Tm 9-805 CHEVROLET 1.5 TON

7/28/2019 Tm 9-805 CHEVROLET 1.5 TON

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NICALMANUAL

P u b l

i c D o m a i n , G o o g l e - d i g i t i z e d

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a t h i t r u s t . o r g / a c c e s s_

u s e # p d - g o o g l e

7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NICALMANUAL

ermasterCorps10—seriesmanuals,seeparagraph1d

ECEMBER1943

RICTEDMATTER—

byvirtueofhisgrade orpositionloknowl-

sifiedmatter.Suchmatteris entrustedonly

officialdutiesrequiresuchknowledgeor

graph234,AR380-5,15March19+4.)

P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ecember1943

ck(Chevrolet),ispublishedforthe

ofallconcerned.

TARYOFWAR:

ls,seeFM21-6.)


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3

ATINGINSTRUCTIONS

...............15-8

ddata. 2-49-12

ration.. .5-1013-23

ntrolsand

-1524-27

l

-2128-30

emainte-

22-2631-41

...27-2942-49

owageon

3250-51

TENANCEINSTRUCTIONS

s.........3352

tive

453-73

quipment35-3674

.......37-5575-95

data,mainte-

vehicle56-6596-112

nstallation66-67113-117

68-70118-124


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vrolet)

TENANCEINSTRUCTIONS(Cont'd)

71-76125-130

stem77-78131-133

4134-139

ruments,

2-174

75-177

05178

79-185

86-190

30191-206

ngs,hubs,and

bsorbers135-138213-216

45217-221

e146-148222-226

49-153227-229

159230-234

241

247

test167-169248-252

orarystorage170-172253-257


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ATINGINSTRUCTIONS

ispublishedfortheinformationand

personnelchargedwiththe operationand

riel.

ionofl^-ton4x4truck(Chevrolet),

nicalinformationrequiredfortheidentifi-

emateriel.This manualisdividedintotwo

roughsectionVIII,containsvehicle

rtTwo,sectionIXthroughsectionXXXV,

anceinstructionsforusingarm personnel

bilityofdoingmaintenanceworkwithin

atureoftherepair,modifications,or

copeorfacilitiesof theunit,therespon-

ouldbeinformedsothattrained personnel

pmentmaybeprovided,or properin-

upersedestheorganizationalmainte-

ollowingQuartermasterCorpspublica-

k,4x4(Chevrolet)

k,4x4(Chevrolet)

,4x4(Chevrolet)

4x4panel

4x4(Chevrolet)

uck,4x4(Chevrolet)

ructionswiththemateriel,thistechnicalmanualhas

eofcompletetechnicalreview.Anyerrorsor

dbychangesor,ifextensive,byan earlyrevision.


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olet)

on,4x4 Truck

hCab

r

Ton,4x4Truck


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


on,4x4Truck

Winch

Winch

Ton,4x4Truck

Winch

Winch


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evrolet)

n,4x4Truck

EarthBorer

on/4x4Truck

eMaintenance


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LATEDDATA

s3

ninthismanualcoversseveralmodels

x4truck.Thesemodelsallhave145-inch

heels.Theyusethesame engine,trans-

dfrontandrearaxles,with theexception

erand telephonemaintenancetruckswhich

d transfercase.Eachvehiclehasaserial

e(fig.7) locatedontheleftsideof the

Thevariousmodelsareidentifiedas

orer

enance

MODELS.

swithCab(fig.1).Thismodeldoes not

hecab mountedonit.

tor(fig.1).Thisvehicleisthe same

atithas afifthwheelforhaulingsemi-

g.2).Thismodelisequippedwith a

othatthecabis partofthebody.Thereis

abandthe body,asitis asingleunit.

ssWinch(fig.3).Thisvehicleis a

withabody mountedbehindthecab.A

betweenthechassisandthe body.The

otedtothe framesothatthefrontof the

rmitthe operatortodumptheloadwhen

edwithstakepocketsto permitthe

ows,andtarpaulin.

thWinch(fig.3).Thisvehicleis

but,in addition,itisequippedwitha

ame.


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evrolet)

ssWinch(fig.4).Thismodelis the

-7106),exceptthatit doesnothavea

untedrigidlytotheframewithU-bolts.

withWinch(fig.4).Thisvehicleis the

07,exceptthatitis equippedwithawinch

frame.

neEarthBorer(fig.5).Thisvehicle

equippedwithanearthboringmachine

acenter-mountedwinch.

neMaintenance(fig.6).Thisvehicle

odythathas severalcompartmentsbuilt

compartmentsareaccessiblethrough

sidepanels.It isequippedwithpole-

conjunctionwithacenter-mountedwinch.


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LATEDDATA


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vrolet)


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OPERATION

neouscontrols6

ofoneof thesevehiclesmustbe

evariouscontrolsandtheirproper use.

gcontrolsareillustratedin figure7,

ofor thekeylettersshowninthe follow-

hiscontrolisused whenstartinga

okecontrolbuttonshutsoffthe airto

arichmixture.Thechokebuttonmustbe

starts.I ftheengineis warm,theuseof

switchisto turnontheignition

Theswitchis offwhentheleverispointed

handthrottleislocatedon theinstru-

oftheignitionswitch;pullingthis button

ntrolmaybe usedwhenstartingor,ifit

neataconstantspeed.

utchpedalisused todisengagethe

onwhenshiftinggears.CAUTION:The

gedquicklywhenthevehicleisin gear.

will causewearofclutchfacingsand

mustbe1inchof freetraveloftheclutch

rtstodisengage.

ngonthebrakepedal appliesthe

wheels.Avoiddrivingwith footonbrake

tially appliedandcauserapidwearof

cceleratorisoperatedbytheright

theengine.

Pedal(AF).Pressingdownonpedal

kingmotorandflywheelgears,andalso

switch,completingtheelectricalcircuit

kingmotor.Rotationofcrankingmotor

rs,crankstheengine.Whentheengine

edfrompedalimmediately.

ever(AD).Thetransmissiongear-

tvariousgearratiosprovidedin thetrans-


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et)

LOADDATA

WITCH

LATE

UTIONPLATE

TRUCTION

NTADJUSTING

LOCK

TLOCK

TOR

ATE

GHTSWITCH

ONTROLLEVER

ITCH

SWITCH

SHIFTLEVER

RSEGEARLATCH

DAL

TINGLEVER

LEVER

-OFFCONTROL

OLLEVER

OFFCONTROL

tment,InstrumentsandControls


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OPERATION

wardspeedsandonereverse speed.Re-

agedwhenlatch(AE) ongearshiftlever

orvariousgears areshownonshifting

Thehandbrakeleveris usedto

ttherear ofthetransfercase.Pullingthe

erearapplies theparkingbrake,while

sthebrake.Wheneverthevehicleis

pulledtowardthe rearasfaras possible.

e,levermustbepushedforwardtothe

ever(AH).Thetransfercaseshift-

HIGH"or"LOW"speedrange,or

ercase.Seeshiftingdiagramplate(D).

tothefrontaxlecontrolleverin such

toshiftinto thelowspeedinthe transfer

e frontaxlebeingengaged.

(AI).Thefront axleshiftinglever

gagingthefrontaxledrive throughthe

verispushed forward,thefrontdriveis

led towardtherear,itis disengaged.

be disengagedwhenoperatingondry,

ever,thefrontaxleshouldbeengaged

rfacedroadssuchassand,dirt,gravel,

tputtingunduestrain ontherearaxle.

waysbeusedwhenapproachinguneven.

etostall beforegoingintofour-wheel

ControlLever(AJ).Thewinch

eristheleverthat controlsthepower

ake-offattachedtothetransmission.

se,ahingedplate locksthewinchcontrol

.For shiftingpositionsrefertoplateon

er(AK).Thehoistvalvecontrol-

evalveinthehydraulichoist.Whenthe

eleverispulled backtowardtheseat.

ntrolLever(AL).Thehoistpower

edinconnectionwiththehoist valve

ulichoist.Instructionscoveringtheoper-

t controlsarecontainedinparagraph163.

CELLANEOUSCONTROLS.

L).Thetemperatureindicatorindi-

heliquidin thecoolingsystematall

umentindicatestemperatureindegrees

stwatchthisinstrumentcloselyforany

mperature.Whenevertheindicatorhand

hedrivermustimmediatelyinvestigatethe


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vrolet)

MSSION

SSION,

NCH

ONTRANSFERCASE

RIVEWHEN

DSURFACEDRDS

ANSFERC«SE

DRIVEWHEN

DSURFACEDRDS

SSION,

ST

MSSION,

ERCASE

EDRIVEWHEN

DSURFACEDRDS.

MSSION,

RFECTIONHOIST

SSION,

HOIST

structionPlates


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OPERATION

kerlights(fig. 9)andtaillight.Inaddi-

urningon theblackoutdrivinglightwhen

witchispulled out,andalsotheblackout

are applied.Toturnonthe regularhead-

utsafetybuttonontopof theswitch,and

o thesecondposition.Inthisposition,

heregulartail andstoplights.Whenthe

ledout tothethirdposition,it provides

p lightduringdaylightdriving.

witch(K).Theblackoutdriving

ontheblackoutdrivinglight locatedon

Theblackoutdrivinglightcanbeturned

t switchispulledoutto firstposition.

witch(X).Thisswitchis usedto

ts (I)whenthelightswitchis inthe

Theselightswillnot operatewiththe

position.

ch(Z).Thisisa foot-operatedswitch

tbeam(upper orlower)desiredafterthe

ydepressingthe switchbuttonwiththe

ethelowerbeamwhenpassingapproach-

portantsafetyrule.

(D).Shiftingdiagramplatesare

etogivethedriver instructionsonthe

ons.Severaldifferentshiftingdiagram

gonthespecialequipmentinstalledon

andi llustratedinfigures10and 11.

sedwithfour-speedtransmissionand

sedwithfour-speedtransmission,

B",fig.10).


C",fig.10).Usedwith eitherHerculesor

Productspowertake-off.


E",fig.10).Usedwith Perfectionhoistand

wertake-off.


hoist("D",fig.10).Usedwitheither the

theWoodorSpicerpowertake-off.


hoist("F",fig.10).UsedwithPerfection

Spicerpowertake-off.

sedon modelsG-7163Telephone

173TelephoneMaintenancetruck(fig.


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vrolet)

DRIVEWHEN

DSURFACEDRDS.

m,TelephoneMaintenanceVehicles

gCautionPlate("E",fig.7).This

ctionsfordraining thecoolingsystem.

InstructionPlate(F).Thisplate

sregardingoperationofthe winch.

oadSpeedsPlate(A).Thisplate

ssibleroadspeedsatwhichthevehicle

ousgearpositionswiththetransfer case

gure12showsa reproductionofthis

missibleRoadSpeedsPlate

DataPlate(B). Thisplateshows

umber,andloaddata.This information

odels;therefore,attentionmustbegiven

hevehiclebeingoperated.

).Thisplateshowsthe numbers

tenancemanualthatapplytothevehicle.


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OPERATION

HICLE.

s.Beforeattemptingtostartthe

cle,makethebefore-operationinspections.

gearshiftleverandtransfercaseshift

g diagramplate).

bout%inch.NOTE:Thisisnot

m.

ontoobtainproperfueland airmix-

gineiswarm,chokingwillbeunnecessary.

"ON"position.

ocranktheengine.Releasepedalas

onandadjusthandthrottleto obtain

scold,it shouldberunseveralminutes

ethevehicle.

wardtodisengagetheclutch.

ever intoeither"HIGH"or"LOW"

gdiagramplate).

rshiftlevertothel eft,andforwardinto

elever.

torpedaltospeed uptheengine.En-

andpushacceleratorpedaldownasneces-

dpreventstallingtheengine asthetruck

es,releaseacceleratorpedal,depress

egearshiftleverto"NEUTRAL",andthen

tep downonaccelerator,andengageclutch

ragraph.Repeatthisoperationuntiltrans-

rCase.The transfercasemaybe

or"LOW"speedrangewhenthe front

otbeoperatedin "LOW"speedrangewhen

ed.

xle,shiftthetransfercaseintoneutral,

verforward.

xle,shift thetransfercaseintoneu-

ift levertowardtherear.

rCasefrom HightoLowSpeed.

emptedexceptwhenthevehicleisbeing

t astandstill.Frontaxlemustbeengaged

al,andmovetransfercaseshift lever


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evrolet)

ndaccelerateenginetoapproximately

.

gain,andmoveshiftlever forward

vepressure)into"LOW"speedposition.

celerateengine.

rCasefrom "LOW"to"HIGH"

complishedatanytime,regardlessof

epressclutchpedal,andmoveshift

ndaccelerateenginetosynchronize

ehicle.

ndmoveshiftlevertowardrear into

n Transmission.Thetransmission

othe nextlowerspeedbeforeenginebegins

peedis reducedappreciably.Shiftingto

edasfollows:

alquickly,maintainingthesamepres-

gearshiftleverto"NEUTRAL,"andat

heclutch.

hpedal,andmovethe gearshiftlever

gagethe clutchslowly,andatthesame

espeedtosynchronizeitwiththat ofthe

metransmissiongeargoingdownhillas

the samehill.^

eforeattemptingtoshiftinto "RE-

broughttoa completestop.

wardtodisengageclutch.

o "NEUTRAL,"raiselatchon

evertoleftas faraspossible,thentoward

amplate).

eleratetheengineinthe samemanner

eleratorpedal,andapplybrakeby

al.

s beenreducedtoidlingspeedof

tch,andmovetransmissiongearshiftlever

oa completestop,releaseclutchpedal

.

PerformtheBefore-operationService

23;thenplace transfercaseshiftinglever

nt axlecontrolleversothatit isoutof


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OPERATION

ransmissiongearshiftleverin eitherthird

theignitionswitch,andholdthe clutch

instthe floorboard.Starttowingthe

h vehiclesattainasteadymomentumof

our,letthe clutchoutslowlyandusethe

samemannerasif startingtheenginewith

onasthe enginestarts,pushintheclutch

nleverin"NEUTRAL",thenstopboth

etowcar.

e.Placethefrontaxlecontrollever

edrive.Thenplacethe transfercaseshift-

iongearshiftlever in"NEUTRAL".Use

eingtowedto slowuporstopthe vehicle


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evrolet)

NTROLSANDOPERATION

n12

eration14

peration15

treferredtoin thissectionconsistsof

ont-mountedwinches,center-mounted

typesofpowertake-offsrequiredfor

nt.Theoperationofpowertake-offswill

asthepowertake-offis onlyusedasa

eotherauxiliaryequipment.

PERATION.

lock,andremoveextinguisherfromthe

andletotheleft,andworkit inandoutlike

of liquidatthebaseof flameunlessused

tinguisherisused onburningliquid,direct

fliquid containerabovesurfaceofliquid.

geextinguisherforonethathasbeen

momentafteruse,as thisunitmustbe

n.

b).Disengagetheclutchandshiftthe

evertothe "INGEAR"positionasshown

telocatedon thewindshieldheader.En-

ethehoistvalvecontrollever tothe

ontheshiftingdiagramplate.This starts

erateengineslightlytoprovidefaster

chesthedesiredangle,shiftthe hoistvalve

"positiontohold thebodyinthis posi-

ositiontolowerthe body.Whenthe

the hoistvalvecontrollevertothe

getheclutch,andshiftthehoistpower

TRAL"position.Thehoistmaybeoper-

einstructionswhenthevehicleis inmotion.

CHOPERATION.

13).Disengagethejaw-typeclutchon

shingclutchyoketowardcenterof vehicle

support.Unreelsufficientcablefromdrum


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NTROLSANDOPERATION

dPowerWinch

agejawclutchby pushingtheclutch

luntilpoppet dropsinholein support.

ral;setthehandbrake,and startthe

tch;shiftthepowertake-off"WINCH"

eed(seeshiftingdiagramplateon

getheclutch,andatthesametime

essarytopullorlift loadonwinch..NOTE:

dependingonloadto behandled;when

Whenloadis tobestopped,depressclutch

ftoneutral;releasejawclutch;disconnect

ullywindcableondrumby handwhile

eoperationin reverseisthesame,except

steadilyreleasethecablefromdrum.

ewinchis beingusedtoassistthe

subparagraphaaboveshouldbefollowed,

seandtransmissionshouldbe in"LOW"

andthepowertake-offin"LOW".

NCHOPERATION

e-offandwinchcontrolleversonthe

enotinthe samepositionsasontheother

ftheseleversreferto figure14.


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et)

BRAKECONTROLLEVER

HIFTLEVER

EVER

TROLLEVER

ER

TelephoneServiceVehicles

sfercaseto"NEUTRAL";startthe

tch,andshiftthetransmissiontosecond

offlevertothe forward("REVERSE")

ifting diagramplateonwindshieldheader

heclutchpedalshouldbeengagedand

erlymatethepowertake-offgears.With

d,movethewinchclutchandbrakecontrol

positiontoengagethewinchclutch.

pedaltounreelthe cable,andpullitout

blecanalsobeunreeledby shiftingthe

verforwardtodisengagetheclutch,and

opreventthecablefromlooseningonthe

eeledby hand.Attachthecabletoload;

hiftthepowertake-offtoforwardgear,

t orpulltheload.When loadisproperly


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NTROLSANDOPERATION

hpedal;shiftwinchclutchandbrakecontrol

H)position;shifttransmissionto

pedal,andshiftpowertake-offto

nottobeused again,shifttransfer

nnectcablefromload,andtightlywind

his winchisalsousedin connectionwith

poles.


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vrolet)

SUALCONDITIONS

yor dustylocalities,itisnecessaryto

eanerandthe carburetoraircleanermore

erextremeconditions,itmaybenecessary

daily.This canbedeterminedbyremoving

nger throughtheoilin theaircleanersto

rdirtin theoilchamber.Itwill alsobe

rovacaircleaneraboutonceamonthor

theconditions.Thiscanbedeterminedby

overandexaminingthewiregauze,and if

oilit.

ghmudit maybenecessarytoshift

to engagethefrontaxledrive.Under

alsobenecessarytouse alowertransmis-

endrivingthroughsoftmud,the mudwill

edrums,andgetonthebrake liningsand

esexcessivewearonthebrakeliningsand

dbe removedassoonasconditionspermit.

ovethebrakedrumssothatthe dirtcan

roughwater,itis necessarytoreduce

asslowas2 to3milesper hourunder

depthofthewater isabovethelowestpoint

derpan,thetransmissionshouldbeshifted

ndtheclutchshouldnot bereleaseduntil

water,as waterontheclutchfacingswill

erthe vehiclehaspassedthroughthe

etestedby applyingthebrakes.Ifthe

perly,it willbenecessaryto"ride"the

eto dryoutthebrakelinings.

ughterrain,thespeed ofthevehicle

conditionofthe terrain.Donotattempt


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SUALCONDITIONS

tthatitjumpsover theroughspots.In

cessarytoshift thetransmissiontoalower

anfollowthe terrainwithoutexcessive

nowissimilar todrivingthroughsand

ofwhichisthe possibilityofskidding,and

nowwillnotcauseexcessivebrakelining

ehicleinsnow,donot applythebrakes

olockthewheelsandcausethe vehicle

sarytoremovethedrumsto cleanout

o thebrakemechanismunlessthebrakes

zesand causesthebrakeshoestobecome

lwayshazardous,astoomuchpower

onwillcausethevehicleto skid.Never

t aspeedthatdoesnot permitfullcontrol

Whenapplyingthebrakes,depressthe

ddonotreleasethe clutchuntilthevehicle

ofthesevehiclesinhightemperatures

tions,morefrequentinspections,andcloser

entsandgages.

mationofscaleandrust occursmore

es;therefore,thewatershouldbedrained

gsystemflushed,wheneverthewaterbe-

ventiveisavailable,itshouldbeaddedto

eltfrequentlytosee thatitisadjusted

pumpfrequentlytoseethatit isoperating

heckthehoseconnectionstoseethat they

donotshowsignsof deterioration;ifso,

heckthethermostattoseethat itisopen-

diatorcoretosee thattheairpassagesin

withbugs,leaves,etc.If thesepassages

dbecleanedout.

leisbeingoperatedin extremelyhot

rinthe batteryelectrolyteevaporatesvery

batteryshould becheckeddaily,and

ngthe electrolyte%mcnabovethetop

yteismuchmoreactiveathigh temperature

hishighlyactiveelectrolytecausesrapid

andseparators,andmorerapid "self-

s.CAUTION:Idlebatteriesmustbe

eriescansafelybe usedinhotclimates

solution,whichwillprolongbatterylife.

erylifeis experiencedintropicalclimates,


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evrolet)

wardedtoa higherechelonforadjustment

endedforuseinhotclimates.

tionandmaintenanceofthesevehicles

resadditionalprecautionsandpreparations

mperateclimates.Lowtemperatureranges

tothreeranges,eachrequiringdefinite

ons:+32°Fto0°F;0°Fto— 20°F;below

ingsystemmustbe protectedwith

eezesolutiontoprotectitagainst freezing

perature.Thebatterymustbekept ina

hefuelsystemmustbekeptfree from

neshouldbekeptproperlytuned.SAE10

ngine.

gsystemmustbe filledwithaperma-

onstrongenoughtoprotectthe cooling

temperaturesaslowas —20°F.A166°F

ed.Thelowerpartof theradiatorcore,and

uvers mustbecovered.Whenparkingthe

me,the frontmustbecoveredwithatar-

bestoredinsidewhenfacilitiesare avail-

gineoilmustbeused. Thebatterymust

theignition systemingoodcondition.To

eshould befrom1/3toy2 open,thechoke

clutchpedalfullydepressed.Whenthe

okeandthrottleto obtainasmooth,fast

sspeeduntilit isthoroughlywarmedup,

tonormal,beforeattemptingtodrivethe

interizingequipmentmustbeinstalled

nthese,temperatures.Theoperatingin-

gequipmentmanualmustbeadheredto

oftheequipmentandthevehicle.


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VEMAINTENANCESERVICE

-.23

24

lyservice26

ficiency,itisnecessarythatthevehicle

edatintervalseachdayitis operatedand

aybediscoveredandcorrectedbeforethey

failure.Certainscheduledmaintenance

atthesedesignatedintervals.Theservices

ethoseperformedbydriverorcrew,before

on,athalt,andafteroperationandweekly.

enanceservicesarelistedontheback

PreventiveMaintenanceServiceRecord,"

ervehiclesofalltypesandmodels.Items

es,butnotlistedonW. D.FormNo.48,are

uresunderitemstowhichtheyarerelated.

orm,that donotpertaintothe vehicle

omtheproceduresaswrittenintothe

onmustthoroughlyschooleachdriverin

nceproceduressetforthinmanuals,whether

cificallyonW.D.FormNo.48.

D.FormNo.48that applytothis

smanualto providespecificprocedures

einspectionsandservices.Theseservices

spectionandconservethetimeof the

arilyinthe samenumericalorderasshown

eitemnumbers,however,areidenticalwith

nofeachitemappliesalso toanysup-

ction,andgenerallyincludesachecktosee

tion,correctlyassembled,secure,orex-

dcondition"isusuallyan external

mineiftheunit isdamagedbeyondsafeor

m"goodcondition"isexplainedfurtherby

wisted,not chafedorburned,notbroken

yed,notdentedor collapsed,nottornorcut.

toseethatit is"correctlyassembled"

linspectionto seeifitis initscorrectly

vehicle.

todetermineifitis "secure"is

examination,wrench,hand-feel,orapry-


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evrolet)

uchaninspectionshouldincludebrackets,

ckingwires,orcotterpinsusedin assembly.

beunderstoodtomeanworncloseto,

its,andlikelytoresultin afailureifnot

cheduledinspection.

ctoryoperatingcharacteristicsbeyond

o correctmustbereportedattheearliest

tedindividualinauthority.

