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TM 5-3895-346-14
TECHNICAL MANUAL
FOR
(NSN 3895-01-012-8875)
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TECHNICAL MANUAL
FOR
NSN 3895-01-012-8875
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TM 5-3895-346-14
WARNING
Consider hazards of job and wear protective gear such as safety glasses, safety
WARNING
When lifting engine, make sure lifting device is fastened securely. Be sure
item to be lifted does not exceed the capacity of the lifting device.
Be sure the engine is securely mounted to overhaul stand before releasing the
lifting sling. Severe injury to personnel and destruction of engine parts will
Hold the flywheel firmly against the crankshaft by hand to prevent it from
slipping off the end of the crankshaft, when removing the attaching bolts. The
When working on an engine that is running, accidental contact with the hot
exhaust manifold can cause severe burns. Remain alert to the location of the
rotating fan, pulleys, and belts. Do not make contact across battery termi-
Explosive hydrogen gas may remain in and around the battery for several hours
after it has been changed. Sparks and flame can ignite this gas.
Loss of shutdown control could result in a runaway engine and can cause
personal injury.
WARNING
WARNING
Use caution when welding on or near the fuel tank. Explosion can result if
regarding the use of air are indicated throughout the manual. Too much air can
rupture or in some other way damage a component and create a hazardous situa-
When making an oil cooler core pressure test, be sure that personnel are ade-
quately protected against any stream of pressurized water from a leak or rup-
Use extreme care while removing coolant pressure control cap. Remove the cap
slowly after the engine has cooled. Sudden release of pressure from a heated
Avoid excessive injection of ether into engine during start attempts. Follow
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TM 5-3895-346-14
WARNING
other chlorinated solvents, use these cleaning agents with caution. Be sure
the work area is adequately ventilated. Use protective gloves, and goggles or
Exercise caution when using oxalic acid to clean the cooling passages of the
engine.
Fuel spray from an injector can penetrate skin. Fuel oil which enters the
bloodstream can cause serious infection. Follow instructions and use proper
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TM 5-3895-346-14
AND
FOR
(NSN 3895-01-012-8875)
You can help improve this publication. If you find any mistakes, or if you
know of a way to improve the procedures, please let us know. Mail your
literature and does not conform with the format and content specified in
NOTE
Page
WARNING i
CHAPTER I - INTRODUCTION 1
WARRANTIES 2
SPECIFICATIONS 4
GENERAL INFORMATION 5
CHAPTER II - OPERATIONS 7
INDEX 657
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TM 5-3895-346-14
CHAPTER I
NOTE
INTRODUCTION
COMPONENT IDENTIFICATION
HYDROSTATIC DRIVE
ENGINE
of some parts.
TRANSMISSION
T20-0063 by Tampo
22-3037 Motor
VIBRATORY DRIVE
20-3010 Motor
DRIVE AXLE
Tampo
POWER STEERING
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TM 5-3895-346-14
WARRANTIES
Bulletin //9630.
Company.
consideration.
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TM 5-3895-346-14
WARRANTIES (Continued)
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TM 5-3895-346-14
Weight
Rolling Width
Roll Diameter
Overall Width
Overall Height
Overall Length
Wheel Base
Turning Radius
Vibration Frequency
Centrifugal Force
Power Unit
Roller Drive
Vibratory Drive
Steering
Brakes
Fuel Capacity
SPECIFICATIONS
RS-28
19,450 pounds
84 inches
60 inches
96 inches
98 inches
108.5 inches
17 feet, 10 inches
flotation tread.
1100-1500 vpm
0-15 mph
clutch.
steering.
shaft.
50 gallons
16 gallons
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TM 5-3895-346-14
GENERAL INFORMATION
ing bases.
(EIR)
storage.
use.
Fire Protection
TB 5-4200-200-10.
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TM 5-3895-346-14
- Always engage the parking brake move the forward-reverse lever to the
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TM 5-3895-346-14
CHAPTER II
OPERATIONS
THEORY OF OPERATION
impacts or pressure.
vibration.
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TM 5-3895-346-14
SAFETY
ROLLER OPERATIONS
SAFETY
tions thoroughly.
it.
rails.
slipping.
serious injury.
units.
level.
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TM 5-3895-346-14
ROLLER OPERATIONS
TO START
TO START ENGINE
NOTE
provided.
seat provided.
machine.
position.
fires.
OPERATING GEARS
another.
applications only.
around roller.
compacting or traveling.
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TM 5-3895-346-14j
ENGINE SHUTDOWN
ROLLER OPERATIONS
transmission.
around roller.
CAPTION
travel desired.
ENGINE SHUTDOWN
normal cutoff.
10
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TM 5-3895-346-14
ROLLER OPERATIONS
HAULING
HAULING
"bouncing.
DRIVE CLUTCH
compartment.
11
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TM 5-3895-346-14
FIRST START
OPERATIONS
FIRST TIME
the engine.
NOTE
or overhauled engine or an
Maintenance Chart.
Cooling System
engine is so equipped.
fluid expansion.
Lubrication System
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TM 5-3895-346-14
OPERATIONS
FIRST START
Fuel System
Specifications.
engine.
NOTE
should be unnecessary.
Lubrication Fittings
hand oiler.
Drive Belts
Maintenance.
Storage Battery
NOTE
of the electrolyte.
Clutch
equipped.
STARTING
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TM 5-3895-346-14
FIRST START
OPERATIONS
weather start.
CAUTION
thetic properties.
CAUTION
running.
14
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TM 5-3895-346-14
OPERATIONS
RUNNING
RUNNING
01 Pressure
Wan Up
a load.
the engine.
Clutch
Inspection
Engine Temperature
160-185F (71-85C).
Crankcase
dipstick.
Specifications.
Cooling System
Coolant),
15
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TM 5-3895-346-14
STOPPING
OPERATIONS
engine.
CAUTION
is necessary, maintain at
STOPPING
Normal Stopping
Emergency Stopping
CAUTION
start again.
Fuel System
Exhaust System
line or silencer.
Cooling System
Crankcase
dipstick.
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TM 5-3895-346-14
OPERATIONS
STOPPING
been in operation.
17
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TM 5-3895-346-14
OPERATING CONTROLS
OPERATIONS
OPERATING CONTROLS
steering column.
Steering
lever.
Control (5)
selected.
CAUTION
range.
the roller.
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TM 5-3895-346-14
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TM 5-3895-346-14
OPERATING CONTROLS
OPERATIONS
Device) (15)
20
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TM 5-3895-346-14
OPERATIONS
ROLLING INSTRUCTIONS
ROLLING INSTRUCTIONS
Rolling Speed
to 3 mph.
Number of Passes
surface.
drive wheels.
Equipment.
21/(22 blank)
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<
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TM 5-3895-346-14
CHAPTER III
MAINTENANCE
Services:
and WARNINGS.
and WARNINGS.
MAINTENANCE weekly.
supervisor.
hurry.
WARNING
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TM 5-3895-346-14
maintenance.
PMCS
checked/inspected.
checked/inspected.
CAUTION
checked/inspected. When in
24
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TM 5-3895-346-14
ITEM
NO
INTERVAL
ITEM TO BE INSPECTED
NEEDED
EQUIPMENT IS NOT
READY/AVAILABLE
IF:
NOTE
weekly.
-or-
GENERAL
are found.
ENGINE CRANKCASE
RADIATOR
filler neck.)
FUEL STRAINER
TIRES
dition.
flat, and/or
unserviceable.
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TM 5-3895-346-14
ITEM
NO
INTERVAL
ITEM TO BE INSPECTED
NEEDED
EQUIPMENT IS NOT
READY/AVAILABLE
IF:
TIRES (CONT)
(16 psi).
ROLL SCRAPER
Clearance incorrect.
1/8 inch.)
Clearance incorrect.
10
pressure, or hy-
abnormal operation.
c. Ammeter
Slight ( + ) charge
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TM 5-3895-346-14
INTERVAL
ITEM TO BE INSPECTED
NEEDED
EQUIPMENT IS NOT
READY/AVAILABLE
IF:
ITEM
NO
10
(CONT)
e. Tachometer
f. Fuel Gage
operation.
11
AIR CLEANER
Element missing.
12
13
14
V-BELTS
belts.
15
BATTERY
and cables.
crank engine.
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TM 5-3895-346-14
ITEM NO
INTERVAL
ITEM TO BE INSPECTED
OR ADJUSTED AS NEEDED
MI
ENGINE
operation.
100
300
200
V-BELTS
Check tension.
AIR CLEANER
required.
500
BLOWER SCREEN
100
BATTERY
each cell.
RADIATOR
required.
1000
Check operation.
28
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TM 5-3895-346-14
ITEM NO
INTERVAL
ITEM TO BE INSPECTED
OR ADJUSTED AS NEEDED
MI
10
TIRES
11
200
NOTE
12
13
14
15
16
29
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TM 5-3895-346-14
LUBRICATION CHART
LUBRICATION
LUBRICATION CHART
(See Fig. 1)
ITEM
NO
LUBRICATION
POINTS
LUBRICANT
INSTRUCTIONS
DAILY
Hydrostatic Drive
Reservoir
Automatic Transmission
Fluid, Type F
gage.
Engine
FIRST WEEK
tenance Section.
18
Hydrostatic Drive
Filter
10 Micron Filter
WEEKLY
Replace.
Section.
Power Steering
Reservoir
Type A
when hot.
Steering Joint
Bearings
GAA Grease
bottom of yoke.
Oscillating Thrust
Washer
GAA Grease
of crossbeam in yoke.
Steering Cylinder
Bearings
GAA Grease
cylinders.
Bearings
GAA Grease
GAA Grease
10
GAA Grease
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31
TM 5-3895-346-14
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TM 5-3895-346-14
LUBRICATION CHART
LUBRICATION
LUBRICATION CHART
LUBRICATION
POINTS
LUBRICANT
INSTRUCTIONS
Drive Axle
Differential
Drive Axle
Planetary
Gear Range
Transmission
Lube
Lube
GO80W/90
GO80W/90
Battery
(located approximately
line of unit).
Maintain level.
top of reservoir.
Hydrostatic Drive
Filter
Hydrostatic Drive
Oil Reservoir
10 Micron Filter
Element
component.)
Gear Range
Transmission
GO80W/90
GO80W/90
to Funk Transmission
Service Manual.
32
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in
u>
00
vO
in
'c/unk
'LU,,ATION'
CLUTCH Apply small amount of lubricant to clutch throwout collar once a day.
cap and fill to check plug on side. Change oil after first 5 hours and after ^ *
IMPORTANT If clutch does not pull, heats, or operating level jumps out, adjustment is
required. To adjust clutch, remove hand hole plate, turn clutch until adjusting lock pin can
be reached. Pull adjusting pin out and turn adjusting yoke to right or clockwise until oper-
ating lever requires a distince pressure to engage. A new clutch requires several adjustments
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TM 5-3895-346-14
LUBRICATION CHART
LUBRICATION
ITEM
NO
LUBRICATION
POINTS
LUBRICANT
INSTRUCTIONS
EVE
19
Hydrostatic Drive
Oil Reservoir
Automatic Transmission
Fluid Type F
Screen (located in
Refer to Sundstrand
troubleshooting procedure.
removed and
.ng properly.
NOTE:
The oil in the unit should be changed whenever the oil shows
Do not overfill.
34
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TM 5-3895-346-14
LUBRICATION
LUBRICATION CHART
LUBRICATION CHART
(See Fig. 3)
LUBRICATION
POINTS
LUBRICANT
INSTRUCTIONS
Bearings
GAA Grease
Jackshaft Pillow
Bearing
Eccentric Shaft
Bearings
GAA Grease
GO80W/90
head.*
is in the top most position. This will put the oil level plug
Drive Sheave
Bearings
Eccentric U-Joint|
Slip Spline
GAA Grease
GAA Grease
joint.
Eccentric Shaft
Bearings
Eccentric U-Joint|
GO80W/90
GAA Grease
special instructions
cross.
35
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36
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37
TM 5-3895-346-14
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38
NO
EVE
ITEM
Drive
POINTS
Repack.
LUBRICANT
GAA Grease
LUBRICATION
LUBRICATION
INSTRUCTIONS
TM 5-3895-346-14
Coupling Vibratory
LUBRICATION CHART
LUBRICATION CHART
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TM 5-3895-346-14
ROLLER MIUBUICI
Engine
Daily Checks:
Coolant level
Exhaust system
cleaner
Coolant hoses
Power Steering
hot.
555.
Brakes
adjustment.
assembly.
Parking Brake
Differential Axle
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TM 5-3895-346-14
ROLLER MAINTENANCE
MAINTENANCE
following points:
securely.
mounted.
of 20 ft-lb.
is out.
Roll Scrapers
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TM 5-3895-346-14
MAINTENANCE
ROLLER MAINTENANCE
roll.
frame.
plugs.
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TM 5-3895-346-14
ROLLER MAINTENANCE
MAINTENANCE
available in appendix D.
sling.
evenly.
plate.
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TM 5-3895-346-14
MAINTENANCE
ROLLER MAINTENANCE
roll.
the shaft.
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TM 5-3895-346-14
ROLLER MAINTENANCE
MAINTENANCE
overtighten.
eccentric shaft).
44
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TM 5-3895-346-14
ENGINE OVERHAUL
GENERAL INFORMATION
45
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TM 5-3895-346-14
PRINCIPLES OF OPERATION
ENGINE OVERHAUL
PRINCIPLES OF OPERATION
heat of compression.
(scavenging).
(compression).
SCAVENGING
COMPRESSION
POWER
EXHAUST
46
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TM 5-3895-346-14
ENGINE OVERHAUL
PRINCIPLES OF OPERATION
burned.
cycle.
47
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TM 5-3895-346-14
GENERAL DESCRIPTION
ENGINE OVERHAUL
GENERAL DESCRIPTION
engines.
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TM 5-3895-346-14
ENGINE OVERHAUL
GENERAL DESCRIPTION
5 043-5101
NUMBER
OF
BASIC ENGINE
ARRANGEMENTS
AND STARTER-BLOWER
ARRANGEMENT
SERIES
53
APPLICATION
DESIGNATIaN
DESIGN
VARIATION
CYLINDERS
(SEE BELOW)
APPLICATION DESIGNATION
DESIGN VARIATION
STARTER-BLOWER ARRANGEMENT
"N" ENGINE
2 VALVE HEAD
4 VALVE HEAD
Rotation: R-(right) and L-(left) designates rotation as viewed from the end of the engine opposite the flywheel.
Type: A-B-C-D designates location of exhaust manifold and blower as viewed from the flywheel end of the engine.
EXHAUST MANIFOLD
BLOWER
LA (XXXX-1XXX)
EXHAUST MANIFOLD
LB (XXXX-2XXX)
LC (XXXX-3XXX)
BLOWERl
LD (XXXX-4XXX)
EXHAUST MANIFOLD
BLOWER
RA (XXXX-5XXX)
EXHAUST MANIFOLD
BLOWER
RB (XXXX-6XXX)
RC (XXXX-7XXX)
BLOWERl
RD (XXXX-8XXX)
49
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TM 5-3895-346-14
GENERAL DESCRIPTION
ENGINE OVERHAUL
4-53
FRONT
()
FIRING
ORDER
RH-1-3-4-2
MODEL
NUMBER
SERIAL
NUMBER
'5047-7240
.4D-I3577
Firing Order
OPTION PLATE
(Fig. 4).
of 4DB (four-cylinder).
order.
OPTION PLATE
assemblies.
GENERAL PROCEDURES
50
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TM 5-3895-346-14
ENGINE OVERHAUL
GENERAL DESCRIPTION
items.
operation.
DISASSEMBLY
an overhaul stand.
dolly.
CLEANING
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TM 5.-3895-346-14
GENERAL DESCRIPTION
ENGINE OVERHAUL
Rinsing Bath
parts.
Drying
Rust Preventive
engine.
INSPECTION
operated.
available.
ASSEMBLY
inspection.
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TM 5-3895-346-14
ENGINE OVERHAUL
GENERAL DESCRIPTION
torques.
the threads.
NOTE
is also applied.
IMPORTANT
manual.
WORK SAFELY
an engine:
WARNING
Engine
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TM 5-3895-346-14
GENERAL DESCRIPTION
ENGINE OVERHAUL
tank is sufficient.
in severe arcing.
54
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55
TM 5-3895-346-14'
ENGINE OVERHAUL
GENERAL DESCRIPTION
Generated for jonatthan.gtz@gmail.com on 2013-05-10 18:02 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
56
Unit (4-53)
TM 5-3895-346-14
ENGINE OVERHAUL
GENERAL DESCRIPTION
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER BLOCK
block.
1. CYLINDER BLOCK
3. SUPPORT-UPPER MAIN
BEARING (REAR)
4. SUPPORT-UPPER MAIN
BEARING (FRONT)
5. BORE-CAM OR BALANCE
SHAFT
6. AIR BOX
COOLER TO BLOCK
COVER
COOLER
COOLER
(FRONT)
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TM 5-3895-346-14
CYLINDER BLOCK
ENGINE OVERHAUL
external piping.
block.
service.
58
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER BLOCK
and 4D-348.
included.
is overhauled.
mounting bracket.
engines.
and fittings.
connections.
CAPTION
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TM 5-3895-346-14
CYLINDER BLOCK
ENGINE OVERHAUL
securely.
WARNING
cylinder block.
manual.
inspected.
3.
air.
60
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER BLOCK
pressurized.
METHOD A
of all parts.
ports).
NOTE
washers.
block.
pressed air.
to prevent rust.
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TM 5-3895-346-14
CYLINDER BLOCK
ENGINE OVERHAUL
METHOD B
by a new block.
air.
to prevent rust.
replaced.
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER BLOCK
longitudinally.
Diagram
63
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TM 5-3895-346-14
CYLINDER BLOCK
ENGINE OVERHAUL
follows:
CAUTION
CAUTION
cap.
CAUTION
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER BLOCK
damage.
3.252 inches.
cap.
NOTE
the atmosphere.
engine as follows:
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TM 5-3895-346-14
CYLINDER BLOCK
ENGINE OVERHAUL
manual.
controls, etc.
66
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TM 5-3895-346-14
ENGINE OVERHAUL
Inspection
nuts.
plate).
CAUTION
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TM 5-3895-346-14
END PLATE
ENGINE OVERHAUL
CAUTION
numbers.
6 - BOLTS
3/8-16 x 7/8"
6 - BOLTS
3/8"-16 x 7/8"
(In-Line Engine)
68
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TM 5-3895-346-14
ENGINE OVERHAUL
cylinders.
cylinder block.
Inspection
69
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER HEAD
bolts.
head.
INJECTOR
EXHAUST
MANIFOLD
STUD
OoOOooo
CAM
FOLLOWER
ROCKER
ARMS
FUEL
PIPE
CONNECTOR
CONTROL
TUBE ASSEMBLY
70
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER HEAD
leaks.
of the failure.
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TM 5-3895-346-14
CYLINDER HEAD
ENGINE OVERHAUL
follows:
the radiator.
head:
liners.
valves.
guides.
and seals.
follows:
silencer.
cylinder head.
the injectors.
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER HEAD
CAUTION
Block).
as follows:
CAUTION
black light.
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TM 5-3895-346-14
CYLINDER HEAD
ENGINE OVERHAUL
black light.
minutes.
NOTE
equipment or material.
torque.
compressed air.
head.
follows:
Generated for jonatthan.gtz@gmail.com on 2013-05-10 18:12 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14,
ENGINE OVERHAUL
CYLINDER HEAD
Maximum Maximum
Longitudinal Transverse
2-53
3- 53, 6V-53
4- 53, 8V-53
0.004-inch
0.005-inch
0.006-inch
TABLE 1
0.004-inch
0.004-inch
0.004-inch
viously removed.
CAUTION
in the engine.
Val ves ).
75
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TM 5-3895-346-14
CYLINDER HEAD
ENGINE OVERHAUL
with solder.
DeOAOeOAOX
o oVo oVo c
Head
height).
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER HEAD
engine.
Preinstallation Inspection
engine tuneup.
counterbores.
CAUTION
gaskets or seals.
taken:
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TM 5-3895-346-14
CYLINDER HEAD
ENGINE OVERHAUL.
mize overspray.
CAUTION
stretched.
NOTE
rebuild.
NOTE
sealing capabilities.
(Fig. 2).
(Fig. 2).
the engine.
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER HEAD
CAUTION
time.
