.

b. Disassembly.

(1) Turn the splined input shaft until the index markon the end of the pitman shaft sector (55, figure 14-3) isperpendicular to the center line of the steering gear(straight ahead position).

(2) Remove the side cover attachment screws (45)and tap lightly on the end of the shaft sector with a soft

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TM 9-2320-277-14&P

42. Lock washer43. Piston rack44. Jam nut45. Special capscrew (6)46. Side cover

24. Flat washer 47. Socket head capscrew (4)25. Adapter 48. Bearing26. Seal (2) 49. Back-up washer27. Back-up washer 50. Leather washer (2)

10. Seal (2) 28. Seal 51. Seal assembly (2)11. Adjusting screw 29. Spiral lock ring 52. Snap ring12. Back-up ring (2) 30. Input worm shaft 53. Retainer13. O-Ring (2) 31. Seal back-up washer 54. Adjusting screw14. Adjustment nut 32. Worm shaft seal 55. Shaft sector

1. Input shaft seal 15. External tang washer 33. Port seal 56. Lock washer2. Retaining ring 16. Internal tang washer 34. Bronze washer 57. Rubber plug3. Washer 17. Washer 35. Washer 58. Nut4. Seal 18. Needle thrus t bearing (2) 36. Retaining ring 59. Adapter5. Needle bearing 19. Spacer (2) 37. Valve seat 60. Jam nut6. Jam nut 20. Washer (2) 38. Lock washer 61. Adjusting screw7. Capscrew (4) 21. Hydraulic control valve 39. Unloader valve 62. Retaining ring8. Flat washer (4) 22. Seal (2) 40. Seal ring 63. Adapter seal9. Cover 23. Capscrew 41. Locking screw 64. Shaft seal

Figure 14-3. Steering Gear Disassembly

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TM 9-2320-277-14&P

hammer to free the side cover (46). Allow the steeringgear housing to drain.

(3) Remove side cover (46) and sector shaft (55) asa unit.

(4) Remove four capscrews (47), sector shaft sealadapter (59) and seal (64) from steering gear housing.

(5) Remove the sector shaft adjustment screw locknut (44). Rotate the adjustment screw (54) clockwiseuntil free of side cover (46).

(6) Remove sector shaft snap ring (62) andbearings (46 and 48). Remove seals, snap ring, andretainer (49 thru 53). Also remove output shaft seal (51),back-up washer (50), and seal adapter (63). Set theseparts aside from the remainder of the steering gearassembly.

(7) Remove capscrews (23) and lock washers (24),and remove control valve (21) and piston rack (43) as aunit.

(8) Remove unloader valve retainer (36), seat (37),lock washer (38), and unloader valve (39) from pistonrack (43).

(9) Clamp the splined input shaft in a soft-jawedvise and remove the dirt and water seal (1), retainingring (2), washer (3), and seal (4). Remove four valvecover screws (7) and washers (8), and carefully removevalve cover (9) and seal (10).

(10) Unstake the thrust bearing adjustment nut lockring (15) and remove adjustment nut (14).

(11) Remove internal tang lock washer (16), thrustbearing race washer (17), needle thrust bearing (18),spacer (19), and thrust bearing race washer (20).

(12) Slide the control valve (21) and valve adapter(25) from the input shaft (30).

(13) Remove spiral lock ring (29), seal (28), andback-up washer (27) from valve adapter counterbore(25).

(14) Remove jam nut (60), pressure unloader valveadjusting screw (61), back-up ring (12) and O-ring (13)from housing.


a. Cleaning.

(1) Clean all metal parts with volatile mineral spiritsand blow dry with compressed air at approximately 40psig. Do not wipe parts with a cloth, as lint may clogclosely fitted parts within the steering gear.

(2) Clean bearings by washing in volatile mineralspirits and repacking. Inspect bearings for wear or

damage, and replace any bearings that exhibitroughness after repacking or appear defective aftercleaning.


(1) Inspect the control valve (21) visually for wear ordamage. Do not disassemble the control valve. Thecontrol valve body and spool are machined to very closetolerances and selectively fitted at the factory. Ifdamage or wear is evident, replace the entire controlvalve assembly.

(2) Inspect piston rack assembly (43) visually forwear or damage. Do not further disassemble the pistonrack assembly unless wear or damage is evident.

(3) Inspect shaft sector teeth (55) and bearingsurfaces for wear or damage. Replace if defective.

(4) Replace all seals and O-rings removed duringdisassembly and replace with new parts duringreassembly.


a. Reassembly.

(1) Reassemble the components of the steeringgear with new seals and new parts where required inreverse of the procedure outlined in paragraph 14-8b.Coat O-ring (13) with oil or grease during reassembly,and leave 7/8 inch of adjusting screw (61) exposed fromhousing before installing jam nut (60).

(2) After reassembly, rotate input shaft through fulltravel for at least six cycles and check shaft sectoradjustment. No rotational lash or bind of the output shaftshould be evident.

(3) Loosen lock nut (44), and secure adjustmentscrew (54) to provide an input shaft torque of not morethan 15 inch-pounds over full travel of the output shaft,as measured by rotating the input shaft with a torquewrench. Tighten the lock nut (44) and recheck torque.

b. Installation.

(1) Position steering gear in vehicle and install gearto frame with four bolts (51, 52 and 53, figure 14-1) andlock washers (54), and tighten.

(2) Connect lower splined yoke (6, figure 14-2) ofsteering universal joint assembly to splined input shaft ofsteering gear and tighten pinch bolt lock nut (10) andcapscrew (8).

(3) Press pitman arm onto pitman shaft in the sameposition as removed; install lock washer (43, figure 14-1)and nut (44), and tighten nut (44) with 80 to 90 lb. ft.torque.

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(4) Connect hydraulic lines to their original locationson steering gear.

(5) Fill pump reservoir to correct level with fluidspecified in Operator's Manual.

(6) Start engine and turn steering wheel throughentire range four or five times. This will allow air toescape and be replaced with fluid. Check steering gearfor leaks.

(7) Check fluid level and refill if necessary.

Section IV. POWER STEERING PUMP

14-11. DESCRIPTION.

The power steering pump is of the rotary vane type (seefigure 14-4). When the pump is operating, centrifugalforce pushes the rotor vanes outward against the pumpring, producing a pumping action and forcing thehydraulic fluid to the control valve in the power steeringgear.

Figure 14-4. Power Steering Pump Operation


a. Removal.

(1) Disconnect hydraulic lines (3 and 1, figure 14-5)at pump. Secure lines in a raised position to preventleakage and cover line ends to prevent contamination.

(2) Remove drive pulley attachment lock nut (15)and washer (14).

(3) Loosen four pump mounting bracket screws (25)and lower bracket and pump to slacken belts. Removebelts (11).

(4) Remove pulley (2) from pump shaft. Do nothammer pulley as this may damage pump shaft.Remove two bracket to pump bolts (28) and removepump from vehicle.

NOTEIf drive pulley resists removal,remove pump from vehicle with drivepulley attached and use bench pressor puller to remove pulley.

a. Disassembly.

(1) Wash the exterior of the pump with cleaningsolvent and blow dry with clean compressed air beforebeginning disassembly. Provide a clean work area onwhich to place internal parts of pump.

(2) Remove wing nut (1, figure 14-6), lock washer(2), flat washer (3), reservoir cover (4) and gasket (5).Remove stud (6) and nut (7).

(3) Remove screws (8), baffles (9 and 10) and plate(11). Remove reservoir (12) and gasket (13) from pump.

(4) Clamp the pump body (26) in a soft jawed viseand remove the cover attachment screws (24), thenremove the cover (36) and compression spring (35).

(5) Hold the pump ring (32) and slide the pressureplate (34) from the pump body (26).

(6) Remove the pump ring (32), headless locatingpins (33), rotor (31), ten vanes (30), and preformedpacking (29 and 28).

(7) Remove retaining ring (14) and tap or pressshaft (16) from pump body.

(8) Remove bearing (27), shaft seal (19), andretaining ring (18).

(9) Remove bearing (17).

(10) Clamp the pump cover subassembly (36) in asoft-jawed vise and use a pin punch to drive theheadless pin (25) from the cover.

(11) Remove plug (20), preformed packing (21),control valve (22) and spring (23) from cover.

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TM 9-2320-277-14&P

1. Hose 11. V-belt 21. Hex head screw (2)2. Clamp (4) 12. Pulley 22. Lock washer (2)3. Hose assembly 13. Pump bracket 23. Flat washer (2)4. Steering gear 14. Flat washer 24. Ground strap5. Union adapter 15. Locknut 25. Hex head screw (4)6. Elbow adapter 16. Hose 26. Lock washer (4)7. Connector 17. Filter bracket 27. Flat washer (4)8. Power steering pump 18. Filter assembly 28. Hex bolt (2)9. Union adapter 19. Hose barb (2)10. Fitting 20. Reducer bushing (2)

Figure 14-5. Power Steering Hydraulics


a. Cleaning.

(1) Clean all parts except bearings by washing withcleaning solvent. Blow dry with clean compressed air.Do not wipe parts with a cloth, as resulting lint depositsmay clog closely fitted parts after assembly.

(2) Wash bearings with volatile mineral spirits andrepack. Replace bearings that appear worn or defectiveafter cleaning or rough after repacking.


(1) Inspect rotor, vanes, ring, and pressure plate forwear, damage, or scoring marks. The pressure platemust be perfectly flat. Replace if warped or buckled.The rotor, vanes, and ring are replaced as the cartridgekit unit.

(2) Check control valve (22) and associated partsfor wear and free movement in the cover. Replace ifdefective.

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TM 9-2320-277-14&P

(3) Replace all seals and preformed packing duringreassembly.

(4) Inspect drive belts (11, figure 14-5) for wear.Always replace both drive belts even if only one belt isdefective.

(5) Inspect input and output hoses (1, 3 and 16) forwear, cracks, or leakage. Replace defective hoses.


(1) Reassemble all parts in reverse order ofdisassembly (see paragraph 14-12b). Immerse metalparts in clean hydraulic fluid and shake off excess duringreassembly. Do not wipe parts.

(2) Vanes should be reassembled in the rotor withthe rounded edges facing the pump ring (32, figure14-6). Be sure vanes move freely in rotor slots duringreassembly.

(3) Lubricate seals and preformed packing withpetroleum jelly, grease, or oil during reassembly.

b. Installation.

(1) Position pump (8, figure 14-5) on bracket (13)and secure with two bolts (28).

(2) Install pulley (12), washer (14) and locknut (15)and tighten.

(3) Install belts and pull bracket and pump up totighten belts. Adjust pump bracket for a belt deflection of3/8 to 1/2 inch midway between the pump pulley andcrankshaft pulley. Tighten four bracket to engine bolts(25) to secure adjustment.

(4) Reconnect hydraulic lines at their originallocations.

(5) Fill the pump reservoir to the correct level withclean, new hydraulic fluid. See Operator's Manual for'recommended fluid specifications.

(6) Start engine and allow fluid to warm. Turn thesteering wheel through full travel four to five times tobleed air from the system.

(7) Stop the engine and refill reservoir, if necessary.Check for leaks, and recheck drive belt tension.

1. Wing nut 16. Shaft2. Lock washer 17. Bearing3. Flat washer 18. Retaining ring4. Reservoir cover 19. Shaft seal5. Gasket 20. Plug6. Stud 21. Preformed packing7. Hex nut 22. Control valve8. Hex head screw (2)9. Baffle

10. Return line baffle11. Reinforcing Plate12. Reservoir13. Gasket14. Retaining Ring15. Shaft key

23. Compression spring24. Hex head screw (4)25. Headless pin26. Pump body27. Bearing28. Preformed packing29. Preformed packing30. Vane (10)31. Rotor32. Ring33. Headless pin (2)34. Pressure plate35. Compression spring36. Cover subassembly

Figure 14-6. Power Steering Pump Disassembly

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TM 9-2320-277-14&P

Section V. FILTER ASSEMBLY


a. Removal.

(1) Remove hose clamps (2, figure 14-5) and hoses(16 and 1) from filter assembly (18). Secure hoses in araised position to prevent leakage and cover hose endsto prevent contamination.

(2) Remove two screws (21), lock washers (22) andflat washers (23); then lower filter assembly frommounting bracket (17) and remove from vehicle.

b. Disassembly.

(1) Remove two hose barbs (19, figure 14-5) andreducer bushings (20).

(2) Remove and discard filter element (8, figure14-7).

(3) Note position of lock nut (3) on machine screw(7) for reassembly; then remove lock nut (3) and bypassvalve (2).

(4) Remove screw (7), bypass spring (6), spacer (5)and guide (4).


a. Cleaning.

(1) Clean all metal parts by washing with cleaningsolvent. Dry clean parts with compressed air atapproximately 40 psig.

(2) Inspect all passages in head casting (1) forbuildup of sludge deposits. Clean where necessary.



(2) Inspect bypass valve for wear or damage.Replace a defective bypass valve.

(3) Inspect spring (6) for broken or weak coils.Replace a defective spring.

(4) Inspect hoses for leaks, wear, cracks or otherevidence of deterioration. Replace defective hoses.


a. Reassembly.

(1) Lightly coat all metallic parts with oil to aid inreassembly.

(2) Install guide (4), spacer (5), bypass spring (6)and machine screw (7).

(3) Install bypass valve (2) and lock nut (3) onmachine screw (7), and tighten lock nut to approximateposition noted during disassembly.

(4) Lightly coat gasket surface with clean oil; theninstall new filter element (8). Hand tighten approximatelyone turn.

(5) Install an adapter hose at the inlet (spring) sideof the filter, and fill with clean fluid.

(6) Apply compressed air at 14 psig to the adapterhose and observe that the bypass valve remains closed.

NOTEIf the bypass valve (2) opens, tightenlock nut (3) and repeat previous step.

(7) Refill hose and filter with clean fluid and applycompressed air at 16 psig. Observe that the bypassvalve opens.

NOTEIf the bypass valve (2) remainsclosed, loosen lock nut (3).

(8) Repeat steps 6 and 7 until the bypass valveopens at 15 ± 1 psig.

(9) Drain fluid from hose and filter and disconnectadapter hose.

(10) Install two reducer bushings (20, figure 14-5)and hose barbs (19) into inlet and outlet ports of filterassembly.

b. Installation.

(1) Install filter assembly in tractor in reverse orderof removal procedure outlined in paragraph 14-15a.

(2) Fill power steering pump reservoir to the correctlevel with clean, new hydraulic fluid. See Operator'sManual for recommended fluid specifications. Startengine and allow fluid to warm.

(3) Check filter assembly and hoses for leaks.(4) Stop engine and refill pump reservoir to correct

level.

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TM 9-2320-277-14&P

1. Head casting2. Bypass valve3. Lock nut4. Bypass guide5. Spacer6. Bypass spring7. Machine screw8. Filter element

Figure 14-7. Filter Disassembly

Section VI. BALL SOCKETS

14-18. DESCRIPTION, REMOVAL ANDDISASSEMBLY.

a. Description.

The drag link connects the steering gear pitman arm tothe steering linkage of the vehicle and is of three-piececonstruction: rod and two ball socket end assemblies.The ball sockets are threaded into the ends of the draglink.


(1) Remove dust covers (48 and 50, figure 14-1) ateach end of drag link (46).

(2) Slacken the clamp assembly (9, figure 14-8) byloosening capscrew and locknut of the ball socketconnected to the ball stud of the pitman arm.

(3) Carefully mark the location of the ball socket onthe drag link, or measure the distance between thegrease fittings of the two ball sockets.

(4) Remove cotter pin (5) and loosen ball socketplug (1).

(5) Unscrew ball socket plug (1) sufficiently toremove pitman arm ball stud, and remove ball socketfrom drag link.

(6) Remove ball socket plug (1), spring (2), and ballset (3).

(7) Remove and disassemble the remaining ballsocket in the same manner as above.

14-19. CLEANING, INSPECTION, REPAIR,REASSEMBLY AND INSTALLATION.

a. Cleaning, Inspection, and Repair.

(1) Clean metal parts with cleaning solvent. Use awire brush, if necessary, to remove heavy deposits ofdried or caked grease within the body (6).

(2) Coat metal parts with a light film of engine oil.

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1. Ball socket plug2. Spring3. Ball set4. Grease fitting5. Cotter pin6. Body7. Capscrew8. Locknut9. Clamp Assembly

Figure 14-8. Ball Sockets Removal and Disassembly

(3) Inspect ball set (3) for wear or damage.Replace if defective.

b. Reassembly and Installation.

(1) Install ball set (3), spring (2), and ball socketplug (1).

(2) Install ball socket on drag link in reverse order ofremoval (see paragraph 14-18b).

(3) Lubricate ball socket grease fitting with greasegun and grease. See Operator's Manual for greasespecifications.

(4) Reassemble and install the remaining ballsocket in the same manner as above.

(5) Install dust covers (48 and 50, figure 14-1).

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TM 9-2320-277-14&P

CHAPTER 15

FRAME AND DECK

Section I. MAIN FRAME, BUMPER AND GRILLEGUARD

15-1. DESCRIPTION.

The frame is an all welded box section steel frame,which provides mounting facilities for the engine,transmission, front and rear axles, operator's tilt cab, andthe fifth wheel boom. Repair of the frame is limited toreplacement of spring bearings, retaining plates, rearcab guard, radiator grille assembly, tow shackles,bumper and grille guard, and welding small cracks orbroken welds.


a. Removing Rear Cab Guard.

(1) Remove hoses and hose tender (Chapter 12)and flood lamp (Chapter 6) from rear cab guard (7, figure15-1).

(2) Remove rear platform (paragraph 15-5).

(3) Block or brace the forward portion of the fueltank guard, and remove two screws, lock washers andnuts securing forward fuel tank guard to rear cab guardand frame.

(4) Attach a suitable hoist to the rear cab guard,remove eight screws (8), lock washers (9) and hex nuts(10) and lift rear cab guard from tractor.

b. Removing Radiator Grille Assembly.

(1) Remove four capscrews (4, figure 15-1), lockwashers (5) and flat washers (6).

(2) Lift radiator grille assembly (3) from front oftractor.

c. Removing Tow Shackles.

(1) Remove six screws (11) and lock washers (12)and remove rear tow shackles (13) from tractor frame.

(2) Remove six hex nuts (8, figure 15-2), screws(10) and lock washers (9) and remove front tow shackles(11) from bumper (15).

d. Removing Bumper and Grille Guard.

(1) Attach a suitable hoist to the top of the grilleguard (7, figure 15-2).

(2) Remove four pin retainers (4), two pins (2)securing grille guard to bumper (15), and two pins (3)securing grille guard to cab deck.

(3) Remove four capscrews (4 and 5) and lock nuts(6), and lift grille guard from tractor.

(4) Attach hoist to front tow shackles (11). If towshackles have been removed, use shackle mountingholes in bumper to attach hoist.

(5) Remove eight capscrews (14), lock washers(13) and hex nuts (12); then lift bumper (15) from tractor.


a. Cleaning.

Clean all parts and hardware by washing with cleaningsolvent and a stiff bristle brush. Dry clean parts withcompressed ax at approximately 40 psig. Lightly coatexposed metal surfaces with engine oil to inhibitcorrosion.



(2) Inspect frame, rear cab guard, radiator grille,bumper, and grille guard for broken welds or cracks.Repair by welding. Replace a rear cab guard, radiatorgrille, bumper, or grille guard beyond economical repair.

(3) Inspect spring pins and tow shackles forexcessive wear, and replace defective parts.


a. Installing Bumper and Grille Guard.

(1) Install bumper and grille guard in reverse ofprocedures outlined in paragraph 15-2d.

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TM 9-2320-277-14&P

1. Mainframe 7. Rear cab guard2. Spring bearing (2) 8. Screw (8)3. Radiator grille assembly 9. Lock washer (8)4. Capscrew (4) 10. Hex nut (8)5. Lock washer (4) 11. Screw (6)6. Flat washer (4) 12. Lock washer (6)

13. Tow shackle (2)

Figure 15-1. Main Frame, Rear Cab Guard and Radiator Grille

15-2

TM 9-2320-277-14&P

8. Hex nut (6)1. Pin retainer (4) 9. Lock washer (6)2. Pin (2) 10. Screw (6)3. Pin (2) 11. Tow shackle (2)4. Capscrew (2) 12. Hex nut (8)5. Capscrew (2) 13. Lock washer (8)6. Lock nut (4) 14. Capscrew (8)7. Grille guard 15. Bumper

Figure 15-2. Bumper and Grille Guard

(2) Lightly lubricate grille guard pivot points withengine oil, and check for freedom of operation bytemporarily removing pin retainers (1, figure 15-2) andpins (2 and 3).

b. Installing Tow Shackles.

(1) Install front tow shackles (11, figure 15-2) onbumper (15) with six hex nuts (8), screws (10) and lockwashers (9).

(2) Install rear tow shackles (13, figure 15-1) onframe with six screws (11) and lock washers (12).

c. Installing Radiator Grille Assembly.

(1) Position radiator grille assembly at front oftractor.

(2) Secure radiator grille assembly (3) to tractor withfour flat washers (6), lock washers (5) and capscrews(4).

d. Installing Rear Cab Guard.

(1) Install rear cab guard in reverse of instructionscontained in paragraph 15-2a.

(2) Install hoses and hose tender (Chapter 12) andfloodlamp (Chapter 6) on rear cab guard.

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Section II. REAR PLATFORM ANDCROSS TIE ASSEMBLY


a. Removing and Disassembling Rear Platform.

(1) Raise handle on toggle clamp (4, figure 15-3),slide toggle clamp hook away from rear platformholddown, and lift rear platform (5) from tractor.

(2) Disassemble rear platform and toggle clamp innumerical sequence as Illustrated on figure 15-3.

b. Removing and Disassembling Cross Tie.

(1) Raise tilt cab, and remove rear platform.

(2) Remove water level warning kit (Chapter 6) fromcross tie assembly.

(3) Remove fuel filter from cross tie assembly (seeChapter 3).

(4) Remove engine air cleaner and mountingbracket (see Chapter 3).

(5) Attach a hoist and sling to rear of transmissionhousing as shown in figure 15-4. Apply sufficient liftingforce to relieve stress on transmission housing andengine flywheel housing when cross tie is removed.

1. Hex nut (2)2. Lock washer (2)3. Screw (2)4. Toggle clamp5. Rear platform6. Hex nut (2)7. Lock washer8. Eyebolt

Figure 15-3. Rear Platform Removal and Disassembly

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TM 9-2320-277-14&P

Figure 15-4. Transmission Sling Attachment

(6) Remove eight capscrews (2, figure 15-5) andlock washers (5) securing transmission housing to crosstie brackets (3).

(7) Remove eight bolts (11), flat washers (12) andlock nuts (13) securing brackets (3) to cross tie (1); thenremove brackets.

(8) Remove two lock nuts (8), snubbing washers (6)and bolts (7) securing cross tie to rubber mounts (4).Attach a suitable hoist to cross tie and lift forward and upfrom tractor.

(9) Remove four lock nuts (10) and bolts (9), and liftrubber mounts (4) from frame members.


a. Cleaning.

Clean all parts except rubber mounts by washing withcleaning solvent and a stiff bristle brush. Dry clean partswith compressed air at approximately 40 psig. Lightlycoat exposed metal surfaces with engine oil to inhibitcorrosion. Clean rubber mounts by washing with a milddetergent solution and rinsing with clear water.



(2) Inspect cross tie assembly and rear platform forbroken welds or cracks. Repair by welding. Replace across tie assembly or rear platform beyond economicalrepair.

(3) Inspect rubber mounts for cracks or otherevidence of deterioration. Replace both mounts ifdamage is found.

(4) Inspect toggle clamp for deformation andfreedom of operation. Replace a damaged toggleclamp.


a. Assembling and Installing Cross Tie.

(1) Assemble and install cross tie using new locknuts (8, figure 15-5) in reverse of procedure outlined inparagraph 15-5b.

(2) Install engine air cleaner and mounting bracket(Chapter 3), fuel filter (Chapter 3) and water levelwarning kit (Chapter 6).

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TM 9-2320-277-14&P

1. Cross tie assembly2. Capscrew (8)3. Bracket (2)4. Rubber mount (2)5. Lock washer (8)6. Snubbing washer (2)7. Bolt (2)8. Lock nut (2)9. Bolt (4)

10. Lock nut (4)11. Bolt (8)12. Flat washer (8)13. Lock nut (8)

Figure 15-5. Cross Tie Removal and Disassembly

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TM 9-2320-277-14&P

Section III. DECK, ENGINE HOOD,SIDE STEP AND MIRROR

15-8. DESCRIPTION.

The welded steel deck supports the operator's cab, frontpanel, engine hood, tool box, right-hand mirror, and sidestep. The deck is secured to the frame by front pivotpins and rear hydraulic latches. Repair of the deck islimited to replacement of the engine hood, front panel,righthand mirror, side step, and welding small cracks orbroken welds. Refer to Chapter 19 for repair of thehydraulic tilt system.


a. Removing Front Panel and Engine Hood.

(1) Remove six nuts and bolts securing rain cap (2,figure 15-6) to engine hood (5), and remove rain cap.

(2) Release hood latches (3), remove latch attachinghardware, and remove latches from deck and enginehood.

(3) Remove six bolts securing front access panel (1)to front panel (7), and remove front access panel.

(4) Remove seven nuts and bolts securing enginehood (5) to hinge, and remove engine hood.

(5) Remove windshield washer reservoir andbrackets from hinge (see Chapter 18).

(6) Remove seven nuts and bolts securing enginehood hinge to cab, and remove hinge.

(7) Remove two screws securing reflectors (11) tolight brackets (9 and 10), and remove reflectors.

b. Removing Side Step.

(1) Remove two lock nuts (1, figure 15-7) andcapscrews (2) securing side step (5) to deck platform(12, figure 15-6).

1. Front access panel2. Rain cap3. Latch assembly (2)4. Handle5. Engine hood6. Hinge7. Front panel

8. Rubber moulding9. Light bracket, left-hand

10. Light bracket, right-hand11. Reflector (2)12. Platform13. Light bracket (2)14. Deck

Figure 15-6. Deck and Engine Hood

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1. Lock nut (2)2. Capscrew (2)3. Lock nut (2)4. Capscrew (2)5. Side step

Figure 15-7. Side Step Removal

(2) Remove two lock nuts (3, figure 15-7) andcapscrews (4) securing side step (5) to deck and removeside step.

c. Removing and Disassembling Mirror.

(1) Remove four hex nuts (2, figure 15-8), lockwashers (3), and screws (4), and remove mirrorassembly from mirror support (1).

(2) Remove three hex nuts (8), lock washers (9) andscrews (10), and remove the mirror support (1) from thedeck.

(3) Remove attaching hardware and disassemblethe support arm (7), brackets (6) and mirror head (5).


a. Cleaning.

Clean all parts except reflectors and mirror head bywashing with cleaning solvent and a stiff bristle brush.Dry clean parts with compressed air at approximately 40psig, and lightly coat exposed metal surfaces withengine oil to inhibit corrosion. Clean reflectors andmirror head by wiping with a clean cloth and milddetergent solution.


(1) Inspect hardware for damaged threads, andchase damaged threads with the correct size tap or die.Replace damaged lock nuts.

1. Mirror support2. Hex nut (4)3. Lock washer (4)4. Screw (4)5. Mirror head6. Bracket (2)7. Support arm8. Hex nut (3)9. Lock washer (3)

10. Screw (3)

Figure 15-8. Mirror Removal and Disassembly

(2) Inspect deck, front panel, rain cap, side step andmirror support for broken welds or cracks. Repair bywelding. Replace a front panel, rain cap, side step ormirror support beyond economical repair.

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(3) Inspect reflectors and mirror head for cracks ordistortion. Replace a defective reflector or mirror head.


a. Reassembling and Installing Mirror.

(1) Reassemble and install mirror in reverse ofprocedure outlined in paragraph 15-9c.

(2) Adjust mirror for proper rear view from operator'scab.

b. Installing Side Step.

(1) Position side step (5, figure 15-7) against driver'sside of deck, and secure to deck with two capscrews (4)and lock nuts (3).

(2) Secure side step to deck platform (12, figure15-6) with two capscrews (2, figure 15-7) and lock nuts(1).

c. Installing Front Panel and Engine Hood.

(1) Install front panel and engine hood in reverse ofinstructions outlined in paragraph 15-9a, but do nottighten hardware attaching hinge to cab and enginehood (5, figure 15-6).

(2) Close engine hood to obtain proper alignmenton mating surfaces of deck, and tighten hardwareattaching hinge to engine hood and cab. Recheck forproper alignment and adjust as necessary.

(3) Reinstall the windshield washer brackets andreservoir (see Chapter 18).

Section IV. SPARE TIRE CARRIER AND MUD FLAP


a. Spare Tire Removal.

(1) Remove two lug nuts (1, figure 15-9), lockwashers (2) and flat washers (3); then lower tire sling (7)and spare tire to ground.

(2) Remove two lug nuts (4) and remove spare tirefrom tire sling (7).

b. Spare Tire Carrier Disassembly.

(1) Remove two lock nuts (8), flat washers (9), andhangers (10).

(2) Remove two capscrews (5) and lock nuts (6),and lower tire sling (7) from tractor.

Figure 15-9. Spare Tire Carrier

c. Mud Flap Removal.

(1) Remove eight screws (3, figure 15-10), lock nuts(1), and flat washers (3).

(2) Remove mud flaps (4) from brackets at rear oftractor.

Figure 15-10. Mud Flap Removal

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a. Cleaning.

Clean all parts except spare tire and mud flaps bywashing with cleaning solvent and a stiff bristle brush.Dry clean parts with compressed air at approximately 40psig, and lightly coat exposed metal surfaces withengine oil to inhibit corrosion. Clean spare tire and mudflaps by wiping with a clean cloth and mild detergentsolution.


(1) Inspect hardware for damaged threads, andchase damaged threads with the correct size tap or die.Replace damaged lug nuts and lock nuts.

(2) Inspect and repair spare tire as described inChapter 13.

(3) Inspect tire sling, lower portion of battery box,and mud flap mounting brackets for broken welds orcracks. Repair by welding. Replace a tire sling orbattery box beyond economical repair.

(4) Inspect mud flaps for cracks and deformation.Replace a defective mud flap.


a. Mud Flap Installation.

(1) Position mud flap (4, figure 15-10) against rearportion of mounting bracket.

(2) Secure mud flap to bracket with four screws (2),flat washers (3). and lock nuts (1).

(3) Install the remaining mud flap in the samemanner as above.

b. Spare Tire Carrier Reassembly and Installation.

(1) Reassemble spare tire carrier in reverse ofprocedure outlined in paragraph 15-12b.

(2) Check that spare tire is inflated to 95 psig.

(3) Install spare tire in reverse of procedure outlinedin paragraph 15-12a.

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CHAPTER 16

FIFTH WHEEL AND BOOM


16-1. INTRODUCTION.

This chapter contains basic description of, specificationsand data for, and overhaul procedures for the fifth wheeland boom. Refer to Chapter 12 for repair of the fifthwheel unlatch cylinder, and to Chapter 17 for repair ofthe fifth wheel hydraulic components.


a. Fifth Wheel Boom.

The boom is an all welded box section steel boom,which provides mounting facilities for the fifth wheelmounting brackets and hydraulic lift cylinders. Twodouble-acting hydraulic cylinders lift the rear of the

boom to adjust fifth wheel height. The boom pivotsabout a front journal and spacer tube. A removableboom platform is provided to allow access formaintenance.

b. Fifth Wheel.

The heavy duty fifth wheel supports the towed trailer,and provides jaws for securing the trailer kingpin. Thefifth wheel pivots about a cross shaft secured to bracketsmounted on the boom. Steel cross shaft supports arecast integral with the fifth wheel plate to maintain shaftalignment. A mechanical spring lock design is used tosecure the fifth wheel jaws. As shown in figure 16-1A,the two jaws are so designed and positioned that as thetrailer kingpin makes contact both jaws close in unison.As the jaws rotate about the jaw pivot pins, the yokespring (figure 16-1B) forces the sliding yoke into positionas a wedge between the jaws and the tapered ribmembers of the fifth wheel plate. The jaws areunlatched by pulling the release handle or actuating thepneumatic unlatch cylinder, which pivots the cam andpulls the sliding yoke from the jaws.

A. JAWS OPEN B. JAWS CLOSED

Figure 16-1. Fifth Wheel Operation

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Specifications and data for the fifth wheel are presentedin Table 16-1. Fifth wheel dimensions are shown infigure 16-2.

Table 16-1. Fifth Wheel Specifications and Data.

Manufacturer HollandModel 1500-BOR-36Type RigidConstruction Cast steel, machined

surfaceLubrication Grooves in plate surfaceWeight (approximate) 300 lbs.Drawbar pull capacity 60,000 lbs.(minimum)Lift capacity 70,000 lbs.Plate height above ground

Elevated 63-1/2 in.Lowered 47-1/2 in.

Figure 16-2. Fifth Wheel Dimensions

Section II. FIFTH WHEEL


a. Removal.NOTE

Fifth wheel components may bedisassembled and repaired with fifthwheel installed on boom. Removeonly if replacement of fifth wheel orremoval of boom is required.

(1) Attach a suitable hoist to fifth wheel.

(2) Remove fifth wheel as instructed on figure 16-3.

(3) If necessary for repair, remove bolts (3, figure16-4), hex nuts (5) and lock washers (4); then lift twobracket assemblies (6) from mounting plate and boom.

b. Disassembly.

(1) Remove unlatch cylinder from fifth wheel (seeChapter 12).

(2) Pull release handle (5, figure 16-5) to unlatchjaws (25).

(3) Remove two cotter pins (26), jaw pivot pins (27),jaws (25) and spring (24).

(4) Push release handle (5) in to relieve tension inyoke spring (10).

Figure 16-3. Fifth Wheel Removal

Figure 16-4. Fifth Wheel Shaft and Brackets

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1. Fifth wheel plate2. Secondary lock3. Torsion spring4. Drive spring5. Release handle6. Spring7. Washer(3)8. Sliding yoke9. Yoke stop boss

10. Yoke spring11. Clevis pin12. Washer13. Bolt14. Cam roller15. Bolt16. Cam roller17. Lock nut (2)18. Cam plate19. Air filter20. Bolt21. Hex nut22. Unlatch cylinder23. Cotter pin24. Spring25. Lock jaw (2)26. Cotter pin (2)27. Jaw pivot pin (2)

Figure 16-5. Fifth Wheel Disassembly

(5) Remove bolt (13), washers (12) and cam roller(14) from sliding yoke (8).

(6) Remove bolt (15), lock nut (17), washers (7) andcam roller (16); then pull cam plate (18) from end ofrelease handle (5).

(7) Remove release handle (5), spring (6) andwasher (7).

(8) Remove drive spring (4), torsion spring (3) andsecondary lock (2).

(9) Remove sliding yoke (8), yoke spring (10) andyoke stop boss (9).


a. Cleaning.

Clean all parts by washing with cleaning solvent. Use astiff bristle brush, if necessary, to remove accumulateddeposits of dirt and grime. Dry parts by wiping with aclean cloth.


(1) Inspect wear surface of shaft (2, figure 16-4),bearings on bracket assemblies (6), and shaft supportson fifth wheel plate for pitting, scoring, flat spots ordamage. Polish rough spots smooth with crocus cloth ora stone. Replace defective parts.

NOTEIf a bracket assembly (6, figure 16-4)Is defective, replace both bracketassemblies as a matched set.

(2) Inspect fifth wheel plate (1, figure 16-5), bracketassemblies (6, figure 16-4) and mounting plate for brokenwelds and cracks. Repair by welding. Replace a fifthwheel or bracket assembly beyond economical repair.

(3) Inspect machined top surface of fifth wheel platefor scores and rough spots. Polish rough spots smoothwith crocus cloth or a stone.

(4) Inspect springs for deformation and broken coils.Replace defective springs.

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(6) Inspect pivot pins, cam, cam rollers, sliding yokeand lock jaws for damage and excessive wear. Replaceworn or damaged parts.

NOTE

If a lock jaw (25, figure 16-5) isdefective, replace both jaws as amatched set.


a. Reassembly.

Reassemble fifth wheel in reverse of procedure outlinedin paragraph 16-4b.

b. Installation.

(1) If bracket assemblies (6, figure 16-4) were notremoved, install fifth wheel in reverse of instructions onfigure 16-3. If bracket assemblies were removed, installfifth wheel as follows:

(a) Position bracket assemblies (6, figure 16-4)on cross shaft supports of fifth wheel, and insert shaft (2)through bracket assemblies and cross shaft supports.

(b) Secure shaft (2) to bracket assemblies (6)with two roll pins (1).

(c) Use a suitable hoist to lower fifth wheel andbrackets onto mounting plate of boom.

(d) Secure bracket assemblies (6) to mountingplate with bolts (3), lock washers (4) and hex nuts (5).

(e) Reconnect air hose to unlatch cylinder (22,figure 16-5).

Section III. FIFTH WHEEL BOOMAND PLATFORM


a. Removal.

NOTERemove fifth wheel boom only ifnecessary for repair.

(1) Release toggle clamps (4, figure 16-6) securingplatform (5) to boom (17); then lift platform from boom.

(2) Remove fifth wheel and brackets as outlined inparagraph 16-4a.

1. Hex nut (4)2. Lock washer (4)3. Screw (4)4. Toggle clamp (2)5. Platform6. Pin retainer (2)7. Pivot pin (2) 14. Flat washer8. Hex nut (2) 15. Journal9. Lock washer (2) 16. Spacer tube10. Screw(2) 17. Boom11. Pivot pin 18. Lubrication fitting (2)12. Spacer tube 19. Fifth wheel13. Lock nut

Figure 16-6. Fifth Wheel Boom and Platform

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(3) Remove pin retainers (6) and pivot pins (7), andlower tops of hydraulic lift cylinders from boom.

(4) Remove battery box as outlined in Chapter 6.

(5) Secure a sling to center rear of boom, and use asuitable hoist to raise boom to vertical position.

(6) Remove boom from tractor as instructed onfigure 16-7.b. Disassembly.

(1) Remove four hex nuts (1, figure 16-6), lockwashers (2) and screws (3); then lift two toggle clamps(4) from boom.

(2) If necessary for repair, remove hydraulic liftcylinders as outlined in Chapter 17; then remove hexnuts (8), lock washers (9), screws (10), lower cylinderpivot pin (11) and spacer tube (12).

16-8. CLEANING, INSPECTION AND REPAIR.a. Cleaning.

Clean all parts by washing with cleaning solvent. Wipeparts dry with a clean cloth.

b. Inspection and Repair.(1) Inspect journal, spacer rubes and pivot pins for

excessive wear, scoring or other damage. Replacedefective parts.

(2) Inspect boom and platform for cracks andbroken welds. Repair by welding. Replace a boom orplatform beyond economical repair.

(3) Inspect toggle clamps for freedom of operationand damage. Replace a defective toggle clamp.

(4) Inspect hardware, journal shaft, and threadedopenings for damaged threads. Chase threadedopenings with the correct size tap. Replace damagedjournal or hardware.

16-9. REASSEMBLY AND INSTALLATION.a. Reassembly.Reassemble boom in reverse of procedure outlined inparagraph 16-7b.b. Installation.

Install boom in reverse of procedure outlined inparagraph 16-7a.

Figure 16-7. Fifth Wheel Boom Removal

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CHAPTER 17

FIFTH WHEEL HYDRAULICS


17-1. DESCRIPTION.

Figure 17-1 illustrates the components of the fifth wheelhydraulic group. Major components include the filter

assembly (19), hydraulic reservoir (34), hydraulic pump(28), power take-off (27), hydraulic cylinders (1) and thehydraulic control valve (16). The following paragraphsprovide repair instructions for the major components.

1. Hydraulic cylinder (2) 9. Hose assembly2. Hose assembly 10. Hose assembly3. Hose assembly 11. Tee (3)4. Hose assembly (2) 12. Pipe plug5. Hose assembly (2) 13. Elbow (2)6. Fitting (2) 14. Elbow7. Hose assembly 15. Adapter8. Bulkhead fitting (2) 16. Control valve

17. Nipple 26. Adapter 35. Mounting rubber (2) 44. Street elbow18. Street elbow 27. Power take-off 36. Spacer (2) 45. Service tee (2)19. Filter assembly 28. Hydraulic pump 37. Bracket spacer (2) 46. Velocity fuse (2)20. Drain plug 29. Capscrew (3) 38. Elbow fitting (4) 47. Reducing bushing (2)21. Filler cap 30. Lock washer (3) 39. Hex nut 48. Street elbow (2)22. Capscrew (2) 31. Hex nut (3) 40. Flat washer 49. Hose assembly (2)23. Lock washer (4) 32. Clamp 41. Capscrew (2) 50. Bleeder valve (2)24. Hex nut (4) 33. Lever 42. Street elbow 51. Reducing bushing (2)25. Capscrew (2) 34. Hydraulic reservoir 43. Street elbow

Figure 17-1. Hydraulic Schematic

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Section II. HYDRAULIC FILTER,RESERVOIR AND PUMP

17-2. HYDRAULIC FILTER.

a. Removal.

WARNING

Pull operator's 5th WHEEL controllever back to lower fifth wheel andrelieve hydraulic pressure beforeproceeding.

(1) Remove and discard filter element (8, figure17-2).

(2) Disconnect hose assembly (9) and cap hoseend to prevent entry of dust and dirt.

(3) Remove plug (20, figure 17-1) and drainhydraulic fluid.

(4) Unscrew filter body (1, figure 17-2) from nipple(10).

(5) Remove nipple (10) and elbow (11) fromhydraulic reservoir. Plug reservoir opening to prevententry of dust or dirt.

b. Disassembly.

(1) Note position of hex nut (3) on screw (7) forreassembly; then remove hex nut (3) and bypass valve(2).

(2) Remove screw (7), bypass spring (6), spacer (5)and guide (4).

c. Cleaning.

Clean all metallic parts by washing in cleaning solvent.Dry clean parts with compressed air at approximately 40psig.



1. Body2. Bypass valve3. Hex nut4. Bypass guide5. Spacer6. Bypass spring7. Screw8. Filter element9. Hose assembly

10. Nipple11. Elbow

Figure 17-2. Filter Removal and Disassembly

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(2) Inspect all metal parts for corrosion, cracks,burrs, breaks, distortion or other damage. Inspectcontact areas for scoring or wear. Remove burrs with afine stone. Replace all damaged parts.

(3) Inspect spring (6) for broken or weak coils.Replace a defective spring.

e. Reassembly.(1) Lightly coat all metallic parts with hydraulic fluid.

(2) Install guide (4), spacer (5), bypass spring (6)and screw (7).

(3) Install bypass valve (2) and hex nut (3) on screw(7), and tighten hex nut to approximate position notedduring disassembly.

(4) Temporarily install a new filter element (8) onthe filter body (1).

(5) Install an adapter hose at the inlet (spring) sideof the filter, and fill with clean hydraulic fluid.

(6) Apply compressed air at 14 psig to the adapterhose and observe that the bypass valve remains closed.

NOTEIf the bypass valve (2) opens, tightenhex nut (3) and repeat previous step.

(7) Refill hose and filter with clean hydraulic fluidand apply compressed air at 16 psig. Observe that thebypass valve opens.

NOTEIf the bypass valve (2) remainsclosed, loosen hex nut (3).

(8) Repeat steps 6 and 7 until the bypass valveopens at 15 ± 1 psig.

(9) Drain hydraulic fluid from hose and filter, removeadapter hose and remove filter element (8).

f. Installation.(1) Install elbow (11) and nipple (10) on hydraulic

reservoir.

(2) Install filter body (1) on nipple (10).

(3) Reconnect hose assembly (9).

(4) lightly coat gasket surface with clean hydraulicfluid; then install new filter element (8). Hand tightenapproximately one turn.

(5) Install plug (20, figure 17-1) and refill reservoirwith clean hydraulic fluid (see Operator's Manual).

(6) Open bleeder valves (50).

(7) With engine running and power take-offengaged, alternately raise and lower fifth wheel boomuntil air is purged from hydraulic system.

(8) Close bleeder valves (50), raise fifth wheelboom and check filter for fluid leaks.

17-3. HYDRAULIC RESERVOIR.

a. Removal.(1) Remove hydraulic filter (see paragraph 17-2a).

(2) Disconnect hose assembly (3, figure 17-1) andremove elbow (43).

(3) Remove the hydraulic reservoir as instructed onfigure 17-3.

Figure 17-3. Hydraulic Reservoir Removal

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b. Cleaning.Clean hydraulic reservoir by washing with cleaningsolvent; then flush interior of reservoir with hydraulic fluidto remove all traces of cleaning solvent.



(2) Inspect reservoir for cracks, breaks, corrosion orother damage. Replace a defective reservoir.

d. Installation.(1) Install the hydraulic reservoir in reverse of

instructions on figure 17-3.

(2) Install elbow (43, figure 17-1) and reconnecthose assembly (3).

(3) Reinstall hydraulic filter (see paragraph 17-2f).

17-4. HYDRAULIC PUMP.a. Description.The hydraulic pump (28, figure 17-1) is a gear type unitdriven from the power take-off (27). The power take-offis driven by the transmission torque converter and thusprovides infinitely variable speeds. The hydraulic pumpconsists of a cover housing (18, figure 17-5), acombination end plate and mounting flange (12), gears(15 and 16), wear plate (3), bushings (13 and 17) andseals (2, 4, 5 and 6).

b. Removal.(1) Remove the rear platform (see Chapter 15) to

gain access to the hydraulic pump.

WARNING

Pull operator’s 5th WHEEL controllever back to Pull operator's 5thWHEEL control lever back to lowerfifth wheel and relieve hydraulicpressure before proceeding.

(2) Remove the hydraulic pump as instructed onfigure 17-4.

Figure 17-4. Hydraulic Pump Removal

c. Disassembly.(1) Remove key (4, figure 17-5) from drive

gear shaft (16).CAUTION

Exercise care when using a vise toavoid distorting any parts. If used,clamp the vise jaws across the rearof the cover (18).

(2) Remove eight screws (8 and 11) and washers (9and 10).

CAUTIONDo not attempt to pry the pumpsections apart in the following step.Prying could scratch the matingsurfaces and cause a leak.

(3) Remove the pump body (12) by lightly tappingthe flange with a soft plastic hammer.

(4) Remove wear plate (3), sealing ring (6) andseals (4 and 5).

(5) Remove idler gear (15) and drive gear (16).

(6) If necessary for replacement, remove bearings(13 and 17) by turning cover (18) and body (12) upsidedown. If bearings stick, lightly tap cover or body on apiece of soft wood to prevent marring mating surfaces.

NOTEIf the front bearings (13) areexcessively tight and difficult toremove, it indicates operation withdirty hydraulic fluid.

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1. Retaining ring 10. Washer (4)2. Seal 11. Screw(4)3. Wear plate 12. Body4. Preload seal 13. Bearing (2)5. Load seal 14. Key6. Sealing ring 15. Idler Gear7. Dowel pin (2) 16. Drive gear8. Screw (4) 17. Bearing (2)9. Washer (4) 18. Cover

Figure 17-5. Hydraulic Pump Disassembly

(7) Use a bearing puller to remove the retaining ring(1) and seal (2). Use care not to damage the sealrecess or bearing.

d. Cleaning.

Clean all metallic parts by washing with cleaning solvent.Dry clean parts with compressed air at approximately 40psig and lightly coat with clean hydraulic fluid.


(1) Inspect body (12) for cracks, breaks, corrosionor other damage. Place a straightedge across themachined surface that faces the pump cover (18) tocheck for a bowed flange or mating surface. Replace adefective body.

(2) Inspect the idler gear (15) and drive gear (16) forburrs, scores, gouges or other damage. Inspect thegear shaft bearing surfaces for scores, pits and spalling.If a gear (15 or 16) is defective, replace the gears in setsunless other components can be restored to a like newcondition

(3) Inspect the hp of the seal (2) for cuts and nicks,and check the rubbing surfaces for cuts, nicks, scratchesand ridges. Replace a damaged seal.

(4) Inspect body side of cover (18) for cracks,breaks, corrosion, nicks and scratches. Replace adefective cover.

f. Reassembly.

NOTEUse all parts included in service partskit unless original part is, in like newcondition.

(1) Use a soft plastic hammer to tap the dowel pins(7) into the cover (18).

(2) Slide bearings (13 and 17) into the body (12)and cover (18).

CAUTIONPlace body (12) on a piece of softwood to prevent marring matingsurfaces.

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(3) Install shaft seal (2), if it was removed, in thebody (12) with the metal case to the outside of the pump.Force seal squarely into place using a flat steel rodslightly smaller in diameter than the outside diameter ofthe seal. Install retaining ring (1).

(4) Install idler gear (15) and drive gear (16) incover (18).

(5) Lubricate lips of seal (2) with general purposegrease (NLGI grade 2).

(6) Assemble preload seal (4), load seal (5), sealingring (6) and wear plate (3). Install the wear plate withthe wear surface facing the gears (15 and 16).

(7) Assemble the body (12) to the cover (18) usingnew washers (9 and 10). Rotate pump shaft as screws(8 and 11) are alternately being tightened to 200 in. lbs.(11)and 370 in. lbs. (8).

(8) Install key (14) on drive gear shaft (16).g. Installation.

(1) Install hydraulic pump in reverse of instructionson figure 17-4. Fill hydraulic pump with clean hydraulicfluid before connecting top fitting and hose.

(2) Allow pump to break-in slowly with engine idling.

(3) If necessary, bleed hydraulic system by openingbleeder valves (50, figure 17-1) until air is purged fromsystem.

(4) With power take-off engaged and engine at afast idle, push 5th WHEEL control lever forward to raisefifth wheel and check for leaks.

(5) Reinstall the rear platform (see Chapter 15).

Section III. POWER TAKE-OFF,HYDRAULIC CYLINDER AND

CONTROL VALVE

17-5. POWER TAKE-OFF.

a. Description.The power take-off (figure 17-6) is a single speed,manually operated speed reduction unit. The shift lever(19) is connected by flexible cable to the PTO controllocated inside the cab. The transmission and hoseassembly (42) provide pressure lubrication. When thepower take-off (PTO) is engaged, power is transmittedfrom the transmission PTO drive gear to the input gear(37); then through a driving gear (39), output gear (11)and output shaft (12) to the hydraulic pump.

b. Removal.(1) Remove the hydraulic pump (paragraph 17-4b).

(2) Remove screw (44, figure 17-6) and clamp (45).

(3) Disconnect PTO cable (46) from shift lever (19).

(4) Disconnect hose assembly (42) and cap hoseend to prevent contamination.

(5) Loosen special screw (17); then remove fourhex nuts (33) and copper gaskets (4).

(6) Remove capscrew (5) and copper gasket (4)and remove PTO from transmission.c. Disassembly.

(1) Remove screw (17), lock washer (18), shift lever(19) and flat washer (20).

(2) Remove four screws (48) and bracket (47).

(3) Remove cover (21), gasket (26), shifter plate(25), preformed packing (24), pin (23) and spring (22).

(4) Remove retaining ring (28) from special screw(27).

(5) Remove four capscrews (16); then tap flange(14) with a plastic hammer and remove flange andgaskets (49).

(6) Remove seal (15) from flange (14) using apulley puller.

(7) Place PTO side of flange (14) on a piece of softwood to prevent marring the mating surface; then drivebearing cup (43) from flange (14).

(8) Remove bearing cone (13) and lock ring (9) fromoutput shaft (12).

(9) Remove four screws (1); then tap bearing cap(2) with a plastic hammer and remove bearing cap andgasket (3).

(10) Remove bearing cup (7), bearing cone (8), lockring (9) and spacer (10).

(11) Pull output shaft (12) from output gear (11); thenremove output gear from case (6).

(12) Remove pipe plug (34) from shaft (36).

(13) Remove set screw (32) and shaft (36).

(14) Remove two thrust washers (35 and 41), twoneedle rollers (38), spacer (40) and driving gear (39).

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1. Screw (4) 18. Lock washer 34. Pipe plug2. Bearing cap 19. Shift lever 35. Thrust washer3. Gasket 20. Flat washer 36. Shaft4. Copper gasket (5) 21. Cover 37. Input gear5. Capscrew 22. Spring 38. Needle roller (2)6. Case 23. Pin 39. Driving gear7. Bearing cup 24. Preformed packing 40. Spacer8. Bearing cone 25. Shifter plate 41. Thrust washer9. Lock ring (2) 26. Gasket 42. Hose assembly

10. Spacer 27. Special screw 43. Bearing cup11. Output gear 28. Retaining ring 44. Screw12. Output shaft 29. Stud (2) 45. Clamp13. Bearing cone 30. Stud (2) 46. PTO cable14. Flange 31. Gasket 47. Bracket15. Seal 32. Set screw 48. Screw (4)16. Capscrew (4) 33. Hex nut (4) 49. Gasket17. Screw

Figure 17-6. Power Take-Off Removal and Disassembly

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d. Cleaning.

(1) Clean all parts, except bearings (8, 13 and 38),by washing m cleaning solvent. Dry clean parts withcompressed air at approximately 40 psig.

(2) Clean bearings by washing with volatile mineralspirits. Repack bearings (8 and 13) immediately aftercleaning, and protect from dust by wrapping in paper.

e. Inspection and Repair.(1) Inspect bearings for pits, spalling and excessive

wear. Replace bearings that are worn or rough aftercleaning and repacking.

(2) Inspect the gears (11, 37 and 39) and outputshaft (12) for burrs, scores, gouges or other damage.Replace damaged gears.

(3) Inspect the gear shaft (12 and 36) bearingsurfaces for scores, pits and spalling. Replace adamaged gear shaft.

(4) Inspect the case (6), bearing cap (2) and flange(14) for cracks, breaks, corrosion, nicks and scratches.

Check for bowed or distorted mating surfaces byplacing a straightedge across the machined surfaces.Replace a damaged case, bearing cap or flange.

(5) Inspect the rubbing surfaces of the seal (15) forcuts, nicks, scratches and ridges. Replace a damagedseal.


f. Reassembly.Reassemble the PTO in reverse of instructionscontained in paragraph 17-5c. When replacing gaskets(3 and 49) use the same thickness and quantity as theoriginal to assure proper preload on the bearings (8 and13).

g. Installation.NOTE

Gasket (31) thickness must beselected to provide 0.005 to 0.025inch backlash between input gear(37) and transmission PTO drivegear.

(1) Use new gasket (31) and secure PTO totransmission with capscrew (5), four hex nuts (33), fivecopper gaskets (4) and special screw (27).

(2) Reconnect hose assembly (42).

(3) Reconnect PTO cable (46) to shift lever (19),and secure to bracket (47) using screw (44) and clamp(45).

(4) Install hydraulic pump according to instructionsin paragraph 17-4g.

17-6. HYDRAULIC CYLINDER.

a. Removal.

WARNINGPull operator's 5th WHEEL controllever back to lower fifth wheel andrelieve hydraulic pressure beforeproceeding.

(1) Disconnect lower hose assembly (5 or 9, figure17-1) and cap hose end to prevent contamination.

(2) Remove elbow fitting (38) from cylinder (1).

(3) Disconnect upper hoses and fittings asnecessary to remove two street elbows (44).

(4) Remove four capscrews (3, figure 17-7) andcastle nuts (2); then remove rod cap (1) from rod (19).

(5) Remove pin retainer (20) and pivot pin (21); thenlower hydraulic cylinder from tractor.

b. Disassembly.Disassemble the hydraulic cylinder in numericalsequence as illustrated in figure 17-7.

c. Cleaning.Clean all parts with cleaning solvent, and dry clean partswith compressed air at approximately 40 psig. Apply alight coat of hydraulic fluid to metallic parts to preventcorrosion, and protect oiled parts from dust.

d. Inspection and Repair.(1) Replace all packings (11, 13, 15 and 17), seal

(16) and lock nut (8).

(2) Inspect all metal parts for corrosion, cracks,burrs, breaks, distortion or other damage. Inspectcontact areas for scoring or wear. Remove burrs with afine stone. Replace all damaged parts.

NOTEIf rod (19) or rod cap (1) is damaged,replace the rod and end capassembly.


17-8

TM 9-2320-277-14&P

1. Rod cap 7. Head 12. Piston 17. Preformed packing2. Castle nut (4) 8. Locknut 13. Preformed packing 18. Tube assembly3. Capscrew (4) 9. Piston ring (2) 14. Back-up washer (2) 19. Rod4. Set screw 10. Seal ring 15. Preformed packing 20. Pin retainer5. Nylon ball 11. Preformed packing 16. Seal 21. Pivot pin6. Retaining ring

Figure 17-7. Hydraulic Cylinder Removal and Disassembly

e. Reassembly.Reassemble the hydraulic cylinder with new packings,seal and lock nut m reverse of numerical sequence asillustrated in figure 17-7.

f. Installation.(1) Install hydraulic cylinder in reverse of

instructions contained in paragraph 17-6a.

(2) Bleed hydraulic system by opening bleedervalves (50, figure 17-1) and alternately raising andlowering fifth wheel until air is purged from system. Addhydraulic fluid as necessary to maintain reservoir level.

(3) Inspect hydraulic cylinder and hose connectionsfor evidence of leaks.

17-7. HYDRAULIC CONTROL VALVE.

a. Removal.(1) Remove the rear platform (see Chapter 15).

WARNINGPull operator's 5th WHEEL controllever back to lower fifth wheel andrelieve hydraulic pressure beforeproceeding.

(2) Disconnect flexible control cable from controlvalve lever (33, figure 17-1).

(3) Remove hydraulic control valve as instructed onfigure 17-8.

17-9

TM 9-2320-277-14&P

Figure 17-8. Hydraulic Control Valve Removal

b. Disassembly.

Disassemble the hydraulic control valve in numericalsequence as Illustrated in figure 17-9.

c. Cleaning.

Clean all parts with cleaning solvent, and dry clean partswith compressed air at approximately 40 psig.


(1) Inspect all parts for broken, cracked or damagedcondition. Replace all damaged parts.

(2) Inspect valve spool (14, figure 17-9) and bore invalve body (13) for burrs or other defects which wouldcause binding when the spool is operated. If the valvespool or body is defective, replace the entire hydrauliccontrol valve assembly.

(3) Inspect springs (7 and 21) for broken or weakcoils. Replace a defective spring.

(4) Inspect hardware and threaded openings fordamaged threads. Replace any parts which havedamaged threads.

e. Reassembly.

(1) Immerse all inner valve parts in clean hydraulicfluid to provide initial lubrication.

(2) Reassemble the control valve with new bonnet(1), seals (9 and 20) and packings (11, 18 and 25) inreverse of numerical sequence as illustrated in figure 17-9.

f. Installation.(1) Install the hydraulic control valve in reverse of

instructions on figure 17-8.

(2) Connect flexible control cable to control valvelever (33, figure 17-1).

(3) Bleed hydraulic system by opening bleedervalve (50, figure 17-1) and alternately raising andlowering fifth wheel until air is purged from system. Addhydraulic fluid as necessary to maintain reservoir level.

g. Adjustment.(1) Disconnect one hose assembly (4, figure 17-1)

from the control valve.

(2) Use a high pressure tee to install a 2000 psipressure gauge between the hose assembly (4) and thehydraulic control valve (16).

(3) Loosen the lock nut (15, figure 17-9) on the reliefvalve subassembly.

(4) Start the engine and, with the power take-offengaged, operate at 1500 rpm.

(5) With the operator's 5th WHEEL control leverforward to raise the fifth wheel, adjust relief valveadjusting nut (16) for 2000 pslg.

(6) Tighten lock nut (15), lower fifth wheel, stopengine, remove pressure gauge and reconnect the hoseassembly (4, figure 17-1).

(7) Reinstall the rear platform (see Chapter 15).

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TM 9-2320-277-14&P

1. Rubber bonnet 14. Valve spool2. Snap ring 15. Lock nut3. Stop disk 16. Adjusting nut4. Bolt 17. Bolt5. Lock washer 18. Preformed packing6. Stop collar 19. Relief valve cap7. Centering spring 20. Seal8. Stop washer 21. Spring9. Seal (2) 22. Plunger

10. Plug 23. Ball11. Preformed packing 24. Seat12. Poppet 25. Preformed packing13. Valve body 26. Poppet

Figure 17-9. Hydraulic Valve Disassembly

17-11

TM 9-2320-277-14&P

CHAPTER 18

OPERATOR'S CAB


18-1. INTRODUCTION.

This chapter provides basic description and repairprocedures for the operator's cab. Refer to Chapter 19for the cab tilt hydraulic system, and to Chapter 6 for theinstrument panel and gauges.

18-2. DESCRIPTION.

a. Arrangement.The fully enclosed one man cab assembly (figure 18-1)includes the cab, operator's seat, cab door, windshieldand windows, heaters and defroster, and windshieldwasher and wiper. The cab is rubber mounted to thesteel deck at four points to provide isolation.

b. Heaters and Defroster.Cab heaters are provided to maintain a comfortableenvironment for the operator in cold climates. The hotwater heater and defroster Is accessible after removingthe front access panel from the deck. A separate blowermotor Is provided for the windshield defroster, which isinstalled to keep the windshield clear of mist and ice. Anauxiliary hot water heater and blower motor Is installedat the right rear of the cab, and provides additional heatduring operation in extremely cold climates.

c. Windshield Washer and Wiper.An electric motor operates the single windshield wiperblade to provide a clear vision area through thewindshield. The wiper control provides for speedadjustment of wiper action, and return of the wiper bladeto the park position when not In use. A windshieldwasher system, using water or water-isopropyl alcoholcleansing solution, aids in cleaning dust, insect debris,etc., from the windshield. The washer system includes aone-gallon reservoir located m the engine compartment,from which fluid is supplied to two washer nozzleslocated below the windshield. The nozzles are adjustedto direct the spray into the path of the wiper blade.

d. Door, Windshield and Windows. One entry/exit door is provided on the left-hand side ofthe cab. The door pivots on a piano-type hinge,and may be opened from the insideor outside. The door handle includes akey lock mechanism to prevent unauthorized

Figure 18-1. Operator’s Cab

18-1

TM 9-2320-277-14&P

access to the operator's cab. The cab windows are oflaminated safety plate glass construction and, except forthe door window, are secured to the cab with rubberweatherstripping. The door window mounts on a windowregulator bracket, and is sealed by U-typeweatherstripping channels. The rear window isprotected by an expanded metal screen-type guard,which is hinge mounted to the rear of the cab.

e. Operator's Seat.The air suspension seat consists of an upper seatassembly and suspension assembly. The upper seatassembly includes vinyl seat cushions, which arecontoured to provide lateral support, and provides foradjustment of seat cushion and back angle tilt andhorizontal position. The seat mounts on the suspensionassembly, which provides for fore-and-aft isolation,vertical adjustment, and damping of vertical vibrations.The fore-and-aft isolation mechanism allows the seat tomove forward and back on steel rollers in a controlledmanner, thus isolating horizontal vibrations. A selectiveshock absorber automatically engages on bumpystretches of road to isolate vertical vibrations.

18-3. SPECIFICATIONS AND DATA,Specifications and data for the heater and defroster,windshield washer and wiper, and operator's seat areprovided in Table 18-1.

Table 18-1. Specifications and DataWindshield Wiper

Manufacturer TricoMotor no. FSVH-731Voltage rating 12 VdcControl no. Fl 680-2NSWiping angle 75 deg.Arm length 19 in.

Windshield WasherManufacturer TricoModel no. AWP-16GReservoir capacity 1 gal.

HeaterManufacturer EvansModel no. HV-210480BTU rating 24,000Air delivery 244 cfmVoltage rating 12 VdcCurrent rating 4.65 amp.

Defroster FanManufacturer EvansModel no. HV-210482Air delivery (at windshield) 115 cfmVoltage rating 12 VdcCurrent rating 4.65 amp.

SeatManufacturer BostromModel no. 44641-004Horizontal travel adjustment 4 in.Vertical travel adjustment 5 1/2 in.Back angle adjustment 15 deg.

Section II. CAB DOOR AND SEAT

18-4. CAB DOOR.a. Removal.

(1) Remove door stops and brackets as instructedon figure 18-2.

(2) Support the cab door and remove hardwareattaching hinge (13, figure 18-3) to tractor cab; then liftdoor from cab.

b. Disassembly.(1) Remove machine screws (10), lock washers

(11) and arm rest (9).