ERVICE.

eisdesignedprimarilyasa checkto

t beendamaged,tamperedwith,orsabo-

ationServicewasperformed.Variouscom-

enderedthevehicleunsafeforoperation,

ver todetermineifthevehicleis incon-

ssiontowhichitmaybe assigned.This

yomitted,evenin extremetactical

erationServiceconsistsofinspecting

ngtotheproceduredescribed,andcorrect-

encies.Uponcompletionoftheservice,

promptlytothe designatedindividualin

DDAMAGE.Lookforinjurytovehicle

orequipment,causedbytamperingor

debris,orshellfire.

SHER.Inspectfireextinguisherfor

annozzle,andsecuremounting.

IL,ANDWATER.Checkamountof

sneeded.NOTE:Anyappreciabledrop

tionServiceshouldbeinvestigated,and

ed.Whenantifreezesolutionisinuse, ifany

terisneeded,haveantifreezevaluetested.

tercansarefullandsecurelymounted.

ANDDRIVES.Examinecarburetor,gener-

motor,fuelpump,fuelfilter,aircleaner,and

magedconnectionsandloosemountings.

drivebelt isingoodconditionandadjusted

suredeflection.

AL.Lookundervehicleandinengine

olant,andlubricantleaks;particularlyat

elfilter,radiator,andwaterpump.

UP.Startengineandobserveif crank-

ankingspeedandengagesanddisengages

oise.Noteanytendencytowarddifficult

e doesnotregisterwithin10seconds,stop

eorreportto designatedauthority.Sethand

nd duringthewarm-upperiodproceed


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operationServices(items8through22).

watchinstrumentindications,andnote

eperformancesuchasmisfiringandrapid

tartingengine,observechokefor

enginewarmsup,resetchokeasrequired

on,andtopreventcrankcaseoildilution.

ressuregageshould shownormal

e,or12to 17poundsatrunningspeeds.

estartsandis runningatfastidle,

ghpositive( +)chargeratefor ashort

orestobatterythe currentusedinstarting.

shouldregistera zeroorslightpositive

daccessoriesturnedoff.

ouldregisterapproximateamountof

ginetemperatureshouldincreasegrad-

od.Temperaturegageshouldregister

:Donotmovevehicleuntilenginetem-

NDSHIELDWIPERS.Testhorn(tactical

operoperationandtone.Inspectwipers,

condition.Seeif bladescontactglassevenly

EARVIEWMIRRORS.Lookforlooseor

ts,orregulators.Cleanwindshieldanddoor

ageordiscoloration.Cleanmirrorandaim

TS)ANDREFLECTORS.Operateall

npermitting)andseeifalllights respond

nd reflectorsaresecure,andlensesare

FLANGENUTS.Seethatall wheel

nutsaresecure.

ctall tiresfordamageorlowpres-

ressure (tirescool),iftimeis available.

tsfromtreadsandfrombetweenduals.Make

rrier.

DSUSPENSION.Examinespringsfor

hiftedleaves,andlooseor missingrebound

bolts,shackles,andshockabsorbersare

.Examineshocksforleaks.

NKAGE.Examinesteeringgear,Pitman

eeringarms forloosenessordamageand

DBUMPERS.Inspectfendersand

ddamage.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

NNECTIONS.Inspecttowhooksand

rdamage,andsee thatpintlehooklocking

ctorily.

D,ANDTARPAULINS.Inspectcaband

Seethatdoorsand latchesoperateproperly.

osenessanddamage.Inspectloadfor

properlydistributed.Oncargobodiesbe

dtarpaulin(ifused)is properlylashedto

mpbodiesbe surebodyisfully lowered

d thattailgateis closed,andleveris

elbodiesbesure reardoorsaresecure.

ceorearthborerequippedvehicles,be

ystowed,andstowagecompartmentdoors

NATOR.Examinedecontaminatorfor

ge,andclosedvalve.

EQUIPMENT.Seethattoolsandequip-

able,andproperlymountedandstowed.

RATION.Enginemaybeassumedto

enitidleswith chokebuttonfullyde-

indicatedonoilpressuregage(5 pounds

runningspeeds).Accelerateengineseveral

normaloperatingtemperature,andlisten

satisfactoryoperatingcharacteristics,or

e.

RMITANDFORMNo.26.Makesure

anual,LubricationGuide,andStandard

present,legible,andsafelystowed.

ERATIONSERVICE.TheDuring-operation

nas vehicleisputinmotion.

ERVICE.

on,listenforsuchsoundsasrattles,

hatmayindicatetrouble.Lookforindica-

system,andsmokefromanypartofthe

detectanyodorofoverheatedcomponents

r,brakes,orclutch,fuelvaporfromaleak

s,orother signsoftrouble.Anytimethe

ted,orvehicleturned,considerthis atest

toryorunusualperformance.Watchthe

oticepromptlyunusualinstrumentindica-

bletroublein systemtowhichthatinstru-

erationServiceconsistsofobserving

ngtotheproceduresfollowingeachitem,

cationsofserioustrouble.Noticeminor

edorreportedatearliestopportunity,usually


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NDBRAKES.Thefootbrakeshould

avel,andshouldoperatesmoothlyand

vehicletooneside,leaving%reserve

aileris connected,noteifelectricbrake

ctorytooperatetrailerbrakeseffectively.

na reasonableincline,handbrakeshould

velevertravelavailable.

ectclutchpedaltoseethat ithas

elbeforeit startstodisengage.Clutch

,orgrabon engagement,orslipwhenfully

N.Astransmission(andpowertake-off,

hatgearsshiftsmoothly,operatequietly,

outofmesh.

stransferanddeclutchingshiftmecha-

fused)areoperated,seethat gearsshift

,anddonotcreeporjump outofmesh.

ONTROLS.Beonthealert forde-

mancesuchaslackofusualpower,mis-

ng,indicationsofoverheating,orunusual

ginerespondstocontrolssatisfactorily,and

properadjustment,andarenotexcessively

S.Observereadingsofallinstruments

ontobesureunits towhichtheypertainare

mperaturegageshouldread140°Fto

estigateandreportexcessiveengineheat

ressuregage shouldread5pounds

satrunning speeds.Ifthereisunusual

essureisnotregistering,engineshouldbe

ation,afterbatteryhasrecoveredfrom

ng,ammetershouldindicateazeroor

withneedlesteady.

ouldcontinueto indicateapproxi-

k.

meter.Speedometershouldindicate

shouldrecordaccumulatingmileage.

AR.Noteanyindicationoflooseness

oeitherside, shimmy,wheeltramp,or

R.Listenforanyunusual noises,such

umpingsoundsfromwheels,axles,orsus-

ynoiseor abnormalconditionthat

osetoptarpaulinorcurtains,looseor dam-


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

ororinspectionplates,ormountedbody

egardedasminimummaintenance

performedunderalltacticalconditions,

vemaintenanceservicesmustbeslighted

viceconsistsofinvestigatingany

operation,inspectingitemslistedbelow

esfollowingtheitems,andcorrectingany

enciesnotcorrectedshouldbereported

dindividualinauthority.

DWATER.Checkamountoffuel,oil,

sary.CAUTION:Donotturnradiator

opuntilhissing hasceased.

ES:HUBS,BRAKEDRUMS,TRANSFER,

ES.Placehandcautiouslyoneachbrakedrum

eif abnormallyhot.Inspecttransmission,

foroverheatingorexcessiveoilleaks.

ANSFERVENTS.Wipecleanandinspect

ng.Ventsmustbekept open.

HAFTS.Inspectallpropellershaftsand

ess,damage,oroilleaks.Removeanyfor-

ndshaftorjoints.

SUSPENSION.Examinespringsfor

amagedorlooseclips,U-bolts,eyebolts,

absorbersandlinkagearesecurelycon-

KAGE.Examinesteeringcontrol

kagefrictionaljointsfordamageorloose-

rregularitiesnotedduringoperation.

LANGENUTS.Seethatwheelmounting

esent andsecure.

etiresfor underinflationordamage.

tsfromtreadsandfrombetweenduals.See

secureincarrier.

RAL.Lookinenginecompartmentand

nsoffuel,oil,coolant,orbrake fluidleaks.

urceand correctorreportthemtoproper

ESANDBOLTS.Inspectfanandwater

orpulleyforlooseness.Examinefanbelt

nganddeflectionofy$inch midwaybe-

ulleys.

RS.Whenoperatingunderextremely

seethatair cleanersandbreathercaps

eanair. Serviceasrequired.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON



DBUMPERS.Inspectfendersorsplash

osenessordamage.

NNECTIONS.Seethattowhooksand

(if used)areingoodconditionand

atpintlehookorfifthwheelis properly

kesuretrailerelectricalconnectionsare

D,ANDTARPAULIN.Examinecab,body,

ting.Besuretarpaulin (ifused)isproperly

tion.

nwindshield,doorandwindowglass,

enses;i nspectfordamage.

DWEEKLYSERVICE.

eisparticularlyimportantbecauseat

shis vehicletodetectanydeficiencies

andcorrectsthoseheispermittedto

romptly,tothedesignatedindividualin

nspection.If thisscheduleisperformed

ouldbereadytoroll againonamoment's

tionService,withafewexceptions,isthen

nwhetherornotthevehicleis inthesame

ft uponcompletionoftheAfter-operation

onServiceshouldneverbeentirelyomitted,

tuations,butmaybereducedto thebare

inedfortheAt-haltService,ifnecessary.

ormingtheAfter-operationServicethe

dconsideranyirregularitiesnoticedduring

eration,During-operation,andAt-halt

tionServiceconsistsofinspectingand

ms.ThoseitemsoftheAfter-operation

yanasterisk(*) requireadditional

eduresforwhichareindicatedinsub-

cableitem.

ATION.Seethatengineidlessatisfac-

elerateengineandnoteanymissing,back-

ation,orexhaustsmoke.Investigateany

duringoperation.

S.Checkallpertinentinstrumentsto

roperly,andcontinuetoregisterorindi-

eoftheunitstowhichtheyapply.

DWATER.Checkfuel,oil,andcoolant

ed.Leavesufficientspaceforexpansion.

reezeisused andanappreciableamount

nt,havevalueofantifreezetested.

yprecautionsforgroundingstaticelec-

line.Donotaddcoolantwhenengineis


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

NDSHIELDWIPERS.Inspecthornfor

connections.Seeifwiperarmsandblades

ectwiperbladesfor evencontactwith

e.

EARVIEWMIRROR.Cleanrearview

herglass.Besureglass andmountingsare

S)ANDREFLECTORS.Operateswitches

d.Duringblackout,inspectlampswith

only.Besureall lampsareoffafter

epressbrakepedalandseethatstoplights

warningreflectors,andinspectfor

ISHER.Inspectfireextinguisherfor

permounting,andclearnozzle.Examinefor

tinguisherhasbeenused,reportit for

ATOR.Inspectdecontaminatorforgood

securemounting.Ifused,reportforrefill

that theyareclean,secure,andnot

hatcellcapsare finger-tight.

topof battery.Ifterminalconnec-

d,cleanthemthoroughlyandapplyfresh,

htenterminalboltsif loose.Removevent

ctrolyte.Addwaterifrequired,taking

ywillnotbe damagedduringfreezing

ouldbesecure,notbulgingorcrackedor

rycarriershouldbesecure,clean,freeof

ountingsare loose,tightenthemcau-

ethebatterycase.Reportanydefects.

IESANDBELTS.

suchascarburetor,generatorand

,andwaterpumpforlooseconnections

ectcarburetor,waterpumpandfuelfilter

or goodconditionanddeflectionof

ulleys.Investigateandcorrectorreport

soryunitsnoticedduringoperation.

oseconnections,linkage,ormount-

LWIRING.Inspectallignitionwiring

wipeoffgreaseor moisture.Alsomakean

elowvoltagewilingandconnectionsfor

besureall wiringissupported,soas not

cleparts.

ERSANDBREATHERCAPS.

damage.Examineoilin reservoirs


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON



sivedirt.Whenoperatinginsandy or

dserviceaircleanersandbreathercaps

nerreservoirsandelements,washin

reservoirswithoil,andreinstallsecurely.

operly,andthatjointsandconnections

RS.

eakage,damage,andloosemounting.

plug;drainwaterandsedimentfrom

tbowlshowsexcessivedirt,removebowl

TROLS.Inspectenginecontrolsfor

ectedlinkage,andforadequatelubrication.

ingsparesfor damageandexcessive

edforeignmatter,suchasnails,glass,or

rcassesandfrombetweenduals.Checkfor

ositionofvalvestem andpresenceof

ctpressure,asneeded(55Ib maximum,

ywornorotherwiseunserviceabletires.

howabnormalwear,shouldberelocatedto

ear.Apparentmechanicaldeficiencies

bereportedtohigher echelonforattention.

DSUSPENSION.Inspectspringsforab-

edleaves,andlooseor missingrebound

bolts,andshacklesaretight,andthat

eandnotleaking.Investigateanyunusual

duringoperation.

NKAGE.Inspectsteeringlinkagefor

lylubricatedparts.Investigateanyunusual

peration.

SHAFTS.Inspectalldriveshaftsand

essordamage,andexcessiveoilleaks.

rialwoundaroundshaftsorjoints.

RANSFERVENTS.

ngandtransferventsarepresent,in

ndnotclogged.

leanaxleandtransfervents,and

ERAL.Inspectaroundenginecompart-

forindicationsoffuel,oil,coolant,or

VELS.Afterunitshavecooled,check

als,transmission,andtransfer;reportif

thunitscoolis */2inchbelowfillerplug


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

DBUMPERS.Examineforloosenessor

NNECTIONS.

wheel,ifused) andpintlehoolfor

pecttowedload(ifany)electricalconnec-

dsecureattachment.

erlandinggear,observingwhether

y,isadequatelylubricated,notdamaged,

ailer.Cleanthecontactingsurfacesofthe

dkingpinthoroughly.Inspectthemfor

plyafreshcoatingof cleangrease.Tighten

thetrailer,noticingif thehandlever

hingmechanismclosescompletelyand

mountingboltsoftowhooks,pintlehook,

required.

D,ANDTARPAULIN,(HOIST,IFUSED),

fullyfordamaged,loose,ormissing

enlydistributed,and thatloadorequip-

rpaulinand curtains(ifused)arein good

metsandropesarepresentand undamaged.

ecurelyto hooksorrings.Examinehoist

umpandpumpvalvefor leaks.

blyforloosenessordamage,andex-

earhousing.See thatwinchdriveshaft

tionandsecure.Besureslidingclutch

ecurely.

eenoperatedin deepwater,sample

on.Ifwaterispresent,reportcondition.If

ently,orisdry orwoundunevenly,unwind

ewindevenlyonwinchdrum,applyinga

ewinding,andsecurecablechainand

hooks.NOTE:Clean,usedoilis satis-

mounted,checkdrivechainadjustment.

chainistight.

orexternalassemblynutsor screws

ehasindicatedthenecessity.

mountingandaxleflangenutsand

,eyebolts,shacklesandreboundclips,

-jointcompanionflanges,bodymount-

ccessoriesorspecialequipmentmountings,

steeringarms,towingconnections,orany

alassemblynutsorscrews,whereinspec-

esthenecessity,onaweeklyormileage

EASNEEDED.

as shackles,hinges,latches,control


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON



anypointwhereinspectionhasindicated

needed.

ointsofthevehicleindicatedon the

nglubricationonaweeklyora mileage

INEANDVEHICLE.

oroildrippingsfrominside cab,and

tandexteriorofengine.Wipeoffexcess

vehicle.

whenpossible.Ifnotpossible,wipe

ntorcamouflagepatternforrust,or for

auselightreflections.Seethatvehicle

sscoveredfortacticalreasons.CAUTION:

er forwashing,caremustbetakento

snotgetintowheelbearings,gear cases,

nitsor wiring,

DEQUIPMENT.

eandtoolliststo seethatallitemsare

eethatthey areingoodcondition,and

ed.

andequipmentof rustordirt,and

necessary,whenpossible.Seethattools

pand properlyprotected,andthatall

edorstowed.NOTE:Whenservicesare

ectionplatesarereplacedsecurely.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

alpartof preventivemaintenance,de-

the serviceabilityofpartsandassemblies.

tructionsforthesevehiclesarecon-

Guide(figs.15 and16).Thesespecify

d,theperiodsoflubrication,andthelubri-

ntotheitemson theLubricationGuide,

suchashingesand latches,mustbe

rvals.

maynotbe possibletosupplya

bricantscalledforbytheLubrication

endations.Itwillbe necessarytomake

able,subjecttoinspectionbytheofficer

nwithresponsibleordnancepersonnel.

ollowinginstructionssupplement

enoteson theLubricationGuidewhich

erviceofindividualunits andparts.All

eitselfare tothesubparagraphsbelow

number.

eapplyinglubricant.Lubricateuntil

mthebearing,unlessotherwisespecified.

spointsafterwashingtruck.

ndicatedarefornormalservice.For

ed,heat,water,sand,mud,snow,rough

tervalby1/&ory2, ormoreifconditions

ENT,dry-cleaning,orOIL,fuel,Diesel,

Useofgasolineforthis purposeispro-

ghlybeforelubricating.

checkengineaircleanerlevelandre-

velwithusedcrankcaseoilorOIL,engine,

10 for+30°Fto0°F.From0°Fto

-absorber,light.Every1,000miles(daily

tions)removeandwashallparts.Below

eratedry.Every1,000milesor more

ovehydrovaccylinderaircleaner,located

partsandreoilcurledhair withused

e,SAE30above+32°F;SAE10for

o-40°F,useFLUID,shock-absorber,


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


handreplacedry.Every1,000miles,prmore

nandoilcrankcasebreatheronlate

dontopofvalvecover.Every3,000miles,

ed,remove,clean,andreoilgovernor

seoilorOIL,engine,SAE30above+32°F;

rom0°Fto-40°F,useFLUID,shock-

0°F,washandreplacedry.

ywhenengineishot.Refillto "FULL"

afew minutesandrecheckoillevel.CAU-

geindicatesoilis circulating.

0miles,drainsediment.Every6,000

becomesclogged,drainfilter,cleaninside

ngineafewminutes,checkcrankcaselevel

ULL"markongage.(SAE30 above

0°F;andrefertoOFSB6-11,below

checklevelwithtruckonlevelground

canttowithiny2 inchofpluglevelwhen

hot.Drain,andrefillat inervalsindicated

peration.Fill differentialstoleveloflower

drainplugontransfer casebeforereplac-

thersclean.

DSLIPJOINTS.

Hoist.ApplyGREASE,generalpur-

andNo.0 below+32°F,tojointuntil

andtoslip jointuntillubricantisforced

generalpurpose,No.1,above+32°F

oint untilitoverflowsatreliefvalveand

sforcedfromventatuniversaljoint

AFTSHEARPIN.Every6,000miles,

joint,removeshearpinanduniversaljoint

endofshaft andinsideofuniversaljoint

alpurpose,No.1above+32°F,and

entrusting.

ERSALJOINTS.Withvehicleonlevel

nplugontopofsteeringknucklehousing

fittingat bottomofsteeringknucklehous-

ectionhole.Replaceplug.Every6,000

,reassemble,andrefill.

ER.Every6,000miles,removepipeplug

ay valveendoftheunit ofsingle-and

removepipeplugatthecenterplate of

catebothtypeswithabout%ounceof

ht,througheachopening.Replaceplugs.

6,000miles,wipedistributorbreaker

generalpurpose,No.1above+32°F,and

bricatebreakerarmpivotand wickunder


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


rolet)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON

http://slidepdf.com/reader/full/tm-9-805-chevrolet-15-ton 44/266 P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

sofOIL,engine,SAE30above+32°F;

OIL,lubricating,preservative,special,

PSHAFT.Removeaircleanerandcar-

pdustcover.Saturatefeltringoncarbure-

IL,engine,SAE30 above+32°F;SAE

bricatingpreservative,special,below

YLINDERS.

omaximumlift,fillcylinderand

werbodytobleedairand surplusoil.

cefillhole coverandgasket.

tomaximumlift,fillcylinder,replace

n,butdo notremove,ventplugandlower

airandsurplus oil.Raisebodyand

onths,disconnectoillinefrompump,

gine,SAE10, foralltemperatures.

THWHEELS.Every1,000miles,clean

ouplerpin,lockingjawsandguide with

+32°F;SAE10for+32°Fto 0°F;and

tive,special,below0°F.

winchcablewithusedcrankcaseoil

ve+32°F; SAE10for+32°Fto

preservative,special,below0°Fafter

otin use,coatoutercoilsweekly.

ING.Wheneverclutchisremovedfor

tercleaningparts,coatthe shiftforkball

utchreleasebearingcollar,packpilotbear-

shaftbehindbearing,coatshaftsplines

shiftforkwithGREASE,generalpur-

notwashclutchreleasebearing.

ry1,000miles,lubricatepintlehookpins

odbushings,clevises,linkage,etc.,with

+32°F;SAE10for+32°Fto 0°F;

tive,special,below0°F.

Every1,000miles,applyFLUID,brake,

berlinkrubberbushings.CAUTION:Do

oLUBRICATIONSERVICE.Thesepoints

utchreleasebearing,generator(late

rshaftcenterbearing(175-in.wheelbase

utchandbrakepedals,frontaxledeclutch,

p,andgovernor.

emovebearingconeassembliesfrom

nside ofhub.Inspectbearingracesand

hespindleandinsideof hubandhubcap


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


pose,No.2,toamiximumthicknessofVig-

earing conesandgreasesealsanddry.

essary.LubricatebearingswithGREASE,

thapackeror byhand,kneadinglubricant

ng.Useextremecaretoprotectbearings

reassembleandreplacewheel.Thelubri-

ficienttoprovidelubricationuntilthenext

ub orhubcap.Anyexcessmightresult

um.

