TM-10-3930-235-35

TM 10-3930-235-35
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
DS, GS, AND DEPOT MAINTENANCE MANUAL
TRUCK, LIFT, FORK, GASOLINE
4,000 LB CAPACITY
TOWMOTOR MODELS
ARMY MODEL FSN
462SG4024-100 (SOLID TIRE)
MHE-191 3930-781-3856
462SG4024-144 (SOLID TIRE)
MHE-191 3930-781-3855
502PG4024-144 (PNEUMATIC TIRE) MHE-190 3930-073-9222
This copy is a reprint which includes current
pages from Changes 1 and 2.
v
HEADQUARTERS,
DEPARTMENT
JANUARY
OF
1965
THE
ARMY
Changes in force: C 2 and 3
CHANGE
TM 10-3930-235-35
C3
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D. C., 30 September 1991
NO. 3
Direct Support,
General Support, and Depot Maintenance Manual
. .
TRUCK, LIFT, FORK, GASOLINE,
4,000-LB CAPACITY
TOWMOTOR MODELS
502PG4024-100 (PNEUMATIC TIRE)
502PG4024-144 (PNEUMATIC TIRE)
502PG4024-144 (PNEUMATIC TIRE)
502PG4024-144 (PNEUMATIC TIRE)
462SG4024-144 (SOLID TIRE)
462SG4024-100 (SOLID TIRE)
502PG4024-144 (PNEUMATIC TIRE)
ARMY MODEL
NSN
MHE-190
MHE-190
MHE-190A
MHE-190B
MHE-191
MHE-191
MHE-220
3930-00-926-3607
3930-00-073-9222
3930-01-044-0075
3930-01-089-8001
3930-00-781-3855
3930-00-781-3856
3930-00-419-5738
TM 10-3930-235-35.5 January 1965, is changed as follows:
Add the following WARNING to the following locations;
Page 2, the following paragraph is added after Section
II. “DESCRIPTION AND DATA.”
inside front cover;
page 5, preceding the, “Troubleshooting Chart,”
A decal has been developed that warns of NBC exposure.
It is to be positioned in a noticeable place on or near the
air cleaner or air filter housing. You may order the decal
using part number 12296626, CAGEC 19207. Refer to
TB 43-0219 for further information. Add the decal to the
air cleaner (page 9, Figure 1. 3/4 Front right side of engine. installed view).
page 14, preceding c. “Remove carburetor air cleaner
(TM 10-3930-235-20);”
page 28, preceding j. “Install air cleaner (TM
10-3930-235-20):”
WARNING
If NBC exposure is suspected, all air
filter media should be handled by
protective
wearing
personnel
equipment. Consult your unit NBC
Officer or NBC NCO for appropriate
handling or disposal instructions.
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
PATRICIA P. HICKERSON
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25-E, block 3937, Direct and General Support maintenance requirements for TM 10-3930-235-35.
PIN: 027697-003
Figure 2.1. 3/4 front right side of engine, installed view (model MHE-220).
2
This manual contains copyrighted material
TM 10-3930-235-35
HEADQUARTERS
DEPARTMENT OF THE ARMY
W A S H I N G T O N, D.C., 5 January 1 9 6 5
T ECHNICAL M A N U A L
No. 10-3930-235-35
DS, GS, and Depot Maintenance Manual
TRUCK, LIFT, FORK, GASOLINE
4,000-LB CAPACITY
ARMY MODEL
FSN
462SG4024-100 (Solid Tire)
MHE-191
3930-781-3856
462SG4024-144 (Solid Tire)
MHE-191
3930-781-3855
502PG4024-144 (Pneumatic Tire)
MHE-190
3930-073-9222
TOWMOTOR MODELS
Paragraph
C HAPTER 1.
Section I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
II. Description and data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,6
C HAPTER 2.
Page
INTRODUCTION
2
2
MAINTENANCE INSTRUCTIONS
Special tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8
Troubleshoot ing . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9−20
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Engine
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,22
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-29
Transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
36
Universal joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,39
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-47
48
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
8
31
34
34
39
52
53
56
59
62
70
71
71
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .
81
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
Section I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV. Hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-58
A PPENDIX I.
1
CHAPTER 1
INTRODUCTION
Section I.
1. Scope
a. These instructions are published for use of personnel responsible for direct support, general support, and depot maintenance of the Truck, Lift,
Fork, Solid Rubber Tired Wheels, 4,000-Lb Capacity, Towmotor Models 462SG4024-100, FSN
3930-781-3856 and 462SG4024-144, FSN 3930781-3855 respectively, Army Model MHE-191,
procured under Contract Number DSA-4-014877MP310, and Towmotor Model 502PG4024-144, FSN
3930-073-9222, Army Model MHE-190, 4,000-Lb
Capacity, Pneumatic Tired Wheels, procured under
Contract Number DSA-4-014863-MP310.
b. The direct reporting, by the individual user,
of errors, omissions, and recommendations for improving this manual, is authorized and encouraged.
DA Form 2028 (Recommended Changes to DA
Publications] will be used for reporting these improvements. This form will be completed in
triplicate using pencil, pen, or typewriter. The
original and one copy will be forwarded direct to
Commanding General, U. S. Army Mobility Equipment Center, ATTN: SMOME-MMP, Post Office
Drawer 58, St. Louis, Mo. 63166. One information
copy will be provided to the individual’s immediate
supervisor (e.g., officer, noncommissioned officer,
supervisor, etc.).
Section II.
A general description of the truck is to be found
in TM 10-3930-235-10. Any required additional
description of a component of the truck will be
found in that section of the manual which applies
2
c. Report all equipment improvement recommendations as prescribed by TM 38-750.
2. Appendix
Appendix I is a list of current references applicable to direct support, general support, and depot
maintenance.
Note. The maintenance allocation chart, which designates the maintenance opcrations to be performed, is published in TM l0-3930-235-20. Repair parts and special tool
lists is published in TM l0-3930-235-35P.
3. Record and Report Forms
For record and report forms applicable to direct
and general and depot maintenance, refer to TM
38-750.
Note. Applicable forms, excluding standard form 46
which is carried by the operator, will be kept in a canvas
bag mounted on the equipment.
4. Orientation.
Throughout this manual, the use of the terms,
right, left, front, and rear with respect to engine and
truck are determined with the operator sitting in
the seat of the truck.
DESCRIPTION AND DATA
5. Description
to the component.
GENERAL
6. Data
a.
Engine.
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Continental
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..FS1 62-6089
Number cylinders . . . . . . . . . . . . . ...4
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3& inches
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4% inches
Displacement . . . . . . . . . . . . . . . . . . . . . . ..162 cu in.
SAE horsepower rating . . . . . . . . . . . . . . 18.8
Brake horsepower at 2200 rpm ., . . . . . . 46
Compression ratio ,., . . . . . . . . . . . . . ...6.3.1
Governed speed . . . . . . . . . . . . . . . . . . . ..2MOrpm
Compression pressures at 1500 rpm or
starting motor speed . . . . . . . . . . . . . . . 110-120 psi
Maximum variations between cylinder. 10 lbs
Camghaft and bushings:
Fronts:
Bushing inside diameter . . . . . . 1.874$1.8755
Journal diameter . . . . . . . . . . . . 1.8715-1.8725
Allowable additional wear on
journal ciirimeter . . . . . . . . . . . 0.001
Clearance . . . . . . . . . . . . . . . . . .. O.0Q2-WN4
Center:
Bushing inside diameter . . . . . . 1.7495-1.7502
Journal diarncter . . . . . . . . . . . 1.7457–1.7465
Allowable additional wear on
journal diameter ,, . . . . . ,.. , 0.001
Clefirance . . . . . . . . . . . . . . . . . .. O.003–O.0Q45
Rear:
Bushing inside diameter . . . . . 1.249$1.2505
Journrd diameter . . . . . . . . . . 1.2465-1.2475
Allowable ~dditional wear on
journal diameter . . . . . . . . . . . 0.001
clearance . . . . . . . . . . . . . . . . . . . 0.002-0.004
Endthrmt . . . . . . . . . . . . . . . . . . . . . . 0.W3WJ.007
Crankshaft and bearings:
Main journal diameter . . . . . . . . . . 2.2442–2.2451
Additional allowable wear on main
journal diameter . . . . . . . . . . . . . . . .0006
Main bearing thickness . . . . . . . . . . . 0.0950-0.0953
Main bearing clearance . . . . . . . . . . . 0.0002-0.0024
Connecting rod journal diameter. 2.0600-2.0607
Additional allowable wear on connecting rod journal diameter. . . . 0.0006
Connecting rod bearing thickness.. 0.0625-0.0628
Additional allowable wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005
Connecting rod bearing clearance. . 0.0002-0.0020
Additional allowable wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0032
Journal out-of-round . . . . . . . . . . . . . 0.0005 max.
Journaltaper . . . . . . . . . . . . . . . . . . . . 0.0005 max.
Crankshaft end thrust . . . . . . . . . . . . 0.004–0.006
Connecting rod:
Thrust or bend . . . . . . . . . . . . . . . . . . 0.002 max.
Cylinder walls:
Taper . . . . . . . . . . . . . . . . . . . . . . . . ...0.0000-0.0005
(lut-of-round . . . . . . . . . . . . . . . . . . . . 0.0005 max.
Cylinder bore . . . . . . . . . . . . . . . . . . . . 3.4375-3.4395
Skirt clearance . . . . . . . . . . . . . . . . . . .0.003
Rin~land clearance . . . . . . . . . . . . . . 3.4045-3.4095
Taper of ~kirt . . . . . . . . . . . . . . . . . . . 0.000%0.0015
Piston pins:
Piston—pin hole diameter . . . . . . . . 0.8593–0,8596
Pin bushing inside diameter . . . . . . 0.8593–0.8596
Pin diameter . . . . . . . . . . . . . . . . . ...0.8591-0.8593
Additional allowable wear on pin
diameter . . . . . . . . . . . . . . . . . . . ...0.001
Pin fitinpistonat70° F. (21”C.).. -0,00(X-+0.0003
Pin fit in bushing . . . . . . . . . . . . . . . . 0.0000-0.0005
Piston rings:
Width:
Top and second . . . . . . . . . . . . . . 0.093–0,094
Third and fourth . . . . . . . . . . . . 0.1545-0,1555
Thickness:
TOP . . . .. <...................0.162-0.172
Second, third and fourth . . . . . 0.143-0.153
Side clearance:
Top . . . . . . . . . . . . . . . . . . . . . . . . . 0.00>0.004
Second . . . . . . . . . . . . . . . . . . . ...0.001-0.003
Third and fourth . . . . . . . . . . . . 0,0005-0.0025
End gap . . . . . . . . . . . . . . . . . . . . . . . . .o.01&0,020
Jralves:
Intake:
Stem diameter . . . . . . . . . . . . . . 0.3405-0.3415
Additional allowable wear on
stem . .,...................0.002
Guide inside diameter ., .,.... 0.3432-0.3440
Guide to stem clearance . . . . . . 0.0017-0.0035
Additional allowable guide to
stem clearance . . . . . . . . . . . . . 0.0046
Valve face . . . . . . . . . . . . . . . ...0.120
Valve seat angle . . . . . . . . . . ...45”
Valve seat width . . . . . . . . . . . . 0.066
I.ifter to valve clearance . . . . . 0.014 (hot)
Exhaust:
Stem diameter . . . . . . . . . . . . . . 0.3405-0.3415
Additional allowable wear on
stem . . . . . . . . . . . . . . . . . . . . .. O.002
Guide inside diameter . . . . . . . 0.3452-0.3460
Guide to stem clearance . . . . . . 0.0037-o .0055
Additional allowable guide to
stem clearance . . . . . . . . . . . . . 0.0075
Valve face . . . . . . . . . . . . . . . ...0.122
Valve seat angle . . . . . . . . . . . . . 45°
Valve seat width . . . . . . . . . . . . 0.086
I,ifter to valve clearance . . . . . 0.014 (hot)
Valve springs
Free length . . . . . . . . . . . . . . . . . . l-45/64 inches
Load required at closed length. 47 to 53 lbs
Additional allowable tolerance. 42 lbs
Oil pump:
Gear backlash . . . . . . . . . . . . . . . . ...0.001-0.003
Gear teeth to body clearance . . . . . 0.W2+.004
Gear face to cover clearance
(with gasket installed) . . . . . . . . . 0.0015-0.006
Idler shaft diameter . . . . . . . . . . . . . 0.501$0.502
Drive shaft bushing (in pump
body) ..,.. ., . . . . . . . . . ..501 . . .. O.5(KLO.5O1
Additional allowable wear on
bushing . . . . . . . . . . . . . . . . . . . . . . . 0.0005
Drive shaft bushing (in block) . . . . 0.9843-0.994
3
.idditionrd a~lowable wear on
bushing . . . . . . . . . . . . . . . . . . . . ...00005
Driveshaft diameter . . . . . . . . . . . . . . 0.498$0.4990
b. Fuel System.
Brush length:
New . . . . . . . . . . . . . . . . . . . . . ...%
Permissible worn length . . . . . . Y%
d. Transmission.
Jet sizes:
Discharge jet ,.. ., . . . . . . . . . . . . . .. No. 60
Fuel valve . . . . . . . . . . . . . . . . . . . . . . No. 35
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . No. 10
Main jet . . . . . . . . . . . . . . . . . . . . . . . hTo. 23-1
Venturi . . . . . . . . . . . . . . . . . . . . . . . . . No. 19
Well vent jet . . . . . . . . . . . . . . . . . . . No. 22
oil pressures . . . . . . . . . . . . . . . . . . . . . . . . (Para.30b)
Float adjustment (measured from top
of float to machined surface of
body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1$,
Clutch facing thickness . . . . . . . . . . 0046-O.(Xi2
c. Electrical System.
Generator:
Rated voltage . . . . . . . . . . . . . . . . . . . 12
Rotation . . . . . . . . . . . . . . . . . . . . . . .. Clockwise
Ground polarity . . . . . . . . . . . . . . . . . Negative
Brush
spring
tension
18
to
36
ounces
Field current draw . . . . . . . . . . . . . . . 1.6 to 1.7 amps at
10 volts
Motoring draw . . . . . . . . . . . . . . . . ..2.9 t03.0 ampsat
10 volts
Output . . . . . . . . . . . . . . . . . . . . . . . ...25 amps at15 volts
at 2200 rpm
Brush length:
h’ew . . . . . . . . . . . . . . . . . . . . . . . . %
Permissible worn length . . . . . . i%
Starting motor:
Rated voltage . . . . . . . . . . . . . . . . . . . 12 volts
Rotation (drive end) . . . . . . . . . . . . . Clockwise
Brush spring tension ., . . . . . . . . . . . 42 to 53 ounces
Armature end play ., ., . . . . . . . . . 0.CQ5 min
No load test . . . . . . . . . . . . . . . . . ...55 amps, 10 volts,
5200 rpm
Stall torque test . . . . . . . . . . . . . . . . .max 235 amps, 4
volts
4
Converter output shaft and bushing:
Bushing inside diameter . . . . . . . . . 1.063-1.366
Shaft diameter . . . . . . . . . . . . . . . . . . . 10615-1.0620
Forward clutch shaft and bushing:
Bushing inside diameter . . . . . . . . . . 1.2515-1.2545
Shaftdiameter . . . . . . . . . . . . . . . 1.249C-12495
Clutch adjustment neutral setting
(fig. 37) . . . . . . . . . . . . . . . . . . . . . . . . . ..o.376-o.39o
e.
Universal Joint.
Alignment (adjust at engine
mountings) . . . . . . . . . . . . . . . . . . . . . . . . max. l% in.
f. Drive Axle.
Differential:
Bevel pinion bearing adjustment. 0.(03-0.002 (tight)
Differential bearing adjustment. . . . 0MWOC05 (tight)
Bevel gear to pinion backlash. . . . . O.OCW3.O1O
g. Power Steering System.
Oil pressures . . . . . . . . . . . . . . . . . . . . . . . . (Para. 44/)
Hydraulic pump cam end clearance. . . max. 0002
h. Hydraulic Lift.
Oil pressures . . . . . . . . . . . . . . . . . . . . . . . . (Para. 52)
Mast column:
Outer to inner column clearance. . . 0.01.$0.025
N4ast carriage:
Thrust plate to narrowest sliding
width of inner column . . . . . . . 0.9?0
I,ifting speed . . . . . . . . . . . . . . . . . . . . . . ..85 feet per minute
CHAPTER 2
MAINTENANCE INSTRUCTIONS
Section I.
SPECIAL TOOLS AND EQUIPMENT
7. Special Tools and Equipment
No special tools or equipment are required for
Section II.
direct support, general support, or depot maintenance of these lift trucks.
TROUBLESHOOTING
8. General
a. This section lists troubleshooting information,
and checks which can be made to determine the
cause of trouble that may develop. Each symptom
of trouble is recorded under an individual symptom
and is followed by a possible cause of the trouble
and the remedy.
b. In the troubleshooting chart below, each symptom of trouble is followed by a list of probable
causes and a suggested procedure for locating and
remedying the trouble.
Troubleshooting Chart
ENGINE AND FUEL SYSTEM
Trouble
Engine hard to start. . . . . . . .
Probable cause
Remedy
Low compression ... . .... . . . . . . . . . . . . . . . .
Valves not seating properly. Either adjust
(TM 10-3930-235-20), or grind valves
(para. 14).
Replace (para. 14).
Remove valve cover and with screwdriver,
free the sticking valve. Valve stem and
guide will have to be cleaned to restore
proper clearance. If condition continues,
valves need regrinding (para. 14).
Replace bearings (para. 14).
Engine misses . . . . . . . . .
Engine knocks . . . . . . . . . . . . .
Loose connecting rod bearings (sharp knock,
low oil preassure).
Loose main bearings (heavy knock, low oil
pressure).
Loose piston pins (sharp double knock) . . . . .
Piston and cylinder wear........... . . . .
Leaky radiator . . . . . . . . . . . . . . . . . . . . . .
Cracked engine block or head. . . . . . . .
Leaky valves. . . . ....... . . . . . . . . . . . . .
Worn piston rings. . . . . . . . . . . . . . . . . . . . . . . .
Carburetor float sticking (black smoke) . . . .
Worn piston rings, and out-of-round and
tapered cylinders (blue smoke).
Thin lubrication oil (blue smoke) . . . . . . . . . .
Replace main bearings (para. 14).
Replace pins or bushings (para. 14).
Recondition cylinder walls (para. 14).
Repair radiator (para. 23).
Replace damaged part (para. 14).
Either adjust (TM l0-3930-235-20) or grind
valves (para. 14 f).
Replace rings (pare. 14a).
Tap carburetor lightly with hammer handle.
If this does not correct the situation, carburetor must be cleaned (para. 21).
Replace rings and rebore cylinder (para. 14a).
Use oil of correct viscosity, LO 10-3930-235-20.
5
ENGINE AND FUEL SYSTEM - Cotinued
Probable
Trouble
Carburetor leaks
when idling,
Remedy
cause
Float stuck (dirty needle valve). . . . . . . . . . . . Tap carburetor gently to dislodge the dirt in
the fuel valve. If this does not correct the
condition, remove the carburetor, and clean
the valve (para. 21).
Drain plug not tight . . . . . . . . . . . . . . . . . . . . . . Tighten (para. 21).
Float level incorrect . . . . . . . . . . . . . . . . . . . . . . . . Adjust (para. 21),
gasoline
I
ELECTRICAL
Ammeter shows rapid fluctuation.
Generator does not charge.
Starting motor failure. . . . . . .
SYSTEM
Shorted or loose connections. . . . . . . . . . . . . . . . . Trace wiring for breaks or looseness.
Dirty, loose or worn generator brushes. . . . . . . Clean and tighten brushes. Replace if worn
(para. 24).
Defective generator . . . . . . . . . . . . . . . . . . . . . . . . Repair or replace (para. 24).
Broken external connection. . . . . . . . . . . . . . . . . . Repair connections.
Shorted armature . . . . . . . . . . . . . . . . . . . . . . . . . . Replace or repair (para. 24).
Shorted field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace or repair (para. 24).
Faulty switches . . . . . . . . . . . . . . . . . . . . . . . . . Check ignition switch or starter solenoid.
Commutator dirty . . . . . . . . . . . . . . . . . . . . . . . . . . Clean (para. 27).
Worn brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace (para. 27).
Broken starting motor drive. . . . . . . . . . . . . . . . Replace (para. 27).
Bad teeth on flywheel, . . . . . . . . . . . . . . . . . . . . . . Replace ring gear (para. 14).
TRANSMISSION
Oil foams or is discharged
from breather.
Vehicle will not move. . . . . .
Lack of acceleration and
power under full throttle.
Low oil pressure (refer to
para. 30b for oil pressure
check).
Oil level too high . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incorrect oil in transmission. . . . . . . . . . . . . . . . .
Air leak in pump suction line . . . . . . . . . . . . . . . .
Low oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linkage worn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission faulty . . . . . . . . . . . . . . . . . . . . .
Low oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air leak in pump suction line . . . . . . . . . . . . . . . .
Transmission and converter parts worn. . . . . . .
Low oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak in pump suction line . . . . . . . . . . . . . . . . . .
Oil pump faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain until oil level is correct.
Drain and refill with correct oil.
Locate and repair.
Check oil pressure (para. 30b).
Replace worn linkage (paras. 34 and 35).
Repair or replace transmission (para. 30).
Check oil pressure (para. 30b).
Locate and repair.
Repair or replace transmission (para. 30).
Fill to correct level.
Locate and repair.
Replace transmission (para. 30).
DRIVE AXLE
Failure to operate. . . . . . . . . . Broken axle shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
Broken teeth on ring gear or pinion. . . . . . . . .
