TM-55-1930-203-34

TM-55-1930-203-34
TM 55-1930-203-34
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
This copy is a reprint which includes current
pages from Changes 1 through 3.
TECHNICAL MANUAL
DIRECT AND GENERAL SUPPORT
MAINTENANCE MANUAL
LIGHTER, AMPHIBIOUS (LARC-LX)
SELF-PROPELLED,
DIESEL STEEL, 60 TON, 61 FT. DESIGN 2303
NSN 1930-00 -392-2981
Approved for public release. Distribution is unlimited.
This manual supersedes TM 55-1930-203-34, 6 April 1971, including change 1.
HEADQUARTERS, DEPARTMENT OF THE ARMY
21 MARCH 1988
TM 55-1930-203-34
C3
CHANGE
NO.
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 16 JULY 1992
3
Direct and General Support Maintenance Manual
LIGHTER, AMPHIBIOUS (LARC-LX)
SELF-PROPELLED, DIESEL,
STEEL, 60-TON, 61 FT, DESIGN 2303,
NSN 1930-00-392-2981
Approved for public release; Distribution is unlimited
TM 55-1930-203-34, 21 March 1988 is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
Insert pages
a and b
a and b
2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
01998
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 1113).
TM 55-1930-203-34
C2
CHANGE
NO.
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 18 MAY 1992
2
Direct and General Support Maintenance Manual
LIGHTER, AMPHIBIOUS (LARC-LX)
SELF-PROPELLED, DIESEL
STEEL 60-TON, 61 FT, DESIGN 2303,
NSN 1930-00-392-2981
Approved for public release; Distribution is unlimited
TM 55 1930-203-34, 21 March 1988 is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
3-121 through 3-124
2. Retain this sheet in front of manual for reference purposes.
Insert pages
3-121 through 3-124
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
01403
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 1113).
TM 55-1930-203-34
C1
CHANGE
NO.
1
}
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 27 July 1988
Direct and General Support Maintenance Manual
LIGHTER, AMPHIBIOUS (LARC-LX)
SELF-PROPELLED; DIESEL;
STEEL; 60-TON; 61 FT; DESIGN 2303,
NSN 1930-00-392-2981
TM 55-1930-203-34, 21 March 1988, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
2.
Remove pages
Insert pages
a and b
a and b
Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
R. L. DILWORTH
Brigadier General, United States Army
7he Adjutant General
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Direct and General Support Maintenance requirements for
Lighter, Amphibious (LARC-LX), Diesel, Self Propelled, Steel, 60-T, 61 Ft (Design 2303)
TM 55-1930-203-34
WARNING
RADIATION HAZARD
This equipment contains the following radioactive items:
COMPASS
ARBITRARY SCALE METER
Located on Operator's Control Panel.
Located on Operator's Control Panel.
Instructions for safe handling, maintenance, storage, and disposition of these items are contained in TM 750-248.
FIRE HAZARD
Fire hazard exists during refueling operations, while performing maintenance on electrical components or while welding
aboard the LARC.
SERIOUS INJURY OR DEATH may result if personnel fail to observe safety precautions.
When refueling, shut down the electrical system on the LARC. Observe the no smoking rule.
Do not permit anyone to operate tools or equipment which may produce sparks near the refueling operation.
Before working on any electrical equipment, make sure the circuits have been deenergized and the cables have been
disconnected from the battery.
When cutting with a torch, or when welding, always station fire watches, ready with fire extinguishers, in the vicinity on
both sides of the plate that is being cut or welded.
TRANSPORTATION HAZARD
Failure to observe this warning may result in SERIOUS INJURY OR DEATH to personnel.
Do NOT go under craft or near propellers while engines are running
Before hoisting large pieces of machinery or equipment, make sure all rigging is secure.
Keep a tight line on the load while it is suspended from the hoist.
Do not permit anyone to stand or walk beneath the load.
AIR AND HYDRAULIC FLUID UNDER PRESSURE
DEATH or severe injury may result if personnel fail to observe safety precautions.
Before breaking line in the hydraulic or compressed air system, bleed the pressure from that portion of the line.
Change 3
a
TM 55-1930-203-34
DANGEROUS CHEMICALS
DANGEROUS CHEMICALS are used in this equipment.
SERIOUS INJURY OR DEATH may result if personnel fail to observe safety precautions.
Avoid contact with the battery electrolyte.
If solution comes in contact with the skin, rinse the area immediately with clear water to avoid skin burns.
Do not smoke or use an open flame in the vicinity when servicing batteries as hydrogen gas, an explosive, is generated.
DANGER OF EXPLOSION
Prior to cutting or welding on the ramp, remove drain plugs on both sides of the ramp and check if ramp interior is primer
coated. If primer coated, flush thoroughly with steam, carbon dioxide, or water. Do not reinstall drain plugs until the cutting and/or welding operation is completed. Failure to take this precaution may result in explosion of accumulated primer
vapors.
Fuel oil and other petroleum products are highly volatile in extreme heat. To minimize the possibility of explosion, wipe
up all spills at once, see that fuel lines and valves are not leaking and pump bilges regularly.
RAMP MAINTENANCE
Ramp hinge pins must be replaced one at a time, allowing three remaining pins to support ramp. Removal of two or
more hinge pins may result in the weight of the ramp misallgning the remaining hinges, resulting in damage to ramp and
possible injury or death to maintenance personnel.
DANGEROUS FUMES
When working inside the hydraulic oil supply tank, a portable -type circulating blower should be used to prevent vapor
accumulation. For extended work periods inside the tank, an air line tube respirator should be worn. Station an observer
outside tank in case worker is overcome by fumes.
BURNS
Acids can cause serious burns or blindness. Avoid contact with eyes, skin, or clothing. Do not breathe vapors. Wear
rubber gloves, goggles, and a rubber apron when handling them. When diluting acids, do not add water to acid; the acid
must be added to the mixture slowly and with constant mixing. In case of contact with acid, flush the affected area with
plenty of water and obtain medical aid immediately.
Change 3
b
*TM 55-1930-203-34
TECHNICAL MANUAL
NO. 55-1930-203-34
}
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON,
D.C., 21 March 1988
DIRECT AND GENERAL SUPPORT MAINTENANCE MANUAL
LIGHTER, AMPHIBIOUS (LARC-LX) SELF-PROPELLED,
DIESEL STEEL, 60 TON, 61 FT, DESIGN 2303
NSN 1930-00-392-2981
Approved for public release. Distribution is unlimited.
Paragraph
CHAPTER
Section
1.
I.
II.
CHAPTER
2.
Section
I.
II.
III.
IV.
CHAPTER
3.
Section
I.
II
III.
IV.
V.
VI.
VII.
VIII.
CHAPTER
CHAPTER
Section
CHAPTER
Section
IX.
X.
XI.
XII.
4.
5.
I.
II.
III.
6.
I.
II.
Page
LIST OF ILLUSTRATION .......................................................................................................... iii
LIST OF TABLES .................................................................................................................... x
INTRODUCTION
General ......................................................................................................
1-1
1-1
Description and data ...................................................................................
1-4
1-1
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
INSTURCTIONS
Repair parts. special tools, and equipment ..................................................
Troubleshooting ..........................................................................................
General maintenance..................................................................................
Removal and installation of major components and auxiliaries ....................
REPAIR OF DIESEL ENGINE. EXHAUST PIPING AND MUFFLER
ASSEMBLY
Introduction ................................................................................................
Engine testing.............................................................................................
Rocker arm assembly and cylinder head assembly .....................................
Exhaust manifold and water manifold .........................................................
Fuel injection controls. fuel injector assembly, and fuel manifolds ...............
Engine accessories.....................................................................................
Oil pan,oil pump inlet screens, Iubricating oil pump assembly,and oil
pump assembly, and oil pressure regulator assembly .................................
Vibration damper assembly,power take-off coupling and flywheel
housing.......................................................................................................
Timing gear train, camshaft and balancer shaft...........................................
Piston, connecting rod, crankshaft, and main bearing assemblies ...............
Cylinder liner and cylinder block assembly ..................................................
Exhaust piping and muffler assembly ..........................................................
REPAIR OF FUEL TANK ............................................................................
REPAIR OF COOLING SYSTEM ........................................... ....................
General ......................................................................................................
Radiator assembly and expansion tank .......................................................
Radiator stern louvers, cooling coils, tubing and fittings ..............................
ELECTRICAL SYSTEM REPAIR INSTRUCTIONS
Generators ............................................. ....................................................
Switches, relays and lighting..................................... ..................................
*This manual supersedes TM 55-1930-203-34, 6 April 1971, including Change 1.
i
2-1
2-3
2-5
2-11
2-1
2-3
2-10
2-11
3-1
3-3
3-5
3-7
3-9
3-12
3-1
3-1
3-3
3-19
3-21
3-39
3-24
3-83
3-28
3-30
3-32
3-34
3-36
5-1
5-3
5-5
3-90
3-96
3-103
3-117
3-122
4-1
5-1
5-1
5-1
5-3
6-1
6-4
6-1
6-11
Paragraph
Page
CHAPTER
Section
7.
I.
II.
REPAIR OF DRIVE SYSTEMS
Land drive system.......................................................................................
Marine drive system....................................................................................
7-1
7-12
7-1
7-96
CHAPTER
Section
8.
I.
II.
STEERING SYSTEM
Land steering system..................................................................................
Marine steering system...................... .........................................................
8-1
8-3
8-1
8-10
CHAPTER
Section
9.
I.
II.
COMPRESSED AIR SYSTEM REPAIR INSTRUCTIONS
Introduction................................................... .............................................
Compressed air system .......................................... ...................................
9-1
9-2
9-1
9-8
CHAPTER
Section
10.
I.
II.
HYDRAULIC SYSTEM REPAIR INSTRUCTIONS
General..................................................... .................................................
Repair instructions .............................................. .......................................
10-1
10-3
10-1
10-14
CHAPTER
Section
11.
I.
II.
CAB AND HULL REPAIR INSTRUCTIONS
General procedures for repair ............................................ ........................
Repair instructions..................................................... .................................
11-1
11-4
11-1
11-3
CHAPTER
12.
GAGES AND INSTRUMENTS................................. ....................................
CHAPTER
Section
13.
I.
II.
HYDRAULIC START AND WHEEL ALIGNMENT SYSTEM
General ......................................... .............................................................
Repair instructions............................................. .........................................
APPENDIX
A.
B.
REFERENCES . .........................................................................................
ILLUSTRATED LIST OF MANUFACTURED ITEMS.................... ................
INDEX
ii
12-1
13-1
13-3
13-1
13-3
A-1
B-1
LIST OF ILLUSTRATIONS
Number
2-1
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-19
2-20
2-21
2-22
2-23
2-24
2-25
2-26
2-26.1
2-27
2-28
2-29
2-30
2-31
2-32
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
3-29
3-30
Title
Page
Engine removal (Sheet 1 of 2) ..............................................................................................................
Engine removal (Sheet 2 of 2) ..............................................................................................................
Torque converter (Model TC-654) ........................................................................................................
Torque converter (Model TC-554) (4 elements)....................................................................................
Torque Converter (Model TC-554) (3 elements)...................................................................................
Removal and installation of torque converter.........................................................................................
Transmission-torque converter oil lines ................................................................................................
Removal of transmission assembly.......................................................................................................
Air brake assembly removal and installation .........................................................................................
Miter box assembly ...............................................................................................................................
Removal of column and wheel drive boot assembly..............................................................................
Column and wheel drive lower pivot bearing assembly .........................................................................
Jacking points.......................................................................................................................................
Tire removal ..........................................................................................................................................
Marine drive system..............................................................................................................................
Fluid coupling, pillow block, flexible coupling and engine adapter flange
(Sheets 1 thru 3)...................................................................................................................................
Gathering box-marine gear angle drive coupling...................................................................................
Gathering box, removal and installation ................................................................................................
Air supply system .................................................................................................................................
Air compressor, Model 3YC, and coupling assembly, removal and installation....................................
Air compressor, Model 3VC, and coupling assembly removal and installation......................................
Installation of 3VC air compressor, (Sheets 1 thru 6) ...........................................................................
Hydraulic master pressure pump, removal and installation...................................................................
Marine gear, removal and installation (Sheets 1 and 2) ........................................................................
Propeller and shafting, removal and installation ....................................................................................
Ramp cylinder, replacement .................................................................................................................
Relief Valve, Ramp Cylinder, Replacement ..........................................................................................
Steering cylinder removal......................................................................................................................
Radiator, removal and installation .........................................................................................................
Radiator fan assembly, removal and installation ...................................................................................
Cargo winch assembly and hydraulic motor, removal and installation...................................................
Bilge pump assembly, removal and installation.....................................................................................
Cargo well pump and pump motor, removal and installation .................................................................
Locating a misfiring cylinder .................................................................................................................
Testing compression pressure .............................................................................................................
Fuel pipes and fuel connectors, removal and installation ......................................................................
Rocker arm assembly ...........................................................................................................................
Removing push rod from cylinder head ................................................................................................
Water manifold .....................................................................................................................................
Governor-throttle controls .....................................................................................................................
Cam follower assembly.........................................................................................................................
Removing or installing cam follower roller and pin with cam follower fixture, part
No. J5840 .............................................................................................................................................
Exhaust valve, guide, and seat insert....................................................................................................
Removing valve seat insert with valve seat insert remover, part No. J4824-01 .....................................
Cylinder head assembly........................................................................................................................
Removal and installation of injector tube...............................................................................................
Relationship between exhaust valve, valve seat insert, and cylinder head ............................................
Cam roller wear and clearance........................ ............................ .......................................................
Reaming injector tube for injector body nut and spray tip with reamer, part
No. J5286-7..........................................................................................................................................
Checking location of injector spray tip relative to lower surface of cylinder head ..................................
Reaming bevel seat in injector tube for injector nut with reamer, part
No. J5286-9..........................................................................................................................................
Installing valve seat insert with valve seat driver, part No. J1736..........................................................
Installing valve guide with valve guide installer, part No. J4144 .............................. .............................
Cylinder head stud nut tightening sequence............................................. ............................................
Exhaust manifold.............................................................. ....................................................................
Fuel injector controls.............................................................................................................................
Fuel injector removal.............................................................................................................................
Checking rack and plunger for free movement.......................................... ...........................................
Injector plunger and follower assembly............................................... ..................................................
Removing injector follower stop pin ......................................................................................................
Fuel injector rack and gear, and valve assemblies ...............................................................................
Removing spray tip from fuel injector nut with tip remover, part No. J1291-02 .....................................
Fuel injector filter assembly ..................................................................................................................
iii
2-12
2-12
2-15
2-16
2-17
2-18
2-19
2-21
2-23
2-25
2-29
2-31
2-33
2-34
2-35
2-37
2-42
2-43
2-47
2-48
2-50
2-53
2-60
2-63
2-66
2-68
2-68.1
2-70
2-71
2-73
2-75
2-77
2-79
3-2
3-2
3-3
3-4
3-5
3-7
3-7
3-8
3-8
3-9
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-17
3-18
3-20
3-22
3-22
3-23
3-26
3-27
3-28
3-29
3-30
Number
3-31
3-32
3-33
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-41
3-42
3-43
3-44
3-45
3-46
3-47
3-48
3-49
3-50
3-51
3-52
3-53
3-54
3-55
3-56
3-57
3-58
3-59
3-60
3-61
3-62
3-63
3-64
3-65
3-66
3-67
3-68
3-69
3-70
3-71
3-72
3-73
3-74
3-75
3-76
3-77
3-78
3-79
3-80
3-81
3-82
3-83
3-84
3-85
3-86
3-87
3-88
3-89
3-90
3-91
3-92
3-93
Title
Page
Reaming injector spray tip with reamer. part No. J1243........................... ............................................
Cleaning spray tip orifices with orifice cleaner. part No. J4298-1................. ........................................
Cleaning injector nut spray tip seat with reamer. part No. J4986-01.....................................................
Sealing surfaces which may require lapping.........................................................................................
Cylinder head with external fuel manifolds......................................... ...................................................
Cylinder head with integral fuel manifolds.............................................................................................
Governor mounting............................................................... ................................................................
Single weight limiting governor assembly..............................................................................................
Governor assembly...............................................................................................................................
Fluid starting aid ...................................................................................................................................
Lubricating oil cooler and full flow oil filter.............................................................................................
By pass oil filter.....................................................................................................................................
Water pump assembly, removal and installation...................................................................................
Water pump assembly..........................................................................................................................
Pressing water pump shaft from impeller......................................... ....................................................
Removing water pump drive coupling from shaft.................................... .............................................
Installing water pump impeller...............................................................................................................
Air starting motor assembly, air filter. and lubricator.............................. ...............................................
Series A31RH6 air starting motor......................................... ...............................................................
Removing motor assembly from motor housing....................................................................................
Removing cylinder dowels...................................................... ..............................................................
Removing rear bearing and end plate ...................................................................................................
Removing front bearing and end plate........................................... .......................................................
Series B21RH6 air starting motor..................... ....................................................................................
Removing bearing retainer................................................ ....................................................................
Removing rotor pinion retainer.................................................. ............................................................
Removing front rotor bearing.................................................... ............................................................
Removing drive gear...................................................... .......................................................................
Removing drive shaft........................................................ ....................................................................
Fuel pump.............................................................................................................................................
Fuel pump assembly right hand pump shown...................................... ................................................
Removing oil seals iron fuel pump body with oil seal remover, part No. J1508-7..................................
Installing outer oil seal in fuel oil pump body with handier part No. J1508-8 and
adapter. part No. J1508-9.....................................................................................................................
Measuring fuel flow from fuel return manifold....................................... ................................................
Air inlet housing............................................................. .......................................................................
Blower assembly and drive assembly............................................... ....................................................
Blower assembly..................................................................................................................................
Removing blower end plate with gear end plate puller part No. J6270-1...............................................
Installing roller bearings in front end plate using gear and roller bearing installer
part No. J6270-6...................................................................................................................................
Minimum blower clearances......................... ........................................................................................
Proper location of shims for correct rotor lobe clearances............................ ........................................
Blower drive gear and coupling............................................ .................................................................
Oil pan.......................................................... ........................................................................................
Oil pump piping relative to lubricating oil pump assembly.....................................................................
Lubricating oil pump assembly..............................................................................................................
Oil pressure regulator assembly................................................. ..........................................................
Vibration damper assembly and power take-off coupling assembly......................................................
Flywheel housing............................................................ ......................................................................
Installing flywheel housing...................................................... ..............................................................
Initial flywheel housing bolt tightening sequence...................................................................................
Final flywheel housing bolt tightening sequence ...................................................................................
Checking flywheel housing concentricity....................................... ......................................................
Engine lifter bracket bolt tightening sequence..................................... .................................................
Gear train timing marks.................................................. ......................................................................
Idler gear details and relative location of parts ...................................... ...............................................
Checking preload of idler gear bearing.... .............................................................................................
Camshaft and balancer shaft................................................................................................................
Balance weight assembly......................................................................................................................
Piston and connecting rod assembly............................................ ........................................................
Removing and installing piston pin bushings in piston..........................................................................
Comparison of used pistons........................................... ......................................................................
Magnetic particle inspection limits for connecting rods.........................................................................
Reaming bushing in piston............................. ......................................................................................
iv
3-31
3-32
3-33
3-34
3-37
3-38
3-40
3-41
3-45
3-46
3-48
3-51
3-52
3-52
3-53
3-53
3-54
3-55
3-57
3-58
3-58
3-58
3-59
3-60
3-62
3-62
3-63
3-64
3-64
3-67
3-68
3-68
3-69
3-71
3-72
3-74
3-76
3-77
3-79
3-80
3-81
3-82
3-84
3-86
3-87
3-89
3-91
3-93
3-94
3-94
3-95
3-95
3-95
3-97
3-98
3-99
3-100
3-101
3-103
3-105
3-106
3-107
3-108
Number
3-94
3-95
3-96
3-97
3-98
3-99
3-100
3-101
3-102
3-103
3-104
3-105
3-106
3-107
4-1
4-2
4-3
5-1
5-2
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-12
6-13
6-14
6-15
6-16
6-17
6-18
6-19
6-20
6-21
6-22
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7-12
7-13
7-14
7-15
7-16
7-17
7-18
Title
Page
Reaming connecting rod bushing in connecting rod........................................ .....................................
Measuring piston-to-liner clearance ......................................................................................................
Measuring piston ring gap with feeler gage...........................................................................................
Measuring piston ring side clearance ...................................................................................................
Installation of spray nozzle in connecting rod........................................................................................
Crankshaft and main bearing assembly................................................................................................
Crankshaft fatigue cracks.....................................................................................................................
Use of spacer on grooved crankshaft ...................................................................................................
Measuring thickness of main bearing shell ...........................................................................................
Removing cylinder with cylinder liner remover, part No. J1918-02........................................................
Checking diameter of cylinder liner with bore gage, part No. J5347............................. ........................
Cylinder liner mounting in block....................................................... .....................................................
Cylinder block assembly..................................................... ..................................................................
Exhaust piping and muffler........................................................... ........................................................
Fuel system schematic............................................................... ..........................................................
Fuel tank...............................................................................................................................................
Engine hand throttle controls ................................................................................................................
Expansion tank and line.......................................................... ..............................................................
Cooling coils........................................................... ..............................................................................
Alternator replacement..........................................................................................................................
Alternator pulley, replacement...............................................................................................................
Master control relay, removal and installation........................................................................................
Hydraulic supply tank liquid level switch replacement...........................................................................
Cab ventilating fan removal and installation................................................. .........................................
Cab heater removal, disassembly, reassembly and installation............................... .............................
Machinery compartment light (old type), removal, disassembly, reassembly and installation................
Machinery compartment light (new type), removal, disassembly, reassembly and installation..............
Wing compartment light (old type), removal, disassembly, reassembly and installation .......................
Wing compartment light (new type), removal, disassembly, reassembly and installation......................
Headlight (old type), removal, disassembly, reassembly, and installation .............................................
Headlight (new type), removal, disassembly, reassembly, and installation (sheet 1 of 2). ....................
Headlight (new type), removal, disassembly, reassembly, and installation (sheet 2 of 2). ....................
Cargo well light, replacement................................................................................................................
Bow light, removal, disassembly, reassembly and installation................................ ..............................
Range light, removal, disassembly, reassembly and installation...........................................................
Running light, removal, disassembly, reassembly and installation........................................................
Searchlight, removal and installation.....................................................................................................
Cab dome light, removal, disassembly, reassembly and installation.......................... ...........................
Instrument panel light removal and installation......................................................................................
Spot and trouble light and reel assembly removal and installation.......................... ..............................
Warning light, removal, disassembly, reassembly and installation........................................................
Warning light assembly wiring diagram......................................................... .......................................
Land drive system.................................................................................................................................
Torque converter (Models TC-554 and TC-654)............................................ ......................................
Removal of oil pump................................................... ..........................................................................
Oil pump............................................................. ..................................................................................
Removal of oil pump driving gear and shaft.............................................. ............................................
Housing assembly (Model TC-654)...................................................... ................................................
Converter pump and hub assembly......... .............................................................................................
Flywheel assembly (Model TC454).......................................................................................................
Converter pump-to-flywheel bolt removal and installation (Model TC-654).. .........................................
Pump-to-flywheel seal ring removal and installation..............................................................................
Bearing retainer bolt removal........ ........................................................................................................
Bearing retainer washer removal and installation ..................................................................................
Pilot bearing and bearing retainer plate removal and installation...........................................................
Turbine assembly removal (Model TC-654)..........................................................................................
Snaprings removal and installation........ ...............................................................................................
Steel and bronze thrust washers removal and installation.....................................................................
First stator assembly removal and installation.......................................................................................
Bronze thrust washer removal................................................ ..............................................................
v
3-109
3-110
3-111
3-111
3-112
3-114
3-115
3-116
3-116
3-117
3-119
3-120
3-121
3-123
4-2
4-3
4-5
5-2
5-4
6-2
6-4
6-4
6-5
6-6
6-8
6-10
6-12
6-14
6-16
6-17
6-19
6-20
6-21
6-23
6-24
6-26
6-28
6-30
6-31
6-33
6-35
6-36
7-1
7-2
7-3
7-5
7-6
7-8
7-9
7-9
7-10
7-10
7-11
7-11
7-12
7-12
7-12
7-12
7-12
7-12
Number
7-19
7-20
7-21
7-22
7-23
7-24
7-25
7-26
7-27
7-28
7-29
7-30
7-31
7-32
7-33
7-34
7-35
7-36
7-37
7-38
7-39
7-40
7-41
7-42
7-43
7-44
7-45
7-46
7-47
7-48
7-49
7-50
7-51
7-52
7-53
7-54
7-55
7-56
7-57
7-58
7-59
7-60
7-61
7-62
7-63
7-64
7-65
7-66
7-67
7-68
7-69
7-70
7-71
7-72
7-73
7-74
7-75
7-76
7-77
7-78
7-79
7-80
7-81
7-82
7-83
Title
Page
Second stator assembly removal and installation..................................................................................
Bronze and steel washers removal and installation...............................................................................
Converter pump removal and installation ..............................................................................................
Hook-type seal ring removal and installation .........................................................................................
Output shaft and flange assembly ........................................................................................................
Plug, seal ring and lockwasher removal and installation .......................................................................
Charging oil pump idler gear shaft removal...........................................................................................
Charging oil pump idler gear reassembly removal and installation........................................................
Charging oil pump drive gear removal...................................................................................................
Ground sleeve removal .........................................................................................................................
Stator assembly (Model (TC-654).........................................................................................................
Stator with rollers, springs and cups.....................................................................................................
Turbine assembly (Model TC-654)................................................. ......................................................
Flexible flywheel disk assembly (Model TC-654).................................... ..............................................
Ground sleeve installation...................................................................................................................
Housing assembly (Model TC-554)................................................. .....................................................
Torque converter pump and hub assembly...........................................................................................
Flywheel assembly................................................................................................................................
Output shaft and flange assembly (Model TC-554) ..............................................................................
Seal ring removal and installation from converter pump flange.............................. ...............................
Snap ring removal and installation from output shaft.................................. ..........................................
Pilot bearing inner race and turbine assembly removal and installation....................... .........................
Turbine locating snapring removal and installation ...............................................................................
First stator assembly removal and installation (Model TC-554)........... .................................................
Thrust washer removal and installation.................................................................................................
Freewheel roller race retaining nut removal and installation........................... .......................................
Freewheel roller race removal and installation.......................................................................................
Split retainer plate removal and installation........................................ ...................................................
Converter pump hub, seal ring and bearing removal and installation ....................................................
Seal ring removal and installation from ground sleeve ..........................................................................
Bearing retainer removal and installation...............................................................................................
Stator assembly (Model TC-554)..........................................................................................................
Flexible flywheel disk assembly (Model TC-554)..................................... .............................................
Freewheel roller, spring and cup installation in stator............................... ............................................
Housing assembly............................................................. ...................................................................
Torque converter pump and hub assembly...........................................................................................
Removing flywheel, turbine and stator assemblies from converter housing ..........................................
Installing flywheel assembly..................................................................................................................
Seal ring and inner race removal and installation.................................... ..............................................
Freewheel roller race and backing plate removal....................................... ...........................................
Stator assembly................................................................ ....................................................................
Installing converter stator assembly......................................................................................................
Checking transmission lube oil pressure............................................ ..................................................
Checking converter in pressure................................................. ...........................................................
Transmission oil strainer.......................................................................................................................
Transmission flange assembly.................................................. ...........................................................
Transmission housing assembly.................................................. ........................................................
Transmission shaft assembly...................................................... .........................................................
Transmission front housing...................................................... ............................................................
Intermediate-range clutch back plate assembly removal and installation.................... ..........................
Intermediate-range clutch plates removal and installation.....................................................................
Removal of internal snapring from clutch drum and sun gear assembly with clutch spring
compressor, part No. J7470.................................................. ...............................................................
High-range clutch back plate removal and installation................................ ..........................................
Using air pressure to remove high-range piston...................................... .............................................
Removal and installation of snapring on transmission main shaft and sun gear.............. .....................
Transmission rear cover removal and installation.................................... .............................................
Bearing retainer removal and installation...............................................................................................
Transmission adapter assembly............................................. ..............................................................
Removal and installation of snapring from ball bearing assembly......................... ................................
Internal cover, low-range clutch, and low-range ring gear removal........................................................
Planetary carrier assembly removal.................................................. ....................................................
Removing snapring that retains reverse-range clutch back plate assembly with clutch
spring compressor, part No. J7470............................................. .........................................................
Reverse-range clutch backplate assembly removal...................................... ........................................
Using air pressure to remove reverse piston.........................................................................................
Transmission main shaft and sun gear removal.................... ...............................................................
vi
7-13
7-13
7-13
7-14
7-14
7-15
7-15
7-16
7-16
7-17
7-17
7-18
7-18
7-19
7-21
7-23
7-24
7-24
7-25
7-26
7-26
7-26
7-26
7-27
7-27
7-28
7-28
7-29
7-29
7-29
7-29
7-30
7-31
7-31
7-33
7-34
7-34
7-34
7-35
7-35
7-36
7-37
7-38
7-39
7-40
7-41
7-42
7-44
7-45
7-45
7-45
7-45
7-46
7-46
7-46
7-46
7-47
7-47
7-47
7-48
7-48
7-48
7-49
7-49
7-50
Number
7-84
7-85
7-86
7-87
7-87.1
7-87.2
7-87.3
7-87.4
7-88
7-89
7-90
7-91
7-92
7-93
7-94
7-95
7-96
7-97
7-98
7-99
7-100
7-101
7-102
7-103
7-104
7-105
7-106
7-107
7-108
7-109
7-110
7-111
7-112
7-113
7-114
7-115
7-116
7-117
7-118
7-119
7-120
7-121
7-122
7-123
7-124
7-125
7-126
7-127
7-128
7-129
7-130
8-1
8-2
8-3
8-4
8-5
8-6
8-7
8-8
8-9
9-1
9-2
9-3
9-4
9-5
9-6
Title
Page
External snapring removal from clutch drum and sun gear assembly...................................................
Clutch drum and sun gear assembly removal.......................................................................................
Using air pressure to remove intermediate range piston.............................. .........................................
Removal and installation of cotter pins in assembly pins with clutch assembly compressed................
Low-range clutch backplate and springs removal and installation.........................................................
Low-range clutch piston plate removal and installation.............................. ...........................................
Loosening low-range clutch piston, using compressed air....................................................................
Seal ring removal and installation on drum and sun gear assembly......................................................
Main shaft and input sun gear removal from planetary carrier assembly.................. ............................
Transmission planetary carrier assembly.............................................................................................
Removal and installation of oil collector ring and oil seal from planetary carrier cover...........................
Pressing planetary pinion pins and planetary cover from planetary carrier assembly............................
Planetary pinion removal................................................... ....................................................................
Planetary cluster pinion removal............................................... ............................................................
Clutch release spring and retainer installation in low-range clutch backplate. using
installation and peening tool, part No. J7473.................................... ....................................................
Transmission low-range clutch assembly...................................... .......................................................
Transmission, intermediate-range clutch assembly..............................................................................
Transmission high-range clutch assembly......................................... ..................................................
Transmission reverse-range clutch assembly.......................................................................................
Installation of cluster pinion showing thrust washer..............................................................................
Installation of planetary cluster pinion pin in planetary carrier.................. .............................................
Thrust washers installed on planetary cluster pinions and pins...................... ......................................
Installation of spacer in planetary cluster pinion....................................................................................
Installation of thrust washer on pinion pin...................................... .......................................................
Installation of spacer in planetary pinion........................................ .......................................................
Properly alined index marks on planetary cluster pinions......................................................................
High-range clutch hub installation.........................................................................................................
High-range clutch plates installation.......................................... ...........................................................
Air brake assembly............................................................. ..................................................................
Removing retractor springs...................................................................................................................
Brake drum assembly.............................................................. .............................................................
Installing retractor springs.................................................. ..................................................................
Bevel gear meshing pattern...................................................... ............................................................
Column and wheel drive assembly (sheets I thru 5 I.............................................................................
Bevel pinion dimensions and wear limits...............................................................................................
Gear spider dimensions and wear limits............................................. ..................................................
Fluid coupling disassembly...................................................................................................................
Gathering box assembly disassembly...................................................................................................
Clutch forward plate dimensions and wear limits..................................... .............................................
Clutch piston dimensions and wear limits.............................................................................................
Forward output gear dimensions and wear limits..................................................................................
Reverse output gear dimensions and wear limits..................................................................................
Bevel pinion shaft, dimensions and wear limits.....................................................................................
Input shaft dimensions and wear limits.................................................................................................
Output shaft dimensions and wear limit................................................................................................
Idler shaft dimensions and wear limits............................................. .....................................................
Forward oil valve dimensions and wear limits...................................... .................................................
Oil coolers.............................................................................................................................................
Propeller shaft sleeves..........................................................................................................................
Stern tube.............................................................. ...............................................................................
Strut tube................................................. .............................................................................................
Steering schematic.......................................................... .....................................................................
Steering column and jackshaft box.................................................. .....................................................
Follow-up system diagram........................................................ ............................................................
Follow-up' system...................................................... ...........................................................................
Steering follow-up adjustment...............................................................................................................
Steering arm assembly.......................................................... ..............................................................
Marine steering................................................................ .....................................................................
Wire rope assembly..............................................................................................................................
Rudder assembly..................................................................................................................................
Air starting control and supply system............................................ ......................................................
Airbrake control and supply system.................................................. ....................................................
Transmission shifting control and engine cutout system................................... ...................................
Throttle control system ........................................................................................................................
Marine gear and radiator fans control system........................................ ...............................................
Tire inflation-deflation control and supply system .................................................................................
vii
7-50
7-50
7-51
7-52
7-52
7-53
7-53
7-54
7-55
7-56
7-57
7-58
7-59
7-59
7-62
7-63
7-64
7-65
7-66
7-66
7-67
7-67
7-68
7-68
7-69
7-70
7-61
7-72
7-74
7-75
7-77
7-79
7-81
7-85
7-91
7-92
7-97
7-99
7-105
7-105
7-106
7-106
7-107
7-107
7-108
7-108
7-108
7-114
7-115
7-116
7-118
8-1
8-3
8-5
8-6
8-8
8-9
8-11
8-13
8-14
9-1
9-2
9-3
9-4
9-5
9-6
Number
9-7
9-8
9-9
9-10
9-11
9-12
9-13
9-13.1
9-14
9-15
9-16
9-17
9-18
9-19
9-20
9-21
9-22
9-23
9-24
9-25
9-26
9-27
9-28
9-29
9-30
9-31
9-31.1
9-31.2
9-31.3
9-32
9-33
9-34
9-35
9-36
9-37
9-38
9-39
9-40
9-41
9-42
9-43
9-44
9-45
9-46
9-47
9-48
9-49
9-50
9-51
9-52
9-53
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
Title
Ramp seat control and supply system...................... ............................................................................
Cargo well pump and ramp control systems.................... .....................................................................
Air compressor, Model 3YC, disassembly and reassembly (sheets 1 thru 5).......................................
Air compressor, Model 3VC, disassembly and reassembly (sheets 1 thru 6).......................................
Connecting rod................................................................ .....................................................................
Actuator positioner removal and installation........................................... ...............................................
Actuator positioner governor control, disassembly and reassembly......................................................
Oil flow, model 3VC compressor................................................... .......................................................
Air compressor governor, removal, disassembly, reassembly and installation......................................
Air horn, disassembly and reassembly................................................ .................................................
Air starting lubricator, removal, disassembly, reassembly and installation ............................................
Air starting relay air valve, disassembly and reassembly................................... ...................................
Air tank removal and installation............................................................................................................
Brake air line relay valve, removal and installation.................................................................................
Brake air line relay valve, disassembly and reassembly................................... .....................................
Double-acting air cylinder, removal and installation...............................................................................
Cargo well pump and ramp cylinder control air cylinder disassembly and reassembly............... ..........
Fan control air cylinder control removal and installation................................... .....................................
Fan control air cylinder disassembly and reassembly...................................... .....................................
Foot throttle and brake control valve, removal and installation...............................................................
Foot throttle and brake control valve, disassembly reassembly.............................................................
Globe valve packing and disk removal and installation..........................................................................
Hand throttle control valve removal and installation...............................................................................
Hand throttle control valve disassembly and reassembly.................................. ....................................
Pilot air valve disassembly and reassembly........................................... ...............................................
Main air supply filter, removal, disassembly reassembly, and installation........................ .....................
Air Dryer, Replacement.........................................................................................................................
Solenoid Valve, Replacement..................................................... ..........................................................
Push Button Switch, Momentary, Replacement....................................................................................
Marine gear shifting and throttle control valve removal and installation........................ .........................
Marine gear shifting and throttle control valve disassembly and reassembly...................... ..................
Marine gear shifting and throttle control valve adjustments...................................................................
Quick release valve, removal, disassembly, reassembly, and installation......................... ....................
Ramp seal removal and installation.......................................................................................................
Reducing valve removal and installation................................................................................................
Reducing valve, disassembly and reassembly......................................................................................
Shuttle valve disassembly and reassembly...........................................................................................
Throttle cutout, cargo -well pump, ramp and tire control valve removal and installation ........................
Throttle cutout, cargo well pump, ramp and tire control valve, old style, disassembly and reassembly...
Throttle cutout, cargo well pump, ramp, and tire control valve, valve new style, disassembly
and reassembly.....................................................................................................................................
Throttle cutout, cargo well pump, ramp, and tire control valve (cut-away view).....................................
Throttle and transmission airline relay valve, removal and installation...................................................
Throttle and transmission airline relay valve, disassembly and reassembly........................ ..................
Tire airline relay valve, disassembly and reassembly..................................... .......................................
Tire inflation control safety relief valve............................................. .....................................................
Transmission control valve operation and port location.........................................................................
Transmission control valve, removal and installation.............................................................................
Transmission control valve, disassembly and reassembly....................................................................
Transmission shifting control cylinder removal and installation.............................................................
Transmission shifting control air cylinder, disassembly and reassembly ..............................................
Windshield wiper assembly ..................................................................................................................
Hydraulic supply and return system......................................................................................................
Ramp hydraulic system ........................................................................................................................
Bilge pump hydraulic system ................................................................................................................
Cargo well pump hydraulic system .......................................................................................................
Radiator fan hydraulic system...............................................................................................................
Cargo winch hydraulic system ..............................................................................................................
Aft steering hydraulic system................................................................................................................
For-ward steering hydraulic system ......................................................................................................
Bilge pump hydraulic motor disassembly and reassembly....................................................................
Bilge pump disassembly and reassembly .............................................................................................
Cargo well pump hydraulic motor, model M2-40-FL-S15, disassembly and reassembly ......................
Cargo well pump hydraulic motor, model MF-2008-30-38-21, disassembly and reassembly ...............
Cargo well pump, disassembly and reassembly (sheets 1 and 2). .......................................................
Cargo winch brake assembly................................................................................................................
Winch brake adjustment.......................................................................................................................
Pouring wire rope ferrule.......................................................................................................................
Cargo winch disassembly...... ...............................................................................................................
Cargo winch hydraulic motor......................... .......................................................................................
viii
Page
9-7
9-7
9-8
9-16
9-25
9-29
9-30
9-32
9-33
9-34
9-36
9-37
9-39
9-40
9-41
9-43
9-44
9-46
9-47
9-48
9-49
9-51
9-52
9-54
9-56
9-58
9-58.1
9-58.2
9-58.3
9-59
9-60
9-62
9-63
9-64
9-65
9-66
9-67
9-68
9-69
9-71
9-73
9-74
9-75
9-76
9-77
9-78
9-79
9-80
9-81
9-82
9-83
10-2
10-3
10-4
10-6
10-8
10-10
10-11
10-13
10-15
10-16
10-18
10-21
10-25
10-28
10-29
10-30
10-31
10-34
Number
10-19
10-20
10-21
10-22
10-23
10-24
10-25
10-26
10-27
10-28
10-29
10-30
10-31
10-32
10-33
10-34
10-35
10-36
10-37
10-38
10-39
11-1
11-2
11-3
11-4
11-5
11-6
11-7
11-8
11-9
12-1
12-2
12-3
12-4
12-5
13-1
13-2
13-3
13-4
13-5
13-6
13-7
13-8
13-9
13-10
13-11
13-12
13-13
13-14
13-15
13-16
13-17
FO-1
FO-2
FO-3
FO-4
FO-5
Title
Page
Cargo winch control stand and linkage............................................ .....................................................
Speed control linkage............................................................................................................................
Hydraulic oil supply tank filter ...............................................................................................................
Master pressure pump..........................................................................................................................
Master pressure pump oil seal installation......................................... ...................................................
Radiator fan hydraulic motor disassembly.......................................... ..................................................
Ramp cylinder disassembly................................................... ...............................................................
Piston installation and welding................................................. .............................................................
Steering cylinder assembly.................................................... ...............................................................
Cargo winch control valve.................................................... .................................................................
Fan control valve...................................................................................................................................
Flow control valve (Model FRG-06-15-10 and FRG-06-20-10).............................................................
Flow control valve (Model FRG-06-24-12)......................................... ...................................................
Steering control valve............................................................................................................................
Gate valve.............................................................. ...............................................................................
Right angle check valve..................................................... ...................................................................
Multiple unit valve removal.................................................. ..................................................................
Multiple unit valve inlet unit ...................................................................................................................
Multiple unit valve control unit................................................ ...............................................................
Series CT10 relief valve........................................................................................................................
Series CF16 relief valve..................................................... ...................................................................
Cab and hull metal distortion limits............................................. ..........................................................
Cab window............................................................. .............................................................................
Stanchion socket removal and installation............................................... .............................................
Brace assembly, removal and installation................................................. ............................................
Hatch cover assembly removal and installation.....................................................................................
Bilge drain valve locations.....................................................................................................................
Valve seat installation............................................................................................................................
Rubber fender removal and installation.................................................................................................
Ramp seal protector, removal and installation.......................................................................................
Gage board...........................................................................................................................................
Instrument panel gages........................................................... .............................................................
Fuel quantity gage.................................................................................................................................
Sight level quantity gage.......................................................... .............................................................
Ramp seal air pressure gage................................................................................................................
Hydraulic Start and Wheel Alignment System................................................ ......................................
Hydraulic starter, Replacement.............................................................................................................
Hydraulic Pump, Replacement................................................... ..........................................................
Accumulator, Replacement...................................................................................................................
Hydraulic Hand Pump, Replacement....................................................................................................
Pressure Gage, Replacement...............................................................................................................
Hydraulic Oil Reservoir, Replacement..................................................... .............................................
High Pressure Filter (Reservoir), Service................................................ .............................................
High Pressure Filter (Accumulator), Service.........................................................................................
High Pressure Filter (Reservoir), Replacement............................................... .....................................
High Pressure Filter (Accumulator), Replacement.................................... ...........................................
Needle Valve, Replacement..................................................................................................................
Ball Valve Replacement.................................................... ....................................................................
Hydraulic Hose Line, Replacement.......................................................................................................
Emergency Start Control Valve, Replacement....................................... ...............................................
Start Valve Cable, Replacement............................................... ............................................................
Wheel Alignment Spool Valve, Replacement........................................................................................
Transmission assembly, exploded view................................................. ...............................................
Removal and disassembly of miter box.................................................................................................
Marine gear assembly (right-hand unit) exploded view................................. ........................................
Marine gear access cover.....................................................................................................................
Illustrated list of manufactured items................................ ....................................................................
ix
10-36
10-38
10-40
10-43
10-45
10-47
10-50
10-51
10-52
10-53
10-55
10-57
10-58
10-60
10-61
10-62
10-64
10-65
10-66
10-67
10-68
11-2
11-4
11-6
11-7
11-8
11-9
11-10
11-11
11-12
12-2
12-4
12-5
12-6
12-7
13-2
13-3
13-4
13-5
13-6
13-6
13-7
13-8
13-9
13-10
13-11
13-12
13-13
13-14
13-16
13-17
13-18
FP-1
FP-3
FP-5
FP-7
FP-9
LIST OF TABLES
Number
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
1-19
1-20
2-1
7-1
10-1
11-9
Title
Page
Engine repair and replacement standards........................................ .....................................
Model TC-554 (3 and 4 element) torque converter repair and replacement standards ...........
Model TC-654 torque converter repair and replacement standards .......................................
Torque converter stall speed chart.............................................. ........................................
Hull and cab welding data...................................................... ...............................................
Transmission wear limits.......................................................................................................
Miter box repair and replacement standards..........................................................................
Air brake assembly repair and replacement standards .......................... ................................
Column and wheel drive repair and replacement standards ....................... ...........................
Gathering box repair and replacement standards ................................ ..................................
Marine gear repair and replacement standards ............................. ........................................
Model 3VC air compressor tolerances and clearances .......................... ................................
Model 3YC air compressor tolerances and clearances .......................... ................................
Models 3VC and 3YC air compressors torque specifications ........................ .......................
Propeller shaft, stern tube, and propeller strut repair and replacement standards ..................
Ramp cylinder dimensions and tolerances.......................................... ..................................
Steering cylinder dimensions and tolerances.........................................................................
Nut, bolt, screw, and stud torque specification.......................................................................
General bolt, screw and stud torque specification for torque converters ................................
Standard nut, bolt, and stud torque specification...................................... .............................
Special tools and equipment.................................................. ...............................................
Torque converter stall speed chart.............................................. ..........................................
Model M2B-40 FL-S15, Cargo well pump hydraulic motor test data ......................................
Ramp seal protector, removal and installation.......................................................................
x
1-13
1-17
1-17
1-18
1-18
1-18
1-19
1-20
1-20
1-21
1-21
1-23
1-23
1-23
1-24
1-24
1-24
1-25
1-25
1-26
2-1
7-39
10-19
11-12
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. Scope
These instructions cover the amphibious lighter (LARC-LX). They provide information on the maintenance of the equipment which is beyond the scope of the tools, equipment, personnel, or supplies normally available at the organization
maintenance level.
1-2. Forms and Records
Maintenance forms, records, and reports which are to be used by maintenance personnel at all maintenance levels are
listed in and prescribed by DA Pam 738-750.
1-3. Reporting of Errors
You can help improve this manual. If you find any mistake 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 directly to: Commander, U.S. Army Troop Support Command, ATTN: AMSTR-MCTS,
4300 Goodfellow Boulevard, St. Louis, MO 63120-1798. A reply will be furnished directly to you.
Section II. DESCRIPTION AND DATA
Turning radius
75 ft
Water operation:
Forward speed empty
7.5 mph
Forward speed, 60 ton load
7 mph
Forward speed, 100 ton load
6.5 mph
b. Diesel Engines.
(1) Engine (starboard side forward and portside aft).
Manufacturer
Detroit Diesel Engine
Div of GMC
Model
6080 RA
Series
6-71
Type
Industrial
No. of cylinders
6
Cycle
2
Bore and stroke
4¼ in. x 5 in.
Displacement
425.6 cu. in.
Compression ratio
17:1
Minimum compression pressure
at 600 rpm
400
Maximum premissible variation
between cylinder
25 psi at 600 rpm
Rating
165 hp cont. at 2100
rpm
Governed speed
2100 rpm
Maximum rpm (no load)
2120 rpm
Idle speed
550 rpm
Crankshaft rotation (from
flywheel end)
CCW
Firing order
1-5-3-6-2-4
Starting method
Compressed air
Lubrication system
Forced feed
Fuel
Diesel oil
Fuel system
Unit injectors
Cooling system:
Marine operation
Cooling coils
Land operation
Radiator
New weight, dry (approximate) 2610 lbs.
1-4. Description
For a complete description of the LARC.LX refer to TM
55-1930-203-10 and TM 55-1930-203-20.
1-5. Difference in Models
For any information relative to difference in models, refer
to TM 55-1930-203-20.
1-6. Tabulated Data
The tabulated data listed gives dimensions, tolerances
and clearances, nut and bolt torque, and pertinent data
necessary for direct and general support maintenance
personnel to properly adjust, repair, or overhaul the
equipment.
a. General
Nomenclature
Ambient temperature range
Gradeability
Hull construction
Overall length
Overall height
Overall width
Wheel base
Dry weight (approx)
Curb weight (approx)
Performance:
Land operation:
Forward speed. Empty
Forward speed, 60 ton lead
Forward speed, 100 ton load
Reverse speed, 60 ton load
Lighter, Amphibious
(LARC-LX), SelfPropelled, Diesel,
Steel 60 Ton, 61 Ft.,
Design 2303, FSN
1930-392-2981
125°F to -25°F
60 % slope
Welded Steel
62 ft. 6½ in.
19 ft. 6 in.
26 ft. 7 in.
28 ft. 6 in.
194,000 lbs.
199,000 lbs.
15.2 mph
14 mph
12.75 mph
2.85 mph
1-1
(2) Engine (port side forward and starboard side aft).
Manufacturer
Detroit Diesel Engine
Division of GMC
Model
6081 RC
Series
6-7 1
Type
Industrial
Note. The specifications and rating for these engines are identical
to the Model 6080 RA Engines. The only difference is the location of
certain components and accessories.
(3) Air cleaners.
Manufacturer
Detroit Diesel Engine
Division of GMC
Type
Oil, bath, light duty
Diameter
10 in.
Mfr. No
5183248
(4) Air starting motor.
Manufacturer
Ingersoll-Rand Co.
Model
Hulls 5 through 18
A31-RH6
Hulls 19 through 60
B21-RH6
Size
Hulls 5 through 18
9BM
Hulls 19 through 60
10BM
Drive assembly manufacturer
Eclipse Machine Div. Of Bendix
Aviation Corp.
Type
Friction Clutch
Operating pressure
Maximum
150 psi
Minimum
45 psi
(5) Fuel filters.
Primary fuel filter:
Manufacturer
AC Spark Plug Div of
GMC
Mfr. No. (Hulls 5-18)
5182041
Mfr. No. (Hulls 19.60)
5575568
Element
Type T-553
Secondary fuel filter:
Manufacturer
AC Spark Plug Div of
GMC
Type (Hulls 5.18)
141
Type (Hulls 19-24)
T67
Type (Hulls 25-60)
T-65
Element (Hulls 5-18)
Type TP-512
Element (Hulls 19-24
Type T-552
Element (Hulb 2540)
TP540X
(6) Fuel injectors.
Manufacturer
Detroit Diesel Engine Div of
GMC
Model
HV7
Type
Volume metering
(7) Fuel pumps.
Manufacturer
Detroit Diesel Engine Div of
GMC
Type
Gear-Position displacement
Mfr. No. (Engine Model 6080RA)
5184531
Mfr. No. (Engine Model 6081RC)
5184532
Fuel pressure at fuel manifold
(1600 rpm engine speed)
Minimum
35 psi
Maximum
65-70 psi
(8) Governors.
Manufacturer
Type
Mfr. No. (Engine Model
6080RA)
Mfr. No. (Engine Model
6081RC)
(9) Oil filters.
Bypass oil filter:
Manufacturer
Type
Element
Full flow oil filter:
Manufacturer
Type
Mfr. No. (Engine Model
6080RA)
Mfr. No. Engine Model
6081RC)
Element .................... Type PF-132
(10) Water pumps.
Manufacturer
GMC
Type
Capacity
Mfr. No. (Engine Model 6080RA)
Mfr. No. (Engine Model 6081RC)
Clearance between pump body
and impeller hub
(11) Thermostat.
Manufacturer
Starts opening
Fully open
c. Electrical System.
(1)
Battery charging generator.
Manufacturer
GMC
Model
Type
Voltage
Amps
Rotation (from driven-end)
Ground polarity
Control
Maximum operating speed
Number of units
(2)
Generator drive belt.
Manufacturer
Type
Mfr. No.
Number of units
(3) Generator regulator.
Voltage
Amps
Ground polarity
Military standard
Number of units
1-2
Detroit Diesel Engine Div of
GMC
Limiting speed, mechanical
5182567
51825(68
AC Spark Plug Div of GMC
S-2
Type P-1I 1
AC Spark Plug Div of GMC
PM 13
5194287
5194288
Detroit Diesel Engine Div of
Centrifugal
8 gpm
5113108
5113109
0.100 in.
Detroit Diesel Engine Div of
GMC
173°F (78.3°C)
Approx. 185°F (85°C)
Delco-Remy Div of
1117478
Heavy duty, ventilated
24 volt dc
40
clockwise
negative
voltage regulator
4000 rpm
2
Dayton Rubber Co.
B
VX21
2
24 volts dc
40
Negative
MS13803-1
2
(4)
Battery-generator indicator.
Manufacturer
Type
Mfr. No
Ordinance No
Number of units
(5)
Batteries.
Type
Volts
Rated capacity at 20 hour rate
Military standard
Number of units
(6)
Circuit breakers.
Type
15 ampere:
Military standard
Number of units
20 ampere:
Military standard
Number of units
(7) Master control relay.
Voltage
Ordinance No.
Number of units
(8) Tachometer indicator.
Manufacturer
Model
Range
Pointers
Number of units
(9) Tachometer generator.
Manufacturer
Model
Rotation (from drive end)
Number of units
(10) Pressure switches.
Engine low oil pressure switch:
Manufacturer
Range
Mfr. No.
Number of units
Marine gear oil pressure switch:
Manufacturer
Range
Mfr. No
Number of units
Transmission low oll pressure switch:
Manufacturer
Range
Mfr. No.
Number of units
(11 ) Thermostatic switches.
Engine high water temperature switch:
Manufacturer
Range
Mfr. No.
Number of units
Gathering box high oil temperature:
Manufacturer
Range
AC Spark Plug Div of GMC .
Indicating
1501371
7354232
1
Mfr. No.
1512366
Number of units
2
Marine gear high oil temperature switch:
Manufacturer
AC Spark Plug Div of GMC
Range
Closes at 240 to 250°F
Mfr. No
1512366
Number of units
2
Transmission high oil temperature switch:
Manufacture
AC Spark Plug Div of GMC
Range
Closes at 240 to 250°F
Mfr. No
1512366
Number of units
4
(12) Searchlight.
Manufacturer Portable Light Co.
Model
18
Size
8 in.
Voltage
24
Rotation
3600
Range
½ mile
(13) Cab ventilating fan.
Manufacturer
Perfection Div, of Hupp Corp.
Mfr. No.
95-24E
Volts
24 volts, dc
Type of base
Swivel
Radio suppression capacitor:
Manufacturer
Cornell-Dubilier
Mfr. No
NF-10299
Capacitance
0.25 MFD
Work voltage
100 volts dc at 20
Number of units
2 amperes
(14) Wiring Size and type
Main circuits leading from power
source to master relay and following relay to first multiple
connector
No. 2, AWG (single
conductor)
First multiple connector from
master relay to circuit breaker
No. 12, AWG (single
conductor)
All lighting including master warning light, heater ventilating fan,
and warning light feeder circuits
Tachometer circuits
No. 16, AWG (Single
conductor)
Trunk cables
No. 14, AWG (12
conductor)
d. Cooling System.
(1) Radiator (land operation).
Manufacturer's:
Hulls 5 through 18
Perflex Corp.
Hulls 19 through 24
Young Radiator Corp.
Hulls 25 through 60
Yates American
Radiator Co.
DA drawing No.
2303-12-40
Water flow
8 gpm
Heat rejection rate (maximum)
10,250 BTU per minute
Allowable pressure drop
3.6 in. of water
6TN
12
100 amp hour
MS35000-3
2
Automatic reset
MS39062-1
6
MS39062-2
4
24 volts, dc
752778
1
General Electric Co.
8DJ120AAG1
0 to 2,250 rpm
Dual
2
General Electric Co.
2CM9ABX6
CCW
4
AC Spark Plug Div of GMC
Opens at 8 to 12 psi
1507289
4
AC Spark Plug Div of GMC
Opens at 120 to 130 psi
1508724
2
AC Spark Plug Div of GMC
Opens at 60 to 65 psi
1507379
4
AC Spark Plug Div of GMC
Closes at 215 to 225°F
1513346
4
AC Spark Plug Div of GMC
Closes at 240 to 250°F
1-3
Normal operating pressure ................ 9 psi
Test pressure .................................... 14 psi air
Number of units.................................. 4
(2)Cooling coils (marine operation).
Location.............................................. Aft wheel wells
Copper pipe size ................................ 2 in.
(3)Oil coolers (gathering box and marine gear).
Manufacturer (Hulls 5
through 24)......................................... Rose Heater and Mfg. co.
Model .. 301-2BFC
Manufacturer (Hulls 25
through 60)......................................... Yates-American Machine Co.
Model ................................................. FB-1-3250-2
Type .................................................. Single pass
Number of units.................................. 8
(4) Radiator fan.
Manufacturer ..................................... Joy Manufacturing Co.
Model ................................................. Axivane, 29¼ –17½ –2000
Series ................................................. 1000
Number of units.................................. 4
(5) Radiator fan motor.
Manufacturer ...................................... Parker Hannifin Corp.
Mfr. No .............................................. MD677939
Type .................................................. Hydraulic, vane
Horsepower ........................................ 20 HP at 1850 rpm and 900 psi
(6)Expansion tank pressure cap.
Manufacturer ...................................... Stant Manufacturing Co.
Mfr. No. (Hulls 5
through 48)......................................... R-6
Mfr. No. (Hulls 49
through 601 ........................................ AAX-0432
Pressure rating................................... 7 psi
Number of units.................................. 4
e. Fuel System.
(1) Fuel system filter.
Manufacturer ...................................... Marvel Engineering Co.
Model ................................................. SLD-3 / 4-8-100
Type .................................................. Line type
Inlet and outlet pipe size ..................... ¾ in-NPTF
Capacity ............................................ 8 gpm
Pressure drop..................................... 0.50 psi
Weight (approximate) ........................ 7 lbs.
Element No......................................... SLD-3 / 4-8pt 6 100 mesh
Number of units.................................. 2
(2)Check valve (fuel supply line).
Manufacturer ...................................... Crane Co.
Size ................................................... ¼ in.
Mfr. No ............................................. 20
Number of units................................. 6
(3)Check valve (fuel tank vent).
Manufacturer ...................................... Jenkins Bros., Inc.
Size ................................................... ¼ in.
Mfr. No .............................................. 54 (see note)
Number of units.................................. 2
Note. Refitted with bronze spring to release at 4 to 6 oz. vacuum,
Mfr. No .............................................. 702GG
Number of units ................................. 11
(5) Plug valve (fuel supply line).
Manufacturer...................................... Republic Mfg. Co.
Size ................................................... 2 in.
Mfr. No. ............................................. 702GG
Number of units ................................. 3
(f) Land Drive System.
(1) Torque converters.
Manufacturer...................................... Allison Div of GMC
Model ................................................ TC-654
Horse power range............................. 75 to 300 hp
Stall torque ratio (maximum) .............. 3.70 : 1
Number of stages............................... 1
Number of phases.............................. 3
Number of elements........................... 4 (pump, turbine, first
stator, second stator)
Model ................................................. TC-554 14 element):
Horse power range............................. 150 to 350 hp
Stall torque ratio (maximum) .............. 3.40 : I
Number of stages............................... 1
Number of phases.............................. 3
Number of elements........................... 4 (pump, turbine, first
stator, second stator)
Model ................................................. TC-554 (3 element):
Horse power range............................. 200 to 400 hp
Stall torque ratio (maximum) .............. 3.40: 1
Number of stages............................... 1
Number phases.................................. 2
Number of elements........................... 3 (pump, turbine, stator)
Maximum input speed ........................ 2500 rpm
Maximum input torque........................ 850 ft-lb
Charging oil pump capacity................ 21 gpm at 1800 rpm
converter input speed
Charging oil pump pressure:
Minimum full throttle stall.................... 50 psi
Maximum full throttle stall................... 80 psi
Maximum full throttle no load.............. 120 psi
Converter oil outlet maximum
temperature ....................................... 250°F
Oil cooled by . .................................... Heat exchanger
Output shaft . ..................................... Automotive
Flywheel housing................................ SAE 1
Weight (dry) ....................................... 420 lb
(2) Flexible coupling (torque converter to transmission).
Manufacturer...................................... Philadelphia Gear Works
Mfr. dwg ............................................ C684071 REV C
Number of units ................................. 4
(3) Transmission.
Manufacturer...................................... Allison Div of GMC
Model ................................................. TG603RM
Type................................................... Torgmatic, Planetary gear
Speeds............................................... Three forwarded, one reverse
Input rotation ...................................... Right-hand
Maximum input speed ........................ 2100 rpm
Maximum input torque ....................... 3000 ft-lbs.
Output rotation ................................... Same as input
Gear train
Constant mesh compound
planetray
Gears ................................................ Spur-type
(4)Plug valve (fuel return and supply lines).
Manufacturer .........Republic Mfr. Co.
Size ................................................... ¼ in.
1-4
Drive range ratios
Low ................................................... 4.375 : 1
Intermediate........................................ 2.33: 1
High ................................................... 1 : 1
Reverse .............................................. 3.50: 1
Clutch type
Multiple disk, automatic wear
compensated
Clutch operation
Hydraulically actuated, spring
released, oil cooled
Number of clutch packs ..................... 4
Control ............................................... Air operated
Oil system
Interconnected with torque
converter
Weight (approximate) ......................... 1,185 lbs.
(4) Flexible coupling (transmission to miter box).
Manufacturer ...................................... Philadelphia Gear Works
Mfr. Dwg ........................................... C684036 REV B
Number of units.................................. 4
(5) Oil filter (transmission-torque contverter).
Manufacturer ...................................... Wm. W. Nugent and Co., Inc.
Figure No ........................................... 1116PY
Size ................................................... IS
Number of units.................................. 4
(6) Miter box.
Manufacturer ...................................... Western Gear Corp.
DA dwg No. ........................................ 2303-09-100
Input rotation....................................... Left-hand for forward direction
Gearing............................................... Right-angle bevel
Number of gears
2 (location of input gear changes
for starboard and port
installations)
Gear backlash ................................... 0.008 to 0.012 in.
Drive ratio ........................................... 1 : 1
Male or female gear coupling:
Pitch .................................................. 8 in.
Pitch diameter .................................... 5½ in.
Number of teeth.................................. 44
Type .................................................. 14 ½ °involute
Addendum.......................................... 0.125 in.
Flange coupling spline:
Number of teeth.................................. 19
Type .................................................. 300 involute
Pitch diameter .................................... 2.375 in.
Pitch .................................................. 0.5 in.
Major diameter.................................... 2.500 / 2.501 in.
Miter gear, left-hand:
Number of teeth.................................. 30
Diametral pitch ................................... 3 in.
Pressure angle ................................... 14½ °
Addendum.......................................... 0.333 in.
Deddendum........................................ 0.396 in.
Type .................................................. Zerol
Carburize............................................ 0.040 to 0.050 in. deep
Heat treat............................................ 55-60 Rockwell C
Miter, gear, right-hand:
Same as for left-hand (except
that rotation would be
right-hand)
Input shaft splne:
Type .................................................. 300 involute
Number of teeth.................................. 19
Diametral pitch ................................... 0.5 in.
Pitch diameter .................................... 2.375 in.
Minor diameter.................................... 2.240 in.
Pin diameter ....................................... 0.240 in.
Weight (approximate)......................... 1000 lbs.
(7) Air brakes, parking and service.
Manufacturer...................................... B.F. Goodrich Co.
Model ................................................ H500-1
Type .................................................. 360°segmented shoe type
Actuated by ........................................ Expander tube
Number of units ................................. 8
(8) Column and wheel drive.
Manufacturer ..................................... Western Gear Corp.
DA dwg No......................................... 2303-09-12
Column height (overall) ...................... 97 ¾ in.
Base dimensions:
Length ............................................... 27 in.
Width ................................................ 14 in.
Drive ratio:
Spiral bevel ........................................ 6.375 : 1
Planetary ........................................... 5.21 : 1
Total reduction (engine
to wheel, including
transmission....................................... 33.2: 1
Planetary ring gear:
Number of teeth ................................. 80
Diametral pitch ................................... ¾ in.
Pitch diameter .................................... 26.66 in.
Addendum ......................................... 0.250 in.
Planet gear:
Number of teeth ................................. 30
Diametral pitch . ................................. ¾ in.
Pitch diameter.. .................................. 10.000 in.
Addendum ......................................... 0.250 in.
Whole depth....................................... 0.562 in.
Spur pinion gear:
Number of teeth ................................. 19
Diametral pitch ................................... ¾ in.
Pitch diameter .................................... 6.666 in.
Addendum ......................................... 0.250 in.
Whole depth....................................... 0.562 in.
Spline:
Number of teeth ................................. 16
Diametral pitch ................................... 0.5 in.
Pitch diameter .................................... 4.000 in.
Reaction member gear:
Number of teeth ................................. 80
Addendum ......................................... 0.250 in.
Pitch .................................................. ¾ in.
Gear spider:
Number of teeth ................................. 180
Diametral pitch ................................... 8 / 10 stub
Pitch diameter .................................... 22.500 in.
Addendum ......................................... 0.100 in.
Axle spline:
Number of teeth ................................. 81
Diametral pitch ................................... ½
Pitch diameter .................................... 16.200 in.
Addendum.......................................... 0.080 in.
Bevel gear spline:
Number of teeth ................................. 16
Diametral pitch ................................... ½
Pitch diameter .................................... 4.000 in.
Addendum ......................................... 0.125 in.
Note. For gear spider dimensions and wear limits, see figure 7-115.
Bevel pinion:
Number of teeth ................................. 8
1-5
1
Diametral pitch ........................... 2.198
Pitch diameter ............................ 3.639
Addendum ................................. 0.562
Dedendum ................................. 0.226
Bevel gear:
Number of teeth ......................... 51
Diametral pitch ........................... 2.198
Pitch diameter ............................ 23.200
Addendum.................................. 0.154
Dedendum ................................. 0.654
Weight (approximate) ........... ............. 4,290 Ibs.
(9) Tires.
Manufacturer ...................................... Firestone Tire and
Rubber Co.
Mfr. No .............................................. 36.00ANSDWGAD
................................................... 16925
Type ................................................... Tubeless, non-directional
Size ................................................... 36.00 by 41
Ply rating ............................................ 48 ply nylon cord
Tread:
Type........................................... Non-skid
Depth ......................................... 1 in.
Rim diameter ...................................... 41 in.
Rim size (width).................................. 26 in.
Over-all width...................................... 38.90 in.
Over-all diameter ................................ 9 ft 6 ½ h in.
Weight................................................ 3325
g. Marine Drive System.
(1) Flexible coupling (engine and gathering box to fluid coupling).
Manufacturer ...................................... Philadelphia Gear Works
Mfr. Dwg............................................. D6840T2A REV B
Number of units.................................. 12
(2) Fluid couplings.
Manufacturer ...................................... Twin Disc Clutch Co.
Model.................................................. 17.5 HM
Type output ........................................ Splined
Maximum speed ................................ 2340 rpm
Number of units.................................. 4
(3) Pillow blocks.
Manufacturer ...................................... SKF Industries Inc.
Mfr. No .............................................. SAF 1513 x 2 1/4
Type .................................................. Split housing
Number of units.................................. 8
(4) Gathering box.
Manufacturer ...................................... Western Gear Corp.
DA drawing No ................................... 2303-09-102
Gear ratio............................................ 1.214 : 1
Maximum output torque ...................... 12,480 in-lbs.
Input shaft spline:
Number of teeth ......................... 19
Diametral pitch ........................... 0.500 in.
Pitch diameter ............................ 1.900 in.
Pitch angle ................................. 30°
Pin diameter ............................... 0.1920 in.
Input shaft pinion:
Number of teeth ......................... 28
Diametral pitch ........................... 4 in.
Pitch diameter ............................ 7.000 in.
Addendum.................................. 0.245 in.
Dedendum ................................. 0.227 in.
Circular thickness ...................... 0.4123 in.
1
Face angle ................................ 42° 1
1
Pitch angle ................................. 39 28
Root angle.................................. 37 6
Output shaft gear:
Number of teeth ......................... 34
Diametral pitch........................... 4 in.
Pitch diameter............................ 8.500 in.
Addendum ................................. 0.180 in.
Dedendum ................................ 0.292 in.
Circular thickness ...................... 0.3733 in.
1
Face angle ................................. 52° 25
1
Pitch angle................................. 50° 32
1
Root angle.................................. 47°30
Oil pump:
Manufacturer ............................. Tuthill Pump Co.
Model......................................... IRCS (modified)
Army drawing No ....................... LX09-102-028
Capacity .................................... 2 gpm
Sprag clutch:
Manufacturer ............................. Borg Warner Corp.
Mfr. No....................................... X 136865
Type .......................................... One-way
Capacity..................................... 1423 ft-lbs
Accessory drive ................................. Vee belt pulley
Number of units ................................ 2
(5) Flexible coupling (gathering box. To marine gear).
Manufacturer ..................................... Philadelphia Gear Works
Mfr. dwg ............................................ C684037 REV G
Number of units ................................ 2
(6) Marine gears.
Manufacturer...................................... Western Gear Corp
Model ................................................. 48B-LH (starboard side)
48B-RH (port side)
Reduction ratio (fwd and rev) ............. 2 : 1
Angle drive gear ratio ........................ 1.473 : 1
Lubrication ......................................... Forced, oil pump
mounted (on unit)
Number of units ................................. 2
(7) Oil sediment strainer.
Manufacturer...................................... Marvel Engineering Co.
Model 1 .............................................. SLB- 1 1/4 -20-100
Type................................................... Line type
Inlet and outlet pipe size..................... 1 1/4 in.-NPTF
Capacity ............................................. 20 gpm
Pressure drop .................................... 0.50 psi
Weight (approximate)......................... 12 1/2 Ibs.
Number of units ................................. 2
(8) Propeller shafts.
Main shaft:
Mfr. (Hulls 5 through 18)........... Treadwell Construction
Co.
Mfr. (Hulls 19 through 24)......... Transval Electronic
Corp.
Mfr. (Hulls 25 through 60)......... Western Gear Corp.
Over-all length ................................... 11 ft. 7 1/8 in.
Material .............................................. Carbon steel
Shaft sleeve:
Material ...................................... Nickel alloy
Length........................................ 17 1/4 in.
Outside diameter ....................... 2.778 to 2.782 in.
Army drawing No................................ LX09-019-017
Weight (approximate)......................... 205 Ibs.
Number of units ................................. 2
1-6
(3) Air compressor governor.
Manufacturer...................................... Westinghouse Air Brake
Co.
Type................................................... NS-16
Mfr. No .............................................. 85270
Pressure range .................................. 80 to 250 psi
Required setting
Cut-in pressure.......................... 135 psi
Cut-out pressure........................ 155 psi
Range differential....................... 20 psi
Number of units ................................. 1
(4) Actuator positioner.
Manufacturer...................................... Westinghouse Air Brake
Co.
Mfr. No .............................................. P50631-2
Type................................................... AB-1
Lever starting control pressure........... 10 psi
Lever maximum travel pressure ......... 60 psi
Optimum distance from connecting
link to rod end ............................ 6 in.
Optimum distance between actuator
positioner and governor.............. 16 19/32 in.
Number of units ................................. 4
(5) Air starting lubricator.
Manufacturer...................................... C.A. Norgren Co.
Model ................................................. 30-41-8L
Oil capacity ........................................ ½ pt.
Number of units ................................. 4
(6) Air starting air filter
Manufacturer ..................................... C.A. Norgren Co.
Model ................................................. 30-AE-8
Number of units ................................. 4
(7) Main air supply filter.
Manufacturer...................................... Westinghouse Air Brake
Co.
Type................................................... E
Strainer
Mfr. No...................................... 502904
Type........................................... Combination curled hair
and felt
Number of units ................................. 1
(8) Air horn.
Manufacturer...................................... Westinghouse Air Brake
Co.
Type................................................... DD-5
Number of units ................................. 1
(9) Windshield wiper motor.
Manufacturer...................................... Trico Products Co.
Type................................................... Air operated
Model ................................................. FPD-60L
Sweep ................................................ 60
Number of units ................................. 1
(10) Wiper control regulating valve.
Manufacturer...................................... Trico Products Co.
Mfr. No .............................................. 75470-5C
Number of units ................................. 1
(11) Air cylinder (cargo well pump and ramp cylinder control).
Manufacturer...................................... Westinghouse Air
Brake Co.
Intermediate shaft {Marine
gear to propeller shaft)
Manufacturer.............................. Thomas Flexible
Coupling Co.
Mfr. No ...................................... 31897
Model ........................................ 375 special (modified)
Type .......................................... Thrust
Material ...................................... Carbon steel
Over-all length............................ 5 ft, 7 15/ 16 in.
Number of units ......................... 2
(9) Propellers.
Mfr. (Hulls 5 through 24 & 49
through 60)................................. Columbian Bronze Co.
Mfr. (Hulls 25 through 48) ................. Coolidge Propeller Co.
Army drawing No.
Right hand propeller................... LX09-032-ORH
Left hand propeller ..................... LXO9-032-OLH
Diameter............................................. 48 in.
Number of blades ............................... 4
Pitch ................................................... 30 in.
Material............................................... Cast manganese bronze
Weight (approximate) ......................... 400 lbs.
h. Compressed Air System.
(1) Air compressors.
Manufacturer ..................................... Le-Roi Div., of Westinghouse
Air Brake Co.
Model numbers................................... 14A-3YC-1-3 and 3VCSpec 454-5 LARC
Type ................................................... 2 stage
Bore
Low pressure cylinder ............... 5 in.
High pressure cylinder .............. 2 ½ in.
Stroke ................................................. 3 ½ in.
Crankshaft rotation (from drive end) .. CCW
Intercooler safety valve setting............ 70 psi
Free air actually delivered at
1174 rpm ................................... 30 cfm
Maximum build-up time for 10.7
cu. ft. tank form 0 to 155
psi at 1174 rpm .......................... 5 minutes
Note.
When LARC engine
compressor shaft rotation is 1174 rpm's.
speed
is
2100
rpm's
the
Oil capacity......................................... 2 ½ qts.
Dry weight (approximate)
Model 3YC ................................. 350 Ibs.
Model 3VC ................................. 235 Ibs.
Distance from bottom of base to
center line of crankshaft:
Model 3YC ................................. 6 ¼ in.
Model 3VC ................................. 6 ¼ in.
(2) Compressor flexible drive coupling.
Manufacturer ...................................... Lovejoy flexible coupling Co.
Mfr. No. (Model 3YC Compressor) .. 101661-C
Mfr. No. (Model 3VC Compressor) .. 020767-C
Type ................................................... Heavy duty
Model.................................................. C-226
Type inserts........................................ Rubber cushions
Maximum parallel misalignment.......... 0.015 in.
Maximum angular misalignment ......... ½
Gap between end of jaws and
opposite flange........................... 1/8 in.
Number of units.................................. 2
1-7
Mfr. No...... ........................................ P-50092
Type..................... .............................. ABO 2 position)
Stroke..................... ............................ 7/8 in.
Number of units.................................. 4
(12) Air cylinder (radiator fan control).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No .................... ......................... 523159
Type ...................... ............................ Single acting
Stroke ..................... ........................... ½ in.
Number of units ................................. 1
(13) Air cylinder (transmission shifting control).
Manufacturer................ ...................... Westinghouse Air Brake
Co.
Mfr. No................... ........................... 192-d58
Model ................................................. KS (5 position)
Number of units.................................. 4
(14) Check valve.
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No................... ........................... P55027
Type ...................... ............................ Inline type
Pipe tap size ...................................... ¾ in.
Number of units ................................. 2
(15) Check valve.
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... 520096
Type ...................... ............................ Inline type
Pipe tap size ...................................... 1 ¼ in.
Number of units ................................. 1
(16) Foot control valves (brake and throttle)
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... P50208-4
Type ................. ................................. H-1
Pressure range .................................. 0 to 150 psi
Number of units .............. ................. 2
(17) Hand throttle control valves.
Manufacturer ................ ..................... Westinghouse Air Broke
Co.
Mfr. No ................... .......................... P50494-11
Type ...................... ............................ H-2-FX
Pressure range .................................. 10 to 65 psi
Weight ............................................... 6 ¾ Ibs.
Number of units ................................. 4
(18) Marine shifting and throttle control valves.
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... P51121-1
Type ...................... ............................ HD-2-FM
Pressure range .................................. 0 to 65 psi
Number of units ................................. 2
(19) Globe valve (air tank drain).
Manufacturer ................ ..................... Crane Co.
Mfr. No. ............................................. 7
Size .................... ............................... ¼ in.
Pressure rating .................................. 150 psi
Number of units ............. .................. 2
(20) Globe valves (brake airline).
Manufacturer ..................................... Crane Co.
Mfr. No. ................... ........................ 362E
Size ....................... ............................ 1 in.
Pressure rating .................................. 300 psi
Number of units ................ ................ 2
(21) Globe valves (portable airlines).
Manufacturer ..................................... Crane Co.
Mfr. No .................... ......................... 362E
Size ........................ ........................... ¾ in.
Pressure rating................................... 300 psi
Number of units ............... ................. 3
(22) Globe valve (:ire air starting cross-over line).
Manufacturer ..................................... Crane Co.
Mfr. No .................... ......................... 362E
Size ........................ ........................... 1 in.
Pressure rating .................................. 300 psi
Number of units .............. .................. 1
(23) Angle valves (tire inflation line).
Manufacturer ..................................... Crane Co.
Mfr. No.................... .......................... 17
Size ........................ ........................... 1 in.
Pressure rating ................................. 150 psi
Number of units .............. .................. 4
(24) Globe valves (air tank shut-off).
Manufacturer .................................... Crane Co.
Mfr. No .................... ......................... 362E
Size ...................... ............................. 1¼ in.
Pressure rating .................................. 300 psi
Number of units ............... ................. 2
(25) Plug valves (ramp seal airline shut-off).
Manufacturer ..................................... Crane Co.
Mfr. No. .................... ......................... 319
Size ....................... ............................ ½ in.
Number of units .............. .................. 2
(26) Pilot air valve (engine starting and air horn control.
Manufacturer ..................................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... P54692
Type ...................... ............................ 2-BA-1
Number of units .............. .................. 9
(27) Pilot air valves (cargo well pump control, engine cutout, ramp
control, and tire inflation-deflation control).
Manufacturer ..................................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... P544260312
Type ...................... ............................ 2-HA-2
Number of units ............. ................... 9
(28) Quick opening - self closing valve (ramp seal control).
Manufacturer ..................................... Crane Co.
Mfr. N o ................... ......................... 12 ½
Size ..................... .............................. ½ in
Number of units ............. ................... 2
1-8
(29) Quick release valves (starting and transmission air line).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No................... ........................... P52935-3
Size ....................... ............................ 3/8 in.
Number of units ................................. 10
(30) Reducing valve (ramp seal pressure).
Manufacturer ................. .................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... P55503-0015
Type ...................... ............................ N-1
Pressure range .................................. 5 to 60 psi, set at 15 psi
Number of units ................................. 1
(31) Relay valves (tire inflation-deflation line).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... 501251
Type ...................... ............................ A-1-B
Number of units ................................. 2
(32) Relay valves (brake air line).
Manufacturer ................ ................... Westinghouse Air Brake
Co.
Mfr. No. .................. ....................... 538975
Type ...................... ............................ C-2
Number of units ................................. 4
(33) Relay valves (engine starting air line).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No. .................. ......................... 850723
Type ....................... ........................... D--A
Number of units ................................ 4
(34) Relay valves (transmission and throttle air line).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... 528681
Type ......................... ......................... H-5
Number of units ................................. 8
(35) Transmission shifting control valve.
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... 192797
Type ...................... ............................ 5-P-1B
Number of units ................................. 1
(36) Shuttle valves (air supply, fan throttle, transmission, and engine
starting air lines).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No .................. ........................... P54340-2
Size ....................... ............................ 4 in.
Number of units ................................. 28
(37) Safety relief valve (tire air line).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No ................... .......................... 10526
Type ...................... ............................ E-1
Pressure range .................................. 35 to 75 psi, set at 70 psi
Male pipe thread size ......................... ½ in.
Number of units ................................. 1
(38) Safety relief valves (air tank).
Manufacturer ................ ..................... Westinghouse Air Brake
Co.
Mfr. No .................... ......................... 850159
Type ...................... ............................ FA
Pressure range ................ ................. 130 to 1 75 psi, set at 165
psi
Male pipe thread size ........... ............. /4 in.
Number of units .............. .................. 2
i. Hydraulic System.
(1) Bilge pumps.
Manufacturer................ ..................... Deming Co.
Model . .................... ......................... 4707FIG4305-3IN
Size discharge ................ .................. 3 in.
Type ...................... ............................ Centrifugal, self-priming
Capacity ....................... ..................... 100 gpm
Motor
Manufacturer ..................................... Pesco Products Div of
Borg-Warner Corp.
Mfr. No .................. ........................... 062547-010-01
Type ..................... ............................. Hydraulic, gear
Rating ................................................ 3 hp at 1800 rpm
Operating pressure ........... ................ 550 psi
Shaft rotation (from drive end)............ CW
Number of units .............. ................. 3
(2) Cargowell pumps.
Manufacturer ..................................... Byron Jackson Div. of
Borg-Warner Corp.
Mfr. No .................... ......................... 265916
Type ...................... ............................ 76-D
Size ......................... .......................... 12 in.
Capacity .................... ........................ 2000 gpm
Motor
Manufacturer ..................................... Vickers Inc.
Model ........................ ........................ MF-2008-30-38-21
(special)
Type ..................... ............................. Hydraulic, Piston
Maximum speed .............. ................ 2200 rpm
Displacement ............... .................... 2.41 cu. in.
Torque at 1000 psi ........... ................. 383.5 in. lb.
Model ...................... .......................... M2B-40-FLS-15
Type ..................... ............................. Hydraulic gear
Maximum speed ................................ 1800 rpm
Displacement .................. .................. 2.51 cu. in.
Torque at 1000 psi .......... .................. 360 in. lb.
Operating speed ................................ 1200 rpm
Operating pressure .............. ............. 1000 psi
(3) Liquid indicators (steering cylinder line).
Manufacturer .................................... Muller Brass Co.
Mfr. No .................... ......................... A13469
Size ........................ ........................... /4 in.
Number of units ................ ................ 2
(4) Supply tank filters.
Manufacturer ..................................... Marvel Engineering Co.
Model ......................... ....................... A-3-100
Type ...................... ............................ Sump
Capacity .................... ........................ 100 gpm
Screen ............................................... 100 mesh wire
Weight (approximate) ........................ 5½ Ibs.
Number of units ................ ............... 8
1-9
(5) Master pressure pumps.
Manufacturer ........... ......................... Vickers Inc.
Type ....................... ........................... Double unit, vane type
Model ................................................. V4235-28-8-11A-LH
Capacity ................... ................. 28 and 8 gpm
Model ................................................. V4235-36-11-11A-LH
Capacity .................... ................ 36 and 11 gpm
Shaft .................................................. Splined
Shaft rotation (from drive end) ............ CCW
(6) Steering cylinders.
DA drawing No.................. ................. 2303-08-17
Bore ................................................... 6 in.
Stroke ........................ ........................ 17 in.
Operating pressure ............................ 1300 psi
Number of units ................................. 8
(7) Ramp cylinders.
DA drawing No.............. ..................... 2303-05-21
Bore ................................................... 4 in.
Stroke ...................... .......................... 42 in.
Operating pressure............................. 1000 psi
Number of units ................................. 2
(8) Check valves (steering cylinder lines).
Manufacturer ................... .................. Vickers Inc.
Mfr. No .................... ......................... DT8P1-02-O5-10
Cracking pressure ............ ................. 5 psi
Capacity .................... ........................ 3.2 gpm
Pipe tread ................. ....................... ¼ in.
Over-all length ................ ................... 2 ¼ in.
Weight ............................................... 6 ½ oz.
Number of units ............... ................. 8
(9) Check valves (pump discharge lines).
Manufacturer ................ ..................... Vickers Inc.
Mfr. No.................... .......................... DT8P1-06-5-11
Cracking pressure .......... ................. 5 psi
Capacity .................... ........................ 20 gpm
Pipe thread ................. ....................... ¾ in.
Over-all length .................. ................. 3 7 / 8 in.
Weight ............................................... 1 ½ Ibs.
Number of units ................................. 8
(10) Check valves (ramp cylinder lines).
Manufacturer ................ ..................... Vickers Inc.
Mfr. No .................... ......................... DT8P1-06-65-11
Cracking pressure ............. ................ 65 psi
Capacity .................... ........................ 20 gpm
Pipe thread ................. ....................... ¾ in.
Over-all length ................ ................... 3 7 / 8 in.
Weight ............................................... 1 ½ Ibs.
Number of units ................................. 6
(11) Check valves (pump discharge lines).
Manufacturer ................ ..................... Vickers Inc.
Mfr. No. ................... ........................ DT8P1-10-5-11
Cracking pressure .......... ................... 5 psi
Capacity .................... ........................ 50 gpm
Pipe thread .................. ..................... 1 ¼ in.
Over-all length........... ......................... 5 ¼ in.
Weight ............................................... 5 lbs.
Number of units ................................. 4
(12) Check valve (winch lines).
Manufacturer ................... .................. Vickers -Inc.
Model ................................................. C2-830
Cracking pressure .............. ............... 5 psi
Capacity ....................... ..................... 65 gpm
Pipe thread ........................................ 1 ½ in.
Weight (approximate) ........................ 10 ½ lbs.
Number of units ................ ................ 1
(13) Flow control valves (bilge pump).
Manufacturer ..................................... Vickers Inc.
Model ........................ ........................ FRG-06-15-1O
Maximum operating pressure............. 2000 psi
Relief valve setting ............. ............... 550 psi
Maximum capacity ............................. 15 gpm
Flow rate ..................... ...................... gpm
Dial setting ................. ....................... 4
Weight (approximate) ........................ 58 Ibs.
Number of units .............. ................. 3
(14) Flow control valves (cargo well pump).
Manufacturer ..................................... Vickers Inc
Model ..................... ........................... FRG-06-2412
Maximum operating pressure............. 2000 psi
Relief valve setting ............. ............... 1000 psi
Maximum capacity ............................. 24 gpm
Flow rate .................... ....................... 16 gpm
Dial setting ................... ..................... 7-8
Weight (approximate) ........................ 58 lbs.
Number of units ............... ................. 2
(15) Four-way control valve (radiator fan).
Manufacturer .................................... Vickers Inc.
Model ..................... ........................... C-572-KNS-MI
Maximum capacity ............................. 3 gpm
Maximum operating pressure............. 2000 psi
Weight (approximate) ........................ 5 Ibs.
Number of units .............. .................. 4
(16) Four-way control valve (winch).
Manufacturer ..................................... Vickers Inc.
Model ..................... ........................... C-145VA-M1
Type ...................... ............................ 3 position, spring
centered
Maximum back pressure on tank
outlet connection ............. .................. 5 psi
Maximum capacity ............................. 65 gpm
Maximum operating pressure .......... 2000 psi
Weight (approximate) ........................ 72 Ibs.
Number of units............... .................. 1
(17) Four-way control valve (steering follow- up).
Manufacturer...................................... Vickers Inc.
Mfr. No ................... .......................... 823064
Model.................... ............................. C-14540M1
Type ........................ ........................ Spring centered
Maximum back pressure on tank
outlet connection ................................ 1000 psi
Maximum capacity.............................. 65 gpm
Maximum operating pressure ........... 2000 psi
Weight (approximate) ........................ 77 Ibs.
Number of units ............... ................. 2
(18) Gate valve (hydraulic oil tank drain).
Manufacturer...................................... Crane Co.
Mfr. No ................... .......................... 410
Size....................... ............................. 1 in.
Number of units ............... ................. 1
(19) Gate valve (hydraulic oil tank supply lines).
Manufacturer...................................... Crane Co.
1-10
Mfr. No .............. ............................... 410
Size .............. ..................................... 2 in.
Number of units ................................. 8
(20) Restrictor (ramp descent control).
DA drawing No. ............... ................. LX12-037-060
Orifice size ....................... ................. 0.156 in.
Number of units ................................. 2
(21) Needle valves (steering cylinder lines)
Manufacturer .................. ................... Crane Co.
Model ................................................. 222H
Size ............................. ...................... 1/4 in.
Number of units ................................ 4
(22) Needle valves (steering cylinder bleed off) .
Manufacturer .................. ................... Vickers Inc.
Model ................................................. DTNS3-02-10
Size ....................... ............................ ¼ in.
Number of units ................................. 14
(23) Multiple unit valve (port side).
Manufacturer .................. ................... Vickers Inc.
Model ................................................. CM2-06-RTDDL-10
Number of control valve section.......... 3'
Maximum capacity . .......................... 24 gpm
Maximum operating pressure ............. 1400 psi
Relief valve setting.............................. 1000 psi
Number of units ................................. 1
(24) Multiple unit valve (starboard side).
Manufacturer ............... ...................... Vickers Inc.
Model ................................................. CM2-06-RTTDDL-10
Number of control valve sections ....... 4
Maximum capacity ............................. 20 gpm
Maximum operating pressure .... ....... 1400 psi
Relief valve setting ............................. 1000 psi
Number of units ................................. 1
(25) Relief valve (forward steering. Cylinder line).
Manufacturer ................ .................... Vickers Inc.
Model ................................................. CF-16-C-10
Type ...................... ............................ Balanced piston type
Pressure range .................................. 500 to 2000 psi, set at
1300 psi
Maximum capacity ............................. 125 gpm
Weight (approximate) .......... .............. 36 Ibs.
Number of units ................................. 1
(26) Relief valves (radiator fan motor).
Manufacturer ................ ..................... Vickers Inc.
Model ................................................. CT-10-B-10
Type ...................... ............................ Balanced piston type
Pressure range .................................. 75 to 1000 psi, set at
1000 psi
Weight (approximate) .......... .............. 20 Ibs.
Number of units ................................. 4
(27) Relief valves (aft steering cylinder and winch lines).
Manufacturer ................ ..................... Vickers Inc.
Model ................................................. CT-10-C-10
Type ...................... ............................ Balanced piston type
Pressure range .................................. 500 to 2000 psi, set at
1300 psi
Weight (approximate)) ....................... 20 Ibs.
Number of units ................................. 2
(28) Cargo winch.
Manufacturer ................ ..................... Pacific Car and Foundry Co.
Model ..................... ........................... E-24 (modified)
Capacity ................... ......................... 23,500 Ibs.
Cable:
Diameter ............................................ 5/8 in.
Number of strands ........... ................. 6
Number of wires per stand................. 19
Core ....................... ........................... Fiber
Length ................... ............................ 380 ft.
Motor:
Manufacturer ..................................... Vickers Inc.
Mfr. No................... ........................... 838964
Model .................... ............................ LM2-540-150-OFC-13
Type .................... .............................. Hydraulic, vane
Horsepower ....................................... 27.3 hp
Maximum speed ................................ 1500 rpm
Torque ............................................... 150 in. Ibs.
Shaft rotation
(from drive end) ................................. CCW
Operating pressure ........... ................ 1300 psi
J. Gages.
(1) Air pressure gage (tire and main air).
Manufacturer ..................................... U.S. Gauge Div. of
Ametek Inc.
Mfr. No .................... ......................... 644
Range ...................... ......................... 0 to 200 psi
Dial size ..................... ....................... 2 in.
Number of units ............. ................... 2
(2) Air pressure gage (ramp seal).
Manufacturer ..................................... Enterprise Div of
................................................... General Metals Corp.
Mfr. No ...................... ....................... B3365
Range....................... ......................... 0 to 60 psi
Dial size .................... ........................ 3 ½ in.
Number of units ............... ................. 1
(3) Hydraulic pressure gage (steering).
Manufacturer ..................................... Instrument and Gauge
Div of Electric AutoLite Co.
Model ..................... ........................... 12882-A
Range ...................... ......................... 0 to 2000 psi
Dial size .................... ....................... 1 7/8 in.
Number of units ................ ................ 2
(4) Oil pressure gage (engine).
Manufacturer ..................................... Dresser Industries Inc.
Mfr. No .................... ......................... 7A478-1776 LARC
Type ..................... ............................. 111
Range ..................... .......................... 0 to 10 psi
Dial size ................... ......................... 3 in.
Number of units .............. .................. 4
(5) Oil pressure gage (gathering box).
Manufacturer ..................................... Dresser Industries Inc.
Mfr. No .................... ......................... 70A478-1774 LARC
Type ..................... ............................. 1010
Range ...................... ......................... 0 to 60 psi
Dial size ................ ............................ 3 ½ in.
Number of units ............... ................. 2
(6) Oil pressure gage (marine gear).
Manufacturer ..................................... U.S. Gauge Co.
Model ................... ............................. 805
1-11
Range................................................. 0 to 300 psi
Dial size ............................................. 2 ½ in.
Number of units ................................ 2
(7) Oil pressure gage (transmission).
Manufacturer................. ..................... Dresser Industries Inc.
Mfr. No. .................... ....................... 70A478-1777 LARC
Range ................................................ 0 to 300 psi
Dial size ............................................ 3½ in.
Number of units ................................. 4
(8) Oil temperature gage (engine and transmission).
Manufacturer ................. ................... Dresser Industries Inc. Type
Hulls 5 through 48 .......... ................... 6170 TW
HuIls 49 through 60 ........................... 6142 TW
Capillary length
Hulls 5 through 48 ........... .................. 12 ft.
Hulls 49 through 60 ......... .................. 18 ft.
Range ................................................ 100°to 300°F
Dial size ............................................. 3½ in.
Number of units ................................ 8
(9) Oil temperature gage (gathering box and marine gear).
Manufacturer ................ ..................... Dresser Industries Inc. Type
Hulls 5 through 48 .......... ................... 6170 TW
Hulls 49 through 60 ........ ................... 6142 TW
Capillary length
Hulls 5 through 48 .......... ................... 12 ft.
Hulls 49 through 60 ......... .................. 18 ft.
Range ................................................ 20° to 220°F
Dial size ............................................. 3 ½ in.
Number of units ................................. 4
(10) Quantity gage (fuel tank).
Manufacturer ................ .................... Liquidometer Corp.
Model ................................................. D6-209
Range ................................................ 0 to 300 gal.
Number of units ................................. 2
(11) Sight level gage (hydraulic oil tank).
Manufacturer ................ ..................... Vickers Inc.
Mfr. No ..................... ........................ 22576
Model ................................................. G-L1
Range ................................................ High-low
Number of units ................................. 1
(12) Water temperature gage (engine).
Manufacturer ................ .................... Dresser Industries Inc. Type
Hulls 5 through 48 .......... ................... 6170 TW
Hulls 49 through 60 ......... .................. 6142 TW
Capillary length
Hulls 5 through 48 .......... .................. 15 ft.
Hulls 49 through 60 ......... .................. 18 ft.
Range ................................................ 20°to 220°F
Dial size ........................................... 3 ½ in.
Number of units ................................. 4
Model ..................... ...........................
Type ...................... ............................
Motor (radio suppressed)
Mfr. No .................. ...........................
Volts . ...............................................
Shaft rotation (from shaft end) ...........
(2) Cab window glass.
Type ...................... ............................
Color ........................ .........................
Thickness ...................... ...................
Number of units ................ ................
(3) Bilge drain valves.
Manufacturer .....................................
Mfr. No ...................... .......................
Size ......................... ..........................
Number of units ............... .................
(4) Life lines.
Material ...................... .......................
K695-4
Hot water
9637
24 volts, dc
CCW
Laminated, safety
green-tinted
½ in.
12
Crane Co.
7
2 ½ in. (less body)
11
steel wire rope, plastic
covered
Diameter ............................................ 5 / 16 in.
Number of strands ............. .............. 6
Number of wires per strand
.... 19
(5) Ramp cable.
Diameter ............................................ 5/8 in.
Number of strands .............. .............. 6
Number of wires per strand ............... 19
Core ......................... ......................... Fiber
(6) Ramp seal
Manufacturer...................................... Huntington Rubber
Mills
Type
Hulls 5 through 18.............................. Pneumatic, single lip
Hulls 19 through 60 ........................... Pneumatic, double lip
Durometer hardness ............ ............. 45
Length ....................... ....................... 37 ft.
Number of units ............... ................. 1
l. Capacities.
Fuel oil tanks (2)................................. 300 gal. each, 600 gal.
total
Hydraulic oil tank ............................... 300 gal.
Spare lube oil tanks (2) ........ ............. 30 gal. each, 60 gal. total
Water cooling systems (4) ...... .......... 52 ½ gal. each, 210 gal.
total
Air compressor crankcases (2) .......... 2 ½ qt. each
Cargo well pump lubricators (2) ......... 4 qt. each
Engine Crankcases (4) . ........ .......... 20 qt. each
Fluid couplings (4) ............. ............... 4.7 gal. each
Gathering boxes (2) ........... ............... 12 qt. each
Marine gears (2) ................................ 60 qt. each
Miter, boxes (4) ................ ................. 15 qt. each
Strating motor lubricators (4).............. ¼ qt. each
Transmission-torque converter (4) ..... 52 qt. each
Wheel columns (4) .......................... 35 gal. each
k. Cab and Hull Components.
(1) Cab heater.
Manufacturer ................ .................... Kysor Heater Co.
1-12
Table 1-1. Engine Repair and Replacement Standards
Part or assembly
CYLINDER BLOCK
Block bore:
Diameter.....................................................................
Out-of-round ..............................................................
Taper..........................................................................
Surface of cylinder block:
Traverse flatness (top) ...............................................
Longitudinal flatness (top) ..........................................
Blower mounting pad flatness ....................................
Cylinder liner counterbore:
Diameter.....................................................................
Depth .........................................................................
Depth of counterbore (top surface) .
Cylinder head seal strip groove . ................................
Large water holes (between cylinders ........................
Small water holes (at ends) .......................................
Combination water and oil holes............................... .
Main bearing bore:
Inside diameter (vertical axis) ....................................
PISTONS
Piston skin-to-4iner clearance ............................................
Length (measured from centerline of piston pin) ................
Diameter at top ...................................................................
Diameter at skirt (below compression ring
grooves to bottom)......................................................
Out-of-round.......................................................................
Taper..................................................................................
PISTON PINS
Diameter.............................................................................
Length ................................................................................
Piston pin bushing inside diameter.....................................
Pin-to piston bushing clearance .........................................
Pin-to-rod bushing clearance..............................................
Pin-to-retainer end clearance (retainer with lock
ring)............................................................................
PISTON RINGS
Compression rings:
Gap ............................................................................
Ring-to groove clearances:
No. 1 (top) .................................................................
No. 2 .........................................................................
No. 3 and No. 4........................................................
Oil control rings:
Gap .......................................................................... .
Ring-to-groove clearance . ........................................
CRANKSHAFT AND CRANKSHAFT
MAIN BEARING
End thrust clearance (end play)..........................................
Main bearing journal diameter.............................................
Connecting rod journal diameter.........................................
Journal out-of-round ...........................................................
Journal taper.......................................................................
Total indicator reading runout on journal.............................
At No. 2 and No. 6 journals . ...................................
At No. 3 and No. 5 journals ......................................
At No. 4 journal .........................................................
Manufacturer’s dimensions
and tolerances in inches
Minimum
Maximum
4.6265
.
Desired clearance
Minimum
Maximum
4.6275
0.0010
0.0010
4.6280
0.0030
0.0020
.
0.0030
0.0090
0.0040
0.0078
0.0120
.
5.0460
0.4785
5.0485
0.4795
0.0920
0.1090
0.0870
0.0870
0.1070
0.1200
0.0980
0.0980
3.8120
3.8130
3.5130
4.2190
3.5180
4.2220
4.2433
4.2455
0.0005
0.0050
1.4996
3.6050
1.5025
1.5000
3.6200
1.5030
0.0040
.
3.4990
2.7490
3.5000
2.7500
0.00025
0.0005
0.0020
0.0040
0.0060
When the runout on adjacent journals is in the opposite
direction, the sum must not exceed 0.003 in. total indicator
reading. When the runout on adjacent journals is in the
same direction, the difference must not exceed 0.003 in.
total indicator reading.
1-13
Maximum
allowable
wear and
clearance
1.4980
0.0025
0.0015
0.0034
0.0024
1.5050
0.0100
0.0100
0.0160
0.0640
0.0640
0.0180
0.0430
0.0600
0.0100
0.0080
0.0060
0.0125
0.0105
0.0085
0.0220
0.0150
0.0130
0.0080
0.0015
0.0230
0.0055
0.0430
0.0080
0.0040
0.0110
0.0180
0.0030
0.0030
Table 1-1. Engine Repair and Replacement Standards-Continued
Part or assembly
Bearing thickness 90° from parting line.............................
Bearing inside diameter (vertical axis) ................................
Thrust washer thickness ...................................................
CRANKSHAFT TIMING GEAR
Backlash.............................................................................
Gear inside diameter .........................................................
Gear-to-crankshaft clearance .............................................
Connecting rod and connecting rod bearings
Upper bushing inside diameter...........................................
Bearing-to-crankshaft journal clearance .............................
Center-to-center length.......................................................
Lower bore diameter ..........................................................
Upper bore diameter ..........................................................
Normal rod end thrust.........................................................
Bearing thickness 90°from parting line..............................
Bearing inside diameter ......................................................
CAMSHAFT AND BALANCE SHAFT
Thrust bearing end journal length.......................................
End thrust ........................................................................
Bushing-to-balance weight hub ..........................................
Camshaft diameter at bearings:.
Front and rear.....................................................................
Center and intermediate .....................................................
Camshaft diameter at gear .................................................
Camshaft and balance shaft thrust washer
thickness ............................................................................
Balance shaft diameter at bearings ....................................
Balance shaft diameter at gear ..........................................
CAMSHAFT AND BALANCE SHAFT
BEARINGS
Inside diameter:
Front and rear ...................................................................
Center and Intermediate . ..................................................
Bearing-to-shaft clearance:
Front and rear (next to flange) ............................................
Center and intermediate .....................................................
Outside diameter of bearings:
Front and rear.....................................................................
Intermediate ......................................................................
Diameter of block bore........................................................
Bearings-to-block clearance:
Front and rear.....................................................................
Intermediate........................................................................
Camshaft and balance shaft gears .
Backlash.............................................................................
Gear inside diameter .........................................................
Gear-to-shaft clearance ....................................................
IDLER GEAR
Backlash.............................................................................
Preload (variation on pull 2 lb 11 oz)...................................
BLOWER TIMING
Clearance between trailing side of upper rotor
and lower side of lower rotor:
Inlet side maximum ...........................................................
Inlet side minimum (desireable)-.........................................
Outlet side minimum ..........................................................
Clearance between rotor and housing ................................
CYLINDER LINERS
Outside diameter ................................................................
Manufacturer’s dimensions
and tolerances in inches
Minimum
Maximum
3.5014
0.1205
3.5034
0.1220
4.7490
4.7500
1.5015
10.1260
3.0630
1.7510
0.0120
2.7514
2.7534
2.8740
2.8760
1.4970
1.4980
1.1875
1.4975
1.4985
1.1880
0.1200
1.4970
1.1875
0.1220
1.4975
1.1880
1.5000
1.5010
1.5010
1.5030
1.1865
0.1553
0.1530
0.0030
0.0080
0.0100
0.0010
press
0.0010
loose
0.0014
0.0044
1.5080
0.0060
0.1548
0.1553
0.1530
0.0040
0.0120
0.0180
0.0035
0.0025
0.0025
0.0040
0.0050
0.0060
0.0090
0 .0010
press
0.0015
0.0015
loose
0.0045
0.0030
0.0080
0.0015
press
0.0000
0.0030
0.0080
.
2.1885
2.1860
2.1885
0.0100
1.1875
½ lb
6¾ lb
0.0060
0.0020
1.0140
0.0020
0.0060
4.6250
4.6260
1-14
Maximum
allowable
wear and
clearance
0.1548
1.5020
10.1240
3.0620
1.7490
0.0060
2.1880
2.1840
2.1875
Desired clearance
Minimum
Maximum
0.0100
½ -6¾ lb
Table 1-1. Engine Repair and Replacement Standards-Continued
Part or assembly
Inside diameter....... ............................................................
Liner-to-block bore clearance...... .......................................
Liner inside diameter out-of-round
...............................
Liner inside of diameter taper ........................................ ....
Depth of liner flange below block........................................
Variation in height between adjacent liners.........................
CYLINDER HEAD
Distance between, top deck and fire deck ..........................
Transverse flatness............................................................
Longitudinal flatness...........................................................
Can follower bore................................................................
Valve seat inserts-to-cylinder head.....................................
Water nozzles ....................................................................
Exhaust valve seat insert counterbores: .
Diameter.............................................................................
Depth..................................................................................
VALVE SEAT INSERTS (30°SEAT ANGLE)
Outside diameter... .............................................................
Seat width...........................................................................
Valve seat runout................................................................
EXHAUST VALVES (30°SEAT ANGLE)
Diameter of head ................................................................
Stem diameter.. ..................................................................
Valve head-to-cylinder head. ..............................................
VALVE GUIDES
Inside diameter ..................................................................
Stem-to guide clearance.....................................................
Height above cylinder head.................................................
CAM FOLLOWERS
Diameter.............................................................................
Follower-to-head clearance.................................................
Width of roller slot ..............................................................
Roller pin hole diameter.... ..................................................
CAM FOLLOWER ROLLERS AND PINS
Pin-to-bushing clearance....................................................
Pin outside diameter...........................................................
Roller outside diameter.......................................................
Roller bushing inside diameter... ........................................
Roller in follower side clearance
Blower Drive Gear:
Backlash.............................................................................
Gear to hub clearance....... .................................................
Manufacturer’s dimensions
and tolerances in inches
Minimum
Maximum
4.2495
Maximum
allowable
wear and
clearance
4.2511
0.0005
0.0025
0.0465
0.0500
0.0020
0.0010
0.0030
0.0030
0.0020
0.0500
0.0020
3.5560
3.5680
1.0620
0.0005
1/32
Recessed
1.0630
0.0025
flush
1.6260
0.3705
1.6270
0.3845
1.6275
1/16
0.0020
1.6285
3/32
0.0020
1.5790
0.3417
0.0020
Recessed
1.5890
0.3425
0.0280
Protrusion
0.3445
0.3445
3.5360
0.0040
0.0100
1.0650
3 / 32
0.3405
0.0020
0.0040
0.3465
0.0060
0.0010
0.0030
0.0060
0.0013
0.0021
0.0100 (horiz)
0.0150
0.0230
0.0230
0.0030
0.0005
tight
0.0080
0.0010
loose
0.010
0.005
tight
0.0025
loose
0.0010
0.0025
0.0050
0.0020
0.0050
0070
0.0080
0.0100
0.001
0.0025
0.004
0.0015
0.003
1 19 / 32
1.0600
1.0610
0.5635
0.4362
0.5685
0.4370
0.4374
0.9020
0.4390
0.4377
0.9070
0.4395
Blower Drive Gear Support:
Support to end plate.... .......................................................
Bearing.... ...........................................................................
Bearing-to-hub clearance ...................................................
Blower Drive Gear Hub:
Diameter at bearing... .........................................................
Hub to cam clearance ........................................................
Gear hub-to-thrust washer clearance
Rocker Arms and Shafts:
Rocker shaft diameter.. ......................................................
Rocker arm shaft bushing id... ...........................................
Rocker shaft to bushing clearance .....................................
Rocker arm outer bushing id... ...........................................
Rocker arm inner bushing od .............................................
Outer-to inner bushing clearance
Rocker arm inner bushing id. .............................................
Desired clearance
Minimum
Maximum
1.6260
1.6240
1.6265
1.6250
0.8725
0.8750
0.8740
0.8760
0.564
0.562
0.565
0.5625
0.4375
0.4385
1-15
Table 1-1. Engine Repair and Replacement Standards Continued
Part or assembly
Manufacturer’s dimensions
and tolerances in inches
Minimum
Maximum
Push rod clevis pin od ........................................................
Pin-to-bushing clearance....................................................
0.4380
Push rod clevis id ...............................................................
Pin-to-clevis clearance ......................................................
0.4370
Clevis-to-rocker arm end play .............................................
End thrush clearance .........................................................
Main bearing to journal clearance .......................................
Connecting rod bearing to journal clearance.... ..................
Journal out of round............................................................
Journal taper.......................................................................
Runnout, total indicator reading, (mounted on
No. 1 and No. 7 journals) at No. 2 and No. 6
journals..... .................................................................
At No. 3 and No. 5 journals.... ..........................................
At No. 4 journal..................................................................
Desired clearance
Minimum
Maximum
Maximum
allowable
wear and
clearance
0.4385
0.001
tight
0.0005
loose
0.0015
tight
0.008
0.0040
0.0014
0.0014
0.0005
loose
0.017
0.0110
0.0044
0.0044
0.4385
0.00025
0.0005
0.0180
0.0060
0.0060
0.0030
0.0030
0.0020
0.0040
0.0060
0.0020*
0.0040*
0.0060*
* When runout on adjacent journals is in the opposite direction, the sum must not exceed 0.0030-inch total indicator reading. When runout on adjacent journals is in the same direction, the difference must not exceed 0.0030-inch total indicator reading.
1-16
Table 1-2. Model TC-554 (3 and 4 Element) Torque Converter Repair
and Replacement Standards
Nominal new
dimensions
Part or assembly
Oil Pump Drive Gear:
Bore .......................................................................................
Gear thickness........................................................................
Stator Assembly: .........................................................................
Thrust...................washer thickness........................................
Bore ...................... diameter..................................................
Freewheel side washer thickness........................ ...................
Stator race outside diameter................................. ..................
Stator back plate thickness................................... ..................
Freewheel roller spring. (3 element converter) ........................
4.162
0.520
0.127
4.764
0.058
4.749
0.298
70 lbs +
0.07 Ibs at
1.07 in. operating height,
free height
1.57
1.17 lb + 0.11
lb at 0.94 in.
operating
height, free
height 1.92 in.
Free wheel roller spring (4 element converter).. .......................
Output Shaft:
Seal ring bore.................................................. .......................
Flywheel:
Pilot diameter................................................ ........................
Turbine:
Turbine hub........................................... .................................
Charging Oil Pump:
Clutch pressure regulating valve clearance with oil pump cover....
Clutch pressure regulating spring............................ ................
Wear
limits
4.172in.
0.006 in.
perface
0.117 in.
4.767 in.
0.048 in.
4.739 in.
0.288 in.
0.9995-1.0005
1.0025 in.
2.435
2.425 in.
0.570
0.550 in.
0.006
26 lb + 2 percent at 1.75 in.
operating height,
free height 2.397
Converter pressure regulating valve clearance with oil pump cover
Converter pressure regulating spring.......................................
88.6 lb + 4.4
percent at 3.52
in. operating
height, free
height 4.72
Gear end clearance.................................................................
0.006
0.002
°Replace if not within dimension given.
Table 1-3. Model TC-654 Torque Converter Repair and Replacement Standards
Nominal new
dimensions
Part or assembly
Oil Pump Drive Gear
Bore ......................................................... ........................
Gear thickness .................................................................
Stator assembly
Thrust washer thickness ...... ........................................ .
Stator retaining snapring thickness................................. ..
Bushing bore ....................................................................
Freewheel roller spring.......................................................
Flywheel
Pilot diameter......................................... ..........................
Wear
limits
4.162
0.520
4.172
0.006 in.
per face
................
................
0.1 10 in.
0.1 10 in.
3.119 in.
0.25 lb +
0.0075 lb at
0.74 in. operating height, free
height 0.92
2.435
1-17
2.425 in.
Table 1-3. Model TC-654 Torque Converter Repair and Replacement Standards–Continued
Nominal new
dimensions
Part or assembly
Wear
limits
Ground Sleeve
Flywheel diameter......................................................... .
Bushing diameter ...........................................................
Seal ring bore.................................................................
Pump Hub Assembly
Bushing bore............................................................ ......
Seal ring bore.................................................................
Charging Oil Pump
Clutch pressure regulating valve clearance with oil pump cover
Clutch pressure regulating spring................................. .
3.078 in.
4.150 in.
2.755 in.
4.175 in.
4.191 in.
0.006 in.
82 lb +4
load at 2.22
in. operating
height, free
height 2.93
Converter pressure regulating valve clearance with oil pump cover 0.006 in.
Converter pressure regulating spring................................
88.6 lb + 4.4
load percent
at 3.52 in.
operating
height, free
height 4.72
* Replace if not within dimension given.
Table 1-4. Torque Converter Stall Speed Chart
Engine
governed
(RPM)
Converter
torque
Converter
Model
Stall
(RPM)
Transmission
lube oil
pressure
Converter
charging
oil pressure
2100
2100
3.6 to I
3.13 to 1
TC-654
TC-554
1710
1840
8-25 psi
8-25 psi
50-80 psi
50-80 psi
Table 1-5. Hull and Cab Welding Data
Location
Shell, deck, and bulkhead lap joints.......................................
Shell, deck, and bulkhead seams and butts ...........................
Flat bar and tee bulkhead boundry bars to plating
in watertight spaces ..............................................................
Flat bar and tee bulkhead boundry bars to plating
in non-watertight spaces
Collar plates.........................................................................
Brackets, chocks, and joints between shapes ........................
Note. Minimum thickness of fillet weld–1/8 inch.
Weld
Thickness of lightest plate, double continuous fillet.
Thickness of lightest plate, continuous bead.
Thickness of plate, double continuous fillet.
thickness of plate, 3 inch x 6 inch intermittent chain fillet
with 6 inch double continuous fillet at ends.
Thickness of plate, fillet all round both sides.
Thickness of lightest member, fillet all round.
Table 1-6. Transmission Wear Limits
Wear limits
Transmission housing:
Bearing housing seal ring bore............................. ..............................................
Transmission main shaft:
Main shaft journal diameter................................. ...............................................
Low range clutch:
Piston thickness............................................ ............................................................
Piston plate thickness.........................................................................................
Friction plate thickness..................................... ..................................................
Reaction plate thickness.....................................................................................
Back plate assembly thickness.................................... .......................................
1-18
3.552 in.
1.9684 in.
0.845 in.
0.414 in.
0.153 in.
0.109 in.
0.615 in.
Table 1-6. Transmission Wear Limits Continued
Wear limits
Intermediate range clutch:
Piston thickness............................................... .....................................................
Friction plate thickness........................... ...............................................................
Reaction plate thickness........................................ ................................................
Back plate assembly thickness................................ ..............................................
High range clutch:
Piston thickness........................................ ............................................................
Friction plate thickness................................... .......................................................
Reaction plate thickness................................ ........................................................
Back plate assembly thickness............................ ..................................................
Reverse range clutch:
External snap ring thickness.................................. ................................................
Back plate assembly thickness................................... ...........................................
Friction plate thickness....................................... ...................................................
Reaction plate thickness................................... .....................................................
Piston thickness........................................ ............................................................
Clutch pin diameter........................................ .......................................................
Planetary gearing:
Thrust washer thickness......................... ...............................................................
Planetary assembly-planetary gear end clearance with unit....................................
Table 1-7. Miter Box Repair and Replacement
Manufacturer’s
dimensions and
tolerance in inches
Part or assembly
Column and wheel Drive Bearing Carrier
Bearing area dia
Seal area dia
Column and Wheel Drive Intermediate
Shaft
Spline od (both ends of shaft)
Coupling Flange
Spline id between teeth
Groove depth in mating seal area
Coupling Gear (Female))
Spline id between teeth
Gear teeth
Coupling Gear (Male)
Spline id between teeth
Gear teeth
Input Shaft
Bearing area od (2 places)
Gear area od
Input Shaft Bearing Retainer
Bearing area dia
Output Shaft
Top hearing area od
Gear and center bearing area od
Spline od
Output Shaft Bearing Carrier
Bearing area dia
Output Shaft Bearing Yoke
Bearing area dia*
Output Shaft Coupling Gear (Male)
Spline id between teeth
Gear teeth
Groove depth in mating seal area
Gear Backlash
0.9195 in.
0.170 in.
0.113 in.
0.620 in.
0.537 in.
0.153 in.
0109 in.
0.646 in.
0.115 in.
0.619 in.
0.153 in.
0.109 in.
0.9125 in.
0.485 in.
0.050 in.
0.063 in. maximum
Standards
Maximum
allowable wear and
clearance
in inches
Minimum
Maximum
13.383
12.498
13.385
12.500
13.386
12.502
2.734
2.735
2.733
2.503
0.005
2.739
2.740
2.741
5.390 between 0.180
dia pins
2.739
2.740
2.741
1.716 chordal measure
over five teeth
2.5010
2.7560
2.5015
2.7570
2.5007
2.7557
5.375
5.376
5.377
2.1660
2.7560
2.734
2.1666
2.7565
2.735
2.1657
2.7557
2.733
4.9211
4.9223
4.9226
3.9365
3.9375
3.9378
2.739
2.740
2.741
1.716 chordal measure
over five teeth
0.005
0.008
0.012
1-19
Table 1-8. Air Brake Assembly Repair and Replacement Standards
Manufacturer’s
dimensions and
tolerance in inches
Part or assembly
Minimum
Brake Shoe Assembly
Lining thickness UI2
Wear in retractor spring area
Brake Retractor Spring
Free spring height
Brake Drum
Diameter
Maximum
Maximum
allowable wear and
clearance
in inches
0.172
0.0625
0.0625
15.060
15.07
15.150
Table 1-9. Column and Wheel Drive Repair and Replacement Standards
Manufacturer’s
dimensions and
tolerance in inches
Part or assembly
Minimum
Planetary:
Idler shaft ...........................................................................
