TM-10-4320-344-24

*TM 10-4320-344-24
TECHNICAL MANUAL
UNIT, DIRECT SUPPORT, AND
GENERAL SUPPORT MAINTENANCE MANUAL
TABLE OF CONTENTS
EQUIPMENT DESCRIPTION
UNIT TROUBLESHOOTING
PUMPING ASSEMBLY, WATER, 600 GPM,
MODEL 609-A
(NSN 4320-01-184-7494)
PUMPING ASSEMBLY, WATER, 600 GPM,
MODEL 609-C
(NSN 4320-01-261-6470)
PUMPING ASSEMBLY, WATER, 600 GPM,
MODEL US636HCCD-1
(NSN 4320-01-201-6937)
GLOSSARY
INDEX
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
* This manual, together with TM 10-4320-344-10, TM 10-4320-303-13, and LO 10-4320-344-12,
supersedes TM 5-4320-303-10 dated 14 April 1986 and TM 5-4320-303-24 dated 13 June 1986.
HEADQUARTERS, DEPARTMENT OF THE ARMY
28 FEBRUARY 1994
TM 10-4320-344-24
FLAMMABLE MATERIAL
.
Do not operate engine around open fuel. Fuel presents an extreme
explosion and fire hazard. Ensure fuel lines are securely connected and
free of leaks. Never refuel hot or running engine. Avoid overfilling
fuel tank. Always use correct type of fuel.
.
To prevent fires or explosion, keep open flame, sparks, and cigarettes away
from fuel tank and battery.
SOLVENT
.
Solvent may cause toxic fumes. To prevent personal injury, work only in
well-ventilated area. DO NOT breathe fumes for a long period of time.
serious personal injury may result from inhalation of toxic fumes.
.
Solvent is flammable. To prevent fire or explosion, DO NOT bring open flame
or sparks near solvent.
OVERHEATED PUMP
DO NOT operate pump against a closed suction or discharge line. This can cause
overheating and explosion. Death or injury may result.
HEARING DAMAGE
To prevent hearing loss, hearing protection must be worn by personnel standing
within 50 feet (15.2 m) of operating pump.
COMPRESSED AIR
To prevent loss of eyesight or personal injury proper personal protection
equipment must be worn when using compressed air.
ELECTRIC SHOCK
To prevent electric shock, or death, always disconnect power before performing
maintenance.
SKIN BURNS
To prevent skin burns, do not touch hot engine or parts. Allow engine to cool
before performing maintenance.
Remove all jewelry prior to performing any preventive maintenance checks and
services or maintenance procedures.
FOR FIRST AID, REFER TO FM 21-11.
a/(b Blank)
*
TM 10-4320-344-24
HEADQUARTERS
DEPARTMENT OF ARMY
WASHINGTON D.C., 28 February 1994
TECHNICAL MANUAL
NO. 10-4320-344-24
UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT
MAINTENANCE MANUAL
FOR
PUMPING ASSEMBLY, WATER, 600 GPM, Model 609-A
(NSN 4320-01-184-7494)
PUMPING ASSEMBLY, WATER, 600 GPM, Model 609-C
(NSN 4320-01-261-6470)
PUMPING ASSEMBLY, WATER, 600 GPM, Model US636HCCD-1
(NSN 4320-01-201-6937)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to
improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located
in back of this manual direct to: Commander, US Army Aviation and Troop Command,
ATTN: AMSAT-I–MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. A reply will be
furnished to you.
Distribution Statement A. Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
Page
CHAPTER 1
HOW TO USE THIS MANUAL .
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INTRODUCTION
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Section I
General
Section II
Equipment
Section
Principles
III
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Information .
Description.
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TABLE OF CONTENTS
Operation.
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vii
1-1
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1-1
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1-2
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1-8
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UNIT MAINTENANCE . . . . . . . . . . . . . . . . . . .
2-1
Section I
Repair Parts; Special Tools; Test, Measurement,
and Diagnostic Equipment (TMDE) ; and Support Equipment .
2-2
Section II
Service Upon Receipt .
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2-2
Section
Unit Preventive Maintenance
Checks and Services (PMCS)
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2-5
CHAPTER 2
III
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*This manual, together with TM 10-4320-344-10, TM 10-4320-303-13 and LO 10-4320-344-12 supersedes
TM 5-4320-303-10 dated 14 April 1986 and TM 5-4320-303-24 dated 13 June 1986.
i
TM
10-4320-344-24
TABLE OF CONTENTS - CONTINUED
Page
Section IV
Unit Troubleshooting
Section V
Unit
Section VI
Preparation
CHAPTER 3
Section I
Maintenance
for
Procedures
Shipment
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and
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2-29
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Storage
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2-37
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2-419
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DIRECT SUPPORT MAINTENANCE . . . . . . . . . . . . . . .
3-1
Repair Parts; Special Tools; Test, Measurement,
and Diagnostic Equipment (TMDE); and Support Equipment .
3-2
Section II
Direct Support Troubleshooting
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3-2
Section
Direct Support Maintenance Procedures
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3-8
GENERAL SUPPORT MAINTENANCE PROCEDURES
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4-1
Repair Parts; Special Tools; Test, Measurement,
and Diagnostic Equipment (TMDE); and Support Equipment .
4-2
III
CHAPTER 4
Section I
Section
II
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4-3
APPENDIX A
REFERENCES . . . . . . . . . . . . . . . . . . . . . . .
A-1
APPENDIX B
MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . .
B-1
Introduction
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B-1
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B-4
Section I
Section
II
General
Support
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Maintenance
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Procedures
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Maintenance Allocation Chart
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Section III
Tool
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B-12
Section IV
Remarks . . . . . . . . . . . . . . . . . . . . . . . . .
B-13
EXPENDABLE AND DURABLE ITEMS LIST . . . . . . . . . . . .
C-1
Section I
Introduction
Section
Expendable
APPENDIX C
and
Test
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C-1
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C-2
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . .
D-1
APPENDIX E
TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . .
E-1
APPENDIX F
SCHEMATICS AND WIRING DIAGRAMS . . . . . . . . . . . . .
F-1
List
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Items
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Durable
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Requirements
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II
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Equipment
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Section I
Abbreviations
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GLOSSARY-1
Section II
D e f i n i t i o n o f Unusual Terms . . . . . . . . . . . .
GLOSSARY-2
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ii
GLOSSARY-1
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INDEX-1
TM 10-4320-344-24
LIST OF ILLUSTRATIONS
Figure
1-1
1-2
1-3
1-4
1-5
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-24
2-25
2-26
2-27
2-28
2-29
2-30
2-31
2-32
2-33
2-34
2-35
2-36
2-37
2-38
2-39
2-40
2-41
2-42
2-43
2-44
2-45
2-46
2-47
2-48
2-49
2-50
2-51
2-52
2-53
2-54
2-55
Title
Location of Major Components, Model 609-A . . . . . . . . . . . . . .
Location of Major Components, Model 609-C . . . . . . . . . . . . . .
Location of Major Components, Model US636HCCD-1 . . . . . . . . . . .
Engine Functional Block Diagram . . . . . . . . . . . . . . . . . . .
Fuel System Functional Block Diagram . . . . . . . . . . . . . . . .
Pumping Assembly with Protective Plywood Cap . . . . . . . . . . . .
Pumping Assembly Model 609-A PMCS Routing Diagram . . . . . . . . . .
Pumping Assembly Model 609-C PMCS Routing Diagram . . . . . . . . . .
Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram . . . . . . .
Data Plate Replacement . . . . . . . . . . . . . . . . . . . . . . .
Removing or Repairing Studs or Screws . . . . . . . . . . . . . . . .
Removing Damaged Threaded Insert . . . . . . . . . . . . . . . . . .
Oversizing Insert Pilot Holes . . . . . . . . . . . . . . . . . . . Preparing Threaded Insert for Installation . . . . . . . . . . . . .
installing Threaded Insert . . . . . . . . . . . . . . . . . . . . .
Door Holder Assembly Replacement . . . . . . . . . . . . . . . . . .
Access Cover Assembly Maintenance . . . . . . . . . . . . . . . . . .
Door Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . .
Top Panel Assembly Maintenance . . . . . . . . . . . . . . . . . . .
Top Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Bulk Head Panel Assembly and Outlet Scoop Assembly Maintenance . . .
Right Side Panel Assembly . . . . . . . . . . . . . . . . . . . . . .
Control Panel Housing Assembly . . . . . . . . . . . . . . . . . . .
Left Side Panel Assembly . . . . . . . . . . . . . . . . . . . . . .
Left Rear Quarter Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Upper Cover Plates Maintenance . . . . . . . . . . . . . . . . . . .
End Panel Assembly Maintenance . . . . . . . . . . . . . . . . . . .
Sound Enclosure Straps . . . . . . . . . . . . . . . . . . . . . . .
Sound Enclosure Baffles . . . . . . . . . . . . . . . . . . . . . . .
Cooling Duct Assembly and Screen Assembly Maintenance . . . . . . . .
Bulkhead Panel Assembly and Belt Guards Maintenance . . . . . . . . .
Support Frame Assembly Maintenance . . . . . . . . . . . . . . . . .
Muffler Maintenance, Model 609-A . . . . . . . . . . . . . . . . . .
Muffler Maintenance, Model 609-C . . . . . . . . . . . . . . . . .
Muffler Maintenance, Model US636HCCD-1. . . . . . . . . . . . . . . .
Exhaust Pipe Assembly Maintenance . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly Maintenance, Model 609-A . . . . . . . . . . . .
Air Cleaner Assembly Maintenance, Model 609-C . . . . . . . . . . . .
Air Cleaner Maintenance, Model US636HCCD-1 . . . . . . . . . . . . .
Air Intake Hose Maintenance, Model 609-C . . . . . . . . . . . . . .
Air Intake Pipe Assembly Maintenance . . . . . . . . . . . . . . . .
Service Lights Maintenance . . . . . . . . . . . . . . . . . . . . .
Battery Box and Cover Maintenance, Model 609-A . . . . . . . . . . .
Battery Box Assembly Maintenance, Model 609-C . . . . . . . . . . . .
Battery Box and Cover Maintenance, Model US636HCCD-1 . . . . . . . .
Battery Cable Assembly Maintenance, Model 609-A . . . . . . . . . . .
Battery Cable Assembly and Power Cable Assembly
Maintenance, Model 609-C . . . . . . . . . . . . . . . . . . . . .
Electrical Connector Receptacle Maintenance . . . . . . . . . . . . .
Power Control Cable and Manual Throttle Control Cable Assembly . . .
Manual Throttle Control Cable and Power Control Cable Assembly
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sheathing and Cable Clamp Positioning . . . . . . . . . . . . . . . .
Power Control Cable Assembly Installation .’. . . . . . . . . . . . .
Limit Switch Assembly Maintenance . . . . . . . . . . . . . . . . . .
Start Alarm Relay Maintenance, Model 609-A . . . . . . . . . . . . .
Control Panel Cover Assembly Removal, Model 609-A . . . . . . . . . .
Control Panel Cover Assembly, Model 609-A . . . . . . . . . . . . . .
Control Panel Cover Assembly Removal, Model US636HCCD-1 . . . . . . .
Control Panel Assembly Disconnection, Model 609-A . . . . . . . . . .
Control Panel Assembly Removal and Installation, Model 609-A . . . .
Control Panel Assembly Removal and Installation, Model 609-C . . . .
Page
1-3
1-5
1-7
1-9
1-10
2-3
2-7
2-14
2-22
2-38
2-39
2-40
2-41
2-43
2-44
2-46
2-47
2-49
2-51
2-53
2-56
2-58
2-60
2-63
2-64
2-66
2-68
2-70
2-72
2-74
2-77
2-80
2-81
2-84
2-87
2-90
2-92
2-96
2-100
2-103
2-105
2-106
2-109
2-112
2-115
2-118
2-120
2-124
2-127
2-128
2-129
2-129
2-132
2-135
2-137
2-139
2-141
2-143
2-145
2-149
iii
TM 10-4320-344-24
LIST OF ILLUSTRATIONS - CONTINUED
Figure
2-56
2-57
2-58
2-59
2-60
2-61
2-62
2-63
2-64
2-65
2-66
2-67
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2-71
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2-73
2-74
2-75
2-76
2-77
2-78
2-79
2-80
2-81
2-82
2-83
2-84
2-85
2-86
2-87
2-88
2-89
2-90
2-91
2-92
2-93
2-94
2-95
2-96
2-97
2-98
2-99
2-100
2-101
2-102
2-103
2-104
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2-106
2-107
2-108
2-109
2-110
2-111
2-112
2-113
2-114
2-115
2-116
iv
Page
Title
Control Panel Assembly, Model US636HCCD-1 . . . . . . . . . . . . .
Control Panel Assembly Removal and Installation, Model US636HCCD-1
Pump Suction and Discharge Gauge Maintenance, Model 609-A . . . . .
Pump Suction and Discharge Gauge Maintenance, Model US636HCCD-1 . .
Low Oil Pressure Cutoff Switch Test . . . . . . . . . . . . . . . .
Oil Pressure Gauge Maintenance, Model US636HCCD-1 . . . . . . . . .
Engine Coolant Temperature Gauge Replacement . . . . . . . . . . .
Oil Pressure Gauge Maintenance, Model 609-C . . . . . . . . . . . .
Tachometer/Hourmeter Assembly Replacement . . . . . . . . . . . . .
Indicator Maintenance . . . . . . . . . . . . . . . . . . . . . . .
Engine Alarm Replacement . . . . . . . . . . . . . . . . . . . . .
Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Alarm Reset Replacement . . . . . . . . . . . . . . . . . .
Toggle Switch Maintenance . . . . . . . . . . . . . . . . . . . . .
Start Switch Maintenance . . . . . . . . . . . . . . . . . . . . .
Start/Stop Switch Maintenance . . . . . . . . . . . . . . . . . . .
Fuse Holder Replacement . . . . . . . . . . . . . . . . . . . . . .
Rheostat Maintenance . . . . . . . . . . . . . . . . . . . . . . .
Resistor Replacement, Model 609-C . . . . . . . . . . . . . . . . .
Control Panel Light Maintenance . . . . . . . . . . . . . . . . . .
Manual Throttle Control Cable Replacement . . . . . . . . . . . . .
Manual Throttle Control Cable Assembly Replacement, Model 609-C . .
Fuel Rack Cable Replacement . . . . . . . . . . . . . . . . . . . .
Auto Defeat Cable Maintenance . . . . . . . . . . . . . . . . . . .
Cold Start Aid Cable Replacement . . , . . . . . . . . . . . . . .
Pressure Regulator Replacement, Model 609-A . . . . . . . . . . . .
Pressure Control Module Replacement . . . . . . . . . . . . . . . .
Location of Engine Protection System Module . . . . . . . . . . . .
Location of Controlling Device, Model US636HCCD-1 . . . . . . . . .
Governor Control Module Maintenance . . . . . . . . . . . . . . . .
Governor Control Module Cover Removal . . . . . . . . . . . . . . .
Governor Control Module Adjustment with Cover Removed . . . . . . .
Process Control Device Maintenance . . . . . . . . . . . . . . . .
Process Control Device . . . . . . . . . . . . . . . . . . . . . .
Terminal Board Maintenance
Pressure Gauge Hose Assembly Diagram, Model 609-A . . . . . . . . . . .
Pressure Gauge Hose Assembly Diagram, Model 609-C . . . . . . . . .
Pressure Gauge Hose Assembly Diagram, Model US636HCCD-1 . . . . . .
Control Panel Maintenance, Model 609-A
Control Panel Maintenance, Model US636HCCD-1 . . . . . . . . . . . . .
Control Panel Frame, Model 609-A . . . . . . . . . . . . . . . . .
Control Enclosure Assembly . . . . . . . . . . . . . . . . . . . .
Base Weldment Maintenance . . . . . . . . . . . . . . . . . . . . .
Drain Plug and Primer Port Nipple Maintenance . . . . . . . . . . .
Suction Elbow and Discharge Elbow Replacement . . . . . . . . . . .
Hood Assembly Maintenance, Model 609-A . . . . . . . . . . . . . .
Rear Panel Assembly Maintenance, Model 609-A . . . . . . . . . . .
Shield Assembly Maintenance, Model 609-A . . . . . . . . . . . . .
Radiator Shell Assembly Removal, Model 609-A . . . . . . . . . . .
Radiator Shell Assembly . . . . . . . . . . . . . . . . . . . . . .
Cooling System Hoses Maintenance, Model 609-A . . . . . . . . . . .
Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Fan Shroud Maintenance, Model 609-A . . . . . . . . .
Radiator Supports and Radiator Shell Assembly Supports . . . . . .
Fuel System Bleeding . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lines, Oil Lines, and Fittings, Model 609-A . . . . . . . . .
Fuel Lines, Oil Lines, and Fittings, Model 609-C . . . . . . . . . . .
Fuel Lines, Oil Lines, and Fittings, Model US636HCCD-1 . . . . . .. . .
Fuel Solenoid Replacement, Model 609-C . . . . . . . . . . . . . .
Fuel Filter and Base Assembly Maintenance, Model 609-A . . . . . .
Fuel Filter and Base Assembly Maintenance, Models 609-C and
US636HCCD-1. . . . . . . . . . . . . . . . . . . . . . . . . .
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2-184
2-185
2-188
2-190
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2-199
2-202
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2-210
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2-218
2-220
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2-269
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2-272
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TM 10-4320-344-24
LIST OF ILLUSTRATIONS - CONTINUED
Figure
Title
Page
2-117
2-118
2-119
2-120
2-121
2-122
2-123
2-124
2-125
2-126
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2-138
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2-140
2-141
2-142
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Fuel Transfer Pump Assembly Servicing
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Fuel Transfer Pump Assembly Test
Fuel Transfer Pump Assembly Replacement . . . . . . . . . . . . .
Fuel Injection Lines and Fuel Leakoff Manifold Line Connections . . .
Fuel Injection Nozzle and Holder Assembly Removal, Model 609-A . . .
Fuel Injection Nozzle Removal, Models 609-C and US636HCCD-1 . . . . .
Fuel Injection Nozzle Test, Models 609-C and US636HCCD-1 . . . . . .
Cold Starting Aid Maintenance, Model 609-C . . . . . . . . . . . . .
V-Belt Guard Maintenance, Model US636HCCD-1 . . . . . . . . . . . . .
V-Belt Replacement, Models 609-C and US636HCCD-1 . . . . . . . . . .
Alternator Belt Maintenance, Model 609-A . . . . . . . . . . . .
Alternator Cover Maintenance, Model US636HCCD-1. . . . . . . . . . . . .
Generator Capacitor Replacement, Model 609-C . . . . . . . . . . . .
Alternator Test. . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Replacement . . . . . . . . . . . . . . . . . . .
Starter Rectifier Replacement, Models 609-A and 609-C. . . . . . . . . .
Starter Replacement. . . . . . . . . . . . . . . . . . . . . . . . .
V-Belt Contact Switch Maintenance . . . . . . . . . . . . . . . . . .
Engine Switch and Transmitter Replacement, Model 609-C . . . . . . .
Exhaust Elbow Pipe Assembly Maintenance, Model 609-A . . . . . . . .
Air Intake Tube Assembly, Model 609-A . . . . . . . . . . . . . . . .
Oil Inlet Tube Assembly Replacement . . . . . . . . . . . . . . . . .
Oil Drain Tube Assembly Replacement . . . . . . . . . . . . . . . . .
. . . . . .
Oil Bypass Line Replacement, Model US636HCCD-1
Oil Filter and Base Assembly Maintenance, Model 609-A . . . . . . . .
Oil Filter and Base Assembly Replacement, Models 609-C and
US636HCCD-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Replacement, Model 609-A . . . . . . . . . . . . . . . . .
Oil Cooler Replacement, Model 609-C . . . . . . . . . . . . . . . . .
Oil Cooler Replacement, Model US636HCCD-1 . . . . . . . . . . . . . .
Oil Breather Assembly Replacement, Models 609-C and US636HCCD-1 . . .
Oil Drain Assembly Replacement . . . . . . . . . . . . . . . . . . .
Turbocharger Assembly Replacement, Model 609-A . . . . . . . . . . .
Turbocharger Assembly and Air Shield Replacement, Models 609-C
andUS636HCCD-1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Outlet Frame Replacement, Model 609-C . . . . . . . . . . . . . .
Manifold Maintenance . . . . . . . . . . . . . . . . . . .
Exhaust Manifold Maintenance, Models 609-C and US636HCCD-1 . . . . . . . .
Intake Manifold Maintenance, Models 609-C and US636HCCD-1 . . . . . .
Cooling Air Blower Replacement, Models 609-C and US636HCCD-1 . . . .
Cowling Assembly Maintenance, Models 609-C and US636HCCD-1 . . . . .
Thermostat Maintenance, Model 609-A . . . . . . . . . . . . . . . . .
Fan Replacement, Model 609-A . . . . . . . . . . . . . . . . . . . .
Water Pump Assembly Maintenance, Model 609-A . . . . . . . . . . . . . .
Tachometer Cable Replacement, Model 609-A . . . . . . . . . . . . . .
Tachometer Angle Drive Maintenance . . . . . . . . . . . . . . . . .
Breather Cap Maintenance, Model 609-A . . . . . . . . . . . . . . . .
Cylinder Head Cover Maintenance, Model 609-A . . . . . . . . . .
Cylinder Head Cover Maintenance, Models 609-C and US636HCCD-1. . . . .
Valve Adjustment, Model 609-A . . . . . . . . . . . . . . . . . . . .
Valve Adjustment, Models 609-C and US636HCCD-1 . . . . . . . . . . .
Filler Neck Assembly Replacement, Model 609-C . . . . . . . . . . . .
Fuel Tank Maintenance . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . .
Hub and Wheel Bearing Maintenance . . . . . . . . . . . . . . . . . .
Front Tripod Assembly Maintenance . . . . . . . . . . . . . . . . . .
Rear Jack Assembly Maintenance . . . . . . . . . . . . . . . . . . .
Brake System Bleeding . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder and Brake Line Maintenance . . . . . . . . . . . . .
Brake Actuator Maintenance, Models 609-A and 609-C . . . . . . . . .
Brake Actuator Maintenance, Model US636HCCD-1 . . . . . . . . . . . .
Wheel Cylinder and Brake Shoe Maintenance . . . . . . . . . . . . . .
2-274
2-275
2-276
2-278
2-279
2-282
2-282
2-285
2-288
2-290
2-292
2-295
2-297
2-298
2-299
2-302
2-304
2-306
2-308
2-310
2-312
2-315
2-317
2-319
2-320
2-143
2-144
2-145
2-146
2-147
2-148
2-149
2-150
2-151
2-152
2-153
2-154
2-155
2-156
2-157
2-158
2-159
2-160
2-161
2-162
2-163
2-164
2-165
2-166
2-167
2-168
2-169
2-170
2-171
2-172
2-173
2-174
2-175
2-176
2-323
2-325
2-328
2-330
2-331
2-334
2-335
2-338
2-341
2-343
2-344
2-346
2-348
2-351
2-353
2-355
2-356
2-358
2-360
2-362
2-364
2-366
2-368
2-370
2-372
2-375
2-377
2-379
2-382
2-384
2-386
2-389
2-392
2-395
2-398
v
TM 10-4320-344-24
LIST OF ILLUSTRATIONS - CONTINUED
Figure
Title
Page
2-177
2-178
2-179
2-180
2-181
2-182
2-183
2-184
2-185
2-186
2-187
2-188
2-189
2-190
2-191
2-192
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
3-29
3-30
3-31
3-32
3-33
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-41
3-42
3-43
3-44
Handbrake Assembly Maintenance . . . . . . . . . . . . . . . . . . .
Intervehicular Cable Maintenance . . . . . . . . . . . . . . . . . .
Intervehicular Cable Connector Maintenance . . . . . . . . . . . . .
Trailer Wiring Harness Maintenance . . . . . . . . . . . . . . . . .
Trailer Wiring Harness Connector Maintenance . . . . . . . . . . . .
Lights Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .
Reflector Replacement. . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber Maintenance, Models 609-A and 609-C . . . . . . . . .
Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . .
Forklift Pocket Maintenance, Model 609-C . . . . . . . . . . . . . . . . .
Sealing Model 609-A Air Intake and Exhaust Pipe Outlet Openings . . .
Securing Air Cleaner and Exhaust Muffler on Model 609-A . . . . . . .
Install Protective Plywood Cap on Model 609-A . . . . . . . . . . . .
Sealing Model US636HCCD-1 Air Intake and Exhaust Pipe Outlet Openings
Securing Air Cleaner and Exhaust Muffler on Model US636HCCD-1 . . . .
Install Protective Plywood Cap on Model US636HCCD-1 . . . . . . . . .
Pump Assembly Replacement . . . . . . . . . . . . . . . . . . . . . .
S-Bolt Removal From Flywheel . . . . . . . . . . . . . . . . . . . .
Intermediate Bracket Assembly Replacement . . . . . . . . . . . . . .
Pump Casing Assembly Repair, Models 609-A and 609-C . . . . . . . . .
pump Casing Assembly Repair, Model US636HCCD-1 . . . . . . . . . . . .
Flexible Coupling Assembly Maintenance, Model 609-A . . . . . . .
Flexible Coupling Assembly Maintenance, Models 609-C and US636HCCD-1
Loosening Impeller . . . . . . . . . . . . . . . . . . . . . . . .
Impeller and Seal Assembly Removal, Model 609-A and 609-C . . . . . .
Centering Impeller, Models 609-A and 609-C . . . . . . . . . . . . .
Rotating Assembly Maintenance, Models 609-A and 609-C . . . . . . . .
Rotating Assembly Maintenance, Model US636HCCD-1 . . . . . . . . . .
Pump Mount Isolators . . . . . . . . . . . . . . . . . . . . .
Pump Support Maintenance; Model US636HCCD-1 . . . . . . . . . . . . . . . .
Engine Assembly Removal . . . . . . . . . . . . . . . . . . . . . . .
Front Engine Support Maintenance, Model 609-A . . . . . . . . . . . .
Engine Supports Replacement, Models 609-C and US636HCCD-1 . . . . . .
Engine Mount Isolators, Model 609-C . . . . . . . . . . . . . . . . .
Magnetic Pickup Unit Replacement . . . . . . . . . . . . . . . . . .
Governor, Mode1 609-A. . . . . . . . . . . . . . . . . . . . . . . .
Governor Control Assembly Controls, Model 609-A . . . . . . . . . . .
Governor Actuator Assembly, Model 609-C . . . . . . . . . . . . . . .
Governor Maintenance, Model US636HCCD-1 . . . . . . . . . . . . . . .
Fuel Injection Pump Assembly Removal, Model 609-A . . . . . . . . . .
Internal Leakage Test Setup . . . . . . . . . . . . . . . . . . . . .
Dial Indicator and Setting Device Installation . . . . . . . . . . .
Pointer and Graduation Magnet Installation . . . . . . . . . . . . .
Fuel Injection Pump Assembly Adjustment . . . . . . . . . . . . . . .
Fuel Injection Pump Assembly, Models 609-C and US636HCCD-1 . . . . .
. . .
Oil Pan Assembly Replacement
Suction Pipe Replacement, Models 609-C and US636HCCD-1. . . . . . . .
Oil Pump Assembly, Model 609-A . . . . . . . . . . . . . . . . . .
Oil Nozzle Replacement, Model US636HCCD-1 . . . . . . . . . . . . .
V-Belt Tensioner Maintenance, Models 609-C and US636HCCD-1 . . . . .
Rocker Arm Assembly Removal, Model 609-A . . . . . . . . . . . . . .
Rocker Arm Disassembly, Model 609-A . . . . . . . . . . . . . . . . .
Rocker Arm Assembly Installation, Model 609-A . . . . . . . . . . . .
Rocker Arm Assembly Bolt Tightening Pattern, Model 609-A . . . . . . . .
Rocker Arm Assembly Maintenance, Models 609-C and US636HCCD-1 . . . . .
Cylinder Head Assembly Removal, Model 609-A . . . . . . . . . . . . .
Cylinder Head Assembly Bolt Tightening Pattern, Model 609-A . . . . .
Cylinder Head Assembly Removal, Models 609-C and US636HCCD-1 . . . .
Vibration Damper and Crankshaft Pulley, Model 609-A . . . . . . . . .
Vibration Damper and Crankshaft Pulley Maintenance, Models
609-C and US636HCCD-1. . . . . . . . . . . . . . . . . . . . . . .
Safety Chains Maintenance . . . . . . . . . . . . . . . . . . . . . .
2-401
2-403
2-404
2-406
2-406
2-409
2-411
2-413
2-416
2-417
2-419
2-420
2-421
2-422
2-423
2-424
3-10
3-11
3-14
3-16
3-17
3-19
3-21
3-24
3-25
3-27
3-29
3-31
3-33
3-34
3-38
3-41
3-43
3-44
3-45
3-48
3-49
3-53
3-55
3-59
3-66
3-67
3-68
3-70
3-70
3-73
3-75
3-77
3-78
3-81
3-83
3-84
3-86
3-87
3-88
3-92
3-93
3-95
3-98
3-45
vi
3-101
3-106
TM 10-4320-344-24
LIST OF ILLUSTRATIONS - CONTINUED
Figure
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8
D-9
D-10
F-1
F-2
F-3
F-4
F-5
Title
Page
Cylinder Head Assembly Disassembly, Model 609-A . . . . . . . . . . . .
Cylinder Head Assembly Disassembly, Models 609-C and US636HCCD-1 . .
Checking Cylinder Head Seating Surface, Models 609-C and US636HCCD-1
Valve Depth Measurement, Models 609-C and US636HCCD-1 . . . . . . . .
Valve Seat Drilling, Models 609-c and US636HCCD-1 . . . . . . . . . .
Cylinder Maintenance, Models 609-c and US636HCCD-1
Cylinder Measurement Locations, Models 609-C and US636HCCD-1 . . . . .
Gear Housing Cover Maintenance, Model 609-A . . . . . . . . . . . . .
Crankcase Front Cover Maintenance, Models 609-C and US636HCCD-1 . . .
Idler Gear and Bearing Maintenance, Model 609-A . . . . . . . . . . . .
Oil pump Assembly and Oil Pipe Replacement, Models 609-C and US636HCCD-1
Idler Gear Replacement, Models 609-C and US636HCCD-1 . . . . . . . .
Positioning of Flywheel, Model 609-A . . . . . . . . . . . . . . . .
Flywheel Removal, Model 609-A . . . . . . . . . . . . . . . . . . . .
Flywheel Maintenance, Models 609-C and US636HCCD-1 . . . . . . . . .
Bellhousing Maintenance . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Cover Maintenance . . . . . . . . . . . . . . . . . . . . .
Crankcase Rear Cover Maintenance, Models 609-C and US636HCCD-1 . . .
Piston and Connecting Rod Assembly, Model 609-A . . . . . . . . . . .
Removing Piston and Connecting Rod Assembly, Model 609-A . . . . . .
Piston Ring Positioning, Model 609-A . . . . . . . . . . . . . . . .
Piston and Connecting Rod Assembly Installation, Model 609-A . . . .
Bearing Clearance Measurement, Model 609-A . . . . . . . . . .
.
.
.
.
Piston Heater Installation, Models 609-C and US636HCCD-1 .
Piston and Connecting Rod Assembly, Models 609-C and US636HCCD-1 . .
Piston Ring Gap Measurement, Models 609-C and US636HCCD-1 . . . . . .
Piston Pin Measuring Locations, Models 609-C and US636HCCD-1 . . . .
Camshaft Maintenance, Model 609-A . . . . . . . . . . . . . . . . . .
Crankshaft and Camshaft Timing Marks, Model 609-A . . . . . . . . . .
Installed Camshaft Assembly, Model 609-A . . . . . . . . . . . . . . . . . . .
Camshaft Maintenance, Models 609-C and US636HCCD-1 . . . . . . . . . . .
Camshaft Inspection, Models 609-C and US636HCCD-1 . . . . . . . . . .
Gear Housing Maintenance, Model 609-A . . . . . . . . . . . . . . . .
Crankshaft Assembly Replacement, Model 609-A . . . . . . . . . . . .
Crankshaft End Thrust, Model 609-A . . . . . . . . . . . . .
Crankshaft Assembly Replacement, Models 609-C and US6363HCCD-1 . . . . .
Crankshaft Assembly Repair, Models 609-C and US636HCCD-1 . . . . . .
Engine Block Repair, Model 609-A . . . . . . . . . . . . . . . . . .
Engine Block Stud Location, Model 609-A . . . . . . . . . . . . . . .
Crankcase Maintenance, Models 609-C and US636HCCD-1 . . . . . . . . .
Sound Enclosure Assembly Insulation Material, Model 609-C . . . . . .
Battery Cable Assembly, Model 609-A . . . . . . . . . . . . . . . . .
Battery Cable Assembly, Model US636HCCD-1 . . . . . . . . . . . . . .
Control Panel Wiring Harness Assembly, Model 609-C . . . . . . . . .
Main Wiring Harness Assembly, Model 609-C . . . . . . . . . . . . . .
Control Panel Wiring Harness Assembly, Model US636HCCD-1 . . . . . .
Main Wiring Harness Assembly, Model US636HCCD-1 . . . . . . . . . . .
Fuel, Oil, Suction, and Discharge Hose Assemblies, Models 609-C
and US636HCCD-l. . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Line Assemblies, Model 609-A . . . . . . . . . . . . . . . . .
Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic Diagram Model 609-A . . . . . . . . . . . . . . . . . . . .
Control Panel Schematic Diagram, Model 609-C . . . . . . . . . . . .
Main Wiring Harness Wiring Diagram, Model 609-C . . . . . . . . . .
Control Panel Schematic Diagram, Model US636HCCD-1 . . . . . . . . .
Main Wiring Harness Diagram, Model US636HCCD-1 . . . . . . . . . . .
4-4
4-9
4-11
4-11
4-12
4-15
4-16
4-19
4-22
4-24
4-27
4-28
4-30
4-31
4-33
4-36
4-38
4-40
4-43
4-44
4-47
4-48
4-49
4-50
4-51
4-52
4-53
4-56
4-58
4-59
4-61
4-62
4-64
4-67
4-70
4-72
4-73
4-76
4-78
4-81
D-2
D-3
D-4
D-5
D-10
D-15
D-19
D-22
D-23
D-24
F-2
F-4
F-6
F-8
F-11
vii
TM 10-4320-344-24
LIST OF TABLES
Number
1-1
1-2
1-3
1-4
2-1
2-2
2-3
2-4
2-5
2-6
2-7
3-1
3-2
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8
D-9
D-10
D-11
D-12
D-13
D-14
F-1
F-2
F-3
F-4
F-5
viii
Title
Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . .
Description of Major Components, Model 609-A . . . . . . . . . . . . . .
Description of Major Components, Model 609-C . . . . . . . . . . . . . . .
Description of Major Components, Model US636HCCD-1 . . . . . . . .
Preventive Maintenance Checks and Services for Pumping Assembly
Model 609-A . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Checks and Services for Pumping Assembly
Model 609-C . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance Checks and Services for Pumping Assembly
Model US636HCCD-1 . . . . . . . . . . . . . . . . . . . . . . . .
Unit Troubleshooting Table . . . . . . . . . . . . . . . . . . . . .
Fuel Line and Oil Line Runs and Terminations, Model 609-A . . . . .
Fuel Line and Oil Line Runs and Terminations, Model 609-C . . . . .
Fuel Line and Oil Line Runs and Terminations, Model US636HCCD-1 . .
Direct Support Troubleshooting Table . . . . . . . . . . . . . . . .
Rocker Arm Shaft Dimensions, Model 609-A . . . . . . . . . . . . . .
Valve Spring Data . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Valve Dimensions . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve Dimensions . . . . . . . . . . . . . . . . . . . . . .
Intake Valve Fits and Tolerances, Models 609-C and US636HCCD-1 . . .
Exhaust Valve Fits and Tolerances, Models 609-C and US636HCCD-1 . .
Piston Pin Dimensions . . . . . . . . . . . . . . . . . . . . . . . .
Piston Dimensions, Model 609-A . . . . . . . . . . . . . . . . . . . . . .
Piston Ring Dimensions . . . . . . . . . . . . . . . . . . . . . . .
Piston Dimensions, Models 609-C and US636HCCD-1 . . . . . . . . . .
Gap Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Tappet Dimensions . . . . . . . . . . . . . . . . . . . . . .
Camshaft Tolerances . . . . . . . . . . . . . . . . . . .
Crankshaft Dimensions; Model 609-A . . . . . . . . . . . . . . . . .
Torque Values . . . . . . . . . . . . . . . . . . . .
Crankshaft Dimensions, Models 609-C and US636HCCD-1 . . . . . . . . .
Cylinder Bore Diameter. . . . . . . . . . . . . . . . . . . . . . .
Stud Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Bearing Journal Bore Dimensions . . . . . . . . . . . . .
Parts List for Sound Enclosure Insulation, Model 609-C . . . . . . .
Parts List for Battery Cable Assembly, Model 609-A . . . . . . . . .
Parts List for Battery Cable Assembly, Model US636HCCD-1 . . . . . .
Parts List for Control Panel Wiring Harness Assembly, Model 609-C .
Control Panel Wire Run List, Model 609-C . . . . . . . . . . . . . .
Parts List for Main Wiring Harness, Model 609-C . . . . . . . . . .
Main Wiring Harness Wire Run List, Model 609-C .
Parts List for Control Panel Wiring Harness Assembly,Model US636HCCD-1
Control panel Wire Run List, Model US636HCCD-1 . . . .
Parts List for Main Wiring Harness Assembly, Model US636HCCD-1 . . .
Main Wiring Harness Wire Run List, Model US636HCCD-1 . . . . . . . .
P a r t s L i s t f o r F u e l , O i l , S u c t i o n , and Discharge Hose Assemblies,
Models 609-C and US636HCCD-1 . . . . . . . . . . . . . . . . . . .
Parts List for Brake Line Assemblies, Model 609-A . . . . . . . . .
Parts List for Chain. . . . . , . . . . . . . . . . . . . . . . . .
Wire Run List, Model 609-A . . . . . . . . . . . . . . . . . . . . .
Control panel Wire Run List, Model 609-C . . . . . . . . . . . . . . .
Main Wiring Harness Wire Run List, Model 609-C . . . . . . . . . . . . .
Control Panel Wire Run List, Model US636HCCD-1 . .. . . . . . . . . . .
Main Wiring Harness Wire Run List, Model US636HCCD-1 . . . . . . . .
Page
1-1
1-4
1-6
1-8
2-10
2-19
2-26
2-29
2-262
2-263
2-264
3-3
3-85
4-5
4-5
4-5
4-9
4-10
4-45
4-45
4-47
4-52
4-53
4-57
4-57
4-68
4-69
4-73
4-77
4-78
4-82
D-2
D-3
D-4
D-6
D-7
D-11
D-12
D-16
D-17
D-20
D-20
D-22
D-23
D-24
F-3
F-5
F-7
F-10
F-12
TM 10-4320-344-24
HOW USE THIS MANUAL
DESCRIPTION OF THE MANUAL.
Manual Organization.
This manual is designed to help you operate and maintain the 600
gallons per minute (GPM) pumping assemblies. Read the warning pages located in the
front of the manual before operating or doing maintenance on the equipment.
The front cover of this manual provides an index that lists subjects that are
commonly used. Each item indexed on the front cover has a black box at the edge of
the cover. There is a corresponding black box on the first text page for each
subject listed on the cover index.
The Table of Contents is provided for quick reference to the subjects covered by
each chapter, section, and appendix. Chapter 2 through 6 also have a subject index
that lists the major paragraphs in alphabetical order under the section title.
The major elements of this manual are its chapters and appendixes.The chapter and
appendixes can be divided into one or more sections. This manual has six chapters
and seven appendixes.
A glossary follows the last appendix. The glossary lists and explains the special
or unique abbreviations and the unusual terms used in this manual.
An alphabetical index follows the glossary. That index is for use in locating
specific items of information.
Locating a Malfunction. Finding the cause of a malfunction, troubleshooting, is the
first step in fixing the equipment and returning it to operation. Follow these
simple steps to determine the root of the problem:
a.
Turn to the Table of Contents in the manual.
b.
Locate "Troubleshooting" under the chapter that covers your level of
maintenance. Turn to the page indicated.
Performing for a Task. Be sure that you understand the entire maintenance procedure
before beginning any maintenance task. Make sure that all parts, materials, and
tools are available. Read all steps before beginning. Be sure to obey all WARNINGS
and CAUTIONS.
ix/(xBlank)
TM 10-4320-344-24
CHAPTER 1
INTRODUCTION
SECTION I. GENERAL INFORMATION
1.1 SCOPE.
This manual is for your use in performing unit, direct support and general support
maintenance procedures on the 600 GPM pumping assemblies, Model 609-A
(NSN, 4320-01-184-7494), Model 609-C (NSN, 4320-01-261-6470), and Model US636HCCD1
(NSN 4320-01-201-6937).
The pumping assemblies are depicted in Figures 1-1, 1-2,
and 1-3, respectively. This manual covers general and specific information needed
by the mechanic, descriptions of the pumping assemblies, f u n c t i o n a l d e s c r i p t i o n s o f
The pumping
how the pumping assemblies work, and maintenance instructions.
assemblies are used as the lead pumping station and up to a maximum of five boost
pumping stations, in the Tactical Water Distribution System (TWDS).
1.2 MAINTENANCE FORMS, RECORDS, AND REPORTS.
Department of the Army forms and procedures used for equipment maintenance will be
those prescribed by (as applicable) DA PAM 738-750, The Army Maintenance Management
System (TAMMS) or AR 700-138, Army Logistics Readiness and Sustainability.
1.3 CALIBRATION.
The 600 GPM pumping assemblies do not contain equipment which requires calibration.
1.4 DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE.
Destruction of Army material to prevent enemy use shall be in accordance with
TM 750-244-3.
1.5 PREPARATION FOR STORAGE AND SHIPMENT.
Refer to Chapter 2, Section VI for instructions regarding preparation for storage or
shipment.
1.6 QUALITY ASSURANCE (QA).
There are no QA procedures applicable to the equipment covered in this technical
manual.
1.7 NOMENCLATURE CROSS-REFERENCE LIST.
Table 1-1 provides a cross-reference listing of the common names to official
nomenclature.
Table 1-1. Nomenclature Cross-reference List.
Common Name
600 GPM Pumping Assembly
Official Nomenclature
Pumping Assembly, Water, 600 GPM, Model
609-A, Pumping Assembly, Water, 600
GPM, Model 609-C, or Pumping Assembly,
Water, 600 GPM, Model US636HCCD-1
1-1
TM 10-4320-344-24
1.8 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).
If your pumping assembly needs improvement, let us know. Send us an EIR. You, the
u s e r , are the only one who can tell us what you don’t like about your equipment.
Let us know why you don’t like the design or performance.
Put it on Standard Form
( S F ) 3 6 8 ( P r o d u c t Q u a l i t y D e f i c i e n c y R e p o r t ) . Mail it to Commander, U.S. Army
Aviation and Troop (ATCOM) Command, ATTN: AMSAT-I-MDO, 4300 Goodfellow Blvd. St
Louis, MO 63120-1798.
1.9 WARRANTY INFORMATION.
The 600 GPM pumping assemblies are not warranted items.
1.10 SAFETY, CARE, AND HANDLING.
WARNING and CAUTION statements have been strategically placed throughout this manual
prior to operating or maintenance procedures, practices, or conditions considered
essential to the protection of personnel (WARNING) or equipment or property
(CAUTION). Prior to the performance of any task read and understand all WARNINGS
Failure to do so may result in
and CAUTIONS pertaining to the task at hand.
personnel injury, damage to the equipment, or both.
1.11 CORROSION PREVENTION AND CONTROL (CPC).
Corrosion prevention and control (CPC) of Army material is a continuing concern. It
is important that any corrosion problems with this item be reported so that the
problem can be corrected and improvements can be made to prevent the problem in
future items.
While corrosion is typically associated with rusting of metals, it can also include
d e t e r i o r a t i o n o f o t h e r m a t e r i a l s , such as rubber and plastic. Unusual cracking,
s o f t e n i n g , s w e l l i n g , or breaking of these materials may be a corrosion problem.
I f a c o r r o s i o n p r o b l e m i s i d e n t i f i e d , it can be reported using SF 368, Product
Q u a l i t y D e f i c i e n c y R e p o r t . Use of key words such as ‘corrosion, " "rust,"
“ d e t e r i o r a t i o n , " o r “ c r a c k i n g ” will ensure that the information is identified as a
c o r r o s i o n p r o b l e m . The form should be submitted to the address specified in DA PAM
738-750.
1.12 LIST OF ABBREVIATIONS/ACRONYMS.
All abbreviations, acronyms, signs, and symbols used in this manual are listed in
the glossary located in the back of the manual.
1.13 GLOSSARY.
All terms used in this manual that are not defined in the text or listed in the Army
Dictionary (AR 310-25) are defined in the glossary located in the
back of the manual.
SECTION II. EQUIPMENT DESCRIPTION
1.14 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.
1.14.1 Pumping Assemblies. Refer to TM 10-4320-344-10, Operator’s Manual for 600 GPM
pumping assemblies, paragraphs 1.10 - 1.13 for characteristics, capabilities,
features, location of major components, difference between models, and equipment
data for pumping assemblies Model 609-A, Model 609-C, and Model US636HCCD-1.
1-2
TM 10-4320-344-24
1.14.2 Location and Description of Components. Figures 1-1, 1-2 and 1-3 illustrate
components of the pumping assemblies in addition to those identified in TM 10-4320344-10. Tables 1-2, 1-3 and 1-4 list the components and provide a description of
each component. The Item No. in Table 1-2 relates to the callouts in Figure 1-1,
the Item No. in Table 1-3 to callouts in Figure 1-2 and the Item No. in Table 1-4 to
callouts in Figure 1-3.
Figure 1-1. Location of Major Components, Model 609-A.
1-3
TM 10-4320-344-24
Table 1-2. Description of Major Components, Model 609-A.
Item
Item Name
No.
1 EXHAUST SYSTEM
2
ROTATING ASSEMBLY
3
AXLE AND WHEEL ASSEMBLY
4
AIR INTAKE FILTER
5
ENGINE HOOD
6
FUEL TANK
7
SLING/TIE DOWN POINTS
8
RADIATOR
1-4
Description and Purpose
Exhaust gases are expelled through the exhaust
manifold to the turbocharger. The gases are
then expelled by the turbocharger through the
muffler exhaust pipes and rain cap. Engine
noise is reduced by passing exhaust through the
muffler and rain is kept out by the rain cap.
Provides the interface between the diesel engine
and the water pump. The pump rotating assembly
contains the impeller shaft of the pump which is
supported by a single, self-lubricated,
permanently sealed, ball bearing. The impeller
shaft drives the impeller which causes the pump
to transfer water.
Used to support and transport the pumping
assembly.
Provides filtered air to the turbocharger at
atmospheric pressure.
Provides protection to the diesel engine from
rain, snow, and blowing debris.
Stores diesel fuel; used to power diesel engine
operation.
Tie down points are used to secure the pump
assembly to transportation vehicles. The sling
load points are hard points used for sling
operations.
Divides engine coolant through many small thin
walled tubes, which have air drawn across them
by a fan, to lower engine temperature.
TM 10-4320-344-24
Figure 1-2. Location of Major Components, Model 609-C.
1-5
TM
10-4320-344-24
Table 1-3. Description of Major Components, Model 609-C.
Item
No.
Item Name
1
SOUND ENCLOSURE
2
3
4
5
6
7
8
9
1-6
Description and Purpose
Consists of metal panels with insulation adhered
to the inner surfaces. Muffles sound to reduce
engine noise in the area near the operating
pumping assembly.
Exhaust gases are expelled through the exhaust
EXHAUST SYSTEM
manifold to the turbocharger. The gases are
then expelled by the turbocharger through the
muffler and exhaust pipes. Engine noise is
reduced by passing exhaust through the muffler.
Stores batteries used to provide electrical
BATTERY STORAGE COMPARTMENT
energy to the pumping assembly.
AIR INTAKE FILTER COMPARTMENT Houses air intake filter used to provide
filtered air to the turbo charger at atmospheric
pressure.
Provides the interface between the diesel engine
ROTATING ASSEMBLY
and the water pump. The pump rotating assembly
contains the impeller shaft of the pump which is
supported by a single, self-lubricated,
permanently sealed, ball bearing. The impeller
shaft drives the impeller which causes the pump
to transfer water.
Tie down points are used to secure the pump
SLING/TIE DOWN POINTS
assembly to transportation vehicles. The sling
load paints are hard points used for sling
operations.
FUEL TANK
Stores diesel fuel, used to power diesel engine
operation.
AXLE AND WHEEL ASSEMBLY
Used to support and transport the pumping
assembly.
FORKLIFT POCKET
Provides access for forklift tines for lifting
and moving the pumping assembly when a towing
vehicle is not available.
TM 10-4320-344-24
Figure 1-3. Location of Major Components, Model US636HCCD-1.
1-7
TM 10-4320-344-24
Table 1-4. Description of Major Components, Model US636HCCD-1.
Item
Item Name
No.
TURBOCHARGER
1
2
EXHAUST SYSTEM
3
ROTATING ASSEMBLY
4
SLING/TIE DOWN POINTS
5
AXLE AND WHEEL ASSEMBLY
6
V-BELT GUARD
7
AIR INTAKE SYSTEM
8
FUEL TANK
Description and Purpose
Driven by the force of the engine exhaust.
Compresses intake air to a density up to four
times that of atmospheric pressure. This
greater amount of dense air allows more fuel to
be burned, thereby doubling the engine’s power
output. The turbocharger also reduces exhaust
emissions and exhaust noise.
Exhaust gases are expelled through the exhaust
manifold to the turbocharger. The gases are
then expelled by the turbocharger through the
muffler, exhaust pipes and rain cap. Engine
noise is reduced by passing exhaust through the
muffler. Rain is kept out by the rain cap.
Provides the interface between the diesel engine
and the water pump. The pump rotating assembly
contains the impeller shaft of the pump which is
supported by a single, self-lubricated,
permanently sealed, ball bearing. The impeller
shaft drives the impeller which causes the pump
to transfer water.
Tie down points are used to secure the pump
assembly to transportation vehicles. The sling
load points are hard points used for sling
operations.
Used to support and transport the pumping
assembly.
Encloses all V-belts to prevent foreign objects
from interfering with operation or personal
injury. Covers crankshaft, alternator, and
tension pulleys.
Maintains a supply of fresh air to each cylinder
so that air can be drawn into each cylinder on
the intake stroke. The turbocharger draws air
through a clean air filter and air intake pipe
assembly. The air supply is kept under pressure
by the turbocharger to provide additional power
from the engine.
Stores diesel fuel, used to power diesel engine
operation.
SECTION III. PRINCIPLES OF OPERATION
1.15
PUMPING ASSEMBLY OVERVIEW.
1.15.1 General. The 600 GPM pumping assembly is a mobile system that transfers
potable water. It is trailer mounted and is towed by a vehicle for short distances.
When relocated, the 600 GPM pumping assembly is disconnected from the vehicle and
stabilized. When used as a source pump the pumping assembly is connected between
the water source and TWDS. When used as a booster pump, the pump disconnected to
hose assemblies. When the engine is started, the water flow through the pump is
controlled by gate valves. The following paragraphs provide a detailed functional
description of the 600 GPM Pumping Assembly.
1-8
TM 10-4320-344-24
1.15.2 Engine. The Deutz BF6L (Models 609-C and US636HCCD-1) and White D3400T (model
609-A) six-cylinder, four-stroke diesel engines drive the water pump. Engine
operating mode is set on the control panel which is mounted on the pump.
Figure 1-4. Engine Functional Block Diagram.
The pumping assemblies may be operated in electric manual or electric automatic
mode. Refer to Figure 1-4 for the engine functional block diagram. Refer to Figure
1-5 for the fuel system functional block diagram.
1-9
TM 10-4320-344-24
Figure 1-5. Fuel System Functional Block Diagram.
1.15.3 Control Panel. Controls pump and engine operations. For an illustration and
description of the controls and indicators, refer to TM 10-4320-344-10, Chapter 2,
Section I. When the pumping assemblies are run in the electric automatic mode the
engine speed is controlled by the pressure regulator for the model 609-A and process
controllers and process devices for Models 609-C and US636HCCD-1. The pressure
regulator, process controller, and controlling devices monitor the suction pressure
of the water pump and control engine speed through the engine governor. When the
pump suction pressure drops below 10 pounds per square inch (psi) (69 kilopascal
(kPa)) the engine is reduced to idle speed to prevent damage to the equipment.
Engine speed is also reduced to idle when the suction pressure rises above 120 psi
(827 kPa) to prevent damage to the equipment.
1.15.4 Centrifugal Pump. The pumping assemblies have the capability of pumping up to
600 GPM at up to 350 feet total discharge head (TDH). The pump is driven by a
direct coupling between the flywheel of the diesel engine and the intermediate
bracket assembly.
1.15.4.1 Pump Casing. The pump casing is a solid cast metal housing to which the
intermediate bracket assembly and suction and discharge elbows are mounted. The
impeller from the intermediate bracket assembly is fitted in the rear of the pump
casing. As the impeller rotates, a vacuum is created which draws water in through
t h e s u c t i o n e l b o w , The water is then slung through the impeller and out through the
discharge elbow.
1.15.4.2 Intermediate Bracket Assembly Housing. The intermediate bracket assembly is the
interface between the diesel engine and pump casing. The intermediate bracket
assembly consists of an impeller, impeller shaft, sealed self-lubricating ball
bearings, cast metal housing, and flexible coupler. The flexible coupler, mounted
on the end of the impeller shaft, is fitted in or over mounting devices attached to
the fly wheel of the diesel engine. As the engine operates the flywheel rotates in
a clockwise direction. The flexible coupler and thus the impeller shaft also
rotates in the clockwise direction. The sealed self-lubricating ball bearings
provide support and spinning capability to the impeller shaft. The impeller is
mounted on the end of the impeller shaft, opposite of the flexible coupler, and is
located inside the pump casing when installed in the pumping assembly. The cast
metal housing is bolted to both the pump casing and the diesel engine for support.
1.15.5 Two-Wheeled Trailer Assembly. Transports pump and engine unit. All models have
rear lights, an inertia-actuated hydraulic braking system, manually operated park
brakes and leveling jacks, and safety chains.
1-10
TM 10-4320-344-24
1.15.6 Sound Enclosure. Provides for noise reduction on Model 609-C only. The
enclosure surrounds the engine and pumping assembly. The internal surfaces of the
metal panels comprising the sound enclosure have a layer of insulation which provide
noise intensity reduction. The control panel is mounted flush against the sound
enclosure.
1-11/(1-12 blank)
TM 10-4320-344-24
CHAPTER 2
UNIT MAINTENANCE
Page
Subject Index
Section I
R e p a i r P a r t s ; S p e c i a l T o o l s ; Test, Measurement, and
Diagnostic Equipment (TMDE); and Support Equipment . . . . . . .
2-2
2.1 Common Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . 2 - 2
2.2 Special Tools, TMDE, and Support Equipment. . . . . . . . . . . . . . 2 - 2
2.3 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Section II
2.4
2.5
2.6
2.7
Service Upon Receipt .
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.
.
Service Upon Receipt . . . . . . . . . . . . . . . . . . . .
Installation Instructions . . . . . . . . . . . . . . . . .
Preliminary Servicing and Adjustment of Equipment . . . . . . .
Pumping Assembly Lubrication . . . . . . . . . . . . . . . .
.
.
. .
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. .
. .
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. 2-2
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2-2
2-5
2-5
2-5
Section III Unit Preventive Maintenance Checks and Services (PMCS) . . . . . 2 - 5
2.8 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.9 PMCS Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
S e c t i o n IV
2.10
Troubleshooting.
Section V
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
Unit
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. . . . . . . . . . 2-29
Procedures
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.
. . . . . . . . . . 2-37
Maintenance
.
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. 2-29
.
General Maintenance Procedures . . . . . . . . . . . .
Sound Enclosure Assembly Maintenance, Model 609-C . . .
Exhaust System Maintenance . . . . . . . . . . . . . .
Air Intake System Maintenance . . . . . . . . . . . . .
Electrical System Maintenance . . . . . . . . . . . . .
Control Panel Assembly Maintenance . . . . . . . . . .
Engine Wiring Harness Maintenance . . . . . . . . . . .
Pumping Assembly Maintenance . . . . . . . . . . . . .
Hood, Rear Panel, and Shield Assembly Maintenance . . .
Radiator Assembly Maintenance . . . . . . . . . . . . .
Engine Assembly Maintenance . . . . . . . . . . . . . .
Fuel Tank Assembly Maintenance . . . . . . . . . . . .
Wheel Mounted Frame Assembly Maintenance . . . . . . .
S e c t i o n VI
2.24
2.25
2.26
2.27
Troubleshooting
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. 2-37
2-45
2-81
. 2-91
. 2-106
. 2-137
. 2-234
. 2-236
. 2-240
. 2-246
. 2-258
. 2-372
. 2-377
Preparation for Shipment and Storage . . . . . . . . . . . . . . 2 - 4 1 9
Preservation Procedures . . . . . . . . . . . . . . . . .
Packing. . . . . . . . . . . . . . . . . . . . . . . . .
Marking. . . . . . . . . . . . . . . . . . . . . . . . .
Storage. . . . . . . . . . . . . . . . . . . . . . . .
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2-419
2-419
2-424
2-424
2-1
TM 10-4320-344-24
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND
DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
2.1 COMMON TOOLS AND EQUIPMENT.
The General Mechanic’s Tool Kit, Appendix B, Section III, Item 1 is authorized. For
authorized common tools and equipment, refer to Modified Table of Organization and
Equipment (MTOE) applicable to you run it.
2.2 SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
Special tools, TMDE, and support equipment are listed in TM 10-4320-344-24P, Repair
Parts and Special Tools List (RPSTL) for the Pumping Assembly, Water, 600 GPM
covering unit, direct support, and general support maintenance, or the Maintenance
Allocation Chart (MAC), Appendix B of this manual.
2.3 REPAIR PARTS.
Repair parts are listed and illustrated in TM 10-4320-344-24P covering unit, direct
support, and general support maintenance of this equipment.
SECTION II. SERVICE UPON RECEIPT
2.4 SERVICE UPON RECEIPT.
2.4.1 Siting and Location. For information on locating and positioning the pumping
assemblies refer to paragraph applicable TWDS technical manual.
2.4.2 Unpacking. Instructions for unpacking the 600 GPM water pumping units are
provided below. A total of one task hour for Military Occupational Specialty (MOS)
63J is required for unpacking each of the three pumping assemblies. Four total task
hours are required for unpacking each of the three pumping assemblies. Use care
when removing the plywood box, braces, and two dust caps from the manifold to
prevent damage to the equipment.
2.4.2.1 Unpacking Models 609-A and US636HCCD-1. A d d i t i o n a l t o o l s w i l l b e r e q u i r e d f o r
unpacking Models 609-A and US636HCCD-1.
The necessary tools will be available as
TWDS Components of End Item (COEI), reference applicable TWDS technical manual. For
other applications, unpacking assistance must be provided by unit maintenance
personnel. If depreservation is needed, depreservation assistance must also be
provided by unit maintenance personnel. Four personnel will be required to remove
the plywood cap. Unpack Models 609-A and US636HCCD-1 as follows:
a.
If this is the initial use of the pumping assembly there should be a packing
list attached to the side of the plywood cap. There may also be a shortage
packing list and a depreservation guide attached to the plywood cap. Remove
and save the document(s).
Steel strapping used to secure plywood cap has sharp edges. To avoid personal
injury, use care when cutting and handling steel strapping.
b.
Using metal cutting shears, carefully cut metal strapping (Figure 2-1, 1) from
plywood cap (2). Remove metal strapping (1).
c.
Using four persons, one at each corner, lift plywood cap (2) from trailer (3).
Save plywood cap for reuse when the pumping assembly is moved to another
location.
2-2
TM 10-4320-344-24
Figure 2-1. Pumping Assembly with Protective Plywood Cap.
Using the packing list(s) removed in step a, inventory the pumping assembly
components. Check missing items against shortage packing list (if any).
Report any discrepancies using DA Form 2404.
d.
2.4.2.2 Unpacking Model 609-C. Usually, unpacking will be required only if this will be
the intial use of Model 609-C. If required, unpack Model 609-C as follows:
Steel strapping used to secure panel doors has sharp edges. To avoid
personal injury, use care when cutting and handling steel strapping.
a.
Panel doors of Model 609-C may have been secured with metal strapping. If so,
use metal cutting shears to carefully cut metal strapping. Remove metal
strapping.
b.
There may be a packing list attached to the outside of the Model 609-C
enclosure, or inside one of the panel doors. There may also be a shortage
packing list and a depreservation guide. Remove and save the document(s).
c.
Using the packing list(s) removed in step b, inventory the Model 609-C
components. Check missing items against shortage packing list (if any).
Report any discrepancies to your supervisor.
2.4.3
Checking Unpacked Equipment. Perform the following checks on unpacked equipment.
a.
Inspect the equipment for damage incurred during shipment. If the
equipment has been damaged, report the damage on SF 364, Report of
Discrepancy. In addition, submit a DA Form 2404, Equipment Inspection and
Maintenance Worksheet, or DA Form 2407, Maintenance Request, as appropriate.
b.
Check the equipment against the packing slip to see if the shipment is
complete. Report all discrepancies in accordance with the instructions of DA
PAM 738-750.
c.
Check to see if the equipment has been modified.
d.
Inspect all pump flanges for loose bolts, nuts, and attaching hardware.
2-3
TM 10-4320-344-24
e.
Inspect pump suction, discharge pressure and vent line fittings, and
connections for condition and security.
f.
Inspect engine for loose nuts, bolts, and screws.
g.
Inspect all controls and instruments for damage and loose mountings.
h.
Inspect all fluid lines and hoses for dents, loose connections, and cuts.
i.
Inspect all air cowlings for cracks, security, and deformations.
j.
Inspect engine and pump mounts for security.
k.
Inspect tires for cuts, bulges, cracks, and deterioration. Ensure that
lug nuts are tight.
l.
Remove all foreign matter from assembly.
m.
Wipe pumping assembly clean.
2.4.4 Processing Unpacked Equipment.
a.
Remove all tape and packing film from the 600 GPM Pumping Assembly.
b.
Remove all plastic tie-wraps necessary to place equipment in operation.
c.
Remove all shipping tags from components.
d.
Refer to DA Form 2258, Depreservation Guide for Vehicles and Equipment, packed
with the equipment. The depreservation guide explains what was done to the
equipment prior to packaging. It also explains what has to be done before
placing the equipment in operation. Perform all depreservation actions
required by the depreservation guide.
Retain tags for future reference.
Instructions for assembling the 600 GPM water
2.4.5 Assembly of 600 GPM Pumping Assembly.
pumping assemblies are provided below.
2.4.5.1 Tools, Test Equipment, and Materials Required for Installation.
tool kit is required for installation of the equipment.
A general mechanic’s
2.4.5.2 Assembly of Model 609-A.
2.4.5.2.1 Air Cleaner Installation. The air cleaner assembly will have been removed
before the protective plywood cap was installed. It will have been taped or
strapped to the trailer chassis, alongside the battery cables. Retrieve the air
cleaner assembly. Install the air cleaner assembly in accordance with paragraph
2.14.1.
2.4.5.2.2 Muffler Installation. The muffler will have been removed before the
protective plywood cap was installed. It will have taped or strapped to the
side of the engine. Retrieve the muffler. Install the muffler in accordance with
paragraph 2.13.1.
2.4.5.3 Assembly of Model 609-C. Model 609-C does not require assembly to prepare it
for use.
2.4.5.4 Assembly of Model US636HCCD-1.
2.4.5.4.1 Air Cleaner Installation. The air cleaner assembly will have been removed and
partially disassembled before the protective plywood cap was installed. It will
have been taped or strapped to top of the battery box. Retrieve the air cleaner
assembly. Also, the air intake pipe should have been retrieved when the muffler was
retrieved. Install the air cleaner assembly in accordance with paragraph 2.14.3.
2.4.5.4.2 Muffler Installation. The muffler will have been removed and partially
disassembled before the protective plywood cap was installed. It will have been
2-4
TM 10-4320-344-24
taped or strapped to the trailer, between the pump and the engine. Retrieve the
muffler and any other components taped or strapped to it. Install the muffler in
accordance with paragraph 2.13.3.
2.5 INSTALLATION INSTRUCTIONS.
Refer to applicable TWDS technical manual for pumping assembly installation
instructions.
2.6 PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT.
NOTE
Crankcase is filled to operating level with preservative oil, MIL-P-21260.
Engine lubricating preservation oil does not have to be drained from
crankcase until first scheduled oil change.
a.
Check engine crankcase oil level. Service as required (refer to
LO 10-4320-344-12).
b.
Fill fuel tank with proper grade fuel.
Do not fill battery without rubber gloves and protective clothing.
Electrolyte causes serious burns. Failure to obey this warning may result in
personal injury or death.
c.
If batteries were shipped dry, remove and fill with electrolyte to a
level 3/8 inch (9.5 mm) above cell plates.
d.
Refer to paragraph 2.15.2 for Model 609-A, paragraph 2.15.3 for Model
609-C, and paragraph 2.15.4 for Model US636HCCD-1 and install batteries,
attach cables, and cover.
e.
Service tires to 40 psi (276 kPa).
f.
Refer to paragraph 2.21.13 and adjust alternator belt.
2.7 PUMPING ASSEMBLY LUBRICATION.
Refer to LO 10-4320-344-12 for lubrication instructions.
SECTION III. UNIT PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS)
2.8 GENERAL.
Tables 2-1, 2-2 and 2-3 (PMCS tables) have been provided so you can keep your
equipment in good operating condition and ready for its primary mission.
2.8.1 Warnings and Cautions. Always observe the WARNINGS and CAUTIONS appearing in
your PMCS table. Warnings and cautions appear before applicable procedures.
Observe these W A R N I N G S to prevent serious injury to yourself and others, and the
CAUTIONS to prevent your equipment from being damaged.
2.8.2 Reporting Deficiencies.
PAM 738-750, TAMMS.
Report any deficiencies using the proper forms. See DA
2.8.3 Removing Assemblies or Equipment. If the PMCS table requires removal of assemblies
or equipment, refer to the maintenance paragraph listed.
2-5
TM 10-4320-344-24
2.9 PMCS PROCEDURES.
2.9.1 Explanation of Table Columns.
The PMCS table lists the inspections and care of
the equipment required to keep it in good operation condition. Following is an
explanation for each column in the table.
2.9.1.1 Item No. Column. Numbers in this column are for reference. When completing DA
Form 2404, Equipment Inspection and Maintenance Worksheet, include the item number
for the check/service indicating a fault. Item numbers also appear in the order
that you must do checks and services for the intervals listed.
2.9.1.2 Interval Column. This column tells you how often to perform the procedure in
the procedure column. Perform procedures such as Monthly or Quarterly at the listed
calendar interval. Perform procedures designated by the number of hours when the
equipment has operated for that number of hours.
2.9.1.3 Location. Item to Check/Service Column. This column provides the location and the
item to be checked or serviced. The item location is underlined.
2.9.1.4 Procedure Column. This column gives the procedure for checking or servicing
the item listed in the Check/Service column to know if the equipment is ready or
available for its intended mission. Perform the procedure at the time stated in the
interval column.
2.9.1.5 Not Fully Mission Capable if: Column. Information in this column tells you what
malfunctions will keep your equipment from performing its primary mission. If your
checks or services show malfunctions listed in this column, do not operate the
equipment. Follow standard operating procedures for maintaining the equipment or
reporting equipment failure.
2.9.2 Other Table Entries. B e s u r e t o o b s e r v e a l l s p e c i a l i n f o r m a t i o n a n d n o t e s t h a t
appear in your PMCS table.
2.9.2.1 Fluid Leakage Classification and Definitions.
defined as indicated below.
CLASSIFICATION
Fluid leakage is classified and
DEFINITION
Class I
Seepage of fluid (indicated by wetness or discoloration)
not great enough to form drops
Class II
Leakage of fluid great enough to form drops but not enough
to cause drops to drip from item being checked
Class III
Leakage of fluid great enough to cause drops to drip from
item being checked
NOTE
Fluid levels of items with Class I and Class II leaks must be checked often so
proper levels can be kept. Notify supervisor of all Class III leaks will be.
2.9.3 Order in Which PMCS Will be Done. Figures 2-2, 2-3, and 2-4 show the order in
which you are to perform your PMCS. Figure 2-2 is for Pumping Assembly Model 609-A,
Figure 2-3 is for Pumping Assembly Model 609-C, and Figure 2-4 is for Pumping
Assembly Model US636HCCD-1. The number callouts on Figures 2-2, 2-3, and 2-4
correspond to the numbers in the Item No. column of tables 2-1, 2-2, and 2-3.
2-6
TM 10-4320-344-24
Figure 2-2. PumpingAssembly Model 609-A PMCS Routing Diagram (Sheet 1 of 4).
2-7
TM 10-4320-344-24
Figure 2-2. Pumping Assembly Model 609-A PMCS Routing Diagram (sheet 2 of 4).
2-8
TM 10-4320-344-24
Figure 2-2. Pumping Assembly Model 609-A PMCS Routing Diagram (Sheet 3 of 4).
2-9
TM 10-4320-344-24
Figure 2-2. Pumping Assembly Model 609-A PMCS Routing Diagram (Sheet 4 of 4).
Table 2-1. Preventive Maintenance Checks and Services
for Pumping Assembly Model 609-A.
Item
No.
Interval
Location
Item to
Check/Service
PUMPING ASSEMBLY
Procedure
Not wily Mission
Capable if:
Do not fill battery without rubber gloves and protective clothing. Electrolyte
causes serious burns. Failure to obey this warning may result in personal
injury or death.
1
Quarterly
Battery and
Battery Cables
2
Quarterly
Pump Assembly
2-10
Check specific gravity.
Replace or recharge as
required. (Refer to TM 96140-200-14). Clean and
service battery cable
assemblies as required.
Inspect for loose or
missing mounting hardware.
Tighten loose mounting
hardware. Replace missing
mounting hardware.
Battery
insufficiently
charged or
damaged. Battery
cables damaged.
Class III leak.
Pump assembly
damaged or
cracked. Missing
mounting
hardware.
TM 10-4320-344-24
Table 2-1. Preventive Maintenance Checks and Services
for Pumping Assembly Model 609-A. (Continued)
Item
No.
Interval
3
Quarterly
Location
Item to
Check/Service
ENGINE
Crankcase Oil,
Oil Filter, and
Oil Lines
Procedure
Inspect oil filter and
lines for leakage or
Replace oil lines
damage.
as required (para 2.21.2).
Service in accordance with
LO 10-4320-344-12.
Not Fully Mission
Capable if:
Class III leak.
Damaged oil
filter.
Damaged
or missing oil
lines.
. Solvent may cause toxic fumes. To prevent personal injury, work only in well
ventilated area. DO NOT breathe fumes for a long period of time.
. Solvent is flammable. To prevent fire or explosion, DO NOT bring open flame
or sparks near solvent.
. To prevent the possibility of embedding foreign objects in the eyes, safety
glass must be worn when using compressed air.
4
Quarterly
Breather Cap
5
Quarterly
Fuel Lines and
Filters
6
Quarterly
Fuel Injection
Lines
7
Quarterly
Alternator Belt
8
Quarterly
Starter Assembly
Inspect breather cap every
time oil is changed. If
required, remove filter and
clean with cleaning solvent
(Appendix C, Item 25).
Blow dry with compressed
air.
Change primary and
secondary fuel filters
(para
2 . 21 .4). Inspect
fuel lines for damage or
leakage. Replace fuel
lines as required (para
2.21.2).
Inspect for loose mounting
hardware and leakage.
Tighten loose mounting
hardware. Replace fuel
injection lines as required
(para 2.21.7).
Check for 1/2 inch
deflection at center of
alternator belt (para
2.21.13). Inspect for worn
or damaged alternator belt.
Adjust or replace
alternator belt as required
(para 2.21.13).
Inspect for damaged and
loose or missing mounting
hardware or wires. Tighten
loose wire connections and
mounting hardware. Replace
missing mounting hardware.
Replace starter as required
(para 2.21.18).
Damaged or
missing breather
cap. Da ma g ed,
missing, or
clogged filter.
Class I, II, or
III leak.
Damaged, clogged,
or missing fuel
filters. Damaged
or missing fuel
lines.
Class I, II, or
III leak.
Damaged or
missing fuel
injection lines.
Alternator belt
loose or damaged.
Missing mounting
hardware.
Damaged starter.
2-11
TM 10-4320-344-24
Table 2-1. Preventive Maintenance Checks and Services
for Pumping Assembly Model 609-A. (Continued)
Item
No.
9
Interval
Semiannually
Location
Item to
Check/Service
PUMPING ASSEMBLY
Control Panel
Assembly
ENGINE
Engine
10
Semiannually
11
Semi annually
Intake and
Exhaust Manifolds
12
Semiannually
Rocker Arm
Assembly
13
Semi annually
Fuel Transfer
Pump Assembly
14
Semiannually
Cooling System
Hoses
15
Semiannually
Water Pump
Assembly and Fan
2-12
Procedure
Not Fully Mission
Capable if:
Remove control panel cover
(para 2.16.1). Inspect for
leaks and loose hose
connections. Tighten loose
hose connections. Inspect
for damaged wiring harness,
loose wires, and corrosion.
Tighten loose wire
connections. Replace or
repair damaged wiring
harness (para 2.17).
Replace damaged or
inoperable gauges and
switches.
Class III leak.
Damaged wiring
harness or hoses.
Inspect engine for cracks
and leaks. Tighten loose
mounting hardware. Replace
missing mounting hardware.
If engine is damaged or
leaking, notify direct
support maintenance.
Inspect for cracks and
leaks. Replace intake or
exhaust manifold as
required (para 2.21.36).
Check and adjust valve
clearance as required (para
2.21.49).
Inspect for loose mounting
hardware and fuel line
connections. Inspect pump
for cracks and leaks.
Tighten loose mounting
hardware and connections.
Replace fuel transfer pump
as required (para 2.21.6).
Inspect cooling system
hoses for leaks, damage,
and wear. Replace hoses as
required (para 2.20.2).
Inspect for loose hose
clamps. Tighten loose hose
clamps.
Inspect water pump assembly
for cracks and leaks.
Inspect fan for damage.
Replace fan or water pump
as required (para 2.21.43
or 2.21.42).
Class III leak.
Damaged or
cracked engine.
Damaged or
missing mounting
hardware.
Damaged or
cracked manifold.
Improper valve
clearance.
Class I, II, or
III
leak.
damaged or
cracked fuel
transfer pump.
Missing mounting
hardware.
Class III leak.
Damaged hoses.
Missing hose
clamps.
Class III leak.
Damaged or
cracked water
pump or fan.
TM 10-4320-344-24
Table 2-1. Preventive Maintenance Checks and Services
for Pumping Assembly Model 609-A. (Continued)
Item
No.
Interval
16
Semi annually
17
Semiannually
18
19
20
21
Location
Item to
Check/Service
ENGINE - CONT
Turbocharger
Assembly
Alternator
Procedure
Inspect for cracks and
damaged turbocharger.
Inspect for loose or missing
mounting hardware. Tighten
loose mounting hardware.
Replace missing mounting
hardware. Replace
turbocharger (para 2.21.33).
Inspect for cracks and
damaged alternator. Inspect
for loose mounting hardware
or wires. Tighten or
replace mounting hardware as
required (para 2.21.16).
Tighten loose wire
connections. Replace
alternator as required (para
2.21.16).
TRAILER ASSEMBLY
SemiSprings, Axle, and Inspect for cracks and bends
to springs or axle. Replace
annually Attaching
damaged parts (para
Hardware.
2.23.16).
Inspect for loose
or missing mounting
hardware. Tighten loose
mounting hardware. Replace
missing mounting hardware.
Check shock absorbers for
leaks. Replace shock
absorber if leaking (para
2.23.15).
Inspect for damaged or
SemiFuel Tank
punctured fuel tank. Open
annually
drain at bottom of fuel tank
and drain off any water or
sediment into suitable
container. Close drain.
Check level of brake fluid
Annually Brake System
in master cylinder. Add
brake fluid (Appendix C,
Item 4) as required (para
Inspect brake
2.23.5).
lines for leakage or damage.
Replace brake line(s) if
leaking or damaged (para
2.23.6).
Inspect brake
shoes for wear. Replace
brake shoes if worn (para
2.23.9).
OnWheels
Check and re-torque wheel
Condition
nuts after first 50, 150,
and 300 miles. Torque to 20
ft-lbs (27 N•m) in an everyother-one sequence.
Not Fully Mission
Capable if:
Damaged or cracked
turbocharger.
Missing mounting
hardware.
Damaged or cracked
alternator.
Missing mounting
hardware. Loose
or missing wires.
Damaged, cracked,
or bent spring or
axle. Loose or
missing mounting
hardware. Leaking
shock absorber.
Damaged or
punctured fuel
tank. Water or
sediment in fuel
tank.
Class I, II, or
III leak.
Insufficient brake
fluid. Damaged or
missing brake
lines. Worn or
damaged brake
shoes.
Wheel nuts not
properly torqued.
2-13
TM 10-4320-344-24
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 1 of 5).
2-14
TM 10-4320-344-24
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 2 of 5).
2-15
TM 10-4320-344-24
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 3 of 5).
2-16
TM 10-4320-344-24
Figure 2-3.
Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 4 of 5).
2-17
TM 10-4320-344-24
Figure 2-3.
2-18
Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 5 of 5).
TM 10-4320-344-24
Table 2-2. Preventive Maintenance Checks and Services
for Pumping Assembly Model 609-C.
Item
No.
Interval
Location
Item to
Check/Service
PUMPING ASSEMBLY
Procedure
Not Fully Mission
Capable if:
Do not fill battery without rubber gloves and protective clothing.
Electrolyte causes serious burns. Failure to obey this warning may result
in personal injury or death.
1
Quarterly
Battery and
Battery Cables
2
Quarterly
Pump Assembly
3
Quarterly
ENGINE
Crankcase Oil,
Oil Filter, and
Oil Lines
4
Quarterly
Fuel Lines and
Filters
5
Quarterly
Fuel Injection
Lines
6
Quarterly
Alternator Belt
and V-Belts
Check specific gravity.
Replace or recharge battery
as required. (Refer to TM
9-6140-200-14). Clean and
service battery cable
assemblies as required.
Inspect for loose or
missing mounting hardware.
tighten loose mounting
hardware. Replace missing
mounting hardware.
Inspect oil filter and
lines for leakage or
damage. Replace oil lines
as required (para 2.21.2).
Service in accordance with
LO 10-4320-344-12.
Change primary and
secondary fuel filters
(para 2.21.5). Inspect
fuel lines for damage or
leakage. Replace fuel
lines as required (para
2.21.2).
Inspect for loose mounting
hardware or leakage.
Tighten mounting hardware.
Replace fuel injection
lines as required (para
2.21.7).
Check for 1/2 inch
deflection at center of
alternator belt (para
2.21.13). Inspect for worn
or damaged alternator belt
and V-belts. Adjust or
replace alternator belt and
V-belts as required (para
2.21.13 and 2.21.12).
Battery
Insufficiently
charged or
damaged. Battery
cables damaged.
Class III leak.
Pump assembly
damaged or
cracked. Missing
mounting
hardware.
Class III leak.
Damaged oil
filter. Damaged
or missing oil
lines.
Class I, II, or
III leak.
Damaged, clogged,
or missing fuel
filters. Damaged
or missing fuel
lines.
Class I, II, or
III leak.
Damaged or
missing fuel
injection lines.
Alternator belt
or V-belts
damaged or loose.
2-19
TM 10-4320-344-24
Table 2-2. Preventive Maintenance Checks end Services
for Pumping Assembly Model 609-C. (Continued)
Item
No.
Interval
7
Quarterly
Location
Item to
Check/Service
ENGINE - CONT
Starter Assembly
8
Semi annually
PUMPING ASSEMBLY
Control Panel
Assembly
9
Semiannually
10
Semiannually
Rocker Arm
Assembly
11
Semiannually
Turbocharger
Assembly
12
Semi annually
Fuel Transfer
Pump Assembly
2-20
ENGINE
Engine
Procedure
Not Puny Mission
Capable if:
Inspect for damaged and
loose mounting hardware or
wires. Tighten loose wire
connections and mounting
hardware. Replace missing
mounting hardware. Replace
starter as required (para
2.21.18).
Missing mounting
hardware.
Damaged starter.
Open panel door. Inspect
for leaks and loose hose
connections. Tighten loose
hose connections. Inspect
for damaged wiring harness,
loose wires, and corrosion.
Tighten loose wire
connections. Replace or
repair damaged wiring
harness (para 2.16.6).
Replace damaged or
inoperable gauges and
switches.
Class III leak.
Improperly
operating gages
or
switches.
Damaged gauges or
switches.
Damaged wiring
harness or hoses.
Inspect engine for cracks
and leaks. Tighten loose
mounting hardware. Replace
missing mounting hardware.
If engine is damaged or
leaking, notify direct
support maintenance.
Check and adjust valve
clearance as required (para
2.21.50).
Inspect for cracks, oil
leaks, and damaged
turbocharger. Inspect for
loose or missing mounting
hardware. Tighten loose
mounting hardware. Replace
missing mounting hardware.
Replace turbocharger as
required (para 2.21.34).
Inspect for loose mounting
hardware and fuel line
connections. Inspect pump
for cracks and leaks.
Tighten loose mounting
hardware and connections.
Replace fuel transfer pump
as required (para 2.21.6).
Class 111 leak.
Damaged or
cracked engine.
Damaged or
missing mounting
hardware.
Improper valve
clearance.
Damaged or
cracked
turbocharger.
Missing mounting
hardware.
Class I, II, or
III leak.
Damaged or
cracked fuel
transfer pump.
Missing mounting
hardware.
TM 10-4320-344-24
Table 2-2. Preventive Maintenance Checks and Services
for Pumping Assembly Model 609-C. (Continued)
Item
No.
Interval
Location
Item to
Check/Service
ENGINE - CONT
Alternator
13
Semi Annually
14
Semi annually
15
Semiannually
Fuel Tank
16
Annually
Brake System
17
OnCondition
Wheels
TRAILER ASSEMBLY
Springs, Axle,
and Attaching
Hardware
Procedure
Not Fully Mission
Capable if:
Inspect for cracks and
damaged alternator.
Replace damaged alternator
as required (para 2.21.16).
Inspect for loose mounting
hardware or wires. Tighten
or replace mounting
hardware as required (para
2.21.16).
Damaged or
cracked
alternator.
Missing mounting
hardware. Loose
or missing wires.
Inspect for cracks and
bends to springs or axle.
Replace damaged parts (para
2.23.16). Inspect for
loose or missing mounting
hardware. Tighten loose
mounting hardware. Replace
missing mounting hardware.
Inspect for damaged or
punctured fuel tank. Open
drain at bottom of fuel
tank and drain off any
water or sediment into
suitable container. Close
drain.
Check level of brake fluid
in master cylinder. Add
brake fluid, (Appendix C,
Item 4), to bottom of
threads in master cylinder.
Inspect brake lines for
damage or leakage. Replace
brake line(s) if damaged
(para 2.23.6). Inspect
brake shoes for wear.
Replace break shoes if worn
(para 2.23.9).
Check and re-torque wheel
nuts after first 50, 150,
and 300 miles. Torque to
20 ft-lbs (27 N•m) in an
every-other-one sequence.
Damaged, cracked,
or bent spring or
axle. Loose or
missing mounting
hardware.
Damaged or
punctured fuel
tank. Water or
sediment in fuel
tank.
Class I, II, or
III leak.
Insufficient
brake fluid.
Damaged or
missing brake
lines. Worn or
damaged brake
shoes.
Wheel nuts not
properly torqued.
2-21
TM 10-4320-344-24
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram
(Sheet 1 of 4).
2-22
TM 10-4320-344-24
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram
(Sheet 2 of 4).
2-23
TM 10-4320-344-24
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram
(Sheet 3 of 4).
2-24
TM 10-4320-344-24
Figure 2-4.
Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram
(Sheet 4 of 4).
2-25
TM 10-4320-344-24
Table 2-3. Preventive Maintenance Checks and Services
for Pumping Assembly Model US636HCCD-1.
Item
No.
Interval
Location
Item to
Check/Service
Procedure
Not Fully Mission
Capable if:
PUMPING ASSEMBLY
D o n o t f i l l battery without rubber gloves and p r o t e c t i v e c l o t h i n g .
E l e c t r o l y t e causes serious burns. F a i l u r e t o obey this warning may r e s u l t
i n p e r s o n a l injury or death.
1
Quarterly
Battery and
Battery Cables
2
Quarterly
Pump Assembly
3
Quarterly
ENGINE
Crankcase Oil,
Oil Filter, and
Oil Lines
4
Quarterly
Fuel Injection
Lines
5
Quarterly
Fuel Lines and
Filters
6
Quarterly
Alternator Belt
and V-Belts
2-26
Check specific gravity.
Replace or recharge battery
as required.
(Refer to TM
9-6140-200-14). Clean and
service battery cable
assemblies as required.
Inspect for loose or
missing mounting hardware.
Tighten lose mounting
Replace missing
hardware.
mounting hardware.
Batterv
insufficiently
charged or
damaged. B a t t e r y
cables damaged.
Inspect oil filter and
lines for leakage or
Replace oil lines
damage.
as required (para 2.21.2).
Service in accordance with
LO 10-4320-344-12.
Inspect for loose mounting
hardware and leakage.
Tighten mounting hardware.
Replace fuel injection
lines as required (para
2.21.7).
Change primary and
secondary fuel filters
(para 2.21.5). Inspect
fuel lines for damage or
leakage. Replace fuel
lines as required (para
2.21.2).
Check for 1/2 inch
deflection at center of
alternator belt (para
2.21.13).
Inspect for worn
or damaged alternator belt
and V-belts. Adjust or
replace alternator belt and
V-belts as required (para
2.21.13 and 2.21.12).
Class III leak.
Damaged or
missing oil
Damaged
filter.
or missing oil
lines.
Class I, II, or
III leak.
Damaged or
missing fuel
injection lines.
Class III leak.
Pump assembly
damaged or
cracked.
Missing
mounting
hardware.
Class I, II, or
III leak.
Damaged, clogged,
or missing fuel
lines.
Alternator belt
or V-belts
damaged or loose.
TM 10-4320-344-24
Table 2-3. Preventive Maintenance Checks and Services
(Continued)
for Pumping Assembly Model US636HCCD-1.
Location
Interval
Item to
Check/Service
7
Quarterly
ENGINE - CON’I’
Starter Assembly
8
Semiannually
PUMPING ASSEMBLY
Control Panel
Assembly
9
Semiannually
10
Semiannually
Intake and
Exhaust Manifolds
11
Semi annually
Rocker Arm
Assembly
12
Semi annually
Fuel Transfer
Pump Assembly
Item
No.
ENGINE
Engine
Procedure
Not Fully Mission
Capable if:
Inspect for damage and
loose or missing mounting
hardware or wires. Tighten
wire connections and
mounting hardware. Replace
missing mounting hardware.
Replace starter as required
(para 2.21.18).
Missing mounting
hardware.
Damaged starter.
Remove fuse and check for
signs of burned element.
Remove four mounting bolts.
Remove control panel cover
(para 2.16.2). Check for
l e a k s , loose wires, and
corrosion.
Replace damaged
or inoperable gauges. If
fuse element is burned,
r e p l a c e i t . If wires are
loose, tighten them.
Replace or repair damaged
wiring harness (para
2.16.6).
Class III leak.
Damaged wiring
harness or hoses.
Inspect for cracks or
l e a k s . Tighten loose
mounting hardware. Replace
missing mounting hardware.
If engine is damaged or
leaking, notify direct
support maintenance.
Inspect for cracks and
l e a k s . Replace intake or
exhaust manifold as
required (para 2.21.37 or
2.21.38).
Check and adjust valve
clearance as required (para
2.21.50).
Inspect for loose mounting
hardware and fuel line
connections.
Inspect fuel
transfer pump for cracks
and leaks.
Tighten loose
mounting hardware and
connections. Service fuel
transfer pump as required
(para 2.21.16). Replace
fuel transfer pump as
required (para 2.21.6).
Class III leak.
Damaged or
cracked engine.
Damaged or
missing mounting
hardware.
Damaged or
cracked manifold.
Improper valve
clearance.
Class I, II, or
III leak.
Damaged or
cracked fuel
transfer pump.
Missing mounting
hardware.
2-27
TM 10-4320-344-24
Table 2-3. Preventive Maintenance Checks and Services
(Continued)
for pumping Assembly Model US636HCCD-1.
Interval
Location
Item to
Check/Service
13
Semiannually
ENGINE - CONT
Turbocharger
Assembly
14
Semiannually
15
Semiannually
16
Semiannually
Fuel Tank
17
Annually
Brake System
18
OnCondition
Wheels
Item
No.
2-28
Alternator
TRAILER ASSEMBLY
Springs, Axle,
and Attaching
Hardware
Procedure
Not Fully Mission
Capable if:
Inspect for cracks, oil
leaks, and damaged
Inspect for
turbocharger.
loose or missing mounting
Replace missing
hardware.
mounting hardware. Replace
turbocharger as required
(para 2.21.34).
Inspect for cracks and
damaged alternator.
Replace alternator as
required (para 2.21.16).
Inspect for loose mounting
hardware or wires. Tighten
or replace mounting
hardware as required (para
2.21.16).
Damaged or
cracked
turbocharger.
Missing mounting
hardware.
Inspect for cracks and
bends to springs and axle.
Replace damaged parts (para
Inspect for
2.23.16).
loose or missing mounting
Tighten loose
hardware.
mounting hardware. Replace
missing mounting hardware.
Inspect for damaged or
Open
punctured fuel tank.
drain at bottom of fuel
tank and drain off any
water or sediment into
s u i t a b l e c o n t a i n e r . Close
drain.
Check level of brake fluid
in master cylinder. Add
brake fluid, (Appendix C,
Item 4), to bottom of
threads in master cylinder.
Inspect brake lines for
damage or leakage. Replace
brake line(s) if damaged
(para 2.23.6). Inspect
brake shoes for wear.
replace brake shoes if worn
(para 2.23.9).
Check and re-torque wheel
nuts after first 50, 150,
and 300 miles. Torque to
20 ft-lbs (27 N•m) in an
every-other-one sequence.
Damaged, cracked,
or bent spring or
a x l e . Lose or
missing mounting
hardware.
Damaged or
cracked
alternator.
Hissing mounting
hardware. Loose
or missing wires.
Damaged or
punctured fuel
Water or
tank.
sediment in fuel
tank.
Class I, II, or
111 leak.
Insufficient
brake fluid.
Damaged or
missing brake
l i n e s . Worn or
damaged brake
shoes.
Wheel nuts not
properly torqued.
TM 10-4320-344-24
SECTION IV. TROUBLESHOOTING
2.10 TROUBLESHOOTING.
2.10.1 General : The malfunction index lists malfunctions that may be observed by
unit level maintenance. The malfunctions are then cross-referenced to the
t r o u b l e s h o o t i n g t a b l e 2 - 4 . Table 2-4 contains information useful in diagnosing and
correcting unsatisfactory operation of the pumping assembly which may be encountered
Use the
during operation or maintenance of the pumping assembly or its components.
malfunction index to locate specific troubleshooting procedures contained in
t a b l e 2 - 4 . After locating the listed malfunction, perform the test/inspections and
c o r r e c t i v e a c t i o n s i n t h e o r d e r l i s t e d i n t a b l e 2 - 4 . The malfunction index and
Table 2-4 cannot list all the malfunctions that may occur, all the test and
i n s p e c t i o n s n e e d e d t o f i n d t h e f a u l t , or all the corrective actions needed to
c o r r e c t t h e f a u l t . If the equipment malfunction is not listed or actions listed do
not correct the fault, notify your supervisor.
2.10.2 References. When paragraphs are referenced in table 2-4 (for example,
paragraph 2.10/2.15/2.27), the paragraph number at the left of the slash, /, refers
to Pumping Assembly 609-A, the number between the slashes refers to Pumping Assembly
609-C, and the number to the right of the slash refers to Pumping Assembly
US636HCCD-1.
MALFUNCTION INDEX
Malfunction Number
in Table 2-4
Engine will not crank. . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine cranks, but will not start. . . . . . . . . . . . . . . . . . . . 2
Engine stops suddenly. . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . 4
Ammeter reading too low . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine smokes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine knocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . .8
Engine overheats (Model 609-A)
Engine overheats (Models 609-C and US636HCCD-1) . . . . . . . . . . . . . 9
Table 2-4.
Unit Troubleshooting Table.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE HILL NOT CRANK.
Step 1.
Check for loose or corroded terminals on battery, starter, start alarm
relay (Model 609-A), and start pilot relay (Model 609-C) and broken or
frayed battery cables.
Clean and tighten terminals.
Step 2.
a.
b.
Check for broken or frayed wires between voltage regulator and
alternator (Models 609-A and US636HCCD-1) and generator capacitor and
alternator (Model 609-C).
Repair wires as necessary.
Replace generator capacitor (paragraph 2.21.15) (Model 609-C).
2-29
TM 10-4320-344-24
Table 2-4.
Unit Troubleshooting Table.
(Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE WILL NOT CRANK. (Continued)
Step 3.
a.
b.
Step 4.
a.
b.
c.
Step 5.
Inspect wiring harness for corroded, dirty, or loose connections, and
broken, frayed, or damaged wires.
Clean and tighten all connections.
Refer to paragraph 2.17.1 and repair or replace wiring harness as
necessary.
Check blower V-belt contact switch.
(Models 609-C and US636HCCD-1)
Ensure V-belt contact switch is not in contact with idler pulley.
Test V-belt contact switch (paragraph 2.21.19).
Replace defective V-belt contact switch (paragraph 2.21.19).
Test battery.
Recharge (TM 9-6140-200-14) or replace battery (paragraph 2.15.2, 2.15.3, or
2.15.4).
Step 6.
Check voltage on voltmeter.
If voltage is less than 12 vdc (Models 609-A and US636HCCD-1) or 24 vdc
(Model 609-C), replace alternator (paragraph 2.21.16).
Step 7.
Set engine switch in run mode.
Disconnect switch. Using multimeter,
set to 200 ohm scale, check engine switch for continuity.
(Model 609-A)
a.
b.
If reading is 1 ohm or less, go to step 13.
If reading is more than 1 ohm, refer to paragraph 2.16.18 and replace
engine switch.
Step 8.
Test main power switch for open.
(Model 609-C).
Replace main power switch (paragraph 2.16.18).
Step 9.
Test start/run switch for open.
(Model 609-C)
Replace start/run switch (paragraph 2.16.18).
Step 10.
Test start switch (paragraph 2.16.19).
(Model US636HCCD-1)
Replace start switch (paragraph 2.16.19).
Step 11.
Test start/stop switch (paragraph 2.16.20).
(Model US636HCCD-1)
Replace start/stop switch (paragraph 2.16.20).
Step 12.
a.
b.
2-30
D i s c o n n e c t s o l e n o i d . Using multimeter, set to 200 ohm scale, check the
starter relay coil at the solenoid connection.
(Model 609-A)
If the reading is 15 ohms or less, go to step 14.
If reading is more than 15 ohms, n o t i f y d i r e c t s u p p o r t m a i n t e n a n c e .
TM 10-4320-344-24
Table 2-4.
Unit Troubleshooting Table.
(Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE MILL NOT CRANK. (Continued)
Step 13.
a.
b.
Step 14.
a.
b.
Step 15.
a.
b.
c.
Disconnect wire, connecting starter motor relay to starter solenoid.
Using multimeter, set to 200 ohm scale, check for continuity in wire
(Model 609-A)
between start motor relay and starter solenoid.
If reading is 1 ohm or less, go to step 12.
If reading is more than 1 ohm, r e p l a c e w i r e ( p a r a g r a p h 2 . 1 7 ) .
Disconnect cable connecting starter motor to battery. Using a 12 volt
power source, energize connection.
Put the engine switch in start
mode. Using multimeter, set to 20 vdc, measure voltage of start alarm
relay outlet.
(Model 609-A)
If 12 vdc or more is measured, replace starter (paragraph 2.21.18).
If measurement is less than 12 vdc, replace start alarm relay
(paragraph 2.15.10).
Hold start switch to start position and check for 24 vdc at starter
(Model 609-C)
power input terminal.
If 24 vdc is measured, replace starter (paragraph 2.21.18).
If 24 vdc is not measured, replace start pilot relay (paragraph
2.15.10).
Notify direct support maintenance.
2. ENGINE CRANKS, BUT WILL NOT START.
Check battery voltage for Model 609-C at control panel.
Step 1.
a.
b.
Step 2.
a.
b.
Step 3.
a .
b .
Step 4.
Using multimeter, set to 20 vdc, check battery voltage.
If 12 vdc (24 vdc on Model 609-C) or more is measured, notify direct
support maintenance.
If less than 12 vdc (24 vdc on Model 609-C) is measured, recharge or
replace battery (paragraph 2.15.3).
Check air filter for cleanliness or air inlet for obstructions.
Clean or replace air filter (paragraph 2.14.1/2.14.2/2.14.3).
Remove obstructions from air inlet.
Visually inspect fuel lines for damage or leakage.
Tighten loose fuel line connections.
Replace damaged fuel lines (paragraph 2.21.2).
Visually inspect to see if drain plug on primary fuel filter is
leaking, clean, or missing.
Replace primary fuel filter (paragraph 2.21.4/2.21.5).
2-31
TM 10-4320-344-24
Table 2-4.
Unit Troubleshooting Table.
(Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. ENGINE CRANKS, BUT WILL NOT START. (Continued)
Step 5.
D i s c o n n e c t o u t l e t l i n e o n f u e l t r a n s f e r p u m p . Using manual pumping
l e v e r , check to see if enough fuel is being pumped.
If not enough fuel is being pumped, replace fuel transfer pump (paragraph
2.21.6).
Step 6.
a.
b.
Step 7.
a.
b.
Step 8.
D i s c o n n e c t d i o d e o n f u e l s o l e n o i d c o i l . Using multimeter, set to 200
ohm scale, c h e c k r e a d i n g a c r o s s f u e l s o l e n o i d c o i l .
(Model 609-A and
Model 609-C)
If reading is between 5 and 6 ohms, go to step 7.
If reading is not between 5 and 6 ohms, notify direct support
For Model 609-C, replace fuel solenoid
maintenance for Model 609-A.
(paragraph 2.21.3).
Test fuel injection nozzles.
Test fuel injection nozzles (paragraph 2.21.8 or 2.21.9).
Replace fuel injection nozzles (paragraph 2.21.8 or 2.21.9).
Check to see if pressure regulating valve is set correctly.
609-A)
(Model
Notify direct support maintenance.
3. ENGINE STOPS SUDDENLY.
Step 1.
See wiring diagram (Appendix F).
positive poles are grounded.
Correct
Step 2.
a.
b.
Step 3.
a.
Step 4.
a.
b.
c.
Step 5.
Check to see if any of the
wiring.
Inspect for loose, dirty, or damaged wires.
Clean and tighten loose or dirty wire connections.
Repair or replace damaged wires or wiring harness (paragraph 2.17).
Inspect exhaust system for damage or restriction.
Replace damaged component(s) (paragraph 2.13).
Check engine warning lights.
(Model 609-C)
If LOW OIL light is on go to step 14.
If HIGH temperature light is on go to step 15.
If overspeed light is on notify direct support maintenance.
Inspect for loose or broken V-belts.
(Models 609-C and US636HCCD-1)
Tighten or replace V-belts as required (paragraph 2.21.12).
Step 6.
Test V-belt contact switch (paragraph 2.21.19).
Replace defective V-belt contact switch (paragraph 2.21.19).
2-32
TM 10-4320-344-24
Table 2-4. Unit Troubleshooting Table. (Continued).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE STOPS SUDDENLY. (Continued)
Step 7.
a.
b.
Step 8.
Inspect fuel lines for damage or leakage.
Tighten loose fuel line connections.
Replace damaged fuel lines (paragraph 2.21.2).
Visually inspect to see if drain plug on primary filter is leaking or
missing or if primary fuel filter is clean.
Replace primary fuel filter (paragraph 2.21.4/2.21.5).
Step 9.
a.
b.
Disconnect outlet line on fuel transfer pump. Using manual pumping
lever, check to see if enough fuel is being pumped.
If not enough fuel is being pumped, replace fuel transfer pump
(paragraph 2.21.6).
If enough fuel is being pumped, notify direct support maintenance.
Step 10. Using multimeter, set to 200 ohms cale, check connections between fuel
solenoid valve and alternator for continuity. (Model 609-A)
a.
b.
Step 11.
a.
b.
If reading is 1 ohm or less, go to step 11.
If reading is more than 1 ohm, replace connection (paragraph 2.17).
D i s c o n n e c t d i o d e a n d w i r e s t o s o l e n o i d f u e l c o i l . Using multimeter,
(Model 609-A)
set to 200 ohm scale, c h e c k s o l e n o i d f u e l c o i l .
If reading is between 5 and 6 ohms, go to step 12.
If reading is not between 5 and 6 ohms, notify direct support
maintenance.
Step 12. Connect diode and wires to starter solenoid. Using multimeter, set to
200 ohm scale, c h e c k s t a r t e r s o l e n o i d c o n t i n u i t y .
a.
b.
If reading is 15 ohms or less, go to step 13.
If reading is more than 15 ohms, replace starter (paragraph 2.21.18).
S t e p 1 3 . C h e c k f o r o p e n f u e l s o l e n o i d . Disconnect diode and check for
continuity, using a multimeter, across pins 1 and 2.
(Model 609-C)
a.
b.
c.
If an open exists, replace solenoid (paragraph 2.20.20).
If an open does not exist, replace engine protection system module
(paragraph 2.16.31).
Notify direct support maintenance.
Step 14. Check dipstick for low oil in engine.
Refer to LO 10-4320-344-12 and add oil as necessary.
Step 15.
a.
b.
c.
C h e c k o i l p r e s s u r e s w i t c h f o r o p e n c o n t a c t s . Using multimeter, check
for open between switch terminal and case ground.
(Model 609-C)
Replace oil pressure switch (paragraph 2.21.20).
If switch is good, replace engine protection system module (paragraph
2.16.31).
Notify direct support maintenance.
2-33
TM 10-4320-344-24
Table 2-4. Unit Troubleshooting Table. (Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. ENGINE STOPS SUDDENLY. (Continued)
Step 16.
If HIGH temperature light is on, check temperature switch for open
contacts. Using multimeter, check for open between switch terminal and
case ground. (Model 609-C)
Replace engine temperature switch (paragraph 2.21.20).
Step 17.
a.
b.
c.
Remove cowling cover and check for dirt accumulation between fins of
cylinders and in air passages. (Models 609-C and US636HCCD-1)
Clean fins and passages.
If fins and passages are clean, replace engine protection system module
(paragraph 2.16.31). (Model 609-C)
Notify direct support maintenance.
4. ENGINE OIL PRESSURE TOO LOW.
Step 1.
Check oil level.
Refer to LO 10-4320-344-12 and add oil as required.
Step 2.
Remove oil filter and check it for clogging.
Refer to LO 10-4320-344-12 and change oil filter.
Step 3.
Check oil lines or oil drain plug for leakage or damage.
Replace oil line or leaking oil drain plug (paragraph 2.21.2).
Step 4.
Check oil cooler for leakage or damage.
Replace leaking oil cooler (paragraph 2.21.28/2.21.29/2.21.30).
Step 5.
Check oil pressure line to oil pressure gauge for leakage or damage.
(Models 609-A and US636HCCD-1 only).
Replace oil pressure line (paragraph 2.16.10).
Step 6.
Check oil pressure switch for damage.
(Model 609-C only)
Replace oil pressure switch (paragraph 2.21.20).
Step 7.
a.
b.
Check oil pressure gauge for damage.
Replace oil pressure gauge (paragraph 2.16.10/2.16.12).
Notify direct support maintenance.
5. AMMETER READING TOO LOW.
Step 1.
a.
b.
Step 2.
Check alternator belt for proper tension or damage.
Adjust alternator belt tension (paragraph 2.21.13).
Replace damaged alternator belt (paragraph 2.21.13).
Check for loose or dirty wire connections at alternator.
Clean and tighten loose wire connections.
2-34
TM 10-4320-344-24
Table 2-4. Unit Troubleshooting Table. (Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. AMMETER READING TOO LOW. (Continued)
Step 3.
a.
b.
Test alternator (paragraph 2.21.16).
Replace alternator (paragraph 2.21.16).
Notify direct support maintenance.
6. ENGINE SMOKES.
Step 1.
Check engine exhaust for black or blue color.
Clean or replace air filter as required (paragraph 2.14.1/2.14.2/2.14.3).
Step 2.
Check oil level.
Refer to LO 10-4320-344-12 and drain excess oil.
Step 3.
a.
b.
Disconnect outlet side of fuel filter and start engine. Check fuel for
contamination.
Change fuel filter (paragraph 2.21.4/2.21.5).
Notify direct support maintenance.
7. ENGINE KNOCKS.
Step 1.
Check engine oil level.
Refer to LO 10-4320-344-12 and add oil as required.
Step 2.
a.
b.
Check to see if oil or oil filter requires changing.
Refer to LO 10-4320-344-12 and change oil and/or filter.
Notify direct support maintenance.
8. ENGINE OVERHEATS. (Model 609-A)
Step 1.
Check coolant level.
Add coolant as required (paragraph 2.20.3).
Step 2.
Check radiator for damage.
Replace radiator (paragraph 2.20.4).
Step 3.
a.
b.
Step 4.
Inspect for broken, missing, or loose alternator belt.
Adjust alternator belt tension (paragraph 2.21.13).
Replace alternator belt (paragraph 2.21.13).
Check fan for damage.
Replace fan (paragraph 2.21.42).
Step 5.
a.
b.
Test thermostat (paragraph 2.21.41).
Replace thermostat (paragraph 2.21.41).
Notify direct support maintenance.
2-35
TM 10-4320-344-24
Table 2-4. Unit Troubleshooting Table. (Continued).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9. ENGINE OVERHEATS. (Models 609-C and US636HCCD-1)
Step 1.
Inspect for blockage of cooling air to cooling fan.
Clean and clear blockage as required.
Step 2 .
a.
b.
Step 3.
Inspect for broken, missing, or loose V-belts.
Tighten V-belts (paragraph 2.21.12).
Replace V-belts (paragraph 2.21.12).
Inspect for broken or damaged cooling air blower.
Replace cooling air blower (paragraph 2.21.39).
Step 4.
a.
b.
2-36
Change oil and oil filter.
Refer to LO 10-4320-344-12 to change oil and filter.
Notify direct support maintenance.
TM 10-4320-344-24
SECTION V. UNIT MAINTENANCE PROCEDURES
2.11 GENERAL MAINTENANCE PROCEDURES.
2.11.1 Data Plate Replacement.
This task covers:
2.11.1.1 Removal
2.11.1.2
Installation
INITIAL SETUP
Use With
Equipment
Conditions
Trailer-Mounted Pump Assemblies
609-A, 609-C and US636HCCD-1
Pumping station shut down, TM
10-4320-344-10.
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
R i v e t e r , Blind, Appendix B,
Section III, Item 4
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
Material/Parts
Rivets (TM 10-4320-344-24P)
NOTE
This procedure applies to all rivet mounted data plates on all pumping
assemblies. The procedures for screw mounted and adhesive backed data plates
are similar.
2.11.1.1 Removal.
a.
Remove four rivets (Figure 2-5, 1).
b.
Remove data plate (2).
2.11.1.2
Installation.
a.
Position data plate (2) on enclosure (3).
b.
Using blind riveter, install four rivets (1).
2-37
TM 10-4320-344-24
2.11.1 Data Plate Replacement. (Continued)
Figure 2-5.
2-38
Data Plate Replacement. (Model 609-C Shown)
TM 10-4320-344-24
2.11.2 Stud and Thread Repair.
This task covers:
Repair
INITIAL SETUP
Use With
Material/Parts
Trailer-Mounted Pump Assemblies
609-A, 609-C and US636HCCD-1
Gloves, Appendix C, Item 11
Oil, General Lubricating, Appendix C,
Item 16
Oil, Transmission, Appendix C, Item 17
Rags, Wiping, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C, Item 26
Tools
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Air Blow Gun, Appendix B, Section
III, Item 2
Electric Portable Drill, Appendix
B, Section III, Item 2
Goggles, Appendix B, Section III,
Item 2
Screw Extractor Set, Appendix B,
Section III, Item 2
Twist Drill Set, Appendix B,
Section III, Item 2
Screw Threading Set, Appendix B,
Section III, Item 3
Equipment
Pumping station shut down, TM
10-4320-344-10.
General
Safety
Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without
standard shop safety precautions.
2.11.2.1 Repairing Studs or Screws Broken Flush.
a.
Conditions
following
(Refer to Figure 2-6, View A)
Center punch broken stud or screw.
Be careful not to drill into the component when repairing studs or screws.
Failure to obey this caution will result in damage to the equipment.
b.
Drill into broken stud or screw using a drill bit 1/16 inch (0.002 mm) less
than the diameter of the broken stud or screw.
c.
Using a screw extractor, remove broken stud or screw.
Figure 2-6. Removing or Repairing Studs or Screws.
2-39
TM
10-4320-344-24
2.11.2 Stud and Thread Repair. (Continued)
2.11.2.2 Removing Studs or Screws That Have Not Broken Flush.
and C)
(Refer to Figure 2-6, Views B
a.
Spray broken stud or screw with general lubricating oil and allow it to
penetrate.
b.
Clamp broken stud or screw using pliers.
c.
Tap broken stud or screw and back out.
d.
If stud or screw can not be removed, repair stud or screw (paragraph
2.11.2.1).
2.11.2.3 Repair Of Damaged Threaded Insert.
a.
Using proper tap and transmission oil, chase insert threads.
b.
If threads can not be restored or excessive damage exists, replace damaged
inserts (paragraph 2.11.2.4).
2.11.2.4 Removing Damaged Threaded Insert. (Refer to Figure 2-7)
Figure 2-7.
Removing Damaged Threaded Insert.
• Do not damage threads of tapped hole when using extraction tool.
Ž Remove inserts from end of tapped hole that the insert is closest to.
in tapped hole can be damaged.
Threads
All sizes for tools and threaded inserts depend on original size.
a.
Place extraction tool (Figure 2-7, 1) in insert (2). Tap top of extraction
tool (1).
b.
Maintaining a steady downward pressure, turn extraction tool (1)
counterclockwise and remove insert (2).
2-40
TM 10-4320-344-24
If insert (2)
c.
If insert (2) does not come out of tapped hole, go to step d.
does come out of tapped hole, go to step h.
d.
Insert scribe (3) between end of insert (2) and tapped hole.
e.
Work end of insert (2) away from tapped hole and form a tang e q u a l i n l e n g t h
to diameter of insert (2).
f.
Using needle nose pliers (4), grasp tang.
g.
Turn insert (2) counterclockwise until insert is out of tapped hole.
insert (2).
h.