RDS.

structionsarecloselyfollowed,

dsatisfactoryresultsarenotobtained,

anceofficerresponsibleforthemainte-

cordoflubricationmaybekeptfor

oster(W.D.AGOForm6).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

STOWAGEONVEHICLE

equippedwiththetools listedinsub-

minorrepairs canbeperformedbythe

ertools,anda toolbagcontainingsmall

veralmodelsas follows:

bUnderdriver'sseat

river'sseatback

boxonrightrunningboard

hITT

fUnderdnversseat

hIIncompartmentunderbodytail

hfgate

hborerITT,

enancefUnderdnversseat

pecialtoolsforsecondechelonuse

.,,

lpeen,16-oz41-H-523

nt,6-in41-P-1650

%2-in41-S-1117-4

%-in41-S-1117-6

y16-in41-S-1117-8

.blade41-S-1104

mobiletype,11-in41-W-448

centtype,8-in41-W-486

-end,%-x7/16-in41-W-991

-end,l/2-x!%2-in41-W-1003

-end,%6-x]Vie-in41-W-1005-5

-end,%-x2%2-in41-W-1008-10

-end,%-x%-in41-W-1012-5

et(winchtrucksonly)

t

coupling(earthboreronly)

ngnutlock(earthboreronly)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


STOWAGEONVEHICLE

ngnut(earthborer only)

earthboreronly)

aftbushing(earthboreronly)

uipmentareincludedwitheach

nthevariousmodelsas outlinedinpara-

e,7.50 x20dual

S.

hiclespareparts arecontainedin

abovethefireextinguisheronthe assistant

arepartsareremovedfromthekit andput

tityshouldbereplacedin thekitatthe

lbe availablewhenneeded.

owingpartsarecontainedinthe

,cotter(unit)

nchdriveshaft shear

3type,Plug,spark (unit)

wide8-oz

outtailroll)

outstopValve,tire(unit)

etailWire,stovepipe

talledon allmodelsatthebackof thedashonthe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

TENANCEINSTRUCTIONS

NS

emblyreplacementrecord33

NITASSEMBLYREPLACEMENT

cleissuppliedwithacopyof AGO

desameansofkeepinga recordofeach

jorunitassemblyreplaced.Thisform

hiclenameandU.S. A.Registration

se,andinformationpertinenttothework

portantthattheformbe usedasdirected,

evehicleuntilthevehicleis removedfrom

sonnelperformingmodificationsor

cementsmustrecordclearlyontheform

ompleted,andmustinitial theformin

eneachmodificationiscompleted,record

eage,andFSMWOnumber.Whenmajor

ngines,transmissions,transfercases,are

hoursand/ormileage,andnomenclature

rrepairs,and minorpartsandaccessory

erecorded.

onreceiptbyathirdor fourthechelon

ormodificationorrepair, maintenance

SMWOnumbersofmodificationsapplied

ormNo.478.


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NTIVEMAINTENANCE

vemaintenanceservices34

EVENTIVEMAINTENANCE

ntenanceinspectionsandservicesarea

functionoftheusing arms,andarethe

dersofoperatingorganizations.

uencyofthepreventivemaintenance

consideredaminimumrequirementfor

es.Underunusualoperatingconditions,

tures,dustyorsandyterrain,itmay be

ainmaintenanceservicesmorefrequently.

CIPATION.Thedriversshouldaccom-

sistthemechanicswhileperiodicsecond

enanceservicesareperformed.Ordinarily

hevehiclefor ascheduledpreventive

easonablycleancondition;thatis,itshould

mud orgreasetosuchan extentthat

illbeseriouslyhampered.However,the

edorwipedthoroughlyclean,sincecer-

ascracks,leaks,andlooseor shiftedparts

dentifthe surfacesareslightlysoiledor

n thosecontainedinthegeneralpro-

4),orthespecificproceduresinsubpara-

requiredforthe correctperformanceof

eservice,orforcorrectionofadeficiency,

eoperator'smanualpertainingtothe item

ndividualinauthority,shouldbe consulted.

S.Thesegeneralproceduresarebasic

efollowedwhenperformingtheservices

pecificprocedures.NOTE:Thesecond

ethoroughlytrainedintheseproceduresso

utomatically.

edsubassembliesareinstalledto cor-

ouldbetakentoseethatthey areclean,

lylubricated,andadjusted.

ricantretainerseals,a coatingofthe

overthesealingsurfaceof thelipofthe

aleatherseal,itshould besoakedinSAE

sible)foratleast30 minutes.Thenthe

dcarefullybyhand beforeinstallingthe

cratchedormarred.

ofeachitemappliesalso toanysup-

ction,andusuallyincludesachecktosee


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evrolet)

ngoodcondition,correctlyassembled,

rn.Themechanicmustbethoroughly

planationsoftheseterms:

condition"isusuallyan external

mineiftheunit isdamagedbeyondsafeor

m"goodcondition"isexplainedfurtherby

wisted,not chafedorburned,notbroken

yed,notdentedor collapsed,nottornorcut.

toseethatit is"correctlyassembled"

linspectionto seewhetherornetit isin

tioninthe vehicle.

todetermineifitis "secure"isusually

ation,ahand-feel,orapry-barcheckfor

tionshouldincludeanybrackets,lockwash-

s,orcotterpins usedinassembly.

beunderstoodtomeanworncloseto,

its,andlikelytoresultin afailureifnot

cheduledinspection.

eareindicatedbyrepeatingtheitem

hichshowtheintervalat whichtheservices

howthat theparts,,orassemblies,areto

yservices.Forexample,anitemnumberin

siteaTighten procedure,meansthatthe

ectmustbe performed.Thespecialserv-

aryadjustmentsinaccordancewith

smanual,specialbulletins,or othercur-

vehiclewithdry-cleaningsolventto

dirt,andotherforeignmaterial.Afterthe

emin cleanfluidanddrythemthoroughly.

s cleanuntilreassembled,andbecertain

yfromrubberor othermaterialthatit

protectivegreasecoatingfrorrjnewparts,

ynot agoodlubricant.

applieseithertolubricationoper-

n thevehicleLubricat'onGuide,andto

uchGuides,butshouldbeperformedin

enanceoperations,ifpartshavebeendis-

orservice.

stsofperformingspecialoperations,

rywater,drainingandrefillingunits with

ngtheoil filterorcartridge.

perationsshouldbeperformedwith

(forceonthewrenchhandle)totightenthe

chanicalpractice.Usetorque-indicating

Donotovertighten,asthismaystripthreads

ningwillalwaysbeunderstoodtoinclude

ockwashers,locknuts,andcotterpins

tening.


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NTIVEMAINTENANCE

itdifficulttoperformthe complete

proceduresatonetime,theycan sometimes

nningtocompleteall operationswithin

ailabletimeat halts,andinbivouacareas,

ry,toassurethat maintenanceoperations

tedbythetacticalsituation,itemswith

mnsshouldbegivenfirst consideration.

eventivemaintenanceproceduresthat

oseoutlinedonW.D.AGOFormNo. 461,

intenanceServiceWorkSheetforWheeled

ertainitemsontheworksheetthatdo

arenotincludedintheproceduresinthis

mericalsequenceofitemsonthe work

anualprocedures,butinsomeinstances

ervationofthemechanic'stimeandeffort.

ES.Theproceduresforperformingeach

nthly)and6,000-mile(6-month)mainte-

cribedinthefollowingchart.Eachpageof

atits leftedgecorrespondingtothe6,000-

aintenancerespectively.Veryoftenitwill

roceduredoesnot applytobothsched-

ertodeterminewhichproceduretofollow,

espondingtothemaintenancedue,and

appears,performtheoperationsindicated

tuationdoesnotpermita

eitemswhichrequire little,

hicle.Whenaroad testis

milespreferably,andnot

PerformtheBefore-oper-

paragraph23.

es.

maloilpressurewithengine

ngspeeds,12to 17pounds

:Whengageindicateszero

e,stopengineimmediatelyand

dshowhighchargefor

ndthen returntozeroor

ights andaccessories

yislow,orelectricalload

ntinueforalonger time.

teady.

METER.Speedometershould

ctly,andoperatewithoutex-

ise.Odometershouldregister

ge.


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a t h i t r u s t . o r g / a c c e s s_ u s e # p d - g o o g l e

7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

ernormalconditionsthe

show140° to170°Fafter

operatingtemperature190°F.

uldregisterapproximate

lltimes.

eldWipers.Testhornfor

(tacticalsituationpermit-

lcontactwithglassthrough-

ng,BrakingEffect,Feel,

ndPedalTravel).Operate

uringroadtest.

ootpedalsufficientlyto

umdistanceandobservetheir

vehicletooneside,unusual

oulddepresswithlittle effort,

ositionwhenreleased.

hicleonreasonableincline;

bserveifit holdsvehicle

tleverhasatleast1/3 travel

tandpawl latchtheapplied

havefreetravelof1 inchto

eratesmoothlywithout

rabbingonengagement,or

edunderload.

r(LeverAction,Declutch-

Leversshouldmoveinto

asilyandquietly.Testde-

rontaxle engagesproperly.

yindicateloosemountings

damaged,execessivelyworn,

dparts.

Wander,Shimmy,Side

Withvehicleinmotion

nbothdirections,andob-

s anyindicationoflooseness

ncyofvehicletowander,

Seethatsteeringcolumn

nditionandsecure.

,Power,Noise,andGov-

gineoperatingcharacteristics

forknocksandrattlesasthe

decelerated,underbothlight

ER.Operatetheengineat

ratios,notingifthevehicle


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NTIVEMAINTENANCE

ndacceleration.Noteany

ting.NOTE:Aslightping

normal.

hevehicleinalowgear,

ratortothetoeboard,andby

erreading,seeifthevehicle

eed,thegovernedspeedspeci-

ents,Cab,andWheels).Be

stforanynoisethat may

attachmentsmountedonve-

ountings,floorplates,doors,

Listenparticularlyforindica-

ings.

Hydrovac.Wheneverbrakes

hydrovacunitappearsto

isfactorily.Afterstopping

istenathydrovacaircleaner

catingunitis operating.

ms,Hubs,Axles,Trans-

cehandcautiouslyonall

bstosee iftheyareabnorm-

ng,transmission,andtrans-

verheating.

coolant,andfuelleaks

underneaththevehicle.Trace

rceand correctorreport

rity.

NS

y

precautionstoblockvehicle

elyingearatreasonablespeeds.

Axles,Transmission,and

ugsinfrontandrear axles,

rcase,andchecklubricant

oweredge offillerhole

whencold.Allowsufficient

ebeforecheckinglevels.Note

oil changeisdueinanyof

ubricantindicatesanoil

nandrefillwithspecifiedoil.

cessivelubricantleaksatoil

elts,Accessories,Trans-

ndJoints,Axles,and

inerunningobserveas


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

SSORIES.Accelerateandde-

entarily,andlistenforany

s thatmightindicatedam-

ywornengineparts,drivebelt,

dcorrectorreportanyunusual

theroad test.

R,PROPELLERSHAFTSAND

ELBEARINGS.Withthetrans-

egear,andfront drivingaxles

nitsataconstant,moderate

hrottle,andlistenforany

dicatedamaged,loose,or

s.Observeallpropellershafts

ndrunout.Locate,correct,

uring roadtest.

aseforcracksandleaks.Clean

es,terminals,bolts,posts,

rgoodcondit'on.Testspecific

ecordonW.D.AGOForm

eadingsbelow1.225indicate

edorreplaced.Electrolyte

f plates,andmayextendl/4

shbyaddingdistilledor

mhigh-ratedischargetest

or"condition"testwhich

nt,andrecordvoltageon

ellvariationshouldnotbe

TE:Specificgravitymustbe

est.Cleanentire batteryand

rroded.Cleanbatterycable

ndnuts,andbatteryposts;

boltsforserviceability.

-downboltscarefullyto

.Examinecylinderheadfor

andgasketsforindica-

pressionleaks.Ifhead bolts

ent,tighten to75to80 foot-

ersequence,accordingto

orbrokenvalvespringsand

ethat valvemechanismparts

andnotexcessivelyworn.Ad-

rancetospecifications.

valve,0.006to0.008inch;

015inch.Heavydutyoper-


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NTIVEMAINTENANCE

nch;exhaustvalve,0.020

justingvalves,engine

30minutesuntil thoroughly

dinsulatorsorgasketsfor

nditionsrequire,plugsmaybe

eandepositsfromelectrodes

cracks.Adjustgapsto0.040

electrodesonly.Usetorque-

maximum)forinstalling

gsaftercompletingitem21.

mpressiontestonall cylinders

andthrottlewideopen.

10pounds,with5to 10

betweencylinders.Record

No.461.

ling,lookforoilleaks

ng-gearcover,valvecover,

nginestopped,checkoil

eorconditionofoil warrants

eandrefilltocorrectlevel

art engineagainuntilitem

oilfilter,andallexterior oil

ngoodcondition,secure,and

drainpluganddrain water

placementisdue,orwhen

overandoilfilter cartridge.

newcartridge,using new

ntings,Hose,Capand

d,andSteamReliefTube).

stoseethat theyareingood

leaking.Examinecondition

contaminatedthatcooling

.Cleanallinsects,dirt,or

airpassagesandinspectfor

N:Useonlyasuitably

untinstrumentto straighten

testitsprotectivevalue,and

nbackofworksheet Form P u b l i c D o m a i n , G o o g l e - d i g i t i z e d

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vrolet)

enessathub;and shroudfor

thfan.Correctorreportif

atdrainhole.

or,andSwitch.Inspectfor

ounting,andclean,secure

atcrankingmotorlinkage

orrectlyassembled,ingood

velyworn.

orandcrankingmotorinspec-

mutatorsandbrushesarenot

shesarefreeinholders,have

holdthemin contactwith

shconnectingwiresaresecure

mmutatorendofgenerator

ompressedair.Ifcommuta-

paper2/0andblowout dust

tengeneratorandcranking

urely.

pectdrivebeltfor evidence

,ordeterioration.Inspectall

ood condition,alinement,

justfanandgeneratordrive

suredeflection.

utorassemblyexternallyfor

ess,conditionofattachments,

aminecapandrotorforcracks

ge;capterminalsandrotor

edorburnedcondition.See

.Inspectbreakerpointsfor

ng,andpropergapadjust-

ndenserleadforchafing,and

rity.NOTE://breakerpoints

wset ofpointsandcon-

e-playlooseness,todeter-

ear.Testcentrifugal-advance

geofmovementbyfinger

ingerisremoved,shaft

sitionwithoutbinding or

pplyasmallamountof

dmovablebreakerarmpin.

awayfrombreakerpoints.

plyinglubricant.

ointgap(0.018in.).

oil mountingistight,and

ged.Inspecthighandlow


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

mpartmentforindications

ing,orloosesupportmount-

onnections.

ol.Inspectintakeand

cks,mountingnutsforpres-

sketsforgoodconditionand

enallmanifold-assembly,

ndcarburetorflangenuts

ectbimetalheatvalvecon-

mblytoheat controlvalve

mtooperate.CAUTION:

oundonlyy2turn at70°F.

retoraircleanertoseethat

urelymountedandconnected,

eservoirandelement,clean

reservoirtoproperlevel

eassemble.Besuregaskets

ndairhornconnectionsare

tle,Linkage,andGover-

re ingoodcondition,cor-

urelyinstalled;thatthecarbu-

e controllinkage,including

ft,isnot excessivelyworn;

s-fullywhenthecontrolis

t thethrottlevalveopens

isfullydepressed;andthat

properlysealed.

ctfuelfilter andlines

ddamage.

fvalve,drainsedimentfrom

wl byopeningshut-offvalve

.Cleanfuelpumpfilterbowl

-offvalve.

bowlandelement.Wash

nt.Reassemblefilter,making

ondition.NOTE://element

pectpumptoseethat itis

ymounted,and.notleaking.

ndwashbowlandscreenin

TE:Besuregasketisinplace

wlisreinstalled.


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evrolet)

rlywithoutexcessivenoise,

ndifthe enginestartsreadily.

rts,noteiftheoil pressuregage

aresatisfactory.

dWater).Withengine

ofoil,fuel,and coolingsys-

undtosourceand correct

uthority.

neselectorsetatzero,

tengineandrunat slowidle

ng.Observewhetherauto-

mingasengineisgradually

ming(par.86).

est.Inspectasfollows:

mgagetotheintakemani-

djusttheengineidlespeed

vacuumgageindicatesa

.

ons,Voltage,Current,and

runittoseethatit isingood

tedandconnected,andclean.

tagecircuittesterand

lator,currentregulator,and

atoroutputproperly.Replace

on.CAUTION:Thistest

he regulatorunithasreached

atures.

msandCaps,Condition,

eCarrier).Inspectand

Observeifallvalvestemsare

orrectposition,andmakesure

ent andfinger-tight.

resforcuts,bruises,breaks,

eddedglass,nails,andstones.

ar,watchingforanysign of

redges,andone-sidedwear.

enciescausingsuchconditions.

enterof tread(orother

xchangeforneworretreaded

ularly,shouldbemovedto

resandnon-directionaltires

thesamevehicle.Directional

be mountedsothatthe"V"

wnwhenviewedfromthe

ontwheelswillordinarily


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

V"ofthechevronswillpoint

ront.

properlyinflated,inspect

tchedaccordingtoover-all

ftread.

eifspare-tirecarriersare

re.

ampringsorflangesshould

cure.

elnutssecurely.

erlyinflated,measurethe

alltires,includingspares.

ntedondualsorondriving

havedifferencesinover-all

^4inch.Mountalldual tires

e.Thevalvestemontheinner

the valvestemonthe

,and shouldbeopposite

resmustbematchedprop-

n oneoftheroadwheelsat

0days.Aconvenienttimeto

ntenanceservices.CAU-

etire-matchingservice,do

il thewheel-bearingservices

ports,Cylinders).Remove

ndserviceasfollows:On

severalwheelbearingandbrake

ervicesandoverlap.Perform

yoftimeandorderlyre-

eandirtandgreasefrom

hields),keepingdry-clean-

gs.Examinedrumsand

areingoodcondition,securely

excessivelywornorscored.

erveifwheelcylindersarein

elymounted.Examinefor

ent,replacewheelcylinder.

upportcapscrewsandhub

,Anchors,Springs).If

indeepwater,mud,or loose

eelandbrakedrum,and

e.Ifthislm;ngmust bere-

,checktheirbrakes,and

wheelsandchecklinings

ondition,tightlysecuredto


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

ngcontactwithdrums,free

texcessivelyworn.Alsosee

ndition,properlysecuredto

ctingspringsandthatsprings

eturnshoesproperlyto re-

sofliningsatmostwornpoint

ast1,000milesofservice

yto contactdrums.

reasefromlinings with

ressedair.

keshoeadjustment.Adjust

stingpinion %turnorfour

tingpinion.Adjustateach

eals,DriveFlanges,and

asfollows:

oseethattheyarein good

heckforloosenessofwheel

olvewheelsandlistenforevi-

earings.Inspectaround

sforlubricantleaks.

S.Noteifthesearein good

ghtenedsecurely.

wheelbearingsandoilseals.

eaningsolvent,andexamine

seethat theyareingood

chinedsurfacestheycontact

hatthere isnoexcessive

henalloftherelateditems

wheelbearingsaretobe

earingsaccordingtoLubrica-

hewheelbearings,reassem-

embliesintoplace,andadjust

33).

s,Supports,andCylin-

oseanddrumsto seethat

thathose isproperlysup-

ed,andnotchafingorleaking.

nspectandserviceasfollows:

Cleanandinspectinsame

mmannerasinitem48.

s,Anchors,andSprings).

in item49.

twheelsandbrakedrums


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

anchors,andspringsinsame

,000-mileservice.

nnerasinitem 49.

keshoeadjustmentas

2aftersubsequentrelated

ompleted.

Bearings,andSeals).

ehousingsarein goodcondi-

racksaroundsteeringarms.

eltsealsand sealflangesare

re.Removelubricationplug

bricanttoseeif itappears

velocityuniversaljoint

lyindry-cleaningsolventand,

ectpartstoseethattheyare

xcessivelyworn.Paypar-

aljointwashers,ballsand

s,andpivotbearings,orbush-

cknewlubricantwellinto

aljointuntilitfills allspace

races.Reassemblesteering

placeanyunserviceablelubri-

ets.

es,U-bolts,Hangers,and

reingood condition,cor-

ure.Springclipsandbolts

eavesshould notbeshifted

.NOTE:Thismaybe an

terbolt.Noteif thedeflec-

malandapproximatelythe

dboltsfor excessivewearby

gU-boltssecurelyand

DragLink,Sealsand

Column,andWheel).See

odcondition,correctlyand

mounted,whetherornotthe

glubricant,andthat the

evel.Payparticularattention

hatitis securelymounted

malshape.Alsoobserveif

oodadjustment.

anarmshaftnutsecurely.

earcaseassemblyandmount-


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

arenot todisturbtheadjust-

AUTION:Loosenthesteer-

ighteningthesteeringcase

distortthecolumn.

dLinks.Seethatshock

elymountedtoframe.Ex-

orwearor looseconnections.

omaxle.Fillbodywith

es,allowinganyexcessfluid

omesdowneasilypartway,

movesdownslowlyrestof

beenadded.Toomuchre-

mayindicatebrokenorinoper-

eals,Flanges,AxleEnd

ontwheels,bearings,seals,

ame mannerasinitem52

s.

an,andinspectthefront

sin thesamemanneras

pplyinsamemanneras

ringsinsamemanneras

djust brakeshoesasdescribed

,Seal,Vent,andAline-

orcracks,leaks,andbentor

rethatdifferentialcarrier

pinionshaftfor endplay,and

g.Inspectfrontaxlealinement

entsfromfrontspringeyebolt

, oneachside.

naxlevent.

ts,Alinement,Seals,

ringsandU-boltsforpres-

ondition.Seethatyokeis

otexcessivelywornatsleeve

fleaksattrunnionbearing

pand gasket.

tsandyokenutssecurely.

dStrap,andSidePans).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

pansandgroundstrapfor

emounting.Seeifenginebrace

dsecure.

Pawl,Linkage,Drum,and

eforwornratchet,pawl,or

m;thinor oilyshoelining.

relymounted.

eliningclearanceto0.010

ganddrum atanchor;0.010

werendsoflining anddrum.

Linkage,andReturn

ntingandoperatinglinkage

n;seethat adjustmentlocking

surepedalreturnspringbrings

osition.

alfreetravelto1 to1%

Linkage,andReturn

ndbrakepedalarmclear-

%m°hbetweenbrakepedal

oard.Examinepedaloper-

secureconnections.Seethat

urnspedalagainstits stop.

nt,FluidLevel,Leaks,

plug ventisopen,thatboot

atunit issecurelymounted.

ks,andseethat stoplight

andterminalssecure.Fill

owithin%mch°f top.Clean

ketwhenneeded.

CleanerandHose,Cylin-

estunit forsecuremount-

amps,plugs,vents,hose,

re.Remove,disassemble,clean,

bricateaccordingtoLubri-

Linkage,Seals,andPower

missionandpowertake-off

scontrolsand drives,for


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

onsofcracks,leaksat seals

nt,andinsecuremounting.

goodcondition.Seethat

Inspectlinkageforwearand

tenallmountingbolts.

nalcaseassemblycap

s,Alinement,Seals,and

sandU-jointboltsfor

oodcondition.Seethatyoke

snotexcessivelywornat

ationofleaksattrunnion

eyokecapand gasket.

ntbolts,andyokenuts

Seals,Vent,andAline-

housingforcracks,leaks,and

estpinionshaft forendplay,

isnotleaking.Makesure

ngcapscrewsaretight.

araxleappearsto bein

vent.

s,U-bolls,Hangers,and

clipsandboltsare inplace,

edout ofposition.Seethat

snormaland approximately

,testhangers,shackles,and

ndlooseness.Tightenallspring

urely.