Planetary Ring Gear
Gear teeth (measurement between 0480 dia pins).............
Backlash.............................................................................
Bearing end play.................................................................
Planet Gear
Gear teeth (chordal measurement over four teeth) .............
Maximum
Maximum
allowable wear and
clearance
in inches
4.000
4.001
3.999
26.248
0.010
26.253
0.012
0.005
26.258
3.582
3.586
3.578
8.718
8.123
8.713
7.103
3.605
0.004
7.107
3.607
0.007
7.100
3.610
4.7300
4.7320
4.7280
5.358
0.4100
5.360
0.4120
5.370
0.4170
7.0864
7.0876
7.0880
7.8750
7.8770
7.8780
9.8425
23.9900
9.8436
2.39950
9.8440
2.39870
16.4990
16.5010
16.5020
15.613
0.012
15.617
0.016
15.6250
0.959
0.004
0.961
0.006
0.957
24.0000
24.0050
7.506
7.510
Note Planet gears should be the same size within 0.004 in
If one planet is worn, all three planet gears should be replaced
Reaction member:
Gear teeth (chordal measurement over 9 teeth) .................
Spur Pinion:
Gear teeth (measurement over O576 dia wires).................
Spline (Measurement between 0360 dia pins)....................
Backlash ............................................................................
Main Axle:
Spline (Measurement over 04800 dia pins) ........................
Bevel Pinion Coupling:
Upper spline diameter (measurement between 0180
pins)
Lower spline distance between teeth..................................
Spider Bearing Housing:
Bearing area diameter ........................................................
Bevel Pinion Bearing Adapter:
Bearing area diameter ........................................................
Spider Bearing Carrier:
Bearing area diameter ........................................................
Bearing carrier od ...............................................................
Bevel Gear Set
Bevel Pinion (fig. 7-114)
Bevel gear:
Spider-to-bevel gear area diameter.....................................
Spline diameter (Measurement between 03750
dia pins)
Backlash.............................................................................
Gear Spider (fig. 7-115)
Oil Pump Gear
Chordal measurement over three teeth...............................
Backlash.............................................................................
Steering Post
Spider bearing carrier outer area diameter .........................
Lower Pivot Bearing Assembly
Bushing id ..........................................................................
1-20
24.0080
7.525
Table 1-10. Gathering Box Repair and Replacement Standards
Part or assembly
Manufacturer’s dimensions and
tolerance in inches
Minimum
Clutch, Inner Race Shaft:
Outer bearing area od
Inner bearing area od
Clutch Outer Race:
outer bearing area od
Inner bearing area od
Groove depth in mating seal area
Output Coupling:
Groove depth in mating seal area
Output Shaft:
Bearing area dia
Bevel gear area dia
Spline area od
Bearing adapter id
Pump bearing adapter id
Input Shaft:
Bearing carrier:
Bearing area id
Ball bearing area id
Bevel pinion area dia
Bearing area dia
Ball bearing area dia
Spline area dia
Maximum
Maximum
allowable wear and
clearance
in inches
2.9525
2.3619
4.5274
3.7400
4.5278
3.7404
4.5280
3.7406
0.005
0.005
Gear Backlash
2.2510
2.5015
2.2490
5.3450
5.3450
2.2515
2.5020
2.2500
5.3460
5.3460
2.2508
2.5013
2.2470
5.3470
5.3465
5.9047
5.1180
2.3765
2.7563
2.3621
5.9057
5.1190
2.3770
2.7568
2.3627
5.9062
5.1195
2.3762
2.7560
2.3618
2.1810 over
0.1920 pins
0.008
0.012
Table 1-11. Marine Gear Repair and Replacement Standards
Part or assembly
BEVEL DRIVE ASSEMBLY
Bearing carrier:
Outer bevel pinion bearing area dia
Inner bevel pinion bearing area dia.
Bevel pinion id
Bevel pinion shaft (fig. 7-122)
INPUT SHAFT ASSEMBLY
Planetary gear:
Chordal measurement over six teeth .
Planetary gear id
Forward pinion:
Chordal measurement
Forward pinion id
Reverse pinion:
Chordal measurement
Reverse pinion id
Bevel gear id
Forward bearing adapter id
Aft bearing adapter id
Input shaft (fig. 7-123)
PUMP PLANETARY DRIVE ASSEMBLY
Planetary pinion:
Chordal measurement over five teeth
Spline teeth thickness
Planetary pinion shaft:
Forward bearing area dia
Aft bearing area dia
Planetary housing adapter:
Bearing area id
Bearing area od
Manufacturer’s dimensions and
tolerance in inches
Maximum
allowable wear and
clearance
in inches
Minimum
Maximum
4.4375
6.3750
3.0000
4.4385
6.3760
3.0010
4.4390
6.3765
3.0013
.....
2.4990
......
2.5000
2.5950
2.5005
......
3.2650
......
3.2660
1.7600
3.2665
......
3.9840
7.6000
5.8760
7.0858
......
3.9850
7.6010
5.8770
7.0872
3.1630
3.9853
7.6030
5.8775
7.0876
0.5610
0.5630
2.1080
0.5750
1.7500
1.7505
1.7505
1.7510
1.7495
1.7500
3.5428
3.9990
3.5438
3.0000
3.5443
3.9980
1-21
Table 1-11. Marine Gear Repair and Replacement Standards-Continued
Part or assembly
Forward bearing adapter id
Aft bearing adapter id
IDLER SHAFT ASSEMBLY
Idler gear:
Chordal measurement
Idler gear id
Forward bearing adapter id
Aft bearing adapter id
Idler shaft (fig. 7-125)
CONTROL TUBE ASSEMBLY
Valve bushing od
Valve bushing id
Spacer od
Spacer id
Beveled washer od
Beveled washer id
Forward oil valve (fig. 7-126)
Reverse oil valve:
Valve od
Valve id
Outer tube:
Spacer area dia
Separator box area dia
OUTPUT SHAFT ASSEMBLY
Forward bearing adapter id
Forward output gear (fig. 7-120)
Reverse output gear (fig. 7-121)
Aft output shaft adapter id
Clutch assembly:
Piston ring on forward plate (side clearance)
Piston rings in forward and reverse plate of drum
(side clearance)
Pressure plate to clutch plate ..
Bevel gears maximum allowable backlash
Clutch forward plate (fig. 7-118)
Clutch bushing cup:
Cup od
Cup id
Clutch reverse plate:
Face flatness
Plate id
Clutch piston (fig. 7-119)
Clutch spring retainer:
Retainer outer area dia
Retainer inner area dia .
Clutch friction plates:
Thickness
Variation in thickness
Deviation from true plane
Backlash
Clutch pressure plates:
Thickness
Deviation from true plane
Backlash
Output shaft (fig. 7-124)
Manufacturer’s dimensions and
tolerance in inches
Maximum
allowable wear and
clearance
in inches
Minimum
Maximum
3.1855
3.1855
3.1865
3.1865
3.1870
3.1870
3.2390
4.7264
5.1174
3.2400
4.7274
5.1186
2.4720
3.2420
4.7279
5.1190
1.8765
1.3760
1.3490
1.0000
1.3490
0.5420
1.8770
1.3770
1.3690
1.0020
1.3690
0.5430
1.8760
1.3790
1.3460
1.0040
1.3460
0.5450
1.3490
0.5420
1.3690
0.5430
1.3460
0.5450
0.9980
1.1190
1.0000
1.1200
0.9960
1.1180
6.6921
6.6935
6.6940
7.8750
7.8770
7.8773
0.005
0.010
0.008
0.035
0.008
0.012
0.050
0.012
0.120
1.5005
1.2505
1.5010
1.2515
1.5003
1.2535
5.2510
5.2520
0.0040
5.2540
1.2405
1.5020
1.2410
1.5025
1.2400
1.5015
0.2450
0.2500
0.2300
0.0060
0.0150
0.0300
.
0.2450
0.2500
1-22
0.2000
0.0060
0.0250
Table 1-12. Model 3VC Air Compressor Tolerances and Clearances
Manufacturer’s dimensions and
tolerance in inches
Part or assembly
Piston to cylinder clearance:
High pressure at skirt ...................................................................................................................................
Low pressure at skirt .....................................................................................................................................
Piston ring gap:
High pressure compression rings..................................................................................................................
High pressure oil ring ....................................................................................................................................
Low pressure compression rings...................................................................................................................
Low pressure oil ring .....................................................................................................................................
Piston ring clearance in ring groove:
High pressure compression rings..................................................................................................................
High pressure oil control ring.........................................................................................................................
Low pressure compression rings ..................................................................................................................
Low pressure oil control ring........................................................................................................................
Top of piston to top of cylinder clearance ......................................................................................................
Connecting rod bearing to crankshaft clearance . .........................................................................................
Connecting rod bushing to piston pin clearance ...........................................................................................
Crankshaft end play......................................................................................................................................
Oil Pump:
Clearance between face of rotor and cover ...................................................................................................
Minimum
Maximum
0.002
0.0045
0.0035
0.0065
0.007
0.007
0.017
0.017
0.017
0.015
0.027
0.027
0.0020
0.0015
0.0025
0.0020
-0.007
0.0025
0.0002
0.003
0.0035
0.0030
0.0045
0.0040
+0.017
0.0044
0.0006
0.005
0.0035
0.0055
Table 1-13. Model 3YC Air Compressor Tolerances and Clearances
Manufacturer’s dimensions and
tolerance in inches
Part or assembly
Crankshaft connecting rod journal diameter ..................................................................................................
Connecting rod bearing bore .........................................................................................................................
Crankshaft to connecting rod clearance .......................................................................................................
Low pressure piston to cylinder clearance:
Skirt top...............................................................................................................................................
Skirt bottom.........................................................................................................................................
Top land..............................................................................................................................................
Bottom land.........................................................................................................................................
High pressure piston to cylinder clearance:
Skirt top...............................................................................................................................................
Skirt bottom.........................................................................................................................................
Top land..............................................................................................................................................
Bottom land.........................................................................................................................................
Piston ring gap:
High pressure compression rings ....................................................................................................
High pressure oil control ring ..............................................................................................................
Low pressure compression rings ........................................................................................................
Low pressure oil control rings .............................................................................................................
*
**
Minimum
Maximum
1.7485
1.7500
0.001
1.7490
1.7505
0.002
0.004
0.003
0.013
0.013
0.0075*
0.006
0.016
0.016**
0.0020
0.0020
0.0020
0.0020
0.0025
0.0025
0.0025
0.0025
0.007
0.007
0.017
0.017
0.017
0.015
0.027
0.027
Clearance measurement must be made on thrust side of piston.
Clearance measurement must be made above wrist pin.
Table 1-14. Model 3VC and 3YC Air Compressor Torque Specifications
Application
Torque
Model 3VC Air Compressor
Connecting rod nuts
Cylinder bolts
High pressure cylinder head:
Suction valve cap
Suction valve sleeve
Discharge valve cap
Discharge valve plug
Cylinder head bolts
350 in - lb.
142 ft - lb.
7Oft- lb.
70 ft - lb.
7O ft - lb.
70 ft - lb.
30 ft lb.
1-23
Table 1-14. Model 3VC and 3YC Air Compressor Torque Specifications-Continued
Application
Torque
Low pressure cylinder head:
Suction valve cap
Suction valve sleeve
Discharge valve cap
Discharge valve plug
Cylinder head bolts
Oil pump cover bolts
Rear retainer bolts
Model 3YC Air Compressor
Connecting rod nuts
Cylinder bolts
High pressure cylinder head:
Unloader capnut
Unloader body
Suction valve plug
Discharge valve cap
Discharge valve plug
Cylinder head bolts
Low pressure cylinder head:
Unloader capnut
Unloader cover
Suction valve plug
Discharge valve cap
Discharge valve plug
Cylinder head bolts
100 ft - lb.
100 ft - lb.
100 ft - lb.
100 ft - lb.
30 ft - lb.
9 ft - lb.
30 ft - lb.
350 in - lb.
142 ft - lb.
70 ft - lb.
70 ft - lb.
70 ft - lb.
70 ft - lb.
70 ft - lb.
30 ft- lb.
100 ft - lb.
100 ft - lb.
100 ft - lb.
100 ft - lb.
100 ft - lb.
30 ft - lb.
Table 1-15. Propeller Shaft, Stern Tube, and Propeller Strut Repair and Replacement Standards
Manufacturer’s dimensions and
tolerance in inches
Part or assembly
Minimum
Propeller shaft sleeve od
Stern tube or propeller strut bushing id
Propeller shaft sleeve to bushing clearance
Maximum
allowable wear and
clearance
in inches
Maximum
2.778
2.787
2.782
2.788
0.010
0.020
0.040
Table 1-16. Ramp Cylinder Dimensions and Tolerances
Manufacturer’s dimensions and
tolerance in inches
Part or assembly
Minimum
Ramp Cylinder Assembly
Body inside diameter........................................................................................
Piston diameter................................ .................................................................
Piston rod diameter ...........................................................................................
Bushing inside diameter....................................................................................
4.000
3.994
1.500
1.503
Maximum
4.004
3.996
1.502
1.504
Table 1-17. Steering Cylinder Dimensions and Tolerances
Manufacturer’s dimensions and
tolerance in inches
Part or assembly
Minimum
Steering cylinder assembly
Body inside diameter.......................... .....................................................................
Piston diameter........................................................................................................
Piston rod diameter............................. ....................................................................
Bushing inside diameter......................... .................................................................
1-24
6.001
5.994
2.745
3.000
Maximum
6.005
5.996
2.747
3.002
Table 1-18. Nut, Bolt, Screw, and Stud Torque Specifications
Table 1-19. General Bolt and Screw Torque Specifications for Torque Converters
1-25
Table 1-19. General Bolt and Screw Torque Specifications for Torque Converters-Continued
Threads
per inch
Size
1/2
Torque ft. lbs., for
standard heat-treated
bolts and screws
13
20
12
18
11
18
10
16
9
14
8
14
9/16
5/8
3/4
7/8
1
67-80
83-100
85-100
100-120
117-140
134-160
180-210
215-250
372-425
372-425
445-500
535-600
Torque ft. lbs., for special
heat-treated bolts, screws,
Allen- headscrews, and selflocking capscrews
81-97
96-115
103-123
122-146
164-192
193-225
284-325
337-385
575-650
575-650
685-770
830-925
Table 1-20. Standard Nut and Bolt Torque Specification
Size nut or bolt Torque (ft-lb)
20 ..............................................................................................
28 ...............................................................................................
18 ...............................................................................................
24 ..............................................................................................
16 ...............................................................................................
24 ...............................................................................................
14 ...............................................................................................
20 .......................................................................................
13 ...............................................................................................
20 .................................................................................................
1/4...1/4... 5/16 5/16 3/8...3/8...7/16.7/16 1/2...1/2 9/16 12 .......................................................................................................................
9/16 - 18 ................................................................................................
5/8
11 ................................................................................................
5/8. 18 .....................................................................................................
3/4. -10 ....................................................................................................
3/4. -16 ....................................................................................................
7/8. - 9 ...................................................................................................
7/8. - 14 .................................................................................................
1 .. - 8 ...................................................................................................
1.. - 14 .................................................................................................
Torque (ft-lb)
7-9
8-10
13-17
15-193-35
35-39
46-50
57-61
7-75
83-93
90-100
107-117
7-147
18-178
240-250
290-30(
410-420
475-485
580-590
685-695
Table 1-21. Piping and tubing color coding
Item
Fuel lines
Lube oil lines
Bilge drainage lines
Hydraulic power lines
Cooling water
Ven ts
Main air
Control air
Color
Color Shade No.
Fed-Std-595
11105
22246
14110
15102
16187
13655
10266
17038
Red
Orange
Green
Blue
Gray
Yellow
Brown
Black
1-26
CHAPTER 2
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT
2-1. Tools and Equipment
Direct support and general support repair parts and tools are listed and illustrated in TM 55-1930-203-35P.
2-2 Special tools and Equipment
The special tools and equipment required to perform direct and general support maintenance are listed in table 2-1.
Table 2-1. Special Tools and Equipment
Item
Valve guide remover
Injector removerJ1227-01
Tool set
Oil seal expander
Piston support fixture
bushings.
Driver handle
bushings.
Bushing remover
Fixture, reaming
connecting rod.
Reaming fixture and arbor
connecting rod.
Reamer
connecting rod.
Front guide bushing
connecting rod.
Valve seat insert driver
Gear installing too]
Cylinder liner remover
Aligning stud
Bearing and bushing driver
coupling.
Piston bushing reamer
Push rod remover
installation.
Oil seal remover and installer
seal.
Injector lapping block set.
Valve guide installer
Assembling tool
converter pump.
Stator assembly sleeve
torque
converter stators.
Spray tip orifice cleaner
Bearing replacer
bearing in torque converter oil
pump.
Mechanical pulIer
cone.
Ball attachment micrometer
bearing shells.
Valve seat insert remover
Part No.
References
Figure Paragraph
J267
Use
J1241-05
J1359
J1513-1
3-79
3-90
3-6
3-10
3-10
3-29
3-32
J1513-2
3-90
3-32
Removing or installing piston pin
J1513-3
J1686-02
3-90
3-94
3-32
3-32
Removing piston pin bushing.
Reaming connecting rod bushing
J1686-9
3-32
Reaming connecting rod bushing in
J1686-10
3-32
Reaming connecting rod bushing
J1686-11
3-32
Reaming connecting rod bushing in
3-6
3-31
3-34
3-29
3-17
Installing valve seat inserts.
Installing gears on camshaft.
Removing cylinder liner.
Flywheel housing installation.
Removal of water pump drive
3-32
3-5
Reaming piston pin bushing.
Rocker arm assembly removal and
3-29
Replacement of flywheel housing oil,
3-10
3-6
7-2
Lapping the injector.
Installing valve guides.
Assembling converter pump hub into
7-2
Assembling and disassembling
7-2
Cleaning injector spray tip.
Installation of drive shaft needle
7-6
Removal of vibration damper outer
3-24
J1 736
J1903
J1918
J1927-01
J1930
J3071-6
J3092-01
3-19
3-103
3-79
3-5
J3154-04
J3179
J4144
J4236
3-20
J4237
J4298-1
J4523
3-32
J4558
Removing valve guides.
Fuel injector removal.
Servicing injector.
Flywheel housing installation.
Removing or installing piston pin
J4757
3-102
3-33
Checking wear of crankshaft main
J4824-01
3-11
3-6
Removing valve seat inserts.
2-1
References
Figure Paragraph
Use
7-2
Removal of needle bearing from
torque converter oil pump body;
installation of needle bearing in
pump driver gear, and installation
of sleeve into pump body.
Bearing remover
J4852
7-2
Removal of rear oil pump bearing
sleeve from torque converter oil
pump.
letter nut spray tip seat reamer
J4986-01
3-33
Cleaning injector nut spray tip seat.
Reaming fixture
J5273
3-93
3-32
Reaming piston pin bushings.
bIeetor tube installer body
J52864
3-13
Removing injector tube from
cylinder head.
Injector tube pilot installer
J5286-5
3-13
Removing injector tube from
cylinder head.
Flaring die iastater
J52864
3-6
Installing injector tube.
Injector tube reamer
J5286-7
3-16
Reaming injector tube for injector
body nut and spray tip.
Tube tip refinisher
J52868
3-6
Refinishing injector tibe tip.
Injector tube reamer
J5286-9
3-18
Reaming bevel seat in injector tube.
Valve guide leaner
J5437
3-6
Cleaning valve guide.
Gage wet
J5438
3-95
3-32
Checking piston to liner clearance.
Cam follower holder fixture
J5840
3-9
Removing and installing cam
follower roller and pin.
Side hammer remover and adapter
J5901
7-2
Removing charging oil pump idler
shaft.
Gear end plate puller
J6270-1
3-22
Removing blower end plate.
Bearing and seal installer
J6270-3
3-22
Installing blower bearing and seal.
'Shaft pilot
J6270-5
3-22
Installing rotors in blower housing.
Gear and role bearing installer
J62706
3-69
3-22
Installing gear and roller bearings.
Gear and baD bearing installer
J6270-7
3-22
Installing blower gear and rear
bearings.
Spanner wrench
J6534
7-44
7-2
Removing or installing freewheel
roller race retaining nut.
Piers set, with 30° and 45°interchangeable J6843
7-2
Removal and installation of retaining
tips
rings.
Injector Resemble fixture
J6868
3-10
Holding injector assembly during
disassembly.
Wrench set, torque multiplier
J6985
3-6
Tightening bolts and nuts.
Comparator
J7041
3-10
Testing fuel output of injector
assembly.
Injector valve seat lapping tool
J 7 I 74
3-11
Removing irregularities from injector
valve seat.
Holding fixture
J7452
3-82
3-29
Holding dial indicator for checking
flywheel housing concentricity.
Pump hub bushing installer
J7464
7-2
Torque converter pump hub bushing
installer.
Spanner wrench
J7466
7-6
Removing and installing
transmission
bearing locknut.
Puller
J7468
7-6
Transmission bearing puller.
Clutch spring compressor
J7470
7-70
7-6
Compressing strings on low-range
and reverme-range clutch backplate.
Peening tool
J7473
7-2
Installing and peening clutch release
springs and retainers into clutch
backplates.
Converter pump hub seal replacer
J7475
7-2
Pressing pump hub oil seal into
torque converter.
Impeller instafer
J9303
3-47
3-11
Installation of water pump impeller
on shaft.
Propeller puller
LXO9-032-OO1
2-28
Propeller removal.
Item
Bearing and bushing driver plug
Part No.
14850
2-2
Section II. TROUBLESHOOTING
2-3. General
This section provides information useful to direct and general support maintenance personnel in diagnosing and correcting
unsatisfactory operation or failure of the LARC-LX or its components.
2-4 Troubleshooting Chart
Chart 2-1 lists the malfunction, probable cause and he corrective action to be taken in correcting failures in the equipment. To list all of the possible malfunction that may occur in the equipment is impossible. Refer to Chart 2-1 for the
most common malfunctions that may occur in the equipment.
Chart 2-1. Troubleshooting
Malfunction
1. Engine fails to turn over.
Probable Cause
Corrective Action
a.
Faulty valve in air starting system.
a.
b.
Defective air starting motor.
b.
a.
b.
a.
b.
c.
Defective fuel pump.
Defective governor.
Defective governor.
Defective fuel injector.
Damper valves in air inlet housing
not fully opening
Defective blower drive assembly.
a.
b.
a.
b.
c.
e.
4. Engine temperature excessive a.
b.
c.
Defective blower.
Defective thermostat.
Water pump not operating.
Coolant leakage in lines or at
radiator.
e.
a.
b.
c.
5. Fuel detonation.
Faulty fuel injector.
Defective blower-to-cylinder block
gasket.
Blower oil seal leaking.
Oil cooler core leaking.
Blower oil seal leaking.
Scored liners, pistons, or oil rings.
a.
b.
d.
e.
a.
Piston and rod misalignment.
Oil control rings worn, broken or
improperly installed
Oil cooler clogged.
b.
Oil pump inlet screens clogged.
b.
2. Engine turns over but will not
start.
3. Engine starts hard, runs uneven,
or lacks power.
d.
6. High engine oil consumption.
a.
b.
c.
a.
b.
c.
d.
e.
7. Low engine oil pressure.
c.
8. Excessive exhaust smoke.
Oil pressure regulator not working
properly.
d.
Excessive wear on crankshaft
bearings.
e.
Oil pump damaged or worn.
a.
Faulty blower, blower drive, or
clogged air inlet screen.
b.
Faulty fuel injector.
Clutch pressure regulating spring or
9. Low transmission oil pressure
(Temperature normal).
10.Low transmission oil pressure a.
Clogged or leaking oil cooler.
and / or high torque convertertransmission oil temperature.
b. Excessive oil flow to transmission.
2-3
d.
c.
a.
b.
c.
a.
c.
d.
e.
a.
Repair or replace defective valve
(para 3-18).
Repair or replace the air starting
motor (para 3-18).
Replace (para 3-19).
Replace (para 3-13).
Replace (para 3-13).
Replace (para 3-10).
Repair air inlet housing
(para 3-21).
Repair blower drive assembly
(para 3-23).
Replace (para 3-22).
Replace (para 3-8).
Repair or replace (para 3-17).
Locate source of leak and repair
Replace a leaking radiator (para
5-3 and 5-6).
Replace (para 3-10).
Replace gasket (para 3-22).
Replace blower (para 3-22).
Replace oil cooler core (para 3-15).
Replace blower (para 3-22).
Replace defective parts (para 3-32
and 3-34)
Replace defective parts (para 3-32).
Replace damaged oil control rings
(para 3-32).
Remove and clean oil cleaner
(para 3-7).
Remove and clean oil inlet screens
(para 3-25).
Remove and repair or replace oil
pressure regulator valve (para 3-27).
Replace bearings (para 3-33).
Repair or replace (para 3-26).
Replace or repair faulty component (para 3-21, 3-22 and 3-23).
b. Replace (para 3-10).
Repair or replace oil pump
valve in oil pump defective. (para 7-2).
a. Repair or replace oil cooler (para
3-15).
b. Repair or replace manifold
assembly (para 7-6).
Chart 2-1. Troubleshooting-Continued
Malfunction
11. Torque converter inoperative
(No oil pressure).
Probable Cause
c.
d.
a.
Low converter charging pressure.
One or both stators locked.
Damaged gears in oil pump.
b.
12. Oil leaking from engine flywheel
housing drain hole.
13. Loss of power from torque
converter
14. Loss of power from transmission.
Damaged oil pump drive gear in
torque converter.
Defective pump hub seal in torque
converter.
a. Low converter charging pressure.
b.
One or both stators locked.
a.
Clutch plate slipping in transmission.
b.
Converter failure.
c.
c.
Stators interchanged in torque
converter.
Stators installed in torque converter without rollers, (low stall
speed).
Exhaust valve sticking or burned.
Compression rings worn or
broken.
Cylinder head gasket leaking.
a.
Defective selector valve assembly
b.
c.
Faulty clutch.
Low clutch pressure in one range
only.
a.
Faulty transmission planetary
gearing.
Converter failure or malfunction.
d.
15. Low engine compression.
16. No output from transmission in
one range.
17. No power from transmission in
any range.
a.
b.
b.
18. Transmission locked in all
ranges.
19. Slow clutch engagement in
transmission.
20. Transmission and/or torque
converter high oil temperature.
Failed transmission parts.
Worn piston seals.
Repair or replace oil pump (para 7-2).
Replace torque converter (para 2-12).
d.
Install rollers properly (para 7-2).
a.
b.
Repair or replace exhaust valves(para 3-6).
a.
Disassemble converter and replace
damaged parts (para 7-2).
Disassemble transmission and
replace clutch (para 7-6).
Check for noise at stall.
Disassemble converter and
replace damaged parts (para 7-2).
Check for loss of power at stall.
Install stators properly (para 7-2).
Repair or replace oil pump
(para 7-2).
b. Replace torque converter
(para 2-12).
Replace torque converter
(para 2-12).
a. Repair or replace oil pump
(para 7-2).
b. Replace torque converter
(para 2-12).
a. Check for low clutch pressure.
Disassemble transmission and
replace worn piston seals (para 7-6).
b. Check for low converter charging
oil pressure. Disassemble converter and replace damaged parts
(para 7-2).
c. Install stators properly (para 7-2).
Replace compression rings
(para 3-32).
c. Replace defective gasket
(para 3-6).
a. Replace selector valve assembly
(para 7-6).
b. Replace transmission (para 2-13).
c. Disassemble transmission and
replace piston seals or broken
back plate (para 7-6).
a. Replace planetary gearing
(para 7-6).
b. Replace damaged converter parts
(para 7-2).
Replace failed transmission
parts (para 7-6).
Replace worn piston seals
(para 7-6).
a. Replace any damaged parts (para
7-2).
b. Disassemble converter and replace
stators as necessary (para 7-2).
c. Reinstall stators properly
(para 7-2).
d. Reinstall rollers and/or springs
properly (para 7-2).
Converter malfunction.
b.
a.
One or both stators in torque
converter locked.
Stators interchanged in torque
converter (low stall speed)
Stator(s) installed in torque
converter without rollers or
spring (low stall speed(.
Converter malfunction.
b.
Clutch slipping.
b.
a.
Converter malfunction.
a.
b.
Stators interchanged.
b.
d.
22. Low engine speed at converter
stall.
c.
d.
a.
a.
c.
21. High engine speed at converter
stall.
Corrective Action
2-4
Chart 2-1. Troubleshooting-Continued
Malfunction
23. Vehicle drives in low range,
creeps forward in neutral but
stalls when shifted to any other range.
24. Vehicle drives in intermediate
range, creeps forward in neutral,
but stalls when shifted to any
other range.
25. Vehicle drives in high range,
creeps forward in neutral, but
stalls when shifted to other range.
26. Vehicle drives in reverse range,
creeps backward in neutral, but
stalls when shifted to any other range.
27. Transmission input shaft does
not turn freely by hand.
28. Erratic or reduced braking
force.
29. Excessive braking force.
Probable Cause
c. Stator installed without rollers.
Corrective Action
c. Install rollers (para 7-2).
Low-range clutch inoperative.
Disassemble transmission and
replace low-range clutch (para 7-6).
Intermediate-range
inoperative.
Disassemble transmission and
replace intermediate range clutch
(para 7-6).
clutch
High-range clutch inoperative.
Reverse-range clutch inoperative.
a.
Range clutch failure.
b.
Converter failure.
a.
Worn out brake lining.
b.
Air leak at expander tube nozzle.
c.
Elongated holes in brake drum
mounting plate or brake drum.
Oil or grease on brake lining.
a.
b.
30. Brakes drag.
a.
b.
31. Noisy or vibrating miter box.
a.
Broken, missing, or deformed
retractor springs.
Excessive cracks in brake drum
Elongated holes in brake drum
mounting plate or brake drum.
Oil leakage around input coupling
flange.
b.
32. Noisy or vibrating column and
wheel drive.
33. Noisy or vibrating wheel.
34. Wheel wobbles.
35. Loss of power at wheel.
Oil leakage around output shaft
into column and wheel drive.
c. Damage gears or bearings.
Defective bearings or gears.
a.
Worn bushing in lower pivot
bearing assembly.
b. Defective column and wheel drive
bearing in miter box.
c. Broken teeth on planetary ring
gear or gears in planet spider assembly.
Broken wheel bearings
a. Broken pinion shaft or stripped
gear coupling.
b. Stripped pinion or bevel gear.
c.
36. Excessive water accumulation in
column and wheel drive.
37. Water accumulates in area
beneath miter box.
Broken intermediate shaft or
stripped gear coupling between
miter box and column and wheel drive.
d. Broken axle.
e. Stripped planetary ring gear or
gears in planet spider assembly.
Defective seals between column and
wheel drive and wheel assembly.
Defective boot assembly.
2-5
Disassemble transmission and
replace high range clutch
(para 7-6).
Disassemble transmission and
replace reverse range clutch (para 7-6).
a.
Disassemble transmission and
replace range clutch (para 7-6).
b. Disassemble converter and replace
damaged parts (para 7-6).
a. Replace brake shoe assemblies
(para 7-7).
b. Replace preformed packing at
expander tube nozzle (para 7-7).
c. Replace mounting plate or brake
drum (para 7-7).
a. Remove air brake assembly (para
2-14), and clean brake drum and
lining.
b Replace damaged retractor
springs (para 7-7).
a. Replace brake drum (para 2-14).
b. Replace mounting plate or brake
drum (para 7-7).
a. Remove air brake assembly (para
2-14), and replace leaking input
seal in miter box bearing retainer
assembly (para 2-15).
b. Replace output shaft bearing seal
in miter box (para 2-15).
c. Repair miter box (para 2-15).
Replace bearing or gears
(para 2-15).
a. Replace bushing (para 2-15).
b.
Replace bearing (para 2-15).
c.
Replace gears (para 2-15).
Replace bearings (para 7-10).
a. Replace pinion shaft or gear
coupling (para 7-10).
b. Replace pinion or bevel gear (para
7-10).
c. Replace intermediate shaft or gear
coupling (para 2-15).
d.
e.
Replace axle (para 7-10).
Replace gears (para 7-10).
Replace seals (para 7-10).
Replace boot and gasket
(para 2-17).
Chart 2-1. Troubleshooting-Continued
Malfunction
38. Grease leakage from lower pivot
bearing assembly at base of
Column and wheel drive.
39. Leakage around output shaft of
fluid coupling.
40. Loss of, or sluggish shaft motion
between gathering box and fluid
coupling.
41. Shaft between gathering box and
fluid coupling vibrates excessively.
42. No power at output shaft of
gathering box.
Probable Cause
Worn seal or bushing in lower pivot
bearing assembly..
Replace seal or bushing (para 7-10)
a. Abrasive material between sealing
faces of carbon mating ring and
seal nose piece.
b. Poor contact by copper gasket
between baffle and bearing.
Fluid coupling inoperative or leaking
around output shaft..
a.
Excessively worn flexible coupling.
Replace flexible coupling (para 2-21)
.
a. Replace defective parts
(para 7-16).
a.
b.
43. High gathering box operating
temperature.
a.
b.
44. Low marine gear oil pressure.
a.
45. Low gathering box oil pressure.
b.
c.
d.
a.
b.
c.
46. Grease leaking from flexible
coupling around engine adapter
plate or where shaft between fluid
coupling and gathering box enter
flexible coupling.
47. Loss of shaft motion between
gathering box and marine gear.
Output gear stripped, output shaft
broken. or output shaft key
sheared.
Input pinions stripped or input
shafts keys sheared.
Bearing failure within gathering
box.
Clogged or restricted oil passage
ways in oil cooler.
Oil leakage at input shaft, bevel
gear input shaft, output shaft,
power take-off, shaft, or bevel
gear hole cover.
Oil cooler leaking.
Defective oil pump.
Defective regulator valve.
Oil leakage around input coupling.
Oil leakage around output
coupling.
Oil cooler leaking.
Defective seal in flexible coupling.
50. Power input to marine gear
power take-off operative but
master pressure pump
inoperative.
a.
Defective gathering box
overruning clutch assembly.
Gear failure in gathering box.
Clogged or restricted oil
passageways in oil cooler.
Clogged or restricted oil
passageways in lube manifold..
Bevel gear input shaft broken, or
bevel gear input shaft key
sheared.
Input bevel gear or bevel pinion
stripped.
Planetary sun gear stripped.
b.
Planetary sun gear key sheared.
51. Power input to marine gear from
gathering box but power take-off
shaft inoperative.
Sheared key in marine gear coupling
half of coupling assembly.
48. High marine gear operating
temperature.
a.
b.
a.
b.
49. Power input to marine gear, but
master pressure pumps and
power take-off inoperative.
Corrective Action
a.
b.
2-6
Replace seal parts (para 7-14).
b.
Replace baffle and copper gasket
(para 7-14).
Replace fluid coupling (para 2-21)
b.
a.
b.
a.
b.
Replace defective parts
(para 7-16).
Replace defective bearing
(para 7-16).
Repair or replace oil cooler
(para 7-18).
Replace defective seals
(para 7-17).
Repair or replace oil cooler (para 7-18).
c.
d.
a.
Replace oil pump (para 7-17).
Replace regulator valve (para 7-17).
Remove over-running clutch
assembly and replace seal
(para 7-16).
b. Remove output coupling and
replace seal (para 7-16).
c. Repair or replace oil cooler
(para 7-18).
Replace seal in flexible coupling
(para 7-13).
a.
b.
a.
b.
a.
b.
Repair overrunning clutch
assembly (para 7-16).
Replace gathering box Ipara 2-22).
Repair or replace oil cooler (para
7-18).
Replace lube manifold (para 7-17).
Replace bevel pinion shaft or bevel
pinion shaft key (para 7-17).
Replace bevel pinion and bevel
gear para 7-17).
a. Replace planetary sun gear and
damaged planet pinions
(para 7-17).
b. Replace planetary aun gear key
(para 7-17).
Replace key at marine gear end of
coupling assembly
(para 7-17).
Chart 2-1. Troubleshooting-Continued
Malfunction
52. No power at propeller (marine
gear inoperative).
Probable Cause
Corrective Action
a.
b.
Missing propeller.
Sheared propeller shaft key.
a.
b.
c.
a.
Broken propeller shaft.
Coupling half key sheared.
c.
a.
b.
a.
Clutch failure.
Forward clutch mechanism
defective.
Idler gear stripped or idler shaft
key sheared.
Forward pinion stripped or forward pinion input shaft key
sheared
Control tube forward valve
clogged.
Reverse clutch mechanism
defective.
or input shaft aft pinion key
sheared.
Control tube reverse valve clogged.
b.
a.
Bent or broken propeller.
Bent propeller shaft or worn
propeller shaft sleeves.
Worn propeller shaft bushing.
Bent intermediate shaft.
Worn bushing in intermediate
shaft.
Broken flexible inserts.
Worn seals in stern tube or strut.
a.
b.
Repair or replace reverse valve
(para 7-17).
Replace propeller (para 2-28).
Replace propeller shaft (para 2-28).
c.
d.
e.
Replace bushing (para 2-28).
Replace shaft (para 2-28).
Replace bushing (para 2-28).
f.
Replace flexible inserts (para 2-28).
Replace seals (para 2-28).
a.
c.
a.
Defect air control valve on marine
gear
Control tube passageways
restricted.
Clutch failure.
Clutch failure.
Replace air control valve
(para 7-17).
Repair or replace control tube
(para 7-17).
Repair or replace clutch (para 7-17).
Repair or replace defective clutch
parts (para 7-17).
b.
Control tube defective.
b.
60. Master pressure pump noisy.
a.
b.
Defective pump.
Excessive pressure.
a.
b.
61. Air compressor knocking.
a.
Bent connecting rod.
a.
b.
Oil pump plunger too tight in its cylinder. b.
c.
d.
Wrist pin worn.
Piston hitting head.
c.
d.
a.
Oil pump failure.
a.
b.
Leaking crankshaft relief valve.
b.
c.
Unloader valve leaking.
c.
53. No power at coupling half in
forward or reverse drive.
54. No power at coupling half in
forward drive.
b.
c.
d.
55. No power at coupling half in
reverse drive.
a.
c.
56. Excessive propeller shaft
vibration.
a.
b.
c.
d.
e.
f.
57. Grease leakage around propeller
shaft at stern tube or strut.
58. Marine gear will not shift (oil)
pressure normal)).
a.
b.
59. Forward or reverse gear of
marine gear output shaft engages
but will not release.
62. Air compressor unloader tube
overheating.
63. Air compressor slinging oil
around crankshaft.
Defective crankshaft seal or gasket.
2-7
b.
c.
d.
a.
b.
c.
b.
c.
a.
Install propeller (para 2-28).
Replace propeller shaft key
(para 2-28).
Replace propeller (para 2-28).
Replace coupling half key
(para 2-28).
Repair or replace clutch (para 7-17).
Repair or replace defective clutch
parts (para 7-17).
Replace idler gear or idler shaft
key (para 7-17).
Replace pinion or pinion input
shaft key (para 7-17).
Repair or replace forward valve
(para 7-17).
Repair or replace defective clutch
Replace aft pinion and aft pinion
key (para 7-17).
Repair or replace control tube (para
7-17).
Replace pump (para 2-26).
Check system relief valve for proper
setting (para 10-40 and 10-41).
Replace connecting rod (para 9-2
and 9-3).
Replace oil pump plunger (para 9-2
and 9-3).
Replace wrist pin (para 9-2 and 9-3)
Add gaskets between cylinder and
crankcase (para 9-2 and 9-3).
Repair or replace oil pump (para 9-2
and 9-3).
Repair or replace relief valve (para
9-2 and 9-3).
Replace unloader valve (para 9-2
and 9-3).
Replace seal or gasket (para 9-2
and 9-3).
Chart 2-1. Troubleshooting-Continued
Malfunction
64. Cargo winch clutch shaft will not
engage.
65. Excessive noise from cargo winch.
66. Clutch disengages with cargo
winch in operation.
67. Cargo winch will not operate or
has insufficient power.
68. Cargo winch brake will not hold.
69. Hydraulic relief valve chatters.
Probable Cause
Clutch shaft bent.
Replace clutch shaft (para 10-10)
a.
Gears not meshing properly
a.
b.
Bearing failure
Worn detent ball or loss of spring
tension on bal..
a. Defective eargo winch hydraulic
motor.
b. Cargo winch to hydraulic motor
adapter bearing defective.
c. Bevel drive gear stripped.
a. Brake lining worn out.
b. Brake cable broken.
c. Brake pivot pin or adjustment pin broken.
a. Piston or valve seat damaged.
71. Hydraulic control valve
inoperative.
72. No pressure or fluctuating
pressure to all hydraulic systems
(all engines operating).
73. No pressure on all hydraulic
systems with engines operating
on one side only.
74. No pressure or fluctuating
pressure to one hydraulic system.
77. Ramp lowers too fast.
78. Bilge pump will not operate or
runs slowly.
a.
Replace motor (para 10-11).
Hydraulic oil supply tank filters
clogged.
Defective marine gear.
Replace marine gear (para 2-27)
a.
Leak in hydraulic line.
a.
b.
c.
Defective master pressure pump.
Control valve leaking at spool.
b.
c.
a.
Foreign matter between piston
and seat.
Piston sticking.
b.
Piston or valve seat damaged.
Valve spool sticking.
d.
75. No pressure or fluctuating
Pressure to ramp, bhige pump,
and / or cargo well pump systems
when operated from one side:
Systems normal when operated
from other side.
76. Ramp will not raise or raises slowly.
Repair or replace gears
(para 10-10).
b. Replace defective bearings (para
10-10).
Replace spring and ball (para 10-10)
Remove cargo winch and replace
bearing (para 10-10).
c. Replace gear (para 10-1).
a. Replace brake lining Ipara 10-8).
b. Replace brake cable (para 10-9).
c. Replace damaged part (para 10-8).
a. Replace damaged parts
(para 10-40 and 10-41).
b. Disassemble and clean valve (para
10-40 and 10-41).
a. Disassemble and clean valve.
Replace defective parts (para 10-40
and 10-41).
b. Replace damaged parts
(para 10-40 and 10-41).
Disassemble and clean valve
(para 10-40 and 10-41).
Remove and clean filters
(para 10-13).
b.
70. Hydraulic control valve
inoperative.
Corrective Action
b.
Check valve not opening or not
opening fully.
Defective relief valve in inlet unit of
multiple unit valve.
d.
a.
Ramp cylinder leaking at rod end.
a.
b.
a.
b.
Ramp cylinder leaking internally.
Leak in hydraulic line.
Ramp cylinder leaking at rod end.
b.
c.
d.
a.
Ramp cylinder leaking internally.
Defective hydraulic check valve.
Flow control valve out of adjustment.
c.
d.
a.
b.
Defective flow control valve.
b.
c.
Defective bilge pump hydraulic motor.
c.
2-8
Replace defective components
(para 10-39).
Replace pump (para 2-26).
Repair or replace control valve
(para 10-39).
Replace check valve (para 10-35).
Replace defective components
(para 10-39).
a.
b.
Replace rod end packing
(para 10-18).
Replace ramp cylinder (para 2-29).
Replace defective line or lines.
Replace rod end packing
(para 10-18).
Replace ramp cylinder (para 2-29).
Replace check valve (para 10-35).
Adjust flow control valve to obtain
1,800 rpm at bilge pump
hydraulic motor (para 10-32).
Remove, disassemble, and clean
valve; replace defective parts
(para 10-32).
Replace motor (para 10-41.
Chart 2-1. Troubleshooting-Continued
Malfunction
79. Cargo well pump will not operate
or runs slowly.
Probable Cause
a.
Flow control valve out of adjustment.
a.
b.
Defective flow control valve.
b.
c.
80. Radiator fan will not run or runs.
slowly
81. Wheels will not align or alignment will not hold.
82. Forward steering normal, aft
steering fails to respond.
c.
a.
b.
c.
Leak in hydraulic line.
Defective needle valve.
Defective steering alignment
cylinder.
Aft follow-up link-age disconnected or broken.
Defective control valve.
a.
Replace defective line or lines.
b.
Replace needle valve (para 10-37).
c.
Replace cylinder (para 2-30).
a.
Forward follow-up linkage
disconnected or broken.
Defective control valve.
a.
Cargo winch control valve offset
spring defective.
Defective steering cylinder.
a.
Repair follow-up linkage
(para 8-2).
Repair or replace control valve
(para 10-33).
Repair follow-up linkage
(para 8-2).
Repair or replace control valve
(para 10-33).
Repair valve (para 10-20).
a.
a.
b.
84. Forward steering normal, aft
steering responds slowly or
erratically.
a.
85. Aft steering normal, forward
steering slowly or erratically.
86. Steering lever hard to move.
Defective steering cylinder.
87. Air pressure too high (adjusting
governor will not bring pressure
within limits).
88. Air pressure too low (adjusting
governor will not bring pressure
within limits).
89. Generator voltage output fails.
90. Generator output high, low, or
erratic.
91. Generator overheats.
b.
Defective bearings on steering
column or in jackshaft box.
Defective air compressor governor.
a.
Defective air compressor
governor.
b. Badly worn rings, pistons, and
cylinders in air compressor.
Open circuit, short circuit, or ground
in generator.
a. Worn generator brushes.
b. Poor commutator or brush
contact.
c.
a.
Loose connections.
Short circuit in windings.
b.
a.
b.
94. No reading on battery generator
indicator.
a.
b.
a.
b.
95. Lights will not illuminate.
a.
Overload.
Worn generator bearings.
Improperly seated or worn
generator brushes
Defective wiring or connector.
Defective indicator.
Loose or broken connection.
Defective battery generator in.
Defective switch.
b.
c.
d.
Defective socket.
Loose connection.
Open wiring.
92. Noisy generator.
93. Tachometer indicator inoperative.
Adjust flow control valve to obtain
1200 rpm at cargo well pump
hydraulic motor (para 10-5).
Remove, disassemble, and clean
valve; replace defective parts
(para 10-32).
Replace motor (para 10-5).
Defective cargo well pump
hydraulic motor.
Defective radiator fan hydraulic motor.
b.
83. Aft steering normal, forward
steering fails to respond.
Corrective Action
2-9
Replace motor (para 10-31).
b.
b.
b.
Replace steering cylinder
(para 2-30).
Replace steering cylinder
(para 2-30).
Replace bearings (para 8-2).
Repair or replace governor (para 9-5)
a.
Repair or replace governor
(para 9-5).
b. Replace air compressor
(para 9-2).
Test and repair generator
(para 6-1).
a. Replace brushes (para 6-1).
b. Refinish commutator, undercut
mica, seat brushes properly, and
adjust tension of springs (para 6-1).
c. Tighten all connections.
a. Trace short circuit and repair or
replace generator (para 6-1).
b. Reduce overload in output circuit.
a. Replace bearings (para 6-1).
b. Seat brushes properly or replace
brushes (para 6-1).
a.
b.
a.
b.
Replace wiring or connector (para 6-3).
Replace indicator (para 6-3).
Repair wiring.
Replace battery generator indicator
(para 6-5).
a. Replace faulty switch (para 6-1).
(See para 6-9 for replacement of
wing compartment light switches).
b. Replace or repair socket.
c. Tighten all connections.
d.. Repair wiring
Chart 2-1. Troubleshooting-Continued
Malfunction
96. All lights stop burning.
97. Headlights inoperative (high,
low bean, or both).
98. High beam indicator inoperative.
99. Hull and cab wiring defective.
100.Cab ventilating fan inoperative.
101.Heater fan inoperative.
Probable Cause
a.
Master control relay defective.
b.
Master control switch defective
a.
b.
Headlight switch defective.
Headlight wire assembly defective.
Dimmer switch defective.
a.
b.
c.
a.
Poor insulation.
Broken conductors.
Grounded or shorted conductors.
Faulty wiring.
b.
Radio suppression capacitor
shorted.
Faulty wiring.
a.
b.
c.
Radio suppression capacitor
shorted.
Defective blower motor.
Corrective Action
a.
Replace master control relay (para
6-4).
b. Replace master control switch
(para 6-4).
a. Replace switch (para 6-4).
b. Replace headlight wire assembly
(para 6-10).
Replace dimmer switch (para
6-4).
a. Replace wiring.
b. Repair wiring.
c. Trace short and repair.
a. Trace and repair short or open in
wiring.
b. Replace capacitor (para 6-6).
a.
b.
Trace and repair short or open in
wiring.
Replace capacitor (para 6-6).
c.
Replace motor (para 6-6).
Section III. GENERAL MAINTENANCE
2-5. General
a. The information contained in this section is not detailed in nature. However, the text is written with enough detail to assist all qualified maintenance personnel to adequately perform disassemble, repair reassembly, adjustments,
and testing of the LARC-LX, its components, and/or attachments.
b. Repair and replacement standards specified within the text of tables are the maximum clearance or wear allowed. This is not the only factor in determining part replacement. Factors such as age, mileage, and/ or hours of operation and usage remaining in part or component will be considered in the final determination.
c. Sheet metal distortion in the form of waves, sags, bulges, or buckles on the cab and/or hull assembly, that exceed 0.017 inches times the distance (in inches) between framing members mist be repaired.
2-6. Ball and Roller Bearings
a. General. Anti-friction bearings receive special handling. Wash bearing in non-flammable cleaning solution and
inspect the races, balls, or rollers. If bearing is serviceable, coat it with light oil and wrap it in clean paper.
b. Removal. Always use proper tools or fixtures for pressing out bearings. Special tools and fixtures are referenced throughout the text where their use is recommended.
c. Installation. When installing a bearing against a shoulder on a shaft, be sure the chamfered side is towards the
shoulder. When a bearing is to be pressed in lubricate mating surfaces prior to assembly. Some bearings have oil holes
which must be carefully aligned with the corresponding oil hole in housing or shaft.
2-7. Oil Seals
a. Removal. Oil seals should not be removed unless absolutely necessary for gaining access to another item or
unless they are to be replaced due to damage or wear. Never use cork seals a second time. Once removed, they must
be discarded and replaced with new ones.
b. Installation. When possible, soak new rawhide seals in warm oil for one half hour before installing. Install seals
with the wiping edge turned in the recommended direction. Do not cut leather seal as it is installed or when installing a
shaft through the seal. Use shim stock if necessary to protect seal from shoulders or sharp edges during installation.
Packing-type seals should always be renewed if contacting part is removed. Lubricant must be applied to lip of all shafttype rubber seals before installation. This will prevent damage to seal during initial running until oil has contacted sealing
face.
2-8. Gears, Shims, and Gaskets
a. Gears. Always use tools recommended (or
2-10
equivalent) in text for removal and installation. Gears must be carefully inspected for damaged or worn teeth. Remove
burrs using an approved method before installing. Lubricate mating surfaces of gear and shaft when pressing gear on
shaft.
b. Shims. Be sure to remove all shims wherever used. Keep the shims together and identify them as to location.
Keep shims clean and flat until they are reinstalled.
c. Gaskets. Install gaskets where required and use new ones where necessary. Never use cork or felt gaskets or
seals a second time. Be sure holes in gaskets correspond with lubricant passages in mating parts. If it is necessary to
make gaskets, select stock with proper type and thickness and be sure to cut sufficient holes in the right places. Blank
gaskets can cause serious damage.
2-9. Sleeve Bearings
Do not remove sleeve bearings unless inspection reveals damage or wear that exceeds the specified clearance or if the
bearing is loose in its mating bore. Sleeve bearings should be pressed out whenever possible. When pressing or driving
(in or out) apply pressure directly in line with bore. If the bearing must be driven, use bearing driver or a bar with a
smooth, flat end. Never drive bearing with a hammer. If bearing has an oil hole, be sure to line up with oil hole in part
with which it is assembled.
2-10.
Shafts
Shafts that offer unexpected resistance to removal, should be checked carefully to see that all nuts and capscrews have
been removed before using force. Always check possibility that another part is interfering which must be removed first.
Shaft fitted to other parts with tapered splines are always very tight. If they are not tight when disassembled, inspect tapered splines and discard part if splines are worn. Before assembling shafts with tapered splines, be sure splines are
clean, dry. and free of burrs. Press mating parts together tightly. Clean rust preventive compound from all machined
surfaces on new parts before installing.
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS AND AUXILIARIES
2-11.
Engine
a. Removal. Refer to figure 2-1 and remove engine as follows:
(1) Close plug valve in fuel supply hose (2) and fuel return hose (29) and disconnect hoses from engine.
(2) Drain oil from torque converter, transmission, and engine crankcase.
(3) Drain engine cooling system below level of the engine. (TM 55-1930-203-20).
(4) Remove oil temperature sensing bulb (19 from cover on oil pan.
(5) Disconnect hoses (5, 23, 24 and 28) from torque converter.
(6) Disconnect starting air supply hose (30) from starting motor.
(7) Close globe valves located in air lines above air supply tanks and open service connection globe valve in
upper machinery area to release pressure from air lines.
(8) Disconnect air hoses from pilot air valve on side of engine.
(9) Disconnect hoses (1 and 27) from actuator positioner.
(10)
Disconnect electrical connection (4) from tachometer generator.
(11)
If equipped with dual tachometer drive, disconnect flexible shaft (3).
(12)
Disconnect electrical connection from low oil pressure sending unit (26), and disconnect oil pressure
gage tubing (25) from tee on cylinder block.
(13)
Remove water temperature sending unit (11) and sensing element (10) from water manifold.
(14)
Remove flexible hose (13) from water manifold and water inlet hose (35) from oil cooler.
(15)
Disconnect hoses (32 and 33) from oil cooler.
(16)
Remove bolts securing exhaust piping to exhaust manifold, and remove gasket.
(17)
Remove fluid coupling, flexible coupling, and engine adapter flange as outlined in paragraph 2-21.
(18)
Remove transmission-to-engine flexible coupling.
(19)
Using a suitable hoist, remove slack from hoisting sling, then remove nuts (14) and lock-washers (15)
from bolts (17 and 31).
(20)
Take up on hoist slowly and guide engine out through hatch opening.
b. Installation.
(1) Install engine in reverse order of removal.
NOTE
Use shims (16 and 18) to raise or lower engine for alignment.
(2) Fill cooling system as outlined in TM 55-1930-203-20.
(3) Remove rocker cover and pour 2 quarts of lubricating oil as specified in LO 55-1930-203-12
2-11
over rocker arms and push rods. Lubricate engine, torque converter, and transmission as directed in LO 55-1930-20312.
(4) Start .engine (TM 55-1930-203-10) and check for leaks.
(5) Allow engine to warm up and adjust governor idling and overspeed settings as outlined in TM 55-1930203-20.
Figure 2-1. Engine removal (sheet 1 of 2).
2-12
Figure 2-1. Engine removal (sheet 2 of 2).
2-13
2-12.
a.
Torque Converter
General
(1) The Allison Torqmatic Converter Model TC-654 is used on hulls 5 through 18. Converter Model TC-554 is
used on hulls 19 through 60. Model TC-654 can be replaced with Model TC-554 on hulls 5 through 18 whenever replacement of a converter assembly is necessary.
(2) Two different Model TC-554 converters are used on the LARC-LX. Assembly number 6758244 is a fourelement converter with two stator members; while assembly number 6830815 is a three-element converter with one stator member. Both of the converters are completely interchangeable, though some of the internal parts are different. (fig.
2-2, 2-3, & 2-4).
b. Removal. Refer to figure 2-5 and proceed as follows:
(1) Remove engine (para 2-11).
(2) Remove most accessible 1 inch pipe plug (13) in flywheel housing (12).
(3) Slowly rotate engine clockwise, using bolt in vibration damper end of crankshaft, until 1 of the 12 capscrews (1) is visible through pipe plug hole in flywheel housing (12).
(4) Remove capscrew through pipe plug hole in flywheel housing.
CAUTION
Take care not to drop capscrews into the flywheel housing as it may prevent rotation of the flywheel.
(5) Repeat steps 3 and 4 above until all 12 capscrews are removed.
(6) Install a lifting eye (5) in top of torque converter housing.
(7) Attach a suitable lifting sling and hoist to lifting eye and take up slack in hoist.
(8) Remove capscrews (7) and lockwashers (6), and pull torque converter (4) clear of flywheel housing.
(9) Remove capscrews (3) and remove flexible flywheel disk assembly (2) from crankshaft.
(10) Remove lifting sling, hoist, and lifting eye from torque converter.
c. Installation (fig. 2-5).
(1) If a new torque converter is to be installed, remove 12 capscrews (1) and remove flexible disk assembly
(2) from torque converter (4).
NOTE
New torque converters have flexible disk assembly attached to them.
(2) Position flexible flywheel disk assembly on crankshaft in flywheel housing (12), making certain that dowel
pins on crankshaft align with corresponding holes in flexible flywheel disk assembly.
(3) Install six capscrews (3). Tighten capscrews to a torque of 150 to 160 foot-pounds.
NOTE
If drilled head capscrews are used secure with lockwire.
(4) Install lifting eye (5) in top of torque converter housing.
(5) Attach a suitable lifting sling and hoist to lifting eye and hoist torque converter.
(6) Position torque converter on flywheel housing, aligning bolt holes on torque converter housing and flywheel housing.
(7) Install all capscrews (7) and lockwashers (6) loosely, then tighten capscrews to a torque of 42 to 50 footpounds.
(8) Remove bolts (11) and lockwashers (10) securing converter housing cover (9) and gasket (8).
(9) Lift off converter housing cover and gasket and place a 3/8 inch socket wrench through opening on an accessible pump to flywheel capscrew to prevent flywheel from turning when crankshaft is rotated.
(10) Slowly rotate engine clockwise, using bolt in vibration damper end of crankshaft, until holes in flywheel and
flexible flywheel disk assembly are lined up as viewed through pipe plug (I 3) opening in flywheel housing.
(11) Working through pipe plug opening, install 1 of 12 capscrews (Do not tighten capscrews.)
(12) Remove 3/8 inch socket wrench from access hole in torque converter housing and repeat steps (10 and
(11) above until all 12 capscrews are installed.
(13) Rotate engine and tighten all 12 capscrews to a torque of 70 to 75 foot-pounds, working through pipe plug
opening in flywheel housing.
(14) Install converter housing cover (9) and gasket (8), using bolts (11) and lockwashers (10).
(15) Install pipe plug (13) in flywheel housing.
(16) Remove lifting sling, hoist, and lifting eye from torque converter.
(17) Install engine (para 2-11).
2-14
Figure 2-2. Torque converter (model TC-654)
2-15
Figure 2-3. Torque converter (Model TC-554) (4 element)
2-16
Figure 2-4. Torque converter (Model TC-554-3 element)
2-17
Figure 2-5. Removal and installation of torque converter.
NOTE
Removal and installation of all models of torque converters used in this equipment is performed in a
similar manner.
2-13.
Transmission Assembly
a. General. The LARC transmission is an Allison Torqmatic Model TG-603RM (FO-1) (Fold-Out 1. (located in
back of manual)). Torque from the torque converter is transmitted to the transmission main shaft through the input
flange assembly. Four multiple-disk range clutches, (low, intermediate, high and reverse) are compactly arranged within
the transmission housing and transmit power to the planetary carrier assembly. The adapter assembly provides an external support for connecting the planetary carrier assembly to the output flange assembly. The oil strainer assembly
filters the oil in the transmission sump which serves as the reservoir for the torque converter and transmission oil system.
The transmission planetary gearing is a compound planetary gear train in constant mesh. The four multiple-disk, oilcooled, friction clutches which are hydraulic applied and spring-released control the planetary gear train. The friction
plates and reaction plates are hydraulically-applied through a manual range selector. The clutches automatically compensate for normal wear.
b. Removal. If the same transmission is to be reinstalled, perform steps (1) through (19) below. If a new transmission is to be installed, perform additional steps (20) through (29) below. Retain parts removed in steps 119) through
129) for installation of new transmission.
(1) Remove pipe plugs (3 and 11, fig. 2-6) and drain transmission oil into a suitable container.
2-18
Figure 2-6. Transmission-Torque converter oil lines.
(2)
Remove transmission-to-miter box flexible coupling (TM 55-1930-203-20).
(3)
Remove transmission-to-torque converter flexible coupling (TM 55-1930-203-20).
(4)
Disconnect transmission-to-oil cooler flexible hose (9, fig. 2-7).
(5)
Disconnect selector valve-to-oil pump flexible hose (21).
(6)
Disconnect transmission-to-oil pump flexible hose (7).
(7)
Disconnect transmission-to-torque converter seal drain flexible hose (44).
(8)
Remove cotter pin (16) and pin (15).
(9)
Remove two bolts (13), bolt (12), and lockwashers (11), and move transmission shifting control air cylinder and mounting bracket (14) away from front of transmission.
(10) Disconnect low oil pressure sending unit connector and cable assembly (22).
(11) Disconnect transmission oil pressure line (101 and move clear of transmission.
(12) Install lifting eyes (8) in transmission.
(13) Attach suitable hoisting equipment to lifting eyes and take up slack in hoisting equipment.
(14) Remove eight nuts (27) and lockwashers (26) and four bolts (1).
(15) Remove four fitted mounting bolts (2) and mark bolts so they may be installed in the same position from
which they were removed.
(16) Lift transmission sufficiently to facilitate removal of mounting shims (20). Remove shims and mark them
so they may be installed in the same position from which they were removed. The outside hole on each shim is reamed
to fit the corresponding fitted mounting bolt (2).
(17) Remove four bolts (25) and lockwashers (24) and remove upper mounting plate (23).
(18) Remove four bolts (18) and lockwashers and remove lower mounting plate (17).
(19) Secure handling lines to prevent transmission from swinging and remove transmission.
(20) Remove bolts (43) and lockwashers (42) and remove manifold assembly (40) and gasket (39).
(21) Remove elbow (41) from manifold assembly and reinstall manifold and gasket on transmission with
bolts (43) and lockwashers (42). Retain elbow (41) for installation.
2-19
(22) Remove low oil pressure sending unit 128) from elbow (33).
(23) Remove elbow (33), bushing (29), and close nipple (30) from tee (31).
(24) Remove elbow (32) from tee (31).
(25) Remove tee, close nipple (34), and bushing (35) from selector valve.
(26) Remove adapter (38), reducer (37), and close nipple (36) from selector valve.
(27) Remove straight adapter (6) from elbow (5).
(28) Remove close nipple (4) and bushing (3).
(29) Remove adapter (45) and elbow (46).
c. Installation.
(1)
Install lifting eyes (8), in transmission.
(2)
Attach suitable hoisting equipment to lifting eyes and position transmission above foundation with
breather cap end facing miter box.
(3)
Position upper mounting plate (23) on breather cap end of transmission and install four bolts (25) and
lockwashers (24).
(4)
Position lower mounting plate (17) on transmission and install four bolts (18) and lock-washers (19).
(5)
Position shims (20) on foundation in same location from which they were removed in a (16) above.
(6)
Lower transmission onto foundation and install four fitted mounting bolts (2) in same location from which
they were removed in a (15) above.
(7)
Install four bolts (1), eight lockwashers (26), and eight nuts (27).
(8)
Install bushing (3), close nipple (4 ), elbow 15), and straight adapter (6) on transmission oil strainer assembly.
(9)
Connect transmission-to-oil pump flexible hose (7) to straight adapter (6).
(10) Connect elbow (46) and adapter (45) on transmission below input flange.
CAUTION
The seal drain flexible hose routing from the torque converter to the transmission oil pump is critical. The
hose must be installed 3 1/2 inches or more below the centerline of the torque converter at every point in
the line. There must never be any kinks or tight bends in the line. Improper installation will result in excessive leakage past the torque converter pump hub seal or output shaft dual oil seal.
(11) Connect transmission-to-torque converter seal drain flexible hose (44) to adapter (45).
(12) Remove bolts (43) and lockwashers (42) and remove manifold assembly (40) and gasket (39).
(13) Install elbow (41) in manifold assembly (40) and reinstall manifold and gasket on transmission with bolts
(43) and lockwashers (42).
(14) Connect transmission-to-oil cooler flexible hose (9) to manifold assembly (40).
(15) Install close nipple (36), reducer (37), and adapter (38) on selector valve.
(16) Connect selector valve-to-oil pump flexible hose (21) to adapter (38).
(17) Install bushing (35), close nipple (34), and tee (31) on selector valve.
(18) Install close nipple (30), bushing (29), elbow (33), and low oil pressure sending unit (28) on tee (31).
(19) Connect connector and cable assembly (22) to low oil pressure sending unit (28).
(20) Install elbow (32) on tee (31).
(21) Connect transmission oil pressure line (10) to elbow (32).
(22) Remove two bolts (13), bolt (12), and lockwashers (11) from transmission.
(23) Position transmission shifting control air cylinder and mounting bracket (14) on front of transmission and
install bolts (12 and 13) and lockwashers (11).
(24) Position transmission shifting control air cylinder coupling on selector valve lever and install pin (15).
(25) Install cotter pin (16) in pin (15).
(26) Install transmission-to-torque converter flexible coupling (TM 55-1930-203-20).
(27) Install transmission-to-miter box flexible coupling (TM 55-1930-203-20).
(28) Fill transmission and torque converter with proper lubricant (LO 55-1930-203-12).
(29) Perform torque converter-transmission stall test (para 7-3).
2-20
Figure 2-7. Removal and transmission assembly.
2-21
Key to figure 2-7
1 Bolt, machine
2 Bolt, mounting, fitted
3 Bushing
4 Nipple, close
5 Elbow, 90°
6 Adapter, straight
7 Hose, flexible transmission-to-oil pump
8 Lifting eye
9 Hose, flexible, transmission-to-oil cooler
10 Pressure line, transmission oil
11 Lockwasher
12 Bolt, machine
13 Bolt, machine
14 Cylinder and mounting bracket, transmission shifting
control air
15 Pin
16 Pin, cotter
17 Lower mounting plate
18 Bolt, machine
19 Lockwasher
20 Shim, mounting
21 Hose, flexible, selector valve-to-oil pump
22 Connector and cable assembly, low-oil pressure sending
unit
23 Upper mounting plate
24 Lockwasher
25 Bolt, machine
26 Lockwasher
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Nut
Sending unit, low oil pressure
Bushing
Nipple, close
Tee
Elbow, male
Elbow, 50°
Nipple, close
Bushing
Nipple, close
Reducer, bell
Adapter, straight
Gasket, manifold assembly
Manifold assembly
Elbow, street, 90°
Lockwasher
Bolt, machine
Hose, flexible, transmission-to-torque converter seal drain
Adapter
Elbow, street, 90°, 3/8 in.
Pin, spring guide
Washer, saddle
Compression spring
Manifold body
Bolt, machine
Lockwasher
Selector valve assembly
Gasket, selector valve assembly
2-14.
Air Brake Assembly
a. Removal. To remove air brake assembly on input side of miter box (17, fig.2-8), perform (1) through (4) and (7)
through (10) below. To remove air brake assembly on opposite side, perform (1) and (5) through (10) below.
(1) Provide a suitable container and remove drain plug (18), and drain lubricant from miter box. Install drain plug
after lubricant is drained.
(2) Remove tire air shut-off valve handle (1), bolts (2), lockwashers (20), and nuts (19), and remove miter boxto-transmission machinery guard (3).
(3) Remove capscrews (24) and lockwashers (23), and remove transmission-to-miter box flexible coupling (TM
55-1930-203-20).
(4) Remove brake drum assembly (22) and gasket (21) from input side of miter box.
(5) Remove bolts (5), lockwashers (15), and nuts (16), and remove machinery guard (4).
(6) Remove bolts (12) and lockwashers (11), and remove brake drum assembly (10).
(7) Disconnect air brake pneumatic line (6) at fitting on brake assembly (7).
(8) Remove lock wire from capscrews (9) and remove capscrews, end plate (13), and coupling flange (14).
(9) Remove lock wire from bolts (8) and remove bolts.
(10) Remove brake assembly (7).
b.
Installation. Install air brake assembly in the reverse order of removal. After brake assemblies are installed,
fill miter box with approved lubricant (LO 55-1930-203-12).
Key to figure 2-8
1
Air shut-off valve handle
2
Bolt, machine
3
Miter box-to-transmission machinery guard
4
Machinery guard
5
Bolt, machine
6
Air brake pneumatic line
7
Brake assembly
8
Bolt, machine
9
Capscrew
10
Brake drum assembly
11
Lockwasher
12
13
14
15
16
17
18
19
20
21
22
2-22
Bolt, machine
End plate
Coupling flange
Lockwasher
Nut
Miter box
Plug, drain
Nut
Lockwasher
Gasket
Miter box input brake drum assembly
Figure 2-8. Air brake assembly removal and installation.
2-23
2-15.
Miter Box Assembly
a. Description. There are four miter box assemblies installed on the LARC and each miter box assembly connects
to a column and wheel drive. The function of the miter box assembly is to convert horizontal rotation of the transmission
output flange into vertical rotation for the column and wheel drive. A right angle bevel gear set on the miter box assembly converts the horizontal input rotation to vertical output rotation. The miter box case forms an oil sump into which the
gears dip. Sufficient oil splash is obtained for adequate gear and bearing lubrication. The miter box case also serves as
an upper support for the column and wheel drive. All four miter box assemblies contain identical parts; however, placement of the left- and right-hand bevel gears, input shaft, bearing yoke, and breather differ between port and starboard
miter box installations (fig. 2-9).
2-24
Figure 2-9. Miter box assembly.
2-25
CAUTION
It is extremely important that the miter box assembly be built up properly for the particular location; otherwise, serious damage to
the LARC may result. If the miter box assembly input shaft and gears are improperly assembled for a particular location, it is possible for the one wheel to rotate in opposite direction from the other three.
NOTE
In order to perform any major repair on or to remove the miter box assembly, the miter box assembly must be disassembled in
place on board the LARC. Also if the column and wheel drive or steering arm is to be removed. the miter box assembly must be
disassembled in place.
b.
Removal and Disassembly.
(1) Removal. In order to remove the miter box assembly, it is necessary to disassemble the miter box assembly in place
as outlined below.
(2) Disassembly.
(a) Disassembly in place.
1. Remove air brake assemblies (para 2-14)
2. Remove ten capscrews (22. FO-2) (located in back of manual) and two capscrews (23) from bearing retainer assemblies (4).
3. Remove four capscrews (2) and eight capscrews (3).
4. Install two of the eight capscrews (3) in tapped holes provided in mounting flange of case cover assembly
(1). Using the two capscrews as jacking bolts, remove case cover assembly, then remove two capserews from case cover assembly.
5. Remove bearing retainer assemblies (4). shim set l5), and input shaft assembly (6).
NOTE
Extreme care must be taken during disassembly that no damage occurs to shims sets. Keep each shim set with its respective
bearing retainer assembly and mark bearing retainer assemblies as to location on case (19). Note relationship of gear on inpuit
shaft assembly with respect to drive or transmission end of miter box assembly.
6. Remove six capscrews (7) and two capscrews (2) and lift out output shaft assembly (20) and shim set (8).
NOTE
Extreme care must be taken during disassembly that no damage occurs to shim set. Note relationship of bearing yoke (29) with
respect to drive or transmission end of miter box assembly.
7. To remove self-aligning bearing (53). remove column and wheel drive as outlined in paragraph 2-1 6a (2)
through (11). Remove capscrews (51) and remove bearing carrier (52). Remove seal (50) from bearing carrier and press bearing
out of bearing carrier.
NOTE
Removal and inspection of self-aligning bearing (53) can only be accomplished after removal of column and wheel drive. Unless
structure damage has occured to destroy unit alignment case (19) need not be removed from LARC.
8. To remove case (19) remove column and wheel drive as outlined in paragraph 2-16a. Steps (2) through
(11) and steering arm as outlined in paragraph 8-2. Attach suitable hoisting tackle to case and take up slack.
9. Remove eight nuts (12) and lock washers (13) and six bolts (17). Lower case slightly and remove shims
(15). Mark shims as to location.
10. Remove two fitted mounting bolts (16) and fitted shims (14), located on extreme opposite ends of miter
box mounting. Mark bolts and shims so they may be installed in dame position from which they were removed.
NOTE
FO-2 shows the starboard forward miter box assembly. The fitted mounting bolts (16)are located as shown in the fixture for the
starboard forward and port aft miter box assemblies. On the starboard aft and port forward miter box assemblies, the fitted
mounting bolts are located on opposite diagonal corners.
11. Lower case, tilt sideways, and lift case out of foundation using hoisting tackle.
(b)
Case cover assembly disassembly.
1. Remove eye bolt (55) and breather (56) from inspection cover (57).
2. Remove capscrew (54) and remove inspection cover and gasket (58).
3. Remove two nuts (60) and taper pins (61) from case cover (59).
(c)
Bearing retainer assembly disassembly. Remove seal (24) from bearing retainer (4) and press bearing cup
(26) out of bearing retainer.
NOTE
Keep bearing cups (26) with their respective bearing retainer.
(d) Input shaft assembly disassembly. Press gear (63) and bearing cone (62) on same end of input shaft (64) off
input shaft simultaneously. Remove key (65) and press the other bearing cone off input shaft.
NOTE
Keep each bearing cone (62) with its respective bearing cup (26)
(e)
Output shaft assembly disassembly.
1. Lift off bearing yoke (29), remove snap ring (27) and press bearing outer race (28) out of bearing yoke.
2-26
2. Remove cotter pin (43), nut (42), and washer (41) , and pull coupling gear (40) from output shaft (32).
3. Support subassembly on upper hub of gear (34), being careful not to damage bearinginner race (31), and
press output shaft out of subassernbly.
4. Remove key (33) and snap ring (30) from output shaft and press bearing inner race (31) off output shaft.
5. Remove eight capscrews (35) securing bearing (36) and remove bearing stop.
6. Remove seal (38) and press bearings (37) out of bearing carrier (39) from seal end.
c. Reassembly and Installation.
(1) Reassembly.
(a) Output shaft assembly reassembly.
1. Install seal (38, FO-2) in bearing carrier (39).
2. Install bearings (37) in bearing carrier.
NOTE
These are angular contact matched bearing sets and must be mounted face to face.
3. Install bearing stop (36) using cap-screws (35). Make certain bearings are clamped in bore of bearing carrier, then secure capscrews with lockwire.
4. Install key (33) in output shaft (32) and press right-hand gear (63) or left-hand gear (34) onto output shaft.
NOTE
If output shaft assembly is being built up for port miter box assembly installation, press right-hand gear (63) onto output
shaft. If output shaft is being built up for starboard miter box assembly installation, press left-hand gear (34) onto output
shaft (fig. 2-9).
5. Press output shaft with gear into bearings (37, FO-2), making certain that hub of gear seats against inner
race of bearing.
6. Install coupling gear (40) on spline of output shaft, being careful not to damage seal.
7. Install washer (41) and nut 142). Tighten nut securely making certain coupling gear hub clamps inner race
of bearing (37). Install cotter pin (43).
8. Press bearing inner race (31) onto upper end of output shaft, then install snap ring (30).
NOTE
Turn gear over by hand to make certain there is no binding. A light preload feel will be normal with the use of matched
bearing set.
9. Press bearing outer race (28) into bearing yoke (29), then install snap ring (27).
10. Install preformed packing (44) on gear coupling (40).
11. Position bearing yoke and bearing outer race onto output shaft and bearing carrier.
(b) Input shaft assembly reassembly.
1. Install key (65, FO-2) on input shaft (64) and press left-hand gear (34) or right-hand gear (63) onto input
shaft.
NOTE
If input shaft is being built up for port miter box assembly installation, press left-hand gear (341 onto input shaft. If input shaft
is being built up for starboard miter box assembly installation, press right-hand gear (63) onto input shaft (fig. 2-9).
2. Heat bearing cones (62) in an oil bath at 250°F (121.1°C) to 300°F (148.8°C) and install bearing cones on
input shaft.
NOTE
Install bearing cones on ends of input shaft corresponding to matching bearing cups (26) in bearing retainer assemblies (4).
See figure 2-9 for input shaft and gear orientation for port or starboard miter box assembly installation.
(c) Bearing retainer assembly reassembly. Press bearing cup (26, FO-2) into bearing retainer (25), then install
seal (24).
NOTE
Make certain that matching bearing cup for bearing cone (62 is installed in corresponding bearing retainer. Assure that seal
lip is facing toward bearing and that the seal is flush with the bearing retainer, not bottomed.
(d) Case cover assembly reassembly.
1. Install taper pin (61, FO-2) and nut (60) on case cover (59).
2. Install breather (56) in inspection cover (57) and install inspection cover and gasket, using capscrews (54).
NOTE
Determine from taper pins in case cover which position case cover will assume when mounted on case (19), then install ni
spection cover so that breather is opposite gear on input shaft (fig. 2-9).
(e) Reassembly in place.
1. If self-aligning bearing (53, FO-2) was removed, lubricate bearing with grease, Military Specification MILG-10924, and press bearing into bearing carrier (52). Install seal (50) in bearing carrier and install bearing carrier with capscrews (51). Secure capscrews with lockwire. Install column and wheel drive as outlined in paragraph 2-16e, (2) through (12)
and (14).
NOTE
Self-aligning bearing (53) has a tapered inner race and must be installed in bearing carrier (52) correctly. Press bearing into
bearing carrier so that large end of inner race faces down.
2. If case (19) was removed, attach suitable hoisting tackle, orient case so that fitted mounting holes on extreme diagonal corners of case
2-27
correspond with fitted mounting holes in foundation, tilt case sideways, and lower into foundation. With case mounting
holes lined up with holes in foundation, insert shims (14 and 15) in their original positions. Install two fitted mounting
bolts (16) and six bolts (17) and secure with lock- washers (13) and nuts (12). Install steering arm as outlined in paragraph 8-2 steps (a) through (d) and column and wheel drive as outlined in paragraph 2-9 e, steps (3) through (12) and
(14).
3. Position shim set (8) in case (19), being careful not to damage shim set. 4. Pack female coupling
gear (49) with grease, Military Specification MIL-G-10924, then lower output shaft assembly (20) into position, making
certain male coupling gear (40) mates with female coupling gear.
NOTE
If bearing is) or gear in output or input shaft assembly has been replaced, it will be necessary to adjust gear mesh and
bearings as outlined in paragraph 7-8 d
5. Position bearing yoke (29) opening as shown in figure 2-9 for the particular miter box installation involved. Install two capscrews (21, FO-2) and six capscrews (7). Secure capscrews with lock wire.
6. Position input shaft assembly (6) over output shaft assembly and assemble each bearing retainer
assembly (4), with corresponding shim set i5), on respective end of input shaft assembly and case. Secure each bearing
retainer with two cap- screws (22). Do not tighten capscrews.
7. Lower case cover assembly (1) onto case being careful not to damage shim sets (5).
NOTE
Make certain inspection cover (57) is installed correctly. Breather (56) should be opposite gear on input shaft assembly (fig. 2-9).
8. Install capscrews (2, FO-2) in case cover assembly and tighten capscrews.
9. Install remainder of capscrews (22) to total ten, and two capscrews (23) in each bearing retainer assembly. Tighten capscrews and secure with lock wire.
10. Install eight capscrews (3) in case cover assembly flange and tighten capscrews. 11. Install air brake
assemblies (para 2- 14).
(2) Installation. If a new miter box assernbly is to be installed, it will be necessary to determine if the miter box
assembly is built up properly for the particular location. Since the miter box assembly must be disassembled to be installed, this can be determined during disassembly.
(a) Remove lock wire from capscrews (9, fig. 2-8) and remove capscrews, end plates (13), and coupling
flanges (14). (b) Disassemble miter box assembly as outlined in b(2) (a), 2 through 6 above.
(c) Determine if input shaft assembly (6, fig. 2-9) and output shaft assembly (20) are built properly for the
particular location (fig. 2-9).
(d) If shaft assemblies are not built up properly, disassemble shaft assemblies as outlined in b (2) (d) and (e)
above and reassemble shaft assemblies as outlined in d (1) (a) and ( b) above.
(e)
Reassemble miter box assembly as outlined in d(l) (e) above.
2-16.
Column and Wheel Drive Assembly
a. Removal.
(1) Disassemble miter box assembly (para 2-15 b (2) ( a) 1 through 6).
(2) Drain lubricant from column and wheel drive assembly.
(3) Jack and shore up LARC at wheel well
(4) Remove tire (para 2-19).
(5) Support weight of column and wheel drive with a forklift truck or similar piece of equipment.
(6) Disconnect flexible hose (3, fig. 7-113) and remove swivel coupling (4) and nipple (5).
(7) Remove capscrew (9, FO-2) and remove column (10).
(8) Match-mark column and wheel drive assembly steering post and steering arm.
WARNING
Prior to removing lower pivot bearing assembly in step (9) below, make certain column and wheel drive assembly is
properly secured and supported on a forklift truck or similar piece of equipment.
(9) Remove lower pivot bearing (para 2-17).
10) Lower column and wheel drive assembly slowly. Column and wheel drive should pass through bearing (53,
FO-2).
(11) Remove coupling gears (46 and 49) and intermediate shaft (48) from column and wheel drive.
(12) Remove column and wheel drive boot assembly (para 2-18).
b Installation.
(1) Remove capscrews (51, FO-2) and remove bearing carrier (52). Remove seal (50) from bearing carrier and
press bearing (53) out of bearing carrier. Inspect bearing for pitted, scored, or burned condition. Replace if defective.
(2) Lubricate bearing with grease, Military Specification MIL-G-10924, and press bearing into bearing carrier
(52). Install a new seal (50) in bearing carrier and install bearing carrier with capscrews (51). Secure capscrews with
lock wire.
2-28
(3) Install a new preformed packing (47) on
male coupling gear 146). Pack female coupling on inside of column and wheel drive steering post with
grease Military Specification MIL-G-10924, and install
male coupling gear (46) in female coupling gear. Install
intermediate shaft (48), and female coupling gear (49)
inside column and wheel drive steering post.
(4) Install boot assembly on steering post
(para 2-18).
(5) Position column and wheel drive assembly
on a support frame. Using a suitable lifting device,
preferably a forklift truck, maneuver column into position
in wheel well.
(6) Slowly raise column into miter box case,
aligning match marks on steering arm and steering post
and being extremely careful not to damage seal 150), as
steering post passes through bearing (53).
(7) Install column nut (10) on steering post and
tighten nut while raising column. After nut is tightened,
install capscrew (9).
(8) Install lower pivot bearing assembly (para
2-17).
(9) Remove forklift truck; coat threads of nipple 15, fig. 7-113) and swivel coupling (4) with Permatex, Military Specification MIL-S-7916, and install
nipple and swivel coupling on bevel gear spider bearing
cover. Connect flexible hose (3).
(10) Install tire (para 2-19).
(11) Fill column and wheel drive with proper
lubricant and lubricate wheel seals (LO 55-1930- 20312).
(12) Remove jack and shoring from LARC.
(13) Reassemble miter box assembly (para
2-15).
(14) Secure mounting ring (3, fig. 2-10) and
gasket 12) to top of wheel well using 14 bolts (1), lockwashers (11), and nuts (10).
Figure 2-10. Removal of column and wheel drive boot
assembly.
2-29
2-17.Column and Wheel Drive Lower Pivot Bearing Assembly
a. Removal and Disassembly (fig. 2-11)
(1) Remove 29 nuts (8) and lockwashers 17), 25 bolts (9), and 4 fitted bolts (5).
(2) Remove lower pivot bearing mounting bracket (6) and shim (10), being careful not to damage shim.
(3) Remove seal (3) and if necessary pull lower pivot bushing (4) from lower pivot bearing mounting bracket.
b. Reassembly and Installation.
(1) If column and wheel drive assembly was removed, inspect steering post bushing (2) for damage during handling of column and wheel drive. If bushing is damaged, pull off old bushing and install a new one.
(2) Press lower pivot bushing (4) into lower pivot bearing mounting bracket (6), then install seal (3).
(3) Install lower pivot bearing mounting bracket and shim (10), using 29 nuts (8) and lock-washers (7), 25 bolts
(91, and four fitted bolts (5).
Key to figure 2-11
1 Column and wheel drive assembly
2 Bushing, steering post
3 Seal
4 Bushing, lower pivot
5 Bolt, fitted
6 Bracket, lower pivot bearing mounting
7 Lockwasher
8 Nut
9 Bolt
10 Shim
2-30
Figure 2-11. Column and wheel drive lower pivot bearing assembly.
2-18. Column and Wheel Drive Boot Assembly
a. Removal (fig. 2-10).
(1) Remove column and wheel drive assembly( para 2-16).
(2) Remove 14 bolts (8), lockwashers (5), and nuts 14); remove retainer ring (7) and boot (6).
(3) Remove 14 bolts (1), lockwashers (11), and nuts (10); remove mounting ring (3) and gasket (2).
b. Installation.
(1) Install retainer ring (7) and a new boot (6) on mounting ring (3) using 14 bolts (8), lock-washers (5), and nuts
(4).
(2) Slip boot and mounting ring down over column and wheel drive steering post to boot area on steering post.
Make certain lip of boot is toward outside to prevent water from entering around steering post.
(3) Position a new gasket (2) over steering post onto mounting ring.
2-31
(4) Install column and wheel drive assembly as outlined in paragraph 2-16 b (1 ) through (3) and (5) through
(13). Secure mounting ring and gasket to top of wheel well using 14 bolts (1) lockwashers (11), and nuts (10).
2-19. Tires
a. .Removal. When replacing a tire, jack the LARC as follows:
NOTE
Be sure that all tire inflation valves are closed. (1) If tire at corner C, (fig. 2-12) is to be replaced, close globe valves
installed in the airlines next to the miter boxes at corners A and C.
(2) Inflate tires at corners B and D to 69 psi.
(3) Close globe valves at corners B and D.
(4) Place jack under jacking pad at corner C on four 2 x 8 inch timbers at least 4 feet long.
CAUTION
The jack shall be used only to tilt the LARC to the. opposite corner of tire being removed. The jack will be damaged
if used to lift the end of the LARC.
(5) Open tire inflation valve at corner A and slowly deflate tire with tire inflation-deflation pilot air valve located
in the cab. At the same time jack the LARC at corner C.
CAUTION
Deflate tire at corner A only enough to allow tire at corner C to clear the ground. If tire at corner A is completely deflated, damage may occur to tire.
(6) Stop deflating the tire at corner A and jacking at corner C when the tire at corner C clears the ground. Close
tire inflation valve at corner A.
NOTE
All wheels may be jacked by the procedure outlined in step (1) through (6) above by inflating and deflating respective
tires and positioning the jack under the proper jacking pads.
(7) Open tire inflation valve at corner C and deflate tire with tire inflation-deflation pilot air valve located in the
cab.
(8) Remove eight bolts 17, fig. 2-13) attaching side ring (15) to bead seat ring (13).
(9) Remove eight plug bolts (9) from bead seat ring (13) and replace eight side ring loosening bolts
(8) Screw in side ring loosening bolts until they make contact with side ring (15).
(10) Tighten each side ring loosening bolt (8) ½ turn in a circular sequence. Continue tightening until side ring
(15) and side of tire (6) are free from wheel.
(11) Remove side ring loosening bolts (8) and replace plug bolts (9).
(12) Loosen opposite side ring (5) from wheel in a manner similar to steps (8) through (11) above.
(13) Remove 24bolts (12) attaching bead seat ring (13) to wheel.
(14) Remove three plug bolts (11) from bead seat ring (1 3) and replace with bead seat ring loosening bolts (10).
Screw in- bead seat ring loosening bolts (10) until they make contact with the wheel.
(15) Tighten each bead seat ring loosening bolt (10) I/2 turn in a circular sequence. Continue tightening until
bead seat ring (13) is loose.
(16) Remove bead seat ring loosening bolts (10) and replace plug bolts (11).
(17) Remove bead seat ring (13) and preformed packing (14 and 16).
(18) Run forks of a forklift truck under tire (6). Secure top and bottom of tire with a wire rope.
(19)Slightly lift tire and slowly back forklift away from LARC.
(20) Remove side rings (5 and-15) from tire (6).
CAUTION
Be extremely careful when removing side rings (5 and 15) so as not to damage the tire.
(21) Remove preformed packing (4) from wheel.
b. Installation.
(1) Using a wire brush, clean all metal surfaces that mate with the tire.
(2) Install preformed packing (4) and side ring (5). Attach side ring to wheel with bolts (3).
(3) Apply a coat of approved lubricant on wheel to aid installation of tire (6) to wheel.
(4) Place tire (6) on forklift.
(5) Raise tire to mounting position and press tire onto wheel.
(6) Install preformed packing 114) and side ring (15) onto bead seat ring (13). Secure side ring
(151 to bead seat ring (I13) with bolts (7).
(7) Position preformed packing (16) and install bead seat ring (13) and side ring (15) on wheel. Secure bead
seat ring (13) to wheel with 24 bolts (12). Tighten bolts to a torque of 600 foot- pounds.
(8) Slowly inflate tires at corners A and C (fig. 2-12) to 69 psi and slowly lower jack.
(9) Open globe valve at corners B and D. Deflate tires to normal operating pressure.
(10) Remove and stow jack and supporting timbers.
2-32
Figure 2-12. Jacking points.
2-33
Figure 2-13. Tire removal
2-34
2-20.
Marine Drive System
The marine drive system (fig. 2-14) consists of two dependent drive systems that are controlled separately. The marine
drive system on the star- board side is basically the same as the port marine drive system. The marine gears control the
direction of rotation for the propellers and also serve as power sources for the hydraulic and compressed air systems.
Each marine gear has an independent oil system which lubricates and supplies. pressure for shifting of the gears. The
marine drive system includes but is not limited to fluid coupling, gathering box, marine gear assembly, angle drive cooping, propeller and propeller shafting.
Figure 2-14. Marine drive system..
2-21. Fluid Coupling, Pillow Block, Flexible Coupling, and Engine Adapter Flange
a. Removal and Disassembly (fig. 2-15).
(1) Remove eight bolts (5), lockwashers (6), and nuts (7).
(2) Remove six bolts (3), lockwashers 12), and nuts (1); remove machinery guard (4).
(3) Drain fluid coupling (20).
(4) Remove four nuts (15), lockwashers (16), bolts (11), flat washers (12).
(5) Attach a suitable lifting sling and hoist to support fluid coupling (20), pillow blocks (21), flexible couplings
(49 and 50), and shafts (43 and 48). Take up slack in hoist.
(6) Remove bolts (8) securing flanged shaft (48) to gathering box, and bolts (17) securing flexible coupling (511
to fluid coupling (20).
(7) Slide flanged shaft (48) and flexible coupling flange with closure plate (19) away from mating flanges.
(8) Lift fluid coupling (20), pillow blocks (21 ), flexible couplings (49 and 50), and shafts (43 and 48) from the
LARC as an assembly.
(9) Remove chocks (13) and shims (14) and
2-35
mark so they may be installed in same position from which they were removed.
(10) Remove closure plate (19) and gasket (18) from flexible coupling (51).
(11) Remove flexible coupling (51) and machine key (36) from engine adapter flange (34).
(12) Remove bolts (35) and remove engine adapter flange (34). Using a puller, remove bearing (33) from engine adapter flange.
(13) Remove fluid coupling 120) from splined shaft (43).
(14) Remove nuts (47) and bolts (44) from flexible couplings (49 and 50). Separate flexible couplings and remove gasket (45) and spacer (46).
(15) Press hub gear (42) from flanged shaft (48) and remove machine key (36).
(16) Remove bolts (29) and lockwashers (30) from housing (28). Separate housings and remove from splined
shaft (43).
NOTE
Mark upper and lower half of each pillow block housing (28) for proper reassemble. The upper halves and lower
halves of pillow block housing are not interchangeable.
(17) Press hub gear (42) from splined shaft (43) and remove machine key (36).
(18) Remove ring seals (22 and 271, stabilizing rings (24A) locknuts (231, lockwashers (24), bearings (25), and
sleeves (26)from splined shaft (43).
(19) Disassemble flexible couplings 149, 50, and 51) as follows:
(a) Separate gear hub (42 from flexible coupling flange (40).
(b) Remove lubrication fittings (39 and 41).
(c) Remove seal retainer (37) and seal (381 from flexible coupling flange (40).
Key to figure 2-15
1 Nut
2 Lockwasher
3 Bolt, machine
4 Machinery guard
5 Bolt, machine
6 Lockwasher
7 Nut
8 Bolt, machine
9 Gasket
10 Pin
11 Bolt, machine
12 Flatwasher
13 Chock
14 Shim
15 Nut
16 Lockwasher
1 7 Bolt, machine
18 Gasket
19 Closure
20 Fluid coupling
21 Pillow block
22 Ring seal
23 Locknut
24 Lockwasher
24A Stabilizing rings
25 Bearing
26 Sleeve
27 Ring seal
28 Housing, pillow block
29 Bolt
30 Lockwasher
31 Plug
32 Pin
33 Bearing
34 Engine adapter flange
35 Bolt, machine
36 Machine key
37' Seal retainer
38 Seal
39 Fitting, lubrication relief
40 Flexible coupling flange
41 Fitting, lubrication
42 Hub gear
43 Splined shaft
44 Bolt, machine
45 Gasket
46 Spacer
47 Nut
48 Flanged shaft
49 Coupling, flexible
50 Coupling, flexible
51 Coupling, flexible
2-36
Figure 2-15. Fluid coupling, pillow block, flexible coupling and engine
adapter flange (Sheet 1 of 3)
2-37
Figure 2-15. Fluid coupling, pillow block, flexible coupling and engine
adapter flange (Sheet 2 of 3)
2-38
Figure 2-15. Fluid coupling, pillow block, flexible coupling, and engine
adapter flange (sheet 3 of 3)
2-39
b. Reassembly and Installation.
(1) Reassemble flexible couplings (49, 50, 51, fig. 2-15) in reverse order of disassembly. Hand- pack couplings with grease, Military Specification MIL-G-23549, prior to installation.
(2) Press bearings 133) into engine adapter flange (34).
(3) Install machine key (36) on engine adapter flange (34) and press flexible coupling (51) onto the engine
adapter flange.
(4) Install engine adapter flange with mounted flexible coupling using bolts (35). Tighten the bolts to a torque of
168-178 foot-pounds and install lockwire through bolt heads.
(5) Position shims (14) and chocks (13) in same location from which they were removed in a(9) above, and
align lower half of pillow block housings (28) on foundation using tapered dowel pins (10). Bolt housings to foundation
using bolts (11), flatwashers (12), lockwashers (16), and nuts (15). Tighten the bolts to a torque of 150 foot- pounds.
(6) Install machine keys (36) on splined shaft (43) and flanged shaft (48).
(7) Press flexible coupling (50) on splined shaft (43) and flexible coupling (49) on flanged shaft (48).
NOTE
It will be noted that stabilizing rings are used in only one of the pillow blocks as shown in figure 2-15.
(8) Assemble ring seals (27), sleeves (26), bearings (25), lockwashers (24), locknuts (23). ring seals (22), and
stabilizing rings (24A) OD splined shaft (43) as shown in figure 2-15.
NOTE
Pack bearings (25) with grease, Military Specification MIL-G-23549, and lubricate chamfered face of locknuts (23)
prior to installation.
NOTE
Locknuts (23) must be installed with chamfered face against lockwashers (24) and tightened only hand tight to allow
alignment of bearings after installation in pillow block housings.
(9) Insert gasket (45) and spacer (46) between flexible couplings (49 and 501 and bolt the couplings together
using bolts (44) and nuts (47). Tighten the nuts to a torque of 45 foot-pounds and install a cotter pin at nut end of each
bolt and lock- wire through bolt heads.
(10) Slide the splined end of shaft (43) into fluid coupling (20).
(11) Attach a suitable lifting sling and hoist to the fluid coupling, shafts, and flexible couplings, and hoist the a
ssembly into position over lower half of pillow block housings installed in (5) above. (12) Lower the assembly slowly and
align bearings 125) with bearing seats and ring seals (22 and 27) with oil seal grooves in lower half of pillow block hou
sings (28).
(13) Install gasket (18) and closure plate (19) on fluid coupling dowel pins. Bolt the flexible coupling (51) to the
fluid coupling using bolts ( 17). Tighten the bolts to a torque of 45 foot-pounds and install lockwire through bolt heads.
(14) Insert gasket (9) between flanged shaft (48) and gathering box inputflange, and bolt the shaft to the gathering box using bolts (8). Tighten the bolts to a torque of 45 foot-pounds and install lockwire through bolt heads.
(15) Center bearings (25) in lower pillow block housings and tighten locknuts (23) hand tight. With a spanner
wrench, tighten the nuts an additional 1/8 turn.
CAUTION
Make certain that bearings 125) rotate freely to insure that locknuts (23) are not excessively tightened. (I 6) Bend tang
of lockwasher (24) into slot of locknut (23).
NOTE
If slot of locknut is slightly past the tang of the lockwasher, do not loosen the locknut, but tighten the locknut to meet
the nearest washer tang.
(17) Fill lower half of pillow block housings (28) half full of grease, Military Specification MIL- G-23549.
CAUTION
Do not over lubricate the pillow blocks as too much lubricant will result in high operating temperature due to churning
of the lubricant.
(18) Apply non-hardening sealing compound, Military Specification MIL-S-45180, to the mating surfaces of the
pillow block housings and install upper half of pillow block housings using bolts (29) and lockwashers (30).
NOTE
Insure that each upper half of pillow block housing (28) is assembled to the mating part from which it was removed in
a (16) above.
(19) Fill fluid coupling (LO 55-1930-203-12).
(20) Position machinery guard (4) over fluid coupling.
(21) Install eight bolts (5), lockwashers (6), and nuts (7), and bolts (3), lockwashers (2), and nuts (1).
2-22. Gathering Box Assembly
a. Removal
(1) Remove bolts (9, fig. 2-16),nuts (11), and
2-40
lockwashers (10) and remove machinery guards (12 and 16).
(2) Remove capscrews (17) and lockwashers (18) from each flexible coupling flange (3).
(3) Slide flanges (3) back and remove marine gear angle drive coupling with gaskets (1).
(4) Remove four capscrews (21, fig. 2-11), lockwashers (22), and nuts (23); remove step guard (20).
(5) Disconnect cable assembly (5, fig. 6-1) from alternator.
(6) Remove cover (2) by removing three capscrews (1).
(7) Remove capscrew (6) and lockwasher (7) attaching generator to adjusting bracket.
(8) Loosen mounting bolts (11) and slightly move 'generator inward toward gathering box and slip belt (8) from
fan pulley.
(9) Remove mounting bolts (11), lockwashers (10), and nut (9) securing generator to mounting bracket (14)
and remove generator (13).
(10) Remove bolts (3 and 5, fig. 2-15), lockwashers (2 and 6), nuts (1 and 7), and remove machinery guards
(4).
(11) Remove bolts (8) securing flanged shaft (48) to gathering box.
(12) Remove nuts (47) and bolts (44) from flexible couplings (49 and 50), and separate flexible coupling
flanges (40).
(13) Remove flanged shaft (48) and flexible coupling (49) from the LARC as an assembly, and remove gaskets
(9 and 45) and spacer (46).
(14) Remove drain plug (12, fig. 2-17), and drain lubricant from gathering box (3) into a suitable container.
After lubricant is drained, replace drain plug.
(15) Remove drain plugs (18), one at a time, and drain lubricant from oil coolers (19). After lubricant is
drained, replace drain plugs.
(16) Disconnect oil bypass flexible hose (1), oil supply-from-oil cooler flexible hose (4), and oil supply-to-oil
cooler flexible hose (11). Tag hoses for identification.
(17) Disconnect oil temperature tube and thermometer (6).
(18) Disconnect cable from high temperature sending unit (15) and remove the sending unit.
(19) Remove adapters (2 and 10), reducer (9), nipple (8), elbow (7) and nipple (5) and retain for installation.
(20) Remove nuts (14) and lockwashers (13).
(21) Mark fitted mounting bolts (17) and shims (16) so they may be installed in the same position from which
they were removed.
(22) Remove fitted mounting bolts (17).
(23) Using a suitable hoist and with necessary personnel, lift gathering box from mounting.
(24) Remove fitted shims (16).
b. Installation.
(1) Position gathering box (3) on mounting and install four fitted shims (16), fitted mounting bolts (17), lockwashers (13), and nuts (14).
(2) Install adapters (2), nipple (5), elbow (7), nipple (8), reducer (9), and adapter (10).
(3) Connect flexible hoses (1, 4, and 11) to gathering box.
(4) Install high temperature sending unit (15) and cable.
(5) Install oil temperature tube and thermometer (6).
(6) Hand pack flexible couplings (49 and 50, fig. 2-15) with grease, Military Specification MIL-G-23549.
(7) Position flanged shaft (48) and flexible coupling (49) between the gathering box input flange and flexible
coupling (50), and in conjunction insert gasket (45) and spacer (46) between flexible couplings (49 and 50) and gasket (9)
between the flanged shaft and gathering box input flange.
(8) Bolt the flexible couplings together using bolts (44) and nuts (47), and bolt the flanged shaft to the gathe
ring box input flange with bolts (8). Tighten nuts (47) and bolts (8) to a torque of 45 foot-pounds.
(9) Install a cotter pin at nut end of each bolt (44) and lockwire heads of bolts (8 and 44).
(10) Position machinery guards (4) over fluid coupling. Install eight bolts (5), lockwashers 16), and nuts (7),
and six bolts (33), lockwashers (2), and nuts (1).
2-41
Figure 2-16.
Gathering box-marine gear angle drive coupling.
2-42
Figure 2-17. Gathering box, removal and installation.
2-43/(2-44 blank)
(11) Install battery charging generator and V-belt on gathering box.
(12) Install gathering box-to-marine gear flexible coupling.
(13) Fill gathering box to proper level as shown on dipstick. Refer to LO 55-1930-203-12 for proper lubricant.
(14) Install step guard (20), using capscrews (21), lockwashers (22), and nuts (23).
(15) Run appropriate engine for a period sufficient to allow oil to circulate through oil coolers. Shut down e
ngine and recheck oil level. Fill as necessary.
2-23. Air Compressor (Model 3YC) and Coupling Assembly
a. Removal
(1) Drain oil from air compressor. (TM 55-1930-203-20).
(2) Close globe valves (6 and 7, fig. 2-19) located in air lines above air supply tanks and open service connection globe valves (5) to vent compressed air from lines.
WARNING
Before attempting to remove any compressed air system lines or components, relieve pressure from system. Failure to
do so may result in injury or death to maintenance personnel.
(3) Disconnect air compressor input and output tubes (1and 5, fig. 2-20) at pipe coupling (2) and union (4).
(4) Disconnect air compressor unloader to governor tube (6) at high pressure cylinder on air compressor.
(5) Loosen setscrews ( 18) in coupling half (20) of coupling assembly (8).
(6) Remove bolts (21), lockwashers (22), and nuts (23) and slide air compressor rearward until crankshaft is
withdrawn from coupling assembly.
(7) Remove key (7) from air compressor.
(8) Remove air compressor.
(9) Loosen setscrews (18) in marine gear end coupling half (17) and remove coupling assembly (8) and key
(15) from marine gear take-off shaft.
b. Installation. Install air compressor and coupling assembly in reverse order of removal.
2-45/(2-46 blank)
Figure 2-19. Air supply system.
2-47
Figure 2-20. Air compressor, Model 3YC, and coupling assembly,
removal and installation
2-48
2-24. Air Compressor (Model 3VC) and Coupling Assembly
a. Removal
(1) Drain oil from air compressor (TM 55-1930-203-20).
(2) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service connection globe valves (5) to vent air pressure from lines.
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from
system. Failure to do so may result in injury or death to maintenance personnel.
(3) Disconnect air compressor input and output tubes 1 4 and 16, fig. 2-21) at pipe coupling (12) and union
(15).
(4) Disconnect air compressor to governor tube (13).
(5) Remove retaining ring (1) from groove and slide retaining ring and collar (2) back. Remove inserts (5) from
coupling.
(6) Remove nuts (20), lockwashers (19), and capscrews (17).
(7) Remove air compressor and shims (18).
(8) Remove capscrew (6), lockwasher (7), flatwasher (8), coupling half (9), and key (10) from compressor
shaft.
(9) Loosen setscrews (3) in marine gear coupling half (4) and remove coupling half and key (11) from marine
gear take-off shaft.
b. Installation. Install the air compressor and coupling assembly in the reverse order of removal.
2-49
Figure 2-21. Air compressor, Model 3VC, and coupling assembly,
removal and installation.
2-50
2-25. Procedures for Replacing Model3YC Air Compressor With Model 3VC Air Compressor
a. Model 3YC air compressors are obsolete, and when either the port or starboard air compressor becomes unec
onomical to repair, both of the air compressors will be replaced with Model 3VC air compressors. Replacement of Model
3YC with Model 3VC require foundation changes and relocation of the air compressor governor. Some LARC's have air
compressor foundations which have been previously changed; therefore, prior to work determine if the complete change
has been accomplished. Measure the distance from the center line of the marine gear power take-off shaft to the top of
the foundation. If the measurement is 7-1/4 inches or more and the foundation is mounted on a double plate, the
change has been accomplished.
b. Remove the Model 3YC air compressor as outlined in paragraph 2-23.
c. Fabricate and install the air compressor foundation in accordance with figure 2-22.
d. Install the straight bore half of coupling (4) onto the marine gear power take-off shaft. Tighten coupling se
tscrews.
e. Install the tapered bore half of the coupling on the air compressor shaft.
f. Set air compressor (1) with shims (5) on bed plate (7). Bring coupling halves together allowing 1/8 inch gap between the end of the jaws and the opposite flange.
g. Using a straight edge over the coupling halves, align to correct elevation within 0.003 inches. This alignment will
be accomplished by appropriate machining of shims (5) or by adding other suitable shim material. The required parallelism in the vertical plain is also 0.003 inches. Angularity as measured at the edge of the coupling flanges will not be
greater than 0.006 inches.
h. When the alignment has been determined to be within tolerances, scribe and drill four 17 / 32 inch compressor
mounting holes in bed plate (7). Mount the air compressor on the bed plate with bolts (6), lockwashers (8), and nuts (9).
i. Assemble the flexible coupling and recheck alignment to insure that it is within tolerances.
j. Fabricate a new air compressor governor bracket (10) and weld to the 7 foot longitudinal bulkhead as shown in
figure 2-22 (6). Mount the air compressor governor on the new bracket. The piping runs are less than those of the cu
rrent governor installation; therefore, piping, fittings, and fastenings will be reused.
2-51
Key to figure 2-22 (sheets 1 thru 6)
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
QTY
2
2
4
2
8
8
2
8
8
2
2
2
2
4
6
2
DESCRIPTION
Air Compressor, 3VC
Pipe Coupling
Key 3/8 x2/8x 2 ½
Coupling
Shim Plate 2”x 2”
½ ”- 13NC2-4 ½ Hex Screw
Bed Plate 15”x 15”
½ -Med Lockwasher
½ -13NC2-Hex Nut
Bracket-Governor
Doubler Plate 21 x 24
End Plate 5 x 18
End Plate 8 x 18
Brace 3”x 16 1/
Gussett 10”x 8”
Gussett 5 ½ ”x 3 ½
MAT’L
Steel
FMS
35301
98625
16603
75665
Steel ½ PL
Steel
Steel 3/8 PL
Steel
Steel
Steel 10G
Steel ½ PL
Steel ¼ PL
Steel ¼ PL
Steel ¼ PL
Steel ¼ PL
Steel ¼ PL
VENDOR P/N
3VC-SPEC-454-5
6500-1-1-4-325
BK-18E
020767-C
SPEC
QQ-S-741
MS-90724-125
QQ-S-741
MS-35337-48
MS-35691-805
QQ-S-741
QQ-S-741
QQ-S-741
QQ-S-741
QQ-S-741
QQ-S-741
QQ-S-741
NOTES:
1. QUANTITIES ARE FOR ONE LARC LX.
2. MATERIAL NOT SHOWN IS FURNISHED WITH COMPRESSOR OR RECLAIMED FROM PRESENT INSTALLATION.
2-52
FSN
4310-917-7352
4730-104-4380
5315-506-1447
4320-168-2023
9515-222-5048
5305-716-8128
9515-222-5040
5310-045-3298
5310-816-1030
9515-237-1861
9515-222-5048
9515-222-5040
9515-222-5090
9515-222-5040
9515-229-0196
9515-229-0196
REF
(1)
(1)
(1)
(1)
(1) (4)
(1)
(1) (2) (4)
(1)
(1)
(4) (6)
(2) (3)
(2) (4)
(2) (4)
(2) (4)
(2) (5)
(2) (5)
Figure 2-22. Installation of 3VC air compressor (Sheet 1 of 6).
2-53
Figure 2-22. Installation of 3VC air compressor (Sheet 2 of 6).
2-54
Figure 2-22. Installation of 3VC air compressor (sheet 3 of 6).
2-55
Figure 2-22. Installation of 3VC air compressor (sheet 4 of 6)
2-56
Figure 2-22. Installation of 3VC air compressor (Sheet 5 of 6).
2-57
Figure 2-22. Installation of 3VC air compressor (Sheet 6 of 6)
2-58
2-26. Hydraulic Master Pressure Pumps
a. General. Eight master pressure pumps (6 and 9. fig. 2-23) provide power for all, LARC hydraulic systems.
Four of the pumps have dual outlets rated at 36 and 11 gpm. The remaining pumps, also with dual outlets, are rated at
28 and 8 gpm. Four pumps, two of each configuration are mounted on each marine gear.
b. Removal.
(1) Close gate valve 110, fig. 2-23) in supply line to pump.
NOTE
When disconnecting flexible hoses in (2) and (3) below. provide a suitable container to drain hydraulic
fluid from hose.
(2) Disconnect pump suction flexible hose (7).
(3) Disconnect flexible hoses (1 and 3 or 8).
(4) Remove six bolts (11) and lockwashers (12) that secure pump (6 or 9) to marine gear.
(5) Pull pump straight out of marine gear.
(6) If pump is to be replaced, remove elbows (2,4, and 5) or elbows (4 and 5) and adapter (18), elbows (16).
nipple C17J), and close nipple (15) and retain for installation.
c. Installation.
(1) If a new pump is being installed, remove six screws (14, fig. 2-23) and position pump mounting plate (13)
on pump body in the same location as the old pump mounting plate, then install screws (14).
(2) If a new pump is being installed, install elbows 12, 4, and 5) or elbows (4 and 5) and adapter (18), elbows
(16), nipple (17), and close nipple (15) on pump.
(3) Position pump (6 or 9) on marine gear pump housing and install six bolts (11) and lockwashers (12).
NOTE
Make certain pump splined shaft fits properly into internal spline in marine gear. Figure 2-23 shows starboard pump arrangement. port is opposite.
(4) Connect pump suction flexible hose (7) and flexible hoses (1 and 3 or 8).
(5) Open gate valve (10) in supply line to pump.
(6) Operate marine gear and check hydraulic fluid level in hydraulic tank through sight gage. Replenish as
necessary (LO 55-1930-203-12).
2-59
Figure 2-23. Hydraulic master pressure pump, removal and installation.
2-60
Key to figure 2-23
1
Hose, flexible fan supply
2
Elbow, 90°, 1 1/4 in.
3
Hose, flexible, ramp and bilge pump supply
4
Elbow, 90°, 2 in.
5
Elbow, 90°, 34 in.
6
Pump, pressure, hydraulic master (28 and 8 gpm)
7
Hose, flexible, pump suction
8
Hose, flexible, steering supply
9
10
12
13
14
15
16
17
18
Pump, pressure, hydraulic master (36 and 11 gpm)
Valve, gate
11
Bolt, pump mounting
Lockwasher
Plate, pump mounting
Screw
Nipple, close
Elbow,.90°, 1 1/4 in.
Nipple, long
Adapter
2-27. Marine Gear Assembly
a. Removal
(1) Drain lubricant from marine gear (TM 55-1930-203-20).
(2) Remove gathering box-to-marine gear flexible coupling (para 2-22).
(3) Remove intermediate shaft as outlined in paragraph 2-28.
(4) Remove marine gear-to-air compressor flexible coupling (para 2-24).
(5) Remove the four hydraulic master pressure pumps (para 2-26).
(6) Disconnect marine gear-to-filter flexible hose (24, fig. 2-24).
(7) Disconnect pump-to-filter flexible hose (23).
(8) Disconnect oil supply-to-oil cooler flexible hose (11).
(9) Remove adapter (18), reducer (17), and close nipple (16) from oil pump and retain for installation.
(10) Disconnect oil supply-from-oil cooler flexible hose (8).
(11) Remove adapter (7), reducer (6), close nipple (5), and elbow (4) from lubrication manifold and retain for
installation.
(12) Disconnect marine gear grease line (12
).
(13) Disconnect marine gear breather tube (3) and move clear of marine gear.
(14) Remove elbow (10) and bushing (9) and retain for installation.
(15) Disconnect control air tubes (13) at control valve and watertight bulkhead. Tag tubes so they may nbe i
stalled in same position from which they were removed.
(16) Disconnect pneumatic tubes (2) from watertight bulkhead and move clear of marine gear. Tag tubes so
they may be installed in same position from which they were removed.
(17) Remove bilge pump hydraulic lines (1)
NOTE
These lines are welded to watertight bulkhead and contain hydraulic fluid.
(18) Remove dunnage from cargo well deck area between frames 7 and 10 to afford access to steel deckt- pla
ing.
NOTE
The marine gear is located between frames 8 and 9.
(19) Remove marine gear access cover as outlined in paragraph 11-4. If the LARC is not equipped with marine
gear access covers, a section of deck plating above each marine gear must be removed to gain access. With a cutting
torch, cut a section of deck plating measuring 4 feet, 2 inches wide (measured from cargo well bulkhead on respective
marine gear side) and 6 feet, 8 inches long, Remove section of deck plating.
NOTE
Cover marine gear with an asbestos blanket for protection from the cutting torch.
(20) With suitable hoisting equipment, attach hoisting slings to marine gear.
(21) Remove eight nuts (14, fig. 2-24) and lockwashers (15) and six bolts (20).
(22) Remove two fitted mounting bolts (22) and mark as to location.
(23) Remove two bolts (26) and lockwashers (25).
(24) Raise marine gear slightly and remove shims (19, 21, and 27) and mark asto location.
(25) Lift marine gear clear of LARC structure.
b. Installation.
(1) With suitable hoisting equipment, attach hoisting slings to marine gear.
(2) Position shims (19, 21, and 27, fig. 2-24) in proper position on marine gear foundation.
(3) Lift marine gear and lower into proper position on marine gear foundation.
(4) Install two fitted mounting bolts (22), sixbolts (20) and eight lockwashers (15) and nuts (14).
(5) Install two bolts (26) and lockwashers (25).
(6) Connect marine gear-to-filter flexible hose (24).
(7) Connect pump-to4filter flexible hose (23).
(8) Install close nipple (16), reducer (17), and adapter (18) on oil pump.
(9) Connect oil supply-to-oil cooler flexible hose (I1).
(10) Install elbow (4), close nipple (5), reducer (6), and adapter (7), on lubrication manifold.
(11) Connect oil supply-from-oil cooler flexible hose (8).
2-61
(12) Connect marine gear grease line (12).
(13) Install bushing (9) and elbow (10) on marine gear.
(14) Connect marine gear breather tube (3).
(15) Connect bilge pump hydraulic line (1).
(16) Connect pneumatic tubes (2) to watertight bulkhead.
(17) Connect control air tubes (13) to control valve. and watertight bulkhead.
(18) Install the four hydraulic master pressure pumps (para 2-26).
(19) Install marine gear-to-air compressor flexible coupling (para 2-24).
(20) Install intermediate shaft as out
lined in paragraph 2-28.
(21) Install gathering box-to-marine gear flexible coupling (para 2-22).
(22) Add proper lubricant to marine gear and fill hydraulic system (LO 55-1930-203-12).
(23) Install marine gear access cover (para 11-4). If the LARC is not equipped with marine gear access covers,
e- r
place deck plating and weld in place (para 11-3 for welding procedures).
(24) Replace dunnage in cargo well area.
