tm 9-1812 ihc h-542-9 and h-542-11, marmon herrington h-542-11 and kenworth h-542-11

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    HNICALMANUAL

    E

    K

    DH-542-11

    -11)

    Publ

    icDomain,Google-digitized

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    ICALMANUAL

    E

    K

    H-542-11

    -11)

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    6MAY1944

    ntenance,5-ton4x2tractortruck

    2-9andH-542-11,Marmon-Herring-

    orthModelH-542-11),ispublished

    danceofall concerned.

    TARYOFWAR:

    C9(3).

    ls,seeFM21-6.)

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    N.............1-25- 6

    ............3-217-63

    ptionanddata.3-47- 11

    to

    2-21

    in-

    7-1922-46

    ...2047-58

    .2159-63

    ...........22-2664-77

    STEM..........27-3778-89

    .........2778

    8-2979-81

    0-3582-87

    6-3788-89

    ..............38-4390-102

    .............44-49103-131

    ON.............50-55132-157

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    E5-TON4x 2TRACTORTRUCK(C.O.E.)

    HAFTSANDCEN-

    66

    s56-59158-160

    ar-

    4167-175

    64-68167-172

    73-175

    EARANDDRAG

    5-80176-187

    0

    91-196

    S89-92197-199

    -98200-204

    01205-210

    OLS102-103211-213

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    nedinthis manualareforthein-

    fpersonnelchargedwiththemaintenance

    tractortruck,InternationalModels

    rmon-HerringtonmodelH-542-11,and

    .Theseinstructionsaresupplementary

    ualspreparedforthe usingarms.This

    formationwhichisintendedprimarily

    uchinformationisavailabletoordnance

    escriptionof,andprocedurefor,the

    ulofallpartsofthe vehicle.

    nicalinformationrequiredforthe

    reofthemateriel,andis designedto

    inperformingmaintenanceworkwithin

    nancepersonnelwillusuallyreceivefor

    es,clutches,transmissions,andother

    vealreadybeenremovedbyusing arm

    econditionedunitstousing armper-

    stallation,theproceduresforremovaland

    nitsare giveninTM9-812andnot

    nancemanualspertainingtothis

    eMaintenance-Electricalequipment

    kingmotor,generator,generatorregu-

    eMaintenance-Carburetors(Zenith),

    vernor.

    eMaintenance-PowerBrakeSystem

    oversairbrakesystemaccessories.

    eMaintenance-Fuelpumps(A-C),

    ilter.

    eMaintenance-AutomotiveSpeedom-

    ecorders,coversspeedometerandtach-

    ASSEMBLYREPLACEMENT

    cleissuppliedwithacopyof

    hprovidesameansofkeepingarecord

    rmajorunitassemblyreplaced.This

    evehiclenameandU.S.A.registration

    se,andinformationpertinenttothe

    eryimportantthattheformbe used

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    ES-TON4x1TRACTORTRUCK(C.O.E.)

    mainwiththevehicleuntilthe vehicleis

    sonnelperformingmodifications

    acementsmustrecordclearlyonthe

    orkcompleted,andmustinitial the

    ed.Wheneachmodificationiscom-

    ursand/ormileage,andMWOnumber.

    essuchasengines,transmissions,or

    d,recordthedate,hoursand/ormileage,

    nitassembly.Minorrepairsandminor

    cementsneednotberecorded.

    onreceipt,byathirdor fourth

    vehicleformodificationorrepair,main-

    ordtheMWOnumbersofmodifications

    fA.G.O.FormNo.478.

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    DDATA

    RATION.

    gasolineengineis a4-cycle,

    d-valvetype.Theengineserialnumber

    efrontofthe leftsideofthecrankcase

    d.Thecylinderdry-typesleevesor

    edetachablecylinderheadcontainsall

    springs.Thecylindersarenumbered

    ear end)torear.Asviewedfromthe

    ginecrankshaftrotationis clockwise.

    anifolds,carburetor,andgeneratorare

    ftheengine.Thecrankingmotor,

    oilfilter arelocatedontheleftside.

    velbayonetgagearealso ontheleft

    atedat thefrontofthe engine.

    3).

    pressor,fan,andwaterpumpare

    mapulley mountedonthefrontendof

    utor,mountedatthetopof thetach-

    eleft sideoftheengine,is drivenbythe

    nsionoftheoilpumpshaft.

    manifoldsarebolted toeachother

    cylinderhead.Theexhaustmanifold

    chareheldtogetherbyexpansionclamps

    foldiscastin onepiece.

    providedatthefrontendof the

    crankcasearecastin onepiece,and

    tmainbearings.Cylindersleevesor

    emovable.Watercirculatingpassages

    ylindersinthecrankcaseandalsopro-

    rhead.

    elubricationissuppliedto allmain,

    haftbearings,andtothetiminggears,

    ms,andpistonpins.Sprayfromthe

    ownplentifullyontothecylinderwalls,

    partsinsidethe engine.

    eof alloysteelandarepressedinto

    engthentheperiodbetweenvalverecon-

    exhaustvalvefaceisgroundatan angle

    alvefaceangleis 15degrees.Valves

    bycontinuouscirculationofwater

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    E5-TON4xSTRACTORTRUCK (C.O.E.)

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    DDATA

    P

    T

    V

    TIO

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    ES-TON4xITRACTOR TRUCK(C.O.E.)

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    DDATA

    erheadisboltedto thecrankcase,and

    tsealis maintainedbymeansofacom-

    sgasket.,

    forgingofheat-treatedsteel,and

    ounterweighted,balancedbothstati-

    dgroundtocloselimits.Theshaftis

    n-type,replaceableshellbearings.

    analuminumalloy,arecamground,

    ompressionringsandoneoilcontrolring.

    full-floatingtype,andareheldin place

    ofthepins bysnaprings.

    inedfromasolid dropforgingand

    placeablebearings.

    and doweledtothecrankshaftflange.

    on theflywheel.

    sdoweledandbolted tothefront

    hichinturnis keyedandpressedonto

    ondamperconsistsofflangeswith

    cts,ina mannersimilartotheflywheel,

    vibrationswhichareabsorbedby the

    nfromagearon thecamshaft.

    99

    A.45.9

    0rpm)143

    y)15qt

    fillincl.newfilters)14qt

    fill)9qt

    36qt

    6J in.

    7%in.

    9J in.

    cessories1,315Ib

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    EINTOSUBASSEMBLIES

    TIONS.

    nstallengine onasuitable

    stand.

    ollowprocedureoutlinedinTM

    lowing'accessories:carburetor,oil

    orandconnectingwires,sparkplugs,

    p,clutch,ignitioncoil,waterpump,

    ressor.

    .Plugall openingstotheinterior

    alldirt andgreasewithdry-cleaning

    equipment.

    e.Removemagneticdrainplug

    drainoil.

    nnectvacuumlinefromintake

    ntilatormeteringvalveatmeteringvalve.

    omoilfiller.Removetwocapscrews

    keManifold

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    EINTOSUBASSEMBLIES

    keManifoldPilot

    eofoil filler,andremoveoilfillerand

    d.Removesixnutsandflat

    foldstudsatcylinderhead.Removetwo

    rsfromcenterofintakemanifold.Lift

    movegaskets(fig.4).Removeintake

    reeintakeports incylinderhead(fig.5).

    old.Removesixnutsandflat

    manifoldtoenginecylinderhead.Lift

    mbly(fig.6),andremovegaskets.

    ustManifold

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    E5-TON4x1TRACTORTRUCK(C.O.E.)

    kerArmDrilledCapScrew

    Breather.Withapipewrench,

    eatherfromcylinderheadcover,andre-

    ValveRockerArm)Cover.Re-

    utsand washersfromcylinderheadcover,

    romhead.

    rmAssembly.Removefour

    pacernuts.Removetworegular

    eRockerArmAssembly

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    EINTOSUBASSEMBLIES

    veLiftRodCover

    emblybracketcapscrewsandflat

    dboltfromtherear ontheleftside of

    Thisboltis drilledtoprovideoilpassage

    rockerarms(fig. 7).Liftvalverocker

    erhead(fig.8).

    ds.Lift12valvepushrods from

    fromcylinderhead.

    MountingBracket.Remove

    ashersfromaircompressormounting

    ndgasket.Removetwocapscrews

    untingbrackettocrankcaseplate,and

    TachometerDriveHousing.

    ndlockwashersfromthedistributorand

    ,lifthousingfrommountingbase,and

    inderHead

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    E5-TON4x1TRACTORTRUCK(C.O.E.)

    Pump

    Cover.Removesixcapscrews

    trodcover,and removecoverandgasket

    Remove22cylinderheadbolts

    derhead.Liftcylinderheadfrom

    movecylinderheadgasket.

    arCaseCover

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    EINTOSUBASSEMBLIES

    .Removenutsandlockwashers

    dofoilpan.Remove10capscrews

    rewswith nutsfromoilpanflange.

    kcase.Removeoilpanside,front,and

    ovetwocapscrewsandlock

    geatcrankcase.Liftoilpump from

    (fig.11),andremovegasket.

    brationDamper.Removesixcap

    romenginecrankshaftvibrationdamper

    ewithsofthammertoremoveit from

    vePulley.Removeenginecrank-

    kshaft.Withapuller,removepulley

    seCover.Removesixcapscrews

    gearcasecover,andliftcoverand

    g.12).

    r.Withadrift,drive oilsealand

    ecover.