79
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TM 5-3895-346-14
CYLINDER HEAD
ENGINE OVERHAUL
CAUTION
CAUTION
and thermostat.
silencer.
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TM 5-3895-346-14
ENGINE OVERHAUL
springs.
INJECTOR
ROCKER
ARM
LOCK
NUT
Operating Mechanism
at all times.
Lubrication
cylinder block.
Service
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TM 5-3895-346-14
ENGINE OVERHAUL
this section.
cover.
CAUTION
entering.
CAPTION
shaft.
CAUTION
CAUTION
original positions.
Inspection
pressed air.
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TM 5-3895-346-14
ENGINE OVERHAUL
the spring.
(Pig. 2).
cylinder head.
location.
follower guide.
83
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TM 5-3895-346-14
ENGINE OVERHAUL
cylinder head.
CAUTION
entering.
arm clevis.
head.
rod.
NOTE
new head.
Inspection
at idle speed.
CAUTION
follower assembly.
camshaft, if necessary.
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TM 5-3895-346-14
ENGINE OVERHAUL
(refer to Specifications).
for wear.
load.
engine 4D-5323.
inches.
spring.
Spring
END
APPROX. 180
OPPOSITE
SPRING WIRE'
END
FORMER
85
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TM 5-3895-346-14
ENGINE OVERHAUL
Replace
proceed as follows:
CAUTION
follower body.
follower body.
follower body.
86
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TM 5-3895-346-14
ENGINE OVERHAUL
to 0.023 inch.
the cavity.
CAUTION
sibility of contamination.
Location of Parts
NOTE
spring.
87
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TM 5-3895-346-14
ENGINE OVERHAUL
spring retainer.
push rod.
rod.
NOTE
FEELER GAGES
Guide Clearance
spring.
fied torque.
Guide
88
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TM 5-3895-346-14
ENGINE OVERHAUL
CAUTION
engine operation.
Head).
injectors.
CAUTION
socket J 8932-01.
CAUTION
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90
TM 5-3895-346-14
ENGINE OVERHAUL
Figure 11. Relationship Between Exhaust Valve Bridge and Valve Stems
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TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST VALVES
EXHAUST VALVES
to a 31 seating angle.
maintained.
temperatures.
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TM 5-3895-346-14
EXHAUST VALVES
ENGINE OVERHAUL
Head Installed)
cover.
line horizontally.
CAUTION
connectors.
CAUTION
the injector.
shaft.
valve lock.
spring seat.
springs as follows:
CAUTION
Generated for jonatthan.gtz@gmail.com on 2013-05-10 18:21 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST VALVES
the shaft.
above.
Inspection
spring.
meter wire.
camshafts installed.
CAUTION
NOTE
Generated for jonatthan.gtz@gmail.com on 2013-05-10 18:22 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
EXHAUST VALVES
ENGINE OVERHAUL
(installed length).
parts.
oil seals.
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TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST VALVES
valve guides.
follows:
if used.
follows:
(Fig. 7)).
NOTE
45 CHAMFER
MACHINED
CURRENT
tZZ7
FORMER
Valve Guides
95
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TM 5-3895-346-14
EXHAUST VALVES
ENGINE OVERHAUL
TOOL
CYL.
VALVE
DIMENSION
NO.
HEAD
GUIDE
"A"
J 7560
2 VALVE
15 CHAMFER
.010"-.040"
J 7832
4 VALVE
15 CHAMFER
.010"-.040"
J 9756
2 VALVE
45 CHAMFER
.010"-.040"
J 9730
4 VALVE
.190"-.220"
Tools
CAUTION
cylinder head).
CAUTION
cylinder head.
cracking.
96
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TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST VALVES
Insert
the tool.
cylinder head.
NOTE
NOTE
required.
180-200F (82-93C).
cylinder head.
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TM 5-3895-346-14
EXHAUST VALVES
ENGINE OVERHAUL
Insert
Seat Insert
(Fig. 12).
Insert
at a time.
98
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TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST VALVES
MAX
VALVE .006"
ABOVE HEAD
VALVE FLUSH
WITH HEAD
MAX
VALVE
BELOW
VALVE
SEAT
INSERT
CYLINDER
HEAD
MAX
VALVE .024
BELOW HEAD
VALVE
SEAT
INSERT
CYLINDER
HEAD
FORMER
CURRENT
Figure 13. Relationship Between Exhaust Valve, Insert, and Cylinder Head
(Four-Valve Head)
fo1lowing too1s:
1. Grinder J 8165-1
3. Pilot J 7792-1
follows:
wheel8.
CAUTION
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TM 5-3895-346-14
EXHAUST VALVES
ENGINE OVERHAUL
insert.
insert.
CAUTION
valves.
head.
NOTE
100
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TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST VALVES
loose item.
CAUTION
VALVE
SPRING
SEAT
follows:
excess length.
valve guide.
NOTE
J 29579.
valve stem.
CAUTION
FORMER
DESIGN
CURRENT
DESIGN
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TM 5-3895-346-14
EXHAUST VALVES
ENGINE OVERHAUL
SPRING
CAP
Oil Seal
(Fig. 2).
CAUTION
seal.
failure.
tuneup.
102
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103
EXHAUST VALVES
TM 5-3895-346-14
ENGINE OVERHAUL
Generated for jonatthan.gtz@gmail.com on 2013-05-10 18:30 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
Cover Assembly
104
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TM 5-3895-346-14
ENGINE OVERHAUL
CRANKSHAFT
CRANKSHAFT
induction hardened.
crankshaft.
components.
Remove Crankshaft
mounting plate.
105
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TM 5-3895-346-14
CRANKSHAFT
ENGINE OVERHAUL
WARNING
stand.
and screen.
housing.
bearing caps.
Inspection
shaft, if necessary.
106
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TM 5-3895-346-14
ENGINE OVERHAUL
CRANKSHAFT
have to be reground.
Crankshaft
at this point.
surfaces.
necessary.
Crankshaft Measurements
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TM 5-3895-346-14
CRANKSHAFT
ENGINE OVERHAUL
must be reground.
black light.
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TM 5-3895-346-14
.ENGINE OVERHAUL
bearing.
at high frequency.
CRANKSHAFT
Zones
shown in Fig. 4.
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TM 5-3895-346-14
CRANKSHAFT
ENGINE OVERHAUL
found.
Crankshaft Grinding
NOTE
unnecessary.
proceed as follows:
110
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TM 5-3895-346-14
ENGINE OVERHAUL
CRANKSHAFT
Bearing
Size
Conn. Rod
Journal Dia.
Main Bearing
Journal Dia.
In-Line Engines
Standard
2.499-2.500 inches
2.497-2.498 inches
*2.489-2.490 inches
*2.479-2.480 inches
*2.469-2.470 inches
2.999-3.000 inches
2.997-2.998 inches
*2.989-2.990 inches
*2.979-2.980 inches
*2.969-2.970 inches
TABLE 1
(V-ENGINES)
(IN-LINE ENGINES)
AVOID
SHARP
CORNERS
/////////
77-7-7777
Install Crankshaft
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TM 5-3895-346-14
CRANKSHAFT
ENGINE OVERHAUL
1.499"
1.501"
.67'
AT
1.299"
1.34"
1.301'
IN-LINE
ENGINE
V-TYPE
ENGINE
surfaces.
CAUTION
removed.
NOTE
Nominal
Size
Thrust Washer
Thickness
Min.
Max.
Standard
0.1190 inch
0.1220 inch
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TM 5-3895-346-14
ENGINE OVERHAUL
CRANKSHAFT
Play
(Cylinder Liner).
(Cylinder Head).
flywheel (Flywheel).
port, if used.
(Crankshaft Pulley).
crankshaft malfunction.
CAUTION
IMPORTANT
follows:
the gage.
113
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TM 5-3895-346-14
CRANKSHAFT
ENGINE OVERHAUL
indicator reading.
NOTE
readings.
realign as necessary.
114
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TM 5-3895-346-14
ENGINE OVERHAUL
(Fig. 1).
(Fig. 2).
as follows:
oil seal.
seal.
115
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TM 5-3895-346-14
ENGINE OVERHAUL
Inspection
flywheel.
Inspection.
on Grooved Crankshaft
(Fig. 3) as follows:
(Fig. 4) as follows:
on Grooved Crankshaft
116
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TM 5-3895-346-14
ENGINE OVERHAUL
NOTE
shaft.
Oil Seals
coating.
serviced.
support.
face down).
on a flat surface.
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118
TM 5-3895-346-14
ENGINE OVERHAUL
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TM 5-3895-346-14
ENGINE OVERHAUL
MAIN BEARINGS
bearings.
interchanged.
not doweled.
ing shells.
INTERMEDIATE
VIN BEARING
CAP
REAR MAIN
BEARING CAP
UPPER MAIN
BEARING SHELL
In-Line Engines
in Place)
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TM 5-3895-346-14
MAIN BEARINGS
ENGINE OVERHAUL
shown in Fig. 3.
Bearing Shell
Inspection
or no oil.
operating freely.
120
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TM 5-3895-346-14
ENGINE OVERHAUL
MAIN BEARINGS
121
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TM 5-3895-346-14
MAIN BEARINGS
ENGINE OVERHAUL
122
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TM 5-3895-346-14
ENGINE OVERHAUL
MAIN BEARINGS
Bearing
Size
Bearing
Thickness
Minimum
Thickness
In-Line Engines
Standard
0.1245-0.1250 inch
0.1255-0.1260 inch
0.1295-0.1300 inch
0.1345-0.1350 inch
0.1395-0.1400 inch
0.1230 inch
0.1240 inch
0.1280 inch
0.1330 inch
0.1380 inch
TABLE 1
CAUTION
inch oversize.
in Place)
removal.
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TM 5-3895-346-14
MAIN BEARINGS
ENGINE OVERHAUL
in Place
CAUTION
NOTE
gasket.
schedule.
124
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TM 5-3895-346-14
ENGINE OVERHAUL
pan.
the crankshaft.
cylinder block.
125
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TM 5-3895-346-14
ENGINE OVERHAUL
pilot studs.
torque.
126
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TM 5-3895-346-14
ENGINE OVERHAUL
CRANKSHAFT PULLEY
shaft pulley.
NOTE
if used.
pulley installation.
PULLET
the installer.
torque.
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TM 5-3895-346-14
CRANKSHAFT PULLEY
ENGINE OVERHAUL
BOLT
PULLEY
OUTER
CONE
INNER
CONE
CRANKSHAFT
RETAINER
128
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TM 5-3895-346-14
ENGINE OVERHAUL
FLYWHEEL
FLYWHEEL
to the flywheel.
Torqmatic converters.
vice manual.
flywheel as follows:
housing.
WARNING
129
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TM 5-3895-346-14
FLYWHEEL
ENGINE OVERHAUL
lifting tool.
attaching bolt.
housing.
Pilot Bearing.
used.
Inspection
assembly procedure.
ring gear.
on the flywheel.
it, if necessary.
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TM 5-3895-346-14
ENGINE OVERHAUL
FLYWHEEL
NOTE
Heat-indicating "crayons",
predetermined temperature,
Install Flywheel
used*
shaft boltholes.
(if used).
CAUTION
required clamping.
NOTE
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TM 5-3895-346-14
FLYWHEEL
ENGINE OVERHAUL
IMPORTANT
132
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TM 5-3895-346-14
ENGINE OVERHAUL
Lubrication
(TransKission Removed)
removed as follows:
place.
WARNING
Inspection
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TM 5-3895-346-14
ENGINE OVERHAUL
transmission.
BOLT
MOUNTING PLATE
SPRING
SPRING WASHER
SNAP RING
HUB
SPACER
Flexible Coupling
Inspection
Nm) torque.
coupling assembly.
Install Coupling
securely.
134
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TM 5-3895-346-14
ENGINE OVERHAUL
FLYWHEEL HOUSING
FLYWHEEL HOUSING
transmission.
housing.
used.
flywheel housing.
CAUTION
Flywheel Housing
dowel pins.
Inspection
135
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TM 5-3895-346-14
FLYWHEEL HOUSING
ENGINE OVERHAUL
IMPORTANT
(Fig. 2).
seal.
of the crankshaft.
studs.
NOTE
housing is installed.
Fig. 3.
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TM 5-3895-346-14
ENGINE OVERHAUL
FLYWHEEL HOUSING
3/8"-16x7/8" 1-2-4-5
base post.
2) - In-Line Engine
Housing Concentricity
137
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TM 5-3895-346-14
FLYWHEEL HOUSING
ENGINE OVERHAUL
NOTE
housing bore.
engine.
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TM 5-3895-346-14
COMPRESSION
RINGS
[CONNECTING
ROO
OIL RING
'(UPPER HALFI
OIL RING
(LOWER HALFI
NATURALLY ASPIRATED
OIL RING
r] OIL RING
l-^J^-"""(ONE PIECEI
^C (UPPER HALF)
piston skirt.
walls.
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TM 5-3895-346-14
ENGINE OVERHAUL
compression pressure.
pan.
(Cylinder Head).
liner.
block.
rod.
follows:
shown in Fig. 2.
Clean Piston
140
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TM 5-3895-346-14
ENGINE OVERHAUL
passage.
Rod.
edge.
Inspection
little wear.
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TM 5-3895-346-14
ENGINE OVERHAUL
INSTALLATION AS IS
FOR USE
NOTE
same manner.
end up).
after installation.
bushing bore.
follows:
142
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TM 5-3895-346-14
ENGINE OVERHAUL
nuts securely.
BUSHING
JOINT
Pin Bushings
Fitting Piston
specifications.
(Fig. 8).
143
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TM 5-3895-346-14
ENGINE OVERHAUL
the clearance.
Clearance
tension expanders.
144
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TM 5-3895-346-14
ENGINE OVERHAUL
ring gap.
Specifications.
Clearance
CAUTION
COMPRESSION RINGS
CAUTION
of the piston.
piston.
145
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TM 5-3895-346-14
ENGINE OVERHAUL
follows:
CAUTION
CAUTION
NOTE
ring expander.
146
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TM 5-3895-346-14
ENGINE OVERHAUL
CONNECTING ROD
CONNECTING ROD
oil.
CAUTION
147
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TM 5-3895-346-14
CONNECTING ROD
ENGINE OVERHAUL
size.
Inspection
clogged.
Cylinder Liner).
CAUTION
crush.
wear.
Remove Bushings
follows:
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TM 5-3895-346-14
ENGINE OVERHAUL
CONNECTING ROD
EXAMPLE OF AN INDICATION
FOLLOWING LONGITUDINAL
NON-CRITICAL
AREA
NON-CRITICAL
AREA
GRINDING NOTES
LONGITUDINAL INDICATIONS
TION.
57
Bushings
nozzle.
Fig. 5.
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TM 5-3895-346-14
CONNECTING ROD
ENGINE OVERHAUL
Install Bushings
(Fig. 7).
SPRAY
NOZZLE'
POSITION HOLES
AS SHOWN
St
Nozzle Holes
counterbore.
connecting rod.
after installation.
follows:
in a bench vise.
torque.
150
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TM 5-3895-346-14
ENGINE OVERHAUL
CONNECTING ROD
in the fixture.
fixture.
reaming fixture.
fixture.
reamer.
piston as follows:
CAUTION
clearance.
Retainer
151
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TM 5-3895-346-14
CONNECTING ROD
ENGINE OVERHAUL
bushings.
Rings.
in Cylinder Liner.
152
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TM 5-3895-346-14
ENGINE OVERHAUL
ing rod.
shell.
follows:
pan.
screen assembly.
Bearing Shells
sharp tool.
Inspection.
153
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TM 5-3895-346-14
Inspection
or no oil.
to Table 1.
ENGINE OVERHAUL
Table 1
Bearing
Size
*New Bearing
Thickness
Minimum
Worn
Thickness
In-Line Engines
Standard
0.1245 -
0.1250 inch
0.1230 inch
0.002 inch
Undersize
0.1255 -
0.1260 inch
0.1240 inch
0.010 inch
Undersize
0.1295 -
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TM 5-3895-346-14
ENGINE OVERHAUL
CAUTION
follows:
engine oil.
bearing cap.
CAUTION
to the nut.
hardened or broken.
gasket.
Instructions.
155
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TM 5-3895-346-14
CYLINDER LINER
ENGINE OVERHAUL
CYLINDER LINER
all engines.
combustion.
operating.
collapse.
Piston Rings.
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER LINER
ffkR"
JNa
ollr
liner.
block.
hammer.
following:
1. Cracks
2. Scoring
4. Flange irregularities
5. Inside diameter
6. Outside diameter
7. Out-of-round
8. Taper
(refer to Specifications).
NOTE
rings.
be lengthened.)
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TM 5-3895-346-14
CYLINDER LINER
ENGINE OVERHAUL
GLAZE GLAZE
UNBROKEN BROKEN
Cylinder Liner
Due to Wear
times.
marks on a 45 axis.
burrs.
NOTE
gage.
new liner.
158
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER LINER
Diagram
CAUTION
liner.
engine).
cylinder liner.
159
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TM 5-3895-346-14
CYLINDER LINER
ENGINE OVERHAUL
of Fig. 8).
CAUTION
J 21793-B
Assembly
CAUTION
compressor.
CAUTION
breakage.
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER LINER
OPERATION 1 OPERATION 2
NOTE
ring.
engine oil.
161
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TM 5-3895-346-14
UPPER
SEAL
RING
LOWER
SEAL
RING
AV CURRENT BLOCK WA
SEAL
RING
IMPORTANT
holddown clamps.
engine oil.
162
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TM 5-3895-346-14
ENGINE OVERHAUL
CYLINDER LINER
163
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TM 5-3895-346-14
ENGINE BALANCE
ENGINE OVERHAUL
couple.
gears.
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TM 5-3895-346-14
ENGINE OVERHAUL
ENGINE BALANCE
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:04 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
the crankshaft.
hub.
R.H. ROTATION
IN-LINE ENGINES
timing.
CAUTION
It is advisable to make a
166
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TM 5-3895-346-14
ENGINE OVERHAUL
idler gear.
Lubrication
ENGINE TIMING
of time.
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TM 5-3895-346-14
ENGINE OVERHAUL
turn.
cylinder head.
pointer.
of the pointer.
CAUTION
fied in Specifications.
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TM 5-3895-346-14
ENGINE OVERHAUL
TABLE 1
Engine
*INDICATOR READING
Retarded
1-Tooth
Advanced
1-Tooth
Correct
STANDARD TIMING
(D4
0.228 inch
0.204 inch
0.245 inch
(2)4
0.206 inch
0.179 inch
0.232 inch
ADVANCED TIMING
(2)4
0.232 inch
0.206 inch
0.258 inch
169
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TM 5-3895-346-14
CAMSHAFT, BALANCE
arrangement.
low-lift camshafts.
ENGINE OVERHAUL
IMPORTANT
failure.
NOTE
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:05 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
follows:
exhaust lobe.
lobe.
Lubrication
bearings.
follows:
NOTE
the camshaft.
Cylinder Block).
stand.
IMPORTANT
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:05 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
camshaft.
pulley.
slinger.
(Fig. 3).
camshaft gear.
as shown in Fig. 2.
Transmission in Place)
engine.
172
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TM 5-3895-346-14
ENGINE OVERHAUL
NOTE
camshaft.
cylinder block.
plugs, as follows:
of the plug.
3/8-16 tap.
NOTE
through g.
Inspection
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TM 5-3895-346-14
CAMSHAFT OVERHAUL
ENGINE OVERHAUL
NOTE
inspection.
thick-
CAUTION
compressed air.
Table 1.
Remove Bearings
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TM 5-3895-346-14
ENGINE OVERHAUL
TABLE 1
Bearing
Location
Dimension
Engine
Minimum
Maximum
End
2.385 inch
2.386 inch
Intermediate
2.375 inch
2.376 inch
Center
2.365 inch
2.366 inch
of Fig. 9.
remaining bearings.
175
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TM 5-3895-346-14
ENGINE OVERHAUL
Camshaft Bearings
NOTE
(Fig. 7).
cylinder block.
shown in Table 2.
and C of Fig. 9.
TABLE 2
Bearing
Position
Color Code
Outside
Diameter
Inside
Diameter
Current
Former
End
Brown
Black
Standard
Standard
Brown
Yellow
0.010 inch
Oversize
Standard (only)
Intermediate
Orange
Red
Standard
Standard
Orange
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TM 5-3895-346-14
ENGINE OVERHAUL
WASHER
bore.
