TM 10-3930-242-34 · TM 10-3930-242-34 WARNING Use a suitable lifting device for lifting major...

TM 10-3930-242-34

TECHNlCAL MANUAL

DIRECT SUPPORT, GENERAL SUPPORT, AND

D E P O T M A I N T E N A N C E M A N U A L

TRUCK, LIFT, FORK; DIESEL ENGINE, PNEUMATIC TIRED

WHEELS, ROUGH TERRAlN, 6,000 LB CAPACITY,

24 INCH LOAD CENTER, (ANTHONY MODEL MLT-6,

ARMY MODEL MHE-200) FSN 3930-903-0900,

(CHRYSLER MODEL MLT-6CH, ARMY MODEL

FSN 3930-937-0220, (ATHEY MODEL ARTFT-6,

ARMY MODEL MHE-222) FSN 3930-419-5744°

This copy is a reprint which includes current

pages from Changes 2 and 3.

H E A D Q U A R T E R S , DEPARTMENT OF T H E A R M Y

MARCH 1974

TM 10-3930-242-34

WARNING

Use a suitable lifting device for lifting major components. Do not allow major components to swing whensuspended in the air. Exercise extreme caution when working near a cable or chain under tension.Failure to follow this warning may result in serious injury or DEATH.

WARNING

Install a lifting eye in threaded holes provided in the top of the transmission. Exercise extreme cautionduring removal and installation; the transmission weighs approximately 1,200 pounds.

WARNING

Never crawl under the forklift truck while performing maintenance unless it is blocked securely. Failureto observe this warning may result in serious injury or DEATH. When removing axles, be sure the truckis blocked to prevent oscillation.

WARNING

Fuel injectors must always be held in such a way as to prevent any fuel from penetrating the skin. Fuel othat enters the bloodstream can cause serious infection or DEATH.

WARNING

Before attempting to weld or braze the fuel tank, steam clean the tank for a minimum of eight (8) hours.Remove fuel cap and open the discharge and return lines during the welding process. Failure to observethis warning may result in serious injury or DEATH.

WARNING

Bleed the brake system pressure by repeated application of the brakes with the engine stopped, until thelow pressure warning buzzer sounds. Continue to apply brakes several times to further reduce ac-cumulator pressure. Carefully open bleed valves at each automatic slack adjuster to bleed off pressure tothe wheels. Failure to bleed pressure from the brake system before servicing or performing maintenancefunction may result in damage to equipment and SERIOUS INJURY to personnel. Use ONLY drynitrogen gas when servicing the accumulator.

Changes in force: C 2 and C 3

TM 10-3930-242-34

C 3

CHANGE

NO. 3

H E A D Q U A R T E R S

D E P A R T M E N T O F T H E A R M YWASHINGTON. D.C., 7 August 1989

DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOTMAINTENANCE MANUAL

FOR

TRUCK, LIFT, FORK, DIESEL ENGINE,PNEUMATIC TIRED WHEELS, ROUGH TERRAIN;

6,000 LB CAPACITY, 24 INCH LOAD CENTER(ANTHONY MODEL MLT-6, ARMY MODEL MHE-200)

(NSN 3930-00-903-0900),(CHRYSLER MODEL MLT-6CH, ARMY MODEL MHE-202)

(NSN 3930-00-937-0220),(ATHEY MODEL ARTFT-6, ARMY MODEL MHE-222)

(NSN 3930-00-419-5744)

TM 10-3930-242-34, 29 March 1974, is changed as follows:

Page 1-1.

Paragraph 1-2 is superseded as follows:

1-2. Maintenance Forms, Records, and Reports

Maintenance forms, records, and reports which are

to be used by maintenance personnel at all mainte-n a n c e l e v e l s a r e l i s t e d i n D A P a m 7 3 8 - 7 5 0 .

Paragraph 1-3 is superseded as follows:

1-3. Reporting Errors and Recommending Im-provements

d u r e s , p l e a s e l e t u s k n o w . M a i l y o u r l e t t e r o rDA Form 2028 (Recommended Changes to Publica-tions and Blank Forms) direct to: Commander, U.S.A r m y Tank-Automot ive C o m m a n d , A T T N :AMSTA-MB, Warren, MI 48397-5000, A reply will

b e f u r n i s h e d t o y o u .

Page 5-39 , paragraph 5-21j. Change the first sen-tence to read: “Start engine and without moving the

steering. wheel, operate the steering mode selectorf r o m 2 - w h e e l t o 4 - w h e e l s t e e r i n g p o s i t i o n s . ” .

You can help improve this manual. If you find any Page A-2 , paragraph A-5. Change “TM 38-750” to

mistakes or know of a way to improve the proce- read “DA Pam 738-750” .

1

By Order of the Secretary of the Army:

CARL E. VUONO

Official:General, United States Army

Chief of Staff

WILLIAM J. MEEHAN HBrigadier General, United States Army

The Adjutant General

Distribution:To be distributed in accordance with DA Form 12-25F, Direct Support and General Support maintenance re-

quirements for Fork Lift, 6000 LB Capacity, Rough Terrain, Pneumatic Tire, Diesel (Model MHE-200, 202, 222).

2

*TM 10-3930-242-34

TECHNICAL MANUAL

No. 10-3390-242-34

H E A D Q U A R T E R SDEPARTMENT OF THE ARMYWASHINGTON, D.C., 29 MARCH 1974

TRUCK,

DIRECT SUPPORT, GENERAL SUPPORT, ANDDEPOT MAINTENANCE MANUAL

LIFT, FORK; DIESEL ENGINE, PNEUMATICROUGH TERRAIN, 6,000 LB CAPACITY, 24 INCH

TIRED WHEELS,LOAD CENTER,

(ANTHONY MODEL MLT-6 ARMY MODEL MHE-200) FSN 393-903-0900,(CHRYSLER MODEL MLT-6CH, ARMY MODEL MHE-202) FSN 3930-937-0220,

(ATHEY MODEL ARTFT-6, ARMY MODEL MHE-222) FSN 3930-419-5744

C H A P T E R 1 .S e c t i o n I .

II.C H A P T E R 2 .Section I.

II.HI.

CHAPTER 3.S e c t i o n I .

II.III.IV.V.

VI.CHAPTER 4.

5.S e c t i o n I .

II.III.IV.

C H A P T E R 6 .Section I.

II.C H A P T E R 7 .

S e c t i o n I .II.

A PPENDIX A .INDEX ------

ParagraphINTRODUCTIONGeneral --------------------------------------------------------------------------------------- 1-1-1-5Description and data ----------------------------------------------------------------- 1-6, 1-7DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONSRepair par ts , specia l tools and equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1 , 2-2Troubleshooting ---------------------------------------------------------------------------- 2-3, 2-4Removal and installation of major components and accessories --------------- 2-5-2-8REPAIR OF ENGINEEngine accessories ------------------------------------------------------------------- 3-1-3-11Fuel system ---------------------------------------------------------------------------------- 3-12-3-17Cylinder head, valves, flywheel, and flywheel housing ---------------------------- 3-18-3-22Oil Pan, oil pump screen, inlet pipe, connecting rods, and pistons ------------------ 3-23-3-26Camshaft , balance shaf t , and crankshaf t - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-27,3-33Cylinder block ----------------------------------------------------------------------------- 3-34, 3-35REPAIR OF TRANSMISSION -------------------------------------------------------- 4-14-5REPAIR OF DRIVE COMPONENTSPropeller shafts ------------------------------------------------------------------------------ 5-1-5-4Front and rear axle assemblies and parking brake ------------------------------- 5-5-5-8Hydraulic brake system -------------------------------------------------------------------- 5-9-5-13Steer ing system ---- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-14-5-22REPAIR OF MAIN HYDRAULIC SYSTEMHydraulic cylinders, hydraulic valves, hydraulic reservoir and hydraulic manifold --- 6-1-6-13Main hydraulic pump and engine driven pump ---------------------------------- (6-14-6-16REPAIR OF CARRIAGE ASSEMBLY, BOOM ASSEMBLY,FRAME, HOOD, AND

PANELSCarr iage and boom assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1-7-3Frame, hood, and panels ---------------------------------------------------------------- 7-4, 7-5REFERENCES ----------------------------------------------------------------------------- A-1-A-8

--------------------------------------------------------------------------------------------- - - - - - - - - - -

Page

1-11-1

2-12-12-4

3-13-263-453-573-633-764-1

5-15-1

5-185-27

6-16-18

7-17-4A-11-1

*This manual supersedes TM 10-3930-242-35, 18 September 1969, and all changes.

i

TM 10-3930-242-34

LIST OF ILLUSTRATIONSFigure

FO-12-12-22-32-43-13-23-33-43-53-63-73-83-93-93-103-113-113-123-133-133-143-153-153-153-153-153-163-173-183-193-203-213-223-233-243-253-263-273-283-293-303-313-323-333-343-353-363-373-383-393-403-413-423-433-443-453-463-473-483-493-503-513-52

ii

TitleHydraulic diagram -----------------------------------------------------------------------------------------Engine, removal and installation ----------------------------------------------------------------------------Torque converter and transmission assembly, removal and installation --------------------------------Front axle assembly, removal and installation --------------------------------------------------------------Boom assembly, removal and installation -------------------------------------------------------------------Oil pump and crankshaft pulley, removal and installation ----------------------------------------Oil pump, disassembly and reassembly ---------------------------------------------------------------------Oil cooler, removal and installation -------------------------------------------------------------------------Oil cooler, disassembly and reassembly --------------------------------------------------------------------Air inlet housing and blower assembly, removal and installation ----------------------------------Air inlet housing, disassembly and reassembly ------------------------------------------------------------Blower, disassembly and reassembly ---------------------------------------------------------------------Blower drive and coupling, removal and installation ----------------------------------------------------Blower drive and coupling, disassembly and reassembly (sheet 1 of 1) ----------------------------------Blower drive and coupling, disassembly and reassembly (sheet 2 of 2) ----------------------------Governor, removal and installation -------------------------------------------------------------Governor assembly, disassembly and reassembly (sheet 1 of 2) ------------------------------------------Governor assembly, disassembly and reassembly (sheet 2 of 2) ------------------------------------Radiator, removal and installation -------------------------------------------------------------Radiator and water pump, disassembly and reassembly (sheet 1 of 2) ------------------------------Radiator and water pump, disassembly and reassembly (sheet 2 of 2) ------------------------------Generator, disassembly and reassembly -------------------------------------------------------------------Voltage regulator adjustment (sheet 1 of 5) --------------------------------------------------Voltage regulator adjustment (sheet 2 of 5) --------------------------------------------------Voltage regulator adjustment (sheet 3 of 5)------------------------------------------------------Voltage regulator adjustment (sheet 4 of 5)------------------------------------------------------Voltage regulator adjustment (sheet 5 of 5)------------------------------------------------------Star ter , on-equipment tes t ing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Starter, disassembly and reassembly -----------------------------------------------------------Fuel injector control lever and tube assembly, removal and installation ----------------------------Fuel injector control lever and tube assembly, disassembly and reassembly ------------------------Fuel injectors, removal and installation ------------------------------------------------------------------Fuel injector follower stop pin, removal and installation ------------------------------------------Defective fuel injector plungers ----------------------------------------------------------------Injector rack, gear, spray tip, and valve assembly components, removal and installation ---------------Fuel injector filter, removal and installation --------------------------------------------------------------Injector follower, spring, and plunger, removal and installation -----------------------------------------Reaming fuel injector spray tip -----------------------------------------------------------------------------Cleaning spray tip orifices ---------------------------------------------------------------------------------Cleaning fuel injector nut spray tip seat -------------------------------------------------------------------Fuel injector sealing surfaces that may require lapping ------------------------------------------Check fuel injector tip concentricity ------------------------------------------------------------------------Rocker arms and push rods, removal and installation --------------------------------------------------Rocker arm and push rod, disassembly and reassembly -------------------------------------------------Cam follower and guide location ----------------------------------------------------------------------------Cam roller wear and clearance diagram --------------------------------------------------------------------Push rod adjustment ------------------------------------------------------------------------------------------Fuel pump, disassembly and reassembly -------------------------------------------------------------------Fuel tank, removal and installation -------------------------------------------------------------------------Fuel tank, disassembly and reassembly ---------------------------------------------------------Cylinder head assembly, removal and installation --------------------------------------------------------Cylinder head, disassembly and reassembly -----------------------------------------------------------Minimum distance between top and bottom faces of cylinder head ---------------------------------Cylinder head bolt tightening sequence ---------------------------------------------------------Removing exhaust valve spring -----------------------------------------------------------------------------Valves and valve and injector operating mechanism ------------------------------------------------------Flywheel and flywheel housing ---------------------------------------------------------------------------Flywheel housing bolt tightening sequence (operation 1) ------------------------------------------------Flywheel housing bolt tightening sequence (operation 2) -------------------------------------------------Oil pan, removal and installation ------------------------------------------------------------------------Oil pan, oil pump screen, and inlet pipe, disassembly and reassembly ----------------------------------Pistons, connecting rods, oil pump, screen, and inlet pipe, removal and installation -------------------Piston, rings, connecting rod and cylinder liner, disassembly and reassembly --------------------------Cylinder liner measurement diagram ------------------------------------------------------------------------

PageFold-In2-52-62-72-73-13-23-33-43-53-53-63-83-83-93-103-113-123-143-153-163-183-193-203-213-223-233-243-253-263-273-283-293-303-313-313-323-333-343-343-343-363-373-383-393-403-413-423-433-443-453-463-473-493-493-503-533-553-563-573-583-593-603-62

TM 10-3930-242-34

Figure3-533-543-553-563-573-583-593-603-613-623-633-644-14-24-24-24-24-24-24-24-24-24-24-24-24-24-34-44-64-64-74-84-95-15-25-35-45-45-45-45-45-45-45-45-45-55-65-75-85-95-105-115-125-135-146-155-165-175-185-185-195-205-216-16-2

TitleEngine front covers, removal and installation -----------------------------------------------Camshaft or balance shaft nut, removal and installation ----------------------------------------------Camshaft and balanee shaft, disassembly and reassembly ----------------------------------------Idler gear assembly, removal and installation ---------------------------------------------------Installing idler gear hub ----------------------------------------------------------------------Installing idler gear ---------------------------------------------------------------------------Upper and lower main bearing shells, bearing caps, and rear main bearing thrust washers ----------Removing rear main bearing upper shell (crankshaft in place) ------------------------------------Rear main bearing thrust washer and mounting -------------------------------------------------Crankshaft, removal and installation -----------------------------------------------------------Gear train and timing marks -------------------------------------------------------------------Cylinder block, disassembly and reassembly -----------------------------------------------------Torque converter, exploded view ---------------------------------------------------------------Torque converter and transmission assembly, disassembly and reassembly (sheet 1 of 13)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 2 of 13)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 3 of 13)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 4 of 10)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 5 of 10)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 6 of 13)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 7 of 13)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 8 of 10)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 9 of 10)-------------Torque converter and transmission assembly, disassembly and reassembly (sheet 10 of 10)----------Torque converter and transmission assembly, disassembly and reassembly (sheet 11 of 10)----------Torque converter and transmission assembly, disassembly and reassembly (sheet 12 of 13) ---------Torque converter and transmission assembly, disassembly and reassembly (sheet 13 of 10)----------Removal oftorque converter housing -----------------------------------------------------------Transmission foward and reverse drive assembly, exploded view ---------------------------------Transmission disconnect valve, removal and installation -----------------------------------------Transmission main oil pressure valve, removal and installation -----------------------------------Transmission main oil pressure regulating valve, disassembly and reassembly ----------------------Transmission control valve, removal and installation ---------------------------------------------Transmission control valve, disassembly and reassembly -----------------------------------------Front propeller shaft, disassembly and reassembly -----------------------------------------------Rear propeller shaft, disassembly and reassembly -----------------------------------------------Engine propeller shaft, disassembly and reassembly ---------------------------------------------Axle assembly, disassembly and reassembly (sheet 1 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 2 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 3 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 4 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 5 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 6 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 7 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 8 of 9)-----------------------------------------Axle assembly, disassembly and reassembly (sheet 9 of 9)-----------------------------------------Differential lockout shift control, disassembly and reassembly ------------------------------------Parking brake, removal and disassembly --------------------------------------------------------Brake assembly, disassembly and reassembly ---------------------------------------------------Automatic slack adjuster, disassembly and reassembly -------------------------------------------Differential pressure switch and brake valve, removal and installation ----------------------------Brake valve, disassembly and reassembly -------------------------------------------------------Hydraulic brake accumulator cylinder, removal and installation -----------------------------------Hydraulic brake accumulator cylinder, disassembly and reassembly -------------------------------Steering cylinder, disassembly and reassembly --------------------------------------------------Three-position cylinder, disassembly and reassembly--------------------------------------------------Rear steering pump, disassembly and reassembly ------------------------------------------------Steering mode selector valve, removal and installation -------------------------------------------Steering mode selector valve, disassembly and reassembly ----------------------------------------Steering gear assembly, disassembly and reassembly (sheet 1 of 2) --------------------------------Steering gear assembly, disassembly and reassembly (sheet 2 of 2) --------------------------------Steering system adjustment -------------------------------------------------------------------Hydraulic power steering valve, removal, disassembly, reassembly, and installation -----------------Rear dragline, disassembly and reassembly -----------------------------------------------------Three-spool valve, removal and disassembly -----------------------------------------------------Dual overcenter reliefand replenishing valve and three-spool valve, removal and installation --------

Page

3-643-663-673-693-693-693-703-703-713-733-753-774-24-34-44-54-64-74-84-94-104-114-124-134-144-154-164-174-184-184-194-194-205-35-45-55-65-75-85-95-105-125-135-145-155-165-175-195-225-235-245-265-275-295-305-315-335-345-355-365-375-385-406-26-3

iii

TM 10-3930-242-34

Figure6-36-46-56-66-76-86-96-106-116-126-136-146-156-166-177-17-27-37-3

TitleDual overcenter relief and replenishing valve, disassembly and reassembly --------------------------Two-spool valve, disassembly and reassembly ----------------------------------------------------Hydraulic tilt cylinder, disassembly and reassembly ----------------------------------------------Hydraulic lift cylinder, disassembly and reassembly ----------------------------------------------Hydraulic oscillating cylinder, disassembly and reassembly ----------------------------------------Oscillating cylinder check valve, removal and installation -----------------------------------------------Hydraulic slave cylinder, disassembly and reassembly --------------------------------------------Hydraulic side shift cylinder, disassembly and reassembly ----------------------------------------Hydraulic extension cylinder, disassembly and reassembly -------------------------------------------Hydraulic reservoir, removal and installation ---------------------------------------------------Hydraulic reservoir, disassembly and reassembly ------------------------------------------------Contamination indicator, removal, disassembly, reassembly and installation ------------------------Hydraulic manifold, removal, disassembly, reassembly, and installation ----------------------------Main hydraulic pump, disassembly and reassembly ----------------------------------------------Engine driven pump, disassembly and reassembly ----------------------------------------------------Carriage assembly, disassembly and reassembly -------------------------------------------------Boom assembly, disassembly and reassembly ----------------------------------------------------Frame, hood, and panels, disassembly and reassembly (sheet 1 of 2) -------------------------------Frame, hood, and panels, disassembly and reassembly (sheet 2 of 2) -------------------------------

Page6-46-56-66-86-96-106-116-126-146-146-156-166-176-196-207-27-37-57-6

iv

TM 10-3930-242-34

CHAPTER 1

INTRODUCTION

Section 1.

1-1. Scope

This manual is for your use in maintainingthe Anthony Co. Model MLT-6 (Army ModelMHE 200 ) , Ch rys l e r Cc rp . MLT-6CH (ArmyModel 202), and Athey Co. Model ARTFT-6(Army Model 222) wheel-mounted rough terrainforklift trucks. They provide information on themaintenance of the equipment that is beyondthe scope of the tools, equipment, personnel, orsupplies that are normally avai lable to usingo rgan i za t i ons .

1-2. Maintenance Forms and Records

Maintenance forms and records that you arerequired to use are explained in TM 38-750.

1-3. Reporting of Errors

You can improve this manual by cal l ing at-t e n t i o n t o e r r o r s a n d b y r e c o m m e n d i n g i m -

GENERAL

p r o v e m e n t s , u s i n g D A F o r m 2 0 2 8 ( R e c o m -mended Changes to Publications) or by a letter,and mail direct ly to Commander, U. S. ArmyTroop Support Command, ATTN: AMSTS-MPP,4300 Goodfellow Boulevard St. Louis Mo. 63120.A reply will be furnished directly to you.

1-4. Destruction of Army Materiel to PreventEnemy Use

P r o c e d u r e s f o r t h e d e s t r u c t i o n o f A r m ymateriel to prevent enemy use and explained inTM 750-244-3.

1-5. Administrative Storage

Administrat ive s torage procedures are exp-lained in TM 740-90-1.

Section II. DESCRIPTION AND DATA

1-6. Description

A general description of the forklift trucks, aswe l l a s t he i den t i f i ca t i on and d i f f e r ences i nmodels, can be found in TM 10-3930-242-12. Re-pair instructions applicable to Direct and Gen-e ra l Suppor t ma in t enance and add i t i ona l de -scr ipt ive mater ial , where required, are to befound in the appropriate sect ions and parag-r a p h s .

1-7. Tabulated Data

a. Identification and Instruction Plate. E a c hforkl i f t t ruck is provided with a Corp of En-g inee r s “A” p l a t e . Th i s i s de sc r ibed in TM10-3930-242-12.

b. Tabulated Data.(1) G e n e r a l . T h i s s u b p a r a g r a p h c o n t a i n s

overhaul data that is applicable to direct andgeneral support personnel. A hydraulic diagram( f i g . F O - 1 ) i s a l s o i n c l u d e d . R e f e r t o T M

10-3930 -242 -12 fo r t he e l e c t r i c a l s chema t i cd i ag ram.

FO-1. Hydraulic diagram.(Located in back of manual)

(2) E n g i n e .Manufacturer ----------------- Detroit DieselModel -------------------- 5043-7000S e r i e s - - - - - - - - - - - - - - - - - - - - - - 5 3 NRpm (Revolutions per

minute) no load ------------ 2700 ±15Stall speed rpm -------- 2280-2310Firing order ----------- 1-3-4-2Number of cylinders --------- 4Bore --------------------- 3.875 in.Stroke --------------------- 4.5 in.Compression ratio --------- 21-to-1Total displacement-Cu. In. 212.4Number of main bearings -- 5

(3) E n g i n e g e n e r a t o r .Manufacturer ---------------- PrestoliteVolts -------------------------------- 24V, dcModel --------------------- GHA-4804 UT

(4) T r a n s m i s s i o n .Manufacturer ----------------- Allison

1-1

TM 10-3930-242-34

Model ---------------------------T y p e - - - - - - - - - - - - - - - - - - - - -

Rating:Maximum input speed ------Maximum input torque ------Maximum input ---------

Rotation, viewed from inputend:Input -------------------------Output, forward opera-

tion.Gear ranges, selector posi-

tions:Forward - - - - - - - - - - - - - - - -Reverse - - - - - - - - - - - - - - - -Range control -----------Direction control --------

Torque converter:T y p e - - - - - - - - - - - - - - - - - - -

Elements -----------------------------Torque multiplications:

Rat ios - - - - - - - - - - - - - - - - - -Gear data:

Direction and rangegears ------------------------------

Transfer gears ---------------Accessory gearing ------------

Clutch data:Type -------------------------

Material ----------------------

Parking brake:Size -------------------------------Type ---------------------------Rating ------------------------------

Flanges:Input (remote mount) ---------

R e a r - - - - - - - - - - - - - - - - - - -

Front ----------------------------

Oil system:Oil pump (pressure) ---------

Oil capacity; US gal -------Oil cooler ------------------------Converter-out oil

temperature -----------------------Main pressure ----------------

Lubrication oil pressure -----Steer pumpd rive:

Rating --------------------------------Ratio to engine speed -----------

Power takeoffRating --------------------------

3331-1Torque converter and plane-

tary gear

300 ft-lb net3,000 rpm175 gross hp (horsepower)

Clockwise

3 speeds3 speedsLow, intermediate, and highForward, neutral, reverse

Single-stage, polyphase, 3-element, free-wheelingstator

Pump, turbine, stator

TC 320-3.50:1

10-pitch, straight spurplanetary

4-pitch, straight spur6-pitch, straight spur

Multidisk, hydraulic-actuatedspring-reieased, oil-cooled;automatic compensation forwear

Reaction plates—steel frictionplates-sintered bronze onsteel

133/8 x 2Expanding shoe, mechanical45,000 inch-pound at 2,100 lb

apply force

Mechanics 6C, 7C; Spicer1500,1600; Rockwell 5N

Mechanics 6C, 7C, 9C; Spicer1500, 1700; Rockewell 5N, 6N

Mechanics 6C, 7C, 9C; Spicer1600; Rockwell 5N, 6N

Input driven, gear type, posi-tive displacement

Initial fill 7.5; refill 5.5Heat exchanger

250 F. maximum110 to 135, or 135 to 155 psi at

full throttle stall20 to 25 psi

15 hp continuous1:1

50 hp continuous, 80 hp inter-mittent (subtract 15 hpwhen steer pump is used)

Ratio to engine speed -------1:1(5) Generator regula tor .

Manufacturer ------------------ Delco-RemyVolts ----------------------- 24V, dc

(6) S t a r t e r .Manufacturer -------------------- Delco-RemyVolts ------------------------ 24V, dc

(7) S t e e r i n g a d j u s t m e n t s .Front steering linkage:

Length between pivotcenters -------------- 13 in.

Rear steering linkage:Length between pivot

centers ----------------- 21.484 in.Length between grease

fittings --------------- 21 7/8 in.Steering mode cylinder:

Length is adjusted soholes in intermediatelink and pitman arm arealigned

Front drag linkLength between pivot

c e n t e r s - - - - - - - - - - - - - - - 3 8 5 / 8 i n .

Rear drag linkLength between pivot

centers --------------- 45 1 5/ 16 i n .

(8) Nut, bolt, stud and pipe plug torque data.The fol lowing speci f ica t ions apply to c lean, drythreads . Reduce the torque 10 percent when thet h r e a d s a r e c l e a n a n d o i l e d .

(a) E x c e p t i o n s t o s t a n d a r d b o l t a n d n u tt o r q u e s p e c i f i c a t i o n s .

Application

Injector Control Shaft BracketBolts

Cam Follower Guide BoltsGovernor to Flywheel HousingIdler Gear Hub and Spacer BoltsIdler Gear Hub and Spacer BoltsFlywheel housing BoltsInjector Clamp BoltsAir Box Cover BoltsConnecting Rod Nuts LubricatedConnecting Rod Nuts (Plain)Flywheel Housing BoltsFuel Line NutsFuel ConnectorRocker arm Bracket Bolts*Flywheel Bolts*Main Bearing Cap Bolts*Cylinder Head BoltsFlange Mounted Air Compressor

Drive Shaft NutCrankshaft End BoltCrankshaft End Bolt (In-Line en-

gines with cone mounted pulleysnot stamped with the letter “A”

Air Compressor Drive Pulley Nut

Size Nutor Bolt

¼-20¼-205/16-185/16-183/8-163/8-163/8–163/8-163/8-243/8-243/8-243/8-243/8-247/16-14½-209/16-125/8-11

3/4-103/4–16

3/4-163/4-16

Torque(ft.lb)

10–1212-1510–1219-23404525-3020-2512-1640-4550-5525-3012-1520-2850-55

110-120120-130170-180

Ø200-220

290-31080-100

Xote. W-1OO lb. ft. plus increase torque to line up cotter pin.● —Lubricate at .awembly with International Compound No. 2 or equival-

e n t

1-2

TM 10-3930-242-34

(b) Standard bolt and nut torque specifications.

Size Nut or Bolt Torque (ft-lb) Size Nut or Bolt Torque (ft-lb) Size Nut or Bolt

¼-20

Torque (ft-lb)

7-9 ½-13¼-28

71-75 7/8-98-10

410-420½-20 83-93

5/16-187/8-14

13-17475-485

9/16-12 90-100 1-8 580-5905/16-24 16-19 9/16-18 107-117 1-14 685-6953/8-16 30-35 5/8-11 137-147 11/8-12 705-7353/8-24 35-39 5/8-18 168-178 1¼-127/16-14

790-84046-50 3/4-10 240-250 1½-12 900-1000

7/16-20 57-61 3/4-16 290-300—

(c) Standard pipe plug torque specifications, (9) Engine repa i r a n d replacement

Pipe plug size Torque (ft-lb) s t a n d a r d s . Table 1-1 l is ts the manufacturer’ssizes, tolerances, clearances, and maximum al-

1/8” -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-12¼ ” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

lowable wear and clearances.14-16

3/8” -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18-22½ ” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23-273/4” -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33-371 ” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75-851 ¼ ” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95-1051 ½ ” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110-130

.Nate: These specifications apply only ta plugs accessible on the outside of a ,finished engine. However, they do not apply to plugs installed below the surfaceof the part of whzchtiey awacamponant. Hea~es5plugs to be flush tox,’’ belowthe surface of cylindarhend. Apply sealin~ compound to plugs used withoutgssketsortefkm tape.

Table 1-1. Repair and Replacement Standards

New partsEngine parts (standard size) Wear

Minumum Maximum limits

CYLINDER BLOCK 1

Block BoresDiameter (Top)-------------------------------------------------------------------------Diameter (Center -------------------------------------------------------------------Diameter (Bottom) ------------------------------------------------------------------O u t - o f - R o u n d - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -T a p e r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Top SurfaceF l a t n e s s - T r a n s v e r s e ( A l l ) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -F l a t n e s s - L o n g i t u d i n a l - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Depth ofCounterbores (Top Surface)Cylinder Head Seal Strip Grove -----------------------------------------Oil Holes ----------------------------------------------------------------------------------------W a t e r H o l e s - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Main Bearing BoreInside Diameter (Vertical Axis) In-Line Engine --------------------------

Cylinder Liner CounterboreD i a m e t e r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -D e p t h - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

CYLINDER LINERS Outside Diameter (Upeer Seal Ring Surface)-------------------------------Outside Diameter (Lower Seal Ring Surface)--------------------------------Inside Dameter -----------------------------------------------------------------------

O u t - o f - R o u n d - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -T a p e r - L i n e r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Depth of Liner Flange Below Block ---------------------------------------PISTON Diameter (At Skirt) -----------------------------------------------------------------------Clearance-Pis ton- to-Liner--- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -O u t - o f - R o u n d - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -T a p e r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Piston Pin Bushing-Inside Diameter ----------------------------------------------

4.5195"4.4865"4.3565"

0.0970"0.0920"0.1090"

3.2510"

4.8200"0.3000"

4.4850"4.3550"3.8752"

0.0465"

3.8693"0.0037"

1.3775"

4.5215"4.4880"4.3575"0.0015"0.0015"

4.6235"4.4900"4.3595"

0.0030"0.0070"

0.1070"0.0980"0.1150"

3.2520"

4.8350"0.3020"

4.4860”4.3560"3,8767"0.0020"O.OO1O"0.0500"

3.871.5"0.0074"0.0005"0.0005"1.3780"

0.003"0.002"0.050"

0.010"

1-3

TM 10-3930-242-34

S(.W ,,art,b:!, c,n, ,,,,,1. ,“1,,,,,[,,,<[ .,,,, ) \\ .,...... .... . .,.Y,, n!!)l u!,, .,, ax! ,,, ”,,,

PISTON PINS1

Diameter ---------------- ------------------------------------------------------------------------Clearance-Pin-to-Piston Bushing -----------------------------------------------Clearance-Pin-to-Rod Bushing --------------------------------------------------PISTON RINGS Compression Rings

Gap (Chrome ring) -----------------------------------------------------Gap (Cast iron ring) ---------------------------------------------------

Clearance-Ring-to-GrooveTop(No.1)--------------------------------------------------------------------------------No.2-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -No.3 and 4 (21:1 Piston) ------------------------------------------------

Oil RingsGap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Clearance-Ring-to-Grove ----------------------------------------------

CONNECTING RODS1

Length-Center-to-Center ---------------------------------------------------------Lower Bore --------------------------------------------------------------------------Upper Bore-Diameter --------------------------------------------------Bushing Inside Diameter -----------------------------------------------------------Normal Rod Side Clearance -------------------------------------------------------CRANKSHAFT 2

Journal Diameter-Main Bearing ---------------------------------------------------Journal Diameter-Connecting Rod ---------------------------------------Journal Out-of-Round ----------------------------------------------------Journal Taper ----------------------------------------------------------Runoutat Journal-Total Indicator Reading 4-53 ----------------------------Thrust Washer Thickness ------------------------------------------------End Thrust Clearance ---------------------------------------------------------------MAIN BEARINGS Bearing Inside Diameter (Vertical Axis) ------------------------------------Bearing Thickness-90° from Parting Line ---------------------------------Clearance-Bearing-to-Journal -------------------------------------------CONNECTING ROD BEARINGS1

Bearing Inside Diameter (Vertical Axis -----------------------------------Bearing Thickness-90° from Parting Line ---------------------------------Clearance-Bearing-to-Crankshaft Journal --------------------------------CYLINDER HEAD 1

Cam Follower Bore-Current ---------------------------------------------Cam Follower Bore-Former ---------------------------------------------

Exhaust Valve Seat Insert Counterbore Diameter --------------------------VALVE SEAT INSERTS1

Outside Diameter -------------------------------------------------------------------Seat Width --------------------------------------------------------------------------Valve Seat Runout ------------------------------------------------------EXHAUST VALVES 1

Stem Diameter Former --------------------------------------------------Stem Diameter ----------------------------------------------------------

VALVE GUIDES 1

Distance Below Top of Head (Plain Guide) ---------------------------------Distance Below Top of Head (Guide Machined for Oil Seal) ------------------Diameter-Inside ------------------------------------------------------------------Clearance-Stem-to-Guide

Former -----------------------------------------------------------------------------------Current ----------------------------------------------------------------------------------------

ROCKER ARMS AND SHAFTS1

Rocker Arm Shaft Diameter ----------------------------------------------Injector Rocker Arm Bushing Inside Diameter -------------------------------Diameter of Bore in Exhaust Valve Rocker Arm for Rocker Arm Shaft -------Clearance-Shaft-to-Injector Rocker Arm Bushing -------------------------

1.3746"0.0025"0.0010"

0.0200"0.0200"

0.0030"0.0070"0.0045"

0.100"0.0015"

8.7990"2.7515"1.6000"1.3760"0.0060"

2.9990"2.4990"

0.1205"0.0040"

3.0020"0.1245"0.0010"

2.5015"0.1245"0.0015"

1.0626"1.0620"

1.1590"

1.1605"3/64"

0.2475"0.2480"

0.0100"0.1900"0.2505"

0.0020"0.0017"

0.8735"0.8750"0.8753"0.0010"

1.3750"0.0034"0.0019"

0.0460"0.0360"

0.0060"0.0100"0.0070"

0.0250"0.0055"

8.8010"2.7525"1.6010"1.3765"0.0120"

3.000"2.5000"

0.00025"0.0005"0.0020"0.1220"0.1100"

3.0030"0.1250"0.0040"

2.5035"0,1250"0.0045"

1.0636"1.0630"

1.1600"

1.1615"5/62"

0.0020"

0.2485"0.2488"

0.0400"0.2200"0.2515"

0.0040"0.0035"

0.8740"0.8760"0.8763"0.0025"

I1!lII1,

0.010"0.010"

0.060"0.060"

0.012"0.014"0.012"

0.044"0.008"

0.0030"

0.0180"

0.1230"0.0060"

0.1230"0.0060"

See Cam Fol-ler Clear-ance

5/64”0.0020"

See GuideClearance

See GuideClearance

0.0050"0.0050"

0.0040"

1 - 4

TM 10-3930-242-34

New partsEngine parts (standard size)

MinimumWear

Maximum limits

Clearance-Shaft-to-Exhaust Valve Rocker Arm Bore”CAM FOLLOWERS 1

Diameter ---------------------------------------------------------------Clearance-Follower-to-Head-Former ------------------------------------Clearance-Follower-to-Head-current------------------------------------Width of Roller Slot -----------------------------------------------------Roller PinHole Diameter ------------------------------------------------CAMFOLLOWER ROLLERSAND PINS1

Roller Outside Diameter -------------------------------------------------Roller Bushing Inside Diameter ------------------------------------------Roller Pin Outside Diameter ---------------------------------------------Clearance-Pin-to-Bushing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Side Clearance-Roller-in-Follower ---------------------------------------CAMSHAFT’Shaft Diameter at Bearings ----------------------------------------------Runout at Center Bearing (when mounted on End Bearings)----------------Thrust Washer Thickness ------------------------------------------------End Thrust -------------------------------------------------------------BALANCE SHAFT 1

Shaft Diameterat Bearings----------------------------------------------Thrust Washer Thickness ------------------------------------------------End Thrust -------------------------------------------------------------CAMSHAFT AND BALANCE SHAFT BEARINGS1

Bearing Inside Diameter -------------------------------------------------Clearance-Bearings-to-Shaft --------------------------------------------CAMSHAFT AND BALANCE SHAFT GEARS’Backlash ---------------------------------------------------------------IDLER GEAR 1

Backlash ---------------------------------------------------------------Idler Gear Bearing Inside Diameter --------------------------------------Idler Gear Hub Outside Diameter ------------------------------------------Clearance-Bearing-to-Hub ----------------------------------------------Thrust Washer Thickness ------------------------------------------------End Play ---------------------------------------------------------------CRANKSHAFTTIMING GEAR1

Backlash ---------------------------------------------------------------BLOWER DRIVE GEAR1

B a c k l a s h - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Blower Drive Gear Shaft End Play ----------------------------------------Thrust WasherThickens (4-53) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -GOVERNOR GEAR DRIVE1

Backlash ---------------------------------------------------------------1 These wear limits also apply to oversize or undersize parts.2 This runout tolerence given for guidance when regrinding crankshafts:NOTE: Crankshaft supported on No. 1 and No. 5 journals; runout measured at No. 2, 8 and 4 journals.

When runout on adjacent journals is in the opposite direction, the sum must not exceed 0.008” total indicator reading when in the same direction, the difference must notexceed 0.008" total indicator reading. When high spots of run out on adjacent journals are at right angles to each other, the sum must not exceed 0.004” total indioator reoding,OrO.CWOnes&Jpurt@

0.0013"

1.0600"0.0010"0.0016"0.5635"0.4362"

0.9020"0.4390"0.4374"0.0013"

0.0150"

2.1820"

0.208"0.008"

2S820"0.208"0.008"

2.187"0.0046"

0.003"

0.003"2.186"2.1825"0.0025"0.118"0.006"

0033"

0.003"0.004"0.093"

0.003"

0.0028"

1.0610"0.0030"0.0036"0.5685"0.4370"

0.9070"0.4396"0.4377"0.0021"

0.230"

2.1826"0.002"0.210"0.016"

2.1825"0.210"0.015"

2.188"0.006"

0.006"

0.005"2.187"2.1835"0.0046"0,120"0.013"

0.006"

0.006"0.006"0.103"

0.006"

0.0040"

0.0060"0.0060"

0.010"Horiz

0.230"

0.019"

0.019"

0.008"

0.007"

0.007"

0.007"

0.017"

0.007"

0.007"

0.007”

1-5

TM 10-3930-242-34

Chapter 2

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT

2-1. Special Tools and Equipment 242-34P/2, and are listed in Table 2-1. Refer-ences indicating the use of these tools are listed

The special tools required to perform direct in the table. No special equipment is required bys u p p o r t a n d g e n e r a l s u p p o r t m a i n t e n a n c e o n direct or general support maintenance person-the forklift trucks are listed and illustrated inT M 1 0 - 3 9 3 0 - 2 4 2 - 3 4 P / 1 a n d T M 1 0 - 3 9 3 0 -

nel for performance of maintenance on the fork-lift truck.

Table 2-1. Special Tools

ReferenceItem FSN or Reference No. Fig. No. Para No. Use

Injector tool, timing ------------------ 5220-387-9581 3-14 Timing fuel injectorsKit, pressure gage -------------------- 3930-73’7-6430 5-13 Charge accumulatorRegulator charging Accumulator Kit ___ 4910-861-2068 5-13 Charge accumulatorSocket, bearing adjusting nut ---------- 5120-009-8602 5-6 Adjust wheel bearing nut

2-2. Maintenance Repair Parts 10-3930-242-34P/2, for direct and general sup-

Repa i r pa r t s and equ ipmen t a r e l i s t ed and port maintenance of this equipment.i l lus t ra ted in TM 10-3930-242-34P/1 and TM

Section II. TROUBLESHOOTING

2-3. GeneralThis sect ion contains t roubleshooting infor-

mation for locating and correcting most of thetroubles that may develop on the forklift truck.

2-4. Troubleshooting Charta. In table 2-2, each malfunction for an indi-

vidual component, unit, or system is followed bya list of tests or inspections that will help you todetermine probable causes or corrective actionsto take. You should perform the tests, inspec-tions and corrective actions in the order listed.

b. This manual cannot l is t al l malfunctionsthat may occur, nor all tests or inspections andcorrective actions. If a malfunction is not listedor is not corrected by listed corrective actions,notify your supervisor.