(2) Remove hardware attaching door handles (4and 5).

(3) Remove the window handle assembly (7) screw,handle, seal and spring.

(4) Remove hardware attaching door panel (2) todoor (1), and remove panel from door.

Figure 18-2. Door Stop Removal

18-2

TM 9-2320-277-14&P

1. Door 8. Glass pane 14. Door stop (2)2. Door panel 9. Arm rest 15. Bracket (2)3. Lock mechanism 10. Machine screw (2) 16. Headed pin (4)4. Inside handle 11. Lock washer (2) 17. Latch bracket5. Outside handle 12. Mounting plate 18. Latch6. Window regulator 13. Hinge 19. Window channel7. Window handle assembly

Figure 18-3. Cab Door Removal and Disassembly

(5) If necessary for repair, remove hardwareattaching lock mechanism (3), latch (18) and latchbracket (17).

WARNINGUse adequate hand and eyeprotection when removing glass.Remove and handle broken glasscarefully to prevent injury.

(6) Temporarily install window handle (7) and lowerglass approximately four inches from closed position;then prop glass lower slide channel with a block of woodto prevent glass and slide channel from falling.

(7) Remove hardware attaching window regulator(6) to door (1), and remove window regulator from doorand glass lower slide channel.

(8) Remove block of wood, and lower glass andlower slide channel from door.

(9) Carefully pull glass from glass lower slidechannel.c. Cleaning.

(1) Clean glass and arm rest by washing with a milddetergent solution and rinsing with clear water. Cleanwindow channel (19) by wiping with a clean cloth.

(2) Clean remaining parts by washing with cleaningsolvent and dry thoroughly.d. Inspection and Repair.


18-3

TM 9-2320-277-14&P

(2) Inspect glass (8) for cracks, breaks anddistortion. Replace a defective glass pane.

(3) Inspect lock mechanism (3), window regulator(6) and hinge (13) for freedom of operation andexcessive wear. Replace defective parts.

(4) Inspect door (1) and door panel (2) for dents andcracks. Repair cracked metal by welding. Repair smalldents by pounding out with a hammer and backingblock. Clean repaired surfaces of all paint with abrasivecloth; then apply primer and spray paint. Replace a dooror panel beyond economical repair.

(5) Inspect window channel (19) for damage andexcessive wear. Replace a defective window channel.

e. Reassembly.

WARNINGUse adequate hand and eyeprotection when handling andinstalling glass.

(1) Reassemble door in reverse of procedureoutlined in paragraph 18-4b.

(2) When installing window regulator (6), be sure toguide regulator arm into glass lower slide channel beforesecuring regulator to door.

f. Installation.(1) Support the door hinge against the forward door

frame, and secure hinge to cab with attaching hardware.Close door and check alignment in door frame. Ifnecessary, loosen hinge hardware, reposition door andtighten hinge hardware to correct door alignment.

(2) Install door stops and brackets in reverse ofinstructions on figure 18-2.

18-5. SEAT.

a. Removal.

(1) Remove hex nuts (3, figure 18-4), lock washers(4) and capscrews (2); then lift seat assembly up and outof operator's cab.

(2) If necessary for replacement, remove hex nuts(8) and capscrews (7), and remove seat belt assemblyfrom operator's cab.

b. Upper Seat Disassembly.

(1) Remove upper seat from suspension assembly asfollows:

1. Seat 5. Flat washer (4)2. Capscrew (4) 6. Seat belt3. Hex nut (4) 7. Capscrew (2)4. Lock washer (4) 8. Hex nut (2)

Figure 18-4. Seat and Seat Belt Removal

(a) Pull adjustment handle (38, figure 18-5) to itsforward most position.

(b) Unlock isolator handle (46) and push seatforward to expose machine screw (42) and hex nut (41).Remove screw (42), nut (41) and tension spring (43).

(c) Slide plate and latch assembly (26) forward toexpose two rear isolator rollers (45) and remove rollers.

(d) Tilt plate and latch assembly (26) forward; thenpull rearward and up to expose two front rollers (47) andremove rollers.

18-4

TM 9-2320-277-14&P

1. Back cushion assembly2. Cover and pad3. Back pan4. Capscrews (4)5. Lock washer (4)6. Flat washer (4)7. Seat cushion assembly8. Cover and pad9. Seat cushion pan

10. Spring11. Latch and handle12. Roll pin13. Plastic knob14. Pivot bracket, RH15. Pivot bracket, LH16. Bushing17. Cam18. Cam assembly19. Shaft20. Snap ring (2)21. Snap ring (3)

22. End plate 31. Roll pin 40. Cotter pin (2)23. Spring 32. Latch bar 41. Hex nut24. Knob assembly 33. Roller channel, RH 42. Machine screw25. Pivot shaft 34. Roller channel, LH 43. Spring26. Plate and latch assembly 35. Edge welt (2) 44. Rubber bumper27. Spring 36. Machine screw 45. Roller (2)28. Capscrew (6) 37. Flat washer 46. Isolator handle29. Lock washer (6) 38. Latch assembly 47. Roller (2)30. Flat washer (6) 39. Spring (2) 48. Bushing

Figure 18-5. Upper Seat Disassembly

18-5

TM 9-2320-277-14&P

NOTEBe sure springs (39) clear shafts onrear bracket assembly (figure 18-6)and latch assembly (38, figure 18-5)clears rear bracket assembly slotwhen removing upper seat assemblyfrom suspension assembly.

(e) Lift upper seat assembly from suspensionassembly.

(2) Turn upper seat assembly upside down; thenbend tabs down on latch assembly (38) and unhook frontof tension springs (39) from tabs.

(3) Remove cotter pins (40) and tension springs(39).

(4) Insert screwdriver in slot at front of plate andlatch assembly as shown in figure 18-7. Pry upward onlatch bar to allow roll pin (31, figure 18-5) in latch bar toclear hole in plate and latch assembly.

NOTELatch bar (32) is used for seat tiltadjustment, and roll pin (31) is usedto center and hold latch bar.

(5) While still prying up on latch bar (figure 18-7),tap latch bar to one side until latch bar disengages fromslots in latch and handle assembly.

(6) Remove snap ring (21, figure 18-5) from end ofpivot shaft (25), and pull shaft from plate and latchassembly (26).

(7) Lift up seat cushion (7) and completedisengagement of latch bar (32) from slots m latch andhandle assembly (11); then remove seat cushionassembly.

(8) Remove four capscrews (4), lock washers (5)and flat washers (6) securing back cushion assembly (1)to pivot brackets (14 and 15).

(9) If necessary for replacement, remove cover andpad kit (2 or 8) from seat cushion (7) or back cushion (1).Leave clips fastened to pan (3 or 9).

(10) Remove six capscrews (28), lock washers (29)and flat washers (30) securing roller channels (33 and34) to plate and latch assembly (26).

(11) Remove back angle adjustment mechanism asinstructed on figure 18-8.

(12) Push bushing (16) and cam assembly (18) to theleft and remove bushing (16).

Figure 18-6. Rear Bracket Assembly Shaft Location

Figure 18-7. Seat Latch Bar Removal

18-6

TM 9-2320-277-14&P

Figure 18-8. Removing Back Angle AdjustmentMechanism

(13) Push cam assembly to the right and removebushing (48) and cam assembly (18).

(14) Disassemble remaining parts as illustrated infigure 18-5.c. Suspension Disassembly.

NOTERemove upper seat assembly fromsuspension assembly (paragraph18-5b) before proceeding.

(1) Refer to figure 18-9 and turn vertical heightadjustment lever clockwise to raise shock absorber rodto its highest position; then remove shock absorbercomponents as instructed on figure 18-9.

(2) Remove two roll pins (3, figure 18-10) from rearhinge pins (2).

NOTEOne end of each hinge pin (2) isserrated. Do not drive serrated endof hinge pin through rear bracketassembly (1).

(3) Using a suitable drift and hammer, drive hingepins (2) out through the right side of rear bracketassembly (1).

(4) Lift rear bracket assembly (1) from suspensionassembly.

(5) Drive roll pin (11) from weight adjustment handle(12) and adjuster stud (10).

(6) Unscrew adjuster stud (10) from adjuster clevis(8), and remove adjuster stud and components.

(7) Remove two roll pins (40 and 43) from fronthinge pins (39 and 42).

NOTEOne end of each hinge pin (39 and42) is serrated. Do not drive serratedend of hinge pin through springsupport bracket assembly (44).

(8) Using a suitable drift and hammer, drive fronthinge pins (39 and 42) out through the left side of springsupport bracket assembly (44).

(9) Swing support bracket assembly (44) down outof the way, and remove lower arm assembly (4) andrubber spring assembly (13).

(10) Remove roll pin (7) and adjuster clevis (8) fromrubber spring assembly (13).

(11) Disassemble remaining parts as illustrated infigure 18-10.

d. Cleaning.

(1) Clean all vinyl, rubber and plastic parts of upperseat assembly and suspension assembly with a clothmoistened in mild detergent solution, rinse with clearwater and dry thoroughly.

(2) Clean edge welt (35, figure 18-5) and seat beltsby wiping with a clean, dry cloth.

(3) Clean exterior of shock absorber (57, figure18-10) and rubber spring assembly (13) with cleaningsolvent and dry thoroughly.

(4) Clean remaining parts by washing with cleaningsolvent. Dry parts thoroughly.

18-7

TM 9-2320-277-14&P

Figure 18-9. Shock Absorber Removal


(1) Inspect seat and back cushions for rips, wornareas and deterioration. Repair small tears or rips invinyl covering by sewing. Replace a vinyl cover and padbeyond economical repair.

(2) Inspect bushings and flanged bearings fordamage and excessive wear. Replace all defectivebushings and bearings.

(3) Inspect hardware and threaded openings fordamaged threads. Chase threaded openings with thecorrect size tap or die. Replace damaged hardware.

(4) Inspect springs for distortion and weak or brokencoils. Replace all defective springs.

(5) Inspect seat belts and remaining parts fordamage, excessive wear and general deterioration.Replace defective parts.

f. Suspension Reassembly.(1) Attach adjuster clevis (8, figure 18-10) to rubber

spring assembly (13).

(2) Place flanged bearing (14) in rubber springassembly (13), and install spring assembly in lower armassembly (4). Be sure flanged bearings (6) are in place,and adjuster clevis ear on spring assembly is to the rearas illustrated.

(3) Raise the spring support bracket (44) and slidethe lower arm assembly (4), and pivot arm (20) withflanged bearing (21), into spring support bracket.

18-8

TM 9-2320-277-14&P

1. Rear bracket assembly2. Hinge pin (2)3. Roll pin (2)4. Lower arm assembly5. Flanged bearing (2)6. Flanged bearing (4)7. Roll pin8. Adjuster clevis9. Drive-lock pin 43. Roll pin

10. Adjuster stud 44. Spring support bracket11. Roll pin (2) 45. Rubber bumper12. Weight adjustment handle 46. Capscrew13. Rubber spring assembly 47. Pivot bushing14. Flanged bearing 48. Insert15. Upper pivot arm 29. Hex nut 49. Ball bearing16. Roll pin 30. Lock washer 50. Flat washer (2)17. Center pin (2) 31. Shoulder bolt 51. Hex nut18. Base 32. Clevis pin 52. Vertical adjuster bracket19. Roll pin 33. Roll pin 53. Lock nut20. Pivot arm assembly 34. Pivot lever assembly 54. Upper arm assembly21. Flanged bearing 35. Wear plate 55. Flanged bearing (4)22. Roll pin 36. Snap ring (2) 56. Flanged bearing (2)23. Tube 37. Flanged bearing 57. Selective shock absorber24. Adjuster stud 38. Tension spring (2) 58. Rubber spacer25. Miter gear (2) 39. Front lower pin 59. Flat washer (2)26. Roll pin (2) 40. Roll pin 60. Rubber spacer (2)27. Thrust washer (3) 41. Height adjuster handle 61. Hex nut28. Release lever 42. Front upper pin 62. Lock nut

Figure 18-10. Seat Suspension Disassembly18-9

TM 9-2320-277-14&P

NOTEInsert front lower pin (39) from leftside of support bracket (44).

(4) Be sure adjuster clevis (8) is on top of pivot arm(20); then secure units by installing front lower pin (39)and roll pin (40).

(5) Place a five inch length of 2 x 4 inch wood underthe support rod of the lower arm assembly as shown infigure 18-11. This holds the lower arm assembly in theraised position, and raises the adjuster clevis (8, figure18-10) to permit installation of the adjuster stud (10).

(6) Use a screwdriver to raise rubber springassembly as shown in figure 18-11; then screw adjusterstud (10, figure 18-10) into adjuster clevis (8) and securewith rear roll pin (11).

(7) Install remaining parts as Illustrated in figure 18-10, and install shock absorber in reverse of instructionson figure 18-9.

NOTETighten hex nut (61, figure 18-10)hand tight only so shock absorber(57) can pivot.

g. Upper Seat Reassembly.

NOTEHeat back cover with steam, hot airor infrared lamps prior to and duringinstallation. If these heat sources arenot available, place cover in directsunlight approximately 15 minutesbefore installation.

(1) Glue cover and pad (2, figure 18-5) to back pan(3); then roll cover over edge of pad and fasten to edgeof pan, inserting plastic welt into clips where provided.

(2) Reassemble upper seat in reverse of procedureoutlined in paragraph 18-5b. Do not install seat cushionassembly (7) at this time.

(3) Adjust isolator channels as follows:

NOTEUse 0.005 inch shim stock for adjustment.

(a) Place plate and latch assembly (26) inforward most position and lock out fore-and-aft isolator(46).

(b) Loosen three capscrews (28) on left sideof plate and latch assembly (26).

Figure 18-11. Adjuster Stud Installation

(c) Place shim stock between right handchannel roller assembly (33) and right rear isolator roller(45). Push channel roller assemblies together andtighten capscrew (28) at rear left only. Remove shimstock.

(d) Move plate and latch assembly (26) torear most position and lock out fore-and-aft isolator (46).

(e) Place shim stock between right handchannel roller assembly and right front isolator roller(47). Push channel roller assemblies together andtighten capscrews (28) at left front and center. Removeshim stock.

(f) Engage fore-and-aft isolator. If travel isnot satisfactory, readjust to tighten or loosen as required.

(4) Install seat cover and pad in same manner aspreviously described for back cover and pad; then installseat cushion assembly (7) on upper seat assembly.h. Installation.

(1) Position seat assembly on floor of cab andsecure with capscrews (2, figure 18-4), lock washers (4)and hex nuts (3).

(2) Secure seat belt assembly to cab floor withcapscrews (7) and hex nuts (8).

Section III. REAR WINDOW SCREEN,SIDE MIRROR AND SUN VISOR

18-6. REAR WINDOW SCREEN.a. Removal and Disassembly.

(1) To open rear window screen, remove two wingnuts (5, figure 18-12), lock washers (7) and flat washers(6) and swing rear window screen (1) away from rearwindow.

18-10

TM 9-2320-277-14&P(2) If necessary for repair, remove tapping screws

(3), rear window screen (1), brackets (4) and hinges (2).

b. Cleaning, Inspection and Repair.(1) Clean all parts by washing with cleaning solvent

and dry thoroughly.

(2) Inspect hardware and brackets for damagedthreads. Replace all damaged parts.

(3) Inspect hinges for damage and excessive wear,and check for freedom of operation. Replace a defectivehinge.

(4) Inspect rear window screen for cracks andbroken welds. Repair by welding. Clean repairedsurfaces of all paint with abrasive cloth; then applyprimer and spray paint. Replace a rear window screenbeyond economical repair.


(1) Install rear window screen and componentsas illustrated in figure 18-12.

(2) If necessary for correct alignment, loosenhardware and reposition brackets or hinges; thentighten hardware and recheck alignment.

18-7. SIDE MIRROR.

a. Removal and Disassembly.(1) Support side mirror while removing four screws

(1, figure 18-13) which secure support arm brackets (2)to cab, and remove side mirror.

(2) Remove hardware securing mirror (5) tobrackets (4) and remove mirror.

(3) Remove hardware securing brackets (2 and 4)to support arm (3) and remove brackets.b. Cleaning, Inspection and Repair.


(2) Inspect mirror for distortion, cracks and flakedsilver backing. Replace a defective mirror.

(3) Inspect support arm for straightness, andsupport arm and brackets for damage. Replacedefective parts.

(4) Inspect hardware for damaged threads.Replace defective hardware.

1. Rear window screen 5. Wing nut (2)2. Hinge (2) 6. Flat washer (2)3. Tapping screw (16) 7. Lock washer (2)4. Bracket (2)

Figure 18-12. Rear Window Screen Removal andDisassembly

1. Screw (4)2. Support arm bracket (2)3. Support arm4. Mirror bracket (2)5. Mirror

Figure 18-13. Side Mirror Removal and Disassembly

18-11

TM 9-2320-277-14&P

(5) Inspect mirror head, brackets and support armfor rust and corrosion. Remove corrosion and rust withcrocus cloth; then prime and spray paint.

c. Reassembly and Installation.(1) Reassemble and install side mirror in reverse of

procedure outlined in paragraph 18-7a.

(2) To adjust mirror, loosen hardware securingmirror (5) to mirror brackets (4), pivot mirror (5), andtighten hardware.

18-8. SUN VISOR.

a. Removal and Disassembly.(1) Support sun visor assembly while removing

tapping screws (1, figure 18-14) which secure brackets(4) to cab,-and remove sun visor assembly.

(2) Remove two wing nuts (2), washers (3) andbrackets (4).

(3) Remove nuts (5), lock washers (6) and screws(7); then pull visor (8) from channel (9).


CAUTIONDo not clean visor with cleaningsolvent, abrasives or a dry cloth.Chemical solvents will craze anddamage visor. Rubbing withabrasives or a dry cloth will scratchvisor.

(1) Clean visor (8) with a mild detergent solutionand rinse with clear water. Do not wipe dry.

(2) Clean remaining parts by washing with cleaningsolvent and dry thoroughly.

(3) Inspect visor for cracks and scratches. Replacea defective visor.

(4) Inspect hardware and channel for damagedthreads. Replace defective parts.

(5) Inspect channel and brackets for breaks anddamage. Replace defective parts.


(1) Insert visor (8) into channel (9) and secure withscrews (7), lock washers (6) and nuts (5).

(2) Secure brackets (4) to visor assembly with twowashers (3) and wine nuts (2).

1. Tapping screw (4) 6. Lock washer (5)2. Wing nut (2) 7. Screw (5)3. Washer (2) 8. Visor4. Bracket (2) 9. Channel5. Hex nut (5)

Figure 18-14. Sun Visor Removal and Disassembly

(3) Support visor assembly against cab and securebrackets (4) to cab with four tapping screws (1).

Section IV. WINDSHIELD, WINDOWSAND UPHOLSTERY

18-9. WINDSHIELD AND WINDOWS.

a. General.All windows installed in the operator's cab, with theexception of the operator's door glass, are retained mwindow opening frames by rubber channel (figure 18-15).A rubber lip on the channel extends over thewindow opening flange. This section provides repairprocedures for the windshield (3, figure 18-16), rearwindow (5) and side windows (2 and 4). Refer toparagraph 18-4 for repair of the cab door glass.

b. Windshield, Rear Window and Left SideWindow Removal.

WARNINGUse adequate hand and eyeprotection when removing glass.Remove and handle broken glasscarefully. Do not break glass out ofrubber channel.

(1) Peel rubber channel (figure 18-15) down oninside of top window opening flange while pushing outon glass.

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TM 9-2320-277-14&P

Figure 18-15. Typical Glass Installation

1. Rubber channel2. Left side window glass3. Windshield glass4. Right side window assembly5. Rear window glass

Figure 18-16. Cab Windshield and Windows

(2) When glass has been pushed away from theupper flange area, pull glass up and out of rubberchannel in lower flange area.

(3) Remove rubber channel from window openingflange of cab.c. Right Side Window Removal andDisassembly.

WARNINGUse adequate hand and eyeprotection when removing glass.Remove and handle broken glasscarefully. Do not break glass out offrame or weatherseal.

(1) Remove screws (1, figure 18-17) and centerpost (2). Pull channel (3) and weatherseal (4) from thecenter post.

(2) Slide glass (5) out of seal (6), and pull seal fromframe (12).

(3) Slide glass (7) out of channel (8), and pullchannel from frame (12).

(4) Remove screws (9) and catch (10), and removelock assembly (11) from glass.

(5) If necessary for repair, remove window frameand rubber channel from cab as follows: (a) Peel rubberchannel (figure 18-15) down on inside of top windowopening flange while pushing out on frame (12, figure18-17).

(b) When frame has been pushed away fromthe upper flange area, pull frame up and out of rubberchannel in lower flange area.

(c) Pull rubber channel from window openingflange of cab.

d. Cleaning, Inspection and Repair.(1) Clean glass and rubber parts by washing with a

mild detergent solution and rinsing with clear water.

(2) Clean remaining parts by washing with cleaningsolvent. Dry parts thoroughly.

(3) Inspect glass for breaks, chipping and distortion.Replace defective glass.

(4) Inspect rubber channel and weatherseals fornicks, cuts, and evidence of deterioration. Replacedefective parts.

(5) Inspect right side window frame and center postfor bent condition and other damage. Replace defectiveparts.

18-13

TM 9-2320-277-14&P

1. Screw (2)2. Center post3. Channel4. Weatherseal5. Glass6. Seal7. Glass8. Channel9. Screw(2)

10. Catch11. Lock assembly12. Frame

Figure 18-17. Right Side Window Removal and Disassembly

e. Right Side Window Reassembly andInstallation.

(1) Install the right side window frame and rubberchannel as follows:

WARNINGUse adequate hand and eyeprotection when installing glass.

NOTENew rubber channel (figure 18-15)must be cut to length. Positionrubber channel in window openingflange of cab to determine properlength.

(a) Install rubber channel (figure 18-15) onwindow frame (12, figure 18-17), and wrap a cordaround outer lip groove of rubber channel. Overlap cordends at the bottom of the frame.

(b) Set bottom end of rubber channel inwindow opening flange.

(c) Apply pressure against window framewhile pulling cord end to lift lip of rubber channel overwindow opening flange completely around frame.

(d) Gently tap frame with heel of hand tofirmly set frame in position.

(2) Secure catch (10, figure 18-17) to window frame(12) with screws (9).

18-14

TM 9-2320-277-14&P

(3) Install channel (8) into frame.

(4) Lubricate channel with a soapy water solutionand slide glass (7) into channel.

(5) Secure weatherseal (4) and channel (3) tocenter post (2), position center post against glass (7),and secure center post with screws (1).

(6) Lubricate seal (6) with a soapy water solutionand install into frame. Slide glass (5) into the seal.

(7) If necessary, secure lock assembly (11) to glass(5) using adhesive (Dow Corning Silastic 738RTV, orGeneral Electric 102RTV Silicone Adhesive).

f. Windshield, Rear Window and Left SideWindow Installation.

WARNING

Use adequate hand and eyeprotection when installing glass.

NOTE

New rubber channel (figure 18-15)must be cut to length. Positionrubber channel in window openingflange of cab to determine properlength.

(1) Generously lubricate rubber channel (1, figure18-16) with a soapy water solution, and install rubberchannel on glass (2, 3, or 5).

(2) Wrap a cord around outer lip groove of rubberchannel, and overlap cord ends at the bottom of theglass.

(3) Set bottom end of rubber channel in windowopening flange from outside of cab. Be sure cord endsare inside the cab.

(4) While an assistant applies pressure againstrubber channel and glass, pull cord end from inside ofcab to lift lip of rubber channel over window openingflange completely around glass.

(5) Gently tap glass with heel of hand to firmly setglass in position.

18-10. HEADLINER, FLOOR MAT ANDUPHOLSTERY.


NOTE

Remove components from cab asrequired for headliner, floor mat andupholstery removal.

(1) Remove headliner, floor mat or upholstery asillustrated in figure 18-18.

(2) Clean non-metallic parts with a cloth lightlymoistened in detergent solution and wipe dry. Do notsaturate upholstery with detergent solution or water.

(3) Clean moulding strips and hardware withcleaning solvent and dry thoroughly.


(1) Inspect headliner, floor mat and upholstery fortears and deterioration. Repair small upholstery tears bysewing or applying pressure-sensitive tape. Replaceparts beyond economical repair.

(2) Inspect moulding strips for straightness, andbend as necessary. Replace a defective trim strip.

(3) Inspect screws for damaged threads and heads.Replace defective hardware.

c. Installation.

(1) Install headliner and floor mat as illustrated infigure 18-18.

(2) Position upholstery as shown in figure 18-18,and secure to cab with moulding strips and screws.

18-15

TM 9-2320-277-14&P

1. Moulding 13. Moulding2. Moulding 14. Tapping screw (4)3. Moulding 15. Moulding4. Moulding 16. Tapping screw (3)5. Moulding 17. Console upholstery6. Tapping screw (6) 18. Moulding7. Side door upholstery 19. Tapping screw (2)8. Moulding 20. Side panel upholstery9. Moulding 21. Console side upholstery

10. Moulding 22. Headliner(2)11. Moulding 23. Floor mat12. Rear panel upholstery

Figure 18-18. Headliner, Floor Mat and Acoustical Upholstery

Section V. WINDSHIELD WASHER AND WIPER

18-11. WINDSHIELD WASHER.

a. Removal and Disassembly.(1) Unscrew cover assembly (16, figure 18-19) from

reservoir (15).

(2) Pull hose (17) from cover assembly (16) andfilter (18).

(3) Lift reservoir (15) from reservoir bracket (14).

(4) Remove nuts (1), lock washers (2) and screws(3), and remove reservoir bracket (14).

(5) Remove nuts (4), lock washers (5), flat washers(6), capscrews (7) and bracket (8).

(6) Pull hoses (9) from cover assembly (16), washercontrol (13), nozzles (10) and hose tee (19).

(7) Remove knob (11) and hex nut (12), andremove washer control (13) from behind instrumentpanel.

(8) Remove nozzles (10) from cab sheet metalbelow windshield.

b. Cleaning, Inspection and Repair.(1) Clean hoses (9 and 17), washer control (13),

nozzles (10), reservoir (15) and hose tee (19) bywashing with detergent solution and rinsing with clearwater.

(2) Clean remaining parts by washing with cleaningsolvent and dry thoroughly.

(3) Check for obstructions in hoses (9 and 17),nozzles (10) and filter (18) using compressed air atapproximately 15 psig. Inspect hoses and hose tee forcuts, cracks and evidence of deterioration. Replace alldefective parts.

(4) Inspect brackets (8 and 14) for cracks,corrosion, and evidence of damage. Replace adefective bracket.

(5) Inspect hardware for damaged threads.Replace damaged hardware.

18-16

TM 9-2320-277-14&P

1. Nut(3) 8. Bracket 14. Reservoir bracket2. Lock washer (3) 9. Hose 15. Reservoir3. Screw (3) 10. Nozzle (2) 16. Cover assembly4. Nut(2) 11. Knob 17. Hose5. Lock washer (2) 12. Hex nut 18. Filter6. Flat washer (2) 13. Washer control 19. Hose tee7. Capscrew (2)

Figure 18-19. Windshield Washer Removal and Disassembly

18-17

TM 9-2320-277-14&P


(1) Reassemble and install windshield washerin reverse of procedure outlined in paragraph 18-11a.

(2) Fill reservoir with water, or water-isopropylalcohol cleansing solution.

(3) Depress washer control knob whileobserving washer spray. If necessary, adjust nozzles todirect spray into the center of windshield wiper path.

18-12. WINDSHIELD WIPER.


(1) Remove wiper blade (8, figure 18-20) fromarm assembly (7).

(2) Remove acorn nuts (19 and 21) and lockwasher (20). Pull arm assembly (7) off the drive shaftand idler shaft.

(3) Loosen tubing nuts (6) and disconnectand plug tubing (1).

(4) Remove knurled driver (18), rain shield(17) and hex nut (16).

(5) Remove two screws (15), pivot assembly(14) and gasket (13).

(6) Remove screws (3), nuts (5) and lockwashers (4), and remove motor assembly (9) from insideof cab.

(7) Remove setscrew (26), knob (25), hex nut(24) and lock washer (23). Be sure all air lines aredisconnected from wiper control (22) ; then removewiper control from behind instrument panel.

(8) Remove connectors (2) from motorassembly (9) and wiper control (22).

(9) Remove two screws (12), plate assembly(10) and spacers (11).

1. Copper tubing (2)2. Connector (4)3. Screw (2)4. Lock washer (2)5. Hex nut (2)6. Tubing nut (4)

7. Arm assembly8. Wiper blade9. Motor assembly10. Plate assembly11. Spacer (2)12. Screw (2)13. Gasket14. Pivot assembly15. Screw (2)16. Hex nut17. Rain shield18. Knurled driver19. Idler arm nut20. Lock washer21. Drive arm nut22. Wiper control23. Lock washer24. Hex nut25. Knob26. Setscrew

Figure 18-20. Windshield Wiper Removal and Disassembly

18-18

TM 9-2320-277-14&P


(1) Visually inspect wiper linkage for bentparts, pivot points and shafts worn out of round, orevidence of sticking, binding, or misalignment.

(2) Clean all metal parts by washing withcleaning solvent and dry thoroughly.

(3) Check knurled driver and shafts forexcessive wear. Replace all defective parts.

(4) Inspect copper tubing for cuts, kinks anddeterioration. Replace defective tubing.


(6) Visually inspect wiper blade. Effects ofsun, dust, and the natural deterioration of the rubber willdetermine the frequency of wiper blade replacement.


(1) Reassemble and install wiper, using newgasket (13, figure 18-20), in reverse of procedureoutlined in paragraph 18-12a.

(2) Wet windshield and operate wiper a fewcycles to check for proper operation; then turn off toposition wiper blade in park position.

Section VI. DEFROSTER, HEATERS AND VENT

18-13. DEFROSTER AND HEATER.

a. Defroster Removal.

(1) Remove front access panel from deck(see Chapter 15).

(2) Disconnect electrical leads from defrosterswitch.

(3) Remove hoses (9, figure 18-21) fromelbows (13).

(4) Remove screws (21) and adapter tee (12).(5) Remove four screws (5) and lift defroster

assembly (2) from heater assembly (1).(6) Remove remaining defroster components

as illustrated in figure 18-21.

b. Heater Removal.

(1) Remove defroster assembly as outlined inparagraph 18-13a.

(2) Disconnect electrical leads from blowerswitch.

(3) Pull heater temperature control out toopen coolant valve (11, figure 18-21) and drain coolingsystem (see Chapter 5).

(4) Loosen two clamps (16) and pull heaterhoses (15) from adapters on heater core.

(5) Loosen two clamps (28) and remove freshair hose (27).

(6) Remove clip (14) and disconnect dampercable (25) from damper (23).

(7) Remove hardware attaching heater (1) totractor and remove heater.

(8) Remove tapping screws (26) and fresh airadapter (20) from heater (1).

(9) Remove remaining heater components asillustrated in figure 18-21.

c. Defroster Disassembly.

(1) Remove three screws (5, figure 18-22)and lift blower assembly from housing (1).

(2) Pull blower cage (2) from shaft of motor(4).

(3) Remove two hex nuts (7) and lockwashers (6) securing motor (4) to plate (3) and removemotor.

(4) Disassemble remaining parts as illustratedin figure 18-22.

d. Heater Disassembly.

(1) Remove tapping screws (15, figure 18-23)and front cover (14).

(2) Remove tapping screws (15) securingshroud plate (4) to shell (1). Pull the shroud plate andmotor assembly from the shell.

(3) Loosen the fan retaining screw and pullfan (5) from shaft of motor (13).

(4) Remove screws (10) and the motor andbracket (6). Remove hex nut (7), lock washer (8) andseparate motor (13) from bracket (6).

18-19

TM 9-2320-277-14&P

1. Heater assembly 17. Right angle adapter (2)2. Defroster assembly 18. Reducer bushing3. Hex nut (4) 19. Service tee4. Tapping screw (4) 20. Fresh air adapter5. Screw (4) 21. Tapping screw (4)6. Heat control cable 22. Washer (2)7. Defroster vent (2) 23. Damper8. Bracket (2) 24. Clip9. Defroster hose (2) 25. Air damper cable10. Vent screen 26. Tapping screw (3)11. Coolant valve 27. Hose12. Adapter tee 28. Clamp (2)13. Defroster elbow 29. Adapter14. Tapping screw (4) 30. Gasket15. Heater hose (3) 31. Vent cover16. Clamp (6) 32. Capscrew (4)

Figure 18-21. Defroster and Heater Removal

18-20

TM 9-2320-277-14&P

1. Housing2. Blower cage3. Plate4. Motor5. Tapping screw (3)6. Lock washer (2)7. Hex nut (2)8. Cover (2)9. Connector10. Wire11. Defroster switch12. Tapping screw (6)

Figure 18-22. Defroster Disassembly

(5) Slide heater core (2) from shell (1). Ifreplacement is required, unscrew and remove adapternipples (20) from the core.

(6) Disassemble remaining heatercomponents as illustrated in figure 18-23.

e. Cleaning, Inspection and Repair.

(1) Clean the exterior of the heater core usinga stiff bristled brush and compressed air atapproximately 25 psig.

(2) Connect a water supply to the core andflush the tubes. Inspect the core for evidence ofleakage. Replace a defective core.

(3) Inspect hoses for cuts, tears and evidenceof deterioration. Replace all defective hoses.

(4) Inspect fan and blower cage for bent ordamaged blades. Replace fan and blower cage ifdefective, or if vibration was noted during operation.

(5) Inspect clamps, fittings and hardware fordamage. Replace all defective parts.

(6) Inspect wiring for frayed insulation andbroken conductors. Replace defective wiring.

(7) Inspect control cables for kinks andfreedom of operation. Replace a binding control cable.

f. Reassembly.

(1) Reassemble heater in reverse ofprocedure outlined in paragraph 18-13d.

(2) Reassemble defroster in reverse ofprocedure outlined in paragraph 18-13c.

g. Installation.

(1) Install heater assembly in reverse ofprocedure outlined in paragraph 18-13b.

(2) With heater temperature and fresh aircontrols pushed in, adjust cables (6 and 25, figure18-21) to fully close coolant valve (11) and damper (23).

(3) Install defroster assembly in reverse ofprocedure outlined in paragraph 18-13a.

18-14. AUXILIARY HEATER.

a. Removal.

(1) Disconnect electrical leads, and draincooling system (see Chapter 5).

18-21

TM 9-2320-277-14&P

1. Heater shell 11. Connector2. Core 12. Wire3. Collar(2) 13. Motor4. Shroud plate 14. Front cover5. Fan 15. Tapping screw (16)6. Motor bracket 16. Hex nut (2)7. Hex nut (2) 17. Blower switch8. Lock washer (2) 18. Hex nut9. Flat washer (2) 19. Knob10. Screw (2) 20. Adapter nipple (2)

Figure 18-23. Heater Disassembly

18-22

TM 9-2320-277-14&P

(2) Loosen two clamps (1, figure 18-24) andpull heater hoses (4) from heater core (15).

(3) Remove hardware attaching auxiliaryheater to cab and remove heater.

b. Disassembly.

(1) Separate cover plate and fan assemblyfrom shell (14), and pull heater core (15) and deflectors(12) from shell.

(2) Remove screws (5), nuts (11) and guard(6).

(3) Loosen the fan retaining screw and pullfan (7) from shaft of motor (9).

(4) Remove two hex nuts (8) and separatemotor (9) and gasket (10) from cover plate (13).

(5) Remove remaining components asillustrated in figure 18-24.


(1) Clean the exterior of the heater core usinga stiff bristled brush and compressed air atapproximately 25 psig.

(2) Connect a water supply to the core andflush the tubes. Inspect the core for evidence ofleakage. Replace a defective core.

1. Clamp (4)2. Coolant valve3. Adapter4. Heater hose (2)5. Screw (2)6. Guard7. Fan8. Hex nut (2)9. Motor

10. Gasket11. Hex nut (2)12. Deflector (2)13. Cover plate14. Shell15. Core

Figure 18-24. Auxiliary Heater Removal and Disassembly

18-23

TM 9-2320-277-14&P

(3) Inspect hoses for cuts, tears and evidenceof deterioration. Replace defective hoses.

(4) Inspect fan for bent or damaged blades.Replace fan If defective, or if vibration was noted duringoperation.

(5) Inspect clamps, fittings and hardware fordamage. Replace all defective parts.

(6) Inspect wiring for frayed insulation andbroken conductors. Replace defective wiring.


(1) Reassemble auxiliary heater, using newgasket (10, figure 18-24), in reverse of procedureoutlined in paragraph 18-14b.

(2) Install heater in reverse of procedureoutlined in paragraph 18-14a.

18-15. CAB VENT.


(1) Remove cab vent as instructed on figure18-25.

(2) Clean all parts by washing with cleaningsolvent and dry thoroughly.

b. Inspection, Repair and Installation.

(1) Inspect vent for freedom of operation anddamage. Replace a defective vent assembly.


(3) Install cab vent m reverse of instructionson figure 18-25.

Figure 18-25. Cab Vent Removal

18-24

TM 9-2320-277-14&P

CHAPTER 19

CAB TILT HYDRAULICS


19-1. DESCRIPTION.

The tractor is equipped with an hydraulic cab tilt system(see figure 19-1). The cab deck is normally secured tothe frame by two hydraulic latches (30). When themanual hydraulic pump (11) is operated, the hydrauliclatches are released and the hydraulic cylinder (19) tiltsthe cab deck forward on the two pivot pins (37). Thesafety bar (21) prevents excessive lifting of the cab deck,and provides a positive mechanical stop to prevent thecab deck from lowering unintentionally.

Section II. HYDRAULIC LATCHES


a. Removal.

WARNINGKeep clear of deck when cab israised or lowered.

(1) Operate hydraulic pump (11, figure 19-1)to tilt cab forward, then engage safety bar (21) and openflow control valve to relieve hydraulic pressure.

(2) Remove the hydraulic latch as instructedon figure 19-2.

b. Cleaning.

Clean all metallic parts by washing in cleaning solvent.Dry clean parts with compressed air at approximately 40psig.


a. Inspection And Repair.

Inspect the hydraulic latch for evidence of fluid leaks.Inspect the latch arm for evidence of cracks or excessiveear. Visually inspect all other parts for general condition.and replace all defective parts.

b. Installation.

(1) Install the hydraulic latch in reverse ofinstructions on figure 19-2.


(2) Loosen hose (12, figure 19-1) athydraulic cylinder, but do not remove.

(3) Purge system by operating hydraulicpump to alternately raise and lower the cab deck.Continue purging until clear hydraulic fluid emerges fromthe loose hose connection; then slowly lower the cabdeck and tighten the fitting. Observe the hydraulic latchfor proper alignment and engagement.

(4) After the cab deck is lowered to the frame,visually confirm that the hydraulic latch engages the holddown bracket (34).

Section III. HYDRAULIC PUMP


a. Removal.

(1) Open flow control valve to relievehydraulic pressure.

(2) Remove two hoses (1 and 5, figure 19-1),elbow (6) and tee (7).

(3) Remove four hex nuts (8), lock washers(9) and screws (10) ; then lift hydraulic pump from theframe support member.

b. Disassembly.

Disassemble the hydraulic pump in numerical sequenceas illustrated in figure 19-3.

19-1

TM 9-2320-277-14&P

1. Hose assembly 11. Hydraulic pump 21. Safety bar 31. Lock nut (8)2. Hex nut (2) 12. Hose assembly 22. Pipe tee 32. Flat washer (8)3. Lock washer (2) 13. Lock nut 23. Male adapter 33. Hex head screw (8)4. Clamp (2) 14. Hex head screw 24. Lock nut (8) 34. Hold down bracket (2)5. Hose assembly 15. Lower cylinder pin 25. Flat washer (8) 35. Lube fitting (2)6. High pressure elbow (2) 16. Lock nut (2) 26. Hex head screw (8) 36. Lock nut (4)7. Service tee 17. Hex head screw (2) 27. Hex head screw (4) 37. Pivot pin (2)8. Hex nut (4) 18. Upper cylinder pin 28. Lock washer (4) 38. Special washer (2)9. Lock washer (4) 19. Hydraulic cylinder 29. Block assembly (2) 39. Flat washer (2)

10. Hex head screw (4) 20. Safety bar pin 30. Hydraulic latch (2) 40. Rubber mount (2)

Figure 19-1. Cab Tilt Hydraulics

19-2

TM 9-2320-277-14&P

Figure 19-2. Hydraulic Latch Removal


a. Cleaning.Clean all parts with cleaning solvent, and dry clean partswith compressed air at approximately 40 psig. Apply alight coat of hydraulic fluid to metallic parts to preventcorrosion, and protect oiled parts from dust.

b. Inspection And Repair.

(1) Inspect the pump body (40), handle (19),beam (32), link (33) and reservoir (2) for cracks or othervisual damage. Replace all defective parts.

(2) Inspect spring (16) for broken or weakcoils. Replace a defective spring.

(3) Inspect sealing surfaces for nicks, gougesor scratches and replace defective parts.

(4) Discard gaskets (9 and 39) and packings(3, 20, 21,35, 36 and 37).


a. Reassembly.

Reassemble the hydraulic pump with new gaskets andpacking m reverse of numerical sequence as illustratedin figure 19-3.

b. Installation.

(1) Position the hydraulic pump on the framesupport member and secure to the vehicle with fourscrews (10, figure 19-1), lock washers (9) and hex nuts(8).

(2) Install the tee (7), elbow (6) and hydraulichoses (1 and 5).

(3) Temporarily remove filler plug (25, figure19-3), and fill pump with hydraulic fluid.

(4) Loosen hose (12) at hydraulic cylinder, butdo not remove.


(5) Purge system by operating hydraulicpump to alternately raise and lower the cab deck.Continue purging until clear hydraulic fluid emerges fromthe loose hose connection; then slowly lower the cabdeck, tighten the fitting, and refill hydraulic pump withfluid.

(6) Close flow control valve and operatehydraulic pump to check for proper operation andabsence of leaks.

Section IV. HYDRAULIC CYLINDER


a. Removal.

(1) Open flow control valve to relievehydraulic pressure.

(2) Disconnect hose (12, figure 19-1).(3) Remove two lock nuts (16) and screws

(17) and remove upper cylinder pin (18).(4) Remove lock nut (13) and screw (14) and

remove lower cylinder pin (15) and hydraulic cylinder(19).

b. Disassembly.Disassemble the hydraulic cylinder in numericalsequence as illustrated in figure 19-4.


a. Cleaning.

19-3

TM 9-2320-277-14&P

1. Capscrew(4) 21. Preformed packing2. Reservoir 22. Spindle3. Preformed packing 23. Plug4. Screen 24. Vent fitting5. Retaining ring 25. Filler plug6. Outlet seat 26. Cotter pin (6)7. Flow control assembly 27. Washer (6)8. Relief valve 28. Piston pin9. Gasket 29. Link pin

10. Inlet seat 30. Beam link pin11. Retaining ring 31. Spring washer (3)12. Screen 32. Beam13. Pin 33. Link14. Plug 34. Plunger15. Lock screw 35. Seal16. Spring 36. Back-up ring17. Ball 37. Quad ring18. Set screw 38. Pump cylinder19. Handle 39. Preformed packing20. Seal 40. Pump body

Figure 19-3. Hydraulic Pump Disassembly

19-4

TM 9-2320-277-14&P

Clean all parts with cleaning solvent, and dry clean partswith compressed air at approximately 40 psig. Apply alight coat of hydraulic fluid to metallic parts to preventcorrosion and protect oiled parts from dust.

b. Inspection And Repair.

(1) Inspect all metal parts for corrosion,cracks, burrs, breaks, distortion or other damage.Inspect contact areas for scoring or wear. Remove burrswith a fine stone. Replace all damaged parts.

NOTEIf plunger (8) or housing (11) isdamaged, replace hydraulic cylinderassembly.

(2) Inspect hardware and threaded openingsfor damaged threads. Chase damaged threads with thecorrect size tap or die. Replace damaged hardware.

(3) Discard wiper (4) and packing (5).


a. Reassembly.

Reassemble the hydraulic cylinder with new wiper (4)and packing (5) in reverse of numerical sequence asillustrated in figure 19-4.

b. Installation.

(1) Position hydraulic cylinder housing againstlower support bracket and install lower cylinder pin (15,figure 19-1), screw (14) and lock nut (13).

(2) Position hydraulic cylinder plunger againstupper support bracket and install upper cylinder pin (18),screws (17) and lock nuts (16).

(3) Reinstall hose (12) but do not tightenfitting.


(4) Purge system by operating hydraulicpump to alternately raise and lower the cab deck untilclear hydraulic fluid emerges from the loose hoseconnection; then slowly lower the cab deck and tightenthe fitting.

(5) Remove filler plug (25, figure 19-3) andadd hydraulic fluid as necessary.

1. Velocity fuse 5. Packing 9. Lock ring2. Reducing bushing 6. Adapter 10. Snap ring3. Gland nut 7. Retaining ring 11. Housing4. Wiper 8. Plunger

Figure 19-4. Hydraulic Cylinder Disassembly

19-5

TM 9-2320-277-14&P

SECTION IIIREPAIR PARTS



NSN 2320-01-044-8376

TM 9-2320-277-14&PTABLE OF CONTENTS

Chapter ChapterSection Section

Paragraph Page Paragraph Page

1. INTRODUCTION AND DESCRIPTION.........1-1 Thermostats and Water Manifold .........2-44I. INTRODUCTION ..............................1-1 Water Pump and Idler Pulley ................2-46

1-1. Scope and Related Publications ....1-1 Water Pump Assembly ..........................2-47II. DESCRIPTION..................................1-1 External Oil Filter.....................................2-48

1-2. Arrangement .....................................1-1 Oil Filter Assembly .................................2-491-3. Alpha-Numeric Cross-...................... IV. FUEL SYSTEM........................................2-50

Reference Index ...............................1-1 Air Cleaner ..............................................2-501-4. Introduction and Description ...........1-1 Air Cleaner Assembly ............................2-52

.............................................................. Restriction Indicator ...............................2-532. PARTS LIST ......................................................2-1 Fuel Tank Group ....................................2-54

I. INTRODUCTION AND...................... Fuel Filter .................................................2-56DESCRIPTION .................................2-1 Ether Starting Aid ...................................2-57

2-1. Introduction .......................................2-1 Accelerator Linkage ...............................2-582-2. Description .........................................2-1 Accelerator Pedal. .................................2-60

II. HOW TO USE PARTS LIST ...........2-1 V. EXHAUST SYSTEM ..............................2-612-3. Locating Parts When Part................ Vertical Muffler Installation ...................2-61

Number is Unknown .........................2-1 Exhaust Outlet Group.............................2-622-4. Locating Parts When Part................ VI. COOLING SYSTEM ...............................2-63

Number is Known..............................2-1 Radiator Overflow....................................2-63III. ENGINE ASSEMBLY AND .............. Radiator Group .......................................2-64

MOUNTING........................................2-2 Radiator Assembly .................................2-67Engine Assembly and Mounting ....2-2 Fan Group ................................................2-69Cylinder Block Assembly..................2-3 Coolant Filter Installation ......................2-71Cylinder Head Assembly..................2-5 VII. ELECTRICAL GROUP ..........................2-72Rocker Cover ....................................2-7 Electrical Group ......................................2-72Upper Front Cover and Breather....2-8 Wiring Diagram ........................................2-74Crankshaft and Pulley ......................2-9 Alternator Installation .............................2-76Flywheel and Housing......................2-11 Alternator Assembly ...............................2-77Piston and Connecting Rod ............2-13 Starter Motor ............................................2-79Camshaft. ........................................2-15 70 AMP Breaker and Solenoid ............2-81Oil Filter Installation .........................2-16 Engine Shutdown Kit .............................2-82Rocker Arms and Valves .................2-17 Water Level Warning KitOil Filter Assembly ...........................2-19 Installation ...............................................2-84Oil Cooler ...........................................2-20 Water Level Warning Kit ........................2-85Dipstick ...............................................2-21 Instrument Panel.....................................2-86Oil Inlet Tube .....................................2-22 Speedometer Group...............................2-88Oil Pan ...............................................2-24 Tachometer Group .................................2-89Lower Front Cover and Oil Pump...2-25 Trailer Cable Group ...............................2-90Front Trunnion Mount ......................2-26 Separate Lighting Cable ........................2-91Air Inlet Housing ...............................2-27 Headlight Assembly ...............................2-92Exhaust Manifold and Clearance Light Group ..........................2-93Connector Group ..............................2-29 Front Turn and Stop Light......................2-94Engine Belt Sets ...............................2-30 Back Up and Tail Light Group ..............2-95Governor and Related Parts ............2-31 Side Marker Light....................................2-96Governor Assembly ..........................2-33 License Plate Light .................................2-97Fuel Pump and Related Parts ........2-37 Horn and Relay .......................................2-98Fuel Pump Assembly........................2-38 Battery Group...........................................2-99Fuel Crossover Lines .......................2-39 VIII. AUTOMATIC TRANSMISSION.............2-101Injector Control Tubes .....................2-40 Automatic Transmission ........................2-101Fuel Injector and Related Parts .....2-41 Housing, Oil Filter andFuel Injector Assembly ....................2-42 Oil Pan Group..........................................2-102

i

TM 9-2320-277-14&PTABLE OF CONTENTS (Continued)



Control Valve Group ........................................2-104 Air Compressor Installation ..................2-167Oil Pump and Front Support Air Compressor .......................................2-169Group ..............................................................2-107 Air Compressor Governor .....................2-172Forward Clutch and Air Strainer................................................2-173Turbine Shaft Group ........................................2-108 Alcohol Evaporator .................................2-174Fourth Clutch Group ........................................2-110 Hose Tender ...........................................2-176Third Clutch, Center Support Brake Control Panel ...............................2-177and Second Clutch Group ..............................2-112 XIII. WHEELS AND TIRES ............................2-178Main Shaft and Gear Unit Group....................2-114 Wheel and Tire Group ...........................2-178First Clutch Group .............................................2-116 XIV. STEERING...............................................2-179Governor and Rear Cover Group ...................2-118 Steering Group ........................................2-179Low Planetary, Low Clutch and Steering Gear ..........................................2-182Adapter Housing Group ...................................2-120 Ball Sockets ............................................2-185Converter Cover Power Steering Hydraulics ...................2-186and Torque Converter Group .........................2-122 Power Steering Pump............................2-188Modulated Lockup Valve .................................2-124 Filter Assembly .......................................2-190Low Shift Valve .................................................2-125 XV. FRAME AND DECK ...............................2-191External Oil Filter ..............................................2-126 Main Frame..............................................2-191Oil Filter Assembly ...........................................2-127 Bumper and Grill Guard.........................2-192Gear Shift and Fifth Wheel Cross Tie Assembly................................2-194Control ..............................................................2-128 Mud Flap ..................................................2-195Gear Shift Cable................................................2-130 Spare Tire Carrier ..................................2-196Shift Lockout .....................................................2-131 Deck and Engine Enclosure..................2-197

IX. DRIVE SHAFT....................................................2-133 Engine Compartment Insulation ...........2-198Drive Shaft .........................................................2-133 Side Step .................................................2-199

X. FRONT AXLE AND Rear Platform ...........................................2-200SUSPENSION ...................................................2-134 XVI. FIFTH WHEEL.........................................2-201Front Axle Assembly ........................................2-134 Fifth Wheel Group ..................................2-201Front Axle Hub and Drum ................................2-136 Fifth Wheel Assembly ............................2-202Front Axle Brakes..............................................2-137 XVII. FIFTH WHEEL HYDRAULICS ..............2-204Brake Air Chamber ..........................................2-138 Fifth Wheel Hydraulic Group.................2-204Front Axle Seal .................................................2-139 Filter Assembly .......................................2-206Front Axle Spring Group .................................2-140 Power Take-Off .......................................2-207Shock Absorber Installation.............................2-142 Hydraulic Pump ......................................2-209

XI. REAR AXLE .......................................................2-143 Hydraulic Cylinder...................................2-210Rear Axle Group................................................2-143 Hydraulic Valve .......................................2-211Differential Carrier Assembly...........................2-145 XVIII. CAB............................................................2-212Rear Axle Shaft, Hub and Drum .....................2-148 Cab............................................................2-212Rear Axle Brakes ..............................................2-149 Cab Door .................................................2-213Rear Axle Brake Chamber ..............................2-151 Rear Window Screen .............................2-214

XII. AIR SYSTEM......................................................2-152 Seat ...........................................................2-215Pneumatic Group ..............................................2-152 Upper Seat Assembly ............................2-216Air Tank Installation ..........................................2-157 Seat Suspension Assembly...................2-218Treadle Valve Assembly ..................................2-158 Acoustical Upholstery ............................2-220Automatic Drain Valve .....................................2-160 Identification and InstructionDouble Check Valve..........................................2-161 Decals ......................................................2-221Check Valve ......................................................2-162 XIX. CAB TILT HYDRAULICS .......................2-223Quick Release Valve.........................................2-163 Cab Tilt Hydraulics ..................................2-223Drain Cock..........................................................2-164 Cab Tilt Pump..........................................2-225Trailer Hand Brake Control .............................2-165 Cab Tilt Cylinder .....................................2-227Fifth Wheel Unlatch Valve ...............................2-166 XX. ACCESSORIES ......................................2-228

ii

TM 9-2320-277-14&PTABLE OF CONTENTS (Continued)



Sun Visor ...........................................................2-228 3. MANUFACTURER'S CODE LIST ANDWindshield Wiper Group .................................2-229 ALPHA-NUMERIC CROSS-Windshield Washer ..........................................2-231 REFERENCE INDEX ..................................3-1Paper Compartment Installation.....................2-233Reflective Safety Group ..................................2-234 I. MANUFACTURER'S CODE LIST.....3-1Mirror Group ......................................................2-235 3-1. Description ..........................................3-1Heater and Defroster .......................................2-237 II. ALPHA-NUMERICHeater Assembly ..............................................2-239 CROSS-REFERENCE INDEX .........3-5Defroster Assembly ..........................................2-241 3-2. Description ..........................................3-5Auxiliary Heater ................................................2-242 3-3. Part Number Column .........................3-5Air Horn 2-243

iii

TM 9-2320-277-14&P

CHAPTER 1

INTRODUCTION AND DESCRIPTION


1-1. SCOPE AND RELATED PUBLICATIONS.

This Repair Parts Manual illustrates, lists, and describesthe assemblies, components, and detail parts of theM878 Yard Type Tractor. The tractor is manufacturedby the Ottawa Truck Division of G + W, Ottawa, Kansas,and is identified as their Model Commando Fifty. Referto the separate operator's manual and maintenancemanual for the operation and maintenance of the tractor.

Section II. DESCRIPTION

1-2. ARRANGEMENT.

This Repair Parts Manual is arranged in the followingmanner:

Cover Page

Table of Contents

Chapter 1. Introduction and Description

Chapter 2. Parts List

Chapter 3. Manufacturer's Code List

Alpha-Numeric Cross-Reference Index

1-3. TABLE OF CONTENTS.

The table of contents shows the location of allillustrations within the parts breakdown and alsoindicates the relation of assemblies to each other by useof the indention method described in Chapter 2.Illustrations and groups are listed in the sequence oftheir appearance in the parts breakdown.

1-4. INTRODUCTION AND DESCRIPTION.

The Introduction and Description consists of generalinformation and instructions regarding the use of thisRepair Parts Manual.

1-1/(1-2 blank)

TM 9-2320-277-14&P

CHAPTER 2

PARTS LIST

Section I. INTRODUCTION AND DESCRIPTION

2-1. INTRODUCTION.

This chapter lists the components and detail parts of thetractor. Illustrations are provided to identify listed parts.When a standard size part can be replaced with oversizeor undersize parts, the latter parts, showing sizes, arealso listed. Repair and service part kits are also listedwhen they are available for replacement.

2-2. DESCRIPTION.

a. Parts Kits.

The parts kits are listed at the end of the page on whichthe component parts are shown. Parts of assembliesthat are available in parts kits are identified in thedescription column of the parts kit listing.

b. Indentation.

The descriptions of parts listed are indented to indicatethe relationship of assembly to component detail parts.Detail parts for most assemblies are contained onseparate parts list pages following the page which liststhe assembly.

c. Dimensions.

All dimensions given in the Description column are ininches unless otherwise specified.

d. Abbreviations.

The following abbreviations have been used in thischapter:

AMP - amperes

AR - as required (used for indefinite quantity)

ASSY - assembly

FSCM - Federal Supply Codes for Manufacturers(refer to Chapter 3)

IN - inch

REF - reference (used when part is listed elsewherewith proper quantity)

e. Notes.

An asterisk (*) occasionally appears in the Descriptioncolumn, and indicates a note pertaining to that item willbe found at the bottom of the page. When more thanone note is needed, other symbols (**) (#) are employed.

Section II. HOW TO USE PARTS LIST

2-3. LOCATING PARTS WHEN PART NUMBER ISUNKNOWN.

a. Using the table of contents determine thefunctional group within which the part belongs. This isnecessary since illustrations are prepared for functionalgroups, and listings are divided into the same groups.

b. Find the illustration covering the functional groupto which the part belongs.

c. Identify the part on the illustration and note theillustration item number of the part.

d. Using the parts listing, find the item numbernoted on the illustration.

2-4. LOCATING PARTS WHEN PART NUMBER ISKNOWN.

a. Using the Alpha-Numeric Cross ReferenceIndex at the end of this manual, find the pertinent partnumber. This index is in ascending alphanumericsequence, cross-referenced to the illustration pagenumber and item number.

b. After finding the page and item number, locatethe page and item number in the parts list (Chapter 2).

2-1

TM 9-2320-277-14&PSection III. ENGINE ASSEMBLY AND MOUNTING

ENGINE ASSEMBLY AND MOUNTING90002237

ITEM PART NUMBER DESCRIPTION QTY.