    CamshaftGearAssembly.Re-

    ockwashersfromcamshaftthrustflange.

    l12 valvetappetsuptotheirretaining

    .Removecamshaftfromfrontofengine.

    magethecamshaftbushingsasthe shaft

    romCrankcase.Lift12valve

    etainerclipsincrankcase.

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    erScrewsinFlywheel

    el.

    vailable,removeclutchpilotbearing

    ook-typepulleris notavailable,leave

    terstep (2)below.

    gcapscrewsfromflywheel.Install

    dholesin flywheel(fig.14),andforce

    flangedowels.Removeflywheelfrom

    nghas beenremoved(step(1)above),

    eelfromrear.

    wheelFigure16 RemovingFlywheelHousing

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    EINTOSUBASSEMBLIES

    nnectingRodCap

    elHousing.Removesixcap

    romengineflywheelhousing.Taphous-

    ockit fromdowels.Removehousing

    odandPistonAssemblies.Re-

    nectingrodcapboltsfromoneconnecting

    pandbearinghalffrom connecting

    ngrodandpiston assemblyoutthrough

    andreinstallconnectingrodcapon con-

    proceduretoremoveremainingfive

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    ificationofMainBearingCops

    arBearingOilSealRetainer

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    EINTOSUBASSEMBLIES

    arkcrankcaseandallcrankshaft

    nchmarkstoassurecorrectreassembly

    aftrearbearingoilsealretainerfrom

    wocapscrewsandlockwashers(fig.20).

    mmainbearingcapbolts.Remove16

    oltsfrom7mainbearingcaps,and lift

    omcrankcase.Temporarilyreinstall

    bearingcaps.NOTE:Self-lockingbolts

    ts requiringlockingwires.Theself-locking

    epressionintheir heads,requirenolock

    mStand.Removeenginecrank-

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    E5-TON4xI TRACTORTRUCK(C.O.E.)

    INSPECTION,

    OF

    ketsadheringto crankcasesur-

    xteriorofcrankcase,andallpassages,

    driflebarrelbrush.Removeall traces

    m crevicesofcrankcase.

    allyforcracksorfractures.Weldor

    uenesswitha straightedge.Test

    0.010-inchfeelergageribbonbetween

    ylinderhead.Ifthis ispossible,either

    ecrankcase.

    plugsforloosenessor evidenceof

    whicharelooseordamaged.

    ngsfordamagedorscoredcondition,

    aceifdamagedorwornbeyondclear-

    eswithaninsidemicrometertodeter-

    orworncondition.Themeasurements

    thetopofthe cylinderborewithinthe

    travel,but alsoinseveralplacesaround

    ofthebore,andagainin severalplaces

    re.Ifthereistaper orout-of-roundof

    heentirelengthofthe bore,orascored

    ecylindersleeveshouldbereplaced.

    PLACEMENT.Ifaboveinspection

    ersleevereplacementuseofspecial

    erandreplacer41-R-2378-800)isrequired.

    s:

    dremoverscrewin positionincyl-

    ure 21.Figure23illustratesthe remover

    ersleevefromcylinderblock.

    ndboreof blockmustbeclean.Cyl-

    itof0.001to0.003 inchinthecrankcase.

    freezingin dryicetofacilitateassembly.

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    INSPECTION,REPAIR,

    SSEMBLIES

    eRemover

    onfor

    eReplacer

    onfor

    reandthesleeveexterior withlightfilm

    stallation,assemblecylindersleeve

    asshowninfigure22.Havecylinder

    tomofbore placedatanangleto the

    etoprovideadequatereplacershoefoot-

    nin crankcase(fig.24).

    ation,grindorhonesleeveswhichare

    t of454to550) toadiameteroffrom

    rtoa diameterwhichwillprovideclear-

    025inchbetweenpistonand sleeve.

    REPLACEMENT.

    acementisnecessary,removefaulty

    earings.

    aftbearings,afterinstallation,with

    videbearingclearanceoffrom0.002to

    forbearingjournaldiameters.)

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    ES-TON4x STRACTORTRUCK(C.O.E.)

    nderSleeve

    DPISTONASSEMBLY.

    ningringsfrom piston(fig.25),and

    istonringgrooves.

    waterand,usinghammeranddrift,

    and connectingrod.Afterpistonpin

    connectingrod.

    .

    rtsindry-cleaningsolvent.CAU-

    csolutionforaluminumpistons.Clean

    ooveswitha brokenpistonringorring-

    ectconnectingrods,caps,and

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    INSPECTION,REPAIR,

    SSEMBLIES

    nderSleeve

    ingrodbearingsandpistonpin bushings

    onesat everymajoroverhaul.Test

    nlyslightlymisalinedcanbe realined

    adlytwistedorbentconnectingrods

    connectingrodboltsforsignsof wear

    evident.

    visuallyforcracks,breakage,or

    nggroovesandringlands forwear.Use

    age.If clearancebetweenringand

    ch,replacepiston.Pistonswhichare

    ereplaced.

    onpinsfor wear,andifwearis

    Ifpistonpinsshowsignsof corrosion

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    ES-TON4x STRACTORTRUCK(C.O.E.)

    EPLACEMENT.Withproperlyfitting

    ushingsfromconnectingrods(fig.26).

    ngin position,alineoilholeinbushing

    od,andpressbushing intorod(fig.27).

    rindpistonpinbushings toprovide

    o0.0006inchwithpistonpins.

    PISTONPINS.Withgrinder(41-G-

    tonPinBushing

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    INSPECTION,REPAIR,

    SSEMBLIES

    esin pistontoprovideatight fitoffrom

    pistonpins. NOTE:Infittingpiston

    oomtemperature(70 F)andthepistons

    mately200Finboilingwater.The pins

    tunderthese conditions.Whenpistons

    do notmix.Keeptogetherassets.

    NGRODSANDPISTONS.Heatpistons

    mately200F.With connectingrod

    ston pinintopistonbosseswhile piston

    stononrod, theslotinthe pistonskirt

    aftsideofthe engine(numberedsideof

    lpistonpinretainerring inpistonat

    rethat retainingringsseatfullyand

    stconnectingrodandpiston assembly

    andcorrectanymisalinement.

    SONPISTONS.Supportpistonand

    esteachpiston ringforpropergapby

    asuringgapwitha feelergage.Gap

    021 inchforoilcontrolrings,and from

    mpressionrings.Wheninstallingpiston

    carefulnot todistortrings.Ifpossible

    expandertool.Alsochecknewpiston

    esforclearancebetweenringandring

    learanceisfrom0.0015to 0.003inru

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    Y.

    ller,andremovecrankshaftgear

    eWoodruffkeyfromshaft.

    .

    crubcrankshaftandcrankshaftgear

    emovealloil andgrease.

    earingandconnectingrodjournals

    withamicrometer.Ifthe journalsshow

    003inchormore,the shaftmusteither

    thundersizebearings,or bereplaced.

    inementbyplacingitonV-blocksat

    .Use adialindicatoratthe center

    crankshaft.Ifrun-outexceeds0.006

    be straightenedorreplaced.

    dflywheeldowelsfordamageand

    damaged.

    earteeth,andreplaceifwornor dam-

    oodruffkeyingrooveincrank-

    asnearthefrontend aspossible,and

    ocrankshaft.

    .

    ywheelandringgearwithdry-

    ealltracesofoil andgrease.

    ggear.If anyteetharedamaged,or

    heel,theringgearmust bereplaced.

    welholesandmountingboltholes for

    ativeoftheflywheelhavingbeenlooseon

    elongated,replacetheflywheel,

    bleto keepittight.

    mblyforstaticbalancebymounting

    onmaindrivegearshaftheld inavise.

    einexceesof0.8inch-ounce,itmustbe

    talfromtheheavysideofthe flywheel.

    REPLACEMENT.Heatringgearwith

    ywheelwithahammerand drift.Heat

    eatingevenlyall thewayaround.

    pressitontothe flywheelandallowit

    .Ifflywheeltestedoutof static

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    INSPECTION,REPAIR,

    SSEMBLIES

    fa transmissionmaingeardriveshaft

    tflywheelmayrevolvefreely.With

    vyspot(atbottom)with chalk.Again

    mittocometorest andagainmark,ifnot

    emore.Fromthethreetest marks,

    adrill toremoveaslightamountof

    spot,and againrecheckforbalance.

    nganddrillinguntil noheavyspotis

    balanceisextreme,removemetalfrom

    istant fromtheexactheavyspot.

    .

    nutfrominfrontofcamshaftgear.

    movecamshaftgearfromcamshaft,and

    ate.RemoveWoodruffkeyfromcam-

    .

    indry-cleaningsolvent,brushing

    udgeor carbondeposits.

    alsforsignsofwear orout-of-round.

    excessof0.005inch,shaft mustbere-

    ournaldiameters.)

    gearoncamshaft.Ifteethareworn

    tmustbereplaced,sincethegearis in-

    s.Ifworn,chipped,orscored,replace

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    ES-TON4x JTRACTORTRUCK(C.O.E.)

    ocksatthefrontand rearbearings.

    ckrun-outattheintermediatebearings.

    ch,thecamshaftmustbestraightened

    andreplaceifwearis perceptibleor

    herwisedamaged.

    aftthrustplateoverendofcamshaft.

    n shaft.Supportcamshaftasnear

    ress gearontoshaftoverWoodruffkey.

    ftnut.