Links.Seethatshock

elymountedtoframe.Ex-

orwearor looseconnections.

omaxle.Fillbodywith

es,allowinganyexcess

rmcomesdowneasily

top andmovesdownslowly

d hasbeenadded.Toomuch

emayindicatebrokenor

Examinecabthree-point

htandleftfrontmountings

missingfabricrubbercush-

onmountingbolts; cabrear

ken,orlooseU-springs;center


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

tssecurely,andadjustcab

CAUTION:Loosensteering

ningcab,ortighteningcab

maybecomedistorted.

mbers).Examineside

bracketsforevidenceofbent,

dition.Lookforlooserivets

nt.

mmets.Examinewiringand

oosesupports,chafedor

pinchedordamagedwiring

ons.Checkgrommetsforpres-

nspecttrailerconnection

orgoodcondition.

es.Examinefueltankfor

cationsofleaks;seethatfiller

ing,andthat capseals

forlooseconnections,loose

mbottomoffueltankto

Drainonlyuntil fuelstartsto

recautionsagainstfire.

ose).Examinebrake

derthe vehicleandataxle

mounting,andgoodcondition.

nspectexhaustpipefor

austmanifoldandmuffler.

ethatmufflerclampsare

cracked,dented,orleaking;

tructed.

ue,lubricateinaccord-

de,sectionVII,andcurrent

ngonlycleanlubricantand

adspeciallubricationduring

agedormissingfittings,vents,

UND

Usethetoe-in gageto

ch.See thatwheelturning

re.Turnfront wheelsfully

f turnislimitedbystops


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

ectwormgearcaseforsecure

,capscrews,andplugsfor

s.Replaceanyimprovised

orfrayedends,sharpkinks,

hati tisevenlywound.Check

oll, cleanliness,andsecure

wclutch,shaft,andoperating

mgearcaseoillevel,andadd

sarytobring tocorrectlevel.

ountedwinchdrivechain

lackis eliminated.

mgearcaseoillevelandadd

rrectlevel.If anoilchangeis

ntwarrants,drainandrefill

hspecifiedoil.

bleandcleanentirelength.

yandtightly,applya coating

oEquipped).Inspect

dbedplateforgoodcondi-

dsecuremounting.Inspect

operatesproperlyandlocks

orexcessivewear.Tighten

gbolts.Cleanfifth-wheel

assislubricant.Lubricate

acklubricantintolatching

WiringandConnections

.Inspectwiringforgood

eningsoitwill notchafeor

ts.Inspectconnectingfittings

dcondition,securelymounted,

orn.

ntrols,Pump,Lines,and

Equipped).Raisebody

oist,pump,lines,drive

stosee thattheyareingood

mbled,andsecurelymounted.

ontrols,andlinkagefor

oilleaksatcylinder,pump,

nderpistonleaksbynoting

to drop.Fillcylinderwith

nnerindicatedforspecific

XIII.Lubricategrease

psofoil topinjointsof lift-

hanism.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

onrodpackingnutandany

dnuts,takingcarenot to

ayscoreshaftsand cause

,Body,Stop,andBlack-

body,stop,andblackout

dsecuremounting.Tactical

ateswitches,andseethat

witchhighand lowbeam

tstomakesuretheydo not

ehicle.Seethat stoplight

depressed.

ams.Adjustblackoutlamp-

esnotshineon anypartof

tforproperposition,cleanli-

securemounting.

,BrushGuards,and

e,goodcondition,andsecure

rs.Seethathoodis alined

,andisnotbent orkinked.

esent,secure,ingoodcondi-

ed.

gBoards.Inspectforloose

nts.

ass,SeatandTrim,Floor-

pCompartment).Inspect

eyareingoodconditionand

orandwindshieldhardware

orsarealinedin theiropen-

andstrikers,andlatchprop-

thermalcircuitbreaker(30

switchto seethatconnec-

horn circuitbreakerlocated

ndhorn;gasgagecircuit

gnitionandgasgageinstru-

ortight connections.

uards.Inspectforsecure

ion.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

allapplicableaboveitemson

ngoodcondition,correctly

obodiesbesurethattailgate

y,thatchainsareintact,that

ot damaged,andthattarpau-

roperlyinstalledandlashed

bodiesbesurethatdoorsfit

ndlatchproperly;thatlocks

ylubricated,andnotexces-

EANDEARTHBORER

maintenanceandearthborer

and stowagebinsaresecure

mpartmentdoorsfit,close,

tanyspecialequipment

eingoodconditionandse-

odiesseethattailgate

y,thatlockingleveroperates

dyisproperlyalinedon sills.

ook.Inspecttheseunitsfor

ty.Examinepintleandlatch

dequatelubrication.Seethat

hatdrawbarisnot exces-

nethepaintofentire ve-

dcondition,payingpar-

htspots infinishthatmight

nspectvehiclemarkingsand

Includeidentificationplates

ished.

uppressors,filters,con-

ndingforproperposition,good

eanliness.NOTE:Reportany

ningandtightening,tosignal

r).Inspectallthestandard

oseethat theyareallpresent

condition,clean,andproperly

ed.Alsoexaminethetools

toseethatthey aresharp.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


NTIVEMAINTENANCE

outsideof thevehiclewhich

faces,shouldbepaintedor

entrust,glare,orreflection.

theyarein goodcondition,

lycharged.Alsobesurethe

sion.

tdecontaminatorisin good

ounted.Makethecheckfor

efillerplug.

Seethatitisin goodcon-

emsarepresentandproperly

enciesimmediately.

26.Thevehicleandequip-

nGuide,andStandardForm

orm),shouldbepresent,

ed.

.Examinetirechainstobe

dition,clean(ifnotinuse),

tectedagainstrust,andprop-

e,andSnatchBlocks).See

evicesarein goodcondition,

d.Towchainsorcablesshould

nstrustwhennotin use.If

d,checktoseethatthey

rackets.Observewhether

bracketsare ingoodcondi-

apsfit tightlyandaresecured

etermineifthecansare

ompleted.Inspectthe

herornotall FieldService

havebeencompleted.

tems2to15-inclusive.Con-

distancenecessarytomake

.Rechecktransmission,trans-

esforlubricantlevelandfor

ldeficienciesfoundduring

erauthority.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

NDEQUIPMENT

S.

individuals(specialists)andorganiza-

allocationinthetables ofequipmentare

ponentsofthesetool setsarealsolisted

olsareallocatedoneeachto aregi-

enanceplatoon.

-J-128014-T-3076-35

head

x,

MO-187-1041-W-2965


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ubs,andtires49

ers50

ormationgiveninthis sectionwillaid

ftroublesthat maydevelopintheunits

Aseparateparagraphis usedfortrouble

nitorsystem.Eachtroublesymptom

adingfollowedbyitemizedpossiblecauses

sorcorrectionprocedures.Ifitis notprac-

r correctionprocedureunderthespecific

erencewherecompleteinformationcan

etransmissiongearshiftleverinneutral

nginewiththehandcrank.Ifthe engine

andcrank,seizureis indicated.Notify

PERATIVE.Seeparagraph42b.

OSITY.Drainandfill withpropergrade


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

otStart.

OMBUSTIONCHAMBERS.Disconnect

owl,turnignitionswitchoff,and work

and downseveralstrokes.Iffueldoes

ckforfuel supplyinmaintank,andsee

pen.Refertoparagraph40for further

NSYSTEM.Makesureignitionswitchis

ndwatchammeterhand;ifammeterhand

uble intheignitionsystem.Seeparagraph

es,makefurthercheckbyremovingspark

ug, holdingwireterminal%mchfrom

ne.Ifsparkdoesnotjump gap,sparkis

paragraph42a(3)for furtherchecks.

ED.Seeparagraph42b(1).

pFullPower.

TEM.Seeparagraph42a.

URE.Seeparagraph40.

DJUSTMENT.Adjustvalves(par.61).

ADGASKET.Replacegasket(par.60).

TLYRESTRICTED.Replaceorclean

ETORORMANIFOLDGASKETS.With

allamountofoil togasketsandnoteany

ranyindicationof theoilbeingdrawninto

ngbolts,orreplaceleakinggaskets(par.

G.Notetemperatureindicatorforoper-

kcoolingcystem(par.41).Checkforcorrect

orcorrectgradeoffuel.Checkignition

oolingsystem(par.57n).Checkspark

aboveitemsare foundsatisfactory,it

carbon(par.59)and exchangethecylinder

ryvalveoperation(par.58).

ROPERATION.Removecarburetorair

etorthrottlevalve.Lookdownthroughthe

sitionofthegovernorthrottlevalve,which

vertical.If inanyotherposition,replace

OUR-WHEELDRIVEONHARDSURFACE

etotwo-wheeldrive(par.5k).

RESSIONORIMPROPERVALVETIMING.

b).Ifpoor compressioniscausedby

replacethegasket.Reportvalvetrouble

acecylinderheadwithone havingcon-

hercompressiontroubles,orimproper

hority.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON



SSION.Seesubparagraphc(11)above.

TURE.Checkforairleaks.Seesub-

ustcarburetoridling(par.72 b).Car-

operly.Notifyhigherauthority.

ADGASKET.Replaceheadgasket

rkKnock.

MANIFOLD.Makesuremanifoldheat

manifold.Disconnectcontrolvalve

heckitstension.Springmustbewoundup

anchorpinat70°F.Replacethermostatic

isdamagedorvalveshaftfrozenin


Seeparagraph40.

PROPERLY.Adjustvalves(par.61).

par57b).

G.Thoroughlyflushcoolingsystem.

e(par.57).

.Remove,inspect,clean,andadjust

.

woctanefuelwillcausesparkknock.

nockonacceleration.Ifhigheroctane

sivesparkknockmaybedecreasedby

neselectorbackafewdegrees.

NCOMBUSTIONCHAMBERS.Remove

on(par.59),andinspectvalvecondition.

USTMENT.Adjustcarburetoridling

VALVENOTSEATING.Thiscondition

outon bodyofcarburetor.Notifyhigher

uretor.

IFOLD.Disconnecthydrovacand

ines,andplugmanifoldfittings.Ifengine

oneofthesesystemsis indicated.Dis-

seventilatormeteringvalve,andplugend

engineidlingindicatesleakincrankcase

meteringvalve.Checkcarburetorand

subpar.c(6)above).

PROPERLY.Adjustvalves(par.61).

57b).

ETLEAK.Testcompression(par.57b).

et(par.58).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

tion.

Checkoilpandrainplugforleaks.If

epluggasket,andrefillcrankcase.Check

ten oilpanbolts(par.63) andreplace

ckforleaksattiminggearcover.If leaks

rauthority.Checkforleaksatfuelpump

placegasket.Checkforleaksatrocker

ver.Replacegasketsifnecessary.Check

ter, andmakenecessaryrepairs.Check

aring,whichisindicatedbyengineoil

ng.Notifyhigherauthority.

yrunningengineatabout% throttle

essivebluesmokeinexhaust.Reportto

ghtoilathighoperatingtemperatures

essure.If pressureistoolow,checkfor

yin crankcase,andcheckforoilleaks.

d,notifyhigherauthority.

pengineandcheckforoil incrankcase.

age,startengine,andcheckforoilbeing

ne.If oilisnot forcedoutoffitting,oil

Donotrun engine.Notifyhigherauthority.

eavyorcoldoilproduceshigh oil

ctgradeofoilis beingused.Runengine

l oiliswarmedup.If pressurestillis

reprobablyrestricted.Notifyhigher

nverydifficulttodeterminetheexact

nusualnoisesdevelopwhichthe driver

eandcorrect,thevehicleshould notbe

beeninspectedbyhigherauthority,and

ngitsuseandrepair. Whenunusualengine

owornooil pressure,andabnormallyhigh

eckforsufficientoilinthecrankcaseand

olingsystem.

thetroublesreferredto under

rrectedwithagoodengine tune-up.See

eparkedandengineidling,push

esitateslightly,andshifttransmissioninto

"draggy"clutchisindicated.,Adjustclutch

of freepedaltravel(par.69*).If thisdoes

tchwillhaveto beremovedandinspected

edparts.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


anbedetectedbyplacingthe vehicle

Adjustclutchpedalto 1%inchesfree

stmentdoesnotcorrecttrouble,clutch

r.70)tocheckfor worn,oil-soaked,or

orweak-clutchspring,damagedclutch

eplatelugs bindingincover.Replace

e necessarytodisassembleclutch

utchfacingsfor excessivewear,alsofor

tion.Replacedamagedparts.

hatteronengagementmaybecaused

s.Checkenginemountingbolts.Dis-

andinspectthediskfacingsfor being

d.Checkpressureplatelugfitin cover.

s.

RINGS.Removeflywheelunderpan,and

rsprings.

OSEONBALL,CLUTCHDISKCUSHION

ESSUREPLATELUGSLOOSEINCLUTCH

chandmakenecessaryreplacements(par.

rburetor.Disconnectfuellinefrom

andcrankengineorpump leveronfuel

outoffuelline, fuelisnotbeingdelivered

uelsupplyinmaintank.

urnonfuellinevalveat fuelfilteron

LUGGED.Cleanventorreplacecap.

D.Removeandcleanfilter(par.74).

emovefuellineandblowoutwith

IVE.Removesedimentbowl,clean

wl,usinganewgasket.Workthe fuel

alstrokes,whichshouldfillthe fuel

operate,replacepump(par.73),ornotify

retor.Thisiscausedby leaking

.Replacecarburetorornotifyhigher

OLSSTICKING.Checktoseethatthrottle

wrestson stop.Lubricateandfree-up


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)



ED.Notifyhigherauthority,orreplace

raph38f.

utonAcceleration.Removecar-

ownintocarburetorairhorn, andopen

acceleratingpumpisworking,asmall

tedintocarburetorfromaccelerating

orking,replacecarburetorornotify

OSING.Removeaircleaner,andpull

e wayout.Ifvalvedoesnotclose,adjust

,looseningchokelevertocontrolscrew,

tighteningscrew.Recheckinchokeposition.

BROKEN.Pullchokebuttonallthe

ngandclosingofchokevalvebypushing

evalve.Replacecarburetor,ornotifyhigher

vespringis broken.

tionisindicatedbyhightemperature

vesparkknock,lossofpower,orboilingof

lcoolingsystem(par.80e).

justfanbelt(par.82).

Replacefanbelt(par.82).

ENING.Replacethermostat(par.83).

OGGED.Thoroughlyflushcoolingsystem

ishedwiththeflushingsolution.

paragraph42a.

Replacewaterpump(par.81).

bylowtemperatureindicatorreading

eto warmup.

.Replacethermostat(par.83).

OFFCOCKOPEN.Closeshut-offcock

ad.Seeinstructionsonmetaltagattached

eplaceradiator(par.80)or notify


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


HOSECONNECTIONS.Tightenorreplace

eplacepump(par.81).

CAPNOTSEALINGPROPERLY.Replace

EADGASKET.Replacegasket(par.58).

ANSIONPLUGSORCRACKEDCYLINDER

ority.

EAD.Replacecylinderhead(par.60).

bparagraphaabove.

y.Removedistributorcap,clean

tted,andadjustgap to0.018inch(par.

move,clean,inspect,andadjustspark

ty.Inspecthightensionwires for

ndcorrodedterminals.Replaceifneces-

aryCircuit.Cleanandtightenall

nitioncircuitbetweenbatteryanddis-

ser.Testbytryingacondenserthat

dcapacity.

edorFaulty.This canusuallybe

speed.Installfullychargedbattery(par.

tbyinstallinga coilthatisknown

.

emFaulty.Seeparagraph40.

T.

e.Troubleinthe startingsystemis

rankingspeed(subpar.bbelow).

eeparagraph40.

rimaryCircuit.Cleanandtightenall

ycircuitbetweenbatteryanddistributor.

rting.Checkhightensionwiring for

acedamagedwires.

nandadjustdistributorpoints and

ckdistributorcapandrotor forcracks

agedparts.

y.Iffacilitiesfor testingarenot

nits(oneatatime) withunitsknownto

nd 88a).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

d.Checkforwethigh-tensionwires,

r;ifwet,dry themthoroughly.Withigni-

theammeterreading.If itishigh,a short

dicated.Checkprimarycircuitwiring

cuit.

paragraph38d.

tbyshorting sparkplugsoneby

derthatis misfiring.Removesparkplugs

celains,badlyburnedelectrodes,excessive

Replaceplugsiffoundin badcondition.

parkplugs(par.88 c).

ty.Checkconditionofhightension

athavepoorinsulation.

Checkdistributorcapforcracksand

acedistributorcapifdamageisfound.

tem.

ED.

ttery.Checkwithhydrometer.If

argeorexchangebattery(par.94).

Testeachcellwithahigh-discharge

wcapacityorshortedcellisfound,replace

minalsinStartingCircuit(fig. 48).

tenallconnectionsandterminalsinthe

rSwitchContacts.Removecranking

econtacts;iftheyareburned,replaceswitch

angeto propergrade(par.28c(4)).

ftheabovechecksdidnot reveal

motorisevidentlyat fault.Notifyhigher

kingmotor(par.90).

LLNOTOPERATE.

estwithhydrometer;ifbelow1.250,

nalsFaulty.Inspect,clean,and

edamagedcables.

nkingMotororCrankingMotor

rity,orreplacecrankingmotor(par.90).

STSOKBUTENGINEDOESNOTTURN.

hifttransmissionto neutral.

ttoturnengine withstartingcrank;

gwaterpump byfanblades.Ifpump

(par.81). Removepistons,andagain

rtingcrank.Ifenginecannotbeturned

notifyhigherauthority.


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D.Testwithbatteryhydrometer.The

eadischargedbattery.

uipment.Checktoseethattheigni-

accessoryswitcheshavenotbeenleft

hargedbattery.Afterconnectingtheposi-

raptonegativeterminalof battery,and

kthatwouldindicatea shortorcomplete

ectgroundstrapandwatchammeterfor

ny dischargeisnoted,athoroughcheck

e.

e.See subparagraphc(4)below.

utoutRelayPointsSticking.Thiscan

dischargewithengineidlingorturnedoff.

c).

or.

ingrateofthe generatorisgoverned

hebattery,itisimportantthat thebattery

schecked(par.94),beforecondemning

tor.Thefollowingparagraphsoutline

t indeterminingwhetherthetroubleis

ator,or thewiring.

TERYANDALowCHARGINGRATE.This

egulatoroperation.Tocheckthecurrent

terywirefromthebattery("BAT")

onnectthepositiveleadof anammeter

e regulator,andthenegativeleadto

gnition switchinthe"OFF"position,

and cranktheengineforabout15

gineand,withit runningatmedium

,and otherelectricalaccessories;note

put,whichshouldbeapproximately40

ights,radio,and otheraccessories,and

erunning.Assoon asthegeneratorhas

currentused incranking,thevoltage

perly,willtapertheoutput downtoa

TERYANDAHIGHCHARGINGRATE.

omthefield("F")terminal ofthe

eneratorfieldcircuit,andthe output

off.Ifitdoes not,thegeneratorandfield

inthe wiringharness.Iftheoutputdrops

leaddisconnected,thetroublehas been

otifyhigherauthority,or replacetheregu-

owORNoCHARGINGRATE.Check

ctions,corrodedbatteryterminals,loose

andfrayedor damagedwires.Thehigh

heseconditionswillpreventnormalcharge

Iftheentire chargingcircuitisingood


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

egulatororgeneratoris atfault.Witha

eldandarmatureterminalstogether.

eed,andchecktheoutput.Ifthe output

quiresattentionandmustbereplaced

oesnotincrease,thegeneratorisnot

ckthefanbeltforproperadjustment.

ndinspectthecommutatorfordirt,which

flint paper,andthedirtblownout.If

crease,flashthearmatureterminalto

,withthegeneratoroperatingatmedium

occur,thetroubleisin thegenerator.

replacegenerator(par.89h).

.

YSIN"HOT"RANGE.Thisindicates

dbyoverheating.Replaceindicator(par.

YSIN"COLD"RANGE.Ifhandstaysin

icateadamagedthermostat;remove

holdingopen(par.83).If handdoesnot

eakin theindicatorline.Replaceindi-

witchmustbe turnedontoprovide

Thegageconsistsofatank unit,dashunit,

eitemsmust betakenintoconsideration

fuelgage.

TALLTIMES.Checkforloosecon-

anddashunit.Disconnecttankunit wire

owsfull,dashunitis OK.Ifgagecon-

acedashunit(par. 91c(2)).Connectwire

ctwirefromtank unit;ifgageshowsfull,

dmustbereplaced(par.91 c(3)).If

e wireisshorted.

ALLTIMES.Checkforlooseconnec-

thetankterminalofdashunit,at the

kunitground wire.Ifgagecontinuesto

fromtankunit,andgroundend ofwire

wsfull,thereisan opencircuitinthe

ashunitto tankwire.Ifgageshows

unded,thereis anopencircuitinthe

placed(par.91c (3)).

PEEDORMILEAGE.Disconnectcable

anddrivevehicleorjackuprear wheels;

ntrolsinpositionfor two-wheeldrive.

edometercableisturning.Ifcableturns,

ereplaced(par.91f).If cabledoesnot

mtransfercase.Ifendofspeedometer

rcaseturns, cableisbrokenandshould


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ergearshaftintransfercasedoes notturn,

ddrivengearmustbe replaced.Notify

PEED.Replacespeedometer(par.

ILEAGE.Replacespeedometer(par.

CCURATELYBUTSPEEDNOTACCURATE.

notifyhigherauthority.

.Disconnectcablefromspeedometer

espeedometerhead.Ifnoisedoes notstop,

tingontransfercase;if noisestops,replaceor

esnotstop,notify higherauthority.

REWITHENGINENOTRUNNING.Dis-

age;ifgagedoes notreturntozero,re-

agereturnstozero,theline isrestricted.

her authority.

PRESSURE.Thisisanindicationof

engine.Checkoil levelincrankcase.Dis-

efromfittingonleft sideofengine;crank

s.Ifoilis notforcedoutoffitting,notify

orcedoutoffitting,replacegage(par.

eristhoughtto befaulty,thesimplest

stallan ammeterthatisknowntobe

ethereadingunderthesameoperatingcon-

estbatterywithhydrometer,andif

eter(par.94b).Replaceorrechargelow

nections.Check,tighten,andclean

atteryandlightingswitch.

LIGHTSBURNDIM.Checktheindi-

or corrodedconnections.Checkthelight

ns.Makenecessarycorrections.

RN.Checkfordischargedbattery

weenbatteryandlightingswitch.With

heckforopen-circuitedlightingswitch

tingthetwoterminalsoncircuitbreaker

ampslightwiththe jumperinplace,the

houldbereplaced.Checkindividualcir-

NOTBURN.Checkforburnedout

ectionsintheindividualcircuit,andpoor

ht.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

CKSONANDOFF.Thisindicatesa

system.Checkthelightswitchineach

inanindividualcircuit.Ifnecessary,

by-onefromtheswitchuntiltheshortis

uit.Tracethewire,and insulateor

orunit.

quipmentisinstalled tocontrolthe

ncebytheelectricalequipmentofthe

hat theequipmenthavetight,clean

ghtenallbondstraps, filter,andcon-

tentheplatedboltsinfrontend sheet

E.

ctions.Tightenallbondstrapattach-

eansurfacesand reinstallbolts,using

ers.

tal.Tightenall sheetmetalattach-

the toothedlockwashersareusedonall

ference.Starttheengine,andrun

aboverepairscorrectedthetrouble.If

pengine andturnoffignitionswitch.If

neratorandregulatorsystem;however,

nitionisturned off,thenoiseisin the

ulatorSystem.Checkthemounting

eefiltersat regulator,andthefilterand

or.Removethegeneratorband;inspectand

ommutatorisbadlyburnedorworn,

stthecircuitasinstructedin subparagraph

sts,changethefiltersandcondenserone-

nstallationuntilthefaultyunit islocated.

m.Ifthetestin subparagraph(c)

oublewasin theignitionsystem,check

ntheprimaryandsecondarycircuitsto

dclean.Check,clean,andadjustorreplace

Check,clean,andadjustorreplace

kforoil-soakedordamagedhighten-

kedordamageddistributorcap.Replace

tributorandignitioncoilfiltersforgood

unting.Startengineandtestforradio

ceexists,replacethetwofiltersandseven

testingbetweenreplacementsuntilinter-

XX).