Axle noise on drive or coast. Excessive wear at ring gear and pinion. . . . . .
Worn pinion gears or side gears in differential
case.
Continuous axle noise. . . . . . Excessive wear in gear train. . . . . . . . . . . . . . . . .
Uneven tire wear. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive backlash in unit. Worn ring gear, pinion or differential case
pinions.
Loose or worn universal joints. . . . . . . . . . . . . . .
Replace
Replace
Replace
Replace
axle shaft (para. 37).
ring gear and pinion (para. 37).
(para. 37).
worn gears (para. 37).
Replace worn parts (para. 37).
Replace tires.
Replace gear and pinions (para. 37).
Tighten or replace (para. 36).
HYDRAULIC BRAKE SYSTEM
Pedal goes to toe board.
6
Low fluid level in master cylinder, . . . . . . . . . . Fill reservoir and bleed lines (para. 42),
External leak in brake system or leak past Check system for leak and repair (para. 40).
master cylinder piston cup.
Air trapped in hydraulic system. . . . . . . . . . . . . Bleed system (para. 42).
HYDRAULIC BRAKE SYSTEM - Continued
Trouble
Probable cause
Remedy
Mineral oil in brake system . . . . . . . . . . . . . . . . . Clean out system, replace cups in brake cylinders, and refill with brake fluid (para. 41).
Breather port in master cylinder clogged . . . . . Clean out breather port (para. 40).
One wheel drags . . . . . . . . . . . . Weak or broken brakeshoe return springs.. . . Replace broken or weak springs (para. 41).
Obstruction in brake line . . . . . . . . . . . . . . . . . . . . Remove obstruction or replace line.
Swollen wheel cylinder piston cups or piston Replace defective or damaged parts (para. 41).
binding.
Truck pulls to one side. . . . . Grease or brake fluid on brake lining. . . . . . . . . Replace with new lining (para. 41).
Uneven tread wear . . . . . . . . . . . . . . . . . . . . . . . . . .Replace tires.
Lining charred or drum scored. . . . . . . . . . . . . . . Replace lining (para. 41) or, repair and replace
drum.
Spongy pedal pressure. . . . . . Air trapped in hydraulic system . . . . . . . . . . . . . Bleed brake system (para. 42).
Shoe surface not square with drum . . . . . . . . . . . Repair (para. 41).
Excessive pedal pressure. . . . Oil or fluid soaked lining . . . . . . . . . . . . . . . . . . . . Replace lining (para. 41).
Lining making only partial contact. . . . . . . . . . Realign brake shoes (para. 41).
Brakes too severe. . . . . . . . . . . Brake shoes twisted . . . . . . . . . . . . . . . . . . . . . . . . .Replace (para. 41).
Brakes squeak . . . . . . . . . . . . . Particles of metal or dust imbedded in lining. . Remove foreign material and sand lining and
drum (para. 41).
Both brakes drag. . . . . . . . . .
STEERING
Hard steering . . . . . . . . . . . . . . . Failure of pump . . . . . . . . . . . . . . . . . . . . . . . . . . Replace or repair (para. 44).
Badly worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Recondition pump (para. 44).
Broken or weak relief valve spring.. . . . . . . . . . Replace spring (para. 44).
Binding relief valve . . . . . . . . . . . . . . . . . . . . . . . . . Free up valve (para. 44).
Low pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . Replace worn or faulty parts (para. 44).
Line leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten connections.
Lack of lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricate (LO 10-3930-235-20).
Leakage in steering cylinder.. . . . . . . . . . . . . . . . Repair (para. 46).
Faulty control valve . . . . . . . . . . . . . . . . . . . . . . . . Recondition valve (para. 47).
Binding steering gear . . . . . . . . . . . . . . . . . . . . . . . .Repair or adjust (para. 45).
Steering too sensitive. . . . . . . . Pump pressure too high . . . . . . . . . . . . . . . . . . . . Check for binding relief valve (para. 44).
Faulty flow control valve . . . . . . . . . . . . . . . . . . . Recondition; free up any binding parts (para.
44) .
Loose steering . . . . . . . . . . . . . . Loose king pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair or recondition (para. 38 or 39).
Steering gear out of adjustment.. . . . . . . . . . . . . Adjust cam and worm shaft (para. 45).
Low oil pressure . . . . . . . . . . . . . Low oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fill reservoir to correct level (LO 10-3930235-20).
Worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recondition or replace (para. 44).
Weak relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace spring (para. 44).
Relief valve stuck open . . . . . . . . . . . . . . . . . . . . . Remove and free up valve (para. 44).
Flow control valve open . . . . . . . . . . . . . . . . . . . . . Free up flow control valve (para. 44).
External leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten or replace fittings, hoses or seals..
Internal leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace seals in pump (para. 44) or cylinder
(para. 46).
HYDRAULIC LIFT
Unable to lift or tilt load. . . . Load too heavy. . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighten load to maximum capacity (4000
pounds).
Insufficient or no oil . . . . . . . . . . . . . . . . . . . . . . . . Check tank for proper oil level and plugged
suction line.
Air leak at suction line . . . . . . . . . . . . . . . . . . . . . . Tighten connections.
Damaged or worn pump................................ . Remove and repair (para. 50).
Relief valve binding open . . . . . . . . . . . . . . . . . . . Remove and repair (paras. 51 and 52).
Damaged lift cylinder . . . . . . . . . . . . . . . . . . . . . . . Check for binding or any cause to make
plunger inoperative (para. 55).
7
HYDRAULIC LIFT - Continued
Remedy
Probable cause
Trouble
Lift and tilt too slow. . . . . .
Load creeps tilting or lowering.
Noisy pump . . . . . . . . . . . . . . .
Oil overheating . . . . . . . . . . . .
Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect for internal leakage or damaged parts
and repair (para. 51).
Internal leakage at pump . . . . . . . . . . . . . . . . . . . Inspect for worn or damaged pints (Para. 50).
Excessive Ieakage at cylinder packing. . . . . . . . Repair or replace packing (paras. 54 and 55).
Air leaks in system . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten all connections.
Misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check masts (para. 56), carriage (para. 57) or
tilt cylinder (para. 54) for cause of binding.
Faulty relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . Check for worn or damaged parts. Repair or
replace. Check relief valve setting (paras.
51 and 52).
Internal leakage in cylinders. . . . . . . . . . . . . . . . . Repair or replace packing (paras. 54 and 55).
Oil leak at parking glands ....... . . . . . . . . . . . Repair or replace packing (paras. 54 and 55).
Leak in control valve . . . . . . . . . . . . . . . . . . . . . . . . Check for worn or damaged plungers (para.
51).
Leak in oil lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten all connections or replace damaged
lines.
Insufficient or no oil . . . . . . . . . . . . . . . . . . . . . . . . Check tank for proper oil level or restricted
suction line.
Air leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten intake connections.
Oil bubbles in intake oil . . . . . . . . . . . . . . . . . . . . Use hydraulic oil with antifoaming characteristics.
Pump loose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten (para. 50).
Worn or broken parts . . . . . . . . . . . . . . . . . . . . . . . Replace (para. 50).
Relief valve set too high . . . . . . . . . . . . . . . . . . . . Valve should be set as recommended (para.
52).
Internal oil leakage . . . . . . . . . . . . . . . . . . . . . . . . . Repair or replace pump (para. 50).
Pump too tight after overhaul. . . . . . . . . . . . . . . Remove and repair (para. 50).
Restricted lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check and repair.
Section III. ENGINE
9. Removal and Installation of Engine
Assembly
a. General. Remove engine with accessories installed and remove as engine and transmission
assembly. Use Safety Lift, or equivalent tool, when
removing engine.
b. Remove Engine and Transmission Assembly
(figs. 1 and 2).
(1) Remove
(2) Remove
(3) Remove
(4) Remove
(5) Remove
(6) Remove
weight.
overhead guard.
operator’s seat.
engine hood.
body side plates and grill.
floor plates.
counterweight hood and counter-
(7) Remove battery and cables.
(8) Drain coolant, disconnect transmission,
cooling pipes, then remove radiator.
8
(9) Remove screws and washers that hold
hydraulic pump to engine timing gear
cover. Separate pump, with hoses connetted, from timing gear cover.
(10) Disconnect hoses at steering hydraulic
pump and drain oil from reservoir. Disengage hoses from clamps that are mounted
on cylinder head and transmission cover.
(11) Remove exhaust pipe.
(12) Remove nut and washer to disconnect
ball joint on accelerator cable at relay
lever. Remove clamp at control cable support. Loosen screw to disconnect choke
control cable at carburetor. Remove fuel
tank to fuel pump tubing.
(13) The following disconnect points are located at left side of frame below rear floor
plate. Disconnect ammeter to regulator
cable at connectors. Disconnect chassis
Figure 1.
wiring harness from engine wiring harness
at disconnect plug. Disconnect tail and
stoplight wires and thermocoupIe wire at
terminal junction.
(14) Remove cotter pin and clevis pin, then
disconnect shift lever linkage at transRemove
mission control valve plunger.
ball joint nut and lockwasher at creeper
pedal, then remove ball joint from pedal.
(15) Remove nuts and washers to disconnect
wires at generator. Disconnect battery
wire at generator regulator.
(16) Remove cotter pin, nut, and washer fastening engine front mounting stud (in
timing
gear
cover)
(17) Remove nuts
to
frame.
and washers fastening
engine side mountings to brackets.
Note. Use Safety Lift or equivalent tool to
fasten engine assembly to hoist during removal
and installation. Connect one end of engine sling
under cylinder head nut (located in center of head
on second stud from fan end of engine.) Install
other end of engine sling on the top center bolt
that fastens torque converter case and transmission case together.
(18) With Safety Lift or equivalent tool in
place on engine and hoist, raise engine
carefully, move engine toward rear of
vehicle to disengage transmission output
shaft from universal joint splined yoke,
then raise engine and transmission assembly up and out of chassis.
c. Remove Transmission from Engine.
Caution:
The following procedure must be
followed to prevent damage to torque converter.
9
Figure 2. 3/4 Front left side of engine, installed view.
Do not allow total weight of transmission to hang
on converter.
(1) Remove screws, washers, and nuts, then
remove cover and seals.
(2) Remove screws and washers fastening
torque converter to engine flywheel. Support weight of transmission with hoist,
then remove screws and washers. Remove
transmission assembly from engine. Slide
torque converter off transmission to prevent damage.
d. Install Transmission on Engine.
Caution: The following procedure must be
followed to prevent damage to torque converter.
Do not allow total weight of transmission to
hang on converter.
10
(1) Prior to installing transmission on engine,
install torque converter carefully aligning
driving lugs with oil pump drive gear.
When mounted properly, converter should
touch the converter case. With converter
in this position, assemble transmission to
engine and secure with washers and screws.
Slide converter toward engine flywheel and
align screw holes. Install screws and
washers.
(2) Position seals on cover, then secure with
screws, washers and nuts.
e. Install Engine and Transmission Assembly.
Note. Install engine with accessories installed and install
as engine and transmission assembly.
(1) Connect Safety Lift or equivalent tool as
in b(18) above.
Figure 3. Cylinder and crankcase, exploded view.
11
MEC 3930-235-35/4
Figure 4. Flywheel and housing, exploded view.
(2) With sling correctly installed on engine
and attached to chain hoist, lower and
maneuver engine into chassis and at the
same time engage transmission output
shaft with universal joint splined yoke.
Lower engine on side mountings and secure with washers and nuts. Fasten engine
front mounting stud to frame with washer,
nut, and cotter pin. Visually check uni-
versal joint alignment. Permissible maximum misalignment is 1/8 of an inch. Adjust
by removing or installing shims at engine
mountings.
(3) Connect battery wire at generator regulator. Connect armature and field wires to
generator and secure with nuts and
washers.
MEC 3930-235-35/5
Figure 5. Relief valve, exploded view.
12
Figure 6. Cylinder head, exploded view.
(4) Connect creeper pedal linkage and shift
lever linkage at transmission control valve
plungers and secure with clevis pins and
cotter pins.
(5) Match wire colors when making the following electrical connections: connect thermocouple wire and tail- and stop-light
wires at terminal junction. Connect ammeter to regulator cable at connectors.
Connect engine wire harness to chassis
wire harness at disconnect plug.
(6) Install muffler and pipes.
(7) Engage hoses in clamps mounted on transmission cover and cylinder head, then connect hoses to steering hydraulic pump. Fill
power steering system and check for leaks.
(8) Install new gasket on timing gear cover
studs, then install hydraulic lift pump,
with hoses connected, on timing gear cover
studs. Secure with nuts and washers.
(9) Install radiator. Fill to level with proper
coolant and check for leaks.
(10) Install battery and cables.
(11) Install counterweight and hood.
(12) Install floor plates.
(13) Install body side plates and grill.
(14) Install engine hood.
(15) Install operat or’s seat.
(16) Install overhead guard.
(17) Fill engine crankcase, transmission and
power steering system with correct lubricant (LO 10-3930-235-20).
10. Removal of Engine Accessories
a. Remove generator (TM 10-3930-235-20).
13
Figure 7. Oil pan, filler blocks and gaskets, exploded view.
b. Remove starting motor (TM 10-3930-235-20).
c. Remove carburetor air cleaner (TM 10-3930–
235-20) .
14
d. Remove accelerator pec al and linkage (TM
10-3930-235-20 .
e. Remove carburetor (TM 10-3930-235-20).
Figure 9. Piston and rings, exploded view.
11. Disassembly of Engine into
Subassemblies
MEC 3930-235-35/8
Figure 8. Connecting rod, exploded view.
f. Remove fuel pump (TM 10-3930-235-20).
g. Remove power steering hydraulic pump (para.
50).
h. Remove exhaust pipe (TM 10-3930-235-20).
i. Disconnect and remove ignition wires from
spark plugs and distributor cap. Disconnect and
remove high tension wire from coil and distributor
cap. Disconnect low tension wire at distributor.
Remove nut, washer, distributor clamp, and distributor. Remove distributor drive shaft. Disconnect low tension and capacitor wire from coil. Remove nuts, washers, and screws, then remove coil
and capacitor.
j. Disconnect wires from temperature indicator
sending unit, oil gage unit, and hour meter pressure
switch. Unscrew and remove temperature sending
unit from cylinder head. Unscrew and remove oil
gage unit and pressure switch from cylinder block.
a. Disconnect oil filter inlet and outlet hoses at
engine. Remove nuts, washers, screws, and oil filter,
assembled on bracket, from air cleaner mounting
bracket.
b. Remove screws, washers, and fan from fan
hub. Remove recirculating tube. Remove screws
and washers fastening water pump to block, then
remove water pump and gasket.
c. Remove nuts, washers, water outlet elbow, gasket, adapter ring, and thermostat from cylinder
head.
d. If replacement is necessary, unscrew and remove filler cap and oil filler body. Remove oil gage
rod and felt seal (fig. 3).
e. Remove flywheel nuts (fig. 4) and washers
from bolts. Flywheel is provided with two puller
screw holes. Remove flywheel from crankshaft
flange using puller screws. If necessary to remove
ring gear from flywheel (para. 14). If replacement
is necessary, remove screws and washers, then remove mounting brackets from flywheel housing.
Remove screws and washers, then remove flywheel
housing from cylinder block.
f. Remove nuts (fig. 16), washers, manifold
assembly, and gasket from cylinder block.
g. Remove relief valve plug (fig. 5), gasket, adjusting washer, spring, and relief valve from
crankcase.
15
h. Remove nuts (fig. 6), washers, cylinder head,
and gasket.
(2) If replacement is necessary, remove bushing from connecting rod (para. 14).
i. Remove drain plug (fig. 7) and gasket• and
drain engine oil. Remove screw assemblies, oil pan,
gaskets, and filler block. Remove screws and washers, then remove front filler block. Remove screws
and washers, then remove rear filler block. Remove
oil pan gaskets.
b. Disassembly of Engine Timing Gear Cover
(fig. 14).
j. Remove nut, washer, oil pump, and washer
from rankshaft bearing cap.
k. Remove cotter pin (fig. 8) and nut from bolt.
Remove conecting rod cap and bearing. Push connecting rod and piston assembly out through top of
cylinder block (fig. 9).
l. Remove nuts (fig. 3), gaskets, valve cover, and
gasket. Using a valve spring compressing tool, compress valve spring (fig. 10), then remove keys,
valve, and cap. Release spring compressor, then
remove seat and spring. Remove all valves in the
same manner.
m. Remove screws and washers fastening timing
gear cover (fig. 14) to cylinder block, then remove
gear cover assembly and gasket.
n. Cut lock wire and remove screws and washers,
then remove crankshaft main bearing caps (fig. 11)
and bearing halves. Remove crankshaft assembly
and other bearing halves from crankcase. Remove
rear filler block seal, rear bearing oil guard, and
oil guard felt from crankcase. To disassemble
crankshaft, remove snap ring. Remove screw, then
remove coupling gear and timing gear from crankshaft. R e m o v e k e y s a n d t h r u s t p l a t e f r o m
crankshaft.
o. Remove screws (fig. 12) and washers, then
remove camshaft assembly from cylinder block. To
disassemble camshaft, remove nut and governor
driver. Pull timing gear (fig. 13) off camshaft, then
remove key and thrust plate. Remove valve lifters
(fig. 10) and adjusting screws from cylinder block.
p. If necessary, remove camshaft bushings (fig.
12), exhaust valve inserts (fig. 10), and valve
guides from cylinder block (para. 14).
Note. Before removing valve guides, measure the distance from the top of the guide to the top surface of the
cylinder block for identification upon reinstallation.
12. Disassembly of Engine Subassemblies
a. Disassembly of Piston and Connecting Rod.
(1) Remove retainers, then push piston pin out
of piston. Remove piston rings from piston.
16
(1) Remove screw and washer, fan drive assembly, and gasket from gear cover. To
disassemble fan drive (fig. 17), remove
pulley from shaft. Loosen nut and remove
screw. Remove adapter from shaft, Remove gear from shaft and bearing.
(2) Loosen nut (fig. 18), then remove governor
adjusting screw and spring.
(3) Remove pin and arm, then remove lever
assembly (fig. 18) from timing gear cover.
If replacement is necessary, remove oil
seal, felt seal, and bearings from gear cover.
(4) Remove governor cup and shaft assembly
from cam-shaft. Remove nut, then remove
governor driver assembly from camshaft.
c. Disassembly of Engine Oil Pump (fig. 15).
(1) Unfasten lock wire and remove screen from
pump.
(2) Remove screw assemblies, spacer, frame,
and gasket from pump.
(3) Remove screw assemblies, cover assembly,
and gasket from pump body. Remove
idler gear from body.
(4) Remove pin from drive gear, then press
shaft out of drive gear and remove drive
shaft and driven gear assembly.
(5) Press driven gear on drive shaft approximately one-fourth of an inch to permit removal of snap ring. Remove snap ring,
then press gear off shaft. Remove key from
shaft.
(6) If replacement is necessary, remove idler
gear shaft and bushing from pump body
(para. 14).
d. Disassembly of Manifold (fig. 16).
(1) Remove pin, then remove lever from valve
shaft.
(2) Remove pin, then remove valve shaft from
manifold, and heat control valve. Lift out
heat control valve.
(3) If replacement is necessary, press bushings
out of manifold.
MEC 3930-235-35/10
Figure 10. Intake and exhaust valves, exploded view.
17
Figure 11. Crankshaft, bearings and caps, exploded view.
18
Figure 12. Camshaft, exploded view.
MEC 3930-235-35/12
Figure 13. Timing gears, exploded view.
19
13. Engine Inspection
a. Cylinder and Crankcase (fig. 3). Inspect cylinder and crankcase. (fig. 3) for cracks or erosion
of water passages. Inspect cylinder walls for scored,
tapered, or out-of-round condition. If cylinder is
worn beyond limits given in paragraph 6, recondition cylinder walls and install new oversize pistons
and rings.
b. Pistons (fig. 9).
(1) Inspect pistons for scored, cracked, or worn
condition. If pistons are worn beyond limits given in paragraph 6, install new pistons and rings.
(2) To measure piston to cylinder wall clearance, place a 0.0015-inch feeler ribbon between piston and cylinder walls and withdraw piston and feeler ribbon from cylinder
with a spring scale. Correct clearance is
indicated when feeler ribbon is removed
with 5 to 10 pound pull.
Figure Timing gear cover, exploded v i e w .
20
Figure 15. Oil pump, exploded view.
Figure 16. Manifold, exploded view.
21
Figure 17. Fan drive, exploded view.
c. Piston Rings (fig. 9).
(1) Inspect for broken or worn piston rings.
If rings are broken or worn beyond limits
given to paragraph 6, install new rings.
(2) To measure piston ring side clearance,
temporarily install rings in piston grooves
and measure clearance with a feeler gage.
To measure end gap, insert ring in cylinder
and square the ring in the cylinder with
head of piston. Ring should be positioned
in the cylinder to a depth of the length of
the piston. Measure end gap with a flat
feeler gage. Clearances should be within
limits given in paragraph 6.
d. Piston Pins (fig. 9). Inspect pin, piston pin
bore, and connecting rod bushing for scored or worn
condition. If dimensions and fits exceed those given
in paragraph 6, replace worn parts.
e. Inspect connecting rod for twisted or bent condition. Straighten connecting rod if twisted beyond
limits indicated in paragraph 6.
f. Crankshaft and Bearings (fig. 11).
(1) Inspect crankshaft journals and bearings
for scored or worn condition. Inspect
22
crankshaft journals for tapered or out-ofround condition. If bearing and journal
dimensions exceed limits indicated in paragraph 6, replace worn parts.