1 90002237 Detroit Diesel 6V-53 w/options 12 90802070 Hex Head Bolt 7/8-14 X 4-1/2 23 95210228 Hex Nut 7/8-14 24 53102297 Rubber Mount 25 98421025 Washer, Flat, Special 46 53102299 Washer, Snubbing 27 98420011 Lockwasher 7/8 28 53500720 Engine Mount L.H. 1

53500721 Engine Mount R.H. 19 90804249 Hex Head Bolt 1/2-13 X 1-1/4 210 98415050 Lockwasher 1/2 211 53502705 Ground Strap 8" 1

2-2

TM 9-2320-277-14&P

CYLINDER BLOCK ASSEMBLY


1 118536 Draincock 3/8 12 186618 Hex Head Bolt 5/16-18 X 5/8 23 MS35338-7 Lockwasher 5/16 24 5108759 Cover 15 5116357 Gasket 16 186627 Hex Head Bolt 3/8-24 X 1 47 MS15795-14 Washer 3/8 Flat 48 105451 Gasket 3/8 Copper 49 5183184 Hand Hole Cover 410 5185416 Cover Gasket 411 5130590 Cover Clamp 4

2-3

TM 9-2320-277-14&P


12 5132287 Air Box Drain Tube 213 125859 Elbow 45° 1/4 Flare 214 9414523 Hex Head Bolt 7/16-14 X 1 815 5125608 Washer 7/16 Flat 816 5141701 Main Bearing Cap Bolt 817 5132695 Stabilizer 418 5199506 Main Bearing Cap 419 186725 Hex Head Bolt 1/2-13 X 1-1/2 220 5188274 Washer 221 179839 Hex Head Bolt 3/8-16 X 1 1222 MS35338-8 Lockwasher 3/8 1223 5126194 End Plate 124 5133397 End Plate Gasket 125 5133981 Main Bearing Cap Washer 826 5121459 Plug Nut 3/8-24 227 - - - - Cylinder Block (not serviced separately) 1

2-4

TM 9-2320-277-14&P

CYLINDER HEAD ASSEMBLY


1 5199527 Injector Tube Assembly 32 5160037 Ring Seal 33 5111467 Exhaust Valve Spring Seat 124 5131961 Exhaust Valve Guide 125 5116361 Exhaust Valve Seat Insert 126 5116262 Injector to Governor Adaptor Link 17* 5119293 Water Nozzle 48 5154453 Special Plug 3/8-16 49 5145009 Pipe Plug 1/8 210 5198655 Fuse Plug 1

2-5

TM 9-2320-277-14&P


11 5121182 Pipe Plug 1/4 612 5151449 Cup Plug 13/16 313 179839 Hex Head Bolt 3/8-16 X 1 414 MS35338-8 Lockwasher 3/8 415 5136610 Water Hole Cover 216 5116242 Cover Gasket 217 - - - - Cylinder Head (not serviced separately) 118 5112899 Stud 7/16-14 X 2-3/32 819 5121263 Cylinder Head Bolt 5/8-11 X 6-1/4 1620 5199811 Cylinder Head Gasket Set 121 5116290 Water Hole End Seal 822 5116122 Nonmetallic Oil Washer 423 5121254 Cylinder Head Compression Gasket 624 5121207 Water Hole Center Seal 825 5116292 Cylinder Head Oil Ring 2

2-6

TM 9-2320-277-14&P

ROCKER COVER


1 5108474 Oil Filler Cap 12 5100104 Screw Assembly w/Plate 5/16-18 X 5/8 83 5125356 Plain Rocker Cover 14 5125355 Rocker Cover 15 5147994 Gasket 2

2-7

TM 9-2320-277-14&P

UPPER FRONT COVER AND BREATHER


1 5128025 Upper Front Cover 12 5119477 Plug 13 5150829 Plug 7/8 Cup 14 5157933 Dowel Pin 5/16 X 7/8 25 179844 Hex Head Bolt 3/8-16 X 1-5/8 116 179848 Hex Head Bolt 3/8-16 X 2-1/4 127 MS35338-8 Lockwasher 3/8 248 5124055 Upper Cover Gasket 19 5116476 Oil Seal 210 5119481 Filter 111 5129064 Hose 7/8 X 2 112 111610 Hose Clamp 1-1/4 213 5129063 Breather Pipe Extension 114 5177001 Clip 1

2-8

TM 9-2320-277-14&P

CRANKSHAFT AND PULLEY


1 271632 Crankshaft Pulley Bolt 3/4-16 X 1-3/4 12 5180291 Crankshaft Pulley Retainer 13 5170484 Crankshaft Pulley, 4 Grooves 14 - - - - Main Bearing Cap Bolt (see cylinder block) 85 5159353 Thrust Washer, Std. 4

5160542 Thrust Washer, 0.005 O/S 45192111 Thrust Washer, 0.010 O/S 4

6 141346 Dowel Pin 3/16 X 1/2 47 - - - - Main Bearing Cap (see cylinder block) 48 5198410 Main Bearing Set, Std. 1

5198411 Main Bearing Set, 0.002 U/S 15198412 Main Bearing Set, 0.010 U/S 15198413 Main Bearing Set, 0.020 U/S 15198414 Main Bearing Set, 0.030 U/S 1

9 5116401 Main Bearing Lower Shell, Std. 45196669 Main Bearing Lower Shell, 0.002 U/S 45196671 Main Bearing Lower Shell, 0.010 U/S 45196673 Main Bearing Lower Shell, 0.020 U/S 45196615 Main Bearing Lower Shell, 0.030 U/S 4

10 5137595 Main Bearing Upper Shell, Std. 45198415 Main Bearing Upper Shell, 0.002 U/S 45198416 Main Bearing Upper Shell, 0.010 U/S 45198417 Main Bearing Upper Shell, 0.020 U/S 4

2-9

TM 9-2320-277-14&P


5198418 Main Bearing Upper Shell, 0.030 U/S 411 5116224 Front Oil Seal, Std. 1

5198503 Front Oil Seal, O/S (use with 5198502 sleeve) 112 5144375 Oil Pump Drive Gear 113 5116229 Rear Oil Seal, Std. 1

5196852 Rear Oil Seal, O/S (use with 5196851 sleeve) 114 5116195 Crankshaft Timing Gear 115 MS35756-35 Woodruff Key 1/4 X 3/4 116 5144616 Crankshaft 117 - - - - - Main Bearing Cap Washer (See cylinder block, page 2-3) 8

2-10

TM 9-2320-277-14&P

FLYWHEEL AND HOUSING


1 9412018 Hex Head Self-lock Bolt 1/2-20 X 2-1T4 62 5148011 Input Drive Plate 13 5148093 Flywheel Assembly 14 5116302 Ring Gear SAE #2 138 Teeth 15 117049 Hex Nut 3/8-24 X 7/8 26 MS90725-84 Hex Head Bolt 7/16-14 X 7/8 27 186310 Hex Head Bolt 3/8-24 X 3-1/2 28 427588 Hex Head Bolt 3/8-16 X 2-1/2 89 179850 Hex Head Bolt 3/8-16 X 2-3/4 210 191249 Hex Head Bolt 3/8-16 X 3-3/4 611 186309 Hex Head Bolt 3/8-24 X 3-1/4 212 MS35338-8 Lockwasher 3/8 2013 9409126 Hex Head Bolt 5/16-18 X 2-1/2 214 5130992 Cup Plug (not illustrated) 215 5140370 Flywheel Housing SAE #2 116 5123802 Housing Shim 2.38 X 0.015 117 5137470 Flywheel Housing Gasket 118 122408 Hex Head Bolt 1/2-13 X 1 819 MS 49005-8 Pipe Plug 1/2 120 - - - - Rear Oil Seal (see crankshaft, page 2-9) 121 141195 Dowel Pin 1/4 X 5/8 122 5152904 Gasket 7/8 123 5150568 Copper Washer 7/16 224 MS35338-10 Lockwasher 1/2 825 5122281 Large Hole Cover 2

2-11

TM 9-2320-277-14&P


26 5117061 Cover Gasket 227 5108939 Inspection Hole Cover 228 MS35338-46 Lockwasher 1/4 429 181309 Bolt 1/4-28 X 1/2 4

5148012 Input Drive Plate Adapter 19409131 Bolt 3/8-24 X 3/4 66836873 Hex Nut 3/8-24 6

2-12

TM 9-2320-277-14&P

PISTON AND CONNECTING ROD


1 5133109 Connecting Rod Assembly 62 839103 Hex Nut 3/8-24 23 5197852 Connecting Rod Bolt 3/8-24 X 2.76 24 5150140 Oil Nozzle 15 5116181 Piston Pin Bushing 26 5197975 Connecting Rod Bearing Set, Std. 6

5197976 Connecting Rod Bearing Set, 0.002 U/S AR5197977 Connecting Rod Bearing Set, 0.010 U/S AR5197978 Connecting Rod Bearing Set, 0.020 U/S AR5197979 Connecting Rod Bearing Set, 0.030 U/S AR

7 5133101 Upper Bearing, Std. 25197963 Upper Bearing, 0.002 U/S AR5197965 Upper Bearing, 0.010 U/S AR

2-13

TM 9-2320-277-14&P


5197967 Upper Bearing, 0.020 U/S AR5197969 Upper Bearing, 0.030 U/S AR

8 5133098 Lower Bearing, Std. 25197964 Lower Bearing, 0.002 U/S AR5197966 Lower Bearing, 0.010 U/S AR5197968 Lower Bearing, 0.020 U/S AR5197970 Lower Bearing, 0.030 U/S AR

9 5198822 Piston Ring Set 610 5180250 Piston Pin Retainer 1211 5116189 Piston Pin 612 5116181 Piston Pin Bushing 1213 5198877 Piston Assembly (includes items 10 and 12) 614 5132803 Cylinder Sleeve 615 5121256 Preformed Packing 6

5198899 Cylinder Service Kit (consists of items 9, 11, 13, 14 and 15) AR

2-14

TM 9-2320-277-14&P

CAMSHAFT


1 5121109 Pulley 22 MS90726-58 Hex Head Bolt 3/8-24 X 3/4 43 5172734 Gear Nut Retainer 24 5150087 Hex Nut 45 MS35338-8 Lockwasher 3/8 46 5199396 LH Camshaft (includes 5151277 plug) 17 5197944 Bearing Set, Std. 2

5198983 Bearing Set, Std. ID, 0.010 O/S O.D. AR5197945 Bearing Set, 0.010 U/S I.D., Std. O.D. AR

8 5133387 RH Helix Gear 19 5133388 LH Helix Gear 110 MS35756-34 Woodruff Key 411 5134388 Oil Slinger 212 MS90728-60 Thrust Washer Bolt 3/8-16 X 1 413 5116198 Thrust Washer 214 5121077 Gear Spacer 215 5199397 RH Camshaft (includes 5151277 plug) 1

2-15

TM 9-2320-277-14&P

OIL FILTER INSTALLATION


1 MS15795-14 Washer 3/8 42 5121205 Gasket, Adapter to Oil Filter 13 5121182 Pipe Plug 1/4 24 454906 Hex Head Bolt 318-16 X 1-1/2 45 MS90725-62 Hex Head Bolt 3/8-16 X 1-1/4 46 MS35338-46 Lockwasher 3/8 87 5129617 Mounting Adapter 450 Offset 18 5128486 Gasket, Adapter to Engine 19 5134392 Oil Filter Assembly (see page 2-19) 110 160221 Self-Tapping Screw #12-24 X 1/2 111 5134456 Spring Retainer 112 5134477 Bypass Valve Spring 113 5133431 Bypass Valve 1

2-16

TM 9-2320-277-14&P

ROCKER ARMS AND VALVES

2-17

TM 9-2320-277-14&P


1 5119198 Hex Head Bolt, Bracket Mounting 122 5116128 Rocker Shaft Bracket 123 5116072 Rocker Arm Shaft Assembly 64 5151272 Special Plug 11/32 X 1/4 15 5135267 Rocker Arm Assembly LH 66 5135268 Rocker Arm Assembly RH 67 5135262 Exhaust Valve Bridge 18 5150314 Hollow Clevis Pin 19 5150312 Rod End Clevis 110 5123700 Sleeve Bushing 211 5123711 Hollow Bridge Pin 112 5179954 Injector Arm Assembly 613 5150314 Hollow Clevis Pin 114 5150312 Rod End Clevis 115 5123700 Sleeve Bushing 116 5150311 Sleeve Bearing 117 5150318 Large Sleeve Bearing 118 5151601 Push Rod Hex Nut 1819 5150303 Snap Ring Retainer 1820 5108919 Injector and Valve Helical Retainer 1821 5108918 Injector and Valve Compression Spring 1822 5123250 Push Rod Lower Seat 1823 5128640 Push Rod 1824 5115087 Cam Follower Assembly 1825 5195220 Roller Set Std. 126 443603 Hex Head Bolt 1/4-20 X 3/4 1227 MS35338-46 Lockwasher 1/4 1228 5116125 Cam Follower Guide 629 5116341 Valve Spring Lock 4830 5123330 Valve Spring Cap 2431 5147424 Compression Valve Spring 2432 5199323 Engine Poppet Valve (includes item 29) 24

2-18

TM 9-2320-277-14&P

OIL FILTER ASSEMBLY


1 5134908 Adapter Assembly 1454557 Tapping Insert 5/8-18 (not shown) 1

2 5573014 Filter Element 13 5571024 Gasket 14 122366 Hex Nut 5/8-18 15 5187309 Retainer 16 5187310 Preformed Packing 17 5154538 Spacer Ring 18 5187308 Helical Compression Spring 19 5120740 Shoulder Bolt 110 6437298 Gasket 111 5574008 Oil Filter Shell 112 5570480 Plug 1

2-19

TM 9-2320-277-14&P

OIL COOLER


1 5145013 Pipe Plug 3/4 12 MS 90724-51 Hex Head Bolt 5/16-18 X 4-3/4 83 MS35338-7 Lockwasher 5/16 84 5154215 * Outer Core Gasket 15 8514600 Core Assembly, 12 Plate 16 5150155 * Inner Core Gasket 17 5135915 Cooler Housing 18 103647 Draincock 1/4 29 53504006 Hose Fitting, 3/4 1

*Included in kit 5196785.

2-20

TM 9-2320-277-14&P

DIPSTICK


1 5162941 Dipstick 12 137408 Tube Connector 7/8 13 5140888 Adapter Assembly 14 5161873 Clip, 7/16" Tube 15 121917 Hex Nut 5/16-24 16 181333 Bolt 5/16-24 X 5/8 17 120293 Flat Washer 5/16 18 MS35338-7 Lockwasher 5/16 19 5114541 Clip Bracket 1

2-21

TM 9-2320-277-14&P

OIL INLET TUBE


1 9409010 Self-Locking Bolt, 5/16-18 X 5/8 22 103340 Flat Washer, 5/16 23 5126143 Strainer Element 14 180120 Hex Head Screw, 3/18-16 X 3/4 45 179827 Hex Head Screw, 5/16-18 X 2-1/4 26 MS35338-7 Lock Washer, 5/16 27 5126473 * Gasket 18 MS35338-8 Lock Washer, 3/8 4

2-22

TM 9-2320-277-14&P


9 5138619 Flat Washer, 25/64 X 3/4 410 192481 Hex Nut, 3/8-24 211 MS15795-14 Flat Washer, 3/8 812 186627 Hex Head Screw, 3/8-24 213 5138420 Bracket 214 5138245 Oil Tube Assembly 1

*Included in kit 5196785

2-23

TM 9-2320-277-14&P

OIL PAN


1 5145012 Pipe Plug 1/2 15146309 Pipe Plug 1/2 (Magnetic) 1

2 840277 Plug Gasket 23/32 ID 13 5130785 Engine Oil Pan 14 5119266 Gasket 15 5148436 Hex Head Bolt w/Lockwasher 5/16-18 X 3/4 22

2-24

TM 9-2320-277-14&P

LOWER FRONT COVER AND OIL PUMP


1 5136227 Oil Pressure Regulator Plug 22 5177773 Oil Pressure Regulator Plug Washer 23 5126436 Helical Compression Spring 24 5143021 Bypass Valve 25 186612 Hex Head Bolt 3/8-16 X 1-318 46 MS35338-8 Lockwasher 127 5119368 Lower Cover Gasket 18 179826 Hex Head Bolt 5/16-18 X 2 69 5116070 Oil Pump Assembly 110 145067 Cover Drive Screw #6 X 3/8 211 5195687 Rotor Set 112 5195685 Oil Pump Cover 113 - - - - Oil Pump Body (Not serviced separately) 114 427588 Hex Head Bolt 3/8-16 X 2-1/2 515 186283 Hex Head Bolt 3/8-16 X 3-1/2 216 455537 Hex Head Bolt 3/8-16 X 4 217 - - - - Front Oil Seal (see Crankshaft) REF18 5136274 Lower Front Cover 119 MS 49005-8 Pipe Plug 1/2 120 5145014 Hex Soc. Head Pipe Plug 3/8 1

2-25

TM 9-2320-277-14&P

FRONT TRUNNION MOUNT


1 5186647 Support and Cap Assembly 12 179867 Hex Head Bolt 7/16-14 X 2-1/4 23 103322 Lockwasher 7/16 24 5166864 Cushion Ring 15 5124762 Trunnion Support 16 180147 Hex Head Bolt 7/16-14 X 1-114 67 103322 Lockwasher 7/16 6

2-26

TM 9-2320-277-14&P

AIR INLET HOUSING53506668


1 Nozzle (see Ether Starting Aid) REF2 90804226 Hex Head Screw, 7/16-14 X 1 43 95210110 Hex Nut, 7/16-14 44 98415045 Lockwasher, 7/16 4

2-27

TM 9-2320-277-14&P


5 5127238 Elbow Aluminum, 90° 16 90002399 Gasket 27 186619 Hex Head Bolt, 3/8-16 X 1-1/8 48 MS35338-8 Lockwasher, 3/8 49 MS15795-14 Flat Washer, 3/8 410 53506558 Adapter, Air Inlet 111 186612 Hex Head Bolt, 3/8-16 X 1-3/8 112 186283 Hex Head Bolt 3/8-16 X 3-1/2 213 179846 Hex Head Bolt 3/8-16 X 1-7/8 314 MS35338-8 Lockwasher 3/8 615 MS15795-14 Flat Washer 3/8 616 5104451 Air Inlet Housing 1

5121182 Pipe Plug 1/4 1

2-28

TM 9-2320-277-14&P

EXHAUST MANIFOLD AND CONNECTOR GROUP


1 127855 Hex Nut 7/16-20 82 5188273 Dished Lockwasher 7/16 X 1-1/4 43 5133435 Bridge Clamp 44 5139176 Exhaust Manifold RH 14 5132495 Exhaust Manifold LH 15 5116205 Manifold Gasket 26 5112899 Plain Stud 7/16-20 X 2-3/32 87 5146165 Clamp Assembly (Marman Flange) 28 5108830 Connector Pipe 3-1/4 O.D. 2

2-29

TM 9-2320-277-14&P

ENGINE BELT SETS


1 90002554 Fan Belts, Matched Set 12 90002246 Alternator Belts, Matched Set 13 5139228 Water Pump Belts, Matched Set 14 - - - - Power Steering Pump Belts REF

(see Power Steering Hydraulics)

2-30

TM 9-2320-277-14&P

GOVERNOR AND RELATED PARTS

2-31

TM 9-2320-277-14&P


1 454813 Hex Head Bolt 1/4-20 X 7/8 12 120380 Lockwasher 1/4 13 5138525 Shutdown Lever 14 MS90728-8 Hex Head Bolt 1/4-20 X 1 15 120380 Lockwasher 1/4 16 - - - - Throttle Arm (See Accelerator Linkage) REF7 103361 Cotter Pin 1/16 X 1/2 28 114783 Straight Clevis Pin 29 454750 Self Locking Hex Nut 1/4-28 210 5121472 Lower Control Link 211 5121453 Upper LH Control Link 1

5121452 Upper RH Control Link 112 111610 Hose Clamp 1-1/4 413 5129706 Right Bank Hose 7/8 X 1.62 1

5129705 Left Bank Hose 13/16 X 0.76 214 5126072 Link Housing LH 115 179850 Hex Head Bolt 3/8-16 X 2-3/4 616 MS35338-8 Lockwasher 3/8 617 5147528 Governor Assembly (see page 2-33) 118 5116262 Plain End Adapter 219 5121345 Gasket, Governor to Engine 120 907674 Ball Bearing 121 5152462 Expansion Plug 1-1/8 122 5119438 Gasket

2-32

TM 9-2320-277-14&P

GOVERNOR ASSEMBLY

2-33

TM 9-2320-277-14&P

GOVERNOR ASSEMBLY

2-34

TM 9-2320-277-14&P

ITEM PART NUMBER DESCRIPTION QTY.1 5133819 Shaft and Carrier Assembly 12 9411504 Retaining Ring 43 5122786 Governor Weight Pin 44 5122771 High Speed Governor Weight 25 5133662 Low Speed Governor Weight 26 5133707 Weight Carrier 17 5125367 Governor Riser Assembly 18 451905 Thrust Bearing 19 5121337 Weight Carrier Shaft 110 5121342 Cover Gasket 111 5183701 Machine Screw, Fil. Head 1/4-20 X 5/8 112 120380 Lockwasher 1/4 113 9417926 Machine Screw w/Lockwasher 1/4-20 X 3/4 614 5103748 Governor Cover Assembly 115 5178581 Retaining Ring 116 5151487 Flat Washer 217 5197150 Back-up Washer AR18 5101691 Preformed Packing 119 457008 Roll Pin 3/16 X 1-1/2 120 5104516 Shutdown Shaft 121 5174429 Retaining Ring 122 5144177 Flat Washer 223 5197151 Back-up Washer AR24 5176557 Preformed Packing 125 5117928 Shaft Assembly 126 5145009 Pipe Plug 1/8 127 113500 Plain Tapered Pin 128 5117927 Fulcrum Pin 129 5129829 Cover Assembly 130 148402 Roller Bearing 231 445520 Hex Head Bolt 5/16-18 X 3-1/2 232 5155596 Copper Washer 5/16 233 5182559 Spring Adjusting Screw Housing 134 5182557 Spring Retainer 135 5152944 Gasket 136 5150899 Spring Retainer Cap 137 5122165 Low Speed Spring (narrow blue stripe) 138 5150892 Low Speed Spring Seat 139 5182556 Low Speed Adjusting Screw 140 122161 Hex Nut 1/2-28 141 5186115 Spring Retainer Locknut 142 5124415 High Speed Spring (white stripe) 143 5151249 Shim 0.078 AR44 5174286 Hex Nut 3/8-24 145 5182555 Low Speed Spring Plunger 146 5172383 Buffer Screw Assembly 147 5152929 Buffer Spring 148 148148 Retaining Clip 1/4 149 5151487 Washer 250 5117693 Link Pin 251 5145820 Lever Assembly 152 447196 Needle Bearing 253 145283 Retaining Clip 13/64 154 5156941 Washer 155 5124209 Differential Lever Assembly 1

2-35

TM 9-2320-277-14&P


56 5150943 Shoulder Pin 157 5145923 Governor Housing Assembly 158 116337 Expansion Plug 1-1/16 159 113903 Round Head Screw #10-24 X 7/16 160 954987 Bearing 261 5138335 Governor Shaft Fork 162 5121458 Shaft Assembly 163 5132962 Gap Adjusting Screw 164 122161 Hex Nut 1/4-28 165 5116011 Lever Assembly 166 5150943 Shoulder Pin 167 9431894 Ball Bearing 168 5121339 Operating Shaft 169 5145823 Special Pin 0.375 X 2.12 170 5150942 Dowel Pin 271 5116071 Dowel Pin 172 5126069 Control Link Boot Adapter 273 9417025 Expansion Plug 1-3/4 174 115545 Lockwasher *10 175 120391 Washer #10 1

2-36

TM 9-2320-277-14&P

FUEL PUMP AND RELATED PARTS


1 5125767 Gear Assembly 12 5196842 Bushing 13 5125774 Drive Gear Hub 14 9409203 Hex Head Bolt 1/2-13 X 2-3/4 15 5125771 Thrust Washer 26 9409073 Hex Head Bolt 1/4-20 X 5/8 27 5125775 Gear Adapter 18 5150199 Coupling Fork 19 5118219 Bolt w/Seal Washer 5/16-18 X 7/8 310 5126672 Retainer 111 5145009 Pipe Plug 1/8 212 5199560 Fuel Pump Assembly 113 5150193 * Gasket 1

*Included in Overhaul Kit 5195078

2-37

TM 9-2320-277-14&P

FUEL PUMP ASSEMBLY


1 3719219 Bolt w/Lockwasher 1/4-20 X 3/4 82 5134560 Cover 13 5181747 * Driven Shaft Assembly 14 5181746 * Drive Shaft Assembly 15 5174975 Drive Gear 16 147481 Steel Ball 1/8 17 5178700 Shaft 18 5230007 * Plain Encased Seal 29 5174971 Machine Thread Plug 110 5161003 * Gasket 111 5184530 * Helical Compression Spring 112 103709 * Straight Pin 5/32 X 1 113 5174973 * Relief Valve 114 141195 Dowel Pin 1/4 X 5/8 215 5146337 Pump Body 1

*Included in Overhaul Kit 5195078

2-38

TM 9-2320-277-14&P

FUEL CROSSOVER LINES


1 5199575 Hose #6,7-1/2" long 12 5199579 Straight Fitting 23 5199588 Hose Fitting 90° 24 442323 Tube Connector 3/8 15 137423 Elbow 3/8 X 90° 16 444000 Pipe Adapter 1/4-18 27 5199575 Hose #6, 26" long 18 5138298 Elbow 19 2488022 Hose Clip 2

2-39

TM 9-2320-277-14&P

INJECTOR CONTROL TUBES


1 9422203 Hex Head Bolt 1/4-20 X 5/8 82 MS35338-46 Lockwasher 1/4 83 5116264 Injector Bracket 24 5116265 LH Helix Spring 25 5176228 Special Screw 1/4-28 X 11/16 126 5115322 Control Rack Lever 67 5196784 Control Tube Assembly, Right Bank 1

5196786 Control Tube Assembly, Left Bank 18 5150259 Tube Shaft 1-1/16 29 142486 Grooved Pin 1/8 X 3/4 210 5150263 Actuating Arm 211 5116264 Injector Bracket 2

2-40

TM 9-2320-277-14&P

FUEL INJECTOR AND RELATED PARTS


1 5116204 Metal Fuel Line Assembly 122 5152138 Tube to Boss Straight Adapter 123 5152148 Flat Copper Washer 9/16 124 179847 Hex Head Bolt 3/8-16 X 2 65 516121 Washer 3/8 66 5121259 Injector Clamp 67 5229350 Fuel Injector Assembly (see page 2-42) 6

2-41

TM 9-2320-277-14&P

FUEL INJECTOR ASSEMBLY

2-42

TM 9-2320-277-14&P


1 5228588 Injector Filter Cap 22 5226186 Gasket 23 5228587 Injector-Filter Element 14 5228608 Injector Stop Pin 15 5228104 Injector Follower Guide 16 5229354 Plunger and Bushing Assembly (C50) 17 5226393 Guide Pin 18 5228739 Plunger Compression Spring 19 5228601 Injector Valve Nut 110 5228694 Injector Check Valve 111 5228696 Check Valve Cage 112 5228596 Valve Compression Spring 113 5228766 Valve Spring Seat 114 5228594 Valve Spring Cage 115 5229034 Fuel Tip Assembly 116 5228109 Spill Deflector 117 5228586 Spacer Sleeve 118 5226400 Injector Spur Gear 119 5226719 Injector Rack 120 5229167 Preformed Packing 121 5229359 Number Tag (C50) 122 5228583 Injector Body Assembly 123 5226416 Dowel Pin 124 5226912 Plug 2

5228701 Overhaul Kit (includes items 2, 3, and 20) AR5228769 Injector Valve Kit (includes items 12 and 13) AR

2-43

TM 9-2320-277-14&P

THERMOSTATS AND WATER MANIFOLD


1 MS 35842-10 Hose Clamp 22 5112425 Hose, 1-1/8 X 1.88 13 96084009 Hose Fitting 3/8 X 5/8 24 5144512 Hose Connector 15 186625 Machine Bolt, 5/16-18 X 7/8 66 MS35338-7 Lock Washer, 5/16 67 5125867 Flange 38 5125150 #Preformed Packing 3

2-44

TM 9-2320-277-14&P


9 5145230 Water Pump, Bypass Pipe 110 5146053 Crossover Tube 111 186679 Hex Head Screw, 3/8-16 X 1-1/4 412 MS35338-8 Lock Washer 3/8 413 5128492 Left Bank Elbow 114 5128493 Right Bank Elbow 115 5122437 Gasket 216 5145014 Pipe Plug, 3/8 NPT 217 MS 49005-8 Pipe Plug, 1/2 NPT 118 186618 Hex Head Screw 5/16-18 X 5/8 219 MS35338-7 Lock Washer 5/16 220 5125868 Thermostat Plate 121 5125024 *Gasket 122 191249 Hex Head Screw 3/8-16 X 3-3/4 223 MS35338-8 Lock Washer 224 5128340 Thermostat Housing 125 450517 Hex Head Screw 3/8-16 X 4-3/4 226 MS35338-8 Lock Washer 3/8 227 5135913 Thermostat Housing 128 5134269 Thermostat Seal 229 5124872 Thermostat 170° 230 5124997 *Gasket 231 186619 Hex Head Screw 3/8-18 X 1-1/8 432 MS35338-8 Lock Washer 3/8 433 5124775 Housing Base 234 5116242 #Gasket 235 5186841 Hose Clamp 1-9/16 X 2-1/2 236 5199778 Nonmetallic hose 137 103870 Pipe Plug 138 5116357 *Gasket 139 179819 Machine Bolt 5/16-18 X 1-1/8 240 MS35338-7 Lockwasher 5/16 241 5135679 Elbow 142 90709027 Reducer Bushing 3/4 X 3/8 143 - - - - Sender, Water Temperature Alarm REF44 90002792 Sender, Water Temperature 145 5116242 Gasket 1

*Included in kit 5196785.#Included in kits 5196785 and 5196578.

2-45

TM 9-2320-277-14&P

WATER PUMP AND IDLER PULLEY


1 179850 Hex Head Bolt 3/8-16 X 2-3/4 22 MS15795-14 Flat Washer 3/8 23 5139237 Idler Pulley Assembly 1

907394 Bearing (not shown) 14 5144685 Water Pump Assembly (see page 2-47) 15 186625 Hex Head Bolt 5/16-18 X 7/8 46 MS35338-7 Lockwasher 5/16 47 5133107 *Gasket 1

*Included in repair kit 5199533

2-46

TM 9-2320-277-14&P

WATER PUMP ASSEMBLY


1 5144503 Water Pump Pulley 12 5148436 Hex Head Bolt w/Lockwasher 5/8-18 X 3/4 73 5119283 Pump Cover 14 5119282 *Gasket 15 5144688 Water Pump Body 16 5145009 Pipe Plug 1/8 17 5113800 *Pump Impeller 18 5130959 *Pump Seal 19 904827 *Shaft and Bearing Assembly 1

*Included in repair kit 5199533.

2-47

TM 9-2320-277-14&P

EXTERNAL OIL FILTER53511253


1 90004439 Hose Fitting, 3/8 42 90004293 Hose, #6 x 10’ 13 96001318 Elbow 24 90709320 Reducing Bushing 25 95210330 Hex Nut, 3/8-16 46 98415042 Lock Washer, 3/8 47 90804495 Capscrew, Hex Head, 3/8-16 X 11/2 48 90001818 Oil Filter Assembly (see page 2-49) 1

2-48

TM 9-2320-277-14&P

OIL FILTER ASSEMBLY90001818


1 OF-276 Center StudOF-278 Shell Assembly 1

2 OF-275 Shell 13 OF-272 Plug 14 G-389 Gasket 15 90002488 Filter Element 16 5571024 Gasket 17 OF-277 Spring Retainer 18 GF-273 Bypass Valve Spring 19 OF-274 Bypass Valve 110 OF-271 Base 1

2-49

TM 9-2320-277-14&P

Section IV. FUEL SYSTEM

AIR CLEANER53506668

2-50

TM 9-2320-277-14&P


1 90002373 Hose Clamp 22 90002372 Rubber Coupling 7 I.D. X 4 13 90812099 Hose Clamp 24 90000577 Rubber Coupling 5-1/2 I.D. X 7-3/4 15 53506572 Air Manifold 16 95210110 Hex Nut 27 98415045 Lockwasher 28 90804226 Hex Head Screw 29 90002231 Air Cleaner Assembly (see page 2-52) 110 90002247 Mounting Band 211 95210330 Hex Nut 3/8-16 712 98415042 Lockwasher 3/8 713 90804185 Hex Head Screw 3/8-16 X 1 714 95210141 Hex Nut 5/8-11 215 98415055 Lockwasher 5/8 216 90804341 Hex Head Screw 5/8-11 X 1-1/4 217 53506664 Mounting Bracket 1

2-51

TM 9-2320-277-14&P

AIR CLEANER ASSEMBLY90002231


90002231 Air Cleaner Assembly REF.1 P10-3198 Vacuator Valve 12 P10-0789 Clamp Assembly 13 P10-6952 Cup Assembly 14 P11-1852 Wing Nut 25 P10-6637 Baffle Assembly 16 90002232 Primary Element 17 90002233 Safety Element 18 P01-7336 Preformed Packing 19 53506757 Body Assembly 1

2-52

TM 9-2320-277-14&P

RESTRICTION INDICATOR53506868


90001772 Restriction Indicator Kit 11 RBX00-2252 Restriction Indicator 12 P10-0089 Filter 13 53100533 Connector 1/4 X 1/8 24 53506867 Hose 1/4 X 120 15 91603080 Elbow 1/8 X 90° 16 95210010 Hex Nut #10-32 27 97205038 Machine Screw, Round Head #10-32 X 3/4 28 53506860 Indicator Mount 1

2-53

TM 9-2320-277-14&P

FUEL TANK GROUP53172821

2-54

TM 9-2320-277-14&P


1 95210295 Hex Nut 1/4-20 42 98415020 Lockwasher 1/4 43 90804016 Capscrew 1/4-20x3/4 44 53500607 Grip Strut Platform 15 - - - - Fuel Return Hose Assembly REF.6 - - - - Connector 90° Male REF.7 - - - - Fuel Supply Hose Assembly REF.8 - - - - Connector 90° Male REF.9 95210194 Hex Nut 410 90003667 Strap Assembly 211 90004013 Rubber Strip 212 53500673 Fuel Tank Assembly 113 95210230 Self-Locking Hex Nut 1/2-13 1214 90805129 Hex Head Screw 1/2-13x2 415 90804267 Hex Head Screw 1/2-13x1-1/2 816 90003570 Bracket Assembly 217 53509110 Bracket Stiffener 218 95210141 Hex Nut 5/8-11 419 98415055 Lockwasher 5/8 420 90804366 Hex Head Screw 5/8-11x2 221 90802050 Hex Head Screw 5/8-11x2-3/4 222 53506389 Tank Guard 1

2-55

TM 9-2320-277-14&P

FUEL FILTER53172821


53507526 Hose Assembly 11 99802355 Hose #10 13"2 53103341 Swivel Connector 23 53103337 Male Connector 1/2-14x3/4-16 14 137423 Elbow 3/8x90° 2

53507525 Hose Assembly 15 99802355 Hose #10 36"6 53103341 Swivel Connector 27 5116440 Inlet Elbow 1

53507527 Hose Assembly 18 99802354 Hose #8 40"9 53103339 Swivel Connector 210 5128522 Extension 111 53103338 Male Connector 1/2-14x7/8-14 112 90804185 Capscrew 3/8-16x1 413 98415042 Lockwasher 3/8 414 53503060 Mounting Bracket 1

5574533 Fuel Filter Assembly 115 6438840 Filter Element 116 5148171 Filter Cover 117 5154453 Plug 3/8-16 2

2-56

TM 9-2320-277-14&P

ETHER STARTING AID53506877


1 90804035 Hex Head Screw 5/16-18x1 22 98415035 Lockwasher 5/16 23 95210080 Hex Nut 5/16-18 24 53101503 Tube Clip 1/4 15 98415020 Lockwasher 1/4 16 95210295 Hex Nut 1/4-20 17 90003606 Pushbutton Switch 1

90002316 Ether Start Kit 18 LP-535 Ether Cartridge 19 QL-1 Decal & Instructions 110 QS-4-3TC Valve, 6 c.c., 12V 111 LP-2299 Cylinder Clamp & Bracket Assembly 212 LP-3239-60 Nylon Tube 60" 113 LP-482-1 Valve Coupler Fitting 114 QA-5-5TC Atomizer 1

2-57

TM 9-2320-277-14&P

ACCELERATOR LINKAGE53505043


1 97252058 Spring 12 53505419 Lever 13 53508319 Clip Bracket 14 90802003 Capscrew 25 98415020 Lockwasher, 1/4 66 95210295 Hex Nut, 1/4-20 67 90002244 Throttle Arm 18 53509114 Bracket 19 90695924 Shoulder Bolt 110 98415035 Lockwasher, 5/16 111 95210080 Hex Nut, 5/16-18 112 95210010 Hex Nut, #10-32 NF 113 53505409 Angle Bracket 114 90000236 Ball Joint Assembly 115 90000186 Spring, Return 116 90001327 Spacer 217 90001326 Clamp 118 98415015 Lockwasher, #10 2

2-58

TM 9-2320-277-14&P


19 95210657 Hex Nut, #10-24 220 97205142 Screw, #10-20 X 1 221 90804016 Capscrew, Hex Head, 1/4-20 X 3/4 622 90000239 Cable Clamp 123 53505420 Throttle Bracket 124 90001700 Cable Assembly, Accelerator 125 97431102 Tie Wrap 226 53101504 Clamp Cable 127 53505386 Bracket 1

2-59

TM 9-2320-277-14&P

ACCELERATOR PEDAL53504235


1 53501743 Accelerator Bracket 12 53504317 Pedal Assembly 13 53501759 Block, Bearing 14 53504330 Accelerator Stop 15 90804016 Capscrew 1/4-20x3/4 46 98415020 Lock Washer 1/4 47 95210295 Hex Nut 1/4x20 48 53501757 Accelerator Lever 19 90804082 Capscrew 3/8-16x2 110 95210330 Hex Nut 3/8-16 211 98415042 Lock Washer 3/8 112 53501762 Accelerator Shaft 113 90804037 Capscrew 5/16-18 214 95210420 Lock Nut 5/16-18" 215 90695924 Bolt, Shoulder 5/16-18 116 53504210 Nylon Roller 117 97135327 Lock Ring 5133-62 118 95210010 Hex Nut #10-32 119 90000236 Ball Joint 120 90000239 Clamp 1

2-60

TM 9-2320-277-14&P

Section V. EXHAUST SYSTEM

VERTICAL MUFFLER INSTALLATION53506319


Ref. 90002314 Muffler Kit 11 90002300 Tailpipe (Cut one 30" and one 18" length) 12 90002307 Cage Assembly 13 90002309 Muffler 14 90002305 Clamp 4" 25 53503364 Bracket, Vertical Muffler 16 90802061 Capscrew 47 98421125 Washer, Flat 48 95210312 Nut, Lock 49 53506822 Spacer, Installation 110 90002321 Self-Locking Nut 1/4-28 811 90802088 Hex Head Screw 1/4-28 X 1/2 812 90002297 Hinge Adapter 113 90002306 Rain Cap 1

2-61

TM 9-2320-277-14&P

EXHAUST OUTLET GROUP53506317


Ref. 90002310 Exhaust Outlet Kit 11 90002301 Exhaust Pipe, R.H. 12 90002302 Exhaust Pipe, L.H. 13 90002299 Swivel, 3" 14 90002304 Clamp, 3" 35 53502444 Bracket Ass’y, Cross Pipe 16 53506754 Tee, Exhaust 17 53506753 Connector, Flex 18 90002305 Clamp, 4" 2

53506751 Elbow 1

2-62

TM 9-2320-277-14&P

Section VI. COOLING SYSTEM

RADIATOR OVERFLOW53506932


1 90000590 Kit, Overflow System 12 - - - - Hose, Radiator to Overflow Tank REF.3 - - - - Hose, Overflow REF.4 53502692 Gasket, Radiator Cap 15 90001448 Decal, Radiator Cap 16 97205032 Self Tapping Screw w/Washer #10-32x5/8 2

2-63

TM 9-2320-277-14&P

RADIATOR GROUP53506489

2-64

TM 9-2320-277-14&P

ITEM PART NUMBER DESCRIPTION QTY.1 90002358 Hose, Radiator, Lower (Flex) 12 90812132 Clamp, Hose 23 53506443 Adapter Tube 14 90001843 Hose, Radiator, Lower 3-1/2x6 15 53105060 Clamp, Hose 26 90709028 Bushing, Reducer (for trans. lines) 27 90001860 Fitting, Adapter 18 53105320 Plug, Pipe 29 53102275 Drain Cock 110 90002357 Hose, Radiator, Upper 211 90812128 Clamp, Hose 412 99802351 Hose, 1" ID x 60" Lg. 113 90812098 Clamp, Hose 214 53504006 Fitting 115 91604100 Elbow, Street 116 99802052 Hose, Vent Line - 30" Lg. 117 90812097 Clamp, Hose 218 96084209 Fitting 119 53506500 Strap Assembly, Radiator 220 90002364 Biscuit, Rubber 421 98421135 Flat Washer 222 90804075 Capscrew 223 95210085 Locknut 424 - - - - Lower Strap Bracket (not serviced separately) REF.25 53506498 Right Hand Bracket, Upper 126 53506497 Left Hand Bracket, Upper (not illustrated) 127 90804037 Capscrew 628 98415035 Lockwasher 629 53506460 Rod, Strut, Radiator 230 90802050 Capscrew 231 53505175 Washer, Special 432 94816009 Isolator, Rubber 233 98410044 Flat Washer 234 95210312 Lock Nut 235 90805132 Capscrew 236 98421130 Flat Washer 437 95210200 Locknut 238 90001801 Radiator (see page 2-67) 139 95210312 Locknut 240 53505175 Washer, Special 241 94816009 Isolator, Rubber 242 53506444 Flange Assembly 243 53505299 Gasket, Flange 244 90804483 Capscrew 645 98415042 Lockwasher 646 53505244 Flange Assembly 147 53505300 Gasket, Flange 148 90804483 Capscrew 249 98415042 Lockwasher 250 53105303 Plug, Pipe 251 53505248 Flange Assembly 152 53505301 Gasket Flange 153 90818006 Clip 154 53506510 Shroud, Fan 155 90804037 Capscrew 10

2-65

TM 9-2320-277-14&P


56 98415035 Lockwasher 1057 98421145 Flatwasher 1058 53507331 Shim AR59 90709300 Bushing, Reducer Heater connection 160 90709027 Bushing, Reducer at engine; not 161 96084009 Fitting, Hose to Pipe illustrated 2

2-66

TM 9-2320-277-14&P

RADIATOR ASSEMBLY90001801

2-67

TM 9-2320-277-14&P


1 G002023 Hex Head Bolt 5/16-18x1 272 G002004 Hex Nut 5/16-18 383 G002009 Lockwasher 5/16 464 G002038 Hex Head Bolt 5/16-18x1-1/4 25 G002039 Hex Head Bolt 5/16-18x1-3/4 36 G002015 Hex Head Bolt 5/16-18x1-1/8 117 G110729 Hex Head Bolt 5/16-18x2 38 A014150 Top Tank 19 6326290 Header 210 G305450 Decal 111 G307160 Bar 212 G002004 Hex Nut 5/16-18 3413 G002009 Lockwasher 5/16 4214 G002032 Hex Head Bolt 5/16-18x7/8 3015 G002023 Hex Head Bolt 5/16-18x1 1216 A023375 Bottom Tank 117 G307160 Core Washer 418 6326291 Header 219 A042050 Sidemember, LH 120 A032050 Sidemember, RH 121 T02554B Core 122 G301565 Sight Glass 2

2-68

TM 9-2320-277-14&P

FAN GROUP


1 - - - - Hex Nut 5/16-18 62 - - - - Lockwasher 5/16 63 - - - - Hex Nut 64 - - - - Lockwasher 65 90002222 Fan Drive (includes items 1 through 4) 16 90002223 Fan Blade 17 90002243 Fan Spacer 48 90004323 Stud 5/16-18x3-1/2 69 53504076 Hex Head Bolt 5/16-18x7 110 53504011 Fan Pulley 111 103340 Flat Washer 5/16 112 179856 Hex Head Bolt 7/16-14x3/4 213 103322 Lockwasher 7/16 214 5109641 Adjusting Bracket 115 106337 Hex Head Screw 416 103322 Lockwasher 417 5108436 Flat Washer 4

5131207 Pulley Assembly 118 5144798 Fan Hub Cap 119 9409060 Self-Locking Bolt 1/2-20x1-1/2 120 5131123 Washer 33/64x 1-1/2 121 5100201 Fan Shaft 122 5108219 Pulley Seal 123 7450630 Roller Bearing, Rear 124 7451080 Roller Bearing, Front 125 5131095 Retainer 126 5131122 Sleeve Bearing 127 5131124 Shim 0.015 AR28 5131205 Shim 0.020 AR

2-69

TM 9-2320-277-14&P


29 5131206 Shim 0.025 AR30 427567 Hex Head Bolt 7/16-14x1-3/4 231 103322 Lockwasher 7/16 232 450517 Hex Head Bolt 3/8-16x4-3/4 233 5109640 Fan Support 1

2-70

TM 9-2320-277-14&P

COOLANT FILTER INSTALLATION53505822


1 90002016 Coolant Filter Kit 12 90002015 Filter Element 13 - - - - Hose Connector 90° 24 90817033 Hose Clamp 65 53505821 Hose, 5/8 ID X 36 16 53505820 Hose, 5/8 ID X 45 17 95210080 Hex Nut, 5/16-18 18 53101500 Hose Clamp 29 90001679 Hose Tee, 5/8 Barb 110 96084009 Hose Connector 111 97415085 Tee, 3/8 112 95205195 Close Nipple, 3/8 1

2-71

TM 9-2320-277-14&P

Section VII. ELECTRICAL GROUP

ELECTRICAL GROUP53502815

2-72

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ITEM PART NUMBER DESCRIPTION QTY.1 90007338 Instrument Panel Harness 12 90007339 Firewall Harness 13 90007340 Engine Harness 14 53500227 Headlamp Harness 15 53500232 Rear Cab Harness 16 53500185 Tail Lamp Harness 17 90004477 Flood Light (side) 2

601 Stainless Steel Door 1529 U-Bracket 14478 Sealed Beam Lamp 1

8 53504738 Neutral Start Switch Harness 19 53500008 Head Lamp Assembly (see page 2-92) 210 53500009 Front Turn Lamp (see page 2-94) 211 53500011 Side Marker Lamp (see page 2-96) 212 94410108 Clearance Lamp - Amber (see page 2-93) 513 53500010 Stop Lamp (see page 2-94) 214 53103712 Air Pressure Sender 115 53102130 Dome Lamp 116 53500119 Terminal Block 117 53102136 Wire, 17' 118 53103701 Fuel Gauge Sender 119 53140041 Temperature Sender, Xmsn 120 90002792 Temperature Sender, Water 121 94410192 Backup Light (see page 2-95) 222 94410191 Tail Light (see page 2-95) 223 94410193 License Plate Light (see page 2-97) 124 53450152 Flood Light (Rear) 1

90001777 Clear Lens 153505142 Bracket, Rear Flood Light 192418023 Grommet 5/32 ID 592418022 Grommet 7/8 ID 192418021 Grommet 1/2 ID 153450452 Grommet 1-1/4 ID 153450133 Plug 253104856 Plug 190812057 Clamp 7/8 253101503 Clamp 1/4 ID 653101504 Clamp 3/8 ID 653101502 Clamp 1/2 ID 290817045 Clip, Cable 1353102804 Bushing, Snap 297205045 Screw, Round Head, # 10-32x5/8 753105014 Screw, Machine # 10-32 x 5/8 3853103044 Screw, Machine, 1/4-20x1/2 990804011 Screw, Hex Head, 1/4-20x1/2 590804016 Screw, Hex Head, 1/4-20x3/4 2090804037 Screw, Hex Head, 5/16-18x3/4 1095210656 Hex Nut, #6-32 995210010 Hex Nut, # 10-32 2495210295 Hex Nut, 1/4-20 4195210080 Hex Nut, 5/16-18 1253500119 Terminal Strip 353102803 Plug, 1" Hole 290698022 Bolt, Stove, 3/16-24x1 698415015 Lockwasher, # 10 697431102 Tyrap 15

2-73

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WIRING DIAGRAM53502815


1 90711006 Buzzer, Low Pressure 12 53102018 Mounting Bracket 23 53102020 Circuit Breaker, 20A 34 53102019 Circuit Breaker, 15A 25 53102021 Circuit Breaker, 30A 16 53504734 Dimmer Switch Harness 17 90828291 Connector, Shell 1

90828293 Connector, Electrical 28 97417522 Connector, Eyelet, # 10x16 Gauge 19 90004137 Converter Kit, 24 Volt 110 MS75021-2 Connector Socket 1

MS75020-2 Jumper Cable, 10' 1

2-74

TM 9-2320-277-14&P

2-75

TM 9-2320-277-14&P

ALTERNATOR INSTALLATION


1 179844 Hex Head Bolt 3/8-16x1-5/8 12 MS35338-8 Lockwasher 3/8 13 5117082 Flat Washer, Special 14 102637 Hex Nut 1/2-13 15 MS35338-10 Lockwasher 1/2 16 5132715 Flat Washer, Special 27 9427945 Hex Head Bolt 1/2-13 x 6-1/4 18 90002245 Pulley 2.76" Dia. 19 90002248 Alternator (see page 2-77) 110 102637 Hex Nut 1/2-13 111 5102065 Adjusting Strap 112 5132715 Flat Washer, Special 113 MS35338-10 Lockwasher 1/2 114 442733 Hex Head Bolt 1/2-13x1-1/4 115 114926 Hex Head Bolt 3/8-16x4-1/4 216 MS35338-8 Lockwasher 3/8 217 5102058 Adjusting Strap Bracket 118 179839 Hex Head Bolt 3/8-16x1 319 5152148 Flat Washer 3/8 Copper 320 5102073 Mounting Bracket 1

2-76

TM 9-2320-277-14&P

ALTERNATOR ASSEMBLY90002248


1 9418881 Hex Nut 12 1905406 Felt Washer 13 1969481 Fan 14 801810 Hex Head Bolt 45 1852038 Slip Ring End Frame 16 801818 Stator 17 453434 Hex Nut #8-32 38 830891 Diode Trio 19 1970145 Screw 210 1847933 Lockwasher 211 1892914 Rectifier Bridge 112 1851612 Screw 213 1869573 Capacitor Bracket 114 1871411 Capacitor 115 9411396 Screw 316 1961867 Bearing Retainer 117 1970384 Inside Collar 118 907940 Ball Bearing 119 1969046 Outside Collar 120 1852040 Rotor 121 1846864 Insulated Screw 222 1876873 Brush Assembly 1

2-77

TM 9-2320-277-14&P


23 1964117 Spring Brush 224 1876808 Grounding Screw 125 1116389 Regulator 126 1852630 Drive End Frame 127 9437171 Bearing 128 1961323 Bearing Seal 129 1846901 Battery Terminal Package 130 1852519 Relay Terminal Package 131 801532 Voltage Adjustment Cap 132 1876806 Rubber Boot 133 9437927 Screw 134 453844 Lockwasher 135 1852043 Bracket 1

2-78

TM 9-2320-277-14&P

STARTER MOTOR

2-79

TM 9-2320-277-14&P

ITEM PART NUMBER DESCRIPTION QTY.1114052 Starter Motor Assembly 1

1 120378 Hex Nut 1/2-13 12 9421427 Lockwasher 1/2 13 1953236 Wire Assembly 14 9414397 Screw 45 1945478 Brush Cover Plate 26 1948512 Gasket 27 1914869 Hex Head Screw 48 9421423 Lockwasher 49 453418 Screw 810 453844 Lockwasher 811 1906986 Brush Assembly 812 - - - - End Plate Assembly (not serviced separately) 113 1916272 Preformed Packing 114 1914842 Thrust Washer 115 1948537 Capscrew 5/16-18x55/64 416 1948536 Capscrew 5/16-18x1-1/2 217 1949606 Drive Housing 1

1945509 Bushing 1453465 Pipe Plug 11/32 Not Illustrated 1273913 Pipe Plug 1/4 11916439 Oil Wick 1

18 1945476 Gasket 119 1914869 Capscrew 520 9421423 Lockwasher 1/4 521 1947262 Lever Housing 1

1923484 Bushing 1453465 Pipe Plug, 11/32 Not Illustrated 11918047 Housing Seal 11916439 Oil Wick 1

22 1916272 Preformed Packing 123 1894214 Drive Clutch Assembly 124 1945356 Inspection Plug 125 1964857 Gasket 126 9412305 Plunger Nut 127 9415235 Retaining Ring 128 1948526 Retainer 129 1948521 Return Spring 130 1948520 Retainer 1-13/64 131 801077 Plunger Boot 132 807736 Flat Washer 133 1948522 Plunger 134 9415235 Retaining Ring 135 1914373 Preformed Packing 15/64 136 1921805 Preformed Packing 1/2 137 1948529 Lever Shaft 138 120238 Hex Nut 1/2-13 139 9421427 Lockwasher 1/2 140 1945468 Terminal Connector 141 1930611 Screw w/washer 442 1119879 Solenoid Switch Assembly 1

9413509 Terminal Nut 1/2-13 29421427 Terminal Lockwasher 1/2 2

43 - - - - Frame and Armature Assembly (not serviced separately) 144 9418228 Bolt, 12 point, 5/8-11 x 1-3/4 345 103325 Lockwasher 5/8 346 5130995 Gasket 1

2-80

TM 9-2320-277-14&P

70 AMP BREAKER AND SOLENOID

53102083


1 95210080 Hex Nut 5/16-18 22 98415035 Lockwasher 5/16 23 95210010 Hex Nut #10-32 NF 24 98415015 Lockwasher #10 25 53452351 8 Ga. Black Wire 16 53452352 8 Ga. Red Wire 17 53503580 Jumper Wire Assembly 18 97262017 Solenoid 19 90000761 Brass Screw, 1/4-28 x 3/8 210 90000747 Circuit Breaker 111 97205142 Machine Screw, Slot Head #10-24 x 1 212 53502878 Bracket 113 97417520 Terminal, Eyelet, 14 Stud, 8 GA. 1

2-81

TM 9-2320-277-14&P

ENGINE SHUTDOWN KIT

53506888

2-82

TM 9-2320-277-14&P


53508016 Hose Assembly 11 53450543 Swivel Fitting 7/16-20 x #4 12 99802352 Hose #4 13"3 53109224 Pipe Fitting, Male 1/8-27 x #4 14 90001535 Adapter 15 90002914 Pipe Tee, Street 1/8 16 53508012 Bracket, Pressure Sender 1

90002241 Shutdown Kit 17 1039-33000-03 Module, Automatic Override 18 1002-04870 Sensor, Water Temperature 19 90000800 Sensor, Oil Pressure 110 1030-35970 Shutdown Solenoid 111 1003-33040-01 Warning Bell 1

2-83

TM 9-2320-277-14&P

WATER LEVEL WARNINGKIT INSTALLATION

53506874


1 90812097 Hose Clamp 62 53506872 Hose 5/8 ID x 42 13 53506873 Hose 5/8 ID x 78 14 96084009 Connector 3/8 x 5/8 ID 35 53105350 Pipe Tee 3/8 16 53101500 Hose Clip 17 53506871 Hose 5/8 ID x 36 18 96084209 Hose Connector 90° 19 90002583 Elbow 3/8 x 900 110 95210330 Hex Nut 3/8-16 211 98415042 Lockwasher 3/8 212 90804185 Capscrew 3/8-16 x 1 2

90002242 Water Level Warning Kit (see page 2-85) 113 8128SS Sensor, Water Level 114 8320 Bracket 115 90711006 Buzzer, Low Pressure 1

2-84

TM 9-2320-277-14&P

WATER LEVEL WARNING KIT

90002242


8320 Bracket REF.8128SS Sensor, Water Level REF.

1 8010 Screw 122 8302 Top Cover 13 8002 Bottom Cover 1

8312 Diaphragm Assembly 14 8299 Cylinder 15 8298 Piston 16 8154 Gasket 27 8291 Ring 18 8314 Arm Assembly 1

8309 Trip Spring Assembly 19 8066 Setscrew 110 8274 Spring 111 8276 Pin 112 8275 Leaf Spring 113 8311 Spring Holder 114 8283 Hex Nut, Self-Locking 115 8215 Contact Cover 116 8014 Hex Nut 117 8210 Wiring Harness 118 8361 Contact Assembly 1

2-85

TM 9-2320-277-14&P

INSTRUMENT PANEL

80560


1 - - - - Tachometer (see page 2-89) REF.2 - - - - Warning Bell (see page 2-82, item 11) REF.3 90002398 Ammeter, 60A 1

53102172 Bulb, #53 14 53452042 Bracket 15 90001804 Voltmeter 16 - - - - Speedometer (see page 2-88, item 5) REF.7 53102177 Light, High Beam Indicator 18 - - - - Switch (see page 2-90, item 5) REF.9 90002287 Fuel Gauge 1

53102172 Bulb, #53 110 53102150 light, Low Air Pressure 1

#68 Bulb, Red 111 - - - - Indicator (see page 2-53) REF.12 - - - - Air Pressure Gauge (see page 2-153, item 52) REF.

53102172 Bulb, #53 113 53102150 Light, Xmsn Temp. Warning 1

#68 Bulb, Red 1

2-86

TM 9-2320-277-14&P


14 - - - - Brake Controls (see page 2-177) REF.15 53102164 Switch, Dome Light 116 97270011 Switch, Headlight 117 - - - - Control, Washer (see page 2-231) REF.18 - - - - Control, Wiper (see page 2-229) REF.19 90002581 Hour Meter (includes bracket) 1

53102172 Bulb, #53 120 53506400 Dash Panel 1

90002366 Decal, Dash Panel 121 - - - - Switch (see page 2-57, item 7) REF.22 53102153 Switch, Engine Stop 123 - - - - Switch (see page 2-239) REF.

53506269 Ignition and Door Lock Group 1 - - - - Door Handle Assembly, (see page 2-213, item 5) REF.

24 90002263 Switch, Key 125 - - - - Switch (see page 2-241) REF.26 90002290 Oil Pressure Gauge 1

53102172 Bulb, #53 127 - - - - Fresh Air Control (see page 2-237) REF.28 53102150 light, Oil Pressure Warning 1

#68 Bulb, Red 129 - - - - Control, Temperature (see page 2-237) REF.30 53506874 Light, Low Water Warning 131 53102150 Light, Water Temperature Warning 1

#68 Bulb, Red 132 90002286 Gauge, Water Temperature 133 90001523 Switch, Dimmer 134 53102101 Flasher, Turn Signal 135 90003061 Toggle Switch, Floor Lamp 336 53511170 Switch Bracket 1

90004137 Converter Kit, 24 Volt REF.37 - - - - Converter Switch 138 - - - - Converter light 1

2-87

TM 9-2320-277-14&PSPEEDOMETER GROUP

53501763


53104757 Lighting Kit 11 53103706 Light Socket 12 53102172 Bulb, #53 13 53104878 Speedometer Cable & Housing 14 92418021 Grommet 1/2 ID 15 53104756 Speedometer Head 16 90000814 Speedometer Adapter (0.4910 Ratio) 17 90002931 Gear and Sleeve Assembly 1

2-88

TM 9-2320-277-14&P

TACHOMETER GROUP

53452243


1 53102344 Tachometer Head 12 53102345 Sender Unit 1

811533 Drive Tip, 0.187 13 53102294 Mounting Kit 1

53502835 Harness Assembly 14 99802110 Loom, Wire, 5/16 10.5 Ft.5 90828291 Socket Housing 16 90828293 Contact, Socket 27 90828290 Pin Housing- 18 90828292 Contact, Pin 2

90004018 Tachometer Drive 19 6451376 R.H. Adaptor (1.500:1) 110 6477956 Drive Shaft 111 5123118 Cover Assembly 112 5135935 Gasket 113 5136249 Adaptor 114 MS35338-7 Lockwasher 5/16 215 121917 Hex Nut 5/16-24 2

186647 Bolt 1/4-20x1 1MS35338-46 Lockwasher 1/4 1

2-89

TM 9-2320-277-14&P

TRAILER CABLE GROUP

53451110


1 90812041 Clamp, Tubing 3/4 22 53102094 Cable Assembly, Coiled (includes plug) 13 92413000 Rubber Grommet 11/16 x 1-5/16 24 53102019 Circuit Breaker, 15A 65 53102164 Switch, Trailer Aux. Light Circuit 1

2-90

TM 9-2320-277-14&P

SEPARATE LIGHTING CABLE

53506698


90002354 Cable Assembly 11 90002355 Cable, 7 Conductor, 7 feet 12 1255 Plug 23 90002596 Chain, #1x10 14 95210080 Hex Nut 5/16-18 25 98415035 Lockwasher 5/16 26 90804039 Capscrew 5/16-18x1-1/4 27 90002353 Cover, Rubber 18 90002351 Receptacle, Female 19 90002352 Plug Holder 2

2-91

TM 9-2320-277-14&P

HEADLIGHT ASSEMBLY

53500008


1 41079 Moulding 12 38805 Screw 13 - - - - Housing (not serviced separately) 14 41080 Moulding Clip 15 41055 Helical Spring 16 41058 Lamp Retainer 17 40697 Screw, Tapping 38 3780 Headlight, 12 VDC 19 - - - - Lampholder (not serviced separately) 110 41057 Shouldered Screw 2

91517 Cable Assembly 111 1927 Connector Housing 112 2128 Electrical Contact 313 31523 Electrical Connector 314 34591 Insulator 215 41060 Strain Relief 1

2-92

TM 9-2320-277-14&P

CLEARANCE LIGHT GROUP

53502984


1 97205047 Self-Tapping Screw #10-32x1/2 2094410108 Clearance Light, Amber REF.

2 5172 Mounting Pad 13 35509 Grommet 14 35138 Machine Screw 25 38689 Lens Retainer 16 3421 Lens 17 1615 Incandescent Lamp 12 VDC 1

53504733 Wiring Harness, Upper Cab 18 90828294 Connector Shell 19 90828292 Connector Pin 310 99802110 Wire Loom 5/16x4.2 Ft. 111 90828080 Splice Connector 14-16 GA 512 90828028 Splice Connector 10-12 GA 113 90828080 Splice Connector 14-16 GA 2

2-93

TM 9-2320-277-14&P

FRONT TURN AND STOP LIGHT

5350000953500010


53500009 Front Turn Light REF.53500010 Stop Light REF.

1 60700 Grommet 12 60201Y Sealed Lamp Unit, Yellow (turn light) 12 60202R Sealed Lamp Unit, Red (stop light) 13 95900 Screw, Self-Tapping, #6x3/8 14 94925 Connector (turn light) 14 94926 Connector (stop light) 1

2-94

TM 9-2320-277-14&P

BACK UP AND TAIL LIGHT GROUP

53502349


94410191 Tail Light Assembly REF.94410192 Back Up Light Assembly REF.

1 40700 Grommet 12 40202R Sealed Lamp Unit, Red (tail light) 12 40204 Sealed Lamp Unit, Clear (back up light) 13 95900 Screw, Self-Tapping, #6x3/8 14 94926 Connector (tail light) 14 94925 Connector (back up light) 1

2-95

TM 9-2320-277-14&P

SIDE MARKER LIGHT

53500011


1 94940 Plug and Socket Assembly 12 97900 Bulb, Wedge, #194 13 6511 Screw #8x5/8 24 99012Y Lens and Housing Assembly 15 97927 Gasket 1

2-96

TM 9-2320-277-14&PLICENSE PLATE LIGHT

94410193


1 94922 Connector, Right Angle 12 COML Screw, Self-Tapping *8x7/8 23 17200 Sealed Lamp Unit, Clear, 3 CP 1

2-97

TM 9-2320-277-14&P

HORN AND RELAY

53502815


53500302 Wire Assembly 11 90828010 Terminal Push On 12 99803014 Wire, Red 16 Ga. 7"3 97420058 Terminal, Spade 14 53105022 Hex Nut 7/8-20 15 92817011 Horn, Electric 16 53105021 Bracket 17 95210010 Hex Nut 18 98415015 Lockwasher 19 53105014 Screw, Machine 110 97115028 Relay, Horn 1

2-98

TM 9-2320-277-14&P

BATTERY GROUP


1 53506463 Battery Box and Spare Tire Carrier 12 90002280 Lead Acid Battery 12V 43 90002335 Terminal Lug (Negative) 44 90002336 Terminal Lug (Positive) 45 90002369 Battery Cable #2x12-1/4 66 90002370 Battery Cable (Negative) #2x33 17 90002371 Battery Cable (Positive) #2x73 18 53511185 Rubber Pad 29 53511053 Battery Hold-Down Bracket 410 53506486 Battery Hold-Down Link 211 90002374 Hex Head Screw 5/16-18x9-1/2 612 98415035 Lockwasher 5/16 613 95210080 Hex Nut 5/16-18 6

Rev. C, 4-20-792-99

TM 9-2320-277-14&PITEM PART NUMBER DESCRIPTION QTY.