Table 2-2. Troubleshooting

MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

1. ENGINE HARD TO START OR FAILS TO START.Step 1. Check for defective starter motor.

Repair or replace starter (para 3-11).


CORRECTIVE ACTION

Step 2. Check for leaking or defective valves.Repair or replace valves (para 3-20).

Step 3. Check for low compression caused by brokenor worn piston rings.

Replace defective piston rings (para 3-26).Step 4. Check for defective fuel pump.

Repair or replace fuel pump (para 3-16).Step 5. Check for defective starter circuit.

Repair starter circuit continuity (para3-11).

2. ENGINE MISSES OR RUNS ERRATICALLY.Step 1. Check fur defective fuel injector.

Repair or replace fuel injector (para 3-14).Step 2. Check for defective valves.

Repair or replace valves (para 3-20).Step 3. Check for low compression caused by broken

or worn piston rings.Replace defective piston rings (para 3-26).

Step 4. Check for inadequate fuel flow.Make a fuel flow test (para 3-16).

3. ENGINE LACKS POWERStep 1. Check for low air box pressure.

Replace air cleaner element or clean blowerscreen (para 3-4), or replace engine endplate gaskets (para 3-35).

2-1

TM 10-3930-242-34

MALFUNCTIONMALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION

Step 2.

Step 3.

Step 4.

Step 5.

Check for defective valves.Repair or replace valves (para 3-20).

Check for low compression caused by brokenor worn piston rings.

Replace defective piston rings (para 3-26).Check for defective push rods or rocker arms.

Replace defective push rods or rocker arms(para 3-15).

Check for proper functioning of governor.Adjust or replace governor.

4. ENGINE OVERHEATS.Step 1. Check for defective radiator.

Repair or replace radiator (para 3-8).Step 2. Check for defective water pump,

Repair or replace water pump (para 3-8).Step 3. Check for cracked cylinder head.

Replace defective cylinder head (para3-19),

5. ENGINE EXHAUST SMOKE EXCESSIVE.Step 1. Check for defective fuel injector.

Repair or replace fuel injector (para 3-14),Step 2. Check for restricted air intake.

Clean blower screen (para 3-4).Step 3. Check for low compression caused by broken

or worn piston rings,Replace defective piston rings (para 3-26).

Step 4. Check for cracked or broken piston.Replace defective piston (para 3-26).

6. ENGINE NOISY.Step 1. Check for defective valves.

Repair or replace valves (para 3-20).Step 2. Check for defective connecting-rod bearings.

Replace defective bearings (para 3-26).Step 3. Check for defective main bearings.

Replace defective bearings (para 3-31).Step 4. Check for loose or broken piston pins.

Replace defective piston pins (para 3-26).Step 5. Check for loose or defective flywheel.

Tighten or replace flywheel (para 3-21).7. ENGINE HAS LOW OR NO OIL PRESSURE.

Step 1. Check for oil dilution caused by leaking fuelline or injector.

Correct leak or replace defective fuel in-jector (para 3-14).

Step 2. Check for defective oil pump,Repair or replace oil pump (para 3-2),

Step 3. Check for defective connecting-rod bearings.Replace defective connecting-rod bearings(para 2-26).

Step 4. Check for loose or defective main bearings.Replace defective main bearings (para3-31),

8. ENGINE OIL CONSUMPTION EXCESSIVE.Step 1. Check for broken or worn piston rings.

Replace defective piston rings (para 3-26).Step 2. Check for cracked, burned, or broken piston.

Replace defective piston (para 3-26).Step 3. Check for worn valve guides.

Replace defective valve guides (para 3-20).9. STARTER FAILS TO CRANK ENGINE.

Step 1. Check for defective engine safety circuit.Isolate circuit trouble and repair.

TEST OR INSPECTIONCORRECTIVE ACTION

Step 2. Check for defective starter.Repair or replace starter (para 3-11).

Step 3. Check for defective flywheel ring gear (para3-21).

10. ENGINE GENERATOR AMMETER SHOWS LOW ORNO CHARGING RATE WHEN BATTERIES ARELoW OR DISCHARGED.

Step 1. Check for defective generator brushes.Replace defective brushes (para 3-9).

Step 2. Check for defective voltage regulator.Repair or replace voltage regulator (para3-10).

Step 3. Check for defective armature.Replace defective armature (para 3-9).

Step 4. Check for defective field windings.Replace defective field windings (para3-9),

11. ENGINE GENERATOR AMMETER SHOWSCHARGE WHEN BATTERIES ARE FULLYCHANGED.

Step 1. Check for grounded field winding.Replace defective field winding (para 3-9).

Step 2. Check for defective voltage regulator.Repair or replace defective voltage reg-ulator (para 3-10).

12. ENGINE GENERATOR OVERHEATS.Step 1. Check for grounded or shorted armature.

Replace defective armature (para 3-9).Step 2. Check for defective generator bearings.

Replace defective bearings (para 3-9),13. TRANSMISSION AND TORQUE CONVERTER

OVERHEATS.Step 1. Check for low oil level.

Service per lubrication order.Step 2. Check for low coolant level in radiator.

Refill with coolant to proper level,Step 3. Check for airated oil (foaming).

Drain and refill. Refer to lubricationorder.

Step 4. Check for clogged or dirty oil cooler.Clean or replace oil cooler (para 3-3).

14. TRUCK MOVES IN ONE DIRECTION ONLY.Step 1. Check for defective control valve.

Repair or replace transmission controlvalve (para 4-5).

Step 2. Check for transmission clutch shippage bychecking clutch pressures.

Repair or replace transmission (para 4-2).15. ENGINE RUNS BUT TRUCK WILL NOT MOVE.

Step 1. Check control valve for proper adjustment.Adjust or repair control valve (para 4-5).

Step 2. Check for defective torque converter.Repair or replace torque converter (para4-2).

Step 3. Check for defective transmission assembly.Repair or replace transmission (para 4-2).

16. STEERING HYDRAULIC CYLINDER LEAKS.Step 1. Check for worn or damaged packing.

Replace defective packing (para 5-15).Step 2. Check for cracked or broken cylinder hous-

ing.Replace defective housing (para 5-15).

2-2

TM 10-3930-242-34

MALFUNCTIONTEST INSPECTION

CORRECTIVE ACTION

Step 3. Check for scored piston rod.Replace defective piston rod (para 5-15).

17. HYDRAULIC SYSTEM LOSES PRESSURE.Step 1. Check for defective hydraulic control valve.

Repair or replace defective hydraulic con-trol valve (para 6-2, 6-3, 64, or 6-8).

Step 2. Check for defective hydraulic pump.Repair or replace defective hydraulicpump (para 6-15 or 6-16).

18. HYDRAULIC VALVES WILL NOT HOLD.Step 1. Check for scored valve spool.

Rep] ace defective valve spool (para 6-2 or6-4).

Step 2. Check for dirt or foreign matter in valve.Clean valve (para 6-2 or 64).

Step 3. Check for weak or broken detent spring.Replace defective spring (para 6-2).

19. TRUCK LOSES FOUR WHEEL DRIVE.Step 1. Check for defective or wrongly adjusted

transmission control cable.Adjust or replace cable (para 4-2i).

Step 2. Check for defective shifter coupling.Replace defective shifter coupling (para5-7).

Step 3. Check for defective planetary gears (finddrive).

Replace defective planetary gears (para4-2).

20. DIFFERENTIALS EXCESSIVELY NOISY.Step 1. Check for broken or worn bearing.

Replace defective bearing (para 5-6).Step 2. Check for defective pinion and ring gear.

Replace defective ring and pinion gear(para 5-6)

21. PLANETARY DRIVES EXCESSIVELY NOISY.Step 1. Check for worn or broken planetary gear.

Replace defective planetary gears (para4-2).

Step 2. Check for worn or broken bearings.Replace defective bearings (para 4-2).

22. TRANSMISSION MAIN PRESSURE LOW.Step 1. Check for low oil level.

Add oil if low. Refer to the lubricationorder,

Step 2. Check for clogged strainer screen.Clean strainer screen (para 4-2).

Step 3. Check for defective main pressure regulatorspring.

Replace defective spring (para 4-4).Step 4. Check for main pressure regulator valve

sticking open,Rebuild main pressure regulator body as-sembly (para 4-4).

Step 5. Check for clutch cutoff valve sticking open.Rebuild control valve body assembly (para4-5).

Step 6. Check for aerated oil (foaming).Oil level high, or of improper grade. Ifhigh, drain to proper level. If impropergrade, drain and fill. Refer to the lubrica-tion order.

Step 7. Check for worn or damaged input oil pump.If damaged, rebuild pump (para 4-2).


CORRECTIVE ACTION

Step 8. Check for dirty lubrication pressure valve,sticking open.

If sticking, clean valve (para 4-4).23. CONVERTER STALL SPEED LOW.

Step 1. Check for improperly adjusted throttle link-age.

If improperly adjusted, adjust throttlelinkage for full governor travel (para 3-7).

Step 2. Check for improperly tuned engine.If improperly tuned, tune engine (para3-7,3-14, and 3-15).

24. CONVERTOR STALL SPEED HIGH.Step 1. Check for low convertor pressure.

If pressure is low, overhaul transmission(para 4-2).

Step 2. Check for slipping clutches.If clutches are slipping, rebuild transmis-sion (para 4-2),

Step 3. Check for freewheeling stator. If stator freewheeling, rebuild transmis-sion (para 4-2).

25. TRANSMISSION OIL TEMPERATURE HIGH.Step 1. Check for low oil level.

If low, add oil to proper level. Refer to thelubrication order.

Step 2. Check for high oil level.If oil level high, drain oil to proper level.

Step 3. Check for low water level in engine coolingsystem.

Allow engine and transmission to cool.Add coolant and check for leaks. Correct asrequired.

Step 4. Check for extended operation in inefficienttransmission range.

Operate unit in lower transmission range.26. FORKLIFT TRUCK HAS POWER LOSS.

Step 1. Check for low engine output.Check engine tune, If necessary, tune en-gine (para 3-7, 3-14, and 3-15).

Step 2. Check for slipping clutch,Check clutch pressure (para 4-2h).

Step 3. Check for low main pressure.Refer to 22, above.

Step 4. Check for improper convertor functioningsuch as stator (or stators) locked, convertorelement interference, or noise at stall.

Overhaul torque converter (para 4-2).27. NO POWER TRANSMITTED IN ANY RANGE.

Step 1.

Step 2.

Step 3.

Check for proper positioning of control val-ves.

Adjust control valve linkage if necessary(para 4-2).

Check for low main pressure.Refer to 22, above.

Check for mechanical failure.Disassemble and rebuild the transmission(para 4-2).

28. NO POWER TRANSMITTED IN ONE RANGE.Step 1. Check for slipping clutch by checking clutch

pressure (para 4-2h) and by checking forworn piston seals.

Rebuild transmission if necessary (para4-2).

2-3

TM 10-3930-242-34


CORRECTIVE ACTION

Step 2. Check for improperly adjusted control val-ves.

Adjust control valve linkage, if necessary(para 4-2).

Step 3. Check for mechanical failure.Disassemble and rebuild transmission(para 4-2).

29. VEHICLE OPERATES IN ALL FORWARD GEARS,BUT STALLS IN ALL REVERSE GEARS.

Check for forward clutch failure (will not re-lease).

Rebuild transmission (para 4-2).

30. VEHICLE OPERATES IN ALL REVERSE, GEARS,BUT STALLS IN ALL FORWARD GEARS.

Check for reverse clutch failure (will not re-lease).



CORRECTIVE ACTION

31.

32.

33.

VEHICLE OPERATES IN FORWARD AND RE-VERSE IN LOW RANGE, BUT STALLS ININTERMEDIATE AND HIGH RANGE.

Check for low range clutch failure (will notrelease).

Rebuild transmission (para 4-2).VEHICLES OPERATES FORWARD AND REVERSEIN INTERMEDIATE RANGE, BUT STALLS IN LOWAND HIGH RANGES.

Check for intermediate clutch failure (willnot release).

Rebuild transmission (para 4-2).VEHICLE OPERATES FORWARD OR REVERSE INHIGH RANGE, BUT STALLS IN LOW ORINTERMEDIATE RANGES.

Check for high range clutch failure (will notrelease).


Section III. REMOVAL AND INSTALLATION OF MAJORCOMPONENTS AND ASSEMBLIES

WARNING

Use a suitable lifting device for lifting themajor components. Do not allow majorcomponents to swing when suspended inthe air. Exercise extreme caution whenworking near a cable or chain under ten-sion. Failure to follow the warning mayresult in Serious injury or death.

2-5. Engine

a. Removal .(1) Remove the hood, fan guard, fan,

f ler , s i de cove r s , a n d e x h a u s t p i p e10–3930-242-12).

(2) Remove hoses , l ines , and l inkage10-3930-242-12).

(3) Disconnect propeller s h a f t10-3930-242-12).

muf-(TM

(TM

(TM

(4) Refer to figure 2-1 and remove engine.NOTE

The engine is equipped with lifting brackets.These brackets are located on top front and rear ofengine.

b. Installation.(1) Refer to figure 2-1 and install engine.(2) Install propeller s h a f t (TM

10-3930-242-12).(3) Instal l hoses , l ines , and l inkage (TM

10-3930-242-12).(4) Ins ta l l hood, fan guard, fan, muff ler ,

s ide covers , a n d e x h a u s t pipe (TM10-3930-242-12).

2-6. Torque Converter and Transmission As-sembly

a. Removal .

NOTERaise the forklift sufficiently, by blocking underthe axle housing, to permit removal of the trans-mission assembly after it has been lowered to thefloor.

(1) Drain the torque converter and t rans-mission assembly from transfer case.

(2) Remove overhead guard, control knobs,and control panels (TM 10-3930-242–12).

(3) Remove hoses, l inkage, and propel lershafts (TM 10–3930–242-12).

(4) Remove the rear s teer ing pump (TM5-3930-242-12).

(5) Refer to figure 2-2 and remove the tor-que converter and transmission assembly as anassembly.

WARNING

Install a lifting eye in threaded holesprovided in the top of the transmission.Exercise extreme caution during removaland installation; the transmission weighsapproximately 1200 pounds.

b. Installation.(1) Refer to f igure 2-2 and insta l l torque

converter and t ransmission assembly.(2 ) I n s t a l l hose s , l i nkage , and p rope l l e r

shafts (TM 10-3930-242-12).

2-4

TM 10-3930-242-34

Figure 2-1. Engine, removal and installation.

(3) Reinstal l control panel , control knobsand overhead guard (TM 10-3930-242-12).

(4) Install the rear steering pump.(5) Refer to the lubrication order, and fill

the t ransmission,

2-7. Axle Assemblies

a. Removal .(1) Use a suitable lifting device and raise

and b lock t he fo rk l i f t t r uck unde r t he ma inframe. Be careful not to crush the brake tubing.

(2) Remove propeller shaft, steering cylin-der and linkage, hydraulic hoses, oscillating cy-linder, and wheels (TM 10-3930-242-12).

{3) Refer to figure 2-3 and remove the axleassembly.

NOTERemove both axles in a similar manner.

WARNING

Never crawl under forklift truck whileperforming maintenance unless i t isblocked securely. Failure to observe thiswarning may result in serious injury or

death. When removing axles, be sure thetruck is blocked to prevent oscillation.

b. Installation.(1) Refer to figure 2-3 and install the axle

assembly.(2) Install propeller shaft, steering cylinder

and linkage, hydraulic hoses, oscillating cylin-der and wheels (TM 10-3930-242-12).

(3) Remove the blocking and lower forklifttruck on to the axle assembly.

2-8. Boom Assembly

a. Removal .(1) Remove o v e r h e a d g u a r d (TM

10-3930-242-12).(2) Remove ca r r i age as sembly (TM

10-3930-242-12).(3) Disconnect hydraulic hoses and discon-

nect slave cylinder and extension cylinder fromthe boom assembly (TM 10-3930-242-12).

(4) Remove the inner boom.(5) Disconnect

10-3930-242-12).(6) Remove fuel

l if t cyl inders (TM

tank (para 3-17).

2-5

TM 10-3930-242-34

t o

Figure 2-2. Torque converter and transmission assembly,removal and installation.

(7) Attach a suitable lifting device and refer ( 3 ) C o n n e c t t h e l i f t c y l i n d e r s ( T Mfigure 2-4 and remove boom assembly. 10-3930–242-12).

b. Installation.(1) Refer to figure

assembly.(2) Install the fuel

2-6

(4) Install the inner boom.2-4 and install the boom (5) Connect the slave cylinder, extension cy-

l i n d e r , a n d h y d r a u l i c h o s e s ( T M 1 0 - 3 9 3 0 -tank (para 3-17). 242-12).

TM 10-3930-242-34

(6) Install carriage assembly (TM 10-3930- ( 7 ) I n s t a l l o v e r h e a d g u a r d ( T M 3 9 3 0 -242-12). 242-12).

Figure 2-3. Front azle assembly, removal and installation.

Figure 2-4. Boom assembly, removal and installation.2-7

TM 10-393-242-34

CHAPTER 3

REPAIR OF ENGINE

Section I. ENGINE ACCESSORIES

3-1. General

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h emaintenance of those items considered to be en-gine accessories. They consist of the oil pump,oil cooler, air inlet housing, blower assembly,speed l im i t i ng gove rno r , r ad i a to r , gene ra to r ,and s t a r t e r .

3-2. Oil Pump and Crank Shaft Pulley

a. General. The rotor-type oil pump is boltedto back of engine lower front cover and drivendirect ly by the crankshaft . Oil is directed tolower engine front cover and then to a main oilgallery in cylinder block under pressure to mainbearings, balance shaft, and camshaft bearings.The c r anksha f t pu l l ey i s u sed t o d r i ve t hegenerator and fan.

b. Removal .(1) Remove the engine (para 2-5).

Figure 3-1. Oil pump and crankshaft pulley, removal andinstallation.

(2) Refer to figure 3-1 and remove oil pumpand crankshaf t pul ley.

c. Disassemble. Refer to figure 3-2 and disas-semble oil pump in numerical sequence.

d. Cleaning and Inspection.( 1 ) C l e a n t h e p u m p t h o r o u g h l y w i t h d r y

cleaning solvent such as P-D-680, or equal, toremove all traces of dirt, sand, or foreign matterthat might damage the pump.

(2) The greatest amount of wear in the oilpump occurs on the lobes of the inner rotor (10,figure 3-2) and outer rotor (11) of each lobe.Clearance should not be less than 0.004 inch normore than 0.011 inch.

(3) Using a micrometer depth gage, meas-ure the distance from the face of the pump cover(12) to sides of inner rotor (10) and outer rotor(11). Clearance should not be less than 0.001 inchnor more than 0.0035 inch,

(4) Discard the gasket (7) and seal (14).(5) Replace all defective parts.

e. Reassembly.

NOTE

Rotors are obtainable only in matched sets.(1) Refer to figure 3-2 and reassemble the

oil pump with the exception of the seal (14).(2) Install the seal with the cup side facing

i n w a r d .

3-3. Oil Cooler

a. General. The oil cooler is attached to an oilcooler adapter a t tached to the cyl inder block.The flow of oil is from oil pump through a pas-sage in the oil cooler adapter to full flow oil filterand then through the oil cooler core and cylin-der block oil galleries,

b. Removal.(1) Drain cooling system by opening drain

cock at bottom of cooler housing.(2) Remove fuel filter, oil filter, and water

pump (TM 10-3930-242-12).(3) Refer to figure 3-3 and remove the oil

cooler.

c. Disassembly. Refer to figure 3-4 and disas-semble oil cooler.

3-1

TM 10-3930-242-34

Figure 3-2. Oil pump, disassembly and reassembly.

d. Cleaning and Inspection.(1) Clean the oil cooler metal parts using an

alkaline cleaning compound such as P-C-436, Ifthe oil cooler core is aluminum, use dry cleaningsolvent P-D-680, or equal.

(2) Clean all lubrication oil passages withcompressed air.

(3) Inspect the housing for cracks, breaks,and other damage.

(4) Inspect all mounting hardware for dam-age. Replace damaged or defective parts.

e. Pressure Test.(1 ) Make a su i t ab l e p l a t e and a t t ach to

flanged side of cooler core (use a gasket madefrom rubber to assure tight seal), Drill and tapthe plate to permit an air hose fitting to be at-tached to inlet side of core.

(2) Apply approximately 75 psi air pressureand submerge the cooler core and plate assem-bly in a container of water. Any leaks will beindicated by air bubbles in the water. If leaksare indicated, replace the core.

f . Reassembly. Refer to figure 3-4 and reas-semble oil cooler. Use new gaskets upon reas-sembly.

3-2

g. In s t a l l a t i on .(1) Refer to figure 3-3 and install the oil

cooler.(2) Instal l the fuel f i l ter , oi l f i l ter , and

water pump (TM 10-3930-242-12),

3-4. Air Inlet Housing

a. General. The air inlet housing is mountedon the side of blower, It contains an air shut-down valve that shuts off air supply and stopsthe engine whenever abnormal operating condi-tions require an emergency shutdown,

b. Removal Refer to f igure 3-5 and removethe air inlet housing,

c. Disassembly. Refer to figure 3-6 and disas-semble air inlet housing in numerical sequence,noting the position of shutdown spring.

d. Cleaning and Inspection,(1) Clean air inle t housing and hardware

using a cleaning solvent such as P-D-680, orequal .

(2) Clean the housing gasket screen of dirtand foreign material, Use solvent P-D-680, orequal, and blow dry with low pressure compres-sed air.

TM 10-3930-242-34

Figure 3-3. Oil cooler, removal and installation.

(3) Inspect springs for cracks and bends.(4) Inspect a l l mounting hardware for de-

fects and wear. Replace a defective part.e. Reassembly. Refer to figure 3-6 and reas-

semble the air inlet housing.f. Installation. Refer to figure 3-5 and install

air inlet housing.

3-5. Blower Assemblya. General . The blower assembly is located

beh ind t he a i r i n l e t hous ing . I t supp l i e s t hefresh air required for combustion and scaveng-ing. The revolving motion of the rotors provide acontinuous and uniform displacement of air.

b. Removal .(1) Remove t h e f u e l f i l t e r (TM

10-3930-242-12).( 2 ) R e f e r t o f i g u r e 3 - 5 a n d r e m o v e t h e

blower assembly.c. Disassembly. Refer to figure 3-7 and disas-

semble blower assembly as follows:(1) Wedge a clean cloth between the blower

r o t o r s t o p r e v e n t t h e i r t u r n i n g a n d r e m o v eb lower d r i ve cam r e t a ine r and b lower d r i vespring support to rotor gear.

(2) Use two pullers to remove both blowergears from rotor shaft at the same time. Markthe upper rotor gear to facilitate identificationat reassembly.

d. Cleaning and Inspection.(1) Clean the blower assembly components,

using a dry cleaning solvent such as P-D-680 orequa l .

(2) Inspect the rotors and housing for deepsc ra t ches . I f deep sc r a t ches ex i s t , d r e s s t hepar ts down.

(3) Inspect the rotors for scoring.(4) Check for leaking oil seals.(5) Check for loose or worn rotor shaft and

rotor shaft bearings. See table 1-1 for replace-men t s t anda rds .

e.

NOTELoose rotor shafts or worn rotor shaft bearingswill result in contact between rotor lobes, rotor,and end plates or rotor and housing, Excessivebacklash between blower timing gears usually re-sults in rotor lobes rubbing together throughouttheir entire length.Reassemble . Refer to figure 3-7 and reas-

semble as follows:

3-3

TM 10-3930-242-34

Figure 3-4. Oil cooler, disassembly and reassembly.

(1) Install retainer spring (21, fig. 3-7), re- NOTE

tainer (20) (disked side up), O-ring (19) and seal Effective with engines serial Nos. 42D-A036 andwasher (18) on the rotor shafts (22 and 23). up, the blower end plates (10 and 17, fig. 3-7) are

(2) Place front end plate (10) on two woodcounterbored and use two teflon oil seals in each

blocks; then install the rotors, gear up, on theend plate in lieu of washer (18), O-ring (19), re-

end plate.tainer (20), and spring (21). The two teflon sealsare pressed into the counterbore of the end plates

NOTE prior to reassembly.

To prevent inadequate lubrication or low oil pres- (3) Instal l a retainer spring (21), retainersure, care must be exercised in the assembly of (20), O-ring (19), and seal (18) on rotor shaft inthe front (10) and rear (17) end plates. The rear the gear end of both rotors and install blowerend plate (17) does not have tapped holes forthrust washer plate bolt (6) and no thrust washer

housing (25) over the rotors.

lubrication oil holes. (4) Place the rear end plate (17) over the

3-4

TM 10-3930-242-34

Figure 3-5. Air inlet housing and blower assembly, removaland installation.

Figure 3-6. Air inlet housing, disassemble and reassembly.

3-5

TM 10-3930-242-34

Figure 3-7. Blower, disassembly and reassembly.

rotor shafts . Be sure that seals are properlypositioned on rotors. Then, secure end plate (17)to blower housing with bolts.

(5) Attach two thrust washers (7) to frontend of blower with bolt (6).

(6) Attach three spacers (5) and thrust plate(4) to front end of blower with three bolts (3).Tighten bolts to 7-9 ft.-lb. torque and check thec l e a r a n c e b e t w e e n t h r u s t p l a t e a n d t h r u s twasher . The clearance should be 0.001-0.003inch.

(7) position the rotors so that the missingserration on the gear end of the rotor shafts are90 degrees apart. This is accomplished by posi-

tioning the rotors with missing serrations in theupper rotor facing to the left, and the missingserration in the lower rotor facing the bottom.Instal l the shim (14) and spacers (15) in thecounterbore in rear face of rotor gears. Placegears on end of the shafts with missing serra-t ion in al ignment with missing serrat ions onsha f t .

(8) Tap the gears lightly with a soft ham-mer to seat the gears on the shaft. Then, rotatethe gears until punch marks on the face of gearsmatch. If the punch marks on the face of gearsdo not match, reposition the gears.

(9) Wedge a clean cloth between the blower

3-6

TM 10-3930-242-34

rotors. Use the blower rotor gear retaining boltsand plain washers to press the gears on rotorsha f t s . Tu rn bo l t s un i fo rmly un t i l gea r s a r et ight against shoulder on the shaf ts . Removegear bolts, plain washers, and cloth.

(10) Place pilot (12) in counterbore of uppergear and start bolt (11) into rotor shaft, Placerotor gear washer on face of lower gear, startbolt into rotor shaft. Torque bolts to 25-30 ft. lb.

(11) Check the backlash between the blowergears. Backlash should be 0,005 inch to 0.0025inch with new gears. Replace the gears if back-lash exceeds 0,0035 inch.

(12) The rotors , when properly posi t ionedrun with a s l ight clearance between the rotorlobes and with a s l ight c learance between thelobes and walls of the housing. The clearancebetween the rotors may be established by mov-ing one of the helical gears out or in on the shaftrelative to other gear. Moving the gears out orin on the rotor is accomplished by adding orremoving shims between the gear hub and rotorspace r s .

( 1 3 ) M e a s u r e m e n t s h o u l d b e t a k e n f r o mboth the inlet and outlet side of the blower byinserting feeler gage between housing (25) andr o t o r s ( 2 2 a n d 2 3 ) . M e a s u r e m e n t s s h o u l d b etaken across the entire length of each rotor lobeto be certain that a minimum clearance of 0.004inch exists at the air outlet side of the blower;and a minimum clearance of 0.0075 inch existsat the air inlet of the blower. Similar ly, theclearance between rotor lobes should be meas-ured across the length of the lobes. By rotatingthe gears, position the lobes so that they are attheir closest relat ive posit ion. Clearance bet-ween the lobes should be a minimum of 0.010inch. The blower rotor end clearances are 0.006inch for front end plate and 0.009 inch for rearend plate.

f . Instal lat ion.(1) Refer to figure 3–5 and install the blower

assembly.(2) Insta l l t h e fuel f i l t e r (TM

10–3930-242-12).

3-6. Blower Drive and Coupling

a. General. The blower drive and coupling islocated on the air inlet housing side of the en-gine and is dr iven from an idler gear on thecamshaft side of the engine.

b. Removal .(1) Remove the blower assembly (para 3-5).( 2 ) R e f e r t o f i g u r e 3 - 8 a n d r e m o v e t h e

blower drive and coupling.

c. Disassembly. Refer to figure 3-9 and disas-semble the blower drive and coupling.

d. Cleaning and Inspect ion.( 1 ) C l e a n t h e b l o w e r d r i v e a n d c o u p l i n g

components using a solvent such as P-D-680, orequal .

(2) Inspect the gear and hub for wear.(3) Inspect support for scor ing. See table

1-1 for engine wear and replacement standards.Replace a defective part.

e. Reassembly. Refer to figure 3-9 and reas-semble the blower drive and coupling.

f . Instal lat ion.(1) Refer to f igure 3-8 and instal l blower

drive and coupling.(2) Install blower assembly (para 3-5).

3-7. Governor

a . G e n e r a l . T h e m e c h a n i c a l g o v e r n o r i smounted on the rear end plate of the engine,The governor is driven by a gear that extendsthrough the end plate and meshes with the bal-ance shaft gear. The governor controls the en-gine idle speed and limits the maximum operat-ing speed of the engine. The governor is lubri-cated by oil splash from engine gear train dis-t r ibuted by revolving weights , Excess oi l is re-turned to the gear t ra in through holes in thegovernor bear ing re ta iner .

b. Operation.(1) The governor holds the injector racks in

the advanced fuel position for starting when thespeed control lever is in the idling position. Im-med ia t e ly a f t e r s t a r t i ng , t he gove rno r movesthe fuel injector racks to that position requiredfor idling.

(2) The centr i fugal force of the revolvinglow and high speed weights is converted into alinear motion which is transmitted through theriser and operating shaft to the operating shaftlever. One end of the lever operates against thehigh and low speed springs through the springcap, while the other end provides a moving ful-crum on which the differential lever pivots.

(3) When the centrifugal force of the revolv-i ng gove rno r we igh t s ba l ances ou t t he t en s ionon the high or low speed spring (depending onthe speed range) , the governor s tabi l izes theengine speed for a given set t ing of the speedcontrol lever.

(4) In low speed range, the centrifugal forceof the low-and-high-speed weights together op-erate against the low speed spring. As the en-gine speed increases, the centrifugal force of thelow and high speed weight together compressthe low speed spring until the low speed weights

3-7

TM 10-3930-242-34

Figure 3-8. Blower drive and coupling, removal and installation.

Figure 3-9. Blower drive and coupling disassembly andreassembly (sheet 1 of 2).

3-8

TM 10-3930-242-34

Figure 3-9. Blower drive and coupling, disassembly andreassembly (sheet 2 of 2).

a r e a g a i n s t t h e i r s t o p s , t h u s l i m i t i n g t h e i rtravel , at which t ime the low speed spring isfully compressed and the low speed spring cap iswithin 0.0015 inch of the high speed plunger.

( 5 ) T h r o u g h o u t t h e i n t e r m e d i a t e s p e e drange the operator has complete control of theengine because both low speed spring and lowspeed weights are not exerting enough force toovercome the high speed spring.

(6) As speed continues to increase, the cen-t r i f uga l f o r ce o f t he h igh speed we igh t s i n -creases until this force can overcome the highspeed spring and the governor again takes con-trol of the engine, limiting the maximum enginespeed.

(7) A fuel rod is connected to the differen-t i a l l e v e r a n d i n j e c t o r c o n t r o l t u b e l e v e rt h r o u g h t h e c o n t r o l l i n k . T h i s a r r a n g e m e n t

provides a means for the governor to change thefuel settings of injector control racks.

(8) The engine idler speed is determined bythe force exerted by the governor low speedspring. When the governor throttle control leveris placed in the idle posi t ion, the engine wil loperate at the speed where the force exerted bythe governor low speed weights will equal theforce exerted by the governor low speed spring.

(9) Adjustment of the engine idle speed isaccomplished by changing the force on the lowspeed sp r ing by means o f t he i d l e ad ju s t i ngscrew.

(10) The engine maximum no-load speed isdetermined by the force exerted by the highspeed spring. When the governor throttle con-trol lever is placed in the maximum speed posi-tion the engine will operate at the speed where

3-9

TM 10-3930-242-34

f o r c e d e x e r t e d b y t h e g o v e r n o r h i g h s p e e dweights will equal the force exerted by governorhigh speed spring. Adjustment of the maximumno-load speed is accomplished by changing thetension on the high speed spring.

c. Removal. Refer to figure 3-10 and removethe governor.

(1) Disconnect linkage to governor controllevers .

(2) Remove screws and lockwashers attach-ing governor cover to governor housing.

(3) Remove two bolts and lockwashers at-taching spr ing housing to governor housing.Remove spring housing and gasket.

( 4 ) L o o s e n h i g h s p e e d s p r i n g r e t a i n i n glocknut and remove the high speed spring re-ta iner and spr ing.

(5) Loosen hose clamp.( 6 ) R e m o v e r o c k e r c o v e r ( T M 1 0 - 3 9 3 0 -

242-12).(7) Disconnect fuel rod from injector control

tube lever. Remove clip holding fuel rod to diffe-rent ial lever .

(8) Disconnect fuel l ines from fuel pumpand remove fuel pump (TM 10-3930-242-12).

(9) Remove five bolts from governor weighthousing and two bol ts f rom governor controlhousing.

(10) Remove governor and gasket from en-gine.

d. Disassembly of Cover. Refer to figure 3-10and disassemble the governor assembly cover ,as follows:

(1) Remove four screws on top of the controlhousing and remove housing cover.

(2) Loosen governor throt t le control leverretaining bolt and lift control lever from throt-tle shaft.

( 3 ) R e m o v e r e t a i n i n g r i n g a n d w a s h e r .Withdraw throttle shaft from cover.

(4) Loosen governor shut down reta iningbolt and remove hardware, as described above.

e. Disassembly of Governor Weight H o u s i n g .(1) Remove the gear retaining nut (1, fig.

3-11 ➀ ) from shaft (8). Remove gear (2), key (3)and spacer (4) from shaft.

(2) Remove screw (5) holding bearing sup-port (32) in place.

(3) Turn bearing support (32) until the largeopening is centered over the fork (10) on operat-ing shaft (8).

(4) Lif t up on weight shaf t unt i l there isenough clearance to insert socket wrench to re-move screws and washers holding fork on tosha f t .

Figure 3-10. Governor, removal and installation.

(5) Remove screws (6) and washers (7) hold-ing fork (10) to operating shaft (14).

(6) Lift the shaft (8) and weight carrier as-sembly (9) f rom the governor weight housing(40).

(7) Remove screw (11) washers (12 and 13)holding bearing (20) in control housing (31).

(8) Lif t the shaf t assembly (14) f rom thehousing (31).

(9) Place a rod approximately 18 inches longthrough control housing and knock out plug (15)from weight housing.

(10) Remove snapring (16) and press bearing(17) from weight housing.

(11) Remove spring clip (18) and washer fromgovernor operating shaft lever (20) and removegovernor differential lever (19).

(12) I f necessary, press bear ing (21) andoperating shaft lever (20) from shaft.

(13) If necessary, press pins (22 and 23) fromlevers (19 and 20).

f. Disassembly of Weight Shaft Assembly.(1) Press bearing retainer support (32) from

weight shaft (8).(2) If necessary, remove snapring (33) and

3-10

TM 10-3930-242-34

Figure 3-11. Governor assembly, disassembly and reassem-bly (sheet 1 of 2).

press bearing (34) from bearing retainer support(32).

(3) Remove weight pin retainer r ings (35)from governor weight pins (36) then drive pinout of carr ier (9) and weights (37) . Removeweights .

NOTE

Drive pins out of carrier from weight pin retainerend. Punch mark the carrier at retainer end of theweight pins to insure pins are place in proper posi-tion when reinstalling weights in carrier.

(4) Sl ide r iser (38) and bearing assembly

from shaft (8). Do not disassemble bearing sinceriser and bearing are serviced only as an as-sembly.

g. Disassembly of Control Housing.(1) Remove two screws (1, fig. 3-11 ➁ ) and

washers (2) securing cover to housing (14).

(2) Remove cover (3) and gasket (4).(3) Remove adjusting screw (5) and nut (6).(4) Remove high speed spring retainer (7).(5) Remove high speed spring (8) shims (9)

and plunger (10).(6) Remove low speed spring cap (11), low

3-11

Figure 3-11.

TM

10-3930-242-34

3-12

TM 10-3930-242-34

speed spring (12) and seat (13) from the housing(14).

h. Cleaning and Inspection.(1) Clean the governor housing components

a n d m o u n t i n g h a r d w a r e . U s e a d r y c l e a n i n gsolvent such as P-D-680, or equal.

( 2 ) C l e a n a l l b e a r i n g s .(3) Inspect bearings for corrosion and flat

spots ,(4) Examine weight carrier pins for wear.(5) Inspect spring seat , plunger adjust ing

s c r e w s , l o c k n u t s , a n d o t h e r p a r t s o f c o n t r o lhousing for defects.

i. Reassembly. Refer to figure 3-11 (sheets 1and 2) and reassemble the govern assembly.

NOTE

Low speed weights are identifiable by their shortcam arms and three center laminations, each ap-proximately 9/64 inch (0.140 inch) thick on weightcarrier. High speed weights are identified by longcam arm and three center laminations; middlelamination is 3/16 inch thick and the outer ones are1/8 inch thick

NOTE

The weight pin retainers must be installed insame position from which they were removed.

j. Installation. Refer to figure 3-10 and reins-tall the governor.

k. Buffer Screw Adjustment. With the enginea t no rma l ope ra t i ng t empera tu re and a t i d l espeed turn the buffer screw (29, f ig . 3-11(1))clockwise until it lightly touches the differentiallever (19). Tighten the buffer screw just enoughthat it eliminates the engine roll. After the buf-fer screw is properly adjusted, tighten the lock-nut by turning it clockwise, while at the sametime holding the buffer screw so it does not turnout of adjustment .

NOTEDo not adjust the engine idle speed more than 15rpm with the buffer screw.

1. Governor Adjustment.(1) Bring engine to operating temperature;

stop the engine.(2) Remove the high spring retainer cover

(3, fig, 3-11 ➁ ).(3) Back out buffer screw until it extends 5/8

inch beyond governor housing.(4) Remove valve rocker cover.(5) Start engine and adjust idle speed screw

to obtain 650 rpm.(6) Shut engine down and remove governor

cover.(7) Start the engine and control speed man-

ua l l y by ope ra t i ng t he i n j ec to r con t ro l t ube

lever. Engine speed should be between 800 and1000 rpm.

(8) Check the gap between the low speedcap (11) and the high speed plunger (10) with a0.0015 inch feeler gage. If gap is incorrect, resetgap adjust ing screw.

(9) Install the governor cover. The governorcover should be placed on the housing (14) withthe pin of the speed control lever projecting intoslot of differential lever.

( 1 0 ) I n s t a l l t h e s c r e w s f i n g e r t i g h t . P u l lc o v e r a w a y f r o m e n g i n e a n d t i g h t e n s c r e w s .This step will properly locate cover on governorhousing.

m . A d j u s t M a x i m u m N o - L o a d E n g i n e S p e e d .(1 ) A t no rma l eng ine ope ra t i ng t empe ra -

ture and throt t le control (accelerator) in ful lfuel position, check engine rpm. Recommendedmaximum no-load rpm is 2,700 ±15.

(2) Stop engine and, if necessary, adjust theno-load speed as follows:

(a) R e m o v e t h e h i g h s p e e d s p r i n g r e -tainer (7, fig. 3-11 ➁ ), high speed spring (8) andplunger assembly (10).

CAUTION

To prevent the low speed spring and capfrom dropping into the governor, be care-ful not to jar the plunger assembly whileit is being removed.

(b) Remove the high spring (8) from thehigh speed pluger and add or remove shims (9)as required to establish desired engine no-loadspeed.

NOTEFor each 0.0010 inch shim added, engine speed willbe increased approximately 10 rpm.

(c) R e p l a c e h i g h s p e e d s p r i n g ( 8 ) o nplunger (10) and assemble spring assembly intogovernor housing (14). Install spring retainer (7)in governor housing and tighten it securely.

(d) Start engine and recheck engine no-load speed. Repeat steps (a), (b), and (c) as neces-sary to establish no-load speed.

3-8. Radiator and Water Pump

a. General. The radiator assembly is bolted tofront of engine base (rear end of forklift). Toincrease cooling efficiency of the radiator, a fanshroud is positioned around the fan. A fan guardis securely attached to shroud. The water pumpis of the high-capacity, centr ifugal- type. I t isbelt driven at greater than engine speed and iteffect ively circulates the coolant through thecooling system.

3-13

TM 10-3930-242-34

b. Radiator.(1) Removal .

( a ) R e m o v e t h e e n g i n e h o o d ( T M10-3930-242-12).

(b) Drain the coolant f rom the radiator .Refer to figure 3-12 and remove radiator.

(2) Disassembly. Refer to figure 3-13 anddisassemble the radiator .

(3) Cleaning and inspection.( a ) I n s p e c t t h e e x t e r n a l c o n d i t i o n o f

r ad i a to r .

(b) Inspect mount ing hardware for rus tand breaks.

(c) Inspect the radiator core and inside ofradiator for scale deposits.