43 Adapter
44 Hose, flexible, lube manifold-to-bevel pinion
input shaft bearings
45 Elbow, 90°
46 Elbow, 45°
47 Lube manifold
48 Capscrew
49 Lockwasher
50 Hose, flexible, lube manifold-to-rever
se gear
mesh
51 Hose, flexible, lube manifold-to4thrust bearing
52 Hose, flexible, lube manifold-to-idler gear
mesh
53 Hose, flexible, lube manifold-to-high speed
pinion shaft intermediate bearing
54 Hose, flexible, lube manifold-to-bevel gear
mesh
55 Hose, flexible, lube manifold-to-pump cluster
drive gears and bearings
56 Adapter, pipe-to-hose, 90°
57 Oil pump
58 Key
59 Gasket, oil pump mounting
60 Bearing
61 Adapter, pump mounting
62 Spur gear, oil pump drive
63 Setscrew
64 Hose, flexible,oil pump-to-control valve
65 Swivel joint
66 Capscrew
67 Elbow, 45°
68 Hose, flexible, marine gear clutch line-fromcontrol valve
69 Elbow, 90°
70 Swivel joint
71 Hose, flexible, exhaust line from control valveto-main housing
72 Hose, flexible, marine gear clutch line-fromcontrol valve
73 Control valve
74 Lockwasher
75 Capscrew
Key to Figure 2-24
1
Line, hydraulic, bilge pump
2
Tube, pneumatic
3
Tube, breather, marine gear
4
Elbow, street, 90°
5
Nipple, close
6
Reducer, bell
7
Adapter
8
Hose, flexible, oil supply-from-oil cooler
9
Bushing
10 Elbow, 45°
11 Hose, flexible, oil supply-to-oil cooler
12 Line, grease, marine gear
13 Tube, control air
14 Nut
15 Lockwasher
16 Nipple, close
17 Reducer, bell
18 Adapter
19 Shim, mounting
20 Bolt, machine
21 Shim, mounting, fitted
22 Bolt, mounting, fitted
23 Hose, flexible, pump-to-filter
24 Hose, flexible, marine gear-to-filter
25 Lockwasher
26 Bolt, machine
27 Shim, mounting
28 Cable assembly
29 Switch, high temperature warning
30 Bushing
31 Bushing
32 Nipple
33 Pressure regulating valve
34 Bushing
35 Cable assembly
36 Sending unit, low pressure warning
37 Tubing, marine gear oil pressure
38 Tee
39 Bushing
40 Cross
41 Nipple
42 Reducer, bell
2-62
Figure 2-24. Marine gear, removal and installation (Sheet 1 of 2)
2-63
Figure 2-2. Marine gear, removal and installation (Sheet 2 of 2).
2-64
2-28. Propeller and Shafting
a. Propeller Removal (fig. 2-25).
(1) Remove lockwire from lockbolt (1) and fairwater nut (2) and remove lockbolt.
NOTE
On hulls 5 through 18, the starboard lockbolt had a right-hand thread, and the port kloc
bolt, a Ieft-hand thread as original equipment. On hulls 19 through 60, both
lockbolts
have right-hand threads.
(2) Remove fairwater nut (2).
NOTE
On hulls 5 through 18, the starboard fairwater nut had left-hand threads, and the port
fairwater nut, right-hand threads as original equipment. On hulls 19 through 60, both
fairwater nuts have left-hand threads.
(3) Remove propeller (3), using propeller puller, part number LX09-032-001, and remove key (4) from keyway
on propeller shaft (5).
b. Installation of Propeller. Install propeller in the reverse order of removal, except when installing propeller on shaft
(5), press or tap with soft-faced hammer until propeller is flush with rope guard (7).
c. Intermediate Shaft Removal (fig. 2-25).
(1) Remove self-locking nuts (23) and shoulder bolts (15) from intermediate shaft (24) coupling closest to the
propeller shaft.
(2) Slide propeller shaft aft slightly and remove flexible inserts (21).
(3) Remove self-locking nuts (25) and shoulder bolts (29) from intermediate shaft (24) coupling closest to marine
gear hub (28). Remove intermediate shaft and flexible inserts (21 and 27).
d. Installation of the Intermediate Shaft. Install the intermediate shaft in reverse order of removal.
e. Propeller Shaft Removal (fig. 2-25).
(1) Remove propeller (para a above).
(21 Repeat steps c(1) and c(2) above if intermediate shaft has not been removed.
(3) Remove capscrews (20) and lockwashers (19) which secure nut lockwasher (18) and remove nut lockwasher.
(4) Remove shaft nut (17) and remove propeller shaft hub (16).
(5) Remove key (6) from propeller shaft (5) and ide
sl propeller shaft aft out of stern tube (9) and propeller strut
tube (8).
f Installation of the Propeller Shaft (fig. 2-25).
(1) Remove capscrews (14) and washers (13) and slide packing gland (12) out of stern tube 19).
(2) Remove packing retainer (11) and packing (I0).
(3) Insert propeller shaft (5) through propeller strut tube (8) and stern tube (9).
(4) Slide packing retainer (11) and packing gland (12) on propeller shaft.
(5) Install key (6) and propeller shaft hub (16) on propeller shaftnd
a tighten shaft nut (17).
(6) Install nut lockwasher (18) and secure with capscrews (20) and lockwashers (19).
(7) Install flexible inserts (21) between propeller shaft and intermediate shaft (24), Using shoulder bolts (15) and
self-locking nuts (23).
(8) Install propeller (para b above).
NOTE
Check fit of propeller to shaft with Prussian blue, Military Specification MIL-P-30501, fit
must be at Ieast 80 percent of total surface.
(9) Install packing (10) and slide packing retainer (11) and gland12)
( down shaft into stern tube (9).
(10) Install capscrews (14) and washers (13) and tighten capscrews sufficiently to prevent leakage.
CAUTION
Do not overtighten capscrews as It will result in overheating of propeller shaft. If the
propellers cannot, be turned by hand, packing gland is too tight.
2-65
Figure 2-25. Propeller and shafting, removal and installation.
2-66
Key to figure 2-25
16 Propeller shaft hub
17 Nut, shaft
18 Nut lockwasher
19 Lockwasher
20 Capscrew
21 Flexible insert
22 Bushing, thrust
23 Nut, self-locking
24 Intermediate shaft
25 Nut, self-locking
26 Bushing, thrust
27 Flexible insert
28 Marine Gear hub
29 Bolt, shoulder
1 Lockbolt
2 Nut, fairwater
3 Propeller
4 Key, propeller
5 Propeller shaft
6 Key, propeller shaft hub
7 Rope guard
8 Strut tube,
9 Stern tube
10 Packing
11 Packing retainer
12 Packing gland
13 Washer
14 Capscrew
15 Bolt, shoulder
2-29. REPLACE RAMP CYLINDER.
a. Removal. (fig. 2-26).
(1) Raise the ramp and engage both ramp latches (TM 55-1930-203-10).
WARNING
Tag ramp latches to indicate ramp hydraulic system is being repaired. Releasing latches with rampl-cy
inder removed could result in major structural damage and injury to personnel.
WARNING
Failure to relieve cable tension could result in serious injury to personnel removing ramp cylinder.
(2) Place ramp control valve in lower position to relieve tension from ramp cables.
(3) Place ramp control valve in neutral po
sition and shut down LARC engines (TM 55-1930-203- 10).
(4) Disconnect hose lines (1) and (2) at fittings in relief valve (3). Cap hydraulic hose lines.
(5) Remove relief valve assembly (3) and install a ¾ inch pipe plug in cylinder opening.
(6) Remove cotter pin (4) and clevis pin (5) at ramp cylinder upper end.
(7) Remove ramp cylinder air vent (6).
(8) Provide support for ramp cylinder lower end and remove cotter pin (7) and ram pin (8).
(9) Using suitable hoisting equipment, lift ramp cyli
nder (9) through scuttle opening in LARC deck.
(10) Remove pipe plug installed in step 5 above and drain cylinder.
(11) Remove pipe union (10).
b. Installation.
(1) Lower ramp cylinder (9) into position and secure lower end with ram pin (8), and cotter pin (7).
(2) Install pipe union (10) and ramp cylinder air vent (6).
(3) Connect ramp cylinder upper end to ramp cable block with clevis pin (5) and cotter pin (4).
(4) Fill ramp cylinder (9) with engine oil, OE-10.
NOTE
Cylinder should be in fully compressed position
(5) Install relief valve assembly (3) and connect hose lines (1) and (2) to fittings in relief valve assembly (3).
(6) Start one engine on side opposite cylinder being installed (TM 55-1930-20310).
(7) Place control valve on side with engine running in raise position.
(8) Place control valve on side opposite running engine in lower position for approximately 3 minutes to allow
air to be forced from hydraulic lines. Return valve to neutral.
2-67
WARNING
If the ramp is not held fully closed by ramp cables, the weight of the ramp will cause the ramp latch lever
to swing sharply forward, possible striking the latch operator or throwing him overboard.
(9) With control valve on side with engine running still in raise position, release ramp latches.
Figure 2-26. Ramp Cylinder, Replacement.
(10) Place control valve on side with engine running in neutral position. Using control valve
on opposite side,
lower the ramp. When ramp is fully lowered, leave valve in lower position and place control valve on side with engine
running in raise position for approximately 3 minutes to insure that all air is forced from hydraulic lines.
(11) Raise the ramp and engage both ramp latches.
(12) Shut down engine.
2-68
2-29.1 REPLACE RELIEF VALVE, RAMP CYLINDER
Figure 2-26.1. Relief Valve, Ramp Cylinder, Replacement.
a. Removal.
(1) Lower ramp to ground to relieve pressure in hydraulicnes.
li
(2) Slowly unscrew hose lines (1) and (2) from adapters (3) and (4), allowing hydraulic fluid to seep around the
connection relieving any pressure in the lines. Disconnect hose lines (1) and (2).
(3) Remove adapters (3) and (4) from relief valve (5).
(4) Remove relief valve (5) from ramp cylinder (6).
b. Installation.
(1) Install new relief valve (5) on ramp cylinder (6).
(2) Install adapters (3) and (4) in relief valve (5).
(3) Connect hose lines (1) and (2) to adapters (3) and (4).
(4) While ramp is being raised, slightly loosen hose line fitting (2) off, allowing air in system to bleed out.
Tighten fitting (2) when there is continuous seepage of hydraulic fluid without air or air bubbles.
2-68.1
2-30. Steering Cylinder
a. Removal.
(1) Provide a suitable control for spillage and disconnect hydraulic lines (fig. 10-7 and 10-8). Cap lines toe-pr
vent excessive leakage.
(2) Cap openings in steering cylinder.
(3) Remove retaining ring (9, fig. 2-27) and clevis pin (1).
(4) Remove retaining ring (7), clevis pin (5), and thrust washers (6).
(5) Using suitable hoisting equipment, lift steering cylinder through deck opening.
(6) Remove plugs from hydraulic ports and drain hydraulic fluid from cylinder.
(7) Remove bushing (8) if elongated or heavily scored.
b.
Installation.
(1) If bushing (8, fig. 2-27) is removed, install new bushing and ream to 3.001 0.001 inch.
(2) Lower cylinder into position and install thrust washers (6), clevis pin (5), and retaining ring).(7
(3) Install clevis pin (1) and retaining ring (9).
(4) Fill cylinder with engine oil, OE-10. Remove caps and connect hydraulic lines.
(5) If cylinder being installed is in the alignment system, perform alignment procedures outlined in apar
graph 10-3. If an actuating cylinder is being installed, perform the following:
(a) Start engines and put LARC in motion (TM 55-1930-203-10). Turn wheels so cylinder being installed
in fully compressed.
(b) Open valve (3) on rod end and allow all air to ble
ed off. Close valve (3).
(c) Turn wheels so cylinder being installed is fully extended. Open valve (4) and allow all air to bleed off.
Close valve (4).
(d) Shut down engines.
2-68.2
2-31. Radiator Assembly
a. Removal (fig. 2-28).
(1) Drain cooling system in which radiator is located (TM 55-1930-203-20).
(2) Remove bolts (1), lockwashers (2). and remove radiator access plate (3) and gasket (4).
(3) Remove clamps (6 and 18) and disconnect hoses (7 and 17) from radiator.
(4) Remove bolts (22) and lockwashers (21) and remove stern louvers (23).
(5) Gain access to adjacent radiator and fan area and remove bolts (13), lockwashers (15), and nuts (16)
e- s
curing vane assembly (14) and remove vane assembly
(6) Remove bolts (25), lockwashers (20), and nuts (19) securing radiator (5).
(7) Lift radiator, using a suitable hoist and sling attached to radiator lifting eyes, out through radiator access
hole.
(8) Remove gaskets (24) and 8) from mounting supports.
b. Installation.
(1) Install gaskets (8 and 24), on mounting supports. Bottom gasket (8) must be watertight.
(2) Using a suitable hoist and sling attached to radiator lifting eyes, lower radiator (5)r in place on supports.
NOTE
Insure proper fit of radiator on bottom support.
(3) Secure radiator in place with bolts (25), lockwashers (20), and nuts (19).
(4) Remove hoisting gear from radiator.
(5) Secure vane assembly (14) with bolts (13), lockwashers (25), and nuts (16).
NOTE
In order for vane assembly to be secured, access to the adjacent radiator and fan area or areas must be
obtained.
(6) Connect hosed (7 and 17) to radiator and secure with clamps (6 and 18).
(7) Secure stern louvers (23) with bolts (22) and lockwashers (21).
(8) Position gaskets (4 and 9) and access plates (3 and 10) in place and secure with bolts (1 and 12) andk-loc
washers (2 and 11).
(9) Fill cooling system with coolant (TM 55-1930-203-20).
2-69
Figure 2-27. Steering cylinder removal.
Key to figure 2-28
1 Bolt, machine
2 Lockwasher
3 Radiator access plate
4 Gasket, radiator access plate
5 Radiator
6 Clamp, hose
7 Hose, radiator inlet
8 Gasket, radiator mounting, lower
9 Gasket, duct access plate
10 Duct access plate
11 Lockwasher
12 Bolt, machine
13 Bolt, machine
14 Vane assembly, lower
15 Lockwasher
16 Nut
17 Hose, radiator outlet
18 Clamp hose
19 Nut
20 Lockwasher
21 Lockwasher
22 Bolt, machine
23 Stern louvers
24 Gasket, radiator mounting, upper
25 Bolt, machine
2-70
Figure 2-28. Radiator, removal and installation
2-71
2-32. Radiator Fan Assembly
a. Removal
(1) Remove access cover (10, fig. 2-28) to radiator fan area.
(2) Provide a suitable container for spillage and disconnect radiator fan motor outlet line and vent line at motor.
(3) Disconnect inlet line at flexible hose, (2, fig. 10-5).
(4) Remove bolts (1, fig. 2-29) and washers (2) ecuring
s
grating (3) to LARC deck. Remove grating (3).
(5) Remove nuts (4) and washers (5).
(6) Using suitable hoisting equipment, lift radiator fan assembly through deck opening.
b. Installation. Install radiator fan assembly in reverse order of removal.
Key to figure 2-29
1 Bolt, grating-to-deck
2 Washer, grating-to-deck
3 Deck grating
4 Nut, inlet adapter-to-deck
5 Washer, inlet adapter-to-deck
6 Inlet adapter
7 Nut, nose piece-to-motor shaft
8 Lockwasher, nose piece-to-motor shaft
9 Seal
10 Seal retainer
11 Washer, adapter-to-casing
12 Pipe
13 Elbow
14 Pipe adapter
15 Hydraulic motor
16 Nut, van assembly-to-casing
17 Washer, vane assembly-to casing
18 Vane assembly
19 Key
20 Nut, adapter-to-casing
21 Bolt, vane assembly-to-casing
22 Casing
23 Washer, motor-to-casing
24 Nut, motor-to-casing
25 Cotter pin
26 Rotor assembly
27 Spacer
28 Nose piece
29 Washer, nose piece-to-rotor assembly
30 Screw, nose piece-to-rotor assembly
31 Bolt, adapter-to-casing
2-72
Figure 2-29. Radiator fan assembly, removal and installation
2-73
2-33. Cargo Winch Assembly and Hydraulic Motor
a. Removal
(1) Remove wire rope from drum (para 10-9) or wind wire rope completely in and fasten end.
(2) Remove drain plug (41, fig. 2.30) and drain lubricant from winch into a suitable container. Replace drain plug.
(3) Remove pin (36) and disconnect shift linkage rod (35).
(4) Remove wire rope guard (2) by removing bolts (1),
lockwashers (6), and nuts (7).
(5) Remove capscrews (39) and lockwashers (40); loosen capscrews (38).
(6) Remove capscrews (3) and remove brake cover (4).
CAUTION
Care should be used when removing brake cover (4) to avoid damaging pins (43).
(7) Remove pins (43).
(8) Reach into brake drum and remove brake cable locking nut (42).
(9) Remove setscrews (37) and pull brake cable (34) from winch.
(10) Remove bolt (32), lockwasher (33), and nut (26) securing aft port leg of winch to deck.
(11) Remove bolts (8), lockwashers (9), and nuts (I 1) securing remaining three legs of winch to deck.
(12) Loosen nuts (23) as far as possible. Raise winch until nuts (23) are snug against adapter (15). Remove nuts
(23) and lockwashers (22).
(13) Lift winch from deck.
CAUTION
Winch must be lifted straight up to avoid damage to bevel gear (16) or shaft of hydraulic motor (27).
NOTE
To remove the winch hydraulic motor perform steps (14) through (19).
(14) Remove gasket (19).
(15) Remove bevel gear (16).
(16) Make sure motor controls are in off position, provide a suitable container for spillage, and disconnect motor
inlet hose (31).
(17) Disconnect motor outlet hose (30) and overflow hose (28).
(18) Remove adapter (10) and elbows (25 and 29).
(19) Remove capscrews ( 12) and lockwashers (13) and lift motor (27) and adapter (15) from deck.
(20) Remove gasket (14), nuts (20) and lockwashers (21).
(21) Remove snap ring (17).
(22) Using a sleeve to protect bearing races, pull adapter (15) away fromotor
m (27) and off bearing (18). Remove
gasket (24).
(23) Pull bearing (18) from shaft, exerting pressure on inner race.
b. Installation.
(1) Place snap ring (17) on bearing (18) and press bearing into adapter (15).
(2) Position gasket (24) on motor (27) and press adapter (15) and bearing (18) onto motor shaft.
(3) Install lockwashers (21) and nuts (20).
(4) Install gasket (14) and fasten adapter (15) to deck with capscrews (12) and lockwasher (13).
(5) Install elbows (25 and 29) and adapter (10).
(6) Connect outlet hose (30), inlet hose (31), and overflow hose (28).
1 Bolt, machine
2 Wire rope guard
3 Capscrew
4 Brake cover
5 Cargo winch
6 Lockwasher
7 Nut
8 Bolt, machine
9 Lockwasher
10 Adapter
11 Nut
12 Capscrew
13 Lockwasher
14 Gasket, adapter-to-deck
15 Winch adapter
16 Bevel gear
I7 Snap ring
18 Bearing
19 Gasket, adapter-to-winch
20 Nut
21 Lockwasher
Key to figure 2-30
22 Lockwasher
23 Nut
24 Gasket, motor4to-adapter
25 Elbow
26 Nut
27 Hydraulic motor
28 Overflow hose
29 Elbow
30 Outlet hose
31 Inlet hose
32 Bolt, machine
33 Lockwasher
34 Brake cable
35 Shift linkage rod
36 Shift linkage pin
37 Setscrew
38 Capscrew, drum shaft cover lower
39 Capscrew, drum shaft cover upper
40 Lockwasher
41 Drain plug
42 Nut
43 Brake cover pin
2-74
Figure 2-30. Cargo winch assembly and hydraulic motor, removal and installation
2-75
Install bevel gear (16).
(7) Place four shims, approximately ¼ inch thick, on deck over winch leg mounting holes. Position gasket (19).
(8) Lower winch so that legs rest on shims and winch mounting studs line up with holes in adapter (15).
CAUTION
Winch must be lowered from directly above mounting position to avoid damaging bevel
gear (16) or shaft of hydraulic motor (27).
(9) Install lockwashers (2-2) and nuts (23), leaving nuts finger tight.
(10) Remove shims from under winch legs and lower winch to deck.
(11) Tighten nuts (23).
(12) Install bolt (32), lockwasher (33), and nut (26) securing aft port leg of winch to deck.
(13) Install bolts (8), lockwashers (9), and nuts (11 securing remaining three legs of winch to deck.
(14) Insert brake cable (34) into winch and install cable locking nut (42).
(15) Install setscrews (37).
(16) Insert pins (43) in winch housing and position brake cover (4) on housing, using pins (43) for alignment.
(17) Install capscrews (3 and 39) and lockwashers (40) and tighten capscrews (38).
(18) Install wire rope guard (2) with bolts (1), lockwashers (6), and nuts (7).
(19) Connect shift linkage rod (35) by inserting pin (36).
(20) Fill winch with proper grade lubricant (LO 55-1930-203-12).
(21) If wire rope was removed from drum, install wire rope (para 10-9).
2-34. Bilge Pump Assembly
a. Removal (fig. 2-31).
(1) Shut off gate valve in hydraulic feed line at pressure pump.
(2) Disconnect hydraulic return line 16) and hydraulic input line (4) from bilge pump motor (2) and tag for reassembly.
(3) Loosen hose clamps (7) from coupling hose (5) atdischarge side of pump.
(4) Remove three bolts (1) and nuts (9) that secure bilge pump (8) to support brackets and remove pump asse
mbly.
(5) Separate pump motor (2) from pump by removing four bolts (31.
b. Installation. Install bilge pump assembly in reverse order of removal.
2-76
Figure 2-31. Bilge pump assembly, removal and installation
2-77
2-35. Cargo Well Pump Motor
a. RemovaL
(1) Disconnect hydraulic lines (2, fig. 2-32) and drain line (1) from pump motor (4).
NOTE
Provide a suitable container to catch hydraulic fluid trapped in lines.
(2) Remove coupling pin (5) and four socket-head capscrews (3) securing motor to pump.
(3) Work motor shaft out of pump coupling and lift off motor.
(4) Remove fittings from motor and retain for installation.
b. Installation. Install cargo well pump motor in reverse order of removal.
2-78
Figure 2-32. Cargo well pump and pump motor, removal and installation.
2-79
2-36. Cargo Well Pump Assembly
a. Removal (fig. 2-32).
(1) Remove fuel tank (para 4-2).
(2) Close oiler metering valve ( 16) in oiler line (15).
(3) Disconnect oiler line at packing ring on pump.
(4) Remove bolts (17), lockwashers (14), and nuts (13) and lift off oil tank (18).
(5) Disconnect hydraulic lines (2) and drain line (1) from pump motor (4).
NOTE
Provide a suitable container to catch hydraulic fluid trapped in lines.
(6) Loosen nuts (10) on coupling (12) between cargo well pump (6) and overboard tube (11). Slide coupling
(12) up away from joint. Tighten several nuts slightly to prevent coupling from slipping off overboard tube.
(7) Remove bolts (7) and lockwashers (8) which secure pump flange to reinforcing ring. Be careful not to
damage neoprene gasket (9).
CAUTION
Before proceeding, inspect both the inside and outside of the cargo well pump area to
ascertain that any obstructions that could interfere with the lifting operation or could
damage the equipment have been removed.
(8) Position crane boom, or other suitable hoist, directly over cargo well pump.
(9) Secure lifting cables to cargo well pump.
(10) Raise cargo well pump and position in predetermined area.
CAUTION
The cargo well pump should be guided by hand until it is clear, to prevent damage to the
pump or surrounding area.
(11) Remove neoprene gasket (9).
b. Installation. Install cargo well pump in the reverse order of removal. Adjust oiler metering valve (16) to meter
3 to 5 drops per minute.
2-80
CHAPTER 3
REPAIR OF DIESEL ENGINE, EXHAUST PIPING
AND MUFFLER ASSEMBLY
Section I. INTRODUCTION
3-1. General
This chapter contains the repair and overhaul of the diesel engine assembly. Information is provided on disassembly,
reassembly, testing and adjustment of the engine and engine components.
3-2. Engine Description
There are four series 71 Detroit Diesel Engines used on the LARC. The engines are two cycle, six cylinder, inline engines
having a 165 continuous horsepower rating at 2100 rpm. Each engine is equipped with an air starting motor, a forced
feed fuel injection system, a full pressure lubrication 3-3. Testing Engine For Misfiring Cylinder system. and a circulating
fresh water cooling system. Engine speed is controlled by a limiting speed governor coupled to the engine fuel system to
limit the flow of fuel oil for engine speed control. Two different models of the series 71 engine are used on the LARC.
Specific model differences and engine model locations are contained in TM 55-1930-203-10. Component locations on
the engines will vary due to the different model engines used and their physical locations on the LARC, but all systems,
testing and repair procedures described herein will apply to both types of engines.
Section II. ENGINE TESTING
3-3. Testing Engine for Misfiring Cylinder
a. Start engine and run at 600 rpm until normal operating temperatures are obtained (TM 55-1930-203-10).
b. Remove rocker cover (TM 55-1930-203-20).
c. Run engine at idle speed (550 rpm) and check valve clearance. Valve clearance should be 0.009 inch.
d. Hold the number 1 injector follower down with a screwdriver as shown in figure 3-1. This prevents operation of
the fuel injector so that the number 1 cylinder does not receive fuel and will not fire.
e. If cylinder number 1 has been firing properly, there will be a noticeable difference in the sound and operation of
the engine. If number 1 cylinder has been misfiring, there will be no change in the sound and operation.
f. If number 1 cylinder is firing properly, repeat the procedure for the five other cylinders or until the misfiring
cylinder is located.
3-4. Testing Engine Compression Pressure
a. Start engine and run at 600 rpm until normal operating temperatures are obtained (TM 55-1930-203-10).
b. Stop engine (TM 55-1930-203-10).
c. Remove fuel injector from cylinder number 1 (para 3-10).
d. Install compression pressure gage (1, fig. 3-2) in fuel injector port (2). Use a suitable adapter for port and gage.
e. Install one of the two fuel pipes removed as a jumper connection between the fuel inlet and return manifold, to
permit fuel flow to bypas the removed injector.
3-1
1 Compression pressure gage
2 Fuel injector post
Figure 3-1. Locating & misfiring cylinder
Figure 3-2. Testing compression pressure.
3-2
Figure 3-3. Fuel pipes and fuel connectors, removal and installation.
f. Start engine (TM 55-1930-203-10). Advance throttle until engine runs at 600 rpm. Observe and record
compression pressure on number 1 cylinder.
NOTE
More accurate and informative readings are obtained if the compression pressure is taken
while the engine is operating under a load condition. This condition can best be obtained
with the LARC in the water and the marine gear engaged. The LARC can be held against
a pier to simulate a full load condition.
g. After reading has been taken on the number 1 cylinder, install the number 1 injector (para 3-10) and repeat the
procedure for the other five cylinders.
h. The compression pressure of any one cylinder should not be less than 400 psi at 600 rpm. In addition, the
variation in pressure between any two cylinders must not exceed 25 psi at 600 rpm.
Section Ill. ROCKER ARM ASSEMBLY AND CYLINDER HEAD ASSEMBLY
3-5. Rocker Arm Assembly
a. Removal and disassembly.
(1) Remove rocker cover (TM 55-1930-203-20).
(2) Remove fuel pipes (9, fig. 3-3) from injector assembly (8) and fuel connectors (6). Install shipping caps (7)
over fuel fittings on injector assembly.
(3) Remove bolts (1, fig. 3-4) securing rocker shaft brackets 12) to cylinder head. Remove rocker shaft brackets
and rocker shaft (6).
CAUTION
When removing rocker shafts, fold back the three rocker arms just far enough so that the shaft may be
removed. Do not force the rocker arms all the way back with the shaft in place as this may impose a load
that could bend the push rods.
(4) Loosen locknuts (11) and unscrew rocker arms from push rods (16). Tag rocker arms for reassembly.
Remove locknuts.
(5) Install push rod remover (4, fig. 3-5), flat washer (3), and locknut (2), with lower end of push rod remover
resting on upper push rod spring seat (13, fig. 3-4).
(6) Screw locknut down on upper end of push rod, thus compressing push rod spring (14) and relieving tension
on retaining ring (12).
(7) Snap retaining ring open with a screwdriver as shown in figure 3-4, and remove retaining ring.
(8) Remove locknut and flat washer from push rod remover. Remove push rod remover.
(9) Pull push rod (16, fig. 3-4), spring. (14), and seats (13 and 15) out through top of cylinder head.
3-3
NOTE
When pulling the push rod through the opening, the cam follower assembly may come out
of it.
(10)
Repeat steps (5) through (9) above for removing the other two push rods on the cylinder.
Figure 3-4. Rocker arm assembly
3-4
b. Cleaning, Inspection, and Repair.
(1) Wash all parts in clean fuel oil and wipe them dry
with a clean, lint-free cloth. Using a small wire, clean out oil
passages in rocker arms (3 and 4, fig. 3-4), rocker shaft (6),
and rocker shaft bracket bolts (1). Blow out each passage with
compressed air.
(2) Inspect rocker shaft (6) and brackets (2) to see
that they are not bent. Check bearing surfaces for scoring.
Replace badly scored or damaged shafts or brackets.
(3) Examine hardened pallet on rocker arms (3 and
4). If pallet is pitted or shows signs of wear, replace rocker
arm.
(4) Using a micrometer and caliper, check
dimensions and clearances of shaft, rocker arm, and rocker
arm bushings (table 1-1). If parts are worn beyond tolerances
listed in table 1-1, replace worn parts.
(5) If the clearance between bushings is excessive,
replace bushings. To replace a bushing proceed as follows:Figure 3-5. Removing push rod from cylinder head.
(a) Secure rocker arm in a vise. Knock out old bushing, using a wooden block and hammer.
(b) Press-fit new bushing into rocker arm.
(c) Ream inside diameter of bushing to produce desired clearance listed in table 1-1.
(6) Examine push rods (16) for being bent. Replace a bent push rod.
(7) Examine springs (14) and retaining rings (12) for loss of tension. Replace defective springsand retaining
rings.
NOTE
Free length of spring is 2 5/8 inches. Replace spring when a load of less than 172 pounds
will compress it to a length of 2 1/8 inches.
(8) Examine upper and lower push rod spring seats (13 and 15) for burring. See that springs fit properly in seats.
Replace spring seats if defective.
c. Reassembly and Installation.
(1) Install lower push rod spring seat (15, fig. 3-4), spring (14), and upper rod spring seat (13) on push rod (16),
and insert the assembly in bore in cylinder block and down into the cam follower.
NOTE
If cam follower was removed during disassembly, insert it into the bore first, positioned
with oil hole in bottom of the follower over trailing edge of roller (hole toward outside of
cylinder head).
(2) Install flat washer (3, fig. 3-5) and locknut (2) on push rod. Place push rod remover (4) on push rod between
washer and upper spring seat.
(3) Screw locknut on push rod until spring is compressed sufficiently to permit retaining ring (5) to be inserted in
bore.
(4) Partially collapse and install retaining ring.
(5) Remove locknut and flat washer on outer end of push rod remover and remove push rod remover.
(6) Screw locknut (11, fig. 3-4) down as far as possible on push rod (16). Screw rocker arm clevis (10) down on
push rod, until end of push rod is flush with bottom of clevis.
NOTE
The injector rocker arm (4) is slightly different from the exhaust valve rocker arms (3). The
boss for the shaft on the exhaust valve rocker arms is longer on one side of the arm than
on the other. The extended boss of each exhaust valve rocker arm must face the injector
rocker arm.
CAUTION
When a push rod has been disconnected from a clevis, the push rod must be
screwed into the clevis until the end of the rod is flush with the bottom of the clevis
yoke. If this is not done before valve clearance is adjusted, the valve may strike the
piston when the crankshaft is turned and cause serious damage to the engine.
3-5
(7) Apply clean engine oil on surface of rocker arm shaft and slide shaft through rocker arms.
(8) Place brackets (2) over ends of rocker shaft with finished face of bracket next to rocker arm.
(9) Position rocker arm shaft bracket bolts (1) in place through brackets and shaft. Tighten bolts to a torque of
90 to 100 foot-pounds.
(10) Remove shipping caps from fuel fittings on injector assembly and connect fuel pipes from injector to fuel
connectors. Tighten connectors to a torque of 12 to 15 foot-pounds.
CAUTION
Do not exceed the specified torque. Excessive tightening will twist or fracture the flared
ends of the fuel pipes and result in leaks.
(11) Adjust valve clearance to O.012 inch with engine cold (TM 55-1930-203-20).
(12) Start engine (TM 55-1930-203-10).
(13) While engine is running in preparation for final valve adjustment, inspect fuel lines for possible leaks. If
leaks at connections are discovered, tighten nut at fuel connection carefully to a torque of 12 to 15 foot-pounds.
CAUTION
Tighten all fuel leaks immediately. Fuel oil which leaks into the crankcase will dilute the
lubricating oil and thus cause serious damage to the engine bearings.
(14) When engine has reached normal operating temperatures, adjust valve clearances to 0.009 inch and stop
engine (TM 55-1930-203-20).
(15) Install rocker cover (TM 55-1930-203-20).
3-6. Cylinder Head
a. General. The cylinder head is a one-piece alloy iron casting securely held to the upper deck of the cylinder block
by steel studs and nuts. Hardened exhaust valve seats pressed into the cylinder head furnish accurate seating or the
valves and prolong cylinder head life. To insure efficient cooling, each injector tube, exhaust valve seat, and exhaust
passage is surrounded by water. Nozzles installed in the cylinder head water inlet ports, direct water to the parts of the
head subjected to the highest combustion temperatures. Compression is sealed by flat laminated metal gaskets, while oil
and water leaks are prevented by seal rings. The cylinder head is removed as an assembly containing cam followers and
guides, push rods, rocker arms, exhaust valves, and injectors.
b. Removal.
(1) Drain cooling system below level of engine (TM 55-1930-203-20).
(2) Disconnect exhaust piping and remove exhaust manifold from engine (para 3-7).
(3) Remove air cleaners (TM 55-1930-203-20).
(4) Remove rocker cover and gasket (TM 55-1930-203-20).
(5) Disconnect water hose and remove thermostat.
(6) Remove water temperature sending unit (11, fig. 3-6) and sensing unit (6) from water manifold.
(7) Remove fuel filters.
(8) Remove governor control housing assembly (para 3-13).
(9) Remove governor-throttle controls (fig. 3-7).
(10) Remove injector control tube assembly (para 3-9).
(11) Remove fuel pipes (9, fig. 3-3) from injectors (8) and fuel connectors (6).
(12) Loosen rocker arm shaft bracket bolts (5, fig. 3-3) to facilitate removal after cylinder head is removed from
engine.
Key to figure 3-6.
1
Tube, 5/8 in. od
2
Gasket, water outlet manifold
3
Stud, water outlet manifold
4
Elbow
5
Socket, water temperature gage
6
Water temperature sensing unit
7
Lockwasher
8
Nut
9
Water manifold
10 Connector, electrical
11 Water temperature sending unit
12 Gasket, thermostat housing
13 Thermostat housing
14 Gasket, outlet manifold
15 Thermostat
16 Outlet elbow
17 Bolt, machine
18 Lockwasher
19 Tube
3-6
Figure 3-6. Water manifold.
Figure 3-7. Governor-throttle controls
3-7
(13) Loosen two bolts which are directly below each lifter bracket and which attach balanceweight cover and
flywheel housing to front and rear plates, respectively. This prevents threaded ends of bolts, which may be bearing
against cylinder head, from interfering with cylinder head removal.
(14) Remove two bolts (12, fig. 3-37) which secure front lifter bracket to balance weight cover.
(15) Remove two bolts (12, fig. 3-7) which secure rear lifter bracket to flywheel housing.
(16) Remove cylinder head stud nuts (10, fig. 3-3).
(17) Insert lifting hooks of hoist in eyes of front and rear lifter brackets. Raise cylinder head uniformly off cylinder
head studs.
(18) Remove cylinder head compression gaskets and oil and water seals.
(19) Set cylinder head on a suitable stand.
CAUTION
Do not set cylinder head with bottom face down on the bench; otherwise, the cam
followers and injector spray tips which project below the bottom surface of the
head will be damaged.
Key to figure 3-8.
1
Follower body
2
Roller pin
3
Cam roller
4
Cam follower
5
Lockwasher
6
Capscrew
c.
Disassembly.
(1) Remove bolts attaching lifter brackets to cylinder head.
Remove lifter brackets.
(2) Remove fuel injectors (para 3-10).
(3) Remove water manifold (para 3-8).
(4) Remove rocker arm assembly (para 3-5).
(5) Remove fuel oil connectors (4, fig. 3-35) and manifolds (7
and 10, fig. 3-35) if manifolds are not cast as part of the cylinder
head (para 3-11).
(6) Remove and disassemble cam followers as follows:
(a) Rest cylinder head on its side and remove capscrews (6, fig. 3-8) that secure cam follower guide (4) to cylinder
head. Remove guide.
Figure 3-8. Cam follower assembly.
(b) Pull cam follower from bottom of cylinder head.
(c) Place cam follower holder fixture, part no. J5840, in
a vise and tighten securely (fig. 3-9).
(d) Place cam follower in groove in top of fixture with
roller pin (2, fig. 3-8) resting on top of corresponding size plunger
in fixture.
(e) Using suitable drift, drive roller pin (2, fig. 3-81 from
roller (fig. 3-9) Exercise care in removing cam follower body (1,
fig. 3-8) and cam roller (3) from fixture as follower pin is seated on
top of a spring loader plunger in fixture body.
(f) Remove cam roller (31 from follower body (1).
(7) Remove exhaust valves as follows:
(a) Place cylinder head so that valve heads are resting
on a block of wood.
(b) With a spring compressor, press down on spring e
rtainer 13, fig. 3-10) to compress valve spring (7). Remove valve
spring retainer lock (12).
Figure 3-9. Removing or installing cam follower roller
and pin with cam follower fixture, part No. J5840.
3-8
(c)
(d)
(e)
(f)
Release spring compressor and remove retainer (3) valve spring (7), and washer (4).
Repeat steps (b) and (c) above until all valve springs have been removed.
Turn cylinder head over, -using care to prevent exhaust valves (1) from dropping out.
Number each valve to assure reinstallation in the same valve seat insert. (5). Withdraw valves from cylinder
head.
1
2
3
4
5
6
7
Exhaust valve
Valve spring retainer lock
Spring retainer
Washer
Valve seat insert
Valve Guide
Valve spring
Figure 3-10. Exhaust valve, guide, and seat insert
(8)
Remove valve guides.
NOTE
Refer to subparagraph d and inspect valve guides in cylinder head to prevent unnecessary
removal.
(a) Support cylinder head bottom up on wood blocks about 2 inches thick.
(b) Drive valve guides (6, fig. 3-10) out, using valve guide remover, part no. J267.
(9) Remove valve seat inserts.
NOTE
Refer to subparagraph d and inspect valve seat inserts in cylinder head to prevent
unnecessary removal.
(a) Turn cylinder head on side and place collet (4, fig. 3-11) of valve seat insert remover, part No. J482401, inside valve seat inserts (5) so that bottom of collet is flush with bottom of insert.
(b) Hold collet handle (2) and turn tee handle (3) to expand collet-cone until insert is held securely by
remover.
(c) Tap drive bar (7) once or twice to move insert 1 / 16 inch away from seat in cylinder head.
(d) Turn tee handle (3) to loosen collet cone. Move remover into insert slightly so that narrow flange at
bottom collet is below valve seat insert (5).
(e) Tighten tee handle and drive insert out of cylinder head.
(f) Repeat (b) through (e) above until all valve seat inserts to be replaced are removed.
1
2
3
4
5
6
7
Cylinder head
Collet handle
Tee handle
Collet
Valve seat insert
Valve guide
Drive bar
Figure 3-11. Removing valve seat insert with valve seat insert remover, part no. J4824-01
3-9
Figure 3-12. Cylinder head assembly
3-10
Figure 3-13. Removal and installation of injector tube
(10) Remove water nozzles (1, fig. 3-12) from water inlet ports by inserting a hook into nozzle opening and
pulling from port. If a nozzle sticks and cannot be pulled from port, drill and ream out nozzle.
(11) Remove injector tubes as follows:
(a) Place installer body, part No. J5286-4 in injector tube. Thread pilot installer, part No. J5286-5, into end
of installer body (fig. 3-13).
(b) Loosen injector tube with a hammer (fig. 3-13).
(c) Remove injector tube and tools from cylinder head.
d. Cleaning, Inspection, and Repair.
(1) Cylinder head.
(a) Remove all traces of old gasket from cylinder head.
(b) Steam clean head thoroughly.
WARNING
Acid can cause serious burns or blindness. Avoid contact with eyes, skin, or clothing. Do
no breathe vapors. When diluting acids, do not add water to acids, the acid must be added
to the mixture slowly with constant mixing. In case of bodily contact with acid, flush the
affected part thoroughly with water and seek medical aid immediately.
(c) If water jackets are heavily scaled, clean as follows:
1.Agitate cylinder head in an approved acid bath.
2.Allow cylinder head to remain in acid bath until bubbling stops. This normally takes 30
minutes.
3.Lift cylinder head from bath, drain, and reimmerse in same solution for 10 minutes. Repeat this
operation until all scale is removed.
4.Rinse cylinder head in clear hot water to remove solution.
3-11
5. Neutralize any remaining acid that may cling to cylinder head by immersing in approved alkaline
bath. Wash in a bath of clean, hot water or steam clean.
6. Inspect cylinder head after cleaning to be certain that all ports, oil galleries, and drain holes have
been cleaned thoroughly.
(d) Check bottom of cylinder head for flatness, using a heavy, accurate, straightedge and a feeler gage as
follows:
1. Place straightedge across width of cylinder head and slip feeler gage between straightedge and fire
deck (bottom of cylinder head) at maximum opening. Check for warpage at each end of fire deck and between all
cylinders. If warpage exceeds 0.004 inch, replace cylinder head.
2. Place straightedge along length of fire deck and check for longitudinal warpage. Take measurements
at each side of fire deck and along both sides of water ports. If warpage exceeds 0.010 inch, replace cylinder head.
(e) Check cylinder head for leaks as follows:
1. Seal off water holes by clamping holes with plates and rubber gaskets. Seals can be held in
place with plate and bolts on the other side of head.
2. Install injector tubes.
3. Install scrap or dummy fuel injectors in cylinder head to insure proper seating of injector tubes.
4. Drill and tap one water hole cover plate for an airline fitting.
5. Connect a compressed air source to tapped water hole cover plate and apply 80- to 100psi air pressure to water jacket.
6. Immerse cylinder head in a tank of water, preheated to 1800 to 2000F., for 15 to 20 minutes.
7. Check for leaks at bottom and top of injector holes tubes, oil gallery, cylinder head stud holes,
exhaust ports, and top, bottom, and sides of head, by observing air bubbles.
8. Relieve air pressure and remove cylinder head from water.
9. Remove water hole plates and gaskets, and dry cylinder head with compressed air.
10.
Replace any leaking injector hole tube. Replace cylinder head if inspection revealed cracks.
(2) Exhaust valves.
(a) Clean valve springs, retainers, and locks in dry-cleaning solvent, Federal Specification P-D-680, and
dry with compressed air (10 psi).
(b) Clean carbon from valves and wash stems with clean drycleaning solvent.
(c) Inspect spring retainers and retainer locks for pitting or damage. Replace, if necessary.
(d) Inspect valve springs for pitted or fractured coils. Replace if pitted or damaged. Springs should have a
free length of 23h inches and require a load of 146±4½ pounds to compress it to a length of 1 49 / 64 inches. Replace
spring when a load of less than 135 pounds will compress it to 1 49 / 64 inches in length.
(e) Inspect valve heads. Heads must be square with valve stem and should not be warped. Replace
defective valves.
(f) Inspect valve stems. Stems must be smooth and free from scratches or scuff marks and not warped,
burned, or worn beyond 0.3415 inch in diameter. Replace a defective valve.
(g) Inspect valve faces to assure faces are smooth, unpitted, and free from ridges and cracks. Carbon on
face of valve indicates a faulty seat and a resultant leak. Replace pitted or damaged valves. If leaking is indicated,
reface valve to a 30-degree angle (fig. 3-14). Edge of valve at valve head must not be less than 0.030 inch in thickness
after refacing. Replace valve if edge is less than 0.030 inch thick.
(3)
Figure 3-14. Relationship between exhaust valve, valve seat insert, and cylinder head
Valve guides.
NOTE
Cleaning and inspection should be accomplished before valve guides are removed from
cylinder head.
(a) Clean inside diameter of valve guides of gum and carbon deposits with valve guide cleaner, part no.
J5437.
(b) Inspect valve guides for fractures, chipping, scoring, or excessive wear. Remove and replace valve
guide if damaged or worn so that stem-to-guide clearance is greater than 0.006 inch.
(4) Valve seat inserts.
NOTE
Cleaning and inspection should be accomplished before valve guides are removed from
cylinder head.
(a) Clean area around insert with dry cleaning solvent, Federal Specification P-D-680 and dry with
compressed air.
3-12
(b) Inspect valve seat insert for pitting, cracking, improper seat angle, or extensive grinding. Remove and
replace insert if serious pitting or cracking condition exists. Place valve into insert and check distance valve recedes into
cylinder head. If valve recedes beyond 0.007 inch (fig. 3-14) or will recede beyond 0.007 inch after valve seat is ground,
replace valve seat. If minor pitting or improper seat angle is noted, recondition insert in cylinder head as follows:
1. Using valve seat grinder set, part No. J8165, grind valve seat insert as follows.
(a) Use a 30-degree grinding wheel on valve seat (fig. 3-14).
(b) Use a 60-degree grinding wheel to open throat of insert.
(c) Grind top surface of insert with a 15-degree wheel to adjust width of valve seat. Width should be
1 / 16 to 3 / 32 inch (fig. 3-14).
2. Set dial indicator in position in valve guide and insert, and rotate indicator to determine concentricity
of each valve seat insert relative to the valve guide. Total runout should not exceed 0.002 inch. If runout exceeds 0.002
inch check for bent valve guide before regrinding insert.
3. Determine position of contact area between valve and valve seat insert as follows:
(a) Apply a light coat of marking compound, Federal Specification TT-R-191, Type II, to valve seat
insert.
(b) Place a valve with clean, smooth face in valve guide and bounce, but do not rotate, valve on
insert. The marking compound will indicate area of contact on valve face. The most desirable area of contact is at the
center of valve face. If contact is too close to top or bottom of valve face, regrind valve seat insert and recheck for
concentricity and retest for area of contact.
(5) Cam followers.
(a) Clean cam follower assembly in dry cleaning solvent, Federal Specification P-D-680, and dry with
compressed air.
(b) Inspect follower cam guide (4, fig. 3-8) for pitting or damage. Replace a defective cam follower guide.
(c) Inspect cam follower bores in cylinder head. Bores should be smooth and free of score marks. If score
marks are noted, remove marks with crocus cloth, Federal Specification P-C-458.
(d) Check clearances between cam follower body and cylinder head bore. Maximum allowable clearance is
0.006 inch. If clearance is greater than 0.006 inch, replace cam follower body. Clearance between new cam follower
body and cylinder head bore is 0.001 to 0.003 inch.
(e) Inspect cam roller 13, fig. 3-8). Roller must turn smoothly and freely on its pin and must be free from flat
spots or scuff marks. If roller does not turn freely or has been scored or worn flat, replace roller and pin. Inspect cam on
which damaged roller operates for wear or damage. Replace camshaft if defective.
(f) Measure diametric clearance between roller bushing and pin (fig. 3-15). If bushing is worn so that a
diametric clearance greater than 0.010 inch exists, replace roller and pin.- Check side clearance between roller and
follower body. If side clearance is less than 0.015 inch or greater than 0.023 inch, replace roller and pin.
NOTE
The cam roller and pin are serviced as a set only.
(g) If roller and pin are removed from follower body, remove any burrs that exist at pinholes of follower
body with a fine hone or crocus cloth, Federal Specification P-C-458.
(6) Clean, inspect, and repair rocker arms and push rods
(para 3-5).
(7) Clean, inspect, and repair fuel injectors (para 3-10).
e. Reassembly and Installation.
(1) Reassembly.
(a) Install water nozzles as follows:
1. Check to assure water inlet ports are free of
all foreign material.
2. Press nozzles into water inlet ports with
nozzle openings parallel to the longitudinal centerline of cylinder
head. Install ½ inch diameter nozzles at ends of cylinder head
with nozzle openings toward center of cylinder head.
3. If inlet ports have been enlarged by corrosion,
preventing a press fit of nozzles and ports, tin outside diameter of
nozzles with solder to provide a tight fit.
CAUTION
When tinning nozzles, do not allow nozzle
openings to be closed with solder.
Figure 3-15. Cam roller wear and clearance
3-13
4. Press all nozzles flush to 1 / 32 inch below (recessed) bottom surface of cylinder head; otherwise,
interference with proper seating of head on cylinder block may be encountered.
(b) Install injector tubes as follows:
1. Place new seal ring in counterbore of injector tube holed.
2. Place installer body in injector tube. Insert pilot installer through small opening of injector tube and
thread pilot installer into tapped end of installer body.
3. Slip injector tube into bore in cylinder head and drive tube in place. Flange at upper end of tube will
seat on seal ring when tube is properly positioned.
4. Turn cylinder head bottom side up, remove pilot installer, and thread flaring die installer, part No.
J5286-6, into tapper end of installer body.
5. Using a torque wrench and socket, apply a torque of 30 foot-pounds on flaring die installer.
6. Remove injector tube installing tools from tube.
7. Use tool No. J5286-7 (fig. 3-16) and ream injector tube for injector nut and spray tip as follows:
NOTE
Ream carefully, without undue force or speed, to avoid cutting through thin wall of
injector tube. Turn reamer in a clockwise direction only, both when inserting and when
withdrawing reamer; otherwise, movement in opposite direction will dull cutting edges of
flutes.
(a) Place cylinder head right side up.
(b) Place a few drops of light cutting oil on flutes and carefully position reamer in injector tube (fig. 3-16).
(c) Turn reamer in a clockwise direction, withdrawing it frequently to remove chips, until lower shoulder of
reamer contacts injector tube.
(d) Clean chips from injector tube.
Figure 3-16. Reaming injector tube for injector body nut and spray tip with reamer, part no. J5286-7
3-14
8. Remove excess at lower end of tube as follows:
(a) With cylinder head bottom side up, insert pilot of tube tip refinisher, part No. J5286-8, into small
hole of injector tube.
(b) Using a socket and speed handle, remove excess stock so that lower end of injector is
flush to 0.005 inch recessed in surface of cylinder head.
9. Ream bevel seat in injector tube to provide a smooth and true seat for lower end of injector nut as
follows:
(a) Install injector in tube and note relationship between numbered surface of spray tip to fire deck of
cylinder head (fig. 3-17). This will determine amount of stock that must be reamed from bevel seat of tube.
(b) Wash interior of injector tube with dry-cleaning solvent, Federal Specification P-D-580, and dry
with compressed air (10 psi).
(c) Place a few drops of cutting oil, Military Specification MIL-L-21041, on bevel seat of injector
tube. Carefully lower reamer, part No. J5286-9, into tube until it contacts bevel seat (fig. 3-18).
(d) Without applying any downward force, make a trial cut by turning reamer steadily. Remove
reamer, blow out chips, and note what portion of bevel seat has been cut.
(e) Proceed carefully with reaming operation. Withdraw reamer occasionally to check progress
made.
(f) Remove chips from injector tube and using an injector as a gage, continue reaming operation
until shoulder of spray tip is flush to 0.0 1 5 inch recessed in surface of cylinder head (fig. 3-17).
Figure 3-17. Checking location of injector spray tip relative to lower surface of cylinder head
3-15
(c) Install valve seat inserts as follows:
1. Clean valve insert counterbore in cylinder head with drycleaning solvent, Federal Specification P-D680. Dry with compressed air (10 psi).
2. Immerse cylinder head for 30 minutes in water heated to a temperature of 180°to 200°F.
3. Rest cylinder head bottom up on work-bench and locate inserts squarely in counterbores, seating
face up.
CAUTION
Install valve inserts in cylinder head while head is still hot and inserts are at room
temperature; otherwise, installation will be difficult and parts may be damaged. Inserts
are installed with a press fit of 0.0005 to 0.0025 inch in cylinder head (fig. 3-14).
4. Drive inserts in place with valve seat insert driver, part No. J1736, until they seat solidly in cylinder
head (fig. 3-19).
5. Set dial indicator in position in each insert and check for concentricity in relation to valve guides. If
total runout exceeds 0.002 inch, regrind valve seat insert.
Figure 3-18. Reaming bevel seat in injector tube for injector nut with reamer, part no. J5286-9
3-16
Figure 3-19. Installing valve seat insert with valve seat insert driver, part no. J1736
(d) Install valve guides as follows:
1. Rest bottom of cylinder head on work-bench.
2. Insert threaded end of valve guide (6, fig. 3-10) into valve guide installer.
3. Locate valve guide squarely in cylinder head and tap gently to start guide in place (fig. 3-20).
4. With guide properly started, drive guide into cylinder head until its upper end projects 1-19/32 inches
above top of cylinder head. This dimension is automatically provided by valve guide installer.
5. Repeat steps I through 4 above until all guides are installed.
CAUTION
Use care not to bend valve guides during installation. Do not use valve guides as a
means of turning cylinder head over or in handling cylinder head.
Figure 3-20. Installing valve guide with valve guide installer, part no. J4144
(e) Install exhaust valves as follows:
1. Lubricate valve stems with a light coat of engine oil, Military Specification MIL-L-2104, and slide
valves into valve guides. If reconditioned valves are used, install them in same relative location from which they were
removed.
2. Hold valves in place with a strip of masking tape, Federal Specification UU-T-106, and place a board
between cylinder and head and workbench to support valves and to provide clearance for cam followers to avoid
damaging rollers. Turn cylinder head right side up on bench and properly position on board.
3. Install washer (4, fig. 3-10), valve springs (7), and spring retainers (3) over valve stem and guide.
3-17
4. Using a spring compressor, compress valve spring (7) and install two-piece tapered valve spring
retainer lock (2). Exercise care to avoid scoring valve stem with spring retainer (3) when compressing spring.
5. Install retainer locks on remaining exhaust valves in the same manner.
NOTE
After valves have been installed, check to make sure that heads of valves do not
protrude more than 0.021 inch beyond the surface of the cylinder head when valves are
fully closed (fig. 3-14).
(f) Reassemble and install cam followers as follows:
1. Reassembly.
(a) Position follower body (1, fig. 3-8) in groove of holding fixture with proper size plunger extending
through roller pinhole in one of legs of follower body. Coat bushing in cam roller (3) and roller pin (2) with engine oil.
(b) Install cam roller (3) in position in cam follower body. The plunger in fixture will extend into roller
bushing and assure accurate alignment of bushing' with roller pinholes in follower body.
(c) Start roller pin (2) squarely into follower. Carefully drive pin into assembly until pin is centered in
legs of follower (fig. 3-9).
(d) Check side clearance between roller and follower body. Clearance must be 0.015 to 0.023 inch
(fig. 3-15).
NOTE
Immerse new or cleaned cam follower assembly in clean engine oil for at least 5 minutes
before placing in cylinder head. This will insure initial lubrication over full length of cam
follower roller pin. Rotating cam roller during this period will aid in introduction of oil to
cam roller pin.
2. Installation.
(a) Note l/8 inch oil hole in bottom of cam follower. With oil hole pointing away from exhaust valves
and injectors, so that hole is not covered by cam follower guide, and with cam roller pointing across cylinder head, slide
cam follower into position from bottom of head.
(b) Attach cam follower guide (4, fig. 3-8) to cylinder head to hold group of three cam followers in
place. Check to assure there is clearance between cam followers and cam follower guide. Tighten capscrews (6) to a
torque of 12 to 15 foot-pounds.
Figure 3-21. Cylinder head stud nut tightening sequence
(g) Install push rods and rocker arms (para 3-5).
(h) Install fuel oil connectors and manifolds if manifolds are not cast as part of cylinder head (para 3-6).
(i) Install fuel injectors (para 3-10).
(j) Attach lifter brackets temporarily to head to permit lifting head into position on engine.
(2) Installation.
(a) Place a new cylinder liner compression gasket on each cylinder liner.
(b) Place new seal rings in counterbores of water and oil holes in cylinder block.
(c) Install a new oil seal in groove at perimeter of cylinder clock. Do not stretch seal.
(d) Position hoist above cylinder head and attach hooks at lifting brackets on cylinder head. Lift head into
position over cylinder block.
(e) Wipe underside of cylinder head clean and lower in place over studs on cylinder block.
(f) Remove hoisting hooks and loosen bolts attaching lifter brackets.
(g) Install a stud nut on each cylinder head mounting stud. Using cylinder head tightening sequence (fig.
3-21), tighten nuts to a torque of 165 to 175 foot-pounds.
(h) Tighten two bolts directly below each lifter bracket.
(i) Using a new gasket, secure rear lifter bracket to cylinder head and flywheel housing. Tighten bolts to a
torque of 55 to 60 foot-pounds.
(j) Using a new gasket, secure front lifter bracket to cylinder head and flywheel housing. Tighten bolts to a
torque of 55 to 60 foot-pounds.
(k) Align fuel pipes and connect pipes (9, fig. 3-3) to injectors (8) and fuel connectors (6).
3-18
Tighten connectors to a torque of 12 to 15 foot-pounds.
(l) Install governor control housing (para 3-12).
(m) Install injector control tube assembly (para 3-9).
(n) Install governor-throttle controls (fig. 3-7).
(o) Install fuel filters.
(p) Install water manifold (para 3-8).
(q) Install temperature gage sending unit (I1, fig. 3-6) and sensing unit (6) in water manifold.
(r) Connect water piping and thermostat.
(s) Install exhaust manifold (para 3-7) and connect exhaust piping (TM 55-1930-203-20).
(t) Install air cleaners (TM 55-1930-203-20).
(u) Adjust valve clearance, time injectors, and position injector control racks (TM 55-1930203-20).
(v) Install rocker cover and gasket on cylinder head (TM 55-1930-203-20).
(w) Fill cooling system (TM 55-1930-203-20).
Section IV. EXHAUST MANIFOLD AND WATER MANIFOLD
3-7. Exhaust Manifold
a. Removal.
(1) Drain cooling system below level of exhaust manifold (TM 55-1930-203-20).
(2) Disconnect tube (1, fig. 3-22) from elbow (20). Disconnect tube (2) from nipple (7).
(3) Open drain cock (18) and drain coolant from water jacket.
(4) Remove bolts and lockwashers attaching exhaust piping to exhaust manifold (TM 55-1930203-20).
(5) Remove nuts (15) and washers (14) securing exhaust manifold (13) to cylinder block.
NOTE
To facilitate removal of number two stud nut (between the two forward manifold legs),
unscrew nut to end of stud; remove all the other manifold nuts and washers; then pull
exhaust manifold away from cylinder block and remove number two nut and washer.
(6) Remove gaskets (5 and 6).
(7) Remove nuts (8) and washers (9), and remove cover plates (10,16, and 19) and gaskets
(11).
3-19
Figure 3-22. Exhaust manifold.
b. Cleaning, Inspection, and Repair.
(1) Clean exhaust manifold in fuel oil and wipe dry with a lintfree cloth. Scrape old gasket from gasket surfaces
on manifold and on cylinder block with a wire brush.
(2) Inspect manifold for signs of cracking. Check closely the areas around gasket surfaces. Replace a cracked
manifold.
(3) Check studs (3, fig. 3-22) for stripped threads and for being loose. If studs are damaged, install new studs
and tighten to 25 to 40 foot-pounds.
(4) Replace gaskets (11).
(5) Check studs (12) for stripped threads and looseness. Replace damaged studs.
c. Installation.
(1) Position gaskets (11, fig. 3-22) and cover plates (10, 16, and 19) on manifold and secure with washers (9)
and nuts (8).
(2) Install bushings (4) and install elbow (20) and nipple (7). Install drain cock (18).
(3) Position new gaskets (5 and 6) over studs (3).
(4) Position exhaust rnanifold on studs so that
3-20
about ½ inch of stud threads extend beyond mounting flanges of manifold legs.
(5) Place bevel washers (14) on studs and screw nuts (15) several turns on studs.
NOTE
Place bevel washers on studs so that the outer diameter will rest on manifold and crown
at center will rest on studs.
(6) Slide manifold up against gaskets.
Starting with center nut and working alternately toward ends of
manifold, tighten nuts to a torque of 30 to 35 foot-pounds.
(7) Connect tubes (1 and 2).
(8) Attach exhaust piping to manifold with bolts and lockwashers.
(9) Fill cooling system and check for leaks (TM 55-1930-203-20).
3-8. Water Manifold
a. Removal.
(1) Drain cooling system below level of water manifold (TM 55-1930-203-20).
(2) Remove water temperature sending unit (11, fig. 3-6) and sensing element (6) from water manifold.
(3) Disconnect rubber hose from bypass tube at water pump and flexible hose fromoutlet elbow on water
manifold.
(4) Remove bolts (17) and lockwashers (18); and remove outlet elbow (16), thermostat housing (13), and
gaskets (12 and 14).
(5) Remove thermostat (15) from thermostat housing.
(6) Disconnect tubes (1 and 19) from elbow (4).
(7) Remove nuts (8) and lockwashers (7) securing water manifold to cylinder block.
(8) Lift water manifold (9) straight up and off studs. Remove and discard gaskets (2).
b. Cleaning, Inspection and Repair.
(1) Clean water manifold (9, fig. 3-6), outlet elbow (16), and thermostat housing (13) in an approved solvent
and rinse thoroughly with clean water. Remove all traces of gasket material from cylinder head.
(2) Inspect water manifold outlet elbow and thermostat housing for cracks, breaks, or evidence of leaks.
Replace defective parts.
(3) Replace gaskets (2, 12, and 14).
(4) Inspect studs (3) for defective threads and for being loose. If studs are defective, install new studs and
tighten to 10 to 25 foot-pounds.
(5) Test thermostat (15) as follows:
(a) Place thermostat and a thermometer in a container of warm water.
NOTE
Do not allow thermometer to touch bottom of container.
(b) Agitate water to maintain an even temperature throughout container and gradually increase temperature
of water. The thermostat should begin to open at 173°F (78.3°C) and be fully open at approximately 185°F (85°C). If
thermostat fails to operate properly, replace thermostat.
(c) Install water manifold in reverse order of removal.
Section V. FUEL INJECTION CONTROLS, FUEL INJECTOR ASSEMBLY, AND FUEL MANIFOLDS
3-9. Fuel Injector Controls
a. Removal.
(1) Remove cotter pins (6, fig. 3-23) and link pin (5) attaching fuel rod (7) to injector control tube lever (4).
(2) Remove pin (8) attaching injector control tube lever (4) to injector control tube (1) and remove injector
control tube lever.
(3) Remove machine bolts (9) and lock-washers (10) securing injector control tube brackets (3) to engine and
remove injector control tube brackets and spring (2) from injector control tube (1).
(4) Loosen inner control lever adjusting screw (12) and outer control lever adjusting screws (13), and slip
injector rack control levers (11) from injector control tube (1).
b. Installation. Install fuel injector controls in the reverse order of removal. After installation is accomplished,
reposition injector rack control levers in the order outlined by paragraph 3-78 in TM 55-1930-203-20.
3-21
Figure 3-23. Fuel injector controls
3-10. Fuel Injector Assembly
a. Removal, Testing, and Disassembly.
(1) Removal.
(a) Remove rocker cover (TM 55-1930-203-20).
(b) Disconnect fuel pipes (9, fig. 3-24) from injector assembly (8) and fuel connectors (6).
(c) Install shipping cap (7) over fuel fittings on injector assembly.
Figure 3-24. Fuel injector removal
3-22
CAUTION
Immediately after removal of fuel pipes, each fitting must be covered with a shipping
cap to prevent dirt from entering injector assembly.
(d) Depress starter button in engine well to bring outer ends of push rods of injector assembly and valve rocker
arms in line horizontally.
(e) Remove two rocker arm bracket bolts (5) and swing rocker assembly away from injector assembly and
valves.
(f) On engines prior to serial No. 6A-84033, remove injector clamp nut, washer (3), and clamp (4). On engines
serial No. 6A-84033 and subsequent, remove bolt (2), washer (3), and clamp (4).
(g) Loosen inner and outer adjusting screws on injector rack control lever and slide lever away from injector
assembly.
(h) Pry injector assembly loose from its seat as shown in figure 3-24 using injector remover (1), and lift injector
assembly from cylinder head.
(2) Testing. Perform the following series of tests to determine condition of fuel injector and to avoid unnecessary
overhauling.
NOTE
Perform all tests before disassembling an injector to correct any one condition.
(a) Fuel injector rack and plunger movement test.
1. Check for free movement of plunger in bushing by placing injector against a bench or other hard
surface and depressing follower to bottom of its stroke (fig. 3-25).
2. At same time follower is depressed, move rack back and forth.
3. Failure to produce a free plunger or rack movement indicates damaged or dirty internal injector parts.
Figure 3-25. Checking rack and plunger for free movement
3-23
WARNING
Hold injector in such a way as to prevent any fuel spray from penetrating skin. Fuel oil
which enters the blood stream can cause blood poisoning.
(b) Valve opening pressure test.
1. Place injector in injector tester, part No. J9787.
2. Position injector support plate and handle support to the proper height.
WARNING
Always place injector in proper position in relation to the spray deflector before it is
tested, in order to prevent fuel spray from penetrating the skin.
3. Close inlet tube of injector by lowering inlet clamp handle.
4. Operate pump handle until all air is purged from test fixture and injector.
5. Close outlet clamp.
6. With injector rack in FULL FUEL position, pump handle of test fixture with smooth, even strokes.
7. Record injector valve opening pressure indicated when injector sprays fuel. Specified valve opening pressure
is 450 to 850 psi.
(c) Valve holding pressure test.
1. Operate pump handle to bring pressure up to a point just before injector valve opening pressure as determined
in the preceding test.
2. Close fuel shutoff valve.
3. Note pressure drop. Time for a pressure drop from 450 to 250 psi must not be less than 40 seconds.
4. Check injector as follows if pressure drops from 450 to 250 psi in less than 40 seconds.
(a) Dry injector with compressed air.
(b) Open test fixture fuel valve.
(c) Operate pump handle to maintain testing pressure (1 above.)
(d) Check for a leak at injector rack opening. If present, a poor bushing-to-body fit is indicated.
(e) Check for leaks around spray tip or seal ring. This is usually caused by a loose injector nut, damaged seal ring, or
brinelled surface on injector nut or spray tip.
(f) Check for a leak around filter cap indicating a loose filter cap or damaged filter cap or damaged filter cap gasket.
(g) Check for leak at spray tip orifices, indicating a leaking valve assembly due to a damaged surface or dirt.
NOTE
If pressure drop from 450 to 250 psi did not exceed 40 seconds, a drop or two of fuel at
spray tip is only an indication of fuel trapped in tip at beginning of test and is not
detrimental.
(d) High pressure test.
1. Dry injector with compressed air.
2. Check fuel connections for leaks. If leaks occur, tighten connection, dry injector, and recheck.
3. With injector rack in FULL FUEL position and test fixture handle locked in position, operate pump handle to
build up and maintain pressure.
4. Use adjusting screw in test fixture handle to depress injector plunger far enough to close both ports in injector,
bushing. (Both ports are closed when injector spray decreases appreciably and a rise in pressure occurs).
5. Operate pump handle a few times. If pressure beyond normal valve opening pressure (established in valve
opening pressure test) cannot be obtained, excessive clearance between plunger and bushing is present. Replacement of
plunger and bushing is required.
6. Operate pump handle to obtain and maintain a pressure of 1600 to 2000 psi.
7. Inspect for leaks at injector filter cap gaskets, body plugs, injector nut seal ring area, and injector rack hole.
WARNING
Do not permit pressure in test fixture to equal or to exceed capacity of pressure gage.
(e) Spray pattern test.
1. With injector rack in FULL FUEL position, operate pump handle to maintain a fuel pressure just below valve
opening pressure ( (b) above).
2. Operate injector several times with pump handle and observe spray pattern emitted from tip orifices. Fuel
should be discharged from each orifice and spray should produce uniform pattern.
(f) Fuel output test.
1. Place injector in comparator, part No. 17041, and tighten hand wheel to seal firmly.
2. Check to be sure counter on comparator is preset to 1000 strokes.
3. Pull injector rack out to NO FUEL position.
4. Start comparator.
5. Push injector rack to FULL FUEL position.
6. Allow injector to run approximately 30 seconds to purge air that may be in system.
7. Press fuel flow start button. This will start flow of fuel into vial. The comparator will automatically stop flow of
fuel after 1000 strokes.
8. When fuel stops flowing into vial, pull injector rack out to NO FUEL position.
9. Turn comparator off.
10. Reset counter.
3-24
11. Observe reading on vial. To be within specified limits of HV7 injector, vial readings should fall between a
minimum of 30 and a maximum of 36.
12. Record injector output. This information aids in selection of a set of injectors which will inject same amount of
fuel in each cylinder at a given throttle setting. The result is a smooth running, well balanced engine.
(3) Disassembly. Consider injector assembly that passes all of tests outlined above to be satisfactory for service without
further disassembly. Disassemble injector which fail to pass one or more of the tests as follows:
(a) Fuel injector plunger and follower assembly disassembly.
1. Support injector assembly upright in injector assembly fixture, part No. J6868-01.
2. Compress follower spring (3, fig. 3-26). Using a screwdriver, raise follower spring above stop pin 15) and
withdraw pin (fig. 3-27).
3. Allow spring to rise gradually.
4.Remove plunger follower (1, fig. 3-26), follower spring (3), and plunger (2).
3-25
Figure 3-26. Injector plunger and follower assembly.
3-26
Figure 3-27. Removing injector follower stop pin
(b) Fuel injector valve assembly disassembly.
1. Invert injector in assembly fixture. Remove nut (15, fig. 3-28) from injector body (1).
2. Lift injector nut straight up, using care not to dislodge spray tip (12) and other small parts resting on
end of bushing (5). If injector has been in use for some time, spray tip (12) will possibly be removed with nut.
3. Lift spray tip (if tip was not removed with nut), check valve (1), valve cage (10), valve stop (9), valve
spring (8), injector valve (7), and valve seat (6) from bushing. (5).
4. If spray tip (12) sticks in nut, support nut on a wood block and drive tip down through nut using tip
remover, part No. J1291-02 (fig. 3-29). Do not drive directly on end of spray tip as damage will occur.
5. Jar and remove the spill deflector (13, fig. 3-28) and seal ring (14) from nut (15).
(c) Fuel injector rack and gear assembly disassembly.
1.Remove bushing (5) from injector body (1).
2.Jar gear retainer (4) and gear (2) from injector body.
3. Pull control rack (3) from injector body.
3-27
Figure 3-28. Fuel injector rack and gear, and valve assemblies.
3-28
Figure 3-29. Removing spray tip from fuel injector nut with tip remover, part no. J1291-02
(d) Fuel injector assembly disassembly.
1. Loosen filter caps (1, fig. 3-30) with 9 / 16 inch deep socket and T-handle wrench.
2. Remove fuel filter caps ( 1), gaskets (2), springs (3), and filters (4) from injector body (5).
3. Discard filters and gaskets.
3-29
Figure 3-30. Fuel injector filter assembly.
b. Cleaning, Inspection, and Repair.
(1) Wash all parts with dry-cleaning solvent, Federal Specification P-D-680, and dry with clean, filtered,
compressed air.
NOTE
Do not use waste or rags for cleaning purposes
(2) Clean out all passages, drilled holes, and slots in all injector parts.
(3) Clean spray tip with reamer, part No. J1243 (fig. 3-31). Turn reamer in a clockwise direction to
remove carbon deposits. Wash spray tip and dry with compressed air.
3-30
Figure 3-31. Reaming injector spray tip with reamer, part No. J1243.
3-31
(4) Clean spray tip orifices with orific cleaner, part No. J4298-1 (fig. 3-32), using a 0.006-inch diameter wire.
Before using wire, hone end until smooth and free of burrs; and taper end a distance of 1/16 inch. Wash, clean, and dry
spray tip.
Figure 3-32. Cleaning spray tip orifices with orifice cleaner, part No. J4298-1
3-32
(5) Clean and brush all passages in injector body. Blow out passages and dry with compressed air.
(6) Remove carbon deposits from injector nut with reamer (fig. 3-33). Insert reamer carefully and turn in a
clockwise direction. Use care in reaming to prevent removal of metal or setting up burrs on spray tip seat.
Figure 3-33. Cleaning injector nut spray tip seat with reamer, part No. J4986-01
(7) Wash injector nut in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(8) Wash plunger and bushing in fuel oil and dry with compressed air. When handling injector plunger, do not
touch finished plunger surfaces with fingers.
(9) Final cleaning of plunger and bushing may be accomplished with soft tissue paper. Wrap tissue paper around
cleaning tool, part No. J1291-02, and clean out bushing bore.
NOTE
Keep plunger and bushing together as they are mated parts. If more than one injector is
disassembled. keep parts of each injector assembly together.
(10) After washing, submerge all parts in a
3-33
clean receptacle containing clean dry-cleaning solvent.
(11) Inspect teeth on control rack and control rack gear for damage. Check bore of gear for chipping or other
damage. Replace damaged parts.
(12) Inspect gear retainer. Replace if damaged.
(13) Inspect injector follower and pin for damage. Replace if necessary.
(14) Inspect both ends of spill deflector for sharp edges or burrs. Remove burrs with a medium stone.
(15) Inspect follower spring for defects and measure free length. Free length should be approximately 2.039
inches. A load of 38 t 3 pounds should be required to compress spring to a length of 1.027 inch. Replace spring if a load
of less than 30 pounds will compress it to 1.027 inch or if defects are found.
(16) Inspect seal ring area on injector body for burrs or scratches.
(1'7) Inspect surface of injector body which contacts injector bushing for scratches, scuff marks, or other damage.
Lap this surface if necessary. A faulty sealing surface at this point will result in high fuel consumption and contamination
of the lubricating oil.
(18) Replace any loose injector body plugs or a loose dowel pin.
(19) Inspect injector plunger for scoring, erosion, or chipping. Check for sharp edges on that portion of plunger
which rides in gear. Remove any sharp edges with a 500 grit stone. Wash plunger after stoning.
(20) Inspect plunger bushing for cracks or chipping. Slip plunger into bushing and check for free movement.
(21) Replace chipped, scored, or loose fitting plunger and bushing as an assembly since they are mated parts.
(22) Inspect spray tip seating surface of injector nut for nicks, burrs, or brinelling. Reseat surface or replace nut if
it is severely damaged.
(23) Replace weak or broken injector valve springs. A load of 5 ¼ + ½ pounds should compress spring to a
length of 0.240 inch. Replace spring if a load of less than 4 ¼ pounds will compress it to the 0.240 inch length.
(24) Inspect sealing surface indicated by heavy black arrows of injector body (J, fig. 3-341, bushing (2), valve
seats (3), valve cage (7), check valve (8), and spray tip (9). Sealing surface should be examined with a magnifying glass
for even the tightest imperfections will prevent injector from operating properly. Check for burrs, nicks, erosion, cracks,
and chipping. Check for enlarged orifices in spray tip. Replace damaged or excessively worn parts.
(25) Lap all sealing surfaces when used valve parts are to be reinstalled in injector. It is a good practice to lightly
lap new valve parts (except injector valve (4)) which may become burred or nicked during handling. Lapping procedures
for sealing surfaces are as follows:
Figure 3-34. Sealing surfaces which may require lapping
(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 lapping powder on one of lapping blocks.
(c) Place part to be lapped flat on block; using a figure eight motion, move it back and forth across block.
Do not press on the part, but use just enough pressure to keep part flat on block. It is important that part be kept
flat on block at all times.
3-34
(d) After four or five passes, clean lapping powder from part by drawing it across a clean piece of tissue placed
on a flat surface; and inspect part. Do not lap excessively.
(e) When part is flat, wash in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(f) Place dry part on second block. Apply lapping powder and move part lightly across block in a figure eight
motion several times. Wash with dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(g) Place dry part on third block. Do not use lapping powder on this block. Keep part flat and move it across block
several times, using the figure eight motion. Lapping dry part in this manner gives it a mirror finish required for perfect
sealing.
(h) Inspect edge of hole in injector valve seat under a magnifying glass. If edge shows small irregularities, lap
hole with lapping tool, part No. J7174. Mount lapping tool in a drill motor and place a small amount of lapping powder and
oil mixture on tool. Place valve seat over pilot of the tool and start drill motor. Touch valve seat lightly against rotating
lapping tool to produce a uniform seat at the hole. After lapping edge of hole, flat lap face of seat lightly. Clean and
examine width of chamfer produced at the edge of hole. Specified width is 0.002 to 0.005 inch. If width is in excess of
these limits, replace valve seat.
(i) Wash all lapped parts in clean fuel oil and dry them with compressed air. Clean inside at injector bushing by
wrapping clean tissue around cleaning tool, part No. J1291-02, and rotating it in and out through bushing.
c. Reassembly, Testing, and Installation.
(1) Reassembly and testing.
(a) Filter assembly reassembly.
1. With injector body (5, fig. 3-30) right side up, place a new filter (4), dimple end down, in each fuel cavity.
2. Place spring (3) above each filter.
3. Place a new gasket (2) against shoulder of each filter cap (1).
4. Lubricate threads of filter caps and install caps.
5. Tighten filter caps to a torque value of 65 to 75 foot-pounds, using 9/ 16 inch deep socket wrench.
6. Install clean shipping caps on filter caps to prevent dirt entering injector.
(b) Fuel injector rack and gear assembly reassembly.
1. Note drill spot marks on control rack (3, fig. 3-28) and gear (2).
2. With injector body (1) bottom end up, slide control rack (3) through hole in body.
3. Looking into bore for gear, move rack so that drill marks can be observed and hold rack in this position. Rack
can be placed in only one position and have teeth marks show in opening for gear.
4. Slide gear into injector body so that marked tooth is engaged between two marked teeth on rack.
5. Slide gear retainer (4) on top of gear.
6. Slide plunger bushing (5) down onto gear retainer (4) with locating pin in bushing guided into slot of injector
body.
(c) Fuel injector valve assembly reassembly.
1. Support injector body (1), bottom end up, in assembly fixture, part No. J6868-01.
2. Place a new seal ring (14) on shoulder of injector body.
3. Slide spill deflector (13) over barrel of bushing (5).
4. Place valve seat (6) on end of bushing.
5. Insert stem of injector valve (7) in one end of valve spring (8) and valve stop (9) in other end.
6. Lower valve cage (10) over assembly formed (5 above) so that valve stop (9) seats in cage.
7. Place valve cage assembly on valve seat (6).
8. Locate check valve (11) centrally on valve cage.
9. Place spray tip (12) over check valve (11) and against valve cage.
10. Lubricate threads and carefully pilot nut (15) over spray tip and valve assembly.
11. Screw nut (15) in place by hand, making sure that valve assembly does not shift. Do not use a wrench to
tighten nut at this time. If valve parts are not centrally located on end of bushing they will not enter counterbore in injector
nut. To facilitate assembly in such a case, turn end of spray tip while threading nut onto injector body.
(d) Fuel injector plunger and follower assembly reassembly.
1. Slide head of plunger (2, fig. 3-26) into follower (1) and insert through follower spring (3)
2. Invert injector in assembly fixture (filter cap end up) and push control rack (8) all the way in.
3. Insert free end of plunger (2) in injector body (4). Insert this assembly through follower spring (3 ).
4. Place stop pin (5) on injector body so that bottom coil of follower spring rests on narrow flange of pin.
5. Align slot in follower (1) with stop pinhole in injector body (4).
3-35
6. Align flat side of plunger (2) with flat in gear.
7. Press down on follower (1) and press stop pin (5) into position. When in place, spring will hold stop pin in position.
8. Invert injector assembly in holding fixture, part No. J6868-0] and tighten nut (6) to a
torque valve of 55 to 65 foot-pounds.
CAUTION
Do not exceed specified torque. Otherwise, nut may be stretched and result in improper sealing of lapped
surfaces in a subsequent injector overhaul.
(e) Testing repaired fuel injector assembly.
1. Test injector for correct alignment.
(a) Place injector in concentricity gage to check for correct alignment.
(b) Adjust dial indicator to zero.
(c) Rotate injector 360 degrees and note total run-out as indicated on dial.
(d) If total run-out exceeds 0.008 inch, remove injector from gage. Loosen injector nut and center spray tip. Tighten
nut.
(e) Recheck spray tip concentricity.
(f) If, after several attempts, spray tip cannot be positioned satisfactorily check assembly of entire injector.
2. Test injector (subpara a(2)).
NOTE
If repaired injector is to be placed in stock, fill with test oil or any good rust preventive. Do not use fuel oil.
(2) Installation.
(a) Before installing injector assembly, be sure that beveled seat of injector tube in cylinder block is free from dirt and
carbon deposits.
(b) Insert injector assembly into injector tube with the locating dowel registering with the locating hole in the cylinder
head and with pin on injector control arm lever registering with the injector control rack lever.
(c) On engines prior to serial No. 6A-84033, place injector clamp (4, fig. 3-24) over stud and install washer (3) and
nut. Tighten nut to a torque of 20 to 25 foot-pounds. On engines serial No. 6A-84033 and subsequent, secure clamp (4)
with bolt (2) and washer (3); tighten bolt to a torque of 20 to 25 foot-pounds.
CAUTION
Excess torque will cause the injector rack to bind.
(d) Move rocker arm assembly into position and install rocker arm bracket bolts (5). Tighten bolts to a torque of 9b to
100 foot-pounds.
(e) Remove shipping caps. Connect fuel pipes (9) to injector assembly and fuel connectors. Tighten connectors to a
torque of 12 to 15 foot-pounds.
NOTE
Before tightening the connector on the fuel outlet side of the injector assembly, set the injector rack in the NO FUEL
position and crank the engine briefly. This will bleed any entrapped air from the injector assembly and avoid the
possibility of scoring the injector parts, due to lack of lubrication upon initial starting.
CAUTION
Do not exceed the specified torque. Excessive tightening will twist or fracture the flared ends of the fuel pipes
and result in leaks.
(f) Set valve clearance and time injector assembly. Readjust injector control racks (TM 55-1930-203-20).
3-11. Fuel Manifolds
a. General. The fuel manifolds on some model cylinder heads, part No. 5196310, are cast as an integral part of the
cylinder head (fig. 3-36). Other engines with an earlier type cylinder head design, part No. 5185344, have the fuel
manifolds externally mounted on the side of the cylinder head (fig. 3-35). These type of manifolds are secured to the
cylinder head by threaded connectors which extend down through, and set into, tapered seat openings in the Tconnectors on the fuel manifolds.
b. External Fuel Manifolds.
(1) Removal
(a) Remove air cleaners (TM 55-1930-203-20).
(b) Remove rocker cover and gasket (TM 55-1930-203-20).
(c) Disconnect fuel pipes (2 and 3, fig. 3-35) from the fuel injectors and the fuel connectors.
(d) Disconnect the fuel lines from the fittings at the ends of the fuel manifolds.
(e) Remove fuel connectors (4) from cylinder head.
(f) Withdraw fuel manifolds (5) carefully from the cylinder head.
(g) Remove pipe plugs (6) and fittings (9 and 11) from ends of fuel manifolds.
(2) Cleaning and Inspection.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(b) Examine tapered seats of fuel connectors for scored condition. If scored, replace fuel connectors.
(c) Inspect fuel connector seats on T-connectors of fuel manifolds for scored condition. If scored, replace manifolds.
(d) Inspect the threads of all parts to insure they are in good condition.
3-36
Figure 3-35. Cylinder head with external fuel manifolds.
3-37
Figure 3-36. Cylinder head with integral fuel manifolds.
3-38
(3) Installation.
(a) Guide T-connectors (8, fig. 3-35) of the fuel manifolds into openings in side of cylinder head so that
the tapered seats are in approximate alignment with the fuel connector openings in top of cylinder head.
(b) Lubricate threads of fuel connectors (4) equipped with a nylon type insert. Thread connectors, by
hand, into tapped holes in top of cylinder head.
(c) Centralize T-connectors (8) of fuel manifolds (5) with fuel connectors (4) by alternately turning fuel
connectors while moving fuel manifold in and out slightly.
CAUTION
Centering the T-connectors is important and necessary to insure 'leak proof joints.
NOTE
If a locknut is used with the fuel connector, install the locknut with the fiber end down. If the locknut, is staked, a new
copper sealing washer must also he used.
(d) Tighten all fuel connectors (4) (and locknuts, if used) uniformly to a torque of 30 to 35 foot-pounds.
(e) Install pipe plugs (6) and fittings (9 and 11) in ends of fuel manifolds.
CAUTION
If restricted fitting (11) is replaced, insure replacement part has the same size orifice as the one removed. Failure
to install correct size fitting will result in improper fuel pressure within the fuel system.
(f) Attach fuel outlet pipes (2) and fuel inlet pipes (3) to fuel connectors and fuel injectors. Tighten the
connections to a torque of 12 to 15 foot pounds.
CAUTION
Insure that the flared ends of the fuel pipes are properly seated before tightening the connections. Excessive
tightening can twist or fracture the flared ends of the pipes and result in fuel leaks.
(g) Connect the fuel lines to the fuel manifolds.
(h) Start engine (TM 55-1930-203-10) and check all fuel connections for leaks.
(i) Stop engine and install rocker cover and air cleaners (TM 55-1930-203-20).
c. Integral Fuel Manifolds.
(1) Fuel connector removal
(a) Remove air cleaners (TM 55-1930-203-20).
(b) Remove rocker cover and gasket (TM 55-1930-203-20)
(c) Disconnect fuel pipes (1 and 2, fig. 3-36) from fuel injectors and fuel connectors.
(d) Remove fuel connectors (3) and washers (4) from cylinder head.
(2) Cleaning and inspection.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(b) Inspect the threads of all parts to insure they are in good condition.
CAUTION
If restricted fitting (5) is replaced, insure replacement part has the same size orifice as the one removed. Failure
to install correct size fitting will result in improper fuel pressure within the fuel system.
(3) Fuel connector installation.
(a) Install fuel connectors (3, fig. 3-36) using new special steel washer (4) between fuel connector and
cylinder head. Tighten fuel connectors to a torque of 30 to 35 foot-pounds.
(b) Attach fuel inlet pipes (1) and fuel outlet pipes (2) to fuel connectors and fuel injectors. Tighten
connections to a torque of 12 to 15 foot pounds.
(c) Start engine (TM 55-1930-203-10) and check all fuel connections for leaks.
(d) Stop engine and install rocker cover and air cleaners (TM 55-1930-203-20).
Section VI. ENGINE ACCESSORIES
3-12. General
This section contains those items which are considered accessories to the engine. They consist of the governor
assembly, fluid starting aid, lubricating oil cooler assembly, oil filter, water pump, air starting motor,. fuel pump, air inlet
housing, blower assembly, and blower drive assembly.
3-13. Governor Assembly
a. Description. A single-weight, limiting speed, mechanical governor is used on each LARC engine. The governor
controls idle speed and limits maximum operating speed while allowing manual control of intermediate 'engine speeds.
During operation, centrifugal force of revolving weights inside the governor housing is transmitted through
3-39
shafts and levers to a spring assembly. The spring assembly,
composed of a low speed spring and a high speed spring,
controls idle and maximum engine speeds. The low speed
spring holds the injector rack in full fuel position for starting.
Immediately after starting, transmitted centrifugal force
compresses the spring, permitting racks to return to idle speed
position. With low speed spring fully compressed, the engine
is manually controlled for intermediate speeds. If engine speed
tends to exceed the allowable maximum, centrifugal force
overcomes tension of the high speed spring. The high speed
spring then compresses, overriding throttle controls and
limiting flow of fuel. Thus maximum speed is not exceeded.
b. Removal
(1) Disconnect throttle linkage from throttle control
lever (1, fig. 3-37).
(2) Remove four screws (11) and lockwashers, and
lift governor cover (5) and gasket from housing,
(3) Remove rocker cover (TM 55-1930-203 20).
(4) Disconnect fuel rod (3) from injector control tube
lever (2) and from lever inside governor control housing (6).
(5) Disconnect oil line at governor weight housing
cover (9).
(6) Remove four bolts (8) and lockwashers and
separate cover (9) from weight housing (7). Remove gasket.
(7) Remove two bolts (4) and lockwashers which
secure governor to cylinder head.
(8) Pull upper end of control housing (6) away from
cylinder head and remove lower end from weight
housing (7). Remove gaskets.
(9) Remove six bolts (10) and copper washers
securing governor weight housing to blower. Pull the
weight housing away from blower. Remove gasket.
c. Disassembly.
(1) Governor cover assembly disassembly.
(a) Loosen capscrew (9, fig. 3-38) and lift
throttle control lever (11) from throttle shaft (7).
(b) Remove pin (12) from throttle control (15).
Lift lever and seal ring retainer (18) from
throttle shaft (7).
(c) Withdraw throttle shaft (7) from cover.
(d) Remove spring retainer (13) and washer
(14), and lift cam (17) off pin.
Figure 3-37. Governor mounting
(e) Remove seal ring (19) from governor
cover.
(f) Wash cover assembly (containing needle bearing) in clean fuel oil and inspect needle bearing for
damage. If throttle shaft bearings (8) are satisfactory, removal is unnecessary.
(g) If needle bearing removal is necessary,
3-40
place inner face of cover over opening in bed of press. Place bearing remover, part No. J4647, on top of bearing and
under ram of press. Press both bearings out of cover.
Figure 3-38. Single weight limiting governor assembly
3-41
Key to figure 3-38.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Setscrew
Locknut
Operating shaft lever
Differential lever
Washer
Spring retainer
Throttle shaft
Throttle shaft bearing
Capscrew
Lockwasher
Throttle control lever
Pin, tapered
Spring retainer
Washer
Throttle control
Cam control spring
Cam
Seal ring retainer
Seal ring
Screw
Lockwasher
Governor cover
Gasket cover
Bolt, machine
Lockwasher
High speed spring retainer
cover
27 Gasket, high speed spring
cover
28 High speed spring retainer
29 Locknut, spring retainer
30 Locknut
31 Screw, idle speed adjusting
32 High speed spring
33 High speed spring plunger
34 Low speed spring seat
35 Low speed spring
36 Low speed spring cap
37 Operating shaft
38 Washer, flat
39 Operating shaft bearing
40 Washer, flat
41 Lockwasher
42 Screw, machine
43 Gasket, governor
44 Washer, copper
45 Capscrew
46 Capscrew
47 Washer, flat
48 Governor control housing
49 Locknut
50 Screw, buffer
51 Retainer ring
52 Weight pin
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
Washer, flat
Governor bearing
Governor weight
Weight shaft
Weight carrier
Governor riser
Gasket, governor
Riser thrust bearing
Weight, housing
Gasket, weight housing cover
Weight housing cover
Lockwasher
Capscrew
Washer, copper
Bolt, weight housing
Weight housing plug
Gasket, weight housing cap
Bolt, machine
Lockwasher, key
Shaft end bearing
Operating shaft fork
Setscrew
Gasket, weight housing
Expansion plug
Operating shaft bushing
(2) Governor control housing assembly disassembly.
(a) Place governor control housing (48) in soft jaws of vise.
(b) Remove two bolts 124) and withdraw high speed spring retainer cover (26) and gasket (27).
(c) Loosen locknut (29). Remove high speed spring retainer (28), locknut (30), screw (31), high speed
spring 132), high speed spring plunger (33), low speed spring (35), low speed spring seat (34), and low speed
spring cap (33) as an assembly.
(d) Remove spring retainer (6 j and washer (5) from lever pin. Lift differential lever 14) from pin of
operating shaft lever (3).
(e) Remove expansion plug (76) out of lower end of control housing.
(f) Remove bearing retaining screw (42), washer (40), and lockwasher (41).
(g) Loosen operating fork setscrew (74).
(h) Support control housing (48) bottom side up. Using a brass rod, press operating shaft (37) from
operating shaft fork (73). Withdraw operating shaft lever (3), operating shaft bearing (39), and washer (38) as an
assembly from control housing.
(i) Support operating shaft and lever on bed of press. Using a brass rod, press shaft (37) from operating
lever (3), bearing (39), and remove washer (38).
(3) Governor weight housing assembly disassembly.
(a) Place weight housing (61) in soft jaws of vise. Remove weight housing plug (68) and gasket (69).
(b) Straighten tang of lockwasher (71) and remove bearing bolt (70).
(c) Thread a 5 / 16-24 x 3 inch-bolt into tapped end of weight shaft (56). Support weight housing (61) on
bed of press. Press shaft from bearing (72).
(d) Slide riser thrust bearing (60) and governor riser (58) from weight shaft (56).
NOTE
This bearing is specially designed to absorb thrust loads; therefore, looseness between mating
parts does not indicate excessive wear.
(e) Remove shaft end bearing (72) from weight housing (61).
3-42
(f) Mark governor weight (55) and weight carrier (57) with a center punch for identification. Note position of washers
(53) between weights so parts can be replaced in original position.
(g) Remove retainer rings (51) and withdraw weight pins (52), washers (53), and governor weights (55).
(h) If weight carrier (57) is damaged, press carrier from governor weight shaft. It is unnecessary to remove carrier if
no dam age is noted.
d. Cleaning, Inspection and Repair.
(1) Clean all governor parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(2) Inspect all bearings for corroded or pitted surfaces. If any damage is noted, replace bearing.
(3) Revolve operating shaft bearing and governor weight shaft bearing slowly by hand. Replace bearings if rough or
tight spots are detected.
(4) Inspect spring seats, plungers, adjusting screws, locknuts, and other parts of control housing tor defects that might
effect governor operation. Replace as necessary.
(5) Inspect operating shaft and shaft bushing for damage. If damageis noted, replace shaft and bushing.
(6) Inspect riser thrust bearing for flat spots; worn race, or corrosion. If any of these conditions
exist, replace thrust bearing assembly.
(7) Inspect roller bearings and throttle shaft for damage or flat spots. If one or both conditions exist, replace bearings
and throttle shaft.
(8) Inspect weight pins and bearings for damage or flat spots. If either condition is noted, replace defective parts.
Assemble weights and check for free movement.
e. Reassembly.
(1) Governor cover assembly reassembly.
(a) If throttle shaft bearings (8, fig. 3-38) were removed from governor cover (22), place governor cover on bed of
arbor press with inner face of cover down. Start upper bearing straight into bearing bore of cover with number on bearing
up.
(b) Insert pilot of bearing installer, part No. J4649, into bearing and under ram of press and press bearing into cover
until stop on tool contacts top of cover. Upper bearing should be approximately 1/8 inch below top surface of upper
bearing boss.
(c) Reverse governor cover on bed of press (inner face of cover up). Start second bearing straight into bearing bore
of cover with number on bearing up; place a flat washer over pilot of bearing remover, part No. J4647; insert pilot of tool
into bearing and under ram of press.
(d) Press bearing down into cover until washer contacts boss on cover. Lower bearing should be flush with end of
bearing boss.
(e) Apply lubricant to retaining pin and place cam (17) over pin with boss of cam up.
(f) Place washer (14) over pin and secure with spring retainer (13).
(g) Lubricate throttle shaft bearings (8) with clean engine oil. Insert throttle shaft (7) through bearings.
(h) Insert seal ring (19) over shaft and into counterbore against throttle shaft bearing (8). Place seal ring retainer (18)
over shaft and against seal ring.
(i) Start throttle control (15) over throttle shaft (7) with holes in lever and shaft for pin (12) in alinement.
(j) Support lower end of throttle shaft on bed of arbor press. Place a hollow sleeve on throttle control (15) and under
ram of press.
(k) Align slot in cam (17) with pin in throttle lever (15) and press lever down on shaft until hole in lever is in line with
hole in shaft.
(l) Insert tapered pin (12) in hole of lever (15). Support lever and cover assembly on steel block and drive pin into
place.
(m) Position throttle control lever (11) on throttle shaft (37) and tighten retaining capscrew (9).
(n) Attach one end of cam control spring (16) in small hole of cam (17).
(2) Governor control housing assembly reassembly.
(a) Place washer (38) over short finished end of operating shaft (37). Start operating shaft bearing (39) over end of
shaft. Support opposite end of shaft on bed of press. Using a hollow sleeve having same diameter as bearing inner race,
press bearing on shaft tight against washer.
(b) With pivot pin in operating shaft lever (3) up, start lever over end of shaft (37) with flat on shaft registering with
flat surface in lever. Press lever on shaft tight against operating shaft bearing (39).
(c) Lubricate bearing (39) and operating shaft bushing (77) in housing with clean engine oil Military Specification MILL-2104.
(d) Insert lever and operating shaft assembly in control housing.
(e) Position operating shaft fork (73) over lower end of operating shaft (37) so finished side of fork finger will rest
against riser thrust bearing (60) when assembled.
(f) Support operating shaft and control housing in an arbor press with upper end of the operating shaft resting on a
steel block. Align flat in the operating fork with flat on operating shaft. Place a sleeve over end of shaft and rest it on
fork.
3-43
Bring ram of press down on sleeve and press fork (73) straight down and tight against shoulder on shaft (37).
(g) Tighten fork setscrew (74).
(h) Apply sealant around periphery of expansion plug (76) and press plug into the lower end of control housing (48).
(i) Place lockwasher (41) and flat washer (40) over bearing retaining screw (42). Thread screw in control housing to
secure operating shaft bearing (39).
(j) Place differential lever (4) over pivot pin of operating lever(3).Install washer (5) and spring retainer (6).
(k) Thread locknut (49) on screw (50) and thread screw into governor control housing (48).
(l) Thread locknut (29) on high speed spring retainer (28w approximately 1lh inches.
(m) Place high speed spring (32) over high speed spring plunger (33) with tightly wound end of spring against
shoulder of plunger.
(n) Insert plunger and spring assembly in high speed spring retainer (28).
(o) Thread screw (31) about 1 inch into tapped end of plunger. Thread locknut (30) over screw.
(p) Insert low speed spring (35) in the low speed spring cap 136) and small end of spring seat (34) in opposite end of
low speed spring.
(q) Insert low speed spring seat and low speed spring and cap assembly in high speed spring plunger (33) with low
speed spring seat (34) against shoulder of screw (31).
(r) Insert governor high speed spring assembly into opening of control housing and thread the high speed spring
retainer (28) in housing about 1 inch.
(s) Installation of high speed spring retainer cover (26) is not required until after governor has been installed on
engine and tune-up procedures have been completed.
(3) Governor weight housing assembly reassembly.
(a) Install retainer ring (51) in groove of weight pin (52). Place a washer (53) over weight pin and against retainer
ring.
(b) Start weight pin (52) through opening in weight carrier (57). Place a second washer (53) over weight pin and
against projecting arm of weight carrier.
(c) Position governor weight (55) between projecting arms of weight carrier (57). Push weight pin (52) through
governor weight.
(d) Place third washer (53) over weight pin (52) and against weight.
(e) Push pin completely through weight carrier and place fourth flat washer over pin and against projecting arm of
weight carrier.
(f) Install retainer ring (51) in groove of weight pin (52).
(g) Install second governor weight (55) same as in (a) through (f)above.
(h) Slide weight shaft (56) through weight carrier (57) and governor riser (58). Slide weight shaft against finished
surfaces of governor weights (55).
(i) Slide riser thrust bearing (601 on weight shaft (56) with bearing race having the smaller inside diameter against
governor riser (58). Incorrect installation of riser thrust bearing will result in erratic operation of the governor.
(j) Insert assembly consisting of governor riser (58), weight carrier (57), add weight shaft (56) into weight housing
(61).
CAUTION
This bearing has thrust capacity in one direction only. Install bearing so that thrust shoulder
is toward governor weights. Otherwise, the force exerted by weights will pull the inner race
and ball assembly away from the outer race and will result in damage to bearing and erratic
governor operation.
(k) Place lockwasher (71) over bolt (70). Thread bolt into tapped end of weight shaft (56) and tighten.
(l) Bend tang of lockwasher against head of bolt.
(m) Place a gasket (69) in weight housing (61) against bearing.
(n) Apply sealant on threads of weight housing plug (68) and thread plug into tapped end of weight housing (611.
Tighten plug.
f. Installation.
(1) Install new gasket on governor weight housing (7, fig. 3-37). Start splined end of drive shaft in upper blower rotor.
(2) Position housing against blower end plate. Install bolts (10), using a new copper washer on each bolt. Tighten
bolts fingertight only.
(3) Install a new gasket over dowels on side of weight housing facing engine.
(4) Move thrust bearing (6, fig. 3-39) and riser (7) toward weight carrier (8) end of shaft.
(5) Position the lower end of control housing (2) over dowel pins on weight housing (1). Be sure that operating shaft
fork (5) is positioned against thrust bearing (6) as shown in figure 3-39.
(6) Install new gasket and secure upper position of governor control housing (6, fig. 3-37) to cylinder head with two
bolts (4) and lockwashers.
(7) Tighten governor mounting bolts (10).
(8) Install new gasket on weight housing cover (9) and install cover with four bolts (8J and lockwashers.
3-44
(9) Connect oil line to fitting on governor weights housing.
(10) Position fuel rod (31 over pin in control housing. Place washer over pin and secure with retainer.
(11) Attach fuel rod to injector control tube lever (2) and secure with pin and cotter pin.
(12) Install new cover gasket on governor control housing and mount cover (5) on housing. Be sure pin on
throttle bracket shaft is engaged with slot in lever in housing as shown in figure 3-39.
(13) Secure cover to housing with four screws (11) and lockwashers.
NOTE
One end of cam spring is anchored to one cover screw.
(14) If injector controls were disturbed, readjust injector rack settings (TM 55-1930-203-20.) Start engine and
adjust governor idling and overspeed settings (TM 55-1930-203-20).
Figure 3-39. Governor assembly.
3-45
3-14. Fluid Starting Aid
a. Removal.
(1) Actuate pump assembly (5, fig. 3-40) approximately 20 times to insure puncturing tool assembly (1) is empty of ether.
(2) Slowly unscrew top of puncturing tool assembly (1) and remove ether capsule (2).
(3) Remove tubes (9 and 7).
(4) Remove spray nozzle elbow (6).
(5) Remove elbows (3 and 8) from pump assembly (5).
(6) Unscrew large nut next to pump assembly handle and remove pump plunger. Remove plunger seals (4) from plunger.
(7) Remove pump body from bracket.
(8) Remove fitting (11) from base of puncturing tool assembly (1).
(9) Remove base of puncturing tool assembly (1) by removing four machine screws (10).
Figure 3-40. Fluid starting aid.
b. Cleaning, Inspection, and Repair.
(1) Clean all parts thoroughly by wiping parts with a cloth dampened in dry-cleaning solvent, Federal Specification P-D680.
CAUTION
Do not immerse pump assembly in drycleaning solvent, as pump plunger seal may be damaged by solution.
(2) Inspect pump plunger seal (4, fig. 3-40) for condition. Seal should be pliable and fit snugly around end of pump
plunger. Replace unserviceable seal.
(3) Inspect all tubing for crimped or ruptured condition. Replace tubing if damaged.
c. Installation. Install all removed parts in the reverse order of removal.
3-15. Lubricating Oil Cooler Assembly
a. Removal
(1) Open drain cock and drain coolant from oil cooler into a suitable container.
3-46
(2) Remove drain plug on oil cooler adapter (10, fig. 3-41) and drain oil from full flow filter into a suitable
container.
(3) Remove clamp connecting oil cooler to water pump (7, fig. 3-43).
(4) Loosen screws and slide hose off engine water inlet.
(5) Disconnect filter-to-cooler and cooler to transmission oil hoses from oil cooler.
(6) Remove bolts (12 and 37, fig. 3-41) and lockwashers (11 and 38) attaching oil cooler to oil cooler adapter and
remove oil cooler and gasket (9).
CAUTION
Do not drop or damage core assembly (8) when removing oil cooler from adapter.
(7) Remove plug (18), washer (17), bypass plunger spring (16), and bypass plunger (15) from oil cooler adapter.
b. Disassembly.
(1) Remove core assembly (8, fig. 3-41) and gasket (7) from oil cooler housing (6).
(2) Remove bolts (1) and lockwashers (2) securing oil cooler cover (36) to cooler housing.
(3) Remove oil cooler cover, gasket (3), core assembly (4), and gasket (5) from cooler housing.
3-47
Figure 3-41. Lubricating oil cooler and full flow oil filter.
3-48
vapors. When diluting acids, do not add water to
acid; acid must be added to the mixture slowly and
with constant mixing. In case of contact with acid,
flush the affected part thoroughly with water and
seek medical aid immediately.
NOTE
The cleaning action is evidenced by bubbling and
foaming. Watch process carefully and when bubbling
stops, remove oil cooler. This usually takes from 30 to
60 seconds.
(3) After removing core assemblies from
cleaning solution, flush core assemblies thoroughly with
clean, hot water and dip in light oil.
(4) Wash cover (36), housing (6), bypass
plunger (15), and bypass plunger spring (16) in clean
fuel oil and then dry with compressed air.
(5) Inspect core assemblies (4 and 8) for cracks
or any evidence of leakage between oil and coolant
sides. Replace core assembly if leakage is suspected.
(6) Inspect housing (6), especially around water
connections, for cracks. Replace cracked housing.
(7) Inspect bypass plunger (15). If plunger is
scored or pitted, replace plunger.
(8) Check plunger spring (16) with a spring
tester. The spring has a free length of approximately 2
1/64 inches. A force of 13 3/8 to 14 5/8 pounds is
required to compress to a length of 1 51/64 inches.
Replace a weak spring.
d. Reassembly.
(1) Apply clean engine oil to outside surface of
bypass plunger (15, fig. 3-41) and place plunger in oil
cooler adapter (10), closed end first.
(2) Place bypass plunger spring (16) in oil cooler
adapter and install washer (17) and plug (18).
(3) Place inner gaskets (5 and 7) over core
assemblies (4 and 8) and position core assemblies in oil
cooler housing (6).
(4) Aline holes in outer gasket 13) with holes in
core assembly (4) and secure oil cooler cover (36) and
gasket to housing with bolts (1) and lock washers (2).
e. Installation.
(1) Aline holes in outer gasket (9, fig. 3-41) with
holes in core assembly (8) and secure oil cooler to oil
cooler adapter (10) with bolts (12 and 37) and
lockwashers (11 and 38).
(2) Install clamp (7, fig. 3-43) connecting oil
cooler to water pump.
(3) Connect water inlet hose to oil cooler.
(4) Connect filter-to-cooler and cooler-totransmission hoses to oil cooler.
(5) Install drain plug in oil cooler adapter and fill
engine crankcase in accordance with LO 55-1930-20312.
(6) Fill cooling system with coolant (TM 55-930203-20).
(7) Start engine and check for leaks (TM 55-1930-20320).
Key to figure 3-41.
1 Bolt, cooler housing
2 Lockwasher
3 Gasket, outer
4 Core assembly
5 Gasket, inner
6 Oil cooler housing
7 Gasket, inner
8 Core assembly
9 Gasket, outer
10 Oil cooler adapter
11 Lockwasher
12 Bolt, oil cooler adapter
13 Gasket, oil cooler adapter
14 Gasket, oil cooler adapter
15 Oil cooler bypass plunger
16 Oil cooler bypass plunger spring
17 Washer, bypass plug
18 Plug
19 Filter bypass valve
20 Filter bypass valve spring
21 Gasket, bypass plug
22 Plug
23 Filter element spring
24 Washer, filter element retainer
25 Preformed packing
26 Retainer, filter element
27 Washer, filter element retainer
28 Washer, nonmetallic
29 Filter element
30 Lockwasher
31 Bolt, oil cooler adapter
32 Filter shell
33 Gasket, filter shell nut
34 Stud, center
35 Nut, filter shell
36 Oil cooler cover
37 Bolt, cooler housing cover
38 Lockwasher
c. Cleaning, Inspection and Repair.
NOTE
Cleaning of core assemblies is not recommended where
history of usage shows an engine failure which has
released metal particles. In such a case, replace the
core assemblies.
(1) Circulate dry-cleaning solvent, Federal
Specification P-D-680, through oil passages of core
assemblies (4 and 8, fig. 3-41). Force solution through
core assemblies with a force pump. If oil passages are
badly clogged, circulate an alkaline solution through
core assemblies and flush with clean, hot water.
(2) To clean water side of core assemblies,
immerse core assemblies in a solution consisting of ½
gallon of oxalic acid to each 2 ½ , gallons of solution
composed of 1/3 muriatic acid and 2/3 water.
WARNING
Acids can cause serious burns or blinding. Avoid
contact with eyes, skin, or clothing. Do not breathe
3-49
3-16. Oil Filters
a. Full Flow Oil Filter.
(1) Removal
(a) Remove drain plug on oil cooler adapter (10, fig. 3-41) and drain oil from full flow oil filter into a
suitable container.
(b) Loosen nut (35) and remove filter shell (32) and filter element (29) from oil cooler adapter. Remove
nonmetallic washer (28).
(c) Remove oil cooler (para 3-15).
(d) Remove bolts (31) and lockwashers (30) securing oil cooler adapter to cylinder block. Remove oil
cooler adapter and gaskets (13 and 14) from cylinder block.
(2) Disassembly.
(a) Withdraw filter element (29, fig. 3-41) from filter shell (32). Remove spring (23), retainer(26),
washers (24 and 27), and packing (25) from filter element.
(b) Remove plug (22), gasket (21), bypass valve spring (20), and bypass valve (19) from oil cooler
adapter.
(c) Remove plug (18), washer (17), bypass plunger spring (16), and oil cooler bypass plunger (15) from
oil cooler adapter.
(3) Cleaning, inspection and repair.
(a) Wash oil cooler adapter (10, fig. 3-41), filter shell (32), springs (16, 20, and 23), valve (19), and
plunger (15) in clean fuel oil and wipe dry with a lint-free cloth. Use a small wire to free oil ports in adapter of sludge and
accumulations. Blow out ports with compressed air.
(b) Inspect adapter for signs of cracking or leaks. Replace adapter if damaged.
(c) Examine valve (19) and plunger (15) for signs of scoring or pitting. Replace a defective valve or
plunger.
(d) Check oil cooler bypass plunger spring (para 3-15).
(e) Check filter bypass valve spring (20) with a spring tester. The spring has a free length of
approximately 3 17/32 inches. A force of 10 ½ to 11 ½ pounds is required to compress spring to a length of 2 ½ inches.
Replace a weak spring.
(f) Replace nonmetallic washer (28), gasket (33), packing (25), and filter element (29).
(g) Scrape oil gasket material from adapter mounting bosses on cylinder block.
(4) Reassembly.
(a) Apply clean engine oil to outside surface of bypass plunger (15, fig. 3-41) and place plunger in
adapter (10), with closed end first.
(b) Install spring 116), washer (17), and plug (18).
(c) Install bypass valve (19), bypass valve spring (20), gasket (2 1), and plug (22) in oil cooler adapter.
(d) Install spring (23), washer (24), packing (25), retainer (26), washer (27), and filter element (29) in filter
shell (32).
(5) Installation.
(a) Position gaskets (13 and 14, fig. 3-41) on bosses of cylinder clock and secure oil cooler adapter to
cylinder block with bolts (311 and lockwashers (30).
(b) Place new washer (28) in oil cooler adapter and position assembled filter element and filter shell on
oil cooler adapter.
(c) Install gasket (33), stud (34), and nut (35).
(d) Install engine oil cooler (para 3-15).
(e) Install drain plug in oil cooler adapter and fill engine crankcase in accordance with LO 55-1 930-20312.
b. Bypass oil Filter.
(1) Removal and disassembly.
(a) Remove drain plug (11, fig. 3-42) from filter cover (10) and drain oil into a suitable container.
(b) Unscrew center stud (1) and lift filter housing, filter element, and stud oil filter cover. Remove gasket
(6).
(c) Withdraw filter element (5) and filter spring (4) from filter housing (3).
(d) Withdraw stud from filter housing and remove gasket (2) from stud.
(e) Disconnect outlet and inlet tubes (12 and 13) from cover.
(f) Remove bolts (9) and lockwashers (8) attaching cover to cylinder block. Remove plug (7) from cover.
(2) Cleaning, inspection and repair.
(a) Wash filter cover (10, fig. 3-42), housing (3), and spring (4) in clean fuel oil and wipe them dry with a
lint-free cloth.
(b) Inspect cover for cracks. Replace a cracked cover.
(c) Replace filter element (5) and gasket (2 and 6).
(3) Reassembly and installation. Reassemble and install in reverse order of disassembly and removal.
3-50
3-17. Water Pump
a. Description. The high capacity water pump
circulates the engine coolant through the engine cylinder
block and cylinder head, and into the expansion tank. The
drive end of the pump shaft is supported by a sealed,
double-row combination radial and thrust ball bearing. The
pump shaft serves as the inner race of the bearing. A springloaded seal assembly and a water slinger prevent coolant
from passing along the shaft to the bearing. The drive
coupling pressed on the end of the shaft has an integral oil
thrower that shrouds the flange end of the pump body and
deflects oil away from the bearing.
b. Removal
(1) Drain applicable cooling system (TM 55-1930203-20).
(2) Loosen clamp (7, fig. 3-43) at top of oil cooler
and remove clamps (6) on bypass hose to water manifold.
(3) Remove bolt and seal assemblies (1) attaching
the water pump (11) to blower housing.
NOTE
Bolt and seal assemblies (1) attaching water pump (1) to
blower require a special wrench, part No.J4242 or
equivalent, to facilitate removal.
(4) Remove bolts and lockwashers attaching outlet
flange (4) to cylinder block. Remove outlet flange and
preformed packing (3) by removing bolts (2) and
lockwashers.
(5) Remove water pump (11) and gasket.
(6) Remove clamp (7) and packing (8).
Figure 3-42. Bypass oil filter.
3-51
(7) Remove sheared pin (11) from shaft
and impeller.
(8) Remove drive coupling (1), as shown in
figure 3-46, using bearing and bushing driver (2).
Figure 3-43. Water pump assembly, removal and
installation.
c. Disassembly.
(1) Remove nuts (13, fig. 3-44) and
lockwashers (14) securing water pump cover (12)
to pump body (4). Remove cover and gasket (6).
(2) Remove drain cock (15) from pump
body.
(3) Place pump on mounting flanges in an
arbor press as shown in figure 3-45.
(4) Using a short steel bar (1), apply
pressure to shaft until pin (11, fig. 3-44) shears.
Separate shaft and bearing assembly from
impeller, seal assembly, and pump body.
(5) Remove impeller (10), spring (9). and
seal assembly (8).
(6) Remove water slinger from shaft.
Figure 3-44. Water pump assembly
3-52
Key to figure 3-44.
1 Drive coupling
2 Shaft and bearing assembly
3 Water slinger
4 Pump body
5 Stud, plain
6 Gasket, cover
7 Bushing
8 Seal assembly
9 Spring
10
Impeller
11
Pin, impeller
12
Water pump cover
13
Nut
14
Lockwasher
15
Drain cock
1 Steel bar
2 Bearing and bushing driver, part no. J1930
3 Drive coupling
4 Steel
Figure 3-46. Removing water pump drive
coupling from shaft.
1
2
3
4
Steel Bar
Impeller
Pump body
Shaft and bearing assembly
Figure 3-45. Pressing water pump shaft from
impeller
3-53
d. Cleaning, Inspection and Repair.
(1) Clean all metal parts except shaft and
bearing assembly (2, fig. 3-44) in dry-cleaning
solvent, Federal Specification P-D-680.
(2) Rotate pump shaft bearing on shaft
and bearing assembly (2). If rough spots are
detected, replace shaft and bearing assembly.
(3) Inspect drive coupling (1) for cracked
or broken legs. Replace a defective drive
coupling.
(4) Inspect impeller (10) for cracks or
broken
blades. Check that hub is smooth and flat. Replace a
defective impeller.
(5) Inspect that seal assembly (8) is not
scratched or marred. Replace a scratched or marred
seal assembly.
NOTE
Seal assembly is available as an assembly only
and includes the carbon washer, seal, ring,
guide, and spring. A seal assembly is included
with a replacement impeller.
(6) Inspect pump body (4) for a cracked
housing or loose or stripped studs (5). Replace housing
if cracked, If studs are defective, install new studs and
tighten to 10 to 12 foot-pounds.
NOTE
A replacement pump body includes studs
and bushing (7).
(7) Check seal contact surface of bushing (7)
for being marred. If seal contact surface of bushing is
marred or if bushing is loose, replace bushing as follows:
(a) Press out old bushing.
(b) Thoroughly clean counterbore in
pump body.
(c) Start the counterbored end of bushing into pump body.
(d) Press bushing in until bushing contacts shoulder in pump body.
NOTE
The bushing has a 0.0015 to 0.0035 inch press
fit in pump body.
(8) Replace gasket (6).
e. Reassembly.