14 90804485 Hex Head Screw 3/8-16x1-1/4 415 98415042 Lockwasher 3/8 416 98421135 Flat Washer 3/8 417 90804369 Hex Head Screw 5/8-11x2-1/4 318 90802050 Hex Head Screw 5/8-11x2-3/4 419 92413008 Grommet 120 98415055 Lockwasher 5/8 721 95210141 Hex Nut 5/8-11 7

2-100

TM 9-2320-277-14&P

Section VIII. AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION


1 53500580 Modulator and Cable 12 91604145 Street Elbow 23 53451852 Hose End, Male 44 53451851 Hose, #12 X 12' 15 90200057 Swivel Adapter 26 53452393 O-Ring Fitting 27 53105360 Street Tee 18 90709320 Bushing Reducer 19 53140041 Sender, Transmission Temp. 110 95205040 Close Nipple 111 97415155 Tee 112 53105375 Reducing Bushing 113 53141128 Hose Assembly 114 53109240 Adapter, Hose 115 90804485 Capscrew 1216 98415042 Lockwasher, 3/8 1217 90002167 Plug, Drain, Magnetic 1

53502154 Dipstick Assembly 118 53502156 Dipstick 119 53506079 Tube, Dipstick 120 53502155 Bracket, Tube 121 53500563 Transmission, MT653 1

2-101

TM 9-2320-277-14&P

HOUSING, OIL FILTER AND OIL PAN GROUP

2-102

TM 9-2320-277-14&P


1 6882757 Vent Assembly Transmission 12 12288013 Gasket, Power Takeoff Cover 13 6774322 Cover, Power Takeoff 14 179837 Bolt, Hex Head, 3/8 - 16 X 3/4 65 6882586 Bolt, Hex Socket Head, 1/4 - 20 X 7/8 26 6881227 Adapter, Lube Valve 17 6884872 Gasket, Adapter, Lube Valve 18 6834538 Ring, Seal 19 6834624 Valve, Lube 110 6830180 Spring, Lube Valve 1

6881144 Housing Assembly, Transmission 111 6880967 Housing 112 6834539 Tube, Valve Guide 113 444612 Plug, 1/8 114 8622361 Screw, Drive 115 6838494 Plate, Name 116 454817 Bolt, Hex Head, 1/4 - 20 X 2-3/4 717 454813 Bolt, Hex Head, 1/4 - 20 X 7/8 218 445567 Bolt, Hex Head, 1/4 - 20 X 1-3/4 119 8625431 Roller and Spring Assembly, Detent 120 445568 Bolt, Hex Head, 1/4 - 20 X 2-1/4 1821 445567 Bolt, Hex Head, 1-1/4 X 1-3/4 4

6882787 Kit, Oil Filter and Gasket 122 6762127 Ring, Seal 123 - - - - - Filter, Oil (not serviced separately) 124 6884733 Gasket, Oil Pan, Sectionalized 125 6883045 Tube, Oil Filter 126 3829139 Screw, Hex Washer Head 1

23012381 Kit, Oil Pan, Drain Plug and Washer 127 3921988 Plug, Oil Pan Drain 128 3921989 Washer, Drain Plug 129 - - - - - Pan, Oil (not serviced separately) 130 3829139 Screw, Hex Washer Head 2131 6834105 Lever, Inside Detent 132 117212 Nut, Hex, 3/8- 24 133 179816 Bolt, Hex Head, 5/16 - 18 X 3/4 134 8627650 Retainer, Modulator to Housing 135 6836634 Bolt, Hex Head, 3/8 - 16 X 2-1/4 136 9422847 Washer, Plain, 3/8 137 147485 Ball, Governor Pressure Check, 0.250 Dia. 138 6831774 Pin, Shaft Retainer 139 444612 Plug, 1/8 240 6839761 Washer, Aluminum 141 445090 Plug, 3/4 - 16 142 8623056 Seal, Selector Shaft 1

6885213 Kit, Selector Shaft and Nut 143 - - - - - Shaft, Manual Selector (not serviced separately) 144 11501033 Nut, Selector Shaft 145 444612 Plug, 118 1

2-103

TM 9-2320-277-14&P

CONTROL VALVE GROUP

2-104

TM 9-2320-277-14&P


23010753 Kit, Valve Assemblies and Governor 11 6838429 Pin, Valve Stop 12 6835729 Spring, Priority Valve 13 6835929 Valve, Priority 14 6831737 Valve, Hold Regulator 15 6836785 Spring, Hold Regulator Valve 16 6884905 Pin, Valve Stop 17 6833949 Washer 18 6833891 Ring, Spring Adjusting 19 6837859 Valve, Range Selector 110 9426920 Pin, Retainer 111 6880463 Valve, 2-3 Shift 112 6836390 Valve, 2-3 Modulator 113 6835309 Spring, 2-3 Shift Valve 114 6833896 Stop, Valve 115 6833891 Ring, Spring Adjusting 116 9428493 Pin, Retainer 117 6887618 Valve, 3-4 Shift 118 6883148 Valve, 3-4 Modulator 119 6833935 Spring, 3-4 Shift Valve 120 6833896 Stop, Valve 121 6833891 Ring, Spring Adjusting 122 9428493 Pin, Retainer 123 6882294 Valve, 4-5 Shift 124 6881033 Valve, 4-5 Modulator 125 6837454 Spring, 4-5 Shift Valve 126 6833896 Stop, Valve 127 6833891 Ring, Spring Adjusting 128 9428493 Pin, Retainer 129 6833888 Valve, 4-5 Relay 130 6832462 Spring, 4-5 Relay Valve 131 6839829 Stop, Valve 132 6883864 Pin, Retainer 133 6833889 Valve, Trimmer Regulator 134 6880186 Spring, Trimmer Regulator Valve 135 6880188 Stop, Trimmer Regulator Valve 136 9428493 Pin, Straight 137 445567 Bolt, Hex Head, 1/4 - 20 X 1-3/4 338 6839085 Pin, Modulator Valve Actuator 139 6839084 Valve, Modulator 140 6833934 Spring, Modulator Valve 141 6833949 Washer 142 6880158 Pin, Valve Stop 143 6833891 Ring, Spring Adjusting 144 6833878 Body, Modulator Valve 145 9428493 Pin, Retainer 146 23010909 Plate Kit, Separator 147 6830319 Ball, Check 148 6884172 Body, Control Valve 149 6835920 Valve, Third Clutch Trimmer 150 6835921 Plug, Trimmer 151 6880045 Spring, Third Clutch Trimmer Valve-Outer 152 6885166 Spring, Third Clutch Trimmer Valve-Inner 153 6839122 Stop, Valve 154 6835920 Valve, First Clutch Trimmer 155 6835921 Plug, Trimmer 1

2-105

TM 9-2320-277-14&P


56 6833945 Spring, First Clutch Trimmer Valve-Outer 157 6885166 Spring, First Clutch Trimmer Valve-Inner 158 6839122 Stop, Valve 159 6835920 Valve, Second Clutch Trimmer 160 6835921 Plug, Trimmer 161 6837692 Spring, Second Clutch Trimmer Valve-Outer 162 6885166 Spring, Second Clutch Trimmer Valve-Inner 163 6839122 Stop, Valve 164 6835920 Valve, Fourth Clutch Trimmer 165 6835921 Plug, Trimmer 166 6880045 Spring, Fourth Clutch Trimmer Valve-Outer 167 6885166 Spring, Fourth Clutch Trimmer Valve-Inner 168 6839122 Stop, Valve 169 6839578 Cover, Trimmer Valve 170 443603 Bolt, Hex Head, 1/4 - 20 X 5/8 871 6703169 Pin, Retainer 272 6833888 Valve, 3-4 Relay 173 6832462 Spring, 3-4 Relay Valve 174 6839829 Stop, Valve 175 6835928 Valve, 2-3 Relay 176 6834528 Spring, 2-3 Relay Valve 177 6835930 Spacer 178 6835817 Tube, Governor 279 6883053 Tube, Trimmer 180 6883052 Tube, Low Clutch Feed 181 6883054 Tube, Drive 1

2-106

TM 9-2320-277-14&P

OIL PUMP AND FRONT SUPPORT GROUP


23012740 Oil Pump and Front Support Assembly 11 6881597 Seal, Oil 12 6834525 Ring, Seal 1

6881598 Body and Gear Assembly, Oil Pump 13 - - - - - Body (Not serviced separately) 14 6772576 Gear, Oil Pump Driven 15 6777849 Gear, Oil Pump Drive 16 274613 Ring, Internal Snap 17 6834412 Stop, Valve 18 6880552 Spring, Main Pressure Regulator Valve (Color Code - White) 19 6834411 Valve, Main Pressure Regulator 110 9414044 Ring, Internal Snap 111 6834413 Stop, Valve 112 6836277 Spring, Lockup Valve (Color Code - Yellow) 113 6834414 Valve, Lockup 114 9409231 Bolt, Hex Head, Self-Locking, 3/8 - 16 X 1-1/2 215 9409225 Bolt, Hex Head, Self-Locking 5/16 - 18 X 1-3/4 12

6881599 Support Assy, Bearing and Front 116 6834410 Guide, Valve 117 6773551 Spring, Converter Pressure Regulator Valve 118 6836202 Valve, Converter Pressure Regulator 1

- - - - - Support Assembly, Front (Not serviced separately) 119 - - - - - Sleeve, Converter Ground (Not serviced separately) 120 - - - - - Support (Not serviced separately) 121 6762187 Plug 122 6760695 Bearing Assy, Needle 123 FG42643 Bearing Assy, Roller 124 6834390 Race, Bearing 125 23014632 Ring, Seal, Step Joint, Teflon 226 6837602 Gasket, Front Support to Main Case 127 6834908 Washer, Plain, Rubber Coated 1228 179397 Bolt, Hex Head, 3/8 - 16 X 3-3/8 12

2-107

TM 9-2320-277-14&P

FORWARD CLUTCH AND TURBINE SHAFT GROUP


1 6839163 Ring, Hook Type Seal 16882633 Clutch and Shaft Assy, Forward 1

2 6833999 Ring, Hook Type Seal 23 6882634 Housing Assy, Turbine Shaft and Clutch 14 8622757 Ball, Check, 0.1875 Dia. 2

2-108

TM 9-2320-277-14&P


5 455734 Pin 16 6882638 Plug, Valve (Color Code - White) 17 6882639 Spring, Valve (Color Code - White) 18 23010017 Valve, Centrifugal (Color Code - White) 19 6838364 Ring, External Snap 110 6835694 Gear, PTO Drive 111 8623121 Ring, Lip Type Seal, Clutch Housing 112 6833981 Ring, Lip Type Seal, Clutch Piston 113 6834669 Piston, Forward Clutch, 0.995 - 1.005 Thk. AR

(Selective, Identified with Letter A)13 6834668 Piston, Forward Clutch, 1.020 - 1.030 Thk. AR

(Selective, Identified with Letter B)13 6834219 Piston, Forward Clutch, 1.045 - 1.055 Thk. AR

(Selective, Identified with Letter C)14 6836773 Spring, Forward Clutch Piston Return 115 6834369 Retainer, Clutch Piston Return Spring 116 6833995 Ring, External Snap 117 6836146 Race, Bearing 118 FA40422 Bearing, Assy, Roller 119 6836147 Race, Bearing 120 6834222 Hub, Forward Clutch 121 6834374 Plate, Forward Clutch, External Tanged 522 6834370 Plate, Forward Clutch, Internal Splined 523 6834221 Hub, Fourth Clutch Driving 124 6834506 Ring, Internal Snap 125 6836147 Race, Bearing 126 FA40422 Bearing Assembly, Roller 127 6836146 Race, Bearing 1

2-109

TM 9-2320-277-14&P

FOURTH CLUTCH GROUP


6882660 Clutch Assy, Fourth 11 6834506 Ring, Internal Snap 12 6882659 Plate, Fourth Clutch Backing 13 6834370 Plate, Fourth Clutch Internal Splined 44 6834374 Plate, Fourth Clutch External Tanged 45 6833995 Ring, External Snap 16 6834369 Retainer, Clutch Piston Return Spring 17 6836773 Spring, Fourth Clutch Piston Return 1

2-110

TM 9-2320-277-14&P


8 6834669 Piston, Fourth Clutch, 0.995 - 1.005 Thk. AR(Selective, identified with letter A)

8 6834668 Piston, Fourth Clutch, 1.020 - 1.030 Thk. AR(Selective, identified with letter B)

9 6833981 Ring, Lip Type Seal, Clutch Piston 110 8623121 Ring, Lip Type Seal, Clutch Housing 1

Housing Assembly, Fourth Clutch 111 8622757 Ball, Check, 0.1875 Dia. 412 -------- Housing (not serviced separately) 113 6834390 Race, Bearing 1

FG42643 Bearing Assy, Roller 114 -------- Bearing (not serviced separately) 115 9432170 Race, Bearing (not serviced separately) 1

2-111

TM 9-2320-277-14&P

THIRD CLUTCH, CENTER SUPPORTAND SECOND CLUTCH GROUP

2-112

TM 9-2320-277-14&P


1 6836267 Ring, Internal Snap 12 6834229 Plate, Third Clutch Backing, 0.476 - 0.486 Thk. AR

(Selective, identified with No. 1)2 6834670 Plate, Third Clutch Backing, 0.450 - 0.460 Thk. AR

(Selective, identified with No. 2)3 6835720 Plate, Third Clutch Internal Splined 34 6835707 Plate, Third Clutch External Tanged 35 6836265 Ring, Internal Snap, 0.148-0.150 Thk (Color Code-Blue) AR5 6836266 Ring, Internal Snap, 0.152-0.154 Thk. (Color Code-Yellow) AR5 6836267 Ring, Internal Snap, 0.155-0.157 Thk. (Color Code-Green) AR5 6836268 Ring, Internal Snap, 0.158-0.160 Thk. (Color Code-Red) AR6 9414220 Ring, Type T, Self-locking Retainer 47 6834354 Ring, Spring Retainer 18 6831656 Spring, Third Clutch Piston Return 209 6834230 Piston, Third Clutch 110 6833986 Ring, Lip Type Seal, Piston ID 111 6883035 Ring, Lip Type Seal, Piston OD 112 23014632 Ring, Step Joint Teflon 2

6834353 Support, Bushing and Center 113 6883088 Bushing (Service Only) 114 453570 Ball, Check 115 - - - - - - - Support (not serviced separately) 116 6883035 Ring, Lip Type Seal, Piston OD 117 6833986 Ring, Lip Type Seal, Piston ID 118 6834230 Piston, Second Clutch 119 6831656 Spring, Second Clutch Piston Return 2020 6834354 Ring, Spring Retainer 121 9414220 Ring, Type T, Self-locking Retainer 422 6836267 Ring, Internal Snap 123 6835707 Plate, Second Clutch External Tanged 324 6835720 Plate, Second Clutch Internal Splined 325 6834229 Plate, Second Clutch Backing, 0.476 - 0.486 Thk. AR

(Selective, identified with No. 1)25 6834670 Plate, Second Clutch Backing, 0.450 - 0.460 Thk. AR

(Selective, identified with No. 2)

2-113

TM 9-2320-277-14&P

MAIN SHAFT AND GEAR UNIT GROUP

2-114

TM 9-2320-277-14&P


1 6839364 Washer, Thrust 12 6835574 Gear, Front Sun 13 6835386 Washer, Thrust 1

6882565 Carrier Assy, Front Planetary 14 6834309 Pin 65 6839514 Washer, Thrust 126 6833991 Washer, Pinion Thrust 127 6882827 Pinion Set (matched set of 6 pinions) 18 9426919 Roller 1209 - - - - - - - Flange and Carrier Assy (not serviced separately) 110 6835385 Bushing 111 6834389 Washer, Thrust 112 6834512 Ring, Internal Snap 113 6835560 Gear, Front Planetary Ring 1

6835562 Carrier Assy, Center Planetary 114 6835567 Pin 415 - - - - - - - Carrier (not serviced separately) 116 6839375 Washer, Thrust 817 6834504 Washer, Pinion Thrust 818 6882804 Pinion Set (matched set of 4 pinions) 119 6834915 Roller 72

6838099 Shaft Assy, Center Sun Gear 120 6834940 Pin, Spring 2

6835558 Shaft and Bushing Assy 121 6834503 Bushing, Sleeve 222 - - - - - - - Shaft (not serviced separately) 123 FA45495 Bearing Assy, Needle Roller 124 JF45496 Race, Roller Bearing 125 6835570 Drum, Planetary Connecting 126 6769319 Ring, External Snap 127 6835561 Gear, Center Planetary Ring 1

6835806 Shaft Assy, Main 128 6883707 Plug, Lube Orifice 129 - - - - - - - Shaft (not serviced separately) 130 6835569 Gear, Rear Planetary Sun 131 6834583 Ring, External Snap 1

6835642 Carrier Assy, Rear Planetary 132 FB47885 Bearing Assy, Needle Roller 133 6835567 Pin 434 6839375 Washer, Thrust 835 6834504 Washer, Pinion Thrust 836 6834915 Roller 7237 6882804 Pinion Set (matched set of 4 pinions) 138 - - - - - - - Carrier (not serviced separately) 139 6834512 Ring, Internal Snap 140 6835386 Washer, Thrust

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FIRST CLUTCH GROUP

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1 6884275 Ring, Internal Snap 12 6835571 Plate, First Clutch Backing, 0.702 - 0.712 Thk. AR

(selective, identified with No. 1)2 6835572 Plate, First Clutch Backing, 0.671 - 0.681 Thk R

(selective, identified with No. 2)2 6835573 Plate, First Clutch Backing, 0.640 - 0.650 Thk. AR

(selective, Identified with No. 3)3 6835687 Plate, First Clutch, Internal Splined 64 6834348 Plate, First Clutch, External Tanged 65 6835641 Gear, First Clutch Ring 16 6835640 Hub, First Clutch Ring Gear 17 6755007 Ring, Internal Snap 18 6833993 Ring, External Snap 19 6834339 Retainer, Clutch Piston Release Spring 110 6880251 Spring, Clutch Piston Release 2611 6837601 Piston, First Clutch 112 6883033 Ring, Lip Type Seal, External 113 6883031 Ring, Lip Type Seal, Internal 1

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GOVERNOR AND REAR COVER GROUP

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1 B-107 Bearing, Needle Roller 16880075 Shaft and Plug Assy 1

2 8623484 Plug, Cup 13 - - - - - - - Shaft (not serviced separately) 14 454512 Pin, Spring 15 - - - - - - - Bearing, Roller (not serviced separately. Included with item 9) 16 6834723 Gear, Governor Drive 17 6836045 Gear, Speedometer Drive w/7 Teeth 18 6834556 Spacer, Sleeve 19 BU1012L-15 Bearing Assy, Roller 110 6837442 Gasket, Rear Cover 1

6882632 Cover Assy, Rear 111 - - - - - - - Cover (not serviced separately) 112 - - - - - - - Race, Outer (not serviced separately. Included with item 9) 113 141231 Pin, Governor Support Dowel 114 444612 Plug, 1/8 NPTF 115 444612 Plug, 1/8 NPTF 1

6884749 Kit, Governor Filter 116 - - - - - - - Filter, Governor (not serviced separately) 117 6882689 Seal, O-Ring 118 9424750 Plug, 7/8-14 119 6883974 Tube, Drain 120 444697 Plug, 3/8 NPTF 121 103343 Washer 1/2 1422 189787 Bolt, Hex Head, 1/2- 13 x 5-1/4 1423 XB-22386 Bearing, Single Row Ball 124 6834567 Ring, Internal Snap 125 6773311 Seal, Oil 126 6757563 Shield, Dust 127 6771144 Nut, Hex, Self-locking 128 6885572 Governor Assy - I.D. No. 463 1

6880353 Kit, Governor Service 129 - - - - - - - Pin (not serviced separately) 230 8623263 Gasket 131 8623262 Cover, Governor 132 115658 Bolt, Hex Head 5/16-18 x 9/16 4

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LOW PLANETARY, LOW CLUTCH ANDADAPTER HOUSING GROUP

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1 6837442 Gasket, Adapter Housing 12 6839386 Washer, Thrust 13 6837439 Housing, Adapter 14 444691 Plug, Hex Socket, 1/4 NPTF 15 6839386 Washer, Thrust 16 6835652 Gear, Low Sun 17 6835397 Washer, Thrust 1

6837675 Carrier Assy, Low Clutch Planetary 18 6831679 Pin 69 6839376 Washer, Thrust 1210 6831680 Washer, Pinion Thrust 1211 6883616 Pinion Set (matched set of 6 pinions) 112 9426920 Roller 11413 - - - - - - - Carrier and Bushing Assy (not serviced separately) 114 6835398 Bushing 115 6835397 Washer, Thrust 116 6835707 Plate, Low Clutch External Tanged 617 6835720 Plate, Low Clutch Internal Splined 518 6837647 Gear, Low Clutch Ring 119 6833993 Ring, Internal Snap 120 6834339 Retainer, Clutch Piston Release Spring 121 6880251 Spring, Clutch Piston Release 2622 6837445 Piston, Low Clutch, 0.858 - 0.868 THK. (selective, AR

identified with letter C)22 6837530 Piston, Low Clutch, 0.829 - 0.839 THK. (selective, AR

identified with letter B)22 6837531 Piston, Low Clutch, 0.800 - 0.810 THK. (selective, AR

identified with letter A)23 6883035 Ring, Lip Type Seal, External 124 6883031 Ring, Lip Type Seal, Internal 1

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CONVERTER COVER AND TORQUECONVERTER GROUP

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1 23010726 Kit, Flex Disk Nut (consists of six 9416484 Nuts) 12 6770019 Retainer, Spacer 63 6758205 Spacer 64 190139 Nut, Lock, 5/16-24 245 6837210 Cover Assy, Torque Converter 16 6756782 Bushing 17 6770822 Retainer, Sealring 18 6770820 Ring, Lockup Clutch Piston Inner Seal 19 6770845 Piston, Lockup Clutch 110 6758036 Ring, Lockup Clutch Piston Outer Seal 111 6833906 Plate, Lockup Clutch 112 6753866 Ring, Seal 113 6756778 Plate, Lockup Clutch Backing 114 6836676 Ring, External Snap 115 JFA 40001 Race, Bearing 116 FA 40001 Bearing Assy, Roller 117 JK46991 Race, Bearing 118 6837429 Spacer, Turbine Thrust Bearing, 0.015, Gold AR18 6837430 Spacer, Turbine Thrust Bearing, 0.030, Silver AR18 6837431 Spacer, Turbine Thrust Bearing, 0.042, Plain AR18 6837432 Spacer, Turbine Thrust Bearing, 0.060, Black AR18 6837433 Spacer, Turbine Thrust Bearing, 0.075, Copper AR19 6837579 Turbine, Torque Converter 120 6836585 Stator Assy, Torque Converter 121 FB 29009 Bearing Assy, Needle Roller 122 6837206 Race, Stator Freewheel Roller 123 6774966 Spring, Stator Freewheel Roller 1024 6774968 Roller, Stator Freewheel 1025 FA45518 Bearing Assy, Needle Roller 126 JD45519 Race, Bearing 127 6755988 Bolt, Special, 5/16-24 x 1.30 2428 6773679 Bolt, Hex Head, 1/4-20 x 5/8 829 6769631 Strip, Locking 430 6881592 Hub, Converter Pump 131 6837993 Bracket, Shipping (used to retain torque converter when 1

removing, shipping or storing transmission)32 6759971 Gasket, Converter Pump Hub 133 6753866 Ring, Seal 134 6779599 Pump Assy, Torque Converter 1

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MODULATED LOCKUP VALVE


6882817 Valve Assy, Modulated Lockup 11 6882818 Body, Valve 12 9428493 Pin 13 6882819 Valve, Modulated Lockup 14 6882820 Spring, Modulated Lockup Valve 15 6833896 Stop 16 6833891 Ring, Spring Adjusting 1

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LOW SHIFT VALVE


1 6835815 Plate, Oil Transfer 12 6880209 Plate, Separator 1

6839018 Valve Assy, Low Shift 13 6836817 Body, Valve 14 6703169 Pin, Retainer 15 9428493 Pin, Retainer 16 6836292 Valve, Low Shift Relay 17 6839214 Spring, Low Shift Relay Valve 18 6881138 Stop, Valve 19 6880464 Valve, Low Shift Signal 110 6839013 Spring, Low Shift Signal Valve 111 6880158 Stop, Valve 112 6833949 Washer 113 6833891 Ring, Spring Adjusting 1

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EXTERNAL OIL FILTER53505329


1 90001818 External Oil Filter (see page 2-127) 12 53505298 Oil Filter Bracket 13 53451851 Hose, # 12 X 10" 14 53451852 Fitting, Hose End 45 90200038 Adapter, Union 90° 16 90200058 Adapter, Union 17 90804495 Capscrew, Hex Head 48 95210330 Nut, Hex 3/8 - 16 49 98415042 Lockwasher, 3/8 4

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OIL FILTER ASSEMBLY


1 OF-276 Center Stud 1OF-278 Shell Assembly 1

2 OF-275 Shell 13 OF-272 Plug 14 G-389 Gasket 15 90002488 Filter Element 16 5571024 Gasket 17 OF-277 Spring Retainer 18 GF-273 Bypass Valve Spring 19 OF-274 Bypass Valve 110 OF-271 Base 1

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GEAR SHIFT AND FIFTH WHEEL CONTROL

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90001513 Control Assembly 11 90001544 Reflector 42 90001545 Pigtail Assembly 23 90001546 Shaft 14 90001547 Nameplate, Patent 15 90001548 Decal, Morse 16 90001549 Knob Assembly 27 90001550 40 Series Hardware Bag 18 90001551 60 Series Hardware Bag 19 90001580 O-Ring 2

10 90001552 Gate Plate, Fifth Wheel 111 90001553 Lever Assembly, Fifth Wheel 112 90001554 Light Pipe 213 90001581 Gate Plate, Gear Shift 114 90001556 Position Strip, Gear Shift 115 90001557 Position Strip, Fifth Wheel 116 90001558 Plate, Adapter, Fifth Wheel 117 90001559 Housing, Gear Shift 118 90001582 Plate, Adapter, Gear Shift 119 90001561 Lever Assembly, Gear Shift 120 90001562 Housing, Fifth Wheel 121 90001563 Screw, Phillips, *632 x 7/16 422 90001564 Screw, Phillips, #10-24 x 5/16 823 90001565 Screw, Fil Head, #10-24 x 1/2 124 90001566 Screw, Hex Head, 3/8-16 x 1 225 90001567 Screw, Hex Head, 3/8-24 x 3/4 226 90001568 Screw, Set, 1/4-20 x 3/8 427 90001569 Lockwashers, 3/8 228 90001570 Nut, Switch 229 90001573 Bulb, #53 230 90001574 Actuator Arm, Switch 131 90001575 Support, Switch 132 90001576 Switch, Neutral Start 1

53500475 Ground Wire Assembly 133 90001577 Screw, Hex Head, 1/4-28 x 1/2 234 90001578 Lockwasher, 1/4 235 90001579 Nut, Elastic Stop, #10-32 236 53506764 Shifter Panel, Dual 137 90001588 Cable, Fifth Wheel 138 53500313 Clevis, Fifth Wheel 139 95620134 Pin, Clevis 140 90831005 Pin, Cotter 1

90804011 Screw, Hex Head 498415020 Lockwasher, 1/4 495210441 Hex Nut, Self-locking 295210442 Hex Nut, Self-locking 2

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GEAR SHIFT CABLE53500581


1 53500578 Gear Shift Cable 12 53502981 Bracket, Shift Cable 1

53500581 Connection Kit, Cable 13 95210010 Hex Nut, #10-32 24 98415017 Lockwasher, #10 25 53141876 Clamp 16 53141877 Shim 17 90831039 Cotter Pin, 3/32 x 5/8 18 53141873 Trunnion 19 95210485 Hex Nut, Self-locking, 3/8-16 1

10 90003208 Lever Arm 190001590 Connection Kit, Transmission 1

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SHIFT LOCKOUT53505339

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1 90000645 Tee, Brass 12 53105382 Tube Sleeve, 1/2 23 53105381 Tube Sleeve, 3/8 24 99802340 Tubing, 3/8 x 2 15 91603176 Elbow, 90 degree 16 98415035 Lockwasher, 5/16 27 90804037 Capscrew, 5/16-18 28 53505340 Bracket, Shift Lock 19 53140875 Air Cylinder and Linkage 1

10 53505365 Adapter 111 53505363 Spacer, Sleeve 112 90000643 Rod Block 113 90000644 Retainer Ring 214 53505341 Lever 215 53505364 Pin 116 95210295 Hex Nut, 1/4-20 217 98421150 Washer, Flat, 1/4 118 90000655 Decal, Instruction 1

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Section IX. DRIVE SHAFT

DRIVE SHAFT


53506287 Drive Shaft Assembly 11 53501039 End Yoke 12 53501014 Journal and Bearing Kit 23 53501015 Sleeve Yoke 14 92408022 Grease Fitting 15 53506288 Driveshaft Subassembly 1

53501034 Dust Cap Kit 16 53501016 Dust Cap 17 53501017 Washer, Cork 18 53501018 Flat Washer 19 - - - - Companion Yoke (see page 2-145, item 38) REF.

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Section X. FRONT AXLE AND SUSPENSION

FRONT AXLE ASSEMBLY90002541

ITEM PART NUMBER DESCRIPTION QTY.90002541 Front Axle Assembly 1

1 90002438 Key, Steering Arm 22 90002440 Cotter Pin 13 90000357 Hex Nut, Castle 14 90002439 Arm, Steering 1

90001427 Knuckle Pin Kit 25 2297Q2681 Cap, Steering Knuckle 26 2208Q823 Gasket 27 1225D836 Bushing, Bronze 18 1205X1428 Seal, Upper 29 2203L3002 Shim, 0.005 19 2203K3001 Shim, 0.010 1

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10 1205B1432 Seal, Lower 111 T-182 Thrust Bearing 112 1227Z780 Hex Nut, Draw Key 213 7X-112 Draw Key, Upper 113 7X-111 Draw Key, Lower 114 S-259-1 Capscrew 615 1229F1669 Washer 616 3101W179 Knuckle Pin 117 90002441 Capscrew 1218 90002443 Cap, Knuckle Dust 419 90002445 Bushing, Knuckle (Bronze) 220 90002453 Axle Center 121 90002440 Cotter Pin, Cross Tube Arm 122 53141802 Nut, Tie Rod End 223 90002457 Bolt, Steering Cross Tube End 224 90002458 Cross Tube Assembly 125 53100736 Clamp, Steering Cross Tube 226 90000349 Nut, Clamp Cross Tube End 227 90000609 Tie Rod End Assembly, LH 127 90000610 Tie Rod End Assembly, RH 128 53141812 Arm, Cross Tube, LH 128 53141811 Arm, Cross Tube, RH 229 90002438 Key, Cross Tube Arm 130 90002462 Stop Screw, Axle Center 231 90002463 Lock Nut, Stop Screw 232 90002442 Fitting, Grease 233 90002442 Fitting, Grease 234 90002444 Gasket, Knuckle Cap 435 90002451 Cotter Pin 236 90002470 Knuckle, Steering Assembly, LH 136 90002469 Knuckle, Steering Assembly, RH 137 90000355 Nut, Cross Tube Arm 138 53141802 Cotter Pin, Cross Tube Ball 239 53100738 Ball, Steering Arm 1

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FRONT AXLE HUB AND DRUM90002541


90002541 Front Axle Assembly REF.1 53505571 Axle Seal Set (see page 2-139) 12 90002485 Gasket, Hub 23 53100721 Nut, Jam, Brg. Jam 24 53100723 Lockwasher, Brg. Nut 25 53100722 Lockwasher, Pierced 26 53140509 Nut, Wheel Brg. Adj. 27 53141813 Bearing, Wheel Cone, Outer 28 90002475 Bearing, Wheel Cup, Outer 29 90002669 Hub and Cup Assembly 2

10 90002225 Stud, Hub and Wheel, LH 110 90002226 Stud, Hub and Wheel, RH 111 48000642 Bearing, Wheel Cup, Inner 212 90002478 Bearing, Wheel Cone, Inner 213 90002479 Seal, Wheel Brg. Oil Assembly 214 90002480 Screw, Hub Cap 1215 90002465 Washer, Hub Cap Screw 1216 53140433 Nut, Hub and Wheel Stud, LH 116 90000373 Nut, Hub and Wheel Stud, RH 117 53140446 Screw, Hub and Drum 2018 90002484 Drum 2

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FRONT AXLE BRAKES


90002541 Front Axle Assembly REF.1 90002382 Brake Shoe 42 90002456 Brake Air Chamber (see page 2-138) 43 90002459 Collet Nut 44 90002210 Wedge Assembly 45 90002207 Brake Shoe Return Spring 46 90002460 Brake Spider 27 90002461 Adjusting Bolt Assembly 48 90002464 Plunger Seal and Retainer 49 90002208 Adjusting Plunger 4

10 90002209 Adjusting Sleeve (Actuator) 411 90002467 Guide Screw 412 90002472 Gasket 813 90002211 Anchor Plunger (Solid) 414 90002474 Hold Down Clip 415 90002477 Hold Down Spring Bolt 816 90002481 Lockwasher 417 90002482 Nut 418 90002483 Plunger Guide and Adjusting Pawl 419 90002492 Spring 420 90002493 Hollow Cap Screw 4

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BRAKE AIR CHAMBER90002456


1 NP-35 Hex Nut 12 0-15-725 Hex Head Bolt 13 2797-100 Clamp Ring 14 A2-3780-62 Pressure Housing 15 2797-56 Diaphragm 16 A28-1779-230 Plate Assembly 17 A-3780-122 Non-Pressure Housing 18 1779433 Wedge Guide 1

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FRONT AXLE SEAL53505571


1 90001850 Hub Cap 290001849 Seals Set 1

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FRONT AXLE SPRING GROUP53506438

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1 53109148 Spring, Front, Right 12 53500054 Spring, Front, Left 13 53024801 Shackle, Inner Spring 24 53053901 Shackle Assembly 25 53502813 Spacer, Front Spring 26 53502863 Spring Pin Assembly 67 53502864 Spring Pin, Front 18 92408022 Fitting, Lubrication 19 98421120 Washer, 3/4 1

10 95210240 Nut, Hex, Self-Locking, 3/4-10 111 53505826 Spring Pad and Shock Mount Assembly REF.12 90003710 Bolt, Hex Head, 3/4-16x9-1/2 813 95210360 Nut, Hex, 3/4-16 814 95210400 Nut, Hex, Self-Locking, 3/4-16 8

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SHOCK ABSORBER INSTALLATION53505514


1 90001839 Hex Nut, Self-Locking 3/4-16 42 98421120 Flat Washer 3/4 43 90000245 Shock Absorber 24 53100777 Axle Stop Bumper 25 53505826 Spring Pad and Shock Mount Assembly 2

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Section XI. REAR AXLE

REAR AXLE GROUP53510108


90004061 Rear Axle Assembly (see pages 2-148 and 2-149) 11 90002389 Differential Carrier Assembly (see page 2-145) 12 90002496 Axle Housing 13 53140859 Plug 14 90003255 Plug, Filler 15 90000420 Breather Assembly 16 90000842 Stud 27 90002388 Heat Indicator 18 90000848 Plug 1

90003256 Cotter Pin 153140448 Capscrew 12

9 53109166 Brake Chamber (see page 2-151) 210 53502708 Clamp Plate, LH 110 53502218 Clamp Plate, RH 111 53504884 Torque Link 412 90804583 Hex Head Screw, 1-14x3-1/2 413 95210475 Hex Nut, Self-Locking, 1-14 1214 90805258 Hex Head Screw, 1-14x9 8

53506404 Bushing 1253506405 Washer, Hardened 24

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90804130 Hex Head Screw, 7/8-14x4 1295210228 Hex Nut Self-Locking, 7/8-14 NF 1253506416 Pad, Rubber 253502709 Locating Pad, LH 153502219 Locating Pad, RH 153506414 Spacer, LH 153506415 Spacer, RH 1

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DIFFERENTIAL CARRIER ASSEMBLY


90002497 Differential Carrier Assembly REF.1 90002503 Carrier and Cap Assembly2 53140474 Capscrew 43 53140473 Flat Washer 44 - - - - Bearing Cap (not serviced separately) 2

48000511 Dowel 290000849 Bushing 190003238 Bushing 1

5 90003245 Capscrew 26 90003222 Flat Washer 27 90000398 Bearing Adjusting Nut 2

90003794 Case and Gear Assembly 18 90002498 Capscrew 129 90002499 Flat Washer 12

10 90002500 Hex Nut, Special 12

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ITEM PART NUMBER DESCRIPTION QTY.90003353 Case and Nest Assembly 1

11 53140348 Case Assembly 112 53140323 Differential Spider 113 53140110 Differential Pinion 414 53140422 Thrust Washer 415 90003114 Side Gear 216 53140421 Thrust Washer 217 53509145 Rivet Replacement Kit 118 53140839 Spur Gear 119 53140328 Bearing Cone 220 53140329 Bearing Cup 221 90000409 Capscrew 1122 90000410 Flat Washer 623 48000584 Plug 124 90000847 Lock Nut 125 90003784 Bevel Gear Assembly 126 90000415 Shim 0.003 327 90000413 Shim 0.005 328 90000414 Shim 0.010 4

90003787 Pinion Cage Assembly 129 90002395 Bearing Cone, Inner 130 53140343 Bearing Cone, Outer 131 53140341 Pinion Cage Assembly 132 53140132 Bearing Cup, Inner 133 53140342 Bearing Cup, Outer 134 90001757 Shim 0.480 AR35 90001758 Shim 0.482 AR36 90001489 Shim AR37 53140334 Oil Seal 138 90002506 Companion Yoke Assembly 1

53141175 Flange Deflector 139 53140484 Plug 140 90000833 Capscrew, Short 141 90000834 Capscrew, Medium 1042 90000850 Capscrew, Long 143 90000410 Flat Washer 1244 53140476 Cage Assembly 145 53140351 Bearing Cup 146 53140481 Shim 0.003 AR47 53140482 Shim 0.005 AR48 53140483 Shim 0.010 AR

Cross Shaft Assembly (not serviced separately) 149 90000856 Capscrew 250 53140350 Bearing Retainer 151 53140352 Bearing Cone 252 53140469 Square Key 153 53140353 Pinion Shaft 154 53140477 Cage Assembly 155 53140351 Bearing Cup 156 53140478 Shim 0.003 357 53140479 Shim 0.005 258 53140480 Shim 0.010 359 90000418 Capscrew 460 90003261 Lockwasher 461 90000416 Cover 1

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62 90000417 Gasket 163 90003245 Capscrew 264 90003246 Flat Washer 265 53140488 Cover 166 53140489 Gasket 1

90000409 Capscrew 790000412 Plug 190000483 Hex Nut 3290001875 Washer, Special 6490001936 Capscrew 32

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REAR AXLE SHAFT, HUB AND DRUM


1 90000483 Hex Nut 162 90000482 Lockwasher 163 90000469 Tapered Sleeve 164 90000830 Axle Shaft, LH 14 90003806 Axle Shaft, RH 1

90000708 Oil Seal Set 25 90000480 Gasket 26 90002392 Oil Seal, Outer 17 90000853 Wiper, Outer Seal 18 53140335 Hex Nut, Outer 29 90000846 Lockwasher 2

10 90000845 Hex Nut, Inner 211 90002394 Bearing Cone, Outer 212 90002393 Bearing Cone, Inner 213 90000852 Oil Seal, Inner 2

90000837 Hub and Drum Assembly RH 190000836 Hub and Drum Assembly LH 1

14 90000839 Brake Drum 190003805 Hub and Stud Assembly 1

15 53140826 Stud 890002491 Hub and Cup Assembly 1

16 90002390 Bearing Cup, Outer 117 90000825 Bearing Cup, Inner 118 - - - - Hub (not serviced separately) 119 90000841 Wheel Stud, RH 1019 90000840 Wheel Stud, LH 1020 53140436 Hex Nut, Inner, RH 1020 53140435 Hex Nut, Inner, LH 1021 53140433 Hex Nut, Outer Wheel Stud 10

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REAR AXLE BRAKES90004061


1 90000859 Return Spring 22 90001807 Retainer 83 53140653 Retainer 84 53140652 Felt 85 90003801 Anchor Pin 46 90003800 Shoe and Lining Assembly 47 - - - - Brake Air Chamber (see page 2-151) REF.8 53140656 Retaining Ring 29 53140655 Retainer 2

10 90000427 Slack Adjuster 211 53140655 Retainer 212 90000472 Flat Washer 213 90003226 Flat Washer 414 53141256 Cam Bushing 215 53140870 Capscrew 816 90002512 Lockwasher 817 90000429 Brake Chamber Bracket, LH 117 90000428 Brake Chamber Bracket, RH 118 90000443 Gasket 219 53140105 Camshaft, LH 119 53140106 Camshaft, RH 120 90000446 Special Washer 221 90001873 Retainer 222 90001874 Preformed Packing 223 90001872 Oil Seal 2

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24 90003799 Bushing 225 90000343 Hex Nut 1226 53140793 Flat Washer 1227 90003122 Capscrew 1228 90000430 Brake Spider 2

90003797 Brake Spider Assembly 129 90000440 Lock Wire AR30 90000439 Capscrew 4

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REAR AXLE BRAKE CHAMBER53109166


1 11M012 Dust Plug 12 11M011 Release Stud (includes nut and washer) 1

1126M005-CA Clamp Assembly 23 11M051 Hex Nut 24 11M052 Carriage Bolt 25 11126M005-1 Clamp Half 26 - - - - Spring Chamber Assembly (not serviced separately) 17 1126M001-1D Adapter 18 1126M009 Diaphragm 29 11428R8 Screw 2

10 11M037 Plate 211 11M014 Return Spring (spring brake) 112 1126M038 Push Rod Adapter 113 11M114 O-Ring 114 53140533 Clevis Assembly (includes 5/8" clevis pin and cotter pin) 115 1126M015 Housing Assembly 116 11M067 Hex Nut 5/8-11 217 11M046 Lockwasher 5/8 218 11M050 Self-Locking Hex Nut 5/8-18 119 1126M017 Push Rod 120 11M016 Return Spring (service brake) 121 11M034 Dust Boot Assembly 1

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Section XII. AIR SYSTEM

PNEUMATIC GROUP53502576


53452255 Air Line Set 11 90001695 Air Line, Red, Coiled 3/8 I.D. x 144 12 90001696 Air Line, Blue, Coiled 3/8 I.D. x 144 13 53500656 Air Line Assembly 1

91603183 Elbow 3/8 x 1/4 199802340 Air Line 3/8 O.D. 17"

4 53500658 Air Line Assembly 291603186 Elbow 1/2 x 1/4 190828103 Connector 1/2 x 1/4 199802341 Air Line 1/2 O.D. 15"


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7 53500646 Air Line Assembly 190824007 Connector 3/8 x 1/4 190828097 Connector 3/8 x 3/8 199802340 Air Line 3/8 O.D. 15"

8 53505971 Air Line Assembly 5/8 O.D. x 22 19 53500644 Air Line Assembly 1

91603180 Elbow 5/8 x 1/2 191603179 Elbow 5/8 x 3/4 199802342 Air Line 5/8 O.D. 53"

10 53509169 Air Line Assembly 3/8 O.D. x 130 111 53500642 Air Line Assembly 1

53109180 Swivel Connector 299803000 Air Line 5/8 O.D. 45½"

12 53451268 Air Line Assembly 5/8 x 64 113 53500622 Air Line Assembly 1

91603178 Elbow 1/2 x 1/2 191603177 Elbow 1/2 x 3/8 199802341 Air Line 1/2 O.D. 152"

14 53500623 Air Line Assembly 191603183 Elbow 3/8 x 1/4 299802340 Air Line 3/8 O.D. 55"

15 53500629 Air Line Assembly 190824007 Connector 3/8 x 1/4 191603191 Elbow 3/8 x 1/4 199802340 Air Line 3/8 O.D. 61"

16 53500630 Air Line Assembly 190828112 Connector #6 x 1/4 190828113 Swivel Connector #6 x 1/4 199802337 Rubber Hose #6 34"



19 53500631 Air Line Assembly 190828112 Connector #6x 1/4 190828113 Swivel Connector #6 x 1/4 199802337 Rubber Hose #6 29"


21 53500639 Air Line Assembly 190824007 Connector 3/8 x 1/4 190828098 Connector 3/8 x 1/8 199802340 Air Line 3/8 O.D. 37"

22 53500640 Air Line Assembly 1

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ITEM PART NUMBER DESCRIPTION QTY.91603196 Elbow 3/8 x 1/2 190828097 Connector 3/8 x 3/8 199802340 Air Line 3/8 63½"

23 90002322 Air Compressor (see page 2-169) 124 92004028 Discharge Fitting 125 53105025 Reservoir, 9-A" Dia. 226 53100506 Drain Cock (see page 2-164) 227 53100563 Automatic Drain Valve (see page 2-160) 128 53100507 Treadle Valve (see page 2-158) 129 53100508 Low Pressure Switch 130 53100509 Quick Release Valve (see page 2-163) 231 53100510 Stop Light Switch 132 53100511 Tractor Protection Valve 133 90829018 Gladhand Coupling, Emergency 134 90829017 Gladhand Coupling, Service 135 98005596 Fifth Wheel Unlatch Valve (see page 2-166) 136 53109165 Check Valve 137 90839008 Cross 1/4 Galvanized 138 90709340 Reducing Bushing 1/4 x 1/8 139 96091402 Elbow 140 53109181 Straight Adapter # 10 x 1/2 141 92003011 Bulkhead Fitting 1/4 842 53109280 Bulkhead Fitting 3/8 143 53100539 Tee, 3/8 x 1/4 144 53105320 Pipe Plug 1/2 NPT Galvanized 245 53105335 Pipe Plug 3/8 NPT Galvanized 346 53103329 Street Elbow 1/4 x 900 Galvanized 647 95205043 Close Nipple 1/4 148 53100548 Safety Valve 149 53100520 Reservoir, 7" Dia. 150 98005591 Check Valve (see page 2-162) 151 53105350 Service Tee 3/8 Galvanized 152 90002291 Air Pressure Gage 153 91603103 Elbow 900 154 96000516 One Piece Elbow 255 92003028 Bulkhead Fitting 1/2 356 95205206 Close Nipple 1/2 257 91603177 Elbow 458 90709245 Reducing Bushing 3/8 x 1/4 359 53500641 Air Line Assembly 1

90828113 Swivel Connector #6 x 1/4 190828106 Spring Connector #6 x 1/4 199802337 Rubber Hose #6 165"

60 99802340 Air Line 3/8 O.D. x 32" 561 90824007 Connector 3/8 x 1/4 1162 91603182 Elbow 3/8 x 1/4 363 90828097 Connector 3/8 x 3/8 364 90000990 Brake Control Panel (see page 2-177) 165 53103400 Street Tee 1/4 Galvanized 266 53001203 Double Check Valve (see page 2-161) 167 91603183 Elbow 3/8 x 1/4 468 99802340 Air Line 3/8 O.D. 20"69 90003484 Stop Light Switch 1

95210658 Hex Nut #8-32 270 99802340 Air Line 3/8 O.D. x 30" 271 91603038 Elbow 3/8 x 3/8 2

2-155

TM 9-2320-277-14&P


72 90709365 Reducing Bushing 1/2 x 3/8 173 53506998 Air Line 3/8 O.D. 60"74 91603196 Elbow 3/8 x 1/2 275 53506999 Air Line 3/8 O.D. 54"76 90001269 Relay Valve 1

95210080 Hex Nut 5/16 298415035 Lockwasher 5/16 290804039 Capscrew 5/16-18 x 1-1/4 2

77 53105347 Service Tee 1/2 178 90828104 Connector 1/2 x 5/8 279 53506997 Air Line 5/8 O.D. 60"80 90709320 Hex Reducing Bushing 3/4 x 1/2 181 53507000 Air Line 3/8 O.D. 72"82 90002278 Ratio Reducing Valve 1

95210080 Hex Nut 5/16-18 298415035 Lockwasher 5/16 290804055 Capscrew 5/16-18 x 1 2

83 53507001 Air Line 3/8 O.D. 14"84 53101212 Trailer Hand Brake Control (see page 2-165) 1

53451261 Tie Strap 153102803 Hole Plug 1" 190812042 Hose Clip #8 253109233 Clip, 9/16 353101502 Coated Clip 1/2 653101504 Coated Clip 3/8 1090812076 Spring Clip 190804035 Hex Head Screw 5/16-18 x 1 2590804109 Hex Head Screw 5/16-18 x 3 295210080 Hex Nut 5/16-18 3198415035 Lockwasher 5/16 2190804485 Hex Head Screw 3/8-16 x 1-1/4 995210330 Hex Nut 3/8-16 1298415042 Lockwasher 3/8 490804267 Hex Head Screw 1/2-11 x 2 495210125 Hex Nut 1/2-11 498415050 Lockwasher 1/2 490804017 Hex Head Screw 1/4-20 x 3/4 195210296 Hex Nut 1/4-20 198415021 Lockwasher 1/4 190805121 Hex Head Screw 3/8-24 x 6 695210085 Hex Nut 3/8-24 6

2-156

TM 9-2320-277-14&P

AIR TANK INSTALLATION53507447


1 53113726 Bracket, 9-1/2" Reservoir 62 53103048 Capscrew 3/8-16x6-1/2 43 98415042 Lockwasher 3/8 144 95210330 Hex Nut 3/8-16 145 53119531 Cross Bar 26 90804267 Capscrew 1/2-13x1-1/2 47 98415050 Lockwasher 1/2 48 95210125 Hex Nut 1/2-13 49 53112311 Bar 2

10 53113727 Bracket, 7" Reservoir 411 90804485 Capscrew 3/8-16x1-1/4 912 90804467 Capscrew 3/8-16x1-1/4 213 98421135 Flat Washer 3/8 214 95210310 Hex Nut, Self-Locking 3/8-16 2

2-157

TM 9-2320-277-14&P

TREADLE VALVE ASSEMBLY53100507

2-158

TM 9-2320-277-14&P


1 90804035 Hex Head Screw 5/16-18x1 32 98415035 Lockwasher 5/16 33 95210080 Hex Nut 5/16-18 3

53100507 Treadle Valve REF.4 210067 Spring Pin 15 238888 Fulcrum Pin 1

226834 Control Pedal 16 210492 Cotter Pin 17 238474 Straight Pin 18 236288 Roller 19 226835 Control Pedal 1

10 236980 Rubber Bumper 111 236982 Dust Boot 112 236981 Valve Plunger 113 236979 Mounting Plate 114 202979 Cap Screw 5/16-18 315 202982 Lockwasher 5/16 316 239688 Piston Retainer 117 239643 Preformed Packing 1

277854 Valve Piston 118 239640 Hex Head Screw, Self-Locking 119 239713 Flat Washer 120 243019 Shouldered Washer 121 241559 Rubber Disk 122 243011 Piston 123 235829 Valve Spring, Compression 124 Valve Body (not serviced separately) 1

229502 Valve Insert Assembly 125 239979 Valve Plunger 126 239136 Preformed Packing 127 240960 Spring Seat 128 239627 Helical Compression Spring 129 239645 Preformed Packing 130 244586 Plunger Retainer 131 239737 Leaf Spring 132 239615 Nonmetallic Valve Disk 133 239708 Disk Retainer 134 242109 Self Tapping Screw, Pan Head 135 239476 Retaining Ring 136 53105320 Pipe Plug 1/2" REF.

289329 Major Parts Kit (includes items 16, 18, 19, 20, 22, and 23) AR276119 Minor Parts Kit (includes items 17, 21, and 25 through 35) AR

2-159

TM 9-2320-277-14&P

AUTOMATIC DRAIN VALVE53100563


1 246262 Body 12 246261 Cover 13 MS3533845 Washer 44 MS90725-33 Screw 45 246264 Packing, Preformed 16 246263 Guide, Valve 17 246266 Valve, Inlet and exhaust 18 233057 Plug 19 246267 Adapter 1

2-160

TM 9-2320-277-14&P

DOUBLE CHECK VALVE53001203


1 99802340 Nylon Tube REF.2 91603183 Tube Fitting 900 REF.3 53500640 Nylon Tube Assembly REF.4 90828097 Tube Fitting REF.5 95670135 Pipe Plug 3/8 1

53001203 Double Check Valve REF.6 237313 Hex Head Screw 27 202678 Flat Washer 28 243588 Valve Cap 19 239658 Preformed Packing 1

10 237497 Shuttle Assembly 111 239949 Shuttle Guide 112 237494 Valve Body 1

2-161

TM 9-2320-277-14&P

CHECK VALVE98005591


1 236742 Body 12 236743 Valve Seat 13 238412 Preformed Packing 14 236744 Valve Disc 15 247919 Compression Spring 16 239758 Screw Cap 1

2-162

TM 9-2320-277-14&P

QUICK RELEASE VALVE53100509


1 95205206 Close Nipple 1/2 REF.53100509 Quick Release Valve REF.

2 240006 Cover 13 245835 Diaphragm 14 240012 Screw 1/4-20 45 240003 Body 16 242837 Gasket 1

2-163

TM 9-2320-277-14&P

DRAIN COCK53100506


1 246686 Cotter Pin 12 246965 Flat Washer 13 246964 Helical Compression Spring 14 246963 Flat Washer 15 246962 Valve Insert 16 246961 Valve Body 1

2-164

TM 9-2320-277-14&P

TRAILER HAND BRAKE CONTROL53101212


1 246226 Knob 12 239940 Handle 13 241556 Spirol Pin 14 232068 Grommet 5/16 O.D. 15 239939 Head 16 240351 Screw 3/8-16 27 233997 Lockwasher 28 240775 Clamp 19 239897 Body 1

10 248334 Piston 1277587 Cam and Cam Follower Assembly 1

11 239907 Cam Follower 112 239908 Cam 113 239909 Spring 1

283732 Valve Assembly 114 239899 Inlet Valve Seat 115 289900 Stem 116 240288 Compression Spring 117 239902 Valve Guide 118 239901 Valve 219 239906 Cover 120 239910 Adjusting Ring 121 239911 Lockwasher 122 231159 Grommet 123 240457 Gasket 124 238327 Grommet 1-5/8 O.D. 125 239904 Return Spring 126 239898 Grommet 1 O.D. 127 239903 Machine Screw 228 239383 Lockwasher 229 248335 Machine Screw 2

2-165

TM 9-2320-277-14&P

FIFTH WHEEL UNLATCH VALVE98005596


1 236241 Push Button 12 202961 Self-Locking Hex Nut 13 237032 Machine Screw # 10-24 2

276454 Valve Assembly REF.4 234840 Cap Nut 15 236728 Gasket 16 235729 Valve Spring 17 249534 Disc Valve 18 211155 Retaining Pin 19 239766 Valve Plunger 1

10 234833 Return Spring 111 214749 Preformed Packing 112 239092 Valve Body 113 91201080 Dial Plate 1

2-166

TM 9-2320-277-14&P

AIR COMPRESSOR INSTALLATION

2-167

TM 9-2320-277-14&P


1 90831060 Cotter Pin 1/8x1-1/2 REF.2 90003325 Pulley, 6.25 Dia. 13 2325715 Elbow 1/2-90° 14 5135078 Water Inlet Hose 1/2x11 15 118752 Connector 1/2 16 5131828 Oil Supply Hose 3/16x20 17 118748 Connector 18 5100136 Pipe Adapter 19 444052 Elbow 45° 1

10 102635 Hex Nut 3/8-16 211 MS35338-8 Lockwasher 3/8 212 179850 Hex Head Bolt 3/8-16x2-3/4 213 271500 Hex Nut 7/16-14 614 103322 Lockwasher 7/16 615 90002322 Air Compressor (see page 2-169) REF.16 90003318 Gasket 117 427567 Hex Head Bolt 7/16-14x1-3/4 618 MS90728-62 Hex Head Bolt 3/8-16x1-1/4 419 MS35338-7 Lockwasher 3/8 420 5102393 Support 121 186283 Hex Head Bolt 3/8-16 222 MS35338-8 Lockwasher 223 5108435 Flat Washer 224 5102395 Bracket 125 5145415 Support 1

2-168

TM 9-2320-277-14&P

AIR COMPRESSOR

2-169

TM 9-2320-277-14&P


1 90003316 Capscrew 62 90804520 Hex Head Screw 3/8-16x3 6

90003284 Cylinder Head Assembly 190003287 Cylinder Head Body Assembly 1

3 53140280 Discharge Valve Seat 24 53140303 Inlet Valve Spring Seat 25 53140258 Discharge Valve 26 90003289 Discharge Valve Spring 27 53140301 Gasket, Discharge Fitting 18 90003315 Gasket, Cylinder Head 1

90003291 Crankcase Assembly 190003294 Crankcase Body Assembly 1

9 53140667 Inlet Valve Seat 210 ------- Crankcase (not serviced separately) 1

90003327 Service Parts Kit, Unloader AR53140268 Piston Assembly, Unloader 2

11 53140672 Unloader Piston 112 53140670 Back-Up Ring 113 53140671 Grommet 114 53140267 Unloader Plunger 215 53140266 Plunger Guide 216 53140265 Spring Saddle, Unloader 117 53140263 Spring Seat, Unloader 118 53140264 Compression Spring 119 53140295 Compression Spring 220 53140293 Inlet Valve Guide 221 53140294 Inlet Valve 222 53140298 Gasket, Air Strainer 223 53140389 Air Strainer Assembly (see page 2-173) REF.24 90802006 Hex Head Bolt 5/16-18x2-1/2 225 98415035 Lockwasher 5/16 226 53140300 Air Governor (see page 2-172) 127 53140297 Gasket, Air Governor 128 95670160 Pipe Plug 1/2 229 90003321 Crankshaft 130 90003308 Ball Bearing 131 90003300 Thrust Washer 132 90003301 Preformed Packing 133 90003297 Cover, Rear End 1

90003298 Cover, Body 190003299 Crankshaft Bearing 1

34 90804120 Hex Head Screw 7/16-14x3/4 435 98415045 Lockwasher 7/16 836 90003307 Gasket, Front End Cover 137 90003310 Cover, Front End 138 90804121 Hex Head Screw 7/16-14x7/8 439 90003309 Oil Seal 140 90003306 Connecting Rod Assembly 241 53140677 Hex Head Bolt 442 90003296 Lock Strap 443 90003304 Base Adapter 1

90003312 Piston and Wrist Pin Kit, Std. 144 292390 Wrist Pin, Std. 245 292386 Piston, Std. 246 90003313 Plug, Wrist Pin 447 90003314 Piston Ring Set, Std. 1

2-170

TM 9-2320-277-14&P


48 90003317 Gasket, Cover 149 53140286 Crankshaft Key 150 53140285 Hex Nut, Castle 151 ------ Discharge Fitting REF.52 90804104 Hex Head Screw 5/16-18x1-3/4 2

90003302 Sealing Ring 490003328 Service Parts Kit, Complete (includes items 5 through 8, AR

11 through 18, 20, 21, 27, and air strainer filter element)

2-171

TM 9-2320-277-14&P

AIR COMPRESSOR GOVERNOR53140300


1 240347 Cover 12 240345 Snap Ring 13 202961 Hex Nut 14 240344 Upper Spring Seat 15 240343 Spring 16 240341 Spring Seat 17 240342 Spring Guide 18 240341 Spring Seat 19 240340 Adjusting Screw 1

10 240339 Exhaust Stem 111 240338 Spring 112 240333 Washer 113 230175 Grommet 114 239658 Preformed Packing 215 240331 Piston 116 240334 Valve 117 240336 Spring 1

275230 Body Assembly 118 240346 Filter 219 240330 Body 1

2-172

TM 9-2320-277-14&P

AIR STRAINER53140389


1 53140699 Hex Head Screw 22 98415035 Lockwasher 5/16 2

53140389 Air Strainer Assembly 13 236733 Screw with Washer 24 236600 Cover 15 226491 Baffle 16 53140694 Filter Element 17 236733 Screw with Washer 68 236596 Base Plate 19 53140696 Gasket 1

10 226491 Baffle 111 236594 Body 1

2-173

TM 9-2320-277-14&P

ALCOHOL EVAPORATOR53506879

2-174

TM 9-2320-277-14&P


90002277 Alcohol Evaporator 11 238956 Plastic Container, 1 pint 12 243940 Gasket 13 243937 Evaporator Tube 14 239071 Preformed Packing 15 239139 Filter 16 242221 Welch Plug 17 242141 Body 18 243939 Filler Plug 19 217224 Tube Connector 1

10 90828137 Tube Connector 111 53506878 Copper Tubing 3/16x42 112 91603080 Elbow 1/8x90° 113 95205170 Close Nipple 114 53100570 Intake Adapter 115 53506880 Loom 1/4x39 116 95210295 Hex Nut 1/4-20 317 98415020 Lockwasher 1/4 318 90804018 Capscrew 1/4-20x1 319 53451331 Reservoir Decal 1

2-175

TM 9-2320-277-14&P

HOSE TENDER53109139


1 53109139 Hose Tender Kit 12 53116502 Hose Assembly, Protection 13 5350069 Dummy Coupling 2

2-176

TM 9-2320-277-14&P

BRAKE CONTROL PANEL90000990


1 114989 Nyloc Screw 8-32x7/8 12 114988 Nyloc Screw 8-32x3/8 13 114987 Nyloc Screw 6-32x3/8 1

90002339 Control Panel Knobs 14 110061 Red Knob 15 110062 Yellow Knob 16 110060 Green Knob 17 114848 Machine Screw 1/4-20x1/2 58 114760 Hex Head Bolt 1/4-28 UNF 29 104075 End Manifold 1

10 106839 Tractor Protection Valve 111 104067 Supply Manifold 112 106848 Spring Brake Valve 1

2-177

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Section XIII. WHEEL AND TIRES

WHEEL AND TIRE GROUP53506244


1 90002238 Wheel & Rim Assembly, 20 X 8.00V X 6.5 Dish Offset 790004160 Tire, Tube & Flap Assembly, 12.00 X 20 X 16 Ply, Load Range H 7

2 193423-200 Tube 13 123-340-988 Tire 14 - - - - Flap 1

2-178

TM 9-2320-277-14&P

Section XIV. STEERING

STEERING GROUP53506087

2-179

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1 53450116 Steering Wheel 12 53450114 Horn Button Kit 1

450143 Push Button and Plate 13 450098 Push Button 14 029037 Spring Seat 15 401286 Compression Spring 16 453088A4 Retainer 17 G148595 Screw, Self-Tapping 28 453087 Electrical Contact 19 G145067 Screw 2

10 53450843 Turn Signal Lever 153501319 Steering Column & Plug 1

11 90828300 Housing, Connector, 9-Pin 112 90828292 Pin, Connector 813 53501529 Steering Column 114 53141347 Wheel Nut 115 53141350 Directional Signal Switch Assembly 1

(Includes Emergency Flasher, Switch & Wire Assy.)16 - - - - Pan Head Screw #10-16 X 5/16 217 - - - - Hex Nut 3/8-24 (Not Shown) 118 - - - - Pan Head Screw #6-32 X 1/4 219 - - - - Roller Contact Assembly 120 53141354 Spacer 121 53141355 Spring Seat 222 53141356 Upper Bearing Assembly 123 - - - - Tube and Jacket Assembly 124 53141357 Pilot Light Housing 125 - - - - Pan Head Screw, Type B #4-24 X 3/8 226 53141360 Socket Assembly 1

2-180

TM 9-2320-277-14&P


27 53102172 Bulb, #53 128 53141357 Cover 129 53141361 Lower Bearing Assembly 130 53141362 Spring 131 53141363 Dust Cap 132 - - - - Steering Shaft 133 53500025 Upper Steering Bracket 234 92418004 Grommet 135 53500032 Clamp 136 53507742 Bracket 137 53505286 Steering Joint Assembly 138 90003682 Upper End Yoke 139 90003683 Journal and Bearing Kit 240 53509251 Sleeve Yoke 141 90003686 Dust Seal 142 90003685 Dust Seal Cap 143 90003687 Splined Yoke 144 90003688 Lower End Yoke 145 53509254 Sleeve Yoke Subassembly 1

(Contains 1 Ea. of Items 38 and 39)46 90003689 Splined Yoke Subassembly 1

(Contains 1 Ea. of Items 39,43, and 44) 147 92408022 Grease Fitting 148 90804500 Capscrew 249 95210485 Locknut 250 90702042 Rubber Boot 151 97135032 Lock Ring 152 53450038 Steering Gear Assembly (see page 2-182) 153 98421024 Lockwasher 154 95210170 Nut 155 53500358 Pitman Arm 156 53500482 Drag Link 157 53450041 Ball Socket (see page 2-185) REF58 53450043 Dust Cover 159 53450042 Ball Socket (see page 2-185) REF60 90838007 Dust Cover 161 90804513 Capscrew 3/4-10 X 1-3/4 162 90804409 Hex Head Screw 3/4-10 X 2-3/4 263 90804405 Hex Head Screw 3/4-10 X 1-3/4 164 98415060 Lockwasher 3/4 4

2-181

TM 9-2320-277-14&P

STEERING GEAR53450038

2-182

TM 9-2320-277-14&P


53450038 Steering Gear Assembly REF1 53451763 Seal, Input Shaft 12 53451764 Ring, Retaining 13 53451765 Washer, Seal Back-Up 14 53451766 Seal, Input Shaft 15 53451767 Bearing, Input Shaft Needle 16 95210442 Nut, Jam 5/16 17 90804090 Capscrew 3/8 X 3-1/4 48 98410025 Washer, Flat 3/8 49 53451768 Cover, Hydraulic Control Valve 1

10 53451769 Seal 211 53451770 Screw, Valve Adjusting 112 53451771 Back-Up Ring 213 53451772 O-Ring, Screw 214 53451773 Nut, Thrust Bearing Adjustment 115 53451774 Washer, External Tang 116 53451775 Washer, Internal Tang 117 53141776 Washer, Thrust Bearing Race (Heavy) 118 53451777 Bearing, Needle Thrust 219 53451778 Spacer, Needle Thrust Bearing 220 53451779 Washer, Thrust Bearing Race (Light) 221 53451780 Valve, Hydraulic Control 122 53451781 Seal, Hydraulic Cylinder Port 223 90804267 Capscrew 1/2 X 1-1/2 124 98410035 Flat Washer 1/2 125 53451783 Adapter, Control Valve 126 53451804 Seal, Control Valve Adapter 227 53451785 Washer, Seal Back-Up 128 53451786 Seal, Control Valve Adapter 129 53451787 Ring, Spiral Lock 130 53451788 Shaft, Input Worm & Follower 131 53451789 Washer, Lower Worm Shaft Seal Backup 132 53451790 Seal, Lower Worm Shaft 134 53451792 Washer Bronze 135 53451793 Washer, Lower Worm Shaft Retaining Ring 136 53451794 Ring, Retaining, Lower Worm Shaft 137 53451795 Seat, Pressure Unloader Valve 138 53451796 Lock Washer 139 53451797 Valve, Pressure Unloader 140 90001816 Performed Packing 141 53451800 Screw, Worm Follower Locking 142 53451801 Lockwasher 143 53451799 Rack, Piston 144 95210410 Nut, Jam, 3/4 145 53451819 Capscrew, Special 646 53451803 Cover, Housing Side 149 53451806 Washer, Seal Back-Up 150 53451807 Washer, Leather, Back-Up 251 53451808 Seal Assembly, Sector Shaft 252 53451809 Ring, Snap 153 53451810 Retainer, Sector Shaft Adjusting Screw 154 53451811 Screw, Sector Shaft Adjusting 1

2-183

TM 9-2320-277-14&P


55 53451812 Shaft Sector 156 98421024 Lock Washer, 1-1/2 157 53451802 Plug, Relief (Rubber) 158 53451820 Nut 160 95210390 Nut, Jam, 7/16 N.F. 161 53451814 Screw, Pressure Unloader Valve Adjusting 162 53451815 Ring, Retaining Sector Shaft Bearing 163 90001888 Seal, Adapter 164 90001887 Adapter, Sector Shaft Seal 165 53451821 Capscrew, Socket Head, 5/16 X 1" 466 53451818 Seal, Sector Shaft Dirt & Water 167 53451782 Seal, Cylinder Port 1

90001528 Seal Kit (Includes items 1, 4, 10, 12, 13, 15, 22, 27, 28, 32, AR42, 50, 51, 57 and 67).

2-184

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BALL SOCKETS5345004153450042

ITEM PART NUMBER PART NUMBER DESCRIPTION QTY.(1-3/4 Ball) (1-1/2 Ball)

53450041 53450042 Ball Socket REF.1 90001088 90001087 Ball Socket Plug 12 90001089 90001584 Spring 13 90001091 90001090 Ball Set 24 90001093 90001092 Grease Fitting 15 90831083 90831068 Cotter Pin 16 90001095 90001094 Body 17 90001096 - - - - Capscrew, 3/8-24x1-3/4 (Grade 8) 18 90001097 - - - - Locknut, 3/8-24 19 - - - - 90001098 Clamp Assembly 1

2-185

TM 9-2320-277-14&P

POWER STEERING HYDRAULICS


1 53506863 Hose 5/8 I.D. x60" 12 90812097 Clamp, Hose 43 48109540 Hose Assembly 14 53450038 Gear, Steering (see page 2-182) REF.5 53100303 Adapter, Union, 90° 16 90001600 Adapter, Elbow, 90° 17 96084009 Connector, Hose 18 53451685 Pump, Power Steering (see page 2-188) 19 90200045 Adapter, Union, 90° 1

10 96003918 Fitting, O-Ring 111 90001249 V-Belt, 1/2x69 212 53451640 Pulley, 2-Groove 113 53503989 Bracket, Pump 1

2-186

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14 98421130 Flat Washer 1/2 115 90002949 Locknut 1/2-20 116 53506864 Hose 5/8 I.D. x 20" 117 53506825 Filter Bracket 118 92001027 Filter Assembly (see page 2-190) 119 96084209 Hose Barb 90° 220 90709027 Reducer Bushing 3/4 to 3/8 221 90804016 Hex Head Screw 1/4-20x3/4 222 98415020 Lockwasher 1/4 223 98421150 Flat Washer 1/4 224 90000659 Ground Strap 14" 125 90804232 Hex Head Screw 7/16-14x1-1/4 426 98415045 Lockwasher 7/16 427 98421135 Flat Washer 7/16 4

2-187

TM 9-2320-277-14&P

POWER STEERING PUMP


1 109609 Wing Nut 12 294050 Lockwasher 13 233037 Flat Washer 14 314269 Reservoir Cover 15 291439 Gasket 16 280956 Stud 17 289283 Hex Nut 18 315934 Hex Head Screw 29 222029 Baffle 1

10 279804 Return Line Baffle 111 381948 Reinforcing Plate 112 294439 Reservoir 113 291667 Gasket 114 172376 Retaining Ring 115 1606 Shaft Key 1

2-188

TM 9-2320-277-14&P


16 250455 Shaft 117 148423 Bearing 118 193732 Retaining Ring 119 263585 Shaft Seal 120 375094 Plug 121 199390 Preformed Packing 122 232794 Control Valve 123 170072 Compression Spring 124 171523 Hex Head Screw 425 32559 Headless Pin 126 923951 Pump Body 127 222440 Bearing 128 174619 Preformed Packing 129 213998 Preformed Packing 1

923091 Cartridge Kit 130 922594 Vane Kit (includes 10 vanes) 131 213859 Rotor 132 296598 Ring 133 154364 Headless Pin 234 276396 Pressure Plate 135 245507 Compression Spring 136 377553 Cover Subassembly 1

992904 Seal Kit (includes items 5, 13, 19, 22, 28, and 29) AR

2-189

TM 9-2320-277-14&P

FILTER ASSEMBLY92001027


1 1545 Head Casting 12 1546 Bypass Valve 13 1550 Hex Nut, Self-Locking 14 1552 Bypass Guide 15 1548 Spacer, Bypass Valve 16 1547 Bypass Spring, 15 PSI 17 1549 Machine Screw, Fil. Head 18 53103500 Filter Element 1

2-190

TM 9-2320-277-14&P

Section XV. FRAME AND DECK

MAIN FRAME53506315


1 - - - - Mainframe (Not Serviced Separately) REF.2 535000027 Bearing, Spring 23 53506849 Radiator Grille Assembly 14 90804485 Capscrew 3/8-16x1-1/4 45 98415041 Lockwasher 3/8 46 98410026 Flat Washer 3/8 47 53506373 Rear Cab Guard 18 90804421 Hex Head Screw 3/4-10x2-1/2 89 98415060 Lockwasher 3/4 810 95210150 Hex Nut 3/4-10 811 90804345 Hex Head Screw 5/8-18 x 1-1/4 612 98415055 Lockwasher 5/8 613 90002240 Tow Shackle 2

2-191

TM 9-2320-277-14&P

BUMPER AND GRILL GUARD53506368


1 90002203 Pin Retainer 42 53506396 Pin 23 53506395 Pin 24 90002326 Capscrew 3/4-10x4-1/2 25 90002327 Capscrew 3/4-10x5-1/2 26 90002328 Hex Nut, Self-Locking 3/4-10 47 53506352 Grill Guard Assembly 18 95210141 Hex Nut 5/8-11 69 98415055 Lockwasher 5/8 6

2-192

TM 9-2320-277-14&P


10 90802064 Hex Head Screw 5/8-11 x1-3/4 611 90002240 Tow Shackle 212 95210141 Hex Nut 5/8-11 1613 98415055 Lockwasher 5/8 1614 90802064 Capscrew 5/8-11x1-3/4 1615 53506379 Bumper Assembly 1

2-193

TM 9-2320-277-14&P

CROSS TIE ASSEMBLY53503863


1 53503864 Cross Tie Assembly 12 90802036 Capscrew 1/2-13x2 83 53503866 Bracket Assembly 4-1/2° 24 53102297 Rubber Mount 25 98415050 Lockwasher 1/2 86 53102299 Snubbing Washer 27 90802070 Hex Head Bolt 7/8-14x4-1/2 28 95210228 Hex Nut, Self-Locking 7/8 29 90804160 Hex Head Bolt 410 90001478 Flexlock Nut 411 90804271 Hex Head Bolt 812 98421130 Flat Washer 813 95210230 Hex Nut, Self-Locking 1/2-13 8

2-194

TM 9-2320-277-14&P

MUD FLAP53504137


1 95210485 Self-Locking Hex Nut 3/8-16 82 90804185 Hex Head Screw 3/8-16 x 1 83 98421135 Flat Washer 3/8 84 92010034 Mud Flap 2

2-195

TM 9-2320-277-14&P

SPARE TIRE CARRIER53506477


1 99207001 Lug Nut, 3/4 RH Thread 22 98415060 Lockwasher 3/4 23 98421120 Flat Washer 3/4 24 99207001 Lug Nut, 3/4 RH Thread 25 90804383 Capscrew 5/8-11x4-1/4 26 95210312 Hex Nut, Self-Locking 5/8-11 27 53506481 Tire Sling 18 95210312 Hex Nut, Self-Locking 5/8-11 29 98421125 Flat Washer 5/8 410 53506506 Hanger 2

2-196

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DECK AND ENGINE ENCLOSURE53506323


1 53501578 Panel, Front Access 12 53506734 Rain Cap 13 99104012 Latch Assembly 24 92802011 Handle 15 53506761 Hood Assembly 16 90002814 Hinge 17 53501574 Panel, Front 18 53501230 Rubber Moulding 1/8x1x150 19 53501437 Bracket, LH Tail Light 110 53503354 Bracket, RH Tail Light 111 53500012 Reflector, Red 212 53506337 Platform, Rear Cab 113 53501357 Bracket, Light 214 - - - - Deck (not serviced separately) REF.