Fig. 9.
the puller.
INTERMEDIATE
AND CENTER
END
further movement.
177
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TM 5-3895-346-14
ENGINE OVERHAUL
support J 7593-12.
installer.
position.
Balance Shaft
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TM 5-3895-346-14
ENGINE OVERHAUL
6a
E]
lilLiiuiwrgj
J-7593-5
J-7593-4
J-7593-1 J7593-2
THRUST SEARING
B.
WASHER
NUT
J-7593-4
J-7593-1
J-7 593-2
/1
\3
PR-
llll
mil
yu
J-7593-1 J-7593-2
J-7593-4
-1
illll
H b3
J-7593-3 J-7593-12
J-7593-1
J-7593-2
IN 6V CYLINDER BLOCK.
torque.
179
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TM 5-3895-346-14
ENGINE OVERHAUL
CAMSHAFT
manual.
180
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TM 5-3895-346-14
ENGINE OVERHAUL
Transmission in Place)
shaft.
in the cover.
torque.
torque.
181
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TM 5-3895-346-14
CAMSHAFT GEARS
ENGINE OVERHAUL
and Timing).
engine balance.
camshaf t gear.
Inspection
if necessary.
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TM 5-3895-346-14
ENGINE OVERHAUL
CAMSHAFT GEARS
Gears
the gear.
(Fig. 2).
cylinder block.
183
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TM 5-3895-346-14
IDLER GEAR
ENGINE OVERHAUL
(Fig. 1).
another.
Hub
rear.
end plate.
(Fig. 3).
assembly.
Inspection
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TM 5-3895-346-14
ENGINE OVERHAUL
IDLER GEAR
4D-9458.
idler gear.
cylinder block.
installed.
hub.
in Fig. 2.
185
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186
IDLER GEAR
TM 5-3895-346-14
ENGINE OVERHAUL
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:15 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
TIMING GEAR
Housing Removed)
crankshaft.
original position.
in Fig. 1.
the crankshaft.
Inspection
Gear
the crankshaft.
NOTE
idler gear.
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TM 5-3895-346-14
TIMING GEAR
ENGINE OVERHAUL
Fig. 2.
Timing Gear
188
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TM 5-3895-346-14
ENGINE OVERHAUL
Housing).
support.
attaching bolts.
damaged.
Inspection
189
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TM 5-3895-346-1A
ENGINE OVERHAUL
support.
it was removed.
arbor press.
plate.
procedure.
torque.
shaft.
190
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TM 5-3895-346-14
ENGINE OVERHAUL
GASKET KEY
Figure 3. Blower Drive Gear and Support Assembly Details and Relative
Gear On Shaft
191
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TM 5-3895-346-14
FRONT COVER
ENGINE OVERHAUL
Remove Cover
J 9790.
as follows:
manual.
and cover.
Inspection
necessary.
cover.
cover.
cover on woodblocks.
hardening sealant.
CAUTION
counterbore.
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TM 5-3895-346-14
ENGINE OVERHAUL
FRONT COVER
NOTE
1/4" TO 5/16"
Front Cover
shaft.
shafts.
193
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TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
CYLINDER BLOCK
SHOP NOTES
exceeded.
as follows:
clearances.
to 0.009 inch.
crankshaft journal.
CAUTION
being checked.
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TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
Measure Bearing-to-Crankshaft
Clearance
the crankshaft.
of taper.
NOTE
when installing the cup plug. 0.180 to 0.210 inch with tool J 24094.
195
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TM 5-3895-346-14
TROUBLESHOOTING
ENGINE OVERHAUL
EXHAUST VALVE
Probable Causes
1. STICKING VALVE
2. IMPROPER VALVE
SEATING
OR OVERHEATED
4. BENT VALVE
5. BROKEN VALVE
6. EXCESSIVE VALVE TO
GUIDE CLEARANCE
7. CARBON DEPOSITS
ON VALVE HEAD
8. VARNISH DEPOSITS
ON VALVE STEM
9. SCORED OR SCUFFED
VALVE STEM
VALVE STEM
196
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TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING
TROUBLESHOOTING
SUGGESTED REMEDY
necessary.
necessary.
parts.
necessary.
pitted, or scored.
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TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
SPECIFICATIONS
text.
Cylinder Block
Block bore:
Out-of-round
Taper
Diameter 4.8200
Depth 0.3000
End 2.3850
Intermediate 2.3750
Center 2.3650
Flatnesstransverse (all)
Flatnesslongitudinal
Waterholes 0.1090
Oilholes 0.0920
Cylinder Liner
4.5215
4.4880
4.3575
0.0015
0.0015
4.8350
0.3020
3.2520
2.3860
2.3760
2.3660
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TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
Piston:
Clearancepiston skirt-to-liner:
Out-of-round 0.0005
Taper 0.0005
Compression rings:
Clearancering-to-groove:
Piston Pins
Connecting Rod
Crankshaft
199
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TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
Main Bearings
Caashaft
Balance Shaft
Runout tolerance given for guidance when regrinding crankshaft. Crankshaft for
4-53 supported on No. 1 and No. 5 journals; runout measured at No. 2, 3, and 4
journals.
When the runout on adjacent journals is in the opposite direction, the sum must
When in the same direction, the difference must not exceed 0.003 inch total
indicator reading. When high spots of runout on adjacent journals are at right
angles to each other, the sum must not exceed 0.004 inch total indicator reading,
200
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TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
Idler Gear
Backlash 0.0030
Clearancebearing-to-hub 0.0025
Backlash 0.0030
Backlash 0.0030
Backlash 0.0030
Cylinder Head
Exhaust Valves
protr.
0.0050
2.1870
2.1835
0.0045
0.0130
0.1200
0.0050
4.0590
4.0610
0.0050
0.1030
0.0060
1.1600
1.1615
0.0781
0.0020
0.2488
0.2485
0.024
recess.
0.018
recess.
0.0070
0.0070
0.0170
0.0070
0.0070
0.0050 0.0070
1.0636
1.0630
0.0781
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TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
MINIMUM
(inch)
MAXIMUM
(inch)
LIMITS
(inch)
Valve Guides
0.0400
0.2200
0.2515
0.0035
0.0040
0.0050
0.0050
0.8740
0.8760
0.8763
0.0025
0.0028
0.0040
0.0040
Cam Followers
1.0610
0.0036
0.0030
0.0060
0.0060
0.0021
0.010
horiz.
0.0230
0.0230
202
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TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
THREAD
SIZE
260M BOLTS
TORQUE THREAD
280M OR BETTER
TORQUE
1 - 8 435-443 590-600
1 - 8 580-590 786-800
Grade Identification markings are normally stamped on the heads of the bolts. To
aid identification of the various bolts used in Detroit Diesel engines, refer to
Grade Identification
Marking on Bolthead
GM
Number
SAE Grade
Designation
Nominal Size
Diameter
(inch)
Tensile
Strength Min.
(psi)
None
GM 255-M
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TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
THREAD
SIZE
TORQUE
(lb ft)
TORQUE
(Nm)
APPLICATION
1/4 -20
1/4 -20
12-15
12-15
16-20
16-20
1/4 -28
10-12
14-16
5/16-18
5/16-18
5/16-18
10-12
19-23
10-20
14-16
26-31
14-27
3/8 -16
3/8 -16
3/8 -16
3/8 -16
12-16
25-30
40-45
20-25
16-22
34-41
54-61
27-34
3/8 -24
3/8 -24
3/8 -24
3/8 -24
40-45
25-30
20-28
12-15
54-61
34-41
27-38
16-20
7/16-14
50-55
68-75
1/2 -20
9/16-12
120-130
163-177
9/16-12
5/8 -11
170-180
231-244
3/4 -16
3/4 -16
3/4 -16
3/4 -10
120-140
80-100
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TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
NPTF SIZE
THREAD
TORQUE
NPTF SIZE
TORQUE
(lb ft)
(Nm)
THREAD
(lb ft)
(Nm)
,10-12
14-16
3/4
45-50
.14-16
19-22
102-115
,18-22
24-30
129-143
,23-27
31-37
150-177
205
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TM 5-3895-346-14
SERVICE TOOLS
Cylinder Block
Cylinder Head
Socket J 8932-01
Crankshaft
Handle J 3154-1
206
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TM 5-3895-346-14
Puller J 24420
Flywheel
Flywheel Housing
Piston and connecting rod bushing installer and remover set J 1513-02
Piston and connecting rod bushing installer and remover set J 7587
Camshaft
Camshaft and balance shaft bearing remover and installer set J 7593-03
207
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TM 5-3895-346-14
208
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TM 5-3895-346-14
ENGINE OVERHAUL
FUEL SYSTEM
FUEL
of each injector.
SYSTEM
In-Line Engines
down.
209
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TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
FUEL INJECTOR
load.
FOLLOWER
FOLLOWER
SPRING
BUSHING .
SPILL
DEFLECTOR-
LOWER PORT.
CHECK VALVE-
VALVE SPRING
NEEDLE VALVE-
SPRAY TIP-
INJECTOR
BODY
FILTER
UPPER PORT
CHECK VALVE
CAGE
SPRING CAGE
SPRING SEAT
NUT
Injector
210
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TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
temperatures.
EFFECTIVE
STROKE
EFFECTIVE EFFECTIVE^.
NO
INJECTION
IDLING
LOAD
HALF
LOAD
FULL
LOAD
LOWER
PORT
TOP START OF
OF INJECTION
STROKE STROKE
END OF BOTTOM
INJECTION OF
STROKE STROKE
of Plunger
CAUTION
injectors in an engine.
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:28 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
IDENTIFICATION MARK
ON PLUNGER
C3
C3
IDENTIFICATION MARK
INJECTOR
SPRAY TIP*
PLUNGER
N35
- .006 - 165A
N35
L40
- .0055 - 165A
4L
N40
- .006 - 165A
4N
N45
- .006 - 165A
45N
N50
- .006 - 165A
5N
C40
- .006 - 165A
4C
C45
- .006 - 165A
45C
C50
- .006 - 165A
5C
5A50
- .0060 - 165A
5A50
5A55
- .0060 - 165A
5A55
5A60
- .0060 - 165A
6N
N55
-.0055- 165A
55N
N60
-.0055- 165A
6N
N65
- .006 - 165A
65N
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:28 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
combustion chamber.
plunger.
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:29 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
tions is required.
electric power.
below:
material.
injector.
NOTE
Generated for jonatthan.gtz@gmail.com on 2013-05-10 19:29 GMT / http://hdl.handle.net/2027/uva.x004830013 Public Domain, Google-digitized / http://www.hathitrust.org/access_use#pd-google
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
CAUTION
Remove Injector
cover.
(Fig. 6).
CAUTION
material.
horizontally.
Cylinder Head
out.
compressed air.
TEST INJECTOR
WARNING
215
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
Movement Test
follows:
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
Stop Pin
CHIPPED AT
LOWER HELIX.
ADVANCED STAGE OF
EROSION CAUSED BY
FOREIGN MATTER IN
FILTRATION.
CAN BE CAUSED BY
AT HIGH SPEEDS OR
WATER IN FUEL.
Plungers
and spring.
J 23010
ADAPTOR
PLATE
STANDARD BODY
INJECTOR
OFFSET BODY
INJECTOR
Clamping Heads
GAGE
PRESS. IN P.S.I.
(OUTER SCALE)
PRESS. IN ATMOSPHERES
(INNER SCALE)
CLEAR DISCHARGE
TUBING
GAGE
REFERENCE
VALUE
DELIVERY
PIPING
ADAPTOR
SEAL
clamping head.
217
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
(Fig. 11).
bracket.
c. Lever 4 up (horizontal)
d. Lever 5 up (horizontal)
(Fig. 12).
NOTE
pressure.
CAUTION
by levers 4 and 5.
Pattern Test
injection begins.
218
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
full-fuel position.
cal position.
tent position.
NOTE
seal ring.
not overtighten.
NOTE
lever 1.
not overtighten.
zontal position.
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
clamping pressure.
up (horizontal) position.
adaptor as follows:
assembly.
Fig. 15.
adaptor J 23010-167.
J 23010-129
on Tester J 23010
220
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
NOTE
tester.
valve seat.
NOTE
tip is permissable.
tor dial.
plunger.
221
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
should be replaced.
J 22410.
Tester J 22640)
(Fig. 17).
(Fig. 18).
(horizontal) position.
system.
NOTE
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
Tester J 22640
tip is permissable.
In calibrator J 22410.
injector components.
223
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
Calibrator J 22410
NOTE
105F (35-40C).
air valve.
NOTE
no-fuel position.
switch.
NOTE
proper pressure.
system.
full-fuel).
224
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
NOTE
reading.
balanced engine.
Injector
Calibrator
J 22410
Min.
Max.
N35
36
41
L40
41
46
N40
42
47
N45
47
52
N50
50
55
C40
42
47
C45
47
52
C50
50
55
5A50
53
58
5A55
56
61
5A60
63
68
N55
53
58
N60
57
62
N65
64
TM 5-3895-346-14
FUEL INJECTOR
Stroke Counter
calibrator.
Disassemble Injector
follows:
CAUTION
ENGINE OVERHAUL
Filter Cap
as an assembly.
assembly.
226
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
Spring
the body.
1 ,1
1"
227
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
(Fig. 27).
CAUTION
i7~\
J'" |i1
/ X An (V)
being buffed.
NOTE
distorted.
orifices.
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
air.
manner.
air.
/ 11
y/
<<v
tion problem.
NOTE
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
NOTE
Troubleshooting.
a 500-grit stone.
1.028 inches.
body.
NOTE
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
during handling.
NOTE
spray tip.
CAUTION
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
time8.
pressed air.
pressed air.
sealing.
FORMER CURRENT
Surface Identification
(Used Parts)
Minimum
Part Name
Thickness
Spray Tip
0.199 inch
(shoulder)
0.163-0.165 inch
Check Valve
0.022 inch
0.602 inch
pressed air.
ASSEMBLE INJECTOR
clean.
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
NOTE
OUTLET
INLET
INLET
STANDARD INJECTOR
OFFSET INJECTOR
FILTER REQUIRED ON
FILTER
CAP
GASKET
FILTER
INJECTOR
BODY
Injector Body
Relative Location
this position.
the gear.
into place.
233
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
BODY
as follows:
J 22396.
CAPTION
CAUTION
J 22396.
234
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
CAUTIOH
separately interchangeable In
first.
CAUTION
sembly is used.
cage.
CAUTION
shorter quill.
(Fig. 41).
crevice.
CAUTION
tor overhaul.
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
NEEDLE VALVE
Nut by Hand
J 4983-01
follows:
236
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
dial.
Injector.
Install Injector
237
TM 5-3895-346-14
FUEL INJECTOR
ENGINE OVERHAUL
follows:
CAPTION
in Specification.
CAUTION
bolts.
20 Nm) torque.
Figure 44. Relationship Between Exhaust Valve Bridge and Valve Stems
238
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL INJECTOR
CAUTION
Leaks).
NOTE
control lever.
239
TM 5-3895-346-14
INJECTOR TUBE
ENGINE OVERHAUL
Injector Tube
Cylinder Head.
head.
(Fig. 2).
240
TM 5-3895-346-14
ENGINE OVERHAUL
INJECTOR TUBE
tube as follows:
(Fig. 3).
below.
injector tube.
CAUTION
the flutes.
follows:
TM 5-3895-346-14
INJECTOR TUBE
ENGINE OVERHAUL
cylinder head.
tor tube:
Fig. 6.
Injector Nut
(Fig. 7).
NOTE
ing instructions.
242
TM 5-3895-346-14
ENGINE OVERHAUL
INJECTOR TUBE
bevel seat.
reaming progress.
compressed air.
243
TM 5-3895-346-14
FUEL PUMP
ENGINE OVERHAUL
FUEL PUMP
line.
be used.
driven shafts.
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL POMP
PLUG PIN
SPRING
DRIVE
GEAR
((((1<(((((H((((1((((I
RELIEF VALVE \
DRIVEN
GEAR
DRIVEN
SHAFT
BODY COVER
DOWEL
A-
8-
C-
D-
PRESSURE SIDE
SUCTION SIDE
Figure 2. Fuel Pump Valving and Rotation (Right Hand Pump Shown)
inner seal.
Operation
TM 5-3895-346-14
FUEL PUMP
ENGINE OVERHAUL
fuel pump.
the pump.
a new coupling.
as follows:
cover.
surface.
only as an assembly.
copper gasket.
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL PUMP
CAUTION
Inspection
only.
necessary.
must be replaced.
in until it bottoms.
TM 5-3895-346-14
FUEL PUMP
ENGINE OVERHAUL
DRIVE GEAR
shown in Fig. 8.
248
TM 5-3895-346-14
ENGINE OVERHAUL
FUEL PUMP
Seal
CAUTION
249
TM 5-3895-346-14
FUEL PUMP
ENGINE OVERHAUL
CAPTION
may result.
pump.
patch bolts.
NOTE
assemblies.
initial starting.
250
TM 5-3895-346-14
ENGINE OVERHAUL
(Bolt-On Type)
CAUTION
injectors.
together.
Operation
251
TM 5-3895-346-14
ENGINE OVERHAUL
INLET
PASSAGE
GASKET
COVER
BOLT
OUTLET
PASSAGE
ELEMENT
SEAT
SPRING
GASKET
COVER
BOLT
PLUG
ELEMENT.
SEAT .
SEAT .
RETAINER
SPRING
SHELL
DRAIN COCK
CAUTION
252
TM 5-3895-346-14
ENGINE OVERHAUL
CAUTION
compressed air.
NOTE
oil.
NOTE
start.
253
TM 5-3895-346-14
ENGINE OVERHAUL
leakage.
filters.
Type)
254
TM 5-3895-346-14
ENGINE OVERHAUL
Filter Replacement
leaks.
255
TM 5-3895-346-14
MECHANICAL GOVERNORS
ENGINE OVERHAUL
MECHANICAL GOVERNORS
injectors.
cal governor.
follows:
fluctuations.
Fuel Injector.
rected as follows:
torque.
TM 5-3895-346-14
ENGINE OVERHAUL
MECHANICAL GOVERNORS
necessary.
governor.
257
TM 5-3895-346-14
ENGINE OVERHAUL
functions:
model.
Operation
tube.
new load.
Adjustment.
258
TM 5-3895-346-14
ENGINE OVERHAUL
Lubrication
retainer.
pressure.
as follows:
stop lever.
weight housing.
tainer in place.
(Fig. 2).
fork.
housing.
TM 5-3895-346-14
ENGINE OVERHAUL
FLAT HEAD
the shaft.
stop lever.
retainer.
NOTE
located.
operating shaft.
operating shaft.
assembly.
Inspection
pressed air.
260
TM 5-3895-346-14
ENGINE OVERHAUL
lubrication.
assembly.
shaft.
PRESS BUSHING
TO DIMENSION SHOWN
Housing
shaft.
the shaft.
TM 5-3895-346-14
ENGINE OVERHAUL
RETAINING RING
WASHER
SPRING
OPERATING
SHAFT
LEVER
OPERATING
SHAFT
FORK
CONTROL
HOUSING
SPEED
CONTROL
LEVER
BEARING
SHIELD
BEARING
VARIABLE
SPEED
SPEED CONTROL
SHAFT ASSY
BOOSTER
SPRING
EYE BOLT
BOOSTER
SPRING
BRACKET
WEIGHT
HOUSING
BEARING
SNAP RINGS
installed.
bracket.
CAUTION
TM 5-3895-346-14
ENGINE OVERHAUL
operating fork.
Install Governor
nor as follows:
balance-shaft gear.
torque.
lines.
263
TM 5-3895-346-14
ENGINE OVERHAUL
head.
levers.
applications.
NOTE
TM 5-3895-346-14
ENGINE OVERHAUL
SPACER
PIN CONTROL
LEVER
CONTROL
TUBE
RETURN
SPRING
BRACKET
BOOT
In-line Engine)
following:
lever.
Inspection
INJECTOR
CONTROL
TUBE
ADJUSTING
SCREW
LOCK NUT
SPRING
INJECTOR RACK
CONTROL LEVER
265
TM 5-3895-346-14
ENGINE OVERHAUL
as follows:
position.
CAUTION
TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
FUEL SYSTEM
SHOP NOTES
the pump.
tale conditions.
267
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
block.
replaced.
pressure test.
TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
imperfections.
container.
period. The piston compresses the Before replacing the injectors, check
burning mixture to excessive tempera- the engine for the cause of preignition
tures and pressures and may eventually to avoid recurrence of the problem,
cause burning of the injector spray Check for oil pullover from the oil
tip, leading to failure of the injec- bath air cleaner, damaged blower hous-
INJECTOR TIMING
is "out of time", the injector rack-to- whether or not the injector rack and
gear timing may be checked without dis- gear are correctly timed. When the
A hole located in the injector body, on will be visible in the hole, indicating
the side opposite the identification that the injector is "in time". If the
269
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
Timing
spray tip.
INJECTOR PLUNGERS
the plunger.
TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
causes.
FUEL LINES
Flexible fuel lines are used to facili- When installing fuel lines, it is recom-
from the fuel tank, and to minimize the only sufficiently to prevent leakage of
effects of any vibration in the fuel; thus flared ends of the fuel
Be sure a restricted fitting of the whether or not all connections are suf-
proper size is used to connect the fuel ficiently tight. If any leaks occur,
return line to the fuel return mani- tighten the connections only enough to
fold. Do not use restricted fittings stop the leak. Also check the filter
271
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
is indicated.
CAUTION
repairs.
TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
NOTE
exists.
shooting) .
Points to Remember
273
TM 5-3895-346-14
TROUBLESHOOTING
ENGINE OVERHAUL
TROUBLESHOOTING
FUEL PUMP
maintenance.
proper order.
power.
fuel system.
fuel tank.
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING
damage.
checked as follows:
275
TM 5-3895-346-14
TROUBLESHOOTING
ENGINE OVERHAUL
Chart 1
Probable Caus*
OF CONTACT
IN INJECTOR
IN SPRAY TIP
SUGGESTED REMEDY
stackup dimension.
opening pressure.
stop.
injector.
purpose.
orifices.
276
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING
Chart 2
Probable Cause
TO SPECIFIED TORQUE
I~
OF CONTACT
7. WORN VALVE
I~
FUEL FITTINGS
IN INJECTOR
SUGGESTED REMEDY
specified torque.
opening pressure.
stackup dimension.
TM 5-3895-346-14
TROUBLESHOOTING
ENGINE OVERHAUL
Chart 3
Probable Cautt
PARTIALLY PLUGGED
ICES ENLARGED
6. CRACKED BUSHING
8. FOREIGN MATT
.RIAL BETWEEN
SUGGESTED REMEDY
1243.
NOTE
ing tested.
assembly.
278
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING
Chart 4
Probable Cause
VALVE QUILL
SPRING
IN INJECTOR
Probable Cause
IN SPRAY TIP
SUGGESTED REMEDY
purpose.
orifices.
279
TM 5-3895-346-14
TROUBLESHOOTING
ENGINE OVERHAUL
Chart 5
Probable Cause
Iz
TO SPECIFIED TORQUE
CLEARANCE
VALVE QUILL
SPRING SEAT
FUEL FITTINGS
IN INJECTOR
seat.
SUGGESTED REMEDY
replaced.
280
TM 5-3895-346-14
ENGINE OVERHAUL
Chart 6
TROUBLESHOOTING
Probable Causa
PARTIALLY PLUGGED
9. CRACKED BUSHING
VALVE QUILL
I~
BUSHING COMBINATION
SUGGESTED REMEDY
J 1243.
NOTE
being tested.
TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
SPECIFICATIONS
THREAD
SIZE
260M BOLTS
TORQUE THREAD
280M OR BETTER
TORQUE
1 - 8 435-443 590-600
1 - 8 580-590 786-800
Grade Identification markings are normally stamped on the heads of the bolts. To
aid identification of the various bolts used in Detroit Diesel engines, refer to
Grade Identification
GM
Number
SAE Grade
Designation
Nominal Size
Diameter
(inch)
Tensile
Strength Min.
(psi)
None
TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
THREAD
TORQUE
TORQUE
APPLICATION
SIZE
(lb ft)
(Nm)
10-12
14-16
20-25
27-34
20-25
27-34
20-28
27-38
12-15
16-20
50-55
68-75
125-135
170-183
65-75
88-102
55-65
75-88
75-85
102-115
283
TM 5-3895-346-14
SERVICE TOOLS
INJECTOR
INJECTOR TUBE
284
TM 5-3895-346-14
FUEL PUMP
MECHANICAL GOVERNOR
285
TM 5-3895-346-14
ENGINE OVERHAUL
efficient combustion.
286
TM 5-3895-346-14
ENGINE OVERHAUL
CAUTION
CAUTION
HOUSING
WASHER
BOLT - 3/8"
16 x 2
SEAL
CAM RING
.CAM PIN
HANDLE
BOLT - 3/8"
16 x 1 - 3/4"
287
TM 5-3895-346-14
ENGINE OVERHAUL
housing.
Inspection
position.
assembled.
housing.
down position.
TM 5-3895-346-14
ENGINE OVERHAUL
follows:
CAUTION
bolts.
position.
Engines)
289
TM 5-3895-346-14
BLOWER
ENGINE OVERHAUL
BLOWER
arrangement.
WARNING
speeds only.
oil leak.
TM 5-3895-346-14
ENGINE OVERHAUL
BLOWER
entire length.
Reaove Blower
cover-to-support seal.
DISASSEMBLE BLOWER
reassembly.
291
TM 5-3895-346-14
BLOWER
ENGINE OVERHAUL
CLAMP
REINFORCEMENT
PLATE
SHAFT
BOLT
292
TM 5-3895-346-14
ENGINE OVERHAUL
BLOWER
blower housing.
Step 9.
blowers.
Inspection
thoroughly.
wear or damage.
installed as follows:
seal sleeve.
washers.
shaft.
the shaft.
the shaft.
NOTE
Assemble Blower
TM 5-3895-346-14
MACHINED COUNTERBORE
'O
O1
Differences
as follows:
follows:
of an arbor press.
NOTE
as follows:
each spring.
zzz
zzzza
!> \
END PLATE
IDENTIFICATION
4 CYL
FRONT
REAR
294
TM 5-3895-346-14
ENGINE OVERHAUL
BLOWER
on each shaft.
CAUTION
blower housing.
in Front-End Plate
Over Rotors
295
TM 5-3895-346-14
BLOWER
ENGINE OVERHAUL
NOTE
shafts.
the gears.
on the shafts.
gears.
Gears
296
TM 5-3895-346-14
ENGINE OVERHAUL
BLOWER
(Fig. 12).
of 0.009 inch.
clearances.
NOTE
Housing Clearance
NOTE
interchangeable.
(Minimum)
TM 5-3895-346-14
BLOWER
ENGINE OVERHAUL
SERRATIONS
4-53
.0075"
.004"
.010"
Clearance
support as follows:
in the support.
pack) in place.
cam in place.
J 5209
Drive Support
298
TM 5-3895-346-14
ENGINE OVERHAUL
BLOWER
IMPORTANT
NOTE
torque.
Install Blower
the blower.
torque.
in place.
0.007 inch.
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
SHOP NOTES
insert.
NOTE
worked.
TOOL HOLDER
J 9533-2
FIXTURE
J 9533-1
UPPER
KNURLED
RING
LOWER
KNURLED
RING
N irj-A
I ,(/'!
II I I ' I
f 1.1/ .'
CUTTING TOOL
J 9533-3
plate.
NOTE
reworked to accommodate a
Step 10.
Fig. 1.
press.
TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
Holder
CAPTION
lubricant.
in Fixture Guide
hole.
301
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
4375
.4365 DIA
1.
.03 R. MAX.
.275 15 \
1 06
285'
DIA."
f - l!o
1 |X
,s
Back Counterbore
NOTE
specified.
Steel Inserts
shaft hole.
plate surface.
302
TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
SPECIFICATIONS
Blower
0.0005
0.0025
Clearances:
0.0030
0.0070
0.0010
0.0030
0.0040
0.0075
0.0060
0.0090
303
TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
THREAD
SIZE
260M BOLTS
TORQUE THREAD
280M OR BETTER
TORQUE
1 - 8 435-443 590-600
1 - 8 580-590 786-800
Grade identification markings are normally stamped on the heads of the bolts. To
aid identification of the various bolts used in Detroit Diesel engines, refer to
Grade Identification
GM
Number
SAE Grade
Designation
Nominal Size
Diameter
(inch)
Tensile
Strength Min.
(psi)
None
GM 255-M
TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
THREAD
APPLICATION SIZE
TORQUE TORQUE
14-18
25-30
25-30
25-30
16-20
16-20
20-24
20-24
20-24
20-25
20-24
54- 59
55- 60
19-24
34-41
34-41
34-41
22-27
22-27
27-33
27-33
27-33
27-34
27-33
73-80
75-81
305
TM 5-3895-346-14
SERVICE TOOLS
BLOWER
Handle J 7079-2
306
TM 5-3895-346-14
ENGINE OVERHAUL
LUBRICATION SYSTEM
LUBRICATION SYSTEM
bypass valve.
crankshaf t.
TM 5-3895-346-14
LUBRICATION SYSTEM
ENGINE OVERHAUL
ROCKER ARM
308
TM 5-3895-346-14
ENGINE OVERHAUL
LUBRICATION SYSTEM
engine life.
oil seal.
dipstick.
accessories.
4-53 LEFT-REAR
4-53 RIGHT-FRONT
Locations
TM 5-3895-346-14
OIL POMP
ENGINE OVERHAUL
Operation
ENGINE
engine.
lined below.
cover.
310
ENGINE OVERHAUL
TM 5-3895-346-14
OIL PUMP
cover.
ceed as follows:
Inspection
of time.
stone.
TM 5-3895-346-14
OIL POMP
ENGINE OVERHAUL
one position.
CAUTION
ENGINE OVERHAUL
TM 5-3895-346-14
OIL PUMP
313
TM 5-3895-346-14
OIL PUMP
ENGINE OVERHAUL
Gear
Drive Gear
(Lower).
CAUTION
314
TM 5-3895-346-14
ENGINE OVERHAUL
TABLE 1
Valve Opening
Pressure
Engine
Front Cover
psi
kPa
In-line
Former
78
538
Current
51
352
and inspected.
Inspection
TM 5-3895-346-14
OIL FILTERS
ENGINE OVERHAUL
cooler.
clogged.
changed.
TM 5-3895-346-14
ENGINE OVERHAUL
OIL FILTERS
(Fig. 2) as follows:
NOTE
seal.
adaptor or base.
filter shell.
CAUTION
318
OIL FILTERS
TM 5-3895-346-14
ENGINE OVERHAUL
TM 5-3895-346-14
ENGINE OVERHAUL
Pressure Regulator.
cooler housing.
position.
cooler core.
gaskets.
TM 5-3895-346-14
ENGINE OVERHAUL
in light oil.
CAUTION
core.
WARNING
CAUTION
TM 5-3895-346-14
ENGINE OVERHAUL
CAUTION
cooler housing.
the clamps.
engine).
proper level.
CLAMPS
321
TM 5-3895-346-14
ENGINE OVERHAUL
on a grade.
OIL PAN
DIPSTICK
Mounting
322
TM 5-3895-346-14
ENGINE OVERHAUL
OIL PAN
OIL PAN
engine is removed.
generally apply.
the oil.
completely.
compressed air.
surface.
NOTE
TM 5-3895-346-14
OIL PAH
ENGINE OVERHAUL
324
TM 5-3895-346-14
ENGINE OVERHAUL
VENTILATING SYSTEM
VENTILATING SYSTEM
ventilating system.
Service
325
TM 5-3895-346-14
VENTILATING SYSTEM
observed.
ENGINE OVERHAUL
326
TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
260M
BOLTS
280M OR
BETTER
THREAD
TORQUE
THREAD
TORQUE
SIZE
(lb ft)
(Nm)
SIZE
(lb ft)
(Nm)
1/4 -20
5-7
7- 9
1/4 -20
7-9
10-12
8-11
11-14
14-18
18-23
5/16-24
11-14
15-19
20-26
3/8 -16
31-35
41-47
35-40
47-53
47-51
62-68
58-62
77-83
72-76
96-102
1/2 -20
62-70
84-95
1/2 -20
83-93
113-126
92-102
122-136
109-119
146-159
140-149
186-200
171-181
228-242
244-254
325-339
295-305
393-407
417-427
556-569
483-494
644-657
590-600
786-800
697-705
928-942
TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
328
TM 5-3895-346-14
SERVICE TOOLS
329
TM 5-3895-346-14
COOLING SYSTEM
ENGINE OVERHAUL
COOLING SYSTEM
BY-PASS RETURN
WHILE THERMOSTAT.
IS CLOSED
WATER IN
330
TM 5-3895-346-14
ENGINE OVERHAUL
ENGINE COOLING
Engine Coolant
recommendations.
amount required.
TABLE 1
(BASIC ENGINE)
ENGINE
CAPACITY
GALLONS
LITRES
4-53
2-1/4
8.5
COOLING SYSTEM
SYSTEM MAINTENANCE
Engine Coolant.
TM 5-3895-346-14
COOLING SYSTEM
ENGINE OVERHAUL
CAUTION
the water.
TABLE 2
Engine
Oil Cooler
or
Side of Block
Opposite Oil
Coolant Inlet
Side of Block
Cooler or
Coolant Inlet
4-53
Bottom of oil
cooler, cool-
lant inlet,
and behind
blower drive
or governor
near rear of
block
Behind blower
drive Or gover-
of block
Flushing
TM 5-3895-346-14
ENGINE OVERHAUL
COOLING SYSTEM
follows:
cap.
engine.
in the hose.
CAUTION
radiator.
follows:
water pump.
airblasts.
operation.
TM 5-3895-346-14
COOLING SYSTEM
ENGINE OVERHAUL
parts.
flushed as follows:
COOLING SYSTEM
of water.
Calgon solution.
clean water.
completely.
LUBRICATION SYSTEM
equivalent, is recommended.
WARNING
clean water.
TM 5-3895-346-14
ENGINE OVERHAUL
COOLING SYSTEM
the fluid.
operation.
CAUTION
to service.
335
TM 5-3895-346-14
WATER PUMP
ENGINE OVERHAUL
WATER
and radiator.
required.
POMP
belts.
NOTE
Disassemble Pump
the gasket.
336
TM 5-3895-346-14
ENGINE OVERHAUL
HATER PUMP
remover J 1930.
CADTIOM
Inspection
air.
DRIFT
CAUTION
cloth.
indications of damage.
Assemble Pump
the body.
337
TM 5-3895-346-14
HATER PUMP
ENGINE OVERHAUL
TOOL
'J 1930
SHAFT
ASSEMBLY
CAUTION
particles.
338
TM 5-3895-346-14
ENGINE OVERHAUL
WATER POMP
the shaft.
of the seal.
lockwashers.
NOTE
leaks.
339
TM 5-3895-346-14
ENGINE OVERHAUL
(Fig. 1).
Inspection
bearing.
0.6252 inch.
. SLEEVE
340
TM 5-3895-346-14
ENGINE OVERHAUL
0.160 inch.
SHAFT AND
BEARING ASSY.
.SLEEVE
PULLEY
lockwashers.
belts.
341
TM 5-3895-346-14
THERMOSTAT
ENGINE OVERHAUL
is automatically controlled by a
engines.
Remove Thermostat
valves.
heat exchanger.
Inspection
PLUG
HOUSING
OUTLET ELBOW
BYPASS TUBE
COVER PLATE
GASKET
342
TM 5-3895-346-14
ENGINE OVERHAUL
THERMOSTAT
Install Thermostat
thermostat as follows:
IN-LINE ENGINE:
thermostat housing.
housing.
leaks.
190-192F(88-89C).
A - STARTS TO OPEN
B - FULLY OPEN
Operation
Housing o.
TM 5-3895-346-14
RADIATOR
ENGINE OVERHAUL
RADIATOR
Coolant Specifications).
(In-Line Engine)
Maintenance.
overheating.
are apparent.
Cleaning Radiator
TM 5-3895-346-14
ENGINE OVERHAUL
RADIATOR
WARNING
cleaning spray.
CAUTION
water pressure.
clean water.
fully.
NOTE
TM 5-3895-346-14
ENGINE OVERHAUL
WARNING
liquid.
346
TM 5-3895-346-14
ENGINE OVERHAUL
serviced.
(Fig. 7).
LUBRICATION
SHAFT AND
BEARING ASSEMBLY
I7TJ
FAN HUB
(PULLEY)
im
FAN ADJUSTING
BRACKET
Assembly
347
TM 5-3895-346-14
ENGINE OVERHAUL
lubrication.
guards.
CAUTION
bracket as an assembly.
IN-LINE ENGINES
assembly purposes.
bracket.
CAUTION
IN-LINE ENGINES
fan hubcap.
348
TM 5-3895-346-14
ENGINE OVERHAUL
assembly.
4-53 ENGINES:
Fig. 6 is used.
assembly.
SPACER SHIM
FAN ADJUSTING
BRACKET
BRACKET
Assembly
INSPECTION
compressed air.
CAUTION
cloth.
TM 5-3895-346-14
ENGINE OVERHAUL
1.7299 inches.
(PULLEY) BRACKET
Figure 8. Typical Fan Hub and Adjusting Bracket Details and Relative Location of
350
TM 5-3895-346-14
ENGINE OVERHAUL
NOTE
assembly.
area.
pulleys.
shaft pulley.
used together.
EXAMPLE
cap.
TM 5-3895-346-14
ENGINE OVERHAUL
IN-LINE ENGINES
lubrication.
IN-LINE ENGINES
in Fig. 5 as follows:
(pulley).
hub.
baffle.
TM 5-3895-346-14
ENGINE OVERHAUL
CAPTION
Do not overgrease
pulley hub.
of the hub.
shaft.
installed.
353
TM 5-3895-346-14
ENGINE OVERHAUL
COOLANT FILTER
parts.
Conditioner (Canister-Type)
CONDITIONER
preventive.
them.
Filter Installation
the filter.
Conditioner (Spin-On-Type)
354
TM 5-3895-346-14
ENGINE OVERHAUL
Filter Maintenance
Conditioner (Clamp-On-Type)
Service
can.
grip pliers.
2. Canister-Type Element:
drain.
355
TM 5-3895-346-14
ENGINE OVERHAUL
3. Spin-On-Type Element:
filter cover.
leakproof seal.
4. Clamp-On-Type Element:
coolant loss.
356
TM 5-3895-346-14
ENGINE OVERHAUL
SHOP NOTES
COOLANT SYSTEM
SHOP NOTES
used together.
serviced.
to bind.
DIM.
.500"
.800"
.18"
2.053"
FORMER SPACER
DIM.
.560"
.800"
.18"-
200'
ALLOWABLE
REWORK
.100"
.200"
2.055"
2.053"
2J053" ,
NEW SPACER
300'
Wa
-.340"
2.055"
2.053"
RADIUS
.160"
390"
357
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
the fan.
NOTE
the bearings.
hubcap.
maintenance schedule.
2 GROOVE PULLEY
3 GROOVE PULLEY
FAN HUB
CAP
DRILL AND
GREASE
FITTING
FAN HUB
<{. OF
PULLEY
ZZZZ)
LOCATION OF FITTING
ON 3-GROOVE PULLEYS
358
TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
SPECIFICATIONS
260M
BOLTS
280M OR
BETTER
THREAD
TORQUE
THREAD
TORQUE
SIZE
(lb ft)
(Nm)
SIZE
(lb ft)
(Nm)
7- 9
10-12
8-11
11-14
14-18
18-23
15-19
20-26
31-35
41-47
35-40
47-53
47-51
62-68
58-62
77-83
72-76
96-102
84-95
113-126
92-102
122-136
109-119
146-159
140-149
186-200
171-181
228-242
244-254
325-339
295-305
393-407
417-427
556-569
483-494
644-657
590-600
786-800
697-705
928-942
Grade identification markings are normally stamped on the heads of the bolts. To
aid identification of the various bolts used in Detroit Diesel engines, refer to
Grade Identification
GM
Number
SAE Grade
Designation
Nominal Size
TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
360
TM 5-3895-346-14
SERVICE TOOLS
Handle J 7092-2
Installer J 22091
Puller J 24420
361
TM 5-3895-346-14
EXHAUST SYSTEM
ENGINE OVERHAUL
EXHAUST SYSTEM
manifold.
cylinder head.
362
TM 5-3895-346-14
ENGINE OVERHAUL
EXHAUST MANIFOLDS
EXHAUST MANIFOLD
plug assembly.
Exhaust Manifold
flange.
manifold.