( d ) S t e a m c l e a n i n g i s t h e p r e f e r r e dmethod of cleaning the radiator . The radiatormay also be cleaned using the alkaline immer-sion process with cleaning compound P-C-436.After use of this process, thoroughly rinse untilfree of alkaline solution.

(e) Examine each part for cracks or otherdamage .

Figure 3-12. Radiator, removal and installation.3-14

TM 10-3930-242-34

Figure 3-13. Radiator and water pump, disassemble andreassembly (sheet 1 of 2).

3-15

TM 10-3930-242-34

(f) When repainting the radiator core, usea thin coat of dull black radiator paint. Ordinaryoil paints do not transmit heat as well.

(g) Repair or replace a defective radiator.Solder all leaks in the core. Replace all defectivepa r t s .

(4) Reassemble. Refer to figure 3-13(1) andreassemble radiator .

(5) Test ing.(a) If a leak in the radiator can not be

located, plug the inlet, filler and overflow pipes.(b) Insert an air hose into outlet pipe and

plug opening.(c) Immerse the radiator in a vat of water

and apply air pressure at 5-10 psi.

CAUTION

Do not exceed 10 pounds per square inch,as it may damage radiator core.

(6) Installation. Refer to figurestall the radiator.

3-12 and in-

c. Water pump.(1) Remove. Remove the water pump (TM

10-3930-242-12).(2) Disassembly. Refer to figure 3-13 ➁ a n d

disassemble the water pump.

(3) Cleaning and inspection.(a) Clean the body, cover, and impeller,

thoroughly, using the steam cleaning method orthe alkaline immersion process P-CA36. Afteruse o f t he a lka l i ne p roces s , r i n se t he pa r t sthoroughly unt i l they are f ree of the alkal inesolut ion.

(b) Clean other parts except the seal andshaft assembly, using cleaning solvent P-D-680or equal. Dry thoroughly.

(c) Inspect the. body, cover, and hardwarefor cracks, breaks and other damage.

(d) Replace all defective parts.(4) Reassembly.

(a) Upon r ea s sembly , u se a new sea l ,shaft assembly, and cover gasket.

Figure 3-13. Radiator and water pump, disassembly andreassembly (sheet 2 of 2).

3-16

(b) Refer to figure 3-13 ➁ and reassemblethe water pump.

(5) Installation. Install the water pump (TM10-3930-242-12).

3-9. Generator

a. General. The forklift truck is equipped witha 24V, dc generator. The generator is introducedinto the electrical system to provide a source ofelectr ical current for maintaining the s toragebat tery in a charged condit ion and to supplysuff icient current to carry any other electr icalload requirements up to the rated capaci ty ofthe generator .

b . R m n o v a l . R e m o v e t h e g e n e r a t o r ( T M10-3930-242-12).

c. Disassembly. Refer to figure 3-14 and dis-assemble the generator in numerical sequence.

d. Cleaning and Inspection. (1) Clean the generator components prefer-

ably using a solvent that complies with Spec.TT-T-291, Grade T, or with solvent P-D-680, ifnecessary. Do not soak parts in solvent . Drywith clean, dry compressed air; take care not todamage insulation, cable or windings.

(2) Clean all bearings.(3) Inspect screws, bolts, nuts and plugs for

worn or damaged threads.(4) Inspect brushes for wear.(5) Inspect commutator bars for roughness

and pitting. Replace all defective parts.e. Tes t ing .

( 1 ) T e s t t h e a r m a t u r e o n a g r o w l e r f o rshorts, open circuits, and grounds as instructedin TM 5-764. Replace a defective armature.

(2) Test the field coils with a multimeter forc o n t i n u i t y a n d g r o u n d a s i n s t r u c t e d i n T M5-764, Replace a defective field coil.

(3) Use a multimeter and test for continuitybetween the insulated brush holder and com-mutator end frame. I f cont inui ty is indicated,t he commuta to r end f r ame i s de fec t i ve andmust be replaced.

f . Reassemble. Refer to figure 3-14 and reas-semble the generator .

g. Bench Testing, Field Current Draw. Instal la suitable adapter plug in the connector. Con-nect a voltmeter between the field terminal andgene ra to r f r ame . Connec t an ammete r , f i e ldrheostat , bat tery switch, and’ a ful ly-charged24-volt bat tery in ser ies with each other andconnect the group, the f ie ld terminal , and thegenerator frame. Close the bat tery switch andadjust field rheostat for a reading of 24 volts onthe vol tmeter . The ammeter reading should bebetween 0.9- and 1.07-amperes. If current does

TM 10-3930-242-34

no t f a l l w i th in t h i s r ange , i n spec t t he f i e ldframe terminals , terminals insulat ion, internalconnections, or field coils that may be defective.

h. Instal lat ion. Instal l the engine generator(TM 10-3930-242-12),

3-10. Voltage Regulator

a. General. The regulator consists essentiallyof a carbon pile variable resistance element anda main relay. It is fitted with an inlet receptacleand an outlet receptacle for cable connection tothe bat tery charging circui t .

b . Remova l . Remove the vo l t age r egu l a to r(TM 10-3930-242-12).

c. Cleaning and Inspection.(1) Clean all metal parts.(2) Inspect the cover assembly, regulator

box and components. Check for loose connec-t ions.

(3) Inspect relay contacts for burned or pit-ted condition. Dress the contacts if necessary.

d. Off-Equipment Adjustment . Refer to fig-ure 3-15 ➀ and 3-15 ➁ and adjust the regulator.These ad ju s tmen t s a r e t o be pe r fo rmed wi thregulator removed from the equipment .

e . In s ta l l a t i on . I n s t a l l t h e r e g u l a t o r ( T M10-3930-242-12).

f. Final adjustment. Refer to figures 3-15 ➂ ,3-15 ➃ , and 3-15 ➄ and perform adjustment onthe equipment .

3-11. S tar tera. General. The 24-V dc starter is mounted to

the f lywheel housing. The s tar ter has a shif tlever and solenoid plunger that are totally in-closed to protect them from road dirt, icing con-ditions, and road splash.

b. On-Equipment Testing. Refer to figure 3-16and test the starter on the equipment.

c. Removal. R e m o v e t h e s t a r t e r ( T M10-3930-242-12).

d. Disassembly. Refer to figure 3-17 and dis-assemble s tar ter in numerical sequence,

e. Cleaning and Inspect ion.(1) Clean all metal parts with dry cleaning

solvent P-D-680, or equal, and dry thoroughly.(2) Clean field coils, armature, and insulat-

ing parts with a cloth s l ight ly dampened withcleaning solvent P-D-680 and dry with low pres-sure pressed air.

(3) Inspect a l l par ts for breaks, damage,and wear .

f . Test ing.( 1 ) T e s t t h e a r m a t u r e o n a g r o w l e r f o r

shorts, open circuits, and grounds as instructedin TM 5-764. Replace a defective armature.

3-17

TM 10-3930-242-34

Figure 3-14. Generator, disassembly and reassembly.

3-18

TM 10-3930-242-34

Figure 3-15. Voltage regulator adjustment (sheet 1 of 5).

(2) Test the field coils for an open circuitand grounds with a mult imeter and with thefield coil assembly installed in the starter hous-ing as instructed in TM 5-764. Test between theterminal stud and each of the four leads of thefield coil. If the multimeter fails to indicate con-tinuity on anyone of the above tests, replace thefield coil.

(3) Test between the terminal stud and thestarter frame. If the mult imeter indicates con-t inui ty the terminal s tud is grounded and thein su l a t i ng washe r on t he i n su l a t i ng bush ingmust be replaced.

g. Reassembly. Refer to figure 3-17 and reas-semble the s tar ter .

h. Bench Testing.(1) No load test. Connect a 24-volt battery in

se r i e s w i th a l oad rheos t a t and an ammete rshunt of a capacity greater than 50 amperes andconnect this group to the s tar ter terminal andthe starter housing. Connect an ammeter to theshun t and a d i r ec t cu r r en t vo l tme te r t o t hestar ter terminal and s tar ter housing. With thev o l t a g e a d j u s t e d t o 2 2 . 5 v o l t s , t h e c u r r e n tshould be 80 amperes maximum at 3,600 rpm. Ifthe current and speed are both low, inspect for

3-19

TM 10-3930-242-34


3-20

TM 10-3930-242-34

1.

2.

3.

4.

5.

6.

7.

CONNECT THE REGULATOR AS SHOWN ABOVE,

POLARIZE THE GENERATOR (FIG. 3-15 ➄ )

START THE UNIT AND OPERATE AT GOVERNED SPEED FOR 15 MINUTES. THE VOLTMETERSHOULD INDICATE 28.2 V.

REMOVE THE REGULATOR COVER AND TURN THE ADJUSTING SCREW CLOCKWISE TO

INCREASE THE VOLTAGE SETTING AND COUNTERCLOCKWISE TO DECREASE THE SETTING.

AFTER EACH ADJUSTMENT, CYCLE THE GENERATOR BY REDUCING THE ENGINE SPEED ANDMOMENTARILY OPENING THE VOLTAGE REGULATOR POINTS BY HAND. THIS ELIMINATESRESIDUAL MAGNETISM IN THE CORE OF THE REGULATOR AND ASSURESA TRUE ADJUSTMENT.REPLACE THE REGULATOR COVER AND BRING UNIT SLOWLY UP TO OPERATING SPEED.

NOTE THE VOLTMETER INDICATION.

REPEAT STEPS 4 AND 5 UNTIL THE DESIRED VOLTAGE IS OBTAINED.

STOP THE UNIT.ME3930-242-34/3-15 ➄

Figure 3-15. Voltage regulated adjustment (sheet 3 of 5).

high resis tance in the internal connections. Ifthe current is high and the speed is low, inspectthe bearing and armature for binding and in-correct al inement .

(2) Stall torgue test. With the starter con-nected as in (1) above, fasten a torque arm and aspring scale to the armature at the dr ive end.Adjust the rheostat to give 3.52 volts. The cor-rect readings are 500 amperes maximum and a

stall torque of 20 ft.-lbs. minimum. The stall tor-que is the product of the spring scale reading inpounds multiplied by the torque arm in feet. Ifthe current and torque are both low, inspect forhigh resistance in the internal connections andfor improper brush contact . High current andlow torque may be caused by a defective arma-ture or field coil.

i . Instal lat ion. I n s t a l l t h e s t a r t e r ( T M10-3930-242-12).

3-21

TM 10-3930-242-34

1.

2.

3.

4.

5.

6.

7.

CONNECT THE REGULATOR AS SHOWN ABOVE.

POLAR IZE THE GENERATOR (FIG. 3-15 ).

START THE UNIT AND OPERATE AT GOVERNED SPEED FOR 15 MINUTES.

REMOVE THE REGULATOR COVER AND MANUALLY CLOSE THE CURRENT REGULATOR CONTACTS.

ADJUST THE VARIABLE LOAD RESISTOR UNTIL THE AMMETER INDICATES 25 AMPERES.

RELEASE THE CONTACTS AND TURN THE CURRENT ADJUSTING SCREW CLOCKWISE TO INCREASETHE CURRENT SETTING OR COUNTERCLOCKWISE TO DECREASE THE CURRENT, UNTIL THE AM-METER INDICATES 25 AMPERES.

STOP THE UNIT.ME 3930-242-34/3-15


3-22

TM 10-3930-242-34

1.

2.

3.

4.

5.

CONNECT THE REGULATOR AS SHOWN ABOVE.

POLARIZE THE GENERATORBY DISCONNECTING THE LINK IN THE FIELD CIRCUIT AT THEADAPTER, AND MOMENTARILY CONNECTING AJUMPER BETWEEN THE TERMINAL CONNECTEDTO THE GENERATOR FIELD AND THE BAT TERMINAL. RECONNECT THE LINK IN THE FIELDCIRCUIT.

START THE UNIT AND SLOWLY INCREASE THE SPEED. THE CUTOUT RELAY CONTACTSSHOULD CLOSE AT 26.0 VOLTS.

TURN THE CLOSING VOLTAGE ADJUSTING SCREW CLOCKWISE TO INCREASE THE CLOSINGVOLTAGE AND COUNTERCLOCKWISE TO DECREASE THE CLOSING VOLTAGE.

STOP THE UNIT.

ME 3930-242-34/3-15 ➄


3-23

TM 10-3930-242-34

1.

2.

3.

4.

5.

DETERMINE THAT BATTERIES ARE FuLLY CHARGED AND THAT ALL BATTERY ANDSTARTER CABLES ARE SERVICEABLE AND PROPERLY INSTALLED.

CONNECT A MULTIMETER AS SHOWN IN B ABOVE. CHECK THE CONTINUITY OF THESOLENOID WITH THE MULTIMETER IN THE UNIT (R-l) POSITION. A GOOD SOLENOIDWILL INDICATE APPROXIMATELY 1.2 OHM RESISTANCE.

INSTALL THE SOLENOID-TO-STARTER CONNECTOR.

CONNECT VOLTMETER AS SHOWN IN CABOVE. IF BATTERY VOLTAGE (24 VOLTS) ISNOT INDICATED, THE STARTER IS DEFECTIVE AND MUSTBE REPLACED.

MOMENTARILY CONNECT A JUMPER AS SHOWN IN D ABOVE. THE VOLTMETER READINGSHOULD DROP TO ZERO AND STARTER SHOULD CRANK ENGINE. IF VOLTMETER READING DOESNOT DROP TO ZERO, STARTER SOLENOID SWITCH IS DEFECTIVE AND MUST BE REPLACED. IFVOLTMETER READING DROPS TO ZERO BUT STARTER FAILS TO CRANKDEFECTIVE AND MUST BE REPLACED.

ENGINE, STARTER IS

ME 3930-242-34/3-16

Figure 3-16. Starter, on-equipment testing.

3-24

TM 10-3930-242-34

Figure 3-17. Starter, disassembly and reassembly.

3-25

TM 10-3930-242-34

Section II.

3-12. General

The engine fuel system consis ts of the fuelinjectors, fuel pump, and fuel tank. A restrictedfitting is located in the cylinder head to main-t a in p r e s su re i n t he fue l sy s t em. The re a r ethree rocker arms and three push rods for eachcylinder. One rocker arm operates the fuel in-jector plunger; the other two operate the ex-haust valves.

3-13. Fuel Injector Control Lever and TubeAssembly

a. General. Each fuel injector is actuated by alever on the injector control tube, which in turn,is connected to the governor by means of a fuelrod, These levers can be adjusted independentlyon the control tube, thus permitting a uniformsetting of all injector racks.

b. Removal,(1) Remove the engine hood and rocker arm

cover (TM 10-3930-242-12).(2) Refer to figure 3-18 and remove the fuel

injector control lever and tube assembly,c. Disassembly, Refer to figure 3-19 and dis-

assemble the fuel injector control lever and tubeassembly,

d. Cleaning and Inspection.(1) Clean fuel injector control levers and

tube, using a cleaning solvent such as P-D-680,or equal,

(2) Inspect the levers for cracks.(3) Inspect the tube assembly for dents and

breaks.(4) Inspect al l hardware for damage. Re-

place a defective part.

FUEL SYSTEM

e. Reassembly. Refer to figure 3–19 and reas-semble fuel injector control lever and tube as-sembly.

f . Instal lat ion and adjustment .(1) Refer to figure 3-18 and install the fuel

injector control lever and tube assembly.(2) Adjust the control levers (TM

10-3930-242-12).(3) Install the rocker arm cover and engine

hood (TM 10-3930-242-12).

3-14. Fuel Injectors (Needle Valve)a. General.

(1) The uni t fuel injector performs fourfunct ions:

(a) Crea t e s t he h igh fue l p r e s su required for efficient injection,

(b) Mete r s and in j ec t s t he fue l i nexact amount required to handle the load,

(c) Atomizes the fuel for mixing withair in the combustion chamber.

(d) Permits continuous fuel flow,

re-

t h e

t h e

(2) Each fuel injector has a circular discpressed into a recess at front side of injectorbody for identification purposes. The identifica-tion tag indicates the nominal output of injectorin cubic mil l imeters . A horizontal bar on theinjector identif icat ion tag between the “GM”and the injector size identifies needle valve.

CAUTIONDo not intermix needle valve injectorswith other types of injectors in an engine.

(3) Fuel in excess of that required for en-gine operation is circulated through the injec-

Figure 3-18. Fuel injector control lever and tube assembly,removal and installation.

3-26

TM 10-3930-242-34

Figure 3-19. Fuel injector control lever and tube assembly,disassembly and reassembly.

tors by the fuel pump and serves as a coolant. Inaddition to serving as a coolant, circulation ofthe surplus fuel bleeds away air or vapor in thesystem back to the fuel tank where it is ventedto the atmosphere. Surplus fuel leaving the in-jectors flows through outlet fuel line to fuel re-turn passage and then through a restricted fit-ting and a tube back to fuel supply tank.

b.fuel

Removal . Refer to figure 3-20 and remove,injectors and fuel lines.

NOTECap the filter caps with shipping cap after lineremoval to keep out foreign material.

c. Fuel Injector Testing.(1) I n j e c t o r r a c k a n d p l u n g e r m o v e m e n t .

Check to see if plunger works freely in its bush-ing by placing injector against a bench and de-pressing fol lower to the bot tom of i ts s t rokewhile moving the rack back and forth. Failure toproduce a free rack indicates internal parts ofin j ec to r a r e d i r t y o r damaged . Wi th i n j ec to r

mounted in tes t s tand, pump and maintain apressure of 1600- to 2000-psi. Inspect for leaks.Relieve test pressure slowly to prevent damageto test gage.

WARNINGThe injector must always be held in sucha way as to prevent any fuel from penet-rating a person’s skin. Fuel oil which en-ters the bloodstream could cause seriousinfection or death.

(2) Injector holding pressure test. O p e r a t ethe tester to bring pressure up to approximately450 psi. Close fuel shut off valve and note pres-sure drop. Time for a pressure drop from 450 psito 250 psi should not be less than 40 seconds.Injector should be checked for leaks as follows:

(a) T h o r o u g h l y d r y i n j e c t o r w i t h c o m -pressed air .

(b) Open t e s t e r f ue l va lve and ope ra t etester to maintain test ing pressure.

3-27

TM 10-3930-242-34

Figure 3-20. Fuel injectors, removal and installation.

(c) Check for leak at injector rack open-ing. A leak indicates a poor bushing-to-body fit.

(d) A leak around spray tip or seal ringusually is caused by a loose injector nut, a dam-aged seal ring, or a rough surface on injectorn u t o r s p r a y t i p .

(e) A leak at filter cap indicates a loosefilter cap or a damaged filter cap gasket.

(f) A “Dribble” at the spray tip orifacesind i ca t e s a l e ak ing va lve a s sembly due t o adamaged surface or dirt.

CAUTION

To prevent damage to the pressure gage,do not exceed 250 psi during test. Oper-ate injector several times in successionby operating tester handle at approxi-mately 40 strokes per minute and ob-

3-28

serve spray pattern to see that all sprayorifaces are open and injecting evenly.The beginning and ending of injectionshould be sharp and fuel injection shouldbe finely atomized.

(3) Spray pattern test. Mount injector in thetester. Place the injector rack in the full fuelposition and operate the pump handle until fuelpressure is 200-250 psi; then close fuel shutoffvalve.

(4) Visual inspection of plunger. An injectorwhich passes the previous test should have theplunger checked visual ly, under a magnifyingglass, for excessive wear or a possible chip onthe bottom helix. There is a small area on thebottom helix and lower portion of upper helix, ifchipped, that will not be indicated in any of the

TM 10-3930-242-34

tests. Remove plunger from injector as follows: d. Disassembly. Refer to figures 3-23, 3-24,(a) Support the injector, right side up in and 3-25 and disassemble the fuel injector in

holding fixture. numerical sequence.

(b) Compress follower spring; then using e. Cleaning and Inspection.

a s c r e w d r i v e r r a i s e s p r i n g a b o v e s t o p s p r i n g (1) Wash all parts with clean fuel oil and dry

and withdraw the pin (fig. 3-21), Release spring with clean, dry compressed air.

gradual ly . (2) Clean out all passages, drilled holes andslots in the injector.

(c) Remove the injector from holding fix-ture and turn injector up side down, to prevent CAUTION

entry of dirt in injector, and catch spring and Care must be exercised when inserting

p l u n g e r i n h a n d . reamer in spray tip to avoid contact in

(d) Inspect plunger (fig. 3-22). If chippedneedle valve seat in tip.

or damaged, replace the plunger and bushing. If (3) Clean the spray t ip with reamer (f igt h e p l u n g e r i s i n g o o d c o n d i t i o n , r e i n s t a l l 3-26). Turn reamer in a clockwise direction toplunger and follower. remove carbon deposits.

Figure 3-21. Fuel injector follower stop pin, removal and installation.

3-29

TM 10-3930-242-34

Figure 3-22. Defective fuel injector plungers.

(4) Clean the spray tip orifices with pin viseand the proper size spray tip cleaning wire (fig.3-27).Use 0.0055 diameter wire to clean the holes. Be-fore using wire, hone the end of wire until it issmooth and free of burs. Allow wire to extend 1/8inch from the tool.

(5) Clean and brush all passages in the in-jector body. Carefully insert reamer into injec-tor nut and ream injector spray t ip seat (f ig3-28).Turn the reamer in a clockwise direction to re-move carbon deposits.

(6) Inspect the teeth on control rack andcontrol rack gear for wear or damage. Inspectboth ends of spill deflector for sharp edges orburs. Remove burs with a medium stone.

(7) Inspect follower spring for defects andproper tension. The spring has a free length of

3-30

app rox ima t l ey 1 .659 i nches . Rep l ace sp r ingwhen load of less than 48 pounds will compressit to 1.028 inch.

(8) Check the seal ring area in the injectorbody and surface which contacts the injectorbushing for damage. If necessary, lap this sur-face.

(9) Inspect the injector plunger for scoring,erosion, chipping, or wear. Check the locatingpin and the bushing. Slip the plunger into thebushing and check for free movement. Plungersand bushings are mated parts and must be re-placed as an assembly.

(10) Inspect the spray tip seating surface ofthe injector nut for nicks, or burs.

(11) Inspect the sealing surface of the injec-tor parts as indicated by arrows (fig. 3-29). In-spect all surfaces with a magnifying glass foreven the s l ightest imperfect ions wil l prevent

TM 10-3930-242-34

Figure 3-23. Injection rack, gear, spray tip, and valve as-sembly components, removal and installation.

the injector from operating properly, Check forburs, nicks, erosion, cracks, chipping, and exces-sive wear. Inspect the spray t ip for enlargedorifices,

f. Needle Valve Test. With the injector nut andspray tip cleaned, clamp the nonthreaded end ofthe body J21012-1 in a bench vise. Then, assem-ble the check valve, check valve cage, spring,

Figure 3-24. Fuel injector filter, removal and installation.

spring seat, spring cage, needle valve, and tipassembly on top of the body, Carefully place theinjector nut over the spray tip and valve parts,and thread it on to the body. Tighten the injec-tor nut to 75-85 ft.-lb. torque. Remove the bodywith the injector parts from bench vise and in-stal l in the injector tester . Operate the pumpunti l the spray t ip valve has opened severaltimes to purge air from the system. Operate the

3-31

TM 10-3930-242-34

Figure 3-25. Injector follower, spring, and plunger, removaland installation.

3-32

TM 10-3930-242-34

Figure 3-26. Reaming fuel injector sprag tip.

Figure 3-27. Cleaning spray tip orifices.

p u m p h a n d l e w i t h s m o o t h e v e n s t r o k e s ( 4 0 and closing action should be sharp and producestrokes per minute) and note the pressure a t a f inely atomized spray. If the valve openingwhich needle valve opens. The valve should pressure is within 2000- and 3200-psi, check foropen between 2000- and 3200-psi. The opening s p r a y t i p s e a t l e a k a g e . A c t u a t e t h e p u m p

3-33

TM 10-3930-242-34

Figure 3-28. Cleaning fuel injector nut spray tip seat.

Figure 3-29. Fuel injector sealing surfaces that may requirelapping.

3-34

handle several times, then hold the pressure at1,500 psi for 15 seconds, Inspect spray tip seatfor leakage. If the spray tip seat is satisfactory,proceed to check the hold time for pressure dropof from 1,500-to 1,000-psi in less than 5 seconds;replace needle valve and tip assembly if the holdtime is less than 5 seconds,

g. Lapping Injector Parts.(1) Clean the lapping blocks with compres-

sed air,(2) Spread lapping powder (600 grit (dry)) on

one of the lapping blocks.(3) Place the part to be lapped flat on the

block, and using a figure eight motion, move itb a c k a n d f o r t h a c r o s s t h e b l o c k u s i n g j u s t

enough pressure to keep the par t f la t on theblock at all times. Do not lap excessively. Whenpart is f lat , wash in cleaning solvent and drythoroughly with compressed air.

(4) Place dry part on second block; applylapping powder. Repeat action.

(5) Place dry part on third block. Do not uselapping powder on this block. Keep the part flatand move across block several times using thef igure e ight motion. Lapping dry par t in thismanner gives the “mirror” f inish required forperfect sealing. Wash all lapped parts in cleansolvent and dry with clean, dry compressed air.

h. Reassemble. Refer to figure 3-23,3-24, and3-25 and reassemble the fuel injector.

i. Spray Tip Concentricity Check.(1) Place the injector in the concentr ici ty

gage (fig. 3-30).(2) Adjust the dial indicator to “O”. Rotate

the injector 360 degrees and note the total run-out as indicated on dial. If total runout exceeds0.008 inch, remove injector from gage. Looseninjector nut, recenter spray tip, tighten the nutto 75-80 foot pounds torque, and recheck con-centr ici ty.

j. Installation. Before installing an injector inan engine, remove carbon deposits from the be-veled seat of injector tube in the cylinder head.This wil l assure correct al ignment of injectorand prevent any undue stress from being emp-loyed against the spray t ip. Use the injectortube bevel reamer to clean carbon from injectortube. Exercise care to remove only the carbon sothat the proper clearance between the injectorbody and cylinder head is maintained, Pack theflutes of reamer with grease to retain carbonremoved from tube. Install fuel injectors as fol-lows:

(1) Refer to figure 3-20 to install in fuel in-jector. Be sure the dowel pin in the injector bodyregisters with the dowel pin hole in the head,Position injector rack control lever so the lowerend of lever engages injector rack.

(2) Instal l the injector bracket and torquebolt to 20-25 foot pounds and recheck to makesure bracket does not interfere with inject or fol-lower spring or exhaust valve spring.

NOTECheek the injector rack for free movement. Ex-cess torque can cause the injector control rack tostick or bind,

CAUTIONThere is a possibility of damaging theexhaust valves i f the exhaust valvebridge is not resting on the ends of ex-

TM 10-3930-242-34

haust valve when tightening rocker shaftbracket bolts. Note position of exhaustvalve bridge, before, during, and aftertightening the rocker shaft bracket bolts.

(3) Move rocker arm assembly into positionand tighten rocker arm bracket bolts.

CAUTIONDo not bend fuel pipes and do not exceedspecified torque. Excessive torque willtwist or fracture flared end of fuel lineand result in leaks. Lubricating oil di-luted by fuel oil can cause serious dam-age to engine bearings.

(4) Remove shipping caps. Al ign the fuelpipes and connect them to the injector and fuelconnectors .k. Fuel Injector Timing.

(1) Place the speed control lever in idlespeed position. If a stop lever is provided, secureit in no-fuel position.

CAUTION

If a wrench is used on crankshaft bolt atthe front of engine, do not turn crank-shaft in a left-hand direction of rotationor the bolt will be loosened.

(2) Rotate the crankshaft, manually or withthe star ter , unti l the exhaust valves are ful lydepressed on the particular cylinder to be timed.

(3) Place small end of the injector t iminggage in hole provided in top of injector body,with flat of gage toward injector.

(4) Loosen push rod locknut.(5) Turn the push rod and adjust the injec-

tor rocker arm until the extended part of gagewill just pass over top of injector follower.

( 6 ) H o l d p u s h r o d a n d t i g h t e n l o c k n u t .Check the adjustment and readjust , i f neces-s a r y .

(7) Time the remaining injectors , as out-lined above.

(8) Use new gaskets and install valve rockercover (TM 10-3930-242-12).

3-15. Rocker Arms and Push Rodsa. General. Located in the cylinder head are

the exhaus t va lves , f ue l i n j ec to r s , and t h r eerocker arms for each cylinder. One rocker armoperates. the injector plunger; the other two op-erate the exhaust valves. The rocker arms areoperated by the camshaft through cam follow-ers and push rods.

b. Removal.( 1 ) R e m o v e r o c k e r a r m c o v e r ( T M

10-3930-242-12).

3-35

TM 10-3930-242-34

Figure 3-30. Checking fuel injector tip concentricity.

(2) Refer to figure 3-31 and remove rockerarms and push rod.

c. Disassembly. Refer to figure 3-32 and dis-assemble rocker arms and push rods.

d. Cleaning and Inspection.(1) Clean all parts thoroughly, using a sol-

vent such as P-D-680, or equal. Dry thoroughly.(2) Clean all lubrication oil passages with

compressed air.

(3) Inspect rocker arms for cracks, breaks,and other damage. Examine bearing surfaces ofthe rocker arms for excessive wear and scoring.Replace damaged or defective rocker arms.

(4) Inspect rocker arm shaft for wear, scor-ing, and ridges from the action of rocker arms onthe sha f t . Rep lace a damaged o r de fec t i verocker arm shaft.

(5) Inspect push rods for warpage, cracks,

3-36

TM 10-3930-242-34

Figure 3-31. Rocker arms and push rods, removal and in-stallation.

breaks, and other damage. Replace damaged ordefective push rods.

(6) Inspect the springs and rocker arm sup-port for cracks, breaks, and other damage. Re-place damaged or defective parts.

(7) Inspect cam follower holes, in the cylin-der head, to make sure they are clean, smoothand free of score marks to permit proper func-tioning, Inspect cam follower and cam followerguide (fig. 3-33).

( 8 ) Check cam fo l l ower - t o - cy l i nde r headc l ea rance . Th i s c l ea rance shou ld no t exceed0.006 inch with used parts . I f replacement ofcam followers is necessary, use the correct type

cam follower to be assured that the cam rollerwill receive proper lubrication.

(9) Check the cam follower roller for smoothand free turning on its pin. Check for flat spotsor scuffed marks.

(10) Measure the total clearance between

the roller bushing and pin, crosswise of pin (fig.3-34). If bushing is worn to the extent that morethan 0.010 inch diametric clearance exists, re-place follower assembly or install a cam rollerand pin. Check total side clearance between rol-ler and fol lower; this c learance should not beless than 0.015 inch nor more than 0.023 inch.

3-37

TM 10-3930-242-34

Figure 3-32. Rocker arm and push rod, disassembly andreassembly.

e. Reassembly. Refer to figure 3-32 and reas-semble the rocker arm and push rod.

f. Installation. Refer to figure 3-31 and installrocker arm and push rods.

g. Adjustment .(1) Refer to f igure 3-35 and adjust push

rods .(2) Insta l l r o c k e r a r m cover (TM

10-3930-242-12).

3-16. Fuel Pump

a. General. The fuel pump is mounted to theg o v e r n o r . T h e p u m p c i r c u l a t e s , o r t r a n s f e r s ,fuel from the fuel supply tank to fuel injectors.

I t i s not a high-pressure- inject ion- type pump.The fuel pump circulates an excess supply offuel through the injectors and unused portionsgo back to the fuel tank by means of a fuel re-turn manifold and fuel return l ine. A spring-loaded relief valve (20, fig. 3-36) is incorporatedin the pump body (5) and is activated when out-let pressure exceeds 65-75 psi. Fuel is returnedthrough an internal passage from pressure sideto suction side of pump. There are two holes inthe pump body (5) between the seals (13 and 14)to provide a means of drawing off leakage. Ifleakage exceeds one drop per minute, the sealsmust be replaced. The fuel pump should main-

3-38

TM 10-3930-242-34

Figure 3-33. Cam follower and guide location

tain 50-to 70-psi on the output side at 1800 rpm,engine speed. Lift on the suction should not ex-ceed 48 inches. To check the fuel flow:

(1) Disconnect fuel return line at fuel tank,or source of supply, and hold open end of pipe ina sui table container ,

(2) Star t and run engine at 1200 rpm andmeasure fuel f low return for one minute. Ap-proximately one-half gal lon of fuel should ber e t u r n e d .

(3) If fuel flow is insufficient for satisfac-tory engine performance, clean or replace fuels t r a ine r .

(4) If fuel flow is still insufficient, replacesecondary fuel filter and recheck fuel flow. Iffuel flow is unsatisfactory, replace fuel pump.

(5) Clean all lines and insure all fuel lineconnections are tight,

b. Remova l .(1) Remove t h e f u e l p u m p (TM

10-3930-242-12).(2) Cap fuel lines.

c. Disassembly. Refer to figure 3-36 and dis-assemble fuel pump.

d. Cleaning and Inspection.(1) Clean all parts, thoroughly, using clean-

i n g s o l v e n t s u c h a s P - D - 0 8 0 , o r e q u a l . D r yt h o r o u g h l y .

(2) Inspect all parts for excessive wear andscoring. Inspect mating surfaces of the pumpbody and cover. They must be smooth and flat.Remove all nicks and burs with a fine file.

(3) Discard and replace all gaskets. Repairor replace all parts as necessary.

e. Reassembly. Refer to figure 3-36 and reas-semble fuel pump, as follows:

(1) Install fuel pump driven gear (10, fig.3-36), if removed, over end of drive shaft (11)which is not squared (with the slot in the gearfacing the plain end of the shaf t ) to preventscoring the gear. Press gear beyond locking ballretaining hold. Place ball in hole and press gearback until end of slot contacts ball.

(2) Place gear (10) and shaft (11) in pumpbody (5) with chamfered end of gear teeth facingpump body.

(3) Apply thin coat of sealer to face of coverand assemble pump. Use the remaining compo-nents, as shown in figure 3-36.

( 4 ) R o t a t e p u m p b y h a n d t o i n s u r e t h a tparts operate freely. I f binding exists , disas-semble and determine cause.

f. Installation.

3-39

TM 10-3930-242-34

Figure 3-34. Cam roller wear and clearance diagram.

3-40

TM 10-3930-242-34

Figure 3-35. Push rod adjustment.

(1) Remove caps from fuel lines.

(2) Install t h e f u e l p u m p (TM10-3930-242-12).

3-17. Fuel Tank

a. General . The fuel tank is located on theright side of forklift opposite the driver’s seat.The fuel tank is made from a heavy gage metaland access steps are made on the fuel tank.

b. Removal.(1) Remove toolbox (fig. 3-37).

(2) Remove console side panel (fig. 3-37).(3) Remove plug f rom fuel tank (17, f ig .

3-38), and drain the fuel.(4) For easier access to the fuel lines and

m o u n t i n g h a r d w a r e , r a i s e e x t e n s i o n b o o m t o“full up” position and install the extension sup-p o r t s .

(5) Remove fuel lines from fuel tank elbows(9 and 11, fig. 3-38).

(6) Remove mounting nuts and screws (fig.3-37).

c. Disassembly. Refer to figure 3-38 and dis-assemble the fuel tank.

d. Cleaning and Inspection.(1) Clean the fuel tank thoroughly, using

steam cleaning as the preferred method.

WARNINGBefore attempting to weld or braze thefuel tank, steam clean the tank for aminimum of eight (8) hours. Remove fuelcap and open the discharge and returnlines during the welding process. Failureto observe this warning may result inserious injury or death.

(2) Inspect for cracks, breaks, and dents.( 3 ) R e p a i r o r r e p l a c e t h e f u e l t a n k , a s

neces sa ry .e. Reassembly. Refer to figure 3-38 and reas-

semble the fuel tank.f. Installation.

(1) Install the plug (10, fig. 3-38) in the fueltank (17).

(2) Secure the fuel tank (fig, 3-37).(3) Connect the fuel lines at the fuel tank

elbows (9, and 11, fig. 3-38).(4) Install the console side panel and tool-

box (fig. 3-37).(5) Fill the fuel tank (TM 10-3930-242-12).(6) If wanted, lower the extension boom and

remove the extension supports .

3-41

TM 10-3930-242-34

Figure 3-36. Fuel pump, disassemblyand reassembly.

TM 10-3930-242-34

Figure 3-37. Fuel tank, removal and installation.

3-43

TM 10-3930-242-34

Figure 3-38. Fuel tank, disassembly and reassembly.

3-44

TM 10-3930-242-34

Section III. CYLINDER HEAD, VALVES, FLYWHEEL,AND FLYWHEEL HOUSING

3-18. GeneralThis sect ion contains maintenance informa-

tion on those items that are considered compo-nents of the engine. These items consist of vari-ous parts which make up the basic engine.

3-19. Cylinder Head and Valvesa. General. The cylinder head is a one piece

casting mounted to cylinder block. The cylinderhead serves as the removable access point to theupper engine components and as a mountingmember for the valves, fuel injectors, and theexhaust manifold.

b. Removal.(1) Drain cooling system and engine block

(TM 10-3930-242-12).(2 ) Remove t he rmos t a t , t he rmos t a t hous -

ing, and exhaust manifold (TM 10-3930-242-12).( 3 ) R e m o v e r o c k e r a r m s a n d p u s h r o d s

(para 3-15). Disconnect and remove fuel rod be-tween governor and injector control tube lever.

(4) Remove fuel injectors (para 3-14).

CAUTION

When resting cylinder head assembly onwork bench, protect cam follower rollersand injector spray tips by resting valveside of head on wooden blocks at least 2inches thick.

(5) Refer to figure 3-39 and remove cylinderhead assembly.

(6) Remove exhaust valve and valve spring(para 3-20).-

c. Disassembly, Refer to figure 3-40, and dis-assemble cylinder head.

d. Cleaning and Inspection.(1) Clean cylinder head. After the cylinder

head has been stripped of all parts, it should bethoroughly s team cleaned. Thoroughly clean aservice cylinder head to remove all of the rustproofing compound, par t icular ly from the in-tegral fuel manifolds, before the plugs are. in-stal led in the fuel manifolds and the head ismounted on an engine. A simple method of re-moving the rust proofing compound is to im-merse the head in solvent , oleum or fuel oi l ;then go over the head and through all openingswith a sof t br is t led brush. After c leaning thehead, it should be blown dry with compressedair to remove all of the solvent.

(2) Inspect cylinder head. Over a prolongedperiod of operation, the cylinder head may as-sume a contour to match that the cylinder block,which is normal. However, if the cylinder headi s a l l owed to become ove rhea t ed because o fcoolant loss, the resul tant high temperaturescause stresses to occur in the casting which will

Figure 3-39. Cylinder head assembly, removal and installation.

3-45

TM 10-3930-242-34

Figure 3-40.

affect the flatness of the head. Therefore, thebottom (fire deck) of the cylinder head should bechecked for flatness as follows:

(a) Using an accu ra t e s t r a igh t edge andfeeler gage, check for t ransverse warpage ateach end and between all cylinders.A l so check fo r l ong i t ud ina l wa rpage i n s i xplaces. Maximum allowable warpage is givenbelow

Cylinder head, disassembly and reassembly.

Maximum Maximumlongitudinal transverse

warpage warpage

0.006 in. 0.004 in.

The maximum allowable warpage limits shouldbe used as a guide in determining the advisabil-ity of reinstalling the head on the engine or ofrefacing it. The number of times a cylinder headmay be refaced will, of course, depend upon theamount of stock removed from the head duringprevious reworking operations. When refacing a

3-46

TM 10-3930-242-34

cy l i nde r head , t he amoun t o f s t ock r emovedshould be stamped on the face of the fire decknear the outer edge of the head, in an area notused as a sealing surface. Not over 0.020 inch ofmetal should be removed from the fire deck ofany cyl inder head. The distance from the topdeck to the bottom (fire deck) of the cylinderhead must not be less than 4.376 inch as shownin figure 3-41. After a cylinder head has beenrefaced, and new injector tubes have been in-s ta l led, the cyl inder head should be pressurechecked. The top surface of the cylinder blockwill not warp to the extent that machining willbecome necessary, therefore, no warpage limitsor machining limits are required.

(b) The cylinder head may be checked forleaks using the following procedure:

1. Seal off the waterholes in the head,using steel plates and sui table rubber gasketsheld in place by bolts.

.

2. Instal l dummy or scrap injectors toinsure seat ing of the injector hole tubes. Thedummy injectors may be made up with old injec-tor nuts and bodies, the injector spray tip is notnecessary. Tighten the injector clamp bolt to25-30 foot-pounds torque.

3. A p p l y 8 0 - 1 0 0 p s i a i r p r e s s u r e t owater jacket by drilling and tapping into one ofthe waterhole cover plates for an air hose con-nect ion. Then immerse the head in a tank ofwater previously heated to 180-200 F. for 20 mi-nutes to thoroughly heat the cylinder head. Ob-serve the water in the tank for bubbles indicat-ing cracks or leaks.

4. Following the pressure tes t , dry thehead with compressed air.

5. Rep lace any l eak ing in j ec to r ho l e

tubes. If inspection revealed cracks in the cylin-der head, it should be replaced.

(c) Inspect cam follower bores in cylinderhead for scoring or wear. Light score marks maybe cleaned up with crocus cloth wet with fuel oil.If bores are excessively scored or worn so thatcam fol lower-to-head clearance exceeds 0.006inch, replace the cylinder head.