2-197

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ENGINE COMPARTMENT INSULATION53506516


1 53506518 Side Insulation 12 53506519 Top Insulation 13 53506520 Box Insulation 1

2-198

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SIDE STEP53500613


1 95210485 Hex Nut, Self-Locking 3/8-16 22 90804185 Capscrew 3/8-16x1 23 95210230 Hex Nut, Self-Locking 1/2-13 24 90001832 Capscrew 1/2-13x5 25 53500603 Side Step 1

2-199

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REAR PLATFORM53506939


1 95210295 Hex Nut 1/4-20 22 98415020 Lockwasher 1/4 23 90804016 Hex Head Screw 1/4-20X3/4 24 90002350 Toggle Clamp 15 53506855 Rear Platform 16 95210330 Hex Nut 3/8-16 27 98415042 Lockwasher 3/8 18 90697031 Eyebolt 3/8-16x1-1/2 1

2-200

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Section XVI. FIFTH WHEEL

FIFTH WHEEL GROUP53506291


1 95210295 Hex Nut 1/4-20 42 98415020 Lockwasher 1/4 43 90804016 Hex Head Screw 1/4-20 X 3/4 44 90002350 Toggle Clamp 25 53506854 Platform 16 53500299 Pin Retainer 27 53118805 Pivot Pin 28 95210125 Hex Nut 1/2-13 29 98415050 Lockwasher 1/2 210 90804301 Hex Head Screw 1/2-13 X 3-3/4 211 53022298 Pivot Pin, Cylinder 112 53125833 Spacer Pin 113 95210450 Hex Nut, Self-Locking 1-1/2-12 NF 114 98410065 Flat Washer 1-1/2 115 53502922 Journal Assembly 116 53500922 Tube, Spacer 117 53506290 Boom Assembly 118 92408022 Fitting, Lubrication 1/8 219 53506966 Fifth Wheel Assembly (see page 2-202) 1

90804495 Hex Head Screw 3/8-16 X 1-1/2 298415042 Lockwasher 3/8 253125834 Spacer 292408020 Fitting, Lubrication 1/8 X 90° 2

2-201

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FIFTH WHEEL ASSEMBLY53506966


90001160 Fifth Wheel Assembly 11 90000562 Fifth Wheel Plate Subassembly 12 53141419 Secondary Lock Subassembly 13 53141422 Torsion Spring 14 53141423 Drive Spring 15 53102522 Release Handle 16 53102507 Spring 1

2-202

TM 9-2320-277-14&P


7 98410035 Washer 1/2 38 53102503 Yoke Subassembly 19 53102508 Boss Yoke Stop 110 53102509 Spring, Yoke 111 53102523 Pin 112 53102525 Washer 113 53103050 Hex Head Bolt 5/8-18 X 1-3/4 114 53102524 Cam Roller 115 90804271 Hex Head Bolt 1/2-20 X 1-3/4 116 53102538 Cam Roller 117 95210490 Locknut 1/2-20 218 53102502 Cam Plate Subassembly 119 53102505 Air Filter 120 90804265 Hex Head Bolt 1/2 X 1-3/4 121 9510282 Hex Nut 1/2 122 53141107 Air Cylinder 123 90831050 Cotter Pin 1/8 X 1 124 90002333 Spring 125 53102519 Lockjaw Subassembly 1 set26 90831099 Pin, Cotter 1/4 X 2 227 53102521 Pin, Lockjaw 228 53103051 Roll Pin 3/8 X 3 229 53102536 Wheel Shaft 130 53102535 Bracket Subassembly 5/8-11 X 4 1 set31 90804382 Hex Head Bolt 2432 53102534 Mounting Plate Subassembly 133 98415055 Lockwasher 5/8 2434 95210141 Hex Nut 5/8-11 24

2-203

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Section XVII. FIFTH WHEEL HYDRAULICS

FIFTH WHEEL HYDRAULIC GROUP53506958


1 79100323 Hydraulic Cylinder (see page 2-210) 22 92818933 Hose Assembly, 3/4 I.D. X 52" 13 92821062 Hose Assembly, 1 I.D. X 72 14 90002075 Hose Assembly, 1/2 I.D. X 90 25 92818929 Hose Assembly, 1/2 I.D. X 24 2

Rev. G, 3-7-782-204

TM 9-2320-277-14&P


6 96081618 Fitting, Male Conn. 27 92818930 Hose Assembly, 1/2 I.D. X 24 18 53109280 Bulkhead Fitting, 3/8 29 92818931 Hose Assembly, 1/2 I.D. X 30 110 92819796 Hose Assembly, 1/2 I.D. X 40 111 96009280 Service Tee, 3/8" 312 95670135 Pipe Plug 113 96000622 Fitting, Elbow 90° 214 96000625 Fitting, Elbow 90° 115 90210007 Adapter, O-Ring, 90° 116 53103572 Valve, Control (see page 2-211) 117 95205306 Nipple 3/4 X 6 118 91604125 Street Elbow 119 92001027 Filter Assembly (see page 2-206) 120 95670019 Plug, Magnetic Drain 121 92001034 Oil Filler Assembly 1

3 Cap and Chain Assembly 15 Flange 18 Gasket 27 Screen 1

22 90802036 Capscrew 223 98415050 Lockwasher 1/2 424 95210125 Nut, Hex, 1/2-13 425 90804321 Capscrew 1/2-13 X 5 226 90200061 Adapter, Pipe-Hose 127 53500575 Power Take-Off (see page 2-207) 128 95690083 Hydraulic Pump (see page 2-209) 129 90804515 Capscrew 330 98415042 Lockwasher 331 95210330 Nut, Hex 332 90812057 Clamp, Hose #2 133 53500111 Lever, Hydraulic Control 134 53500882 Hydraulic Reservoir 135 53500913 Mounting Rubber 236 53506957 Spacer 237 53506779 Spacer, Bracket 238 96000515 Fitting, Elbow 90° 439 95210080 Nut, Hex, 5/16-18 140 98415035 Flatwasher, 5/16 141 90804467 Capscrew 242 96091420 Street Elbow 143 91604105 Street Elbow 90° 144 96091518 Street Elbow 45° 445 97415071 Service Tee 246 90001259 Velocity Fuse 247 90709245 Reducing Bushing 248 96091408 Street Elbow, 90° 249 90000821 Hose Assembly, 1/4 X 75 250 99106824 Bleeder Valve 251 90709340 Reducing Bushing 2

90812042 Clamp, 1/2 I.D. Hose 153113750 Bracket, Hose Clamp 1

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FILTER ASSEMBLY92001027


1 1545 Head Casting 12 1546 Bypass Valve 13 1550 Hex Nut, Self-Locking 14 1552 Bypass Guide 15 1548 Spacer, Bypass Valve 16 1547 Bypass Spring, 15 PSI 17 1549 Machine Screw, Fil. Head 18 53103500 Filter Element 19 92818933 Hose Assembly REF.10 95205306 Nipple REF.11 91604125 Street Elbow REF.

2-206

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POWER TAKE-OFF53500575


53500575 Power Take-Off REF.1 90804035 Screw, Hex Head 82 99103878 Bearing Cap Assembly 13 53140084 Gasket, Bearing Cap AR3 53140085 Gasket, Bearing Cap AR4 99103853 Gasket, Copper Bolt 55 99103854 Screw, Hex Head Cap 16 99103855 Case 17 99103856 Cup, Bearing 18 53140086 Cone, Output Bearing 19 53140092 Ring, Locking 210 53140089 Spacer 111 99103857 Gear, Output 112 99103858 Shaft, Output 113 53140093 Cone, Output Bearing 114 99103859 Flange Assembly 115 53140096 Seal, Output Shaft 116 99103860 Allan Capscrew 417 53103040 Screw, Hex Head 118 98415035 Lockwasher 119 53140149 Lever, Shift 1

2-207

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20 53140148 Washer, Flat 121 53140146 Cover, Shifter 122 53140099 Spring, Poppet 123 99103877 Pin, Poppet 124 53140147 Preformed Packing 125 53140097 Shifter Plate Assembly 126 53140088 Gasket 127 99103861 Screw, Socket Head Cap (Special) 128 99103862 Ring, Retaining 129 99103863 Stud 230 99103864 Stud 231 53140075 Gasket, Mounting, 0.010 Thick AR31 53140076 Gasket, Mounting, 0.020 Thick AR32 53103037 Screw, Set 133 95210085 Nut, Hex 434 95670076 Plug, Pipe 135 99103865 Washer, Thrust, 1-1/2 O.D. 136 99103866 Shaft, Idler (Pressure Lubricated) 137 99103867 Gear, Input Sliding 138 99103868 Needle Roller (Caged) 239 99103869 Gear, Driving 140 99103870 Spacer, Needle Roller 141 99103871 Washer, Thrust 142 53141128 Hose Assembly 143 99103879 Bearing Cup 1

90000954 Cable, PTO 190001924 Bracket, Cable 1

2-208

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HYDRAULIC PUMP95690083


95690083 Hydraulic Pump REF.1 53140966 Ring, Retaining 12 90001197 Seal 1

90000556 Wear Plate Assembly 13 53141857 Wear Plate 14 53141853 Preload Seal 15 53141854 Load Seal 16 53141855 Sealing Ring 17 90001194 Dowel Pin 28 53140973 Screw, Socket Head, 3/8-16 X 1-1/2 49 53141851 Washer 410 53141852 Washer 411 53140974 Screw, Socket Head 5/16-18 X 1-1/4 412 90001196 Body Assembly, RH 113 53140970 Bearing 214 53140975 Key, Shaft 115 90000560 Idler Gear Assembly 116 90000559 Drive Gear Assembly 117 90000557 Cover Assembly 1

90001195 Service Parts Kit (includes items 1 thru 6,9, 10, and 14) AR

2-209

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HYDRAULIC CYLINDER79100323


79100323 Hydraulic Cylinder REF.1 97100146 Rod Assembly 12 95210595 Hex Nut, Castle 43 79040353 Capscrew, Special 44 97205235 Set Screw 15 90430026 Nylon Ball, 3/16 16 79100319 Retaining Ring 17 79100320 Head 18 95210505 Hex Nut, Self-Locking 19 95410076 Piston Ring 210 95410075 Seal Ring 111 95410074 Preformed Packing 112 79100317 Piston 113 95410073 Preformed Packing 114 97135074 Washer, Back-Up 215 97140123 Preformed Packing 116 98430132 Seal, Rod Wiper 117 97140121 Preformed Packing 118 79100322 Tube Assembly 1

2-210

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HYDRAULIC VALVE53103572


53103572 Valve Assembly, Hydraulic REF.1 99207046 Rubber Bonnet 12 99207047 Stop Disk Snap Ring 13 99207048 Stop Disk 14 99207049 Spring Assembly Bolt 15 99207050 Center Spring Lockwasher 16 99207051 Stop Collar 17 99207052 Centering Spring 18 99207053 Stop Washer 19 99207054 Spool Seal 210 99207057 Check Plug 111 99207058 Preformed Packing 112 99207059 Check Poppet 113 - - - - Valve Body (not serviced separately) 114 53140150 Relief Valve Subassembly 115 - - - - Valve Spool (not serviced separately) 1

2-211

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Section XVIII. CAB

CAB53506380


1 90002324 Cab, Sheetmetal 12 53501315 Panel and Window Assembly 1

53501314 Rear Panel 153501311 Rear Window 1

3 53500122 Window Assembly, RH Sliding 14 99104107 Windshield, Glass 15 99104105 Window Assembly, LH 16 53500143 Window Moulding, 10' 17 92802011 Handle 18 53506439 Filler Panel, Shifter 1

90001981 Screw, Sheet Metal, #10x1/2 49 92804010 Headliner 210 53511356 Floor Mat 111 99104106 Door (see page 2-213) 1

53502672 Brace, Cab 190804031 Capscrew, 1/4-20x1-1/2 298421150 Flat Washer, 1/4 1095210280 Hex Nut, Self-Locking, 1/4-20 290002281 Mirror, Inside 197205028 Screw, Self-Tapping, #10-24x1/2 2

2-212

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CAB DOOR99104106


1 90001076 Door, Outside Panel 12 90001075 Door, Inside Panel 13 99103971 Lock, Door (Side Door) 14 99103975 Handle, Inside Door 1

53506269 Ignition and Door Lock Group REF.90002263 Switch, Ignition REF.

5 90002264 Door Handle Assembly 16 99103987 Regulator Assembly, Window 17 53140321 Handle and Parts, Window 18 - - - - Glass, Door REF.9 53501887 Arm Rest 110 90002334 Machine Screw, 1/4x3/4 NF 211 98415020 Lockwasher, 1/4 212 53501858 Plate, Mounting 113 99103988 Hinge 114 53450746 Stop, Door, Steel w/Detent 215 53450805 Bracket, Hinge 416 53452019 Pin, Headed 3/8x3 417 90000183 Angle, Latch Mounting 118 99101310 Catch, Door 119 - - - - Channel AR

2-213

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REAR WINDOW SCREEN53506640


1 53506573 Rear Window Screen 12 90002397 Hinge 6" 23 90001840 Self-Tapping Screw w/Washer 164 53506652 Wing Nut Bracket 25 95210572 Wing Nut 5/16-18 26 90001922 Flat Washer 5/16 27 98415034 Lockwasher 5/16 2

2-214

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SEAT53511294


1 90004564 Seat Assembly (see pages 2-216 and 2-218) 12 90804467 Capscrew, Hex Head, 3/8-16 x 1 1/4 43 95210311 Hex Nut, 3/8-16 44 98415041 Lockwasher, 3/8 45 98410026 Flat Washer, 3/8 46 53104880 Seat Belt Assembly 1

2-215

TM 9-2320-277-14&P

UPPER SEAT ASSEMBLY90004564

2-216

TM 9-2320-277-14&P


1 45643-046 Back Cushion Assembly 12 45643-007 Cover and Pad Kit 13 42626-013 Back Pan 14 351134-801 Capscrew, Hex Head 45 353034-801 Lock Washer 46 353043-801 Flat Washer 47 45644-012 Seat Cushion Assembly 18 45644-004 Cover and Pad Kit 19 42190-009 Seat Cushion Pan 110 46488-003 Spring 111 42185-004 Latch and Handle 112 359113-002 Roll Pin 113 42874-003 Plastic Knob 114 46406-011 Pivot Bracket RH 115 46406-012 Pivot Bracket, LH 116 46872-002 Bushing 217 46146-003 Cam 118 46809-007 Shaft Assembly 119 46562-002 Shaft 120 25989-801 Snap Ring 221 24427-801 Snap Ring 322 47012-006 End Plate Kit 123 47011-002 Spring 124 47010-003 Knob Assembly 125 49255-002 Shaft, Pivot 126 45153-005 Plate and Latch Assembly 127 45062-002 Spring 128 351177-801 Capscrew, Hex Head, 5/16-18 X 5/8 629 353034-801 Lock Washer, 5/16 630 353043-801 Flat Washer 631 45213-002 Roll Pin 132 44937-007 Latch Bar 133 43306-014 Roller Channel, RH 134 43306-015 Roller Channel, LH 135 31906-801 Edge Welt 236 349036-801 Machine Screw, 3/8-16 X 1/2 137 353086-002 Flat Washer 138 45486-006 Latch Assembly 139 32865-802 Spring 240 359103-002 Cotter Pin 241 350039-002 Hex Nut, 5/16-18 142 351152-801 Machine Screw, 5/16-18 X 5/8 143 47901-002 Spring 144 32998-801 Bumper, Rubber 145 45481-004 Roller and Bearing 4

2-217

TM 9-2320-277-14&P

SEAT SUSPENSION ASSEMBLY90004564


1 46417-003 Rear Bracket Assembly 12 23936-801 Hinge Pin 23 22526-801 Roll Pin 24 23567-811 Lower Arm Assembly 15 23784-801 Flanged Bearing 26 23783-801 Flanged Bearing 4

25595-808 Adjuster Stud Assembly 1

2-218

TM 9-2320-277-14&P


7 22525-801 Roll Pin 18 22453-802 Adjuster Pin 19 24129-801 Drive-Lock Pin 110 25594-801 Adjuster Stud 111 22525-801 Roll Pin 212 25595-809 Bracket 113 23188-808 Rubber Spring Assembly 114 23094-801 Flanged Bearing 115 23565-804 Upper Pivot Arm 116 22525-801 Roll Pin 117 23562-802 Center Pin 218 25706-806 Base 119 22705-801 Roll Pin 120 25834-806 Pivot Arm Assembly 121 25833-801 Flanged Bearing 122 25525-801 Roll Pin 123 25695-802 Tube 124 42326-002 Adjuster Stud 1

36918-004 Miter Gear Kit 125 - - - - Miter Gear 226 - - - - Roll Pin 227 23581-801 Thrust Washer 328 26084-801 Release Lever 129 351119-801 Hex Nut, 5/16-18 130 353024-801 Lock Washer, 5/16 131 26153-801 Shoulder Bolt 132 26085-801 Clevis Pin 133 22525-801 Roll Pin 134 26082-801 Pivot Lever Assembly 135 41905-003 Wear Plate 136 26343-801 Snap Ring 237 22879-801 Flanged Bearing 138 26299-802 Tension Spring 239 26228-803 Front Lower Pin 140 22525-801 Roll Pin 141 28841-804 Height Adjuster Handle 142 23840-802 Front Upper Pin 143 22525-801 Roll Pin 144 26443-810 Spring Support Bracket 145 26444-801 Rubber Bumper 146 351096-801 Capscrew, 3/8-16 X 1 (GR5) 147 22517-802 Pivot Bushing 148 22519-802 Insert 149 22518-801 Ball Bearing 150 353027-801 Flat Washer 251 350003-801 Hex Nut, 3/8-16 152 25700-802 Vertical Adjuster Bracket 153 350023-801 Lock Nut 154 23566-802 Upper Arm Assembly 155 23783-801 Flanged Bearing 456 23784-801 Flanged Bearing 257 26298-802 Selective Shock Absorber 158 26421-801 Rubber Spacer 159 353014-801 Flat Washer, 7/16 260 24128-801 Rubber Spacer 261 351113-801 Hex Nut, 3/8-24 NF 162 351097-801 Lock Nut, 3/8-24 NF 1

2-219

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ACOUSTICAL UPHOLSTERY


1 53506260 Moulding, Door Bottom 12 53506256 Moulding, Outer Door Edge 13 53506257 Moulding, Lower, Inner Door Edge 14 53506258 Moulding, Upper, Inner Door Edge 15 53506259 Moulding, Door Top 16 97205028 Screw, Self Tapping 67 53502570 Upholstery, Acoustical, Side Door 18 53506435 Moulding, Bottom, Rear Panel 19 53506437 Moulding, R. Side, Rear Panel 110 53506436 Moulding, L. Side, Rear Panel 111 53506434 Moulding, Top, Rear Panel 112 53506417 Upholstery, Acoustical, Rear Panel 113 53506432 Moulding, Front Console 114 90002269 Screw, Self Tapping 415 53506433 Moulding, Rear Console 116 90002269 Screw, Self Tapping 317 53506429 Upholstery, Acoustical, Console, Top 118 53506431 Moulding, Right Side Panel 119 97205028 Screw, Self Tapping 220 53506430 Upholstery, Acoustical, Right Side Panel 121 53506428 Upholstery, Acoustical, Console Side 122 92804010 Headliner REF.23 53511356 Mat, Floor REF.

2-220

TM 9-2320-277-14&P

IDENTIFICATION AND INSTRUCTION DECALS

Rev. C, 5-30-70

2-221

TM 9-2320-277-14&P


1 90002407 Decal, Identification 12 90002408 Decal, Identification 13 90002148 Decal, Instruction 14 90002404 Decal, Instruction 15 90002406 Decal, Identification 16 90002410 Decal, Identification 17 90000655 Decal, Instruction REF.8 90002256 Decal, Identification 19 94408069 Decal, Instruction 210 90001998 Decal, Identification 111 90002405 Decal, Identification 112 90002193 Decal, Identification 113 90004162 Decal, Instruction 114 90004419 Decal, Identification 115 90004418 Decal, Instruction (Towing Caution) 116 90004404 Decal, Instruction (Hearing Protection Caution) 117 90004478 Decal, Instruction (Fuel Tank Caution) 118 91201080 Decal, Instruction (5th Wheel Unlatch) REF.

90002383 Decal, Identification (Electrical Schematic) 1

2-222

TM 9-2320-277-14&P

Section XIX. CAB TILT HYDRAULICSCAB TILT HYDRAULICS


1 90000819 Hose Assembly, 25" 12 95210080 Hex Nut, 5/16-18 23 98415035 Lockwasher, 5/16 24 53101502 Clamp, 1/2 25 90000821 Hose Assembly, 75" 16 96091402 Elbow, High Pressure, 1/8x1/4 27 97415024 Service Tee, High Pressure, 1/4 18 95210295 Hex Nut, 1/4-20 49 98415020 Lockwasher, 1/4 410 90804019 Hex Head Screw, 1/4-20x1 411 90003107 Cab Tilt Pump (see page 2-225) 112 90000820 Hose Assembly 50" 1

2-223

TM 9-2320-277-14&P


13 95210420 Hex Nut, Self-Locking, 5/16-18 114 90802006 Hex Head Screw, 5/16-18x2-1/2 115 53501515 Cylinder Pin, Lower 116 95210485 Hex Nut, Self-Locking, 3/8-16 217 90804500 Hex Head Screw, 3/8-16x2 218 53501232 Cylinder Pin, Upper 119 53500464 Cab Tilt Cylinder (see page 2-227) 120 53505305 Pin, Safety Bar 121 53501361 Safety Bar 122 96091756 Pipe Tee, High Pressure, 1/4 123 96091102 Adapter, Male, 1/8x1/4 124 95210485 Hex Nut, Self-Locking, 3/8-16 825 98421135 Flat Washer 3/8 826 90804182 Hex Head Screw, 3/8-16x1-1/2 827 90804485 Hex Head Screw, 3/8-16x1-1/4 428 98415042 Lockwasher, 3/8 429 53503050 Block Assembly 230 90000785 Latch, Hydraulic 231 95210485 Hex Nut, Self-Locking, 3/8-16 832 98421135 Flat Washer, 3/8 833 90804485 Hex Head Screw, 3/8-16x1-1/4 834 53508003 Bracket, Hold Down 235 92408022 Fitting, Lubrication 1/8 236 95210215 Hex Nut, Self-Locking 437 53508962 Pivot Pin, Cab Tilt 238 53502619 Washer, Special 239 98421125 Flat Washer 240 97430033 Rubber Mount 2

2-224

TM 9-2320-277-14&P

CAB TILT PUMP

2-225

TM 9-2320-277-14&P

ITEM PART NUMBER DESCRIPTION QTY.90003107 Hydraulic Pump Assembly REF.

1 90003545 Capscrew 42 90003544 Reservoir 13 - - - - Preformed Packing 14 90003557 Screen 15 90003556 Retaining Ring 16 90003554 Outlet Seat 17 90003553 Flow Control Assembly 18 90003559 Relief Valve 19 - - - - Gasket 110 90003558 Inlet Seat 111 90003564 Retaining Ring 112 90003565 Screen 113 - - - - Pin 114 90003562 Plug 115 90003563 Lock Screw 116 90003551 Spring 117 90003550 Ball, 7/32 118 - - - - Set Screw 119 - - - - Handle 120 - - - - Seal 121 - - - - Preformed Packing 122 - - - - Spindle 123 90003560 Pipe Plug 124 90003548 Vent Fitting 125 90003547 Filler Plug 1

90003555 Beam and Link Kit 126 - - - - Cotter Pin 627 - - - - Washer 628 - - - - Piston Pin 129 - - - - Link Pin 130 - - - - Beam Link Pin 131 - - - - Spring Washer 332 - - - - Beam 133 - - - - Link 1

90003561 Pump Assembly Kit 134 - - - - Plunger 135 - - - - Seal 136 - - - - Back-Up Ring 137 - - - - Quad Ring 138 - - - - Pump Cylinder 139 - - - - Preformed Packing 140 90003546 Pump Body 1

90003549 Spindle Assembly Kit (Includes Items 13, 18, 19, 21 and 22) AR90003552 Seal and Packing Kit (Includes Items 3, 9, 20, 21, 35, 36, 37 and 39) AR

2-226

TM 9-2320-277-14&P

CAB TILT CYLINDER


53500464 Cab Tilt Cylinder REF1 53500093 Fuse, Velocity 12 90709245 Bushing, Reducing 3/8x1/4 13 53141486 Gland Nut 14 * Wiper 15 * Packing 16 * Adapter 17 * Retaining Ring 18 - - - - Plunger (not serviced separately) 19 53141488 Lock Ring 110 53141490 Snap Ring 111 - - - - Housing (not serviced separately) 1

53141485 Service Parts Kit (includes items 4 thru 7) AR

2-227

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Section XX. ACCESSORIESSUN VISOR


1 53502832 Sun Visor Kit 12 97205129 Screw, #10-24x3/4 13 95210657 Nut, #10-24 14 98415015 Lockwasher, #10 15 53502804 Plate, Lock Out 26 97205028 Screw, Self Tapping, #10-24x1/2 4

2-228

TM 9-2320-277-14&P

WINDSHIELD WIPER GROUP


1 99800420 Copper Tubing 3/16 O.D. AR2 90828137 Male Connector 43 90804016 Hex Head Screw 1/4-20x3/4 24 98415021 Lockwasher 1/4 25 95210295 Hex Nut 1/4-20 26 92002008 Tubing Nut 4

53500072 Windshield Wiper Kit 17 53500163 Wiper Arm (19") 18 53108202 Wiper Blade 1

53500162 Wiper Motor Assembly 19 VH-23731-2 Motor Assembly 110 F-1494-7 Plate and Bushing Assembly 111 F-3-16J Spacing Collar (not illustrated) 212 1771-24J Flat Head Screw #12-24 213 86246 Gasket 114 86238-NS Spacer and Pivot 115 1851-20NS Round Head Screw #10-32 216 86197-1J Hex Nut 9/16-24 UNF 1

2-229

TM 9-2320-277-14&P


17 C6161 Rain Shield 118 86324-J Knurled Driver 119 75072-NS Idler Arm Nut 120 2397-7J Lockwasher 3/8 121 75026 Drive Arm Nut 3/8-24 UNF 1

53141169 Control Valve Assembly 122 F-1680-2 Valve Assembly 123 2397-10J Lockwasher 9/16 124 F-1343 Hex Nut 9/16-24 UNF 125 82415-15NS Knob and Set Screw 1

2-230

TM 9-2320-277-14&P

WINDSHIELD WASHER

2-231

TM 9-2320-277-14&P


1 95210010 Hex Nut, #10-32 32 98415015 Lockwasher, #10 33 97205132 Screw, Round Head, #10-32x1/2 34 95210080 Hex Nut, 5/16-18 25 98415035 Lockwasher, 5/16 26 98421145 Flat Washer, 5/16 27 90804035 Hex Head Screw, 5/16-18x1 28 53506839 Bracket 1

53108203 Windshield Washer Kit 19 81846-156 Hose 156"10 78778-58NS Nozzle 211 88752-2 Knob 112 86197-1J Hex Nut 113 89515-6 Button, Air Pressure 1

87900-54J Reservoir Kit 114 78364-81 Bracket 115 828954 Reservoir 116 88841-20 Cover Assembly 117 81848-8-1/2 Hose 8-1/2"18 87883 Filter 119 81087-5 Hose Tee 1

2-232

TM 9-2320-277-14&P

PAPER COMPARTMENT INSTALLATION


1 53502634 Pocket, Form 12 53502635 Bracket, Pump Handle 13 90804011 Capscrew, Hex Head, 1/4-20x1/2 44 98415020 Lockwasher, 1/4 45 95210295 Hex, Nut 1/4-20 46 53506894 Bracket, Form Pocket (not shown) 17 90804039 Capscrew, Hex Head, 5/16-18x1-1/4 28 98415035 Lockwasher, 5/16 29 95210080 Hex, Nut, 5/16-18 2

2-233

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REFLECTIVE SAFETY GROUP


1 95210080 Hex Nut 5/16-18 22 98415035 Lockwasher 5/16 23 98421145 Flat Washer 5/16 24 90804103 Hex Head Screw 5/16-18x1-1/2 25 90002249 Reflective Triangle Set 16 90002250 Triangle Bracket 1

2-234

TM 9-2320-277-14&P

MIRROR GROUP

2-235

TM 9-2320-277-14&P

ITEM PART NUMBER DESCRIPTION QTY

1 90804017 Hex Head Screw, 1/4-20x3/4 42 95210296 Hex Nut, 1/4-20 43 98415021 Lockwasher, 1/4 84 90804033 Hex Head Screw, 1/4-20x2 4

90003200 Mirror Kit 25 90003205 Mirror Head 16 53507756 Bracket 17 99101448 Support Arm 18 95210125 Hex Nut, 1/2-13 39 98415050 Lockwasher, 1/2 310 90804304 Hex Head Screw 1/2-13x4 311 53502172 Mirror Support 1

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HEATER AND DEFROSTER

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1 90000264 Heater (see page 2-239) 12 90000265 Defroster (see page 2-241) 14 90000532 Heater Switch - 2 Speed REF.5 90000533 Defroster Switch REF.6 53500161 Heater Cable 17 99100215 Defroster Vent 28 99100216 Defroster Bracket 2

90000598 Screw, Self-Tapping, #8-18x3/8 29 99100217 Defroster Hose 42" 110 99100218 Defroster Hose 30" 111 53450837 Shut-Off Valve 112 90000266 Hose Adapter 113 99100213 90° Elbow 214 90000598 Self-Tapping Screw 8-32x3/8 415 99802052 Heater Hose 5/8 ID 12'16 90812097 Hose Clamp 1-1/4 ID. 617 96084209 90° Barb Hose Stem 5/8 ID. x 3/8 NPT 218 90709027 Reducing Bushing 3/4 to 3/8 NPT 119 97415146 Service Tee 3/4 NPT 120 53502574 Adapter Assembly - Fresh Air Vent 121 90000597 Self-Tapping Screw 6-32x3/8 422 98410062 Flatwasher 1/8 223 53502576 Damper Assembly - Fresh Air Vent 124 90000631 Cable Clip 125 90000630 Control Cable - Fresh Air Vent 126 97205021 Self-Tapping Screw 1/4-20x3/8 327 90000628 Hose 4" dia. x 48" 428 90000629 Hose Clamp 4" 229 90000626 Hose Ring Adapter 4" 130 90000627 Gasket Material 4" 131 53502563 Cover - Fresh Air Vent 132 90804024 Hex Hd. Bolt 1/4-20x1-1/4 433 95210295 Hex Nut 1/4-20 434 53502560 Vent Screen 1

90000865 Auxiliary Heater Kit (see page 2-242) 1

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HEATER ASSEMBLY

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1 HV210472 Shell Assembly 12 HV029118 Heater Core 13 HV210596 Collar, 2" 24 HV210476 Shroud Plate 15 HV029783 Fan Blade 16 HV022943 Motor Bracket 17 GM120622 Hex Nut #8-32 28 GM178378 Lockwasher 29 GM446152 Flat Washer 110 HV026848 Screw 211 HV020658 Connector 112 HV205436 Lead Wire 113 HV210475 Motor, 12 VDC 114 HV210474 Front Cover 115 SP00868 Screw 1616 GM120614 Hex Nut 217 90000532 Switch, 2 Speed 118 HV010667 Hex Nut 119 HV020565 Knob 120 HV22341 Nipple, Adapter, 5/8 I.D. Hose 2

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DEFROSTER ASSEMBLY


1 HV210484 Blower Housing 12 HV20331 Blower Cage 13 HV18106 Plate 14 HV210475 Motor, 12 VDC 15 SP1868 Screw 36 GM178373 Lockwasher #10 27 GM120622 Hex Nut #8-32 28 HV22947 Cover 29 HV20658 Connector 110 HV205436 Lead Wire 111 90000533 Switch 112 SP1868 Screw 6

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AUXILIARY HEATER


1 90001658 Hose Clamp 42 90001664 Shut-Off Valve 13 90001660 Pipe Connector 14 90001667 Heater Hose 25 60547-G1 Screw 26 90001665 Fan Guard 17 90001662 Fan Assembly 18 42-0832-13 Hex Nut 29 90001651 Electric Motor, 12V 110 90001652 Gasket 111 41-1224-13 Hex Nut 212 90001654 Deflector 213 90001657 Cover Plate 114 90001666 Top Assembly 115 90001661 Core Assembly 116 90001655 Wire Assembly 117 90001659 Wire Assembly 118 90001663 Wire Nut 1

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AIR HORN


1 95210080 Hex Nut 5/16-18 12 98415035 Lockwasher 5/16 13 90804035 Hex Head Screw 5/16-18x1 1

92817012 Air Horn Kit 1228278 Air Horn 1

4 204781 Hex Nut 15 201777 Lockwasher 16 231436 Flat Washer 17 231435 Gasket 18 230081 Screen 2

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9 99103894 Long Bell 110 99103959 Short Bell 111 244095 Hex Nut 212 53100532 Air Valve 113 94415046 Repair Link 114 99803039 Chain, #2 3'15 98828099 Tubing Connector 116 97415065 Pipe Tee 117 99802339 Air Line, 1/4 O.D. 7'18 91603036 Elbow Connector 90° 1

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CHAPTER 3

MANUFACTURER'S CODE LIST ANDALPHA-NUMERIC CROSS-REFERENCE INDEX

Section I. MANUFACTURER'SCODE LIST

3-1. DESCRIPTION.

a The following code-to-name list defines all FederalManufacturer's Code (FSCM) numbers that appear inthe Numerical Index. The FSCM is a five-digit numeric

CODE NAME AND ADDRESS

00410 Bostwick Braun Co.PO Box 912Toledo, OH 43601

00624 Aeroquip Corp.,Aeroquip Aerospace Div.300 S. East Ave.Jackson, MI 49203

01652 Riker Mfg. Co.4901 Stickney Ave.Toledo, OH 43612

02249 Gresen Mfg. Co.600 Hoover St. N.E.Minneapolis, MN 55413

04618 AMP Special IndustriesDiv. of AMP Products Corp.PO Box 1776Paoli, PA 19301

06383 Panduit Corp.17301 RidgelandTinley Park, IL 60477

06651 McCay Tool and Engineering Co. Inc.1449 W. Lark Industrial ParkFenton, MO 63026

06853 Bendix CorporationThe Bendix Heavy Vehicle Group901 Cleveland StreetElyria, OH 44035

06970 Cablecraft Inc.2011 PO Box Mildred St. WestTacoma, WA 98411

code listed in SB 708-42 which is used to identify themanufacture, distribution, or Government

b. The Manufacturer’s Code is arranged in numericalsequence of the code number, and in accordance withthe information In Cataloging Handbooks H 4-1/4-2/4-3,Federal Supply Code for Manufacturers. Eachmanufacturer's name and mailing address is included.


08108 Lamp Industry for use with industrydesignations and abbreviations for lamps

09386 The Budd Co.12141 CharlevoixDetroit, Ml 48215

10051 Leland Div. of Maremont Corp.168 N. Michigan Ave.Chicago, IL 60601

10125 Sealco Air Brakes Inc.13530 E. NelsonCity of Industry, CA 91746

11331 Williams Air Controls DivisionThe Weatherhead Co.14100 S.W. 72nd StreetPortland, OR 97223

13445 Cole-Hersee Co.20 Old Colony Ave.Boston, MA 02127

13548 Truck-Lite Co. Inc.PO Box 387Jamestown, NY 14701

13556 TRW Cinch Manufacturing Co.was Cinch Jones1015 S. Sixth St.Minneapolis, MN 55415

15434 Cummins Engine Co.1000 Fifth St.Columbus, IN 47201

16764 Delco-Remy Div. General Motors Corp.2401 Columbus Ave.Anderson, IN 46011

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18265 Donaldson Co. Inc.8265 Donaldson Co. Inc.PO Box 1299Minneapolis, MN 55440

21102 Evans Products Co.Automotive Div.701 Ann St. N.W.Grand Rapids, MI 49504

23040 Ford Parts and Service Div.Ford Motor Co. Government Parts Sales29500 Plymouth Rd.PO Box 3000Livonia, MI 48151

24161 Gates Rubber Co.999 South BroadwayDenver, CO 80217

26151 Stemco Mfg. Co. Inc.PO Box 1989Longview, TX 75601

26953 Power-Packer Div.of Applied Power Inc.16901 Glendale DriveNew Berlin, WI 53151

26992 Hamilton Watch Co. Inc.941 Wheatland Ave.Lancaster, PA 17604

30780 Parker-Hannifin Corp.Tube Fittings Div.17325 Euclid Ave.Cleveland, OH 44112

31033 TRW Inc. Replacement Div.8001 E. Pleasant Valley RoadCleveland, OH 44131

31509 PSI Mobile Products Inc.14000 HoveyWarren, MI 48089

32705 Sperry Vickers Mobile Div.Sperry Rand Corp.Crook and Maple RoadTroy, MI 48084

33955 Teleflex Inc.Electrical Systems Div.1816-57th StreetSarasota, FL 33580

39428 McMaster Carr Supply Co.2828 N. Paulina Ave.PO Box 4355Chicago, IL 60680


41625 Morse ControlsDiv. of Incom International Inc.21 Clinton St.Hudson, OH 44236

43334 New Departure-Hyatt Bearings Div.General Motors Corp.2509 Hayes AvenueSandusky, OH 44870

46529 Perfex Group McQuay-Perfex Inc.500 W. Oklahoma Ave.Milwaukee, WI 53207

46552 Hupp Inc.-Mobile Products Div.1135 Ivanhoe Rd.Cleveland, OH 44110

51377 Kysor of CadillacDiv. Kysor Industrial Corp.1100 Wright StreetCadillac, MI 49601

52179 Autac Inc.PO Box 1302New Haven, CT 06505

53591 Schwitzer Engineered Components Div.Wallace-Murray Corp.1125 Brookside Ave.PO Box 80-BIndianapolis, IN 46206

56933 Rockwell InternationalAutomotive Operations Spring Division2135 W. Maple RoadTroy, MI 48084

57733 Stewart-Warner Corp.1826 Diversey ParkwayChicago, IL 60614

59730 Thomas and Betts Div.Thomas and Betts Corp.920 Route 202Raritan, NJ 08869

60380 Torrington Co., The Bearings Div.Subsidiary of Ingersoll-Rand Corp.59 Field StreetTorrington, CT 06790

60703 Trico Products Corp.817 Washington StreetBuffalo, NY 14203

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CODE NAME AND ADDRESS61112 Turner Co.

Div. of Cleanweld Products Co.821 Park AvenueSycamore, IL 60178

64294 Webster Electric Co., Inc.Fluid Power Division1900 Clark StreetRacine, WI 53403

66295 Wlttek Mfg., A Microdot Co.1421 Barnsdale RoadLaGrange Park, IL 60525

70040 AC Spark PlugDlv. of General Motors Corp.1300 N. Dort HighwayFlint, MI 48556

70485 Atlantic India Rubber Works Inc.571 Polk StreetChicago, IL 60607

71044 Bostrom Div. UOP Inc.133 W. Oregon StreetMilwaukee, WI 53204

71913 De-Sta-Co Corp.350 Midland Ave.Detroit, MI 48203

71951 Doray Lamp Co., Inc1466 S. MichiganChicago, IL 60605

72582 Detroit Diesel AllisonDiv. of General Motors Corp.13400 W. Outer DriveDetroit, MI 48228

72635 R.E. Dietz Co.225 Wilkinson St.PO Box 1214Syracuse, NY 13201

73342 Detroit Diesel AllisonDiv. of General Motors Corp.PO Box 894 E7Indianapolis, IN 46206

73842 Goodyear Tire and Rubber Co.1144 E. MarketAkron, OH 44316

74410 Holland Hitch Co.430 W. 18th StreetHolland, MI 49423

CODE NAME AND ADDRESS74687 Huntington Rubber Co.

Div. of New Idria Inc.030 S.W. MacadamPortland, OR 97219

75175 K-D Lamp Co.1910 Elm StreetCincinnati, OH 45210

75272 KMC StampingsDiv. of Kickhaefer Mfg. Co.1221 S. Park StreetPort Washington, WI 53074

76005 Lord KinematicsLord Corp.1635 West 12th StreetPO Box 2051Erie, PA 16512

76385 Minor Rubber Co. Inc.49 Ackerman StreetBloomfield, NJ 07003

76761 C.E. Niehoff and Co.4925 WV. Lawrence Ave.Chicago, IL 60630

77132 Dot Div. A United-Carr Div. of TRW Inc.250 Knotter RoadPO Box 767Cheshire, CT 06410

77640 TRW Inc. Ross Gear Div.800 Heath StreetLafayette, IN 47902

77915 Sheller-Globe Corp. Portland Div.S Bridge StreetPortland, IN 47371

77977 Signal-Stat Corp.1200 Commerce Ave.Union, NJ 11211

78500 Rockwell International AutomotiveOperations Government Sales2135 W. Maple RoadTroy, Ml 48084

79470 The Weatherhead Co.300 East 131st StreetCleveland, OH 44108

80201 CR IndustriesChicago Rawhide Mfg. Co.900 N. State StreetElgin, IL 60120

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80535 Campbell Chain Co.3990 E. Market StreetYork, PA 17402

81486 Special Products Co.Silver Spring, MD

82271 I-T-E Imperial Corp.Subsidiary of Gould Inc.Fluid Components Div.was Waterman6565 Howard StreetChicago, IL 60648

82795 Ohio National Inc.Upper Sandusky, OH

85757 Samuel Moore and Co.Main and OrchardMantua, OH 44255

90915 Gulf and Western Mfg. Co.Ottawa Truck Div.415 Dundee StreetOttawa, KS 66067

92850 Anchor Industries Inc.1725 London RoadCleveland, OH 44112

94808 Phillips Mfg. Co.7869 Paramount Blvd.Pico Rivera, CA 90660

95019 Dana Corp. Spicer Transmission Dlv.4100 Bennett RoadPO Box 986Toledo, OH 43601

95993 Crenlo Div. of GF Business Equipment Inc.1600 Fourth Ave. N.W.Rochester, MN 55901


97576 The Lenz Company3301 Klepinger RoadPO Box 1044Dayton, OH 45401

98076 Lear Siegler Inc. AnchorlokTransportation Support Center11135 Condor Ave.Fountain Valley, CA 92708

98343 The Berg Mfg. Co.2702 N. State StreetIola, KS 66749

98440 Snyder Tank Corp.S-3774 Lake Shore Rd.PO Box 1914Buffalo, NY 14219

98441 Stratoflex Inc.220 Roberts Cut-offPO Box 10398Fort Worth, TX 76114

99739 Hanna Rubber Co Inc.1512 MainKansas City, MO 64108

96906 Military Standards Promulguted byMilitary Departments Under Authorityof Defense StandardizationManual 4120 3-M

97484 Technical Development Co.24 E. Glenolden Ave.Glenolden, PA 19036

3-4

TM 9-2320-277-14&PSection II. ALPHA-NUMERICCROSS-REFERENCE INDEX

3-2. DESCRIPTION.

The numerical index is a complete alpha-numericaltabulation of all part numbers contained in the parts list.The prime contractor part numbers are cross-referencedto vendor part numbers where applicable.

3-3. PART NUMBER COLUMN.

The part number column is arranged according to thealpha-numerical part number filing sequence describedbelow.

a. Part number numerical arrangement starts withthe left hand digit or alphabetical letter and continuesfrom left to right, one space or character at a time, untilthe part number numerical arrangement is determined.

The order of precedence in beginning the part numberarrangement is as follows:

Letters A through Z (alphabetical O's are considered asnumerical zeros).Numerals 0 through 9.

b. The order of precedence in continuing partnumber arrangement in the second and succeedingportions of the part number is as follows' Space (blank)

Diagonal (slant / )Point (period)Dash ( - )

Letters A through Z (alphabetical O's are considered asnumerical zeros.) Numerals 0 through 9.

3-5

TM 9-2320-277-14&P

MFR VENDOR VENDOR MFR VENDOR VENDORPART NO. PAGE/ITEM CODE PART NO. CODE PART NO. PAGE/ITEM CODE PART NO. CODE

A-3780-122 2-138-7 78500 MS35338-10 2-76-11 96906A014150 2-68-8 46529 MS35338-10 2-76-5 96906A023375 2-68-16 46529 MS35338-45 2-160-3 90915A032050 2-68-20 46529 MS35338-46 2-12-28 96906A042050 2-68-19 46529 MS35338-46 2-16-6 96906A2-3780-62 2-138-4 78500 MS35338-46 2-18-27 96906A28-1779-230 2-138-6 78500 MS35338-46 2-40-2 96906B-107 2-119-1 60380 9418483 73342 MS35338-46 2-89 96906BU1012L-15 2-119-9 43334 7451990 73342 MS35338-7 2-168-19 96906C6161 2-230-17 60703 MS35338-7 2-20-3 96906F-1343 2-230-24 60703 MS35338-7 2-21-8 96906F-1494-7 2-229-10 60703 MS35338-7 2-22-6 96906F-1680-2 2-230-22 60703 MS35338-7 2-3-3 96906F-3-16J 2-229-11 60703 MS35338-7 2-44-6 96906FA40001 2-123-16 60380 9428135 73342 MS35338-7 7-45-19 96906FA40422 2-109-18 60380 9432024 73342 MS35338-7 2-45-40 96906FA40422 2-109-26 60380 9432024 73342 MS35338-7 2-46-6 96906FA45495 2-115-23 60380 9432513 73342 MS35338-7 2-89-14 96006FA45518 2-123-25 60380 9432554 73342 MS35338-8 2-11-12 96906FB29009 2-123-21 60380 9417499 73342 MS35338-8 2-15-5 96906FB47885 2-115-37 60380 9434057 73342 MS35338-8 2-168-11 96906FG42643 2-107-23 60380 9432169 73342 MS35338-8 2-168-22 96906FG42643 2-111 60380 9432169 73342 MS35338-8 2-22-8 96906G-389 2-127-4 70040 MS35338-8 2-25-6 96906G-389 2-49-4 70040 MS35338-8 2-28-14 96906GF-273 2-127-8 70040 MS35338-8 2-28-8 96906GF-273 2-49-8 70040 MS35338-8 2-32-16 96906GM120614 2-240-16 21102 MS35338-8 2-4-22 96906GM120622 2-240-7 21102 MS35338-8 2-45-12 96906GM120622 2-241-7 21102 MS35338-8 2-45-23 96906GM178373 2-241-6 21102 MS35338-8 2-45-26 96906GM178378 2-240-8 2110? MS35338-8 2-45-32 96906GM446152 2-240-9 21102 MS35338-8 2-6-14 96906G002004 2-68-12 46529 MS35338-8 2-76-16 96906G002004 2-68-2 46529 MS35338-8 2-76-2 96906G002009 2-68-13 46529 MS35338-8 2-8-7 96906G002009 2-68-3 46529 MS35756-34 2-15-10 96906G002015 2-68-6 46529 MS35756-35 2-10-15 96906G002023 2-68-1 46529 MS75020-2 2-74 96906G002023 2-68-15 46529 MS75021-2 2-74-10 96906G002032 2-68-14 46529 MS90725-33 2-160-4 90915G002038 2-68-4 46529 MS90725-62 2-16-5 96906G002039 2-68-5 46529 MS90725-84 2-11-6 96906G110729 2-68-7 46529 MS90726-58 2-15-2 96906G145067 2-190-9 77640 MS90728-60 2-15-12 96906G148595 2-180-7 77640 MS90728-62 2-168-18 96906G301565 2-68-22 46529 MS90728-8 2-32-4 96906G305450 2-68-10 46529 NP-35 2-138-1 78500G307160 2-69-11 46529 OF-271 2-127-10 70040G307160 2-68-17 46529 OF-271 2-49-10 70040HV010667 2-240-18 21102 OF-277 2-127-3 70040HV020565 2-240-19 21102 OF-272 2-49-3 70040HV020658 2-240-11 21102 OF-274 2-127-9 70040HV022943 2-240-6 21102 OF-274 2-49-9 70040HV026848 2-240-10 21102 OF-275 2-127 70040HV029118 2-240-2 21102 OF-275 2-49-2 70040HV029783 2-240-5 21102 OF-276 2-127-1 70040HV18106 2-241-3 21102 OF-276 2-49-1 70040HV20331 2-241-2 21102 OF-277 2-127-7 70040HV205436 2-240-12 21102 OF-277 2-49-7 70040HV205436 2-241-10 21102 OF-278 2-127-2 70040HV20658 2-241-9 21102 OF-278 2-49 70040HV210472 2-240-1 21102 P01-7336 2-52-8 18265HV210474 2-240-14 21102 P10-0089 2-53-2 18265HV210475 2-240-11 21102 P10-0789 2-52-2 18265HV210475 2-241-4 21102 P10-3198 2-52-1 18265HV210476 2-240-4 21102 P10-6617 2-52-5 18265HV210484 2-241-1 21102 P10-6952 2-52-3 18265HV210596 2-240-3 21102 P11-1852 2-52-4 18265HV22341 2-240-20 21102 QA-5-57C 2-57-14 61112HV22947 2-241-8 21102 QL-1 2-57-9 61112JFA40001 2-123-15 60380 9428137 73342 QS-4-3TC 2-57-10 61112JF45496 2-115-24 60380 9432512 73342 RBX00-2252 2-53-1 18265JK46991 2-123-17 60380 9433344 73342 S-259-1 2-135-14 78500LP-2299 2-57-11 61112 SP1868 2-240-15 21102LP-3239-60 2-57-12 61112 SP1868 2-241-12 21102LP-482-1 2-57-13 61112 SP1868 2-241-5 21102LP-535 2-57-8 61112 T-182 2-135-11 78500MS15795-14 2-16-1 96906 T02554B 2-68-21 46529MS15795-14 2-23-11 96906 VH-23731-2 2-229-9 60703MS15795-14 2-28-15 96906 XB-22386 2-119-23 43334 908215 73342MS15795-14 2-28-9 96906 XM878 90915MS15795-14 2-3-7 96906 0-15-725 2-138-2 78500MS15795-14 2-46-2 96906 029037 2-180-4 77640MS35338-10 2-11-24 96906 1002-04870 2-83-8 51377* See auxiliary list on page 3-27.3-6

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TM 9-2320-277-14&P


1003-33040-01 2-83-11 51377 122161 2-35-40 72582102635 2-168-10 72582 122161 2-36-64 72582102637 2-76-10 72582 122366 2-19-4 72582102637 2-76-4 72582 122408 2-11-18 729821030-35970 2-83-10 51377 1225D836 2-134-7 78500103322 2-168-14 72582 1227Z780 2-135-12 78500103322 2-26-3 72582 1229F1669 2-135-15 78900103322 2-26-7 72582 123-340-988 2-178-3 73842103322 2-69-13 72582 1255 2-91-2 13445103322 2-69-16 72582 127855 2-29-1 72582103322 2-70-31 72582 137408 2-21-2 72582103325 2-80-45 72582 137423 2-39-5 72582103340 2-22-2 72582 137423 2-56-4 72582103340 2-69-11 72582 141195 2-11-21 72582103343 2-119-21 73342 141195 2-38-14 72582103361 2-32-7 72582 141231 2-119-13 73342103647 2-20-8 72582 141346 2-9-6 72582103709 2-38-12 72582 142486 2-40-9 72582103870 2-45-37 72582 145067 2-25-10 725821039-33000-03 2-83-7 51377 145283 2-35-53 72582104067 2-177-11 11331 147481 2-38-6 72582104075 2-177-9 11331 147485 2-103-37 73342105451 2-3-8 72582 148148 2-35-48 72582106337 2-69-15 72582 148402 2-35-30 72582106839 2-177-10 11331 148423 2-189-17 32705106848 2-177-12 11331 154364 2-189-33 32705109609 2-188-1 32705 1545 2-190-1 0224911M011 2-151-2 98076 1545 2-206-1 0224911M012 2-151-1 98076 1546 2-190-2 0224911M014 2-151-11 98076 1546 2-206-2 0224911M016 2-151-20 98076 1547 2-190-6 0224911M034 2-151-21 98076 1547 2-206-6 0224911M037 2-151-10 98076 1548 2-190-5 0224911M046 2-151-17 98076 1548 2-206-5 0224911M050 2-151-18 98076 1549 2-190-7 0224911M051 2-151-3 98076 1549 2-206-7 0224911M052 2-151-4 98076 1550 2-190-3 0224911M067 2-151-16 98076 1550 2-206-3 0224911M114 2-151-13 98076 1552 2-190-4 02249110060 2-177-6 11331 1552 2-206-4 02249110061 2-177-4 11331 160221 2-16-10 72582110062 2-177-5 11331 1606 2-188-15 327051114052 2-80 16764 170072 2-189-23 32705111610 2-32-12 72582 171523 2-189-24 32705111610 2-8-12 72582 17200 2-97-3 135491116389 2-78-25 16764 172376 2-188-14 327051119879 2-80-42 16764 174619 2-189-28 327051126M001-1D 2-151-7 98076 1771-24J 2-229-12 607031126M005-CA 2-151 98076 1779-433 2-138-8 785001126M005-1 2-151-5 98076 179397 2-107-28 733421126M009 2-151-8 98076 179816 2-103-33 733421126M015 2-151-15 98076 179819 2-45-39 725821126M017 2-151-19 98076 179826 2-25-8 725821126M038 2-151-12 98076 179827 2-22-5 72582113500 2-35-27 72582 179837 2-103-4 73342113903 2-36-59 72582 179839 2-4-21 7258211428R8 2-151-9 98076 179839 2-6-13 72582114760 2-177-8 11331 179839 2-76-18 72582114783 2-32-8 72582 179844 2-76-1 72582114848 2-177-7 11331 179844 2-8-5 72582114926 2-76-15 72582 179846 2-23-13 72582114987 2-177-3 11331 179847 2-41-4 72582114988 2-177-2 11331 179848 2-8-6 72582114989 2-177-1 11331 179850 2-11-9 7258211501033 2-103-44 73342 179850 2-168-12 72582115545 2-36-74 72582 179850 2-32-15 72582115658 2-119-32 73342 179850 2-46-1 72582116337 2-36-58 72582 179856 2-69-12 72582117049 2-11-5 72582 179867 2-26-2 72582117212 2-103-32 73342 180120 2-22-4 72582118536 2-3-1 72582 180147 2-26-6 72582118748 2-168-7 72582 181309 2-12-29 72582118752 2-168-5 72582 181333 2-21-6 72582120238 2-80-38 16764 1846864 2-77-21 16764120293 2-21-7 72582 1846901 2-78-29 16764120378 2-80-1 16764 1847933 2-77-10 16764120380 2-32-2 72582 1851-20NS 2-229-15 60703120380 2-32-5 72582 1851612 2-77-12 16764120380 2-35-12 72582 1852038 2-77-5 16764120391 2-36-75 72582 1852040 2-77-20 167641205B1432 2-135-10 78500 1852043 2-78-35 167641205X1428 2-134-8 78500 1852519 2-78-30 167641207WB 2-123-27 43334 7451994 73342 1852630 2-78-26 16764121917 2-21-5 72582 186283 2-168-21 72582121917 2-89-15 72582 186283 2-25-15 72582

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*

TM 9-2320-277-14&P


186283 2-28-12 72582 213998 2-189-29 32705186309 2-11-11 72582 214749 2-166-11 06853186310 2-11-7 72582 217224 2-175-9 06853186612 2-25-5 72582 2203K3001 2-134-9 78500186612 2-28-11 72582 2203L3002 2-134-9 78500186618 2-3-2 72582 2208Q823 2-134-6 78500186618 2-45-19 72582 222029 2-188-9 32705186619 2-28-7 72582 222440 2-189-27 32705186619 2-45-31 72582 22453-802 2-219-8 71044186625 2-44-5 72582 22517-802 2-219-47 71044186625 2-46-5 72582 22518-801 2-219-49 71044186627 2-23-12 72582 22519-802 2-219-48 71044186627 2-3-6 72582 22525-801 2-219-11 71044186647 2-89 72582 22525-801 2-219-16 71044

22255-801 2-219-33 71044186679 2-45-11 72582 22525-801 2-219-40 71044186725 2-4-19 72582 22525-801 2-219-43 710441869573 2-77-13 16764 22525-801 2-219-7 710441871411 2-77-14 16764 22526-801 2-219-3 710441876806 2-78-32 16764 226491 2-173-10 068531876808 2-78-24 16764 226491 2-173-5 068531876873 2-77-22 16764 226834 2-159 068531892914 2-77-11 16764 226835 2-159-9 068531894214 2-80-23 16764 22705-801 2-219-19 710441895 2-93-7 08108 1615 75175 228278 2-243 06853189787 2-119-22 73342 22879-801 2-219-37 71044190139 2-123-4 73342 229502 2-159 068531905406 2-77-2 16764 229502 2-159 068531906986 2-80-11 16764 2297Q2681 2-134-5 78500191249 2-11-10 72582 230081 2-243-8 06853191249 2-45-22 72582 23010017 2-109-8 733421914373 2-80-35 16764 23010726 2-123-1 733421914842 2-80-14 16764 23010753 2-105 733421914869 2-80-19 16764 23010909 2-105-46 733421914869 2-80-7 16764 230175 2-172-13 068531916272 2-80-13 16764 23094-801 2-219-14 710441916272 2-80-22 16764 231159 2-165-22 068531916439 2-80 16764 231435 2-243-7 068531916439 2-80 16764 231436 2-243-6 068531918047 2-80 16764 23188-808 2-219-13 710441921805 2-80-36 16764 232068 2-165-4 068531923484 2-80 16764 2325715 2-168-3 72582192481 2-23-10 72582 232794 2-189-22 327051927 2-92-11 75175 233037 2-188-3 32705193-423-200 2-178-2 73842 233057 2-160-8 909151930611 2-80-41 16764 233997 2-165-7 06853193732 2-189-18 32705 234833 2-166-10 06853194 2-96-2 08108 234840 2-166-4 068531945356 2-80-24 16764 23562-802 2-219-17 710441945468 2-80-40 16764 23565-804 2-219-15 710441945476 2-80-18 16764 23566-802 2-219-54 710441945478 2-80-5 16764 23567-811 2-219-4 710441945509 2-80 16764 235729 2-166-6 068531947262 2-80-21 16764 23581-801 2-219-27 710441948512 2-80-6 16764 235829 2-159-23 068531948520 2-80-30 16764 235829 2-159-23 068531948521 2-80-29 16766 236241 2-166-1 068531948522 2-80-33 16764 236288 2-159-8 068531948526 2-80-28 16764 236594 2-173-11 068531948529 2-80-37 16764 236596 2-173-8 068531948536 2-80-16 16764 236600 2-173-4 068531948537 2-80-15 16764 236728 2-166-5 068531949606 2-80-17 16764 236733 2-173-3 068531953236 2-80-3 16764 236733 2-173-7 068531961323 2-78-28 16764 236742 2-162-1 968531961867 2-77-16 16764 236743 2-162-2 068531964117 2-78-23 16764 236744 2-162-4 068531964857 2-80-25 16764 236979 2-159-13 068531969046 2-77-19 16764 236980 2-159-10 068531969481 2-77-3 16764 236981 2-159-12 068531970145 2-77-9 16764 236982 2-159-11 068531970384 2-77-17 16764 237032 2-166-3 06853199390 2-189-21 32705 237313 2-161-6 06853201777 2-243-5 06853 237494 2-161-12 06853202678 2-161-7 06853 237497 2-161-10 06853202961 2-166-2 06853 23783-801 2-219-55 71044202961 2-172-3 06853 23783-801 2-219-6 71044202979 2-159-14 06853 23784-801 2-219-5 71044202982 2-159-15 06853 23784-801 2-219-56 71044204781 2-243-4 06853 238327 2-165-24 06853210067 2-159-4 06853 23840-802 2-219-42 71044210492 2-159-6 06853 238412 2-162-3 06853211155 2-166-8 06853 238474 2-159-7 068532128 2-92-12 75175 238888 2-159-5 06853213859 2-189-31 32705 238956 2-175-1 06853* See auxiliary list on page 3-27.