    VALVES.

    withavalvespring compressor

    espringretainer.Removevalvespring

    vespring(fig.29).Removeinnervalve

    cer(fig.30). Notethatvalvesprings

    ledendstowardthecylinderhead.

    soutlined.

    emoveallvalvesfromtheirvalve

    peallcarbonfromcylinderhead

    dcleananygasketmaterialfromsurfaces

    nderheadwith dry-cleaningsolvent,

    pment.

    ondepositsfromvalveheadsand

    ush,andwashvalvesin dry-cleaning

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    INSPECTION,REPAIR,

    SSEMBLIES

    erValveSpringandSpacer

    allvalvespringsandretainersin

    suallyforsignsof cracksorfractures.

    ad.

    eatinsertrings forlooseness,orfor

    eatsurface.Ifinsertsareloose,r eplace.

    slygroundtosuchextentthatit cannot

    ing toproperpositionnearcenterof

    bereplaced.

    rwarpagebyplacingona surface

    ointstoinsert a0.012-inchfeelergage

    dandsurfaceplate.Ifgagecan bein-

    mustberesurfacedorreplaced.

    eaningwithsuitablecleaningtool,

    ththestemofa newvalve(fig.31).

    tovalveguide clearanceisfrom0.0015

    lves,andfrom 0.002to0.004inchfor

    einexcessof0.006inchforintake,or

    ves,requiresguidereplacement.

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    E-S-TON4x2TRACTORTRUCK(C.O.E.)

    DE

    veGuide

    0)

    Guide Figure34-ReamingValveGuides

    0)UsingReamer(41-R-2310)

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    INSPECTION,REPAIR,

    SSEMBLIES

    valveforwarpage,forseverely

    excessivegrindingonthevalvehead.

    ffmarksorperceptiblewear.Inspect

    contactsurfacewithvalverockerarm.

    velyburned,orhasbeenpreviously

    eheadis thinatedge,replacevalve.

    conditionedandreinstalled.

    ensionofeachvalvespringatvalve

    ring tester.Checkinnerspringsat

    ceifpressureisless than76pounds.

    4%-inchlength,and replaceifpressure

    checkshowedwarpageinexcessof

    surfacegrinder.Removeonlyenough

    e.

    wedexcessclearanceorout-of-round

    mheadwithspecialdrivertool(41-R-

    newguide,anddrive intoheaduntil

    thetop surfaceofthehead.Astopsleeve,

    cilitatethis operation(fig.33).Ream

    iontofrom0.4365to 0.4375inchwith

    2310)(fig.34).

    atinserts showedreplacementof

    einserts.

    linderheadto45-degreeanglefor

    egreeangleforintakevalves.Follow

    requipmentmanufacturer.

    emsagainstface ofgrinder.Remove

    esurface.

    sidenticalwiththosein thecylinder

    and15-degreeintakevalveangles(step

    valvefaceandvalveseat anglesmust

    head.Placelightcoatingof fine

    onvalveface,andlapvalvelightlyto

    standproofofresults ofrefacingand

    orgrindingjobcannotbecorrectedby

    rseatposition.The seatshouldbe

    alveface,andshouldbefromVfe to%

    alveseatswith dry-cleaningsolvent

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    ARM

    T

    NG

    T

    ArmandShaftAssembly

    ding compound.Coatvalvestemsand

    stallvalvesin sameseatstowhichthey

    ers,andinstall innerandoutervalve

    ndstowardthecylinderhead.Compress

    pring compressor,andinstallvalve

    atretainersand locksareperfectly

    haftLocatingWasher

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    INSPECTION,REPAIR,

    SSEMBLIES

    g

    g

    BLY.

    erarmassemblyiscomposedof

    at thecenter,onwhicharemounted

    sionsprings(fig.35).Theshaftsare

    arepreventedfromturning inthe

    acketswhichcontainlocatingorlocking

    theshafts(fig.36).Removelocating

    ckets,andremovebracketsfromshafts.

    andbracketsfromshafts.

    uballparts indry-cleaningsolvent,

    cumulatedsludgeorcarbondeposits

    rarmshaftsforlossof endplugsor

    onasurfaceplate forsignsofbending.

    erarms.Ifa shaftisbentor shows

    ereplaced.

    trockerarmadjustingscrewsfor

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    austManifoldExpansionClampScrew

    dforthreadwear.If worn,replace.

    sforwear.Ifclearanceonshaftexceeds

    gs.Inspectvalvestemcontactsurface

    s perceptible,resurfacebygrindingto

    ius(subpar.d (2)below).

    onspringsforbreakageorloss of

    ve.

    GREPLACEMENT.

    bushingfromrockerarm(fig.37).

    rockerarmwitharbor(fig.38),mak-

    withchannelinsiderockerarm,sothat

    dholenearest splitisatvalveend of

    ngon agrinder(40-G-103)tofrom

    vide0.0025-to 0.003-inchclearance.

    rmwithdry-cleaningsolventtoremove

    aterial.

    CTPAD.Ifrockerarmcontactpad

    esurfaceonagrindertoa radiusoffrom

    carefultoremoveas littlemetalas

    cessively,replacerockerarm.

    erockerarms,brackets,andspacer

    earrockerarmshaftsinorder shown

    etwo centerbracketshavethe

    NOTE:Whenassemblingrearshaft,be

    acketislocatedbetweenNos.4and 5cyl-

    acetensionspringbetweenfrontand

    hafts.

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    INSPECTION,REPAIR,

    SSEMBLIES

    AION.

    ORMETERINGVALVE.Thecrankcase

    sdisassembledbyunscrewingthetwo

    and liftingoutthevalveweight.

    THER.Unhooktwoclips-holding

    ptobreatherbase. Lifttopportionof

    ovegasketfromcleanerelement.

    ORMETERINGVALVE.Washpartsin

    ,andflushwithdry-cleaningsolvent.

    THER.Washpartsindry-cleaning

    ORMETERINGVALVE.Placemetering

    onofshell withflatsurfacedownward.

    rhalfofshell.

    THER.Dipfilterelementinlight

    ain. Placefilterelementoveroilcup.

    ntilit isinstalledonengine.)Place

    nnecttwoclipstobase.

    TMANIFOLDS.

    eintakemanifoldisaone-pieceunit

    ldbytwo capscrewsatthecenter.

    emoveintakemanifoldandgasketbe-

    ustmanifolds.

    Theexhaustmanifoldisinthree

    onclampscrew(fig.39),andseparate

    erportion.Removeclampandclamp

    atoppositeclamp.

    in dry-cleaningsolvent.

    pectintakemanifoldvisuallyfor

    manifoldonsurfaceplate,andcheck

    broken,replaceorweld.If warped,

    ,orreplaceif warpageisextreme.

    Inspectexhaustmanifoldsections

    reakage.Testeachsectionindividually

    page.Ifanysectioniscrackedorbroken,

    rpageisextreme,itmaybe corrected

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    E5-TON4x STRACTORTRUCK(C.O.E.)

    xhauttManifold

    ANDCLAMPSCREWS.Inspectclamps

    ar ofthreads,andreplaceifdefective.

    hreadwear,andreplaceiffaulty.

    ndexhaustmanifoldsshouldbe

    foreinstallationontheengine.Thiswill

    ftheunitswith eachotherandwiththe

    NUT

    hometerSleeveNut

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    INSPECTION,REPAIR,

    SSEMBLIES

    tributorandTachometerDriveShaft

    fig.40).Joinend,sectionstocenter

    austmanifoldgasketsaroundjointsunder

    nclampscrewsonlyenoughtohold

    cenewgasketbetweentheintake

    dinstalltwocapscrews.Donot tighten

    CHOMETERDRIVEHOUS-

    andremovetachometerdriven

    dtachometerdrivehousing(fig.41),and

    rwithshaftfromhousing.Liftdistribu-

    haftwithgearfrom housing(fig.42).

    uballparts indry-cleaningsolvent.

    pectgearsanddriveshaftsand,

    eptible,replaceparts.

    utorandtachometerdriveshaft

    rtend first.Installtachometerdriven

    tachometerdrivensleeveintohousing.

    OAT.Removecotterpinholding

    loatfrompump(fig. 43).

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    E5-TON4*2TRACTORTRUCK(C.O.E.)

    Float

    DY.Removesixcapscrewsand

    pbodycover.Removebodycoverand

    Removeoilpumpidlergearfromoil

    45).

    AFTDRIVEGEARANDDRIVESHAFT.

    efrompumpshaft.With hammerand

    PumpCover

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    INSPECTION,REPAIR,

    SSEMBLIES

    lPumpIdlerGear

    PublicDomain,Google-digitized

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    mpshaft drivegear(fig.46).With

    dapterarborthatwill fitdownintoslot

    mpshaftoutof oilpumpshaftdrive

    lpump shaftandbodygeararenot

    theyareservicedasan assembly.

    assembly,washorscruballparts

    e shaftforwearatpointsof contact

    eptible,theshaftandgear,whichare

    mustbereplaced.

    yfor warpage,damage,andwear.

    orcracked,orif shaftboreiswornso

    haftandboreisin excessof0.005inch.

    eenthelowerendofthepumpgears

    anceinexcessof0.004inchrequires

    er,orreplacementofparts.Wearlimits

    ears,andreplaceifwearis perceptible.