Lubricate finishing tap (5) with transmission oil.
i.
U s i n g f i n i s h i n g t a p ( 5 ) a n d t a p h a n d l e , slowly thread tap in and out of tapped
hole.
Compressed air can blow dust into the eyes.
exceed 30 psi (207 kPa) air pressure.
Wear eye protection.
Discard
Do not
Dry cleaning solvent is highly toxic and can ignite
o r g a n i c m a t e r i a l s , n i t r a t e s , c a r b i d e s , a n d c h l o r a t e s . Wear eye, skin, and
respiratory protection. Use only in well ventilated area.
j.
Using compressed air, blow out dirt and any loose metal chips in tapped hole.
k.
Use wiping rag dampened with cleaning solvent to clean tapped hole.
l.
If threads can not be restored or excessive damage exists, go to 2.11.2.5. If
threads are not damaged, go to 2.11.2.6.
2.11.2.5
Oversizing Insert Pilot Holes. (Refer to figure 2-8)
Figure 2-8.
Oversizing Insert Pilot Holes.
A l l s i z e s f o r tools and threaded inserts depend on original bolt size.
to repair kit for proper drill and tap sizes.
a.
Refer
U s i n g d r i l l ( F i g u r e 2 - 8 , 1) bore out damaged threads (2) to original depth.
2-41
TM 10-4320-344-24
2.11.2 Stud and Thread Repair. (Continued)
Compressed air can blow dust into the eyes.
exceed 30 psi (207 kPa) air pressure.
Wear eye protection.
b.
Clean newly bored hole using compressed air.
c.
Lubricate thread cutting tap (3) with transmission oil.
d.
Using tap handle and tap (3), cut new threads.
Compressed air can blow dust into the eyes.
exceed 30 psi (207 kPa) air pressure.
Wear eye protection.
Do not
Do not
Dry cleaning solvent is highly toxic and can
i g n i t e o r g a n i c m a t e r i a l s , n i t r a t e s , c a r b i d e s , a n d c h l o r a t e s . Wear
e y e , s k i n , a n d r e s p i r a t o r y p r o t e c t i o n . Use only in well ventilated
area.
e.
Using compressed air, blow out dirt and any loose metal chips in threads.
f.
Using rag dampened with cleaning solvent, clean hole.
2-42
TM 10-4320-344-24
2.11.2.6 Installing Threaded Insert. (Refer to Figure 2-9)
Figure 2-9.
Preparing Threaded Insert for Installation.
a.
Loosen setscrew (Figure 2-9,
b.
Turn handle until shaft (2) extends past tip of insertion tool (3)
slightly longer than length of new insert (4).
c.
Screw insert (4) on shaft until tang (5) of insert (4) goes into shaft notch
(6).
d.
Adjust distance (7) between insert end(8) and tip (9). Turn handle
until distance is equal to installation depth below surface of tapped hole.
e.
Push down stop collar (10) until it contacts body of insertion tool (3).
f.
Tighten setscrew (1).
g.
Remove insert (4) from shaft (2).
h.
Turn handle until insert (4) can be slipped into tool barrel.
i.
Thread insert (4) onto shaft (2) while inside tool barrel. until shaft notch
(6) engages tang (5).
j.
Turn handle until tang of insert (4) is even with tip of insertion tool (3).
1) and slide collar (10) back.
2-43
TM 10-4320-344-24
2.11.2 Stud and Thread Repair. (Continued)
Figure 2-10.
Installing Threaded Insert.
Insertion tool must be straight and not allowed to wobble when installing
i n s e r t . Equipment can be damaged.
Do not force insert into tapped hole.
Threads will be damaged.
k.
Put tip of insertion tool (Figure 2-10, 1) against tapped hole being sure that
insertion tool is straight.
l.
Slowly turn handle of insertion tool (1) clockwise until stop collar (2)
contacts body of insertion tool (1).
m.
Turn handle of insertion tool (1) counterclockwise until insertion tool (1)
can be removed.
n.
Place tang breakoff tool (3) in tapped hole with threaded insert (4).
o.
Push down end of breakoff tool (3) until tang (5) breaks off insert.
2-44
TM 10-4320-344-24
2.12 SOUND ENCLOSURE ASSEMBLY MAINTENANCE, MODEL 609-C.
2.12.1 Door Holder Assembly Replacement, Model 609-C.
This task covers:
2.12.1.1 Removal
2.12.1.2
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
111, Item 1
Pumping station shut down, TM
10-4320-344-10.
General Safety I n s t r u c t i o n s
Material/Parts
To prevent rolling or sliding, do not work
on equipment that-is not securely
stabilized.
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment without following
standard shop safety precautions.
T h i s p r o c e d u r e a p p l i e s t o a l l d o o r h o l d e r a s s e m b l i e s . Two different hook
This
configurations are used, two screw mounted and four screw mounted.
procedure covers the hook configuration secured by two mounting screws.
2.12.1.1 Removal.
a.
Remove two screws (Figure 2-11,
(2).
b.
Remove h o o k ( 3 ) f r o m e n c l o s u r e ( 7 ) .
c.
Remove f o u r s c r e w s ( 4 ) a n d l o c k w a s h e r s ( 5 ) .
d.
Remove h o l d e r ( 6 ) f r o m e n c l o s u r e ( 7 ) .
2.12.1.2
1) and lock washers (2).
Discard lock washers
Discard lock washers (5).
Installation.
a.
Position hook (3) on enclosure (7).
b.
Install two new lock washers (2) and screws (l).
c.
Position holder (6) on enclosure (7).
d.
Install two new lock washers (5) and screws (4).
2-45
TM 10-4320-344-24
2.12.1 Door Holder Assembly Replacement. Model 609-C. (Continued)
Figure 2-11.
2-46
Door Holder Assembly Replacement.
TM 10-4320-344-24
2.12.2 Access Cover Assembly Maintenance, Model 609-C.
This task covers:
2.12 .2.1 Removal
2.12.2.2 Inspection
2 .12.2.3 Repair
2.12.2.4 Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Euipment Conditions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down,
TM 10-4320-344-10.
2.12.2.1 Removal.
Figure 2-12.
Access Cover Assembly Maintenance.
a.
Remove fourteen screws (Figure 2-12, 1).
b.
Remove access cover assembly (2) from enclosure ( 3 ) .
2-47
TM 10-4320-344-24
2.12.2 Access Cover Assembly Maintenance, Model 609-C.
(Continued)
2.12.2.2 Inspection. Inspect access cover assembly (2) for deterioration or damage of
insulation material on inner surface, corrosion, bends, or cracks.
2.12.2.3 Repair.
a.
Replace access cover assembly (2) if metal plate is damaged.
b.
Replace damaged or deteriorated insulation material on inner surface of access
c o v e r a s s e m b l y ( 2 ) . Refer to Appendix D to manufacture new insulation
material.
2.12.2.4
Installation.
a.
Position access cover assembly (2) on enclosure (3).
b.
Install fourteen screws (1).
2-48
TM 10-4320-344-24
2.12.3 Door Assembly Maintenance. Model 609-C.
This task covers:
2.12.3.1 Removal
2.12.3.2 Inspection
2.12.3.3 Repair
2.12.3.4 Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B , S e c t i o n I I I ,
Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
Do not work on equipment without following
standard shop safety precautions.
Conditions
Pumping station shut down ,
TM 10-4320-344-10.
This procedure applies to all door assemblies.
2.12.3.1 Removal.
Figure 2-13.
Door Assembly Maintenance.
2-49
TM 10-4320-344-24
a.
Remove four bolts (Figure 2-13,
1) and flat washers (2).
b.
Remove two door latch catches (3) from enclosure (4).
c.
Remove nine bolts (5).
d.
Remove door assembly (6) from enclosure (4).
2.12.3.2 Inspection.
a.
Inspect door assembly (6) for deterioration or damage of insulation material
on inner surface, corrosion, bends, or cracks.
b.
Inspect two door latches (8) and door assembly hinge (9) for damage.
c.
Inspect door assembly seal trim (7) for cracks or deterioration.
2.12.3.3 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of door
a s s e m b l y ( 6 ) . Refer to Appendix D to manufacture new insulation material.
b.
Replace door assembly (6) if door latches (8) or hinge (9) are defective.
c.
Replace damaged door assembly seal trim (7).
2.12.3.4
Installation.
a.
Position door assembly (6) on enclosure (4).
b.
Install nine bolts (5).
c.
Position two door latch catches (3) on enclosure (4).
d.
Install four flat washers (2) and bolts (1).
2-50
TM 10-4320-344-24
2.12.4 Top Panel Assembly Maintenance. Model 609-C.
This task
2.12.4.1
2.14.2.2
2.12.4.3
covers:
Removal
Disassembly
Inspection
2.12.4.4 Repair
2.12.4.5 Assembly
2.12.4.6 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Pumping station shut down, TM
10-4320-344-10.
Material/Parts
Lock Nut (TM 10-4320-344-24P)
Personnel
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not lift top panel assembly alone.
Two people are required to lift
the top panel assembly.
Do not work on equipment without following
standard shop safety precautions.
2.12.4.1 Removal.
Figure 2-14.
Top Panel Assembly Maintenance.
(Sheet 1 of 2)
2-51
TM 10-4320-344-24
2.12.4 Top Panel Assembly Maintenance, Model 609-C. (Continued)
Figure 2-14.
Top Panel Assembly Maintenance.
a.
Remove lock nut (Figure 2-14, 1) and flat washer (2).
b.
Lower exhaust cover (3).
(Sheet 2 of 2)
Discard lock nut (1)
Some top panel assembly mounting screws are secured with nuts.
of screw and nut combinations to facilitate reinstallation.
c.
2-52
Mark location
Remove screws (4) and nuts (5) from top panel assembly (6). Mark location of
screw and nut combinations.
TM 10-4320-344-24
Two people are required to lift the top panel assembly from the enclosure.
Failure to obey this warning may result in personal injury or damage to the
equipment.
d.
Remove top panel assembly (6) from enclosure (7).
2.12.4.2 Disassembly.
Figure 2-15.
Top Panel Assembly.
a.
Remove two screws (Figure 2-15, 1) from top panel assembly ( 4 ) .
b.
Remove exhaust cover assembly (2).
c.
Remove hinge spacer (3).
d.
Remove fifteen nuts (5) and screws (6) from t o p p a n e l a s s e m b l y ( 4 ) .
e.
Remove four screws (7) and remove air duct crossover (8) from air duct entry
assembly (9) and air duct exit assembly (10).
2-53
TM 10-4320-344-24
2.12.4 Top Panel Assembly Maintenance, Model 609-C.
(Continued)
2.12.4.3 Inspection.
a.
Inspect top panel assembly (4), air duct crossover (8), air duct entry
a s s e m b l y ( 9 ) , and air duct exit assembly (10) for deterioration or damage of
insulation material on inner surfaces, corrosion, bends, or cracks.
b.
Inspect air duct crossover (8) and air duct assemblies (9 and 10) for
obstructions which restrict air flow through the assembly.
c.
Inspect exhaust cover assembly (2) for corrosion, bends, cracks, and smooth
operation of hinge (11).
2.12.4.4 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of top
p a n e l a s s e m b l y ( 4 ) , a i r d u c t c r o s s o v e r ( 8 ) , air duct entry assembly (9), and
a i r d u c t e x i t a s s e m b l y ( 1 0 ) . Refer to Appendix D to manufacture new
insulation.
b.
Replace top panel assembly (4), a i r d u c t c r o s s o v e r ( 8 ) , a i r d u c t e n t r y
a s s e m b l y ( 9 ) , air duct exit assembly (10), and exhaust door cover assembly (2)
if corrosion or damage, which does not permit proper mounting or securing of
top panel, is present.
c.
Replace exhaust cover assembly (2) and securing arm (12) if damaged.
2.12.4.5 Assembly.
a.
Install four screws (7) into air duct crossover (8), air duct entry assembly
(9), and air duct exit assembly (10).
b.
Position air duct entry assembly (9) and air duct exit assembly (10) on top
panel assembly (4).
c.
Install fifteen screws (6) and nuts (5).
d.
Position hinge spacer (3) and exhaust cover assembly (2) on top panel
assembly (4).
e.
Install two screws (1).
2.12.4.6
Installation.
Two people are required to lift the top panel assembly onto the enclosure.
Failure to obey this warning may result in personal injury or damage to the
equipment.
a.
Position top panel assembly (Figure 2-14, 6) on enclosure (7).
Ensure screw and nut combinations are installed in locations marked during
removal.
b.
I n s t a l l s c r e w s ( 4 ) a n d n u t s ( 5 ) , at locations marked during removal.
c.
Lift exhaust cover assembly (3) and install flat washer (2) and new lock
nut (1).
2-54
TM 10-4320-344-24
2.12.5 Bulk Head Panel Assembly and Outlet Scoop) Assembly Maintenance, Model 609-C.
This task
2.12.5.1
2.12.5.2
2.12.5.3
covers:
Removal
Disassembly
Inspection
2.12.5.4 Repair
2.12.5.5 Assembly
2.12.5.6 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Top Panel Assembly removed, paragraph
2.12.4.
General Safety I n s t r u c t i o n s
Personnel
Two people are required to lift
the bulk head panel assembly.
Equipment
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Conditions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM
10-4320-344-10.
2.12.5.1 Removal.
Some bulk head panel assembly mounting screws are secured with nuts.
location of screw and nut combinations to facilitate reinstallation.
a.
Mark
Remove screws (Figure 2-16, 1) and nuts (2) from bulk head panel assembly (3).
Mark location of screw and nut combinations.
Two people are required to lift the bulk head panel assembly from the pumping
assembly.
Failure to obey this warning may result i n p e r s o n a l i n j u r y o r
damage to the equipment.
b.
Remove bulk head panel assembly (3) from pumping a s s e m b l y ( 4 ) .
2.12.5.2 Disassembly.
a.
Remove two screws (5), flat washers (6), and flange b e a r i n g ( 7 ) .
b.
Remove five nuts (8) and screws (9).
outlet frame assembly (11).
c.
Remove nut (12 , f l a t w a s h e r ( 1 3 ) , a n d b o l t ( 1 4 ) .
d.
Remove exhaust c o v e r l i n k ( 1 5 ) .
e.
Remove nut (16 , f l a t w a s h e r ( 1 7 ) , and exhaust cover link
f.
Remove nut (19 , s c r e w ( 2 0 ) , flat washer (21), and linkage bracket
assembly (22).
g.
R e m o v e t w o n u t s ( 2 3 ) , f l a t w a s h e r s ( 2 4 ) , s c r e w s ( 2 5 ) , f l a t washers
handle (27) from outlet scoop (28).
Remove outlet scoop assembly (10) from
18).
(26), and
2-55
TM 10-4320-344-24
2.12.5 Bulk Head Panel Assembly and Outlet Scoop Assembly Maintenance. Model 609-C. (Continued
Figure 2-16.
2-56
Bulk Head Panel Assembly and Outlet Scoop Assembly Maintenance.
TM 10-4320-344-24
h.
Remove five screws (29) .
i.
Remove outlet frame assembly (11) from bulk head panel assembly (3)
2.12.5.3
Inspection.
a.
Inspect bulk head panel assembly (3) and outlet scoop (28) for deterioration
or damage of insulation material on inner surface, corrosion, bends, or
cracks.
b.
I n s p e c t o u t l e t f r a m e a s s e m b l y ( 1 1 ) , exhaust cover links (15 and 18), and hinge
(30) for damage.
2.12.5.4 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of bulk
Refer to Appendix D to
head panel assembly (3) and outlet scoop (28).
manufacture new insulation material.
b.
Replace bulk head panel assembly (3) or outlet frame assembly (11) if corroded
or damaged to the extent that they can not be properly, mounted or secured.
2.12.5.5 Assembly.
a.
Install outlet frame assembly (11) on bulk head panel assembly (3) and secure
with five screws (29).
b.
Secure handle (27) to outlet scoop (28) with two flat washers (26),
b o l t s ( 2 5 ) , flat washers (24), and nuts (23).
c.
Insert screw (20), flat washer (21), linkage bracket (22), and nut (19) on
outlet scoop (28).
d.
Install exhaust cover link (18) on linkage bracket (22) with flat washer (17)
and nut (16).
e.
Install exhaust cover link (15) on exhaust cover link (18) and secure with
screw (14), flat washer (13), and nut (12).
f.
Position outlet scoop assembly (10) in outlet frame assembly (11) and secure
with five screws (9) and nuts (8) with outlet scoop assembly (10) pulled out.
Install two flange bearings (7), flat washers (6), and screws (5).
2.12.5.6
Installation.
Two people are required to lift the bulk head panel assembly onto the pumping
assembly.
Failure to obey this warning may result in personal injury or
damage to the equipment.
a.
Position bulk head panel assembly (3) on pumping assembly (4).
Ensure screw and nut combinations are installed at locations marked during
removal.
b.
Install screws (1) and nuts (2), at locations marked during removal.
2-57
TM 10-4320-344-24
2.12.6 Right Side Panel Assembly Maintenance. Model 609-C.
This task covers:
2.12.6.1 Removal
2.12.6.2 Inspection
2.12.6.3 Repair
2.12.6.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Right Side Engine Access Door Assembly
removed, paragraph 2.12.3.
Top Panel Assembly removed,
paragraph 2.12.4.
Personnel
people are required to lift
the right side panel assembly.
TWO
Equipment
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Conditions
Pumping station shut down, TM
10-4320-344-10.
Do not work on equipment without following
standard shop safety precautions.
Door Holder Assembly removed,
paragraph 2.12.1.
2.12.6.1 Removal.
Some right side panel assembly mounting bolts are secured with nuts.
location of bolt and nut combinations to facilitate reinstallation.
a.
Remove bolts (Figure 2-17, 1) and nuts (2) from right side panel assembly (3).
Mark location of screw and nut combinations.
Figure 2-17.
2-58
Mark
Right Side Panel Assembly.
TM 10-4320-344-24
Two people are required to lift the right side panel assembly from the
pumping assembly.
Failure to obey this warning may result in personal injury
or damage to the equipment.
b.
Remove right side panel assembly (3) from pumping assembly (4).
2.12.6.2 Inspection. I n s p e c t r i g h t s i d e p a n e l a s s e m b l y ( 3 ) f o r d e t e r i o r a t i o n o r
damage of insulation material on inner surface, corrosion, bends, or cracks.
2.12.6.3 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of right
s i d e p a n e l a s s e m b l y ( 3 ) . Refer to Appendix D to manufacture new insulation
material.
b.
R e p l a c e r i g h t s i d e p a n e l a s s e m b l y (3) if corroded or damaged, to the extent
that it can not be properly mounted or secured.
2.12.6.4
Installation.
Two people are required to lift the right side panel assembly onto the
pumping assembly. Failure to obey this warning may result in personal injury
or damage to the equipment.
a.
Position right side panel assembly (3) on pumping assembly (4).
Ensure screw and nut combinations are installed in locations marked during
removal.
b.
I n s t a l l s c r e w s ( 1 ) a n d n u t s ( 2 ) , at locations marked during removal.
2-59
TM 10-4320-344-24
2.12.7 Control Panel Housing Assembly Maintenance, Model 609-C.
This task covers:
2.12.7.1 Removal
2.12.7.2
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Manual Throttle Control Cable removed,
paragraph 2.16.26.
Equipment
Auto Defeat Cable removed, paragraph
2.16.28.
Conditions
Pumping station shut down,
10-4320-344-10.
TM
Top Panel Assembly removed,
paragraph 2.12.4.
Control Panel Assembly removed,
paragraph 2.15.3.
Cold Start Aid Cable removed, paragraph
2.16.29.
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.12.7.1 Removal.
Some control panel housing assembly mounting bolts are secured with nuts.
Mark location of bolt and nut combinations to facilitate reinstallation.
a.
Remove bolts (Figure 2-18, 1) and nuts (2) from control panel housing assembly
( 3 ) . Mark location of screw and nut combinations.
Figure 2-18.
b.
2-60
Control Panel Housing Assembly.
Remove control panel housing assembly (3)
from pumping assembly (4).
TM 10-4320-344-24
2.12.7.2
a.
Installation.
Position control panel housing assembly (3) on pumping assembly (4).
Ensure bolt and nut combinations are installed at locations marked during
removal.
b.
I n s t a l l b o l t s ( 1 ) a n d n u t s ( 2 ) , at locations marked during removal.
2-61
TM 10-4320-344-24
2.12.8 Left Side Panel Assembly Maintenance, Model 609-C.
This task covers:
2 .12.8.1 Removal
2.12.8.2 Inspection
2.12.8.3 Repair
2.12.8.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Top Panel Assembly removed,
paragraph 2.12.4.
Electrical Receptacle Connector removed,
paragraph 2.15.7.
Personnel
Two people are required to lift
the left side panel assembly.
Equipment
Auxiliary Fuel Supply and Fuel Return Lines
removed from left side panel assembly,
paragraph 2.21.2.
Conditions
Pumping station shut down,
10-4320-344-10.
TM
Filler Neck Assembly removed, paragraph
2.22.1.
General Safety I n s t r u c t i o n s
Access Cover Assembly removed,
paragraph 2.12.2.
Air Cleaner and Left Side Engine
Access Door Assemblies removed,
paragraph 2.12.3.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.12.8.1 Removal.
Some left side panel assembly mounting screws are secured with nuts.
location of screw and nut combinations to facilitate reinstallation.
a.
Mark
Remove screws (Figure 2-19, 1 ) a n d n u t s ( 2 ) f r o m l e f t s i d e p
. anel assembly (3).
Mark location of nut and screw combination.
Two people are required to lift the left side panel assembly from the pumping
assembly.
F a i l u r e t o o b e y this warning may result in personal injury or
damage to the equipment.
b.
Remove left side panel assembly (3) from pumping assembly (4).
c.
Remove screws (5) securing side screen assembly (6) to left side panel
assembly (3).
2.12.8.2 Inspection. I n s p e c t l e f t s i d e p a n e l a s s e m b l y ( 3 ) f o r d e t e r i o r a t i o n o r d a m a g e
of insulation material on inner surface, corrosion, bends, or cracks.
2.12.8.3 Repair.
a.
2-62
Replace damaged or deteriorated insulation material on inner surface of left
s i d e p a n e l a s s e m b l y ( 3 ) . Refer to Appendix D to manufacture new insulation
material.
TM 10-4320-344-24
Figure 2-19.
b.
Left Side Panel Assembly.
Replace left side panel assembly (3) if corroded or damaged to the extent that
it can not be properly mounted or secured.
2.12.8.4 Installation.
a.
Install side screen assembly (5) on left side panel assembly (3) and secure
with screws (5).
Two people are required to l i f t t h e l e f t s i d e p a n e l a s s e m b l y o n t o t h e p u m p i n g
F a i l u r e t o o b e y this warning may result in personal injury or
assembly.
damage to the equipment.
b.
P o s i t i o n l e f t s i d e p a n e l assembly (3) on pumping assembly (4).
Ensure screw and nut combinations are installed in locations marked during
removal.
c.
Install screws (1) and nuts (2), at locations marked during removal.
2-63
TM 10-4320-344-24
2.12.9 Left Rear Quarter Panel Assembly Maintenance, Model 609-C.
This task covers:
2.12.9.1 Removal
2.12.9.2 Inspection
2.12.9.3 Repair
2.12.9.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Top Panel Assembly removed,
paragraph 2.12.4.
General Safety I n s t r u c t i o n s
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Battery Compartment Door Assembly
removed, paragraph 2.12.3.
Do not work on equipment without following
standard shop safety precautions.
2.12.9.1 Removal.
Figure 2-20.
Left Rear Quarter Panel Assembly.
Some left side panel assembly mounting screws are secured with nuts.
location of screw and nut combinations to facilitate reinstallation.
Mark
a.
Remove screws (Figure 2-20, 1) and nuts (2) from left rear quarter panel
a s s e m b l y ( 3 ) . Mark location of screw and nut screw combinations.
b.
Remove left rear quarter panel assembly (3) from pumping assembly (4).
2-64
TM 10-4320-344-24
2.12.9.2
Inspection.
a.
I n s p e c t l e f t r e a r q u a r t e r p a n e l a s s e m b l y f o r ( 3 ) f o r d e t e r i o r a t i o n o r damage
of insulation material on inner surface, corrosion, bends, or cracks.
b.
Inspect screen (5) for damage or separation from inner surface of left rear
quarter panel assembly (3).
2.12.9.3 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of left
r e a r q u a r t e r p a n e l a s s e m b l y ( 3 ) . Refer to Appendix D to manufacture new
insulation material.
b.
Replace left rear quarter panel assembly (3) if corroded or damaged to the
extent that it can not be properly mounted or secured.
c.
Replace left rear quarter panel assembly (3) if screen (5) is damaged or
separated from left rear quarter panel assembly (3).
2.12.9.4
a.
Installation.
P o s i t i o n l e f t r e a r quarter panel assembly (3) on pumping assembly (4).
Ensure screw and nut combinations are installed in locations marked during
removal.
b.
I n s t a l l s c r e w s ( 1 ) a n d n u t s ( 2 ) , a t l o c a t i o n s marked during removal.
2-65
TM 10-4320-344-24
2.12.10 Upper Cover Plate Maintenance. Model 609-C.
This task covers:
2.12.10.1 Removal
2.12.10.2 Inspection
2.12.10.3 Repair
2.12.10.4 Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
Do not work on equipment without following
standard shop safety precautions.
Conditions
Pumping station shut down, TM
10-4320-344-10.
2.12.10.1 Removal.
Figure 2-21.
a.
2-66
Remove screws (Figure 2-21,
cover plate (3).
Upper Cover Plates Maintenance.
1) from left upper cover plate (2) and right upper
TM 10-4320-344-24
b.
Remove seal trim (4) from left u p p e r c o v e r p l a t e ( 2 ) a n d r i g h t u p p e r c o v e r
plate (3).
c.
Remove left upper cover plate
enclosure (5).
2) and right upper cover plate (3) from
2.12.10.2 Inspection.
a.
Inspect left upper cover plate ( 2 ) a n d r i g h t u p p e r c o v e r p l a t e ( 3 ) f o r
deterioration or damage of insulation material on inner surface, corrosion,
bends, o r c r a c k s .
b.
Inspect seal trim (4) for cracks or deterioration.
2.12.10.3 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of left
u p p e r c o v e r p l a t e ( 2 ) a n d r i g h t u p p e r c o v e r p l a t e ( 3 ) . Refer to Appendix D to
manufacture new insulation material.
b.
Replace upper cover plates (2 or 3) if corroded or damaged to the extent that
they can not be properly mounted or secured.
c.
Replace damaged seal trim (4).
2.12.10.4 Installation.
a.
Position right upper cover plate (3) and left upper cover plate (2) on
enclosure (5).
b.
Install seal trim (4) on right upper cover plate (3) and left upper cover
plate (2).
c.
Install screws (1).
2-67
TM 10-4320-344-24
2.12.11 End Panel Assembly Maintenance, Model 609-C.
This task covers:
2.12.11.1 Removal
Inspection
2.12.11.2
2.12.11.3
Repair
2.12.11.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Trailer Service Lights removed, paragraph
2.15.1
Drain Plug and Primer Port removed,
paragraph 2.18.1
Personnel
Two people are required
the end panel assembly.
Equipment
to
lift
Conditions
Pumping station shut down, TM
10-4320-344-10.
Top Panel Assembly removed,
paragraph 2.12.4.
Suction and Discharge Elbows removed,
paragraph 2.18.2
General Safety Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions
Upper Cover Plates removed,
paragraph 2.12.10.
2.12.11.1 Removal.
Figure 2-22. End Panel Assembly Maintenance.
2-68
TM 10-4320-344-24
Some end panel assembly mounting screws are secured with nuts.
of screw and nut combinations to facilitate reinstallation.
a.
Mark location
Remove screws (Figure 2-22, 1) and nuts (2) from end panel assembly (3).
location of nut and screw combinations.
Mark
Two people are required to lift the end panel assembly from the pumping
assembly.
F a i l u r e t o o b e y this warning may result in personal injury or
damage to the equipment.
b.
Remove end panel assembly (3) from pumping assembly (4).
2.12.11.2 Inspection. I n s p e c t e n d p a n e l a s s e m b l y f o r ( 3 ) f o r d e t e r i o r a t i o n o r d a m a g e
of insulation material on inner surface, corrosion, bends, or cracks.
2.12.11.3 Repair.
a.
Replace damaged or deteriorated insulation material on inner surface of end
p a n e l a s s e m b l y ( 3 ) . Refer to Appendix D to manufacture new insulation
material.
b.
Replace end panel assembly (3) if corroded or damaged to the extent that it
can not be properly mounted or secured.
2.12.11.4 Installation.
Two people are required to lift the end panel assembly onto the pumping
assembly.
Failure to obey this warning may result in personal injury or
damage to the equipment.
a.
Position end panel assembly (3) on pumping assembly (4).
Ensure screw and nut combinations are installed at locations marked during
removal.
b.
I n s t a l l s c r e w s ( 1 ) a n d n u t s ( 2 ) , at locations marked during removal.
2-69
TM 10-4320-344-24
2.12.12 Strap Replacement, Model 609-C.
This task covers:
2.12.12.1 Removal
2.12.12.2 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
End Panel Assembly removed, paragraph
2.12.11.
Equipment
General Safety I n s t r u c t i o n s
Conditions
Pumping station shut down, TM
10-4320-344-10.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Top Panel Assembly removed,
paragraph 2.12.4.
Do not work on equipment without following
standard shop safety precautions.
2.12.12.1 Removal.
Figure 2-23.
Sound Enclosure Straps.
a.
Remove two nuts (Figure 2-23, 1) and bolts (2).
b.
Remove two straps (3) from bulkhead panel assembly (4).
2.12.12.2 Installation. Position two straps (3) against bulkhead panel assembly (4)
and secure with two bolts (2) and nuts (1).
2-70
TM 10-4320-344-24
2.12.13 Baffle Maintenance. Model 609-C.
This task covers:
2.12.13.1 Removal
2.12.13.2 Inspection
2.12.13.3
Repair
2.12.13.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
End Panel Assembly removed, paragraph
2.12.11.
General Safety I n s t r u c t i o n s
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Top Panel Assembly removed,
paragraph 2.12.4.
Do not work on equipment without following
standard shop safety precautions.
2.12.13.1 Removal.
1), bolts (2), and right side baffle (3) from
a.
Remove ten nuts (Figure 2-24,
bulkhead panel assembly (4).
b.
Remove five nuts (5), b o l t s ( 6 ) , a n d l e f t s i d e b a f f l e ( 7 ) f r o m b u l k h e a d p a n e l
assembly (4).
2.12.13.2 Inspection.
a.
Inspect baffles (3 and 7) for deterioration or damage to insulation material,
corrosion, bends, or cracks.
2.12.13.3 Repair.
a.
Replace damaged or deteriorated insulation material on baffles (3 and 7).
Refer to Appendix D to manufacture new insulation material.
b.
Replace baffles (3 or 7) if corroded or damaged to the extent that they can
not be properly mounted or secured.
2.12.13.4 Installation.
a.
Position left side baffle (7) against bulkhead panel assembly (4) and secure
with five bolts (6) and nuts (5).
b.
Position right side baffle (3) against bulkhead panel assembly (4) and secure
with ten bolts (2) and nuts (1).
2-71
TM 10-4320-344-24
2.12.13 Baffle Maintenance. Model 609-C. (Continued)
Figure 2-24.
2-72
Sound Enclosure Baffles.
TM 10-4320-344-24
2.12.14 Cooling Duct Assembly and Outlet Duct Frame Assembly Maintenance, Model 609-C.
This task covers:
2.12.14.1 Removal
2.12.14.2 Inspection
2.12.14.3 Repair
2.12.14.4 Installation
INITIAL SETUP
(Continued)
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Left Side Panel Assembly removed, paragraph
2.12.8.
Material/Parts
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
End Panel Assembly removed, paragraph
2.12.11.
Muffler removed, paragraph 2.13.2.
General Safety I n s t r u c t i o n s
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Top Panel Assembly removed,
paragraph 2.12.4.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
not work on equipment without following
standard shop safety precautions.
DO
2.12.14.1 Removal.
a.
Remove and disassemble outlet duct frame assembly (Figure 2-25, 1) as follows:
(1) Remove fourteen screws (2) and lock washers (3). Discard lock washers (3).
(2) Remove eight nuts (4), lock washers (5), and screws (6). Discard lock
washers (5).
(3) Remove two nuts (7), screws (8), and outlet duct frame assembly (1).
(4) Remove twenty-two nuts (9), flat washers (10), lock washers (11), and screws
Discard lock washers (11).
(12).
(5) Remove and discard gasket (13).
b.
Remove screws (14) and end cover screen (15) from cooling duct assembly (16).
c.
Remove screws (17) and back screen (18) from cooling duct assembly (16).
d.
R e m o v e t w e n t y - s e v e n n u t s ( 1 9 ) , b o l t s ( 2 0 ) , and cooling duct assembly (16) from
bulkhead panel assembly (21) and support frame assembly (22).
2.12.14.2 Inspection.
a.
Inspect cooling duct assembly (16) for deterioration or damage to insulation
material.
b.
Inspect outlet duct frame assembly (1), end cover screen (15), cooling duct
a s s e m b l y ( 1 6 ) , and back screen (18) for damage.
2.12.14.3 Repair.
a.
Replace damaged or deteriorated insulation material on muffler side of cooling
d u c t a s s e m b l y ( 1 6 ) . Refer to Appendix D to manufacture new insulation
material.
2-73
TM 10-4320-344-24
2.12.14 Cooling Duct Assenbly and Outlet Duct Frame Assembly Maintenance, Model 609-C. (Continued)
Figure 2-25.
2-74
Cooling Duct Assembly and Screen Assembly Maintenance.
TM 10-4320-344-24
b.
Replace outlet duct frame assembly (1), end cover screen (15), cooling duct
assembly (16), and back screen (18) if corroded or damaged to the extent that
they can not be properly mounted or secured.
2.12.14.4 Installation.
a.
Position cooling duct assembly (16) on bulkhead panel assembly (21).
b.
Install twenty-seven bolts (20) through cooling duct assembly (16), bulkhead
panel assembly (21), and support frame assembly (22) and secure with twentyseven nuts (19).
c.
Position back screen (18) on cooling duct assembly (16) and secure with screws
(14) .
d.
Position end cover screen (15) on cooling duct assembly (16) and secure with
screws (14) .
e.
Assemble and install outlet duct frame assembly (1) as follows:
(1) Position new gasket (13) in outlet duct frame assembly (1) and secure with
twenty-two screws (12), new lock washers (11), flat washers (10), and nuts
(9).
(2) Insert outlet duct frame assembly (1) into cooling duct assembly (16).
(3) Install two screws (8) and nuts (7).
(4) Install eight screws (6), new lock washers (5), and nuts (4).
(5) Install fourteen new lock washers (3) and screws (2).
2-75
TM 10-4320-344-24
2.12.15 Bulkhead Panel Assembly and Belt Guard Maintenance, Model 609-C.
This task covers:
2.12.15.1 Removal
2.12.15.2 Disassembly
2.12.15.3 Inspection
2.12.15.4 Repair
2.12.15.5 Assembly
2.12.15.6 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
End Panel Assembly removed, paragraph
2.12.11.
Straps removed, paragraph 2.12.12.
Material/Parts
Baffles removed, paragraph 2.12.13.
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Cooling Duct Assembly and Outlet Duct Frame
Assembly removed, paragraph 2.12.14.
Air Intake Hose removed, paragraph 2.14.4.
General Safety Instructions
Top Panel Assembly removed,
paragraph 2.12,4.
Right Side Panel Assembly removed,
paragraph 2.12.6.
Left Side Panel Assembly removed,
paragraph 2.12.8.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.12.15.1 Removal.
a.
Remove bolts (Figure 2-26, 1).
b.
Remove bulkhead panel assembly (2) from trailer (3).
2.12.15.2 Disassembly.
a.
Remove two screws (4), lock washers (5), flat washers (6), and right side belt
guard (7) from bulkhead panel assembly (2).
Discard lock washers (5)
b.
Remove four screws (8), four lock washers (9), four flat washers (10), and
left side belt guard (11) from bulkhead panel assembly (2). Discard lock
washers (9).
2.12.15.3 Inspection.
a.
Inspect bulkhead panel assembly (2) for deterioration or damage to insulation
material.
b.
Inspect bulk head assembly (2) and belt guards (7 and 11) for corrosion,
bends, or cracks.
2.12.15.4 Repair.
a.
2-76
Replace damaged or deteriorated insulation material on hitch side of bulkhead
panel assembly (2). Refer to Appendix D to manufacture new insulation
material.
TM 10-4320-344-24
Figure 2-26.
b.
Bulkhead Panel Assembly and Belt Guards Maintenance.
R e p l a c e b u l k h e a d p a n e l a s s e m b l y ( 2 ) a n d b e l t g u a r d s (7 and 11) if corroded or
damaged to the extent that they can not be properly mounted or secured.
2-77
TM 10-4320-344-24
2.12.15 Bulkhead Panel Assembly and Belt Guard Maintenance, Model 609-C.
(Continued)
2.12.15.5 Assembly.
a.
b.
Position left side belt guard (11) against bulkhead panel assembly (2) and
secure with four new lock washers (9), flat washers (10), and screws (8).
Position right side belt guard (7) against bulkhead panel assembly (2) and
secure with four new lock washers (5), flat washers (6), and screws (4) .
2.12.15.6 Installation.
with bolts (1) .
2-78
Position bulkhead panel assembly (2) on trailer (3) and secure
TM 10-4320-344-24
2.12.16 Support Frame Assembly Maintenance, Model 609-C.
This task covers:
2 .12.16.1 Removal
2.12.16.2 Disassembly
2.12.16.3 Repair
2.12.16.4
Assembly
2.12.16.5 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Left Side Panel Assembly removed, paragraph
2.12.8.
Equipment
Conditions
Left Rear Quarter Panel Assembly removed,
paragraph 2.12.9.
Pumping station shut down, TM
10-4320-344-10.
Cooling Duct Assembly and Outlet Duct Frame
Assembly removed, paragraph 2.12.14.
Top Panel Assembly removed,
paragraph 2.12.4.
General Safety I n s t r u c t i o n s
Right Side Panel Assembly removed,
paragraph 2.12.6.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Control Panel Housing Assembly
removed, paragraph 2.12.7.
Do not work on equipment without following
standard shop safety precautions.
2.12.16.1 Removal.
a.
Remove four nuts (Figure 2-27, 1) and screws (2).
b.
Remove support frame assembly (3) from trailer (4).
2.12.16.2 Disassembly.
a.
Remove four nuts (5), bolts (6), and frame assembly (7) from horizontal frame
assembly (8) .
b.
R e m o v e f o u r n u t s ( 9 ) , b o l t s ( 1 0 ) , and frame assembly (11) from horizontal
frame assembly (8).
2.12.16.3 Repair.
a.
Replace frame assemblies (7 and 11) and horizontal frame assembly (8) if
corroded or damaged to the extent that they can not be properly mounted or
secured.
2.12.16.4 Assembly.
a.
Position frame assembly (11) on horizontal frame assembly (8) and secure with
four bolts (10) and nuts (9).
b.
Position frame assembly (7) on horizontal frame assembly (8) and secure with
four bolts (6) and nuts (5).
2.12.16.5 Installation.
a.
Position support frame assembly (3) on trailer (4) and secure with four screws
(2) and nuts (1).
2-79
TM 10-4320-344-24
Figure 2-27. Support Frame Assembly Maintenance.
2-80
TM 10-4320-344-24
2.13 EXHAUST SYSTEM MAINTENANCE.
2.13.1 Muffler Maintenance, Model 609-A.
This task covers:
2.13.1.1
Removal
2.13.1.2 Inspection
2.13.1.3
2.13.1.4
Repair
Installation
INITIAL SETUP
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Pumping station shut down, TM
10-4320-344-10.
General Safety I n s t r u c t i o n s
Material/Parts
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.13.1.1 Removal.
Figure 2-28.
Muffler Maintenance, Model 609-A.
2-81
TM 10-4320-344-24
2.13.1 Muffler Maintenance, Model 609-A. (Continued)
a.
Remove nut (Figure 2-28, 1 ) , b o l t ( 2 ) a n d p r o t e c t i v e c a p a s s e m b l y ( 3 ) f r o m
muffler exhaust outlet (4).
b.
Remove two nuts (5), lock washers (6), clamp (7), and U-bolt (8) from muffler
i n t a k e s l e e v e ( 9 ) . Discard lock washers (6).
c.
Rem ove nut (1 0 ), b o lt (1 1 ), a nd ex haust muffler body (12) from loop
clamp (13).
d.
Remove two retaining clamp mounting nuts (14), lock washers (15), screws (16)
and loop (13). Discard lock washers (15).
e.
Remove two nuts (17), lock washers (18), screws (19), mounting bracket (20),
and mending plate (21). Discard lock washers (18).
2.13.1.2 Inspection. Inspect protective cap assembly (3), exhaust muffler (12), and
all mounting hardware for damage.
2.13.1.3 Repair.
2.13.1.4
Replace all defective components.
Installation.
a.
Position mending plate (21) and mounting bracket (20) and secure with two
s c r e w s ( 1 9 ) , new lock washers (18), and nuts (17).
b.
Position loop clamp (13) on mounting bracket (20) and secure with two
s c r e w s ( 1 6 ) , new lock washers (15), and nuts (14) .
B e f o r e i n s t a l l i n g m u f f l e r , r e m o v e a n y o b s t r u c t i o n s from intake and exhaust
sleeves on exhaust muffler body.
Damage to engine may result.
c.
Position exhaust muffler (12) in loop clamp (13)
sleeve (9) on exhaust pipe.
Do not over tighten nut on loop clamp.
result.
and mount muffler intake
Damage to exhaust muffler body may
d.
Secure loop clamp (13) with bolt (11) and nut (10).
e.
Position U-bolt (8) around muffler intake sleeve (9) and secure with clamp
(7), two new lock washers (6), and nuts (5).
When installing protective cap assembly, make sure cap arm is positioned to
a l l o w f u l l l i m i t o f t r a v e l , or exhaust may not be properly vented.
Damage to
engine may result.
f.
2-82
Position protective cap assembly (3) on muffler exhaust outlet (4) and secure
with bolt (2) and nut (1).
TM 10-4320-344-24
2.13.2 Muffler Maintenance, Model 609-C.
This task
2.13.2.1
2.13.2.2
2.13.2.3
covers:
Removal
Disassembly
Inspection
2.13.2.4 Repair
2.13.2.5 Assembly
2.13.2.6 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit Appendix B, Section
III, Item 1
Exhaust Cover disconnected, paragraph
2.12.4.
Outlet Scoop Assembly Bearing Bushings
removed, paragraph 2.12.5.
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
General Safety Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without
standard shop safety precautions.
following
a.
Remove two nuts (Figure 2-29, 1), lock washers (2), and U-bolt (3).
lock washers (2).
Discard
b.
Remove exhaust elbow (4) and exhaust baffle assembly (5).
c.
Remove two nuts (6), lock washers (7),
lock washers (7).
d.
Remove two nuts (10), lock washers (11), flat washers (12), bolts (13), and
s i l e n c e r s u p p o r t s a d d l e ( 1 4 ) f r o m e x h a u s t m u f f l e r ( 1 5 ) . Discard lock
washers (11).
e.
Remove exhaust muffler (15) from exhaust elbow assembly (16).
f.
Open left side engine access door (17) and remove two screws (18) and silencer
support assembly (19).
Access Cover Assembly removed,
paragraph 2.12.2.
2.13.2.1 Removal.
2.13.2.2 Disassembly.
clamp (8), and U-bolt (9). Discard
Disassemble exhaust baffle assembly (5) as follows:
a.
Remove three screws (20) .
b.
Separate baffle subassembly (21) from acoustic panel (22) and baffle
screen (23) .
2.13.2.3
Inspection.
a.
Inspect exhaust muffler (15) for holes, cracks, or burned out internal
components.
b.
Inspect exhaust baffle subassembly components for craks or burns.
c.
Inspect all mounting hardware for damage.
2.13.2.4 Repair.
Replace all defective components.
2-83
TM 10-4320-344-24
2.13.2 Muffler Maintenance, Model 609-C. (Continued)
Figure 2-29.
2.13.2.5 Assembly.
Muffler Maintenance, Model 609-c.
Assemble baffle assembly (5) as follows:
a.
Position acoustic panel (22) in baffle screen (23) and install this assembly
in baffle subassembly (21).
b.
Secure assembly with three screws (20).
2-84
TM 10-4320-344-24
2.13.2.6
Installation.
a.
Position silencer support assembly (19) against engine and secure with two
screws (18) .
b.
Close left side engine access door (17).
Before installing exhaust muffler, remove any obstructions from intake and
exhaust sleeves on exhaust muffler body, otherwise damage may result.
c.
Install exhaust muffler (15) on exhaust outlet pipe (16) and silencer
support (19) .
Do not over tighten nut on loop clamp. Damage to muffler body may result.
d.
Position silencer support saddle (14) on muffler (15) and secure with two
bolts (13), two flat washers (12), new lock washers (11), and nuts (10).
e.
Position U-bolt (9) over exhaust elbow assembly (16) and exhaust muffler (15)
securing with clamp (8), two new lock washers (7), and nuts (6).
f.
Position exhaust elbow (4) on exhaust muffler (15).
g.
Place exhaust baffle assembly (5) under exhaust elbow (4) and exhaust muffler
(15) securing with U-bolt (3), two new lock washers (2), and nuts (1).
2-85
TM 30-4320-344-24
2.13.3 Muffler Maintenance. Model US636HCCD-1.
This task covers:
2.13.3.1
Removal
2.13.3.2 Inspection
2.13.3.3
Repair
2.13.3.4 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III. Item 1
Pumping station shut down, TM
10-4320-344-10.
General Safety Instructions
Material/Parts
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.13.3.1 Removal.
a.
Remove nut (Figure 2-30, 1), bolt (2), and protective cap assembly (3) from
exhaust elbow pipe (4) .
b.
Remove two nuts (5), clamp (6), U-bolt (7), and exhaust elbow pipe (4) from
exhaust muffler (8).
c.
Remove two nuts (9), clamp (10), and U-bolt (11).
d.
Remove two nuts (12), lock washers (13), and bolts (14) from two loop
clamps (15). Discard lock washers (13).
e.
Carefully remove exhaust muffler (8) from manifold exhaust pipe (16) and two
loop clamps (15).
f.
Remove two bolts (17), lock washers (18), and loop clamps (15). Discard lock
washers (18).
g.
Remove two screws (20), lock washers (21), and two weldment braces (19).
Discard lock washers (21).
2.13.3.2
Inspection.
a.
Inspect exhaust muffler (8) for holes, cracks, or burned out internal
components.
b.
Inspect all mounting hardware for damage.
2.13.3.3 Repair.
2.13.3.4
Replace all defective components.
Installation.
a.
Place two weldment braces (19). on flywheel cover and secure with two new
lock washers (21) and screws (20).
b.
Position two loop clamps (15) on weldment braces (19) and secure with two new
lock washers (18) and bolts (17).
2-86
TM 10-4320-344-24
Figure 2-30.
Muffler Maintenance, Model US636HCCD-1.
B e f o r e i n s t a l l i n g e x h a u s t m u f f l e r , remove any obstructions in intake and
exhaust sleeves on muffler body, otherwise damage may result.
c.
Install exhaust muffler (8) in two loop clamps (15) and connect muffler (8) to
manifold exhaust pipe (16).
2-87
TM 10-4320-344-24
2.13.3 Muffler Maintenance. Model US636HCCD-1.
(Continued)
Do not over tighten nut on loop clamp. Damage to muffler body may result.
d.
Install two bolts (14) into loop clamps (15) and secure with two new lock
washers (13) and nuts (12).
e.
Position U-bolt (11) over manifold exhaust pipe (16) and exhaust muffler (8)
securing with clamp (10) and two nuts (9) .
f.
Install exhaust elbow (4) on exhaust muffler (8) and secure with U-bolt (7),
clamp (6), and two nuts (5).
NOTE
Ensure top of protective cap assembly is level with top of exhaust elbow.
g.
2-88
Position protective cap assembly (3) on exhaust elbow (4) and secure with bolt
(2) and nut (1).
TM 10-4320-344-24
2.13.4 Exhaust Pipe Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
2.13.4.1 Removal
2.13.4.2 Inspection
2.13.4.3 Repair
2.13.4.4 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Muffler removed, paragraph 2.13.2 or 2.13.3.
Material/Parts
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Conditions
(Continued)
General Safety Instructions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM
10-4320-344-10.
NOTE
This procedure applies to Model US636HCCD-1. The procedures for Model 609-C
are similar.
2.13.4.1 Removal.
a.
Remove two nuts (Figure 2-31, 1), lock washers (2), clamp (3), U-bolt (4).
Discard lock washers (2).
b.
Remove manifold exhaust pipe connector (5) from exhaust elbow (6).
c.
Remove three nuts (7), bolts (8), exhaust elbow (6), exhaust flange (9), two
g a s k e t s ( 1 0 ) , and gasket (11) .
d.
R e m o v e f o u r b o l t s ( 1 2 ) , l o c k w a s h e r s ( 1 3 ) , exhaust pipe connector (14), and
g a s k e t ( 1 5 ) . Discard lock washers (13) and gasket (15).
2.13.4.2
Inspection.
a.
Inspect two gaskets (10) and gasket (11) for any signs of damage or warping.
b.
Inspect all mounting hardware for damage.
c.
Inspect all exhaust pipes for corrosion or damage.
2.13.4.3 Repair.
2.13.4.4
Replace all defective components.
Installation.
a.
Position new gasket (15) and exhaust pipe connector (14) on turbocharger and
secure with four new lock washers (13) and bolts (12) .
b.
Position two gaskets (10) and gasket (11) against exhaust pipe connector (14).
c.
Position exhaust elbow (6) and exhaust flange (9) against exhaust pipe
connector (14) and secure with three bolts (8) and nuts (7).
2-89
TM 10-4320-344-24
2.13.4 Exhaust Pipe Assembly Maintenance, Models 609-C and US636HCC0-1.
Figure 2-31.
d.
2-90
Exhaust Pipe Assembly Maintenance.
(Continued)
(Model US636HCCD-1 Shown)
Install manifold exhaust pipe connector (5) on exhaust elbow (6) and secure
with U-bolt (4), clamp (3), two new lock washers (2), and nuts (1).
TM 10-4320-344-24
2.14 AIR INTAKE SYSTEM MAINTENANCE.
2.14.1 Air Cleaner Assembly Maintenance, Model 609-A.
This task
2.14.1.1
2.14.1.2
2.14.1.3
2.14.1.4
covers:
Removal
Disassembly
Inspection
Service
2.14.1.5 Repair
2.14.1.6 Assembly
2.14.1.7 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM
10-4320-344-10.
Conditions
General Safety Instructions
Hose Assembly, Nonmetallic,
Appendix B, Section III, Item 2
Goggles, Appendix B, Section III,
Item 2
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Gun, Air Blow, Appendix B, Section
III, Item 2
Do not use cleaning solvent without proper
ventilation or clothing. Do not smoke or
use near open flame or excessive heat.
Material/Parts
Use compressed air only with proper
personal protective equipment.
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment without following
standard shop safety precautions.
2.14.1.1 Removal.
a.
Loosen two hose clamps (Figure 2-32, l) and remove preformed hose (2) and two
hose clamps (1) from air cleaner (3).
b.
Remove two nuts (4), bolts (5) and air cleaner (3) from mounting brackets (6).
c.
Remove two nuts (7), lock washers (8), bolts (9), and mounting brackets (6)
from air cleaner plate (10). Discard lock washers (8).
d.
Remove two nuts (11), lock washers (12), bolts (13), and air cleaner mounting
plate (10) from mounting bracket (14). Discard lock washers (12).
e.
Remove two nuts (15), lock washers (16), bolts (17), mounting bracket (14),
and mending plate (18). Discard lock washers (16).
2.14.1.2 Disassembly.
a.
Loosen screw (19) on end cap retaining clamp (20).
b.
Remove end cap retaining clamp (20) and air cleaner cup assembly (21) from air
cleaner (3) .
c.
Remove vacuum diaphragm (22) and air cleaner baffle (23) from air cleaner cup
assembly (21) .
d.
Remove wing nut (24) and filter element (25) from air cleaner (3).
e.
Remove air cleaner cap (26) and pressure indicator (27) from air cleaner (3).
2-91
TM 10-4320-344-24
2.14.1 Air Cleaner Assembly Maintenance, Model 609-A. (Continued)
Figure 2-32.
Air Cleaner Assembly Maintenance, Model 609-A
2.14.1.3 Inspection.
a.
Inspect preformed hose (2) for deterioration, cracks, or holes.
b.
Inspect vacuum diaphragm (22) and air cleaner baffle (23) for deterioration,
cracks, or damage.
c.
Inspect air cleaner cup assembly (21), end cap retaining clamp (20), filter
element (25), air cleaner (3), air cleaner cap (26), and pressure indicator
(27) for cracks, holes, or damage.
d.
Inspect all mounting hardware for damage.
2-92
TM 10-4320-344-24
2.14.1.4 Service.
Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment.
Failure to obey this warning may result in personal injury.
a.
U s i n g c o m p r e s s e d a i r h o s e c l e a n f i l t e r e l e m e n t ( 2 5 ) . Blow dust from inside of
filter element (25) outward. Clean outside of filter element (25) with
compressed air.
b.
If light
Cover large end and look through small end of filter element (25).
cannot be seen through paper element or hole is present, replace filter
element (25).
2.14.1.5 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
Dry cleaning solvent is
smoke or use near open flame or excessive heat.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
a.
Using cleaning rag dampened with cleaning solvent, w i p e i n s i d e o f a i r c l e a n e r
(3), end cap assembly (21), vacuum diaphragm (22), and air cleaner
baffle (23).
b.
Replace all defective components.
2.14.1.6 Assembly.
a.
Install pressure indicator (27) and air cleaner cap (26) on air cleaner (3).
b.
Install filter element (25) in air cleaner (3) and secure with wing nut (24).
c.
Install air cleaner baffle (23) in vacuum diaphragm (22) on air cleaner cup
assembly (21).
d.
Position retaining clamp (20) and air cleaner cup assembly (21) on air cleaner
(3).
e.
Center retaining clamp (20) over air cleaner cup assembly (21) and air cleaner
( 3 ) . Tighten screw (19) to secure air cleaner cup assembly (21).
2.14.1.7
Installation.
a.
Position mending plate (18) and mounting bracket (14) and secure with two
b o l t s ( 1 7 ) , new lock washers (16), and nuts (15).
b.
Position air cleaner mounting plate (10) on mounting bracket (14) and secure
w i t h t w o b o l t s ( 1 3 ) , new lock washers (12), and nuts (11) .
When installing mounting brackets on mounting plate, make sure that the open
end of each mounting bracket is on same side of mounting plate facing towards
the radiator.
2-93
TM 10-4320-344-24
2.14.1 Air Cleaner Assembly Maintenance. Model 609-A.
c.
(Continued)
Position two retaining clamps (6) on air cleaner mounting bracket (10) and
secure with two bolts (9), new lock washers (8), and nuts (7).
Do not over tighten nuts on mounting brackets.
damaged if nuts are too tight.
d.
Air cleaner body could be
Position air cleaner (3) in two mounting brackets (6) and secure with two
bolts (5) and nuts (4).
Make sure that there are no obstructions in preformed hose or air cleaner
b o d y p r i o r t o i n s t a l l a t i o n o f r u b b e r h o s e , otherwise damage to engine may
result.
e.
2-94
Slide two hose clamps (1) onto preformed hose (2) and install preformed
h o s e ( 2 ) o n a i r c l e a n e r ( 3 ) . Secure with two hose clamps (1).
TM 10-4320-344-24
2.14.2 Air Cleaner Assembly Maintenance. Model 609-C.
This task covers:
2 .14.2.1 Removal
2.14.2.2 Disassembly
2.14.2.3 Inspection
2.14.2.4 Service
2.14.2.5
Repair
2.14.2.6 Assembly
2.14.2.7 Installation
INITIAL SETUP
Tool S
Material/Parts
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Lock Washers (TM 10-4320-344-24P)
Goggles, Appendix B, Section III,
Item 2
Pumping station shut down, TM
10-4320-344-10.
Gun, Air Blow, Appendix B,
Section III, Item 2
General Safety I n s t r u c t i o n s
Hose Assembly, Nonmetallic,
Appendix B, Section III, Item 2
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
(Continued)
Conditions
Do not use cleaning solvent without proper
v e n t i l a t i o n o r c l o t h i n g . Do not smoke or
use near open flame or excessive heat.
Material/Parts
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Use compressed air only with proper
personal protective equipment.
Do not work on equipment without following
standard shop safety precautions.
2.14.2.1 Removal.
a.
Open air cleaner access door (Figure 2-33, 1) on pumping assembly (2).
b.
Remove air cleaner (3) as follows:
(1) Disconnect rubber hose (4) at rear of air cleaner (3) and restriction
gauge (5).
(2) Remove two nuts (6), lock washers (7), bolts (8), and air cleaner (3) from
two retaining clamps (9). Discard lock washers (7).
(3) Loosen hose clamp (10) and remove air duct hose (11) from air cleaner (3).
c.
Remove two nuts (12), lock washers (13), screws (14), and retaining
clamps (9). Discard lock washers (13).
d.
R e m o v e f o u r n u t s ( 1 5 ) , b o l t s ( 1 6 ) , and air cleaner mounting bracket (17).
e.
Remove two nuts (18), lock washers (19), bolts (20), and restriction gauge
bracket assembly (21). Discard lock washers (19).
2.14.2.2 Disassembly.
a.
Disassemble air cleaner (3) as follows:
(1) Remove wing nut (25) and air cleaner cover (26).
(2) Remove wing nut assembly (27) and filter element (28) from air cleaner (3).
2-95
TM 10-4320-344-24
2.14.2 Air Cleaner Assembly Maintenance, Model 609-C. (Continued)
Figure 2-33.
2-96
Air Cleaner Assembly Maintenance, Model 609-C.
TM 10-4320-344-24
(3) Remove rain cap (29) from air cleaner (3).
b.
Disassemble restriction gauge bracket assembly (21) as follows:
(1) Remove two screws (22) and remove restriction gauge (5).
(2) Remove rubber tube (4) from adapter (23) and remove adapter (23) from
restriction gauge (5).
2.14.2.3 Inspection.
a.
Inspect air cleaner (3), filter element (28), rain cap (29), and cover (26)
for cracks, holes, or damage.
b.
Inspect rubber hose (4) for deterioration, cracks, or damage.
c.
Inspect all mounting hardware for damage.
2.14.2.4 Service.
Compressed air used for cleaning purposes must not exceed 30 psi (206.7 kPa).
Use only with effective chip guarding and personal protective equipment.
Failure to obey this warning may result in p e r s o n a l i n j u r y .
a.
Using compressed air hose clean filter element (28). Blow dust from inside of
filter element (28) outward. Clean outside of filter element (28) with
compressed air.
b.
Cover large end and look through small end of filter element (28). If light
cannot be seen through paper element or hole is present, replace filter
element (28).
2.14.2.5 Repair.
Do not use cleaning solvent without proper ventilation and clothing. Do not
smoke or use near open flame or excessive heat. Dry cleaning solvent is
potentially dangerous to personnel and property. Clean parts in a wellventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber
gloves to protect eyes and skin. Wash exposed skin throughly. Failure to
obey this warning may result in personal injury or death.
a.
Using cleaning rag dampened with cleaning solvent, wipe inside of air cleaner
(3), air cleaner cover (26), and wing nut assembly (27).
b.
Replace all defective components.
2.14.2.6 Assembly.
a.
Assemble restriction gauge bracket assembly (21) as follows:
(1) Install adapter (23) in restriction gauge (5) and install rubber tube (4) on
adapter (23).
(2) Position restriction gauge (5) in restriction gauge bracket (21) and secure
with two screws (22).
2-97
TM 10-4320-344-24
2.14.2 Air Cleaner Assembly Maintenance, Model 609-C.
b.
(Continued)
Assemble air cleaner (3) as follows:
(1) Install rain cap (29) on air cleaner (3).
(2) Insert filter element (28) in air cleaner (3). Install and tighten wing nut
assembly (27).
(3) Position air cleaner cover (26) on air cleaner (3) and secure with wing
nut (25).
2.14.2.7
Installation.
a.
Position restriction gauge bracket assembly (21) against pumping assembly (2)
and secure with two bolts (20), new lock washers (19), and nuts (18).
b.
Position air cleaner mounting bracket (17) in pumping assembly (2) and secure
with four bolts (16) and nuts (15).
c.
Position retaining clamps (9) on air cleaner mounting bracket (17) and secure
with two bolts (14), new lock washers (13), and nuts (12).
d.
Install air intake hose (11) on air cleaner (3) and secure with hose clamp
(10) .
Do not over tighten nuts on retaining clamps. Air cleaner body could be
damaged if nuts are too tight.
e.
Slide air cleaner (3) in retaining clamps (9) and secure with two bolts (8),
new lock washers (7), and nuts.
f.
Connect rubber hose (4) to rear of air cleaner (3) and restriction gauge (5).
g.
Close air cleaner access door (1) on pumping assembly (2).
2-98
TM 10-4320-344-24
2.14.3 Air Cleaner Assembly Maintenance, Model US636HCCD-1.
This task
2.14.3.1
2.14.3.2
2.14.3.3
2.14.3.4
covers:
Removal
Disassembly
Inspection
Service
2.14.3.5 Repair
2.14.3.6 Assembly
2.14.3.7 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM
10-4320-344-10.
General Safety Instructions
Goggles, Appendix B, Section III,
Gun, Air Blow, Appendix B,
Section III, Item 2
Hose Assembly, Nonmetallic,
Appendix B, Section III, Item 2
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Don not use cleaning solvent without
proper ventilation or clothing, Do not
smoke or use near open flame or excessive
heat.
Material/Parts
Gloves, Appendix C, Item 11
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Lock Washers (TM 10-4320-344-24P)
Use compressed air only with proper
personal protective equipment.
Do not work on equipment without following
standard shop safety precautions.
2.14.3.1 Removal.
a.
Loosen hose clamp (Figure 2-34,
cleaner (3).
b.
Remove two nuts (4) and bolts (5) from retaining clamps (6).
c.
Remove air cleaner (3) from retaining clamps (6).
d.
Remove four bolts (7), lock washers (8), and each retaining clamp (6). Discard
lock washers (8).
1) and remove preformed hose (2) from air
2.14.3.2 Disassembly.
a.
Remove wing nut (9) and cover (10) from air cleaner (3).
b.
Remove wing nut (11) and filter element (12).
c.
Remove hose clamp (13) and air cleaner intake cap (14).
d.
Remove knob (15) and vacuum diaphragm (16).
2.14.3.3 Inspection.
a.
Inspect air cleaner (3), cover (10), filter element (12), air cleaner intake
cap (14), knob (15), and vacuum diaphragm (16) for cracks, holes, and damage.
b.
Inspect all mounting hardware for damage.
2-99
TM 10-4320-344-24
2.14.3 Air Cleaner Assembly Maintenance, Model US636HCCD-1. (Continued)
Figure 2-34. Air Cleaner Maintenance, Model US636HCCD-1.
2.14.3.4 Service.
Compressed air used for cleaning purposes must not exceed 30 psi (206.7 kPa).
Use only with effective chip guarding and personal protective equipment.
Failure to obey this warning may result in personal injury.
a.
Using compressed air hose clean filter element (12). Blow dust from inside of
filter element (12) outward. Clean outside of filter element (12) with
compressed air.
b.
If light
Cover large end and look through small end of filter element (12).
cannot be seen through paper element or hole is present, replace filter
element (12).
2-100
TM 10-4320-344-24
2.14.3.5 Repair.
not use cleaning solvent without proper ventilation and clothing. Do not
smoke or use near open flame or excessive heat. Dry cleaning solvent is
potentially dangerous to personnel and property. Clean parts in a well.
ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber
gloves to protect eyes and skin. Wash exposed skin throughly. Failure to obey
this warning may result in personal injury or death.
DO
a.
Using cleaning rag dampened with cleaning solvent, wipe inside of ai cleaner
(3), air cleaner cover (10), and vacuum diaphragm (16).
b.
Replace all defective components.
2.14.3.6 Assembly.
a.
Install vacuum diaphragm (16) and knob (15) on air cleaner (3).
b.
Secure air cleaner intake cap (14) on air cleaner (3) with hose clamp (13).
c.
Install filter element (12) in air cleaner (3) and secure with wing nut (11).
d.
Position cover (10) on air cleaner (3) and secure with wing nut (9).
2.14.3.7
Installation.
NOTE
Retaining clamps must face away from engine when installed.
a.
Position two retaining clamps (6) on mounting brackets and secure with four
new lock washers (8) and bolts (7).
D O not over tighten nuts on retaining clamps. Air cleaner body could be
damaged if nuts are too tight.
b.
Slide air cleaner (3) into two retaining clamps (6) and secure with two bolts
(5) and nuts (4).
c.
Slide preformed hose (2) on air cleaner (3) and secure with clamp (1).
2-101
TM 10-4320-344-24
2.14.4 Air Intake Assembly Maintenance, Model 609-C.
This task covers:
2.14.4.1 Removal
2.14.4.2 Inspection
2.14.4.3 Repair
2.14.4.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Air Cleaner Assembly removed, paragraph
2.14.2.
General Safety Instructions
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Conditions
Pumping station shut down, TM
10-4320-344-10.
Do not touch engine after shutting down
pumping assembly. Allow time for engine
to cool.
Do not work on equipment without following
standard shop safety precautions.
2.14.4.1 Removal.
a.
O p e n l e f t s i d e e n g i n e a c c e s s d o o r ( F i g u r e 2 - 3 5 , 1) on pumping assembly (2).
b.
Loosen hose clamp (3) and remove air intake hose (4) from intake adapter (5).
c.
Remove hose clamps (3 and 6) from air intake hose (4).
d.
Remove two nuts (7), lock washers (8), clamp (9), U-bolt (10), and intake
adapter (5) from turbocharger (11). Discard lock washers (8).
2.14.4.2 Inspection.
a.
Inspect air intake hose (4) and intake adapter (5) for cracks, holes, damage,
and corrosion of intake adapter (5).
b.
Inspect all mounting hardware for damage.
2.14.4.3 Repair.
2.14.4.4
Replace all defective components.
Installation.
a.
Install intake adapter (5) on turbocharger (11) and secure with U-bolt (10),
clamp (9), two new lock washers (8), and nuts (7).
b.
Install hose clamps (3 and 6) on air intake hose (4).
c.
Slide air intake hose (4) on intake adapter (5) and secure with hose
clamp (3).
2-102
TM 10-4320-344-24
Figure 2-35.
Air Intake Hose Maintanence, Model 609-C.
2-103
TM 10-4320-344-24
2.14.5 Air Intake Pipe Assembly Maintenance, Model US636HCCD-1.
This task
2.14.5.1
2.14.5.2
2.14.5.3
covers:
Removal
Disassembly
Inspection
2.14.5.4 Repair
2.14.5.5 Assembly
2.14.5.6 Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
Do not work on equipment without following
standard shop safety precautions.
Conditions
Pumping station shut down, TM
10-4320-344-10.
2.14.5.1 Removal.
a.
Loosen hose clamps (Figure 2-36, 1 and 2).
b.
Remove air intake pipe assembly (3) from air cleaner assembly (4) and
turbocharger (5).
2.14.5.2 Disassembly.
a.
Remove hose clamps (1 and 2).
b.
Loosen hose clamps (6 and 7) and slide hose clamps (6 and 7) over pipe
elbow (8).
c.
Remove preformed hoses (9 and 10) from pipe elbow (8).
d.
Remove hose clamps (6 and 7) from pipe elbow (8).
2.14.5.3 Inspection.
a.
Inspect pipe elbow (8), preformed hoses (9 and 10) for deterioration and
damage.
b.
Inspect hose clamps (1, 2, 6, and 7) for damage or missing components.
2.14.5.4 Repair.
Replace all defective components.
2.14.5.5 Assembly.
a.
Slide hose clamps (6 and 7) over pipe elbow (8).
b.
Slide preformed hoses (9 and 10) over pipe elbow (8) and secure with hose
clamps (6 and 7).
c.
Slide hose clamps (1 and 2) on preformed hoses (9 and 10).
2.14.5.6 Installation. Slide preformed hose (9) over air cleaner assembly (4) and
preformed hose (10) over turbocharger (5) securing with hose clamps (1 and 2).
2-104
TM 10-4320-344-24
Figure 2-36.
Air Intake Pipe Assembly Maintenance.
2-105
TM 10-4320-344-24
2.15 ELECTRICAL SYSTEM MAINTENANCE.
2.15.1 Service Lights Maintenance. Model 609-C.
This task covers:
2.15.1.1 Removal
2.15.1.2 Repair
2.15.1.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down and Intervehicular
Cable Assembly disconnected, TM
10-4320-344-10.
Material/Parts
General Safety Instructions
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
NOTE
This procedure applies to the left side service light. The procedure for the
right side service light is identical.
2.15.1.1 Removal.
Figure 2-37.
2-106
Service Lights Maintenance.
TM 10-4320-344-24
a.
Remove three nuts (Figure 2-37, 1), lock washers (2), and screws (3).
lock washers (2).
Discard
b.
Pull service light assembly (4) away from pumping assembly (5).
c.
Disconnect service light connector (6) from main wiring harness connector (7).
d.
Remove service light assembly (4) from pumping assembly (5).
2.15.1.2 Repair.
a.
Replace defective light bulb (10) by removing retaining ring (8), lens (9),
and bulb (10) from service light housing (11).
b.
Replace all defective components.
2.15.1.3
Installation.
a.
If light bulb (10) was defective, install new bulb (10), lens (9), and
retaining ring (8) in service light housing (11).
b.
Insert service light connector (6) into pumping assembly (5) and connect
harness connector (7) and service light connector (6).
c.
Insert service light assembly (4) into pumping assembly (5) and secure with
three screws (3), new lock washers (2), and nuts (1).
2-107
TM 10-4320-344-24
2.15.2 Battery Box and Cover Maintenance, Model 609-A.
This task covers:
2.15.2.1 Removal
2.15.2.2
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Material/Parts
Fumes from battery acid may cause explosion,
which could result in personal injury. Keep
sparks and open flame away from battery.
G l o v e s , Appendix C, Item 11
Tags, Appendix C, Item 31
Lock Washer (TM 10-4320-344-24P)
Equiptxnent Conditions
Pumping station shut down, TM
10-4320-344-10.
Personnel
Battery electrolyte contains sulfruric acid,
which can cause severe burns. If
electrolyte should contact skin or clothing,
rinse immediately with clean water and seek
medical attention.
Do not work on equipment without following
standard shop safety precautions.
Two people are required to lift
the storage battery.
2.15.2.1 Removal.
a.
Remove two nuts (Figure 2-38, 1), lock washers (2), four flat washers (3), and
t w o s c r e w s ( 4 ) . Discard lock washers (2).
Fumes from battery acid may cause explosion, which could result in personal
injury.
Keep sparks and open flame away from storage battery.
b.
Remove cover (5).
Remove negative battery cable first. Failure to obey this warning may result in
death or personnel injury.
c.
Tag positive (+) and negative (-) battery cables (6). Loosen battery cable
terminals (7) and remove from storage battery (8).
2-108
TM 10-4320-344-24
Figure 2-38.
Battery Box and Cover Maintanance, Model 609-A.
2-109
TM 10-4320-344-24
2.15.2 Battery Box and Cover Maintenance, Model 609-A.
(Continued)
• Fumes from battery acid may cause explosion, which could result in
personal injury.
Keep sparks and open flame away from battery.
• Battery electrolyte contains sulfuric acid, which can cause severe
burns.
Wear rubber gloves to avoid burns from battery acid. If
electrolyte should contact skin or clothing, rinse immediately with
clean water and seek medical attention.
• Two personnel required to lift storage battery.
• Failure to obey these warnings may result in serious personal
injury.
d.
Remove storage battery (8) from battery box (9).
e.
Remove four nuts (10), lock washers (11), flat washers (12), and screws (13).
Discard lock washers (11).
f.
Remove battery box (9).
2.15.2.2
a.
Installation.
Position battery box (9) on trailer assembly and secure with four screws (13),
f l a t w a s h e r s ( 1 2 ) , new lock washers (11), and nuts (10).
• Fumes from battery acid may cause explosion, which could result in
p e r s o n a l i n j u r y . Keep sparks and open flame away from battery.
• Battery electrolyte contains sulfuric acid, which can cause severe
b u r n s . Wear rubber gloves to avoid burns from battery acid. If
electrolyte should contact skin or clothing, rinse immediately with
clean water and seek medical attention.
• Two personnel required to lift storage battery.
• Failure to obey these warnings may result in serious personal
injury.
b.
Place storage battery (8) in battery box (9).
Install positive battery cable first.
result in death or personnel injury.
Failure to obey this warning may
e.
Refer to tags and install positive (+) and negative (-) battery cables (6).
Install terminals (7) on storage battery (8). Remove and discard tags.
f.
Position cover (5) on battery box (9) and secure with two bolts (4), flat
w a s h e r s ( 3 ) , new lock washers (2), and nuts (1) .
2-110
TM 10-4320-344-24
2.15.3 Battery Box Assembly Maintenance, Model 609-C.
This task covers:
2.15.3.1 Removal
2.15.3.2
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Material/Parts
Fumes from battery acid may cause explosion,
which could result in personal injury. Keep
sparks and open flame away from battery.
Gloves, Appendix C, Item 11
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery electrolyte conains sulfuric acid,
which can cause severe burns. If
electrolyte should contact skin or clothing,
rinse immediately with clean water and seek
medical attention.
Do not work on equipment without following
standard shop safety precautions.
2.15.3.1 Removal.
a.
Open battery access door assembly (Figure 2-39, 1) on pumping assembly (2).
Fumes from battery acid may cause explosion, which could result in personal
injury. Keep sparks and open flame away from battery.
b.
Pull up and out on two locking handles (3) and open battery cover (4).
Remove negative battery cable first. Failure to obey this warning may result
in death or personnel injury.
c.
Tag positive (+), negative (-), and connector battery cable assemblies (6).
Loosen four battery terminals (5) and remove battery cable assemblies (6) from
storage batteries (7 and 8).
2-111
TM 10-4320-344-24
2.15.3 Battery Box Assembly Maintenance. Model 609-C. (Continued)
Figure 2-39.
2-112
Battery Box Assembly Maintenance, Model 609-C.
TM 10-4320-344-24
Fumes from battery acid may cause explosion, which could result in
p e r s o n a l i n j u r y . Keep sparks and open flame away from battery.
Battery electrolyte contains sulfuric acid, which can cause severe
burns. Wear rubber gloves to avoid burns from battery acid. If
electrolyte should contact skin or clothing, rinse immediately with
clean water and seek medical attention.
Failure to obey these warnings may result in serious personal injury.
d.
Using lift handles (9) remove storage batteries (7 and 8) from battery box
assembly (10).
e.
Remove four nuts (11), lock washers (12), flat washers (13), and battery box
Discard lock washers (12).
assembly (10) from pumping assembly (2).
2.15.3.2
a.
Installation.
Position battery box assembly (10) in pumping assembly (2) and secure with
four flat washers (13), new lock washers (12), and nuts (11).
Fumes from battery acid may cause explosion, which could result in
p e r s o n a l i n j u r y . Keep sparks and open flame away from battery.
Battery electrolyte contains sulfuric acid, which can cause severe
burns. Wear rubber gloves to avoid burns from battery acid. If
electrolyte should contact skin or clothing, rinse immediately with
clean water and seek medical attention.
Failure to obey these warnings may result in serious personal
injury.
b.
Using lift handles (9) place storage batteries (7 and 8) in battery box
assembly (10) .
c.
As required,
2.15.6.
service battery cable assemblies (6) in accordance with paragraph
Install positive battery cable first. Failure to obey this warning may
result in death or personnel injury.
d.
Refer to tags and install three battery cable assemblies (6). tighten four
b a t t e r y t e r m i n a l s ( 5 ) . Remove and discard tags.
e.
Close battery cover (4).
f.
pull up and out on two locking handles (3) and lock battery cover (4).
g.
Close battery access door assembly (1) on pumping assembly (2).
2-113
TM 10-4320-344-24
2.15.4 Battery Box and Cover Maintenance. Model US63611HCCD-1.
This task covers:
2.15.4.1
Removal
2.15.4.2
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Material/Parts
Fumes from battery acid may cause explosion,
which could result in personal injury. Keep
sparks and open flame away from battery.
Gloves, Appendix C, Item 11
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Personnel
Battery electrolyte contains sulfuric acid,
which can cause severe burns. If
electrolyte should contact skin or clothing,
rinse immediately with clean water and seek
medical attention.
Do not work on equipment without following
standard shop safety precautions.
Two people are required to lift the
storage battery.
2.15.4.1 Removal.
a.
Remove two nuts (Figure 2-40, 1), lock washers (2), and flat washers (3).
Discard lock washers (2).
Fumes from battery acid may cause explosion, which could result in personal
injury.
Keep sparks and open flame away from battery.
b.
Remove battery box cover (4).
Remove from battery cable first. Failure to obey this warning may result
in death or personnel injury.
c.
2-114
Tag positive (+) and negative (-) battery cable assemblies (6). Loosen
battery cable terminals (5) and remove two battery cable assemblies (6) with
two grommets (7) from storage battery (8) and battery box (9).
TM 10-4320-344-24
Figure 2-40.
Battery Box and Cover Maintenance, Model US636HCCD-1.
2-115
TM 10-4320-344-24
2.15.4 Battery Box and Cover Maintenance, Model US636HCCD-1.
(Continued)
Fumes from battery acid may cause explosion, which could result in
personal injury. Keep sparks and open flame away from battery.
Battery electrolyte contains sulfuric acid, which can cause severe
burns. Wear rubber gloves to avoid burns from battery acid. If
electrolyte should contact skin or clothing, rinse immediately with
clean water and seek medical attention.
Two personnel are required to lift battery.
Failure to obey these warnings may result in serious personal
injury.
d.
Remove storage battery (8) from battery box (9).
e.
Remove four nuts (10), lock washers (11), and two weldment supports (12).
Discard lock washers (11).
f.
Remove battery box (9) from trailer assembly (13).
2.15.4.2
Installation.
a.
Position battery box (9) on trailer assembly (13).
b.
Install two weldment supports (12) through battery box (9) and trailer
assembly (13) securing with four new lock washers (11) and nuts (10).
Fumes from battery acid may cause explosion, which could result in
p e r s o n a l i n j u r y . Keep sparks and open flame away from battery.
B a t t e r y e l e c t r o l y t e contains sulfuric acid, which can cause severe
burns. Wear rubber gloves to avoid burns from battery acid. If
electrolyte should contact skin or clothing, rinse immediately with
clean water and seek medical attention.
Two personnel are required to lift battery.
Failure to obey these warnings may result in serious personal
injury.
Install storage battery (8) in battery box (9).
c.
Install positive battery cable first. Failure to obey this warning may
result in death or personnel injury.
d.
Place two grommets (7) and battery cable assemblies (6) in battery box (9).
Install positive (+) and negative (-) battery cable assemblies (6) and two
battery cable terminals (5) on storage battery (8). Remove and discard tags.
e.
Install cover (4) on battery box (9) and secure with two flat washers (3), new
lock washers (2), and nuts (1).
2-116
TM 10-4320-344-24
2.15.5 Battery Cable Asssembly Maintenance, Models 609-A and US636HCCD-1.
This task covers:
2.15.5.1 Removal
2.15.5.2 Testing
2.15.5.3
2.15.5.4
Repair
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery Cable Assemblies disconnected from
battery, paragraph 2.15.2 or 2.15.4.
General
Multimeter, Appendix B, Section
III, Item 2
Safety
Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Soldering Torch Kit, Appendix B,
Section III, Item 2
Fumes from battery acid may cause
explosion, which could result in personal
injury. Keep sparks and open flame away
from battery.
Material/Parts
Solder, Appendix C, Item 25
Strap, Electrical Tiedown, Appendix C,
Item 29
Tags, Appendix C, Item 31
Tape, Electrical, Appendix C,
Item 33
Lock Washers (TM 10-4320-344-24P)
Battery electrolyte contains sulfuric
acid, which can cause severe burns. If
electrolyte should contact skin or
clothing, rinse immediately with clean
water and seek medical attention.
Equipment Conditions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM
10-4320-344-10.
NOTE
This procedure applies to Model 609-A.
is similar.
The procedure for Model US636HCCD-1
2.15.5.1 Removal.
a.
Remove three nuts (Figure 2-41, 1), lock washers (2), screws (3), and cable
c l a m p s ( 4 ) . Discard lock washers (2).
b.
Remove screw ( 5 ) , l o c k w a s h e r ( 6 ) , a n d n e g a t i v e b a t t e r y c a b l e a s s e m b l y ( 7 )
from engine frame (8). Discard lock washer (6).
c.
Remove and discard electrical tiedown straps (9).
NOTE
The following step is applicable to model 609-A only.
d.
Desolder control panel ground wire (10) from battery cable terminal (11) of
negative battery cable assembly (7).
e.
Remove nut (12), lock washer (13), wire (14), and positive battery cable
assembly (15) from stater (16). Discard lock washer (13). -
2.15.5.2 Testing. Using multimeter test continuity of battery cable assemblies (7 and
15). If reading is greater than 1 ohm, repair or replace defective battery cable
assembly (7 or 15).
2-117
TM 10-4320-344-24
2.15.5 Battery Cable Assembly Maintenace, Models 609-A and US636HCCD-1. (Continued)
Figure 2-41.
Battery Cable Assembly Maintenance, Model 609-A.
2.15.5.3 Repair.
a.
Refer to Appendix D and repair battery cable assembly as required.
b.
Replace all defective mounting hardware.
2.15.5.4 Installation.
a.
2-118
Install positive battery cable assembly cable terminal (17) and wire (15) on
starter (16) and secure with new lock washer (13), and nut (12).
TM 10-4320-344-24
NOTE
The following step applies to Model 609-A only.
b.
Solder control panel ground wire (10) to battery cable terminal (11) of
negative battery cable assembly (7) .
c.
Install two new electrical tiedown straps (9) to secure control panel ground
wire (10) to negative battery cable assembly (7).
d.
Secure negative battery cable assembly (7) to engine frame (8) with new lock
washer (6) and screw (5).
e.
Install one cable clamp (4) on negative battery assembly (7) and two cable
clamps (4) on positive battery cable assembly (15) securing
(3), new lock washers (2), and nuts (1).
2-119
TM 10-4320-344-24
2.15.6 Battery Cable Assembly and Power Cable Assembly Maintenance, Model 609-C.
This task covers:
2.15.6.1
Removal
2.15.6.2 Testing
2.15.6.3 Repair
2.15.6.4 Installation
INITIAL SETUP
Tools
Equiment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery Cable Assemblies disconnected from
battery, paragraph 2.15.3
Multimeter, Appendix B, Section
III, Item 2
Battery Cable Assemblies and Power Cable
Assemblies disconnected, paragraph 2.15.7.
General Safety Instructions
Soldering Torch Kit, Appendix B,
Section III, Item 2
Material/Parts
Solder, Appendix C, Item 25
Straps, Electrical Tiedown,
Appendix C, Item 29
Tags, Appendix C, Item 31
Tape, Electrical, Appendix C,
Item 33
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Fumes from battery acid may cause explosion,
which could result in personal injury. Keep
sparks and open flame away from battery.
Equipment Conditions
Battery electrolyte contains sulfuric acid,
which can cause severe burns. If
electrolyte should contact skin or clothing,
rinse immediately with clean water and seek
medical attention.
Pumping station shut down, TM
10-4320-344-10.
Do not work on equipment without following
standard shop safety precautions.
2.15.6.1 Removal.
Figure 2-42.
2-120
Battery Cable Assembly and Power Cable Maintenance,
Model 609-C. (Sheet 1 of 2)
TM 10-4320-344-24
Figure 2-42.
Battery Cable Assembly and Power Assembly Maintenance,
Model 609-C
(Sheet 2 of 2)
2-121
TM 10-4320-344-24
2.15.6 Battery Cable Assembly and Power Cable Assembly Maintenance, Model 609-C. (Continued)
a.
Remove and discard electrical tiedown straps (Figure 2-42, 1).
b.
Tag and remove negative battery cable assembly (2) and positive battery cable
assembly (3) from battery.
c.
Remove two screws (4) and cable clamps (5).
d.
Remove nut (6), bolt (7), and tag and remove two negative rower cable
assemblies (8) from trailer frame assembly (9).
e.
Remove nut (10), lock washer (11), and tag and remove negative power cable
a s s e m b l y ( 1 2 ) f r o m s t a r t e r ( 1 3 ) . Discard lock washer (11) .
f.
Remove nut (14), l o c k w a s h e r ( 1 5 ) , w i r e ( 1 6 ) , a n d t a g and remove positive
power cable assembly (17) from starter (13). Discard l o c k w a s h e r ( 1 5 ) .
2.15.6.2 Testing. Using multimeter r test continuity of negative battery cable
a s s e m b l y ( 2 ) , p o s i t i v e b a t t e r y c a b l e a s s e m b l y ( 3 ) , negative power cable assemblies
If reading is greater than 1
(8 and 12), and positive power cable assembly (17)
ohm, replace or repair defective cable assembly (2, 3, 8, 12, or 17) .
2.15.6.3 Repair.
a.
Refer to Appendix D and repair battery cable assembly or power cable assembly.
b.
Replace all defective mounting hardware.
2.15.6.4
Installation.
a.
Install positive power cable assembly (17) and wire (16) on starter (13) and
secure with new lock washer (15) and nut (14) .
Remove and discard tags.
b.
Install negative power cable assembly (12) on starter (13) and secure with new
lock washer (11) and nut (10). Remove and discard tags.
c.
Secure two negative power cable assemblies (8) to trailer frame assembly (9)
with bolt (7) and nut (6). Remove and discard tags.
d.
Install two cable clamps (5) and secure with two screws (4).
e.
S e c u r e p o s i t i v e b a t t e r y c a b l e a s s e m b l y ( 3 ) a n d n e g a t i v e b a t t e r y cable assembly
(2) with new electrical tiedown straps (1).
2-122
TM 10-4320-344-24
2.15.7 Electrical Connector Receptacle Maintenance, Model 609-C.
This task covers:
2.15.7.1 Removal
2.15.7.2 Repair
2.15.7.3
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Material/Parts
Disconnect negative battery cable at
negative battery to prevent possible
electrocution.
Tags, Appendix C, Item 31
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment without following
standard shop safety precautions.
Equipment Conditions
Pumping station shut down,
TM 10-4320-344-10.
2.15.7.1 Removal.
Do not work on electrical connector receptacle with negative battery cable
connected to battery terminal. Failure to obey this warning may result in
death or serious personal injury.
a.
O p e n l e f t s i d e e n g i n e a c c e s s d o o r ( F i g u r e 2 - 4 3 , 1) on pumping assembly (2).
b.
Remove two screws (3) and lock washers (4).
c.
Tag and remove negative power cable assemblies (5) and positive power cable
assemblies (6) from electrical connector receptacle (7).
d.
Remove four nuts (8), lock washers (9), screws (10) , and electrical connector
receptacle (7) from pumping assembly (2). Discard lock washers (9) .
e.
Remove insulator plate (11) and gasket (12). Discard gasket (12).
f.
Remove protective dust cap (13).
Discard lock washers (4).
2.15.7.2 Repair.
a.
Inspect electrical connector receptacle (7), insulator plate (11), and
p r o t e c t i v e d u s t c o v e r ( 1 3 ) f o r c r a c k s , h o l e s , deformations, and damage.
b.
Inspect mounting hardware for damage.
c.
Replace all defective components.
2.15.7.3
Installation.
a.
Install protective dust cover (13) on electrical connector receptacle (7).
b.
Position new gasket (12) and insulator plate (11) on electrical connector
receptacle (7) .
2-123
TM 10-4320-344-24
2.15.7 Electrical Connector Receptacle Maintenance, Model 609-C. (Continued)
Figure 2-43.
2-124
Electrical Connector Receptacle Maintenance.
TM 10-4320-344-24
c.
Install electrical connector receptacle (7) in pumping assembly (2) and secure
with four screws (10), new lock washers (9), and nuts (8).
d.
Refer to tags and position positive power cable assemblies (6) and negative
power cable assemblies (5) on electrical connector receptacle (7) and secure
Remove and discard tags.
with new lock washers (4) and screws (3).
e.
Close roadside engine access door (1) on pumping assembly (2).
2-125
TM 10-4320-344-24
2.15.8 Power Control Cable Assembly Maintenance, Model 609-A.
This task covers:
2.15.8.1 Removal
2.15.8.2 Installation
2.15.8.3 Adjustment
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.2.
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.15.8.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . F a i l u r e t o o b e y this warning may result in
death or serious personal injury.
a.
Loosen screw (Figure 2-44, 1) on universal wire stop (2) and remove universal
wire stop (2) from power control cable assembly ( 3 ) .
b.
Loosen screw (4) and remove universal wire stop ( 5 ) f r o m w i r e ( 6 ) .
c.
Remove nut (7) and lock washer (8) from end of power control cable assembly
(3) and remove power control cable assembly (3) from cable connector
b r a c k e t ( 9 ) . Discard lock washers (8).
d.
Remove flat washer (10) and nut (11) from end of power control cable
assembly (3).
e.
Remove three nuts (12), lock washers (13), three cable clamp mounting bolts
(14), and three cable clamps (15). D i s c a r d l o c k w a s h e r s ( 1 3 ) . -
2.15.8.2
Installation.
Do not tighten cable clamps securely until power control cable assembly has
been adjusted.
a.
I n s t a l l p o w e r c o n t r o l c a b l e a s s e m b l y 3) in three cable clamps (15) and secure
with three cable clamp mounting bolts (14), new lock washers (13), and nuts
(12).
b.
Install nut (11) and flat washer (10) on end of power control cable assembly
(3).
2-126
TM 10-4320-344-24
Figure 2-44.
Power Control Cable and Manual Throttle Control Cable Assembly.
c.
I n s t a l l p o w e r c o n t r o l c a b l e a s s e m b l y ( 3 ) i n c a b l e c o n n e c t o r bracket (9) and
secure with new lock washer (8) and nut (7).
d.
Adjust nut (11) so that knurled wire ends (16) are equal distance from cable
connector bracket (9).
Inboard throttle arm on fuel injection pump must be in vertical position (12
o’clock) when manual throttle control is turned at least one full turn but no
more than three full turns.
e.
Turn manual throttle control (Figure 2-45, 1) left until inboard throttle arm
(2) on fuel injection pump (3) is in vertical position (12 o’clock). If
required, adjust power control cable assembly (4) and manual throttle control
cable (5) lengths to allow inboard throttle arm (2) to be in vertical position
(12 o’clock) within one to three turns of manual throttle control (1).
2-127
TM 10-4320-344-24
2.15.8 Power Control Cable Assembly Maintenance, Model 609-A. (Continued)
Figure 2-45.
f.
2-128
Manual Throttle Control Cable and Power Control Cable Assembly
Adjustment .
Cut sheathing on power control cable assembly (Figure 2-46, 1 ) and position
three cable clamps (2) to dimensions shown in Figure 2-46. (Dimensions are in
inches and identified by an asterisk.)
TM 10-4320-344-24
Figure 2-46.
Sheathing and Cable Clamp Positioning.
g.
Install universal wire stop (Figure 2-47, 1) on wire (2) approximately 1 3/8
inches from center of pivot arm (3) on limit switch (4). Tighten screw (5) on
universal wire stop (l).
h.
Install universal wire stop (6) on power control cable assembly (7)
approximately 3/8 inch from power control cable assembly (7) end.
Tighten
screw (8) on universal wire stop (6).
Figure 2-47.
Power Control Cable Assembly
Installation.
2-129
TM 10-4320-344-24
2.15.8 Power Control Cable Assembly Maintenance, Model 609-A. (Continued)
2.15.8.3 Adjustment.
Limit switch must click off when manual throttle control is fully in and
inboard throttle arm on fuel injection pump is in OVER TRAVEL position.
Inboard throttle arm on fuel injection pump is in OVER TRAVEL position when
it is at the point where spring tension is exerted from fuel injection pump.
a.
Turn manual throttle control (Figure 2-45, 1 ) r i g h t u n t i l i t i s f u l l y i n . T h e
inboard throttle arm (2) on the fuel injection pump (3) should be at about the
2 o’clock position.
When limit switch clicks it is in the open (or off) position.
b.
Turn manual throttle control (1) left no fewer than one and no more than three
full turns and listen for limit switch to click. If limit switch does not
click, manual throttle cable (Figure 2-44, 13) and power control cable
assembly (3) are not in adjustment.
c.
I f r e q u i r e d , readjust position of universal stop (Figure 2-47, 6) on end of
p o w e r c o n t r o l c a b l e a s s e m b l y ( 7 ) a s f o l l o w s , to ensure proper operation of
limit switch assembly:
(1) Turn manual throttle control (Figure 2-45, 1 ) r i g h t u n t i l i n b o a r d t h r o t t l e
arm (2) on fuel injection pump (3) is into OVER TRAVEL position.
(2) While watching throttle arm (2) linkage, slowly turn manual throttle control
(1) left to determine exact point of OVER TRAVEL engagement.
(3) Loosen screw (Figure 2-47, 8) and set universal stop (6) on power control
cable assembly (7) to allow limit switch to open and close at this point.
d.
2-130
Tighten four nuts (Figure 2-44, 19) to secure three cable clamps (22).
TM 10-4320-344-24
2.15.9 Limit Switch Assembly Maintenance. Model 509-A.
This task covers:
2.15.9.1 Removal
2.15.9.2 Repair
2.15.9.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1.
Material/Parts
Conditions
(Continued)
Power Control Cable Assembly disconnected,
paragraph 2.15.8.
Strap, Electrical Tiedown, Appendix C, General Safety I n s t r u c t i o n s
Item 29
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.2.
Do not work on equipment with battery
Electrocution hazard is present
connected.
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.15.9.1 Removal.
Electrocution hazard is
Do not work on equipment with battery connected.
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
R e m o v e e l e c t r i c a l t i e d o w n s t r a p s ( F i g u r e 2 - 4 8 , 1) from plastic sheathing (2)
around wiring harness (3) and remove plastic sheathing (2) from wiring
harness (3).
b.
Remove electrical tiedown straps (4) from wiring harness (3).
c.
Remove and retain nut (5), and remove lock washer (6) and limit switch wire
(7) from start alarm relay (8). Discard lock washer (6).
d.
Remove and retain screw (9) and remove lock washer (10), and limit switch
assembly wire (11) from mode switch (12). Discard lock washer (10) .
e.
Remove two nuts (13), four lock washers (14 and 15), bolts (16), and remove
limit switch mounting plate (17). Discard lock washers (14 and 15).
f.
Remove two nuts (18), lock washers ( 1 9 ) , a n d l i m i t s w i t c h a s s e m b l y ( 2 0 ) f r o m
limit switch mounting plate (17). D i s c a r d l o c k w a s h e r s ( 1 9 ) .
2.15.9.2 Repair.
a.
Inspect limit switch assembly (20)
damage.
b.
Inspect limit switch wires (7 and 11) for missing terminals, burns or damage
insulation.
for cracks, holes, missing components, or
2-131
TM 10-4320-344-24
2.15.9
Limit Switch Assembly Maintenance, Model 609-A. (Continued)
Figure 2-48.
Limit Switch Assembly Maintenance.
c.
Inspect limit switch mounting plate (17) for cracks, holes, or damage.
d.
Inspect mounting hardware for damage.
2-132
TM 10-4320-344-24
e.
Replace all defective components.
2.15.9.3
Installation.
a.
Position limit switch assembly (20) on limit switch mounting plate (17) and
secure with two new lock washers (19) and nuts (18).
b.
Position limit switch mounting plate (17) on rear panel plate (21) and secure
w i t h t w o b o l t s ( 1 6 ) , four new lock washers (15 and 14), and nuts (13).
c.
Install limit switch assembly wire (11), new lock washer (10), and screw (9)
on mode switch (12).
d.
I n s t a l l l i m i t s w i t c h w i r e ( 7 ) , new lock washer (6), and nut (5) on start alarm
relay (8).
e.
Install new electrical tiedown straps (4) on wiring harness (3) and insert
wiring harness (3) in plastic sheathing (2).
f.
Secure plastic sheathing (2) with new electrical tiedown straps (l).
2-133
TM 10-4320-344-24
2.15.10 Start Alarm Relay and Start Pilot Relay Maintenance, Models 609-A and 609-C
This task covers:
2.15.10.1 Removal
2.15.10.2 Installation
INITIAL SETUP
Tool S
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.2 or
2.15.3.
Conditions
(Continued)
General Safety I n s t r u c t i o n s
Material/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down,
10-4320-344-10.
TM
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
This procedure applies to Model 609-A.
relay of Model 609-c is similar.
The procedure for the start pilot
2.15.10.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
Tag diode at left terminal.
a.
Tag wires (Figure 2-49, 1 , 2 , 3 , 4 , a n d 5 ) a n d d i o d e ( 6 ) c o n n e c t e d t o s t a r t
alarm relay (7).
b.
Remove nut (8), lock washer (9), wire (1), nut (10), lock washer (11), and
f l a t w a s h e r ( 1 2 ) . Discard lock washers (9 and 11).
c.
Remove nut (13), lock washer (14), w i r e ( 5 ) , d i o d e ( 6 ) , n u t ( 1 5 ) , l o c k w a s h e r
( 1 6 ) , a n d f l a t w a s h e r ( 1 7 ) . Discard lock washers (14 and 16).
d.
Remove nut (18), lock washer (19), wire (4), diode (6), nut (20), lock washer
( 2 1 ) , a n d f l a t w a s h e r ( 2 2 ) . Discard lock washers (19 and 21).
e.
Remove nut (23), lock washer (24), wires (2 and 3), nut (25), lock washer
( 2 6 ) , a n d f l a t w a s h e r ( 2 7 ) . Discard lock washers (24 and 26).
f.
Remove two nuts (28), lock washers (29), flat washers (30), bolts (31), flat
w a s h e r s ( 3 2 ) , and one wire (5).
Discard lock washers (29).
g.
Remove start alarm relay (7) from engine mounting bracket (33).
2-134
TM 10-4320-344-24
Figure 2-49.
Start alarm Relay Maintenance, Model 609-A.
2-135
TM 10-4320-344-24
2.15.10 Start Alarm Relay and Start Pilot Relay Maintenance, Models 609-A and 609-C. (Continued)
2.15.10.2
Installation.
a.
Position start alarm relay (7) against engine mounting bracket (33) and secure
with two bolts (31), flat washers (32), one wire (5), two flat washers (30),
new lock washers (29), and nuts (28).
b.
I n s t a l l f l a t w a s h e r ( 2 7 ) , new lock washer (26), n u t ( 2 5 ) , w i r e s ( 2 a n d 3 ) , n e w
lock washer (24), and nut (23) .
Install untagged d i o d e t e r m i n a l d i s c o n n e c t e d i n s t e p c .
c.
Install flat washer (22), new lock washer (21), nut (20), diode (6), wire (4),
new lock washer (19), and n u t ( 1 8 ) .
d.
I n s t a l l f l a t w a s h e r ( 1 7 ) , new lock washer (16), n u t ( 1 5 ) , d i o d e ( 6 ) , w i r e ( 5 ) ,
new lock washer (14), and n u t ( 1 3 ) .
e.
I n s t a l l f l a t w a s h e r ( 1 2 ) , new lock washer (11), n u t ( 1 0 ) , w i r e ( 1 ) , n e w l o c k
washer [9), and nut (8).
f.
Remove tags from wires (1, 2, 3, 4 , and 5) and diode (6) and discard.
2-136
TM 10-4320-344-24
2.16 CONTROL PANEL ASSEMBLY MAINTENANCE.
2.16.1 Control Panel Cover Assembly Maintenance, Model 609-A.
This task
2.16.1.1
2.16.1.2
2.16.1.3
covers:
Removal
Disassembly
Repair
2.16.1.4 Assembly
2.16.1.5 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM
10-4320-344-10.
Material/Parts
Tags, Appendix C, Item 31
Tape, Antiseize, Appendix C,
Item 32
Lock Washers (TM 10-4320-344-24P)
Conditions
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.16.1.1 Removal.
Figure 2-50.
Control Panel Cover Assembly Removal, Model 609-A.
2-137
TM 10-4320-344-24
2.16.1 Control Panel Cover Assembly Maintenance, Model 609-A.
(Continued)
a.
Tag and disconnect tachometer/hourmeter cable (Figure 2-50, 1) from control
panel assembly (2).
b.
Disconnect discharge gauge pump hose assembly ( 3 ) f r o m t e e p i p e a s s e m b l y ( 4 ) .
c.
Disconnect discharge elbow hose assembly (5) from tee pipe assembly (4).
d.
Remove tee pipe assembly (4).
e.
Remove three cover mounting bolts (6), lock washers (7), and flat washers (8).
Discard lock washers (7).
f.
Remove rear support bolt (9), lock washer (10), and flat washer (11).
g.
Remove control panel cover (12).
2.16.1.2 Disassembly.
a.
Disassemble and inspect control panel cover assembly (Figure 2-51, 1) as
follows:
(1) Open door (2).
(2) Remove two screws (3), flat washers (4), and stud balls (5).
(3) Remove four screws (6), lock washers (7), flat washers (8), and friction
r e c e p t a c l e s ( 9 ) . Discard lock washers (7).
(4) Remove rubber bumper (10).
2.16.1.3 Repair.
a.
Inspect control panel cover (11) for cracks, holes, separation of welds,
improper operation of door (2), or damage.
b.
Inspect all mounting hardware and door securing hardware for corrosion or
damage.
c.
Inspect rubber bumper (10) for deterioration.
d.
Inspect data plate (12) for damage.
damaged data plate (12).
e.
Replace all defective components.
2.16.1.4 Assembly.
Refer to paragraph 2.11.1 and replace
Assemble control panel cover assembly (1) as follows:
a.
Install rubber bumper (10) in control panel cover (11).
b.
Install two friction receptacles (9) and secure with four flat washers (8),
new lock washers (7), and screws (6).
c.
Install two stud balls (5) and secure with two flat washers (4) and
screws (3).
d.
Close door (2).
2.16.1.5
a.
2-138
Installation.
Position control panel cover assembly (Figure 2-50, 12) on control panel
assembly (2) and secure with flat washer (11), new lock washer (10), rear
support bolt (9), three flat washers (8), new lock washers (7), and bolts (6).
TM 10-4320-344-24
Figure 2-51.
Control Panel Cover Assembly, Model 609-A.
Wrap antiseize tape in direction of pipe threads.
b.
Apply antiseize tape to pipe threads and install tee pipe assembly ( 4 ) .
c.
Install discharge elbow hose assembly (5) and discharge gauge pump hose
assembly (3) on-tee pipe assembly (4).
d.
Connect tachometer/hourmeter cable (1) to control panel assembly (2). Remove
and discard tag.
2-139
TM 10-4320-344-24
2.16.2 Control Panel Cover Assembly Maintenance, Model US636HCCD-1.
This task
2.16.2.1
2.16.2.2
2.16.2.3
covers:
Removal
Disassembly
Repair
2.16.2.4 Assembly
2.16.2.5 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Pumping station shut down, TM
10-4320-344-10.
General Safety I n s t r u c t i o n s
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Serrated Lock Rings
(TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment without following
standard shop safety precautions.
2.16.2.1 Removal.
a.
R e m o v e f o u r n u t s ( F i g u r e 2 - 5 2 , 1 ) , l o c k w a s h e r s ( 2 ) , flat washers (3), and
Discard lock washers (2).
screws (4) .
b.
Remove control panel cover assembly (5)
from base weldment (6).
2.16.2.2 Disassembly.
a.
Open door (7) and remove two serrated lock rings (8) and thumbscrew (9) .
Discard serrated lock rings (8).
b.
Remove two nut spring sheets (10).
2.16.2.3 Repair.
a.
Inspect for missing or damaged noise caution plate (11). Refer to paragraph
2.11.1 and replace damaged or missing noise caution plate (11).
b.
Inspect control panel cover assembly (5) for cracks, holes, separation of
w e l d s , improper operation of door (7), or damage.
c.
I n s p e c t a l l mounting hardware and door (7) securing hardware for corrosion or
damage.
d.
R e p l a c e a l l damaged components.
2.16.2.4 Assembly.
a.
Install two nut spring sheets (10).
b.
I n s t a l l t w o thumbscrews (9) and secure with two new serrated lock rings (8) .
2.16.2.5 Installation. Install control panel cover assembly (5) on base weldment (6)
and secure with four screws (4), flat washers (3), new lock washers (2), and nuts
(1) .
2-140
TM 10-4320-344-24
Figure 2-52.
Control Panel Cover Assembly Removal, Model US636HCCD-1.
2-141
TM 10-4320-344-24
2.16.3 Control Panel Assembly Removal and Installation. Model 609-A.
This task covers:
2.16.3.1 Removal
2.16.3.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Battery disconnected, paragraph 2.15.2
Material/Parts
General Safety I n s t r u c t i o n s
Straps, Electrical Tiedown, Appendix C,
Item 29
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not
work on equipment that is not securely
stabilized.
Equipment
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
(Continued)
Engine Coolant drained, paragraph 2.20.2.
Conditions
Pumping station shut down,
10-4320-344-10.
Conditions
TM
Control Panel Cover Assembly removed,
paragraph 2.16.1.
Do not work on equipment without
following standard shop safety
precautions.
2.16.3.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
Tag, unscrew, and remove connectors (Figure 2-53, 1 and 2) from pressure
regulator (3).
b.
Tag wires (4) on engine switch (5). Remove four screws (6), lock washers (7),
a n d w i r e s ( 4 ) . Discard lock washers (7).
c.
Tag wires (8) on mode switch (9).
Remove five screws (10), lock washers (11),
and wires (8). Discard lock washers (11).
d.
Turn manual throttle control knob (12) clockwise until it is fully in.
e.
Unscrew cable sheathing connector (13) and disconnect manual throttle cable
(14) from ball of manual throttle control knob (12).
f.
Tag two ground wires (15).
panel plate (17).
Remove screw (16) and wires (15) from control
Locate wire which runs from engine lubrication oil pressure gauge to engine
alarm reset, and wire which runs from engine coolant temperature gauge to
engine alarm reset.
g.
2-142
Cut electrical tiedown straps (18) on wiring harness (19) and open plastic
s h e a t h i n g ( 2 0 ) o n w i r i n g h a r n e s s ( 1 9 ) . Tag wires (21 and 24) and separate
them from rest of wiring harness (19).
TM 10-4320-344-24
Figure 2-53.
Control Panel Assembly Disconnection, Model 609-A (Sheet 1 of 2).
2-143
TM 10-4320-344-24
2.16.3 Control Panel Assembly Removal and Installation. Model 609-A. (Continued)
Figure 2-53.
Control Panel Assembly Disconnection, Model 609-A (Sheet 2 of 2).
h.
Tag four wires (26) on engine alarm reset (23). Remove two screws (27), lock
washers (28), and wires (26). Discard lock washers (28).
i.
Tag three wires (29) on engine ammeter (30). Remove and retain two nuts (31),
lock washers (32), flat washers (33), and three wires (29). Discard lock
washers (32) .
Engine lubrication oil pressure gauge hose assembly may leak engine oil when
disconnected.
Plug or secure line to prevent possibility of engine oil
leakage.
2-144
TM 10-4320-344-24
j.
Tag and disconnect engine lubrication oil pressure gauge hose assembly (34).
k.
Loosen screw (35,
cable (37).
l.
Remove nut (38), screw (39), a n d c a b l e c l a m p ( 4 0 ) f r o m f u e l r a c k c a b l e ( 3 7 ) .
m.
Remove electrical tiedown straps (18) around wiring harness (19) and fuel rack
cable (37).
n.
Remove electrical tiedown straps (18) securing sheathing (20), wiring harness
(19) and engine coolant temperature gauge tube (41).
o.
Remove engine temperature gauge tube (41) from engine (42) and wiring
harness (19).
p.
Remove two nuts (43, sheet 1), lock washers (44), c o n d u i t c l a m p s ( 4 5 ) , f o u r
f l a t w a s h e r s ( 4 6 ) , t w o b o l t s ( 4 7 ) , and wiring harness (19) from control panel
assembly frame (48). D i s c a r d l o c k w a s h e r s ( 4 4 ) .
q.
Tag and disconnect suction elbow hose assembly (49) from elbow on suction
elbow.
Figure 2-54.
sheet 2) and remove universal wire stop (36) from fuel rack
Control Panel Assembly Removal and Installation, Model 609-A.
r. Remove two bolts (Figure 2-54, 1), lock washers (2), and flat washers (3) from
front supports (4).
s. Remove two bolts (5), lock washers (6), and flat washers (7) from rear
supports (8).
2-145
TM 10-4320-344-24
2.16.3 Control Panel Assembly Removal and Installation, Model 609-A.
(Continued)
When removing control panel assembly, be careful not to damage engine coolant
temperature gauge tube.
t.
Remove control panel assembly (9) pulling fuel rack cable (Figure 2-53, Sheet
2, 36) and engine coolant temperature gauge tube through grommet (50) in rear
panel plate (51).
2.16.3.2
Installation.
a.
Position rear supports (Figure 2-54, 8) of control panel assembly (9) on
flange of pump discharge elbow (10) and secure with two flat washers (7), lock
washers (6), and bolts (5).
b.
Position front supports (4) on flange of pump suction elbow (11) and secure
with two flat washers (3), lock washers (2), and bolts (1).
Do not to damage engine coolant temperature gauge tube.
c.
Insert engine coolant temperature gauge (Figure 2-53 sheet 1, 25) and fuel
rack cable (37) through grommet (Sheet 2, 5 0 ) i n r e a r p a n e l p l a t e ( 5 1 ) .
d.
Connect suction elbow hose assembly (Sheet 1,
Remove and discard tags.
e.
Install two bolts (47), four flat washers (46), two conduit clamps (45), new
l o c k w a s h e r s ( 4 4 ) , and nuts (43) on control panel frame (48) and install
wiring harness (19) in conduit clamps (45).
f.
Place engine temperature gauge tube (41, sheet 2) in wiring harness (19) and
install in engine (42).
g.
Install wiring harness (19) and engine temperature gauge tube (41) in plastic
sheathing (20) and secure plastic sheathing (20) around wiring harness with
new electrical tiedown straps (18).
h.
Install cable clamp (40) on fuel rack cable (37) and secure with screw (39)
and nut (38).
i.
Install universal wire stop (36) on fuel rack cable (37) and secure with (35).
j.
Secure fuel rack cable (37) to wiring harness (19) with new electrical tiedown
straps (18).
k.
Connect engine lubrication oil pressure gauge hose assembly (Sheet 1, 34).
Remove and discard tag.
l.
Install three wires (29), two flat washers (33), new lock washers (32), and
nuts (31) on engine ammeter (30).
Remove and discard tags.
m.
I n s t a l l f o u r w i r e s ( 2 6 ) , two new lock washers (28), and screws (27) on engine
a l a r m r e s e t ( 2 3 ) . Remove and discard tags.
n.