(d) Check valve seat inserts for cracks orburning. Also check valve guides for scoring.

(e) Check water nozzles for t ightness infour valve cyl inder heads. Water nozzles areused only in the passages between cylinders. Toinstall or replace cylinder head water nozzles:

1. Be sure water inlet ports in bottom ofhead are clean and free of scale. Water holesmay be cleaned up with a 5/6-inch diameter drill.Break the edges of holes slightly.

2. Check for press fit of nozzles in cylin-der head. If water holes in head have been en-larged by corrosion, use wooden plug or othersuitable tool to expand nozzle, so that they willremain t ight af ter instal lat ion.

3. Press the nozzles into place with out-let holes positioned toward longitudinal center-l ine of cyl inder head. The angle between theoutlet holes in the nozzle is 90°. Nozzles shouldbe from flush to 1/32inch below bottom surface ofcy l i nde r head , o t h e r w i s e i n t e r f e r e n c e w i t hproper seating of the head on the cylinder blockmay be encountered.

CAUTION

When installing plugs in fuel manifolds,apply a small amount of sealant that ismerchandised as a “dual purpose sealer”to threads of plugs only. Work sealant

Figure 3-41. Minimum distance between top and bottomfaces of cylinder head.

3-47

TM 10-3930-242-34

into threads and wipe off excess withclean, lintfree cloth so that sealant willnot be washed into the fuel system andresult in serious damage to the injectors.When a new cylinder head is to be used,the parts listed below should be removedfrom the old head and installed in the newhead. If the old cylinder head is to bereused, the parts listed below should beinstalled in the old head prior to assembl-ing the cylinder block.

e. Install Parts in Cylinder Head. New se rv i cecy l i nde r heads fo r r ep l acemen t pu rpose s a r eequipped with valve guides, valve seat inserts,exhaust manifold studs, water nozzles, injectorhole tubes, and necessary plugs.

(1) Exhaust valves and springs (para 3-20).(2) Push rod assemblies, cam followers, cam

follower guides, rocker arm shaft , and rockerarms (para 3-15).

(3) Place new washers on fuel connectors;then install fuel connectors and tighten to 20-28foot-pounds torque.

(4) Install fuel injectors (para 3-14) at thistime or after installing cylinder head.

f . Preinstal lat ion inspect ion. T h e f o l l o w i n ginspections should be made just prior to instal-ling the cylinder head on the engine. These in-spections should be made regardless of whetherthe head was removed from the engine for ser-vicing only the head assembly, or to facilitateother repairs to the engine. Wipe bottom of cy-l inder head clean. Lower cyl inder head overstuds and into place on cylinder block. A finalvisual check of al l cyl inder head gaskets andseals should be made to insure that they are inplace just before the cylinder head is loweredonto the cylinder block. This is a very importantcheck. Compression gaskets and seals which arejarred out of their proper position will lead toleaks and “blow-by” with resultant poor engineperformance and damage to engine.

(1) Check cylinder liner flange height withrelationship to the cylinder block.

(2) Check to be sure tops of pistons are cleanand free of foreign material.

(3) Check to see that ALL of the push rodsare threaded into their clevis until the end ofthe push rod projects through the clevis. This isimportant since serious engine damage will beprevented when the engine is cranked or barredover during tuneup.

(4) Check cylinder block and cylinder headgasket surfaces and counterbores to ascertainthat these seal ing surfaces are clean and freefrom foreign material.

3-48

g. Install Cylinder Head.

NOTEWater seals, oil seals, and compression gasketsshould NEVER be reused.

(1) Install new cylinder head compressiongaskets, and seals, as outlined below:

(a) Instal l new compression gaskets oneach cylinder liner.

(b) Place new seal rings in counterboresof water and oil holes in cylinder block.

(c) Install new oil seal in rectangular mil-led groove near the outer edge of the area co-vered by the cylinder head.

(2) To install the cylinder head without dis-t u rb ing t he ga ske t s and s ea l s , spec i a l gu idestuds must be used. Instal l the cyl inder headguide studs, diagonally opposite, in end cylinderblock bolts holes.

(3) The cyl inder head must be gradual lyand uniformly drawn down against the gasketsand seals to insure a good seal between the cy-linder head and block. Therefore, it is vitallyimportant that the cylinder head be instal ledwi th t he u tmos t ca re . I n s t a l l cy l inde r headbolts; then, beginning on camshaft side of headtake up tension in follower springs by tighten-i n g b o l t s l i g h t l y . F i n a l l y , t i g h t e n b o l t s t o1 7 0 - 1 8 0 f o o t - p o u n d s t o r q u e w i t h a t o r q u ewrench, about one-half turn at at time, in sequ-ence shown in figure 3-42. Under no circums-tances should the torque exceed the specif iedlimits, o t h e r w i s e t h e b o l t s m a y b e c o m estretched beyond their elastic limits.

(4) If the injectors were not previously in-stalled, refer to paragraph 3-14 and install in-jectors .

(5) Set injector control tube assembly inplace on cyl inder head and t ighten holddownbolts, fingertight only. When positioning injec-tor control tube, be sure that ball end of injectorcontrol rack levers engage the slots in the injec-tor control racks. With one end of the controltube, return spring hooked around one injectorrack control lever and the other end hookedaround the control tube bracket; tighten brac-ket bolts with a 7/16-inch universal socket wrenchto 10-12 foot-pounds torque. After t ighteningbolts, revolve tube and see if the return springpulls the injector racks OUT (NO FUEL POSI-TION) after they have been moved all the wayIN (FULL FUEL POSITION). Since the injec-t o r con t ro l t ube i s moun ted i n s e l f - a l i gn ingbearings, tapping the tube l ight ly with a sof thammer will remove any bind that exists. Theinjector racks MUST return to the no fuel posi-

3-49

Figure 3-42. Cylinder head bolt tightening sequence.

TM 10-3930-242-34

tion freely by aid of the return spring only. DONOT bend the return spring to bring about thiscondition.

(6) Install fuel rod (para 3-13).(7) Install exhaust manifold, thermostat

housing, and thermostat (TM 10-3930-242-12).

3-20. Exhaust Valves, Springs, Guides, andseats

a. General. The exhaust valves, springs,guide, and seat are mounted to the cylinderhead. It is possible, if occasion requires, to re-move or replace exhaust valve springs withoutremoving cylinder head. The springs, however,are normally removed when cylinder head isremoved from engine block. Both methods arecovered in this section.

b. Removal of Exhaust Valve Spring andValve.

(1) An exhaust valve spring may be re-moved, without removing the cylinder headfrom the engine, as follows:

(a) R e m o v e r o c k e r a r m c o v e r ( T M10-3930-242-12).

(b) Bar engine over to bring valve and in-jector rocker arms in line horizontally.

(c) Disconnect and remove fuel lines frominjectors and fuel connectors (para 3–14).

(d) Remove the two bolts holding rockerarm shaft brackets to cylinder head and removebrackets and shaft (para 3-15).

(e) Remove cylinder block air box cover sothat piston travel may be observed, then turncrankshaft until piston is at top of stroke.

(f) Thread valve spring compressor adap-tor into rocker shaft bolt hole in cylinder head.

Apply pressure to end of valve spring compres-sor handle to compress valve spring (fig. 3-43).Remove the two-piece tapered spring lock (13,fig. 3-44)

(g) Release tool and remove valve springcap, valve spring and spring seat.

(2) To remove the exhaust valve springwith the cylinder head removed from the en-gine, use the following procedure:

(a) Support cylinder head on wood blocks2 inches above the workbench so as to keep thecam followers clear of workbench.

(b) Remove fuel lines from injector andfuel connectors (para 3-14).

(c) Remove the two bolts holding rockerarm shaft brackets to cylinder head. Lift rockerarms and brackets up and away from injector(para 3-15).

(d) Remove fuel injector (para 3-14).(e) Remove exhaust valve spring from cy-

linder head as previously outlined above. In ad-

Figure 3–43. Removing exhaust valve spring.

TM 10-3930-242-34

Figure 3-44. Valves and injector operating mechanism,

dition, use a block of wood under cylinder headto support exhaust valve.

(f) Remove cam fol lowers and push rodassemblies (para 3-15).

c. Inspect Exhaust Valve Spring. Af te r r e -moving valve spring, clean with fuel oil and drywith compressed air. Check spring for pitted orfractured coils. Replace defective springs. Theexhaust valve spr ing has an approximate f reelength of 2.08 inches when new, and requires aload of 29 ±2 pounds to compress it to 1.93-inchl eng th .

d. Remove Exhaust Valve. With the cylinderhead removed from the engine, and the valvesprings removed as outlined above, turn the cy-linder head over and withdraw the exhaust val-ves .

e. Inspect Exhaust Valves. Scrape the carbonfrom valve stem, wash with clean fuel oil, andcheck for scratches or scuff marks. The diame-ter of a new valve stem is 0.2480-to-0.2488-inch.Valve faces should be smooth, unpitted and freeof ridges or cracks. Carbon on the face of thevalve indicates a faul ty seat and a resul tant

3 - 5 0

TM 10-3930-242-34

leak (or blow-by) . I f any of these condi t ionsexis t , a new valve should be instal led or thevalve refaced, Valve heads should be squarewith the valve stem and should not be warped.If the valve heads are not square or warped,new valves must be installed.

f. Inspect Valve Guide. After the valves havebeen removed, clean valve guides. After clean-ing, inspect valve guides for fractures, scoring,or excessive wear, and replace if necessary. Theinside diameter of a new guide is 0 .2505- to0 . 2 5 1 5 - i n c h . T h e r e f o r e , w i t h n e w p a r t s , t h eva lve s t em to gu ide c l ea r ance i s 0 .002 - t o0.004-inch. If this clearance exceeds 0.005 inch,install a new valve guide and/or valve.

g. Remove Value Guide. If the clearance bet-ween t he gu ide and va lve s t em exceeds t heabove limits or if the valve guide is defective,the guide should be removed as follows:

(1) Support the cylinder head (bottom sideup) on wood blocks 3 inches above the work-b e n c h .

(2) Drive valve guide out of cylinder head.h. Install Valve Guide. Rest the bottom of the

cylinder head on a workbench, and proceed withinstallation as follows:

( 1 ) I n s e r t t h e t h r e a d e d e n d o f t h e v a l v eguide into the installing tool.

(2) Locate the valve guide squarely in thecylinder head and tap gently to s tar t i t intoplace.

(3) With the guide properly started, drive itin unt i l i ts upper end is 0 .010- to 0.030-inchbelow top of cylinder head. This dimension isautomatical ly provided by the valve guide in-s t a l l e r t oo l . Se rv i ce va lve gu ides a r e “p re -finished,” therefore, do not require reaming.

i . Inspect Valve Seat Insert . I n s p e c t v a l v eseat inserts for excessive wear, pitting, crack-ing, or improper seat angle. The proper angle forthe seating face of both valve and insert is 30degrees. When a valve insert has been ground tosuch an extent that further grinding will causegrinding wheel to contact cylinder head, a newinsert should be installed.

j . Remove Valve Seat Insert . The valve seatinserts are pressed into the cylinder head and,therefore , must be removed as out l ined in thefollowing procedure to avoid damage to the cy-l inder head:

(1) Place cylinder head on its side on work-bench.

(2) Place collet of tool inside valve insert sothat bottom of collet is flush with bottom of in-se r t .

( 3 ) Ho ld t he co l l e t hand l e and t u rn t he

T-handle to expand collet cone until the insert isheld securely by the tool,

(4) Insert the drive bar of the tool throughthe valve guide.

(5) Tap the drive bar once or twice to movethe insert about 1/16-inch away from its seat inthe cylinder head.

(6) Loosen the collet cone and move the toolinto the insert slightly so that the narrow flangeat the bottom of the collet is below the valveseat insert .

(7) Tighten the collet cone and continue todrive the insert out of the cylinder head.

k. Install Valve Seat Insert.(1) Wash the counterbores in the cyl inder

head for the valve seat inserts with P-D-680solvent . Also, wash the valve inser ts with thesame solvent. Dry the counterbores and insertswith compressed air.

(2) Inspect the counterbores for cleanliness,concentr ici ty, f latness, and cracks. The coun-terbores for the valve inserts have a diameter of1.159- to 1.160-inches and a depth of 0.298- to0.302-inch.

(3) Immerse the cylinder head for at least30 minutes in water heated to 180- to 200-F.

(4) Rest the cylinder head, bottom side up,on bench and lay an insert in counterbore-valveseat up. This must be done quickly while thecylinder head is still hot and the insert is cold(room temperature) . I f the temperature of thetwo parts is allowed to become nearly the same,installation may become difficult and damage tothe parts may resul t .

( 5 ) Dr ive t he i n se r t down t i gh t i n to t hec o u n t e r b o r e .

(6) Grind the valve insert and check it forconcentricity in relation to the valve guide.

l. Recondition Exhaust Valve and Valve Seat,

CAUTIONFor the best results, do not permit grind-ing wheel to contact the cylinder headwhen grinding the inserts. Valve headrelation to cylinder head surface shouldbe within specified limits. After severalgrindings of the insert, the seat diameterbecomes enlarged; thus, the valve willseat farther down into the cylinder head.

Exhaust valves which are to be reused may berefaced, if necessary. To provide sufficient valves t r e n g t h a n d s p r i n g t e n s i o n t h e e d g e o f t h evalve head should never be less than 1/32 inch.Before either a new or used valve is installed,t he s ea t i n t he cy l i nde r head fo r t he va lveshould be examined for proper valve seat ing.

3-51

TM 10-3930-242-34

The proper angle for the seating face of both thevalve and valve insert is 30 degrees. The angleof the valve seat insert must be exact ly thesame as the angle of the valve face so as toprovide proper seating of the valve. When newvalve inserts are installed or old inserts refaced,the work must be done with a grinding wheel,Grind the inserts as follows:

(1) First apply a 30 degree grinding wheelon valve seat insert.

(2) Use a 60 degree grinding wheel to openthe throat of the insert.

(3) Then grind top surface with a 15 degreewheel to narrow width of the seat from 3/64- to5/64-inch. The 30 degree face of the insert may beadjusted relative to the center of the valve facew i t h t h e 1 5 d e g r e e a n d 6 0 d e g r e e g r i n d i n gwheels .

( 4 ) A f t e r t h e v a l v e i n s e r t s h a v e b e e nground, the cylinder head should be thoroughlycleaned. Then check the concentr ici ty of thevalve seats relative to the valve guides. Totalrunout for a good valve seat should not exceed0.002 inch. If total runout exceeds 0.002 inch,check for bent valve guide before regrinding in-se r t .

(5) After valve seats have been ground, theposition of the contact area between the valveand valve inser t should be determined in thefollowing manner:

(a) Apply a light coat of valve grindingcompound paste to the valve seat insert.

(b) Lower stem of valve in the valve guideand “bounce” valve on seat. DO NOT ROTATEVALVE. This procedure will show (on the valveface) the area of contact . The most desirablearea of contact is at the center of the valve face.

m. Install Exhaust Valves. With the cylinderh e a d t h o r o u g h l y c l e a n e d , t h e v a l v e g u i d e schecked or replaced, the valves and valve seatinserts ground, install the valves as follows:

(1) Apply a light coat of engine oil on thevalve stems and install the valves in the cylin-der head.

(2) Secure valves in place temporarily withmask ing t ape . Then t u rn head ove r , r e s t i ngvalve heads on wood block or board and installspr ing seats , valve spr ings, valve spr ing capsand locks (fig. 3-44).

NOTEThe distance from the top of the cylinder head tothe bottom of the valve spring seat counterbore is11/64inches.

(3) Check the position of the exhaust valves.

(4) Install cam followers, push rod assemb-

l ies , rocker arms, and rocker arm shaft (para3-14).

(5) Install cylinder head and injectors (para3-19).

(6) Prior to starting the engine, a completetuneup should be performed (paras 3-7 , 3-13,3-14, and 3-15.

(7) Start the engine and check for leaks inthe fuel, water and lubrication system.

(8) Install rocker a r m cover (TM10-3930-242-12).

3-21. Flywheela. General. The flywheel assembly is bolted

securely to rear end of crankshaft with six boltsin any one of six positions. A heat-treated steelspur gear, having chamfered teeth, is shrunkfiton the rim of flywheel.

b. Removal.(1) Remove engine (para 2-5).

CAUTIONWhen removing or installing attachingbo l t s , ho ld f l ywhee l f i rmly aga ins tcrankshaft by hand to prevent it fromslipping off end of crankshaft. The fly-wheel is not dowelled to crankshaft.

(2) Remove f lywheel at taching bolts andscuff plate while holding flywheel in position byhand, then reinstall one bolt (fig. 3-45).

(3) Attach flywheel lifting tool to flywheelwith two 3/8 inch -16 bolts of suitable length.

(4) Attach chain hoist to lifting tool.(5) Remove the remaining flywheel attach-

ing bolt.(6) Move upper end of tool back and forth to

loosen flywheel, then withdraw flywheel fromcrankshaft and flywheel housing.

c. Cleaning and Inspection.(1) Cleaning. Clean the flywheel and attach-

ing parts using solvent P-D-680, or equal. Drythoroughly .

(2) In spec t i on . After removal , check f ly-wheel for cracks, scoring, or overheating of theclutch contact face. If flywheel clutch surface isscored, it may be refaced. However, not morethan 0.020 inch of metal should be removed fromflywheel and all radii should be maintained. Al-t h o u g h f l y w h e e l s s e l d o m w e a r t o t h e p o i n twhere replacement is required, f lywheel r inggears may become worn due to normal usage ordamaged by improper use of the starting motorto the extent where they must be replaced. Theteeth on the ring gear should be examined. Ifreplacement of the ring gear is necessary, followthe procedure outlined below.

3-52

TM 10-3930-242-34

Figure 3-45. Flywheel and flywheel housing.

(3) Remove ring gear from flywheel. B e f o r eremoving the ring gear from the flywheel, notewhether teeth are chamfered. The replacementgear must be instal led so that the chamfer onteeth faces same direction with relationship toflywheel as on gear that is to be removed. Thenremove ring gear as follows:

(a) Place t he f l ywhee l , c r anksha f t s i dedown, on a sol id surface or hardwood blockwhich is slightly less in diameter than the fly-wheel .

(b) Drive the r ing gear off the f lywheelu s ing a su i t ab l e d r i f t and hammer . The r i nggear may be heated with a torch to faci l i ta teremoval. Work around the circumference of thering to avoid binding ring gear on the flywheel.Remove pilot bearing, if required.

(4) Replace ring gear on flywheel.(a) Support the f lywheel on a sol id f la t

surface with ring gear side of flywheel up.(b) Rest the ring gear on a metal or con-

c r e t e s u r f a c e a n d , u s i n g a b l o w t o r c h o racetylene torch, heat ring gear uniformly, keep-ing the blow torch moving around the circum-ference of the r ing gear to avoid hot spots .Under no circumstances should the ring gear beheated over 400° F., as excessive heating may

destroy the original heat t reatment. Heat indi-cators of “crayon” which are placed on work andme l t a t a p r ede t e rmined t empera tu re . Use o fone of these “crayons” will insure against over-heating of the ring gear.

(c) Pick the ring gear up with tongs andplace in posi t ion on f lywheel with r ing gearchamfer, if any, facing the same direction as theone just removed.

( d ) T a p r i n g g e a r i n t o p l a c e a g a i n s tshoulder on f lywheel . I f r ing gear cannot betapped into place readily, remove ring gear andapply addit ional heat , heeding the above cau-t ion about overheat ing.

d. Instal lat ion.(1) If a pilot bearing is used in bore of fly-

wheel and was removed, install bearing. Installnew seal ring if one was previously used.

(2) Mount flywheel, using lifting tool andchain hoist , into posi t ion against rear end ofc r a n k s h a f t .

(3) While holding flywheel in place by hand,remove flywheel lifting tool and install flywheelattaching bolts and scuff plate. Tighten bolts to130-140 foot-pounds torque.

(4) Mount a dial indicator on flywheel hous-ing and check runout of flywheel at clutch con-

3-53

TM 10-3930-242-34

tact face. Maximum allowable runout is 0.005inch total indicator reading.

(5) Install the engine (para 2-5).

3-22. Flywheel Housing

a. General. A combinat ion f lywheel housingand gear train cover is attached to the rear cy-linder block end plate and houses the flywheeland gear train.

b. Removal. The flywheel housing may be re-m o v e d f r o m t h e e n g i n e b y t w o d i f f e r e n tmethods; either by mounting the engine on theoverhaul stand, or by removing the oil pan, oilpump inlet pipe and screen and supporting theengine on wood blocks or a steel frame.

(1) Remove the engine (para 2-5).(2) Remove the oil pan (para 3-24).(3 ) Remove t he f l ywhee l a s ou t l i ned i n

paragraph 3-21.(4) Remove t h e fuel p u m p (TM

10-3930-242-12).( 5 ) R e m o v e t h e e n g i n e d r i v e n h y d r a u l i c

pump (TM 10-3930-242-12).( 6 ) Remove t he l im i t i ng speed gove rno r

(para 3-7).(7) Remove the fuel and hydraul ic pump

drive (TM 10-3930-242-12).(8) Remove t h e b r e a t h e r (TM

10-3930-242-12).(9) Remove the two outs ide blower dr ive

support - to-end-plate a n d f l y w h e e l h o u s i n gbolts, lockwasher and plain washer.

NOTEWhen removing the flywheel housing bolts, notethe location of the various size bolts, lockwashers,and copper washers, so they may be reinstalled intheir proper location at reassembly.

(10) Remove the bolts and lockwashers in-side of flywheel housing (flywheel cavity), whichat tach the housing to end plate and cyl inderblock. Remove the remaining bolts around theupper portion of housing also, the bolts which gothrough the rear end plate from the front andthread into the housing,

(11) Thread eye bolts into tapped holes inpads on top or sides of flywheel housing. Attacha chain hoist with sui table s l ing to eyebolts ,then strike the front face of housing alternatelyon each side of engine with a soft hammer toloosen and work it off dowel pins. Lift the hous-ing away from cylinder block rear end plate.

(12) Remove all traces of old gasket mater-ial from the cylinder block rear end plate andhousing. Do not scratch gasket flange surface.

c. Cleaning and Inspection.

(1) After removal, dean flywheel housing,thoroughly, using solvent P-D-680, or equal.

(2) It is very important that all old gasketmaterial be thoroughly removed from flywheelhousing and end plate , otherwise, run out ofpilot aid face of housing may be affected whenhousing is installed on engine.

(3) Inspect the crankshaft rear oil seal.d. Instal lat ion.

NOTELubricate the gear train teeth before instal l ingflywheel housing.

(1) Affix a new housing-to-end plate gasketto the rear face of end plate.

(2) Apply a light coat of high temperaturecup grease to lip of crankshaft rear oil seal. Donot use hypoid gear lubricants.

(3) To pi lot the seal onto the crankshaftsuccessfully, use an oil seal expander tool on theend of crankshaft . Also thread two al igningstuds into cylinder block, to guide the housinginto place.

(4) With housing suitably supported, posi-tion housing over crankshaft and up against cy-linder block rear end plate and gasket.

(5) Instal l the f lywheel housing at tachingbolt-s, lockwashers, and copper washers in re-verse sequence from which they were removed,f inger t ight only.

(6) For the sequence of initial tightening,refer to figure 3-46. Starting at No. 1, draw all ofthe housing bolts up snug.

(7) For the final tightening sequence, referto figure 3-47. Starting at No. 1, tighten all ofthe housing bolts to their specified torque. The5/16inch-18 and 3/8 inch-16 idler gear hub andspacer bolts should be tightened to 19-23 and40-45 foot-pounds torque. Tighten al l the re-maining 3/8 inch-16 bolts to 30-35 foot-poundstorque, and the 3/8 inch-24 bolts to 35-40 foot-pounds torque.

( 8 ) I n s t a l l t h e b r e a t h e r ( T M 1 0 - 3 9 3 0 -242-12).

( 9 ) I n s t a l l t he two ou t s i de b lower d r i vesupport to flywheel housing bolts, lockwashers,and plain washers. Tighten bolts to 30-35 foot-pounds torque.

NOTE

A long bolt or stud threaded into one of the tappedholes in the end of the crankshaft IS NOT a suita-ble support for the dial indicator and use of such asupport probably wil l result in inaccurate read-i n g s

(10) Using a dial indicator, check flywheel

3-54

TM 10-3930-242-34

Figure 3-46. Flywheel housing bolt , t ightening(operation 1).

housing concentricity in relation to the crank- flange face. Rotate the crankshaft one completeshaft as follows:

(a) Attach dial indicator holding f ixtureacross the end of the crankshaft with two boltsdiametrical ly opposi te to each other , Indicators u p p o r t a r m s h o u l d e x t e n d f r o m t h e f i x t u r ealong the axis of the crankshaft.

(b) Tap the f ront end of the crankshaf twith a soft (rawhide or plastic) hammer to in-sure end play of crankshaft is in one directiononly.

(c) Adjust the dial indicator to read zeroat the 12:00 o’clock position of the pilot (inneredge) of f lywheel housing bel l . Rotate crank-shaft one complete revolut ion. Maximum totalindicator reading should not exceed 0.013 inch.

(d) Adjust the dial indicator to zero at the12:00 o’clock position on flywheel housing bolt

revolution, Maximum runout should not exceed0.013 inch. If runout and concentricity exceedthe above max imum l imi t s , l oosen f l ywhee lhousing attaching bolts, tap housing, retightenbolts and recheck, I t may be necessary to re-move the flywheel housing and check for dirt orforeign material , such as old gasket mater ialbetween rear end plate and f lywheel housing,wh ich may r e su l t i n wa rpage . The f l ywhee lhousing must be replaced i f above l imits areunob ta inab l e .

( 1 1 ) I n s t a l l t h e f u e l p u m p a n d h y d r a u l i cpump drive (TM 10-3930-242-12).

(12) Install t h e fuel p l u m p ( T M10-3930-242-12).

( 1 3 ) I n s t a l l t h e e n g i n e d r i v e n h y d r a u l i cpump (TM 10-3930-242-12),

3-55

TM 10-3930-242-34

Figure 3-47. Flywheel housing bolt, tightening sequence(operation 2).

(14) Install the flywheel (para 3-21). from overhaul stand and install all accessories(15 ) I n s t a l l t he l im i t i ng speed gove rno r that were previously removed.

(para 3-7).(16 ) In s t a l l t he o i l pump in l e t p ipe and

(18) Install the engine (para 2-5).

screen assembly (para 3-25). (19) Refer to the current lubrication order,and refill crankcase to FULL mark on dipstick.(17) Affix a new gasket to the oil pan, and

i n s t a l l o i l p a n ( p a r a 3 - 2 4 ) . I f e n g i n e w a s (20) Refill cooling system, if drained (TMmounted on an overhaul stand, remove engine 10-3930-242-12).

3-56

Section IV. OIL PAN, OIL PUMP SCREEN, INLETCONNECTING RODS AND PISTONS

TM 10-3930-242-34

PIPE,

3-23. GeneralThe oil pan houses the lower engine compo-

nents and also contains lubricating oil for theengine. The oil pump screen is secured to thema in bea r ing cap w i th two bo l t s and l ock -washers . The inlet pipe is secured to the oi lpump. The pistons are secured to the connectingrods with wris t pins and connect ing rods andbear ings mounted around the crankshaf t .

3-24. Oil Pana. General. The oil pan is secured to the bot-

tom side of the engine block by 24 bolts andwashers, A drain plug is located in bottom of oilpan for draining engine oil, at oil change inter-vals or for oil pan removal.

b. Removal.(1) Remove plug and drain the engine oil.(2) Refer to figure 3-48 and remove the oil

p a n .c. Disassembly. Refer to figure 3-49 and dis-

assemble the oil pan.d. Cleaning and Inspection.

(1) Clean oi l pan and at taching hardware,thoroughly using solvent P-D-080, or equal.

(2 ) Remove a l l ga ske t ma te r i a l f rom the

gasket area.(3) Inspect the oil pan for cracks, excessive

dents, or other damage.e. Instal lat ion.

(1) Affix a new gasket to oil pan.

(2) Refer to figure 3-48 and reinstall the oilp a n .

(3) Refer to the lubrication order and ser-vice engine lubrication system.

3-25. Oil Pump Screen and Inlet Pipea. General. As the oil pump rotors revolve, a

vacuum is formed on the inlet side of the pumpand oi l is drawn from the crankcase, throughthe oil pump screen and inlet pipe, into the rotorcompartment of the pump.

b. Removal.(1) Drain engine oi l and remove oi l pan

(para 3-24).(2) Remove oil screen and inlet pipe (fig.

3-50).c. Disassembly. Refer to figure 3-49 and dis-

assemble oil pump screen and inlet pipe.

d. Cleaning and Inspection.(1) Clean all metal parts thoroughly, using

solvent P-D-080, or equal.(2) Inspect the inlet pipe for evidence of

clogging.(3) Inspect the inlet pipe for deep dents and

cracks.( 4 ) I n s p e c t m o u n t i n g h a r d w a r e a n d t h e

screen assembly for damage.(5) Replace all defective parts.

e. Instal lat ion.(1) Install inlet pipe and screen (fig. 3-50).(2) Install oil pan (para 3-24).

Figure 3-48. Oil pan, removal and installation. 3-57

TM 10-3930-242-34

Figure 3-49. Oil pan, oil pump screen and inlet pipe, disas-sembly and reassembly.

3-58

TM 10-3930-242-34

(3)e n g i n e

3-26.

Figure 3-50. Pistons, connecting rods, oil pump screen, andinlet pipe, removal and installation.

Refer to lubricat ion order and servicelubricat ion system.

Piston, Rings, Connecting Rod, and Cy-linder liner

a. General. The pistons are cooled by fresh airfrom the blower to top of piston in the combus-t ion chamber and by the water jacket aroundcylinder. Also, piston is cooled by a spray of lub-ricating oil directed at underside of piston froma nozzle in top of connecting rods on all enginesequipped with an oi l cooler . The pis ton r ingsmaintain uniform compression pressures in a l lcylinders. The cylinder liner houses the piston.

b. Removal ,

(1) Drain engine oi l and remove oi l pan(para 3-24).

(2) Remove cylinder head (para 3-19).(3) Refer to figure 3-50 and remove the pis-

tons arid connecting rods,(a) Remove carbon from the upper sur-

face of cylinder liner,. .

(b) Remove ridge from the liner at top ofring travel, if present.

c. Disassembly.

CAUTIONWhen removing or instal l ing pistonrings, do not spread rings more thannecessary to avoid overstressing therings.

NOTEPunch a hole through center of a piston pin re-tainer with a narrow chisel or punch and pry theretainer from piston, being careful not to damagepiston or bushings. Remove and disassemble thepistons, rings, connecting rod, and cylinder linerin numerical sequence (fig. 3-51).

d. Cleaning and Inspection.(1) Piston and rings.

(a) Clean all parts thoroughly with fuel oiland dry with compressed air. If fuel oil will notremove carbon deposits, use P-D-680 solvent, orequal, that will not attack the bushings or tinplating on the piston. The piston ring groovesmay be cleaned with a suitable tool, such as abroken half of a compression ring that has beensharpened to a bevel edge.

(b) The cooling surfaces on the inside ofthe piston should also be cleaned. Oil returnholes in the pis ton skir t must be thoroughlycleaned. Care must be exercised so that holesare not enlarged during the c leaning process .

3-59

TM 10-3930-242-34

nance will reduce to a minimum the amount ofabrasive dust and foreign material introducedinto the cylinder and will, in turn, reduce therate of wear.

(c) The protective coating on the skirt ofthe piston is from 0.0007- to 0.0015-inch thick.The presence of this coating of tin will, there-fore, indicate very little wear. A careful exami-nation of the piston should be made for scoring,burning, worn or damaged r ing grooves andcracks inside the piston across the s truts . Ab a d l y s c o r e d p i s t o n s h o u l d n o t b e r e u s e d ,whereas a pis ton only s l ight ly scored may becleaned up and reused.

( d ) E x a m i n e t h e i n s i d e o f t h e p i s t o nclosely for cracks across the struts and discardpiston if such cracks are present.

(e) Inspect the top of the piston crown forburned spots or other indications of overheatingsuch as carbon formation on the underside ofthe piston.

(f) Inspect the piston rings for free fit inthe grooves and side clearance.

(g) I n s p e c t a n d m e a s u r e t h e i n s i d ediameter of the piston pin bushings in each pis-ton, and, if worn excessively, replace the bush-ings o r p i s t on a s sembl i e s . A l so i n spec t andmeasu re t he p i s t on p in . The s t anda rd i n s idediameter of bushings in a piston is 1.3775-1.3780

Figure 3-51. Piston, r ings, connecting rod, and cyl inderliner, disassembly and reassembly,

Excessively worn or scored pistons, rings andcylinder l iners indicate abnormal maintenanceor operating conditions that should be correctedas quickly as possible. Proper types of lubricat-ing oil filters and air cleaners and their mainte-

3-60

inches and the standard outside diameter of thepiston pin is 1.3746-1.3750 inch. Thus, the stan-dard clearance between the piston pin and bush-ing, in a piston is 0.0025–0.0034 inch with a max-imum allowable wear limit of 0.010 inch.

(h) The p i s ton t ape r mus t no t exceed0.0005 inch from 7/16 inch below the bottom com-pression ring to the lower end of piston skirt.The diameter of a new standard pis ton belowthe compression ring grooves to bottom of pis-ton skirt is 3.8693-3.8715 inch.

(i) Check the p i s ton - to - l i ne r c l ea r ancewhile the piston is held upside down in the liner.The l iner should be in place in the cyl inderblock. This clearance should always be checkedwhen installing either new or used positions andliners. The clearance of a piston in a liner maybe checked with liner in the cylinder block, byinserting a ½-inch-wide feeler ribbon about 15inches long between the piston and liner, thenwithdraw feeler ribbon, measuring the force re-quired with a spring scale. This force should notexceed six pounds. When this force is approxi-mately 6 pounds, the actual clearance betweenthe piston and the l iner is 0.001 inch greaterthan the thickness of the feeler r ibbon used.Feeler ribbon used for checking this clearance

TM 10-3930-242-34

must be perfectly flat and free from nicks andsc ra t ches .

NOTE

If any bind between the piston and l iner is de-tected, remove the piston and l iner and inspectthem for burs. If either part is marred, the partsmust be cleaned up, using a fine hone on the-linerand fine file on the piston before proceeding.

NOTE

New piston rings should always be used whenevera piston is removed for inspection or replacement.

(j) When fitting piston rings, the gap bet-ween the ends of the rings should be measuredbefore installing the rings on the piston.

NOTE

The ring gap for the third compression ring and thelower compression r ing is from 0.020-0.036 inchand t he gap fo r t he o i l con t ro l r i ng i s f r om0.010-0.025 inch.

(k) Check the ring clearances in the pis-ton grooves. Nominal ring groove widths, whichmay vary ± 0.001 inch, and ring clearances ingrooves should be as follows:

Upper compression(fire) ring (straightface) -0.007 in. -0.010 in.

Upper compression(fire) ring (taperedface) -0.003 in. -0.006 in.Second compressionr i n g -0.007 in. -0.010 in.

Third compression r ing -0.0045 in. -0.007 in.Lower compression r ing -0.0045 in. -0.007 in.Upper oil control ring -0.0015 in. -0.0055 in.Lower oil control ring -0.0015 in. -0.0055 in.

(2) Wear limits. For al lowable wear l imitsrefer to table 1-1.

(3) Connecting rod, piston pins, and bear-ings .

(a) Check rod for straightness. Hydrosta-tic lock caused by fuel or water leakage to thepiston crown may result in a bent and possiblebroken connecting rod.

(b) Check the connecting rods for cracks.(c) If nozzle type connecting rod, inspect

and open holes in spray nozzle at upper end ofconnecting rod, if necessary. Blow dry compres-sed air through drilled oil passage in rod nozzleto be sure all passages are open.

(d) Check rod bushings for signs of scor-ing or other damage.

(e) Measure the outside diameter of pis-ton pin to determine wear. The standard diame-ter of new piston pins is 1.3746-1.3750 inches.

(f) The standard inside diameter of a newbushing in a connecting rod is 1.3760-1.3765 in-ches. The specified clearance between the pistonpin and bushing in upper end of connecting rodis 0.0010-0.0019 inch with new parts, and theallowable wear limit 0.010 inch. The piston pinand/or rod bushings must be replaced i f theabove limits are not obtained.

(g) Visual inspection, as well as the di-mensional measurements wil l be made to de-termine whether used bearings are sat isfactoryfor further service or must be replaced.

(h) Inspect the back of the bearing shellsfor bright spots which indicate they have beenmoving in their supports, If such spots are pres-en t , d i s ca rd t he bea r ing she l l s . A l so i n spec tc o n n e c t i n g r o d b e a r i n g s b o r e s f o r b u r s a n dforeign part ic les .

(i) Measure the thickness of the bearingshells and check the clearance between eachconnecting rod crank throw and the correspond-ing bea r ing she l l s . Connec t i ng rod cap nu t smust be tightened to 40-45 foot-pounds torquewith the bearing shells in place when measuringthe inside diameter . Use a micrometer and aball attachment, for measuring the shell thick-ness. If the standard size bearing shells are lessthan 0.123 inch in thickness and have more than0.006 inch clearance between any crank throwand i t s bea r ings , a l l she l l s , bo th uppe r andlower, must be discarded and new ones instal-led.

NOTEOne connecting rod shell alone should not be re-placed. If one bearing shell requires replacement,both upper and lower shells should be installed.

(4) Cylinder liner.CAUTION

To avoid damage to the top land of piston,do not at any time try to loosen cylinderliner by inserting a long bolt or rodthrough the port openings in cylinderliner and turning the crankshaft, thuspushing the liner up with the piston.

(a) When the cyl inder l iner is removedf rom the eng ine , i t shou ld be c l eaned , andchecked for-out-of-round, taper , cracks, scor-ing, flange irregularities, erosion.

(b) A cracked or excessively scored cylin-der liner must be discarded. A slightly scoredcylinder liner may be cleaned up and reused.

(c) Install the cylinder liner in the blockand measure the inside diameter of the liner atthe various points shown in figure 3-52. If thetaper exceeds 0.002 inch or the out-of-round ex-

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TM 10-3930-242-34

ceeds 0.003 inch, replace the liner. To check thedimensions, use a dial bore gage which has adial indicator cal ibrated in 0,0001 inch incre-men t s .

CAUTION

Do not drop or slam liner against the bot-tom of counterbore in the block.

(d) Fitting cylinder liner to bore in block:1. Clean inside and outside of cylinder

liner. Also, clean block bore and counterbore toinsure proper seating. Then, slide the liner intoblock until flange on liner rests on bottom ofcounterbore in the block.

2. T a p t h e l i n e r l i g h t l y w i t h a s o f thammer to make certain the liner flange seatson bottom of counterbore.

3. Clamp the liner in place with a hold-down clamp and measure distance from top ofthe liner flange to top of the block. The top of theliner flange should be 0.0465-0.050 inch belowtop of the block; and there must not be over0.0015 inch difference between any two adjacentl iners when measured along the cyl inder lon-gitudinal centerline. If above limits are not met,install liner in another bore, and recheck, or usea new liner.

4. Match mark the liner and block withchalk or paint on the seral number side of en-gine to insure the liner is reinstalled in sameposition in the same bore.

5. Remove holddown clamp and liner.e. Reassembly.

(1) With the piston (13, fig. 3-51) assembled

Figure 3-52. Cylinder liner measurement diagram.

3-62

TM 10-3930-242-34

to connecting rod (16) and rings (9, 10, and 11) inplace, apply clean oil to piston, rings, and insideof sleeve ring compressor,

(2) Place ring compressor on a woodblockwith taper end up.

(3) Stagger the piston ring gaps properly onthe piston. Insure that oil control ring expan-ders are not overlapped.

(4) Start the piston straight into the r ingcompressor and push the pis ton down unt i l i tcontacts the wood block,

(5) Note position of the matched mark onthe liner and place the liner on a block of wood.

(6) Place the ring compressor and the pistonand rod assembly on the liner, so that the num-bers on the rod and cap are a l igned with thematch mark on the liner.

NOTEThe numbers, or number and letter on the side ofthe rod and cap identify the rod with the cap andindicate the cylinder in which they are to be used.If new rods are used, etch or stamp the same iden-tification, in the same location as on the connect-ing rod/rods replaced.

CAUTIONDo not force the piston into the liner. Theexpanders apply considerable force onthe oil ring; therefore, extra care mustbe taken during the “loading” operationto prevent ring breakage.

(7) Push the piston and rod assembly downinto the liner until the piston is out of the com-pressor .

(8) Remove the connecting rod cap and thering compressor.

(9) Push the piston down into the liner untilthe compression ring passes the liner ports.

f . Instal lat ion After the piston and connect-i ng rod a s sembly have been i n s t a l l ed i n t hel iner , the entire assembly may be instal led inthe engine as follows:

(1) Make sure the seal ring groove in thecylinder block is clean, then install the seal ring.