3-8

TM 9-2320-277-14&P


239071 2-175-4 06853 24427-801 2-217-21 71044239092 2-166-12 06853 244586 2-159-30 06853239136 2-159-26 06853 245507 2-189-35 32705239139 2-175-5 06853 245835 2-163-3 0685323936-801 2-219-2 71044 246226 2-165-1 06853239383 2-165-28 06853 246261 2-160-2 90915239476 2-159-35 06853 246262 2-160-1 90915239476 2-159-35 06853 246263 2-160-6 90915239615 2-159-32 06853 246264 2-160-5 90915239627 2-159-28 06853 246266 2-160-7 90915239640 2-159-18 06853 246267 2-160-9 90915239640 2-159-18 06853 246686 2-164-1 06853239643 2-159-17 06853 246961 2-164-6 06853239643 2-159-17 06853 246962 2-164-5 06853239645 2-159-29 06853 246963 2-164-4 06853239658 2-161-9 06853 246964 2-164-3 06853239658 2-172-58 06853 246965 2-164-2 06853239688 2-159-16 06853 247919 2-162-5 06853239688 2-159-16 06853 248334 2-165-10 068532397-10J 2-230-23 60703 248335 2-165-29 068532397-7J 2-230-20 60703 2488022 2-39-9 72582239708 2-159-33 06853 249514 2-166-7 06853239713 2-159-19 06853 250455 2-189-16 32705239713 2-159-19 06853 25525-801 2-219-22 71044239737 2-159-31 06853 25594-801 2-219-10 71044239758 2-162-6 06853 25595-808 2-219 71044239766 2-166-9 06853 25595-809 2-219-12 71044239897 2-165-9 06853 25695-802 2-219-23 71044239898 2-165-26 06853 25700-802 2-219-52 71044239899 2-165-14 06853 25706-806 2-219-18 71044239901 2-165-18 06853 25833-801 2-219-21 71044239902 2-165-17 06853 25834-806 2-219-20 71044239903 2-165-27 06853 25989-801 2-219-20 71044239904 2-165-25 06853 26082-801 2-219-34 71044239906 2-165-19 06853 26084-801 2-219-28 71044239907 2-165-11 06853 26085-801 2-219-32 71044239908 2-165-12 06853 26153-801 2-219-31 71044239909 2-165-13 06853 26228-803 2-219-39 71044239910 2-165-20 06853 26298-802 2-219-57 71044239911 2-165-21 06853 26299-802 2-219-38 71044239939 2-165-5 06853 26343-801 2-219-36 71044239940 2-165-2 06853 263585 2-189-19 32705239949 2-161-11 06853 26421-801 2-219-58 71044239979 2-159-25 06853 26443-810 2-219-44 71044240003 2-163-5 06853 26444-801 2-219-45 71044240006 2-163-2 06853 271500 2-168-13 72582240012 2-163-4 06853 271632 2-9-1 72582240288 2-165-16 06853 273913 2-80 16764240330 2-172-19 06853 274613 2-107-6 73342240331 2-172-15 06853 275230 2-172 06853240333 2-172-12 06853 276119 2-159 06853240334 2-172-16 06853 276396 2-189-34 32705240336 2-17-17 06853 277587 7-165 06853240338 2-172-11 06853 277854 2-159 06853240339 2-172-10 06853 2797-100 2-138-3 78500240340 2-172-9 06853 2797-56 2-138-5 78500240341 2-172-6 06853 279804 2-188-10 32705240342 2-172-7 06853 280956 2-188-6 32705240343 2-172-5 06853 283732 2-165 06853240344 2-172-4 06853 28841-804 2-219-41 71044240345 2-172-2 06853 289283 2-188-7 32705240346 2-172-18 06853 289329 2-159 06853240347 2-172-1 06853 289900 2-165-15 06853240351 2-165-6 06853 291439 2-188-5 32705240457 2-165-23 06853 291667 2-188-13 32705240775 2-165-8 06853 292386 2-170-45 06853240960 2-159-27 06853 292390 2-170-44 0685324128-801 2-219-60 71044 294050 2-188-2 3270524129-801 2-219-9 71044 294439 2-188-12 32705241556 2-165-3 06853 296598 2-189-32 32705241559 2-159-21 06853 3 2-205 97576241559 2-159-21 06853 3101W179 2-135-16 78500242109 2-159-34 06853 314269 2-188-4 32705242141 2-175-7 06853 31523 2-92-13 75175242221 2-175-6 06853 315934 2-188-8 32705242837 2-163-6 06853 31906-801 2-217-35 71044243011 2-159-22 06853 32559 2-189-5 32705243011 2-159-22 06853 32865-802 2-217-39 71044243019 2-159-20 06853 32998-801 2-217-44 71044243019 2-159-20 06853 3421 2-93-6 75175243588 2-161-8 06853 34591 2-92-14 75175243937 2-175-3 06853 349036-801 2-217-36 71044243939 2-175-8 06853 350003-801 2-219-51 71044243940 2-175-2 06853 350023-801 2-219-53 71044244095 2-244-11 90915 350039-002 2-217-41 71044

3-9

**

TM 9-2320-277-14&P


351096-801 2-219-46 71044 45253 2-209-4 64294 53141853 90914351097-801 2-219-62 71044 453087 2-180-8 77640351113-801 2-219-61 71044 453088A4 2-180-6 77640351119-801 2-219-29 71044 453418 2-80-9 16764351134-801 2-217-4 71044 453434 2-77-7 16764351152-801 2-217-42 71044 453465 2-80 16764351177-801 2-217-28 71044 453465 2-80 1676435138 2-93-4 75175 453570 2-113-14 73342353014-801 2-219-59 71044 453844 2-78-34 16764353024-801 2-219-30 71044 453844 2-80-10 16764353027-801 2-219-50 71044 454512 2-119-4 73342353034-801 2-217-29 71044 454557 2-19 72582353034-801 2-217-5 71044 454750 2-32-9 72582353043-801 2-217-30 71044 45481-004 2-217-45 71044353043-801 2-217-6 71044 454813 2-103-17 73342353086-002 2-217-37 71044 454813 2-32-1 7258235509 2-93-3 75175 454817 2-103-16 73342359103-002 2-217-40 71044 45486-006 2-217-38 71044359113-002 2-217-12 71044 454906 2-16-4 7258236918-004 2-219 71044 455537 2-25-16 725823719219 2-38-1 72582 455734 2-109-5 73342375094 2-189-20 32705 45643-007 2-217-2 71044377553 2-189-36 32705 45643-046 2-217-1 71044381948 2-188-11 32705 45644-004 2-217-8 710443829139 2-103-26 73342 45644-012 2-217-7 710443829139 2-103-30 73342 457008 2-35-19 7258238689 2-93-5 75175 46146-003 2-217-17 7104438805 2-92-2 75175 46406-011 2-217-14 710443921988 2-103-27 73342 46406-012 2-217-15 710443921989 2-103-28 73342 46417-003 2-219-1 71044401286 2-180-5 77640 46488-003 2-217-10 7104440202R 2-95-2 13548 46562-002 2-217-19 7104440204 2-95-2 13548 46909-007 2-217-18 7104440697 2-92-7 75175 46872-002 2-217-16 7104440700 2-95-1 13548 47010-003 2-217-24 7104440700 2-95-1 13548 47011-002 2-217-23 7104441-1224-13 2-242-11 90915 47012-006 2-217-22 7104441055 2-92-5 75175 47901-002 2-217-43 7104441057 2-92-10 75175 48000511 2-145 9091541058 2-92-6 75175 48000584 2-146-23 9091541060 2-92-15 75175 48000642 2-136-11 9091541079 2-92-1 75175 48109540 2-186-3 9091541080 2-92-4 75175 49255-002 2-217-25 7104441905-003 2-219-35 71044 5 2-205 9757642-0832-13 2-242-8 90915 5100104 2-7-2 7258242185-004 2-217-11 71044 5100136 2-168-8 7258242190-009 2-217-9 71044 5100201 2-69-21 7258242326-002 2-219-24 71044 5101691 2-35-18 7258242626-013 2-217-3 71044 5102058 2-76-17 72582427567 2-168-17 72582 5102065 2-76-11 72582427567 2-70-30 72582 5102073 2-76-20 72582427588 2-11-8 72582 5102393 2-168-20 72582427588 2-25-14 72582 5102395 2-168-24 7258242874-003 2-217-13 71044 5104451 2-28-16 7258243306-014 2-217-33 71044 5108219 2-69-22 7258243306-015 2-217-34 71044 5108435 2-168-23 72582442323 2-39-4 72582 5108436 2-69-17 72582442733 2-76-14 72582 5108474 2-7-1 72582443603 2-106-70 73342 5108759 2-3-4 72582443603 2-18-26 72582 5108830 2-29-8 72582444000 2-39-6 72582 5108918 2-18-21 72582444052 2-168-9 72582 5108919 2-18-20 72582444612 2-103-13 73342 5108939 2-12-27 72582444612 2-103-39 73342 5109640 2-70-33 72582444612 2-119-14 73342 5109641 2-69-14 72582444612 2-119-15 73342 5111467 2-5-3 72582444691 2-121-4 73342 5112425 2-44-2 72582444697 2-119-20 73342 5112899 2-29-6 72582445090 2-103-41 73342 5112899 2-6-18 72582445520 2-35-31 72582 5113800 2-47-7 72582445567 2-103-18 73342 5114541 2-21-9 72582445567 2-103-21 73342 5115087 2-18-24 72582445567 2-105-37 73342445568 2-103-20 73342447196 2-35-52 725824478 2-73 08108 5115322 2-40-6 7258244937-007 2-217-32 71044 5116011 2-36-65 72582450098 2-180-3 77640 5116070 2-25-9 72582450143 2-180 77640 5116071 2-36-71 72582450517 2-45-25 72582 5116072 2-18-3 72582450517 2-70-32 72582 5116122 2-6-22 7258245062-002 2-217-27 71044 5116125 2-18-28 7258245153-005 2-217-26 71044 5116128 2-18-2 72582451905 2-35-8 72582 5116181 2-13-5 7258245213-002 2-217-31 71044 5116181 2-14-12 72582* See auxiliary list on page 3-27.

3-10

TM 9-2320-277-14&P


5116189 2-14-11 72582 5125774 2-37-3 725825116195 2-10-14 72582 5125775 2-37-7 725825116198 2-19-13 72582 5125867 2-44-7 725825116204 2-41-1 72582 5125868 2-45-20 725825116205 2-29-5 72582 5126069 2-36-72 725825116224 2-10-11 72582 5126072 2-32-14 725825116229 2-10-13 72582 5126143 2-22-3 725825116242 2-45-34 72582 5126194 2-4-23 725825116242 2-45-45 72582 5126436 2-25-3 725825116242 2-6-16 72582 5126473 22-7 725825116262 2-32-18 72582 5126672 2-37-10 725825116262 2-5-6 72582 5127238 2-28-5 725825116264 2-40-11 72582 5128025 2-8-1 725825116264 2-40-3 72582 5128340 2-45-24 725825116265 2-40-4 72582 5128486 2-16-8 725825116290 2-6-21 72582 5128492 2-45-13 725825116292 2-6-25 72582 5128493 2-45-14 725825116302 2-11-4 72582 5128522 2-56-10 725825116357 2-3-5 72582 5128640 2-18-23 725825116357 2-45-38 72582 5179063 2-8-13 725825116361 2-5-5 72582 5120064 2-8-11 725825116401 2-9-9 72582 5129617 2-16-7 725825116440 2-56-7 72582 2-35-20 725825116476 2-8-9 72582 2-35-14 725825117061 2-12-26 72582 5129705 2-32-13 725825117082 2-76-3 72582 5129706 2-32-13 725825117693 2-35-50 72582 5129829 2-35-29 725825117927 2-35-28 72582 5130590 2-3-11 725825117928 2-35-25 72582 5130785 2-24-3 725825118219 2-37-9 72582 5130959 2-47-8 725825119198 2-18-1 72582 5130992 2-11-14 725825119266 2-24-4 72582 5130995 2-80-46 725825119282 2-47-4 72582 5131095 2-69-25 725825119283 2-47-3 72582 5131122 2-69-26 725825119293 2-5-7 72582 5131123 2-69-20 725825119368 2-25-7 72582 5131124 2-69-27 725825119438 2-32-22 72582 5131205 2-69-28 725825119477 2-8-2 72582 5131206 2-70-29 725825119481 2-8-10 72582 5131207 2-69 725825120740 2-19-9 72582 5131828 2-168-6 725825121077 2-15-14 72582 5131961 2-5-4 725825121109 2-15-1 72582 5132495 2-29-4 725825121182 2-16-3 72582 5132695 2-4-17 725825121182 2-28 72582 5132715 2-76-12 725825121182 2-6-11 72582 5132715 2-76-6 725825121205 2-16-2 72582 5132803 2-14-14 725825121207 2-6-24 72582 5132962 2-36-63 725825121254 2-6-23 72582 5133098 2-14-8 725825121256 2-14-15 72582 5133101 2-13-7 725825121259 2-41-6 72582 5133107 2-46-7 725825121263 2-6-19 72582 5133109 2-13-1 725825121337 2-35-9 72582 5133387 2-15-8 725825121339 2-36-68 72582 5133388 2-15-9 725825121342 2-35-10 72582 5133397 2-4-24 725825121345 2-32-19 72582 5133431 2-16-13 725825121452 2-12-11 72582 5133435 2-29-3 725825121453 2-32-11 72582 5133662 2-35-5 725825121458 2-36-62 72582 5133707 2-35-6 725825121459 2-4-26 72582 5133819 2-35-1 725825121472 2-32-10 72582 5133981 2-4-25 725825122165 2-35-37 72582 5134269 2-45-28 725825122281 2-11-25 72582 5134388 2-15-11 725825122437 2-45-15 72582 5134392 2-16-9 725825122771 2-35-4 72582 5134456 2-16-11 725825122786 2-35-3 72582 5134477 2-16-12 725825123118 2-89-11 72582 5134560 2-38-2 725825123250 2-18-22 72582 5134908 2-19-1 725825123700 2-18-10 72582 5135078 2-168-4 725825123711 2-18-11 72582 5135262 2-18-7 725825123802 2-11-16 72582 5135267 2-18-5 725825124055 2-8-8 72582 5135268 2-18-6 725825124209 2-35-55 72582 5135679 2-45-41 725825124415 2-35-42 72582 5135913 2-45-27 725825124762 2-26-5 72582 5135915 2-20-7 725825124775 2-45-33 72582 5135935 2-89-12 725825124872 2-45-29 72582 5136227 2-25-1 725825124997 2-45-30 72582 5136249 2-89-13 725825125024 2-45-21 72582 5136274 2-25-18 725825125150 2-44-8 72582 5136610 2-6-15 725825125355 2-7-4 72582 5137470 2-11-17 729825125356 2-7-3 72582 5137595 2-9-10 725825125367 2-35-7 72582 5138245 2-23-14 725825125608 2-4-15 72582 5138298 2-39-8 725825125767 2-37-1 72582 5138335 2-36-61 725825125771 2-37-5 72582 5138420 2-23-13 72582* See auxiliary list on page 3-27.

3-11

TM 9-2320-277-14&P


5138525 2-32-3 72582 5160542 2-9-5 725825138619 2-23-9 72582 5161003 2-38-10 725825139176 2-29-4 72582 * 5161873 2-21-4 725825139228 2-30-3 72582 5162941 2-21-1 725825139237 2-46-3 72582 5166864 2-26-4 725825140370 2-11-15 72582 5170484 2-9-3 725825140888 2-21-3 72582 5172 2-93-2 751755141701 2-4-16 72582 5172383 2-35-46 725825143021 2-25-4 72582 5172734 2-15-3 725825144177 2-35-22 72582 5174286 2-35-44 725825144375 2-10-12 72582 5174429 2-35-21 725825144503 2-47-1 72582 5174971 2-38-9 725825144512 2-44-4 72582 5174973 2-38-13 725825144616 2-10-16 72582 5174975 2-38-5 725825144685 2-46-4 72582 5176228 2-40-5 725825144688 2-47-5 72582 5176557 2-35-24 725825144798 2-69-18 72582 5177001 2-8-14 725825145009 2-35-26 72582 5177773 2-25-2 725825145009 2-37-11 72582 5178581 2-35-15 725825145009 2-47-6 72582 5178700 7-38-7 725825145009 2-5-9 72582 5179954 2-18-12 725825145012 2-24-1 72582 5180250 2-14-10 725825145013 2-20-1 72582 5180291 2-9-2 725825145014 2-25-20 72582 5181746 2-38-4 725825145014 2-45-16 72582 5181747 2-38-3 725825145230 2-45-9 72582 5182555 2-35-45 725825145415 2-168-25 72582 5182556 2-35-39 725825145820 2-35-51 72582 5182557 2-35-34 725825145823 2-36-69 72582 5182559 2-35-33 725825145923 2-36-57 72582 5183184 2-3-9 725825146053 2-45-10 72582 5183701 2-35-11 725825146165 2-29-7 72582 5184530 2-38-11 725825146309 2-24-1 72582 5185416 2-3-10 725825146337 2-38-15 72582 5186115 2-35-41 725825147528 2-32-17 72582 5186647 2-26-1 725825147994 2-7-5 725825148011 2-11-2 72582 5186841 2-45-35 725825148012 2-12 72582 5187308 2-19-8 725825148093 2-11-3 72582 5187309 2-19-5 725825148171 2-56-16 72582 5187310 2-19-6 725825148436 2-24-5 72582 5188273 2-29-2 725825148436 2-47-2 72582 5188274 2-4-20 725825150087 2-15-4 72582 5192111 2-9-5 725825150140 2-13-4 72582 5195220 2-18-25 725825150155 2-20-6 72582 5195685 2-25-12 725825150193 2-37-13 72582 5195687 2-25-11 725825150199 2-37-8 72582 5196615 2-9-9 72582

5196669 2-9-9 725825150259 2-40-8 72582 5196671 2-9-9 725825150263 2-40-10 72582 5196673 2-9-9 725825150303 2-18-19 72582 5196784 2-40-7 725825150312 2-18-14 72582 5196786 2-40-7 725825150314 2-18-13 72582 5196842 2-37-2 725825150314 2-18-8 72582 5196852 2-10-13 725825150568 2-11-23 72582 5197150 2-35-17 725825150829 2-8-3 72582 5197151 2-35-23 725825150892 2-35-38 72582 5197852 2-13-3 725825150899 2-35-36 72582 5197944 2-15-7 725825150941 2-35-54 72582 5197945 2-15-7 725825150942 2-36-70 72582 5197963 2-13-7 725825150943 2-36-56 72582 5197964 2-14-8 725825150943 2-36-66 72582 5197965 2-13-7 725825151249 2-35-43 72582 5197966 2-14-8 725825151272 2-18-4 72582 5197967 2-14-7 725825151277 2-15-15 72582 5197968 2-14-8 725825151277 2-16-6 72582 5197969 2-14-7 725825151449 2-6-12 72582 5197970 2-14-8 725825151487 2-35-16 72582 5197975 2-13-6 725825151487 2-35-49 72582 5197976 2-13-6 725825151601 2-18-18 72582 5197977 2-13-6 725825152138 2-41-2 72582 5197978 2-13-6 725825152148 2-41-3 72582 5197979 2-13-6 725825152148 2-76-19 72582 5198410 2-9-8 725825152462 2-32-21 72582 5198411 2-9-8 725825152904 2-11-22 72582 5198412 2-9-8 725825152929 2-35-47 72582 5198413 2-9-8 725825152944 2-35-35 72582 5198414 2-9-8 725825154215 2-20-4 72582 5198415 2-9-10 725825154453 2-5-8 72582 5198416 2-9-10 725825154453 2-56-17 72582 5198417 2-9-10 725825154538 2-19-7 72582 5198418 2-10-10 725825155596 2-35-32 72582 5198503 2-10-11 725825157933 2-8-4 72582 5198655 2-5-10 725825159353 2-9-5 72582 5198822 2-14-9 725825160037 2-5-2 72582 5198877 2-14-13 72582* See auxiliary list on page 3-27.

3-12

TM 9-2320-277-14&P


5198899 2-14 72582 53102130 2-73-19 909155198983 2-15-7 72583 53102136 2-73-17 909155199396 2-15-6 72582 53102150 2-86-10 90915 PL16 134455199397 2-15-15 72582 53102153 2-87-22 90915 1996097 167645199506 2-4-18 72582 53102164 2-87-15 909155199527 2-5-1 72582 53102164 2-90-5 909155199560 2-37-12 72582 53102172 2-180-27 90915 53 081085199575 2-39-1 72582 53102172 2-86 90915 53 081085199575 2-39-7 72582 53102172 2-88-2 90915 53 081085199579 2-39-2 72582 53102177 2-86-7 909155199588 2-39-3 72583 53102275 2-65-9 90915 C4JZ-8115-A 230405199778 2-45-36 72582 53102294 2-89-3 90915 366JH 577335199811 2-6-20 72582 53102297 2-194-4 90915 J9977-3 760055226186 2-43-2 72582 53102297 2-2-4 90915 166897 154345226393 2-43-7 72582 53102299 2-194-6 90915 193135 154345226400 2-43-18 72582 53102299 2-2-6 909155276416 2-43-23 72582 53102344 2-89-1 90915 997-AH 577335226719 2-43-19 72582 53102345 2-89-2 90915 811532 577335226912 2-43-24 72582 53102502 2-203-18 90o155228104 2-43-5 72582 53102503 2-203-8 909155228109 2-43-16 72582 53102505 2-203-19 909155228583 2-43-22 72582 53102507 2-202-6 909155228586 2-43-17 72582 53102508 2-203-9 909155228587 2-43-3 72582 53102509 2-203-10 909155228588 2-43-1 72582 53102519 2-203-25 909155228594 2-43-14 72582 53102521 2-203-27 909155228596 2-43-12 72582 53102522 2-202-5 909155228601 2-43-9 72582 53102523 2-203-11 909155228608 2-43-4 72582 53102524 2-203-14 909155228694 2-43-10 72582 53102525 2-203-12 909155228696 2-43-11 72582 53102534 2-203-32 909155228701 2-43 72582 53102535 2-203-30 909155228739 2-43-8 72582 53102536 2-203-29 909155228766 2-43-13 72582 53102538 2-203-16 909155228769 2-43 72582 53102803 2-156 909155229034 2-43-15 72582 53102803 2-73 909155229167 2-43-20 72582 53102804 2-73 909155229350 2-41-7 72582 53103037 2-208-32 909155229354 2-43-6 72582 53103040 2-207-17 909155229359 2-43-21 72582 53103044 2-73 909155230007 2-38-8 72582 53103048 2-157-2 90915529 2-73 71951 53103050 2-203-13 9091553001203 2-161 90915 278596 06853 53103051 2-203-28 9091553022298 2-201-11 90915 53103329 2-155-46 9091553024801 2-141-3 90915 53103337 2-56-3 90015 1024-8-8 9844153053901 2-141-4 90915 53103338 2-56-11 90915 1024-8-10 984415307001 2-156-83 90915 53103339 2-56-9 90915 4401-8S 0062453100303 2-186-5 90915 53103341 2-96-2 90915 725-10-10S 9844153100506 2-155-26 90915 278351 06853 53103341 2-56-6 90915 725-10-10S 9844153100507 2-159 90915 278352 06853 53103400 2-155-65 9091553100508 2-155-29 90915 284833 06853 53103500 2-190-8 90915 1553 0224953100509 2-155-30 90915 229844 06853 53103500 2-206-8 90915 1553 0224953100510 2-155-31 90915 228600 06853 53103572 2-205-16 90915 GSP-Z4-H.P. 0224953100511 2-155-32 90915 279000 06853 53103701 2-73-18 90915 6426779 7004053100520 2-155-49 90915 226911 06853 53103706 2-88-1 9091553100532 2-244-12 90915 53103712 2-73-14 90915 6460032 7004053100533 2-53-3 90915 53104756 2-88-5 90915 550-JS 5773353100539 2-155-43 90915 217619 06853 53104757 2-88 9091553100548 2-155-48 90915 110718 98343 53104856 2-73 90915 XS-51171-K5900 7713253100563 2-155-27 90915 281923 06853 53104878 2-88-3 9091553100570 2-175-14 90915 236701 06853 53104880 2-215-6 9091553100721 2-136-3 90915 1227-B-106 78500 53105014 2-73 9091553100722 2-136-5 90915 53105014 2-98-9 9091553100723 2-136-4 90915 53105021 2-98-6 90915 1958666 1676453100736 2-135-25 90915 53105022 2-98-4 90915 1965698 1676453100738 2-135-39 90915 53105025 2-155-25 90915 220521 0685353100777 2-142-4 90915 48-1107 92850 53105060 2-65-5 90915 7400-72 2416153101212 2-156-84 90915 229666 06853 53105303 2-65-50 9091553101500 2-71-8 90915 CCV-1713 75272 53105320 2-155-44 9091553101500 2-84-6 90915 CCV-1713 75272 53105320 2-159-36 9091553101502 2-156 90915 COV-0913 75272 53105320 2-65-8 9091553101502 2-223-4 90915 COV-0913 75272 53105335 2-155-45 9091553101502 2-73 90915 COV-0913 75272 53105347 2-156-77 9091553101503 2-57-4 90915 COV-0509 75272 53105350 2-155-51 9091553101503 2-73 90915 0COV-0509 75272 53105350 2-84-5 9091553101504 2-156 90915 COV-0713 75272 53105360 2-101-7 9091553101504 2-59-26 90915 COV-0713 75272 53105375 2-101-12 9091553101504 2-73 90915 COV-0713 75272 53105381 2-132-3 90915 246089 0685353102018 2-74-2 90915 1512-0-6 98343 53105382 2-132-2 90915 246090 0685353102019 2-74-4 90915 1512-1-15 98343 53108202 2-229-8 90015 M-874-67-TM 6070353102019 2-90-4 90915 1512-1-15 98343 53108203 2-232 90915 SPAWP-16G 6070353102020 2-74-3 90915 1512-1-20 98343 53109139 2-176-1 90915 2750AG-40 9834353102021 2-74-5 90915 1512-1-30 98343 53109148 2-141-1 90915 YS-102 5693153102094 2-90-2 90915 8027-05P 52179 53109165 2-155-36 90915 10200 1012553102101 2-87-34 90915 180/550 77977 53109166 2-143-9 90915 160526 98076

3-13

TM 9-2320-277-14&P


53109180 2-154-11 90915 FC9215-1010S 00624 53140448 2-143 9091553109181 2-155-40 90915 2000-8-108 00624 53140469 2-146-52 9091553109224 2-83-3 90915 53140473 2-145-3 9091553109233 2-156 90915 COV-1013 75272 53140474 2-145-2 9091553109240 2-101-14 90915 53140476 2-146-44 9091553109280 2-155-42 90915 53140477 2-146-54 9091553109280 2-205-8 90915 53140478 2-146-56 90915 2803-Z-1300 7850053112311 2-157-9 90915 53140479 2-146-57 90915 2803-A-1301 7850053113726 2-157-1 90915 53140480 2-146-58 90915 2803-Z-2002 7850053113727 2-157-10 90915 53140481 2-146-46 90915 2803-B-782 7850053113750 2-205 90915 53140482 2-146-47 90915 2803-C-783 7850053116502 2-176-2 90915 53140483 2-146-48 90915 2803-S-1085 7850053118805 2-201-7 90915 53140484 2-146-39 9091553119531 2-157-5 90915 53140488 2-147-65 9091553125833 2-201-12 90915 53140489 2-147-66 9091553125834 2-201 90915 53140509 2-136-6 90915 1227-U-541 7850053140041 2-101-9 90915 6402717 70040 53140533 2-151-14 90915 11M018-1 9807653140041 2-73-19 90915 6402717 70040 53140652 2-149-4 9091553140075 2-208-31 90915 53140653 2-149-3 9091553140076 2-208-31 90915 53140655 2-149-11 9091553140084 2-207-3 90915 53140655 2-149-9 9091553140085 2-207-3 90915 53140656 2-149-8 9091553140086 2-207-8 90915 53140667 2-170-9 9091553140088 2-208-26 90915 53140670 2-170-12 9091553140089 2-207-10 90915 53140671 2-170-13 9091553140092 2-207-9 90915 53140672 2-170-11 9091553140093 2-207-13 90915 53140677 2-170-41 9091553140096 2-207-15 90915 53140694 2-170-21 90915 239292 0685353140097 2-208-25 90915 53140694 2-173-6 90915 239292 0685353140009 2-208-22 90915 53140696 2-173-9 90915 236595 0685353140105 2-149-19 90915 53140699 2-173-1 9091553140106 2-149-19 90915 53140793 2-150-26 9091553140110 2-146-13 90915 53140876 2-148-15 9091553140132 2-146-32 90915 53140839 2-146-18 9091553140146 2-208-21 90915 53140859 2-143-3 9091553140147 2-208-24 90915 53140870 2-149-15 9091553140148 2-208-20 90915 53140875 2-132-9 90915 D-11999 5137753140149 2-207-19 90915 53140966 2-209-1 90915 29641-125 6429453140150 2-211-14 90915 53140966 2-209-1 90915 29641-125 6429453140258 2-170-5 90915 230935 06853 53140970 2-209-13 90915 33870 6429453140258 2-170-5 90915 230935 06853 53140973 2-209-8 90915 29531-44 6429453140263 2-170-17 90915 53140974 2-209-11 90915 29531-73 6429453140264 2-170-18 90915 53140975 2-209-14 90915 17665 6429453140265 2-170-16 90915 53140975 2-209-14 90915 17665 6429453140266 2-170-15 90915 53141107 2-203-22 9091553140267 2-170-14 90915 53141128 2-101-13 9091553140268 2-170 90915 53141128 2-208-42 9091553140280 2-170-3 90915 237291 06853 53141169 2-230 90915 F-1680-2NS 6070353140285 2-171-50 90915 202926 06853 53141175 2-146 9091553140286 2-171-49 90915 211347 06853 53141256 2-149-14 9091553140293 2-170-20 90915 239395 06853 53141347 2-180-14 9091553140293 2-170-20 90915 239395 06853 53141350 2-180-15 90915 480862 7764053140294 2-170-21 90915 236125 06853 53141354 2-180-20 9091553140294 2-170-21 90915 236125 06853 53141355 ?-180-21 9091553140295 2-170-19 90915 236126 06853 53141356 2-180-22 9091553140297 2-170-27 90915 53141357 2-180-24 9091553140297 2-170-27 90915 53141357 2-180-28 9091553140298 2-170-22 90915 236170 06853 53141360 2-180-26 9091553140300 2-170-26 90915 276336 06853 53141361 2-180-29 900l553140301 2-170-7 90915 53141362 2-180-30 9091553140301 2-170-7 90915 53141363 2-180-31 9091553140303 2-170-4 90915 53141419 2-202-2 9091553140321 2-213-7 90915 53141422 2-202-3 9091553140323 2-146-12 90915 53141423 2-202-4 9091553140328 2-146-19 90915 53141485 2-227 9091553140329 2-146-20 90915 53141486 2-227-3 9091553140334 2-146-37 90915 53141488 2-227-9 9091553140335 2-148-8 90915 53141490 2-227-10 9091553140341 2-146-31 90915 53141776 2-183-17 9091553140342 2-146-33 90915 53141802 2-135-22 9091553140343 2-146-30 90915 53141802 2-135-38 9091553140348 2-146-11 90915 53141811 2-135-28 9091553140350 2-146-50 90915 53141812 2-135-28 9091553140351 2-146-45 90915 53141813 2-136-7 9091553140351 2-146-55 90915 53141851 2-209-9 90915 29602-130 6429453140352 2-146-51 90915 53141851 2-209-9 90915 29602-130 6429453140353 2-146-53 90915 53141852 2-209-10 90915 29602-36 6429453140389 2-173 90915 226469 06853 53141852 2-209-10 90915 29602-36 6429453140421 2-146-16 90915 53141854 2-209-5 90915 45254 6429453140422 2-146-14 90915 53141855 2-209-6 90915 45249 6429453140433 2-136-16 90915 53141855 2-209-6 q0915 45249 6429453140433 2-148-21 90915 53141857 2-209-3 90915 45252 6429453140435 2-148-20 90915 53141873 2-130-8 9091553140436 2-148-20 90915 53141876 2-130-5 9091553140446 2-136-17 90915 53141877 2-130-6 90915

3-14

TM 9-2320-277-14&P


53450038 2-181-52 90915 HF-64066 77640 53451821 2-184-65 9091553450041 2-185 90915 53451851 2-101-4 90915 FC-107-12 0062453450042 2-185 90915 53451851 2-126-3 90915 FC-107-12 0062453450043 2-181-58 90915 53451852 2-101-3 90915 FC9212-1212S 0062453450114 2-180-2 90915 465573 77640 53451852 2-126-4 90915 FC9212-1212S 0062453450116 2-180-1 90915 71-62 77915 53452019 2-213-16 9091553450133 2-73 90915 53452042 2-86-4 9091553450152 2-73-24 90915 258-2305 75175 53452255 2-152 90915 326-C-78060 8575753450452 2-73 90915 Z-262 76385 53452351 2-81-5 9091553450543 2-83-1 90915 53452352 2-81-6 9091553450746 2-213-14 90915 53452393 2-101-6 90915 0502-10-1Z 3078053450805 2-213-15 90915 535000027 2-191-2 9091553450837 2-238-11 90915 HV-22498 21102 53500008 2-73-9 90915 920-3301 7517553450843 2-180-10 90915 452207 77640 53500009 2-73-10 90915 60001Y 1354853451261 2-156 90915 55T-4 06383 53500010 2-73-13 90915 60002R 1354853451268 2-154-12 90915 502-43012 79470 53500011 2-73-11 90915 18300Y 1354853451331 2-175-1Q 90915 53500012 2-197-11 90915 8-752R 7263553451640 2-186-12 90915 53500025 2-180-33 9091553451685 2-186-8 90915 VTM27-50-40-12-0 32705 53500032 2-180-35 90915

7-RI-14 53500054 2-141-2 90915 YS-104 5693353451763 2-183-1 90915 53500072 2-229 90915 8917-3-LR 6070353451763 2-183-1 90915 53500093 2-227-1 9091553451764 2-183-2 90915 53500111 2-205-33 9091553451765 2-183-3 90915 53500119 2-73 90915 9-150 1355653451766 2-183-4 90915 53500119 2-73-16 90915 9-150 1355653451766 2-183-4 90915 53500122 2-212-3 9091553451767 2-183-5 90915 53500143 2-212-6 90915 40523 9599353451768 2-183-9 90915 53500161 2-238-6 9091553451769 2-183-10 90915 53500162 2-229 90915 FSVH-731 6070353451769 2-183-10 90915 53900163 2-229-7 90915 82126-219-TM 6070353451770 2-183-11 90915 53500185 2-73-6 9091553451771 2-183-12 90915 53500227 2-73-4 9091553451771 2-183-12 90915 53500232 2-73-5 9091553451772 2-183-13 90915 53500299 2-201-6 9091553451772 2-183-13 90915 53500302 2-98 9091553451773 2-183-14 90915 53500313 2-129-38 9091553451774 2-183-15 90915 53500358 2-181-55 90915 K52202 7764053451774 2-183-15 90915 53500464 2-224-19 9091553451775 2-183-16 90915 53500475 2-129 9091553451777 2-183-18 90915 53500482 2-181-56 9091553451778 2-183-19 90915 53500563 2-101-21 90915 6885630 7334253451779 2-183-20 90915 53500575 2-205-27 9091553451780 2-183-21 90915 53500578 2-130-1 90915 A43-C-112 4162553451781 2-183-22 90915 53500580 2-101-1 90915 D63048-48 4162553451781 2-183-22 90915 53500581 2-130 90915 P-67544 4162553451782 2-184-67 90915 53500603 2-199-5 9091553451782 2-184-67 90915 53500607 2-55-4 9091553451783 2-183-25 90915 53500622 2-154-1 9091553451785 2-183-27 90915 53500623 2-154-14 9091553451785 2-183-27 90915 53500629 2-154-15 9091553451786 2-183-28 90915 53500630 2-154-16 9091553451786 2-183-28 90915 53500631 2-154-19 9091553451787 2-183-29 90915 53500633 2-154-20 9091553451788 2-183-30 90915 53500636 2-154-17 9091553451789 2-183-31 90915 53500637 2-154-18 9091553451790 2-183-32 90915 53500639 2-154-21 9091553451790 2-183-32 90915 53500640 2-154-22 9091553451792 2-183-34 90915 53500641 2-155-59 9091553451793 2-183-35 90915 53500642 2-154-11 9091553451794 2-183-36 90915 53500644 2-154-9 9091553451795 2-183-37 90915 53500646 2-154-7 9091553451796 2-183-38 90915 53500647 2-154-6 9091553451797 2-183-39 90915 53500656 2-152-3 9091553451799 2-183-43 90915 53500658 2-152-4 9091553451800 2-183-41 90915 53900659 2-152-5 9091553451801 2-183-42 90915 53500673 2-55-12 9091553451801 2-183-42 90915 5350069 2-176-3 90915 203044 0685353451802 2-185-57 90915 53500720 2-2-8 9091553451802 2-185-57 90915 53500721 2-2-8 9091553451803 2-183-46 90915 53500882 2-205-34 9091553451804 2-183-26 90915 53500913 2-205-35 9091553451806 2-183-49 90915 53500922 2-201-16 9091553451807 2-183-50 90915 53501014 2-133-2 90915 5-280X 9501953451807 2-183-50 90915 53501015 2-133-3 90915 6-3-2671X 9501953451808 2-183-51 90915 53501016 2-133-6 90915 4-14-79 9501953451808 2-183-51 90915 53501017 2-133-7 90915 6-16-123 9501953451809 2-183-52 90915 53501018 2-133-8 90915 6-15-93 9501953451810 2-183-53 90915 53501034 2-133 90915 D-10-A 9501953451811 2-183-54 90915 53501039 2-133-1 90915 6-4-4771 9501953451812 2-184-55 90915 53501230 2-197-8 9091553451814 2-184-61 90915 53501232 2-224-18 9091553451915 2-184-62 90915 53501311 2-212 9091553451818 2-184-66 90915 53501314 2-212 9091553451819 2-183-45 90915 53501315 2-212-2 9091553451820 2-184-58 90915 53501319 2-180 90915

3-15

TM 9-2320-277-14&P


53501357 2-197-13 90915 53505820 2-71-6 9091553501361 2-224-21 90915 53505821 2-71-5 9091553501437 2-197-9 90915 53505826 2-141-11 9091553501515 2-224-15 90915 53505826 2-142-5 9091553501529 2-180-13 90915 53505971 2-154-8 9091553501574 2-197-7 90915 53506079 2-101-19 9091553501578 2-197-1 90915 53506256 2-220-2 9091553501743 2-60-1 90915 53506257 2-220-3 9091553501757 2-60-8 90915 53506258 2-220-4 9091553501759 2-60-3 90915 53506259 2-220-5 9091553501762 2-60-12 90915 53506260 2-220-1 9091553501858 2-213-12 90915 53506269 2-213 9091553501887 2-213-9 90915 53506269 2-87 9091553502154 2-101 90915 53506287 2-133 90915 905569-1720 9501953502155 2-101-20 90915 53506288 2-133-5 9091553502156 2-101-18 90915 53506290 2-201-17 9091553502172 2-236-11 90915 53506337 2-197-12 9091553502218 2-143-10 90915 53506352 2-192-7 9091553502219 2-144 90915 53506373 2-191-7 9091553502415 2-73-1 90915 53506379 2-193-15 9091553502444 2-62-5 90915 53506389 2-55-22 9091553502560 2-238-34 90915 53506395 2-192-3 9091553502563 2-238-31 90915 53506396 2-192-2 9091553502570 2-220-7 90915 53506400 2-87-20 9091553502574 2-238-20 90915 53506404 2-143 9091553502576 2-238-23 90915 53506405 2-143 9091553502619 2-224-38 90915 53506414 2-144 9091553502634 2-233-1 90915 53506415 2-144 9091553502635 2-233-2 90915 53506416 2-144 9091553502672 2-212 90915 53506417 2-220-12 9091553502685 2-73-3 90915 53506428 2-220-21 9091553502686 2-73-2 90915 53506429 2-220-17 9091553502692 2-63-4 90915 53506410 2-220-20 9091553502705 2-2-11 90915 53506431 2-220-18 9091553502708 2-143-10 90915 5350643? 2-220-13 9091553502709 2-144 90915 53506433 2-220-195 9091553502804 2-228-5 90915 53506434 2-220-11 9091553502813 2-141-5 90915 53506435 2-220-8 9091553502832 2-228-1 90915 53506416 2-220-10 9091553502835 2-89 90915 53506417 2-220-9 9091553502863 2-141-6 90915 53506439 2-212-8 90q1553502864 2-141-7 90915 53506443 2-65-3 9091553502878 2-81-12 90915 53506444 2-65-42 9091553502922 2-201-15 90915 53506460 2-65-29 9091553502981 2-130-2 90915 53506463 2-99-1 9091553503050 2-224-29 90915 53506481 2-196-7 9091553503060 2-56-14 90915 53506486 2-99-10 9091553503354 2-197-10 90915 53506497 2-65-26 9091553503364 2-61-5 90915 53506498 2-65-25 9091553503580 2-81-7 90915 53506500 2-65-19 9091553503864 2-194-1 90915 53506506 2-196-10 9091553503866 ?-194-3 90915 53506510 2-65-54 9091553503989 2-186-13 90915 53506518 2-198-1 9091553504006 2-20-9 90915 53506519 2-198-2 9091553504006 2-65-14 90915 53506520 2-198-3 9091553504011 2-69-10 90915 53506598 2-28-10 9091553504076 2-69-9 90915 53506572 2-51-5 9091553504210 2-60-16 90915 53506573 2-214-1 9091553504317 2-60-2 90915 53506652 2-214-4 9091553504330 2-60-4 90915 53506664 2-51-17 9091553504733 2-93 90915 53506714 2-197-2 9091553504734 2-74-6 90915 53506751 2-62 9091553504738 2-73-8 90915 53506753 2-62-7 9091553504884 2-143-11 90915 53506754 2-62-6 9091553505142 2-73 90915 53506757 2-52-9 9091553505175 2-65-31 90915 53506761 2-197-5 9091553505175 2-65-40 90915 53506764 2-129-36 9091553505244 2-65-46 90915 53506779 2-205-37 9091553505248 2-65-51 90915 53506822 2-61-9 9091553505286 2-180-37 90915 53506825 2-187-17 9091553505298 2-126-2 90915 53506839 2-232-8 9091553505299 2-65-43 90915 53506849 2-191-3 9091553505300 2-65-47 90915 53506854 2-201-5 9091553905301 2-65-52 90915 53506855 2-200-5 9091553505305 2-224-20 90915 53506860 2-53-8 9091553505340 2-132-8 90915 53506863 2-186-1 9091553505341 2-132-14 90915 53506864 2-187-16 9091553505363 2-132-11 90915 53506867 2-53-4 9091553505364 2-132-15 90915 53506871 2-84-7 9091553505365 2-132-10 90915 53506872 2-84-2 9091553505386 2-59-27 90915 53506873 2-84-3 9091553505409 2-58-13 90915 53506874 2-87-30 9091553505419 2-58-2 90915 53506878 2-175-11 9091553505420 2-59-23 90915 53506880 2-175-15 9091553505571 2-136-1 90915 53506894 2-233-6 90915

3-16

TM 9-2320-277-14&P


53506957 2-205-36 90915 6831656 2-113-8 7334253506966 2-201-19 90915 6831679 2-121-8 7334253506997 2-156-79 90915 6831680 2-121-10 7334253506998 2-156-73 90915 6831717 2-105-4 7334253506999 2-156-75 90915 6831774 2-103-38 7334253507000 2-156-81 90915 6832462 2-105-30 7334253507331 2-66-58 90915 6832462 2-106-73 7334253507525 2-56-4 90915 6833878 2-105-44 7334253507526 2-56 90915 6833888 2-105-29 7334253507527 2-56 90915 6833888 2-106-72 7334253507742 2-180-36 90915 6833889 2-105-33 7334253507756 2-236-6 90915 6833891 2-103-15 7334253508003 2-224-34 90915 6833891 2-103-8 7334253508012 2-83-6 90915 6833891 2-105-21 7334253508016 2-83 90915 6833891 2-105-27 7334253508319 2-58-3 90915 6833891 2-105-43 7334253508962 2-224-37 90915 6833891 2-124-6 7334253509110 2-55-17 90915 6833891 2-125-13 7334253509114 2-58-8 90915 6833896 2-103-14 7334253509145 2-146-17 90915 6833896 2-105-20 7334253509169 2-154-10 90915 6833896 2-105-26 7334253509251 2-180-40 90915 6833896 2-124-5 7334253509254 2-180-45 90915 6833906 2-123-11 7334253511053 2-99-9 90915 6833934 2-105-40 7334253511170 2-87-36 90915 6833935 2-103-19 7334253511185 2-99-8 90915 6833945 2-106-56 7334253511356 2-212-10 90915 6833940 2-103-7 733425570480 2-19-12 72582 6833949 2-105-41 733425571024 2-127-6 72582 6833940 2-125-12 733425571024 2-19-3 72582 6833981 2-109-12 733425571024 2-49-6 72582 6833981 2-111-9 733425573014 2-19-2 72582 6833986 2-113-10 733425574008 2-19-11 72582 6833986 2-113-17 733425574533 2-56 72582 6833991 2-115-6 73342601 2-73 71951 6833993 2-117-8 733426014 2-92-8 08108 3780 75175 6833993 2-121-19 7334260201Y 2-94-2 13548 6833995 2-109-16 7334260202R 2-94-2 13548 6833995 2-110-5 7334260547-G1 2-242-5 90915 6833999 2-108-2 7334260700 2-94-1 13548 6834105 2-103-31 7334260700 2-94-1 13548 6834219 2-109-13 733426326290 2-68-9 46529 6834221 2-109-23 733426326291 2-68-18 46529 5834222 2-109-20 733426437298 2-19-10 72582 6834229 2-113-2 733426438840 2-56-15 72582 6834229 2-113-25 733426451376 2-89-9 72582 6834230 2-113-18 733426477956 2-89-10 72582 6834230 2-113-9 733426511 2-96-3 13548 6834309 2-115-4 733426703169 2-106-71 73342 6834339 2-117-9 733426703169 2-125-4 73342 6834339 2-121-20 733426753866 2-123-12 73342 6834384 2-117-4 733426753866 2-123-33 73342 6834353 2-113 733426755007 2-117-7 73342 6834354 2-113-20 733426755988 2-123-35 73342 6834354 2-113-7 733426756778 2-123-13 73342 6814368 2-111 733426756782 2-123-6 73342 6834369 2-109-15 733426757563 2-119-26 73342 6834369 2-110-6 733426758036 2-123-10 73342 6834370 2-109-22 733426758205 2-123-3 73342 6834370 2-110-3 733426759971 2-123-32 73342 6834374 2-109-21 733426760695 2-107-22 73342 6834374 2-110-4 733426762127 2-103-22 73342 6834389 2-115-11 733426762187 2-107-21 73342 6834390 2-107-24 733426769319 2-115-26 73342 6834390 2-111-13 733426769631 2-123-29 73342 6834410 2-107-16 733426770019 2-123-2 73342 6834411 2-107-9 733426770820 2-123-8 73342 6834412 2-107-7 733426770822 2-123-7 73342 6834413 2-107-11 733426770845 2-123-9 73342 6834414 2-107-13 733426771144 2-119-27 73342 6834503 2-115-21 733426772576 2-107-4 73342 6814504 2-115-17 733426773311 2-119-25 73342 6834504 2-115-35 733426773551 2-107-17 73342 6834506 2-109-24 733426773679 2-123-28 73342 6834506 2-110-1 733426774322 2-103-3 73342 6834512 2-115-12 73342

6834512 2-115-39 733426774966 2-123-23 73342 6834525 2-107-2 733426774968 2-123-24 73342 6834528 2-106-76 733426777849 2-107-5 73342 6834538 2-103-8 733426779599 2-123-34 73342 6834539 2-103-12 7334268 2-86 08108 6834556 2-119-8 733426830180 2-103-10 73342 6834567 2-119-24 733426830187 2-123-31 73342 6834583 2-115-31 733426830319 2-105-47 73342 6834624 2-103-9 733426831656 2-113-19 73342 6834668 2-109-13 73342

3-17

TM 9-2320-277-14&P


6834668 2-111-8 73342 6837432 2-123-18 733426834669 2-109-13 73342 6837433 2-123-18 733426834669 2-111-8 73342 6837439 2-121-3 733426834670 2-113-2 73342 6837442 2-119-10 733426834670 2-113-25 73342 6837442 2-121 733426834723 2-119-6 73342 6837445 2-121-22 733426834908 2-107-27 73342 6837454 2-105-25 733426834915 2-115-19 73342 6837530 2-121-22 733426834915 2-115-36 73342 6817531 2-121-22 733426834940 2-115-20 73342 6837579 2-123-19 733426835309 2-103-13 73342 6837601 2-117-11 733426835385 2-115-10 73342 6837602 2-107-26 733426835386 2-115-3 73342 6837647 2-121-18 733426835386 2-115-40 73342 6837675 2-121 733426835397 2-121-15 73342 6837692 2-106-61 733426835397 2-121-7 73342 6837859 2-103-9 733426835398 2-121-14 73342 6837993 2-123-36 733736835558 2-115 73342 6838099 2-115 733426835560 2-115-13 73342 6838364 2-109-9 733426835561 2-115-27 73342 6838429 2-105-1 733426835562 2-115 73342 6838404 2-103-15 733426835567 2-115-14 73342 6839013 2-125-10 733426835567 2-115-33 73342 6839018 2-125 733426835569 2-115-30 73342 6839084 2-105-39 733426835570 2-115-25 73342 6839085 2-105-38 733426835571 2-117-2 73342 6839122 2-105-53 733426835572 2-117-2 73342 6839122 2-106-58 733426835573 2-117-2 73342 6839122 2-106-68 733426835574 2-115-2 73342 6839122 6-102-63 733426835640 2-117-6 73342 6839163 2-108-1 733426835641 2-117-5 73342 6839214 2-125-7 733426835642 2-115 73342 6839364 2-115-1 733426835652 2-121-6 73342 6839375 2-115-16 731426835687 2-117-3 73342 6839375 2-115-34 733426835694 2-109-10 73342 6839376 2-121-9 733426835707 2-113-23 73342 6839386 2-121-2 733426835707 2-113-4 73342 6839386 2-121-5 733426835707 2-121-16 73342 6839514 2-115-5 733426835720 2-113-24 73342 6839578 2-106-69 733426835720 2-113-3 73342 6839761 2-103-40 733426835720 2-121-17 73342 6839829 2-105-31 733426835729 2-105-2 73342 6839829 2-106-74 733426835806 2-115 73342 6880045 2-105-51 733426835815 2-125-1 73342 6880045 2-106-66 733426835817 2-106-78 73342 6880075 2-119 733426835920 2-103-64 73342 6880158 2-105-42 733426835920 2-105-49 73342 6880156 2-125-11 733426835920 2-105-54 73342 6880188 2-105-34 733426835920 2-106-59 73342 6890188 2-105-35 733426835921 2-105-50 73342 6880209 2-125-2 733426835921 2-105-55 73342 6880251 2-117-10 733426835921 2-106-60 73342 6880251 2-121-21 733426835921 2-106-65 73342 6880353 2-119 733426835928 2-106-75 73342 6880463 2-103-11 733426835929 2-105-3 73342 6880464 2-125-9 733426835930 2-106-77 73342 6880552 2-107-8 733426836045 2-119-7 73342 6880967 2-103-11 733426836146 2-109-17 73342 6881033 2-105-24 733426836146 2-109-27 73342 6881138 2-125-8 733426836147 2-109-19 73342 6881144 2-103 733426836147 2-109-25 73342 6881227 2-103-6 733426836202 2-107-18 73342 6881592 2-123-30 733426836265 2-113-5 73342 6881596 2-123-26 733426836266 2-113-5 73342 6881597 2-107-1 733426836267 2-113-1 73342 6881598 2-107 733426836267 2-113-22 73342 6881599 2-107 733426836267 2-113-5 733426836268 2-113-5 733426836277 2-107-12 73342 6882294 2-105-23 733426836292 2-125-6 73342 6882565 2-115 733426836390 2-103-12 73342 6882586 2-103-5 733426836585 2-123-20 73342 6882632 2-119 733426836676 2-123-14 73342 6882633 2-108 73342

6882634 2-108-3 733426882638 2-109-6 73342

6836773 2-109-14 73342 6882639 2-109-7 733426836773 2-110-7 73342 6882659 2-110-2 733426836785 2-103-5 73342 6882660 2-110 733426836817 2-125-3 73342 6882689 2-119-17 733426836873 2-12 72582 6882757 2-103-1 733426837206 2-123-22 73342 6882787 2-103 733426837210 2-123-5 73342 6882804 2-115-18 733426837429 2-123-18 73342 6882804 2-115-37 733426837430 2-123-18 73342 6882817 2-124 733426837431 2-123-18 73342 6882818 2-124-1 73342

3-18

TM 9-2320-277-14&P


6882819 2-124-3 73342 86197-1J 2-279-16 607036882820 2-124-4 73342 86197-1J 2-232-12 607036882827 2-115-7 73342 8622361 2-103-14 733426883031 2-117-13 73342 8622757 2-108-4 733426883031 2-121-24 73342 8622757 2-111-11 733426883033 2-117-12 73342 8623056 2-103-42 733426883035 2-113-11 73342 8623121 2-109-11 733426883035 2-113-16 73342 8623121 2-111-10 733426883035 2-121-23 73342 8623262 2-119-31 733426883045 2-103-25 73342 8623263 2-119-30 733426883052 2-106-86 73342 8623484 2-119-2 733426883053 2-106-79 73342 86238-NS 2-229-14 607036883054 2-106-81 73342 86246 2-229-13 607036883088 2-113-13 73342 8625431 2-103-19 733426883148 2-103-18 73342 8627650 2-103-34 733426893616 2-121-11 73342 86724-J 2-230-10 607036883707 2-115-28 73342 87883 2-232-18 607036883864 2-105-32 73342 97900-54J 2-232 607036883974 2-119-19 73342 88752-2 2-232-11 607036884172 2-105-48 73342 88841-20 2-232-16 607036884275 2-117-1 73342 89515-6 2-232-13 607036884733 2-103-24 73342 90000183 2-213-17 909156884749 2-119 73342 90000186 2-58-15 90915 555724 154346884872 2-103-7 73342 90000236 2-58-14 90915 A31126 416256884905 2-103-6 73342 90000736 2-60-19 90915 A31126 416256885166 2-105-52 73342 90000239 2-59-22 90915 A37704 416256885166 2-106-57 73342 90000239 2-60-20 90015 A37704 416256885166 2-106-62 73342 90000245 2-142-3 90915 59009 100516885166 2-106-67 73342 98000264 2-232-1 90915 HV-210480 211026885213 2-103 73342 90000265 2-238-2 90915 HV-210482 211026885572 2-119-28 73342 90000266 2-238-12 909156887618 2-103-17 73342 900003238 2-145 90915 1825-P-120 785007 2-205 97576 90000343 2-150-25 90915 N-410 785007X-111 2-135-13 78500 93000349 2-135-26 90915 N-710-C 785007X-112 2-135-13 78500 90000355 2-135-37 90915 13-X-159 785007450630 2-69-23 72582 90000357 2-134-3 90915 N-214 785007451080 2-69-24 72582 99000373 2-136-16 90915 1199-N-118 7850075026 2-230-21 60703 90000409 2-146-51 90915 5-2914-1 7850075072-NS 2-230-19 60703 90000409 2-147 90915 5-2914-1 7850078364-81 2-232-14 60703 90000410 2-146-22 90915 1229-Y-1507 7850078778-58NS 2-232-10 60703 90000410 3-146-43 90915 1229-Y-1507 7850079040353 2-210-3 90915 90000412 2-147 90915 1850-Q-43 7850079100317 2-210-12 90915 90000415 2-146-26 90915 2803-V-802 7850079100319 2-210-6 90915 90000416 2-146-61 90915 3855-R-70 7850079100320 2-210-7 90915 90000417 2-147-62 90915 2808-4-727 7850079100322 2-210-18 90915 90000418 2-146-59 90915 S-267-1 7850079100323 2-204-1 90915 90000420 2-143-5 90015 A1199-P-1394 785008 2-205 97576 90000427 2-149-10 90915 A25-3275-X-518 785008002 2-85-3 90915 90000428 2-149-17 90915 A1-3299-V-1556 785008010 2-85-1 90915 90000429 2-149-17 90915 A1-3299-W-1557 78500801077 2-80-31 16764 90000430 2-150-29 90915 A-3211-T-1372 785008014 2-85-16 90915 90000439 2-150-30 90915 5-266-D-1 78500801532 2-78-31 16764 90000440 2-150-20 90915 LW-1912 78500801810 2-77-4 16764 90000443 2-149-18 90915 22Q8-T-514 78500801818 2-77-6 16764 90000446 2-149-2 90915 1229-L-844 785008066 2-85-9 90915 90000469 2-148-3 90915 1246-D-290 78500807736 2-80-32 16764 90000472 2-149-12 90915 1229-Q-771 7850081087-5 2-232-19 60703 90000480 2-148-5 90915 2208-W-413 78500811533 2-89 57733 90000492 2-148-2 90915 1229-X-518 785008128SS 2-84-13 90915 90000483 2-147 90915 N-110-1 785008154 2-85-6 90915 90000483 2-148-1 90915 N-110-1 7850081846-156 2-232-9 60703 90000532 2-240-17 90915 HV020089 2110281848-8 1/2 2-232-17 60703 90000533 2-241-11 90915 HV-4039 211028210 2-85-17 90915 90000556 2-209 90915 41881-1 642948215 2-85-15 90915 90000546 2-209 90915 41881-1 642-482415-15NS 2-230-25 60703 90000557 2-209-17 90915 41888 642948274 2-85-10 90915 90000559 2-209-16 90915 42127-7 642948275 2-85-12 90915 90000960 2-209-15 90915 42128-3 642948276 2-85-11 90915 90000562 2-202-1 90915 1501-CA2-36 744108283 2-85-14 90915 90000577 2-51-4 90915 3C355X 9844182895-4 2-232-15 60703 90000540 2-63-1 90915 670252 310338291 2-85-7 90915 90000597 2-238-21 909158298 2-85-5 90915 90000598 2-238 909158299 2-85-4 90915 90000598 2-238-14 909158302 2-85-2 90915 90000609 2-135-27 90915 A-3144-N-456 78500830891 2-77-8 16764 90000610 2-135-27 90915 A-3144-P-458 785008309 2-85 90915 90000626 2-238-29 90915 B-60931-G1-1 469528311 2-85-13 90915 90000627 2-238-30 90915 B-60011-G1 465528312 2-85 90915 90000628 2-238-27 90915 52592-G4 465528314 2-85-8 90915 90000629 2-238-28 90915 52593-G1 465528320 2-84-14 90915 90000630 2-238-25 90915 63441-G3 465528361 2-85-18 90915 90000631 2-238-24 90915 61047-G1 46552839103 2-13-2 72582 90000643 2-132-12 90915 B-10832 51377840277 2-24-2 72582 90000644 2-132-13 90915 B-7426 513778514600 2-20-5 72582 90000645 2-132-1 90915 228836 06853

3-19

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TM 9-2320-277-14&P


90000655 2-132-18 90915 90001565 2-129-23 90915 A50112-045 4162590000708 2-148 90915 963-000 78500 90001566 2-129-24 90915 A50414-001 4162590000747 2-81-10 90915 C3TZ-14526-P 23040 90001567 2-129-25 90915 A50407-842 4162590000761 2-81-9 90915 90001568 2-129-26 90915 A50602-528 4162590000785 2-224-30 90915 00001569 2-129-27 90915 A50803-099 4162590000800 2-83-9 90915 1042-24900Z 51377 90001070 2-129-28 90915 A43716 4162590000814 2-88-6 90915 777F/0.491 57733 90001573 2-129-29 90915 53 0810890000819 2-223-1 90915 90001574 2-129-30 90915 B43681 4162590000820 2-223-12 90915 90001575 2-129-31 90915 B43684 4162590000821 2-205-49 90915 90001576 2-129-32 90915 B62473 4162590000871 2-223-5 90915 90001577 2-129-33 90915 A50407-033 4162590000875 2-148-17 90915 1228-K-453 78500 90001578 2-129-34 90015 A50801-327 4162590000810 2-148-4 90915 3202-F-3516 78500 90001579 2-129-35 90015 A50908-296 4162590000833 2-146-4 0 90915 S-2913 78500 90001590 2-129-9 90915 A51200-024 4162590000814 2-146-41 90915 S-2914 78500 90001591 2-129-13 90915 B61877 4162590000836 2-148 90915 A3-333-M-1365 78500 90001582 2-129-18 90915 D45331-2 4162590000837 2-148 90915 A2-333-M-1365 78500 90001584 2-185-2 9091590000839 2-148-14 90915 A1-3219-W-2623 78500 90001588 2-129-37 90915 63BC116 4162590000840 2-148-19 90915 20-X-853 78500 90001590 2-130 90915 A67776 4162590000841 2-148-19 90915 20-X-852 78500 90001600 2-186-6 90915 8-3/8AEOG-5 3078090000842 2-143-6 90915 SN-1021 78500 90001651 2-242-9 90915 60601-G5 4655290000845 2-148-10 90915 1227-W-517 78500 90001652 2-242-10 90915 60489-G1 4655290000846 2-148-9 90915 1220-U-1009 78500 90001654 2-242-12 90915 60488-G1-1 4655290000847 2-146-24 90915 1227-A-937 78500 90001655 2-242-16 90915 60479-G1 4655290000848 2-143-8 90915 1850-V-48 78500 90001657 2-242-13 90915 61824-G1-1 4655290000840 2-145 90915 1825-Q-121 78500 90001658 2-242-1 90915 60509-G1 4655296000850 2-146-42 90915 S-2920 78500 90001659 2-242-17 90915 60403-G2 4655290000852 2-148-13 90915 A1205-T-774 78500 90001660 2-242-3 90915 60458-G1-1 4655290000853 2-148-7 90915 A1199-H-1698 78500 90001661 2-242-15 90915 61819-G1 4655290000856 2-146-49 90915 S-2910-1 78500 90001662 2-242-7 90915 60000-G2-1 4655290000859 2-149-1 90915 2258-K-349 78500 90001663 2-242-18 90915 7072-G1 4655290000865 2-238-35 90915 455H 46552 90001664 2-242-2 90915 60453-G1 4655290000890 2-155-64 90915 106704 11331 90001665 2-242-6 90915 60337-G1 4655290001075 2-213-2 90915 90001666 2-242-14 90915 61822-G1-1 4655290001076 2-213-1 90915 90001667 2-242-4 90915 60483-G1 4655290001087 2-185-1 90915 90001670 2-71-9 9091590001088 2-185-1 90915 90001679 2-152-1 90915 326-C-78042 8575790001089 2-185-2 90915 90001696 2-152-2 90915 326-C-78043 8575790001090 2-185-3 90915 90001700 2-59-24 90915 184-VGG-3-132 0697090001091 2-185-3 90915 90001757 2-146-34 90915 2203-U-1711 7850090001092 2-185-4 90915 90001758 2-146-15 90915 2203-W-1713 7850090001093 2-185-4 90915 90001772 2-53 90915 RAX00-2392 1826590001094 2-185-6 90915 90001777 2-73 90915 3553-031 7517590001095 2-185-6 90915 90001801 2-65-38 90915 P09108 4652990001096 2-185-7 90915 90001804 2-86-5 90915 40223-8 3395590001097 2-185-8 90915 90001807 2-149-2 90915 1229-X-1116 7850090001098 2-185-9 90915 90001816 2-183-40 90915 032590 7764090001160 2-202 90915 1500BOR-36 74410 90001818 2-126-1 90915 PM-13-2 7004090001104 2-209-7 90915 32235-24 64294 90001818 2-48-8 90915 PM-13-2 7004090001195 2-209 90915 46099-6 64294 90001832 2-199-4 9091590001106 2-209-12 90915 47142-1 64294 90001839 2-142-1 9091590001197 2-209-2 90915 26813 64294 90001840 2-214-3 9091590001197 2-209-2 90915 26813 64294 90101843 2-65-4 9091590001249 2-186-11 90915 8365 24161 90001849 2-139 90915 380-8036 2615190001259 2-205-46 90915 252-3-15 82271 90001850 2-139-1 90915 343-4141 2615190001269 2-156-76 90915 286370 06853 90001860 2-65-7 90915 2242-16-165 0062490001326 2-58-17 90915 A031532 41625 90001872 2-149-23 90915 1779-J-1024 7850090001327 2-58-16 90915 A031538 41625 90001873 2-149-21 90915 1705-D-290 7850090001427 2-134 90915 195 78500 90001874 2-149-22 90915 3870-A-131 7850090001448 2-63-5 90915 90001875 2-147 90915 1229-W-1557 7850090001478 2-194-10 90915 90001887 2-184-64 90915 0-402285-A1 7764090001489 2-146-36 90915 2203-U-463 78500 90001888 2-184-63 90915 0-32346 7764090001513 2-129 90915 D-300671 41625 90001922 2-214-6 9091590001523 2-87-33 90915 FF-146 76761 90001924 2-208 9091590001528 2-184 90915 HF640000 77640 90001936 2-147 90915 S-11016-1 7850090001535 2-83-4 90915 48X4 79470 90001981 2-212 9091590001544 2-129-1 90915 A44654 41625 90001998 2-222-10 9091590001545 2-129-2 90915 A45063-1 41625 90002015 2-71-2 9091590001546 2-129-3 90915 A46136-1 41625 90002016 2-71-1 9091590001547 2-129-4 90915 A48449 41625 90002075 2-204-4 9091590001548 2-129-5 90915 A60058 41625 90002148 2-222-3 9091590001549 2-129-6 90915 A68444 41625 90002167 2-101-17 9091590001550 2-129-7 90915 A300125 41625 90002193 2-222-12 9091590001551 2-129-8 90915 A66994 41625 90002203 2-192-1 90915 P792 8148690001552 2-129-10 90915 B44810 41625 90002207 2-137-5 90915 2258-K-583 7850090001553 2-129-11 90915 B44851 41625 90002208 2-137-9 90915 2297-L-2378 7850090001554 2-129-12 90915 B44406 41625 90002209 2-137-10 90915 A2297-N-3212 7850090001556 2-129-14 90915 B61126-2 41625 90002210 2-137-4 90915 A2747-J-114 7850090001557 2-129-15 90915 P00247-B 41625 90002211 2-137-13 90915 2797-G-423 7850090001558 2-129-16 90915 D43683-1 41625 90002222 2-69-5 90915 156339 5359190001559 2-129-17 90915 D45322-1 41625 90002223 2-69-6 90915 915993 5359190001561 2-129-19 90915 D300042 41625 90002225 2-136-10 90915 20X1381 7850090001562 2-129-20 90915 B60158-1 41625 90002226 2-136-10 90915 20X1380 7850090001563 2-129-21 90915 A50151-289 41625 90002231 2-51-9 90915 FHG16-0078 1826590001564 2-129-22 90915 A50152-274 41625 90002232 2-52-6 90915 P11-7443 18265* See auxiliary list on page 3-27.