Place wires (21 and 24) in wiring harness (19) and secure plastic sheathing
(20) with new electrical tiedown straps (18).
o.
Secure ground wires (15) to control panel plate (17) with screw (16).
and discard tags.
2-146
49) to elbow on suction elbow.
Remove
TM 10-4320-344-24
p.
Install manual throttle cable (14) on ball of manual throttle control knob
(12) and secure cable sheathing connector (13) on to end of manual throttle
control cable knob (12).
q-
I n s t a l l w i r e s ( 8 ) , f i v e n e w l o c k w a s h e r s 11), and screws (10) on mode switch
(9).
Remove and discard tags.
r.
I n s t a l l w i r e s ( 4 ) , four new lock washers
( 5 ) . Remove and discard tags.
s.
Screw connectors (1 and 2) on to pressure r e g u l a t o r
tags.
7), and screws (6) on engine switch
(3).
Remove and discard
2-147
TM 10-4320-344-24
2.16.4 Control Panel Assembly Removal and Installation, Model 609-C.
This task covers:
2.16.4.1 Removal
2.16.4.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.3.
Material/Parts
Compound, Silicon Caulking,
Appendix C, Item 9
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down,
10-4320-344-10.
Conditions
(Continued)
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
TM
2.16.4.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . F a i l u r e t o o b e y this warning may result in
death or serious personal injury.
a.
O p e n r i g h t s i d e e n g i n e a c c e s s d o o r ( F i g u r e 2 - 5 7 , 1) on pumping assembly (2).
b.
Disconnect electrical connector J9 (3) and J10 (4) from bracket (5) behind
control panel assembly (6).
c.
Open control panel assembly door (7) and control panel (8).
d.
Tag and disconnect flexible tube assemblies (9 and 10) from tee pipes (11 and
12).
e.
Remove silicon caulking compound from grommet (13) in rear of control panel
assembly (6).
f.
Remove flexible tube assemblies (9 and 10) through grommet (13) in rear of
control panel assembly (6).
g.
Remove six nuts (14), screws (15), lock washers (16), flat washers (17), and
control panel assembly (6) from pumping assembly (2) .
Discard lock washers
(16).
2.16.4.2
Installation.
a.
Position control panel assembly (6) on pumping assembly (2) and secure with
six flat washers (17), new lock washers (16), screws (15), and nuts (14).
b.
Insert flexible tube assemblies (9 and 10) through grommet (13) in rear of
control panel assembly (6).
2-148
TM 10-4320-344-24
Figure 2-55.
Control Panel Assembly Removal and Installation, Model 609-C.
2-149
TM 10-4320-344-24
2.16.4 Control Panel Assembly Removal and Installation, Model 609-C.
c.
(Continued)
Connect flexible tube assemblies (9 and 10) to tee pipes (11 and 12),
Remove and discard tags.
respectively.
Ensure that the silicon caulking compound fills grommet.
d.
Insert duct sealing compound in grommet (13) in rear of control panel assembly
(6).
e.
Close control panel (8) and control panel assembly door (7).
f.
Connect electrical connector J10 (4) and J9 (3) to bracket (5) behind control
panel assembly (6).
g.
Close right side engine door (1) on pumping assembly (2).
2-150
TM 10-4320-344-24
2.16.5 Control Panel Assembly Removal and Installation. Model US636HCCD-1.
This task covers:
2.16.5.1 Removal
2.16.5.2
Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.4.
Control Panel Cover Assembly removed,
paragraph 2.16.2.
Material/Parts
General Safety I n s t r u c t i o n s
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected.
Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.5.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . F a i l u r e t o o b e y this warning may result in
death or serious personal injury.
a.
Tag and remove s u c t i o n e l b o w h o s e ( F i g u r e 2 - 5 6 , 1) from suction gauge assembly
(2).
b.
Tag and remove discharge elbow hose (3) from discharge gauge assembly (4).
c.
Tag and remove e n g i n e o i l p r e s s u r e g a g e h o s e ( 5 ) f r o m o i l p r e s s u r e g a u g e ( 6 ) .
d.
Tag and remove engine tachometer drive cable (7) from tachometer/hourmeter
gauge (8).
e.
Tag ten wires (9) from wiring harness (10) attached to terminal block (11).
Loosen ten screws (12) and disconnect wires (9).
f.
Tag wire (13) attached to terminal 2 of controlling device (14).
(15) and disconnect wire (13).
g.
Tag wire (16) attached to alternator light (17).
(18), pull forward and disconnect wire (16).
h.
Pull wiring harness (10), hose assemblies (1, 3 and 5), engine tachometer
d r i v e c a b l e ( 7 ) , and wires (13 and 16) through control panel assembly mounting
plate (19).
Loosen screw
Holding terminal connector
2-151
TM 10-4320-344-24
2.16.5 Control Panel Assembly Removal and Installation. Model US636HCCD-1. (Continued)
Figure 2-56.
2-152
Control Panel Assembly, Model US636HCCD-1.
TM 10-4320-344-24
Figure 2-57.
i.
Control Panel Assembly Removal and Installation, Model US636HCCD-1.
Remove four attaching nuts (Figure 2-57, 1), lock washers (2), and control
panel assembly (3)
2.16.5.2 Installation.
a.
Position control panel assembly (3) on pumping assembly and secure with four
lock washers (2) and nuts (1).
b.
Insert wiring harness (Figure 2-56, 10), hose assemblies (1, 3 and 5), engine
tachometer drive cable (7), and wires (13 and 16) through control panel
assembly mounting plate (19).
c.
Holding terminal connector (18) push backward and connect wire (16) on
a l t e r n a t o r l i g h t ( 1 7 ) . Remove and discard tag.
d.
Connect wire (13) to screw (15) at terminal 2 of controlling device (14).
Tighten screw (15) and remove and discard tag.
e.
Connect ten wires (9) from wiring harness (10) to ten screws (12) on terminal
b l o c k ( 1 1 ) . Tighten screws (12) and remove and discard tags.
f.
Install engine tachometer drive cable (7) on tachometer/hourmeter gauge (8).
Remove and discard tag.
g.
Install engine oil pressure gauge hose (5) on oil pressure gauge (6).
and discard tag.
h.
Install discharge elbow hose (3) on discharge gauge assembly (4).
discard tag.
i.
Install suction elbow hose (1) on suction gauge assembly (2).
discard tag.
Remove
Remove and
Remove and
2-153
TM 10-4320-344-24
2.16.6 Control Panel Assembly Hiring Maintenance, Models 609-C and US636HCCD-1.
This task covers:
2.16.6.1 Test
2.16.6.2
Repair
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.3 or
2.15.4.
Multimeter, Appendix B, Section
III, Item 2
Soldering Gun, Appendix B,
Section III, Item 2
Materials/Parts
Conditions
(Continued)
Control Panel Assembly Cover removed,
paragraph 2.16.2, (US636HCCD-1).
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Solder, Appendix C, Item 25
Straps, Electrical Tiedown,
Appendix C, Item 29
Tags, Appendix C, Item 31
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Equipment Conditions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM
10-4320-344-10.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
2.16.6.1 Test.
Using multimeter set for continuity, refer to Appendix F, as
a p p l i c a b l e , and check continuity of wires.
2.16.6.2 Repair. If any wire does not give continuity, refer to Appendix D and repair
wiring harness as required.
2-154
TM 10-4320-344-24
2.16.7 Pump Suction and Discharge Gauge Assemblies Maintenance, Models 609-A and 609-C.
This task covers:
2.16.7.1 Removal
2.16.7.2 Repair
2.16.7.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1 (609-A) or Control Panel
open (609-C).
Material/Parts
General Safety I n s t r u c t i o n s
Tape, Antiseize, Appendix C,
Item 32
Lock Washers (TM 10-4320-344-24P)
Fluid Pressure Dampener
(TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Conditions
(Continued)
Do not work on equipment with battery
connected.
Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
Battery disconnected, paragraph
2.15.2 or 2.15.3.
This procedure applies to both the pump suction and pump discharge gauge
a s s e m b l i e s f o r Model 609-A. The procedure for Model 609-C is similar.
2.16.7.1 Removal.
DO not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i S c o n n e c t e d . F a i l u r e t o o b e y this warning may result in
serious personal injury.
a.
Disconnect elbow and hose assembly (Figure 2-58,
(2).
1) from straight pipe adapter
b.
Model 609-A only, disconnect fluid pressure dampener (2) from pump suction
gauge assembly (3).
Discard fluid pressure dampener (2).
c.
Remove four screws (4), lock washers (5), spacers (6), and pump suction gauge
a s s e m b l y ( 3 ) f r o m c o n t r o l p a n e l ( 7 ) . Discard lock washers (5).
d.
Remove three screws (8), lock washers (9), and pump suction gauge assembly (3)
from mounting plate (10).
Discard lock washers (9).
2.16.7.2 Repair.
a.
Inspect pump suction gauge assembly (3) for cracks, broken glass, or damage.
b.
Inspect all mounting hardware for damage.
c.
Replace all defective components.
2-155
TM 10-4320-344-24
2.16.7 Pump Suction and Discharge Gauge Assemblies Maintenance. Models 609-A and 609-C. (Continued)
Figure 2-58.
Pump Suction and Discharge Gauge Maintenance, Model 609-A
2.16.7.3 Installation.
Wrap antiseize tape in direction of threads on all pipe threads prior to
installation.
a.
Position pump suction gauge assembly (3) on mounting plate (10) and secure
with three new lock washers (9) and screws (8).
b.
Position pump suction gauge assembly (3) against control panel (7) and secure
with three spacers (6), new lock washers (5), and screws (4).
c.
Model 609-A only, install new fluid pressure dampener (2) on pump suction
gauge assembly (3).
d.
Install elbow and hose assembly (1) on fluid pressure dampener (2).
2-156
TM 10-4320-344-24
2.16.8 Pump Suction and Discharge Gauge Maintenance, Model US636HCCD-1.
This task covers:
2.16.8.1 Removal
2.16.8.2 Repair
2.16.8.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.4.
Conditions
(Continued)
Control Panel Cover Assembly removed, refer
to paragraph 2.16.2
Material/Parts
General Safety I n s t r u c t i o n s
Tape, Antiseize, Appendix C,
Item 32
Fluid Pressure Dampener (TM
10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected.
Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
This procedure applies to both the pump suction and pump discharge gauge.
2.16.8.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
serious personal injury.
a.
Disconnect electrical connector (Figure 2-59, 1).
b.
Remove pressure sensor (2) from pipe tee (3).
c.
Loosen hose clamp (4) that secures hose (5) to female to female coupling (6)
and remove hose assembly (5) from female to female coupling (6).
d.
Remove female to female coupling (6) from fluid pressure dampener (7).
e.
Remove fluid pressure dampener (7) from pipe tee (3).
dampener (7).
f.
Remove pipe tee (3) from pump discharge connection (8) on pump discharge gauge
assembly (9).
g.
R e m o v e t h r e e s c r e w s ( 1 0 ) , f l a t w a s h e r s ( 1 1 ) , and pump discharge gauge assembly
(9) from control panel (12).
h.
Remove three spacers (13), flat washers (14), spacer ring (15), three flat
washers (16), and gauge cover (17) from control panel (12).
Discard fluid pressure
2-157
TM 10-4320-344-24
2.16.8 Pump Suction and Discharge Gauge Maintenance. Model US636HCCD-1. (Continued)
Figure 2-59.
Pump Suction and Discharge Gauge Maintenance, Model US636HCCD-3.
2.16.8.2 Repair.
a.
Inspect pump discharge gauge assembly (9) for cracks, broken glass, or damage.
b.
I n s p e c t p r e s s u r e s e n s o r ( 2 ) f o r c r a c k s , h o l e s , and burned or damaged wiring.
c.
Inspect electrical connector (1) for cracks and missing contacts.
d.
Inspect all mounting hardware for damage.
e.
Replace all defective components.
2-158
TM 10-4320-344-24
2.16.8.3
Installation.
Wrap antiseize tape in direction of threads on all pipe threads prior to
assembly.
a.
Install gauge cover (17), three flat washers (16), spacer ring (15), three
flat washers (14), and spacers (13) on control panel (12).
b.
Install pump discharge gauge assembly (9) and secure with three flat washers
(11) and screws (10).
c.
Install pipe tee (3) on pump discharge connection (8).
d.
Install new fluid pressure dampener (7) on pipe tee (3).
e.
Install female to female coupling (6) on fluid pressure dampener (7).
f.
Install hose assembly (5) on fluid pressure dampener (7) and secure with hose
clamp (4).
g.
Install pressure sensor (2) on pipe tee (3) and connect electrical connector
(1).
2-159
TM 10-4320-344-24
2.16.9 Low Oil Pressure Cutoff Switch Test. Model US636HCCD-1.
This task covers:
2.16.9.1 Test
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed, refer
to paragraph 2.16.2.
General Safety I n s t r u c t i o n s
Multimeter, Appendix B, Section
III, Item 2
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.4.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.9.1 TEST.
Electrocution hazard is
Do not work on equipment with battery connected.
p r e s e n t i f b a t t e r y i s c o n n e c t e d . F a i l u r e t o o b e y this warning may result in
serious personal injury.
Any incorrect reading indicates a defective switch.
a.
Remove screw (Figure 2-60,
assembly (3).
b.
Check continuity between terminal of wire (2) and switch terminal (4).
Correct reading is 0.
c.
Check continuity between terminal of wire (2) and switch terminal (5).
Correct reading is 0.
d.
Push in and hold switch button on face of oil pressure gauge (6).
steps b and c.
Correct readings should be infinity.
e.
Release switch button on face of oil pressure gauge (6).
f.
Refer to paragraph 2.16.10 and replace oil pressure gauge (6) if defective.
g.
Install wire (2) on horn (3) and secure with screw (l).
2-160
1) and oil pressure gauge wire (2) from horn
Repeat
TM 10-4320-344-24
Figure 2-60.
Low Oil Pressure Cutoff Switch Test.
2-161
TM 10-4320-344-24
2.16.10 Oil Pressure Gauge and Hose Assembly Maintenance, Models 609-A and US636HCCD-1.
This task covers:
2.16.10.1 Removal
2.16.10.2 Repair
2.16.10.3 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i tr Appendix B, Section
III, Item 1
Oil Pressure Gauge Wire disconnected and
removed from wiring harness, paragraph
2.16.3 (609-A).
Material/Parts
Oil Pressure Gauge Wire disconnected for
horn, paragraph 2.16.9 (US636HCCD-1).
Tags, Appendix C, Item 31
Tape, Antiseize, Appendix C,
Item 32
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Conditions
(Continued)
General Safety I n s t r u c t i o n s
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Battery disconnected, paragraph 2.15.2
(609-A) or 2.15.4 (US636HCCD-1)
Do not work on equipment without following
standard shop safety precautions.
Control Panel Cover Assembly
removed, refer to paragraph 2.16.2.
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-A
2.16.10.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
serious personal injury.
a.
Loosen two hose clamps (Figure 2-61, 1) and disconnect oil hose assembly (2)
from oil pressure gauge (3) and from elbow (4) on oil filter (5).
b.
Remove two nuts (6) and lock washers (7).
c.
Tag and remove three wires (8).
d.
Remove gauge mounting bracket (9) and oil pressure gauge (3) from control
panel (10).
Discard lock washers (7).
2.16.10.2 Repair.
a.
I n s p e c t oil hose assembly (2) for cracks, holes, leaks, or damage.
b.
Inspect oil pressure gauge wire for cracked or missing insulation, damaged or
missing terminal, or burns.
c.
Replace damaged oil hose assembly (1).
2-162
TM 10-4320-344-24
Figure 2-61.
0il Pressure Gauge Maintenance, Model US636HCCD-1.
(3) if oil pressure gauge wire is damaged.
d.
Replace oil pressure gauge
e.
Replace damaged mounting hardware.
2.16.10.3 Installation.
a.
Install oil pressure gauge (3) and mounting bracket (9) on control panel (10).
b.
R e f e r t o t a g s a n d i n s t a l l t h r e e w i r e s (8) on oil pressure gauge (3). Remove
tags.
c.
Install two new lock washers (7) and nuts (6) on oil pressure gauge (3).
Wrap antiseize tape in direction of threads on hose assembly.
d.
Install oil hose assembly (1) on elbow (4) and oil pressure gauge (3) and
secure with two hose clamps (1).
2-163
TM 10-4320-344-24
2.16.11 Engine Coolant Temperature Gauge Assembly Maintenance. Model 609-A.
This task covers:
2.16.11.1 Removal
2.16.11.2 Repair
2.16.11.3 Installation
INITIAL SETUP
Tool s
Equipment Conditions (Conditions)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Temperature Gauge Wire disconnected and
removed from wiring harness, paragraph
2.16.3.
Material/Parts
General Safety I n s t r u c t i o n s
Antifreeze, Appendix C,
Item 3
Straps, Electrical Tiedown,
Appendix C, Item 29
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.11.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . F a i l u r e t o o b e y this warning may result in
death or serious personal injury.
R e m o v e e l e c t r i c a l t i e d o w n s t r a p s (Figure 2-62,
a.
1) from plastic sheathing (2).
Engine coolant may scald.
Use suitable container to catch engine coolant.
Loosen nut (4) and remove engine coolant temperature gauge tube (3) from
engine block (5) and plastic sheathing (2).
b.
When removing engine coolant temperature gauge from the control panel, be
careful not to damage engine coolant temperature gauge tube.
c.
2-164
Remove two nuts (6), lock washers (7), mounting bracket (8), and engine
c o o l a n t t e m p e r a t u r e g a u g e ( 9 ) f r o m f r o n t o f c o n t r o l p a n e l ( 1 0 ) . Discard
lockwashers.
TM 10-4320-344-24
Figure 2-62.
Engine Coolant Temperature Gauge Replacement.
2-165
TM 10-4320-344-24
2.16.11 Engine Coolant Temperature Gauge Assembly Maintenance, Model 609-A.
(Continued)
2.16.11.2 Repair.
a.
Inspect engine coolant temperature gauge (9) for cracks, broken glass, or
damage.
b.
Inspect engine coolant temperature gauge tube (6) for cracks, holes, or
damage.
c.
Inspect engine coolant temperature gauge wire (11) for cracked or missing
insulation, damaged or missing terminal, or burns.
d.
Inspect all mounting hardware for damage.
e.
Replace all defective components.
2.16.11.3 Installation.
a.
Install engine coolant temperature gauge (9) in control panel (10) and secure
with mounting bracket (8), two new lock washers (7), and nuts (6).
When installing engine coolant temperature gauge through the control panel,
be careful not to damage engine coolant temperature gauge tube.
b.
Install engine coolant temperature gauge tube (3) in plastic sheathing (2) and
e n g i n e b l o c k ( 5 ) . Secure engine coolant temperature gauge tube (3) with nut
(4).
c.
Secure plastic sheathing (2) with electrical tiedown straps (1).
d.
Fill radiator with antifreeze.
2-166
TM 10-4320-344-24
2.16.12 Meter Assembly Maintenance.
This task c o v e r s :
2.16.12.1 Removal
2.16.12.2 Repair
2.16.12.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Control Panel Door open, Model 609-C.
INITIAL SETUP
Material/Parts
(Continued)
Control Panel Cover Assembly removed,
paragraph 2.16.1 (609-A) or 2.16.2
(US636HCCD-1).
T a g s ( Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
General Safety I n s t r u c t i o n s
Equipment
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2 . 1 5 . 2 ( 6 0 9 - A ) , 2.15.3 (609-C), and 215-4 (US636HCCD-1)
•
Do not work on equipment with battery
connected.
Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
This is a general maintenance procedure for meter assemblies.
procedure applies to the following meter assemblies:
This
Ammeter Assembly (Models 609-A and US636HCCD-1)
Engine Temperature Gauge Assembly (Model 609-C)
Hourmeter Assembly (Model 609-C)
Oil Pressure Gauge Assembly (Model 609-C)
Tachometer Assembly (609-C)
Voltmeter (Model 609-C)
•
A l l m e t e r a s s e m b l i e s a r e i d e n t i f i e d o n t h e c o n t r o l p a n e l f o r each
pumping assembly. For further information on meter assembly
locations reference TM 10-4320-344-10.
2.16.12.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
Remove two nuts (Figure 2-63, 1).
b.
Tag and remove wires (2) from meter or gauge assembly (3).
c.
Remove two nuts (4), lock washers (5), bracket (6), and meter or gauge
a s s e m b l y ( 3 ) . Discard lock washers (5).
2-167
TM 10-4320-344-24
2.16.12 Meter Assembly Maintenance. (Continued)
Figure 2-63.
Oil Pressure. Gauge Maintenance, Model 609-c.
2.16.12.2 Repair.
a.
Inspect meter or gauge assembly (3) for cracks, holes, broken glass, or
damage.
b.
Inspect all mounting hardware for damage.
c.
Replace defective components.
2.16.12.3 Installation.
a.
Install meter or gauge assembly (3) and secure with mounting bracket (6),
new lock washers (5), and nuts (4).
b.
Refer to tags and install wires (2) on meter or gauge assembly (3) and secure
w i t h n u t s ( 1 ) . Remove and discard tags.
2-168
two
TM 10-4320-344-24
2.16.13 Tachometer/HoumeterAssemblyMaintenance. Models 609-A and US636HCCD-1.
This task covers:
2.16.13.1 Removal
2.16.13.2 Repair
2.16.13.3 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1 (609-A) or 2.16.2
(US636HCCD-1).
Materials/Parts
General Safety I n s t r u c t i o n s
Lock Washers (TM 10-4320-344-24P)
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Battery disconnected, paragraph
2.14.2 (609-A) or 2.14.4
(US636HCCD-1).
Do not work on equipment without following
standard shop safety precautions.
This procedure applies to Model 609-A.
is similar.
The procedure for Model US636HCCD-1
2.16.13.1 Removal.
Electrocution hazard is
Do not work on equipment with battery connected.
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
D i s c o n n e c t t a c h o m e t e r c a b l e ( F i g u r e 2 - 6 4 , 1) from tachometer/hourmeter
assembly (2).
b.
Remove two nuts (3), lock washers (4), mounting bracket (5), and
t a c h o m e t e r / h o u r m e t e r ( 2 ) f r o m c o n t r o l p a n e l ( 6 ) . Discard lock washers (4).
2.16.13.2 Repair.
a.
Inspect tachometer/hourmeter assembly (2) for cracks, broken glass, or damage.
b.
Inspect all mounting hardware for damage.
c.
Replace all defective components.
2.16.13.3 Installation.
a.
Install tachometer/hourmeter assembly (2) in control panel (6) and secure with
mounting bracket (5), two new lock washers (4), and nuts (3).
b.
Connect tachometer cable (1) to tachometer/hourmeter assembly (2).
2-169
TM 10-4320-344-24
2.16.13 Tachomter/Hourmeter Assembly Maintenance, Models 609-A and US636HCCD-1. (Continued)
Figure 2-64.
2-170
Tachometer/Hourmeter Assembly Replacement.
TM 10-4320-344-24
2.16.14 Indicator Maintenance, Models 609-C and US636HCCD-l.
This task covers:
2.16.14.1 Removal
2.16.14.2 Repair
2.16.14.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.3
(609-C) or 2.15.4 (US636HCCD-1).
INITIAL SETUP
Soldering Gun, Appendix B,
Section III, Item 2
(Continued)
Control Panel Cover Assembly removed,
paragraph 2.16.2, (US636HCCD-1).
General Safety I n s t r u c t i o n s
Material/Parts
Solder, Appendix C, Item 25, (609-C)
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
Control Panel open (609-C).
•
This procedure applies to the engine high temperature, engine
overspeed, and engine low oil indicators of Model 609-C. The
alternator indicator removal and installation procedure for Model
US636HCCD-1 is similar.
•
Indicators are identified on control panel for each pumping
For further information on indicator location reference
assembly.
TM 10-4320-344-10.
2.16.14.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
Tag and desolder wires (Figure 2-65, 1) from indicator (2).
b.
Remove light cover (3) and bulb (4).
c.
Remove outer nut (5), indicator (2), lock washer (6), and nut (7) from
i n d i c a t o r ( 2 ) . Discard lock washer (6).
2.16.14.2 Repair.
a.
Check bulb (4) for broken filament.
b.
Inspect indicator (2) for corrosion, damage to contacts, cracks, or damage.
c.
Inspect light cover (3) for cracks or holes.
2-171
TM 10-4320-344-24
2.16.14 Indicator Maintenance, Models 609-C and US636HCCD-1.
Figure 2-65.
(Continued)
Indicator Maintenance.
d.
Inspect all mounting hardware for damage.
e.
Replace all defective components.
2.16.14.3 Installation.
a.
Install indicator (2) and secure with nut (7), new lock washer (6), and outer
nut (5).
b.
Insert bulb (4) in indicator (2) and install light cover (3).
c.
Refer to tags and solder wires (1) to indicator (2).
2-172
Remove and discard tags.
TM 10-4320-344-24
2.16.15 Engine Alarm Assembly Replacement, Model 609-A.
This task covers:
2.16.15.1 Removal
2.16.15.2
Installation
Tools
Equipment
Conditions (continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1.
INITIAL SETUP
General Safety I n s t r u c t i o n s
Materials/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.2.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected.
Electrocution hazard is present
if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.15.1 Removal.
Electrocution hazard is
Do not work on equipment with battery connected.
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
Remove screw (Figure 2-66, 1 ) , l o c k w a s h e r ( 2 ) , a n d w i r e ( 3 ) f r o m e n g i n e a l a r m
r e s e t ( 4 ) . Discard lock washer (2) and tag wire (3).
b.
Remove two nuts (5), wires (6), lock washers (7), and screws (8).
(6) and discard lock washers (7).
c.
Remove engine alarm assembly (9) from control panel (10).
Tag wires
2.16.15.2 Installation.
a.
Position engine alarm assembly (9) on control panel (10) and secure with two
s c r e w s ( 8 ) , n e w l o c k w a s h e r s ( 7 ) , w i r e s ( 6 ) , a n d n u t s ( 5 ) . Remove and discard
tags.
b.
I n s t a l l w i r e ( 3 ) , new lock washer (2), and screw (1) on engine alarm reset
( 4 ) . Remove and discard tag.
2-173
TM 10-4320-344-24
2.16.15 Engine Alarm Assembly Replacement, Model 609-A. (Continued)
Figure 2-66. Engine Alarm Replacement.
2-174
TM 10-4320-344-24
2.16.16 Horn Replacement, Model US636HCCD-1.
This task covers:
2.16.16.1 Removal
2.16.16.2 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.2.
General Safety Instructions
Materials/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.4.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without
standard shop safety precautions.
following
2.16.16.1 Removal.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Remove two screws (Figure 2-67, 1), locking tabs (2), and three wires (3).
Tag wires.
b.
Remove two nuts (4), lock washers (5), screws (6), and horn (7) from control
panel (8). Discard lock washers (5).
2.16.16.2 Installation.
a.
Position horn (7) on control panel (8) and secure with two screws (6), new
lock washers (5), and nuts (4).
b.
Install three wires (3) and secure with two locking tabs (2) and screws (1).
Remove and discard tags.
2-175
TM 19-4320-344-24
2.16.16 Horn Replacement, Model US636HCCD-1. (Continued)
Figure 2-67. Horn Replacement.
2-176
TM 10-4320-344-24
2.16.17 Engine Alarm Reset Assembly Replacement, Model 609-A.
This task covers:
2.16.17.1 Removal
2.16.17.2 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1.
General Saftey Instructions
Material/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.2.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected.
Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.17.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Remove two screws (Figure 2-68, 1,), lock washers (2), and four wires (3) from
engine alarm reset (4). Tag wires (3) and discard lock washers (2).
b.
Remove screw (5), lock washer (6), and wire (7). Tag wire (7) and discard
lock washer (6).
c.
Remove screw (8), lock washer (9), and wire (10). Tag wire (10) and discard
lock washer (9).
d.
Remove nut (11), lock washer (12), and engine alarm reset (4) from control
panel (13). Discard lock washer (12).
2.16.17.2
Installation.
a.
Position engine alarm reset (4) in control panel (13) and secure with new lock
washer (12) and nut (11).
b.
Install wire (10), new lock washer (9), and screw (5).
tag.
c.
Install wire (7), new lock washer (6), and screw (5). Remove and discard tag.
d.
Install four wires (3), two new lock washers (2), and screws (1). Remove and
discard tags.
Remove and discard
2-177
TM 10-4320-344-24
2.16.17 Engine Alarm Reset Assembly Replacement, Model 609-A. (Continued)
Figure 2-68. Engine Alarm Reset Replacement.
2-178
TM 10-4320-344-24
2.16.18 Toggle Switch Maintenance.
This task covers:
2.16.18.1 Removal
2.16.18.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1 (609-A) or 2.16.2
(US636HCCD-1).
Material/Parts
Control Panel Door open (609-C).
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
General Safety Instructions
Equipment
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.2 (609-A), 2.15.3 (609-C),
or 2.15.4 (US636HCCD-1).
Conditions
(Continued)
Do not work on equipment with battery
Electrocution hazard is
connected.
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
NOTE
•
This is a general maintenance procedure for toggle switches.
procedure applies to the following toggle switches:
This
Auto Select Switch (609-C)
Engine Switch (609-A and 609-C)
Main Power Switch (609-C)
Mode Switch (609-A and US636HCCD-1)
Throttle Select Switch (609-C)
•
All switch assemblies are identified on the control panel for each
pumping assembly. For further information on toggle switch
locations, reference TM 10-4320-344-10.
2.16.18.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Remove four screws (Figure 2-69, 1), washers (2), and wires (3) from toggle
switch (4). Tag wires (3). If applicable, discard lock washers.
b.
Remove nut (5), lock washer (6), flat washer (7), and toggle switch (4) from
control panel (8). Discard lock washer (6).
2.16.18.3 Installation.
a.
Install toggle switch (4) in control panel (8) and secure with flat washer
(7), new lock washer (6), and nut (5).
2-179
TM 10-4320-344-24
2.16.18 Toggle Switch Maintenance. (Continued)
Figure 2-69. Toggle Switch Maintenance.
NOTE
Install new lock washers, if applicable.
b.
2-180
Install wires (3), washers (2), and screws (1). Remove and discard tags.
TM 10-4320-344-24
2.16.19
Start Switch Maintenance, Model US636HCCD-1.
This task covers:
2.16.19.1 Removal
2.16.19.2 Test
2.16.19.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.2.
INITIAL SETUP
Multimeter, Appendix B, Section
III, Item 2
Material/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM
10-4320-344-10.
(Continued)
Control Panel Cover Assembly removed,
paragraph 2.16.2.
General Safety Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
Electrocution hazard is
connected.
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.19.1 Removal.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Remove two screws (Figure 2-70, 1), lock washers (2), and three wires (3).
Tag wires (3) and discard lock washers (2).
b.
Unscrew rubber button cover (4) and remove start switch (5) from control panel
(6).
2.16.19.2 Test.
a.
Test continuity between switch terminals (7 and 8). Correct reading is
infinity.
b.
Push in and hold switch contact button and test continuity between switch
terminals (7 and 8). Correct reading is 0.
c.
Replace defective start switch (5).
2.16.19.3 Installation.
a.
Insert start switch (5) in control panel (6) and secure with rubber button
cover (4) .
b.
Install three wires (3), new lock washers (2), and screws (1). Remove and
discard tags.
2-181
TM 10-4320-344-24
2.16.19 Start Switch Maintenance. Model US636HCCD-1. (Continued)
Figure 2-70. Start Switch Maintenance.
2-182
TM 10-4320-344-24
2.16.20 Start/Stop Switch Maintenance, Model US636HCCD-1.
This task covers:
2.16.20.1 Removal
2.16.20.2 Test
2.16.20.3
Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.2.
General Safety Instructions
Multimeter, Appendix B, Section
III, Item 2
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Material/Parts
Tags, Appendix C, Item 31
Equipment
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Conditions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.4.
2.16.20.1 Removal.
Do not work on equipment with battery connected. Electrocution hazards is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Remove four screws (Figure 2-71, 1), wire retainers (2), and six wires (3)
from start/stop switch (4). Tag wires (3).
b.
Remove knob (5), locknut (6), tab washer (7), two spacers (8), gasket (9), and
start/stop switch (4) from control panel (10).
2.16.20.2 Test.
a.
Ensure knob (5) is mounted on start/stop switch (4). Push knob (5) to STOP
position.
b.
Test continuity between terminals (11) and (12) on right side of switch.
Correct reading is infinity.
c.
Test continuity between terminals (13) and (14) on left side of switch.
Correct reading is infinity.
d.
Pull knob (5) to START position.
e.
Repeat steps b and c above.
f.
Replace defective start/stop switch (4) if any reading is incorrect.
Correct reading is 0.
2-183
TM 10-4320-344-24
2.16.20 Start/Stop Switch Maintenance, Model US636HCCD-1. (Continued)
Figure 2-71. Start/Stop Switch Maintenance.
2.16.20.3
Installation.
a.
Install start/stop switch (4) in control panel (10) and secure with gasket
(9), two spacers (8), tab washer (7), and locknut (6).
b.
Install knob (5) on start/stop switch (4).
c.
Install six wires (3), four wire retainers (2), and screws (1). Remove and
discard tags.
2-184
TM 10-4320-344-24
2.16.21 Fuse Holder Replacement, Model US636HCCD-1.
This task covers:
2.16.21.1 Removal
2.16.21.2
Installation
INITIAL SETUP
(Continued)
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.2.
General Safety Instructions
Material/Parts
Tags, Appendix C, Item 31
Equipment
Conditions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Pumping station shut down,
TM 10-4320-344-10.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Battery disconnected, paragraph
2.15.4.
Do not work on equipment without following
standard shop safety precautions.
2.16.21.1 Removal.
Figure 2-72. Fuse Holder Replacement.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Tag and disconnect two wires (Figure 2-72, 1).
b.
Unscrew and remove cover (2) and fuse (3).
c.
Remove nut (4), flat washer (5), and fuse holder (6) from control panel (7).
2-185
TM 10-4230-344-24
2.16.21 Fuse Holder Replacement, Model US636HCCD-1. (Continued)
2.16.21.2
Installation.
a.
Insert fuse holder (6) in control panel (7) and secure with flat washer (5)
and nut (4).
b.
Insert fuse (3) into cover (2) and install cover (2) in fuse holder (6).
c.
Connect two wires (1) to fuse holder (6). Remove and discard tags.
2-186
TM 10-4320-344-24
2.16.22 Rheostat Replacement, Models 609-C and US636HCCD-1.
This task covers:
2.16.22.1 Removal
2.16.22.2
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Control Panel open (609-C).
INITIAL SETUP
Solder Gun, Appendix B, Section III,
Item 2
Material/Parts
Solder, Appendix C, Item 25
Tags, Appendix C, Item 31
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
(Continued)
Control Panel Cover Assembly removed,
paragraph 2.16.2 (US636HCCD-1).
General Safety Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected.
Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
Battery disconnected, paragraph 2.15.3,
(609-C) or 2.15.4 (US636HCCD-1).
NOTE
This procedure applies to the lights dimmer rheostat on Model 609-C. The
procedure for the Model 609-C auto throttle rheostat and Model US636HCCD-1
manual throttle select rheostat is similar.
2.16.22.1 Removal.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected.
Failure to obey this warning may result in
death or serious personal injury.
a.
Tag and desolder wires (Figure 2-73, 1).
b.
Loosen set screw (2) and remove knob (3).
c.
Remove nut (4), lock washer (5), a n d r h e o s t a t ( 6 ) f r o m c o n t r o l p a n e l ( 7 ) .
2.16.22.2 Installation.
a.
Install rheostat (6) in control panel (7) and secure with lock washer (5) and
nut (4).
b.
Install knob (3) on rheostat (6) and secure with set screw (2).
c.
Solder wires (1) to rheostat (6). Remove and discard tags.
2-187
TM 10-4320-344-24
2.16.22 Rheostat Replacement. Models 609-C and US636HCCD-1. (Continued)
Figure 2-73. Rheostat Maintenance.
2-188
TM 10-4320-344-24
2.16.23 Resistor Replacement, Model 609-C.
This task covers:
2.16.23.1
Removal
2.16.23.2
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Battery disconnected, paragraph 2.15.3.
Solder Gun, A p p e n d i x B , S e c t i o n I I I ,
Item 2
General Safety Instructions
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Material/Parts
Solder, Appendix C, Item 25
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM 10-4320344-10.
NOTE
This procedure applies to both resistors R1 and R2.
2.16.23.1 Removal.
Do not work on equipment with battery connected. Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
death or serious personal injury.
a.
Open control panel door assembly (Figure 2-74, 1) and control panel (2).
b.
Tag and desolder wires (3).
c.
Remove two nuts (4), lock washers (5), screws (6), and resistor (7).
lock washers (5).
Discard
2.16.23.2 Installation.
a.
Position resistor (7) on control panel (2) and secure with two screws (6), new
lock washers (5), and nuts (4).
b.
Solder wires (3) to resistor (7).
c.
Close control panel (2) and control panel door assembly (1).
Remove and discard tags.
2-189
TM 10-4320-344-24
2.16.23 Resistor Replacement, Model 609-C. (Continued)
Figure 2-74. Resistor Replacement, Model 609-C.
2-190
TM 10-4320-344-24
2.16.24 Control Panel Lights Maintenance. Model 609-C.
This task covers:
2.16.24.1 Removal
2.16.24.2 Repair
2.16.24.3 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix C, Item 31
Item 1
Battery disconnected, paragraph 2.15.3.
(Continued)
General Safety Instructions
Material/Parts
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Tags, Appendix C, Item 31
Butt (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following
standard shop safety precautions.
2.16.24.1 Removal.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
death or serious personal injury.
a.
Open control panel door assembly (Figure 2-75, 1) and control panel (2).
b.
Tag wire (3) and remove from butt (4).
c.
Remove two screws (5), lock washers (6), and light assembly (7) from control
panel (2). Discard lock washers (6).
2.16.24.2 Repair.
a.
Remove bulb (8) from light assembly (7).
filament, broken glass, or damage.
Inspect bulb (8) for broken
b.
Inspect light assembly (7) for bends, cracks, loss of spring tension in arm,
or damage.
c.
Inspect wire (3) for burns, missing insulation, or damage.
d.
Inspect all mounting hardware for damage.
e.
Replace all defective components.
2.16.24.3 Installation.
a.
Install bulb (8) in light assembly (7).
b.
Position light assembly (7) on control panel (2) and secure with two new lock
washers (6) and screws (5).
c.
Install wire (3) in butt (4).
Crimp butt (4) and remove and discard tag.
2-191
TM 10-4320-344-24
2.16.24 Control Panel Lights Maintenance, Model 609-C. (Continued)
Figure 2-75. Control Panel Light Maintenance.
d.
2-192
Close control panel (2) and control panel door assembly (1).
TM 10-4320-344-24
2.16.25 Manual Throttle Control Cable Replacement, Model 609-A.
This task covers:
2.16.25.1 Removal
2.16.25.2 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1.
General
Conditions
Safety
(Continued)
Instructions
Material/Parts
Straps, Electrical Tiedown, Appendix C,
Item 29
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph 2.15.2.
To prevent rolling or sliding, do not work
on equipment that is not securely
stabilized.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without
standard shop safety precautions.
following
Power Control Cable Assembly removed,
paragraph 2.15.8.
2.16.25.1 Removal.
Do not work on equipment with battery connected.
Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury.
a.
Turn manual throttle control knob assembly (Figure 2-76, 1) clockwise until it
is fully in.
b.
Unscrew cable sheathing connector (2) and unsnap manual throttle control cable
connector (3) from manual throttle control knob assembly ball (4).
c.
Remove backing nut (5), lock washer (6), and manual throttle control knob
assembly (1).
d.
Remove nut (8) and lock washer (9) that secure pivot leg (10) to inboard
throttle arm (11) on fuel injection pump.
e.
Remove pivot leg (10), two lock washers (12), bracket (13), and nut (14) from
end of manual throttle control cable (15).
f.
Remove three cable clamps (16).
g.
Cut electrical tiedown straps (17) holding manual throttle control cable (15)
to wiring harness (18).
h.
Pull manual throttle control cable (15) through grommet in rear panel (19).
2.16.25.2 Installation.
a.
Insert manual throttle control cable (15) through grommet in rear panel (19).
2-193
TM 10-4320-344-24
2.16.25 Manual Throttle Control Cable Replacement, Model 609-A. (Continued)
Figure 2-76.
2-194
Manual Throttle Control Cable Replacement.
TM 10-4320-344-24
b.
Secure manual throttle control cable (15) to wiring harness (18) with
electrical tiedown straps (17).
NOTE
Do not tighten cable clamps until cable has been adjusted.
c.
Install three cable clamps (16) on manual throttle control cable (15).
d.
Install nut (14), two lock washers (12), bracket (13), and pivot leg (10) on
manual throttle control cable (15).
e.
Insert pivot leg (10) through inboard throttle arm (11) and secure with lock
washer (9) and nut (8).
f.
Insert manual throttle control knob assembly (1) through front of control
panel (7) and secure with lock washer (6) and backing nut (5).
g.
Install cable connector (3) on manual throttle control knob assembly ball (4)
and secure with cable sheathing connector (2).
2-195
TM 10-4320-244-24
2.16.26 Manual Throttle Control Cable Maintenance, Model 609-C.
This task covers:
2.16.26.1 Removal
2.16.26.2 Repair
2.16.26.3 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Battery disconnected, paragraph 2.15.3.
Material/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
General Safety Instructions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM 10-4320344-10.
2.16.26.1 Removal.
a.
Open rightside engine access door (Figure 2-77, 1), remove nut (2), lock
washer (3), and remove manual throttle control cable (4) from fuel injection
pump throttle lever (5).
b.
Loosen two nuts (6 and 7) and remove manual throttle control cable (4) from
bracket assembly (8).
c.
Remove manual throttle control cable (4) from all cable ties (9).
d.
Loosen nut (10) and remove elbow (11) from manual throttle control cable (4).
e.
Remove three nuts (6, 7, and 10) and two lock washers (12) from manual
throttle control cable (4).
f.
Remove nut (13), lock washer ( 1 4 ) , a n d m a n u a l t h r o t t l e c o n t r o l c a b l e ( 4 ) f r o m
pumping assembly (15).
g.
Remove two screws (16), lock washers (17), flat washers (18), and bracket (8)
from pumping assembly (15). Discard lock washers (17).
2.16.26.2 R e p a i r .
a.
Inspect manual throttle control cable (4) for broken or damaged cable.
b.
Inspect bracket assembly (8) for bends, cracks, or damage.
c.
Inspect all mounting hardware for damage.
d.
Replace all defective components.
2.16.26.3 Installation.
a.
Position bracket assembly (8) on pumping assembly (15) and secure with two
flat washers (18), new lock washers (17), and screws (16).
b.
Install manual throttle control cable (4) in pumping assembly (15) and secure
with lock washer (14) and nut (13).
c.
Install three nuts (6, 7, and 10) and two lock washers (12) on manual throttle
control cable (4).
2-196
TM 10-4320-344-24
Figure 2-77. Manual Throttle Control Cable Assembly Replacement, Model 609-C.
d.
Install elbow (11) on manual throttle control cable (4) and secure with nut
(10).
e.
Position manual throttle control cable (4) and secure with cable ties (9).
f.
Insert manual throttle control cable (4) in bracket (8) and secure with two
lock washers (12) and nuts (6 and 7).
g.
Insert manual throttle control cable (4) through fuel injection pump lever
(5) and secure with flat washer (3) and nut (2).
h.
Close rightside engine access door (1).
2-197
TM 10-4320-344-24
2.16.27 Fuel Rack Cable Replacement, Model 609-A.
This task covers:
2.16.27.1 Removal
2.16.27.2 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1.
General
Conditions
Safety
(Continued)
Instructions
Material/Parts
Straps, Electrical Tiedown, Appendix C,
Item 29
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph 2.15.2.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without
standard shop safety precautions.
following
2.16.27.1 Removal.
•
Do not work on equipment that is not securely stabilized to prevent
rolling or sliding. Ensure both wheels of equipment have chocks that
are secure.
•
Do not work on equipment with battery connected.
present if battery is connected.
•
Failure to obey these warnings may result in serious personal injury.
Electrocution hazard is
a.
Push fuel rack handle (Figure 2-78, 1) fully in and turn clockwise to LOCK
position.
b.
Loosen screw (2) and remove universal wire stop (3) from end of fuel rack
cable (4).
c.
Remove nut (5), lock washer (6), cable clamp mounting bolt (7), and cable
clamp (8).
d.
Remove and discard electrical tiedown straps (9) securing fuel rack cable (4)
to wiring harness (10).
e.
Unscrew cable mounting nut (11).
Remove cable mounting nut (11) and lock
washer (12) from threaded portion of fuel rack handle (1).
f.
Using fuel rack handle (1), pull fuel rack cable (4) through grommet in rear
panel plate (13), pressure regulator mounting bracket (14), and control panel
(15) and remove cable mounting nut (11) and lock washer (12).
2-198
TM 10-4320-344-24
Figure 2-78. Fuel Rack Cable Replacement.
2-199
TM 10-4320-344-24
2.16.27 Fuel Rack Cable Replacement, Model 609-A. (Continued)
2.16.27.2 Installation.
NOTE
Ensure that fuel rack handle for fuel rack cable is pushed fully in and turned
clockwise to LOCK position prior to installation.
a.
Insert fuel rack cable (4) through control panel (15) and slide lock washer
(12) and cable mounting nut (11) on fuel rack cable (4).
b.
Insert fuel rack cable (4) through pressure regulator mounting bracket (14)
and grommet in rear panel plate (13) and secure to control panel with lock
washer (12) and cable mounting nut (11).
c.
Secure fuel rack cable (4) to wiring harness (10) with new electrical tiedown
straps (9).
d.
Install cable clamp (8) on fuel rack cable (4) and secure to cable clamp
mounting bracket (16) with clamp mounting bolt (7), lock washer (6) and
nut (5).
NOTE
With fuel rack handle turned fully in and clockwise to LOCK position, universal
wire stop should be just clear of bracket (so it will not interfere with operation).
e.
2-200
Install universal wire stop (3) on end of fuel rack cable (4) and secure with
screw (2).
TM 10-4320-344-24
2.16.28 Auto Defeat Cable Maintenance, Model 609-C.
This task covers:
2.16.28.1 Removal
2.16.28.2 Repair
2.16.28.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Battery disconnected, paragraph 2.15.3.
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Conditions
(Continued)
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without
standard shop safety precautions.
following
Pumping station shut down, TM 10-4320344-10.
2.16.28.1 Removal.
1) on pumping assembly (2).
a.
Open rightside engine access door (Figure 2-79,
b.
Push handle (3) in and turn clockwise to LOCK position.
c.
Loosen screw (4) and remove universal wire stop (5) from end of auto defeat
cable (6) at governor actuator (7).
d.
Loosen nut (8) and pull auto defeat cable (6) away from cable bracket (10).
e.
Pull auto defeat cable (6) through stop plate (11) and remove two nuts (8) and
flat washers (9).
f.
Remove screws (12), cable clamps (13), nut (14), and lock washer (15) from
auto defeat cable (6).
g.
Using handle (3) pull auto defeat cable (6) out from pumping assembly (2).
h.
Remove two screws (16), lock washers (17), flat washers (18), and cable
bracket (10) from support (19). Discard lock washers (17).
2.16.28.2 Repair.
a.
Inspect cable bracket (10) and mounting hardware for damage.
b.
Replace all defective components.
2.16.28.3 Installation.
a.
Position cable bracket (10) on support (19) and secure with two flat washers
(18), new lock washers (17), and screws (16).
NOTE
If mounting hardware is mounted on auto defeat cable, remove all mounting
hardware.
b.
Feed auto defeat cable (6) through pumping assembly (2) and secure with lock
washer (15), nut (14), cable clamps (13), and screws (12).
2-201
TM 10-4320-344-24
2.16.28 Auto Defeat Cable Maintenance, Model 609-C. (Continued)
Figure 2-79. Auto Defeat Cable Maintenance.
c.
Install two nuts (8) and flat washers (9) on auto defeat cable (6).
d.
Insert auto defeat cable (6) through stop plate (11) and cable bracket (10)
and secure with two nuts (8).
e.
Install universal wire stop (5) on end of auto defeat cable (6) at governor
actuator (7).
f.
Adjust auto defeat cable (6) at cable bracket (10) so that universal wire stop
(5) is positioned about 2 inches from stop plate (11) when handle (3) is fully
depressed and tighten screw (4) to secure universal wire stop (5).
g.
2-202
Close rightside engine access door (1) on pumping assembly (2).
TM 10-4320-344-24
2.16.29 Cold Start Aid Cable Replacement, Model 609-C.
This task covers:
2.16.29.1 Removal
2.16.29.2 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Battery disconnected, paragraph 2.15.3.
Equipment
Conditions
Conditions
(Continued)
General Safety Instructions
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM 10-4320344-10.
2.16.29.1 Removal.
a.
Open Cold Start Aid access door (Figure 2-80,
1) on pumping assembly (2).
b.
Loosen screw on universal wire stop (3) and remove cold start aid cable (4)
from actuator (5).
c.
Loosen wire nut stop (6) and remove cold start aid cable (4) from bottom
bracket (7).
d.
Remove screw (8), cable clamp (9), and pull cold start aid cable (4) out
through grommet (10).
e.
Remove lock nut (11), handle (12), and cold start aid cable (4) from pumping
assembly (2).
2.16.29.2 Installation.
a.
Install cold start aid cable (4) in pumping assembly (2).
b.
Install handle (12) on cold start aid cable (4) and secure with lock nut (11).
c.
Insert cold start aid cable (4) through grommet (10) and secure with cable
clamp (9) and screw (8).
d.
Insert cold start aid cable (4) through wire nut stop (6), bracket (7), and
universal wire stop (3) on actuator (5). Tighten universal wire stop (3).
NOTE
Ensure, when handle is pushed completely down, actuator is in fully down
(released) positioned and when handle is pulled out actuator can be raised to
maximum open position.
e.
Loosen universal wire stop (3) and adjust cold start aid cable (4) as required
to ensure proper operation.
f.
Tighten wire nut stop (6) and universal wire stop (3) and close Cold Start Aid
access door (1) on pumping assembly (2).
2-203
TM 10-4320-344-24
2.16.29 Cold Start Aid Cable Replacement, Model 609-C. (Continued)
Figure 2-80. Cold Start Aid Cable Replacement.
2-204
TM 10-4320-344-24
2.16.30 Pressure Regulator Maintenance, Model 609-A.
This task covers:
2.16.30.1
Removal
2.16.30.2 Repair
2.16.30.3
Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Control Panel Cover Assembly removed,
paragraph, 2.16.1.
General Safety Instructions
Material/Parts
Tags, Appendix C, Item 31
Tape, Antiseize, Appendix C, Item 32
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph 2.15.2.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.30.1 Removal.
•
Do not work on equipment that is not securely stabilized to prevent
rolling or sliding. Ensure both wheels of equipment have chocks that
are secure.
•
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected.
•
Failure to obey these warnings may result in serious personal injury.
a.
Tag and disconnect wiring harness connectors (Figure 2-81, 1 and 2).
b.
Disconnect suction hose assembly (3) at pipe elbow (4) and remove pipe elbow
(4) from pressure regulator (5).
c.
Remove pipe nipple (6) from pipe elbow (7) and remove pipe elbow (7) from
pressure regulator (5).
Use caution when opening cover to prevent damage to electrical connections. Do
not attempt to rapidly remove cover.
d.
Remove four cover mounting screws (8) and carefully open cover (9) from
pressure regulator (5).
e.
Remove two mounting bolts (10) and remove pressure regulator (5) from control
panel frame (11).
f.
Remove two clips (12) from control panel frame (11).
2-205
TM 10-4320-344-24
2.16.30 Pressure Regulator Maintenance, Model 609-A. (Continued)
Figure 2-81. Pressure Regulator Replacement, Model 609-A.
2-206
TM 10-4320-344-24
2.16.30.2 Repair.
a.
Inspect all mounting hardware for damage.
b.
Replace
all
defective
components.
2.16.30.3 Installation.
NOTE
Wrap antiseize tape in direction of threads on all pipe threads prior to
installation.
a.
Install two clips (12) on control panel frame (11).
b.
Insert pressure regulator (5) in control panel frame (11) and secure with two
mounting bolts (10).
Use caution when closing cover to prevent damage to electrical connections. Do
not attempt to rapidly move cover.
c.
Carefully close cover (9) and secure with four cover mounting screws (8).
d.
Install pipe elbows (4 and 7) in pressure regulator (5).
e.
Install pipe nipple (6) on pipe elbow (7).
f.
Connect suction hose assembly (3) to pipe elbow (4).
g.
Refer to tags and install wiring harness connectors (1 and 2). Remove and
discard tags.
2-207
TM 10-4320-344-24
2.16.33 Control Module Maintenance. Models 609-C and US636HCCD-1.
This task covers:
2.16.33.1
Removal
2.16.33.2 Repair
2.16.33.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Control Panel Open (609-C).
Control Panel Cover Assembly removed,
paragraph 2.16.2 (US636HCCD-1).
Material/Parts
General Safety Instructions
Tags, Appendix C, Item 31
Tape, Antiseize, Appendix C, Item 32
Lock Washers (TM 10-4320-34-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment with battery
connected.
Electrocution hazard is
present if battery is connected.
Battery disconnected, paragraph 2.15.3
(609-C) or 2.15.4 (US636HCCD-1).
Do not work on equipment without following
standard shop safety precautions.
NOTE
This procedure applies to the Pressure Control Module for Model 609-C. The
procedure for the Engine Protection System (EPS) module, Model 609-C, and
Controlling Device module, Model US63HCCD-1, are similar. Refer to figure
2-83 and 2-84, respectively, for the location of the EPS and Controlling
Device.
2.16.31.1 Removal.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury.
a.
Tag and disconnect wiring harness connectors P7 (Figure 2-82, 1), P8 (2), and
disconnect two pressure hose assemblies (3) from pressure control module (4).
b.
Remove six screws (5), lock washers (6), cable clamp (7), and pressure control
module (4) from control panel assembly (8). Discard lock washers (6).
2.16.31.2 Repair.
a.
Inspect mounting hardware for damage.
b.
Replace all defective components.
2.16.31.3 Installation.
a.
2-208
Position pressure control module (4) in control panel assembly (8) and secure
with cable clamp (7), six new lock washers (6), and screws (5).
TM 10-4320-344-24
Figure 2-82. Pressure Control Module Replacement.
NOTE
Wrap antiseize tape in the direction of threads on all pipe threads prior to
installation.
b.
Refer to tags and connect two pressure hose assemblies (3), wiring harness
c o n n e c t o r s P 8 ( 2 ) a n d P 7 ( 1 ) t o p r e s s u r e c o n t r o l m o d u l e ( 4 ) . Remove and
discard tags.
2-209
TM 10-4320-344-24
2.16.33 Control Module Maintenance, Models 609-C and US636HCCD-1.
Figure 2-83. Location of Engine Protection System Module.
2-210
TM 10-4320-344-24
Figure 2-84. Location of Controlling Device, Model US636HCCD-1.
2-211
TM 10-4320-344-24
2.16.32 Governor Control Module Maintenance, Model 609-C.
This task covers:
2.16.32.1 Removal
2.16.32.2 Repair
2.16.32.3
Installation
2.16.32.4 Adjustment
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Battery disconnected, paragraph 2.15.3.
Material/Parts
Lock Washers (TM 10-4320-344-24P
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
General
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment with battery
connected.
Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.32.1 R e m o v a l .
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury.
a.
Open control panel door assembly (Figure 2-85, 1) and control panel (2).
b.
Disconnect electrical connector P6 (3) from governor control module (4).
c.
Remove four screws (5), lock washers (6), one cable clamp (7), and governor
control module (4) from control panel assembly (8). Discard lock washers (6).
2.16.32.2 Repair.
a.
Inspect mounting hardware for damage.
b.
Replace all defective components.
2.16.32.3 Installation.
a.
Position governor control module (4) in control panel assembly (8) and secure
with cable clamp (7), four new lock washers (6), and screws (5).
b.
Connect electrical connector P6 (3) to governor control module (4).
2-212
TM 10-4320-344-24
Figure 2-85. Governor Control Module Maintenance.
2.16.32.4 Adjustment.
NOTE
If control module has been replaced or original module is suspected of being
out of adjustment, adjust as follows:
a.
Open control panel door assembly (Figure 2-86,1) and control panel (2).
b.
Remove and retain four screws (3), two nuts (4), and six lock washers (5).
c.
Remove cover (6) from governor control module (7).
d.
Perform adjustment to governor control module (7) as follows:
2-213
TM 10-4320-344-24
2.16.32 Governor Control Module Maintenance, Unit 609-C.
(Continued)
Figure 2-86. Governor Control Module Cover Removal.
NOTE
Refer to figure 2-87 for location of named adjustment devices in the following
steps.
(1) Set the I adjustment at one division and the GAIN adjustment at the third
division from zero.
(2) Set the DROOP adjustment to the minimum setting.
(3) Set AUTO THROTTLE rheostat (Figure 2-86, 8) on control panel to mid range
and select SPEED on AUTO SELECT switch (9) on control panel.
(4) Refer to TM 10-4320-344-10 and start engine. Adjust SPEED potentiometer on
governor control module until engine is operating at approximately 1,575
rpm.
2-214
TM 10-4320-344-24
Figure 2-87. Governor Control Module Adjustment With Cover Removed.
(5)
If system is unstable (oscillates), slightly reduce the I and GAIN settings
until oscillation stops.
(6)
Turn AUTO THROTTLE rheostat (Figure 2-86, 8) to the IDLE position.
(7)
Slowly turn the GAIN adjustment clockwise (CW) until the governor actuator
lever begins to oscillate, then turn back until oscillation stops.
(8)
Upset the governor actuator lever by hand and note how many oscillations it
takes for the lever to again stabilize. If no more than 5 oscillations are
required, adjustment is correct.
(9)
If adjustment is not correct (3-5 oscillations in step 8 above) reduce GAIN
setting counter–clockwise (CCW) one division and while observing the
actuator lever turn the I adjustment CW until the governor actuator lever
oscillates.
e.
If the governor actuator lever does not become unstable, upset it by hand.
f.
When the governor actuator lever oscillates, slowly turn the I adjustment CCW
until the lever is stable.
g.
Upset the governor actuator lever again, it should oscillate 3 to 5 times and
then become stable.
h.
If unit cannot be adjusted, replace governor control module with another
governor control module.
2-215
TM 10-4320-344-24
2.16.32 Governor Control Module Maintenance, Unit 609-C. (Continued)
i.
If second governor control does not correct problem refer to troubleshooting
table, table 2-4, and troubleshoot the system.
j.
Install cover (Figure 2-86, 6) on governor control module (7) and secure with
six lock washers (5), two nuts (4), and four screws (3).
k.
Close control panel (2) and control panel door assembly (1).
2-216
TM 10-4320-344-24
2.16.33 Process Control Device Maintenance, Unit US636HCCD-1.
This task covers:
2.16.33.1 Removal
2.16.33.2 Repair
2.16.33.3 Test
2.16.33.4 Installation
INITIAL SETUP
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Battery disconnected, paragraph 2.15.4.
Multimeter, Appendix B, Section III,
Item 2
Material/Parts
10k Resistor, Appendix C, Item 21
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Conditions
(Continued)
Tools
Control Panel Cover Assembly removed,
paragraph 2.16.2.
General
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Equipment Conditions
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following
standard shop safety precautions.
2.16.33.1 Removal.
Figure 2-88. Process Control Device Maintenance.
2-217
TM 10-4320-344-24
2.16.33 Process Control Device Maintenance, Unit US636HCCD-1. (Continued)
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury.
a.
Remove and retain twelve screws (Figure 2-88, 1) and tag remove wires (2)
from process control device (3).
b.
Tag wires (4) on process control device (3). Remove four nuts (5), lock
washers (6), screws (7), wires (4), and process control device (3) from
control panel (8). Discard lock washers (6).
2.16.33.2 Repair.
a.
Inspect all mounting hardware for damage.
b.
Replace all defective components.
2.16.33.3 Test.
Figure 2-89. Process Control Device.
2-218
TM 10-4320-344-24
Ensure that all wires and external connections are disconnected from process
control device prior to performing this test.
Failure to disconnect all
external connections may resulting damage to process control device.
NOTE
Refer to figure 2-89 for location of identified terminals in the following
steps.
a.
Ensure all external connections and wires leading to and from process control
device are disconnected.
b.
Connect 12 or 24 VDC power source to terminals 1 (+) and 2 (-).
NOTE
A 10K resistor must not be connected if low or high output impedance is used.
c.
If low-signed selected output is used, connect 10K resistor from terminal 16
to terminal 10.
d.
If high-signed select setting is selected, connect 10K ohm resistor from
terminal 16 to terminal 17.
e.
Set droop gain and low-limit potentiometers to full counter-clockwise (CCW)
position.
f.
Set high-limit direct control point and inverse control point potentiometers
to fully clockwise (CW) position.
g.
Measure output voltage from terminal 16 (+) to terminal 17 (-) to verify that
output voltage is -0.5 ± 1 . 0 V D C .
If process control device output voltage ramps properly but process control
device is still operating incorrectly, check system for correct wiring. Examine
other components in system for correct operation. Verify that input sensing
device is wired to correct terminals necessary for the desired controlling
action (inverse or direct).
h.
Quickly rotate inverse control point adjustment to fully CCW position.
NOTE
Output should slowly ramp up to 9.4 ± 2.0 VDC. If the output is not within
this range, the unit is defective.
i.
Replace defective process control device.
2.16.33.4 Installation.
NOTE
Install wires on screw located at bottom right mounting point of process
control device.
a.
Position process control device (Figure 2-88, 3) on control panel (8) and
secure with four screws (7), new lock washers (6), and nuts (5). Remove and
discard tags.
b.
Install wires (2) on process control device (3) with screws (1).
discard tags.
Remove and
2-219
TM 10-4320-344-24
2.16.34 Terminal Board Replacement, Model US636HCCD-1.
This task covers:
2.16.34.1 Removal
2.16.34.2 Installation
INITIAL SETUP
Equipment
Tools
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n
Item 1
III,
Conditions
(Continued)
Control Panel Cover Assembly removed,
paragraph 2.16.2.
General Safety Instructions
Material/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph
2.15.4.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
2.16.34.1 Removal.
Figure 2-90. Terminal Board Maintenance.
2-220
TM 10-4320-34-24
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury.
a.
Loosen twenty screws (Figure 2-90, 1) and tag and disconnect twenty wires (2).
b.
Remove four nuts (3) and screws (4).
c.
Remove terminal board (5) from control panel (6).
2.16.34.3 Installation.
a.
Position terminal board (5) on control panel (6) and secure with four screws
(4) and nuts (3).
b.
Refer to tags and connect twenty wires (2) on terminal board (5) securing with
t w e n t y s c r e w s ( 1 ) . Remove and discard tags.
2-221
TM 10-4320-344-24
2.16.35 Pressure Gauge Hose Assembly Maintenance.
This task covers:
2.16.35.1 Disassembly
2.16.35.2 Repair
2.16.35.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Control Panel Open (609-c).
Tool Kit, Appendix B, Section III,
Item 1
Control Panel Cover Assembly removed,
paragraph 2.16.1 (609-A) or 2.16.2
Material/Parts
(US636HCCD-1).
Compound, Silicone Caulking, Appendix C, G e n e r a l S a f e t y I n s t r u c t i o n s
Item 9 (609-c)
Do not work on equipment that is not
Tape, Antiseize, Appendix C, Item 32
securely stabilized to prevent rolling or
sliding.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following
standard shop safety precautions.
2.16.35.1 R e m o v a l .
NOTE
•
This procedure applies to all three models of 600 GPM pumping
assemblies.
•
Refer to figure 2-91 for pressure gauge hose assembly diagram for Model
609-A.
•
Refer to figure 2-92 for pressure gauge hose assembly diagram for Model
609-C.
•
Refer to figure 2-93 for pressure gauge hose assembly diagram for Model
US636HCCD-1.
2.16.35.1 Disassembly. Refer to figure for applicable pumping assembly and disassemble
hose and adapters as required.
2.16.35.2 Repair.
Replace all damaged components.
2.16.35.3 Assembly.
NOTE
•
Wrap antiseize tape in the direction of threads on all pipe threads
prior to installation.
•
Replace silicone sealant on Model 609-C as required.
a.
Refer to figure for applicable pumping assembly and identify component
location.
b.
Assemble components as required.
2-222
TM 10-4320-344-20
Figure 2-91. Pressure Gauge Hose Assembly Diagram, Model 609-A.
2-223
TM 10-4320-344-24
2.16.35 Pressure Gauge Hose Assembly Maintenance. (Continued)
Figure 2-92. Pressure Gauge Hose Assembly Diagram, Model 609-C.
2-224
TM 10-4320-344-24
Figure 2-93.
Pressure Gauge Hose Assembly Diagram, Model US636HCCD-1.
2-225
TM 10-4320-344-24
2.16.36 Control Panel Maintenance, Model 609-A.
This task covers:
2.16.36.1 Removal
2.16.36.2 Repair
2.16.36.3 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Oil Pressure Gauge removed, paragraph
2.16.10.
Conditions
(Continued)
Engine Coolant Temperature Gauge removed,
paragraph 2.16.11.
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Rivets (TM 10-4320-344-24P)
Ammeter removed, paragraph 2.16.12.
Equipment Conditions
Tachometer/Hourmeter
2.16.13.
Pumping station shut down, TM 10-4320344-10.
Engine Alarm removed, paragraph 2.16.15.
Battery disconnected, paragraph 2.15.2.
Control Panel Cover Assembly removed,
paragraph 2.16.1.
removed,
paragraph
Engine Alarm Reset removed, paragraph
2.16.17.
General Safety Instructions
Ground Wires disconnected, paragraph
2.16.3.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Pump Suction and Discharge Gauges
removed, paragraph 2.16.7.
Do not work on equipment without following
standard shop safety precautions.
2.16.36.1 Removal.
Figure 2-94.
2-226
Control Panel Maintenance, Model 609-A.
TM 10-4320-344-24
a. Remove four nuts (Figure 2-94, 1), lock washers (2), flat washers (3), and
control panel (4). Discard lock washers (2).
b.
Remove four nuts (5), lock washers (6), flat washers (7), and sandwich mounts
(8) from control panel frame assembly (9). Discard lock washers (6).
2.16.36.2 Repair.
a.
Inspect control panel (4) for damage.
b.
Inspect for damaged or missing data plates on control panel (4). Refer to
paragraph 2.11.1 to replace damaged or missing data plate.
c.
Inspect all mounting hardware for damage.
d.
Replace all defective components.
2.16.36.3 Installation.
a.
Install four sandwich mounts (8) in control panel frame assembly (9) and
secure with four flat washers (7), new lock washers (6), and nuts (5).
b.
Install control panel (4) in control panel frame assembly (9) and secure with
four flat washers (3), new lock washers (2), and nuts (1).
2-227
TM 10-4320-344-24
2.16.37 Control Panel Maintenance, Model US636HCCD-1.
This task covers:
2.16.37.1
Removal
2.16.37.2 Repair
2.16.37.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Horn removed, paragraph 2.16.16.
Mode Switch removed, paragraph 2.16.18.
Material/Parts
Start Switch removed, paragraph 2.16.19.
Lock Washers (TM 10-4320-344-24P)
Rivets (TM 10-4320-344-24P)
Start/Stop Switch removed, paragraph
2.16.20.
Equipment
Fuse Holder removed, paragraph 2.16.21.
Conditions
Pumping station shut down, paragraph
2.5, TM 10-4320-344-10.
Manual Throttle Select Rheostat removed,
paragraph 2.16.22.
Battery disconnected, paragraph 2.15.4.
Controlling Device removed, paragraph
2.16.31.
Control Panel Cover Assembly removed,
paragraph 2.16.2.
Process Control Device removed, paragraph
2.16.33.
Control Panel Harness removed, paragraph
2.16.6.
Terminal Board removed, paragraph 2.16.34.
Pump Suction and Discharge Gauges
removed, paragraph 2.16.8.
Oil Pressure Gauge removed, paragraph
2.16.10.
Ammeter removed, paragraph 2.16.12.
Tachometer/Hourmeter
2.16.13.
removed,
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
paragraph
2.16.37.1 Removal.
a.
Remove four nuts (Figure 2-95, 1), lock washers (2), and control panel (3)
from base weldment (4). Discard lock washers (2).
b.
R e m o v e f o u r n u t s ( 5 ) , l o c k w a s h e r s ( 6 ) , and sandwich mounts (7) from base
welement (4). Discard lock washers (6).
c.
Remove four grommets (8) from control panel (3).
2.16.37.2 Repair.
a.
Inspect control panel (3) for damage.
b.
Inspect control panel (3) for damaged or missing data plates.
paragraph 2.11.1 to replace damaged or missing data plates.
c.
Inspect grommets (8) for corrosion, cracks, slices, tears, or damage.
d.
Replace all defective components.
2-228
Refer to
TM 10-4320-344-24
Figure 2-95.
Control Panel Maintenance, Model US636HCCD-1.
2.16.37.3 Installation.
a.
Install four grommets (8) in control panel (3).
b.
Install four sandwich mounts (7) on base weldment (4) and secure with four new
lock washers (6) and nuts (5).
c.
Install control panel (3) on sandwich mounts (7) and secure with four new lock
washers (2) and nuts (1).
2-229
TM 10-4320-344-24
2.16.38 Control Panel Frame Maintenance, Model 609-A.
This task covers:
2.16.38.1 Removal
2.16.38.3
Installation
Tool S
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Manual Throttle Control Cable Assembly
removed, paragraph 2.16.25.
INITIAL SETUP
(Continued)
Equipment Conditions
Fuel Rack Cable removed, paragraph
2.16.27.
Pumping station shut down, TM 10-4320344-10.
Pressure Regulator removed, paragraph
2.16.30.
Battery disconnected, paragraph 2.15.2.
Control Panel removed, paragraph 2.16.36.
Control Panel Cover Assembly removed,
paragraph 2.16.1.
General Safety Instructions
Control Panel Assembly remove
paragraph 2.16.3.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Engine Switch and Mode Switch removed,
paragraph 2.16.18.
Do not work on equipment without following
standard shop safety precautions.
2.16.28.1 Removal. Remove control panel frame (Figure 2-96, 1).
Figure 2-96.
2.16.38.2
2-230
Control Panel Frame Model 609-A.
Installation. Install control panel frame (1).
TM 10-4320-344-24
2.16.39
Control Enclosure Assembly Maintenance, Model 609-C.
This task covers:
2.16.39.1 Removal
2.16.39.2 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, ppendix B, Section III,
Item 1
Control Panel Toggle Switches removed,
paragraph 2.16.18.
Rheostats removed, paragraph 2.16.22.
Equipment Conditions
Resistors removed, paragraph 2.16.23.
Pumping station shut down, TM 10-4320344-10.
Control Panel Lights removed, paragraph
2.16.24.
Battery disconnected, paragraph 2.15.3.
Control Panel Assembly removed,
paragraph 2.16.4.
Control Panel Assembly Wiring Harness
removed, paragraph 2.16.6.
Pump Suction and Discharge Gauge
removed, paragraph 2.16.7.
Oil Pressure Gauge and Engine
Temperature Gauge removed, paragraph
2.16.12.
Engine Protection System Module removed,
paragraph 2.16.31.
Pressure Control Module removed, paragraph
2.16.31.
Governor Control Module removed, paragraph
2.16.32.
Suction Gauge and Discharge Gauge Hose
Assemblies removed, paragraph 2.16.35.
Tachometer removed, paragraph 2.16.12.
Suction and Discharge Pressure Regulator
Hose Assemblies removed, paragraph
2.16.35.
Hourmeter removed, paragraph 2.16.12.
General Safety Instructions
Voltmeter removed, paragraph 2.16.12.
Indicators removed, paragraph 2.16.14.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Main Power Switch removed, paragraph
2.16.18.
Do not work on equipment without following
standard shop safety precautions.
2.16.39.1
Removal.
Remove control enclosure assembly (Figure 2-97, 1).
2.16.39.2 Installation.
Install control enclosure assembly (1).
2-231
TM 10-4320-344-24
2.16.39 Control Enclosure Assembly Maintenance, Model 609-C. (Continued)
Figure 2-97.
2-232
Control Enclosure Assembly.
TM 10-4320-344-24
2.16.40 Base Weldment Maintenance, Model US636HCCD-1.
This task covers:
2.16.40.1
Removal
2.16.40.2 Repair
2.16.40.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section III,
Item 1
Control Panel Assembly removed, paragraph
2.16.5.
Equipment
General
Conditions
Safety
(Continued)
Instructions
Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph 2.15.4.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
2.16.40.1 Removal.
Figure 2-98.
Base Weldment Maintenance.
a.
Remove base weldment (Figure 2-98, 1).
b.
Remove four grommets (2) from base weldment (1).
2.16.40.2 Repair. I n s p e c t g r o m m e t s ( 2 ) f o r c o r r o s i o n , c r a c k s , s l i c e s , o r t e a r s .
Replace defective grommets (2).
2.16.40.3 Installation.
a.
Install four grommets (2) on base weldment (1).
b.
Install base weldment (1).
2-233
TM 10-4320-344-24
2.17
ENGINE WIRING HARNESS MAINTENANCE.
2.17.1 Engine Wiring Harness Maintenance.
This task covers:
2.17.1.1 Removal
2.17.1.2 Inspection
2.17.1.3 Test
2.17.1.4 Repair
2.17.1.5 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Battery disconnected, paragraph 2.14.2
(609-A), paragraph 2.14.3 (609-c), and
paragraph 2.14.4 (US636HCCD-1).
Multimeter, Appendix B, Section III,
Item 2
General Safety I n s t r u c t i o n s
Solder Gun, Appendix B, Section III,
Item 2
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Material/Parts
Solder, Appendix C, Item 25
Straps, Electrical Tiedown, Appendix C,
Item 29
Tags, Appendix C, Item 31
Equipment
Conditions
(Continued)
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following
standard shop safety precautions.
Conditions
Pumping station shut down, TM 5-4320344-10.
NOTE
This procedure applies to pumping assembly Model 609-A. The procedure for
pumping assemblies Model 609-c and Model US636HCCD-1 is similar. When
performing engine wiring harness maintenance for pumping assemblies Model 609-C
and Model US636HCCD-1 refer to appendix F for wiring and cable diagrams.
2.17.1.1
Removal.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury.
NOTE
This removal procedure applies to Model 609-A only.
a.
Refer to paragraph 2.14.6.1 steps d through f and disconnect ground wire from
battery and battery cable.
b.
Refer to Appendix F and disconnect and remove wiring harness.
2.17.1.2 Inspection. Inspect wiring harness for damaged or missing terminals and
connectors and burned, frayed, or damaged wires.
2.17.1.3 T e s t .
2-234
Refer to Appendix F and check continuity of wires.
TM 10-4320-344-24
NOTE
Model 609-A only, replace wiring harness assembly if any wire does not give
continuity.
2.17.1.4 Repair. I f a n y w i r e d o e s n o t g i v e c o n t i n u i t y , r e f e r t o A p p e n d i x F a n d r e p a i r
main wiring harness for Model 609-C and Model US636HCCD-1.
NOTE
This installation procedure applies to Model 609-A only.
2.17.1.5 Installation.
assembly.
Refer to Appendix F and install and connect wiring harness
2-235
TM 10-4320-344-24
2.18 PUMPING ASSEMBLY MAINTENANCE.
2.18.1 Drain Plug and Primer Port Maintenance, Model 609-C.
This task covers:
2.18.1.1 Removal
2.18.1.2 Repair
2.18.1.3 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Pumping stations shut down, TM 10-4320-344-10.
Tool Kit, Appendix B, Section III,
Item 1
General Safety Instructions
Material/Parts
Do not work on equipment that is not securely
stabilized to prevent rolling
Tape, Antiseize, Appendix C, Item 32 o r s l i d i n g .
Gasket (TM 10-4320-344-24P)
Do not work on equipment without following
standard shop safety precautions.
2.18.1.1 Removal.
a.
Level pump assembly (Figure 2-99, 1) using rear jacks (2) and tongue jack (3).
b.
Remove screw (4) and plug assembly (5). Allow pump assembly (1) to drain.
c.
Remove screw (6), end coupling (7), bead chain (8), and pipe plug (9).
d.
Remove pipe coupling (10) and pipe nipple (11) from bottom of pump
assembly (1).
e.
Remove cover (12), two gaskets (13 and 14), and quick half coupling (15).
Discard gaskets (13 and 14).
f.
Remove four nuts (16), bolts (17), mounting plate (18), and gasket (19) from
end panel (20). Discard gasket (19).
g.
R e m o v e p i p e n i p p l e ( 2 1 ) , p i p e e l b o w ( 2 2 ) , and priming port (23) from pump
assembly (1).
2.18.1.2 Repair.
a.
Inspect all components for damage.
b.
Replace all defective components.
2.18.1.3 Installation.
a.
Install priming port (23), pipe elbow (22), and priming port nipple (21) on
pump assembly (1).
b.
Position new gasket (19) and mounting plate (18) on end panel assembly (20)
and secure with four bolts (17) and nuts (16).
c.
Install quick half coupling (15), two new gasket (13 and 14), and cover (12).
d.
Install pipe nipple (11) and pipe coupling (10) on pump assembly (1).
e.
Install bead chain (8) and end coupling (7) on pipe plug (9) and secure with
screw (6).
f.
Install plug assembly (5) and secure with screw (4).
2-236
TM 10-4320-344-24
Figure 2-99. Drain Plug and Primer Port Nipple Maintenance.
2-237
TM 10-4320-344-24
2.18.2 Suction Elbow and Discharge Elbows Replacement.
This task covers:
2.18.2.1 Removal
2.18.2.2 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Upper Cover Plates removed,
paragraph 2.12.10 (609-C).
Torque Wrench, Appendix B, Section
III, Item 2
Materials/Parts
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping stations shut down, 111 104320-344-10.
Suction Elbow and Discharge Elbow Hose
Assemblies removed, paragraph 2.16.35.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety precautions.
2.18.2.1 Removal.
Figure 2-100. Suction Elbow and Discharge Elbow Replacement.
2-238
TM 10-4320-344-24
a.
Remove eight nuts (Figure 2-100, suction elbow (2), and gasket (3) from
pump assembly (4). Discard gasket (3).
NOTE
Step b applies to Model 609-C only.
b.
Remove eight nuts (5), screws (6), discharge elbow (7), and gasket (8) from
discharge elbow (9).
Discard gasket (8).
c.
Remove eight nuts (10), discharge elbow (9), and gasket (11) from pump
assembly (4). Discard gasket (11).
NOTE
Step d applies to Model US636HCCD-1 only.
d.
Remove two pipe couplings from suction elbow (2) and discharge elbow (9).
2.18.2.2 Installation.
NOTE
Step a applies to Model US636HCCD-1 only.
a.
Install two pipe couplings on suction elbow (2) and discharge elbow (9).
b.
Install new gasket (11) and discharge elbow (9) securing with eight nuts (10).
Progressively torque nuts (10) to 190 ft-lbs (258 Nm).
NOTE
Step c applies to Model 609-C only.
c.
Install new gasket (8) and discharge elbow (7) securing with eight screws (6)
and nuts (5).
Progressively torque nuts (5) to 190 ft-lbs (258 Nm).
d.
Install new gasket (3) and suction elbow (2) on pump assembly (4) securing
with eight nuts (1).
Progressively torque nuts (1) to 190 ft-lbs (258 Nm).
2-239
TM 10-4320-344-24
2.19 HOOD, REAR PANEL, AND SHIELD ASSEMBLY MAINTENANCE.
2.19.1 Hood Assembly Maintenance, Model 609-A.
This task
2.19.1.1
2.19.1.2
2.19.1.3
covers:
Removal
Disassembly
Repair
2.19.1.4 Assembly
2.19.1.5 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n 1 1 1 ,
Item 1
Muffler removed, paragraph 2.13.1.
Air Cleaner Assembly removed, paragraph
2.14.1.
Material/Parts
General Safety Instructions
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
2.19.1.1 Removal.
a.
Open two side panel doors (Figure 2-101, 1).
b.
R e m o v e s i x t e e n s c r e w s ( 2 ) , f l a t w a s h e r s ( 3 ) , and hood assembly (4) from
pumping assembly (5).
2.19.1.2 Disassembly.
a.
Remove two bolts (6), flat washers (7), lock washers (8), hood support (9),
and two spacers (10) from hood (11).
Discard lock washers (8).
b.
Remove two nuts (12), lock washers (13), flat washers (14), bolts (15), and
two side panel support brackets (16) from hood support (9).
discard lock
washers (13).
c.
Remove four screws (17) and two retention clips (18) from two side panel
support brackets (16).
2.19.1.3 Repair.
a.
Inspect hood support (9), hood (11), and side panel support brackets (16) for
cracks, bends, holes, or damage.
b.
Inspect all mounting hardware for damage.
c.
Replace all defective components.
2.19.1.4 Assembly.
a.
Position two retention clips (18) on side panel support brackets (16) and
secure with two screws (17).
b.
Position two side panel support brackets (16) on hood support (9) and secure
with two bolts (15), flat washers (14), new lock washers (13), and nuts (12).
c.
Install two spacers (10) and hood support (9) in hood (11) and secure with two
new lock washers (8), flat washers (7), and bolts (6).
2-240
TM 10-4320-344-24
Figure 2-101. Hood Assembly Maintenance, Model 609-A.
2.19.1.5 Installation.
a.
Position hood assembly (4) on pump assembly (5) and secure with sixteen flat
washers (3) and screws (2).
b.
Close two side panel doors (1).
2-241
TM 10-4320-344-24
2.19.2 Rear Panel Assembly Maintenance. Model 609-A.
This task covers:
2.19.2.1 Removal
2.19.2.2 Repair
2.19.2.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Limit Switch Assembly removed, paragraph
2.15.9.
Hood Assembly removed, paragraph 2.19.1.
Material/Parts
Grommet (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
Tachometer Cable disconnected and
removed from Rear Panel, paragraph
2.21.44
2.19.2.1 Removal.
Figure 2-102. Rear Panel Assembly Maintenance, Model 609-A.
a.
2-242
Remove grommet (Figure 2-102, from rear panel plate (2).
TM 10-4320-344-24
b.
Remove grommet (3) from rear panel plate (2) and slide along and remove from
engine wiring harness (4).
c.
Remove nuts (5), bolts (6), and lock washers (7) that secure rear panel plate
( 2 ) t o r e a r p a n e l ( 8 ) . Discard lock washers (7).
d.
Remove five bolts (9) and lock washers (10) from rear panel plate (2).
Discard lock washers (10).
e.
Slide rear panel plate (2) along engine wiring harness (4) away from rear
panel (8).
f.
Remove engine wiring harness (4) through notch (11) in rear panel plate (2)
and remove rear panel plate (2).
g.
Remove six bolts (12), lock washers (13), and rear panel (8).
washers (13).
Discard
lock
2.19.2.2 Repair.
a.
Inspect rear panel plate (2) and rear panel (8) for cracks, holes, and damage.
b.
Inspect all mounting hardware for damage.
c.
Replace all defective components.
2.19.2.3 Installation.
a.
Position rear panel (8) on engine bellhousing and secure with six new lock
washers (13) and bolts (12).
b.
Install engine wiring harness (4) into rear panel plate
(11).
c.
Slide rear panel plate (2) along engine wiring harness (4) and position on
rear panel (8).
d.
Secure rear panel plate (2) to rear panel (8) with five new lock washers (10)
and bolts (9).
e.
Install three new lock washers (7), bolts (6), and nuts (5).
f.
Install grommet (3) on engine wiring harness (4) and insert in rear panel
plate (2).
g.
Install new grommet (1) in rear panel plate (2).
(2) through notch
2-243
TM 10-4320-344-24
2.19.3 Shield Assembly Maintenance, Model 609-A.
This task covers:
2.19.3.1
Removal
2.19.3.2 Repair
2.19.3.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Hood Assembly removed, paragraph 2.19.1.
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM 10-4320344-10.
2.19.3.1 Removal.
Figure 2-103. Shield Assembly Maintenance, Model 609-A.
a.
2-244
Remove screw (Figure 2-103, 1), lock washer (2), flat washer (3), and friction
receptacle (4). Discard lock washer (2).
TM 10-4320-344-24
b.
Remove two screws (5), flat washers (6), and shield assembly (7) from pumping
assembly (8).
c.
Remove screw (9),
flat washer (10), and bracket (11) from turbocharger (12).
2.19.3.2 Repair.
a.
Inspect shield assembly (7), bracket (11), and all mounting hardware for
cracks, holes, bends, or damage.
b.
Replace all defective components.
2.19.3.3 Installation.
a.
Position bracket (11) on turbocharger (12) and secure with flat washer (10)
and screw (9).
b.
Position shield assembly (7) on pumping assembly (8) and secure with two flat
washers (6) and screws (5).
c.
Secure bracket (11) to shield assembly (7) with friction receptacle (4), flat
w a s h e r ( 3 ) , new lock washer (2), and screw (1).
2-245
TM 10-4320-344-24
2.20 RADIATOR ASSEMBLY MAINTENANCE.
2.20.1 Radiator Shell Assembly and Side Panels Maintenance, Model 609-A.
This task covers:
2.20.1.1 Removal
2.20.1.2 Disassembly
2.20.1.3 Repair
2.20.1.4 Assembly
2.20.1.5 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Battery Box and Cover removed, paragraph
2.15.2.
Hood Assembly removed, paragraph 2.19.1.
Materials/Parts
General Safety Instructions.
Lock Washers (TM 10-4320-344-24P)
Equipment
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Conditions
Pumping stations shut down,
4320-344-10.
TM
10Do not work on equipment without following
standard shop safety precautions.
2.20.1.1 Removal.
Hot antifreeze can scald.
Hot radiator and engine components can burn.
Failure to obey these warnings may result in serious personal injury.
a.
Remove radiator cap (Figure 2-104, 1).
b.
Remove two mounting nuts (2), four flat washers (3), and two bolts (4) from
two support brackets (5).
c.
Remove eight bolts (6), twelve flat washers (7), twelve lock washers (8), and
four nuts (9).
Discard lock washers (8).
d.
Lift radiator shell (10) above radiator neck (11) and remove radiator
shell (10).
2.20.1.2 Disassembly.
a.
Remove sixteen screws (Figure 2-105, 1) and two side panel assemblies (2) from
radiator shell (3).
b.
Remove four nuts (4), lock washers (5), bolts (6), and two support brackets
(7).
Discard lock washers (5).
c.
Remove two ball studs (8), two lock washers (9), four flat washers (11)), and
two screws (11) from two side panels (2). Discard lock washers (9).
2.20.1.3 Repair.
a.
2-246
Inspect side panel assemblies (2), radiator shell (3), support brackets (7),
and all mounting hardware for damage.
TM 10-4320-344-24
Figure 2-104. Radiator Shall Assembly Removal, Model 609-A.
b.
Replace all defective components.
2.20.1.4 Assembly.
a.
Install two bolts (11), four flat washers (10), two new lock washers (9), and
two ball studs (8) on two side panel assemblies (2). Hand tighten bolts (11).
b.
Position two support brackets (7) on radiator shell (3) and secure with four
bolts (6), new lock washers (5), and four nuts (4).
c.
Position two side panel assemblies (2) on radiator shell (3) and secure with
sixteen screws (1).
2.20.1.5 Installation.
a.
Install radiator shell (Figure 2-104, 10) over radiator neck (11).
b.
Position radiator shell (10) on radiator shell supports (12) and radiator
supports (13).
NOTE
Four nuts are used with four lower bolts.
c.
Install eight bolts (6), twelve flat washers (7), twelve new lock washers (8),
and eight nuts (9).
2-247
TM 10-4320-244-24
2.20.1 Radiator Shell Assembly and Side Panels Maintenance, Model 609-A. (Continued)
Figure 2-105. Radiator Shell Assembly
d.
Install two bolts (4), four flat washers (3), and two mounting nuts (2) on two
support brackets (5).
e.
Install radiator cap (1).
f.
Adjust position of ball studs (Figure 2-105, 8) to align with friction
receptacles of hood assembly and secure in position with two bolts (11).
2-248
TM 10-4320-344-24
2.20.2 Cooling System Hoses Maintenance, Model 609-A.
This task covers:
2.20.2.1 Disassembly
2.20.2.2
Repair
2.20.2.3 Assembly
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping stations shut down, TM 10-4320344-10.
Conditions
General Safety I n s t r u c t i o n s
Materials/Parts
Antifreeze, Appendix C, Item 3
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
NOTE
This procedure applies to the lower radiator hose assembly.
The procedures for
the upper radiator hose, water pump bypass hose, and oil cooler outlet hose are
similar.
2.20.2.2 Disassembly.
Do not work on equipment that is not securely stabilized to prevent rolling
or sliding. Ensure both wheels of equipment have chocks that are secure.
Drain antifreeze and allow radiator to cool. Hot radiator or antifreeze can
cause serious burns.
Failure to obey these warnings may result in serious personal injury.
a.
Place pan underneath metal elbow (Figure 2-106, 1) and remove drain plug (2)
to drain antifreeze from cooling system hoses.
Install drain plug (2) in
metal elbow (1).
NOTE
To remove upper radiator hose, water pump bypass hose, oil cooler outlet
hose, oil cooler inlet hose, radiator outlet hose, or metal elbow perform
step b.
b.
Loosen two hose clamps (3) and remove hose (4).
2.20.2.2 Repair.
a.
Inspect hose (4) for cracks, slices, tears, holes, or damage.
b.
Inspect hose clamps (3) for damage.
c.
Replace all defective components.
2-249
TM 10-4320-344-24
2.20.2 Cooling System Hoses Maintenance, Model 609-A. (Continued)
Figure 2-106. Cooling System Hoses Maintenance, Model 609-A.
2.20.2.3 Assembly.
To install upper radiator hose, water pump bypass hose, oil cooler outlet
hose, oil cooler inlet hose, radiator outlet hose, or metal elbow perform
steps a and b.
a.
Slide two hose clamps (3) on hose (4).
b.
Install hose (4) and secure with two hose clamps (3).
2-250
TM 10-4320-344-24
2.20.3 Radiator Service. Model 609-A.
This task covers:
2.20.3.1 Changing Engine Coolant
2.20.3.2 Flushing Radiator
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Materials/Parts
Antifreeze, Appendix C, Item 3
Cleaning Compound, Appendix C, Item 7
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Equipment
Antifreeze drained, paragraph 2.20.2.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
Conditions
Pumping stations shut down, TM 10-4320344-10.
2.20.3.1 Changing Engine Coolant.
Figure 2-107. Radiator Cap.
2-251
TM 10-4320-344-24
2.20.3 Radiator Service, Model 609-A. (Continued)
Do not work on equipment that is not securely stabilized to prevent rolling
or sliding.
Ensure both wheels of equipment have chocks that are secure.
Allow engine to cool before removing radiator cap to avoid being scalded by
hot antifreeze.
Open radiator cap slowly to release pressure.
Drain antifreeze and allow radiator to cool.
cause serious burns.
Hot radiator or antifreeze can
Failure to obey these warnings may result in serious personal injury.
a.
Remove radiator cap (Figure 2-107, 1).
b.
Visually check, t h r o u g h r a d i a t o r f i l l e r n e c k ( 2 ) f o r a c c u m u l a t i o n o f r u s t o r
scale inside radiator (3).
If required, refer to paragraph 2.20.3.2 and flush
radiator (3).
c.
Add new antifreeze until fluid level is visible in radiator filler neck (2).
NOTE
Antifreeze level will drop when thermostat opens.
d.
Refer to TM 10-4320-344-10 and start engine. When thermostat opens, add
antifreeze until fluid level is visible in radiator filler neck (2).
e.
Refer to TM 10-4320-344-10 and stop engine.
radiator (3).
Install radiator cap (1) on
2.20.3.2 Flushing Radiator.
Do not work on equipment that is not securely stabilized to prevent rolling
or sliding.
Ensure both wheels of equipment have chocks that are secure.
Allow engine to cool before removing radiator cap to avoid being scalded by
hot antifreeze.
Open radiator cap slowly to release pressure.
Drain antifreeze and allow radiator to cool.
cause serious burns.
Hot radiator or antifreeze can
Failure to obey these warnings may result in serious personal injury.
a.
Add cleaning compound to radiator (3), fill radiator (3) with clean water, and
install radiator cap (1) on radiator (3).
NOTE
Normal operating temperature is between 175°F (79°C) and 210°F (99°C).
b.
2-252
Refer to TM 10-4320-344-10 and start engine.
When normal operating
temperature is reached, refer to TM 10-4320-344-10 and stop engine.
TM 10-4320-344-24
Do not work on equipment that is not securely stabilized to prevent rolling
or sliding.
Ensure both wheels of equipment have chocks that are secure.
Allow engine to cool before removing radiator cap to avoid being scalded by
hot cleaning compound.
Open radiator cap slowly to release pressure.
Drain cleaning compound and allow radiator to cool.
cleaning compound can cause serious burns.
Hot radiator or
Failure to obey these warnings may result in serious personal injury.
c.
Remove radiator cap (Figure 2-107,1) and drain radiator (3). Properly
dispose of cleaning compound in accordance with local hazardous waste standing
operating procedure.
d.
Add new antifreeze until fluid level is visible in radiator filler neck (2).
NOTE
Antifreeze level will drop when thermostat opens.
e.
Refer to TM 10-4320-344-10 and start engine. When thermostat opens, add
antifreeze until fluid level is visible in radiator filler neck (2).
f.
Refer to TM 10-4320-344-10 and stop engine.
radiator (3).
Install radiator cap (1) on
2-253
TM 10-4320-344-24
2.20.4 Radiator and Fan Shroud Replacement, Model 609-A.
This task covers:
2.20.4.1 Removal
2.20.4.2 Repair
2.20.4.3 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Radiator drained, paragraph 2.20.2
Upper and Lower Radiator Hoses
disconnected, paragraph 2.20.2.
Material/Parts
General Safety Instructions
Cotter Pins (TM 10-4320-344-24P)
Mounting Pads (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM 10-4320-344-10.
Radiator Shell Assembly removed, paragraph
2.20.1.
Do not work on equipment that is not
securely stabilized to prevent
rolling or sliding.
Do not work on equipment without
following standard shop safety
precautions.
2.20.4.1 Removal.
Figure 2-108. Radiator and Fan Shroud Maintenance, Model 609-A.
2-254
TM 10-4320-344-24
Do not work on equipment that is not securely stabilized to prevent rolling
o r s l i d i n g . Ensure both wheels of equipment have chocks that are secure.
To prevent injury to personnel, drain antifreeze and allow radiator to cool
before removing radiator from pump assembly.
Hot antifreeze in radiator or
hot radiator can cause serious burns.
Failure to obey these warnings may result in serious personal injury.
a.
Remove two cotter pins (Figure 2-108, 1), radiator nuts (2), flat washers (3),
resilient mount (4), radiator (5), and four resilient mounts (6).
Discard.
cotter pins (1) and resilient mounts (6).
b.
Remove eight mounting screws (7) and fan shroud (8).
c.
Remove rubber drain hose (9) and radiator cap (10) from radiator filler
neck (11).
2.20.4.2 Repair.
a.
Inspect resilient mounts (4) for wear or damage.
b.
Inspect radiator (5) for corrosion, cracks, holes, or other damage.
c.
Inspect rubber drain hose (9) for cracks, slices, holes, tears, or damage.
d.
Inspect radiator cap (10) for damaged or missing spring and gasket.
e.
Replace all defective components.
2.20.4.3 Installation.
a.
Install radiator cap (10) and rubber drain hose (9) on radiator filler neck
(11).
Insert rubber drain hose (9) in two clamps (12) on radiator (5).
b.
Position fan shroud (8) on radiator (5) and secure with eight screws (7).
c.
Install two new resilient mounts (6) on each mounting stud (13) and position
radiator (5) on radiator supports (14).
d.
Secure radiator (5) with two new resilient mounts (6), resilient mount (4),
flat washers (3), radiator nuts (2), and new cotter pins (1).
Bend tines of
cotter pins (1) back to secure nuts (2) on mounting studs (13).
2-255
TM 10-4320-344-24
2.20.5 Radiator Support Brackets Repair, Model 609-A.
This task covers:
2.20.5.1 Disassembly
2.20.5.2 Repair
2.20.5.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Radiator removed, paragraph 2.20.4.
Materials/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following
standard shop safety precautions.
Pumping station shut down, TM 10-4320344-10.
NOTE
This procedure applies to the left side radiator support and radiator shell
assembly support.
The procedure for the right side radiator support and
radiator shell support is similar.
2.20.5.1 Disassembly.
Figure 2-109. Radiator Supports and Radiator Shell Assembly Supports.
2-256
TM 10-4320-334-24
a.
Remove two nuts (Figure 2-109, 1), lock washers (2), screws (3), and double
angle bracket (4). Discard lock washers (2).
b.
Remove two nuts (5), lock washers (6), screws (7), and lower bracket
support (8) from left hand radiator support (9).
c.
Remove nut (10), l o c k w a s h e r ( 1 1 ) , s c r e w ( 1 2 ) , a n d l e f t h a n d r a d i a t o r
support (9) from rear engine support (13). Discard lock washers (11).
2.20.5.2 Repair.
a.
Inspect all components for damage.
b.
Replace all defective components.
2.20.5.3 Assembly.
a.
Position left hand radiator support (9) on rear engine support (13) and secure
with screw (12), new lock washer (11), and nut (10).
b.
Position lower support bracket (8) on left hand radiator support (9) and
secure with two screws (7), new lock washers (6), and nuts (5).
c.
Position double angle bracket (4) between lower support bracket (8) and left
hand radiator support (9) and secure with two screws (3), new lock washers
(2), and nuts (1).
2-257
TM 10-4320-344-24
2.21 ENGINE ASSEMBLY MAINTENANCE.
2.21.1 Fuel System Bleeding.
This task covers:
2.21.1.1
Bleeding
Fuel
Lines
2.21.1.2 Bleeding Fuel Injection Lines
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping station shut down, TM 10-4320344-10.
Material/Parts
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Personnel
Two personnel are required for the Model
609-A Pumping Assembly.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from
fuel system components while working on
engine assembly.
Do not work on equipment without following standard safety precautions.
2.21.1.1 Bleeding Fuel Lines.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks, cigarettes, and open flame away from
fuel system components while working on engine.
NOTE
This procedure applies to Models 609-C and US636HCCD-1. The procedure
for unit 609-A is similar.
For Model 609-A two personnel are required because the fuel transfer
pump assembly is located on opposite side of engine from bleeder valve.
a.
Place pan under pumping assembly.
b.
Set manual stop control in STOP position, reference TM 10-4320-344-10.
NOTE
Loosen bleed valve by the larger hexagon fitting (19mm) next to banjo fitting.
c.
Open bleed valve at (Figure 2-110, 1) on fuel injection pump (2).
NOTE
The fuel transfer pump will only work if camshaft of injector
position that diaphragm of fuel transfer pump is not lifted.
fuel transfer pump lever, commencement of lifting movement of
occur in the first quarter of its total travel.
If not, turn
slightly tapping start button, but do not crank engine.
d.
2-258
pump is in such
When operating
diaphragm must
engine over by
Hand pump lever (3) on fuel transfer pump (4) until air bubbles disappear from
fuel flow.
TM 10-4320-344-24
Figure 2-110. Fuel System Bleeding (Models 609-C and US636HCCD-1 Shown).
e.
Close bleed valve (1).
f.
Start engine, refer to TM 10-4320-344-10, and check for leaks.
g.
Stop engine, refer to TM 10-4320-344-10.
h.
Remove pan from under pumping assembly and properly dispose of fuel in
accordance with standing operating procedure.
2-259
TM 10-4320-344-24
2.21.1 Fuel System Bleeding. (Continued)
2.21.1.2 Bleeding Fuel Injection Lines.
Diesel fuel is flammable.
Keep sparks, cigarettes, and open flame away from
fuel system components while working on engine.
NOTE
This procedure applies to Models 609-C and US636HCCD-1.
609-A is similar.
a.
The procedre for Model
Place pan under pumping assembly.
Diesel fuel is flammable.
Keep sparks, cigarettes, and open flame
away from fuel system components while working on engine.
When bleeding fuel injection lines, loosen fuel line nuts one-quarter
to one-half turn.
Fuel injection line nuts that are too loose may
come off, causing fuel spray that could injure personnel.
Failure to obey these warnings may result in personal injury or death.
b.
Loosen fuel injection line nut (5) at fuel injector nozzle (6).
c.
Start engine, refer to TM 10-4320-344-10, and let fuel flow until air bubbles
disappear from fuel flow.
d.
Tighten fuel injection line nut (5).
e.
Repeat steps b, c, and d for remaining fuel injector nozzles (6).
f.
Stop engine, refer to TM 10-4320-344-10.
g.
Remove pan from under pumping assembly and properly dispose of fuel in
accordance with standing operating procedure.
2-260
TM 10-4320-344-24
2.21.2 Fuel and Oil Lines. Hoses. and Fittings Maintenance.
This task covers:
2.21.2.1 Disassembly
2.21.2.3 Assembly
2.21.2.2 Repair
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
pumping station shut down, TM 10-4320-34410.
Conditions
General Safety Instructions
Goggles, Appendix B, Section III, Item 2
Gun, Air Blow, Appendix B, Section III,
Item 2
Materials/Parts
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Tape, Antiseize, Appendix C, Item 32
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
system components.
Do not work on equipment without following standard shop safety practices.
Diesel fuel is flammable. Keep sparks, cigarettes, and open flames
away from fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of
properly.
Failure to obey these warnings may result in personal injury or death.
Plug fuel tank and fuel injection pump assembly after removing fuel
lines.
Plug engine block or crankcase after removing oil lines.
Failure to obey this caution may allow contaminants to enter pumping
assembly and result in damage to the equipment.
NOTE
This general maintenance procedure applies to all three models of
the 600 GPM pumping assemblies.
Refer to figure 2-111 and table 2-5 fuel and oil line terminations and
runs for Model 609-A.
Refer to figure 2-112 and table 2-6 fuel and oil line terminations and
runs for Model 609-C.
Refer to figure 2-113 and table 2-7 fuel and oil line terminations and
runs for Model US636HCCD-1.
2.21.2.1 Disassembly.
Refer to figure and table for applicable pumping assembly and
tag, disconnect, and remove line and fittings as required.
2-261
TM 10-4320-344-24
2.21.2 Fuel and Oil Lines, Hoses. and Fittings Maintenance. (Continued)
Figure 2-111.
Table 2-5.
TERMINATION
TYPE
View A
View C
View C
View C
View E
View F
View F
View G
2-262
Fuel Lines, Oil Lines, and Fittings, Model 609-A.
Fuel Line and Oil Line Runs and Terminations, Model 609-A.
FROM
TO
Fuel Tank
Transfer Pump
Assembly
Primary Fuel
Filter
Secondary Fuel
Filter
Fuel Injection
Pump Assembly
Fuel Tank
Transfer Pump
Assembly
Primary Fuel
Filter
Secondary Fuel
Filter
Fuel Injection
Pump Assembly
Engine Block
Oil Filter
Oil Cooler
Oil Filter
Oil Cooler
Engine Block
TERMINATION
TYPE
View B
LINE
TYPE
FUEL
View C
FUEL
View C
FUEL
View D
FUEL
View A
FUEL
View F
View F
View G
OIL
OIL
OIL
TM 10-4320-344-24
Figure 2-112. Fuel Line and Fittings, Model 609-C.
Table 2-6. Fuel Line and Oil Line Runs and Terminations, Model 609-C.
FROM
TO
Auxiliary Fuel
Return
Fuel Tank
View F
Return Selection
Switch
Return Selection
Switch
Return Selection
Switch
Fuel Selection
Switch
Fuel Selection
Switch
Fuel Selection
Switch
Fuel Transfer Pump
Assembly
Fuel Filter
View F
Crankcase
TERMINATION
TYPE
View A
View A
View D
View A
View C
View A
View F
TERMINATION
TYPE
View B
View C
Fuel Leakoff
Manifold Assembly
Auxiliary Fuel
Supply
Fuel Tank
View E
Fuel Transfer
Pump Assembly
Fuel Filter
View F
Fuel Injection
Pump Assembly
Fuel Injection
Pump Assembly
View F
View B
View C
View F
View F
2-263
TM 10-4320-344-24
2.21.2 Fuel and Oi1 Lines, Hoses, and Fittings Maintenance.
(Continued)
Figure 2-113. Fuel Lines, Oil Lines, and Fittings, Model US636HCCD-1
Table 2-7. Fuel Line and Oil Line Runs and Terminations, Model US636HCCD-1.
TERMINATION
TYPE
View A
View B
View B
View C
View B
2-264
FROM
TO
Fuel Tank
Fuel Transfer
Pump Assembly
Fuel Filter
Fuel Transfer
Pump Assembly
Fuel Filter
Fuel Leakoff
Manifold
Assembly
Crankcase
TERMINATION
TYPE
View B
Line
Type
Fuel
View B
Fuel
Fuel Injection
Pump Assembly
Fuel Tank
View B
Fuel
View D
Fuel
Fuel Injection
Pump Assembly
View B
Oil
TM 10-4320-344-24
2.21.2.2 Repair.
a.
Clean all fittings and lines (exterior) with clean cloth.
To prevent the possibility of embedding foreign objects in the eyes, safety
goggles must be worn when using compressed air.
b.
Induce 25-35 psi (172.2-241.09 kPa) of air into lines to clear any foreign
matter.
c.
Inspect lines and fittings for damage.
d.
Replace all defective fittings and nonreparable line assemblies.
e.
Refer to Appendix D to repair damaged rubber hose assemblies on Models 609-C
and US636HCCD-1.
2.21.2.3 Assembly.
NOTE
Wrap antiseize tape in direction of threads for all pipe fittings prior to
installation.
a.
Refer to table of applicable pumping assembly for location and type of
hardware.
b.
Refer to figure of applicable pumping assembly and assemble components as
required.
Remove and discard tags.
2-265
TM 10-4320-344-24
2.21.3 Fuel Solenoid Replacement, Model 609-C.
This task covers:
2.21.3.1 Removal
2.21.3.2
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Do not work on equipment with battery
connected.
Electrocution hazard is present if battery is connected.
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph 2.15.3.
Diesel fuel is flammable.
Keep sparks
cigarettes, and open flame away from fuel
system components.
Do not work on equipment without following standard shop safety practices.
Fuel Supply Line disconnected from fuel
injection pump assembly, paragraph
2.21.2.
2.21.3.1 Removal.
Figure 2-114. Fuel Solenoid Replacement, Model 609-C.
2-266
TM 10-4320-344-24
Diesel fuel is flammable. Keep sparks, cigarettes, and open flames away from
fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of properly.
Do not work on equipment with battery connected.
present when battery is connected.
Electrocution hazard is
Failure to obey these warnings may result in personal injury or death.
When removing fuel solenoid, cap or plug fuel lines and fuel injection pump
assembly to prevent foreign particles from entering the engine fuel system.
Failure to cap or plug openings may result in damage to the equipment.
a.
Disconnect wiring harness (Figure 2-114, 1) from receptacle connector (2).
b.
Remove receptacle connector (2) from fuel solenoid (3).
c.
Remove banjo bolt (4), two flat washers (5), and fuel solenoid (3) from fuel
injection pump assembly (6).
2.21.3.2 Installation.
a.
Position fuel solenoid (3) and two flat washers (5) on fuel injection pump
assembly (6) and secure banjo bolt (4).
b.
Install receptacle connector (2) on fuel solenoid (3).
c.
Connect wiring harness (1) to receptacle connector (2).
2-267
TM 10-4320-244-24
2.21.4 Fuel Filter and Base Assembly Maintenance. Model 609-A.
This task covers:
2.21.4.1
Removal
2.21.4.2 Servicing
2.21.4.3 Repair
2.21.4.5 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Pumping Station shut down, TM 10-4320-34410.
Goggles, Appendix B, Section III,
Item 2 Gun, Air Blow, A p p e n d i x B , S e c t i o n
III, Item 2
Torque Wrench, A p p e n d i x B , S e c t i o n
III, Item 2
Fuel Filter drained, TM 10-4320-344-10.
Fuel Line Hoses removed or disconnected
and capped, paragraph 2.21.2.
G e n e r a l S a f e t y Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Materials/Parts
Diesel Fuel, Appendix C, Item 10
Oil, Appendix C, Item 15
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Water Separator Fluid Filter
(TM 10-4320-344-24P)
Fluid Filter Element
(TM 10-4320-344-24P)
Diesel fuel is flammable. Keep sparks,
cigarettes, and open flame away from fuel
system components.
Do not work on equipment without following standard shop safety practices.
2.21.4.1 Removal.
Diesel fuel is flammable. Keep sparks, cigarettes, and open flames away
from fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of properly.
Failure t o obey t hese w arnin gs m a y r e s u l t i n p e r s o n a l i n j u r y o r d e a t h .
a.
Place pan under water separator fluid filter (Figure 2-115, 1) and fluid
filter element (2).
b.
Remove and discard water separator fluid filter (1) and fluid filter
element (2).
c.
Remove two nuts (3), lock washers (4), screws (5), and fluid filter heads (6).
Discard lock washers (4).
d.
Remove two screws (7), lock washers (8), spacers (9), and angle mounting
bracket (10). Discard lock washers (8).
e.
Remove two tube couplings (11) from fluid filter heads (6).
2.21.4.2 S e r v i c i n g . Servicing consists of removing and replacing water separator
fluid filter (1) and fluid filter element (2).
2-268
TM 10-4320-344-24
Figure 2-115. Fuel Filter and Base Assembly Maintenance, Model 609-A.
2.21.4.3 Repair.
a.
Clean all parts with clean cloth.
b.
Inspect fluid filter heads (6) and tube couplings (11) for cracks, stripped
threads, distortions and blocked fuel passages.
To prevent the possibility of embedding foreign objects in the eyes, safety
goggles must be worn when using compressed air.
c.
Using compressed dry air dry all parts.
thoroughly dried.
Ensure all fuel passages are
d.
Induce 25-35 psi (172.2-241.09 kPa) of air into fluid filter heads (6) and
tube couplings (11) to clear any foreign matter.
e.
Inspect all fittings and attaching hardware for damage.
f.
Replace all defective components.
2-269
TM 10-4320-344-24
2.21.4 Fuel Filter and Base Assembly Maintenance. Model 609-A. (Continued)
2.21.4.4 Installation.
Diesel fuel is flammable.
Keep sparks, cigarettes, and open flames away
from fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of properly.
Failure to obey these warnings may result in personal injury or death.
a.
Install two tube couplings (11) in fluid filter heads (6).
b.
Position two spacers (9) and angle mounting bracket (10) on pumping assembly
and secure with new two new lock washers (8) and mounting screws (7). Torque
bolts (7) to 20 ft-lbs (27 Nm).
c.
Position two fluid filter heads (6) on angle mounting bracket (10) and secure
with two screws (5), new lock washers (4), and nuts (3).
NOTE
Water separator fluid filter is mounted on fluid filter head closest to
the radiator.