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    INSPECTION,REPAIR,

    SSEMBLIES

    PumpShaftTopGuide

    ANDDRIVESHAFTGEAR.Installoil

    gearin pumpbody.Installnew

    alloilpump shaftdrivegearonupper

    table geardriver(fig.48).Drivethe

    pproximately5^-inchclearanceremains

    ndtopof body.Ifnewshaftisinstalled,

    nstall pininoil pumpshaftdrivegear,

    ongear(fig.49).

    nstalloilpumpidlergear onidler

    DY.Installnewoilpumpbody

    odycoverwithsix capscrewsandlock

    ofshaft. Ifinexcessof0.004inch,

    gasketandrecheck.

    AT.Connectoilpumpfloattooil

    wcotterpin toretainfloat.

    g andfittinggasketfromtopof

    ecover,spring,andgasketfromtopof

    utofshell.

    xagonsocketwrench,approximately

    es acrossflats,downoverthecenter

    tertubeandoil filtershellretaining

    e,bolt,andplate.Liftoilfilter shell

    egasketfromrecessin oilfilterbase.

    d (3)onremainingoilfilter shell.

    andgasketfromoil filterpress11

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    E-5-TON4x JTRACTORTRUCK(C.O.E.)

    sembled

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    INSPECTION,REPAIR,

    SSEMBLIES

    ft outreliefvalvespring,andremove

    ercartridgesandall gaskets.

    ywashingand scrubbingwithdry-

    ountingcapscrewsforthread

    .Inspectfiltershellgasketsurfaces

    ons.Smoothoffedgesor projectionsif

    efvalveandspringforwearorbreakage,

    ed.Inspectoilfilter baseandifwarped,

    E.Placeoilpressurereliefvalvein

    ftermakingsureseatis clean.Insert

    g.Installa newgasket,andinstalland

    rely.,

    LSANDCENTERTUBES.Placefilter

    efiltershells withconvexsurfaceup-

    ovesin theoilfilterbase areclean

    sketsingroovesaftercoatingwith

    d.Placeshellsinpositionon gaskets,

    dcentertube bolts.Tightencenter

    specialsocketwrench(seesubpar.a

    RIDGES.Placenewfiltercartridgesin

    tubes.Installnewgasketsonfilter cover

    gson filtercovertopfittingsatunder

    rsonfilters,and tightenfittingssecurely.

    TS.

    aneousparts,suchasbrackets,

    pan,engineflywheelhousing,removed

    ubassembliesin paragraphs7to18

    scrubbedindry-cleaningsolvent.

    mustbemadeofall otherengine

    semblyofthe engineandnotcoveredin

    eck12valvepushrodsforstraight-

    bentor havelooseends.

    ksordeepdents,andstraightenor

    eplateininvertedposition.Check

    gtoinserta 0.015-inchfeelergagebe-

    te.Grindflangesurfacetotrue-up if

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    E5-TON4x 8TRACTORTRUCK(C.O.E.)

    uganddrainplugboss forfitand

    seorthreadsaredamaged,replaceplug.

    rewornor damaged,repairorreplace

    ONDAMPER.Inspectcrankshaft

    enceofrubbercomingloosefromsteel

    ewanddowelholesfor wear.Replace

    sencountered.

    VEPULLEY.Inspectcrankshaftfan

    ehubbore.Ifinner diameterofbore

    placepulley.

    VER.Inspectenginegearcasecover,

    roken.

    keachof12enginevalvetappetsfor

    racking,orscores.Replacetappetsif

    USING.Inspectengineflywheel

    kage.Inspectflywheelhousingto

    esforwear.Alsoinspectdowelsforwear.

    EARINGSEALRETAINER.Inspectpilot

    erandlowerhalvesofrear bearingoil

    rred,cleanuporreplaceretainers.

    eplateto checkfordistortion,and

    NDLOCKWASHERS.Inspectallcap

    shersforthreadwearorbreakage,and

    ALS.Allgasketsandoilseals mustbe

    ormajorrepair.

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    E.

    einEngineOverhaulStand.

    eanedandi nspected,andnecessary

    ured,installenginecrankcaseinengine

    mbly.

    rankshaftMainBearings.

    crankshaftmainbearingjournals,

    rankcase.Removebearingcapbolts

    ehalfofbearingshellsinposition,making

    eatedinthe-bores.Besure thatoilholes

    holesinbearingshells lineup,andthat

    itinto recesses.Wipebearingboresfor

    pebacksofbearingshells.Placeshell

    he rearmainbearingismadeup of

    withfourthrust flanges.Thetwolower

    positionbydowelsinthe mainbearing

    alight filmofheavyengineoilon

    cecrankshaftinpositioninshells.Install

    ringandThrustFlangesin Cap

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    E S-TON42TRACTORTRUCK(C.O.E.)

    ainBearingCapBoltsUsingWrench(41-W-3630)

    uretoplacecaps inrespectivepositions

    marksmadeattimeofdisassembly,and

    bearingboltstoatension of85foot-

    ankshaftrearmainbearingreplace-

    nengineoverhaul,requiresremovaland

    SealRetainer

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    nbearing oilsealretainerandrear main

    resthatthe crankshaftbesoplacedthat

    sareparallelto thecrankcase.

    clearanceseitherusingvirginlead

    meters,or,ifthismaterialis notavail-

    t asfollows:Removeonemainbearing

    Cuta 34-inchsquarepieceofpaper

    0.002to 0.004inch.Placethispieceof

    ournal.Reinstallthebearing capand

    85foot-pounds.Theadditionofpaper

    edragonthe crankshaft.Incaseitdoes

    differentbearingshell.CAUTION:

    llowthis procedurethroughallseven

    nddestroythetestpaper.

    caps,andcoatbearingshellswith

    mainbearingcapsandmainbearing

    85 foot-poundswithatensionwrench.

    e crankshafttocenteritselfbetterin

    allmainbearingbolts(unlessself-

    ).

    ealRetainer.Coatnewgasket

    ound,andplaceinposition onrear

    case.Placeloweroilsealretainerin

    pscrewsandlockwashers(fig.53).

    ely.

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    ES-TON4x STRACTORTRUCK(C.O.E.)

    oothMarking

    rankcase.Insertall12 valve

    incrankcase.Pushupintoretaining

    onofcamshaft(fig.54).

    koase.

    journalsurfacesandcamlobeswith

    mshaftintopositionincrankcasefrom

    to damagethecamshaftbearings.Be

    rankshaftgearandon camshaftgear

    ncamshaftisin position,installtwo

    ersincamshaftthrustflange.Release

    ngclipstopermitthem torestonthe

    etsforfreedomofmovement.Ifbind-

    toseeifclips wereinsertedtoofar.

    dcamshaft,andnotetiminggear

    ceisfrom0.004to0.006inch.Check

    012inch,replacegears.

    ousingonCrankease.

    nthe crankshaftrearmainbearing

    all newgasket,andinstallupperseal

    threecapscrewsandlockwashers.

    nerseats squarelyandthatlower

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    chPilotBearing

    es inupperretainer.Ifnot,remove

    elongatecapscrewholesslightly.

    engineflywheelhousing,andinstall

    sandlockwashers.Taphousingwith

    overdowels.

    onCrankshaft.Placeengine

    osition oncrankshaftflangedowels.

    et startedoverdowels.Installsixself-

    ghtenevenlyandsecurelytoatension

    nsionwrench.

    ngin Flywheel.Packanew

    lland rollerbearinggrease.Install

    haftwitha driftorpieceofbar stock

    Cover.Insert oildeflectorand

    rcasecover.Afteroilsealand deflector

    ofnewgear casecovergasketwithjoint

    dplaceongearcasecover,aliningcap

    secoveroverendofcrankshaft,and

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    CES-TON4x2TRACTORTRUCK(C.O.E.)

    xcap screwsandlockwashers(fig.57).

    SOto 35foot-poundswithatensionwrench.

    Pulley.Thepulleyhubisa tight

    m0.0035to0.002inch.Heathub in

    stallationoncrankshaft.Placehub on

    noverWoodruffkeyin crankshaft.

    ximately30-inchleveragetotightennut.

    tionDamperonCrankshaft

    brationdamperonpilotdowelsof

    capscrewsandlockwashers,and

    ot-poundswithatensionwrench.