Inspection
363
TM 5-3895-346-14
EXHAUST MANIFOLDS
ENGINE OVERHAUL
height).
cylinder head.
lockwashers.
364
TM 5-3895-346-14
ENGINE OVERHAUL
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
wiring.
365
TM 5-3895-346-14
alternator.
ADJUSTING
STRAP
ALTERNATOR MOUNTING
BRACKET
specific application.
eliminated.
NOTE
Ml6X1 thread.
adjustment procedure.
Alternator Maintenance
TM 5-3895-346-14
ENGINE OVERHAUL
BATTERY-CHARGING ALTERNATOR
CAPTION
adjusting slot.
Reaove Alternator
reinstallation.
drive belts.
replaced.
Alternator Service
Install Alternator
Retaining Nut
NOTE
proper torque.
frame.
TM 5-3895-346-14
BATTERY-CHARGING ALTERNATOR
ENGINE OVERHAUL
ALTERNATOR PRECAUTIONS
easily destroyed.
used.
positive).
battery output.
alternator.
is correctly installed.
368
TM 5-3895-346-14
ENGINE OVERHAUL
REGULATOR
REGULATOR
AC CHARGING CIRCUIT
NOT interchangeable.
relay.
relay.
designated as Circuit A.
CAUTION
to interchange regulators.
two units.
Operation
speed.
TM 5-3895-346-14
REGULATOR
ENGINE OVERHAUL
load.
CONTROL RELAY
Operation
TM 5-3895-346-14
ENGINE OVERHAUL
REGULATOR
TRANSISTORIZED REGULATOR
system.
bolthole.
CAUTION
coil.
Operation
371
TM 5-3895-346-14
REGULATOR
ENGINE OVERHAUL
contacts.
CAUTION
generator.
TRANSISTOR REGULATOR
charging circuit.
is closed.
TM 5-3895-346-14
ENGINE OVERHAUL
REGULATOR
REGULATOR PRECAUTIONS
the circuit.
373
TM 5-3895-346-14
resistance.
374
TM 5-3895-346-14
ENGINE OVERHAUL
STORAGE BATTERY
STORAGE BATTERY
Function of Battery
generator.
Types of Batteries
today.
NOTE
Install Battery
early failure.
when installed.
crack.
TM 5-3895-346-14
STORAGE BATTERY
ENGINE OVERHAUL
failure.
edly.
been.
ventilation is poor.
WARNING
376
TM 5-3895-346-14
ENGINE OVERHAUL
STARTING MOTOR
STARTING MOTOR
material.
FLYWHEEL
HOUSING
follows:
(In-Line Engines)
COMMUTATOR
END FRAME
NKAGE
SHIFT LEVER
LEVER HOUSING
NOSE HOUSING
GROUNDED
BRUSH HOLDER
INSULATED
BRUSH HOLDER
COMMUTATOR / ARMATURE
ATTACHING
BOLT
BRONZE
TM 5-3895-346-14
STARTING MOTOR
ENGINE OVERHAUL
end frame.
bolts.
wrench.
required position.
CAUTION
11-15 lb ft torque.
Lubrication
Maintenance).
starting motor.
TM 5-3895-346-14
ENGINE OVERHAUL
STARTING MOTOR
handbook.
to 20-25 lb ft torque.
379
TM 5-3895-346-14
INSTRUMENTS
ENGINE OVERHAUL
a separate panel.
engine.
GAGE / PANEL
OIL
PRESSURE
GAGE
the mount.
TM 5-3895-346-14
ENGINE OVERHAUL
INSTRUMENTS
Ammeter
speed is reduced.
Tachometer
Throttle Control
solenoid current.
NOTE
(4-5.5 Nm).
TM 5-3895-346-14
INSTRUMENTS
the engine.
TACHOMETER
ENGINE OVERHAUL
is started again.
DRIVE
slide hammer.
CAUTION
382
TM 5-3895-346-14
ENGINE OVERHAUL
MANUAL SHUTDOWN
mechanism.
Operation
Service
Housing.
383
TM 5-3895-346-14
SHOP NOTES
ENGINE OVERHAUL
contacts.
engine is made.
Shaft Alignment
384
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING
generator-regulator operation.
regulator operation.
components.
tor setting.
385
TM 5-3895-346-14
SPECIFICATIONS
ENGINE OVERHAUL
SPECIFICATIONS
260M
BOLTS
280M OR
BETTER
THREAD
TORQUE
THREAD
TORQUE
SIZE
(lb ft)
(Nm)
SIZE
(lb ft)
(Nm)
7- 9
10-12
8-11
11-14
14-18
18-23
15-19
20-26
31-35
41-47
35-40
47-53
47-51
62-68
58-62
77-83
72-76
96-102
84-95
113-126
92-102
122-136
109-119
146-159
140-149
186-200
171-181
228-242
244-254
325-339
3/4 -16
295-305
393-407
417-427
7/8 - 9
556-569
483-494
644-657
590-600
786-800
697-705
928-942
Grade identification markings are normally stamped on the heads of the bolts. To
aid identification of the various bolts used in Detroit Diesel engines, refer to
Grade Identification
GM
Number
SAE Grade
TM 5-3895-346-14
ENGINE OVERHAUL
SPECIFICATIONS
APPLICATION
THREAD
TORQUE
TORQUE
SIZE
(lb ft)
(Nm)
7/16 -14
30-35
41-47
30-35
41-47
20-25
27-34
55-65
75-88
SERVICE TOOLS
TOOL NAME
TOOL NO.
387
TM 5-3895-346-14
ENGINE OVERHAUL
Lubrication System
2200 rpm
2500 rpm
2800 rpm
40-60
40-60
32
32
Air System
200-235
205-240
4.8
6.1
8.0
9.3
23.0
25.0
14.0
16.0
8.7
10.0
0.8
0.9
1.0
1.2
1.3
max.:
t 4.0
+ 4.0
Fuel System
2.1
t 2.7
++ 2.7
45-70
45-70
35
35
0.6
0.6
6.0
6.0
Cooling System
12.0
12.0
160-185
160-185
170-195
170-195
. t 5.0
t 5.0
TM 5-3895-346-14
ENGINE OVERHAUL
Compression
the oil pan at the oil pump inlet. When measuring the oil temperature at the
cylinder block oil gallery, it will be 10 lower than the oil pan temperature.
389
TM 5-3895-346-14
later date.
run-in.
Time Minutes
Speed RPM
Injector Size
4-53
NA
10
600
All
10
1500
All
20
5A50
5A55
10
Rated
Speed
5A60
N-65
5N65*
5A50
5A55
10
TM 5-3895-346-14
ENGINE OVERHAUL i
RUN-IN INSTRUCTIONS
thermostats.
comparison purposes.
Dynamometer
required.
following formula:
BHP - (T x RPM)/5250
Where
T = torque in lb ft or Nm
TM 5-3895-346-14
RUN-IN INSTRUCTIONS
ENGINE OVERHAUL
air box.
case .
inlet.
inlet passage.
charger.
helpful.
CAUTION
it is of extreme importance to
Operations.
Run-in Procedure
Test Report.
A. PRESTARTING
in Chapter II Operations.
Operations.
TM 5-3895-346-14
ENGINE OVERHAUL
RUN-IN INSTRUCTIONS
dynamometer resistance.
are no leaks.
power.
run-in.
TM 5-3895-346-14
ENGINE OVERHAUL
RUN-IN INSTRUCTIONS
E. FINAL RUN-IN
the installation.
started anew.
observed.
specified range.
Specifications.
of mercury.
TM 5-3895-346-14
ENGINE OVERHAUL
RUN-IN INSTRUCTIONS
and ducting.
Report.
adjustment.
TM 5-3895-346-14
RUN-IN INSTRUCTIONS
ENGINE OVERHAUL
Date.
Unit Number
Model Number.
PRIME LUBE
OIL SYSTEM
PRIME FUEL
SYSTEM
3. ADJUST VALVES
TIME
4" INJ.
ADJ.
3< GOV.
ADJUST INJ.
6- RACKS
PRE-STARTING
TIME
AT
TIME
WATER
TEMP.
LUBE
OIL
PRESS.
RPM
BHP
SPEED
START
STOP
6.
6.
FINAL RUN-IN
TIME
TOP RPM
FULL LOAD
EXHAUST BACK
PRESSURE F/L
CRANKCASE
PRESSURE F/L
BHP
START
STOP
NO LOAD
FULL LOAD
BLOWER INTAKE
RES. - F/L
WATER TEMP.
FULL LOAD
LUBE OIL
TM 5-3895-346-14
ENGINE OVERHAUL
GENERAL CONSIDERATIONS
NOTE
this practice.
Specification or
VV-F-
ASTM
VV-F-
ASTM
Classification Grade
800
D-975
800
D-975
DF-1
1-D
DF-2
2-D
104F
100F
122F
125F
40C
38C
50C
52C
0.15
0.15
0.20
0.35
residuum), % max.
TM 5-3895-346-14
ENGINE OVERHAUL
in this specification.
operator.
wax crystals.
TM 5-3895-346-14
ENGINE OVERHAUL
Final
Typical
Application
General Fuel
Classification
Boiling
Cetane
No.
Sulfur
Content
Point
(Max)
(Min)
(Max)
City Buses
No. 1-D
550F
45
0.30%
(288C)
All Other
Applications
675F
675F
(357C)
45
40
0.50%
0.50%
deposits.
it is continuously contaminated by
TM 5-3895-346-14
ENGINE OVERHAUL
available.
RECOMMENDATION
by weight Is allowed.
supplier.
be approved.
API Letter
Code Service
Military
SAE
Class.
Specification
Grade
CB
MIL-L-2104A
TM 5-3895-346-14
ENGINE OVERHAUL
SYNTHETIC OILS
ring conditions.
scuffing.
deposits.
401
TM 5-3895-346-14
OIL
systems.
NOTE
complete descriptions:
intervals.
Aspirated Engines
791a.
CLASSIFICATION SYSTEM
API CODE
LETTERS
CA
MIL-L-2104A
CB
Supplement 1
CC
CD
MIL-L-45199B (Series B)
TM 5-3895-346-14
ENGINE OVERHAUL
laboratories.
D-2161).
NOTE
oil.
Full-Flow Filters
By-Pass Filters
LUBRICANT ADDITIVES
TM 5-3895-346-14
ENGINE OVERHAUL
NOTE
thereafter.
404
TM 5-3895-346-14
ENGINE OVERHAUL
COOLANT SPECIFICATIONS
COOLANT
properly maintained.
COOLANT REQUIREMENTS
transfer.
2. Provide a corrosion-resistant
coolant.
WATER
deposits.
CORROSION INHIBITORS
TM 5-3895-346-14
TABLE 1
PARTS PER
GRAINS PER
MILLION
GALLON
Chlorides iMaximum!
40
2.5
Sulfates iMaximumi
100
S.K
MO
20
170
10
coolant solution.
TABLE 2
In The Water
And
And
Determ
Hardness 0
ne Total
f The Water
Or
ar
Distill. De-mineralize
Total Hardness
Total Hardness
Soften
The Water
Use in Coolant
Plus Inhibitors
Use In Coolant
Pius Inhibitors
TM 5-3895-346-14
ENGINE OVERHAUL
COOLANT SPECIFICATIONS
INHIBITOR SYSTEMS
Inhibitor or
Inhibitor System
Sodium chromate
Potassium dichromate
S-453 (Spin-on)
S-373 (Spin-on)
S-473 (Spin-on)
DCA (canister)
DCA (Spin-on)
AC filter elements:
DCA (canister)
DCA (Spin-on)
LW-4739 (canister)
LFW-4744 (spin-on)
Sy-Cool (liquid)
Lubercool (liquid)
(liquid)
(liquid)
Aqua-Tane (liquid)
Corrosion
Inhibitor
Type
Chromate
Chromate
Chromate
Chromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Nonchromate
Inhibitor Compatability
Complete Ethylene
Inhibitor Glycol
Base
TM 5-3895-346-14
COOLANT SPECIFICATIONS
ENGINE OVERHAUL
deposit.
solutions.
ANTIFREEZE
TM 5-3895-346-14
ENGINE OVERHAUL
COOLANT SPECIFICATIONS
320
300
280
260
240
220
T 200
^ 180
E 160
A 140
U '20
E 100
'Fl
80
60
40
20
-20
-40
-60
-80
-90
-100
^"
BOILING POINTS
- FR
EEZI
NG P
OIN"
RECOMMENDED
:ONCENTRATION
RANGE 30-67%
|g
160
149
138
127
116
104
93 T
82 M
71 E
60 A
49 u
TM 5-3895-346-14
COOLANT SPECIFICATIONS
ENGINE OVERHAUL
antifreeze.
410
TM 5-3895-346-14
ENGINE OVERHAUL
ENGINE TUNEUP
parts.
4. Hydraulic.
engine is started.
NOTE
If a supplementary governing
TM 5-3895-346-14
ENGINE TUNEUP
clearance.
control levers.
ENGINE OVERHAUL
412
TM 5-3895-346-14
ENGINE OVERHAUL
ENGINE TUNEUP
3. Camshaft timing.
model year.
built.
Year
1970
1971
1972
1973
Engines
4-53N
4-53N
4-53N
4-53N
Injectors
N40
N45
N50
N40
N45
N50
N40
N45
N50
C40
C45
C50
Maximum Full-load
Engine Speed t
2800
2800
2800
2800'
Camshaft Timing
Adv.
Adv.
Adv.
Adv.
1.460 inches
1.460 inches
1.460 inches
TM 5-3895-346-14
ENGINE TUNEUP
ENGINE OVERHAUL
Year
1974
1975
1976
Engines
4-53N
4-53N
4-53N
Injectors
C40
C40
C40
C45
C45
C45
C50
C50
C50
2800
2800
2800
Camshaft Timing
Adv.
Adv.
Adv.
Injector Timingt
1.470 inches
1.470 inches
1.470 inches
Timing Gage
J 24236
J 24236
J 24236
Throttle Delay
Yes*
Yesf
Yesf
Yield Link
Yes
Yes
Yes
*No-Load engine speed will vary with injector size and governor type.
TThe adjusted height of the fuel injector follower in relation to the injector
body.
$0,250 inch diameter fill hole 0.016 inch diameter discharge orifice.
414
TM 5-3895-346-14
ENGINE OVERHAUL
ENGINE TUNEDP
Engine
4-53N
(a) Injectors
C40
C45
C50
2800
2800 (C40)
2400 (C45)
2500 (C50)
Adv.
Injector Timing
1.470 inches
Timing Gage
J 24236
Throttle
(e)
Yield Link
Yes
Setting
0.454 inch
Compression Ratio
0.840 inch
21:1
2.487:1
Governor Type
Limiting Speed
Thermostat
170-180F(77-82C)
(a) Not to exceed injector size and maximum operating speed that has been
established. No-load speed will vary with injector size and governor type.
(e) Large fill hole (0.250 inch dia.) 0.016-inch discharge orifice. Use a minimum
415
TM 5-3895-346-14
ENGINE TDNEUP
ENGINE OVERHAUL
AUTOMOTIVE CONFIGURATIONS
AUTOMOTIVE CONFIGURATIONS
Engine
Families
4-53TC
Engine Families
4L-53N
Injectors (a)
5A55
5A60
Injectors (a)
C40
C45
C50
APPROVED CONSTANT
APPROVED CONSTANT
MAXIMUM (b)
2500
MAXIMUM FULL
2800
MINIMUM FULL
LOAD SPEED
2500
MINIMUM FULL
LOAD SPEED
2400
CAMSHAFT
LOBE POSITION
CAMSHAFT
LOBE POSITION
STD
ADV.
INJECTOR
TIMING
5A55-1-496
5A60-1-508
INJECTOR
TIMING
1.470
THROTTLE DELAY
YIELD LINK
Fuel
THROTTLE DELAY
YIELD LINK
(e)
REQ
Modulator
TURBOCHARGER
A/R
T04B98
96
TURBOCHARGER
A/R
3LM353
(a) Not to exceed injector size and maximum operating speed that has been
established. No-load speed will vary with injector size and governor type.
(b) No-load engine speed will vary with injector size and governor type,
(e) Large fill hole (0.250 inch dia.) 0.016-inch discharge orifice.
to
UJ
<
DC
LU
01
in a
in id
<<
m in
as
00 CC
en it
CD <
in
cn
II
_j rr
(O 10
in
co to
aa
in in
CM
cn
Cn
co
<
II
If
13
LL V
-i
5 _i
I- CO
tr
f.
<
0)
CD
cjnr
(0
.o
h-
HZ
Q_ .
11
CO z
TM 5-3895-346-14
ENGINE OVERHAUL
started.
(Cold Engine)
cover.
CAUTION
gage.
wrench.
(Four-Valve Head)
TM 5-3895-346-14
ENGINE OVERHAUL
above .
necessary.
Adjustment
clearance.
rod.
419
TM 5-3895-346-14
ENGINE OVERHAUL
injector body.
order.
follows:
CAUTION
loosened.
Tuneup).
420
TM 5-3895-346-14
ENGINE OVERHAUL
TABLE 1
Timing
Timing
Camshaft
Injector
Dimension
Gage
Timing
Engine
40
1.484 inches
J 1242
Standard
53
45
1.484 inches
J 1242
Standard
53
S40
1.460 inches
J 1853
Standard
53
S45
1.460 inches
J 1853
Standard
53
N35
1.460 inches
J 1853
N40
1.460 inches
J 1853
Standard
53N
N45
1.460 inches
J 1853
Standard
53N
N50
1.460 inches
J 1853
Standard
53N
421
TM 5-3895-346-14
ENGINE OVERHAUL
control levers.
outer locknut.
2).
the adjustment.
NOTE
load .
Eyebolt
422
TM 5-3895-346-14
ENGINE OVERHAUL
remaining levers.
stop lever.
control tube.
adjustment.
423
TM 5-3895-346-14
ENGINE OVERHAUL
justing screws.
CAUTION
control levers.
applications.
CAUTION
obtained.
424
TM 5-3895-346-14
ENGINE OVERHAUL
Engine Speed
CAUTION
screw setting.
adjustment.
CAUTION
as in Step 3.
425
TM 5-3895-346-14
ENGINE OVERHAUL
speed position.
NOTE
readjusted.
426
TM 5-3895-346-14
ENGINE OVERHAUL
PREVENTIVE MAINTENANCE
ENGINE
as possible to obtain long life and best performance from a Detroit Diesel
engine. The intervals indicated on the chart are time or miles (in thou-
The time or mileage increments shown apply only to the maintenance func-
and not to a new engine or one that has not been operated for a consider-
able period of time. For new or stored engines, carry out the instructions
427
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
DAILY
1.
Lubricating Oil
2.
Fuel Tank
3.
Fuel Lines
4.
Cooling System
EMISSION CONTROL
MAINTENANCE
5.
Battery
6.
Tachometer Drive
SERVICE
CHART'
(VEHICLE 1
3NGIN1
SS)
8.
Drive Belts
9.
Throttle Control
15,000 MILE
INTERVALS
(2.)
Fuel Tank
25,000 MILE
INTERVALS
10.
6 MOl
RI
IS OR 10,000
MONTHS
12
18
24
30
36
42
48
54
TM 5-3895-346-14
ENGINE OVERHAUL
PREVENTIVE MAINTENANCE
6 MONTHS OR 10,000
MONTHS
12
18
24
30
36
42
48
54
60
MILK INTERVALS
MILES (1000)
10
20
30
40
50
60
70
80
90
100
Mounts
ANNUALLY
(IF NECESSARY)
R = REPLACE
* = SEE ITEM
33. - Fan
AS REQUIRED
429
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
INDUSTRIAL
OFF HIGHWAY
AND MARINE
TIME INTERVALS
HRS.
MILES
DLY.
240
50
1.500
100
3,000
150
4,500
200
6,000
300
9,000
500
15,000
700
20,000
1,000
30,000
2,000
60,000
1. Lubricating Oil
2. - Fuel Tank
3. Fuel Lines
4. Cooling System
5. - Battery
6. Tachometer Drive
7. Air Cleaners
8. - Drive Belts
19. - Radiator
Mounts
TM 5-3895-346-14
ENGINE OVERHAUL
PREVENTIVE MAINTENANCE
CAUTION
crankcase is overfilled.
lines.
Specifications.
NOTE
readily.
sediment.
431
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
tanks.
fuel tank.
treated tank.
system.
rect proportions.
a clean rod.