3-20

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TM 9-2320-277-14&P


90002233 2-52-7 90915 P11-9372 18265 90002406 2-222-5 9091590002237 2-2-1 90915 5067-5040 72582 90002407 2-222-1 9091590002238 2-178-1 90915 45520-3 09386 90002408 2-222-2 9091590002240 2-191-13 90915 850 74410 90002410 2-222-6 9091590002240 2-193-11 90915 850 74410 90002418 2-134-1 90915 16X-204 7850090002241 2-83 90015 1030-33800-31 51377 90002438 2-135-29 90915 16X-204 7850090002242 2-84 90915 90002439 2-134-4 90915 3133-T-1034 7850090002243 2-69-7 90915 5144797 72582 90002440 2-134-2 90915 K-2616 7850090002244 2-58-7 90915 5164318 72582 90002440 2-135-21 90915 K-2616 7850090002245 2-76-8 90915 5148796 72582 90002441 2-135-17 90915 S-259-1 7850090002246 2-30-2 90915 5133175 72582 90002442 2-135-32 90915 1199-N-1860 7850090002247 2-51-10 90915 AAH00-0351 18265 90002442 2-135-33 90915 1199-N-1860 7850090002248 2-76-9 90915 1100080 16764 90002443 2-135-18 90915 2297-C-2681 7850090002249 2-234-5 90915 610-4645 75175 90002444 2-135-34 90915 2208-Q-823 7850090002250 2-234-6 90915 616-9000 75175 90002445 2-135-10 90915 1225-D-836 7850090002256 2-222-8 90915 90002451 2-135-35 90915 K-2412 7850090002263 2-87-24 90915 9579 13445 90002453 2-135-20 90915 3100-T-6156 7850090002264 2-213-5 90915 90002456 7-137-2 90915 Z20-3276-L12 7850090002264 2-213-5 90915 90002457 2-135-23 90915 5-11022-C 7850090002269 2-220-14 90915 90002498 2-135-24 90915 A1-3102-Y-3457 7850090002269 2-220-16 90915 90002459 2-137-3 9091590002277 2-175 90915 284641 06853 90002460 2-137-6 9091590002278 2-156-82 90915 287276 06853 90002461 2-137-7 9091590002280 2-99-2 90915 1980175 16764 90002462 2-135-30 90915 26-X-219 7850090002291 2-212 90915 064-74000 72635 90002463 2-135-31 90915 N-48-1 7850090002286 2-87-32 90915 8992879 70040 90002464 2-137-8 9091590002787 2-86-9 90915 6432375 70040 90002465 2-136-15 90915 1229-E-1669 7850090002290 2-87-26 90915 6464910 13445 90002467 2-137-11 9091590002291 2-155-52 90915 6464935 70040 90002469 2-135-36 90915 A3111-P-2070 7850090002297 2-61-12 90915 SPH400Z 01652 90002470 2-135-36 90q15 A3111-C-2187 7850090002299 2-62-3 90915 BJ-300-Z 01652 90002472 2-137-12 9091590002300 2-61-1 90915 SP040848AL 01652 p0002474 2-137-14 9091590002301 2-62-1 90915 R-582-AL 01652 90002479 2-136-8 90915 1228-M-403 7850090002302 2-62-2 90915 R-581-AL 01652 90002477 2-137-15 9091590002304 2-62-4 90915 U-300-Z 01652 90002478 2-136-12 90915 HM-212047 7850090002305 2-61-4 90915 U-400-Z 01652 90002479 2-136-13 90915 A-1205-L-1338 7850090002305 2-62-8 90915 U-400-Z 01652 90007480 2-136-14 90915 S-256 7850090002306 2-61-13 90915 RC400-Z 01652 90002481 2-137-16 9091590002307 2-61-2 90915 SP1490AL 01652 90002582 2-137-17 9001590002309 2-61-3 90915 9XD407-AL 01652 90002483 2-137-18 9091590002310 2-62 90915 RK037 01652 900024R4 2-136-18 90915 3219-H-3570 7850090002314 2-61 90915 RK036 01652 90002485 7-136-2 90915 2208-M-819 7850090002316 2-57 90915 QK-2164-823 61112 90002488 2-127-5 90915 PF-132 7004090002321 2-61-10 90915 90002488 2-40-5 90915 PF-132 7004090002322 2-155-23 90915 285924 06853 90002401 2-148 90915 333-M-136S 7850090002326 2-192-4 90915 90002402 2-137-19 9091590002327 2-192-5 90915 93002493 2-137-20 9091590002328 2-192-6 90915 90002498 2-145-9 90915 15-X-1497 7850090002333 2-203-24 90915 GT-13-1 74410 90002499 2-145-9 90915 1229-Y-2443 7850090002334 2-213-10 90915 90002500 2-145-10 90915 NL-19-1 7850090002335 2-99-3 90915 MS75004-2 96906 90002503 2-145-1 90915 E43-3800N-456 7850090002336 2-99-4 90915 MS75004-1 96906 90002506 2-146-38 90915 43208-F-1982 7850090002339 2-177 90915 90002512 2-149-16 90915 1229-C-1511 7850090002350 2-200-4 90915 351-BSS 71913 90002541 2-134 90915 FF-931RDAX-48 7850090002350 2-201-4 90915 351-BSS 71913 90002554 2-30-1 90915 5136272 7258290002351 2-91-8 90915 12065 13445 90002581 2-87-19 90915 772 2699290002352 2-91-9 90915 11750 13445 90002593 2-84-9 9091590002353 2-91-7 90915 11163 13445 90002506 2-91-3 90915 075-0127 8053590002354 2-91 90915 11242 13445 90002660 2-136-9 90915 A333E-2397 7850090002355 2-91-1 90915 40121 13445 90002792 2-45-44 90915 8992016 7004090002357 2-65-10 90915 4176HD 24161 90002792 2-73-20 90915 8992016 7004090002358 2-65-1 90915 90002814 2-197-6 9091590002364 2-65-20 90915 90002914 2-83-5 9091590002366 2-87 90915 90002931 2-88-7 90915 890289 5773390002369 2-99-5 90915 90002949 2-187-15 9091590002370 2-99-6 90915 90003061 2-87-35 90915 5582 1344590002371 2-99-7 90915 90003107 2-223-11 90915 HP5003-30-13 2695399002372 2-51-2 90915 705540 74687 90003114 2-146-15 90915 2234-F-344 7850090002373 2-51-1 90915 P11-5207 18265 90003122 2-150-27 90915 S-21013-1 7850090002374 2-99-11 90915 90003208 2-130-10 90915 B63632 4162590002382 2-137-1 90915 90003222 2-145-6 90915 WA-310 7850090002383 2-222 90915 90003226 2-149-13 9091590002398 2-143-7 90915 A1199-S-1709 78500 90003245 2-145-5 90915 S-2106-1 7850090002389 2-143-1 90915 K51-3800N-456 78500 90003245 2-147-63 90915 S-2106-1 7850090002390 2-148-16 90915 742 78500 90003246 2-147-64 90915 WA-310 7850093002392 2-148-6 90915 A1205-U-619 78500 90003255 2-143-4 90915 A1250-X-338 7850090002393 2-148-12 90915 782 78500 90003256 2-143 90915 K-236 7850090002394 2-148-11 90915 749 78500 90003261 2-146-60 90915 WA-16 7850090002395 2-146-29 90915 H715345 78500 90003284 2-170 90915 282089 0685390002397 2-214-2 90915 1586A13 39428 90003287 2-170 90915 282090 0685390002308 2-86-3 90915 6474386 70040 90003289 2-170-6 90915 292375 0685390002399 2-28-6 90915 5127247 72582 90003289 2-170-6 90915 292375 0685390002399 2-28-6 90915 90003291 2-170 90915 288445 0685390002404 2-222-4 90915 90003294 2-170 90915 288455 0685390002405 2-222-11 90915 90003296 2-170-42 90915 249959 06853* See auxiliary list on page 3-27.

3-21

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*

TM 9-2320-277-14&P


90003297 2-170-33 90915 282064 06853 90006959 2-187-24 9091590003298 2-170 90915 246417 06853 9002324 2-212-1 9091590003299 2-170 90915 246430 06853 9002496 2-143-2 90915 C3121-N-40 7850090003300 2-170-31 90915 246439 06853 90200038 2-126-5 9091590003301 2-170-32 90915 292438 06853 90200045 2-186-9 90915 6MA-6UFS 9285090003302 2-171 90915 292437 06853 90200057 2-101-5 9091590003304 2-170-43 90915 290561 06853 90200058 2-126-6 9091590003306 2-170-40 90915 282068 06853 90200061 2-205-26 90915 16MA-16UFS 9285090000307 2-170-36 90915 249962 06853 90210007 2-205-15 90915 600-12-8C 9285090003308 2-170-30 90915 236120 06853 90430026 2-210-5 9091590003309 2-170-39 90915 243063 06853 904827 2-47-9 7258290003310 2-170-37 90915 249961 06853 90695924 2-58-9 9091590003312 2-170 90915 289113 06853 90695924 2-60-15 9091590003313 2-170-46 90915 292392 06853 90697031 2-200-8 9091590003314 2-170-47 90915 286183 06853 90698022 2-73 9091590003315 2-170-8 90915 246433 06853 90702042 2-180-50 9091590003315 2-170-8 90915 246433 06853 90700027 2-187-20 9091590003316 2-170-1 90915 290560 06853 90709027 2-238-18 9091590003317 2-171-48 90915 290667 06853 90709027 2-45-42 9091590003318 2-168-16 90915 235907 06853 90709027 2-66-60 9091590003371 2-170-29 90915 246415 06853 90709028 2-65-6 9091590003315 2-168-2 90915 5162966 72582 90709245 2-155-58 9091590003327 2-170 90915 279615 06853 90709245 2-205-47 9091590003327 2-170 90915 279615 06853 90709245 2-227-2 9091590003328 2-171 90915 90709300 2-66-59 9091590003393 2-146 90915 A8-3835-B-340 78500 90709320 2-101-8 9091590063484 2-155-69 90915 286392 06853 90709320 2-156-80 9091590003544 2-226-2 90915 90709320 2-48-4 9091590003545 2-226-1 90915 BL20177 26953 90709340 2-155-38 9091590003546 2-226-40 90915 C8060-191 26953 90709340 2-205-51 9091590003547 2-226-25 90915 A8069-006 26953 90700365 2-156-72 9091590003548 2-226-24 90915 A8562-900 26953 90711006 2-74-1 90915 1116882 1676490003550 2-226-17 90915 B1006-016 26953 90711006 2-84-15 90915 1116882 1676490003551 2-226-16 90915 A8049-110 26953 907394 2-46 7798790003553 2-226-7 90915 A8569-900 26953 907674 2-32-20 3037990003554 2-226-6 90915 A8591-900 26953 907940 2-77-18 1676490003555 2-226 90915 KH5011 26953 90802003 2-58-4 9091590003556 2-226-5 90915 A8081-049 26953 90802006 2-170-24 9091590003557 2-226-4 90915 P307-18 26953 90802006 2-224-14 9091590003558 2-226-10 90915 A8637-900 26953 90802036 2-194-2 9091590003559 2-226-8 90915 A8581-900 26953 90802036 2-205-22 9091590003560 2-226-23 90915 A1004-006 26953 90802050 2-100-18 9091590003561 2-225 90915 KH5009 26953 90802090 2-55-21 9091590003562 2-226-14 90915 A8053-006 26953 90802050 2-65-30 9091590003563 2-226-15 90915 A8042-027 26953 90802061 2-61-6 9091590003564 2-226-11 90915 A8020-049 26953 90802064 2-193-10 9091590003565 2-226-12 90915 A8001-018 26953 90802064 2-193-14 9091590003570 2-55-16 90915 HSB-945-5 98440 90802070 2-194-7 909 1590003606 2-57-7 90915 90051-11 13445 90802070 2-2-2 9091590003667 2-55-10 90915 781-18 98440 90802088 2-61-11 9091590003682 2-180-38 90915 10-4-371 95019 90804011 2-129 9091590003683 2-180-39 90915 5-103X 95019 90804011 2-233-3 9091590003685 2-180-42 90915 10-14-29 95019 90804011 2-73 9091590003686 2-180-41 90915 10-16-63 95019 90804016 2-187-21 9091590003687 2-180-43 90915 10-82-121-13X 95019 90804016 2-200-3 9091590003688 2-180-44 90915 10-4-601 95019 90804016 2-201-3 9091590003689 2-180-46 90915 907350 95019 90804016 2-229-3 9091590003710 2-141-12 90915 90804016 2-55-3 9091590003784 2-146-25 90915 90804016 2-59-21 9091590003787 2-146 90915 A15-3226-K-29 78500 90804016 2-60-5 9091590003794 2-145 90915 90804016 2-73 9091590003797 2-150 90915 A9-3211-T-1372 78500 90804017 2-156 9091590003709 2-150-24 90915 1225-U-827 78500 90804017 2-236-1 9091590003800 2-149-6 90915 A35-3722-T-436 78500 90804018 2-175-18 9091590003801 2-149-5 90915 1259-R-252 78500 90804019 2-223-10 9091590003805 2-148 90915 A1-333-M-1365 78500 90804024 2-238-32 9091590003806 2-148-4 90915 3202-V-7379 78500 90804031 2-212 909159000398 2-145-7 90915 2814-L-64 78500 90804033 2-236-4 9091590004013 2-55-11 90915 90804035 2-156 9091590004018 2-89 90915 90804035 2-156 9091590004061 2-143 90915 U240-PX101 78500 90804035 2-159-1 909159000413 2-146-27 90915 2803-C-705 78500 90804035 2-207-1 9091590004137 2-74-9 90915 12T24 31509 90804035 2-232-7 909159000414 2-146-28 90915 2803-D-706 78500 90804035 2-243-3 9091590004160 2-178 90915 12X20SRL-1 73842 90804035 2-57-1 9091590004162 2-222-13 90915 90804037 2-132-7 9091590004293 2-48-2 90915 90804037 2-60-13 9091590004323 2-69-8 90915 90804037 2-65-27 9091590004404 2-221-16 90915 90804037 2-65-55 9091590004418 2-221-15 90915 90804037 2-73 9091590004419 2-221-14 90915 90804039 2-156 9091590004439 2-48-1 90915 90804039 2-233-7 9091590004477 2-73-7 90915 525 71951 90804039 2-91-6 9091590004478 2-221-17 90915 90804055 2-156 9091590004564 2-215-1 90915 44641-004 71044 90804075 2-65-22 90915*See auxiliary list on page 3-27.

3-22

TM 9-2320-277-14&P


90804082 2-60-9 90915 90828010 2-98-1 90915 42332-2 0461890804090 2-183-7 90915 90828028 2-93-12 90915 34072 0461890804103 2-234-4 90915 90828058 2-154-17 90915 215539 0685390804104 2-171-52 90915 90828058 2-154-18 90915 215539 0685390804109 2-156 90915 90928080 2-93-11 90915 R88217-200 5973090804120 2-170-34 90915 246442 06853 90828080 2-93-13 90915 R88217-200 5973090804121 2-170-38 90915 246451 06853 90828097 2-154-7 90915 283122 0685390804130 2-144 90915 90828097 2-155-22 90915 283122 0685390804160 2-194-9 90915 90828097 2-155-63 90915 283122 0685390804182 2-224-26 90915 90828098 2-154-21 90915 283124 0685390804195 2-195-2 90915 90828098 2-154-6 90915 283124 0685390804185 2-199-2 90915 90828103 2-152-4 90015 283149 0685390804185 2-51-13 90915 90828103 2-152-5 90915 283149 0685390804185 2-56-12 90915 90828104 2-156-78 90915 1468X10 7947090804185 2-84-12 90915 90828106 2-155 90915 226137 0685390804226 2-27-2 90915 90828112 2-154-16 90915 226134 0685390804226 2-51-8 90915 90928112 2-154-19 90915 226134 0685390804232 2-187-25 90915 90828112 2-154-20 90915 226134 0685390804249 2-2-9 90915 90828113 2-154-16 90915 226293 0685390804265 2-203-20 90915 90828113 2-154-17 90915 226293 0685390804267 2-156 90915 90828113 2-154-18 90915 226293 0685390804267 2-157-6 90915 90828113 2-154-19 90915 226293 0685390804267 2-183-23 90915 90928113 2-154-20 90915 226293 0685390804267 2-55-15 90915 90828113 2-155 90915 226293 0685390804271 2-194-11 90915 90928137 2-175-10 90915 3BI 3078090804271 2-203-15 90915 90828137 2-229-2 90915 3BI 3078090804301 2-201-10 90915 90828900 2-89-7 90915 1-480319-0 0461890804304 2-236-10 90915 90828291 2-74-7 90915 1-480318-0 0461890804321 2-205-25 90915 90828291 2-89-5 90915 1-480318-0 0461890804341 2-51-16 90915 90828222 2-180-12 90915 6118-1 0461890804345 2-191-11 90915 90828292 2-89-8 90915 6118-1 0461890804166 2-55-20 90915 90828292 2-93-9 90915 6118-1 0461890804369 2-100-17 90915 90828293 2-74 90915 6117-1 0461890804382 2-203-31 90915 90828293 2-89-6 90915 6117-1 0461890804383 2-196-5 90915 90828294 2-93-8 90915 1-480305-0 0461890804405 2-181-63 90915 90828300 2-180-11 90915 480277-1 0461890804409 2-181-62 90915 90820017 2-155-34 90915 278852 0685390804421 2-191-8 90915 90829018 2-155-31 90915 278853 0685390804467 2-157-12 90915 90831005 2-129-40 9091590804467 2-205-41 90915 90831039 2-130-7 9091590804467 2-215-2 90915 90831050 2-203-23 9091590804483 2-65-44 90915 90831068 2-185-5 9091590804483 2-65-48 90915 90831003 2-185-5 9091590804485 2-100-14 90915 90831009 2-203-26 9091590804485 2-101-15 90915 90838007 2-181-60 9001590804485 2-156 90915 90839008 2-155-37 9001590804485 2-157-11 90915 91201080 2-166-13 90915 240366 0685390804485 2-191-4 90915 91517 2-92 7517590804495 2-224-27 90915 91603036 2-244-18 90915 205102 0685390804485 2-224-33 90915 91603080 2-155-71 90915 205829 0685390804495 2-126-7 90915 91603080 2-175-12 90915 T6-168 8279590804495 2-201 90915 91603080 2-53-5 90915 T6-168 8279590804495 2-48-7 90915 91603103 2-155-53 90915 2024-8-105 0062490804500 2-180-48 90915 91603176 2-132-5 9091590804500 2-224-17 90915 91603177 2-154-13 90915 283142 0685390804513 2-181-61 90915 91603177 2-155-57 90915 28342 0685390904515 2-205-29 90915 91603178 2-154-1 90915 283145 0685390804520 2-170-2 90915 249832 06853 91603179 2-154-9 90915 283169 0685390804583 2-143-12 90915 91603180 2-154-9 90o15 1469X10 7947090805121 2-156 90915 91603182 2-155-62 90915 ?83111 0685390805129 2-55-14 90915 91603183 2-152-3 90015 283116 0685390805132 2-65-35 90915 91603183 2-154-14 90915 283116 0689390805258 2-143-14 90915 91603183 2-155-67 90915 283417 0685390812041 2-90-1 90915 232826 06853 91603186 2-152-4 90915 283150 0685390812042 2-156 90915 1503-8=900729-4 00624 91603186 2-152-5 90915 283150 0685390812042 2-205 90915 COV-1313 75272 91603188 2-154-6 90915 283112 0685390812057 2-205-32 90915 CDV-1411 75272 91603191 2-154-15 90915 283116 0685390812057 2-73 90915 CDV-1411 75272 91603196 2-155-22 90915 283113 0685390812076 2-156 90915 91603196 2-156-74 90915 283113 0685390812097 2-186-2 90915 12H 66295 91604100 2-65-15 9091590812097 2-238-16 90915 12H 66295 91604105 2-205-43 9091590812097 2-65-17 90915 12H 66295 91604125 2-205-18 9091590812097 2-84-1 90915 12H 66295 91604145 2-101-2 9091590812098 2-65-13 90915 16H 66295 92001027 2-187-18 90915 FA-103 0224990812099 2-51-3 90915 C92PS 66295 92001027 2-205-19 90915 FA-103 0224990812128 2-65-11 90915 24H 66295 92001034 2-205-21 90915 FCS-537-W 9757690812132 2-65-2 90915 32H 66295 92002008 2-229-6 90915 105X3 7947090817033 2-71-4 90915 92003011 2-155-41 90915 205465 0685390817045 2-73 90915 92003028 2-155-55 90915 222279 0685390818006 2-65-53 90915 COV-2511 75272 92004028 2-155-24 90915 211333 0685390821062 2-204-3 90915 92010034 2-195-4 9091590824007 2-154-15 90915 283121 06853 922594 2-189-30 3270590824007 2-154-71 90915 283121 06853 923091 2-189 3270590824007 2-154-7 90915 283121 06853 923951 2-189-26 3270590824007 2-155-61 90915 283121 06853 92408020 2-201 90915

3-23

TM 9-2320-277-14&P


92408022 2-133-4 90915 95205043 2-155-47 9091592408022 2-141-8 90915 95205170 2-175-13 9091592408022 2-180-47 90915 95205195 2-71-12 9091592408022 2-201-18 90915 95205206 2-155-56 9091592408022 2-224-35 90915 95205306 2-205-17 9091592413000 2-90-3 90915 2866 70485 95210010 2-130-3 9091592413008 2-100-19 90915 2775 70485 95210010 2-232-1 9091592418004 2-180-3 4 90915 2804 70485 95210010 2-53-6 9091592418021 2-73 90915 1862 70485 95210010 2-58-12 9091592418021 2-88-4 90915 1862 70485 95210010 2-60-18 9091592418022 2-73 90915 2870 70485 95210010 2-73 9091592418023 2-73 90915 1259 70485 95210010 2-81-3 9091592802011 2-197-4 90915 16464 95993 95210010 2-98-7 9091592802011 2-212-7 90915 16464 95993 95210080 2-156 9091592804010 2-212-9 90915 95210080 2-156 9091592817011 2-98-5 90915 9000130 16764 95210080 2-156 9091592817012 2-243 90915 207945 06853 95210080 2-156 9091592818929 2-204-5 90915 95210080 2-159-3 9091592818930 2-205-7 90915 95210080 2-205-39 9091592818931 2-205-9 90915 95210080 2-223-2 9091592818933 2-204-2 90915 95210080 2-232-4 9091592819796 2-205-10 90915 95210080 2-233-9 909159409010 2-22-1 72582 95210030 2-234-1 909159409060 2-69-19 72582 95210080 2-243-1 909159409073 2-37-6 72583 95210080 2-57-3 909159409126 2-11-13 72582 95210080 2-58-11 909159409131 2-12 72582 95210080 2-71-7 909159409203 2-37-4 72582 95210080 2-73 909159409225 2-107-15 73342 95210080 2-81-1 909159409231 2-107-14 73342 95710080 2-91-4 909159411396 2-77-15 16764 95210080 2-99-13 909159411504 2-35-2 72582 95210085 2-156 909159412018 2-11-1 72582 95210085 2-208-33 909159412305 2-80-26 16764 95210085 2-65-23 909159413509 2-80 16764 95210110 2-27-3 909159414044 2-107-10 73342 95210110 2-51-6 909159414220 2-113-21 73342 95210125 2-156 909159414220 2-113-6 73342 95210125 2-157-8 909189414397 2-80-4 16764 95210125 2-201-8 909159414523 2-4-14 72582 95210125 2-205-24 909159415239 2-80-27 16764 95210125 2-236-8 909159415235 2-80-34 16764 95210141 2-100-21 909159416484 2-123-1 73342 95210141 2-192-8 909159417025 2-36-73 72582 95210141 2-193-12 909159417926 2-35-13 72582 95210141 2-203-34 909159418228 2-80-44 72582 95210141 2-51-14 909159418881 2-77-1 16764 95210141 2-55-18 909159421423 2-80-20 16764 95210150 2-191-10 909159421423 2-80-8 16764 95210170 2-181-54 909159421427 2-80 16764 95210194 2-55-9 909159421427 2-80-2 16764 95210200 2-65-37 909159421427 2-80-39 16764 95210215 2-224-36 909159422203 2-40-1 72582 95210228 2-144 909159422847 2-103-36 73342 95210228 2-194-8 909159424750 2-119-18 73342 95210228 2-2-3 909159426919 2-115-8 73342 95210230 2-194-13 909159426920 2-103-10 73342 95210230 2-199-3 909159426920 2-121-12 73142 95210230 2-55-13 909159427945 2-76-7 72582 95210240 2-141-10 909159428493 2-103-16 73342 95210280 2-212 909159428493 2-105-22 73342 95210282 2-203-21 909159428493 2-105-28 73342 95210295 2-132-16 909159428493 2-105-36 73342 95210295 2-175-16 909159428493 2-105-45 73342 95210295 2-200-1 909159428493 2-124-2 73342 95210295 2-201-1 909159428493 2-125-5 73342 95210295 2-223-8 909159431894 2-36-67 72582 95210295 2-229-5 909159437171 2-78-27 16764 95210295 2-233-5 909159437927 2-78-33 16764 95210295 2-238-33 9091594408069 2-222-9 90915 95210295 2-55-1 9091594410108 2-73-12 90915 541-1105 75175 95210295 2-57-6 9091594410191 2-73-22 90915 400028 13548 95210295 2-58-6 9091594410192 2-73-21 90915 40004 13548 95210295 2-60-7 9091594410193 2-73-23 90915 17001 13548 95210295 2-73 9091594415046 2-244-13 90915 461 06651 95210296 2-156 90915

95210296 2-236-2 9091594816009 2-65-32 90915 J-7165-3 76005 95210310 2-157-14 9091594816009 2-65-41 90915 J-7165-3 76005 95210311 2-215-3 9091594922 2-97-1 13548 95210312 2-196-6 9091594925 2-94-4 13548 95210312 2-196-8 9091594925 2-95-4 13548 95210312 2-61-8 9091594926 2-94-4 13548 95210312 2-65-34 9091594926 2-95-4 13548 95210312 2-65-39 9091594940 2-96-1 13548 95210330 2-126-8 9091595205040 2-101-10 90915 95210330 2-156 90915

3-24

TM 9-2320-277-14&P


95210330 2-157-4 90915 97205028 2-228-6 9091595210330 2-200-6 90915 97205032 2-63-6 9091595210330 2-205-31 90915 97205038 2-53-7 9091595210330 2-48-5 90915 97205045 2-73 9091595210330 2-51-11 90915 97205047 2-93-1 9091595210330 2-60-10 90915 97705129 2-228-2 9091595210330 2-84-10 90915 97205132 2-232-3 9091595210360 2-141-13 90915 97205142 2-5-20 9091595210390 2-184-60 90915 97205142 2-81-11 9091595210400 2-141-14 90915 97205235 2-210-4 9091595210410 2-183-44 90915 97252058 2-58-1 9091595210420 2-224-13 90915 97262017 2-81-8 9091595210430 2-60-14 90915 97270011 2-87-16 90915 7124 1344595210441 2-129 90915 97415024 2-223-7 9091595210442 2-129 90915 97415065 2-244-16 9091595210442 2-183-6 90915 97415071 2-205-45 9091595210450 2-201-13 90915 97415085 2-71-11 9091595210475 2-143-13 90915 97415146 2-238-19 9091595210485 2-130-9 90915 97415155 2-101-11 9091595210485 2-180-49 90915 97417520 2-81-13 9091595210485 2-195-1 90915 97417522 2-74-8 9091595210485 2-199-1 90915 97420058 2-98-3 90915 52421 0461895210485 2-224-16 90915 97430013 2-224-40 90915 H-9004-1 7600595210485 2-224-24 90915 97431102 2-59-25 90915 TY-525-M 5973095210485 2-224-31 90915 97431102 2-73 90915 TY-525-M 5973095210490 2-203-17 90915 97927 2-96-5 1354895210505 2-210-8 90915 98005501 2-155-50 90915 229603 0685395210572 2-214-5 90915 08005506 2-155-35 90915 229615 0685395210595 2-210-2 90915 98410025 2-183-8 9091595210656 2-73 90915 98410026 2-191-6 9091595210657 2-228-3 90915 98410026 2-715-5 9091595210657 2-59-19 90915 98410015 2-183-24 9091595210658 2-155 90915 98410035 2-203-7 9091595410073 2-210-13 90915 98410044 2-65-33 9091595410074 2-210-11 90915 98410062 2-238-22 9091595410075 2-210-10 90915 714427 80201 98410065 2-201-14 9091595410076 2-210-9 90915 715330 80201 98415015 2-228-4 90915954987 2-36-60 72582 98415015 2-232-2 9091595620134 2-129-39 90915 98415015 2-58-18 9091595670019 2-205-20 90915 A-7664 97484 98419015 2-73 9091595670076 2-208-34 90915 98415015 2-81-4 9091595670135 2-161-5 90915 98415015 2-98-8 9091595670135 2-205-12 90915 98415017 2-130-4 9091595670160 2-170-28 90915 238822 06853 98415010 2-129 90915

98415020 2-175-17 9091595690083 2-205-28 90915 155YC-021-RF 64294 98415020 2-187-22 9091595900 2-94-3 13548 98415020 2-200-2 9091595900 2-94-3 13548 98415070 2-201-2 9091595900 2-95-3 13548 98415020 2-213-11 9091595900 2-95-3 13548 98415020 2-723-9 9091596000515 2-205-38 90915 98415020 2-233-4 9091596000516 2-155-54 90915 98415020 2-55-2 9091596000622 2-205-13 90915 98415020 2-57-5 9091596000625 2-205-14 90915 98415020 2-58-5 9091596001318 2-48-3 90915 98415020 2-60-6 9091596003918 2-186-10 90915 98415021 2-156 9091596009280 2-205-11 90915 98415021 2-229-4 9091596081618 2-205-6 90915 98415021 2-236-3 9091596084009 2-186-7 90915 98415034 2-214-7 9091596084009 2-44-3 90915 7207-64 24161 98415035 2-132-6 9091596084009 2-66-61 90915 98415035 2-156 9091596084009 2-71-10 90915 98415035 2-156 9091596084009 2-84-4 90915 7207-64 24161 984150A5 2-156 9091596084209 2-187-19 90915 HV-19989 21102 98415035 2-156 9091596084209 2-238-17 90915 HV-19989 21102 98415035 2-159-2 9091596084209 2-65-18 90915 69-80 23040 98415035 2-170-25 9091596084209 2-84-8 90915 HV19989 21102 98415035 2-173-2 9091596091102 2-224-23 90915 98415035 2-205-40 9091596091402 2-155-39 90915 98415035 2-207-18 9091596091402 2-223-6 90915 98415035 2-223-3 9091596091408 2-205-48 90915 98415035 2-232-5 9091596091420 2-205-42 90915 98415035 2-233-8 9091596091518 2-205-44 90915 98415035 2-234-2 9091596091756 2-224-22 90915 98415035 2-243-2 9091597100146 2-210-1 90915 98415035 2-57-2 9091597115028 2-98-10 90915 1116781 16764 98415035 2-58-10 9091597135032 2-181-51 90915 98415035 2-65-28 9091597135074 2-210-14 90915 98415035 2-66-56 9091597135327 2-60-17 90915 98415035 2-81-2 9091597140121 2-210-17 90915 98415035 2-51-5 9091597140123 2-210-15 90915 98415035 2-99-12 9091597205021 2-238-26 90915 98415041 2-191-5 9091597205028 2-212 90915 98415041 2-215-4 9091597205028 2-220-19 90915 98415042 2-100-15 9091597205028 2-220-6 90915 98415042 2-101-16 90915

3-25

TM 9-2320-277-14&P


98415042 2-126-9 90915 99103866 2-208-36 9091598415042 2-156 90915 99103867 2-208-37 9091598415042 2-157-3 90915 99103868 2-208-38 9091598415042 2-200-7 90915 99103869 2-208-39 9091598415042 2-201 90915 99103870 2-208-40 9091598415042 2-205-30 90915 99103871 2-208-41 9091598415042 2-224-28 90915 99103877 2-208-23 9091598415042 2-48-6 90915 99103878 2-207-2 9091598415042 2-51-12 90915 99103879 2-108-43 9091598415042 2-56-13 90915 99103894 2-244-9 90915 212678 0685398415042 2-60-11 90915 99103959 2-244-10 90915 212679 0685398415042 2-65-45 90915 99103971 2-213-3 9091598415042 2-65-49 90915 99103975 2-213-4 9091598415042 2-84-11 90915 99103987 2-213-6 9091598415045 2-170-35 90915 246441 06853 99103998 2-213-13 9091598415045 2-187-26 90915 99104012 2-197-3 9091598415045 2-27-4 90915 99104105 2-212-5 9091598415045 2-51-7 90915 99104106 2-212-11 9091598415050 2-156 90915 99104107 2-212-4 9091598415050 2-157-7 90915 99106874 2-205-50 9091598415050 2-194-5 90915 99207001 2-196-1 9091598415050 2-2-10 90915 99207001 2-196-4 9091598415050 2-201-9 90915 99207046 2-211-1 9091598415050 2-205-23 90915 99207047 2-211-2 9091598415050 2-236-9 90915 99207048 2-211-3 9091598415055 2-100-20 90915 99207049 2-211-4 9091598415055 2-191-12 90915 99207050 2-211-5 9091598415055 2-192-9 90915 99207051 2-211-6 9091598415055 2-193-13 90915 99207052 2-211-7 9091598415055 2-203-33 90915 99207053 2-211-P 9091598415055 2-51-15 90915 99207054 2-211-9 9091598415055 2-55-19 90915 99207057 2-211-10 9091598415060 2-181-64 90915 99207058 2-211-11 9091598415060 2-191-9 90915 99207059 2-211-12 9091598415060 2-196-2 90915 992904 2-189 3270598420011 2-2-7 90915 99800420 2-229-1 9091598421024 2-18 1-53 90915 99802052 2-238-15 9091598421024 2-184-56 90915 99802052 2-65-16 90915 4230-0145 2416198421025 2-2-5 90915 99802110 2-89-4 9091598421120 2-141-9 90915 99802110 2-93-10 9091598421120 2-142-2 90915 99802337 2-154-16 90915 304-M 0685398421120 2-196-3 90915 99802337 2-154-17 90915 304-M 0685398421125 2-196-9 90915 99802337 2-154-18 90915 304-M 0685398421125 2-224-39 90915 99802337 2-154-19 90915 304-M 0685398421125 2-61-7 90915 99802337 2-154-20 90915 304-M 0685398421130 2-187-14 90915 99802337 2-155 90915 304-M 0685398421130 2-194-12 90915 99802339 2-244-17 9091598421130 2-65-36 90915 99802340 2-132-4 9091598421135 2-100-16 90915 99802340 2-152-3 9091598421135 2-157-13 90915 99802340 2-154-14 9091598421135 2-187-27 90915 99802340 2-154-15 9091598421135 2-195-3 90915 99802340 2-154-21 9091598421135 2-224-32 90915 99802340 2-154-6 9091598421135 2-225-25 90915 99802340 2-154-7 9091598421135 2-65-21 90915 99802340 2-155-22 9091598421145 2-232-6 90915 99802340 2-155-60 9091598421145 2-234-3 90915 99802340 2-155-68 9091598421145 2-66-57 90915 99802340 2-155-70 9091598421150 2-132-17 90915 99802341 2-152-4 9091598421150 2-187-23 90915 99802341 2-152-5 9091598421190 2-212 90915 99802341 2-154-73 9091598430132 2-210-16 90915 99802342 2-154-9 9091598828099 2-244-15 90915 99802351 2-65-12 9091599012Y 2-96-4 13548 99802352 2-83-2 9091599100213 2-238-13 90915 99802354 2-56-8 9091599100715 2-238-7 90915 99802355 2-56-1 90915 213-10 9844199100216 2-238-8 90915 99802355 2-56-5 90915 213-10 9844199100217 2-238-9 90915 99803000 2-154-11 90915 FC107=10 0062499100218 2-238-10 90915 99803014 2-98-2 9091599101448 2-236-7 90915 99803039 2-244-14 90915 F-341-363 00410

9910310 2-213-18 9091599103853 2-207-4 9091599103854 2-207-5 9091599103855 2-207-6 9091599103856 2-207-7 9091599103857 2-207-11 9091599103858 2-207-12 9091599103859 2-207-14 9091599103860 2-207-16 9091599103861 2-208-27 9091599103862 2-208-28 9091599103163 2-208-29 9091599103864 2-208-30 9091599103865 2-208-35 90915

3-26

TM 9-2320-277-14&P

AUXILIARY LISTING

MFR VENDOR VENDORPART NO PAGE / ITEM CODE PART NO CODE

MS 35842-10 2-44-1 96906

MS 49005-8 2-11-19 96906

MS 49005-8 2-25-19 96906

MS 49005-8 2-45-17 96906

MS 90724-51 2-20-2 96906

12288013 2-103-2 19207

23012381 2-103 73342

23012740 2-107 73342

23014632 2-107-25 73342

23014632 2-113-12 73342

5103748 2-35-14 72582

5104516 2-35-20 72582

516121 2-41-5 24617

90000954 2-208 90915

90003200 2-236-4 90915

90003205 2-236-5 90915

90003549 90915 KH5015 26953

90003552 90915 KH5003-30-01 26953

90007338 2-73-1 90915

90007339 2-73-2 90915

90007340 2-73-3 90915

3-27

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APPENDIXES

TABLE OF CONTENTS

Page

APPENDIX A References A-1

APPENDIX B Maintenance Allocations Chart B-1

Section I. Introduction B-1II. Maintenance Allocation Chart B-3III. Tool and Test Equipment

Requirements B-13IV. Remarks B-14

APPENDIX C Maintenance and Operating Supply List C-1

APPENDIX D Preventive Maintenance Checks and Services D-1

Section I. Operator/Crew Preventive MaintenanceChecks and Services D-3

II. Organization Preventive MaintenanceChecks and Services D-11

APPENDIX E Basic Issue Items List E-1

APPENDIX F Prescribed Load List/Authorized Stockage List F-1

TM 9-2320-277-14&P

APPENDIX A

REFERENCES

A-1. Publication Indexes and General References

Indexes should be consulted frequently for latest changes or revisions of references given in this appendix and for newpublications relating to material covered in this publication.

a. Military Publication Index.

b. General ReferencesDictionary of United States Army Terms .............................................................................................AR 310-25Authorized Abbreviations and Brevity Codes ......................................................................................AR 310-50How to Prepare and Conduct Military Training ...................................................................................... FM 21-6Military Symbols ................................................................................................................................FM 21-30

A-2. Other Publications

The following publications contain information pertinent to the major item materiel and associated equipment.

a. DecontaminationChemical, Biological, and Radiological (CBR) Decontamination.............................................................TM 3-220Chemical, biological, Radiological, and Nuclear Defense ......................................................................FM 21-40

b. GeneralAccident Reporting and Records ........................................................................................................AR 385-40Basic Cold Weather Manual ................................................................................................................FM 31-70Cooling Systems: Tactical Vehicles .................................................................................................TM 750-254Manual for Wheeled Vehicle Driver ...................................................................................................FM 21-305Army Motor Transport Units and Operations ........................................................................................FM 55-30Mountain Operations ........................................................................................................................... FM 90-6Northern Operations ...........................................................................................................................FM 31-71Operation and Maintenance of Ordnance Materiel in

Cold Weather (0°F to-65°F..............................................................................................................FM 9-207Principles of Automotive Vehicles .....................................................................................................TM 9-8000Prevention of Motor Vehicle Accidents ..............................................................................................AR 385-55Procedures for Destruction of Tank Automotive Equipment to

Prevent Enemy Use ................................................................................................................TM 750-244-6c. Maintenance and Repair.

Organizational Care Maintenance and Repair: Pneumatic Tires,Inner Tubes and Radial Tires ............................................................................................ TM 9-2610-200-20

Inspection, Care and Maintenance of Antifriction Bearings ....................................................................TM 9-214Materials Used for Cleaning, Preserving, Abrading, and

Cementing Ordnance Materiel and Related Materials IncludingChemicals .....................................................................................................................................TM 9-247

A-1

TM 9-2320-277-14&P

Metal Body Repair and Related Operations .......................................................................................... FM 43-2Material Management for Using Units, Support Units and Installations....................................................AR 710-2Requisitioning, Receipt, and Issue System .........................................................................................AR 725-50Supply Operations Manual: Vol. I: Distribution Systems Procedures .................................................. AR 735-110Operation and Organizational, Maintenance Manual for Lead-Acid

Storage Batteries.............................................................................................................. TM 9-6140-200-14Organization, Policies, and Responsibilities for Army Materiel Maintenance Concepts

and Policies ...................................................................................................................................AR 750-1Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling System............................... TB 750-651Welding Theory and Application...........................................................................................................TM 9-237Color, Marking, and Camouflage Painting of Military Vehicles Construction

Equipment, and Materials Handling Equipment............................................................................. TB 43-0209d. Shipment and Limited Storage.

Administrative Storage of Equipment...............................................................................................TM 740-90-1Color Marking and Preparation of Equipment for Shipment of Army Materiel ..........................................AR 746-1Preservation, Packaging, Packing, and Marking Materials, Supplies and

Equipment Used by the Army........................................................................................................ SB 38-100The Army Maintenance Management System (TAMMS) .....................................................................TM 38-750General Procedures for Shipment ......................................................................................................FM 55-15

A-2

TM 9-2320-277-14&P

APPENDIX BMAINTENANCE ALLOCATION CHART



NSN 2320-01-044-8376

TM 9-2320-277-14&P

APPENDIX B

MAINTENANCE ALLOCATION CHART

SECTION I

INTRODUCTION

B-1 General

a. This section provides a general explanation of all maintenance and repair functions authorized at variousmaintenance categories.

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for theperformance of maintenance functions on the identified end item or component. The application of the maintenancefunctions to the end item or component will be with the capacities and capabilities of the designated maintenancecategories.

c. Section III lists the tools and test equipment (both special tools and common tool sets) required for eachmaintenance function as referenced from section II.

B-2 Maintenance Functions: Maintenance functions are as follows:

a. Inspect: To determine the serviceability of an item by comparing its physical, mechanical and/or electricalcharacteristics with established standards through examination.

b. Test: To verify serviceability and detect incipient failures by measuring the mechanical or electrical characteristicsof an item and comparing those characteristics with prescribed standards.

c. Service: Operations required periodically to keep an item in proper operating condition; i.e., to clean(decontaminate), to preserve, to drain, to paint or to replenish fuel, lubricants, hydraulic fluids or compressed air supplies.

d. Adjust: To maintain, within prescribed limits, by bringing into proper or exact position or by setting the operatingcharacteristics to specified parameters.

e. Align: To adjust specified variable elements of an item to bring about optimum or desired performance.

f. Replace: The act of substituting a serviceable like type part, subassembly or module (component or assembly)for an unserviceable counterpart.

g. Repair: The application of maintenance services or other maintenance actions to restore serviceability to an itemby correcting specific damage, fault, malfunction or failure in a part, subassembly, module (component or assembly), enditem or system.

B-3 Explanation of Columns in the MAC, Section II

a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identifymaintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. End itemgroup number shall be "00."

B-1

TM 9-2320-277-14&P

B-3 Explanation of Columns in the MAC, Section II (Continued)

b. Column 2, Component/Assembly. Column 2 contains the names of components, assemblies, subassemblies,and modules for which maintenance is authorized.

c. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in Column 2.(For detailed explanation of those functions, see paragraph B-2.)

d. Column 4, Maintenance Category. Column 4 specifies, by the listing of a work time figure in the appropriatesubcolumn(s), the category of maintenance authorized to perform the function listed in Column 3. This figure representsthe active time required to perform that maintenance function at the indicated category of maintenance. If the number orcomplexity of the tasks within the listed maintenance function vary at different maintenance categories, appropriate worktime figures will be shown for each category. The work time figure represents the average time required to restore anitem (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical fieldoperating conditions. This time includes preparation time (including any necessary disassembly/assembly time),troubleshooting/fault location time, and quality assurance/quality control time in addition to the time required to performthe specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. The symboldesignations for the various maintenance categories are as follows:

C .............................................Operator or crew

O .............................................Organizational maintenance

F .............................................Direct Support Maintenance

H .............................................General Support Maintenance

L .............................................Specialized Repair Activity (SRA)

D .............................................Depot maintenance

e. Column 5, Tools and Equipment. Column 5 specified, by code, those common tool sets (not individual tools) andspecial tools, TMDE, and support equipment required to perform the designated function.

f. Column 6, Remarks. This column shall, when applicable, contain a letter code, in alphabetic order, which shall bekeyed to the remarks contained in Section IV.

B-4 Explanation of Columns in Tool and Test Equipment Requirements, Section III.

a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the MAC,Section II, Column 5.

b. Column 2, Maintenance Category. The lowest category of maintenance authorized to use the tool or testequipment.

c. Column 3, Nomenclature. Name or identification of the tool or test equipment.

d. Column 4, National Stock Number. The National stock number of the tool or test equipment.

e. Column 5, Tool Number. The manufacturer's part number.

B-2

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Section II. MAINTENANCE ALLOCATION CHART

NOTE: Maintenance Support is organic through Direct Support (F). All maintenance supportbeyond F will be as required from commercial sources.

01 ENGINE

0100 Engine Service 0.1 1Adjust 2.5Replace 2Repair 2.7

Engine Mount Replace 2.0

0101 Block, Engine Inspect 1.0 1

Cylinder, Head Replace 10.1Repair 12.0

0102 Damper, Vibration Replace 4.5 1

Seals, Main Replace 7.2

0103 Flywheel Replace 6.9 1Repair 1.0

Flywheel Housing Replace 9.5

0105 Valves and Tappets Adjust 1.5Replace 4.0

Timing Gears Replace 3.5

Arm Rocker Replace 2.5

0106 Oil Pump Replace 3.5 1

Filter, Oil Service 0.5Replace 1.0

Lines, External Replace 1.0.

Valve, Breather Service 0.2

*The subcolumns are as followsC-operator/crew H-general supportO-organizational D-depotF-direct support ** Worktimes are included in DMWR

B-3

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Coolers, Oil Test 1.0Replace 3.0Repair 11.5

Level Gage Replace 0.1

Oil Pan Replace 2.0Repair 4.0

Valve, Regulator and Replace 0.2 Relief Repair 0.2

0108 Manifolds Replace 2.0 1

0109 Accessory Drive Repair 2.0 1Replace 4.5

03 FUEL SYSTEM

0301 Injector Assembly Replace 1.0 1 Fuel Repair 1.5

Rack, Fuel Injector Adjust 1.0Replace 1.3

0302 Pump Assembly, Fuel Test 0.5 1Replace 1.5Repair 1.0

0304 Air Cleaner Assembly Service 0.1Replace 1.0Repair 1.0

Air Cleaner Replace 1.0 Restriction Indicator

0305 Air Inlet Replace 1.0 1

Blower, Gear Driven Replace 6.0Repair 4.0

Blower, Drive Replace 6.0

*The subcolumns are as followsC-operator/crewO-organizationalF-direct supportH-general supportD-depot

** Worktimes are included in DMWRB-4

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

0306 Tank, Fuel Service 1.0 1Replace 3.0Repair 1.5

Lines and Fittings, Replace 1.0 Fuel

0308 Governor Adjust 1.0Replace 6.0Repair 2.0

0309 Fuel Filter Service 0.1 1Replace 0.3

0311 Ether Kit, Engine Service 0.3 1 Starting Replace 1.0

0312 Accelerator & Throttle Adjust 0.3 1Replace 0.5Repair 0.5

04 EXHAUST SYSTEM

0401 Exhaust Pipes Replace 1.5 1

Muffler Replace 2.0

05 COOLING SYSTEM

0501 Radiator Test 0.1 1Service 0.2Replace 8.0Repair 4.0

Heat Exchanger Replace 3.0Repair 4.0

0502 Shroud, Radiator Replace 1.5 1

0503 Thermostats Test 0.2 1Replace 1.5


** Worktimes are included in DMWR

B-5

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Hoses Replace 0.5

0504 Pump, Water Replace 2.5 1Repair 2.0

Water Seal Replace 2.0

0505 Fan Replace 1.5 1Repair 1.0

Belts, Fan Drive Adjust 0.2Replace 1.7

06 ELECTRICAL SYSTEM

0601 Alternator Test 1.0 1Replace 1.3Repair 2.0

Belts, Drive Adjust 0.3Replace 1.4

0603 Starter Test 1.4 1Replace 2.0Repair 3.0

Cable Replace 1.5

Solenoid, Relay Test 0.4Replace 0.3

0607 Instrument Panel Replace 1.5 1Repair 3.0

Circuit Breaker Test 0.5Replace 2.0

0608 Switches Test 0.4 1Replace 0.5

Turn Signal Control Replace 0.4Repair 0.6

* The subcolumns are as follows.C-operator/crewO-organizationalF-direct supportH-general supportD-depot


(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

0609 Lights; Head Adjust 0.2 1Replace 0.4Repair 1.0

Lights, Tail & Park, Repair 0.4 Turn Signal & Marker Replace 0.3

Floodlights Replace 0.3Repair 0.2

0610 Unit, Sending Replace 0.5 1

0611 Switch and Relay Replace 1.0 1

Horn Test 0.2Replace 0.5Repair 0.5

0612 Batteries Test 0.6 1Service 0.5Replace 0.4

Box, Battery Replace 1.0Repair 1.0

Cables, Battery Replace 0.4Repair 0.8

0613 Wiring Test 2.5 1Replace 10.0Repair 2.0

07 TRANSMISSION

0708 Torque Converter Repair 6.0 1Replace 10.0

0710 Transmission Test 0.5 1Service 0.2Replace 6.5Repair 16.0

* The subcolumns are as followsC-operator/crewO-organizationalF-direct supportH-general supportD-depot


(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Shift Linkage Adjust 1.0Replace 2.0Repair 1.0

0721 Filter Replace 0.5 1

09 PROPELLER SHAFTS

0900 Shaft, Assembly and Service 0.2 1 U-joints Replace 1.0

10 FRONT AXLE

1000 Axle, Assembly Service 1.0 1Replace 6.0Repair 8.0

1004 Steering Knuckle Service 0.1 1Replace 0.7

11 REAR AXLE

1100 Axle, Assembly Service 1.0 1Replace 6.0Repair 8.0

Shaft, Axle Replace 8.0

1102 Differential Service 1.0Replace 9.8

12 BRAKES

1202 Brake Assembly, Adjust 0.5 1 Foundation Replace 3.0

Repair 4.0

1206 Linkage, Mechanical Adjust 1.0 1Replace 3.0Repair 2.0

1208 Lines and Fittings, Replace 2.2 1 Air Repair 1.6



B-8

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Tanks, Air Service 0.1Replace 1.1Repair 1.1

Air Chamber Brakes Replace 2.0Repair 2.2

Wedge Assembly Adjust 0.3Replace 2.0Repair 2.5

1209 Air Compressor, Assem- Service 0.2 1 bly Including Adjust 1.0 Governor & Belts Replace 3.0

Repair 1.0

1211 Lines & Couplings, Replace 1.0 1 Trailer Brakes Repair 1.5

13 WHEELS

1311 Hub, Assembly Service 1.0 1Adjust 0.5Replace 1.0

Drum Replace 2.0Repair 3.0

Bearings and Seals Replace 1.6

1313 Tires Service 0.3Replace 2.1Repair 1.3

14 STEERING

1401 Wheel, Steering Replace 0.5

Column, Steering Replace 4.0Repair 3.5

Idler Arm Replace 2.5



B-9

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Tie Rod Align 0.3Replace 1.5

Gear, Steering Adjust 0.2 1Service 0.3Replace 3.2Repair 7.0

1407 Unit, Power Steering Service 0.5 1Replace 6.8Repair 8.0

1410 Pump, Hydraulic, Main Test 0.2 1Replace 3.0Repair 3.0

1411 Lines and Fittings, Replace 0.6 1 Hydraulic Repair 1.0

Hydraulic Filter Replace 0.5 Element

1412 Cylinder, Power Adjust 1.0 1 Steering Replace 2.0

Repair 1.5

1414 Valves, Hydraulic Adjust 1.0 1Replace 3.0Repair 2.0

15 FRAME AND TOWING ATTACHMENTS

1501 Frame Repair 1.5 3.0 1

1504 Spare Tire Mount Replace 1.0 1Repair 1.0

1506 Fifth Wheel Service 0.2 1Replace 3.0Repair 2.0



B-10

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

16 SPRINGS AND SHOCK ABSORBERS

1601 Springs & Spring Seats Service 0.2 1Replace 4.0Repair 2.0

1604 Shock Absorbers Replace 1.8 1

1605 Torque Rods Replace 2.0 1

18 CAB AND BODY

1801 Cab Mounts Replace 3.0 1Repair 1.0

Doors Replace 2.0Repair 6.0

Panels and Engine Replace 0.5 Shroud Repair 0.3

Ventilators Replace 0.2Repair 0.5

Splash Shields Replace 0.3Repair 0.4

1802 Fenders Replace 1.5 1Repair 0.5 2.6

Windshield Replace 1.2

1806 Seats Replace 0.5 1Repair 1.5

22 ACCESSORY ITEMS

2202 Arm and Wiper Replace 0.2 1

Motor, Windshield Replace 1.0 Wiper Repair 1.5



B-11

(1)

GROUPNUMBER

(2)

COMPONENT/ASSEMBLY

(3)

MAINTENANCEFUNCTION

(4)

MAINTENANCECATEGORY

(5)

TOOLSAND

EQUIP-

(6)

REMARKS

C O F H D MENT

TM 9-2320-277-14&P

Mirror, Rearview Adjust 0.1Replace 0.3

Windshield Washer and Service 0.2 Motor Replace 0.5

2207 Heater Replace 2.0 1Repair 2.0

Air Ducts Replace 1.0Repair 1.0

Heater, Control Panel Replace 1.0Repair 1.0

2210 Plates, Data and Replace 0.5 1 Instruction

47 GAGES, NON ELECTRIC

4701 Shaft, Speedometer Replace 0.5 1

4702 Gages, Pressure Test 0.5 1Replace 0.5

4703 Hourmeter Replace 1.0



B-12

TM 9-2320-277-14&P

MAINTENANCE ALLOCATION CHART FORTractor, Yard Type, 4X2NSN 2320-01-044-8376,

Model 50, P/N WG50 2000

SECTION III - TOOL AND TEST EQUIPMENT REQUIREMENTS

TOOL OR TESTEQUIPMENTREFERENCE MAINTENANCE NATIONAL/NATO TOOL

CODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBERUnless otherwise noted, all organizational and direct support maintenance functions can be accomplished with the toolscontained in the following tool sets. No special tools are required.

1 F Shop Equipment Contact 4940-00-294-9518 LIN T10138Maintenance Truck Mounted

F Shop Equipment General 4940-00-287-4894 LIN T10549Purpose Repair Semi-trailer Mounted

O F Shop Equipment Org. Re- 4940-00-294-9516 LIN T13152pair Light Truck Mounted

F Tool Kit Automotive Fuel 4910-00-754-0655 LIN W32456& Electrical SystemRepair

O H Tool Kit Auto Maintenance 4910-00-754-0654 LIN W32593Org. Maintenance Common#1

O F Tool Kit Auto Maintenance 4910-00-754-0650 LIN W32730Org. Maintenance Common#2

O F Tool Kit Auto Maintenance 5180-00-177-7033 LIN W33004Light Weight

F Tool Kit Master Mech: 5180-00-699-5273 LIN W45060Equipment Maintenance &Repair

F Wrench Set Socket: 3/4" 5130-00-357-5135 LIN Y75239Drive Hex Type

F Wrench Torque: 3/4" 5120-00-542-5577 LIN Y84966Drive 100-500 Lb. Capa-city

F Shop Equipment Fuel & 4910-00-754-0714 LIN T30414Electrical System Engine

B-13

TM 9-2320-277-14&P

MAINTENANCE ALLOCATION CHART FORTractor, Yard Type, 4X2NSN 2320-01-044-8376,

Model 50, P/N WG50 2000

TOOL OR TESTEQUIPMENTREFERENCE MAINTENANCE NATIONAL/NATO TOOL

CODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBER

O F Shop Equipment Auto 4910-00-754-0653 LIN W32867Maintenance & RepairOrganizational Supple-mental No. 1, Less Power

F Shop Equipment Machine 3740-00-754-0708 LIN T15644Shop

F Tool Kit, Machinist 5280-00-511-1950 LIN W44512

F Shop Equipment, Welding 3740-00-357-7268 LIN T16714

F Tool Kit, Body & Fender 5180-00-754-0643 LIN-W33689Repair

SECTION IV - REMARKS (NOMENCLATURE OF END ITEMS)

A Remarks: All repair and replacement of parts performed by organizationalmaintenance limited to authorized items listed in MAC Chart.

B-14

TM 9-2320-277-14&P

APPENDIX CMAINTENANCE AND OPERATING SUPPLY LIST



NSN 2320-01-044-8376

TM 9-2320-277-14&P

APPENDIX C

MAINTENANCE & OPERATING SUPPLY LIST

NOMENCLATURE: MAKE MODEL:Truck, Tractor, Yard Type, 5 Ton, DED Ottawa Truck Division 50

MFR PART NO.: NSN SERIAL NO RANGE: DATEWG50 2000 2320-01-044-8376 51748 thru 51763 1979COMPONENT MFR PART NO. QTY REQ QTY REQAPPLICATION OR DESCRIPTION F/INITIAL F/8 HRS NOTES

NATL STOCK NO. OPN OPNEngine 9150-00-188-9858 OE/HDO-30 (5 Gal) None See Attached Sheet

9150-00-188-9859 OE/HDO-30 (55 Gal)9150-00-188-9860 OE/HDO-40 (5 Gal)9150-00-188-9861 OE/HDO-40 (55 Gal)

Fuel Tank 9140-00-286-5294 Type DF2 to -20 F (-29°C), BULK 50 Gal 64 Gal

Radiator 6850-00-181-7929 Antifreeze, Ethylene Glycol, NoneInhibited, Heavy DutyMIL-A-46153A (5 Gal)

Hydraulic System Hydraulic Fluid9150-00-223-4134 MIL-H-5606 (1 Gal) None9150-00-265-9408 MIL-H-5606 (55 Gal)

Hydraulic PowerSteering and 9150-00-698-2382 Dexron Automatic Trans F (1 Qt) NoneTransmission 9150-00-657-4959 Dexron Automatic Trans F (5 Gal)

LubricationFittings 9150-00-190-0907 GAA (35 Lb Can) None As Req

Differential 9150-01-035-5393 GO80W/90 (5 Gal) None9150-01-035-5395 GO85W/140 (5 Gal)

C-1

TM 9-2320-277-14&P

APPENDIX C

LUBRICANTS CAPACITY ABOVE 32°F BELOW 32°F

OE/HDO Oil, Engine, Heavy Duty OE/HDO 40 OE/HDO 30

Engine Crankcase (See Note 1) 14 Qts

Oil Can Points OE/HDO 10 OE/HDO 10

Hydraulic Power Steering 4 Qts Dexron Auto Dexron Auto

Transmission 18 Qts Trans F. Trans F.