(1) Install water slinger (3, fig. 3-44) on shaft
and bearing assembly (2) with flange of slinger approximately 3/16 inch from end of outer race of bearing.
(2) Support impeller end of pump body on an
arbor press and insert slinger end of shaft and bearing
assembly into pump body.
(3) Press against outer race of bearing until
bearing contacts shoulder in pump body. Stake end of
pump body in three places to prevent bearing from
moving endwise.
(4) Apply a thin film of 10 weight oil to seal
contact surface of bushing (7).
(5) Apply a thin coat of liquid soap on inside
diameter of rubber seal of seal assembly (8).
(6) Slide seal assembly (8) on pump shaft
and bearing assembly (2) until the carbon seal washer is
seated firmly against bushing (7).
(7) Install spring (9) with small end toward
seal assembly.
(8) Place impeller I1 0) on shaft with pin hole
in shaft aligned midway between two adjacent blades of
the impeller.
(9) Support bearing end of bearing and shaft
assembly on an arbor press as shown in figure 3-47.
(10) Using impeller installer (1) as shown in
figure 3-47, press impeller (2) on shaft.
NOTE
Impeller installer (1) is used to obtain specified
distance of 0.099 to 0.101 inch between end of
shaft and face of impeller hub.
(11) Insert a 0.184 inch drill in pin hole of shaft
and bearing assembly (2, fig. 3-44) and drill through m
i peller hub. Secure impeller to shaft with pin (11).
(12) Support impeller end of shaft on a suitable arbor and, using a brass hammer, tap drive coupling (1) onto shaft until coupling is flush with outer end.
NOTE
If installing a used coupling, check for a tight fit
on shaft. If coupling is loose on shaft, replace
coupling.
(13) Place cover gasket (6) on studs in pump
body and secure water pump cover (12) to pump body
with lockwashers (14) and nuts (13).
(14) Install drain cock (15) in pump body.
Figure 3-47. Installing water pump impeller.
f.
Installation. Install water pump in reverse order
of removal using new gasket between water pump and
blower housing and new preformed packing between
outlet flange and cylinder block.
3-18. Air Starting Motor
a. Description. The air starting motor assembly
3-54
contains a rotor and a friction-clutch type drive assembly. The drive assembly consists of a series of driving and driven clutches
that are spring-loaded by a small spiral spring. There are two series of air starting motors used, the A31RH6 and the B21RH6.
The A31RH6 air starting motor was originally installed on the engines of hulls 5 through 18, and the B21RH6 on the engines of
hulls 19 through 24. These motors differ structurally and
will be treated separately in disassembly and reassembly.
b. Removal.
(1) Close globe valves located in air lines above air supply tanks and open service connection glove valve in upper
machinery area to release pressure from air lines (para 2-11).
(2) Disconnect flexible hose (3, fig. 3-48) from starting motor (para 2-11).
(3) Disconnect air hoses from pilot air valve (10).
(4) Remove bolts (9), lockwashers (11), and nuts (12) securing pilot air valve to bracket and lift valve from bracket.
(5) Remove bolts and lockwashers securing air starting motor to flywheel housing, and remove air starting motor and
gasket (1).
Figure 3-48. Air starting motor assembly, air filter, and lubricator
c. Disassembly.
(1) Series A31RH6 motor disassembly.
NOTE
Reference marks listed in disassembly procedure will facilitate reassembly and insure assembly for proper direction of rotation.
(a) Place reference marks on housing cover (4, fig. 3-49), motor housing (19), gear case (27), and drive housing
(35).
(b) Remove capscrews (22) and lockwashers (21), and remove gearcase (27) with assembled parts from motor
housing (19).
3-55
(c) Remove capscrews (1) and lockwashers (2), and remove housing cover (4), housing cover gasket (6),
and rotor bearing spring (5) from motor housing (19). Remove grease fitting (3) from housing cover (4). Mark
rear end plate (10), cylinder (15), and motor housing (19) for position.
(d) Tap the end of rotor pinion (14) lightly with a soft hammer or block of wood until motor assembly is
loose and can be withdrawn from motor housing (19), (fig. 3-50). Mark position of front end plate (16, fig. 3-49)
with reference to cylinder (15).
(e) Push cylinder dowel (9) from dowel holes in rear and front end plates (10 and 16) and cylinder (151
with a punch or rod (fig. 3-51).
(f) Secure rotor pinion (14, fig. 3-49) in a soft-jawed vise, and unscrew lockscrew (7) from rotor. This
lockscrew has a left-hand thread; turn clockwise to remove.
(g) Insert a 5/16 inch diameter steel rod about 5M2 inches long into the hole from which lockscrew (7)
was removed. Grasp cylinder (15) with one hand and drive on rod until rear rotor bearing (8) and rear end plate
(10) are free from rotor (13) (fig. 3-52). Press rear rotor bearing (8, fig. 3-49) from end plate (10).
NOTE
Do not clamp cylinder in a vise.
(h) Remove rotor bearing spacer (11), cylinder (15), and vanes (12) from rotor (13).
NOTE
Further disassembly is not necessary for vane replacement.
(i) Support front end plate (16) as close to rotor (13) as possible and press on end of rotor pinion (14)
until front rotor bearing (17) and front end plate are free of rotor hub (fig. 3-53). Press front rotor bearing (17, fig.
3-49) from front end plate (16).
NOTE
Do not remove pinion unless broken or damaged.
(j) Press rotor pinion (14) out of rotor (13) with a 5/16-inch diameter arbor.
(k) Remove plug (20) and air port gasket (18). Note from which cavity gasket was removed.
(l) Remove bolts (41) and lockwashers (42) attaching drive housing (35) to gear case (27).
(m) Tap drive housing (35) loose from gear case (27) and remove starter drive (34).
(n) Remove bushing oiler plug (36) and bushing oiler (37), and press out drive housing (38) with arbor.
(o) Secure splines on drive shaft (33) in copper-covered vise jaws, unscrew drive gear retaining screw
(23), and remove washer (24).
(p) Support front face of gearcase (27) outside gearcase grease seal (32). Place a suitable arbor against
gear end of drive shaft (33), and press shaft from drive gear (26). The drive shaft bearing spacer (30),
drive shaft bearings (29), drive shaft collar (31), and gear case grease seal (32) will remain on drive
shaft.
NOTE
When drive shaft 133) in removed, the gearcase grease seal 1321 will be damaged. A new seal must be used when
reassembling.
(q) Remove drive gear key (25) from end of drive shaft (33). Support face of drive shaft collar (31) and
press end of shaft through bearings (29), drive shaft bearing spacer (301, and drive shaft collar (31). Remove
gearcase grease seal (32) from drive shaft collar (31).
3-56
Figure 3-49. Series A31RH6 air starting motor.
3-57
Figure 3-50. Removing motor assembly from
motor housing.
Figure 3-52. Removing rear bearing and end
plate.
Figure 3-51. Removing cylinder dowels.
3-58
Figure 3-53. Removing front bearing and end plate.
3-59
Figure 3-54. Series B21RH6 air starting motor.
3-60
Key to figure 3-54.
1 Capscrew, motor housing cover
2 Lockwasher, cover capscrew
3 Oil chamber plug
4 Oiler felt
5 Screw, oiler adjusting
6 Motor housing cover
7 Motor housing cover gasket
8 Rear rotor bearing retainer
9 Rear rotor bearing
10 Rear end plate
11 Vane
12 Rotor
13 Cylinder
14 Front end plate
15 Front rotor bearing
16 Cylinder dowel
17 Rotor pinion
18 Rotor pinion retainer
19 Motor housing
20 Gearcase gasket
21 Drive housing bushing
22 Mounting bolt bushing
23 Lockwasher, mounting bolt
24 Starter drive
25 Drive shaft
26 Drive shaft grease seal
27 Gearcase cover
28 Drive shaft front bearing
29 Drive gear
30 Washer, bearing ejecting
31 Gearcase
32 Angle grease fitting
33 Drive shaft rear bearing
34 Drive shaft collar
35 Drive gear key
36 Lockwasher
37 Capscrew, drive housing
38 Drive housing
39 Bushing oiler
40 Bushing oiler plug
(2) Series 821RR6 motor disassembly.
NOTE
Reference marks listed in disassembly procedure will facilitate reassembly and insure assembly for proper direction of
rotation.
(a) Place reference marks on motor housing cover (6, fig. 3-54), motor housing (19), gearcase (31), gearcase
cover (27), and drive housing (38).
(b) Remove motor housing capscrews (1) and lockwashers (2) and remove motor housing cover (6) and motor
housing cover gasket (7) from motor housing (19). Remove oiler adjusting screw (5), oiler felt (4), and oil chamber plug
(3) from motor housing cover (6).
(c) Mark rear end plate (10), cylinder (13), and motor housing (11) for position. Separate motor housing (19) from
gearcase (31).
(d) Draw motor assembly out of motor housing (19) and mark front end plate (14) position with references to
cylinder (13). Remove ,gearcase gasket (20) from front end plate (14).
(e) Position motor assembly vertically, grasping rotor pinion (17) in copper-covered vise jaws. Using retaining
ring pliers (fig. 3-55), remove rear rotor bearing retainer (8, fig. 3-54), and lift off rear rotor bearing (9), rear end plate
(10), and cylinder (13). Remove cylinder dowel (16).
(f) Remove vanes (11) from rotor (12).
NOTE
Further disassembly of the motor is not necessary for vane replacement.
(g) Position rotor (12) vertically, pinion end up, and hold bottom rotor hub in copper-covered vise jaws. Remove
rotor pinion retainer (18) with a screwdriver (fig. 3-56).
(h) Support front end plate (14, fig. 3-54) on wooden blocks as close to rotor as possible and press rotor from
rotor pinion (17), freeing front rotor bearing (15) and front end plate (14). Do not let rotor fall when pressed free (fig.
3-57).
(i) Remove bolts (37, fig. 3-54) and lockwashers (36) attaching drive housing (38) to gear case (3 1).
(j) Tap drive housing (38) loose from gearcase (31) and remove starter drive (24).
(k) Withdraw drive shaft (25) and drive gear (29) from gearcase (31).
(l) Pull gearcase cover (27) and drive shaft grease seal 126) from front end of drive shaft (25). Remove drive
shaft grease seal (26) from gearcase cover and discard seal.
(m) Support drive gear (29) and press out drive shaft (25) (fig. 3-54). Remove drive gear key (35, fig. 3-54).
(n) Stand drive shaft (25), bearing end up, in a pressing sleeve (fig. 3-59). Press drive shaft (25, fig. 3-54) from
bore of drive shaft from bearing (28) and drive shaft collar (34).
(o) Screw a 5/16 inch capscrew into bearing ejecting washer (30) and pull drive shaft rear bearing (33) from
gearcase (31) Remove angle grease fitting (32) from gearcase.
(p) Press drive housing bushing (21) from end of drive housing (38). Remove bushingoiler plug (40) and bushing
oiler (39) from drive housing.
3-61
Figure 3-55. Removing bearing retainer.
Figure 3-56. Removing rotor pinion retainer.
3-62
Figure 3-57. Removing front rotor bearing.
3-63
Figure 3-58. Removing drive gear.
Figure 3-59. Removing drive shaft.
d. Cleaning, Inspection and Repair.
(1) Clean all parts in dry-cleaning solvent, Federal Specification I-D-680, and dry with compressed air (10 psi).
(2) Examine front end plate face for scoring. Clean with crocus cloth, Federal Specification P-C-458, if scoring is
not too deep. Replace front end plate if necessary.
(3) Inspect rotor pinion for broken or chipped teeth. When only slight burrs exist, remove with soft stone, Military
Specification MIL-S.2389. Replace pinion if teeth are chipped or broken.
(4) Examine drive housing bushing for excessive wear. Replace if worn or out-of-round.
(5) Inspect rubber air port gasket. Replace if defective.
(6) Examine all bearings for scored, scratched, cracked, pitted, or chipped races. Rotate manually and determine
if rough. Replace if defective.
(7) Examine all bearing housings and shaft for grooved, burred, or galled conditions which would indicate that
bearings have been turning in their housings or on their shafts. When damage cannot be repaired with crocus cloth,
Federal Specification P-D-458, replace defective parts.
(8) Examine vanes for straightness, nicks, or burrs. When vanes are badly burned or bent, replace. Clean up
minor imperfections with crocus cloth, Federal Specification P-C-458.
(9) Inspect cylinder bore to assure it is smooth and free of scores. Replace cylinder if necessary.
(10) Inspect reduction gears for scoring or chipped teeth. Replace damaged gears.
e. Reassembly.
(1) Series A31RH6 motor reassembly.
(a) If rotor pinion (14, fig. 3-49) was removed from rotor (13), align-serrations on the new pinion shank
with grooves in rotor bore and start squarely into rotor. Support rear face and press in pinion until shoulder
contacts rotor hub.
(b) Support front end plate (16). Use an arbor that will contact only the outer ring of front rotor bearing
(17). Press bearing, shielded side first, into end plate recess. Replace rear rotor bearing (8) in rear end plate (10)
by the same procedure.
(c) Slip front rotor bearing (17), in front end plate (16), over pinion. Use a sleeve that will pass over
pinion and contact bearing inner ring. Press bearing onto rotor hub until only running clearances exist between
faces of front end plate (16) and rotor (13).
(d) Hold rotor vertically and secure pinion in copper-covered or lead vise jaws. Enter vanes (12) into
each slot in rotor. Make sure vances are all the same length.
(e) Place cylinder (15) over rotor (13). Reference marks made at disassembly should all agree. If
cylinder is inverted, direction of rotation will be reversed.
(f) Install rotor bearing spacer (11), chamfered end first, over rotor rear hub.
3-64
(g) Remove rotor with assembled parts from vise and press rear rotor bearing (8), in rear end plate (10), onto rotor
hub until bearing inner ring contacts spacer, but does not create a bind against rotor.
(h) Replace rotor with assembled parts in vise, clamping it by pinion (14), and screw lockscrew (7 into rotor tightly.
This is a left-hand thread; turn counter clockwise to tighten.
(i) Replace rubber air port gasket (18), large open end first, into inlet air port. Install plug (20) in motor housing (19).
(j) Aline dowel holes in each end plate with hole in cylinder. The cylinder dowel is the smallest of four holes drilled
lengthwise through cylinder wall. Insert a ¼ /4 inch diameter by 12 inch long rod through aligned holes, allowing rod to
protrude from pinion end of motor assembly.
NOTE
Reference marks made during disassembly should align.
(k) Enter rod into dowel hole at bottom motor housing bore and slide motor assembly, pinion end first, into motor
housing (19). Tap housing lightly on front face to jar motor into position. Remove rod and replace it with cylinder dowel
(9).
(l) Install housing cover gasket (6) on rear end plateface and position rotor bearing spring (5) with its prongs resting
on outer ring or rear rotor bearing (8).
(m) Replace housing cover (4) on motor housing (19), and install capscrews (1) and lockwashers (2). Rotate pinion
while tightening capscrews. Install grease fitting (3).
NOTE
Rotor must spin freely with the housing cover drawn tightly against the motor housing.
(n) Slide drive shaft collar (31) over drive gear end of drive shaft (33) until it contacts shoulder. Outer surface of this
collar contacts lip of gearcase grease seal (32). Make sure collar is smooth and free from nicks or burrs which could
cause damage to seal.
(o)Support inner ring of drive shaft bearing (29) and press drive shaft (33) through bearing until inner ring contacts
drive shaft collar. Slide drive shaft bearing spacer (30) onto shaft until it contacts inner ring of bearing. Press second
drive shaft bearing on shaft until inner ring contacts spacer. The collar, bearings, and spacer must contact each other
along shaft.
(p) Replace drive gear key (25) in drive shaft keyway.
(q)Position drive shaft and assembled parts squarely in gearcase bore and press this assembly in until outer ring of
leading drive shaft bearing seats on shoulder in gearcase.
(r)Support splined end of drive shaft, and align keyway in drive gear (26) with key. Press gear, hub side first, on
drive shaft until it contacts inner ring of bearing.
(s)Place above assembly in a vise with soft copper or lead-covered jaws and grasp splines on drive shaft. Place
washer (24), small hole side first, in gear counter bore and run drive gear retaining screw (23) into tapped hole in drive
shaft. Tighten screw, and lock to prevent rotation by upsetting rim of washer into screw head slot with a punch or chisel.
(t) Coat surface of drive shaft collar (31) with lightweight grease, Military Specification MIL-G-10924. Place gearcase
grease seal 132), lip side first, over collar, and with firm, even pressure, press seal into gearcase bore. Seal should seat
square against bore shoulder.
(u) Match reference marks on flange of motor housing (19) and gearcase (27). Join both assemblies, meshing pinion
with drive gear, and bolt them together with capscrews (22) and lockwashers (21).
(v) Install starter drive (34).
(w) If drive housing bushing (38) was removed, stand drive housing (35), small end up, on a table, and press a new
bushing into the small bore. Position bushings so oil slot in side of bushing is alined with oil hole that breaks into drive
housing bore. Press bushing until its leading face is flush with inner face of drive housing boss.
NOTE
Any excess in the bushing's length must protrude from the outer side of the boss.
(x)Saturate bushing oiler (37) with oil and insert into drive housing oil hole. Attach bushing oiler plug (36).
(y) Install drive housing (35).
(2) Series B21RH6 motor reassembly.
(a)Reverse disassembly procedure with the following exception.
NOTE
Refer to paragraph (b) through (e) below must be read carefully, and in order, before attempting to reassemble air
starting motor assembly.
(b)Press drive shaft grease seal (26, fig. 3-54), Jip side first, into gearcase cover (27).
(c) Press drive shaft rear bearing (33) unstamped end first, into gearcase (31).
(d) Install front and rear end plates (14 and 10) and push front and rear rotor bearings (15 and 9), sealed side first,
onto the rotor (12).
CAUTION
The three air ports in upper face
3-65
cylinder (13) must be to the left of dowel hole.
(e) Press drive housing bushing (21) into small end of drive housing (38). Position bushing so oil slot in side of
bushing is alined with the oilhole that breaks into drive housing bore. Press bushing until its leading face is flush with
inner face of drive housing boss.
(f) Install air starting motor on engine in reverse order of removal.
3-19. Fuel Pump Assembly
a. Description. The fuel pump is a positive displacement gear-type pump which transfers fuel oil from the supply tank
to the engine intake manifold. Fuel enters the pump on the inlet side and fills the space between the gear teeth which
are exposed at that instant. The gear teeth carry the fuel oil to the discharge or outlet side of the pump, and as the gear
teeth mesh in the center of the pump, fuel is forced from the outlet. Since this is a continuous cycle and fuel is continuously being forced from the outlet. fuel flows through the engine fuel system under pressure.
b. General. Fuel pump rotation of Model 6080 engines is counterclockwise and for Model 6081 engines rotation is
clockwise. A spring-loaded relief valve, set to operate at 65-70 psi. is installed in the outlet side of the pump to prevent
excessive pressures in the event of a clogged filter or blocked line. When operating properly, the pump will maintain a
fuel pressure at the fuel inlet manifold of 44) to 60 psi at 1800 rpm engine speed.
c. Removal. Refer to figure 3-60 and remove fuel pump assembly from blower assembly.
d. Disassembly.
(1) Place fuel pump in holding fixture, part No. J1508-10.
(2) Remove pump cover (5, fig. 3-61) from pump body (1). Use care not to damage finished faces of pump body
and cover.
(3) Remove drive shaft, drive gear (4), and ball (9) as an assembly from pump body (1)
(4) Press drive shaft through gear just far enough to remove steel locking ball. Invert shaft and gear assembly in
press and press shaft from gear. Do not misplace steel ball. Do not press Squared end of shaft through gear as slight
score marks will damage oil seal contact surface.
(5) Remove driven shaft (3) and driven gear
(8) as an assembly from pump body. Do not remove gear from shaft. Driven gear and shaft are serviced as an
assembly only.
(6) Remove relief valve plug (14) and gasket (13), holding hand on plug to relieve valve spring tension.
(7) Remove spring (12), pin (11), and relief valve (10) from valve cavity in pump body.
(8) Remove oil seals (15) with oil seal remover, part No. J1508-7 (fig. 3-62). Clamp pump body in bench vise and
screw threaded end of tool shaft into outer oil seal (seal nearest bolting flange). Tap pilot end of shaft with hammer to
remove seal. Repeat this operation to remove seal. Repeat this operation to remove inner oil seal.
3-66
1.
2.
3.
4.
5.
Fuel pump coupling fork
Gasket
Bolt and seal washer assembly
Fuel pump
Drain line
Figure 3-60. Fuel pump.
3-67
1 Pump body
2 Drive shaft
3 Driven shaft
4 Drive gear
5 Pump cover
6 Bolt, machine
7 Dowel pin
8 Driven gear
9 Ball, gear retaining
10 Relief valve
11 Pin
12 Spring
13 Gasket
14 Plug
15 Oil seals
Figure 3-61. Fuel pump assembly, (right hand pump shown)
e. Cleaning, Inspection and Repair.
(1) Wash all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(2) Discard old oil seals removed from pump body. New seals should fit snugly around pump shaft and must be free
of nicks or cracks.
(3) Plump gear teeth should be checked for scoring, chipping, or cracks. Check retaining ball slot in gear for chipping
or erosion. Replace gear if necessary.
(4) Inspect drive and driven shafts for scoring or erosion. Replace shafts if necessary. (Driven shaft is serviced as a
gear and shaft assembly only).
(5) Inspect mating faces of pump body and cover. Mating faces must be flat and smooth and fit tightly together.
Any scratches or slight damage may result in pressure leaks. Check for wear in areas of contact by gears and shafts. If
cover and/or body is defective, replace pump.
(6) Inspect relief valve to assure that it is free from score marks and burrs and fits properly in pump body. If relief
valve is scored and cannot be cleaned with fine emery cloth or crocus cloth, Federal Specification P-D-458, replace
valve.
Figure 3-62. Removing oil seals from fuel pump body with oil seal remover, part No. J1508-7
3-68
(7) Check valve spring for a free length of 1.97 inch. Spring should require a load of 7.3± 0.2 pounds to compress it
to a length of 1.18 inches. If spring falls below the above specifications, replace.
f. Reassembly.
(1) Place oil seals in pump body as follows:
(a) Lubricate lips of oil seals (15, fig. 3-61) with a light coat of vegetable oil.
(b) Place inner oil seal on pilot of installer handle so that lip of seal will face flanged end of pump.
(c) Insert pilot of installer handle into pump body so seal starts straight into pump flange.
(d) Support pump on wood blocks and drive seal into place in counterbore of flange until it bottoms.
(e) Place shorter end (end stamped 0.110) of adapter over pilot and against shoulder of installer handle (fig. 3-63).
(f) Place outer oil seal on pilot of installer handle with lip of seal facing adapter.
(g) Insert pilot of installer handle into pump so seal starts straight in pump flange, and drive seal into pump body
until shoulder of adapter contacts pump body. Seals will then be positioned so that space between seals
corresponds with drain holes in bottom of pump body.
Figure 3-63. Installing outer oil seal in fuel oil pump body with handler part No. J1508-8 and adapter, part No. J1508-9.
(2) Install relief valve assembly in pump body as follows:
(a)Clamp pump body (1, fig. 3-61) in soft jaws of bench vise with relief valve (10) cavity up.
(b) Lubricate outside diameter of relief valve (IO), and place valve in cavity with hollow end up.
(c) Insert spring (12) inside valve and pin (11) inside spring.
(d) Place new gasket (13) next to head of plug (14).
(e) Place plug over spring and thread into pump body. Tighten plug.
(3) Install gear and shaft assemblies in pump body as follows:
(a) Place fuel pump drive gear (4) over end of drive shaft 42) which is not squared (so slot in gear will face plain end
of shaft when installed). This step is very important; otherwise, fine score marks caused by pressing gear into position
from square end of shaft may cause rapid wear of oil seals (15).
(b)Press drive gear (4) slightly beyond gear retaining ball detent.
(c) Place ball (9) in detent and press gear back until end of slot contacts ball. Place shaft assembly in pump body.
(d) Place driven shaft (3) and driven gear (8) in pump body.
NOTE
Driven gear must be centered on shaft to give proper end clearance. Also chamfered
end of gear teeth must face pump body. If replacement gear with slot is used, slot must
face toward pump cover.
3-69
(e) Lubricate gears and shafts with clear engine oil.
(4) Apply two thin coatings of approved sealer an face of pump cover (5) outside of gear pocket area. Place cover
against pump body with two dowel pins (7) in cover entering holes in pump body (I). Pump cover (5) can be installed in
only one position over the two shafts.
CAUTION
Coating of sealant must be extremely thin since pump clearances have been set up on
basis of metal-to-metal contacts. Use care that sealant is not squeezed into gear
compartment; otherwise, damage to gears and shafts may result.
(5) Secure pump cover in place with eight bolts (6) and lockwashers, tightening bolts alternately and evenly.
(6) Rotate pump shaft by hand to make certain that parts rotate freely. If binding exists, tap corner of pump with a
hammer to relieve binding.
(7) Use plastic shipping plugs in inlet and outlet openings to prevent dirt or foreign material entering pump while
it is not in use.
g. Installation.
(1) Install gasket (2, fig 3-60) on fuel pump mounting flange.
NOTE
Two types of fuel pumps are used on the LARC, one for Model 6080RA engines, and the
other for Model 6081RC engines. These pumps are not interchangeable. When
installing a new fuel pump on an engine, always check the markings on the pump. Use
only pumps marked RH IN for Model 6081RC engines and LH IN for Model 6080RA
engines.
(2) Place coupling fork (1) over squared end of pump drive shaft with prongs of fork directed away from pump.
(3) Place pump in position in blower assembly with inlet opening in pump cover (marked LH IN or RH IN) on side
toward cylinder block. Be sure that prongs of coupling fork seat correctly in drive unit.
(4) Secure pump to blower with three bolt and seal washer assemblies (3).
(5) Connect fuel pipe from primary fuel filter to inlet opening (cylinder block side) on fuel pump.
(6) Connect fuel pipe from secondary fuel filter to outlet port on fuel pump.
(7) Connect drain line (5) to fuel pump.
3-20. Fuel Pump Assembly Testing
a. Disconnect flexible fuel return line at some point between fuel return manifold and supply tank. Hold open end
of line in a 1-gallon container (fig. 3-64).
b. Start and run engine at 1200 rpm and measure fuel flow return from manifold for a period of I minute.
Approximately 0.8 gallon of fuel per minute should flow from return line.
c. Immerse end of fuel line in container of fuel. Air bubbles rising to surface indicate air is being drawn into fuel
system.
NOTE
If pump output is below amount specified above, disassemble and repair.
3-70
Figure 3-64. Measuring fuel flow from fuel return manifold
3-21. Air Inlet Housing
a. Description. The air inlet housing is mounted on the blower assembly and provides a passage for air from the air
cleaners to the blowers. Air enters the air inlet housing through the air cleaners and passes through a fine mesh screen
to the blower assembly. Two damper type valves are installed in the outlet openings of the housing on a common shaft
connected to a lever mounted on the outside of the housing. Pulling upon the lever moves the damper valves up to a
position that blocks all flow of air to the engine preventing further combustion, this acting as an emergency shutdown
device,
b. Removal.
(1) Remove air cleaners from air inlet housing (TM 55-1930-203-20). Lift out air cleaner mounting tubes (2, fig.
3-65).
(2) Disconnect engine starting aid tube from nozzle assembly on air inlet housing and remove nozzle assembly (para
3-14).
(3) Remove bolts (22) and lockwashers (23) securing housing (I ) to blower and lift off housing.
(4) Remove gasket (15), striker plate (14), and screen (13).
c. Disassembly.
(1) Remove cotter pin (8, fig. 3-65) and remove emergency stop lever (7).
3-71
(2) Remove cotter pin (19), washer (20), and felt packing (2 1) from end of valve shaft (16).
(3) Knock out pins (17) securing shutdown valves (18) to valve shaft.
(4) Knock out pin 16) and remove valve lever (9), ball bearing (5), and spring (10).
(5) Remove two bolts (11), and lockwashers (12). Remove lock plate (4) and felt packing (3).
(6) Withdraw valve shaft (16) from air inlet housing (1) and remove shutdown valves (18).
1 Air inlet housing
2 Air cleaner mtg tube
3 Packing, felt
4 Lock plate
5 Ball bearing
6 Pin, valve lever
7 Emergency stop lever
8 Cotter pin
9 Valve lever
10 Spring
11 Bolt, machine
12 Lockwasher
13 Screen
14 Striker plate
15 Gasket, striker plate
16 Valve shaft
17 Pin
18 Valve, shutdown
19 Cotter pin
20 Washer, flat
21 Packing, felt
22 Bolt, housing mtg
23 Lockwasher
Figure 3-65. Air inlet housing.
d. Cleaning, Inspection and Repair.
(1) Clean all parts except gasket (15, fig. 3-65) and screen (13) in dry-cleaning solvent, Federal Specification PD-680, and blow dry with compressed air. Remove particles lodged in screen (13) carefully, to avoid widening mesh.
(2) Inspect to see that screen is not pulling away from frame. Replace a damaged or defective screen.
(3) Inspect to see that striker plate (14) and finished face of valves (18) are perfectly flat. Replace a damaged
striker plate or valve.
(4) Replace striker plate gasket (15).
(5) Replace valve shaft felt packings (3 and 21).
(6) Check spring (10) for breaks or distortion. Examine ball bearing for roundness. Replace a defective spring or
ball bearing.
3-72
(7) Inspect housing (1) for cracks or other damage, especially around inlet and outlet flanges. Replace a defective
housing.
(8) Inspect air cleaner mounting tubes (2) for being bent, cracked, or warped. Replace defective tubes.
e. Reassembly.
(1) Reassemble air inlet housing in reverse order of disassembly.
(2) Place a steel straightedge lengthwise on finished face of housing flange and close valves (18, fig. 3-65) against
straightedge. The finished pads at each end of valves must be flush against straightedge when straightedge is moved
from top to bottom of housing flange.
(3) Turn straightedge crosswise on housing flange and move straightedge from end to end on housing. The upper
and lower finished pads of valves must be flush against straightedge throughout length of valves.
(4) If valves are not flush against straightedge freely or close completely, disassemble air inlet housing and replace
the shutdown mechanism.
f. Installation. Install air inlet housing on blower in reverse order of removal. Tighten bolts (22, fig 3-65) to a torque
of 17 to 20 foot-pounds.
3-22. Blower Assembly
a. Description. Each diesel engine on the LARC is equipped with a blower which supplies fresh air needed for co
mbustion and scavenging. Its operation is similar to that of a gear-type oil pump. Two hollow three lobe rotors revolve
with very close clearances within a housing bolted to the cylinder block. To provide continuous and uniform displacement of air, rotor lobes are made with a helical (spiral) form. Each rotor is supported in the doweled end plates of the
blower housing by a roller bearing at the front end and a two-row preloaded radial and thrust ball bearing at the gear end.
The rotors turn at approximately twice engine speed and are driven by the blower drive shaft which is coupled to the p
uper rotor timing gear by means of a flexible drive hub.
b. General The blower may be inspected for any of the following conditions without being removed from the engine.
However, the air cleaners and air inlet housing must be removed (para 3-21).
(1) Dirt or chips. Dirt or chips drawn through the blower will make deep scratches in the rotors and housing and
throw up burrs around such abrasions. With the engine stopped, examine the rotors for such abrasions. If the burrs
cause interference between rotor or between rotor and housing, replace blower assembly.
(2) Leaking oil seal The presence of oil on the blower rotors or inside surfaces of the housing usually indicates a
leaking oil seal. To check for this condition, run the engine at low speed and direct a light into the compartment at the
end plates and oil seals. A thin film of oil radiating away from the seal indicates a defective seal. If seal is leaking, e
rplace blower assembly.
WARNING
When inspecting a blower with the engine running, keep hands and clothing away from
moving parts of the blower. Run engines at low speeds only.
(3) Worn blower drive. A worn blower drive, usually indicated by a rattling noise inside the blower, may be detected
by grasping the top rotor (with the engine stopped) and rotating it by hand. Rotors should have only from 3/8 to 5/8 inch
movement and should spring back at least I/4 inch when released. If the rotors do not move or move too freely, the
blower drive coupling should be removed, inspected, and replaced if necessary (para 3-23).
(4) Loose rotor shafts or damaged bearings. With the engine stopped, inspect the blower for signs of rubbing or
scoring. Rubbing and scoring of blower parts usually indicate a loose rotor shaft or damaged bearing. A loose rotor shaft
will normally cause rubbing between the rotors and the end plates. A defective bearing will cause rubbing between rotor
lobes or between rotor and housing, generally at the end where the bearings have failed. If rotor shafts are loose or
bearing is defective, replace blower assembly.
(5) Timing gear backlash. Excessive backlash in timing gears will result in rotor lobes rubbing throughout their entire
length. If rotor lobes are rubbing, replace blower assembly.
c. Removal
(1) Remove air cleaners (TM 55-1930-203-20).
(2) Remove air inlet housing (para 3-21).
(3) Remove water pump (para 3-17).
(4) Remove governor assembly (para 3-13).
(5) Remove fuel pump (para 3-19).
(6) Remove bolts (16 and 19, fig. 3-66), nuts (20), and lockwashers (18 and 21) securing cover (22) to flywheel
housing. Remove cover and gasket (23).
(7) Remove retaining ring (24) and pull blower drive shaft (25) straight out from drive assembly.
(8) On blower assemblies, part No. 5120996 and 5120993, loosen clamp (51 on seal (6). On blower assemblies,
part No. 5114472 and 5114469, remove bolts securing drive cover and gasket to blower.
(9) Support blower assembly (3) and remove mounting bolts (1) and lockwashers (2) at top and bottom of blower
housing.
3-73
(10) Slide blower assembly away from flywheel housing and pull blower assembly away from cylinder block. Remove mounting gasket (4)
1 Bolt, machine, 7/16 x 2 in.
2 Lockwasher, 1/16 in.
3 Blower assembly
4 Gasket, blower mtg
5 Clamp
6 Seal, blower drive tube
7 Blower, drive cover tube.
8 Seal, blower drive cover
9 Clamp
10 Nut, blower drive gear hub
11 Washer, key
12 Washer, thrust
13 Bolt, machine, 3/8 x 7/8 in.
14 Lockwasher, 7/8 in.
15 Elbow, oil pipe
16 Bolt, machine, 38 x 5 in.
17 Drive gear hub support
18 Lockwasher, 7/8 in.
19 Bolt, machine, 3/8 x 7/8 in.
20 Nut, 3 / 8 in.
21 Lockwasher, 3/8 in.
22 Cover
23 Gasket, cover
24 Retaining ring
25 Blower drive shaft
26 Bolt, blower drive coupling
27 Lockwasher, 516 in.
28 Drive coupling retainer
29 Drive coupling cam
30 Spring seats
31 Spring pack
32 Spring end seat
33 Drive coupling support
34 Blower drive gear
35 Drive gear hub
36 Ball bearing
37 Thrust washer
38 Gasket, hub support
Figure 3-66. Blower assembly and drive assembly
3-74
d. Disassembly.
(1) Remove bolts (1, fig. 3-67) and lockwashers 12); pull front end plate cover (3) off dowel pins of front end plate
(12). Remove gasket (4).
(2) Remove bolts (33) and lockwashers (32); pull rear end plate cover (31) off dowel pins of rear end plate 119).
Remove gasket (30).
(3) Place a clean cloth between upper blower rotor (17) and lower blower rotor (18) to lock rotors in position.
Remove capscrew (5) from shaft coupling (6). Pull coupling from shaft by threading a I / 2-20 inch bolt into tapped hole
in coupling.
(4) Remove capscrews (29), lockwashers (28), and washers (27) attaching drive hub plates 126) to rear face of upper
rotor gear (23). Remove drive hub plates, drive gear hub (34), and spacers (25) from upper rotor gear. Separate drive
gear hub from drive hub plates by removing capscrews (37), lockwashers (36), and washers (35).
(5) Remove bolts (38), lockwashers (39), washer (24), and coupling disk (40) from center of
rotor gears.
(6) Remove upper rotor gear (23) and lower rotor gear (411, using pullers, part No. J6270-1.
CAUTION
Be sure to pull the two rotor gears from rotor shafts at the same time.
(7) Remove rotor gear shims (20) from rotor shafts.
CAUTION
Note the number and thickness of shims on each rotor shaft. Reinstall
accordingly when reassembling.
(8) Remove capscrews (22) and lockwashers (21), and lift rear bearing retainer (42) off rear end plate (19). Repeat
procedure to remove other rear bearing retainer.
(9) Remove capscrews (7) and lockwashers (8), and lift front bearing retainer (9) off front end plate (12). Repeat
procedure for other front bearing retainer.
(10) Remove screws (11) retaining front end plate (12) to blower housing (14), and loosen screws (44) securing rear
end plate (19) to blower housing (approximately three turns).
(11) Back out center screws of gear end plate pullers far enough to permit flange on each puller to lay flat on face of
rear end plate. Align holes in each puller flange with tapped holes in end plate and secure pullers to end plate with six
5/16 inch bolts. Turn tow puller screws uniformly clockwise (fig. 3-68). Rotor shafts will be pushed from rear and plate.
Front end plate, with rotor shafts still assembled in front rotor bearings (10, fig. 3-67) will be pushed away from blower
housing (14).
(12) Remove pullers from rear end plate (19) and remove two screws (44). Pull rear end plate from blower housing
(14) by hand.
(13) Remove rotor shafts from front end plate (12) in the same manner as described in step (10)
above.
(14) Support outer face of front end plate (12) on wood blocks on bed of arbor press. Insert long end of bearing and
seal installer, part No. J6270-3, through front end plate oil seal (13) and front rotor bearing (10). Press bearing and seal
from end plate. Repeat procedure for other bearing and seal.
(15) Support outer face of rear end plate (19) on wood blocks on bed of arbor press. Insert long end of bearing and
seal installer, part No. J6270-3, through rear end plate oil seal (45) and rear rotor bearing (43). Press bearing and seal
from end plate. Repeat procedure for other bearing seal.
3-75
1 Bolt, machine, 5/16 x 3½ in.
2 Lockwasher, 5/16 in.
3 Front end plate cover
4 Gasket, front end plate
5 Capscrew, 5/16 x I½ in.
6 Shaft coupling
7 Capscrew I / 4 x 3 / 4 in.
8 Lockwasher, 1/ 4 in.
9 Front bearing retainers
10 Front rotor bearings
11 Screw, 5/16 x 1½ in.
12 Front end plate
13 Front end plate oil seals
14 Blower housing
15 Washer, plain, 7/16in.
16 Capscrew, 7/16 x 2in.
I7 Upper blower rotor
18 Lower blower rotor
19 Rear end plate
20 Shim
21 Lockwasher, I/4in.
22 Capscrew, I/4 x 3/4in.
23 Upper rotor gear
24 Washer, 1/4 in.
25 Spacer
26 Drive hub plates
27 Washer, plain, 5/16 in.
28 Lockwasher, 5/16 in.
29 Capscrew, plate-to-hub
30 Gasket, rear end plate
Figure 3-67. Blower assembly
3-76
31 Rear end plate cover
32 Lockwasher, 5/16 in.
33 Bolt, machine, 5/16 x 3½ in.
34 Drive gear hub
35 Washer, plain, 5/ 6in.
36 Lockwasher, 5/16in.
37 Capscrew, plate-to-gear
38 Bolts, 1/4 x 1¼ in.
39 Lockwashers, 1/4in.
40 Coupling disk
41 Lower rotor gear
42 Rear bearing retainers
43 Rear rotor bearings
44 Screw, 5/16 x 1½ /in.
45 Rear end plate oil seals
Figure 3-68. Removing blower end plate with
gear end plate puller, part No. J6270-1
e. Cleaning; Inspection, and Repair.
(1) Clean all parts thoroughly in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air
(2) Inspect blower housing for warps, cracks, burrs, or scoring. The inside of housing must be smooth for efficient
operation of blower. Check cylinder block flange and end plate flanges to assure they are smooth and flat. Remove
rough spots or burrs with fine mill file or scraper. Replace housing if badly scored, warped, or cracked.
(3) Inspect blower rotor lobes and sealing rib for burrs or scoring. If slightly scored or burred; rotor may be dressed
down with crocus cloth, Federal Specification P-C-458. Replace badly scored rotors.
(4) Inspect rotor shaft serrations and bearing surfaces for burrs or other damage. Replace rotors if shafts are
damaged.
(5) Check races and balls or rollers of bearings for corrosion or pitting. Apply light engine oil, Military Specification
MIL-L-2104, to bearings and revolve outer race slowly while holding inner race from turning. Bearings should roll freely
on races. Replace bearings if rough spots are present.
(6) Check blower gears for wear or damage. If gears are damaged or worn so that backlash exceeds 0.004 inch;
replace gears.
NOTE
Gears should be replaced as a set.
(7) Inspect oil seals for score marks and signs of leaking. Replace. seals if damaged.
(8) Inspect end plates for cracks, especially around bearing bosses and bearing retainer holes. Flat faces of end
plates must be smooth and unscored. Bearings should fit counterbores in plates with slight press fit. Remove all burrs or
minor score marks by filing or scraping carefully. Replace plates that are cracked, badly scored, distorted, or have worn
bearing counterbores.
(9) Check serrations in drive gear hub for damage. Replace hub if necessary.
f. Reassembly.
(1) Support front end plate (1 2, fig. 3-67) with finished surface facing up, on wood blocks on bed of arbor press.
Start front end plate oil seals (13) straight into bore in front end plate with sealing edge facing down (toward bearing
bore). Insert short end of bearing and seal installer, part No. J6270-3, in seal and press until flange of installer contacts
front end plate.
(2) Support rear end plate (19) with finished surface facing up, on wood blocks on bed of arbor press. Start rear end
plate oil seals (45) straight into bore in rear end plate with sealing edge facing down (toward bearing bore). Insert short
end of bearing and seal installer, part No. J6270-3, in seal and press until flange of installer contacts rear end plate.
(3) Install blower front end plate (12) on blower housing (]4), making sure the mark TOP on outer ribbed side of end
plate is at top of housing. Tap dowels and end plate lightly with rawhide hammer to fit end plate to housing.
(4) Insert screws (I 1) through front end plate (12) and thread into blower housing (14). Tighten screws securely. Do
not use lockwashers with screws. Check for 3/8 inch dowel projection from outer face of front end plate to assure proper
alignment.
(5) Install a shaft pilot, part No. J6270-5, over short, nonsplined end of each rotor shaft. With upper and lower
blower rotors (17 and 18) in mesh and omitted serrations on the drive ends of rotor shafts toward top, slip rotors into
blower housing (14) and short shaft ends into place in front end plate. Remove shaft pilots.
CAUTION
The upper rotor and gear must have right-hand helices and the lower rotor and gear
must have left-hand helices.
(6) Install a shaft pilot over serrated end of each rotor shaft and mount rear end plate (19) on blower housing (14).
Tap dowels and end plate lightly with rawhide hammer to fit end plate to housing.
(7) Insert screws (44) through rear end plate and thread into blower housing (14). Tighten
3-77
screws securely and check for 3/8 inch dowel projection from outer face of end plate. Remove shaft pilots.
(8) Start front rotor bearings (10) onto rotor shafts with numbered faces of bearings facing out from blower housing
(14). Tap front rotor bearing into front end plate (12), using gear and roller bearing installer, part No. J6270-6 (fig. 3-69).
(9) Attach front bearing retainers (9, fig. 3-67) with capscrews (7) and lockwashers (8).tighten capscrews to a
torque of 7 to 9 foot-pounds.
(10) Insert splined end of shaft coupling (16) into lower rotor shaft. Install capscrew (5) and draw shaft coupling
tightly against bearing. Wedge a clean cloth between rotors and tighten capscrew to a torque of 18 foot-pounds with an
Allen wrench.
(11) Attach a new gasket (4) to front endplate cover (3). Install end plate cover over dowel pins in end plate and
secure with bolts (1) and lockwashers (2). Tighten bolts to a torque of 13 to 17 foot-pounds
(12) Reverse position of blower, resting it on front end cover on wood blocks. Start rear rotor bearings (43) onto
rotor shaft with numbered face of bearings facing away from end plate. Tap rear rotor bearings into rear end plate (19),
with gear and ball bearing installer, part No. J6270-7.
(13) Attach rear bearing retainers (42) with capscrews (22) and lockwashers (21) . Tightencapscrews securely.
(14) Install shims (20) on rotor shafts. Replace same number and thickness of shims as were removed in
disassembly.
(15) Start upper and lower rotor gears (23 and 41) onto rotor shafts with omitted serrations of gears in alignment
with omitted serrations of. A center punchmark in end of each rotor shaft at omitted serration will assist in aligning gears
on shafts.
CAUTION
A right-hand helix gear must be used on right-hand helix rotor, and a
left-hand helix gear must be used on a left-hand helix rotor.
(16) Use bolts (38) and lockwashers (39) to hold upper and lower rotor gears (23 and 41) onto upper and lower
shafts. Turn bolts into ends of shafts uniformly, drawing gears into position tight against bearing races. Remove bolts
and lockwashers.
(17) Place lockwasher (39) next to head of bolt (38). Slide washer (24) on bolt (38) to be used for upper rotor gear
(23). Install bolt in gear, making certain that lugs on washer engage slots in gear hub and that ear lockwasher (39) will
engage slot in washer (24). Tighten bolt to a torque of 55 to 60 foot-pounds.
(18) To lock lower rotor gear (41) install lockwasher (39) and coupling disk (40) on bolt (38). Install bolt in lower
rotor gear (41) so lugs of disk engage slot in hub of gear and lockwasher ear engages in slot in coupling disk. Tighten
bolt to a torque of 55 to 60 foot-pounds.
(19) Position upper and lower blower rotors (17 and 18) in blower housing (14) with a slight clearance between
lobes. This clearance may be varied by moving one of the helical gears in or out the rotor shaft, by adding or removing
shims (20) between gear hub and bearing. If the upper rotor gear is moved out. the upper rotor will turn
counterclockwise when viewed from the gear end. If the lower rotor gear is moved out, the lower rotor will turn clockwise.
This positioning of the rotor gear to obtain proper clearance between the rotor lobes is known as blower timing.
(20) Check rotor lobe clearance with 1/2 inch feeler ribbons. Measure from both inlet and outlet sides of blower, 1
inch from governor end of blower, at center of blower, and 1 inch from drive end of blower. Insert feeler ribbon through
air outlet side of blower and between the leading edge of the lower rotor and the trailing edge of the upper rotor. Time
rotors to have from 0.002-inch minimum to 0.006-inch maximum clearance, indicated by the CC dimension (fig. 3-70).
Then check clearance between leading edge of upper rotor and trailing edge of lower rotor; minimum clearance is 0.014
inch, indicated by the C dimension.
(21) Having determined the amount one rotor must be revolved to obtain the proper clearance, add shims (20, fig.
3-67) back of either and upper or lower rotor gears (fig. 3-71). To do this, remove both rotor gears from the rotor shafts.
Placing a 0.003-inch shim in back of a rotor gear will revolve the rotor 0.001 inch. Install required thickness of shims
back of proper gear and draw gears tight into place. Recheck clearances between rotor lobes. After correct clearances
are obtained, lock rotor gears in place as directed in (16) and (17) above.
(22) Insert feeler gage between end plates and rotors and check minimum clearance at indicated points A and B,
on side view of blower (fig. 3-70). Minimum clearance is 0.007 inch at A and 0.014 inch at B. This operation must be
performed at the ends of each rotor lobe, making 12 measures in all.
(23) Check clearance between each rotor lobe and blower housing at both inlet and outlet side, at points D and E.
Minimum clearance is 0.016 inch at D and 0.004 inch at E (fig. 3-70).
(24) Using three capscrews (37, fig. 3-67), Iockwashers (36), and washers (35), assemble drive hub plates (26) to
drive gear hub (34). Using three capscrews (29), lockwashers (28), and washers (27), attach drive hub plates to outer
face
3-78
of upper rotor gear (23), installing three spacers (25) between plate and face of gear.
(25) Affix a new gasket (30) to blower rear end plate cover (31). Start cover over dowel pins in rear end plate (19)
and push it tightly against end plate. Install bolts (33) and lockwashers (32) and tighten to a torque of 13 to 17 footpounds.
CAUTION
Before installing end plate cover (31,fig. 3-67), oil the rotor bearings and gears with
clean engine oil, Military Specification MIL-L-2104. If the bearings and gears are not
lubricated, they could be damaged before oil reaches the blower through the engine
lubrication system.
Figure 3-69. Installing roller bearings in front end plate,
using gear and roller bearing installer, part No. J6270-6.
3-79
Figure 3-70. Minimum blower clearances.
3-80
SERIES 71 - VIEW FROM GEAR END
Figure 3-71. Proper location of shims for
correct rotor lobe clearances
g. Installation.
(1) Before attaching blower assembly to engine, examine inside of blower assembly for foreign material. Turn rotors by hand,
checking for smooth turning. If rotors turn hard, rub, or bind, report condition to depot maintenance personnel.
(2) Install a new gasket (4, fig. 3-66) on cylinder block mounting base using a nonhardening gasket cement on cylinder block
side of gasket only.
(3) Slide a new seal (6) with clamp (5) over end of cover tube ( 7).
(4) Position blower assembly in place on cylinder block, being careful not to disturb mounting gasket,and install mounting bolts
(1) and lockwashers (2). Tighten bolts to a torque of 55 to 60 foot-pounds.
(5) On blower assemblies, part No. 5120996 and 5120993, slide seal (6) and clamp (5) against blower and tighten clamp. On
blower assemblies, part No. 5114472 and 5114469, secure drive cover and gasket to blower with bolts.
(6) Install blower drive shaft (25) from flywheel housing end of engine by pushing the plain end (end without square hole) of
shaft through blower drive coupling. Mate shaft with splines in rotor gear hub.
NOTE
It may be necessary to revolve rotors slightly to engage splines of drive shaft with splines of
gear hub.
(7) Secure shaft with retaining ring (24).
(8) Install gasket (23) and cover (22) or flywheel housing with bolts (16) and (19), nuts (20), and lockwashers (18 and 21).
(9) Install fuel pump (para 3-19).
(10) Install governor assembly (para 3-13).
(11) Install water pump (para 3-17).
(12) Install air inlet housing (para 3-21).
(13) Install air cleaners (TM 55-1930-203-20).
3-23. Blower Drive Assembly
a. Description. The blower drive assembly is driven from the engine gear train and drives the air intake blower. The governor,
water pump, and fuel pump are also driven from the drive assembly through gearing on the blower. The blower drive is cushioned
by a flexible coupling attached to the blower drive gear. This coupling is formed by an elliptical cam driven by two bundles of leaf
springs riding on four semi-cylindrical supports. The coupling prevents the transfer of minor engine torque fluctuations to the
blower rotors, assuring uniform rotation and a smooth flow of scavenging air.
b. Removal.
(1) Remove blower assembly (para 3-22).
(2) Loosen clamp (9. fig. 3-66) on seal (8) and withdraw cover tube (71 with clamp and seal.
(3) Disconnect blower drive oil line from elbow (15) on blower drive gear hub support (17).
(4) Straighten ears on washer (11) and loosen drive gear hub nut (10).
(5) Remove bolts (13) and lockwashers (14) securing blower drive gear hubsupport (17) to cylinder block end plate.
(6) Tap support lightly and withdraw drive assembly from cylinder block end plate. Remove gasket (38).
c. Disassembly.
(1) Remove bolts (26, fig. 3-66) and lockwashers (27), and remove drive coupling retainer (28) and support (33).
(2) Remove drive gear hub nut (10), washer (11), ball bearing (36), and thrust washer (12).
(3) Withdraw drive gear hub (35) with drive gear (34) from drive gear hub support (17).
(4) Remove thrust washer (37) from bearing on support (17).
(5) Press drive gear hub (35) out of drive gear (34).
(6) Remove oil pipe elbow (15) from support. (7) Press drive coupling cam (29), drive coupling spring packs (31), spring end
seats (32), and spring seats (30) from support (33).
d. Cleaning, Inspection and Repair.
(1) Clean all metal parts in clean fuel oil and
3-81
blow dry with compressed air. Use a small wire to remove accumulations of dirt from oil passages.
(2) Check clearance between bearings in support (17, fig. 3-66) and hub (35). Clearance should not exceed 0.0050
inch. If clearance exceeds maximum limit of 0.0050 inch, press out bearings from support and press in new bearings. Bore inside
Diameter of bearings to 1.6260 to 1.6265 inches after installation in support and check that clearance between new bearings and
hub is 0.0010 to 0.0025 inch.
NOTE
On supports, part No. 5122528, install outer bearing with end flush to 0.030 inch below surface
of face of support. Bearing on flywheel housing end of support should protrude 0.045 to 0.055 inch above surface of face to
facilitate installation of blower drive thrust washer (37). Replacement bearings must withstand a 2,000-pound
end load without turning and bearing bores must be square with the inner and outer faces of the support within
0.001-inch total indicator reading.
(3) Inspect thrust washers (12 and 37) for being scored or damaged. Replace scored or damaged thrust washers.
(4) Inspect blower drive coupling support (33), cam (29), and spring packs (31) for cracks and obvious defects. e-R
place defective parts.
(5) Inspect blower drive shaft (25) for being bent or having damaged serrations. Replace a defective drive shaft.
(6) Inspect blower drive gear (34) for scored or pitted gear teeth. Replace gear if damaged.
e. Reassembly.
(1) Press drive gear hub (35, fig. 3-66) into drive gear (34).
(2) Lubricate drive gear hub (35), bearings and thrust surfaces of support (17), and thrust washer (37) with clean
n- e
gine oil.
(3) Place thrust washer (37) on protruding bearing on flywheel housing side of support and insert blower drive gear
hub and gear assembly in support.
(4) Place ball bearing (36) on gear hub and slide thrust washer (12) with tapered face of washer toward threads on
hub, into position over ball bearing (36).
(5) Place washer (11) and nut (10) on hub. Tighten nut finger tight.
(6) Install two bolts in threaded holes of drive gear hub (35). Place a suitable holding bar across bolts to keep hub
from turning and tighten nut (10) to a torque 50 to 60 foot-pounds. Bend ears of washer (11) against flats on nut and remove the
holding bar and two bolts.
(7) Assemble drive coupling as follows:
(a) Place drive coupling support (33) on two blocks of wood.
(b) Place spring end seats (32) on spring packs (31).
(c) Place spring seats (30) in coupling support (33).
(d) Lubricate spring packs (31) with clean engine oil and insert spring packs in coupling support.
(e) Using a spreader to spread spring packs apart, insert cam (29) in coupling support.
(8) Place coupling support against drive gear with blower drive shaft ring groove in cam (29) facing away from drive
gear.
(9) Place coupling retainer (28) against coupling support with flared edge away from support.
(10) Revolve coupling assembly on hub flange until cam lobes are in line with oil grooves (6, fig. 3-72).
(11) Secure gear, coupling support, and retainer to drive gear hub with lockwashers (27, fig. 3-66) and bolts (26).
Tighten bolts to a torque of 20 to 25 foot-pounds.
(12) Install elbow (15) on support.
1 Spring seats
2 Spring end seat
3 Spring pack
4 Blower drive gear
5 Drive gear hub
6 Oil grooves
7 Drive coupling cam
8 Drive coupling support
Figure 3-72. Blower drive gear and coupling
f.
Installation.
(1) Place gasket (38, fig. 3-66) on mounting face of hub support.
(2) Attach blower drive gear and support assembly to cylinder block rear end plate with two bolts (13) and lockwas
h-
ers (14).
(3)
(4)
(5)
Connect blower drive gear oil line to elbow (15).
Place cover tube (7) against support (17) and install seal (8) and clamp (9).
Install blower (para 3-22).
3-82
Section VII. OIL PAN, OIL PUMP INLET SCREENS, LUBRICATING
OIL PUMP ASSEMBLY, AND OIL PRESSURE REGULATOR ASSEMBLY
3-24. Oil Pan
a. Removal.
(1) Remove oil dipstick and disconnect oil dipstick guide from oil pan.
(2) Remove pipe plug (6, fig. 3-73) and allow lubricating oil to drain into a suitable container.
(3) Remove oil temperature thermometer bulb (para 2-11) from oil pan cover (11).
(4) Remove bolts (5) and remove lower oil pan (4) and gasket (3).
(5) Remove bolts (12) and remove cover (11), gasket (10), spacer (9), and gasket (8).
(6) Remove bolts (7) and remove upper oil pan (2) and gasket (1).
b. Cleaning, Inspection and Repair.
(1) Using a wire brush, remove sludge accumulations from oil pans and cover. Wash oil pans and cover in
clean fuel oil and wipe dry with a lint free cloth. Remove all trace of gasket from gasket surfaces with wire brush.
(2) Examine all parts for cracks or evidence of leakage. Replace defective parts.
3-83
1.
2.
3.
4.
5.
6.
Gasket, upper oil pan
Oil pan, upper
Gasket, lower oil pan
Oil pan, lower
Bolt, machine, 5/16 x 1 in.
Plug, pipe, oil pan drain
Figure 3-73. Oil pan.
3-84
7. Bolt, machine, 5/16 x 1 in
8. Gasket, cover
9. Spacer, steel
10. Gasket
11. Cover, oil pan
12. Bolt, machine, 5/6 x 1 ¼ in
c. Installation.
(1) Place new gasket (1, fig. 3-73) on upper oil pan (2). Secure upper oil pan and gasket to engine with bolts (7). Tighten
bolts snugly and then starting at the center and working toward each end, tighten bolts to a torque of 10 to 12 foot-pounds.
(2) Place new gasket (3) on lower oil pan (4). Secure lower oil pan to upper oil pan with bolts (5).
Tighten bolts as outlined in (1) above.
(3) Secure gasket (8) spacer (9), gasket (10), and cover (11) to upper oil pan with bolts (I2). Tighten bolts to a torque of 10 to
12 foot-pounds.
(4) Replace pipe plug (61 and tighten to a torque of 3S to 40 foot-pounds.
(5) Install oil temperature thermometer bulb in oil pan cover (para 2-11).
(6) Secure oil dipstick guide to oil pan and replace oil dipstick.
(7) Fill crankcase with lubricating oil in accordance with LO 55-1930-203-12.
3-25. Oil Pump Inlet Screens
a. Upper Oil Pan Screen Removal
(1) Remove oil temperature thermometer bulb (para 2-11) from oil pan cover (I l, fig. 3-73).
(2) Remove bolts (12) and remove cover (11), gasket (10), spacer (9), and gasket (8).
(3) Unlock pump screen retainer and remove screen from cover.
(4) Remove bolts and washers securing cover to brackets and remove cover.
b. Lower Oil Pan Screen Removal.
(1) Remove pipe plug (6, fig. 3-73) and drain engine crankcase into a suitable container.
(2) Remove bolts (5) and remove lower oil pan (4) and gasket (3).
(3) Unhook pump screen retainer and remove screen from cover.
(41 Remove bolts and washers securing cover to brackets and remove cover.
c. Cleaning, Inspection and Repair.
(1) Remove accumulations of sludge from screen using dry-cleaning solvent, Federal Specifications P-D-680. Swish screen
through a bath of solvent to remove all particles in mesh.
(2) Blow screen dry with low-pressure, compressed air.
CAUTION
Do not use high-pressure air, which may widen the screen mesh. Do not clean spaces in
screen with any tool which may damage or widen the mesh.
(3) Examine screen for holes or rotting. Inspect closely around edges where screening meets frame to be sure that screen is
not pulling away from frame. Replace screen if damaged.
(4) Wash screen cover in clean fuel oil and wipe dry with a lint free cloth. Inspect cover for being bent or warped, especially
around the outlet port. If cover is damaged. replace it.
(5) Assemble screen into cover and lock in place with retainer. If retainer does not hold screen securely in place, replace
retainer.
d. Installation.
(1) Install oil pump inlet screens in reverse order of removal.
(2) Fill crankcase with lubricating oil in accordance with LO 55-1930-203-12.
3-26. Lubricating Oil Pump Assembly
a. Description. The oil pump assembly consists of two separate gear type pumps, each with an individual set of gears in
respective housings and driven from a common shaft. One is a pressure pump which is used to circulate oil through the
lubricating system, and the other is a scavenge pump used to transfer oil from the upper oil pan to the lower oil pan. The pressure
pump contains an integral plunger-type relief valve which bypasses excess oil to the inlet side when the pressure at the outlet
exceeds 100 psi. The scavenge pump does not include a relief valve but in all other features is identical to the pressure pump.
The pump assembly is mounted on the first and second main bearing caps and is gear driven from the front end of the crankshaft.
b Removal.
(1) Remove oil pan (para 3-24).
(2) Remove oil pump screens and screen holders (para 3-25).
(3) Remove two bolts and lockwashers securing tube assembly (3, fig. 3-74) and screen support (2) to inlet pipe (7).
Remove tube assembly and screen support. Separate tube assembly and screen support by removing two connecting bolts and
lockwashers. Remove gaskets.
(4) Remove two bolts and lockwasher securing screen support bracket (1) to bottom of engine. Remove bracket.
(5) Remove four bolts and lockwashers connecting outlet pipe (5) to pump assembly (6) and oil pressure regulator. Lift
away outlet pipe and gaskets.
(6) Loosen four bolts and lockwasher attaching inlet pipe (7) to pump assembly (6). Remove inlet pipe and gasket.
(7) Remove two bolts securing scavenging outlet pipe (4) to pump body and remove pipe and gasket.
(8) Remove four pump-to-bearing cap attaching capscrews and lockwashers, and remove pump assembly.
3-85
1.
2.
3.
4.
Screen support bracket
Screen support
Tube assembly
Scavenging outlet pipe
5. Outlet pipe
6. Pump assembly
7. Inlet pipe
Figure 3-74. Oil pump piping relative to lubricating oil pump assembly.
NOTE
Shims are used between the oil pump mounting feet and bearing cap to secure the necessary clearance
of 0.005 to 0.012 inch between the idler gear and the pump drive gear. Note the number of shims under
each mounting foot, as the same shims or an equal number of new identical shims must be reinstalled
under each mounting foot. The number is then adjusted to obtain the proper clearance between gear
teeth
3-86
c.
Disassembly
(1) Remove relief valve plugs (20, fig. 3-75) and gaskets (19) from each side of pressure pump body (34), and
jar relief valve spring (I 8) and relief valve (17) from body.
(2) Straighten lip of lockwasher (3) and unscrew bolt (2). Remove lockwasher (3), washer (4), and idler gear (5).
Note that the side of idler gear, having extended hub, faces away from idler gear support (8).
(3) Clamp pressure pump body (34) in bench vise. Apply suitable gear puller and pull pump drive gear (6) from
outer end of drive shaft (10). Remove key (35).
(4) Remove four bolts and lockwashers (29), and separate scavenging pump body from pressure pump body
(34). Press drive shaft sleeve bearing (31) from scavenging pump body (28).
(5) Slide driven gear (24) off scavenging pump end of driven gear shaft (26). Remove driven gear sleeve
bearing (25) from driven, gear. Slide driven gear shaft from pump body spacer (27).
(6) Remove pump body spacer (27) and drive shaft (10) with drive gears (33) assembled from pressure pump
body (34).
(7) Withdraw second driven gear (24) from cavity in pressure pump body. Remove gear sleeve bearing (25)
from driven gear.
(8) Position pump body spacer, drive shaft, and gears on bed of suitable press, and press drive gea
rs (33) off
drive shaft (10). Remove keys (32) and slide pump body spacer (27) off drive shaft (I0).
(9) Remove bolt (7) and idler gear support 48) from pressure pump body. Remove pins (1 and 9) from idler
gear support.
Key to Figure 3-75.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
.15
16
17
18
Pin, locating
Bolt, 5/ 16 x 7 /8 in.
Lockwasher, idler gear
Washer, thrust
Idler gear
Pump drive gear
Bolt, self-locking,
3/8 x 7/8 in.
Idler gear support
Pin, locating
Drive shaft
Bolt, 5/16 x 3/4 in.
Lockwasher, pad cover
Capscrew, 3/8 x I in.
Lockwasher, 3/8 in
Access cover plate
Gasket, pad cover
Relief valve
Relief valve spring
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Gasket, copper
Relief valve plugs
Screw, inlet
Washer, inlet
Gasket, inlet pipe
Driven gears
Driven gear sleeve
bearings
Driven gear shaft
Pump body spacer
Scavenging pump body
Lockwasher, 5/16 in.
Bolt, 5/ 16 x 3/4 in.
Drive shaft sleeve bearing
Keys, 1/8 x 5/8 in.
Drive gears
Pressure pump body
Key, 1/ 8 x 5 / 8 in.
d. Cleaning, Inspection and Repair.
(1)
Clean all parts in dry-cleaning solvent, FederalSpecification, P-D-680, and dry with compressed air.
(2)
Inspect all gears for score marks, burrs, or broken teeth.
Replace damaged gears.
NOTE
When one of the helical gears (24 or 33, fig. 3-75) is damaged, both
should be replaced.
Figure 3-75. Lubricating oil pump assembly.
3-87
(3) Inspect driven gear bearings and drive shaft bearing for excessive wear. Bearing-to-shaft clearance should
not exceed 0.0025 inch. If clearance exceeds 0.0025 inch, replace bearing.
NOTE
Replacement bearings in driven gears must be reamed after assembly to 0.625±0.0005
inch.
(4) Inspect pump bodies for splits or cracks; check inside pump bodies for signs of scoring. Replace if
damaged.
(5) Inspect gear shafts for damage, scoring, or burrs. Replace if damaged. Remove scores or burrs with
crocus cloth, Federal Specification P-C-458.
(6) Replace damaged screws, bolts, or oil piping.
(7) Inspect relief valve for damage. Replace if necessary.
(8) Inspect relief valve spring for damage of pitting. Valve spring has a free length of 2 23/64 inches, and
should require a force of 48 to 53 pounds to compress it to a length of 1.596 inches. Replace spring if damaged or if
a force of less than 48 pounds will compress it to a length of 1.596 inch.
(9) Replace all gaskets.
e. Reassembly.
(1) Set key (32, fig. 3-75) in drive shaft (10) and press drive gear (33), which is housed in pressure pump
body (34), in place on shaft. When drive gear is positioned correctly, the distance between drive gear and the end of
the drive shaft on which the pump drive gear (6) is located in 6 15/32 inches.
(2) Install pins (9 and 1) in idler gear support (8). Place idler gear support against forward end of pressure
pump body (34) and secure support to pump body with bolt (7).
(3) Press driven gear sleeve bearings (25) into driven gears (24).
(4) Install end of driven gear shaft (26) onto shaft and into cavity in pressurepump body (34).
(5) Position drive gear (33) and drive shaft spacer (27) over shafts (10 and 26) and into position against
pressure pump body (34).
(6) Slide second driven gear (24), into place on outer end of driven gear shaft (26). Set key (32) in outer
end of drive shaft (10) and press second gear (33) in place on shaft.
(7) Install drive shaft sleeve bearing (31) in scavenging pump body (28).
(8) Mount scavenging pump body (28) on pressure pump body (34), and secure with four bolts (30) and
lockwashers (29).
NOTE
No gaskets are used between pump bodies.
.
(9) Support drive gear end of drive shaft on bed of an arbor press and insert key (35) in keyway of shaft.
Position pump drive gear (6) on end of drive shaft with extended hub side up away from pump body. Insert a 0.005
inch feeler ribbon between pump drive gear and pump body to proper position gear on shaft. Press gear on shaft just
far enough to allow 0.005 inch feeler to be readily slipped from between pump body and gear.
.
(10) Lubricate idler gear bearing with engine oil and place idler gear (5) in position on idler gear support (8)
with side of gear having face of hub flush with gear teeth facing support.
.
(11) Place lockwasher (3) next to head of bolt (2) and washer (4) next to lockwasher. Start bolt into bearing
boss of idler gear support (8) and rotate washer and lockwasher so that slot at inner diameter of each washer
engages pin (1).
.
(12) Tighten idler gear bolt (2) so that one side of bolt head will be over end of pin (1). Bendlockwasher (3)
against one side of bolt head.
.
(13) Screw relief valve plug (20), with gasket (19), into place at side of pressure pump body opposite inlet
opening. Place relief valve (17) and relief valve spring (18) in bore at inlet side of pressure pump body. Install
second relief valve plug (20) with gasket (19) into body. Tighten plug.
.
(14) If access cover plate (15) and gasket (16) were removed from pressure pump body, reinstall plate and
gasket and secure with two bolts (11) and lockwashers (12).
.
f.
Installation.
.
(1) Hold pump assembly against main bearing caps so that idler gear (5, fig. 3-75) meshes with gear on
crankshaft.
.
(2) Insert four capscrews (13), with lockwashers (14), through mounting feet of pressure pump body (34)
and into bearing caps. Aline pump so that teeth of gear on crankshaft and idler gear (5) are parallel and tighten
bolts. Check clearance between gear teeth and a feeler gage. Proper clearance is from 0.005 to 0.012 inch.
Replace shims, if used, between pump mounting feet and bearing caps. Adjust number of shims to obtain proper
clearance between gear teeth. If installing new gears, a larger number of shims will be required under mounting feet.
NOTE
Maintain equal number of shims under each pump mounting foot so pump will always be
level on cylinder block. Fill pump with engine oil to aid initial prime.
(3) Using a new gasket, attach scavenging outlet pipe (4, fig. 3-74) to scavenge pump body with two bolts and
lockwashers.
(4) Secure inlet pipe (7) and gasket to pump assembly (6) with four bolts and lockwashers.
(5) Place new gaskets at outlet pipe con.
3-88
nections to pressure pump body and pressure regulator. Secure outlet pipe (5) to pump body regulator with four bolts and
lockwashers.
(6) Install screen support bracket (1) to bottom of engine with two bolts and lockwashers.
(7) Using a new gasket, join tube assembly (3) to screen support (2) with two bolts and lockwashers.
(8) Place a new gasket between tube assembly (3) and inlet pipe (7). Secure tube assembly (3) to inlet pipe
with two bolts and lockwashers.
(9) Replace oil pump screen-holders and screens (para 3-25).
(10) Replace oil pan (para 3-24).
3-27. Oil Pressure Regulator Assembly
a. Description. Stabilized lubricating oil pressure is maintained within the engine at all speeds, regardless of oil
temperature, by an oil pressure regulator assembly installed between the oil pump outlet pipe and the cylinder block. The
regulator assembly consists of a hollow piston-type valve, a compression spring, and a plug, all mounted in a housing.
The valve is held on its seat by the spring which is compressed by the plug screwed into the regulator housing. The
regulator assembly is bolted to the lower flange of the cylinder block and sealed against oil leaks by a gasket. When oil
pressure at the valve exceeds 45 psi, the valve is forced from its seat and oil from the engine gallery is by-passed to the
oil pan, dropping the oil pressure. When the pressure returns to normal, the valve closes and oil pressure builds up.
b. Removal.
(1) Drain engine crankcase and remove oil pan (para. 3-24).
(2) Remove bolts (6, fig. 3-76) and lockwashers (7) securing oil pump pipe to oil pressure regulator.
(3) Remove bolts (9) and lockwashers (10) securing regulator housing to cylinder block.
(4) Tap lower end of regulator housing lightly to loosen it from gasket and cylinder block.
(5) Remove regulator assembly and gaskets (I and 8).
c. Disassembly.
(1) Clamp flange of regulator housing (2, fig. 3-76) in a vise. Remove plug (5) from regulator housing.
(2) Lift out spring (4) and relief valve (3).
d. Cleaning, Inspection and Repair.
(1) Wash regulator parts in clean fuel oil and blow dry with compressed air. Use a wire brush to remove old
gasket. Be sure that oil passages are clean and free of all sludge.
(2) Examine regulator housing (2, fig. 3-76) for cracks. Check valve seat for scoring or burrs. If
1
2
3
4
5
6
7
8
9
10
Gasket, oil pressure regulator
Oil pressure regulator housing
Relief valve
Spring, relief valve
Plug
Bolt, machine, 5/16 x 7/8 in.
Lockwasher, 5 / 16 in.
Gasket, oil pipe outlet
Bolt, machine, 5/16 x 1/8 in.
Lockwasher, 5/ 16 in.
Figure 3-76. Oil pressure regulator assembly.
3-89
regulator housing or valve seat is damaged, replace entire regulator assembly.
(3) Examine relief valve (3) for pitting or burrs, especially on outside or seating surfaces. If valve surfaces are
not smooth, replace valve.
(4) Apply a coating of engine oil to outer surface of relief valve and slide valve into housing. See that valve
fits snugly against housing and moves freely. If valve binds or is too loose, replace entire regulator assembly.
(5) Using a spring tester, check spring tension of spring (4). Approximate free length of spring is 2 31/64
inches. The spring requires a force of 14-15 pounds to compress it to a length of 1 21/32 inches. If spring shows a loss of
tension, replace.
e. Reassembly . Reassemble the oil pressure regulator assembly in reverse order of disassembly.
f.
Installation.
(1) Remove all traces of old gasket from cylinder block and pump outlet pipe flange.
(2) Install a new gasket (1, fig. 3-76) on regulator housing (2) with oil passage holes in gasket in alinement with
oil passages in regulator housing.
(3) Position regulator assembly on cylinder block and secure with bolts (9) and lockwashers (10).
(4) Place a new gasket (8) between regulator assembly and pump outlet pipe. Install bolts (6) and
lockwashers (7).
(5) Install oil pan (para 3-24).
Section VIII. VIBRATION DAMPER ASSEMBLY, POWER
TAKEOFF COUPLING AND FLYWHEEL HOUSING
3-28. Vibration Damper Assembly and Power Takeoff Coupling
a. Description. Each engine is equipped with a double vibration damper assembly to reduce crankshaft stresses.
The dampers are made up of rubber blocks bonded to an inertia mass in the form of a metal ring on one side and a
stamped metal disc on the other. The two metal parts are, therefore, free to move within prescribed limits set by the
elasticity of the rubber and will absorb vibration set up in the crankshaft. The power takeoff coupling assembly serves to
connect the
fluid and flexible coupling to the engine crankshaft and as a cone retainer for the outer cone of the vibration damper
assembly.
b. Removal and Disassembly.
(1) Remove fluid coupling, flexible coupling, and engine adapter flange (para 2-21).
(2) Remove bolt (11, fig. 3-77) and washer (10) securing power takeoff coupling assembly (9) tocrankshaft
and, using a puller, remove power takeoff coupling assembly. Remove keys (8).
(3) Slide vibration dampers (5 and 4) and hub assembly (2) off crankshaft as an assembly.
(4) Insert a 1/8-inch hooked rod in each of the two puller holes in inner cone (1) and pull inner cone off
crankshaft.
CAUTION
Do not damage front main bearing oil seal when removing inner cone from crankshaft.
(5) Remove bolts (7) and lockwashers (6) holding vibration dampers (4 and 5) to hub assembly (2). Pull
vibration dampers off dowel pins (3) on hub assembly.
3-90
1.
2.
3.
4.
5.
6.
Cone, inner
Hub assembly
Pin, dowel
Vibration damper, heavy
Vibration damper, light
Lockwasher
7.
8
9
10.
11.
Bolt. vibration damper
Key
Power take off coupling assembly
Washer, flat
Bolt. power takeoff coupling
Figure 3-77. Vibration damper assembly and power takeoff coupling assembly.
c.
Cleaning, Inspection and Repair.
(1) Clean inner cone and hub assembly in clean fuel oil and wipe dry. Clean metal sides of vibration dampers
and power takeoff coupling assembly with a cloth moistened with fuel oil and blow dry with compressed air.
CAUTION
Do not allow fuel oil to contact rubber portion of dampers or power
takeoff coupling assembly as fuel oil will tend to loosen the rubber from
metal.
(2) Inspect that rubber blocks of vibration dampers are firmly bonded on each side and that metal sides are not
bent. Replace vibration dampers if rubber blocks have become loosened from metal sides or if metal sides are bent.
NOTE
A loose or defective vibration damper, after extended operation, may result in a cracked crankshaft.
(3) Inspect inner cone and hub assembly for signs of scoring. Replace a scored or damaged cone or hub
assembly and examine crankshaft end for possible cause.
(4) Examine dowel pins in hub assembly for being bent or loose. Replace bent or loose dowel pins.
(5) Inspect power takeoff coupling assembly to see that rubber is firmly bonded to metal. Replace power
takeoff coupling assembly if rubber has become loose.
d. Reassembly and Installation.
(1) Assemble dampers (4 and 5, fig. 3-77) over pins (3) and against hub assembly (2) with flat faces of
dampers facing each other. Install bolts (7) and lockwashers 16).
(2) Apply a light coat of cup grease to front main bearing oil seal. Slide inner cone (1) into opening between
crankshaft and front main bearing oil seal with tapered end of cone pointing toward front end of crankshaft.
3-91
(3)
Slide assembled vibration dampers and hub assembly into position with long ends of hub assembly toward
engine.
(4) Install keys (8) on crankshaft.
(5) Position power takeoff coupling assembly (9) on crankshaft and install washer (10) and bolt (11). Tighten
bolt to a torque of 180 to 200 foot-pounds.
(6) Install fluid coupling, flexible coupling and engine adapter flange (para. 2-21).
3-29. Flywheel Housing
a. Description . The flywheel housing is a one-piece casting mounted against the rear end plate which, in turn, is
mounted to the cylinder block. The flywheel housing provides a cover for the torque converter flywheel and gear train
and also serves as a mounting for the torque converter assembly. The flywheel housing is counterbored for a lip-type
seal that contacts the crankshaft.
b. Removal
(1) Remove engine from LARC (para. 2-11).
(2) Remove torque converter from engine (para. 2-12).
(3) Remove air starting motor (para. 3-18).
(4) Remove tachometer generator (para. 6-3).
(5) If equipped with a dual tachometer drive adapter, remove the adapter.
(6) Remove primary fuel filter.
(7) Remove oil pan (para. 3-24).
(8) Disconnect throttle control linkage from shaft in engine hoisting eye ITM 55-1930-203-201. Remove two
bolts and lockwashers securing engine lifter bracket 14, fig. 3-78) to cylinder head.
(9)
NOTE
This will leave the lifter bracket attached to the flywheel housing for convenience in handling.
Position hoist above flywheel housing with hoisting hook through eye of lifter bracket.
NOTE
Do not take slack out of hoisting gear until all mounting bolts have been loosened to prevent binding.
(10) Remove 12 bolts (11 and 13), lockwashers (12), and washer (10) in flywheel cavity. Tag bolts for
reassembly.
(11) Remove bolts (5, 7, and 8), nuts (1), and lockwashers (2, 6, and 9) from around upper portion of flywheel
housing. Tag bolts for reassembly.
(12) Remove two bolts (15) and lockwashers (16). Tag bolts for reassembly.
(13) Take up slack on chain hoist and strike front face of flywheel housing alternately on each side with a soft
hammer to work flywheel housing off dowels.
(14) Guide flywheel housing away from end plate to a clear working area.
3-92
1
2
3
4
5
6
7
8
9
Nut, 3/8 in.
Lockwasher, 3 / 8 in.
Flywheel housing
Engine lifter bracket
Bolt, machine, 3 / 8 x 5 in.
Lockwasher, 3 / 8 in.
Bolt, machine, 3/8 x 3 1/4 in.
Bolt, machine, 3/8 x 4¼ in.
Lockwasher, 3 / 8 in.
10
11
12
13
14
15
16
17
Washer, flat, 13/32 in.
Bolt, machine, 3/8 x I in.
Lockwasher, 3 / 8 in.
Bolt, machine, 1½ x 31/4 in.
Seal, plain, encased
Bolt, machine, 3/8 x 1 in.
Lockwasher, 3 / 8 in.
Gasket, mounting
Figure 3-78. Flywheel housing.
c. Cleaning, Inspection and Repair.
(1) Remove bolts and lockwashers securing covers and remove covers and gaskets.
(2) Clean flywheel housing with fuel oil and wipe dry with a lint-free cloth.
NOTE
Do not disturb oil seal when cleaning flywheel housing.
(3) Remove all traces of old gasket from flanges of flywheel housing and end plate with a wire brush.
(4) Inspect flywheel housing for cracks, damage, or any unusual conditions.
(5) Examine oil seal for scored, cracked, or charred surfaces and any hardness or brittleness. Press sealing lip of
seal in with hand and check if sealing lip returns to proper position after being pressed in. If oil seal is defective, replace
as follows:
(a) Support rear face of flywheel housing on wood blocks.
(b) Drive oil seal (14, fig. 3-78) out and clean seal bore in flywheel housing with clean fuel oil and wipe dry.
(c) Position new seal with lip pointed toward inner face (shoulder in counterbore) of flywheel housing.
NOTE
Do not remove plastic coating on outside diameter of seal.
(d) Using oil seal remover and installer, part No. J3154-04, drive seal into counterbore, flywheel housing until
seal is seated on shoulder in counterbore.
(6) Inspect rear end of crankshaft for ridges Crankshaft surface must be clean and smooth. Remove slight ridges
with 120 grit emery cloth followed by 240 grit emery cloth. Use crocus cloth wet with fuel oil, to polish surface.
3-93
NOTE
Rotate crankshaft occasionally to prevent an out-of-round condition.
d. Installation.
(1) Affix new cover gaskets to flywheel housing and install covers on flywheel housing. Affix new mounting
gasket (17, fig. 3-78) to flywheel housing.
(2) Apply a coating of heavy cup grease to oil seal lip.
(3) Install studs (1, fig. 3-79), into cylinder block and set oil seal expander (2) over dowels on end of crankshaft
as shown in figure 3-79.
(4) Using a hoist, guide flywheel housing into place,
tight against end plate and gasket.
(5) Remove mounting studs and oil seal expander
installed in (3) above.
(6) Install six bolts (11, fig. 3-78) and washers (10) in
tapped holes of idler gear hub and idler gear hole spacer
fingertight.
NOTE
Self-locking type bolts and steel washers can
be used in sets of three to attach the flywheel
housing to the idler gear hub and hole spacer.
If self-locking bolts are not used, the drilled
head bolts must be secured with lockwire, in
sets of three, after final tightening.
(7)
Install six bolts (I3) and lockwashers (12) in
flywheel housing cavity fingertight.
(8) Install bolts (5, 7, and 8) lockwashers (2, 6, and 9)
and nuts (1), in upper portion of flywheel housing fingertight.
(9) Install bolts (15) and lockwashers (16) fingertight.
(10) Check that flywheel housing is properly alined and
oil seal is correctly seated.
1. Alining stud, part No. J1927-01
2. Oil seal expander, No. J1359
Figure 3-79. Installing flywheel housing.
(11) Tighten bolts to within 10 to 15 foot-pounds of their specified torques in sequ
ence shown in figure 3-80. Turn
engine crankshaft when tightening bolts to prevent binding in the
idler gear tapered bearing.
NOTE
Numbers indicated on figure 3-80 should not be
mistaken for callouts. They are the order of
sequence to be followed in installation of flywheel
housing.
NOTE
The specified torque of the 3/8 inch idler gear hub
and hole spacer bolts if 40 to 45 foot-pounds. All
other 3/8 inch bolts require a torque of 25 to 30
foot-pounds. The 1/2 inch bolts require a torque of
90 to 100 foot-pounds.
(12) Tighten bolts and nuts to torque specified above in
sequence shown it figure 3-81. Secure bolts (11, fig. 3-78) in
sets of three with lockwire if self-locking bolts were not used.
(13) Check flywheel housing concentricity in relation to
crankshaft as follows:
Figure 3-80. Initial flywheel housing bolt tightening sequence.
(a) Attach dial indicator holding fixture (2, fig. 3-82) across end of crankshaft with two bolts diametrically
opposed to each other as shown in figure 3-82.
(b) Install a suitable dial indicator (1) as shown in figure 3-82 on holding fixture.
(c) Tap front end of crankshaft with a soft hammer to insure end play of crankshaft is in one direction only.
3-94
Figure 3-81. Final flywheel housing bolt tightening sequence
NOTE
Numbers indicated on figure 3-81 should not be mistaken for callouts. They are the order of sequence to
be followed in installation of flywheel housing.
(d) Adjust dial indicator to read zero at 12 o'clock position of pilot (inner edge) of flywheel housing bell.
(e) Rotate crankshaft one complete revolution. Maximum total indicator reading should not exceed 0.013 inch.
(f) Adjust dial indicator to zero at 12 o'clock position on flywheel housing bolting flange face.
(g) Rotate crankshaft one complete revolution. Maximum run-out should not exceed 0.013 inch.
NOTE
If indicator readings exceed the above limits, remove flywheel housing and check for dirt or foreign
material. such as old gasket material between end plate and flywheel housing. Reinstall flywheel housing
and recheck flywheel housing concentricity.
(14) Remove bolts and lockwashers securing engine lifter bracket to flywheel housing and remove hoisting eye
and gasket.
(15) Remove all traces of old gasket material and affix a new gasket to lifter bracket.
(16) Attach lifter bracket to cylinder head and flywheel housing with bolts and lockwasher. Draw bolts down
snugly and then tighten to a torque of 55 to 60 foot-pounds in sequence shown in figure 3-83.
NOTE
Numbers indicated on figure 3-83 should not be mistaken for callouts. They are the order of sequence to
be followed in installation of flywheel housing.
1. Dial indicator
2. Holding fixture, part No. J7452
Figure 3-82. Checking flywheel housing concentricity
Figure 3-83. Engine lifter bracket bolt tightening sequence
3-95
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Connect throttle control linkage to shaft engine lifter bracket(TM 55-1930-203-20).
Install oil pan (para. 3-24).
Install primary fuel filter.
Install dual tachometer drive adapter, if removed.
Install air starting motor (para. 3-18).
Install torque converter (para. 2-12).
Install engine in LARC (para. 2-11).
Section IX.
TIMING GEAR TRAIN, CAMSHAFT AND BALANCER SHAFT
3-30. Timing Gear Train
a. Description. A timing gear train composed of five helical gears is located at the rear end of the engine. A gear
bolted to the crankshaft flange drives the camshaft and balancer shaft gears, as well as the blower drive gear, through an
idler gear mounted between the crankshaft and balancer shaft gears on the RC engines, and between the crankshaft and
camshaft on the RA engines. The camshaft gear and balancer shaft gear mesh with each other and run at the same
speed as the crankshaft. Since these two gears must be in time with each other and the two as a unit in time with the
crankshaft gear, a letter is placed on one tooth of each gear with a corresponding mark at the root of the mating teeth of
the gear with which it meshes. The idler gear rotates on a double row, tapered roller bearing mounted on a stationary
hollow hub. Identification marks are located on two teeth of the idler gear with corresponding match marks stamped on
the crankshaft gear and the camshaft or balancer shaft gear, depending on engine model.
b. Removal.
(1) Remove engine (para. 2-11).
(2) Remove torque converter (para. 2-12) and flywheel housing (para. 3-29).
(3) Remove camshaft gear (para. 3-31).
(4) Remove balancer shaft drive gear (para 3-31).
(5) Remove bolt and lockwasher from center of idler gear hole spacer (3, fig. 3-84). Remove idler gear hole
spacer from cylinder block end plate (5).
(6) Remove bolt and washer securing idler gear (7) to cylinder block end plate (5). Withdraw idler gear, and
disassemble as follows:
(a) Remove six bolts (1, fig. 3-85) and three bolt locks (2) which secure bearing retainer (9) to idler gear (6).
(b) Place idler gear (6) and bearing assembly in arbor press with inner race supported on steel blocks.
While rotating gear assembly, press idler gear hub (3) out of bearing assembly. Remove gear assembly from arbor
press and remove bearing cones (4) and spacer (7).
NOTE
Component parts of idler gear bearing are mated therefore, matchmark parts during disassembly to assure
they will be reassembled in their original positions.
(c) Tap upper bearing race (5) from idler gear, (6), using a brass drift alternately at four notches provided
around shoulder of idler gear.
(7) Remove six bolts and lockwashers retaining crankshaft timing gear (4, fig. 3-84) to crankshaft (6). Place a
steel plate across large hole in end of crankshaft to provide a solid base and remove crankshaft gear using puller, part
No. J3051.
3-96
1
2
3
4
5
6
7.
Camshaft gear
Balance shaft gear
Idler gear hole spacer
Crankshaft timing gear
Cylinder block end plate
Crankshaft
Idler gear
Figure 3-84. Gear train and timing marks.
3-97
c. Cleaning, Inspection and Repair.
(1) Clean gears and related parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed
air.
(2) Inspect gear teeth for evidence of scoring, pitting, or burning. Replace damaged gear.
(3) Inspect idler gear bearing for pitting, scoring, or flat spots on rollers or races. If damage is noted, replace bearing
assembly.
(4) Inspect idler gear hub and idler gear bole spacer for pitting or other damage. Replace as necessary.
(5) Reassemble idler gear as follows:
(a) Support idler gear (6, fig. 3-85) with shoulder down, on bed of arbor press and start upper bearing race (5)
squarely into bore of idler gear. Press bearing race tight against shoulder of gear, using a steel plate between ram of
press and bearing race.
(b) Place a bearing cone (4), numbered side down, on bed of arbor press and lower idler gear(6) and upper
bearing race (5) down over bearing cone.
(c) Lay spacer (7) on face of bearing cone.
(d) Place second bearing cone (4), numbered side up, in idler gear and bearing cup assembly against spacer (7).
(e) Position idler gear hub (3) over bearing cones (4) so that oil hole in hub is 180 degrees from gap in spacer
(7).
(f) Press idler gear hub (3) into idler gear bearing cones, while rotating idler gear (to seat rollers properly
between cones), until face of hub which will be adjacent to cylinder block end plate (5, fig. 3-84) is flush with
corresponding face of bearing cone.
(g) Secure bearing retainer (9, fig. 3-85) and bolt locks (2) to idler gear with six bolts (1).
1
2
3
4
5
Bolt
Bolt lock
Idler gear hub
Bearing cone
Upper bearing race
6
7
8
9
Idler gear
Spacer
Pin, hollow
Bearing retainer
Figure 3-85. Idler gear details and relative location of parts.
NOTE
Bearing cones should be supported so as not to load bearing rollers during this operation.
(6) Check idler gear preload as follows:
(a) Mount idler gear assembly on engine.
(b) Install center bolt and washer through ,ear hub and thread into cylinder block. Tighten bolt to a torque
of 80 to 90 foot-pounds.
(c) Place a steel plate against hub and bearing. Insert three 3/8 inch bolts through plate and thread into
hub. Tighten bolts to a torque of 25 o 40 foot-pounds.
(d) Tie one end of a piece of lintless 1/8 inch cord around a 1/8 inch round piece of wood. Place wood
between teeth of gear, then wrap cord around periphery of gear several times. Attach other end of cord to spring scale.
See figure 3-86. Maintain a straight, steady pull on scale, 90 degrees to axis of hub, and note pull, in pounds and
ounces, required to start gear rotating. Make several checks to obtain an average reading. If pull is from 1/2 pound to 6
pounds, 12 ounces and does not fluctuate more than 2 pounds 11 ounces, idler gear and bearing assembly are
satisfactory for use. If scale ,reading is within specified limits but fluctuates
3-98
more than permissible 2 pounds 11 ounces, idler gear bearing assembly should be inspected for cause of fluctuation and
corrected, or a new bearing assembly installed.
d. Installation.
(1) Position crankshaft timing gear (4, fig. 3-84) in rear of crankshaft with flat finished hub end of gear facing
toward cylinder block and with all six bolt holes in timing gear alined with taped holes in crankshaft flange. Since one bolt
hole is offset, the crankshaft timing gear can be attached. in only one position on crankshaft (6).
(2) Start six bolts and lockwashers through crankshaft timing gear (4) and into crankshaft. Draw gear tight
against shoulder of crankshaft. Tighten bolts to a torque of 180 to 200 foot-pounds.
(3) Install camshaft gear (para 3-31).
(4) Install balancer shaft gear (para 3-31).
(5) Position crankshaft timing gear (4, fig. 3-84) and either balance shaft gear (2) or camshaft gear (1),
depending on engine model, so that match marks will aline with those of idler gear 17).
(6) With marks in alinement, start idler gear (7) into mesh with crankshaft timing gear (4) and either camshaft
gear or balancer shaft gear, and simultaneously rotate gear hub so hollow pin (8, fig. 3-85) at inner face of hub nearly
registers with oil hole in end plate.
(7) Roll idler gear (6) into position; aline hollow pin with hole in end plate. Gently tap hub until it seats against
end plate.
(8) Secure idler gear assembly in place with bolt and washer. Tighten bolt to a torque of 80 to 90 foot-pounds,
and lubricate idler gear and bearing liberally with clean engine oil.
(9) Check backlash between mating gears. Backlash must be 0.003 to 0.008 inch.
(10) Install idler gear hole spacer (3, fig. 3-84) and secure with bolt and lockwasher. Tighten bolt to a torque of
80 to 90 foot-pounds.
(11) Install flywheel housing (para 3-29) and torque converter (para 2-12).
(12) Install engine (para 2-11).
Figure 3-86. Checking preload of idler gear bearing.
3-99
3-31. Camshaft and Balancer Shaft
a. Description. A camshaft and balancer shaft are located near the top of the cylinder block and each may be
located on either side of the engine, depending upon engine model (RC or RA). The camshaft operates the exhaust
valves and injector assembly, is a one piece drop forging with case-hardened cams and journals. The balancer shaft
runs parallel to the camshaft and is the same distance from the crankshaft. Both ends of the camshaft and balancer
shaft are supported by bearing assemblies, each consisting of a flanged housing and two bushings. The eccentrically
positioned weights at the front and rear ends of both camshaft and balancer shaft, are so designed to dampen out
unbalanced forces within the engine. This permits the engine to operate smoothly and in balance throughout its entire
speed range.
b. Removal.
(1) Remove engine (para 2-11).
(2) Remove cylinder head (para 3-6).
(3) Remove torque converter (para 2-12), and flywheel housing (para 3-29).
(4) Remove engine starting aid (para 3-14).
(5) Remove bolts (13, fig. 3-37) securing engine starting aid mounting plate (14) to balance weight cover (15)
and remove plate.
(6) Remove bolts (16) and washers from balance weight cover (15). Lift cover from engine.
(7) Place a wood block between balance weight assemblies (14, fig. 3-87).
(8) Remove capscrews (1) and lockwashers (2) securing gear nut retainers (3) to camshaft gear(4) and
balancer shaft gear (20). Remove gear nut retainers.
(9) Loosen nuts (15) on each end of camshaft (10) and balancer shaft (16). Remove nuts from balance weight
assembly end of each shaft. Do not remove nuts from drive gear end of shafts.
(10) Force balance weight assembly off end of each shaft, using two heavy screwdrivers between heads of
bearing retaining capscrews (5) and balance weight assembly. Remove keys (13).
(11) Remove setscrews (11) securing camshaft intermediate bearings.
(12) Remove six capscrews (5) and lockwashers (6) that attach camshaft and balancer shaft bearing assemblies
(8) to rear end plate of engine, by inserting a socket wrench through hole in web of camshaft and balancer shaft gears (4
and 20).
(13) Withdraw camshaft (10) and balancer shaft (16) from rear end of cylinder block.
(14) Remove six capscrews (5) and lockwashers (6) securing camshaft and balancer shaft bearing assemblies to
front end plate and cylinder block. Pry under bearing flange with a suitable tool if bearing cannot be withdrawn by hand.
1 Capscrew, 3/8 x 1 in.
2 Lockwasher
3 Gear nut retainer
4 Camshaft gear
5 Capscrew, 3/8 x 1 ½ in.
6 Lockwasher
7 Washer
8 Bearing assembly
9 Camshaft plug
10 Camshaft
11 Setscrew
12 Upper camshaft bearing half
13 Key
14 Balance weight assembly
15 Nuts, extended washer
16 Balancer shaft
17 Retaining ring
18 Lower camshaft bearing half
19 Balance weight
20 Balancer shaft gear
21 Capscrew, 3/8 x 1 ½ in.
Figure 3-87. Camshaft and balancer shaft.
3-100
c.
Disassembly.
(1) Support camshaft (10, fig. 3-87) in soft jaws of bench vise, being careful not to damage cams.
(2) Remove nut tl51 from camshaft.
(3) Using a suitable puller, remove camshaft gear (4) from camshaft (10).
(4) Remove balancer shaft gear as outlined in steps (1) through (3) above.
(5) Slide bearing assembly (8) and washers (7) from shafts.
(6) Remove retaining rings (17) from camshaft intermediate bearings and free upper and lower camshaft bearing
halves (12 and 18) of each bearing.
(7) Drill and tap a 3, inch hole in one of camshaft plugs (9). Thread a 3h inch screw into hole and remove plug
with suitable remover. Insert a 3/8 inch diameter steel rod into camshaft oil passage and drive remaining plug out.
(8) Disassemble balance weight assembly (14) as follows:
(a) Remove cotter pin (6, fig. 3-88) from nut (7).
(b) Remove bolt (1) and spring retainer (2).
(c) Separate balance weight (9) from balance weight hub (8).
(d) Push balance weight springs (3) and spring spacer (10) from balance weight (9).
(e) Press balance weight bushing (4) from balance weight (9).
1
2
3
4
5
6
7
8
9
10
Bolt, 3/8 x 1 13/32 in.
Spring retainer
Balance weight springs
Balance weight bushing
Keyway
Cotter pin
Nut, 3 / 8 in.
Balance weight hub
Balance weight
Spring spacer
Figure 3-88. Balance weight assembly.
d. Cleaning, Inspection and Repair.
(1) Clean camshaft, balancer shaft, and related parts in drycleaning solvent, Federal Specification P-D-680.
Dry with compressed air (10 psi).
(2) Inspect camshaft cam and journals for uneven wear, scoring, pitting, or other damage, Replace camshaft if
damaged.
(3) Inspect both faces of thrust washers for scoring or wear. Replace washersf idamaged or worn so that thrust
washer-to-thrust shoulder clearance exceeds 0.018 inch.
(4) Inspect faces of shaft end bearings and other surfaces that contact thrust washers for marring or scratches.
Replace badly marred parts. Slight scratches may be cleaned up with an oil stone, Military Specification MIL-S-2389.
(5) Inspect bushings in shaft end bearing assemblies for wear or damage. Replace bearing assembly if
damaged or worn so that end bearing bushing-to-end journals exceed 0.006 inch.
(6) Inspect camshaft intermediate bearings for excessive scoring or wear. Replace bearings if scored or worn
so that camshaft journals-to-intermediate bearings exceeds 0.009 inch.
(7) Inspect balance weight and balance weight hub for damage. If either is damaged, replace entire balance
weight assembly.
(8) Inspect balance weight bushing for wear. If worn so that bushing-to-balance weight hub exceeds 0.0035
inch, replace bushing.
(9) Examine balance weight springs for wear. Each spring should be 0.015 to0.016 inch thick, and each of four
packs containing 17 springs should measure 0.243 to 0.259 inch total thickness. Pack thickness should be measured
while springs are clamped tightly in vise. Replace springs as required.
e. Reassembly
(1) Reassemble balance weight assembly as follows:
(a) Press balance weight bushing (4, fig. 3-88) into place in balance weight (9) until edge of bushing is
flush with shoulder on drilled (balancing hole) side of balance weight.
(b) Place balance weight (9), machined face down, flat on workbench.
(c) Dip balance weight spring pack in lubricating oil, Military Specification MIIL-L-2104, completely coating
all springs, and arrange one spring pack on either side of the balance weight spring cavity.
(d) Place spring spacer (10 ) on screwdriver blade and install spring spacer, tapered end first, between
balance weight springs (3). As spring spacer moves downward, tilt it into upright
3-101
position, bolt hole up. Press spring spacer into place.
(e) Place journal of balance weight hub (8) into balance weight bushing (4) of balance weight (9). Balance
weight should swing freely on balance weight hub (8). Burnish split bushing if required clearance of 0.005 inch to 0.0035
inch is not available.
(f) Place spring retainer (2) on spring spacer (10 and insert bolt (1) through spring retainer, spring spacer,
and balance weight hub (8). Secure with nut (7) and cotter pin (6).
(g) Check clearance between balance weight (9) and balance weight hub (8), using a feeler ga
ge.
Clearance should be from 0.010 inch to 0.023 inch. Adjust clearance by tightening or loosening nut (7), then lock nut in
position with cotter pin (6).
(2) Install new camshaft plugs (9, fig. 3-87) in camshaft (10).
(3) Apply grease, Military Specification MIL-G-10924, to steel face of washers (7). Place a washer against each
end of camshaft and balancer shaft rear bearing assemblies (8). The steel faces of thrust washers must be toward
bearing.
(4) Lubricate rear camshaft and balance shaft journals and slide bearing assemblies (8) on each shaft with
mounting flange of bearing toward gear end of shaft.
(5) Install keys (13) for camshaft gear (4) and balancer shaft gear (20) in shafts.
NOTE
Note that the teeth of one gear form a right-hand helix and on the other a left-hand helix. When
viewing engine from flywheel end, the gear with right-hand helical teeth is located on the left side
and the gear with left-hand helical is located on the right side.
(6) Rest the nongear end of camshaft (10) on ablock of wood and start proper gear onto the other end of shaft
so keyway alines with key (13) and with flat finished face of gear away from bearing.
(7) Using gear installer, part No. J1903, drive gears on camshaft and balancer shaft tight against shoulders of
shafts.
(8) Start nuts (15) on their respective shafts and hand tighten.
(9) Lubricate camshaft intermediate bearing journals. Place upper and lower camshaft bearing half (12 and 18)
of each intermediate bearing on a camshaft journal and lock halves together with retaining rings (17). Install each
retaining ring with gap over upper camshaft bearing half and ends equal distance above split line of bearing halves.
f. Installation.
(1) Insert front end of camshaft (10, fig. 3-87) into cylinder block and push camshaft into cylinder block until
camshaft gear teeth almost engage teeth of idler gear. Use care when installing camshaft to avoid damaging cam lobes.
(2) Aline timing marks on mating gears and slide camshaft gear (4) in place.
(3) Secure bearing assembly (8) to cylinder block with three capscrews (5) and lockwashers 6). Tighten
capscrews to a torque of 35 to 40 foot-pounds.
(4) Insert balancer shaft (16) into bore in cylinder block and push it in until teeth of balancer shaft gear (20)
almost engage camshaft gear teeth.
(5) Aline timing marks on mating gears and slide balancer shaft gear (20) into place.
(6) Secure bearing assembly 18) to cylinder block as in (3) above.
(7) Install camshaft and balancer shaft front end bearing assemblies with capscrews (5) and lockwashers (6).
Tighten bolts to a torque of 35 to 40 foot-pounds.
(8) Turn camshaft intermediate bearings until holes in bearings are in alinement with threaded holes in cylinder
block. Install setscrews (11) and tighten them to a torque of 15 to 20 foot-pounds.
(9) Install keys (13) in keyways at front end of camshaft (10) and balancer shaft (16).
(10) Aline keyway in balance weight assembly (14) with key in shaft. Slide balance weight assembly on shaft.
Repeat operation of other shaft.
(11) Place a nut (15) on end of each shaft and hand tighten.
(12) Using a wood block between balance weights to prevent shaft from turning, tighten nuts (15) to a torque of
300 to 325 foot-pounds.
(13) Install gear nut retainers (3) with cap-screws (1) and lockwashers (2). Tighten bolts to a torque of 35 to 40
foot-pounds.
(14) Check backlash between mating gears. Backlash should be within a 0.003 to 0.010 inch limit.
(15) Install balance weight cover (15, fig. 3-37) and secure to cylinder block with bolts (16) and washers.
(16) Install engine starting aid mounting plate (14) and secure with bolts (13).
(17) Install engine starting aid (para 3-14).
(18) Install flywheel housing (para 3-29) and torque converter (para 2-12).
(19) Install cylinder head (para 3-6).
(20) Install engine (para 2-11).
3-102
Section X. PISTON, CONNECTING ROD, CRANKSHAFT, AND MAIN BEARING ASSEMBLIES
3-32. Piston and Connecting Rod Assembly
a. Description. The mallable cast iron piston is joined to the upper end of the drop-forged carbon steel connecting
rod by a floating piston pin. The top of the piston forms a combustion chamber and is designed to displace air into close
proximity to the fuel spray. Each piston is fitted with four chrome-plated steel compression rings and two 3-piece oil
control rings. A protective tin plate has been applied to the piston skirt to provide a close piston-to-liner fit and prolong
piston life. The piston and connecting rod assembly is attached to crankshaft by a cap at the lower end of the connecting
rod.
b. Removal.
(1) Remove cylinder head (para 3-6).
(2) Remove oil pan assembly (para 3-24).
(3) Remove lubricating oil pump (para 3-26).
(4) Using a ridge cutter, remove any ridge in cylinder liner at top of piston ring travel.
CAUTION
Use holddown clamps to hold cylinder liners in place when rotating crankshaft to prevent
moving of cylinder liners and possible breakage of oil control rings and damage to pistons.
NOTE
Move piston to bottom of its travel and place a cloth over the top of piston to collect
cuttings. After ridge has been removed, turn crankshaft to bring piston to top of its stroke
and carefully remove cloth with cuttings.
(5) Remove cotter pins (18, fig. 3-89) from end of bolts (5). Remove nuts (1) and slide connecting rod bearing
cap (17) and lower connecting rod bearing shell (2) from lower end of connecting rod (4).
(6) Push piston and rod assembly out through top of cylinder block.
NOTE
Pistons cannot he removed from the bottom of cylinder block.
(7) With connecting rod (4) and piston (15) removed, reassemble connecting rod bearing cap (17) and lower
connecting rod bearing shell (2) to connecting rod.
(8) Remove remaining piston and rod assemblies in a similar manner.
Figure 3-89. Piston and connecting rod assembly.
3-103
Key to figure 3-89.
1
2
3
4
5
6
T
8
9
10
11
12
13
14
15
16
17
18
Nut, slotted
Lower connecting rod bearing shell
Upper connecting rod bearing shell
Connecting rod
Bolt, connecting rod
Connecting rod bushing
Connecting rod spray nozzle
Lower oil control ring
Upper oil control ring
Oil control ring expander
Retaining ring
Piston pin retainer
Piston pin bushing
Compression rings
Piston
Piston pin
Connecting rod bearing cap
Cotter pins
c. Disassembly.
(1) Remove lower and upper connecting rod bearing shells (2 and 3, fig. 3-89) from lower end of connecting rod (4)
and connecting rod bearing cap (17).
(2) Secure connecting rod in vise equipped with soft jaws and remove piston rings.
(3) Using a pair of thin nose pliers, remove retaining ring ( 1) which holds piston pin retainer (12) at end of
piston pin (16).
(4) Punch a hole through center of piston pin retainer (12) with a narrow chisel or punch, and pry retainer from
piston (15), being careful not to damage piston.
(5) Remove piston (16) through open pinhole.
(6) Place piston (15) in piston support fixture, part No. J1513-1 (4, fig. 3-90), so that bore in piston pin bushings
(13, fig. 3-89) alines with hole in base of fixture. Remove piston pin bushings from piston using driver handle, part No.
J1513-2, (1, fig. 3-90), and bushing remover, part No. J1513-3(3).
(7) Place connecting rod in connecting rod holder so that connecting rod bushings (6, fig. 3-89) aline with hole
in base of holder. Drive connecting rod bushings from connecting rod (4), using driver handle and bushing remover.
(8) Remove connecting rod spray nozzle (7) from connecting rod (4) as follows:
(a) Insert spray nozzle through upper end of connecting rod, and insert pin in curved side of remover in
opening in bottom of connecting rod spray nozzle (7).
(b) Support connecting rod (4) and spray nozzle remover in an arbor press. Place a short sleeve directly
over spray nozzle and press nozzle from connecting rod.
3-104
1 Driver handle, No. J1513-2
2 Installer
3 Bushing remover, part No. J1513-3
4 Piston support fixtures, part No. J1513-1
Figure 3-90. Removing or installing piston pin bushings in piston.
3-105
d. Cleaning, Inspection and Repair.
(1) Clean piston as follows:
(a) Clean all surfaces with dry-cleaning solvent, Federal Specification P-D-680.
(b) Using a wire brush, remove carbon and gum from upper part of piston that is not tin-plated.
(c) Clean ring grooves with a ring groove cleaner. If not available, a piece of used compression ring that
has been ground to a level edge may be used.
(d) Clean oil return holes in lower half of piston skirt.
(e) Rewash in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
CAUTION
When cleaning, use care not to damage tin plating on piston skirt or to enlarge oil return holes in lower half of
skirt.
(2) Clean piston pin, connecting rod, bearing cap, bearing shells, spray nozzle, and bushings in clean, drycleaning solvent, Federal Specification P-D-680, and dry with compressed air. Using compressed air, blow out drilled oil
passage in connecting rod to be sure it is clean and open.
(3) Inspect bearing shells for scoring, pitting, flaking, chipping, cracking, signs of overheating, or excessive wear.
Check backs of bearing shells for bright spots which indicate shells have been shifting in their support. Discard shells if
damaged, if right spots on back are noted, or if worn so that shell is less than 0.153 inch in thickness.
(4) Inspect piston pin for damage or wear. Replace pin if damaged or if pin-to-new-bushing clearance exceeds
0.010 inch. Check pin-to-retainer end clearance by subtracting length of piston pin from the dimension found by
measuring distance from outer edge of one of piston bushings to outer edge of other bushing. Pin-to-retainer end
clearance is not sufficient, grind end of piston pin opposite the end with stamp identification letters.
NOTE
During grinding operation, be sure end of piston pin is kept square and smooth.
(5) Inspect piston for scoring, cracks, damaged ring groove lands, and indications of having been overheated. A
piston with score marks that can be cleaned may be reused (fig. 3-91). Replace piston if badly scored, overheated, or
burned or if groove lands are damaged. Measure piston skirt diameter lengthwise and crosswise of piston pin bore. The
taper and out-of-round, measured from a point approximately 1.88 inches from the top of the piston to the bottom of the
piston. must not exceed 0.0005 inch.
Figure 3-91. Comparison of used pistons.
3-106
NOTE
Examine cylinder liner and block bore for indications of being out-of-round, tapered, or having high spots which could
cause piston failure.
(6) Inspect connecting rod for cracks by using magnetic particle method. Replace a defective connecting rod
(fig. 3-92).
NOTE
If a new connecting rod is installed, stamp cylinder number on connecting rod and cap.
Figure 3-92. Magnetic particle inspection limits for connecting rod.
(7) Inspect piston pin for damage or wear. Outside diameter of new piston pin is 1.4996 to J.5000 inches.
Maximum allowable pin-to-bushing clearance is 0.010 inch. Replace piston pin if necessary.
(8) Inspect spray nozzle for damage or closed nozzle holes. Replace nozzle if necessary.
(9) Inspect piston pin bushing and connecting rod bushing for damage or excessive wear. Inside diameter of new
piston pin bushings is 1.5025 to 1.5030 inches and inside diameter of new connecting rod bushings is 1.5015 to 1.5020
inches. Maximum allowable pin-to-bushing clearance is 0.010 inch. Replace bushings if damaged, or if worn so that pinto-bushing clearance exceeds 0.010 inch.
(10) Ream piston pin bushings as follows:
(a) Install piston pin bushings in piston as outlined in d(3) below.
(b) Clamp reaming fixture, part No. J5273 (1, fig. 3-93) in a vise (4). Insert bushing guide in fixture and
secure guide with setscrews.
(c) Place piston in fixture and insert pilot end of reamer part No. J3071-6 (3), through clamping bar,
piston pin bushings, and into guide bushing.
(d) With piston (2), reaming fixture (1) and reamer (3) in alinement, tighten wing nuts securely.
(e) Ream bushings by turning reamer (3) in a clockwise direction only. Use only moderate pressure on
reamer.
(f) Withdraw reamer (3) and remove piston (2) from reaming fixture (1). Remove chips with compressed
air and measure inside diameter of bushings. Diameter must be 1.5025 to 1.5030 inches.
3-107
1 Reaming fixture, part No. J5273
2 Piston
3 Reamer, part No. J3071-6
4 Vise
Figure 3-93. Reaming bushing in piston.
(11) Ream connecting rod bushings as follows:
(a) Install connecting rod bushings in connecting rod as outlined in d (2) below.
(b) Clamp reamer fixture and arbor, part No. J1686-9 (2, fig. 3-94), in a vise (5).
(c) Place large end of connecting rod (3) over reamer fixture and arbor (2), and tighten connecting rod
cap nuts to a torque of 65 to 75 foot-pounds.
(d) Slide front guide bushing, part No. J1686-11 (4), into front guide boss with pin end facing out.
(e) Aline upper end of connecting rod (3) with opening in reaming fixture and arbor (2).
(f) Install rear guide bushing, part No. J1686-5 (6), on reamer, part No. J1686-10 (1), and insert reamer
and bushing through rear guide boss of fixture.
(g)Turn reamer (1) in a clockwise direction only, when reaming or withdrawing reamer.
(h) Remove reamer (1) and connecting rod (3) from reamer fixture and arbor (2), blow out chips, and
measure inside diameter of bushings. Inside diameter of bushings must, be 1.5015 to 1.5020 inches.
3-108
1 Reamer, part No. J1686-10
2 Reamer fixture and arbor part No. J1686-9
3 Connecting rod
4 Front guide bushing, part No. J1686-11
5 Vise
6 Rear guide bushing, part No. J1686-5
Figure 3-94. Reaming connecting rod bushing in connecting rod.
(12) Fit piston to cylinder liner as follows:
(a) Measure piston diameter and cylinder liner bore, preferably at a room temperature of 70°F.
(b) Hold piston (2, fig. 3-95) upside down in cylinder liner(1). Using gage set, part No. J5538 (3), check
piston-to-liner clearance. Select a feeler gage with a thickness that will require a pull of 6 pounds to remove.
Check clearance in four places, 90 degrees apart, around circumference of piston. Piston-to-liner clearance will
be 0.001 inch greater than the thickness of feeler gage used. (A 0.004 inch feeler gage will indicate a 0.005 inch
clearance when withdrawn with a 6 pound-pull). Maximum allowable piston-to-liner clearance is 0.012 inch. If
maximum clearance is exceeded, replace cylinder liner (para 3-34).
NOTE
If binding occurs between piston and liner, remove piston and examine piston and liner for burrs. If marred, polish either
part with fine hone before proceeding with clearance check.
(13) Fit piston ring to piston and liner as follows:
3-109
1 Cylinder liner
2 Piston
3 Gage set, part No. J5438
Figure 3-95. Measuring piston-to-liner clearance.
NOTE
Install new piston rings whenever a piston is removed, regardless of whether a new or used piston is installed.
(a) Insert one ring at a time inside cylinder liner bore far enough to be within normal area of ring travel.
Use a piston to push ring down to assure ring is parallel with top of liner.
(b) Measure ring gap with a feeler gap with a feeler gage (fig. 3-96). Compression ring gap must be
0.018 to 0.043 inch and oil control ring gap, 0.008 to 0.023 inch. If piston ring gap is insufficient, increase gap by
filling or stoning ends of ring. File or stone ring so that cutting action is from outer surface to inner surface. This
prevents chipping or peeling of chrome plate on compression rings. Ends of ring must remain square and
chamfer must be 0.015 on outer edge.
(c) Check ring clearance in piston ring grooves (fig. 3-97). Maximum ring-to-groove clearances for the
compression rings are: top compression ring, 0.0220 inch; second compression ring, 0.0150 inch; third and fourth
compression rings, 0.0130 inch. Oil control ring maximum allowable clearance is 0.0080 inch. If ring-to-groove
clearances exceed maximum, replace piston.
3-110
Figure 3-96. Measuring piston ring gap with feeler gage.
Figure 3-97. Measuring piston ring side clearance.
3-111
e. Reassembly.
(1) Install connecting rod spray nozzle (7, fig. 3-89) in connecting rod (4) as follows:
(a) Start connecting rod spray nozzle, (7), with holes positioned as shown in figure 3-98, straight into
counterbore in top of connecting rod (4, fig. 3-89).
(b) Support connecting rod in arbor press. Place a short 3/8 inch inside diameter sleeve on top of spray
nozzle and under ram of press.
(c) Press connecting rod spray nozzle (7) into connecting rod (4) until it bottoms in counterbore.
(2) Install connecting rod bushing (6) in connecting rod 14) as follows:
(a) Start one connecting rod bushing (6) straight into bore of connecting rod.
NOTE
This bushing joint must be toward the
top of the connecting rod.
(b) Insert bushing installer, part No.J15
13-6, in bushing. Insert driver handle, part No. J1513-2
(1, fig. 3-90) in installer and drive connecting rod
bushing 16, fig. 3-89) until flange of installer bottoms on
connecting rod (4).
(c) Turn connecting rod over in holder,
align bore in rod with hole in base of holder, and install
second bushing as outlined in steps (a) and (b) above.