Fill water separator fluid filter and fluid filter element with clean
diesel fuel prior to installation.
d.
Apply light coating of oil to seals on water separator fluid filter (1) and
fluid filter element (2) and install filters (1 and 2) on fluid filter
heads (6).
e.
Wipe fluid filter heads (6) with clean cloth.
f.
Refer to paragraph 2.21.1 and bleed fuel system.
2-270
TM 10-4320-344-24
2.21.5 Fuel Filter and Base Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
2.21.5.1
Removal
2.21.5.2 Servicing
2.21.5.3 Repair
2.21.5.4 Installation
INITIAL SETUP
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping Station shut down, TM 10-4320-34410.
Fuel Filters drained, TM 10-4320-344-10.
Goggles, Appendix B, Section III,
Item 2
Fuel Line Hoses disconnected and capped,
paragraph 2.21.2.
Gun, Air Blow, Appendix B, Section
III, Item 2
General Safety Instructions
Materials/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Diesel Fuel, Appendix C, Item 10
Oil, Appendix C, Item 15
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Water Separator Fluid Filter
(TM 10-4320-344-24P)
Fluid Filter Element
(TM 10-4320-344-24P)
Diesel fuel is flammable. Keep sparks,
cigarettes, and open flame away from fuel
system components.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model 609-C.
similar.
The procedure for Model US636HCCD-1 is
2.21.5.1 Removal.
Diesel fuel is flammable. Keep sparks, cigarettes, and open flames
away from fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of
properly.
Failure to obey these warnings may result in personal injury or death.
a.
Open access door (Figure 2-116, 1) on pumping assembly (2).
b.
Place pan under drain hoses (3).
c.
Remove screw (4), two cable clamps (5), and grommets (6).
d.
Disconnect two drain hoses (3) from two drain plugs (7) and remove drain
plugs (7) from fluid filters (8).
e.
Unscrew and remove two fluid filters (8).
f.
Remove two nuts (9), lock washers (10), flat washers (11), bolts (12), and
f l u i d f i l t e r h e a d ( 1 3 ) . Discard lock washers (10).
2-271
TM 10-4320-344-24
2.21.5 Fuel Filter and Base Assembly Maintenance, Models 609-C and US636HCCD-1.
Figure 2-116.
2-272
(Continued)
Fuel Filter and Base Assembly Maintenance, Models 609-C and
US636HCCD-1.
TM 10-4320-344-24
2.21.5.2 Servicing. Servicing consists of removing and replacing fuel filters (8).
2.21.5.3 Repair.
a.
Clean all parts with clean cloth.
To prevent the possibility of embedding foreign objects in the eyes, safety
goggles must be worn when using compressed air.
b.
Using compressed air dry all parts.
dried.
Ensure fuel passages are thoroughly
c.
Induce 25-35 psi (172.2-241.09 kPa) of dry air into fluid filter head (13) to
clear any foreign matter.
d.
Inspect all components for damage.
e.
Inspect fluid filter head (13) for bends, cracks, distortions, or blocked fuel
passages.
f.
Replace all defective components.
g.
Refer to Appendix D to repair damaged drain hoses (3).
2.21.5.4 Installation.
NOTE
Prior to installation of fuel lines, hoses, and fittings, remove plugs or caps
installed to prevent contamination.
a.
Position fluid filter head (13) on bulkhead and secure with two bolts (12),
flat washers (11), new lock washers (10), and nuts (9).
D i e s e l f u e l i s f l a m m a b l e . Keep sparks, cigarettes, and open flames away
from fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of properly.
Failure to obey these warnings may result in personal injury or death.
NOTE
Fill fluid filters with clean diesel fuel prior to installation.
b.
Apply a light coating of oil to seals on fluid filters (8) and install on
fluid filter head (13).
c.
Install two drain plugs (7) and connect two drain hoses (3) to drain
plugs (7).
d.
Install two cable clamps (5) on two drain hoses (3) and secure with screw (4).
e.
Install two grommets (6).
2-273
TM 10-4320-344-24
2.21.6 Fuel Transfer Pump Assembly Maintenance.
This task covers:
2.21.6.1 Service
2.21.6.2 Test
2.21.6.3 Removal
2.21.6.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
For replacement, Fuel Inlet and Fuel
Outlet Hoses removed and capped,
paragraph 2.21.2.
Materials/Parts
General Safety Instructions
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Gasket (TM 10-4320-344-24P)
Fuel Transfer Pump Assembly Repair Kit
(TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent
rolling or sliding.
Diesel fuel is flammable.
Keep
sparks, cigarettes, and open flame
away from fuel system components.
Equipment Conditions
Pumping station shut down, TM 10-4320-344-10.
Do not work on equipment without
following standard shop safety
Air Cleaner Assembly removed, paragraph 2.14.3 practices.
(US636HCCD-1).
NOTE
This procedure applies to Model US636HCCD-1.
and 609-C are similar.
The procedures for Model 609-A
2.21.6.1 Service. (Models 609-C and US636HCCD-1 only.)
Figure 2-117. Fuel Transfer Pump Assembly Servicing.
2-274
TM 10-4320-344-24
D i e s e l f u e l i s f l a m m a b l e . Keep sparks, cigarettes, and open flames away
from fuel system components while working on engine.
Ensure container is used to catch fuel and fuel is disposed of properly.
Failure to obey these warnings may result in personal injury or death.
a.
Remove bolt (Figure 2-117, 1), washer (2), cover (3), o-seal (4), and screen
(5).
b.
Discard components (1, 2, 3, 4, and 5) and replace with new fuel transfer pump
assembly repair kit.
2.21.6.2 Test.
Figure 2-118.
Fuel Transfer Pump Assembly Test.
•
Diesel fuel is flammable. Keep sparks, cigarettes, and open flames away
from fuel system components while working on engine.
•
Ensure container is used to catch fuel and fuel is disposed of properly.
•
Failure to obey these warnings may result in personal injury or death.
a.
Place pan under fuel transfer pump assembly (Figure 2-118, 1).
b.
D i s c o n n e c t f u e l o u t l e t h o s e (2) f r o m f u e l t r a n s f e r p u m p a s s e m b l y ( 1 ) .
2-275
TM 10-4320-344-24
2.21.6 Fuel Transfer Pump Assembly Maintenance. (Continued)
c.
Start engine, refer to TM 10-4320-344-20.
d.
Check to see if fuel is being forcefully ejected from fuel transfer pump
assembly (1).
NOTE
Pressure output from fuel transfer pump assembly is 3-5 psi (20-34 kPa).
e.
If fuel is not being forcefully ejected from fuel transfer pump assembly (1),
service fuel transfer pump assembly (1).
f.
Stop engine, refer to TM 10-4320-344-10.
g-
Remove pan from under fuel transfer pump assembly (1) and properly dispose of
fuel in accordance with standing operating procedures.
2.21.6.3 Removal.
Figure 2-119.
Fuel Transfer Pump Assembly Replacement (Model US636HCCD-1 Shown).
a.
Place pan under engine.
b.
Remove three nuts (Figure 2-119, 1), lock washers (2), fuel transfer pump
assembly (3), and gasket (4) from fuel injection pump assembly (5. Discard
gasket (4).
2.21.6.4 Assembly.
NOTE
Torque mounting nuts for Model 609-A to 15 f t - l b s ( 2 0 N • m ) .
a.
I n s t a l l n e w g a s k e t ( 4 ) a n d p o s i t i o n f u e l t r a n s f e r pump assembly (3) on fuel
injection pump assembly (5) and secure with three new lock washers (2) and
nuts (1).
b.
Remove pan from under engine and properly dispose o f f u e l i n a c c o r d a n c e w i t h
standing operating procedures.
2-276
TM 10-4320-344-24
2.21.7 Fuel Injection Lines and Fuel Leakoff Manifold Assembly Maintenance.
This task covers:
2.21.7.1
Removal
2.21.7.2 Repair
2.21.7.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Fuel Return Line disconnected and capped,
paragraph 2.21.2 (609-C and US636HCCD-1).
Goggles, Appendix B, Section III,
Item 2
Gun, Air Blow, Appendix B, Section
III, Item 2
Hood Assembly removed, paragraph 2.19.1
(609-A).
Shield Assembly removed, paragraph 2.19.3
(609-A).
General Safety I n s t r u c t i o n s
Material/Parts
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Tape, Antiseize, Appendix C, Item 32
Lock Washers (TM 10-4320-344-24P)
Equipment
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
system components.
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
Air Cowling removed, TM 10-4320-344-10
(609-C and US636HCCD-1).
•
This general maintenance procedure applies to all three models of the
600 GPM pumping assembly.
•
Remove pipe tee from fuel injector and nozzle holder assembly when
removing both the fuel injection line and fuel leakoff manifold line
from a fuel injector and nozzle holder assembly on Model 609-A.
2.21.7.1 Removal. Refer to figure 2-120 and t a g a n d d i s c o n n e c t f u e l i n j e c t i o n l i n e o r
fuel leakoff manifold line and fittings as required.
2.21.7.2 Repair.
a.
Inspect all fuel injection lines and fuel leakoff manifold lines for kinks,
h o l e s , cracks, blockages, or damaged nuts.
b.
Inspect fittings for cracks, damaged threads, blockages, or distortions.
To prevent foreign objects from embedding in eyes, w e a r e y e p r o t e c t i o n g o g g l e s
when using compressed air.
Failure to obey this warning may result in personal
injury.
c.
Using compressed dry air remove any blockages in f u e l i n j e c t i o n l i n e s a n d f u e l
leakoff manifold lines and fittings.
2-277
TM 10-4320-344-24
2.21.7 Fuel Injection Lines and Fuel Leakoff Manifold Assembly Maintenance. (Continued)
Figure 2-120.
Fuel Injection Lines and Fuel Leakoff Manifold Line Connections.
d.
I n s p e c t a l l mounting hardware for damage.
e.
Replace all defective components.
NOTE
Wrap antiseize tape in the direction of threads for all pipe fittings prior
to installation.
2.21.7.3 Installation. Refer to figure 2-120 and assemble components as required.
Remove and discard tags.
2-278
TM 10-4320-344-24
2.21.8 Fuel Injection Nozzle and Holder Assembly Maintenance. Model 609-A.
This task covers:
2.21.8.1
Removal
2.21.8.2 Test
2.21.8.3
Installation
INITIAL SETUP
Tools
Materials/Parts
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Tags, Appendix C, Item 31
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Goggles, Appendix B, Section III, Item 2
Equipment
Gun, Air Blow, Appendix B, Section III,
Item 2
Fuel Leakoff Manifold Assembly and Fuel
Injection Lines disconnected and capped,
paragraph 2.21.7.
Torque Wrench, Appendix B, Section 111,
Item 2
General Safety Instructions
Static Fuel Nozzle Testing Fixture,
Appendix B, Section III, Item 5
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
system components.
Material/Parts
Diesel Fuel, Appendix C, Item 10
Rags, Appendix C, Item 20
(Continued)
Conditions
Do not work on equipment without
following standard shop safety
precautions.
2.21.8.1 Removal.
Figure 2-121.
Fuel Injection Nozzle end Holder Assembly Removal, Model 609-A.
2-279
TM 10-4320-344-24
2.21.8 Fuel Injection Nozzle and Holder Assembly Maintenance, Model 609-A. (Continued)
a.
Tag each fuel injection nozzle and holder assembly (Figure 2-121, 1) to
identify its position in cylinder head (2).
b.
Remove twelve screws (3), lock washers (4) six fuel injection nozzle and
holder assemblies (1), and gaskets (5) from cylinder head (2). Discard lock
washers (4) and gaskets (5).
2.21.8.2 Test.
Ž D i e s e l f u e l i s f l a m m a b l e . Keep sparks, cigarettes, and open flame
away from fuel system components while working on engine.
• To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
Ž Failure to obey these warnings may result in personal injury.
a.
Clean fuel injection nozzle and holder assembly (1) in clean diesel fuel and
dry thoroughly with filtered, compressed dry air.
b.
Insert fuel injection nozzle and holder assembly (1) in static fuel nozzle
testing fixture.
NOTE
• Nozzle opening pressure should be 2,750 psi (18,943 kPa).
New fuel
injection nozzle and holder assembly will have an opening pressure
of 2,900 psi (19,956 kPa).
• Turn adjusting screw in nozzle holder clockwise to increase pressure
required to open fuel injection nozzle and counterclockwise to
decrease pressure required to open fuel injection nozzle.
c.
To adjust fuel injection nozzle and holder assembly (1), remove cover
attaching nut (6) and turn screw in nozzle holder (1).
d.
Install cover attaching nut (6) on nozzle holder (1).
e.
If fuel injection nozzle fails to open at proper psi, replace fuel injection
nozzle and holder assembly (1).
2.21.8.3
Installation.
a.
Install six new gaskets (5) in cylinder head (2).
b.
Refer to tags and install six fuel injection nozzle and holder assemblies (1)
in their original position in cylinder head (2). Remove and discard tags.
c.
Install twelve new lock washers (4) and screws (3).
30 ft-lbs (34-41 N•m).
2-280
Torque screws (3) to 25-
TM 10-4320-344-24
2.21.9 Fuel Injection Nozzle Maintenance. Models 609-C and US636HCCD-I.
This task covers:
2.21.9.1 Removal
2.21.9.2 Test
2.21.9.3
Installation
INITIAL SETUP
Tools
Material/parts
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Diesel Fuel, Appendix C, Item 10
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Sealing Ring, TM 10-4320-344-24p
Goggles, Appendix B, Section III,
Item 2
(Continued)
Equipment Conditions
Gun, Air Blow, Appendix B, Item 2
Fuel Leakoff Manifold Assembly and
Fuel Injection Lines disconnected and
capped, paragraph 2.21.7.
Torque Wrench, Appendix B, Section
III, Item 2
General Safetv Instructions
Nozzle Puller, Appendix B, Section
III, Item 6
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
system components.
Pulling Device, Appendix B, Section
III, Item 7
Do not work on equipment without
following standard shop safety
precautions.
Gasket Puller, Appendix B, Section
III, Item 8
Nozzle Tester, Appendix B, Section
III, Item 9
2.21.9.1 Removal.
a.
Remove six nuts (Figure 2-122,
b.
Tag and remove six f u e l
c.
Remove six sealing r i n g s ( 4 ) f r o m c y l i n d e r h e a d ( 5 ) .
(4).
1) and injection nozzle yokes (2).
injection
nozzles
(3).
Discard sealing rings
2.21.9.2 Testing.
• Diesel fuel is flammable. Keep sparks, cigeretts, and open flame away from
fuel system components while working on engine.
a.
•
To prevent the possibility of embedding foreign objects in the eyes, safety
glasses must be worn when using compressed air.
•
Failure to obey these warnings may result in personal injury.
Clean fuel injection nozzle (3) in clean diesel fuel and dry thoroughly with
filtered, compressed dry air.
2-281
TM 10-3420-344-24
2.21.9 Fuel Injection Nozzle Maintenance. Models 609-C and US636HCCD-1.
Figure 2-122.
Figure 2-123.
2-282
(Continued)
Fuel Injection Nozzle Removel, Model 609-C and US636HCCD-1.
Feul Injection Nozzle Test, Models 609-C and US636HCCD-1.
TM 10-4320-344-24
• Do not smoke or use open flames around fuel. Ensure container is used to
catch fuel and fuel is disposed of properly.
• Do not allow body parts to come in contact with fuel during test. Fuel under
test is under extremely high pressure and may cut through skin.
• Failure to obey these warnings may result in personal injury or death.
b.
Connect fuel injection nozzle (Figure 2-123, 1) to injection timing pump (2).
c.
With pressure gauge cut in, press nozzle tester pump lever several times.
NOTE
Readings should be 2,537-2,653 psi (17,728-18,538 kPa) for used nozzle.
Readings should be 2,610-2,726 psi (18,234-19,044 kPa) for new nozzle, or
new spring in nozzle. The jet pattern must be solid without surrounding
mist.
d.
Read opening pressure and inspect spray pattern (3).
e.
Reduce pressure to 362.5-435 psi (2,533-3,039 kPa) below specified opening
pressure, check that no fuel drips from fuel injector nozzle (1).
f.
If fuel injection nozzle (1) fails to open at proper psi, replace fuel
injection nozzle (1).
2.21.9.3
Installation.
a.
Install six new sealing rings (Figure 2-122, 4), with metal side down, in
cylinder head (5).
b.
Refer to tags and install six fuel injection nozzles (3) securing with six
i n j e c t i o n n o z z l e y o k e s ( 2 ) a n d n u t s ( 1 ) . Torque nuts (1) to 17 ft-lbs (23
N*m). Remove and discard tags.
2-283
TM 10-3420-344-24
2.21.10 Cold Starting Aid Maintenance. Model 609-C.
This task covers:
2.21.10.1 Removal
2.21.10.2 Repair
2.21.10.3 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive Tool
Kit, Appendix B, Section III,
Item 1
Cold Start Aid Cable disconnected,
paragraph 2.16.29.
Riveter, Blind, Appendix B, Section III,
Item 4
Materials/Parts
Lock Washers (TM 10-4320-303-24P)
Rivets (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM 10-4320-34410.
General Safetv Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Flammable contents under pressure.
Keep sparks, flame, or excessive heat
away. Do not puncture container.
Do not work on equipment without
following standard shop safety
practices.
2.21.10.1 Removal.
a.
Open cold starting aid access door (Figure 2-124, 1), right side engine access
door (2), and left side engine access door (3) on pumping assembly (4).
b.
Remove tubing assembly (5) and elbow (6) from valve (7).
c.
Remove two rivets (8) and cable clamps (9) from tubing assembly (5). Discard
r i v e t s (8) .
d.
Remove grommet (10) from bulkhead panel (11) and tubing assembly (5).
e.
Remove t u b i n g a s s e m b l y ( 5 ) f r o m a t o m i z e r ( 1 2 ) .
f.
Remove atomizer (12) and adapter bushing (13) from engine (14).
Flammable contents under pressure. Do not smoke near equipment. Keep
sparks, flame, and excessive heat away.
Do not puncture container.
Failure
to obey this warning may result in death or personnel injury.
g.
Loosen clamp (15) and remove cartridge (16) from valve (7).
h.
Remove two nuts (17), lock washers (18), and cap screws (19), from valve (7).
Discard lock washers (18).
i.
Remove two nuts (20), bolts (21), and clamp (15).
2.21.10.2 Repair.
a.
I n s p e c t t u b i n g a s s e m b l y ( 5 ) , v a l v e ( 7 ) , cable clamps (9), grommet (10), and
cartridge (16) for damage.
b.
Inspect all mounting hardware for damage.
2-284
TM 10-4320-344-24
Figure 2-124.
Cold Starting Aid Maintenance, Model 609-C.
2-285
TM 10-4320-344-24
2.21.10 Cold Starting Aid Maintenance, Model 609-C.
c.
(Continued)
Replace all defective components.
2.21.10.3
Installation.
a.
Position clamp (15) on bulkhead panel (11) and secure with two bolts (21) and
nuts (20).
b.
Position valve (7) on bulkhead panel (11) and secure with two cap screws (19),
new lock washers (18), and nuts (17).
c.
Install cartridge (16) in valve (7) and secure with clamp (15).
d.
Install adapter bushing (13) and atomizer (12) into engine (14).
e.
Install tubing assembly (5) on atomizer (12).
f.
Insert tubing assembly (5) through grommet (10) and bulkhead panel (11).
Install grommet (10) in bulkhead panel (11).
g.
Place tubing assembly (5) in two cable clamps (9) and secure cable clamps (9)
to bulkhead panel (11) with two new rivets (8).
h.
Install elbow (6) in valve (7) and install tubing assembly (5) on elbow (6).
i.
C l o s e l e f t s i d e e n g i n e a c c e s s d o o r ( 3 ) , right side engine access door (2), and
cold starting aid access door (1) on pumping assembly (4).
2-286
TM 10-4320-344-24
2.21.11 V-Belt Guard and Mounting Supports Maintenance, Model US636HCCD-1.
This task covers:
2.21.11.1 Removal
2.21.11.2 Disassembly
2.21.11.3 Repair
2.21.11.4 Assembly
2.21.11.5 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Air Intake Pipe Assembly removed, paragraph
2.14.5.
General Safety Instructions
Materials/Parts
Lock Washers (TM 10-4320-303-24P)
Equipment
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following
standard shop safety practices.
2.21.11.1 Removal.
a.
Remove five screws (Figure 2-125, 1), flat washers (2), and V-belt guard (3).
b.
Remove bolt (4), flat washer (5), and bushing (6) from retainer bracket (7).
c.
Remove two bolts (8) and retainer bracket (7) from cover plate (9).
d.
Remove bushing (10), f l a t w a s h e r ( 1 1 ) , s t u d ( 1 2 ) , f l a t w a s h e r ( 1 3 ) , c o v e r
plate (9), and three flat washers (14).
e.
Remove bushing (15), s p a c e r ( 1 6 ) , f l a t w a s h e r ( 1 7 ) , a n d s t u d ( 1 8 ) f r o m c o o l i n g
air blower (19).
f.
Remove bushing (20), f l a t w a s h e r ( 2 1 ) , s t u d ( 2 2 ) , s p a c e r ( 2 3 ) , a n d f l a t
washer (24) from retainer bracket (25).
g.
Remove bushing (26), flat washer (27), two screws (28), lock washers (29),
flat washers (30), and retainer (31). Discard lock washers (29).
2.21.11.2 Disassembly.
a.
Remove three screws (32), flat washers (33), and cover plate (34).
b.
Remove grommet (35) from cover plate (34).
2.21.11.3 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.11.4 Assembly.
a.
Insert grommet (35) into cover plate (34).
b.
Position cover plate (34) against V-belt guard (3) and secure with three flat
washers (33) and screws (32) .
2-287
TM 10-4320-344-24
2.21.11 V-Belt Cover Assembly and Mounting Supports Maintenance, Model US636HCCD-1. (Continued)
Figure 2-125.
V-Belt Guard Maintenance, Model US636HCCD-1.
2.21.11.5 Installation.
a.
Position retainer (31) against engine mounting support and secure with two
f l a t w a s h e r s ( 3 0 ) , new lock washers (29), and screws (28).
b.
Install flat washer (27) and bushing (26) on retainer (31).
c.
I n s t a l l f l a t w a s h e r ( 2 4 ) , s p a c e r ( 2 3 ) , stud (22), flat washer (21), and
bushing (20) on retainer bracket (25).
d.
I n s t a l l s t u d ( 1 8 ) , f l a t w a s h e r ( 1 7 ) , s p a c e r ( 1 6 ) , and bushing (15) on cooling
air blower (19).
e.
Install three flat washers (14], cover plate (9), flat washer (13), stud (12),
f l a t w a s h e r ( 1 1 ) , and bushing (10) on engine.
f.
Position retainer bracket (7) against cover plate (9) and secure with two
bolts (8).
g.
Position bushing (6) on retainer bracket (7) and secure with flat washer (5)
and bolt (4).
2-288
TM 10-4320-344-24
h.
Position V-belt guard (3) on engine and secure with five flat washers (2) and
screws (1).
2-289
TM 10-4320-344-24
2.21.12 V-Belt Replacement, Models 609-C and US636HCCD-1.
This task covers:
2.21.12.1 Removal
2.21.12.2
Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Do not work on equipment without following standard shop safety practices.
Pumping station shut down, TM 10-4320344-10.
V-Belt Guard removed, paragraph 2.21.11
(Model US636HCCD-1).
2.21.12.1 Removal.
Figure 2-126. V-Belt Replacement, Models 609-C and US636HCCD-1.
2-290
TM 10-3420-344-24
2.21.12 V-Belt Replacement, Models 609-C and US636HCCD-l. (Continued)
I d l e r p u l l e y i s u n d e r s p r i n g t e n s i o n . Use care when pushing idler pulley.
Failure to obey this warning may result in personal injury.
a.
Push idler pulley (Figure 2-126, 1) up to relieve tension on blower V-belts
(2).
b.
Remove two blower V-belts (2) from cooling air blower pulley (3), crankshaft
pulley (4), and idler pulley (1).
2.21.12.2 Installation.
a.
Place two blower V-belts (2) on idler pulley (1).
I d l e r p u l l e y i s u n d e r s p r i n g t e n s i o n . Use care when pushing idler pulley.
Failure to obey this warning may result in personal injury.
b.
Push idler pulley (1) up to provide relief for two blower V-belts (2).
c.
Place two blower V-belts (2) over cooling air blower pulley (3) and two
outside grooves of crankshaft pulley (4).
e.
Release idler pulley (1).
2-291
TM 10-4320-344-24
2.21.13 Alternator Belt Maintenance.
This task covers:
2.21.13.1 Adjust
2.21.13.2 Removal
2.21.13.3 Installation
INITIAL SETUP
(Continued)
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
V-Belts removed, paragraph 2.21.12 (609-C
and US636HCCD-1).
General Safety Instructions
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Left Side Panel open (Model 609-A).
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model 609-A. The procedures for models 609-C and
US636HCCD-1 are similar.
2.21.13.1 Adjust.
Figure 2-127.
a.
2-292
Alternator Belt Maintenance, Model 609-A.
Loosen hinge screw (Figure 2-127, 1) on alternator mounting bracket (2).
TM 10-4320-344-24
b.
Loosen bolt (3) in alternator adjusting arm (4).
NOTE
There should be approximately 1/2 inch deflection at center of alternator
belt.
c.
Slide alternator (5) away from water pump assembly (6) to apply tension to
alternator belt (7).
d.
Tighten bolt (3) and hinge bolt (1).
2.21.13.2 Removal.
a.
Loosen hinge screw (1) on alternator mounting bracket (2).
b.
Loosen belt (3) in alternator adjusting arm (4).
c.
Slide alternator (5) towards water pump assembly (6).
d.
Remove alternator belt (7) from pulley on alternator (5), water pump assembly
pulley (8), and crankshaft pulley (9).
e.
Slip alternator belt (7) over fan (10) and remove.
2.21.13.3 Installation.
a.
Place alternator belt (7) over fan (10).
b.
Place alternator belt (7) on crankshaft pulley (9), water pump assembly pulley
(8), and pulley on alternator (5).
c.
Adjust alternator belt (7) tension.
2-293
TM 10-4320-344-24
2.21.14 Alternator Cover Maintenance, Model US636HCCD-1.
This task covers:
2.21.14.1 Removal
2.21.14.2 Disassembly
2.21.14.3 Repair
2.21.14.4 Assembly
2.21.14.5 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
V-Belt Guard removed, paragraph 2.21.11.
Materials/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-303-24P)
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Conditions
(Continued)
General Safety I n s t r u c t i o n s
Do not work on equipment with battery
connected. Electrocution hazard is present
with battery connected.
Do not work on equipment without following standard shop safety practices.
Battery Cables disconnected, paragraph
2.15.4.
2.21.14.1 Removal.
a.
Remove three mounting screws (Figure 2-128,
1) and flat washers (2).
When removing alternator cover from mounting bracket do not allow alternator
c o v e r t o r e s t o n a l t e r n a t o r w i r e s . Ensure alternator wires are not caught on
a l t e r n a t o r c o v e r . Failure to obey this caution may result in damage to
equipment.
b.
Pull alternator cover (3) away from retainer bracket (4).
c.
Tag and disconnect three alternator wires (5) and remove alternator wires (5)
from alternator cover (3).
2.21.14.2 Disassembly.
a.
Remove grommet (6) from alternator cover (3).
b.
Remove three nuts (7) and resilient mounts (8).
c.
Remove two nuts (9), lock washers (10), one spacer (11), two screws (12), and
retainer bracket (4). Discard lock washers (10).
2.21.14.3 Repair.
a.
Inspect
b.
Replace all defective components.
a l l components and mounting hardware for damage.
2.21.14.3 Assembly.
a.
2-294
P o s i t i o n r e t a i n e r b r a c k e t (4) on engine and secure with two screws (12), one
spacer (11), two new lock washers (10), and nuts (9).
TM 10-4320-344-24
Figure 2-128.
Alternator Cover Maintenance, Model US636HCCD-1.
b.
Install three resilient mounts (8) and secure with three nuts (7).
c.
Install grommet (6) in alternator cover (3).
2.21.14.5 Installation.
When installing alternator cover on retainer bracket do not allow alternator
c o v e r t o r e s t o n a l t e r n a t o r w i r e s . Ensure alternator wires are not caught on
a l t e r n a t o r c o v e r . Failure to obey this caution may result in damage to
equipment.
a.
Insert three alternator wires (5) through grommet (6) in alternator cover (3).
R e f e r t o t a g s a n d c o n n e c t a l t e r n a t o r w i r e s ( 5 ) . Remove and discard tags.
b.
Position alternator cover (3) against resilient mounts (8) and secure with
three flat washers (2) and screws (1).
2-295
TM 10-4320-344-24
2.21.15 Generator Capacitor Replacement, Model 609-C.
This task covers:
2.21.15.1 Removal
2.21.15.2
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
V-Belt Guard removed, paragraph 2.12.15.
General Safetv I n s t r u c t i o n s
Materials/Parts
Lock Washers (TM 10-4320-303-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Battery disconnected, paragraph 2.15.3
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following standard shop safety practices.
2.21.15.1 Removal,
a.
Open left side engine access door (Figure 2-129, 1) on pumping assembly (2).
Do not work on equipment with battery connected.
Electrocution hazard is
p r e s e n t i f b a t t e r y i s c o n n e c t e d . Failure to obey this warning may result in
serious personal injury or death.
b.
Remove two nuts (3), lock washers (4), a n d g e n e r a t o r c a p a c i t o r ( 5 ) f r o m
a l t e r n a t o r ( 6 ) . Discard lock washers (4).
2.21.15.2
Installation.
a.
Mount generator capacitor (5) on alternator (6) and secure with two new lock
washers (4) and nuts (3).
b.
Close left side engine access door (1) on pumping assembly (2).
2-296
TM 10-4320-344-24
Figure 2-129.
Generator Capacitor Replacement, Model 609-C.
2-297
TM 10-4320-344-24
2.21.16 Alternator Maintenance.
This task covers:
2.21.16.1 Testing
2.21.16.2 Removal
2.21.16.3 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Alternator Belt removed, for replacement
only, paragraph 2.21.13.
Multimeter,
Item 2
Appendix B, Section III,
Alternator Cover removed, paragraph 2.21.14
(US636HCCD-1).
General Safety Instructions
Materials/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-303-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment with battery
connected. Electrocution hazard is present
Pumping station shut down, T N 1 0 - 4 3 2 0 - w i t h b a t t e r y c o n n e c t e d .
344-10.
Do not work on equipment without following standard shop safety practices.
Battery disconnected, paragraph 2.15.2
(609-A), paragraph 2.15.3 (609-C), and
paragraph 2.15.4 (US636HCCD-1).
Equipment Conditions
2.21.16.1 Testing.
Figure 2-130.
2-298
Alternator Test (Model 609-A Shown).
TM 10-4320-344-24
NOTE
This testing procedure applies to Model 609-A.
The testing procedure for
Model US636HCCD-1 is identical.
To read alternator output voltage for Model
609-c read voltmeter on control panel.
a.
Connect multimeter to alternator ground terminal (Figure 2-130, 1) and
positive output terminal (2). Set multimeter for voltage test.
To prevent electrical shock, use caution when testing voltage output.
b.
Refer to TM 10-4320-344-10 and start engine.
1,000 rpm.
Run pumping assembly at about
NOTE
The voltage value to check for on Model US636HCCD-1 is 12 to 14.8 volts. The
voltage value to check for on Model 609-C is approximately 28 volts.
c.
If voltage is not between 13.8 and 14.8 volts, replace alternator (3).
d.
Refer to TM 10-4320-344-10 and stop engine.
NOTE
The removal, inspection, and installation procedures apply to Model 609-A.
The removal, inspection, and installation procedures for Models 609-C and
US636HCCD-1 are similar.
2.21.16.2 Removal.
Figure 2-131. Alternator Replacement (Model 609-A Shown).
a.
Loosen nut (Figure 2-131, 1) and screw (2) on alternator mounting bracket (3).
2-299
TM 10-4320-344-24
2.21.16 Alternator Maintenance. (Continued)
b.
Remove screw (4), lock washer (5), and flat washer (6) from adiusting arm (7)
and swing alternator (8) out from engine. Discard lock washer (5).
c.
Remove nut (9), washer (10), and tag and remove wire (11) from alternator (8).
d.
Unclip diode connector (12).
To prevent alternator damage, be sure to support it while removing bolt.
e.
Remove nut (1), lock washer (13), s c r e w ( 2 ) , a n d a l t e r n a t o r ( 8 ) f r o m
alternator mounting bracket (3). Discard lock washer (13).
2.21.16.4 Installation.
NOTE
Hand-tighten nut to allow for alternator belt adjustment.
a.
Position alternator (8) in mounting bracket (3) and secure with screw (2), new
lock washer (13), and nut (1).
b.
Connect diode connector (12).
c.
Refer to tag, Install wire (11) on alternator (8) and secure with washer (10)
a n d n u t ( 9 ) . Remove and discard tag.
NOTE
Hand-tighten bolt to allow for alternator belt adjustment.
d.
Swing alternator (8) towards engine and secure to alternator adjusting arm (7)
with flat washer (6), new lock washer (5), and screw (4).
e.
Adjust alternator belt.
2-300
TM 10-4320-344-24
2.21.17 Starter Rectifier Replacement, Models 609-A and 609-C.
This task covers:
2.21.17.1 Removal
2.21.17.2 Repair
2.21.17.3 Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Materials/Parts
Tags, Appendix C, Item 30
Lock Washers (TM 10-4320-303-24P)
Equipment
Conditions
Do not work on equipment with battery
c o n n e c t e d . Electrocution hazard is present if battery is connected.
Do not work on equipment without following standard shop safety practices.
Pumping station shut down, TM 10-4320-34410.
Battery disconnected, paragraph 2.15.2
(609-A) or 2.15.3 (609-C).
This procedure applies to Model 609-A.
similar.
The procedure for Model 609-C is
2.21.17.1 Removal.
a.
Remove nut (Figure 2-132, 1), lock washer (2), screw (3), and tag and remove
lead (4) from rectifier (5). Discard lock washer (2).
b.
Remove nut (6), lock washer (7), and tag and remove lead (4) from solenoid
(8).
Discard lock washer (7).
c.
Remove nut (9), lock washer (10), a n d r e c t i f i e r ( 5 ) f r o m z e e b r a c k e t ( 1 1 ) .
Discard lock washer (10).
d.
Remove bolt (12) and zee bracket (11) from starter (13).
2.21.17.2 Repair.
a.
Inspect lead (4) for damaged, burned, or missing insulation or terminals.
b.
Inspect rectifier (5) for burns or damage.
c.
Inspect all mounting hardware for damage.
d.
Replace all defective components.
2.21.17.3 Installation.
a.
Position zee bracket (11) on starter (13) and secure with new lock washer (13)
and bolt (12).
b.
Insert rectifier (5) in zee bracket (11) and secure with new lock washer (10)
and nut (9).
c.
Refer to tags and attach lead (4) to solenoid (8) and secure with new lock
washer (7) and nut (6).
Remove and discard tag.
2-301
TM 10-4320-344-24
2.21.17 Starter Rectifier Replacement. Models 609-A and 609-C. (Continued)
Figure 2-132.
d.
2-302
Starter Rectifier Replacement, Models 609-A and 609-C.
Attach lead (4) to rectifier (5) and secure with screw (3), new lock washer,
( 2 ) , a n d n u t ( 1 ) . Remove and discard tag.
TM 10-4320-344-24
2.21.18 Starter Assembly Replacement.
This task covers:
2.21.18.1 Removal
2.21.18.2
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Negative Power Cable Assembly disconnected
from starter, paragraph 2.15.6 (609-C).
INITIAL SETUP
(Continued)
General Safety Instructions
Materials/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-303-24P)
Equipment
Conditions
Pumping station shut down, TM 104320-344-10.
Battery disconnected, paragraph
2.15.2 (609-A), paragraph 2.15.3
(609-C) and paragraph 2.15.4
(US636HCCD-1).
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment with battery
Electrocution hazard is preconnected.
sent if battery is connected.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1.
and 609-C are similar.
The procedures for Models 609-A
2.21.18.1 Removal.
a.
Remove two nuts (Figure 2-133, 1), lock washers (2), and tag and remove
b a t t e r y c a b l e ( 3 ) a n d l e a d ( 4 ) . Discard lock washers (2).
b.
Remove screw (5) and tag and remove lead (6).
Do not let starter assembly fall when removing.
result.
c.
Damage to equipment may
Remove three bolts (7), lock washers (8), and starter (9) from engine.
Discard lock washers (8).
2.21.18.2
Installation.
a.
P o s i t i o n starter (9) on engine and secure with three new lock washers (8) and
bolts (7).
b.
Refer to tag, install lead (6) and secure with screw (5).
tag.
c.
Refer to tags, install lead (4) and battery cable (3) securing with new lock
washers 2 ) a n d n u t s ( 1 ) . Remove and discard tags.
Remove and discard
2-303
TM 10-4320-344-24
2.21.18 Starter Assembly Replacement. (Continued)
Figure 2-133.
2-304
Starter Replacement.
TM 10-4320-344-24
2.21.19 V-Belt Contact Switch Maintenance, Models 609-C and US636HCCD-1.
This task covers:
2.21.19.1 Testing
2.21.19.2 Removal
2.21.19.3 Repair
2.21.19.4 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
V-Belt Guard and Mounting Stud removed,
paragraph 2.21.11 (US636HCCD-1).
Multimeter, Appendix B, Section III,
Item 2
Materials/Parts
Loop Clamp (TM 10-4320-303-24P)
Equipment
Conditions
Pumping station shut down, TM 104320-344-10.
Conditions
(Continued)
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment with battery
c o n n e c t e d . Electrocution hazard is present if battery is connected.
Do not work on equipment without following standard shop safety practices.
Battery disconnected, paragraph
2.15.3 (609-C) and paragraph 2.15.4
(US636HCCD-1).
2.21.19.1 Testing.
To prevent electrical shock, use caution when performing this test.
NOTE
Ensure V-belts are in proper position.
a.
Disconnect connector (Figure 2-134, 1) from V-belt contact switch (2).
NOTE
Pin numbers are l o c a t e d i n c o n n e c t o r .
Correct reading is
b.
T e s t r e s i s t a n c e f r o m p i n 1 t o p i n 2 and pin 1 to pin 4.
infinity.
c.
Test resistance from pin 2 to pin 4.
d.
Push in and hold contact button (3) on V-belt contact switch (2).
e.
Test resistance from pin 2 to pin 1 and pin 2 to pin 4.
f.
Test resistance from pin 1 to pin 4.
g.
Release contact button (3).
h.
Replace defective V-belt contact switch (2).
i.
Connect connector (1) to V-belt contact switch (2).
Correct reading is 0.
Correct reading is 0.
Correct reading is infinity.
2-305
TM 10-4320-344-24
2.21.19 V-Belt Contact Switch Maintenance. Models 609-C and US636HCCD-l.
(Continued)
2.21.19.2 Removal.
Figure 2-134.
V-Belt Contact Switch Maintenance.
a.
Disconnect connector (1) from V-belt contact switch (2).
b.
Remove nut (4) and V-belt contact switch (2) from retainer bracket (5).
c.
Remove loop clamp (6).
d.
Disconnect connector (7) and remove wiring harness (8).
e.
Remove screw (9) and retainer bracket (5).
Discard loop clamp (6).
2.21.19.3 Repair.
a.
Inspect retainer bracket (5), wiring harness (8), and all mounting hardware
for damage.
b.
Replace all defective components.
2.21.19.4 Installation.
a.
Position retainer bracket (5) against engine and secure with screw (9).
b.
Connect wiring harness (8) to engine wiring harness with connector (7).
2-306
TM 10-4320-344-24
c.
Secure wiring harness (8) to front stay plate (10) with new loop clamp (6).
d.
Insert V-belt contact switch (2) into retainer bracket (5) and secure with
nut (4).
e.
Connect connector (1) to V-belt contact switch (2).
.
2-307
TM 10-4320-344-24
2.21.20 Engine Switch and Transmitter Replacement, Model 609-C.
This task covers:
2.21.20.1 Removal
2.21.20.2 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.3.
Materials/Parts
Tags, Appendix C, Item 31
Equipment Conditions
Pumping station shut down, TM 104320-344-10.
Cowling removed, TM 10-4320-344-10.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment with battery
c o n n e c t e d . Electrocution hazard is present if battery is connected.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to the engine temperature switch.
The procedures for the
o i l p r e s s u r e s w i t c h , engine temperature transmitter, and oil temperature
transmitter are similar.
2.21.20.1 Removal.
Figure 2-135.
2-308
Engine Switch and Transmitter Replacement, Model 609-C.
TM 10-4320-344-24
a.
Tag, disconnect, and remove wiring harness (Figure 2-135, 1) from engine
temperature switch (2).
b.
Remove engine temperature switch (2) from number 2 cylinder (3).
2.21.20.2 Installation.
a.
Install engine temperature switch (2) into number 2 cylinder (3).
b.
Refer to tag and connect wiring harness (1) to engine temperature switch (2).
Remove and discard tag.
2-309
TM 10-4320-344-24
2.21.21 Exhaust Pipe Elbow Assembly Maintenance, Model 609-A.
This task covers:
2.21.21.1 Disassembly
2.21.21.2 Repair
2.21.21.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Hood Assembly removed, paragraph 2.19.1.
Material/Parts
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Equipment
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Conditions
Pumping station shut down, TM 10-4320344-10.
2.21.21.1 Disassembly.
Figure 2-136.
2-310
Exhaust Elbow Pipe Assembly Maintenance, Model 609-A.
TM 10-4320-344-24
To prevent burns or other injury, allow exhaust pipe elbow assembly to cool
b e f o r e r e m o v a l . Failure to obey this warning may result in serious personal
injury.
a.
Remove two screws (Figure 2-136, 1), lock washers (2), spacers (3), and
m a n i f o l d n u t s ( 4 ) . Discard lock washers (2).
b.
Remove two screws (5), flat washers (6), and exhaust pipe support (7).
c.
Remove four nuts (8), l o c k w a s h e r s ( 9 ) , b o l t s ( 1 0 ) , e x h a u s t p i p e e l b o w ( 1 1 ) ,
g a s k e t ( 1 2 ) , a n d c o m p a n i o n f l a n g e ( 1 3 ) . Discard lock washers (9) and
gasket (12).
d.
Remove two bolts (14), lock washers (15), and flat washers (16) and exhaust
pipe mounting plate (17). Discard lock washers (15).
2.21.21.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.21.3 Assembly.
a.
Position exhaust pipe mounting plate (17) on turbocharger adapter flange (18)
and secure with two flat washers (16), new lock washers (15), and bolts (14).
b.
I n s t a l l c o m p a n i o n f l a n g e ( 1 3 ) , n e w g a s k e t ( 1 2 ) , exhaust pipe (11) and secure
with four bolts (10), new lock washers (9), and nuts (8).
c.
Position exhaust pipe support (7) against exhaust pipe elbow (11) and secure
with two flat washers (6) and screws (5).
d.
Secure lower portion of exhaust pipe support (7) with two manifold nuts (4),
spacers (3), new lock washers (2), and screws (1).
2-311
TM 10-4320-344-24
2.21.22 Air Intake Pipe Assembly Maintenance. Model 609-A.
This task covers:
2.21.22.1 Disassembly
2.21.22.2 Repair
2.21.22.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Hood Assembly removed, paragraph 2.19.1.
Material/Parts
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Equipment
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Conditions
Pumping station shut down, TM 10-4320344-10.
2.21.22.1 Disassembly.
Figure 2-137.
Air Intake Tube Assembly, Model 609-A.
a.
Loosen hose clamp (Figure 2-137, 1), remove air intake pipe (2) from rubber
elbow (3), and remove hose clamp (1).
b.
Loosen hose clamp (4) and remove rubber elbow (3) from turbine housing (5) and
hose clamp (4).
c.
Loosen hose clamp (6) that secures hose (7) to turbine housing (5) and air
i n t a k e t u b e ( 8 ) . Remove hose (7) and two hose clamps (6).
d.
Remove two screws (9), lock washers (10), air intake tube (8), and
g a s k e t ( 1 1 ) . Discard lock washers (10) and gasket (11).
2-312
TM 10-4320-344-24
2.21.22.2 Repair.
a.
Inspect
a l l components and mounting hardware for damage.
b.
Replace all defective components.
2.21.22.3 Assembly.
a.
I n s t a l l n e w gasket (11) and air intake tube (8) on intake manifold (12) and
secure with two new lock washers (10) and screws (9).
b.
Install hose (7) and secure to air intake tube (8) and turbine housing (5)
with two hose clamps (6).
c.
I n s t a l l r u b b e r e l b o w ( 3 ) o n t u r b i n e h o u s i n g (5) and secure with hose clamp
(4).
d.
I n s t a l l a i r i n t a k e p i p e ( 2 ) i n r u b b e r e l b o w (3) and secure with hose clamp
(1).
2-313
TM 10-4320-344-24
2.21.23 Oil Inlet Tube Assembly Replacesment.
This task covers:
2.21.23.1 Removal
2.21.23.2 Repair
2.21.23.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Engine Oil drained, LO 10-4320-344-12.
Material/Parts
Hood Assembly removed, paragraph 2.19.1
(609-A).
General Safety I n s t r u c t i o n s
Rags, Appendix C, Item 20
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1. The procedures for Models 609-A
and 609-C are similar.
2.20.34.1 Removal.
a.
Unfasten,
b.
Remove two nuts (Figure 2-138, 1), lock washers ( 2 ) , f o u r f l a t w a s h e r s ( 3 ) ,
two mounting screws (4), and two tube retaining c l a m p s ( 5 ) . Discard lock
washers (2).
c.
Disconnect hose (6) from elbow (7) on oil filter assembly (8).
d.
Remove elbow (7), pipe reducing bushing (9), two flat washers (10), and oil
inlet tube (11) from oil filter assembly (8).
e.
Remove two mounting bolts (12), lock washers (13), o i l i n l e t t u b e ( 1 1 ) a n d
g a s k e t ( 1 4 ) . Discard lock washers (13) and gasket (14).
open, and remove upper air cowling.
2.21.23.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.23.3
Installation.
M a k e s u r e g a s k e t i s c o r r e c t l y a l i g n e d f o r p r o p e r s e a l . An improperly sealed
gasket could result in oil leakage and damage to turbocharger.
a.
Install new gasket (14) on turbocharger mounting flange (15) and secure with
two new lock washers (13) and mounting bolts (12).
b.
Align banjo end of oil inlet tube (11) with oil filter assembly (8) and secure
with two flat washers (10) and pipe reducing bushing (9).
2-314
TM 10-4320-344-24
Figure 2-138.
Oil Inlet Tube Assembly Raplacement.
c.
Install elbow (7) and hose (6) on pipe reducing bushing (9).
d.
Position two retaining clamps (5) over oil inlet tube (11) and secure with two
mounting screws ( 4 ) , f o u r f l a t w a s h e r s ( 3 ) , t w o n e w l o c k w a s h e r s ( 2 ) , a n d
nuts (1).
e.
Install upper air cowling.
2-315
TM 10-4320-344-24
2.21.24 Oil Drain Tube Assembly Maintenance.
This task covers:
2.21.24.1 Disassembly
2.21.24.2 Repair
2.21.24.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Hood Assembly removed, paragraph 2.19.1
(609-A).
Material/Parts
V-belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Preformed Packing (TM 10-4320-344-24P)
General Safetv I n s t r u c t i o n s
Equipment Conditions
Do not work on equipment without following standard shop safety practices.
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Pumping station shut down, TM 10-4320344-10.
NOTE
This procedure applies to Model US636HCCD-1.
and 609-C are similar.
The procedures for Models 609-A
2.21.24.1 Removal.
a.
Remove two mounting screws (Figure 2-139, 1) and lock washers (2) that secure
o i l d r a i n t u b e ( 3 ) t o t u r b o c h a r g e r ( 4 ) . Discard lock washers (2).
b.
Loosen two hose clamps (5) and remove oil drain tube (3), gasket (6), hose
(7), and two hose clamps (5). Discard gasket (6).
NOTE
Mounting bolts are three different lengths.
e.
Tag bolts when removing them.
Remove three bolts (8), lock washer (9), two flat washers (10), spacer (11),
v e n t c o v e r ( 1 2 ) , and preformed packing (13). Discard lock washer (9) and
preformed packing (13).
2.21.24.2 Repair.
a.
I n s p e c t a l l components and mounting hardware for damage.
b.
Replace all defective components.
2.21.24.3 Assembly.
NOTE
Mounting bolts are three different lengths.
Refer to tags when installing bolts.
a.
Install new preformed packing (13) and vent cover (12) on enqine (14) and
s e c u r e w i t h o n e s p a c e r - (ll), two flat washers (10), new lock washer (9), and
three bolts (8).
b.
Install hose (7) on vent cover (12) and secure with hose clamp (5).
2-316
TM 10-4320-344-24
Figure 2-139.
c.
Oil Drain Tube Assembly Replacemmt.
Install oil drain tube (3) in hose (7) and secure with hose clamp (5).
M a k e s u r e g a s k e t i s c o r r e c t l y a l i g n e d f o r p r o p e r s e a l . An improperly sealed
gasket could result in oil leakage and damage to turbocharger.
d.
Install new gasket (6) on flange of oil drain tube (3) and secure oil drain
tube (3) to turbocharger (4) with two new lock washers (2) and screws (1).
e.
Refer to LO 10-4320-344-12 and add engine oil.
f.
Refer to TM 10-4320-344-10 start engine, check for leaks, and stop engine.
g.
Refer to LO 10-4320-344-12 and add engine oil as required.
2-317
TM 10-4320-344-24
2.21.25 0i1 Bypass Line Rpair, Model US636HCCD-1.
This task covers:
2.21.25.1 Removal
2.21.25.2 Repair
2.21.25.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Oil drained, LO 10-4320-344-12.
Material/Parts
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
General Safetv I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Pumping station shut down, TM 10-4320344-10.
2.21.25.1 Removal.
To prevent burns or other injuries allow oil bypass line, oil cooler, and
e n g i n e t o c o o l b e f o r e r e m o v i n g o i l b y p a s s l i n e . Failure to obey this warning
may result in serious personal injury.
a.
Unfasten,
b.
Remove nut (Figure 2-140, 1), lock washer (2), bolt (3), pipe clamp halves (4
and 5), bolt (6), lock washer (7), and spacer (8). Discard lock washers (2
and 7).
c.
Loosen two retaining nuts (9) and remove oil bypass line (10).
open and remove upper air cowling.
2.21.25.2 Repair.
a.
Inspect all mounting hardware for damage.
b.
Replace all defective components.
2.21.25.3
Installation.
a.
Install oil bypass line (10) in engine (11) and secure with two retaining nuts
(9).
b.
Install spacer (8) and two pipe clamp halves (4 and 5)
and secure-with new
l o c k w a s h e r ( 7 ) , b o l t s ( 3 a n d 6 ) , and new lock washer (2) and nut (1).
c.
Install upper air cowling.
2-318
TM 10-4320-344-24
Figure 2-140.
Oi1 Bypass Line Replacement, Model US636HCCD-1.
2-319
TM 10-4320-344-24
2.21.26 Oil Filter and Base Assembly Replacement. Mel 609-A.
This task covers:
2.21.26.1 Removal
2.21.26.2 Repair
2.21.26.3 Installation
INITIAL SETUP
Tools
Material/Parts (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Oil Filter (TM 10-4320-344-24P)
Goggles, Appendix B, Section III,
Item 2
Pumping station shut down, TM 10-4320-34410.
Gun, Air Blow, Appendix B, Section
I I I , Item 2
Oil Filter Inlet and Outlet Lines removed,
paragraph 2.21.2.
Torque Wrench, Appendix B, Section
III, Item 2
General Safety I n s t r u c t i o n s
Material/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Oil, Appendix C. Item 15
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Do not work on equipment without following standard shop safety practices.
2.21.26.1 Removal.
Figure 2-141.
2-320
0il Filter and Base Assembly Maintenance, Model 609-A.
TM 10-4320-344-24
To prevent burns or other injuries allow oil filter and base assembly to cool
Failure to obey this warning may result in serious
before removing them.
personal injury.
a.
Place pan under oil filter (Figure 2-141, 1).
b.
Remove and discard oil filter (1).
c.
Remove two nuts (2), lock washers (3), screws (4), and fluid filter head (5)
f r o m a n g l e b r a c k e t ( 6 ) . Discard lock washers (3).
d.
Remove stud (7) from fluid filter head (5).
f.
Remove two screws (8), lock washers (9), angle bracket (6), and two mounting
spacers (10). Discard lock washers (9).
2.21.26.2 Repair.
a.
Clean all fittings and components with clean cloth.
To prevent the possibility of embedding foreign objects in the eyes, safety
goggles must be worn when using compressed air.
b.
Induce 25-35 psi (172.2-241.09 kPa) of air into lines to clear any foreign
matter.
c.
Inspect all components and mounting hardware for damage.
d.
Replace all defective components.
2.21.26.3 Installation.
a.
Install angle bracket (6) and two mounting spacers (10) on intake manifold
flange and secure with two new lock washers (9) and screws (8).
Torque screws
(8) to 20 ft-lbs (27 N•m).
b.
Install stud (7) in fluid filter head (5).
c.
Position fluid filter head (5) on angle bracket (6) and secure with two
s c r e w s ( 4 ) , new lock washers (3), and nuts (2).
d.
Lightly coat gasket on new oil filter (1) w i t h e n g i n e o i l a n d i n s t a l l o i l
filter (1) on fluid filter head (5).
e.
Refer to LO 10-4320-344-12 and add engine o i l .
f.
Refer to TM 10-4320-344-10, start engine,
engine.
g.
Refer to LO 10-4320-344-12 check and add engine oil as required.
h.
Remove pan from under oil filter (1) and properly dispose of oil in accordance
with standing operating procedure.
check for oil leaks, and stop
2-321
TM 10-4320-344-24
2.21.27 Oil Filter and Base Assembly Replacement, Models 609-C and US636HCCD-1.
This task covers:
2 .21.27.1 Removal
2.21.27.2 Repair
2.21.27.3 Installation
INITIAL SETUP
Tools
Equiment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Oil drained, LO 10-4320-344-12.
Oil Temperature Transmitter removed, paragraph 2.21.20 (609-C).
Goggles, Appendix B, Section III,
Item 2
Oil Inlet Tube Assembly disconnected,
paragraph 2.21.23.
Material/Parts
General Safetv I n s t r u c t i o n s
Oil, Appendix C, Item 15
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Oil Filter (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
NOTE
This procedure applies to Model 609-C.
similar.
The procedure for Model US636HCCD-1 is
2.21.27.1 Removal.
To prevent burns or other injuries allow oil filter and base assembly to cool
before removing them.
Failure to obey this warning may result in serious
personal injury.
a.
Place pan under oil filter (Figure 2-142, 1).
b.
Remove and discard oil filter (1).
c.
R e m o v e t w o b o l t s ( 2 ) , l o c k w a s h e r s ( 3 ) , support (4), two gaskets (5), and
adapter (6). Discard lock washers (3) and gaskets (5).
d.
Remove plug (7) and flat washer (8).
Discard flat washer (8).
2.21.27.2 Repair.
a.
2-322
Clean all fittings and components with clean cloth.
TM 10-4320-344-24
Figure 2-142. Oil Filter and Base Assembly Replacement, Models 609-C and
US636HCCD-1.
To prevent the possibility of embedding foreign objects in the eyes, saftey
goggles must be worn when using compressed air.
b.
Induce 25-35 psi (172.2-241.09 kPa) of air into lines to clear any foreign
matter.
c.
Inspect all components and mounting hardware for damage.
d.
Replace all defective components.
2-323
TM 10-4320-344-24
2.21.27 Oil Filter and Base Assembly Replacement, Models 609-C and US636HCCD-1. (Continued)
2.21.27.3 Installation.
a.
Install new flat washer (8) and plug (7) on support (4).
b.
P o s i t i o n a d a p t e r ( 6 ) , t w o n e w g a s k e t s ( 5 ) , and support (4) against engine (9)
and secure with two new lock washers (3) and bolts (2).
c.
Lightly coat gasket on new oil filter (1) with engine oil and install oil
filter (1) on support (4).
d.
Refer to LO 10-4320-344-12 and add engine oil.
e.
Refer to
engine.
f.
Refer to LO 10-4320-344-12 check and add engine oil as required.
g.
Remove pan from under oil filter (1) and properly dispose of oil in accordance
with standing operating procedures.
2-324
TM
10-4320-344-10, start engine, check for oil leaks, and stop
TM 10-4320-344-24
2.21.28 Oil Cooler Replacement, Model 609-A.
This task covers:
2 .21.28.1 Removal
2.21.28.2 Repair
2.21.28.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Oil Cooler Inlet Hose and Oil Cooler
Outlet Hose disconnected, paragraph
2.20.2.
Material/Parts
Oil Cooler Inlet and Outlet Lines
disconnected, paragraph 2.21.2.
INITIAL SETUP
Antifreeze, Appendix C, Item 3
O i l , Appendix C, Item 15
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
(Continued)
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.21.28.1 Removal.
Figure 2-143.
Oil Cooler Replacement, Model 609-A.
2-325
TM 10-4320-344-24
2.21.28 Oil Cooler Replacement, Model 609-A. (Continued)
To prevent burns or other injuries allow oil lines, oil, engine coolant, and
e n g i n e t o c o o l b e f o r e r e m o v i n g o i l c o o l e r . Failure to obey this warning may
result in serious personal injury.
a.
Remove four nuts (Figure 2-143, 1), lock washers (2), screws (3), two clamps
( 4 ) , a n d o i l c o o l e r ( 5 ) . Discard lock washers (2).
b.
R e m o v e t w o s c r e w s ( 6 ) , l o c k w a s h e r s ( 7 ) , s p a c e r ( 8 ) , and mounting bracket (9).
Discard lock washers (7).
2.21.28.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.28.2 Installation.
a.
Position spacer (8) and mounting bracket (9) against engine and secure with
two new lock washers (7) and screws (6).
b.
Position oil cooler (5) and two clamps (4) on mounting bracket (9) and secure
with four screws (3), new lock washers (2), and nuts (1).
2-326
TM 10-4320-344-24
2.21.29 Oil Cooler Replacement, Model 609-C.
This task covers:
2.21.29.1 Removal
2.21.29.2 Repair
2.21.29.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Oil drained, LO 10-4320-344-12.
INITIAL SETUP
Material/Parts
Oil, Appendix C, Item 15
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Gasket (TM 10-4320-344-24P)
Equipment
(Continued)
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment w i t h o u t f o l l o w ing standard shop safety p r a c t i c e s .
Conditions
Pumping station shut down, TM 10-4320344-10.
2.21.29.1 Removal.
To prevent burns or other injuries a l l o w o i l l i n e s , o i l , e n g i n e c o o l a n t , a n d
Failure to obey this warning may
engine to cool before removing oil c o o l e r .
result in serious personal injury.
a.
Place pan under oil cooler (Figure 2-144, 1).
b.
Unfasten, open, and remove upper air cowling.
c.
Remove two mounting bolts (2) and four flat washers (3).
d.
Remove three bolts (4) and flat washers (5).
e.
Disconnect oil cooler (1) at two fittings (6) and remove oil cooler (1) and
gasket (7). Discard gasket (7).
2.21.29.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.29.3 Installation.
a.
Position new gasket (7) and oil cooler (1) on engine and secure with two
fittings (6).
b.
Install three flat washers (5) and bolts (4).
c.
Install four flat washers (3) and two mounting bolts (2).
d.
Refer to LO 10-4320-344-12 and add engine oil.
2-327
TM 10-4320-344-24
2.21.29
0il Cooler Replacement. Model 609-C. (Continued)
Figure 2-144. Oil Cooler Replacement, Model 609-C.
start engine, check for oil leaks, and stop
e.
Refer to TM 10-4320-344-10,
engine.
f.
Refer to LO 10-4320-344-12 check and add engine oil as required.
g.
Remove pan from under oil cooler (1) and properly dispose of oil in accordance
with standing operating procedures.
h.
Install upper air cowling.
2-328
TM 10-4320-344-24
2.21.30 Oil Cooler Replacement, Model US636HCCD-1.
This task covers:
2.21.30.1 Removal
2.21.30.2 Repair
2.21.30.3 Installation
INITIAL SETUP
(Continued)
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Oil drained, LO 10-4320-344-12.
Conditions
Oil filter and base assembly removed,
paragraph 2.21.27.
Material/Parts
General Safety I n s t r u c t i o n s
Oil, Appendix C, Item 15
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Gasket (TM 10-4320-344-24P)
Equipment
Conditions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Pumping station shut down, TM 10-4320344-10.
2.21.30.1 Removal.
To prevent burns or other injuries allow engine to cool before removing oil
c o o l e r . Failure to obey this warning may result in serious personal injury.
a.
Place pan under oil cooler (Figure 2 - 1 4 5 , 1 ) .
b.
Remove screw (2), flat washer (3), oil cooler (1), and gasket (4).
gasket (4).
Discard
2.21.30.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.30.3 Installation.
a.
Position new gasket (4) and oil cooler (1) on engine and secure with flat
washer (3) and screw (2).
b.
Refer to LO 10-4320-344-12 and add engine oil.
c.
Refer to TM 10-4320-344-10, start engine, check for oil leaks, and stop
engine.
d.
Refer to LO 10-4320-344-12 check and add engine oil as required.
e.
Remove pan from under oil cooler (1) and properly dispose of oil in accordance
with standing operating procedures.
2-329
TM 10-4320-344-24
2.21.30 Oil Cooler Replacement. Model US636HCCD-1. (Continued)
Figure 2-145.
2-330
Oil Cooler Replacement, Model US636HCCD-1.
TM 10-4320-344-24
2.21.31 Oil Breather Assembly Replacement, Models 609-C and US636HCCD-1.
This task covers:
2.21.31.1 Removal
2.21.31.2 Repair
2.21.31.3 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
V-belt contact switch cable disconnected,
paragraph 2.21.19
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Conditions
Pumping station shut down, TM 10-4320344-10.
Figure 2-146.
(Continued)
General Safety Instructions
Material/Parts
Equipment
Conditions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Oil Breather Assembly Replacement, Models 609-C and US636HCCD-1.
2-331
TM 10-4320-344-24
2.21.31 Oil Breather Assembly Replacement, Models 609-C and US636HCCD-1.
This procedure applies to Model US636HCCD-1.
is similar.
(Continued)
The procedure for Model 609-c
2.21.31.1 Removal.
a.
Remove bolt (Figure 2-146, 1), lock washer (2), hose retainer (3), and spacer
(4) from engine (5). Discard lock washer (2).
b.
Remove bolt (6), lock washer (7), flat washer (8), oil breather (9), and
r e t a i n e r b r a c k e t ( 1 0 ) f r o m e n g i n e ( 5 ) . Discard lock washer (7).
c.
Loosen hose clamp (11) and remove hose clamp (11) and hose (12) from oil
breather (9).
2.21.31.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.31.3 Installation.
a.
Install hose (12) on oil breather (9) and secure with hose clamp (11).
b.
Position retainer bracket (10) and oil breather (9) against engine (5) and
secure with flat washer (8), new lock washer (7), and bolt (6).
c.
Slide hose retainer (3) over hose (12), position against engine (5) and secure
with spacer (4), new lock washer (2), and bolt (1).
2-332
TM 10-4320-344-24
2.21.32 Oil Drain Assembly Replacement.
This task covers:
2.21.32.1 Disassembly
2.21.32.2 Repair
2.21.32.3
Assembly
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Oil drained, LO 10-4320-344-12.
Material/Parts
(Continued)
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Equipment
Conditions
Do not work on equipment without following standard shop safety practices.
Conditions
Pumping station shut down, TM 10-4320344-10.
This procedure applies to Model 609-C.
US636HCCD-1 are similar.
The procedures for Models 609-A and
2.21.32.1 Disassembly.
a.
Loosen two hose clamps (Figure 2-147, 1) and remove hose (2) and two hose
clamps (1).
b.
Remove banjo fitting (3) from oil pan (4).
c.
Remove male adapter (5) from trailer frame (6).
d.
Remove two screws (7),
trailer frame (6).
coupling (8), bead chain (9), and pipe plug (10) from
2.21.32.2 Repair.
a.
I n s p e c t a l l components and mounting hardware for damage.
b.
Replace all defective components.
2.21.32.3 Assembly.
a.
Secure bead chain (9) and c o u p l i n g ( 8 ) t o t r a i l e r f r a m e
with two screws (7).
b.
Install pipe plug (10) in trailer frame (6).
c.
Install male adapter (5) into trailer frame (6).
d.
Install banjo fitting (3) on oil pan (4).
e.
I n s t a l l h o s e ( 2 ) o n t o m a l e a d a p t e r ( 5 ) a n d b a n j o f i t t i n g (3) and secure with
two hose clamps (1).
6) and pipe plug (10)
2-333
TM 10-4320-344-24
2.21.32 0il Drain Assembly Replacement. (Continued)
Figure 2-147. 0il Drain Assembly Replacement.
2-334
TM 10-4320-344-24
2.21.33 Turbocharger Assembly Replacement, Model 609-A.
This task covers:
2.21.33.1 Removal
2.21.33.2 Repair
2.21.33.3 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Air Intake Pipe Assembly removed,
paragraph 2.21.22.
Material/Parts
Oil Inlet Tube Assembly disconnected,
paragraph 2.21.23.
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Oil Drain Tube Assembly disconnected,
paragraph 2.21.24.
Equipment
General Safety I n s t r u c t i o n s
Conditions
Pumping station shut down, TM 10-4320344-10.
Exhaust Pipe Elbow Assembly removed,
paragraph 2.21.21.
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.21.33.1 Removal.
Figure 2-148.
Turbocharger Assembly Replacement, Model 609-A.
2-335
TM 10-4320-344-24
2.21.33 Turbocharger Assembly Replacement. Model 609-A. (Continued)
Do not work on equipment that is not securely stabilized to prevent rolling
o r s l i d i n g . Ensure both wheels of equipment have chocks that are secure.
Failure to obey this warning may result in serious personal injury.
a.
Remove bolt (Figure 2-148, 1) and flat washer (2) that secures heat shield
mounting bracket (3) to flange on turbocharger assembly (4).
b.
Remove three bolts (5), flat washers (6), turbocharger (4), and gasket (7)
from exhaust manifold adapter (8). Discard gasket (7).
c.
Remove four nuts (9), lock washers (10), exhaust manifold adapter (8), and
g a s k e t ( 1 1 ) f r o m e x h a u s t m a n i f o l d ( 1 2 ) . Discard lock washers (10) and gasket
(11).
2.21.33.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.33.3 Installation.
a.
Install new gasket (11) and exhaust manifold adapter (8) on exhaust manifold
(12) and secure with four new lock washers (10) and nuts (9).
b.
Position new gasket (7) and turbocharger assembly (4) on exhaust manifold
adapter (8) and secure with three flat washers (6) and bolts (5).
c.
Position heat shield mounting bracket (3) on flange of turbocharger assembly
(4) and secure with flat washer (2) and bolt (1).
2-336
TM 10-4320-344-24
2.21.34 Turbocharger Assembly and Air Shield Maintenance. Models 609-C and US636HCCD-1.
This task covers:
2.21.34.1 Removal
2.21.34.3 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Air Intake Pipe Assembly removed,
paragraph 2.14.5 (US636HCCD-1).
Material/Parts
V-Belt Guard removed, paragraph
2.21.11 (US636HCCD-1).
Rags, Appendix C, Item 20
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Oil Inlet Tube Assembly disconnected from
turbocharger, paragraph 2.21.23.
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Oil Drain Tube Assembly disconnected from
turbocharger, paragraph 2.21.24.
General Safety I n s t r u c t i o n s
Left Side Engine Access Door open
(609-C).
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Exhaust Pipe Assembly removed, paragraph
2.13.4 (609-C).
Do not work on equipment without following standard shop safety practices.
Exhaust Pipe Assembly disconnected,
paragraph 2.13.4 (US636HCCD-1).
Air Hose disconnected, paragraph 2.14.4
(609-C).
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-C
2.21.34.1 Removal.
Engine and engine components may be hot.
Allow engine to cool prior to
p e r f o r m i n g maintenance.
Failure to obey this warning may result in serious
personal injury.
a.
Remove four nuts (Figure 2-149, 1 ) , l o c k w a s h e r s ( 2 ) , b o l t s ( 3 ) , a n d s h i e l d
(4) from turbocharger (5). Discard lock washers (2).
b.
R e m o v e f o u r s c r e w s ( 6 ) , l o c k w a s h e r s ( 7 ) , and two shield mounting brackets
(8).
Discard lock washers (7).
c.
Loosen two hose clamps (9) that secure intake manifold hose (10) to
turbocharger (5).
d.
Remove four screws (11), flat washers (12), gasket (13), and turbocharger (5)
from manifold (14). Discard gasket (13).
e.
Remove two hose clamps (9) and intake manifold hose (10) from intake manifold
(15).
2-337
TM 10-4320-344-24
2.21.34 Turbocharger Assembly and Air Shield Replacement, Models 609-C and US636HCCD-1. (Continued)
Figure 2-149.
Turbocharger Assembly and Air Shield Replacement, Models 609-C and
US636HCCD-1.
2.21.34.2 Repair.
a.
Inspect all components and mounting hardware for damage and presence of air in
air intake of turbocharger (5).
b.
Replace all defective components.
2.21.34.3 Installation.
a.
2-338
Install intake manifold hose (10) on intake manifold (15), slide two hose
clamps (9) over intake manifold hose (10) and hand-tighten.
TM 10-4320-344-24
b.
Insert turbocharger assembly (5) into intake manifold hose (10) and position
for installation to exhaust manifold (14).
c.
Install new gasket (13), four flat washers (12), and four bolts (11) securing
turbocharger (5) to exhaust manifold (14).
d.
Tighten two hose clamps (9).
e.
Position two shield mounting brackets (8) on turbocharger (5) and secure with
four new lock washers (7) and screws (6).
f.
Position shield (4) on shield mounting brackets (8) and secure with four bolts
(3), new lock washers (2), and nuts (1).
2-339
TM 10-4320-344-24
2.21.35 Air Outlet Frame Maintenance. Model 509-C.
This task covers:
2.21.35.1
Disassembly
2.21.35.2 Repair
2.21.35.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Left Side Engine Access Door open.
Turbocharger removed, paragraph 2.21.34.
Material/Parts
General Safety I n s t r u c t i o n s
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
2.21.35.1 Disassembly.
a.
Remove four bolts (Figure 2-150, 1), lock washers (2), flat washers (3), and
c o v e r p l a t e ( 4 ) . Discard lock washers (2).
b.
Remove two bolts (5), lock washers (6), six bolts (7), lock washers (8), and
t o p c o v e r ( 9 ) f r o m b o t t o m c o v e r ( 1 0 ) . Discard lock washers (6 and 8).
c.
Remove bolt (11), lock washer (12), end plate (13), and cover plate (14).
Discard lock washer (12).
d.
Remove six screws (15), t w e l v e f l a t w a s h e r s ( 1 6 ) , s i x s p a c e r s ( 1 7 ) , s i x f l a t
washers (18), and slide bottom cover (10) off exhaust manifold (19).
2.21.35.2 Repair.
a.
I n s p e c t a l l components and mounting hardware for damage.
b.
Replace all defective components.
2.21.35.3 Assembly.
a.
Slide bottom cover (10) over exhaust manifold (19) and secure with six flat
washers (18), spacers (17), twelve flat washers (16), and six screws (15).
b.
Position cover plate (14) and end plate (13) and secure with new lock washer
(12) and bolt (11).
c.
Position top cover (9) on bottom cover (10) and secure with six new lock
washers (8), bolts (7), two new lock washers (6), and bolts (5).
d.
Position cover plate (4) against bottom cover (10) and secure with four flat
washers (3), new lock washers (2), and bolts (1).
2-340
TM 10-4320-344-24
Figure 2-150.
Air Outlet Frame Replacement, Model 609-C.
2-341
TM 10-4320-344-24
2.21.36 Exhaust and Intake Manifold Maintenance, Model 609-A.
This task covers:
2.21.36.1 Removal
2.21.36.2 Repair
2.21.36.4 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Shield Assembly removed, paragraph
2.19.3.
(Exhaust)
Goggles, Appendix B, Section III, Item 2
Fuel Filter and Base Assembly removed,
paragraph 2.21.4 (Intake)
Torque Wrench, Appendix B, Section III,
Item 2
Air Intake Pipe Assembly removed,
paragraph 2.21.22 (Intake)
Material/Parts
Oil Filter and Base Assembly removed,
paragraph 2.21.26 (Intake).
Brush, Appendix C, Item 5
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Turbocharger Assembly removed, paragraph
2.21.33. (Exhaust)
General Safety I n s t r u c t i o n s
Equipment Conditions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
This procedure applies to the exhaust manifold.
manifold is similar.
The procedure for the intake
2.21.36.1 Removal. Remove ten nuts (Figure 2-151, 1), lock washers (2), exhaust
manifold (3), and six gaskets (4). Discard lock washers (2) and gaskets (4).
2.21.36.2 Repair.
a.
Clean exhaust manifold (3) with brush.
Do not use cleaning solvent without proper ventilation and clothing.
Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
b.
Using rag dampened in cleaning solvent clean all gasket mounting surfaces of
exhaust manifold (3) and cylinder head.
c.
Inspect all components and mounting hardware for damage.
d.
Replace all defective components.
2-342
TM 10-4320-344-24
Figure 2-151.
Manifold Maintenance (Exhaust Manifold Shown).
Begin tightening nuts from center of manifold and work outward.
20 ft-lbs (27 N•m) for intake and exhaust manifold.
Torque nuts
2.21.36.3 Installation. I n s t a l l s i x n e w g a s k e t s ( 4 ) , e x h a u s t m a n i f o l d ( 3 ) , t e n n e w
l o c k w a s h e r s ( 2 ) , a n d n u t s ( 1 ) . Tighten nuts (1) in progressive steps and torque to
prescribed limit.
2-343
TM 10-4320-344-24
2.21.37 Exhaust Manifold Pipes Maintenance, Models 609-C and US636HCCD-1.
This task covers:
2.21.37.1 Removal
2.21.37.2 Disassembly
2.21.37.3 Repair
2.21.37.4 Assembly
2.21.37.5 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Pumping station shut down, TM 10-4320344-10.
Goggles, Appendix B, Section III,
Item 2
Material/Parts
Brush, Appendix C, Item 5
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Conditions
(Continued)
Muffler removed, paragraph 2.12.2 (609-C)
and paragraph 2.12.3 (US636HCCD-1).
Exhaust Pipe Assembly removed, paragraph
2.12.4 (609-C) and 2.12.5 (US636HCCD-1).
Air Outlet Box removed, paragraph 2.20.48
(609-C).
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model US636HCCD-1.
similar.
The procedure for Model 609-c is
2.21.37.1 Removal.
Figure 2-152. Exhaunt Manifold Maintenance, Models 609-C and US636HCCD-1.
2-344
TM 10-4320-344-24
a.
Remove twelve nuts (Figure 2-152, 1 ) a n d f l a t w a s h e r s ( 2 ) t h a t s e c u r e f r o n t
(3) and back (4) exhaust manifolds to engine.
b.
Remove four bolts (5) and flat washers (6) that secure exhaust manifold pipe
assembly (3) to turbocharger (7).
2.21.37.2 Disassembly. Remove back manifold (4), f r o n t m a n i f o l d ( 3 ) , g a s k e t ( 8 ) ,
m a n i f o l d r i n g s ( 9 ) , a n d s i x g a s k e t s ( 1 0 ) . Discard gaskets (8 and 10) and manifold
rings (9).
2.21.37.3 Repair.
a.
Clean front (3) and back (4) manifolds with brush.
Do not
Do not use cleaning solvent without proper ventilation and clothing.
Dry cleaning solvent is
smoke or use near open flame or excessive heat.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
b.
Using rag dampened in cleaning solvent, clean all gasket mounting surfaces of
front (3) and back (4) manifolds and cylinder head.
c.
Inspect all components and mounting hardware for corrosion, cracks,
distortion, damaged threads, and other damage.
d.
Replace all defective components.
2.21.37.4 Assembly. Install two new manifold rings (9) on back manifold (4) and
install back manifold (4) in front manifold (3).
2.21.37.5 Installation.
a.
Install six new gaskets (10) on exhaust manifold pipe assembly mounting studs
and new gasket (8) on turbocharger (7).
b.
Install exhaust manifold pipe assembly on engine and secure to turbocharger
assembly (7) with four flat washers (6) and bolts (5).
c.
Secure exhaust manifold pipe assembly to engine with twelve flat washers (2)
and nuts (1).
2-345
TM 10-4320-344-24
2.21.38 Intake Manifold Maintenance. Models 609-C and US636HCCD-1.
This task covers:
2.21.38.1 Removal
2.21.38.2 Disassembly
2.21.38.2 Repair
2.21.38.4 Assembly
2.21.38.5 Installation
INITIAL SETUP
Too 1 S
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Pumping station shut down, TM 10-4320344-10.
Goggles, Appendix B, Section III,
Item 2
Material/Parts
Brush, Appendix C, Item 5
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Exhaust Manifold pipes removed, paragraph
2.21.37.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-c
2.21.38.1 Removal.
Figure 2-153. Intake Manifold Maintenance, Models 609-C and US636HCCD-1.
2-346
TM 10-4320-344-24
1) on intake manifold assembly (2).
a.
Loosen upper hose clamp (Figure 2-153,
b.
Remove twelve nuts (3), lock washers (4), intake manifold assembly (2), and
six gaskets (5). Discard lock washers (4) and gaskets (5).
2.21.38.2 Disassembly.
a.
Loosen two hose clamps (6) at center of intake manifold (2).
sections of intake manifold (2).
b.
Remove two hose clamps (6) and coupler sleeve (7).
Separate two
2.21.38.3 Repair.
Dust and dirt inside intake manifold indicates poor air cleaner operation.
a.
Inspect inside of two intake manifold sections (2) for dirt and dust.
b.
Clean two intake manifold sections (2) with brush.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
Dry cleaning solvent is
smoke or use near open flame or excessive heat.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
c.
Using rag dampened in cleaning solvent, clean all gasket mounting surfaces of
two intake manifold sections (2) and cylinder head.
d.
Inspect all components and mounting hardware for damage.
e.
Replace all defective components.
2.21.38.4 Assembly.
a.
Install coupler sleeve (7) on one section of intake manifold (2), slide two
h o s e c l a m p s ( 6 ) o v e r c o u p l e r s l e e v e ( 7 ) , and insert remaining intake
manifold (2) into coupler sleeve (7).
b.
Position and tighten two hose clamps (6) securing coupler sleeve (7) to two
sections of intake manifold (2).
2.21.38.5 Installation.
a.
Install six new gaskets (5) on engine with flat end of gaskets (5) facing up.
Make sure inlet end of manifold fits into hose on turbocharger.
b.
Install intake manifold assembly (2) on engine and secure with twelve new lock
washers (4) and nuts (3).
c.
Tighten upper hose clamp (1) securing intake manifold (2) to hose (8).
2-347
TM 10-4320-344-24
2.21.39 Cooling Air Blower Replacement, Models 609-C and US636HCCD-1.
This task covers:
2.21.39.1
Removal
2.21.39.2 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
V-belts removed, paragraph 2.21.12.
Equipment
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
General Safety I n s t r u c t i o n s
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
Bulkhead Panel Assembly removed,
paragraph 2.12.15.
V-belt Guard and Mounting Supports
removed, paragraph 2.21.11 (US636HCCD-1).
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-C
2.21.39.1 Removal
Figure 2-154.
a.
2-348
Cooling Air Blower Replacement, Models 609-C and US636HCCD-1.
Remove nut (Figure 2-154,
air blower (4).
1 ) , t w o f l a t w a s h e r s ( 2 ) , and screw (3) from cooling
TM 10-4320-344-24
b.
Remove three screws (5), flat washers (6), and cooling air blower (4).
2.21.39.2 Installation.
a.
Position cooling air blower (4) on engine and secure with three flat
washers (6) and screws (5).
b.
I n s t a l l s c r e w ( 3 ) , two flat washers (2) and nut (1).
2-349
TM 10-4320-344-24
2.21.40 Cowling Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
2.21.40.1 Disassembly
2.21.40.2 Repair
2.21.40.3 Assembly
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Oil Inlet Tube Assembly removed,
paragraph 2.21.23.
Material/Parts
Oil Bypass Line removed, paragraph
2.21.25 (US636HCCD-1).
Lock Washers (TM 10-4320-344-24P)
Equipment
Oil Cooler removed, paragraph 2.21.29
(609-C) or 2.21.30 (US636HCCD-1).
Conditions
Pumping station shut down, TM 10-4320344-10.
Bulkhead Panel Assembly removed,
paragraph 2.12.15.
Oil Breather Assembly removed, paragraph
2.21.31 (US636HCCD-1).
Air Outlet Frame removed, paragraph
2.21.35 (609-C).
General Safety I n s t r u c t i o n s
Battery disconnected, paragraph 2.15.3
(609-C) and paragraph 2.15.4
(US636HCCD-1).
Fuel Leakoff Return Line removed,
paragraph 2.21.7.
Fuel Injection Lines removed, paragraph
2.21.7.
V-Belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model US636HCCD-1.
similar.
The procedure for Model 609-C is
2.21.40.1 Disassembly.
a.
Unlatch, open and remove upper air cowling (Figure 2-155, 1).
b.
Remove lower air cowling (2) as follows:
(1) Remove five screws (3) and flat washers (4).
(2) Remove nut (5), lock washer (6), flat washer (7), bolt (8), and lower air
cowling (2) .
Discard lock washer (6).
c.
Remove three bolts (9), lock washers (10), flat washers (11), and rear stay
p l a t e ( 1 2 ) . Discard lock washers (10).
d.
Remove cowling guide rail (13) as follows:
(1) Remove twelve screws (14) and lock washers (15).
Discard lock washers (15).
(2) Remove nut (16), lock washer (17), two flat washers (18), and bolt (19), and
cowling guide rail (13) from front stay plate (20).
2-350
TM 10-4320-344-24
(3) Remove cowling mounting plate (13).
Figure 2-155. Cowling Assembly Maintenance, Models 609-C and US636HCCD-1.
Remove four bolts (21), lock washers (22), flat washers (23), and front stay
p l a t e ( 2 0 ) . Discard lock washers (22).
e.
Do not work on equipment with battery connected. Electrocution hazard is
present if battery is connected. Failure to obey this warning may result in
serious personal injury or death.
Note or mark location of wiring harness
mounting hardware.
f.
cable clamp when removing air shield
Remove four screws (24), lock washers (25), flat washers (26), and air shield
Discard lock washers (25).
(27).
2.21.40.2 Repair.
a.
I n s p e c t a l l components and mounting hardware for damage.
b.
Replace all defective components.
2-351
TM 10-4320-344-24
2.21.40 Cowling Assembly Maintenance, Models 609-C and US636HCCD-1.
(Continued)
2.21.40.3 Assembly.
Place engine wiring harness cable clamp in location marked during step f of
the disassembly procedure.
a.
Position rear air shield (27) against engine and secure with four flat washers
(26), new lock washers (25), and screws (24).
b.
Position front stay plate (20) against cylinder head and air shield (27) and
secure with four flat washers (23), new lock washers (22), and bolts (21).
c.
Install cowling guide rail (13) as follows:
(1) Position cowling guide rail (13) on cylinder heads and secure with
bolt (19), two flat washers (18), new lock washer (17), and nut (16).
(2) Install twelve new lock washers (15) and screws (14).
d.
Position rear stay plate (12) against cylinder head and secure with three flat
washers (11), new lock washers (10), and bolts (9).
e.
Install lower air cowling (2) as follows:
(1) Position lower air cowling (2) on crankcase and secure with bolt (8), flat
w a s h e r ( 7 ) , new lock washer (6), and nut (5).
(2) Install four flat washers (4) and screws (3).
f.
2-352
position upper air cowling (1) on cowling guide rail (13) and latch to lower
air cowling (2).
TM 10-4320-344-24
2.21.41 Thermostat Maintenance. Model 609-A.
This task covers:
2.21.41.1 Removal
2.21.41.2 Repair
2.21.41.3 Testing
2.21.41.4 Installation
INITIAL SETUP
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Pumping station shut down, TM 10-4320344-10.
Radiator drained, paragraph 2.20.2.
Goggles, Appendix B, Section III,
Item 2
General Safety I n s t r u c t i o n s
Torque Wrench, Appendix B, Section
I I I , Item 2
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
G l o v e s , Appendix C, Item 11
Pail, Appendix C, Item 18
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment without following standard shop safety practices.
2.21.41.1 Removal.
Figure 2-156.
Thermostat Maintenance, Model 609-A.
2-353
TM 10-4320-344-24
2.21.41 Thermostat Maintenance, Model 609-A. (Continued)
Allow engine to cool before removing thermostat to avoid being burned by hot
Failure to obey this warning may result in serious personal injury.
engine.
1) and disconnect water return hose (2) from
a.
Loosen hose clamp (Figure 2-156,
thermostat housing (3).
b.
Remove four bolts (4), lock washers (5), water outlet (3), and gasket (6).
Discard lock washers (5) and gasket (6).
c.
Remove thermostat (7).
2.21.41.2 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
Dry cleaning solvent is
smoke or use near open flame or excessive heat.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly. F a i l u r e t o
obey this warning may result in personal injury or death.
a.
Clean all gasket (6) mounting surfaces with rag dampened in cleaning solvent.
b.
I n s p e c t a l l components and mounting hardware for damage.
c.
Replace all defective components.
2.21.41.3 Testing.
Ensure thermostat is not resting on bottom of container.
a.
Place thermostat (7) in boiling water.
b.
Thermostat (7) should fully open.
c.
If thermostat (7) does not fully open, replace it.
2.21.41.4 Installation.
Place cone shaped end of thermostat away from cylinder head assembly.
Failure to do so will result in damage to equipment.
a.
Install thermostat (7) in cylinder head (9).
b.
Position new gasket (6) and water outlet (3) on cylinder head (9) and secure
with four new lock washers (5) and bolts (4).
Torque bolts (4) to 15 ft-lbs
(20 N•m).
c.
Slide water return hose (2) on water outlet (3) and secure with hose
clamp (1).
2-334
TM 10-4320-344-24
2.21.42 Fan Replacement, Model 609-A.
This task covers:
2.21.42.1 Removal
2.21.42.2 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Alternator belt removed, paragraph
2.21.13.
General Safety I n s t r u c t i o n s
Material/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Lock Washer (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
Radiator removed, paragraph 2.20.4.
2.21.42.1 Removal. Remove four bolts (Figure 2-157, 1), lock washers (2), and fan (3)
from water pump shaft (4). Discard lock washers (2).
Figure 2-157.
Fan Replacement, Model 609-A.
2.21.42.2 Installation. Install fan (3) on water pump s h a f t ( 4 ) a n d s e c u r e w i t h f o u r
new lock washers (2) and bolts (1).
2-355
TM 10-4320-344-24
2.21.43 Water Pump Assembly Maintenance, Model 609-A.
This task covers:
2.21.43.1 Removal
2.21.43.3 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM
344-10.
Goggles, Appendix B, Section III,
Item 2
Torque Wrench, Appendix B, Section
III, Item 2
Material/Parts
10-4320-
Bypass Hose and Water Intake Hose
removed, paragraph 2.19.2.
Alternator Belt removed, paragraph
2.20.23.
Fan removed, paragraph 2.20.56.
General Safety I n s t r u c t i o n s
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.21.43.1 Removal. Remove three screws (Figure 2-158, 1), lock washers (2), Water
pump assembly (3), and gasket (4) from engine.
Discard lock washers (2) and
gasket (4).
Figure 2-158. Water Pump Assembly Maintenance, Model 609-A.
2-356
TM 10-4320-344-24
2.21.43.2 Installation.
Do not
Do not use cleaning solvent without proper ventilation and clothing.
Dry cleaning solvent is
smoke or use near open flame or excessive heat.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
a.
Clean gasket mounting surface of engine with rag dampened in cleaning solvent.
b.
Ensure gasket mounting surface of engine is dry and position new gasket (4)
and water pump assembly (3) against cylinder head assembly and secure with
three new lock washers (2) and screws (1). T o r q u e s c r e w s ( 1 ) t o 2 4 f t - l b s
(33 N•m).
2-357
TM 10-4320-344-24
2.21.44 Tachometer Cable Replacement, Models 609-A and US636HCCD-1.
This task covers:
2.21.44.1
Removal
2.21.44.2 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
V-Belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
General Safety I n s t r u c t i o n s
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
Tachometer Cable disconnected and removed
from Control Panel Assembly, paragraph
2.16.13.
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model 609-A.
US636HCCD-1 is similar.
The procedure for Model
The tachometer drive cap on Model US636HCCD-1 is located above the
crankshaft pulley on the front of the engine.
2.21.44.1 Removal.
Figure 2-159.
Tachometer Cable Replacement, Model 609-A.
a.
Disconnect
(2).
b.
Remove grommet (3) from rear panel plate (4) and tachometer drive cable (1).
c.
Pull tachometer drive cable (1) through rear panel plate (4) from tachometer
drive cap (2) side.
2-358
tachometer d r i v e c a b l e ( F i g u r e 2 - 1 5 9 , 1) from tachometer drive cap
TM 10-4320-344-24
2.21.44.2 Installation.
a.
Insert tachometer drive cable (1) through rear panel plate (4) from tachometer
drive cap (2) side.
b.
Install grommet (3) on tachometer drive cable (1) and insert grommet (3) in
rear panel plate (4).
c.
Install tachometer drive cable (1) on tachometer drive cap (2).
2-359
TM 10-4320-344-24
2.21.45 Tachometer Angle Drive Maintenance, Models 609-A and US636HCCD-1.
This task covers:
2.21.45.1
Removal
2.21.45.2 Repair
2.21.45.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM 10-4320344-10.
Goggles, Appendix B, Section III,
Item 2
Tachometer Drive Cable disconnected,
paragraph 2.21.44.
General Safety I n s t r u c t i o n s
Material/Parts
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , - Dry Cleaning, Appendix C,
Item 26
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.21.45.1 Removal.
Figure 2-160.
Tachometer Angle Drive Maintenance.
L o o s e n c o u p l i n g ( F i g u r e 2 - 1 6 0 , 1) that secures tachometer drive cap (2) to
drive adapter (3) and remove tachometer drive cap (2).
a.
When removing tachometer angle drive, be careful not to drop drive shaft into
engine.
Engine damage could result.
b.
Remove two bolts (4), drive adapter (3) (with attached drive shaft (5) and
gear (6)), and gasket (7) from cylinder block. Discard gasket (7).
c.
Pull drive shaft (5) and gear (6) out of drive adapter (3).
2-360
TM 10-4320-344-24
2.21.45.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing. Do not
Dry cleaning solvent is
smoke or use near open flame or excessive beak.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . wash exposed skin thoroughly. F a i l u r e t o o b e y
this warning may result in personal injury or death.
a
Using solvent, clean gasket mounting surfaces on cylinder block and drive
a d a p t e r ( 3 ) . Dry thoroughly.
b.
Inspect all components and mounting hardware for damage.
c..
Replace all defective components.
2.21.45.3 Installation.
a.
Insert drive shaft (5) and gear (6) into drive adapter (3).
b.
Carefully align tachometer drive gear (6) with oil pump drive gear in cylinder
block.
c.
Install new gasket (7) and drive adapter (3) (with attached tachometer drive
shaft (5) and gear (6)) on cylinder block securing with two bolts (4).
When installing drive cap on drive adapter, make sure cap shaft is aligned
with gear shaft in drive adapter.
d.
Align shaft in tachometer drive cap (2) with gear shaft (5) in drive adapter
(3) and install tachometer drive cap (2) on drive adapter (3). Tighten
coupling (1) until drive cap (2) is firmly secured to drive adapter (3).
2-361
TM 10-4320-344-24
2.21.46 Breather Cap Maintenance, Model 609-A.
This task covers:
2.21.46.1 Removal
2.21.46.2 Service
2.21.46.3 Repair
2.21.46.4 Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Do not work on equipment without following standard shop safety practices.
Lock Washer (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
2.21.46.1 Removal. Remove wing nut (Figure 2-161, 1), lock washer (2), breather cap
( 3 ) , f l a t w a s h e r (4), and mounting stud (5) from cylinder head cover (6). Discard
lock washer (2).
Figure 2-161.
2.21.46.2
2-362
Service.
Breather Cap Maintenance, Model 699-A.
C l e a n f i l t e r element of breather cap (3) as required.
TM 10-4320-344-24
2.21.46.3 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.21.46.4 Installation. I n s t a l l m o u n t i n g s t u d ( 5 ) , f l a t w a s h e r ( 4 ) , b r e a t h e r c a p ( 3 ) ,
new lock washer (2), and wing nut (1) on cylinder head cover (6).
2-363
TM 10-4320-344-24
2.21.47 Cylinder Head Cover Maintenance. Model 609-A.
This task covers:
2.21.47.1 Removal
2.21.47.2 Repair
2.21.47.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Pumping station shut down, TM 10-4320344-10.
Breather Cap removed, paragraph 2.21.46.
Goggles, Appendix B, Section III,
Item 2
Material/Parts
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gasket (TM 10-4320-344-24P)
Plastic Washers (TM 10-4320-344-24P)
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.21.47.1 Removal. Remove three nuts (Figure 2-162, 1 ) , p l a s t i c w a s h e r s ( 2 ) , c y l i n d e r
head cover (3), and gasket (4). Discard plastic washers (2) and gasket (4).
Figure 2-162.
2-364
Cylinder Head Cover Maintenance, Model 609-A.
TM 10-4320-344-24
2.21.47.2 Repair.
Do not
Do not use cleaning solvent without proper ventilation and clothing.
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to obey
this warning may result in personal injury or death.
a.
Clean cylinder head cover (3) and gasket mounting surfaces with rag dampened
i n c l e a n i n g s o l v e n t . Dry thoroughly.
b.
Inspect all components and mounting hardware for damage.
c.
Replace all defective components.
2.21.47.3 Installation. Position new gasket (4) and cylinder head cover (3) on
cylinder head and secure with three new plastic washers (2) and nuts (1).
2-365
TM 10-4320-344-24
2.21.48 Cylinder Head Cover Maintenance. Models 609-C and US636HCCCD-1.
This task covers:
2.21.48.1 Removal
2.21.48.2 Repair
2.21.48.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Pumping station shut down, TM 10-4320344-10.
INITIAL SETUP
Goggles, Appendix B, Section III, Item 2
Material/Parts
Gloves, Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry cleaning, Appendix C,
Item 26
Gasket (TM 10-4320-344-24P)
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-C
2.21.48.1 Removal. Remove screw (Figure 2-163, 1), flat washer (2), cylinder head
c o v e r ( 3 ) , and gasket (4). Discard gasket (4).
Figure 2-163.
2-366
Cylinder Read Cover Maintenance, Models 609-C and US636HCCD-1.
TM 10-4320-344-24
2.21.48.2 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat. Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
a.
Clean cylinder head cover (3) and gasket mounting surfaces with rag dampened
i n c l e a n i n g s o l v e n t . Dry thoroughly.
b.
Inspect all components and mounting hardware for damage.
c.
Replace all defective components.
2.21.48.3 Installation. Position new gasket (4) and cylinder head cover (3) on
cylinder head (5) and secure with flat washer (2) and screw (1).
2-367
TM 10-4320-344-24
2.21.49 Rocker Arm (Valve) Adjustment, Model 609-A.
This task covers:
2.21.49.1
Cold
Engine
Adjustment
2.21.49.2 Warm Engine Valve
Adjustment
Valve
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment
Do not work on equipment without following standard shop safety practices.
Conditions
Pumping station shut down, TM 10-4320344-10.
Cylinder Head Cover removed, paragraph
2.21.47.
(Cold Adjustment Only.)
2.21.49.1 Cold Engine Valve Adjustment.
Figure 2-164.
Valve Adjustment, Model 609-A.
Cylinder is at top dead center (TDC) when both intake and exhaust valves are
fully closed.
a.
Rotate crankshaft until cylinder no. 1 is at TDC.
b.
Insert 0.016-0.017 (0.4-0.425 mm) feeler gauge (Figure 2-164, 1) between
rocker arm (2) and intake valve stem (3).
c.
Adjust setting screw (4) until rocker arm (2) just touches feeler gauge (1).
2-368
TM 10-4320-344-24
d.
Remove feeler gauge (1). W h e n p r o p e r l y a d j u s t e d , t h e r e w i l l b e a s l i g h t d r a g
on feeler gauge (1) when is is removed.
e.
Repeat steps b through d for exhaust valve.
Adjust valves in cylinder firing order.
The firing order is 1-5-3-6-2-4.
f.
Repeat steps b through e to adjust valve clearance on remaining cylinders.
Adjust valve clearance in cylinder firing order: 1-5-3-6-2-4.
g.
Refer to paragraph 2.21.47 and install cylinder head cover.
h.
Perform warm engine valve adjustment procedures of paragraph 2.21.49.2.
2.21.49.2 Warm Engine Valve Adjustment.
a.
Refer to TM 1 0 - 4 3 2 0 - 3 4 4 - 1 0 a n d s t a r t e n g i n e . Allow engine to warm up to
normal operating temperature and then adjust engine speed to slow idle.
b.
Refer to paragraph 2.21.47 and remove cylinder head cover.
When properly adjusted,
it is removed.
there will be a slight drag on feeler gauge (1) when
c.
Insert 0.015 (0.375 mm) feeler gauge (1) between rocker arm (2) and intake
valve stem (3) and test for proper adjustment.
d.
If valve clearance is incorrect adjust setting screw (4) until rocker arm (2)
just touches feeler gauge (1).
e.
Repeat steps c and d, as necessary, for all valves.
f.
Refer to TM 10-4320-344-10 and stop engine when all valves are properly
adjusted.
g.
Refer to paragraph 2.21.47 and install cylinder head cover.
2-369
TM 10-4320-344-24
2.21.50 Rocker Arm (Valve) Adjustment, Models 609-C and US636HCCD-1.
This task covers:
Valve Adjustment Only
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Cylinder Head Covers removed, paragraph
2.21.48.
Equipment
General Safety I n s t r u c t i o n s
Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
V-Belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
Do not work on equipment without following standard shop safety practices.
Figure 2-165.
a.
2-370
Valve Adjustment, Models 609-C and US636HCCD-I.
Turn crankshaft in direction of rotation until valves of number one cylinder
overlap (pushrods move freely).
TM 10-4320-344-24
b.
Adjust intake (I) and exhaust (E) valves, indicated by shading, at cylinders
2 , 3 , 4 , 5 , a nd 6 (Figur e 2-165, 1) as follows:
(1) Loosen locknut of slotted adjusting screw (2).
(2) Insert 0.006 inch (0.15 nun) feeler gauge (3) between rocker arm (4) and
valve stem (5).
(3) Adjust slotted adjusting screw (2) until rocker arm (4) just touches feeler
gauge (3).
(4) While holding slotted adjusting screw (2), tighten locknut of slotted
adjusting screw (2).
(5) Remove feeler gauge (3). When properly adjusted, there will be a slight
pull on feeler gauge (3) when it is removed.
(6) Recheck clearance and repeat steps (1) through (5) as necessary.
c.
Rotate crankshaft one complete revolution (3600).
d.
Adjust remaining intake (I) and exhaust valves (E) valves, as indicated by
shading, at cylinders 1, 2, 3, 4, and 5 (6) as in step b.
2-371
TM 10-4320-344-24
2.22 FUEL TANK ASSEMBLY MAINTENANCE.
2.22.1 Filler Neck Assembly Replacement, Model 609-C.
This task covers:
2.22.1.1 Removal
2.22.1.2 Repair
2.22.1.3
Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Materials/Parts
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from
fuel tank.
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Do not work on equipment without following standard shop safety practices.
Equipment Conditions
Pumping station shut down, TM 104320-344-10.
2.22.1.1 Removal.
Figure 2-166.
2-372
Filler Neck Assembly Replacement, Model 609-C.
TM 10-4320-344-24
.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks, c i g a r e t t e s , a n d o p e n f l a m e s
away from fuel system components while working on engine.
.
Ensure container is used to catch fuel and fuel is disposed of
properly.
.
Failure to obey these warnings may result in personal injury or death.
a.
Remove two clamps (Figure 2-166, 1) and hose (2).
b.
Remove eight nuts (3), bolts (4), and filler neck assembly (5) from sound
enclosure panel (6).
c.
Remove cap (7) from filler neck assembly (5).
2.22.1.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.22.1.3 Installation.
a.
Install cap (7) in filler neck assembly (5).
b.
Position filler neck assembly
eight bolts (4) and nuts (3).
3) on sound enclosure panel (6) and secure with
c.
Install hose (2) on fuel tank
two hose clamps (1).
8) and filler neck assembly (5) and secure with
2-373
TM 10-4320-344-24
2.22.2 Fuel Tank Maintenance.
This task covers:
2.22.2.1 Removal
2.22.2.2 Disassembly
2.22.2.3 Repair
2.22.2.4 Assembly
2.22.2.5 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Filler Neck Assembly disconnected from
fuel tank, paragraph 2.22.1 (609-C).
Conditions
(Continued)
General Safety I n s t r u c t i o n s
Material/Parts
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
tank.
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
Fuel Lines disconnected from fuel tank
and capped, paragraph 2.21.2.
.
This procedure applies to Model 609-C.
and US636HCCD-1 are similar.
.
Fuel tank should be empty for removal.
The procedures for Models 609-A
2.22.2.1 Removal.
.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks, c i g a r e t t e s , a n d o p e n f l a m e s
away from fuel system components while working on engine.
.
Ensure container is used to catch fuel and fuel is disposed of
properly.
.
Failure to obey these warnings may result in personal injury or death.
a.
Place pan under fuel tank (Figure 2-167,
fuel.
b.
Remove eight screws (3), lock washers (4), flat washers (5), four straps (6),
a n d f u e l t a n k ( 1 ) . Discard lock washers (4).
1) and remove drain plug (2) to drain
2.22.2.2 Disassembly.
a.
Remove straight adapter (7).
b.
Remove four screws (8), flat washers (9), fuel gauge (10), and gasket (11).
Discard gasket (11).
2-374
TM 10-4320-344-24
Figure 2-167.
Fuel Tank Maintenance.
2.22.2.3 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.22.2.4 Assembly.
a.
Position new gasket (11) and fuel gauge (10) in fuel tank (1) and secure with
four flat washers (9) and screws (8).
b.
Install straight adapter (7) in fuel tank (1).
2.22.2.5
a.
Installation.
Install fuel tank (1) on trailer and secure with four straps (6), eight flat
washers (5), new lock washers (4), and screws (3).
2-375
TM 10-4320-344-24
2.22.2
Fuel Tank Maintenance. (Continued)
b.
Install drain plug (2) in fuel tank (1).
c.
Remove pan from under fuel tank (1) and properly dispose of fuel in accordance
with standing operating procedures.
2-376
TM 10-4320-344-24
2.23 WHEEL MOUNTED FRAME ASSEMBLY MAINTENANCE.
2.23.1 Wheel Assembly Replacement.
This task covers:
2.23.1.1
Removal
2.23.1.2
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, item 1
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Torque Wrench, Appendix B, Section III,
Item 2
Do not work on equipment that is not
properly supported.
Equipment
Do not work on equipment without following standard shop safety precautions.
Conditions
Pumping Station shut down, TM 10-4320344-10.
NOTE
This procedure applies to Model 609-C.
US636HCCD-1 are similar.
The procedures for Models 609-A and
2.23.1.1 Removal.
Figure 2-168.
Wheel Assembly Replacement.
2-377
TM 10-4320-344-24
2.23.1 Wheel Assembly Replacement.. (Continued)
●
Do not work on equipment that is not securely stabilized to prevent
rolling or sliding.
Ensure both wheels of equipment have chocks that
are secure.
•
Place braces or jack stands under frame assembly for support.
•
F a ilur e to o b e y the se wa r nin g s may result in serious personal injury or
death.
a.
Set handbrakes and, using trailer jacks, jack trailer so tire (Figure 2-168,
1 ) is not to uc hing gr o und .
b.
Remove five stud nuts (2), wheel clamps (3), and wheel (4) with mounted
tire (1).
2.23.1.2 Installation.
NOTE
Install wheel clamps with side marked WHEEL next to spoke and side marked RIM
next to rim (flat face of clamps out).
a.
P l a c e w h e e l ( 4 ) w i t h m o u n t e d t i r e ( 1 ) on h u b ( 5 ) w i t h v a l v e s t e m ( 6 ) f a c i n g
away from trailer and secure with five wheel clamps (3) and stud nuts (2).
Hand tighten stud nuts (2).
b.
Tighten stud nuts (2) in an every-other-one sequence to 20 ft-lbs. (27 N•m).
Continue tightening around wheel in the same order. Increase torque by
10 ft-lbs. (14 N•m) each time until each nut is torqued to 90 ft-lbs.
(122 N•m).
c.
Lower trailer to ground.
2-378
TM 10-4320-344-24
2.23.2 Hub and Wheel Bearing Maintenance.
This task covers:
2.23.2.1
Removal
2.23.2.2
Repair
2.23.2.3
Service
2.23.2.4 Installation
INITIAL SETUP
Tools
Materials/Parts
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Cotter Pins ( TM 1 0 - 4 3 2 0 - 3 4 4 - 2 4 P )
Seals (TM 10-4320-344-24P)
Equipment Conditions
Bearing Packer, Appendix B, Section
III, Item 2
Pumping Station shut down, TM 10-4320344-10.
Goggles, Appendix B, Section III,
Item 2
Wheel Assembly removed, paragraph 2.23.1.
Material/Parts
General Safety I n s t r u c t i o n s
Gloves, Appendix C, Item 11
Grease, Appendix C, Item 12
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without following standard shop safety precautions.
NOTE
This procedure applies to Model 609-C.
US636HCCD-1 are similar.
The procedures for Models 609-A and
2.23.2.1 Removal.
Figure 2-169.
a.
Hub and Wheel Bearing Maintenance.
Remove grease cap (Figure 2-169, 1), cotter pin (2), castle nut (3), and
washer (4) . Discard cotter pin (2).
2-379
TM 10-4320-344-24
2.23.2 Hub and Wheel Bearing Maintenance.
b.
(Continued)
Remove outer bearing cone (5), hub (6); then remove inner cup (7), inner
bearing cone (8), seal (9), and outer cup (10) from hub (6). Discard seal
(9) .
2.23.2.2 Repair.
a.
Wipe all components free of grease and dirt.
Do not use cleaning solvent without proper ventilation and clothing. Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
potentially dangerous to personnel and property. Clean parts in a wellventilated area.
Avoid inhalation of solvent fumes.
Wear goggles and rubber
gloves to protect eyes and skin. Wash exposed skin thoroughly. Failure to
obey this warning may result in personal injury or death.
NOTE
If bearing cone or cup is damaged replace both components as a set.
b.
Inspect bearings (5 and 8) for pitting, scratches, wear, and other damage. If
bearing (5 or 8) is reused clean thoroughly with cleaning solvent and dry
thoroughly.
c.
Inspect all components and mounting hardware for damage.
d.
Replace all defective components.
NOTE
If bearing packer is not available, lubricate bearings by hand by kneading
grease into and around each and every roller.
2.23.2.3 Service.
Pack bearing assemblies (5 and 8).
2.23.2.4 Installation.
a.
Install outer cup (10) in hub (6).
b.
Install new seal (9), inner bearing cone (8), inner cup (7), and hub (6).
c.
Install outer bearing cone (5) and washer (4).
d.
While rotating hub (6), install castle nut (3) until drag is felt.
e.
Back off castle nut (3) until new cotter pin (2) can be installed.
f.
Install new cotter pin (2) and grease cap (1).
2-380
If
TM 10-4320-344-24
2.23.3 Tongue Jack and Tripod Assembly Maintenance.
This task covers:
2.23.3.1 Removal
2.23.3.2 Disassembly
2.23.3.3 Repair
2.22.3.4
2.23.3.5
Assembly
Installation
INITIAL SETUP
Equipment
Conditions
Tools
Pumping station shut down, TM 10-4320344-10.
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
General
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Motor Vehicle Maintenance Trestle,
Appendix B, Section III, Item 2
Material/Parts
Do not work on equipment without following standard shop safety practices.
Cotter Pins (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
NOTE
This procedure applies to Model 609-C.
US636HCCD-1 are similar.
The procedures for Models 609-A and
2.23.3.1 Removal.
To prevent injury to personnel, use caution when installing and removing
trestles beneath trailer assembly.
Ensure trestles are adequate to support
weight of pumping assembly.
Equipment slippage or falling could result in
serious personnel injury or death.
a.
Install trestles beneath trailer (Figure 2-170, 1) to support weight of
trailer at a minimum of three points.
b.
Remove two cotter pins (2), flat washers (3), and drive out pivot pin (4).
Discard cotter pins (2).
c.
Remove two nuts (5), lock washers (6), bolts (7), and tongue jack and tripod
assembly.
Discard lock washers (6).
2.23.3.2 Disassembly.
a.
Remove nut (8), lock washer (9), bolt (10), and tongue jack (11).
lock washer (9).
Discard
b.
Remove nut (12), lock washer (13), bolt (14), and pad (15) from tripod (16).
Discard lock washer (13).
2.23.3.3 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2-381
TM 10-4320-344-24
2.23.3 Tongue Jack and Tripod Assembly Maintenance. (Continued)
Figure 2-170.
2-382
Front Tripod Assembly Manintenance.
TM 10-4320-344-24
2.23.3.4 Assembly.
a.
Position pad (15) under tripod (16) and secure with bolt (14), new lock washer
(13), and nut (12).
b.
Position jack (11) on tripod (16) and secure with bolt (10), new lock washer
(9), and nut (8).
2.23.3.5
Installation.
a.
Position tripod (16) against trailer (1) and secure with two bolts (7), new
lock washers (6), and nuts (5).
b.
Position tongue jack (11) against trailer (1) and secure with pivot pin (4),
two flat washers (3), and two new cotter pins (2).
2-383
TM 10-4320-344-24
2.23.4 Rear Jack Assembly Maintenance.
This task covers:
2.23.4.1
Removal
2.23.4.2 Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
111, Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Equipment Conditions
Do not work on equipment without following
standard shop safety precautions.
Pumping Station shut down, TM 10-4320344-10.
NOTE
This procedure applies to Model US636HCCD-1.
and 609-C are similar.
The procedure for Models 609-A
2.23.4.1 Removal.
Figure 2-171.
Rear Jack Assembly Maintenance.
Do not work on equipment that is not securely stabilized to prevent rolling or
sliding.
Ensure both wheels of equipment have chocks that are secure.
Failure
to obey this warning may result in serious personal injury.
NOTE
Support trailer on tires, remaining rear jack, anf tongue jack and front tripod.
a.
2-384
If rear jack (Figure 2-171, 1) is deployed, rotate turncrank (2) and retract
rear jack (1).
TM 10-4320-344-24
b.
Remove lock pin (3), jack pin (4), and rear jack (1) from trailer support
tube .