NOTEThe current cylinder block has an additional sealr ing groove approximately 1/8" below the topgroove. This groove will permit further use of the

cylinder block where erosion or corrosion of theupper seal ring groove has occurred. The lowerseal ring groove in the current cylinder block hasbeen eliminated, Reinstallation of the seal ring inthe former block is not required.

( 2 ) A p p l y v e g e t a b l e t y p e s h o r t e n i n g o rpermanent type ant i freeze solut ion to the sealr ing.

(3) If any pistons and liners are already inplace, use holddown clamps to keep the liners inplace when the crankshaft is rotated.

(4) Rotate the crankshaft until the connect-ing rod journal of the particular cylinder beingworked on is at the bottom of its travel, wipe thejournal clean and lubricate it with clean engineoil.

(5) Install the upper bearing shell (the onewith a short groove at each parting line) in theconnecting rod. Lubricate the shel l with cleanengine oil.

(6) Hold the pis ton, rod and l iner in l inewith the block bore so that the identif icat ionnumber of the rod is facing the serial numberside of the block. Also align the match marks onthe l iner and block. Sl ide the entire assemblyinto the block bore and seal ring, being carefulnot to damage the seal ring,

(7) Pull or push the piston and connectingrod down until the upper bearing seats firmly onthe c r anksha f t j ou rna l ; u se ca r e so t ha t t hebearing shell will not be dislodged from the rod.

(8) Place the lower bearing shell (the onewith the continuous oil groove) in the connect-ing rod cap with the tang on the groove in thenotch in the cap. Lubricate the bearing shel lwith clean engine oil.

(9) Install the bearing cap and shell on theconnecting rod with the number on the cap androd adjacent to each other. Tighten the connect-ing rod nuts (3/8-24 bolts) to 45-50 ft-lbs. torque(lubricated) or 50-55 ft-lbs. torque (plain).

(10) Check the connecting rod side clearance.The clearance should be 0.006-0.012 in. with newpar t s .

(11) Remove the holddown clamps, Insta l lnew compression gaskets , water and oi l sealsand install the cylinder head (para 3-19).

(12) Install oil pan (para 3-24) and refer tothe lubrication order and fill crankcase with oil.

Section V. CAMSHAFT, BALANCE SHAFT, AND CRANKSHAFT

3-27. General t ha t meshes w i th t he camsha f t gea r . C rank -The camshaft lobes that operate the push rods shaft thrust is taken through two-piece washers

that directly operate the valves and fuel injec- on each side of the rear main bearing. All main-tors . The balance shaft operates from a gear a n d c o n n e c t i n g - r o d b e a r i n g j o u r n a l s u r f a c e s

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TM 10-3930-242-34

nd oi l seal surfaces are induct ion hardened.r anksha f t wea r i s u sua l ly a s soc i a t ed w i thearing troubles. Therefore, whenever main- or

c o n n e c t i n g - r o d b e a r i n g s a r e i n s p e c t e d t h ecrankshaft should also be inspected. The cam-shaft and balance shaft are located just belowthe top of the cyl inder block. The shaf ts aresupported by bear ings (bushing type) that arepressed into bores in the cyl inder block. Thebalance shaft is supported by front and rearbea r ing on ly ; whe rea s , t he camsha f t i s sup -ported by end, intermediate , and center bear-ings. Lubrication is supplied under pressure tothe end bearings by way of passages in the cy-linder block which lead from the main oil gal-lery. From the end bearings, oil passes throughthe hollow camshaft to the intermediate andcenter bearings.

3-28. Engine Front Cover (Upper)a. The engine upper front cover is attached to

the cyl inder block with at taching bol ts . Thecamshaft and balance shaft oil seals are pressedinto the cover.

b. Removal.(1) Remove var ious par ts and assemblies

from engine upper front cover as out l ined intheir respective paragraphs of this manual.

(2) Refer to figure 3-53 and remove frontcover.

c. Disassembly. After the front cover is re-moved, press oil seal from front cover.

d. Cleaning and Inspection.(1) Clean the front cover thoroughly, using

solvent P-D-680 or equal. Dry thoroughly.(2) Inspect the cover for cracks or damage.(3) Inspect the oil seals for wear or damage,

replace if necessary.e. Install Oil Seals.

CAUTIONKeep the lip of the oil seal clean and freeof scratches.

(1) Support the inner face of cover on woodblocks.

(2) If the outside diameter of the oil seal isnot precoated with sealant , coat the bore incover with nonhardening sealant .

(3) Position the oil seal in the cover with lipof seal pointing toward inner face of cover.

(4) Press the oil seal into the cover until theseal is flush with bottom of counterbore.

(5) Install second oil seal in same manner.(6) Remove excess sealant from the cover

and seals.f . Instal lat ion.

(1) Affix a new gasket to the cover.(2) Install cover on engine, Tighten bolts to

35 foot-pounds torque.(3) Apply grease to the outside diameter of

Figure 3-53. Engine front cover, removal and installation.3-64

TM 10-3930-242-34

oil seal spacers; then, slide them on the shaft.(4) Install a woodruff key in each shaft.(5) Install pulleys on the shaft.(6) Install and tighten pulley retaining nuts

to 300-325 foot-pounds torque.(7 ) I n s t a l l va r ious pa r t s and a s sembl i e s

previously removed as outlined in their respec-tive paragraphs of the manual.

3-29. Camshaft, Balance Shaft and Bearingsa. General. The camshaft , balance shaft and

bearings are located just below the top of thecylinder block. The camshaft and balance shaftare described in paragraph 3-27.

b. Removal of Camshaft or Balance Shaft,NOTE

Whenever an engine is being completely recon-dit ioned or the bearings, thrust washers, or thegears on the shafts need replacing, the shaftsshould be removed from the engine in the follow-ing manner:

(1) Drain the engine cooling system.(2) Remove the engine (para 2-5) and at-

t a ch ing pa r t s nece s sa ry t o moun t eng ine onoverhaul s tand.

(3) Mount the engine on an overhaul stand.Be sure the engine is securely mounted on thestand before releasing the lifting sling.

(4) Remove the cylinder head (para 3-19).(5) Remove the flywheel and the flywheel

housing (para 3-21 and 3-22),(6) Remove the bolts which secure the gear

nut retainer plates (if used) to the gears; thenremove the retainer plates .

(7) Wedge a clean rag between the gears asshown in f igure 3-54; then, remove the nutsf r o m e a c h e n d o f b o t h s h a f t s w i t h a s o c k e tw r e n c h .

(8) Remove the balance weights f rom thefront end of the shafts (fig. 3-55).

(9) Remove the upper engine front cover(para 3-28).

(10) Remove the oil slinger from the frontend of both shafts.

(11) Remove the two thrust washer re ta in .ing bol ts that secure the camshaft or balanceshaft thrust washer to the cyl inder block, byinserting a socket wrench through a hole in the—web of the gear,

(12) Withdraw the shaft, thrust washer, andgear, as an assembly, from the rear end of thecylinder block.

c. Disassemble Camshaft or Balance Shaft.(1) Refer to figure 3-55 and disassemble the

cam and balance shaft.

(2) To permit cleaning out any foreign mat-erial that may be lodged at the ends of the oilpassage, remove the end plugs from the cam-shaft as follows:

(a) Clamp the camshaft in a vise equippedwith soft jaws. Use care to prevent damage tothe cam lobes and machined surfaces of thesha f t .

(b) Make an indentation in the center ofone of the end plugs with a 31/64-inch carboloy tipdri l l .

(c) To aid in breaking through the har-d e n e d s u r f a c e o f t h e p l u g , p u n c h a h o l e a sdeeply as possible with a center punch.

(d) Then, use a 1/4-inch carboloy tip drill todrill a hole through the center of the plug.

(e) Redrill the end plug with a 5/16-inchcarboloy tip drill.

(f) Thread t he ho l e i n t he p lug w i th a3/8-inch-16 tap.

(g) Remove the end plug from the cam-sha f t .

(h) Insert a 3/8-inch steel rod in the cam-shaft oil gallery and drive the remaining plugout. If a steel rod is not available perform steps(a) through (g) above to remove the remainingplug.

d. Cleaning, Inspection, and Repair.(1) Clean al l parts thoroughly, using sol-

vent P-D-680, or equal. Be sure the oil holes inthe camsha f t ( s ) a r e c l ean . S ludge accumula -tions, which might restrict the oil flow, must beremoved.

(2) Inspect the cams and journals , and, i fthey are badly scored or worn, replace the cam-sha f t .

(3) I f cams are scored, the cam fol lowersshould also be inspected para 3-15).

( 4 ) E x a m i n e b o t h f a c e s o f t h e t h r u s twashers. If either face is scored or if the thrustw a s h e r s a r e w o r n e x c e s s i v e l y , r e p l a c e t h ewashers . New thrust washers are 0.208-0.210inch thick.

(5) Also, examine surfaces which the thrustwashers contact; if these surfaces are scratchedbut not severely scored, they may be smootheddown with an oil stone. However, if score marksare too deep to be removed, or if parts are badlyworn, new parts must be used.

(6) The clearance between new shafts andnew bearings is from 0.0045-0.006 inch or a max-imum of 0.008 inch with worn parts. Excessiveclearance between the shafts and the bearingswill cause low oil pressure and excessive back-lash between the gears.

e. Remove Bearings.

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TM 10-3930-242-34

Figure 3-54. Camshaft or balance shaft nut, removal andinstallation.

NOTEEnd bearings must be removed prior to removingthe intermediate bearings.

CAUTIONWhen removing bearings be sure to notethe position of the bearings in the borewith respect to the notch in the bearings.Replacement bearings must be installedin the same position.

(1) Remove all accessories and assemblieswith their attaching parts as is necessary.

(2) Press the end bearing out of the cylinderblock. The nearest intermediate and/or centerbearings can now be removed in the same man-n e r .

(3) To facilitate assembly, the camshaft andbalance shaft bearings are color coded as fol-lows:

3-66

Bearing Color Insideposition

Outsidecode diameter diameter

E n d Black Standard StandardIn te rmedia te Red Standard StandardC e n t e r Green Standard Standard

f. Sequence for Installing Bearings.

CAUTIONAll replacement bearings must be instal-led with the notch located at the sameposition in the case of original bearings.The center, rear intermediate, and rearbearings are installed in that order bypressing the bearings from the rear tofront of block. The front intermediateand front bearings are installed by pres-sing the bearings from the front to therear of the block.

g. Reassemble. Refer to figure 3-55 and reas-semble cam and balance shaft.

TM 10-3930-242-34

3-67

Figure 3-55. Camshaft and balance shaft, disassembly andreassembly.

TM 10-3930-242-34

h. In s t a l l a t i on .(1) Lubricate bearings and shafts with en-

gine oil and slide the shaft assemblies into thecylinder block being careful not to damage thebearings or the cams and journals. Make surethat the appropriate timing marks on the gearsare aligned. “Gear Train and Engine Timing” iscovered in paragraph 3–33.

(2) Slide an oil slinger on the front end ofboth shaf ts .

( 3 ) I n s t a l l t h e u p p e r e n g i n e f r o n t c o v e r(para 3-28).

(4) Secure the thrust washers in place andtighten the bolts to 30-35 foot-pounds torque.

(5) Instal l the front balance weights ( f ig .3-55).

(6) Attach the gear nut retainer plates tot h e g e a r s w i t h b o l t s a n d l o c k w a s h e r s a n dtighten the bolts to 35-39 foot pounds torque.

(7) Check the clearance between the thrustwasher and the gear on both shafts. The clear-ance should be 0.008–0.015 inch, or a maximumof 0.019 inch with used parts.

(8) Check the backlash between the matinggears. The backlash should be 0.003–0.005 inchand should not exceed 0.007 inch between usedgea r s .

(9) Install the flywheel housing (para 3-22).(10) Install the cylinder head (para 3-19).(11) Install the engine (para 2-5).

3-30. Idler Gear Assemblya. General. The engine idler gear and bearing

assembly, located at the flywheel end of engine,m e s h e s w i t h t h e c a m s h a f t a n d c r a n k s h a f tgears, and rotates on a stationary hub. The hubis secured directly to the cylinder block by a boltthat passes through the hub, and three bol tsthat pass through the f lywheel housing, hub,and end plate.

b. Remova l .(1) Remove flywheel housing (para 3-22).(2) Refer to figure 3-56 and remove idler

gear assembly.

c. Cleaning y Inspection, and Repair.(1) Clean the idler gear and bearing assem-

bly, hub, and thrust washers thoroughly. Usec l e a n i n g s o l v e n t P - D - 6 8 0 , o r e q u a l a n d d r ythoroughly. Examine gear teeth and bearing forscoring, pi t t ing, and wear . I f gear teeth areworn or bearing is scored, pitted or worn exces-sively, the gear and bearing and bearing assem-bly must be replaced, or a new bearing installedin the gear. Also, examine the outside diameterof the idler gear hub and thrust washers forbeing scored and worn. If the thrust washers or

3-68

gear hub are scored and worn excessively, theymust be replaced.

NOTEWhen a new bearing is being installed in the idlergear, it must not protrude beyond the gear face oneither side.

(2) Slide the idler gear straight back off ofthe idler gear hub.

(3) Remove bolt which secures the idlergear hub to the cylinder block. Then, remove theidler gear hub and the rear idler gear thrustwasher, as an assembly, from the engine.

d. Instal lat ion.(1) Place the inner thrust washer over the

forward end of the idler gear hub with the flat inthe inner diameter of the thrust washer overthe flat on the end of the gear hub, and the oilgrooves in the thrust washer facing the idlergea r .

(2) Place the smal l protruding end of theidler gear hub through the end plate and intothe counterbore in the cylinder block.

(3) Insert two 3/8-inch-16 bolts through theidler gear hub and thread them into the cylinderblock, as shown in figure 3-57, to be sure the boltholes wil l be in al ignment when the f lywheelhousing is installed.

(4) Insert the 3/8-inch-16 by 1 3/4-inch specialbolt through the center of the idler gear hub andthread it into the cylinder block. Tighten bolt to30-35 foot pounds torque. Then, remove the two3/8-inch-16 bolts previously installed for align-ment of the gear hub.

(5) Lubricate the idler gear hub and idlergear bearings liberally with clean engine oil.

(6) Posi t ion the crankshaft gear and cam-shaft gear or balance shaft gear so that theirmatchmarks will align with those on the idlergea r .

(7) With these matchmarks in al ignment ,install the idler gear, as shown in figure 3-58.

(8) Apply a thin film of cup grease to theinner face (face with oil grooves) of the outeridler gear thrust washer. The, place the thrustwasher over the end of the idler gear hub withthe oil grooves in side of thrust washer facingthe idler gear, and the flat in the inner diameterof thrust washer over the flat on the end of theidler gear hub.

(9) Install the idler gear hole spacer.(10) Install the flywheel housing (para 3-22).

3-31. Crankshaft Main Bearinga. General . The main bearing shells are of

precision type and are readily replaceable with-out machining. They are used at each journal

TM 10-3930-242-34

Figure 3-56. Idler gear assembly, removal and installation.

Figure 3-57. Installing idler gear hub.

and consist of an upper shell seated in cylinderblock main bear ing support and a lower shel lseated in main bearing cap. The bearings arenumbered 1, 2, 3, etc., indicating their respectivep o s i t i o n , a n d w h e n r e m o v e d m u s t a l w a y s b ere in s t a l l ed i n t he i r o r ig ina l pos i t i on , Lowermain bearing shells have no grooves; thereforethe upper and lower bearing shells must not btinterchanged. An oil hole in the groove of eachupper shel l midway between the part ing l inerregisters with a vertical oil passage in the cylin-

Figure 3-58. Installing idler gear.

der Mock. Lubricating oil, under pressure pas-ses from the cylinder block by way of the bear-ing shell to the drilled passages in the crank-shaft then to the connecting rods. Rear mainbear ing thrust washers absorb the crankshaf tthrust a t each s ide of the rear main bearing.Each washer is made of two halves; the lower

3-69

TM 10-393-242-34

halves are doweled to the bearing cap, the upperhalves are not doweled.

b. Removal (Crankshaft in Place).(1) Remove the engine (para 2-5).(2) Remove the oil pan to expose the main

bearing caps (para 3-24).(3) Remove the oi l pump inlet pipe and

screen assembly (para 3-25),(4) Remove all except the rear main bear-

ing, dress down the head of a 1/4” x 3/4” bolt to athickness of 1/16”. (The thickness of the dresseddown bolt head, must be less than the thicknessof the bearing shel l ) . Inser t the bol t into thec r anksha f t j ou rna l o i l ho l e and r evo lve t hecrankshaft so that the bol t head contacts thebearing shell opposite the bearing locating tangand roll the bearing out of the block.

NOTERemove one main bearing cap at a time, inspect asoutlined under INSPECTION in this section, andcomplete replacement of shell and reinstallation ofcap before another cap is removed.

(5) Two-piece thrust washers are used oneach side of the rear main bearing (fig. 3–59).The lower half of these washers will be removedw h e n r e m o v i n g t h e r e a r m a i n b e a r i n g c a p ;upper half can be removed by pushing on end ofwasher with a small rod, thus forcing washeraround and out on opposite side of bearing.

(6) Remove rear main bear ing upper shel lby driving on the edge of the bearing shell witha small curved rod (fig. 3-60) at the same time

Figure 3-59. upper and lower main bearing sheels, bearingcaps, and rear main bearing thrust washers.

Figure 3-60. Removing rear main bearing upper shell(crankshaft in place).

revolving the crankshaft, thus rolling the shellfrom its position.


(1) After removal, clean the bearing shells,thoroughly, with P-D-680, or equal, and dry. In-spect them for scoring, pi t t ing, f laking, chip-ping, cracking, loss of babbitt, or signs of over-heating. If any of these defects are present, thebearings must be discarded. However, the bab-bitt plated bearings may develop minute cracksor small isolated cavities on the bearing surfaceduring engine operation. These are characteris-tics of and are not detrimental to this type ofbearing. The bearings should not be replaced forthese minor surface imperfect ions s ince func-tioning of the bearings is in no way impairedand they wil l give many addit ional hours oftrouble-free operation. The lower bearing shells,which carry the load, will normally show signsof distress before the upper shells do.

(2) Inspect the back of the bearing shells forbright spots that indicate they have been mov-ing in the caps or cylinder block. If such spotsare present, discard the bearing shells.

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TM 10-3930-242-34

(3 ) The t h i cknes s o f t he bea r ing she l l sshould be measured at point C, 90° from partingline.

NOTEMinimum thickness of a worn standard main bear-ing shell is 0.123 inch and, if any of the shells arethinner than this dimension, al l shells must bediscarded and replaced with new shells . A newbearing shell has a thickness of 0.1245-0.1250 inch.

(4) In addit ion to this thickness measure-ment, the clearance between main bearings andc r a n k s h a f t j o u r n a l s s h o u l d b e c h e c k e d . T h i sclearance may be determined with the crank-shaft in place by means of a soft plastic measur-ing strip which is squeezed between the journaland bearing, or with the crankshaft removed bymeasuring the outside diameter of the crank-s h a f t m a i n b e a r i n g j o u r n a l s a n d t h e i n s i d ediameter of the main bearing shells when instal-led in place with the proper troque of 120-130foot-pounds on the main bearing cap bolts. If theclearance between any crankshaft main bearingjou rna l and i t s bea r ing she l l s exceeds 0 .006inch, all bearings shells must be discarded andreplaced with new shells. The proper clearanceis 0.0013-0.0042 inch.

CAUTIONOne main bearing shell, alone, should notbe replaced. If one bearing shell re-quires replacement, a new upper andlower shell should be installed.

( 5 ) W h e n m a i n b e a r i n g r e p l a c e m e n t i snecessary, it is very important that the crank-shaf t journals be thoroughly inspected beforenew replacement bearings are instal led. Veryoften, after prolonged engine operation, a ridgeis formed on the circumference of the crank-shaft journals in line with the journal oil holes.This ridge must not exceed 0.0002 inch and, if itis not removed before new bearings are instal-led, then during engine operation, localized highunit pressures in the center area of the bearingshell will cause pitting of the bearing surface.A l so , damaged bea r i ngs may cause bend ingfat igue and resul tant cracks in the crankshaft .

d. Installation (Crankshaft in Place).NOTE

Make sure all parts are clean. Apply clean engineo i l t o a l l c r anksha f t j ou rna l s and i n s t a l l ma inbearing shells by reversing the sequence of opera-tions given for removal,

CAUTIONMain bearing shells should not be re-placed separately. If bearing shell re-quires replacement, a new upper and

lower shell should be installed. If a newcrankshaft is used all new bearing shellsshould be installed.

(1) When installing the upper main bearingshells with crankshaft in place, start the end ofthe shell having no tang around the crankshaftjournal, so that when shell is in place the tangwill fit into the groove in the shell support.

(2) Assemble crankshaft thrust washer be.fo re i n s t a l l i ng r ea r ma in bea r ing cap , C leanboth halves of thrust washer carefully, remov-ing any burs from the seats-the slightest parti-c l e o f d i r t may dec rease c l ea rance be tweenwashe r s and c r anksha f t beyond l im i t s . S l i deupper halves of thrust washers into place intheir grooves, as shown in figure 3-61, then as-semble lower halves over dowel pins in bearingcap.

NOTE

M a i n b e a r i n g c a p s a r e b o r e d i n p o s i t i o n a n dmarked 1, 2, 3, 4, and 5. They must be replaced intheir original positions with marked side of capsfacing the same side of cylinder block that carriesthe engine serial number.

(3) With the lower main bearing shells in-stalled in bearing caps, install caps in their orig-inal position and draw bolts up snug. Then tapcaps l ightly with a soft hammer to seat themproperly, and draw bearing cap bolts uniformlytight, starting with center cap and working al-ternately towards both ends of block, to 120-130foot-pounds torque.

Figure 3-61. Rear main bearing thrust washer andmounting.

3-71

TM 10-3930-242-34

NOTEIf the bearings have been installed properly, thecrankshaft will turn freely with all main bearingcaps bolted tight.( 4 ) C h e c k c r a n k s h a f t e n d p l a y a t t h r u s t

washers. This clearance should be from 0.004 to0.011 inch. Insuff icient clearance wil l usual lydenote misalignment of the rear main bearing.In such case, loosen and retighten the rear mainbearing cap. If lack of clearance is still present,dirt or a bur on inner face of one or more of theth ru s t washe r s may be t he cause , o r washe rmay be bent.

NOTE

If end play has increased to the point where clear-ance is in excess of 0.004-0.011 inch, new washersshould be installed.(5) Instal l lubricat ing oi l pump inlet pipe

assembly (para 3-25).(6) Instal l oi l pan with new gasket (para

3-24).(7) Install the engine (para 2-5).

3-32. Crankshaft

a. General. The crankshaft is secured to theengine block by means of main bearings. Thecrankshaft has four journals on which connect-ing rods are mounted with enough clearance sothat they will move freely over surface of crank-sha f t .

b. Removal.(1) Remove engine (para 2-5).(2) Remove oil pan (para 3-24).(3) Remove oil screen and inlet pipe (para

3-25).(4) Remove flywheel housing (para 3-22).(5) Remove front cover and oil pump (para

3-2).( 6 ) R e m o v e r o c k e r a r m c o v e r ( T M

10-3930-242-12), then remove fuel oil pipes frominjectors and fuel connectors. Install dust capson injectors and fuel injectors. (para 3-13).

( 7 ) L o o s e n a l l r o c k e r a r m s h a f t s u p p o r tbracket bol ts to prevent valves from openingwhen crankshaft is rotated (para 3-15).

(8) Refer to figure 3-62 and remove crank-sha f t .

c. Cleaning, Inspection, and Repair.(1) Remove crankshaft plugs and clean out

a l l o i l p a s s a g e s t h o r o u g h l y , u s i n g s o l v e n tP-D-680, or equal.

(2) Support crankshaft on its front and rearjournals in a V-block or in a lathe and checkrunout on intermediate main bear ing journals ,using a dial indicator. When runout on adjacentjournals is in opposite direction, the sum must

3-72

not exceed 0.003 inch total indicator reading.W h e n r u n o u t o n a d j a c e n t j o u r n a l s i s i n t h esame direction, the difference must not exceed0.003 inch total indicator reading. When highs p o t s o r r u n o u t o n a d j a c e n t j o u r n a l s a r e a tr ight angles to each other , the sum must notexceed 0.004 inch total indicator reading, or0.002 inch on each journal. If runout limit isgreater than given above, crankshaft must bereplaced.

(3) Measure al l main and connect ing rodbearing journals. Journals should be measuredat several places on the circumference in orderto determine the smallest diameter, in case thejournals have worn out-of-round. Taper on thejournals of a used shaft should not exceed 0.003inch, and out-of-round should not exceed 0.003inch. The maximum taper on a new shaft is0.0005 inch and maximum out-of-round is 0.0025inch.

(4) Used crankshafts will sometimes show acertain amount of ridging caused by the groovein the upper main bearing shell. If this ridge isnot removed before new bearing shells are in-s tal led, local ized high uni t pressures on thebearings will result during engine operation. Aridge exceeding 0.0002 inch or more must beremoved. If ridges are greater than 0.001 inch,the crankshaft may have to be replaced.

(5) Check surfaces of the crankshaft forevidence of cracks as follows: Several methodsof determining presence of minute cracks notreadily visible to the eye are-

(a)(b)

Method(c)

Magnetic Particle MethodF luo re scen t Magne t i c Par t i c l e

Fluorescent Penetrant Method

NOTEMost of the indications revealed by the above in-spect ion methods are normal and harmless andonly in a small percentage of cases is reliability ofthe part impaired when indicat ions are found.S i n c e i n s p e c t i o n r e v e a l s h a r m l e s s i n d i c a t i o n swith the same intensity as the harmful ones, de-tection is but one step in the procedure. Interpre-tat ion of the indications is the most importantstep.

(6) Check thrust surfaces for evidence ofexcessive wear or roughness. In many instancesonly s l ight gr inding or “dress ing up” of thethrust surfaces is necessary. In such cases, useof new standard thrust washers wil l probablyh o l d t h e e n d t h r u s t c l e a r a n c e w i t h i n t h especified limits of 0.004-0.011 inch for new partsor a maximum of 0.018 inch with a used crank-

TM 10-3930-242-34

Figure 3-62. Crankshqft, removal andinstallation.

shaft . Otherwise, i t may be necessary to use0.005 inch oversize rear thrust washers.

(7) Inspect keyways for evidence of cracksor worn condition, and replace shaft if neces-s a r y .

(8) Carefully inspect crankshaft in the areaof the front and rear oil seal contact surface forevidence of rough or grooved condition. Any im-perfections of oil seal contact surface will resultin oil leakage at this point.

NOTE

Slight ridges of approximately 0.0002 inch in vari-ation may be removed with crocus cloth, wet withfuel oil. The crankshaft should be rotated at in-tervals to remove r idges from the complete cir-cumference of the shaft without disturbing theconcentricity. Ridges which approach 0.0005 inchor greater should first be cleaned up with 120 gritemery cloth, followed by use of 240 grit emerycloth for finishing. Crocus cloth, wet with fuel oil,should then be used for final polishing. If exces-sive wear or grooving is present, and cannot becleaned up satisfactorily, the oil seal may be pres-sed in the flywheel housing and front cover ap-proximately 1/8 inch from its original position.

(9) Check the lube oil pump drive gear andc r a n k s h a f t t i m i n g g e a r f o r w o r n o r c h i p p e dteeth and replace if necessary.

(10) I f the crankshaf t i s worn so that thec o n n e c t i n g r o d o r m a i n b e a r i n g m a x i m u mjourna l - t o -bea r ing she l l c l ea r ance (w i th newshells) exceeds 0.0044 inch and 0.0046 inch, orthe maximum journals taper or out-of-round isgreater than 0.003 inch, the crankshaft must bereplaced. M e a s u r e m e n t s o f t h e c r a n k s h a f tshould be accurate to the nearest 0.002 inch.

d. Instal lat ion.(1) Install upper grooved bearing shells in

the cylinder block.(2) Apply clean engine oil to all crankshaft

journals and set crankshaft in place.(3) Install the upper halves of the rear main

bearing thrust washers on each side of the bear-ing, and the doweled lower halves on each sideof the rear main bearing cap.

(4) With the lower main bearing shells in-stalled in bearing caps, tap the caps lightly witha soft hammer to seat them properly and draw

3-73

TM 10-3930-242-34

the bearing cap bolts unlformly tight startingwith center cap and working alternately towardboth ends of the block, to 120-130 foot-poundstorque. Tighten the bolts to the high side of thetorque specification but do nut exceed the limit.

NOTEIf bearings have been instal led properly, thecrankshaft will turn freely with all main bearingcap bolts drawn to specified torque.

( 5 ) C h e c k c r a n k s h a f t e n d p l a y a t t h r u s twashers. The cranks shaft clearance with newthrust washers should be from 0.0040.011 inch.Insufficient clearance will usually denote mis-al ignment of the rear main bearing. In suchcase, loosen the bearing cap, then retighten asdescribed above. If lack of clearance is still pres-ent, either dirt or a burr on the inner face of oneor more of the thrust washers may be the cause.

(6 ) Re fe r t o f i gu re 3 -62 and i n s t a l l t hec r a n k s h a f t .

(7) Reposition the rocker arms and adjust(para 3-15).

(8) Install the fuel oil pipes on the fuel in-jectors (para 3-14), and install the rocker armcover (TM 10-3930-242-12).

(9) Instal l the front cover and oi l pump(para 3-2).

(10) Install the flywheel housing (para 3-22).(11) Install the oil screen and inlet pipe (para

3-25).(12) Install the oil pan (para 3-24).(13) Install the engine (para 2-5).

3-33. Gear Train and Engine Timinga. General. The gear train consists of a crank-

shaft gear, and idler gear, a camshaft gear and abalance shaft gear . The crankshaft gear , cam-shaft gear, and balance shaft gears are pressedon and keyed to their respective shafts and eachgea r i s s ecu red by a r e t a in ing nu t and l ockplate. The idler gear rotates on a s tat ionaryh u b .

b. Engine Timing.(1 ) The co r r ec t r e l a t i onsh ip be tween t he

crankshaft and camshaft must be maintained toproperly control fuel injection and the openingand closing of the exhaust valves.

NOTEAn engine which is “but of t ime” may result inpreignition, uneven running, and a loss of power.

( 2 ) T h e c r a n k s h a f t t i m i n g g e a r c a n b emounted in only one position due to its beingkeyed to the crankshaft. The camshaft gear can

also be mounted in only one position as result ofthe location of the keyway relative to the, cams.Therefore, when the engine is properly timedd,the markings on the various gears will match asshown in figure 3-63.

(3) When an engine is suspected of beingout of time, due to an improperly assembledgear train, a quick check can be made withouthaving to remove the f lywheel and f lywheelhousing by fol lowing the procedure out l inedbelow.

c. Checking Engine Timing. Access to thecrankshaft pulley, to mark the top-dead-centerposition of the selected piston and to the frontend of the crankshaft or flywheel for barring theengine over is necessary in performing the tim-ing check. Then, proceed as follows:

(1) Remove the cylinder head rocker armcover (TM 10-3930-242-12).

(2 ) Se l ec t any cy l i nde r fo r t he t im ingcheck–it is suggested that a cylinder adjacent toone of the cylinder head cover studs be chosensince the stud may be used for mounting a dialindicator .

(3) Remove the fuel jumper lines (at the cy-linder selected) and install shipping caps on in-jector fuel fittings to prevent the entry of dirt.Make sure that the valve and injector rockerarms are in the “up” position, then remove therocker shaft bracket bolts and swing the rockerarm assemblies back out of the way. Remove theinjector assembly.

(4) Carefully place (do not drop) a weldingrod or drill rod approximately 12 inches longthrough the injector hole and on top of the pis-ton. With the throttle in the NO FUEL position,bar the crankshaft s lowly in the direct ion ofrotation of the engine, and stop barring whenthe rod reaches the end of its upward travel.Remove the rod and bar the crankshaft oppositethe direction of rotation between 1/16 and 1/8 of at u r n .

(5) Select a dial indicator having 0.001 inchgraduations and with a spindle movement of atl ea s t 1 i nch . Use su i t ab l e moun t ing a t t ach -m e n t s f o r t h e i n d i c a t o r s o t h a t i t c a n b emounted over the injector hole in the cylinderhead. Provide an extension for the spindle of theindicator. The extension must be long enough tocontact the piston as it is approaching its upperposition.

(6) Mount the indicator over the injectorhole and tighten mountings sufficiently to holdthe indicator rigid.

3-74

TM 10-3930-242-34

Figure 3-63. Gear train and timing marks.

NOTEThe mounting leg may be threaded into the rockercover retaining screw hole on the injector rack sideof the cylinder head. Make sure that the spindleextension is free in the injector hole, does not bind,and is free to travel its full 1 inch movement,

(7) Provide a suitable pointer and attach itto the lower engine front cover. The pointer

should extend over the crankshaft pulley.(8) Turn the crankshaft in the direction of

rotation, slowly, until the hand on the dial indi-ator just stops moving.

(9) Turn the crankshaft in the direction ofrotat ion unti l the indicator hand just s tar ts tomove. Reset the dial to “0”. Continue barr ings lowly un t i l i nd i ca to r r e ad ing i s 0 . 010 - thenstop turning.

(10) Scribe a line on the crankshaft pulley inline with the end of the pointer.

(11) Turn the crankshaft the opposite the di-rection of rotation slowly until the hand on thedial indicator just stops moving.

(12) Turn the crankshaft opposite the direc-t ion of rotat ion unt i l the indicator hand juststarts to move. Reset the dial to “0”. Continueb a r r i n g s l o w l y u n t i l i n d i c a t o r r e a d i n g i s0 .010- then s top turning.

(13) Scribe a second line on the crankshaftpulley in the same manner, as in step 10.

(14) Scribe a third line halfway between thefirst two lines. This is positive top-dead-center.Remove the indicator from the engine.

3-75

TM 10-3930-242-34

NOTEMake sure that the crankshaft pulley retaining boltis not loosened during the turning operation. Thebolt may be tightened to a torque of 200-220 foot-pounds if it becomes loose.

(15) Remove the dial indicator and the weld-ing rod or drill rod from the injector tube.

( 1 6 ) I n s t a l l t h e i n j e c t o r a s s e m b l y a n dtighten the injector clamp bolt to 25-30 foot-pounds torque. Swing the injector and valverocker arm back into position and install rockerarm brackets and t ighten bol ts to 50-55 foot-pounds torque. Adjust the exhaust valve clear-ance and t ime the injector . Turn engine overuntil the exhaust valves in the selected cylinderare completely open.

(17) Install the dial indicator once again sothat the spindle of the indicator rests on top ofthe injector follower. Set indicator dial to “O”.Bar the crankshaft s lowly in the direct ion of

r o t a t i o n , a n d s t o p w h e n T D C m a r k o n t h ecrankshaft pulley lines up with the pointer.

(18) When checking the engine timing, notethe reading on the indicator and compare it withthe dimensions l is ted below for the camshaftbeing used.

(a) If the indicator reading is 0.204-0.207inch, the engine is in time.

(b) If the indicator reading is 0.177-0.180inch, the timing is one tooth retarded.

(c) If the indicator reading is 0.234-0.237inch, the timing is one tooth advanced.

(19) After completing the timing check, re-move the dial indicator; remove shipping capsfrom injector fuel fittings, and install the injec-tor fuel pipes, making sure that they are tight-ened to prevent any fuel leaks. Remove thepointer attached to the front of the engine.

(20) Instal l the cyl inder head rocker armcover (TM 10-3930-242-12).

Section VI. CYLINDER BLOCK

3-34. GeneralThi s s ec t i on p rov ides t he ma in t enance i n -

structions needed by direct support and generalsupport maintenance for the cylinder block andend plate.

3-35. Cylinder Block and End Platea. General. The cylinder block is a one-piece

cast ing, serving as the main structural part ofthe engine. A flat steel plate is bolted to the rearend of the cylinder block to provide a means ofat taching the f lywheel housing, camshaft , andcrankshaft cover. The block has drilled passagesfor carrying lubricating oil to all moving parts,and fuel to the injectors , thus el iminat ing oi ltubing and connect ions throughout the block.T h e m o d e l n u m b e r a n d s e r i a l n u m b e r a r estamped on right-hand side of cylinder block onthe upper rear corner.

b. Removal.(1) Remove the engine (para 2-5).(2) Remove the cylinder head (para 3-19).( 3 ) R e m o v e t h e b l o w e r ( p a r a 3 - 5 ) a n d

blower drive (para 3-6).(4) Remove the crankshaft (para 3-32).(5) Remove the camshaft, balance shaft and

bearings (para 3-29).(6) Remove pistons and rods (para 3-26).(7) Remove the idler gear (para 3-30).

c. Disassembly. Refer to figure 3-64 and dis-assemble the cylinder block and end plates.

3-76

d. Cleaning, Inspection, and Repair.(1) Clean cyl inder block. First remove al l

plugs and scrape all old gaskets from the cylin-der block as follows:

(a) Thoroughly clean the cyl inder blockusing live steam. During the cleaning, specialattention should be paid to the oil galleries, airb o x f l o o r , a n d a i r b o x d r a i n o p e n i n g s . J e t smachined in camshaft and balance shaft bush-ing block bores permit oil to be sprayed on thecam followers and should be checked to makesure they are not plugged. Use a 0.020-inch wireto clean the jets.

(b) Dry the cylinder block with compres-sed air.

(2) Pressure test cylinder block.(a) Make sure the seal ring grooves in cy-

linder liner bore of block are clean. Then, installseal rings in the grooves.

(b) Apply a light coating of vegetable-typeshortening or permanent- type ant i freeze solu-tion to the inner diameter surface of seal ring incontact with cylinder liner.

(c) Carefully slide the liner into the cylin-der block bore, and through seal r ings, beingcareful not to roll or damage seal rings. Do notforce. Hold the liners in position with suitablemetal plates bolted to the top of the cylinderblock. Tighten retaining plate bolts sufficientlyto hold liners in place.

(d) Seal off the water inlet and out letholes airtight. This can be done by using plates

TM 10-3930-242-34

1 Gasket 10 Screw 19 Nut2 Ring 11 Washer 20 Guide3 Ring 12 Plate 21 Block4 Ring 13 Gasket 22 Screw5 Ring 14 Capscrew 23 Lockwasher6 Ring 15 Cap 24 Cover7 Ring 16 Clip 25 Gasket8 Ring 17 Tube assembly 26 Plug9 Screw 18 Elbow 27 Dipstick

Figure 3-64. Cylinder block, disassembly and reassembly.

and sui table rubber gaskets held in place bybolts.

(e) Immerse the cylinder block for 20 mi-nutes in a tank of water heated to 180-200 F.

(f) Using a suitable fitting at one of thewater inlet or outlet openings, apply 15 poundsper square inch air pressure to water jacket andobserve water in the tank for bubbles indicatingcracks or leaks.

(g) Following the pressure test, blow outpassages with dry compressed air.

(3) Inspect cyl inder block. Af te r c l ean ingand pressure testing the cylinder block shouldbe inspected as follows:

(a) Check the main bearing bores. Checkbore inside diameter with main bearing capssecured in place with bolts tightened to 120-130

foot-pounds torque. Caps are numbered to cor-respond with their respect ive posi t ions in theblock. The number of the front and rear mainbearing caps is stamped on the face of the oilpan mounting flange of the cylinder block, adja-cent to their permanent location in the engine,as established at the time of manufacture. Thenumber 1 cyl inder and main bear ing cap arealways located at the end opposite the flywheelend of the cylinder block, regardless of enginerotation. The standard bearing bore diameter is3.251-3.353 inches.

(b) Check the cylinder liner counterborekf o r s q u a r e n e s s , p r o p e r d e p t h , a n d d i a m e t e r .C o u n t e r b o r e sin d i ame te r .s m o o t h a n d

should be from 4.825-4.835 inchesC o u n t e r b o r e d s u r f a c e s m u s t b es q u a r e w i t h t h e c y l i n d e r b o r e

3-77

TM 10-3930-242-34

within 0.001 inch total indicator reading. Thel ine r c o u n t e r b o r e d e p t h s h o u l d b e f r o m0.300-0.302 inch and must not vary in depthmore than 0.001 around the ent i re circumfer-ence.

(c) After inspection, if the cylinder blockis not going to be assembled for a temporaryperiod of t ime, sp ray t he mach ined su r f ace swith engine oil. If the cylinder block is not goingto be assembled for an extended period of time,spray or dip the block in a polar-type rust pre-ven t i ve compound . Cas t i ngs t ha t a r e f r ee o fgrease and oil will rust immediately when ex-posed to the atmosphere.

(4) Inspection of end plates.(a) When the end plate is removed, it is

essential that all of the old gasket material beremoved from both surfaces of the end plate andthe end plate then cleaned.

(b) Check the surfaces of the end plate fornicks, dents , scratches, or score marks; also

check the end plate for flatness. Plug type nutsin the end plate should also be checked forc r a c k s a n d d a m a g e d t h r e a d s . I f n i c k s o rscratches on the seal ing surfaces of the endplate are too deep to be cleaned up, or the plugtype nuts are damaged, the end plate or plugnuts should be replaced.

e. Reassembly. Refer to figure 3-64 and reas-semble the cylinder block and end plates.

f . Instal lat ion.(1) Install crankshaf t (para 3-32) .(2) Install the pistons and connecting rods

(para 3-26).(3) Install the camshaft, balance shaft and

bearings (para 3-29).(4) Install the idler gear (para 3-30).(5) Install the cylinder head (para 3-19).(6) Install the blower drive (para 3-6) and

blower (para 3-5).(7) Install the engine (para 2-5).