(2) To measure crankshaft journal to bearing
clearances, use a well-oiled 0.002 inch brass
shim (1/2 inch wide and approximate length
of bearing) as follows: Place shim between
bearing and journal. Tighten bearing cap
and loosen all other bearing caps. If there
is a light drag resistance to turning rod or
crankshaft, correct clearance is indicated.
g. Camshaft and Bushings (fig. 12).
(1) Inspect camshaft journals and bushings for
scored or worn condition. If dimensions
or clearances exceed limits given in paragraph 6, replace worn parts.
(2) Inspect camshaft thrust plate for scoring or
wear. Inspect camshaft end thrust during
reassembly (para. 6). If thrust plate is
scored or if camshaft end thrust is beyond
limits given in paragraph 6, replace thrust
plate.
h. Valves (fig. 10).
(1) Inspect valve faces and seats for pitted or
Figure 18. Governor, exploded view.
burned condition. Reface faulty seating
surface (para. 14) or replace faulty parts.
(2) Inspect valve and guide for wear. If valve
or guide dimensions and clearances exceed
limits given in paragraph 6, replace worn
parts.
(3) Inspect for broken or weak valve springs.
If spring lengths are beyond specifications
given in paragraph 6, replace springs.
i. Timing Gears (fig. 13). Inspect timing gears
for chipped, broken, or worn teeth. If one or more
gears are faulty, replace both gears. Inspect timing
gear backlash during reassembly (para. 6). If backlash is beyond limits given in paragraph 6, replace
both gears.
j. Flywheel Ring Gear (fig. 4). Inspect ring gear
for chipped or broken teeth. Replace faulty gear
(para. 14h).
k. Cylinder Head (fig. 6). Inspect cylinder head
for cracks or warped condition. Inspect for erosion
of water passages. Replace cylinder head if faulty
or warped.
23
l. Gear Cover (fig. 14). Inspect gear cover for
cracks or damage. Replace faulty cover.
m. Fan Drive (fig. 17).
(1) Inspect bearing for binding or excessive
looseness. Bearing should rotate freely on
shaft without perceptible side play or
looseness. Replace a binding or loose bearing.
(2) Inspect gear for chipped or broken teeth.
n. Governor (fig. 18).
(1) Inspect fit of governor lever shaft in bearing. Shaft should rotate freely without perceptible side play. Replace worn shaft or
bearing.
(2) Inspect ball race for scoring or evidence
of wear. Inspect bearing balls for flat
spots or scoring. Replace faulty parts.
o. Oil Pump (fig. 15).
(1) Inspect gears for chipped or broken teeth.
Inspect idler shaft for scored or worn con-
(2) Recondition cylinder wails with cylinder
hone or boring machine. Remove only
enough material to clean and true-up
cylinder, then hone or bore until the next
available oversize piston fits with correct
clearance (para. 6). If removal of 0.004
inch of material will clean worn cylinder,
recondition with a cylinder hone. If necessary to remove over 0.004 inch material,
recondition with a boring machine, then
polish with a finishing hone. If boring or
honing operation is performed with crankshaft and camshaft installed, cover these
parts to protect them from chips and emery
dust. After reconditioning procedure, thoroughly clean cylinder walls and engine
parts, using SD.
(3) Select new oversize rings to match oversize
pistons. Before installing rings on pistons,
temporarily insert rings in cylinder and
dition. Inspect gear backlash and clearances during reassembly (para. 6). Replace parts worn beyond limits given in
paragraph 6.
(2
Inspect body bushings and drive shaft for
scored or worn condition. If worn beyond
limits given in paragraph 6, replace worn
parts. Refer to paragraph 1 4 i .
p. Manifold (fig. 16).
(1) Inspect manifolds for cracked or warped
condition. Replace faulty manifold.
(2) Inspect heat control valve shaft and bushing for binding. S h a f t s h o u l d r o t a t e i n
bushing with hand pressure. Replace faulty
parts.
q. Drive Belts. Inspect as indicated in TM 103930-235-20.
r. Thermostat. Inspect and test thermostat. Refer to TM 10-3930-235-20.
14. Engine Repair
Note. Refer to TM 1O-393O-235-35P for available repair
kits referenced in Engine Repair.
a. Cylinder Walls, Pistons and Rings (figs. 3 and
5).
(1) Recondition worn cylinder walls and fit
new pistons and rings as necessary.
24
Figure 19. Measuring ring gap.
Figure .!?0. Filing ring gap.
measure end gap (fig. 19). If end gap is
not sufficient, file ends of rings (fig. 20) to
obtain correct- gap. Temporarily insert
rings in piston grooves and measure side
clearances. See figure 21.
b. Pins, Pistons, and Connecting Rod Bushings
(fig. 9).
(1) If pin is a loose fit in piston pin bore, replace pin or piston. If necessary, ream new
piston to specifications given in paragraph
6.
(2) If pin is a loose fit in connecting rod bushing, replace pin or bushing. Use arbor
press to replace bushing in connecting rod.
If necessary, ream to specification given in
paragraph 6,
c. Connecting Rod. If connecting rod is bent or
twisted beyond limits (para. 6), straighten rod using
suitable bending tools.
d. Crankshaft and Bearings (fig. 11).
(1) Crankshaft main and connecting rod bearings are of the split insert type and should
not be repaired or altered. Replace bearings that are worn or faulty.
(2) Clean up slightly scored or scratched
crankshaft bearing journals with an india
stone. Replace crankshaft with journals
worn beyond limits given in paragraph 6.
e. Camha)t and Bushings (fig. 12). Replace
worn camshaft bushings. Drive old bushings out of
cylinder block using a brass pilot drift. The rear
bushing is accessible after removal of the expansion
plug at the flywheel end of the cylinder. When installing center bushing, make certain that bushing
hole is aligned with opening for oil pump drive gear
and that slotted edges are aligned with up and down
movement of tappets. When installing front and
rear bushings, be sure bushing oil holes are aligned
with holes in block. Use a brass pilot to install new
bushing. If necsssary, ream new bushings to specifications given in paragraph 6.
j, Valves and Seats (fig. 1 0 ) .
(1) Recondition faulty seating face of valve
heads using a valve refacing machine. Machine seats at angles indicated in paragraph 6.’ Do not burn face of valve or remove more material than is necessary to
eliminate burned or pitted areas.
(2) Recondition valve seats in cylinder block
with a cutter or grinding machine. Machine seats to angles specified in paragraph
6. If exhaust valve seat will not refinish
within specification, replace seat insert as
follows. Remove exhaust valve seat insert
from cylinder block using a suitable puller.
To install, chill inserts with dry ice, then
tap insert in cylinder block with a driving
tool. Make certain that seat insert is
aligned squarely with counterbore during
installation.
g. Valves and Guides (fig. 10). Replace worn
guides or valves with scored or worn stems as follows: Remove guides with a pilot drift. Install
guides with a pilot drift, positioning guide in block
so that the distance between top surface of cylinder
block and top of valve guide is the same measurement made before removal of old guide. If necessary, ream new guides to specifications given in
paragraph 6.
h. Flywheel Ring Gear (fig. 4). Replace faulty
ring gear. To remove gear from flywheel, heat gear,
then press or tap gear off flywheel. To install new
gear, chill flywheel in dry ice and press or tap new
gear on flywheel.
i. Oil Pump (fig. 15)
(1) Replace worn body bushings. Use arbor
piess to remove and install bushings. If
necessary, ream bushing to fit drive shaft,
within limits given in paragraph 6.
25
lect the required valve position opening,
then secure with screw and nut. Adjust
sector to fully open position for temperature below 32° F. (0° C); fully closed
position for temperature above 70 F. (21°
C) and between open and closed for temperatures between 32° F. and 70° F. (0° C
and 21° C).
b. Reassembly of Oil Pump (fig. 15).
(1) If idler gear shaft or bushing were removed
from pump body, install new bushing or
shaft (para. 1 4 i ) .
(2) Insert key in drive shaft slot, then press
driven gear on drive shaft until snap ring
groove extends one-fourth of an inch out
of gear. Install snap ring, then press gear
toward snap ring until snap ring is firmly
seated in gear bore shoulder. Install drive
shaft in body.
Figure 21. Measuring ring groove clearance.
(2) Replace worn or scored idler gear shaft.
Use arbor press to remove and install shaft.
Press shaft into body until end of shaft is
flush with body. Make certain that shaft
does not extend past idler gear face on
cover side.
(3) If gears are worn or faulty, it is recommended that parts contained in repair kit
be replaced.
15. Reassembly of Engine Subassemblies
a. Reassembly of Manifold (fig. 16).
to body clearance as follows: Insert a flat
feeler gage between gear teeth and pump
body and measure clearance. Clearance
should be within limits given in paragraph
6.
(1) If bushings were removed from exhaust
manifold, install new bushings using an
arbor press.
(4) Place drive gear, hub end toward pump
body, on shaft end. Press gear on shaft and
install pin. Peen ends to secure pin.
(2) Position valve in recess of exhaust manifold, then install valve shaft through
manifold and heat control valve and secure
with pin.
(5) Before installing cover, lubricate gears and
shafts with engine oil OE 10. Install gasket, cover, screw assemblies, gasket, frame,
(3) With valve in closed position, install lever
on valve shaft and position so that valve
can be opened or closed when rotating
lever. Secure lever to shaft with pin. Se-
26
(3) Install idler gear on idler gear shaft, then
inspect gear backlash as follows: Place
dial indicator pin on driven gear tooth,
then secure idler gear with one hand and
rotate drive shaft back and forth and observe dial indicator reading for gear backlash. Backlash should be within limits
given in paragraph 6. Inspect gear face to
body cover clearance as follows: Position
lead gasket (0.007-inch-thick) on body,
then place a straight edge on gasket and
measure clearance between straight edge
and outer gear face, using a flat feeler
gage. Clearance should be within limits
given in paragraph 6. Inspect gear tooth
spacer, and screw assemblies. Install screen
and secure with lock wire.
c. Reassembly of Timing Gear Cover (fig. 14).
(1) If bearings, dust seal, oil seal, dowel, and
pipe plug were removed from gear cover,
install new parts.
(2) I n s t a l l l e v e r a s s e m b l y i n c o v e r . I n s t a l l
arm on lever assembly and secure with pin.
(3) Press shaft and bearing in adapter until
groove of bearing is aligned with setscrew
hole in adapter. Install setscrew and tighten screw against bearing. Secure setscrew
with nut. Press gear and pulley on ends of
shaft. Position gasket on gear cover, then
install fan drive assembly and secure with
washers and screws.
d. Reassembly of Piston and Connecting Rod
(figs. 8 and 9).
(1) If bushing was removed from connecting
rod, install new bushing (para. 14b).
(2) Position connecting rod in piston and install piston pin and retainers.
marked tooth on crankshaft gear rests between the two
marked teeth in the camshaft gear.
(3) Install rings on piston.
(4) Install connecting rod bearings during engine reassembly.
16. Reassembly of Engine
Note. When
ing
parts
reassembling
with
engine,
lubricate
internal
mov-
OE.
a. If camshaft bushings; exhaust valve seat inserts or valve guides were removed, install new
parts as necessary (para. 14).
b. With cylinder and crankcase inverted, install
valve lifters and adjusting screws in cylinder block,
then insert camshaft, and adjust end play. Refer
to paragraph 6 for permissible end play. Secure
camshaft with thrust plate, washers, and screws.
c. Install thrust plate, key, timing gear, key, and
coupling gear on crankshaft, then secure with screw
and lock screw. Install snap ring on coupling gear.
d. Install upper halves of bearings in cylinder
block. Make certain bearing oil holes are aligned
with oil holes in cylinder block and that bearing
lugs rest in slot provided. Install oil guard felt,
rear bearing oil guard, and half of filler block seal
in crankcase. Carefully install crankshaft in cylinder block. Install lower halves of bearings in bearing caps. Install bearing caps, aligning dowels with
holes in caps and crankcase. Secure caps with screws
and washers. Tighten screws to torque of 100 to
110 foot pounds then lock wire screw heads.
Note. Timing
timing.
When
gears
installing
are
punch
camshaft
marked
gear,
Figure 22. Measuring and adjusting tappet clearance.
for
engage
correct
gears
valve
so
that
e. Install key, timing gear, and governor driver on
camshaft, engaging timing gears for correct valve
timing. Secure parts with nut.
f. Install valve spring and retainer on boss in
cylinder block. Using a valve spring compressing
tool, compress valve spring, then install valve, keys,
and cap. Remove spring compressor. Install all
valves in the same manner. Adjust valve to lifter
clearances (fig. 22) by holding lifter and turning adjusting screw. Measure clearance with a feeler gage.
When engine is assembled and operating, recheck
valve to lifter clearance (0.014 inch, hot), then install gasket, valve cover, gaskets, and nuts.
g. Place upper half of bearings in connecting rod
making certain that bearing lugs rest in slots. Install lower half of bearings in connecting rod cap.
Lubricate piston rings and piston with OE, then
install ring compressor over piston rings. Position
connecting rod assembly in top of cylinder, then
carefully tap piston with a wood block or hammer
handle until piston and rings enter cylinder. Tap
piston further until connecting rod upper half engages crankshaft journal. Install connecting rod
cap and bearings on crankshaft and secure with
bolts and nuts. Tighten nuts to a torque of 35 to
40 foot pounds, then install cotter pins. Install all
piston and connecting rod assemblies in the same
manner.
27
p. Install distributor drive shaft assembly in cylinder head and engage slot in oil pump.
q. Install oil gage rod and felt seal in crankcase.
Install oil filler body, and filler cap in crankcase.
r. P o s i t i o n w a t e r p u m p g a s k e t o n b l o c k , t h e n
install water pump and secure with screws and
washers.
s. Install thermostat and adapter ring in water
outlet elbow. Position gasket on cylinder head, then
install water outlet elbow and secure with washers
and nuts. Install elbows in water outlet elbow and
water pump and install recirculating tube.
Figure 23. Flywheel timing mark.
h. Place washer on stud in crankshaft bearing
cap, then install oil pump assembly and secure with
washer and nut.
i. Install new oil pan gaskets on crankcase. Install front and rear filler blocks and secure with
washers and screws. Install filler block gaskets.
j. Install oil pan and secure with screw assemblies. Install gasket and drain plug.
k. Place head gasket, with side marked TOP up
or if not marked install with seams on top, and
cylinder head on cylinder block and secure with
washers and nuts. Tighten nuts to a torque of 35
to 40 foot-pounds following tightening sequence
shown in figure 24.
l. Install relief valve, spring, adjusting washer,
gasket, and plug in crankcase.
m. I n s t a l l g o v e r n o r c u p a n d s h a f t i n c a m s h a f t
bore. Install gasket and timing gear cover assembly
on cylinder block, then secure with screws and
washers. Copper washers are used on screws and
these screws and washers are to be installed in the
two lowest holes of the timing gear cover. Install
nut and spring on screw, then install screw assembly
in timing gear cover. Adjust governor after engine
is installed and operating.
t. I n s t a l l f a n o n w a t e r p u m p a n d s e c u r e w i t h
washers and screws. Install drive belt on fan drive
pulley and fan hub and adjust (TM 10-3930-23520) .
17. Installation of Accessories on Engine
a. Place engine wire harness in clips, then secure
to cylinder head studs with nuts.
b. Install pressure switch, oil gage and thermo
unit, then connect wires to terminals.
c. I n s t a l l c o i l a n d c a p a c i t o r a n d s e c u r e w i t h
screws, nuts, and washers. Connect low tension wire
and capacitor wire to coil.
d. I n s t a l l d i s t r i b u t o r ( T M l 0 - 3 9 3 0 - 2 3 5 - 2 0 ) .
e. Install exhaust pipe (TM 10-3930-235-20).
f. Install power steering hydraulic pump (para.
50).
g. I n s t a l l c a r b u r e t o r ( T M 1 0 - 3 9 3 0 - 2 3 5 - 2 0 ) .
h. Install accelerator pedal and linkage (TM 103930-235-20).
i. Install fuel pump (TM 10-3930-235-20).
j. Install air cleaner (TM l0-3930-235-20).
k. Install starting motor (TM l0-3930-235-20).
l. Install generator (TM 10-3930-235-20).
18. Installation of Transmission on Engine
n. Install gasket and manifold assembly on cylinder block and secure with washers and nuts.
o. P o s i t i o n f l y w h e e l h o u s i n g a g a i n s t c y l i n d e r
block and secure with washers and screws. Install
left and right hand mounting brackets on flywheel
housing, then secure with washers and screws. Install screws in crankshaft, then install engine flywheel and secure with washers and nuts.
28
see paragraph 9d.
19. Installation of Engine and Transmission
Assembly
See paragraph 9e.
Note. With
and
graph
perform
20.
engine
assembled,
necessary
start
adjustments
as
and
operate
indicated
in
engine
para-
Figure 24. Sequence for tightening cylinder head nuts.
20. Run-In Procedure After Engine Overhaul
c. With engine at normal operating temperatures,
a. Make certain oil and coolant levels are correct,
then start engine and accelerate to a fast idle speed
(approx. 1000 rpm). Immediately after starting,
check for correct engine oil pressure (30 to 40 psi)
and listen for unusual noise which may indicate
faulty operation of engine parts.
recheck valve lifter clearances (fig. 22), then install
b. Keep engine operating at fast idle speed during warmup period. Reset choke during warmup
period to assure smooth engine operation and prevent over-choking.
the following schedule for run-in period.
C a u t i o n : Operating engine at idle speed will
not provide adequate lubrication for newly fitted
cylinders, rings and pistons and may result in
scuffing. Over-choking will wash lubricating oil
off pistons and rings and will cause crankcase
oil dilution.
hicle.
gasket, valve cover, gaskets, and nuts.
d. Adjust carburetor idle (TM 10-3930-235-20).
e. Adjust governor (TM 10-3930-235-20).
j. After engine is operating satisfactorily, observe
g. Operate overhauled engines for a period of 2
hours at fast idle before carrying loads with ve-
h. Change engine oil after the first 25 hours operation. Thereafter, change oil every 50 hours operation. Use oil specified in lube order LO 10-3930235-20 published in TM 10-3930-235-20.
29
Figure 25. Carburetor, exploded view.
30
Section IV. FUEL SYSTEM
21. Carburetor.
a. Description. The carburetor used in this fuel
system is a single-barrel up-draft type with fixed
jets covering all speeds except idle. The flow of
fuel through the main jet system is controlled by
the size of the main jet. The idle adjusting screw
controls the fuel mixture for the idle system. Refer
to paragraph 6 for specific jet sizes.
b. Removal. Refer to TM 1 0 - 3 9 3 0 - 2 3 5 - 2 0 .
c. Disassembly (fig. 25).
(1) Remove screws and washers, then separate throttle body assembly from fuel
bowl assembly.
(2) To disassemble throttle body, remove venturi and gasket. Remove axle, float, fuel
valve and seat, and washer. Remove idle
adjusting screw and spring. Remove idle
jet.
(3) To remove throttle valve and shaft from
throttle body, remove screws and throttle
plate, then withdraw throttle valve and
shaft from throttle body. If replacement
Figure 26. Throttle body, bottom view.
is necessary remove shaft seal retainer,
shaft seal, shaft bushings, and plug from
throttle body.
(4) To disassemble throttle shaft, remove
throttle stop screw, taper pin, and stop
lever from throttle shaft.
(5) To remove choke valve and shaft, remove
screws and washers and choke plate, then.
withdraw choke shaft and lever. If replacement is necessary, remove screws,
choke bracket, and retainer felt seal plug
from fuel bowl.
(6) To disassemble fuel bowl, remove main
jet channel screw, washer, main jet, and
washer. Remove well vent jet. Remove
discharge jet and washer. Remove idle
channel filler tube. If necessary, remove
plug and intake drain, disk.
d. Cleaning and Inspection.
(1) Clean all parts except gaskets and fiber
washers in SD.
(2) Blow out all passages in the fuel bowl
and throttle body with compressed air.
(3) Inspect float for leaks. Inspect top side
of float lever for wear where it contacts
fuel valve needle and float axle bearing
points. Inspect float axle for wear.
(4) Inspect throttle and choke plates for burrs
or damaged edges.
(5) Inspect throttle and choke shafts for bent
condition and wear.
e. Adjustment.
(1) Three adjustments should be made when
assembling the carburetor. Preliminary
adjustments, (3) and (4) below, should be
repeated after carburetor is installed on
engine (TM 10–3930–235-20).
(2) With the float assembled to the throttle
body, adjust the float lever (fig. 27) to
inch. Measure from the machined
surface to the highest point at top side of
float with the throttle body inverted. To
increase or decrease distance between float
and machined surface, use long-nosed pliers
and bend lever close to throttle body.
(3) Install idle adjusting screw (fig. 27) and
spring in throttle body. Seat lightly with
screwdriver and back out 1¼ 4 full turns.
31
Figure 27. Throttle body—side view.
(4) Hold the throttle lever (fig. 27) in a closed
position and turn the throttle stop screw
in until it just contacts the stop on the
body; then turn in 1½ additional turns.
f. Assembly and Repair. Reverse procedure in c
above. Replace parts with parts in carburetor repair and gasket kits. Refer to figures 26, 27, and
28 for installed views of float, linkage, and internal
views of carburetor.
g. Installation. Install and adjust carburetor
(TM 10-3930-235-20) .
22. Governor
a. Description. The governor assembly consists
of a governor driver and a governor cup, which are
mounted to the camshaft gear. See figure 18.
b. Operation (fig. 29). Centrifugal force created
by rotation of camshaft gear causes governor drive
32
ball bearings to move outward in their sockets.
Pressure caused by movement of the bearings moves
cup away from camshaft gear. This force is then
transferred through a lever mounted in the timing
gear cover to the governor and carburetor rods.