Insert rear jack (1) in trailer support tube and secure with
2.23.4.2 Installation.
jack pin (4) and lock pin (3).
2-385
TM 10-4320-344-24
2.23.5 Brake System Servicing.
This task covers brake system bleeding only.
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
111, Item 1
Pumping station shut down, TM 10-4320-34410.
General Safety Instructions
Material/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Brake Fluid, Appendix C, Item 4
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Do not work on equipment without following standard shop safety practices.
Personnel
Two required for this procedure.
NOTE
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
Figure 2-172.
2-386
The procedures for Models 609-C and
Brake System Bleeding.
TM
10-4320-344-24
a.
Remove cap (Figure 2-172, 1) and fill master cylinder (2) with brake fluid.
b.
Loosen bleeder screw (3) on right side wheel cylinder.
NOTE
Periodically check fluid level while bleeding brakes and add brake fluid as
required.
c.
Person no. 1: Pump breakaway lever (4) approximately ten times and hold in
the applied position.
d.
Person no. 2:
Open bleeder screw (3) after final pressure is applied and
check brake fluid for air bubbles.
e.
Person no. 2:
Close bleeder screw (3) when brake fluid stops flowing from
bleeder screw (3).
f.
Repeat steps c through e until there are no air bubbles in brake fluid
draining from bleeder screw (3).
g.
Tighten right side wheel cylinder bleeder screw (3).
h.
Repeat steps b through g for left side wheel cylinder bleeder screw (3).
i.
Check brake fluid level in master cylinder (2) and refill as required.
j.
Pump breakaway lever (4) and check system for leaks.
k.
Properly dispose of brake fluid in accordance with standing operating
procedure.
2-387
TM 10-4320-344-24
2.23.6 Master Cylinder and Brake Line Maintenance.
This task covers:
2.23.6.1 Disassembly
2.23.6.2 Repair
2.23.6.3
Assembly
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM 10-4320344-10.
Flaring Tool, Appendix B, Section III,
Item 2
Tongue Jack and Tripod Assembly removed,
paragraph 2.23.3 (US636HCCD-1).
General Safety Instructions
Tube Bender, Appendix B, Section III,
Item 2
Material/Parts
Brake Fluid, Appendix C, Item 4
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
The procedures for Models 609-C and
2.23.6.1 Disassembly.
Do not work on equipment that is not securely stabilized to prevent rolling
or sliding. Ensure both wheels of equipment have chocks that are secure.
Failure to obey this warning may result in serious personal injury.
a.
Place pan beneath master cylinder (Figure 2-173, 1).
b.
Disconnect metal brake line (2) from rear of master cylinder (1) and drain
brake fluid into pan.
Properly discard brake fluid in accordance with
standing operating procedures.
c.
Remove two nuts (3), bolts (4), four spacers (5), wiring harness clamp (6),
and master cylinder (1) from trailer (7).
d.
Remove four mounting screws (8) and brake line mounting clamps (9) from
trailer (7).
e.
Disconnect and remove metal brake line (2) from rubber brake line (10).
f.
Remove retaining clip (11) and rubber brake line (10) from mounting bracket
(12) and disconnect and remove rubber brake line (10) from tee fitting (13) on
axle (14).
g.
Disconnect metal brake line (15) from backing plate (16) on right side wheel
and tire assembly (17).
h.
Disconnect other end of metal brake line (15) from tee fitting (13) and remove
metal brake line (15).
2-388
TM 10-4320-344-24
Figure 2-173.
Master Cylinder and Brake Line Maintenamce.
i.
Remove two screws (18) from each brake line mounting clamp (19) on axle (14)
and remove two brake line mounting clamps (19).
j.
Repeat steps g and h and remove metal brake line (20).
2-389
TM 10-4320-344-24
2.23.6 Master Cylinder and Brake Line Maintenance. (Continued)
2.23.6.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Refer to appendix D to repair damaged or defective metal brake lines (2, 15,
and 20).
c.
Replace all defective components.
2.23.6.3 Assembly.
a.
Connect metal brake line (20) to backing plate (16) on left side wheel and
tire assembly and tee fitting (13).
b.
Position two brake line clamps (19) on metal brake line (20) and secure with
two screws (18).
c.
Repeat step a to connect metal brake line (15) to backing plate (16) on right
side wheel and tire assembly (17).
d.
Connect rubber brake line (10) to tee fitting (13).
e.
Insert rubber brake line (10) in mounting bracket (12) and secure with
retaining clip (11).
f.
Connect metal brake line (2) to rubber brake line (10) and secure to trailer
frame with four brake line mounting clamps (9) and screws (8).
NOTE
Ensure brake actuator pushrod properly engages master cylinder when master
cylinder is installed in trailer.
g.
Insert master cylinder (1) in trailer (7) and secure with wiring harness clamp
(6), four spacers (5), two bolts (4) and two nuts (3).
h.
Connect metal brake line (2) to master cylinder (1).
i.
Refer to paragraph 2.23.5, bleed brake system and check for leaks.
2-390
TM 10-4320-344-24
2.23.7 Brake Actuator Maintenance. Models 609-A and 609-C.
This task covers:
2.23.7.1
Removal
2.23.7.2 Disassembly
2.23.7.3 Repair
2.23.7.4 Assembly
2.23.7.5 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , I t e m 1- -
Pumping station shut down, TM 10-4320344-10.
General
Goggles, Appendix B, Section III,
I t e m
2
Conditions
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Do not work on equipment without following standard shop safety practices.
Gloves, Appendix C, Item 11
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Rivet (TM 10-4320-344-24P
NOTE
This procedure applies to Model 609-A.
similar.
The procedure for Model 609-C is
2.23.7.1 Removal.
a.
Remove nut (Figure 2-174, 1) and screw (2) that secure shock absorber (3) to
rear of brake actuator housing (4).
b.
Remove eight connecting link mounting nuts (5), four connecting links (6),
four coupler assembly mounting studs (7), and eight bushings (8).
c.
Remove nut (9), screw (10), and breakaway lever (11).
d.
Remove chain (12) from breakaway lever (11).
e.
Remove coupler assembly (13) from brake actuator housing (4).
2.23.7.2 Disassembly.
a.
Remove nut (14), screw (15), and shock absorber (3) from coupler
assembly (13).
b.
Remove rivet (16), pushrod (17), spring (18), and pushrod washer (19) from
coupler assembly (13).
2-391
TM 10-4320-344-24
2.23.7 Brake Actuator Maintenance, Models 609-A and 609-C. (Continued)
Figure 2-174.
2-392
Brake Actuator Maintenance, Models 609-A and 609-C.
TM 10-4320-344-24
2.23.7.3 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
a.
Clean all metal parts with rag dampened in cleaning solvent.
b.
Inspect shock absorber (3) for leaks and damage.
c.
Inspect all remaining components and mounting hardware for damage.
d.
Replace all defective components.
2.23.7.4 Assembly.
a.
Install pushrod washer (19), spring (18), and pushrod (17) into coupler
assembly (13) and secure with new rivet (16).
b.
Insert shock absorber (3) into coupler assembly (13) and secure with
screw (15) and nut (14).
2.23.7.5 Installation.
NOTE
En sur e p ushr o d fits into mast er cy linder when inst alling coupler as s emb l y .
a.
Install coupler assembly (13) in brake actuator housing (4).
b.
Install chain (12) on breakaway lever (11).
c.
Insert breakaway lever (11) into coupler assembly (13) and secure with
screw (10) and nut (9).
d.
Insert eight bushings (8), four coupler assembly mounting studs (7), four
connecting links (6) over coupler assembly mounting studs (7), and secure with
eight connecting link mounting nuts (5).
e.
Install screw (2) and nut (1) securing shock absorber (3) to rear of brake
actuator housing (4).
2-393
TM 10-4320-344-24
2.23.8 Brake Actuator Maintenance. Model US636tlCC0-1.
This task covers;
2.23.8.1
Removal
2.23.8.2 Disassembly
2.23.8.3 Repair
2.23.8.4
Assembly
2.23.8.5 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM 10-4320344-10.
Goggles, Appendix B, Section III,
Item 2
Lubricating Gun, Hand, Appendix B,
Section III, Item 2
Material/Parts
Gloves, Appendix C, Item 11
Grease, Appendix C, Item 12
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Cotter Pins ( TM 1 0 - 4 3 2 0 - 3 4 4 - 2 4 P )
Lock Washers (TM 10-4320-344-24p)
Master Cylinder removed, paragraph
2.23.6.
General Safetv Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.23.8.1 Removal.
a.
Remove four bolts (Figure 2-175, 1), lock washers (2), two brakeaway
locks (3), chain (4), gasket (5), breakaway brake lever (6), and pushrod (7).
Discard lock washers (2).
NOTE
A punch may be required to remove top master pin. When the top master pin is
removed, t w o r e a r r o l l e r s w i l l d r o p t o b o t t o m o f o u t e r c a s e a s s e m b l y .
b.
Remove two cotter pins (8), flat washers (9), master pins (10), and rear
r o l l e r s ( 1 1 ) . Discard cotter pins (8).
c.
Pull inner slide assembly (12) from front of outer case assembly (13).
d.
Remove nut (14), lock washer (15), front roller bolt (16), front roller (17),
a n d f r o n t r o l l e r c o v e r ( 1 8 ) f r o m o u t e r c a s e a s s e m b l y ( 1 3 ) . Discard lock
washer (15).
2.23.8.2 Disassembly.
a.
Remove grease fitting (19) from front roller bolt (16).
b.
Remove pushrod block (20), two side bearings (21), and top bearings (22) from
rear of inner slide assembly (12).
c.
Remove two cotter pins (23), s h o c k a b s o r b e r r e t a i n i n g p i n s ( 2 4 ) , a n d s h o c k
absorbers (25) from inner slide assembly (12). Discard cotter pins (23).
d.
Remove two nuts (26), bolts (27), and lunette eye (28) from front of inner
slide assembly (12).
2-394
TM 10-4320-344-24
Figure
2-175.
Brake Actuator Maintenance, Model US636HCCD-1.
2.23.8.3 Repair.
Do not use cleaning solvent without proper ventilation and clothing. Do not
smoke or use near open flame or excessive heat. Dry cleaning solvent is
potentially dangerous to personnel and property. Clean parts in a wellventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubble
gloves to protect eyes and skin. Wash exposed skin thoroughly. Failure to
obey this warning may result in personal injury or death.
a.
Clean all metal parts with rag dampened in cleaning solvent.
b.
Inspect shock absorbers (25) for leaks.
c.
Inspect all components and mounting hardware for damage.
d.
Replace all defective components.
2-395
TM 10-4320-344-24
2.23.8 Brake Actuator Maintenance, Model U56WCCD-1. (Continued)
2.23.8.4 Assembly.
a.
Position lunette eye (28) against inner slide assembly (12) and secure with
two bolts (27) and nuts (26).
b.
Insert two shock absorbers (25) in inner slide assembly (12) and secure with
two shock absorber retaining pins (24) and new cotter pins (23).
c.
I n s t a l l t w o t o p b e a r i n g s ( 2 2 ) , s i d e b e a r i n g s ( 2 1 ) , and one pushrod block (20).
d.
Install grease fitting (19) in roller bolt (16).
2.23.8.5 Installation.
a.
Position front roller cover (18) and front roller (17) on outer case assembly
(13) and secure with front roller bolt (16), new lock washer (15), and nut
(14).
b.
Slide inner slide assembly (12) into outer case assembly (13).
c.
Install lower master pin (10) through outer case assembly (13), inner slide
assembly (12), and lower shock absorber (25) securing with flat washer (9) and
new cotter pin (8).
d.
Install upper master pin (10) through outer case assembly (13), inner slide
assembly (12), two rear rollers (11), and upper shock absorber (25) securing
with flat washer (9) and new cotter pin (8).
e.
Install gasket (5) and chain (4) on breakaway brake lever (6).
f.
Install pushrod (7) and breakaway brake lever (6), into outer case assembly
(13), and two brakeaway locks (3) securing with four new lock washers (2) and
bolts (1).
g.
Grease front roller (17).
2-396
TM 10-4320-344-24
2.23.9 Wheel Cylinder and Brake Shoes Replacement.
This task covers:
2.23.9.1 Disassembly
2.23.9.2 Repair
2.23.9.3 Assembly
2.23.9.4 Adjustment
INITIAL SETUP
(Continued)
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Hub and Wheel Bearing removed, paragraph
2.23.2.
Conditions
Trestle, Appendix B, Section III, Item 2
Brake Lines disconnected from backing
plate, paragraph 2.23.6.
Material/Parts
General
Brake Fluid, Appendix C, Item 4
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
Safety
Instructions
Do not work on equipment without following standard shop safety practices.
The procedures for Models 609-c and
2.23.9.1 Disassembly.
Do not work on equipment that is not securely stabilized to prevent rolling
or sliding. Ensure both wheels of equipment have chocks that are secure.
Failure to obey this warning may result in serious personal injury.
a.
Remove horseshoe clamp (Figure 2-176,
of handbrake actuator (3).
b.
Remove two springs (4) and washer (5) from anchor pin (6) and brake shoes (7
and 8).
c.
Remove four hold down caps (9), two springs (10) and two hold down pins
d.
Remove adjusting s c r e w ( 1 2 ) a n d p u l l b a c k s p r i n g ( 1 3 ) .
e.
Remove two brake shoes (7 and 8) and hand brake actuator arm (14) .
f.
Remove handbrake actuator (3) from secondary brake shoe (7) and remove
handbrake cable (15) from handbrake actuate; (3).
g.
Remove handbrake cable (15) and cable clamp (16) from backing plate (17).
h.
Remove spring (18) from primary brake shoe (8).
i.
Remove two bolts (19) and wheel cylinder (20) from backing plate (17).
j.
Remove five nuts (21), bolts (22), and backing plate (17) from axle (23).
1) and flat washer (2) from mounting pin
(11).
2.23.9.2 Repair.
a.
Inspect all components and mounting hardware for damage.
2-397
TM 10-4320-344-24
2.23.9 Wheel Cylinder and Brake Shoes Replacement. (Continued)
Figure 2-176.
2-398
Wheel Cylinder end Brake Shoe Maintenance (Model 609-A Shown)
TM 10-4320-344-24
b.
Replace all defective components.
2.23.9.3 Assembly.
a.
Position backing plate (17) on axle (23) and secure with five bolts (22) and
nuts (21).
b.
Position wheel cylinder (20) on backing plate (17) and secure with two
bolts (19).
c.
Install spring (18) on primary brake shoe (8).
d.
Install cable clamp (16) and handbrake cable (15) in backing plate (17).
e.
Install handbrake cable (15) into handbrake actuator (3) and install handbrake
actuator (3) into secondary brake shoe (7).
NOTE
Primary brake shoe may have shorter brake lining.
f.
Install primary brake shoe (8) on backing plate (17), wheel cylinder (20), and
handbrake actuator arm (14). Ensure primary brake shoe (8) engages wheel
cylinder (20).
g.
Install hold down pin (11), spring (10), and two hold down caps (9) on hold
down pin (11) securing primary brake shoe (8) to backing plate (16).
h.
Install secondary brake shoe (7) and hand-brake actuator (3) to backing plate
Ensure secondary brake shoe (7) engages handbrake actuator arm (14).
(17).
i.
Install hold down pin (11), spring (10), and two hold down caps (9) on hold
down pin (11) securing secondary brake shoe (7) to backing plate (17).
j.
Install flat washer (2) and horseshoe clamp (1) on mounting pin of handbrake
actuator (3).
NOTE
•
If new brake shoes have been installed, it may be necessary to shorten
adjusting screw to make installation of brake-drum assembly easier.
•
Adjusting wheel of adjusting screw must be aligned w i t h a c c e s s h o l e i n
backing plate.
k.
Install adjusting screw (12) and pullback spring (13) between bottom of
primary and secondary shoes (7 and 8).
1.
Install washer (5) and two pullback springs (4) to primary and secondary shoes
(7 and 8) and anchor pin (6).
2.23.9.4 Adjustment.
a.
Using trailer jacks, raise tires off ground.
b.
Release handbrakes.
c.
Remove cover (24) from backing plate (17).
d.
Insert flat-tip screwdriver through access hole in backing plate (17).
e.
Adjust adjusting screw (12) until slight drag is felt when turning tire and
wheel assembly.
f.
R e m o v e f l a t - t i p s c r e w d r i v e r a n d r e p l a c e c o v e r (24) in backing plate (17
g.
Engage handbrake and lower trailer to ground.
2-399
TM 10-4320-344-24
2.23.10 Handbrake Assembly Maintenance.
This task covers:
2.23.10.1 Disassembly
2.23.10.2 Repair
2.23.10.3
Assembly
INITIAL SETUP
Conditions ( C o n t i n u e d )
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Handbrake Cable disconnected from Brake
Actuator, paragraph 2.23.9.
General Safety Instructions
Material/Parts
Cotter Pin (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
The procedures for Models 609-C and
2.23.10.1 Disassembly.
Do not work on equipment that is not securely stabilized to prevent rolling
o r s l i d i n g . Ensure remaining wheel of equipment has chocks that are secure.
Failure to obey this warning may result in serious personal injury.
a.
Move handbrake actuator (Figure 2-177,
1) up to release handbrake.
b.
Remove h a n d b r a k e c a b l e ( 2 ) f r o m h a n d b r a k e a c t u a t o r ( l ) .
c.
Remove handbrake cable (2) and spring retention clip (3) from backing plate
(4) .
d.
Remove s c r e w ( 5 ) a n d c a b l e h a n g e r c l a m p ( 6 ) f r o m t r a i l e r c h a s s i s ( 7 ) .
e.
Remove c o t t e r p i n ( 8 ) , f l a t w a s h e r ( 9 ) , a n d c a b l e r e t a i n i n g p i n ( 1 0 ) .
cotter pin (8).
f.
Remove two mounting bolts (11), nuts (12), and handbrake lever assembly (13)
from trailer chassis (7).
g.
Remove handbrake cable housing clamp (14) from handbrake lever assembly (13)
and handbrake cable (2).
2.23.10.2 Repair.
a.
Inspect handbrake cable (2) for damage and free movement of cable in
sheathing.
b.
Inspect
c.
Replace all defective components.
2-400
a l l components and mounting hardware for damage.
Discard
TM 10-4320-344-24
Figure 2-177. Handbrake Asemnbly Maintanence (Model 609-A Shown).
2.23.10.3 Assembly.
a.
Install handbrake cable (2) in handbrake cable housing clamp (14) and install
handbrake cable housing clamp (14) in handbrake lever assembly (13).
2-401
TM
10-4230-344-24
2.23.10 Handbrake Assembly Maintenance.
NOTE
Ensure rear bolt passes through handbrake cable housing clamp when installing
handbrake lever assembly.
b.
Position handbrake lever assembly (13) against trailer chassis (7) and secure
with two mounting bolts (11) and nuts (12).
c.
Install cable retaining pin (10), flat washer (9), and new cotter pin (8).
d.
Place cable hanger clamp (6) around handbrake cable (2) and secure with screw
(5).
e.
Install spring retention clip (3) and handbrake cable (2) through backing
plate (4).
2-402
TM 10-4320-344-24
2.23.11 Intervehicular Cable Maintenance.
This task covers:
2.23.11.1 Removal
2.23.11.2 Repair
2.23.11.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , I t e m 1- -
Pumping station shut down, TM 10-4320344-10.
Crimping Tool, Appendix B, Section
111, Item 2
General Safety Instructions
Material/Parts
Do not work on equipment that i s n o t
securely stabilized to prevent rolling
or sliding.
Tags, Appendix C, Item 31
Lock washers (TM 10-4320-344-24P)
Do not work on equip~ment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1.
609-A and 609-c are similar.
The procedures for Models
2.23.11.1 Removal.
Figure 2-178.
Intervehicular
Cable Maintenance.
2-403
TM 10-4320-344-24
2.23.11 Intervehicular Cable Maintenance. (Continued)
a.
Remove three nuts (Figure 2-178, 1), lock washers (2), screws (3), two cable
c l a m p s ( 4 ) , a n d i n t e r v e h i c u l a r c a b l e ( 5 ) f r o m t r a i l e r ( 6 ) . Discard lock
washers (2).
b.
Tag all wires (7) and disconnect intervehicular cable (5) from trailer wiring
harness (8).
2.23.11.2 Repair.
a.
Inspect intervehicular cable (5) for damaged connectors (9), burns, slices,
t e a r s , or damaged wiring.
b.
Inspect all mounting hardware for damage.
c.
Replace defective mounting hardware and damaged intervehicular cable (5).
Figure 2-179.
Intervehicular Cable Connector Maintenance.
NOTE
Replace damaged connectors on Models 609-C and US636HCCD-1 only.
d.
Replace damaged connector (9) as follows:
( 1 ) S l i d e r u b b e r b o o t ( F i g u r e 2 - 1 7 9 , 1) away from connector (2).
(2) Cut damaged connector (2) form wire (3).
(3) Crimp new connector (2) on wire (3) and cover with boot (1).
2.23.11.4 Installation.
a.
Refer to tags and connect intervehicular cable (Figure 2-178, 5) to wiring
h a r n e s s ( 8 ) . Remove and discard tags.
b.
Position intervehicular cable (5) on trailer (6) and secure with two cable
c l a m p s ( 4 ) , t h r e e s c r e w s ( 3 ) , new lock washers (2), and nuts (1).
2-404
TM 10-4320-344-24
2.23.12 Trailer Wiring Harness Maintenance.
This task covers:
2.23.12.1 Removal
2.23.12.2 Repair
2.23.12.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping station shut down, TM 10-4320344-10.
INITIAL SETUP
General Safetv I n s t r u c t i o n s
Crimping Tool, Appendix B, Section
I I I , Item 2
Material/Parts
Tags, Appendix C, Item 31
Do not work on eouipment that i s n o t
securely stabilized-to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1.
609-A and 609-C are similar.
The procedures for Models
2.23.12.1 Removal.
a.
Tag all wires (Figure 2-180, 1) of trailer wiring harness (2).
b.
Disconnect trailer wiring harness (2) from i n t e r v e h i c u l a r c a b l e ( 3 ) , l e f t a n d
right front and rear clearance lights (4), and left and right service lights
(5).
c.
Carefully pull trailer wiring harness (2) through grommets (6)
trailer chassis (7).
and remove from
2.23.12.2 Repair.
a.
Inspect trailer wiring harness (2) for damaged connectors (8), b u r n s ,
t e a r s , or damaged wiring.
b.
Inspect grommets (6) f o r c o r r o s i o n , s l i c e s , t e a r s , o r d a m a g e .
slices,
NOTE
Replace damaged connectors on models 609-C and US636HCCD-1 only.
c.
Repair of wiring harness consists of replacing defective or damaged
connectors (8) as follows:
(1) Slide rubber boot (Figure 2-181, away from connector (2).
(2) Cut damaged connector (2) from wire (3).
(3) Crimp new connector (2) on wire (3) and cover with boot (1).
d.
Repair damaged or defective wiring by replacing trailer wiring harness (Figure
2-180, 2).
e.
Replace damaged grommets (6).
2-405
TM 10-4320-344-24
2.23.12 Trailer Wiring Harness Maintenance. (Continual)
Figure 2-180. Trailer Wiring Harness Maintenance.
Figure 2-181. Trailer Wiring Harness Connector Maintenance.
2-406
TM
10-4320-344-24
2.23.12.3 Installation.
a.
Insert trailer wiring harness (Figure 2-180, 2) through grommets (6) and
position on trailer chassis (7).
b.
Refer to tags and connect trailer wiring harness (2) to left and right service
l i g h t s ( 5 ) , left and right front and rear clearance lights (4), and
i n t e r v e h i c u l a r c a b l e ( 3 ) . Remove and discard tags.
2-407
TM 10-4320-344-24
2.23.13 Lights Miantenance.
This task covers:
2.23.13.1 Removal
2.23.13.2 Testing
2.23.13.3 Repair
2.23.13.4 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Multimeter, Appendix B, Section
III, Item 2
Material/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P
Pumping station shut down, TM 10-4320-344
10.
General Safety I n s t r u c t i o n s
Do not work on equipment that i s n o t
securely stabilized-to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1.
609-A and 609-C are similar.
The procedures for Models
2.22.14.1 Removal.
a.
Remove service light (Figure 2-182, 1) as follows:
Do not apply excessive pressure to bulb when removing bulb.
t h i s warning may result - in personal injury.
Failure to obey
(1)
Remove two lens mounting screws (2), lens (3), and bulb (4).
(2)
Clean socket of any dirt, debris, or corrosion.
(3)
Tag and disconnect two wires (5) from wiring harness connectors.
(4)
Remove two service light mounting nuts
light (l). Discard lock washers (7).
b.
(6), lock washers (7), and service
Remove clearance light (8) as follows:
Do not apply excessive pressure to bulb when removing bulb.
this warning may result in personal injury.
Failure to obey
(1) Pry lens (9) from clearance light (8) and remove bulb (10).
( 2 ) C l e a n d i r t , d e b r i s , or corrosion from socket.
(3) Tag and unplug wire (11) from wiring harness connector.
(4) Remove two clearance light mounting nuts (12), lock washers (13), screws
(14), and clearance light (8). Discard lock washers (13).
2-408
TM 10-4320-344-24
Figure 2-182.
Lights Maintenance.
2.23.13.2 Testing.
a.
Test wiring and socket of service light (1) and clearance light (8) for
continuity.
If resistance is greater than 1 ohm, replace defective service
light (1) or clearance light (8).
b.
Test bulbs (4 and 10) for continuity between metal casing and bottom
terminals.
If resistance is greater than 1 ohm, replace defective bulb (4 or
10).
2.23.13.3 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.23.13.4 Installation.
a.
Install clearance light (8) as follows:
2-409
TM 10-4320-344-24
2.23.13 Lights Maintenance. (Continued)
(1) Position clearance light (8) on trailer Chassis (15) and secure with two
mounting screws (14), new lock washers (13), and nuts (12).
(2) Refer to tags and connect wire (11) into wiring harness connector. Remove
and discard tags.
Do not apply excessive pressure to bulb when installing bulb.
obey this warning may result in personal injury.
Failure to
(3) Install bulb (10) in socket and install lens (9) on clearance light (8).
b.
Install service light (1) as follows:
(1) Position service light (1) on trailer chassis (15) and secure with two
mounting nuts (6) and new lock washers (7).
(2) Refer to tags and connect two wires (5) to wiring harness connectors.
Remove and discard tags.
Do not apply excessive pressure to bulb when installing bulb.
obey this warning may result in personal injury.
Failure to
(3) Install new bulb (4) in socket and install lens (3) on service light (1)
securing with two lens mounting screws (2).
2-410
TM 10-4320-344-24
2.23.14 Reflector Replacement.
This task covers:
2.23.14.1
Removal
2.23.14.2
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, item 1
Pumping Station shut down, TM 10-4320344-10.
General Safety Instructions
R i v e t e r , Blind, Appendix B, Section
III, Item 4
Material/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Lock Washers (TM 10-4320-344-24P)
Rivets (TM 10-4320-344-24P)
Do not work on equipment without following standard shop safety precautions.
This procedure applies to Model 609-C.
and US636HCCD-1 are similar.
The procedures for Models 609-A
This procedure is for rivet mounted reflectors. The procedures for
screw mounted and adhesive mounted reflectors are similar.
Figure 2-183. Reflector Replacement.
2-411
TM 10-4320-344-24
2.23.14 Reflector Replacement. (Continued)
2.23.14.1 Removal. Remove two rivets (Figure 2-183, 1) and reflectors (2) from
trailer chassis (3). Discard rivets (1).
2.23.14.2 Installation. Position reflectors (2) on trailer chassis (3) and secure with
two new rivets (1).
2-412
TM 10-4320-344-24
2.23.15 Shock Absorber Maintenance, Models 609-A and 609-C.
This task covers:
2.23.15.1 Removal
2.23.15.2 Repair
2.23.15.3
Installation
INITIAL SETUP
Tools
General Safety Instructions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Do not work on equipment without following standard shop safety practices.
Locknut (TM 10-4320-344-24P)
Equipment
Conditions
pumping station shut down, TM 10-4320344-10.
This procedure applies to Model 609-A.
similar.
The procedure for Model 609-C is
2.23.15.1 Removal.
Figure 2-184.
Shock Absorber Maintenance, Models 609-A and 609-C.
2-413
TM 10-4320-344-24
2.23.15 Shock Absorber Maintenance, Models 609-A and 609-C. (Continued)
Some shock absorbers may contain a locknut on lower mounting stud.
remove and discard locknut.
a.
If so,
While holding lower shock absorber stud (Figure 2-184, 1) secure, remove lower
mounting nut (2), washer (3), and rubber bushing (4).
Some shock absorbers may contain a locknut on upper mounting stud.
remove and discard locknut.
If so,
b.
While holding upper shock absorber stud (5) secure,
( 6 ) , w a s h e r ( 7 ) , and rubber bushing (8).
c.
Compress shock absorber (9) and remove from upper mounting bracket (10) and
lower mounting bracket (11).
d.
Remove rubber bushing (12) from each end of shock absorber (9).
remove upper mounting nut
2.23.15.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
2.23.15.3 Installation.
a.
Install rubber bushing (12) on each end of shock absorber (9).
b.
Compress shock absorber (9) and install lower stud (1) into lower mounting
bracket (11).
c.
Extend shock absorber (9) and install upper stud (5) in upper mounting bracket
(10).
If locknut was present during removal procedures, install new locknut.
d.
I n s t a l l r u b b e r b u s h i n g ( 8 ) , w a s h e r ( 7 ) , and while holding upper shock absorber
s t u d ( 5 ) s e c u r e , install upper mounting nut (6).
If locknut was present during removal procedures, install new locknut.
e.
2-414
I n s t a l l r u b b e r b u s h i n g ( 4 ) , w a s h e r ( 3 ) , and while holding lower stud (1)
secure install lower mounting nut (2).
TM 10-4320-344-24
2.23.16 Axle Maintenance.
This task covers:
2.23.16.1 Removal
2.23.16.2 Disassembly
2.23.16.3 Repair
2.23.16.4 Assembly
2.23.16.5 Installation
INITIAL SETUP
Tools
Equipment Conditions ( C o n t i n u e d )
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Shock Absorbers removed, paragraph
2.23.15 (609-A and 609-C).
Motor Vehicle Maintenance Trestles,
Appendix B, Section III, Item 2
Equipment
Conditions
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment that is not
properly supported.
Brake Lines removed, paragraph 2.23.6.
Do not work on equipment without following standard shop safety practices.
Wheel Cylinder, Brake Shoes, and Backing
Plate removed, paragraph 2.23.9.
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
The procedures for Models 609-C and
2.23.16.1 Removal.
T o p r e v e n t i n j u r y t o p e r s o n n e l , use caution when installing and removing
t r e s t l e s b e n e a t h t r a i l e r a s s e m b l y . Equipment slippage could result in death
or serious injury to personnel.
a.
Remove two front spring nuts (Figure 2-185,
front hangers (3).
b.
Remove four rear spring nuts (4). mounting screws (5), and shackle plates (6)
from two spring assemblies (7) and remove - a x l e a s s e m b l y ( 8 ) .
1) and mounting screws (2) from
2.23.16.2 Disassembly.
a.
R e m o v e e i g h t n u t s ( 9 ) , f o u r U - b o l t s ( 1 0 ) , two spring clamps (11), and two
spring assemblies (7) from axle (8).
b.
Remove eight nylon bushings (12) from two s p r i n g a s s e m b l i e s ( 7 ) .
c.
Remove four nylon bushings (13) from two rear hangers (14).
2.23.16.3 Repair.
a.
Inspect
a l l components and mounting hardware for damage.
b.
Replace all defective components.
2-415
TM 10-4320-344-24
2.23.16 Axle Maintenance. (Continued)
Figure 2-185.
Axle Maintenance.
2.23.16.4 Assembly.
a.
Install four nylon bushings (13) in two rear hangers (14) .
b.
Install eight nylon bushings (12) in two spring assemblies (7).
Ensure spring assembly center bolt is inserted in hole of saddle on axle
assembly.
c.
Position two spring assemblies (7) on axle assembly (8) and secure with two
spring clamps (11), four U-bolts (10), and eight nuts (9).
Do not fully tighten shackle plate mounting bolts against nuts until spring
a s s e m b l i e s h a v e b e e n i n s t a l l e d o n t r a i l e r c h a s s i s . Shackle plates may have
to be repositioned to allow for spring installation.
d.
Position four shackle plates (6) on two rear hangers (14) and secure with two
mounting screws (5) and spring nuts (4).
2.23.16.5 Installation. Position spring assemblies (7) in two front hangers (3) and
four shackle plates (6) securing with four mounting screws (5), four rear spring
nuts (4), two mounting screws (2), a n d t w o f r o n t s p r i n g n u t s ( 1 ) .
2-416
TM 10-4320-344-24
2.23.17 Forklift Pocket Maintenance. Model 609-C.
This task covers:
2.23.17.1
Removal
2.23.17.2 Repair
2.23.17.3
Installation
Tools
Equipment
Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Pumping station shut down, TM 10-4320344-10.
Material/Parts
Lock Washers (TM 10-4320-344-24P)
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
2.23.17.1 Removal.
Figure 2-186. Forklift Pocket Maintenance, Model 609-c.
2-417
TM 10-4320-344-24
2.23.17 Forklift Pocket Maintenance, Model 609-C. (Continued)
a.
Remove four cap screws (Figure 2-186,
( 3 ) . Discard lock washers (2).
1), lock washers (2), and flat washers
If a 3.0 inch (76.2 mm) cap screw is used mark location of screw.
b.
R e m o v e t w o n u t s ( 4 ) , f l a t w a s h e r s ( 5 ) , machine screws (6), and forklift p ock et
(7) from pumping assembly (8).
2.23.17.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
R e p l a c e a l l d e f e c t i v e components.
2.23.17.3 Installation.
If a 3.0 inch (76.2 mm) machine screw is used,
marked in step 2.23.17.1 b.
install screw in location
a.
Position forklift pocket (7) on pumping assembly (8) and secure with two
machine screws (6), flat washers (5), and nuts (4) .
b.
Install four flat washers (3), new lock washers (2), and cap screws (1).
2-418
TM 10-4320-344-24
SECTION VI. PREPARATION FOR SHIPMENT AND STORAGE
2.24 PRESERVATION PROCEDURES.
No special preservation procedures are required for the 600 GPM pumping assemblies.
2.25 PACKING.
2.25.1 Packing of Pumping Assenbly Model 609-A. Prepare Pumping Assembly Model 609-A for
movement as follows:
Tools
General Mechanic’s Tool Kit, Appendix B, Section III, Item 1
S e a l e r , s t e e l s t r a p p i n g , h a n d , refer to TM 10-4320-303-14.
Personnel
Four personnel required for installation of protective plywood cap.
Components/Materials
Pressure Sensitive Adhesive
Pressure Sensitive Adhesive
Protective plywood cap (saved
Steel Strapping (Appendix C,
T a p e , l - i n c h (Appendix C, Item 34)
T a p e , 4 - i n c h (Appendix C, Item 35)
when Model 609-A was unpacked, paragraph 2.4.2.1).
Item 30)
a.
Remove muffler in accordance with paragraph 2.13.1.
b.
Remove air cleaner in accordance with paragraph 2.14.1.
Figure 2-187. Sealing Model 609-A Air Intake and Exhaust Pipe Outlet Openings.
c.
Seal air intake and exhaust pipe outlet openings as follows:
(1) Place 4-inch tape (Figure 2-187, 1) over opening in air intake pipe (2).
Fold 4-inch tape (1) down along sides of air intake pipe (2).
(2) Secure 4-inch tape (1) with l-inch tape (3).
2-419
TM 10-4320-344-24
2.25.1 Packing of Pumping Assembly Model 609-A. (Continued)
(3) Repeat steps (1) and (2) for exhaust pipe outlet opening.
Figure 2-188. Securing Air Cleaner and Exhaust Muffler on Model 609-A.
d.
Secure air cleaner and exhaust muffler on Model 609-A trailer as follows:
(1) Place air cleaner (Figure 2-188, 1) on trailer chassis (2), alongside
If needed, loosen hose clamp (3) and swivel rubber hose (4)
battery cables.
t o s i d e . Tighten hose clamp (3).
(2) Check that air cleaner (1) does not extend over trailer side rail (5). Tape
or strap air cleaner (1) to trailer chassis (2).
( 3 ) P l a c e m u f f l e r ( 6 ) o n t r a i l e r c h a s s i s ( 2 ) , alongside radiator outlet hose
(7).
(4) Check that muffler (6) does not extend over trailer side rail (8). Tape or
strap muffler (6) to lower radiator hose assembly (7) and trailer chassis
(2).
e.
Refer to paragraph 2.15.2 and disconnect battery cables from battery.
f.
U s i n g f o u r p e r s o n n e l , install protective plywood cap on Model 609-A as
follows:
(1) Lift plywood cap (Figure 2-189, 1 )
chassis (2).
2-420
at
each
corner
and
position
it
on
trailer
TM 10-4320-344-24
Figure 2-189.
Install Protective Plywood Cap on Model 609-A.
Steel strapping has sharp edges.
handling steel strapping.
To avoid personal injury, use care when
(2) Secure plywood cap (1) to trailer chassis (2) with four strips of steel
Using
strapping.
Route two strips over sides and two strips over ends.
strapping seals and strapping sealer, tighten and seal the steel strapping.
2.25.2 Packing of Punping Assembly Model 609-C. Model 609-C does not require any packing
procedures to prepare it for movement.
2.25.3 Packing of Pumping Assembly Model US636HCCD-1.
for movement as follows:
Prepare Pumping Assembly US636HCCD-1
Tools
General Mechanic’s Tool Kit, Appendix B, Section III, Item 1
S e a l e r , s t e e l s t r a p p i n g , hand, refer to TM 1 0 - 4 3 2 0 - 3 0 3 - 1 4
Personnel
Four personnel are required for installation of protective plywood cap.
2-421
TM 10-4320-344-24
2.25.3 Packing of Pumping Assembly Model US636HCCD-1. (Continued)
Components/Materials
Pressure Sensitive Adhesive Tape,
Pressure Sensitive Adhesive Tape,
Protective plywood cap (saved when
Steel Strapping (Appendix C, Item
l-inch (Appendix C, Item 34)
4-inch (Appendix C, Item 35)
US636HCCD-1 was unpacked, paragraph 2.4.2.3)
30)
a.
Remove muffler in accordance with paragraph 2.13.3.
b.
Remove air cleaner in accordance with paragraph 2.14.3.
c.
Remove air intake pipe assembly in accordance with paragraph 2.
Figure 2-190.
Sealing Model US636HCCD-1 Air Intake and Exhaust Pipe
0utlet Openings.
Seal air intake and exhaust outlet openings as follows:
d.
(1) Place 4-inch tape (Figure 2-190, 1) over turbocharger air intake opening
(2).
Fold 4-inch tape (1) down along sides of turbocharger air intake
opening (2).
(2) Secure 4-inch tape (1) with l-inch tape (3).
(3) Place 4-inch tape (4) over opening in manifold exhaust pipe (5). Fold
4-inch tape (4) down along sides of manifold exhaust pipe (5).
(4) Secure 4-inch tape (5) with l-inch tape (6).
e.
Refer to paragraph 2.15.4 and disconnect battery cable from battery.
f.
S e c u r e a i r c l e a n e r , m u f f l e r , and related parts on Model US636HCCD-1 trailer as
follows:
( 1 ) P l a c e a i r c l e a n e r ( F i g u r e 2 - 1 9 1 , 1) and weather cap (2) on top of battery
box (3).
(2) Secure air cleaner (1) and weather cap (2) with tape (4).
2-422
TM 10-4320-344-24
Figure 2-191.
Securing Air Cleaner and Exhaust Muffler on Model US636HCCD-1.
(3) Place muffler (5), exhaust pipe (6), and air intake pipe (7) on trailer
c h a s s i s ( 8 ) . Position them between the engine and the Pump, under the
intermediate housing assembly.
( 4 ) S e c u r e m u f f l e r ( 5 ) , exhaust pipe (6) and air intake pipe assembly (7) to
trailer chassis (8) with tape (9).
g.
U s i n g f o u r p e r s o n n e l , install protective plywood cap on Model US636HCCD-1 as
follows:
(1) Lift plywood cap (Figure 2-192, 1) at each corner and position it on trailer
chassis (2).
Steel strapping has sharp edges.
handling steel strapping.
To avoid personal injury, use care when
(2) Secure plywood cap (1) to trailer chassis (2) with four strips of steel
Using
strapping.
Route two strips over sides and two strips over ends.
strapping seals and strapping sealer, tighten and seal the steel strapping.
2-423
TM 10-4320-344-24
2.25.3 Packing of Pumping Assembly Model US636HCCD-1. (Continued)
Figure 2-192.
Install Protective Plywood Cap on Model US636HCCD-1.
2.26 MARKING
Refer to MIL-STD-129 for information on marking.
2.27
STORAGE.
a.
Store equipment so as to provide maximum protection from the elements and to
provide access for inspection, maintenance, and servicing.
b.
Take into account environmental conditions, such as extreme cold or heat, high
humidity, blowing snow, earthquakes, and take adequate precautions.
c.
Placement of equipment in administrative storage should be for short periods
of time when a shortage of maintenance effort exists.
Items should be in
mission readiness within 24 hours or within the time factors as determined by
t h e d i r e c t i n g a u t h o r i t y . During the storage period appropriate maintenance
records will be kept.
d.
Before placing equipment in administrative storage, current preventive
maintenance checks and services should be completed, shortcomings and
deficiencies should be corrected, and all modification work orders (MWO’s)
should be applied.
2-424
TM 10-4320-344-24
CHAPTER 3
DIRECT SUPPORT MAINTENANCE
Page
Subject Index
Repair Parts; Special Tools; Test, Measurement, and
Diagnostic Equipment (TMDE); and Support Epuipment . . . . . .
3-2
Common Tools and Equipment . . . . . . . . . . . . . . . . . . . .
Special Tools, TMDE, and Support Equipment . . . . . . . . . . . .
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3-2
3-2
Section I
3.1
3.2
3.3
Section II
3.4
Section
3.5
3.6
3.7
3.8
3.9
3.10
Troubleshooting
Troubleshooting.
III
Direct
.
Support
.
.
.
.
.
.
.
.
.
.
.
Maintenance
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Procedures
.
.
.
.
Control Panel Assembly Maintenance . . .
Pumping Assembly Maintenance . . .
Radiator Assembly Maintenance . . . .
Engine Assembly Maintenance . . . . . .
Fuel Tank Repair . . . . . . . . . .
Wheel Mounted Frame Assembly Repair .
.
. . .
. .
. . . .
. . . .
. . . .
. . . .
.
.
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. .
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. .
. .
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3-2
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3-2
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3-8
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3-8
3-9
3-36
3-37
3-102
3-103
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. . . . . .
3-1
TM 10-4320-344-24
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND
DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
3.1 COMMON TOOLS AND EQUIPMENT.
For authorized common tools and equipment, refer to Modified Table of Organization
and Equipment (MTOE) applicable to your unit.
3.2 SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
Special tools, TMDE, and support equipment are listed in TM 10-4320-344-24P, Repair
Parts and Special Tools List (RPSTL) for the Pumping Assembly, Water, 600 GPM
covering unit, direct support, and general support maintenance, or the Maintenance
Allocation Chart (MAC), Appendix B of this manual.
3.3 REPAIR PARTS.
Repair parts are listed and illustrated in TM 10-4320-344-24P covering unit, direct
support, and general support maintenance of this equipment.
SECTION II. TROUBLESHOOTING
3.4 TROUBLESHOOTING.
3.4.1 General. The malfunction index lists malfunctions that may be observed by
direct support level maintenance. The malfunctions are then cross-referenced to the
troubleshooting Table 3-1 contains information useful in diagnosing and
correcting unsatisfactory operation of the pumping assembly which may be encountered
during operation or maintenance of the pumping assembly or its components.
Use the
malfunction index to locate specific troubleshooting procedures contained in
table 3-1. After locating the listed malfunction, perform the test/inspections and
corrective actions in the order listed in table 3-1. The malfunction index and
Table 3-1 cannot list all the malfunctions that may occur, all the test and
inspections needed to find the fault, or all the corrective actions needed to
correct the fault. If the equipment malfunction is not listed or actions listed do
not
correct
the
fault,
notify
your
supervisor.
3.4.2 R e f e r e n c e s . When paragraphs are referenced in table 3-1 (for example, paragraph
3.10.2/3.10.5/3.10.7), the paragraph number at the left of the slash, "/", refers to
Pumping Assembly 609-A, the number between the slashes refers to Pumping Assembly
609-C, and the number to the right of the slash refers to Pumping Assembly
US636HCCD-1.
MALFUNCTION INDEX
Malfunction Number
in Table 3-1
Engine
will
not
start
.
.
.
Engine
starts
and runs
Engine
tachometer gauge
.
.
shows
Improper
governor operation
Improper
governor system
Improper
governor operation
No
or
low
Centrifugal
3-2
s u c t i o n or
pump
noisy
.
.
.
.
.
.
.
h i g h RPM
operation
.
.
.
.
(Model
.
(Model
.
.
.
.
.
.
.
.
.
.
.
.
609-C)
.
.
.
.
.
.
.
.
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.
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.
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.
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.
.
.
.
.
.
.
.
.
.
.
609-A)
.
( M o d e l US636HCCD-1)
pressure
.
warmup.
( M o d e l 609-A)
discharge
.
.
e r r a t i c a l l y after
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1
.
.
2
.
3
.
.
.
.
.
.
4
.
.
5
.
.
.
6
.
.
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.
.
.
7
.
.
.
.
.
.
.
8
Table
3-1.
Direct
Support
Troubleshooting
Table.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1.
ENGINE HILL NOT START.
Remove Idler Pulley and inspect fuel injection timing gear for alignment and
slippage.
Set fuel injection pump timing (paragraph 3.8.10/3.8.11).
2.
ENGINE STARTS AND RUNS ERRATICALLY AFTER WARMUP.
Step 1.
a.
b.
Step 2.
Check governor assembly adjustment.
Adjust governor assembly (paragraph 3.8.6/3.8.8).
Replace governor assembly (paragraph 3.8.6/3.8.7/3.8.8).
Remove Idler Pulley and inspect fuel injection timing gear for
alignment and slippage.
Set fuel injection pump timing (paragraph 3.8.10/3.8.11).
3. ENGINE TACHOMETER GAUGE SHOWS HIGH RPM. (Model 609-A)
Step 1.
a.
b.
Step 2.
a.
b.
4.
Check to see if governor linkage is sticking or loose.
If linkage is sticking or loose adjust or replace linkage (paragraph
3.8.6).
If linkage is in full load position go to step 2.
Remove governor control box from governor (paragraph 3.8.6). Using
multimeter, set to 200-ohm scale, check for shorts between pins A and B
on governor 5 pin connector.
If reading is 1 ohm or less replace governor (paragraph 3.8.6).
If reading is greater than 1 ohm go to step 3.
Step 3.
Using
Remove governor control box from governor (paragraph 3.8.6).
multimeter set to 200-ohm scale, check for open circuits between pins A
and C on governor 5 pin connector.
a.
b.
If reading is 1 ohm or less adjust governor assembly (paragraph 3.8.6).
If reading is greater than 1 ohm replace governor assembly (paragraph
3.9.4).
IMPROPER GOVERNOR OPERATION. (Model 609-A)
Step 1.
a.
b.
Step 2.
a.
b.
Using multimeter, set to 20 vdc scale, measure voltage between A and C
on 10 pin connector while engine is running.
If reading is not 12 vdc, go to MALFUNCTION 7.
If reading is 12 vdc, go to step 2.
Using multimeter, set to 20 vdc scale, measure voltage between A and B
on 3-pin connector.
If reading is not 9.6 vdc, go to MALFUNCTION 7.
If reading is 9.6 vdc, go to step 3.
3-3
TM 10-4320-344-24
Table 3-1. Direct Support Troubleshooting Table. (Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. IMPROPER GOVERNOR OPERATION. (Model 609-A) (Continued)
Step 3.
a.
b.
c.
5.
Check to see if governor output shaft lever on the governor actuator
makes a quick correction at fuel throttle position without a change in
load.
If lever makes a quick connection check wiring for proper shielding
(paragraph 2.17).
If lever does not make quick correction check wiring for proper
connections and shorts (paragraph 2.17) .
Replace wiring harness (paragraph 2.17).
IMPROPER GOVERNOR SYSTEM OPERATION. (Model 609-C)
Step 1.
Check and see if governor linkage is stuck, loose or out of
adjustment.
Adjust or replace governor linkage as necessary (paragraph 3.8.7).
Step 2.
a.
b.
Step 3.
a.
b.
Step 4.
a.
b.
Step 5.
a.
b.
Step 6.
a.
b.
3-4
Check for loose electrical connections and open wires, using
multimeter.
Tighten loose electrical connections.
Repair or replace wiring as necessary (paragraph 2.17).
Disconnect cable at governor control module. Using multimeter, check
for magnetic pick-up unit signal between pins K an J. (Signal will be
a small AC voltage).
If signal is present go to step 4.
If signal is not present replace magnetic pick-up unit (paragraph
3.8.5).
Disconnect cable from governor control module. Using multimeter,
measure resistance between pins C and H on cable while turning auto
throttle rheostat, R4, through its full range.
If resistance varies as auto throttle rheostat, R4, is turned through
its full range go to step 5.
If resistance does not vary as auto throttle rheostat, R4, is turned
throughout its full range replace auto throttle rheostat, R4 (paragraph
2.16.22).
Using multimeter, check auto throttle switch, S2, for open/shorted
contacts.
If no open/shorted contacts are present go to step 6.
Replace
auto
throttle
switch,
S2,
if
defective
(paragraph
2.16.18).
Using multimeter, check pressure/speed switch, S3, for open/shorted
contacts.
If no open/shorted contacts are present go to step 7.
Replace throttle select switch, S3, if defective (paragraph 2.16.18).
TM 10-4320-344-24
Table 3-1. Direct Support Troubleshooting Table. (Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. IMPROPER GOVERNOR SYSTEM OPERATION. (Model 609-C) (Continued)
Step 7.
a.
b.
c.
Disconnect cable from governor control module. Using multimeter, check
for governor actuator output signal between pins N and M. Signal
should be a positive DC voltage which changes in magnitude when auto
throttle rheostat, R4, is turned.
If signal is not present replace governor control module (paragraph
2.16.32).
If signal is present replace governor actuator (paragraph 3.8.7).
Replace pressure control module (paragraph 2.16.31).
6. IMPROPER GOVERNOR OPERATION. (Model US636HCCD-1)
Step 1.
Check and see if governor linkage is stuck, loose or out of
adjustment.
Adjust or replace governor linkage as necessary (paragraph 3.8.8).
Step 2.
a.
b.
Check for proper governor adjustment.
Adjust governor (paragraph 3.8.8).
Replace governor (paragraph 3.8.8).
7. NO OR LOW SUCTION OR DISCHARGE PRESSURE.
Step 1.
Check and see if governor linkage is stuck, loose or out of
adjustment. (All pumping units)
Adjust or replace governor linkage as necessary (paragraph
3.8.6/3.8.7/3.8.8).
Step 2 .
a.
b.
Step 3 .
a.
b.
Step 4.
a.
b.
Turn power
Disconnect 10 pin connector from governor control box.
switch to "ON" position. Using multimeter set to 20 vdc measure
voltage between pins A (+) and C (-). (Model 609-A
If voltage is 12 vdc go to step 4.
If voltage is not 12 vdc go to step 3.
Using multimeter set to 200 ohm scale, check for continuity between A
(+) to A (+) and C (-) to D (-). (Model 609-A)
If reading is more than 1 ohm repair or replace wires as necessary
(paragraph 2.17).
If reading is less than 1 ohm go to step 4.
Using multimeter set to 200 ohm scale, c h e c k f o r c o n t i n u i t y b e t w e e n D
(Model 609-A)
(-) to D (-) and A (+) to B (+).
If reading is more than 1 ohm repair or replace wires as necessary
(paragraph 2.17).
If reading is less than 1 ohm refer to wiring diagram (Appendix F) for
further fault isolation.
3-5
TM 10-4320-344-24
Table 3-1.
Direct Support Troubleshooting Table.
(Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. NO OR LOW SUCTION OR DISCHARGE PRESSURE. (Continued)
Step 5.
a.
b.
Step 6.
a.
b.
D i s c o n n e c t g o v e r n o r c o n t r o l b o x f r o m g o v e r n o r ( p a r a g r a p h 3 . 8 . 6 ) . Using
multimeter set to 200 ohm scale, check continuity from A to A and C to
c.
(Model 609-A)
If reading is more than 1 ohm replace governor control box (paragraph
3.8.6).
If reading is 1 ohm or less go to step 6.
Remove cover from governor control box.
Place jumper between TP1 and
TP2 . Turn power switch to “ON” position.
Using multimeter set to 20
v d c s c a l e , measure voltage between pins A and B on the three pin
connector.
(Model 609-A)
If reading is 9.6 vdc go to step 7.
If reading is not 9.6 vdc replace governor control box (paragraph
3.8.6).
NOTE
AC input impedance of meter must be 5,000 ohms per volt or greater.
Step 7.
a.
b.
Step 8.
a.
b.
Step 9.
a.
b.
Step 10.
a.
b.
Step 11.
a.
b.
3-6
Disconnect 10 pin connector from governor control box.
Using
multimeter, measure AC voltage between pins I and J while cranking
(Model 609-A)
motor.
If reading is 1.5 volts go to step 11.
If reading is not 1.5 volts go to step 8.
Turn power switch to “OFF’ position.
Using multimeter set to 200 ohm
scale, check pins C and J on 10 pin connector that could cause pin J to
be grounded.
(Model 609-A)
If reading is 1 ohm or less repair or replace wiring as necessary
(paragraph 2.17).
If reading is more than 1 ohm, go to step 9.
Using multimeter set to 200 ohm scale, check continuity between C and
D, C and E, C and G, and C and H on 10 pin connector.
(Model 609-A)
If reading is 1 ohm or less repair or replace wiring as necessary
(paragraph 2.17).
If reading is more than 1 ohm go to step 10.
Using multimeter, check governor control box connector for shorts
between C and D, C and E, C and G, C and H, and C and J.
(Model 609-A)
If reading is 1 ohm or less replace governor control box (paragraph
3.8.6).
If reading is more than 1 ohm go to step 11.
Using multimeter set to 200 ohm scale, check leads I and J from 10 pin
connector to magnetic pick-up unit.
(Model 609-A)
If reading is 1 ohm or less replace magnetic pick-up unit (paragraph
3.8.5).
If reading is more than 1 ohm repair or replace wiring as necessary
(paragraph 2.17).
TM 10-4320-344-24
Table 3-1.
Direct Support Troubleshooting Table.
(Continued)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. NO LOW SUCTION OR DISCHARGE PRESSURE.
Step 12.
(Continued)
Replace actuator (paragraph 3.8.6).
(Model 609-A)
If problem is not corrected go to step 13.
Step 13.
a.
b.
Step 1 4 .
a.
b.
Step 15.
a.
b.
Step 16.
a.
b.
Step 17.
a.
b.
Measure
Remove governor control box from governor (paragraph 3.8.6).
resistance between governor case and pins on governor 5 pin connector.
(Model 609-A)
If any reading is less than 100 ohms replace governor (paragraph
3.8.6).
If all readings are more than 100 ohms go to step 14. .
Remove cover from governor control box and place jumper between TP1 and
TP2 . M a k e s u r e c o r r e c t p o w e r i s a v a i l a b l e t o g o v e r n o r c o n t r o l b o x .
Actuator output lever should move to full fuel position and remain
(Model 609-A)
there until jumper between TP1 and TP2 is removed.
If actuator output lever does not move to full fuel position replace
governor control box (paragraph 3.8.6).
If actuator output lever does move to full fuel position go to step 15.
Inspect flexible coupling
(All pumping units).
Inspect flexible coupling (paragraph 3.6.5/3.6.6).
Replace flexible coupling (paragraph 3.6.5/3.6.6).
Inspect impeller (All pumping units).
Inspect impeller (paragraph 3.6.7).
Replace impeller (paragraph 3.6.7).
Inspect impeller shaft and bearings (All pumping units).
Inspect impeller shaft and bearings (paragraph 3.6.8/3.6.9).
Replace impeller shaft and bearings (paragraph 3.6.8/3.6.9).
8. CENTRIFUGAL PUMP NOISY.
Step 1.
Inspect flexible coupling.
a. Inspect flexible coupling (paragraph 3.6.5/3.6.6).
b.
Replace flexible coupling (paragraph 3.6.5/3.6.6).
Step 2.
Inspect
impeller.
a. Inspect impeller (paragraph 3.6.7).
b.
Replace impeller (paragraph 3.6.7).
Step 3.
Inspect impeller shaft and bearings.
a. Inspect impeller shaft and bearings (paragraph 3.6.8/3.6.9).
b.
Replace impeller shaft and bearings (paragraph 3.6.8/3.6.9).
3-7
TM 10-4320-344-24
SECTION III.
DIRECT SUPPORT MAINTENANCE PROCEDURES
3.5 CONTROL PANEL ASSEMBLY REPAIR.
This task covers repair.
INITIAL SETUP
Tools
Equipment Conditions
Acetylene Welding Equipment
Appendix B, Section III, Item 3
Control Panel Frame removed, paragraph
2.16.38 (609-A).
Material/Parts
Control Enclosure Assembly, paragraph
2.16.39 (609-C).
Paint
Reference
Base Weldment, paragraph 2.16.40
(US636HCCD-1).
TM 43-0139
TM 9-237
General Safety I n s t r u c t i o n s
Equipment Conditions
T O prevent burns do not touch heated
metal components.
Control Panel Cover Assembly removed,
paragraph 2.16.1 (609-A) or 2.16.2
(US636HCCD-1).
Do not work on equipment without
following standard shop safety
precautions.
Control Panel removed, paragraph 2.16.36
(609-A) or 2.16.37 (US636HCCD-1).
This procedure applies to the following components:
Control Cover Assembly (609-A and US636HCCD-1)
Control Panel (609-A and US636HCCD-1)
Control Panel Frame (609-A)
Control Enclosure Assembly (609-C)
Base Weldment (US636HCCD-1)
a.
Weld component in accordance with and TM 9-237.
b.
Paint component in accordance with TM 43-0139.
3-8
TM 10-4320-344-24
3.6 PIMPING ASSEMBLY MAINTENANCE.
3.6.1 Pumpming Assembly Replacement.
This task covers:
3.6.1.1 Removal
3.6.1.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Top Assembly removed, paragraph 2.12.4
(609-C).
Wrench Set, Socket, Appendix B,
Section III, Item 2
Key Set, Socket Head Screw, Appendix
B, Section III, Item 2
Motor Vehicle Maintenance Trestle,
Appendix B, Section III, Item 2
Materials/Parts
Conditions
(Continued)
End Panel Assembly removed, paragraph
2.12.11 (609-C).
Control Panel Assembly removed, paragraph
2.16.3 (609-A) or 2.16.5 (US636HCCD-1).
Suction and Discharge Elbow Hose
Assemblies removed, paragraph 2.16.35.
Drain Plug and Primer Port removed,
paragraph 2.18.1 (609-C).
Antisieze Sealing Compound, Appendix
General Safety Instructions
C, Item 22
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
Pump Mount Isolator (TM 10-4320-344-24P) s e c u r e l y s t a b i l i z e d t o p r e v e n t r o l l i n g
or sliding.
Personnel
Do not stand or put arms, legs, or any
Three personnel are required to perform o t h e r p a r t o f b o d y u n d e r h o i s t e d l o a d .
this procedure.
Do not work on equipment without following
Equipment Conditions
standard shop safety precautions.
Pumping station shut down and pump
assembly drained, TM 10-4320-344-10.
3.6.1.1 Removal.
To prevent personal injury, stabilize the trailer using trestles.
stabilize trailer may result in personal injury.
Failure to
a.
Remove four nuts (Figure 3-1, 1 ) , l o c k w a s h e r s ( 2 ) , f l a t w a s h e r s ( 3 ) , a n d
bolts (4) securing pump assembly (5) to trailer (6). Discard lock
washers (2) .
b.
Remove twelve bolts (7) and lock washers (8) securing pump assembly (5) to
e n g i n e b e l l h o u s i n g ( 9 ) . Discard lock washers (8).
3-9
TM 10-4320-344-24
3.6.1 Pump Assembly Replacement. (Continued)
Figure 3-1.
Pump Assembly Replacement.
The pump assembly is not equipped with a lifting device. Three personnel
required when using chains or cables for lifting.
Position chains or cables
so that load will be balanced and pump assembly is not damaged.
c.
Connect a sling and suitable lifting device to pump assembly (5).
lifting device to support weight of pump assembly (5).
Raise
Do not stand or put arms, legs, or any other part of body under hoisted load.
Failure to obey this warning may result in serious personal injury or death.
d.
3-10
Carefully slide impeller shaft (10) away from engine flywheel (11), and lift
pump assembly (5).
TM 10-4320-344-24
e.
Set pump assembly (5) down and block so that it will be secure and remove
lifting device and sling.
f.
Remove shims (12), if present.
g.
Press pilot bushing (13) from engine flywheel (11).
Step h applies to Model 609-A only.
h.
Remove eight bolts (14), lock washers (15), and drive coupling (16) from
engine flywheel (11). Discard lock washers (15).
Figure 3-2.
S-Bolt Removal From Flywheel.
Step i applies to Models 609-C and US636HCCD-1 only.
i.
Remove four S-bolts (Figure 3-2,
1) from engine flywheel (2).
3.6.1.2 Installation.
Step a applies to Models 609-C and US636HCCD-1 only.
a.
Install four S-bolts (1) in engine flywheel (2).
Step b applies to Model 609-A only.
b.
P o s i t i o n d r i v e c o u p l i n g ( F i g u r e 3 - 1 , 16) on engine flywheel (11) and secure
with eight new lock washers (15) and b o l t s ( 1 4 ) .
c.
Lubricate bore of pilot bushing (13) with antisieze sealing compound and
install pilot bushing (13).
3-11
TM 10-4320-344-24
3.6.1 Pump Assembly Replacement. (Continued)
Do not stand or p u t a r m s , l e g s , o r a n y o t h e r p a r t o f b o d y u n d e r h o i s t e d l o a d .
F a i l u r e t o o b e y this warning may result in serious personal injury or death.
The pump assembly is not equipped with a lifting device.
Three personnel are
required.
When using chains or cables for lifting, position them so that the
load will be balanced and pump assembly is not damaged.
d.
U s i n g a s u i t a b l e l i f t i n g d e v i c e , raise pump assembly (5) and position it on
trailer (6).
e.
Align the splined end of i m p e l l e r s h a f t ( 1 0 ) w i t h b o r e o f p i l o t b u s h i n g ( 1 3 ) .
Do not put stress on the castings or shaft.
Damage to equipment may result.
f.
Slide pump assembly (5) in place, seating impeller shaft (10) in pilot
bushing (13) and pump drive-in drive coupling (16).
g.
I n s t a l l t w e l v e n e w l o c k w a s h e r s ( 8 ) a n d b o l t s ( 7 ) s e c u r i n g pump assembly (5)
to engine bellhousing (9).
h.
Align mounting holes of pump assembly (5) and trailer (6),
device:
and lower lifting
Do not tighten nuts.
i.
Install four mounting bolts (4), flat washers (3),
. . new lock washers (2). and
n u t s ( 1 ) . Do not tighten nuts (1).
j .
Make sure pump assembly (5) is level and aligned with engine.
as necessary to attain level.
k.
R e m o v e l i f t i n g d e v i c e a n d s l i n g f r o m pump assembly (5).
1.
Tighten nuts (1).
3-12
Add shims (12)
TM 10-4320-344-24
3.6.2 Intermediate Bracket Assembly Replacement.
This task covers:
3.6.2.1 Removal
3.6.2.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n
Item 1
III,
Conditions
Pumping station shut down, TM 10-4320-34410.
Pumping Assembly removed, paragraph 3.6.1.
Hoist, Lifting Sling, Appendix B,
Section III, Item 2
Materials/Parts
Lock Washers (US636HCCD-1 only,
(TM 10-4320-344-24P)
Gaskets (TM 10-4320-344-24P)
General S a f e t y I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not stand or put arms, legs, or any part
of body under hoisted load.
Personnel
Two personnel are required to perform
this procedure.
Do not work on equipment without
standard shop safety precautions.
following
This procedure a p p l i e s t o the intermediate bracket assembly for Model 609-C.
The procedures for Models 609-A and US636HCCD-1 are similar.
3.6.2.1 Removal.
a.
Remove twelve nuts (Figure 3-3,
pump casing assembly (3).
b.
Remove and discard gasket (4).
1) and intermediate housing assembly (2) from
3.6.2.2 Installation.
a.
Place new gasket (4) over studs (5) on pump casing assembly (3).
b.
Install intermediate bracket assembly (2) on pump casing assembly (3) and
secure with twelve nuts (1).
3-13
TM 10-4320-344-24
3.6.2 Intermediate Bracket Assembly Replacement. (Continued)
Figure 3-3. Intermediate Bracket Assembly Replacement.
3-14
TM 10-4320-344-24
3.6.3 Pump Casing Assembly Repair, Models 609-A and 609-C.
This task covers:
3 .6.3.1 Disassembly
3 .6.3.2 Repair
3 .6.3.3 Assembly
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping station shut down, TM 10-4320-34410.
Puller Kit, Mechanical, Gear and
Bearing, Appendix B, Section III,
Item 3
Tap and Die Set, Appendix B,
Section III, Item 3
T o o l K i t , Coil Insert, Appendix B,
Section III, Item 3
Conditions
Suction Elbow and Discharge Elbow removed,
paragraph 2.18.2.
Intermediate Bracket Assembly removed,
paragraph 3.6.2.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or s l i d i n g .
Materials/Parts
Antisieze Tape, Appendix C Item 32
Gasket (TM 10-4320-344-24P)
Do not work on equipment without following standard shop safety practices.
This procedure applies to pumping assembly Model 609-C.
pumping assembly Model 609-A is similar.
The procedure for
3.6.3.1 D i s a s s e m b l y . Remove six nuts (Figure 3-4, 1), cover plate (2),
from studs (4). Discard gasket (3).
and gasket (3)
3.6.3.2 Repair.
a.
Inspect pump casing assembly (5) for corrosion, cracks, holes, or damage.
b.
I n s p e c t s t u d s ( 4 , 6, and 7) for stripped or damaged threads or c r a c k s .
to paragraph 2.11.2 and replace damaged studs (4, 6, and 7).
c.
Inspect wear ring (8) for wear or damage.
Refer
Wrap antisieze tape in direction of threads prior to installation of pipe
plugs .
d.
Inspect all pipe plugs (9) for damage.
e.
Replace all defective components.
3.6.3.3 Assembly. Install new gasket (3) and cover plate (2) on studs (4) and secure
with six nuts (1).
3-15
TM 10-4320-344-24
3.6.3 Pump Casing Assembly Repair, Models 609-A and 609-C. (Continued)
Figure 3-4. Pump Assembly Repair, Models 609-A and 609-c.
3-16
TM 10-4320-344-24
3.6.4 Pump Casing Assembly Repair, Model US636HCCD-1.
This task covers:
3 .6.4.1 Disassembly
3 .6.4.2 Repair
3.6.4.3 assembly
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping station shut down, TM 10-4320-34410.
Puller Kit, Mechanical, Gear and
Bearing, Appendix B, Section III,
Item 3
Tap and Die Set, Appendix B,
Section III, Item 3
T o o l K i t , Coil Insert, Appendix B,
Section III, Item 3
Conditions
Suction Elbow and Discharge Elbow removed,
paragraph 2.18.2.
Intermediate Bracket Assembly removed,
paragraph 3.6.2.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Materials/Parts
Antisieze Tape, Appendix C, Item 32
Do not work on equipment without following standard shop safety practices.
3.6.4.1 Disassembly. Remove two plugs (Figure 3-5,
pump casing assembly (5).
1) and plugs (2, 3, and 4) from
Figure 3-5. Pump Casing Assembly Repair, Model US636HCCD-1.
3-17
TM 10-4320-344-24
3.6.4 Pump Casing Assembly Repair, Model US636HCCD-1. (Continued)
3.6.4.2 Repair.
a.
Inspect pump casing assembly (5) for corrosion, cracks, holes, or damage.
b.
Inspect studs (6) and (7) for stripped or damaged threads or cracks. Refer to
paragraph 2.11.2 and replace damaged studs (6 and 7).
c.
Inspect wear ring (8) for wear or damage.
d.
Inspect plugs (1, 2, 3, and 4) for worn or damaged threads or cracks.
e.
Replace defective components.
Wrap antisieze tape in direction of threads prior to installation of pipe
plugs.
3.6.4.3 A s s e m b l y . Install two plugs (1) and plugs (2, 3, and 4) in pump casing
assembly (5).
3-18
TM 10-4320-344-24
3.6.5 Flexible Coupling Assembly Repair, Model 609-A.
This task covers:
3.6.5.1
Disassembly
3.6.5.2
Repair
3.6.5.3
Assembly
INITIAL SETUP
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Intermediate Bracket Assembly removed,
paragraph 3.6.2.
General Safety Instruction
Vernier Caliper, Appendix B, Section
III, Item 3
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Set Screws (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without
following standard shop safety
precautions.
3.6.5.1 Disassembly.
Figure 3-6. Flexible Coupling Assembly Maintenance, Model 609-A.
3-19
TM 10-4320-344-24
3.6.5 Flexible Coupling Assembly Repair, Model 609-A. (Continued)
Note distance between mounting surface of intermediate bracket assembly and
engine side of flexible coupler to ensure proper installation and operation
of flexible coupler.
a.
Measure distance between intermediate bracket assembly mounting surface
(Figure 3-6, 1) and engine side of flexible coupler (2).
b.
Remove and discard two setscrews (3).
c.
Slide flexible coupler sleeve (4) off of impeller shaft (5).
d.
Remove six cap screws (6) and lock washers (7).
e.
Remove plate (8) and flexible coupler (2) from flexible coupler sleeve (4).
Discard lock washers (7).
3.6.5.2 Repair.
a.
Inspect
a l l components and mounting hardware for damage.
b.
Replace all defective components.
3.6.5.3 Assembly.
a.
Slide flexible coupler (2) and plate (8) onto flexible coupler sleeve (4) and
secure with six new lock washers (7) and cap screws (6).
b.
Slide flexible coupler sleeve (4) onto impeller shaft (5).
c.
Position flexible coupler (2) to meet the dimension recorded in disassembly
and secure with two new set screws (3).
3-20
TM 10-4320-344-24
3.6.6 Flexible Coupling Repair, Models 609-C and US636HCCD-1.
This task covers:
3.6.6.1
Disassembly
3.6.6.2 Repair
3.6.6.3 Assembly
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Intermediate Bracket Assembly removed,
paragraph 3.6.2.
Torque Wrench, 0-150 ft-lbs, Appendix B,
Section III, Item 3
Vernier Caliper, Appendix B, Section
III, Item 3
Material/Parts
General
Conditions
Safety
Instsurction
Do not work on equipment that is not
securely stabilized to prevent rolling or
sliding.
Do not work on equipment without
following standard shop safety
precautions.
Set Screws (TM 10-4320-344-24P)
Woodruff Key (TM 10-4320-344-24P)
3.6.6.1 Disassembly.
Figure 3-7. Flexible coupling Assembly Maintenance, Models 609-C and US636HCCD-1.
3-21
TM 10-4320-344-24
3.6.6 Flexible Coupling Repair. Models 609-C and US636HCCD-1
Ž
This procedure applies to Model 609-C.
US636HCCD-1 is similar.
•
Note distance between mounting surface of intermediate bracket assembly
and engine side of flexible coupler to ensure proper installation and
operation of flexible coupler.
The procedure for Model
a.
Measure distance between intermediate bracket assembly mounting surface
(Figure 3-7, 1) and engine side of flexible coupler (2).
b.
Remove two setscrews (3).
c.
Install one setscrew (3) in remaining hole on bushing (4).
(3) until bushing (4) breaks free from impeller shaft (5).
d.
Remove bushing (4), f l e x i b l e c o u p l e r a s s e m b l y ( 6 ) , and woodruff key (7) from
impeller shaft (5). Discard set screws (3) and woodruff key (7).
e.
Remove four bolts (8) and flexible coupler (2) from hub (9).
Tighten setscrew
3.6.6.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
3.6.6.3 Assembly.
a.
Position flexible coupler (2) on hub (9) and secure with four bolts (8).
Torque belts (8) to 150 ft-lbs (203 N•m).
b.
I n s t a l l n e w w o o d r u f f k e y ( 7 ) , flexible coupler assembly (6), and bushing (4)
on impeller shaft (5).
c.
Install two new set screws (3).
d.
Position flexible coupler assembly (6) to meet the dimension recorded in
disassembly and torque setscrews (3) to 23 ft-lbs (31 N•m).
3-22
TM 10-4320-344-24
3.6.7 Impeller Maintenance
This task covers:
3.6.7.1
Disassembly
3.6.7.2
Repair
3.6.7.3 Assembly
INITIAL SETUP
Tools
Material/Parts (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Antisieze Sealing Compound, Appendix C,
Item 22
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Two steel bars, Appendix C, Item 27
Two steel rods, Appendix C, Item 28
Seal Assembly (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2
Torque Wrench, Appendix B, Section III,
Item 3 (609-A and 609-C)
Equipment
Vernier Caliper, Appendix B,
Section III, Item 3
Intermediate Bracket Assembly removed,
paragraph 3.6.2.
Material/Parts
General Safety I n s t r u c t i o n s
Gloves, Appendix C, Item 11
Lubricant, Appendix C, Item 14
Rags, Appendix C, Item 20
Do not work on equipment without
following standard shop safety
precautions.
Conditions
This procedure applies to Models 609-A and 609-C.
Model US636HCCD-1 is similar.
The procedure for
3.6.7.1 Removal.
Steps a and b are applicable to Model 609-A. When removing Model 609-C
impeller, insert two 1 inch (25.4 mm) steel rods through mounting holes of
flexible coupling assembly.
a.
Remove and retain two cap screws (Figure 3-8, 1) and lock washers (2),
diagonally opposite each other, from flexible coupling assembly (3).
b.
Measure thread diameter of cap screw (1) and o b t a i n t w o s c r e w s 3 i n c h e s l o n g
and same thread diameter as cap screw (1).
c.
Install two 3 inch (76.2 mm) long screws (4)
coupling assembly (3).
d.
P l a c e s t e e l b a r ( 5 ) , 1 1/4 inch (31.75 mm) x 3/8 inch (9.525 mm) x 14 inches
(355.6 mm) between screws (4) and remove cap s c r e w ( 6 ) a n d s l e e v e s p a c e r ( 7 ) .
e.
Place second steel bar (8) into impeller (9) between vanes as shown.
into threaded holes of flexible
3-23
TM 10-4320-344-24
3.6.7 Impeller Maintenance. (Continued)
Figure 3-8. Loosening Impeller.
Ensure that steel bar is held rigid while striking with hammer. Impeller is
made of brass and damage to vanes may occur. F a i l u r e t o o b e y t h i s c a u t i o n
may cause damage to impeller.
f.
While holding steel bar (5) at flexible coupling assembly (3) securely in
position, and steel bar (8) in impeller (9) rigid, firmly strike steel bar (8)
in counterclockwise direction while facing impeller (9) until impeller (9)
unscrews.
g.
Remove steel bars (5 and 8). impeller (Figure 3-9, 1), shims (2), if Present,
seal washer (3), spring (4) seal assembly (5), and stationary seat (6) from
i m p e l l e r s h a f t ( 7 ) . Discard seal assembly ( 5 ) .
3.6.7.2 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
a.
3-24
Using cloth soaked in cleaning solvent, c l e a n i m p e l l e r s h a f t ( 7 ) , b o r e o f s e a l
r e t a i n i n g p l a t e ( 8 ) , a n d s l e e v e s p a c e r ( F i g u r e 3 - 8 , 7 ) . Allow all components
to thoroughly air dry.
TM 10-4330-344-24
Figure 3-9. Impeller and Seal Assembly Removal, Models 609-A and 609-C.
Avoid touching wear surfaces of seal assembly; doing so could damage seal and
cause pump to leak.
b.
Inspect faces of new seals to be used to ensure they are free of grit or other
abrasive matter.
c.
Inspect all components for damage.
d.
Replace all defective components.
3.6.7.3 Assembly.
a.
Lightly lubricate stationary seal (Figure 3-9, 6) with silicone lubricant.
Install polished side of seal assembly toward impeller.
b.
Install stationary seal (6) on impeller shaft (7) and press into seal housing
bore in seal retaining plate (8).
Ž Take precautions to protect seal face from damage when assembling
components. Damaged seal will cause pump to leak.
• Never use grease to lubricate seal assembly.
seal and cause pump to leak.
Use of grease will damage
c.
Lubricate interior diameter of seal assembly with light coating of silicone
lubricant.
d.
Lubricate faces of precision seals of seal assembly with silicone lubricant.
e.
Slide seal assembly (5) on impeller shaft (7) until it comes in contact with
polished side of stationary seal (6).
3-25
TM 10-4320-344-24
3.6.7 Impeller Maintenance. (Continued)
Ensure chamfer of spring centering washer faces towards spring.
f.
Install spring (4) and seal washer (3) on impeller shaft (7).
g.
Install impeller adjusting shims (2), if any were present.
h.
Install impeller (1) on impeller shaft.
i.
Apply antisieze sealing compound to cap screw (Figure 3-8, 6) and install
sleeve spacer (7) and cap screw (6).
j.
Install bar (5) between two bolts (4) and torque cap screw (6) to 90 ft-lbs
(122 NŽm).
Maximum allowable impeller shaft end play is 0.002 (0.051 mm) to 0.010 inches
(0.254 mm).
Using vernier calipers, center impeller (Figure 3-10, 1) in volute scroll (2)
as follows:
k.
Write down HALF
1)
Measure distance across narrowest point of volute channel.
of measurement (Dimension A).
2)
Measure distance from engine side of narrowest point of volute channel to
b a c k o f v o l u t e g a s k e t . Ensure gasket is flush against face of volute
c a s i n g . Write down measurement (Dimension B).
3)
Add Dimension A and Dimension B (Dimension AB).
4)
Measure distance between faces of inner and outer shrouds of impeller (1).
Write down HALF of measurement (Dimension C).
When measuring face of seal plate to rear shroud of impeller, make sure
impeller shaft is horizontal. Because of ball bearing play of 0.20 inches
(5.08 mm), impeller shaft may tilt slightly.
3-26
5)
Measure distance from face of seal plate to rear shroud of impeller (1).
Write down measurement (Dimension D).
6)
Add Dimension C and Dimension D (Dimension CD).
7)
Subtract Dimension CD from Dimension AB.
This value gives correct
thickness of impeller adjusting shims (Figure 3-9, 2) required to center
impeller (Figure 3-10, 1) in volute scroll (2).
8)
Remove impeller (1) and measure thickness of installed impeller shims
( F i g u r e 3 - 9 , 2 ) . Add or remove shims (2), as necessary, to reach correct
thickness and center impeller (1) in volute scroll (2).
9)
I n s t a l l i m p e l l e r ( 1 ) , refer to steps h through j.
TM 10-4320-344-24
Figure 3-10. Centering Impeller, Models 609-A and 609-c.
3-27
TM 10-4320-344-24
3.6.8 Impeller Shaft and Bearings Maintenance, Models 609-A and 609-C.
This task covers:
3.6.8.1 Disassembly
3.6.8.2 Repair
3.6.8.3
Assembly
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Solvent, Dry Cleaning, Appendix C,
Item 26
Balance Ring (TM 10-4320-344-24P)
Ball Bearing (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Set Screw (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2
Pipe Wrench, Appendix B, Section III,
Item 2
Equipment Conditions
Flexible Coupling Assembly removed,
paragraph 3.6.5 (609-A) or 3.6.6 (609-C).
Puller Set, Appendix B, Section III,
Item 2
Impeller removed, paragraph 3.6.7.
Snap Ring Pliers, Appendix B, Section
III, Item 2
General Safety I n s t r u c t i o n s
Material/Parts
Gloves, Chemical and Oil Protective,
Appendix C, Item 11
Rags, Appendix C, Item 20
Antisieze Sealing Compound, Appendix C,
Item 22
Do not work on equipment without
following standard shop safety
precautions.
This procedure applies to both Models 609-A and 609-C.
3.6.8.1 Disassembly.
a.
Remove two screws (Figure 3-11,
intermediate housing (3).
b.
Remove balance ring (4) from seal retaining plate (2).
ring (4).
c.
L o o s e n f o u r s c r e w s ( 5 ) , guard clip (6) on two intermediate guard
a s s e m b l i e s ( 7 ) , and remove intermediate bracket (3).
d.
R e m o v e f o u r s c r e w s ( 5 ) , l o c k w a s h e r s ( 8 ) , and two guard clips (6) from each
i n t e r m e d i a t e g u a r d ( 9 ) . Discard lock washers (8).
e.
Remove set screw (10) and pipe plug (11) from intermediate bracket (3).
Discard set screw (10).
f.
Remove packing nut (12), spacer ( 1 3 ) , a n d i m p e l l e r s h a f t ( 1 4 ) f r o m
intermediate bracket (3).
g.
Remove two retaining rings (15) a n d b a l l b e a r i n g ( 1 6 ) f r o m i m p e l l e r s h a f t
( 1 4 ) . Discard ball bearing (16).
3-28
1) and seal retaining plate (2) from
Discard balance
TM 10-4320-344-24
Figure 3-11. Rotating Assembly Maintenance, Mosels 609-A and 609-c.
3-29
TM 10-4320-344-24
3.6.8 Impeller Shaft and Bearings Maintenance, Models 609-A and 609-C. (Continued)
3.6.8.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
a.
Using a cloth dampened with cleaning solvent clean all components and allow
all components to thoroughly air dry prior to installation.
b.
Inspect
c.
Replace all defective components.
a l l components and mounting hardware for damage.
3.6.8.3 Assembly.
a.
I n s t a l l n e w ball bearing (16) on impeller shaft (14) and secure with two
retaining rings (15).
b.
Install impeller shaft (14) into intermediate bracket (3) and secure with
spacer (13) and packing nut (12).
c.
Apply antisieze sealing compound to pipe plug (11) and new setscrew (10).
Install pipe plug (11) and new set screw (10).
d.
Position four guard clips (6) on two intermediate guards (9) and secure with
four new lock washers (8) and screws (5).
Hand tighten screws (5).
e.
Install two intermediate guard assemblies (7) into intermediate bracket (3)
and secure by turning four guard clips (6) on two intermediate guard
assemblies (7) and tightening four screws (5).
f.
Press new balance ring (4) into seal retaining plate (2) and install seal
retaining plate (2) on impeller shaft (14) against intermediate bracket (3).
g.
Align mounting holes of seal retaining plate (2) and intermediate bracket (3).
h.
Apply antisieze sealing compound to screws (1) and install screws (1).
3-30
TM 10-4320-344-24
3.6.9 Impeller Shaft and Bearings Maintenance. Model US636HCCD-1.
This task covers:
3.6.9.1
Disassembly
3.6.9.2 Repair
3.6.9.3
Assembly
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Bearings (TM 10-4320-344-24P)
Seals (TM 10-4320-344-24P)
Wear Rings (TM 10-4320-344-24P)
G o g g l e s , Industrial, Appendix B,
Section III, Item 2
Equipment
Snap Ring Pliers, Appendix B, Section
III, Item 2
Conditions
Flexible Coupling Assembly removed,
paragraph 3.6.6.
Impeller removed, paragraph 3.6.7.
Material/Parts
General Safety Instructions
Grease, Appendix C, Item 12
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 22
Do not work on equipment without
following standard shop safety
precautions.
3.6.9.1 Disassembly.
Figure 3-12. Rotating Assembly Maintenance, Model US636HCCD-1
a.
Remove two retaining rings (Figure 3-12,
retaining ring (4) .
b.
Remove retaining ring (5), wear ring (6), and seal (7).
and seal (7).
c.
Remove spacer (8) and seal (9) from impeller shaft (10).
d.
Remove impeller shaft (10) from intermediate housing (11).
e.
Remove bearing (12) from impeller shaft (10). Discard bearing (12).
1 and 2), ball bearing (3), and
Discard wear ring (6)
Discard seal (9).
3-31
TM 10-4320-344-24
3.6.9 Impeller Shaft and Bearings Maintenance. Model US636HCCD-1. (Continued)
3.6.9.2 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
a.
Using a cloth dampened with cleaning solvent clean all components and allow
all components to thoroughly air dry prior to installation.
b.
Inspect all remaining components for damage.
c.
Replace all defective components.
3.6.9.3 Assembly.
Pack new bearings by kneading grease into bearings.
Failure to observe this
caution could result in damage to impeller shaft and bearing.
a.
Pack and install new bearing (12) on impeller shaft (10).
b.
Insert impeller shaft (10) into intermediate bracket assembly (11).
c.
Slide new seal (9) and spacer (8) onto impeller shaft (10).
d.
Install new seal (7) in new wear ring (6).
Ensure seal sits level in wear ring.
e.
Insert wear ring (6) in intermediate bracket assembly (11) and secure with
retaining ring (5).
f.
I n s t a l l r e t a i n i n g r i n g ( 4 ) , n e w b e a r i n g ( 3 ) , and two retaining rings (1 and 2)
on impeller shaft (10).
3-32
TM 10-4320-344-24
3.6.10 Pump Mount Isolators Replacement, Model 609-C.
This task covers:
3.6.10.1
Removal
3.6.10.2
Tools
Equipment Conditions ( C o n t i n u e d )
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping assembly removed, paragraph 3.6.1.
Materials/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
Installation
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Conditions
Pumping station shut down, TM 10-4320344-10.
3.6.10.1 Removal. Remove four nuts (Figure 3-13, 1), lock washers (2), cap screws (3)
and two pump mount isolators (4). Discard lock washers (2).
Figure 3-13. Pump Mount Isolators.
3.6.10.2 Installation. Position two pump mount isolators (4) on t r a i l e r ( 5 ) a n d s e c u r e
with four cap screws ( 3 ) , n e w l o c k w a s h e r s ( 2 ) , a n d n u t s ( 1 ) .
3-33
TM 10-4320-344-24
3.6.11 Pump Support Maintenance, Model US636HCCD-1.
This task covers:
3.6.11.1 Removal
3.6.11.2 Repair
3.6.11.3
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Pumping Assembly removed, paragraph 3.6.1.
Materials/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment
Conditions
Pumping station shut down, TM 10-4320344-10.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
3.6.11.1 Removal. R e m o v e f o u r n u t s ( F i g u r e 3 - 1 4 , 1 ) , l o c k w a s h e r s ( 2 ) , f l a t w a s h e r s
(3), mounting bolts (4), and two pump supports (5) from trailer chassis (6).
Discard lock washers (2).
Figure 3-14. Pump Support Maintenance, Model US636HCCD-1.
3.6.11.2 Repair.
a.
Inspect
b.
Replace all defective components.
3-34
a l l components and mounting hardware for damage.
TM 10-4320-344-24
Do not secure pump supports to trailer until pump assembly is aligned with
engine.
3 . 6 . 1 1 . 3 I n s t a l l a t i o n . Place two pump supports (5) on trailer chassis (6) and secure
with four mounting bolts (4), flat washers (3), new lock washers (2), and nuts (1).
3-35
TM 10-4320-344-24
3.7 RADIATOR ASSEMBLY MAINTENANCE.
3.7.1 Radiator Repair, Model 609-A.
This task covers:
Radiator repair only.
INITIAL SETUP
Tools
General Safety Instructions
Acetylene Welding Equipment,
Appendix B, Section 111, Item 3
To prevent burns do not touch heated
metal components.
Reference
Do not work on equipment without
following standard shop safety
precautions.
TB-SIG-222
TM 9-237
Equipment Conditions
Radiator removed, paragraph 2.20.4.
a.
Solder radiator following procedures in TB-SIG-222.
b.
Weld radiator in accordance with TM 9-237.
3-36
TM 10-4320-344-24
3.8 ENGINE ASSEMBLY MAINTENANCE.
3.8.1 Engine Replacement.
This task covers:
3.8.1.1
Removal
3.8.1.2
Installation
INITIAL SETUP
Tools
Equipment Conditions ( C o n t i n u e d )
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Air Intake Pipe Assembly removed,
paragraph 2.14.5 (US636HCCD-1).
H o i s t , Appendix B, Section III, Item 2
Battery Cables disconnected,
paragraph 2.15.5 (609-A and US636HCCD-1).
Lifting Sling, Appendix B, Section III,
Item 2
Battery and Power Cable Assemblies
disconnected, paragraph 2.15.6 (609-C).
Motor Vehicle Maintenance Trestle,
Appendix B, Section III, Item 2
Power Control Cable Assembly removed,
paragraph 2.15.8 (609-A).
Engine Stand, Appendix B,
Section III, Item 3
Oil Pressure Gauge Hose Assembly disconnected, paragraph 2.16.10 (609-A and
US636HCCD-1).
Eye, Lug (609-C and US636HCCD-1),
Appendix B, Section III, Item 10
Engine Coolant Temperature Gauge Sensor
removed, paragraph 2.16.11 (609-A).
Materials/Parts
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Engine Mount Isolators (TM
10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Manual Throttle Control Cable Assembly
removed, paragraph 2.16.25 (609-A).
Manual Throttle Control Cable
disconnected, paragraph 2.16.26 (609-C).
Personnel
Fuel Rack Cable disconnected, paragraph
2.16.27 (609-A).
Three personnel are required to
perform this procedure.
Auto Defeat Cable removed, paragraph
2.16.28 (609-C).
Equipment Conditions
Wiring Harness removed, paragraph 2.17.
Pumping station shut down, TM 10-4320344-10.
Rear Panel Assembly removed, paragraph
2.19.2 (609-A).
Oil drained, LO 10-4320-344-12 (609-A and Radiator removed, paragraph 2.20.4
609-C).
(609-A),
Top Panel Assembly removed, paragraph
2.12.4 (609-C).
Fuel Supply and Return Lines
disconnected, paragraph 2.21.2.
Belt Guards removed, paragraph 2.12.15
(609-C).
Cold Start Aide Hose disconnected,
paragraph 2.21.10 (609-C).
Exhaust Pipe Assembly removed, paragraph
2.13.4 (609-C and US636HCCD-1).
Oil Drain Assembly disconnected,
paragraph 2.21.32 (609-A and 609-C).
Air Cleaner Assembly removed, paragraph
2.14.3 (US636HCCD-1).
Tachometer Cable removed, paragraph
2.21.44 (US636HCCD-1).
Air Intake Assembly removed, paragraph
2.14.4 (609-C).
Pump Assembly removed (609-C) or
disconnected (609-A and US636HCCD-1),
paragraph 3.6.1.
3-37
TM 10-4320-344-24
3.8.1 Engine Replacement. (Continued)
INITIAL SETUP (Continued)
General Safety Instructions
General Safety Instructions (Continued)
Do not work on equipment that is not securely stabilized to prevent rolling or
sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from
fuel system components while working on
engine assembly.
Do not stand or put arms, legs, or any
o t h e r p a r t o f t h e b o d y u n d e r h o i s t e d l o a d . Do not work on equipment without following standard shop safety precautions.
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
The procedures for Models 609-C and
3.8.1.1 Removal.
Figure 3-15. Engine Assembly Removal (Model 609-A Shown).
3-38
TM 10-4320-344-24
Ensure lifting eye mounting holes on Models 609-c and US636HCCD-1 are
clean before installing lifting eyes.
Do not over tighten lifting eyes.
Failure to observe this caution may result in damage to engine.
a.
Place pan under engine assembly (Figure 3-15, 1).
b.
A t t a c h l i f t i n g s l i n g and hoist to lifting eyes on top of engine assembly (1).
c.
Remove two nuts (2),
washers (3).
d.
Remove two bolts (5) and lock washers (6).
lock washers (3), and mounting bolts (4).
Discard lock
Discard lock washers (6).
Do not stand or put arms, legs, or any other part of the body under hoisted
load. Failure to observe this could result in personal injury or death.
Three personnel are required to remove engine.
caution may result in damage to engine.
Failure to observe this
Ensure all disconnected electrical wires and hoses are clear of engine
assembly.
e.
Using hoist, slowly take up weight of engine assembly (1) and carefully slide
engine assembly (1) away from pump assembly to separate pump drive coupling
from e n g i n e f l y w h e e l .
Do not stand or put arms, l e g s , o r a n y o t h e r part of the body under hoisted
load.
Failure to observe this warning could r e s u l t i n p e r s o n a l i n j u r y o r
death.
Do not rest engine assembly on oil pan or damage will result.
f.
Hoist engine assembly (1) from trailer (7) and lower onto blocks or s u i t a b l e
engine stand.
For Model 609-C, refer to paragraph 3.8.4 and replace engine mount isolators
after engine assembly is removed.
g.
Remove lifting sling and hoist from lifting eyes on top of engine assembly
(1).
3-39
TM 10-4320-344-24
3.8.1 Engine Replacement. (Continued)
3.8.1.2 Installation.
a.
Attach lifting sling and hoist to lifting eyes on top of engine assembly (1).
Do not stand or put arms, legs, or any other part of the body under hoisted
load.
Failure to observe this warning could result in personal injury or
death.
Three personnel are required to remove engine.
caution may result in damage to engine.
Failure to observe this
b.
Hoist engine assembly (1) and position slightly above engine support (8) and
trailer (7).
c.
Align pump drive coupling with engine flywheel and carefully slide engine
assembly (1) towards pump assembly to engage pump drive coupling with engine
flywheel.
Lower hoist.
d.
Install two new lock washers (6) and bolts (5).
e.
Install two mounting bolts (4), new lock washers (3), and nuts (2).
Remove lifting eyes from Models 609-C and US636HCCD-1.
f.
Remove lifting sling and hoist from lifting eyes on top of engine
assembly (1).
Ensure engine assembly is securely mounted to trailer before starting engine.
g.
3-40
Refer to TM 10-4320-344-10 and start engine, check for fuel leaks, and stop
engine.
TM 10-4320-344-24
3.8.2 Front Engine Support Replacement. Model 609-A.
This task covers:
3.8.2.1 Removal
3.8.2.2 Installation
INITIAL SETUP
Tools
Equipment
General Mechanic's Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
Radiator Support Brackets removed, paragraph
2.20.5.
Conditions
(Continued)
Engine Assembly removed, paragraph 3.8.1.
Materials/Parts
General Safety Instructions
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Do not work on equipment that is not securely stabilized to prevent rolling or sliding.
Pumping station shut down, TM 10-4320- Do not work on equipment without following
344-10.
standard shop safety precautions.
3.8.2.1 Removal. R e m o v e f o u r n u t s ( F i g u r e 3 - 1 6 , 1 ) , l o c k w a s h e r s ( 2 ) , b o l t s ( 3 ) , a n d
front engine support (4) from trailer (5). Discard lock washers (2).
Figure 3-16.
Front Engine support Maintenance, Model 609-A.
3.8.2.2 Installation. P o s i t i o n f r o n t e n g i n e s u p p o r t ( 4 ) o n t r a i l e r ( 5 ) a n d s e c u r e w i t h
f o u r b o l t s ( 3 ) , new lock washers (2), and nuts (1).
3-41
TM 10-4320-344-24
3.8.3 Engine Support Replacement, Models 609-C and US636HCCD-1.
This task
3.8.3.1
3.8.3.2
3.8.3.3
covers:
Removal
Disassembly
Repair
3.8.3.4 Assembly
3.8.3.5 Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic's Automotive
Tool Kit, Appendix B, Section III,
Item 1
V-belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
(Continued)
General Safety Instructions
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shutdown, TM 10-4320344-10.
Do not work on equipment without following standard shop safety precautions.
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-C
3.8.3.1 Removal.
a.
Remove four bolts (Figure 3-17, 1) and two rear mounting feet (2).
b.
Remove four bolts (3), lock washers (4), flat washers (5), V-belt guard
Discard
mounting bracket (6), a n d c r o s s m e m b e r ( 7 ) f r o m e n g i n e a s s e m b l y ( 8 ) .
lock washers (4).
3 . 8 . 3 . 2 D i s a s s e m b l y . R e m o v e f o u r n u t s ( 9 ) , b o l t s ( 1 0 ) , and front mounting feet (11)
from crossmember (7).
3.8.3.3
Repair.
a.
Inspect all components for damage.
b.
Replace all defective components.
3.8.3.4 Assembly.
Position two front mounting feet (11) on crossmember (7) and secure with four
bolts (10) and nuts (9). Tighten nuts (9).
3.8.3.5 Installation.
a.
Position V-belt cover mounting bracket (6) on crossmember (7), and crossmember
(7) on engine assembly (8), securing with four flat washers (5), new lock
washers (4), and bolts (3).
b.
Position two rear mounting feet (2) on engine assembly (8) and secure with
four bolts (1).
3-42
TM 10-4320-344-24
Figure 3-17. Engine Supports Replacement, Models 609-c and US636HCCD-1.
3-43
TM 10-4320-344-24
3.8.4 Engine Mount Isolators Replacement, Model 609-C.
This task covers:
3.8.4.1 Removal
3.8.4.2
Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Engine removed, paragraph 3.8.1.
Materials/Parts
Lock Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping Station shutdown,
344-10.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
TM
10-4320-
3.8.4.1 R e m o v a l . Remove eight nuts (Figure 3-18, 1), lock washers (2), cap screws
(3), and four engine mount isolators (4) from trailer (5).
Figure 3-18.
Engine Mount Isolators, Model 609-c.
3.8.4.2 I n s t a l l a t i o n . Position four engine mount isolators (4) on trailer (5) and
secure with eight cap screws (3), new lock washers (2), and nuts (1).
3-44
TM 10-4320-344-24
3.8.5 Magnetic Pickup Replacement.
This task covers:
3.8.5.1 Removal
3.8.5.2
Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shut down,
TM 10-4320-344-10.
Battery disconnected, paragraph
2.15.5 (609-A and US636HCCD-1) or
paragraph 2.15.6 (609-C).
This procedure applies to Model 609-A.
US636HCCD-1 are similar.
Do not work on equipment with battery
Electrocution hazard is presconnected.
ent if battery is present.
Do not work on equipment without
following standard shop safety practices.
The procedures for Models 609-C and
3.8.5.1 Removal.
Figure 3-19. Magnetic Pickup Unit Replacement.
a.
Disconnect wiring harness (Figure 3-19, 1).
b.
Loosen jam nut (2) and remove magnetic pickup unit (3) from engine (4).
3-45
TM 10-4320-344-24
3.8.5 Magnetic Pickup Replacement. (Continued)
3.8.5.2 Installation.
a.
Insert magnetic pickup unit (3) into engine (4) until it bottoms out on ring
gear.
Failure to back magnetic pickup unit off one quarter turn may result in damage
to ring gear, if not backed off far enough, or improper operation if backed
off too far.
b.
Back off magnetic pickup unit (3) one quarter turn and secure with jam
nut (2).
d.
Connect wiring harness (1).
3-46
TM 10-4320-344-24
3.8.6 Governor Maintenance, Model 609-A.
This task covers:
3.8.6.1 Removal
3.8.6.2 Repair
3.8.6.3 Installation
3.8.6.4 Calibration and Adjustment
INITIAL SETUP
(Continued)
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Fuel Rack Cable disconnected from
governor, paragraph 2.16.27 (disassembly
only) .
Vernier Calipers, Appendix B,
Section III, Item 3
This
Pumping Assembly removed, 3.6.1.
applies for calibration and adjustment.
Material/Parts
General Safety Instructions
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Battery disconnected, paragraph
2.15.5 (disassembly only).
Conditions
Do not work on equipment with battery
Electrocution hazard is presconnected.
ent if battery is present.
Do not work on equipment without following
standard shop safety practices.
Alternator removed, paragraph
2.21.16 (disassembly only).
3.8.6.1 Removal.
a.
Disconnect wiring harness (Figure 3-20, 1 ) f r o m g o v e r n o r c o n t r o l a s s e m b l y ( 2 ) .
Measure length of governor linkage, before disassembling bearings and nuts
from rod, t o f a c i l i t a t e i n s t a l l a t i o n a n d a d j u s t m e n t p r o c e d u r e s .
b.
Remove self-locking nut (3), two flat washers (4), and screw (5) that secure
bearing (6) to fuel injection pump shut off lever (7).
c.
Measure length of governor linkage assembly.
d.
Remove four nuts (8), lock washers (9), socket-head screws (10), and governor
( 11 ) fr o m a c tua to r b r a c ket (12). Discard lock washers (9).
e.
Remove two screws (13), lock washers (14), and actuator bracket (12). Discard
lock washers (14).
3.8.6.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
If governor control assembly (2) or governor assembly (11) are damaged or
require repair return them as a set to the manufacturer.
c.
Replace all other defective components.
3-47
TM 10-4320-344-24
3.8.6 Governor Maintenance. Model 609-A. (Continued)
Figure 3-20. Governor, Model 609-A.
3.8.6.3 Installation.
a.
3-48
Position actuator bracket (12) on engine and secure with two new lock washers
(14) and screws (13).
TM 10-4320-344-24
b.
Position governor assembly (11) on actuator bracket (12) and secure with four
socket-head screws (10), new lock washers (9), and nuts (8).
Ensure governor linkage is assembled to length measured during removal.
c.
Install bearing (6) on governor linkage rod and align bearing (6) with fuel
injection pump shut off lever (7) securing with screw (5), two flat washers
(4), and nut (3).
d.
Connect wiring harness (1) to governor control assembly (2).
e.
Refer to paragraph 3.8.6.4 and adjust governor.
3.8.6.4 Calibration and Adjustment.
Figure 3-21.
a.
Governor Control Assembly Controls, Model 609-A.
Remove four screws ( F i g u r e 3 - 2 1 , 1 ) , w a s h e r s ( 2 ) , a n d c o v e r ( 3 ) f r o m g o v e r n o r
control box (4).
3-49
TM 10-4320-344-24
3.8.6 Governor Maintenance. Model 609-A. (Continued)
To adjust the A potentiometer, engine must be disconnected from pump
impeller and running unloaded.
The amount of droop for a given setting depends on pick-up frequency
a n d n o l o a d t o f u l l l o a d a c t u a t o r s h a f t r o t a t i o n . Lower pick-up
frequency or smaller shaft rotation results in less droop:
b.
Set potentiometers (pot) as indicated below:
A (5) at 3 o’clock
Gain (6) at 9 o’clock
D (7) at 10 o’clock
I (8) at 8 o’clock
L (9) is factory adjusted and should be at about 10 o’clock
Droop (10) at 9 o’clock.
10-4320-344-10 and start engine.
c.
Refer to
d.
Adjust
e.
Turn the A pot (5) slowly to the right until the governor actuator oscillates
(jiggles) rapidly.
f.
Turn the A pot (5) slowly to the left until the rapid oscillation just stops.
g.
If the governor
Excite governor actuator by tapping governor actuator lever.
actuator lever oscillates rapidly, turn the A pot (5) slowly to the left until
the rapid oscillation just stops.
TM
c o n t r o l l e r “SPEED” pot (11) until engine is operating at desired speed.
Hunting is when the engine RPM is not stable (moving up and down).
h.
If governor is hunting, turn GAIN pot (6) slowly to the left until it is
stable.
A moving governor actuator lever and a constant speed means unit is governing
and not hunting.
i.
If governor is stable, turn GAIN pot (6) slowly to the right until governor
starts to hunt, then turn GAIN pot (6) slowly to the left until governor is
stable.
j.
Excite governor by tapping governor actuator lever.
quickly to its command speed without hunting.
k.
Turn D pot (7) to the right until governor actuator lever begins to hunt.
(Governor may have to be excited by tapping governor actuator lever.)
l.
Turn D pot (7) slowly to the left until engine is stable.
m.
Refer to T M 1 0 - 4 3 2 0 - 3 4 4 - 1 0 a n d t u r n e n g i n e s w i t c h o f f .
to about half-speed.
n.
Refer to T M 10-4320-344-10 and turn engine switch on.
3-50
Engine should return
Let engine slow down
Observe engine RPM.
TM 10-4320-344-24
o.
If engine speed overshoots command speed, turn I pot (8) a small amount to the
left. Repeat steps m and n until engine no longer overshoots coxmnand speed.
NOTE
Changing the adjustments A, D, DROOP, and GAIN may cause a slight engine
speed change which will require resetting the SPEED adjustment.
p.
If engine speed changes during adjustments, readjust engine speed.
q.
Position cover (3) on governor control box (4).
r.
Install four washers (2) and screws (1). Tighten screws (1).
3-51
TM 10-4320-344-24
3.8.7 Governor Actuator Assembly Maintenance, Model 609-C.
This task covers:
3 .8.7.1 Removal
3.8.7.2 Repair
3.8.7.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Auto Defeat Cable disconnected from
Actuator and Auto Defeat Cable Mounting
Bracket removed, paragraph 2.16.28.
Vernier Calipers, Appendix B,
Section III, Item 3
General Saftey Instructions
Material/Parts
Lock Washers (TM 10-4320-344-24P)
Self-locking Nut (TM 10-4320-344-24P)
Conditions
(Continued)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Do not work on equipment with battery
connected. Electrocution hazard is
present if battery is connected.
Pumping stations shut down, TM
10-4320-344-10.
Do not work on equipment without following
standard safety precautions.
Battery disconnected, paragraph 2.15.6.
3.8.7.1 Removal.
•
a.
Do not work on equipment with battery connected. Electrocution hazaed
is present if battery is connected. Failure to obey this warning may
result in serious personal injury.
Open right side engine access door (Figure 3-22, 1).
NOTE
Measure length of governor linkage, before disassembling bearings and nuts
from rod, to facilitate installation and adjustment procedures.
b.
Remove self-locking nut (2), two flat washers (3), and screw (4) that secure
bearing (5) to fuel injection pump lever (6). Discard self-locking nut (2).
c.
Using vernier calipers, measure length of governor linkage assembly.
d.
Disconnect cable connector (7) from governor actuator assembly (8).
e.
Remove four governor actuator
actuating assembly (8).
f.
Remove two cap screws (11), lock washers (12), and mounting bracket (13).
Discard lock washers (12).
mounting
bolts
(9),
nuts
(10),
governor
3.8.7.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
If governor actuator assembly (8) is damaged or requires repair, replace
governor actuator assembly (8).
3-52
TM 10-4320-344-24
Figure 3-22.
Governor Actuator Assembly, Model 609-C.
3-53
TM 10-4320-344-24
3.8.7 Governor Actuator Assembly Maintenance, Model 609-C. (Continued)
c.
Replace all other defective components.
3.8.7.3 Installation.
a.
Position mounting bracket (13) on engine and secure with two new lock washers
(12) and cap screws (11).
b.
Position governor actuator assembly (8) on mounting bracket (13) and secure
with four nuts (10) and bolts (9).
c.
Connect cable connector (7) to actuator assembly (8).
NOTE
Ensure length of governor linkage assembly meets measurement taken during
removal.
d.
Align bearing (5) with fuel injection pump lever (6) and secure with screw
(4), two flat washers (3), and new self-locking nut (2).
e.
Close right side engine access door (1).
f.
Refer to paragraph 2.16.32 and adjust governor control module.
3-54
TM 10-4320-344-24
3.8.8 Governor Maintenance. Model US636HCCD-1.
This task covers:
3.8.8.1 Removal
3.8.8.2 Repair
3.8.8.3 Installation
3.8.8.4 Calibration and Adjustment
INITIAL SETUP
(Continued)
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Battery disconnected, paragraph 2.15.5.
Multimeter, Appendix B, Section III,
Item 2
Conditions
Control Panel Cover Assembly removed,
paragraph 2.16.2 (for calibration and
adjustment only).
General Safety Instructions
Vernier Calipers, Appendix B, Section
III, Item 3
Material/Parts
Tags, Appendix C, Item 31
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment with battery
connected. Electrocution hazard is present if battery is present.
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Do not work on equipment without following standard shop safety practices.
3.8.8.1 Removal.
Figure 3-23.
Governor Maintenance, Model US636HCCD-1.
3-55
TM 10-4320-344-24
3.8.8 Governor Maintenance, Model US636HCCD-1.
a.
(Continued)
Remove two screws (Figure 3-23, 1), lock washers (2), and tag and remove two
w i r e s ( 3 ) f r o m g o v e r n o r ( 4 ) . Discard lock washers (2).
NOTE
Measure length of governor linkage before removing governor, to facilitate
installation and adjustment procedures.
b.
Remove nut (5) and bolt (6) that secure bearing (7) to fuel injection pump
lever (8).
c.
Measure length of governor linkage assembly.
d.
Remove three mounting bolts (9), lock washers (10), and mounting bracket (11)
from engine (12). Discard lock washers (10).
e.
Remove four mounting bolts (13), lock washers (14), and governor (4) from
mounting Discard lock washers (14).
3.8.8.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
If governor (4) is damaged or requires repair return it to the manufacturer.
c.
Replace all defective components.
3.8.8.3 Installation.
a.
Position qovernor (4) on mountinq bracket (11) and secure with four new lock
washers (14) and mounting bolts (13).
b.
Position mounting bracket (11) on engine (12) and secure with three new lock
washers (10) and mounting bolts (9).
NOTE
Ensure length of governor linkage assembly meets measurement taken during
removal.
c.
Align bearing (7) with fuel injection pump lever (8) and secure with bolt (6)
and nut (5).
d.
Refer to tags, position two wires (3) against governor (4), and secure with
two new lock washers (2) and screws (1). Remove and discard tags.
3.8.8.4 Calibration and Adjustment.
a.
Tag and disconnect wire from pin 16 of process control.
b.
Turn on supply to both controls, and start engine, reference TM 10-4320-34410, with mode select switch on control panel set to "MANUAL" and speed
potentiometer on control panel set to "IDLE”.
c.
Slowly increase control panel speed potentiometer until fully clockwise. Then
adjust speed potentiometer 8290-040 so that engine is operating at 2,350-2,400
RPM .
d.
Adjust "GAIN” and “STABILITY” potentiometers to smooth out engine operation.
3-56
TM 10-4320-344-24
NOTE
The correct setting is 6.31 ± 0.05 V between pins 8 and 9 when the engine is
running.
e.
Measure voltage between pins 8 and 9 of process control while engine is
running.
f.
Refer to TM 10-4320-344-10 and stop engine.
g.
Carefully reconnect wire pin 16 of process control.
Remove and discard tag.
NOTE
For the remaining steps the pumping assembly must be connected to a water
source capable of supplying adequate water to maintain inlet pressure up to
30 psi (207 kPa) and discharge pressure of 150 ± 5 psi (1033 ± 34 kPa).
h.
Refer to TM 10-4320-344-10 and restart engine manually, and again slowly
increase control panel speed potentiometer setting to fully clockwise
position.
i.
Set inlet pressure above 20 psi (142 kPa) and outlet pressure to approximately
150 psi (1033 kPa) at pumping assembly.
j .
Move control mode toggle switch to “NORMAL" position.
NOTE
The engine should be controlling at 150 ± 5.0 psi (1033 ± 34 kPa).
k.