TINGBOLTSLOOSE.Tightenthefour

issiontoclutchhousing.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


EAKORBROKEN.Disengageclutchand

betweenhighgear,neutral,andthird

roppingin shaftgroove.Ifapronounced

ted,thespringis weakorbroken.Notify

etransmission(pars.97and98).

TPILOTBEARING.Thiscanusuallybe

withclutchengaged,ordrivingin third

ngnoise.Notify higherauthority,or

EAKORBROKEN.Testbyshifting

neutral,andsecondgear.Ifa pronounced

n thethreepositions,thespringis

Notifyhigherauthorityorreplacetrans-

RS.Usuallyresultsingearnoise as

r.Notifyhigherauthority,orreplacetrans-

erauthority,orreplacetransmission

LowGear.When shiftingintolow

er toleftasfar asitwill go,andattempt

d;ifshifts cannotbemade,movelever

ain;ifshift canbemade,thereverse

leverorinterlockguideplateis worn.

replacetransmission(pars.97and98).

tchHousing.

CANTLEVELHIGH.Draindowntocor-

GRETAINERLOOSE.Removetrans-

crews,andinstalltransmission(par.98).

ofTransmission.

OOSE.Tightenbearingretainerscrews.

ASKETDAMAGED.Notifyhigherauthor-

n(pars.97and 98).

OSE.Notifyhigherauthority,orreplace

98).

XXI).

LOOSE.Tightenbearingretainercap

ASKETSDAMAGED.Replacegasketsor

Notifyhigherauthority,orreplace

d102).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

yhigherauthority,orreplacetransfer

EAKORBROKEN.Notifyhigherauthor-

e(pars.101and 102).

INSHAFTEXTENSION.Notifyhigher

fercase(pars.101and102).

NTOFSHIFTERSHAFTCONTROLRODS.

00).

ec.XXII).

AFT.Replaceshaft(pars.104and105).

SSEMBLED.Checktoseethattheslip

ftwiththesleeveyokein thesameplane

oppositeendofshaft.

DLYWORN.Replacewornjointor

nd105).

NTS.Replacepropellershaft(pars.

LAMPSLOOSE.TightenU-clamps.

Lubricatejoints.

NT.Replacejointorpropellershaft

BLE.Seeparagraph51.

Lubricatetierod endsandsteeringcon-

flatefronttiresto55 pounds.

Adjusttierod boltsbyremoving

sjustwrench-tight,andbackingthemoff

EARINGSDRYORTooTIGHT.Notify

usttoe-in(par.108).

UCKLESUPPORT.Replacesealand

NGCOVERGASKET.Tightenattaching

,removecover,andreplacegasket.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ALCARRIERGASKET.Tightencarrier

gasket.Seethirdmemberreplacement

BLE.Seeparagraph51.

RN.Notifyhigherauthority.

TION.Inflatefronttiresto55pounds.

BEARINGS.Adjustfrontwheelbearings

EARINGSLOOSE.Notifyhigher

otifyhigherauthority.

BS.Tightenwheelattachingnuts.

NGSOUTOFADJUSTMENT.Adjustfront

SHEAREDANDAXLESHIFTED.Replace

oltssecurely.

usttoe-in(par.108).

Filldifferentialtocorrectlevel.

ARINGS.Reporttohigherauthority.

NGCOVER.Tightencoverretaining

emovecover,installnewgasket,and

ALCARRIERGASKET.Tightencarrier

gasket.Seethirdmemberassemblyre-

E.Installnewgasketsandtighten

Filldifferentialtocorrectlevel.

ARINGS.Reporttohigherauthority.

LOOSE.Installnewterneplategasket

ANDSIDEGEARSPACERS.Notifyhigher

NTS.Replacepropellershaft,(par.104).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

Spongy"brakepedalactionindi-

m.Bleedbrakes(par.123).

BOARDCLEARANCE.Adjustpedaltoe-

b).

DERCOMPENSATINGPORT.Replace

.

M.Replacemasterandwheelcylin-

llwithcorrectfluid (pars.124and125).

NGS.Adjustwheelbearings(par.133).

TRACTORSPRING.Replaceretractor

OEADJUSTMENT.Readjustbrakeshoes.

R.Adjustbrake(par.122).

CYLINDER.Fillmastercylinderand

kesbutPedalGraduallyGoesto

plybrakes,forcepedalondownto

d checkforexternalleaksatmastercylin-

lllines.Makenecessaryrepairsor replace-

AKPASTPRIMARYCUP.Ifexternal

abovetest,itis evidentthatthemaster

king.Replacemastercylinder(par.124).

ughlycleanbrakemechanismand

6).Correctcauseof oilleakingonbrake

FLATED.Inflatetiresaccordingto

SHEAREDANDSPRINGSHIFTEDON

tandtightenU-boltssecurely.

reRequired,PoorBrakes.

ERONLININGS.Removedrumsand

SNOTCONTACTINGDRUMS.Free-up

orreplaceshoesor drumsifdamaged.

S.Replacedrums(par.126).

OTOPERATINGPROPERLY.Seesub-


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


oOperate.

ACAIRCLEANER.Cleanandlubricate

Thisgenerallyproducesaroughidling

trouble.Correctairleaks.

CKVALVESTICKING.Removevalve,

oroughly.

NHYDROVACCYLINDER.Lubricate

ARTSINHYDROVAC.Replacehydrovac

RINGS,HUBS,ANDTIRES.

D.Inflatetirestorecommendedpres-

ONTAXLETROUBLES(pars.46and51).

ghtenorreplacevalvecore.

tireandchecktubeforleaks(par.

be.

eWear.

usttoe-in(par.108).

URE.Maintaincorrecttirepressure.

RCAMBER.Ifthecasteror camberare

tifyhigherauthority.

UR-WHEELDRIVE.Usefour-wheeldrive

tionisrequired.

ckwheelsbyjackingupvehicleand

heelshavingexcessiverun-out.

NGSEAT.Replacespringcenterboltif

bolts.

lts.Improperlytightenedor elon-

runningwithloosewheelnuts.Tighten

gated,replacewheel.

ED.Adjustaccordingtoinstructionsin

DAMAGED.Replacebearings(par.134).

ABSORBERS.

ATION.Lubricatechassis(par.28).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

GER,SHACKLEPIN,ORSPRINGEYE.

ifyhigherauthority.

ACTION.Disconnectshockabsorber

down.Ifmovementisnotcontrolled,fill

),andrecheck.Ifconditionis notcorrected,

ar.138a).Ifshockabsorberarm catchesor

rber.

ES.Replacespring(par.137).

UIDLow.Fillshockabsorber(par.

RBER.Disconnectshockabsorberlink,

n.Ifshockabsorberarmbindsor moves

laceassembly(par.138a).

ANDBUSHINGS.Replacewornparts

authority.

ubricatespring,ornotifyhigher

Tightenspringclips.

KLES.Notifyhigherauthority.

RBER.Disconnectshockabsorberlink

;if thereisfreemovementfora short

comestoa definitestop,replaceshock

N.Lubricatesteeringgear,tierod ends,

od.

TIGHT.Removetierodbolt cotter

ht,andbackoff%turn.Install cotterpin.

S.Innatefronttiresto55pounds.

GEARADJUSTMENT.Adjuststeeringgear

GEDSTEERINGKNUCKLEBEARINGS.

LEALINEMENT.Seeparagraph106b.

GEARADJUSTMENT.Adjuststeeringgear

NECTINGRODJOINTS.Adjuststeering

141),orreplacewornparts.

USHINGS.Notifyhigherauthority.

.

URE.Innatefronttiresto55pounds.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


djustbrakes(par.122).

HEELBEARINGS.Adjustorreplace

RCAMBER.Notifyhigherauthority.

.Adjuststeeringgear(par.143).

R.Adjuststeeringgear(par.143).

GEDSTEERINGKNUCKLEBEARINGS.

DALINEMENT.Notifyhigherauthority.

edtoSteeringWheel.

NGRODASSEMBLEDWRONGORIM-

paragraph141.

OPERLYADJUSTED.Adjuststeering

ME.

ethewindshieldadjustingarmsallthe

eld,andlockthecenterof windshieldwith

atchfor leakswhileanassistantsprays

ontofcab.Leaksmayoccurbetween

shieldframe,betweenwindshieldglassand

dshieldcenterchannel.

DDIVISIONCHANNEL.Removethe

tachingsscrewsandinnerchannel.Sealwith

ngcompound.

DSHIELDWEATHERSTRIPANDCAB

ountingtocenterwindshieldinopening.

tripifitisdamaged(par.146 c).Whenthe

dition,andthewindshieldhas beenad-

ghtleakatoneor twopointscanbecor-

dshield,pushingthelip ofweatherstrip

g,andworkingastripoffrictiontape

nbetweentheouteredge ofweatherstrip

eldframe.Insome casesitmaybeneces-

ngesand windshieldframetoincreasethe

etop.

N.Lubricatedoorhinges,doorcheck

ockstrikerplate,door dovetailplate,and

G.Replacedoorhinges.

aise.Checkfordamagedrun

nwindowopening.Notifyhigherauthority.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

NotOperate.

ONINVACUUMLINE.Disconnectvacuum

fornormalvacuum.Makenecessary

ATE.Notifyhigherauthority,or

Notifyhigherauthority.

ifyhigherauthority.

Tightenmountingbolts,orreplace

ke-offandtransmission(par.155c).

E-OFFCOVERGASKET.Tightencover

ALS.Tightencapretainingscrews,

higherauthority.

sconnectshiftpullrod,shiftgear

dropsintogroove,andadjustpullrod to

position.If thisdoesnotcorrecttrouble,

eplacepowertake-off.

cantlevelinpowertake-off.Notify

otHold.I fthewinchcableloosens

inpositioninhole incrossmember,the

par.161c (1)).

AFTJOINTBROKEN.Replaceshear

AGED.Engagejawclutch.

TOPERATING.Checktoseethatpower

.If powertake-offoutputshaftdoeshot

yorreplacepowertake-off.

d.If thewinchwillnothold a

rcutoff,the wormbrakeshouldbe

eaksat allflange,plate,cover,and

achingscrews,bolts,ornuts.Checkfor

ghtenifnecessary.Checkforleaksatpipe

ghtenif necessary.Iftheabovechecks

e leaks,notifyhigherauthority,replace

sable,orreplacehoistassembly.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


rUp. Checkforlackofoilin

s.164b, 165b,or166 b).

Position.

AGENOTADJUSTEDPROPERLY.Adjust

ngth,andrecheckuntilcorrectoperation

.Notifyhigherauthority,orreplace

m(pars.164b, 165b,or166 b).

NING.Checkfordisconnecteddrive

pumpdriveshaft.Makenecessaryrepairs


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

TA,MAINTENANCE,

CLE

data56

emoval58

nstallation60

61

oldsandgaskets62

BULATEDDATA.

isa4-cycle,gasoline,6-cylinder,in-

heenginenumberisstampedona ma-

side oftheblockjustbackof the

renumberedconsecutivelyfromthefan,

Theenginerunsin aclockwisedirection,

up

3l%6in.

5cuin.

1

wer—at

0.4

h574Ib

kof

rearofpan


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

IRCLEANER

ANER

TORUNIT

OFFCOCK

ACUUMLINE

HECKVALVE

ROLVALVE

IONVACUUM

(BELLCRANK

(BELLCRANK

REW

W

sis,LeftSide

timportantoperationsin themain-

oper enginetune-up.Thisoperation,more

inewhetherornot theenginedelivers

nceandeconomy.

9).

cksonanengine,runit forseveral

lubricatethevalvemechanism.Thecom-

tbe checkedfirstwhentuninganengine,

evencompressioncannotbetuned


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

AIRCLEANER

TIONSWITCH

TORVACUUM

NG

RETORLINE

GMOTOR

WITCH

BLE

ONDENSER

RTOIGNITION

TO

OILTO

74

sis,RightSide

.Besure theignitionisturnedoff,

theopenposition.

gage(41-G-124)in asparkplug

nkthe enginewiththecrankingmotor

highestreading.Thisrequiresonlyafew

tthesame testonallcylinders,and make

noneachcylinder.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

neCompression,UsingGage

cylindersshouldbe 110poundsor

ouldreadalike,within 5to10pounds,

formance.

compressionreadingontwoadjacent

ssibleintercylinderleak,usuallycaused

dgasket.

ingsarelow orvarywidely,the

e determinedbyinjectingaliberalsupply

pistonsofthe low-readingcylinders.

everaltimes,and thentakeasecond

spracticallynodifferenceinthe readings

rsttest,it indicatesstickyorpoorlyseat-

compressionreadingonthelow-reading

withtheother cylinders,itindicates

pistonsandrings.

evencompressionmustbecorrected

enginetune-upjob.

oroughly,usingan abrasive-type

rebadlyglazedor blistered,thespark


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

PlugGap

Allsparkplugs mustbeofthesamemake

apsto0.040inch,usinga round

notbendthecenterelectrode.

eninstallingthe10-millimeterspark

maybechanged.Ifatorquewrenchis

ugs,the propertorqueis15foot-pounds.

henegativeterminalofavoltmeter

nal,andthe positiveterminalofthe

d.Closethecrankingmotorswitch,and

onds.If thecrankingmotorturnsthe

eofspeedwiththevoltmeterreading5 volts

tisfactorystartingcircuit.Thisincludes

y,terminals,andcables.However,ifthe

he voltmeterreadingisunder5volts,

ry,andbatterycableterminalsshouldbe

catethesourceofthetrouble(par.42 !>)•

wiresfromthe distributorcap,and

corrosion.Thewiresmustalsobe checked

ndforbeingoil-soaked.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

cap,andcheckthecapand dis-

burnedcontacts.

dvancemechanismbyturningthe

isedirectionasfaras possible;then

thespringsreturnit toitsretardedposi-

eturnreadily,thedistributormustbe

rpoints.Dirtypoints shouldbe

npointsshouldbe replaced.Checkthe

linethemif necessary.

ntAdjustment

untilthecamfollowerrests onthe

epoint gapto0.018inch,usinga feeler

onmustbe performedveryaccurately,

engthof timepointsstaytogether.

tilthecamfollowerislocatedbetween

ndofa pointscaleoverthemovable


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

he springscaleuntilthepoints just

thereadingon thescaleshouldbe

.

at"0"onthescale. Reassembledis-

wires.Makesurethattheterminalsof

nition coiltothedistributorare clean

18and 21).Checkignitioncoiland

88 a).

ovethefilter bowlandscreen,and

ry-cleaningsolvent.Whenreassembling,

asketis ingoodconditionandproperly

mpconnections.

irCleaners

ArmCoverAir Cleaners(fig.17).

sfromthe carburetorandrockerarm

utfromthetop,and removethecover.

assembly.CAUTION:Donotprythe

e elementmustberemovedbyhandto

lementflange,whichmustlie flatagainst


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

seat,andpreventairleakswhen thecover

ecleaner,andcleanoutall oiland

odywithdry-cleaningsolventandwipe

yslushingup anddownindry-cleaning

therwithanairhose,or bylettingit

dyofthecleanerwithengineoil,crank-

eoilthefilter element,asthisisdone

ehicleisdriven.

ementinthe bodyofthecleaner,

sitsflatagainstthetop flangeofthebody.

makingsurethatthegasketis clean

ts entiresurface,sothatatight sealis

llwing nut.

erstothecarburetorandrockerarm

anermustbeputonso thatitrestsagainst

ood seatatthispoint;then tightenclamp.

onlyadjustmentsthatshould be

msare thethrottlestopscrewandidling

)•

ve(fig.17).Unhookthethermo-

orpin, andcheckforcorrectinstallation.

equiresonly% turnofthespringto

Shouldthethermostaticspringbedis-

dbereplaced.

octaneselectorsetat "0"attach

glighttoNo.1 sparkplug,andtheother

gwire.Markthesteelball imbeddedin

fchalk.Start theengineandrunit at

butorclamp,androtatedistributorbody

kwiseuntilthesteelball intheflywheellines

flywheelhousing(fig.49).Tightenthe

hileitiswarmingup, tightenthe

rarmshaftsupportboltsand nuts,and

s.Wheretorquewrenchesareavailable,

uldbe tightenedto75or80 foot-pounds,

pportbolts to25to30 foot-pounds.

ndadjust thevalves(par.61).

cover,usinganewgasket,andcheck

7).Adjustthecarburetoridle and

binationswitheachothertosecurethe

dlingspeedshouldbeset at500to550


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

nallhoseconnections,andexamine

rleaks.Checkthefanbelt forcracks,

ropertension;andadjustit ifnecessary

mpletionoftheaboveoperations,the

tedforperformance.Duringthistimethe

adjustedforthegradeof fuelbeingused.

maximumgasolineeconomy,theoctane

produceaslightpingwhenacceleratingat

Installation

GASKETREMOVAL.

Removethecarburetoraircleaner.

rottlerod.Disconnectthemanifoldfrom

ldandcarburetorassemblytothe left

head,andwireitto theradiatorbrace

rtits weight.Removefuelpumpto

nkcaseventilatortomanifoldline.

r.Draincoolingsystem.Remove

esparkplugs.Removepushrodcover.

Disconnectsteamrelieftubehose and

ermostathousing.Disconnecttemperature

ckerarm.Removethetworockerarm

efourboltsandtwo nuts.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

LE


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

andCasket.Liftoutthepush rods,

eadbolts.Liftoffthe cylinderheadand

emperatureindicatorfitting.

dcarbonbrush,removeallcarbon

mbersandvalveportseverytimethehead

rbonfromtheheadsof thepistonsand

l.Removeanysludgeandgumforma-

andshafts.Clean alloilholesandpas-

d shafts.

EMBLIES

kerArmsandShafts

GASKETINSTALLATION.

.23).Placethe headgasketonthe

HISSIDEUP,"up andonthecamshaft

twocylinderheadguidepinsinthe block,

therinthe rearholesonthemanifoldside,

egasketwhilethe headisbeingset in

eadandtightenthe 15headboltsfinger-

renchandtightenallheadboltsto

ounds,followingthesequenceshownin

ofollowthissequencewhentightening

rleaksinto thecylinders,orcompression

orintothewaterjacket.

nstallrockerarm shaftswithcon-

them(fig.25),andtightenretainingbolts


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

enrockerarmoil linetoconnector

tureindicatorfitting.Installsteamrelief

reindicator.Installthermostathousing.

stallsparkplugs.Installrockerarm

s.Connectmanifoldassemblyandtighten

tocarburetorlineand crankcaseventi-

ment

TMENT.

rmalizetheexpansionofall parts

re,runtheengine atafastidle (approxi-

ktheoil temperaturewithathermometer

valverockershaftconnector.Whena

sreachedforaperiod of5minutes,the

eadyforvalveadjustment.If ather-

orcheckingtheoil temperature,theengine

for 30minutesbeforemaking'the


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

bricatevalvestemstoinsurefree

theirguides.Adjustthe clearancebetween

vestems asfollows:

ontrolValve

TMANIFOLDSANDGASKETS.

exhaustmanifoldsareboltedtogether

m,andshouldnotbe disassembledunless

gasketrequiresreplacement.Thethermo-

locatedintheexhaustmanifold(fig.27)

exhaustgasesto bedirectedintothe

valveaidsin"warmingup"the engine,

ofthefuelmixture.Thetensionof the

yimportantforproperengineoperation.

dup justenoughfortheend toslipover

hisisapproximatelyy2turnofthe spring

8).Removethetwonutsattaching

anifold.Removeaircleaner,carburetor,

sconnectwires,andremovehornwith

vacvacuumline,windshieldwiperline,


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

acement

nefromfour-wayfittingonmanifold.

atorline.Removethetwonutsand sixcap

foldstothecylinderhead.Removethe

emovefour-wayfittingandmeteringvalve

acenewgasketsinposition,and

enallnutsand capscrewsevenlyand

gasketleaks.Installthegovernorand

kets.Installaircleaner.Fitexhaustpipe

kingifnecessary.Installandtightenre-

ayfittingandmeteringvalvein manifold.

indshieldwiperline,andhydrovacvacuum

ctwires.


/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

n theoilpanare adjustedtothe

connectingroddipperswilldipintothe

atlowengine speeds.Astheengine

oil pressurebuildsup,theoil streams

areinterceptedbythedippers,forcingthe

bearingsunder highpressure.CAUTION:

o bendtheoilnozzlesso thattheoil

connectingroddippers.

pan.Removeoilgagerod and

ncapscrews.Bumptheoil pantoloosen

werittothefloor, beingcarefulnotto

troughsinthepan.

entReplacement

cnewgasketsto theblock.Install

e oilpanupinto position,beingcareful

screen.Installand tightenretainingcap

tube andoilgagerod.Install thedrain

seasonalgradeengineoil.

elementtypeoilfilterisusedto re-

theoil.Theelementshould beinspected

dependingonhowfrequentlytheoilis

oilused,severityofservice,climaticcon-


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


TA,MAINTENANCE,

CLE

fig29).Removedrainpluganddrain

ket.Liftouttheelement.Cleantheoil

cleanrag.Installdrainplug.Placenew

ebody,and installgasketandcover.

connectoillines.Removeupperand

tsononeside ofclamps,andloosen

mitwithdrawaloffilter.Toinstalloil filter,

eentheclampsandtightentheclamps.

AOR.

aseandrockerarmcoverareventi-

hroughthe crankcase,providedbycon-

fillertubetothe intakemanifold.Fresh

bathaircleanermountedon thevalve

opoftheengine,and downpastthevalve

ase.Airandanyfumesinthecrankcaseare

he oilfillertubethroughthe connecting

tothei ntakemanifold.

eraircleaneronthevalve rockerarm

eriodicallyatthesametimeas thecar-

b). Bothaircleanersusethesametype

ebreatheraircleanerfromthevalve

outtheoldoil, andcleanoutanyaccumu-

rbodywith dry-cleaningsolventand,

elementin dry-cleaningsolventand

nkcasebreatheraircleanerwith

sed intheenginetothe levelindicatedon

dy(fig.22).Thecapacityofthecrankcase

pint.

,000miles,removethecrankcase

vepipeassembly,andthemeteringvalve

emeterine;valve,andcleanallpartsthor-

vent.Wipeallpartsdry,and reassemble

outthecrankcaseventilatortometering

ompressedair,orcleanoutwith dry-

oughly.

eventilatortometeringvalvepipe

gvalveonengine,beingsure thatallpipe

yairleakinthe passagefromtheoilfiller


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

willreducetheefficiencyoftheventilating

onsofoperationsuchasunusual

theair,or wherethereareothertypes

used,itmaybe necessarytocleanthe

ssemblymoreoften.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


STALLATION

rainboththeradiatorand thecylinder

idepanels.Removetheradiator,frontend

sa unit(par.150).

nes.Removebatterycableandam-

motorswitchterminal.Tapeendof

onnectthenegativecable,topreventshorts.

topofcoil.Drain theoilfilter,anddis-

es atconnectors.Turnoffvalveatfuel

elfeedline atthefuelpump.Remove

onnecttheradiosuppressiongroundstraps

andsideof clutchhousing.Disconnect

vehorn.Disconnectcarburetorendof

Removecarburetoraircleaner.Discon-

tureindicator,windshieldwiper,and

mengineassembly.

eBraceRodsandLevers.Disconnect

nifolds.Removeleftenginesidepan and

uppressiongroundstrapsfromtheleft

efloorandtoeboards.Splitthe universal

on.Removetransfercasecontrollevers

erattachingboltsonrightsideof trans-

erplantbracerodtotransmissionbracket

backspringat leftrearcorneroftrans-

ellershaft(orshafts)andshiftlinkage

ake-off,ifvehicleissoequipped.