No direct connection is provided between the accelerator pedal and carburetor throttle plate. The
throttle opening and engine speed are controlled by
means of spring tension applied to the governor
rod. Accelerator pedal pressure moves pivot relay
lever forward against spring tension on governor
rod. Carburetor rod moves forward also allowing
carburetor throttle plate to slowly open and increase
engine speed. Higher engine speeds increase the
governor force until this governor force applied to
the governor lever is strong enough to overcome the
spring tension on governor rod. When this condition occurs, governor force prevents further move-
Figure 28. Fuel bowl - internal view.
Figure 29. Schematic of governor control.
33
ment of rods and levers which would open throttle
past the maximum governed speed.
c. Removal.
(1) Remove counterweight and side plates.
(2) Remove radiator (TM 10-3930-235-20).
(3) Remove drive belts (TM 10-3930-235-20).
(4) Remove hydraulic lift pump (para. 50).
(5) Disconnect linkage at governor lever.
(6) Remove fan drive and timing gear cover
( p a r a . 12b).
d. Disassembly. Refer to paragraph 12b.
e. Cleaning. Clean all parts in SD and dry them
thoroughly.
balls or any binding condition of the balls
in the race.
(2) Inspect cup and shaft for excessive grooving where balls contact level surface.
Check for any binding of the shaft in the
camshaft. Shaft should move in and out
of the camshaft smoothly and without perceptible side play.
(3) Inspect lever assembly for cracks, damage or wear. Make certain lever moves
back and forth without binding in the
needle bearings.
(4) Replace oil seal and felt seal with new
parts.
(5) Replace defective parts as necessary.
g. Assembly. Reverse procedures in d a b o v e .
f. Inspection and Repair.
(1) Inspect driver assembly for flat spots on
h. Installation.
Reverse procedures in c a b o v e .
Section V. COOLING SYSTEM
apply 4 to 6 psi air pressure at drain cock
opening.
23. Radiator
a. Removal. Refer to TM 10-3930-235-20.
b. Cleaning.
(3) Watch for air leaks and mark points for
soldering.
Refer to TM 10-3930-235-20.
c. T e s t i n g .
(4) Solder leaks and repeat test.
(1
Plug upper and lower radiator openings
with expansion balls and close overflow
pipe.
(2
Submerge radiator in tank of water and
Section VI.
a. Removal and Installation. Refer to TM 103930-235-20.
b. Disassembly (fig. 30).
(1) Remove nut, lockwasher then remove pull e.y , a n d f a n f r o m a r m a t u r e s h a f t . R e move key from keyway.
(2) Remove two thru-bolts and lockwashers,
then remove end heads from armature.
Remove two screws and lockwashers
fastening brush leads and pull brushes out
of brush holders. Pull brush arm and spring
off pins together.
(4) Lift armature out of frame and field.
34
d. Installation. Refer to TM 10-3930-235-20.
ELECTRICAL SYSTEM
24. Generator
(3)
(5) T e s t r a d i a t o r c a p . C a p s h o u l d r e l e a s e
under 7 pounds pressure. Replace if defective.
(5) Press bearing and cover from commutator
end head.
(6) Remove screws and lockwashers attaching retainer to drive end head. Remove
retainer, gasket, bearing, retainer, and felt
washer from end head.
c. Cleaning and Inspection.
(1) Clean end heads, pulley and fan with SD.
(2) Clean frame and field assembly and armature thoroughly with compressed air. Wipe
brushes with a clean dry cloth.
(3) R e p l a c e b r u s h e s w o r n t o l e s s t h a n h a l f
their original length (original length is %
inch).
Figure 30. Generator, exploded view.
(4) Visually inspect armature commutator for
scored, burned, or pitted condition. Repair faulty commutator (para. 25) or replace generator assembly.
(5) Test armature windings for ground using
test lamp. Touch shaft with one test probe
and each commutator bar with the other
probe. If lamp lights, a ground is indicated. Replace generator assembly if
grounded condition is indicated.
(6) Test armature windings for shorted condition using a growler. Place armature in
growler and while holding a thin steel strip
on the armature core, rotate armature. If
a short is present, the steel strip will become magnetized and vibrate as armature
is rotated. Replace generator assembly if
a short is indicated.
(7) V i s u a l l y i n s p e c t f i e l d c o i l w i n d i n g s f o r
burned condition or faulty insulation. Test
for grounded condition with test lamp.
Touch one test probe on each field coil
terminal and ground the other probe to
frame. If lamp lights, a ground is indicated. Replace generator assembly, if field
coils are grounded.
(8) I n s p e c t c o m m u t a t o r e n d h e a d f o r d a m aged or loosely mounted brush holders.
Replace end head assembly if brush holders are loose or faulty.
(9) Temporarily install commutator end head
(with bushing assembled) on armature
shaft and inspect for side movement of
shaft in bushing. Armature should rotate
in bushing without side play. If play is
present, replace worn parts.
35
(10) With commutator end head positioned on
install
shaft,
temporarily
armature
brushes. Hook spring scale in brush arm
hole. Pull on scale and note reading just
as brush leaves commutator. If scale reading (para. 6) is not within specifications,
replace springs.
(11) Inspect ball bearing for binding or looseness. Replace defective bearing.
d. Assembly. Reverse procedure in b above. Refer
to electrical schematic in TM 1O-393O-235-2O for
electrical connections.
25. Repair
a. R e m o v e d i r t o r s l i g h t s c r a t c h e s f r o m c o m mutator with No. 000 sandpaper. If rough or deeply
scored, turn down in a lathe by taking successive
light cuts. Undercut mica to depth of + to 3/64
inch. After cutting commutator, remove burrs with
No. 00 to No. 000 sandpaper.
b. I f i n s p e c t i o n r e v e a l s t h a t b u s h i n g i n c o m mutator end head is worn, replace bushing using
an arbor press. If necessary, ream bushing so
that armature shaft rotates freely in bushing without perceptible side play.
26. Testing
a. Field Coil Draw Test.
(1) Measure field coil draw as follows: Connect an ammeter and a variable resistance
in series with positive battery post and
generator armature terminal “A”. Connect negative battery post to generator
terminal “F”. Connect a voltmeter to generator field terminal “F” and armature
terminal “A”.
(2) A d j u s t v a r i a b l e r e s i s t a n c e t o o b t a i n 1 0
volts across field coil. Current draw should
be within limits shown in paragraph 6. If
current draw is not within specifications,
check for incorrect connections. If connections are satisfactory, field coils are
shorted, open, or grounded. Replace generator assembly if field coils are faulty.
b. Motoring Draw Test.
(1) Measure generator motoring draw as follows: Connect a jumper lead between generator terminal “F” and generator frame.
Connect an ammeter and a variable resistance in series with the generator armature terminal “A” and positive battery
36
post. Connect negative battery post to
generator frame.
A
djust variable resistance to obtain 10
(2)
volts across generator. Current draw
should be within limits shown in paragraph
6 and generator should operate as a motor
with the armature turning slowly. If current draw is not within specifications or
generator does not operate as a motor, internal electrical units are faulty or armature is not free to rotate. Repair a faulty
generator.
27. Starting Motor
a. Removal and Installation. Refer to TM 103930-235-20.
b. Disassembly (fig. 31).
(1) To remove solenoid switch, remove nuts
and washers, then remove connector. Remove screws and washers, then lift off
solenoid switch assembly, with nut and
washer installed.
(2) Loosen nut and screw, then slide inspection band off frame.
(3) Raise brush springs, then life grounded and
insulated brushes from brush holders.
(4) Remove screws, washers, then remove commutator end head assembly from end of
armature shaft. Do not remove brush
springs, brush holders, rivets, and grounded
brushes unless brush replacement is necessary (para. 28). Do not remove bushing
from commutator end head.
(5) Remove screws and washers and pull drive
housing assembly off frame. Do not remove bushing from housing unless replacement is necessary. Refer to paragraph 28.
(6) Remove armature, with starter drive assembled, from frame. Remove thrust
washers from commutator end of armature.
(7) T o r e m o v e s t a r t e r d r i v e f r o m a r m a t u r e ,
pry anchor plate away from intermediate
support and remove locating screw. Remove starter drive assembly from armature shaft.
(8) To disassemble starter drive, remove locking ring, then remove anchor plates and
drive spring. Remove retaining ring at
bore of pinion and withdraw shaft assembly and meshing spring from pinion.
Thread antidrift spring off shaft assembly.
Do not disassemble pinion assembly.
Figure 31. Starting Motor, exploded view.
(9) Remove key, then remove intermediate
support. Do not remove bushing from support unless replacement is necessary. Refer
to paragraph 28.
(4) Visually inspect armature commutator for
scored, burned, or pitted condition. Repair faulty commutator (para. 28) or replace starting motor assembly.
(10) Remove thrust washer from drive end of
armature shaft.
(5) Test armature windings for ground using
a test lamp. Touch shaft with one test
probe and commutator with other probe.
If lamp lights, a ground is indicated. Replace starting motor if test indicates a
grounded condition.
(11) Do not disassemble frame and field assembly, however, if replacement is necessary, insulated brushes can be replaced.
Refer to paragraph 28.
c. Reassembly. Reverse procedures in b a b o v e .
Refer to electrical schematic in TM 10-3930-235-20
for electrical connections.
d. Cleaning and Inspection.
(1) Clean all parts with SD except armature
and frame and field assembly.
(2) Clean frame and field assembly and armature thoroughly with compressed air. Wipe
brushes with a clean dry cloth.
(3)
Replace brushes worn to less than half
their original length (original length is
½ inch).
(6) Test armature winding for short-circuits
using a growler. Place armature in growler
and while holding a thin steel metal strip
on armature core, rotate armature. If a
short-circuit is present, the steel strip will
become magnetized and vibrate as armature is rotated. Replace starting motor
if a short-circuit is indicated.
(7) Visually inspect field coil windings for
burned condition. Test for grounded condition with test lamp. Touch one test
probe on each field terminal and ground
other probe to frame. If lamp lights, a
37
ground is indicated. Replace starting motor if a ground is indicated.
(8) Temporarily install commutator end head
on armature shaft and inspect fit of bushing on shaft. Armature should rotate
freely without excessive side play. If excessive side play is present, replace end
head and bushing assembly.
(9) With commutator end head positioned on
temporarily
install
armature
shaft,
brushes. Hook a spring scale on brush
spring. Pull on scale and note reading just
as brush leaves commutator. If scale reading (para. 6) is not within specifications,
replace springs.
(10) Temporarily install intermediate support
(with bushing assembled) on armature
shaft and check fit of bushing on shaft.
Temporarily install drive housing (with
bushing installed) on armature shaft and
check fit of bushing to shaft. Armature
should rotate freely in bushings without
excessive side play. If side play is excessive, replace worn parts.
(11) Inspect starter drive parts for scoring or
other indication of wear. Inspect barrel
pinion for chipped or broken teeth. Inspect springs for distortion.
28. Repair
a. Clean dirty or slightly scratched commutator
with No. 00 to No. 000 sandpaper. If commutator
is rough, scored or pitted, turn down in a lathe,
taking successive light cuts. Remove burrs with 00
to 000 sandpaper. Undercut mica to a depth of
X*Z inch and 0.002 inch wider than the mica.
b. If brushes are worn, replace as follows: To
remove brushes connected to field coil leads, unsolder terminal and spread connector loop. Install
new brush, then clinch loop securely and resolder
connection. To remove brushes connected to commutator end head, punch out rivets, then remove
brush holder and grounded brush. Install new brush
and brush bolder, then secure with new attaching
parts.
c. If commutator end head bushing is worn, replace end head and bushing assembly.
d. If drive housing or intermediate support bushings are worn, replace bushings using an arbor
38
press. If necessary, ream bushings so that armature rotates freely in bushing without excessive
side play.
e. If fields coils are faulty, replace starting motor.
29. Testing
a. No Load Test.
(1) Measure no load current and speed of motor as follows: Connect starting motor
terminal to battery positive post with a
carbon pile rheostat and ammeter in series.
Connect voltmeter to starting motor terminal and ground to motor frame. Connect
battery negative post to ground motor
frame, placing single-pole switch in the
lead wire.
(2) Close switch, operate starting motor and
note voltage, current and starting motor
speed. Readings should be 55 amperes
at 10 volts and 5,200 rpm. If specifications are not as indicated, operate starting
motor under no-load conditions for a short
period, then recheck readings.
(3) I f c u r r e n t a n d s p e e d a r e l o w , h i g h r e sistance is indicated. If current is high and
speed is low, a binding armature or interference with armature rotation is indicated.
If speed and current are far from specified
values, a ground, short or open circuit is
present in the starting motor. If speed,
voltage and current are not within specifications, overhaul starting motor.
b. Stall Torque Test.
(1) Measure starting motor stall torque as
follows: Connect starting motor in test
circuit same as indicated for no-load test
(a above). Connect torque measuring unit
to starter drive.
(2) Close switch to operate motor. Apply load
and note current and voltage. Current
should be 235 amperes maximum at 4 volts.
If current and torque are both low, high
internal resistance is indicated. High current with low torque indicates faulty
armature or field coil condition. I f p e r formance is not within specification, overhaul starting motor.
Section Vii. TRANSMISSION
30.
Transmission
a. Description.
(1) G e n e r a l .
(a) The transmission is a hydraulic torque
converter type and consists of two case
assemblies. One case assembly contains
a torque converter and an oil pump,
and the other houses a directional clutch
and gear train. A control valve and
shift cylinder are externally mounted
on the gear train case for controlling
clutch operation. Drive is from the engine flywheel through the torque converter, directional clutch and gear train
to a propeller shaft.
(b) The hydraulic torque converter (fig. 32)
is a combination fluid coupling and
torque converter of the single stage,
three-element type. The three elements
are the impeller which is driven by the
engine flywheel, the turbine which drives
the clutch, and the stator which provides
the means for the converter to multiply
torque.
(c)
A gear type pump (fig. 32) driven by
the converter, supplies oil flow to operate the shift cylinder and lubricates the
transmission parts. It also circulates oil
through the bottom of the engine coolant
radiator for cooling purpose.
(d) A directional shift lever (fig. 40) and
a creeper pedal (fig. 39) controls the
position of the control valve plungers.
The control valve plunger movement
controls oil flow to the shift cylinder.
The double-acting shift cylinder incorporates a spring loaded piston and
piston rod, which actuate mechanical
linkage to engage or disengage the directional clutch.
(e) The duplex directional clutch (fig. 33)
consists of a clutch flywheel driven by
the converter, a double-faced pressure
plate, and forward and reverse clutch
plates. These parts, plus operating
levers and links are enclosed in a cover
plate. In operation, the shift cylinder
actuates the link, yoke and carrier to
move the shifter ring. The shifter ring
actuates the clutch levers to engage
either the forward or reverse clutch plate
for the desired travel direction.
(f) The gear train (fig. 34) is of the dropdown type consisting of spur type gears.
The forward gear train includes a forward drive shaft and gear which is connected by splines to the forward clutch
plate and an idler gear which is in
constant mesh with an output gear, and
the forward drive gear. Power flow is
from the forward clutch plate through
the forward drive shaft and gear, the
idler gear, output gear, and to the propeller shaft. The reverse gear train includes a reverse drive shaft and gear
which is in constant mesh with the same
output gear that meshes with the forward idler gear. Power flow is from the
reverse clutch plate through the reverse
drive shaft and gear, output gear, and to
the propeller shaft.
(g) Transmission operation is as follows:
With engine operating and creeper pedal
in a released position, and with directional shift lever in a neutral position,
oil flow from the pump is blocked at the
control valve directional plunger. The
clutch remains disengaged and the drive
line from engine to drive axle wheels
is disconnected. When the directional
shift lever is moved for forward or reverse
travel, oil flow is directed through the
control valve to the shift cylinder which
in turn engages the clutch for desired
travel direction. As the engine is accelerated, torque buildup in the torque
converter drives the vehicle. Control of
vehicle speed is through movement of
the accelerator pedal. For creeping
operation, the creeper pedal is depressed
and released by the operator. Operation
as follows: When the creeper pedal is
fully depressed with the vehicle in motion, oil flow to the shift cylinder is
blocked by the creeper plunger. The
shift cylinder piston is automatically
moved to a neutral position and the
clutch is disengaged, thus disconnecting
the drive line from engine to the axle
39
wheels. When the creeper pedal is released from a fully depressed position to
an approximate halfway position, oil
flow to the shift cylinder is partially
restricted in such a manner that gradual
clutch engagement occurs. With engine
accelerated, repeated action of pushing
the creeper pedal down quickly and releasing it slowly to an approximate halfway position will cause short period of
drive motion to the drive axle wheels
and the vehicle will move at a smooth
controlled creeping speed. At the same
time, the high engine speed will allow
efficient operation of the hydraulic lift
system.
b. Oil Pressure Check. N o r m a l t r a n s m i s s i o n
operating oil pressures are as follows:
Engine
speed,
rpm
Transmission
range
Main oil
pressure at
pump outlet
tee, psi
Shift cylinder inlet
pressure, psi
Forward
Reverse
500
N e u t r a l . . . 40 min . . . . . 4 0 m i n .
40
2400
N e u t r a l . . . 85-90 . . . . .
70-90
1050-1100
Forward*.
. 60
m i n . . . . . 55
R e v e r s e * . . 60 min . . . . .
1100-1300
Forward*.
Forward*.
min.
min.
min..... 0
. 70 min . . . . . 65
R e v e r s e * . . 70 min . . . . . 0
min.
0
55 min.
0
. 65 min . . . . . 60
Reverse* . . 6 5
1300-1500
70-90
min.
(6) O p e r a t e e n g i n e w i t h t r a n s m i s s i o n s h i f t
lever in neutral position and with creeper
pedal depressed and note pressure reading.
If pressures are not as indicated in b a b o v e ,
refer to troubleshooting (para. 8) for possible troubles.
c. Removal of Engine and Transmission Assembly. Refer to paragraph 9b and c .
d. Disassembly.
(1) Disconnect and remove hose assemblies.
(2) Cut lock wire, then remove screws, washers, converter oil pump (fig. 32), remove
screws and washers, then remove collector
ring and seal rings. If necessary, remove
bushing from collector ring (g(5) below).
Scribe a mark, for identification purposes
during reassembly, then remove pump
gears from pump housing. Pump housing
includes a matched set of gears. If either
gear requires replacement, replace complete pump housing. Remove oil seal from
pump housing.
(3)
0
60
inlet ports to determine pressure reading
at these points.
min.
0
65 min.
Disconnect and remove hoses (fig. 38) and
unions from shift cylinder. Disconnect and
remove tubing, elbow, strainer and elbow.
Remove adapter, elbow and plug.
* Transmission output shaft is to be held stationary as throttle is
advanced from idle to full throttle (governor set at 2400 rpm-no-load).
(1) Main oil pressure at the tee connection may
be adjusted by turning the relief valve
adjusting screw (fig. 35) at the front side
of the valve body. Main pressure should
never be adjusted to pressures above 90
psi because of detrimental effects to the
converter and clutch linkage.
(2) The accumulator valve is to be adjusted
in the following manner: the adjusting
screw on the left side of the valve assembly
is to be turned in and bottomed.
(3) To check oil pressure, proceed as in (4)
through (6) below.
40
(4) Remove cotter pin and washer, then lift off
upper lever. Remove locking plug from
cross shaft, then remove cotter pins, washers, cam plate and creeper control lever.
Remove screws and washers then remove
upper creeper lever support, control valve
assembly and gasket from transmission
case.
(5) Disassemble shifter control valve. Refer
to paragraph 32.
(6) Remove screw assemblies (fig. 32), screw,
washer, cover, and gasket from transmission case.
(7) Cut lock wire and remove screws fastening
clutch assembly to clutch flywheel.
(4) Operate engine and vehicle until transmission is at normal operating temperature.
(8) Remove screw assemblies, nuts, washers,
(5) Remove pipe plug from pressure line fitting, located in converter case. Install a
150 psi pressure gage in fitting. Install
gages and connect hoses at shift cylinder
and screws, then remove torque converter
case, with clutch flywheel and output shaft
assembled. Remove seal ring and needle
bearing.
Figure 32. Converter, case, and oil pump, exploded view.
(9) Remove retainer ring (fig. 33), then press
flywheel and shaft assembly out of bearing. Cut lock wire and remove screws,
then remove output shaft from flywheel.
Remove retainer ring and press bearing out
of converter case.
(10) Remove forward clutch plate (fig. 33),
then lift out clutch assembly.
(11) Before disassembling clutch assembly,
note match markings, one on the extension
lug of the pressure plate and one on the
cover adjacent to it. Identify parts so that
they may be returned to their original
location. Remove cotter pins (fig. 33) and
lever anchor pins fastening operating levers
to clutch cover plate. Slide out clutch pressure plate, then remove pivot pins, links,
and operating levers from clutch pressure
plate. Lift out reverse clutch plate from
clutch cover plate.
(12) Remove cotter pins (fig. 33), washers,
and pins. Remove link. Remove plug from
yoke shaft, then using a brass drift and
hammer, drive against yoke shaft until
plug is removed and the yoke shaft is exposed. Drive on the exposed yoke shaft,
in the opposite direction, until yoke shaft
is removed. Remove yoke.
(13) Remove carrier and bearing (fig. 33)
from shifter sleeve. To disassemble car41
Figure
33.
Converter
clutch
rier and bearing, remove retainer ring and
press carrier out of bearing. Remove retainer ring and press bearing out of shifter
ring. If necessary, remove pin from shifter
ring.
(14) Remove screw assemblies (fig. 33), then
remove shifter sleeve from transmission
case.
(15) Remove screws and washers, then remove
shift operating cylinder and spacers. Remove seal ring from cylinder.
(16) Disassemble shift operating cylinder. Refer to paragraph 33.