(3) Install piston pin bushings (13) in piston (15)
as follows:
(a) Place spacer, part No. J1513-4, in
hole in piston support fixture, part no. J1513-1 (4, fig.
3-90).
(b) Set piston on piston support fixture,
Figure 3-98. Installation of spray nozzle in connecting
part No. J1513-1 (4), so that spacer protrudes into
rod.
bushing bore.
(c) Insert bushing installer, part No. J1513-6 in bushing. Position bushing and installer over lower bushing
bore.
NOTE
The bushing joint should be located toward the bottom of the piston.
(d) Insert driver handle (1) in bushing installer (2) and drive bushing in until it bottoms on spacer.
(e) Install other bushing as outlined in (a) through (d) above.
(4) Rest piston in piston support fixture (4) and install a piston pin retainer (12, fig. 3-89) into one end of piston
(15). Retainer-to-piston fit may vary from 0.001 inch loose to 0.005 inch press fit; therefore, it may be necessary to drive
piston pin retainer in piston.
CAUTION
Do not drive too hard on retainer when installing piston pin retainer in piston, since bushing may move inward
and decrease piston pin end clearance.
(5) Secure piston pin retainer (12) with retaining ring (11) and with prongs of ring bearing against piston pin
retainer. Make sure retainer ring is seated firmly in groove.
(6) Coat piston pin and bushings with clean engine oil.
(7) Place upper end of connecting rod (4) between piston pin bosses and in line with piston pin holes. Slide piston
pin (16) in place. If piston pin-to-bushing clearances are within specified limits, pin will slip into place without use of force.
(8) Install second piston pin retainer as outlined in (4) and (5) above.
(9) Install oil control rings on piston as follows:
NOTE
Scraping edges of rings must face toward bottom of piston.
(a) Place oil control ring expanders (10) in two ring grooves of piston (15) below piston pin.
(b) Install upper oil control rings (9) in grooves with gaps 180 degrees from gaps in oil control ring
expanders (10).
(c) Install lower oil control rings (8) in grooves with gaps 45 degrees from gaps of upper oil control rings
(9).
(10) Using piston ring remover and installer, install compression rings (14) on piston (15). Position compression
rings so that gaps are staggered around piston.
CAUTION
When installing rings, do not spread them-any more than necessary to slip
3-112
them over piston. This will avoid breaking or overstressing piston rings.
f. Installation.
(1) Note that the lower end of each connecting rod and cap is marked in sequence, 1 to 6. These numbers
identify caps with rods and show particular cylinder in which each rod is used.
(2) Make certain piston ring gaps are staggered around piston (15, fig. 3-89), then apply generous film of clean
engine oil, Military Specification MIL-L-2104, to piston and rings.
(3) Place piston and connecting rod assembly on bench with head of piston (15) down and slide ring compressor
down over the assembly with tapered end of tool toward head of piston, thus compressing piston rings.
(4) Rotate crankshaft until journal of connecting rod (4) is at bottom of its travel, wipe journal clean, and lubricate
with engine oil.
(5) Install upper connecting rod bearing shell (3), the one with short groove and oil hole at each parting line, in
connecting rod (4).
(6) Aline piston and connecting rod assembly with ring compressor in place, with top of cylinder liner and line up
lower end of connecting rod (4) with crankshaft, then push piston (15) down into place.
(7) Install lower connecting rod bearing-shell (2) into connecting rod bearing shell (2) into connecting rod bearing
cap (17) with tang or bearing shell in cap groove.
(8) Install connecting rod bearing cap (17), lock cap securely in place with bolts (5), nuts (1), and cotter pins (18);
tighten nuts to a torque of 65 to 75 foot-pounds.
(9) Install lubricating oil pump (para 3-26).
(10) Install oil pan assembly (para 3-24).
(11) Install cylinder head (para 3-6).
3-33. Crankshaft and Main Bearing Assembly
a. Description. The crankshaft is a one-piece steel forging, heat treated to insure strength and durability. All main
bearing, rod bearing, and oil seal surfaces are induction hardened. Complete static and dynamic balance of the
crankshaft is achieved by the use of counterweights. Replaceable main bearing shells are used on each main bearing
journal and consist of an upper and lower shell. Thrust washers, located on each side of the rear main bearing, absorb
crankshaft thrust. Two oil seals, one pressed into the crankshaft front cover and the other pressed into flywheel housing,
prevent oil from seeping out along the journals at either end of the crankshaft.
b. Removal
(1) Remove engine (para 2-11).
(2) Remove oil pan assembly (para 3-24).
(3) Remove lubricating oil pump assembly (para 3-26).
(4) Remove torque converter (para 2-12) and flywheel housing (para 3-29).
(5) Remove vibration damper and power takeoff coupling (para 3-28).
(6) Remove capscrews (4, fig. 3-99) lockwashers (5), and support assembly (6).
(7) Remove trunnion support ring (7) from crankshaft front cover (12).
(8) Remove capscrews securing crankshaft front cover (12) to engine block. Remove cover and gasket (13) with
crankshaft front seal (1). Remove seal from cover.
(9) Slide oil slinger (2) from crankshaft.
(10) Remove connecting rods and pistons (para 3-32).
(11) Remove two bolts (26) and lockwashers (25) from each main bearing cap (24) and remove bearing caps.
(12) Remove thrust washers from each side of rear main bearing.
(13) Remove crankshaft, including crankshaft timing gear (18) and oil pump drive gear (3).
3-113
1 Crankshaft front seal
2 Oil slinger
3 Oil pump drive gear
4 Capscrew, 7/16 x 2 ¼
5 Lockwasher, 7/16 in.
6 Support assembly, front trunnion
7 Ring, front trunnion support
8 Capscrew, 3/8 x 1 ¼
9 Lockwasher, 3/8 in.
10 Capscrew, ½ x 2 ¼
11 Lockwasher, ½ in.
12 Crankshaft front cover
13 Gasket, crankshaft front cover
14 Key
15 Upper bearing shelf
16 Plug
17 Washer
18 Crankshaft timing gear
Figure 3-99. Crankshaft and main bearing assembly.
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19 Crankshaft oil baffle
20 Crankshaft dowel
21 Special plug
22 Lower bearing shell
23 Pin
24 Main bearing cap
25 Lockwasher
26 Bolt, main bearing cap
27 Crankshaft
c. Disassembly.
(1 ) Screw cone retainer bolt into tapped hole in
front end of crankshaft (27, fig. 3-99). Attach jaws of gear
puller behind oil pump drive gear (3) and locate point of
puller screw in center of retainer bolt. Pull oil pump drive
gear off crankshaft, and remove key (14) from crankshaft.
(2) Remove crankshaft timing gear (18) (para 330).
(3) Remove upper bearing shell (15) from cylinder
block and lower bearing shells (22) from main bearing
caps (24).
(4) Using a small punch, punch a hole in
crankshaft oil baffle (19) and pry from crankshaft.
Figure 3-100. Crankshaft fatigue cracks.
(5) Remove plugs (16) from crankshaft.
d. Cleaning, Inspection and Repair.
(1) Clean crankshaft and related parts in dry-cleaning solvent, Federal Specification P-D-680. Clean out all oil
passages in crankshaft. Dry with compressed air (10 psi).
(2) Place crankshaft on its front and rear journals in a lathe or blocks and check alinement at adjacent journals,
using a dial indicator. If runout (total indicator reading) at number two and number six journals exceeds 0.002 inch, or at
number three and number five journals exceeds 0.004 inch, or at number four journal exceeds 0.006 inch, replace
crankshaft.
(3) Measure all main and connecting rod bearing journals. Journals should be measured at several places on
circumference, in case journals have worn out-of-round condition. If taper or out-of-round condition exceeds the
dimensions given in table 1-1, replace crankshaft.
(4) Inspect crankshaft main bearing journals for ridging caused by the groove in upper main bearing shell. Ridges
exceeding 0.0002 inch must be removed. Remove ridges by working crocus cloth, Federal Specification P-C-458, wet
with fuel oil, around the circumference of crankshaft journal. If ridges are greater than 0.0005 inch, first use 120 grit
emery cloth to clean up ridge, followed by use of 240 grit emery cloth for finishing. Then wet crocus cloth, Federal
Specification P-C-458, should be used for polishing. If ridges are greater than 0.001 inch, replace crankshaft.
(5) Inspect surfaces of crankshaft for evidence of cracks. Cracks originating in or around journal fillets and
oilholes and running at an angle of 45°to axis (fig. 3-100) indicate torsional fatigue. Crankshafts with this condition are
not suitable for repair and should be replaced. Use magnetic partical inspection process, Military Specification MIL-L6868, to determine presence of minute cracks not visible to the eye. Demagnetize crankshaft in accordance with Military
Specification MIL-I-6868. Replace a defective crankshaft.
(6) Inspect thrust surfaces for evidence of excessive wear or roughness. Grind thrust surfaces slightly to dress up
a rough condition. If surface is worn so that new thrust washers will not hold end thrust clearance within specified
maximum limit of 0.018 inch, use 0.005 inch oversize thrust washers; or regrind or replace crankshaft.
(7) Inspect thrust washers for scoring, damage, or wear. Replace thrust washers if scored, damaged, or worn so
that crankshaft end thrust exceeds 0.018 inch.
(8) Inspect keyway for evidence of cracks or other damage. Replace a defective shaft.
(9) Inspect oil seals for scored, cracked, or charred surfaces. Check seals for hardness or brittleness. Replace
seals if necessary. Inspect crankshaft in area of rear oil seal contact for evidence of rough or grooved condition.
Crankshaft surface must be smooth to prevent damaging seal lip when oil seal is installed. Remove a slight groove with
120 grit emery cloth followed by 240 grit emery cloth, rotating crankshaft during operation to prevent out-of-round
condition. Use crocus, Federal Specification P-C-458, wet with fuel oil, to polish surface. If crankshaft (3, fig. 3-101) or
rear oil seal (1 ) surface is grooved excessively, spacer (2) may be installed between the counterbore in flywheel housing
and oil seal to establish a new contact surface.
(10) Inspect crankshaft timing gear for chipped teeth or other damage. Replace a defective gear.
(11) Inspect oil pump gear for uneven wear of broken, or chipped teeth. Replace a defective gear.
(12) Replace a damaged shaft key.
(13) Inspect front cover for cracks and warpage. Replace defective cover. Replace front cover gasket.
(14) Inspect main bearing shells for scoring, pitting, flaking, chipping, cracking, or signs of
3-115
overheating. Check back of bearing shells for bright spots which indicate they have been moving in their caps or
crankcase. If any of the above conditions are noted, replace bearings.
(15) Inspect bearing shells for excessive wear. Using ball attachment micrometer, part No. J4757 (3, fig. 3-102)
place between main bearing shell (1) and micrometer (2), measure shell thickness at a point 90 degrees from parting
line. The bearing shell thickness will be total thickness of steel ball in tool and shell, less diameter of ball. Minimum
thickness of bearing shell is 0.153 inch. Check clearance between main bearing shells and crankshaft journals. The
clearance is determined by measuring outside diameter of crankshaft main bearing journals and inside diameter of main
bearing shells when installed in place with proper torque of 180 to 190 foot-pounds. Clearance between any crankshaft
main bearing journal and its bearing shell should not exceed 0.006 inch. If shell thickness is less than minimum or
bearing journal-to-shell clearance exceed 0.006 inch, replace all bearing shells.
Figure 3-101. Use of spacer on grooved crankshaft.
Figure 3-102. Measuring thickness of main bearing shell.
e. Reassembly.
(1) Replace plugs (1 6, fig. 3-99) in crankshaft.
(2) Repack grease in crank cavity and press crankshaft oil baffle (19) into crank cavity until it seats firmly against
special plug (21).
(3) Install crankshaft timing gear (18) para 3-30).
(4) Install key (14) in crankshaft (27).
(5) Position oil pump drive gear (3) so that chamfer on gear hub is toward main bearing and start gear on
crankshaft and over key (I14). Using a cup or pipe, drive oil pump drive gear (3) tight against shoulder on crankshaft.
(6) Install oil slinger (2) on crankshaft and in place next to oil pump drive gear (3) with dished
outer diameter of oil slinger away from gear.
f. Installation.
(1) Install upper bearing shells (15, fig. 3-99) in cylinder block.
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(2) Apply clean engine oil to all crankshaft journals and set crankshaft in place so that timing marks on crankshaft
timing gear (18) and gear train idler gear match.
(3) Install upper half of rear main bearing washers (17) on each side of bearing, and doweled lower halves on
each side of rear main bearing cap (24).
(4) Install lower bearing shells (22) in main bearing caps (24) and install caps in their original position and draw
bolts (26) up snug. Tap caps sharply with a soft hammer to seat them properly. Draw bearing cap bolts tight and
uniformly, starting with center cap and working alternately toward both ends of block, to a torque of 180 to 190 footpounds. Torque in 30-40 foot-pounds increments and rotate crankshaft at each increment to check for binding.
NOTE
Main bearing caps are bored in position and marked 1. 2. 3, etc. They must be replaced in their original
positions with marked side of caps toward blower side of cylinder block.
(5) Check crankshaft end play at thrust washers. Clearance should be from 0.004 to 0.011 inch with new parts or
a maximum of 0.18 inch with used parts. Insufficient clearance will usually denote misalinement of rear main bearing.
Loosen and retighten rear main bearing and recheck clearance.
(6) Install connecting rods and pistons (para 3-32).
(7) Apply grease, Military Specification MIL-G-1 0924, to crankshaft front seal 111 and press into crankshaft front
cover (12) so that lip of seal is pointed toward inner face of cover. Secure cover and gasket (13) to engine block.
(8) Install trunnion support ring (7), and support assembly (6), on crankshaft front cover (12).
(9) Install vibration damper and power takeoff coupling (para 3-28).
(10) Install flywheel housing (para 3-29) and torque converter (para 2-12).
(11) Install lubricating oil pump assembly (para 3-26).
(12) Install oil pan assembly (para 3-24).
(13) Install engine (para 2-11).
Section XI. CYLINDER LINER AND CYLINDER BLOCK ASSEMBLY
3-34. Cylinder Liner
a. Removal.
(1) Remove cylinder head (para 3-6).
(2) Remove piston and connecting rod assembly (para
3-32).
NOTE
Even though the cylinder liners are a loose fit in the
engine block, after the engine has been in service
for an extended period, considerable effort may be
required to loosen the liners from their position.
(3) Using cylinder liner remover, part No. J1918-02,
remove cylinder liner as follows:
(a) Slip lower puller clamp up puller rod and off its
tapered seat. Tilt clamp on rod off its tapered seat and lower rod
through center of cylinder liner. Clamp will drop into its proper
position on tapered seat.
(b) Slide upper puller clamp down against top edge
Figure 3-103. Removing cylinder with cylinder
of cylinder liner.
liner remover, part No. J1918-02.
(c) Strike a sharp blow with puller weight on upset
head at top of puller rod. This will release liner.
(d) Remove cylinder liner from engine (fig. 3-103).
(4) Remove liner insert from cylinder block bore.
b. Cleaning, Inspection and Repair.
(1) Clean cylinder liner with dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
(2) Inspect cylinder liners for cracks, scoring, nicks, scratches, or burrs. Replace liners if cracked or scored.
Liners that are nicked, scratched, or burred may be cleaned with a soft stone, Military Specification MIL-S-2389, and
reused.
3-117
(3) Inspect flange of cylinder liner to assure it is smooth and flat on both top and bottom surfaces. Check for
cracks at liner flange. Replace liner if flange is damaged.
(4) Inspect outside diameter of cylinder liner for fretting. Fretting is caused by slight movement of liner in block
bore during engine operation and causes material from block to adhere to liner. Remove these metal particles from liner
with a coarse, flat stone.
(5) Measure inside diameter of cylinder liner bore and outside diameter of cylinder liner. Replace liner if
maximum clearance of 0.003 inch is exceeded.
NOTE
Steps (6) through (7) will be performed with liner in cylinder block.
(6) Using bore gage, part No. J5347, check inside diameter of cylinder liner for wear, taper, and out-of-round
condition (fig. 3-104). Taper must not exceed 0:002 inch and out-of-round must not exceed 0.003 inch. If liner inside
diameter is more than 0.002 inch out-of-round, rotate liner 90 degrees and recheck. If inside diameter is tapered or outof-round beyond specified limits or worn in excess of 4.251 1 inches, replace cylinder liner.
(7) If inside diameter wear, taper, or out-of-round condition does not exceed wear limits, hone liner to remove
ridge at top of piston ring travel and remove glaze formed by rubbing action of piston rings. Remove glaze with a 120 grit
stone in such a manner as to produce a criss-cross pattern with hone marks on 45 degrees axes.
NOTE
Do not modify the factory finish on the bore of a new service cylinder liner. Any change in a new surface finish will greatly
affect ring seating. However. never install new rings in a used liner unless the glaze is broken.
(8) After honing cylinder liner, wash liner in clean fuel oil and dry with compressed air. Liner must still conform to
same limits of taper and out-of-round condition as a standard size liner.
3-118
Figure 3-104. Checking diameter of cylinder liner with bore gage, part No. J5347.
c. Installation
(1) Wipe inside and outside of cylinder liner clean and be sure that bore in engine block is clean.
(2) Install a cylinder liner inset (3, fig. 3-105) into the counterbore to receive liner flange.
(3) Push cylinder liner into position in cylinder block by hand until flange rests on cylinder liner insert (3). When liner
is in place, top face of liner upper flange should be from 0.0465 to 0.050 inch below top surface of cylinder block. The
difference
3-119
in depth below top of block between any two adjacent liners must not exceed 0.002 inch.
(4) Install compression gasket (2) on upper side of liner flange.
(5) Install pistons and connecting rod assemblies (para 3-32).
CAUTION
Use holddown clamps to hold each installed cylinder liner in place when rotating crankshaft to prevent moving
of liner and possible breaking of oil control rings.
(6) Replace cylinder head (para 3-6).
1
2
3
4
Cylinder liner
Compression gasket
Cylinder liner insert
Cylinder block
Figure 3-105. Cylinder liner mounting in block.
3-35. Cylinder Block Assembly
a. Description. The cylinder block assembly is an integral casting forming the primary structure part of the engine.
Both ends of the cylinder block are similar; the same flywheel housing and gear train can be installed on either end.
Transverse members, cast integrally, provide rigidity and strength and insure alinement of bores and bearings under
load. Water jackets extend full length of the cylinder bores and are divided into upper and lower sections connected by
hollow struts. Drilled passages in the cylinder block carry lubricating oil to all moving parts, thus eliminating the need for
external piping. Hand hole covers on the side opposite the blower permit access to the air chamber and inspection of
pistons and rings through air intake parts in the cylinder walls.
b. Removal Remove engine (para 2-11).
c. Disassembly.
(1) Remove governor (para 3-13).
(2) Remove cylinder head (para 3-6).
(3) Remove fluid starting aid (para 3-14).
(4) Remove lubricating oil cooler assembly (para 3-15).
(5) Remove oil filters (para 3-16).
(6) Remove blower (para 3-22).
(7) Remove blower drive (para 3-23).
(8) Remove flywheel housing (para 3-29).
(9) Remove power take-off coupling and vibration damper (para 3-28).
(10) Remove lubricating oil pump (para 3-26).
(11) Remove oil pressure regulator (para 3-27).
(12) Remove timing gear train (para 3-30).
(13) Remove camshaft and balance shaft (para 3-31).
(14) Remove pistons and connecting rods (para 3-32).
(15) Remove crankshaft and main bearings (para 3-33).
(16) Remove cylinder liners and inserts (para 3-34).
(17) Remove handhole covers (4, fig. 3-106) and water hole covers (16).
(18) Remove airbox drain tube (18, fig. 3-106) and elbow (19).
(19) Remove capscrews and lockwashers attaching rear end plate (1) to cylinder block. Lift end plate off dowel
pins (20) and remove end plate gasket (2). Remove front end plate ( 12) and gasket in similar manner.
(20) Remove plugs from cylinder block.
(21) Remove dowel pins (20) if loose or damaged.
(22) Remove cylinder head studs (8) if damaged.
d. Cleaning, Inspection and Repair.
(1) Steam clean block to remove grease.
3-120
1 Rear end plate
2 End plate gasket
3 Gasket
4 Cover
5 Gasket (copper)
6 Washer, flat 3/8 in.
7 Capscrew, 3/8 x 2 1/8 in.
8 Stud, plain
9 Lockwasher
10 Capscrew, 5/ 16 x 3/4 in.
11 Drain cock
12 Front end plate
13 Lockwasher, ½ in.
14 Capscrew, ½ x 1 1/8 in.
15 Cylinder block
16 Water hole cover
17 Gasket
18 Air box drain tube
19 Elbow
20 Dowel pin
21 Lockwasher, 3/8 in.
22 Capscrew, 3/8 x 1 in.
Figure 3-106. Cylinder block assembly.
(2) If water jacket is heavily scaled, clean as follows:
(a) Agitate block in suitable acid bath.
(b) Allow block to remain in acid bath until bubbling action stops (approximately 30 minutes).
(c) Lift block, drain, andreimmerse in same acid solution for 10 minutes.
(d) Repeat operation in (c) above until all scale is removed.
(e) Rinse block in clear, hot water to remove acid solution. Neutralize remaining acid that may cling to
casting by immersing in suitable alkaline bath.
(f) Wash in bath of clean water.
(3) Check cylinder block for leaks and cracks as follows:
(a) Install plugs in cylinder block.
(b) Make all water inlet and outlet openings air tight with cover plates. Drill and tap one cover plate to
provide a connection for an air line.
(c) Immerse cylinder block for 20 minutes in a tank of water heated to 180°to 200°F.
(d) Connect airhose to fitting in cover plate and apply 80 to 1 00
psi air pressure to water jacket.
Observe water for bubbles which would indicate a crack or leak in block.
(e) Replace cylinder block if cracks or leaks are indicated.
(4) Inspect cylinder block face for flatness, using an accurate straightedge. Top face of block must not vary over
0.003 inch transversely or 0.009 inch longitudinally. Blower mounting pad must not vary more than 0.004 inch over its
entire surface. Replace cylinder block if these tolerances are exceeded.
(5) Inspect cylinder block bores as follows:
(a) Hone cylinder bore throughout its entire length and check contact area as revealed by honed surface.
There should be no low spots which are larger than a half dollar.
(b) Measure entire bore with a dial indicator. Block bore diameter should not exceed 4.6280 inches. Bore
out-of-round should not exceed 0.003 inch, or taper exceed 0.002 inch.
(c) Replace block if bores do not meet specifications for diameter, taper, and out-of-round or if liner-toblock fit is greater than 0.003 inch.
(6) Inspect main bearing bores as follows:
3-121
(a) Measure main bearing bore inside diameter with main bearing caps secured in their proper location
with bolts tightened to a torque of 180 to 190 foot- pounds. If bearing bore diameters exceed 3.813 inch, replace cylinder
block.
(b) Check main bearing bores for alignment. If crankshaft can be rotated freely by hand after new main
bearing shells have been installed, bearing bores may be considered properly alined. If any main bearing bore is more
than 0.001 inch out of alinement, replace block.
(7) Inspect cylinder liner counterbore for squareness, proper depth, and correct diameter. Counterbores should
have a depth of 0. 4785 to 0.4795 inch and diameter of 5.0460 to 5.0485 inch. Counterbored surfaces must not vary in
depth more than 0.001 inch around entire circumference. Replace cylinder block if these tolerances are exceeded.
(8) Inspect both surfaces on each end plate for scratches or score marks. All surfaces must be smooth and flat.
Remove slight scratches or nicks with a soft stone. Military Specification MIL-S-2389 and polish smooth with crocus
cloth, Federal Specification P-C-458.
CAUTION
If cylinder block is not used immediately, spray machined surfaces with engine oil to prevent rust.
d. Reassembly.
(1) Install new dowel pins (20, fig. 3-106) and cylinder head studs (80 where damaged dowel pins and studs were
removed.
(2) Attach new end plate gaskets (2) to each end of cylinder block ( 15), using nonhardening cement.
(3) Using dowel pins (20), set front end plate (12) next to cylinder block (15) and loosely install capscrews (I 4)
and lockwashers (13). Insert a camshaft end bearing through small bearing bore in front end plate (12) and into bore of
block to accurately aline end plate and cylinder block. Tighten capscrews to a torque of 71 to 75 foot-pounds. Reove
camshaft end bearing.
(4) Install rear end plate (1) in the same manner as in step (3) above, except tighten capscrews (22) to a torque
of 30 to 35 foot-pounds.
(5) Install handhole covers (4, fig. 3-106) and water hole covers (16).
(6) Install elbow (19) and air box drain tube (18).
(7) Install cylinder liners and inserts (para 3-34).
(8) Install crankshaft and main bearings (para 3-33).
(9) Install pistons and connecting rods (para 3-32)
(10) Install oil pressure regulator (para 3-27).
(11) Install lubricating oil pump (para 3-26).
(12) Install camshaft and balance shaft (para 3-31).
(13) Install timing gear train (para 3-30).
(14) Install flywheel housing (para 3-29).
(15) Install oil pan (para 3-24).
(16) Install vibration damper and power take-off coupling (para 3-28).
(17) Install torque converter (para 2-12).
(18) Install blower drive (para 3-23).
(19) Install blower (para 3-22).
(20) Install air starting motor (para 3-18).
(21) Install fuel pump assembly (para 3-19).
(22) Install water pump (para 3-17).
(23) Install lubricating oil cooler assembly (para 3-15).
(24) Install oil filters (para 3-16).
(25) Install cylinder head (para 3-6).
(26) Install governor assembly (para 3-13).
(27) Install electrical tachometer generator (para 6-3).
(28) Install fluid starting aid (para 3-14).
e. Installation. Install engine (para 2-11).
Section XII. EXHAUST PIPING AND MUFFLER ASSEMBLY
3-36. Exhaust Piping.
a. Description. The engine exhaust piping is composed of stainless steel tubing which carries the exhaust gages
from the engines to the mufflers. The piping consists of replaceable tubes, elbows and flanges, and is insulated by
fiberglass.
b. Removal
(1) Remove insulation.
(2) Remove bolts securing exhaust piping assembly (9, fig. 3-107) to exhaust manifold and muffler.
(3) Remove exhaust piping assembly and gaskets (22 and 25).
(4) Remove flexible hose assembly (7) from exhaust piping. Remove gaskets (24).
3-122
Change 2
1 Backup flange
14 Gasket packing ring to hull connection
2 Flange stub
15 Packing ring
3 Exhaust pipe tube 7-13/16 in. Ig
16 Lockwasher, 3/8 in.
4 Elbow
17. Bolt, machine 3/8 x 1 in.
5 Exhaust pipe tube, 2-3/16 in. Ig
18 Nut, 3/8 in.
6 Backup flange
19 Muffler Assembly
7 Flexible hose assembly
20 Nut, No. 10
8 Exhaust pipe tube, 6-13/16 in. Ig
21 Hanger strap
9 Exhaust piping assembly
22 Gasket. muffler to exhaust pipe
10 Bolt, machine, No. 10 x 1-1/4 in.
23 Insulating blanket
11 Insulation pad
24 Gasket. exhaust pipe to flexible hose assembly
12 Bolt. machine, 3/8 x 1-1/4 in
25 Gasket, exhaust pipe to manifold
13 Seal plate
26 Lockwasher
Figure 3-107. Exhaust piping and muffler
c. Cleaning, Inspection and Repair. Inspect exhaust piping for corrosion and cracks. Grind away and replace
defective parts.
NOTE
If welded parts of the exhaust piping are being replaced, install piping in correct position to properly align
connections before welding. For welding procedures refer to paragraph 11-3.
d
Installation.
(1) Assemble flexible hose assembly (7, fig. 3-107) and gaskets (24) to backup flanges (6).
(2) Install exhaust piping assembly (9) and gaskets (22 and 25) between exhaust manifold and muffler.
(3) Install insulating blanket (23) on flexible hose assembly (7) and wrap balance of exhaust
3-123
piping with 1 inch thick insulation. Military Specification MIL-1-16411, Type 2.
(4) Cover insulation, except insulating blanket, with fibrous cloth, Military pecification MIL-1-16411, Type2.
3-37. Exhaust Muffler Assembly
a. Removal.
(1) Remove enough insulation from around exhaust muffler and piping to permit working on joints at exhaust
muffler ends.
(2) Remove bolts (10, fig. 3-107), nuts (20), and lockwashers (26) attaching muffler assembly to exhaust
piping. Remove gasket (22).
(3) Remove bolts (17) and lockwashers (16) attaching muffler assembly to hull connection.
(4) Support muffler assembly and remove bolts (12), insulation pad (11), and nuts (18) securing hanger straps
(21) to main power train foundation.
(5) Pull muffler assembly away from hull connection until tail pipe is clear of connection and remove muffler
assembly and gasket (14).
(6) Remove remainder of insulation from exhaust muffler.
(7) If muffler assembly is being replaced, remove weld from around packing ring (15) and slide packing ring
off tail pipe.
b
Cleaning, Inspection and Repair.
(1) Tap outside surfaces of muffler assembly with a wooden mallet or rubber hammer to break loose any
deposits. Clean muffler assembly with a wire brush and compressed air.
(2) Inspect muffler assembly for corrosion and cracks. Replace a corroded or cracked muffler assembly.
(3) Inspect hanger straps on muffler assembly for breaks or distortion. If hanger straps are broken or
distorted, remove weld from around hanger straps and remove hanger straps. Bend new hanger straps around muffler
and weld in place with a double fillet weld.
(4) Inspect gaskets for cracks and brittleness. Replace cracked or brittle gaskets
c. Installation.
(1) If seal plate (13, fig. 3-107) was removed, smooth welding area with grinder, and insert new seal plate.
Weld seal plate in place.
NOTE
Install muffler in correct position to properly aline seal plate before welding. For welding procedures
refer to paragraph 11-3.
(2) If packing ring (15) was removed, slide packing ring and gasket (14) over tail pipe, and insert tail pipe
through hull connection.
NOTE
Tail pipe should be flush with outside shell plate.
(3) Position gasket (22) in place and secure muffler to exhaust piping with bolts (10),lockwashers (26), and
nuts (20).
(4) Secure muffler hanger straps (21) to main power train foundation withbolts (12), insulation pads (11), and
nuts (18).
(5) Secure packing ring (15) and gasket (14) to hull connection with bolts (17) andlockwashers (16) .
(6) Weld packing ring to tail pipe with a 1/4- inch single fillet weld.
(7) Wrap muffler assembly with 1 inch thick insulation fiberous, Military Specification MIL-1-6411, Type 2.
(8) Cover insulation with fiberous cloth, Military Specification MIL-1-16411, Type 2.
Change 2
3-124
CHAPTER 4
REPAIR OF FUEL SYSTEM
Section I . FUEL TANK
4-1. Description
A 300-gallon fuel tank is located on the forward port and starboard sides, on the wing compartments. The
tanks are constructed of 12-gage sheet Corten steel, and the top is covered by a 3 /16 inch thick steel plate.
A vent valve fitted with a 4 to 6 ounce bronze spring is located on top of each fuel tank and is designed to
open at a ,vacuum of 6.5 to 0.75 inch of water. Cross-over transfer lines connect the two tanks (fig. 4-1).
Access to the tanks is provided through the scuttles at the forward port and starboard wing compartments.
4-1
1 Plug valve
2 Fluid pressure filter
3 Plug valve
4 Plug valve
5 Plug valve
6 Check valve
Figure 4-1. Fuel system schematic
4-2
4-2. Fuel Tank
a. Removal
(1) Close plug valves (5 and 6, fig. 4-2).
(2) Disconnect fuel lines from plug valves.
(3) Remove capscrews (1) which secure fuel tank to deck.
(4) Remove capscrews (3) in the four corners of fuel tank top and insert four lifting eyes in their place.
(5) Using a crane, lift and remove fuel tank. Remove old gasket.
b. Cleaning, Inspection and Repair.
(1) Clean exterior of fuel tank with clean fuel oil and dry thoroughly.
(2) Flush interior of fuel tank with water and steam to remove sediment and foreign matter.
(3) Scrape gasket surfaces clean.
(4) Inspect all threaded surfaces for defective threads. Chase threads to remove minor damage. Replace
badly damaged threaded parts.
(5) Inspect fuel tank for damage or signs of leakage. Repair fuel tank leaks by welding (para 11-3).
WARNING
Fill fuel tank with water before welding to prevent the danger of exploding fuel fumes which may be
trapped in a tank.
1 Capscrew, flat head, 3/ 8 x 2 in.
2 Gasket
3 Capscrew, hex head, 3/ 4 x 1 in.
Figure 4-2. Fuel tank
4-3
4 Fuel tank
5 Plug valve 1/4 in.
6 Plug valve 1/2 in.
c.
Installation
(1) Using fuel tank as a template, punch holes in new gasket and place in position.
(2) Lower fuel tank into position with a crane.
(3) Secure fuel tank to deck with capscrews (1, fig. 4-2).
(4) Remove four lifting eyes and install capscrews 13).
(5) Connect fuel lines to plug valves (5 and 6).
d.
Fluid Pressure Filter Removal
(1) Close plug valve (1, fig. 3-64, TM 55-1930-203-20) in a supply line at base of fuel tank.
(2) Remove fuel oil lines and fittings from casting head (3, fig. 3-65, TM 55-1930-203-20).
(3) Loosen mounting bracket and remove fluid pressure filter.
e.
Fluid Pressure Filter Installation. Install fluid pressure filter in reverse order of removal.
Section II
ENGINE HAND THROTTLE CONTROLS
4-3. General
Four throttle control levers, one for each engine are located on the instrument board in the cab. Each throttle
control lever is connected to a throttle control valve by a control rod. The throttle control levers revolve on
needle bearings on a common shaft. Two outside control levers utilize two sets of needle bearings each,
whereas the two inside control levers use only one set each. Rod end bearings must be adjusted to 21
13/32 inches between centers to provide full travel of the throttle control levers from idle to full throttle.
4-4. Maintenance
a. Removal and Disassembly (fig. 4-3).
(1) Remove bolts (15), lockwashers (18), and nuts (19) from both ends of control rods (14). Remove
control rods.
(2) Loosen setscrews (4) and remove knobs
(3) Remove bolts (2) and lockwashers (1) and remove throttle control levers (5 through 8) as an
assembly from beneath the instrument board.
(4) Loosen three setscrews (10) and remove the two outside throttle lever rod supports 111).
(5) Remove throttle control levers (5 through 8), washers (12), needle bearings (13), and center throttle
lever rod support (11) from throttle lever rod (9).
b.
Cleaning, Inspection, and Repair.
(I) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air
(10 psi).
(2) Inspect condition of needle bearings 113, fig. 4-3) and rod end bearings, Replace if necessary.
(3) Inspect throttle control components for damage and repair or replace as necessary; fabricate new
part using old part as a model.
c. Reassembly and Installation. Reassemble and install throttle controls in the reverse order of removal and
disassembly. Pack needle bearings (13) with grease, Military Specification MIL-G- I 0924, prior to installation.
Adjust rod end bearings (17) on control rod (14) to obtain 21 13 / 32 inches between rod end bearing centers
and secure with jamnuts (16), prior to installation.
4-4
I Lockwasher
2 Bolt
3 Knob
4 Setscrew
5 Throttle control lever
6 Throttle control lever
7 Throttle control lever
8 Throttle control lever
9 Throttle control lever rod
10 Setscrew
11 Throttle control lever rod support
12 Washer
13 Needle bearing
14 Control rod.
15 Bolt
16 Jamnut
17 Rod end bearing
18 Lockwasher
19 Nut
Figure 4-3.
Engine handle throttle controls.
4-5
CHAPTER 5
REPAIR OF COOLING SYSTEM
Section I. GENERAL
5-1. Description
The LARC cooling system is composed of four radiators, water pumps, expansion tanks, and cooling coil and
oil cooler installations along with necessary tubing and fittings. The oil cooler installation consists of two oil-towater heat exchangers connected in parallel in each engine cooling water system. They are used for cooling
the marine gear and gathering box lubricating oil.
5-2. Cooling System Service
The procedures for draining, refilling, and cleaning the cooling system are contained in TM 55-1930-203-20.
Section II. RADIATOR ASSEMBLY AND EXPANSION TANK
5-3. Radiator
a.
Description. The four radiators, one for each engine cooling system, are of copper and brass
construction, and are mounted on the aft section of the LARC. During land operation the radiators expel heat
to the atmosphere in the conventional manner. During marine operation heat is transferred- to surrounding
water by submerged cooling coals in the aft wheel wells.
b.
Removal. For radiator assembly removal, refer to paragraph 2-31.
c.
Disassembly
(1 Remove flathead screws, nuts, and washers from around top flange of radiator.
(2) Pull off radiator top header and separate cork gasket.
(3) Remove bottom header in the same manner.
(4) Remove vibration damper in each side of radiator by loosening setscrew and nut, and unscrewing
the damper.
(5) Pull side members off core.
c.
Cleaning, Inspection and Repair.
(1l Flush radiator core with steam or hot water. If sediment within the core cannot be completely removed
by this method, radiator should be rodded out. This procedure consists of passing a metal rod through the
inside diameter of the tubing which makes up the radiator core, thereby removing trapped sediment.
(2) Clean top and bottom headers with steam or hot water. Dry with low pressure compressed air.
(3) Clean radiator fins with compressed air. Remove all foreign matter from air passages.
(4) Inspect radiator for visual signs of leakage, rust content, clogged cores, and bent cooling fins. Repair as
necessary.
(5) Inspect interior and exterior radiator surfaces for corrosion and pitting. Repair or replace as necessary.
(6) Inspect inside surfaces of top and bottom headers. Make sure surfaces are clean and smooth.
(7) Inspect screws, nuts, and washers for cracks, deformation, structural damage, and corrosion. Replace
as necessary.
(8) Inspect air vent petcock located on top of radiator. If petcock is inoperable or damaged, replace.
(9) Inspect painted surfaces of radiator for flaking, chipping, and scratches. Repair as necessary.
d.
Reassembly. Reassembly is in reverse order of disassembly. In replacing gaskets, use cork strip 1 /4
inches wide by 1/16 inch thick. Coat both sides with an adhesive sealer, and place gasket over the bolting
area of the top and bottom tanks. At the corners, be sure gasket strips are cut evenly where they join to
provide a flush fitting watertight seal. Boltholes in gaskets are made with a gasket punch.
e.
Testing. Plug up the inlet and outlet of radiator and immerse the radiator in water and apply air
pressure approximately IO psi to radiator. Watch for air bubbles as an indication of leakage.
f.
Installation. Refer to paragraph 2-31.
5-4. Expansion Tank
a.
Description .An expansion tank (fig. 5-1), with a 7-psi pressure cap, is mounted by each engine. The
expansion tanks are of welded steel construction and are used as reservoirs for maintaining a full system.
b.
Removal.
(1) Drain cooling system below level of expansion tank (TM 55-1930-203-20).
5-1
(2) Disconnect expansion tank inlet and outlet hoses (3, fig. 5-1).
(3) Remove bolts (2) lockwashers, and nuts which secure expansion tank to bulkhead and lift off tank.
(4) Remove pressure cap (1)
Figure 5-1. Expansion tank and line.
c.
Cleaning, Inspection and Repair.
(1) Flush interior of expansion tank with steam or hot water. Dry with low pressure compressed air.
(2) Clean exterior surfaces of expansion tank with a cloth moistened with dry-cleaning solvent,
Federal Specification P-D-680. Dry with low pressure compressed air.
(3) Inspect expansion tank for cracks, breaks dents, loose welds, leaks, structural damage, and
corrosion. Repair as necessary.
(4) Inspect painted surfaces on expansion tank for flaking, chipping, and scratches. Repaint as
necessary.
(5) Inspect bolts, lockwashers, and nuts for cracks, deformation, structural damage, and corrosion.
Replace as necessary.
d. Installation. Installation of expansion tank is in reverse order of removal.
5-2
Section III
RADIATOR STERN LOUVRES, COOLING COILS ,
TUBING AND FITTINGS
5-5. Radiator Stern Louvers
a.
Description. There are four radiator stern louvers installed on the aft end of the LARC. The louvers are
of welded steel construction and are used to admit air to the radiator ducts and to keep foreign matter from
entering the radiator air system
b.
Removal.
(1) Remove bolts and lockwashers securing radiator louvers to the stern of the LARC.
(2) Lift off radiator louvers.
c.
Cleaning, Inspection and Repair.
(1) Clean radiator louvers with a wire brush to remove foreign particles and loose paint.
(2) Inspect radiator louvers for dents, cracks, bends, broken welds, and structural damage. Repair as
necessary.
(3) Repaint radiator louvers upon completion of repairs.
d.
Installation. Installation of radiator stern louvers is in reverse order of removal.
5-6. Cooling Coils, Tubing and Fittings
a.
Description. The cooling coils, located in the aft wheel wells; are constructed of copper tubing with
bronze fittings. The cooling coils are secured to the inside plating of the wheel wells by steel straps and
hangers. During marine operation, the cooling effect of the outside water is transferred to the engine cooling
water as it circulates through the coils.
b.
Removal and Disassembly.
(1) Drain cooling system (TM 55-1930-203-20).
(2) Remove bolts (12, fig. 5-2), lockwashers
(3), and nuts (4), and remove straps (1) from pipe hangers.
(3) Separate elbow (18) from tubing (5), connected to cross (17) by heating with an oxyacetylene
flame to melt silver solder, and pulling up on elbow to free it from tubing.
(4) Remove elbow (8) in the same manner, and separate from tubing connected to tee (7).
(5) In a like manner remove elbows (10 and 16), and separate from tubing connected to tee (9),and cross
(17).
(6) Unsolder tubing connected to couplings (I 1) and sleeves (2) and lift off cooling coils.
(7) Unsolder crosses (15 and 17), couplings (11 ), threaded adapters (I4), elbow (6), and tees (7 and 9) and
remove from tubing (5).
5-3
I Strap , 1 x 3/16 x 20 in.
2 Sleeve, pipe,2 ½ in.
3 Lockwasher. 3/8 in.
4 Nut. Plain 3/8 in.
5 Tubing copper 2 in.
6 Elbow, tube, 90 ° 2 in.
7 Tee tube 2 in.
8 Elbow, tube, 90 ° 2 in.
9 Tee tube 2 in.
10 Elbow, tube, 90 ° 2 in.
11 Coupling tube ,2 in.
12 Bolt ,machine, 3/8 x1 ¼ in.
13. Plug ,pipe , 2 in.
14. Adapter pipe to tube, 2 in.
15.Cross tube , 2 in.
16 Elbow, tube, 90 ° 2 in.
17.Cross tube , 2 in.
18. Elbow, tube, 90 ° 2 in.
Figure 5-2. Cooling coils
c.
Cleaning, Inspection and Repair.
(1) Clean removed parts with a wire brush to remove dirt and loose paint.
(2) Inspect drain plugs (13, fig. 5-2), and adapters 14) for cracks, breaks, corrosion, or damaged
threads. Replace as required.
(3) Inspect all mating surfaces for burrs, scratches, and nicks. Remove such defects with crocus
cloth, Federal Specification P-C-458, or a soft stone, Military Specification MIL-S-2389.
(4) Inspect tubing for dents, cracks, breaks, holes, and signs of corrosion. Replace as required. Use
old tubing as a guide and cut to size. Make sure tubing is cut square and is free from burrs and is not out
of round.
(5) Inspect straps (1) for cracks, breaks, and signs of corrosion. Replace as required.
(6) Inspect pipe hangers for loose welds, cracks, or breaks. Repair welds or replace pipe hangers as
required.
(7) Inspect attaching hardware for stripped threads, cracks, and signs of corrosion. Replace as
required.
d. Reassembly and Installation.
(1) Reassembly. Reassembly is essentially in reverse order or disassembly with the exception of the
method employed for installing new silver brazing fittings (Walseal or equal). Install fittings in place of those
removed as follows:
(a) With crocus cloth, Federal Specification
5-4
P-C-458, clean tubing ends a distance equal to twice the length of fitting recess.
(b) Thoroughly clean each fitting outlet.
(c) Flux both tubing and fitting recesses. Slide the fitting on the tubing until tubing contacts shoulder.
(d) When installing new fittings, the heating method requires an oxyacetylene torch equipped with a No. 8
tip. Apply heat to tubing approximately 1 1/2 inches back from fitting end for 21/4 minutes. Heating expands
tubing. When sufficient heat has been applied, surface becomes blue-black and flux becomes liquid. Flame is
then directed on bead of fitting and in direction of tubing, using a wiping motion, while traveling back and
forth between fitting and pipe (this expands a section of fitting). As this motion is continued, a slight gap
opens between fitting and tubing. When heating is stopped, fitting contracts, forcing out silver brazing alloy,
and a fillet forms at edge of fitting. A 2 inch section only is heated at a time. When fillet is clearly visible,
apply heat to next adjacent 2 inch segment. Do not heat joint in its entire circumference at one time.
NOTE
Excess heat. while enlarging the clearance. retards rather than hastens the flow of the alloy. If. in a section
being heated. the fitting or tubing becomes bright in color remove torch.
(e) Joints must be well supported during silver brazing process, and they must not be strained while
cooling. Parts must be permitted to cool until only hot to the hand before washing or quenching.
(f) Discolored tubing and fittings may be restored to their original color by brushing.
NOTE
Removed fittings may be reused(1 provided they are thoroughly cleaned and are in good condition.. However.
they will have to be silver soldered in the conventional manner (TM 9-237 ) since the silver brazing alloy.
which is an integral part o)f new fittings. will not be present in fittings which have been removed.
(2) Installation. Installation of cooling coils is in reverse order of removal. Do not paint cooling coils after
installation.
5-5
CHAPTER 6
ELECTRICAL SYSTEM REPAIR INSTRUCTIONS
Section I. ALTERNATORS
6-1. REPLACE ALTERNATORS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
12.
13
14.
Cap screw
Cover
Nut
Washer
Cable
Screw
Washer
Drive belt
Nut
Lock washer
Bolt
Washer
Alternator
Bracket
Figure 6-1. Alternator Replacement
a. Removal.
(1) Remove capscrews (1) and cover (2).
(2) Remove nuts (3), washers (4), and disconnect cables (5). Reinstall nuts (3) and washers (4) after cables
(5) are disconnected.
(3) Remove screw (6) and washer (7) loosening tension drive belt (8) and remove belt from alternator
pulley.
(4) Remove nuts (9), lockwasher (10), bolts (11), and washers (12).
(5) Remove alternator (13) from mounting bracket (14).
6-1
b. Reinstall.
(1) Place alternator (13) on mounting bracket (14) aligning alternator mounting holes with holes in bracket.
(2) Insert bolts (11) through washers (12) and mount- ing holes in bracket (14). Install lockwashers (10) and
nuts (9) securing alternator (130 to bracket (14). Leave nuts (9) lossen until tensioning drive belt.
(3) Place drive belt (8) on alternator pulley. Install capscrew (6) through washer (7) and adjusting bracket
(15) into alternator (13). Do not tighten until adjusting belt tension.
(4) Using wooden pry bar between gathering box (16) and alternator (13) pull alternator away from
gathering box until belt tension allows only 7/8 to 1 inch deflection- . Hold alternator at this position.
(5) Tighten nuts (9) and capscrew (6) holding alternator (13) in position.
(6) Secure cables (5) to alternator (13) using nuts (3) and washer (4).
(7) Install cover (2) using capscrews (1).
6-2. REPLACEMENT ALTERNATOR PULLY.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
Capscrew
Washer
Cover
Capscrew
Drive belt
Pulley
Locknut
Washer
Alternator
Gathering
box
Figure 6-2. Alternator Pulley Replacement.
6-2
a.
Remove.
(1) Remove capscrews (1), washers (2), and cover (3).
(2) Loosen capscrews (4), washers (11) releasing tension drive belt (5).
(3) Remove belt (5) from around pulley (6).
(4) Remove locknut (7), washer (8), and pulley (6).
b.
Install.
(1) Place pulley (6) on alternator shaft. Install washer (8) andlocknut (7) to secure pulley (6).
(2) Place drive belt (5) around pulley (6). Place a wooden rod between the alternator (9) and gathering box
(10). Adjust belt (5) tension by levering alternator (9) away from gathering box (10) until belt (5) tension is 7/8 to 1 inch.
(3) Tighten capscrews (4) with washers (11) to hold alternator (9) in proper position for belt tension.
(4) Install cover (3) and secure to gathering box (10) washers (2) andcapscrews (1).
Section II. SWITCHES , RELAYS AND LIGHTING
6-3. Switches and Master Control Relay
a.
Master Control Relay.
(1) Testing
(a) Operate master control switch in cab to check operation of relay.
(b) Disconnect electrical power to relay. Remove cover (fig. 6-3).
(c) Inspect relay contacts for pitting and burning. If they are pitted, clean them. If they are badly worn,
replace master control relay.
(d) Adjust contact surface between points to an opening of 0.040 inch by turning the tiedowncapscrew
clockwise to enlarge contact gap or counterclockwise to shorten gap.
(e) Inspect spring tension on movable contact with a scale. This should be between 10 to 15 ounces
pull.
(f) Replace cover.
(2) Removal.
(a) Remove screws (1, fig. 6-3), lockwashers (2), and cover (3) from relay (7).
(b) Disconnect power cable terminal from relay unit by removing screw (10) and lockwasher (9).
(c) Unscrew cable adapter (8) at housing wall and withdraw cable.
(d) Disconnect two plug connectors (4) and tag for reassembly.
6-3
(e) Remove relay mounting bolts (6) and lockwashers (5) and remove relay.
WARNING
Disconnect battery leads before removing master control relay.
1 Screw
2 Lockwasher
3 Cover
4 Connector
5 Lockwasher
6 Bolt
7 Relay
8 Cable Adapter
9 Lockwasher
10 Screw
Figure 6-3. Master control relay, removal and installation
(3) Installation. Install master control in reverse order of removal.
Instrument Panel and Circuit Breaker Panel Switches.
(1) Removal.
(a) Remove screws securing switch to support frame.
(b) Pull out switch from back of panel, and disconnect wires by loosening retaining screws. Tag
each wire removed for identification.
(2) Installation. Install switches in reverse order of removal.
c. Headlight Dimmer Switch.
(1) Removal.
(a) Remove electrica connectors from dimmer switch.
(b) Remove three capscrews and lockwashers securing dimmer switch to mounting plate.
(c) Lift out dimmer switch.
(2) Installation. Install headlight dimmer switch in reverse order of removal.
d. Machinery Compartment Light Switch.
(1) Removal.
(a) Disconnect wires from switch by loosening retaining screws.
(b) Remove two thread-cutting screws securing switch to mounting bracket.
(c) Lift off switch.
(2) Installation. Install machinery compartment light switch in reverse order of removal.
e. Hydraulic Supply Tank Liquid Level Switch Replacement.
(1) Removal.
(a) Disconnect liquid level switch ground wire at ground terminal.
(b) Disconnect liquid level switch lead wire at plug in port bilge machinery area inboard bulkhead.
b.
6-4
(c) Drain hydraulic oil supply tank as follows:
1. Provide suitable containers and remove pipe plug located under the LARC in supply tank drain
line.
2. Open supply tank gate valve and drain fluid from tank.
(d) Remove access covers from both ends of tank by removing attaching bolts and washers. Remove
access cover gaskets.
(e) Remove packing gland nut (11, fig. 6-11) and spring washer (10) from packing gland washer (9).
(f) Remove packing gland washer (9) and packing gland gasket (8) from adapter (7).
(g) Disconnect neoprene hose protecting switch wiring by removing clamp (2) at tank outlet end.
WARNING
While working inside the hydraulic oil supply tank, a portable-type circulating blower should be
used to prevent vapor accumulation. For extended work periods inside the tank, an air line type
respirator should be worn. Station an observer outside tank in case worker is overcome by
fumes.
(h) Lift switch (3) from mounting bracket and remove, pulling wires through tank opening.
(i) Remove clamp (2) securing neoprene hose (1) to switch and remove hose.
1 Hose
2 Clump
3 Switch
4 Nipple
5 Bushing
6 Coupling
7 Adapter
8 Gasket
9 Washer
10 Washer
11 Nut
Figure 6-4. Hydraulic supply tank liquid level switch replacement.
6-5
(2) Installation.
(a) Secure neoprene hose to new switch.
(b)
(c)
(d)
(e)
(f)
NOTE
If neoprene hose shows evidence of deterioration, install new hose.
Install switch (3), in mounting bracket and feed wires through tank opening.
Install clamp (2 on neoprene hose at tank opening.
Install packing gland gasket (8) and packing gland washer (9) on adapter (7).
Install spring washer (10) and packing gland nut (11) on packing gland washer (9).
Connect ground wire to ground terminal. Connect lead wire to plug in port bilge machinery area inboard
bulkhead.
(g) Install access covers and gaskets.
NOTE
If access cover gaskets are torn or deteriorated, install new gaskets.
(h) Close supply tank gate valve and install pipe plug in supply tank drain line under the LARC.
(i) Fill hydraulic oil supply tank (LO 55-1930-203-12).
6-4. Battery Generator Indicator
a. Removal
(1) Remove electrical connector from indicator.
(2) Remove two nuts, two lockwashers, and clamp.
(3) Lift indicator off instrument panel.
b. Installation. Install battery generator indicator in reverse order of removal.
6-5. Cab Ventilating Fans
a. General. The cab ventilating fans (6, fig. 6-5) contain a capacitor (3) connected in series with the 24-volt line and
the positive brush for radio interference suppression. The capacitor bracket is bonded to the fan base by four tooth-type
lockwashers (4), and the fan base is bonded to the cab frame by four tooth-type lockwashers (2).
b. Replacement of Fan Capacitor.
(1) Unsolder 24-volt supply lead from capacitor terminal.
(2) Remove screws (5), and tooth-type lock- washers (4) securing capacitor (3) to fan mounting base.
(3) Pull capacitor out of fan mounting base and unsolder wire from capacitor terminal.
(4) Solder wire from positive brush of fan to terminal of new capacitor.
(5) Insert capacitor (3) in fan mounting base and secure with screws (5) and tooth-type lock- washers (4).
(6) Solder 24-volt supply lead to capacitor terminal.
1
2
3
4
5
6
Screw
Lockwasher
Capacitor
Lockwasher
Screw
Fan
ME 1930-203-34/6-12
Figure 6-5. Hydraulic supply tank liquid level switch replacement
c.
Fan Removal
(1) Disconnect cable connector.
(2) Remove screws and tooth-type lockwashers securing fan base to mounting pad and remove fan.
d. Fan Installation. Install ventilating fans in reverse order of removal.
6-6. Cab Heater
a. General. The cab heater blower motor is integrally suppressed by a capacitor connected in series with the 24-volt
line and the positive brush at the heater motor housing. The cab heater capacitor mounting bracket is bonded to the motor
housing by two plated tooth-type lockwashers. The heater motor is bonded to the heater housing with a plated tooth-type
lockwasher at each of the two mounting screws. The heater housing is bonded to the fan housing by four tooth-type
lockwashers and the fan housing is bonded to the deck with a tooth-type lockwasher at each of the four mounting bolts.
b. Removal and Disassembly
(1) Removal
6-6
(a)
(b)
(c)
(d)
(e)
(f)
Drain the Aft Port Engine Cooling System (TM 55-1930-203-20).
Disconnect electrical leads to heater motor (27, fig. 6-6) at connector assembly (24).
Remove clamps (2) and rubber defrosted hose (1) from defroster outlets (3).
Remove screws (17) and collar (18) from around hot water inlet and outlet tubes (12 and 13).
Remove clamps (14) and rubber hose (15) from hot water inlet and outlet tubes (12 and 13).
Remove screws (38) and tooth-type lockwashers (39) from heater intake flange (37) and remove
flange.
(g) Remove capscrews (16) securing heater to steel angle under cab flooring.
(h) Lower heater through cab flooring.
(2) Disassembly.
(a) Remove screws (21). tooth-type lockwashers (20), and ground strap (22). Remove screws (25),
tooth-type lockwashers (26), and radio suppression capacitor (23).
(b) Remove four screws (28) and four tooth-type lockwashers (29) securing motor mounting flange (30)
to blower housing assembly (19).
(c) Remove setscrew (35) in impeller hub and remove impeller (36).
(d) Remove locknuts (32) and tooth-type lockwashers (31) securing motor flange (30) to motor (27) and
separate them.
(e) Remove screws (33) and lockwashers (34) securing blower housing assembly (19) to core housing (4)
and separate them.
(f) Remove setscrew (9) securing defroster control lever assembly (10) and remove assembly.
(g) Unsolder copper elbows (11) from hot water inlet tube (12) and outlet tube (13).
(h) Remove screws (8) securing cover (7) of core housing (4) and pullout core assembly (6) and core
side spacers (1).
(i) Remove bolts, nuts, and lockwashers securing defroster tubing to cab top beneath windows.
(j) Lift out defroster tubing.
c. Cleaning, Inspection and Repair.
(1) Wash metal parts, except core assembly (6, fig. 8-142), with dry-cleaning solvent, Federal Specification PD-680. Wash rubber parts with soap and water.
(2) Clean core assembly by blowing through openings with low-presort air. Remove any lodged particles.
(3) Check core assembly for pitting, corrosion, or leakage. Replace a badly pitted, corroded, or leaking core
assembly.
(4) Replace a defective motor (27).
(5) Check impeller (36) for cracks or breaks. Replace a damaged impeller.
(6) Check hoses (1 and 15) for signs of deterioration. Replace a defective clamp.
(7) Check hose clamps (2 and 14) for good condition. Replace a defective clamp.
(8) If defroster is defective, replace as follows:
(a) Using 1-1/4 inch hard copper tubing and old defroster as a model, cut tubing to size.
(b) Fit points and braze them together. Seal ends with flat copper sheet.
(c) Cut slots in tubing similar to those in old tubing.
d. Reassembly and Installation. Reassemble and install cab heater in reverse order of disassembly and removal.
Fill cooling system (TM 55-1930-203-20).
6-7
Figure 6-6. Cab heater , removal disassembly, reassembly and installation.
6-8
Key to Figure 6-6.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Hose, rubber, defroster
Clamp, hose
Defroster outlet
Core housing
Core side spacer
Core assembly
Cover
Screw
Setscrew
Defroster, control lever assembly
Elbow
Tube
Tube
Clamp
Hose, rubber, radiator to heater
Capscrew
Screw
Collar
Blower housing assembly
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Lockwasher
Screw
Ground strap
Capacitor, feed-thru
Connector assembly
Screw
Lockwasher
Motor
Screw
Lockwasher
Motor mounting flange
Lockwasher
Locknut
Screw
Lockwasher
Setscrew
Impeller
Flange
Screw
Lockwasher
6-7. Machinery Compartment Lights
NOTE
Two types of machinery compartment lights were used on the LARC's as shown in figures
6-14 and 6-15. When the obsolete light in figure 6-14 cannot be repaired, it will be
replaced with the light shown in figure 6-15.
a. Removal and Disassembly.
(1) Figure 6-7.
(a) Remove securing ring (7), slip ring (6), centering gasket (5), glove (4), and nonmetallic washer (3) from
box assembly (2).
(b) Remove electric light lamp (1O) from lampholder (11).
(c) Remove screws securing wiring to lampholder (11).
(d) Remove two screws (8) and shakeproof washers (9) securing lampholder to mounting plate (14), and
remove lampholder.
(e) Remove two screws (12) and shakeproof washers (13) securing mounting plate (14), and remove
mounting plate.
(f) Remove screws securing wiring to terminal block (16) and remove wiring.
(g) Remove two screws (15), securing terminal block (16) to box assembly (2), and remove terminal block.
(h) Remove bushing (19) and connector (17) from box assembly.
(i) Remove packing gland gasket (18) from connector (17).
(j) Remove bolt (1), lockwasher (21), and nut (20). Lift off box assembly.
6-9
Figure 6-7. Machinery compartment light (old type), removal, disassembly, reassembly and installation.
6-10
(2) Figure 6- 8.
(a) Remove four window mounting screws (15), packings (16), window (17), and packing (18) from housing
(20).
(b) Remove lamp (9) from lampholder (11).
(c) Remove two screws (10) securing reflector (19) to housing (20), and remove reflector.
(d) Remove terminal nuts (13) securing wiring to terminal board assembly (12).
(e) Remove screw (10 securing lampholder (11) to housing (20), and remove lampholder.
(f) Remove screws (14) securing terminal board assemblies (12) to housing (20), and remove the terminal
board assemblies.
(g) Remove two screws (8), lockwashers (7), and cable clamp (6) from gland nut (5).
(h) Unscrew gland nut (5) from housing (20), and remove wiring.
(i) Remove gland gasket washer (4), gland gasket washer (2), gland gaskets (3), and second gland gasket
washer (2) from housing (20).
(j) Remove four screws and washers which secure housing (20) to its mounting, and remove the housing.
b. Reassembly and Installation. Reassembly and install machinery compartment light in reverse order of
disassembly and removal.
6-11
1
2
3
4
5
6
7
8
9
10
Plug
Washer
Gasket
Washer
Gland nut
Clamp
Lockwasher
Screw
Lamp
Screw
11
12
13
14
15
16
17
18
19
20
Lampholder
Terminal board assembly
Nut
Screw
Screw
Packing, performed
Window
Packing, preformed
Reflector
Housing
Figure 6-8. Machinery compartment light (new type) removal, disassembly, reassembly and installation.
6-12
6-8. Wing Compartment Lights
NOTE
Two types of wing compartment lights were used on the LARC's as shown in figures 6-9
and 6-10. When the obsolete light in figure 6-9 cannot be repaired, it will be replaced with
the light shown in figure 6-10.
a. Removal and Disassembly.
(I) Figure 6-9.
(a) Remove securing ring (9), slip ring (8), centering gasket (7), globe (6), and nonmetallic washer (5) from
box assembly (2).
(b) Remove electric light lamp (101 from lampholder (13).
(c) Remove screws securing wiring to lampholder (13).
(d) Remove two screws (1) and shakeproof washers (12) securing wiring to lampholder.
(e) Remove two screws (14) and shakeproof washers (15) securing mounting plate (16). Remove mounting
plate.
(f) Remove screws securing wiring to terminal block and remove wiring.
(g) Remove nut (24) and withdraw switch (19) from box assembly (2).
(h) Remove nut (20) from switch (19) .
(i) Remove two screws (17) securing terminal block (18) to box assembly (2) and remove terminal block.
(j) Remove bushing (23) and connector (21) from box assembly (2).
(k) Remove packing gland gasket (22) from connector (21).
(I) Remove bolt (1), lockwasher (3), and nut (4). Lift off box assembly (2).
6-13
1
2
3
4
5
6
7
8
Bolt
Box assembly
Lockwasher
Nut
Washer
Globe
Centering Gasket
Slip ring
9
10
11
12
13
14
15
16
Securing ring
Lamp
Screw
Washer
Lampholder
Screw
Washer
Mounting plate
17
18
19
20
21
22
23
24
Screw
Terminal block
Switch
Nut
Connector
Gasket
Bushing
Nut
Figure 6-9. Wing compartment light (old type), removal, disassembly, reassembly and installation.
6-14
(2) Figure 6- 10.
(a) Remove four window mounting screws (17), packings (18), window (19), and packing (20) from housing
(22).
(b) Remove lamp (11) from lampholder (13).
(c) Remove two screws (12) securing reflector (21) to housing (22) and remove reflector.
(d) Remove terminal nuts (15) securing wiring to terminal board assembly (14).
(e) Remove screw (12) securing lampholder (13) to housing (22), and remove lampholder.
(f) Remove sealnut (3) and toggle switch (1) from housing (22).
(g) Remove screws (16) securing terminal board assemblies (14) to housing (22), and remove the terminal
board assemblies.
(h) Remove two screws (10), lockwashers (9), and cable clamp (8) from gland nut (7).
(i) Unscrew gland nut (7) from housing (22), and remove wiring.
(j) Remove gland gasket washer (6), gland gasket washer (4), gland gaskets (5), and second gland gasket
washer (4) from housing (22).
(k) Remove four screws and washers which secure housing (22) to its mounting, and remove the housing.
6-15
1
2
3
4
5
6
7
8
Switch, toggle
Plug
Sealnut
Washer
Gasket
Washer
Gland nut
Clamp
9
10
11
12
13
14
15
Lockwasher
Screw
Lamp
Screw
Lampholder
Terminal board
Nut
16
17
18
19
20
21
22
Screw
Screw
Packing, preformed
Window
Packing preformed
Reflector
Housing
Figure 6-10. Wing compartment light (new type) removal, disassembly, reassembly and installation.
6-16
b. Reassembly and Installation. Reassemble and install wing compartment light in reverse order of disassembly and
removal.
6-9. Headlights
NOTE
Two types of headlights were used on the LARC's as shown in figures 6-11 and 6-12.
When the light figure 6-11 requires replacement, it will be replaced with the light shown in
figure 6-12.
a. Removal and Disassembly.
(1) Figure 6-11.
(a) Uncouple connectors (2) on headlight wire assembly (1), and remove nut and lockwasher securing
ground terminal (3) to ground stud.
(b) Loosen three screws 1)01 securing door assembly (9) to body and mounting ring assembly (5). and
remove door assembly.
(c) Remove eight self-tapping screws (6), and remove headlight and mounting gasket (4).
(d) Remove three screws (11) securing retaining ring (8) to body and mounting ring assembly (5), and
remove retaining ring.
(e) Remove lamp (7) from body and mounting ring assembly (5) and uncouple and remove lower half of
headlight wire assembly (1).
(f) Remove grommet (12) and withdraw upper half of headlight wire assembly (1) from body and mounting
ring assembly (5).
1
2
3
4
5
Headlight wire assembly
Connector
Ground terminal
Mounting gasket
Body and mounting ring assembly
6
7
8
9
Screw
Lamp
Retaining ring
Door assembly
10
11
12
13
Screw
Screw
Grommet
Screw
Figure 6-11. Headlight (old type), removal, disassembly, reassembly and installation.
6-17
(2) Figure 6-12.
(a) Remove capscrews (9), retaining ring (8), lens (7), gasket (6), screws (5), and retaining ring (4).
(b) Remove lamp (3) from body of headlight.
(c) Uncouple connectors (16) from headlight.
(d) Remove three nuts (10) and lock-washers (11) from end of capscrew (12). Withdraw headlight housing
from the headlight casing.
b. Reassembly and Installation. Reassemble and install headlight in reverse order of disassembly and removal.
6-18
1
2
3
4
5
6
7
8
9
Screw, horizontal adjustment
Screw, vertical adjustment
Lamp
Retaining ring
Screw
Gasket
Lens
Retaining ring
Capscrew
Figure 6-12. Headlight (new type), removal, disassembly, reassembly and installation (Sheet 1 of 2).
6-19
10
11
12
13
14
15
Nut, hex
Washer, lock
Capscrew
Washer, flat
Screw
Washer, lock
16
17
18
19
20
21
Connector
Body, stuffing box
Washer, stuffing box, rubber
Bushing, stuffing box, rubber
Washer, stuffing box, rubber
Cap, stuffing box
Figure 6-12. Headlight (new type), removal, disassembly, reassembly and installation (Sheet 2 of 2).
c.
Headlight Adjustment.
NOTE
Low beam should start to illuminate the roadway in front of the LARC, 142 feet from
centerline of the front wheel.
(1) Figure 6-11.
(a) Remove door assembly (9).
(b) Adjust headlights by turning screws (13) in or out to vary the angle of lamp (7).
(c) Install door assembly.
(2) Figure 6-12.
(a) Adjust headlights by loosening nuts (10), and moving bolts (12) in or out to vary angle of headlight.
(b) If further adjustment is required, remove screws (9), retaining ring (8), lens (7), and gasket (6). Adjust
headlights by turning screws (1 and 2) in or out to vary the angle of lamp (3).
(c) Install retaining ring, lens, and gasket in reverse order of removal.
6-10. High-Beam Indicator Light
a. Removal.
(1) Remove two screws, and two lockwashers securing high-beam indicator light assembly to instrument
panel and remove high-beam indicator light assembly from rear of instrument panel.
(2) Disconnect cable wiring at electrical connector. Tag wiring for reassembly.
b. Installation. Install high-beam indicator light in reverse order of removal.
6-11. Cargo Well Lights
a. Removal and Disassembly.
(1) Remove capscrews (1, fig. 6-13), lock-washers (2), and protector plate (3).
(2) Remove screw 141 securing cover (5) and lens (6) to base (9).
(3) Remove four thread cutting screws (7) and lockwashers (8) securing base (9) and gasket (12) to side of
cargo well.
(4) Disconnect wiring (10) at connector (11).
(5) Remove lampholder (13) from base (9). If la
mpholder shows signs of corrosion, loosen wiring, or other
damage, replace with new component.
b. Reassembly and Installation. Reassemble and install cargo well light in reverse order of disassembly and
removal.
6-20
Figure 6-13. Cargo well light, replacement.
6-21
Key to Figure 6-13.
1
2
3
4
5
6
7
8
9
10
11
12
13
Capscrew
Lockwasher
Protector plate
Screw
Cover
Lens
Screw
Lockwasher
Base
Wiring
Electrical connector
Mounting gasket
Lampholder
6-12. Bow Light
a. Removal and Disassembly.
(1) Remove cable cap (16, fig. 6-14) from tube and retainer cap assembly (13), and remove packing (14) and
washer (15).
(2) Remove tube and retainer cap assembly (13) from base (20), and remove gasket (12).
(3) Disconnect electrical wiring from lamp holder (4).
(4) Remove nut (11), washer (10), and spacer (9), from base (20) of light assembly.
(5) Loosen screw (6) and hinge up housing (5).
(6) Remove screw (7), shakeproof washer (18), and nut (17) securing base (20) to top of cab.
(7) Lift off light assembly and gasket (19).
(8) Remove globe assembly (1) and gasket (2).
(9) Remove lamp (3), lampholder (4), and lampholder adapter (8).
b. Reassembly and Installation. Reassemble and install bow light in reverse order of disassembly and removal.
6-22
1
2
3
4
5
6
7
8
9
10
Globe assembly
Gasket
Lamp
Lampholder
Housing
Screw
Screw
Lampholder adapter
Spacer
Washer
11
12
13
14
15
16
17
18
19
20
Nut
Gasket
Tube and retainer cap assembly
Packing, preformed
Washer
Cable cap
Nut
Washer
Gasket
Base
Figure 6-14. Bow light, removal, disassembly, reassembly and installation.
6-23
6-13. Range Light
a. Removal and Disassembly.
(1) Unthread and remove globe assembly (1, fig. 6-15) from base (5) at top of mast.
(2) Remove gasket(2).
(3) Remove lamp (3).
(4) Remove lampholder (4) from base (5) and disconnect electrical wiring.
(5) Remove four 1/2 inch bolts (7), lockwashers (9), and nuts (10) securing mast assembly (6) and
gasket (8).
(6) Withdraw electrical wiring from bottom of mast and remove mast assembly (6) and gasket (8).
b. Cleaning, Inspection and Repair.
(1) Clean exterior of globe assembly (1) and mast assembly with a lint-free cloth dampened with dry-cleaning
solvent, Federal Specification P-D-680. Wipe out inside of globe assembly (1) with a dry cloth. Wash rubber gaskets (2
and 8) with soap and water. Clean lampholder (4) with trichlorethylene, Military Specification MIL-T-7003. Dry with lowpressure compressed air. Wash base (5) in dry-cleaning solvent, Federal Specification P-D-680.
(2) Inspect globe assembly (1) for structural damage and broken or cracked globe. Replace globe assembly if
damaged.
(3) Inspect gaskets (2 and 8) for breaks, cracks, and nonuniformity. Replace as required.
(4) Inspect lampholder (4) for signs of corrosion, contact damage, or loose wiring. Replace socket if damaged.
(5) Inspect base (5) for cracks or structural damage. Replace base if damaged.
(6) Inspect mast assembly (6) for cracks or structural damage. Replace any damaged part.
(7) Inspect wiring for breaks and cracked or frayed insulation. Replace wiring if damaged.
c. Reassembly and Installation. Reassemble and install range light in reverse order of disassembly and removal.
Key to Figure 6-15.
1
2
3
4
5
6
7
8
9
10
Globe assembly
Gasket
Lamp
Lampholder
Base
Mast assembly
Bolt
Gasket
Lockwasher
Nut
Figure 6-15. Range light removal, disassembly,
reassembly, and installation.
6-24
6-14.Running Lights
a. Removal and Disassembly.
(1) Remove terminal box cover.
(2) Disconnect cable cap (9, fig. 6-16) from tube and retainer cap assembly (6), and remove packing (7) and
washer (8).
(3) Remove tube and retainer cap assembly (6) from base (13), and remove gasket (5).
(4) Disconnect electrical wiring from lamp holder (20).
(5) Remove nut (4), washer (3), and spacer (2) from base (13) of light assembly.
(6) Loosen screw (15), and hinge up housing (16).
(7) Remove screw 1141. shakeproof washer (11) and nut (10) securing base (13) to mounting
plate.
(8) Lift off light assembly and gasket (12).
(9) Remove globe assembly (17) and gasket (18).
(10) Remove lamp (19). Iampholder (20), and lampholder adapter (1).
b. Reassembly and Installation. Reassemble and install running light in reverse order of disassembly and removal.
6-25
Figure 6-16. Running light, removal, disassembly, reassembly and installation
6-26
13. Base
14. Screw
15. Screw
16. Housing
17. Globe
18. Gasket
19. Lamp
20-. Lampholder
21. Screw
22. Lockwasher
23. Cover
24. Packing, preformed
25. Terminal box
Key to Figure 6-16.
1. Lampholder adapter
2. Spacer
3. Washer
4. Nut
5. Gasket
6. Tube and retainer cap assembly
7. Packing, preformed
8. Washer
9. Cable cap
10. Nut
11. Washer
12. Gasket
6-15. Replace Searchlight.
a. Removal.
(1) Disconnect electric wire (1).
(2) Remove rollpin (2) from control handle (3).
(3) Remove control handle (3), pivot bearing (4), control rod bracket (5) and nut (6).
(4) Loosen setscrews (7) and remove fulcrum (8).
(5) Remove screws (9) and lift searchlight (10) free of pilothouse roof. Remove gasket (11).
NOTE
Escutcheon plate was not removed from inside pilothouse. When replacing searchlight you can use the old
escutcheon plate.
b. Installation.
(1) Prepare a replacement searchlight for installation by removing control handle (3), pivot bearing (4),
control rod bracket (5) and nut (6) from end of vertical control rod (12).
(2) Place a bead of sealant on pilothouse roof where gasket (11) seats. Place gasket (11) on
pilothouse roof and line up holes in gasket with mounting holes for mounting screws (9).
(3) Place a second bead of sealant on base gasket (11) along outer edge of gasket. Then insert vertical
control rod (12) and electrical cable (13) through holes in pilothouse roof and seat searchlight base (14) on
mounting gasket (11) aligning mounting holes.
(4) Install screws (9) securing searchlight base (14) to pilothouse roof.
(5) Install fulcrum (8) on vertical control rod (12) and secure in place using setscrews (7).
(6) Install nut (6) and control rod bracket (5) on end of vertical control rod (12).
(7) Install pivot bearing (4) and control handle (3) in control rod bracket (5) and secure control handle
(3) to fulcrum (8) using rollpin (2).
(8) Connect electric wire (1)
6-27
Figure 6-17. Searchlight, removal and installation.
6-28
6-16. Cab Dome Light
a. Removal.
(1) Remove electrical connector (5, fig. 6-18) from cab dome light.
(2) Remove four screws (4), lockwashers (2), and nuts (1) securing dome light to ceiling straps.
(3) Lift off dome light.
b. Disassembly.
(1) Remove screw (22), lockwasher (21), and knob assembly (20) from switch shaft.
(2) Remove switch mounting nut assembly (19), washer (18), and gasket (17).
(3) Loosen eight screws (23) and separate door assembly (16) from body assembly (3).
(4) Remove screws (10) securing lamp socket wiring, and wire assembly (11) to switch (12).
(5) Remove four screws (7) securing socket, plate, and wire assemblies (8) to door assembly (16).
(6) Remove gasket (13) from door assembly (16).
(7) Remove screws (6) securing partition (27) and lift off partition.
(8) Remove screws (26) securing lens retaining plate (9) and lift out white lens (14), gasket (15), red
lens (25), and gasket (24).
c. Cleaning, Inspection and Repair.
(1) Wash metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash rubber gaskets and
lenses with soap and water, and dry with a lint-free cloth. Clear electrical connector, receptacle, and sockets
with trichloroethylene, Military Specification MIL-T-7003. Dry with low-pressure compressed air.
(2) Inspect gaskets (13, 15, 17, and 24) for breaks, cracks, and nonuniformity. Replace any damaged
gasket.
(3) Inspect body assembly (3) and door assembly (16) for cracks or structural damage. Replace if
damaged.
(4) Inspect lenses (14 and 25) for breaks or cracks. Replace if damaged.
(5) Inspect socket, plate, and wire assemblies (8) for signs of corrosion, contact damage, or loose
wiring. Replace if damaged.
(6) Inspect wiring for breaks and cracked or frayed insulation. Replace wiring if, damaged.
(7) Inspect terminals and lugs on wiring for corrosion and security of attachment. Replace as required.
(8) Inspect switch (12) for external contact corrosion and case damage. Operate switch through a
complete cycle and ensure that a positive contact is made in all positions. This operation can best be
performed by making a continuity check with an ohmmeter.
d. Reassembly and Installation. Reassemble and install dome light in reverse order of disassembly and
removal.
6-29
Figure 6-18. Cab dome light, removal, disassembly, reassembly, and installation.
6-30
Key to Figure 6-19
1
Nut
2
Lockwasher
3
Body assembly
4
Screw
5
Electrical connector
6
Screw
7
Screw
8
Socket
9
Lens retaining plate
10 Screw
11 Wire assembly
12 Switch
13 Gasket
14 Lens
15 Sealing gasket
16 Door assembly
17 Gasket
18 Washer
19 Switch mounting nut assembly
20 Knob assembly
21 Lockwasher
22 Screw
23 Screw
24 Sealing gasket
25 Lens
26 Screw
27 Partition
6-17. Instrument Panel Light
a. Removal.
(1) Remove screws (4, fig. 6-19), lockwashers (5), and nuts (6) securing light assembly (3) and resistor
and base assembly (1) to cab roof stiffener. (Note position of ground lug (2) when removing screws).
(2) Disconnect wiring at resistor and base assembly (1) by removing screws (7).
b. Installation. Install instrument panel light in reverse order of removal.
Figure 6-19. Instrument panel light removal and installation.
6-31
6-18. Spot and Trouble Light and Reel Assembly
a. Spot and Trouble Light Removal.
(1) Separate spot and trouble light from trigger switch (8, fig. 6-20).
(2) Remove three screws (5), and lift off door assembly (6) and sealed unit assembly (7) from body
assembly (2).
(3) Uncouple connector (1), and remove screw (9), lockwasher (3), and nut (4) securing ground lead to
body assembly (2).
b. Reel Assembly Removal
(1) Remove connector (12) from reel assembly (13).
(2) Remove nut (11) and lockwasher (10) securing reel assembly (13) to studs.
(3) Remove reel assembly (13).
c. Cleaning, Inspection and Repair.
(1) Clean exterior of spot and trouble light, trigger switch (8), and reel assembly (13), with a lint-free
cloth dampened with dry-cleaning solvent, Federal Specification P-D-680. Wipe out inside of body assembly (2)
with a dry cloth. Clean connectors and receptacle with trichloroethylene, Military Specification MIL-T-7003. Dry
with low-pressure compressed air.
(2) Inspect body assembly (2) and door assembly (6) for dents, cracks, or structural damage. Replace
parts as required.
(3) Inspect sealed unit assembly (7) for dents, cracked glass, or defective lamp, reflector, socket, or
electrical wiring. Replace sealed unit assembly if damaged.
(4) Inspect connector (1) for signs of corrosion or loose wiring. Replace connector or repair wiring if
damaged.
(5) Inspect wiring for breaks and cracked or frayed insulation. Replace wiring if damaged.
(6) Inspect trigger switch (8) for cracks or structural damage. Replace trigger switch if damaged.
(7) Inspect reel assembly for dents or structural damage. Insure that reel unit is operative by extending
extension cord and observing that reel unit rewinds. Replace reel assembly if defective.
(8) Inspect reel assembly to connector (12) for signs of corrosion or loose wiring. Replace connector or
repair wiring if damaged.
d. Spot and Trouble Light Installation. Install spot and trouble light in reverse order of removal.
e. Reel Assembly Installation. Install reel assembly in reverse order of removal.
6-32
Figure 6-20. Spot and trouble light and reel assembly removal and installation.
6-33
6-19. Master Warning Light
a. General. The master warning light is located on the left side of the instrument panel in the cab. The
master warning light will illuminate when any of the port or starboard warning lights located on the cab
bulkheads illuminate. The lamp for the master warning light is 24-volt, bayonet base, single filament type.
b. Removal
(1) Remove two screws and two lockwashers securing warning light assembly to instrument panel and
remove warning light assembly from the rear of the instrument panel.
(2) Disconnect cable wiring at electrical connectors. Tag wiring for reassembly.
c. Installation. Install master warning light in reverse order of removal.
6-20. Warning Lights
a. Removal
(1) Disconnect wiring at connector (17, fig. 6-21) in rear of warning light.
(2) Remove four screws (1) and lockwashers (2) securing light assembly to mounting bracket.
(3) Lift off warning light assembly.
b. Disassembly.
(1) Remove screws (19), frame (3), front assembly (4), and gasket (5) from top of box (6).
(2) Remove screws (13), cover (12), and gasket (9) from bottom of box (6).
(3) Remove screws (8) and socket and lamp assembly (7) from cover (12).
(4) Remove screws (10) securing lower and upper rectifiers (11 and 18) to cover (12) and remove
rectifiers.
(5) Remove screws (16), electrical receptacle (15), and gasket (14) from cover (12).
c. Cleaning, Inspection and Repair.
(1) Wash metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash face and rubber
parts with soap and water, and dry thoroughly. Clean electrical receptacle, connector, rectifiers, and sockets
with trichloroethylene, Military Specification MIL-T-7003. Dry with low-pressure compressed air.
(2) Inspect frame (3) and front assembly (4) for cracks and breaks. Replace any damaged part.
(3) Inspect gaskets (5, 9, and 14) for breaks, cracks, and nonuniformity. Replace as required.
(4) Inspect box (6) and cover (12) for cracks, breaks, or other structural damage.
(5) Remove lamps from socket and lamp assembly (7) and inspect sockets for signs of corrosion,
contact damage, or loose wiring. If sockets are damaged, unsolder associated wiring and tag each wire for
reassembly. Replace sockets and resolder wiring.
(6) Inspect rectifiers (11 and 18) for signs of burning, corrosion, or arcing. If rectifiers are suspected of
being defective, unsolder wiring from terminals, tag each wire and terminal with the appropriate color for
reassembly, and check rectifiers.
(7) Inspect receptacle (15) for signs of corrosion, contact damage, or loose wiring. If receptacle is
damaged, unsolder associated wiring and tag each wire for reassembly. Replace receptacle.
(8) Inspect wiring for breaks, cracked or frayed insulation, or bad solder joints. Replace wiring and
resolder joints as necessary.
6-34
Figure 6-21. Warning light, removal, disassembly, reassembly and installation.
6-35
d. eassembly and Installation. Reassemble and install warning light in reverse order of disassembly and
removal.
NOTE
When a warning light assembly is replaced by a new assembly the new assembly must be
modified prior to installation. This modification is accomplished by rewiring a portion of the new
assembly as shown in figure 6-22.
Figure 6-22. Warning light assembly wiring diagram.
6-36
CHAPTER 7
REPAIR OF DRIVE SYSTEMS
Section I. LAND DRIVE SYSTEM
7-1. Description
The LARC is equipped with four wheel drive system (fig. 7-1 ). Each wheel is independently driven by a diesel
engine. The four diesel engines transmit power from their flywheel ends through respective torque convertors.
flexible couplings, transmissions, miter boxes, column and wheel drives, and wheels. Air brakes for the LARC
are located on the forward and aft sides of each miter box.
Figure 7-1. Land drive system
7-2. Torque Converter Assembly
a. Description.
(1) General. The torque converter assembly consists of a housing bolted to the engine, with a series of
flexible flywheel disks connecting the engine crankshaft to the converter flywheel. There are two different
model converters used on the LARC's. The earlier models contain four elements; a converter pump, a turbine,
and two stators. The latter models contain three elements; a converter pump, a turbine, and one stator. The
converter pump is the input member of the torque converter assembly and is connected to the converter
flywheel. The turbine drives the output shaft which transmits power to the transmission. The stator(s) is a
7-1
reaction member necessary for torque multiplication. A charging oil pump, mounted on the converter housing, provides
oil pressure for filling the converter and charging the hydraulic system of the transmission. The transmission sump serves
as a reservoir for both converter and transmission. Flow of oil in the system is from the transmission sump through the
charging pump to the converter and back to the transmission sump. The converter and transmission oil system contains
an oil filter, oil cooler, pressure regulating valves, and pressure and temperature gages. Engine power is transmitted from
the crankshaft, through flexible disks attached to the converter flywheel, then to the converter pump. The converter pump
hub drives the charging oil pump which fills the converter with oil. Blades of the converter pump impel the oil smoothly
but with tremendous force against the turbine outer blades. This causes the turbine to turn in the same direction as the
pump. Oil leaves the turbine blades at the turbine's inner circumference, flowing in a direction opposite pump rotation.
The stator(s) redirect this flow so the oil, with its unexpended energy, enters the pump in the same direction as its
rotation. As turbine speed increases, torque ratio decreases and pump and turbine approach a 1 to 1 speed ratio. When
this occurs, angle of oil flow through the stator(s) changes, causing oil to strike stator(s) on their opposite sides. In the
four element converter, the first stator begins to freewheel on the ground sleeve in the direction of pump rotation and is
soon followed by the second stator. In the three element converter, the single stator begins to freewheel. The converter
then functions as a fluid coupling. The oil flows through the converter pump and turbine, then out between the turbine
and stator, inside the ground sleeve along the turbine shaft, then out through a passage-way in the converter housing to
the filter and cooler. From the cooler, the oil returns to the transmission sump.
(2) Differences in models.
(a) The Allison Torqmatic Converter (fig. 7-2) Model TC-654 is used on hulls 5 through 18. Converter
Model TC-554 is used on hulls 19 through 60. Model TC-654 can he replaced with Model TC-554 on hulls 5 through 18
whenever replacement of a converter assembly is necessary.
(b) Two different Model TC-554 converters are used on the LARC's, converter assembly number
6758244 is a four element converter with two stator members; while assembly number 6830815 is a three element
converter with one stator member. Both of the converters are completely interchangeable, though some of the internal
parts are different.
Figure 7-2. Torque converter (Models TC-554 and TC-654).
b.
Charging Oil Pump Assembly.
(1) Removal
(a) Drain transmission (LO 55-1930-203-12).
(b) Disconnect flexible hoses (6 and 8, fig. 7-3). Provide a suitable container to catch any oil remaining
in hoses.
(c)
(d)
Remove elbows (5 and 9), bell reducer (4), and nipples (3 and 10).
Remove six bolts (1) and lockwashers (2) and lift off oil pump (11) and gasket (7).
7-2
Figure 7-3. Removal of oil pump.
(2) Disassembly.
(a) Remove plug (10, fig. 7-4) and annular gasket (9) from oil pump body cover (6).
(b) Remove converter pressure regulating spring (8) and valve (7).
(c) If oil pump has externally mounted clutch pressure regulating spring and valve, remove
plug (1) and shim set (2) from oil pump body cover and remove spring (3) and valve (4).
(d) Remove six bolts (29) and lockwashers (28) which secure oil pump body cover to oil pump
body (19), and remove cover and gasket (11).
(e) If oil pump has internally mounted clutch pressure regulating spring and valve, remove
snap ring (30), valve (31), and spring (32) from cover (34).
(f) Remove oil pump driven gear (27) and needle bearing (26) as an assembly.
7-3
(g) Press needle bearing (26) from driven gear, only if bearing replacement is necessary.
(h) Remove oil pump driving gear shaft (13) and oil pump driving gear (18, fig. 7-5).
(i) Remove seal ring (16, fig. 7-4) from oil pump driving gear shaft.
(j) Press or drive seal ring (14) and needle bearing (15), using bearing and bushing driver plug,
part No. J4850, out of bore into pump driving gear pocket in pump body, only if bearing replacement is
necessary.
(k) If inspection shows replacement of pump bearing sleeve (17) is necessary, remove sleeve
using bearing remover, part No. J4852. If this tool is not available, remove pipe plug (21) to gain
access to sleeve. Place a disk, 1/8 to ¼ inch thick by 1.370 inches in diameter, in slot behind the
sleeve, alining disk with the sleeve. Insert a drift through pipe plug hole in rear of pump body and place
drift against disk. Press or drive sleeve out of its bore and into driving gear pocket.
(1) If replacement of needle bearing (12) is necessary, collapse needle bearing cage with a hammer
and punch, and remove it from cover.
Key to figure 7-4.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Plug
Shim set
Regulating spring, clutch pressure
Regulating valve, clutch pressure
Plug, pipe
Cover, oil pump body
Regulating valve, converter pressure
Regulating spring, converter pressure
Gasket, annular
Plug
Gasket, oil pump body cover
Needle bearing
Gear shaft, oil pump driving
Seal ring
Needle bearing
Seal ring, input shaft
Sleeve, pump bearing
Gear, oil pump driving
Oil pump body
Plug, pipe, hexagon head socket
Plug, pipe hexagon socket
Plug, pipe, countersunk headless
Plug, pipe
Pin, dowel
Shaft, oil pump driven gear
Needle bearing
Gear, oil pump driven
Lockwasher, 3/8 in.
Bolt, machine
Snap ring
Regulating valve, clutch pressure
Regulating spring, clutch pressure
Plug, pipe
Cover, oil pump body
7-4
Figure 7-4. Oil pump.
7-5
Figure 7-5. Removal of oil pump driving gear and shaft.
(3) Cleaning, inspection and repair.
(a) Clean all parts, except gasket (11,
fig. 7-4) and seal rings (14 and 16), in drycleaning solvent, Federal Specification P-D-680,
and dry with low pressure air (10 psi). Clean all
oil passages in oil pump body (19) and cover (6)
by working a wire back and forth through
passages and flushing in dry-cleaning solvent.
(b) Replace gasket (11) and seal rings
(14 and 16).
(c) Inspect needle bearings (12, 15 and
26) for pitted, scored, or burned condition.
Replace if defective.
(d) Check that a pressure of 82±4.1
pounds is required to compress clutch pressure
regulating spring (3) to a height of 2.22 inches.
Replace spring if not within limits.
(e) Check that a pressure of 26 ± 0.52
pounds is required to compress clutch pressure
regulating spring (32) to a height of 1.75 inches.
Replace spring if not within limits.
(f) Check that a pressure of 88.6 ± 4.43
pounds is required to compress converter
pressure regulating spring (8) to a height of 3.52
inches. Replace spring if not within limits.
(g) Check that a clearance of 0.006 inch
is obtained between clutch pressure regulating
valve (4) and oil pump body cover (6). If proper
clearance is not obtained, replace valve.
(h) Check that a clearance of 0.006 inch
is obtained between converter pressure
regulating valve (7) and oil pump body cover. If
proper clearance is not obtained, replace valve.
(i) Inspect gears (18 and 27) and gear
shaft (13) for chipped or broken teeth or for
wear that may have destroyed original tooth
shape. If any of these conditions are found,
replace gear or gear shaft.
7-6
(j) Check oil pump body (19), cover (6 or
34), plugs (1 and 10), and shim set (2) for good
condition. Replace a defective part.
(4) Reassembly
(a) If needle bearing (12, fig. 7-4) in oil
pump body cover (6) was removed, press a new
needle bearing into bore in cover, using an arbor
press and bearing and bushing driver plug, part
No. J4850. Press only on numbered end of
bearing.
(b) If pump bearing sleeve (17) was
removed, install a new sleeve into bore in oil
pump body (19), using an arbor press and bearing
and bushing driver plug, part No. J4850.
(c) Press needle bearing (15) into bore in
pump body, using bearing replacer, part No.
J4523-01. Press on numbered end of bearing
only. Press seal ring (14) into bore with lip of seal
toward bearing, using bearing replacer, part No.
J45 23-0 1. Seal edge should be 1 / 32 inch
below surface.
(d) If needle bearing (26) was removed,
place oil pump driven gear (27) on an arbor press
so that beveled edge of bearing bore is up. Using
bearing and bushing driver plug, part No. J4850,
press new needle bearing into bore of gear. Press
only on numbered end of bearing.
(e) Press new oil pump driven gear shaft
(2 5) into pump body if shaft has been removed.
(f) Install seal ring (16) on oil pump driving
gear shaft (13).
(g) Place driving gear (18) in pocket in
pump body and insert driving gear shaft in pump
and through driving gear (fig. 7-5). The seal ring
should slip easily into bearing sleeve, since the
sleeve is beveled to receive the seal ring.
(h) Install oil pump driven gear (27, fig. 74) with needle bearing (26) on driven gear shaft.
(i) If oil pump has internally mounted
clutch pressure regulating spring and valve, install
spring (32), valve (31), and snap ring (30) in oil
pump body cover (34).
(j) Install oil pump body cover (6 or 34)
and gasket (11) on oil pump body using six bolts
(29) and lockwashers (28).
(k) Install converter pressure regulating
valve (7) and spring (8).
(l) Install annular gasket (9) on plug (10)
and install plug, making certain spring is properly
seated in plug.
(m) If oil pump has externally mounted
clutch pressure regulating spring and valve, install
(m) If oil pump has externally mounted clutch pressure regulating spring and valve, install valve (4),
closed end first, and spring (3). Install shim set (2) and plug (1).
(5) Installation.
(a) Install oil pump (11, fig. 7-3) and a new gasket (7) on torque converter housing using six bolts (1) and
lockwashers (2).
(b) Install nipple (10) and elbow (9) in pump intake port and nipple (3), reducer (4), and elbow (5) in
discharge port.
NOTE
If a new pump is being installed, remove dust cover from intake port and pipe plug (22, fig. 7-4) from
discharge port.
(c) Connect oil pump to transmission selector valve flexible hose (6, fig. 7-2) to elbow (5).
(d) Connect oil pump suction flexible hose (8) to elbow (9).
(e) Fill transmission with proper lubricant (LO 55-1930-203-12).
(f) Perform torque converter transmission stall test (para 7-3).
(g) If transmission oil pressure gage does not indicate proper pressure on oil pumps with externally
mounted clutch pressure regulating valve and spring, stop engine and add shims to or remove shims from shim set (2.
fig. 7-4) until proper pressure is obtained. Removing shims increases pressure; adding shims decreases pressure.
c. Torque Converter, Assembly Model TC-654 (fig. 2-2 and 7-2).
(1) Removal. Refer to paragraph 2-12.
(2) Disassembly.
(a) Charging oil pump assembly removal. Remove charging oil pump assembly, as outlined in b(1)
above.
(b) Flywheel assembly removal.
1. Position torque converter assembly with flywheel up.
2. Remove converter housing cover (6. fig. 7-6) and gasket (5).
7-7
Figure 7-6. Housing assembly (model TC-654).
3. Using a long, thin-wall, 9/ 16 inch socket, and working through converter housing cover opening, remove 36
bolts (11, fig. 7-7) that secure converter pump (7) to flywheel (4, fig. 7-8), (fig. 7-9).
7-8
Figure 7-7. Converter pump and hub assembly.
Figure 7-8. Flywheel assembly (model TC-654)
7-9
Figure 7-9. Converter pump-to-flywheel bolt removal and installation (model TC-654)
4. Using a 9/16 inch wrench, remove six bolts (1, fig. 7-8) and seal rings (2) from flywheel (4).
5. Install two ½ -20 NF eyebolts or suitable lifting lugs 180 degrees apart in outer bolt circle of
flywheel. Using a hoist and a suitable lifting sling, remove flywheel assembly from converter.
(c) Torque converter elements removal
1. Bend down edge of tabbed lockwasher that secures bolt in end of output shaft (fig. 7-10).
Using a 1 inch wrench, remove bolt and lockwasher (fig. 7-11). Remove bearing retainer washer (fig. 7-12).
2. Use any suitable bearing puller to remove pilot bearing and bearing retainer plate (fig. 7-13).
Figure 7-10. Pump-to-flywheel seal ring removal and
installation
Figure 7-11. Bearing retainer bolt removal.
7-10
Figure 7-12. Bearing retainer washer
removal and installation.
Figure 7-14. Turbine assembly removal (model TC654).
Figure 7-13. Pilot bearing and bearing retainer plate
removal and installation.
Figure 7-15. Snaprings removal and installation.
NOTE
The pilot bearing has a split inner race. The bottom half of the race will remain on output shaft and will he
removed with converter turbine assembly.
3. Install bolts of any suitable bar-type puller in tapped holes provided in turbine hub (fig. 7-14).
Remove remaining half of pilot bearing inner race and
4. Using snapring pliers, remove turbine locating snapring from output shaft (fig. 7-15).
7-11
5.
Remove
ground
sleeve
snapring from ground sleeve (fig. 7-15).
6. Remove steel thrust washer and
bronze thrust washer (fig. 7-16).
8. Remove bronze thrust washer if it
did not stick to bottom of first stator assembly (fig. 7-18).
Figure 7-16. Steel and Bronze thrust washers removal
and installation.
Figure 7-18. Bronze thrust washer removal.
7. Pull first stator assembly half way
off ground sleeve and insert stator assembly sleeve,
part No. J-4237, to keep the rollers, springs, and cups
from falling out of stator (fig. 7-17). Remove first stator
assembly from ground sleeve by lifting it and rotating it
clockwise.
9. Remove second stator assembly in
the same manner as first stator assembly (fig. 7-19).
Figure 7-17. First stator assembly removal and
installation.
NOTE
If stator assembly cannot be rotated, use a soft
drift and drive against rivet heads on stator
assembly to turn it clockwise. Do not drive nor
apply force on stator blades. If this method fails,
ground sleeve will have to be pressed out of
stator assemblies. See 31(a) below for removal
procedure
7-12
Figure 7-19. Second stator assembly removal and installation.
10. Remove bronze thrust washer and steel thrust washer if they did not come off with second stator
assembly (fig. 7-20).
Figure 7-20. Bronze and steel washer removal and installation.
11. Converter pump can now be lifted from housing (fig. 7-21).
Figure 7-21. Converter pump removal and installation.
12. Remove two hook-type seal rings from ground sleeve (fig. 7-22).
7-13
Figure 7-22. Hook-type seal ring removal and installation.
(d) Torque converter output shaft removal.
1. Position converter on table so output shaft is horizontal.
2. Remove six bolts (12, fig. 7-23) lockwashers (11) from bearing retainer (10).
Figure 7-23. Output Shaft and Flange Assembly (Model TC-654).
7-14
3. Tap lightly with soft hammer on opposite end of output shaft to loosen bearing retainer from
converter housing.
4. Remove output shaft and flange assembly (parts 6 through 17, fig. 7-23).
(3) Subassemblies disassembly.
(a) Housing assembly disassembly.
1. Using a 3/4 inch wrench, remove charging oil pump idler gear shaft plug, seal ring, and lockwasher
from rear of converter housing (fig. 7-24).
Figure 7-24. Plug, seal ring and lockwasher removal and installation.
2. Install slide hammer remover and adapter, part No. J5901, in the ½ -2ONF threaded hole in oil
pump idler gear shaft (fig. 7-25).
Figure 7-25. Charging oil pump idler gear shaft removal
3. Remove shaft (17, fig. 7-6), being careful charging oil pump idler gear (18) does not drop out.
4. Remove charging oil pump idler gear assembly (fig. 7-26). Do not remove bearing from gear.
7-15
Figure 7-26. Charging oil pump idler gear assembly removal and installation.
5. The charging oil pump drive gear (3, fig. 7-6) and converter pump hub oil seal (2) are generally not
removed. If gear or seal needs to be replaced, collapse oil seal with drift and hammer and remove oil seal. Gear can
then be removed (fig. 7-27).
Figure 7-27. Charging oil pump drive gear removal.
7-16
6. Ordinarily, the converter ground sleeve is not removed. If it needs to be replaced, position converter
housing in a press, front side up, and press ground sleeve out of housing (fig. 7-28). Remove ground sleeve key (13, fig.
7-6) and dowel pin (12) from ground sleeve.
Figure 7-28. Ground sleeve removal.
7. Some converter models have an orifice in the converter oil out passage. No Service is required for
this part under normal conditions.
(b) Converter pump and hub assembly disassembly.
1. Do not disassemble converter pump and hub assembly unless replacement of parts is needed (fig.
7-7).
2. If converter pump hub bushing (1 needs replacing, cut out bushing.
3. If it is evident pump hub seal ring (3) has been leaking, disassemble converter pump and hub
assembly by removing snapring (10) from converter pump hub (2). Support converter pump (7) as close to hub as
possible and press against tang end of hub to remove hub. Remove seal ring.
NOTE
Do not remove converter balance weights (8). Do not remove bolts (4), unless seal rings (5) need replacing.
(c) Stator assemblies disassembly. Remove stator assembly sleeve, part No. J4237, used to retain rollers
during disassembly of converter. Remove rollers (11, fig. 7-29), springs (9), and cups (10) (fig. 7-30).
Figure 7-29. Stator assembly (model TC-654).
7-17
Figure 7-30. Stator with rollers, springs, and cups.
NOTE
Do not remove bushings (3, 5, 6, and 8, fig. 7-29) unless bushings must be replaced.
(d) Turbine assembly disassembly. The turbine assembly (1, fig. 7-31) is a riveted assembly consisting of a
hub, turbine, and rivets. If any of these parts need replacing, replace entire assembly. If turbine hub adapter (3) requires
replacing, remove two screws (2) and remove adapter.
Figure 7-31. Turbine assemble (model TC-654).
(e) Output shaft and flange assembly disassembly.
1. Using a vise with soft jaws, clamp flange of output flange (14, fig. 7-23).
2. Using a ¾ inch wrench, remove bolt (17) that secures output flange to output shaft (6). Remove
lockwasher (16), output flange washer (15), and output flange.
3. Use soft hammer to remove bearing retainer from output shaft assembly.
4. The output flange dual oil seal (13, fig. 7-23) is not removed unless replacement is necessary.
When replacing, press seal out of bearing retainer (10).
5. Remove two-hook type seal rings from output shaft.
6. To remove bearing from output shaft. support bearing and output shaft assembly, rear end up, on
bearing inner race. Press shaft out of bearing using arbor press.
7-18
(f) Flywheel assembly disassembly. Bolts (1, fig. 7-8), seal rings (2), pilot bearing (6), and bearing retainer
plate (7) were removed in tear- down of converter into subassemblies. The flywheel ring gear (3) is not ordinarily
disassembled from flywheel (4). If it needs replacement, press or drive ring gear off flywheel.
(g) Flexible flywheel disk assembly disassembly. The flexible flywheel disk assembly (fig. 7-32) is not
disassembled. If components (1, 3. 4, or 5) require replacement, the flexible flywheel disk assembly must be replaced as
an assembly.
Figure 7-32. Flexible flywheel disk assembly (model TC-654).
(4) Cleaning, inspection and repair.
(a) Dirt and other abrasive material. Whenever converter contains dirt or other abrasive material,
unnecessary wear will result. Inspect all parts for abrasive material any time converter is disassembled. Thorough
cleaning includes cleaning oil passages in oil cooler, and cleaning any other parts of hydraulic system common to the
converter. Inspect parts for defects any time converter is disassembled.
NOTE
If oil in hydraulic system becomes contaminated with metal particles, all components of hydraulic system including
the transmission, torque converter, oil lines, filters, screens, coolers, valves. and oil pumps. must be thoroughly
cleaned. This usually means disassembly of components. Metal particles in the oil are evidence of failure of
some part, either in the torque converter or transmission.
(b) Cleaning procedures. All metallic parts of converter, except bearings, should be thoroughIy cleaned with
dry-cleaning solvent, Federal Specification P-S-680, or by the steam-cleaning method. Parts cleaned in the dry-cleaning
solvent should be dried with compressed air until they are entirely dry. Parts stearn-cIeaned should be dried with
compressed air, and then oiled immediately with lubricating oil. military Specification MIL-L- 2104. Examine housings
and parts carefully for grit, dirt. and abrasive after cleaning and reclean if necessary. Clean oil passages by 'working a
piece c)f wire back and forth through passages and flushing with dry-cleaning solvent. Dry passages with compressed
air.
(c) Cleaning and inspecting bearings. Clean and inspect bearings for pitted, scored. or burned condition.
Replace as necessary.
(d) Inspecting housings. cast parts. and machined surfaces.
1. Inspect bores for wear, grooves. scratches, and dirt. Remove burrs and scratches with crocus cloth.
Federal Specification P-C-458. Remove foreign matter. Replace deeply grooved or scratched parts.
7-19
2.
Inspect oil passages for obstructions. If an obstruction is found, remove it with compressed ai
r or by
working wire back and forth through passage and flushing with dry-cleaning solvent, Federal Specification P-D-680.
3. Inspect mounting faces for burrs, scratches, nicks, and foreign matter. Remove such defects with crocus
cloth, Federal Specification P- C-458, or soft stone, Military Specification MIL-S- 2389. If scratches are deep, replace defective
part.
4 .Inspect threaded openings for damaged threads. Chase damaged threads with correct size tap.
5. Replace housings or other cast parts that are cracked.
6. Inspect all machined surfaces for damage that could cause oil leakage or other malfunction of the part.
Rework or replace defective parts.
(e) Inspecting bushings and thrust washers.
1. Inspect bushings for roundness, scores, burrs, sharp edges and evidence of overheating. Remove scores
with crocus cloth, Federal Specification P-C-458. Remove burrs and sharp edges with a scraper or knife blade. If bushing is
out-of-round, deeply scored, or excessively worn replace with proper size replacement.
NOTE
Sometimes it is necessary to cut out a defective bushing. Be careful not to damage bore into which bushing fits.
2. Inspect thrust washers for distortion, scores, burrs, and wear. Replace thrust washer if defective or worn.
(f) Inspecting oil seals and gaskets.
1. Inspect hook-type seal rings for wear, broken hooks, and distortion. Sides of seal ring should be smooth
(0.005 inch maximum side wear). Sides of shaft groove (or bore) in which seal ring runs should be smooth (50 microinches equivalent) and square with axis of rotation within 0.002 inch. If side of ring grooves have to be reworked (0.20 inch
maximum side wear), install new seal ring. Also install new seal ring if ring is worn so there is no gap between hooks of seal
ring when installed.
2. Inspect seal rings for cuts and hardness. Replace seal rings if defects are found.
3. Replace lip-type seal rings, making sure spring-loaded side is toward oil to be sealed in (toward in
side of
unit). Use sealing compound, Military Specification MIL-S-7916, on outside diameter of seal to prevent oil leaks.
4. Install new composition gaskets.
(g) Inspecting gears.
1. Inspect gears for scuffed, nicked, burred, or broken teeth. If defect cannot be removed with soft stone,
Military Specification MIL-S-2389, replace gear.
2. Inspect gear teeth for wear that rnay have destroyed original tooth shape. If this condition is found, replace
gear.
3. Inspect thrust faces of gears for scores, scratches, and burrs. Remove defects with soft stone, Military
Specification MIL-S-2389. If scores and scratches cannot be removed with soft stone, replace gear.
(h) Inspecting splined parts. Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove burrs
with soft stone, Military Specification MIL-S-2389. Replace part if other defects are found.
(i} Inspecting threaded parts. Inspect parts for burred or damaged threads. Remove burrs with soft stone, Military
Specification MIL-S-2389, and chase damaged threads. Replace damaged parts.
(j) Inspecting snaprings. Inspect all snaprings for nicks, distortion and excessive wear. Replace part if one of
these defects is found. The snapring mtust snap tight in its groove for proper functioning.
(k) Inspecting springs. Inspect all springs for signs of overheating. permanent set, or wear due to rubbing
adjacent parts. Replace spring if any defects are found.
(l) Stator assembly.
1. Do not remove rivets from stator assemblies. If any part of a stator assembly is worn or damaged, the
assembly must be replaced.
2. Inspect roller ramps on stator cam for wear, pits, or scores. If any of these conditions are found, replace
stator assembly.
3. Inspect stator vanes for dents, nicks, or burrs. If these conditions are found, remove them with a fine file
and soft stone, Military Specification MIL-S-2389. If there are dents that cannot be removed with a file or if there are cracks,
replace stator assembly.
4. Inspect freewheel rollers for nicks, burrs, and signs of galling. If these conditions cannot be corrected with
crocus cloth, Federal Specification P-C-458. replace rollers.
5. Inspect freewheel roller. springs for distortion. Replace if distorted.
6. Make sure freewheel rollers do not bind or drag in roller slots. 151 Subassemblies reassembly.
(a) Flywheel assembly reassembly.
1. To install flywheel ring gear 13, fig. 7- 8) on flywheel 14), heat ring gear and pressor drive it on flywheel.
NOTE
Be careful not to drive or press on rings gear teeth when installing ring gear. Do not heat ring gear to more than 400°F.
7-20
2. Bolts (I), seal rings (2J, pilot bearing (6), and bearing retainer plate (7) will be installed when
converter is assembled.
(b) Output shaft and flange assembly reassembly.
1. Press bearing assembly on shaft, using an arbor press. Be certain to press only on bearing inner
face.
NOTE
Bearing must be seated against shoulder on shaft.
2. Install two hook-type seal rings.
3. If output flange dual oil seal (13, fig. 7-23 ) was removed, press new seal in bearing retainer (IO1
from front (chamfered end) of bearing retainer bore using sealing compound, Military Specification MIL-S-7916, between
seal outside diameter and bore of retainer. Spring side of seal must be toward front of retainer.
4. Install bearing retainer (10) on bearing (8J and output shaft (6).
5. Install output flange (14), output flange washer (15), lockwasher (16) and 3/4 inch bolt (17) on
output shaft.
6. Support output flange (14) in vise and tighten bolt (17) to a torque of 120 to 140 foot-pounds.
(c) Stator assemblies reassembly. Install freewheel springs (9, fig. 7-29) in cups (10) and insert into bore
in stator (fig. 7-30). Install rollers (11, fig. 7-29) and replace assembly sleeve, part No. J4237, to retain the rollers for assembly purposes.
(d) Converter pump and hub assembly reassembly.
1. Using an arbor press and pump hub bushing installer, part No. J7464, install new converter
pump hub bushing (1, fig. 7-7). Bore bushing to 4.161 to 4.163 inches. Bore must be concentric with 4.750 inch hub i-d
ameter within 0.002 inch total indicator reading.
2. If converter pump hub assembly (2) was removed, heat converter pump (7) to 212:° F. (in oil)
and cool converter pump hub assembly in dry ice for 2 hours.
NOTE
An alternate procedure for installing hub in pump is to heat converter pump to 240°to 250°F. and proceed with 3
below.
3. Install seal ring (3J on converter pump hub (2J and using assembling tool, part No. J4236- 01,
press hub assembly in converter pump (7).
4. Remove assembling tool and install snapring (10J on converter pump hub (2).
5. Grease converter pump hub with grease, Military Specification MIL-G-10924, to prevent rust.
6. Install seal rings (5) and bolts (4) in converter pump (7). Tighten bolts to a torque of 25 to 32
foot-pounds.
(e) Housing assembly reassembly.
1. If ground sleeve (10, fig. 7-6) was removed, install dowel pin (12) in ground sleeve key (13), and
install key on new ground sleeve so end of key is flush with face of ground sleeve. Notice dowel pinhole in the key is off
center. Press ground sleeve and key into housing (fig. 7-33).
2. If oil pump drive gear (3, fig. 7-6) and converter pump hub oil seal (2) were removed, install
gear. Using converter pump hub seal replace, part No. J7475, install oil seal with spring side toward gear.
3
Position converter with rear end up on table.
4. Install charging oil pump idler gear assembly by positioning gear (18, fig. 7-6) in housing, alining
gear bore with housing bore, and installing oil pump idler gear shaft (17, fig. 7-6) in its bore. Use soft drift or bolt of
proper size threaded into shaft and tap shaft in place.
5. Install lockwasher (16), seal ring (15), and plug (14) into oil pump idler gear shaft bore. (fig.
7-24). Tighten plug to a torque of 80 to 100 foot-pounds.
Figure 7-33. Ground sleeve installation.
(6) Reassembly.
(a) Torque converter output shaft installation.
1. Position converter housing assembly on table.
7-21
2. Install new bearing retainer gasket (9, fig. 7-23) on rear of converter housing.
3. Install output shaft and output flange assembly into ground sleeve.
4. Secure bearing retainer (10) to housing with six bolts (12) and lockwashers (11). Tighten bolts to a
torque of 67 to 80 foot-pounds.
(b) Torque converter elements installation.
1. Support converter, rear end down,
2. Install hook-type seal rings on ground sleeve (fig. 7-22).
3. Install converter pump on ground sleeve, making sure tangs on pump hub are engaged with slots in
pump drive gear (fig. 7-21).
4. Install one steel washer and one bronze thrust washer on converter ground sleeve (fig. 7-20). Be
sure steel washer is against shoulder on ground sleeve.
NOTE
Lay both stator assemblies, flat side up, on a table. Close examination will show a difference in
thickness of edges of stator blades. Stator with thin-edge blades is the first stator. Stator with
thick-edge blades is the second stator.
5. Install second stator assembly flat side up on ground sleeve (fig. 7-19). Rotate stator clockwise as it
is lowered to keep rollers from locking on ground sleeve. Stator assembly sleeve, part No. J4237, will be removed as
stator is installed on ground sleeve.
6. Install bronze thrust washer on second stator assembly (fig. 7-18).
7. Install first stator assembly, flat side down, on ground sleeve (fig. 7-17). Rotate stator clockwise as it
is lowered to keep rollers from locking on ground sleeve. Remove stator assembly sleeve, Part No. J4237.
8. Install bronze thrust washer on first stator assembly. Install steel thrust washer on bronze thrust
washer (fig. 7-16).
9. Install ground sleeve snapring on ground sleeve (fig. 7-15).
CAUTION
Be sure stators can freewheel clockwise after installation and will lock up when rotated counterclockwise.
10. Install turbine locating snapring on end of output shaft (fig. 7-15).
11. Install turbine assembly on output shaft.
12. Install bearing retainer plate (7, fig. 7-8) on turbine hub (fig. 7-12).
13. Position pilot bearing (6, fig. 7-8) on end of output shaft (fig. 7-12). Place bolt (1, fig. 7-23) and
bearing retainer washer (3) on pilot bearing (6, fig. 7-8) and thread bolt into output shaft (6, fig. 7-23) to seat bearing. Be
careful to aline hole in washer with dowel in shaft.
14. Remove bolt from end of output shaft. Install lockwasher (2, fig. 7-23) and replace bolt. Tighten bolt
to a torque of 75 to 90 foot-pounds. Bend up lip of special tabbed lockwasher to lock bolt (fig. 7-10).
(c) Flywheel assembly installation.
1. Install new seal ring (5, fig. 7-8) on converter pump flange (fig. 7-10).
2. Support flywheel above converter, using a hoist and a suitable lifting sling.
3. Keeping flywheel level, lower it on converter pump and pilot bearing.
4. Working through converter housing cover opening, install four self-locking bolts in pump. Space
bolts 90 degrees apart (fig. 7-9).
5. Screw bolts in evenly to draw flywheel on pilot bearing.
CAUTION
If flywheel becomes cocked on pilot bearing, remove flywheel and repeat 3 through 5 above
6. Install remaining 32 self-locking bolts. tighten bolts to a torque of 30 to 35 foot-pounds.
7. Install seal ring (2, fig. 7-8) on each of six bolts (1) that secure bearing retainer plate (7) to flywheel.
Inspect six bolt holes in flywheel, making sure chamfered seats for seal rings are smooth. Install six bolts through flywheel and into bearing retainer plate. Tighten bolts to a torque of 40 to 45 foot-pounds.
8. Install converter housing cover (6, fig. 7-6) and gasket (51 using bolts (8) and lockwashers (7).
(d) Charging oil pump assembly installation. Install charging oil pump assembly as outlined in b (5) above.
(7) Installation. Refer to paragraph 2-12.
d. Torque Converter Assembly Model TC-554 (4 Element) (fig. 2-3 and 7-2).
(1) Removal Remove torque converter assembly as outlined in paragraph 2-12.
(2) Disassembly.
(a) Charging oil pump assembly removal. Remove charging oil pump assembly as outlined in b(1) above.
(b) Flywheel assembly removal .