TM 5-3895-346-14
ENGINE OVERHAUL
PREVENTIVE MAINTENANCE
Item 5 - Battery
manufacturer's recommendations.
Figure 3. Item 6
Dry Type
Spcjifications).
433
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
NOTE
Fan Drive
Two 3/8
inch or
1/2 inch
belts
Alternator/Generator Drive
Model
2 or 3
belts
Single
belt
One
1/2 inch
belt
One Wide
belt
3, 4-53
M 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
Figure 5. Item 8
XXXXXXXXXXXXX or XXXXXXX.
engine.
Figure 6. Item 11
435
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
VEHICLE ENGINES
NONVEHICLE ENGINES
Figure 7. Item 13
periodically.
TM 5-3895-346-14
ENGINE OVERHAUL
PREVENTIVE MAINTENANCE
Figure 8. Item 16
compartment.
CAUTION
charging generator/alternator,
Item 19 - Radiator
'
1 3'
loi 1
Mi
Willi
Figure 9. Item 19
20,000 miles.
Item 22 - Governor
necessary.
437
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
Overspeed Governor
is running.
Clearance
to emission control.
delay.
Item 25 - Alternator
frayed Insulation.
necessary.
Mounts
as necessary.
438
TM 5-3895-346-14
ENGINE OVERHAUL
PREVENTIVE MAINTENANCE
(Engine)).
multipurpose grease.
seal leakage.
service.
Item 33 - Fan
TM 5-3895-346-14
PREVENTIVE MAINTENANCE
ENGINE OVERHAUL
rent housing.
440
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
TROUBLESHOOTING
ENGINE OPERATION
pages.
primarily on:
sion pressure.
of sufficient air.
operating temperature.
valve-rocker cover(s).
engine.
located.
follows:
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
reached.
gage.
NOTE
Pressure
EXAMPLE
and corrected.
action.
TABLE 2
Cylinder
Gage
Reading
psi
kPa
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
injectors.
litres) of fuel.
Step 2.
NOTE
rocker cover.
filler plug.
Troubleshooting.
Crankcase Pressure
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Exhaust-Back Pressure
temperatures.
exhaust system.
pipe plug.
measurement.
pressure.
tube.
Conditions Specifications.
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Conditions Specifications.
the scale.
not impaired.
measurement.
Hg
HEIGHT
OF
COLUMN
HoO
TABLE 3
inch water
0.0735 inches
of
mercury
inch water
0.0361 psi
inch mercury
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 1
Probable Causes
Check For
FUEL DISTRIBUTION
BLUE SMOKE
Check For
IN CYLINDER (BLOWN
SCAVENGING PERIOD)
WHITE SMOKE
Check For
5. MISFIRING CYLINDERS
446
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Chart 1
SUGGESTED REMEDY
it if necessary.
nor tuneup.
tuneup.
Specifications.
replace as necessary.
Specifications.
447
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 2
HARD STARTING
Probable Causes
LOW COMPRESSION
Check For
OR FAULTY STARTER
INTERNAL SEIZURE
Check For
VISCOSITY
OR FAULTY STARTER
Check For
OR BURNED
OR BROKEN
GASKET LEAKING
CLEARANCE ADJUSTMENT
NO FUEL
Check For
Check For
FAULTY INSTALLATION
FULL-FUEL POSITION
448
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Chart 2
HARD STARTING
SUGGESTED REMEDY
switch.
cause.
corroded.
time.
damaged.
necessary.
clearance.
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 3
Probable Causes
'i
UNEVEN RUNNING OR
FREQUENT STALLING
Check For
2. INSUFFICIENT FUEL
3. FAULTY INJECTORS
5. GOVERNOR INSTABILITY
(HUNTING)
LACK OF POWER
1 Check For |
7. INSUFFICIENT FUEL
8. INSUFFICIENT AIR
9. ENGINE APPLICATION
DETONATION
| Check For
450
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Chart 3
SUGGESTED REMEDY
chart.
Fuel chart.
is not satisfactory.
cycle.
faulty injectors.
orifice.
damaged parts.
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
SUGGESTED REMEDY
necessary.
452/(453 blank)
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 4
| Probable Causes
AIR LEAKS
Check For
GASKET
FLOW OBSTRUCTION
Check For |
Check For
FAULTY INSTALLATION
Check For
TEMPERATURE
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
TROUBLESHOOTING (ENGINE)
Chart 4
SUGGESTED REMEDY
tube.
strainer element.
fuel.
seat assembly.
defective parts.
valve assembly.
position.
455
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 5
Probable Causes
EXTERNAL LEAKS
Check For
INTERNAL LEAKS
| Check For
Check For
OR IMPROPERLY INSTALLED
OIL RINGS
456
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Chart 5
SUGGESTED REMEDY
defective parts.
seals.
Pressure chart.
Operation chart.
cooling system.
parts.
defective parts.
angle.
level only.
457
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 6
Probable Causes
CYLINDER BLOW-BY
OR AIR BOX
Check For
1. CYLINDER HEAD
GASKET LEAKING
2. PISTON OR
LINER DAMAGED
3. PISTON RINGS
WORN OR BROKEN
BREATHER RESTRICTION
| Check For
4. OBSTRUCTION OR
DAMAGE TO BREATHER
Check For
5. DAMAGED BLOWER-
TO-BLOCK GASKET
EXCESSIVE EXHAUST
BACK PRESSURE
, L_
Check For
7. EXCESSIVE MUFFLER
RESISTANCE
458
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Chart 6
SUGGESTED REMEDY
breather assembly.
gasket.
obstruction is found.
459
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 7
Probable Causes
LUBRICATING OIL
Check For
1. SUCTION LOSS
POOR CIRCULATION
Check For
3. COOLER CLOGGED
FUNCTIONING PROPERLY
5. PRESSURE REGULATOR
VALVE NOT
FUNCTIONING PROPERLY
PRESSURE GAGE
Check For
8. FAULTY GAGE
OIL PUMP
| Check For
CLOGGED
6. EXCESSIVE WEAR ON
CRANKSHAFT BEARINGS
7. GALLERY, CRANKSHAFT OR
460
TM 5-3895-346-14
ENGINE OVERHAUL
TROUBLESHOOTING (ENGINE)
Chart 7
SUGGESTED REMEDY
viscosity of oil.
cooler core.
parts.
oil filters.
found faulty.
orifice.
electrical equipment.
filters.
parts.
the gasket.
461
TM 5-3895-346-14
TROUBLESHOOTING (ENGINE)
ENGINE OVERHAUL
Chart 8
OPERATING TEMPERATURE
Probable Causes
ABOVE NORMAL
Check For
~~1
BELOW NORMAL
1. INSUFFICIENT HEAT
TRANSFER
Check For
3. IMPROPER CIRCULATION
2. POOR CIRCULATION
4. EXCESSIVE LEAKAGE
AT THERMOSTAT SEAL
SUGGESTED REMEDY
to prevent slippage.
inadequate shrouding.
shutters.
is low.
damaged impeller.
defective parts.
if necessary.
heater.
TM 5-3895-346-14
ENGINE OVERHAUL
STORAGE
STORAGE
no load.
NOTE
pressed air.
of entrapped air.
run.
if used.
TM 5-3895-346-14
STORAGE
ENGINE OVERHAUL
(P10), or equivalent.
minutes.
shell.
IN EXTENDED STORAGE
preventive.
the flywheel.
oil.
Specifications).
TM 5-3895-346-14
HYDROSTATIC SYSTEM
INTRODUCTION
INTRODUCTION
hydrostatic transmissions.
performed.
to implementation.
465
TM 5-3895-346-14
HYDRAULIC CIRCUITS
HYDROSTATIC SYSTEM
HYDRAULIC CIRCUITS
motion.
on the system.
transmission.
466
TM 5-3895-346-14
HYDROSTATIC SYSTEM
HYDRAULIC CIRCUIT^
MANIFOLD
BEARING
PLATE
PISTONS
SHUTTLE
VALVE
HIGH
PRESSURE
RELIEF VALVE
FIXED
SWASHPLATE
CYLINDER
BLOCK
PORT B
CHARGE
PRESSURE
CONTROL VALVE
VALVE
PLATE
PORT A
CHARGE
PUMP
CYLINDER
BLOCK
REVERSIBLE
SWASHPLATE
PISTON
END CAP
PORT B
SERVO
CYLINDER
SERVO
PISTON
Figure 1.
467
468
TM 5-3895-346-14
HYDRAULIC CIRCUITS
HYDROSTATIC SYSTEM
TM 5-3895-346-14
HYDROSTATIC SYSTEM
HYDRAULIC CIRCUITS
leakage makeup.
main circuit.
application of load.
COOLING CIRCUIT
TM 5-3895-346-14
HYDRAULIC CIRCUITS
HYDROSTATIC SYSTEM
auaasd
3UnSS3d 3SV0
3UnSS3bd "IaU1NO0
no Nouons
3UnSS3tld HDIH
3UnSS3Ud 30dVH3
idVHS ndno
uoiovm
. !N3W3DVTdSia Q3Xld
dwnd
N3lftl33VldSia
318ISbl3A3H
-Sy Haa3d33W
472
TM 5-3895-346-14
HYDRAULIC CIRCUITS
HYDROSTATIC SYSTEM
so
eo u
mU
0> H
00 J
o-i 5
m2
><
l-l
<
9 aangjj
3df>SS3dd 3SV0
3dflSS3dd "ladlNOO
no Naiions
3HnSS3Bd HOIH
3dflSS3dd 30UVH3
aUVaHOd :N0lllS0d
3H0NVH
noHiNoo ^
dwnd
lN3W30VldSia
3T8ISd3A3d
CI
474
TM 5-3895-346-14
HYDRAULIC CIRCUITS
HYDROSTATIC SYSTEM
TM 5-3895-346-14
HYDROSTATIC SYSTEM
CONTROLS
CONTROLS
effort.
angle.
swashplate to neutral.
pressure.
476
CONTROLS
TM 5-3895-346-14
HYDROSTATIC SYSTEM
477
CONTROLS
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TM 5-3895-346-14
CONTROLS
HYDROSTATIC SYSTEM
port (F).
decrease.
override pressure.
(load).
478
479
CONTROLS
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TM 5-3895-346-14
HYDROSTATIC SYSTEM
below.
COMPLEMENTARY COMPONENTS
the system.
ITEM 2)
contamination.
TM 5-3895-346-14
HYDROSTATIC SYSTEM
1. RESERVOIR
2. SHUT-OFF VALVE
3. FILTER
6. INLET LINE
481
TM 5-3895-346-14
HYDROSTATIC SYSTEM
is required.
ing conditions.
Item 3).
HYDRAULIC FLUID
Transmission Startup,
9 AND 11)
ing limits.
482
TM 5-3895-346-14
HYDROSTATIC SYSTEM
HZ
'Z M
M CQ
2P
MW
Z C/5
Hd
as
HZ
a! o
OH
Ou H
CO
EH
MN
OS H
H co
C/i
as
00 T3
J- (3
ma
<o o
Cu i-l
4J
o at bo
UH C
r-I i-t
tt) w S
im co g
U CI H
K H Oi
to
co
r-1 M
H CU
< Crt
>
<u
to
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MZ
ZM
ap
HH
dE
a cu z
oz
Hd
zu
co
CL,
OS
CM
HZ
dM
Cm H
CJ
HE
E2
MU
C/>
WE
MN
OS H
Ed CO
CO
CO
in
00
CM CM
d CM
CM CM CM
-a
CO
CO
X!
CO
po
NO
>
NO
cn
IsM
Nd.
SERIES
SIZE
INLEa Psa
CdNNECTIaN
CAaE Psa
CdNNECaIdN
HIGH PRES.
PONT
CdNNECaIaN
MINIMUM
HdSE ID
MINIMUM
TUBING dD
REMARKS
12.
Fillcap
Bdeathed
(Nesedvoid)
13. All
Heat Sedies
Exchanged
Bypass
Valve
at appdoximately
15 psi
TM 5-3895-346-14
TRANSMISSION STARTUP
HYDROSTATIC SYSTEM
TRANSMISSION STARTUP
PROCEDURE
Recommendations).
filled by hand.
Engine: (Diesel)
Troubleshooting.)
CAUTION
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TRANSMISSION STARTUP
approximately 5 minutes.
Troubleshooting.)
NOTE
4-cubic-inches/rev. charge
should be:
487
TM 5-3895-346-14.
FLUID RECOMMENDATIONS
HYDROSTATIC SYSTEM
FLUID RECOMMENDATIONS
HYDROSTATIC TRANSMISSIONS
able supplier.
should include:
Viscosity
Oxidation
Thermal Stability
Shear Stability
Antiwear
Anticorrosion
Antifoam
Elastomers
satisfactory.
Antiwear
Hydraulic
Oil
7000
200
50
130
-30
0-200F
Type-F
3200
212
57.2
208
-40
-15-200F
Hydraulic
Transmission
Oil
12,000
233
49
100 Min.
-35
0-200F
*Pydraul 312
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
TROUBLESHOOTING PROCEDURE
HYDROSTATIC SYSTEM
NOTE
information.
an inoperable transmission.
startup.
pressure gages.
NOTE
489
490
TM 5-3895-346-14
TROUBLESHOOTING
HYDROSTATIC SYSTEM
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
D. GAGE CONNECTION = REDUCER FITTING FROM CASE PORT THREAD SIZE TO GAGE
491
TM 5-3895-346-14
TROUBLESHOOTING
HYDROSTATIC SYSTEM
TROUBLESHOOTING PROCEDURE
CAUSE INDICATED BY
REMEDY
A.
System low on
fluid
B.
Faulty control
linkage
C. Disconnected
coupling
D. Filter or suction
voir to charge
pump plugged or
collapsed
E. Charge pressure
relief valve in
charge pump or
motor manifold
damaged or stuck
open
pressure
charge pressure
pressure
NOTE
If problem is in
in neutral. If in
manifold, pressure
stroke.
slipping or broken.
key or shaft
broken
or when trying to go
into stroke
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
CAUSE
G. Internal damage
to pump or motor
or both
INDICATED BY
rapidly or fall to or
system pressure is
reached
setting
Pieces or flakes of
brass in reservoir or
filter
motor)
REMEDY
ing procedure:
ment motors:
reservoir.
at maximum speed.
493
TM 5-3895-346-14
TROUBLESHOOTING
HYDROSTATIC SYSTEM
CAUSE
INDICATED BY
REMEDY
line.
It is recommended if the
NOTE
lowing formula:
(GPM)
231
be replaced.
Procedure.)
H.
Disconnected
control valve
internal
linkage
J.
Plugged control
orifice
into stroke
494
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
CAUSE
INDICATED BY
REMEDY
K. Rotary bypass
valve, if used,
open (located
on motor manifold
assembly)
L. If pressure over-
ride valve is
used, adjusted
ball missing,
or broken parts
in both directions
than normal
normal
develop pressure
or erratic
CAUTION
fice or O-rings to
case.
setting.
or replace. (Refer to
Repair Procedure.)
CAUSE INDICATED BY
A. Faulty control
linkage
REMEDY
adjustment.
495
TM 5-3895-346-14
TROUBLESHOOTING
HYDROSTATIC SYSTEM
CAUSE
INDICATED BY
B. Faulty high-
pressure relief
valve
faulty
normal
D. Control valve
spool jammed or
sticking in one
direction or
misadjusted
E. Shuttle valve
spool jammed
(located in
motor manifold)
neutral
in one direction
CAUSE
A. Faulty linkage
INDICATED BY
REMEDY
or ball is missing.
NOTE
Repair Procedure.)
REMEDY
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
CAUSE
INDICATED BY
REMEDY
of adjustment
procedure:
centering-spring mechanism.
play.
plugs.
497
498
STEP 2
Figure 3.
TM 5-3895-346-14
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
CAUSE
INDICATED BY
REMEDY
of adjus tment
B.
C.
D.
E.
F.
G.
Fluid cooler
clogged
Fluid in cooler
being bypassed
(Cooler bypass
valve, if used,
stuck open)
Clogged filter
or suction line
Rotary bypass
valve, if used,
partially open
(located on
motor manifold)
Excessive internal
leakage
improperly plumbed
H. Continued opera-
tion at high-
pressure relief
valve setting
charge pressure
motor speed
or both directions
is reached
Loss of acceleration
and power
TM 5-3895-346-14
TROUBLESHOOTING
HYDROSTATIC SYSTEM
CAUSE
INDICATED BY
REMEDY
V. SYSTEM NOISY
A. Air in system
Considerable amount of
foam in reservoir
charge pressure
Spongy control
B. Plumbing not
properly insulated
CAUSE INDICATED BY
A. Air in system
B. Control orifice
plug partially
blocked
C. Rotary bypass
valve, if used,
partially open
(located on
motor manifold)
system pressure
level.
in fluid.
board.
noise.
REMEDY
CAPTION
orifice port.
500
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TROUBLESHOOTING
CAUSE
D. Internal wear or
damage in pump
or motor or both
INDICATED BY
REMEDY
manual.
CAUSE
A. Control pressure
to motor not
connected
B. Displacement
control valve
not adjusted
properly
C. Plugged orifice in
motor control
INDICATED BY
1. Connect line.
the orifice.
CAPTION
501
TM 5-3895-346-14
MAINTENANCE
HYDROSTATIC SYSTEM
SYSTEM MAINTENANCE
conditions.
required.
required.
502
TM 5-3895-346-14
HYDROSTATIC SYSTEM
REPAIR
REPAIR PROCEDURE
REMOVAL
reservoir.
NOTE
to Fig. 1.)
Figure 1.
pump.
NOTE
seal.
RELIEF VALVE
SLOT
INSTALLATION
gasket.
position.
Figure 2.
DRIVE TANG
& SLOT
Figure 3.
503
TM 5-3895-346-14
REPAIR
HYDROSTATIC SYSTEM
(18.98-27.12 Nm).
NOTE
leaks or malfunction.
REMOVAL
NOTE
It is advisable to replace
Figure 5.
Figure 6.
INSTALLATION
504
TM 5-3895-346-14
HYDROSTATIC SYSTEM
REPAIR
NOTE
to Fig. 5.)
Figure 7.
REPLACEMENT OF MANIFOLD
REMOVAL
end cap.
catch oil.
INSTALLATION
Figure 8. Figure 9.
505
TM 5-3895-346-14
REPAIR
HYDROSTATIC SYSTEM
REPLACEMENT OF HIGH
REMOVAL
NOTE
manifold block.
Figure 11.
Figure 10.
INSTALLATION
3. Tighten valve to 20 lb ft
Figure 12.
506
TM 5-3895-346-14
HYDROSTATIC SYSTEM
REPAIR
REPLACEMENT OF DI
REMOVAL
Fig. 13).
pump.
Figure 13.
ffffft**
NOTE
INSTALLATION
valve dry.
NOTE
grease) is advised.
Ml
Figure 14
Figure 15
507
TM 5-3895-346-14
REPAIR
HYDROSTATIC SYSTEM
REMOVAL
Figure 17.
Figure 20.
508
TM 5-3895-346-14
HYDROSTATIC SYSTEM
REPAIR
INSTALLATION
NOTE
parts.
Fig. 20).
Figure 22.
Fig. 23).
out.
Figure 23.
Figure 24.
509
TM 5-3895-346-14
REPAIR
HYDROSTATIC SYSTEM
REMOVAL
trol valve.
pump.
Figure 26.
INSTALLATION
NOTE
valve dry.
Figure 25.
510
TM 5-3895-346-14
HYDROSTATIC SYSTEM
REPAIR
Figure 27.
NOTE
valve.
REMOVAL
cap.
catch oil.
INSTALLATION
O-ring.
511
TM 5-3895-346-14
REPAIR
HYDROSTATIC SYSTEM
BYPASS
VALVE
MANIFOLD
Figure 28.
MOTOR
MANIFOLD
BYPASS
VALVE
Figure 29,
Figure 30.
512
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
warranty.
NOTE
SYSTEM PRESSURE
SHUTTLE VALVE
HIGH PRESSURE
RELIEF VALVE
CARTRIDGE
CHARGE RELIEF
VALVE FOR
FORWARD AND
REVERSE
SHUTTLE VALVE
HIGH PRESSURE
RELIEF VALVE
CARTRIDGE
CHARGE PRESSURE
IN FORWARD AND
REVERSE(NOT
NEUTRAL)
Figure 1,
513
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
Minor Repairs
2. Torque Wrench
Figure 2.
removal.