(17) Remove retainer ring (fig. 34), then press
forward clutch shaft out of bearing. Slide
forward gear off shaft splines, then remove
42
and
linkage,
exploded
view.
s h a f t . R e m o v e bearing from transmission
case.
(18) Remove retainer ring (fig. 34) and press
reverse clutch shaft, with bearing assembled, out of transmission case. Lift out
reverse gear. R e m o v e k e y , t h e n p r e s s
bearing off reverse clutch shaft. Remove
retainer ring. If necessary, remove bushing
from shaft (g(6) below).
(19) Remove screw assemblies (fig. 34), then
remove cover and gasket. Remove retainer
rings, then press shaft with bearing assembled, out of transmission case. Remove idler gear and spacer. Press shaft
out of bearing. Remove key from shaft.
Remove bearing from transmission case.
Figure
34.
Case,
cover,
gems, and
(20) Remove screws (fig. 34) and washers,
then remove cover and gear assembly. Remove gasket. Remove oil seal from cover.
Remove retainer ring, then press gear assembly out of bearing.
shafts,
exploded
view.
f. Inspection.
(1) R e p l a c e s s e a l s a n d g a s k e t s w h e n t r a n s mission has been disassembled.
(2) Inspect hoses for worn, chafed, or deteriorated condition. Replace defective hoses.
(21) Remove retainer ring (fig. 34), then press
bearing out of cover. If necessary, remove
plug from cover.
(3) Inspect converter and transmission cases
for cracks or damage. Replace defective
cases.
(22) Remove retainer ring, then press bearing
(4) Visually inspect converter for evidence of
oil leakage or damage. Replace converter
assembly if faulty.
off output shaft gear. If necessary, remove
plug from gear.
(23) Remove plug, breather cap and drain
plug from transmission case.
e . C l e a n i n g . Clean all parts with SD and dry
thoroughly with compressed air.
(5) I n s p e c t c o n v e r t e r f o r s h e a r e d o r w o r n
pump drive lugs. Inspect bushing (mounted in pump housing) and converter sleeve
bushing surface for scoring or wear. Converter sleeve should rotate freely in bush43
ing without perceptible side play. Replace
converter assembly if sleeve is faulty or
worn. Replace pump housing assembly if
bushing is faulty or worn.
(6) Inspect oil pump gears for chipped, broken,
or worn teeth. Gears and housing are
matched parts and should be replaced as
an assembly. If gears or housing are faulty,
replace housing assembly.
(7) I n s p e c t b u s h i n g ( m o u n t e d i n c o l l e c t o r
ring) and output shaft for scored or worn
condition. If parts are worn beyond limits
given in paragraph 6, replace worn parts.
shaft) for plugged condition. If valve operation is faulty, replace output shaft and
valve assembly.
(18) Inspect inlet screen for damaged or
clogged condition. Clean or replace defective screen.
g. Repair.
(1) Converter assembly cannot be repaired. If
converter is faulty, replace converter assembly.
(2) Oil pump gears and housing are matched
parts. If oil pump gears or housing are
faulty, replace oil pump housing assembly.
(8) Inspect bushing (mounted in reverse clutch
shaft) and forward clutch shaft for scored
or worn condition. If parts are worn beyond limits given in paragraph 6, replace.
(3) Output shaft and relief valve cannot be
repaired. If output shaft or relief valve
are faulty, replace output shaft and valve
assembly.
(9) Inspect clutch shift yoke, links and clevis
pins for worn pivot or friction points. Replace worn parts. Inspect carrier lugs (at
yoke contact points) for wear. Replace
worn carrier.
(4) The clutch assembly consists of parts that
are matched for correct operation. If reverse clutch plate, clutch cover plate,
clutch pressure plate, lever, link, anchor
pin, or pivot are worn or faulty, replace
clutch assembly.
(10) Inspect
surfaces
parts. If
present,
carrier and shifter sleeve sliding
for scoring or binding between
binding or excessive looseness is
replace defective parts.
(11) Inspect forward and reverse clutch plate
facings for scored or worn condition. Inspect clutch plates for loose rivets. Replace
clutch plates if faulty or if facing is worn
beyond limits given in paragraph 6.
(12) Inspect faces of clutch plate and flywheel for scoring. Replace defective plates
or flywheel.
(13) Inspect friction and pivot points of clutch
links, levers, pivot pins and anchor pins,
and clutch plates for grooves, elongated
holes, or worn condition. If parts are worn
or defective replace clutch assembly.
(14) Inspect gears for chipped or broken
teeth. Replace defective gears.
(15) Inspect shafts for scoring or worn condition. Replace defective shafts.
(16) Inspect ball and needle bearings for binding or looseness. Replace defective bearings.
(5) Replace scored or worn output shaft. Use
an arbor press to remove and install bushing in collector ring. Shaft should fit bushing as indicated in paragraph 6.
(6) R e p l a c e s c o r e d o r w o r n f o r w a r d c l u t c h
shaft bushing. Use an arbor press to remove and install bushing in reverse clutch
shaft. Shaft should fit bushing as indicated in paragraph 6.
h. Reassembly of Transmission.
(1) Install drain plug (fig. 34), breather cap,
and oil level plug in transmission case.
(2) Press bearing (fig. 34) on gear and install
retainer ring. If removed, install plug in
gear.
(3) Press bearing (fig. 34) in cover and install
retainer ring.
(4) Support bearing in arbor press, then press
gear with bearing assembled, into bearing.
Secure gear with retainer ring.
(17) Inspect output shaft and relief valve as
(5) Install oil seal and oil level plug in cover.
Install gasket and cover and gear assembly
on transmission case, then secure with
washers and screws.
follows: Inspect holes in shaft and valve
seat (mounted in splined end of output
(6) I n s t a l l k e y ( f i g . 3 4 ) i n s h a f t . P o s i t i o n
gear in transmission case, then press shaft
44
and key into gear. Install spacer on outer
end of shaft, then install bearings. Secure
bearings with retainer rings. Install gasket, cover, then secure with screw assemblies.
(7) I f b u s h i n g w a s r e m o v e d f r o m r e v e r s e
clutch shaft, install new bushing (g(6)
above).
(8) Install rear retainer ring (fig. 34) in reverse clutch shaft groove. Press bearing,
with snap ring on bearing facing rear retainer ring, on shaft and against retainer
ring. Install key in shaft slot. Install
shaft and bearing in transmission case and
press until bearing snap ring bottoms
against case. Support reverse clutch shaft
in press, then install gear and secure with
retainer ring.
(9) Install bearing (fig. 34) in transmission
case. Place gear in position and carefully
slide forward clutch shaft through hollow
shaft and engage splines in gear. Press
shaft into bearing, then secure with retainer ring.
(10) Reassemble shift operating cylinder
(para. 32).
Note. During
cylinder,
install
correct
clutch
mission
must
(para.
installation
spacers
neutral
be
of
as
necessary
setting
assembled
shift
to
operating
to
obtain
adjustment.
Trans-
check
adjustment
31).
(11) To install shift operating cylinder, install
seal ring, on cylinder, then install shift
operating cylinder and spacers, as necessary, then secure with washers and screws.
(12) Install shifter sleeve (fig. 33) and secure
with screw assemblies.
(13) If removed, install pins (fig. 33) in shifter
ring. Press bearing in shifter ring and secure with retainer ring. Press shifter carrier (fig. 33) in bearing, then secure with
retainer ring. Install carrier and bearing
assembly on shifter sleeve.
(14) Place shift operating yoke (fig. 33) in
position and install yoke shaft. Threaded
end of yoke shaft to be positioned on the
side opposite the shift cylinder. Install
plug at shift cylinder end of shaft. Install
link and secure with pins, washers, and
cotter pins.
(15) With index markings in proper relation
on pressure plate and cover, place clutch
plate (fig. 33) on face of clutch cover. Assemble links to pressure plate and levers,
then secure with pivot pins. Slide pressure
plate, with links, pins, and levers attached,
in slots provided in clutch cover plate.
Align operating levers with holes in clutch
cover and install clevis pins and cotter
pins.
(16) Install complete clutch assembly (fig.
33) and make certain that all clutch levers
are inserted in shifter ring groove and that
reverse clutch plate splines are fully engaged on reverse clutch shaft. Install forward clutch plate and make certain that
splines of clutch plate are fully engaged
on forward clutch shaft.
(17) Press bearings (fig. 32) in converter case
and secure with retainer ring. Install output shaft in flywheel and secure with
screws. Lock wire screw heads. Install
flywheel and output shaft in converter case
bearing and secure with retainer ring. Install needle bearing in flanged end of output shaft.
(18) Place new seal ring (fig. 32) in position
on transmission case, then install torque
converter case assembly. Secure cases together with screws, washers, nuts, and
screw assemblies. Align screw holes in
clutch cover and clutch flywheel, then install screws. Lock wire screw heads in
pairs.
Note. At
justment
of
this
point
clutch
of
neutral
reassembly,
setting
check
(para.
ad-
31).
(19) After adjustment of the clutch neutral
setting is satisfactory, install gasket (fig.
34) and cover, then secure with washer,
screw and screw assemblies.
(20) Reassemble shifter control valve (para.
32) .
(21) To install shifter control valve, position
gasket (fig. 35) on case, then install shifter
control valve and secure with washer,
screw and screw assemblies.
(22) Install plug, elbow, and adapter in converter case. Install elbow, strainer, elbow.
Connect tubing.
Install unions in shift
45
cylinder, then connect hoses. See figure
38.
(23) If bushing was removed from collector
ring, install new bushing (g(5) above).
(24) Install new oil seal (fig. 32) in pump
housing. Install gears in pump housing
and align scribe marks. Make sure the side
of the internal gear with drivng lugs is
toward the outside. Place seal rings on
collector ring, then install on pump housing. Secure with washers and screws. Place
gasket in position, then install pump assembly and secure with washers and
screws. Lock wire screw heads.
(25) Install hose assemblies (fig. 38).
i. Install Transmission on Engine. Refer to paragraph 9d.
j. Install Transmission and Engine Assembly.
Refer to paragraph 9e.
31. Clutch Neutral Setting Adjustment
(fig 37)
a. No adjustments are required or provided for
clutch wear. The stroke of the shift cylinder is designed to completely wear out both clutch plates.
Adjustment shims located under the shift cylinder
mounting flange are factory adjustments for neutral
setting. In the event of clutch plate, or shift cylinder replacement, dimensions, for neutral setting
must be measured so that correct neutral setting
can be obtained through removal or replacement
of shift cylinder adjusting spacers.
b. Measure the distance between the face of the
clutch flywheel and the edge of one or more of the
pressure plate driving lugs. Dimensions should be
as shown in paragraph 6. Adjust setting by removing or installing spacers (fig. 37) between shift
operating cylinder and case.
32. Shifter Control Valve
a. Remove Creeper Pedal Plunger (fig. 35).
(1) R e m o v e r e t a i n i n g r i n g , t h e n w i t h d r a w
creeper pedal plunger assembly from valve
body. If necessary, remove nut and separate plunger bracket from plunger.
(2) Remove screws, then remove retainer, and
wiper ring. Remove seal ring from body.
Figure 35. Shifter control valve, exploded view.
46
b. Remove Forward and Reverse Plunger ( f i g .
35).
(1) Remove plunger housing.
Note. When
removing
cise
care
as
plunger
fall
out.
Remove
plunger
detent
detent
balls
balls
housing,
and
and
spring
exerwill
spring.
(2) R e m o v e r e t a i n i n g r i n g a n d f l a t w a s h e r
from forward and reverse plunger, then
withdraw plunger from valve body.
(3) Remove screws, then remove retainer, and
wiper ring. Remove seal ring from body.
(4) Unscrew and remove safety switch.
c. Remove Relief Valve (fig. 35).
(1) Unscrew and remove acorn nut, seal, jamnut, seal, and adjusting screw from relief
valve cap.
(2) Unscrew and remove relief valve cap with
seal ring assembled. Remove seal ring
from cap.
(3) Remove guide spacer, spring, and retainer
and ball assembly from valve body.
(4) R e m o v e r e t a i n i n g r i n g a n d r e l i e f v a l v e
seat from valve body.
(5) Remove oil seal and orifice plug from valve
body.
d . R e m o v e A c c m u l a t o r V a l v e (fig. 35).
(1) U n s c r e w a n d r e m o v e a c c u m u l a t o r v a l v e
cap assembly. Remove cap gasket. To
disassemble cap, cut seal wire and remove
seal. Hold adjusting screw then remove
jamnut. Unscrew and remove adjusting
screw from cap. Remove seal ring from
cap bore.
(2) Remove compression spring and accumulator valve from valve body.
e . C l e a n i n g . Clean all parts with SD and dry
thoroughly with compressed air.
f. Inspection.
(1) I n s p e c t a c c u m u l a t o r v a l v e p l u n g e r f o r
binding or sticking in control valve body
bore. Inspect for broken or distorted
spring. Replace faulty parts.
(2) I n s p e c t r e t a i n e r a n d b a l l a s s e m b l y , a n d
relief valve seat surfaces for nicks,
scratches, or other defects that may cause
poor seating. Inspect for broken or distorted spring. Replace faulty parts.
(3) I n s p e c t f i t o f c r e e p e r p l u n g e r a n d s h i f t
plunger in control valve body. Plungers
should slide freely in control valve body
w i t h o u t p e r c e p t i b l e s i d e p l a y . Replace
faulty parts.
(4) Inspect detent balls for flat spots. Inspect
for broken or distorted spring. Replace
faulty parts.
(5) Replace seals, wiper rings and gasket when
valve has been disassembled.
g. Repair. Replace parts as necessary if found
to be faulty.
h . R e a s s e m b l y . Reverse procedures given in d ,
c, b, and a a b o v e . Adjust relief valve setting and
accumulator valve (para. 30b).
i. Test Control Valve. Control valve should be
tested after transmission has been installed and is
in operating condition. Test under actual driving
conditions to see how vehicle functions.
33. Shift Operating Cylinder
a. Disassembly (fig. 36).
(1) Remove retainer ring from body. Screw a
%–16 NC bolt in tapped hole of end plug
and remove plug assembly, using screw as
a puller. To disassemble end plug assembly, use a vise or arbor press and compress against spring guide, then remove retainer ring. Release vise or press slowly,
to relieve tension, then remove spring
guide and spring from end plug. Remove
seal ring.
(2) Remove piston rod assembly from body,
then remove seal ring. Remove nut, then
separate piston from piston rod.
(3) I n s e r t b o d y i n p r e s s a n d p r e s s a g a i n s t
spring guide, then remove retaining ring.
Release press slowly, to relieve tension,
then remove spring guide and spring.
(4) Remove seal ring from body.
b . C l e a n i n g . Clean all parts with SD and dry
thoroughly with compressed air.
c. Inspection and repair.
(1) I n s p e c t c y l i n d e r b o r e f o r s c r a t c h e s o r
grooves which would cause cutting or
scratching of seal ring and cause leakage.
(2) Inspect piston rod surface where it slides
back and forth in end plug for scoring or
binding condition. Replace faulty parts.
47
Figure 37. Adjustment of clutch neutral setting.
(3) I n s p e c t p i s t o n f o r s c o r i n g o n s u r f a c e
w h i c h c o n t a c t s c y l i n d e r b o r e . Replace
faulty piston.
(4) Replace all seals when cylinder has been
disassembled.
d . R e a s s e m b l y . Reverse procedures given in a
above.
34. Creeper Pedal and Linkage
a. Removal and Disassembly (fig. 39).
(1) Unhook all return springs.
(2) U n s c r e w a n d r e m o v e b a l l j o i n t n u t a n d
lockwasher at pedal lever, then separate
ball joint from lever.
(3) Remove cotter pin and clevis pin then disconnect cable yoke from lever.
(4) Loosen clamping screw, then slide lever
off creeper pedal shaft. Remove key from
pedal shaft.
(5) Cut lock wire then remove setscrew from
creeper control arm. Slide creeper pedal
out of bracket and at same time remove
control arm, from between bracket uprights. If necessary remove pedal shaft
bushings from bracket uprights.
(6) Unscrew and remove ball joint nut and
lockwasher at upper lever, then separate
rod assembly from lever.
(7) Remove cotter pin and flat washer, then
lift off upper support lever.
Figure 36. Shift operating cylinder, exploded view.
48
(8) Remove screws and washers, then remove
upper support assembly from control valve
body.
Figure 38. Converter lines and fittings.
(9) Remove cotter pin and flat washer then
lift off lever support lever from plunger
bracket. Remove cotter pins, and flat
c. R e p a i r . Replace parts as necessary to maint a i n smooth linkage operation.
d. R e a s s e m b l y . Reverse procedures in a above.
washer then remove lower support lever
from control lever.
(10) Remove locking plug from cross shaft.
Remove cotter pins, washers, spacer washers, and cam plate. Remove bushings from
control lever pins.
b. Cleaning and Inspection. Clean all parts with
e. Adjust Creeper Pedal and Linkage. Refer to
T M 10-3930-235-20.
3 5 . Transmission Shift lever and Linkage
a. R e m o v a l a n d D i s a s s e m b l y ( f i g . 4 0 ) .
(1) Remove steering wheel (para. 45).
SD and dry thoroughly with compressed air. Inspect
(2) Remove cotter pin and clevis pin then dis-
parts for worn pins, oblong holes, broken welds
connect shift rod from shift lever lower
or damaged parts.
lever.
49
Figure 39. Creeper pedal and linkage, exploded view.
(3) Loosen lower lever clamping nut, then remove lower lever from shift lever.
(4) Knock out groove pin in collar, then remove shift lever by raising up and out of
upper bracket.
Note. When
plunger
will
lever
is
raised,
the
c. Repair. Replace parts as necessary to main-
spring
out.
(5) If necessary, remove pin and shift lever
stop from shift lever.
50
spect parts for damage and wear.
tain smooth shift lever operation.
shift
fall
b. Cleaning and Inspection. Clean all parts with
SD and dry thoroughly with compressed air. In-
d. Reassembly. Reverse procedures in a a b o v e .
e. Shift Lever and Linkage Adjustment. R e f e r
to TM 10-3930-235-20.
Figure 40. Transmission shift lever and linkage.
51
Section Viii.
UNIVERSAL JOINT
36. Universal Joint
a. Removal and Disassembly (fig. 41).
(1) Remove lock wires and screws fastening
four bearings to the coupling plate. Carefully pry bearings out of coupling plate
retaining lugs and slide bearings off spider
journals. Remove coupling plate.
(2) To remove spider, remove screws fastening
bearings to yoke or brake flange. Pry
bearing out of retaining lugs and remove
spider and bearing assembly.
b. Cleaning and Inspection. Clean all parts with
SD and thoroughly dry with compressed air. Inspect bearings and spider journal for wear or scoring
caused by lack of lubrication. Replace spider and
bearing as an assembly if parts are worn.
c. Repair. Do not repair universal joint bearings
or spiders. If bearings or spiders are faulty, replace
spider and bearing assemblies.
d. Reassembly and Installation.
(1) Lubricate bearings during reassembly
(LO 10-3930-235-20) and place them
temporarily on spider journals to remove
excess lubricant.
(2) Remove the bearings and install new cork
gaskets.
(3) Slide drilled bearings on spider journals
and install assemblies on yoke and brake
flange. Insert coupling plate between the
two spiders. Slide two drilled bearings on
spider adjacent to transmission and two
tapped bearings on spider adjacent to drive
axle. Install screws through drilled bearings and coupling plate and into tapped
bearings. After tightening retaining screws,
secure with lock wires.
Figure 41. Universal joint, exploded view.
52
Section iX. DRIVE AXLE
joint splined yoke from transmission, then
remove axle assembly.
37. Drive Axle
a. Removal.
(1) Disconnect brake pedal and creeper pedal
return springs.
(2) Disconnect hydraulic brake tubing at tee
mounted on axle housing.
(5) Drain lubricant.
b. Disassembly.
(1) Disassembly of drive axle.
(a) R e m o v e d r i v e w h e e l s ( T M 1 0 - 3 9 3 0 235-20).
(3) D i s c o n n e c t p a r k i n g b r a k e c a b l e f r o m
brake pivot lever by removing return
spring, cotter pin, washer, and pin.
(b) R e m o v e s e r v i c e b r a k e s h o e s ( T M 1 0 3930-235-20).
(c) Remove drive axle shaft (TM 10-3930235-20).
(4) Raise vehicle, then remove nuts, washers,
bolts, power steering cylinder mounting
plate, and washer fastening drive axle to
frame. Pull drive axle assembly toward
(d) Remove parking brake (para. 43).
(e) Remove universal joint (para. 36).
front of vehicle, disengaging universal
(f) R e m o v e s c r e w s a n d w a s h e r s f a s t e n i n g
Figure 42.
Figure 42.
53
Figure 43. Differential carrier.
differential carrier to axle housing (fig.
42), then remove differential carrier assembly and gasket.
(9) I f r e p l a c e m e n t i s n e c e s s a r y , r e m o v e
rivets, and dust shield (fig. 42) from axle
housing. Remove nut, then remove spindle from axle housing. Remove vent
plug, drain plug, and level plug from
axle housing.
(h) O n M o d e l M H E - 1 9 1 , r e m o v e s c r e w s ,
housing cover, and gasket from axle
housing.
(2) Disassembly of differential (fig. 44).
(a) Mark position of bearing adjusters for
identification in reassembly. Remove
cotter pins and locks. Cut lock wire,
loosen carrier cap screws, then remove
adjusters. Remove bolts and bearing
caps, then remove differential subassembly and bearing cups from carrier.
(fig. 43)
(b) Mark the two case halves (fig. 44) for
identification then separate case halves.
Remove thrust washers, pinions and
spider, side gears and thrust washers
54
from case halves. If replacement is necessary, pull bearing cones off case halves.