3-78

TM 10-3930-242-34

REPAIR

CHAPTER 4

OF TRANSMISSION

4-1. General

T h i s c h a p t e r c o n t a i n s i n f o r m a t i o n o n t h emaintenance of transmission assembly. This in-cludes the transmission, torque converter, con-trol valves and main pressure regulator valve.The transmission has three speeds and a trans-fer case and is the fullpower shift type, consist-ing of a torque converter coupled to planetarygearing control led by hydraul ic c lutches. Thegear ing and clutches give forward and reverseoperat ion in every range. The t ransmission isthe four element type, which are the pump, tur-bine, and double free-wheel stator.

4-2. Torque Converter and Transmission As-sembly

a. General . The torque converter and trans-mission assembly is removed as an assembly.T h e t o r q u e c o n v e r t e r e l e m e n t s a r e v a n e d ,aluminum castings. The pump element is drivenby the engine. The turbine element is driven bythe planetary gearing. The stator is a react ionmember which mult ipl ies torque between en-g ine and t r ansmi s s ion gea r ing . O i l i s d r awnfrom the sump through the oil strainer, by thei n p u t d r i v e n p r e s s u r e p u m p a n d s e n t t o t h ehydraulic system through the oi l f i l ter . Fromthe f i l ter oi l is directed to the main-pressurer e g u l a t o r v a l v e , t o t h e f o r w a r d a n d r e v e r s e ,selector valve and to the range selector valve.The main pressure regulator is of the bypass-type with a pressure range of 110-, 135-psi. Thefour e lement converter consis ts mainly of thepump (14, fig. 4-1), the turbine (28), the firststator assembly (27), the second stator assembly(23), rollers (21), and springs (22), and roller race(20). The pump, turbine, and stators are vaned,aluminum castings. The pump is the input ele-ment, driven by the engine. The turbine is theoutput element , dr iving the gears . The statorsare reaction elements and are mounted on rol-lers that free wheel on a race on the stationaryg r o u n d s l e e v e . T h e e l e m e n t s o p e r a t e i n o i lwhich is circulated for cooling. When the enginerotates, oil is thrown by pump blades into theblades of the turbine causing i t to rotate . Oil

returns between the stator blades to the pump.The stator blades direct the oil so that its unex-pended ene rgy a s s i s t s i n t he ro t a t i on o f t hep u m p . W h e n t h e s p e e d o f t h e t u r b i n e a p -proaches the speed of the pump, the stators freewheel on their race on the ground sleeve. Whenturbine speed is s ignif icant ly less than pumpspeed, the stators lock up on the free wheel race.Torque is multiplied only when the stators arelocked up.

b. Remova l . Remove t o rque conve r t e r andtransmission assembly (para 2-6).

c. Disassembly. The t ransmission should becleaned externally and as much oil as possibles h o u l d b e d r a i n e d f r o m t h e a s s e m b l y . T h etransmission and torque converter is disassem-bled in numerical sequence. Refer to figure 4-2,sheets 1 through 13.

(1) Torque converter (fig. 4-1).(a) Posit ion the transmission on i ts rear

surface, blocking it evenly on the floor.(b) Install a bolt into one of the holes in

t h e c o n v e r t e r h o u s i n g f l a n g e . U s e a w r e n c hbraced against the bolt, to prevent the conver-ter f rom rotat ing. Remove the 24 self- locking.nuts (10, fig. 4-2 (1)) which secure the converterpump cover.

(c) R e m o v e t h e c o n v e r t e r p u m p c o v e r ,using jackscrews in the tapped holes provided.

(d) Remove the seal ring which is behindt h e d r i v e t e e t h o f t h e c o v e r .

(e) Lift the turbine (14) from the conver-ter shaft . Remove the bal l bearing only if re-placement is necessary.

CAUTION

There are ten free wheel rollers and tensprings in this assembly which may fallout when the stator assembly is removed.Make sure that all of these parts are re-moved from the torque converter pump.

(f) Remove t he t o rque conve r t e r s t a to rassembly and free wheel roller race (15 thru 20).

(g) Remove the snap ring and spacers (21thru 23).

(h) Flat ten the corners of the three lock

4-1

TM 10-3930-242-34

Figure 4-1. Torque converter, exploded view.

strips (25). Remove the six screws (24). Do notremove the bearing retainers .

(i) Install a steel sleeve over the turbineshaft , and against the front of the converterground s leeve. In s t a l l a pu l l e r on the s t ee ls l e eve , t hen u s ing two s tuds , nu t s and f l a twashers, pull the converter pump assembly (26)from the ground sleeve by tightening the nutsevenly.

NOTE

The steel sleeve must have a minimum length ofone and three-quarter inches, a minimum inside

diameter of one and five-sixteenths inches, and am a x i m u m o u t s i d e d i a m e t e r o f o n e a n d t h r e e -quarter inches. The studs must be 5/16 inch diame-ter and have a minimum thread length of ½ i n c hat one end. Overall length of stud must be of suffi-cient length to allow a nut travel of 1¼ incheswhen nuts are tightened. The threads must be 5/16in.-24.

(j) Disassemble the converter pump as-sembly (26) by removing the bearing retainersand tapping the accessory drive gear (28) andbearing (27) out of the converter pump. Removethe bearing from the accessory drive gears.

4-2

TM 10-3930-242-34

Figure 4-2. Torquedisassembly

converter and transmission assembly,and reassembly (Sheet 1 of 19).

4-3

TM 10-3930-242-34

Figure 4-2. Torque converter and transmission assembly,disassembly and reassembly (sheet 2 of 13).

CAUTION

When removing torque converter hous-ing from the transmission housing, sup-port the reverse range clutch piston (84)in rear of housing from falling out.

(k) Remove the 13 bolts and lockwashersw h i c h s e c u r e t o r q u e c o n v e r t e r h o u s i n g t otransmission housing and remove torque con-verter housing assembly and gasket (fig. 4-3).

(2) Transmission Input Oil Pump.(a) Remove 6 bolts (48 and 49, fig. 4-2) and

washers (50) from the outer perimeter of pumpassembly, noting position of shorter bolt (49).

(b) Remove pump assembly, pump coupl-ing (35) and gasket (33). To disassemble pump:

1. R e m o v e f o u r b o l t s ( 4 5 ) a n d l o c k -washers (44) which retain cover assembly (47).

4-4

2. Remove gears (39 and 40) from bodyassembly (37).

3. D o n o t r e m o v e c o m p o n e n t s f r o mcover assembly (47) unless parts replacement isnecessary. If dowel pin (43) must be removed,grasp each pin in a vise and rotate cover whilepulling it off the dowel pin.

4. I f o i l s e a l ( 4 6 ) m u s t b e r e m o v e d ,punch it out, toward the front of cover assembly.

5. I f u p p e r b e a r i n g ( 4 2 ) m u s t b e r e -moved, it can be pressed out of cover assembly,toward rear of cover. If lower bearing (43) mustbe removed, remove i ts rol lers and col lapseouter shell.

6. Do not remove bear ings (38) f rombody assembly (37) unless replacement is neces-sary. They must be removed by pressing themout of the front of body.

TM 10-3930-242-34

(3) Forward and reverse components ( f ig .4-4).

(a) If not previously removed, remove thealuminum spacer which posi t ions the reverserange planetary carr ier assembly.

(b) Remove 12 forward-reverse clutch pis-ton return springs (97, fig. 4-2), and pins (96).

(c) Remove f ive external tanged reverser a n g e c l u t c h p l a t e s ( 8 8 ) a n d f o u r i n t e r n a lsplined reverse range clutch plates (89).

(d) Remove the reverse range planetarycarrier (1) and remaining intern al splined clutchplate (89).

(e) Remove the forward and reverse sungear (98) and the thrust washer (92) beneath it.

Figure 4-2. Torque converter and transmission assembly,didaddembly and reassembly (sheet 3 of 13).

(f) Remove the forward and reverse an.chor pin (125).

( g ) R e m o v e t h e f o r w a r d a n d r e v e r s eclutch anchor assembly (99).

NOTE

The forward carrier, ring gear, and two remainingforward clutch plates cannot be removed until therange gears and clutches are removed from therear of the transmission housing.

(h) Remove two external tanged and twointernal splined forward clutch plates (88).

(4) Removal of transmission housing.(a) Position the transmission upright, at-

tach a sling to the transmission housing (120,fig. 4-2).

(b) While support ing the housing with a

4-5

TM 10-3930-242-34


hoist, remove the 18 bolts (119) and lockwashers(118) which retain the housing to the transfercase.

NOTELeave four equally spaced bolts while removing theothers, then loosen these four bolts evenly to re-lieve the compression of the clutch return springs.

(c) Carefully separate transmission hous-ing sect ion from transfer housing sect ion toavoid dropping clutch piston return springs (97),and pins (96), and low range clutch plate (89).

(d) While t ransmission housing assemblyis suspended, remove the 12 clutch piston returnspr ings and pins . Remove a l so two ex t e rna ltanged (88) and one internal splined (89), lowrange clutch plate.

(e) Posi t ion t ransmission housing, f rontdownward, on blocks. Leave sufficient room tor e m o v e f o r w a r d p l a n e t a r y c a r r i e r a s s e m b l y

4-6

(103) from transmission housing. This will re-quire a minimum of 4 inches of blocking.

(5) Forward p l a n e t a r y carrier a n dcomponents .

(a) Place a block of soft metal or hardwood on the hub of the forward planetary; usinga heavy drif t and hammer, dr ive the forwardplanetary carrier (103) out of the ball bearing(110).

(b) Lift the transmission housing off theforward planetary carrier. Remove bearing andretainers and inspect for damage.

CAUTIONBecause of the necessary tight fit bet-ween the hub of the forward planetarycarrier and the bore of the ball bearing,the bearing retainers usually bend whenthe carrier is driven from the bearing.Thus, it is important that retainers and

TM 10-3930-242-34

Figure 4-2. Torquedisassembly

converter and transmission assembly,and reassembly (sheet 5 of 13).

bearings be removed and inspected be-fore the transmission is reassembled.

(c) Remove two clutch plates and forwardplanetary ring gear from the carrier assembly.

(d) Remove the snap r ing (104) and re-verse planetary ring gear (101) from the forwardcarrier assembly (103).

(e) R e m o v e t h e f o r w a r d c l u t c h p i s t o n(130) assembly from the transmission housing.

(6) Transfer housing assembly.(a) Remove the low range clutch piston

(164) and hook type seal ring (168) from the frontof the transfer housing.

(b) Remove the front output f lange andbearing retainer (181).

(c) Remove the shifter fork (206) from thetransfer housing. Remove the oil strainer (166).

(d) Posi t ion the t ransfer housing assem-bly, front downward on blocks. Remove the rear

cover (171) with jackscrews in the holes pro-vided.

(e) Remove the output dr ive gear (187) ,Do not remove the ball bearing assemblies fromthe hub of the gear unless replacement is neces-s a r y .

(f) Remove t he bo l t s and washe r s t ha tsecure the transfer idle gear spindle (174). Re-move the transfer idle gear (19), bearing assem-bly, and idler gear spacer (189). Do not removethe bearing assembly from the idler gear unlessreplacement is necessary. The bearing may ber e m o v e d b y r e m o v i n g e i t h e r o f t h e i n t e r n a lsnap rings (188) which retain it and pressing thebear ing out .

(g) Remove t he bo l t s and l ockwashe r swhich secure the rear output shaft bearing re-tainer, and remove the bearing retainer. Do notremove the oil seal unless replacement is neces-s a r y .

4-7

TM 10-3930-242-34


(h) Position the transfer housing upright,and using a sof t dr i f t , dr ive the rear outputshaft (194), bearing (197), and spacer (196) farenough toward the rear to free it from the out-put transfer driven gear (195) and the bearingand spacer.

(i) P o s i t i o n t h e t r a n s f e r h o u s i n g , f r o n tdownward, and remove the transfer driven gear(195) . Remove the bear ing remaining in thetransfer housing,

(j) Remove t he r ema in ing p lugs i n t hehousing as necessary for cleaning or repair. Donot remove the rear output, disconnect shaft oilseal unless replacement is necessary.

d. Cleaning and Inspection.(1) Clean al l parts with solvent such as

P-D-680, or equal. Dry thoroughly.(2) Inspect all parts for nicks, dents, burrs,

scratches, evidence of overheating, or other de-fects . Discard gaskets and replace with new

4-8

TM 10-3930-242-34

Figure 4-2. Torque converter and transmission assemblydisassembly and reassembly (sheet 7 of 13).

ones, When it is necessary to remove oil seals, s n a p r i n g s w h i c h h a v e b e e n d a m a g e d d u r i n greplace seals with new ones. Discard and re- r emova l .place all cotter pins, lock strips, and washers or (3) During all rebuild procedures, parts and

4-9

TM 10-3930-242-34


subas sembl i e s mus t be hand led ca r e fu l l y t oprevent nicking, scratching, or dent ing. Par tswhich fit closely but with operating clearancewill stick if slightly damaged. Parts which de-pend on smooth surfaces for sealing may leak ifscratched.

(4) Inspect all oil passages for obstruction.If an obstruct ion is found, remove with com-pressed air, or by working a wire back and forththrough the passage and f lushing the passageout with cleaning solvent.

e. Lubrication. To insure that the componentswil l be adequately lubricated when the trans-mission is initially put into service after rebuild,a l l c lu t ch p l a t e s , bea r ings , bush ings , gea r s ,seals , shaf ts and other moving par ts must begenerously oiled when installed with the operat-

ing fluid that is recommended for the transmis-sion. Refer to the lubrication order. Lubricateall bronze-faced clutch plates byin transmission fluid for at leastmediately prior to installation.

f . Reassembly. Refer to f iguresemble the t ransmission.

NOTE

soaking them2 minutes im-

4-2 and reas-

Both the first and second stator assemblies are ser-viced in the following manner:

(1) Remove any rollers (21 and 25, fig. 4-1)and springs (22 and 26) not previously removed.

(2) Position the first stator (front) assembly(28), flat side upward, on work bench. Positionthe second stator (rear) assembly (23) flat side

4-10

TM 10-3930-242-34

126 Packing 1 3 3 R i n g 1 3 9 C a r r i e r1 2 7 D r u m 1 3 4 R i n g 1 4 0 W a s h e r1 2 8 S e a l 1 3 5 S h a f t 1 4 1 P i n i o n129 Expander 1 3 6 H u b 1 4 2 R o l l e r130 Pis ton 1 3 7 G e a r 1 4 3 R o l l e r131 Spr ing 1 3 8 P l a t e 1 4 4 G e a r1 3 2 R i n g


downward on work bench. Coat the cam pocketsof each stator with oil soluble grease.

(3) Install eight rollers (21 and 25) into theshallow ends of the cam pockets of each statorassembly.

(4) Install eight springs (22 and 26) into thedeep ends of the cam pockets of each stator as-sembly.

g. lnstal lat ion. Instal l torque converter andtransmission (para 2-6).

h. Pressure Checking.(1) Main pressure check.

(a) The main pressure may be checked bythe gage on the instrument panel.

(b) The main pressure at full throttle stallshould be approximately 110-135 psi.

(2) Converter-out-pressure check.(a) T h e c o n v e r t e r - o u t - p r e s s u r e m a y b e

checked at the point provided for attaching thetemperature gage sending unit at the upper leftside of the converter housing.

(b) M a x i m u m c o n v e r t e r - o u t - p r e s s u r e a tfull throttle top speed is 65 psi, with transmis-

4-11

TM 10-3930-242-34

1 4 5 R i n g1 4 6 H o u s i n g1 4 7 P i s t o n148 Expander1 4 9 S e a l1 5 0 P l a t e1 6 1 G e a r

1 5 2 A n c h o r1 5 3 S p r i n g1 5 4 G e a r1 5 5 G e a r1 5 6 W a s h e r1 5 7 W a s h e r1 5 8 P i n i o n

1 5 9 R o l l e r1 6 0 S p a c e r1 6 1 P i n1 6 2 S e a l1 6 3 E x p a n d e r1 6 4 P i s t o n1 6 5 C a r r i e r


4-12

TM 10-3930-242-34


sion at normal operat ing temperature (180° to200° F.).

(3) Lubrication oil pressure. The lubricationo i l p r e s s u r e s h o u l d b e 2 0 - 2 5 p s i w h e n t h etransmission is in low range, forward, with theoutput s ta l led and the t ransmission at normaloperating temperatures (180° to 200°F.) and theengine running at 1,000 rpm.

i . Linkage Adjustment .

(1) Range selector linkage. The linkage mustbe adjusted so that the operator’s control isposi t ioned to correspond exact ly to the detentpositions of the range selector valve. With thel inkage disconnected, place both the selectorvalve and the operator’s control in neutral posi-tion. Adjust the linkage so that it can be freely

4-13

TM 10-3930-242-34

1 8 6 B e a r i n g 1 9 2 B e a r i n g1 8 7 G e a r 1 9 3 B u s h i n g1 8 8 R i n g 1 9 4 S h a f t1 8 9 S p a c e r 1 9 5 G e a r1 9 0 G e a r 1 9 6 S p a c e r1 9 1 B e a r i n g 1 9 7 B e a r i n g


connected without moving the valve or the con- (3) T r a n s m i s s i o n disconnect controltrol. Then try the control in each range position. l inkage. The t r ansmi s s ion d i s connec t con t ro lMake minor adjustments, if necessary, to insure valve is linked to a manual control valve, ex-tha t t he e l ec to r va lve de t en t s ea t s a t eve ry pressly for inching. This valve is the transmis-range position of the operator’s control. sion disconnect control valve. The transmission

(2) Forward-reverse l inkage. T h e f o r w a r d disconnect control valve is located under theand reverse control linkage must be adjusted so driver’s floor board. For removal and installa-that the neutral , forward, and reverse detent tion, refer to figure 4–5. The linkage must bepositions of the valve correspond exactly with adjusted to insure full application and full re-those of the operator’s control. This adjustment lease. The disconnect control valve has a totalis made in a manner similar to the adjustment linear movement of 3/8 inch from full retract (re-of the range selector linkage ((1) above). leased) to full extension (applied).

4-14

TM 10-3930-242-34


(4) Outpu t d i s connec t l i nkage . There a r etwo points of adjustment for the rear outputd i s connec t on t he t r ansmis s ion . The sh i f t e rshaft must be adjusted first, and then the link-age. Put the shifter shaft in (rearward) until theengaged detent seats . Adjust the shif ter shaftby rotat ing i t unt i l the center of the l inkageconnect ion hole is 0 .610-0.650 inch f rom thefront surface of the t ransfer case. When theshif ter shaf t is pul led outward (rearward) , thedisconnect detent should seat when the centerof the shaft hole is approximately 2-3/8 inchesfrom the transfer case surface. Adjust the link-age so that the engaged and disconnect posi-t ions of the operator’s control correspond ex-actly with the detent positions of the shaft.

4-3. Torque Converter Stall Test

a. General. The torque converter stall testis atest of the engine and t ransmission as a uni t ,wherein the transmission output is stalled whilethe engine is operated at full throttle. This testwil l indicate , by the speed which the enginereaches, whether the engine and transmissionare performing sat isfactory under ful l load. Alower or higher speed than that established asn o r m a l a r e i n d i c a t i o n s o f e i t h e r e n g i n e o rt ransmission malfunct ion.

b. Procedures.(1) The test is made while the engine and

transmission are instal led. The vehicle wheelsmust be blocked securely to prevent movement.

4-15

TM 10-3930-242-34

Figure 4–3. Removal and installation of torque converterhousing.

The brakes should be appl ied except on those(3) Shift the transmission controls to high

installations which include a clutch cutoff valve.range and forward.

(2) Start the engine and al low the t rans-(4) Use a tachometer to show the engine

mission to warm up to normal operating temp-speed attained at full throttle.

erature (180° to 200°F.).

4-16

TM 10-3930-242-34

Figure 4-4. Transmission forward and reverse drive assem-bly, exploded view.

CAUTIONDo not allow the converter-out tempera-ture to exceed 250°F. Do not maintain afull stall condition longer than 30 sec-onds.

(5) Increase the engine speed to full throt-tle. Converter stall speed shown should be 2280to 2310 engine rpm.

(6) The only reading significant to the stalltest is engine speed. The difference between es-t ab l i shed no rma l speed and ac tua l speed r e -corded is significant only if it varies 150 rpm.

4-4. Transmission Main Oil Pressure Regulat-ing Valve

a . Genera l . T h e m a i n p r e s s u r e r e g u l a t i n gvalve is located on lower side of transmissionsecured to the torque converter housing andsupplies pressure to the control valve.

b. Removal . Refer to figure 4-6 and removet r a n s m i s s i o n m a i n o i l p r e s s u r e r e g u l a t i n gvalve.

c. Disassembly. Refer to figure 4-7 and disas-semble transmission main oil pressure regulat-ing valve in numerical sequence.

d. Cleaning and Inspection.(1) Clean al l parts thoroughly, using sol-

vent P-D-680, or equal.(2) Clean oil passages by working a piece of

wire back and forth through passages and flushwith cleaning solvent.

( 3 ) I n s p e c t b o r e s f o r w e a r , g r o o v e s ,scratches, and dirt. Remove scratches and burrswith crocus cloth.

(4) Clean and inspect the gasket area. Re-place a defective part.

e. Reassembly. Refer to figure 4-7 and reas-semble the transmission main oil pressure reg-ulat ing valve.

4-17

TM 10-3930-242-34

NOTE

The main oil pressure regulating valve may be ad-justed by adding or removing shims. Each shim willraise or lower pressure approximately 10 psi.

f. Installation. Refer to figure 4-6 and reins-tal l t ransmission main oi l pressure regulat ingvalve.

4-5. Transmission Control Valve

a. General. The transmission control valve issecured to the side of transmission housing by11 bol ts and lockwashers . The control valvebody assembly houses the forward-reverse con-trol valve assembly, the range selector valveand the clutch cut off valve.

b. Removal.

(1) Remove access panel f rom under r ightrear fender .

(2) Refer to figure 4-8 and remove the con-trol valve.

c. Disassembly. Refer to figure 4–9 and disas-semble control valve in numerical sequence.


vent P-D-680, or equal.

(2) Clean all oil passages.

(3) Inspect cast for nicks, scratches, andgrooves. Remove burrs with crocus cloth. Re-p l a c e p a r t s t h a t a r e d e e p l y g r o o v e d o rsc ra t ched .

(4) Inspect threaded openings for damagedt h r e a d s .

e. Reassemble. Refer to figure 4–9 and reas-semble control valve.

f. Installation. Refer to figure 4-8 and installthe control valve.

Figure 4-5. Transmission disconnect valve, removal and in-stallation.

Figure 4-6. Transmission main oil pressure regulat-ing valve, removal and installation.

4-18

TM 10-3930-242-34

Figure 4-7. Transmission main oil pressure regulat-ing valve, disassembly and reassembly.

Figure 4-8. Transmission control valve, removal and instal-lation.

4-19

TM 11-3930-242-34

Figure 4-9. Transmission control valve, disassembly andreassembly.

4-20

TM 10-3930-242-34

CHAPTER 5

REPAIR OF DRIVE COMPONENTS

Section I. PROPELLER SHAFTS

5-1. GeneralThi s chap t e r con t a in s i n fo rma t ion on t he

maintenance of the propeller shafts . This in-cludes the front propeller shaft, rear propellershaft, and the engine propeller shaft. The frontpropeller shaft drives the front wheels, the rearpropeller shaft drives the rear wheels, and theengine propeller shaft is mounted to the engineand the input shaf t on the t ransmission. Theuniversal joints are disconnected in order toremove the shaf ts .

5-2. Front Propeller Shafta. Removal. Remove the front propeller shaft

(TM 10-3930-242-12).b. Disassemble. Refer to figure 5–1 and disas-

semble the front propel ler shaf t in numericalsequence.

c. Cleaning and Inspection.(1) Clean al l parts thoroughly, using sol-

vent P-D-680, or equal.(2) Inspect a l l par ts for cracks, abrasions,

scoring, and looseness.(3) Replace unserviceable parts with ser-

viceable parts .d . Reassemb ly . Refer to f igure 5-1 and as-

semble the front propeller shaft.e . In s ta l l a t i on . In s t a l l t he f ron t p rope l l e r

shaf t (TM 10-3930-242-12) . Torque universaljoint bearing capscrews to 55-60 ft-lbs.

5-3. Rear Propeller Shafta. Removal . Remove the rear propel ler shaf t

(TM 10-3930-242-12).

b. Disassembly. Refer to figure 5-2 and disas-semble the rear propeller shaft.



(2) Inspect all parts for cracks, breaks, ex-cessive wrar, or any other damage.

(3) Replace any unserviceable par t with aserviceable part .

d. Reassembly. Refer to figure 5-2 and reas-semble the rear propeller shaft.

e . I n s t a l l a t i o n . I n s t a l l t h e r e a r p r o p e l l e rshaf t (TM 10-3930-242-12) . Torque universaljoint bearing capscrews to 55-60 ft-lbs.

5-4. Engine Propeller Shafta . Remova l . R e m o v e t h e e n g i n e p r o p e l l e r

shaft (TM 10-3930-242-12).b. Disassemble. Refer to figure 5-3 and disas-

semble the engine propeller shaft in numericals equence .


vent P-D-680, or equal.(2) Inspect for nicks and burrs.(3) Inspect all parts for cracks, breaks, and

looseness .(4) Replace all unserviceable parts.

d. Reassembly. Refer to figure 5-3 and reas-semble the engine propeller shaft.

e. Instal lat ion. In s t a l l t he eng ine p rope l l e rshaft (TM 10-3930-242-12). Torque the univer-sal joint bearing capscrews to 55 ft-lbs.

Section II. FRONT AND REAR AXLE ASSEMBLIES AND PARKING BRAKE

5-5. General 5-6. Axle Assemblies

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e a. R e m o v a l . Refer to paragraph 2-7 and re-

maintenance of the front and rear axle assemb- move the axle assembly.

lies, differential lockout, and parking brake. The b. Disassembly.

maintenance on the front and rear axle assemb- (1) Refer to figure 5-4 and disassemble the

lies are almost identical. axle assembly in numerical sequence.

5-1

TM 10-3930-242-34

NOTE

Before disassembly of the axle, remove the plug (15)and drain oil from hub assembly (45) and removetheplug (157) and drain the oil from the axle hous-ing (163).

(2) Remove outside trunnion (1 thru 8). Re-move bearing (9) and remove rear trunnion as-sembly.

(3) Remove planetary gears and hub (15thru 56) . Do not disassemble spider assemblyunless necessary.

NOTE

Use wrench, FSN 5120-009-8602 to remove spindlenut (40).

(4) Remove brake hose at fitting (57) andremove the brake assembly (57 thru 61).

(5) Remove spindle assembly (62 thru 66)and remove axle (66) from support (83) and hous-ing (90).

(6) Remove steering support (83) from hous-ing (90) and remove housing from axle housing(163).

(7) Remove opposite axle and steering sup-port in the same manner as described above.

NOTE

Both axles must be removed in order to removecarrier assembly.

(8) Remove carr ier assembly (96) . Breakcarrier loose from axle housing (164) with a raw-hide mallet.

NOTE

Do not disassemble the carrier assembly unless ab-solutely necessary.

(9) Center punch one differential carrier leg(96) and bearing cap (103) to identify for properr ea s sembly .

(10) Disassemble the carr ier assembly (96thru 123).

(11) Punch mark case (123) and gear (122) toidentify for proper reassembly.

(12) Remove differential bearings and piniongear (124 thru 143).

c. Cleaning and Inspection.(1) Clean all parts.(2) Inspect al l bearings, cups, cones and

gears for excessive wear, looseness, ridges, pit-ted, and scoring.

(3) Inspect axle shafts for torsional frac-ture, stress, excessive wear or other impendingfai lures .

(4) Inspect housing for cracks or damage.(5) Replace parts i f worn, pi t ted or dam-

aged. Replace al l gaskets and seals with newp a r t s .

(6) Remove nicks , burrs , and mars f rommachined or ground surfaces with crocus cloth.Insure that threads are clean and free and arenot worn beyond limitations.

d. Reassembly.

NOTE

Refer to the lubrication order for bearings, shaft,gear, differential oil and oil for other intricate mov-ing parts that require lubrication.

(1) Refer to figure 5-4 and reassemble theaxle assembly.

( 2 ) I n s t a l l m o u n t i n g h a r d w a r d ( 1 4 4 t h r u162) on axle housing (163 and 164).

(3) Reassemble the differential pinion andbearings (124 thru 143) as follows:

(a) Lubricate bearings (134, 139, and 142)with specified light oil. Coat bearing cups (135and 139) with a thin film of oil.

(b) Press rear thrust bearing (138) andradial bearing (141) firmly against pinion gearshoulders (140) with a proper sleeve that will fitonly on inner bearing race (141).

(c) Adequately support pinion shaf t in aholding device. Instal l radial bearing lockring(143) and place into pinion shaft groove. Insurethat lockring seats properly into the groove.

(d) Place pinion (140) and bearing assem-bly (134) into pinion cage (136) and posi t ionspacer (137) over the pinion shaf t (140) . Thes p a c e r i s g r o u n d t o p r o p e r l e n g t h t o o b t a i nspecific bearing preload of 13 to 20 inch poundsrolling pinion bearing resistance.

( e ) P r e s s f r o n t b e a r i n g ( 1 3 4 ) f i r m l yagainst spacer (137).

(f) Slowly rotate cage several turns to in-sure normal bear ing contact .

(g) Lubricate pinion shaft oi l seal (132)and cover outer edge of seal body with a non-hardening seal ing compound.

(h) Install flange (127), washer (126), andnut (125). Tighten to 525 foot pounds.

(i) Install pinion and bearing assembly incarrier assembly (96) until outer pinion bearingcup cage (136) is approximately 1/4 inch from faceof carrier. During this operation, insure that oilreturn holes are in line.

(j) I n s t a l l s h i m s b e t w e e n b e a r i n g c u pcage (136) and face of carrier (96).

(k) Drive pinion assembly (14) into posi-tion and install the bearing case bolts. Torque tospecified torque. Refer to paragraph 1-7b(8).

NOTE

There are 6 bolts holding in the retainer (131) andbearing case (136). The locating bolt is ½ inch andthe other 5 bolts are 9/16 inch.

5-2

TM 10-3930-242-34

Figure 5-1. Front propeller shaft, disassembly and reas-sembly.

(4 ) Reas semble d i f f e r en t i a l a s sembly in (a) If backlashes too great, back off ad-carrier (96 thru 123). Insure that punch marks justing nut on plain half case and tighten oppo-on case (123) and gear (122) are properly aligned site side until all lash is removed. Tighten nutand that center punch marks on carrier leg (96) on plain half case solidly to seat bearings. Backand cap (103) are aligned for proper fit. Tighten off nuts on flange side, one notch at a time andto specified torque. follow with opposite nut until correct backlash

(5) Adjust backlash 0.008-0.011 as follows: is obtained.

5-3

TM 10-3930-242-34

Figure 5-2. Rear propeller shaft, disassembly and reassem-bly.

(b) If backlash is under minimum specifi-cation, back off nut on flange half and tightennut on opposite side. Operation should be donein one notch steps until correct backlash is ob-t a ined .

(c) Tighten carrier cap bolts to specifiedtorque (see torque chart). Recheck backlash. Ifbacklash is not within limits, repeat above pro-cedure to correct. Install bearing adjusting nutlocks and secure with screw and lockwasher;lockwire to prevent loosening.

(6) Install carrier housing (96) to axle hous-ing (164).

(7 ) Reas semble ax l e a s sembly i n r eve r seorder of disassembly.

NOTE

Torque all bolts and screws to torque as specified inparagraph 1-7b(8).

e. Instal lat ion. Refer to paragraph 2–7 andinstall the axle assembly.

5-7. Differential Lockout Shift Controla . Genera l . The f ron t d i f f e r en t i a l l ockou t

mechanism is mounted on the forward portionof the axle housing just to the right of the diffe-r e n t i a l a s s e m b l y ( r e f e r e n c e p o i n t f r o m t h eoperator’s seat) . The rear different ia l lockoutmechanism is mounted on the rear of the axlehousing just to the left of the differential as-sembly. Both lockout mechanisms are actuatedhydraulically by depressing the left pedal in theoperator’s compartment . The different ial lock-

5-4

TM 10-3930-242-34

Figure 5-3. Engine propeller shaft, disassembly and reas-sembly.

5 - 5

TM 10-3930-242-34

Figure 5-4. Axle assembly, disassembly and reassembly(sheet 1 of 9).

out actuator mounted on the driver’s compart- (5) Replace any defective parts and replacement bulkhead, is swing-pedal operated and hasthe general appearance of a brake master cylin-der (TM 10–3930-242-12). The differential lock-out actuator is serviced by l i f t ing the rubberboot and filling the cylinder to within ¾“ of topof the cylinder with OE–10. In the event bleed-ing is necessary, bleeding valves are provided ate a c h l o c k o u t m e c h a n i s m . R e f e r t o T M10–3930–242–12 for bleeding procedure.

b. Removal.(1) Disconnect hose at f i t t ing on side of

lockout control and cap line.(2) Remove six bolts and lockwashers and

remove lockout control.(3) Remove gasket from housing flange.

c. Disassembly. Refer to figure 5-5 and disas-semble the differential lockout shift control innumerical sequence.

d. Cleaning and Inspection.(1) Clean differential lockout shift control

thoroughly, using solvent P-D-680, or equal.(2) Inspect(3) Inspect

wea r .(4) Inspect

shaft for pitting and scoring.f o r k f o r b r e a k s o r e x c e s s i v e

housing for cracks or breaks.

gaske t s .e. Reassembly. Refer to figure 5-5 and reas-

semble differential lockout shift control.f . Instal lat ion.

(1) Install new gasket to housing flange.(2) Set differential lockout shift control as-

sembly in place insuring that the fork (11, fig.5-5) is aligned with the hub (13).

(3) Instal l s ix bol ts and lockwashers andtighten to proper torque.

(4) Remove the cap and install the hose onelbow (16).

5-8. Parking Brakea. Removal .

(1) Remove the f ront propel ler shaf t (TM10-3930-242-12).

(2) Flatten the lock strip, remove two boltsand the flange retainer washer and remove theflange and brakedrum as an assembly. Removebrakedrum, i f required, f rom the output dr ivef lange.

(3) Remove the brake return springs (4, fig.5-6) and brakeshoe assemblies (3) from the back-ing plate, then remove the roller from the brakelink and remove the cam lever.

5-6

TM 10-3930-242-34


(4) Remove three screws (8) and remove thebacking plate assembly.

b. Disassembly. Refer to figure 5-6 and disas-semble the parking brake.

c. Cleaning and Inspection.(1) Clean all parts thoroughly, Use solvent

P-D-680, or equal, for cleaning of metal parts.Do not saturate, the brake linings with solvent.

(2) Inspect the parking brakedrum (6, fig.5-6) for warping, cracks, or scores. If scores areevident after removing 0.010 inch, replace drum.

(3) Inspect linings on brakeshoe (3). If lin-ings are worn to within 1/16 inch of rivet head,replace linings.

(4) Replace other unserviceable parts withserviceable parts .

d. Reassembly. Refer to figure 5-6 and reas-semble parking brake assembly.

e. instal lat ion.(1) Install the cam lever on the brake link

and on the backing plate, Install the brakeshoeassemblies and return springs (4, fig. 5-6).

(2) Install the brakedrum if removed, on theoutput drive shaft. Install the lockstrip and tworetainer bolts. Secure the bolts with the lock-str ip .

(3) Instal l the10-3930-242-12).

f r o n t p r o p e l l e r s h a f t ( T M

5-7

TM 10-3930-242-34

Figure 5-4. Axle assembly, disassembly(sheet 3 of 9).

and reassembly.

5-8

TM 10-3930-242-34


5-9

5-10

TM 10-3930-242-34

5-11

TM 10-3930-242-34

Figure 5-4.

TM 10-3930-242-34


5-12

TM 10-3930242-34


5-13

TM 10-3930-242-34


5-14

TM 10-3930-242-34


5-15

TM 10-3930-242-34

Figure 5-5. Differential lockout shift control, disassemblyand reassembly.

5-16

TM 10-3930-242-34

Figure 5-6. Parking brake, removal and disassembly.

5-17

TM 10-3930-242-34

Section III. HYDRAULIC BRAKE SYSTEM

5-9. GeneralThi s s ec t i on con t a in s i n fo rma t ion on t he

ma in t enance o f t he hyd rau l i c b r ake sy s t em.This includes the brake assembly, brake adjus-ter , brake valve, the accumulator , and enginedriven pump.

5-10. Brake Assemblya. General. The brake assembly on the rough

terrain forklift is of the expander tube brake,360° segmented, shoe-type, actuated by an ex-pander tube. Its components include a cast, tor-q u e p l a t e u p o n w h i c h t h e e x p a n d e r t u b e i smounted and an inlet connection into which thenozzle of the expander tube is inser ted. Steelside frames with welded steel torque bars areattached to both sides of the torque plate. Brakelinings mounted on steel shoes are inserted be-tween the torque bars and side frames and heldin position by retracting springs. Steel shieldsare used to bridge the gap between shoes andprotect the expander tube. The spring insertedunder the center of the l inings and over thesteel brakeshoes withdraw the block and shoeassemblies from the surface of the brakedrumafter the actuation pressure has been released.T h i s b r a k e s y s t e m r e c e i v e s i t s o i l s u p p l y(OE/HDO–10), from the forklift’s main hydraulicoil supply tank. Pressure is provided by an en-gine driven pump and application is controlledby an applicator valve. An accumulator is incor-porated in the brake system to provide operat-ing pressure when the engine has stopped.

CAUTION

Check the lining, frequently, for wear. Tocheck wear, apply the brakes and lookinto the spring openings in the brakeframes. If the brakeshoe tends to shearthe spring at a point between the frameand the shoe (approximately 1/8 inch spacebetween top of spring opening and theledge of the shoe upon which springrests), travel is at a maximum. Replacethe linings and springs before this condi-tion is reached. Continued operation inthis condition will damage the brakestructure.

b. Removal.(1) Remove wheel (TM(2) Refer to figure 5-4

move the brake assemblyence.

5-18

10-3930-242-12).(15 thru 60) and re-in numerical sequ-

c. Disassembly. Refer to figure 5–7 and disas-semble the brake assembly as follows:

(1) Hold the brake either vertically or hori-zontally so that both frames (9) are exposed.

(2) Place a screwdriver against the hook ofthe retracting spring (1) and with a sharp blow,disengage the spring from the frame, Drive thesprings through the brake and out of the as-sembly.

(3) Lift the block and shoe assembly (2) fromthe frame.

(4) Remove brake frame bolts (4).(5) Use center punch to mark upper and

lower frames for same location on reassemblyand lift upper half of frame from torque plate(8).

(6) Slide expander tube (5) and inlet connec-tion (6) from the torque plate.

NOTE

If expander tube is stuck to the torque plate, worka thin piece of steel between the torque plate andexpander tube and draw i t around the plate tofree tube.

(7) Remove inlet connection from nozzle ofexpander tube, and remove O-r ings (7) f romnozzle.

d . C lean ing , I n spec t i on , Repa i r , and Re -placement .

(1) Clean the brake assembly. Use a clothdampened in acetone or lacquer thinner. Do notsaturate components .

(2) Inspect expander tube for signs of ex-cessive heat shown by brittleness, or loose fab-ric or rubber around the nozzle base that mightpermit fluid leakage.

(3) Check for loose expander tube shields.Recement all shields as described in (11) below.

for(4) Inspect brake block and shoe assembliesseparation of lining from shoe.

NOTE

The friction on the braking surface of the liningmay develop ridges and grooves. The leading edge,that which is in the direction of rotation, tends towear slightly unevenly. Either of these conditionsis normal.

(5) Inspect the frame assemblies for un-usual wear or distortion of torque bars, cracksat the welds of torque bars, and for cracks orelongation of frame bolt holes. Frames shouldnot have more than 1/16 inch longation of the boltholes.

TM 10-3930-242-34

Figure 5-7. Brake assembly, disassembly and reassembly.

(6) Check for broken or distorted retracting(7 ) I n spec t i n l e t c o n n e c t i o n b l o c k b o r e

springs, comparing quest ionable springs withwhere O-rings seal for scratches and grooves.

new ones.(8) Inspect brakedrums for cracks, checks,

5-19

TM 10-3930-242-34

distortion, and scored surfaces. Scored braked-rums can be repaired by turning on a lathe. Nobrake lining is any better than the drum it con-t ac t s . The max imum a b r aked rum shou ld beturned is 0.060 to 0.080 inch.

(9) If any linings have come loose from theshoes, re-rivet them.

(10 ) I f t he f r ame a s semb ly i s c r acked o rbroken, replace it.

(11) Recement expander tube shields. If anyshields are loose, all shields should be removedand recemented, revers ing the block and shoeassemblies from their original installation. Pro-cure a good neoprene base adhesive compoundand use per instructions.