    .Placenewoilpumpgasketin

    8

    ftSlotLocation

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    ngCompressor(47-C-2550)

    ertoilpumpbodyin boreofcase,

    and thegearonthe camshaft.NOTE:

    alledwiththeslotat thetopofthe oil

    hown infigure58whenthe engineis

    ylinder.Thiswillassureproper installa-

    ll twocapscrewsandlockwashersin

    ectingRodAssemblyinCylin-

    nnectingrodand pistonassemblyin

    nnectingrodsarenumberedthesame

    eyare used.Compresspistonrings

    or(41-C-2550)whilepushingpistoninto

    emblymustbeinstalledwitharrowon

    f engine.

    earingsandConnectingRod

    grodand backsofbearingshells

    sinconnectingrodbore,beingsure that

    aringshelllinesupwith oilholeincon-

    gtangsof bearingshellsfitintorecesses

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    Pullconnectingrodandpiston as-

    topermitplacingin positiononcrank-

    installationofconnectingrodcapwith

    gshellsurfaceswithengineoil, andin-

    eingsurethatpilot lugsofcapfit into

    d.Installself-lockingconnectingrodbolts,

    f60foot-poundswithatorquewrench.

    nnectingRodBoltsUsingWrench(41-W-3630)

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    asket

    asket

    et

    hafttoestablishfeelordrag ofrod

    dcapboltsandremovecapandbear-

    gclearancebyplacingapieceof paper

    a thicknessoffrom0.0015to0.0035

    ingrodbearingshellandthe crankshaft

    bearing,andtightenconnectingrod

    sion.Revolvecrankshaftandnote

    paper hasimposedanoticeabledrag.

    ngand repeattest.CAUTION:

    dtightenconnectingrodboltsto 60-

    orquewrench(fig.61).

    ectingRodsandPistons.Re-

    chremainingconnectingrodandpiston

    gineoil pansidegasketswithjoint

    dplaceinpositiononflangesof crank-

    anfrontand reargasketswithjointand

    ceinpositionatfrontand rearofcrank-

    E:Thesidegasketsmust joinbutnot

    tainergasket(fig.62),andtherear gasket

    askets(fig. 63).

    n,installtwonutsandlockwashers

    pan,and install10capscrewswithout

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    CE-5-TON4S TRACTORTRUCK(C.O.E.)

    41-W-2964-710)

    41-W-2964-715)

    ningSequence

    linderHeadBoltt

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    h nutsinoilpan flange.Tightenall

    yandsecurely.

    dGasketon Engine.

    derheadlocatingstud attopofeach

    gasketandcylinderhead.Withsurfaces

    erblockcleanedofforeignmatter,coat

    andthreadcompound,andplacegasket

    tsidemarked"THISSIDE OUT"

    ylinderheadonblockover locating

    uds.

    boltsandflatwashers,omittingthe

    theleftsideas thisrequiresthespecial

    totherockerarms andholdstherocker

    htenevenly,alternately,andsecurely

    undswithatorquewrench(41-W-3630)

    41-W-2964-715and41-W-2964-710)

    newgaskets,andtightento30-foot-

    andShaftAssembly.

    dsinsocketsincylinderhead.In-

    shaftassemblyon cylinderhead.Turn

    ckerarmsas faraspossible.Installsix

    oltsandflatwashers,andtighten to30

    ledoilbolt atthethirdhole fromthe

    videoilto therockerarmsandshafts.

    dcoverspacernuts.

    ckerArmClearance.Toadjust

    eachrespectivecylindershouldbeon top

    ssionstrokeatthe timeofvalveadjust-

    rrectposition,turntheenginecrank-

    ttop deadcenteroncompressionstroke

    eignitiontimingmark onthevibration

    pointeronthe timinggearcover.Adjust

    onNo.1cylinderto from0.018to0.020

    -thirdturnandadjustvalvesonNo. 5

    order1-5-3-6-2-4,turningcrankshaft

    ngvalvesforeachcylinderin theabove

    een adjusted.NOTE:Recheckvalve

    tartedandhasreachednormaloperating

    eisstartedandhasoperatedat least30

    erheadboltsandreadjustvalveclearance.

    er.Coatnewvalvelift rod

    threadcompound,andplaceinposition

    r,sixcapscrews,andlockwashers.

    chometerDriveHousing.

    ometerdrivehousinginpositionon

    ocoincidewithdrivelugsonoil pump

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    E5-TON4x 2TRACTORTRUCK(C.O.E.)

    screwsandlockwashersin drivehous-

    ountingBracket.Coatair

    mountingbracketplategasketwithjoint

    dinstallgasketandplatein positionon

    ercapscrewsandlockwashers.Coat

    tingbrackettoplategasketwithjoint

    dinstallinpositionon crankcase.Install

    tallfourcapscrewsandlockwashers.

    securely.

    stManifolds.

    pilotrings inintakemanifoldports

    wintakeandexhaustmanifoldgaskets

    eintakeandexhaustmanifoldsover

    flatwashers.Tightenallnutsevenly

    oundtension.

    oldexpansionclampscrews,and

    manifoldcapscrews.

    woil fillergasketwiththread

    laceinpositionon crankcase.Install

    pscrewsandlockwashersinbaseof oil

    atorMeteringValve.Install

    eringvalveonoilfiller,havingarrowpoint

    mlineatventilatormeteringvalveand

    lveRockerArm)Cover.Pour

    over topofvalverockerarms,valve

    ds.Coatnewcylinderheadcovergasket

    ound,andplaceinposition around

    ment.Installcover,fourflatwashers,

    s.

    reather.Screwcylinderhead

    dcoverboss.

    lowprocedureoutlinedinTM

    followingaccessories:carburetor,oil

    orandconnectingwires,crankingmotor,

    coil,waterpump,thermostats,andair

    ermakingcertainthat oilpan

    fill enginecrankcasewithengineoil.

    enstartedandhas runforatleast 30

    level.

    OverhaulStand.

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    ES.

    wParts

    d0.008in.

    in.

    2495to 3.2505in.

    rnalout-of-round.0.003in.

    7510to2.7520in.

    urnalout-of-

    4to0.012in.

    ay0.020in.

    erun-out0.002in.

    n-out0.004in.

    bearing

    atintermediate

    onfrontand

    4in.

    tofshaftat in-

    6in.

    pulley0.0005to 0.002in.

    gs(7).

    002to0.004in.

    arance0.008in.

    n.-oz

    within8in.-oz

    e0.005in.

    oreonface0.006in.

    oreinbore0.010in.

    ntisnecessary.

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    E5-TON4x JTRACTORTRUCK(C.O.E.)

    e0.0015to0.0025in.

    ondata:

    8to 1.1090in.

    to0.1280in.

    n.

    6in.

    1in.

    00to0.0002in.

    F0.001in.

    odat70 F0.0005to0.0006in.

    ectingrodat

    sion.

    e0.0015to0.003in.

    learance0.005in.

    ol.

    e0.0015to0.0035in.

    learance0.005in.

    995to9.005in.

    hell

    hing

    80to2.8985in.

    8to1.219in.

    rallelwithin0.005in.

    bores,parallel

    ntisnecessary.

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    s.

    007to0.013in.

    e0.0015to0.0035in.

    clearance0.006in.

    :

    .

    n.

    earingswhen

    rontandrear

    ediatebearings0.006in.

    105to0.2125in.

    mmended)0.002to0.0035in.

    ce0.008in.

    standintakeHeto%m-

    .020in.

    255in.

    .4340in.

    75in.

    0015to0.0035in.

    arance0.006in.

    eg

    ntisnecessary.

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    E 5-TON4x2TRACTORTRUCK(C.O.E.)

    ued

    40deg

    .........2in.

    .......0.018to0.020in.

    eg

    ...........1.534to1.544in.

    ........0.4335to0.4345in.

    .....0.4365to0.4375in.

    ................0.002to0.004in.

    arance...................0.008in.

    ........................55deg

    ........................15deg

    250deg

    ........................1%in.

    ......;.......2%in.

    .......................1H in.

    .........................86lb

    eat1J in..................76lb

    in.

    ......................14%in.

    .......................136lb

    eat14%in .................126lb

    ......0.004to0.006in.

    ......0.012in.

    o300 rpm).........10to15lb

    00rpm.................2to5 lb

    00to1,800

    ..........40to45Ib

    ..........0.003to0.006in.

    .........................0.012in.

    ntisnecessary.

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    5in.

    92in.

    gear0.4885to0.4890in.

    7to 0.488in.

    5in.

    0.488in.

    13to0.003in.

    ody0.006in.

    Press fit

    to 0.0035in.

    aft0.0006in.

    02to0.004in.

    cover0.006in.

    5to0.006 in.

    r0.872to0.873in.

    0.0015to0.004in.

    o0.9535in.

    25in.

    110in.

    ming0.862to0.864in.

    ingorhoning..0.8745to0.8760in.

    to0.004in.

    ntisnecessary.

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    ES-TON4x STRACTORTRUCK(C.O.E.)

    TA,

    clampingadrivendisk betweenthe

    eclutchpressureplate,therebytrans-

    ughthetransmissiontodrivingunits of

    s splinedtothetransmissiondrive

    efacingoneachside. Toobtainsmooth

    nalView

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    ressureplatemovesperpendicularlytothe

    sothatthe completefrictionsurfaceis

    amemoment.Theheatgeneratedby

    y 20clutchpressureleverstoprevent

    ndiskfacingand clutchpressureplate.

    espringactson asleevewhichtrans-

    20clutchpressurelevers.Thelevers

    ndthentransmitthe increasedpressure

    evers haveraisededgesthatactasfan

    rthroughthe clutchspringandintothe

    uniformpressureagainstthepressure

    atthemovementofthepressureplate

    perpendiculartotheplane ofthefriction

    engagedbydepressingtheclutchpedal,

    owardtheflywheel.Actionontheclutch

    tothe forceoftheclutchpressurespring

    elievespressureagainst thepressure

    byfourclutchretractorsprings,thus

    rivendisk.

    hismade byremovingshimsfrom

    ngstraps.Thismethodofadjustment

    ceoftheclutch.Inthevehicle,theclutch

    inorder tomaintaintheproperamount

    releasebearingandclutchpressuresleeve.

    securedto theengineflywheelby12

    ecapscrewsmakesitpossibletoli ft

    eassemblyandthe drivendisk.

    s4

    tingstrap 6

    ngball%in.

    ePlate.

    ateassemblyinhydraulicpresswith

    efacingupward.Compressclutchpres-

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    E-S-TON4x 2TRACTORTRUCK(C.O.E.)