Figure 3.
Figure 4.
Figure 5.
514
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
CAUTION
when handling.
Figure 6.
Fig. 7).
Figure 7.
Fig. 8).
Figure 8.
Figure 9.
515
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
Fig. 10).
Fig. 11).
Figure 11.
516
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
Figure 14.
Fig. 16).
Figure 16.
Fig. 17).
Figure 15.
Figure 17.
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
Fig. 18).
Shuttle Valve
o._ o
OO
Figure 19.
Figure 18.
Figure 20.
518
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
Major Repairs
CAUTION
Pliers
2. Torque Wrench
Figure 1.
damaged.
Figure 3.
to Fig. 4).
Figure 2.
Figure 4.
519
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
CAUTION
to avoid damage.
Figure 7.
Figure 5.
Fig. 6).
Figure 6.
Figure 8.
520
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
Figure 9.
*]
iY
Figure 10.
'i Tm
Figure 11.
Fig. 12).
Figure 12.
521
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
Fig. 13).
Figure 13.
Figure 14.
Drive Shaft
Bearings
End Cap
Housing
Figure 16.
522
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
end cap.
Figure 17.
Figure 18.
MISSING TOOTH
Figure 20.
523
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
Figure 21.
Figure 22.
Fig. 23).
Figure 23.
Figure 24.
524
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR REPAIR
Fig. 25).
Figure 25.
Fig. 26).
Figure 27.
Figure 26.
Figure 28.
Fig. 29).
525
TM 5-3895-346-14
MOTOR REPAIR
HYDROSTATIC SYSTEM
hydraulic oil.
Figure 29.
526
TM 5-3895-346-14
HYDROSTATIC SYSTEM
MOTOR PARTS
NO./LTR.
DESCRIPTION
QTY.
Screw-hex hd cap
Screw-hex hd cap
Washer-plain
10
End cap
11
Shim-bearing
AS REQ'D
12
Gasket-end cap
13
Bearing kit-rear
14
Pin-locating
IS
Valve plate
29
Swashplate-f ixed
30
Shaft
31
Bearing kit-front
32
Pin
33
Plug-hex hd
34
O-ring
35
Housing
parts. For part numbers consult the Parts List for the
527
528
MOTOR PARTS
TM 5-3895-346-14
HYDROSTATIC SYSTEM
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
PUMP
warranty.
REPAIR
DISPLACEMENT
PUMP
CHARGE PRESSURE
IN NEUTRAL, FORWARD
AND REVERSE
Figure 1
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Minor Repairs
3. Torque Wrench
88 B
cr- i oi
Figure 2.
removal.
Figure 3.
Figure 4.
Figure 5.
530
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Figure 6.
Fig. 7).
0 0 0 0 D 0/^==^5s.
Figure 7.
Fig. 8).
Figure 8.
Figure 9.
531
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Fig. 10).
Figure 10.
Figure 11.
CAUTION
Figure 12.
Figure 13.
532
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Figure 14.
Figure 15.
Figure 16.
to Fig. 17).
Figure 17.
533
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 18.
Figure 19.
Fig. 20).
Figure 20.
Figure 21.
Figure 22.
534
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Figure 23.
Figure 24.
Figure 25.
Fig. 26).
Figure 26.
535
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 28.
Fig. 29).
Fig. 30).
Figure 30.
Fig. 31).
Figure 31.
Figure 29.
536
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Major Repair
Pliers.
4. Torque Wrench
Figure 1.
CAUTION
Figure 3.
to Fig. 4).
Figure 2.
Figure 4
537
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
CAUTION
to avoid damage.
Figure 5.
Figure 6.
Fig'. 7).
Figure 7.
Figure 8.
538
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Fig. 9).
Figure 11.
Figure 10.
Figure 12.
to Fig. 13).
539
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 13.
Figure 16.
Figure 14.
Fig. 15).
Figure 17.
Fig. 18).
Figure 15.
Figure 18.
540
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Fig. 19).
Figure 19.
Figure 20.
to Fig. 21).
Figure 21.
Figure 22.
541
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 23.
==
Figure 24.
Figure 26.
Figure 27.
Figure 25.
Figure 28.
542
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
to Fig. 29).
Figure 29.
Figure 30.
Figure 31.
Figure 32.
Figure 33.
543
TM 5-3895-346-14
POMP REPAIR
HYDROSTATIC SYSTEM
Figure 34.
Figure 35.
Figure 36.
Figure 37.
Fig. 38).
544
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Figure 38.
Figure 40.
EE
Figure 41.
Figure 42.
Figure 43.
545
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 44.
Fig. 45).
to Fig. 45).
swashplate).
the swashplate.
previously.
Figure 46.
Figure 45.
Figure 47.
546
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Fig. 48).
Fig. 48).
Spa
MT
Figure 49.
Figure 48.
checked:
Drive Shaft
Bearings
Housing
Front Cover
End Cap
and 50).
Figure 50.
Figure 51.
547
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 52.
Figure 53.
Figure 54.
Figure 55.
548
TM 5-3895-346-14
HYDROSTATIC SYSTEM
POMP REPAIR
and 56).
Figure 56.
Figure 57.
Fig. 58).
Figure 58.
Figure 59.
549
TM 5-3895-346-14
PUMP REPAIR
HYDROSTATIC SYSTEM
Figure 60.
Figure 61.
Fig. 62).
Figure 62.
Figure 63.
Fig. 64).
550
TM 5-3895-346-14
HYDROSTATIC SYSTEM
PUMP REPAIR
Figure 64.
Figure 66.
Figure 67.
Figure 68.
Procedures.
CAUTION
551
TM 5-3895-346-14
PARTS
HYDROSTATIC SYSTEM
7 Screw-hex hd cap 3
8 Screw-hex hd cap 5
9 Washer-plain 8
10 End cap 1
11 Shim-bearing AS REQ'D
12 Gasket-end cap 1
13 Bearing kit-rear 1
14 Pin-locating 2
15 Valve plate 1
29 Thrust plate 1
30 Screw 4
31 Retainer 2
43 Swashplate 1
44 Pin 2
45 Ring-retaining 4
46 Pin 1
47 Ring-retaining 2
48 Link-feedback 1
49 Shaft 1
50 Bearing kit-front 1
51 Gasket-front cover 1
52 Pin-locating 2
53 Front cover 1
54 Washer-plain 12
55 Screw-hex.hd.cap 12
65 Screw-hex.hd.cap 6
66 Washer-plain 6
67 Trunnion 2
68 Shims-trunnion AS REQ'D
69 O-ring 2
70 Bearing kit-trunnion 2
parts. For part numbers consult the Parts List for the
552
TM 5-3895-346-14
TORQUE VALUES
HYDROSTATIC SYSTEM
TORQUE VALUES
Location
20
21
22
23
24
25
26
27
16
16
16
16
16
16
16
16
Valve Manifold
21
21
21
21
21
21
21
21
27
27
27
45
67
134
240
240
End Cap
37
37
37
54
82
165
290
290
10
10
10
10
27
27
27
27
Charge Pump
11
11
11
11
37
37
37
37
10
10
10
10
10
TM 5-3895-346-14
POWER STEERING
INTRODUCTION
POWER STEERING
INTRODUCTION
Purpose of Manual
General
555
TM 5-3895-346-14
DESCRIPTION
POWER STEERING
DESCRIPTION
General
NOTE
NOTE
VTM41 pumps.
Application
556
TM 5-3895-346-14
POWER STEERING
DESCRIPTION
INDEX
Vane Type
MOBILE APPLICATION^
\ DESIGN
SHAFT TYPE
PUMP SERIES \
27 41
28 42
40
PUMP CAPACITY
L- Counterclockwise
10
15
20
30
40
50
60
1.0 GPM
1.5 GPM
2.0 GPM
3.0 GPM
4.0 GPM
5.0 GPM
6.0 GPM
15
1.5
GPM
20
2.0
GPM
25
2.5
GPM
30
3.0
GPM
35
3.5
GPM
40
4.0 GPM
45
4.5
GPM
55
5.5
GPM
65
6.5
GPM
75
7.5
GPM
TM 5-3895-346-14
OPERATION
POWER STEERING
OPERATION
Pimp Operation
operation.
the ring.
maximum.
Fig. 6.
TM 5-3895-346-14
POWER STEERING
OPERATION
RESERVOIR
RELIEF VALVE
ASSEMBLY
PRESSURE
PLATE
VANE
NEEDLE
BEARINGS
RING
COVER
ROTOR
VANE
BODY
SHAFT
SEAL
COVER
SHAFT
BUSHING
ROTOR
RELIEF VALVE
ASSEMBLY
PRESSURE
PLATE
RESERVOIR
RESERVOIR
RELIEF VALVE
ASSEMBLY
PRESSURE.
PLATE
VANE
BUSHING
RING
COVER
ROTOR
VANE
RING
BODY
COVER
SHAFT
SEAL
RELIEF VALVE
ASSEMBLY
RESERVOIR
PRESSURE
PLATE
559
TM 5-3895-346-14
OPERATION
POWER STEERING
OUTLET
VANE
OUTLET
ROTOR
DRIVE SHAFT |
INLET
SCHEMATIC VIEW
Figure 5.
LIGHT SPRING
HOLDS RELIEF
VALVE CLOSED
WHEN PRESSURE
IS EQUAL ON
BOTH ENDS
PILOT
POPPET
SPOOL BLOCKS
EXCESS FLUID
THROTTLED
PAST VALVE
TO TANK
TO TANK
PRESSURE IN
SPRING CHAMBER
LOWER THAN
SYSTEM DUE TO
PRESSURE DROP
ACROSS ORIFICE
TO TANK
SYSTEM PRESSURE
SENSED IN
SPRING CHAMBER
THROUGH ORIFICE
ORIFICE
DETERMINES
FLOW RATE
6A
DELIVERY
FROM
PUMPING
CARTRIDGE
6B
POPPET FORCED
OFF SEAT AS
RELIEF VALVE
SETTING IS
REACHED
PRESSURE
PORT
6C
DELIVERY TO SYSTEM
NORMAL OPERATION
FIGURE 6
Figure 6.
IN SYSTEM
560
TM 5-3895-346-14
POWER STEERING
OPERATION
CAPTION
561
TM 5-3895-346-14
INSTALLATION
POWER STEERING
INSTALLATION
Drive Connections
Shaft Rotation
Hydraulic Tubing
sharply.
resistance.
connections.
and scale.
Oil Type
TM 5-3895-346-14
POWER STEERING
INSTALLATION
Viscosity
Viscosity Index
type of service.
Additives
result.
oil's film.
Cleanliness
TM 5-3895-346-14
INSTALLATION
POWER STEERING
Grade
considerable care.
TABLE I
API
Service
Hydraulic System
SAE
Classi-
Operating Range
Viscosity
fication
(Min. to Max.)
0F. to 180F.
10W
MS
15F. to 210F.
20-20W
MS
32F. to 230F.
30
MS
0F. to 210F.
10W-30
MS
Miscellaneous
of Vickers Incorporated.
Overload Protection
TM 5-3895-346-14
POWER STEERING
MAINTENANCE
Service Tools
Service Inspection
Daily Inspection
operation.
screened funnel.
Periodic Inspection
Maintenance
Removal Of Units
of foreign matter.
Adjustments
alignment.
Replacement Parts
Catalogs.
Troubleshooting
TM 5-3895-346-14
MAINTENANCE
POWER STEERING
TROUBLESHOOTING CHART
TROUBLE
PROBABLE CAUSE
REMEDY
OIL
TION OF ROTATION
Valve.
SLIPPING OR BROKEN
needed parts.
STUCK OPEN
forth. No stickiness in
recommended in Operation.
ROTOR SLOTS
TO PICK UP PRIME
BLOCKED
data Table I.
566
TM 5-3895-346-14
POWER STEERING
MAINTENANCE
STRAINER
CLOGGED FILTER
SHAFT SEAL
COUPLING MISALIGNMENT
RESERVOIR OR MANIFOLD
SEAL LEAKAGE
REMEDY
clogged.
by recommended procedures.
this manual.
shaft misalignment.
reservoir at replenishing
dirt.
567
TM 5-3895-346-14
PUMP OVERHAUL
POWER STEERING
PUMP OVERHAUL
DISASSEMBLY
CAUTION
of unit to be serviced, be
cleaned.
follows:
TM 5-3895-346-14
POWER STEERING
PUMP OVERHAUL
DIPSTICK
ASSEMBLY
WING NUT
WASHER
COVER
COTTER PIN
WASHER
GASKET
FILTER
RETAINER
MANIFOLD
MANIFOLD MODELS
CAP
BYPASS SCREW
TUBE
COPPER WASHER
0" RINGS
PUMP
COVER
ROTOR /
C^_^BODY
'PUMP RING / 1
CAP SCREW
(33.W0.68 NM)
PLATE
PLUG
O" RING
/ BEARING
SNAP RING
KEY>.
SHAFT
SNAP RING
BEARING
BODY
VTM41SHAFT END
KEY
SHAFT \
BODY \ \ SEAL
^l^^J^J^*^ BEARING
'SPACER
BEARING
RESERV0IR
Figure 7. VTM27, VTM28, VTM40, VTM41, and VTM42 Pump Exploded Views
CAP SCREW
569
TM 5-3895-346-14
PUMP OVERHAUL
POWER STEERING
Shaft End
separately.
NOTE
rings at reassembly.
necessary.
TM 5-3895-346-14
POWER STEERING
PUMP OVERHAUL
.015 inch.
NOTE
bearing.
plate.
7. Install pressure-compensating
TM 5-3895-346-14
POMP TESTING
POWER STEERING
PUMP TESTING
installation drawings.
572
TM 5-3895-346-14
POWER STEERING
STEERING CONTROL
CONTROL
to over 200F.
attempts.
oil stream.
WARNING
TM 5-3895-346-14
STEERING CONTROL
POWER STEERING
TM 5-3895-346-14
POWER STEERING
STEERING CONTROL
cause of difficulty.
575
TM 5-3895-346-14
POWER STEERING
leaking.
Figure 1.
576
TM 5-3895-346-14
POWER STEERING
NOTE
be identified by a one-piece
577
TM 5-3895-346-14
POWER STEERING
Fig. 4).
Figure 2.
Figure 4.
Figure 3.
Figure 5.
578
TM 5-3895-346-14
POWER STEERING
Figure 7.
Fig. 9).
Figure 9.
Fig. ID.
579
TM 5-3895-346-14
POWER STEERING
Figure 11.
Figure 12.
Figure 13.
Fig. 14).
580
TM 5-3895-346-14
POWER STEERING
Figure 14.
Figure 15.
Fig. 16).
Figure 17.
to Fig. 18).
581
TM 5-3895-346-1A
POWER STEERING
Figure 18.
Figure 19.
and 22).
Figure 20.
Figure 21.
similarily.
582
TM 5-3895-346-14
POWER STEERING
Figure 22.
only.
lightly.
assembled.
Figure 23.
583
TM 5-3895-346-14
POWER STEERING
proper function.
Figure 25.
Figure 24.
Figure 26.
end.
584
TM 5-3895-346-14
POWER STEERING
Figure 27.
Figure 28.
Figure 29.
Fig. 30).
Figure 30.
Figure 31.
585
TM 5-3895-346-14
POWER STEERING
Fig. 34).
Figure 34.
Figure 32,
Figure 33.
Figure 35,
586
TM 5-3895-346-14
POWER STEERING
Figure 36.
Figure 37.
NOTE
Figure 38.
Figure 39.
587
TM 5-3895-346-14
POWER STEERING
fingertips.
Figure 40.
Figure 41.
NOTE
seal groove.
Fig. 43.)
Figure 42.
588
TM 5-3895-346-14
Figure 43.
to Fig. 44).
Figure 45.
Fig. 48).
^^Yp?
Figure 44.
Figure 46.
589
TM 5-3895-346-14
POWER STEERING
Figure 47.
/ \^
r\
Figure 49.
Figure 48.
Figure 50.
Figure 51.
590
TM 5-3895-346-14
POWER STEERING
CAPTION
Figure 53.
Figure 52.
Figure 54.
service.
reassembly.
TM 5-3895-346-14
POWER STEERING
Figure 55.
Figure 56.
used.
Figure 57.
592
TM 5-3895-346-14
REPLACEMENT
BRAKESHOE
web.
HYDRAULIC
spring.
assemblies.
lines.
in line.)
lockrings.
BRAKESHOE
REPLACEMENT
Figure 1.
BRAKE LAYOUT
cylinder.
ADJUSTMENT
clearance.
TM 5-3895-346-14
BRAKESHOE
REPLACEMENT
BRAKE SHOE
RETURN SPRING
GUIDE PIN
SPRING WASHER
ASSEMBLY ECCENTRIC
ADJUSTER
LINING ASSEMBLY
ANCHOR PIN
"C" WASHER
ANCHOR PIN
Figure 2.
Figure 3,
Figure 4,
594
595
BRAKESHOE
REPLACEMENT
TM 5-3895-346-14
TM 5-3895-346-14
WRENCH TORQUES
LUG NUTS
LUG NUTS
correctly torqued.
consistent.
Highway Vehicles
3/4--16 450-500
l-l/8"-16 450-500
Off-The-Road Vehicles
DCN Mtg.
3/4"-16 450-500
l-l/8"-16 450-500
l-l/8"-16 650-750*
15/16"-12 750-900
l-5/16"-12 750-900
Backnut
3/4"-16 175-200
1"-14 175-300
DCN = Double Cap Nut Mounting with 7/8" and 1" thread
596
TM 5-3895-346-14
LUG NUTS
CHECKS
CHECKS
complete line.
improper maintenance.
operation.
597
TM 5-3895-346-14
REPLACING STUDS
LUG NUTS
hub face.
forward.
Figure 2.
598
TM 5-3895-346-14
LUG NUTS
TIGHTENING PROCEDURE
FOR TROUBLE-]
Keep it tight
ball seats.
Figure 3.
i IS OF UTMOST IMPORTANCE
PERFORMANCE
Air wrench
cause problems.
damage threads.
Figure 4.
599
TM 5-3895-346-14
TIGHTENING PROCEDURE
LUG NUTS
A bar wrench
torque:
540 lb ft of torque.
torque accuracy.
gauge.
600
601
<Y>
DUAL
SINGLE
Figure 7.
TM 5-3895-346-14
PILOTED MOUNTINGS
602
DUAL
DUAL
SINGLE
SINGLE
60 90
Figure 8.
CONICAL
IN-OUT COINED
IN-OUT COINED
TM 5-3895-346-14
ALTERNATE MOUNTINGS
NON-PILOTED MOUNTINGS
TM 5-3895-346-14
AXLE
PLANETARY AXLES
wheel hubs.
wheels.
type).
603
TM 5-3895-346-14
DISASSEMBLY
AXLE
be taken:
lubricant.
604
TM 5-3895-346-14
AXLE
DISASSEMBLY
Figure 3.
Figure 4.
gasket.
Figure 5.
Figure 6.
605
TM 5-3895-346-14
DISASSEMBLY
AXLE
Fig. 7).
Figure 7.
NOTE
locations.
606
TM 5-3895-346-1'
AXLE
DISASSKK
NOTE
sun gear.
on model.)
Figure 11.
TM 5-3895-346-14
DISASSEMBLY
AXLE
a suitable puller.
Figure 12.
ASSEMBLY
Fig. 13).
Figure 13.
Fig. 14).
Figure 14.
608
TM 5-3895-346-14
AXLE
DISASSEMBLY
Fig. 13).
assemblies.
camshafts.
NOTE
is necessary.
on PR models.
Fig. 15).
Figure 15.
609
TM 5-3895-346-14
AXLE
NOTE
orthosilicates, or phosphates.
thorough cleaning.
Rough Parts
alkali.
WARNING
cleaners.
Complete Assemblies
assembly.
Drying
TM 5-3895-346-14
AXLE
parts.
the following:
washers.
pins.
pinions.
REPAIR
overhaul.
611
TM 5-3895-346-14
REASSEMBLY
AXLE
driver.
CAUTION
steel hammer.
flange studs.
Figure 1,
Figure 2.
612
TM 5-3895-346-14
AXLE
REASSEMBLY
Figure 3.
rods.
shoulder.
Figure 4.
torque. <
two.
INSTALL
bearing rolls.
613
TM 5-3895-346-14
REASSEMBLY
AXLE
adjusting nut.