(a) Clean the shields with lacquer thinneror acetone. Do not use petroleum base solvents.

(b) Place one shoe in the brake assembly.Reverse the shoe to expose a clean section oftube, free from initial cement. Mark the positionof the extended end of the shoe on the tube.Note the position of the mark in relation to thetorque bar of the frame assembly. Mark relativepositions for the remaining shields.

(c) Coat cement on the tube at each of thetwelve marks. Coat a spot 3 in. x 1½ in. with the1½-in dimension being centered over the mark.The 3-inch dimension should be centered bet-ween the frames.

(d) Coat the inside, or concave side, of theshields with cement. Keep cement confined tothe center 3 inches of the shields.

(e) Allow the cement to dry for 5 minutes.(f) Place a shield on the tube so that one

half of the shield protrudes from under the endof the shoe.

(g) Remove the shoe assembly and pressthe shield firmly to the tube.

(h) In s t a l l t he nex t shoe wi th a sh i e ldcentered under the protruding end of the shoe.Press the shield firmly to tube and install re-t ract ing spr ing.

(i) Continue in the same manner with thebalance of the shields, shoes and springs untilall brake shoes and shields are in place.

( 1 2 ) R e p l a c e e x p a n d e r t u b e i f c r a c k e d ,charred-or if the nozzle is loose.

(13) Replace brake lining if worn beyond theminimum thickness i f torque bar forms r idgeson the end face of the linings that may cause theblock and shoe assemblies to hang up, or if ex-cessive cracking or chipping is evident.

(14) Replace the frame assemblies i f dis-torted from any crack or damage.

(15) Replace retract ing spr ings i f they arebroken or distorted, and when new linings are

installed to replace worn out linings. Replace alltwelve springs to insure uniform retraction.

e. Reassembly. Refer to figure 5-7 and reas-semble the brake assembly as follows:

(1) Install two new O-rings (7) on expandertube nozzle (5), lubricating them with vaseline,and install inlet connectio-n (6).

CAUTION

Be sure that the inlet connection openingfaces the vehicle, and that the inlet con-nection drum bolt clearance notch facesthe wheel side of the torque plate.

(2) If the torque plate (8) has been removedfrom axle housing, install with opening at top.Sl ide expander tube (5) with inlet connect ionover the torque plate.

(3) Position lower half of frame (9) over ex-pander tube and torque plate (8) , and securewith bolts (4). Tighten bolts 3/8 in. -38-42, ½ in .-95-100, 5 /8 in . -170-185 ft-lbs. torque; dryth r ead .

NOTE

If necessary to line up frame the bolt holes, startat one end and install five bolts; then install aclamp across the frame to l ine up the last twoholes, and install these bolts.

(4) Position upper half of frame over expan-de r t ube and t o rque p l a t e , mak ing su r e t ha tinlet connection lines up with frame cutout. In-stall bolts. Tighten bolts 3/8 in. -38-42, ½ i n .-95-100, 5/8 in. - 1 7 0 - 1 8 5 f t - l b s . t o r q u e ; d r yt h r e a d .

(5) Place a block and shoe assembly (2), be-tween the torque bars so that projecting end ofshoe is approximately centered on a shield (3).Part ial ly insert retract ing spring (1) to tem-porarily hold the lining assembly in place.

(6) Dovetail a second block and shoe assem-bly into the first block and shoe, and partiallyinsert a second retracting spring. Drive the firstspring fully into position.

(7) Install the remaining block and shoe as-semblies in a similar manner, that is , alwayskeep one shoe assembly ahead of the one inwhich the retracting spring is being completelyin se r t ed .

f . Instal lat ion.(1) Refer to f igure 5-4 and reinstal l the

brake assembly.(2) Replace the wheel (TM 10-3930-242-12).

g. Bleeding. Bleed the hydraulic brake system(TM 10-3930-242-12).

5-20

TM 10-3930-242-34

5-11. Automatic Slack Adjustersa. Removal. Remove the automatic slack ad-

justers (TM 10-3930-242-12).b. Disassembly. Refer to figure 5-8 and disas-

semble the automatic slack adjuster in numeri-cal sequence.

c. Cleaning and Inspection.( 1 ) C l e a n t h e a u t o m a t i c s l a c k a d j u s t e r ,

using solvent P-D-680, or equal. Do not saturatethe diaphragm with solvent .

(2 ) In spec t t he au toma t i c s l ack ad jus t e rhousing for cracks and breaks.

(3) Inspect the diaphragm for damage.(4) Inspect hardware for damage.

d. Reassembly. Refer to figure 5-8 and reas-semble the automatic s lack adjuster .

e. Installation. Install the automatic slack ad-ju s t e r and b l eed t he hyd rau l i c b r ake sy s t em(TM 10-3930-242-12).

5-12. Brake Applicator Valve and Differen-tial Pressure Switch

a. Removal .(1) Remove the driver’s floor plate and ac-

c e s s p a n e l u n d e r t h e l e f t f e n d e r ( T M10-3930-242-12).

(2) Refer to figure 5-9 and remove the diffe-r en t i a l p r e s su re sw i t ch and b rake app l i ca to rvalve.

NOTE

Replace a defective differential pressure switchwith a new switch.

b. Disassembly of Brake Valve. Refer to figure5-10 and disassemble the brake valve assemblyin numerical sequence as follows:

NOTE

Measure the depth that the adjusting plug (32) isbelow the surface of valve body (3). Scribe a mark inline with plug slot. Record this information, as itmust be used in reassembly of valve.

(1) The piston (6) pulls out of the valve body(3).

(2) Shims (7 and 8) will be found inside pis-ton. The shims are used for adjusting the brakeline pressure and must be used in the reassem-b l y o f v a l v e . N e v e r m i x p a r t s f r o m a n o t h e rvalve.

(3) Remove O-ring (10) from valve body.(4) Remove snapring (11) and washer (12).(5) Remove plunger (13) from valve.(6) Remove plug (15) from valve and remove

spring (20) and guide (21).(7) Use a wooden dowel or other soft mater-

ia1 to push out ball valve and seat (22).

(8) Remove plug (24) and remove pilot valvespring (26), ball (27), spool (28) and seat (29).

(9) Remove pilot valve plug (32) and removespring (34), seat (35) and ball (36).

(10) Remove plug (38) and remove spr ing(40), stop (41), and charging valve spool (42).

(11) Loosen locknut (45). Remove screw (46)and remove spring (48), poppet (49), seat (50) andfilter (52).


vent P-D-680, or equal.(2) Inspect the piston (6, fig. 5-10) for nicks

and scratches.(3 ) I n spec t su r f ace o f t he va lve s ea t i n t he

plunger (13) for proper seating and outside signsof wear.

(4) Inspect the seat in the bronze plunger.(5) Inspect valve seat in end of pilot valve

insert (29).(6) Assemble pilot valve spool (28) inside

pilot valve insert (29) and place the steel balls(27) in their respective seats and measure with amicrometer . Record this measurement ,

(7) Remove spool and place the steel balls inthe i r r e spec t ive s ea t s and measu re . Sub t r ac tthe smaller dimension. If difference is less than0.004 inch, replace the spool.

(8) Inspect the nylon pins in the chargingvalve plug and the pilot valve adjusting plug forwear or damage. These pins are used to keep theplugs from working loose.

d. Reassemble.

NOTE

Always use new seals when overhauling the brakevalve.

(1) Install the filter (52, fig. 5-10) into thevalve body (3).

(2) Install the steel washer (51).(3) Install O-ring (25).(3) Install O-ring (25).(4) Install the check valve seat (50), check

valve (49), spring (48), and screw plug (46) onwhich a new 0-ring (47) has been placed into thevalve body (3).

(5) Torque the screw plug (46) to 35-40 ft-lbs.

(6) Instal l the locknut (45) and torque to35-40 ft-lbs.

(7) Install the ball valve and seat (22) in thevalve body with the flange up. Be sure that theseat is properly placed in the valve body. Use awooden dowel to push this assembly into place.

5-21

TM 10-3930-242-34

Figure 5-8. Automatic slack adjuster,reassembly.

disassembly

(8) Place the spring (20) on the ball guide(21) and then the washer (19), seal (18) (with liptoward the steel washer) and the teflon backupring (17).

(9) Place a new O-ring (16) on the plug (14)and place the assembled parts inside the plugand assemble to the body.

(10) Tighten the plug (15) to 35-40 ft-lbs.(11) Place a new O-ring (30) on the pilot valve

seat (29) and install in the valve body (3).(12) Push the pilot valve seat into place with

a wooden dowel.(13) Install the pilot valve spool (28), the long

end of the spool in the “up” position.(14) Place the steel ball (¼ inch diameter) on

its seat in the pilot valve insert.(15) Install a new O-ring (25) on the plug (15).

Place a small amount of grease on the end of thes p r i n g ( 2 6 ) a n d i n s e r t i t i n t o t h e p l u g . T h egrease is to hold the spring in the plug duringassembly.

(16) Tighten the plug (15) to 30-35 ft-lbs.(17) Install the spring (34), ball seat (35), and

steel ball (36) (¼ in. diameter) using grease tohold the ball and seat to the spring.

CAUTION

Be sure that the steel ball is on the seatbefore proceeding further.

and

(18) Instal l the pi lot valve adjust ing plug(32) on which a new O-ring (33) has been instal-led.

(19) Screw the plug (32) down to the dimen-sion, which was recorded at the time of disas-sembly, and line up the slot in the plug with themark on the face of the valve body (3). If newparts have been used to service the valve at thispoint, there is a possibility that the accumulatorcharging limits have changed. This is checkedwhen the brake valve is installed on the vehicle.One full turn of the adjusting plug changes thehigh limit by 200 psi. The high limit is raised byscrewing the plug into the body and lowered byscrewing the plug out of the body.

(20) Install a new quad ring seal (42) on thecharging valve spool (43) and install the spool inthe body. Use extra care in installing this spoolso as not to damage the lands on either the spoolor the body. Be sure that the spool is pushed allthe way into the body so that the end of thespool contracts the plug in the end of the valve.At no time is it necessary to force this spool.

(21) Install the charging valve spring (40).

(22) Install the stop (41) inside the spring.

(23) Install a new O-ring (39) on the chargingvalve plug (38), and insert it into the valve body.Install retainer ring (37).

(24) Install a new “V” block seal (14) on the

5-22

TM 10-3930-242-34

Figure 5-9. Differential pressure switch and brake valve,removal and installation.

plunger (13) with the edge of the seal toward thevalve seat (22). Install the plunger.

(25) Install the washer (12).(26) Install the snap ring (11) and engage it

in the groove about the washer.(27) Install the O-ring (10).(28) Install the shims (7 and 8) and spring (9)

in the piston (6) and push it into the valve body.(29) Make sure the piston is operating freely,

and then slowly release it. Check the clearanceunder the flange of the piston. If new parts havebeen used, it may be necessary to either add orsubtract shims (7 and 8) from inside the piston(6) in order to get the proper clearance at thispoint. Proper clearance is from 0.199-0.211 inch.

(30) Install the boot (5) and ring (4).e. Test Procedure.

(1) Before the brake valve is installed in theforkl i f t , gage tes t i t on work bench to insurethat it is properly assembled. Brake pressure isthe regulated accumulator pressure al lowed topass through the valve to apply the brakes. It is

a t max imum when t he b r ake va lve p i s t on i scomple t e ly dep re s sed . Max imum p re s su re a tthe valve is controlled by shims assembled be-neath the operat ing pis ton. Add shims to in-crease pressure, remove shims to decrease pres-sure. Use a 0-2,000 pounds-per-square-inch (psi)gage to test the valve.

(a) Screw gage into brake port on valve.

(b) Fill pump with hydraulic oil, and at-tach it to accumulator port on valve.

(c) Pump up valve to 1,900 psi,

(d) Remove boot (5) and depress operatingpis ton (6) a l l the way in and read gage. Thecorrect brake line pressure should read 225-275psi.

(2) Accumulator pressure is the pressure ofthe oil in the accumulator used for applying theb r a k e s . T h e m a x i m u m a c c u m u l a t o r o r h i g hl imit pressure is control led by the pi lot valvespring. This is purposefully set below the steer-ing relief valve for safety reasons, otherwise the

5-23

TM 10-393-242-34

Figure 5-10. Brake valve, disassembly and reassemble.

5-24

TM 10-3930-242-34

Figure 5-10. Brake valve, disassembly and reassembly-Continued.

components beyond the brake would not oper-a t e . A f t e r t h e b r a k e s h a v e b e e n a p p l i e d anumber of times, the pressure decreases to a lowlimit, at which time the accumulator recharges.The pressure is the low limit that valve starts torecharge the accumulator. The high limit is theadjustable pressure, and once this is set au-tomatically, brake valve design determines thelow limit or cut in pressure to start the rechargecycle. The high limit is adjusted by turning thepilot valve adjusting plug (32). One full turn ofthe plug changes the limit by 200 psi, ½ turn by100 psi and ¼ by 50 psi. The high limit is raisedby screwing the plug into the body and loweredby screwing the plug out of the body.

(a) Fil l pump with hydraulic oi l and at-tach it to accumulator port on valve.

(b) Pump up valve until a decisive click isheard, caused by shifting of pilot valve, and notegage reading. The reading should be 1,300 psi, ifnot, adjust the pilot valve plug (32).

(c) After adjust ing high l imit pressure,let the pressure leak down until another click isheard when the low pressure reaches between650-550 psi.

(3) While pressure testing valve, check forleakage. Leakage from either the brake port orreturn port should be less than 60 drops perminu te . No l eakage i s pe rmi s s ib l e f rom thepressure port (38). It is not necessary to exceed1,900 psi for testing pressure as system pressureis always less.

f . Instal lat ion.(1) Refer to f igure 5-9 and reinstal l the

brake valve.(2) Instal l the access panel under the lef t

f ende r and i n s t a l l d r i ve r ’ s f l oo r p l a t e (TM10-3930-242-12).

5-13. Hydraulic Brake Accumulator Cylinder

a. General . The accumulator is provided tostore energy for a limited number of brake ap-plications in case the engine stops running. Theaccumulator cyl inder has a f ree r iding pis ton.Nitrogen is introduced through a valve on theend of the cylinder to charge the cylinder. Afterthe cylinder has been charged, oil from the hyd-raulic system enters the cylinder at the oppositee n d , f o r c i n g t h e p i s t o n t o w a r d t h e n i t r o g e n ,c o m p r e s s i n g t h e n i t r o g e n t o a p p r o x i m a t e l y1,300 psi.

b. Removal.

WARNING

Bleed the brake system pressure by re-peated application of the brakes with theengine stopped, until the low pressurewarning buzzer sounds. Continue toapply brakes several times to further re-duce accumulator pressure. Carefullyopen bleed valves at each automatic slackadjuster to bleed off pressure to thewheels. Failure to bleed pressure frombrake system before servicing or per-forming maintenance function may resultin damage to equipment and serious in-jury to personnel. Use only dry nitrogengas when servicing the accumulator.

Refer to figure 5-11 and remove the hydraulicbrake accumulator cyl inder .

c. Disassemble, Refer to figure 5-12 and dis-assemble the hydraulic brake accumulator innumerical sequence.

d. Cleaning and Inspection.(1) Clean the accumulator parts,(2) Inspect hose for deterioration.

5-25

TM 10-3930-242-34

(3) Inspect piston for scores and scratches. the accumulator. Exercise extreme care(4) Inspect strap and body for cracks or any

damage. Replace a defective part.when testing, charging, or otherwise ser-vicing the accumulator.

e. Reassembly. Refer to figure 5–12 and reas-semble the hydraulic brake accumulator. (1) Attach the regulator charging kit.

f. Installation. Refer to figure 5-11 and reins- (2 ) Open t he accumula to r va lve t o r ead

tall the hydraulic brake accumulator cylinder. p r e s s u r e .

g. Charging the Accumulator . Exercise cau- (3) Open the valve on the ni t rogen bot t le

tion when testing or charging accumulator. and set the regulator to charge the accumulator

WARNINGcylinder to 275 psi.

(4) Close the nitrogen bottle valve and de-Use only dry nitrogen gas when charging tach the charging kit.

Figure 5-11. Hydraulic brake accumulator cylinder,removal and installation.

5-26

TM 10-3930-242-34

Figure 5-12. Hydraulic brake accumulator, disassemblyand reassembly.

Section IV. STEERING SYSTEM

5-14. General

The steering system is fully-hydraulic with amechanical follow up. The machine has a two- orfour-wheel steer capability, with either a crab orcramp mode in four-wheel s teer . The turningradius in four-wheel steer, outside to outside, is30 feet. In two-wheel steer, outside to outside,the turning radius is 43 feet. It is recommendedthat four-wheel steer not be used with vehiclespeeds in excess of 10 miles per hour. For convoyoperat ion or extended periods of use in two-wheel s teer mode, i t is recommended that thesafety detent be locked in. to prevent accidentalact ivat ion of four-wheel s teer . The four-wheel

steer capability is controlled by a system of linkslocated under the driver’s compartment. The 3separate modes of s teer ing ( two-wheel s teer ,four-wheel s teer cramp, and four-wheel s teerobl ique) are control led by three-posi t ion hyd-raulic cylinder anchored on the pitman and act-ing upon the intermediate l ink. The valve lo-cated in the l ink anchored on the rear crossshaft bell crank and forward end of the inter-med ia t e l i nk con t ro l s t he ac t i on o f t he r ea rsteer ing cyl inder .5-15. Steering Cylinders

a. Removal . Remove the s t ee r ing cy l inde r s(TM 10-3930-242-12).

5-27

TM 10-3930-242-34

b. Disassembly. Refer to figure 5–13 and dis-assemble the steering cylinders.

NOTE

The Army model 200 and Army model 222 cylin-ders are of identical construction and have identi-cal components. The cylinders used on the Armymodel 202 have slightly different internal compo-nents , but maintenance procedures are s imilar .The steering cylinders for the Army model 202 areillustrated in TM 10-3930-242-34P/2.

c. Cleaning and Inspection.(1) Clean the cyl inder and metal compo-

n e n t s t h o r o u g h l y , u s i n g s o l v e n t P - D - 6 8 0 , o requal .

(2) Inspect rod end bushings for excessivewea r .

(3) Inspect extension rod for smoothnessand insure rod is straight.

(4) Inspect mount ing hardware for cracks ,breaks, damage, and excessive wear. Replace alldefect ive parts .

d. Reassembly. Refer to figure 5–13 and reas-semble the s teering cyl inder . Tighten rod endnut in accordance with specifications in parag-raph 1-7b (8).

e. Test.(1) Packing drag test.

(a) With cylinder horizontal, fill rod endof cylinder with oil.

(b) Open head end part of the piston to thea tmosphe re .

(c) With rod end under no load exceptnormal seal and wiper drag, pressurize the rodend of the cyl inder and record the maximumpressure reached before the piston moves.

(b) Repeat the above for the head end ofthe cylinder.

(e) The piston may be operated as neces-sary for wear in.

(f) Piston rod will extend with maximumof 15 psi on the rod side of the piston.

(2) Piston leakage test.(a) Fill the cylinder with oil. Seal the rod

end and load the head end of the piston to notless than 2,000 psi and hold this pressure for 15minutes. The packing gland should be tightenedjust tight enough that leakage stops.

(b) Measure and record the travel of thepiston during the 15 minutes.

(c) Repeat procedure for rod end of thecyl inder .

(d) Maximum piston rod drift should notexceed one inch per hour.

f . Instal lat ion. In s t a l l t he s t ee r ing cy l inde r(TM 10-3930-242-12).

5-16. Three-Piston Cylindera. Removal .

(1) Tag, disconnect, and cap hydraulic lines.(2) Disconnect the cyl inder ( rod end bal l

joint), from the intermediate link; do not changethe ball joint adjustment (length) on the cylin-der rod unless replacement of the ball joint as-sembly is required.

b. Disassembly. Refer to figure 5-14 and dis-assemble the three-position cylinder.

NOTE

The Army model 200 and Army model 222 cylin-ders are of identical construction and have identi-cal components. The cylinders used on the Armymodel 202 have slightly different internal compo-nents , but maintenance procedures are s imilar .The three-position cylinders for the Army model202 are illustrated in TM 10-3930-242-34P/2.

c. Cleaning and Inspection.( 1 ) C l e a n t h e c y l i n d e r a n d a l l p a r t s

thoroughly, using solvent, P-D-680, or equal.(2) Inspect all parts for wear or damage,(3) Inspect the cyl inder body, pis ton rod,

and pis ton for scored areas and damage. Re-place all defective parts.

d. Reassembly. Refer to figure 5–14 and reas-semble the three-position cylinder.

e. Test.(1) Packing drag test.

(a) With the cylinder horizontal, fill therod end of the cylinder with oil.

(b) Open the head end part of the piston tothe atmosphere.

(c) With rod end under no load exceptnormal seal and wiper drag, pressurize the rodend of the cyl inder and record the maximumpressure reached before the piston moves.

(d) Repeat the above for the head end ofthe cylinder.


(f) Piston rod will extend with maximumof 15 psi on the rod side of the piston.

(2) Piston leakage test.(a) Fill the cylinder with oil. Seal the rod

end and load the head end of the piston to notless than 2,000 psi and hold this pressure for 15minutes. The packing gland should be tightenedjust tight enough that leakage stops.

(b) Measure and record the travel of thepiston during the 15 minutes.

(c) Repeat the procedure for the rod endo f t h e c y l i n d e r .

(d) Maximum piston rod drift should notexceed one inch per hour.

5-28

TM 10-3930-242-34

Figure 5-13. Steering cylinder, disassembly and reassem-bly.

f . Instal lat ion. (3) Remove the caps and connect hydraulic

(1) Mount the three-position cylinder on the l ines.

pitman arm and secure the base end in the pit- 5-17. Rear Steering Pumpman arm clevis with a retaining pin.

(2) Instal l the pis ton rod end by securinga. General Therear steer pump is mounted on

the transfer case and supplies pressure for thethe rod end ball joint to the intermediate arm. rear steering cylinders only.

5-29

TM 10-3930-242-34

Figure 5-14. Three-position cylinder, disassembly and reas-sembly.

b. Removal . Remove the rear s teering pump (2) Remove the ring (1) and seal (2) from the(TM 10-3930-242-12). body (4).

c. Disassembly.

(1) Remove the gasket (3, fig. 5-15).

(3) Remove the screws (16) and lift off thecover (14), plate (21), and spring (20) as an as-sembly.

5-30

TM 10-3930-242-34

Figure 5-15. Rear steering pump, disassembly and reas-sembly.

5-31

TM 10-3930-242-34

(4) Remove the packing (19) from the cover(14).

(5) Lift off the cover (22) from the body (4).(6) Remove the packing (23) from the body

(4).(7) Remove the rotor (9) and vanes (10).(8) Remove the key (25) from the shaft (24).(9) Remove the shaft (24), bearing (7), and

ring (8) from the body (4) as an assembly, thenremove the ring (8) from the shaft.

(10) Press the bearing (7) from the shaft (24).(11) Remove the elbows (15) and (17) and the

plug (18).(12) Remove the plug (11), spring (12), and

valve (13) from the cover (14).d. Cleaning and Inspect ion.

(1) Clean al l parts thoroughly, using sol-vent P-D-680 or similar solvent. Dry all partsthoroughly .

(2) Inspect the body, the cover in contactwith the rotor, and the rotor for scored areas.

(3) Inspect the bearing for smoothness.(4) Inspect the shaft for wear at the point

where the seal contacts.(5) Inspect all parts for excessive wear or

what can be determined as a damaged condi-t ion.

(6) Replace all defective parts.e. Reassembly.

(1) Press the bear ing (7, fig. 5-15) on theshaft (24) and secure with the ring (8).

(2) Install the assembled shaft and bearingin the body (4).

(3) Install a new seal (2) and secure with thering (l). Install the seal with the lip facing in-w a r d .

(4) Install a new packing (23) in the face ofthe body (4).

(5) Install the key (25) in the shaft (24) andinstall the rotor (9) on the shaft.

(6) Position the cover (22) in position on thebody (4) and over the installed rotor.

(7) Insert the vanes (10) into their slots inthe rotor.

(8) Install a new packing (19) in the face ofthe cover (14).

(9) Position the spring (20) in position on thecover (21) and insert the assembled cover (21)and spring (20) into their position in the cover(14).

(10) Hold the assembled cover componentstogether and position the cover onto the cover(22) with it and the assembled components inthe body (4).

(11) Secure the complete assembly togetherwith the screws (16).

(12) Insert the valve (13), spring (12), andplug (11) into the cover (14).

(13) Install the elbows (15) and (17) into thecover and install the plug (18) in the elbow (17).

f. Installation. Install the rear steering pump(TM 10-3930-242-12).

5-18. Steering Mode Selector Valvea. Removal .

(1 ) Acces s i s t h rough t he s t e e r i ng com-partment door beneath the operator compart-men t .

(2) Refer to f igure 5-16 and remove thesteering mode selector valve.

NOTE

Tag all hydraulic lines before removal.

b. Disassembly. Refer to figure 5-17 and dis-assemble the steering mode selector valve.

c. Cleaning and Inspection.(1) Clean all parts thoroughly, using clean

solvent P-D-680, or equal.(2) Inspect the components for scored or

worn areas, burrs, scratches, or other defects.(3) Replace all defective parts.

d. Reassembly. Refer to figure 5–17 and reas-semble the steering mode selective valve.

e. Instal lat ion. Refer to figure 5-16 and in-stall the steering mode selector valve.

5–19. Steering Gear Assemblya. General.

(1) When the cam is turned to the left orr ight by the operator’s effor t in turning thesteering wheel , the s tud of the inner lever ismoved through the groove of the cam (worm),thus rotating the lever shaft and providing an-gu l a r movemen t o f t he s t ee r i ng gea r p i tmana rm. Wheneve r t he ope ra to r ’ s e f fo r t a t t hesteering wheel exceeds the preload of the cen-t e r i n g s p r i n g s a n d “hydrau l i c r eac t i on , ” t hecon t ro l va lve i s a c tua t ed and t he hyd rau l i cpower i s app l i ed t o p rov ide t he d r i ve r w i thpower steering. The action of the steering sys-tem is hydraulic with mechanical follow up. Thepitman arm is splined to the main steering gearlever shaft and provides required feedback tothe ope ra to r g iv ing some “ road f ee l ” and asteering reference point. Mechanical disadvan-tage is such that manual steering is not feasible.The engine must be running to provide hyd-raulic pressure for the steering system. To forcethe s teering system (with the engine not run-ning) may result in damage to the system. Thissteering system incorporates a hydraul ic con-t r o l v a l v e o n a s i n g l e s t u d c a m a n d l e v e rmechanical s teer ing gear .

5-32

TM 10-3930-242-34

Figure 5-16. Steering mode selector valve, removal and in-stallation.

(2) Power steering control valves generallyuti l ize the hydraulic pressure in the steeringsystem to urge the valve spool to i ts neutralposi t ion. This is cal led hydraulic react ion. Asthe pressure in the hydraulic cylinder builds up,the hydraul ic center ing force increases . Thus,the operator’s effort on the s teering wheel inturning a corner is greater than in a s t ra ightahead road correct ion condi t ion. Because thehydraulic pressure is low in the straight aheaddriving conditions, it is necessary to add center-ing springs to assis t the hydraulic react ion ingiving the system road feel. The feel and steer-ing effor t created by the center ing spr ings isconstant for any steering condition and is gen-erally tailored to suit the vehicle application bychanging the spring load to give the degree ofsteering effort desired.

(3) When the valve is in the center position,the oil pressure at its two cylinder ports is lowand equal and produces ineffective forces in thecyl inder . This resul ts in no movement of the

piston and no circulation of oil in the lines to thecyl inder; however , oi l is c i rculat ing from thepump through the control valve to the reservoirwith sufficient pressure only to overcome fric-tion of lines and fittings,

(4) Whenever the operator’s efforts at thesteering wheel overcome the centering effect ofthe springs and/or hydraulic reaction, the valvespool is moved axial ly , res tr ic t ing one of thereturn passages to the outlet port, thus causingan immediate increase in pressure at one of thecylinder ports and in one end of the cylinder. Atthe same time, the other return passage is en-larged, al lowing the oi l f rom the dischargingend of the cyl inder f ree passage to the out le tport and return to the reservoir. The immediateeffect is increased pressure in one end of thecy l inde r t o ac tua t e t he p i s ton wh ich app l i e shydraulic power direct ly to the s teering gearpitman arm or linkage part to which the cylin-der is attached. Full pressure is obtained with aspool travel of about sixty-five one-thousandthsof an inch. The slightest movement results in apressure different ia l .

b. Removal.(1) Remove the horn button steering wheel

b y g r i p p i n g w i t h a d o w n w a r d p r e s s u r e a n dturning counterclockwise.

(2) Use a sui table pul ler and remove thesteering wheel (TM 10-3930-242-12).

(3) Use a sui table pul ler and remove thesteering wheel arm from the pitman arm.

(4) Tag and disconnect hydraul ic l ines asnecessary. Place dust caps over openings to pre-vent foreign matter from entering the hydraulicsys t em.

( 5 ) R e m o v e c o l u m n f r o m u p p e r s u p p o r tb racke t .

(6) Remove mounting flange bolts and re-move gear from chassis.

c. Disassembly. Refer to figure 5-18 and dis-assemble the steering gear assembly.

d. Cleaning and In spec t i on .(1) Clean all parts thoroughly, using clean

solvent P-D-680, or equal.(2) Inspect the components for wear, burrs,

scored areas and other damage.(3) Replace all defective parts,

e. Reassemble. Refer to figure 5-18 and reas-semble the steering gear assembly.

f. Installation. Install the steering gear as-sembly in the reverse order of removal.

g. Thrust Bearing Ajustment Procedure.(1) Remove capscrews (39, fig. 5-18) holding

upper cover (37) and remove cover and jackettube assembly (40).

5-33

TM 10-3930-242-34

Figure 5-17. Steering mode selector valve, disassembly andreassembly.

Figure 5-18. Steering gear assembly, disassembly and reas-sembly (sheet 1 of 2).

5-34

TM 10-3930-242-34

Figure 5-18. Steering gear assembly, disassembly and reassembly (sheet 1 of 2)-Continued.

5 - 3 5

TM 10-3930-242-34

(2) Reassemble screws in actuation housing(25) using 3/8-inch thick spacers under the headof the screws. This is to hold the actuator (31)and cam assembly (44) in the gear when makingthe ad jus tmen t .

(3) Stra ighten prong of lockwasher (34) .Remove nut (35) , tongued washer (33) , upperthrust washer (26) and bearing (27).

(4) Insure that the threads of the nut andcam shaft are free of interference by runningthe nut onto the cam shaf t by using only thef ingers to turn the nut . I f the nut cannot betightened in this manner, use of a thread file or

other means wil l be necessary to correct thisfault until the nut goes on freely.

(5) Reassemble thrust washers , bear ings,tongued washers (with internal lug) , prongedwasher (with 13 external prongs), and nut.

(6) Tighten nut to 10 ft-lbs torque then backoff nut 10–20 degrees which can be done by mov-ing the nut approximately the width of one andone-half lugs. Bend the lug, nearest alinement,with a notch in the nut into a notch root on then u t .

(7) Reassemble upper cover and jacket tubeassembly and at taching parts .

Figure 5-18. Steering gear assembly, disassembly and reas-sembly (sheet 2 of 2).

5-36

TM 10-3930-242-34

Figure 5-19. Steering system adjustment.

5-20. Hydraulic Power Steering Valve (RearSteer)

a. Removal. Tag and disconnect the hydraulichoses from the power steering valve (fig. 5-19).Measure and record length of the valve link be-fore removal of the valve assembly, Approxi-mate length of the link with valve assembly is21-7/8 inches between pivot centers or measurefrom center to center of the grease f i t t ings,M e a s u r e m e n t m a y v a r y a f r a c t i o n , p l u s o rminus, from one machine to another. Refer tofigure 5-20 and remove the hydraulic steeringvalve.

b. Disassembly. Refer to figure 5-20 and dis-assemble the hydraulic power steering valve.

c. Cleaning and Inspection,( 1 ) C l e a n t h e h y d r a u l i c p o w e r s t e e r i n g

v a l v e a s s e m b l y c o m p o n e n t s using solvent

P-D-680, or equal.(2) Inspect the end cap and housing for

cracks or damage.(3) Inspect i n t e r n a l p a r t s f o r n i c k s ,

scratches, burrs, or damage. Replace a defectivep a r t .

d. Refer to f igure 5-20 and reassemble thehydraulic power steering valve.

5-37

TM 10-3930-242-34

Figure 5-20. Hydraulic power steering valve, removal, dis-assembly, reassembly and installation.

e. Installation. Reinstall the hydraulic powersteer ing valve (f ig . 5-20) . Remove caps f romhydrau l i c l i ne and r e in s t a l l t he l i ne s t o t hevalve.

NOTE

No pressure setting at the valve is required. Checkpressure at the pump. Correct pressure is 2,000 ±25psi.

5-21. Steering System AdjustmentT h i s a d j u s t m e n t p r o c e d u r e w i l l p r o v i d e

proper functioning of the steering system. Be-cause part dimensions and installation locations

may vary from vehicle to vehicle, the dimen-sional settings listed in paragraph 1-7b shouldbe regarded as being of nominal values and astarting point for the following procedure:

a. Lift vehicle so that rear wheels are offground. Although not mandatory, it is recom-mended that the front wheels be raised off theground also.

b. Turn s t e e r i ng whee l t o pos i t i on whe rescribe mark on steering sector shaft is 6° clock-wise from the horizontal. This establishes thestraight ahead position (fig. 5-19).

5-38

TM 10-3930-242-34

c. Check to see that the scr ibe mark on thepi tman arm l ines up with scr ibe mark on thesteering sector shaft . Disassemble and reposi-tion if required.

d. Place vehicle in 2-wheel steering mode.e. Disconnect valve link arm at end opposite

from valve.f. P a s s s n u g - f i t t i n g , r o u n d r o d o r t u b e

through al igning hole in intermediate s teeringarm, and, if necessary, adjust the 3-position cy-l i nde r un t i l t he a l i gn ing ho l e i n t he i n t e r -med ia t e s t ee r ing a rm l i ne s up wi th a l i gn inghole in pitman arm.

g. Disconnect f ront and rear drag l inks. Ad-just front and rear wheels to aim straight aheadand to have zero toe-in. Toe-in is adjusted bychanging tie rod setting. Wheel position is ad-justed by using long pry bar wedged betweenaxle hub and wheel rim. Considerable force isr equ i r ed a s hyd rau l i c f l u id mus t be fo r cedthrough the power-s teer ing system. Alignmenti s v e r i f i e d b y p a s s i n g a s t r i n g c o m p l e t e l yaround the outs ide of the vehicle at the axlecenterline. Proper alignment exists when stringtouches each tire sidewall in two places.

h. R e m o v e t h e a l i g n m e n t r o d f r o m i n t e r -mediate s teer ing arm and reconnect the valvelink arm. Adjust the valve link arm by turningthe threaded section until ball stud at valve endof arm is directly opposite lower pivot center inintermediate steer arm and also opposite end ofr e a r c r o s s s h a f t t u b e .

i. Adjust f ront and rear drag l inks to dropinto axle steering arms. The rear drag link con-tains a spring which must not be extended orcompressed dur ing reconnect ion.

j. Start engine, and wi thou t mov ing s t ee r ingwheel , operate the steering mode selector intothe crab and cramp or 4-wheel s teer ing posi-t i ons . Wi th t he f ron t whee l s a imed s t r a igh tahead, there should be no movement of the rearwheels as the steering mode selector is shiftedthrough the var ious modes. I f movement doesoccur, the links in the system have been dam-aged. The steering system can be adjusted tocompensa t e fo r pa r t s wh ich have su s t a inedminor deformations. Satisfactory operation canbe accomplished by adjusting the valve link armand the rear drag l ink to el iminate the move-men t o f t he r ea r whee l s . On ly i f ab so lu t e lynecessary should the position of the pitman arm

be changed to accomplish this adjustment. Turnsteering wheel slightly to obtain correct posi-tion of pitman arm, As a final check, after suchan adjustment , ver ify that a l l four wheels areaimed straight ahead using the s tr ing methoddesc r ibed above . Read jus t d r ag l i nks i f r e -quired.

k. Operate the s teering through ful l lef t andright positions and in all three steering modesto check for proper functioning and no binding.

l. Carefully check the arm on the inboard endof the front cross shaft for looseness. Any loose-ness in this arm that allows relative motion be-tween it and the cross shaft must be eliminated,as it will cause eventual loss of control.

5-22. Rear Drag linka. Removal . Remove the rear drag l ink (TM

10-3930-242-12).b. Disassembly. Refer to figure 5-21 and dis-

assemble the rear drag link.c. Cleaning and Inspection.

( 1 ) C l ean t he r ea r d r ag l i nk componen t sthoroughly, using solvent P-D-680, or equal.

(2) Inspect the drag link for worn bearing,worn s tud, broken spr ing, damage, or cracks .Replace all defective parts.

d. Reassemble. Refer to figure 5–21 and reas-semble the rear drag link as follows:

(1) Apply a light coat of grease on the non-chromed portion of the shaft (30).

(2) Coat the sleeves (25), and spring (26)with grease and install the shaft (30).

(3) Install spacer (25) and nut (23) on theshaft , then t ighten the nut unti l one thread isexposed on the back side of the nut.

(4) Assemble nut (27) , adapter (28) , andwiper (29). Install on shaft (30).

(5) Install shaft assembly into tube (22) andtighten the adapter unti l there is no free playbetween shaft assembly and the tube, Excessivet ightening of the adapter can also cause freep l ay .

(6) After the assembly has been adjusted,tighten locknut (27) against the tube (22).

NOTERefer to paragraph 1-7b for s teering adjustmentspecifications.

e. Installation. Install the rear drag link (TM10-3930-242-12).

5-39

TM 10-3930-242-34

Figure 5-21. Rear drag link, disassembly and reassembly.

5-40

TM 10-3930-242-34

CHAPTER 6

REPAIR OF MAIN HYDRAULIC SYSTEM

Section I. HYDRAULIC CYLINDERS, HYDRAULIC VALVES, HYDRAULICRESERVOIR AND HYDRAULIC MANIFOLD

6-1. GeneralT h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e

maintenance of the hydraul ic cyl inders , hyd-raulic valves, hydraulic reservoir, and hydraulicmanifold that are the responsibi l i ty of directand general support maintenance personnel .

WARNINGRelieve oil pressure by operating con-trols with engine OFF before openinglines or connections.

N O T E

Tag all hydraulic lines before removal of the lines.After removal, cap or plug all openings to preventthe entrance of dirt.

6-2. Three-Spool Valvea. Removal . Remove t he t h r ee - spoo l va lve

(TM 10-3930-242-12).

b. Disassembly. Refer to figure 6-1 and disas-semble the three-spool valve.

c. Cleaning and Inspection.(1) Clean all parts of the three-spool valve

carefully, using solvent P-D-680, or equal.(2) Inspect the pilot plunger (18, fig. 6-1)

and the pi lot seat (19) for nicks, burrs , andscratches.

(3) Inspect the spool (27) for scratches andother damage.

(4) Inspect a l l o ther par ts for dis tor t ion,scratches , burrs and other damage.

(5) Replace all defective parts.

d. Reassembly. Refer to figure 6-1 and reas-semble the three-spool valve.

e. Instal lat ion. Instal l the three-spool valveTM 10-3930-242-12).

NOTE

Check the pressure at the hydraulic pump. Thecorrect pressure is 2000-2100 psi. Adjust the pres-sure set t ing at the valve to obtain the correctreading at the hydraulic pump, as necessary.

6-3. Dual Overcenter Relief and Replenish-ing Valve

a. Removal .(1) Remove the console panel located at the

right side of the driver’s seat.(2) Tag and disconnect tubing and hoses

and cap.(3) Refer to figure 6-2 and remove the dual

overcenter relief and replenishing valve.

b. Disassembly. Refer to figure 6-3 and disas-semble the relief and replenishing valve.


vent P-D-680, or equal.(2) Inspect a l l par ts for cracks, breakage,

and burrs .(3) Inspect all threads for damage.(4) Replace defective parts.

d. Refer to figure 6-3 and reassemble the dualovercenter relief and replenishing valve.

e. Instal lat ion.(1) Refer to figure 6-2 and install the dual

overcenter relief and replenishing valve.(2) Remove any caps and connect the previ-

ously tagged hoses and tubing.(3) Install the console panel located at the

right side of the driver’s seat.

NOTE

The dual relief valve is preset at 2100 to 2400 psi.The overcenter relief valve is preset at 3000 psi.

6-4. Two-Spool Valve

a. Removal. Remove the two-spool valve (TM10-3930-242-12).

b. Disassembly. Refer to figure 6-4 and disas-semble the two-spool valve.

c. Cleaning and Inspection.(1) Clean al l par ts of the two-spool valve

carefully, using solvent P-D-680, or equal.(2) Inspect the plunger (6, fig. 6-4) and the

pilot seat (7) for nicks, burrs, and scratches.

6-1

TM 10-3930-242-4

Figure 6-1. Three-spool valve, disassembly and reassembly.

6-2

TM 10-3930-242-34

Figure 6-2. Dual overcenter relief and replenishing valveand three-spool valve, removal and installation.