1. Place converter assembly on flywheel end.
2. Remove two bolts (6, fig. 7-34) and lockwashers (5) that secure converter housing cover (4) and er move housing cover and gasket (3).
7-22
Figure 7-34. Housing assembly (model TC-554).
3. Using a 9 /16 inch socket, and working through converter housing cover opening, remove 36 bolts
(10, fig. 7-35) that secure converter pump (7) to flywheel (2, fig. 7-36).
7-23
Figure 7-35. Torque converter pump and hub assembly.
Figure 7-36. Flywheel assembly.
7-24
4. Remove bolt (12, fig. 7-37), lockwasher (11), washer (10), and output flange (9).
Figure 7-37. Output shaft and flange assembly (model TC-554).
5. Using an eyebolt in output shaft, or sling attached to housing, lift converter up leaving flywheel on
table.
6. Turn converter over and place on blocks (fig. 7-38)
7-25
Figure 7-38. Seal ring removal and installation from
converter pump flange.
Figure 7-40. Pilot bearing inner race and turbine assembly removal and installation.
7. Remove large seal ring (3, fig. 7-36)
from converter pump flange (fig. 7-38).
(c) Torque converter elements removal.
1. Remove snapring from output shaft
(fig. 7-39).
3.
Remove snapring that locates
turbine (fig. 7-41).
Figure 7-39. Snap ring removal and installation from
output shaft.
2. Install bolts of any suitable bar-type
bearing puller in tapped holes provided in turbine hub.
Remove bearing inner race and turbine assembly (fig.
7-40).
Figure 7-41. Turbine locating snapring removal and
installation.
7-26
4. Remove thrust washer between turbine and first stator (fig. 7-41).
5. Remove first stator assembly (fig. 7-42)
6. Remove thrust washer between first and second stators (fig. 7-43).
Figure 7-42. First stator assembly removal and installation (model TC-554).
Figure 7-43. Thrust washer removal and installation.
7-27
7. Remove second stator assembly (fig. 7-43)
8. Straighten staked section of freewheel roller race retaining nut (fig. 7-43).
9. Using spanner wrench, part No. J653 remove retaining nut (fig. 7-44).
Figure 7-44. Freewheel roller race retaining nut removal and installation.
10 Removal freewheel roller race (fig. 7-45).
Figure 7-45. Freewheel roller race removal and installation.
7-28
11. Remove spacer (fig. 7-45).
12. Straighten bent part of lock strips
and remove 12 bolts (fig. 7-45).
13. Remove two halves of retainer
plate (fig. 7-46).
16. Remove two seal rings from
ground sleeve (fig. 7-48)
Figure 7-48. Seal ring removal and installation from
ground sleeve.
(d) Torque converter output shaft removal.
1. Remove six bolts (7, fig. 7-37) and
lockwashers (6) from bearing retainer (5).
2. Remove output shaft and bearing
retainer (fig. 7-49).
Figure 7-46. Split retainer plate removal and
installation.
14. Remove converter pump (fig.
7-46).
15. Converter pump hub, seal ring,
and bearing may come off with converter pump. If not,
remove hub, seal ring, and bearing from ground sleeve
(fig. 7-47).
Figure 7-49. Bearing retainer removal and installation.
Figure 7-47. Converter pump hub, seal ring, seal ring,
and bearing removal and installation.
7-29
(3) Subassemblies disassembly.
(a) Housing assembly disassembly.
1. Remove plug (14, fig. 7-34), seal ring (15), and lockwasher (16) from rear of converter housing (fig.
7-24).
2. Install slide hammer remover and adapter, part No. J5901 in threaded hole in charging oil pump
idler gear shaft (fig. 7-25).
3. Remove oil pump idler gear shaft (17, fig. 7-34), being careful that oil pump idler gear (18) does not
drop out of housing.
4. Remove charging oil pump idler gear assembly (fig. 7-26). Do not remove bearing from gear.
5. Oil pump drive gear (2, fig. 7-34) and converter pump hub oil seal (1 generally are not removed. If
either gear or seal needs replacing, collapse oil seal with drift and hammer and remove oil seal. Gear can then be er
moved.
6. Ordinarily, ground sleeve (11) is not removed. If it needs replacing, position converter housing in a
press, front side up, and press ground sleeve out of housing (fig. 7-28). Remove ground sleeve key (12, fig. 7-34) and
dowel pin (13) from ground sleeve (11).
(b) Converter pump and hub assembly disassembly. If bearing (4, fig.7-35) requires replacement, press
bearing out of converter pump hub (9).
NOTE
Do not remove balance weights (5)..
(c) Stator assembly disassembly. Remove rollers (9, fig. 7-50), springs (7), and cups (8) from stators.
Figure 7-50. Stator assembly (model TC-554).
7-30
(d) Turbine assembly disassembly. The
turbine assembly is a riveted assembly consisting of a
hub and turbine (3, fig. 2-3). If either is defective, replace entire assembly.
(e) Output shaft and flange assembly disassembly.
1. Use soft hammer to remove bearing
retainer from output shaft assembly.
2 Remove two hook-type seal rings
from output shaft.
3. To remove bearing from output
shaft, support bearing and shaft assembly, rear end up,
on bearing inner race. Press shaft out of bearing, using
arbor press.
4. Output flange dual oil seal (8, fig.
7-37) is not ordinarily removed unless replacement is
necessary. When replacing, press seal out of bearing
retainer (5).
(f) Flywheel assembly disassembly.
1. If roller bearing (4, fig. 7-36) requires replacement, remove snapring (5) and remove
roller bearing.
2. The flywheel ring gear (1, fig. 7-36)
is not ordinarily disassembled from flywheel (2). If it
needs replacement, press or drive ring gear off flywheel.
NOTE
Be sure to note exact mounting position
of damaged ring gear before removal.
The new gear must be assembled in the
same position.
(g) Flexible flywheel disk assembly disassembly. The flexible flywheel disk assembly (fig. 7-51)
is not disassembled. If components (1, 4, 5, or 6) require replacement, the flexible flywheel disk assembly
must be replaced as an assembly.
(4) Cleaning, Inspection and Repair Procedures
will be the same as outlined in c(41'above.
(5) Subassemblies reassembly.
(a) Flywheel assembly reassembly.
1. To install flywheel ring gear (1, fig.
7-36) on flywheel (2), heat ring gear and press or drive
in on flywheel.
NOTE
Be careful not to drive or press on ring
gear teeth when installing ring gear. Do
not heat ring gear to more than 400°F.
2. Install roller bearing (4) in flywheel
bore and secure with snapring (5).
(b) Output shaft and flange assembly reassembly.
1. Press bearing on output shaft, using
an arbor press. Be certain to press only on bearing ni
ner race.
NOTE
Bearing must be seated against shoulder on shaft.
2. Install two hook-type seal rings.
3. If output flange dual oil seal (8, fig.
7-37) was removed, press new seal in bearing retainer(5) from front (chamfered end) of bearing retainer
bore using sealing compound, Military Specification
MIL-S-7916, between seal outside diameter and bore of
retainer. Spring side of seal must be toward front of
retainer.
(c) Stator assembly reassembly. Install springs
(7, fig. 7-50) on cups (8) and insert into bore in stator
(fig. 7-52). Install rollers (9) (fig. 7-50).
Figure 7-52. Freewheel roller, spring, and cup installation in stator.
Figure 7-51. Flexible flywheel disk assembly
(model TC-554)
7-31
(d) Converter pump and hub assembly reassembly. Press bearing (4, fig. 7-35) in converter pump hub (9).
(e) Housing assembly reassembly.
1. If ground sleeve (11, fig. 7-34) was removed, install dowel pin (13) in ground sleeve key (12) and install key on new ground sleeve so end of key is flush with face of ground sleeve. Notice dowel pinhole in key is off ce
nter. Press ground sleeve and key- into converter housing assembly (7).
2. If oil pump drive gear (2) and converter pump hub oil seal (1) were removed, install gear. Install oil
seal with spring side toward gear using converter pump hub seal replacer, part No. J7475.
3. Position converter on table with rear end up.
4.
Install charging oil pump idler gear (18) by positioning gear in housing bore and in-stalling oil pump
idler gear shaft (17) in bore. Use soft drift or bolt of the proper size threaded into shaft and tap shaft in place.
5. Install lockwasher (I6), seal ring (15), and plug (14 in oil pump idler gear shaft bore. Tighten plug (14)
to a torque of 80 to 100 foot-pounds (fig. 7-24).
(6) Reassembly.
(a) Torque converter output shaft installation.
1. Install new bearing retainer gasket (4, fig. 7-37) on rearof converter housing.
2. Install output shaft (1) and bearing (3) into ground sleeve.
3. Position bearing retainer on converter housing (fig. 7-49).
4. Secure bearing retainer (5,fig. 7-37) to converter housing with six bolts (7) and lock washers (6).
Tighten bolts (7) to a torque of 67 to 80 foot-pounds.
(b) Torque converter elements installation.
1. Support converter, front end up.
2
Install seal rings on ground sleeve (fig. 7-48).
3. Install converter pump hub and bearing on ground sleeve, making sure tangs on pump hub are engaged with slots in pump drive gear (fig. 7-47).
4. Install new seal ring in groove of converter pump hub (fig. 7-47).
5. Install converter pump (fig. 7-46).
6. Install two halves of retainer plate (fig. 7-46).
7. Install six lock strips and 12 bolts. Bend one corner of lock strip against each bolt head (fig. 7-45).
8. Install spacer (fig. 7-45).
9. Install freewheel roller race (fig. 7-45).
10. Install freewheel roller race retaining nut using spannerwrench, part No. J6534 (fig. 7-44). Tighten
nut to a torque of 275 to 325 foot-pounds.
11. Stake retaining nut (fig. 7-43).
12. Lay stator assembly, flat side up, on table. Examination will show second stator to have blades that
spiral clockwise. First stator will have either straight blades or blades that spiral counterclockwise.
13. Install second stator assembly, flat side up, on ground sleeve. Rotate stator clockwise
as it is lowered to keep rollers from locking on ground sleeve (fig. 7-43).
14. Install thrust washer (fig. 7-43).
15 Install first stator assembly, flat side down, on ground sleeve (fig. 7-42). Rotate stator clockwise as it
is lowered to keep rollers from locking on ground sleeve.
CAUTION
Be sure stators can freewheel clockwise after installation and will lock up when rotated countercloc
kwise.
16. Install thrust washer (fig. 7-41).
17. Install snapring that locates turbine (fig. 7-41).
18. Install turbine assembly (fig. 7-40).
19. Install flywheel bearing inner race on output shaft (fig. 7-39).
20. Install snapring on end of output shaft (fig.7-39).
(c) Flywheel assembly installation.
1. Install new seal ring on converter pump flange (fig. 7-38).
2. Install eyebolt in end of output shaft or tie sling on converter housing and hoist converter above flywheel assembly.
3. Lower converter, guiding inner race of pilot bearing in bearing. After inner race slides in bearing,
aline boltholes in converter pump with holes in flywheel. Lower converter until converter pump makes contact with flywheel.
4
Working through converter housing cover opening, install four bolts in pump. Space bolts 90 degrees
apart.
5. Tighten bolts evenly to draw flywheel on pilot bearing.
CAUTION
If flywheel becomes cocked, remove flywheel and repeat 1 through 5, above.
6. Install remaining 32 self-locking bolts. Tighten bolts to a torque of 30 to 35 foot-pounds.
7.
Remove eyebolt from output shaft.
8. Install output flange (9, fig. 7-37), output flange washer (10), lockwasher (11), and bolt (12) on output
shaft.
9. Tighten bolt to a torque of 120 to 130 foot-pounds.
7-32
10. Install converter housing cover (4, fig. 7-34) and gasket (31 using bolts (61 and lock-washers (5).
(d) Charging oil pump assembly installation. Install charging oil pump assembly as outlined in b (5)
above.
(7) Installation. Install torque converter assembly as outlined paragraph 2-12.
Torque Converter Assembly, Model TC-554 (3 Element) (fig. 2-4 and 7-2).
(1) Removal. Remove torque converter assembly as outlined in paragraph 2-12.
(1) Disassembly.
(a) Remove charging oil pump assembly as outlined in b (1) above.
(b) Output shaft flange removal.
1. Place converter assembly on flywheel end.
2. Remove bolt (12, fig. 7-37), lockwasher (11) , washer (10), and output flange (9).
(c) Flywheel, turbine. and stator removal.
1. Remove two bolts (6, fig. 7-53) and lockwashers (5) that secure converter cover (4) and remove
cover and gasket (3).
e.
Figure 7-53. Housing assembly.
7-33
2. Using a 9/16 inch socket, and
working through converter housing cover opening, remove 36 bolts (10, fig. 7-54) and washers (11) that secure converter pump (7) to flywheel (2, fig. 7-36).
Figure 7-55. Removing flaywheel, turbine and stator
assemblies from converter housing.
4. Lift stator assembly, thrust washer,
and turbine assembly from flywheel (fig. 7-56).
Figure 7-54. Torque converter pump and hub assembly.
3. Using an eyebolt in output shaft, or
sling attached to housing, lift converter up, leaving flywheel assembly, turbine assembly, thrust washer, and
stator assembly on table (fig. 7-55).
Figure 7-56. Installing flywheel assembly.
7-34
11. Remove two seal rings from ground sleeve
(fig. 7-48).
5. Turn converter over and place it on
wooden blocks (fig. 7-57).
6. Remove seal ring from converter
pump (fig. 7-57).
1
2
3
4
5
6
7
8
9
Figure 7-58. Freewheel roller race and backing plate
removal.
Backing plate
Freewheel roller race
Retaining nut
Torque
Output
Snap ring
Inner bearing race
Snap ring
Seal ring
Figure 7-57. Seal ring and inner race
removal and installation.
(d) Converter pump and hub removal.
1. Remove snapring from end of output shaft (fig. 7-57).
2. Remove inner bearing race from
output shaft (fig. 7-57).
3. Remove snapring that locates turbine (fig. 7-57).
4. Straighten staked section of freewheel roller race retaining nut (fig. 7-57).
5. Using spanner wrench, part No.
J6534, remove retaining nut (fig. 7-44).
6. Remove freewheel roller race and
backing plate (fig. 7-58).
7. Straighten bent part of locking strips
and remove 12 bolts and locking strips (fig. 7-58).
8. Remove split retainer plates (fig.
7-46).
9. Remove converter pump (fig. 7-46).
10. Converter pump hub, seal ring, and
bearing may come off with converter pump. If not, remove hub, seal ring, and bearing from ground sleeve
(fig. 7-47). Remove the seal ring from the hub.
7-35
(e) Output shaft removal.
1. Remove six bolts (7, fig. 7-37) and
lockwashers (6) from bearing retainer (5).
2. Remove output shaft and bearing
retainer using jackscrews in the tapped holes provided
in the retainer (fig. 7-49).
(3) Subassemblies disassembly.
(a) Housing assembly disassembly.
1. Remove plug (14, fig. 7-53'), seal
ring (15), and lockwasher (16) from rear of converter
housing (fig. 7-24).
2. Install slide hammer remover and
adapter, part No. J5901 in threaded hole in charging oil
pump idler gear shaft (fig. 7-25).
3. Remove oil pump idler gear shaft
(17, fig. 7-53), being careful that oil pump idler gear (18)
does not drop out of housing.
4. Remove charging oil pump idler
gear assembly (fig. 7-26). Do not remove bearing from
gear.
5. Oil pump drive gear (2, fig. 7-53)
and converter pump hub oil seal (1) generally are not
removed. If either gear or seal needs replacing, collapse oil seal with drift and hammer and remove oil seal.
Gear can then be removed.
6. Ordinarily, ground sleeve (11) is not
removed. If it needs replacing, position converter
housing in a press, front side up, and press ground
sleeve out of housing (fig. 7-28). Remove ground
sleeve key (12, fig. 7-53) and dowel pin (13) from
ground sleeve (11).
(b) Converter pump and hub assembly disassembly. If bearing (4, fig. 7-54) requires replacement,
press bearing out of converter pump hub (9).
NOTE
Do not remove balance weights 15).
(c) Stator assembly disassembly. Remove twelve rollers (6, fig. 7-59), twelve springs (5), twelve needle rollers
(4), and twenty-four cups (3).
(d) Turbine assembly disassembly. The turbine
assembly is a riveted assembly consisting of a hub and
turbine (3, fig. 2-4). If either part is defective, replace
entire assembly.
(e) Output shaft and flange assembly disassembly.
1. Use soft hammer to remove bearing
retainer from output shaft assembly.
2. Remove two hook-type seal rings from
output shaft.
3. To remove bearing from output shaft,
support bearing and shaft assembly, rear. end up, on
bearing inner race. Press shaft out of bearing, using press.
4. Output flange dual oil seal (8, fig. 7-37) is
not ordinarily removed unless replacement is necessary.
When replacing, press seal out of bearing retainer (5).
Flywheel assembly disassembly.
1. If roller bearing (4, fig. 7-36) requires
replacement, remove snapring (5) and remove roller
bearing.
2. The flywheel ring gear (1, fig. 7-36) is not
ordinarily disassembled from flywheel (2). If it needs
replacement, press or drive ring gear off flywheel.
NOTE
Be sure to note direction of chamfered
teeth of damaged ring gear before
removal. The new gear must he
assembled in the same position.
(g) Flexible flywheel disk assembly disassembly.
The flexible flywheel disk assembly (fig. 7-51) is not
disassembled. If components (1, 4, 5, or 6) require
replacement, the flexible flywheel disk assembly must be
replaced as an assembly.
(4) Cleaning, inspection and repair procedures will be
same as outlined in c (4) above.
(5) Subassemblies reassembly.
(a) Flywheel assembly reassembly.
1. To install flywheel ring gear (1, fig. 7-36) on
flywheel (2), heat ring gear and press or drive in on
flywheel.
NOTE
Chamfered teeth must face
same direction as those on
Figure 7-59. Stator assembly.
original gear. Be careful not to
drive or press on ring gear
teeth when installing ring gear. Do not heat ring gear to more than 400°F.
2. Install roller bearing (4) in flywheel bore and secure with snapring (5).
(b) Output shaft and flange assembly reassembly.
1. Press bearing on output shaft, using an arbor press. Be certain that bearing inner race is supported
during pressing operation.
NOTE
Bearing must he seated against shoulder on shaft.
2. Install two hook-type seal rings.
3 If output flange dual oil seal (8, fig. 7-37) was removed, press new seal in bearing-retainer (5) from front
(chamfered end) of bearing retainer bore using sealing compound, Military Specification MIL-S-7916, between seal
outside diameter and bore of retainer. Spring side of seal must be toward front of retainer.
7-36
(c) Stator assembly reassembly.
1. Install twelve springs (5, fig. 7-59) on twelve needle rollers (4). Install a cup (3) at each spring end and
insert the assembly into bore of stator.
2. Install rollers (6, fig. 7-59).
3. Install stator freewheel roller race (8) into stator assembly (2).
(d) Converter pump and hub assembly reassembly. Press bearing (4, fig. 7-54) in converter pump hub (9).
Groove in bearing outer race must be away from hub.
(e) Housing assembly reassembly.
1. If ground sleeve (11, fig. 7-53) was removed, install dowel pin (13) in ground sleeve key (12) and install
key on new ground sleeve so end of key is flush with face of ground sleeve. Notice dowel pinhole in key is off center.
Press ground sleeve and key (fig. 7-33) into converter housing assembly (7, fig. 7-53).
2. If oil pump drive gear (2, fig. 7-53) and converter pump hub oil seal (1) were removed, install gear. Install
oil seal with spring side toward gear using converter pump hub seal replacer, part No. J7475.
3. Position converter on table with rear end up.
4. Install charging oil pump idler gear (18) by positioning gear in housing bore and installing oil pump idler
gear shaft (17) in bore. Use soft drift or bolt of the proper size threaded into shaft and tap shaft in place.
NOTE
Gear teeth are offset from the hub, toward front of converter.
5. Install lockwasher ( 16), seal ring ( 15),and plug (14) in oil pump idler gear shaft bore. Tighten plug (14) to
a torque of 80 to 100 foot-pounds (fig. 7-24).
(6) Reassembly
(a) Torque converter output shaft installation.
1. Install new bearing retainer gasket (4, fig. 7-37) on rear of converter housing.
2. Install lout put shaft (1) and bearing (3) into ground sleeve.
3. Position bearing retainer on converter housing (fig 7-49).
4. Secure bearing retainer (5, fig. 7-37) to converter housing with six bolts (7) and lock-washer (6).
Tighten bolts (7) to a torque of 67 to 80 foot-ponds.
(b)
Converter pump and hub installation.
1. Support converter, front end up.
2. Install two seal rings on ground sleeve (fig. 7-48).
3. Install converter pump hub and bearing on ground sleeve, making sure tangs on pump hub are e
ngaged with slots in oil pump drive gear (fig. 7-47).
4. Install new seal ring in groove of converter pump hub (fig. 7-47).
5. Install converter pump (fig. 7-46).
6. Install two split retainer plates (fig. 7-46).
7. Install six lock strips and 12 bolts. Bend one
corner of lock strip against each bolt head (fig. 7-58).
(c) Stator, turbine, and flywheel installation.
1. Install new seal ring on converter pump flange
(fig. 7-57).
2. Install backing plates, flat side up-ward, onto
ground sleeve (fig. 7-58).
3. Position converter housing upright on assembly table (fig. 7-60).
4. Install the assembled stator assembly onto the
ground sleeve (fig. 7-60).
NOTE
The stator should rotate freely in a clockwise
Figure 7-60. Installation converter stator assembly.
direction, and lockup when an attempt is
made to turn it in the opposite direction.
5. Position converter on wooden blocks with flywheel end up (fig. 7-57).
6. Install' freewheel roller race retaining nut using spanner wrench, part No. J6534 (fig. 7-44). Tighten
nut to a torque of 275 to 325 foot-pounds.
7. Stake retaining nut (fig. 7-57).
8. Install snapring that locates turbine (fig. 7-57).
9. Install flywheel bearing inner race on output shaft (fig. 7-57).
7-37
10. Install snapring on end of output shaft (fig.7-57).
11. Position converter housing upright on assembly table.
12. Install thrust washer (1, fig. 7-50) onto freewheel roller race.
13. Install turbine assembly on output shaft.
14. Using a sling and a guide bolt, install the flywheel assembly onto the torque converter(fig. 7-56).
A line bolt holes in the flywheel with the bolt holes in the converter pump.
15. Working through converter housing cover opening, install four bolts and flat washers in pump.
Space bolts 90 degrees apart.
16. Tighten bolts evenly to draw flywheel onto the flywheel bearing inner race on output shaft.
17. Remove guide bolt (fig. 7-56).
18. Install remaining 32 self-locking bolts and 32 flat washers. Tighten bolts to a torque of 41 to 49
foot-pounds.
(d) Output flange installation. Install output flange (9, fig. 7-37), flange washer (10),lockwasher (11), and
bolt (12) on output shaft. Tighten the bolt to 120 to 140 foot-pounds.
(e) Housing cover installation. Install converter housing cover gasket (3, fig. 7-53), cover (4), two
locwashers (5), and two bolts (6).
(f) Charging oil pump assembly installation. Install charging oil pump assembly as outlined in b (5)
above.
(7) Installation. Install torque converter assembly as outlined in paragraph 2-12.
7-3. Torque Converter Stall Check
a. The stall check is for determining whether or not the engine and the torque converter are functioning satisfact
orily as a unit.
b. Install a tee fitting at the inlet side of transmission lube manifold and install a 0 to 60 psi gage(fig. 7-61).
c. Install a 0 to 200 psi gage at inlet side of converter charging oil pump (fig. 7-62).
Figure 7-61. Checking transmission lube oil pressure.
7-38
Figure 7-62. Checking converter in pressure.
NOTE
Before a stall check is performed. it is necessary to check oil level in transmission and
converter system.
d. Start engine and allow temperature and pressure readings to stabilize.
NOTE
Normal operating temperature for both engine and transmission must be reached before
performing stall check to evaluate true stalled speed.
e. Run engine at idling speed.
f. Apply brakes. As an added precaution the wheels can be blocked.
g. Shift transmission into high range and move engine throttle to full speed position.
CAUTION
Do not stall converter output shaft at full engine throttle over 20 seconds maximum. Do not
let converter oil temperature exceed 2500 F. This temperature can be read on TOR.CONV.
OIL TEMP. gage on the gage board.
h. Table 7-1 gives theoretical stall speeds on Models TC-654 and TC-554 converters. Stall speeds may vary
considerably because of accessory drag. However. acceptable figures will not fall more than 100 rpm below those
listed.
NOTE
Stall speeds more than 2% above thoselisted should be investigated immediately.
i. Charging oil pump IN pressure should be 500 psi minimum and 80 psi maximum at full throttle stall condition.
Maximum permissible pressure at full throttle with transmission in neutral range is120 psi.
j. Transmission lube oil pressure should be 8 psi minimum and 25 psi maximum at full throttle
k. Transmission clutch pressure should be 140 psi minimum at full throttle stall as indicated on TRANS. OIL
PRESS. gage on the gage board.
NOTE
Altitude must be considered in stalled readings.
l. Checking stall speed is not practical if engine tachometer is inaccurate. This should be first item checked if stall
speed is above figure listed.
m. Stall speeds should be the same in all transmission ranges. If there is a variation between ranges, there is a
possibility of slipping transmission clutches.
Table 7-1. Torque converter stall speed chart.
Engine
Transmission
Converter
governed
Converter
Converter
Stall
lube oil
charging
(RPM)
torque
model
(RPM)
pressure
oil pressure
2100
3.6 to 1
TC-654
1710
8-25 psi
50-80 psi
2100
3.13to 1
TC-554
1840
8-25 psi
50-80 psi
7-39
7-4. Flexible Coupling, Torque Converter to Transmission
Refer to TM 55-1930-203-20 for removal. installation, disassembly. reassembly, cleaning, and inspection instructions.
7-5. Flexible Coupling, Transmission to Miter Box
Refer to TM 55-1930-203-20 for removal, installation, disassembly, reassembly, cleaning, and inspection instructions.
7-6. Transmission Assembly
a. Description. Refer to paragraph 2-13 for a complete description of the LARC Transmission Assembly.
b. Removal. Refer to paragraph 2-13.
c. Disassembly.
(1) Minor subassemblies removal.
(a) Place transmission. bottom side down. on worktable on wood block, or mount transmission on ove
rhaul stand.
(b) Remove bolts (43, fig. 2-7) and lockwashers (42) and remove manifold assembly (40) and gasket
(39).
(d) Remove four bolts (51) and lockwashers (52) and remove selector valve assembly (53) and gasket
(54).
(d) Remove capscrews (1, fig. 7-63), lockwashers (2), and strainer (3) and gasket (4) from transmission.
Figure 7-63. Transmission oil strainer.
(e) Straighten stake marks to unlock nut from out put shaft. Remove nut (1, fig. 7-64), seal (2), internal
snapring (3), and output flange (4).
7-40
Figure 7-64. Transmission flange assembly.
(f) Remove bolt (5) and lockwasher (6) from input flange (8), and remove input flange.
NOTE
The flange is an outside diameter (tight) fit on the shaft. Proceed as outlined in (g) through
(i) below.
(g) Using a suitable puller, bolt the puller to face of input flange (8).
CAUTION
A puller that pulls on the outside diameter of flange may deform the flange.
(h) Install spacer between the jackscrew and shaft.
(i) Remove input flange by tightening puller screw against spacer and shaft.
CAUTION
To avoid damage, do not hammer or pry on flange.
(2) Transmission front housing and cover removal.
(a) Remove 15 bolts (39, fig. 7-65), bolt (40), and 16 lockwashers (38 and 41).
7-41
Figure 7-65. Transmission housing assembly.
7-42
Key to figure 7-65.
1 Bolt, machine
2 Lockwasher
3 Carrier, bearing retainer
4 Internal cover
5 Pin
6 Oil transfer tube
7 Bolt, machine
8 Lockwasher
9 Bolt, self4ocking
10 Transmission housing
11 Manifold gasket
12 Lockwasher
13 Bolt, machine
14 Manifold
15 Dowel pin
16 Spring
17 Valve
18 Screw
19 Nameplate
20 Bearing assembly
21 Seal ring
22 Bearing housing
23 Seal ring
24 Retaining ring
25 Plug
26 Gasket
27 Cover
28 Lockwasher
29 Bolt, machine
30 Front housing gasket
31 Front housing
32 Dowel pin
33 Plug
34 Lockwasher
35 Bolt, machine
36 Cover gasket
37 Front housing cover
38 Lockwasher
39 Bolt, machine
40 Bolt, machine
41 Lockwasher
42 Input flange oil seal
43 Bolt, machine
44 Lockwasher
(b) Remove front housing cover (37) and cover gasket (36).
(c) Remove bolt (11, fig. 7-66), lockwasher (10) and washer (9).
7-43
Figure 7-66. Transmission shaft assembly.
(d) Remove upper transfer gear bearing (8) and lower transfer gear bearing (13), upper input transfer gear
(7), and lower input transfer gear (14).
NOTE
The lower input transfer gear (14) is secured to input shaft (12) by an external snapring (151
on inner side of input shaft. The input shaft must be removed with lower input transfer gear.
The external snapring can then be removed and lower input transfer gear can be removed
from input shaft.
7-44
(e) Remove upper transfer gear bearing (61 and lower transfer gear bearing (16).
(f) Remove 14 bolts (35, fig. 7-65), 4 bolts (43), and 16 lockwashers (34 and 44).
(g) Remove transmission front housing (31). Use jackscrews if necessary (fig. 7-67).
Figure 7-67. Transmission front housing
Figure 7-68. Intermediate-range clutch back
plate assembly removal and installation
(3) High-range and intermediate range clutch assemblies removal.
(a) Using a suitable lifting sling, lifting eyes, and hoist, tilt transmission backward to a 45- degree angle.
(
b) Remove intermediate-range clutch backplate assembly (fig. 7-68).
(c) Remove intermediate-range clutch plates (fig. 7-69).
(d) Install clutch spring compressor, part No. J7470 (fig. 7-70) to compress high-range clutch pack. Remove
internal snapring from high- range clutch drum and sun gear assembly (fig. 7-70). Remove clutch spring compressor.
(e) Remove high-range clutch backplate (fig. 7-71) hub. clutch release springs, and clutch plates.
Figure 7-69. Intermediate-range clutch places
removal and installation.
Figure 7-70. Removal of internal snapring from
clutch drum and sun gear assembly with clutch
spring compressor, Part No. J7470.
7-45
Figure 7-71. High-range clutch back plate
removal and installation.
Figure 7-72. Using air pressure to remove highrange piston.
Figure 7-73. Removal and installation of snapring
on transmission main shaft and sun gear.
Figure 7-74. Transmission rear cover removal and
installation.
(f) Using air pressure in indicated hole. force high-range piston out of its seal bore and remove (fig. 7-72).
(g) Remove snapring from transmissior main shaft and sun gear (fig. 7-73).
(4) Transmission adapter assembly removal
(a) Hoist transmission, shift its position and lower it with front end down. Use three wooden blocks to support
front end (fig. 7-74).
(b) Remove bearing retainer (fig. 7-75). Use jackscrews if necessary.
7-46
(c) Remove bearing retainer seal ring (fig. 7-75).
(d) Remove 20 bolts (9, fig. 7-76), lock- washers (10) at
transmission rear cover (6).
(e) Using a suitable lifting sling, remove transmission
rear cover (6) and adapter gasket (7). Use jackscrews if necessary (fig. 7-74).
(5) Low-range clutch and planetary carrier assemblies removal.
(a) Using improvised tool threaded on shaft end of
planetary carrier assembly, lift planetary carrier assembly and
remove snapring from ball bearing assembly (fig. 7-77).
NOTE
The improvised tool can be made from a
bearing locknut, part No. 179207, and a short
piece of steel bar, welded together (fig. 7-77.)
Figure 7-75. Bearing retainer removal and
(b) Remove improvised tool from shaft end of planetary carinstallation
rier assembly.
(c) Remove 12 bolts (7, fig. 7-65) and 12 lockwashers (8) from internal cover (4, fig. 7-77).
(d) Hoist internal cover, low-range clutch plates and low-range ring gear out of transmission (fig. 7-78).
Figure 7-76. Transmission adapter assembly.
Figure 7-77. Removal and installation of snapring from
ball bearing assembly.
7-47
(e) Using improvised tool, hoist planetary carrier gearing assembly out of transmission (fig. 7-79).
(6) Reverse-range clutch assembly removal.
(a) Using clutch spring compressor, part No. J7470 (fig. 7-70), compress reverse-range clutch backplate
assembly and remove snapring.
(b) Remove clutch spring compressor, part No. J7470, and remove reverse-range ring gear (fig. 7-80).
(c) Remove reverse-range clutch backplate assembly (fig. 7-81).
(d) Remove reverse-range clutch plates (fig. 7-81).
Figure 7-78. Internal cover, low range clutch, and low
range ring gear removal.
Figure 7-80. Removing snapring that retains
reverse-range clutch back plate assembly with clutch
spring compressor, part no. J7470.
Figure 7-79. Planetary carrier assembly removal.
7-48
Figure 7-81. Reverse-range clutch backplate assembly removal
(e) Using air pressure in indicated hole, lift reverse-range piston out of its seal bore and remove (fig. 7-82).
Figure 7-82. Using air pressure to remove reverse piston.
(7) Clutch drum and sun gear assembly removal
(a) If transmission main shaft and sun gear remained in transmission when planetary carrier gearing assembly
was removed, remove transmission main shaft (fig. 7-83).
7-49
Figure 7-83. Transmission main shaft and sum gear removal
(b) From rear side of transmission, remove snapring from clutch drum and sun gear assembly (fig. 7-84).
Figure 7-84. External snapring removal from clutch drum and sun gear assembly.
c) Tap clutch drum and sun gear assembly from transmission housing (fig. 7-85). (Turn transmission back over at this
point).
Figure 7-85. Clutch drum and gear assembly removal.
(d) Using air pressure in indicated hole, force intermediate-range piston out of its seal bore and remove (fig. 7-86).
7-50
Figure 7-86. Using air pressure to remove intermediate-range piston.
(8) Transmission housing assembly and related parts disassembly.
(a) Parts that were not removed from transmission housing assembly during disassembly into subassemblies
need not be removed except for replacement of parts.
(b) If bearing housing needs to be replaced, remove eight bolts (9, fig. 7-65) from bearing housing (22) using
three bolts as jackscrews and remove bearing housing.
(c) If bearing assembly (20, fig. 7-65) needs to be replaced, drive bearing out of bearing housing (22).
(9) Transmission main shaft assembly disassembly.
(a) Parts in this assembly were removed from transmission during disassembly into subassemblies.
(b) Remove transmission main shaft sun gear (2. fig. 7-66) only if replacement is necessary.
(c} Remove external snaprings (I and 3) and remove transmission main shaft sun gear (2).
(10) Low-range clutch assembly disassembly.
(a) Low-range clutch assembly was removed during disassembly of transmission into subassemblies (fig. 7-78).
(b) Place the low-range clutch assembly, front side down, on worktable.
(c) Use a C-clamp to compress assemblies slightly so cotter pins can be removed. Remove cotter pins from
three assembling pins (fig. 7-87). Remove assembling pins.
7-51
Figure 7-87. Removal and installation of cotter pins assembly pins with clutch assembly compressed.
(d) Hold clutch assembly together and turn it over.
(e) Remove low-range clutch backplate and springs (fig. 7-87.1).
(f) Remove the seven clutch plates (7 and 8, fig. 7-95).
(g) Remove piston plate (fig. 7-87.2)
(h) Remove ring gear (5, fig. 7-95).
(i) Do not remove the 12 clutch-release springs and clutch-release spring retainers from low-range clutch bac
kplate except for replacement of parts. To aid in removing low-range clutch piston, direct compressed air through oil port
in internal cover (fig. 7-87.3). Remove piston (2, fig. 7-95).
Figure 7-87.1. Low-range clutch backplate and springs removal and installation.
7-52
Figure 7-87.2. Low range clutch piston plate removal and installation.
Figure 7-87.3. Loosening low-range clutch piston, using compressed air.
7-53
Figure 7-87.4. Seal ring removal and installation on drum and sun gear assembly.
(j) Remove seal rings (3) from piston (2).
(11) Intermediate-range clutch assembly disassembly.
(a) Remove seal ring from piston.
(b) The remaining parts in this group were removed from transmission during disassembly into subassemblies.
(12) High-range clutch assembly disassembly.
(a) Most parts in this group were removed from transmission during disassembly into subassemblies. Remove
two seal rings (fig. 7-87.4) and bearing from shaft end of clutch drum and sun gear assembly. Pry bearing up with pry
bars far enough to use a puller, part No. J7468.
(b) Remove remaining seal ring from small hub of drum and sun gear assembly.
(I3) Reverse-range clutch assembly disassembly.
(a) Remove seal ring from reverse-range clutch piston.
(b) Other parts in this group were removed from transmission during disassembly into subassemblies.
(14) Transmission adapter assembly disassembly.
(a) Parts in this assembly were removed from transmission during disassembly into subassemblies.
(b) The ball bearing (2, fig. 7-76) and oil seal (I) are generally not removed. If either ball bearing or oil seal
needs to be replaced, collapse oil seal with drift and hammer and remove oil seal. Tap ball bearing with a drift and
hammer from bearing retainer (3).
(I5) Planetary carrier assembly disassembly.
(a) The planetary gearing was removed from transmission along with transmission main shaft and planetary sun
gear assembly (fig. 7-79)
(b) If main shaft and sun gear assembly remained with planetarycarrier assembly, .slide main shaft and sun gear
assembly from planetary carrier (fig. 7-88).
7-54
Figure 7-88. Main shaft and input sun gear removal from planetary carrier assembly
(c) Place planetary carrier assembly, small end up, on worktable.
(d) Bend down tab on bearing lockwasher (21, fig. 7-89).
7-55
Figure 7-89. Transmission planetary carrier assembly.
7-56
(e) Using special spanner wrench. part No. J7466, tap wrench and remove bearing locknut (22) from planetary
carrier (18).
(f) Remove ball bearing assembly (20) from the planetary carrier (18) using puller assembly, part No. J7468, or
any other suitable puller and a sleeve or piece of pipe that will fit over the output shaft (19. fig. 7-89).
(g) Place planetary carrier (18. fig. 7-89) on its side on worktable and remove nine bolts from oil collector ring
(13).
(h) Remove oil collector ring (13) and oil seal II 51 from planetary carrier cover (I6). (fig. 7-90).
Figure 7-90. Removal and installation of oil collector ring and oil seal from planetary carrier cover.
(i) Using alinement cover {fabricated from discarded planetary carrier cover, press the six planetary pins and
cover from carrier {fig. 7-91).
7-57
Figure 7-91. Pressing planetary pinion pins and planetary cover from planetary carrier assembly.
(j) Remove three washers (3, fig. 7-89) from rear of planetary cluster pinions (4) and three washers (9) from rear
of planetary pinions (10).
(k) Press each of the planetary cluster pinion pins (1) and each of the planetary pinion pins (7) and locking balls
(2 and 8) from planetary carrier cover (I6). Drive against locking ball end of each pin.
(l) Remove three planetary pinions (I0, fig. 7-89) along with washers (9), spacers (11), and needle bearings (12),
(fig. 7-92).
7-58
Figure 7-92. Planetary pinion removal.
(m) Remove three planetary cluster pinions (4, fig. 7-89) along with the washers (3), spacers (5), and needle
bearings (6), (fig. 7-93).
Figure 7-93. Planetary cluster pinion removal.
7-59
d. Cleaning, Inspection and Repair.
(1) Dirt and other abrasive material. Whenever the transmission contains dirt or other abrasive material, unnecessary wear will result. Inspect all parts for abrasive material any time transmission is disassembled. Metallic contamination of oil is evidence of failure of some part in either transmission or converter. When metal particles are found, both
the transmission and converter must be thoroughly cleaned.
NOTE
It oil in the hydraulic system becomes contaminated with metal particles, all components of the hydraulic
system-transmission, torque converter, oil lines, filters, screens, coolers, valves, ad oil pumps must be
thoroughly cleaned. This usually means disassembly of the components. Metal particles in the oil are
evidence of some part, either in the torque converter or in the transmission
(2) Cleaning procedures.
(a) All metallic parts of the transmission except bearings should be cleaned thoroughly with dry-cleaning so
lvent, Federal Specification P-D-680, or by the steam-cleaning method.
(b) Parts should be dried with compressed air. Steam-cleaned parts should be oiled immediately after
drying with lubricating oil, Military Specification MIL-L-2 104.
(c) Clean oil passages by working a piece of wire back and forth through the passages and flushing them with
dry-cleaning solvent, Federal Specification P-D-680. Dry passages with compressed air.
(d) After cleaning, examine parts, especially oil passages, to make certain they are entirely clean. Reclean if necessary.
(3) Cleaning bearings.
(a) Thoroughly wash bearings that have been in service in dry-cleaning solvent, Federal Specification P-D680.
(b) If bearings are particularly dirty or filled with hardened grease, soak in solvent before trying to cleanthem.
(c} Before inspection, oil bearings with same type of oil that will be used in transmission, Military Specification MIL-L-2 104.
NOTE
Never dry bearings with compressed air. Do not spin bearings while they are not lubricated.
(4) Keeping bearings clean. Since the presence of dirt or grit in ball bearings is usually responsible for bearing
failures, it is important to keep bearings clean during installation and removal. Observance of the following rules will do
much to insure maximum bearing lift:
(a) Do not remove wrapper from new bearings until ready to install them.
(b) Do not remove grease in which new bearings are packed.
(c) Do not lay bearings on a dirty bench; place them on clean paper.
(d) If assembly is not to be completed at once, wrap or cover exposed bearings with clean paper or cloth to
keep out dust.
(5) Inspecting cast parts and machined surfaces.
(a) Inspect bores for wear, grooves, scratches, and dirt. Remove burrs and scratches with crocus cloth,
Federal Specification P-C-458. Remove foreign matter. Replace parts that are deeply grooved or scratched.
(b) Inspect all oil passages for obstructions. If an obstruction is found, remove it with compressed air or by
working wire back and forth through passage and flushing it out with dry-cleaning solvent, Federal Specification P-D-680.
(c) Inspect mounting faces for burrs, scratches, nicks, and foreign matter. Remove such defects with crocus
cloth, Federal Specification P-C-458, or a soft stone, Military Specification MIL-S-2389. If scratches are deep, replace
defective part.
(d) Inspect threaded openings for damaged threads. Chase damaged threads with the correct size tap.
(e) Replace housings or other cast parts that are cracked.
(f) Inspect all machined surfaces for damage that could cause oil leakage or other malfunction of the part.
Rework or replace defective parts.
(6) Inspecting bearings. Inspect bearing for pitted, scored, or burned condition.
NOTE
When installing bearing on shaft, heat bearing to 300°F. in an oil bath. Coat mating surfaces with white
lead, Federal Specification TT-W-251, and use proper size installation sleeve and an arbor press to seat
bearing.
NOTE
If a bearing must be removed or installed without a sleeve, be careful to press only on the race which is
adjacent to the mounting surface. If an arbor press is not available, seat bearing with a drift and ha
mmer, driving against the supported race.
(7) Inspecting bushings and thrust washers.
(a) Inspect bushings for roundness, scores, burrs, sharp edges, and evidence of overheating. Remove
scores with crocus cloth, Federal Specification P-C-458. Remove burrs and sharp edges with a scraper or knife blade. If
bushing is out-of-round, deeply scored, or excessively worn, replace it using proper size replacement.
7-60
NOTE
Sometimes it is necessary to cut out a defective bushing. Be careful not to damage bore into which
bushing fits.
(b) Inspect thrust washers for distortion, scores, burrs, and wear. Replace thrust washer if defective or
worn.
(c) Planetary gearing thrust washer thickness is 0.050 inch minimum. Groove depth of planetary gearing
thrust washer is 0.005 inch minimum.
(8) Inspecting oil seals and gaskets.
(a) Install new seals and gaskets.
(b) Inspect seal rings for cuts and hardness. Replace seal rings if these defects are found. Replace all
gaskets, worn seal rings, and cotter pins. If converter has been overheated, replace all springs. Handle rubber and
metal seal rings with care to prevent damage.
(c) When replacing lip-type seal rings, make sure spring loaded side is toward the oil to be sealed in
(toward the inside of the unit). Use sealing compound, Military Specification MIL-S-7916, on the outside diameter of the
seal to help prevent oil leaks.
(d) Replace all composition gaskets with new gaskets.
(e) Inspect hook-type seal rings for wear, broken hooks, and distortion.
(f) Install new hook-type seal ring if it is worn so much that there is no gap between the hooks of the seal
ring when it is installed.
(g) Sides of seal ring should be smooth (0.005 inch maximum side wear). Sides of shaft groove (or bore)
in which seal ring fits should be smooth (50-microinch equivalent) and square with the axis of rotation within 0.002 inch.
If sides of ring grooves have to be reworked (0.020 inch maximum side wear), install new seal ring.
(9) Inspecting gears.
(a) Inspect gears for scuffed, nicked, burred, or broken teeth. If defect cannot be removed with a soft
stone, Military Specification MIL-S-2389, replace gear.
(b) Inspect gear teeth for wear that may have destroyed original tooth shape. If this condition is found,
replace gear.
(c) Inspect thrust faces of gears for scores, scratches, and burrs. Remove such defects with a soft stone,
Military Specification MIL-S-2389. If scores and scratches-cannot be removed with a soft stone, replace gear.
(10) Inspecting splined parts. Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove
burrs with a soft stone, Military Specification MIL-S-2389. Replace part if other defects are found. Spline wear is not
considered detrimental except where it affects tightness of fit of splined parts. Transmission main shaft journal diameter
wear limit is 1.9684 inch minimum.
(11) Inspecting threaded parts. Inspect parts for burred or damaged threads. Chase threads or replace da
maged parts.
(12) Inspecting snaprings. Inspect all snaprings for nicks, distortion, and excessive wear. Replace part if one
of these defects is found. Snapring must snap tight in its groove for proper functioning.
(13) Inspecting springs.
(a) Inspect all springs for signs of overheating, permanent set, or wear due to rubbing adjacent parts.
(b) Replace spring if any defects are found.
(14) Low-range clutch assembly.
(a) In cleaning low-range clutch piston, make certain seal ring grooves are free from deposits of gum (2,
fig. 7-95).
(b) Notice condition of low-range, clutch-friction plates (7), and clutch-reaction plates (8). These plates
should not be warped, cracked, or scored deeply.
NOTE
Clutch-friction plate wear limit of 0.153 inch minimum thickness is desired with maximum cone of 0.020
inch. Clutch-reaction plate wear limit of 0.109 inch minimum thickness is desired, with maximum cone of
0 020 inch.
(c) If a low-range, clutch-release spring is removed for replacement, special attention should be given to
installing new spring. Note that end of outer coil of springs should point toward center of the backplate (fig. 7-94). If
springs are not properly installed, there will be interference between the springs and transmission housing. When pee
ning spring retainer into place, place internal snapring under backplate. Use the clutch-release spring retainer installation
and peening tool, part No. J7473, to install and peen the retainer.
7-61
Figure 7-94. Clutch release spring and retainer installation in low-ranger clutch backplate.
Using installation and penning tool, Part No. J7473.
(15) Intermediate-range clutch assembly.
(a) When cleaning intermediate-range clutch piston, make certain seal ring groove is free from deposits of gum.
(b) Notice condition of clutch-friction plates and reaction plates. These plates should not be warned, cracked. or
scored deeply.
NOTE
Clutch-friction plate wear limit of 0.170 inch minimum thickness is desired, with maximum cone of 0.020
inch. Clutch-reaction plate wear limit of 0.113 inch minimum thickness is desired, with maximum cone of
0.020 inch.
(c) If an intermediate-range, clutch-release spring is removed for replacement, special attention should be given
to installing new spring. Note that end of outer coil of springs should point toward center of backplate. When peening
spring retainer into place, place the internal snapring under back-plate. Use the clutch-release spring retainer installation
and peening tool to install and peen retainer.
(16) High-range clutch assembly.
(a) In cleaning the high-range clutch piston, made certain seal ring grooves are free from deposits of gum.
(b) Note that the high-range clutch-release springs are separate from the high-range clutch-backplate. The other
clutches have backplates and release springs assembled together by means of spring retainers.
NOTE
Clutch-friction plate wear limit of 0.153 inch minimum thickness is desired, with maximum cone of 0.020
inch. Clutch-reaction plate wear limit of 0.190 inch minimum thickness is desired with maximum cone
of 0.020 inch.
(c) See (5), (8), (10), and (13) above for cleaning and inspection procedures.
(17) Reverse-range clutch assembly.
(a) In cleaning the reverse-range clutch piston, be sure seal ring groove is free from deposits of gum.
(b) Notice condition of clutch-friction plates and reaction plates. These plates should not be warped, cracked, or
scored deeply.
NOTE
CIutch-friction plate wear limit of 0.153 inch minimum thickness is desired. with maximum cone of 0.020
inch. CIutch-reaction plate wear limit of 0.109 inch minimum thickness is desired, with maximum cone
0.020 inch.
(c) If a reverse-range clutch-release spring is removed for replacement. special attention should be given to
installing the new spring. Note that the end of the outer coil of the springs should point toward the center of the backplate
(fig. 7-94). When peening the spring retainer into place, place the internal snapring under the backplate. Use the clutchrelease spring retainer installation and peening tool, part No. J7473 to install and peen the retainer.
(18) Oil strainer assembly.
(a) If transmission has overheated during a period of malfunction. the oil strainer screen may have become clogged with
a varnish-like deposit. Remove this varnish by using a suitable brush and dry-cleaning solvent, Federal Specification PD)-680.
(b) Inspect the oil strainer screen, especially at the seam, for openings that need solder.
(19 )Manifold assembly.
(a) Clean manifold assembly (40, fig. 2-7) in dry-cleaning solvent, Federal Specification P-D-680, and dry with
low pressure air (10 psi).
7-62
(b) Apply air pressure 10 to 25 psi) to inlet of
manifold assembly with port closest to inlet covered up.
Air should escape from other port between 8 and 25 psi.
(c) If correct indication is not obtained in (b)
above drive pin (47) from manifold body 150) and remove spring (49) and washer (48). Replace washer (48)
and spring 149). Repeat (b) above.
e. Reassembly.
NOTE
At reassembly of carrier assembly. remember the carrier and its cover are a
matched assembly.
Be sure serial
numbers on cover and carrier are the
same and are alined. Covers and carriers of different planetaries should never
be switched. Serial numbers on both
pieces must be the same. New eightpitch gears have been released to replace the formerly used ten-pitch gears.
(1) Transmission housing assembly and related
parts reassembly.
(a) If bearing housing was removed from
transmission housing. install two headless guide bolts in
bearing housing (22, fig. 7-65).
(b) Chill bearing housing and install into front
cover end of transmission housing. aligning oil passages and bolt holes in bearing housing with transmission housing.
(c) Install self-locking bolts (9, fig. 7-65) that
retain bearing housing (22) through rear end of transmission housing (10). Tighten two bolts to a torque of
36 to 43 foot-pounds.
(d) Install two new seal rings (21 and 23) on
bearing housing (22).
(e) If bearing assembly (20) was removed from
rear end of bearing housing (22) install it with numbered
side out.
(f) Other parts in this group will be installed
when transmission is assembled from subassemblies.
(2) Transmission main shaft assembly reassembly.
If transmission main shaft sun gear (2, fig. 7-66) was
removed, install it and install external snaprings (1 and
3). Parts in this group will be installed when transmission is assembled from subassemblies.
(3) Low-range clutch assembly reassembly.
(a) Place transmission internal cover (4, fig.
7-65) hub side down, on worktable.
(b) Install two seal rings (1 and 3, fig. 7-95) on
low-range clutch piston (2).
Figure 7-95. Transmission low-range clutch assembly.
7-63
(c) Lubricate bearing surfaces of piston and corresponding surfaces in internal cover (4.fig. 7-65). Install piston,
hub side down, into cover.
(d) With external snapring (4, fig. 7-95) installed on low-range ring gear (5), install ring gear, snapring side down,
on piston (2).
(e) Install piston plate (6) spring-seat side up, in internal cover.
(f) Install four low-range clutch-friction plates (7) (internal splines) alternately with low-range clutch-reaction
plates (8) (external splines). Begin with an internal spline plate.
(g) With clutch-release springs (9) and clutch-release spring retainers (10) installed in clutch -backplate (11),
install backplate on top of clutch plates. Use a small diameter pin to make sure clutch-release springs are seated pro
perly in the counterbored seats of piston plate 161.
(h) Carefully install three assembling pins and cotter pins (fig. 7-87). Use a press or C-clamps to press down
evenly on low -range clutch backplate while installing three pins and cotter pins. After three pins and cotter pins areni
stalled, again check to make sure clutch-release springs (9, fig 7-95 ) are seated properly in piston plate (6).
(4) Intermediate-range clutch assembly reassernbly.
(a) Install seal ring (1, fig. 7-96) on piston (2).
Figure 7-96. Transmission, intermediate-range clutch assembly.
(b) Other parts in this group will be installed when transmission is assembled from subassemblies (131 below.
(5) High-range clutch assembly reassembly.
(a) Press ball bearing assembly on shaft end of clutch drum and sun gear assembly.
(b) Install small seal ring (6, fig. 7-97) on small hub of clutch drum (4) and sun gear assembly (2).
7-64
Figure 7-97. Transmission high-range clutch assembly.
(c) On later models, the high-range clutch-piston assembly includes two ball-type valves. The balls (7) must
move freely in their passages and should be retained by staking.
(d) Install two seal rings (1) on shaft end of clutch drum (4) and sun gear assembly (2).
(e) Other parts in this group will be installed when transmission is assembled from subassemblies.
(6) Reverse-range clutch assembly reassembly.
(a) Install seal ring (11, fig. 7-98) on piston (9).
7-65
(a) If ball bearing (2, fig. 7-76) and oil seal (1)
were removed, install bearing. If necessary, press ball
bearing into place. Press oil seal into position.
(b) Other parts in this group will be installed in
transmission during assembly from subassemblies.
(8) Planetary carrier assembly reassembly.
(a) Place planetary carrier assembly (18, fig.
7-89) small end down, on worktable.
(b) Install a well greased thrust washer (3) in
each of three cluster pinion cavities (the three deep
cavities) of carrier (fig. 7-99).
Figure 7-99. Installation of cluster pinion showing thrust
washer.
(c) Place a planetary cluster pinion (4, fig.
7-89), large end down on each of three thrust washers
(3).
(d) Remove pins from alinement cover fabricated from discarded planetary carrier cover. Chill
planetary cluster pinion pins (1). Install one chilled
planetary cluster pinion pin in alinement cover. Use
headless guide bolts to guide cover. Place a steel
spacer (5) under planetary cluster pinion (4) and, using a
screwdriver, lift thrust washer (3) against planetary
cluster pinion (fig. 7-100). Carefully press home planetary cluster pinion pin (1, fig. 7-89), making sure large
diameter of pin enters thrust washer. Check by rotating
thrust washer after pin is pressed home. Remove
spacer from underneath planetary cluster pinion. Repeat this operation for the other two cluster pinions.
Figure 7-98. Transmission reverse-range clutch assembly.
(b) Other parts in this group will be installed
when the transmission is assembled from subassemblies.
(7) Transmission adapter assembly reassembly.
7-66
Figure 7-100. Installation of planetary cluster pinion pin in planetary carrier.
(e) Place thrust washer (3) over pins, on planetary cluster pinion (4). If shoulder at top of pin is flush with thrust
washer, the pin is in proper position (fig. 7-101). If lower shoulders of pins have not entered thrust washers or thrust
washers are damaged, damage can lead to malfunctioning of transmission. Remove three thrust washers from the pins.
Figure 7-101. Thurst washers installed on planetary cluster pinions and pins.
7-67
(f) Fill a cluster pinion with oil soluble grease, Military Specification MIL-G-10924.
(g) Place a steel spacer (5, fig. 7-89) over planetary cluster pinion pin (1) and into planetary cluster pinion
(4)(fig. 7-102). With two needle bearings (6, fig. 7-89) push spacer down about ½ inch inside pinion and again put
grease between pinion pin and pinion.
Figure 7-102. Installation of spacer in planetary cluster pinion.
(h) Install needle bearings (6) in pinion to fill out row.
(i) Place a second steel spacer (5) on planetary clusterpinion pin (1). With two needle bearings (6), push
spacers and needle bearings down so that second row of needle bearings can be installed. Again, use grease, Military
Specification MIL-G-10924, to help keep needle bearings upright.
(j) Install a third steel spacer (5) and a third row of needle bearings (6).
(k) Install a fourth steel spacer (5) and push entire group of spacers and needle bearings (6) into planetary
cluster pinion (4). Note that steel spacer should be slightly less than flush with face of pinion.
(l) Repeat (f) through (k) above for the other two cluster pinions.
(m) Chill three planetary pinion pins (7). Place one chilled planetary pinion pin (7) in alignment cover, and using
headless bolts threaded in planetary carrier (19) to guide alinement cover, press planetary pinion pin (7) in carrier.
Repeat this operation for the other two planetary pinion pins.
(n) Install a washer (9) over each planetary pinion pin (7), (fig. 7-103).
(o) Install a planetary pinion (10, fig. 7-89) on each planetary pinion pin (7). Install spacer (11) over each pinion
in and into the planetary pinion (fig. 7-104).
Figure 7-103. Installation of thrust washer on pinion pin.
7-68
Figure 7-104. Installation of spacer in planetary pinion
(p) Install needle bearings (12, fig. 7-89) in planetary pinions (10), using grease to help keep them upright.
(q) Install second spacer (11. fig. 7-89) over planetary pinion pin (7) and into planetary pinion (10). Spacer must
be slightly less than flush with face of pinion.
(r) Install second washer 191 over planetary pinion pin (7) and into planetary pinion (10).
(s) Place planetary carrier cover (16) over pins. Aline indexing marks of planetary carrier cover with indexing
marks of planetary carrier (19). Check alinement of locking ball grooves. Press planetary carrier cover into position
against planetary carrier.
(t) Install locking balls (2 and 8) into grooves between pins and cover (fig. 7-90).
(u) Install oil seal (15, fig. 7-89) and oil collector ring (13) on planetary carrier cover (16) as shown in figure 7-90.
Secure with bolts (14, fig. 7-89). Bend metal of oil collector ring (13) up and against bolts.
(v) Press ball bearing assembly 1201. snapring groove up, on shaft end of planetary carrier. Use white lead, Fe
deral Specification TT- W-251, to lubricate the close fit.
NOTE
When pressing bearing on shaft. be sure assembly is resting on the bolt heads and not on oil collector
ring. Press or drive only on the inner race.
(w) Install bearing lockwasher (21, fig. 7-89) and bearing lock nut (22) on shaft end of planetary carrier (18). Use
special spanner wrench. part No. J4558, to tighten the nut. Bend tab of bearing lockwasher into slot in bearing locknut.
(x) Planetary gear end clearance with unit assembled is 0.063 inch maximum.
(9) Clutch drum and sun gear assembly installation.
(a) Lubricate seal ring (1. fig. 7-96) on intermediate-range clutch piston (2) and seal ring (23, fig. 7-65) on bearing
housing (221. Install piston.
(b) Install clutch drum (4. fig. 7-97) and sun gear assembly (2) in front cavity of transmission housing. Tap in position. Lay housing over on drum and sun gear assembly and tap other bearing (20. fig. 7-65) in place.
(c)Install external snapring on shaft end of clutch drum and sun gear assembly (fig. 7-84).
(10) Reverse-range clutch assembly installation.
(a) Lubricate seal ring (11, fig. 7-98) on piston (9) and seal ring (2). fig. 7-65) on bearing housing (22). Install piston
(9. fig. 7-98).
(b) Install reverse-range clutch plates (fig. 7-81). Install four reverse-range clutch-friction plates (7, fig. 7-98) n
iternal splines alternately with three reverse-range clutch-reaction plates c81 (external splines. Begin with an internalspline plate.
(c) Install reverse-range. clutch back plate assembly fig. 7-81).
NOTE
The slots on clutch friction plate. clutch-reaction;)n plates. and clutch backplates must be aligned (on
clutch pins (10. fig. 7-98). It is ) that the reverse-range clutch release springs (6) be squarely seated in
counterbores of reverse-range piston (9). Use a small diameter pin to seat springs.
7-69
(d) Install clutch spring compressor, part No. J7470 (fig. 7-80), to compress reverse-range clutch-back plate assembly. Install internal snapring in transmission housing.
(11) Planetary carrier and low-range clutch assemblies installation.
(a) Rotate each of the three sets of planetary pinions in planetary carrier assembly as a final check for free rot
ation. Place assembly on its side. Move pinions so index marks on planetary cluster pinions point toward center of carrier
(fig. 7-105).
Figure 7-105. Properly aligned index marks on planetary cluster pinions
(b) If two external snaprings and main shaft sun gear were removed, install them on center most spline of main shaft
(fig. 7-88). The three index marks and other etched markings on face of sun gear must face toward front end of transmi
ssion main shaft (front end is splined in two places .
NOTE
The etched T on certain sun gears indicates tapered teeth. This mark is for parts identification only.
(c) With the main shaft sun gear and two external snaprings installed on transmission main shaft, install main shaft
into carrier assembly (fig. 7-88). Turn main shaft approximately 60 degrees. This will keep main shaft from sliding out of
planetary gearing.
CAUTION
The main shaft sun gear must enter planetary cluster pinions so single index marks on sun gear
are between 7-70 double index marks on planetary cluster pinions (fig. 7-105). Rotate main shaft
several times after it is in place to make sure there is no binding between pinions and sun gear. If
there is bind- ing, gears are not indexed properly. Withdraw main shaft and sun gear and reindex
sun gear with planetary cluster pinions.
(d) Install reverse-range ring gear (2. fig. 7-98). Turn ring gear to pick up clutch-friction plates (7), and clutch-reaction
plates (8) until external snapring (1) on reverse-range ring gear (2) is in position against reverse clutch backplate (4).
(e) Using the improvised tool threaded on shaft end of planetary carrier assembly and a hoist. lower planetary gea
ring into transmission housing (fig. 7-79).
NOTE
Index reverse-range planetary pinions with reverse-range sun gear and reverse-range ring gear (fig. 7-105).
7-70
(f) Install the internal cover, low-range clutch plates and low-range ring gear (fig. 7-78). Install bolts.
NOTE
Index low-range clutch housing with transmission housing so low-range oilhole is alined in both housings.
(g) Install improvised tool on threaded end of output shaft (19, fig. 7-89). Lift up on output shaft so snapring
groove in ball bearing assembly 1201 is exposed. Install snapring (fig. 7-77),.
(12) Transmission adapter assembly installation.
(a) Install transmission rear cover (6, fig. 7-76), adapter gasket (7), bolts (9), and lockwashers (10).
(b) Install seal ring (5) on bearing retainer (3) and lubricate seal ring. Install bearing retainer on transmission
rear cover (6), and install bolts (12).
(13) High-range and intermediate-range clutch assemblies installation.
(a) Hoist transmission and tilt it with rear end down.
(b) Install external snapring that locates high-range clutch hub on transmission main shaft (fig. 7-73). If necessary, lift main shaft out enough to install snapring in groove.
(c) Lubricate large seal ring (5, fig. 7-97), small seal ring (6), piston (8), high-range clutch drum (4), and sun
gear assembly (2). Install piston, clutch-release spring seats facing out. (fig. 7-72) showing removal). Be sure balls (7, fig.
7-97) in piston move freely in their passages.
(d) Install high-range clutch hub (15) flat side down (fig. 7-106).
Figure 7-106. High range clutch hub installation
(e) Install three high-range clutch-friction plates (10, fig. 7-97) (internal splines) alternately with two high-range
clutch-reaction plates (11) (external splines). Begin with an internal-splined plate (fig. 7-107).
7-71
Figure 7-107. High range clutch plates installation
NOTE
The slots in clutch friction plates, clutch reaction plates, and clutch backplates must be aligned on clutch
pins (10, fig. 7-98).
(f) Place high-range clutch-release springs (12, fig. 7-97)in counterbored seats of high-range piston (8). Use
grease, Military Specification MIL- L-10924, on ends of springs to help keep them in place in piston.
(g) Place high-range clutch backplate (13) on clutch-release springs (12). Using a small- diameter pin, be sure
springs are seated properly in high-range piston (8) and clutch backplate.
(h) Install clutch spring compressor, part No. J7470. Compress high-range clutch pack. Install internal snapring
(14) in high-range clutch drum and sun gear assembly.
(i) Install two intermediate-range clutch- friction plates (3, fig. 7-96) (internal splines) alternately with one intermediate-range, clutch- reaction plate (4) (external spline) (fig. 7-69).
(j) Install intermediate-range clutch back- plate (7, fig. 7-96). Using a small diameter pin, be sure clutch-release
springs (5) are seated in counterbored seats of piston (2).
(14) Transmission front housing and cover installation.
(a) Carefully place front housing (31, fig. 7-65) and front housing gasket (30) on transmission housing (10). To
prevent unseating any intermediate-range clutch-release springs, draw down evenly bolts and lockwashers (35, 43, 34,
and 44) that retain front housing (31) .
(b) Install upper and lower transfer gear bearings (6 and 16, fig. 7-66) in transmission front housing (31, fig.
7-65).
(c) Install lower input transfer gear (I 4, fig. 7-66) on input shaft (12) and install external snapring (15).
(d) Press assembled shaft and gear into lower transfer gear bearing (16) in transmission front housing (31, fig.
7-65).
(e) Install upper input transfer gear (7, fig.7-66) on transmission main shaft (4).
(f) Install upper transfer gear bearing (8) on gear (7) and install washer (9), lockwasher (10), and bolt (11) on
shaft (4).
(g) Install bearing (13) on gear (14).
(h) Install cover gasket (36, fig. 7-65) and front housing cover (37) using dowel pins (32) to aline cover.
(i) Install lockwashers and bolts (38, 41, 39, and 40). Install oil seal (42) in front housing cover (37).
(j) Set transmission reasonably level on bottom of transmission housing.
(15) Minor subassemblies installation.
(a) Slide output flange (4, fig. 7-64) onto output shaft and install retainer ring (3i.
(b) Apply a coating of sealing compound, Military Specification MIL-S-7916, to retainer nut (1) face and threads
and mating surface on output flange. Place seal (2) in retainer nut and install retainer nut. Stake lip of retainer nut into
slots on output shaft.
(c) Coat lip of input flange oil seal (42,.fig. 7-65) and input shaft (12, fig. 7-66) splines with a
7-72
thin layer of bearing grease, Military Specification MIL-G-10924.
(d) Install input flange (8, fig. 7-64) on input shaft and secure with lockwasher (6) and bolt (5), torquing bolt to proper
specifications.
CAUTION
If flange seizes to the shaft prior to its final assembled position, it is necessary to pull flange and
repeat entire assembly procedure. Do not attempt to force flange with a hammer.
(c) Install oil strainer assembly (3, fig. 7- 63) and gasket (4) on transmission with capscrews (1) and lockwashers (2).
(f) Install range selector valve assembly (53, fig. 2-7) and gasket (54) on transmission with bolts (51) and
lockwashers (52).
(g) Install elbow (41) in manifold assembly (40) and install manifold assembly and gasket (39) on transmission with
bolts (43) and lockwashers (42).
f. Installation. Refer to paragraph 2-13.
7-7. Air Brake Assembly
a. Description. The air brake assembly is of the 360° segmented, shoe type, actuated by an ex- pander tube. The
brake assembly consists of an aluminum torque plate upon which the expander tube is mounted. Aluminum spacers and
steel side frames are attached to each side of the torque plate and held in position by bolts. Brake linings, mounted on
aluminum shoes, are inserted between torque bars bolted between the frames. The brake shoe assemblies are held in
position by retractor springs which also act as a positive means of exerting a retracting force to withdraw the lining from
the surface of the brake drum after air pressure has been released. The brake assembly is actuated by air which enters
the expander tube through a reducer inlet. The air pressure is exerted 360°around the expander tube, forcing the brake
shoe assemblies, which are bearing against the tube, to move radially against the inside diameter of the brake drum. Two
air brake assemblies are used on each miter box. A torque plate, which supports the expander tube, brake shoe
assemblies, and retractor springs, is mounted over each end of the miter box input shaft and is secured to the miter box
mounting surface with bolts. The brake drums are mounted on each end of the miter box input shaft and are secured to
the coupling flanges with bolts. When the brakes are applied, the brake assemblies restrain the miter box input shaft.
b. Removal Refer to paragraph 2-14.
c. Disassembly.
(1) To disassemble brake drum assembly (2) fig. 7-108), remove 12 capscrews (22), lockwashers (20), and nuts (19)
and separate brake drum (17) from mounting plate (18).
7-73
Figure 7-108. Air break assembly
(2) To remove brake shoe assemblies (4), place a screwdriver, padded with leather or heavy canvas to prevent
nicking frame (11), against spring hooks of retractor springs (5) and with a sharp blow disengage springs from frame.
Drive the springs through the brake assembly (14) and out of the assembly (fig. 7-109).
7-74
Figure 7-109. Removing retractor springs.
7-75
(3) After retractor springs (two per brake shoe assembly) have been removed, the brake shoe assemblies and
expander tube shields 16, fig. 7-108) may be lifted from their position.
NOTE
If brake shoe assemblies are to be reused, keep the brake shoe assemblies in the same order as they were removed.
Brakes may be relined without further disassembly. To complete disassembly, perform the following steps.
(4) Remove 12 bolts (9), washers (2), and self-locking nuts (1 ) and remove 12 torque bars (3).
(5) Remove 11 bolts (10), washers (2), self- locking nuts (1), frames (11), and spacers (12).
(6) Slip expander tube assembly (15) off torque plate (13). Remove two preformed packings (16) from expander
tube assembly nozzle.
(7) Remove reducer (7) and preformed packing (8) from torque plate.
d. Cleaning, Inspection and Repair.
(1) Clean all parts, except preformed packings (8 and 16, fig. 7-108), in dry-cleaning solvent, Federal Specification
P-D-680, and dry with low pressure air (10 psi).
(2) Check lining of brake shoe assembly (4)
The lining may be worn down to approximately 11/64 (0.172) inch minimum thickness if it is in good condition without
evidence of cracking or chipping.
NOTE
When new, the lining is approximately 0.431 inches thick; but this dimension varies slightly because the brake
lining is ground in assembly. The brake diameter is held rather than the lining thickness. The bonded, curved
lining may tend to straighten out after considerable app6cadon of pressure and temperature, giving the
appearance of bond failure between lining and shoe. The bond, however, is still intact and usefulness of the
lining is unaffected. The friction or braking surface of the shoe may develop ridges and grooves and the leading
edge. that which is in the direction of rotation. tends to wear slightly uneven. This situation is normal.
(3) Inspect the area of the brake shoe assembly upon which the retractor spring (5) rests. If the spring has worn to a
depth greater than 1 / 16 (0.0625) inch. replace the brake shoe assembly.
(4) Check for broken or deformed retractor springs. Replace spring if broken or deformed or if permanent set
reduces free spring height more than 1/16 (0.0625) inch.
(5) Inspect torque bars (3) for unusual wear or distortion. Replace torque bar if unusual wear or distortion is present.
(6) Inspect frames (11) for distortion and elongation of torque bar and frame holes. Replace frame if these conditions
exist.
(7) Inspect torque plate (13) for cracks or distortion. Replace torque plate if cracked or distorted.
(8) Check expander tube assembly (15) for cracks, charring, or hardness of outer surface. If any of these conditions
exist, replace expander tube assembly.
(9) Check expander tube assembly for leaks. by applying 75 psi (maximum) and immersing expander tube assembly
in water. Replace a leaking expander tube assembly.
(10) Not all drums will show the conditions in figure 7-110. Some drums may show none of them. and others may
have them in various combinations. The flux used to help bond the cast iron to the steel sometimes works to the surface
of the drum at the junction of shell and cast iron lining, at the outer machined edge, or may appear on the braking inner
diameter of the drum. When exposed to the atmosphere, it absorbs moisture and gives the appearance of corrosion. This
condition is not harmful and requires no special service.
7-76
Figure 7-110. Brake drum assembly.
(11) Excessive heat at the braking surface is called a heat check. When the heat check progresses to the steel shell,
remove drum from service and replace it with a new brake drum. Transverse heat checks do not aggravate lining wear,
as indicated if one or two circumferential cracks appear extending around the drum and to the shell. If this condition
increases the drum diameter to 15.150 inches, replace it with a new drum. The outer surface of the drum is painted with a
heat resisting paint which will withstand temperatures up to 1,500° F. Because of the various high and low rises in
temperature, rust will form; but this does not affect the braking and will not cause failure. The drum bolt holes are 0.333
inch diameter and can tolerate 1 / 32 inch elongation and are serviceable. If elongation is of a greater diameter, replace
the brake drum.
(12) The steel reinforcing ring welded to the outside diameter of the brake drum is a safety feature to strengthen the
drum. This steel ring may loosen in normal service and rattle, but this does not warrant removing the drum.
e. Reassembly.
(1) Install preformed packing (8, fig. 7-108) on reducer (7), being careful not to damage packing on threads.
(2) Install reducer in inlet port of torque plate (13). Tighten reducer until it bottoms tightly on spot faced surface.
(3) Install two preformed packings (16) on nozzle of expander tube assembly (15).
(4) Lubricate preformed packings to prevent damage to packings, then insert expander tube assembly. nozzle into
cast inlet on torque plate and hold in position. Slide expander tube assembly onto torque plate 'by applying downward
pressure in progressive moves around the torque plate in both directions away from nozzle.
(5) Assemble spacers (12) and frames in position and install 1I bolts (10), washers (2), and nuts (1). Tighten bolts to
a torque of 80 to 100 inch-pounds.
(6) Install 12 torque bars (3), with wide portion of bar positioned so that it will be between adjacent brake shoe
assemblies, using 12 bolts (9),
7-77
washers 2 1, and nuts (1). Tighten bolts to a torque of 80 to 100 inch-pounds.
(7) Place a brake shoe assembly (4) between torque bars and insert an expander tube shield 16) between brake shoe
assembly and expander tube assembly.
NOTE
All brake shoe assembly linings should be approximately the same thickness. Large differences, in
thickness will put undue strain on expander tube assembly.
(8) Place a second brake shoe assembly in an adjacent opening on top of the expander tube shield.
(9) Install two retractor springs (5) in the brake assembly between the two brake shoe assemblies (fig. 7-111).
7-78
Figure 7-111. Installing retractor springs.
7-79
(10) Insert an expander tube shield under the loose end of the two previously installed brake shoe assemblies.
(11) Repeat steps (8) through (10) above until all brake shoe assemblies are installed.
(12) Check brake assembly (14, fig. 7-108) dimension to see that brake diameter does not exceed 14.965 inches. If
diameter exceeds this dimension, grind brake until within limits. Maximum diameter is 14.965 inches and minimum
diameter is 14.935 inches.
(13) Pressure test the completed brake assembly (14) in a brake drum assembly (21) at 100 psi for 5 minutes.
(14) Assemble brake drum (17) to brake drum mounting plate (18) using 12 capscrews (22), lockwashers (20), and
nuts (19). Tighten moderately four capscrews diametrically opposite and at 90' . Stragger-tighten remaining diametrically
opposite bolts.
NOTE
The brake drum flange is machined to fit on the mounting plate register with slight clearance.
f. Installation. Refer to paragraph 2-14.
7-8. Miter Box Assembly
a. Removal and Disassembly. Refer to paragraph 2-15.
NOTE
In order to remove the miter box assembly, it is necessary to disassemble the miter box assembly in place.
b. Cleaning, Inspection and Repair.
(1) Clean all parts except seals (24, 38, and 50, FO-2), preformed packings (44 and 47), and gasket (58), in drycleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10 psi).
(2) Check coupling flange (14, fig. 2-8) for grooved condition where coupling flange mates with seal (24,FO-2). If
groove depth exceeds 0.005 inch, replace coupling flange.
(3) Check coupling flange spline id between teeth. If id exceeds 2.503 inches, replace coupling flange.
(4) Check od of spline teeth on input shaft assembly (6). If od of spline teeth is less than 2.495 inches, replace input
shaft (64).
(5) Inspect contact areas of gears (34 and 63) for spalling, pitting, or wear. If more than 20 units of the contact area
of any face is damaged by spalling or pitting, or if more than 0.015 inch of metal is worn from any face, replace gear.
(6) Inspect bearing cups (26), bearing cones (62), bearing inner race (31), and outer race (28) for pitted, scored, or
burned condition.
(7) If bearing cups (26) and cones are defective, check diameter of input shaft bearing retainer (25) in bearing cup
area and od of input shaft in bearing cone area. If wear exceeds limits specified in table 2-1, replace input shaft bearing
retainer and/or input shaft.
(8) If bearing inner race (31) and bearing outer race (28) is defective, check diameter of output shaft bearing yoke
(29) in outer race area and od of output shaft (32) in inner race area. If wear exceeds limits specified in table 2-1, replace
output shaft bearing yoke and / or output shaft.
(9) Check output shaft assembly (20) for roughness of rotation. If output shaft binds or feels rough when rotated,
disassemble output shaft assembly and check bearings (37) for pitted, scored, or burned condition. If either bearing is
defective, replace bearings with a new matched set.
(10) If bearings (37) are defective, check diameter of output shaft bearing carrier (39) in bearing area and od of
output shaft in bearing area. If wear exceeds limits specified in table 2-1, replace bearing carrier and / or output shaft.
(11) If output shaft assembly is disassembled, replace output shaft bearing seal (38).
(12) If output shaft coupling gear (40) is removed, check spline wear on coupling gear and output shaft. If wear
exceeds limits specified in table 2-1, replace coupling gear and / or output shaft. Check for a grooved condition on
coupling gear where coupling gear mates with output shaft bearing seal (38). If groove depth exceeds 0.005 inch, replace
coupling gear.
(13) Check gear teeth of output shaft coupling gear for wear. Chordal measurement over any five teeth should not be
less than 1.716 inches. If chordal measurement is less than 1.1716 inches, replace coupling gear.
(14) If gear teeth of output shaft coupling gear are excessively worn, remove column and wheel drive and check
female coupling gear (49), male coupling gear (46), intermediate shaft (48), and female coupling gear on column and
wheel drive for excessive wear (table 2-1). Replace coupling gear (46 and 49) and intermediate shaft (48) if defective. If
coupling gear on column and wheel drive is defective, report to fourth echelon. Replace preformed packing (47).
(15) If bearing carrier (52) is removed, inspect bearing (53) for pitted, scored, or burned condition and replace seal
(50).
(16) Replace seals (24) and preformed packing (44).
(17) Inspect shim sets (5 and 8),for damage. If shim set is damaged, replace damaged shim with a new shim of
same thickness.
(18) Inspect case (19) and case cover (59) for cracks, breaks, or other structural damage. Replace a damaged case
or case cover.
7-80
(19) Check breather (56) for obstructions or damage. If breather cap will turn loosely, breather is satisfactory.
(20) Inspect inspection cover (57) and eye bolt (55) for good condition. If inspection cover was removed, er place gasket (58).
c.
Reassembly and Insulation. Refer to paragraph 2-15.
d.
Gear Mesh and Bearing Adjustment.
(1) Remove female coupling gear (49, FO-2) from intermediate shaft (48)
(2) Position shim set (8) in case (19), being careful not to damage shim set.
(3) Lower output shaft assembly (20) into case. Position bearing yoke (29) opening as shown in figure 2-9 for
the particular miter box assembly installation involved.
(4) Install two capscrews (21, FO-2) and two capscrews (7) Tighten to hold yoke securely. Dc not secure with
lock wire.
(5) Lightly coat several teeth on gear in output shaft assembly with gear marking compound, red lead, Federal
Specification TT-R-191 B, Type 1, or equivalent.
(6) Position input shaft assembly (6) over output shaft assembly and assemble each bearing retainer assembly
(4), with corresponding shim set (5) on respective end of input shaft assembly and case. Install six capscrews (22) in
each bearing retainer assembly. Do not secure capscrews with lock wire.
(7) If input shaft assembly is axially loose, remove the same amount of shims from each shim set (5) until a
slight amount of drag is felt in bearings when input shaft is rotated, then add 0.003 inch shim to each shim set. If input
shaft is tight, add shims equally to each shim set until a slight amount of drag is felt in bearings when input shaft is or
tated, then add 0.003 inch shim to each shim set.
(8) Check backlash in gear set by securing indicator rigidly to case with actuator point against and perpendic
ular to gear tooth face. Backlash should be 0.008 to 0.012 inch.
(9) Rotate input shaft sufficiently to mark pinion tooth contact with compound painted-on driven gear. Ideal
tooth contact is slightly nearer the toe than the heel as shown in detail A. figure 7-112.
Figure 7-112. Bevel gear meshing pattern
(10) When the contact is too high on pinion and too low on driven gear. as shown in detail B. figure 7-112, the
pinion is too near the center. If the backlash was too small. move pinion away from center by shimming. If the backlash
was too great. shim driven gear toward pinion.
NOTE
When shimming pinion. take shims from one shim set and add to the other to maintain input shaft assembly bearing adjustment.
7-81
(11) When the contact is too low on pinion and too high on driven gear. as shown in detail B. figure 7-112, the
pinion is too far from center. If the backlash was too great, shim pinion toward center. If the backlash is too small, shim
driven gear away from center.
NOTE
When shimming pinion. take shims from one shim set and add to the other to maintain input shaft assembly bearing adjustment.
(12) Repeat steps (10 and 11) above until proper tooth contact and backlash are obtained.
(13) Remove capscrews (22, FO-2) and lift off bearing retainer assemblies (4). shim sets (5) and input shaft assembly 16i. Keep each shim set with its respective bearing retainer assembly.
(14) Remove capscrews 1(7 and 21) and remove output shaft assembly (20) and shim set (8).
(15) Install female coupling gear (49) on intermediate shaft (48). and reassemble miter box assembly as outlined in paragraph 2-15, c(1), (e), 3 through 10 above.
7-9. Tires
a. Tire Removal. Refer to paragraph 2-19.
b. Cleaning. Inspection and Repair.
(1) Remove all penetrating objects from tire.
(2) Inspect for cuts, ply separation is sidewall or tread. damaged beads, softened rubber due to oil or solvent
soaking, and weakening due to age or exposure.
(3) Tire repair will be performed only at depot maintenance level. Unserviceable tires should be exchanged
through proper channels for suitable replacement.
c. Tire Installation. Refer to paragraph 2-19.
7-10. Column and Wheel Drive Assembly
a. Description. The column and wheel drive assembly Fig. 3-113) transmits the output torque of the miter box assembly to the wheels. The vertical output rotation from the miter box assembly is converted to horizontal rotation by a
bevel pinion and gear. The bevel gear in turn is splined to the axle, which drives a spur gear in the planetary reduction
gearing. The spur gear drives three planet gears, attached to the wheel, which walk around the stationary planetary ring
gear. The column and wheel drive assembly swivels to facilitate steering, thereby serving as a link in the steering system
between the wheel and steering cylinders. The miter box case serves as the upper pivot support and a bracket assembly
attached to the frame at the bottom of the column and wheel drive assembly serves as the lower pivot support. The bevel
gear, axle, planetary gears, and associated bearings run in an oil bath; however, the bevel pinion and associated bea
rings are force- lubricated by an oil pump. The wheel bearings also run in the oil bath. An air tube runs through the center
of the axle to provide for tire inflation and deflation. The air tube, planetary reduction gearing, and axle can be removed
without removing the column and wheel drive assembly from the LARC or the tire and wheel assembly from the column
and wheel drive assembly. In order to remove the column and wheel drive assembly. the tire must be removed and the
miter box assembly disassembled. The wheel assembly may be removed *with the column and wheel drive assembly.
b.
Removal. Refer to paragraph 2-16.
c.
Disassembly.
(1) Loosen end plug (111. fig. 7-113) and remove capscrews (118) Iockwashers (119). and remove air line
pipe and seal assembly (110).
CAUTION
Exercise care during removal of air line pipe approximate length is 4-1/2 feet) to prevent bending or
scoring surface.
(2) Remove pipe plug (111) and remove seals (112).
(3) Remove end plug (111) and preformed packing (112)
(4) Remove air line pipe (117) - and preformed packing (113).
(5) Remove preformed packing (116) and gasket (115) from air seal retainer (113).
(6) Remove check release pin assembly and gasket (82).
(7) Remove cross pin (81) and remove preformed packing (79) and check release pin 78) from check release
pin bushing (80)
(8) Remove check release pin seat (83), gasket (84) preformed packing (85) gasket (86). check valve body
(89). and spring (87)
(9) Remove 12 nuts (120).
(10) Remove three capscrews (92) and lockwashers (91).
(11) Install three 1 x 14 NF2 x 3 inch long jacking bolts (93) in place of capscrews (92) with suitable sling attached to jacking bolts. Remove collets (121) by driving a wedge into the opening of collet.
CAUTION
Jacking out the collets with the planet spider housing, could result in damage to the housing if a collet is
frozen to a wheel stud.
(12) Using jacking bolts. disengage planet spider assembly (95) from wheel assembly (123)
(13) Remove planet spider assembly and 12 collets (121).
7-82
(14) Remove 12 capscrews (107) and retainers with seal washers (106).
(15) Remove 18 capscrews (108) and lock- washers (109) and remove end plates (105) and shim sets (104).
NOTE
Keep each shim set with its respective end plate and mark as to location on planet spider (103). Matchmark idler shafts (102) and planet spider.
(16) Successively press idler shafts out of planet spider from end plate end, then remove corresponding planet gear
and bearing assembly (96).
NOTE
Mark each idler shaft and planet gear and bearing assembly as to location in planet spider (103).
(17) Remove spur pinion (101) from planet spider.
(18) Separate bearing cones (97) from bearing cups (98) and with drift, drive one bearing cup from planet gear (99).
Remove snapring (100) and press out other bearing cup.
NOTE
Each bearing cone and cup must be kept together as an assembly. Do not interchange if original shim sets
are to be used.
(19) Install a 1 1/4 x 7NC x 12 inch long bolt in threaded end of main axle (94) and pull the axle straight out.
CAUTION
Do not allow the axle to drop free when it clears spline in the planetary ring gear.
(20) Remove four capscrews (72) and slide reaction member and planetary ring gear assembly (73) out of spindle.
(21 ) Remove snapring (76) and slide planetary ring gear (74) off reaction member (75).
(22) Remove capscrew (129) and remove locknut (71).
(23) Pull wheel assembly (123) off spindle using a forklift truck or similar piece of equipment.
NOTE
Outer bearing cone (70) will come off with wheel assembly and inner bearing cone (125) should remain on
spindle. Bearing cups (124) and (69) will remain in wheel assembly. It is not necessary to remove bearing
cups from wheel assembly unless inspection reveals bearing cups or cones to be defective.
(24) Pull inner bearing cone (125) from spindle.
(25) Remove seals (126) from seal ring (25).
(26) Remove 12 capscrews (127) and lock-washers (128) and remove seal ring (25).
(27) Place steering post (8) in horizontal position with spindle (19) up. Remove capscrews (26) and lockwashers (27)
from spindle.
(28) Remove capscrews (23), lockwashers (24), and install bolts (22) in place of cap screws (23).
(29) Loosen capscrews (21) and, using bolts (22), separate spindle (19) from steering post (8).
(30) Attach suitable sling to spindle (19), remove capscrews (21), lockwashers (20), and spindle from steering post
(8).
(31) Remove retainer plate (18) from spindle (19).
(32) Install eyebolts (17) in holes provided in bearing carrier (16). Lift out bearing carrier and forward spider bearing
(15) by attaching suitable sling to carrier.
(33) From opposite side of steering post (8), remove capscrews (48), lockwashers (47), capscrews (50), and retainers
with seal washers (49) from bevel gear spider bearing cover (6). Remove bevel gear spider bearing cover and bevel gear
shim (7).
CAUTION
Be extremely careful not to damage shim set. This shim set in conjunction with the pinion shim set
adjusts the bevel gear set.
(34) Remove two capscrews (14), 180 degrees apart, from spider assembly (10). Replace with eyebolts (13).
(35) Remove cotter pin (32), nut (40), and washer (41) and pull pump gear (33) from oil pump shaft.
(36) Attach suitable sling to spider assembly (10) and lift spider assembly, gear (9), bearing housing (28), aft spider
bearing (29), washer (30), and locknut (31) from steering post (8) as an assembly.
(37) Remove locknut (31), washer (30), after spider bearing (29), and bearing housing (28) from spider assembly
(10).
(38) Remove capscrews (14) and bevel gear (9) from spider assembly (10).
(39) The spur gear (11) is not ordinarily removed from spider (12). If replacement is required, press or drive spur
gear off spider.
(40) Remove hose (45) at elbow (44). Remove nuts (38), retainers with seal washers (37) and copper washers (36)
from bolts (35). Pull oil pump assembly from steering post (8).
(41) Remove capscrews (34) and oil pump (43) from oil pump bracket (42).
(42) From inside of steering post (8), remove capscrews (62) and pull bevel pinion assembly (51) from steering post.
(43) Remove cotter pin (68), nut (67), bevel
7-83
pinion shin (52), and bevel pinion coupling 165) from bevel pinion (56).
(44) Remove capscrews (61), retainer plate (60), and bevel pinion bearing yoke 159) from bevel pinion (56). Remove
retainer ring (57) from bevel pinion bearing yoke and press out bevel pinion bearing (58).
(45) Using suitable press, support assembly at lower portion of bevel pinion bearing adapter (53). Press bevel pinion
(56) from bevel pinion bearing adapter.
(46) Press lower bevel pinion bearing cone (55) from bevel pinion (56). Remove upper bevel pinion bearing cone
(64), upper bevel pinion bearing cup (63), and lower bevel pinion bearing cup (54) from bevel pinion bearing adapter (53)
only if replacement is necessary.
7-84
Figure 7-113. Column and wheel drive assembly (sheet 1 of 5 )
7-85
Figure 7-113. Column and wheel drive assembly (sheet 2 of 5 ).
7-86
Figure 7-113. Column and wheel drive assembly (sheet 3 of 5 ).
7-87
Figure 7-113. Column and wheel drive assembly (sheet 4 of 5 ).
7-88
Key to figure 7-13.
1 Pipe plug
2 Seal
3 Hose, flexible
4 Coupling, swivel
5 Nipple
6 Bevel gear spider bearing. cover
7 Bevel gear shim
8 Steering post
9 Bevel gear
10 Spider assembly
11 Gear, spur
12 Spider
13 Eyebolt
14 Capscrew
15 Forward spider bearing
16 Bearing carrier
17 Eyebolt
18 Retainer plate
19 Spindle
20 Lockwasher
21 Capscrew
22 Bolt, jacking
23 Capscrew
24 Lockwasher
25 Seal ring
26 Capscrew
27 Lockwasher
28 Bearing housing
29 Aft spider bearing
30 Washer, gear spider
31 Slotted nut, gear spider
32 Cotter pin
33 Pump gear
34 Capscrew
35 Bolt
36 Washer, copper
37 Retainer with seal washer
38 Nut
39 Key
40 Nut, castellated
41 Washer
42 Oil pump bracket
43 Oil pump
44 Elbow
45 Hose, oil
46 Plug
47 lockwasher
48 Capscrew
49 Retainer with seal washer
50 Capscrew
51 Bevel pinion assembly
52 Bevel pinion shim
53 Bevel pinion bearing adapter
54 Lower bevel pinion bearing cup
55 Lower bevel pinion bearing cone
56 Bevel pinion
57 Retaining ring
58 Bevel pinion bearing
59 Bevel pinion bearing yoke
60 Retaining plate
6I Capscrew
62 Capscrew
63 Upper bevel pinion bearing cup
64 Upper bevel pinion bearing cone
65 Bevel pinion coupling
66 Washer
67 Nut, castellated
68 Cotter pin
69 Cup, bearing outer
7O Cone, bearing, outer
71 Locknut
72 Capscrew
73 Gear assembly, reaction member and
planetary ring
74 Planetary ring gear
75 Reaction member
76 Snap ring
77 Tire inflation valve
78 Pin, check release
79 Packing, preformed
80 Bushing, check release pin
81 Pin, cross
82 Gasket
83 Seat, check release pin
84 Gasket
85 Packing, preformed
86 Gasket
87 Spring
88 Guide rod
89 Check valve body
90 Cushion
91 Lockwasher
92 Capscrew
93 Bolt, jacking
94 Main axle
95 Planet spider assembly
96 Planet gear and bearing assembly
97 Cone, bearing
98 Cup, bearing
99 Planet gear
100 Snapring
101 Spur pinion
102 Idler shaft
103 Planet spider
104 Shim set
105 End plate
106 Retainer with seal washer
107 Capscrew
108 Capscrew
109 Lockwasher
110 Pipe and seal assembly, air line
I11 Plug, end
112 Packing, preformed, air line end plug
113 Packing, preformed, air line
114 Air seal retainer
115 Gasket
116 Packing, preformed, air seal retainer
1 1T Pipe, air line
118 Capscrew
119 Lockwasher
120 Nut
121 Collet
122 Fitting, lubrication
123 Wheel assembly
124 Cup bearing, inner
125 Cone, bearing, inner
126 Seal
12 7 Capscrew
128 Lockwasher
129 Capscrew
7-89
Figure 7-113. Column and wheel drive assembly (sheet 5 of 5 ).
7-90
d. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Dry with compressed air (10 psi).
(2) Inspect upper and lower bevel pinion bearing cups (54 and 63, fig. 7-113), and upper and lower bevel pinion
bearing cones (55 and 64) for pitted, scored, or burned condition. Replace if defective.
(3) Inspect contact areas of bevel gear (9) and bevel pinion (56) for spalling, pitting, or wear. If more than 20 percent
of contact area of any face is damaged by spalling or pitting, or if more than 0.015 inch of metal is worn from any face,
replace bevel gear and bevel pinion.
(4) If inspection revealed a defective bearing cone (55 and 64), check bevel pinion (56) for signs of scoring in bearing
areas. Check bearing and splined areas of bevel pinion for dimensions given in figure 7-114. If dimensions do not meet
limits given in figure 7-114, replace bevel pinion.
(5) Inspect bevel pinion coupling (65, fig. 7-113) splined areas for stripped, twisted, chipped, or burred condition.
Remove burrs with soft stone, Military Specification MIL-S-2389. If dimensions of bevel pinion coupling exceed limits
specified in table. 1-2, replace coupling.
(6) Check bearing housing (28) and bevel pinion bearing adapter (53) for wear. If dimensions exceed limits specified
in table 1-2, replace housing and / or adapter.
(7) Check bearing carrier (16) id. If id exceeds 9.8440 inches, replace bearing carrier.
(8) Inspect spider assembly (10) for structural defects such as cracks, breaks, or wear Replace damaged spider
assembly. If dimensions do not meet limits given in figure 7-115, replace spider assembly.
Figure 7-114. Bevel pinion dimensions and wear limits.
7-91
Figure 7-115. Gear spider dimensions and wear limits.
(9) Inspect pump gear (33, fig. 7-113) for chipped or broken teeth, or for wear that may have destroyed original tooth
shape. Replace damaged gear. If chordal measurement over three teeth is less than 0.957 inch, replace gear.
(10) Replace air line pipe (117) if bent or scored-in seal area.
(11) Inspect spring (87) for full free length of 8 1/2 inches. If length is shorter, replace spring ,with a new one.
(12) Inspect cushion (90) for deterioration. Replace deteriorated cushion.
(13) Inspect spur pinion (101) and planet gears (99) for excessive wear (table 1-2). If more than 20 percent of the
area of any gear tooth is damaged by spalling or pitting, replace gear.
(14) Inspect bearing cones (97) and cups (98) for pitted, scored, or burned condition. Replace if defective.
NOTE
If inspection revealed a frozen or damaged bearing cone, check od of idler shaft in bearing area. If od of
idler shaft is less than 3.999 inches in bearing area, replace idler shaft.
(15) Check snaprings (100), end plates (105), and shim sets (104) for good condition. Replace a defective snapring,
end plate, or shim.
NOTE
If a shim is defective and original bearing cups and cones, idler shaft, and gear are to be used, replace
shim with a new shim of same thickness.
(16) Inspect planet spider (103) for structural
7-92
defects such as cracks or breaks. Replace a defective planet spider.
(17) Inspect main axle (94) for chipped or worn splines. If od of splines, when measured over 0.4800 inch
diameter pins, is less than 4.71280 inches, replace axle.
(18) Inspect planetary ring gear (74) and reaction member (75) for excessive wear (table 1-2). If more than 20
percent of any gear tooth on planetary ring gear or reaction member is damaged by spalling or pitting, replace ring gear
or reaction member. Check snapring (76) for good condition. Replace a defective ring gear, reaction member, or
snapring.
(19) Replace seals (126).
(20) Inspect bearing cones (125 and 701 and cups (124 and 69) for pitted, scored, or burned condition. Replace if
defective.
(21) Check wheel assembly 1123) for fractures- or cracks. Replace a defective wheel.
(22) Check studs on wheel assembly for good condition. Replace a defective stud.
(23) Check locknut (71) for good condition.
Replace a defective locknut.
e. Reassembly.
(1) Press lower bevel pinion bearing cup (54, fig. 7-113) and upper bevel pinion bearing cup (63) into bevel
pinion bearing adapter.
(2) Install lower bevel pinion bearing cone (55) on bevel pinion (56).
(3) Position bevel pinion (56) in bevel pinion bearing adapter (53) and install upper bevel pinion bearing cone
(64) on bevel pinion.
(4) Install bevel pinion coupling (65), washer (66), and nut (67). Tighten nut to obtain a 2½ to 3½ pound preload
on the outside diameter of bevel pinion bearing adapter (53) and install cotter pin (68).
NOTE
To measure amount of preload. wrap a string around the outside of bevel pinion bearing adapter (53) and
attach a spring scale to free end of string. A force of 2½ to 3½ pounds should just cause the adapter to rotate.
(5) Install bevel pinion bearing 158) and retainer ring 157) in bevel pinion bearing yoke (59).
(6) Install bevel pinion bearing yoke 1591 on bevel pinion (56) and secure with retainer plate 160) and
capscrews 1611.
(7) Mount bevel pinion assembly 1511 in steering post 18) with original bevel pinion shim (52) in place. Secure
with capscrews 162). Do not secure with lock wire.
NOTE
Before installing oil pump (43) in wheel column, submerge the pump in oil and rotate pump shaft several
revolutions in each direction to insure that the pump %ill pump oil in both directions.
(8) Position oil pump (43) on oil pump bracket (42) and secure with capscrews (34).
(9) Mount oil pump and oil pump bracket in steering post 181 with bolts 1351, using copper washers (36) under
bolt heads and sealing compound Military Specification MIL-S-7916. around bolts to prevent leakage. Secure oil pump
bracket 142) to steering post (8) with seal washers (37) and nuts (38).
(10) Install elbow 1441 and hose 14.;) to oil pump 1431.
(11) If spur gear (11) was removed from spider (12). heat spur gear and press or drive on spider.
CAUTION
Be careful not to drive or press on gear teeth when installing spur gear. Do not heat spur
gear to more than 400°F.
(12) Install bevel gear (9) on spider assembly (10) with capscrews (14) and secure with lock wire.
(13) Install bearing housing (28) over aft spider bearing (29).
(14) Place aft spider bearing (29) on spider assembly (10) with flange of bearing housing (28) toward bevel gear
(9).
(15) Install washer (30) and slotted nut (31) on spider assembly (10) tighten locknut securely and lock by bending
flange of washer into nut slot.
(16) Press forward spider bearing (15) onto forward end of spider assembly (10).
(17) Paint several teeth of bevel gear (9) with gear marking compound. red lead. Federal Specification TT-R191 Type 1. and insert spider assembly into steering post.
(18) Install bevel gear spider bearing (over (6) with original bevel gear shim (7) in place. Secure bevel gear
spider bearing cover to steering post (8) with lockwashers (47), capscrews (48). seal washers (49). and capscrews (50).
(19) Install washer (41). key (39), and pump gear (33), and secure with nut (40) and cotter pin (32). Reposition
pump if necessary, for proper gear backlash (0.004 to 0.006 inch).
(20) Install bearing carrier (16) on steering post (8). Aline notch on bearing carrier with dowel pin on steering post
and tap the bearing carrier with a soft mallet until it bottoms on seat.
(21) Check backlash in bevel gear set by securing an indicator rigidly to case with activator point against and
perpendicular to gear face. Use value etched on gear. If backlash is not etched on gear, correct backlash should be
0.012 to 0.016 inch).
7-93
(22) Rotate pinion shaft sufficiently to mark contact of pinion teeth with compound painted on driven gear. Ideal
tooth contact is slightly nearer the toe than the heel (detail A, fig. 7-112).
(23) When contact is too high on pinion and too high on driven gear, pinion is too near center (detail B)
. Shim
pinion away from center, making adjustments with bevel pinion shim (52, fig. 7-113)
(24) When contact is too low on pinion and too high on driven gear, pinion is too far from center (detail C,
fig. 7-112). Shim pinion toward center, making adjustments with bevel pinion shim (52, fig. 7-113).
(25) Repeat steps (24) and (25) above until proper tooth contact is obtained. Check backlash of gear. Adjust
bevel gear shim (7) to obtain correct backlash (0.012 to 0.016 inch if value is not etched on gear ).
(26) Install two guide pins (5/8 in. - 11 NC, 10 in Ig., threaded on one end) into retainer plate (18) for alinement of
reaction member with the retainer plate during mounting of reaction member.
(27) Place retainer plate (18) with installed guide pins into spindle (19).
(28) Apply sealing compound. Military Specification MIL-S-7916, around bolting flange of spindle (I9) and install
spindle on steering post (8).
(29) Secure spindle to steering post with lock- washers (20) and capscrews (21). Tightencap- screws to a torque
of 1000 to 1200 foot-pounds.
(30) Install lockwashers (27) and capscrews (26). Tighten capscrews to torque of 600 to 700 foot-pounds.
(31)I Install lockwashers (24) and capscrews (23) to provide dust covers for jacking holes.
(32) Test steering post and spindle for leaks as follows:
(a) Blank off spindle (19) using locknut (7) 1/8 inch thick rubber gasket material, Military Specification MIL-R1149A, Type 1, Class 2, 1/4 inch thick flat metal plate and four "C" clamps.
(b) Blank off steering post (8) using column nut (10, FO-2), I/8 inch thick rubber gasket material, Military
Specification MIL-R-1149A, Type 1, Class 2, 1/4 inch thick flat metal plate and four "C" clamps.
(c) Connect air hose to plug hole (46, fig. 7-113).
(d) Apply 10 psi gage air pressure and test steering post and spindle for leaks, using soap solution method.
Upon completion of test, remove blanks from spindle (19). Do not remove blanks from steering post (8) at this time.
(33) Tap and thread tire air inlet-outlet hole in center of wheel rim with a 1 1/4 inch pipe tap, 3/4 inch deep. Clear
cuttings from air passages in wheel with compressed air.
(34) If bearing cups (69) and 124 were removed, press bearing cups into wheel assembly (123).
(35) Install three seals (126) in -.heel hub. Install the first two seals with lips toward the exterior to exclude water.
Install the last or third seal with lip toward the interior of wheel assembly (I23) to retain oil.
(36) Insert seal ring (25) into seals (126).
(37) Press inner bearing cone (125) onto spindle (19).
(38) Install wheel assembly (123) on spindle.
(39) Install outer bearing cone (70) using locknut (7) to press bearing cone (70) in place.
(40) Coat mating surfaces of seal ring (25) and spindle (19) with sealing compound. Military Specification
MIL-S-7916. Secure seal ring to spindle with retaining screws (127) and lock- washers (128).
(41) Rotate wheel, and retighten locknut (71). Back off locknut slightly and install capscrew (129) in locknut.
(42) Slide planetary ring gear (72) over reaction member (75) and install snapring (76).
(43) Insert reaction member and planetary ring gear assembly (73) so that mounting holes in reaction member
(75) aline with guide pins in retainer plate (18). Install capscrews (72) and remove guide pins installed in (27) above.
Secure the capscrews with lock wire.
(44) Insert main axle (94) through reaction member and planetary ring gear assembly (73) into steering post
assembly (8).
NOTE
Axle must be oriented so that long splines on axle enter steering post assembly.
(45) Install snapring 110(11 in planet gear
(46) Press bearing cups (98) into planet gear bore and install bearing cones (97) in bearing cups.
NOTE
Earth bearing cup and cone must be kept together as an assembly.
(47) Center spur pinion (101) in planet spider (103) and position the three planet gear and bearing assemblies
(96) in planet spider.
(48) Press idler shafts 11(021 through planet gear and hearing assemblies, aline match marks on idler shafts and
planet spider, and press idler shafts into planet spider.
(49) Install shim sets (104) and end plates (105) using 12 capscrews (107) and seal washers (106) and 18
capscrews (108) and lockwashers (109).
(50) Check end clearance of planet gear and
7-94
bearing assemblies. End clearance should be 0.005 inch after a slight drag is felt in bearings.
(51) If end clearance is incorrect, remove end plate and substitute shims of appropriate thickness until proper
clearance is obtained.
(52) Attach a suitable sling to planet spider assembly (95) using capscrews (92) and lock- washers (91).
(53) Coat flange area of planet spider assembly, where planet spider assembly mates with wheel assembly (123)
with sealing compound Military Specification MIL-S-7916.
(54) Using suitable hoisting equipment, position planet spider assembly on wheel assembly.
NOTE
Make certain tire inflation valve assembly boss on planet spider assembly alines with corresponding hole in
wheel assembly. It will also be necessary to work splines of main axle (94) into splines of spur pinion (101).
(55) Install 12 collets (121) and nuts (120).
(56) Remove capscrews (92) and lockwashers (91) and remove sling, then reinstall capscrews and lockwashers.
(57) Install gasket (84) and preformed packing (85) on check release pin seat (83).
(58) Install spring (87), check valve body (89) with guide rod (88), gasket (86), and check release pin seat (83) in
wheel assembly (123).
(59) Install preformed packing (79) on check release pin (78). Insert check release pin into check release pin
bushing (80) and install cross pin (81).
(60) Install gasket (82) on check release pin bushing (80). Insert check release pin assembly into check release
pin seat (83) and tighten securely.)
(61) Install preformed packing (113) on air line pipe (117) and insert air line pipe in air seal retainer (114).
(62) Install preformed packing (112) on end plug (111). Coat threads of end plug with sealing compound, Military
Specification MIL-S-7916, and install in air seal retainer.
(63) Install gasket (115) and preformed packing (116) on air seal retainer. Use sealing compound, Military
Specification MIL-S-7916, between gasket and air seal retainer.
(64) Install seals (2) in bevel gear spider bearing cover (6).
(65) Coat mating surface of air line pipe and seal assembly ( 110) and planet spider assembly 19S5) with sealing
compound,. Military Specification MIL-S-7916, and install air line pipe and seal assembly, being careful not t9 damage
seals (2).
(66) Install capscrews (118) and lockwashers (119). Tighten end plug (111).
(67) Coat threads of pipe plug (1) with sealing compound, Military Specification MIL-S-7916, and install pipe plug.
(68) Test planetary and bevel gear spider bearing cover for leaks as follows:
(a) With air hose connected to plug hole (46, fig. 7-113), apply 2 psi gage air pressure and test air seal
retainer (114), end plates (105), capscrews, nuts, spider to wheel interface, and spider bearing cover (6) for leaks, using
soap solution method.
(b) Upon completion of test, remove blanks from steering post (8), column nut (10, FO-2), air connection
from plug hole (46, fig. 7-113) and install plug.
(69) Test tire inflation valve for leaks as follows:
(a) Close tire inflation valve (77) in wheel by releasing valve stem.
(b) Connect air hose to tire air inlet-outlet hole in center of wheel rim.
(c)Apply 70 psi gage air pressure and hold pressure for 15 minutes to insure no leakage in valve.
(70) Test airline pipe packings and seals for leaks as follows:
(a) Install a 1 inch pipe plug in bevel gear spider bearing cover (6) at hose connection.
(b) Open tire inflation valve (77) in wheel by depressing valve stem and locking in position.
(c) With air hose connected to tire air inlet-outlet hole in center of wheel rim, apply 70 psi air gage pressure
and hole pressure for 15 minutes to insure that the air line pipe packings and seals are not leaking. Upon completion of
test, remove air hose and pipe plug.
f. Installation. Refer to paragraph 2-16.
7-11. Column and Wheel Drive Lower Pivot Bearing Assembly
a. Removal and Disassembly. Refer to paragraph 2-17.
b. Cleaning, Inspection and Repair.
(1) Clean all parts, except seal (3, fig. 2-11) in dry-cleaning solvent, Federal Specification P-D- 680, and dry with low
pressure air (10 psi).
(2) Replace seal (3).
(3) Inspect lower pivot bushing (4) for excessive wear. Maximum id wear is 7.525 inches. If id of bushing exceeds 7.525
inches, replace bushing.
(4) Inspect shim.(10) for damage. If shim is damaged, replace shim with- a new shim of same thickness.
(5) Check lower pivot bearing mounting bracket (6) for cracks or breaks. Replace a damaged bracket.
c. Reassembly and Installation. Refer to paragraph 2-17.
7-95
Section II. MARINE DRIVE SYSTEM
7-12. Description
For a general description of the Marine Drive System, refer to paragraph 2-20.
7-13. Flexible Coupling, Pillow Block Fluid Coupling, and Engine Adapter Flange
a. Removal and Disassembly. Refer to paragraph 2-21.
b. Cleaning, Inspection and Repair.
(1) Clean all parts, except seals (38, fig. 2-15) and gaskets (9, 18, and 45), in dry-cleaning solvent, Federal
Specification P-D-680 and dry with low pressure air (10 psi). For cleaning, inspection, and repair of fluid coupling, refer
to paragraph 7-14.
(2) Replace seals (38) and gaskets (9, 18 and 45).
(3) Inspect bearing (25 and 33) for pitted, scored, or burned condition.
(4) Inspect gear teeth in flexible coupling flange (40) and gear hub (42) for broken or chipped teeth or wear
that may have destroyed original tooth shape. If a gear hub or coupling flange is damaged, replace the complete flexible
coupling assembly.
(5) Inspect engine adapter flange (34) and closure plate (19) for cracks, breaks, orwarpage. Replace if necessary.
(6) Inspect machine keys (36) and seal retainers (37) for good condition. Replace a damaged key or retainer.
(7) Inspect splined shaft (43) and flanged shaft (48) for damage. Replace a damaged shaft.
(8) Remove any paint and burrs from the mating surfaces of the pillow block housings (28).
NOTE
The vertical hole at the bottom of each inclosure groove in the lower half of pillow block housing (21)
must be free from foreign matter.
c. Reassembly and Installation. Refer to paragraph 2-21.
7-14. Fluid Coupling
a. Removal. Remove fluid coupling as outlined in paragraph 2-21.
b. Disassembly.
(1) Remove filler plug (17, fig. 7-116), gasket (18), and dust seal (28).
(2) Remove screws (29), washers (30), and seal carrier (31). Remove seal ring (21) from rear impeller (20).
(3) Remove nuts (11), screws (33), and washers (34) securing rear impeller (20) to front impeller (10). Lift
rear impeller from front impeller.
(4) Remove corprene gasket (19), carbon mating ring (1), and washer (2) from front impeller (10).
(5) Remove snapring (3) holding mating ring carrier (4) on runner hub (8). Remove oil seal packing (5) from
inside diameter of mating ring carrier.
(6) Remove roll pin (6) and slide rear ball bearing (7) from runner hub (8).
(7) By using seal carrier (31) to protect the ground seal surface, depress nose piece (23) of the seal surface
and remove internal retaining ring (22) holding it in seal carrier. While still depressed, remove step key (32) between
nose piece and seal carrier. Gradually release pressure on nose piece until spring tension is relieved and lift nose piece
from seal carrier.
(8) Remove compression springs (24), washer (25), garter spring (26), and rubber seal (27).
(9) Invert runner and front impeller. Remove front oil seal packing (16) and retaining ring (15).
(10) Remove front ball bearing (14), retaining ring (13), and baffle plate (9) from impeller hub. Lift front impeller from runner hub (8).
7-96
Figure 7-116. Fluid coupling disassemble.
7-97
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Dry thoroughly with compressed
air (10 psi).
(2) Inspect impellers for dents, nicks, burrs, or other obstacles that would hinder the smooth flow of oil through the
blades, core, or cooling fins.
If there is damage to any part of impeller, replace impeller.
(3) Inspect runner for damage to blades, core rings, or steel stampings. If there is damage to any part of runner,
replacement is necessary.
(4) Inspect bearings for roughness of rotation, out-of-roundness, and broken or chipped rollers. If any defects are
found, replace bearings.
(5) Inspect packings and gaskets for cuts, hardness, and deterioration. Replace damaged packings and gaskets.
(6) Inspect screws, nuts, and bolts for -corroded, stripped, or damaged threads. Replace a1 damaged hardware.
(7) Check to see that springs are not broken, compressed, or stretched out of shape. Replace springs if broken
and if free length is not 0.125 inch.
d. Reassembly. Reassemble fluid coupling in reverse order of disassembly.
e. Installation. Install fluid coupling as outlined in paragraph 2-21.
7-15. Gathering Box - Marine Gear Angle Drive Couplings.
a. Removal. Refer to paragraph 2-22.
b. Disassembly.
(1) Remove shaft (8, fig. 2-16) and keys (7) from flexible coupling assemblies.
(2) Remove hub gears (2 and 13). Press button (15) and thrust plate (14) from lower hub gear (13).
(3) Remove retaining rings (6) and seals (5) from flanges (3).
(4) Remove lubrication plugs (4) from flanges (3).
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680.
(2) Inspect retaining rings for cracked or warped condition. If damaged, replace retaining rings.
(3) Inspect each flange and gear hub for uneven wear and broken teeth. If flange and gear hub are damaged,
replace angle drive coupling.
(4) Inspect button (15, fig. 2-16) and thrust plate (14) on lower coupling for broken or malformed condition. If
damaged, replace button or thrust plate.
d. Reassembly. Reassemble angle drive couplings in rev---t order of disassembly.
NOTE
Replace all flexible coupling seals.
e. Installation.
(I) Pack flexible couplings with grease, Military Specification MIL-G-23549, prior to installation.
(2) Install angle drive coupling in reverse order of removal.
NOTE
Replace all angle drive coupling mounting gaskets.
7-16. Gathering Box Assembly
a. Removal. Refer to paragraph 2-22.
b. Disassembly.
(1) Dipstick and inspection cover removal Remove dipstick (18, fig. 7-117), capscrews (51), lockwashers (50),
inspection cover (53), and cover plate gasket (54) from housing (37).
7-98
Figure 7-117. Gathering box assembly disassembly.
7-99
(2) Major components removal
(a) Overrunning clutch assembly removal. Remove capscrews (t from input shaft end plate (2) and pull
overrunning clutch assembly from input shaft spline. Remove input shaft spacer (8) from carrier (49).
(b) Input shaft assembly removal Remove capscrews (48) from carrier (491 and pull input shaft assembly
from housing (37).
(c) Output shaft assembly removal.
1. Disconnect pump suction tube (17) from oil pump (15). Remove capscrews (13), lock- washers
(14), and oil pump (15) from pump bearing retainer (11).
2. Remove capscrews (12) from pump bearing retainer (11). Remove pump bearing retainer,
pump bearing shim set (10), and pump bearing adapter (9). Remove output shaft bearing cup (28) from pump bearing
adapter.
3. Invert gathering box and remove capscrews (19) from output shaft bearing adapter (20). Lift
output shaft assembly from housing and remove output shaft bearing shim set (21) and output shaft (26).
(3) Major components disassembly.
(a) Overrunning clutch assembly disassembly.
1. Support assembly on small end of inner race shaft (3). Press outer race (6) and inner clutch
bearing (7) off shaft.
2. Remove clutch unit (5), and press outer clutch bearing (4) off of inner race shaft (3).
(b) Input shaft assembly disassembly.
1. Remove input shaft seal (43), capscrews (44), bearing retainer (45), and input shaft bearing shim
set (46) from carrier (49).
2. Support assembly on bolting flange of carrier (49) and press input shaft (40) together with input
bevel pinion (39) and input shaft bearing (41) from carrier.
3. Remove input shaft bearing (41), input bevel pinion (39), and bevel pinion key (38) from input
shaft (40).
4. Remove input shaft ball bearing (47) from carrier (49).
(c) Output shaft assembly disassembly.
1. Remove capscrews (35), output shaft end plate (34), and gasket (33); and pull coupling (32) from
output shaft (26).