    ClutchFigure67 RemovingClutch

    rePlateRetractorSpringPin

    MBLY

    Clutch

    ngRemoval

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    RingRemovingPressureLevers

    Ring

    gClutchFlywheelKing

    of woodonthethrustsurfaceofthe

    Caremustbetakenwhileperforming

    exertedbythe clutchpressurespringis

    ertoliftupthefour clutchretractor

    mitr emovalofretractorspringretaining

    ofthesprings(fig.67).

    assemblyfromclutchpressureplate

    ssurePlateAssembly.Unhook

    ractorspringsfromtheclutchpressure

    ng.

    bybending a25J -inchpieceof

    eelbarto forma"U".Thecrosspiece

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    E5-TON4* >TRACTORTRUCK(C.O.E.)

    TE

    RemovingAdjustingShims

    justingPlateandShims

    r-all.Thelegsformedbythe"U"should

    g.If materialorfacilitiestoconstruct

    e,threehardwoodblockscanbe used

    eofhardwood toformacrosspiece

    egs(fig. 69).

    ngassemblyonpresswithclutch

    gdownward(fig.69).

    dblockson clutchflywheelring,and

    crosspieceto compressclutchpressure

    ingsnapring,and pryoutofrecess

    rdistortionofsnap ringbyexcessive

    wheelRing(fig.71).

    rumring.Lift off20clutchpressure

    pressureleverlockingballs,andliftoff

    Releasehydraulicpressgently,and

    ocks.Liftclutchflywheelringfrom

    essuresleeve.

    wheelringstudnutsand lockwashers.

    outofclutchflywheelring,tapping

    essary(fig.72).Removeallclutchad-

    four clutchflywheelringstuds(fig.72).

    xclutchadjustingshimson eachclutch

    are lessthantwoshimsremainingon

    ndiskfacingis undoubtedlywornand

    ON,ANDREPAIR.

    assemblyoftheclutch,allparts

    edwithdry-cleaningsolvent,anddried

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    tchPressurePlateforDistortion

    ATE.

    racks.Placeclutchpressureplate

    ionsurfacedownward(fig.73).Attempt

    rgagebetweenthesurfaceplate and

    ththefeelergageat theboreofthe

    outeredge.Repeatthischeckatsixor

    ndthepressureplatebore. Ifpressure

    ginsertionofthe feelergage,discard

    all anewplate.

    eenlugsonpressureplateandmilled

    (step(10) below).

    ATERETRACTORSPRINGS.Visually

    actorsprings.Ifsprings arestretched

    ecoils,discardthe springs.Springs

    itionandhavenogap betweencoils

    NGS.Placeeachclutchfulcrumring

    emptto inserta0.002-inchfeelergage

    ndthesurfaceplate.It shouldbeim-

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    E5-TON4x1TRACTORTRUCK(C.O.E.)

    69

    chFlywheelKing

    r

    gagebladeifthefulcrumrings areflat

    spectfulcrumringsfora wornorscored

    herethe leverlockingballsroll.If

    newfulcrumrings.

    LATE.Makeavisualinspectionofthe

    gplate,and fileoffanyburs.

    allyinspecttheboreoftheclutch

    urswitha file.Testsleevefitin the

    eshouldbean easyfitinthe adjusting

    ustbetappedi nwithahammer.The

    sleevemustbe freeofanyridgesor

    isworn.

    VERS.Visuallyinspectthe20clutch

    points ofcontactwiththeadjusting

    e,andclutchfulcrumring.Ifdeeply

    vers.

    suallyinspectclutchsnapring,and

    of-round.

    VERLOCKINGBALLS.Inspectthe20

    ngballsforwearor flatspots.Replace

    und,ordo notmeasure%inchin

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    ASSEMBLY.

    hichholdtheclutchdrivendiskto the

    replaceanythatare loose.

    utchdrivendiskon surfaceplate.

    dordistortion.

    sin thedrivendiskhub.Dressoff

    rivendiskbysliding intoclutchshaft

    of thediskshouldslideeasily intothe

    nd drivegearwithoutbinding,andwith

    ay.Ifside playismorethanbarelyper-

    k jsbent,itmust bereplaced.

    RING(fig.74).

    ngona surfaceplatesothatthe

    facingupward.

    ateonclutchflywheelring,with

    ediatelyabove"O"markingonring,

    gmilled slots.Atthesametimeinsert

    toaslot nexttoalug.

    eplatesidewiseand awayfromthe

    ismovedtothe farsideoftheclutch

    betweenlugandslotis from0.004to

    ximumclearancebypullingthe0.006-

    snug.Ifitis loose,useanewclutch

    hflywheelring,or both.

    earancewitha0.004-inchfeelergage.

    t, useanewclutchpressureplate

    ,orboth.

    rtswith0.006-inchand0.004-inch

    PRING.Visuallyinspecttheclutch

    es,andreplaceifbroken.Testspring

    es.Pressuremust befrom525to575

    NGSTUDS.Ifclutchflywheelring

    d,"removethemfromtheflywheelring

    ACINGS.Drilloutthe36 rivetsthat

    ingsto theclutchdrivendisk.Drill

    of rivet.Liftthefacingsfromtheclutch

    UTION:Donotuseabrakerelining

    ortheclutchdrivendiskwill besprung.

    DiskFacing.Placethetwo

    ontheclutchdrivendisk,and rivetfac-

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    E

    AND

    CKINGBALLS

    embled

    diskfacingrivets.Makecertainall

    formthickness.Rivetsmustbebeneath

    k.Visuallyinspectthe clutchdriven

    tbeendistortedor bentduringthe

    disk,ifdistortedorbent.

    eelRing.

    ngplatein theclutchflywheelring.

    plateiswithinaninch oftheclutch

    76).

    ngshimson eachofthefourclutch

    fourclutchadjustingstraps.Tap

    nontoshims.

    eelringstud nutlockwashersand

    e.

    pringsleeveonsurfaceplatewith

    ceclutchsleevepilotconeinclutch

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    TE

    TUD

    CH

    L

    DNUT

    chAdjustingShims

    ONE

    chPilotBearingCone

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    CE5-TON4xSTRACTORTRUCK(C.O.E.)

    sideofsleevewithball androllerbearing

    urespringontheclutch sleeve,small

    eelringandclutch adjustingplateon

    Rotateflywheelringuntil stopon

    ndof spring(fig.78).

    ClutchPressureSpring

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    UP

    chSnapRing

    keorwoodenblocksonclutchflywheel

    ress,compressclutchpressurespring

    eevepilotcone.

    evers.

    umring,cuppedsideup,overthe

    tchpressureleversontheclutchflywheel

    the lockingballmustrestonthe clutch

    siteendmust restjustinsidetheretain-

    eelring.

    everlockingball inholeineach

    ballsmustresti nthecupofthe clutch

    umring,cuppedsidedown,over the

    gdownfirmly.Makecertainthat

    eleverlockingballs havebeendisplaced.

    ot coneintheclutchsleeve(fig.80),

    p ringontotheconeas faraspossible.

    tcuponclutchsleevepilot cone.The

    ot cupmustfitintothe pilotcone.The

    trestagainsttheclutchsnapring (fig.80).

    epilotcuponeormoresharp blows

    sinits grooveintheclutchsleeve.

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    INGTOOL

    D32J576

    hSnapRing

    ot cupandclutchsleevepilotcone

    of clutchsnapringareoutof line

    sleeve.Iftheyhappento beinline,use

    mmer(rawhide)tomovetheclutchsnap

    Usingaclutchsnapringstakingtool and

    tightlyinto theclutchsleevegroove.

    ap ringandtapfromcentertowardthe

    lyin clutchsleevegroove(fig.81).

    ureLevers.Makecertainthat

    ockedinplacebyclutchpressurel ever

    ingtheouter endofeachleveruntil

    ofthefulcrumring. Releasehydraulic

    woodenblocks.

    ate.

    ateonthe clutchflywheelring

    edonthe edgeoftheclutchpressure

    placedadjacenttotheletter"O"stamped

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    of theclutchflywheelring.Ifletter"O"

    othoftheseparts, disregardthisstep.

    tchpressureplatelugsinclutchfly-

    (10)).