Slowly lower inlet pressure to just above 20 psi (138 kPa); and slowly adjust
high limit potentiometer counterclockwise until engine speed decreases.
l.
Move high limit potentiometer clockwise until engine returns to previous speed
setting.
NOTE
T h e “ G A I N= potentiometer can be used to help stabilize the engine when
pumping at 150 psi (1033 kPa) discharge pressure and approximately 30 psi
(207 kPa) inlet pressure.
m.
Slowly lower the inlet pressure to 10 psi (69 kPa) and adjust low limit
potentiometer so that engine is idling at 900 ± 50 RPM.
3-57
TM 10-4320-344-24
3.8.9 Fuel Injection Pump Assembly Maintenance, Model 609-A.
This task covers:
3.8.9.1 Removal
3.8.9.2 Repair
3.8.9.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Manual Throttle Control Cable
disconnected, paragraph 2.16.25.
Torque Wrench, Appendix B, Section
III, Item 2
Fuel Injection Nozzle and Holder Assembly
removed from number 1 cylinder, paragraph
2.21.8.
Material/Parts
Pan,
Rags,
Tags,
Lock
Appendix C, Item 19
Appendix C, Item 20
Appendix C, Item 31
Washers (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
(Continued)
Starter Assembly removed, paragraph
2.21.18.
Governor removed, paragraph 3.8.6.
General Safety Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
Fuel Return Line disconnected and capped, cigarettes, and open flame away from fuel
paragraph 2.21.2.
system components.
Fuel Injection Lines and Fuel Leakoff
Manifold Assembly Return Line
disconnected and capped, paragraph
2.21.7.
Fuel Supply Line Hose removed, paragraph
2.21.2.
Do not work on equipment with battery
connected.
Electrocution hazard is present if battery is present.
Do not work on equipment without following standard shop safety practices.
3.8.9.1 Removal.
D i e s e l f u e l i s f l a m m a b l e . K e e p s p a r k s , c i g a r e t t e s , and open flame away from
fuel system components. Failure to obey this warning may result in personal
injury or death.
Do not allow dirt or foreign matter to enter fuel injection pump assembly or
fuel lines, equipment damage may result.
a.
Clean all areas adjacent to fuel injection pump (FIP) assembly (Figure 3-24,
1) to prevent dirt from entering the fuel system. Cap or plug all fuel entry
and exit ports on FIP (1).
b.
Remove two screws (2), cover plate (3), and gasket (4) from side of FIP (1).
c.
Place thumb over the number 1 cylinder fuel injection nozzle opening in
cylinder head.
3-58
TM 10-4320-344-24
Figure 3-24.
Fuel Injection Pump Assembly Removal, Model 609-A.
3-59
TM 10-4320-344-24
3.8.9
d.
Fuel Injection Pump Assembly Maintenance, Model 609-A. (Continued)
Turn crankshaft slowly in the direction of normal rotation and feel for air
being forced out during the compression stroke. When compression is felt
turn crankshaft until timing marks (5) on the FIP (1) are aligned in the
center of the timing hole (6).
The exact pump timing will be indicated by the flywheel degree mark aligned
with the timing pointer.
e.
Aline FIP timing marks (5) exactly and check timing mark on flywheel (7).
Record flywheel degree.
f.
Remove two nuts (8) securing three wires (9) to top of FIP (1). Tag and
remove three wires (9). Install and hand tighten two nuts (8).
g.
Remove four screws (10), lock washers (11), thrust plate gear hausing cover
(12), and gasket (13) from gear housing (14). Discard lock washers (11) and
gasket (13).
h.
Remove thrust plug (15), spring (16), nut (17), and lock washer (18) that
secure drive gear (19) to FIP drive shaft (20). Discard lock washers (18).
i.
Remove two bolts (21) and lock washers (22) that secure FIP (1) to gear
housing.
Discard lock washers (22).
When the FIP is removed for repair, secure the throttle in the wide open
position after removal. This will prevent internal damage while in transit
or storage.
Place clean rag against drive gear to keep it from falling into gear housing.
j.
Move FIP (1) from gear housing approximately 1/4 inch (6.35 mm).
mallet, tap FIP drive shaft (20) to remove FIP (1).
Using a
3.8.9.2 Repair.
a.
Inspect FIP (1) for damage.
b.
Inspect all mounting hardware for damage.
c.
Replace all damaged or defective components.
3.8.9.3 Installation.
a.
Place thumb over the number 1 cylinder fuel injection nozzle opening on
engine.
b.
Turn crankshaft slowly in the direction of normal rotation and feel for air
being forced out during the compression stroke. When compression is felt,
turn crankshaft until flywheel degree pointer aligns with degree marks as
recorded during removal of FIP. (1).
c.
Remove two bolts (2), cover plate (3), and gasket (4) from side of FIP (1).
3-60
TM 10-4320-344-24
Do not rotate FIP drive shaft backwards to align the internal timing marks.
Always rotate FIP drive shaft in same direction as engine crankshaft when
viewed from front or timing gear end of engine.
Failure to obey this caution
will damage FIP.
d.
Turn FIP drive shaft (20) in the direction of engine rotation until timing
marks (5) are aligned in the center of the timing hole (6).
e.
Insert FIP drive shaft (20) into taper of the drive gear (19) and align FIP
(1) mouinting holes.
f.
Install two new lock washers (22) and bolts (21).
g.
I n s t a l l n e w l o c k w a s h e r ( 1 8 ) a n d n u t ( 1 7 ) o n F I P d r i v e s h a f t ( 2 0 ) . Adjust FIP
drive shaft (20) until timing marks (5) are aligned in the center of timing
h o l e ( 6 ) . Torque nut (17) to 65 ft-lbs (88 N•m).
e.
Insert spring (16), and thrust plug (15) in end of FIP drive shaft (20).
f.
Install new gasket (13) and thrust plate gear housing plate (12) on gear
housing (14) and secure with four new lock washers (11) and screws (10).
g.
Remove two nuts (8), r e f e r t o t a g s a n d i n s t a l l t h r e e w i r e s ( 9 ) .
h.
Secure wires (9) with two nuts (8) and remove and discard tags.
i.
Install gasket (4) and cover plate (3) securing with two screws (2).
j .
Remove caps or plugs from all fuel entry and exit ports on FIP (1).
Hand tighten bolts (21).
3-61
TM 20-4320-344-24
3.8.10 Fuel Injection Pump Assembly Test and Adjustment, Model 609-A.
This task covers:
Test and adjustment.
INITIAL SETUP
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Fuel Injection Pump Assembly removed,
paragraph 3.8.9.
General Safety I n s t r u c t i o n s
Goggles, Industrial, Appendix B,
Section III, Item 2
Do not work on equipment without following standard shop safety practices.
Gun, Air Blow, Appendix B, Section
III, Item 2
NOTE
The bench test procedure is based on the following conditions:
Injection lines are 3/32 inch (2.38 mm) ID by 30 inches (762 mm) long.
Fuel readings are based on fuel with a viscosity of 34-36 SSL at 100° F
(37.78° C).
Fuel temperature is at 110° to 115° F (43.33 to 46.11° C).
N o z z l e s , part number 12SD12, are adjusted to opening pressure of 2,500
psi (17,538 kPa).
a.
Install fuel injection pump on test stand.
b.
Using two wrenches, i n s t a l l a p p l i c a b l e t r a n s f e r p u m p i n l e t c o n n e c t o r .
sure outlet fitting does not get moved at the same time.
c.
Install transfer pump gage connector.
d.
Install a shutoff valve to isolate gage when not in use.
e.
Connect a pressure gage to adapter on gage c o n n e c t o r .
Make
NOTE
Some pumps require one-quarter of one degree s e t t i n g a c c u r a c y .
p e r f o r m s t e p f . Otherwise, perform step g.
If so,
f.
Remove timing line cover and install advance gage.
g.
Remove timing line cover and install advance window.
h.
Determine proper direction of pump rotation.
from drive end of pump.
i.
If pump is equipped with an “ENERGIZED-TO-RUN” electric shutoff device,
energize it at lowest speed with specified voltage.
j .
Move pump throttle lever to full load position.
k.
When transfer pump is primed, allow fuel to bleed for several seconds from
loosened injection line nuts at nozzles.
l.
Securely tighten line n u t s .
3-62
Rotation is determined as viewed
TM 10-4320-344-24
ERPM in step m refers to engine rpm.
Keep in mind that most test bench
tachometers register pump RPM, which is one half engine speed for four stroke
cycle engines.
m.
Operate pump at 1,000 ERPM wide open throttle (WOT) for 10 minutes.
To prevent the possibility of embedding foreign objects in the eyes, safety
glasses must be worn when using compressed air.
n.
Using compressed air, completely dry pump.
o.
Check for leaks and correct as required.
p.
Back out high idle, low idle, and torque screw.
q.
Perform vacuum check as follows:
(1) Close valve in fuel supply line.
(2) Operate pump at 400 ERPM.
Transfer pump must be capable of creating vacuum of at least 18 inches of
mercury.
(3) If pump does not meet minimum specifications, check for air leaks between
pump inlet and shutoff valve.
( 4 ) I f n o l e a k s a r e p r e s e n t , check for damaged or defective transfer pump
components.
r.
Fill graduates to bleed air from test stand and to wet glass.
s.
Direct return oil flow into appropriately calibrated graduate for a given time
and check return oil quantity.
t.
Operate at specified speeds with wide open throttle and observe transfer pump
pressure.
Do not exceed 130 psi (912 kPa) under any circumstances.
result.
u.
Damage to pump may
To raise or lower transfer pump pressure, adjust pressure regulating spring
plug as follows:
(1) Remove line to transfer pump inlet connector.
(2) Using 5/32 inch (3.97 mm) hex key wrench, adjust plug.
Do not over-adjust plug.
Damage to plug or pump may result.
(3) Turn plug right to increase pressure.
v.
Turn plug left to decrease pressure.
Check for minimum delivery at cranking speed.
3-63
TM 10-4320-344-24
3.8.10 Fuel Injection Pump Assembly Test and Adjustment, Model 609-A. (Continued)
w.
Operate pump at high speed.
delivery.
x.
Recheck transfer pump pressure and correct as required (steps q through u
above).
y.
Adjust low idle screw to correct low idle delivery.
z.
Check automatic advance as follows:
Adjust high idle screw to obtain specified
(1)
Check cam position at specified points in speed range.
(2)
Adjust trimmer screw as required to obtain proper advance operation.
(3)
After setting- advance, check to see that cam returns to its initial position
at 0 RPM.
aa.
Recheck transfer pump pressure and correct as required (steps q through u
above).
Roller settings should not be readjusted on the test bench.
injection pump assembly may result
Damage to fuel
When recording check points, micrometer and dial indicator settings provide
more consistent,
accurate results. Variations in test bench drives,
instrumentation, nozzles, l i n e s , a n d f u e l s i n d i f f e r e n t a r e a s s o m e t i m e s
r esults in n o nc o nfo r ming flo w r e ading s.
ab. Record fuel delivery check points shown on pump specifications.
a c . Operate pump at full-load governed speed.
delivery.
Set torque screw to specified
a d . Recheck transfer pump pressure (steps q through u above) and advance movement
(step z). Correct as required.
a e . Recheck delivery at lowest speed check point.
a f . Check governor cutoff at specified speed.
ag. Check electric shutoff at speed indicated on specification.
ah.
Remove pump from test stand.
a i . Assemble all sealing wires.
3-64
TM 10-4320-344-24
3.8.11 Fuel Injection Pump Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
3.8.11.1 Internal Leakage Test
3.8.11.2 Start-of-Delivery Test
3.8.11.3 Adjustment
3.8.11.4 Removal
3.8.11.5 Repair
3.8.11.6 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Air Cleaner Assembly removed,
paragraph 2.14.3 (US636HCCD-1).
Dial Indicator, Appendix B,
Section III, Item 3
Injection Pump Tester, Appendix
B, Section III, Item 11
P o i n t e r , Appendix B, S e c t i o n I I I ,
Item 12
Setting Device, Appendix B,
Section III, Item 13
Pump Lever, Appendix B, Section
III, Item 14
Graduation Magnet, Appendix B,
Section III, Item 15
Battery disconnected, paragraph 2.15.6
(609-C) or 2.15.5 (US636HCCD-1).
Fuel Lines and Oil Line disconnected from
Fuel Transfer Pump Assembly and Fuel
Injection Pump Assembly and capped,
paragraph 2.21.2.
Fuel Injection Lines disconnect and
capped, paragraph 2.21.7.
V-Belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
Cylinder Head Cover removed, paragraph
2.21.48.
Governor Linkage disconnected, paragraph
3.8.7 (609-C) or 3.8.8 (US636HCCD-1).
Material/Parts
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Preformed Packing (TM 10-4320-344-24P)
Equipment Conditions
Pumping station shut down, TM
10-4320-344-10.
Top Panel Assembly removed,
paragraph 2.12.4. (609-C).
V-Belt Tensioner Assembly removed,
paragraph 3.8.16.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
system components.
Right Side Panel Assembly removed,
paragraph 2.12.6. (609-C).
Do not work on equipment with battery
Electrocution hazard is presconnected.
ent if battery is present.
Bulkhead Panel Assembly removed,
paragraph 2.12.15. (609-C).
Do not work on equipment without following standard shop safety practices.
3-65
TM 10-4320-344-24
3.8.11 Fuel Injection Pump Assembly Maintenance, Models 609-C and US636HCCD-1. (Continued)
3.8.11.1 Internal Leakage Test.
Figure 3-25.
Internal Leakage Test Setup.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks, cigarettes, and open flame away from
fuel system components.
Failure to obey this warning may-result i n p e r s o n a l
injury or death.
Do not allow dirt or foreign matter to enter fuel injection pump assembly or
f u e l l i n e s , equipment damage may result.
a.
Place pan under fuel injection pump (FIP) assembly (Figure 3-25, 1).
b.
Remove two screws, flat washers, cover, and gasket f r o m l o c a t i o n “ A ” o f F I P
assembly (1).
Cylinders are numbered from the flywheel end of engine.
c.
R o t a t e c r a n k s h a f t u n t i l n u m b e r 1 i n j e c t i o n t a p p e t in FIP assembly (1) is in
bottom position.
d.
Disconnect and cap number 1 fuel injection line (2) from FIP assembly (1).
3-66
TM 10-4320-344-24
e.
Install injection pump tester (3) on number 1 outlet port of FIP assembly (1).
Do not tighten injection pump tester (3) at this time.
f.
Install pump lever tool (4) under number 1 tappet spring in FIP assembly (1).
g.
Pump the lever on the fuel transfer pump assembly (5) and pump number 1 tappet
w i t h p u m p l e v e r t o o l ( 4 ) . Continue pumping until fuel flowing from number 1
outlet port is free of air bubbles.
h.
Tighten injection pump tester (3).
i.
pump lever on fuel transfer pump assembly (5) and p u m p l e v e r t o o l ( 4 ) o n
number 1 tappet until injection pump tester (3) reads 2,175 psi (1,492 kPa) .
Stop pumping.
If pressure on injection pump tester (3) falls more than 145
psi (1,013 kPa) in 1 minute, F I P a s s e m b l y ( 1 ) i s d e f e c t i v e .
j.
Pump lever on fuel transfer pump assembly (5) and pump lever tool (4) on
number 1 tappet until injection pump tester (3) reads 5,075 psi (34,442 kPa) .
If 5,075 psi (34,442 kPa) can not be obtained, FIP assembly (1)
Stop pumping.
is defective.
k.
Release pressure from injection pump tester (3).
l.
Remove pump lever tool (4) and injection pump tester (3) from FIP assembly
(1).
m.
Uncap and connect fuel injection line to number 1 outlet port on FIP assembly
(1).
n.
Repeat steps d through m until fuel outlet ports 2 through 6 on FIP assembly
(1) have been tested.
o.
Position gasket and cover on FIP assembly (1) in location a and secure with
two washers and screws.
p.
Remove pan and properly dispose of fuel in accordance with standing operating
procedures.
3.8.11.2 Start-of-Delivery Test.
Figure 3-26.
Dial Indicator and Setting Device Installation.
3-67
TM 10-4320-344-24
3.8.11 Fuel Injection P ump Assembly Maintenance, Models 609-C and US636HCCD-1.
(Continued)
If top dead center (TDC) and fuel injection point are marked on
crankshaft pulley, perform step a and proceed to step s.
Cylinders are numbered from flywheel end of engine.
a.
Place pan under FIP assembly and turn crankshaft until number 1 cylinder is at
TDC.
If TDC and fuel injection point are not marked on crankshaft pulley, perform
steps b through r to determine TDC and fuel injection point.
b.
Turn crankshaft until valves on cylinder number 1 overlap.
c.
Mount setting device (Figure 3-26, 1).
d.
Depress rocker arm (2) 0.197-0.236 inches (5-6 mm).
e.
Mount dial indicator (3) on setting device (1) and preload.
Figure 3-27.
Pointer and Graduation Magnet Installation.
f.
Attach pointer (Figure 3-27, 1) to dowel sleeve.
g.
Attach graduation magnet (2) to crankshaft pulley (3).
h.
Align 0
i.
Turn crankshaft slowly to the right until depressed valve (Figure 3-26, 2)
moves upward. Continue turning crankshaft until pointer on dial indicator (3)
s t a r t s t o c h a n g e d i r e c t i o n . Stop turning crankshaft.
j.
Set dial indicator (3) to 0.
k.
Turn crankshaft to the left until pointer of dial indicator (3) completes one
revolution and dial indicator (3) reads 0.004 inches (0.1 mm) from 0.
l.
Record the crankshaft position from the graduation magnet
indicated by the pointer (1).
3-68
on graduation magnet (2) with pointer (1).
(Figure 3-27, 2) as
TM 10-4320-344-24
m.
Turn crankshaft to the right until dial indicator (Figure 3-26, 3) reads 0.004
inches (0.1 mm) from 0.
n.
Record crankshaft position from the graduation magnet (Figure 3-27, 2) as
indicated by pointer (1).
o.
Determine midpoint between the two readings recorded in steps l and n above.
p.
Turn crankshaft and align pointer (1) with midpoint reading calculated in step
o a b o v e . Number 1 cylinder is now at TDC.
q.
Move graduation magnet (2) so that 0
r.
Turn crankshaft to the left one-quarter turn.
s.
Turn crankshaft to the right until pointer (1) is aligned with the 28° mark
before 0 on graduation magnet (2), fuel injection point.
t.
Place drip pan under FIP assembly.
aligns
with pointer (1).
NOTE
Cylinders are numbered from flywheel side of engine.
u.
Disconnect fuel injection line from FIP assembly for number 1 cylinder.
v.
Connect overflow pipe to number 1 injection port on FIP assembly.
w.
Turn crankshaft one-quarter turn to the left.
x.
Pump lever on bottom of the fuel transfer pump assembly until fuel flows from
overflow pipe.
y.
Continue pumping lever while slowly turning crankshaft to the right. Stop
turning crankshaft when fuel flowing from overflow pipe slows to 5-8 drops per
second.
NOTE
If reading is not correct, adjust FIP assembly.
z.
Take reading from graduation magnet (2) as indicated by pointer (1).
reading is 28° to 29°.
Correct
3.8.11.3 Adjustment.
a.
Turn crankshaft to the left one-quarter turn from TDC.
b.
Turn crankshaft to the right until pointer (Figure 3-27, 1) aligns with 28°
mark before TDC on the graduation magnet (2), o r f u e l i n j e c t i o n p o i n t m a r k .
c.
Loosen three pump drive gear screws (Figure 3-28, 1).
d.
Begin pumping lever on fuel transfer pump assembly.
e.
Slowly turn injection pump drive shaft (2) to the left until fuel flow from
overflow pipe is 5-8 drops per second.
Stop turning shaft and pumping lever
on fuel delivery pump.
f.
Tighten three injection pump drive gear screws (1).
g.
Remove graduation magnet (Figure 3-27, 2) and pointer (1).
h.
Remove dial indicator (Figure 3-26, 3) and setting device (1).
i.
Remove pan and properly dispose of fuel in accordance with standing operating
procedures.
3-69
TM 10-4320-344-24
3.8.11 Fuel Injection Pump Assembly Maintenance, Models 609-C and US636HCCD-1. (Continued)
Figure 3 - 2 8 .
3.8.11.4
Removal.
Figure 3-29.
a.
3-70
Fuel Injection Pump Assembly Adjustment.
Fuel Injection Pump Assembly, Models 609-C and US636HCCD-1.
Place drip pan under fuel injection pump assembly (Figure 3-29, 1).
TM 10-4320-344-24
NOTE
To prevent difficulty when reinstalling fuel injection pump assembly,
do no t tur n c r a nksha ft while fuel inject ion pump is removed.
P l a c e c l e a n c l o t h against fuel injection pump drive gear when fuel
injection pump is removed to keep gear from falling i n t o f r o n t c o v e r .
b.
Remove three screws (Figure 3-28,
gear (3).
1) and flat washers from FIP assembly drive
c.
Remove four nuts (Figure 3-29, 2) and flat washers (3) from FIP assembly
mounting studs (4) .
d.
Remove FIP assembly (1) and preformed packing (5).
(5).
Discard preformed packing
3.8.11.5 Repair.
a.
Inspect FIP assembly (1) for damage.
b.
Inspect all mounting hardware for damage.
c.
Replace all damaged or defective components.
3.8.11.6
Installation.
a.
Remove two screws (6), flat washers,
(1).
b.
Rotate FIP drive shaft (8) until the f i r s t p l u n g e r o f F I P a s s e m b l y ( 1 ) i s a t
TDC .
c.
Position gasket and cover (7) on FIP assembly (1) and secure with two flat
washers and screws (6).
d.
Install new preformed packing (5) on mounting flange of FIP assembly (1).
cover (7), and gasket from FIP assembly
NOTE
Mounting studs should be centered in elongated holes of FIP assembly.
Remove clean cloth used to stabilize fuel injection pump drive gear.
e.
Install FIP assembly (1) on mounting studs (4) and secure with four flat
washers (3) and nuts (2).
f.
I n s t a l l t h r e e w a s h e r s a n d s c r e w s ( F i g u r e 3 - 2 8 , 1) in fuel injection pump drive
gear (3).
g.
Test and adjust fuel injection pump start-of-delivery paragraph 3.8.11.2,
above.
h.
Remove pan and properly dispose of fuel in accordance with standing operating
procedures.
3-71
TM 10-4320-344-24
3.8.12 0il Pan Assembly Maintenance.
This task covers:
3.8.12.1
Removal
3.8.12.2
Repair
3.8.12.3
Installation
INITIAL SETUP
Tools
Reference
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
TM 9-237
Equipment
Goggles, Industrial, Appendix B,
Section III, Item 2
Pumping station shut down, TM 10-4320-34410.
Torque Wrench, Appendix B, Section
III, Item 2 (609-A only)
Oil drained, LO 10-4320-344-12.
Acetylene Welding Equipment,
Appendix B, Section III, Item 3
Conditions
Oil Drain Assembly removed, paragraph
2.21.32.
Engine Assembly removed, paragraph 3.8.1.
Material/Parts
General Safety I n s t r u c t i o n s
G l o v e s , Appendix C, Item 11
Grease, Appendix C, Item 12
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Gasket Sealing Compound, Appendix C,
Item 23
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gaskets (TM 10-4320-344-24P)
Lock Washer (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1.
and 609-C are similar.
The procedures for Models 609-A
3.8.12.1 Removal.
NOTE
Note or mark location of long screw and spacer.
a.
Remove 26 short screws (Figure 3-30, 1 ) a n d f l a t w a s h e r s ( 2 ) , o n e l o n g s c r e w
(3), one lock washer (4), and one spacer (5). Discard lock washer (4).
b.
Remove oil pan (6),
gaskets (7).
two gaskets (7) and intermediate plate (8).
Discard
3.8.12.2 Repair.
a.
3-72
Inspect gasket mounting surfaces on oil pan (6), intermediate plate (8), and
crankcase block. Remove all gasket particles from gasket mounting surfaces.
Ensure gasket mounting surfaces of oil pan (6) are clean and free from burrs.
TM 10-4320-344-24
Figure 3-30.
0il Pan Assembly Replacement.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
Dry cleaning solvent is
smoke or use near open flame or excessive heat.
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
Failure to
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
obey this warning may result in personal injury or death.
b.
Using solvent, clean oil pan (6), all gasket mounting surfaces, and all
Dry thoroughly.
mounting parts.
3-73
TM 10-4320-344-24
3.8.12 0i1 Pan Assembly Maintenance. (Continued)
c.
Inspect all components and mounting hardware for damage.
d.
Weld oil pan in accordance with TM 9-237 or replace as required.
e.
Replace all other defective components.
NOTE
When installing new gaskets on Model 609-A use sealing compound.
Progressively torque bolts on Model 609-A to 20 ft-lbs (27 N•m).
3.8.12.3
Installation.
a.
Lightly grease two new gaskets (7).
b.
Position intermediate plate (8), new gaskets (7), and oil pan (6) against
engine and secure with one spacer (5), one new lock washer (4), and long screw
(3) in location noted or marked in 3.8.12.1 step a, and 26 flat washers (2)
and short screws (1).
3-74
TM 10-4320-344-24
3.8.13 Suction Pipe Replacement, Models 609-C and US636HCCD-1.
This task covers:
3.8.13.1 Removal
3.8.13.2 Repair
3.8.13.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic's Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Oil pan removed, paragraph 3.8.12.
Material/Parts
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
Conditions
General Safety I n s t r u c t i o n s
D O not work on equipment without
following standard shop safety practices.
3.8.13.1 Removal.
Figure 3-31.
Suction Pipe Replacement, Models 609-C and US636HCCD-1.
a.
Remove two nuts (Figure 3-32, 1), lock washers (2), and retaining bolts (3)
from retaining bracket (4). Discard lock washers (2).
b.
Loosen nut (5) and remove tube assembly (6) from retaining bracket (4) and oil
pump assembly (7).
c.
Remove two mounting bolts (8), flat washers (9), a n d r e t a i n i n g b r a c k e t ( 4 ) .
3-75
TM 10-4320-344-24
3.8.13.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
3.8.13.3 Installation.
a.
Position retaining brackets (4) against crankcase and secure with two flat
washers (9) and bolts (8).
b.
Install tube assembly (6) in retaining brackets (4) and secure to oil pump
assembly (7) with nut (5).
c.
Secure retaining bracket (4) with two retaining bolts (3), new lock washers
(2), and nuts (1).
3-76
TM 10-4320-344-24
3.8.14 Oil Pump Assembly Maintenance. Model 609-A.
This task covers:
3.8.14.1 Removal
3.8.14.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Tachometer Shaft and Angle Drive removed,
paragraph 2.21.45.
Conditions
Oil pan removed, paragraph 3.8.12.
Torque Wrench, Appendix B, Section
III, Item 2
Material/Parts
General Safety I n s t r u c t i o n s
Do not work on equipment without following standard shop safety practices.
Rags, Appendix C, Item 20
Lock Washers (TM 10-4320-344-24P)
3.8.14.1 Removal.
Figure 3-32.
Oil Pump Assembly, Model 609-A.
a.
Turn crankshaft so no. 1, 4, or 6 piston is at TDC.
b.
Remove two bolts (Figure 3-31, 1) and lock washers (2) that secure flange of
o i l p u m p a s s e m b l y ( 3 ) t o c y l i n d e r b l o c k . Discard lock washers (2).
c.
Rotate crankshaft and, at the same time,
spiral motion.
3.8.14.2
remove oil pump assembly (3) with
Installation.
a.
Turn engine crankshaft so no. 1, 4, or 6 piston is at TDC.
b.
Rotate crankshaft and, at the same time, i n s t a l l o i l p u m p a s s e m b l y ( 3 ) w i t h
s p i r a l m o t i o n . Ensure arrow on oil pump gear is aligned with arrow on fuel
pump attaching pad.
c.
Install two new lock washers (2) and bolts (1) securing oil pump assembly (3)
to cylinder block. Torque bolts (1) to 25 ft-lbs (34 N•m).
3-77
TM 10-4320-344-24
3.8.15 Oil Nozzle Replacement, Model US636HCCD-1.
This task covers:
3.8.15.1
Removal
3.8.15.2
INITIAL SETUP
Installation
Material/Parts
Tools
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Screw, 0.25 inch diameter by 1.50 inches
long
Equipment Conditions
Drill, Mechanical, Appendix B,
Section III, Item 2
Pumping station shut down, TM 10-4320344-10.
Drill Set, Twist, Appendix B,
Section III, Item 2
Oil Cooler removed, paragraph 2.21.30.
Puller Kit, Mechanical, Appendix B,
Section III, Item 2
Threading Set, Screw, Appendix B,
Section III, Item 3
Nozzle Tool, Appendix B, Section III,
Item 16
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
3.8.15.1 Removal.
Figure 3-33.
a.
3-78
Oil Nozzle Replacement, Model US636HCCD-1.
Drill and tap 0.250 inch (6.35 mm) diameter hole in oil nozzle (Figure 3-33,
1), approximately 1.5 inches (38.1 mm) deep.
TM 10-4320-344-24
b.
Put 0.250 inch (6.35 mm) diameter screw
oil nozzle (1).
c.
Remove oil nozzle (1) from crankcase (2).
3.8.15.2
(about 1.5 inches (38.1 mm) long) into
Installation.
NOTE
Point index pin of oil nozzle toward cylinder head.
a.
Insert oil nozzle (1) in crankcase (2).
b.
Install nozzle tool on oil nozzle (1), with end of tool over adjacent oil
nozzle.
c.
Insert oil nozzle (1) until index pin (3) is against crankcase (2) and remove
nozzle tool.
3-79
TM 10-4320-344-24
3.8.16 V-Belt Tensioner Maintenance. Models 609-C and US636HCCD-1.
This task covers:
3.8.16.1 Removal
3.8.16.2 Disassembly
3.8.16.3 Repair
3.8.16.4 Assembly
3.8.16.5 Installation
INITIAL SETUP
Tools
Equipment
Conditions
(Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
V-Belts removed, paragraph 2.21.12.
V-Belt Contact Switch and Mounting
Bracket removed, paragraph 2.21.19.
Material/Parts
General Safety I n s t r u c t i o n s
Rags, Appendix C, Item 20
Gasket (TM 10-4320-344-24P)
Preformed Packing (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
V-Belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-C
3.8.16.1 Removal.
a.
Remove screw (Figure 3-34, 1) a n d f l a t w a s h e r ( 2 ) .
b.
Remove nut (3) and flat washer (4).
c.
Remove V-belt tensioner housing (5) and preformed packing (6).
preformed packing (6).
Discard
3.8.16.2 Disassembly.
a.
Remove three screws (7), cover (8), and gasket (9) from pulley assembly (10).
Discard gasket (9).
b.
Remove nut (11), f l a t w a s h e r ( 1 2 ) , p u l l e y s c r e w ( 1 3 ) , p u l l e y a s s e m b l y ( 1 0 ) ,
and shims (14) if present.
3.8.16.3 Repair.
a.
Inspect pulley assembly (10) for free rotation without grinding or seizing.
b.
Inspect all other components and mounting hardware for damage.
c.
Replace all damaged or defective components.
3.8.16.4 Assembly.
a.
3-80
Position pulley assemblv (10) on V-belt tensioner assemblv (5) and secure with
shims (14) if present during disassembly, pulley screw (13); flat washer (12),
and nut (11).
TM 10-4320-344-24
Figure 3-34.
b.
V-Belt Tensioner Maintenance, Models 609-C and US636HCCD-1.
Position new gasket (9) and cover (8) on pulley assembly (10) and secure with
three screws (7).
3.8.16.5
Installation.
a.
Position V-belt tensioner assembly (5) and new preformed packing (6).
b.
Install nut (3) and washer (4).
c.
Install flat washer (2) and screw (1).
3-81
TM 10-4320-344-24
3.8.17 Rocker Ann Assembly Maintenance, Model 609-A.
This task covers:
3.8.17.1 Removal
3.8.17.2 Disassembly
3.8.17.3 Repair
3.8.17.4
3.8.17.5
Assembly
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
G l o v e s , Appendix C, Item 11
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Wire, Appendix C, Item 36
Goggles, Industrial, Appendix B,
Section III, Item 2
(Continued)
Equipment Conditions
Gun, Air Blow, Appendix B, Section
III, Item 2
Cylinder Head Cover removed, paragraph
2.21.47.
Torque Wrench, Appendix B, Section
III, Item 2
General Safety I n s t r u c t i o n s
Inside Micrometer, Appendix B,
Section III, Item 3
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Vernier Calipers, Appendix B, section
III, Item 3
To prevent burns do not work on hot
engine components. A l l o w e n g i n e t o c o o l .
Material/Parts
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Do not work on equipment without following standard shop safety practices.
3.8.17.1 Removal.
To prevent burns do not work on hot engine components. A l l o w e n g i n e t o c o o l .
Failure to obey this warning may result in serious personal injury.
a.
Tie a wire between number 1 rocker arm (Figure 3-35, 1) and number 12 rocker
arm (2). Ensure wire is tied tightly enough to maintain tension on spacing
springs when rocker arm assembly (3) is removed.
When removing mounting nuts on rocker arm assembly, start at center nut and
work outward. T O p r e v e n t a c c i d e n t a l d i s a s s e m b l y , l o o s e n e a c h n u t a f e w t u r n s
at a time so that tension on valve springs is released gradually.
b.
Remove seven nuts (4) and flat washers (5) that secure rocker arm assembly (3)
to cylinder head (6).
c.
Lift rocker arm assembly (3) from cylinder head (6).
3-82
TM 10-4320-344-24
Figure 3-35.
Rocker Arm Assembly Removal, Model 609-A.
3.8.17.2 Disassembly.
To prevent accidental disassembly, carefully remove holding wire from rocker
arm assembly. Tension on spacing springs will be released when wire is
removed.
a.
Remove holding wire from rocker arm assembly (3).
b.
Carefully remove two rocker arm shafts (Figure 3-36, 1) from center shaft
support (2).
NOTE
To make reassembly of rocker arm shafts easier, tag and lay out
parts in the order removed.
c.
Slide following parts from each rocker arm shaft (1):
1
6
3
11
3
d.
center spacer (3)
rocker arms (4)
shaft springs (5)
spacers (6)
shaft supports (7)
Remove retaining ring (8) and plug (9) from end of each rocker arm shaft (1).
3-83
TM 10-4320-344-24
3.8.17 Rocker Ann Assembly Maintenance. Model 609-A. (Continued)
Figure 3-36.
Rocker Arm Disassembly, Model 609-A.
3.8.17.3 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Dry cleaning
Do not smoke or use near open flame or excessive heat.
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash exposed
skin thoroughly.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
Failure to obey these warnings may result in personal injury or death.
a.
3-84
Clean all parts of rocker arm assembly (Figure 3-35,
Dry thoroughly with compressed air.
3) with cleaning solvent.
TM 10-4320-344-24
b.
U s i n g d r y , f i l t e r e d , compressed air blow out lubricating passages on two
rocker arm shafts (Figure 3-36, 1) and twelve rocker arms (4).
c.
Inspect two rocker arm shafts (1) for cracks, burrs, dents, distortion, wear,
Inspect
scoring, or shoulders and ridges due to action of rocker arms (4).
each rocker arm shaft (1) for the following dimensions:
Table 3 - 2 .
d.
Rocker Arm Shaft Dimensions, Model 609-A.
Shaft
Minimum
Maximum
Length
13.699 (347.95 mm)
13.739 (348.97 mm)
Diameter
0.8560 (21.7424 mm)
0.8600 (21.8440 mm)
Inspect center shaft support (2), center spacer (3), twelve rocker arms (4),
2 2 s p a c e r s ( 6 ) , and six shaft supports (7) for cracks, burrs, or damage.
NOTE
Adjusting screws are self-locking and take a minimum of 3 ft-lbs (4 N•m) of
torque to turn into rocker arms.
e.
Check for damaged threads on all adjusting screws (10) and rocker arms (4).
f.
Inspect each rocker arm (4) for worn shaft bore diameter.
bore diameter: 0.8625/0.8665 in. (21.9075/22.0091 mm).
g.
I n s p e c t s i x s p a c e r s p r i n g s ( 5 ) f o r d a m a g e d e n d s a n d m i s a l i g n e d c o i l s . Using a
Each spacer spring
10 lb load, test compression of each spacer spring (5).
(5) should compress with load to 1 inch.
h.
Replace all damaged, defective or worn components.
Minimum/maximum
3.8.17.4 Assembly.
a.
Lightly coat rocker arm shaft (Figure 3-37, 1) with clean engine oil.
b.
Install plug (7) and retaining ring (8) on end of each rocker arm shaft (1).
To avoid improper lubrication, refer to tags and install parts on rocker arm
shaft in same order as removed.
c.
Slide following parts on each rocker arm shaft (1):
•
•
•
•
•
3 shaft supports (2)
11 spacers (3)
3 shaft springs (4)
6 rocker arms (5)
1 center spacer (6)
Remove and discard tags from all components after installation.
d.
Ensure that spacers (3) are installed on rocker arm shaft (1) as indicated in
Figure 3-37.
(Quantities are in parenthesis under callout.)
e.
Carefully install two rocker arms shafts (1) in center shaft support (9).
3-85
TM 10-4320-344-24
3.8.17 Rocker Arm Assembly Maintenance. Model 609-A. (Continued)
Figure 3-37.
f.
Rocker Arm Assembly Installation, Model 609-A.
Tie a wire between number 1 rocker arm (Figure 3-35, 1) and number 12 rocker
arm (2). Make sure wire is tied tightly enough to maintain tension on spacing
springs while rocker arm assembly (5) is being installed.
3.8.17.5 Installation.
NOTE
B e f o r e i n s t a l l i n g rocker arm assembly on cylinder head, check that rocker
arms are properly installed and move freely on rocker arm shaft.
a.
Install rocker arm assembly (5) over center head studs on cylinder head (6)
a n d s e a t r o c k e r a r m a s s e m b l y ( 5 ) f i r m l y o n c y l i n d e r h e a d ( 6 ) . Ensure rocker
arm adjusting screws (Figure 3-36, 1 0 ) a r e p o s i t i o n e d o v e r p u s h - r o d s i n
cylinder head (Figure 3-35, 6).
b.
Install seven flat washers (4) and nuts (3) on center head studs of cylinder
h e a d ( 6 ) . Hand tighten nuts (3).
c.
Remove wire from rocker arm assembly (5).
NOTE
When tightening mounting nuts on rocker arm assembly, start at center nut and
work outward. Tighten each nut a few turns a t a t i m e s o t h a t e q u a l t e n s i o n
is placed on all valve springs.
d.
Following sequence shown in Figure 3-38, torque nuts to 75 ft-lbs (102 N•m),
then to 125 ft-lbs (170 N•m), a n d f i n a l l y t o 1 4 7 f t - l b s ( 1 9 9 N • m ) .
e.
Refer to paragraph 2.21.49 and perform cold valve adjustment.
3-86
TM 10-4320-344-24
Figure 3-38.
Rocker Arm Assembly Bolt Tightening Pattern, Model 609-A.
3-87
TM 10-4320-344-24
3.8.18 Rocker Arm Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
3.8.18.1
Removal
3.8.18.2 Disassembly
3.8.18.3 Repair
3.8.18.4
3.8.18.5
Assembly
Installation
INITIAL SETUP
ToolS
Material/Parts (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Locknuts (TM 10-4320-344-24P)
Lock Washer (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2 Gun, Air Blow, Appendix B, Section
III, Item 2
Torque Wrench, Appendix B, Section
III, Item 2
Material/Parts
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Bushing (TM 10-4320-344-24P)
3.8.18.1
Cylinder Head Cover removed, paragraph
2.21.48.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
To prevent burns do not work on hot
engine components. A l l o w e n g i n e t o c o o l .
Do not work on equipment without following standard shop safety practices.
Removal.
Figure 3-39.
3-88
Equipment Conditions
Rocker Arm Assembly Maintenance, Models 609-C and US636HCCD-1.
TM 10-4320-344-24
Allow engine to cool.
To prevent burns do not work on hot engine components.
Failure to obey this warning may result in serious personal injury.
a.
Remove three nuts (Figure 3-39,
b.
Remove rocker arm assembly from rocker arm mounting studs (2).
1) from rocker arm mounting studs (2).
3.8.18.2 Disassembly.
NOTE
This procedure applies to both rocker arms.
a.
Tag and remove nut (4), lock washer (5), and flat washer (6) from stud (7).
Discard lock washer (5).
b.
Tag and remove rocker arm (8), stud (7), and shaft (9) from rocker arm
support (3).
c.
Tag and remove locknut (10) and adjusting screw (11) from rocker arm (8).
Discard locknut (10).
d.
Tag and remove locknut (12) and oil nozzle (13) from rocker arm (8).
locknut (12).
e.
Remove bushing (14) from rocker arm (8).
f.
Tag and remove thrust pad (15) from rocker arm (8).
Discard
Discard bushing (14).
3.8.18.3 Repair.
• Do not use cleaning solvent without proper ventilation and clothing. Do
Dry cleaning solvent
not smoke or use near open flame or excessive heat.
Clean parts in a
is potentially dangerous to personnel and property.
w e l l - v e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles
a n d r u b b e r g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin
Failure to obey this warning may result in personal injury
thoroughly.
or death.
• To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent.
b.
Thoroughly dry all components with compressed dry air.
c.
Inspect rocker arm (8) for cracks, chips, wear, or damage.
d.
Inspect thrust pad (15) for uneven wear or damage.
e.
Inspect all components for cracks, wear, or damage.
f.
Replace all damaged, worn, o r d e f e c t i v e c o m p o n e n t s .
3-89
TM 10-4320-344-24
3.8.18 Rocker Arm Assembly Maintenance, Models 609-C and US636HCCD-1.
(Continued)
3.8.18.4 Assembly.
a.
Refer to tag and install thrust pad (15) in rocker arm (8).
discard tag.
b.
Install new bushing (14) in rocker arm (8).
Remove and
NOTE
Chamfered side of nozzle thrust pad and one thread of nozzle should be
visible above locknut when tightened.
c.
Refer to tags and install oil nozzle (13) and new locknut (12) in rocker arm
( 8 ) . Tighten locknut (12) and remove and discard tags.
d.
Refer to tags and install adjusting screw (11) and new locknut (10) in rocker
arm (8). Tighten locknut (10) and remove and discard tags.
e.
R e f e r t o t a g s a n d i n s t a l l s h a f t ( 9 ) , stud (7), and rocker arm (8) in rocker
a r m s u p p o r t ( 3 ) . Remove and discard tags.
f.
Refer to tags and install flat washer (6), new lock washer (5), and nut (4) on
s t u d ( 7 ) . Tighten nut (4) and remove and discard tags.
3.8.18.5 Installation.
a.
Install rocker arm assembly (3) on rocker arm mounting studs (2).
b.
Install three nuts (1) on rocker arm mounting studs (2) and torque nuts to
21 ft-lbs (28 N•m).
c.
Refer to paragraph 2.21.50 and adjust valves.
3-90
TM 10-4320-344-24
3.8.19 Cylinder Head Assembly Replacement, Model 609-A.
This task covers:
3.8.19.1 Removal
3.8.19.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Cooling System Hoses removed, paragraph
2.20.2.
G o g g l e s , I n d u s t r i a l , Appendix B,
Section III, Item 2
Conditions
Exhaust and Intake Manifolds removed,
paragraph 2.21.36.
Thermostat removed, paragraph 2.21.41.
Gun, Air Blow, Appendix B, Section
I I I , Item 2
Torque Wrench, Appendix B, Section
III, Item 2
Fuel Injection Nozzle and Holder
Assemblies removed, paragraph 2.21.8.
Rocker Arm Assembly removed, paragraph
3.8.17.
Material/Parts
General Safety I n s t r u c t i o n s
Adhesive (Gasket), Appendix C, Item 1
Brush, Appendix C, Item 5
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment without following standard shop safety practices.
3.8.19.1 Removal.
a.
Remove t w e l v e p u s h - r o d s ( F i g u r e 3 - 4 0 , 1 ) .
b.
Remove t w o n u t s ( 2 ) , f l a t w a s h e r s ( 3 ) , a n d l i f t i n g e y e s ( 4 ) .
c.
Remove eighteen nuts (5) and lock washers (6) that secure cylinder head (7) to
engine block . Discard lock washers (6).
Do not pry on cylinder head or contact surfaces, to remove cylinder head.
Damage to cylinder head or engine block may result.
NOTE
A soft hammer may be necessary to loosen cylinder head.
d.
Remove cylinder head (7), cylinder head gasket (8).
a clean, flat surface and discard gasket (8).
Set cylinder head (7) on
3-91
TM 10-4320-344-24
3.8.19 Cylinder Head Assembly Replacement, Model 609-A. (Continued)
Figure 3-40.
3.8.19.2
Cylinder Head Assembly Removal, Model 609-A.
Installation.
Do not use cleaning s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvet is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
a.
Clean cylinder head mounting surface of engine block thoroughly with cleaning
s o l v e n t , wire brush, and scraper.
To prevent the possibility of embedding foreign objects in the eyes, safety
glasses must be worn when using compressed air.
b.
Using compressed air, dry cylinder head engine block.
c.
Install cylinder head gasket (8) with the bead down using gasket adhesive.
d.
Install cylinder head assembly (7) on engine block.
e.
Install eighteen new lock washers (6) and nuts (5).
3-92
Hand-tighten nuts (5).
TM 10-4320-344-24
f.
Install two lifting eyes (4), flat washers (3), and nuts (2).
nuts (2).
Figure 3-41.
Hand-tighten
Cylinder Head Assembly Bolt Tightening Pattern, Model 609-A.
g.
Tighten nuts in
and 19-20 to 75
final 175 ft-lbs
(102 N•m), then
sequence shown in Figure 3-41.
Torque nuts 1-4, 7-10, 13-16,
ft-lbs (102 N•m), then to 125 ft-lbs (169 N•m), then to a
( 2 3 7 N • m ) . Torque nuts 5-6, 1 1 - 1 2 , a n d 1 7 - 1 8 t o 7 5 f t - l b s
to 125 ft-lbs (169 N•m), t h e n t o a f i n a l 1 4 7 f t - l b s ( 1 9 9 N • m ) .
h.
Install 12 push-rods (1).
i.
Refer to paragraph 2.21.49 and perform cold valve adjustment.
j .
Refer to TM 10-4320-344-10 and start engine.
Operate engine for one hour.
The cylinder head nuts must be retorqued and the valves readjusted after 1
h o u r o p e r a t i o n . Failure to observe this caution could result in damage to
equipment.
k.
R e f e r t o TM
l.
R e f e r t o step c above and torque cylinder head nuts.
m.
R e f e r t o paragraph 2.21.49 and perform warm valve adjustment.
10-4320-344-10
and
stop
engine.
3-93
TM 10-4320-344-24
3.8.20 Cylinder Head Assembly Replacement, Models 609-C and US636HCCD-1.
This task covers:
3.8.20.1 Removal
3.8.20.2 Adjustment
3.8.20.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, S e c t i o n I I I ,
Item 1
Fuel Leakoff Manifold Assembly removed,
paragraph 2.21.7.
(Continued)
Fuel Injection Nozzles removed, paragraph
2.21.9.
Torque Wrench, Appendix B, Section
III, Item 2
Engine Temperature Transmitter removed,
paragraph 2.21.20 (609-C).
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
Pushrod Tube Spring Compressor, Appendix
B, Section III, Item 17
Square Socket Insert, Appendix B,
Section III, Item 18
Conditions
Exhaust Manifold Pipes removed, paragraph
2.21.37.
Intake Manifold removed, paragraph
2.21.38.
Cowling Assembly removed, paragraph
2.21.40.
Material/Parts
Grease, Appendix C, Item 13
Rags, Appendix C, Item 20
Solder, Appendix C, Item 25
Tags, Appendix C, Item 31
Washers (TM 10-4320-344-24P)
Ring Spacer (TM 10-4320-344-24P)
Rocker Arm Assembly removed, paragraph
3.8.18.
General Safety I n s t r u c t i o n s
Equipment Conditions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Top Panel Assembly Removed, paragraph
2.12.4.
To prevent burns do not work on hot
engine components.
Allow engine to cool.
Right Side Panel Assembly removed,
paragraph 2.12.6.
Do not work on equipment without following standard shop safety practices.
3.8.20.1 Removal.
To prevent malfunction of parts, reinstall pushrods in same position from
which they were removed.
a.
Tag and remove two pushrods (Figure 3-42, 1).
b.
Using square recess socket, remove two plugs (2) and washers (3) from cylinder
head assembly (4).
Discard washers (3).
NOTE
Loosen bolts in a diagonal sequence.
c.
3-94
Progressively loosen four cylinder head bolts (5).
bolts (5) and flat washers (6).
Remove four cylinder head
TM 10-4320-344-24
Figure 3-42.
Cylinder Head Assembly Removal, Models 609-C and US636HCCD-1.
3-95
TM 10-4320-344-24
3.8.20 Cylinder Head Assembly Replacement, Models 609-C and US636HCCD-1.
(Continued)
d.
Slowly lift cylinder head assembly (4) from cylinder (7) while keeping pushrod
cover tube assemblies (8) steady; then remove the pushrod cover tube
assemblies (8).
e.
Remove washer (9), pushrod cover tube (10), spring (11), retainer (12), and
washer (13) from each pushrod cover tube assembly (8).
Discard washers (9 and
13).
f.
Remove and discard ring spacer (14).
3.8.20.2 Adjustment.
a.
Coat a piece of 2 mm resin core solder (15) and place it in position on piston
crown (16) at right-angles to center line of engine, but not on any stenciling
on piston. Secure in position with grease.
b.
Measure length of each cylinder head bolt (5).
(212.50 mm) replace cylinder head bolt (5).
c.
With piston positioned a little before TDC perform following:
If length exceeds 8.37 inches
(1) Apply grease to and install new ring spacer (14) on cylinder (7).
(2) Install cylinder head assembly (4), four flat washers (6), and cylinder head
b o l t s ( 5 ) c y l i n d e r ( 7 ) . Hand-tighten cylinder head bolts (5).
d.
Using straight edge, align inlet and exhaust flanges of cylinder head
assemblies (4).
e.
Tighten cylinder head bolts (5) in sequence shown in Figure 3-42 through first
stage 45° angle.
f.
Turn crankshaft through 360° in direction of engine rotation.
g.
Remove cylinder head assembly (4), and measure the thickness of the resin core
solder (15) at its smallest point.
h.
If the thickness is not between 0.039 inches (0.991 mm) and 0.047 inches
(1.194 mm), notify General Support maintenance. When thickness is correct,
install cylinder head assembly (4).
3.8.20.3
Installation.
a.
Install new ring spacer (14) and cylinder head assembly (4) on cylinder (7).
b.
Install four flat washers (6) and cylinder head bolts (5) in cylinder head
assembly (4).
d.
Using straight edge, align inlet and exhaust flanges of cylinder head
assemblies (4).
e.
Preload cylinder head mounting bolts (5) to 30 ft-lbs (40 N•m).
f.
Using angle-of-turn indicator tighten cylinder head bolts (5) in sequence
shown in Figure 3-44 to 450 first, second, and third stage, and 300 fourth
stage.
g.
Install new washers (3) and cover plugs (2).
ft-lbs (80-90 N•m).
h.
Using spring compressor tool, assemble and compress spring (11) on pushrod
cover tube (10).
i.
Install retainer (12) with open side towards spring and new washer (13) with
wide end facing toward end of pushrod cover tube (10).
3-96
Torque cover plugs (2) to 59-66
TM 10-4320-344-24
j.
Install new washer (9) with wide end facing toward upper shoulder on pushrod
cover tube (10).
k.
Insert spring end of pushrod cover tube assembly (8) in crankcase hole (17)
and position upper end of pushrod cover tube (10) with cone in cylinder head
assembly (4).
l.
Slowly remove spring tensioning tool while guiding upper end of pushrod cover
tube assembly (8) into cylinder head assembly (4).
m.
Repeat steps h through m for the other pushrod cover tube assembly (8).
p.
Remove tags and install pushrods (1).
q.
Refer to paragraph 2.21.50 and perform cold rocker arm adjustment.
3-97
TM 10-4320-344-24
3.8.21 Crankshaft Pulley and Vibration Damper Replacement, Model 609-A.
This task covers:
3.8.21.1 Removal
3.8.21.2
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Alternator belt removed,
paragraph 2.21.13.
Conditions
(Continued)
General Safety I n s t r u c t i o n s
Torque Wrench, Appendix B, Section
III, Item 2,
Material/Parts
Lock Washer (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Equipment Conditions
Radiator removed, paragraph 2.20.4.
3.8.21.1 Removal.
Figure 3-43.
Vibration Damper and Crankshaft Pulley Replacement, Model 609-A.
a.
Remove six screws (Figure 3-43,
pulley (3).
b.
Remove pulley mounting nut (4), lock washer (5), tapered bushing (6), and
key (7). Discard lock washer (5).
c.
Remove crankshaft pulley (3) and pulley cone washer (8) from crankshaft.
3.8.22.2
1) and vibration damper (2) from crankshaft
Installation.
a.
I n s t a l l pulley cone washer (8) and crankshaft pulley (3) on crankshaft.
b.
I n s t a l l tapered bushing (6) and key (7) in crankshaft pulley (3).
3-92
TM 10-4320-344-24
c.
Install new lock washer (5) and pulley mounting nut (4).
125 ft-lbs (170 N•m).
d.
Position vibration damper (2) on crankshaft pulley (3) and secure with six
mounting screws (1). T o r q u e s c r e w s ( 1 ) t o 2 5 f t - l b s ( 3 4 N • m ) .
Torque nut (4) to
3-99
TM 10-4320-344-24
3.8.22 Crankshaft Pulley and Vibration Damper Replacement. Models 609-C and US636HCCD-1.
This task covers:
3.8.22.1 Removal
3.8.22.2
Installation
INITIAL SETUP
Tool S
Equipment
General Mechanic's Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Top Panel Assembly removed, paragraph
2.21.4 (609-C).
(Continued)
Right Side Panel Assembly removed,
paragraph 2.12.6 (609-C).
Torque Wrench, Appendix B, Section
I I I , Item 2
Bulkhead Panel Assembly removed,
paragraph 2.12.15 (609-C).
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
R e t a i n e r , Appendix B, S e c t i o n
Item 19
Conditions
V-Belt Guard removed, paragraph 2.21.11
(US636HCCD-1).
III,
Alternator Belts removed, paragraph
2.21.13.
Material/Parts
Grease, Appendix C, Item 13
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
General Safety I n s t r u c t i o n s
Equipment Conditions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Pumping station shut down, TM 10-4320344-10.
Do not work on equipment without following standard shop safety practices.
3.8.22.1 Removal.
a.
Using retainer, (Figure 3-44, 1 ) h o l d c r a n k s h a f t p u l l e y ( 2 ) s t a t i o n a r y .
NOTE
Pulley mounting tilt is a left-hand threaded bolt.
bolt, turn bolt to the clockwise.
To remove pulley mounting
b.
Turn pulley mounting bolt (3) clockwise. Remove pulley mounting bolt (3),
flat washer (4), and crankshaft pulley (2).
c.
Remove eight pulley mounting screws (5), flat washers (6), and pulley (2) from
damper (7).
3.8.22.2
Installation.
a.
Position damper (7) on crankshaft pulley (2) and secure with eight flat
washers (6) and pulley mounting screws (5).
b.
Measure gap between crankshaft pulley (2) and damper (7).
(25.4 mm) or less.
c.
Lightly coat damper shaft of crankshaft pulley (2) and front seal with grease.
d.
Align index hole in damper shaft of crankshaft pulley (2) with index pin on
crankshaft gear. S l i d e c r a n k s h a f t p u l l e y ( 2 ) a n d d a m p e r ( 7 ) i n t o p o s i t i o n .
e.
Lightly coat pulley mounting bolt (3) threads with oil.
crankshaft pulley (2).
f.
Using retainer (1), hold crankshaft pulley (2) stationary.
3-100
Gap must be 1 inch
Install bolt (3) in
TM 10-4320-344-24
Figure 3-44.
Vibration Damper Crankshaft Pulley Maintenance, Models 609-C and
US636HCCD-1 .
Pulley mounting bolt is a left-hand threaded bolt. To install pulley
mounting bolt turn bolt counter-clockwise.
g . Turn pulley mounting bolt (3) to the left and hand-tighten. Preload m o u n t i n g
bolt (3) to 37 ft-lbs (50 N•m).
Pulley mounting bolt is a left-hand threaded bolt. To install pulley
mounting bolt turn bolt counter-clockwise.
h.
Using angle-of-turn indicator, tighten bolt (3) 210°.
3-101
TM 10-4320-344-24
3.9 FUEL TANK MAINTENANCE.
3.9.1 Fuel Tank Repair.
This task covers repair.
INITIAL SETUP
Tools
Equipment Conditions
Acetylene Welding Equipment, Appendix
B, Section III, Item 3
Fuel Tank removed, paragraph 2.22.2.
General Safety I n s t r u c t i o n s
Reference
TM 9-237
Do not work on equipment without
following standard shop safety practices.
Weld fuel tank in accordance with TM 9-237.
3-102
TM 10-4320-344-24
3.10 WHEEL MOUNTED FRAME ASSEMBLY.
3.10.1 Wheel Mounted Frame Assembly Maintenance.
This task covers:
3.10.1.1
Removal
3.10.1.2 Inspection
3.10.1.3
Installation
INITIAL SETUP
(Continued)
Tools
Equipment
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Starter Rectifier removed, paragraph
2.21.17 (609-C).
Conditions
Fuel Tank removed, paragraph 2.22.2.
Material/Parts
Pump Assembly removed, paragraph 3.6.1.
Pan, Appendix C, Item 19
Rags, Appendix C, Item 20
Equipment
Supports
(US636HCCD-1).
Pump
removed,
paragraph
3.6.5
Conditions
Pumping station shut down, TM 10-4320344-10.
Pump Mount Isolators removed, paragraph
3.6.6 (609-C).
Engine removed, paragraph 3.8.1.
Sound Enclosure removed, paragraph 2.12
(609-C).
Air Cleaner Assembly removed, paragraph
2.14.2 (609-C) or 2.14.3 (US636HCCD-1).
Battery Box removed, paragraph 2.15.2
(609-A), 2.15.3 (609-C), or 2.15.4
(US636HCCD-1).
Battery Cable Assemblies removed, paragraph 2.15.5 (609-A and US636HCCD-1).
Battery Cable and Power Cable Assemblies
removed, paragraph 2.15.6 (609-C).
Start Alarm Relay and Start Pilot Relay
removed, paragraph 2.15.10 (609-A and
609-C) .
Front Engine Support removed, paragraph
3.8.2 (609-A).
Engine Mount Isolators removed, paragraph
3.8.4 (609-C).
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
D i e s e l f u e l i s f l a m m a b l e . Keep sparks,
cigarettes, and open flame away from fuel
tank.
Do not work on equipment without following standard shop safety practices.
3.10.1.1 Removal. Placing the wheel mounted frame assembly in the equipment
c o n d i t i o n s s p e c i f i e d a b o v e , for the applicable model, will remove the wheel mounted
frame assembly.
3.10.1.2 Inspection. Inspect wheel mounted frame assembly for cracked or broken welds
and seams, c o r r o s i o n , b e n d s o r d i s t o r t i o n s , damaged tie down points, or damage.
3.10.1.3 Installation. R e f e r t o t h e p a r a g r a p h s i d e n t i f i e d i n t h e e q u i p m e n t c o n d i t i o n s
s p e c i f i e d a b o v e , f o r t h e a p p l i c a b l e m o d e l , and install the removed components to
place the wheel mounted frame assembly in service.
3-103
TM 10-4320-344-24
3.10.2 Wheel Mounted Frame Assembly Repair.
This task covers repair.
INITIAL SETUP
Tools
Equipment
Conditions
Acetylene Welding Equipment,
Appendix B, Section III, Item 3
Wheel Mounted Frame Assembly removed,
paragraph 3.10.1.
Reference
General Safety I n s t r u c t i o n s
TM 9-237
Do not work on equipment without following standard shop safety practices.
Weld wheel mounted frame assembly in accordance with TM 9-237.
3-104
TM 10-4320-344-24
3.10.3 Brake Line Repair.
This task covers repair.
INITIAL SETUP
Tools
General Safety Instructions
Acetylene Welding Equipment,
Appendix B, Section III, Item 3
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Reference
Do not work on equipment without following standard shop safety practices.
TM 9-237
Equipment
Conditions
Master Cylinder and Brake Lines removed,
paragraph 2.23.6.
I f t e e f i t t i n g ( F i g u r e 2 - 1 7 3 , 13) is damaged or leaking,
new tee fitting (13) to axle (14).
refer to TM 9-237 and weld
3-105
TM 10-4320-344-24
3.10.4 Safety Chains Maintenance.
This task covers:
3.10.4.1 Removal
3.10.4.2 Repair
3.10.4.3
Installation
INITIAL SETUP
Tools
General Safety I n s t r u c t i o n s
General Mechanic’s Tool Kit, Appendix
B, Section III, Item 1
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Acetylene Welding Equipment, Appendix
B, Section III, Item 3
Material/Parts
Do not work on equipment without following standard shop safety practices.
Cotter Pin (TM 10-4320-344-24P)
Reference
TM 9-237
This procedure applies to Model US636HCCD-1.
and 609-C are similar.
The procedures for Models 609-A
3.10.4.1 Removal.
Figure 3-45.
Safety Chains Maintenance.
a.
Cut weld (last link) holding chain (Figure 3-45, 1) from trailer chassis (2).
b.
Remove chain (1).
3-106
TM 10-4320-344-24
c.
Remove cotter pin (3), retaining bolt (4), and hook (5) .
pin (3).
Discard cotter
3.10.4.2 Repair.
a.
I n s p e c t c h a i n ( 1 ) , r e t a i n i n g b o l t ( 4 ) , and hook (5) for damage.
b.
Refer to Appendix D and manufacture new chain 29 inches or 27 links in length.
3.10.4.4
Installation.
a.
Install retaining bolt (4) and new cotter pin (3) to secure hook (5) to
chain (1).
b.
Install safety chain (1) by welding (last link) to trailer chassis (2) in
accordance with TM 9-237.
3-107/(3-106 Blank)
TM 10-4320-344-24
CHAPTER 4
GENERAL SUPPORT MAINTENANCE
Page
Subject Index
Section I
4.1
4.2
4.3
.
4-2
Common Tools and Equipment . . . . . . . . . . . . . . . . . . . . . 4-2
S p e c i a l T o o l s , TMDE, and Support Equipment . . . . . . . . . . . . . 4-2
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section II
4.4
Repair Parts; Special Tools; Test, Measurement, and Diagnostic
Equipment (TMDE); and Support Equipment . . . . . . . . . . .
General
Engine
Support
Maintenance
.
Maintenance
.
.
.
.
.
Procedures
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
4-3
.
4-3
4-1
TM 10-4320-344-24
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND
DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
4.1
COMMON TOOLS AND EQUIPMENT.
For authorized common tools and equipment, r e f e r t o M o d i f i e d T a b l e o f O r g a n i z a t i o n
and Equipment (MTOE) applicable to your unit.
4.2
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
S p e c i a l t o o l s , TMDE, and support equipment are listed in TM 10-4320-344-24P, Repair
Parts and Special Tools List (RPSTL) for the Pumping Assembly, Water, 600 GPM
c o v e r i n g o r g a n i z a t i o n a l , direct support, and general support maintenance, or the
Maintenance Allocation Chart (MAC), Appendix B of this manual.
4.3
REPAIR PARTS.
Repair parts are listed and illustrated in TM 10-4320-344-24P covering
o r g a n i z a t i o n a l , d i r e c t s u p p o r t , and general support maintenance of this equipment.
4-2
TM 10-4320-344-24
SECTION II. GENERAL SUPPORT MAINTENANCE PROCEDURES
4.4
ENGINE ASSEMBLY MAINTENANCE .
4.4.1 Cylinder Head Assembly, Intake Valve, and Exhaust Valve Maintenance, Model 609-A.
This task covers:
4.4.1.1 Disassembly
4.4.1.2 Repair
4.4.1.3
Assembly
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
I I I , Item 1
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
G o g g l e s , I n d u s t r i a l , Appendix B,
Section III, Item 2
(Continued)
Depth Gauge, Appendix B, Section III,
Item 3
Equipment
Inside Micrometer, Appendix B, Section
III, Item 3
Conditions
Cylinder Head Assembly removed, paragraph
3.8.19.
Valve Cleaner, Appendix B, Section III,
Item 3
General Safety I n s t r u c t i o n s
Valve Spring Compressor, Appendix B,
Section III, Item 3
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Vernier Calipers, Appendix B, Section
111, Item 3
To prevent burns do not work on hot
Allow engine to cool.
engine components.
Material/Parts
Brush, Appendix C, Item 6
Gloves, Appendix C, Item 11
DO not work on equipment without following standard shop safety practices.
4.4.1.1 Disassembly.
a.
Remove four screws (Figure 4-1, 1 ) , l o c k w a s h e r s ( 2 ) , p i p e p l u g ( 3 ) , w a t e r
o u t l e t c o v e r ( 4 ) , a n d g a s k e t ( 5 ) f r o m c y l i n d e r h e a d ( 6 ) . Discard lock washers
(2) and gasket (5).
b.
Remove seat lock (7), v a l v e s p r i n g s e a t ( 8 ) , v a l v e s p r i n g ( 9 ) , a n d v a l v e
insert (10) for each intake valve (11) to be removed.
c.
Remove seat lock (12), valve rotator (13), and valve spring (14) for each
exhaust valve (15) to be removed.
To prevent equipment malfunction,
from which they were removed.
d.
install valves in same position in cylinder
Remove intake valves (11) and exhaust valves (15) and tag location in cylinder
head (6).
4-3
TM 10-4320-344-24
4.4.1 Cylinder Head Assembly. Intake Valve, and Exhaust Valve Maintenance. Model 609-A. (Continued)
Figure 4-1.
Cylinder Head Assembly Disassembly, Model 609-A.
4.4.1.2 Repair.
a.
Clean valve stem guides (16) by running a valve cleaner and wire brush through
the valve stem guides (16).
b.
Using a straight edge and a 0.005 inch (1.2700 mm) feeler gauge r c h e c k s u r f a c e
o f c y l i n d e r h e a d ( 6 ) f o r w a r p a g e . Also, inspect surface of cylinder head (6)
for cracks, erosion, pits, burrs, scratches, or blemishes.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat. Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
c.
Inspect cylinder head (6) for free water flow.
If restriction is evident
remove plugs (17), s i x f l a t w a s h e r s ( 1 8 ) , a n d n o z z l e s l e e v e s ( 1 9 ) . Clean
water jackets by submerging cylinder head (6) in heated cleaning solution.
d.
Inspect cylinder head (6) for loose or damaged nozzle sleeves (19), studs
(20), and pitted or shouldered intake and exhaust valve seats.
4-4
TM 10-4320-344-24
e.
Inspect cylinder head (6) for loose valve stem guides (16).
f.
Inspect inside diameter of valve stem guides for the following dimensions:
Minimum bore diameter of 0.3735 (9.4869 mm) and maximum bore diameter of
0.3750 (9.5250 mm).
g.
Inspect valve springs (9 and 14) for dimensions listed in Table 4-1.
Table 4-1.
Dimension
Free Length
Total Coils
Diameter wire
Outside Diameter
Test Load at 1.4920
inches (37.8968 mm)
Test Load at 1.0820
inches (27.4828 mm)
h.
Valve Spring Data.
Minimum
1.702 in. (43.231 mm)
Maximum
1.722 in. (43.739 mm)
6
0.172 in. (4.369 mm)
0.286 in. (7.264 mm)
1.302 in. (33.020 mm)
45 lbs (20 Kg)
51 lbs (23 Kg)
130 lbs (59 Kg)
144 lbs (65 Kg)
Inspect intake valve (11) for pits, bent valve stem, and dimensions listed in
Table 4-2.
Table 4-2.
Dimension
Head Diameter
Stem Diameter
Stem to Valve Guide
Clearance
Seat Diameter in Head
Intake Valve Dimensions.
Minimum
1.6825 in. (42.7355 mm)
0.3700 in. (9.38900 mm)
0.0015 in. (0.0381 mm)
Maximum
1.6925 in. (42.9895 mm)
0.3732 in. (9.4793 mm)
0.0025 in. (0.0635 mm)
1.6470 in. (41.8338 mm)
1.6530 in. (41.9862 mm)
0.2344 in. (0.3594 mm)
Seat Width in Head
Top of Valve Recessed
Below Cylinder Head
Deck
Valve Seat Angle
i.
0.020 in. (0.508 mm)
0.030 in. (0.762 mm)
30°
Inspect exhaust valve (15) for pits, bent valve stem, and dimensions listed in
Table 4-3.
Table 4-3.
Dimension
Head Diameter
Stem Diameter
Stem to Valve Guide
Clearance
Seat Diameter in Head
Seat Width in Head
Top of Valve Recessed
Below Cylinder Head
Deck
Valve Seat Angle
Exhaust Valve Dimensions.
Minimum
1.4950 in. (37.9730 mm)
0.3700 in. (9.3890 mm)
0.0015 in. (0.0381 mm)
Maximum
1.5050 in. (38.2270 nun)
0.3732 in. (9.4793 mm)
0.0035 in. (0.0189 mm)
1.618 in. (41.097 mm)
1.630 in. (41.402 mm)
0.2344 in. (0.3594 mm)
0.045 in. (1.143 mm)
0.035 in. (0.889 mm)
45°
4-5
TM 10-4320-344-24
4.4.1 Cylinder Head Assembly, Intake Valve, and Exhaust Valve Maintenance, Model 609-A. (Continued)
I f v a l v e g u i d e s a r e t o b e r e p l a c e d , they must be replaced prior to any
refinishing on the valve seats.
j.
Replace excessively worn or damaged valve guides (16).
Position valve guides
(16) so that distance between gasket surface of cylinder head (6) and bottom
of valve guide (16) is 1.3800 inches (35.0520 mm).
k.
After installing new valve guides (16) ream the inside diameter to correct any
s q u e e z i n g o r d i s t o r t i o n . Ream intake valve guides (16) to 0.3740 inches
(9.4496 mm) to 0.3750 (9.5250 mm). Ream exhaust valve guides (16) to 0.3750
inches (9.5250 mm) to 0.3760 inches (9.5504 mm).
If valve seats are pitted or new valve guides were installed the valve seats
must be refinished.
l.
Grind valves (11 and 15) valve seats of cylinder head (6) sufficiently to
remove pits and burrs. Valve seat angles are 30° for intake valves and 45° for
exhaust valves.
m.
Make ten or twelve pencil marks, equally spaced,
head (6).
n.
Insert valve (11 or 15) in valve seat of cylinder head (6), apply pressure
firmly, and rotate valve (11 or 15) in valve seat of cylinder head (6).
o.
Remove valve (11 or 15) from valve seat in cylinder head (6) and inspect
pencil marks.
I f a l l p e n c i l m a r k s a r e n o t rubbed out repeat steps 1 through
n.
across valve seat in cylinder
4.4.1.3 Assembly.
Assemble valves in the same seats to which they were ground.
Valves not
ground must be assembled in the same seats from which they were removed.
a.
Lubricate stems of valves (11 and 15) with a few drops of oil and insert them
into the valve seats on cylinder head (6) to which they were ground or from
which they were removed.
Remove tags.
b.
Using a valve spring compressor install valve springs (14), valve rotator
(13), and seat lock (12) on stems of exhaust valves (15).
c.
Insert intake valve inserts (10) over ends of intake v a l v e s
exposed ends of valve guides (16).
d.
Using valve spring compressor, install valve springs ( 9 ) , v a l v e s p r i n g
seat (8) and seat lock (7).
e.
Turn cylinder head (6) on the exhaust manifold side.
4-6
(11).
Secure on
TM 10-4320-344-24
Do not use cleaning solvent without proper ventilation and clothing.
Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
f.
Pour solvent into intake manifold openings in cylinder head (6).
If solvent
seeps around any intake valve (11), remove intake valve (11) and regrind.
g.
Turn cylinder head (6) on the intake manifold side.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
h.
Pour solvent in exhaust manifold openings of cylinder head (6).
If solvent
seeps around any exhaust valve (15), remove exhaust valve (15) and regrind.
i.
Position new gasket (5) and water outlet cover (4) against cylinder head (6)
and secure with four new lock washers (2) and bolts (1).
Tighten bolts (1).
j .
Install pipe plug (3) in water outlet cover (4).
Tighten pipe plug (3).
4-7
TM 10-4320-344-24
4.4.2 Cylinder Head Assembly, Intake Valve, and Exhaust Valve Repair, Models 609-C and US636HCCD-l.
This task covers:
4.4.2.1 Disassembly
4.4.2.2 Repair
4.4.2.3
Assembly
INITIAL SETUP
Tools
Tools (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Cutter, Appendix B, Section III,
Item 26
Drill, Appendix B, Section III, Item 3
Pilot Pin, Appendix B, Section III,
Item 27
Micrometer, Appendix B, Section III,
Item 3
Material/Parts
Vernier Calipers, Appendix B, Item 3
Valve Spring Compressor, Appendix B,
Section III, Item 20
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Locating Ring (TM 10-4320-344-24P)
Valve (TM 10-4320-344-24P)
Equipment Conditions
Cutting Device, Appendix B, Section
I I I , Item 21
Reamer, Appendix B, S e c t i o n I I I ,
Item 22
Mandrel (Intake), Appendix B, Section
I I I , Item 23
Mandrel (Exhaust), Appendix B, Section
I I I , Item 24
Mandrel, Appendix B, S e c t i o n 1 1 1 ,
Item 25
Cylinder Head Assembly removed, paragraph
3.8.20.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
To prevent burns do not work on hot
engine components. A l l o w e n g i n e t o c o o l .
Do not work on equipment without following standard shop safety practices.
4.4.2.1 Disassembly.
a.
Install cylinder head (Figure 4-2, 1) in clamping s t a n d .
b.
Using valve spring compressor, remove two tapered v a l v e s p r i n g l o c k s ( 2 ) ,
spring retainers (3), and springs (4).
Valve rotator is mounted on exhaust valve.
c.
Remove one valve rotator or retainer (5).
d.
Tag and remove valves (6 and 7) from cylinder head (l).
4.4.2.2 Repair.
a.
Inspect cylinder head assembly components for obvious defects.
defective components.
b.
M e a s u r e l e n g t h o f v a l v e s p r i n g s ( 4 ) . Minimum length is 2.205 inches (56 mm).
Replace valve springs (4) if less than minimum length.
4-8
Replace
TM 10-4320-344-24
Figure 4-2.
c.
Cylinder Head Assembly Disassembly, Models 609-C and US636HCCD-1.
Inspect valves (6 and 7)
4-4 and 4-5.
for cracks, pits, and the dimensions listed in Tables
For intake valves on Model 609-C which have a 30° seat angle, measure for
values given in Table 4-4.
Table 4-4.
Intake Valve Fits and Tolerances, Models 609-C and US636HCCD-1.
Minimum
Maximum
Stem Diameter
0.3127 inches (7.945 mm)
0.3134 inches (7.960 mm)
Head Diameter
1.6889 inches (42.9 mm)
1.6969 inches (43.1 mm)
Valve Seat Width
0.059 inches (1.50 mm)
{0.079 inches (2.00 mm)}
0.079 inches (2.00 mm)
{0.098 inches (2.5 mm)}
Dimension
4-9
TM 10-4320-344-24
4.4.2 Cylinder Head Assembly, Intake Valve, and Exhaust Valve Repair, Models 609-C and US636HCCD-1.
(Continued)
Table 4-4.
Intake Valve Fits and Tolerances, Models 609-C
and US636HCCD-1.
(continued)
Dimension
Minimum
Valve stem Clearance 0.0016 inches (0.04 mm)
Standard
Valve stem Clearance - Wear
Limit
Seat Bore Diameter In
1.7913 inches (45.50 mm)
Cylinder Head
Valve Recessed Below
Cylinder Head Deck
Table 4-5.
Maximum
0.0028 inches (0.07 mm)
0.0059 inches (0.15 mm)
1.7923 inches (45.525 mm)
1.7969 inches (45.64 mm)
45°
(30°)
1.7976 inches (45.66 mm)
0.0197 inches (0.50 mm)
{0.0512 inches (1.30 mm)}
0.0393 inches (1.00 mm)
{0.0709 inches (1.80 mm)}
0.20 inches (5.08 mm)
0.2598 inches (6.6 mm)
with intermediate ring
Exhaust Valve Fits and Tolerances, Models 609-C and US636HCCD-1.
Dimension
Minimum
Maximum
Stem Diameter
0.3118 inches (7.92 mm)
0.3126 inches (7.94 mm)
Head Diameter
1.4528 inches (36.9 mm)
1.4606 inches (37.1 mm)
Valve Seat Width
Valve Stem Clearance Standard
Valve Stem Clearance - Wear
Limit
0.059 inches (1.50 mm)
0.079 inches (2.00 mm)
0.0024 inches (0.06 mm)
0.0037 inches (0.095 mm)
0.0079 inches (0.2 mm)
Seat Bore Diameter In
Cylinder Head
1.5748 inches (40 mm)
1.5758 inches (40.025 mm)
Seat outside diameter
1.5803 inches (40.14 mm)
45°
1.5811 in. (40.16 mm)
0.0276 inches (0.70 mm)
0.0591 inches (1.50 mm)
0.20 inches (5.08 mm)
0.2598 inches (6.6 mm)
with intermediate ring
Seat Angle
Valve Rim Thickness
Valve Recessed Below
Cylinder Head Deck
d.
Replace any valves (6 and
e.
Inspect cylinder head (1) for damage and replace if damaged.
f.
Check that cylinder head seating surface (Figure 4-3, 1) is flat and square.
Seating surface can be ground.
g.
A f t e r r e w o r k i n g , measure clearance between cylinder head bottom and cylinder
h e a d s e a t i n g s u r f a c e . The measured value may not be lower than 0.2323 inches
(5.9 nun) with intermediate ring.
4-10
7) which are damaged or out of tolerance.
TM 10-4320-344-24
Figure 4-3.
Chocking Cylinder Head Seating Surface, Models 609-C and US636HCCD-1.
Figure
h.
i.
4 - 4 . Valve Depth Measurement, Models 609-C and US636HCCD-1.
I n s e r t v a l v e i n seat and measure distance from crown of valve to cylinder head
If distance exceeds specifications on either
seating surface (Figure 4-4).
valve, Tables 4-4 and 4-5, seat must be replaced.
Check clearance of valve stems in guides of both valves. If it exceeds values
specified in Tables 4-4 and 4-5, replace valve guides.
4-11
TM 10-4320-344-24
4.4.2 Cylinder Head Assembly, Intake Valve, and Exhaust Valve Repair, Units 609-C and US636HCCD-1
(Continued)
Figure 4-5.
Valve Seat Drilling, Models 609-C and US636HCCD-1
Mandrels (intake and exhaust) come in two sizes. One will fit exhaust valve
seat and other will fit intake valve seat.
4-12
TM 10-4320-344-24
j.
Remove valve seat as follows:
( 1 ) P l a c e m a n d r e l ( F i g u r e 4 - 5 , 1) on valve seat and insert guide through mandrel
(1) into valve stem. Tighten guide so that mandrel (1) is firmly in place.
Do not drill into cylinder head.
equipment damage.
Failure to obey this caution will result in
(2) Insert drill (2) into mandrel (1) and drill through valve seat at two
positions 180° apart.
(3) Remove guide and mandrel (l).
(4) Remove drilled seat.
(5) Measure diameter of valve seat bore in cylinder head (4).
Intake valve seats have larger outside diameter than exhaust valve seats.
(6) Measure outside diameter of new valve seat. Subtract the diameter of bore
from diameter of seat.
Difference must not be less than
0.003 inches (0.076 mm).
Heating cylinder head for more than 30 minutes or at a higher temperature
than 430° F (220° C) may cause cylinder head to warp.
Failure to obey this
caution could result in equipment damage.
k.
Heat cylinder head (4) in oven to a temperature of 430° F (220° C).
heat cylinder head more than 30 minutes.
Do not
Do not touch cylinder head, w h i l e i t i s h o t , w i t h o u t p r o t e c t i v e g l o v e s .
Exercise care when working around hot cylinder head.
Severe burns can result
i f p r o t e c t i v e m e a s u r e s a r e n o t t a k e n . Failure to obey this warning may
result in personal injury.
l.
Remove cylinder head (4) from oven.
If valve guides are in need of replacement.
Replace at this time.
m.
Insert arbor (3) into chamber side of valve guide and drive valve guide out of
cylinder head (4).
n.
Place new retaining ring (Figure 4-2, 8) on new valve guide (9) and drive
longer end of valve guide (9) into bore of cylinder head (1) from the rocker
arm side. Drive valve guide (9) in until retaining ring (8) seats in valve
o.
Place new valve seat (Figure 4-5, 5) on drift with chamfered side up and drive
valve seat (5) into recess of cylinder head (4). Ensure that valve seat is
fully inserted.guide bore of cylinder head (1).
4-13
TM 10-4320-344-24
4.4.2 Cylinder Head Assembly, Intake Valve. and Exhaust Valve Repair, Units 609-C and US636HCCD-1.
(Continued)
p.
After cylinder head (4) cools, ream valve guides (Figure 4-2, 9) using special
8.0 mm (0.3149 in) reamer (Figure 4-5, 6).
q.
Reseat valve seats (5).
4.4.2.3 Assembly.
a.
Install valves (Figure 4-2, 6 and 7) into cylinder head (l).
Valve rotator is installed on exhaust valve.
b.
Install valve rotator or retainer (5).
c.
Install springs (4) and spring retainers (3).
d.
Using valve spring compressor,
4-14
install two tapered valve spring locks (2).
TM 10-4320-344-24
4.4.3 Cylinder Maintenance. Models 609-C and US636HCCD-1.
This task covers:
4.4.3.1 Removal
4.4.3.2 Repair
4.4.3.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
I I I , Item 1
V-Belt Guard removed, paragraph 2.21.11.
Piston Ring Compressors, Appendix B,
S e c t i o n I I I , Items 28 and 29
Material/Parts
Grease, Appendix C, Item 12
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
O-Ring Seal (TM 10-4320-344-24P)
4.4.3.1
Conditions
Cylinder Head Assembly removed, paragraph
3.8.20.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Removal.
Figure 4-6.
Cylinder Maintenance, Models 609-C and US636HCCD-1.
a.
Position piston (Figure 4-6, 1) for cylinder (2) to be replaced, at bottom
dead center (BDC).
b.
Rotate crankshaft until piston (1) lifts cylinder (2) out of crankcase (3).
c.
Remove cylinder (2) from piston (1).
4-15
TM 10-4320-344-24
4.4.3 Cylinder Maintenance, Models 609-C and US636HCCD-1.
(Continued)
d.
Remove shims (4) and O-ring seal, if present, from cylinder (2).
thickness of shims (4) and discard O-ring seal.
e.
Place two blocks under piston (1).
Record
4.4.3.2 Repair.
To prevent malfunction of parts, piston must be replaced if new cylinder is
being installed.
a.
Inspect walls of cylinder (2) for scratches or other damage.
b.
Check machined mating surfaces at top and bottom of cylinder (2).
is not flat or is damaged, replace cylinder (2).
Figure 4-7.
If surface
Cylinder Measurement Locations, Models 609-C and US636HCCD-1.
Measurements at all four levels must be made along center line “a” (Figure 47, 1) and cross-line “b” (2).
c.
Measure cylinder bore (3) of cylinder (Figure 4-6, 2) at depth levels 1, 2, 3,
and 4, (Figure 4-7, 4).
d.
Replace cylinder if any measurement exceeds 4.0217 inches (102.150 mm) for
Model 609-c and 3.9418 inches (100.122 mm) for Model US636HCCD-1.
e.
Inspect cylinder mating surface on crankcase (Figure 4-6, 3) for scratches or
burrs.
4-16
TM 10-4320-344-24
4.4.3.3 Installation.
If shims are used, shims must be equal in thickness to shims which were
removed.
a.
Apply light coating of g r e a s e t o s h i m s ( 4 ) a n d i n s t a l l s h i m s o n c y l i n d e r ( 2 ) .
b.
Install new O-ring seal, if used, on cylinder (2).
c.
Coat rings on piston (1) and interior surface of cylinder (2) lightly with
oil.
d.
Ensure ring gaps on piston (1) are spaced equally around piston (1).
e.
Install ring compressor on piston (1).
f.
Slide cylinder (2) down piston (1) until rings on piston (1) are inside
cylinder (2).
g.
Remove ring compressor from piston (1) and remove wood blocks from under
piston (1).
h.
Rotate cylinder (2) until cutout side of cylinder (2) is facing pushrod bores
(5).
i.
Install cylinder (2) on crankcase (3) and align cylinder (2) with adjacent
cylinders (6).
4-17
TM 10-4320-344-24
4.4.4 Gear Housing Cover Maintenance, Model 609-A.
This task covers:
4.4.4.1 Removal
4.4.4.2 Repair
4.4.4.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Oil Seal (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2
Equipment Conditions
Gun, Air Blow, Appendix B, Section
III, Item 2
Puller Kit, Appendix B, Section III,
Item 2
(Continued)
Radiator Support Brackets removed,
paragraph 2.20.5.
Alternator Belt removed, paragraph
2.21.13.
Oil Cooler removed, paragraph 2.21.28.
Torque Wrench, Appendix B, Section
III, Item 2
Material/Parts
Crankshaft Pulley and Vibration Damper
removed, paragraph 3.8.21.
General Safety I n s t r u c t i o n s
Adhesive (Gasket Cement), Appendix C,
Item 1
Abrasive Cloth (Emery), Appendix C,
Item 8
Gloves, Appendix C, Item 11
Sealing Compound, Appendix C, Item 23
Oil Soap, Appendix C, Item 24
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.4.1 Removal.
a.
Remove gear housing attaching nut (Figure 4-8, 1) and lock washer (2).
Discard lock washer (2).
b.
Remove thirteen cover attaching screws (3), lock washers (4), gear housing
c o v e r ( 5 ) , and gasket (6). Discard lock washers (4) and gasket (6).
c.
Remove four screws (7), lock washers (8), thrust plate (9), and gasket (10)
from gear housing cover (5). Discard lock washers (8) and gasket (10).
d.
Press oil seal (11) from gear housing cover (5).
4.4.4.2 Repair.
a.
4-18
Wipe clean all gasket mounting surfaces.
Discard oil seal (11).
TM 10-4320-344-24
Figure 4-8.
Gear Housing Cover Maintenance, Model 609-A.
•
Do not use cleaning solvent without proper ventilation and clothing.
Dry cleaning
Do not smoke or use near open flame or excessive heat.
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wash
Wear goggles and rubber gloves to protect eyes and skin.
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
•
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
b.
Clean gear housing cover (5) and attaching components with cleaning solvent.
Dry thoroughly with compressed air.
c.
Inspect all components and mounting hardware for damage.
d.
Replace all damaged components.
4.4.4.3 Installation.
W h e n i n s t a l l i n g n e w o i l s e a l , use a small amount of sealing compound in gear
housing cover before pressing in seal.
If new seal is pre-coated, sealing
compound is not required.
a.
Install new oil seal (11) in gear housing cover (5).
4-19
TM 10-4320-344-24
4.4.4 Gear Housing Cover Maintenance, Model 609-A.
b.
(Continued)
Position new gasket (10) and thrust plate (9) against gear housing cover (5)
and install four new lock washers (8) and s c r e w s ( 7 ) . Torque screws (7) to 9
ft-lbs (12 N•m).
Nicks and scratches in crankshaft can damage oil seal during installation.
Remove nicks and scratches prior to installation of gear housing cover.
Failure to obey his caution may result in equipment damage.
c.
Using very fine emery cloth, f i r s t c l e a n a n d t h e n p o l i s h o i l s e a l s u r f a c e s o f
c r a n k s h a f t . Remove nicks or scratches that could damage seal.
T O Prevent damage to oil seal. keep seal surface clean during assembly. If
crankshaft has a key-way, cover key way with a t h i c k f e e l e r g a g e t o p r o t e c t
o i l s e a l d u r i n g i n s t a l l a t i o n . F a i l u r e t o o b e y his caution may result in
equipment damage.
If oil seal is already oil treated, additional lubricant is not required for
assembly.
d.
Apply thin coat of oil soap to oil seal (11) and seal surface of crankshaft.
e.
Apply adhesive to gasket mounting surface of g e a r h o u s i n g c o v e r ( 5 ) .
f.
Install new gasket (6) and gear housing cover (5) over gear housing, carefully
installing oil seal (11) over crankshaft.
g.
Install thirteen new lock washers (4) and cover attaching screws (3).
screws (3) to 15 ft-lbs (20 N•m).
h.
Install new lock washer (2) and gear housing attaching nut (1).
(1).
i.
Start engine, refer to TM 10-4320-344-10, and check for fluid leaks.
4-20
Torque
Tighten nut
TM 10-4320-344-24
4.4.5 Crankcase Front Cover Maintenance. Models 609-C and US5636HCCD-1.
This task
4.4.5.1
4.4.5.2
4.4.5.3
covers:
Removal
Disassembly
Repair
4.4.5.4 Assembly
4.4.5.5 Installation
INITIAL SETUP
Tools
Equipment Conditions (Continued)
General Mechanic’s Automotive
T o o l K i t , Appendix B, Section
III, Item 1
Alternator and Alternator Mounting
Bracket removed, paragraph 2.21.16.
G o g g l e s , I n d u s t r i a l , Appendix B,
Section III, Item 2
Gun, Air Blow, Appendix B, Section
III, Item 2
P u l l e r K i t , Appendix B, S e c t i o n I I I ,
Item 2
Material/Parts
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
Sealing Compound, Appendix C, Item 23
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Shaft Seal (TM 10-4320-344-24P)
Equipment Conditions
Engine Support Crossmember removed,
paragraph 3.8.3
Oil Drain Tube Assembly removed,
paragraph 2.21.24.
Cooling Air Blower removed, paragraph
2.21.39.
Tachometer Angle Drive removed, paragraph
(US636HCCD-1 only).
2.21.45.
Fuel Injection Pump Assembly removed,
paragraph 3.8.11.
V-Belt Tensioner removed, paragraph
3.8.16.
Crankshaft Pulley and Vibration Damper
removed, paragraph 3.8.22.
General Safety I n s t r u c t i o n s
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model US636HCCD-1.
similar.
The procedures for Model 609-C are
4.4.5.1 Removal.
a.
Remove two bolts (Figure 4-9, 1) and flat washers (2).
b.
Remove two bolts (3) and lock washers (4).
c.
Remove two screws (5), lock washers (6), spacers (7), and front cover (8).
Discard lock washers (6).
Discard lock washers (4).
4.4.5.2 Disassembly.
a.
Remove sleeve bushing (9).
b.
Remove oil cooler plug (10), gasket (11), plug (12), spacer (13), cap (14),
and spring (15). Discard gasket (11).
4-21
TM 10-4320-344-24
4.4.5 Crankcase Front Cover Maintenance. Models 609-C and US636HCCD-1. (Continued)
Figure 4-9.
Crankcase Front Cover Maintenance, Models 609-C and US636HCCD-1
Discard shaft seal
c.
P r e s s s h a f t s e a l ( 1 6 ) f r o m crankcase front cover (8).
(16).
d.
Remove oil filler cap (17) a n d r e m o v e g a s k e t ( 1 8 ) f r o m o i l f i l l e r c a p ( 1 7 ) .
Discard gasket (18).
4-22
TM 10-4320-344-24
4.4.5.3 Repair.
•
Do not use cleaning solvent without proper ventilation and clothing.
Dry cleaning
Do not smoke or use near open flame or excessive heat.
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
•
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent and thoroughly air dry all
components with compressed dry air.
b.
Inspect all components for damage.
c.
Replace all defective components.
4.4.5.4 Assembly.
a.
Install new gasket (18) in oil filler cap (17) and install oil filler cap (17)
on crankcase front cover (8).
b.
Install new shaft seal (16) in crankcase front cover (8).
c.
Install spring (15), with locating tang towards engine, cap (14), spacer (13),
and secure with plug (12).
d.
Install new gasket (11) and secure with oil cooler plug (10).
e.
Install sleeve bushing (9) in crankcase front cover (8).
4.4.5.5 Installation.
a.
Apply sealing compound to crankcase front cover (8).
b.
Position crankcase front cover (8) on engine.
c.
Install two spacers (7), new lock washers (6), and screws (5).
d.
Install two flat washers (4) and bolts (3).
e.
Install two flat washers (2) and bolts (1).
f.
Start engine, refer to TM 10-4320-344-10, and check for leaks.
4-23
TM 10-4320-344-24
4.4.6 Idler Gear and Bearing Maintenance. Model 609-A.
This task covers:
4.4.6.1 Removal
4.4.6.2 Repair
4.4.6.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Gear Housing Cover removed, paragraph
4.4.4.
Torque Wrench, Appendix B, Section,
III, Item 2
General Safety I n s t r u c t i o n s
Scales for 32 lb. test, Appendix B
Section III, Item 3
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Adhesive (Loctite), Appendix C, Item 2
Rags, Appendix C, Item 20
Bearings (TM 10-4320-344-24P)
Do not work on equipment without following standard shop safety practices.
4.4.6.1 Removal.
Figure 4-10.
Idler Gear and Bearing Maintenance, Model 609-A.
a.
R e m o v e s c r e w ( F i g u r e 4 - 1 0 , 1 ) , f l a t w a s h e r ( 2 ) , and outer bearing (3) from
i d l e r g e a r ( 4 ) . Discard bearing (3).
b.
Remove retaining ring (5) from idler gear (4).
4-24
TM 10-4320-344-24
NOTE
Do not remove idler shaft unless it is damaged.
Mark idler gear for ease of installation.
c.
Mark and remove idler gear (4) from idler gear shaft (6).
d.
Remove spacer (7) and bearing (8) from idler gear shaft (6). Discard
bearing (8).
4.4.6.2 Repair.
a.
Inspect idler gear (4) for chipped, cracked, or broken teeth. Replace
gear (4) if damaged.
NOTE
Idler gear shaft must withstand direct pull of 32 lbs (14.5 Kg).
b.
Ensure idler gear shaft (6) is tightly fitted in gear housing (9). Replace a
loose-fitting idler gear shaft (6).
4.4.6.3 Installation.
a.
Install new bearing (8) and spacer (7) on idler shaft (4).
Ensure marks placed on gear interfaces in removal coincide when installing
idle gear. Failure to obey this warning may result in damage to equipment.
b.
Install idler gear (4) on idler gear shaft (6).
c.
Install retaining ring (5) and new outer bearing (3) in idler gear (4).
d.
Apply a thin coat of adhesive on threads of bolt (1) and install washer (2)
and screw (1). Torque screw (1) to 25 ft-lbs (34 N•m).
4-25
TM 10-4320-344-24
4.4.7 Oil Pump Assembly and Oil Pipe Maintenance. Models 609-C and US636HCCD-1,
This task covers:
4.4.7.1
Removal
4.4.7.3 Repair
4.4.7.2 Disassembly
4.4.7.4 Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive
Tool Kit, Appendix B, Section III,
Item 1
Gloves, Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Lock Washers (TM 10-4320-344-24P)
Gaskets (TM 10-4320-344-24P)
Goggles, Appendix B, Section III,
Item 2
Gun, Air Blow, Appendix B, Section
III, Item 2
Equipment Conditions
Suction Pipe removed, paragraph 3.8.14.
Torque Wrench, Appendix B, Section
I I I , Item 2
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
Crankcase Front Cover removed, paragraph
4.4.5.
General Safety I n s t r u c t i o n s
Do not work on equipment without following standard shop safety practices.
This procedure applies to Model US636HCCD-1.
is similar.
The procedure for Model 609-C
4.4.7.1 Removal.
a.
Remove screw (Figure 4-11, 1) from idler gear (2).
b.
Remove two screws (3), lock washers (4), and oil pump assembly (5) from
c r a n k c a s e ( 9 ) . Discard lock washers (4).
4.4.7.2 Disassembly.
a.
Remove oil pipe (6) from oil pump assembly (5).
b.
Remove mounting bracket (7) and two gaskets (8) from oil pipe (6).
gaskets (8).
Discard
4.4.7.3 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Do not smoke or use near open flame or excessive heat.
Dry cleaning
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wash
Wear goggles and rubber gloves to protect eyes and skin.
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
4-26
Clean all components with cleaning solvent and thoroughly air dry all
components with compressed dry air.
TM 10-4320-344-24
Figure 4-11.
0il Pump Assembly and Oil Pipe Replacement, Models
609-C and US636HCCD-1.
b.
Inspect all components and mounting hardware for damage.
c.
Replace all defective components.
4.4.7.4 Assembly.
a.
Position two new gaskets (8) and mounting bracket (7) on oil pipe (6).
b.
Install oil pipe (6) in oil pump assembly (5).
4.4.7.5 Assembly.
a.
Position oil pump assembly (5) against crankcase (9), with oil pipe assembly
( 6 ) i n s t a l l e d i n c r a n k c a s e ( 9 ) , and secure with two new lock washers (4) and
s c r e w s ( 3 ) . Torque screws to 26 ft-lbs (35 NŽm).
b.
Install screw (1) securing mounting bracket (7) to idler gear (2).
screw to 22 ft-lbs (30 N•m) .
c.
Using angle-of-turn indicator tighten screw (1) 60°.
Torque
4-27
TM
10-4320-344-24
4.4.8 Idler Gear Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.8.1 Removal
4.4.8.2 Repair
4.4.8.3
Installation
INITIAL SETUP
Tools
Material/Parts (Continued)
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Bearing Sleeve (TM 10-4320-344-24P)
Bushing Sleeve (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2
Gun, A i r B l o w , A p p e n d i x B , S e c t i o n I I I ,
Item 2
Torque Wrench, Appendix B, Section, III,
Item 2
Equipment Conditions
Oil Pump Assembly and Oil Pipe removed,
paragraph 4.4.7.
General Safety I n s t r u c t i o n s
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
Micrometer,
Item 3
Appendix B, Section III,
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
Material/Parts
G l o v e s , Appendix C, Item 11
4.4.8.1 Removal. R e m o v e i d l e r g e a r ( F i g u r e 4 - 1 2 , 1 ) , s l e e v e b u s h i n g ( 2 ) , b e a r i n g
j o u r n a l ( 3 ) , a n d s l e e v e b u s h i n g ( 4 ) . Discard sleeve bushings (2 and 4).
Figure 4 - 1 2 .
4-28
Idler Car Replacement, Models 609-C and US636HCCD-1.
TM 10-4320-344-24
4.4.8.2 Repair.
•
Do not use cleaning solvent without proper ventilation and clothing.
Do not smoke or use near open flame or excessive heat.
Dry cleaning
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
•
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent and thoroughly dry all components
with compressed dry air.
b.
Measure diameter of bearing journal (3).
If diameter is not within 1.57381.5744 inches (39.975-39.991 mm) replace bearing journal (3).
c.
Inspect all other components for damage.
d.
Replace damaged or defective items.
4.4.8.3 Installation.
a.
Install new sleeve bushing (4), bearing journal (3), and new sleeve bushing
(2) on crankcase (5).
Ensure timing marks on gears coincide when installing idler gear.
obey this warning may result in damage to equipment.
b.
Failure to
I n s t a l l i d l e r g e a r ( 1 ) . Ensure oil hole of new sleeve bushing (2) and bearing
journal (3) are aligned when installing idler gear (1).
4-29
TM 10-4320-344-24
4.4.9 Flywheel Maintenance, Model 609-A.
This task covers:
4.4.9.1
Removal
4.4.9.2 Repair
4.4.9.3
Installation
INITIAL SETUP
Tools
Equipment Conditions
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Pumping Assembly removed, paragraph
3.6.1.
Acetylene Welding Equipment, Appendix B,
Section III, Item 2
Starter Assembly removed, paragraph
2.21.18.
Goggles, Appendix B, Section 111,
Item 2
General Safety I n s t r u c t i o n s
Torque Wrench, Appendix B, Section III,
Item 2
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Do not work on equipment without following standard shop safety practices.
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Locker Washer (TM 10-4320-344-24P)
4.4.9.1 Removal.
Figure 4-13.
Positioning of Flywheel, Model 609-A.
a.
Turn crankshaft until “DC” mark (Figure 4-13,
timing mark (2) on bellhousing (3).
b.
Secure crankshaft to eliminate crankshaft rotation.
d.
Remove six bolts (Figure 4-14, 1) that secure flywheel (2) to crankshaft (3).
4-30
1) on flywheel aligns with
TM 10-4320-344-24
Spur gear should not be removed from flywheel unless spur gear is damaged or
needs to be replaced.
e.
Remove flywheel (2) from crankshaft (3).
Figure 4-14.
Flywheel Removal, Model 609-A.
4.4.9.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
a.
Clean all components with cleaning solvent and thoroughly dry all components.
b.
Inspect flywheel (2) for cracks, distortions, discoloration, wear, or other
damage.
c.
Inspect spur gear (4) for broken or cracked teeth, chips, or other damage. If
s p u r g e a r- ( 4 )- is damaged, r e p l a c e a s f o l l o w s :
Note chamfer, if present, on spur gear.
(1) Remove spur g e a r ( 4 ) f r o m f l y w h e e l ( 3 ) a n d d i s c a r d .
4-31
TM
10-4320-344-24
4.4.9 Flywheel Maintenance, Model 609-A. (Continued)
To avoid burns, or other injury to personnel, use tongs when handling heated
ring gear.
D o n o t o v e r h e a t r i n g g e a r . Overheating ring gear may cause warpage.
ring gear may cause damage to equipment.
Warped
(2) Heat replacement spur gear (4) to 600° F (315.60 C).
(3) Place heated spur gear (4) on flywheel (2).
onto flywheel (2).
d.
Inspect all mounting hardware for damage.
e.
Replace all damaged or defective components.
Quickly drive spur gear (4)
One of six mounting bolts is off center so that flywheel can only be
installed in one position. This ensures proper location of flywheel on
crankshaft for timing purposes.
4.4.9.3 Installation. P o s i t i o n f l y w h e e l ( 2 ) o n c r a n k s h a f t ( 3 ) a n d i n s t a l l s i x
b o l t s ( 1 ) . Torque bolts (1) to 80 ft-lbs (109 N•m).
4-32
TM 10-4320-344-24
4.4.10 Flywheel Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.10.3
4.4 .10.1 Removal
4.4.10.2 Repair
Installation
INITIAL SETUP
Tools
Equipment
Conditions
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Pumping Assembly removed, paragraph
3.6.1.
General Safety I n s t r u c t i o n s
Acetylene Welding Equipment, Appendix B,
Section III, Item 2
Torque Wrench, Appendix B, Section III,
Item 2
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
DO
Do not work on equipment without following standard shop safety practices.
4.4.10.1 Removal. Remove ten flywheel mounting screws (Figure 4-14, 1) and flywheel
(2) from crankshaft (3).
Figure 4-15.
Flywheel Maintenance, Models 609-c and US636HCCD-1.
4.4.10.2 Repair.
a.
Inspect flywheel (2) for cracks, distortions, discoloration, wear, or other
damage.
b.
Inspect ring gear (4) for broken or cracked teeth, chips, or other damage. If
ring gear (4) is damaged, replace as follows:
(1) Remove ring gear (4) from flywheel (3) and discard.
4-33
TM 10-4320-344-24
4.4.10 Flywheel Maintenance, Models 609-C and US636HCCD-1.
(Continued)
To avoid burns, o r o t h e r i n j u r y t o p e r s o n n e l , do not touch heated ring. Use
tongs when handling heated ring gear.
Do not overheat ring gear.
Overheating ring gear may cause warpage.
ring gear may cause damage to equipment.
Warped
( 3 ) H e a t r e p l a c e m e n t r i n g g e a r ( 4 ) t o 2 4 8 ° F (120°C).
NOTE
P l a c e b e v e l e d s i d e o f r i n g g e a r t e e t h facing away from flywheel.
( 4 ) P l a c e h e a t e d r i n g g e a r ( 4 ) o n f l y w h e e l ( 2 ) . Quickly drive ring gear (4)
until it seats against shoulder of flywheel (2).
c.
Inspect all mounting hardware for damage.
d.
Replace all damaged or defective components.
4.4.10.3
Installation.
a.
Position flywheel (2) on crankshaft (3) and install ten flywheel mounting
screws (1).
Preload screws (1) to 22 ft-lbs (30 N•m).
b.
Using angle-of-turn indicator, tighten screws (1) 30° first stage.
c.
Tighten screws (1) an additional 30° second stage.
4-34
TM 10-4320-344-24
4.4.11 Bellhousing Maintenance. Model 609-A.
This task covers:
4.4.11.1 Removal
4.4.11.2 Repair
4.4.11.3
Installation
INITIAL SETUP
(Continued)
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Oil Soap, Appendix C, Item 24
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Gasket (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Oil Seal( TM 10-4320-344-24P)
Goggles, Appendix B, Section III,
Item 2
Gun, Air Blow, Appendix B, Section
III, Item 2
Equipment
P u l l e r K i t , Appendix B, S e c t i o n 1 1 1 ,
Item 2
Conditions
Oil Pan removed, paragraph 3.8.12.
Magnetic Pickup removed, paragraph 3.8.5.
Torque Wrench, A p p e n d i x B , S e c t i o n I I I ,
Item 2
Flywheel removed, paragraph 4.4.9.
Material/Parts
General Safety I n s t r u c t i o n s
A b r a s i v e C l o t h (Emery), Appendix C,
Item 8
Adhesive (Gasket Cement), Appendix C,
Item 1
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.11.1 Removal.
Discard lock
a.
Remove two nuts (Figure 4-16, 1) and lock washers (2).
washers (2).
b.
Remove four bolts (3), lock washers (4), and oil pan adapter (5) from
b e l l h o u s i n g ( 6 ) . Discard lock washers (4).
c.
Remove six bolts (7) and lock washers (8) that secure bellhousing (6) to
e n g i n e b l o c k . Discard lock washers (8).
It may be necessary to tap bellhousing with soft hammer to loosen from studs
or gasket.
d.
Remove two nuts (9), lock washers (10) and bellhousing (6) from studs on
cylinder block. Discard lock washers (10).
e.
Remove bellhousing gasket (11).
f.
Press rear oil seal (12) from bellhousing (6).
Discard gasket (11).
Discard oil seal (12).
4.4.11.2 Repair.
a.
Clean gasket mounting surfaces on all components.
4-35
TM 10-4320-344-24
4.4.11 Bellhousing Maintenance, Model 609-A. (Continued)
Figure 4-16.
Bellhousing Maintenance.
•
Do not use cleaning solvent without proper ventilation and clothing.
Do not smoke or use near open flame or excessive heat.
Dry cleaning
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
•
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
b.
Clean all components with cleaning solvent and dry with compressed dry air.
c.
Inspect all components and mounting hardware for damage.
d.
Ensure bellhousing studs in engine block are tight and in good condition.
Check for worn or stripped threads.
Tighten loose studs.
e.
Replace all defective components.
4-36
TM 10-4320-344-24
4.4.11.3
Installation.
W h e n i n s t a l l i n g n e w o i l s e a l , use a small amount of sealing compound in bore
of bellhousing before pressing in seal.
If new seal is pre-coated, sealing
compound is not required.
a.
Install new rear oil seal (12) in bellhousing (6).
b.
Using emery cloth, clean and polish oil seal surface of crankshaft to remove
nicks or scratches.
Allow cement to dry long enough to prevent gasket from slipping during
installation.
c.
Cement new gasket (11) to bellhousing (6).
To avoid leakage after installation, keep seal surface clean during
reassembly.
If seal is already oil treated, additional lubricant is not required.
d.
Apply thin coat of oil soap to inside of oil seal (12) and oil seal surface of
crankshaft.
.
Make sure top rear cam thrust plate attaching screw hole is plugged
with a set-screw. This hole runs into an oil hole in block.
.
Forcing bellhousing on cylinder block can damage seal.
.
Failure to obey these cautions may result in equipment damage.
e.
A l i g n h o l e s o n b e l l h o u s i n g ( 6 ) w i t h m o u n t i n g s t u d s o n c y l i n d e r b l o c k . Ensure
bellhousing (6) is firmly seated to cylinder block and secure with two new
lock washers (10) and nuts (9). Hand tighten nuts (9).
f.
Install six new lock washers (8) and bolts (7). Hand tighten bolts (7).
g.
Position oil pan adapter (5) against bellhousing (6) and secure to bellhousing
(6) with four new lock washers (4) and bolts (3).
h.
Secure oil pan adapter (5) to cylinder block with two lock washers (2) and
nuts (1).
i.
Torque nuts (9) and bolts (7) to 60 ft-lbs (81 NŽm).
4-37
TM 10-4320-344-24
4.4.12 Flywheel Cover Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.12.1 Removal
4.4.12.2 Repair
4.4.12.3
Installation
INITIAL SETUP
Tools
Equipment
General Mechanic’s Automotive Tool Kit,
Appendix B, Section 11,1, Item 1
Magnetic Pickup removed, paragraph 3.8.5.
Conditions
(Continued)
Flywheel removed, paragraph 4.4.10.
Material/Parts
General Safety I n s t r u c t i o n s
Lock Washers (TM 10-4320-344-24P)
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Equipment Conditions
Muffler removed, paragraph 2.12.3
(US636HCCD-1).
Do not work on equipment without following standard shop safety practices.
4.4.12.1 Removal.
Figure 4-17.
4-38
Flywheel Cover Maintenance.
TM 10-4320-344-24
a.
Remove four bolts (Figure 4-17, 1 ) , l o c k w a s h e r s ( 2 ) , a n d c o v e r p l a t e ( 3 ) f r o m
f l y w h e e l c o v e r ( 4 ) . Discard lock washers (2).
b.
Remove bolt (5) and lock washer (6).
c.
Remove nine bolts (7), lock washers (8), and flywheel cover (4) from
Discard lock washers (8).
crankcase.
d.
Remove three bolts (9), lock washers (10), and cover plate (11).
washers (10).
Discard lock washer (6).
Discard lock
4.4.12.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all damaged or defective components.
4.4.12.3
Installation.
a.
Position cover plate (11) against flywheel cover (4) and secure with three new
lock washers (10) and bolts ( 9 ) .
b.
Position flywheel cover (4) against crankcase and secure with nine new lock
washers (8) and bolts (7).
c.
Install new lock washer (6) a n d b o l t ( 5 ) .
d.
Position cover plate (3) on flywheel cover (4) and secure with four new lock
washers (2) and bolts (1).
4-39
TM 10-4320-344-24
4.4.13 Crankcase Rear Cover Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.13.1 Removal
4.4.13.2 Repair
4.4.13.3
Installation
INITIAL SETUP
Tools
Material/Parts (Continued)
General Mechanic’s Automotive
Tool Kit, Appendix B, Section
III, Item 1
Sealing Ring (TM 10-4320-344-24P)
Equipment
Puller Kit, Appendix B, Section III,
Item 2
Oil Pan Assembly removed, paragraph
3.8.12.
Material/Parts
Flywheel Cover removed, paragraph 4.4.12.