Hydraulic System OHA 8 Gals All Temp. All Temp.

GO - Lubricating Oil, Gear 38 Pts GO 85W/140 GO 80W/90

GAA - Grease, Automotive & Artillery All Temperatures

NOTES:

1. Engine Crankcase. Add two quarts 4. Wheel Bearings. Every 500 hours remove the front(1.893 liters) when the oil filter is wheels, clean & inspect all parts, replace damaged orreplaced. worn parts, repack bearings using 1 Lb. Grease (GAA)

and reassemble.2. For Operation of Equipment inProtracted Cold Temperatures Below 5. Lubricants: The following is a list of lubricants32°F. Remove lubricants prescribed with the military symbols & applicable specificationin the key for temperatures above numbers: OE/HDO MIL-L-2104C, GO MIL-L-2105B,32°F. Relubricate with lubricants OHA MIL-H-5606C, GAA MIL-G-10924.below 32°F.

3. Oil Can Points. Every 50 hourslubricate brake treadle hinge & roller.C2

TM 9-2320-277-14&P

APPENDIX D

PREVENTIVE MAINTENANCE CHECKS AND SERVICES

Maintenance Forms and Records

Every mission begins and ends with the paperwork. There isn't much of it, but you have to keep it up. The forms andrecords you fill out have several uses. They are a permanent record of the services, repairs, and modifications made onyour vehicle. They are reports to organizational maintenance and to your commander. And they are a checklist for youwhen you want to know what is wrong with the vehicle after its last use, and whether those faults have been fixed. For theinformation you need on forms and records, see TM 38-750.

Preventive Maintenance Checks and Services

1. Do your (B) PREVENTIVE MAINTENANCE just before you operate the M878. Pay attention to the CAUTIONS andWARNINGS.

2. Do your (D) PREVENTIVE MAINTENANCE during operation. (During operation means to monitor the M878 and itsrelated components while they are actually being operated).

3. Do your (A) PREVENTIVE MAINTENANCE right after operating the M878. Pay attention to the CAUTIONS andWARNINGS.

4. Do your (W) PREVENTIVE MAINTENANCE weekly.

5. Do your (M) PREVENTIVE MAINTENANCE once a month.

6. If something doesn't work, troubleshoot it with the instructions in this manual and notify your supervisor.

7. Always do your PREVENTIVE MAINTENANCE in the same order so it gets to be a habit. Once you've had somepractice, you'll spot anything wrong in a hurry.

8. If anything looks wrong and you can't fix it, write it on your DA Form 2404. If you find something seriously wrong,report it to organizational maintenance RIGHT NOW.

9. When you do your PREVENTIVE MAINTENANCE, take along the tools you need to make all the checks. You alwaysneed a rag or two.

A - Keep it clean: Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as youwork and as needed. Use dry cleaning solvent (SD-2) on all metal surfaces. Use soap and water when you clean rubberor plastic material.

WARNING

Dry cleaning solvent, used to clean parts is potentially dangerous to personnel andproperty. Do not use near open flame or excessive heat. Flash point of solvent is:138°F.

D-1

TM 9-2320-277-14&P

B - Bolts, nuts, and screws: Check them all for obvious looseness, missing, bent or broken condition. You can't try themall with a tool, of course, but look for chipped paint, bare metal, or rust around bolt heads. If you find one you think isloose, tighten it, or report it to organizational maintenance if you can't tighten it.

C - Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report itto organizational maintenance.

D - Electric wires and connectors: Look for cracked or broken insulation, bare wires, and loose or broken connectors.Tighten loose connectors and make sure the wires are in good shape.

E - Hoses and fluid lines: Look for wear, damage, and leaks, and make sure clamps and fittings are tight. Wet spotsshow leaks, of course. But a stain around a fitting or connector can mean a leak. If a leak comes from a loose fitting orconnector, tighten it. If something is broken or worn out, report it to organizational maintenance.

10. It is necessary for you to know how fluid leakage affects the status of your vehicle. The following are definitions of thetypes/classes of leakage an operator or crew member needs to know to be able to determine the status of his/her vehicle.Learn, then be familiar with them and REMEMBER WHEN in DOUBT, NOTIFY YOUR SUPERVISOR!

Leakage Definitions for Crew/Operator PMCS

Class I Seepage of fluid (as indicated by wetness or discoloration)not great enough to form drops.

Class II Leakage of fluid great enough to form drops but not enough tocause drops to drip from item being checked/inspected.

Class III Leakage of fluid great enough to form drops that fall from theitem being checked/inspected.

CAUTION

EQUIPMENT OPERATION is ALLOWABLE WITH MINOR LEAKAGE (CLASS I OR II).OF COURSE, CONSIDERATION MUST BE GIVEN TO THE FLUID CAPACITY in THEITEM/SYSTEM BEING CHECKED/INSPECTED. WHEN in DOUBT, NOTIFY YOURSUPERVISOR.

D-2

TM 9-2320-277-14&P

SECTION I

OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICESB-BEFORE D-DURING A-AFTER W-WEEKLY M-MONTHLY

INTERVALITEM TO BE INSPECTED EQUIPMENT IS NOT READY/

ITEM B D A W M PROCEDURE: CHECK FOR AND HAVE REPAIRED, FILLED OR AVAILABLE IF:NO. ADJUSTED AS NEEDED

NOTE

Within designated intervals, these checks are to be performed inthe order listed.

NOTE

Perform weekly as well as before PMCS’s if:

a. You are the assigned driver, but have not operated thevehicle since the last weekly.

b. You are operating the vehicle for the first time.

Make the following walk-around checks:

1 TIRES

Check tires for correct air pressure:

X Front axle tires 105 PSI

X Rear axle tires 95 PSI

D-3

TM 9-2320-277-14&P




2 EXTERIOR OF VEHICLE

X a. Check for body, undercarriage and components damage.

X b. Check tires for cuts, gouges or cracks. Tires have cuts, gouges orcracks, which would result intire failure. One or moretires are unserviceable.

X c. Look for evidence of fluid leakage (oil, fuel, brake fluid Class III leakage evident.and water). No fuel leakage allowed.

d. Check condition of:

X (1) Windshield and windows.

X (2) Windshield wiper arms and blades.

X (3) Mirrors.

3 EXHAUST SYSTEM

X Visually inspect the muffler, shield and exhaust pipes fordamage and security of hardware.

D-4

TM 9-2320-277-14&P




4 BATTERIES

WARNING

Do not smoke or allow any flame in the vicinity while checking orfilling the battery. The battery generates hydrogen; a highlyexplosive gas.

X Check terminals for damage or corrosion. Inspect for obvious Battery cracked or discharged.defects. Add distilled water to split ring, if required(reference TM 9-6140-200-14).

X Check battery compartment for broken latches, cracks in thecover and insure mounting hardware/bolts are tight.

5 AIR RESERVOIRS

X Open drain cocks to drain moisture from the three reservoirslocated under the cab of the truck.

6 FIFTH WHEEL

WARNING

Do not remove fill cap when hydraulic fluid is hot. Hot fluid cancause severe injury. Make sure when removing cap, it isremovedslowly.

X Check for leaks or damage at the reservoir and loose ordamaged fittings and hoses. Check fluid level.

D-5

TM 9-2320-277-14&P

SECTION I




X Check lift cylinders for leaks, damaged hydraulic lines and Class III cylinders or linesfittings. are leaking, air cylinder is

inoperative or air leakage.

X After engine has been started and air pressure is up; checkair cylinder for proper operation, air leaks, and damagedlines.

7 SEAT

X Check operator seat for loose mountings and damage. Make Missing/unserviceable seatsure operator’s seat is properly adjusted. Check for belt.damaged or missing seat belt.

8 FIRE EXTINGUISHER (IF EQUIPPED)

X Check for missing or damaged fire extinguisher Check gagefor proper pressure (150 PSI). Make sure the mounting issecure.

9 INSTRUMENT GAGES, CONTROLS, AND INDICATORS

X Check to make sure gages, controls and indicators areoperating properly and registering the proper readings.

X Make sure engine oil pressure gage indicates normal operating Oil pressure gage isrange (at 1800 to 2100 rpm, 50 to 70 psi is normal; minimum inoperative.for safe operation is 30 psi).

D-6

TM 9-2320-277-14&P




X After warm-up, make sure engine water temperature gage Temperature gage isindicates normal operation temperature (160° to 185°F). inoperative.

X Check fuel gage and make sure tanks have sufficient fuel.

X Make sure air pressure gage is functioning properly and that low Air pressure gage isair pressure warning light and buzzer remains off (when air inoperative.system pressure exceeds approximately 80 psi).

X Check all cab controls for proper operation. Cab control does not operateproperly.

X Check foot controls for proper operation. Foot control does not operateproperly.

X Check emergency flasher control.

X Check all lights for operation.

10 TRANSMISSION

X When the main transmission has reached normal operating Class III leakage evident.temperature range (160° to 220°F), shift through the positions Shifts roughly, slips,on the range selector and return the lever to the N position. vibrates, is unusually noisy(Make sure the truck is on level ground), apply the parking or the hydraulic retarder isbrake, leave the engine running at idle speed, and check the not properly operating.

D-7

TM 9-2320-277-14&P




transmission fluid level on the dipstick (safe operatinglevel is between FULL and ADD marks on dipstick). If level islow, add DEXRON rated only (transmission fluid) up to FULL markon dipstick (be careful not to overfill transmission). Iffluid level is above FULL mark on dipstick, notify organiza-tional maintenance.

X While driving, check transmission operation through all rangeselector positions.

11 POWER STEERING OPERATION

X With the engine running, turn the steering wheel to the right Steering binds or isand left checking for any unusual noise, binding or difficulty unresponsive.in steering.

12 BRAKES

X a. Check for chatter, noise and side pull. Service or parking brakesdo not operate properly.

X b. Make sure that brakes are operating properly.

X c. Check for proper operation of the parking brakes.

13 WINDSHIELD WASHER FLUID LEVEL

X Check to make sure windshield washer fluid reservoir containssufficient fluid. Add fluid if necessary. Reservoir willhold one gallon of fluid.

D-8

TM 9-2320-277-14&P




14 POWER STEERING FLUID LEVEL, LINES AND CONNECTIONS

X Check fluid level in the power steering fluid reservoir forproper level. If level is low, add oil to bring level toFULL mark. Check lines and connections for leaks.

15 ALL BELTS

X Check for cracked, worn and frayed belts.

16 AIR CLEANER RESTRICTION INDICATOR

X Check indicator for clogged air cleaner element (red indicatesclogging). If indicator shows red, notify organizationalmaintenance.

17 ALCOHOL EVAPORATOR

X In freezing temperatures: Check level of alcohol in theevaporator. Fill as necessary with alcohol. Alcohol evapora-tor is located on the firewall.

18 COLD WEATHER STARTING AID (COLD WEATHER ONLY)

X a. Check for loose or damaged mountings and linkages.

X b. Check the canister for damage.

D-9

TM 9-2320-277-14&P




19 COLD WEATHER STARTING AID (ENGINE OPERATION)

X Check for excessive exhaust smoke, unusual noise, roughrunning, or misfiring. Engine should run smoothly.

20 ENGINE OIL

X a. Check for presence of oil on dipstick.

X b. After engine has warmed-up, stop the engine and check forproper oil level on the dipstick (should be between L(LOW) and F (FULL) marks.

21 ENGINE COOLANT

X Check coolant level at the radiator filler neck (level shouldbe approximately 1 inch from bottom of filler neck). Iflevel is low, add a mixture of ethylene glycol antifreeze andclean water to bring coolant to proper level (check withorganizational maintenance for the proper mixture).

22 RADIATOR

X Check for leaks, clogged or damaged fins and loose or damagedhoses to and from the engine.

D-10

TM 9-2320-277-14&P

SECTION II

ORGANIZATIONALPREVENTIVE MAINTENANCE CHECKS AND SERVICES

1. Do your (Q) PREVENTIVE MAINTENANCE once each 3 months.

2. Do your (S) PREVENTIVE MAINTENANCE once each 6 months.

3. Do your (A) PREVENTIVE MAINTENANCE once each year.

4. Do your (W) PREVENTIVE MAINTENANCE once each week.

5. Do your (H) PREVENTIVE MAINTENANCE at the hour interval listed.

6. Do your (MI) PREVENTIVE MAINTENANCE when the mileage of the vehicle reaches the amount listed.

7. If something doesn't work, troubleshoot it with the instructions in your commercial manual or notify your supervisor.

8. Always do your PREVENTIVE MAINTENANCE in the same order so it gets to be a habit. Once you've had somepractice, you'll spot anything wrong in a hurry.

9. If anything looks wrong and you can't fix it, write it on your DA Form 2404. If you find something seriously wrong,report it to direct support maintenance RIGHT NOW.

10. When you do your PREVENTIVE MAINTENANCE, take along the tools you will need to make all the checks. Takealong a rag, you'll always need at least one.

WARNING

DRY CLEANING SOLVENT, USED TO CLEAN PARTS is POTENTIALLYDANGEROUS TO PERSONNEL AND PROPERTY. DO NOT USE NEAR OPENFLAME OR EXCESSIVE HEAT. FLASH POINT OF THIS SOLVENT is 138°F.

A - Keep it clean: Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as youwork and as needed. Use dry cleaning solvent (SD-2) on all metal surfaces. Use soap and water when you clean rubberor plastic material.

B - Bolts, nuts, and screws: Check them all for obvious looseness, missing, bent or broken condition. You can't try themall with a tool, of course, but look for chipped paint, bare metal, or rust around bolt heads. If you find one you think isloose, tighten it, or report it to direct support maintenance if you can not tighten it.

C - Welds: Look for loose or chipped paint, rust or gaps where parts are welded together. If you find a bad weld, report itto direct support maintenance.

D-11

TM 9-2320-277-14&P

D - Electric wires and connectors: Look for cracked or broken insulation, bare wires, and loose or broken connectors.Tighten loose connectors and make sure the wires are in good shape.

E - Hoses and Fluid Lines: Look for wear, damage, and leaks, and make sure clamps and fittings are tight. Wet spotsshow leaks, of course. But a stain around a fitting or connector can mean a leak. If a leak comes from a loose fitting orconnector, tighten it. If something is broken or worn out, report it to direct support maintenance.

11. It is necessary for you to know how fluid leakage affects the status of your vehicle. The following are definitions of thetypes/classes of leakage an operator or crew member needs to know to be able to determine the status of your vehicle.Learn, then be familiar with them and REMEMBER WHEN in DOUBT, NOTIFY YOUR SUPERVISOR!

Leakage Definitions for Organizational PMCS

Class I Seepage of fluid (as indicated by wetness or discoloration)not great enough to form drops.

Class II Leakage of fluid great enough to form drops but not enoughto cause drops to drip from item being checked/inspected.

Class III Leakage of fluid great enough to form drops that fall fromthe item being checked/inspected.

CAUTION

EQUIPMENT OPERATION is ALLOWABLE WITH MINOR LEAKAGES (CLASS I ORII). OF COURSE, CONSIDERATION MUST BE GIVEN TO THE FLUID CAPACITY INTHE ITEM/SYSTEM BEING CHECKED/INSPECTED. WHEN IN DOUBT, NOTIFYYOUR SUPERVISOR.

WHEN OPERATING WITH CLASS I OR II LEAKS, CONTINUE TO CHECK FLUIDLEVELS AS REQUIRED IN YOUR PMCS.

CLASS III LEAKS SHOULD BE REPORTED TO YOUR SUPERVISOR OR DIRECTSUPPORT.

D-12

TM 9-2320-277-14&PORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES

Q-QUARTERLY S-SEMIANNUALLY A-ANNUALLY B-BIENNIALLY H-HOURS MI-MILES MO-MONTHLY

INTERVAL

ITEM NO.Q S A B H MI MO

ITEM TO BE INSPECTEDPROCEDURE: CHECK FOR AND HAVE REPAIRED, FILLED, OR ADJUSTED AS NEEDED

PERFORM ALL OPERATOR PMCS FIRST

1. Engine

150 Change oil, replace oil filter and clean crankcase breather cap. Clean primary air cleanerelement with compressed air. Replace element every third service interval.

WARNING

Maximum air pressure will not exceed 30 PSI.

NOTE: For Army Oil Analysis Program Procedures, refer to TB 43-0210.

2. Drive Belts

150 Check tension of belts and adjust as necessary.

3. Engine and Transmission Mounts

2000 Check condition of mounting bolts and pads. Repair or replace if necessary.

4. Air Cleaner and Indicator

X Check safety filter on restriction indicator and clean or replace as necessary.

5. Fuel Filter

300 Replace filter element.

D-13



INTERVAL




6. Control Linkage

300 Lubricate all pivot points on transmission, accelerator and throttle controls with engine oil.

7. Chassis

X Provide complete chassis lubrication. Force grease into fittings until old lubricant, dirt, and waterare expelled.

8. Exhaust System

600 Check system for leaks. Repair or replace parts as necessary.

9. Engine Tune Up

600 Perform engine tune up.

10. Engine Governor

600 a. Check governor with tachometer.

600 b. Change oil filter.

11. Transmission

600 a. Replace filter element.

600 b. Change oil when warm. Refill with proper lubricant, clean breather.

X c. Inspect for missing components, loose bolts, leakage or damage. Replace missingcomponents, tighten loose hardware, repair as necessary.

D-14



INTERVAL




12. Fifth Wheel

X Lubricate fifth wheel plate.

X Lubricate pivot points.

X Lubricate lift cylinders.

X Lubricate boom pivot pin.

X Lubricate unlatch cylinder clevis pin.

X Lubricate jaw pin.

13. Cab

X Lubricate vent hinge.

X Lubricate door handle and door hinge.

X Lubricate engine hood hinges and latches.

X Lubricate tiedown shackles.

X Lubricate accelerator pedal hinge and roller.

X Lubricate cab pivot points.

600 Lubricate speedometer cable.

600 Lubricate seat.

D-15



INTERVAL




14. BrakesX Lubricate slack adjustor pivot.

X Lubricate brake chamber clevis.

X Lubricate hinge and roller.

15. Steering and Front Axle

600 Lubricate axle knuckle pins.

600 Lubricate link ball sockets.

600 Lubricate steering shaft U-joint.

600 Clean and repack wheel bearings.

600 Change power steering filter.

16. Hydraulic System

X Hydraulic reservoir - clean breather cap monthly.

X Hydraulic reservoir - drain, clean and refill monthly.

X Hydraulic reservoir - clean magnetic plug monthly.

X Hydraulic filter - change monthly.

17. Fuel System

300 Change fuel filter.

D-16



INTERVAL




18. Drive Axle

X Lubricate drive shaft (pressure fitting).

X Differential: Fill as needed and clean breather.

X Differential: Drain and refill.

600 Axle bearings, clean and repack.

D-17 (D-18 blank)

TM 9-2320-277-14&P

APPENDIX E

Basic Issue Items List

DESCRIPTIONSMR NATIONAL STOCK REF NO. USABLE UNIT QTY

CODE NUMBER AND ON OF AUTHMFG CODE CODE MEASURE

NOTE: The followingitems are overpackedwith the Ottawa TruckModel 50, 1609 Lb.

7520-00-559-9618 Case, Cotton Duck: ea 1MIL-B-11743

7530-01-065-0166 Equipment Record Folder ea 1

E-1 (E-2 blank)

TM 9-2320-277-14&PAPPENDIX F

PRESCRIBED LOAD LIST/AUTHORIZED STOCKAGE LIST

ITEM: Truck, Tractor, Yard Type, 43,500 (GVW) Diesel Engine Driven (DED)

CONTRACT NO.: DAAEO7-78-C-6799

CONTRACTOR: Ottawa Truck Division, Ottawa, Kansas

QUANTITY: 16 each

PREVIOUS PROCUREMENTS:

Contractor Quantity YearOttawa 28 FY77

PLL ASL UNITSMR NSN PART NUMBER FSCM PART DESCRIPTION U.M. 1-5 1-5 PRICE

PAOZZ 2940-00-117-0047 90002232 70040 Filter Element Air Ea 1 1 38.47(90915) A394C

PAOZZ 2940-01-091-7193 90002233 18265 Filter Element Air Ea 1 1 25.73(90915) Donaldson #PH-9372

PAOZZ 2940-00-755-6584 53103500 02249 Element Ea 2 2 3.70(90915) Gresen #K-22002

PAOZZ 2940-00-580-6283 MS35802-3 96906 Element, Lube Oil Ea 1 1 3.20Filter

PAOZZ 2910-01-025-6853 6438839 72582 Cartridge, Fuel Ea 1 1 5.71Strainer

PAOZZ 2910-01-022-8183 6438840 72582 Cartridge, Fuel Ea 1 1 5.71Filter

PAOZZ 3030-00-982-1208 5135942 72582 Belt, Crankshaft Set 1 1 9.00Pulley

F-1

TM 9-2320-277-14&P


PAOZZ 5925-00-247-7935 1512-1-15 98343 Circuit Breaker 15 AMP Ea 1 1 2.15

PAOZZ 5925-00-110-3150 30056-20 13445 Circuit Breaker 20 AMP Ea 1 1 2.15

PAOZZ 5925-01-091-7191 1512-1-30 98434 Circuit Breaker 30 AMP Ea 1 1 2.15

PAOZZ 6140-00-057-2554 NS35000-3 96906 Battery 6 TN 12 Volt Ea 1 1 59.28

PAOOF 2610-00-489-8041 123-340-988 73842 Tire, Pneumatic: 16 Ply Ea 1 1 191.00Polyamide Nylon12.00X20

PAOOF 2610-00-051-9454 193-423-200 73842 Inner Tube, Pneumatic Ea 1 1 10.84Tire: Pneumatic;12.00X20

PAOOF 2610-00-158-5617 20R 73808 Flap, Inner Tube Ea 1 1 4.64

PAOZZ 3030-00-421-1553 5139228 72582 Belt, Water Pump Drive Set 1 1 2.11(2 Belts, 36.76"L X.380"W)

PAOZZ 3030-00-844-4773 5133175 72582 Belt, Alternator (2 Belts, Set 1 1 1.5239"LX, 380"W)

PAOZZ 6240-00-013-1282 53 08108 Bulb, Speedometer 12V Ea 5 5 .25

PAOZZ 6240-00-924-7526 1156 08108 Lamp, Flood 12V Ea 1 1 .17

PAOZZ 6240-00-009-0242 6014 08108 Lamp, Head 12V Ea 2 2 1.51

PAOZZ 6240-00-946-9654 1895 08108 Lamp, Clearance 12V Ea 3 3 .11

PAOZZ 6240-00-763-3450 1893 08108 Lamp, Inc; Dome Ea 1 1 .12

F-2

TM 9-2320-277-14&P


PAOZZ 6240-00-155-8664 MS15569-6 96906 Lamp, Inc; Pilot Ea 1 1 .17

PAOZZ 6220-01-086-5689 40204 13548 Lamp, Sealed: Back-up Ea 1 1 6.10

PAOZZ 6220-01-047-4059 40202R 13548 Lamp, Sealed: Red Tail Ea 1 1 6.20

PAOZZ 6220-01-086-5690 60201Y 13548 Lamp Sealed: Turn Ea 2 2 8.65Front

PAOZZ 6220-01-086-5691 60202R 13548 Lamp Sealed: Stop & Ea 2 2 6.20Tail

PAOZZ 6240-00-944-1264 194 08108 Lamp, Inc; Side Marker Ea 2 2 .11

F-3

TM 9-2320-277-14&P

INDEX



NSN 2320-01-044-8376

TM 9-2320-277-14&P

INDEX

A

BookSection Para Page

Accelerator cable and engine linkage .......................................................... II 3-6 3-9

Accelerator linkage, parts list ...................................................................... III 2-58Accelerator pedal........................................................................................ II 3-7 3-9Acoustical upholstery, parts list.................................................................... III 2-220

Adapter, low planetary and low clutch, parts list ........................................... III 2-120See Low Planetary

Air cleaner assembly, parts list ................................................................... III 2-52Air cleaner, parts list ................................................................................... III 2-50

Air compressor components: ....................................................................... IIAir compressor .................................................................................... 12-6 12-9Air compressor governor ....................................................................... 12-7 12-13Air strainer ........................................................................................... 12-4 12-7Alcohol evaporator ................................................................................ 12-5 12-9

Air compressor wear limits, fits and tolerances ............................................. II Table 12-2 12-12

Air horn ..................................................................................................... II 12-18 12-26Air horn, parts list ....................................................................................... III 2-243

Air inlet housing.......................................................................................... II 2-10 2-9Air inlet housing, parts list ........................................................................... III 2-27

Air system, detailed description.................................................................... I 1-4g 1-3

Air system, general description: .................................................................. II 12-2 12-1Air compressor .................................................................................... 12-2b 12-1Air compressor governor ....................................................................... 12-2b 12-3Air tanks .............................................................................................. 12-2d 12-4Arrangement......................................................................................... 12-2a 12-1Automatic drain valve ............................................................................ 12-2d 12-4Brake control panel .............................................................................. 12-2e 12-5Quick release valve............................................................................... 12-2h 12-6

Air system, parts list: .................................................................................. IIIAir compressor .................................................................................... 2-169Air compressor governor ....................................................................... 2-172Air compressor installation..................................................................... 2-167Air strainer ........................................................................................... 2-173Air tank installation................................................................................ 2-157

Index 1

TM 9-2320-277-14&P


Air system specification and data ................................................................ II 12-3 12-6

Air tanks .................................................................................................... II 12-8 12-14

Alpha-numeric cross reference list .............................................................. III 3-1 3-1

Alternator: ................................................................................................. II 6-1 6-1Assembly, parts list .............................................................................. III 2-77Cleaning inspection and repair............................................................... II 6-4 6-2On vehicle tests ................................................................................... II 6-2 6-1Reassembly and installation ................................................................. II 6-5 6-6Removal and disassembly..................................................................... II 6-3 6-2

Antifreeze specifications ............................................................................. I Table 2-1 2-2

Automatic drain valve .................................................................................. II 12-9 12-15

Automatic drain valve, parts list ................................................................... III 2-160

Automatic transmission, parts list................................................................. III 2-101

Auxiliary heater .......................................................................................... II 18-14 18-21

Auxiliary heater, parts list ........................................................................... III 2-242

B

Backup and tail lights .................................................................................. II 6-17 6-22

Backup and tail lights, parts list ................................................................... III 2-95

Ball sockets................................................................................................ II 14-18 14-11

Ball sockets, parts list ................................................................................. III 2-185

Batteries .................................................................................................... II 6-27 6-29

Batteries and cables - preservation and packaging........................................ I 2-8h 2-2

Battery Box ................................................................................................ II 6-26 6-28

Battery group, parts list .............................................................................. III 2-99

Battery water level -under hood check.......................................................... I 2-3f 2-1

Index 2

TM 9-2320-277-14&P


Blower assembly:Cleaning, inspection and repair ............................................................. II 2-73 2-97Inspection, removal and disassembly ..................................................... II 2-72 2-97Reassembly and installation ................................................................. II 2-74 2-98

Brake control panel ..................................................................................... II 12-14 12-21

Brake control panel, parts list ..................................................................... III 2-177

Brake treadle valve ..................................................................................... II 12-12 12-19

Brake, detailed description........................................................................... I 1-4f 1-3

Breather, upper front cover, parts list .......................................................... III 2-8

Bumper and grille guard, parts list................................................................ III 2-192

C

Cab ........................................................................................................... See also Operator's Cab

Cab, parts list ............................................................................................. III 2-212

Cab door:Cleaning............................................................................................... II 18-4c 18-3Disassembly......................................................................................... II 18-4b 18-2Inspection and repair............................................................................. II 18-4d 18-3Installation............................................................................................ II 18-4f 18-4Parts list .............................................................................................. III 2-213Reassembly. . ..................................................................................... II 18-4e 18-4Removal............................................................................................... II 18-4a 18-2

Cab tilt hydraulics:Cab tilt hydraulics, parts list .................................................................. III 2-223Hydraulic cylinder ................................................................................. II 19-7 19-3Hydraulic cylinder, parts list .................................................................. III 2-227Hydraulic latches ................................................................................. II 19-2 19-1Hydraulic pump..................................................................................... II 19-4 19-1Hydraulic pump, parts list ...................................................................... III 2-225

Cab vent .................................................................................................... II 18-15 18-24

Camshaft and timing gear:Parts list .............................................................................................. III 2-15Reassembly and installation ................................................................. II 2-59 2-81Removal and disassembly..................................................................... II 2-59 2-75

Index 3

TM 9-2320-277-14&P


Center support and second clutch, installation of........................................... II 8-11a 8-52

Center support, second clutch, and thirdclutch, parts list .......................................................................................... III 2-112

Check valve................................................................................................ II 12-10 12-16

Check valve, parts list ................................................................................. II 2-162

Clearance light group, parts list.................................................................... III 2-93

Clearance lights ......................................................................................... II 6-15 6-21

Connecting rod, piston, parts list.................................................................. III 2-13See Piston, connecting rod

Control valve group, parts list ..................................................................... III 2-104

Control valve, low shift valve and tubes,installation of ....................................................................................... II 8-11h 8-57

Converter cover and torque converter group,parts list ............................................................................................... III 2-122

Coolant filter .............................................................................................. II 5-9 5-15

Coolant hoses and fittings ........................................................................... II 5-3 5-3

Coolant piping, thermostat ........................................................................... II 5-6 5-9See Thermostat and coolantpiping

Coolant system:Detailed description............................................................................... I 1-4j 1-7Fan group, parts list.............................................................................. III 2-69Filter installation, parts list ..................................................................... III 2-71Preservation and packaging................................................................... I 2-8a 2-2

Coupling to trailer ....................................................................................... I 3-5 3-6

Crankshaft and pulley, parts list .................................................................. III 2-9

Crankshaft, main bearings:Cleaning, inspection and repair ............................................................. II 2-62 2-85Reassembly and installation .................................................................. II 2-63 2-89Removal and disassembly..................................................................... II 2-61 2-83

Crankshaft journal dimensions .................................................................... II Table 2-5 2-87

Index 4

TM 9-2320-277-14&P


Crankshaft thrust washer thickness.............................................................. II Table 2-7 2-89

Cross-reference index ................................................................................ III 3-2 3-5

Cross tie assembly, parts list ...................................................................... III 2-194

Cylinder block:Assembly, parts list .............................................................................. III 2-3Cleaning, inspection and repair ............................................................. II 2-69 2-95Pressure test and disassembly .............................................................. II 2-68 2-94Reassembly and installation ................................................................. II 2-70 2-96

Cylinder compression test chart .................................................................. II Table 2-4 2-36

Cylinder heads:Assembly, parts list .............................................................................. III 2-5Cleaning, inspection and repair ............................................................. II 2-28 2-39On-vehicle tests ................................................................................... II 2-26 2-35Reassembly and installation ................................................................. II 2-29 2-41Removal and disassembly .................................................................... II 2-27 2-36

Cylinder liners:Cleaning, inspection and repair ............................................................. II 2-65 2-91Installation............................................................................................ II 2-66 2-92Removal .............................................................................................. II 2-64 2-91

D

Deck and engine enclosure, parts list .......................................................... III 2-197

Deck, engine hood, side step and mirror....................................................... II 15-8 15-7

Defroster and heater .................................................................................. II 18-13 18-19

Defroster assembly, parts list ..................................................................... III 2-241

Diesel fuel properties ................................................................................. I 4-5 4-1

Dipstick, parts list ....................................................................................... III 2-21

Disassembly, preservation and packaging.................................................... I 2-8j 2-2

Double check valve..................................................................................... II 12-11 12-17

Double check valve, parts list ..................................................................... III 2-161

Drain cock, parts list ................................................................................... III 2-164

Index 5

TM 9-2320-277-14&P


Drive shaftsCleaning, inspection and repair.............................................................. II 9-3 9-2Parts list............................................................................................... III 2-133Reassembly and installation .................................................................. II 9-4 9-2Removal and disassembly..................................................................... II 9-2 9-1

E

Electrical group, parts list ............................................................................ III 2-72

Engine adjustment procedures..................................................................... IICool engine .......................................................................................... 2-5b 2-2Hot engine............................................................................................ 2-5c

Engine alarm and shutdown kit .................................................................... II 6-8 6-12

Engine assembly and mounting, parts kit ..................................................... III 2-2

Engine assembly torque valves.................................................................... II Table 2-2 2-11

Engine belt sets, part list ............................................................................. III 2-30

Engine coolant level, under hood check ....................................................... I 2-3a 2-1

Engine, detailed description......................................................................... I 1-4b 1-3

Engine hood (See Deck, engine hood,side step and mirror)

Engine oil level, under hood check............................................................... I 2-3c 2-1

Engine specification and data ...................................................................... I Table 1-1 1-2

Engine troubleshooting chart ....................................................................... II Table 2-8 2-103

Engine wear limits, fits and tolerances .......................................................... II Table 2-3 2-30

Ether starting aids ....................................................................................... II 3-5 3-7

Ether starting aids parts list ......................................................................... III 2-57

Exhaust manifolds....................................................................................... II 2-11 2-10

Exhaust manifold and connector group, parts list .......................................... III 2-29

Exhaust pipe and tee................................................................................... II 4-1 4-1

Index 6

TM 9-2320-277-14&P


Exhaust system, detailed description............................................................ I 1-41 1-8

Exterior surfaces, preservation and packaging .............................................. I 2-8f 2-2

Extreme cold weather, operation in ............................................................. I 3-9 3-8

External oil filter, parts list: .......................................................................... IIIfor Engine ............................................................................................ 2-48for Transmission ................................................................................... 2-126

Exhaust outlet group, parts list .................................................................... III 2-62

F

Fan and fan drive........................................................................................ II 5-2 5-2

Fifth wheel assembly, parts list .................................................................... III 2-202

Fifth wheel boom ........................................................................................ II 16-7 16-4

Fifth wheel group, parts list.......................................................................... III 2-201

Fifth wheel hydraulic system, detailed description ......................................... I 1-4m 1-8

Fifth wheel hydraulic group, parts list ........................................................... III 2-204

Fifth wheel specifications and data............................................................... II 16-3 16-2

Fifth wheel unlatch cylinder.......................................................................... II 12-16 12-24

Fifth wheel unlatch valve ............................................................................. II 12-17 12-25

Fifth wheel unlatch valve, parts list .............................................................. III 2-166

Filter assembly ........................................................................................... II 14-15 14-10

Filter assembly, parts list: ........................................................................... IIIfor Fifth wheel hydraulics....................................................................... 2-206for Steering .......................................................................................... 2-190

Filters, changing of ..................................................................................... II 72 7-1

First clutch group, parts list ......................................................................... III 2-116

First clutch gear unit, installation of .............................................................. II 8-11d 8-54

Index 7

TM 9-2320-277-14&P


Flood lights ................................................................................................ II 6-20 6-23

Flushing the cooling system ........................................................................ II 5-1 5-1

Flywheel:.................................................................................................... IICleaning, inspection and repair ............................................................. 2-45 2-64Reassembly and installation ................................................................. 2-46 2-64Removal and disassembly .................................................................... 2-44 2-63

Flywheel housing:Cleaning, inspection and repair.............................................................. II 2-48 2-66Parts List.............................................................................................. III 2-11Reassembly and installation .................................................................. II 2-49 2-66Removal and disassembly..................................................................... II 2-47 2-65

Forward clutch, installation of....................................................................... II 8-11f 8-56

Forward clutch and turbine shaft group, parts list ......................................... III 2-108

Fourth and third clutch, installation of ........................................................... II 8-11e 8-55

Fourth clutch group, parts list ..................................................................... III 2-110

Frame detailed description........................................................................... I 1-4a 1-3

Front axle and suspension, parts list: .......................................................... IIIAssembly ............................................................................................ 2-134Brakes ................................................................................................ 2-137Chamber.............................................................................................. 2-138Hub and drum....................................................................................... 2-136Seal ..................................................................................................... 2-139Shock Absorber installation ................................................................... 2-142Spring group ........................................................................................ 2-140

Front axle, detailed description .................................................................... I 1-4e 1-3

Front axle, inspect, repair and replace: ........................................................ IIBearings............................................................................................... 10-6a 10-5Brake air chamber parts ....................................................................... 10-6e 10-5Brake drums and wheel hubs................................................................. 10-6c 10-5Brake parts .......................................................................................... 10-6d 10-5Knuckles, arms, cross tube, and axle center........................................... 10-6b 10-5

Front axle, reassembly and installation......................................................... IIBrakes ................................................................................................. 10-7b 10-7Brake air cleaner .................................................................................. 10-7c 10-9Steering knuckles and cross tube assembly............................................ 10-7a 10-5Wheel hubs and brake drums ................................................................ 10-7d 10-10

Index 8

TM 9-2320-277-14&P


Front axle, removal and disassembly: ......................................................... IIBrake air chamber ................................................................................ 10-4b 10-2Brake drums and wheel assembly.......................................................... 10-4a 10-1Brakes ................................................................................................. 10-4c 10-2Cross tube assembly and steering knuckles ........................................... 10-4d 10-3

Front axle specifications and data................................................................ II 10-3 10-1

Front support and oil pump, installation of..................................................... II 8-11g 8-56See Oil pump installation

Front support group and oil pump, parts list.................................................. III 2-107See Oil pump and front supportgroup

Front turn and stop lights, parts list ............................................................. III 2-94

Front turn and stop lights ............................................................................ II 6-16 6-21

Front trunion mount, parts list ...................................................................... III 2-26

Fuel crossover lines ................................................................................... II 2-12 2-12

Fuel crossover lines, parts list ..................................................................... III 2-39

Fuel filter ................................................................................................... II 3-4 3-5

Fuel filter, parts list .................................................................................... III 2-56

Fuel injector:Assembly, parts list .............................................................................. III 2-42Continuous fuel flow.............................................................................. II 2-14c 2-16Disassembly and cleaning ..................................................................... III 2-17 2-21Fuel metering ....................................................................................... II 2-14b 2-15Injector control...................................................................................... II 2-14 2-16Inspection and repair ............................................................................ II 2-18 2-24Installation............................................................................................ II 2-20 2-26Reassembly ......................................................................................... II 2-19 2-25Removal............................................................................................... II 2-15 2-16Related parts, parts list ......................................................................... III 2-41

Fuel injector timing...................................................................................... II 2-6 2-3

Fuel level, under hood check ....................................................................... I 2-3b 2-1

Fuel pump: ................................................................................................. II 2-13 2-12Assembly, parts list .............................................................................. III 2-38Related parts, parts list ......................................................................... III 2-37

Index 9

TM 9-2320-277-14&P


Fuel system, detailed description ................................................................. I 1-4k 1-7

Fuel tank ................................................................................................... II 3-3 3-5

Fuel tank group, parts list ............................................................................ III 2-54

Fuel tank, preservation and packing ............................................................. I 2-8d 2-2

G

Gear shaft adjustment ................................................................................. II 7-7 7-8

Gear oil selection chart................................................................................ I Table 4-8 4-11

Gear shift: .................................................................................................. IICleaning, inspection and repair ............................................................. 7-16 7-15Reassembly and installation ................................................................. 7-17 7-15Removal and disassembly..................................................................... 7-15 7-13

Gear shift and fifth wheel control, parts list ................................................... III 2-128

Gear shift cable, parts list ........................................................................... III 2-130

Gear unit group and main shaft, parts list .................................................... III 2-114See Main shaft

Governor:Assembly, parts list .............................................................................. III 2-33Cleaning............................................................................................... II 2-32 2-50Disassembly......................................................................................... II 2-32 2-50Inspection and repair ............................................................................ II 2-33 2-50Reassembly and installation ................................................................. II 2-34 2-50Related parts, parts list ........................................................................ III 2-31Removal .............................................................................................. II 2-31 2-47

Governor and rear cover group, parts list ..................................................... III 2-118

Governor, installation of............................................................................... II 8-11c 8-54See Output shaft, rear cover andgovernor

H

Headlight assembly, parts list ..................................................................... III 2-92

Headlights ................................................................................................. II 6-14 6-19

Index 10

TM 9-2320-277-14&P


Headliner, floor mat and upholstery .............................................................. II 18-10 18-15

Heater assembly, parts list .......................................................................... III 2-239

Heater ....................................................................................................... II 18-13 18-19See Defroster and heater

Heater and defroster, parts list .................................................................... III 2-237

Horn, electric .............................................................................................. II 6-23 6-25

Horn relay .................................................................................................. II 6-22 6-24

Horn relay, parts list ................................................................................... III 2-98

Hose tender, parts list ................................................................................. III 2-176

Housing, flywheel, parts list ......................................................................... III 2-11See Flywheel housing

Housing, oil filter and oil pan group, parts list................................................ III 2-102

How to use parts list .................................................................................. III 2-3&4 2-1

How to use this manual ............................................................................... I

Hydraulic control valve ................................................................................ II 17-7 17-9

Hydraulic cylinder ....................................................................................... II 17-6 17-8

Hydraulic cylinder, parts list ........................................................................ III 2-210

Hydraulic filter............................................................................................. II 17-2 17-2

Hydraulic fluid levels, under hood check....................................................... I 2-3e 2-1

Hydraulic pump........................................................................................... III 17-4 17-4

Hydraulic pump, parts list ............................................................................ III 2-209

Hydraulic reservoir ...................................................................................... II 17-3 17-3

Hydraulic system, preservation and packaging.............................................. I 2-8e 2-2

Hydraulic valve, parts list............................................................................. III 2-211

I

Identification and instruction decals, parts list ............................................... III 2-221

Index 11

TM 9-2320-277-14&P


Idler gear: ................................................................................................... IICleaning, inspection and repair ............................................................. 2-57 2-77Reassembly and installation ................................................................. 2-58 2-81Removal and disassembly..................................................................... 2-56 2-77

Idler pulley and water pump, parts list ......................................................... III 2-46

Injector control tubes, parts list ................................................................... III 2-40

Instrument controls .................................................................................... I 3-2 3-1

Instrument panel ........................................................................................ II 6-10 6-16

Instrument panel, parts list .......................................................................... III 2-86

K

Keys, preservation and packaging................................................................ I 2-8g 2-2

L

License plate lights .................................................................................... II 6-19 6-23

License plate light, parts list ........................................................................ III 2-97

Low clutch and rear cover, installation of ..................................................... II 8-11b 8-53

Lower front cover and oil pump, parts list ..................................................... III 2-25

Low planetary, low clutch and adapter housinggroup, parts list .................................................................................... III 2-120

Low shift valve, parts list ............................................................................. III 2-125

Lubrication ................................................................................................. I 2-6 2-2

M

MAC (Maintenance Allocation Chart)............................................................ Appendix B B-1

Main bearings, crankshaft............................................................................ See Crankshaft, main bearings

Main bearing shell thickness........................................................................ II Table 2-6 2-88

Index 12

TM 9-2320-277-14&P


Main frame, bumper and grille guard ............................................................ II 15-1 15-1

Main frame, parts list .................................................................................. III 2-191

Main shaft and gear unit group, parts list...................................................... III 2-114

Maintenance and Operating Supply List ...................................................... Appendix C C-1

Manufacturer's code list .............................................................................. III 3-1 3-1

Mirror group, parts list ................................................................................ III 2-235

Mirror......................................................................................................... II 15-8 15-7See Deck, engine hood, side stepand mirror

Modulated lockup valve, parts list ................................................................ III 2-124

Modulated lockup valves, lockup valves,oil filter and oil pan ................................................................................ II 8-11i 8-57

Mud flap, parts list ...................................................................................... III 2-195

Muffler and exhaust stack ........................................................................... II 4-3 4-2

O

Oil:Additional performance levels ............................................................... I Table 4-5 4-10Changing.............................................................................................. II 7-2 7-1Changing oil and filter............................................................................ II 2-36 2-54Dipstick................................................................................................ II 2-39 2-58External oil filter.................................................................................... II 2-36b 2-55Hydraulic selection chart ...................................................................... I Table 4-7 4-10Not recommended ................................................................................ I Table 4-6 4-10Inlet tube and strainer............................................................................ II 2-38 2-58Inlet tube, parts list .............................................................................. III 2-22Pan...................................................................................................... II 2-37 2-56Recommended performance levels ........................................................ I Table 4-4 4-10

Oil cooler.................................................................................................... II 5-8 5-13

Oil cooler, parts list ..................................................................................... III 2-20

Oil filter assembly, parts list:........................................................................ IIIEngine ................................................................................................. 2-49Transmission ........................................................................................ 2-127

Index 13

TM 9-2320-277-14&P


Oil filter, external:........................................................................................ IIInspection, repair, reassembly and installation........................................ 7-11 7-11Removal, disassembly and cleaning....................................................... 7-10 7-10

Oil filter, external installation of ................................................................... II 7-11 7-11See Modulated lockup valves,oil filter and oil pan

Oil filter, installation, parts list ...................................................................... III 2-16

Oil level ...................................................................................................... II 7-1 7-1

Oil pan, installation of.................................................................................. II 8-11i 8-57See Modulated lockup valve, oilfilter and oil pan

Oil pan, parts list ........................................................................................ III 2-24

Oil pressure specifications .......................................................................... II Table 7-2 7-5

Oil pump..................................................................................................... II 2-42 2-62

Oil pump and front support, installation of ..................................................... II 8-11g 8-56

Oil pump and front support group, parts list .................................................. III 2-107

Oil pump, lower front cover, parts list .......................................................... III 2-25See lower front cover, oilpump, parts list

Operator's cab: .......................................................................................... IIDoor, windshield and windows ............................................................... 18-2d 18-1Heaters and defroster ........................................................................... 18-2b 18-1Operator's seat .................................................................................... 18-2e 18-2Specifications and data ........................................................................ 18-3 18-2Windshield washer and wiper ................................................................ 18-2c 18-1

Output shaft, rear cover, governor, installation of........................................... II 8-11c 8-54

Output shaft speeds at shift power .............................................................. II Table 8-2 8-4

Overflow recovery system ........................................................................... II 5-5 5-6

Index 14

TM 9-2320-277-14&P


P

Paper compartment installation, parts list ..................................................... III 2-233

Parts cleaning procedures, front axle ........................................................... II 10-5 10-5

Parts cleaning procedures, rear axle ............................................................ II 11-5 11-7

Pistons and connecting rods:Cleaning, inspection and repair ............................................................. II 2-52 2-70Parts list .............................................................................................. III 2-13Reassembly and installation .................................................................. II 2-53 2-73Removal and disassembly..................................................................... II 2-51 2-69

Pneumatic group (air system), parts list........................................................ III 2-152

Pneumatic tires, preservation and packaging ................................................ I 2-8i 2-2

Power steering group.................................................................................. II 14-11 14-7

Power steering hydraulics, parts list ............................................................. III 2-186

Power steering pump, parts list.................................................................... III 2-188

Power take-off ........................................................................................... II 17-5 17-6

Power take-off, parts list ............................................................................. III 2-207

Preventive maintenance checks and services: ............................................. Appendix D D-1Operator............................................................................................... I D-3Organizational ..................................................................................... II D-11

Pulley, crankshaft, parts list......................................................................... III 2-9

Q

Quick release valve, parts list ..................................................................... III 2-163

Quick release valves ................................................................................... II 12-13 12-20

R

Radiator overflow, parts list ........................................................................ III 2-63

Radiator assembly, parts list ......................................................................: III 2-67

Index 15

TM 9-2320-277-14&P


Radiator group, parts list ............................................................................ III 2-64

Radiator and fan shroud .............................................................................. II 5-4 5-4

Rear axle, detailed description ..................................................................... I 1-4d 1-3

Rear axle, disassembly: .............................................................................. IIAxle shafts, brake drums, and wheelhubs, removal ...................................................................................... 11-4c 11-3Brake chambers, disassembly ............................................................... 11-4b 11-3Brake chambers, removal...................................................................... 11-4a 11-2Brakes, removal and disassembly ......................................................... 11-4d 11-5Carrier assembly, disassembly .............................................................. 11-4f 11-5Carrier assembly, removal .................................................................... 11-4e 11-5

Rear axle, inspection, repair, replace parts: ................................................. IIAxle shafts, brake drums,and wheel hubs ................................................................................... I 11-6d 11-8Bearings............................................................................................... 11-6a 11-8Brake parts .......................................................................................... 11-6e 11-9Differential............................................................................................ 11-6c 11-8Gears and pinions ................................................................................ 11-6b 11-8

Rear axle; nut torque values and press loadsrequired to preload input impact bearings .............................................. II Table 11-3 11-12

Rear axle, parts list: ................................................................................... IIIDifferential carrier assembly .................................................................. 2-145Brake Chamber..................................................................................... 2-151Brakes ................................................................................................. 2-149Rear axle group.................................................................................... 2-143

Rear Axle, reassembly ................................................................................ IIBrake chambers.................................................................................... 11-7h 11-15Brakes ................................................................................................. 11-7g 11-15Carrier assembly and axle housing......................................................... 11-7f 11-13Check and adjust backlash in used gear sets ......................................... 11-7c 11-12Check and adjust tooth contact and backlashin new gear and pinion sets .................................................................. 11-7d 11-12Differential............................................................................................ 11-7e 11-13Input pinion and cage............................................................................ 11-7b 11-9Pinion shaft and bevel gear ................................................................... 11-7a 11-9Wheelhubs, axle shafts and brake drums ............................................... 11-7i 11-15

Rear axle specifications and data................................................................. II 11-3 11-2

Rear axle, torque specifications for screws, nuts .......................................... II Table 11-2 11-10

Index 16

TM 9-2320-277-14&P


Rear cover group and governor, parts list..................................................... III 2-118

Rear platform, parts list............................................................................... III 2-200

Rear platform and cross tie assembly........................................................... II 15-5 15-4

Rear window screen.................................................................................... II 18-6 18-10

Rear window screen, parts list..................................................................... III 2-214

References................................................................................................. Appendix A A-1

Reflective safety groups, parts list................................................................ III 2-234

Repair parts manual ................................................................................... III i

Restriction indicator .................................................................................... II 3-1 3-1

Restriction indicator, parts list ..................................................................... III 2-53

Rocker arms and valves, parts list .............................................................. III 2-17

SSeal openings, preservation and packaging.................................................. I 2-8c 2-2

Seat:Cleaning............................................................................................... I 18-5d 18-7Installation............................................................................................ II 18-5h 18-10Inspection and repair ............................................................................ II 18-5e 18-8Parts list .............................................................................................. III 2-215Removal............................................................................................... II 18-5a 18-4Suspension assembly, parts list............................................................. II 2-218Suspension disassembly ...................................................................... II 18-5c 18-7Suspension reassembly ........................................................................ II 18-5f 18-8Upper seat assembly, parts list .............................................................. III 2-216Upper seat disassembly ....................................................................... II 18-5b 18-4Upper seat reassembly ......................................................................... II 18-5g 18-10

Second clutch group, center supportand third clutch, parts list....................................................................... III 2-112

Seperate lighting cable, parts list ................................................................ III 2-91

Service brake treadle valve.......................................................................... II 12-2g 12-5

70 amp breaker and solenoid, parts list ........................................................ III 2-81

Index 17

TM 9-2320-277-14&P


Shift lock: .................................................................................................. IICleaning, inspection and repair ............................................................. 7-13 7-12Reassembly and installation ................................................................. 7-14 7-13Removal and disassembly..................................................................... 7-12 7-11

Shift lockout, parts list ................................................................................. III 2-131

Shift speed adjustments .............................................................................. IIEngine ................................................................................................. 7-6 7-5Transmission ....................................................................................... 8-5 8-3

Side marker lights ....................................................................................... II 16-18 6-23

Side marker lights; parts list ........................................................................ III 2-96

Side mirror.................................................................................................. II 18-7 18-11

Side step.................................................................................................... II 15-8 15-7See Deck, engine hood, sidestep and mirror

Side step, parts list ..................................................................................... III 2-199

Solenoid and 70 amp circuit breaker ........................................................... II 6-6 6-7

Snap ring selection chart ............................................................................. II Table 8-7 8-53

Spacer selection chart ................................................................................. II Table 8-6 8-51

Spare tire carrier and mud flap..................................................................... II 15-12 15-9

Spare tire carrier, parts list .......................................................................... III 2-196

Specific gravity and battery charge............................................................... II Table 6-2 6-29

Speedometer ............................................................................................. II 6-11 6-17

Speedometer group, parts list...................................................................... III 2-88

Specifications ............................................................................................ I Table 1-1 1-2

Spring data................................................................................................. II Table 8-4 8-33

Standard torque data .................................................................................. II Table 1-1 1-2

Starter bench testing troubleshooting chart ................................................... II Table 6-1 6-10

Starter motor ............................................................................................. II 6-7 6-8

Index 18

TM 9-2320-277-14&P


Starter motor, parts list ............................................................................... III 2-79

Starting the engine...................................................................................... I 3-3 3-1

Steering column: ......................................................................................... IICleaning, inspection and repair ............................................................. 14-3 14-1Reassembly and installation .................................................................. 14-4 14-3Removal and disassembly..................................................................... 14-2 14-1

Steering gear.............................................................................................. II 14-8 14-4

Steering gear, parts list ............................................................................... III 2-182

Steering group, parts list ............................................................................. III 2-179

Steering system, detailed description .......................................................... I 1-4h 1-6

Stopping the tractor..................................................................................... I 3-7 3-7

Sun visor.................................................................................................... II 18-8 18-12

Sun visor, parts list .................................................................................... III 2-228

Switches, gages and lights .......................................................................... I 2-4 2-1

T

Table of contents:Maintenance section ............................................................................. II iOperator's section ................................................................................ I iParts list .............................................................................................. III i

Tachometer ................................................................................................ II 6-12 6-18

Tachometer group, parts list ....................................................................... III 2-89

Tail lights.................................................................................................... III 2-95See backup and tail lights

Thermostats and coolant piping .................................................................. II 5-6 5-9

Thermostats and water manifold, parts list ................................................... III 2-44

Third clutch, center support, andsecond clutch groups, parts list ............................................................. III 2-112

Third clutch and fourth, installation of ........................................................... II 8-11e 8-55

Index 19

TM 9-2320-277-14&P


Torque specifications for screws and nuts ................................................... II Table 10-2 10-8

Torque converter, installation of................................................................... II 8-11j 8-57

Torque converter and converter covergroup, parts list..................................................................................... III 2-122

See converter cover

Towing the tractor ....................................................................................... I 3-16 3-8

Trailer cable group, parts list ....................................................................... III 2-90

Trailer hand brake control ........................................................................... II 12-2f 12-5

Trailer hand brake control valve ................................................................... II 12-15 12-24

Trailer hand brake control, parts list ............................................................. III 2-165

Trailer light circuits...................................................................................... IISeparate lighting................................................................................... 6-25 6-27Trailer cable and converters .................................................................. 6-24 6-26

Trailer towing operations ............................................................................ I 3-6 3-7

Transmission assembly torque values .......................................................... II Table 8-5 8-45

Transmission, detailed description ............................................................... I 1-4c 1-3

Transmission fluid level, under hood check................................................... I 2-3d 2-1

Transmission overhaul, disassembly of major parts: ..................................... IIAdapter-housing .................................................................................. 8-7m 8-27Center support and second clutch.......................................................... 8-7i 8-24Checking converter end play.................................................................. 8-7a 8-15Control valve ........................................................................................ 8-7e 8-21Converter disassembly.......................................................................... 8-7b 8-15Forward clutch and turbine shaft ............................................................ 8-7g 8-23Fourth clutch ........................................................................................ 8-7h 8-24Gear unit and main shaft ....................................................................... 8-7j 8-24Governor ............................................................................................. 8-7o 8-27Low planetary gear................................................................................ 8-7n 8-27Low shift valve ...................................................................................... 8-7d 8-21Modulated lockup valve ......................................................................... 8-7c 8-19Oil pump and front support .................................................................... 8-7f 8-22Output shaft ......................................................................................... 8-7k 8-25Rear cover............................................................................................ 8-7l 8-26

Index 20

TM 9-2320-277-14&P


Transmission overhaul; removal of majorparts groups: ....................................................................................... IIAdapter, housing and first clutch piston assembly ................................... 8-10c 8-36Center support assembly....................................................................... 8-10g 8-41Control valve ........................................................................................ 8-10k 8-46Forward clutch and turbine shaft assembly ............................................ 8-10i 8-43Fourth clutch assembly ......................................................................... 8-10h 8-42Gear unit and main shaft assembly ....................................................... 8-10f 8-38Governor assembly............................................................................... 8-10a 8-35Low planetary gear assembly ............................................................... 8-10b 8-35Low shift valve ...................................................................................... 8-10l 8-48Modulated lockup valve ......................................................................... 8-10m 8-49Oil pump and front support assembly .................................................... 8-10j 8-44Output shaft assembly........................................................................... 8-10e 8-37Rear cover assembly ........................................................................... 8-10d 8-36Torque converter assembly ................................................................... 8-10n 8-49Transmission housing assembly ............................................................ 8-10o 8-52

Transmission overhaul; removal of externalparts groups: ....................................................................................... IICenter support group ............................................................................ 8-6j 8-9Forward clutch ..................................................................................... 8-6g 8-8Fourth clutch ........................................................................................ 8-6h 8-9Gear unit and main shaft group, secondclutch, and first clutch plates .................................................................. 8-6k 8-13Governor assembly............................................................................... 8-6l 8-13Low planetary components and lowclutch components ............................................................................... 8-6n 8-13Modulated lockup valve, low shift valve,and control valve................................................................................... 8-6d 8-8Modulator retainer................................................................................. 8-6b 8-5Oil filter, oil pan, and oil tube ................................................................. 8-6c 8-5Oil pump and front support assembly ..................................................... 8-6f 8-8Rear cover and output shaft................................................................... 8-6m 8-13Third clutch........................................................................................... 8-6i 8-9Torque converter ................................................................................. 8-6a 8-4

Transmission repair:.................................................................................... IIRemoval, disassembly and cleaning....................................................... 7-8 7-9Repair, reassembly and installation........................................................ 7-9 7-9

Transmission shift speeds .......................................................................... II Table 7-1 7-4

Transmission specifications and data........................................................... II 8-3 8-1

Transmission vent assembly ....................................................................... II 7-3 7-3

Transmission wear limits data...................................................................... II Table 8-3 8-29

Index 21

TM 9-2320-277-14&P


Treadle valve assembly, parts list ................................................................ III 2-158

Troubleshooting chart, transmission ............................................................ II 7-5 7-5

Turbine shaft group and forward clutch, parts list ......................................... See forward clutch and turbineshaft group

Trunion mount, front ................................................................................... II 2-40 2-60

U-V

Upper front cover, breather, parts list .......................................................... III 2-8

Uncoupling from trailer ................................................................................ I 3-8 3-8

Valves, rocker arms .................................................................................... III 2-17See rocker arms, valves, parts list

Vertical muffler, installation, parts list .......................................................... III 2-61

WWarning pages ........................................................................................... Inside front cover

Warranty ................................................................................................... I 1-5 1-9

Water level warning kit: .............................................................................. II 6-9 6-14Engine shutdown kit, parts list ............................................................... III 2-82Installation............................................................................................ III 2-84

Water manifold and thermostats, parts list ................................................... III 2-44

Water pump and idler pulley, parts list.......................................................... III 2-46

Water pump assembly, parts list ................................................................. III 2-47

Wheels and tires:Cleaning, inspection and repair ............................................................. II 13-3 13-1Mounting and installation....................................................................... II 13-4 13-2Parts group........................................................................................... III 2-178Removal and dismounting ..................................................................... II 13-2 13-1

Windshield and windows ............................................................................. II 18-9 18-12

Windshield washer ..................................................................................... II 18-11 18-16

Windshield washer, parts list ...................................................................... III 2-231

Index 22

TM 9-2320-277-14&P


Windshield wiper ........................................................................................ II 18-12 18-18

Windshield wiper group, parts list ................................................................ III 2-229

Wiring diagram, parts list ............................................................................ III 2-74

Index 23

TM 9-2320-277-14&P

By Order of the Secretary of the Army:

JOHN A. WICKHAM, JR.General, United States Army

Chief of Staff

Official:

ROBERT M. JOYCEMajor General, United States Army

The Adjutant General

Distribution:

To be distributed in accordance with DA Form 12-25B, DS/GS for DED Truck Tractor M878.

I U.S. GOVERNMENT PRINTING OFFICE: 1984-654-114:4079

TM 9-2320-277-14&P

TM 9-2320-277-14&P

THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE SQUARE MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq. Centimeter = 100 Sq. Millimeters = 0.155 Sq. Inches1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq. Meter = 10,000 Sq. Centimeters = 10.76 Sq. Feet1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq. Kilometer = 1,000,000 Sq. Meters = 0.386 Sq. Miles

WEIGHTS CUBIC MEASURE

1 Gram = 0 001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu Centimeter = 1000 Cu Millimeters = 0 06 Cu Inches1 Kilogram = 1000 Grams = 2.2 Lb 1 Cu Meter= 1,000,000 Cu Centimeters = 35 31 Cu. Feet1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

LIQUID MEASURE TEMPERATURE5/9 (°F - 32) = °C

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212° Fahrenheit is equivalent to 100° Celsius1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 90° Fahrenheit is equivalent to 32 2° Celsius

32° Fahrenheit is equivalent to 0° Celsius9/5 (°C + 32) = °F

APPROXIMATE CONVERSION FACTORS

TO CHANGE TO MULTIPLY BYInches ........................................................ Centimeters .................................................................. 2.540Feet............................................................ Meters ........................................................................... 0.305Yards ......................................................... Meters ........................................................................... 0.914Miles .......................................................... Kilometers .................................................................... 1.609Square Inches .......................................... Square Centimeters .................................................... 6.451Square Feet............................................. Square Meters ............................................................. 0.093Square Yards ........................................... Square Meters ............................................................. 0.836Square Miles ........................................... Square Kilometers ...................................................... 2.590Acres ......................................................... Square Hectometers ................................................... 0.405Cubic Feet................................................ Cubic Meters................................................................ 0.028Cubic Yards .............................................. Cubic Meters................................................................ 0.765Fluid........................................................... Ounces Milliliters ........................................................ 29.573Pints .......................................................... Liters .............................................................................. 0.473Quarts ....................................................... Liters .............................................................................. 0.946Quarts ....................................................... Liters .............................................................................. 0.946Gallons ...................................................... Liters .............................................................................. 3.785Ounces ...................................................... Grams ........................................................................... 28.349Pounds ...................................................... Kilograms...................................................................... 0.45Short Tons................................................ Metric Tons................................................................... 0.0907Pound-Feet............................................... Newton-Meters ............................................................ 1.356Pounds per Square Inch ........................ Kilopascals ................................................................... 6.895Miles per Gallon ...................................... Kilometers per Liter..................................................... 0.425Miles per Hour ......................................... Kilometers per Hour.................................................... 1.609

TO CHANGE TO MULTIPLY BYCentimeters .............................................. Inches ............................................................................ 0.394Meters ....................................................... Feet................................................................................ 3.280Meters ....................................................... Yards ............................................................................. 1.094Meters ....................................................... Yards ............................................................................. 1.094Kilometers ................................................ Miles .............................................................................. 0.621Square Centimeters ................................ Square Inches .............................................................. 0 155Square Meters ......................................... Square Feet . ............................................................... 10.764Square Meters ........................................ Square Yards ............................................................... 1.195Square Kilometers .................................. Square Miles ................................................................ 0.386Square Hectometers ............................... Acres ............................................................................. 2.471Cubic Meters............................................ Cubic Feet.................................................................... 35.315Cubic Meters............................................ Cubic Yards .................................................................. 1.308Milliliters Fluid .......................................... Ounces .......................................................................... 0.034Liters .......................................................... Pints .............................................................................. 2.113Liters .......................................................... Quarts ........................................................................... 1.057Liters .......................................................... Gallons .......................................................................... 0.264Grams ....................................................... Ounces .......................................................................... 0.035Kilograms.................................................. Pounds .......................................................................... 2 205Metric Tons............................................... Short Tons.................................................................... 1.102Newton-Meters ........................................ Pound-Feet................................................................... 0.738Kilopascals ............................................... Pounds per Square Inch ............................................ 0.145Kilometers per Liter................................. Miles per Gallon .......................................................... 2.354Kilometers per Hour................................ Miles per Hour ............................................................. 0.621 TAO89991

PIN: 055828-000

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