(3) Inspect the spool (32) for scratches andother damage.

(4) Inspect a l l o ther par ts for dis tor t ion,scratches, burrs and other damage.

(5) Replace all defective parts.d. Reassembly. Refer to figure 6-4 and reas-

semble the two-spool valve.e. Instal lat ion. In s t a l l t he two- spoo l va lve

TM 10-3930-242-12).

NOTE

Check the pressure at the hydraulic pump. Thecorrect pressure is 2000–2100 psi. Adjust the pres-sure set t ing at the valve to obtain the correctreading at the hydraulic pump, as necessary.

6-5. Hydraulic Tilt Cylindera. Removal. Remove the hydraulic tilt cylin-

der (TM 10-3930-242-12).

b. Disassembly. Refer to figure 6-5 and disas-semble the hydraulic tilt cylinder.

NOTE

The Army model 200 and Army model 222 cylin-ders are of identical construction and have identi-cal components. The cylinder used on the Armymodel 202 has slightly different internal compo-nents , but maintenance procedures and similar .The tilt cylinder for the Army model 202 is illus-trated in TM 10-3930-242-34P/2.

6-3

TM 10-3930-242-34

Figure 6-3. Dual overcenter relief and replenishing valve,disassembly and reassembly.

6-4

TM 10-3930-242-34

Figure 6-4. Two-spool valve, disassembly and reassembly.

6 - 5

TM 10-3930-242-34

Figure 6–5. Hydraulic tilt cylinder, disassembly andreassembly.

c. Cleaning and Inspection. (2) Inspect the parts for wear, scored areas

(1) Clean al l metal parts thoroughly, with scratches, nicks, and burrs.

s o l v e n t P - D - 6 8 0 , o r equal . D r y p a r t s

thoroughly .(3) Inspect the cylinder body for cracks.

6-6

TM 10-3930-242-34

( 4 ) R e p l a c e d e f e c t i v e p a r t s . d. Reassembly. Refer to figure 6-5 and reas-

semble the hydraulic tilt cylinder,

NOTE

Upon reassembly, use new packing. Torque the rodend nut to 900-1000 ft-lbs torque, as specified inparagraph 1-7b(8).

e. Test.(1) Packing Drag Test.

(a) With the cylinder horizontal, fill ther o d e n d o f t h e c y l i n d e r w i t h o i l .

(b) Open head end part of the piston to thea tmosphe re .

(c) With the rod end under no load exceptnormal seal and wiper drag, pressurize the rodend of the cyl inder and record the maximumpressure reached before piston moves.

(d) Repeat the above for head end of thecyl inder .


(f) Piston rod will extend with maximumof 15 psi on the piston. Piston rod will retractwith maximum of 25 psi on the rod side of thepis ton.

(2) Piston Leakage Test.(a) Fill cylinder with oil Seal the rod end

and load the head end of the piston to not lessthan 2000 psi and hold this pressure for 15 mi-nutes . The packing gland should be t ightenedjust tight enough that leakage stops,

(b) Measure and record the travel of thepiston during the 15 minu te s .

(c) Repeat the procedure for the rod endof the cylinder.

(d) Maximum pis ton rod dr i f t must notexceed one inch per hour.

f. Installation. Install the hydraulic tilt cy-linder (TM 10-3930-242-12).

6-6. Hydraulic Lift Cylindera. Removal and Intsallation. Remove and in-

s t a l l t h e h y d r a u l i c l i f t c y l i n d e r (TM10-3930-242-12).

b. Disassembly. Refer to figure 6-6 and disas-semble the hydraulic lift cylinder.

NOTE

The Army model 200 and Army model 222 cylinderare of identical construct ion and have identicalcomponents. The cylinder used on the Army model202 has slightly different internal components, butmaintenance procedures are similar. The hydrauliclift cylinder for the Army model 202 is illustrated inTM 10-3930-242-34P/2.

c. Cleaning and Inspection.(1) Clean all metal parts thoroughly, using

s o l v e n t P - D - 6 8 0 , o r e q u a l . D r y p a r t sthoroughly ,

(2) Inspect the parts for wear, scored areas,scratches, nicks, and burrs.

(3) Inspect the body of the cyl inder forcracks and for distortion.

(4) Replace defective parts.d. Reassemble. Refer to figure 6-6 and reas-

semble the hydraulic lift cylinder.

NOTE

Upon reassembly, use new packing, Torque the rodend nut to the valve specified in paragraph 1-7b(8).

e. Test. Refer to paragraph 6-5e and test thehydraulic lift cylinder in a similar manner.

f. Installation. Install the hydraulic lift cylin-der (TM 10-3930-242-12).

NOTE

The hydraulic lift circuit has a holding and over-center rel ief valve located inside the r ight handframe. This valve does not require any mainte-nance, service or adjustment. It is pre-set at 3000psi.

6-7. Hydraulic Oscillating Cylindera. Removal and Installation. Remove and in-

s t a l l t he hyd rau l i c o sc i l l a t i ng cy l inde r (TM10-3930-242-12).

b. Disassembly. Refer to figure 6-7 and disas-semble the hydraulic oscillating cylinder.

NOTE

The Army model 200 and Army model 222 cylindersare of identical construct ion and have identicalcomponents. The cylinder used on the Army model202 has slightly different internal components, butmaintenance procedures are similar. The hydraulicoscillating cylinder for the Army model 202 is illus-trated in TM 10-3930-242-34P/2.

c. Cleaning and Inspection.(1) Clean al l metal parts thoroughly, using

s o l v e n t P - D - 6 8 0 , o r e q u a l . D r y p a r t st h o r o u g h l y .

(2) Inspect the parts for wear, scored areas,scratches, nicks and burrs.

( 3 ) I n s p e c t t h e b o d y o f t h e c y l i n d e r f o rcracks and distortion.

(4) Replace defective parts.d. Reassembly. Refer to figure 6-7 and reas-

semble the oscillating cylinder.

N O T E

Upon reassembly, use new packing. Torque the rodend nut to the value specified in paragraph 1-7b(8).

e. Test. Refer to paragraph 6-5e and test thehydraulic oscillating cylinder in a similar man-n e r .

f . instal lat ion. Instal l the hydraulic oscil lat-ing cylinder (TM 10-3930-242-12).

6-7

TM 10-3930-242-34

Figure 6-6. Hydraulic lift cylinder, disassembly and reas-sembly.

6 - 8

TM 10-3930-242-34

Figure 6-7. Hydraulic oscillating cylinder, disassembly andreassembly.

6-9

TM 10-3930-242-34

6-8. Oscillating Cylinder Check Valvea. General. The purpose of the oscillating cy-

linder check valve is to hold the machine stableduring any type of operation. Should the checkvalve malfunction the machine will lean to theside when operating on a slope. The oscillatingcylinder check valve is located on the front ofthe forklift between the two automatic slack ad-j u s t e r s .

b. Removal.(1) Raise the extension boom assembly and

install safety supports.(2) Refer to figure 6-8 and remove the oscil-

lating cylinder check valve.

c. Cleaning and Inspection.(1 ) C lean the o sc i l l a t i ng cy l inde r check

valve thoroughly, using solvent P-D-680, orequal .

(2) Inspect the valve for leakage, cracks anddamage .

(3 ) Rep lace a damaged o r l e ak ing checkvalve. A slight leak will cause the valve to mal-funct ion.

d. Instal lat ion.(1) Refer to figure 6-8 and install the oscil-

lating cylinder check valve.(2) Remove safety supports and lower the

extension boom assembly.

6-9. Hydraulic Slave Cylindera. Removal and Installation. Remove and in-

Figure 6-8. oscillating cylinder check valve, removal andinstallation.

s ta l l t h e h y d r a u l i c slave c y l i n d e r ( T M10-3930-242-12).

b. Disassembly. Refer to figure 6–9 and re-move the hydraulic slave cylinder.

NOTE

The Army model 200 and Army model 222 cylindersare of identical construct ion and have identicalcomponents. The cylinder used on the Army model202 has slightly different internal components, butmaintenance procedures are similar. The hydraulicslave cylinder for the Army model 202 is illustratedin TM 10-3930-242-34P/2.


s o l v e n t P - D - 6 8 0 , o r equal . D r y p a r t sthoroughly .

(2) Inspect the parts for wear, scored areas,scratches, nicks, and burrs.

(3) Inspect the cylinder for cracks and dis-tor t ion.

(4) Replace defective parts.d. Reassembly. Refer to figure 6-9 and reas-

semble the hydraulic slave cylinder.

NOTE

Upon reassembly, use new packing. Torque therod end nut to the value specified in paragraph1-7b (8),

e. Test. Refer to paragraph 6-5e and test thehydraulic slave cylinder in a similar manner.

f. Installation. Install the hydraulic slave cy-linder (TM 10-3930-242-12).

6-10. Hydraulic Side Shift Cylinder

a. Removal. Remove the hydraulic side shiftcylinder (TM 10-3930-242-12).

b. Disassembly. Refer to figure 6–10 and dis-assemble the hydraulic side shift cylinder.

NOTE

The Army model 200 and Army model 222 cylin-ders are of identical construction and have identi-cal components. The cylinder used on the Armymodel 202 has slightly different internal compo-nents , but maintenance procedures are s im i la r .The hydraulic s ide shif t cyl inder for the Armymodel 202 is illustrated in TM 10-3930-242-34P/2.


s o l v e n t P - D - 6 8 0 , o r e q u a l . D r y a l l p a r t sthoroughly .

(2) Inspect the parts for wear, scored areas,scratches, nicks and burrs.


(4) Replace defective parts.

d. Reassembly. Refer to figure 6-10 and reas-semble the hydraulic side shift cylinder.

6-10

TM 10-3930-242-34

Figure 6-9. Hydraulic slave cylinder, disassembly andreassembly.

6-11

TM 10-3930-242-34

Figure 6-10. Hydraulic side shift cylinder, disassembly andreassembly.

6-12

TM 10-3930-242-34

NOTE

Upon reassembly, use new packing. Torque therod end nut to the value specif ied in paragraph1-7b (8).

e. Test. Refer to paragraph 6-5e and test thehydraulic side shift cylinder.

f. Installation. Install the hydraulic side shiftcylinder (TM 10-3930-242-12).

6-11. Hydraulic Extension Cylinder

a. Removal. Remove the hydraulic extensioncylinder (TM 10-3930-242-12).

b. Disassembly. Refer to figure 6-11 and dis-assemble the hydraulic extension cylinder.

NOTE

The Army model 200 and Army model 222 are ofidentical construction and have identical compo-nents. The cylinder used on the Army model 202h a s s l i g h t l y d i f f e r e n t c o m p o n e n t s b u t m a i n t e -nance procedures are s imilar . The hydraulic ex-tension cylinder for the Army model 202 is illus-trated in TM 10-3930-242-34P/2.


s o l v e n t P - D - 6 8 0 , o r e q u a l . D r y a l l p a r t st h o r o u g h l y .

(2) Inspect the parts for wear, scored areas,scratches. nicks. and burrs.


(4) Replace all defective parts.d. Reassembly. Refer to figure 6-11 and reas-

semble the hydraulic extension cylinder.

NOTE

Upon reassembly, use new packing. Torque therod end mut to the value specified in paragraph1-7b (8).

e. Test. Refer to paragraph 6-5e and test thehydraulic extension cylinder.

f . Instal lat ion. In s t a l l t he hyd rau l i c ex t en -sion cylinder (TM 10-3930-242-12).

6-12. Hydraulic Oil Reservoira. R e m o v a l .

CAUTION

When removing any hydraulic hoses orlines, cap all openings to prevent foreignmaterial from entering the system andpossibly causing serious damage.(1) Remove the drain plug (fig. 6-12) from

the bot tom of the hydraul ic oi l reservoir anddrain the reservoir .

CAUTION

After draining the oil from the reservoir,do not start the engine for any reason,

because by so doing, permanent damageto the hydraulic pumps will result.(2) Disconnect the hose located at the left

side of the driver’s seat.( 3 ) D i s c o n n e c t t h e m a i n o u t l e t h o s e a t

shutoff valve located at the r ight s ide of thedriver’s seat (Army models 200 and 202 only).

(4) Remove the hydraulic oil reservoir (fig.6-12).

b. Disassemble.(1) Disassemble the hydraulic oi l reservoir

(fig. 6-13).

NOTE

As the result of an engineering change, the hyd-raulic reservoir on late model rough terrain fork-l if t t rucks is equipped with f i l ter contaminationindicators mounted on top of the reservoir and inplace of the former filter cover plate (16, fig. 6-13).The purpose of the contamination indicator is tosignal when the main hydraulic oi l f i l ter is in“by-pass” and is no longer serviceable. On modelsso equipped, see step (2) below.

(2) On a model that is equipped with a con-taminat ion indicator , remove and disassemblethe indicator (fig. 6-14).

c. Cleaning and Inspection.(1) Clean t h e h y d r a u l i c r e se rvo i r

thoroughly, us ing solvent P-D-680, or equal .Dry all parts thoroughly.

(2) Inspect the reservoir for cracks, breaks,distortion, broken welds and other damage.

(3) Inspect the small parts and mountinghardware for wear and damage.

(4 ) Rep lace a l l de fec t ive pa r t s . Use newpacking upon reassembly of the hydraul ic re-servoir .

d. Reassembly.(1) If the unit is equipped with a contami-

nation indicator, reassemble and install the in-dicator (fig. 6-14).

(2) Reassemble the hydraulic oi l reservoir(fig. 6-13).

e. Instal lat ion.(1) Position the hydraulic oil reservoir in

position and secure it (fig. 6-12).(2 ) Connec t t he ma in ou t l e t hose a t t he

shutoff valve located at the right of the driver’sseat (Army models 200 and 202 only).

(3) Disconnect the hose, located at the leftside of the driver’s seat.

(4) Instal l the plug in the bot tom of thehyd rau l i c o i l r e se rvo i r and f i l l t he r e se rvo i rwith the proper oi l . Refer to the lubricat ionorder .

6-13

TM 10-3930-242-34

Figure 6–11. Hydraulic extension cylinder, disassemblyand reassembly.

Figure 6-12. Hydraulic reservoir, removal and installation.6-14

TM 10-3930-242-34

Figure 6-13. Hydraulic reservoir, disassembly and reas-sembly.

6 - 1 5

TM 10-3930-242-34

Figure 6-14. Contamination indicator, removal, disassem.bly, reassembly and installation.

6-16

TM 10-3930-242-34

Figure 6-15. Hydraulic manifold, removal, disassembly,reassembly, and installation.

6-17

TM 10-3930-242-34

6-13. Hydraulic Manifolda. General. The hydraulic manifold is located

to the r ight s ide of dr iver under the consolepanel. The purpose of the manifold is to distri-bute hydraulic oil to the various pumps on themach ine .

NOTE

Because of an engineering change, the manifold (1,fig. 6-15), together with cock (5), elbow (6), flange (7),and various hoses and connect ions are no longerused on forklif t t rucks after Anthony Serial No.LT1-688 (Army Model 200), Chrysler Serial No.CC0789 (Army Model 202), and all Athey forkliftt r u c k s ( A r m y M o d e l 2 2 2 ) . I n s t e a d , t h e v a r i o u spumps are individually fed from the hydraulic oilreservoir . The information in this paragraph ap-plies to the specified equipment and should be ac-cepted on an “as applicable” basis.

b. Removal and Disassembly.(1) Drain the hydraulic oil reservoir (para

6-12).

(2) Remove and disassemblehoses and manifold (fig. 6-15).


the hydraul ic

(1) Clean all metal parts thoroughly, usingsolvent P-D-680, or equal.

(2) Wipe hoses clean.(3) Inspect the manifold for cracks, distor-

tion, broken welds and other damage.(4) Inspect hoses for abrasion, cracks, and

other damage.(5) Inspect clamps and mounting hardware

for damage.(6) Replace all defective parts,

d. Reassembly and Installation.( 1 ) A s s e m b l e a n d i n s t a l l t h e h y d r a u l i c

hoses and manifold (fig. 6-15).(2) Fill the hydraulic oil reservoir. Refer to

the lubrication order.

Section II. MAIN HYDRAULIC PUMP AND ENGINE DRIVEN PUMP

6-14. Generala. The main hydraulic pump is driven by the

transmission where i t has avai lable considera-ble torque, a requirement of this pump. I t isactual ly two separate pumps that are assem-bled into a single unit and driven by a singleshaft that is common to both pump sections. It isdriven at engine speed by the transmission.

b. The engine driven pump is of the single-uni t - type. I t is coupled to the engine balanceshaft where it turns at engine speed at all times.

6-15. Main Hydraulic Pumpa. Gene ra l . The ma in hyd rau l i c pump i s a

dual pump. The longer portion of the pump sup-plies hydraulic pressure to the lift cylinders andto the extension cylinders. The front or smallerportion of the pump supplies pressure for frontwheel s teer ing.

b. Removal. R e m o v e t h e m a i n h y d r a u l i cpump (TM 10-3930-242-12).

c. Disassembly. Refer to figure 6–16 and dis-assemble the main hydraulic pump in numericalsequence.


vent P-D-680, or equal.(2) Inspect the bearings for roughness and

looseness or wear.(3) Inspect the shaf t for scratches, nicks,

and worn areas.(4) Inspect the rotors for scored areas and

for wear and other damage.

6-18

(5) Inspect al l other parts for wear andother damage.

(6) Replace all seals, packing, and defectivepar ts dur ing reassembly.

e. Reassembly. Refer to figure 6-16 and reas-semble the main hydraulic pump.

NOTE

After reassembly, run the pump for 30 minutes at2000 rpm while pumping SAE No. 10 oil at 0 psipressure.

f. Test. Bench test the pump by driving it at2800 rpm while loading the pump to 1600 psi.Pump capacity is 30 gallons per minute.

g . I n s ta l l a t i on . In s t a l l t he ma in hyd rau l i cpump (TM 10-3930-242-12).

NOTE

Pressure setting is on the hydraulic 3-spool valve.Check pressure at the pump, 2000-2100 psi.

6-16. Engine Driven Pumpa. General. The single-unit- type engine dri-

ven pump is coupled directly to the engine bal-ance shaft drive gear, where it is driven at en-gine speed. It supplies oil under pressure to op-erate the brakes, side shift cylinder, and oscil-lator cylinder.

b. Removal. Remove the engine driven pump(TM 10-3930-242-12).

c. Disassembly. Refer to figure 6-17 and dis-assemble the engine driven pump.



6-19

TM 10-3930-242-34

Figure 6-16. Main hydraulic pump, disassembly and reas-sembly.

(2) Inspect the bearings for roughness and e. Reassembly. Refer to figure 6–16 and reas-looseness or wear. semble the engine driven pump.

(3) Inspect the shaf t for scratches, nicks, NOTE

and worn areas. After reassembly, run the pump for 30 minutes at

(4) Inspect the rotor for scored areas and2000 rpm while pumping SAE No. 10 oil at 0 psip r e s s u r e .

f o r w e a r a n d o t h e r d a m a g e .

(5) Inspect all other parts for cracks, wear,f. Test. Bench test the pump by driving it at

and other damage.2800 rpm while loading the pump to 1600 psi.

(6) Replace all seals, packings,t ive par ts during reassembly.

Pump capacity is 30 gallons per minute.

and defec- g . I n s t a l l a t i o n . I n s t a l l t h e e n g i n e d r i v e npump (T.M. 10-3930-242-12).

TM 10-3930-242-34

Figure 6-17. Engine driven pump, disassembly and reas-sembly.

6-20

TM 10-3930-242-34

CHAPTER 7

REPAIR OF CARRIAGE ASSEMBLY, BOOM ASSEMBLY, FRAME, HOOD, AND PANELS

Section I. CARRIAGE AND BOOM ASSEMBLIES

7-1. GeneralThe carr iage assembly and the boom assem-

bly work together to form the load retr ieval ,l i f t ing, and carrying members of the forkl i f ttruck. These are the members that do the actuall i f t ing and posi t ioning of the load. The loadforces arc transmitted by these members to theframe of the forklift truck.

7-2. Carriage Assembly

a. General . The carr iage assembly includesthe forks and is the unit that immediately con-tacts and carr ies the load. I t is the uni t thatprovides for the side shifting of the forks and forthe immediate support of the load.

b. Removal . Remove the ca r r i age a s sembly(TM 10-3930-242-12).

c. Disassembly. Refer to figure 7-1 and disas-semble the carriage assembly.


vent P-D-680, or equal.(2) Use a wire brush to remove rust de-

posi ts .(3) Inspect the carriage frame and the two

arms for cracks, breaks, dis tor t ion, and dam-aged or broken welds.

(4) Inspect the clevis for breaks and distor-t ion.

(5) Inspect the sprockets for wear and otherdamage .

(6) Inspect the small components for wear,distortion, and other damage.

(7) Weld cracks in the carr iage frame orforks. After welding, remove flux deposits andinspect the welded areas with the magnaflux ordye penetrant process .

(8) Replace all defective parts.

e. Installation. Instal l the carriage assembly(TM 10-3930-242-12).

7-3. Boom Assembly

a. General. The boom assembly serves as anintermediate load support ing member betweenthe frame of the lift truck and the carriage as-sembly. It also is the member that provides forthe extension and retraction of the forks, as wellas the tilting of the carriage assembly and forks,

b. Removal.( 1 ) R e m o v e t h e c a r r i a g e a s s e m b l y ( T M

10-3930-242-12).(2) Remove the boom assembly (para 2-8).

c. Disassembly. Refer to figure 7-2 and disas-semble the boom assembly.

d. Cleaning and Inspection.(1) clean al l parts thoroughly, using sol-

vent P-D-680, or equal.(2) Remove rust deposits with a wire brush.( 3 ) I n s p e c t t h e i n n e r b o o m f o r c r a c k s ,

breaks, broken welds, distortion, and for worn orp i t t ed uppe r o r s i de wea r s t r i p s . (These a r ewelded to the inner boom and may be removedonly by use of a cutting torch. Wear is usuallylow and replacement is seldom required.)

( 4 ) I n s p e c t t h e o u t e r b o o m f o r c r a c k s ,breaks, broken welds, distortion and other dam-age .

(5) Inspect the small components for wear,dis tor t ion and other damage.

(6) Weld cracks in the inner or outer boom.After welding, remove f lux deposi ts , In areasthat form a sliding surface, carefully grind thewelds smooth. Then, inspect the welded areaswith the magnaflux or dye penetrant inspectionprocess .

(7) Replace all defective parts.e. Reassembly, Refer to figure 7-2 and reas-

semble the boom assembly.f. Installation.

(1) Install the boom assembly (para 2-8).( 2 ) I n s t a l l t h e c a r r i a g e a s s e m b l y ( T M

10-3930-242-12).

7-1

TM 10-3930-242-34

Figure 7-1. Carriage assembly, disassembly and reassem-bly.

7-2

TM 10-3930-242-34

Figure 7-2. Boom assembly, disassembly and reassembly.

7-3

TM 10-3930-242-34

Section II. FRAME, HOOD, AND PANELS

7-4. GeneraI

The fo rk l i f t t r uck f r ame i s cons t ruc t ed o fwelded steel channel in the conventional man-ner. The frame is then completed by attachmentof various brackets, fittings, counterweight, andcovers , a l l a t t a ched by u se o f conven t iona lhardward. The hood and panels are provided toenclose and protect the components of the fork-lift truck that are mounted in the frame undertheir protective cover.

7-5. Frame, Hood, and Panels

a. Disassembly. Refer to figure 7-3 and disas-semble the frame, hood, and panels.

NOTE

This manual is set up in the order of logical sequ-ence of disassembly and reassembly. Previouschapters , sect ions and paragraphs describe thesequence of removal , disassembly, and reassem-bly of various major and minor components of theforklift truck.

b. Cleaning and Inspection.(1) Clean al l parts thoroughly, using sol-

vent P-D-680, or equal.(2) Remove rust with a wire brush.( 3 ) I n s p e c t t h e f r a m e f o r d i s t o r t e d o r

twisted areas or areas where the steel channelsections have collapsed or crimped. Inspect forbroken welds or cracks and other damage.

(4) Inspect all small parts and hardware forwear, cracks, and other damage.

(5) Inspect the hood and panels for dents,cracks, and other damage.

(6) Straighten minor dents in the hood orpanels and weld cracks.

(7) A frame that has only minor distortionm a y b e s t r a i g h t e n e d a n d t h e n r e i n f o r c e d b ywelding a sui table plate over the area. Weldcracks and broken welds. Remove welding fluxand inspect the area with a dye penetrant pro-cess.

(8) Replace all defective parts.c. Reassembly. Refer to figure 7-3 and reas-

semble the frame, hood, and panels.

7-4

TM 10-3930-242-34

Figure 7-3. Frame, hood, and panels, disassemble and reas-sembly (sheet 1 of 2).

7-5

TM 10-3930-242-34

Figure 7-3. Frame, hood, and panels, disassembly and reas-sembly (sheet 2 of 2).

7-6

TM 10-3930-242-34

APPENDIX A

REFERENCES

A-1. Fire Protection and SafetyTB 54200-200-10TB 5-4200-201-10

TB 700-3

A-2. LubricationC9100ILLO 10-3930-242-12-1-

2

TB 703-1

TB 55-6650-300-15

A-3. Paint ingAR 740-1AR 746-5TB 740–93-1

TB 750-260

A-4. CleaningC6800ILP-C-436P - D - 6 8 0SB 725-7930-1TB SIG-327TM 38-230-1

TT-T-291

A-5. MaintenanceSB 700-50TB ORD-1031TB 9-2800-200-50TB 9-2800-236-50/1TB 43-0142TB 750-(See SFC)TB 750-236TB 750-255

TB 750-651

TB 5-764TM 9-6140-200-14

Hand Portable Fire Extinguishers Approved for Army UsersHand Portable Fire Extinguishers for Rai l , Marine, Amphibious, and

Off-Road EquipmentHandling, Storage, and Disposal of Self-Luminous Devices

Fuels, Lubricants, Oils, and WaxesTruck, Lift, Fork; Diesel Engine, Pneumatic Tired Wheels, Rough Ter-

rain, 6,000 lb. Capacity, 24-Inch Load Center (Anthony Model MLT-6,Army Model MHE-200, Chrysler Model MLT-6CH, Army Model 202,and Athey Model ARTFT-6 Army Model MHE-222)

Specification List of Standard Liquid Fuels, Lubricants, Preservatives,and Related Products Authorized for Us3 by U. S. Army

Spectrometric Oil Analysis

Color, Marking, and Preparation of Equipment for ShipmentColor and Marking of Army MaterielColor and Marking of Military Vehicles, Construction Equipment and

Materials Handling EquipmentPaint Instruct ions for Operator and Organizat ional Maintenance Per-

s o n n e l

Chemicals and Chemical ProductsCleaning Compound, Alkali, Boiling Vat (Soak) on HydrosteamDry Cleaning SolventHand and Soft-Water Cleaning CompoundsSubst i tutes for Carbon Tetrachlor idePreservation, Packaging, and Packing of Military Supplies and Equip-

ment (Cleaning)Thinner, Paint, Volatile Spirits (Petroleum spirits)

Expendable Limits (Up to $25.)Purging and Cleaning Fuel TanksOrdnance Engine Run-in and Test ProceduresReclamation of Crankshafts by Grinding UndersizeSafety Inspection and Testing of Lifting DevicesMaintenance Expenditure Limits (See index 310-4)Calibrat ion Requirements for Maintenance of Army MaterielUniform Policy for Hourmeters and Odometers on Overhauled or Re-

paired USAMECOM End I temsUse of Antifreeze Solutions and Cleaning Compounds in Engine Cooling

Sys t emsElectr ic Motor and Generator RepairStorage Batter ies , Lead-Acid Type

A-1

TM 10-3930-242-34

TM 10-3930-242-12 Operator and Organizat ional Maintenance Manual : Truck, Lif t , Fork;Diesel Engine, Pneumatic Tired Wheels , Rough Terrain, 6 ,000 lb .Capacity, 24-Inch Load Center, (Anthony Model MLT-6, Army ModelM H E - 2 0 0 ) F S N 3 9 3 0 - 9 0 3 - 0 9 0 0 , C h r y s l e r M o d e l M L T - 6 C H , A r m yModel 202, FSN 3930-937-0220 (Athey Model ARTFT-6, Army ModelMHE-222) FSN 3930419-5744

TM 10-3930-242-34P/1 Direct and General Support Repair Parts and Special Tools Lists (In-cludes Depot Maintenance Repair Parts and Special Tools Lists) :Truck, Lif t , Fork; Diesel Engine, Pneumatic Tired Wheels , RoughTer r a in , 6 , 000 l b . Capac i t y , 24 - Inch Load Cen t e r , (A they Mode lARTFT-6, Army Model MHE-222) FSN 3930419-5744

TM 10-3930-242-34P/2 Direct Support and General Support Repair Parts Lists (Includes DepotMaintenance Repair Parts and Special Tools Lists): Truck, Lift, Fork;Diesel Engine, Pneumatic Tired Wheels , Rough Terrain, 6 ,000 lb .Capacity, 24-Inch Load Center (Anthony Model MLT-6, Army ModelMHE-200, FSN 3930-903-0900) (Chrysler Model MLT-6CH, ArmyModel MHE-202, FSN 3930-937-0220)

TM 11-483 Radio Interference SuppressionTM 38-750 The Army Maintenance Management System

A-6. Shipment and StorageSB 38-100 A r m y P r e s e r v a t i o n , Pack ing and Mark ing Ma te r i a l s , Supp l i e s , and

E q u i p m e n tSB 740-1 Storage and Supply Activities, Covered and Open StorageTB 740-97-2 Preservation of USAME COM Mechanical Equipment for StorageTM 38-230-2 Preservation, Packaging and Packing of Military Supplies and Equip-

ment (Packing)TM 740-90-1 Adminis t ra t ive Storage of Equipment

A-7. DemolitionTM 750-24473 Destruct ion of Equipment to Prevent Enemy

A-8. OperationTM 5-331B Lif t ing, Loading, and Handl ing Equipment

U s e

A - 2

TM 10-3930-242-34

I N D E X

Paragraph PageA

Accumulator cylinder, hydraulic brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13Adjusters, slack, automatic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11

5-255-21

Administrative storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5Air inlet housing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4

1-1

Automatic slack adjusters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-113-2

Axle assemblies:5-21

Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7 2-5Repair - - - - - - - - - - - - - - - - - - - - - - - - - - ------------------ - - - - - - - - - - - - -

BBearing, main, crankshaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Block and end plate, cylinder - - - - - - - - - - - - - - - - - - - - - - - ---- - - - - - - - - - - - - - - --Blower:

Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Drive and coupling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Boom assembly:Removal and installationR e p a i r

Brake:Applicator valve and differential pressure switch

5-6

3-313-35

3-53-6

2-87-3

5-12

5-1

3-683-76

3-33-7

2-57-1

5-21A s s e m b l y - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 1 0 5-18P i n k i n g - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 - 8 5-6

CCamshaft, balance shaft and bearingsCarriage assemblyControl lever and tube assembly, fuel injectorControl , shif t , different ial lockoutCoo le r , o i lC o v e r ( u p p e r ) , e n g i n e f r o n tC r a n k s h a f tCrankshaft main bearingCylinder block and end plateCylinder head and valvesCylinder, hydraulic:

E x t e n s i o n

3-297-23-135-73-33-283-323-313-353-19

6-11

3 - 6 5 7-1

3-265-43-1

3-643-723-683-763-45

6-13Lift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ------------ - - - - - - - - - - - - - - - - - - - - 6-6 6-7Oscillating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-7 6-7Side shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10 6-10Slave- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-9 6-10Tilt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- -- 6-5 6-3

Cylinder, three-position - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-16 5-28Cylinder, steering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - 5-15 5-27

DData, tabulated - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Destruction of army material to prevent enemy use - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - -Differential lockout shift control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Drive and coupling, blower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -D u a l o v e r c e n t e r r e l i e f a n d r e p l e n i s h i n g v a l v e - - - - - - - - - - - - - -

EEngine:

Front cover (upper) -------------------------------------------------------------------------Removal and installation --------------------------------------------------------------------

Engine driven pump ----------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Engine propeller shaft ------------------------------------------------------------------------Exhaust valves, springs, guides and seats -------------------------------------------------------

1-71-61-45-73-66-3

3-282-56-165-43-20

1-11-11-15-43-76-1

3-642-4

6-185-1

3-49

l-1

TM 10-3930-242-34

ParagraphF

Flywheel ----------------------------------------------------------------------------------------------------- 3-21Flywheel housing -------------------------------------------------------------------------------------- 3-22Frame, hood, and panels -------------------------------------------------------------------------------------- 7-5Front propeller shaft ----------------------------------------------------------------------------------------- 5-2Fuel:

Injector control lever and tube assembly ----------------------------------------------------------------- 3-13Injectors (needle valve) ----------------------------------------------------------------------------------- 3-14Pump ------------------------------------------------------------------------------------------------------- 3-16Tank -------------------------------------------------------------------------------------------------------- 3-17

GGear train and engine timing ------------------------------------------------------------------ 3-33Generator -------------------------------------------------------------------------------------------------------3-9General:

Camshaft, balance shaft, and crankshaft ------------------------------------------------------ 3-27Carriage and boom assemblies --------------------------------------------------------------- 7-1Cylinder block ------------------------------------------------------------------------------ 3 - 3 4Cylinder head, valves, flywheel and flywheel housing ------------------------------------------- 3-18Engine accessories -------------------------------------------------------------------------------------- 3-1Frame, hood, and panels --------------------------------------------------------------------- 7-4Front and rear axle assemblies and parking brake ------------------------------- 5-5Fuel system ------------------------------------------------------------------------------------------------- 3-12Hydraulic brake system -------------------------------------------------------------------------- 5-9Hydraulic cylinders, hydraulic valves, hydraulic reservoir, and hydraulic manifold--------------- 6-1Main hydraulic pump and engine driven pump ----------------------------------------------------- 6-14Oil pan, oil pump screen, inlet pipe, connecting rods, and pistons ------------------------------------ 3-23Propeller shafts ------------------------------------------------------------------------------------------- 5-1Repair of transmission --------------------------------------------------------------------------- 4-1Steering system ------------------------------------------------------------------------------------------- 5-14Troubleshooting ----------------------------------------------------------------------------------------- 2-3

Governor ----------------------------------------------------------------------------------------------------- 3-7H

Housing, air inlet -------------------------------------------------------------------------------------------- 3-4Housing, flywheel -------------------------------------------------------------------------------------------- 3-22Hydraulic:

Brake accumulator cylinder ----------------------------------------------------------------------------- 5-13Extension cylinder ---------------------------------------------------------------------------------- 6-11Lif t cyl inder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-6Manifold ----------------------------------------------------------------------------------------- 6-13Oil reservoir -------------------------------------------------------- 6-12Oscillating cylinder -------------------------------------------------------------------------------------- 6-7Power steering valve (rear steer) ------------------------------------------------------------------------- 5-20Side shift cylinder -------------------------------------------------------------------------------------- 6-10Slave cylinder ----------------------------------------------------------------------------------------------- 6-9Tilt cylinder ------------------------------------------------------------------------------------------------- 6-5

IIdler gear assembly --------------------------------------------------------------------------------------- 3-30Injectors, fuel (needle valve) ---------------------------------------------------------------------------- 3-14

LLiner, cylinder, piston, rings, connecting rod and --------------------------------------- 3-26Link, drag, rear ---------------------------------------------------------------------------------------------- 5-22

MMain hydraulic pump ------------------------------------------------------------------------------------- 6-15Maintenance forms and records ---------------------------------------------------------------- 1-2Maintenance repair parts ---------------------------------------------------------------------- 2-2

0Oil:

Cooler ------------------------------------------------------------------------------------------------------- 3-3Pan ---------------------------------------------------------------------------- 3-24Pump and crankshaft pulley ----------------------------------------------------------------- 3-2Pump screen and inlet pipe --------------------------------------------------------------------- 3-25

Oscillating cylinder check valve ---------------------------------------------------------------- 6-8

Page

3-523-54

7-45-1

3-263-263-383-41

3-743-17

3-637-1

3-713-41

3-17-45-1

3-265-186-1

6-183-57

5-14-1

5-272-13-7

3-23-54

5-256-13

6-76-186-13

6-75-376-106-10

6-3

3-683-26

3-595-39

6-181-12-1

3-13-57

3-13-576-10

I-2

TM 10-3930-242-34

P a n , o i l - - - - - - - - - - - - -Parking brake --------------------

P------------------------------------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

---------------- - - - - - - - - - - - -

- - - - - -- - - - - - -

Paragraph

- - - - - - - - - 3-24- - - - - - - - - 5-8

Parts, maintenance repair --------------------------------------------------------------------------------------------- 2-2Piston, rings, connecting rod and cylinder liner -------------------------------------------------- 3-26Pulley, crankshaft, oil pump and --------------------------------------------------------------- 3-2Pump:

Engine driven ------------------------------------------------------------------------------------------------------- 6-16Fuel ----------------------------------------------------------------------------------------------------------------------- 3-16Main hydraulic -------------------------------------------------------------------------------------------------- 6-15Rear steering ----------------------------------------------------------------------------------------------------- 5-17

Pump, water, radiator and -------------------------------------------------------------------------- 3 - 8Push rods, rocker arms and -------------------------------------------------------------------- 3-15

RRadiator and water pump ---- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8Rear:

Drag link ----------------------------------------------------------------------------------------------------- 5-22Propeller shaft ---------------------------------------------------------------------------------------------- 5-3Steering pump ---------------------------------------------------------------------------------------------- 5-17

Regulator, voltage -------------------------------------------------------------------------------------------- 3-10Reporting of errors ----------------------------------------------------------------------------------- 1-3Reservoir, hydraulic oil ----------------------------------------------------------------------------- 6-12Rocker arms and push rods -------------------------------------------------------------------- 3-15

SScope ------------------------------------------------------------------------------------------------------------------- 1-1

Engine propeller shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4Front propeller shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2Rear propeller shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3

Special tools and equipment ------------------------------------------------------------------- 2-1Starter ------------------------------------------------------------------------------------------------------------------ 3-11Steering:

Cylinders --------------------------------------------------------------------------------------------------------- 5-15Gear assembly ------------------------------------------------------------------------------------------- 5-19Mode selector valve ----------------------------------------------------------------------------- 5-18System adjustment ------------------------------------------------------------------------------------ 5-21

Storage, administrative ----------------------------------------------------------------------------------- 1-5Switch, differential pressure, brake applicator valve and ----------------------------------------- 5-12

TTabulated data ----------------------------------------------------------------------------------------------- 1-7Tank, fuel ------------------------------------------------------------------------------------------------------ 3-17Test, torque converter stall -------------------------------------------------------------------- 4-3Three-position cylinder ------------------------------------------------------------------------------------- 5-16Three-spool valve -------------------------------------------------------------------------------------------- 6-2Timing, gear train and engine ------------------------------------------------------ 3-33Tools and equipment, special ------------------------------------------------------------------- 2-1Torque converter and transmission assembly:

Removal and installation --- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6Repair ------------------------------------------------------------------------------------------------------------- 4-2

Torque converter stall test -------------------------------------------------------------------- 4-3Transmission assembly, torque converter and:

Removal and installation --- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6Repair ------------------------------------------------------------------------------------------------------------- 4-2

Transmission control valve -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5Transmission main oil pressure regulating valve ------------------------------------------------- 4-4Troubleshooting chart -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4Two-spool valve --- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4

VValve:

Brake applicator and differential pressure swtich ---------------------------------------------- 5-12Dual overcenter relief and replenishing ------------------------------------------------------- 6-3Oscillating cylinder check ------------------------------------------------------------------------------ 6-8(Rear steer), hydraulic power steering -------------------------------------------------------- 5-20Steering mode selector -------------------------------------------------------------------------------------- 5-18Three-spool ----------------------------------------------------------------------------------------------------------------- 6-2

Page

3-575-62-1

3-593-1

6-183-386-185-293-133-35

3-13

5-395-1

5-293-17

1-16-133-35

1-15-15-15-12-1

3-17

5-275-325-325-38

1-15-21

1-13-414-155-286-1

3-742-1

2-44-1

4-15

2-44-1

4-184-17

2-16-1

5-216-1

6-105-375-326-1

I-3

TM 10-3930-242-34

ParagraphTransmission control ------------------------------------------------------------------------------------------- 4-5Transmission main oil pressure regulating ---------------------------------------------------- 4-4Two-spool ----------------------------------------------------------------------------------------------------------------- 6-4

Valves, cylinder head and -------------------------------------------------------------------------------- 3-19Voltage regulator -------------------------------------------------------------------------------------------------- 3-10

WWater pump, radiator and ------------------------------------------------------------------------------ 3-8

Page

4-184-176-1

3-453-17

3-13

I-4

TM 10-3930-242-34

By Order of the Secretary of the Army:

Official:

CREIGHTON W. ABRAMSGeneral, United States ArmyChief of Staff

VERNE L. BOWERSMajor General, United States ArmyThe Adjutant General

Distribution:To be distributed in accordance with DA Form 12-25A (qty rqr block No. 199) direct and general

support maintenance requirements for Truck, Rough Terrain.

U.S. GOVERNMENT PRINTING OFFICE : 342-421 (63271)

PIN : 027716-000

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