(c) D o n o t r e m o v e b e v e l g e a r f r o m c a s e
replacement is n e c e s s a r y ( d
unless
below).
(d) R e m o v e c o t t e r p i n ( f i g . 4 4 ) a n d n u t ,
then pull brake flange off bevel pinion.
Drive out pinion using a brass drift and
hammer. Remove shims, spacer, and
inner bearing cone from bevel pinion.
Remove oil seal, and outer bearing cone
from differential carrier by carefully
tapping cone from inside of carrier.
Note. During
size
and
tween
removal
number
inner
of
cup
of
shims
and
drive
at
pinion,
spacer,
carrier.
To
and
note
be-
facilitate
adjustment, use same size and number of shims
during
reassembly.
(e) Remove inner bearing cup (fig. 44) from
carrier, using a puller. Remove outer
cup by tapping from inside of carrier,
driving through slots in carrier.
(f) I f n e c e s s a r y , r e m o v e p a r k i n g b r a k e
anchor pin from carrier.
Figure 44. Differential, exploded view.
c. Cleaning and Inspection.
(1) C l e a n a l l p a r t s w i t h S D a n d d r y t h o r oughly with compressed air.
(2) I n s p e c t t a p e r e d r o l l e r b e a r i n g c u p s a n d
cones for scoring, nicks, or flat spots. Replace faulty bearings.
(3) Inspect bevel gear and pinion for worn,
chipped, or broken teeth. Replace faulty
gear or pinion. Refer to 7d below for instructions covering removal and installation of bevel gear.
(4) Inspect differential side gears and pinions
for chipped, broken, or worn teeth. Replace faulty gears or pinions. Inspect friction surfaces of thrust washers, side gears,
pinion, and differential case for scoring or
wear. Replace faulty parts.
(5) R e p l a c e a l l o i l s e a l s a n d g a s k e t s w h e n
drive axle has been disassembled.
d. Repair.
(1) Replace faulty bevel gear as follows: Heat
rivets, then drive them out of gear and
differential case. Install new gear on case
and secure with new rivets. Peen rivets
cold.
(2) Replace faulty parts as necessary.
e. Reassembly of Differential (fig. 44).
(1) Install same size and number of shims that
were removed during disassembly in carrier, then install inner bearing cup.
(2) I n s t a l l o u t e r b e a r i n g c u p u s i n g a b r a s s
drift and hammer.
(3) Install inner bearing cone on bevel pinion,
then install pinion assembly in carrier.
Place bearing spacer, original number of
shims and outer bearing cone on pinion.
Note. Do
is
not
completely
install
oil
seal
until
differential
adjusted.
55
(4) Install brake flange and nut. Tighten nut
and inspect for proper adjustment. Refer
to f below for pinion bearing adjustment.
Install oil seal after correct adjustment is
obtained.
(5) P l a c e t h r u s t w a s h e r s a n d s i d e g e a r i n
flanged half of differential case. Place
pinions and thrust washers on journals of
spider, then place this assembly on flanged
half of differential case. Place the other
side gear and thrust washer on pinion
assembly. Position plain half of differential case on flanged half, aligning identification marks made in disassembly, then
install bolts and nuts. Lock wire nuts.
(6) If bearing cones were removed from differential case, install new bearing cones
using an arbor press.
(7) Place bearing cups on cones, then position
differential case assembly in carrier and
install caps and screws. Do not tighten
screws completely. Install bearing adjusters and tighten until marks previously
made during disassembly are aligned.
(8) Adjust differential bearings as described in
g below. Adjust drive gear to pinion backlash as described in h b e l o w .
(9) A f t e r d i f f e r e n t i a l i s c o r r e c t l y a d j u s t e d ,
tighten screws and install locks and cotter
pins. Remove nut and brake flange from
bevel pinion, then install oil seal. Reinstall brake flange and secure with nut and
cotter pin.
Adjustment of Bevel Pinion Bearings.
(1) Adjust pinion outer bearing assembly to
obtain a preload of 0.000- to 0.002-inchtight clearance. Adjust by removing or
installing shims between outer bearing
cone and bearing spacer.
(3) If a dial indicator is used, measure pinion
end play and install or remove shims as
necessary to obtain correct adjustment.
F o r e x a m p l e : If end play is 0.008 inch,
remove shim or shims totaling 0.010 inch.
This will remove end play and create a
0.002-inch preload on bearings.
g. Adjustment of Differential Bearings.
(1) Adjust bevel gear and pinion backlash to
approximately 0.006 to 0.010 inch. Make
final backlash adjustment (h below) after
differential bearings are adjusted.
(2) Tighten bearing adjusters as much as possible to seat bearing cones in cups. Loosen
adjusters until a slight drag is felt when
turning bevel gear by hand. This slight
drag should indicate a bearing adjustment
of 0.000 to 0.005 inch tight.
h. Adjustment of Bevel Gear to Pinion Backlash.
Adjust bevel gear to pinion backlash by turning
bearing adjusters equal distances in opposite directions, to remove ring gear toward or away from
pinion and still retain correct differential bearing
adjustment made in g above. To adjust, loosen
bearing cap screws, then turn one bearing adjuster
c o u n t e r c l o c k w i s e a n d t u r n t h e o p p o s i t e b e a r i n g—
adjuster clockwise. Each time adjustment is made,
tighten bearing cap screws and reinspect gear backlash. Backblash should be 0.006 to 0.010 inch.
i. Reassembly of Drive Axle. Reverse
in b(1) above.
procedures
j. Installation. Reverse procedure in a a b o v e .
Section X.
38. Steering Axle (MHE-191)
a. Removal of Axle and Spring Assembly.
(1) Raise vehicle until wheels just rest on
floor. Disconnect rear drag link from center steering lever ball stud by removing
cotter pin and unscrewing end plug.
56
(2) Inspect adjustment by measuring pinion
end play with a dial indicator or by rotation of pinion by hand. Correct adjustment is indicated if a slight drag (with oil
seal removed) is felt when rotating pinion.
Install shims if pinion cannot be rotated.
Remove shims if pinion is too loose.
STEERING AXLE
(2) Remove nuts and washers then drive out
shackle bolts to disconnect springs from
frame hanger brackets. Remove axle
assembly.
(3) Remove springs from axle (para. 47).
b. Disassembly of Steering Axle (fig. 45).
Figure 45. Steering axle, exploded view (MHE-191).
(1) R e m o v e s t e e r i n g w h e e l s ( T M 1 0 - 3 9 3 0 235-20).
(2) Remove tie rods (TM 10-3930-235-20).
(3) Cut lock wire, then remove lock screw and
pivot shaft. Remove steering lever assembly from axle beam. If necessary, remove
needle bearings from steering level using
an arbor press.
(4) Remove snap rings, seal caps, felt washers,
lock screws, and king pins, then remove
steering knuckles and thrust bearings from
axle beam. Press needle bearings from
axle beam. Remove opposite steering
knuckle in the same manner.
(5) If necessary, remove stop screws and nuts.
Remove lubricant fittings.
c. Cleaning and Inspection.
(1) Clean all parts in SD and dry thoroughly
with compressed air.
(2) Inspect king pin for scoring or grooves.
Inspect king pin bearings for scored, pitted,
or damaged condition. Inspect steering
knuckle thrust bearing for binding condi-
tion. Inspect steering knuckles for fractures or damage.
(3) I n s p e c t c e n t e r s t e e r i n g p i v o t s h a f t a n d
bearings for scored or worn condition.
Shaft should rotate freely in bearings without perceptible side play.
(4) Inspect ball studs for scored condition.
d. Repair. Replace faulty parts as necessary.
e. Reassembly. Reverse procedures in b a b o v e .
f. Installation. Reverse procedures in a a b o v e .
g. Adjust Toe-In. Refer to TM 10-3930-235-20.
3 9 . Steering Axle (MHE-190)
a. Removal of Axle Assembly.
(1) Raise vehicle until wheels just rest on floor.
Disconnect rear drag link from center
steering level ball stud by removing cotter pin and unscrewing end plug.
(2) Remove nuts, spacers, and bolts fastening
trunnion frame brackets. Remove axle
assembly.
b. Disassembly of Steering Wheels.
(1) Remove steering wheels (TM 10-3930235-20).
57
Figure 46. Steering axle, exploded view (MHE–190).
(2) Remove tie rods (TM 10-3930-235-20).
(3) Remove pivot pin setscrew, then drive out
pivot pin, with collar and roll pin assembled, from trunnion. If necessary, remove
bushings from steering lever (d b e l o w ) .
(4) Remove snap rings, seal caps, felt washers,
lock screws, and king pins, then remove
steering knuckles and thrust bearings from
axle beam. Press needle bearings out of
axle beam.
(5) If necessary, remove stop screws and nuts.
Remove lubricant fittings.
58
(6) Remove bolts, nuts, and washers, then
separate axle beam from trunnion.
(7) If necessary press bonded center joint out
of trunnion.
c. Cleaning and Inspection. Same as paragraph
38c, except inspect center bonded joint for oilsoaked condition. Replace bonded joint if rubber
is oil-soaked and gummy.
d. Repair. S a m e a s f o r p a r a g r a p h 3 8 d , e x c e p t
replace scored or worn bushings in center steering
lever using an arbor press. If necessary, ream bush-
ings so that shaft rotates freely in bushing without
perceptible side play.
f. Installation. Reverse procedures in a a b o v e .
g. Adjust Toe-in. Refer to TM 10-3930-235-20.
e. Reassembly. Reverse procedures in b a b o v e .
Section Xi. BRAKES
4 0 . Brake Pedal and Master Cylinder
a. R e m o v a l .
nut, and washer, then remove lever and
key. Remove pedal and pad. If necessary,
remove pedal shaft bushings from frame.
(1) R e m o v e f l o o r p l a t e s . D i s c o n n e c t r e t u r n
spring from spring clip. Remove cotter
pin and clevis pin to disconnect yoke from
lever.
(3) T o r e m o v e m a s t e r c y l i n d e r , d i s c o n n e c t
stoplight switch wires. Disconnect brake
tubing at master cylinder fitting. Remove
(2) To remove pedal (fig. 47), loosen screw,
bolts (fig. 48), nuts, and lockwashers
Figure 47. Brake pedal, exploded view.
59
Figure 48. Master cylinder, exploded view.
fastening master cylinder to frame, then
remove master cylinder assembly.
b. Disassembly of Master Cylinder (fig. 48).
(1) Loosen nut and remove yoke from push
rod.
(2) R e m o v e f i l l e r c a p a n d g a s k e t . R e m o v e
push rod and boot.
(3) Remove piston stop wire, stop plate, secondary cup, piston, primary cup, return
spring, and valve from supply tank. If
necessary, r e m o v e f i t t i n g s f r o m s u p p l y
tank.
c. Inspection.
(1) I n s p e c t p e d a l t o m a s t e r c y l i n d e r y o k e ,
lever, and pins for wear or elongated holes
at linkage connecting points. Replace
faulty or worn parts.
(2) Inspect supply tank bore, piston, and cups
for nicks, scratches, or scoring. Replace
faulty parts. When cylinder has been disassembled for repair, it is recommended
that parts contained in repair kit be
replaced.
d. Repair. When master cylinder has been disassembled and supply tank bore is in satisfactory
condition, it is recommended that parts contained
in repair kit be replaced.
e. Reassembly of Master Cylinder. Reverse procedures in b a b o v e , except coat internal parts with
brake fluid.
60
f. Installation. Reverse procedures in a a b o v e .
g. Bleed Brake System. Refer to paragraph 42.
h. Adjust Brake Pedal Free Travel. Refer to
TM 10-3930-235-20.
41. Brakeshoes and Wheel Cylinders
a. Removal (fig. 49).
(1) Remove wheels (TM 10-3930-235-20).
(2) Cut lock wire, then remove cap screws and
grease shield.
(3) Using proper tool, disconnect heel return
spring and toe return spring.
(4) Lift off brakeshoes.
(5) Disconnect brake line at wheel cylinder.
(6) Remove screws and washers, then remove
wheel cylinder from backing plate.
b. Disassembly of Wheel Cylinder (fig. 50). Remove pins, boots, pistons, cups, and spring from
body. Remove bleeder screw.
c. Inspection.
(1) Inspect brakeshoe lining for grease-soaked
or worn condition. If linings are greasesoaked or worn to less than l/g-inch thick,
replace brakeshoe assembly.
(2) Inspect pistons, piston cups, and cylinder
bore for nicks, scratches, or scoring. Replace faulty parts. When cylinder has been
disassembled for repair, it is recommended
that parts contained in the repair kit be
replaced.
Figure 49. Brakeshoes, exploded view.
d. Repair.
(1) Linings are bonded to brakeshoes. If linings are faulty or worn, replace shoe
assembly.
e. Reassembly of Wheel Cylinder. R e v e r s e p r o cedures in b above, except coat internal parts with
brake fluid.
f. Installation. Reverse procedures in a a b o v e .
(2) When wheel cylinder has been disassembled and cylinder bore is satisfactory, it is
recommended that parts contained in
repair kit be replaced.
g. Adjust Brake Shoes.
Refer to TM 10-3930-
235-20.
h. Bleed Brake System. Refer to paragraph 42.
Figure 50. Wheel cylinder, exploded view.
61
Figure 61. Parking brakeshoes, exploded view.
42. Bleeding Hydraulic Brake System
a. Fill master cylinder. Attach a rubber hose to
the end of the wheel cylinder bleeder screw and
extend the open end of the hose in a receptacle containing hydraulic brake fluid.
b. Loosen the bleeder screw one-half turn. Then
slowly depress and release the brake pedal until
fluid runs out of the hose in a steady stream without bubbles. Tighten bleeder screw.
(4) Remove snap rings, inner and outer brakeshoes, and friction washers from mounting
pins in pivot lever.
b. Inspection.
(1) Inspect lining for grease-soaked or worn
condition. R e p l a c e l i n i n g s i f t h e y a r e
grease-soaked or worn.
(2) Inspect brakedrum for scoring. Replace
scored drum.
43. Parking Brakeshoes
a. Removal and Disassembly (fig. 51).
(1) Disconnect spring and remove cotter pin,
washer, and pin to disconnect cable from
pivot lever.
c. Repair. Replace grease-soaked or worn brakeshoe linings by replacing brakeshoe assembly. Linings are bonded to shoe. Keep new linings free of
oil or grease during installation.
(2) R e m o v e s c r e w s a n d w a s h e r s f a s t e n i n g
brakedrum to brake flange, then slide drum
over propeller shaft toward transmission.
d. Reassembly and Installation. R e v e r s e p r o c e dures in a a b o v e .
(3) Loosen nut and adjusting screw. Remove
snap ring fastening brakeshoe assembly to
e. Adjust Parking B r a k e s h o e s . R e f e r t o T M
10-3930-235-20.
Section Xii.
STEERING SYSTEM
44. Power Steering Pump
a. Removal. Refer to TM 10-3930-235-20.
b. Disassembly (fig. 52).
(1) Remove screw, washer, pulley, and key
from pump drive shaft.
(2) Remove adapter bolt, adapter, and adapter
gasket from pump body.
62
pin mounted in drive axle differential
carrier. Remove brakeshoe assembly.
(3) Remove cap, seal ring, spring, and valve
assembly from pump cover. With valve
assembly removed, ball spring and ball will
drop out of cover.
(4) Remove screws and mounting studs, then
lift cover vertically from body. Remove
seal rings from grooves in body.
Figure 52. Power steering pump and reservoir, ezploded view.
(5) Remove cam assembly by lifting cam carrier, rollers and insert from body.
(6) Remove key from shaft and snap ring from
body, then remove shaft assembly from
body. Remove bearing from shaft.
(7) Remove oil seal from body.
(8) Do not remove dowel pins, venturi, bushings, tube seat, or ball from body unless
replacement is necessary.
c. Inspection.
(1) Inspect shaft friction surface and bushings
in body and cover for scoring or wear.
Shaft should rotate freely in bushings without perceptible side play. Replace faulty
shaft, If bushings are faulty, replace cover
or body assembly.
(2) Inspect shaft ball bearing for binding or
looseness. Replace faulty bearing.
(3)
. Inspect shaft seal surface for scratches,
scoring, or other defects that may cause
leakage. Rep] ace faulty shaft. Replace oil
seal when pump has been disassembled.
(4) Inspect end of cam rollers for scoring or
wear. Measure cam assembly and clear63
ance with cam assembly and drive shaft
installed in body. Use straight edge and
feeler gage. If end clearance exceeds 0.002
inch, replace cam assembly. If end of cam
rollers are scored, replace cam assembly.
(5) Inspect flow control valve body for nicks
or defects that may cause sticking. If any
of the flow control valve parts are faulty,
replace valve assembly.
(6) Install new element, oil seals, and gaskets
when pump has been disassembled.
d. Repair.
(2) If cam carrier, rollers, or insert are faulty,
replace cam assembly.
e. Reassembly. Reverse procedures in b a b o v e ,
except use new oil seal, gaskets, and seal rings.
f. Testing Power Steering Pump Oil Pressure.
(1) Check reservoir for correct oil level (fig.
52).
(2) With engine stopped, disconnect pressure
hose at pump and install a tee in the pump
discharge port. Install a 1,500 psi gage in
tee. Connect shutoff valve to tee, then
connect pressure hose to valve.
(3) Turn shutoff valve to a fully-opened position. Start engine and idle until oil has
reached operating temperature.
To prevent damage to pump
not allow valve to remain
more than 3 to 4 seconds
following tests.
(4) Close shutoff valve and note pressure reading, then quickly open the valve.
(5) If pressure reading is less than 750 psi, the
pump is faulty.
(6) If pressure reading is between 750 psi and
900 psi, the pump is delivering sufficient
pressure and test should be continued to
determine if there is a loss of pressure in
the hydraulic cylinder.
Caution: To prevent damage to power
steering system units, do not maintain
full pressure in the system for longer
than 10 seconds during the following
test.
64
(8) If the pressure reading is 750 psi or above,
the hydraulic cylinder is operating correctly. If reading is less than 750 psi, the
hydraulic cylinder is faulty.
4 5 . Steering Gear
a. General.
(1) If drive shaft bushings in pump body or
cover are faulty, replace pump body
assembly or cover assembly.
Caution:
parts, do
closed for
during the
(7) With shutoff valve open, turn the wheels
against a curb or suitable object and maintain sufficient force on the steering wheel to
apply full pressure in the hydraulic cylinder. Note pressure reading, then release
wheel.
(1) The action of the steering gear is both
manual and hydraulic in effect. When the
cam is turned to the left or right, by the
driver’s effort on the steering wheel, the
levershaft stud is moved through the
groove of the cam (worm), thus rotating
the levershaft and providing angular movement of the steering gear pittman arm.
Whenever the driver’s effort at the steering wheel exceeds the preload of the actuator centering springs, the control valve is
actuated and the hydraulic system comes
into operation automatically; thus providing the driver with power steering.
(2) The valve spool is moved axially as the
cam is moved. However, movement is restricted by the actuator centering springs.
The effect of these springs is to center the
spool. When the valve spool is in the
center position, oil pressure to the two
cylinder ports is equal and results in no
effective forces in the cylinder.
(3) Operation is as follows: When the driver’s
effort at steering wheel overcomes effect of
the centering spring, the actuator and valve
spool move axially. Movement of the valve
spool restricts one of the valve return passages to the valve outlet port, thus causing
an immediate increase in pressure at one
end of the hydraulic cylinder. At the same
time, the other valve return passage is
enlarged, allowing the oil, from the opposite end of cylinder, to return to the reservoir. The immediate effect is increased
pressure in one end of the cylinder which
actuates the cylinder piston and causes
hydraulic power to be applied to steering
linkage. Full hydraulic pressure is applied
with a spool travel of approximately 0.050
inch. Slightest movement of valve spool
results in a pressure differential.
(4) When effort at steering wheel is released,
the valve spool is returned to the center or
neutral position.
(5) If the steering axle wheels are subjected
to shock loads, the pittman arm, acting
through the lever shaft, shifts the cam and
control valve spool axially in the appropriate direction, to direct hydraulic pressure
to the correct side of the cylinder piston to
resist the shock forces. This action prevents kickbacks at the steering wheel.
b. Adjustments.
(1) Adjust
thrust
bearing.
It is recommended that the steering gear
be removed to adjust thrust bearings.
If it is desirable to make the adjustment
with the steering gear installed, the shift
lever must be removed and jacket tube
bracket must be disconnected from the
support strap. Then proceed to remove
upper cover as described below.
To adjust bearings with steering wheel
installed and gear removed from vehicle,
proceed as follows.
Remove horn button, contact cup,
spring, contact cap, base plate, nut, and
steering wheel. Remove screws fastening
upper cover and actuator housing. Slide
assembly, consisting of jacket tube and
upper cover, off cam and wheel tube.
Note. Take
(mounted
moving
on
upper
care
not
cam
and
to
damage
wheel
contact
tube)
when
ring
re-
cover.
Reassemble screws fastening actuator
h o u s i n g , u s i n g 3/8-inch-thick spacers
under screw heads. This will keep actuator intact while making the adjustment.
Remove contact ring from cam and
wheel tube.
Before adjusting bearings, check nut for
binding. Straighten lug of lockwasher,
then remove adjusting nut, lockwasher,
tongued washer, upper thrust washer,
and upper thrust bearing. M a k e s u r e
that nut turns freely (finger torque) on
cam and wheel tube threads. Then reassemble upper thrust bearing, upper
thrust washer, tongue washer, lockwasher, and adjusting nut.
(f) To adjust bearings, turn gear off midposition to free stud in cam groove.
Then tighten adjusting nut to obtain a
light preload of thrust bearings without
lash or heavy drag. Adjust as follows:
Tighten nut to 10 foot-pounds torque.