Grease, Appendix C, Item 12
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Sealing Compound, Appendix C, Item 23
Gasket (TM 10-4320-344-24P)
General Safety I n s t r u c t i o n s
Conditions
Do not work on equipment without following standard shop safety practices.
4.4.13.1 Removal.
Figure 4-18.
Crankcase Rear Cover Maintenance, Models 609-C and US636HCCD-1.
a.
R e m o v e e i g h t r e a r c o v e r b o l t s ( F i g u r e 4 - 1 8 , 1 ) , f l a t washers (2) and rear
cover (3) from crankcase (4).
b.
Remove rear cover gasket (5).
c.
Remove crankshaft sealing ring ( 6 ) f r o m r e a r c o v e r ( 3 ) . D i s c a r d s e a l i n g r i n g
(6).
4-40
Discard gasket (5).
TM 10-4320-344-24
4.4.13.2 Repair.
a.
Inspect all components and mounting hardware for damage.
b.
Replace all defective components.
4.4.13.3 Installation.
Coat outside of sealing ring with sealing compound.
a.
Install crankshaft sealing ring (6) in rear cover (3), lip toward crankcase
(4) side of rear cover (3). Outer side of sealing ring (6) should be even
with outer side of rear cover (3).
b.
U s i n g g r e a s e , p o s i t i o n n e w g a s k e t ( 5 ) . o n c r a n k c a s e ( 4 ) . Trim bottom of gasket
(5) to be flush with oil pan assembly mounting surface of crankcase (4).
c.
Inspect surface of crankshaft where sealing ring (6) contacts the crankshaft.
If surface is grooved, add additional gaskets (5), to alter the contact
surface between sealing ring (6) and crankshaft.
d.
Lightly coat sealing lip of sealing ring (6) with oil.
e.
Position rear cover (3) on crankcase (4) and secure with eight flat washers
(2) and bolts (1).
4-41
TM 10-4320-344-24
4.4.14 Piston and Connecting Rod Assembly Maintenance, Model 609-A.
This task
4.4.14.1
4.4.14.2
4.4.14.3
covers:
Removal
Disassembly
Repair
4.4.14.4 Assembly
4.4.14.5 Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Gloves, Appendix C, Item 11
Engine Assembly Grease, Appendix C,
Goggles, Appendix B, Section III,
Item 2
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Bearings (TM 10-4320-344-24P)
Piston Rings (TM 10-4320-344-24P)
Torque Wrench, Appendix B, Section
Item 2
III ,
Vise, Appendix B, Section III, Item 2
Inside Micrometer, Appendix B, Section
I I I , Item 3
Micrometer, Appendix B, Section 111,
Item 3
Piston Ring Expander, Appendix
Section III, Item 3
(Continued)
Equipment Conditions
Oil Pump Assembly removed, paragraph
3.8.13.
Cylinder Head Assembly removed, paragraph
3.8.19.
B,
General Safety I n s t r u c t i o n s
Ridge Reamer, Appendix B, section
III, Item 3
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Material/Parts
Brush, Appendix C, Item 5
Abrasive Cloth (Emery), Appendix
Item 8
C,
Do not work on equipment without following standard shop safety practices.
4.4.14.1 Removal.
Ensure carbon deposits have been scraped from cylinder bores to avoid
damaging piston rings during removal.
It may be necessary to use ridge reamer on excessively worn cylinder bores.
a.
Remove top wear ridge in each cylinder bore and, using wire brush,
carbon deposits from top of each cylinder bore.
b.
Crank engine so that number 1 piston is at BDC.
4-42
clean
TM 10-4320-344-24
Figure 4-19. Piston and Connecting Rod Assembly, Model 609-A.
When removing pistons and connecting rods, do not mix parts. Keep connecting
rod, cap, bearings, and piston together. Failure to obey this caution will
result in damage to equipment.
c.
Remove two cap screws (Figure 4-19, 1), connecting rod cap (2), and lower
bearing (3). Tag cylinder location on each item removed.
4-43
TM 10-4320-344-24
4.4.14 Piston and Connecting Rod Assembly Maintenance, Model 609-A. (Continued)
Figure 4-20.
Removing Piston and Connecting Rod Assembly, Model 609-A.
d.
Using hammer handle (Figure 4-20,1) carefully push piston and connecting rod
assembly through top of cylinder block (2). Tag cylinder location on each
assembly removed.
e.
Repeating steps b through d, rotate crankshaft and remove remaining pistons
and connecting rod assemblies.
4.4.14.2 Disassembly.
a.
Place piston and connecting rod assembly in vise equipped with soft jaws.
b.
Using piston ring expander tool, remove four piston rings (Figure 4-19, 4, 5,
6, and 7). Discard piston rings (4, 5, 6, and 7).
c.
Remove two piston pin retaining rings (8).
d.
Push pin (9) out of piston (10) and piston pin bushing (11). Remove
connecting rod (12) from piston (10).
e.
Repeat steps a through d for five remaining piston and connecting rod
assemblies.
4-44
TM 10-4320-344-24
4.4.14.3 Repair.
Do not use cleaning solvent without proper ventilation and clothing. Do not
smoke or use near open flame or excessive heat. Dry cleaning solvent is
potentially dangerous to personnel and property. Clean parts in a wellventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber
gloves to protect eyes and skin. Wash exposed skin thoroughly. Failure to
obey this warning may result in personal injury or death.
If chemical carbon solvent is used to clean parts, make sure it will not
damage aluminum pistons or bronze piston bushings.
NOTE
If cleaning solvent does not remove carbon deposits, use chemical carbon
solvent.
a.
Clean all components with cleaning solvent and wire brush.
b.
Clean ring grooves on piston (10).
c.
Allow all components to thoroughly air dry.
d.
Using standard aligning fixture, check connecting rod (12) for distortion and
misalignment.
e.
Check screws (1), caps (2), and connecting rods (12) for cracks or damage.
f.
Check piston pin bushings (11) for scoring and wear. Measure diameter of
bushings (11). The measurement should be no larger than 1.2523 inches
(31.81 mm).
g.
Inspect piston pin (9) for wear or scoring. Inspect piston pin (9) for the
dimensions listed in Table 4-6.
Table 4-6.
Dimension
Length
Diameter
Clearance in piston
Clearance in connecting
rod
h.
Pinton Pin Dimensions.
Minimum
3.025 inches (76.835
1.2478 inches (31.694
0.0000 inches (0.000
0.0005 inches (0.0127
mm)
mm)
mm)
mm)
Maximum
3.035 (77.089 mm)
1.2500 inches (31.750 mm)
0.0005 inches (0.0127 mm)
0.0012 inches (0.0305 mm)
Inspect pistons (10) for damaged ring grooves, scoring, or cracks. Remove
light scoring with emery cloth. Inspect piston (10) to the dimensions listed
in Table 4-7.
Table 4-7. Piston Dimensions, Model 609-A.
Dimension
Clearance in cylinder
bore - 4" Bohn
Piston pin bore
Minimum
0.0016 inches (0.0406 mm)
Maximum
0.0024 (0.0610 mm)
1.2490 inches (31.7246 mm) 1.2502 inches (31.7551 mm)
4-45
TM 10-4320-344-24
4.4.14 Piston and Connecting Rod Assembly Maintenance, Model 609-A. (Continued)
Table 4-7.
Dimension
Width of ring groovetop-Keystone
Width of ring groove 2nd
Width of ring groove oil control
i.
Piston Dimensions, Model 609-A. (Continued)
Minimum
0.125 inches (3.175 mm)
nominal
0.1210 inches (3.0734 mm)
Maximum
0.1270 inches (3.2258 mm)
0.1830 inches (4.6482 mm)
0.1890 inches (4.8006 mm)
Inspect crankshaft for any rough or scored marks that might damage bearings (3
and 13). If any rough marks are found, polish shaft with emery cloth.
Thoroughly clean shaft after polishing.
All parts should be measured at room temperature; otherwise, dimensional
tolerances during piston and ring fitting may be incorrect.
Measure size of cylinder bores.
j.
NOTE
.
Piston size is identified by letter stamped on top of piston.
.
If new standard piston is installed, make sure size letter stamped
o n t o p o f p i s t o n - a g r e e s w i t h bore size l e t t e r s t a m p e d o n c y l i n d e r
block.
k.
Check fit of piston (10) without piston rings (4, 5, 6, and 7) in cylinder
bore. If any binding occurs, remove piston (10) and check for burrs on piston
(10) and cylinder wall.
l.
Insert new piston rings (4, 5, 6, and 7) one at a time inside cylinder bore.
Ensure each piston ring (4, 5, 6, and 7) is at bottom of piston ring (4, 5, 6,
and 7) travel.
m.
Using a piston (10), push piston ring (4, 5, 6, and 7) down so it is parallel
with top of cylinder bore.
NOTE
All ring gaps should be between 0.0100 inches (0.2540 mm) and 0.0200 inches
(0.5080 mm).
n.
Measure gap in piston ring (4, 5, 6, and 7). After checking clearance, remove
piston rings (4, 5, 6, and 7).
o.
Inspect piston rings (4, 5, 6, and 7) for the clearances listed in Table 4-8.
4-46
TM 10-4320-344-24
Table 4-8. Piston Ring Dimensions.
Minimum
Dimension
Clearance in groove top
Maximum
Keystone taper
Clearance in groove 2nd
0.0040 inches (0.1016 mm)
0.0060 inches (0.1524 mm)
Clearance in groove oil control
0.0015 inches (0.0381 mm)
0.0030 inches (0.0762 mm)
4.4.14.4 Assembly.
a.
Place upper end of connecting rod (12) between piston pin bosses in piston
(10), and in line with piston pin holes in piston (10).
b.
Slide piston pin (9) into place.
c.
Install two piston pin retaining rings (8).
Figure 4-21. Piston Ring Positioning, Model 609-A.
Do not spread rings anymore than necessary to slip them over piston. Rings
could be over-stressed and break.
NOTE
If piston rings have undercut grooves on outside diameter of ring,
place undercut or groove facing toward bottom of piston. (Reference
Figure 4-21)
If piston rings have undercut grooves on inside diameter of ring,
place undercut or groove facing toward top of piston. (Reference
Figure 4-21)
d.
Using expander tool, install four piston rings (Figure 4-19, 4, 5, 6, and 7)
on each piston (10). Stagger positions of gaps on piston rings (4, 5, 6, and
7) around piston (10) to minimize compression loss. No two gaps of piston
rings (4, 5, 6, and 7) should be in line.
e.
Repeat steps a through d for five remaining piston and connecting rod
assemblies.
4-47
TM 10-4320-344-24
4.4.14 Piston and Connecting Rod Assembly Maintenance, Model 609-A. (Continued)
4.4.14.5 Installation.
NOTE
Cylinder number is stamped on connecting rods and caps on front,
camshaft-side of engine.
a.
Select proper piston and connecting rod assembly for first cylinder bore.
b.
Turn crankshaft so connecting rod journal for number 1 cylinder is at BDC.
c.
Coat cylinder bores, piston (10), rings (4, 5, 6, and 7), piston pin (9), and
crankshaft journal with lubricating oil.
NOTE
Piston is inserted from top of cylinder block.
Figure 4-22.
d.
Piston and Connecting Rod Assembly Installation, Model 609-A.
Using ring compressor (Figure 4-21, 1), compress piston rings to help in
installation of piston and rod assemblies (2).
When installing piston, make sure connecting rod is in line with, and will
not score crankshaft journal.
e.
Place hammer handle (3) against top of piston and rod assembly (2) and push
piston into cylinder bore in engine block (4). Remove ring compressor (1).
f.
With piston and rod assembly (2) entirely in cylinder bore in engine block
(4), insert upper bearing (Figure 4-19, 13) in connecting rod (12).
g.
Pull piston and rod assembly (Figure 4-21, 2) down until upper rod bearing
Figure 4-18, 13) seats firmly on crankshaft journal.
4-48
TM 10-4320-344-24
h.
Place piece of plastic gauge material the full width of lower bearing (3),
about 0.250 inches (6.350 mm) off-center.
i.
Install connecting rod cap (2) and two cap screws (1). Torque cap screws (1)
to 70 ft-lbs (95 N•m).
j.
Remove two cap screws (1) and connecting rod cap (2).
Figure 4-23.
k.
Boaring Clearance Measurement, Model 609-A.
Flattened plastic gauge material (Figure 4-23, 1) will be sticking to either
lower bearing (2) or crankshaft.
NOTE
Required clearance for new parts is 0.001-0.003 inches (0.02540.0762 mm).
Maximum allowable clearance for used parts is 0.005 inches (0.1270
mm)
l.
Measure width of flattened gauge material (1) at its widest point as shown in
Figure 4-23.
NOTE
Coat upper and lower bearing shells with engine assembly grease.
m.
If clearance is within required limits, remove limits, remove gauge material (1) and install
connecting rod bearing (Figure 4-19, 3), cap (2), and cap screws (1). Torque
cap screws to 70 ft-lbs (95 N•m) and remove tags.
NOTE
Connecting rod side clearance should be 0.005-0.012 inches (0.1270.305 mm) with maximum clearance of 0.020 inches (0.508 nun).
n.
Check connecting rod (12) side clearance.
o.
Repeat steps a through n for five remaining piston and connecting rod
assemblies.
4-49
TM 10-4320-344-24
4.4.15 Piston and Connecting Rod Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.15.1 Removal
4.4.15.2 Repair
4.4.15.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Engine Assembly Grease, Appendix C
Item 13
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Tags, Appendix C, Item 31
Piston Rings (TM 10-4320-344-24P)
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
Arbor Press, Appendix B, Section III,
Item 3
Equipment Conditions
Inside Micrometer, Appendix B, Section
III, Item 3
Oil Pan Assembly removed, paragraph
3.8.12.
Micrometer, Appendix B, Section III,
Item 3
Cylinder removed, paragraph 4.4.3.
Piston Ring Gauge, Appendix B, Section
III, Item 30
Piston Heater, Appendix B, Section III,
Item 31
General
Safety
Instructions
Use extreme caution when handling heated
components. Heated components can cause
severe burns.
Do not work on equipment without following standard shop safety practices.
4.4.15.1 Removal.
Figure 4-24.
4-50
Piston Heater Installation, Models 609-C and US636HCCD-1.
TM 10-4320-344-24
Use extreme caution when handling heated components. Heated components can
cause severe burns.
a.
Using piston heater (Figure 4-24, 1) heat piston (Figure 4-25, 1) to 176°F
(80° C).
Figure 4-25.
Piston and Connecting Rod Assembly, Models 609-C and US636HCCD-1.
b.
Remove two retaining rings (2) and piston pin (3) from piston (1).
c.
Remove piston (1) from connecting rod (4).
When removing pistons and connecting rods, do not mix parts. Keep connecting
rod, cap, bearings, and piston together. Failure to obey this caution may
result in damage to equipment.
d.
Remove two cap screws (5), connecting rod cap (6), and outer bearing (7). Tag
components with cylinder number.
e.
Remove connecting rod (4) and upper bearing (8). Tag components with cylinder
number.
f.
Remove piston rings (9) and expander spring from piston (1).
4-51
TM 10-4320-344-24
4.4.15 Piston and Connecting Rod Assembly Maintenance, Models 609-C and US636HCCD-1. (Continued)
4.4.15.2 Repair.
NOTE
If piston does not meet inspection requirements, is defective or damaged, and
needs to be replaced, the piston pin, piston rings, and cylinder must also be
replaced.
a.
Inspect piston (1) and piston rings (9) for cracks, chips, and burrs. Ensure
piston (10) ring grooves are free of foreign matter.
b.
Using piston ring, insert pin on gauge into first ring groove of piston (1).
If gauge body touches piston (1), piston (1) is defective.
c.
Using micrometer, inspect piston (1) to the dimensions listed in Table 4-9.
NOTE
The values in { } are for Model US636HCCD-1 when different from Model 609-C.
Table 4-9.
Dimension
Diameter
Number of oversizes
Distance between
piston and cylinder
head
Bore for piston pin
2nd and 3rd ring
groove height
4th ring groove
height
Piston Dimensions, Models 609-C and US636HCCD-1.
Minimum
Maximum
3.9331 inches (99.901 mm)
3.9338 inches (99.919 mm)
{4.0107 inches (101.872 mm)} (4.0121 inches (101.907 mm)}
2 {1}
0.0394 inches (1.000 mm)
0.0472 inches (1.200 mm)
1.3780
{1.5748
0.0988
{0.1016
0.1980
inches
inches
inches
inches
inches
(35.000 mm)
(40.000 mm)}
(2.509 mm)
(2.580 mm)}
(5.030 mm)
1.3782
{1.5750
0.1028
{0.1024
0.1988
inches
inches
inches
inches
inches
(35.006 mm)
(40.006 mm)}
(2.610 nun)
(2.600 mm)}
(5.050 mm)
Figure 4-26. Piston Ring Gap Measurement, Models 609-C and US636HCCD-1.
d.
4-52
Insert ring into cylinder (Figure 4-26, 1). Use piston to push ring down to a
point 1.18 inches (30 mm) from top of cylinder (1). Measure and record ring
end gap. Remove ring.
TM 10-4320-344-24
e.
Repeat step d until all rings (Figure 4-25, 9) have been checked. The correct
gap dimensions should be as listed in Table 4-10.
Table 4-10. Gap Dimensions.
Dimension
1st
2nd
3rd
4th
ring
ring
ring
ring
gap
gap
gap
gap
0.0177
0.0177
0.0197
0.0157
Minimum
inches (0.450
inches (0.450
inches (0.500
inches (0.400
Maximum
mm)
mm)
mm)
mm)
0.0315
0.0315
0.0315
0.0315
inches
inches
inches
inches
(0.800
(0.800
(0.800
(0.800
mm)
mm)
mm)
mm)
f.
Inspect piston pin (3) for burrs, discolorations, wear, or damage. Inspect
piston pin (3) diameter for the following dimension: 1.3780 inches
(34.994-35.000 mm) on Model 609-C and 1.5746-1.5748 inches (39.994-40.000 mm)
on Model US636HCCD-1.
g.
Inspect connecting rod (4) for straightness and visible damage.
Figure 4-27.
Piston Pin Measuring Locations, Models 609-C and US636HCCD-1.
h.
Inspect piston pin bushing (Figure 4-27, 1) for burrs, worn spots, and
discoloration. Measure inside diameter of piston pin bushing (1) at points 1
and 2 in planes a and b, as shown in Figure 4-27. ‘The correct measurement is
1.3795-1.3813 inches (35.040-35.086 mm) for Model 609-C and 1.5764-1.6079
inches (40.040-40.084 mm) for Model US636HCCD-1.
i.
Remove any worn piston pin bushing (1) and press in new piston pin bushing
(1). Ensure oil holes are aligned between piston pin bushing (1) and
connecting rod (2).
j.
Position connecting rod cap (Figure 4-25, 6) on connecting rod (4) and secure
with two cap screws (5). Torque cap screws to 22 ft-lbs (30 N•m).
k.
Using angle-of-turn indicator, tighten cap screws (5) 60° first stage, then
30° second stage.
l.
Measure inside diameter of connecting rod bearing bore at points 1 and 2 in
the planes of a and b as shown in Figure 4-27. The correct measurement is
2.5197-2.5204 inches (64.000-64.019 mm) for Model 609-C and 2.7559-2.7567
inches (70.000-70.019 mm) for Model US636HCCD-1.
m.
Remove two cap screws (Figure 4-25, 5) and connecting rod cap (6) from
connecting rod (4).
4-53
TM 10-4320-344-24
4.4.15 Piston and Connecting Rod Assembly Maintenance. Models 609-C and US636HCCD-1. (Continued)
NOTE
All components not meeting the dimensions specified in the inspection
procedure are defective.
n.
Replace all defective or damaged components
4.4.15.3 Installation.
a.
Install new upper bearing (Figure 4-25, 8) in connecting rod (4) bore.
b.
Lightly coat upper bearing (8) and crankshaft journal with engine assembly
grease.
NOTE
Ensure proper piston and connecting rod assemblies are used in the proper
cylinders.
c.
Position connecting rod (4) and upper bearing (8) on crankshaft journal.
d.
Lightly coat crankshaft journal and lower bearing (7) with engine assembly
grease.
e.
Insert lower bearing (7) in connecting rod cap (6).
f.
Position connecting rod cap (6) on connecting rod (4) and install cap screws
( 5 ) . Torque cap screws to 22 ft-lbs (30 N•m).
g.
Using angle-of-turn indicator, tighten cap screws 60° first stage, then 30°
second stage.
h.
Install expander spring in bottom ring groove on piston (1).
Do not spread rings anymore than necessary to slip them over piston. Rings
could be over-stressed and break.
i.
Install four new piston rings (9). Start at bottom ring groove on piston (1).
and work towards top of piston (1). Space end gaps of piston rings (9) evenly
around piston (1).
j.
Insert one retaining ring (2) in groove in piston pin bore of piston (1).
Use extreme caution when handling heated components. Heated compnonents can
cause severe burns.
k.
Using piston heater (Figure 4-24, 1), heat piston (Figure 4-25, 1) to 176° F
(80° C).
l.
Install piston (1) on connecting rod (4). Ensure arrow on top of piston (1)
is pointing toward pushrod bores in crankcase.
m.
Insert piston pin (3) into piston pin bore of piston (1). Piston pin must
contact retaining ring (2) installed in step j above.
n.
Install second retaining ring (2).
4-54
TM 10-4320-344-24
4.4.16 Camshaft Maintenance, Model 609-A.
This task covers:
4.4.16.1 Removal
4.4.16.2 Repair
4.4.16.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Solvent, Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Camshaft Gear (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Woodruff Key (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2
(Continued)
Gun, Air Blow, Appendix B, Section III,
Item 2
Equipment
Torque Wrench, Appendix B, Section III,
Item 2
Oil Pump Assembly removed, paragraph
3.8.13.
Arbor Press, Appendix B, Section III,
Item 3
Rocker Arm Assembly removed, paragraph
3.8.17.
Micrometer, Appendix B, Section III,
Item 3
Gear Housing Cover removed, paragraph
4.4.4.
Material/Parts
Bellhousing removed, paragraph 4.4.11.
Abrasive Cloth (Emery), Appendix C,
Item 8
Gloves, Appendix C, Item 11
Grease (Engine Assembly), Appendix C,
Item 13
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
General
Conditions
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.16.1 Removal.
a.
Place engine upside down, and support with suitable blocks so cylinder head
studs will clear.
b.
Push valve tappets (Figure 4-27, 1) down from camshaft assembly (2) and into
engine block (3).
c.
Rotate engine crankshaft (4) until two thrust plate mounting bolts (5) show
through two holes in camshaft gear (6).
d.
Remove two bolts (5) and lock washers (7) that secure camshaft thrust plate
(8) to engine block (3). Discard lock washers (7).
Carefully remove camshaft assembly through bearings located in engine block.
Failure to obey this caution may result in damage to the equipment.
e.
Pull camshaft assembly (2) forward out of engine block (3).
f.
Remove twelve valve tappets (1) from engine block (3). As each valve tappet
(1) is removed, tag valve tappet (1) for location in engine block (3).
g.
Remove nut (9) that secures camshaft gear (6) to camshaft (10).
4-55
TM 10-4320-344-24
4.4.16 Camshaft Maintenance, Model 609-A. (Continued)
Figure 4-28.
4-56
Camshaft Maintenance, Model 609-A.
TM 10-4320-344-24
h.
Place camshaft (10) in arbor press.
i.
Place suitable supports under camshaft gear (6).
j.
Press camshaft (10) out of camshaft gear (6). Discard camshaft gear (6).
k.
Remove woodruff key (11) from camshaft (10). Discard woodruff key (11).
l.
Remove camshaft thrust plate (8) from camshaft (10).
4.4.16.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Do not smoke or use near open flame or excessive heat. Dry cleaning
solvent is potentially dangerous to personnel and property. Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash
exposed skin thoroughly. Failure to obey this warning may result in
personal injury or death.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent and dry with compressed air.
b.
Inspect valve tappets (1) for scoring, burrs, damage, and dimensions in Table
4-11.
Table 4-11. Valve Tappet Dimensions.
Dimension
Body diameter
Overall
length
Clearance in bore
(cylinder block)
Maximum
Minimum
0.7455 inches (18.9357 mm)
0.7490 inches (19.0246 mm)
2.2450 inches (57.0230 mm)
2.2550 inches (57.2770 mm)
0.0005 inches (0.0127 mm)
0.0015 inches (0.0381 mm)
c.
Inspect thrust plate (8) for worn or scored thrust surfaces and distortion.
d.
Inspect camshaft (10) for:
Scored or worn cams and bearing surfaces.
Damaged oil pump gear.
Damaged threads or key-way.
Worn thrust surfaces.
Dimensional tolerances in Table 4-12.
Table 4-12.
Camshaft Tolerances.
Dimension
Minimum
Bearing journal
2.0510 inches (52.0954 mm) 2.0540
diameter - all
Lobe diameter - base 1.7100 inches (43.4340 mm) 1.7250
to tip
Journal run-out in
0.0140
vee blocks
Bearing clearance
0.0060
0.0010 inches (0.0254 mm)
Maximum
inches (52.1716 mm)
inches (43.8150 mm)
inches (0.3556 mm)
inches (0.1524 mm)
4-57
TM 10-4320-344-24
4.4.16 Camshaft Maintenance, Model 609-A. (Continued)
e.
If camshaft (10) is damaged or does not meet the dimensional tolerances,
replace camshaft (10) .
f.
Inspect all mounting hardware for damage.
g.
Replace all defective or damaged components.
h.
Refer to paragraph 4.4.21 and replace camshaft bearings (12).
4.4.16.3 Installation.
a.
Install thrust plate (8) on camshaft (10).
b.
Install new woodruff key (11) on camshaft (10).
c.
Install new camshaft gear (6) on camshaft (10).
d.
Install nut (9) on camshaft (10). Torque nut (9) to 130 ft-lbs (176 N•m).
To avoid damage to equipment, ensure valve tappets are installed in their
original cylinders block holes.
e.
Remove tags and insert valve tappets (1) into their respective holes in engine
block (3). Push valve tappets (1) all the way in, so they will clear camshaft
assembly (2).
Carefully remove camshaft assembly through bearings located in engine block.
Failure to obey this caution may result in damage to the equipment.
f.
Lightly coat camshaft assembly (2) with engine assembly grease and carefully
install camshaft assembly (2) into engine block (3).
Figure 4-29.
g.
4-58
Crankshaft and Camshaft Timing Marks, Model 609-A.
Align camshaft gear timing mark (Figure 4-29, 1) with crankshaft gear timing
mark (2).
TM 10-4320-344-24
Figure 4-30.
h.
Installed Camshaft Assembly, Model 609-A.
Install two new lock washers (Figure 4-28, 7) and bolts (5). Torque bolts (5).
to 7 ft-lbs (9 N•m).
Normal camshaft end play is 0.005-0.008 inches (0.127-0.203 mm) and should
not exceed 0.012 inches (0.305 mm).
i.
Check camshaft assembly (Figure 4-30, 1) end play.
j.
To decrease end play, use a draw file and remove small amount of metal from
camshaft thrust plate (2).
k.
To increase end play:
(1) Add a shim between camshaft gear hub and camshaft bearing, (reference
figure 4-30, 3).
(2) Using piece of very fine emery cloth on surface plate, polish thrust plate
(Figure 4-28, 8) to desired thickness.
Backlash of camshaft gear to crankshaft gear must be 0.0015-0.0025 inches
(0.0381-0.0635 mm).
1.
Check backlash of camshaft gear (Figure 4-28, 6) to crankshaft gear (4).
4-59
TM 10-4320-344-24
4.4.17 Camshaft Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.17.1
Removal
4.4.17.2 Repair
4.4.17.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Solvent, Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
(Continued)
Goggles, Industrial, Appendix B,
Section III, Item 2
Equipment Conditions
Gun, Air Blow, Appendix B, Section III,
Item 2
Oil Pump Assembly removed, paragraph
4.4.7.
Inside Micrometer, Appendix B, Section
III, Item 3
Rocker Arm Assembly and Pushrods removed,
paragraph 3.8.18.
Micrometer, Appendix B, Section III,
Item 3
Idler Gear removed, paragraph 4.4.8.
General
Safety
Instructions
Material/Parts
Gloves, Appendix C, Item 11
Grease, Appendix C, Item 13
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.17.1 Removal.
a.
Place engine upside down, and support with suitable blocks so cylinders will
clear.
b.
Push valve tappets (Figure 4-31, 1) down from camshaft assembly (2) and into
crankcase (3).
Carefully remove camshaft assembly through bearings located in engine block.
Failure to obey this caution may result in damage to the equipment.
c.
Remove camshaft assembly (2) from crankcase (3).
d.
Remove pin (4) from camshaft assembly (2).
e.
Remove thrust washer (5) from camshaft assembly (2).
g.
Tag and remove valve tappets (1) from crankcase (3).
4-60
TM 10-4320-344-24
4.4.17.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing. Do
not smoke or use near open flame or excessive heat. Dry cleaning solvent
is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles
and rubber gloves to protect eyes and skin. Wash exposed skin
thoroughly. Failure to obey this warning may result in personal injury
or death.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent and dry thoroughly using
compressed air.
Figure 4-31.
Camshaft Maintenance, Models 609-C and US636HCCD-1.
b.
Inspect valve tappets (1) for scoring, burrs, or damage.
c.
Inspect pin (4) and thrust washer (5) for cracks, bends, discoloration, or
damage.
4-61
TM 10-4320-344-24
4.4.17 Camshaft Maintenance, Models 609-C and US636HCCD-1. (Continued)
d.
Inspect camshaft assembly (2) for scored or worn cams and bearing surfaces and
worn thrust surfaces.
e.
Inspect camshaft gear (6) for burrs, chips, cracks, damaged or missing teeth,
or damage.
f.
Measure diameter of camshaft bearing journal at drive end of camshaft assembly
(2). Record measurement.
Figure 4-32.
Camshaft Inspection, Models 609-C and US636HCCD-1.
g.
Using micrometer, measure inside diameter of camshaft bearing sleeve (Figure
4-32, 1) in crankcase (2) at points "1" and "2" in planes "a" and "b" as shown
in Figure 4-32. Record measurement.
h.
If camshaft bearing sleeve (1) measurement is not within 1.8890 - 1.8911
inches (47.980 - 48.034 mm) refer to paragraph 4.4.22 and replace camshaft
bearing sleeve (1).
i.
Subtract measurement taken in step f from measurement taken in step g. If
resultant value is greater than or equal to 0.0394 inches (1.000 mm), replace
camshaft assembly (Figure 4-31, 2) and refer to paragraph 4.4.22 and replace
camshaft bearing-sleeve (Figure 4-32, 1).
4.4.17.3 Installation.
To avoid damage to equipment, ensure valve tappets are installed in their
original cylinders block holes.
a.
Lightly coat valve tappets (Figure 4-31, 1) with oil, remove tags, and insert
valve tappets (1) into-their respective holes in crankcase (3). Push valve
tappets (1) all the way in, so they will clear camshaft assembly (2).
b.
Install thrust washer (5) on camshaft assembly (2).
c.
Install pin (4) in camshaft assembly (2).
4-62
TM 10-4320-344-24
Carefully remove camshaft assembly through bearings located in engine block.
Failure to obey this caution may result in damage to the equipment.
d.
Lightly coat camshaft assembly (2) with oil and insert it into crankcase (3).
4-63
TM 10-4320-344-24
4.4.18 Gear Housing Maintenance, Model 609-A.
This task covers:
4.4.18.1 Removal
4.4.18.2 Repair
4.4.18.3
Installation
INITIAL SETUP
Tools
Material/Parts (Continued)
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Lock Washers (TM 10-4320-344-24P)
Equipment
Goggles Industrial, Appendix B,
Section III, Item 2
Gun, AirBlow, Appendix B, Section III,
Item 2
Conditions
Fuel Injection Pump Assembly removed,
paragraph 3.8.9.
Gear Housing Cover removed, paragraph
4.4.4.
Torque Wrench, Appendix B, Section III,
Item 2
Idler Gear removed, paragraph 4.4.6.
Material/Parts
Camshaft removed, paragraph 4.4.16.
Adhesive (Gasket Cement), Appendix C,
Item 1
Gloves, Appendix C, Item 11
Rags, Appendix C, Item 20
Solvent, Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Gaskets (TM 10-4320-344-24P)
General
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.18.1 Removal.
Figure 4-33.
4-64
Gear Housing Maintenance, Model 609-A.
TM 10-4320-344-24
a.
Remove five bolts (Figure 4-33, 1) and lock washers (2). Discard lock
washers (2).
NOTE
Use of a soft hammer may be necessary to loosen gear housing from engine block.
b.
Remove gear housing (3) from engine block.
c.
Remove gasket (4) from engine block. Discard gasket (4).
4.4.18.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Do not smoke or use near open flame or excessive heat. Dry cleaning
solvent is potentially dangerous to personnel and property. Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash
exposed skin thoroughly. Failure to obey this warning may result in
personal injury or death.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent. Ensure all gasket (4) material is
removed from gear housing (3) and engine block.
b.
Thoroughly dry all components with compressed air.
c.
I ns p e c t ge a r ho using (3 ) for cracks, bends, holes, dist ort ions, or d a ma g e.
d.
Inspect all mounting hardware for damage. Ensure dowel pins and studs in
engine block are tight.
e.
Replace all damaged or lose components.
4.4.18.3 Installation.
NOTE
Allow cement to dry long enough to prevent gasket from slipping during
installation.
a.
Using adhesive, cement new gasket (4) to gear housing (3).
b.
Position gear housing (3) on engine block and secure with five new lock
washers (2) and bolts (1). Torque bolts (1) to 40 ft-lbs (54 N•m).
4-65
TM 10-4320-344-24
4.4.19 Crankshaft Assembly Maintenance, Model 609-A.
This task covers:
4.4.19.1
Removal
4.4.19.2 Repair
4.4.19.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Solvent, Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Bearings (TM 10-4320-344-24P)
Crankshaft Gear (TM 10-4320-344-24P)
Woodruff Key (TM 10-4320-344-24P)
Goggles, Appendix B, Section III,
Item 2
(Continued)
Gun, Air Blow, Appendix B, Section
III, Item 2
Equipment Conditions
Arbor Press, Appendix B, Section III,
Item 3
Oil Pump Assembly removed, paragraph
3.8.13.
Micrometer, Appendix B, Section III,
Item 3
Bellhousing removed, paragraph 4.4.10.
Sling, Engine, Appendix B, Section III,
Item 3
Piston and Connecting Rod Assemblies
removed, paragraph 4.4.13.
Gear Housing removed, paragraph 4.4.17.
Material/Parts
General
Tube Brush, Appendix C, Item 6
Abrasive Cloth (Emery), Appendix C,
Item 8
G l o v e s , Appendix C, Item 11
Grease (Engine Assembly), Appendix C,
Item 13
Oil, Appendix C, Item 15
Rags, Appendix C, Item 20
Safety
Instructions
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.19.1 Removal.
NOTE
Tag and mark all components with match marks on camshaft side.
a.
Remove four bolts (Figure 4-34, 1), center main bearing cap (2), and lower
center main bearing (3). Discard lower main bearing (3).
b.
Remove twelve bolts (4), six lower main bearing caps (5), and six lower main
bearings (6). Tag lower main bearing caps (5). Discard lower main bearings
(6).
c.
Using sling, lift crankshaft assembly (7) from engine block.
d.
Remove and discard six upper main bearings (8) and upper center main
bearing (9).
e.
Using arbor press, remove crankshaft gear (10) and woodruff key (11) from
crankshaft (7). Discard crankshaft gear (10) and woodruff key (11).
4-66
TM 10-4320-344-24
Figure 4-34.
Crankshaft Assembly Replacement, Model 609-A.
4.4.19.2 Repair.
Do not use cleaning solvent without proper ventilation and clothing.
Dry cleaning
Do not smoke or use near open flame or excessive heat.
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wash
Wear goggles and rubber gloves to protect eyes and skin.
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using compressed air.
a.
Clean all components with cleaning solvent.
b.
Clean oil passages in crankshaft (7) with tube brush.
c.
Using compressed air, thoroughly dry all components.
d.
Inspect bolts (1 and 4) for distortions, damaged threads, cracks, or bends.
e.
Inspect center main bearing cap (2) and lower main bearing caps (5) for
cracks, distortions, and damage.
4-67
TM
10-4320-344-24
4.4.19 Crankshaft Assembly Maintenance, Model 609-A. (Continued)
f.
Measure crankshaft (7) for the dimensions listed in Table 4-13.
Table 4-13.
Dimension
Main bearing journal
diameter - all
Main bearing journal
out of round
Main bearing journal
taper
Main bearing run-out
at center
Connecting rod journal
diameter - all
Connecting rod journal
out of round
Connecting rod journal
taper
Fillet radii
Crankshaft main
bearing clearance
Seal surface
diameter - rear
Seal surface diameter front
Center main bearing
journal width
Main bearing journals
Connecting rod journals
Crankshaft Dimensions, Model 609-A.
Minimum
2.8704 inches (72.9084 mm)
Maximum
2.8744 inches (73.0098 mm)
0.0020 inches (0.0508 mm)
0.0015 inches (0.0381 mm)
0.0030 inches (0.0762 mm)
2.3710 inches (60.2234 mm)
2.3740 inches (60.2996 mm)
0.0020 inches (0.0508 mm)
0.015 inches (0.3810 mm)
0.1400 inches (3.5560 mm)
0.0009 inches (0.0229 mm)
0.1700 inches (4.3180 mm)
0.0034 inches (0.0864 mm)
4.2950 inches (109.0930 mm)
4.3150 inches (109.6010 mm)
1.8590 inches (47.2186 mm)
1.8750 inches (47.6250 mm)
2.1240 inches (53.9496 mm)
2.1270 inches (54.0258 mm)
1.3125 inches (33.3375 mm)
1.4950 inches (37.9730 mm)
1.5000 inches (38.1000 mm)
g.
Inspect crankshaft (7) for cracks invisible to the eye by magnetic particle,
fluorescent magnetic particle, or fluorescent penetrant method.
Inspect for
circumferential fillet cracks at the critical areas and 45° cracks starting
from either the critical fillet locations or the crankshaft holes.
If these
cracks are present, r e p l a c e c r a n k s h a f t ( 7 ) .
h.
Replace all damaged or defective components.
4.4.19.3 Installation.
Ensure timing mark on crankshaft gear faces away from crankshaft.
a.
Install new woodruff key (11) on crankshaft (7).
b.
Using arbor press, install new crankshaft gear (10) on crankshaft (7).
c.
Lightly coat six new upper main bearings (8) and new upper center main
bearing (9) with engine assembly grease and install them in engine block.
d.
Lightly coat all journals of crankshaft (7) with engine assembly grease.
4-68
TM 10-4320-344-24
Ensure timing marks of crankshaft gear and camshaft gear are aligned.
e.
Using sling, carefully lower crankshaft (7) into engine block.
f.
Install six new lower main bearings (6) in the main bearing caps (5).
g.
Install new lower center main bearing (3) in center main bearing cap (2).
h.
Coat all bearing caps (2 and 5) and bearings (3 and 6) with engine assembly
grease.
i.
Refer to tags and position center main bearing cap (2) and six main bearing
c a p s ( 5 ) o v e r c r a n k s h a f t ( 7 ) . Remove and discard tags.
j.
Install four bolts (1) in center main bearing cap (2) and twelve bolts (4) in
main bearing caps (5). Hand-tighten bolts (1 and 4).
k.
Using soft hammer, sharply rap center main bearing cap (2) and six main
bearing caps (5) to properly seat them.
l.
Check center main bearing cap (2) and six main bearing caps (5) for a “T”
stamped on the side opposite the cylinder number to determine the required
torque limits.
m.
Starting in the center and working alternately towards both ends of the engine
block, progressively torque bolts (1 and 4) to torque values defined in
Table 4-14.
Table 4-14.
Torque Values.
TORQUE BOLTS (1 AND 4) TO:
Bolts
9/16 inch (14.29 mm)
bolts for main
bearing caps (5)
1/2 inch (12.70 mm)
bolts for center
main bearing cap (2)
"T" Stamped Caps
Plain Caps
130 ft-lbs (176 N•m)
80 ft-lbs (109 N•m)
100 ft-lbs (136 N•m)
80 ft-lbs (109 N•m)
n.
Ensure crankshaft (7) rotates freely.
o.
Check end shaft thrust of crankshaft (7) as follows:
(1) Using feeler gauge (Figure 4-35, 1), measure distance between center thrust
bearing (2) and crankshaft (3).
(2) Minimum allowable clearance is 0.005 inches (0.127 mm). Maximum allowable
clearance is 0.015 inches (0.381 mm).
(3) If clearance is less than 0.005 inches (0.127 mm), remove crankshaft (3),
clean all components as necessary, and reinstall crankshaft (3).
(4) Repeat step 4.4.19.3.0.(1) above. If clearance is still less than 0.005
inches (0.127 mm), remove crankshaft (3) and using emery cloth polish center
thrust bearing (2) until proper clearance is obtained.
4-69
TM 10-4320-344-24
4.4.19 Crankshaft Assembly Maintenance, Model 609-A. (Continued)
Figure 4-35.
4-70
Crankshaft End Thrust, Models 699-A.
TM 10-4320-344-24
4.4.20 Crankshaft Assembly Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.20.1 Removal
4.4.20.2 Repair
4.4.20.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Rags, Appendix C, Item 20
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Tags, Appendix C, Item 31
Bearings ( TM 10-4320-344-24P)
Crankshaft Gear (TM 10-4320-344-24P)
Dowel (TM 10-4320-344-24P)
Spring Pin (TM 10-4320-344-24P)
Stop Rings (TM 10-4320-344-24P)
G o g g l e s , I n d u s t r i a l , Appendix B,
Section III, Item 2
Gun, Air Blow, Appendix B, Section III,
Item 2
(Continued)
Angle-of-Turn Indicator, Appendix B,
Section III, Item 3
Equipment
Engine Sling, Appendix B, Section III,
Item 3
Oil pump Assembly and Oil Pipe removed,
paragraph 4.4.7.
Height Gauge, Appendix B, Section III,
Item 3
Crankcase Rear Cover removed, paragraph
4.4.13.
Micrometer,
Item 3
Piston and Connecting Rod Assemblies
removed, paragraph 4.4.15.
Appendix B, Section III,
Conditions
Material/Parts
General Safety I n s t r u c t i o n s
Tube Brush, Appendix C, Item 6
Gloves, Appendix C, Item 11
Grease (Engine Assembly), Appendix C,
Item 13
Oil, Appendix C, Item 15
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
Do not work on equipment without following standard shop safety practices.
4.4.20.1 Removal.
Tag all crankshaft bearing cap mounting bolts.
a.
Remove fourteen bolts (Figure 4-36,
b.
Tag and remove seven bearing caps (3) and lower bearings (4).
bearings (4).
c.
Using sling, remove crankshaft assembly (5).
d.
Remove two stop rings (6 and 7).
e.
Tag and remove fourteen dowels (8).
f.
Remove and discard seven upper bearings (9).
g.
Remove and discard spring pin (10).
h.
Remove six plugs (11) and flat washers (12).
i.
Remove crankshaft gear (13) and dowel (14).
dowel (14).
1) and flat washers (2).
Discard
Discard stop rings (6 and 7)
Discard crankshaft gear (13) and
4-71
TM 10-4320-344-24
4.4.20 Crankshaft Assembly Maintenance, Models 609-C and US636HCCD-1. (Continued)
Figure 4-36. Crankshaft Assembly Replacement, Models 609-C and US636HCCD-1.
4.4.20.2 Repair.
Do
Do
not use cleaning solvent without proper ventilation and clothing.
not smoke or use near open flame or excessive h e a t . Dry cleaning
s o l v e n t i s p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean
parts in a well-ventilated area. Avoid inhalation of solvent fumes.
Wear goggles and rubber gloves to protect eyes and skin. Wash
e x p o s e d s k i n t h o r o u g h l y . Failure to obey this warning may result in
personal injury or death.
To prevent the possibility of embedding foreign objects in the eyes,
safety glasses must be worn when using-compressed air.
a.
Clean all components with cleaning solvent.
b.
Clean oil passages in crankshaft (5) with tube brush.
c.
Using compressed air, thoroughly dry all components.
d.
Inspect bolts (1) for distortions, damaged threads, cracks, or bends.
e.
Inspect bearing caps (3) for cracks, distortions, and damage.
f.
Inspect dowels (8) and plugs (11) for cracks, dents, burrs, or damage.
g.
Measure and record all crankshaft journals at points 1 and 2 in planes "a" and
Acceptable values are listed in Table 4-15.
“b” as shown in Figure 4-37.
4-72
TM 10-4320-344-24
Figure 4-37.
h.
Crankshaft Assembly Repair, Models 609-C and US636HCCD-1.
Measure and record width of journal for locating bearing ‘3” in Figure 4-37.
Acceptable values are listed in Table 4-15.
The values in { } are for Model US636HCCD-1.
Table 4-15.
Crankshaft Dimensions, Models 609-C and US636HCCD-1.
Dimension
Crankpin width - all
Crankpin diameter
standard I
Crankpin diameter
standard II
Crankpin hardness
Main journal width
Main journal diameter
- standard I
Main journal diameter
- standard II
Main journal
Eccentricity - All
Main journal radius of
fillet - All
Main journal hardness
Thrust bearing journal
width - standard I
Thrust bearing journal
width - standard II
i.
1.3386
2.5185
{2.5973
2.5087
{2.5874
Minimum
1.3401
inches (34.0000 mm)
inches (63.9710 mm)
2.5193
inches (65.9710 mm)}
{2.5980
inches (63.7210 mm)
2.5094
inches (65.7210 mm)} {2.5882
55 HRc
Maximum
inches (34.0390
inches (63.9900
inches (65.9900
inches (63.7400
inches (65.7400
61 HRc
1.4567
{1.4173
2.8729
{2.9516
2.8630
(2.9418
inches
inches
inches
inches
inches
inches
inches
inches
inches
inches
inches
inches
inches
(37.0000
(36.0000
(72.9710
(74.9710
(72.7210
(74.7210
mm)
mm)}
mm)
mm)}
mm)
mm)}
0.1693 inches (4.3000 mm)
1.4567
{1.4173
1.4665
(1.4272
55 HRc
inches (37.0000
inches (36.0000
inches (37.2500
inches (36.2500
1.4606
{1.4213
2.8736
{2.9524
2.8638
{2.9425
0.0039
mm)
mm)
mm)}
mm)
mm))
(37.1000 mm)
(36.1000 mm)}
(72.9900 mm)
(74.9900 mm)}
72.7400 mm)
74.7400 mm)}
(0.1000 mm)
0.1772 inches (4.5000 mm)
61 HRc
mm)
mm))
mm)
mm))
1.4577 inches (37.0250 mm)
{1.4183 inches (36.0250 mm)}
1.4675 inches (37.2750 mm)
{1.4281 inches (36.2750)1
Replace all damaged or defective components.
4-73
TM-10-4320-344-24
4.4.20 Crankshaft Assembly Maintenance, Models 609-C and US636HCCD-1. (Continued)
4.4.20.3 Installation.
Ensure long end of dowel points away from side of crankshaft gear with timing
mark.
a.
Insert new dowel (Figure 4-36,
b.
With height gauge, ensure long end of new dowel (14) is 0.6693 inches (17 mm)
from surface of new crankshaft gear (13).
c.
Install new crankshaft gear (13) on crankshaft assembly (5).
d.
Install six flat washers (12) and plugs (11).
e.
Install new spring pin (10) in crankshaft (5).
f.
Install seven new upper bearings (9) and coat with engine assembly grease.
g.
Install seven new lower bearings (4) in bearing caps (3) and coat with engine
assembly grease.
h.
Refer to tags and install fourteen dowels (8) in crankcase.
discard tags.
i.
Lightly grease new stop rings (6 and 7), and install them in bearing cap (3)
and crankcase with smooth side facing bearing cap (3) and crankcase.
j.
Lightly grease crankshaft assembly (5) and using sling, carefully install
crankshaft assembly (5) in crankcase.
14) in new crankshaft gear (13).
Remove and
Identification numbers on bearing caps must correspond to and face same
direction as identification numbers stamped in crankcase.
k.
Refer to tags and lightly grease and install seven new lower bearings (4) and
bearing caps (3) in crankcase. Remove and discard tags.
Start torque at center bearing cap.
caps torqued last.
Work from side to side with end bearing
l.
Refer to tags and install fourteen flat washers (2) and bolts (1) in bearing
c a p s ( 3 ) . Preload bolts (1) to 22 ft-lbs (30 N•m).
m.
Using angle-of-turn indicator, tighten bolts (1) to 60° first stage and 45°
second stage.
n.
Push crankshaft (5) towards front of crankcase.
Clearance can be adjusted by removing bearing cap and replacing stop ring
halves with appropriate size stop ring halves.
o.
4-74
Using feeler gauge, measure crankshaft (5) endplay.
0.0055-0.0117 inches (0.1397-0.2972 mm).
Correct clearance is
TM 10-4320-344-24
4.4.21 Engine Block Maintenance. Model 609-A.
This task covers:
4.4.21.1 Removal
4.4.21.2 Repair
4.4.21.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Camshaft Bearings (TM 10-4320-344-24P)
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
G o g g l e s , I n d u s t r i a l , Appendix B,
Section III, Item 2
Equipment
Gun Air Blow, Appendix B, Section III,
Item 2
(Continued)
Conditions
Oil Dipstick removed.
Oil Lines removed, paragraph 2.21.2.
Dial Gauge, Appendix B, Section III,
Item 3
Engine Sling, Appendix B, Section III,
Item 3
Engine Stand, Appendix B, Section III,
Item 3
Micrometer, Appendix B, Section III,
Item 3
Fuel Transfer Pump Assembly removed,
paragraph 2.21.6.
Water Pump Assembly removed, paragraph
2.21.43.
cylinder Head Assembly removed, paragraph
3.8.19.
Crankshaft Assembly removed, paragraph
4.4.19.
Material/Parts
General Safety I n s t r u c t i o n s
Adhesive (Loctite), Appendix C, Item 2
Tube Brush, Appendix C, Item 6
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
Sealing Compound, Appendix C, Item 23
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
not work on equipment without following standard shop safety practices.
DO
4.4.21.1 Removal.
a.
Performing equipment c o n d i t i o n s s p e c i f i e d a b o v e w i l l r e m o v e e n g i n e b l o c k
(Figure 4-38, 1).
b.
Remove two nuts (2), l o c k w a s h e r s ( 3 ) , c o v e r ( 4 ) , a n d g a s k e t ( 5 ) .
lock washers (3) and g a s k e t ( 5 ) .
c.
R e m o v e t w e l v e b o l t s ( 6 ) , l o c k w a s h e r s ( 7 ) , two side cover plates (8), and
gaskets (9). Discard lock washers (7) and gaskets (9).
d.
Remove filler neck (10) and six oil passage pipe plugs (11) from engine
block (1).
e.
Remove four pipe plugs (12) from engine block (1).
f.
DO
g.
Remove front camshaft bearing (14), two intermediate camshaft bearings (15),
and rear camshaft bearing (16) from engine block (1). Discard bearings (14,
15, and 16).
Discard
not remove five expansion plugs (13) in core openings, unless they show
signs of leakage.
4-75
TM 10-4320-344-24
4.4.21 Engine Block Maintenance, Unit 609-A. (Continued)
Figure 4-38.
4-76
Engine Block Repair, Model 609-A.
TM 10-4320-344-24
h.
Do not remove studs (17) or dowel pins (18) from engine block (1), unless they
are damaged and need to be replaced.
i.
Remove set screw (19) from engine block (1).
4.4.21.2 Repair.
Do not
Do not use cleaning solvent without proper ventilation and clothing.
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
a.
U s i n g s l i n g a n d a d e q u a t e l i f t i n g d e v i c e , lower engine block (1) into tank of
h e a t e d c l e a n i n g s o l v e n t . Circulate cleaning solvent around engine block (1)
to increase cleaning effectiveness.
To prevent the possibility of embedding foreign objects in the eyes, safety
glasses must be worn when using compressed air.
b.
Remove engine block (1) from tank of cleaning solvent and using compressed
air, dry thoroughly.
c.
Place engine block (1) on suitable engine stand and remove sling and lifting
device.
d.
Using tube brush,
e.
Visually inspect engine block (1) for cracks and other obvious damage.
f.
Check for cracks in engine block (1) using dye penetrant.
g.
Check for excessive cylinder bore wear as follows:
clean all oil passages.
(1) Determine diameter of wear area. Gauge at intervals of
approximately 45°.
(2) Check for letter stamped on engine block (1). Letter will indicate standard
cylinder bore diameter as listed in Table 4-16.
Table 4-16.
Letter
A
B
C
D
E
3.9987
3.9992
3.9997
4.0002
4.0007
Cylinder Bore Diameter.
Minimum
inches (101.5670
inches (101.5797
inches (101.5924
inches (101.6051
inches (101.6178
mm)
mm)
mm)
mm)
mm)
3.9991
3.9996
4.0001
4.0006
4.0011
Maximum
inches (101.5771
inches (101.5898
inches (101.6025
inches (101.6152
inches (101.6279
mm)
mm)
mm)
mm)
mm)
(3) Measure diameter of cylinder in piston wear area. Compare
measurement with standard cylinder bore diameter values given in
T a b l e 4 - 1 6 . Maximum allowable wear is 0.005 inches (0.127 mm).
(4) If wear appears to be excessive, check for original cylinder bore size by
g a g i n g d i a m e t e r o f c y l i n d e r b e l o w p i s t o n r i n g w e a r a r e a . Cylinder may have
already been rebored for over-sized pistons.
4-77
TM
10-4320-344-24
4.4.21 Engine Block Maintenance, Unit 609-A.
(Continued)
Irregularities in cylinder bore may result in g a l l i n g a n d s e i z i n g o f p i s t o n s .
h.
C h e c k c y l i n d e r b o r e o u t - o f - r o u n d a n d t a p e r . Out-of-round must not exceed
0.003 inches (0.076 mm).
Taper must not be more than 0.002 inches (0.051 mm)
in each cylinder bore.
i.
Using accurate straight edge and a feeler gage, check top of engine block (1)
f o r f l a t n e s s . Top of surface may not vary-more than 0.005 inches (0.127 mm)
on width or length. Out-of-flatness should vary gradually and uniformly from
end to end and side to side.
j .
Replace any damaged, loose, or broken dowel pin (18).
k.
Refer to paragraph 2.11.2 and replace any damaged, loose, or broken studs
(17).
Figure 4-39.
Engine Block Stud Location, Model 609-A.
Install end oil passage studs so t h a t o i l h o l e s a r e w i t h i n a 4 0 ° a n g l e w i t h
center line of rocker arm shaft.
1.
If necessary, add adhesive in hole and install new stud(s) (17) in engine
block (1) to dimensions indicated in Table 4-17.
(Refer to Figure 4-39.)
Table 4-17.
Stud Dimensions.
6 Cylinder
Stud
A
B
C - Oil Supply
D - Cover
E - Lift
F
m.
4-78
0.562
0.625
0.625
0.625
0.625
0.625
A-Diameter
inches (14.275
inches (15.875
inches (15.875
inches (15.875
inches (15.875
inches (15.875
mm)
mm)
mm)
mm)
mm)
mm)
4.620
4.680
6.620
7.430
5.810
6.620
B-Height
inches (117.348
inches (118.872
inches (168.148
inches (188.722
inches (147.574
inches (168.148
Check main bearing bores of engine block (Figure 4-38, 1) as follows:
mm)
mm)
mm)
mm)
mm)
mm)
TM 10-4320-344-24
NOTE
To maintain bearing bore alignment, make sure main bearing caps are installed
in their original positions.
(1) Install main bearing caps in their original positions in accordance with the
installation procedures given in paragraph 4.4.19.
(2) Measure main bearing bores. Bearing bores must be 3.0665-3.0670 inches
(77.8891-77.9018 mm). If bearing bores do not fail within these limits.
replace engine block (1).
(3) Check bearing bores for alignment. If crankshaft can be rotated freely by
hand, bores are properly aligned.
n.
Check camshaft bearing bores of engine block (1). Internal diameter of bores
must be 2.1870-2.1889 inches (55.5498-55.59806 mm). If camshaft bearing bores
do not meet tolerance, replace engine block (1).
o.
Check plugs in vertical oil passages in corners of engine block (1). Make
sure they are flush with or below top surface of block (1).
p.
Check all machined accessory mounting pads for flatness, nicks, and burrs.
Remove nicks and burrs with a fine file.
q.
Inspect all components for damage.
r.
Replace all damaged or defective components.
4.4.21.3
a.
Installation.
Install set screw (19) in engine block (1).
Damage to equipment could result if bearings are not correctly aligned.
NOTE
•
There are four camshaft bearings,
bearings, and one rear bearing.
one
Ž
Replacement
reaming.
bearings
are
precision
•
Ensure oil holes in bearings
passageways of engine block.
are
aligned
camshaft
front
bearing,
cut
with
and
oil
two
intermediate
require
holes
in
no
line
drilled
b.
Install new rear camshaft bearing (16), two intermediate camshaft bearings
(15), and front camshaft bearing (14) in engine block (1). Using bearing
driver, tap bearings into place.
c.
Apply sealant and install four pipe plugs (12) in engine block (1).
d.
Apply sealant and install six oil passage pipe plugs (11) and filler neck (10)
in engine block (1).
e.
Inspect for leaks around filler neck (10), oil passage pipe plugs (11), and
pipe plugs (12). Remove, apply sealant, and reinstall leaking components.
f.
Position two new gaskets (9) and side cover plates (8) on engine block (1) and
secure with twelve new lock washers (7) and bolts (6).
g.
Position new gasket (5) and cover (4) on engine block (1) and secure with two
new lock washers (3) and nuts (2).
4-79
TM 10-4320-344-24
4.4.22 Crankcase Maintenance, Models 609-C and US636HCCD-1.
This task covers:
4.4.22.1 Removal
4.4.22.2 Repair
4.4.22.3
Installation
INITIAL SETUP
Tools
Material/Parts
General Mechanic’s Automotive Tool Kit,
Appendix B, Section III, Item 1
Sealing Compound, Appendix C, Item 23
S o l v e n t , Dry Cleaning, Appendix C,
Item 26
Bearing Bushing (TM 10-4320-344-24P)
Gaskets (TM 10-4320-344-24P)
Lock Washers (TM 10-4320-344-24P)
Notched Pins (TM 10-4320-344-24P)
Goggles, Industrial, Appendix B,
Section III, Item 2
Gun Air Blow, A p p e n d i x B , S e c t i o n I I I ,
Item 2
Engine Sling, Appendix B, Section III,
Item 3
(Continued)
Equipment Conditions
Oil Dipstick removed.
Engine Stand, Appendix B, Section III,
Item 3
Fuel Injection Pump Assembly removed,
paragraph 3.8.11.
Micrometer, Appendix B, Section III,
Item 3
Oil Nozzle removed, paragraph 3.8.15
(US636HCCD-1.)
Bearing Sleeve Remover and Installer,
Appendix B, Section III, Item 31
Camshaft Assembly removed, paragraph
4.4.17.
Camshaft Plug Press, Appendix B,
Section III, Item 32
Crankshaft Assembly removed, paragraph
4.4.20.
Refacing Device, Appendix B,
Section III, Item 33
General Safety I n s t r u c t i o n s
Material/Parts
Do not work on equipment that is not
securely stabilized to prevent rolling
or sliding.
G l o v e s , Appendix C, Item 11
Rags, Appendix C, Item 20
Do not work on equipment without following standard shop safety practices.
NOTE
This procedure applies to Model US636HCCD-1.
609-c are similar.
The procedures for Model
4.4.22.1 Removal.
a.
Performing equipment conditions specified above will remove crankcase (Figure
4-40, 1).
b.
Remove five plugs (2) and flat washers (3).
c.
Remove two plugs (4).
d.
Remove cap screw (5) and flat washer (6).
e.
Remove seven plugs (7), gaskets (8), and plugs (9).
f.
Remove plug (10) and flat washer (11).
g.
Remove plug (12) and flat washer (13).
4-80
Discard gaskets (8).
TM 10-4320-344-24
Figure 4-40.
Crankcase Maintenance, Models 609-C and US636HCCD-1.
NOTE
On Model 609-C remove six oil nozzles and lock washers from the bearing webs
of the crankshaft bearings. Discard the lock washers.
h.
Remove notched pins (14) and deflector plate (15).
i.
Remove plug (16) and flat washer (17).
j.
Remove and discard camshaft bearing bushing (18) from crankcase (1).
Discard notched pins (14).
4.4.21.2 Repair.
D o n o t u s e c l e a n i n g s o l v e n t w i t h o u t p r o p e r v e n t i l a t i o n a n d c l o t h i n g . Do not
smoke or use near open flame or excessive heat.
Dry cleaning solvent is
p o t e n t i a l l y d a n g e r o u s t o p e r s o n n e l a n d p r o p e r t y . Clean parts in a wellv e n t i l a t e d a r e a . A v o i d i n h a l a t i o n o f s o l v e n t f u m e s . Wear goggles and rubber
g l o v e s t o p r o t e c t e y e s a n d s k i n . Wash exposed skin thoroughly.
Failure to
obey this warning may result in personal injury or death.
a.
Using sling, lower crankcase (1) into tank of heated cleaning solvent.
Circulate cleaning solvent around crankcase (1) to increase cleaning
effectiveness.
4-81
TM 10-4320-344-24
4.4.22 Crankcase Maintenance, Models 609-C and US636HCCD-1. (Continued)
To prevent the possibility of embedding foreign objects in the eyes, safety
glasses must be worn when using compressed air.
b.
Remove crankcase (1) from tank of cleaning solvent and using compressed air,
dry thoroughly.
c.
Place crankcase (1) on suitable engine stand and remove s l i n g a n d l i f t i n g
device.
d.
I n s p e c t c r a n k c a s e ( 1 ) f o r c r a c k s , l e a k s , o r d a m a g e . I f crankcase is cracked,
leaking, or damaged, replace crankcase.
e.
Inspect cylinder bores and cylinder seating surface of crankcase (1) for
scoring, burrs, discoloration, pits, or damage.
If scoring, burrs,
discoloration, pits, or damage is present, replace crankcase (1).
f.
Inspect deflector plate (15) for bends, cracks, or deformations.
g.
Inspect for leaks around oil dipstick bushing (19).
If leaks are present,
r e m o v e o i l d i p s t i c k b u s h i n g ( 1 9 ) , apply sealant to oil dipstick bushing (19)
and install in crankcase (1).
h.
Inspect for leaks around plugs (20 and 21).
If leaks are present, remove
plugs (20 and 21), apply sealant to plugs (20 and 21) and install in crankcase
(1).
i.
Inspect sleeve bushing (22) for bends, cracks, or deformations.
j .
Inspect all components for damage.
k.
Install crankshaft bearing caps in accordance with the installation procedure
given in paragraph 4.4.20 and using micrometer, check crankshaft bearing
journal bores for the dimensions listed in Table 4-18.
If the journal bores
do not meet the specifications, discard crankcase.
Table 4-18.
Crankshaft Bearing Journal Bore Dimensions.
Mode 1
Dimensions
609-c
3.0512-3.0519 inches (77.500-77.519 mm)
US636HCCD-1
3.1102-3.1110 inches (79.000-79.019 mm)
l.
Inspect cylinder seat surfaces of crankcase (1) for scratches, burrs, pits, or
damage.
If damage is present, resurface damaged cylinder seat surfaces of
crankcase (1) using refacing device.
m.
Replace all damaged components.
4.4.22.3 Installation.
NOTE
On Model 609-c install six new lock washers and oil nozzles in the bearing webs
of the crankshaft bearings.
a.
Install new camshaft bearing bushing (18). Ensure oil hole in camshaft
bearing bushing (18) is in line with oil hole in crankcase (1).
b.
Install flat washer (17) and plug (16).
4-82
TM 10-4320-344-24
c.
Position deflector plate (15) against crankcase (1) and secure with two new
notched pins (14).
d.
Install flat washer (13) and plug (12).
e.
Install flat washer (11) and plug (10).
f.
Install seven plugs (9), new gaskets (8), and plugs (7).
g.
Install flat washer (6) and cap screw (5).
h.
Install two plugs (4).
i.
Install five flat washers (3) and plugs (2).
4-83/(4-84 Blank)
.
TM 10-4320-344-24
APPENDIX A
REFERENCES
A.1 SCOPE.
This appendix lists all forms, field manuals, technical manuals, and miscellaneous
publications referenced in this manual.
A. 2 FORMS.
Depreservation Guide for Vehicles and Equipment . .
Equipment Inspection and Maintenance Worksheet . .
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .
Report of Discrepancy (ROD) . . . . . .. . . .. . . .
Product Quality Deficiency Report . . . . . . .
.
.
..
.
. . .
. . .
.....
. . .
. .
. . .
. . .
.....
. . .
. .
DA Form 2258
DA Form 2404
. DA Form 2407
.SF 364
.SF 368
A.3 TECHNICAL MANUALS.
Operator’s Manual for Welding, Theory and Applications . . . . . TM 9-237
Painting Instructions for Army Materiel . . . . . . . . . . . . TM 43-0139
O p e r a t o r ’ s , U n i t , Intermediate Direct Support and
Intermediate General Support Maintenance Manual for
Lead-Acid Storage Batteries; 4HN, 24 V (NSN 614000-059-3528) MS75047-1; 2HN, 12 V (6140-00-0572553) MS35000-1; 6TN, 12 V (6140-00-057-2554)
MS35000-3; 6TL, 12 V (NSN 6140-01-210-1964)
MS52149-1 . . . . . . . . . . . . . . . . . . . . . . . . TM9-6140-200-14
Operator’s, Unit, Direct Support, and General Support
Maintenance Manual, Tactical Water Distribution
Equipment System (TWDS) Set 10-Mile Segment, Models
06749-0183-81, 110-00-0000, 919 and 10 (NSN 432001-122-3547) (NSN 4320-01-168-0591) (NSN 4320-01-1680590) (NSN 4320-01-221-6006) . . . . . . . . . . . . . . . . TM 10-4320-303-13
operator Manual for Pumping Assembly, Water, 600 GPM,
Model 609-A, Model 609-C, and Model US636HCCD-1 . . . . . . . TM 10-4320-344-10
O r g a n i z a t i o n a l , Direct Support, and General Support
Repair Parts and Special Tools List for Pumping
Assembly, Water, 600 GPM, Model 609-A (NSN 43200 1 - 1 8 4 - 7 4 9 4 ) , Model 609-C (NSN 4320-01-261-6470),
and Model US636HCCD-1 (NSN 4320-01-201-6937) . . . . . . . . TM 10-4320-344-24P-1,
Procedures for Destruction of Equipment to Prevent
-2 and -3
Enemy Use (Mobility Equipment Command) . . . . . . . . . . . TM 750-244-3
A.4 LUBRICATION ORDER.
Lubrication Order for Pumping Assembly, Water, 600
Gallons Per Minute (GPM), Unit 609-A (4320-01-1847494) , Pumping Assembly, Water, 600 Gallons Per
Minute (GPM), U n i t 6 0 9 - c ( 4 3 2 0 - 0 1 - 2 6 1 - 6 4 7 0 ) ,
Pumping Assembly, Water, 600 Gallons Per Minute
(GPM) US636HCCD-1 (4320-01-201-6937) . . . . . . .
.
.
.
.
.
LO
10-4320-344-12
A.5 MSCELLAEOUS PUBLICATIONS.
Dictionary of United States Army Terms . . . . . . . . .
Army Logistics and Readiness . . . . . . . . . . . . . .
Functional User’s Manual for the Army Maintenance
Management System (TAMMS) . . . . . . . . . . . . . .
Functional User’s Manual for the Army Mainance
Management System-Aviation (TAMMS-A) . . . . . . . .
L u b r i c a t i n g O i l , Internal Combustion Engine,
Preservative and Break-In . . . . . . . . . . . . . .
Abbreviations for Use on Drawings, and in Specifications,
Standards and Technical Documents . . . . . . . . . .
.
.
.
.
.
.
.
.
. . . .
AR 310-25
AR 700-138
DA Pam 738-750
.
.
.
.
DA Pam 738-751
.
.
.
.
MIL-P-21260
. . . .
MIL-STD-12
A-1
TM 10-4320-344-24
A.5 MISCELLANEOUS PUBLICATIONS. (Continued)
Marking for Shipment and Storage . . . . . . . . . . . . . . . .
Arc Welding Procedures for Structural Steels . . . . . . . . . .
Solder and Soldering . . . . . . . . . . . . . . . . . . . . . .
A-2
MIL-STD-129
MIL-STD-1261
TB-SIG-222
TM 10-4320-344-24
APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC)
SECTION 1.
INTRODUCTION
B.1 THE ARMY MAINTENANCE SYSTEM MAC.
B.1.1 Introduction. This introduction (Section I) provides a general explanation of
all levels of maintenance and repair functions authorized at various maintenance
levels under the standard Army Maintenance System concept.
B.1.2 Maintenance Allocation Chart Section II. The Maintenance Allocation Chart (MAC) in
section II designates overall authority and responsibility for the performance of
The application of
maintenance functions on the identified end item or component.
the maintenance functions to the end item or component will be consistent with the
capacities and capabilities of the designated maintenance levels, which are shown on
the MAC in column (4) as:
includes two subcolumns, C (operator/crew) and O (unit)
Unit
maintenance
D i r e c t s u p p o r t - includes an F sub-column
General support - includes an H sub-column
Depot - includes a D sub-column
B.1.3 Tools and Test Equip ment Introduction. S e c t i o n I I I l i s t s t h e t o o l s a n d t e s t
equipment (both special tools and common tool sets) required for each maintenance
function as referenced from section II.
B.1.4 Supplemental Instructions Introduction. S e c t i o n I V c o n t a i n s s u p p l e m e n t a l
instructions and explanatory notes for a particular maintenance function.
B.2 MAINTENANCE FUNCTIONS.
Maintenance functions are limited to and defined as follows:
B.2.1 Inspect. T o d e t e r m i n e t h e s e r v i c e a b i l i t y o f a n i t e m b y c o m p a r i n g i t s p h y s i c a l ,
mechanical, a n d / o r e l e c t r i c a l c h a r a c t e r i s t i c s w i t h e s t a b l i s h e d s t a n d a r d s t h r o u g h
examination (e.g., by sight, sound, or feel) .
B.2.2 Test. To verify serviceability by measuring the mechanical, pneumatic,
hydraulic, or electrical characteristics of an item and comparing those
characteristics with prescribed standards.
B.2.3 Service. O p e r a t i o n s r e q u i r e d p e r i o d i c a l l y t o k e e p a n i t e m i n p r o p e r o p e r a t i n g
condition,
i.e.,
to
clean
(includes
decontaminate,
when
required),
to
preserve,
to
drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.
B.2.4 Adjust. To maintain or regulate, within prescribed limits, by bringing into
proper or exact position, or by setting the operating characteristics to specified
parameters.
B.2.5 Align. To adjust specified variable elements of an item to bring about optimum
or desired performance.
B.2.6 Calibrate. To determine and cause corrections to be made or to be adjusted on
instruments or test, measuring, a n d d i a g n o s t i c e q u i p m e n t u s e d i n p r e c i s i o n
measurement.
Consists of comparisons of two instruments, one of which is a
certified standard of known accuracy, to detect and adjust any discrepancy in the
accuracy of the instrument being compared.
B-1
TM 10-4320-344-24
B.2.7 Remove/Install. To remove and install the same item when required to perform
service or other maintenance functions. Install may be the act of emplacing,
s e a t i n g , o r f i x i n g i n t o p o s i t i o n a s p a r e , r e p a i r p a r t , or module (component or
assembly) in a manner to allow the proper functioning of an equipment or system.
B.2.8 Replace. T o r e m o v e a n u n s e r v i c e a b l e i t e m a n d i n s t a l l a s e r v i c e a b l e c o u n t e r p a r t
in its place.
"Replace" is authorized by the MAC and assigned maintenance level is
shown as the 3d position code of the SMR code.
B.2.9 Repair. T h e a p p l i c a t i o n o f m a i n t e n a n c e s e r v i c e s1 , including fault
l o c a t i o n / t r o u b l e s h o o t i n g 2 , r e m o v a l / i n s t a l l a t i o n , and disassembly/assembly 3
p r o c e d u r e s , a n d m a i n t e n a n c e a c t i o n s4 to identify troubles and restore
serviceability to an item by correcting specific damage, fault, malfunction, or
f a i l u r e i n a p a r t , subassembly, module (component or assembly) , end item, or system.
B.2.1O Overhaul. T h a t m a i n t e n a n c e e f f o r t ( s e r v i c e / a c t i o n ) p r e s c r i b e d t o r e s t o r e a n
item to a completely serviceable/operational condition as required by maintenance
s t a n d a r d s i n a p p r o p r i a t e t e c h n i c a l p u b l i c a t i o n ( i . e . , D M W R ) . Overhaul is normally
the highest degree of maintenance performed by the Army.
Overhaul does not normally
return an item to like new condition.
B.2.11 Rebuild. C o n s i s t s o f t h o s e s e r v i c e s / a c t i o n s n e c e s s a r y f o r t h e r e s t o r a t i o n o f
unserviceable equipment to a like new condition in accordance with original
manufacturing standards.
Rebuild is the highest degree of materiel maintenance
applied to Army equipment.
The rebuild operation includes the act of returning to
zero those age measurement (e.g., hour/miles) considered in classifying Army
equipment/components.
B.3 EXPLANATION OF COLWNS IN TNE MAC, SECTION II.
B.3.1 Column 1, Group Number. Column 1 lists functional group code numbers, the purpose
of which is to identify maintenance significant components, assemblies,
s u b a s s e m b l i e s , and modules with the next higher assembly.
B.3.2 Column 2. Component/Assembly. Column 2 contains the item names of components,
a s s e m b l i e s , subassemblies, and modules for which maintenance is authorized.
B.3.3 Column 3, Maintenance Function. Column 3 lists the functions to be performed on
the item listed in Column 2. (For detailed explanation of these functions, see
paragraph B.2.)
B.3.4 Column 4, Maintenance Level. Column 4 specifies each level of maintenance
authorized to perform each function listed in Column 3, by indicating work-time
required (expressed as man-hours in whole hours or decimals) in the appropriate
subcolumn . T h i s w o r k - t i m e f i g u r e r e p r e s e n t s t h e a c t i v e t i m e r e q u i r e d t o p e r f o r m
that maintenance function at the indicated level of maintenance.
If the number or
complexity of the tasks within the listed maintenance function vary at different
maintenance levels, appropriate work-time figures are to be shown for each level.
The work-time figure represents the average time required to restore an item
(assembly, subassembly, component, module, end item, or system) to a serviceable
condition under typical field operating conditions. This time includes preparation
time (including any necessary disassembly/assembly time),
troubleshooting/fault
l o c a t i o n t i m e , and quality assurance time in addition to the time required to
perform the specific tasks identified for the maintenance functions authorized in
1
Services - inspect, test, service, adjust, align, calibrate, and/or replace.
2
Fault location/trouble shooting - The process of investigating and detecting the cause of
equipment malfunctioning; the act of isolating a fault within a system or unit under test (UUT).
3
Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group
coded item to the level of its least component that is assigned an SMR code for the level of
maintenance under consideration (i.e., identified as maintenance significant).
4
Actions - welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
B-2
TM 10-4320-344-24
the maintenance allocation chart. The symbol d e s i g n a t i o n s f o r t h e v a r i o u s
maintenance levels are as f o l l o w s :
C . . . . . . . . . . . . . . . Operator or crew maintenance
0 . . . . . . . . . . . . . . . Unit maintenance
F . . . . . . . . . . . . . . . Direct Support maintenance
5
L . . . . . . . . . . . . . . . Specialized Repair Activity (SRA)
H . . . . . . . . . . . . . . . General support maintenance
D . . . . . . . . . . . . . . . Depot maintenance
9.3.5 Column 5, Tools and Test Equipment Reference Code. Column 5 s-p e c i f i e s , b y c o d e , t h o s e
common tool sets (not individual tools), common TMDE, and special tools, special
TMDE, and special support equipment required to perform the designated function.
Codes are keyed to tools and test equipment in Section III.
B.3.6 Column6. Remarks. When applicable, this column contains a letter code, in
alphabetic order, which is keyed to the remarks contained in Section IV.
B.4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQIPMENT REQUIREMENTS. SECTION III.
B.4.1 Column 1, Reference Code. T h e t o o l a n d t e s t e q u i p m e n t r e f e r e n c e c o d e c o r r e l a t e s
with a code used in the MAC, Section II, Column 5.
B.4.2 Column 2. Maintenance Level.
the tool or test equipment.
The lowest level of maintenance authorized to use
B.4.3 Column 3. Nomenclature. Name o r i d e n t i f i c a t i o n o f t h e t o o l o r t e s t e q u i p m e n t .
B.4.4 Column 4, National Stock Number. The National Stock Number of t h e t o o l o r t e s t
equipment.
B.4.5 C O lU mn 5, Tool Number. The manufacturer’s part number, model number, or type
number.
B-5 EXPLANATIN OF COLUNNS IN REMARKS, SECTIOM IV.
B.5.1 Column 1, Remarks Code.
The code recorded in Column 6, Section II.
B.5.2 Column 2. Remarks. This column lists information pertinent to the maintenance
function being performed as indicated in the MAC, Section II.
5
This maintenance category is not included in Section II, column (4) of the Maintenance
Allocation Chart. TO identify functions to this category of maintenance, enter a work time figure
in the “H” column of Section II, column (4), and use an associated reference code in the Remarks
columnn (6). Key the code to Section IV, Remarks, and explain the SRA complete repair application
there. The explanatory remark(s) shall reference the specific Repair Parts and Special TOO lS List
(RPSTL) TM which contains additional SRA criteria and the authorized spare/repair Parts.
B-3
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER)
(4)
Maintenance
(3)
(2)
(1)
I
Unit
Group
Number
Component/
Assembly
Direct
Support
General
Depport
Depot
F
H
D
Tools and
Equipment
Ref Code
Maintenance
Function
C
Inspect
Replace
Repair
.2 0 . 2
2.0
2.0
1
1
O
(6)
(5)
Level
Remarks
Code
00
600 GPM Pump
Assembly
01
Enclosure
Assembly
02
Exhaust System
0201
Muffler Assembly I n s p e c t
Replace
Repair
0.1 0 . 1
0.5
0.5
1
1
Inspect
Replace
Repair
0.1
0.3
0.5
1
1
B
Inspect
Service
Replace
Repair
0.1 0 . 1
0.2
0.5
0.5
2
1
1, 4
D, B
Inspect
Replace
Repair
0.1
0.4
0.4
1
1
Inspect
Replace
Repair
0.1
0.5
0.5
1
1
0.4
1
0202
Exhaust Pipe
Assembly
03
Air Intake
System
0301
Air Cleaner
Assembly
0302
Air Intake
Assembly
A
C
C
04
Electrical
System
0401
Service
0402
Battery Box and
Cover
Inspect
Replace
0.1
0403
Batteries and
Battery Cable
Assembly
Inspect
Test
Replace
Repair
0.1 0 . 3
0.2
1.0
0.5
14134
Power Control
Cable Assembly
Replace
Repair
0.5
0.3
1
1
0405
Limit Switch
Assembly
Inspect
Replace
Repair
0.1
0.5
0.2
1
1
1406
Start Alarm
Relay Switch
Inspect
Replace
B-4
Lights
B
B
A
1, 2
1
1, 2
E
F
G
H
H
I,
0.1
0.4
1
J
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued)
(1)
Group
Number
(2)
Component /
Assembly
Maintenance
Function
(5)
(6)
Tools and
Equipment
Ref Code
Remarks
Code
(4)
Level
Maintenance
(3)
General
Support Depot
Un
it
Direct
Support
C
—
O
F
0.1
0.2
1.0
2.0 2 . 0
1
1, 3
0.5
2.0
1
0.5
1.0
1, 2
1, 2
H
D
05
Control Panel
0501
Control Panel
Cover Assembly
Inspect
Replace
Repair
0502
Control Panel
Assembly
Inspect
Replace
0503
Control Panel
Test
Assembly Wiring Repair
0504
Gauges and Meter I n s p e c t
Assemblies
Test
Replace
Repair
0.1
0.3
0.5
0.5
0.5
0505
Indicator
Assembly
Inspect
Replace
Repair
0.1
0.1
0.5
0.5
1, 2
1
0506
Switches
Inspect
Test
Replace
0.1
0.2
1.0
1.0
1, 2
1
M, O
0507
Fuse Holder
Replace
0.2
1
P
0508
Rheostats and
Resistors
Inspect
Replace
0.2
1.0
1, 2
0509
Lights
Replace
Repair
4.4
0.2
1
1
A
0510
Cables
Replace
Repair
0.5
0.5
1
1
I
B
0511
Pressure
Regulator
Inspect
Replace
Repair
0.2
1.5
1
0.1
K
C
C, Q
H
R
0.2
Pressure Control Replace
Module, Engine IRepair
Protection
System Module,
and Controlling
Device
1.0
0.5 0 . 2
1
1
0513
Governor Control A d j u s t
Module
Replace
Repair
0.5
1.0
1
Process Control
Device
0.5
1.0
0515
Pressure Gauge
Hose Assemblies
Inspect
Repair
R
1, 2
1
0.2
0.5
P
R
0.2
0.2
c
R
A
0.2
Test
Replace
Repair
C, M
N
0512
0514
B, L
1
B
B-5
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued)
(1)
(2)
(3)
Unit
Group
Number
0516
0517
06
07
08
Component/
Assembly
Control Panel
100101
100102
B-6
Tools and
Equipment
Ref
F
H
D
Remarks
Code
Control Panel
Frame, C e n t r o l
Enclosure
Assembly, and
Base Weldment
Inspect
Replace
Repair
0.1
0.3
0.3 1 . 0
1
1, 3
Main Wiring
Harness
Inspect
Test
Replace
Repair
0.2 0 . 5
1.0
1.0
1.0
Pumping Assembly I n s p e c t
Replace
Repair
0.1 0 . 2
Hood, Rear
Panel, and
Shield Assembly
0.2
Radiator Shell
and Side Panel
1001
O
Depot
1
1, 3
0901
10
C
Direct General
Support Support
0.2
0.3
0.3 1 . 0
Radiator
Assembly
0903
(6)
Inspect
Replace
Repair
09
0902
Maintenance
Function
(5)
(4)
Maintenance Level
Inspect
Replace
Repair
K
B,L
H
L,S
1
1, 2
1
1, 2
M
C
3.0
1.0 6.0
1, 2, 3
1, 2
B
0.4
0.5
1
1
H
B
H
Inspect
Replace
Repair
0.2
0.5
0.5
1
1
B
Cooling System
Hoses
Inspect
Repair
0.1 0 . 1
0.5
1
B
Radiator
Service
Replace
Repair
0.5
0.5
0.5 1.0
1
1
1, 3
H,T
Inspect
Replace
Repair
0.3
Inspect
Service
0.2
0.8
Fuel Lines,
Hoses, and
Fittings
Inspect
Replace
Repair
0.1 0.2
0.2
0 .2
1, 2
1, 2
C
Fuel Filter and
Base Assembly
Inspect
Se r v i c e
Replace
Repair
0.10 .2
0 .2
1 .0
1 .0
1,2
1,2
B
Engine Assembly
Fuel System
5.0
0.5
1,
1
2,
B,L
3, 1O
B
1
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued)
(1)
(3)
(2)
Direct
Unit Supper
Group
Number
100103
Component/
Assembly
Maintenance
Function
(5)
(6)
Tools and
Equipment
Ref Code
Remarks
Code
(4)
Maintenance Level
C
O
F
General
Support
Depot
H
D
Fuel Transfer
Pump Assembly
Inspect
Service
Test
Replace
0.2
0.4
0.4
0.8
1
1
1, 2
Fuel Injection
Lines and Fuel
Leakoff Manifold
Assembly
Inspect
Replace
Repair
0.2
0.5
0.5
1
1, 2
Fuel Injection
Nozzle and
Holder Assembly
Test
0.3
Replace
0.4
Governor
Adjust
Replace
Repair
1.0
0.8
0.2
1, 2, 3
1, 3
B, R
10010601 Governor
Actuator
Assembly
Replace
Repair
0.5
0.2
1, 3
1, 3
A
B, R
100107
Test
2.0
Adjust
Replace
Repair
2.0
2.0
0.2
1,
11,
14,
1,
1,
1,
B, R
100104
100105
100106
Fuel Injection
Pump Assembly
100108
Cold Starting
Aid
1002
Electrical
System
100201
V-Belt Guard
100202
100203
100204
1003
Alternator
Assembly and Vbelt
Starter Assembly
V-Belt Contact
Switch
Elbow Assembly,
Exhaust Pipe
1, 2, 5,
7, 8, 9,
1, 2
C
U
B
6,
U
K
2, 3,
12, 13,
15
2
2
2
Replace
Repair
0.4
0.4
1
1, 4
A
D, B
Replace
Repair
0.5
0.5
1
P
B
0.2
0.4
0.3
0.7
0.5
1
1, 2
1
1
Inspect
Replace
0.1
0.5
1
Inspect
Test
Replace
Repair
0.2
0.2
0.5
0.5
1, 2
1
1
Replace
Repa i r
0.4
0.4
Inspect
Adjust
Test
Replace
Repair
0.2
1
1
V
W, X
B, Y
C
M
B
H
B
B-7
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued)
(1)
(2)
(3)
(4)
Maintenance Level
—Unit
.
Group
Number
Component/
Assembly
Maintenance
Function
C
—
Replace
Repair
0
—
0.4
0.4
Oil Inlet Tube
and Oil Drain
Tube Assembly
Replace
Repair
100502
Oil Bypass Line
Replace
Repair
100503
Oil Filter and
Base Assembly
100504
Oil Cooler
1004
Pipe Assembly,
Air Intake
1005
Lubrication
System
100501
100505
Oil Breather
100506
Oil Drain
Assembly
100507
Direct
Supper
F
General
Support
Depot
H
D
(5)
(6)
Tools and
Equipment
Ref Code
Remark
Code
1
1
H
B
0.5
0.5
1
1
B
1
1
P
B
Replace
Repair
0.3
0.3
0.5
0.5
1, 2
1, 2
B
Inspect
Replace
Repair
0.2 0.2
0.5
0.5
1
1
B
Inspect
Replace
Repair
0.2
0.5
0.5
1
1
B
Replace
Repair
0.3
0.3
1
1
B
C
Oil Pan Assembly Re p l a c e
Re p a i r
0.4
1.0
1, 2
1, 2, 3
B, L
100508
Suction Pipe
Re p l a c e
Re p a i r
0.3
0.3
1
1
C
B
100509
Oil Pump
Assembly
Re p l a c e
1.0
1, 2
H
100510
Oil Nozzle
Re p l a c e
0.5
1, 2, 3, 16
P
1006
Turbocharger
Assembly
Inspect
Re p l a c e
Re p a i r
0.1 0.3
0.5
0.5 0.2
Inspect
Re p l a c e
Re p a i r
0.2,
0.5
0.5
1, 2
1, 2
Cooling Air
Replace
Blower and
Repair
Cowling Assembly
0.5
0.5
1
1
1009
Thermostat
Test
Replace
Repair
0.5
0.5
0.5
1, 2
1, 2
1, 2
1010
Fan
Inspect
Replace
:;
1
1007
Maifold
Assembly
1008
I
B-8
P
1
1
B, R
K
B
C
B
H
B
H
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued)
(1)
(2)
(3)
D i r e c t General
Support Support Depot
Unit
Group
Number
1011
Component/
Assembly
Water Pump
Assembly
Maintenance
Function
Inspect
Replace
C
(6)
Tools and
Equipment
Ref Code
H
D
Remarks
Code
H
1, 2
1
1
C
B
1, 2
1, 2
K
C
0.2
0.2
0.2
1
1
1
H
Z
0.3
0.3
0.5
0.5
1, 2
1, 2
B
1
1
1, 2, 3
1, 2, 3
B
V-Belt Tensioner Replace
Assembly
Repair
1013
Angle Drive,
Tachometer and
Gear Shaft
Replace
Repair
0.3
0.5
1014
Breather Cap
Inspect
Service
Replace
1015
Cylinder Head
Cover
Replace
Repair
1016
Rocker Arm
Assembly
Inspect
Adjust
Replace
Repair
Adjust
Cylinder Head
Assembly Valves,
Replace
Intake and
Exhaust)
Repair
F
O
—
0.2
1.0
1012
1017
(5)
(4)
Maintenance Level
1.0
1.5
0.2
1.0
2.0
1.0
1.0
8.0
1, 2, 3,
17, 18
1, 2, 3,
17, 18
1, 2, 3,
20, 21, 22,
23, 24, 25,
26, 27
B
C
B
1018
Cylinder
Replace
Repair
4.0
4.0
1, 28,
1, 28,
1019
Gear Housing
Cover and
Crankcase Front
Cover
Replace
Repair
1.0
1.0
1, 2
1, 2
B
1020
Oil Pump
Replace
Assembly and Oil Repair
Pipe
0.5
0.5
1, 2, 3
1, 2, 3
C
B
1021
Idler Gear and
Replace
Bearing Assembly Repair
0.4
0.8
1, 2, 3
1, 2, 3
B
Replace
Repair
0.8
2.0
1, 2
1, 2, 3
B
Replace
IRepair
Piston Assembly Replace
and Connecting
Repair
Rod Assembly
0.5
0.5
1, 2
1, 2
C
B
6.0
6.0
1, 2, 3, 31
1, 2, 3, 30
B
1022
1023
1024
Flywheel, Ring
Gear, Flywheel
Cover, and Bell
Housing
Crankcase Rear
Cover
29
29
B-9
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued)
(1)
(2)
(3)
Unit
Group
Number
Component/
Assembly
Maintenance
Function
(5)
(6)
Tools and
Equipment
Ref Code
Remark:
Code
(4)
Maintenance Level
C
Direct
Support
General
Support
Depot
F
H
D
O
1025
Camshaft
Replace
Repair
3.0
3.0
1, 2, 3
1, 2, 3
B
1026
Gear Housing
Replace
Repair
1.0
1.0
1, 2
1, 2
H
B
1027
Crankshaft
Assembly
Replace
Repair
4.0
3.0
1, 2, 3
1, 2, 3, 15
B
1028
Engine Block
Replace
Repair
3.0
3.0
1, 2, 3
1, 2, 3
H
B
1029
Crankcase
Replace
Repair
3.0
3.0
1, 2, 3, 32
1, 2, 3,
31, 33
C
11
Fuel Tank
Inspect
Replace
Repair
0.1 0.3
1.5
0.5
Inspect
Replace
Repair
0.2 0.2
Inspect
Service
Replace
Repair
0.1 0.2
0.5
0.5
0.5
1, 2
1, 2
1, 2
Jack Assemblies
and Tripod
Inspect
Replace
Repair
0.2 0.2
0.5
0.5
1, 2
1, 2
B
1203
Brake System
Service
0.5
1
AB
120301
Master Cylinder
and Brake Lines
Replace
Repair
1.0
1.0
1, 2
1, 2, 3
B, L
Actuator,
Replace
Repair
2.0
2.0
1, 2
1, 2
B
Inspect
Adjust
Replace
Repair
0.5
0.2
1.0
1.0
1, 2
1, 2
1, 2
B
1.0
1.0
1
1
B
1, 2
M, AC
1
1
1, 3
1, 3
B
12
1201
1202
120302
120303
120304
1204
1205
B-10
Wheel Mounted
Frame Assembly
Wheels, Hubs,
and Tires
Brake
Wheel Cylinder
and Brake Shoes
Handbrake
Assembly
0.5
Inspect
Adjust
Replace
Repair
0.1
0.1
Wiring Harness,
Intervehicular
Cable, and
Lights
Inspect
Test
Replace
Repair
0.2 0.2
0.5
1.0
1.5
Chains, Safety
Inspect
Replace
Repair
0.1
2.0
1
1, 3
B, L
6.0
8.0
2
3
L
0.5
0.5
0.5
AA
B
L
B, L
TM 10-4320-344-24
SECTION II. MAINTENANCE ALLOCATION CHART
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (HATER) (continued)
(3)
(2)
(1)
(4)
Maintenance
Unit
Group
Number
1206
Component/
Assembly
Absorber,
Shock
Maintenance
Function
C
O
Replace
Repair
1.0
1.0
1207
Axle
Inspect
Replace
Repair
0.1 0.2
2.0
2.0
1208
F o r k l i f t P o c k e t Replace
Repair
0.5
0.5
D i r e c t General
Support Support Depot
F
(5)
(6)
Tools and
Equipment
Ref Code
Remarks
Level
H
D
1
1
B
1, 2
1, 2
1
1
A
B
B-11
TM 10-4320-344-24
S E C T I O N I I I . T O O L A N D T E S T EQUIPMENT REQUIREMENTS
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER)
B-12
TM 10-4320-344-24
SECTION IV. REMARKS
FOR
PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER)
(1)
REFERENCE
CODE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
AA
AB
AC
(2)
REMARKS
Applicable to Model 609-c only.
Repair by replacing defective components.
Applicable to Models 609-C and US636HCCD-1 only.
Blind riveter tool is used for data plate replacement and trailer
reflector replacement procedures.
Unit level service is to add distilled water to battery cells. Direct
support level service is to add electrolyte to dry batteries.
Check specific gravity and test battery in accordance with TM 9-6140200-14.
Battery cables only.
Applicable to Model 609-A only.
Applicable to Models 609-A and 609-C only.
This procedure is applicable to the start pilot relay of Model 609-C.
Applicable to Models 609-A and US63HCCD-1 only.
Repair by welding.
Continuity test.
This test is applicable to the low oil pressure cutoff switch for Model
US636HCCD-1 only.
This test is applicable to the Start Switch and Start/Stop Switch of
Model US636HCCD-1 only.
Applicable to Model US636HCCD-1 only.
Resistor replacement applies to Model 609-C only.
Return to manufacturer for repair.
Repair at Unit level applies to Model US63HCCD-1 only.
Service by draining, flushing, and replacing engine coolant.
Test pressure output.
Adjust belt tension.
Insulation breakdown and continuity test.
Test for known voltage.
Repair is replacement of generator capacitor on Model 609-C.
Service by cleaning filter.
Pack wheel bearings.
Bleed brake lines.
Applicable to trailer lights only.
B-13/(B-14Blank)
TM 10-4320-344-24
APPENDIX C
EXPENDABLE AND DURABLE ITEMS LIST
SECTION I. INTRODUCTION
C.1 SCOPE
This appendix lists expendable and durable items that you will need to maintain the
600 GPM pumping assemblies. T h i s l i s t i n g i s f o r i n f o r m a t i o n a l p u r p o s e s o n l y a n d i s
n o t a u t h o r i t y t o r e q u i s i t i o n t h e l i s t e d i t e m s . These items are authorized to you by
CTA 50-790, expendable items (except medical, class V repair parts, and Heraldic
Items).
C.2 EXPLANATION OF COLUMNS
C.2.1 Column (1) - Item Number. This number is assigned to the entry in the listing
referencing when required.
C.2.2 Column (2) - Level. T h i s c o l u m n i d e n t i f i e s t h e l o w e s t l e v e l o f m a i n t e n a n c e t h a t
requires the listed item.
C
O
F
H
Operator/Crew
Unit Maintenance
Direct Support Maintenance
General Support Maintenance
C.2.3 Colmn (3) - National Stock Number. This is the national stock number assigned to
the item; use it to request or requisition the item.
C.2.4 Colunn (4) - Description. Indicates the federal item name and, if required, a
description to identify the item. The last line for each item indicates the
Commercial and Government Entity Code (CAGEC) parentheses followed by the part
number.
C.2.5 Column (5) - Unit of Measure (UM)/Unit of Issue (UI). This measure is expressed by a
two character alphabetical abbreviation (eg., EA, IN, PR). If the unit of measure
differs from the unit of issue as shown in the Army Master Data File (AMDF)
requisition the lowest unit of issue that will satisfy your requirements.
C-1
TM 10-4320-344-24
SECTION II.
EXPENDABLE AND DURABLE ITEMS LIST
(1)
(2)
(3)
(4)
(5)
Item
Number
Level
National Stock
Number
Description
(U/M) /
(U/I)
1
F
8040-00-995-0590
ADHESIVE (GASKET CEMENT)
(71984) SILASTIC 140
TU
2
F
8040-01-284-3984
ADHESIVE (LOCKTITE)
(05972) 38050
OZ
3
0
6850-00-181-7929
ANTIFREEZE
(81349) MIL-A-46953
GL
4
0
9150-01-292-8849
BRAKE FLUID, AUTOMOTIVE
(81348) W-B-680
GL
5
0
7920-01-067-6190
BRUSH, PLATER’S, HAND
(81348) HB178/2-3
EA
6
F
7920-01-010-7378
BRUSH, WIRE, TUBE
(93052) 947
EA
7
0
6850-00-965-2359
CLEANING COMPOUND
(81349) MIL-C-22230
CN
8
F
5350-00-584-4654
CLOTH, ABRASIVE (EMERY)
(58536) A-A-1049
PG
9
0
8030-01-141-0805
COMPOUND, SILICONE CAULKING
TU
10
F
9140-00-286-5284
DIESEL FUEL
(81348) w-F-800
DR
11
0
8415-01-112-1885
GLOVES, CHEMICAL
EA
12
0
9150-00-935-1017
GREASE, AUTOMOTIVE AND ARTILLERY
(81349) MIL-G-10924
CA
13
H
GREASE, ENGINE ASSEMBLY
CN
14
F
LUBRICANT, GASKET, POTABLE WATER
SYSTEM
(19853) 13225E9192
CN
15
0
9150-00-186-6681
OIL, LUBRICATING, ENGINE
(81349) MIL-L-2104
QT
16
0
9150-01-205-3116
OIL, LUBRICATING, GENERAL
(09137) 42110
CN
17
0
3510-01-326-8235
OIL, TRANSMISSION (16974)
180412
QT
18
0
7240-00-274-3875
PAIL, UTILITY, 2.5 GALLON
(58536) A-A-1273
EA
19
0
4910-00-387-9592
PAN, DRAIN, 4 GALLON
(05463) 450
EA
20
0
7920-00-205-1711
RAGS, WIPING
(58536) A-A-2522
BE
21
0
5905-00-141-0591
RESISTOR, FIXED, COMPOSITION
(81349) RCR20G103JS
EA
22
F
8030-01-134-0436
SEALING COMPOUND, ANTISIEZE
(81349) MIL-C-47167
LB
C-2
TM 10-4320-344-24
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (Continued)
(1)
(2)
(3)
(4)
(5)
Item
Number
Level
National Stock
Number
Description
(U/M) /
(U/I)
23
F
8030-00-088-7818
24
F
25
0
3439-01-036-5762
SOLDER, TIN ALLOY
(81348) SN60WRAP2
SL
26
0
6850-01-377-1809
SOLVENT, DRY CLEANING
GL
27
F
STEEL BARS, 1 1/4 = X 3/8 = X 14”
(31.75 X 9.525 X 355.6 mm)
EA
28
F
STEEL RODS, 1“ X 36”
(25.4 X 914.4 1110)
EA
29
0
5975-00-111-3208
STRAP, TIEDOWN, ELECTRICAL
(96906) MS 3367-5-9
HD
30
0
8135-00-283-0669
STRAPPING
(58536) A-A-880
CL
31
0
9905-00-111-0671
TAGS, INSTRUCTION
(81348) UU-T-81
EA
32
0
8030-00-889-3535
TAPE, ANTISEIZING
(81349) MIL-T-27730
SL
33
0
5970-00-547-0966
TAPE, INSULATION, ELECTRICAL
(75037) MIL-I-3825
RO
34
0
7510-00-789-3368
TAPE, PRESSURE SENSITIVE, 1 INCH
(58536) A-A-1586
RO
35
0
7510-01-015-7320
TAPE, PRESSURE SENSITIVE, 4 INCH
(07124) 506
RO
36
F
9525-00-249-7438
WIRE, NONELECTRICAL
(96906) MS 52005c003
CL
SEALING COMPOUND, GASKET
(81349) MIL-S-7916
CN
SOAP, OIL
C-3/(C-4Blank)
TM 10-4320-344-24
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS
This appendix includes complete instructions for making items authorized to be
manufactured at unit and direct support maintenance levels.
All bulk materials needed for manufacture of an item are listed by part number or
specification number in a tabular list on the illustration.
Refer to TM 10-4320-344-24P for parts and materials required for manufacture of the
items identified in this appendix.
D-1
TM 10-4320-344-24
Figure D-1. Sound Enclosure Assembly Insulation Material, Model 609-C.
PROCEDURE:
1.
Remove damaged insulation material from internal surface of sound enclosure
component.
2.
Scrape all adhesive from surface of sound enclosure component.
3.
Using sound enclosure component as a template cut new insulation material to
appropriate size.
4.
Apply adhesive to internal surface of sound enclosure component and install
insulation material.
Table D-1. Parts List for Sound Enclosure Insulation, Model 609-c.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
1
13221E9359
(97403)
AR
Sound, Foam, Plain,
Without Adhesive
2
EC765
AR
Adhesive, General
Purpose
D-2
NSN
3040-00-664-0439
TM 10-4320-344-24
Figure D-2. Battery Cable Assembly, Model 609-A.
PROCEDURE:
1.
Identify battery cable assembly.
2.
Cut battery cable to length.
a.
Positive battery cable length is 72 inches (182.88 cm).
b.
Negative battery cable length is 36 inches (91.44 cm).
3.
Strip 0.500 inches (1.27 cm) of insulation from each end of battery cable.
4.
Heat cable terminal; fill with solder.
5.
Insert cable into terminal and let connection cool. If negative battery
cable assembly, install panel ground wire in negative battery terminal with
battery cable.
6.
Wrap battery cable and terminal connections in electrical tape.
Table D-2. Parts List for Battery Cable Assembly, Model 609-A.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
NSN
1
CS00V
AR
Cable
6145-01-283-4530
2
BP5
1
Terminal, Lug
5940-01-263-7802
3
BP11U
1
Terminal, Lug
5940-01-263-7801
4
SN60WRAP2
AR
Solder
3439-01-036-5762
5
MIL-I-3825
AR
Tape, Insulation,
Electrical
5970-00-547-0966
D-3
TM 10-4320-344-24
Figure D-3. Battery Cable Assembly, Model US636HCCD-1.
PROCEDURE:
1.
Identify battery cable assembly.
2.
Cut cable to length.
a.
Positive battery cable length is 30 inches (76.20 cm).
b.
Negative battery cable length is 16 inches (40.64 cm).
3.
Strip 0.500 inches (1.27 cm) of insulation from each end of battery cable.
4.
Heat cable terminal; fill with solder.
5.
Insert battery cable into terminal and let connection cool.
6.
Insert cable into lug; crimp lug.
7.
Wrap battery cable and terminal connections in electrical tape.
Table D-3. Parts List for Battery Cable Assembly, Model US63HCCD-1.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
NSN
1
CS00V
AR
Cable
6145-01-283-4530
2
BP319
1
Terminal, Lug
5940-01-263-7803
3
BP11U
1
Terminal, Lug
5940-01-263-7801
4
SN60WRAP2
AR
Solder
3439-01-036-5762
5
MIL-I-3825
AR
Tape, Insulation,
Electrical
5970-00-547-0966
D-4
TM 10-4320-344-24
Figure D-4. Control Panel Wiring Harness Assembly, Model 609-c.
D-5
TM 10-4320-344-24
PROCEDURES:
1.
Refer to appendix F, Figure F-2, and using a multimeter, determine which
wire is defective.
2.
If defective wire is soldered, desolder wire from connector.
3.
Remove defective wire from wiring harness.
4.
Refer to table D-4 and cut wire from bulk. Wire assembly numbers in table
D-4 are for information only, they are not marked on wiring harness, refer
to terminations to determine what components comprise damaged wire.
5.
Strip approximately 0.250 (0.635 cm) inch of insulation from each end of
wire.
6.
Crimp or solder terminal(s) to wire.
7.
For all soldered assemblies install heat-shrink tubing over solder
connections.
8.
a.
For all wire assembly numbers in table D-5, noted with a
shrink tubing 18763-245.
1
use heat-
b.
For all wire assembly numbers in table D-5, noted with a
shrink tubing part number 18763-244.
2
use heat-
Install repaired wire in wiring harness.
Table D-4. Parts List for Control Panel Wiring Harness Assembly, Model 609-C.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
1
27228-505
4
Connector, Pin
2
27214-514
6
Terminal
3
27214-513
18
Terminal
4
27214-515
4
Terminal
5
27214-505
1
Terminal
6
S-1790
2
Connector
7
27214-504
1
Terminal
8
27214-503
1
Terminal
9
27228-515
8
Connector, Socket
10
27284-202
1
Splice, Wire
11
S-1950
1
Assembly, Connector
12
27215-312
11
Terminal
13
27215-321
1
Terminal
14
27215-302
3
Terminal
15
18142-421
AR
Wire, Cable,
Electrical
16
18142-411
AR
Wire, Cable,
Electrical
17
18763-245
AR
Tubing, Heat-Shrink
18
18763-244
AR
Tubing, Heat-Shrink
D-6
NSN
TM 10-4320-344-24
Table D-4. Parts List for Control Panel Wiring Harness Assembly,
Model 609-C. (Continued)
Find
Number
Part or
Identifying Number
Quantity
Required
Description
19
SN60WRAP2
AR
Solder
NSN
3439-01-036-5762
Table D-5. Control Panel Wire Run List, Model 609-C.
D-7
TM 10-4320-344-24
Table D-5. Control Panel Wire Run List, Model 609-C. (Continued)
Wire Run
Wire
Assy
Detail
Configuration
21
From
Terminal
Find No.
To
Terminal
Find No.
Wire
Find
No.
Wire
Length
D
R1
(LINE)
SOLDER
S1(1)
3
15
28.5
inches
22
I
S1(1)
3
EPS(14)
12
15
64.5
inches
23
J
EPS(14)
R1
(LOAD)
12
EPS(11)
12
15
24 inches
SOLDER
OP(I)
2
15
9.5
inches
1
24
25
26
K
D
OP(S)
R2
(LOAD)
2
P10(10)
9
15
91 inc h es
SOLDER
ET(I)
2
15
9.5
inches
27
K
ET(S)
2
P10(11)
9
15
94 inches
28
L
P10(3)
9
EPS(13)
13
15
82 inches
29
L
P10(6)
9
EPS(13)
13
15
82 inches
30
I
EPS(13)
12
S2(2)
3
15
71.5
inches
31
c
S2 (2)
3
TACH ( + )
3
15
33 inches
32
F
TACH ( + )
3
HM(+)
6
15
26 inch es
M
EPS(20)
14
BG5(2)
SOLDER
16
72 inch es
2
33
34
35 2
L
EPS(3)
12
P10(8)
9
15
99 inches
M
EPS(18)
14
BG6(2)
SOLDER
16
72 inch es
36
L
EPS(4)
12
P10(9)
9
15
99 inches
M
EPS(19)
14
BG7 (2)
SOLDER
15
75 inch es
J
EPS(10)
12
EPS(6)
12
15
10 inches
39
EPS(6)
12
P9(B)
86 inches
40
EPS(6)
12
P6 (K)
46 inches
TACH
(SIG)
3
EPS(5)
42
EPS(5)
12
P9 (A)
86 inches
43
EPS(5)
12
P6(J)
46 inches
44
S2(1)
3
P6(1)
74 inches
45
P6(A)
P7 (A)
20 inches
46
S2(4)
3
P7 (B)
48 inches
37
2
38
41
I
12
15
83.5
inches
47
C
S1(4)
3
S2(5)
3
15
29 inches
48
K
P10(4)
9
S2(6)
3
15
86 inches
S2(6)
3
P7 (E)
49
D-8
1
D
48 inches ,
TM 10-4320-344-24
Table D-5. Control Panel Wire Run List, Model 609-C. (Continued)
Wire Run
Wire
Assy
Detail
Configuration
From
Terminal
Find No.
To
Terminal
Find No.
S3(2)
3
S3(3)
3
Wire
Find
No.
Wire
Length
38
inches
50
P8 (A)
51
P8(B)
52
P6
P9
4 8 i n ch es
53
P8
R4
3 0 i n ch es
54
P6
P7
2 0 i n ch es
3
15
3 8 i n ch es
D-9
TM 10-4320-244-24
Figure D-5. Main Wiring Harness Assembly, Model 609-C.
D-10
TM 10-4320-344-24
PROCEDURES:
1.
Refer to appendix F, Figure F-3, and using a multimeter, determine which
wire is defective.
2.
If defective wire is soldered, desolder wire from connector.
3.
Remove defective wire from wiring harness.
4.
Refer to table D-6 and cut wire from bulk. Wire assembly numbers in table
D–6 are for information only, they are not marked on wiring harness, refer
to terminations to determine what components comprise d a m a g e d w i r e .
5.
Strip approximately 0.250 (0.635 cm) inch of insulation from each end of
wire.
6.
Crimp or solder terminal(s) to wire.
7.
For all soldered assemblies install heat-shrink tubing over solder
connections.
8.
a.
For all wire assembly numbers in table D-7, noted with a ¹ use heatshrink tubing 18763-249.
b.
For all wire assembly numbers in table D-7, noted with a ² use heatshrink tubing part number 18763-248.
Install repaired wire in wiring harness.
Table D-6. Parts List for Main Wiring Harness, Model 609-C.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
1
27213-028
5
Lug, Terminal
2
27216-565
3
Lug, Terminal
3
27214-528
2
Terminal
4
27214-527
1
Terminal
5
27214-525
1
Terminal
6
27228-515
7
Socket, Connector
7
27216-576
3
Lug, Terminal
8
27216-564
1
Lug, Terminal
9
27214-527
2
Terminal
10
27284-202
6
Splice, Wire
11
27214-516
2
Terminal
12
27214-515
4
Terminal
13
27215-322
1
Terminal
14
27215-313
1
Terminal
15
27214-527
1
Terminal
16
27228-505
11
Connector, Pin
1
Strip
1
Pigtail, Voltage,
Regulator
17
18
29331-941
NSN
D-11
TM 10-4320-344-24
Table D-6. Parts List for Main Wiring Harness, Model 609-C.
(Continued)
Find
Number
Part or
Identifying Number
Quantity
Required
Description
NSN
19
27236-043
1
Connector
2222-22-222-2222
20
S-1790
1
Connector
21
27236-225
1
Terminal, Disconnect
22
18124-005
AR
Wire, Cable,
Electrical
23
18124-007
AR
Wire, Cable,
Electrical
24
18142-421
AR
Wire, Cable,
Electrical
25
18142-421
AR
Wire, Cable,
Electrical
26
18111-008
AR
Wire, Bus Bar
27
18142-411
AR
Wire, Cable,
Electrical
28
18149-035
AR
Wire, Cable,
Electrical
29
18763-249
AR
Tubing, Heat-Shrink
30
18763-248
AR
Tubing, Heat-Shrink
31
SN60WRAP2
AR
Solder
3439-01-036-5762
Table D-7. Main Wiring Harness Wire Run List, Model 609-C.
Wire Run
Wire
Assy
Detail
Configuration
1
From
Terminal
Find No.