AXLE MODEL
PRELOAD TORQUE
PR-50,
PR-100
PR-150
PR-200
PR-250
PR-300
PR-500
PR-700
PR-60
to 5 lb ft
to 8 lb ft
to
to
lb ft
lb ft
6 to 10 lb ft
8 to 12 lb ft
10 to 14 lb ft
14 to 18 lb ft
Figure 6.
Figure 7.
614
TM 5-3895-346-14
AXLE
REASSEMBLY
NOTE
by 5 lb ft
pound feet.
above.
tire.
Figure 8.
Fig. 10.)
Figure 9.
615
TM 5-3895-346-14
REASSEMBLY
AXLE
Figure 10.
thrust washer.
teeth.
nuts.
INSTALL COVER
correct torque.
LUBRICATION
OIL PAN
DRAIN
PLUG
Figure 11.
616
TM 5-3895-346-14
AXLE
REASSEMBLY
Fig. 11).
tighten securely.
NOTE
cants only.
CAPSCREWS
TORQUES
TORQUES
LOCATION
DIA.
THDS.
MIN. MAX.
LOCATION
DIA.
THDS.
MIN. MAX.
Planetary
7/16"
1/2"
14
13
TM 5-3895-346-14
REASSEMBLY
AXLE
TORQ
UES
TORQUES
LOCATION
DIA.
THDS.
MIN.
MAX.
LOCATION
DIA.
THDS.
MIN.
MAX.
Planetary
spider to
hub
1/2"
3/4"
13
10
81
290
104
370
Tie rod
clamp
1/2"
5/8"
20
18
92
185
118
235
Steering
knuckle
to flange
7/16"
9/16"
3/4"
14
12
10
53
116
290
67
149
370
Tie rod
ball
3/4"
1"
16
14
12
12
18
320
780
1120
1540
1620
415
1000
1420
<r>
00
<^
^*
I ajngTiJ
d~IVH 3DNVTd
3SVD ddia
3Aiy BV30
H3HSVAAX301 aSdOSdVO
ION NOINI,
3X0A NOINId
A3X lHOIVbliS
ldVHS NOINId
AT9W3SSV "IV3S
fclSHSVaXOOl ION
DNIHXDOT DNIUV3S
lOlId NOINId
3A33TSaNVy3IUHV3 ddia
H3HSVAA 1SDHH1
IH3HSVa ISndHl
TM 5-3895-346-14
AXLE
DRIVE UNIT
Figure 2.
housing drive units are single- bearing pre load controlled by bearing
roller bearings with the cups assembled On hypoid geared units the pinion shaft
in the case and cover halves of the is splined to accommodate the flange
housing. The straddle mounted pinion and the bearing pre load controlled by
has two tapered roller bearings located hardened and ground spacers of the
forward of the pinion teeth and a correct thickness between the bearings,
REMOVE AXLE
the cover half of the housing from the 4. Remove spring clips,
vehicle.
2. Disconnect universal at
shaft.
of axle 5. Remove
pinion 6. Remove
lockwashers,
620
TM 5-3895-346-14
AXLE
IMPORTANT
drift.
CAUTION
DISASSEMBLE
ASSEMBLY
Figure 3.
8. Remove wheels.
half.
DISASSEMBLE AXLE
assembly.
half.
assembly.
4. Remove pipe.
DRIVE UNIT
Fig. 3).
center of head.
head.
TM 5-3895-346-14
AXLE
Figure 5.
Figure 7.
groove.
622
TM 5-3895-346-14
AXLE
Figure 8.
bearing cover.
thrust washer.
Figure 9.
Fig. 9).
bearing cover.
CLEAN
orthosilicates, or phosphates.
623
TM 5-3895-346-14
AXLE
thorough cleaning.
ROUGH PARTS
alkali.
WARNING
cleaners.
compressed air.
CORROSION PREVENTION
INSPECT
COMPLETE ASSEMBLIES
TM 5-3895-346-14
AXLE
differential gears.
mature failure.
to teeth.
reading.
REPAIR
overhaul.
follows:
installation.
Figure 10.
TM 5-3895-346-14
AXLE
Fig. 11).
Fig. 12).
hammering.
wire breakage.
Figure 11,
Figure 12.
REASSEMBLE AYT-K
assembly.
to Fig. 1).
Figure 1.
626
TM 5-3895-346-14
AXLE
cage shoulders.
pinion shaft.
against spacer.
to Fig. 2).
NOTE
preload.
15 lb in preload torque.
nut.
Figure 2.
nut.
torque.
NOTE
foregoing procedure.
cover.
TM 5-3895-346-14
AXLE
Figure 3.
,/
/\
Figure 4.
shaft shoulder.
Figure 5.
shoulders.
locknut.
CAUTION
seal driver.
on keyway.
628
TM 5-3895-346-14
AXLE
shaft nut.
CAUTION
NOTE
er gauge.
eccentricity.
lubricant.
assembly.
thrust washer.
equally spaced.
Figure 7.
629
TM 5-3895-346-14
AXLE
necessary.
LASH ADJUSTMENTS
assembled.
Hypoid-Splined Shaft
to Fig. 8).
NOTE
housing.
flange.
Figure 9.
630
TM 5-3895-346-14
AXLE
Figure 10.
NOTE
available in increments of
housing.
of the assembly.
gear lash.
follows:
play.
paragraph.
cage assembly.
mallet.
631
TM 5-3895-346-14
AXLE
Specifications).
Figure 11.
ASSEMBLIES
torque.
Torgue Specifications).
bearings.
assembly if required.
specified torque.
6. Connect brakes.
shaft.
632
TM 5-3895-346-14
AXLE
LUBRICATION
capacities.)
of the assembly.
CAUTION
pins.
same speed.
TORQUE SPECIFICATIONS
NO.
TORQUE -
LB. FT.
LOCATION
DIAMETER
THREADS
MIN.
MAX.
3/8"
16
27
35
3/8"
24
31
39
7/16"
20
42
54
1/2"
20
75
96
3/8"
16
27
35
3/8"
24
31
39
7/16"
20
42
54
9/16"
12
94
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
Maintenance Category
(4)
(5)
Tools &
Equip-
ment
(6)
Remarks
Group
Number
Component/Assembly
Maintenance
Function
01
ENGINE
0100
Engine Assembly
Test
2.0
1,2,3,4
Service
0.1
Replace
16.0
Repair
21.0
Overhaul
48.0
Engine Mounts
Replace
3.0
0101
Cylinder Block
Test
5.0
1,2,3,4
Replace
40.0
Repair
20.0
Cylinder Sleeve
Replace
3.0
Cylinder Head
Replace
4.0
Repair
4.0
Overhaul
8.0
0102
Crankshaft
Replace
5.0
1,2,3,4
Main Bearings
Replace
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
(4)
(5)
Tools &
Equip-
ment
(6)
Remarks
Maintenance Category
Group
Number
Maintenance
Function
Component/Assembly
0104
Rods
Replace
3.0
1,2,3,4
Repair
2.0
Replace
0.5
0105
Rocker Arms
Replace
0.5
1,2
Valve Springs
Test
0.8
Replace
0.3
Valves, Exhaust
Adjust
2.0
Replace
1.0
Camshaft, Bearings,
Repair
2.0
and Gears
Replace
4.0
0106
Oil Cooler
Service
0.2
1,2
Replace
1.0
Oil Pan
Replace
1.5
Repair
1.0
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
(4)
(5)
Tools &
Equip-
ment
(6)
Maintenance Category
Group
Number
Maintenance
Function
Component/Assembly
Remarks
Adjust
Replace
0.2
0.5
Service
Replace
0.2
1.0
Replace
0.5
0108
Exhaust Manifold
Replace
Repair
1.0
1.0
1,2,3,4
02
CLUTCH
0200
Clutch Assembly
Replace
8.0
4.0
8.0
6.0
2.0
1,2,3,4
Repair
Drive Ring
Clutch Housing
Replace
Replace
Repair
0202
Replace
6.0
1,2
Linkage
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
Maintenance Category
(4)
(5)
Tools &
Equip-
ment
(6)
Group
Number
Component/Assembly
Maintenance
Function
Remarks
0205
Replace
Repair
8.0
4.0
1,2
03
FUEL SYSTEM
0301
Fuel Injector
Test
Replace
1.0
1.5
1,2
0302
Fuel Pump
Replace
Repair
1.0
1.0
1,2
0304
Air Cleaner
Service
Replace
Repair
Replace
0.4
0.5
1.0
0.5
0305
Air Shutdown
Service
0.3
Replace
1.0
2.0
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
Maintenance Category
(4)
(5)
Tools &
Equip-
ment
(6)
Group
Number
Component/Assembly
Maintenance
Function
Remarks
0306
Fuel Tank
Service
0.2
1,2
Replace
1.5
Repair
2.0
Replace
1.0
1.0
Repair
0308
Test
Adjust
Replace
Repair
0.5
0.5
1.0
2.0
1,2
0309
Fuel Filters
Service
Replace
0.2
0.5
0312
Throttle Control
Linkage
Adjust
0.5
0.5
0.5
Replace
OA
EXHAUST SYSTEM
TM 5-3895-346-14
APPENDIX A
(2)
Component/Assembly
(3)
Maintenance
Function
(4)
Maintenance Category
(5)
Tools &
Equip-
ment
(6)
Remarks
COOLING SYSTEM
Radiator
Thermostat
Water Pump
Fan Assembly
Fan Guard
Fan Belts
ELECTRICAL SYSTEM
Alternator
Service
Replace
Repair
Replace
Replace
Replace
Repair
Replace
Repair
Replace
Repair
Inspect
Adjust
Replace
Test
Replace
0.2
2.0
2.0
1.0
0.5
2.0
1.0
1.0
1.0
0.1
0.5
1.0
0.5
0.6
1.0
1.0
1,5
Coperator/crew
0organizational
Fdirect support
Hgeneral support
Ddepot
639
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
(4)
(5)
Tools &
Equip-
ment
(6)
Maintenance
Category
Group
Number
Maintenance
Function
Component/Assembly
Remarks
Repair
1.5
Inspect
0.1
0.5
1.0
Adjust
Replace
0603
Starting Motor
Test
0.5
1.0
1,5
Replace
0607
Instrument Panel
Accessories
Repair
1.5
0608
Miscellaneous Electri-
Replace
Repair
0.5
0.5
Replace
Repair
0.5
0.5
0609
Headlight Assembly
Replace
0.3
0.5
0.3
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
Maintenance Category
(4)
(5)
Tools &
Equip-
ment
(6)
Group
Number
Component/As sembly
Maintenance
Function
Remarks
0612
Battery
Test
0.3
1,5
Service
0.2
Replace
0.5
0.4
0.5
0.5
Battery Cables
Replace
Repair
Repair
0613
Wiring Harness
Replace
Repair
1.0
07
TRANSMISSION SYSTEM
1.0
0700
Transmission Assembly
Test
2.0
1,2,3,4
Service
1.0
Replace
16.0
16.0
Repair
Overhaul
20.0
0705
Service
Adjust
TM 5-3895-346-14
APPENDIX A
(2)
Component/Assembly
(3)
Maintenance
Function
(4)
Maintenance Category
(5)
Tools &
Equip-
ment
(6)
Remarks
Hydrostatic Pump
(propelling)
Hydrostatic Motor
(propelling)
Direction/Speed Control
Assembly
Service
Replace
Repair
Replace
Replace
Repair
Overhaul
Replace
Repair
Overhaul
Replace
Repair
Adjust
Replace
Repair
Replace
0.3
1,2
1.0
1.0
2.0
2.0
3.0
3.0
2.0
2.0
1.5
2.0
2.0
2.0
4.0
4.0
1.0
Coperator/crew
0organizational
Fdirect support
Hgeneral support
Ddepot
642
TM 5-3895-346-14
APPENDIX A
Group
Number
(2)
Component/Assembly
(3)
Maintenance
Function
(4)
Maintenance Category
(5)
Tools &
Equip-
ment
(6)
Remarks
Hydrostatic Pump
(Vibratory)
Replace
Repair
Replace
Repair
Overhaul
Replace
Repair
Inspect
Adjust
Replace
Replace
Repair
Service
Replace
Repair
Adjust
1.0
1.0
2.0
2.0
2.0
2.0
4.0
0.2
0.5
2.0
0.5
3.0
3.0
8.0
8.0
1.0
1,2
Coperator/crew
0organizational
Fdirect support
Hgeneral support
Ddepot
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
(4)
(5)
Tools &
Equip-
ment
(6)
Maintenance Category
Group
Number
Maintenance
Function
Component/Assembly
Remarks
Replace
2.0
09
PROPELLOR SHAFT
Repair
1.0
0900
Replace
Repair
1.5
1.0
11
REAR AXLE
1100
Replace
Repair
8.0
8.0
1102
Differential Assy
Planetary Drive
Replace
Repair
Replace
Repair
8.0
8.0
4.0
4.0
12
BRAKES
1201
Adjust
0.5
3.0
3.0
Replace
Repair
1202
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
Maintenance Category
(4)
(5)
Tools &
Equip-
ment
(6)
Remarks
Group
Number
Component/Assembly
Maintenance
Function
1204
Master Cylinder
Service
0.5
Replace
2.0
Repair
1.0
Wheel Cylinders
Replace
2.0
Repair
0.5
Replace
2.0
13
WHEELS
Repair
1.0
1311
Wheel Assembly
Replace
1.5
Service
1.0
Adjust
1.0
Replace
2.0
1313
Tires
Inspect
0.5
Replace
2.0
14
STEERING
Repair
2.0
TM 5-3895-346-14
APPENDIX A
(1)
(2)
(3)
(4)
(5)
Tools &
Equip-
ment
(6)
Maintenance Category
Group
Number
Maintenance
Function
Component/As sembly
Remarks
Replace
8.0
Repair
8.0
1407
Replace
Repair
2.0
2.0
1,2
1410
Replace
2.0
2.0
Repair
1411
Fittings
Overhaul
4.0
1412
Hydraulic Steering
Cylinders
Replace
Repair
1.0
1.0
1,2
15
FRAME
Service
Replace
Repair
1.0
1.5
2.0
1,2
1501
Repair
Repair
APPENDIX A
(1)
(2)
(3)
(4)
(5)
Tools &
Equip-
ment
(6)
Group
Number
Maintenance Category
Component/Assembly
Function C
Remarks
1806
Seat Assembly
Replace
Repair
1.0
1.0
1,2
74
COMPONENTS
7466
Roll Assembly
Replace
Repair
4.0
4.0
1,2
7470
Roll Scrapers
Service
Replace
Repair
0.5
1.5
1.5
1,2
Ddepot
TM 5-3895-346-14
NATIONAL/NATO TOOL
two sets.
TOOL OR TEST
EQUIPMENT
REFERENCE MAINTENANCE
CODE CATEGORY
1 0, F, H
1 0, F, H
1 0, F, H
1 0, F, H
1 0, F, H
1 0, F, H
1 0, F, H
1 0, F, H
2 F, H
05)
97-CL-E04)
4910-95-CL-A74)
4910-95-CL-A72)
(SC 5180-90-CL-W26)
(SC 4910-95-CL-A73)
Sugg #2 SC 4940-95-CL-A08
CL-E03)
4940-00-294-9518 T10138
4940-00-294-9516 T13152
4910-00-754-0654 W32593
4910-00-754-0650 W32730
5180-00-177-7033 W33004
4910-00-754-0653 W32867
3470-00-357-7268 T16714
4940-00-754-0743 W65747
4940-00-287-4894 T10549
648
TM 5-3895-346-14
TOOL OR TEST
EQUIPMENT
4910-95-CL-A50)
(SC 5180-90-CL-E05)
(SC 4910-95-CL-A01)
n (SC 4910-95-CL-A65)
3470-95-CL-A02)
CL-A02)
Repair
500 lb Cap
0, F, H Multimeter
5180-00-699-5273 W45060
4910-00-754-0714 T30414
4910-00-390-7775 T30688
3470-00-754-0708 T15644
5280-00-511-1950 W44512
5180-00-754-0643 W33689
5310-00-754-0743 W65747
5120-00-542-5577 Y84966
6625-00-999-7465 M80242
649
TM 5-3895-346-14
APPENDIX B
NOMENCLATURE:
MANUFACTURER:
DATE:
QUANTITY
FURNISHED
MFR PART NO. MFR FED CODE DESCRIPTION UNIT OF ISSUE W/EQUIP
(1) (2)
CODE NUMBER
(3)
DESCRIPTION
CODE
USABLE
ON CODE
NOTE
(81349)
NOTE
roller.
Rigid
Flex
(4)
UNIT
OF
MEAS
EA
EA
EA
EA
EA
EA
(5)
QTY
AUTH
650
APPENDIX C
MAKE: aAMPd
NSN: 3895-01-012-8875
MdDEL: NS-28
DAs: FEB 79
(1)
COMPdNENT
APPLICATIaN
Ddive Axle
Diffedential
Ddive Axle
Planetady
accentdic Shaft
Beadings
Genedal Applica-
tion
(2)
9150-01-035-5395
9150-01-035-5395
9150-01-035-5392
(3)
DsCNIPTIdN
MIL-L-2105C
MIL-L-2105C
MIL-L-2105C
(4)
QTY NEQ
F/INITIAL
sN
8 qt
4 qt
14 qt
A/N
(5)
QTY NEQ
F/8 HRS
sN
(6)
Ndsa
5 gal
5 gal
1 qt
25 qt
50-50 solution
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TM 5-3895-346-14
INDEX
Page
Block, Cylinder 57
Blower 290
Gears 182
Clutch, Drive 11
Component Identification 1
Coolant 405
Crankshaft 105
Cylinder Block 57
Cylinder Head 71
Page
Description 48
Drive Clutch 11
Weights 164
Maintenance 427
Specifications 388
TM 5-3895-346-14
INDEX (Continued)
Page
Gears, Operating 9
Mechanical 258
Hauling 11
Head, Cylinder 71
Assembly 184
Adjustment 422
Installation, Hydrostatic
System 480
Drive 380
Lubrication 30
Lubrication Chart 30
Maintenance 427
Page
Maintenance, Hydrostatic
System 502
Maintenance, Roller 39
Operating Controls 18
Operating Gears 9
and Injector 81
Operation, Preparation of
TM 5-3895-346-14
INDEX (Continued)
Page Page
. . 383
. 463
Troubleshooting, Engine
Troubleshooting, Hydrostatic
Troubleshooting, Power
. . 397
Startup Procedure,
659/(660 blank)
TM 5-3895-346-14
TABLE OF CONTENTS
Page Number
Figure
Number
Title
Illustration
Parts List
Fig.
E-9
Fig.
E-13
Fig.
E-15
Fig.
E-17
Fig.
E-19
Fig.
E-21
Fig.
E-23
Fig.
E-25
Fig.
E-27
Fig.
10
. . E-28
E-29
Fig.
11
E-31
Fig.
12
E-35
Fig.
13
E-37
Fig.
14
E-41
Fig.
15
E-43
Fig.
16
. . E-44
E-45
Fig.
17
. . E-46
E-47
Fig.
18
E-49
Fig.
TM 5-3895-346-14
Page Number
Figure Number
Title
Illustration
Parts List
Fig.
48
E-118
E-119
Fig.
49
E-120
E-121
Fig.
50
E-126
E-127
Fig.
51
E-130
E-131
Fig.
52
E-134
E-135
Fig.
53
E-136
E-137
Fig.
54
E-138
E-139
Fig.
55
E-142
E-143
Fig.
56
E-146
E-147
Fig.
57
E-150
E-151
Fig.
58
E-154
E-155
Fig.
59
E-156
E-157
Fig.
60
E-160
E-161
Fig.
61
E-162
E-163
Fig.
62
Chief of Staff
Official:
DONALD J. DELANDRO
Distribution:
To be distributed in accordance with DA Form 12-25B, Operator; Organizational; Direct and General Support Mainte-
LINEAR MEASURE
WEIGHTS
1 Kilogram*1000 Grams-2.2 Lb
LIQUID MEASURE
SQUARE MEASURE
CUBIC MEASURE
TEMPERATURE
5'9 (F - 32) = C
9'5 C +32=F
TO CHANGE
TO
MULTIPLY BY
Pints Liters . . . .
Quarts Liters . . . .
6allons Liters . . . .
Ounces Grams
Pounds Kilograms. . .
Pound-Feet Newton-Meters.
29.573
0.473
0.946
..... 3.785
28.349
0.454
0.907
1.356
TO CHANGE
TO
MULTIPLY BY