Back off nut 10° to 20° or move nut
back a distance equal to 1½ times the
width of a lockwasher lug. Bend lockwasher lug to secure nut position.
(g) After adjustment is made, install contact
ring on cam and wheel tube. Remove
screws and temporary spacers from actuator housing. Install gasket, upper
cover, and jacket tube, then fasten actuator housing and upper cover with
washers and screws. Assemble contact
brush to jacket tube. Install steering
wheel, nut, base plate, contact cap,
spring, contact cup, and horn button.
(2) Adjust levershaft backlash.
(a) Backlash is determined by the position
of the stud to the cam groove. To adjust
levershaft backlash, place steering gear
in mid-position. L o o s e n l o c k n u t a n d
tighten adjusting screw until a slight
drag (high spot) is felt when turning
gear back and forth through midposition.
When adjustment is made to a positive
high spot, back off nut one-sixteenth of
a turn and tighten locknut.
Note. A
0.010-,
shim
and
pack
washers),
mounted
stud
being
from
(consisting
0.020-inch
on
pulled
shims
levershaft,
into
cam
of
0.003-,
between
two
prevents
groove.
When
shim pack is correct, it should be of sufficient
thickness
but
still
to
not
hold
stud
prevent
out
of
adjusting
cam
to
the
groove
high
but
spot.
(b) I f t h e h i g h s p o t c a n n o t b e f e l t w h e n
adjusting levershaft screw, remove levershaft then remove shims from pack until
the high spot can be noticed.
Note. Remove
feel
of
high
only
enough
shims
to
permit
spot.
(c) If the high spot can be felt when adjusting levershaft screw, it is not an indication that the shim pack is correctly adjusted. The only positive method of
knowing is to add shims until high spot
cannot be felt, then remove shims and
adjust as described above.
65
(d) A f t e r c o r r e c t a d j u s t m e n t i s o b t a i n e d ,
turn gear through full travel to check
adjustment.
(3) Adjust stud roller bearing unit.
(a) In nearly every instance, the levershaft
and thrust bearing adjustments are
sufficient to bring the steering gear up
to serviceable standards. However, in
some cases it may be necessary to remove levershaft and adjust the stud
roller bearing unit.
(b) The stud roller bearing unit should be
adjusted to obtain a preload on the bearings at all times. Adjust as follows:
Straighten lockwasher lug and tighten
adjusting nut to obtain noticeable drag
(3 inch-pounds torque to rotate stud).
Rotate stud several times, then recheck
adjustment. Lock adjustment by bending lockwasher lug over nut.
Removal of Steering Gear.
(1) Remove floor plates. Disconnect hydraulic
hoses to aid in reconnecting hoses during
gear installation. Disconnect linkage at
pittman arm. Disconnect horn cable at
contact brush.
(2) Remove horn button, contact cup, spring,
contact cap, and base plate. Remove nut
and steering wheel.
(3) D i s c o n n e c t s h i f t l e v e r l i n k a g e a t l o w e r
shift lever. Remove screws and lower shift
lever. Loosen setscrews in lever collars and
remove collars. Then, remove shift lever
and stop assembly from bearing in jacket
t u b e b r a c k e t .
(4) Disconnect strap from jacket bracket to
cowl. Remove nuts, screws, and washers
fastening steering gear to frame. Remove
steering gear assembly.
d. Disassembly of Steering Gear (fig. 53).
(1) R e m o v e l e v e r s h a f t . D r a i n l u b r i c a n t . R e move nut, lockwasher, and pittman arm.
Loosen locknut and adjusting screw in
gear housing side cover. Remove screws,
washers, side cover, and gasket. Turn cam
and wheel tube until levershaft engages
center of cam, then remove levershaft.
Note.
Keep
shim
pack
intact
to
aid
in
re-
assembly.
(2) R e m o v e a n d d i s a s s e m b l e c o n t r o l v a l v e .
66
Remove screws fastening control valve to
actuator housing, then remove control
valve assembly and gasket. If control
valve operation i s s u s p e c t e d o f b e i n g
faulty, disassemble as follows: Remove
retaining ring, cover plate and seal ring
from valve body. Remove screws, washers,
and end cover from valve body. Remove
two small seal rings from valve body. Remove nut and washer from flexure rod,
then withdraw rod from valve spool. Push
spool out of valve body in same direction
that rod is removed, then remove three
centering washers, seal ring, and spring.
Remove seal ring from spool. If it is desirable, remove bypass valve plug, seal
ring, spring, and ball from valve body.
(3) Remove jacket tube and upper cover. R e move screws and contact brush from jacket
tube. Remove screws fastening upper
cover and actuator housing to gear housing.
Slide assembly consisting of jacket tube
and upper cover off cam and wheel tube.
Note. Take
(mounted
ing
from
care
on
cover
cam
and
not
and
jacket
to
damage
wheel
tube.
tube)
Remove
contact
when
ring
remov-
contact
ring
tube.
(4) Remove and disassemble cam and wheel
tube and actuator assembly. Loosen actuator screw and washer. Remove complete
assembly of cam and wheel tube and actuator from gear housing. If it is desirable
to disassemble these parts, proceed as
follows: Straighten lugs of lockwasher,
then remove adjusting nut, lockwasher,
tongued spacer washer, upper thrust
washer, upper thrust bearing, and another
upper thrust washer from cam and wheel
tube. Remove upper centering washer
from actuator, then remove actuator and
housing.
Note. Take
(mounted
washer,
bearing
in
care
lower
from
not
actuator).
thrust
cam
and
to
lose
Remove
washer
wheel
centering
lower
and
rings
centering
lower
thrust
tube.
e. Inspection and Repair.
(1) Inspect and replace levershaft oil seal and
bushings. Visually inspect bushings for
scoring or pitted condition. Check condition of oil seal. To restore parts, pry old
oil seal out of housing. Press bushings out
of housing using an arbor press. Press new
Figure 53. Steering gear, exploded view.
67
bushings in housing and check fit of levershaft in bushings. Line ream if necessary
until levershaft rotates freely and clearance between bushing and levershaft does
not exceed .002 inch. After levershaft and
bushings are fitted correctly, press new oil
seal in housing.
(2) I n s p e c t a n d r e p l a c e l e v e r s h a f t a n d s t u d
roller bearing unit.
(a) Check levershaft for twisted or damaged
splines and wear on bushing surface.
Replace faulty levershaft. Inspect roller
bearing unit stud for nicks, flat spots, or
spalling. Replace faulty bearing unit.
(b) To replace roller bearing unit, straighten
lug of lockwasher, then unscrew nut and
remove lockwasher, spring washer, flat
washer, and conical washer. Remove
bearing rollers and stud will drop out.
(c) Inspect rollers for flat spots or pit marks.
Replace all rollers if one or more are
faulty.
(d) To install roller bearing unit, position
rollers on stud and hold in position with
heavy grease. Install stud in levershaft.
Install rollers on opposite side, holding
them in position with heayy grease. Install conical washer (cupped side toward
rollers), flat washer, spring washer ( C U P
end toward rollers), lockwasher, and
nut. Tighten nut as required, then revolve stud several turns and check adjustment b(3) above. After correct adjustment is obtained, bend lug of lockwasher over nut to secure nut position.
Wash heavy grease from rollers and
lubricate with correct lubricant.
(3) Inspect and replace cam bearings. Visually
inspect cam bearings for binding, pit
marks, or scoring. Replace faulty bearings.
Replace bearings with an arbor press.
Note. Take
care
not
to
exert
excessive
pres-
sure on bearing and retaining ring when installing
bearings.
against
However,
retaining
make
sure
bearings
are
seated
rings.
(4) Inspect cam and wheel tube. Inspect cam
groove for chipping, scoring or brinelling
(cam is copper plated). Normal operation
of stud in groove will wear away the plating. (This is a normal condition and does
not necessarily indicate abnormal wear.)
Inspect condition of bearing surface on
68
cam. Replace cam and wheel tube assembly if cam is faulty.
(5) Inspect control valve parts. It is impractical to measure spool and body for wear
in the field. Spool is lubricated by circulating oil and should not wear appreciably.
Check for free fit of spool in body. Visually inspect spool and body contact surfaces for scoring or other faulty conditions.
If spool or body are faulty, replace valve
assembly. Replace all seal rings when
valve has been disassembled.
f. Reassembly of Steering Gear.
(1) A s s e m b l e a n d i n s t a l l a c t u a t o r , c a m a n d
wheel tube, and jacket tube. Lubricate
internal parts as they are assembled.
(2) Preassemble and adjust actuator on cam
and wheel tube.
Note. Make
(finger
torque)
sure
on
adjusting
tube
threads
nut
turns
before
freely
assembling
parts.
(3) P l a c e l o w e r t h r u s t b e a r i n g o n c a m a n d
wheel tube, then install lower thrust
washer, lower centering washer, actuator,
springs ( i n a c t u a t o r ) , u p p e r c e n t e r i n g
washer, upper thrust washer, upper thrust
bearing, a second upper thrust washer,
tongued washer, lockwasher, and adjusting
nut. Adjust nut to obtain a light preload
of thrust bearings without lash or heavy
drag (b(1) above).
(4) Insert cam into gear housing and check for
free rotation. Install gasket and actuator
housing, positioning housing for correct
location of valve mounting. Install washer
and retaining screw in actuator housing.
(5) Install contact ring on cam and wheel tube.
Install gasket, upper cover, and jacket
tube, then fasten actuator housing and
upper cover to gear housing with washers
and screws. Assemble contact brush to
jacket tube.
(6) I n s t a l l l e v e r s h a f t . A s s e m b l e s h i m p a c k
(0.003-, 0.010-, 0.020-inch shims between
two washers) to levershaft and install
levershaft in gear housing. Prior to installing side cover, pack housing with grease
specified in LO 10–3930–235–20. Use approximately 2½ pounds. Install gasket
and side cover on gear housing and fasten
with screws and washers. Install adjusting screw and locknut. Tighten adjusting
screw until a very slight drag (or high spot)
is felt when turning gear through midposition (b(2) above). Install pittman
arm, lockwasher, and nut.
and washers. Use shims (between strap
and bracket) as necessary to provide correct gear alignment without strain on
jacket or cam and wheel tubes. When gear
is correctly aligned, tighten all mounting
screws.
(7) Assemble and install control valve. Install
seal ring on spool, then install spool in
valve body.
(2) W i t h b e a r i n g p o s i t i o n e d i n j a c k e t t u b e
mounting bracket, install shift lever and
stop assembly in bearing. Slide collars on
shift lever. Install lower shift lever. Place
detent spring and ball between shift lever
stop and jacket tube bracket. Adjust position of collars on shift lever to provide free
movement of lever with minimum end
play. Tighten collar setscrews. Connect
lower shift lever to linkage.
Note. Use a twisting motion for easier installation of spool in body. At end cover side of valve
body,
install
centering
washer.
of
centering
washer,
Insert
spool
Tighten
and
nut
seal
flexure
fasten
to
125
washer,
ring,
rod
spring,
a
a
centering
third
through
rod
to
and
with
150
second
opposite
washer
and
inch-pounds
end
nut.
torque.
(8) If bypass valve was removed, install seal
ring on plug, then install ball, spring, and
plug in valve body.
(9) Install actuator lever in actuator housing.
Note.
groove
Seat
and
stud
end
position
rod
engage
flexure
bly
mounted.
is
rod
of
lever
so
clevis
that
pin
in
lever
when
actuator
slot
valve
will
assem-
(10) Install gasket and valve assembly, then
carefully install and tighten screws.
Note.
lightly,
torque.
Tighten
then
all
tighten
Careful
four
to
screws
10
tightening
to
will
15
evenly
and
foot-pounds
prevent
pulling
spool off center.
(11) Before proceeding with further assembly,
make sure that spool moves properly in
both directions. Temporarily install steering wheel. Turn steering wheel to move
pittman arm against a stop. Apply sufficient effort at steering wheel to actuate
spool. Reverse pittman arm against an
opposite stop to move spool in opposite
direction.
(12) If spool is operating properly, install
small seal rings on valve body, then install
end cover, washers, and screws. Assemble
seal ring, cover plate, and retaining ring
at opposite end of valve body.
g. Install Steering Gear.
(1) Position steering gear for mounting. Install
mounting screws, washers, and nuts. Do
not tighten mounting screws until jacket
tube bracket is correctly adjusted. With
jacket tube bracket clamp screw loose,
fasten strap to bracket with shims, screws,
(3) Install steering wheel and nut, base plate,
contact cap, spring, contact cup, and horn
button. Connect horn cable to contact
brush.
(4) Connect steering linkage to pittman arm.
Connect hydraulic hoses to control valve.
Install floor plates.
46. Power Steering Cylinder
a. Description. The power steering cylinder is of
the double acting type and is interconnected in the
steering linkage. Its function is to assist the operator in steering the vehicle through the use of
hydraulic pressure.
b. Operation. In operation, the steering gear control valve directs hydraulic pressure to the appropriate cylinder port for right or left steering. Hydraulic pressure applied to the cylinder piston
extends or compresses the double acting cylinder.
This action, in turn, is transmitted to the steering
linkage to assist manual steering effort.
c. Removal. Refer to TM 10-3930-235-20.
d. Disassembly of Cylinder (fig. 54).
(1) R e m o v e s c r e w s , w a s h e r s , a n d e n d p l a t e
from cylinder.
(2) Remove retaining ring from bore of cylinder, then withdraw gland and rod and
piston assembly from cylinder.
(3) Remove gland from piston rod.
(4) To remove seals from gland, remove retaining ring, spacer washer, oil seal, spacer
washer, retaining ring, backup ring, and
seal ring.
69
Figure 54. Power steering cylinder, exploded view.
and
oil
seal
disassembled.
(5) To disassemble piston and rod, remove
nut, spacer washer, and piston from piston
rod. Remove piston rings from piston.
e. Inspection.
(1) Inspect for scored piston or rings which
would cause pressure leak or binding in
cylinder. Replace faulty rings. If piston
is faulty, replace cylinder assembly.
(2) Inspect piston rod surface for scoring or
defects that would cause damage to a new
oil seal. Replace cylinder assembly, if
piston rod is faulty. Replace seal rings
Section Xiii.
48. Rear Springs (MHE-191)
each
time
cylinder
is
f. Repair. Replace faulty parts as necessary. Always use new seals and gaskets when reassembling.
g. Reassembly. Reverse procedures in d a b o v e .
h. Installation. Refer to TM 10-3930-235-20.
47. Power Steering Control Valve
This valve is a component of the steering gear
assembly and instructions for removal, inspection,
repair, and reassembly will be found under “Disassembly of Steering Gear” (para. 45d). See figure
53.
SPRINGS
d. Inspection and Repair. Inspect spring assem-
a. Removal. Refer to paragraph 38a for removal
of steering axle and spring assembly.
blies for broken leaves. Replace broken main leaf
b. Remove Spring from Axle. R e m o v e l o c k n u t s ,
nuts, and U-bolts, then remove spring assemblies
from axle beam.
broken. Inspect shackle bolt and main leaf bushing,
c. Disassembly (fig. 55).
(1) Press shackle bushing out of spring main
leaf if necessary.
(2) Clamp spring in an arbor press and remove
nut and center bolt. Spread spring clips
enough to clear width of main leaf. Release press slowly and remove leaves.
70
or replace spring assembly if other leaves are
for wear or damage. If new main leaf bushing is
installed, shackle bolt should fit without binding.
Ream bushing as necessary.
e. Reassembly. Reverse procedures in c a b o v e .
f. Install Spring on Axle. Reverse procedures in
b above.
g. Installation. Reverse procedures in paragraph
38a.
Figure 55. Spring (MHE-191).
Section XiV. BODY
49. Seat and Backrest Cushions
a. Removal and Installation. Refer to TM 103930-235-20.
b. Inspection and Repair.
(1) Inspect cushion and backrest for wear, rips,
and other visible damage. If it is possible
Section XV.
50. Hydraulic Pump
a. Removal.
(1) Raise and block up vehicle to a suitable
working height.
(2) Disconnect and cap hydraulic lines at
pump.
(3) Remove cap screws and washers, then remove pump and gasket from timing gear
cover. Discard gasket. Remove fittings
from pump as necessary.
b. Disassembly (fig. 56).
to do so, install new covers on cushions.
(2) Inspect seat frame for bends, breaks, and
distortion. If it is possible to do so,
straighten bends and distortions. Repair
breaks by welding.
(3) Replace faulty parts as necessary.
HYDRAULIC LIFT
(1) S c r i b e a m a r k a c r o s s c o v e r s a n d b o d y .
Remove retaining ring and loosen set
screw, then remove coupling gear from
pump shaft. Remove key.
(2) Remove screws and washers, then separate
front cover from body. Remove oil seal
from cover.
(3) Remove seal ring, gasket seal, and spacer
from front cover groove.
(4) Remove front cover drive and driven bearings, drive gear and shaft, driven gear and
shaft, and body drive and driven bearings.
71
Figure 56. Hydraulic pump, exploded view.
Note. Mark
if
they
are
bearings
used
in
to
facilitate
identification
reassembly.
(5) Remove screws and washers, then separate
rear cover from body. Remove seal ring
from cover groove.
(6) Do not remove dowel pins from body unless replacement is necessary.
c . C l e a n i n g . Clean all parts with SD and dry
thoroughly with compressed air.
d. Inspection and Repair.
(1) Inspect bearings for nicks, grooves, or deep
scoring. I n s p e c t g e a r s f o r c h i p p e d o r
broken teeth. Inspect covers and body for
cracks, stripped threads, or damage.
(2) If original bearings are to be reused, nicks,
scratches, or scoring can be removed by
dressing bearing faces on a piece of crocus
cloth placed on a flat surface plate. Dress
bearings by rubbing lightly over the cloth
in a circular motion until a smooth finish
72
is obtained. Bearing diameters and surfaces must be parallel, square, and concentric with each other.
e. Reassembly. Reverse procedures in b a b o v e
except, if new bearings are to be installed, it may
be necessary to dress the flats to facilitate installation. To dress the flats, place both bearings of a set
end to end on a shaft that accurately fits the bearing bores. Hold flats squarely against a piece of
crocus cloth placed on a flat surface plate. Move
bearings lightly over cloth in a circular motion.
Check for correct fit of bearings in bore after each
stroke. Bearings must not bind or wedge when
installing.
f. Installation. Reverse procedures in a above.
g. Test Pump. Refer to paragraph 52.
51. Hydraulic Control Valve
a. Removal.
(1) Remove screws and washers, then remove
control valve hood.
Figure 57. Hydraulic control valve, exploded view.
73
(2) Remove cotter pins and clevis pins to disconnect links at control valve plungers.
(3) Disconnect hydraulic lines at valve and
catch oil in a receptacle.
(4) Remove bolts, nuts, and washers, then remove control valve from mounting plate.
(5) Remove fittings from valve if necessary.
b. Disassembly (fig. 57).
(1) R e m o v e s c r e w s f a s t e n i n g p l u n g e r c a p s ,
then remove plunger caps and withdraw
plungers by grasping spring end. Mark
plungers for identification in reassembly.
Clamp plunger assembly in a soft-jawed
vise. Compress plunger spring, then remove cap screws and outer spring seats.
Release spring tension slowly, then remove
spring and inner spring seats.
(2) Remove wiper seal retainer plates, wiper
seals, and wiper seal support rings from
each end of the housing.
(3) Remove relief valve plug, seal ring, relief
valve spring, and relief valve poppet.
(4) Unscrew and remove castle nut. Loosen
adjusting screwnut, then unscrew adjusting
screw with nut assembled. Unscrew and
remove relief valve adjusting plug. Remove relief valve pilot plug and seal ring.
Remove relief valve pilot spring and spring
guide from bore of relief valve seat.
(5) Unscrew and remove check valve plug and
seal ring. Remove check valve spring and
poppet from housing bores.
c. Inspection and Repair.
(1) Wash all parts in SD and dry thoroughly
with compressed air.
(2) Blow out all passages in body with compressed air.
(3) Replace all broken or distorted springs.
(4) Inspect plungers for grooves or wear. See
that plungers fit in body with a slight
hand pressure. There should not be any
perceptible side clearance. If plunger is
faulty or if body bore is scored, replace
entire valve.
(5) Inspect relief valve poppet seat and its
mating seat in housing for nicks or
scratches.
(6) Replace faulty parts as necessary.
d. Reassembly. Reverse procedures in b a b o v e
74
except do not attempt to adjust relief valve to its
proper setting at this point. Refer to paragraph 52
to adjust relief valve and paragraph 53 to adjust
lowering speed.
e. Installation. Reverse procedures in a a b o v e .
52. Adjust Relief Valve
a. Description. The relief valve “blows off” or
unloads pressure when operating cylinders have
reached their maximum extent of operation When
the oil pressure is above the predetermined maximum value, the valve plunger is forced off its seat
and the oil is bypassed back to the supply tank.
When the pressure is lowered to its correct maximum value, the spring overcomes the oil pressure,
forces the valve plunger on its seat, closes the valve,
and stops further decrease in pressure.
b. Adjustment. The relief valve is adjusted and
set at the factory and should only require adjustment after overhaul. To test hydraulic pump output after overhaul and to regulate the hydraulic
system pressure after overhaul of control valve,
proceed with the following steps:
(1) Remove 1¼-inch pipe plug from fitting in
control valve, and install a 0-3000-psi
gage.
(2) Remove acorn nut from relief valve. Hold
jamnut and back off adjusting screw until
no tension is felt on relief valve.
(3) Start engine and operate at 2,250 rpm.
(4) O p e r a t e t i l t c y l i n d e r i n e i t h e r d i r e c t i o n
and hold until (5) below is completed.
(5) Turn adjusting screw clockwise until gage
registers 1950 psi. Hold screw and tighten
jamnut. Secure with acorn nut.