To
Terminal
Find No.
Wire
Find
No.
Wire
Length
A
POS BATT
( POS )
1
SLAVE(+)
1
22
30 inches
2
A
SLAVE(+)
2
CMR(+)
2
23
64 inches
3
B
CMR(+)
3
SR (BAT)
4
24
37.5
inches
C1
4
D-12
ALT
OUTPUT
5
B
POS BATT
( POS )
3
ALT
OUTPUT
5
24
81 inches
6
c
POS BATT
( POS )
3
J10(1)
6
25
67 inches
7
A
NEG BATT
(NEG)
7
SLAVE(-)
1
22
42
8
A
SLAVE ( - )
1
TRAILER
FRAME
7
22
37 inch es
inches
I
TM 10-4320-344-24
Table D-7. Main Wiring Harness Wire Run List, Model 609-C. (Continued)
Wire Run
Wire
Assy
Detail
Configuration
9
10
Wire
Length
From
Terminal
Find No.
To
Terminal
Find No.
Wire
Find
No.
A
TRAILER
FRAME
8
CM
MOUNTING
BOLT
2
23
20.5
inches
D
NEG BATT
(NEG)
9
J10(12)
6
25
78
inches
11
D
NEG BATT
(NEG)
9
J10(15)
6
25
78
inches
12
D
NEG BATT
(NEG)
9
J10 (14)
6
25
78
inches
13
E
P2(1)
PR
(GROUND )
26
1.5
inches
P3
(BLACK)
SPLICE
10
14
23
inches
15
F
SPLICE
10
SR MTG
SCREW
11
25
54
inches
16
B
SR MTG
SCREW
11
SR (COIL)
12
25
14.5
inches
17
A
POS BATT
(NEG)
7
NEG BATT
(+)
1
22
9 inches
13
24
33.5
inches
15
25
31.5
inches
18
CMR
(LOAD)
CM
19
G
SR
(LOAD)
9
20
G
CMR
(COIL)
14
CMR
(COIL)
(CATHODE)
21
H
J10(12)
16
Jll(1)
6
27
60
inches
22
I
J11(2)
6
Jll(1)
6
27
4 inches
23
I
J11(2)
6
J11(3)
6
27
4 inches
24
P11(1)
16
BG3
25
P11(2)
16
BG4
26
P11(3)
16
BG8
27
J
J10(10)
16
OPX
12
25
51
inches
28
J
J10(11)
16
ETX
12
25
49
inches
29
K
J10(3)
16
P2(2)
17
25
71
inches
30
L
J10(6)
16
SPLICE
10
25
84
inches
D-13
TM 10-4320-344-24
Table
Wire
Assy
D-7.
Main
Wiring
Harness
Wire
Run
List,
Model
609-C.
Wire Run
Detail
Configuration
31
From
Terminal
Find No.
To
Terminal
Find No.
SPLICE
10
ALT
(YELLOW)
18
Wire
Find
‘0 “
Wire
Length
32
M
J10(8)
16
LOPS
19
25
43
inches
33
N
J10(9)
16
ETS
20
28
70
inches
34
?
ETS
21
SPLICE
10
28
120
inches
SPLICE
10
P3 (BLU)
J10(4)
16
SR (COIL)
35
36
J
23
inches
12
25
48
inches
37
J9
P4
20
inches
38
J9
P5
35
inches
D-14
TM 10-4320-344-24
Figure D-6.
Control Panel Wiring Harness Assembly, Model US636HCCD-1.
PROCEDURES:
1.
Refer to appendix F, Figure F-4, and using a multimeter, detrmine which
wire is defective.
2.
If defective wire is soldered, desolder wire from connector.
D-15
TM 10-4320-344-24
3.
Remove defective wire from wiring harness.
4.
Refer to table D-8 and cut wire from bulk.
Wire assembly numbers in table
D-8 are for information only, they are not marked on wiring harness, refer
to terminations to determine what components comprise damged wire.
5.
Strip approximately 0.250 (0.635 cm) inch of insulation from each end of
wire.
6.
Crimp or solder terminal(s) to wire.
7.
Install repaired wire in wiring harness.
Table D-8.
Parts List for Control Panel Wiring Harness Assembly, Model US636HCCD-1.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
NSN
1
MS25036-106
17
Terminal, Lug
5940-00-283-5280
2
MS25036-108
6
Terminal, Lug
5940-00-143-4780
3
MS25036-153
5
Terminal, Lug
5940-00-143-4774
4
76896
24
Terminal, Lug
5940-01-281-5104
5
MS25036-103
4
Terminal,
5940-00-143-4771
6
76895
2
Connector, Plug,
Electrical
5935-01-275-7932
7
76934
3
Terminal, Taper,
Receptacle
5940-01-275-7972
8
76935
3
Terminal, Taper, Pin
5940-01-276-3721
9
76899
1
Terminal, Spade
10
MS25036-102
2
Terminal, Lug
1
Connector for
Alternator Light
11
D-16
Lug
5940-00-204-8966
12
MIL-M-5086
/1/14/2
AR
Wire, 14 AWG
6145-01-276-1531
13
MIL-M-5086
/1/14/4
AR
Wire, 14 AWG
6145-01-237-6926
14
MIL-M-5086
/1-14-1
AR
Wire,
6145-01-237-9480
15
MIL-M-5086
/1-14-8
AR
Wire, 14 AWG
16
MIL-M-5086
/1-14-7
AR
Wire, 14 AWG
17
MIL-M-5086
/1-14-5
AR
Wire, 14 AWG
18
76884SA
AR
19
MIL-M-5086
/1-14-3
AR
Wire, 14 AWG
6145-01-239-0679
20
MIL-M-5086
/1-18-0
AR
Wire, 18 AWG
6145-01-276-7554
21
MIL-M-5086
/1-18-2
AR
Wire, 18 AWG
Wire,
14 AWG
Shielded
6145-01-237-3990
6150-01-275-2178
TM 10-4320-344-24
Table D-8.
Parts List for Control Panel Wiring Harness Assembly, Model US636HCCD-1.
Table D-9. Control Panel Wire Run List, Model US636HCCD-1.
D-17
TM 10-4320-344-24
Table D-9.
D-18
Control Panel Wire Run List, Model US636HCCD-1.
(Continued)
TM 10-4320-344-24
Figure D-7.
Main Wiring Harness Assembly, Model US636HCCD-1.
PROCEDURES:
1.
Refer to appendix F, Figure F-5, and using a multimeter, determine which
wire is defective.
2.
If defective wire is soldered, desolder wire from connector.
D-19
TM 10-4320-344-24
3.
Remove defective wire from wiring harness.
4.
Refer to table D-10 and cut wire from bulk. Wire assembly numbers in table
D-10 are for information only, they are not marked on wiring harness, refer
to terminations to determine what components comprise damaged wire.
5.
Strip approximately 0.250 (0.635 cm) inch of insulation from each end of
wire.
6.
Crimp or solder terminal(s) to wire.
7.
Install repaired wire in wiring harness.
Table D-10.
Parts List for Main Wiring Harness Assembly, Model US636HCCD-1.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
NSN
1
76930
2
Insert, Electrical
Connector
5935-01-273-7634
2
MS25036-106
11
Terminal, Lug
5940-00-283-5280
3
76019
1
Lead, Electrical,
Magnetic Pickup with
Connector
6150-01-273-7464
4
MIL-M-5086
/1-14-2
AR
Lead,
Electrical
6145-01-276-1531
5
MIL-M-5086
/1-14-4
AR
Lead, Electrical
6145-01-237-6926
6
MIL-M-5086
/1-14-1
AR
Lead, Electrical
6145-01-237-9480
7
MIL-M-5086
/1-14-0
AR
Lead,
6145-01-237-9480
8
MIL-M-5086
/1-14-7
AR
Lead, Electrical
9
MIL-M-5086
/1-14-5
AR
Lead, Electrical
Table D-11.
Electrical
6145-01-237-3990
Main Wiring Harness Wire Run List, Model US636HCCD-1.
Wire Run
Wire Length
Terminal
Find No.
Wire
Find
No.
S3-2
1
4
67.00 inches
1
A2-B
1
5
98.00 inches
TB1-3
1
S3-1
1
6
67.00 inches
A
TB1-4
1
A1-1
1
7
80.00 inches
5
A
TB1-5
1
A1-2
1
7
80.00 inches
6
B
TB1-6
1
P2-1
3
8
98.00 inches
7
B
TB1-7
1
P2-4
3
9
98.00 inches
8
TB1-8
1
M1
9
TB1-9
1
M2
Wire
Assy
Detail
Configuration
From
Terminal
Find No.
To
1
A
TB1-1
1
2
A
TB1-2
3
A
4
D-20
TM 10-4320-344-24
Table D-11.
Main Wiring Harness Run List, Model US636HCCD-1.
(continued)
Wire Run
Wire
Assy
Detail
Configuration
10
From
Terminal
Find No.
To
Terminal
Find No.
Wire
Find
Wire Length
No.
MGROUND
TB1-10
11
A
C2-2
1
ENGINE
GROUND
1
7
75.00 inches
12
A
A2-A
1
ALT
LIGHT
(+)
1
7
98.00 inches
D-21
TM 10-4320-344-24
Figure D-8. Fuel, Oil, Suction, and Discharge Hose Assemblies,
Models 609-C and US636HCCD-1.
PROCEDURES:
1.
Identify correct hose, fittings, clamps, and washers.
2.
Cut hose to proper length.
3.
Install hose on fitting.
4.
Secure hose to hose fitting with hose clamp.
5.
Insert hose and fitting assembly in banjo fitting.
6.
Install hose assembly with washers and banjo bolt or hose clamps.
Table D-12.
Parts List for Fuel, Oil, Suction, and Discharge Hose Assemblies,
Models 609-C and US636HCCD-1.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
1
111-9246
1
Bolt, Banjo
2
32056
4
Clamp, Hose
3
912900579
1
Fitting, Banjo
4
76483
2
Fitting, Hose
5
MIL-M-13444
AR
Hose, Rubber
6
111-9246
2
Washer
D-22
NSN
TM 10-4320-344-24
Figure D-9.
Brake Line Assemblies, Model 609-A.
PROCEDURES :
1.
Only tubing is manufactured.
2.
Identify correct tubing and nuts.
3.
Install nuts on end of tubing, with threaded end facing out.
4.
Using flaring tool, flare end of tubing.
5.
Install brake line assembly on trailer.
Table D-13.
Parts List for Brake Line Assemblies, Model 609-A.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
1
1620
6
Nut, Tubing
2
1617-A
1
Tubing, Steel
3
1617-B
1
Tubing, Steel
4
1617-C
1
Tubing, Steel
NSN
D-23
TM 10-4320-344-24
Figure D-10. Chain.
PROCEDURES :
1.
Cut chain to length.
Table D-14.
Parts List for Chain.
Find
Number
Part or
Identifying Number
Quantity
Required
Description
1
RRC271TY1cLASS2
AR
Chain, Welded
D-24
NSN
TM 10-4320-344-24
APPENDIX E
TORQUE LIMITS
SAE Grade Number
Quality of
Material
1 o r 2
5
6 o r 7
Indeterminate
Minimum
Commercial
Medium
Commercial
8
Best
Commercial
Capscrew Head
Markings
Head marking may vary with different manufacturers.
Capscrew Body Size
(Inches)-(Thread)
Torque
Ft Lb (N·m)
Torque
Ft Lb (N·m)
Torque
Ft Lb (N·m)
Torque
Ft Lb (N·m)
1/4
20
28
5
6
(7)
(8)
8
10
(11)
(14)
10
(14)
12
14
(16)
(19)
5/16
18
24
11
13
(15)
(18)
17
19
(23)
(26)
19
(26)
24
27
(33)
(37)
3/8
16
24
18
20
(24)
(27)
31
35
(42)
(47)
34
(46)
7/16
14
20
28
30
(38)
(41)
49
55
(66)
(75)
55
(75)
44
49
70
78
(60)
(66)
(95)
(106)
1/2
13
20
39
40
(53)
(56)
75 (102)
85 (115
85
(115)
105 (142)
120 (163)
9/16
12
18
51
55
(69)
(75)
110 (149)
120 (163)
120 (163)
155 (210)
170 (231)
5/8
11
18
83
95
(113)
(129)
150 (203)
170 (231)
167 (226)
210 (285)
240 (325)
3/4
10
16
105 (142)
115 (156)
270 (366)
295 (400)
280 (380)
375 (508)
420 (569)
7/8
9
14
160 (217)
175 (237)
395 (536)
435 (590)
440 (597)
605 (820)
675 (915)
1
8
14
235 (319)
250 (339)
590 (800)
660 (895)
660 (895)
910(1234)
990(1342)
If replacement capscrews are of a higher grade than orginally supplied, use
t o r q u e s p e c i f i c a t i o n s f o r t h a t p l a c e m e n t . This will prevent equipment damage
due to over torquing.
Always use the torque values listed above when specific torque values are
not available.
E-1/(E-2 Blank)
TM 10-4320-344-24
APPENDIX F
SCHEMATICS AND WIRING DIAGRAMS
This appendix includes schematics and/or wiring diagrams for pumping assemblies 609A, 609-c, and US636HCCD-1. Each schematic or wiring diagram will have an associated
wire run table detailing the termination points for all wires and cables used on the
pumping assemblies.
F-1
TM 10-4320-344-24
F-2
Figure F-1.
Schematic Diagram, Model 609-A
TM 10-4320-344-24
Table F-1.
Wire Run List, Model 609-A.
Wire Run
Wire Run
Wire Assy
Wire Assy
FROM
To
11
SS1
SS2
Alt
12
SS2
PR-D
AR-B
FS
13
ILS
SR
4
AR-B
SS1
14
SS2
PR-C
5
SS1
SS2
15
SS2
ILS
6
AH-G
AR-G
16
AH-+
AR-NO
7
SR
CMR
17
PR-A
Battery
8
AR-B
LOP
18
CMR-+
Battery
9
AR-B
HT
19
AM-+
SR
10
SS2
PR-B
20
CMR-+
Battery
FROM
TO
1
SS1
AM-
2
AM-
3
F-3
TM 10-4320-344-24
Figure F-2.
F-4
Control Panel Schematic Diagram, Model 609 -C.
TM 10-4320-344-24
Table F-2.
Control Panel Wire Run List, Model 609-C.
Wire Run
Wire Run
Wire R u n
To
Wire
Assy
FROM
To
OP(I)
47
S1(4)
S2 (5)
OP(S)
P10(10)
48
P10(4)
S2 (6)
26
R2
(LOAD)
ET(I)
49
S2(6)
P7(E)
TACH ( - )
27
ET(S)
P10 (11)
50
P8 (A)
S3 (2)
P10 (14)
PANEL
GROUND
28
P10(3)
EPS(13)
51
P8 (B)
S3 (3)
6
PAN-EL
GROUND
SWING
PANEL
GROUND
29
P10(6)
EPS(13)
52
P6
P9
7
SWING
PANEL
GROUND
BG7(3)
30
EPS(13)
S2(2)
53
P8
R4
8
BG7(3)
BG6(3)
31
S2(2)
TACH ( + )
54
P6
P7
9
BG6(3)
BG5(3)
32
TACH ( + )
HM(+)
10
SWING
PANEL
GROUND
HM(-)
33
EPS(20)
BG5 (2)
11
MAIN C/B
(LOAD)
34
EPS(3)
P10(8)
Wire
Assy
FROM
TO
Wire
Assy
1
P10(1)
MAIN C/B
(LOAD)
24
R1
(LOAD)
2
P12 (12)
P6(C)
25
3
P6(C)
P7(C)
4
P10(15)
5
R3
FROM
(WIPER)
12
MAIN C/B
(LOAD)
S1(2)
35
EPS(18)
BG6(2)
13
S1(2)
S1(5)
36
EPS(4)
P10(9)
14
S1(5)
BG5(1)
37
EPS(19)
BG7(2)
15
BG5(1)
BG6(1)
38
EPS(10)
EPS(6)
16
BG6(1)
BG7(1)
39
EPS(6)
P9 (B)
17
P10(2)
R3(CW)
40
EPS(6)
P6 (K)
18
R3(CW)
BG1 &
BG2
41
TACH
(SIG)
EPS(5)
19
J1 (VM)
R2
(LINE)
42
EPS(5)
P9 (A)
20
R2
R1
(LINE)
43
EPS(5)
P6 (J)
(LINE)
21
R1
(LINE)
S1(1)
44
S2(1)
P6(1)
22
S1(1)
EPS(14)
45
P6 (A)
P7 (A)
23
EPS(14)
EPS(11)
46
S2(4)
P7 (B)
F-5
TM 10-4320-344-24
Figure F-3.
F-6
Main Wiring Harness Wiring Diagram, Model 609-C.
TM 10-4320-344-24
Table F-3.
Main Wiring Harness Wire Run List, Model 609-C.
F-7
TM 10-4320-344-24
Figure F-4.
F-8
Control Panel Schematic Diagram, Model US636HCCD-1.
(Sheet 1 of 2)
TM 10-4320-344-24
Figure F-4.
Control Pared Schamatic Diagram, Model US636HCCD-1. (Sheet 2 of 2)
F-9
TM 10-4320-344-24
Table F-4.
Control Panel Wire Run List, Model US636HCCD-1.
Wire Run
Wire Assy
F-10
Wire Run
FROM
To
1
TB1-1
G5-2
2
TB1-2
3
Wire Assy
FROM
To
20
C1-3
C1-8
S1-2
21
C1-3
C1-15
TB1-3
S2-2
22
C1-4
J1-3
4
TB1-4
C2-3
23
C1-7
J1-1
5
TB1-5
C2-4
24
C1-8
J1-2
6
TB1-6
H1-1
25
C1-4
P1-3
7
TB1-7
G3-1
26
C1-14
P1-1
8
TB1-8
C2-5
27
C1-15
P1-2
9
TB1-9
C2-6
28
C2-2
G3-2
10
TB1-1o
C2-G
29
R1-1
C2-9
11
H1-2
S1-2
30
R1-2, R1-3
C2-10
12
G3-3
H1-1
31
13
S1-1
S1-3
32
C2-10
C1-16
14
S1-2
S2-1
33
C2-12
C1-17
15
S1-4
F1-1
34
16
F1-2
C1-1
35
S3-1
C1-18
17
C1-1
C2-1
36
S3-2
C1-19
18
C1-2
G3-1
37
19
C1-2
C1-G
38
C2 -G
C1-G
C1-G
S1-4
ALT LIGHT
(+)
Figure F-5.
TM 10-4320-344-24
Main Wiring Harness Wiring Diagram, Model US636HCCD-1.
F-11
TM 10-4320-344-24
Table F-5.
Main Wiring Harness Wire Run List, Model US636HCCD-1.
Wire Run
Wire Assy
F-12
Wire Run
FROM
TO
1
TB1-1
S3-2
2
TB1-2
3
Wire Assy
FROM
To
7
TB1-7
P2-4
A2-B
8
TB1-8
M1
TB1-3
S3-1
9
TB1-9
M2
4
TB1-4
A1-1
10
TB1-10
M-GROUND
5
TB1-5
A1-2
11
C2-2
ENGINE GROUND
6
TB1-6
P2-1
12
A2-A
ALT LIGHT (+)
TM 10-4320-344-24
GLOSSARY
SECTION I. ABBREVIATIONS
COMMON ABBREVIATIONS.
The common abbreviations used in this manual are in accordance with MIL-STD-12D.
SPECIAL OR UNIQUE ABBREVIATIONS.
The following is a list of abbreviations and symbols that are used in this manual
but are not listed in MIL-STD-12D.
ABBREVIATION
DEFINITION
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U I . . . .
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WOT.. . .
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AMDF .
AOAP .
AR
ATCOM
BE. . .
C . . .
CAGEC .
CL. . . .
COEI .
CPC . .
D A . .
DA Pam
DR. . .
EIR . .
ERPM .
F . . .
FIP . .
GL . . .
HD. . .
kPa . .
MAC..
mm. . . .
MOS . .
N•m . .
MTOE .
NSN . .
Pam..
PG
PMCS. .
RO
RPSTL .
SF. . . .
SL
TAMMS .
TAMMS-A
TDH . .
TMDE .
TU
TWDS .
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. . . . . . . . . . . . Army Master Data File
. . . . . . . . . . Army Oil Analysis Program
. . . . . . . . . . . . . . . Army Regulation
. U.S. Army Aviation and Troop Support Command
. . . . . . . . . . . . . . . . . . . . . Bale
. . . . . . . . . . . . . . . Degrees Celsius
. . . . Commercial and Government Entity Code
. . . . . . . . . . . . . . . . . . . . . Coil
. . . . . . . . . . . . Components of End Item
. . . . . . . Corrosion Prevention and Control
. . . . . . . . . . . . Department of the Army
. . . . . . . Department of the Army Pamphlet
. . . . . . . . . . . . . . . . . . . . . Drum
. . . . . Equipment Improvement Recommendation
. . . . . . . . Engine Revolutions Per Minute
. . . . . . . . . . . . . . Degrees Fahrenheit
. . . . . . . . . Fuel Injection Pump Assembly
. . . . . . . . . . . . . . . . . . . . Gallon
. . . . . . . . . . . . . . . . . . . Hundred
. . . . . . . . . . . . . . . . . . Kilopascal
. . . . . . . . . Maintenance Allocation Chart
. . . . . . . . . . . . . . . . . Millimeters
. . . . . . . Military Occupational Specialty
. . . . . . . . . . . . . . . . Newton Meters
. Modified Table of Organization and Equipment
. . . . . . . . . . . . National Stock Number
. . . . . . . . . . . . . . . . . . . Pamphlet
. . . . . . . . . . . . . . . . . . . Package
. . Preventive Maintenance Checks and Services
. . . . . . . . . . . . . . . . . . . . . Roll
. . . . . Repair Parts and Special Tools List
. . . . . . . . . . . . . . . . Standard Form
. . . . . . . . . . . . . . . . . . . . Spool
. . . . The Army Maintenance Management System
The Army Maintenance Management System-Aviation
. . . . . . . . . . . . . . Total Discharge Head
. . Test, Measurement, and Diagnostic Equipment
. . . . . . . . . . . . . . . . . . . . . Tube
. . . . . . . . . . Tactical Water Distribution
Equipment System Set 10-Mile Segment
. . . . . . . . . . . . . . . . . . Unit of Issue
. . . . . . . . . . . . . . . . . Unit of Measure
. . . . . . . . . . . . . . . . Wide Open Throttle
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GLOSSARY-1
TM 10-4320-344-24
SECTION II. DEFINITION OF UNUSUAL TERMS
UNUSUAL TERMS.
This section provides definitions for terms used in this manual which are not
defined in the United States Army Dictionary (AR 310-25).
The term appears on the
l e f t o f t h e h y p h e n , " - " . The definition for the term appears immediately to the
right of the hyphen, "-".
TERM
DEFINITIONS
Head
-The pressure against which a pump forces liquid,
e x p r e s s e d i n f e e t . Each pound of pressure per square
inch against which the liquid is forced is equivalent
to lifting a column of water 1 inch high square 2.31
f e e t h i g h . The head includes the height to which the
liquid must be raised plus the force required to
overcome friction losses in the pipeline or hoseline.
Suction Pressure
-As used on pump suction gauges, the negative or
positive pressure at the pump suction inlet.
It will
be negative pressure if the inlet liquid is exposed to
the atmosphere below the suction inlet (such as a
source pump taking water from a well, stream, or
lake).
It will be a positive pressure if the inlet
liquid is from an elevated source (such as a storage
tank) or an upline pump.
Total Discharge Head
-The sum of the suction pressure and the discharge
pressure expressed in feet.
GLOSSARY-2
TM 10-4320-344-24
INDEX
Subject . . . . . . . . . . . . . . . . . . . Paragraph
A
Abbreviations/Acronyms,
List of . . . . . . . . . . . . . . . . . . . 1.12
Absorber, Shock,
Maintenance, Models
609-A and 609-C . . . . . .
2.23.15
Access Cover Assembly
Maintenance, Model 609-C . . 2.12.2
Actuator, Brake,
Maintenance, Models
609-A and 609-C . . . . . . . 2.23.7
Actuator, Brake,
Maintenance, Model
US636HCCD-1 . . . . . . . . . 2.23.8
Adjustment, Fuel
Injection Pump
Assembly, Model
609-A . . . . . . . . . . . . 3.8.10
Adjustment of Equipment,
Preliminary Servicing and . . 2.6
Adjustment, Rocker Arm
(Valve), Model 609-A . . . 2.21.49
Adjustment, Rocker Arm
(Valve), Models 609-C
and US636HCCD-1 . . . . . .
2.21.50
Aid, Cold Starting,
Maintenance, Model 609-C .
2.21.10
Air Cleaner Assembly
Maintenance, Model 609-A . . 2.14.1
Air Cleaner Assembly
Maintenance, Model 609-C . . 2.14.2
Air Cleaner Assembly
Maintenance, Model
US636HCCD-1 . . . . . . . . . 2.14.3
Air Intake Assembly
Maintenance, Model 609-C . . 2.14.4
Air Intake Pipe Assembly
Maintenance, Model 609-A .
2.21.22
Air Intake Pipe Assembly
Maintenance, Model
US636HCCD-1 . . . . . . . . . 2.14.5
Air Intake System
Maintenance . . . . . . . . . . 2.14
Air Outlet Frame
Maintenance, Model
609-C . . . . . . . . . . .
2.21.35
Air Shield Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
2.21.34
Alarm Assembly, Engine,
Replacement, Model 609-A .
2.16.15
Alarm Reset Assembly,
Engine, Replacement,
Model 609-A . . . . . . . .
2.16.17
Alternator Belt
Maintenance . . . . . . .
2.21.13
Alternator Cover
Maintenance, Model
US636HCCD-1 . . . . . . . .
2.21.14
Alternator Indicator
Maintenance, Model
US636HCCD-1 . . . . . . . . .
Alternator Maintenance . . . .
Ammeter Assembly
Maintenance, Models
609-A and US636HCCD-1 . . . .
Angle Drive, Tachometer,
Maintenance, Models 609-A
and US636HCCD-1
Army Materiel, Destruction
of to Prevent Enemy Use . . .
Assembly, Access Cover,
Model 609-C, Maintenance . .
Assembly, Air Cleaner,
Model 609-A, Maintenance . .
Assembly, Air Cleaner,
Model 609-C, Maintenance . .
Assembly, Air Cleaner,
Model US636HCCD-1,
Maintenance . . . . . . . . .
Assembly, Air Intake Pipe,
Maintenance, Model 609-A . .
Assembly, Air Intake Pipe,
Maintenance, Model
US636HCCD-1 . . . . . . . . .
Assembly, Ammeter, Models
609-A and US636HDDC-1,
Maintenance . . . . . . . . .
Assembly, Base,
Maintenance, Model
609-A . . . . . . . . . . . .
Assembly, Base,
Maintenance, Models
609-C and US636HCCD-1 . . . .
Assembly, Battery Box,
Maintenance, Model 609-C . .
Assembly, Battery Cable,
Models 609-A and
US636HCCD-1, Maintenance . .
Assembly, Battery Cable,
Model 609-C, Maintenance . .
Assembly, Bulk Head Panel,
Model 609-C, Maintenance . .
Assembly, Bulk Head Panel,
Model 609-C, Maintenance . .
Assembly, Control Panel
Cover, Model 609-A,
Maintenance . . . . . . . . .
Assembly, Control Panel
Cover, Model US636HCCD-1,
Maintenance . . . . . . . . .
Assembly, Control Panel
Housing, Model 609-C,
Maintenance . . . . . . . . .
Assembly, Control Enclosure,
Maintenance, Model 609-C . .
Assembly, Control Panel,
Maintenance . . . . . . . . .
Assembly, Control Panel,
Removal and Installation,
Model 609-A . . . . . . . . .
2.6.14
2.21.16
2.16.12
2.21.45
. .
1.4
2.12.2
2.14.1
2.14.2
2.14.3
2.21.22
2.14.5
2.16.12
2.21.4
2.21.5
2.15.3
2.15.5
2.15.6
2.12.5
2.12.15
2.16.1
2.16.2
2.12.7
2.16.39
.
2.16
2.16.3
INDEX-1
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
A (Continued)
Assembly, C o n t r o l P a n e l ,
Removal and Installation,
Model 609-C . . . . . . . . . 2.16.4
Assembly, C o n t r o l P a n e l ,
Removal and Installation,
Model US636HCCD-1 . . . . . . 2.16.5
Assembly, C o n t r o l P a n e l ,
Repair . . . . . . . . . . . . 3.5
Assembly, Cooling Duct,
Model 609-C, Maintenance .
2.12.14
Assembly, Cowling,
Maintenance, Models
609-C and US636HCCD-1 . . .
2.21.40
Assembly, Crankshaft,
Maintenance, Model
609-A . . . . . . . . . . . 4 . 4 . 1 9
Assembly, Crankshaft,
Maintenance, Models
609-C and US636HCCD-1 .
.
.
. 4.4.20
Assembly, Cylinder Head
Maintenance, Model
609-A . . . . . . . . .
4.4.1
Assembly, Cylinder Head. .
Repair, Models
609-C and US636HCCD-1 . . . .
4.4.2
Assembly, Cylinder Head,
Replacement, Model 609-A
. . 3.8.19
Assembly, Cylinder Head,
Replacement, Models 609-C
and US636HCCD-1 . . . . . . . 3 . 8 . 2 0
Assembly, Door Holder,
Model 609-C, Replacement . . 2.12.1
Assembly, Door, Model
609-C, Maintenance . . . . . 2.12.3
Assembly, End Panel,
Model 609-C, Maintenance .
2.12.11
Assembly, Engine,
Maintenance, Direct
Support . . . . . . . . . . . . 3.8
Assembly, Engine,
Maintenance, General
Support . . . . . . . . . . . . 4.4
Assembly, Engine,
Maintenance, Unit . . . . . . . 2.21
Assembly, Engine Alarm,
Replacement, Model 609-A .
2.16.15
Assembly, Engine Alarm
R e s e t , Replacement,
Model 609-A . . . . . . . .
2.16.17
Assembly, Engine Coolant
Temperature Gauge
Maintenance, Model 609-A .
2.16.11
Assembly, Exhaust Pipe
Elbow, Maintenance,
Model 609-A . . . . . . . .
2.21.21
Assembly, Exhaust Pipe,
Maintenance Models
609-C and US636HCCD-1, . . . 2.13.4
Assembly, Filler Neck,
Replacement, Model
609-C . . . . . . . . . . . 2.22.1
INDEX-2
Assembly, Frame, Wheel
Mounted, Maintenance . . . . .
2.23
Assembly, Fuel Injection
Pump, Adjustment,
Model 609-A . . . . . . . . .
3.8.10
Assembly, Fuel Injection
Pump, Test, Model 609-A . . .
3.8.10
Assembly, Fuel Tank,
Maintenance . . . . . . . . . .
2.22
Assembly, Fuel Transfer
Pump, Maintenance . . . . . .
2.21.6
Assembly, Governor
Actuator, Maintenance,
Model 609-C . . . . . . . . . . 3 . 8 . 7
Assembly, Handbrake,
Maintenance . . . . . . . . . 2 . 2 3 . 1 0
Assembly, Hood
Maintenance, Model 609-A . .
2.19.1
Assembly, Hourmeter,
Model 609-C, Maintenance . . 2.16.12
Assembly, Intermediate
Bracket, Replacement . . . . . 3 . 6 . 2
Assembly, Left Rear
Quarter Panel, Model
609-C, Maintenance . . . . .
2.12.9
Assembly, Left Side Panel,
Model 609-C, Maintenance . .
2.12.8
Assembly, Limit Switch,
Model 609-A, Maintenance . .
2.15.9
Assembly, Meter,
Maintenance
2.16.12
Assembly of 600 GPM . . . . . .
Pumping Assembly
2.4.5
Assembly of Model 609-A . . . . 2.4.5.2
Assembly of Model 609-C . . . . 2 . 4 . 5 . 3
Assembly of Model
US636HCCD-1 . . . . . . . . . 2 . 4 . 5 . 4
Assembly, Oil Breather,
Replacement, Models
609-C and US636HCCD-1 . . . . 2.21.31
Assembly, Oil Drain,
Replacement . . . . . . . . . 2 . 2 1 . 3 2
Assembly, Oil Drain Tube,
Maintenance . . . . . . . . . 2 . 2 1 . 2 4
Assembly, Oil Inlet Tube,
Replacement
2.21.23
Assembly, Oil Pan,
Maintenance . . . . . . . . .
3.8.12
Assembly, Oil Pressure
Gauge Hose, Models 609-A
and US636HCCD-1,
Maintenance . . . . . . . . . 2 . 1 6 . 1 0
Assembly, Oil Pressure
Gauge, Model 609-C,
Maintenance . . . . . . . . . 2 . 1 6 . 1 2
Assembly, Oil Pump,
Maintenance, Model
609-A . . . . . . . . . . . .
3.8.13
Assembly, Oil Pump,
Maintenance, Models
609-C and US636HCCD-1 . . . . . 4.4.7
Assembly, Outlet Duct
Frame, Model 609-C,
Maintenance . . . . . . . . . 2 . 1 2 . 1 4
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
A (Continued)
Assembly, Outlet
Scoop, Model 609-C,
Maintenance . . . . . . . . . 2.12.5
Assembly, Piston and
Connecting Rod,
Maintenance, Model
609-A . . . . . . . . . . . .4.4.14
Assembly, Piston and
Connecting Rod,
Maintenance, Models
609-C and US636HCCD-1 . . . . 4.4.15
Assembly, Power
Cable, Model 609-C,
Maintenance . . . . . . . . . . 2 . 1 5 . 6
Assembly, Power
Control Cable, Model
609-A, Maintenance . . . . . . . . 2 . 1 5 . 8
Assembly, Pumping,
Lubrication . . . . . . . . . . 2.7
Assembly, Pumping,
Maintenance . . . . . . . . . . 3.6
Assembly, Pump Casing,
Repair, Models 609-A
and 609-C . . . . . . . . . .
3.6.3
Assembly, Pump Casing,
Repair, Model US636HCCD-1 . .
3.6.4
Assembly, Pump Discharge
Gauge, Models 609-A
and 609-C, Maintenance . . . 2.16.7
Assembly, Pumping,
Replacement . . . . . . . . .
3.6.1
Assembly, Pump Suction
Gauge, Models 609-A
and 609-C, Maintenance . . . 2.16.7
Assembly, Pumping,
Maintenance . . . . . . . . . . 2.18
Assembly, Pumping,
Overview . . . . . . . . . . . 1.15
Assembly, Radiator,
Direct Support . . . . . . . . 3.7
Assembly, Radiator,
Maintenance, Unit . . . . . . . 2.20
Assembly, Rear Jack,
Maintenance . . . . . . . . . 2.23.4
Assembly, Rear Panel,
Maintenance, Model
609-A . . . . . . . . . . . .2.19.2
Assembly, Right Side
Panel, Model 609-C,
Maintenance . . . . . . . . . 2.12.6
Assembly, Rocker Arm,
Maintenance, Model
609-A . . . . . . . . . . . . . 3 . 8 . 1 7
Assembly, Rocker Arm,
Maintenance, Models
609-C and US636HCCD-1 . . . . 3 . 8 . 1 8
Assembly, Shield,
Maintenance, Model
609-A . . . . . . . . . . 2 . 1 9 . 3
Assembly, Sound
Enclosure, Model
609-C, Maintenance . . . . . . 2.12
Assembly, Starter,
Replacement . . . . . .
Assembly, Support
Frame Assembly,
Model 609-C,
Maintenance . . . . . .
Assembly, Tachometer
Maintenance,
Model 609-C . . . . . .
Assembly, Top Panel,
Model 609-C,
Maintenance . . . . . .
Assembly, Tripod,
Maintenance . . . . . .
Assembly, Turbocharger,
Maintenance, Models
609-C and US636HCCD-1
Assembly, Turbocharger,
Replacement, Model
609-A . . . . . . . . .
Assembly, Water Pump,
Maintenance, Model
609-A . . . . . . . . .
Assembly, Wheel,
Replacement
Assurance, Quality . . .
Auto Defeat Cable
Maintenance, Model
609-C . . . . . . . . .
Auto Select Switch
Maintenance, Model
609-C . . . . . . . . .
Axle Maintenance . . . .
.
.
.
2.21.18
.
.
.
2.12.16
.
.
.
2.16.12
.
.
.
2.12.4
.
.
.
2.23.3
. . . .
2.21.34
. . .
2.21.33
. . .
2.21.43
.
2.23.1
. . . 1.6
.
. . .
2.16.28
. . .
. . .
2.16.18
2.23.16
B
Baffle Maintenance,
Model 609-C . . . . . . .
Base Assembly, Oil Filter
and, Replacement, Model
609-A . . . . . . . . . .
Base Assembly, Oil Filter
and , Replacement, Models
609-C and US636HCCD-1 . .
Base Assembly
Maintenance, Model
609-A . . . . . . . . . .
Base Assembly
Maintenance, Models
609-C and US636HCCD-1 . .
Base Weldment
Maintenance, Model
US636HCCD-1 . . . . . . .
Battery Box and
Cover Maintenance,
Model 609-A . . . . . . .
Battery Box and
Cover Maintenance,
Model US636HCCD-1 . . . .
Battery Box Assembly
Maintenance, Model 609-C
Battery Cable Assembly
Maintenance, Models
609-A and US636HCCD-1 . .
Battery Cable Assembly
Maintenance, Model 609-C
.
.
2.12.13
. .
2.21.26
. .
2.21.27
. .
2.21.4
. .
2.21.5
. .
2.16.40
.
.
2.15.2
. .
2.15.4
. .
2.15.3
. .
2.15.5
. .
2.15.6
INDEX-3
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
B (Continued)
B e a r i n g , I d l e r Gear
and, Maintenance,
Model 609-A . . . . . . . . .
4.4.6
Bearings, Impeller Shaft
and, Maintenance, Models
609-A and 609-C . . . . . .
3.6.8
Bearings, Impeller Shaft
and, Maintenance, Model
US636HCCD-1 . . . . . . . . .
3.6.9
Bearing, Wheel,
Maintenance . . . . . . . . . 2.23.2
Bellhousing Maintenance,
Model 609-A . . . . . . . . . . 4.4.11
Belt, Alternator
Maintenance . . . . . . . .
2.21.13
Belt Guard Maintenance,
Model 609-C . . . . . . . .
2.12.15
Bleeding, Fuel System . . . . . 2 . 2 1 . 1
Block, Engine,
Maintenance, Model
609-A . . . . . . . . . . . . 4 . 4 . 2 1
Blower, C o o l i n g A i r ,
Replacement, Models
609-C and US636HCCD-1 . . .
2.21.39
Board, Terminal,
Replacement, Model
US636HCCD-1
. . .
2.16.34
Brackets, Radiator . . .
Support, Repair,
Model 609-A . . . . . . . . . 2 . 2 0 . 5
Brake Actuator
Maintenance, Models
609-A and 609-C . . . . . . . 2 . 2 3 . 7
Brake Actuator
Maintenance, Model
US636HCCD-1 . . . . . . . . . 2 . 2 3 . 8
Brake Line Maintenance
. . . . 2.23.6
Brake Line Repair . . . . . . . 3 . 1 0 . 3
Brake Shoes Replacement . . . . 2 . 2 3 . 9
Brake System Servicing
. . . . 2.23.5
Breather Assembly, Oil,
Replacement, Models
609-C and US636HCCD-1 . . .
2.21.31
Breather Cap
Maintenance, Model
609-A . . . . . . . . . . .
2.21.46
Bulk Head Panel
Assembly Maintenance,
Model 609-C . . . . . . . . . 2 . 1 2 . 5
Bulk Head Panel
Assembly Maintenance,
Model 609-C . . . . . . . .
2.12.15
Bypass Line, Oil,
Repair, Model
US636HCCD-1 . . . . . . . .
2.21.25
C
Cable Assembly, Battery,
Maintenance, Models 609-A
and US636HCCD-1 . . . . .
INDEX-4
.
.
2.15.5
Cable Assembly, Battery,
Model 609-C, Maintenance . .
2.15.5
Cable, Manual Throttle
C o n t r o l , Replacement,
Model 609-A . . .
2.16.25
Cable Assembly, Power . - . . .
Control, Model 609-A,
Maintenance . . . . . . . . .
2.15.8
Cable, Auto Defeat,
Maintenance, Model
609-C . . . . . . . . . . . . 2 . 1 6 . 2 8
Cable, Cold Start
Aid, Replacement,
Model 609-C . . . . . . . . . 2 . 1 6 . 2 9
Cable, Fuel Rack,
Replacement, Model
609-A . . . . . . . . . . . . 2 . 1 6 . 2 7
Cable, Intervehicular,
Maintenance . . . . . . . . . 2.23.11
Cable, Manual Throttle
Control Maintenance,
Model 609-C . . . . . . . . . 2.16.26
Cable, Tachometer,
Replacement, Models
609-A and US636HCCD-1 . . . . 2.21.44
Calibration . . . . . . . . . . . . 1.3
Camshaft Maintenance,
Model 609-A . . . . . . . . .
4.4.16
Camshaft Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . . .
4.4.17
Capabilities, Features,
and Characteristics,
Equipment . . . . . . . . . .
1.14
Capacitor, Generator
Replacement, Model
609-C . . . . . . . . . . . . 2.21.15
Cap, Breather,
Maintenance, Model
609-A . . . . . . . . . . . . 2.21.46
Care, Handling, and
S a f e t y . . . . . . . . . . . . . . . . 1.10
Chains, Safety,
Maintenance . . . . . . . . .
3.10.4
Characteristics,
Capabilities, and
Features, Equipment . . . . .
1.14
Chart, Maintenance
Allocation . . . . . . . . . . . B.1
Checking Unpacked
Equipment . . . . . . . . . . . 2.4.3
Cold Start Aid Cable
Replacement, Model
609-C . . . . . . . . . . . . 2 . 1 6 . 2 9
Cold Starting Aid
Maintenance, Model
609-C . . . . . . . . . . . . 2 . 2 1 . 1 0
Common Tools and
Equipment, Direct
Support . . . . . . . . . . . . . 3.1
Common Tools and
Equipment, General
Support . . . . . . . . . . . . . 4 . 1
TM 10-4320-344-24
Subject . . . . . . . . . . . Pararagraph
C (Continued)
Common Tools and
Equipment, Unit . . . . .
Components, Description
and Location of . . . . .
Connecting Rod and
Piston, Assembly
Maintenance, Model
609-A . . . . . . . . . .
Connecting Rod and
Piston Assembly,
Maintenance, Models
609-C and US636HCCD-1 . .
Control Enclosure
Assembly Maintenance,
Model 609-C . . . . . . .
Control Module Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . .
Control Panel
Maintenance, Model
609-A . . . . . . . . . .
Control Panel
Assembly Maintenance . .
Control Panel Assembly
Removal and Installation,
Model 609-A . . . . . . .
Control Panel Assembly
Removal and Installation,
Model 609-C . . . . . . .
Control Panel Assembly
Removal and Installation,
Model US636HCCD-1 . . . .
Control Panel Assembly
Repair . . . . . . . .
Control Panel Assembly
Wiring Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . .
Control Panel Cover
Assembly Maintenance,
Model 609-A . . . . . . .
Control Panel Cover
Assembly Maintenance,
Model US636HCCD-1 . . . .
Control Panel Frame
Maintenance, Model
609-A . . . . . . . . . .
Control Panel Housing
Assembly Maintenance,
Model 669-C . . . . . . .
C o n t r o l P a n e l Lights
Maintenance, Model
609-C . . . . . . . . . .
Control Panel
Maintenance, Model
US636HCCD-1 . . . . . . .
Cooler, Oil, Replacement,
Model 609-A . . . . . . .
C o o l e r , Oil, Replacement,
Model 609-C . . . . . . .
Cooler, Oil, Replacement,
Model US636HCCD-1 . . . .
.
. .
.
.
2.1
1.14.2
. . 4.4.14
.
. 4.4.15
.
2.16.39
.
2.16.31
.
2.16.36
.
. . 2.16
. .2.16.3
.
.2 . 1 6 . 4
.
.2.16.5
.
. .
.
.
.
.
3.5
. 2.16.6
.2.16.1
2.16.2
2.16.38
. . 2.12.7
.
2.16.24
.
2.16.37
.
2.21.28
.
2.21.29
.
2.21.30
Cooling Air Blower
Replacement, Models
609-C and US636HCCD-1
Cooling Duct Assembly
Maintenance, Model
609-C . . . . . . . .
Cooling System
Hoses Maintenance,
Model 609-A . . . . .
Corrosion Prevention
and Control . . . . .
Coupling Assembly,
Flexible, Repair,
Model 609-A . . . . .
Coupling, Flexible,
Repair, Models 609-C
and US636HCCD-1 . . .
Cover, Alternator
Maintenance, Model
US636HCCD-1 . . . . .
Cover and Battery Box,
Model 609-A,
Maintenance . . . . .
Cover and Battery Box,
Model US636HCCD-1,
Maintenance . . . . .
Cover, Flywheel,
Maintenance, Model
609-C and US636HCCD-1
Cover, Front, Crankcase
Maintenance, Models
609-C and US636HCCD-1
Cover, Gear Housing,
Maintenance, Model
609-A . . . . . . . .
Cowling Assembly
Maintenance, Models
609-C and US636HCCD-1
Crankcase Front Cover
Maintenance, Models
609-C and US636HCCD-1
Crankcase Maintenance,
Models 609-C and
US636HCCD-1 . . . . .
Crankcase Rear Cover
Maintenance, Models
609-C and US636HCCD-1
Crankshaft Assembly
Maintenance, Model
609-A . . . . . . . .
Crankshaft Assembly
Maintenance, Models
609-C and US636HCCD-1
Crankshaft Pulley
Replacement, Model
609-A . . . . . . . .
Crankshaft Pulley
Replacement, Models
609-C and US636HCCD-1
Cross-Reference,
Nomenclature, List
Cylinder Head Assembly.
Maintenance, Model
609-A . . . . . . . .
. . . .
2.21.39
.
. .
2.12.14
. . . .
2.20.2
. . . . .
1.11
. . . .
.
3.6.5
. . . .
.
3.6.6
. . . .
2.21.14
. . . .
2.15.2
. . . .
2.15.4
. . . .
4.4.12
. . . .
.
4.4.5
. . . .
.
4.4.4
. . . .
2.21.40
. . . .
.
4.4.5
. . . .
4.4.22
. . . .
4.4.13
. . . .
4.4.19
. . . .
4.4.20
. . . .
3.8.21
. . . .
3.8.22
. . . .
. .
. . . .
.
1.7
4.4.1
INDEX-5
TM 10-4320-344-24
Subject
.
.
.
. . . . . . .
Paragraph
C (Continued)
Cylinder Head Assembly
Repair, Models 609-C
and US636HCCD-1
. .
Cylinder Head Assembly
Replacement, Model 609-A
. .
Cylinder Head Assembly
Replacement, Models 609-C
and US636HCCD-1 . . . . . . .
Cylinder Head Cover
Maintenance, Model
609-A . . . . . . . . . . .
Cylinder Head Cover
Maintenance, Models
609-C and US636HCCD-1 . . .
Cylinder Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . . .
. .
Cylinder, Master,
Maintenance . . . . . . . . .
Cylinder, Wheel,
Replacement . . . . . . . . .
4.4.2
3.8.19
3.8.20
2.21.47
2.21.48
4.4.3
2.23.6
2.23.9
D
Damper, Vibration,
Replacement, Model
609-A . . . . . . . . . . . . 3.8.21
Damper, Vibration,
Replacement, Models
609-C and US636HCCD-1 . . . . 3.8.22
Data Plate
Replacement . . . . . . . . . 2.11.1
Description and
Location of
Components . . . . . . . . . 1.14.2
Destruction of Army
Materiel to
Prevent Enemy Use . . . . . . . 1.4
D e v i c e , Process
C o n t r o l , Maintenance,
Model US636HCCD-1 . . . . .
2.16.33
Direct Support, Common
Tools and Equipment . . . . . . 3.1
Direct Support, Repair Parts . . 3.3
Direct Support, Troubleshooting . 3.4
Discharge Elbow
Replacement . . . . . . . . . 2.18.2
Discharge Gauge
Assembly, Maintenance,
Models 609-A and 609-C . . . 2.16.7
Door Assembly Maintenance,
Model 609-C . . . . . . . . . 2.12.3
Door Holder Assembly
Replacement, Model 609-C . . 2.12.1
Drain Assembly, Oil
Replacement . . . . . . . .
2.21.32
Drain Plug Maintenance,
Model 609-C . . . . . . . . . 2.18.1
Durable Items, Expendable
and, List . . . . . . . . . . . C.1
INDEX-6
E
Elbow, Discharge,
Replacement . . . . . . .
Elbow, Suction,
Replacement . . . . . . .
Electrical Connector
Receptacle Maintenance,
Model 609-C . . . . . . .
Electrical System
Maintenance . . . . . . .
End Panel Assembly
Maintenance, Model
609-C . . . . . . . . . .
Engine Alarm Assembly
Replacement, Model
609-A . . . . . . . . . .
Engine Alarm Reset
Assembly, Replacement,
Model 609-A . . . . . . .
Engine Assembly
Maintenance, Direct
Support . . . . . . . . .
Engine Assembly
Maintenance, General
Support . . . . . . . . .
Engine Assembly
Maintenance, Unit . . . .
Engine Block Maintenance,
Model 609-A . . . . . . .
Engine Coolant
Temperature Gauge
Assembly Maintenance,
Model 609-A . . . . . . .
Engine High
Temperature Indicator
Maintenance, Model 609-C
Engine Low Oil
Indicator Maintenance,
Model 609-C . . . . . . .
Engine Mount Isolators
Replacement, Model
609-C . . . . . . . . . .
Engine Overspeed
Indicator Maintenance,
Model 609-C . . . . . . .
Engine Protection
System Module
Maintenance, Model
609-C . . . . . . . . . .
Engine Replacement . . . .
Engine Support
Replacement, Models
609-C and US636HCCD-1 . .
Engine Switch
Replacement, Model
609-C . . . . . . . . . .
Engine Switch
Maintenance, Models
609-A and 609-C . . . . .
Engine Temperature
Gauge Assembly,
Maintenance, Model
609-C . . . . . . . . . .
.
.
2.18.2
.
.
2.18.2
. .
2.15.7
.
2.15
. .
2.12.11
. .
2.16.15
. .
2.16.17
.
.
. .
3.8
.
.
. .
4.4
.
.
.
.
2.21
. .
4.4.21
. .
2.16.11
. .
2.16.14
. .
2.16.14
. .
.
3.8.4
2.6.14
. .
. .
. .
.
2.16.31
3.8.1
. .
.
3.8.3
. .
2.21.20
. .
2.16.18
. .
2.16.12
TM 10-4320-344-24
Subject . . . . . . . . . . . . . . . . . . Paragraph
E (Continued)
Engine Temperature
Switch Replacement,
2.21.20
Model 609-C . . . . . . . .
Engine Temperature
Transmitter Replacement,
2.21.20
Model 609-C . . . . . . . .
Engine Transmitter
Replacement, Model
2.21.20
609-C . . . . . . . . . . .
Engine Wiring
Harness Maintenance . . . . . . 2.17
Equipment and Common
Tools, Direct Support . . . . . 3.1
Equipment and Common
Tools, General Support . . . . 4.1
Equipment and Common
Tools, Unit . . . . . . . . . . 2.1
Equipment Characteristics,
Capabilities, and
Features . . . . . . . . . . . 1.14
Equipment, Checking
2.4.3
Unpacked . . . . . . . . . .
Equipment Improvement,
Reporting
Recommendations . . . . . . . . 1.8
Equipment, Processing
2.4.4
Unpacked . . . . . . . . .
Exhaust Manifold
Maintenance, Model
609-A . . . . . . . . . . . . . . . . . 2 . 2 1 . 3 6
Exhaust Manifold
Pipes Maintenance,
Models 609-C and
2.21.37
US636HCCD-1 . . . . . . . .
Exhaust Pipe Assembly
Maintenance, Models
609-C and US636HCCD-1 . . . . 2.13.4
Exhaust Pipe Elbow
Assembly Maintenance,
2.21.21
Model 609-A . . . . . . . .
Exhaust System
Maintenance . . . . . . . . . . 2.13
Exhaust Valve
Maintenance, Model
4.4.1
609-A . . . . . . . . . . . .
Exhaust Valve Repair,
Models 609-C and
US636HCCD-1 . . . . . . . . . . . . . 4.4.2
Expendable and Durable
Items List . . . . . . . . . . C.1
F
Fan Replacement,
2.21.42
Model 609-A . . . . . . . .
Fan Shroud Replacement,
Model 609-A . . . . . . . . . 2.20.4
Features, Characteristics,
and Capabilities,
Equipment . . . . . . . . . . 1.14
Filler Neck Assembly
Replacement, Model
609-C . . . . . . . . . . .
Filter, Fuel, Maintenance,
Model 609-A . . . . . . . .
Filter, Fuel, Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
Flexible Coupling Assembly
Repair, Model 609-A . . . .
Flexible Coupling Repair,
Models 609-C and
US636HCCD-1 . . . . . . . .
Flywheel Maintenance,
Model 609-A . . . . . . . .
Flywheel Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
Flywheel Cover
Maintenance, Models
609-C and US636HCCD-1 . . .
Forklift Pocket Maintenance,
Model 609-C . . . . . . . .
Forms, Records, and
Reports, Maintenance . . .
Frame, Air Outlet,
Maintenance, Model
609-C . . . . . . . . . . .
Frame Assembly, Wheel
Mounted, Direct Support . .
Frame Assembly, Wheel
Mounted, Maintenance,
Direct Support . . . . . .
Frame Assembly, Wheel
Mounted, Maintenance,
Unit . . . . . . . . . . .
Frame Assembly, Wheel
Mounted, Repair,
Direct Support . . . . . .
Front Engine Support
Replacement, Model
609-A . . . . . . . . . . .
Fuel Filter Maintenance,
Model 609-A . . . . . . . .
Fuel Filter Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
Fuel Injection Lines
Maintenance . . . . . . . .
Fuel Injection Nozzle
and Holder Assembly
Maintenance, Model 609-A .
Fuel Injection Nozzle
Maintenance, Models
609-C and US636HCCD-1 . . .
Fuel Injection Pump
Assembly Adjustment,
Model 609-A . . . . . . . .
Fuel Injection Pump
Assembly Maintenance,
Model 609-A . . . . . . . .
Fuel Injection Pump
Assembly Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
.
2.22.1
.
2.21.4
.
2.21.5
.
.
3.6.5
.
.
3.6.6
.
.
4.4.9
.
4.4.10
.
4.4.12
.
2.23.17
.
. .
.
2.21.35
.
.
1.2
3.10
.
3.10.1
.
2.23
.
3.10.2
.
3.8.2
.
2.21.4
.
2.21.5
.
2.21.7
.
2.21.8
.
2.21.9
.
3.8.10
.
3.8.9
.
3.8.11
INDEX-7
TM 10-4320-344-24
Subject . . . . . . . . . . . . . . . Paragraph
F (Continued)
F u e l I n j e c t i o n Pump
Assembly Test, Model
609-A . . . . . . . . . .
Fuel Leakoff Manifold
Assembly Maintenance . . .
Fuel Line Hoses and
Fittings Maintenance . . .
Fuel Rack Cable
Replacement, Model
609-A . . . . . . . . . . .
Fuel Solenoid
Replacement, Model
609-C . . . . . . . . . .
Fuel System Bleeding . . . .
Fuel Tank Maintenance, Unit .
Fuel Tank Maintenance,
Direct Support . . . . .
Fuel Tank Assembly.
Maintenance, Unit . . . . .
Fuel Tank Repair . . . . . .
Fuel Transfer Pump
Assembly Maintenance . . .
Fuse Holder Replacement,
Model US636HCCD-1 . . . . .
.
.3.8.10
. 2.21.7
. 2.21.2
2.16.27
. .2.21.3
. 2.21.1
. 2.22.2
.
.
.
.
.
3.9
2.22
3.9.1
. 2.21.6
2.16.21
G
Gauge Assembly, Engine
Temperature, Maintenance,
Model 609-C . . . . . . .
Gauge Assembly, Oil
Pressure, Model 609-C,
Maintenance . . . . . . .
Gauge Assembly, Pump
Discharge, Models
609-A and 609-C,
Maintenance . . . . . . .
Gauge Assembly, Pump
Suction, Models
609-A and 609-C,
Maintenance . . . . . . .
Gauge, Oil Pressure,
Models 609-A and
US636HCCD-1,
Maintenance . . . . . . .
Gauge, Pump Discharge,
Model US636HCCD-1,
Maintenance . . . . . . .
Gauge, Pump Suction,
Model US636HCCD-1,
Maintenance . . . . . . .
Gear Housing Cover
Maintenance, Model
609-A . . . . . . . . . .
Gear Housing
Maintenance, Model
609-A . . . . . . . . .
Gear, I d l e r ,
Maintenance, Models
609-C and US636HCCD-1 . .
INDEX-8
.
2.16.12
.
2.16.12
.
.
.
.
.
2.16.7
2.16.7
2.16.10
.
.
.
.
. .
.
. .
2.16.8
2.16.8
4.4.4
.
.4.4.18
4.4.8
General Maintenance
Procedures . . . . . .
General Support, Common
Tools and Equipment . .
General Support, Repair
Parts . . . . . . . . .
Generator Capacitor
Replacement, Model
609-C . . . . . . . . .
Glossary . . . . . . . .
Governor Actuator
Assembly Maintenance,
Model 609-C . . . . . .
Governor Maintenance,
Model 609-A . . . . . .
Governor Maintenance,
Model US636HCCD-1 . . .
Governor Control
Module Maintenance,
Model 609-C . . . . . .
Guard, V-Belt, and
Mounting Supports, Model
US636HCCD-1 . . . . . .
.
.
.
.
.
.
.
. .
4.1
.
.
. . .
4.3
. . .
. . .
.
. . .
2.11
2.21.15
1.13
3.8.7
. . .
.
3.8.6
. . .
.
3.8.8
. . .
2.16.32
. . .
2.21.11
H
Handbrake Assembly
Maintenance . . . . . . .
Handling, Safety,
and Care . . . . . . . .
Harness, Engine
Wiring, Maintenance . . .
High Temperature,
Engine, I n d i c a t o r
Maintenance, Model
609-C . . . . . . . . . .
Holder, Fuse,
Replacement, Model
US636HCCD-1 . . . . . . .
Hood Assembly
Maintenance, Model 609-A
Horn Replacement, Model
US636HCCD-1 . . . . . . .
Hose Assembly, Oil
Pressure Gauge,
Maintenance, Models
609-A and US636HCCD-1 . .
Hose Assembly,
Pressure Gauge,
Maintenance . . . . . . .
Hoses, Cooling System,
Maintenance, Model
609-A . . . . . . . . . .
Hoses and Fittings,
Fuel Line, Maintenance .
Hoses and Fittings, Oil
Line, Maintenance . . . .
Hourmeter Assembly
Maintenance, Models
609-A and US636HCCD-1 . .
Hourmeter Assembly,
Maintenance, Model
609-C . . . . . . . . . .
Housing, Gear,
Maintenance, Model
609-A . . . . . . . . . .
.
.
.
.
.
.
.
.
2.23.10
1.10
2.17
. .
2.16.14
. .
2.16.21
. .
2.19.1
. .
2.16.16
. .
2.16.10
.
2.16.35
. .
2.20.2
. .
2.21.2
.
.
2.21.2
. .
2.16.13
. .
2.16.12
. .
4.4.18
.
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
H (Continued)
Hub
Maintenance
.
.
.
.
.
.
.
.
2.23.2
I
Idler Gear and Bearing
Maintenance, Model
609-A . . . . . . . . . .
Idler Gear Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . .
Impeller Maintenance . . .
Impeller Shaft and
Bearings Maintenance,
Models 609-A and 609-C .
Impeller Shaft and
Bearings Maintenance,
Model US636HCCD-1 . . .
Improvement, Equipment,
Reporting Recommendations
Indicator, Alternator,
Maintenance, Model
US636HCCD-1 . . . . . . .
I n d i c a t o r , Engine High
Temperature, Maintenance,
Model 609-C . . . . . . .
Indicator, Engine Low
Oil, Maintenance,
Model 609-C . . . . . . .
Indicator, Engine
Overspeed, Maintenance,
Model 609-C . . . . . . .
Indicator Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . .
Information, Warranty . . .
Installation Instructions .
Installation of:
Control Panel Assembly,
Model 609-A . . . . . .
Control Panel Assembly,
Model 609-C . . . . . .
Control Panel Assembly,
Model US636HCCD-1 . . .
Intake Manifold
Maintenance, Model
609-A . . . . . . . . . .
Intake Manifold
Maintenance, Models
609-C and US636HCCD-1 . .
Intake Valve
Maintenance, Model
609-A . . . . . . . . . .
Intake Valve Repair,
Models 609-C and
US636HCCD-1 . . . . . . .
Intermediate Bracket
Assembly Replacement . .
Intervehicular Cable
Maintenance . . . . . . .
I s o l a t o r s , Engine Mount,
Replacement, Model 609-C
Isolators, Pump Mount,
Replacement, Model
609-C . . . . . . . .
. .
.
.
3.6.10
Jack, Tongue, Maintenance . . .
2.23.3
J
L
. .
4.4.6
.
.
.
.
4.4.8
3.6.7
.
.
3.6.8
.
3.6.9
.
. .
1.8
.
2.6.14
.
2.16.14
.
2.16.14
. .
2.6.14
.
2.16.14
. . .
1.9
. . .
2.5
.
. 2.16.3
. . 2.16.4
.
.
M
.
2.21.36
.
.
2.16.5
2.21.38
.
4.4.1
.
.
4.4.2
.
.
3.6.2
.
.
Left Rear Quarter Panel
Assembly Maintenance,
2.12.9
Model 609-C . . . . . . . . .
Left Side Panel
Assembly Maintenance,
Model 609-C . . . . . . . . .
2.12.8
Lights, Control Panel,
Maintenance, Model
609-C . . . . . . . . . . . . 2 . 1 6 . 2 4
Lights, Service, Model
609-C, Maintenance . . . . .
2.15.1
. . . 2.23.13
Lights Maintenance
Limit Switch Assembly
Maintenance, Model
609-A . . . . . . . . . . . .
2.15.9
Line, Brake,
2.23.6
Maintenance . . . . . . . . .
Line, Brake, Repair . . . . . .
3.10.3
Lines, Fuel Injection,
2.21.7
Maintenance . . . . . . . . .
List, Nomenclature
Cross-Reference . . . . . . . . . 1.7
List of Abbreviations/
1.12
Acronyms . . . . . . . . . . .
Location and
Description of
Components . . . . . . . . . 1 . 1 4 . 2
Location and Siting . . . . . . . 2.4.1
Low Oil Indicator,
Engine, Maintenance,
Model 609-C . . . . . . . . . 2.16.14
Low Oil Pressure
Cutoff Switch
Test, Model
2.16.9
US636HCCD-1 . . . . . . . . .
Lubrication,
Pumping Assembly . . . . . . . . 2 . 7
2.23.11
.
Magnetic Pickup
Replacement . . . . . .
Main Power Switch
Maintenance, Model
609-C . . . . . . . . .
Maintenance Allocation
Chart . . . . . . . . .
Maintenance Forms,
Records, and Reports .
Maintenance of:
Access Cover Assembly,
Model 609-C . . . . .
Air Cleaner Assembly,
Model 609-A . . . . .
.
.
.
.
3.8.5
. . .
2.16.18
.
.
.
. .
B.1
.
.
. .
1.2
.
.
.
2.12.2
.
.
.
2.14.1
.
3.8.4
INDEX-9
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
M (Continued)
Maintenance of: (continued)
Air Cleaner Assembly,
Model 609-C . . . . . . .
Air Cleaner Assembly,
Model US636HCCD-1 . . . .
Air Intake Assembly,
Model 609-C . . . . . . .
Air Intake Pipe
Assembly, M o d e l 6 0 9 - A . .
Air Intake Pipe
Assembly Maintenance,
Model US636HCCD-1 . . . .
Air Intake System . . . . .
Air Outlet Frame,
Model 609-C . . . . . . .
Air Shield, Models
609-C and
US636HCCD-1 . . . . . . .
Alternator
.
.
. . . . . .
Alternator Belt . . . . . .
Alternator Cover.
Model US636HCCD-1 . . . .
Alternator Indicator,
Model US636HCCD-1 . . . .
Ammeter Assembly,
Models 609-A and
US636HCCD-1 . . . . . . .
Auto Defeat Cable,
Model 609-C . . . . . . .
Auto Select Switch,
Model 609-C . . . . . . .
Axle . . . . . . . . . . .
Baffle, Model 609-C . . . .
Base Assembly,
Model 609-A . . . . . . .
Base Assembly,
Models 609-C and
US636HCCD-1 . . . . . . .
Base Weldment, Model
US636HCCD-1 . . . . . . .
Battery Box and Cover,
Model 609-A . . . . . . .
Battery Box and Cover,
Model US636HCCD-1 . . . .
Battery Box Assembly,
Model 609-C . . . . . . .
Battery Cable Assembly,
Models 609-A and
US636HCCD-1 . . . . . . .
Battery Cable Assembly,
Model 609-C . . . . . . .
Bellhousing, Model
609-A . . . . . . . . . .
Belt Guard, Model 609-C . .
Brake Actuator, Models
609-A and 609-C . . . . .
Brake Actuator, Model
US636HCCD-1 . . . . . . .
Brake Line . . . . . . .
Breather Cap, Model
609-A . . . . . . . . . .
INDEX-10
.
2.14.2
. 2.14.3
.
2.14.4
2.21.22
. 2.14.5
. . 2.14
2.21.35
2.21.34
2.21.16
2.21.13
2.21.14
. 2.6.14
2.16.12
2.16.28
2.16.18
2.23.16
2.12.13
.
2.21.4
.
2.21.5
2.16.40
.
2.15.2
. 2.15.4
.
2.15.3
.
2.15.5
.
2.15.6
.
4.4.11
2.12.15
.
2.23.7
.
.
2.23.8
2.23.6
2.21.46
Bulk Head Panel Assembly,
Model 609-C . . . . . . . .
2.12.5
Bulk Head Panel Assembly,
Model 609-C
2.12.15
Camshaft, Model 609-A . . . . .
4.4.16
Camshaft, Models 609-C
and US636HCCD-1 . . . . . .
4.4.17
Cold Starting Aid,
Model 609-C . . . . . . . . 2.21.10
C o n t r o l Enclosure Assembly,
Model 609-C . . . . . . . . 2.16.39
C o n t r o l Module, Models
609-C and US636HCCD-1 . . . 2 . 1 6 . 3 1
C o n t r o l Panel, Model
609-A . . . . . . . . . . . 2 . 1 6 . 3 6
C o n t r o l Panel Assembly . . . .
2.16
C o n t r o l Panel Assembly
Wiring, Models 609-C
and US636HCCD-1 . . . . . .
2.16.6
Control Panel Cover,
Model 609-A . . . . . . . .
2.16.1
Control Panel Cover,
Model US636HCCD-1 . . . . .
2.16.2
Control Panel Frame,
Model 609-A . . . . . . . . 2.16.38
Control Panel Housing,
Model 609-C . . . . . . . .
2.12.7
Control Panel Lights,
Model 609-C . . . . . . . . 2 . 1 6 . 2 4
Control Panel, Model
US636HCCD-1 . . . . . . . . 2 . 1 6 . 3 7
Cooling Duct Assembly,
Model 609-C . . . . . . . . 2 . 1 2 . 1 4
Cooling System Hoses
Maintenance, Model
609-A . . . . . . . . . . .
2.20.2
Cowling Assembly,
Models 609-C and
US636HCCD-1 . . . . . . . . 2.21.40
Crankcase Front Cover,
Models 609-C and
US636HCCD-1 . . . . . . . . . 4 . 4 . 5
Crankcase, Models
609-C and
US636HCCD-1 . . . . . . . .
4.4.22
Crankcase Rear Cover,
Models 609-C and
US636HCCD-1 . . . . . . . .
4.4.13
Crankshaft Assembly,
Model 609-A . . . . . . . .
4.4.19
Crankshaft Assembly,
Models 609-C and
US636HCCD-1 . . . . . . . . . .
4.4.20
Cylinder Head Assembly
Model 609-A . . . . . . . . . 4 . 4 . 1
Cylinder Head Cover,
Model 609-A . . . . . . . . 2 . 2 1 . 4 7
Cylinder Head Cover,
Models 609-C and
US636HCCD-1
2.21.48
Cylinder, Models 609-C
and US636HCCD-1 . . . . . . . 4.4.3
Door Assembly, Model
609-C . . . . . . . . . . .
2.12.3
Drain Plug, Model
609-C . . . . . . . . . . .
2.18.1
TM 10-4320-344-24
Subject . . . . . . . . . . . . . . Paragraph
M (Continued)
Maintenance of: (continued)
Electrical Connector
Receptacle, Model
609-C . . . . . . . . . . . 2.15.7
Electrical System . . . . . . . 2.15
End Panel Assembly,
2.12.11
Model 609-C . . . . . . .
Engine Assembly,
Direct Support . . . . . . . 3.8
Engine Assembly,
Unit . . . . . . . . . . . . 2.21
Engine Block, Model
609-A . . . . . . . . . . . 4.4.21
Engine Coolant
Temperature Gauge
Assembly, Models
2.16.11
609-A . . . . . . . . . .
Engine High Temperature
Indicator, Model
2.16.14
609-C . . . . . . . . . .
Engine Low Oil
Indicator, Model
2.16.14
609-C . . . . . . . . . .
Engine Overspeed
Indicator, Model
609-C . . . . . . . . . . .2.6.14
Engine Protection
System Module,
2.16.31
Model 609-C . . . . . . .
Engine Switch, Models
2.16.18
609-A and 609-C . . . . .
Engine Temperature
Gauge Assembly,
2.16.12
Model 609-C . . . . . . .
Engine Wiring Harness . . . . . 2.17
Exhaust Manifold,
2.21.36
Model 609-A . . . . . . .
Exhaust Manifold Pipes,
Models 609-C and
2.21.37
US636HCCD-1 . . . . . . .
Exhaust Pipe Assembly,
Models 609-C and
US636HCCD-1 . . . . . . . . 2.13.4
Exhaust Pipe Elbow
2.21.21
Assembly, Model 609-A . .
. . . . . . . . . . . . . 2.13
Exhaust System
Exhaust Valve, Model
4.4.1
609-A . . . . . . . . . . .
Flywheel Cover, Models
609-C and US636HCCD-1 . . . 4.4.12
4.4.9
Flywheel, Model 609-A . . . .
Flywheel, Models 609-C
and US636HCCD-1 . . . . . . 4.4.10
Forklift Pocket,
2.23.17
Model 609-C . . . . . . .
Fuel Filter, Model
609-A . . . . . . . . . . 2 . 2 1 . 4
Fuel Filter, Models
609-C and
US636HCCD-1 . . . . . . . 2 . 2 1 . 5
Fuel Injection Lines . . . . 2.21.7
Fuel Injection Nozzle
and Holder Assembly,
Model 609-A . . . . .
Fuel Injection Nozzle,
Models 609-C and
US636HCCD-1 . . . . .
Fuel Injection Pump
Assembly, Model
609-A . . . . . . . .
Fuel Injection Pump
Assembly, Models
609-C and
US636HCCD-1 . . . . .
Fuel Leakoff
Manifold Assembly . .
Fuel Line Hoses and
Fittings . . . . . .
Fuel Tank Assembly . .
Fuel Tank, Direct
Support . . . . . . .
Fuel Tank, Unit . . . .
Fuel Transfer Pump
Assembly . . . . . .
Gear Housing,
Model 609-A . . . . .
Gear Housing Cover,
Model 609-A . . . . .
Governor Actuator
Assembly, Model
609-C . . . . . . . .
Governor Control Module,
Model 609-C . . . . .
Governor, Model
609-A . . . . . . . .
Governor, Model
US636HCCD-1 . . . . .
Handbrake Assembly . .
Hood Assembly,
Model 609-A . . . . .
Hourmeter Assembly,
Models 609-A and
US636HCCD-1 . . . . .
Hourmeter Assembly,
Model 609-C . . . . .
Hub . . . . . . . . . .
Idler Gear and Bearing
Maintenance, Model
609-A . . . . . . . .
Idler Gear, Models
609-C and US636HCCD-1
Impeller . . . . . . .
Impeller Shaft and
Bearings, Models
609-A and 609-C . . .
Impeller Shaft and
Bearings, Model
US636HCCD-1 . . . . .
Indicators, Models
609-C and US636HCCD-1
Intake Valve, Model
609-A . . . . . . . .
Intake Manifold, Model
609-A . . . . . . . .
Intake Manifold, Models
609-C and US636HCCD-1
Intervehicular Cable . .
. . .
2.21.8
. . .
2.21.9
. . .
.
3.8.9
. . .
3.8.11
. . .
2.21.7
. . .
. . .
2.21.2
2.22
. . .
. . .
. . 3.9
2.22.2
. . .
2.21.6
. . .
4.4.18
. . .
.
4.4.4
. . .
3.8.7
. . .
2.16.32
. . .
.
. . .
. . .
3.8.8
2.23.10
. . .
2.19.1
. . .
2.16.13
. . .
. . .
2.16.12
2.23.2
. . .
.
4.4.6
. . .
. . .
.
.
4.4.8
3.6.7
. . .
.
3.6.8
. . .
.
3.6.9
. . .
2.16.14
. . .
3.8.6
.
4.4.1
. . .
2.21.36
. . .
. . .
2.21.38
2.23.11
INDEX-11
TM 10-4320-344-24
Subject
. . . . . . . . . . . . . Paragraph
M (Continued)
Maintenance of: (continued)
Left Rear Quarter Panel
Assembly, M o d e l 6 0 9 - C . .
Left Side Panel
Assembly, Model 609-C . .
Lights . . . . . . . . . .
Limit Switch Assembly,
Model 609-A . . . . . .
Main Power Switch,
Model 609-C . . . . . .
Manual Throttle
Control Cable,
Model 609-C . . . . . . .
Master Cylinder . . . . . .
Meters . . . . . . . . . .
Mode Switch, Models
609-A and US636HCCD-1 . .
M u f f l e r , M o d e l 609-A . . .
M u f f l e r , M o d e l 609-C . . .
Muffler, Model
US636HCCD-1 . . . . . . .
Oil Drain Tube
Assembly . . . . . . . .
Oil Line Hoses and
Fittings . . . . . . . .
Oil Pan Assembly
O i l P i p e , Models 609-C . . .
and US636HCCD-1 . . . . .
Oil Pressure Gauge
Assembly, Model
609-C . . . . . . . . . .
Oil Pressure Gauge,
Models 609-A and
US636HCCD-1 . . . . . . .
Oil Pressure Gauge
Hose Assembly,
Models 609-A and
US636HCCD-1 . . . . . . .
Oil Pump Assembly,
Model 609-A . . . . . . .
Oil Pump Assembly,
Models 609-C and
US636HCCD-1 . . . . . . .
Outlet Duct Frame
Assembly, Model
609-C . . . . . . . . . .
Outlet Scoop Assembly,
Model 609-C . . . . . . .
Piston and Connecting
Rod Assembly, Model
609-A . . . . . . . . .
Piston and Connecting
Rod Assembly, Models
609-C and US636HCCD-1 . .
Power Cable Assembly,
Model 609-C . . . . . . .
Power Control Cable
Assembly, Model
609-A . . . . . . . . . .
Pressure Control Module,
609-C . . . . . . . . . .
INDEX-12
. 2.12.9
. 2.12.8
2.23.13
.
2.15.9
2.16.18
2.16.26
. 2.23.6
2.16.12
2.16.18
. 2.13.1
. 2.13.2
. 2.13.3
2.21.24
. 2.21.2
3.8.12
.
.
4.4.7
2.16.12
2.16.10
2.16.10
.
3.8.13
.
4.4.7
2.12.14
.
.
2.12.5
.4.4.14
. 4.4.15
.
2.15.6
.
2.15.8
2.16.31
Pressure Gauge Hose
Assembly . . . . . . . .
Pressure Regulator,
Model 609-A . . . . . . .
Primer Port, Model
609-C . . . . . . . . . . .
Process Control
Device, Model
US636HCCD-1 . . . . . . . .
Pump Discharge Gauge,
Model US636HCCD-1 . . . . .
Pump Discharge Gauge
Assembly,
Mode 1s
609-A and 609-C . . . . . .
Pumping Assembly,
Direct Support . . . . . .
Pumping Assembly,
Unit . . . . . . . . . . .
Pump Suction Gauge,
Model US636HCCD-1 . . . . .
Pump Suction Gauge
Assembly, Models
609-A and 609-C . . . . . .
Pump Support, Model
US636HCCD-1 . . . . . . . .
Radiator Assembly,
Direct Support . . . . . .
Radiator Assembly, Unit . . .
Radiator Shell
Assembly, Model
609-A . . . . . . . . . . .
Rear Jack Assembly
. . . .
Rear Panel Assembly,
Model 609-A . . .
. . . .
Right Side Panel
Assembly, Model
609-C . . . . . .
. . . .
Rocker Arm Assembly,
Model 609-A . . . . . . . .
Rocker Arm Assembly,
Models 609-C and
US636HCCD-1 . . .
. . . .
Safety Chains . . . . . . . .
Service Lights,
Model 609-C . . .
. . . .
Shield Assembly,
Model 609-A . . .
. . . .
Shock Absorber, Models
609-A and 609-C . . . . . .
Side Panels, Model
609-A . . . . . . . . . . .
Sound Enclosure
Assembly, Model
609-C . . . . . . . . . . .
Start Alarm Relay,
Model 609-A . . . . . . . .
Start Pilot Relay,
Model 609-C . . . . . . . .
Start Switch,
Model US636HCCD-1 . . . . .
Start/Stop Switch,
Model US636HCCD-1
. . . .
Support Frame Assembly
Maintenance, Model
609-C . . . . . . . . . . .
.
2.16.35
.
2.16.30
2.18.1
2.16.33
2.16.8
2.16.7
. .
.
3.6
2.18
2.16.8
2.16.7
3.6.11
. . 3.7
.
2.20
2.20.1
2.23.4
2.19.2
2.12.6
3.8.17
3.8.18
3.10.4
2.15.1
2.19.3
2.23.15
2.20.1
.
2.12
2.15.10
2.15.10
2.16.19
2.16.20
2.12.16
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
M (Continued)
Maintenance of: (continued)
Tachometer Angle Drive,
Models 609-C and
US636HCCD-1 . . . . . .
Tachometer Assembly,
Models 609-A and
US636HCCD-1 . . . . . .
Tachometer Assembly,
. . . . .
Model 609-C
Thermostat, Model
609-A . . . . . . . .
Throttle Select Switch,
Model 609-C . . . . . .
Toggle Switch . . . . . .
Tongue Jack . . . . . . .
Top Panel Assembly,
Model 609-C . . . . . .
Trailer Wiring Harness .
Tripod Assembly . . . . .
Turbocharger Assembly,
Models 609-C and
US636HCCD-1 . . . . . .
Upper Cover Plate,
Model 609-C . . . . . .
V-Belt Contact Switch
Maintenance, Models
609-C and US636HCCD-1 .
V-Belt Guard and Mounting
Supports, Model
US636HCCD-1 . . . . . .
V-Belt Tensioner,
Models 609-C and
US636HCCD-1 . . . . . .
Voltmeter, Model
609-C . . . . . . . . .
Water Pump Assembly,
Model 609-A . . . . . .
Wheel Bearing . . . . . .
Wheel Mounted Frame
Assembly, Direct Support
Wheel Mounted Frame
Assembly, Unit . . . .
Maintenance Procedures,
General . . . . . . . .
Manifold Assembly, Fuel
Leakoff Maintenance . . .
Manifold, Exhaust,
Maintenance, Model
609-A . . . . . . . . . .
Manifold, Exhaust,
Pipes, Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . .
Manifold, Intake,
Maintenance, Model
609-A . . . . . . . . . .
Manifold, Intake,
Maintenance, Models
609-C and US636HCCD-1 . .
Manual Throttle Control
Cable Maintenance, Model
609-C . . . . . . . . . .
.
2.21.45
.
2.16.13
.
2.16.12
.
2.21.41
2.16.18
.
2.16.18
.
. . 2.23.3
. . 2.12.4
2.23.12
.
. . 2.23.3
.
2.21.34
.
2.12.10
.
2.21.19
.
2.21.11
Manual Throttle Control
Cable Replacement, Model
609-A . . . . . . . . . . .
Manufactured Items,
Illustrated List of . . . .
Marking. . . . . . . . . . .
Master Cylinder
Maintenance . . . . . . . .
Meter Assembly
Maintenance . . . . . . . .
Mode Switch Maintenance,
Models 609-A and
. . . . . . . .
US636HCCD-1
Model 609-A, Assembly of . .
Model 609-C, Assembly of . .
Model US636HCCD-1,
Assembly of . . . . . . . .
Model 609-A Unpacking . . . .
Model 609-C Unpacking . . . .
Model US636HCCD-1
Unpacking . . . . . . . . .
Module, Engine Protection
System, Maintenance,
Model 609-C . . . . . . . .
Module, Governor Control,
Maintenance, Model 609-C .
Module, P r e s s u r e C o n t r o l ,
Maintenance, Model 609-C .
Muffler Maintenance,
Model 609-A . . . . . . . .
Muffler Maintenance,
Model 609-C . . . . . . . .
Muffler Maintenance,
Model US636HCCD-1 . . . . .
.
2.16.25
.
.
. .
D-1
2.26
.
2.23.6
.
2.16.12
.
.
2.16.18
2.4.5.2
2.4.5.3
.
.
.
2.4.5.4
2.4.2.1
2.4.2.2
.
2.4.2.1
.
2.16.31
.
2.16.32
.
2.16.31
.
2.13.1
.
2.13.2
.
2.13.3
. .
2.22.1
N
. . 3.8.16
.
2.16.12
2.21.43
. . 2.23.2
. 3.10.1
. . . 2.23
. . . 2.11
. . 2.21.7
Neck, Filler, Assembly,
Replacement, Model
609-C . . . . . . . . . .
Nomenclature CrossReference List . . . . .
Nozzle, Fuel Injection
and Holder Assembly
Maintenance, Model 609-A
Nozzle, Fuel Injection,
Maintenance, Models 609-C
and US636HCCD-1 . . . . .
Nozzle, Oil, Replacement,
Model US636HCCD-1 . . . .
.
.
.
.
1.7
. .
2.21.8
. .
2.21.9
. .
3.8.15
O
.
2.21.36
.
2.21.37
.
2.21.36
.
2.21.38
.
2.16.26
Oil Breather Assembly
Replacement, Models
609-C and US636HCCD-1 .
Oil Bypass Line Repair,
Model US636HCCD-1 . . .
Oil Cooler Replacement,
Model 609-A . . . . . .
Oil Cooler Replacement,
Model 609-C . . . . . .
Oil Cooler Replacement,
Model US636HCCD-1 . . .
Oil Drain Assembly
Replacement . . . . . . .
. . . 2.21.31
.
.
.
2.21.25
.
.
.
2.21.28
.
.
.
2.21.29
.
.
.
2.21.30
.
.
2.21.32
INDEX-13
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
O (Continued)
Oil Drain Tube Assembly
Maintenance . . . . . .
Oil Filter and Base
Assembly Replacement,
Model 609-A . . . . . .
Oil Filter and Base
Assembly Replacement,
Models 609-C and
US636HCCD-1 . . . . . .
Oil Inlet Tube Assembly
Replacement . . . . . .
O i l , Low, Engine,
Indicator Maintenance,
Model 609-C . . . . . .
Oil Line Hoses and
Fittings Maintenance
.
Oil Nozzle Replacement,
Model US636HCCD-1 . . .
Oil Pan Assembly
Maintenance . . . . . .
Oil Pipe Maintenance,
Models 609-C and
US636HCCD-1 . . . . . .
Oil Pressure Gauge
Assembly, Maintenance,
Model 609-C . . . . . .
Oil Pressure Gauge
Maintenance, Models
609-A and US636HCCD-1 .
Oil Pressure Switch,
Replacement, Model
609-C . . . . . . . . .
Oil Pump Assembly
Maintenance, Model
609-A . . . . . . . . .
Oil Pump Assembly,
Maintenance, Models
609-C and US636HCCD-1 .
Oil Temperature
Transmitter
Replacement,
Model 609-C . . . . . .
Outlet Duct Frame
Assembly Maintenance,
Model 609-C . . . . . .
Outlet Scoop Assembly
Maintenance, Model
609-C . . . . . . . . .
Overspeed, Engine
Indicator, Maintenance,
Model 609-C . . . . . .
Overview, Pumping
Assembly . . . . . . .
. .
2.21.24
. .
2.21.26
. .
2.21.27
. .
2.21.23
. .
2.16.14
. . . 2.21.2
. . . 3.8.15
. . . 3.8.12
. . .
4.4.7
. .
2.16.12
. .
2.16.10
. .
2.21.20
. . . 3.8.13
. . .
. .
4.4.7
2.21.20
. .
2.12.14
. . .
.
.
.
.
2.12.5
.
.
2.6.14
.
1.15
P
Packing. .
Packing of
Assembly
Packing of
Assembly
INDEX-14
. . . . . . . . . . . 2.25
Pumping
Model 609-A . . . . 2.25.1
Pumping
Model 609-C . . . . 2.25.2
Packing of Pumping
Assembly Model
US636HCCD-1 . . . . . . . .
Pan, Oil, Assembly,
Maintenance . . . . . . .
Panel, Cont rol,
Maintenance, Model
609-A . . . . . . . . . . .
Panel, C o n t r o l ,
Maintenance, Model
US636HCCD-1 . . . . . . . .
Panel, Control, Frame,
Maintenance, Model
609-A . . . . . . . . . . .
Panel, Rear, Assembly
Maintenance, Model
609-A . . . . . . . . . . .
Panels, Side,
Maintenance, Model
609-A . . . . . . . . . . .
Pickup, Magnetic,
Replacement . . . . . . . .
P i p e , O i l , Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
Pipe, Suction,
Replacement, Models
609-C and US636HCCD-1 . . .
Piston and Connecting
Rod Assembly Maintenance,
Model 609-A . . . . . . . .
Piston and Connecting Rod
Assembly Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . .
Plug, Drain,
Maintenance, Model
609-C . . . . . . . . . . .
PMCS Procedures . . . . . . .
Pocket, F o r k l i f t ,
Maintenance, Model
609-C . . . . . . . . . . .
Port, Primer,
Maintenance, Model
609-C . . . . . . . . . . .
Power Cable Assembly
Maintenance, Model
609-C
.
.
. . . . .
Power Control Cable
Assembly Maintenance,
Model 609-A . . . . . . . .
Preliminary Servicing
and Adjustment of
Equipment . . . . . . . . .
Preparation for Storage
and Shipment . . . . . . .
Preservation Procedures . . .
Pressure Control Module
Maintenance, Model 609-C .
Pressure Gauge Hose
Assembly Maintenance . . .
Pressure Regulator
Maintenance, Model
609-A . . . . . . . . . . .
Prevention and
C o n t r o l , Corrosion . . . .
.
2.25.3
.
3.8.12
.
2.16.36
.
2.16.37
.
2.16.38
.
2.19.2
.
2.20.1
.
3.8.5
.
.
4.4.7
.
3.8.14
.
4.4.14
.
4.4.15
.
.
2.18.1
. . 2.9
.
2.23.17
.
2.18.1
.
2.15.6
.
2.15.8
.
. .
.
.
. . 1.5
.
2.24
.
2.16.13
.
2.16.35
.
2.16.30
.
.
2.6
1.11
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
P (Continued)
Primer Port
Maintenance, Model
609-C . . . . . . . . . . .
Process Control
Device Maintenance,
Model US636HCCD-1 . . . . .
Processing Unpacked
Equipment . . . . . . . . . .
Pulley, Crankshaft,
Replacement, Model
609-A
.
.
.
. . . . . . .
P u l l e y , Crankshaft,
Replacement, Models
609-C and US636HCCD-1 . . . .
Pump Assembly, Fuel
Injection, Adjustment,
Model 609-A . . . . . . . . .
Pump Assembly, Fuel
Injection, Maintenance,
Model 609-A . . . . . . . . .
Pump Assembly, Fuel
I n j e c t i o n , Maintenance,
Models 609-C and
US636HCCD-1 . . . . . . . . .
Pump Assembly, Fuel
Injection, Test,
Model 609-A . . . . . . . . .
Pump Assembly, Oil,
Maintenance, Model
609-A . . . . . . . . . . . .
Pump Assembly, Oil,
Maintenance, Models 609-C
and US636HCCD-1 . . . . . . .
Pump Assembly
Replacement . . . . . . . . .
Pump Casing Assembly
Repair, Models 609-A
and 609-C . . . . . . . . . .
Pump Casing Assembly
Repair, Model
US636HCCD-1 . . . . . . . . .
Pump Discharge Gauge
Maintenance, Model
US636HCCD-1 . . . . . . . . .
Pump Discharge Gauge
Assembly Maintenance,
Models 609-A and
609-C . . . . . . . . . . . .
Pumping Assembly, 600
GPM, Assembly of . . . . . .
Pumping Assembly, Model
609-A, Packing of . . . . . .
Pumping Assembly, Model
609-C, Packing of . . . . . .
Pumping Assembly, Model
US636HCCD-1, Packing of . . .
Pumping Assembly
Lubrication . . . . . . . . .
Pumping Assembly Maintenance,
Direct Support . . . . . . .
Pumping Assembly
Maintenance, Unit . . . . . .
.
2.18.1
2.16.33
2.4.4
3.8.21
Pumping Assembly
. . . . . . . . . .
Overview
Pumping Assembly
.
.
.
.
.
Replacement .
Pump Mount Isolators
Replacement, Model
609-C . . . . . . . . . .
Pump Suction Gauge
Maintenance, Model
US636HCCD-1 . . . . . . .
Pump Suction Gauge
Assembly Maintenance,
Models 609-A and 609-C .
Pump Support Maintenance,
Model US636HCCD-1 . . . .
1.15
. .
.
.
3.6.1
. .
3.6.10
. -
2.16.8
. .
2.16.7
. .
3.6.11
Q
3.8.22
3.8.10
3.8.9
3.8.11
3.8.10
3.8.13
4.4.7
3.6.1
3.6.3
3.6.4
2.16.8
2.16.7
2.4.5
2.25.1
2.25.2
2.25.3
.
2.7
.
3.6
.
2.18
Quality
Assurance
.
.
.
.
.
.
. .
1.6
. .
. .
3.7
.
R
Radiator Assembly
Maintenance, Direct
Support . . . . . . . . .
Radiator Assembly
Maintenance, Unit . . . .
Radiator Repair,
Model 609-A . . . . . . .
Radiator Replacement,
Model 609-A . . . . . . .
Radiator Service,
Model 609-A . . . . . . .
Radiator Shell Assembly
Maintenance, Model 609-A
Radiator Support Brackets
Repair, Model 609-A . . .
Rear Cover, Crankcase,
Maintenance, Models 609-C
and US636HCCD-1 . . . . .
Rear Jack Assembly
Maintenance . . . . . . .
Rear Panel Assembly
Maintenance, Model 609-A
Receipt, Service Upon . . .
Receptacle, Electrical
Connector, Model 609-C,
Maintenance . . . . . . .
Recommendations,
Equipment Improvement,
Reporting . . . . . . . .
Records, Reports, and
Forms, Maintenance
. . .
Rectifier, Starter
Replacement, Models
609-A and 609-C . . . . .
References . . . . . . . .
Reflector Replacement . . .
Regulator, Pressure,
Maintenance, Model
609-A . . . . . . . . . .
Relay, Start Alarm,
Model 609-A, Maintenance
Relay, Start Pilot, Model
609-C, Maintenance . . .
2.20
. .
. .
.
.
3.7.1
. .
2.20.4
. .
2.20.3
. .
2.20.1
. .
2.20.5
. .
4.4.13
. .
2.23.4
. .
. .
2.19.2
. . 2.4
. .
2.15.7
. .
. .
1.8
. .
. .
1.2
. .
. .
. .
2.21.17
A.1
2.23.14
. .
2.16.30
. .
2.15.10
.
2.15.10
INDEX-15
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
R (Continued)
Removal of:
C o n t r o l P a n e l Assembly,
Model 609-A . . . . . . . . 2 . 1 6 . 3
C o n t r o l P a n e l Assembly,
Model 609-C . . . . . . . . 2 . 1 6 . 4
C o n t r o l P a n e l Assembly,
Model US636HCCD-1 . . . . . 2.16.5
Repair of:
Brake Line . . . . . . . . . 3.10.3
Control Panel
Assembly
3.5
Cylinder Head Assembly . . . . .
Models 609-C and
US636HCCD-1 . . . . . . . .
4.4.2
Exhaust Valve, Models
609-C and US636HCCD-1 . . .
4.4.2
Flexible Coupling
Assembly, Model 609-A . . .
3.6.5
Flexible Coupling,
Models 609-C and
US636HCCD-1 . . . . . . . .
3.6.6
Intake Valve, Models
609-C and US636HCCD-1 . . .
4.4.2
Oil Bypass Line,
Model US636HCCD-1 . . . .
2.21.25
Pump Casing Assembly,
Models 609-A and 609-C . .
3.6.3
Pump Casing Assembly,
Model US636HCCD-1 .
.
.
.
3.6.4
Radiator, Model 609-A. . . . .
3.7.1
Radiator Support
Brackets, Model
609-A . . . . . . . . . . .2.20.5
Stud and Thread . . . . . 2.11.2
Wheel Mounted Frame
Assembly, Direct
Support . . . . . . . . . . 3.10.2
Repair Parts, D i r e c t S u p p o r t . . 3 . 3
Repair Parts, General Support . . 4.3
Repair Parts, Unit . . . . . . . 2.3
Replacement of:
Brake Shoes . . . . . . . . . 2.23.9
Cold Start Aid Cable,
Model 609-C . . . . . . .
2.16.29
Cooling Air Blower,
Models 609-C and
US636HCCD-1 . . . . . . .
2.21.39
Crankshaft Pulley,
Model 609-A . . . . . . . . 3.8.21
Crankshaft Pulley,
Models 609-C and
US636HCCD-1 . . . . . . . . 3.8.22
Cylinder Head Assembly,
Model 609-A . . . . . . . . 3.8.19
Cylinder Head Assembly,
Models 609-C and
US636HCCD-1 . . . . . . . . 3.8.20
Data Plate
. . . . . . . 2.11.1
Discharge Elbow. . . . . . . . 2 . 1 8 . 2
Door Holder Assembly,
Model 609-C . . . . . . . . 2.12.1
Engine . . . . . . . . . . .
3.8.1
INDEX-16
Engine Alarm Assembly,
Model 609-A . . . . . . .
Engine Alarm Reset
Assembly, Model
609-A . . . . . . . . . .
Engine Mount Isolators,
Model 609-C . . . . . . .
Engine Support, Models
609-C and US636HCCD-1 . .
Engine Switch,
Model 609-C . . . . . . .
Engine Temperature
Switch, Model
609-C . . . . . . . . . .
Engine Temperature
Transmitter,
Model 609-C . . . . . . .
Engine Transmitter,
Model 609-C
Fan, Model 609-A . . . . . .
Fan Shroud, Model
609-A . . . . . . . . . .
Filler Neck Assembly,
Model 609-C . . . . . . .
Front Engine Support,
Model 609-A . . . . . . .
Fuel Rack Cable,
Model 609-A . . . . . . .
Fuel Solenoid, Model
609-C . . . . . . . .
Fuse Holder, Model
US636HCCD-1 . . . . . . .
Generator Capacitor,
Model 609-C
Horn, Model US636HCCD-1 . . .
Intermediate Bracket
Assembly . . . . . . . .
Magnetic Pickup . . . . . .
Manual Throttle
Control Cable,
Model 609-A . . . . . . .
Oil Breather Assembly,
Models 609-C and
US636HCCD-1 . . . . . . .
Oil Cooler, Model
609-A . . . . . . . . . .
Oil Cooler, Model
609-C . . . . . . . . .
Oil Cooler, Model
US636HCCD-1 . . . . . . .
Oil Drain Assembly . . . .
Oil Filter and Base
Assembly, Model
609-A . . . . . . . . . .
Oil Filter and Base
Assembly, Models
609-C and US636HCCD-1 . .
Oil Inlet Tube
Assembly . . . . . . . .
Oil Nozzle, Model
US636HCCD-1 . . . . . . .
Oil Pressure Switch,
Model 609-C . . . . . . .
Oil Temperature
Transmitter,
Model 609-C . . . . . . .
.
2.16.15
.
2.16.17
.
3.8.4
.
3.8.3
.
2.21.20
.
2.21.20
.
2.21.20
.
2.21.20
2.21.42
.
2.20.4
.
2.22.1
.
3.8.2
.
2.16.27
.
2.21.3
.
2.16.21
.
2.21.15
2.16.16
.
.
.
.
2.16.25
.
2.21.31
.
2.21.28
.
2.21.29
.
.
2.21.30
2.21.32
.
2.21.26
.
2.21.27
.
2.21.23
.
3.8.15
.
2.21.20
.
2.21.20
3.6.2
3.8.5
TM 10-4320-344-24
Subject . . . . . . . . . . . . . Paragraph
R (Continued)
Replacement of: (continued)
Pumping Assembly . . . . . .
3.6.1
Pump Mount Isolators,
Model 609-C
3.6.10
Radiator, Model 609-A . . . . 2.20.4
Reflector . . . . . . . . . . .
2.23.14
Resistor, Model 609-C. . . .
2.16.23
Rheostat, Models
609-C and US636HCCD-1 . .
2.16.22
Starter Assembly . . . . .
2.21.18
Starter Rectifier,
Models 609-A and 609-C .
2.21.17
Strap, Model 609-C . . . .
2.12.12
Suction Elbow . . . . . . . . 2.18.2
Suction Pipe, Models
609-C and US636HCCD-1 . . . 3.8.14
Tachometer Angle
Drive . . . . . . . . . .
2.21.45
Tachometer Cable,
Models 609-A and
US636HCCD-1 . . . . . . .
2.21.44
Terminal Board,
Model US636HCCD-1 . . . .
2.16.34
Turbocharger Assembly,
Model 609-A . . . . . . .
2.21.33
V-Belt, Models 609-C
and US636HCCD-1 . . . . .
2.21.12
Vibration Damper,
Model 609-A . . . . . . . . 3.8.21
Vibration Damper,
Models 609-C and
US636HCCD-1 . . . . . . . . 3.8.22
Wheel Assembly . . . . . . . 2.23.1
Wheel Cylinder . . . . . . . 2.23.9
Reporting Equipment
Improvement
Recommendations . . . . . . . . 1.8
Reports, Forms, and
R e c o r d s , Maintenance . . . . . 1.2
Resistor Replacement,
Model 609-C . . . . . . . .
2.16.23
Rheostat Replacement,
Models 609-C and
US636HCCD-1 . . . . . . . .
2.16.22
Right Side Panel
Assembly Maintenance,
Model 609-C . . . . . . . . . 2.12.6
Rocker Arm (Valve)
Adjustment, Model
609-A . . . . . . . . . . .
2.21.49
Rocker Arm (Valve)
Adjustment, Models
609-C and US636HCCD-1 . . .
2.21.50
Rocker Arm Assembly
Maintenance, Model
609-A . . . . . . . . . . . .3.8.17
Rocker Arm Assembly
Maintenance, Models
609-C and US636HCCD-1 . . . . 3.8.18
S
Safety, Care, and
Handling . . . . . . .
Safety Chains
Maintenance . . . . . .
Schematic Diagrams . . .
Scope.. . . . . . . . .
Servicing, Brake System .
Service Lights
Maintenance, Model
609-C . . . . . . . . .
Service, Radiator,
Model 609-A . . . . . .
Service Upon Receipt . .
Shell, Radiator,
Assembly Maintenance,
Model 609-A . . . . . .
Shield, Air, Maintenance,
Models 609-C and
US636HCCD-1 . . . . .
Shield Assembly
Maintenance, Model
609-A . . . . . . . . .
Shipment and Storage,
Preparation for . . . .
Shock Absorber
Maintenance, Models
609-A and 609-C . . . .
Shoes, Brake, Replacement
Shroud, Fan, Replacement,
Model 609-A . . . . . .
Side Panels Maintenance,
Model 609-A . . . . . .
Siting and Location . . .
Solenoid, Fuel,
Replacement ,Model
609-C . . . . . . . . .
Sound Enclosure
Assembly Maintenance,
Model 609-C
S p e c i a l T o o l s , TMDE,
and Support Equipment,
Direct Support . . . .
Special Tools, TMDE, and
Support Equipment,
General Support . . . .
Special Tools, TMDE,
and Support Equipment,
Unit . . . . . . . . .
Start Alarm Relay
Maintenance, Model
609-A . . . . . . . . .
Start Pilot Relay
Maintenance, Model
609-C . . . . . . . . .
Start Switch
Maintenance, Model
US636HCCD-1 . . . . . .
Start/Stop Switch
Maintenance, Model
US636HCCD-1 . . . . . .
Starter Assembly
Replacement . . . . . .
1.10
.
3.10.4
. . .
. . . . . F-1
. . . . . 1.1
2.23.5
. . .
. . .
. . .
2.15.1
. . .
. . .
2.20.3
. . 2.4
. . .
2.20.1
. . .
2.21.34
. . .
2.19.3
. . .
. .
1.5
. . .
. . .
2.23.15
2.23.9
. . .
2.20.4
. . .
. . .
2.20.1
2.4.1
. . .
2.21.3
. . .
.
2.12
. . .
. .
3.2
. .
4.2
. . .
. .
2.2
. . .
2.15.10
. . .
2.15.10
. . .
2.16.19
. . .
2.16.20
. . .
2.21.18
INDEX-17
TM 10-4320-344-24
Subject . . . . . . . . . . . . Paragraph
S (Continued)
Starter Rectifier
Replacement, Models
609-A and 609-C . . . .
Starting, Cold Aid,
Maintenance, Model
609-C . . . . . . . . .
Storage. . . . . . . . .
Storage and Shipment,
Preparation for . . . .
Strap Replacement,
Model 609-C . . . . . .
Stud Repair . . . . . . .
Suction Elbow
Replacement . . . . . .
Suction Gauge Assembly,
Pump, Maintenance,
Models 609-A and 609-C
Suction Pipe Replacement,
Models 609-C and
US636HCCD-1 . . . . . .
Support, Engine,
Replacement, Models
609-C and US636HCCD-1 .
Support Frame Assembly
Maintenance, Model
609-C . . . . . . . . .
Support, Front Engine,
Replacement, Model
609-A . . . . . . . . .
Switch Assembly, Limit,
Model 609-A,
Maintenance . . . . . .
Switch, Auto Select,
Maintenance, Model
609-C . . . . . . . . .
Switch, Engine t
Maintenance, Models
609-A and 609-C . . . .
Switch, Engine,
Replacement, Model
609-C . . . . . . . . .
Switch, Engine
Temperature, Model
609-C . . . . . . . . .
Switch, Low Oil
Pressure Cutoff, Test,
Model US636HCCD-1 . . .
Switch, Main Power,
Maintenance, Model
609-C . . . . . . . . .
Switch, Mode,
Maintenance, Models
609-A and US636HCCD-1 .
Switch, Oil Pressure,
Replacement, Model
609-C . . . . . . . . .
Switch, Start,
Maintenance, Model
US636HCCD-1 . . . . . .
Switch, S t a r t / S t o p
Maintenance, Model
US636HCCD-1 . . . . . .
INDEX-18
. .
2.21.17
.
.
.
2.21.10
. . . 2.27
.
.
. .
. .
.
. .
1.5
2.12.12
. 2.11.2
.
2.18.2
. .
.
2.16.7
. .
.
3.8.14
. .
.
3.8.3
.
.
.
.
.
3.8.2
.
.
.
2.15.9
.
.
2.16.18
. .
2.16.18
.
.
2.21.20
.
.
2.21.20
. .
2.16.9
.
2.12.16
.
2.16.18
. .
2.16.18
.
.
2.21.20
. .
2.16.19
. .
2.16.20
Switch, Throttle
Select, Maintenance,
Model 609-C . . . . . . . .
Switch, Toggle,
Maintenance . . . . . . . .
Switch, V-Belt Contact,
Maintenance, Models
609-C and US636HCCD-1 . . .
System, Air Intake,
Maintenance . . . . . . . .
System, Brake, Servicing . .
System, Fuel, Bleeding . . .
.
2.16.18
.
2.16.18
.
2.21.19
.
.
.
.
2.14
2.23.5
2.21.1
T
Tachometer Angle Drive
Replacement, Models
609-A and US636HCCD-1 . . .
Tachometer Assembly
Maintenance, Models
609-A and US636HCCD-1 . . .
Tachometer Assembly,
Maintenance, Model
609-C . . . . . . . . . . .
Tachometer Cable
Replacement, Models
609-A and US636HCCD-1 . . .
Tank, Fuel, Assembly,
Maintenance . . . . . . . .
Tank, Fuel, Maintenance,
Direct Support . . . . . .
Tank, Fuel, Maintenance,
Unit . . . . . . . . . . .
Tank, Fuel, Repair . . . . .
Temperature Gauge
Assembly, Engine
Coolant Maintenance,
Model 609-A . . . . . . . .
Tensioner, V-Belt,
Maintenance, Models
609-C and US636HCCD-1 . . .
Terminal Board
Replacement, Model
US636HCCD-1 . . . . . . . .
Test, Low Oil Pressure
Cutoff Switch, Model
US636HCCD-1 . . . . . . . .
Thermostat Maintenance,
Model 609-A . . . . . . . .
Thread Repair . . . . . . . .
Throttle Control Cable,
Manual Maintenance,
Model 609-C . . . . . . . .
Throttle Control Cable,
Manual, Replacement,
Model 609-A . . . . . . . .
Throttle Select
Switch Maintenance,
Model 609-C . . . . . . . .
TMDE, Special Tools,
and Support Equipment,
Direct Support . . . . . .
TMDE, Special Tools,
and Support Equipment,
General Support . . . . . .
.
2.21.45
.
2.16.13
.
2.16.12
.
2.21.44
.
.
2.22
.
. .
.
.
.
3.9
2.22.2
3.9.1
.
2.16.11
.
3.8.16
.
2.16.34
.
2.16.9
.
.
2.21.41
2.11.2
.
2.16.26
.
2.16.25
.
2.16.18
.
. .
3.2
.
. .
4.2
TM 10-4320-344-24
Subject . . . . . . . . . . Paragraph
T (Continued)
TMDE, Special Tools,
and Support Equipment,
Unit . . . . . . . . .
Toggle Switch
Maintenance . . . . . . .
Tongue Jack Maintenance . . .
Top Panel Assembly
Maintenance, Model
609-C . . . . . . . . . .
Torque Limits . . . . . . . .
Trailer Wiring Harness
Maintenance . . . . . . . .
Transmitter, Engine,
Replacement, Model
609-C . . . . . . . . . . .
Transmitter, Engine
Temperature,
Replacement, Model
609-C . . . . . . . . . . .
Transmitter, Oil
Temperature,
Replacement,
Model 609-C . . . . . . . .
Tripod Assembly Maintenance .
Troubleshooting, Unit . . . .
Troubleshooting,
Direct Support . . . . . .
Turbocharger Assembly
Replacement, Model
609-A . . . . . . . . . . .
Turbocharger Assembly
Maintenance, Models
609-C and US636HCCD-1 . . .
.
.2.2
2.16.18
. 2.23.3
. .2.12-4
. . E-1
2.23.12
2.21.20
2.21.20
2.21.20
. 2.23.3
. . 2.10
.
.
3.4
2.21.33
2.21.34
U
Unit, Common Tools
and Equipment . . . . . .
Unit Engine Assembly
Maintenance . . . . . . .
Unit Repair Parts . . . . .
Unit, S p e c i a l T o o l s ,
TMDE, and Support
Equipment . . . . . . . .
Unpacked Equipment,
Checking . . . . . . . .
Unpacked Equipment,
Processing . . . . . . .
Unpacking. . . . . . . . .
Unpacking Model 609-C . . .
Unpacking Models
609-A and US636HCCD-1 . .
Upper Cover Plate
Maintenance, Model
609-C . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
2.1
2.21
. .2.3
.
2.2
.
.
2.4.3
.
.
.
.
.
2.4.4
2.4.2
2.4.2.2
.
2.4.2.1
.
2.12.10
V
Valve, Exhaust,
Maintenance, Model
609-A . . . . . . . . . . . .
4.4.1
Valve, Exhaust,
Repair, Models 609-C
and US636HCCD-1 . . . .
Valve, Intake,
Maintenance, Model
609-A . . . . . . . . .
Valve, Intake, Repair,
Models 609-C and
US636HCCD-1 . . . . . .
V-Belt Contact Switch
Maintenance, Models
609-C and US636HCCD-1 .
V-Belt Guard and Mounting
Supports Maintenance,
Model US636HCCD-1 . . .
V-Belt Replacement,
Models 609-C and
US636HCCD-1 . . . . . .
V-Belt Tensioner
Maintenance, Models
609-C and US636HCCD-1 .
Vibration Damper
Replacement, Model
609-A . . . . . . . . .
Vibration Damper
Replacement, Models
609-C and US636HCCD-1 .
Voltmeter, Maintenance,
Model 609-C . . . . . .
4.4.2
. . .
. . .
.
4.4.1
. . .
.
4.4.2
. . .
2.21.19
. . .
2.21.11
. . .
2.21.12
. . .
3.8.16
. . .
3.8.21
. . .
3.8.22
. . .
2.16.12
W
Warranty Information . . .
Water Pump Assembly
Maintenance, Model
609-A . . . . . . . . . .
Weldment, Base,
Maintenance, Model
US636HCCD-1 . . . . . . .
Wheel Assembly Replacement
Wheel Bearing
Maintenance . . . . . . .
wheel Cylinder
Replacement . . . . . . .
Wheel Mounted Frame
Assembly, Direct
Support . . . . . . . .
Wheel Mounted Frame
Assembly Maintenance,
Direct Support . . . . .
Wheel Mounted Frame
Assembly Maintenance,
Unit . . . . . . . . . .
Wheel Mounted Frame
Assembly Repair,
Direct Support . . . . .
Wiring, Control
Panel Assembly,
Models 609-C and
US636HCCD-1,
Maintenance . . . . . . .
Wiring Diagrams . . . . . .
Wiring Harness,
Engine, Maintenance . . .
Wiring Harness,
Trailer, Maintenance . .
1.9
. .
. .
. .
2.21.43
. .
. .
2.16.40
2.23.1
.
.
2.23.2
.
.
2.23.9
.
.
3.10
.
-
3.10.1
.
.
2.23
.
.
3.10.2
. .
. .
2.16.6
. . F-1
.
2.17
. .
2.23.12
.
INDEX-19/(INDEX-20 Blank)
TM 10-4320-344-24
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
06491
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25-E, block no. 5943,
requirements for TM 10-4320-344-24.
*U.S. GOVERNMENT OFFICE: 1994 - 555-028/00196
PIN: 072521-000
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