2. Remove capscrews (30) and coupling retainer (29) from output shaft bearing adapter (20). R
emove output shaft bearing cup (22) from output shaft bearing adapter (20) and oil seal (31) from coupling retainer (29).
3. Press output bevel gear (25), bevel gear key (24), and output shaft bearing cones (23 and 27)
from output shaft (26).
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry cleaning solvent, Federal Specification P-D-680. Dry with compressed air (10
psi).
(2) Inspect housing (37. fig 7-117) for cracks and damage to machined surfaces that could cause oil leakage
or malfunction of parts. Replace damaged housing.
(3) Inspect output shaft bearing cups (22 and 28) and bearing cones (23 and 27) for pitted, scored, or burned
condition.
(4) Inspect contact areas of output bevel gear (25) and input bevel pinion (39) forspalling, pitting. or wear. If
more than 20 percent of contact area of any face is damaged by spalling or pitting. or if more than 0.015 inch of metal is
worn from any face, replace gear.
(5) Inspect output shaft (26) for burred and/or scored condition that would indicate the bearing has been tur
ning on the shaft. If od of upper and/or lower bearing areas is less than 2.2508 inches, replace output shaft. If od of spline
teeth is less than 2.2470 inches replace output shaft.
(6) Inspect input shaft (40) for burred and/or scored conditions that would indicate the bearing has been tur
ning on the shaft. If od of input shaft bearing (41) area is less than 2.7560 inches and / or od of input shaft ball bearing
(47) area is less than 2.3618 inches, replace shaft. Ifod of spline teeth is less than 2.1810 inches over 0.1920 inch pins.
replace shaft.
(7) Check bearing areas of carrier (49) for limits specified in table 1-3. If bearing areas exceed maximum allowable wear. replace carrier.
(8) Check output shaft bearing adapter (20) and pump bearing adapter (9) for limits specified in table 1-3. If
maximum allowable wear is exceeded, replace adapter.
(9) Inspect all threaded openings and inserts for damaged threads. If damage cannot be removed by chasing
threads with proper size tap. replace parts. Replace damaged inserts.
(10) Replace all seals.
(11) Inspect bearings (7 and 4) for pitted, scored or burned condition.
(12) Check outer race (6) and inner race shaft (3) for wear in areas where outer bearing (4) and inner bearing
(7) are located. If wear exceeds limits specified in table 1-3, replace outer race or inner race shaft.
(13) Check outer race (6) and inner race shaft (3) for a pitted or spalled condition in clutch unit area. If spalling
or pitting at any point on clutch unit area exceeds 10 percent of clutch unit area width, replace outer race or inner race
shaft.
(14) Check outer race (6) for grooved condition where outer race mates with input shaft seal.
7-100
(43). If groove depth exceeds 0.005 inch, replace outer race.
(15) Check that all sprags in clutch unit (5) are oriented in same direction and are free in cages.
Cage holes must be square with the flange within + I / 2°. Replace a defective clutch unit.
d. Reassembly.
(1) Major components reassembly.
(a) Output shaft assembly reassembly.
1. Press output bevel gear (25, fig. 7-117) on output shaft (26) with bevel gear key (24) in place. Make sure gear
hub is against shaft shoulder.
2. Heat output shaft bearing cones (23 and 27) in oil (temperature not to exceed 250
° F) and slide in place on
output shaft.
3. Assemble output shaft bearing adapter (20) and coupling retainer (29), and secure with capscrews (30) and lock
wire.
4. Press oil seal (31) into coupling retainer (29), and output shaft bearing cup (22) into output shaft bearing adapter
(20) until cup seats against coupling retainer. Install assembly on output shaft (26).
NOTE
Place oil seal (31) with lip side toward coupling retainer (29).
5. Install coupling(32), gasket (33), and output shaft end plate (34), and secure to output shaft with capscrews (35).
(b) Input shaft assembly reassembly.
1. Press input shaft ball bearing (47) into carrier (49) and seat against shoulder of bore. Heat input shaft bearing
(41) and install on input shaft (40).
2. Turn carrier on end so input shaft ball bearing (47) is down. Support bearing on inner race.
3. Lower input shaft (40), with input shaft bearing (41), into carrier until shaft starts into bearing bore. Check
alinement of input shaft bearing outside diameter to bore of carrier. Tap with a soft hammer to level. Press shaft until
shoulder of shaft rests against input shaft ball bearing (47). Input shaft bearing need not be flush with carrier shoulder.
4. Install input shaft bearing shim set (46), bearing retainer (45), and input shaft seal (43) on carrier (49). Install
capscrews (44) and secure with lock wire.
NOTE
Place input shaft seal (43) with lip side toward carrier (49).
5. Press input bevel pinion (39) on input shaft (40) with bevel pinion key (38) in place.
(c) Overrunning clutch assembly reassembly.
1. Press outer clutch bearing (4) on inner race shaft (3).
2. Slide clutch unit (5) on inner race shaft. Clutch must freewheel when inner race shaft is rotated clockwise as
viewed from small end.
3. For clutch assembly purposes only, slide large end of inner race shaft (3) on splines of input shaft (40). With a
twisting action start outer race (6) onto clutch sprags. After clutch sprags start into outer race, seat outer race against
outer clutch bearing (4) with a soft hammer. Insert inner clutch bearing (7) simultaneously onto inner race shaft and
outer race.
4. Remove overrunning clutch assembly from input shaft (40).
(2) Major components installation.
(a) Output shaft assembly installation.
1. Install output shaft bearing shim set (21 ) and lower output shaft assembly into housing (37). Secure with
capscrews (19).
2. Invert gathering box and install pump bearing adapter (9) in housing, making sure that bolt clearance holes are
aligned with holes in housing. Press in output shaft bearing cup (28) and seat lightly on output shaft bearing cone (27).
3. Install oil pump (15) on pump bearing retainer (11) with lockwashers (14) and capscrews (13).
4. Install pump bearing shim set (10), pump assembly, and capscrews (12).
5. Adjust output shaft bearing cones (27 and 23) with pump bearing shim set (10) and output shaft bearing shim
set (21) until output shaft rotates freely with no end play. After final adjustment lock wire capscrews (30, 19, and 12).
(b) Input shaft assembly installation. Install each input shaft assembly in housing with original input shaft bearing
shim set (42), and secure to housing with capscrews (48).
(c) Overrunning clutch assembly. installation. Slide input shaft spacer (8) on input shaft, install clutch assembly,
and lock in place with input shaft end plate (2) and capscrews (1).
Secure with lock wire.
(3) Gathering box bevel gear set adjustment.
NOTE
If bevel gear set mountings, which secure bevel gear and bevel pinion to housing, or
housing has been replaced, the bevel gear set must be readjusted.
(a) Lightly coat several teeth on output bevel gear (25) with gear marking compound, red lead, Federal
Specification TT-R-191, Type II.
(b) Check backlash in gear set by securing.
7-101
indicator rigidly to case with actuator point against and perpendicular to gear face. Backlash should be 0.008 to 0.012
inch.
(c) Rotate input shaft (40) sufficiently to mark pinion tooth contact with compound painted on driven gear. Ideal
tooth contact is slightly nearer the toe than the heel (A, fig. 7-112).
(d) When contact is too high on pinion and too low on driven gear, pinion is too near center (B, fig. 7-112). If
backlash was too small, shim pinion away from center. If backlash was too great, shim driven gear toward pinion.
(e) When contact is too low on pinion and too high on driven gear, pinion is too far from center (C, fig. 7-112). If
backlash was too great, shim pinion toward center. If backlash was too small, shim driven gear away from center.
(f) Repeat (d) and (e) above until proper tooth contact is obtained; check backlash of gear.
Adjust to correct backlash (0.008 to 0.012 inch), using input shaft bearing shim set (42, fig. 7-117) for pinion
adjustment and output shaft bearing shim set (21) for driven gear adjustment. Secure capscrews 119 and 48) with
lockwire after proper adjustment has been made.
(4) Inspection cover and dipstick installation. Install cover plate gasket (54), inspection cover (53), lockwashers
(50), capscrews (51), and dipstick (18).
e. Installation. Refer to paragraph 2-22.
7-17. Marine Gear Assembly
a. Removal Refer to paragraph 2-27.
b. Disassembly.
NOTE
The disassembly and reassembly procedures given are for right-hand unit. The left-hand
units and right-hand units are the same except for housing. For right-hand units, bevel
gearcase is on upper half housing. For left-hand units, bevel gearcase is on lower half.
(1) Remove flexible hoses (44, and 50 through 55, fig. 2-24) from marine gear.
(2) Remove elbows (45 and 46) from lube manifold (47).
(3) Remove capscrews (48) and lockwashers (49) and remove lube manifold.
(4) Remove flexible hoses (64, 68, and 71) from marine gear.
(5) Remove swivel joint (70) and elbow (69) from control valve (73).
(6) Remove capscrews (75) and lockwashers 174) and remove control valve.
(7) Remove capscrews (66) and withdraw oil pump (57) from marine gear.
(8) Remove adapter (56), elbow (67), and swivel joint (65) from oil pump.
(9) Remove staked marks around setscrew (63) and loosen setscrew.
(10) Remove oil pump drive gear (62) and key (58) from pump shaft.
(11) Remove mounting adapter (61), bearing (60), and gasket (59).
(12) Major components removal.
(a) Control tube assembly removal. Remove capscrews (133, FO-3 (located in back of manual)) and pull
control tube assembly from housing.
(b) Pump planetary drive assembly removal. Remove capscrews (55) and washers (54); and with suitable hoist,
remove pump planetary drive assembly.
(c) Bevel drive assembly removal. Remove capscrews (10) and washers (11), and lift bevel drive assembly from
marine gear housing.
(d) Housing removal.
1. Remove control tube assembly, pump planetary drive assembly, and bevel drive assembly as outlined in (a)
through (c) above.
2. Lay marine gear with upper housing (20) facing up.Remove capscrews (23), washers (22), and inspection
covers (21).
3. Reach through inspection holes and remove three capscrews (38) fastening forward bearing adapter (43) to
upper housing.
4. Remove capscrews (26) and washers (27) from aft high speed bearing adapter (28).
5. Remove three capscrews (155) and washers (154) from aft output shaft adapter (149).
6. Remove capscrews 1113 ) from for- ward bearing adapter (114).
7. Remove three nuts (162), three washers (161), and three bolts (24) from aft of upper housing (20). Reach
through inspection holes and remove three bolts from forward flange of housing.
8. Remove nuts (164), washers (163), and bolts (25) from housing flange.
9. Lift upper housing (20) from lower housing (165) with suitable hoist.
(e) Output shaft assembly removal.
1. Remove housing as outlined in (d) above.
2. With a suitable hoist, lift output shaft assembly from lower housing (165).
(f) Input shaft assembly removal.
1. Remove output shaft assembly as outlined in (e) above.
2. Remove two capscrews (38) and lift input shaft assembly from lower housing (165).
(g) Idler shaft assembly removal.
1. Remove input shaft assembly as outlined in (f) above.
2. Remove capscrews (87), aft bearing adapter (86), and aft bearing cup (85) from lower housing (165).
3. Remove capscrews (74), idler shaft
7-102
end plate 175), and press idler shaft (82) from housing by supporting idler gear (81) on a suitable pipe or cylinder
(maximum outside diameter 5 1/2 inches; minimum inside diameter 3 3/4 inches). Ram pressure should be applied from
forward end of idler shaft.
4. Remove bolts (71), bearing retainer (72), forward bearing retainer gasket (73), and forward bearing adapter
(78).
5. Remove forward bearing cones (76) and forward bearing cups (77) from forward bearing adapter (78).
(13) Major components disassembly.
(a) Control tube assembly disassembly.
1. Remove cotter pin (119), nut (118), and washer (120). Pull out washers (121 and 122), reverse oil valve (123),
piston ring (124), forward oil valve (12'5), and control tube spacer (126).
2. Pull outer tube (128) from inner tube (129). If inner tube is disassembled from separator box (131), inner tube
must be replaced.
3. Remove separator box cap (132) from separator box (131).
(b) Pump planetary drive assembly disassembly.
1. Remove capscrews (60) and washers (59), and pull out planetary housing adapter (58).
Remove planetary housing bearing (57) from adapter.
2. Remove capscrews (70) from aft bearing adapter (69). Pull out bearing adapter together with aft bearing cup
(67) and remove aft bearing shim set (68).
3. Support planetary pinion (64), using a section of cylinder (maximum outside diameter, 3 3/8 inches; minimum
inside diameter, 3 inches) through the clearance between planetary gear housing (53) and forward bearing cone (63) and
through forward bearing adapter (61) and forward bearing cup (62). Press planetary pinion shaft (65) from spline end out
of forward bearing cone.
4. Slide planetary pinion (64) and forward bearing cone (63) from planetary gear housing (53).
5. Remove screws (56) and forward bearing adapter (61) from housing.
(c) Bevel drive assembly disassembly.
1. Remove capscrews (3), washers (4), and bevel pinion oil seals (2). Pull out bevel pinion seal carrier (5) from
bevel pinion shaft (16).
2. Remove locknuts (6) and washer (7).
3. Support bearing carrier (12) at the bolting flange and press bevel pinion shaft (16) from carrier.
4. Remove outer bevel pinion bearing cone (8), outer bevel gear bearing cup (9), and inner bevel pinion bearing
cup (14).
5. Remove bevel pinion (18) and bevel pinion key (17) from bevel pinion shaft.
6. Press inner bevel pinion bearing cone (15) from bevel pinion shaft.
(d) Output shaft assembly disassembly.
1. Remove capscrews (160), packing retainer (159), and packing (158) from output shaft (102).
2. Pull off coupling half (157) using a suitable puller.
3. Remove capscrews (155), washers (154), coupling bearing retainer (153), oil seals (156), and output shaft shim
set (150).
4. Remove capscrews (116) and forward retaining plate (115).
5. Use a heavy duty press, horizontal if possible, and place supports between forward output gear (105) and clutch
piston (134). Press ram to push output shaft (102) from forward output gear (105), forward bearing cup (107), forward
bearing cone (108), forward bearing spacer (109), and forward bearing adapter assembly. Press forward bearing cup
(104) from forward output gear.
6. Remove forward retaining ring (110), forward bearing cup (111), and forward bearing cone (112) from forward
bearing adapter (114).
7. Use a section of pipe (maximum outside diameter, 61/2 inches; minimum inside diameter, 5-5/8 inches) to
support forward plate (92) inside clutch plate spline. Press shaft from coupling end through aft bearing cones (151), aft
bearing cup (152), reverse spacer (148), reverse gear assembly, and clutch assembly.
NOTE
Each part must be handled as it comes free, and adequate support for the assembly
must be maintained at all times.
8. Support assembly on forward bearing cone (103) and press output shaft free of forward bearing cone (103), and
forward bearing spacer (106).
9. Remove reverse bearing cones (142 and 147), reverse bearing cups (143 and 146), and reverse bearing spacer
(145) from reverse output gear (144).
10. Place clutch assembly on bench and remove forward retaining ring (99), forward backing plate (98), forward
friction plates (96), forward pressure plates (97), reverse retaining ring (141 ), reverse backing plate (140), reverse
friction plates (138), and reverse pressure plate (139) from clutch piston (134).
11. Drive out clutch dowel pins (93) and remove capscrews (94).
12. Cut three pieces of steel rods, 5/16 inch diameter by 2 inch length; and grind a 3/16
7-103
inch width plane the length of each rod. Lay these rods into inner spline of clutch piston to serve as retainment guides for
forward piston rings (95). Tap out forward plate (92). Remove piston ring (91 and 95) from forward plate.
13. Switch steel rods to opposite side. Remove reverse plate (136), then remove reverse piston ring (137) from
reverse plate.
14. Remove clutch compression springs (88) from both sides of piston.
NOTE
If necessary to remove clutch bushing cups (90), use a filler block slightly smaller than
diameter of closed end to press out bushing. If necessary to remove clutch spring
retainers (89) press from clutch pinion (134).
(e) Input shaft assembly disassembly.
1. Pull off aft high speed bearing adapter (28). Remove input shaft oil seals (29), aft retaining ring (31), and input
shaft bearing (30) from adapter.
2. Remove planetary sun gear (51), and planetary sun gear key (52) from input shaft (32).
3. Remove locknuts (49) and washer (50).
4. On suitable press, disassemble forward pinion (35), forward pinion spacer (37), forward bearing retainer (39),
forward bearing adapter (43), input shaft shim set (45), bevel gear (48), and bevel gear hub (46) together from shaft.
5. Remove capscrews (38) and forward bearing retainer (39) from forward bearing adapter (43). Press tapered
bearing cones (40), tapered bearing cups (41), and forward pinion bearing spacer (42) from forward bearing adapter.
6. Remove capscrews (44) from bevel gear hub (46), and separate bevel gear (48) and bevel gear hub.
7. Press reverse pinion (33) from input shaft (32).
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent. Federal Specification P-D-680. Dry parts thoroughly with
compressed air (10 psi).
(2) Inspect roller bearing for cracks, chipping, and blue-black discoloration. Bearings must rotate smoothly with no
noise, binding, or excessive radial or axial play. Replace defective bearings.
(3) Inspect contact areas of bevel pinion (18, fig. FO-3) and bevel gear (48) for spalling, pitting, or wear. If more
than 20 percent of contact area of any face is damaged by spalling or pitting, or if more than 0.015 inch of metal is worn
from any face, replace.
(4) Inspect screws, nuts, and bolts for corroded, -tripped, or damaged threads. Replace all damaged hardware.
(5) Inspect clutch compression springs (88) for broken or distorted coils. Replace damaged springs.
(6) Inspect clutch dowel pins (93) for looseness of fit in dowel pinholes. If a dowel pinhole is worn, rebore and
sleeve the hole and replace dowel pin.
(7) Inspect input shaft reverse pinion (33), input shaft forward pinion (35), planetary sun gear (51), planetary pinion
(64), and idler gear (81) for scuffed, nicked, burred, or broken teeth. If gears or pinions are worn beyond limits specified
in table 1- 3, replace. If scuffs, nicks, and/or burrs cannot be removed with crocus cloth, Federal Specification P- C-458,
replace damaged part.
(8) Inspect forward friction plate (96) and reverse friction plate (138) for cracks, burrs, wear, and distortion. If
friction plates are worn beyond limits specified in table 8-17, replace. Replace damaged friction plates.
(9) Inspect piston rings (91, 95 and 137) for scored surfaces, breaks, and wear. Check side clearance of piston
rings in forward plate (92) and reverse plate (136) (piston ring (91) should be 0.008 inch to 0.012 inch and piston rings
(95 and 137) should be 0.005 inch to 0.010 inch. If piston rings are damaged and / or side clearance exceeds above
limits, replace piston rings.
(10) Inspect clutch forward plate (92) for scoring, pitting, and / or warpage. Replace damaged plate. If dimensions
given in figure 7-118 are exceeded, replace forward plate.
7-104
Figure 7-118. Clutch forward plate dimensions
Figure 7-119. Clutch piston dimensions
and wear limits.
and wear limits.
NOTE
Clutch forward plate (92, FO-31. reverse plate (136), and clutch piston (134) are
replaced as a set if either part is damaged.
(11) Inspect clutch piston (134) for scoring, pitting. or warpage. Replace damaged clutch piston. If dimensions
given in figure 7-119 are exceeded, replace clutch piston.
(12) Inspect clutch reverse plate (136, FO-3) for scoring. pitting. or warpage. Replace damaged plate. If flatness
of reverse plate face is worn beyond 0.0040 inch. replace plate.
7-105
(13) Inspect clutch bushing cups (90) for cracks or looseness. Replace damaged clutch bushing cup. If clutch
bushing cup is worn beyond limits specified in table 1-3. replace cup.
(14) Inspect forward output gear (105) and reverse output gear (144) for scuffed, nicked. burred, or broken teeth.
If gears are worn beyond dimensions given in figures 7-120 and 7-121, replace. If scuffs, nicks, and/or burrs cannot be
removed with crocus cloth, Federal Specification P-C-458, replace damaged gear.
Figure 7-120. Forward output gear dimensions
and wear limits
Figure 7-121. Reverse output gear dimensions
and wear limits .
7-106
(15) Inspect bevel pinion shaft (16, FO-3), input shaft (32), output shaft (102), and idler shaft (82) for cracks,
galling, and/or damaged splines. Replace defective shaft.
(16) Check areas of bevel pinion shaft (16) for wear. If any area of bevel pinion shaft exceeds dimensions given
in figure 7-122, replace shaft.
.
Figure 7-122. Bevel pinion shaft dimensions
and wear limits
Figure 7-123. Input shaft dimensions and
wear limits.
(17) Check areas of input shaft (32, FO-3) for wear. If any area of input shaft exceeds dimensions given in
figure 7-123, replace shaft.
(18) Check areas of output shaft (102, FO-3) for wear. If any area of shaft exceeds dimensions given in
figure 7-124, replace shaft.
7-107
Figure 7-124. Output shaft dimension and
wear limits.
Figure 7-126. Forward oil valve dimensions
and wear limits.
Figure 7-125. Idler shaft dimensions and
wear limits.
(19) Check areas of idler shaft (82, fig.
7-118) for wear, galling, or fretting. If any area
of idler shaft exceeds dimensions given in fig.
7-125, replace shaft.
(20) Inspect control tube forward oil valve
(125, FO-31 !or scores, pits, and burrs. Check
areas of forward oil valve as given in figure
7-126. If valve is worn beyond dimensions
given, replace forward oil valve.
(21 ) Inspect all threaded openings for
damaged threads with proper size tap. Chase
damaged threads with correct size tap and replace damaged inserts.
(22) Inspect bores for scratches, burrs,
and scores. Replace damaged parts.
(23) Inspect tapered bearing cones and a
tpered bearing cups for pitted, scored, or burned
condition.
(24) Install new seals and gaskets.
Reassembly.
(1) Major components reassembly.
(a) Input shaft assembly reassembly.
1. Press reverse pinion (33, FO-3) on input shaft (32) with reverse pinion key (34) in place.
2. Press forward pinion (35) on input shaft with forward pinion key (36) in place.
NOTE
Reverse and forward pinion must be tight against shoulder.
3. Install forward pinion spacer (37) and forward bearing retainer (39) with gasket (170) on input
shaft (32).
4. Press tapered bearing cups (41) and forward pinion bearing spacer (42) into forward bearing
adapter (43).
5. Fasten bevel gear hub (46) to bevel gear (48) with capscrews (44) and lock wire.
6. Heat forward bearing adapter (43), tapered bearing cones (40), and bevel gear and hub .
d.
7-108
in oil (250°to 300°F.). Install adapter assembly and input shaft shim set (45). Install heated bevel gear with bevel gear
key (47) in place. These parts should rest firmly against shoulders so bearings roll freely but have no end play.
7. Secure bevel gear hub (46) on shaft with locknuts (49) and washer (50).
8. Press planetary sun gear (51) on shaft with planetary sun gear key (52) in place.
9. Press planetary housing bearing (57) on shaft.
(b) Output shaft assembly reassembly.
1. Lay forward plate (92) in press with clutch face up. Place clutch hub key (1 0 1) in center keyway of output shaft
(102). Locate two drilled passages running at right angles to, and in bore of, forward plate. Locate drilled holes in output
shaft and press output shaft into forward plate so drilled passages line up and keyways mate. Press forward plate to
shoulder of output shaft.
2. Install piston ring (91) and forward piston ring (95) in grooves of forward plate (92), and install clutch bushing
cups (90).
3. Press clutch spring retainer (89) into clutch piston (134).
NOTE
Lay clutch piston so that forward plate, piston drum assembly bushing cups, and spring
retainers match. Support drum at a suitable height so that output shaft will clear the floor
when assembled with piston.
4. Lightly coat piston rings (91) and forward piston ring (95) on the forward plate and their respective fits in piston
drum with grease, Military Specification MIL-L-17331. Install four clutch compression springs (88) and center piston rings
on forward plate.
5. Place piston ring guides at three places in piston drum splines and gently lower forward plate into place.
NOTE
Tap piston ring (91) into bore. Be sure that end of ring does not catch grooves in piston
drum.
6. Lift coupling end of shaft and turn assembly upside down so assembly rests on forward end of output shaft.
Install clutch hub gasket (135) on forward plate hub.
7. Install reverse piston ring (137) on reverse plate (136), using grease, Military Specification MIL-G-10924. Install
four clutch compression springs (88) and grease ring bore.
8. Use piston ring guides to guide ring into place as reverse plate (136) is lowered into place. Gently tap reverse
place to start ring over chamfer.
9. Install clutch dowel pins (93) and capscrews (94) securing reverse plate (136) to forward plate (92). The dowels
must not stick out on either side.
10. To test clutch action, insert control tube assembly in the forward bore of the output shaft. Push tube assembly
in until rings slide into valve bushing (117). Use air pressure at oil inlet fittings or passages of separator box (I 3 11.
Correct positioning of tube can be obtained by sliding fore and aft until air pressure actuates the forward or reverse.
Apply pressure to clutch assembly; piston drum should move without delay. Release pressure; piston drum should return
to neutral position. Any drag or delay indicates faulty assembly and necessitates repair.
11. Assemble forward friction plates (96), forward pressure plate 197), and forward backing plate (98). Secure
with forward retaining ring (99).
12. Install reverse friction plates (138), reverse pressure plate (139), and reverse backing plate 1140). Secure
with reverse retaining ring 1141).
13. Heat forward bearing cone (103), and reverse bearing cone (142) in oil (250° to 300°F.). Install forward
bearing cone (1031 and reverse bearing cone (142) to rest against shoulders of output shaft (102).
14. Press forward bearing cups (107 and 104) into forward output gear (105) to rest tightly against shoulders.
15. Install forward bearing spacer (106) tightly against forward bearing cone (103).
16. Position forward output gear (105) into inner splines of forward friction plates (96).
Heat forward bearing cone (108) in oil (250°to 300°F.). Install bearing cone against forward bearing spacer (106).
17. Heat forward bearing spacer (1091 and forward bearing cone (112) in oil (250°to 300°F.). Install spacer and
bearing cone into output shaft (102). Fasten with forward retaining plate (115), capscrews (116), and lock wire.
18. Install reverse bearing spacer (145) against reverse bearing cone (142) from coupling side. Install reverse
bearings cups (143 and 146) into reverse output gear (144).
19. Heat reverse bearing cone (147) and aft bearing cones (151) in oil (250°to 300°.F.).
Start reverse output gear (144 into splines of reverse friction plates (138). Install reverse bearing cone (147),
reverse spacer (148), aft bearing cone (151), aft output shaft adapter (149), aft bearing cup (152), and aft bearing cone
(151) on output shaft (102).
NOTE
All parts must rest against shoulders.
7-109
20. Install output shaft shim set (150), coupling bearing retainer (153), and oil seals (156). Secure with washers
(154), and capscrews (155).
NOTE
Lip of outer oil seal must face outside of case and lip of inner seal must face inside of case.
21. Heat coupling half (157) in oil (250°to 300°F.), and install coupling on output shaft with coupling key (100) in
place.
22. Install packing (158), packing retainer (159), and capscrews (160). Secure with lock wire.
23. Install forward bearing cup (111) in forward bearing adapter (114) and secure with forward retaining ring
(110). Install forward bearing adapter on forward end of output shaft.
(c) Bevel drive assembly reassembly.
1. Press inner bevel pinion bearing cone (15) against shoulder of bevel pinion shaft (16).
2. Press bevel pinion (18) with bevel pinion key (17) on shaft tight against shoulder.
3. Press outer bevel pinion bearing cup (9) and inner bevel pinion bearing cup (14) tightly against shoulder of
bearing carrier (12).
4. Position shaft and inner bevel pinion bearing cone (15) in bearing carrier (12) and press outer bevel pinion
bearing cone (8) on shaft until shaft runs freely without end play.
5. Secure bearing to carrier with locknuts (6) and washer (7).
6. Pack bevel pinion oil seals (2) with grease, Military Specification MIL-G-10924, and install bevel pinion seal
carrier (5) and bevel pinion oil seals (2) into position on shaft. Install washers (4) and capscrews (3) to secure bevel
pinion seal carrier (5) to bearing carrier (12).
NOTE
Lip of outer oil seal must face outside of case and Ii) of inner seal must face inside of case.
(d) Pump planetary drive assembly reassembly.
1. Install forward bearing adapter (61) and forward bearing cup (62). Secure to planetary gear housing (53) with
screws (56) from outside and stake heads of screws in position.
2. Heat forward and aft bearing cones (63 and 66) in oil (250°to 300°F.). With planetary gear housing laying flat
on bench, install forward bearing cone (63) in housing. Position planetary pinion (64) in housing, and insert planetary
pinion shaft (65) through inner spline of planetary pinion and forward bearing cone (63).
Position aft bearing cone (66) on planetary pinion shaft (65) against planetary pinion (64).
3. Install aft bearing cup (67) into aft bearing adapter (69). Install adapter with aft bearing shim set (68). Pinion
must have no end play and no binding. Secure adapter to housing with capscrews (70) and lock wire.
(e) Control tube assembly reassembly.
1. Replace inner tube (129) and outer tube (128) into separator box (131).
2. Install washers (121 and 122), control tube spacer (126), forward oil valve (125), piston ring (124), and reverse
oil valve (123), on tube assembly. Secure with nut (118), washer (120), and cotter pin (119).
(2) Major components installation.
(a) Idler shaft assembly installation.
1. Stand lower housing (165) on aft end with forward end of housing facing up, slide idler gear (81) and forward
bearing spacer (79) in place with chamfer side of spacer facing forward or up.
Press aft bearing cone (84) on idler shaft (82).
2. Insert idler shaft (82) from aft through idler gear (81) and forward bearing spacer (79) with idler gear key (80) in
place.
3. Install one forward bearing cone (76) by using idler shaft end plate (75) and a suitable section of pipe
(maximum outside diameter 3 I inches; minimum inside diameter 21/2 inches).
Place pipe between bearing cone and retainer plate, and press bearing in place by tightening idler shaft end plate
with capscrews (74). Remove capscrews and end plate after cone is installed.
NOTE
The cone must rest tightly against idler gear (81) to insure a good fit between the conical
surfaces of idler gear bore and idler shaft.
4. Press forward bearing cup (77) against shoulder of forward bearing adapter (78).
5. Press forward bearing cone (76) on shaft by tightening evenly on capscrews (74) securing idler shaft end plate
(75) to idler shaft and secure with lock wire.
6. Install forward bearing retainer gasket (73) and bearing retainer (72) and secure with bolts (71).
7. Install aft bearing cup (85) in aft bearing adapter (86) and secure adapter to housing with capscrews (87) and
lock wire.
8. Install input shaft assembly as outlined in (b) below.
(b) Input shaft assembly installation.
NOTE
If bevel pinion (18), bevel gear (48), train of mountings locating gear and pinion to the
housing, or housing has been replaced, the bevel gear set (bevel pinion and bevel gear
must be replaced as a set (must be readjusted (e) below.
1. Install idler shaft assembly as outlined in (a) above.
7-110
2. Position input shaft assembly in lower housing (165). Install two socket head capscrews to secure forward
bearing adapter (43) and forward bearing retainer (39) to lower housing.
3. Apply sealing compound, Military Specification MIL-S-7916, to aft high speed bearing adapter (28) to seal
adapter to housing.
Install three washers (27) and three capscrews (26). Do not tighten.
4. Install two capscrews (38) on forward bearing adapter (43) in lower housing.
5. Install output shaft assembly as outlined in (c) below.
(c) Output shaft assembly installation.
1. Install input shaft assembly. as outlined in (b) above.
2. Position output shaft assembly in lower housing (165) with suitable hoist.
Lubricating hole in aft output shaft adapter (149) and coupling bearing retainer (153) must match with hole in boss
of lower housing. This hole provides a passage for the return of lubricant.
3. Install three washers 1154). three capscrews (1551, and two capscrews ( 1131. Do not tighten.
4. Install housing as outlined in (d) below.
(d) Housing installation
1. With suitable hoist, position upper housing (20) on lower housing (165). Install three bolts (24), three washers
(161), and three nuts (165). Reach through inspection holes and replace three bolts on forward flange of upper housing.
2. Install bolts (25), washers (163). nuts (164). and taper pins (19) on flange of housing.
3. Install three capscrews (38) which secure forward bearing adapter (43) to upper housing (20).
4. Install washer (27) and capscrews (26) on aft high speed bearing adapter (28).
5. Install washers (154) and capscrews (155) on aft output shaft adapter (149).
6. Install capscrews (113) on forward bearing adapter (114).
7. Install bevel drive assembly. pump planetary drive assembly, and control tube assembly as outlined in (e), (f)
and (g) below.
8. Install inspection covers (21), washers (22), and capscrews (23).
(e} Bevel drive assembly installation.
NOTE
If bevel pinion (18), bevel gear (48), train of mounting securing gear and pinion to housing. or housing has been
replaced. the bevel gear set (bevel pinion and bevel gear must be replaced as a set) must be readjusted as
outlined in e below.
1. Install bevel drive assembly with original bevel pinion shim set (13) in upper housing (20) of right-hand unit
(lower housing (165 of left-hand unit).
2. Secure bevel drive assembly to housing with washers (11) and capscrews (10).
(f) Pump planetary drive assembly installation.
l. With suitable hoist. position planetary drive assembly and start planetary sun gear (51) into planetary pinions
(64). Rotate pinion to mesh with gear teeth.
2. Apply sealing compound. Military Specification MIL-S-7916 to flange and secure with washers (54) and
capscrews (55).
(g) Control tube assembly installation.
1. Install separator gasket (130) and slide control tube assembly in output shaft.
2. Apply sealing compound. Military Specification MIL-S-7916 to contact surface of separator box cap (132).
3. Position cap with two pipe threads across upper and lower housing matching holes in separator box (131).
(3) Press bearing (60. fig. 2-24) into pump mounting adapter (61).
(4) Position gasket (59) on oil pump (57) and install pump mounting adapter on pump.
(5) Install key (58) and oil pump drive spur gear (62) on pump shaft with gear hub flush with end of pump shaft.
Tighten setscrew (63) and stake mark around setscrew to present loosening.
(6) Install adapter (56), elbow (67) and swivel joint (65) on oil pump.
(7) Insert oil pump into marine gear, engaging gear, and install capscrews (66).
(8) Secure control valve (73) to marine gear with capscrews (75) and lockwashers (74).
(9) Install swivel joint (70) and elbow (69) on control valve.
(10) Install flexible hoses (64. 68 and 71).
(11) Secure lube manifold (47) to marine gear with capscrews (48) and lockwashers (49).
(12) Install elbows (45 and 46) on oil manifold.
(13) Install flexible hoses (44 and 50 through 55).
e. Adjustment. Adjust marine gear bevel gear set as follows:
NOTE
The bevel gear set must be readjusted if any gear set (bevel pinion (18) and bevel gear (48) must de replaced as a
set) or the train of mountings securing the gear and pinion to housing, or housing has been replaced.
(1) Lay upper housing (20) with inside facing up (lower housing (165) for left-hand units). Lower input shaft
assembly in upper housing with original input shaft shim set (45). Install three capscrews .
7-111
(38) to secure input shaft assembly to upper housing.
(2) Install bevel drive assembly in upper housing with original bevel pinion shim set (13). Secure with washers (11)
and capscrews (1O).
(3) Lightly coat several teeth on bevel gear (48) with gear marking compound, red lead, Military Specification
TT-R-191, Type 11.
(4) Check backlash in gear set by securing indicator rigidly to case with actuator point against and perpendicular to
gear face. Backlash should be 0.008 to 0.012 inch.
(5) Rotate bevel pinion shaft (16) sufficiently to mark pinion tooth contact with compound painted on driven gear.
Ideal tooth contact is slightly nearer toe than heel (A, fig. 7-112).
(6) When contact is too high on pinion and too low on driven gear, pinion is too near center (B, fig. 7-112). If
backlash is too small, shim pinion away from center. If backlash is too great, shim driven gear toward pinion.
(7) When contact is too low on pinion and too high on driven gear, pinion is too far from center (C, fig. 7-112). If
backlash is too great, shim pinion toward center. If backlash is too small, shim driven gear away from center.
(8) Repeat (6) and (7) above until proper tooth contact and backlash is obtained.
(9) Remove capscrews (10, FO-3), and washers (11), and lift bevel drive assembly from upper housing. Keep
bevel pinion shim set (13) with bevel drive assembly.
(10) Remove capscrews (38) from input shaft assembly, and lift input shaft assembly from upper housing (20).
f. Installation. Refer to paragraph 2-27.
7-18. Oil Coolers
a. Description. The LARC employs four cooling systems, one for each engine, so that failure of any engine will not
affect the other engines. Two oil coolers are connected in parallel in each cooling system and are used for cooling the
marine gear and gathering box lubricating oil. The oil coolers function as heat exchangers. Water circulates through a
tube in the center of the oil cooler and lubricating oil around the tube through passageways. One marine gear and one
gathering box oil cooler are associated with each cooling system; therefore in the event of an engine failure, the
lubricating oil will still be cooled. The top two oil coolers on each side are associated with the aft engine cooling system,
whereas, the bottom two oil coolers are associated with the forward engine cooling system.
b. Removal and Disassembly.
(1) Determine which cooling system is associated with oil cooler (8 or 27, fig. 7-127) to be removed, and drain
coolant from that system (TM .55-1930-203-20).
(2) Provide a suitable container, remove drain plugs (24), and drain lubricant from oil cooler.
(3) Loosen hose clamps 1181 and slide hoses (17) off nipples (19).
(4) Remove oil lines and fittings from oil cooler.
(5) Remove four bolts (23), lockwashers (2) nuts (1), and straps (3) and remove oil cooler.
(6) Remove nipples (19) from oil cooler.
(7) Remove capscrews (20) and remove oil cooler bonnets (21) and gaskets (22) from oil cooler core (25).
c. Cleaning, Inspection and Repair.
(1) Clean oil cooler bonnet (21, fig. 7-127) and core (25) using procedure and solution as outlined in
paragraph 3-15c(1) through (3).
(2) Replace oil cooler bonnet or core if split, cracked, or otherwise rendered unserviceable. Replace gaskets (22).
(3) Inspect zinc anodes (36) and clean or replace as necessary.
d. Reassembly and Installation.
(1) Install oil cooler bonnets (21, fig. 7-127) and gaskets (22) on core (25) using capscrews (20).
(2) Install nipples (19) in oil cooler (8 or 27).
(3) Position oil cooler and work hoses (17) onto nipples (19).
(4) Secure oil cooler using straps (3), bolts (23), lockwashers (2). and nuts (1), then tighten hose clamps (18).
(5) Install drain plugs (24) and oil lines and fittings on oil cooler.
(6) Fill associated cooling system (TM 55-1930-203-20).
(7) If oil cooler (8) has been removed, fill gathering box to proper level as shown on dipstick. If oil cooler (27) has
been removed. fill marine gear to proper level as shown on dipstick. Refer to LO .55-1930-203-12 for proper lubricant.
(8) Run appropriate engine for a period sufficient to allow oil to circulate through oil coolers. Shut down engine and
recheck oil level. Fill as necessary.
7-19. Propeller
a. Removal. Refer to paragraph 2-28.
b. Cleaning.
(1) Apply hydrochloric acid or muriatic acid to propeller with a brush to remove all underwater corrosion.
(2) Wipe propeller clean with a damp cloth and then dry thoroughly with a dry cloth.
7-112
Key to figure 7-127.
1 Nut
2 Lockwasher
3 Strap
4 Hose, flexible, oil cooler-to-oil cooler, gathering box
5 Adapter, 90°
6 Elbow, street, 900
7 Bushing
8 Oil cooler, gathering box
9 Tubing, gathering box oil pressure
10 Nipple
11 Bushing
12 Hose, flexible, oil supply to oil cooler, gathering box
13 Bushing
14 Tee
15 Nipple, close
16 Bushing
17 Hose
18 Clamp, hose
19 Nipple
20 Capscrew
21 Oil cooler bonnet
22 Gasket, oil cooler
23 Bolt, machine
24 Drain plug
25 Oil cooler core
26 Elbow, street
27 Oil cooler, marine gear
28 Elbow, street
29 Nipple
30 Elbow, 90°
31 Adapter, straight
32 Hose, flexible, oil cooler-to-oil cooler, marine gear
33 Hose, flexible, oil supply-from oil cooler, gathering box
34 Adapter, 90°
35 Hose, flexible, oil supply-from-oil cooler, marine gear
36 Zinc anode .
7-113
Figure 7-127. Oil coolers
7-114
(3) Rub jewelers rouge over both sides of propeller blades and polish blades with a buffing wheel.
Inspection and Repair.
(1) Inspect propeller for bent blades and chipped or curled edges. If propeller is badly damaged, replace it with
a new one.
(2) Inspect lockbolt (1, fig. 2-25), fairwater nut (2), and machine key (4) for good condition. Replace defective
part.
d. Installation. Refer to paragraph 2-28.
c.
7-20. Propeller Shafting
a. Intermediate shaft.
(1) Removal. Refer to paragraph 2-28.
(2) Cleaning, inspection and repair.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(b) Inspect thrust bushings (22 and 26, fig. 2-25) for elongation of holes and flexible inserts (21 and 27) for
signs of chipping or cracking. Replace damaged bushings or flexible inserts.
(c) Replace a bent intermediate shaft (24).
(3) Installation. Refer to paragraph 2-28.
b. Propeller Shaft.
(1) Removal. Refer to paragraph 2-28.
(2) Cleaning and inspection.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi). Remove corrosion or rust from propeller shaft (5, fig. 2-25) with emery paper.
(b) Inspect propeller shaft sleeves for wear (table 1-3). If sleeves are worn below maximum allowable
tolerance, refer to depot maintenance personnel.
NOTE
If sleeves were replaced because of worn condition, disassemble stern tube and strut
tube and check bushings.
(c) Check propeller shaft hub (16, fig. 2-25), shaft nut (17), and nut lockwasher (18) for good condition.
Replace a damaged hub, nut, or lockwasher.
(3) Installation. Refer to paragraph 2-28.
Figure 7-128. Propeller shaft sleeves.
7-21. Stern Tube
a. Disassembly, Cleaning, Inspection, Repair and Reassembly.
(1) Disassembly.
(a) Remove propeller shaft (para 2-28).
(b) Remove capscrews (15, fig. 7-129) and washers (14) which secure packing gland (13) to stuffing box
(10).
(c) Slide gland out and remove packing retainer (12).
(d) Remove packing (11) from stuffing box.
(e) Remove capscrews (16) and washers
7-115
(17) which secure stuffing box to stern tube (7) and remove stuffing box and gasket (9).
(f) Remove capscrews (1 and washers (2) which secure seal retainer (3) and remove seal retainer and
gasket (5).
(g) Press seal (4) out of seal retainer.
Figure 7-129. Stern tube.
(h) Remove setscrews (8) and slide bushings (6) out of stern tube.
Cleaning, inspection and repair.
(a) Clean all parts, except seal (4, fig. 7-129), gaskets (5 and 9), and packing (11), in dry-cleaning solvent,
Federal Specification P-D-680 and dry with low pressure air (10 psi).
(b) Replace seal (4), gaskets (5 and 9), and packing (11).
(c) Inspect bushings (6) for excessive wear (table 1-3). Replace bushing if worn beyond permissible limits.
(d) Check seal retainer (3), stuffing box (10), packing retainer (12), and packing gland (13) for good
condition. Replace a damaged part.
(e) Check stern tube for damage. Replace if necessary.
(3) Reassembly.
(a) Slide bushings (6, fig. 7-129) into position with open end of grease grooves toward center of stern tube
(7).
(2)
7-116
NOTE
If new bushings are to be installed, locate bushings so that bushing end is flush with face
of stern tube and punch-nark bushing through setscrew hole. Drill a 5/16 inch hole
through bushing at punch-mark. Remove burrs and filings from bushing.
(b) Install setscrews (8).
(c) Press seal (4) into seal retainer (3) and install seal retainer and gasket (5). using capscrews
(1) and washers (2).
(d) Install stuffing box (10) and gasket (9) using capscrews (16) and washers (17).
(e) Install propeller shaft (para 2-28).
b. Removal and Installation. These are depot functions.
7-22. Strut Tube
a. Disassembly. Cleaning, Inspection. Repair and Reassembly.
(1) Disassembly.
(a) Remove propeller shaft (para 2-28).
(b) Remove capscrews (1, fig. 7-130) and washers (2) and remove seal retainers (3), gaskets (5), and rope
guard (6).
(c) Press seal (4) out of seal retainer.
(d) Remove setscrews (9) and slide bushings (7) out of strut casting (8).
(2) Cleaning. inspection and repair.
(a) Clean all parts, except seals (4, fig. 7-130) and gaskets (5), in dry-cleaning solvent, Federal Specification P-D-680,. and dry with low pressure air (10 psi).
(b) Replace seals (4) and gaskets (5).
(c) Inspect bushings (7) for excessive wear (table 1-3). Replace bushing if worn beyond permissible limits.
(d) Check seal retainer (3) and rope guard (6) for good condition. Replace a damaged seal retainer or rope
guard.
(e) Check strut casting (8) for damage. Replace if necessary.
7-117
(3)
Figure 7-130. Strut tube.
Reassembly.
(a) Slide bushings (7, fig. 7-130) into position with open end of grease grooves toward center of strut
casting (8).
NOTE
If new bushings are to be installed, locate bushings so that bushing end is flush with face
of strut casting and punch-mark bushing through setscrew hole. Drill a 5/16 inch hole
through bushing at punch-mark. Remove burrs and filings from bushing.
(b) Install setscrews (9).
(c) Press seal (4) out of seal retainer (3) and install seal retainers (3), gaskets (5) and rope guard (6) using
capscrews (1) and washers (2).
(d) Install propeller shaft (para 2-28).
b. Removal and Installation. This is depot function.
7-118
CHAPTER 8
STEERING SYSTEM
Section I. INTRODUCTION
8-1. Description
Land steering (fig. 8-1) is accomplished by turning the column and wheel drives. Hydraulic steering cylinders are used to
turn the column and wheel drives. Control of the hydraulic steering cylinders is effected by hydraulic control valves and a
mechanical differential linkage. The steering levers in the cab operate their respective hydraulic control valves through
jackshafts, steering rods, and bell cranks. The follow-up rods, attached to the port wheel columns, center corresponding
hydraulic control valves when wheels turn to the desired direction.
NOTE
Hydraulic components of the steering system are covered in Chapter 10. The column and
wheel drive assemblies are covered in paragraph 7-10.
Figure 8-1. Steering schematic.
8-2. Land Steering
a. Steering Column and Jackshaft Box.
(1) Removal and disassembly of steering column.
(a) Disconnect tie rods (11, fig. 8-2) from bellcranks (39 and 46) by removing cotter pins (33), bolts (42),
lockwashers (41), washers (32), and nuts (37).
(b) Remove cotter pin (34), nut (35), and washer (36) from lower end of inner steering column (6).
(c) Loosen setscrew (38) and slide lower steering column bellcrank (39) and key (40) off inner steering
column.
(d) Remove bolts (43), lockwashers (47),
8-1
and nuts (48) and remove lower steering column bearing (44).
(e) Raise inner steering column, slide washer (8) up shaft, and remove inner needle bearings (59).
(f) Loosen setscrew (49), and slide upper steering column bellcrank (46) and key (50) off of outer steering
column (9) and inner steering column.
(g) Remove bolts (51), lockwashers (53), and nuts (54) and remove upper steering column bearing (52).
(h) Remove screws (55) from bearing retainer ring (56). Slide bearing retainer down outer steering column
and remove outer needle bearings (57).
(i) Unbolt upper steering column support from instrument panel and remove inner steering column (6), flat
washer (58), and outer steering column (9).
(j) Loosen cap (41 holding spring (5).
(k) Remove screw (3) and pin (2).
(l) Remove cap (4) and remove spring (5).
8-2
Key to figure 8-2.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Hand grip
Pin
Screw, machine
Cap
Spring
Inner steering column
Lubrication fitting
Washer, flat
Outer steering column
Bolt, machine
Tie rod
Nut, castellated
Pin, cotter
Washer
Key
Upper jackshaft bellcrank
Setscrew
Pin, cotter
Bolt, machine
Doubler
Jackshaft bearing
Lockwasher
Lockwasher
Nut
Steering arm
Gasket
Jackshaft
Washer
Washer
Bolt, machine
Nut, castellated
Washer
Pin, cotter
Pin, cotter
Nut, castellated
Washer
Nut, castellated
Setscrew
Lower steering column bellcrank
Key
Lockwasher
Bolt, machine
Bolt, machine
Lower steering column bearing
Jackshaft box
Upper steering column bellcrank
Lockwasher
Nut
Setscrew
Key
Bolt, machine
Upper steering column bearing
Lockwasher
Nut
Screw, machine
Bearing retainer ring
Outer needle bearings
Washer, flat
Inner needle bearings
Figure 8-2. Steering column and jackshaft box.
8-3
(2)
Removal and disassembly of jackshaft box.
(a) Remove tie rods (11, fig. 8-2) from upper jackshaft bellcrank (16) and steering arms (25) from jackshaft
(27) by removing cotter pins (18), bolts (10), lockwashers (22), washers (28), and nuts (31).
(b) Remove bolts (30) and washers (29) securing jackshaft box (45) to doubler (20) and remove jackshaft
box and gasket (26).
(c) Remove cotter pin (13), nut (12), and washer (14). Loosen setscrew (17) and slide upper jackshaft
bellcrank (16) and key (15) off jackshaft.
(d) Remove bolts (19), lockwashers (23), and nuts (24) and remove jackshaft bearings (21).
(e) Lift jackshaft and remove from open end of jackshaft box.
(3) Cleaning, inspection and repair.
(a) Clean all metal parts in dry-cleaning solvent, Federal Specification P-S-661. Dry parts thoroughly with
compressed air (10 psi).
(b) Inspect needle bearings for free rotation, broken or missing rollers, and tightness of fit in bore. If any
defects are found, replace bearing.
(c) Inspect thrust washers for distortion, burrs, and wear. Replace damaged washers.
(d) Examine gasket for deterioration, cuts, and hardness. Replace defective gasket.
(e) Inspect bearings for scored, scratched, cracked, or chipped races and for indication of excess wear of
rollers. Replace damaged bearing.
(f) Inspect bearing housing and shaft for burred, galled, and scored conditions that would indicate the
bearing has been turning in its housing or on its shaft. If the damage cannot be repaired pith crocus cloth, Federal
Specification P-C-458, replace defective part.
(g) Inspect columns for burrs, nicks, cracks, and warpage. If any defect is found, rework or replace column.
(h) Inspect hand grips (1, fig. 8-2) for loose, broken, or deteriorated condition. If hand grips are damaged,
remove grips and clean pipes. Apply adhesive, Military Specification MIL-A-1154, to new hand grips and install hand
grips. If hand grips are loose, replace adhesive.
(i) Inspect jackshaft (27) for a bent shaft and signs of scoring or loose fit in bearing area. If any of these
conditions exist, replace jackshaft.
(4) Reassembly and installation.
(a) Reassemble and install steering column in reverse order of removal and disassembly.
(b) Reassemble and install jackshaft box in reverse order of removal and disassembly.
b. Follow-up-System.
(1) Description. The follow-up system is a mechanical differential linkage consisting of steering rods, follow-up
rods, and differential arms which connects the steering hydraulic system to the steering column assembly. The
differential arms are connected to the steering control valves, steering rods, and follow-up rods to provide a means for
controlling the fluid flow to the steering cylinders (fig. 8-3).
8-4
1
2
3
4
5
6
7
8
9
10
Bellcrank
Nut
Steering rod joint
Jamnut
Steering rod
Ball joint
Follow-up rod
Bolt, machine
Aft differential arm
U-bolt
11
12
13
14
15
16
17
18
19
20
Bearing support
Steering rod bearing assembly
Seal
Ball bushing
Steering rod
Jamnut, control valve
Tie rod
Bolt, machine
Clevis, differential arm
Forward differential arm
Figure 8-3. Follow-up system diagram.
(2)
Removal and disassembly.
(a) Disconnect steering rod-end bearing (6, fig. 8-4) nearest to steering rod to be removed by removing
cotter pin (12), bolt C7), washer (8), lockwasher (10), and nut (11).
(b) Loosen jamnut 121 at nearest joint and unscrew steering rod.
(c) Disconnect steering rod at rod joint (15) on each side of steering rod bearing assembly (21).
(d) Remove nuts (18), washers (19), and
8-5
U -bolt (23) which secure steering rod bearing assembly.
(e) Remove jamnuts from steering rod and slide steering rod out of steering rod bearing assembly, being
careful not to damage ball bushing (34) with threads on steering rod.
(f) Remove seals (32) and ball bushing from steering rod bearing housing (33).
(g) Remove ball joints (17) and follow-up arm connectors (16).
(h) Remove nut (28) and washer (27) and remove bellcrank (26) and washer (25).
(3) Cleaning, inspection and repair.
(a) Clean all parts, except seals (32, fig. 8-4). in dry-cleaning solvent, Federal Specification P-D-680, and
dry with low pressure air 110 psi).
(b) Inspect steering rods (5) and steering rod joints (15) for wear and corrosion. Replace badly worn or co
rroded parts.
(c) Inspect bellcrank spindle (24) for scored condition. Replace a badly scored spindle.
(d) Inspect ball bushing (34) and bearings in steering rod-end bearings for pitted. scored, or burned cond
ition.
(e) Replace seals (32).
(f) Inspect bellcrank (26) for cracks, breaks, or elongated holes. Replace bellcrank if any of these cond
itions are found.
Figure 8-4. Follow-up system.
8-6
Key to figure 8-4.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Steering rod end bearing, jackshaft box
Jamnut
Steering stop
Steering limit bracket
Steering rod
Steering rod-end bearing
Bolt, machine
Washer, flat
Aft differential arm
Lockwasher
Nut
Pin, cotter
Control valve end shackle
Jamnut, control valve
Steering rod joint
Follow-up arm connector
Ball joint
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Nut
Washer
Bearing support
Steering rod bearing assembly
Steering rod connector
U-bolt
Bellcrank spindle
Washer, flat
Bellcrank
Washer, flat
Nut
Steering stop
Steering limit block
Forward differential arm
Seal
Steering rod bearing housing
Ball bushing
(4) Reassembly and installation. Reassemble and install follow-up system in the reverse order of removal and
disassembly.
(5) Adjustment.
NOTE
Bulkhead no. 14 access cover (21, fig. 1-2, TM55 1930-203-20) must be removed to gain
access to aft steering follow-up stops.
(a) Loosen jamnuts (2, fig. 8-5) on forward steering several turns and back off steering stops (3
and 5).
(b) Push left steering lever forward and hold.
(c) After port forward steering cylinder is fully extended, screw aft steering stop (5) until stop strikes
steering limit block (4).
(d) Continue screwing aft steering stop (5) until steering pressure gage in cab indicates pressure drop.
(e) Lock aft steering stop with jamnut (2).
(f) Pull left steering lever aft and hold.
(g) After port forward steering cylinder is fully retracted, screw forward steering stop (3) until stop strikes
steering limit block (4).
(h) Continue screwing forward steering stop (3) until steering hydraulic pressure gage in the cab indicates
pressure drop.
8-7
Figure 8-5. Steering follow-up adjustment.
(i) Lock forward steering stop (3) with jamnut (2).
NOTE
If port front wheel steering cylinder will not travel full stroke in both directions after the
steering stops (3 and 5, fig. 8-5) have been backed off, the starboard front wheel is mi
salined. (For alinement of the wheels, refer to paragraph 10-3).
(j) Adjust aft steering as outlined in (a) through (i) above.
c. Steering Arm Assembly.
(1) General. The steering arm assembly connects the steering cylinders to the column and wheel drive. Four
assemblies are used on each LARC. The port, aft and 'forward steering arm assemblies consist of a steering arm, bus
hings, and a follow-up arm. The starboard forward assembly consists of a steering arm with a connecting arm for the wire
rope from the rudders and bushings. The starboard aft assembly consists of a steering arm and bushings.
(2) Removal.
(a) Remove clevis pins from steering cylinder assemblies at steering arm.
(b) On port forward and aft steering arms (1, fig. 8-6) disconnect ball joint (17, fig. 8-4) from steering arm
follow-up arm. To remove follow-up
8-8
arm (4, fig. 8-6), remove capscrews 15) and lockwashers (6) and remove follow-up arm.
(c) On forward starboard steering arm (2), disconnect wire rope from steering arm.
(d) Remove column and wheel drive assembly as outlined in paragraph 2-16.
(e) Remove steering arm.
(f) If necessary, remove bushings (7) from steering arm.
Figure 8-6. Steering arm assembly.
8-9
(3)
Cleaning, inspection and repair.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(b) Inspect bushing (7, fig. 8-6) for scoring or elongation. If these conditions exist, replace bushings.
(c) Inspect steering rm (1, 2, or 3) for cracks, chipped or broken splines, or loose fit. Replace steering arm
if any of these conditions exist.
(d) Inspect follow-up arm (4) for a bent arm, cracks, or breaks. If any of these conditions exist, replace
follow-up arm.
(4) Installation.
(a) Perform (1) and (2) of paragraph 2-16 b.
(b) Install clevis pins in steering cylinder assemblies at steering arm.
(c) On port forward and aft steering arms (1, fig. 8-6), install follow-up arm (4) using capscrews (5) and
lockwashers (6). Connect ball joint (17, fig. 8-4) to follow-up arm.
(d) On forward starboard steering arm (2, fig. 8-6), connect wire rope to steering arm.
(e) Perform (3) through (14) of paragraph 2-16b.
Section II. MARINE STEERING SYSTEM
8-3. Description
Marine steering (fig. 8-1) is accomplished by two rudders located aft of the propellers. The rudders are steered with the
forward wheels by a wire rope connected between the quadrant and starboard wheel column steering arm. Sheaves are
provided at various bends and turns of the wire rope to insure smooth operation.
8-4. Marine Steering
a. Crossrod Assembly.
(1) Inspect crossrod (13, fig. 8-7) and clevis (11) for broken and bent condition. If damaged, repair or replace if
necessary.
8-10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Nut
Washer
Pin, cotter
Key
Bolt, machine
Capscrew
Key plate
Pin
Bushing
Tiller arm
Clevis
Jamnut
Crossrod
Washer
Nut
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Quadrant
Washer
Nut
Lubrication fitting
Key plate
Capscrew
Pin
Spacer
Pulley
Bushing
Wire rope
Turnbuckles
Pin
Spacer
Figure 8-7. Marine steering.
(2)
Replacement and adjustment.
(a) Remove capscrews (6), key plate (7), and pin (8) at either end of crossrod assembly.
(b) Loosen jamnut (12) and back jamnut off several turns.
(c) Support crossrod assembly and align rudder assemblies parallel to each other.
(d) Screw clevis (11) in or out until crossrod assembly is at correct length. secure clevis with
jamnut (12).
(e) Replace crossrod assembly and install pin (8), key plate (7), and capscrews (6).
b. Tiller Arm.
(1) Removal.
8-11
(a) Remove capscrew (6, fig. 8-7), key plate (7), and pin (8).
(b) Remove and support crossrod assembly.
(c) Support port rudder assembly from under the LARC and remove cotter pin (3), nut (1), and washer (2)
from rudder shaft.
(d) Remove nut (15), washer (14), and bolt (5) securing tiller arm to rudder shaft.
(e) Slip tiller arm (101 and key (4) from rudder shaft.
NOTE
If tiller arm bushing (9) is worn enough to allow end play of crossrod assembly, press
bushing front tiller arm (10) and replace.
(2) Cleaning, inspection and repair.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low air pressure (10
psi).
(b) Inspect tiller arm for broken and malformed condition. If damaged, replace tiller arm.
(3) Installation. Install tiller arm in reverse order of removal.
c. Quadrant.
(1) Removal.
(a) Loosen turnbuckles (27, fig. 8-7) and remove nuts (18), washers (17), and wire rope (26).
(b) Remove capscrews (6), key plate (7), and pin (8).
(c) Remove and support crossrod assembly.
(d) Support starboard rudder assembly from under the LARC and remove cotter pin (3), nut (1), and washer
(2) from rudder shaft.
(e) Remove nut ( 15), washer ( 14), and bolt (5) securing quadrant (16) to rudder shaft.
NOTE
If quadrant bushing (9) is worn enough to allow end play of crossrod assembly, press
bushing from quadrant (16) and replace.
(2) Cleaning, inspection and repair.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low air pressure (10)
psi).
(b) Inspect quadrant for broken or malformed condition. If damaged, replace quadrant.
(3) Installation. Install quadrant in reverse order of removal.
d. Wire Rope.
(1) Removal.
(a) Loosen locknuts at turnbuckles (27, fig. 8-7) and loosen turnbuckle.
(b) Remove nut (18) and washers (17), and remove wire rope (26) from quadrant (16).
(c) Remove turnbuckles (27) with locknuts from wire rope (26).
(d) Remove sleeves (3, fig. 8-8) from socket (5).
(e) Remove plug (4) and wire rope (1) from sleeve (3).
(f) Remove wire rope (26, fig. 8-7).
(2) Installation.
(a) Cut new rope to same length as rope being replaced.
(b) Thread new wire rope through sheaves.
NOTE
Use an assembled sleeve (3, fig. 8-8) and socket (5) to determine position of sleeve on
the wire rope.
(c) Seize wire rope (1. fig. 8-8) just below the sleeve position to pressure lay of wire rope.
(d) Fan out strands and cut off hemp center at a point which will be just inside sleeve (3).
(e) Hold strands together and slip sleeve (3) on wire rope (3) and up against seizing (2).
(f) Fan out strands again and insert plug (4).
(g) Drive plug (4) into sleeve (3) making sure wire rope strands are laying in plug grooves.
(h) Hold strands together and slip in socket (5).
(i) Screw socket (5) onto sleeve (3) and tighten, making sure that wire rope strands are visible through
inspection hole inside of socket.
8-12
Figure 8-8. Wire rope assembly.
8-13
Figure 8-9. Rudder assembly
8-14
(j) Install locknuts and turnbuckles (27, fig. 8-7) on wire rope (26).
(k) Attach wire rope (26) in proper position.
(l) Adjust wire rope (26) by backing locknuts off several turns and screwing turnbuckles (27) until slack is
removed. Secure turnbuckes with locknuts.
e. Pulley.
(1) Removal.
(a) Loosen wire rope at turnbuckles (27, fig. 8-7) and quadrant (16), and remove wire rope from pulleys.
(b) Remove capscrew (21), key plate (20), and pin (22) attaching pulley (24).
(c) Remove pulley (24) and spacer (23).
NOTE
If pulley bushing (25) is worn enough to allow play in the pulley, press bushing from
pulley and replace.
(2) Installation. Install pulley in reverse order of removal.
f. Rudder and Rudder Sleeve Assembly.
(1) Removal.
(a) Remove quadrant assembly or tiller arm assembly.
(b) Lower rudder assembly (8, fig. 8-9) straight down to remove rudder assembly. If vertical clearance
does not permit, it may be necessary to dig a hole in the ground to obtain clearance for the rudder assembly.
(c) Remove eight bolts (2) and sixteen washers (4) and nuts (5), and remove rudder sleeve assembly (3)
and gasket (7).
(d) Remove upper bushing (1) and lower bushing (6) from rudder sleeve assembly.
(2) Cleaning, inspection, and repair.
(a) Clean all parts, except gasket (7, fig. 8-9) in dry-cleaning solvent, Federal Specification P-D-680, and
dry with low pressure air (10 psi).
(b) Inspect bushings (1 and 6) for scored or elongated condition. Replace bushings if badly scored or
elongated.
(c) Inspect rudder sleeve assembly (3) for pitting or cracks. Replace a badly pitted or cracked rudder sleeve
assembly.
(d) Inspect rudder assembly (8) for a bent shaft or broken, cracked, or bent rudder. Fair up bent rudder and
bent shaft. Replace rudder assembly if shaft is broken.
(e) Replace gasket (7).
(3) Installation. Install in reverse order of removal.
8-15
CHAPTER 9
COMPRESSED AIR SYSTEM REPAIR INSTRUCTIONS
SECTION I. INTRODUCTION
9-1. General
The compressed air system consists of an air supply system (fig. 2-19) connected to an air starting control and supply
system (fig. 9-1), airbrake control and supply system (fig. 9-2), transmission shifting control and engine cutout systems
(fig. 9-3), throttle control system (fig. 9-4), marine gear and radiator fan control system (fig. 9-5), tire inflation-deflation
control and supply system (fig. 9-6), ramp seal control and supply system (fig. 9-7), cargo well pump and ramp control
systems (fig. 9-8), windshield wiper control and supply system, and the air horn control and supply system.
Figure 9-1. Air starting control and supply system.
9-1
Key to figure 9-1.
1
2
3
4
5
6
7
8
9
Air starting pilot air valve
Quick-release valve
Lubricator
Air starting pilot air valve
Plug valve
Air starting gage
Air starting filter
Relay air valve
Shuttle valve
Figure 9-2. Airbrake control and supply system.
9-2
Figure 9-3. Transmission shifting control and engine cutout systems.
9-3
Figure 9-4. Throttle control system.
9-4
Figure 9-5. Marine gear and radiator fans control system.
9-5
Figure 9-6. Tire inflation-deflation control and supply system.
9-6
Figure 9-7. Ramp seal control and supply system.
Figure 9-8. Cargo well pump and ramp control systems.
9-7
Section II. COMPRESSED AIR SYSTEM
9-2. Air Compressor (Model 3YC) and Coupling Assembly
a. Removal and Installation.Refer to paragraph 2-23 to remove and install the compressor.
b. Disassembly (fig. 9-9.
(1) Cylinder heads removal.
(a) Disconnect unloader tube (1 1, between high- and low- pressure cylinder heads.
(b) Disconnect and remove vent tube (3) and unloader tube (7).
(c) Remove attaching bolts (15) and nuts (141 securing clamp (13) to intercooler.
(d)Remove bolts (IO) and nuts (11) from intercooler connections securing intercooler assembly to air compressor
cylinder head.
(e)Remove gaskets (16) and unscrew safety valve (9) from intercooler assembly.
(f)Remove bolts securing cylinder heads to cylinders. Remove cylinder heads and gaskets.
(2) High-pressure cylinder head disassembly.
(a)Remove valve cap (18), from plug (17).
(b) Unscrew plug (17) from cylinder head (36).
(c) Lift discharge valve assembly (39) and gasket (35) from cylinder head (36).
(d) Unscrew tee (20) and cap nut (211, allowing unloader valve (22) to slip free.
(e)Unscrew unloader body (231 and remove from cylinder head (36).
(f) Lift out intercooler valve (24) and plunger assembly (29).
(g)Remove retainer (26), washer (27), and spring (28) from plunger (30).
(h) Remove return spring (32) from head.
(i) Remove valve plug (19) and lift out suction valve assembly (34) and gasket (35) from cylinder head.
(3) Low-pressure cylinder head disassembly.
(a)Unscrew elbow (401, from cap nut (64).
(b) Unscrew cap nut (64) and remove unloader valve (63).
Figure 9-9. Air compressor, Model 3YC, disassembly and reassembly
(Sheet 1 of 5).
9-8
Figure 9-9. Air compressor, Model 3YC, disassembly and reassembly
(Sheet 2 of 5).
9-9
Figure 9-9. Air compressor, Model3YC, disassembly and reassembly
(Sheet 3 of 5).
9-10
Figure 9-9. Air compressor, Model 3YC, disassembly and reassembly
(Sheet 4 of 5).
9-11
Figure 9-9. Air compressor, Model 3YC, disassembly and reassembly
(Sheet 5 of 5).
9-12
Key to figure 9-9.
1 Unloader tube
2 Intercooler
3 Vent tube
4 Drain pipe
5 Cap
6 Filler plug
7 Unloader tube
8 Valve body
9 Safety valve
1O Bolt
11 Nut
12 Intercooler
13 Clamp
14 Nut
15 Bolt
16 Gasket
17 Plug
18 Valve cap
19 Valve plug
20 Tee
21 Cap nut
22 Unloader valve
23 Unloader body
24 Intercooler valve
25 Cylinder head assembly
26 Retainer
27 Washer
28 Spring
29 Plunger assembly
30 Plunger
31 Pin
32 Spring
33 Unloader assembly
34 Suction valve assembly
35 Gasket
36 Cylinder head
3 7 Gasket
38 Bolt
39 Discharge valve assembly
40 Elbow
41 Cap
42 Plug
43 Discharge valve assembly
44 Cylinder head assembly
45 Gasket
46 Stud
47 Cylinder head
48 Gasket
49 Bolt
50 Gasket
51 Suction valve assembly
52 Plug
53 Spring
54 Pin
55 Unloader plunger
56 Spring
57 Plunger assembly
58 Washer
59 Retainer
60 Compressor unloader
61 Intercooler valve
62 Cover
63 Unloader valve
64 Cap nut
65 Capscrew
66 End cover
67 Gasket
68 Unloader ball
69 Ball seat valve
70 Ball check plunger
7 1 Lever support
72 Cotter pin
73 Unloader lever oin
74 Unloader lever
75 Lever spring
76 High-pressure cylinder
77 Capscrew
78 Gasket
79 High-pressure piston rings
80 High-pressure oil piston ring
81 High-pressure piston
82 High-pressure piston pin
83 Piston pin retaining ring
84 Piston pin bushing
85 Connector rod pin
86 High pressure connector rod
87 Palnut
88 Nut
89 Shim
90 Connector rod cap
9 1 Crankcase
92 Bearing
93 Spacer
94 Gasket
95 Flange
96 Capscrew
97 Oil seal
98 Capscrew
99 Low-pressure cylinder
1 00 Capscrew
101 Gasket
102 Low-pressure piston rings
103 Low-pressure oil piston ring
104 Low-pressure piston
105 Low-pressure piston pin
106 Piston pin retaining ring
107 Low-pressure connector rod pin
108 Low-pressure connector rod
109 Piston pin bushing
110 Palnut
I11 Nut
112 Shim
113 Connector rod cap
114 Stud
115 Oil drain cap
1 16 Strainer
117 Strainer retaining ring
118 Bearing spacer
119 Bearing
120 Crankshaft
121 Ball
122 Oil control valve cap
123 Oil pump plunger
124 Plug
125 Plug
126 Oil pump body
127 Cotter pin
128 Oil relief valve body
129 Ball
130 Spring
131 Spring retainer
132 Oil pump piston
Figure 9-9. Air compressor, model 3YC, disassembly and reassembly.
9-13
(c) Remove cover (62) from inlet valve plug (52).
(d) Lift intercooler valve (61), plunger assembly (57), and return spring (53) from inlet valve plug (52) and
remove retainer (59), washer (58), and unloader plunger spring (56) from unloader plunger (55).
(e) Unscrew inlet valve plug (52) and remove suction valve assembly (51) and gasket
(50).
(f) Remove valve cap (41) and discharge 7alve plug (42) from cylinder head (47).
(g) Lift discharge valve assembly (43) and gasket (45) from cylinder head.
(4) Low-pressure cylinder removal.
(a) Remove low-pressure cylinder head (1) above.
(b) Remove capscrews (77), and lift high- pressure cylinder from high-pressure piston (81). Remove gasket (78)
from crankcase (91).
(5) End cover removal.
(a) Remove capscrews (65), and pull end cover (66) from crankcase (91). Remove end cover gasket (67).
(b)Remove cotter pins (72), and unloader lever pin (73), freeing unloader lever (74), and lever support (71).
(c)Remove unloader lever (74), lever spring (75), ball check plunger (70), unloader ball (68), and ball seal valve
(69) from end cover (66).
(6) Oil pump removal.
(a) Remove end cover ( (6) above).
(b) Pull oil pump from crankcase.
(c) Remove oil pump plunger (123), oil pump piston (132), and plug (135).
(d) Remove oil relief valve body (128).
(e) Disassemble by removing cotter pin (127), spring retainer (131), spring (130), and ball (129).
(f)Remove strainer retaining ring (117) and strainer (1 16) from crankcase. t7) Low-pressure piston and connector
rod removal.
(a) Remove low-pressure cylinder and oil pump ( (4) and (7) above).
(b)Remove palnuts (110), and nuts (111) from studs and remove connector rod cap (113), and shims (112).
(c) Pull low-pressure piston (104) with attached low-pressure connector rod (108) from crankcase (91).
(d)Remove piston pin retaining rings (106) and press low-pressure piston pin (105) from low- pressure piston
(104).
(e) Remove low-pressure piston rings (1 02) and low-pressure oil piston rings (103) from low-pressure piston
(104). Remove pin (107) and press out piston pin bushing (109) from low-pressure connector rod (108).
(8) High-pressure piston and connector rod removal.
(a) Remove high-pressure cylinder and oil pump ((5) and (7) above).
(b) Remove palnuts (87), and nuts (881 from studs and remove connector rod cap (90), and shims (89).
(c) Pull high-pressure piston (81) with attached high-pressure connector rod (86) from crankcase.
(d)Remove piston pin retaining rings (83) and press high-pressure piston pin (82) from high- pressure piston (81).
(e) Remove high-pressure piston ring (79) and high-pressure oil piston ring (80) from high- pressure piston (81).
Remove connector rod pin
(85) and press piston pin bushing (84) from high- pressure connector rod (86).
(9) Crankshaft removal.
(a) Remove high-pressure piston and connector rod, and low-pressure piston and connector rod ((8) and (9)
above).
(b) Remove capscrews (96), and (98) and remove flange (95) with oil seal (97). Remove flange gasket (94) from
crankcase (91). Press oil seal (97) from flange (95).
(c) Press drive end of crankshaft from spacer (93) and bearing (92), and remove crankshaft from crankcase (91).
(d) Pull bearing spacer (I 118) and bearing
(119) from crankshaft (120).
(e)Press bearing (92) from crankcase 191).
(f) Remove oil control valve cap (122) and ball (121) from crankshaft counterweight.
c. Cleaning, Inspection and Repair.
NOTE
Refer to table 1-13 to tolerances and clearances.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Dry with compressed air (16 psi).
Make certain oil header in crankcase is thoroughly clean and crankcase is free of metal chips and grit.
(2) Examine pistons for scores, cracks, or wear. Check each piston with a micrometer in relation to the cylinder bore
diameter for clearance of 0.0020 to 0.0025 inch for high-pressure piston and 0.0040 to 0.0075 inch for low-pressure
piston. Replace defective pistons.
NOTE
Clearance measurement must be made on thrust side of piston.
(3) Examine fit of piston rings in grooves of piston. The piston rings should be free in the
9-14
grooves and show an even bearing surface on the entire circumference. If rings are broken, they must be replaced.
(4) Examine fit of piston pin in piston and in connector rod. Piston pin must be a press fit in piston. If piston
pin is loose in the piston, the piston, piston pin, or both must be replaced.
(5) Inspect connector rod bearing clearance on crankshaft journals. Clearance should be 0.001 to 0.002 inch.
If babbitt is worn, cracked, or broken, replace the connector rod. If clearance cannot be adjusted with shims, replace the
connector rod.
(6) Inspect crankshaft for scoring and overheating and wear to main bearing journal. If main bearing journal
prevents roller bearings from being a tight press fit, replace bearing, crankshaft, or both. Replace damaged crankshaft.
(7) Inspect bearings for grooving, discoloration, or uneven wear. Replace defective bearings.
(8) Install new oil seals.
(9) Inspect oil pump spring and ball checks; make sure plunger works freely in the pump body. Assure ball
checks are not held off their seats by dirt or foreign matter. If cleaning does not correct defective parts, replace.
(10) Inspect oil pressure relief valve for dirt, broken spring, and damaged ball or seat. Clean relief valve and
replace defective parts.
(11) Examine all valve mating surfaces for smooth conditions. Replace defective parts.
NOTE
Replace all gaskets in high- and low-pressure cylinder heads.
d.
(12) Examine safety valve 191 for corrosion and stripped threads. Replace safety valve if defective.
Reassembly. Reassemble compressor in the reverse order of removal.
NOTE
Refer to table 1-14 for torque specifications.
9-3. Air Compressor (Model 3VCJ and Coupling Assembly
a. Removal and Installation. Refer to paragraph 2-24 to remove and install the compressor.
b. Disassembly (fig. 9-10).
(1) Cylinder heads removal.
(a) Disconnect and remove unloader tube (1) between high and low pressure cylinder heads.
(b) Remove capscrew (16), flatwasher (17), clamp (18), and spacer (19) from air compressor.
(c) Remove screw (1) and nut (8) securing clamp (10) to intercooler.
9-15
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
(Sheet 1 of 6).
9-16
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
(Sheet 2 of 6).
9-17
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
(Sheet 3 of 6).
9-18
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
(Sheet 4 of 6).
9-19
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
(Sheet 5 of 6).
9-20
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
(Sheet 6 of 6).
9-21
Key to figure 9-10.
I Unloader tube
2 Filler plug
3 Drain plug
4 Capscrew
5 Lockwasher
6 Safety} relief valve
7 Gasket
8 Nut
9 Bracket
10 Clamp
11 Screw
12 IntercoolIer
13 Gasket
14 Lockwasher
15 Capscrew
16 Capscrew
17 Flatwasher
18 Clamp
19 Spacer
20Cal)
21 Sleeve
22 Packing
23 Seal
24 Packing
25 Plunger
26 Valve assembly. suction
27 Gasket
28 Cap
29 Gasket
30 Plug
31 Valve assembly discharge
32 Gasket
33 Head, high-pressure
34 Gasket
35 Screw
36 Cap. valve
37 Sleeve
38 Packing
30 Seal
40 Packing
41 Plunger
42 Valve assembly. suction
43 Gasket
44 Cap
45 Gasket
46 Plug
47 Valve assembly. discharge
48 Head. low-pressure
49 Gasket
50 Screw
51 Gasket
52 Packing
53 Breather tube
54 Capscrew
55 Cylinder. low-pressure
56 Gasket
57 Ring. piston. compression
58 Ring. piston. oil
59 Piston. low-pressure
60 Retainer. piston pin
61 Piston pin. low pressure
62 Locknut
63 Washer
64 Connecting rod. Low pressure
64.1 Piston pin bushing
65 Bolt
66 Bearing insert
67 Plug
68 Connecting rod. high-pressure
69 Retainer. piston pin
70 Piston pin. high-pressure
71 Piston. high-pressure
72 Ring. piton oil
73 Ring. piston compression
74 Cylinder. high-pressure
75 Capscrew
76 Gasket
77 Locknut
78 Washer
79 Bearing insert
80 Bolt. connecting rod
81 Baffle
82 Lockwasher
83 Screw
84 Crankcase
85 Seal
86 Packing. preformed
87 Roll pin
88 Insert. oil pump
89 Rotor. oil pump
90 Cover. oil pump
91 Lockwasher
92 Screw
93 Pipe Plug
94 Packing. preformed
95 Cover
96 Lockwasher
97 Screw
98 Rear retainer assembly
99 Capscrew
100 Lockwasher
101 Ball
102 Tube. oil intake
103 Fitting. oil intake tube
104 Sleeve. rubber
105 Spring
106 Roll pin
107 Retainer. oil relief spring
108 Shim
109 Shim
110 Shim
111 Cup bearing
112 Cone and rollers
113 Crankshaft
114 Plug
115 Cup, Bearing
116 Vane
117 Spring
Figure 9-10. Air compressor, model 3VC, disassembly and reassembly
9-22
(d)
Remove capscrews (4 and 15), lock-washers (5 and 14), and intercooler (12) from cylinder heads.
(e)
Remove gaskets (7 and 13) and unscrew safety relief valve (6) from intercooler.
(f)
Remove bolts securing cylinder heads to cylinders. Remove cylinder heads and gaskets.
(g)
Remove crankcase breather tube (53) and packings (52).
(2)
High-pressure cylinder head disassembly.
(a)
Remove valve cap (28), and gasket (29).
(b)
Unscrew plug (30) from cylinder head (33) and lift discharge valve assembly (31) and gasket (32) from cylinder
head (33).
(c)
Remove valve cap (20) and packing (22).
(d)
Unscrew sleeve (21) from cylinder head and remove plunger (25), seals (23), and packing (24) from bore of
sleeve.
(e)
Lift suction valve assembly (26) and gasket (27) from cylinder head.
(3)
Low-pressure cylinder head disassembly
(a)
Remove valve cap (36), and packing (38).
(b)
Unscrew sleeve (37) from cylinder head (49) and remove plunger (41), seals (39), and packing (40) from bore
of sleeve.
(c)
Lift suction valve assembly (42) and gasket (43) from cylinder head.
(d)
Remove valve cap (44) and gasket (45).
(e)
Unscrew plug (46) from cylinder head and lift discharge valve assembly (47) and gasket (48) from cylinder
head.
(4)
High-pressure cylinder removal.
(a)
Remove high-pressure cylinder head ( (1) above).
(b)
Remove capscrews (75), and lift high-pressure cylinder (74) from high-pressure piston (71). Remove gasket
(76) from crankcase (84).
(5)
Low-pressure cylinder removal
(a)
Remove low-pressure cylinder head ( (1) above).
(b)
Remove capscrews (54), and lift low-pressure cylinder (55) from low-pressure piston (59). Remove gasket (56)
from crankcase (84).
(6)
Oil pump removal.
(a)
Remove screw (97), lockwashers (96), cover (95), and packing (94) from oil pump cover (90).
(b)
Remove screws (92), lockwashers (91), oil pump cover (90), and packing (86) from rear retainer assembly (98).
(c)
Remove oil pump rotor (89), vanes (116), and springs (117).
(d)
Remove oil pump insert (88) from roll pin (87). Pu1l roll pin from rea r retainer assembly (98).
(7)
High-pressure piston and connecting rod removal.
(a)
Remove high-pressure cylinder ( (2) above).
(b)
Remove locknuts (77), and flatwashers (78) from connecting rod bolts (80) and remove connecting rod cap and
bolts.
(c)
Pull high-pressure piston (71) with attached high-pressure connecting rod (68) from crankcase and remove
bearing inserts (79).
(d)
Remove piston rings (73 and 72) from high-pressure piston.
(e)
Remove piston pin retaining rings (69) and press high-pressure piston pin (70) from high-pressure piston (71)
and remove connecting rod (68).
(8)
Low-pressure piston and connecting rod removal
(a)
Remove low-pressure cylinder ( (3) above).
(b)
Remove locknuts (62), and flatwashers (63) from connecting rod bolts (65) and remove connecting rod cap and
bolts.
(c)
Pull low-pressure piston (59) with attached low-pressure connecting rod (64) from crankcase and remove
bearing inserts (66).
(d)
Remove piston rings (57 and 58) from low-pressure piston.
(e)
Remove piston pin retaining rings (60) from low-pressure piston (59) and .heat the piston in 130° to 150°F
water. Push piston pin (61) from piston (59) and remove connecting rod (64).
CAUTION
Do not drive the piston pin from the aluminum piston or use an open flame to heat the piston.
(9)
Crankshaft removal
(a)
Remove high-pressure piston and connecting rod, and low-pressure piston and connecting rod ( (7) and (8)
above).
(b)
Remove oil pump ( (6) above).
(c)
Remove capscrews (99), and Iockwashers (100) and remove rear retainer assembly (98). Disassemble rear
retainer assembly as follows:
1. Remove oil intake tube (102) and rubber sleeve (104).
2. Remove roll pin (106), oil relief spring retainer (107), oil relief spring (105), and nylon ball (101).
3. Press bearing cup (111) from rear retainer assembly.
(d)
Remove shims (108, 109 and 110) from crankcase (84).
(e)
Remove crankshaft (113) from crankcase and pull cone and rollers from crankshaft.
9-23
(f)
Remove screws (83), lockwashers (82), baffle (81), and oil seal (85) from crankcase. Press bearing cup (115)
from crankcase.
c.
Cleaning, Inspection and Repair.
(1)
Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Dry with compressed air (10 psi).
NOTE
Make certain that drilled oil passages in crankshaft are thoroughly clean
and crankcase is free of metal chips and grit.
(2)
Examine pistons for scores, cracks, or wear. Check each piston with a micrometer in relation to the cylinder
bore diameter for clearance of 0.002 to 0.0035 inch for high-pressure piston and 0.0045 to 0.0065 inch for low-pressure
piston. Replace defective pistons.
NOTE
Clearance measurement must be made at piston skirt.
(3)
Examine fit of piston pin in piston and connecting rod. Piston pin must be a palm push fit in piston at 70ºF. If
piston pin is loose in the piston, replace the piston pin and piston assembly.
(4)
Check piston rings for groove and gap clearance. If clearances exceed limits specified in table 1-12, replace
piston rings.
(5)
Check clearance between piston pin and connecting rod bushing. Clearance should be 0.0002 to 0.0006 inch.
Replace connecting rod bushing if clearance exceeds 0.0006 inch.
NOTE
Rifle drilled connecting rods, part No. AH6-96-3, are no longer manufactured and have been replaced with part No.
AH7-96-4 connecting rods, which are not rifle drilled. The new connecting rod is furnished with a replaceable piston pin
bushing, part No. H21-577. This bushing can be installed in the obsolete rifle drilled rods as shown in figure 9-11. when
bushing replacement is required.
CAUTION
Do not substitute the bushing because the bushing material is
"special".
(6)
Inspect connecting rod for straightness (fig. 9-11). Connecting rod must be parallel with piston. If twisted,
replace connecting rod.
(7)
Inspect connecting rod bearing inserts for grooving, discoloration, or uneven wear. Replace defective bearing
inserts.
(8)
Inspect connecting rod bearing clearance on crankshaft journals. Clearance should be 0.0025 to 0.0044 inch.
This type of bearing is not adjustable. If clearance exceeds 0.0044 inch, replace bearing inserts.
(9) Inspect crankshaft for scoring and overheating and wear to main bearing journals. If a main bearing journal
prevents a roller bearing from being a tight press fit, replace bearing, crankshaft, or both. Replace a damaged
crankshaft.
(10) Inspect roller bearings for grooving, discoloration, or uneven wear. Replace defective bearings.
(11) Inspect oil pump insert, rotor, springs, and vanes for damage and wear. Assure that vanes slide freely in oil
pump rotor. Replace defective parts.
(12) Inspect oil pressure relief valve for broken spring and damaged ball or seat. Replace defective parts.
(13) Inspect suction and discharge valves for damage or wear. Replace defective valves.
(14) Check intercooler safety valve for proper operation. The valve must release at 60 psi. Replace safety valve if
defective.
(15) Inspect intercooler assembly for crimping or rupture. Replace intercooler if defective.
(16) Replace all seals and gaskets.
9-24
A.
Location of bushing split when pressed into rod— split ± 15ºwith center line.
B.
Diameter of rod bore before bushing is pressed in — 1.375 ± .0003.
C.
Finished bore diameter of bushing-1.2501 inch minimum, 1.2503 inch maximum.
D.
Surface finish requirements of bushing — 8 micro inch maximum.
E.
Tolerance requirements with respect to parallelism and squareness with the large end of the rod.
ME 1930-203-34/9-11
Figure 9-11. Connecting rod.
d.
(1)
Reassembly.
Install baffle (81, fig. 9-10) in crankcase (84) with screws (83) and lockwashers (82).
NOTE
Prior to installation of screws (83), coat threads of screws with nonhardening sealing compound, Military Specification MIL-S-45180.
(2)
Press bearing cup (115) into bearing counterbore of crankcase. Make sure bearing cup is' seated tightly against
bottom of counterbore.
(3)
Press cone and rollers (112) on crankshaft (1 13). Make sure cone and rollers are tight against the machined
cheeks on counterweights of crankshaft.
9-25
(14) Insert crankshaft assembly into crank-case (84).
(5)
Press bearing cup (111) into bearing counterbore of rear retainer assembly (98). Make sure the bearing
cup is seated tightly against bottom of counterbore.
(6)
Press roll pin (87) into hole provided in the bore of rear retainer assembly until it bottoms. The pin should
not protrude more than the thickness of oil pump insert (88).
(7)
Install rubber sleeve (104) on oil intake tube (102). Push the tube into tapped hole in rear retainer
assembly (98) until it bottoms and hold in position while fitting (103) is firmly tightened.
NOTE
The oil intake tube must be positioned in the rear retainer assembly so that the screen will lie
horizontally along the bottom of the crankcase.
(8)
Start roll pin ( 106) in the hole provided at the relief valve bore in rear retainer assembly. Do not allow the
pin to protrude into the bore. Place nylon ball (101), oil relief spring (105), and oil relief spring retainer (107) into oil relief
valve bore. Push the spring retainer into the bore until it passes the roll pin hole and tap the roll pin through the relief
valve bore until it is flush with the casting face.
(9)
Install three shims (110) and rear retainer assembly (98) on crankcase using lockwashers (100) and
capscrews (99). Tighten the capscrews evenly to a torque of 30 foot-pounds. Check crankshaft end clearance and adjust
if required
((10) below).
NOTE
When installing shims and rear retainer assembly the flats on the outer diameter of the retainer and
flats of the shims must be in line with the cylinder mounting faces.
NOTE
Plastic shims (108, 109, and 110, fig. 9-10) are placed between rear retainer assembly and crankcase to adjust crankshaft end clearance and are color coded to identify thickness. The blue is 0.005 inch,
translucent 0.0075 inch, and the yellow 0.020 inch. The normal requirement to start the adjusting
procedure should be 0.060 inch or three yellow shims between rear retainer assembly and crankcase.
(a)
Check crankshaft end clearance with dial indicator. End clearance should be 0003 to 0.005 inch.
(b)
Remove or add shims between retainer and crankcase until proper crankshaft end clearance is obtained.
CAUTION
Check total thickness of shims after proper crankshaft end clearance is obtained. If thickness
is more than 0.068 inch or less than 0.025 inch, a complete crankshaft recheck should be made to
determine whether all parts are correctly installed.
(11) Install oil seal in crankcase as follows:
(a)
Turn crankshaft so that keyway is up. Coat exposed length of crankshaft with same type of oil that will be used
in the crankcase, Military Specification MIL-L-2 104.
(b)
Place oil seal (85), over end of crankshaft with lip of seal facing the crankcase. Lift the seal against the lower
side of the shaft opposite the keyway and slide it to the crankcase bore.
(c)
Coat outer diameter of the oil seal with non-hardening sealing compound, Military Specification MIL-S-45180.
(d) Using a suitable seal driving tool, drive the seal squarely into the crankcase bore until it is flush with
outside of crankcase.
12) Install oil pump as follows:
(a)
Slide oil pump insert (88), over guide pin (87) into counterbore of rear retainer assembly (98).
NOTE
An arrow, etched on the face of the reversible insert indicates rotation necessary for oil pump
operation. The insert must be installed with the arrow pointed in direction of compressor rotation.
CAUTION
For LARC application, the insert must be installed with arrow pointed clock-wise.
(b)
Place rotor (89), over crankshaft into the oil pump insert (88).
(c)
Check clearance between face of rotor and oil pump cover. Correct clearance is 0.0035 to 0.0055 inch. If
clearance is not within specified limits, replace oil pump rotor (89), rear retainer assembly (98), or both.
(d) Install a vane spring (117) and vane ( 116) in the rotor slot at the widest opening between rotor and oil
pump insert. Turn the crankshaft 90º and install second spring and vane. Repeat until all four springs and vanes are
installed.
NOTE
The relief provided on one side of the vane must be on the leading edge or toward the direction of
rotation.
(e)
Lightly grease performed packing (86) and place it in rear retainer assembly groove. Install oil pump cover (90)
using lockwashers (91) and screws (92). Tighten screws to a torque of 9 foot-pounds.
(f)
Lightly grease performed packing (94)
9-26
and place it in cover (95) groove. Install cover (95) using lockwashers (96) and screws (97).
(13) Heat low-pressure piston (59), in 130° to 150°F water. Place upper end of connecting rod (64) between piston
pin bosses and push piston pin (61) in place. Install piston pin retainers (60).
NOTE
Lubricate piston pins with same type (of oil that will be used in the crankcase. Military Specification
MIL-L-2 104. prior to installation.
CAUTION
Do not drive the piston pin into the aluminum piston or use and open flame to heat the piston.
(14) Place upper end of connecting rod (78) between piston pin bosses of high-pressure piston (71) and press piston
pin (70) in place. Install piston pin retainers (69).
(15) Install oil ring (58) and compression rings (57) on low-pressure piston (59), and oil ring (72) and compression
rings (73) on high-pressure piston (71).
CAUTION
An identifying mark, either the word "top" of a black dot is etched on one side of each co mpression ring. The rings must be installed with these identifying marks toward top of piston.
(16) Wipe crankshaft journal clean and lubricate with same type of oil that will be used in crankcase, Military Specification MIL-L-2104.
(17) Install low-pressure and high-pressure piston and connecting rod assemblies as follows:
(a)
Install connecting rod bearing inserts (66 or 79) in connecting rods (64 or 68).
NOTE
Before installing bearing inserts. make certain insert backs and connecting rod bore surfaces are
clean and free of oil.
CAUTION
When installing bearing inserts, be sure tang of each insert is engaged in the notches pr ovided in the connecting rod and cap bore.
(b)
Lower connecting rod into place on crankshaft and secure connecting rod bearing cap to the connecting rod
using bolts (65 or 80), flatwashers (63 or 78) and locknuts (62 or 77). Tighten locknuts to a torque of 350 inch-pounds.
CAUTION
When installing connecting rod bolts, be sure flats on bolt heads engage with the milled flats
on the connecting rod caps. (18) Install low- and high-pressure cylinders as follows:
NOTE
Before attempting to install the cylinders over the positions and rings, support the piston so that the connecting rod is
not accidentally bent or twisted. Wooden blocks should be placed between the bottom of the pistons and the cylinder
mounting faces of the crankcase. The blocks should be approximately ¼ " shorter than the distance between the bottom
of the piston and the crank-case cylinder mounting face when the piston is at the top end of its stroke. Always use the
blocks when installing the cylinders. Remove blocks after piston and piston rings have entered cylinder.
CAUTION
The cast rib running vertically through the cooling fins of the cylinders must be positioned on the
same plane as the crankshaft in order to assure proper cooling and also provide proper positioning of the
valve reliefs cast in the top face of the cylinder. The low pressure cylinder has a relief cast in one side of
the cylinder mounting flange. This relief must be positioned to make the crankcase breather tube hole
accessible.
(a)
Position gasket (56 or 76). on crankcase (84) and install cylinder (55 or 74) using capscrews (54 or 75). Tighten
the capscrews to a torque of 30 foot-pounds.
NOTE
Before installing the cylinders. position piston ring gaps 90 apart and apply a film of lubricating oil. Military Specification MIL-L-2104 to the pistons and rings.
(b)Check top of piston to top of cylinder clearance as follows:
1. Rotate the crankshaft to bring either piston to the top of its travel.
2.Check top of piston to top of cylinder clearance with a dial indicator. depth micrometer, or by placing a straight edge
across the top face of the cylinder and then measuring the clearance with feeler gages. Clearance should be -0.007 to +
0.01, inch. If clearance is not within these limits, improper thickness cylinder mounting gasket has been installed or connecting rod is bent.
3. Rotate crankshaft to bring other piston to the top of its travel and repeat step 2 above.
(19) Low-pressure cylinder head reassembly and installation.
(a) Reassembly.
1. Install gasket (48), and discharge valve assembly (47) into cylinder head (49).
NOTE
Rotate valve on gasket and seat to assure proper locating.
2.Screw plug 1461 into cylinder head (49)
9-27
against discharge valve assembly (47). Tighten plug to a torque of 100 foot-pounds.
3. Install gasket (45) and valve cap (44). Tighten valve cap to a torque of 100 foot-pounds.
4. Install gasket (43) and suction valve assembly (42) into cylinder head (49).
NOTE
Rotate valve on gasket and seat to assure proper locating.
5. Install seals (39) and packing (40) in the three grooves provided in bore of sleeve (37).
CAUTION
The packing must be placed in center groove to provide a seal between the plunger and sleeve.
The seals must be placed in the upper and lower grooves to facilitate lubrication.
6. Apply a light coat of grease (MIL-L-4343) to packing and seals in sleeve (37), and coat outside of
plunger (41) and install the plunger into bore of sleeve.
7. Screw sleeve (37) into cylinder head (49) against suction valve assembly (42), and tighten to a
torque of 100 foot-pounds.
8. Apply a light coat of grease (MIL-L-4343) to packing (38) and place it over sleeve (37) so that it
rests in the undercut provided in the threaded area of the sleeve.
9. Install valve cap (36). Tighten to a torque of 100 foot-pounds.
(b) Installation. Install cylinder head in reverse order of removal (b) (1) above.
(20) High-pressure cylinder head reassembly and installation.
(a) Reassembly.
1. Install gasket (27), and suction valve assembly (26) into cylinder head (33).
NOTE
Rotate valve on gasket and seat to assure proper locating.
2. Install seals (24) and packing (23) in the three grooves provided in bore of sleeve (21).
CAUTION
The packing must be placed in center groove to provide a seal between the plunger and sleeve.
The seals must be placed in the upper and lower grooves to facilitate lubrication.
3. Apply a light coat of grease (MIL-L-4343) to the packing and seals in sleeve (21), and coat ou
tside of plunger (25) and install the plunger into bore of sleeve.
4. Screw sleeve (21) into cylinder head (33) against suction valve assembly (26), and tighten to a
torque of 70 foot-pounds.
5. Apply a light coat of grease( MIL-L-4343) to packing (22) and place it over sleeve (21) so that it
rests in the undercut provided in the threaded area of the sleeve.
6. Install valve cap (20). Tighten to a torque of 70 foot-pounds.
7. Install gasket (32) and discharge valve assembly (31) into cylinder head (33).
NOTE
Rotate valve on gaskets and seat to assure proper location
8. Screw plug (30) into cylinder head (33) against discharge valve assembly (31). Tighten plug to a
torque of 70 foot-pounds.
9. Install gasket (29) and valve cap (28). Tighten valve cap to a torque of 70 foot-pounds.
(b) Installation. Install cylinder head in reverse order of removal (b)(1) above.
9-4. Actuator Positioner Governor Control
a. Description. The actuator positioner governor control is a Type AB-1 actuator positioner used to control engine
speed by varying the position of the engine governor control shaft. The actuator positioner operates between 10 and 60
psi control pressure applied to its diaphragm. A rod takes specific positioning relative to the position of the speed controls
in the cab. The rod end operates the governor control shaft through a linkage. The actuator positioner has a separately
controlled stop cylinder. When air is admitted to the stop cylinder, the rod will be returned 2 inches in the opposite dire
ction, regardless of the position of the rod within its 2 inch nominal stroke. Thus if the rod is in full speed position, it will be
returned to idle position, or if it is in idle position, it will be returned to stop position.
b. Removal and Disassembly.
(1) Removal
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (51 to vent compressed air from lines.
(b) Disconnect hoses from elbows (I and 6, fig. 9-12) installed in actuatorpositioner (5).
(c) Remove cotter pin (4), washers (3), and connecting pin (2) attaching control rod to governor throttle
control shaft.
(d) Remove bolts (7). nuts (9), and lockwashers (8) attaching actuator positioner (5) to mounting bracket
on torque converter and remove actuator positioner.
(e) Remove elbows (1 and 6) from actuator position (5).
9-28
Figure 9-12. Actuator positioner removal and installation
12) Disassembly.
(a) Remove capscrews (1, fig. 9-13) and nuts (4) securing diaphragm cover (2) to actuator positioner body (7).
Exercise caution as cover is under spring load.
(b) Remove cover and diaphragm (3).
(c)Remove diaphragm spring (6) and shims (8).
(d)Remove bolt (14), nut, (17), and spring washers (16).
(e) Pull out needle bearing (15).
(f) Pull out piston rod (51.
(g)Loosen locknut (9) and unscrew adjuster (1I0).
(h) Loosen jamnut (13) and unscrew rod (12).
(i)Remove cotter pin (22) and push out pin (21)
(j)Remove auxiliary body cap (26) and pull out auxiliary push piston (27) and attaching parts, including auxiliary piston
spring (29).
(k) Pull out piston packing cup (31).
(I) Remove lubricator swab (30) from auxiliary push piston.
(m) Remove cotter pin (19) and press out fulcrum pin (24).
9-29
Figure 9-13. Actuator positioner governor control ,disassembly and reassembly.
9-30
Key to figure 9-13.
I Capscrew
17 Nut
2 Diaphragm cover
18 Lever arm
3 Diaphragm
19 Cotter pin
4 Nut
20 Needle bearing
5 Piston rod
21 Pin, piston rod
6 Diaphragm spring
22 Cotter pin
7Body
23 Washer
8 Shims
24 Pin, fulcrum
9 Locknut
25 Connecting link
10 Adjuster
26 Auxiliary body cap
11 Grease fitting
27 Auxiliary push piston
12 Rod
28 Auxiliary piston body
13 Jamnut
29 Auxiliary piston spring
14 Bolt
30 Lubrication swab
15 Needle bearing
31 Packing cup
16 Washer
32 Rivet
(n) Separate spring washers (23) lever arm 118), and connecting link (25).
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash rubber parts in soap and water
and dry with a low pressure air stream.
(2) Inspect diaphragm (3), and packing cup (31) from cracks and broken sealing beads. Replace a defective
diaphragm or packing cup.
(3) Check springs (6 and 29) for breaks or distortion. Replace defective springs.
(4) Check that auxiliary piston body (28) is securely mounted to actuator body (7). If piston body is loose, replace
rivets (32).
(5) Inspect needle bearings (15 and 20) for scoring or roughness. Replace actuator positioner if bearings are
defective.
(6) Inspect grease fittings (I1) for clogging or breaks. Replace grease fittings if clogged or broken.
d. Reassembly and Installation.
(1) Reassemble and install actuator positioner in reverse order of disassembly and removal.
(2) Lubricate actuator positioner as outlined in LO 55-1930-203-12.
e. Adjustment. Adjustments are provided for spring height. and final travel of the rod end. As assembled, these
adjustable elements are so matched that lever travel starts at 10 psi control pressure and attains maximum rod end
travel at about 60 psi control pressure. The rod end travel can be changed to match the operated device by backing off
the jamnut (13, fig. 9-13) and moving the rod end (12) to any desired operating length and tightening the jamnut. If
necessary to change the pressure at which initial travel occurs, add or remove one or more shims (8) until the rod end
starts to move at the desired initial pressure. This is normally required only when the spring is replaced. The adjuster (10)
is used to match total travel with smaller or higher pressure than the normal 60 psi. After loosening the locknut (9),
adjuster (10) is turned in to cause maximum travel to occur at higher pressure. After installation, the distance between
the connecting link (25) and the pin hole in the rod end (12) should be 6 inches. Check that the distance between the
holes at each end of the link between the actuator positioner and governor is 16 19 / 32 inches. If not, loosen the jamnuts
and adjust the 16 19 / 32 inches. Tighten jamnuts.
9-5. Air Compressor Governor
a. Removal and Disassembly.
(1) Removal
(a) Open globe valves on base of air tanks and vent compressed air from air supply tanks.
(b)Disconnect tubing (20 and 24, fig. 9-14) from elbows (21 and 22).
(c) Remove bolts (27), lockwashers (26), and nuts (25) securing governor to bracket and remove governor.
(2) Disassembly.
(a)Remove capscrews (23), and lift off pipe bracket (19) and gasket (18).
(b)Remove screws (28), and remove cutout seat (29) and cutout valve (30).
(c)Remove screws (13) and remove cut-in valve spring (12), cut-in tail valve seat (17), cut-in valve spring (16), cut-in
tail valve (15), and cut-in valve (14).
(d) Remove nuts (6) from stems (8), and remove adjusting spring seats (11), sleeves (10), adjusting springs (9), and
stems (8).
(e)Remove sediment strainer (1) from valve body (7) and disassemble as follows:
1. Remove retaining ring (5) from sediment strainer housing (2).
2.Remove strainer (4) and strainer plates(3) from sediment strainer housing (2).
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Make sure that air passages and
exhaust port are free from dirt.
9-31
(2) Replace gasket (18).
NOTE
Refer to figure 9-13.1 for oil flow on model 3VC compressor.
Figure 9-13.1. Oil flow model 3VC compressor
Key to figure 9-14.
1 Sediment strainer
2 Sediment strainer housing
3 Strainer plate
4 Strainer
5 Retaining ring
6 Nut
T Valve body
8 Stem
9 Adjusting spring
1O Sleeve
11 Adjusting spring seat
12 Cut-in valve spring seat
13 Screw
14 Cut-in valve
15 Cut-in tail valve
16 Cut-in tail valve spring
17 Cut-in tail valve seat
18 Gasket
19 Pipe bracket
20 Tubing
21 Elbow
22 Elbow
23 Capscrew
24 Tubing
25 Nut
26 Lockwasher
27 Bolt, machine
28 Screw
29 Cutout valve seat
30 Cutout valve
9-32
Figure 9-14. Air compressor governor removal ,disassembly reassembly and installation.
(3) Check springs C9 and 16) for breaks or distortion. Replace defective springs.
(4) Inspect seats (11, 12, 17, and 29) and valves (14, 15, and 30) for grooves, burrs, or score marks. If seats
or valves are defective, replace governor.
(5) Replace strainer if ruptured or cannot be cleaned properly.
c. Reassembly and Installation. Apply a light coat of oil to surfaces of valves (14 and 30), and reassemble and
install governor in reverse order of disassembly and removal.
d. Adjustment. Refer to TM 55-1930-203-20.
9-6. Air Horn
a. Removal and Disassembly.
(1) Removal.
(a) Disconnect air line from fitting installed in air horn.
(b) Remove fitting from air horn.
(c) Remove attaching bolts. nuts, and lock-washers to remove air horn.
(2) Disassembly.
(a) Remove nut (1, fig. 9-15).
(b) Remove lockwasher (2).
(c) Remove screw (8).
(d) Lift off cover (7) and diaphragm (3) from body (10).
9-33
Figure 9-15. Air horn ,disassembly and reassembly
(e) Unscrew nut (91 and remove spring seat i6).
(f) Remove spring (5) and spring contact (4).
b. Cleaning, Inspection and Repair.
(1) Clean parts with lint-free cloth moistened with dry-cleaning solvent, Federal Specification P-D-680.
(2) Inspect diaphragm (3). for cracks or breaks. Replace a defective diaphragm.
(3) Inspect spring 151 for breaks and distortion. Replace a defective spring.
(4) Check spring contact 141 and spring seat (6) for good condition. Replace a defective contact or seat.
c. Reassembly and Installation. Reassemble
9-34
and install air horn in reverse order of disassembly and removal.
d. Adjustment. Refer to TM 55-1930-203-20.
9-7. Air Starting Lubricator
a. Removal and Disassembly.
(1) Removal. Disconnect tubing from air starting lubricator and remove lubricator.
(2) Disassembly.
(a) Unscrew filler plugs (5 and 12, fig. 9-16) and remove gaskets (6 and 13).
(b) Unscrew sight-feed dome (1) and remove gasket (2) and lockwasher (11).
(c) Remove adjusting screw (4) and packing (31.
(3) Remove screws (14), clamp-ring (10), lubricator bowl (8) and gasket (7).
b. Cleaning, Inspection and Repair.
(1) Clean parts in dry-cleaning solvent,, Federal Specification P-D-680.
(2) Inspect gaskets (2, 6, 7, and 13) and packing (3) for broken or deteriorated condition. Replace defective gaskets
and packings.
c. Reassembly and Installation.
(11 Reassemble and install air starting lubricator in 'reverse order of disassembly and removal.
(2) Refill lubricator (LO 55-1930-203-12).
d. Adjustment. Refer to TM 55-1930-203-20.
9-35
Figure 9-16. Air starting lubricator ,disassembly reassembly and installation
9-36
9-8. Air Starting Relay Air Valve
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in air lines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
WARNING
Failure to release pressure may result in injury to personnel removing air system components.
(b) Disconnect air lines from inlet, outlet, control, and accessory ports.
(c) Remove three mounting bolts, washers, and nuts. Remove relay air valve.
(2) Disassembly.
(a) Remove nuts (1, fig. 9-17) securing control piston cover (2) to body (4). Exercise caution as cover is
under spring load.
(b) Remove cover and gasket (15).
(c) Remove control piston (13) and spring (3) from body.
(d) Remove packing (141 from control piston.
(e) Remove nuts (7) and remove inlet valve cover (8) and gasket (6) from body.
(f) Slide inlet valve (5) out of body. valve.
Figure 9-17. Air starting relay air valve, ,disassembly and reassembly
b.
Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure
air (10 psi).
(2) Replace gaskets (6 and 15), and packing (14).
(3) Inspect springs (3, 10, and 11) for breaks or distortion. Replace a broken or deformed spring.
(4) Inspect inlet valve (5) for scores or pits on valve surface that mates with body (4) and valve surface that
mates with inlet pilot valve (12). If inlet valve is defective, replace relay air valve.
(5) Inspect pilot air valve for scores or pits on valve surface that mates with inlet valve. If pilot air valve is
defective, replace relay air valve.
(6) Check body for scores or pits in inlet valve seat area. If scored or pitted, replace relay air valve.
c. Reassembly and Installation.
(1) Reassembly. At reassembly, apply a light coat of approve grease to packing and all friction surfaces. Reassemble air relay valve in the reverse order of disassembly.
9-37
(2) Installation.
(a) Mount relay air valve with three bolts, washers, and nuts.
(b) Connect air lines to inlet, outlet, control, and accessory ports.
(c) Close service connection globe valve opened in a(1)(a) above. Open globe valves located in air lines
above air supply tank.
9-9. Air Supply Tanks
a. General. There are two air tanks, each having a capacity of 10.7 cubic feet, installed under the cargo well deck
at watertight bulkhead number six. Each tank is connected to the other. Globe valves in the tank outlet lines permit shu
tting off either or both tanks from the remainder of the system. A flange is welded on the forward side of air tank 1 foot
from aft crown of tank. The flange is welded to aft side of bulkhead number six with a continuous weld assuring a wate
rtight integrity when installed in LARC.
b. Removal.
NOTE
Repairs should be made without removing air tank if possible.
(1) Depressurize pneumatic system, disconnect lines, and drain air tank.
(2) Remove dunnage from cargo well deck area between frames four and six.
(3) With a cutting torch, cut a section of deck plating measuring 60 inches long and 20 inches wide, forward of
bulkhead number six and over air tank to be removed.
(4) Remove section of deck plating to gain access to air tank for removal.
(5) With a cutting torch, cut flange (1, fig. 9-18) of air tank free of bulkhead number six.
(6) Remove nuts (6), washers (5), and tie rod (3) from air tank (2).
(7) With suitable hoisting equipment, remove air tank (2).
9-38
Figure 9-18. Air tank removal and installation
c.
Cleaning, Inspection and Repair.
(1) Remove all rust and scale from exterior of air tanks using a wire brush.
(2) Repair damage by welding in accordance with the AWS (American Welding Society) welding handbook.
NOTE
After repairs have been made to tanks. hydrostatically test tanks with 300 psi. pressure and check for
leaks. After hydrostatic test. air test tanks at 187 psi pressure and check for leaks using a soapy solution.
(3) If inside of air tank is corroded, so that wall thickness is less than 0.1875 inches. replace air tank.
Installation.
(1) With suitable hoisting equipment, lower air tank into LARC with ports aligned with inlet and outlet service
lines from air compressor.
(2) Replace tie rod (3), washers (5), and nuts (6) used to secure air tank to LARC.
(3) Weld flange (1) to aft side of bulkhead number six to assure a watertight compartment.
(4) Replace section of cargo well deck and
d.
9-39
weld in accordance with the AWS welding handbook.
(5) Connect lines and pressurize pneumatic system.
9-10.
a.
Brake Air Line Relay Valves
Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in air lines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
(b) Disconnect airlines from couplings (3 and 4, fig. 9-19) installed in relay air valve (5).
WARNING
Before attempting to remove any compressed air system lines or components, relieve pressure
from system. Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching bolts (6), nuts (2). and lockwashers (1) securing relay air valve (5) to bracket.
(d) Remove couplings (3 and 4) from relay air valve.
Figure 9-19. Brake air line relay ,valve removal and installation
9-40
(2) Disassembly.
(a) Remove supply valve cage retaining ring (12, fig. 9-20) and remove supply valve assembly.
(b) Remove preformed packing (13).
(c) Remove bolts (7) and nuts (6) securing diaphragm cover (5) and remove cover.
(d) Lift diaphragm assembly (4) off diaphragm stem (11).
(e) Remove preformed packing (1).
(f) Remove retaining ring (9) and lift out exhaust valve assembly and diaphragm spring (10).
(g) Remove preformed packing (11).
(h) If pipe bracket (17) was removed with valve, remove nuts (2 and 3) and bolts and remove pipe
bracket and gaskets.
(i) Remove sediment strainers (14) and retaining rings (15) from valve body (8).
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry- cleaning solvent, Federal Specification P-D-680.
(2) Check springs for breaks or distortion. Replace defective springs.
(3) Replace preformed packings.
(4) Inspect diaphragm for cracks or broken sealing beads. Replace diaphragm assembly if diaphragm is d
efective.
c. Reassembly and Installation. Apply a light coat of approved grease to all friction surfaces and preformed
packings. Reassemble and install brake air line relay valves in reverse order of disassembly and removal.
Figure 9-20. Brake air line relay valve , disassembly and reassembly.
9-41
Key to figure 9-20.
1 Preformed packing
2 Nut
3 Nut
4 Diaphragm assembly
5 Diaphragm cover
6 Nut
7 Bolt
8 Body
9 Retaining ring, exhaust valve cage
10 Diaphragm spring
11 Diaphragm stem
12 Retaining ring, supply valve cage
13 Preformed packing
14 Sediment strainer
15 Retaining ring, strainer
16 Gasket
17 Pipe bracket
18 Preformed packing
9-11. Cargo Well Pump and Ramp Cylinder Control Air Cylinder.
a. Removal and Disassembly.
(1) Removal
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent air pressure from lines.
(b) Disconnect airlines from elbows (11, fig. 9-21) installed in double-acting air cylinder (10).
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pre ssure from system. Failure to do so may result in injury or death to maintenance personnel.
(c)
(d)
(e)
(f)
(g)
Remove cotter pin (7) and pin (8) attaching double-acting air cylinder (10) to multiple unit valve.
Remove bolts (9), nuts (4), and lock- washers (3) attaching brackets to bulkhead bracket.
Loosen jamnut (5) and unscrew piston rod (6) from cylinder shaft.
Remove elbows (11) from double-acting air cylinder.
Remove bolts (9) securing upper and lower mounting brackets (2) to double-acting air cylinder.
9-42
Figure 9-21. Double- acting air cylinder , removal and installation.
9-43
(2) Disassembly.
(a) Remove screws (3, fig. 9-22) and lock-washers (4) and lift off locking clamps J2).
(b) Pull off blind end head (1) and rod end head (13) and remove preformed packings (5).
(c) Remove retaining ring (18) from rod end head and push out guide (16), packing (15), and retainer
(14). Remove preformed packing (17) from guide.
(d) Remove piston rod (12) with attaching parts out of cylinder (6).
(e) Remove nut (7), followers (8), compression cups (9), and piston (10).
(f) Remove preformed packing (I1) from piston rod (12).
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air
(10 psi).
(2) Replace preformed packings (5, 11, and 17), compression cups (9), and packing (15).
c. Reassembly and Installation. At reassembly, apply a light coat of approved grease to all friction surfaces and
preformed packings. Reassemble and install control air cylinder in the reverse order of disassembly and removal.
Figure 9-22. Cargo well pump and ramp cylinder control air cylinder ,disassembly and reassembly.
9-44
9-12. Fan Control Air Cylinder
a. Removal and Disassembly.
(1) Removal
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) and release compressed air from lines.
(b) Disconnect and remove airlines from elbows (6, fig. 9-22) and couplings (10) installed in shuttle
valves (7 and 11).
(c) Remove elbows (6) and couplings (10) from shuttle valves.
WARNING
Before attempting to remove any compressed air system lines or components, relieve pressure
from system. Failure to do so may result in injury or death to maintenance personnel.
(d) Remove bolts (8). nuts (14). and lockwashers (13) securing single-acting cylinder (5) to bracket.
(e) Remove fan control knobs (1) lock washer (2). and bushing 13) from radiator fan control valves.
(f) Lift single-acting cylinder (5) up and out; remove shuttle valves (7 and 11) and nipples (9) from shuttle valve (12).
(g) Remove shuttle valve (12) and nipple (9) from base of single-acting cylinder (5).
(h) Unscrew single-acting cylinder (5) from plunger (4) and remove components.
9-45
Figure 9-23. Fan control air cylinder control removal and installation
b.
(2) Disassembly.
(a) Remove capscrews (1, fig. 9-23) and lift off cover (2).
(b) Remove piston spring (4) and piston rod (10) with attaching parts from body (3).
(c) Remove cotter pin (5) and remove nut (6).
(d) Remove follower (7) packing cup (8). and piston (9) from piston rod (10).
Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air
(10 psi).
9-46
(2) Replace packing cup (8).
(3) Inspect piston spring (4) for breaks or distortion. Replace a broken or deformed spring.
c. Reassembly and Installation. At reassembly, apply a light coat of grease to all friction surfaces. Reassemble
and install fan control air cylinder in the reverse order of disassembly and removal.
Figure 9-24. Fan control air cylinder control disassembly and reassembly
9-13. Foot Throttle and Brake Control Valves
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
(b) Disconnect airlines from couplings (5) fig. 9-251 installed in foot control valve (1).
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pre ssure from system. Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching bolts (2), nuts (4), and lockwashers (3) securing foot control valve to cab floor.
(d) Remove couplings (5) from foot control valve (1).
9-47
Figure 9-25. Foot throttle and brake control valve removal and installation
(2) Disassembly.
(a) Remove bolts (30, fig. 9-26) and nuts (13); lift off spring housing (12). Exercise caution as spring
housing is under spring load.
(b) Lift out exhaust valve seat (6), diaphragm (7), follower (8), and exhaust valve seat nut (9) as an assembly. Remove preformed packing (5) from exhaust valve seat (6).
(c) Remove diaphragm spring seat (11) and diaphragm spring (10).
(d) Remove retaining rings (20) and shaft (21)
(e) Remove pedal (1) and remove foot pedal spring (23).
(f) Remove capscrews (15) and lift bracket (22) from valve body (17).
(g) Remove gaskets (19) and air filters (18).
(h) Remove cotter pins (27), pin (26), and cam dog (28).
(i) Remove dirt protector (29).
(j) Push inlet and exhaust valve assembly (3) and exhaust valve spring (4) from valve body (17). Remove preformed packings (2) from inlet and exhaust valve assembly.
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash
9-48
rubber parts with soap and water and blow dry with low pressure air.
(2) Check springs (4, 10, and 23), for breaks or distortion. Replace defective springs.
(3) Inspect diaphragm 171 and exhaust valve seat (6) for cracks or broken sealing beads. If diaphragm or e
xhaust valve seat is defective, replace defective parts.
(4) Replace preformed packings (2 and 5).
(5) Inspect dirt protector (129) for cracks or deterioration. Replace a defective dirt protector.
(6) Inspect inlet and exhaust valve assembly (3) for scores, burrs, or pitting. Replace a defective inlet and exhaust valve assembly.
(7) Examine air filters (18) for broken mesh or enlarge holes. Replace defective air fillers.
c. Reassembly and Installation. At reassembly, apply a light coat of grease, Military Specification MIL-G-4343B to
all rubber parts and grease, Federal Specification VV-G-632, Grade 1, Type B, to all friction surfaces. Reassemble and
install foot throttle and brake control valves in reverse order of disassembly and removal.
Figure 9-26. Foot throttle and brake control valve disassembly and reassembly.
9-49
Key to figure 9-26.
1 Pedal
2 Preformed packing
3 Inlet and exhaust valve assembly
4 Exhaust valve spring
5 Preformed packing
6 Exhaust valve seat
7 Diaphragm
8 Follower
9 Nut
10 Diaphragm spring
11 Diaphragm spring seat
12 Spring housing
13 Nut
14 Screw
15 Capscrew
16 Stuf
17Valve body
18 Air filter
19 Gasket
20 Retaining ring
21 Shaft
22 Bracket
23 Foot pedal spring
24 Nut
25 Screw
26 Pin
27 Cotter pin
28 Cam dog
29 Dirt protector
30 Bolt
d. Adjustment.
NOTE
Pedal stop screw (25, fig. 9-26) changes the angle of pedal travel and, if not compensated for by the
delivery pressure adjustment, will change the maximum pressure slightly. The pedal stop screw should be
set to provide minimum pedal travel to protect the valve assembly from unnecessary mechanical force.
(1) Foot throttle control valve delivery pressure adjustment.
(a) Start engines (TM 55-1930-203-10) and place foot control valve in the maximum rpm position.
(b) Observe the tachometers on the instruments panel for maximum engines rpm (2100 + 50 rpm)
(c) Adjust foot control valve delivery pressure if all engines fail to reach maximum rpm as follows:
1. Turn adjusting screw (14, fig. 9-26) on base of foot control valve clockwise to increase delivery pressure and
engine rpm.
2. Turn adjusting screw (14) counterclockwise- to decrease delivery pressure engine rpm.
3. Observetachometers for maximum engine rpm (21 00 5 0 rpm).
(2) Brake control valve delivery pressure adjustment.
(a) Start engines (TM 55-1930-203-10) and place LARC in motion.
(b) Slowly apply foot control valve and observe breaking action of LARC.
(c) If brakes do not lock all wheels at desired pedal position, adjust delivery pressure as follows:
1. Increase delivery pressure by turning adjusting screw (14), clockwise.
2. Decrease delivery pressure by turning adjusting screw (14) counterclockwise.
(d) Place LARC in motion and repeat (c) above.
(e) If foot control valve is properly adjusted, secure engines.
9-14. Globe and Angle Valves
a. Packing Removal and Installation.
(1) Packing removal.
(a) Open globe valve fully.
(b) Unscrew nut from stem and remove hand wheel.
(c) Unscrew packing retaining nut (2, fig. 9-27) and remove packing (7) from stuffing box.
(2) Packing installation. Install packing in reverse order of removal.
b. Disk Replacement.
(1) Vent or secure compressed air in line in which valve is located.
(2) Unscrew union (4) between bonnet (3) and valve body (6) and remove stem (1) and bonnet.
(3) Examine disk seat in valve body for grooves or burrs. If seat is damaged to extent that a tight seal cannot be
made, replace valve.
(4) On valves with metal disk, unscrew disk (5) from stem and screw new disk on stem.
(5) On valves with composition disk, remove disk retaining nut from stem and remove disk and disk holder. Place new
disk and disk holder on stem and secure with retaining nut.
(6) Position stem and bonnet on valve body and tighten union (4).
9-50
Figure 9-27.
Globe valve packing and disk removal and installation
9-15. Hand Throttle Control Valves
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service connection
globe valves (51 and release compressed air from lines.
(b) Disconnect airlines from couplings (8, fig. 9-28) installed in hand throttle control valve (9,).
WARNING
Before attempting to remove any compressed air system lines or compressed., relieve air
pressure from system- .Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching bolt (14), nut (1), and lockwasher (2) from control linkage.
(d) Remove attaching bolts (3), nuts (6), and lockwashers (5) securing valve to bracket.
(e) Remove all fittings from hand throttle control valve.
(2) Disassembly. Refer to figure 9-29.
(a) Remove nuts 1241, and lockwashers (25) and lift off housing (7)
(b) Remove pin (6) and pull off handle (5).
(c) Loosen nut (14) and setscrew (9).
(d) Unscrew capnut (1) and pull out camshaft 141, allowing cam (8) and brake shoe assembly ( 11) to drop out
bottom of housing.
(e) Remove brake drum (2) and key (3)from camshaft.
(f) Remove nut (14), washer (13). And spring (12) from brake shoe assembly.
(g) Remove bolts C20t and remove bracket (19)
(h) Remove gaskets 1181 and strainers (17)
(i) Remove bolts (261 and nuts 1291 and remove spring housing (31). Exercise caution as spring housing is under
spring tension.
9-51
(j) Lift out exhaust valve seat (37), diaphragm (36), follower (35) and nut (34) as an assembly. Remove exhaust
compression spring (39) and preformed packing (38) from exhaust valve seat (37).
(k)Remove cotter pins (28) and remove pin (27) and cam dog (15).
(l)Push inlet and exhaust valve 122) out of body (16)
(m)Remove preformed packings 1231 from inlet and exhaust valve.
Figure 9-28.
Hand throttle control valve removal and installation
b. Cleaning, Inspection and Repair.
(I ) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10 psi).
(2) Replace preformed packings (23 and 38, fig. 9-29) and gaskets (181.
(3) Inspect diaphragm (36) for cracks or broken sealing beads and exhaust valve seat (37) for scores or pits in seat
area. If these conditions exist, replace defective parts.
(4) Inspect inlet and exhaust valve (22) for scores or pits on valve surface that mates with exhaust valve seat (37).
Replace a defective inlet and exhaust valve.
(5) Inspect springs (12, 33, and 391 for breaks or distortion. Replace a broken or deformed spring.
(6) Inspect strainers (17) for deterioration or deformation. Replace a deteriorated or deformed strainer.
c. Reassembly and Installation. At reassembly, apply a light coat of grease Military Specification MIL-G-4343B to all
rubber parts and grease, Federal Specification VV-G-632, Grade 1, Type B, to all friction surfaces, except brake shoe
assembly (11 ). Reassemble and install hand throttle control valve in reverse order of disassembly and removal.
d. Adjustment.
(11 Brake shoe assembly adjustment. The
9-52
handle force of the control valve can be varied by adjusting nut (14). This adjustment increases or decreases the
manual force required to move and hold the handle in any desired position.
(2) Pressure setting adjustment.
(a)Place all hand throttle control valves in the idle position.
(b) Start engines and observe tachometers on instrument panel for proper engine idle speed (550 rpm).
(c) If engines fail to idle at 550 rpm, disconnect actuator positioner rod assembly and observe engine tachometers.
Tachometers should indicate 550 rpm. If engines still fail to idle at 550 rpm, comply with paragraph 3-77, TM 55-1930203-20.
(d) Reconnect linkage. Engines failing to idle at 550 rpm require adjustment of corresponding hand throttle
control valves. Adjust delivery pressure of throttle control valves as follows:
1 .Turn adjusting screw (7, fig. 9-28) on base of hand throttle control valve clockwise to increase delivery pressure
and engine rpm.
2. Turn adjusting screw (7) counterclockwise to decrease delivery pressure and engine rpm.
3. Observe tachometers for proper idle speed (550) rpm) of engines.
9-53
Figure 9-29.
Hand throttle control valve disassembly and reassembly
9-54
Key to figure 9-29.
1 Housing capnut
2 Brake drum
3 Key
4 Camshaft
5 handle
6 Pin
7 Housing
8 Cam
9 Setscrew
10 Stud
11 Brake shoe assembly
12 Brake shoe spring
13 Washer
14 Nut
15 Cam dog
16 Body
17 Strainer
18 Gasket
19 Bracket
20 Bolt
21 Stud
22 Inlet and exhaust valve
23 Packing, preformed
24 Nut
25 Lockwasher
26 Bolt
27- Pin
28 Pin
29 Nut
30 Bolt
31 Spring housing
32 Spring seat
33 Diaphragm compression spring
34 Nut
35 Follower
36 Diaphragm
37Exhaust valve seat
38 Packing, preformed
39 Exhaust compression spring
9-16. Horn Control and Engine Starting Pilot Air Valves
a. Removal and Disassembly.
(1) Removal
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open a service
connection globe valve (5) to vent compressed- pressed air from lines.
WARNING
Failure to release pressure may result in injury to personnel removing air system components.
(b) Disconnect pilot air valve inlet and outlet lines at valve.
(c) Remove four pilot air valve mounting bolts and remove valve.
(2) Disassembly.
(a) Remove two screws (15, fig. 9-30) and Iockwashers (16) securing cover (3) to body (17)
(b) Remove pin (1), cam dog (5), and cover (3). Remove retaining ring (4) and control button (2).
(c) Remove two screws (6) and lockwashers (7) securing retaining flange (8) to body (17). Remove er
taining flange (8) and packing (9).
(d) Remove plunger guide (10), plunger (12), spring (13), valve seat (14), and washer (22). Remove
packing (11 and 23).
(e) Remove valve (21), spring (20), spacer(19), and filter (18).
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent Federal Specification P-D-680, and allow to drain dry.
(2) Inspect plunger (12, plunger guide (10), valve (21), and valve seat (14) for scoring on their mating surfaces. Replace defective parts.
(3) Inspect springs (13 and 20) for distortion and replace if defective.
(4) Inspect retaining ring (4) for distortion. Replace retaining rings that do not fit tightly in their grooves.
(5) Replace filter (18) if all foreign particles cannot be removed by cleaning.
(6) Replace all packing.
c. Reassembly and Installation.
(1) Reassembly. At reassembly, apply a light coat of grease, Military Specification MIL-G-4343B to all rubber
parts and grease, Federal Specification VV-G-632, Grade 1, Type B, to all friction surfaces. Reassembly pilot air valve in
the reverse order of disassembly.
(2) Installation.
(a) Secure valve to mounting surface with tour mounting bolts.
(b) Connect inlet and outlet lines.
(c) Close service connection globe valve (5, fig 2-19) and open globe valves (6 and 7) located in air lines
above air supply tanks.
9-55
Figure 9-30.
Pilot air valve disassembly and reassembly.
9-17. Main Air Supply Filter
a. General. The main air supply filter (fig. 9-31) is located below the cab deck in the port aft storage compartment
area below the service brake foot valve. The main air supply filter purifies the compressed air from the supply tank and
serves to prevent water and foreign matter from entering the cab air control valves.
b. Removal and Disassembly.
(1) Removal
(a) Close globe valves (6 and 7, fig. 2-19) located in air lines above air supply tanks and open service
connection globe valves (5) to vent air supply lines.
(b) Disconnect air lines from fittings installed in air supply filter.
9-56
WARNING
Before attempting to remove any compressed air system lines or components, relieve pressure
from system. Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching capscrews (1, fig. 9- 31) securing main air supply filter to bracket.
(2) Disassembly.
(a) Drain water and foreign matter accumulations from main air supply filter by removing drain plug (9).
(b)Remove capscrews (81 and remove dirt chamber (71, gasket (6X, element support (5), and element (41 from filter
body (3).
(c) Remove elbow 12) and tee (101 from filter body (3).
c. Cleaning, Inspection and Repair.
1 Rinse all parts except the filter element in a clean solution of dry-cleaning solvent. Federal Specification P-D-680;
wipe all parts dry using a clean, lint-free cloth.
(2) Clean element (4 in a clean solution of carbon tetrachloride, Federal Specification O-C- (4). Blow filter element dry
using dry compressed air not exceeding 10 psi.
(3) Inspect element for deterioration of curled hair and felt mesh. Replace element if curled hair and felt mesh are
deteriorated.
d. Reassembly and Installation. Reassemble and install main air supply filter in reverse order of disassembly and
removal.
9-57
Figure 9-31.
Main air supply filter removal, disassembly , reassembly and installation
9-58
Figure 9-31.1. Air dryer, replacement
a.
Removal.
(1) Disconnect tube fittings (1), (2) and (3).
(2) Remove capscrews (4) and lockwashers (5).
(3) Remove fittings and pipe nipple (6) and filter (7) from air dryer (8). Replace air dryer as required.
b. Installation
(1) Install fittings and pipe nipple (6) and filter (7) on air dryer (8). Ensure that sight window (9) is facing out
when air dryer is mounted on bulkhead.
9-58.1
Figure 9-31.2. Solenoid valve replacement
a. Removal
(1) Open drain valve (1 figure. 9-30.2) to make sure air pressure is relieved.
(2) Remove cover (2) to wiring junction box (3).
(3) Cut wires (4) and (5) and disconnect cord connectors (6) and (7) from junction box (3) pulling wires (8) and (9)
from the junction box (3).
(4) Disconnect wiring junction box (3), nipple (1O), and solenoid valve (11). Remove valve (11).
b. Installation.
(1) Screw new solenoid valve, (11) onto nipple (12) using antiseize tape around threads to ensure tightness.
(2) Feed wires (4) and (5) through nipple (10) and then screw nipple (10) into solenoid valve (11) using antiseize tape around threads.
(3) Feed wires (4) and (5) into wiring junction )ox (3) and screw box (3) onto nipple using antiseize tape
around threads.
(4) Feed wires (8) and (9) into wiring junction I)ox (3). Secure wires (8) and (9) to the junction wiring t)ox (3) using
cord connectors (6) and (7).
(5) Splice wires (4) and (5) to wires (8) and (9) using insulated solderless connectors. Make sure the positive lead
from the solenoid is connected to the positive lead and the negative lead to the ground wire.
(6) Replace cover (2) on wiring junction box (3).
(7) Close drain valve (1).
(8) Pressurize the compressed air system and test the solenoid valve (11) by operating momentary contact switch.
9-58.2
Figure 9-31.3. Push button switch momentary replacement
a. Removal.
(1) Back screws (1 fig. 9-30.3) out and move lid clips (2) aside, remove lid (3).
(2) Unsolder wires (5) and (6) from the back of push button switch (6).
(3) Remove nut (8) and lockwasher (9).
(4) Pull push button switch (7) out of junction box (10).
b. Installation.
(1) Install new push button switch (7) in junction box (10) and secure with lockwasher (9) and nut (8).
(2) Connect wires (5) and (6) to push button switch (7).
(3) Install lid (3) on junction box (10) and clamp ;shut using clips (2) and screw (1).
9-58.3/(9-58.4 /blank)
9-18. Marine Gear Shifting and Throttle Control Valve
a. Removal and Disassembly.
(1) Removal.
(a)Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent compressed- pressed air from lines.
(b) Disconnect airlines from coupling (7, fig. 9-32) installed in control valve (1).
WARNING
Before attempting to remove any compressed air system lines or components, relieve pressure
from system. Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching bolts (2), nuts (4), and lockwashers (3) and remove control valve (1) from instrument
panel.
(d) Remove couplings (6) from control valve.
Figure 9-32. Marine gear shifting and throttle control valve removal and installation.
(2) Disassembly. Disassemble the control valve in the numerical sequence as illustrated on figure 9-33.
9-59
Figure 9-33. Marine gear shifting and throttle control valve disassembly and reassembly
9-60
Key to figure 9-33.
1 Capscrew
38 Lever, pilot valve (RH)
2 Bracket
39 Lever, pilot valve LH
3 Gasket
40 Roll pin
4 Filter
41 Roller
5 Screw
42 Setscrew
6 Lockwasher
43 Screw
7 Shaft-hub
44 Nut
8 Roll pin
45 Spring housing
9 Handle
46 Spring
10 Nut
47 Diaphragm assembly
11 Nut
48 Spring
12 Lockwasher
49 Spring seat
13 Housing
50 Nut
14 Stud
51 Follower
15 Setscrew
52 Diaphragm
16 Setscrew
53 Seat
17 Camshaft
54 Packing, preformed
18 Key
55 Inlet and exhaust valve
19 Bushing
56 Packing, preformed
20 Cam
57 Stud
21 Pin
58 Retaining ring
22 Brake shoe assembly
59 Protector
23 Brake drum
60 Retaining ring
24 Disc
61 Washer
25 Nut
62 Guide
26 Washer
63 Packing, preformed
27 Brake spring
64 Plunger
28 Screw
65 Packing, preformed
29 Lockwasher
66 Spring
30 Latch body
67 Seat
31 Retaining ring
68 Supply valve assembly
32 Latch
69 Packing, preformed
33 Spring
70 Retaining ring
34 Pin
71 Spring
35 Cam dog
72 Supply valve
36 Pin
73 Spacer
37 Pin
74 Body
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(2) Replace preformed packings (54, 56, 63, 65, and 69), and gaskets (3).
(3) Inspect diaphragm (52) for cracks or broken sealing beads and exhaust valve seat (53) for scores or pits in seat
area. Replace defective parts.
(4) Inspect valve spacer (73) for scores or pits in seat area and supply valve (72) for scores or pits on the valve
surface that mates with the valve spacer seat. Replace defective parts.
(5) Inspect inlet and exhaust valve (55) for scores or pits on valve surface that mates with exhaust valve seat (53).
Replace defective inlet and exhaust valve.
(6) Inspect springs (27, 33, 46, 66, and 71) for breaks or distortion. Replace a broken or deformed spring.
(7) Inspect filters (4) and protectors (59) for deterioration or deformation. Replace a defective filter or protector.
c. Reassembly and Installation.
(1) Reassembly. At reassembly, apply a light coat of grease, Military Specification MIL-G- 4343B to all rubber parts
and grease, Federal Specification VV-G-632, Grade 1, Type B, to all friction surfaces. Reassemble the control valve in
reverse at numerical sequence as illustrated on figure 9-33.
NOTE
Adjust friction brake during reassembly as outlined in d (1) below.
(2) Installation. control valve in reverse order of removal.
d. Adjustment.
(1) Brake shoe assembly adjustments. The handle force of the control valve can be varied by adjusting nut (25, fig.
9-33). This adjustment increases or decreases the manual force required to move or hold the handle in any desired
position.
(2) Pilot valve lever adjustment.
(a) Remove retaining ring (58, fig. 9-33) and protector (59).
(b)Move handle (9) back and forth on both sides of the "neutral" position, observing the action of levers (38 and 39).
The corresponding pilot
9-61
valve should be fully open after the handle moves through the first 10 degrees travel arc.
(c) If the pilot valve levers need adjusting, place the handle in a maximum increasing pressure position. With a 3 / 32
inch Allen wrench, turn setscrew (42) out, just far enough to crack the exhaust valve. The gage (port 1 or port 3, fig. 9-34)
will show a drop in pressure. From this point turn the setscrew in a full three turns. This will open the supply valve of the
pilot valve to its maximum capacity. Move the handle to the extreme position of the opposite quadrant and repeat the
adjustment for the other pilot valve lever.
Figure 9-34. Marine gear shifting and throttle control valve adjustments.
(d) Reinstall protector (59, fig. 9-33) and retaining ring (58).
(3) Pressure setting adjustment. Place control valve handle (9, fig. 9-33) in the maximum increasing pressure position
and turn adjusting screw (43) in or out until the gage at port 8, figure 9-34 registers 68 psi.
(4) Cam dog adjustment.
(a) Place control valve handle (9, fig. 9-33) in neutral position.
(b) Insert a screwdriver through hole in flange of cover (13) and turn cam dog pin (34) to position cam dog (35) in
the center of cam (20) for zero delivery pressure reading on gages at ports 1 and 3, figure 9-34.
9-62
9-19. Quick Release Valve
a. Removal and Disassembly.
(1) Removal.
(a) Disconnect airlines from couplings (1, fig. 9-35) and remove quick release valve.
(b) Remove couplings (1) from the quick release valve.
(2) Disassembly.
(a) Remove screws (6) and washers (5) securing cover (7) to body (2).
(b) Separate cover (7) from body (2) and remove gasket (4) and diaphragm (3).
b. Cleaning. Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash all rubber parts with soap
and water and rinse thoroughly. Dry parts with low pressure air (10 psi).
(2) Inspect diaphragm (3) and gasket (4) for deterioration or breaks. Replace defective parts.
c. Reassembly and Installation. Reassemble and install quick release valve in reverse order of disassembly and
removal.
Figure 9-35. Quick release valve, removal, disassembly, reassembly, and installation.
9-20. Ramp Seal
a. Removal.
(1) Unlatch and lower ramp to deflate ramp seal (4, fig. 9-36) and gain access to seal retainers (5).
(2) Loosen union (1) and remove air pipe (2).
(3) Remove elbow (3) from ramp seal valve stem.
(4) Remove retainer bolts (6).
(5) Remove seal retainers (5).
(6) Remove ramp seal (4).
b. Installation. Install ramp seal in reverse order of removal.
NOTE
New ramp seals do not have mounting holes. Punch holes to correspond with existing mounting holes on hull.
9-63
1 Union
2 Pipe
3 Elbow
4 Ramp seal
5 Seal retainer
6 Bolt
Figure 9-36. Ramp seal removal and installation.
9-21. Ramp Seal Air Supply Reducing Valve
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
(b) Disconnect air piping at pipe coupling (6, fig. 9-37).
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from system. Failure
to do so may result in injury or death to maintenance personnel.
(c) Disconnect tubing from coupling (5).
(d) Remove attaching bolts (3), nuts (1), and lockwashers (2) securing valve (10) to bracket.
(e) Remove pipe coupling (6), pipe nipple (7), pipe elbow (8), and pipe nipple (9).
(f) Remove coupling (5) from reducing valve (10).
9-64
Figure 9-37. Reducing valve removal and installation.
(2) Disassembly.
(a) Remove nuts (13, fig. 9-38) and remove bracket (6).
(b) Remove gaskets (5) and strainers (4).
(c) Remove bolts (15) and nuts (22) and remove spring housing (20). Exercise caution as spring housing
is under spring tension.
(d) Lift out exhaust valve seat (11), diaphragm (12), follower (16), and nut (17) as an assembly. Remove
exhaust compression spring (9) and preformed packing (10) from exhaust valve seat (11).
(e) Remove diaphragm compression spring (18) and spring seat (19) from spring housing (20).
(f) Remove protector (1) and push inlet and exhaust valve (3) out of body (14).
(g) Remove preformed packings (2) from inlet and exhaust valve.
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash rubber parts with soap and
water and blow dry with low pressure air.
(2) Replace preformed packings (2 and 10), and gaskets (5).
(3) Inspect diaphragm (12) for cracks or broken sealing beads and exhaust valve seat (11) for scores or pits in
seat area. If these conditions exist, replace defective parts.
(4) Inspect inlet and exhaust valve (3) for scores or pits on valve surface that mates with exhaust valve seat (11).
Replace a defective inlet and exhaust valve.
(5) Inspect springs (9 and 18) for breaks or distortion. Replace a broken or deformed spring.
9-65
Figure 9-38. Reducing valve, disassembly and reassembly
(6) Inspect strainers (4) for deterioration or deformation. Replace a deteriorated or deformed strainer.
c. Reassembly and Installation. At reassembly, apply a light coat of grease, Military Specification MIL-G-4343B, to
all rubber parts and grease, Federal Specification VV-G-632, Grade 1, Type B, to all friction surfaces. Reassembly and
install reducing valve in reverse order of disassembly and removal.
CAUTION
After installation of reducing valve, check ramp seal air pressure gage (2, fig. 9-7) to insure air pressure does
not exceed 15 psi with ramp raised and seal inflated.
d. Adjustment.
(1) Raise the ramp into full closed position (TM 55-1930-203-10).
(2) Turn adjusting bolt (4, fig. 9-37) on base
9-66
of reducing valve counterclockwise until adjusting screw turns freely.
(3) Turn adjusting bolt (4) slowly clockwise until air gage registers 15 psi.
9-22. Shuttle Valve
NOTE
Double check valves, type 18-A and 22-A, will be replaced with shuttle valves as they become unserviceable.
a. Removal and Disassembly.
(1) Removal.
(a) Disconnect air lines at shuttle valve.
(b) Remove two mounting bolls, washers, and nuts.
(2) Disassembly.
(a) Remove four screws (1, fig. 9-39) and lockwashers (2) securing cover (3) to body (6). Remove cover
(3).
(b) Remove gasket (5) and diaphragm (4).
b. Cleaning, Inspection and Repair.
(1) Inspect diaphragm (4) and its seating surfaces for scoring. Replace defective parts.
(2) Inspect gasket (5) for deterioration or breaks and replace if defective.
c. Reassembly and Installation. Reassemble and install shuttle valve in reverse order of disassembly and removal.
Figure 9-39. Shuttle valve disassembly and reassembly.
9-23. Throttle Cutout, Cargo Well Pump, Ramp, and Tire Control Valves
a. Removal
(1) Close globe valve (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service connection
globe valves (5) to vent air pressure from lines.
(2) Disconnect airlines from couplings installed in pilot air valve.
9-67
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from system.
Failure to do so may result in injury or death.
(3) Remove attaching bolts (1, fig. 9-40), nuts (4), and lockwashers (5) securing pilot air valve.
(4) Remove couplings (3) from pilot air valve.
Figure 9-40. Throttle cutout, cargo well pump, ramp, and tire control valve removal and installation.
NOTE
Two types of throttle cutout, cargo well pump, ramp. and tire control valves are used as shown in figures 9-41 and 9-42.
When the valve shown in figure 9-41 cannot be repaired it will be replaced by the valve shown in figure 9-40.
b. Disassembly.
(1) Figure 9-41 (old style valve).
(a) Remove nut (2), handle shaft (4), and ball (5).
(b) Pull handle yoke (3) off camshaft (1).
(c) Remove screws (15) and lockwashers (14); lift off housing (6).
(d) Remove setscrews (7) and slide out camshaft (1). Remove cams (8).
(e) Remove cotter pins (17) from cam dog shaft (18) and remove cam dogs (19) and cam dog shaft.
(f) Remove screws (20) and clamp (23) from body (16).
9-68
(g) Lift out plunger guides (10) and remove preformed packings (9) from plunger guide.
(h) Remove valve plungers (12) and remove preformed packings (11) from plungers.
(i) Remove exhaust valve springs (13).
(j) Lift valve assemblies (21) from body (16). Remove preformed packings (22).
Figure 9-41. Throttle cutout, cargo well pump, ramp and tire control valve, old style, disassembly and reassembly.
9-69
12
13
14
15
16
17
18
19
20
21
22
23
Key to figure 9-41.
1
2
3
4
5
6
7
8
9
10
11
Camshaft
Nut
Handle yoke
Handle shaft
Ball
Housing
Setscrew
Cam
Preformed packing
Plunger guide
Preformed packing
Valve plunger
Exhaust valve spring
Lockwasher
Screw
Body
Cotter pin
Cam dog shaft
Cam dog
Screw
Valve assembly
Packing, preformed
Clamp
(2) Figure 9-42 (new style valve).
(a) Remove machine screws (1), lockwashers (2), and separate cam housing (12) from valve body (3).
(b) Remove valve cam followers (18), detent cam follower (19), and detent cam spring (20) from valve
body.
(c) Loosen camshaft setscrew (15) and remove handle assembly (14).
(d) Pull capscrew (9), camshaft (10), and handle shaft (11) from cam housing (12) as an assembly.
Remove valve cams (16) and detent cam (17) from the cam housing.
(e) Separate camshaft (10) from handle shaft (11) by removing capscrew (9).
(f) Remove screws (21), lockwashers (22), and retaining flanges (23) from valve body (3).
(g) Lift out plunger guides (25) and remove preformed packings (24) from plunger guides.
(h) Remove valve plungers (27) and remove preformed packings (26) from plungers.
(i) Remove plunger springs (28). inlet valve seats (29). preformed packings (8). flatwashers (7), supply
valves (6), supply valve springs (5), and valve spacers (4) from valve body.
9-70
Figure 9-42. Throttle cutout, cargo well pump, ramp, and tire control valve, new style, disassembly and reassembly.
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680. Wash rubber parts with soap and
water and blow dry with low pressure air.
(2) Check springs for breaks or distortion. Replace defective springs.
(3) Inspect valves, valve spacers, valve plungers and valve guides for grooves, burrs, or cracks. Replace
defective parts.
9-71
(4) Replace preformed packings.
d. Reassembly.
NOTE
During reassembly, apply a light coat of grease, Military Specification MIL-G-4343B to all rubber parts and grease.
Federal Specification VV-G-632, Grade 1, Type B, to all friction surfaces.
(1) Figure 9-41 (old style valve). Reassembly control valve in reverse order of disassembly.
(2) Figure 9-42 (new style valve).
(a) Assemble handle shaft (11) to camshaft (25) with capscrew (9), and insert the assembly partially
through cam housing (12), with the handle shaft in the position shown in view A-A, figure 9-43.
(b) Install valve cams (16, fig. 9-42) and detent cam (17) on the shaft assembly in the positions indicated
in figure 9-43.
NOTE
The valve cams are multi-purpose cams used in various valve models. Their position on the camshaft determines the
valve operation. Therefore, it is important that they be assembled correctly.
(c) Place handle assembly (14, fig. 9-42) on the shaft assembly in vertical position as shown in view A-A,
figure 9-43. Secure the handle assembly to the shaft assembly with setscrew (15, fig. 9-42).
(d) Install valve spacers (4), supply valve springs (5), supply valves (6), flatwashers (7), preformed
packings (8), inlet valve seats (29), and plunger springs (28) in valve body (3).
(e) Install preformed packings (26) on valve plungers (27) and insert the valve plungers in valve body
(3).
(f) Install preformed packings (24) on plunger guides (25) and slide the plunger guides over ends of valve
plungers (27) into the valve body.
(g) Position retaining flanges (23) on valve body and secure with screws (21) and lockwashers (22).
(h) Install detent cam spring (20), detent cam follower (19), and valve cam followers (18) on valve body.
NOTE
Position detent cam spring as shown in Section C-C, figure 9-43.
(i) Assemble the cam housing. Assemble to the valve body assembly using machine screws (1, fig. 9-42)
and lockwashers (2).
(j) Adjust detent force on detent cam (17) with setscrew (13). Tighten setscrew to increase detent force;
loosen to decrease force.
9-72
Figure 9-43. Throttle cutout, cargo well pump, ramp, and tire control valve (cut-away view).
9-73
e. Installation. Install control valve in reverse order of removal.
9-24. Throttle and Transmission Air Line Relay Valve
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
(b) Disconnect airlines from couplings (3, fig. 9-44) installed in relay air valve (5).
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from system.
Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching bolts (4), nuts (1), and lockwashers (2) securing relay air valve to bracket.
(d) Remove couplings (3) from relay air valve (5).
’
Figure 9-44. Throttle and transmission airline relay valve, removal and installation.
.
(2) Disassembly.
(a) Remove nuts (24, fig. 9-45) and lift off bracket (1).
(b) Remove bracket port gasket (2), strainer gasket (27), strainer (26), and retaining ring (25).
(c) Remove nuts (15) and remove check valve body cover (16), spring (17), lower check valve (18), and
preformed packing (19).
(d) Remove check valve body (21), gaskets (20 and 22), and upper check valve (23).
(e) Remove bolts (14) and nuts (5) and lift off diaphragm cover (4). Exercise caution as cover is under
spring tension.
(f) Lift out diaphragm (7) and diaphragm follower (8).
(g) Remove diaphragm port gasket (6) and follower preformed packing (9).
(h) Remove spring seat retainer (13) and remove spring seat (12) and springs (10 and 11) from follower.
9-74
Figure 9-45. Throttle and transmission airline relay valve, disassembly and reassembly.
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(2) Replace preformed packings (9 and 19), and gaskets (2, 6, 20, 22, and 27).
(3) Inspect diaphragm (7) for cracks or broken sealing beads. Replace a defective diaphragm.
(4) Inspect springs (10, 11, and 17) for breaks or distortion. Replace a broken or deformed spring.
(5) Inspect upper and lower check valves (23 and 18) for scores or pits on valve surface that mates with seats in
check valve body (21). Replace a defective upper or lower check valve.
(6) Inspect check valve body for scores or pits in seat areas. Replace a defective check valve body.
(7) Inspect strainer (26) for deterioration or deformation. Replace a deteriorated or deformed strainer.
c. Reassembly and Installation. At reassembly, apply a light coat of approved grease to all friction surfaces and
preformed packings. Reassemble and install throttle and transmission airline relay valve in the reverse order of
disassembly and removal.
9-75
9-25. Tire Airline Relay Valve
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in the airlines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
(b) Disconnect airlines from fittings installed in relay air valve.
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from system.
Failure to do so may result in injury or death to maintenance personnel.
(c) Remove attaching hardware securing relay air valve.
(d) Remove fittings from relay air valve.
(2) Disassembly.
(a) Remove capscrews (8, fig. 9-46) and lift off valve cover (7) and gasket (6).
(b) Loosen setscrews (5) and lift cage (4) and gasket (11) out of body (3).
(c) Remove valve spring (14).
(d) Remove cotter pin (13) and nut (12) and remove small piston (1) and seal (2).
(e) Remove large piston (9) from cage.
(f) Spread piston ring (10) and remove ring from large piston.
b. Cleaning. Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(2) Replace seal (2). and gasket (11).
(3) Inspect spring (14) for breaks or distortion. Replace a broken or deformed spring.
(4) Inspect pistons (1 and 9) and piston ring (10) for cracks. scores. or pits. Replace a defective piston or ring.
c. Reassembly and Installation. At reassembly, apply a light coat of approved grease to all friction surfaces.
Reassemble and install tire air line relay valve in the reverse order of disassembly and removal.
Figure 9-46. Tire airline relay valve, disassembly and reassembly.
9-76
9-26. Tire Inflation Control Safety Relief Valve
a. Removal
(1) Close tire inflation valves in the wheels.
(2) Position pilot air valve (2, fig. 9-6) to deflate.
WARNING
Before attempting to remove any compressed air system lines or components, relieve pressure
from system. Failure to do so may result in injury or death to maintenance personnel.
(3) Unscrew safety relief valve (4).
Installation. Install safety relief valve in reverse order of removal.
Adjustment.
(1) Close all angle globe valves (1, fig. 9-6) and while observing the tire gage (7), slowly inflate the airlines to
70 psi with the pilot air valve (2).
(2) Adjust as follows if safety relief valve (fig. 9-47) does not open at 70 psi.
(a) Remove capnut from safety relief valve.
(b) Turn regulating nut clockwise to increase release pressure or counterclockwise to decrease release
pressure.
(c) Set safety relief valve to release at 70 psi.
b.
c.
NOTE
If safety relief valve will not release or take adjustment, replacement is required.
(d) Install and tighten capnut when proper adjustment is achieved.
(3) Open all angle globe valves.
Figure 9-47. Tire inflation control safety relief valve.
9-27. Transmission Control Valve
a. Description. The transmission control valve (Type 5-P-1B) is a five-position multi-way valve used to control the
four transmission shifting control air cylinders (five-position cylinders). The control valve contains five delivery ports, a
supply port, and an exhaust port. To prevent unintentional operation of the control valve, the hand lever has a latch
which requires a manual release before the hand lever position may be changed. The control valve ports are connected
to corresponding ports in the shifting control air cylinders. When the hand lever is moved to the positions indicated in
figure 9-48, supply pressure is discharged from ports indicated through internal passageways in the control valve.
9-77
Figure 9-48. Transmission control valve operation and port location.
b. Removal and Disassembly.
(1) Removal
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines.
(b) Disconnect airlines from couplings (5, fig. 9-49) installed in control valve (1).
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from
9-78
system. Failure to do so may result in injury or death to maintenance personnel.
(c) Remove bolts (2), nuts (4), and lockwashers (3) securing control valve to bracket.
(d) Remove couplings (5) from base of control valve (1).
Figure 9-49. Transmission control valve, removal and installation.
(2) Disassembly.
(a) Remove nut (7, fig. 9-50) and unscrew handle assembly (1).
(b) Slide plunger (4), plunger spring (3), and stud tube (2) off handle assembly.
(c) Pull off yoke (5).
(d) Remove two screws (8) and lift off index plate (9) and shim (17).
(e) Remove four screws (11) and remove body (10) and gasket (12) from valve seat (13).
(f) Lift out rotary (15) and rotary spring (14).
(g) Push key (6) out of body.
(h) Remove preformed packing (16) from key.
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(2) Replace preformed packing (16) and gasket (12).
(3) Inspect springs (3 and 14) for breaks or distortion. Replace a broken or deformed spring.
(4) Inspect rotary (15) and mating surface on
9-79
valve seat (13) for dents, pitting, or scoring. If any of these conditions are found, replace valve.
d. Reassembly and Installation. At reassembly apply a light coat of approved grease to friction surfaces and
preformed packing. Reassemble and install transmission control valve in reverse order of disassembly and removal.
Figure 9-50. Transmission control valve, disassembly and reassembly.
9-28. Transmission Shifting Control Air Cylinder
a. Removal and Disassembly.
(1) Removal.
(a) Close globe valves (6 and 7, fig. 2-19) located in airlines above air supply tanks and open service
connection globe valves (5) to vent compressed air from lines:
(b) Remove cotter pin (6, fig. 9-51) and pin (5) from piston rod (7).
(c) Disconnect air hoses from the transmission shifting control cylinder.
WARNING
Before attempting to remove any compressed air system lines or components, relieve air pressure from system.
Failure to do so may result in injury or death to maintenance personnel.
NOTE
Tag air hoses on transmission control cylinder before disconnecting hoses so hoses may be easily installed in the correct
ports when replacing the transmission shifting control cylinder.
(d) Remove attaching bolts (4), nuts (1), and lockwashers (2) securing transmission shifting control
cylinder (3) to bracket.
9-80
Figure 9-51. Transmission shifting control cylinder removal and installation.
(2) Disassembly.
(a) Remove capscrews (2, fig. 9-52) and remove rod-end head (3) and blind-end head (15).
(b) Push piston rod (7) and stop rod (12) with attached parts out blind-end head end of body (17).
(c) Push rod-end free piston (6) out rod-end head end of body.
(d) Remove nut (10) and slide operating piston (9) off piston rod (7).
(e) Slide blind-end free piston (11) off stop rod (12).
(f )Remove nut (14) and slide stop piston (13) off stop rod.
(g) Remove preformed packings (1, 4, 5, 8, and 16).
b. Cleaning , Inspection, and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with low pressure air (10
psi).
(2) Replace preformed packings (1,4, 5, 8, and 16).
c. Reassembly and Installation. At reassembly, apply a light coat of approved grease to all friction surfaces and
preformed packings. Reassemble and install transmission shifting control air cylinder in the reverse order of disassembly
and removal.
9-81
Figure 9-52. Transmission shifting control air cylinder, disassembly and reassembly.
9-29. Windshield Wiper Motor
a. Removal.
(1) Remove nut (4, fig. 9-53) and lockwasher (5), and pull wiper arm and blade assembly from adapter (6).
(2) Remove adapter (6), shield (7), flat washer (8), and gasket (9).
(3) Remove mounting bolts (2), nuts (17), and lockwashers (16).
(4) Pull wiper motor from window frame and remove spacers (10 and 13).
(5) Remove hose (14) from elbow (15) and remove elbow from wiper motor.
b. Installation. Install windshield wiper motor in reverse order of removal. Check that wiper arm is positioned
properly before tightening the retaining nut.
9-82
Figure 9-53. Windshield wiper assembly.
9-83
CHAPTER 10
HYDRAULIC SYSTEM REPAIR INSTRUCTIONS
Section I. GENERAL
10-1. Description
For a complete description of the hydraulic system refer to TM 55-1930-203-20.
10-2. General Repairs
a. All hoses, pipes, fittings, tubing, and gaskets in the hydraulic system are designed to withstand a continuous
pressure equal to that supplied in the system (fig. 10-1 thru 10-8). Refer to TM 55-1930- 203-35P for replacement parts.
b. Hangers and straps, strong enough to take all shocks required of the vehicle, are located so that piping
vibrations are at a minimum. These items will be replaced when damaged or worn to the extent that functional ability is
affected.
c. Piping passing through watertight bulkheads is welded at these points to maintain watertight integrity of the
vehicle. Any time the piping is removed the welding must be replaced.
d. Two fluid indicators (43, fig. 10-7) are located in the steering alinement circuit and are used to detect the
presence of air in the circuit. To replace these indicators, proceed as follows:
(1) Disconnect each end of indicator (43) at coupling (45). Remove indicator.
(2) Remove valve connectors (44).
(3) Install valve connectors on new indicator.
(4) Install new indicator in line with couplings (45).
10-1
Figure 10-1. Hydraulic supply and return system.
10-2
Figure 10-2. Ramp hydraulic system.
10-3
Figure 10-3. Bilge pump hydraulic system.
10-4
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Key to figure 10-3.
1
2
3
4
5
6
7
8
9
10
11
12
13
Elbow
Pipe
Bilge pump hydraulic motor
Adapter
Adapter
Hose
Reducer
Hose
Union
Flow control valve
Hose
Adapter
Coupling
10-5
Adapter
Pipe
Union
Tee
Coupling
Tee
Check valve
Elbow
Elbow
Hose
Reducer
Nipple
Cross
Reducer
Figure 10-4. Cargo well pump hydraulic system.
10-6
Key to figure 10-4.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Elbow
Pipe
Check valve
Hose
Adapter
Hose
Adapter
Tee
Elbow
Pipe
Tee
Coupling
Coupling
Coupling
Hose
Tee
Reducer
10-7
Pipe
Reducer
Tee
Pipe
Elbow
Flow control valve
Adapter
Adapter
Hose
Adapter
Coupling
Tee
Hose
Cargo well pump hydraulic motor
Reducer
Hose
Figure 10-5. Radiator fan hydraulic system.
10-8
Key to figure 10-5.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Nipple
Hose
Hydraulic motor
Pipe
Hose
Adapter
Bushing
Elbow
Adapter
Union
Adapter
Adapter
Coupling
Elbow
Elbow
Hose
Hose
Elbow
Tee
Bushing
Hose
Elbow
Control valve
Hose
10-9
Elbow
Pipe
Coupling
Hose
Tee
Pipe
Bushing
Bushing
Hose
Tee
Coupling
Reducer
Tee
Relief valve
Pipe
Elbow
Hose
Adapter
Coupling
Hose
Nipple
Hose
Pipe
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Hose
Adapter
Hose
Cargo winch hydraulic motor
Adapter
Adapter
Hose
Coupling
Cargo winch control valve
Elbow
Nipple
Hose
Hose
Pipe
Elbow
Elbow
Coupling
Hose
Adapter
Relief valve
Tee
Elbow
Check valve
Adapter
Adapter
Hose
Adapter
Check valve
Coupling
Pipe
Reducer
Cross
Figure 10-6. Cargo winch hydraulic system.
10-10
Figure 10-7. Aft steering hydraulic system.
10-11
Key to figure 10-7.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Adapter
Pipe
Hose
Elbow
Adapter
Coupling
Hose
Pipe
Elbow
Coupling
Coupling
Adapter
Cargo winch control valve
Hose
Elbow
Hose
Tee
Right angle check valve
Elbow
Needle valve
Elbow
Pipe
Union
Pressure gage
Aft steering control valve
Tee
10-12
Steering cylinder
Tee
Relief valve
Tee
Check valve
Adapter
Hose
Adapter
Check valve
Pipe
Elbow
Tee
Adapter
Coupling
Tee
Street elbow
Fluid indicator
VaIve connector
Coupling
Check valve
Needle valve
Hose
Reducer
Coupling
Adapter
Figure 10-8. Forward steering hydraulic system.
10-13
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Key to figure 10-8.
1 Hose
2 Adapter
3 Hose
4 Check valve
5 Adapter
6 Tee
7 Check valve
8 Pipe
9 Elbow
10 Pipe
11 Flange
12 Relief valve
13 Elbow
14 Adapter
15 Coupling
16 Tee
17 Tee
18 Hose
Elbow
Adapter
Adapter
Adapter
Adapter
Coupling
Adapter
Forward steering control valve
Pipe
Elbow
Coupling
Hose
Steering cylinder
Needle valve
Tee
Coupling
Hose
Adapter
Section II. REPAIR INSTRUCTIONS
10-3. Hydraulic Wheel Alinement
a. To check wheel alinement, open steering pressure gage needle valves, located in the cab beneath the
instrument panel. Start engines and put LARC in motion (TM 55-1930-203-10). Turn steering levers sharply in both
directions, observing that pressure builds up and then drops off. If pressure does not drop off, steering is misalined.
b. To realine the hydraulic wheel alinement cylinders refer to TM 55-1930-203-20.
10-4. Bilge Pump Assembly
a. Removal and Installation. Refer to paragraph 2-34 to remove and install the bilge pump assembly.
b. Disassembly.
(1) Pump motor.
(a) Cut lock wire and remove bolts (6, fig. 10-9) and washers (5) securing body (7) to cover (14).
Separate body and cover and remove gasket (12).
NOTE
Separate body and cover if necessary with a soft-faced hammer.
(b) Pull idler gear (11) and drive gear (15) out of cover.
(c) Remove O-ring seal (13) from groove in drive gear bore.
(d) Remove two plugs (8) from cover flange and body and dowel pins (9) from cover, if necessary.
(e) Pull two needle bearings (10) from cover (14) and body (7) only if they are to be replaced with new
parts.
(f) Remove two plugs (1), two valve springs (2), and two balls (3) from body.
(g) Pull two valve seats (4) from body only if they are to be replaced with new parts.
10-14
1
2
3
4
5
6
7
8
Plug
Valve spring
Ball
Valve seat
Washer
Bolt
Body
Plug
9
10
11
12
13
14
15
Dowel pin
Needle bearing
Gear
Gasket
O-ring
Cover
Gear
Figure 10-9. Bilge pump hydraulic motor disassembly and reassembly.
(2) Pump.
(a) Remove three screws (16, fig. 10-10) and lockwashers (15) from case (13) and remove strainer (14).
(b) Remove eight bolts (6) and remove housing (7) and gasket (12) from case (13).
(c) Pry up tab of key-lockwasher (10) and remove bolt (11) and key-lockwasher.
(d) Using a puller, remove impeller (9).
(e) Remove key (4) and retaining ring (1) from shaft (3). Place housing in a universal press and pressing
down on impeller end of shaft, press shaft assembly out of housing (7).
(f) Pull two bearings (2) from shaft (3).
(g) Push two oil seals (8) from housing (7).
10-15
1
2
3
4
5
6
7
8
Retaining ring
Bearing
Shaft
Key
Plug (for shipping only)
Bolt
Housing
Seals
9
10
11
12
13
14
15
16
Impeller
Key-lockwasher
Bolt
Gasket
Case
Strainer
Washer
Screw
Figure 10-10. Bilge pump disassembly and reassembly.
c. Cleaning, Inspection and Repair.
(1) Pump motor.
(a) Wash all metal parts thoroughly in kerosene, Federal Specification VV-K-211, or mineral spirits, and
dry with compressed air.
(b) Pressure flush all bores in body and cover with dry-cleaning solvent, Federal Specification P-D-680,
and blow out with compressed air.
(c) Inspect all threaded parts for stripped or crossed threads and replace as necessary.
(d) Inspect body and cover for cracks and all bores for scratches, scores, and burrs. Repair or notify
supporting higher echelon maintenance.
(e) Inspect needle bearings. Be sure they are free to turn and have not rough or sticky spots. Replace as
necessary.
(f) Inspect gears and shafts for wear, cracks, burrs, and scores. Repair or replace as necessary.
(g) Inspect check valve ball seats in body. If there is evidence of improper seating, install new parts.
(2) Pump.
(a) Wash all parts with dry cleaning solvent, Federal Specification P-D-680, and dry with compressed air.
Remove rust and scale. If badly pitted, replace with new part.
(b) Inspect case and housing for damage or cracks. Discard oil seals and gasket. Check bearings for
scoring or excessive wear. Inspect splines for wear or burrs. Inspect impeller blades for damage or distortion.
Inspect strainer for holes or damage. Replace defective parts with serviceable parts.
d. Reassembly.
(1) Pump motor.
(a) Install two needle bearings (10, fig. 10-9) to cover (14) and body (7) if they have been removed from
bores of body.
(b) Install two valves seats (4) to ports in body if they are to be replaced with new parts.
(c) Install two balls (3), two valve springs (2), and two plugs (1) in body.
(d) Install two plugs (8) in body and cover flange.
(e) Install new O-ring seal (13) in groove in drive gear bore.
(f) Install dowel pins (9) in cover, if they have been removed.
(g) Press idler gear (11) and drive gear (15) into cover through needle bearings.
(h) Install new gasket (21) of the same thickness as the original gasket in place on the cover.
(i) Press body (7) onto cover (14) and secure with bolts (6) and washers (5).
(j) Secure bolts with lock wire.
10-16
(2) Pump
(a) Press two bearings (2, fig. 10-10) on shaft (3).
(b) Press two oil seals (8) into housing (7).
NOTE
Both oil seals must be installed with lips facing the impeller.
(c) Press shaft assembly into housing (7) and install key (4) on shaft.
(d) Install retaining ring (1). Press impeller (9) on key and shaft.
(e) Install key-lockwasher (10) on impeller end of shaft, and install and tighten bolt (11). Lock bolt with
tab on key-lockwasher (10).
(f) Replace gasket (12) and install housing on case (13), in position required, with eight bolts (6).
(g) Install strainer (14) on case (13) with three screws (16) and lockwasher (15).
10-5. Cargo Well Pump, Motor, Model M2B-40-FL-S15
a. Removal and Installation. Refer to paragraph 2-35 to remove and install the cargo well pump motor.
b. Disassembly (fig. 10-11).
(1) Fasten motor snugly in a bench vise, or other suitable fixture, in a vertical position with shaft end up.
(2) Remove key (7), screws (16), flange (15), and dowel pin (17).
(3) Using a small punch drive out dowel pins (4 and 23).
(4) Remove and discard seal rings (3).
(5) Remove screws (13) and reposition motor with shaft end down. Be careful that body (10) and covers (2 and
11) do not separate in the process.
(6) To disengage cover (2), insert a small punch in drain hole and tap lightly until shaft (5) clears cover bore.
(7) Remove cover (2) and spacer (25).
(8) Using a bearing puller, remove bearing (24) from shaft (22).
(9) Lift off body (10), gear (8), and gear (9).
(10) Remove key (6).
(11) Using a soft hammer, lightly tap shaft (5) through bore of cover (11) dislodging plug (12) in the process.
(12) Tap cover end of shaft (22) lightly to dislodge shaft and bearing (14) from cover (11) and remove spacer
(18).
NOTE
If necessary to remove bearing (14) from shaft (22), support inner race in an arbor press while pressing shaft out.
(13) Remove seal (19) and washer (20) by tapping on edge of washer with a punch inserted in bore of cover (11).
(14) Remove screws (27) and nameplate (26) only when it is necessary to repaint motor.
10-17
Figure 10-11. Cargo well pump hydraulic motor, model M2-40-FL-S15 disassembly and reassembly.
c. Cleaning, Inspection and Repair.
(1) Discard used oil seal and seal rings. Clean all parts in dry cleaning solvent, Federal Specification P-D-680,
and place them on a clean, protected surface for inspection.
(2) Check inner and mating surfaces of body and mating surfaces of covers for score marks or excessive wear.
Light scratches may be removed by careful lapping of mating surfaces and by polishing inner surface of body with crocus
cloth, Federal Specification P-C-458.
(3) Check dowel pinholes and shaft bores in covers for out-of-roundness, oversize, or burrs caused by a shearing
action. Presence of any of these defects is cause for rejection.
NOTE
Covers and body are machined in matched sets. If defective, replace the model M2B-40-FLS15 motor with model MF2008-30-38-21 motor.
(4) Check gears for chipped or worn teeth, shaft bore and bushing for out-of-roundness, or other excessive wear.
If gears are defective, replace the model M2B-40-FL-S15 motor with model MF 2008-30-38-21 motor.
(5) Check bearings for wear and looseness. Rotate bearings, applying pressure to outer race, to check for pitted
or cracked races.
(6) Inspect oil seal journal on shaft for scoring or wear. Replace shaft if marks cannot be removed by lapping with
crocus cloth, Federal Specification P-C-458.
10-18
d. Reassembly (fig. 10-11).
(1)Coat all parts with clean engine oil, OE-10, to facilitate assembly and provide initial lubrication.
(2) To install seal (19), place cover (11) in an arbor press with mating surface down. Insert washer (20). Press
seal (19) into cover with sealing lip facing in. Use a driver which will apply force near seal outer edge only. Be sure seal
is firmly in place and is not cocked or sheared.
(3) To install bearing (14) on shaft (22), place spacer (18) and bearing in 'an arbor press and press shaft down
until inner race of bearing bottoms evenly on drive shaft shoulder.
(4) To install shaft (5), place cover (11) in an arbor press with shaft end down. Place gear (8) subassembly in
position over cover bore to act as a guide, since the shaft must be held perpendicular to prevent shearing of cover bore
during installation. Press shaft down with an even steady force until the center of the cross-drilled drain holes in shaft are
alined with sides of gear teeth.
NOTE
Measure depth from flange mounting surface of cover (11) to end of shaft (5) through expansion plug hole with a depth
gage. Make note of dimension and check measurement after motor is assembled to be sure shaft did not change position
during installation of cover (2).
(5) Install key (6) in shaft (22), and install gear (9) on shaft. Slide body (10) carefully over the assembled shafts
and gears.
(6) To install bearing (24), place assembled shaft (22) in an arbor press with shaft end down. Apply an even
steady force on inner race of bearing until it bottoms on shaft shoulder. Be sure inner race of bearing (14) is supported
during the process.
(7) Install spacer (25) in cover (2) and install cover. Be careful that body (10) and covers (2 and 11) do not
separate in the process.
(8) Install screws (13) finger tight.
(9) Place new seal rings (3) in grooves in dowel pins (4 and 23) and lightly tap dowel pins into the assembled
motor.
NOTE
Lubricate dowel pins with clean engine oil, OE-10, before installation to prevent binding and damage to seal rings.
(10) Install dowel pin (17) in flange (15).
(11) Install flange (15) on motor and secure with screws (16).
(12) Install key (7) in shaft (22).
(13) Rotate drive shaft several times by hand to determine freedom of movement.
(14) Check shaft bore depth as outlined in note. If shaft did not change position, insert plug (12) in cover (11).
e. Testing.
(1) Mount motor on a suitable test stand. Connect a relief valve set at 1 100 psi and a pressure gage into
pressure line of a 4-way valve. Provide for 15 psi back pressure at drain port.
(2) With motor loaded to produce 1000 psi, intermittently stall motor and check drain port and outlet port leakage.
Stall leakage should not exceed values given in table 10-1.
Table 10-1. Model M2B-40-FL-S15, Cargo well pump hydraulic motor test data.
RPM
(MAX)
1800
Stall Leakage
Outlet port
Drain port
(GPM)
(cu. in. per
min)
4.5
50
Volume (GPM)
Motor unMotor
loaded inlet
loaded inlet
pressure 0
pressure
1000 psi
19.1 to 20.6
21.1 to 23.6
Approximate
running
torque
(in. lb)
360
(3) With motor unloaded and running at 1800 rpm, check for volume in both directions as given in table 10-1.
(4) With motor loaded to produce 1000 psi inlet pressure and running at 1800 rpm, check for volume and
approximate running torque in both directions as given in table 10-1.
NOTE
Both loaded and unloaded, the motor should respond instantly when direction of rotation is reversed with 4-way value,
and should operate without excessive noise.
10-6. Cargo Well Pump Motor, Model MF-2008-30-38-21
a. Removal and Installation. Refer to paragraph 2-35 to remove and install the cargo well pump motor.
b. Disassembly. Refer to figure 10-12.
NOTE
Prepare a clean, lint-free surface on which to place parts as they are disassembled.
(1) Remove cotter pin (1), nut (2), washer (3), spring (50), and retainer (49) from pin (14).
10-19
(2) Remove valve block mounting screws (4 and 5) from block (6) and lift block off angle housing (9). Be sure
plate (8) does not adhere to block.
(3) Remove gasket (7).
NOTE
Do not remove pin (48) unless damaged or worn.
(4) Fasten motor snugly in a bench vise or other suitable fixture in a vertical position with the shaft end down.
(5) Remove six screws (34).
NOTE
These screws extend through the retainer (35) and housing (38) and are threaded into the angle housing (9).
CAUTION
Be careful to prevent components from separating when removing screws.
(6) Remove key (32) from drive shaft and piston subassembly (31).
(7) While exerting an even downward pressure on plate (8), ease angle housing (9) off housing (38).
(8) Remove plate (8) and gasket (10).
(9) Press down on housing (38) and lift block (12), drive shaft and piston subassembly (31), and bearings (41, 44,
and 46) out of housing as an assembly.
CAUTION
Be careful not to allow block (12) to separate from the drive shaft and piston subassembly (31).
(10) Separate retainer (35) from housing (38) and disassemble gasket (37), ring (40), and pins (39).
(11) Press oil seal (36) out of retainer (35).
(12) Separate block (12) from drive shaft and piston subassembly (31) slowly so that pistons do not strike against
each other.
(13) Remove bearing (24) from retainer (23).
(14) Using long-nose pliers, compress ears of snap ring (22) and extract snap ring and retainer (23) from bore of
block (12).
(15) Remove snap ring (11), pin (14), and seal (13) from block (12).
(16) Remove screw (21) and washer (20) from pin (14).
(17) Remove bearing (19), spacer (18), bearing (17), and thrust washer (16).
(18) Extract universal link (26) from drive shaft and piston subassembly (31) and remove knuckles (25) from
universal link.
(19) Remove bearing (27), spring (28), retainer (29), and key (30) from drive shaft and piston subassembly (31).
NOTE
It is not recommended that bearings and retainers be removed from drive shaft and piston subassembly unless they
require thorough cleaning or replacement.
(20) To remove bearings (41, 44, or 46), place drive shaft and piston subassembly (31) in an arbor press and
support bearing to be removed with two steel straps. Press bearing off shaft by exerting force on shaft, using a length of
steel rod.
NOTE
Bearings to be removed must be pressed off individually and only after any retaining rings, spacers, or nuts have been
removed.
CAUTION
Do not attempt to disassemble pistons from shaft assembly.
10-20
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Cotter pin
Nut
Washer
Screw
Screw
Block
Gasket
Plate
Angle housing
Gasket
Snapring
Block
Seal
Pin
Key
Thrust washer
Bearing
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Spacer
Bearing
Washer
Screw
Snapring
Retainer
Bearing
Knuckle
Universal link
Bearing
Spring
Retainer
Key
Drive shaft and piston subassembly
Key
Flange
Screw
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Retainer
Oil seal
Gasket
Housing
Pin
Ring
Bearing
Locknut
Lockwasher
Bearings
Spacer
Bearing
Retainer
Pin, valve plate locating spring
Retainer
Spring
Figure 10-12. Cargo well pump hydraulic motor, model MF-2008-30-38-21, disassembly and reassembly.
10-21
c.
Cleaning, Inspection and Repair.
(1) Clean all parts except seals and gaskets in dry-cleaning solvent, Federal Specification P-D- 680.
(2) Place all bearings, which have been removed for closer inspection in a wire basket and immerse in drycleaning solvent. Agitate basket frequently to allow solvent to reach all parts of bearings and to loosen dirt and sludge.
(3) Using a spray gun equipped with an air filter, flush bearings with clean solvent. Turn bearing races slowly
during this operation to assure thorough cleaning.
(4) Visually inspect bearings for rusted balls or raceways caused by oxidation or water in system.
(5) Check for fractured rings caused by too heavy a press fit, excessive loading, or by forcing a cocked
bearing on or off shaft.
(6) Inspect bearings for worn, galled, or rough surfaces caused by dirt locking and bearing while shaft
continued to turn.
(7) Check bearings for broken or bent separators.
NOTE
Do not attempt to repair damaged bearings. Always replace them with new ones.
(8) Inspect bearings for discolored balls or races.
NOTE
Moderate discoloration of balls, rollers, or ball track does not necessarily mean replacement is required.
(9) If none of the above defects are found and the cleaning and flushing operation restores bearings to their
original smooth working condition, rinse bearings in clean engine oil, OE-10, and wrap in a clean piece of paper barrier
material, Military Specification MIL-B-121, and lay bearings aside until reassembly.
(10) Inspect housing (38, fig. 10-12) and angle housing (9) for damage or excessive wear, obstructions of
internal passages, stripped threads of tapped holes, burrs and nicks in bearing bores, and out-of-round or burred locating
pinholes. Remove burrs and nicks with crocus cloth, Federal Specification P-C-458. Repair threads using proper size
tap. Clean passages by working a piece of wire back and forth through the passages and flushing them with dry-cleaning
solvent, Federal Specification P-D-680. Dry passages with compressed air. (
(11) Inspect block (6) for deep nicks or scratches on valving surface, stripped threads in connection ports, and
nicks and burrs on edges of mating surfaces. Remove nicks and scratches with crocus cloth, Federal Specification P-C458. Repair threads with proper size tap.
(12) Inspect drive shaft and piston subassembly (31) for deep scratches, scores or nicks on pistons, binding rod
bearings in flange and piston ends, grooves or deep scratches of drive shaft oil seal journal. Remove scratches, scores,
or nicks from pistons with crocus cloth, Federal Specification P-C-458. If grooves and scratches cannot be removed
from shaft oil seal journal, replace entire assembly.
(13) Inspect plate (8) for grooves or deep 3cratches and nicks or burrs on contacting surfaces. Check for
flatness of contracting surfaces and excessive wear or burrs in kidney slots and pressure holes. Remove scratches,
nicks, and burrs with crocus cloth, Federal Specification P-C-458.
NOTE
The plate (8) and block (12) are precision parts and valving action of
motor is entirely dependent upon flatness of their contacting surfaces.
These parts should be lapped in accordance with procedures outlined in
step (17) below.
(14) Inspect block (12) for out-of-round or scored cylinder bores or grooved, burred, or nicked valving surface.
Check retainer positioning ears of the block for excessive wear and retainer bore for out-of-round condition. Remove
burrs and nicks with crocus cloth, Federal Specification P-C-458 (See note above).
(15) Inspect universal link subassembly as follows:
(a) Check link pins of universal link (26) for wear or flatness on one side, bent pins, or twisted link.
(b) Check knuckles (25) for enlarged or out-of-round link pinholes, excessive wear, and burrs. Remove burrs
with crocus cloth, Federal Specification P-C-458.
(c) Inspect bearings (24) for feathered edges or other indications of excessive wear.
(d) Inspect retainer (23) for burrs, nicks, or worn key slot. Remove burrs and nicks with crocus cloth,
Federal Specification P-C-458.
(16) Check springs, nuts, washers, and pins for signs of severe wear or distortion. Replace as required.
(17) Inspect parts for roughness and scored areas. If parts are rough or scored to the extent that would impair
proper function of motor, perform lapping procedures as follows: (a) On bronze parts use abrasive paper, Federal
Specification P-P-101, on a surface plate to remove imperfections. Clean thoroughly with clean dry-cleaning solvent,
Federal Specification P-D- 680.
10-22
(b) Use abrasive paper, Federal Specification P-P-101, on a surface plate to polish parts. Clean thoroughly
with clean dry-cleaning solvent.
NOTE
Never use polishing paper on a bronze part after using it on a steel part.
Particles of steel will cut into bronze part. Use a new polishing paper for
each part to be lapped.
(c) For steel parts. use lapping compound. Military Specification MIL-L-17862, on a grooved lapping plate.
After lapping. clean thoroughly with clean dry-cleaning solvent.
(d) Polish parts with abrasive paper. Federal Specification P-P-IOI, on a surface plate. Clean thoroughly with
clean dry-cleaning solvent.
(e) Check surface and flatness of lapped parts on a checking plate with a thin film of oil. Press lapped part
firmly into film of oil and twist part approximately one-eighth turn.
(f) Lift part clear of checking plate. Impression of part on oil film should be nearly perfect.
(18) After all parts have been thoroughly cleaned, inspected and repaired or replaced. rinse parts in clean
engine oil, OE-10, prior to reassembly. This protects and lubricates parts and aids reassembly.
d. Reassembly.
NOTE
If bearings (41, 44, or 46, fig. 10-12) were not removed during disassembly, omit
steps (1) through (5).
(1) Mount drive shaft and piston subassembly (31) in an arbor press with pistons down, but not resting on
them. Use a piece of steel tubing slightly larger than diameter of drive shaft for bearing installation.
CAUTION
When installing bearings, tubing must press on inner race only.
NOTE
Install bearings individually.
(2) Install retainer (47), bearing (46) and spacer (45) followed by second bearing (46) and spacer (45).
(3) Install bearings (44).
(4) Install tab lockwasher (43) and locknut (42). Tighten locknut securely and position slots in locknut to match
tabs of lockwasher. Bend tabs of lockwasher down into slots to prevent locknut from loosening. (5) Install bearing (41) on
drive shaft.
NOTE
Rotate each bearing by hand to determine freedom ofrotation.
(6) Install key (30). retainer (29). spring (28), and bearing (27), in central bore of shaft.
(7) Install knuckles (25) on link pins with the grooved end up. Hold universal link (26) and pins at an angle and
slide one knuckle in retainer slot.
CAUTION
Do not permit pistons to strike each other.
(8) Install thrust washer ( 16). bearing (17) spacer (18). bearing (19). and snapring(11) on pin (14).
(9) Install washer (20) and screw (21) on pin (14).
(10) Install seal (13) and cylinder bearing pin assembly in block (12).
(11) Place snapring (22) around recess in retainer (23). Compress ears of snapring with long- nose pliers and
install retainer with snapring in block (12) 90 degrees from final position. Seat retainer with a twisting downward motion.
(12) Install bearing 1241 in retainer 1231 with a small amount of petrolatum. Federal Specification 'VV-P-236. to
hold it in place.
(13) To install block (12) on pistons. match pistons t(o their respective cylinder bores. position one (cylinder bore
in line with retainer slots.
NOTE
This is No.1 cylinder bore while the piston in line with its retainer slots is No.1 piston.
(14) Insert No.1 piston in No. I cylinder bore. Be sure piston is not cocked.
(15) Insert remaining pistons alternately on each side of No. I piston in their respective 1)ores. When only two
pistons remain to be inserted. tilt block (12) back and slip first knuckle (25) in retainer slot. 'Tilt block forward and
slide remaining knuckle in opposite retainer slot.
(16) Install two remaining pistons and test assembly by quickly pushing block (12) straight down. This action
should he smooth and springy.
(17) Rotate block (12) to test for erratic action or binding.
(18) Press oil seal (30) in retainer (35) with sealing lip facing inside.
(19) Support the assembled block (12) and drive shaft and piston subassembly (13), making sure parts do not
separate, and carefully press housing (38) over bearings from shaft end.
(20) Install pins (39) and ring (40) in retainer (35).
(21) Install gasket (37) and install retainer (35) over shaft and down against housing (38).
10-23
(22) Install plate (8) and gasket (10).
(23) Install angle housing (9) carefully over plate (8) and block (12) and press angle housing firmly against
housing (38).
(24) If pin (48) was removed from block (6). press a new pin in place.
(25) Install new gasket (7)on angle housing (9).
(26) Position block (6)over pin (14) and over plate (8) so pin (48) enters hole in plate. If necessary. rotate plate,
pin (14). and block C61 so screw holes in block are aligned with holes in angle housing (9).
NOTE
Arrangement o)f holes limits assembly to two positions either of which is correct.
(27) Install valve block mounting screws C4 and 51 securing block 161 to angle housing 191. Tighten only finger
tight at this time.
CAUTION
Until screws (34) are installed to secure retainer (35), housing (38), and angle housing (9), extreme care
must be taken to prevent motor components from separating.
(28) Lift assembled motor from support and install six screws C34). Tighten screws tight enough to secure
motor components.
(29) Tighten the valve block mounting screws (4 and 51.
(30) Install retainer (491, spring C50I. washer (3). and nut 121. To obtain proper clearance of 0.
0I0 to 0.015
inch, tighten nut so block 161. plate C81. and block (12) are clamped snugly together. Then back nut off from 90 to 120
degrees to align the cotter pin slot in nut with whole in pin C 141.
(31) Insert and secure cotter pin (1) to maintain adjustment.
(32) Insert key (32) in drive shaft slot.
e. Testing.
NOTE
Before mounting motor (on test stand. check shaft for free rotation without bind in both directions when rotated
by hand.
(1) Mount motor on suitable test stand. Fill motor case with engine oil, OE-1O.
(2) Install a 5 psi check valve in drain port.
(3) Install a needle valve in inlet and outlet ports.
(4) Connect inlet port to a 2000 psi maximum pressure source.
(5) With outlet needle valve fully open. gradually open inlet needle valve permitting motor to accelerate until
discharge oil is free of air.
(6) With inlet valve fully open, gradually close off outlet needle valve until motor stops.
(7) With 2000 psi inlet pressure, case drain leakage must not exceed 30 cubic inches per minute.
(8) With 5 psi applied to case through 5 psi check valve, there must not be any external leakage.
10-7. Cargo Well Pump
a. Removal and Installation. Refer to paragraph 2-35 to remove and install the cargo well pump.
b. Disassembly.
(1) Remove cargo well pump hydraulic motor front pump (para 2-35).
(2) Knock out pin (2. fig. 10-13) and remove coupling (1) from pump shaft.
(3) Close oiler metering valve (7) and disconnect oiler line (6) from packing ring (4).
(4) Remove tension nut (3) from pump upper column sleeve bearing and remove packing ring (4).
(5) Remove preformed packing (5).
(6) Remove bolts (19), lockwashers (11), and nuts (12) securing discharge elbow (8) to stator case (10).
(7) Separate stator case (10) from discharge elbow (8) and withdraw inner column (17) together with sleeve
bearing (18), and pump shaft (13) with stator case.
(8) Withdraw pump shaft (13) with impeller (15) from stator case.
(9) Remove upper column sleeve bearing (!8) from inner column (17).
(10) Unscrew inner column (17) from stator case upper sleeve bearing (9).
(11) Remove stator case upper sleeve bearing (9).
(12) Remove lower sleeve bearing (14), from stator case (10), if replacement is necessary.
(13) Drive pin (16) from impeller (15) and remove impeller.
10-24
Figure 10-13. Cargo well pump, disassembly and reassembly. (Sheet 1 of 2).
10-25
Figure 10-13. Cargo well pump, disassembly and reassembly. (Sheet 2 of 2).
10-26
c.
Cleaning, Inspection and Repair.
(1) Clean all metal parts with dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed
air.
(2) Inspect impeller blades for burrs, scratches, nicks, and distorted blades. Remove burrs with a fine file.
Remove scratches and nicks with crocus cloth, Federal Specification P-C-458.
NOTE
If impeller is cracked or any blades are distorted or cracked, replace impeller.
(3) Inspect threaded parts for burred or damaged threads. Replace damaged parts.
(4) Inspect stator case upper sleeve bearing (9), stator case lower sleeve bearing (14), and upper column
sleeve bearing (18) for scores, burrs, sharp edges, and evidence of overheating. Remove. scores with crocus cloth,
Federal Specification P-C-458. Remove burrs and sharp edges with a scraper or knife blade. Replace bearings that are
out-of- round, deeply scored, or excessively worn.
(5) Inspect pump shaft (13) for grooves or deep scratches at bearing surface contact at upper and lower end
of shaft. Remove grooves and scratches with crocus cloth, Federal Specification P-S-458. If defects cannot be
removed, replace shaft.
(6) Inspect stator case (10) for cracks at stator case bearing and sleeve bearing support.
NOTE
If stator case is cracked or damaged in any way, replace it.
(7) Inspect mounting faces on discharge elbow (1) for burrs, scratches, and nicks. Remove burrs with a fine
file. Remove scratches and nicks with crocus cloth, Federal Specification P-C-458.
d. Reassembly.
(1) Install stator case lower sleeve bearing (14) in stator case (10), if bearing was removed during
disassembly.
(2) Install stator case upper sleeve bearing (9) in stator case.
CAUTION
Tighten stator case upper sleeve bearing carefully. Damage to bearing or stator case will result if
bearing is forced.
(3) Install impeller (15) on pump shaft (13) and insert pin (16).
(4) Install assembled pump shaft and impeller in stator case (10).
(5) Slide inner column (17) over pump shaft and screw onto stator case upper sleeve bearing (9).
(6) Screw upper column sleeve bearing (18) into inner column (17).
(7) Attach stator case with assembled parts to discharge elbow (8), with bolts (19), lockwasher (11), and nuts
(12).
(8) Place new preformed packing (5) around pump inner column and install packing ring (4) and tension nut
(3).
(9) Place coupling (1) on pump shaft and install pin (2).
(10) Install hydraulic motor in reverse order of removal as outlined in paragraph 10-5.
(11) Connect oiler line (6) to packing ring (4).
10-8. Cargo Winch Brake Assembly
a. Removal and Disassembly.
(1) Remove wire rope guard (2, fig. 2-30) by removing bolts (1), lockwashers (6), and nuts (7).
(2) Remove capscrews (39) and lockwashers (40); loosen capscrews (38).
(3) Remove capscrews (3) and remove brake cover (4).
CAUTION
Care should be used when removing brake cover (4) to avoid damaging pins (43).
(4) Remove pins (43).
(5) Remove capscrews (15, fig. 10-14) and lockwashers (14). Remove brake cover plate (13).
(6) Loosen brake band (7) by turning brake adjustment bolt (16) clockwise.
(7) Remove retaining rings (6) and pins (5). Remove adjustment link assembly.
(8) Remove pins (11 and 12) and differential lever (10).
(9) Remove brake band (7) by pulling straight to the rear over brake drum.
(10) Remove brake cable locknut (2) and lift out lever (4). Remove pin (1) and universal block (3).
(11) Remove setscrews (37, fig. 2-30) and pull brake cable (22, fig. 10-14) from winch. Remove brake cable
jamnut (23).
(12) Disassemble adjustment link assembly by removing adjustment bolt (16).
b. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal Specification P-D-680.
(2) Inspect brake lining (9, fig. 10-14) for wear and condition. Replace lining if worn to the point where rivets
(8) are contacting drum or if lining has become oil-soaked.
(3) Inspect all threaded parts for stripped or damaged threads and replace if defective.
(4) Inspect pins (1, 5, 11, 12, and 18) and their mating parts for cracks and replace if defective.
10-27
Figure 10-14. Cargo winch brake accessory.
10-28
c. Reassembly and Installation. Reassemble and install winch brake assembly in reverse order of disassembly and
removal.
d. Brake Adjustment.
(1) Remove brake cover (3, fig. 10-15) by removing four capscrews (1) and lockwashers (2).
(2) Loosen locknuts (9) and jamnut (8) turn brake adjusting bolt (5) clockwise until cable drum can be turned
freely by hand.
(3) Tighten brake band (4)by turning brake adjusting bolt (5) counterclockwise until a slight drag is felt on cable
drum.
(4) Tighten jamnut (8) and locknut (9).
(5) Replace brake cover (3).
10-9. Cargo Winch Wire Rope
a. Removal.
(1) Unwind wire rope from cable drum.
(2) Slide ferrule end of wires out of slot in
cable drum..
b. Installation.
NOTE:
If ferrule is assembled in to wire
rope, install wire rope in reverse
order of removal. The following
instructions apply to installation of
new wire rope that does not have
a ferrule.
(1) Apply whipping (1, fig. 10-16) to new
wire rope approximately 3 inches from end of wire
rope, using heavy safety wire.
(2) Place wire rope upright in a vise;
unwind strands and broom out wire in each strand.
(3) Remove wire rope from wise and
carefully clean wires back to whipping (1) with drycleaning solvent. Federal Specification P-D-680.
(4) Replace wire rope in vise; hold wire
ends together and temporarily whip with three or
four turns of light wire.
(5) Install ferrule (4) on temporarily
whipped end of wire rope and remove temporary
whipping (2).
(6) Place molder’s putty (5) around
outside base of ferrule (4) to prevent molten zinc
from running our ferrule end next to whipping (1).
(7) Fill ferrule (4) with molten zinc (3).
When zinc has returned to its solid form, place
end of wire rope with ferrule (4) into water to cool.
(8) Remove solder’s putty (5) and trim
protruding strands flush with end of ferrule (4).
(9) Install wire rope ferrule (4) in cable
drum ferrule slot and underwind wire rope on
cable drum.
Figure 10-15. Winch brake adjustment.
10-29
10-10. Cargo Winch Assembly
a. Removal and Installation. Refer to paragraph 2-33 to
remove and install the cargo winch assembly.
b. Disassembly.
(1) Remove wire rope (para 10-91.
(2) Remove packing nut 173, fig. 10-17) and packing
rings (721 from stuffing box 1711. Remove stuffing box.
(3) Remove brake assembly (para IQ-8).
(4) Remove bull gear end cover (3, fig. 10-17) and drum
shaft shim set 14i from winch housing (221 by removing bolts (1)
and lockwashers (2).
(5) Remove gear cover C 1i, and gasket 1101 by
removing capscrews 112. Shift clutch shaft to free-spooling and
remove bull gear 17) and gear hub assembly.
(6) Remove spacer (9) from bore of annular ball bearing
(5). Remove annular ball bearings, snapring (6), and gear hub (8)
from bull gear (7).
(7) Remove clutch shaft cover (19) and clutch shaft shim
set (18) by removing capscrews (21) and lockwashers (20).
Remove drum (13) and clutch shaft assembly from housing.
(8) Pull clutch shaft (14) from brake end of drum. taking
care to recover bearing (15) and clutch shaft spring (11).
Figure 10-16. Pouring wire rope ferrule.
Remove annular ball bearing (17) from drum.
(9) Remove capscrew (31). washer (30). and reduction
gear plate (29). Drive reduction gear shaft (23) from outside toward center of winch assembly until spacer (28) and
reduction gear (27) are free. Remove spacer. reduction gear assembly. and reduction gear shaft from winch housing
(22).
(10) Remove spacers (24) reduction gear bearings (25) and reduction gear snaprings (20) from reduction gear
(27).
(11) Remove compartment cover (56) and gasket (55) by removing capscrews (58) and washers (57).
(12) Remove capscrews (68). washer (67). and back gear plate (66). Drive back gear shaft (60) from outside
toward center of winch until spacer (65) and back gear (64) are free. Remove shaft, -;pacer. and gear from winch
housing (22).
(13) Remove spacers (61). back gear roller bearings (62). and back gear snaprings (63) from back gear (64).
(14) Loosen nut (45) a shifter shaft (44). Unscrew control rod (46) from shifter shaft. Remove nut and pull
control rod from winch housing (22).
(15) Remove capscrew (43). washer (42). and pull shifter shaft (44) toward brake side of case until shifter fork
(47) is free. Remove shifter fork, shifter shaft, bearing (41) and spring (48).
(16) Remove bevel gear snaprings (50) from bevel gear shaft (49).
(17) Remove capscrews (32). washers (33). and bearing retainer plate (34).
(18) Pry bearing housing (38) and shaft assembly from winch, taking care not to damage bevel gear shim (39).
(19) Remove bevel gear shaft (49), bevel gear (54), spacer (53) and sliding pinion (40) from winch.
(20) Remove nut (35), washer (36), bearing housing (38), and bevel gear shaft outer bearing (37).
(21) Drive bevel gear shaft inner bearings (52) from winch housing and remove bearing adapter (51) from
bearings.
10-30
Figure 10-17. Cargo winch disassembly.
10-31
Key to figure 10-17.
1 Capscrew
2 Lockwasher
3 Bull gear end cover
4 Drum shaft shim set
5 Annular ball bearing
6 Snapring
7 Bull gear
8 Gear hub
9 Spacer, hub gear bearing
10 Gasket
11 Gear cover
12 Capscrew
13 Drum
14 Clutch shaft
15 Bearing
16 Clutch shaft spring
17 Annular ball bearing
18 Clutch shaft shin set
19 Clutch shaft cover
20 Lockwasher
21 Capscrew
22 Winch housing
23 Reduction gear shaft
24 Spacer, reduction gear bearing
25 Reduction gear bearing
26 Reduction gear snapring
27 Reduction gear
28 Spacer, reduction gear
29 Reduction gear plate
30 Washer
31 Capscrew
32 Capscrew
33 Washer
34 Bearing retainer plate
35 Nut, plain
36 Washer, key
37 Bevel gear shaft outer bearing
38 Bearing housing
39 Bevel gear shim
40 Sliding pinion
41 Shifter fork
42 Washer, shifter fork
43 Capscrew
44 Shifter shaft
45 Nut
46 Control rod
47 Bearing
48 Spring
49 Bevel gear shaft
c.
50 Bevel gear snapring
51 Bearing adapter
52 Bevel gear shaft inner bearing
53 Spacer, bevel gear
54 Bevel gear
55 Gasket
56 Compartment cover
57 Washer
58 Capscrew
59 Setscrew
60 Back gear shaft
61 Spacer, back gear bearing
62 Back gear roller bearing
63 Back gear snapring
64 Back gear
65 Spacer, back gear
66 Back gear plate
67 Washer
68 Capscrew
69 Plug, pipe
70 Plug, pipe
71 Stuffing box
72 Packing ring
73 Packing nut
Cleaning, Inspection and Repair
(1) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680, and dry with compressed air (10 psi).
(2) Inspect all parts for abrasive material while disassembled. Reclean if necessary.
(3) Inspect bores for grooves, scratches, and burrs. Remove burrs and scratches with crocus cloth, Federal
Specification P-C-458. Replace deeply grooved or scratched parts.
(4) Inspect mounting surfaces for burrs, scratches, and nicks. Remove defects with crocus cloth, Federal
Specification P-C-458. If defects cannot he removed without disfiguring the surface, replace part.
(5) Inspect all threaded openings and inserts for damaged threads and chase threads as necessary. Replac
e
damaged part.
(6) Inspect bearings for pitted, scored, or burned condition. Replace as necessary.
(7) Inspect gears for scuffed, nicked, burred, or broken teeth. Remove defects with crocus cloth, Federal
Specification P-C-458. If defects cannot be removed without changing teeth profile, replace gear.
(8) Inspect snaprings for proper fit. Snaprings must snap tight in their grooves for proper functioning.
(9) Inspect splined parts for stripped, twisted, chipped, or burred splines. Remove burrs with crocus cloth,
Federal Specification P-C-458. Replace stripped or twisted splined parts.
(10) Inspect stuffing box (71, fig. 10-17) and packing nut (73) for damaged threads and replace as necessary.
(11) Replace packing rings (72).
d.
Reassembly (fig. 10-17).
(1) Place bevel gear shaft inner bearings (52), and bearing adapters (5 1) into winch housing (22)
with adapters shoulders to outside of winch.
(2) Install bevel gear shaft outer bearing (37), bearing housing (38), washer (36), nut (35), and shim (39) on
bevel gear shaft (49).
(3) While sliding bevel gear shaft (49) into winch housing (22) position sliding pinion (40), spacer (53), and
bevel gear (54) on bevel gear shaft (49).
(4) Install bearing retainer plate (34), washers (33), and capscrews (32) to secure bevel gear assembly in
housing.
10-32
(5) Install bevel gear snaprings (50) on bevel gear shaft (49).
(6) Install shifter fork (41) and shifter shaft (44) with bearing (47) and spring (48) into winch housing (22).
Secure shifter fork (41) with washer (42) and capscrew (43).
(7) Install control rod (46) into s hifter shaft (44) and tighten nut (45) securing control rod to shifter shaft.
(8) Install back gear snaprings (63) and back gear roller bearings (62) into bore of back gear (64).
(9) Slide one spacer (61) on back gear shaft (60) to rest against shoulder of shaft.
(10) Position back gear (64) in winch housing (22) and slide back gear shaft (60) into back gear. Position
spacers (61 and 65) into place and slide back gear shaft into position in housing.
(11) Install back gear plate (66) into slot of back gear shaft (60) and secure with washer (67), and capscrew (68).
(12) Install reduction gear snaprings (26) and reduction gear bearings (25) into bore of reduction gear (27).
(13) Slide one spacer (24) on reduction gear shaft (23). Position reduction gear (27) in winch housing (22), slide
reduction gear shaft into reduction gear. Position spacers (24 and 28) into place and slide reduction gear shaft into
position in winch housing (22).
(14) Install reduction gear plate in slot of reduction gear shaft (23) and secure with washer (30), and capscrew
(31).
(15) Install gear hub (8) in bull gear (7) and secure with snaprings (6). Replace annual ball bearings (5) on hub.
(16) Install clutch shaft (14) into brake end of drum (13) with clutch shaft spring (16) and bearing (15).
(17) Install annular ball bearings (5 and 17) on drum and place drum and shaft in winch housing (22). Install
clutch shaft shim set (18) and clutch shaft cover (19), and secure with lock- washers (20) and capscrews (21).
(18) Install spacer (9) into bore of bearing (5) on drum. Install bull gear and hub assembly into housing.
(19) Install gasket (10) and gear cover (II), and secure with capscrews (12).
(20) Install drum shaft shim set (4) and bull gear end cover (3), and secure to housing with lock- washers (2) and
capscrews (1).
NOTE
Drum shaft shim set (41 and clutch shaft shim set (18) are provided to bring bull gear into correct
alinement with face of bull pinion. Sufficient shims must be used to take up the space between the
winch housing and cover, with an additional 0.01 O inch of shims to avoid preload on the drum line
bearings.
(21) Replace gasket (55) and compartment cover (56), and secure with washers (57) and capscrews (58).
(22) Install and adjust brake assembly (para 10-8).
(23) Install stuffing box (71, fig. 10-17). packing rings (72), and packing nut (73).
10-11. Cargo Winch Hydraulic Motor
a. RemovaL Remove cargo winch and motor as
outlined in paragraph 2-33.
b. Disassembly (fig. 10-18).
(1) Drain fluid from motor.
(2) Remove bolts (1), and washers (2) and lift off cover (3) and packing (7).
(3) Remove washer (8), pressure plate assembly (9), and packing (10).
(4) Remove vanes (14) from rotor (13) and slide the rotor from shaft (19).
(5) Remove rotor ring (11), pins (12), and packing (15) from body (16).
(6) Remove snapring (21) and press shaft (19) and bearing (20) out of body (16).
NOTE
Do not remove bearing (17) from the body unless bearing is defective.
(7) Remove seal (18) from body (16).
(8) Remove capscrews (6), flanges (5), and packings (4).
10-33
Figure 10-18. Cargo winch hydraulic motor.
c. Cleaning, Inspection and Repair.
(1) Clean all parts except packings in dry- cleaning solvent, Federal Specification P-D-680, and allow to drain
dry.
(2) Inspect all mating surfaces for signs of scoring or roughness. Slight scoring may be removed by lapping.
CAUTION
Sides of rotor (13, fig. 10-18) and lapped face of pressure plate (9) must be parallel and flat within
0.0002 inch. If any burrs result in rotor slots from lapping, these must be removed. (3) Inspect all
vanes (14) for wear defects. Replace defective vanes.
(4) Check fit of vanes in all rotor slots. Vane must move freely in slot without any angular motion. Replace a
rotor with enlarged slots.
(5) After thorough cleaning, check bearings for cracked races or roughness of rotation. Replace defective
bearings.
(6) Inspect bevel gear (16, fig. 2-30) for cracks or damage. If damage cannot be repaired without altering
profile of gear, replace part.
(7) Replace all packings and seal (18, fig. 10-18).
d. Reassembly (fig. 10-18).
(1) Coat all mating surfaces with clean engine oil, OE-10, prior to reassembly.
(2) If bearing (17), was removed, press bearing into body (16).
(3) Press new seal (18) into body (16).
NOTE
Seal (18) must be installed with its sealing lip pointing toward the rotor end of the body.
(4) Press bearing (20) onto shaft (19) and insert shaft in body (16). Install snapring (21).
(5) Insert new packing (15) in groove on body (16).
(6) Install pins (12) and rotor ring (11).
NOTE
Be sure arrow on rotor ring (11) points in counterclockwise direction, as viewed from shaft end of motor.
Inverting the ring will reverse direction of rotation.
10-34
(7) Install rotor (13) and vanes (14).
NOTE
Each vane (14) must be installed in the rotor with its radius edge toward rotor ring (11).
(8) Place pressure plate assembly (9) on pins (12) with lapped face against rotor (13). Install washer (8).
(9) Place packing (7) in cover (3) and secure cover in place with bolts (1) and washers (2). Tighten the bolts to a
torque of 250 foot-pounds.
(10) Install packings (4) and flange (5) and secure with capscrews (6).
e. Installation. Refer to paragraph 2-33 to install the motor and winch assembly.
10-12. Cargo Winch Controls
a. Control Stand.
(1) Removal (fig. 10-19).
(a) Loosen jamnuts 1274 and 28). and remove cotter pins (24 and 29) and yoke pins (22 and 25).
(b)Remove yokes (23 and 261 and jamnuts (27 and 281 from control rod and brake cable.
(c) Loosen jamnuts (30) and remove set screws (31).
(d)Remove control stand (33) by removing attaching capscrews (20 and 32) and lockwashers (21).
Key to figure 10-19.
I Grip latch
2 Nut, plain
3 Washer, plain
4 Spring
5 Screw, machine
6 Rod end
7 Pawl and rod
8 Pawl and rod
9 Brake lever
10 Shift lever
11 Screw, pawl and rod retaining
12 Nut
13 Lockwasher
14 Spacer
15 Sector
16 Stud, plain
11 Spacer
18 Ratchet
19 Spacer
20 Capscrew
21 Lockwasher
22 Pin, yoke
23 Yoke
24 Pin, cotter
25 Pin, yoke
26 Yoke
27 Jamnut
28 Jamnut
29 Pin, cotter
30 Jamnut
31 Setscrew
32 Capscrew
33 Control stand
34 Rod
35 Universal joint
36 Pin
37 Brake cable
10-35
Figure 10-19. Cargo winch control stand and linkage.
10-36
(2) Disassembly.
(a) Remove pawl screws (11) and remove pawl and rods (7 and 8) from rod ends (6).
(b) Remove screws (5), nuts (2), and washers (3) and remove rod end (6) and grip latch (1) with spring
(4).
(c) Remove spacers (14, 17, and 19), sector (15), and ratchet ( 18) by removing nuts (12), lock- washers
(13), and stud (16).
NOTE
Notches are not required in the shift [ever sector (15) for forward or reverse positions because detents in
winch assembly shift fork hold the shifter in place.
(3) Cleaning, Inspection and Repair.
(a) Clean all parts in dry-cleaning solvent, Federal Specification P-D-680. Dry with compressed air (10
psi).
(b) Inspect for broken or bent levers (9 and 10) and damaged control stand (33). Repair or replace
defective items.
(c) Inspect grip latches (1), pawl and rods (7 and 8), sector (15), and ratchet (18) for broken or bent
condition. Replace parts if damaged.
(4) Reassembly. Reassemble control stand in reverse order of disassembly.
(5) Installation. With exception of yoke (23) and jamnut (28), install control stand in reverse order of removal.
Install and adjust shifting yoke (23) as follows:
(a) Install jamnut (28) and yoke (23) on control rod.
(b) Pull knob on port center side of the winch assembly to disengage internal-external gear type clutch.
(c) Move shift lever (10) to vertical position and allow pawl and rod (8) to drop into notch on shift sector
(15).
(d) Move control rod in or out until winch assembly is in neutral position.
NOTE
The control rod must shift the winch assembly to neutral before the winch assembly will free spool.
b.
(e) Hold control rod down and turn yoke (23) until yoke holes aline with hole in bottom of shift lever (10).
(f) nstall yoke pin (22) and cotter pin (29).
(g) Lock yoke (23) to control rod with jamnut (28).
Speed Control Linkage.
(1) Removal (fig. 10-20).
(a) Remove connecting bars (15) by removing cotter pins (16) and clevis pins (3).
(b) Remove speed control handle (1) by removing cotter pin (19) and clevis pin (2).
(c) Loosen jamnut (6) and unscrew stuffing box nut (17).
(d) Remove cotter pin (11) and clevis pin (14) and remove shaft (18) and stuffing box nut (17).
(e) Remove jamnut (6) and packing rings (4) from stuffing box (7).
(f) Remove stuffing box (7) and gasket (8) by removing bolts (5), nuts (10), and lockwashers (9).
(g) Loosen jamnut (13) and remove clevis (12).
(h) Remove jamnut (13).
10-37
Figure 10-20. Speed control linkage.
10-38
(2) Cleaning, inspection and repair.
(a) Wash all parts in dry-cleaning solvent, Federal Specification P-D-680. Dry with compressed air (10 psi).
(b) Inspect speed control handle, connecting bars, and shaft for bent or broken condition.
Replace handle, connecting bars, and shaft if bent or broken.
(c) Insure all attaching hardware is in good operating condition.
(3) Installation. Install speed control linkage in reverse order of removal.
10-13. Hydraulic Oil Supply Tank Filters
a. Removal.
(1) Drain hydraulic oil supply tank (para 10- 14a(1) ).
(2) Remove access covers from both ends of tank by removing attaching bolts and washers.
Remove access cover gaskets.
(3) Remove filters by unthreading from supply line.
WARNING
While working inside the hydraulic oil supply tank, a portable-type circulating
blower should be used to prevent vapor accumulation. For extended work periods inside
the tank, an air line type respirator should be worn. Station an observer outside tank in
case worker is overcome by fumes.
b. Disassembly (fig. 10-21).
(1) Remove coupling (1) and lift off cover (7) and washer (6).
(2) Slide housing (5), insert (2), and washer (3) off centering tube (4).
c. Cleaning, Inspection and Repair.
(1) Immerse insert (2) in dry-cleaning solvent, Federal Specification P-D-680, until all residue is loosened. Shake
off excess solvent and blow dry from inside with compressed air. Replace insert if all impurities cannot be removed.
(2) Clean coupling (1), cover (7), housing (5), and centering tube (4) in dry-cleaning solvent, Federal Specification
P-D-680, and allow to drain dry on a clean, lint-free cloth.
(3) Inspect washer (3 and 6) for deterioration and replace as necessary. Replace washers damaged in removal.
(4) Inspect coupling (1) and centering tube (4) for damaged threads. Replace defective parts.
(5) Replace access cover gaskets if torn or deteriorated.
10-39
Figure 10-21. Hydraulic oil supply tank filter.
10-40
d.
e.
Reassembly. Reassemble filters in the reverse order of disassembly.
Installation.
(1) Connect filters to supply line.
WARNING
While working inside the hydraulic oil supply tank, a portable-type circulating blower should be used to
prevent vapor accumulation. For extended work periods inside the tank, an air line type respirator
should be worn. Station an observer outside tank in case worker is overcome by fumes.
(2) Install access covers and gaskets.
(3) Fill hydraulic oil supply tank (LO 55- 1930-203-12).
10-14. Hydraulic Oil Supply Tank
a.
Disassembly.
(1) Drain hydraulic fluid from tank as follows:
(a) Provide suitable containers and remove pipe plug located under the LARC in supply tank drain line.
(b) Open supply tank gate valve and drain fluid from tank (TM 55-1930-203-20).
NOTE
All repairs and replacement of parts can be accomplished without removal of the hydraulic tank.
Component parts can be disassembled while the tank is in place.
(2) Remove access covers from both ends of tank.
(3) Remove filters from tank (para 10-13a).
(4) Remove low level warning switch from tank (para 6-4e(1).
b. Cleaning, Inspection and Repair.
(1) Clean interior of tank with dry-cleaning solvent, Federal Specification P-D-680. Apply solvent to tank
interior by spraying or swabbing. Allow solvent to drain from tank.
WARNING
While performing cleaning operations or repairs inside the tank, a portable- type, air-circulating blower
must be used to prevent vapor accumulation.
WARNING
For extended work periods inside the tank, an airline-type respirator should be worn. Personnel should
not work alone while cleaning the tank interior. Explosion-proof lighting fixtures must be used inside the
tank during cleaning operations.
(2) If sludge deposits do not flush off readily, use a soft cloth or brush to remove deposits.
CAUTION
Under no circumstances will a wire brush, metal wool, or abrasive be applied.
(3) Examine interior of tank for evidence of pitting or corrosion. Remove surface corrosion with a clean, lintfree cloth or brush using dry-cleaning solvent, Federal Specification P-D-680. Remove excess solvent and wipe dry with
clean cloth.
CAUTION
Do not use wire brush, metal wook, or abrasive for cleaning tank interior.
(4) Examine all metal parts for cracks, corrosion, and wear. Cracks in inspection covers may be repaired by
welding. Repairs to plating around stud holes will be smoothed with a file to insure adequate sealing of cover gasket.
(5) Repairs on tank may be accomplished by welding. Refer to paragraph 11-1b for welding instructions.
WARNING
Before welding hydraulic tank, remove residual hydraulic fluid by steam cleaning tank interior. Refill tank
with water. Provide a vent for release of pressure generated in tank by heat of the welding process.
NOTE
Before steam cleaning tank, inlet line and supply line filter mounting outlets be capped or plugged to
prevent water from entering hydraulic system.
(6) Accomplish repairs as soon as possible after tank has been drained and cleaned.
(7) Remove all flammable material from immediate vicinity of welding operation. If removal is impractical,
provide a suitable fire-resistant shield.
WARNING
Forced ventilation must be provided when natural ventilation is inadequate to keep concentration of
injurious fumes in the cleaning or welding operation below harmful levels. Suitable respiratory
equipment must be worn when fumes cannot be kept to a minimum.
(8) Inspect surrounding area upon completion of welding operations to determine any potential fire hazard.
(9) Drain water from hydraulic tank as soon as repairs are completed and dry tank interior.
(10) Clean repaired area with abrasive paper, Federal Specification P-P-101, and repaint as necessary.
10-41
c. Reassembly.
(1) Install low level warning switch on tank (para 6-4e(2)).
(2) Install filters in tank para 10-13e).
(3) Install access covers and gaskets.
NOTE
Before refilling tank with fluid, reinstall supply lines if they have been disconnected.
(4) Fill hydraulic oil supply tank (LO 55-1930-203-12).
10-15. Hydraulic Master Pressure Pumps
a. Removal and Installation. Refer to paragraph 2-26 to remove and install the hydraulic master pressure pumps.
b. Disassembly (fig. 10-22).
(1) Drain excess oil from pump before beginning disassembly by turning shaft and allowing oil to drain from ports.
Position pump vertically with shaft end down for convenience of disassembly.
NOTE
Prepare a clean, Iint-free place for disassembled parts.
(2) Remove capscrews (30) and washers (29). Remove pump cover 128) from large rotor ring (I0).
(3) Remove pump cover packing 1271, spring washer (26), spacer 125), sleeve 1241, and sleeve packings (22) from
rotor drive shaft (5).
(4) Remove screws (23) from rotor cover (21). Remove small rotor plate spring washer (20), small rotor pressure plate
(19), and pull small rotor pins (18) from small rotor ring (15).
15) Remove small rotor ring (15). small rotor (17)., and small rotor vanes (16) from rotor drive shaft (5).
CAUTION
Remove small rotor (17) and small rotor vanes (16) carefully to protect their finished surfaces.
(6) Remove large rotor pressure plate (14). Remove large rotor pins (11), large rotor ring (10), Iarge rotor (13), and
large rotor vanes (12) from rotor drive shaft (5). Remove pump body packing
CAUTION
Remove large rotor (13) and large rotor vanes (12) carefully to protect their finished surfaces.
(7) Remove screws (9) and mounting bracket (8) from pump body (2).
(8) Remove retaining ring (7) which secures rotor drive shaft (5), bearings (3 and 6) and oil seal (4) to pump body.
(9) Using arbor press, press rotor drive shaft (5) from pump body (2). Press bearing (6) from rotor drive shaft.
(10) Press oil seal (4) and bearing (3) from pump body.
10-42
1 Pump body packing
2 Pump body
3 Bearing, shaft, driven end
4 Oil seal
5 Rotor drive shaft
6 Bearing, shaft, drive end
7 Retaining ring
8 Mounting bracket
9 Screw, mounting bracket
10 Large rotor ring
11 Large rotor pin
12 Large rotor vane
13 Large rotor
14 Large rotor pressure plate
15 Small rotor ring
16 Small rotor vane
17 Small rotor
18 Small rotor pin
19 Small rotor pressure plate
20 Spring washer, small rotor plate
21 Rotor cover
22 Sleeve packing
23 Screw, rotor cover
24 Sleeve
25 Spacer
26 Spring washer, shaft
27 Pump cover packing
28 Pump cover
29 Washer
30 Capscrew, pump cover
Figure 10-22. Master pressure pump.
10-43
d. Cleaning, Inspection and Repair.
(1) Wash all metal parts, except seals, in dry- cleaning solvent, Federal Specification P-D-680, and let parts drain
dry.
(2) Clean bearings thoroughly by repeated washing with dry-cleaning solvent, Federal Specification P-D-680, and
shake off excess solvent.
WARNING
Use dry-cleaning solvent in a well- ventilated area. Avoid breathing fumes. Keep away
from flame or extremely high temperatures.
CAUTION
Do not use compressed air for drying pump parts. Moisture and small particles of dirt in
airstream will damage polished surfaces.
(3) Inspect large rotor ring and small rotor ring for wear, grooves, burrs, and scratches. Remove burrs and
scratches with crocus cloth, Federal Specification P-C-458. Replace deeply grooved or scratched parts.
(4) Check all threaded openings for damaged threads. Replace parts as necessary.
(5) Check all slots of large rotor and small rotor for sticking vanes or loose, worn slots. Inspect all vanes on flat
sides and ends for wear and defects. Defective vanes and rotors with enlarged slots must be replaced. Slight scratches
on parallel sides of rotors may be removed by light lapping on a flat, smooth surface using crocus cloth, Federal
Specification P-C-458. Any slight burrs in slots resulting from lapping must be removed.
NOTE
Sides of rotors must be parallel and flat within 0.0002 inch.
(6) Check sides of small rotor pressure plate and large rotor pressure plate. Scratches may be removed by light
lapping using crocus cloth, Federal Specification P-C-458.
NOTE
Faces of pressure plates must be flat within 0.0002 inch.
(7) Inspect bearings by exerting pressure on inner race while turning slowly. Any scored, pitted, cracked, or
chipped races require replacement of bearing.
(8) Discard pump body packing, pump cover packing, sleeve packing, and oil seal and replace with new parts.
(9) Inspect bearing housing in pump body and mounting bracket for grooved, burred, or galled condition. If
damage cannot be repaired with crocus cloth, Federal Specification P-C-458, replace defective parts.
(10) Check rotor drive shaft for twisted, chipped, or burred splines and bearing surfaces for grooves. Remove
burrs with crocus cloth, Federal Specification P-C-458. Replace shaft when damage cannot be repaired.
(11) Inspect retaining ring for nicks and distortion. Retaining ring must snap tight in groove. Replace defective ring.
(12) Examine spring washers for signs of overheating or wear caused by rubbing adjacent parts. Replace
washers where any defect is noted.
e. Reassembly (fig. 10-22).
(1) Place pump body packing (1), oil seal (4), pump cover packing (27), and sleeve packings (22) in clean engine
oil, OE-10, and allow to soak before reassembly.
(2) Press bearing (3) and oil seal (4) into pump body (2).
NOTE
Apply grease, Military Specification MIL-G- 3545, to pockets of oil seal (4). (fig. 10-23 ).
NOTE
The oil seal must be inserted with solid flat side against bearing (3, fig. 10-22).
(3) Press bearing (6) on rotor drive shaft (5) and push shaft carefully through oil seal (4) and bearing (3).
(4) Install retaining ring (7) against outer race of bearing (6) and into groove of pump body (2).
(5) Position mounting bracket (8) on pump body (2) and secure with screws (9).
(6) Stand pump body (2) up vertically with drive end of rotor drive shaft (5) down. Insert pump body packing (1)
into recessed groove in pump body (2).
NOTE
Apply a thin coat of clean engine oil, OE-1O, to all mating surfaces.
(7) Install large rotor ring (10) on pump body (2). Insert large rotor pins (11) into locating holes of large rotor ring
and pump body.
CAUTION
The correct direction of rotation is indicated by the arrow stamped on large rotor ring
(10). The correct rotation is counterclockwise as viewed from drive shaft end. Reverse
rotation will result if large rotor ring is inverted.
(8) Install large rotor (13) on rotor drive shaft (5) and insert large rotor vanes (12) with radius edges toward large
rotor ring (10).
(9) Install large rotor pressure plate (14) on rotor drive shaft (5) with large face against large rotor (13).
10-44
(10) Install small rotor ring (15) on large rotor pressure plate (14). Insert small rotor pins (18) in locating holes of
small rotor ring.
CAUTION
Direction of rotation as indicated by the arrow on the small rotor ring (15) must be the same
as the arrow in the large rotor ring (10).
(11) Install small rotor (17) on rotor drive shaft (5) and insert small rotor vanes (16) with
radius toward small rotor ring (15).
(12) Place small rotor pressure plate (19) on shaft (5) with lapped face against small rotor (17).
(13) Place spring washer (20) on small rotor pressure plate (19). Replace rotor cover (21) and secure to large rotor
pressure plate (14) with screws (23). Tighten screws to a torque of 10 foot-pounds.
(14) Install sleeve packings (22) on sleeve (24) and insert one end of sleeve into rotor cover (21).
(15) Install spacer (25) and spring washer (26).
(16) Place pump cover packing (27) in pump cover (28). Install pump cover on large rotor ring (10) and secure with
washers (29), and capscrews (30). Tighten capscrews to a torque of 140 to 160 foot-pounds.
10-16. Radiator Fan Assembly
a. Removal and Installation. Refer to paragraph 2-32 to remove
and install the radiator fan assembly.
b. Disassembly
(1) Remove radiator fan motor (para 10-17a).
(2) Remove seal retainer (10, fig. 2-29) and seal (9) from
casing (22).
(3) Separate nose piece (28) and rotor assembly (26) by
removing screws (30) and washers (29). Remove spacer (27).
(4) Separate inlet adapter (6) and casing (22) by removing
bolts (31), washers (11), and nuts (20).
c. Cleaning, Inspection and Repair.
(1) Clean all metal parts in dry-cleaning solvent, Federal
Specification P-D-680, and allow
to drain dry.
(2) Inspect inlet adapter (6), nose piece (28), rotor assembly
(26), and casing (22) for cracks or dents caused by foreign objects being
drawn into fan. Minor damage to inlet adapter (6) and casing (22) can be
repaired by straightening or welding.
CAUTION
Nose piece (28) and rotor assembly (26)
should be replaced if damaged since repair
could create an unbalanced condition.
(3) Inspect key (19) for cracks or chips and replace if
damaged.
(4) Inspect seal retainer (10) for cracks or distortion and
replace if damaged.
Figure 10-23. Master pressure
(5) Replace seal (9).
pump oil seal installation.
d. Reassembly.
(1) Insert spacer (27) and secure nose piece (28) to rotor assembly (26) with screws (30) and washers (29).
Secure screws (30) with lock wire.
(2) Secure inlet adapter (6) to casing (22) with bolts (31) ,washers (11),and nuts (20).
(3) Press seal (9) into seal retainer (10), then press seal and retainer in casing with lip of seal facing outward
(towards rotor assembly). Install radiator fan motor as outlined in steps (1) through (4) of paragraph 10-17 e.
10-17. Radiator Fan Motor
a. Removal.
(1) Remove radiator fan assembly as outlined in paragraph 10-16a.
(2) Remove bolts (21, fig. 2-29), washers (17), and nuts (16) securing vane assembly (18) to casing (22).
(3) Remove pipe (12), elbow (13), and adapter (14).
(4) Remove nut (7) and lockwasher (8) from motor shaft. Lift off nose piece (28) and rotor assembly (26).
(5) Remove key (19).
(6) Remove cotter pins (25), nuts (24), and washers (23) securing hydraulic motor (15) to casing (22).
Remove motor (15).
b. Disassembly. Refer to figure 10-24.
10-45
NOTE
Clean exterior of motor thoroughly before beginning disassembly. Prepare a clean, lint-free
place for disassembled parts.
(1) Remove four screws (1) which secure flange mounting adapter (3) to front housing (32) and remove
adapter.
(2)
(3)
(4)
(5)
Remove shaft (5) with bearing (6). Remove retaining ring (7) and press bearing from shaft.
Remove front housing O-ring packing (8) and seal (9) from front housing (32).
Turn motor on end and support in vertical position with rear housing (40) facing upward.
Remove two screws (36) and eight screws (37) from rear housing (40) and remove rear housing.
CAUTION
Do not use tools to pry off housing. If housing sticks, tap lightly with rawhide mallet.
(6) Remove sequence check plate assembly consisting of check plate (14) and segment (15). Disassemble
sequence check plate assembly by loosening nut (27) and removing two segments (15), check plate (14), large spring
(30), and small spring (28) from screw (29).
(7) Remove rear port plate (34) and rear bushing (33). Disassemble rear port plate by removing piston ring
(16) and port plate O-ring (17). Remove port plate plug (18), ball (19), and spring (20).
NOTE
Place parts in separate container with port plate to prevent loss or mixing with other port
plate.
(8) Remove vanes (26) and rotor (23).
(9) Remove housing O-ring seal (35) and dowel pin (25).
(10) Remove cam ring (24).
(11) Remove front port plate (21) and front bushing (22). Disassemble front port plate by removing piston ring
(16) and port plate O-ring (17). Remove port plate plug (18), ball (19), and spring (20).
NOTE
Place parts in separate container with port plate to prevent loss of mixing with other port
plate.
(12) Remove front sequence check plate assembly consisting of check plate (14) and segments (15).
Disassemble sequence plate assembly by removing nut (27) and removing two segments (15), check plate (14), large
spring (30), and small spring (28) from screw (29).
(13) Remove screws (13) from pipe flange (12) and remove pipe flange. Remove small and large pipe flange
O-rings (10 and 11).
(14) Disassemble front housing (32) by removing screws (13) from pipe flange (12) and remove pipe flange.
Remove small and large pipe flange O-rings (10 and 11). Remove front housing plug (31)
Key to figure 10-24.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Screw, socket head
Nut, slotted
Flange mounting adapter
Bolt, machine
Shaft
Bearing
Retaining ring
Front housing O-ring packing
Seal
Small pipe flange O-ring
Large pipe flange O-ring
Pipe flange
Screw, socket head
Check plate
Segments
Piston ring
Port plate O-ring
Port plate plug
Ball
Spring
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
10-46
Front port plate
Front bushing
Rotor
Cam ring
Dowel pin
Vane
Nut, check plate
Small spring
Screw, check plate
Large spring
Front housing plug
Front housing
Rear bushing
Rear port plate
Housing O-ring seal
Screw, socket head
Screw, socket head
Screw, nameplate
Nameplate
Rear housing
Figure 10-24. Radiator fan hydraulic motor disassembly.
10-47
c.
Cleaning, Inspection and Repair.
(1) Wash all metal parts in dry-cleaning solvent, Federal Specification P-D-680, and let parts drain dry.
(2) Clean bearing by repeated washing with dry-cleaning solvent, Federal Specification P-D-680, and shake
off excess solvent.
WARNING
Use dry-cleaning solvent in a well ventilated area. Avoid breathing fumes. Keep away
from flame or extremely high temperatures.
CAUTION
Do not use compressed air to dry motor parts. Moisture and small particles of dirt in air
stream will damage polished surfaces.
(3) Inspect cam ring for wear and damaged inner surface. Remove minor burrs and scratches with crocus
cloth, Federal Specification P-C-458. Inner surface of cam ring should be smooth. Replace defective cam ring.
(4) Examine all slots of rotor for sticking vanes or loose, worn slots. Rotor slots must be square and parallel
and 0.004 to 0.006 inch wider than combined width of two vanes. Measure clearance with a feeler gage.
(5) Inspect all vanes for wear and defects. Slight imperfections, such as scratches and burrs in the vane
surface can be removed with crocus cloth, Federal Specification P-C-458. Vanes showing excessive wear, deep
grooves, or scratches should be replaced.
(6) Check bore of front bushing and rear bushing for wear. Replace bushings if badly worn plate
(7) Check port assemblies for wear on vane side. Wear in vane patch should not exceed 0.004 inch. Port
plates can be reground or polished with a sheet of crocus cloth, Federal Specification P-C-458, on a smooth flat surface.
A maximum of 0.005 inch can be removed from face of port plates. After polishing, faces of port plates must be flat
within 0.0005 inch. Measure both inner and outer edges of port plates.
(8) Check port plate plugs, balls, and springs for serviceability. Ball should be smooth and free from grooves
or scratches. Replace defective balls and broken springs.
(9) Examine mating surfaces of check plate and segment. Surfaces should be smooth and free from nicks,
burrs, or scratches. Minor defects can be removed with crocus cloth, Federal Specification P-C-458. Replace defective
plates and segments.
(10) Inspect threads in pipe flanges for damage. Repair minor damage with a fine file. Replace flanges if
repair results in a loose fit or misalignment of parts.
(11) Inspect bearing for scored, pitted, or cracked races. Any defect requires replacement of bearing.
(12) Check shaft for twisted or burred splines and bearing surfaces for grooves. Remove burrs with crocus
cloth. Federal Specification P-C-458. Replace shaft if damage cannot be repaired.
d. Reassembly (fig. 10-24).
NOTE
Before reassembly, coat all parts with clean engine oil, OE-10
(1) Place front housing (32), on bench with internal portion facing upward.
(2) Place small spring (28) and large spring (30) over each screw (29), and install screws and springs in check
plate. Place segments (15) in correct position on check plate (14) and tighten each nut (27).
NOTE
Vanes must be assembled so a groove is formed between the two vanes.
CAUTION
Improper assembly of vanes will cause motor noise and wear port plates. Install vanes
carefully.
(3) Install one sequence cheek plate assembly in front housing (32) with segments 15) facing upward.
(4) Install spring (20), ball (19), and port plate plug (I8) in front port plate (21). Install new port plate 0-ring (I7)
and replace piston ring (16) in front port plate.
NOTE
Surface of piston ring must be smooth to seat properly on housing hub.
(5) Install front port plate (21) in front housing (32).
(6) Install front bushing (22) in front port plate (21). Shoulder of front bushing (22) will fit in recess of port
plate.
(7) Install cam ring (24) in front housing (32). Line up dowel hole in cam ring with dowel hole in front port
plate (21) and install dowel pin (25).
(8) Install rotor (23) inside cam ring (24) and install vanes (26) in rotor slots.
(9) Place new housing O-ring seal (35) around cam ring (24).
(10) Install spring (20), ball (19), and port plate plug (18) in rear port plate (34). I