(6) To make certain hydraulic pump is producing sufficient volume after overhaul,
operate control valve and check rate of
lifting speed. Lifting speed should be 85
feet per minute. If speed is within this
limit, pump is producing sufficient volume
and the system is regulated correctly.
53. Adjust lowering Speed
The single acting plunger cap (fig. 57) is equipped
with an adjusting screw and a locknut for controlling the “lowering speed” of the load. If this
adjustment was disturbed during valve repair, it
will be necessary to readjust the “lowering speed”.
Trucks shipped from the factory have been set for
Figure 58
Tilt cylinder, exploded view.
maximum “lowering speed,” loosen locknut and turn
the adjusting screw “in”. Tighten locknut when
proper “lowering speed” has been determined.
54. Tilt Cylinder
a. Removal. Refer to TM 10–3930-235–20.
b. Disassembly (fig. 58).
(1) L o o s e n s c r e w a n d w a s h e r , t h e n r e m o v e
pivot eye from piston rod. If replacement
of bushing is necessary, remove snap rings,
then remove bushing using an arbor press.
(2) Unscrew packing nut from stuffing box,
then remove wiper ring and packing.
except when installing piston rod packing in stuffing
box, make certain that the ring lip is worked in
smoothly and that ring is not twisted or distorted.
Use a small screwdriver to start rings into stuffing
box, then use a blunt end tool to push the rings to
the bottom of the stuffing box. First install the
molded forming ring (flat side down), then install
four leather rings, one rubber ring, one leather ring,
one rubber ring, in that sequence and repack the
remaining area in the stuffing box with leather rings
until there is 0- to l/6-inch compression after gland
nut is tightened.
N o t e . For
should
(3) Using a spanner wrench or equivalent tool,
unscrew stuffing box from tube. Remove
seal ring and leather washer from box.
(4) Pull piston rod assembly from tube. To
disassemble piston rod, remove locknut,
nut, and piston from piston rod. Remove
packing and seal ring from piston. Remove
spacer from piston rod.
c. Inspection and Repair.
(1) Inspect bushings in pivot eye for scored or
worn condition. Inspect pivot pins for
worn or scored condition. Replace faulty
parts.
(2) Inspect the piston rod surface that contacts packing for scoring or defects that
will wear or damage packing. Replace
faulty piston rod.
(3) Replace seals, packings, and wiper rings
when reassembling cylinder.
d. Reassembly. R e v e r s e p r o c e d u r e s in b a b o v e
correct
adjustment
b e +s- t o ?z-inch
stuffing
box.
of
packing
to
adjust
This
nut.
the
gap
Add
gap
provides
or
of
packing
between
subtract
rings,
packing
space
for
leather
future
rings,
as
there
gland
and
adjustment
necessary,
gap.
c. Installation. Refer to TM 10-3930-235-20.
55. Lift Cylinder
a. General. B e f o r e r e m o v i n g o r d i s a s s e m b l i n g
lift cylinder for repairs, it is suggested that a thorough inspection of the cylinder be performed as
indicated in b b e l o w .
b. Inspection and Repair (fig. 59).
Note. The
replaced,
replace
if
the
necessary
to
two
top
packings
necessary,
with
packing
at
remove
the
the
of
the
the
lift
bottom
cylinder
lift
cylinder
cylinder
can
be
installed.
To
of
the
cylinder,
from
the
mast
it
is
column.
(1) If oil is seeping past any of the packing
nuts, tighten nuts. If leak does not stop or
if leak is excessive, continue inspection of
cylinder.
(2) Raise carriage high enough to expose all
polished surfaces of the cylinder plungers.
75
Figure 59. Lift cylinder, exploded view.
76
Carefully inspect these exposed surfaces
for scratches or scored condition. Remove
scratches or score marks, using an india
stone. If plungers will not clean up to a
smooth finish, it is recommended that the
cylinder be replaced.
Note. If a cylinder, with a scratched or scored
plunger
is
repacked,
the
new
packing
will
soon
be cut and will leak oil.
(3) If plungers are in good condition, repack
cylinder as follows: Unscrew and remove
packing nut using a spanner wrench to
prevent damaging nut. Pull out old packing rings, using a sharp pointed tool. Make
certain all old packing material is removed
from stuffing box, then proceed to install
new packing. When installing rings, make
certain that the ring lip is worked in
smoothly and that ring is not twisted or
distorted. Use a small screwdriver to start
rings into stuffing box. Then use a bluntend tool to push the rings to the bottom
of the stuffing box. First, install the
molded forming ring (flat side down). This
ring provides a seat for the succeeding
rings. Then install four leather rings, one
rubber ring, one leather ring, one rubber
ring, in that sequence and repack the remaining area in the stuffing box with
leather rings until there is 0- to l/16-inch
compression after gland nut is tightened.
Note
rings,
1. For
there
packing
vides
Add
gland
space
or
adjust
for
the
and
future
cylinder.
adjustment
leather
rings
of
packing
gap
This
of
as
between
gap
pro-
packing
nut.
required
to
gap.
After
packing
a
few
may
tend
growling
noise
condition
occurs,
one-quarter
smoothly
adjustment
b e A- to &-inch
nut
subtract
N o t e 2.
inder
correct
should
when
turn
without
days
to
hoist
loosen
until
operation
swell,
is
the
the
the
resulting
operated.
cylinder
If
packing
plunger
cylin
a
this
nut
operates
noise.
c. Removal (fig. 59).
(1) R e m o v e s c r e w s a n d w a s h e r s , t h e n l i f t
backrest off carriage.
(2) Remove forks.
(3) Raise carriage until mast inner column is
lifted about l0 inches. Block carriage and
inner slide in this position.
(4) R e m o v e c o t t e r p i n s , t h e n d r i v e o u t p i n
fastening lift cylinder to mast inner col-
umn. Lower the lift cylinder plunger to
disconnect from the inner column.
(5) Disconnect hydraulic line and catch oil in
a receptacle.
(6) Disconnect chains at lift cylinder, then lift
off crosshead and rollers.
(7) Remove setscrew fastening lift cylinder at
bottom of stationary mast column.
(8) Raise cylinder up and out of mast column.
d. Installation. Reverse procedures in c a b o v e .
e. Disassembly.
(1) Remove secondary cylinder packing nut,
follower ring, and packing from secondary
cylinder tube. Remove wiper ring from
packing nut.
(2) Unscrew and remove secondary cylinder
cap from secondary cylinder tube. Remove backing ring and seal ring from cap.
Do not remove bleeder screw and gasket
unless replacement is necessary.
(3) P u s h s e c o n d a r y c y l i n d e r p l u n g e r o u t o f
secondary cylinder tube. Remove guide
rings from plunger.
(4) Remove primary cylinder plunger packing
nut, follower ring, and packing from primary cylinder plunger tube. Remove
wiper ring.
(5) Remove setscrew and lock plug from primary cylinder tube. Unscrew and remove
locking ring. Remove secondary cylinder
tube. Remove backing ring and seal ring
from secondary cylinder tube.
(6) R e m o v e p r i m a r y c y l i n d e r t u b e p a c k i n g
nut, follower ring, and packing from primary cylinder tube. Remove primary cylinder plunger tube from primary cylinder
tube. If necessary, remove retaining ring
and guide ring from primary cylinder
plunger tube. Remove bleeder screw and
gasket from primary cylinder tube, if
necessary.
f. Reassembly. Follow procedures in e a b o v e ,
except as follows:
(1) Secondary cylinder plunger is fitted with
two guide rings which ride in the inside
diameter of the secondary cylinder tube.
(2) When a new secondary cylinder tube is
required during overhaul, it will be necessary to measure the inside diameter to
77
determine selection of the proper guide
f. Installation. Reverse procedures in a a b o v e .
rings to be used. Select the proper guide
ring from the following chart.
S,,c,, r,,{,,,, c, l,,, dm’ tul),.
(1,15, (1,, d,:, r,l,.t,, r)
2 4%5
2.4!)()
2.4!)5
2.500
I
Gu, de ring Icqu, red,
part rl”lnl,er
T
5 7 . Mast Carriage
a. R e m o v a l .
(1) Remove forks.
22325-Cl
22325–C2
22325-C3
2232SC4
(2) R e m o v e b a c k r e s t .
(3) Raise carriage about 2 feet above floor
level and block in this position. Disconnect chains at carriage.
56. Mast Assembly
(4) Remove carriage stop screws and washers
a. Removal.
at top of outer mast column. Raise car-
(1) Remove carriage backrest.
(2) Remove forks.
(3) Remove carriage (para. 57).
riage up and out of mast column.
b. Disassembly (fig. 60).
(1) Remove roller pin and shims from outside
(4) Remove lift cylinder (para. 54).
of carriage bracket.
(5) Support mast column with a chain hoist,
(2) Remove roller assembly from side of carriage bracket. Remove thrust washers and
then remove snap rings and pivot pins at
tilt cylinder pivot eye.
bearing from roller.
(6) Remove nuts, screws, blocks, and bushings,
then lift mast column off mast tilt shaft,
using chain hoist or equivalent mechanism.
(1) To separate inner and outer mast column,
slide columns apart.
(2) With columns separated remove wear strip
shims and wear plates.
Inspect carriage for broken welds and reweld if
necessary.
d. Reassembly.
mine quantity of shims necessary to pro-
(1) Clean parts thoroughly with SD and dry
vide 0.020-inch clearance between roller
pin and narrowest sliding width of inner
with compressed air.
for fractures or
breaks in welds.
d. Repair. No repairs are feasible except that, if
broken, they can be rewelded. Care should be taken
to avoid excessive heat which could cause distortion
of the columns.
e. Reassembly. Reverse procedure in b a b o v e
except that wear strips arc provided at eight places
in the mast inner column. When reassembling and
shimming for the required clearance of 0.015 to 0.025
inch, add wear strip shims to the rear wear strips
78
bearing for scoring or flat spots. Temporarily install
(1) Before installing carriage rollers, deter-
c. Cleaning and Inspection.
only.
I n s p e c t i o n a n d R e p a i r . Inspect roller and
bearing on roller pin and check for free rotation.
b. Disassembly (fig. 60).
(2) Inspect both columns
C.
mast column.
(2) To assemble rollers, place bearing in roller
and one thrust washer on each side of
roller.
(3) Place necessary shims on roller pin, then
position roller assembly in carriage bracket
and insert roller pin assembly from the
outside of the carriage bracket and through
the roller assembly. Roller pins are held
in place when the carriage is installed in
the inner mast column.
e. Installation. Reverse procedures in b a b o v e .
Figure 60. Mast column and carriage, exploded view.
79
58. Hydraulic Oil Tank
a. Removal (fig. 61).
(1) Drain oil from tank by removing drain
plug.
(2) Disconnect hydraulic lines and catch any
remaining oil from the lines.
(3) Remove screws and washers fastening tank
to cowl. Remove oil tank.
b. Installation. Reverse procedures in a a b o v e .
Fill tank to proper level. Start engine and inspect
for leaks.
Figure 61. Hydraulic oil tank, exploded view.
80
APPENDIX I
REFERENCES
AR 310-1
General Policies.
AR 320-5
Dictionary of United States Army Terms.
AR 320-50
Authorized Abbreviations and Brevity Codes.
AR 600-55
Motor Vehicle Driver Selection, Testing, and Licensing.
AR 750-5
Organization, Policies, and Responsibilities for Maintenance Operation.
AR 700-58
Report of Damaged or Improper Shipment.
AR 700-3900-5
Registration of Materials Handling Equipment and Special Purpose Vehicles.
AR 743-505
Limited Storage of Engineers Mechanical Equipment.
AR 746-5
Color and Marking of Army Materiel.
AR 750-5
Organization, Policies, and Responsibilities for Maintenance Operations.
AR 750-3900-1
Materials Handling Equipment.
AR 754-9130-1
Utilization of Automotive Gasoline.
FSC 9100-IL
Fuels, Lubricants, Oils, and Waxes.
DA Pam 108-1
Index of Army Motion Pictures, Filmstrips, Slides, Tapes, and Phono-Recordings.
DA Pam 310-1
Index of Administrative Publications.
DA Pam 310-2
Index of Blank Forms.
DA Pam 310-3
Index of Doctrinal, Training, and Organizational Publications.
DA Pam 310-4
Index of Technical Manuals, Technical Bulletins, Supply Manuals (types 4, 6, 7,
8, and 9), Supply Catalogs (type CL) Supply Bulletins, Lubrication Orders,
and Modification Work Orders.
DA Pam 310-5
Index of Graphic Training Aids and Devices.
DA Pam 310-25
Index of Supply Manuals - Engineers Type Items.
FM 5-25
Explosive and Demolition.
FM 21-5
Military Training.
FM 21-6
Techniques of Military Instruction.
FM 21-30
Military Symbols.
TB ENG 60
Preservation and Painting of Serviceable Corps of Engineers Equipment.
TB ENG 347
Winterization Techniques for Engineer Equipment.
TM 5-687
Repair and Utilities: Fire Protection Equipment and Applications: Inspection,
Operations, and Preventive Maintenance.
TM 5-764
Electric Motor and Generator Repair.
TM 9-200
General Packaging Instructions for Ordnance General Supplies.
TM 9-6140-200-15
Operation and Organizational, Field and Depot Maintenance: Storage Batteries,
Lead-Acid Type.
81
TM 10–3930–235–10
TM 10-3930-235-20
TM 10-3930-235-20P
TM 10-3930-235-35P
TM 11-483
TM 21-300
TM 38-230
TM 38-750
MIL-STD-162A
LO 10-3930-235-20
82
Operator’s Manual: Truck, Lift, Fork, Gasoline, Solid and Pneumatic Tired
Wheels, 4,000 Lbs. Capacity, Towmotor Models 462SG4024-100 (Solid Tire),
462SG4024-144 (Solid Tire), 502PG4024-144 (Pneumatic Tire), FSN’S 3930781-3856, 3930-78l-3855 and 3930-073-9222 respectively. Army Model MHE191 (462SG4024-100 and 462SG4024-144), MHE-190 (502PG4024-144).
Organizational Maintenance Manual; Truck, Lift, Fork, Gasoline, Solid and
Pneumatic Tired Wheels, 4,000Lbs Capacity, Towmotor Models 462SG4024100 (Solid Tire), 462SG4024-144 (Solid Tire), 502PG4024-144 (Pneumatic
Tire), FSN’S 3930-781-3856, 3930-781–3855 and 3930-073–9222 respectively.
Army Model MHE-191 (462SG4024-100 and 462SG4024-144), MHE-190
(502PG4024-144).
Organizational Maintenance Manual; Repair Parts and Special Tools List; Truck,
Lift, Fork, Gasoline, Solid and Pneumatic Tired Wheels, 4,000 Lbs Capacity,
Towmotor Models 462SG4024-100 (Solid Tire), 462SG4024-144 (Solid Tire),
502PG4024-144 (Pneumatic Tire), FSN’S 3930-781-3856, 3930-781-3855 and
3930-073-9222 respectively. Army Model MHE-191 (462SG4024-100 and
462SG4024-144), MHE-190 (502PG4024-144).
Direct and General Support, and Depot Maintenance Repair Parts and Special
Tools List; Truck, Lift, Fork, Gasoline, Solid and Pneumatic Tired Wheels,
4,000 Lbs Capacity, Towmotor Models 462SG4024-100 (Solid Tire), 462SG4024-144 (Solid Tire), 502PG4024-144 (Pneumatic Tire), FSN’S 3930-7813856, 3930-781-3855 and 3930-073-9222 respectively. Army Model MHE-191
(462SG4024-100 and 462SG4024-144), MHE-190 (502PG4024-144).
Radio Interference Suppression.
Driver Selection and Training (Wheeled Vehicles).
Preservation, Packaging, and Packing of Military Supplies and Equipment.
Army Equipment Record Procedures.
Preparation for Delivery of Warehouse Materials Handling Equipment for
Domestic and Oversea Shipment and Storage.
Lubrication Order; Truck, Lift, Fork, Gasoline, Solid and Pneumatic Tired
Wheels, 4,000 Lbs Capacity, Towmotor Models 462SG4024-100 (Solid Tire),
462SG4024-144 (Solid Tire), 502PG4024-144 (Pneumatic Tire), FSN’S 3930781-3856,3930-781-3855 and 3930-073-9222 respectively. Army Model MHE191 (462SG4024-100 and 462SG4024-144), MHE-190 (502PG4024-144).
INDEX
Paragraph
Page
Adjustments:
21e
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
Clutch neutral setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential adjustments:
37g
Bearinga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37h
Bevel gear to pinion backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37f
Bevel pinion bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic lift adjustment:
Lift cylinder packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55b(3)
53
Lowering speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57d
Mast carriage rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56e
Mast column clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ...... . . .
54d
Tilt cylinder packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45b
Axles:
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . 37
39
Steering (MHE-190) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Steering (MHE-191) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. ..... ..
63
57
66
Brakes:
Bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master cylinder, service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking brakeshoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service brakeshoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel cylinder, service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
40
43
40
41
41
62
59
62
59
60
60
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carriage, mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .
Changes, recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances and fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creeper pedal and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cushions, seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders:
Lift, hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilt, hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission shift operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21e
57
1b
6
23
34
49
31
31
78
2
2
34
48
71
55
40
46
54
33
41
75
59
69
75
47
60
Data, tabulated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... . . . . . . . . . . . .
Differential:
Bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel gear to pinion adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive axle data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2
37g
37h
37f
37
6
56
56
56
53
2
31
46
56
56
56
77
74
78
78
74
75
65
83
Paragraph
Electrical system:
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine:
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .
Disassembly of engine subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of engine into subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of accessories on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly of engine subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of engine accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . .
Run-in procedures after overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
6
24
27
2
34
36
6
12
11
13
17
9e
16
15
9
10
14
20
2
16
15
20
28
10
27
26
8
13
24
29
Forms and records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... ...
6
Fuel system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
31,32
2
Gear, steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
24
22
64
34
32
Hydraulic system:
Carriage, speed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mast assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mast carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
51
6
66
66
67
58
60
52
64
74
72
2
75
78
78
80
71
74
76
Joint, universal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
52
Lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linkage, transmission creeper pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Linkage, transmission shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
66
34
36
76
48
49
Mast assembly,lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master cylinder, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, starting, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
40
27
78
69
36
Oil pressure relief valve, hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure, power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
30b
44f
4
74
40
64
2
43
Parking brakeshoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . .
40
Pedal, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering:
46
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 44
44 f
Pump preseure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pumps:
60
Hydraulic lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
69
84
69
62
64
71
62
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Records and forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
References (App I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paragraph
23
lb
3
49
Seat cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
Service brakeshoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Shifter control valve, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Shift lever, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift operating cylinder, transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
43
Shoes, parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
Shoes, service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Springs, rear (MHE-191) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27
Starting motor, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering:
Axle (MHE-190) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
38
Axle (MHE-191) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
Cylinder, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45b
Gear adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
Pump, hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
2
2
81
71
60
46
49
47
62
60
70
36
57
56
69
64
65
62
Tests:
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting motor . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission:
Clutch neutral setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creeper pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil preasure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifter control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift operating cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
44f
29
54
36
64
38
75
31
34
6
30a
30b
32
35
33
8
46
48
2
39
40
46
49
47
5
Universal joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
52
Valves:
Hydraulic lift control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission shifter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
32
72
46
Wheel cylinder, brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
60
85
By Order of the Secretary of the Army:
HAROLD K. JOHNSON,
General, United States Army,
Chief of Staff.
Official:
J. C. LAMBERT,
Major General, United States Army,
The Adjutant General.
Distribution:
Active Army:
USASA (1)
DCSLOG (1)
CNGB (1)
CAR (1)
USAMC (12)
USAMOCOM (2)
USAWECOM (5)
USAMICOM (5)
USAMUCOM (5)
USAECOM (5)
USATECOM (5)
USASMC (1)
USCONARC (2)
CofEngrs (6)
CofSpts (1)
Directorate of Transportation (1)
CC-E (1)
ARADCOM (2)
ARADCOM Rgn (2)
OS Maj Comd (3)
LOGCOMD (1)
MDW (1)
Armies (5)
USA Mbl Equip Cen (46)
NLABS (4)
Svc Colleges (2)
Br Svc Sch (2) except
USAQMS (10)
USMA (1)
Army Dep (4)
POE (OS) (2)
USA Tml Comd (2)
Army Tml (2)
Arsenals (2)
PG (2)
Instl (2)
QM Fld Maint Shops (2)
Units org under fol TOE :-2 ea.
5-267
5-347
10-22
10-105
10-106
10-107
10-349
10-407
10-446
10-447
10-448
10-521
11–155
11-158
1 1–159
11-415
12-512 (X, Y, Z)
55-117
NG: State AG (3).
USAR: None.
For explanation of abbreviations used, see AR 320-50.
* U.S. GOVERNMENT PRINTING OFFICE : 1991 0 - 281–486 (42803)
86
PIN : 027697-000
This fine document...
Was brought to you by me:
Liberated Manuals -- free army and government manuals
Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly
available information, slap “watermarks” and other junk on it, and sell it.
Those masters of search engine manipulation make sure that their sites that
sell free information, come up first in search engines. They did not create it...
They did not even scan it... Why should they get your money? Why are not
letting you give those free manuals to your friends?
I am setting this document FREE. This document was made by the US
Government and is NOT protected by Copyright. Feel free to share,
republish, sell and so on.
I am not asking you for donations, fees or handouts. If you can, please
provide a link to liberatedmanuals.com, so that free manuals come up first in
search engines:
<A HREF=http://www.liberatedmanuals.com/>Free Military and Government Manuals</A>
– Sincerely
Igor Chudov
http://igor.chudov.com/
– Chicago Machinery Movers