    Springs.

    retractorsprings.Hookoneend of

    pressureplate (fig.67).

    replateand flywheelringassembly,

    ss.

    lutchretractorspringthroughholein

    aiseendofspring withspringforktool

    gjustfarenoughto pushclutchretractor

    g.Followthisprocedureforeachof

    ES.

    ensionsof

    edrivinglugsin

    0.006in.

    ebearingY%to6{2m-

    eelringinclutch

    releverlockingball%m-

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    E5-TON4x8TRACTORTRUCK(C.O.E.)

    gsystemofthisvehicleconsistsof

    iontank,fan,waterpump,a recirculat-

    twothermostats,andsuitableconnec-

    sundera pressureof3Yito 4*/pounds.

    eefficiencyofthecoolingsystem,since

    raisedabout3degreesforeachpound

    typesurgetankcaphasa pressure

    sesat3^ to4^pounds,anda vacuum

    1-inchvacuum.Therecirculatingsys-

    olanttocirculatein theengineuntilit is

    circulationthroughtheradiator.

    miscontrolledbytwothermostats

    ostatisfullyopenwhenthe enginei

    140Fto150 F.Theoutletthermostat

    s cold,startstoopenat145 Fto150F.

    .Whentheengineis cool,theclosed

    by-passthermostatcausethewater

    antthroughtheenginewithoutpassing

    eengineand coolantwarm,the

    opensandtheby-passthermostatcloses,

    ulatethroughtheradiatorin thenormal

    ansionchamberoftheradiatorpro-

    coolantwhichexpandsasitwarmsand

    adiator proper.Astheliquidcools,

    anttakesplace,theliquidin theexpan-

    ntothecoolingsystem.

    nofthecoolingsystem,wateris

    heradiator upintothe'waterpumpand

    theenginecrankcaseandcylinderhead

    ace.Thehotwaterthenisforcedout the

    housing)intotheupperportionof the

    esdownthroughthe radiatortubes

    awnthroughtheradiatorby thefan.

    backovertheenginetoaid inthecool-

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    TA.

    orofthisvehicleis oftubularde-

    getank(expansionchamber)inits upper

    ntedonthefrontofthe frameontwo

    ngstudsarespring-loaded,thusim-

    unting.Theradiatoris protectedat

    abrushguardgrille, anditis surrounded

    g.83).

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    ES-TON4x2TRACTORTRUCK(C.O.E.)

    lled

    ............2^6

    ..........2>gx

    r(2used)

    CTION.

    movaloftheradiatorcore,itmust

    ccumulateddebris.Foreignmattermust

    f thefinopenings.Theradiatormust

    byreverseflushingto removeallaccumu-

    .Washingsoda isaneffectiveagentfor

    eflat andmaybecleanedoutbyuse of

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    er,suchservicewillrequireremovalof

    romthe coreassembly.

    ectradiatorfillercapandsurgetank

    ey fittightlyontheir respectiveopenings.

    helugs untilthecapdoesfit snugly.

    eplaceifdefective.Inspectspringsand

    rereliefcap.

    cktheradiatorcoreforleaks.Plug

    pertankinlet opening.Insertanair

    nkinletfitting.Connecttheair com-

    oundair pressureintotheradiatorcore.

    kofwater.Markpointswhereairbubbles

    eaks,andagain inspect.CAUTION:

    ssufficient.Strongerairpressuremay

    NTINGS.Visuallyinspectthefabric

    fwornordamaged,replacewithnew

    coremountingcapscrews,andreplace

    estmountingspringsfor breakageor

    fweakorbroken.

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    ES-TON4x8TRACTORTRUCK(C.O.E.)

    'd

    TA,

    umpisofcentrifugaltypeand isof

    dto thefrontendofthe engineandis

    requiresnoexternaladjustment.

    eimpellershaftandbearingsfromthe

    84).Thewaterpumpassemblyiscom-

    rplatewhichareboltedtogetherand

    gmountedpumpshaftandimpeller.

    SEALWASHER

    ectionalView

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    aterPumpSnapRing

    sare pressedontotheshaftandare

    ngeris heldinplacebytwohalf ring

    withitstwobearingsis heldinplacein

    snapring.Thefanpulleyis pressed

    0.0007to0.0018inch)andheld inplace

    .Theimpellersealassemblyconsistsof

    g, rubberseal,sealspringguide,and

    partsare heldinplaceinthe impeller

    erandsealassemblyispressedonto

    of0.002to0.0035inch).

    rpumpisdrivenbytwoV-beltsfrom

    bymeansof centrifugalforcedeveloped

    awswaterupfrom thelowerpartof

    pump bodyandforcesitintothe water

    eandcylinderhead.Thewatercirculates

    dcylinderheadandthenoutthrough the

    rintotheradiatoruppertankafter it

    totherecirculatingsystemandbackinto

    nedoperatingtemperature(par.27b).

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    terPumpShaftFromImpeller

    Removefourcapscrewsandlock

    ey.Removefanbladeassemblyfrom

    movenutandflatwasherholding

    L

    Disassembled

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    LLER

    movepulleyfromwaterpumpshaft

    ate.Removefivecapscrewsfrom

    erplateandgasketfrompumpbody.

    ngs.Removesnapringfromin

    mp shaftbearing(fig.85).Supporting

    ,pushshaft andbearingsasanassembly

    ear(fig.86).

    Bearings.Supportingtheshaft

    narborpress, forceshaftoutofbearings,

    bearing.Becarefulnotto losethetwo

    undertheslinger.

    dSealAssembly.Removesnap

    ontofimpeller,andliftout thesealparts

    CTION.

    assembly,washallexceptrubber

    nt.

    alpartsforwear,corrosion,or

    newpartsasnecessary.Examinethe

    ce.Iffaceof surfaceisscored,itmust

    eakage.Inspectpumpshaftbearingsfor

    r corroded,replacebearings.Examine

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    E5-TON4xSTRACTORTRUCK(C.O.E.)

    fordamagedthreadsatfrontend.Re-

    aged.

    seatsurfaceisscored,pitted,or

    ed.Usespecialwaterpumpbody seal

    83).

    ShaftandBearings.Installrear

    bearingontowaterpumpshaft.Place

    ear bearing.Placetwohalvesofretainer

    t,andpressshaftintobearingsfrom rear

    t firmlyagainstslingerandslinger

    SealAssembly.Placesealclamp

    g guide,rubberseal,andsealcarbon

    eller.Holddownin positionwhile

    ellergroove.

    s.Installwaterpump shaftand

    y,andholdin placebyinsertingsnap

    ontbearing.

    llerSeal Assembly.Sup-

    tfrontend, pressimpellerandseal

    waterpumpshaft.Press impelleronly

    .88).

    y.Supportingimpellerendof

    aterpumppulleyontoshaft.Install

    ntendofimpellershaft.

    newgasketinposition onwater

    verplateandfive capscrews.

    Removepipeplugfromsideof

    ctabout2ouncesof generalpurpose

    ousingapproximatelyone-halffull.

    deassemblyin positiononfront

    p screwsandlockwashers.

    ES.

    ensionsof

    n.

    n.

    6693in.

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    4in.

    .6262to0.6267in.

    002to0.0035in.

    0.0007to0.0018in.

    ubshaft

    re0.6232to 0.6242in.

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    ES-TON4x2TRACTORTRUCK(C.O.E.)

    'd

    TA.

    ostats,oneanengineoutletand

    sthermostat,areusedin thisengine

    atsarelocatedin ahousingatthe

    ginecylinderhead.Eachthermostatis

    eraturechangesaffectacoilspringwhich

    toclose.Thethermostathousingiscon-

    andalso totheradiatoruppertank.

    MOSTAT.Theclosedvalveofa cool

    preventscoolantfromleavingtheengine

    vestartstoopenat 145Fto150F.

    pproximately180F.

    .Theopenvalveofa coolengineby-

    olanttoleavetheenginebut preventsit

    bypassingit backintothewaterpump

    assthermostatstartstocloseat140 F

    edatapproximately165Fto170 F.

    thermostatpreventscoolantfromre-

    ntilit haspassedthroughtheengine

    radiator,whereitiscooledforrecir-

    ner.

    MOSTAT.

    0F

    .

    0F

    F

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    CTION.

    moval,thethermostatsmustbe

    lvent.

    ermostatbyimmersioninwater

    ermometer.

    mostatshouldbe fullyclosedincold

    oximately145F to150Fas thewater

    enatapproximately180F.

    rmostatshouldbefully openincold

    eris heatedto140Fto 150F,andbe

    ely165Fto170F.

    toshowsatisfactoryopeningand

    nnotberepairedbutmustbereplaced.

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    TA(fig.89).

    xleofthis vehicleisofI-beamtype

    untedattheends.Theaxleis attached

    thefrontsprings,andto thesteering

    esteeringgeararm tothefrontaxle

    ringknucklesareconnectedbyatie rod.

    X3

    modelT-163

    knuckle1

    ,582

    AMBER

    embly

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    dRing

    Cone

    one

    ontWheelHubandBearings

    521

    4,367

    ,320

    bandBearings.

    movethreescrewsandlockwashers

    ,and removecapandgasket.

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    E5-TON4x1TRACTORTRUCK(C.O.E.)

    Washers

    s

    k

    ontWheelBrakeShoes

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    E5-TON4x 1TRACTORTRUCK(C.O.E.)

    keCamshaftandSlackAdjuster

    ningcapscrew,lockwashers,and

    siteendofanchorpins. Driveanchor

    eswitha drift.