Cover.Disconnectacceleratorrod

sideofengine.Removethethreecap

ndbrakepedalshaftassemblytoclutch

utchpull-backspring.Disconnectclutch

geyeandbrakepull rodlinkfromlever.

ssembly.Removecrankingmotorcross

nkandspring from^crankingmotorgear-

nsmissioncoverandcovertopoftrans-

.Disconnectthefrontandrear

leisequippedwithtransmissionpower

nemounting.Removesteamrelieftube

rfitting.Removethethirdcylinderhead

eftside,andinstall theengineliftingeye-

othe eyeboltandraisetheengine,clutch,

chassisasa unit.Ifthisengine istobe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


t)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


STALLATION


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

blyRemoval

uilt engine,transferallaccessories,fit-

charenotfurnished)fromthe oldtothe

Install aliftingeyeboltinthe

efromthe rearontheleft sideofthe

ewitha hoist.Swingitoverthe chassis

oplace.Installleft rearenginemounting

neremoval.Installenginemountingbolts

.Installtransmissioncover,placingthe

ketinpositionunder theleftreartwo

ill notdropthroughbracketandenter

hofbrace rodsothattheywill enter

plant.Installthe twoboltsthatattach

sandemergencybrakelevermounting

nsmission.Removeliftingeyebolt.

mperatureindicatorfitting,temperature

tube.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


STALLATION

s.Installcrankingmotorcrossshaft

rely.Hookupthecrankingmotorgearshift

rakepedalshaftwith pedalsinposition,

olts,connectclutchpedalto adjusting

ackspringandbrakepullrod. Hookthe

ngtoclipat leftreartransmissioncover

rrodandattachit tobellcrankonleft

.Placetheuniversaljointinposition

ockwashers,andnuts.Connectdrive

inkagetotransmissionpowertake-off,

nstallthefloorandtoeboards.Install left

hthetwo radiosuppressiongroundstraps

necttheexhaustpipetoexhaustmanifold.

ostervacuumlineandwindshieldwiperline.

es.Connectoilpressuregageandoil

eft sideofengine.Connectchokeand

andattachhornwires.Connectther adio

storockerarmcoverstudand clutchhous-

e panandtightenscrews.Attachgasoline

d turnonvalveatfuel filter.Attachthe

Attachthebatterycableandammeterwire

l.

llthe radiatorfrontendsheetmetal

.151).Installaircleaner.Installhood and

andtransmission.Lubricatetheuniversal

d.Tuneengine;testlights,horn,and gen-

eckoillevel.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

data68

dalTravelAdjustment

BULATEDDATA.

sasingle-plate,dry-disktype,incor-

dhub.Theengagementpressureissupplied

ng.Theclutchis controlledbytheclutch

owoutfork,andthrowoutbearing.

43in.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

ewDepartureCT-22

in.to1% in.

02in.to 0.006in.

005into0.0055in.

PO32248

ingRemoval

orethe throwoutbearingcontactsthe

ebetween1inchand 1%inches.Tomake

eadjustinglocknut(fig.33), andturn

nchfreetravel ofthepedalis obtained.

T(fig.34).

ONASSEMBLY(par.97).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


K.Removethrowoutbearingfromthe

kspring,andremoveadjustinglinkfrom

eclutchforkbypressingit awayfrom

riveruntilthe forksnapsloosefromthe

aybe removedfromtheforkbyprying

ndatatime.Removethethrowoutfork

eclutchhousing.

MBLYANDDISK.Loosenthenineclutch

t atime(topreventcoverdistortion),

pressureis released.Removetheclutch

omtheclutchhousing.

fBallInThrowoutFork

(fig.35).Removethethreeclutchpres-

gs,andremovethepressureplate fromthe

eclutchcover,diaphragmspring,andtwo

therand servicedasanassembly.

tthethrowoutbearinganddisk)in

teand flywheelforscoresorcracks

utchoperation.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

replatedrive lugsforexcessivewear

hecover.Theyshouldhavefrom0.002-

ce(fig.35).

aringforroughnessandfree fitonthe

ionmaindrivegearbearingretainer.

entlylubricatedbearing,andmustnot

solvent.

AssemblywithFlywheel

dinthe throwoutfork(fig.36).

withoutside play.

or worn,loose,oroil-soakedfacings,

oose hubrivets.Checktoseethatthe

yworn,andthattheymovefreelyon the

f thesplinesareworn,thedisk shouldbe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


tchshaft,andturn shafttocheckfor

OVER.Installthepressureplatein the

uretomatethe"O"markonthe pressure

on thecover(fig.35).Thisis necessary

e.Installthethreepressure plateretracting

eadyto bereassembledtotheengine.

ringCollarLubrication

DISK.Hand-cranktheengineuntilthe

at thebottom.Installtheclutchdisk,

assembly.Turntheclutchassemblyuntil

nes upwiththe"X"markon thefly-

ne bolts,andtightenthemeachaturn

tingthecoverasthespring pressureis


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

K.Installthethrowoutforkmounting

ackthe ballseatinthe forkwithasmall

bearinggrease.Installanewspringre-

clutchforkiftheold retaineriswornor

eretainerisinstalledwiththe highside

mthe ballbearing,andtheopenend of

tal.Replacetheforkin positioninthe

heforkontothe ball.

BEARING.Lubricatetherecessoninside

andcoatthethrowoutforkgroovewith

drollerbearinggrease(fig.38).Then

thethrowoutfork.CAUTION:Becare-

bricant.Installtheadjustmentlinkand

ON.Installthetransmission(par.98).

L.Adjusttheclutchpedal(par.69).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


sofa largefuelsupplytank,afuel

pump,carburetor,aircleaner,andthe

gs.

edData.

buretorusedisoftheCarterdown-

datthetopcenterofthe intakemanifold.

46

djustmentsonthiscarburetorare

eed)andidlingmixture.Beforeattempting

akesurethecarburetorto manifoldand

boltsaretight topreventairleaks.Make

perlycleaned,andthatthevalvesareprop-

eand throttlestopscrews(fig.17)in

hertosecurethebestidling performance.

500 to550revolutionsperminute.

oveaircleaner,disconnectchokeand

onnectthefuellinefromfloatchamber

twonutsthatattachthecarburetorand

removethecarburetorassembly.

gasket,placethe carburetorin

ainingnuts.Connectthethrottle and

theiroperation.Opentheidleadjusting

hefuelline,andinstall theaircleaner.Fill

berbyworkingleveronfuelpump.Start

hrottle andidleadjustingscrewsincom-

obtaina smoothidleatbetween500and

e.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


edData.

Thediaphragm-typefuelpumpis

oftheenginecrankcase,andisoperated

shaft.Thefloatcontrolledneedlevalve

heamountoffuel flow,andacoilspring

stantpressureinpump tocarburetorfuel

providesameansofprimingthe pumpand

torBowl


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

attachingcapscrewsandfuelline

veandcleanglasssedimentbowlontopof

ateror.sedimentisnoticed.

hefuelpumpinletandoutletlines.

erspring,removetheretainingcapscrews,

gasket(fig.39).

gasketonthe flangeoffuelpump,

againstthe enginecrankcase,andinstall

Connecttheinletandoutletfuellines

rimerspring.Fillthe fuelpumpandlines

0).

edData.

Themultiple-disktypefuelfilteris

the rightframesiderail.It isconnected

efueltankandfuelpump.A shut-off

k sideoffilter,anda drainplugisin the

uelenters thefilter,isfilteredbetween

thefilter element,andthenpassestothe

hat accumulateinthefiltercanbe

edrainplug.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


Makesurethatallconnectionsare

airleaks.Drainandflushout thefilter

heshut-offcockandremovingthedrain

bowlbyopeningvalveand admittinga

lthe drainplugandopenshut-offvalve.

closethe shut-offvalve,removethecover

nt.Washallparts ofthefilterin dry-

efilterelementbackandforthin clean

clesofdirt. Assemblethefilterelement,

newgaskets.Opentheshut-offvalve.

mentReplacement

mmaintankuntilfuel levelisbelow

efuelinletandoutlet lines,andremove

achingbolts.

terassemblyinposition againstthe

ningbolts.Connectthefuel linestothe

ve,fillfuel tank,andcheckforfuelleaks.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

steelseam-weldedtankisfitted

ntsurgingof thefuelandto giveadditional

mountedontwosupportbracketsextend-

merightside rail.Thetankisheld inplace

ooverthetankandattachto thesupport

ceisattachedtothetwosteelstraps at

vybracketextendsfromtheframeleft

othecenteroftheL-bracebyone bolt.

kis 30gallons.

fromtankand installdrainplug.

couplinghose,thetanktofilter fuelline,

e.Removethesupportbrackettoframe

eboltthatattachesthe sidesupportat

tbracket.Lowerthetankandbracket

hepropellershaft,thentipouter edgeof

meside rail.Removethenutsfromstrap

dswingthestraps upawayfromtank.

nkinpositionon thebracketswith

sidetowardframeendofbracket.Securely

support bracketnuts.Placethetank

llthesupportbracketto framebolts,and

ankside supportbolt.Connectthefiller

clamp.Connectthefuelline totankand

agetankunit.Fill thefueltank,and

edData.

Theadjustablegovernorisdesigned

gineand vehiclespeed.Itismounted

ndintakemanifold.Thegovernorthrottle

ension andclosedbymanifoldvacuum

uscontrollingthe volumeoffuelmixture

buretor(par.72).Liftthegovernorand

studs.

gasketinpositionon themanifold

governorin position.Installthecarburetor


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


STEM

edData.

Theoil-bathtypeaircleanermounts

or,andfiltersdirtfromthe airbeforeit

e(fig.22).Loosentheclampscrew

emovethewingnutfromtop ofcleaner,

vethefilterelementassembly.NOTE:Do

ordamagewillresult.Emptytheoil out

shit thoroughlywithdry-cleaningsolvent.

hingit upanddownindry-cleaning

entwithan airhose.Fillthecleaner

eoil.Installthe filterelement,making

onthetopofthe cleanerbody.Installthe

ut,makingsurethatthegasketmakesa

ndbody.Installcleaneroncarburetorand

stsystemconsistsoftheexhaustpipe,

systemcarriesthe exhaustgasesfrom

ssisframe,andoutfrpm undertheleft

muffleremploysthereverse-flowand

cetheexhaust.

ent(fig.43).

hemufflersuoportspringfrom ex-

oveclamp.Loosentheexhaustpipeclamp,

omanifoldstudnuts,and removethe

mufflersupportspringanchorclamp.

hpackingflangeinposition,and hookthe

xhaustpipe.Placea newexhaustpipe

stalltheexhaustpipe tomanifoldstud

pipeclampatmuffler,and theexhaust

ecurely.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


t)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


STEM

Disconnectthetailpipesupportat

wobracketsatframesiderail. Loosenthe

ndpull thepipeoffmuffler.Placethe

stall thetailpipeclampbracketsand

emovethetailpipe(subpar.cabove).

amp,anddisconnectthemufflerstrap.

haustpipe.Placethenewmufflerinposition

p,butdo nottightenit.Connectthe

atethemufflerslightly,if necessary,to

andoutlettubes.Tightenthe muffler

,tailpipeclamp,tailpipe brackets,and


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

data79

83

BULATEDDATA.

ecoolingsystemconsistsofa radi-

mostat,centrifugalwaterpump,fanbelt,

m

7/4^

gal

manentlysealedandlubricated


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ator

at140° to147°F

Removal

Approximatelyly^in.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

UMP

emoval


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


orcoreisof thetubeandfinconstruc-

er.Thecoreissupportedina steelanchor-

rt.Thesupportisboltedto thefrontcross

cushion.

(fig.45).Removeradiatorcap,drain

llhoseconnections.Disconnectthesteam

emovethetwoboltsthat attachradiator

ort,loosenbracerod nutsatthedash,and

ohood.Removethefanblades.Disconnect

mtheclipsalongthe topandsidesof

apscrews(threeoneachside) thathold

he support.Pushthefanshroudto one

hatattachesradiatorsupport,andliftfan

ator coreupandout,beingcarefulnot

on.Lowertheradiatorcoreintoplace,

ositionbackof radiator.Installthesix

roudandradiatorcoreto thesupport.

minclips alongtopandsidesof radiator.

nectradiatorbracetoradiatorsupport.

sandclamps.Connectsteamrelieftube

bracerods atdash.Refillcoolingsystem,

ereare nowaterleaks.

m.Todraintheradiator,remove

velocatedatbottomofradiatoronthe

inderblock,openthevalvelocatedon

earcylinder(fig.30).

Whencoolingsystemhasbeen

gspeed whilefillingradiatortoprevent

thecoolingsystem.CAUTION:Never

orwhenengineis unusuallyhot,asthe

ylinderhead.Whenusingantifreeze,

Leaveabout1inchofair spacebetween

iatortoallowfor expansionoftheanti-

ssof antifreeze.

ecentrifugal-typewaterpumpis

e cylinderblock,andisbelt-drivenfrom

shaftisball-bearingmounted.Thebear-

meltingpointlubricantandrequireno

g.46).Removeradiatorcapand

hoseclampsthatsecurehoseto water

eawayfromwaterpump.Loosenbolt

orbraceandmountingbracket,andloosen

waterpumppulley.Removethefourcap


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

ocylinderblock,andremovepumpand

by turningitasit isremoved.

pandfanbladeassemblyinposition,

the fourcapscrewsthatholdthepump

nbeltover thethreepulleys,andadjust

seconnectionoverwaterpumpopening,

Closebothdraincocks,fillthe radiator,

o waterleaks.

tment

tis oftheV-typeanddrivesthe fan,

or.

.47).Loosenboltat generator

ofslottedbrace.Rockthegeneratoron

inggeneratorawayfromenginetightens

rtowardengineloosensthebelt.The


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


inedwhenthebeltcanbe depressed^inch

oltatgeneratormountingbracketand

echeckforpropertension.

EMENT.

rainradiator,andloosenupperhose

wsthatattachwateroutletconnectionto

4).Removewateroutletconnectionand

lthermostat,makingsureexposedparts

rear.Installnewgasketandwateroutlet

onnectionandhoseclamps.Fillcooling

g.30).

connectedtothetopoftheradiator

side ofcylinderheadattherear.It isfor

yair pocketsthatmaybecausedbysteam

e vehicleisdescendingsteepgrades.The

noattentionother thankeepingitfrom

ontend oftube,tightenorreplacehose

atrearoftube,tightenpackingnut to

offvalveclosedexceptwhenoperating

hetemperatureisabove60°F.


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rolet)

RUMENTSANDGAGES

h,andsparkplugs88

9

h90

ment95

onsistsoftheignitionsystem,gener-

ngmotorandswitch,instrumentsandgages,

ession,andthenecessarybatterycables

ttheoctaneselectorsothat center

distributorclampis inlinewiththe mark

ock.

necta timinglighttotheNo. 1

engineandrunitat idlingspeed.Loosen

turnthe distributorbodyeitherina

kwisedirection,untilsteelballin flywheel

wheelhousing.Tightenthedistributor

edistributordirectsthe hightension

dersatexactlythe propertime.

gal

.

n17-21oz

0rpm


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

edistributorcapandrotor,andinsert

betweenthe points.Filewithastraight

pointsflat.

Removethedistributorcapandrotor.

tilthebreakerarmcamfolloweris on

es.Loosenthestationarymountlockscrew

nt),andturn theeccentricadjustingscrew

0.018-inchfeelergagejust fitsinthegap.

drecheckthegapclearance.

movethedistributorcapandliftoff

at retainsthemovablearmspringtothe

edistributor,andliftout themovable

rypointlockscrewandliftout thesta-

stationarypointinposition indistrib-

rew,but donottightenit.Placethe mov-

he springinplaceonthe terminalon

theterminalnut securely.Hand-crank

rarm camfollowerisonthepeakof one

eccentricadjustingscrewtotherightor

ergagejust fitsinthegap. Tightenthe

hegap.

distributorcapand liftofftherotor.

the condenserpigtailtotheterminal,

erminal.Removethescrewthatretains

butor,andlift outthecondenser.

thecondenserinpositioninthedis-

ning screwandlockwasher.Connectthe

tightenthenutsecurely.

nt.

allation.Removethevalvecover

r;thenhand-cranktheengineuntilNo. 6

ens,andcontinuetohand-cranktheengine

closes.Removethecapfrom thedis-

konthe distributorhousinginlinewith

butor rotor.NOTE:Thisprocedure

gpositionto insurethatthetimingwill

utoris installed.

emovethenutandwasherthat

totheprimaryterminal,and removethe

orclampscrew,andthenworkthedis-

utof thecylinderblock.

).

Obtaina neworrebuiltdistributor

arkonthehousingin thesamelocation


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


)

AS

3—


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

ES

P u b l i c D o m a i n ,

G o o g l e - d

i g i t i z e d

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a t h i t r u s t . o r g / a c c e s s

_ u s e # p d - g

o o g l e

7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

K

Timing

tallation


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

istributorjustremoved.Removethecap

ndtransferthe sparkplugwiresfromthe

eatatime,to makesurethefiringorder

allation.Iftheenginecrankshafthas

ributorwasremoved,hand-crankthe

n No.1cylinderfiringposition.Turnthe

or inaclockwisedirectionuntilthecon-

pwiththe scratchmarkmadeonthe

$inchfurther.This isnecessarytocom-

e distributorgearwhenitengagesthe

ldistributorthroughdistributor

blockwithgreasecup ondistributorat

ck;continuetopushdistributor down

ed.Ifthedistributorbottomsbeforeitis

willbenecessarytocranktheengine

imepressingdownlightlyonthe dis-

ormovesall thewaydown.Thisisneces-

edrivetang ontheoilpumpshaft.Tighten

stsnugwhilemakingsurethat greasecup

nderblock.

nstall capondistributorandclamp

orsothatcentercalibrationmarkon rear

newithmarkonmachinedsurfaceofthe

atiminglightto theNo.1sparkplug;

runitat idlingspeed.Loosenthedistrib-

stributor bodyeitherinaclockwiseor

n,untilsteelballin flywheellinesupwith

g(fig.49).Tightenthe distributorclamp,

erandvalvecoveraircleaner.

ONSWITCH,ANDSPARK

movethetwonutsandlockwashers

op ofthecoil.Tagthe wires"positive"

theycanbeinstalledonthe proper

sionwireout ofterminalatbottomof

wsthatretaincoilto sideofengine,and

coilinpositiononengine,andinstall

ndlockwashers.Pushthehigh tension

erminal.Installpositivewireonpositive

eonnegativeterminalontop ofcoil,and

d lockwashers.Tightenthenutsand

y.

P u b l i c D o m a i n ,

G o o g l e - d

i g i t i z e d

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a t h i t r u s t . o r g / a c c e s s

_ u s e # p d - g

o o g l e

7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


olet)

ment.Unscrewtheignitionswitch

trumentpanel,and pushtheswitchout

erpanel andbringtheswitchdownas

willbeaccessible.Obtainanewswitch,and

oldswitchto thenewswitch.Placeswitch

tainingring.

fig.20).Removesparkplugs,and

osetthegap at0.040inch.Placeanew

lugi nfinger-tight;thentighten%to ^

//it isnecessaryfousetheold gasket,

awrench.

embly

GULATOR,

edData.

Thegeneratorismountedona bracket

enearthe front,andisdrivenby thefan

neratoris toconvertasmallamountof

heengineintoelectricalenergywhichis

utput ofthegeneratoriscontrolledby

dcurrentregulatormountedonthedash.

o preventthevoltagerisingabove7.5


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

TER

ROVAC

EGAGE

E

ACUUMLINE

HECKVALVE

ECKVALVE

CTIONBLOCK

ator(CoverRemoved)

rising above40amperes,therebypre-

hebatteryor generator.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

ot)

ot)

hethreewiresfrom terminalsontop

hwirewithatag.Removethecap screw

f generator.Pushgeneratortowardengine,

eratorpulley.Removethetwoboltsand

rthat retaingeneratortomounting

erator.

orandPedalLinkage

thegeneratorinpositiononthemount-

wo retainingbolts,nuts,andlock

atwasher,lockwasher,andslottedbrace,

tandnut.Placefanbelt ongeneratorpulley

r.82).Installthethree wiresonthesame

mwhichtheywereremoved.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

hefourwiresfrom theregulator.

g andtapeendofwirethat wasremoved

eventitfrom touchingmetal,causing

efournutsand lockwashersattaching

offtheregulator.

ndmakesurethe dashiscleanat

andalsothatthefour mountinglegson

placeregulatorinpositionon dashand

oltswith alockwasheroneachsideof

efourwiresonthe sameterminalsfrom

.Startengineandchecktheoperationby

r.

RYCABLE

orRemoval

NDSWITCH.

edData.

Thestartingsystemconsistsofthe

rankingmotorswitch,batterycable,and

suppliestheelectricalenergyto turnthe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

witchisclosed,andthecrankingmotor

ergyintomechanicalenergywhichdoesthe

eengine.

co-Remy

movethenutandlockwasherthat

dammeterwireto thecrankingmotor

TOR

GHTS

ON

ONTROL

NTROLLEVER

GHTSWITCHN—INSTRUMENTPANELLIGHTSWITCH

ndSwitches

eand ammeterwire.Wraptapearound

t theterminaldoesnotcontactanymetal.

gepull-backspring.Thenremovethe

pedallinkfromtopof drivemechanism

onutsandlockwashersthat retaincrank-

chhousing,andlift outtheassembly.


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RUMENTSANDGAGES

thecrankingmotorinpositioninclutch

retaining nutsandlockwashers.Connect

chanismlever,andinstallthespringclip

pull-backspring.Placethebatterycable

rankingmotorswitchpost,and installthe

her.

nutand lockwasherthatretainthe

terminalandlift thecable,ammeter

offtheswitch.Tapeendof cabletoprevent

rewsthatretainswitchtocrankingmotor,

embly.

surethatthetwobakeliteinsulatorsare

sideofswitch,thenplacetheswitchin

r,andinstallthecondenserandtwo

washers.Placethecondenserlead,battery

ontheswitchterminal,'andinstallthe

her.

AGES.

einstrumentsandgagesare located

umentpanel,andconsistofa temperature

reesFahrenheit,fuelgage,speedometer,

er,andlightswitches.

Replacement.Draintheradiatorand

adapterat leftrearofcylinderhead.

hingtemperatureindicatorleadtobond

sandlockwashersthatretain indicator

strumentpanel,andpullindicatorunit

anel,at thesametimepullingtheheat

alla newassemblyinthereversemanner.

uelgageiscomposedoftwounits:the

mentpanel,andthe unitinthefuel tank.

ACEMENT.Disconnectthetwowires

.Removethetwonutsfrom backofunit,

ewunitin thereversemanner,making

rsoverpostsandinholes inclamp.

ENT(fig.56).Removethewirefrom

e groundwirefromunderoneofthe

ethescrewsthatattachtankunittotop

it.Install anewtankunitin thereverse

ent.Loosenthe-setscrewinsideof

ntilitcomesoffthe shaft.Removethe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

kUnitReplacement

elease buttonhousing,andliftoffthe

retainstheswitchtothe panel.Push

oveonewireata time,andinstalliton the

chinthe reversemanner.

witchReplacement.Loosentheset

rewthe knob.Removenutthatretains

witchoutof panel.Removeonewireat

enewswitch.Installthe switchinthe

edometerisdrivenbyaflexibleshaft

earsinthe transfercase.Theflexible

nnecttheflexiblecablefromthehead,

hatretain headtoclampbracket,and

rumentpanel.Installanewspeedometer

r.