    S.Thetwobrakeshoescannowbe

    rake backingplate.Aftertheshoes

    brakeshoereturnspringsfromthe brake

    .Removecotterpinfrombrake

    epinat slackadjuster,andremoveyoke

    ngwirefrombrakecamshaftcollarset

    ndslipcollarfromshaft.Slide slack

    haft,andremovecamshaftfrombracket

    ber.Removetwonutsandlock

    ACKET

    BrakeChamberandBracket

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    ambermountingbolts,andliftbrake

    ketfrombackingplate(fig.95).Remove

    boltsfromthebackingplate.

    ftBracket.Removetwonutsand

    pscrewsretainingbrakecamshaftbracket

    ketfrombrakebackingplate(fig.96).

    womountingcapscrewswithlock

    te.

    ease(>uard(fig.97).Remove

    meightcapscrewsholdingbrake drum

    kingplate.Removegreaseguardand

    .

    eeringArm.Removecotterpin

    emovenutfromballstud.Strike end

    o drivestudoutofsteering arm.Re-

    asherandspring.

    etoBrakeBackingPlateBolts.

    ourbrakebackingplatetosteering

    efournuts,andbolts.

    kleKingPill(fig.98).

    topof steeringknucklekingpin,and

    asherretainer.

    asherfromkingpin drawkeyand,

    keyfromaxleI-beam.

    eeringknucklewithadrift.

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    E5-TON4x1TRACTORTRUCK(C.O.E.)

    al

    eyRAPD323588

    eeringKnuckleKingPin

    kleandBackingPlate(fig.99).

    ckle,thrustbearing,brakebacking

    omaxleI-beam.

    s.Removecotterpinandnutfrom

    teeringarmoutof steeringknuckle

    ovekey.

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    kle

    CTION.

    ngsindry-cleaningsolventtoloosen

    saroundindry-cleaningsolvent,revolv-

    movalofgreaseand oil.Whenbearings

    ection.

    agraph66a.

    ERSANDBRAKECHAMBERS.Clean

    kechambersexternally,wipingwith

    eaningsolvent.

    rscruballotherparts withdry-

    avebeencleaned,inspectas

    aringsvisuallyforbroken,rough,or

    rs,andcups,andfordamagedbearing

    veparts.

    CheckaxleI-beamvisually,and

    esarefound.Useaxlealinementcheck-

    dor twist.Specifiedkingpininclination

    morethan1-degreedeviationfromthis

    han^-degreedifferencebetweenends,

    .Inspectsteeringknucklekingpinholes

    ausedbya loosekingpinmakesthe

    outhed.Thisconditionrequiresreplace-

    eI-beam.

    Inspectsteeringknucklesvisually,

    und.Inspectkingpin bushingsfor

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    E5-TON4K 2TRACTORTRUCK(C.O.E.)

    edorif wornsothatclearancebetween

    eeds0.018inch,replacebushings.

    ectsteeringarmsforcracksorsigns

    ound.Makenoattemptto straighten

    forstraightness.Ifbent,tierod

    pecttierodends forlooseness,wear,or

    acedefectiveends.

    INGS.Seeparagraph66.

    spectslackadjustersforwearof

    mage.RefertoTM 9-1827Afordis-

    spectairbrakechambersforsigns

    pring failure.RefertoTM9-1827A

    .

    NGPIN.Inspectknucklekingpin,

    arelyperceptible,replacepin.

    TES.Checkbrakebackingplates,and

    broken.

    RACKETS.Measurewearofcamshaft

    ncebetweencamshaftandbushingis

    placebushing.

    heckbrakecamshaft,andifwearis

    shaft.

    eI-beamistobe straightened,the

    old.Donotheat anaxleI-beam,asit

    kingpinhas beenlooseandholes

    pair canbemadebyboringout holes

    chmustthenbe reamedto1.6095to

    eoldkingpin bushingsfrom

    newbushingsinto place,makingsure

    newbushingsto 1.6095to1.6105

    onusinggrinder (41-G-103).

    end isdefective,eitherreplace

    dreplacedefectivepartsasfollows:

    pressplate,applypressureagainsttie

    spring,andremovesnapringfromabove

    mplug,andremovepartsfromtie rod

    rofremoval.Replacedefectiveparts,

    .

    raph67a.

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    ets.

    brakecamshaftbracketbushings

    ewbushingsintoplace.

    bushingsto adimensionoffrom1.499

    andBackingPlate.

    ateoverendof axleI-beam,andplace

    nwiththrustbearingat bottombetween

    Placespacershimattopof axlebetween

    kingpinfrom top,withkingpin

    hholeinendof axle,andinstalldraw

    Tightensecurely.

    ntop ofkingpin,andinstall washer

    ckleto brakebackingplatebolts

    rely.Installcotterpins.

    seGuard.Install newgasket

    dinstallbrakedrum greaseguardwith

    dlockwashers.

    stalleachsteeringarm withkey

    kle,installnuts andtightensecurely,

    dustcover,washer,shield,and

    vertie rodballstud.Placeballstud in

    ngarm.I nstallendnutonball stud,

    llcotterpin.

    Bracket.Placebrakecamshaft

    ebackingplate,andinstall twocap

    shers.Tightensecurely.

    randBracket.Placeairbrake

    ndboltlockinpositiononbrake backing

    tingboltsfromoppositeside. Placeair

    ertwocapscrewsandagainstbracket.

    sherson capscrews.

    ndBrakeSlackAdjuster.

    rombrakeshoeside ofbackingplate

    dpositioncamhorizontally.

    erin almostverticalposition,and

    s.

    ainingcollaron endofcamshaft,

    alllockingwirearoundretaining collar

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    E5-TON4x2TRACTORTRUCK(C.O.E.)

    mberpushrodat slackadjuster,and

    n andcotterpinatslackadjuster arm.

    onsides andconnectbrakeshoes

    s.

    aceon brakebackingplatewithcam

    kecam.

    einto anchorpinbracketandinsert

    rakeshoe.Guide lowershoeinto

    sertanchorpin.

    groovesinanchorpins,andinstall

    rtoretainlockto backingplate.Place

    chorpins,and installnutsonanchor

    y,andbendlockplateoverlock nuts.

    Placenewfrontwheelhuboil

    erendofsteeringknucklespindle.Slide

    inisentered inlocatingholeinknuckle.

    heelHub. Placebrakedrumin

    line upmountingholes.Install10

    edrum holes.andinstall10nuts and

    ssecurely.

    arings.

    ngconewithwheelbearinggrease,

    onon spindleagainsttheoilseal retainer.

    umon steeringknuckleoverbrake

    conewithwheelbearinggrease,and

    nspindle.

    gnut onspindle,usingslottedend

    adjustingnutwhilerevolvingwheel

    nitebearingdragisfelt.Backoffad-

    thturn.

    erspindleagainstadjustingnut,

    justing nutindexeswithholeinlock

    tlockring. Installlocknutand

    certainthatadjustmenthasnotaltered.

    kthenut.

    newhubcapgasket.Placehub

    installthreescrewsinhubcap.

    rocedureoutlinedinpara-

    n.Afteraxlehasbeen installed

    vehiclerestsonaxle,adjustfront

    chasmeasuredfromcentertocenter

    telyhubheight.

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    ES.

    wParts

    %in.

    abovespring

    .

    ngarmball

    faxleCenter

    teeringknuckle.1.733to1.735in.

    2.3743to2.3748in.

    1.5618to1.5623in.

    rknuckle).

    kle0.005in.

    5to 1.6105in.

    0.0025in.

    0in.

    005to0.0025in.

    et.

    497to1.499in.

    etBushings(2perbracket).

    0.007in.

    o 1.256in.

    004to0.008in.

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    E 5-TON4x1TRACTORTRUCK(C.O.E.)

    in.

    ......1.248to1.250in.

    ..............0.004to0.008in.

    et.

    ..............1.623to1.625in.

    gs(2perbracket).

    .............Split

    ..............1.499to1.501in.

    ......0.003to0.007in.

    ..............0.004to0.008in.

    ......1.493to1.495in.

    ..............0.004to0.008in.

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    TA(fig.100).

    einthis vehicleisofdouble-

    pe.Thedifferentialismountedontop

    g.100).Thefull-floatingdesignpermits

    edriveshaftsmayberemovedor installed

    wheels.Theaxledriveshaftscarry

    ,butare concernedonlywithtrans-

    the rearwheels.Therearwheelsare

    pressedinto therearaxlehousing.The

    hedtothe vehiclebytherearsprings

    sconnectedtothetransmissionand

    afts.Theflowof powerthroughthe

    pellershaftinto thebeveldrivepinion

    e beveldrivegearforthefirst reduction,

    ear throughthespurpinionshaftand

    fferentialspurgearforthe secondreduc-

    smittedto theaxledriveshaftsand

    ).

    WX5

    sembly

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    E 5-TON4xaTRACTORTRUCK(C.O.E.)

    AR

    ewofRearAxleDifferential

    EARINGS.

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    108/227

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  • 8/10/2019 Tm 9-1812 Ihc H-542-9 and H-542-11, Marmon Herrington H-542-11 and Kenworth H-542-11

    109/227

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  • 8/10/2019 Tm 9-1812 Ihc H-542-9 and H-542-11, Marmon Herrington H-542-11 and Kenworth H-542-11

    110/227

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    111/227

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  • 8/10/2019 Tm 9-1812 Ihc H-542-9 and H-542-11, Marmon Herrington H-542-11 and Kenworth H-542-11

    112/227

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