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RUMENTSANDGAGES

cement.Disconnecttheoillinefrom

finstrumentpanel,andremovegagefrom

nstallanewgage inthereversemanner.

t.Disconnectwiresfrombackofalti-

let thepositivewiretouchanymetal.

etainammetertoclampbracket,andpull

sConnectionstoJunctionBlock

rumentpanel.Installa newammeterin

ngsuretoinstallinsulators overterminal

systemthatconnectsthevarious

e batteryconsistsofabatterycable,indi-

rnesseswhichconsistofseveralwiresin


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

n harnesses(fig.57);namely,thefront

yharness,andthegenerator-to-regulator

understandingthe variouselectricalcir-

andjunctionblockareexplainedand

eofthecircuitand colorofthewire.

odyharnessleadsfromtheswitches,

dinstrumentsontheinstrumentpanel

leftsideofthe dash.

frontharnessleadsfromthejunction

edashtothe headlightjunctionblockson

with leadstakenoffforthehorn.

WiringHarnessConnections

earharnessleadsfromthejunction

edashtothe taillightjunctionsattheleft

leadisalsotakenofffor thefuelgage

LATORHARNESS.Thegenerator-to-

sthreewires,connectingthearmature,

softhegeneratorto theregulatoronthe

AMMETERANDCOILWIRING.The

erandcoilwiresleadfromthe cranking

ter,andalsofromthe ignitionswitchto


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RUMENTSANDGAGES

tothefuelgagecircuitbreaker.The

nkingmotorswitchto theammeter

oftheinstrumentpanelconnections.

.58,59,and60).Thefront andrear

tothebodyharnessatthe junctionblock

hehood.Theterminalsare notnumbered,

ses,theterminalsinthe illustrationsare

erencedtothe wiringdiagram(fig.48).In

rcuit,andthe colorandsizeofthe wires

nsandexplanationswillsimplifythe

harnesses,andcheckingthevariouscircuits

nnectionTable(fig.58).

er

s

er

er

iringHarnessConnections


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evrolet)


t

er

WiringHarnessConnections



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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

entracer

K

Naturalwithblackcross

er

er

er

-

l

er

er

s

er

elight switchhasfourpositions.

n alltheway,theswitchis inthe"OFF"

utto thefirstpositionturnson theblack-

kouttaillights,andalsoprovidesa circuit

nd blackoutdrivinglight.Pullingthe

rns onthemaindrivinglights andservice

heswitchisallthe wayout,theservice

se indaylightdriving.Theterminalsare

61,and theconnectionstothejunction

owninthefollowingtable.


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vrolet)

NECTIONTABLE

struction


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RUMENTSANDGAGES

ectsto

llightsNo.1terminalon junction

meter

topNo.3terminalonjunction

ock

rminalonjunction

No.12terminalon junction

Theheadlightsarethe"sealedbeam"

ndlensarea completeunit,andcanonly

lowerbeamfilamentispositionedslightly

ntinthe reflector.Thisresultsindeflect-

rightsideof theroadwhenapproaching

oppositedirection.Theheadlightsuse

atttriple-contactlamp.

GHT(fig.9).Theblackoutdriving

tfrontfenderalongsidetheheadlight.It

lackout.Thediffusedbeampatterndoes

entratedontheroad;itcastsillumination

tofthe vehicle.Theblackoutdrivinglight

unit thathasa6-volt,10-candlepower

kthat diffusethebeamandprevent

IGHTS(fig.9).Theblackoutmarker

ront fenders;adowelinthe fenderassures

ht.Theselights usea6-to 8-volt,3-

ct,bayonet-baselamp.

TOPLIGHT.Theblackouttailand

herearofchassisat therightside,and

oneforthe taillight,andtheotherforthe

tsof ahousing,alampsolderedto the

Bothunits usea6-to 8-volt,3-candle-

mp.

VICETAILANDSTOPLIGHT.Theblack-

op lightismountedatthe rearofthe

sconstructedsimilartothe blackouttail

cebeingin theservicetailandstoolight

-filamentlamp,3-candlepowerforthe

werforthestoplight,anda lensmadeof


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evrolet)

M

ngDiagram

).Headlightsmaybeaimedbythe use

which canbeconstructedveryeasily.

mately5feethighand8 feetlong.The

fcommonlumberapproximately1inch

mewithapieceoflight-coloredcloth; make

pedownthecenter, andtwostripes,18

hecenterstripeandparallel toit,asshown

llustration.Thenplacenails ontheend

atthenailsare1 inchapart,beginningat

omofthescreenandcontinuingupward

pieceofblacktapeaboutyz- or3^-inch

ongerthanscreeniswide.Fastena weight

keepthetapestretched whenlaidacross

"A"inthe illustration.

acethescreen againstawallina

hat isfairlylevel.Runthe vehicledirectly

attheheadlightsare 25feetfromthe

loortothe centeroftheheadlights,and

thescreensothatit is3inches below

s.Turn ontheupperbeamofthe head-

lights.Checkthelocationofthebeam

f thehotspotshouldbe centeredonthe

andhorizontallines asshowninfigure63.

senthenutonthe headlightmounting

htbodyon itsballandsocketjoint until


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RUMENTSANDGAGES

t.Removethetwoheadlightharness

rom terminalblockortinsideofhoodside

wiresthroughholeinsideof vehiclein

movethenutand washerthatretainlight

liftoffthe light,andpullthewire harness

alla newlightinthereverse manner,

eplacement.Pullthesleevecon-

ads fromdrivinglighttofront wiring

sidepanel.Pullthewirethroughhole

thefrontfender.Removenutfrombottom

ofender,liftoffthe light,andpullthe

.Install anewlightjn thereversemanner.

eplacement.Theblackoutmarker

samemannerastheblackoutdrivinglight.

ghtReplacement.Pushthebayonet

the sametimeturningthemcounter-

ch;thenpull theconnectionoutofthe

tsandlockwashersthat retainlightto

offthelight.Install anewlightin the

ail,andStopLightReplacement.

ail,andstoplight isreplacedinthesame

landstop light.

UnitReplacement.Removethethree

mountingbrackettofender,andturn

e.Loosenthelensrim clampscrew,and

three screwsthatsecureretainerringto

ering.Pull thesealedbeamunitoutof the

twiringconnectorfromrearoftheunit.

nit inthereversemanner.NOTE:By

etmountingboltstoturnthe headlight,

reaimtheheadlightafterreplacinga

mpReplacement.Removethe

ndpull therimoutat thebottom;then

thestampedcatchincoverfromslotin

helampandat thesametimeturnit

°fan inch;thenpulloutthe lamp.Install

emanner.

nitReplacement.Removerim

ofrim,and pulloutrimand lightunit.

romthelight.Releasethespring retainers

retainerandlampunit.Install* anew

manner.

ghtUnitReplacement.Pushin

roflight,turnit counterclockwiseabout

hebayonetconnection.Removethetwo

ghtbody,andliftoffthe lightrim.Pull


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evrolet)

tyTestofBattery

cketandlightbody.Installa newlamp

ail,andStopLightUnitReplace-

rvicetail,andstoplight unitsarereplaced

eblackouttailandstoplight units.

edData.

Thebatteryismountedin ahanger

esiderail totherearof cabsteponthe

protectedbya removablecover,attached

providesaccessfortestingand fillingthe


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RUMENTSANDGAGES

0-hourrate150

ance.Operationofthevehicleinzero

makesfrequentcheckingofthespecific

mperative,asadischargedorpartially

ezeatahigher temperaturethanafully

peraturesatwhichelectrolytewillfreeze

ture(Fahrenheit)

battery,installthethreefillerplugs,then

thatthey aretightandfreeof corrosion.

heterminal,andapplya coatingofgrease

seethat thebatteryistightin thehanger

getothebattery.Installthe batterycover,

uts securely.

wothumbscrews,andliftoffthe

tsoncableclampboltsseveralturns,and

osenthem;then liftthecableswith

ts.Removethetwonutsand lockwashers

ner,andlift offtheretainer.Liftthe

ryinhangerwithpositiveor largest

laceretainer onbattery,installthetwo

dtightenthemalternatelyuntilthey are

nalpostsand cableterminals,andtap

nonthe posts.Tightentheclampbolts

coatingofgreaseon theterminals;then

andtightenthe thumbscrewssecurely.

EQUIPMENT,

pmentisinstalledtocontrolthe

ncebytheelectricalequipmentofa

noisein thevehicleradioreceivingset.

ppressionsystembemaintainedinperfect

radiateinterferencecanbeeasilylocated

steningdevicesinthehandsof theenemy.

complishedonthesevehiclesbythe

ngresistor suppressors,filters,condensers,

rusing suppressors,shieldingandcon-

sused onearlierproductionvehicles,and

s.


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et)

DistributorFilter,andCranking

randCondenser


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RUMENTSANDGAGES

meter,andFieldFilters

m.

productionmodelsincludedradiosup-

firsttypementionedin subparagrapha(2)

pressors,6filters,2 condensers,13flexible

screen,anda numberofplatedbolts,

shers.

).Suppressorsareusedoneachhigh

plugs,andalsoonthehigh tensionlead

rofthedistributorcap.Wheninstalling

nsionwire,thewireandinsulationshould

essorscrewedontothewire,makingsure

nterofthewirestrands.Thesnap-onter-

contactwiththesparkplug. Theresistance

proximately10,000ohms.

7,and 68).Sixfiltersareused topre-

issionofanydisturbancealongthewires

our areusedinthe generatorcircuit,

cuit.Whenreplacingafilteriti simportant

ndmountingboltsbe tightenedsecurely.

ndensersareused;oneonthegenerator

thecrankingmotor(fig.65),to accomplish


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et)

er

nBonding


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


RUMENTSANDGAGES

dLocations

derandHood

ters mentionedinsubparagraph(3)above.

crewsandterminalsmustbekepttight.

ccomplishedbytheuseof13 flexible

enweldedatthe hoodsidepanellouvers,

s,nuts,andtoothedlockwashers.The

eepallmetalpartsat acommonpotential.

the flexiblemetalstrapsisillustratedin

are locatedatthefollowingpoints:


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

denser

edashand hood.

peedometercable,throttlecontrol,and

enrearbolton rockerarmcoverand

hechokecontrolandtemperatureindicator

diatorsupportbracketandradiator

uippedwithfrontwinch,thelowerends

achedtothefrontcrossmember.

hside betweenthefenderlowerskirt

side betweencabsidesillandframe

chhousingandleftside panrear

tofoil panandframefrontcross

versareshieldedbyweldingapiece

e ofthesidepanel.It willbenotedthat

placedundertheheadof theboltandalso

ndedparts areremoved,makesure

ecleanat theboltlocationsbeforeinstall-

ashers;alsotighten theboltsand


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RUMENTSANDGAGES

densers

Y

L

dingParts


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vrolet)

O.3679110E—LOWERSHIELDASSEMBLY

KETF—NO.1SPARKPLUGWIRE

O.3679109G—CRANKINGMOTORCONDENSER

IGNITIONSWITCH

emovedforServicing

nd71show thelocationsatwhichplated

ckwashersareused.

.

oductionmodelsareequippedwith

mconsistingofsevensuppressors,fivecon-

metalshieldwhichenclosestheignition

essorsareusedasoutlinedinsubpara-

econdensersusedonthissystemare

oints:a generatorcondensermountedon

orhousing(fig. 72),tworegulatorcon-

thegeneratorregulator(fig.73),an igni-

nthelowerhalfof theignitionshielding

denserattachedtothecrankingmotor

wo-piecemetalshieldis usedto

stributor,coil,andwiring.Thelower

dtotheengineside coverbyfourboltsand

ockwasheroneachside ofthebolting

tionwirefromtheignitionswitchis

erminalpost,andthe ignitionprimary

coilby aleadfromtheterminal postto


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RUMENTSANDGAGES

talled

ontop ofthecoil(fig.75). Thecircuit

permitstheremovalofthe uppershield

ectionandadjustments,withoutdisturbing

.Theuppershieldassemblyis attached

ialstuds (fig.75)inthe sidecoverattach-

rews(fig. 76).Theuppershieldis retained

ewingnutsandlockwashers.


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evrolet)

data96

BULATEDDATA.

31).The selectivesliding-geartype

sfourforwardspeedsandonereversespeed.

t sideofthecasefor mountingapower

sequippedwithawinchor hoist.The

boltedtotheclutchhousing,andbecomes

antassembly.

r

e

dDrainLubricant.Removethefloor

bricant,andreinstallthe drainplug.

transmissioncoverbolts.Removetransfer

ergencybrakebracketboltsfromrightside

controlleversawayfromtransmission.

connectpull-backspringfromtransmis-

sionisequippedwitha powertake-off,

haft(orshafts)andcontrols,andremove

aft.RemovetheU-clampsfromthe

sepropellershaftfrontuniversaljoint.

inplace andslidethe.jointbackon splines

sonthe trunnions,holdingtheminplace

pedendwiseoverthebearings.

Removetheflywheelunderpan.Re-

lutchhousingattachingbolts.Slidethe

thesplinesin theclutchdisk,andlower

or.NOTE:It isveryimportantthatthe

besupporteduntil theendoftheclutch

splinesinthe clutchdisk.


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Removal


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evrolet)

eanthematingsurfacesofthetrans-

g.Raisethetransmissionuntilthemain

iththesplinesin clutchdisk,andwork

ntilthecasecontactsclutchhousing.

eightof transmissionuntilthemain

rpilotsinto clutchhousing,ortheclutch

llthe fourtransmissiontoclutchhousing

Installtheflywheelunderpan.

.Removetapefromtrunnionbear-

ershaftslip jointinpositionagainstthe

andtightensecurely.

lwithLubricant.Hookupthe

ng.Removethetworightreartransmis-

emergencybrakeleverandtransfercase

positionon rightsideoftransmission,and

olts.If vehicleisequippedwithapower

sionandconnectpropellershaft(or

etransmissioncaseto correctlevel(par.

ersaljoint, andinstallthefloorboards.

orrectoperation.


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data99

ustment100

BULATEDDATA.

ercaseisa two-speedgearboxmounted

ransmissionandrear axle.Itprovidesa

raxles.

axle

TROLRODADJUSTMENT.

romtheadjustingeyes ofboththe

ifter shaftpullrodsatthe transfercase

eyelocknuts.Witha punch,installed

ftershaft,forcebothtransfercaseshifter

ntil thelockballsseatin theshaftsinthe

ontheuppershaftwillplacethe transfer

ge,and thelowershaftwillbe inthe

ge.Next,positiontheshifterlevers

axledrivelever isinthe "DRIVE"posi-

ndthe lowspeedshifterleverisin the

yback).Centerthetwol eversinthe

rovideend clearance.Holdingthetwo

theadjustingeyeonthel owspeedpull

dropthroughtheadjustingeyeand the

peedpull rodclevispinin place,hold

everforward,andadjustthepullrod until

oughadjustingeyeandshiftershaft.

nfromthis positionfornormalclearance,

kthemovementofbothshifter leversto

alllocksin placeintheshiftershaftsin all

stingeyelocknutsandinstall cotterpins.

the transfercase.Disconnectall

heshifter pullrodsfromthetransfercase.

etercablefromthespeedometerdrivengear.

e transfercasefromtherightside ofthe

supporttheunit(fig.78).Removethe

screwsthatattachthe transfercasetothe

hetransfercasewhilethejackis being

nd caseoutfromunderthetruck.


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Removal

na rollerjack.Movethejackand

ckfromther ightside.Raisethejack

position.Usingataper punch,lineupthe

sfercaseto framebracketbolts.Tighten

wire inbolts.Connectspeedometercable

arintransfercaseidler shaftfrontretainer.

ullrodsto theshiftershafts,andinstall

Connectthethreeuniversaljoints tothe

erplug,andfilltransfercaseto correctlevel

plug,andtightenthefiller anddrain


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

data103

emoval104

nstallation105

ABULATEDDATA.

epropellershaftsare oftubularcon-

ransmitthe powerfromthetransmission

omthe transfercasetothefrontand rear

versaljointsareusedat eachendofthe

ERSALJOINTS.

eedlebearing

berused—6

SSEMBLYREMOVAL(fig.80).

dingtheuniversaljointto theyoke

ndtapethetrunnionsto theyokessothat

ff.Removetheshaftwithjoints.

SSEMBLYINSTALLATION.

on,installtheU-bolts,andtighten

tethejoints(par.28 c).

gUniversalJoint


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data106

t109

lreplacement:110

eplacement112

3

114

ABULATEDDATA.

xleassemblyisa frontwheeldriving

typehousing,onwhichthereis provision

knuckle,andaconventionaltypediffer-

edrivenby axleshaftsequippedwith

versaljointsthatare enclosedinthesteer-

ng.

degree

e,30min.to

y%in.

ENT.

wotierodbolts,andremovethe tie

Removethelefttierod yokeclampbolt

nd removethelock.Loosenthethree

mpbolts,andremovebothtie rodyokes.

e rodyokesonendsoftie rod,and

ountuntiltierod-is 54%incheslong

boltholes).Placethetierod inposition

readsto theright,andinstallthe tierod

dyokeclampboltslooselyineachyoke,

theinnerboltatl eftyoke.Turnthefront

entoright,untilthey hitthestops;and

ntierodandlowerribofdifferentialat each

n*4mcnofdifferentialwhenwheelsare

odyokeontotie rod,andrightyokeoff

comeswithinl/sinchofthedifferential

right,turn righttierodend onfurther,

distance.Tightentierodyokeclampbolts

e-in(par.108b).


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evrolet)

ODBOLT•YOKECLAMPBOLT

ment

T.

ecktoe-in,markafinechalklineat

bothfronttires.Setthe twotiressothat

efront ofthevehicleona linewiththe

arefullymeasurethedistancefromthe

theother.Nowrevolvethewheelssothat

e backofthecarandon centerwiththe

distancebetweenthechalkmarks.For

hedifferencebetweenthemeasurements

en0inchandy8 inch,withtheshorter

t.

.Removetierodbolt. Removethe

mpboltandwasher,andloosentheouter

yokeontorodtodecreasetoe-in,and

-in.Ifdifficultyisexperiencedinsecuring

cessaryto disconnectthetierodfrom

screwtheendeitheronor offthetierod

fttie rodendonor offtherodto secure

eone tierodandclampbolt,and lock

Install thenutsonthe tierodbolts.

,andbackoff1/3to1/2turn. Lockthe

ACEMENT(fig.82).

ectingrodendatarmbyremovingcot-

removesafetyplug,tensionspring,and

ectingrodoffarmball. Removethefour

klesupport.Removethetwostudsnear-

movesteeringarm.Install newarm,the

kwashers,and securelyplacethesteer-


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kleArmRemoval

ball.Whenassemblingthe partsinthe

re assembledintheordertheywerere-

ssemblyrelievessteeringgearfrom road

Toadjusttheball joint,screwendplugin

nefullturn.Locktheadjustingplugs

ERENDSEALREPLACEMENT

2capscrewsattachinginnerretainer

rt,andremoveinnerretainer.Slidethe

randsealbackonhousingas thespring-

acedwithoutremovingsteeringknuckle.

t andrubber)outofthe sealretainer,

g,asthis sealissplit.Removetheseal


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evrolet)

DRUBBER))

LOADED)]

TAINER}

ETAINER^^^^RAPD33046

lacement

seal retainergasketonknucklesup-

asclosetotop aspossible,andmakesure

hesealretainer.Placethenewouter end

eretainersothatthe taperofsealfits

ter endball,andthediagonalcut will

ring-loadedsealandsealretaineragainst

ndinstallthelowerhalfof theinner

withtwoorthreecap screwsinstalled

-loadedsealuniformlyaroundthe

screwdriver,andinstalltheupperhalf

andtightenallofthe retainercap

MENT(EITHERSHAFT).

senthesixwheelstud nutsonfront

ntofvehicleuntil thewheelclearsthe

ousingonjack standorsuitableblocks.

nutsthat werepreviouslyloosened,and

theeightboltsand lockwashers

ub.Install twoboltsinthetappedholes

ernatelyto removeflange.Raisethetangs


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ftRemoval

gouterlocknut andremovethenut,lock

washer,rollerbearingassembly,andwheel

linderclamp.

TE.Removebrakeretractingspring.

sthatattachthebrakeshoe anchorplateto

emoveanchorplate.Removethe12cap

hoeanchorplatespacer,inneroildeflector,

eringknuckletothesteeringknuckle

erandoildeflector.Slidebrakeflangeplate

dsupportit withapieceofwire.This

gthebrakelinehoseandbleedingbrakes

rs.

Removesteeringknucklefromsupport

mthehousing,supportingitthroughout

amagingoilsealinthe endofhousing.

Packaxleshaftuniversaljointwith

o.0,andrub athinlayerof greaseonthe

bushingandthrustwasher.CAUTION:

aft,caremustbe takennottodamagethe


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vrolet)

ersaljoint shouldbesupportedfrom

haftinthe differentialgear.

GEPLATE.Placenewgasketinposition

ringknuckleinpositionover axleshaft

brakeflangeplateandoil deflectorin

uckle,withthewheelcylinderat top.

espacerinposition sothattwobosses

ferencetothewheelcylinder,andinstall

ten.Placeanchorplatewith brakeshoes

stallcapscrews;tightenthemsecurely.

RINGS.Hookoneendofbrakespring

ndbrakeshoe,andstretchspring tofitin

oe.Hand-packtheinnerandouterbear-

greaseNo.2. Placehubassemblyinposi-

dinstallthe outerbearing,washer,and

adjustingnutsnugly,wrench-tight,then

eequaltothatbetweentwoadjacentflange

o 45degrees.Placenutlockinposition,

utwithashort tangonnutlock.Bend

fnut.Installlockingnutand tighten

angsto fitinslotof locknut.

E(fig.84).Placeanewdriveflange

eandinstall theflange,makingsureto

gewiththosein thegasket.Installthe

washersandtightensecurely.Filluni-

rplugholewithgeneralpurpose grease

moveblocking.

EMBLYREPLACEMENT.

odboltatleft endoftierod andswing

ay.Pullbothfrontaxleshafts backto

).Jackupfrontend offrametoprovide

llowinstructionsinparagraph116 a,

xleshafts.

uctionsinparagraph116b,except

ts.Install axleshafts(par.111).Place

erodbolt andnut;tightennutwrench-

tol/zturn.Install cotterpin.Lubricate

tocorrectlevel(par.28c(6)). Remove

e.

MOVAL(fig.85).

andsupporttheframeonsuitable

tandtape trunnionbearingstoprevent

onyoke.Disconnectsteeringconnecting

offthe knucklearmball.Disconnect

orberHnks.Supporttheaxlewith aroller

sfromthetwofront springU-boltson

U-boltsandbumperretainer.Remove


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emblyRemoval

jackcarefully,androlltheentire front

dervehicle.Blockupaxleandremove

hwheel andremovewheels.

TALLATION.

ont axleassemblyundervehicleand

hsuitable jack.PlaceU-boltsinposition

ontsprings,and installbumperretainer,

ghtennutssecurely.Connectshockabsorber

ns,andinstallsteeringconnectingrod.

saljointtrunnionbearingsandinstall

nuts.Tightennuts.Lubricategreasefit-

lforlubricant.Removejackstandsand

toe-in(par.108),and bleedbrakesystem


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evrolet)

data115

eplacement116

7

8

119

ABULATEDDATA.

ofthesingle-reduction,full-floating,

e-mountedpiniongear,anda high-

Beingofthefull-floatingtype,theaxle

htheweightof thevehicleonitswheels.

EMBLYREPLACEMENT.

thedifferential,removetheaxle

bothaxleshafts outfarenoughtoclear

earuniversaljointU-clamps,tapethe

nnions,andtie thepropellershafttoa

ecapscrewsthatretain thirdmember

Beforethelastcapscrewis removed,place

pper boltholeinthird memberand

ember.Placearoller jackunderthird

pportthe assembly.Worktheassembly

axlehousing,steadythirdmemberon

erthethirdmemberto floor.

memberonjackandblockit inposi-

ollthe assemblyundervehicle,raiseit

andplacealongdriftpunchthrough upper

axlehousing.Worktheassemblyintoaxle

todamagegasket.Installthecap screws,

.Removetapefromuniversaljointtrun-

opellershaftin position,andinstallthe

haftsandretainingcapscrews.Filldif-

ar.28c (6)).


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/ h t t p : / / w w w . h


7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

ftfromHub

CEMENT.

ovecapscrewsandlockwashers.

wsinthethreadedholesprovidedin axle

gthesecap screwsalternately,remove

ceanew terneplategasketonaxle

ntoplace,turningitslightlyto engagethe

ears.Install thecapscrewsintheflange

nately,drawthemuptight.

MOVAL(fig.89).

e,andsupporttheframeonsuitable

elstoprovideclearanceatthefenders.

oint,andlowertheshaftto floor.Tape


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


eShaft

tokeepthem fromfallingoff.Disconnect

nderwhereitjoins thelinerunningacross

.Placeajackunder differentialtosup-

heeight (fouroneachside)springU-bolt

kabsorberlinkandbracketupoutof the

plate.Steadytheassembly,andpullit out

TALLATION.

ona rollerjack,andmovethejack

rthe vehicle.Raisetheaxleupagainst

anchorplate,shockabsorbers,anchor

shers.Connectthebrakehoseto axle

necttheuniversaljointtopinionshaft

hejoint.Install thewheels.Checkthe

,andaddlubricantifnecessary(par.28

r.123).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


t)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


data120

121

122

3

ment124

ent125

26

ement127

8

rol129

ABULATEDDATA.

gsystemcombineshydraulicallyoper-

rovacboostersystem,andmechanically

Electricallycontrolledtrailerbrakesare

eaboveoncertainmodels.

elhydraulic

haft

gon drum,back

es

g ondrum,back

r4sidesof hexhead

arance%"*•

3.3

2P-51


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

NING

OCKNUTS

WERSHOE)

SE)

ADJUSTING)

S(UPPER

Adjustment

USTMENT(fig.90).

tmentshouldbecheckedeachtime

esareadjusted.Sethandbrakeleverin

ndetachpullrod.Removerearanchor

headjustingscrewto secure0.010-inchto

weenthebrakebandand drumunderneath

choradjustingscrewwithalockwire.

mentlocknut,andturntheadjusting

hclearancebetweenthelowerendofthe

justingscrewlocknut.Loosenlocknut

backit offuntilitis freeoftheadjust-

onadjustingbolttosecure0.020-inch

endofbandandthedrum.Then tighten

holdingtheadjusting nut.Checkthe

vingtheoperatingcamsforwarduntil

akebandbracket.Setthe brakepedalin

y releasedposition.Thepinholeinthe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


es,FrontWheel

kes/RearWheel


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


rolet)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

Filler

pwiththeholesin theoperatingcams

eydonot lineup,loosenthelocknut

pedalendofthe pullrod,andturnthe

roperadjustmentasmentionedabove,

utatclevis,and installcotterpininpull

nalsurfacesofthebrake controllinkage

neoil.

USTMENT.

Raisethetruckandplacejackstands

ourwheelsrotatefreely.Removethe

thefrontflangeplates,insert ascrew-

ghole,andengagethe teethonthe

elcylinder(fig.91).Turn theadjusting

ion,lookingattheendof thecylinder,


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


Cylinder

ghtdragonthedrum. Turntheadjusting

Backingofftheadjustingcovermovesthe

drumto insureproperrunningclearance

Replacetheadjustingholecovers.To

theadjustingpinion(fig.92)in aclock-

usesaslight dragonthedrum.Turn the

a turn,orfoursidesof thehexagonon

ningclearance.

g.93).Toeboardclearanceveryseldom

pedalstop, whichislocatedinthebrake

nt.Beforeattemptingtoadjusttoeboard

thepedalreturnsto thefull-releasedposi-

,andthat thepedalretractingspring

oosenthechecknutontherearof the

erpushrod.Removeclevispin,and turn

mastercylinderpushrod intheproper


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

toeboardclearance,measurementbeing

andundersideoftoe-pan.Tightenthe

s.

STEM.

brakesystemmustbebledwhenever

nnected,orwhenaleakhasallowedairto

rovacboostersystemshouldbebledfirst,

ers;followthebleedingsequenceshownin

ig.95).Cleanall dirtfromaround

ug.Removethefiller plugandinstallthe

maticfiller(41-F-2982).Opentheauto-

Cylinder

). Removethebleedervalvescrew

ntube(41-T-4170)to thebleedervalve

hehydrovac(No.1,fig.94).Placethe

wthesurfaceofbrakefluidin ajar.

bleedervalvey2to54turn. Depress

wingit toreturnslowly.Continuingthis

fluidthroughthelines andoutatthe

hitanyair inthesystem.Whenbubbles


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ofthebleederdrainhose andthestream

tenthebleedervalveand removethe

ghtenthescrewatthe endofthebleeder

nce,proceedinthesamemannerwiththe

erthebleedingoperationhasbeencom-

wheelcylinders,startthe engine,and

veraltimes.Thenbleedagain atpoint

eplacement

points,fillthemastercylinderreservoir

erplug.NQTE:Fluidwithdrawninthe

notbeusedagain.

EPLACEMENT(fig.97).

omthemaster cylinderlinktoidler

kepipefromthemastercylinderendplug.

plightswitch.Removethefourbolts

derandbrackettotheframe,andlift off

nderfrombracket.Wheninstallinganew

verseorderofremovalandfill thecylinder

sarytobleedtheentiresystem(par. 123).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

SHOE

ction,FrontWheel

EPLACEMENT.

pot andremovethewheel.Remove

hingscrewsandbrakedrums(fig. 98).

omthewheelcylinder.Disconnectthe

ngwithpliers(41-P-1579).Removethetwo

ndertotheflange plateandremovecyl-

stallanewwheelcylinderassemblyin

al,andbleedthe entiresystem(par.123).

CEMENT(figs.99and100).

injackstandsandremoveallwheels.

thatattacheachbrakedrum(fig.98),

tallwheelcylinderclamps(fig.101)to

uid.Usingbrakespringpliers (41-P-1579)

ractingsprings.Removethebrakeshoe

eon frontbrakes,twoonrear;andlift

hearticulatinglinkfrictionspringpin

semblethearticulatinglinksfromthe

kandpin.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ESHOE

HOE

uction,RearWheel

ylinderClamp


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


rBrakeAdjustment

rticulatinglinks,pins,frictionsprings,

shoes.Then assembleshoestoanchor

n guiderivetedtoanchorplate.NOTE:

thoutexcessivesidemovement.Install

pring,andremovewheelcylinderclamp.

eels.Jackupvehicleand removestands.

NDREPLACEMENT.

asher,adjustingnut,flatwasher,and

tingbolt (fig.90).Removeclevispin

djustingbolt.Removeadjustingboltand

ershoeadjustingscrew,nut,andwasher.

crewlockwireandthescrew.Thenslide

anchor,andcatchtherelease springat

kebandtothedrum,andform itasneces-

pe ofthedrum.Adjustaccordingtoin-

ph121.

EMENT(fig.102).

akelinesfromthehydrovacunit.

tionstotheaircleanerandthe vacuum

sretainingthehydrovacunitto theframe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

t.Installationis thereverseofremoval,

esystemmustbe bled(par.123).

RAKECONTROL.

rtainvehiclesanelectriccontrolunit

ountedunderthedrivercompartment

nitisconnectedbyanadjustablerod

pedalpull rod,sothatwhenthetruck

etrailerbrakesalso areapplied.Astop

atedin thisunitwhichcontrolsboth

,accordingtomain lightswitchposition.

trolunitmountedon theinstrument

light, medium,medium-heavy,andheavy

umbers1,2,3, and4.Ifthe loadinthe

ntrolshouldbesetat No.1;ifit isheavy,

otherwords,theloadcontrolshouldbe

weightofthe loadinthetrailer.

232

ttingToolKM-KMO-3A(41-C-2825)

evispinfromfrontclevisatclamp.

garminfull "OFF"position(toward

withoperatingarm infull"OFF"posi-

releasedposition,clevispjncanbe

therthearmor pedalposition.Install

. Tightenclevislocknut.Theswitch

becleanedoccasionallywithNo.00flint

G.

tothedesiredlength,usingtube

gthetubing(fig.104). Square-offtheend


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


n reamthesharpedgeswiththe reamer

cutter.

enewinvertedflaredtubenutson

ngtobeflaredin hydraulicbrakefluid.

ultsinabetter formationoftheflare.

ontheflaringtool (41-T-3076-35),and

ubinginthechannelofthe dieuntilit

(fig.105).

eInToolKM-J-1280(41-T-3076-35)

rmingOperation,UsingSpecial

-T-3076-35)

en theclampingnutsbyhand,and

hvise.Thentightendowntheclamping

andremovethe stoppinfromthedie.

pped inthedie,and readyforthefirst


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

ration.Usingtheflare-formingtool

econcavedie,inserttheformingtoolin

ws,usinga1-poundhammer,untilthe

tsthetop ofthedie.Thecross-section

efirst stepinformingthedouble-flap

peration.Next,usingtheflare-

5)havingthe46-degreedieatits lower

dieandstrikefirm blows,usinga1-pound

rofthetool contactsthetopofthedie.

g(fig.107)showsthesecondandfinal

ngadouble-lapflare.

rmingOperation,UsingSpecial

-T-3076-35)


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


GS,HUBS,ANDTIRES

data131

nt132

t133

nt134

ABULATEDDATA.

ablepierced-steeldisk-typewheelsare

he wheelisattachedtothehub withsix

used attherear,andthe constructionis

chedat thefrontforsevereoperating

mkentaperedrollerbearingsareused

le Hyattrollerbearingsareusedin the

withanexternalflangeforattaching

Thesearemachinedto taketheinner

upsandoil seal.Theouterendofhub has

ngthe axleflangeordriveflange.

d-andsnow-typetiresareusedonall

mpringholdsthetireon thewheel.

ONT).

mblyTimken33275

mblyTimken399A

EAR).

2051Z

-11786Y

55Ib

7%Ib

55Ib

0Ib


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

ngAdjustmentParts

PLACEMENT.

velplace,loosenwheelto hubretain-

ckwheelatoppositeendofvehicle.NOTK:

eofvehiclehaveleft-handthreads.Those

ndthreads.Raiseaxle untilwheelisfree;

heelandtireassembly.Deflatetirecom-

nuntilit dropsintogrooveinwheel.

rintotherecessin theclampring,and

over theedgeofwheel.Workthering

d removethetireandtubeassembly.

beintire, placethetireonwheel,

TE:Makesurethe clampringisseated

eelthroughoutitsentirecircumference

atetire slowlyandwatchtoseethatthe

wheel,tightennuts,andremovejackand

USTMENT(frontorrearwheels).

eFlange.Setemergencybrakeor

wheelstudnutsone turnonthewheelto


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


GS,HUBS,ANDTIRES

gAdjustment

tilwheelis free,removewheelstudnuts

ovetherearaxleshaftboltsor frontaxle

shaft orflange.

etangofthe locknutlock(fig.108),

ealassemblyandl ocknutlock.Tighten

rench-tight(fig.109).Thenbackthe

s,whichis equaltothedistancebetween

oles.Installlocknutlock andaline

t withshorttangonlocknut lock,and

locknutandseal,andtightensecurely.

i ntoslotinnut.

Wheel.Placeanewterneplate

fig.110), oraxleshaft(fig.88),and

Installthelockwashersandflangebolts.

dremoveblockingandjack.Tightenaxle

dof 95to115foot-pounds.

PLACEMENT,

wheelandaxle flange(par.Illa).

tinglocknutandlock.Removethebearing


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

veFlange

acerwasher,rollerbearing,andwheel

seal.Drivetheouterbearingcupout

end ofhub.Washthebearingsandinside

olventandinspectthebearingsfor being

.Replacealldamagedparts.

hebearingcupsintohubwiththe bear-

wayfromcenterofhub. Driveorpress

Hand-packtheinnerbearing rolleras-

8c(10)). Installthebearing,coatthe

ithsealingcompound,anddriveitinto

Coattheoilseal lightlywithengineoil

ub,hand-packtheouterbearingroller

rendof steeringknuckleandintohub.

djustingnut.Adjustbearingand re-

wheelandaxle shaft(par.117aand

gadjustinglocknutandlock.Removethe

cerwasher,androllerbearingandwheel

ringandoil seal.Taptheouterbearing

g.Ill), removering,andpressordrive

hebearings,insideofhub,and endof

ningsolvent,andinspectthebearingsfor

eplacealldamagedparts.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


S,HUBS,AND TIRES


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

thesnapringandpressboth bearing

thickedgeofcupstowardcenterofhub.

ngwithgrease(par.28c 10).Installthe

foil seallightlywithsealingcompound,

instbearingcup.Lockthesealinplace

ubinthree equallyspacedplaces.Coat

gineoiltolubricateit. Installthehub,

ngrollerassembly,andplaceitoverend

ohub.Install spacerwasherandadjusting

assemble(par.133).


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


SORBERS

data135

placement136

ABULATEDDATA.

rethe semielliptictype.Bronzebush-

eyesattheendsof thesprings.ABerlin

ofthesecondleafof thefrontspringas

hemainl eafshouldbreak.Thefront

front endofthespring,and therear

rear end.Onsomemodelsanauxiliary

usedinconjunctionwiththerearspring.

eshockabsorbersarethe hydraulic

ylindertype,andareusedto providea

ngthespringvibrationas thetruck

ntheroad.

center2(%in.

%2in.

ackets)31in.

5in.

876in.to0.880in.

R2J

ng..LOG2


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

le

ERPINREPLACEMENT(fig.112).

weightisoffthesprings, andsupport

tandnutthat lockstheshackleboltin

shacklepin(s)out fromtheinside.When

,besureto lineupthegroovein thebolt

ricatetheshacklepins.

NT.

dhangerpins(par.136),and remove

ngcanthen beliftedfromtheaxle.

s,besure toplacethespringcenterbolt

at,andtheBerlin eyeonthefrontspring

icle.Lubricatetheshacklepins.

figs.82and113).

ectthelinkfromthe shockabsorber

ramemountingbolts.Liftthe shock


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


SORBERS

BOLTPLATE

er,Rear


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

nstalltheshockabsorberin thereverse

maroundfillerplug,andremovethe

ll shockabsorberfulloffluid.Work

ddownwhilefilling toeliminatetrapped

tity(about2 tablespoonfuls)offluid

fteritis fulltoprovideexpansionspace.


/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


40

placement141

nt142

143

4

45

moval,UsingPuffer(4J-P-2952J

herecirculatingballtype,having a

1.Whenthesteeringwheelis turned,helical

causeball bearingstoclimbupor down

mthe ballnut.Therackteeth ontheball

onthePitmanshaftto followthem,thus

dPitmanarm.The steeringconnecting


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

kettype,havingidenticalballseats,springs,

ends;butthesafetyplugsare ofdifferent

ngwheelisofthe three-spoketypewhich

aft,andheldinplacewith aretainingnut.

smisbuiltinto themastjacketand

CEMENT(fig.114).

mthe rearendofthesteering connect-

ftheball onthePitmanarm.Remove

mthe endofthePitmanshaft,andpull

anshaft withpuller(41-P-2952).Install

washer,andnut;andtighten thenut

ngconnectingrodonthePitmanarm ball,

seatsareintheproper positionaroundthe

the endpluguntilit bottoms,backit

ewcotterpin.Lubricatethefittingon the

T

GROD

ectingRod

ODREPLACEMENT.

omeachend oftheconnectingrod,

oballends.Install thesteeringconnecting

ndPitmanarmballwiththe springs,safety

ecorrectpositionintherod (fig.115),

seatsfitproperlyaroundtheballs.Tighten

kthemoff*/2turn,and installanewcotter

connectingrod.

PLACEMENT.

thatretainthehorn button,andlift

enutfromthe upperendofthemainshaft

off themainshaft,usingpuller(41-P-

wheelonthemain shaft,andinstallthe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


rAdjustment

enthenut securely.Installthehornbutton

plate,hornbutton,retainerplate,and

USTMENT(fig.116).

mBearing.Disconnectthesteering

tmanarm(par.141).Loosenthemast

clampnutsatthe instrumentpanel;then

knut,and turnthelashadjustertwo or

ockwisedirectiontoremoveanyworm

semeshingofthe rackandsectorteeth.

ad.Turnthesteeringwheelslowly

ops; thenturnitbackonecompleteturn.

wheelhardagainstthe stopasdamage

ult.Loosenthewormbearingthrustscrew

hesteeringgear,andtightenthe thrust

een1-and 1^-pcnindpulltokeepthe

ngthethrust screwproperly,tightenthe

oseethat itrequiresbetween1-and

wheelin motion.Ifthereisa noticeable

eeringwheelafteradjustingthebearings,

damaged,andthesteeringgear mustbe


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

mp.Tightenthemastjackettoin-

s,andagaincheckthetensionon the

he shaftisnotbinding,causedbytighten-

uiresmorethan1/^-poundpullto keep

ntheclampnuts again;thenloosenthe

teeringgeartotheframeside rail,and

hattheclampnutsat theinstrumentpanel

bindwhenthenutsare tightened.Then

the fourmountingbolts,andagaincheck

torTeeth.Locatethecenterofthe

ngthe steeringwheelgentlyfromtheleft

ecountingthenumberofturns thesteering

ewheelback%the numberofturns;this

in thecenterposition.Markthesteering

helashadjusterclockwisetotake

ar teeth.Checkthepullatthe steering

ssingthrough thecenterposition.NOTE:

een2 and2l/2poundstopull thewheel

n.Adjustthelashadjuster untilallthe

beeneliminated;thentightenthelocknut,

ectingRod.Installthesteeringcon-

thePitmanarm,makingsuretheparts

tothesequenceshowninfigure115.Then

ntil itbottoms,andbackitoffy2 turn

Lubricatethefittingonthesteering

OVAL.

landDisconnectHornWire.Re-

etainthe hornbutton,andliftoffthe

dwasherandpull offthesteeringwheel,

earingtensionspring.Removetheclamp

tto theinstrumentpanel.Removethe

lon themastjacket.

.Removethefloorandtoeboards;

fromthe brakepedalpullrodat the

hebrakepedalbackas farasitwill go.

Disconnectsteeringconnectingrod.

asherfromthePitmanshaft,and pull

vetheleftengineside panbolts.Remove

thesteeringgeartothe framesiderail,

utthroughtheleftdooropening.


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TALLATION.

desteeringgear assemblyinthrough

positionthe housinginframesiderail.

woanchorplates,andstartthefour

andtightenthe clampbracketatthe

htenthemountingboltnuts securely,and

ustment.Installthesteeringwheel

quiresbetween2-and2%-poundpullto

centerposition.If not,itwillbe necessary

(par.143).

ingRod.InstallthePitmanarm,

ightensecurely.Installthesteering con-

rm,makingsure theballseatsfit around

y;thentighten theendpluguntilit

urn, andinstallanewcotterpin. Install

olts.Connectthebrakepedaltothemaster

eboardandfloorboard.

nectthehornwire totheterminal,

Lubricatethe steeringgearandsteering


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hevrolet)

onstructionfittedwithahingedV-type

tor,adjustabledoorwindows,andasta-

three-pointcabtoframemountingpro-

,cabmounting.

Back.

seatandseatbackcushionsareadjust-

itionforthe individualdriver.Toadjust,

seatforwardorbacktoline uponeofthe

ftheseatframewiththe pins(oneoneach

kets.Theseatcushionishookedtothe

ore,whentheseatcushionismovedforward

djustment,thebackcushionmoveswithit.

Raisethefrontedgeofseatcushionand

nhooktheseatcushionfrombackcushion,

aisetheseatbackcushionto unhookit

dremovebackcushion.

ON.Placetheseatcushionandseat back

k thebracketsonthebottomofback

kedgeofseat cushion.Raisetheback

cketsatthetop ofcushioninthebrackets

ssemblybacktothe desiredposition,and

esover theseatriserbracketpins.

nd/orWeatherstripReplacement.

ewindshieldclampatcenterofwind-

hieldadjustingarmbrackettowindshield

ofwindshield.Removethetwoscrews

ndshieldframe,andremovewindshield

herstripoutofthegroovein thewindshield

heweatherstripgrooveinwindshield

cetheouter(front) edgeofweatherstrip

edge intoplace,usingaputtyknife.Care-

dassemblyinthewindshieldopening,

ewindshield,andinstallthescrews.Install


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


rmbracketscrews.Pushbothwindshield

e windshield,andhooktheclampat

cktoseethatwindshieldisproperly

hattheweatherstripsealsall theway

cement.

eithertheleftorright windshield

windshieldheadercoverpanelcoveringthe

d.Disconnectthehosefrommotor,remove

sembly,andremovethe mountingnuton

thewipermotorinposition,andinstall

e wiperarmandbladeassembly.Connect

engine,andcheckwiperoperation.Install

erplate.

G-7105).Thepanelbodyisasingle

passengerspace,aswellas afullyenclosed

ofthe panelbodyisconstructedlikethe

er,theroofandsidepanelsextendbackto

Therearendof bodyisfittedwitha large

venienceinloading.

elcargobodyisfittedwith fivebowsto

tarpaulinwhencompletelyinstalledfully

Hooksareprovidedaroundthebodyfor

.Thetail gateishingedat thebottomand

nwiththeendgatechains.The lowersec-

beloweredtoprovidetroopseats.A tool

underthebackendofbody.

pbodyconstructionisverysimilarto

tismountedona subframeabovethe

meisfittedwitha hydraulichoistsocon-

of bodycanberaisedto automatically

ilgateis sohingedthatit canbere-

goutas thebodyisraised.

ORERBODY(MODELG-7163).This

imarilyformountingan earthborer(for

ear-mountedwinchtouseinconnection

kfor settingpoles.Specialsupportsare

of thebody;thesesupportsareto be

r endofbodywhenearthboreris inuse.

ANCEBODY(MODELG-7173).Thisis

providefor useofarear-mountedwinch,


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

s.Speciallockers,compartments,and

arryingstandardlineman'ssupplies,tools,

arpaulinReplacement.

rpaulinropesfromthehooksaround

inassembly.Untiethefrontandrear

.Foldorrollthe tarpaulinandendcurtains.

olded orrolledunlessthoroughlydry.

theendcurtainsinposition,andproperly

nd body.Placethetarpaulininposition

tie theropessecurelytohooksonbody.

wsReplacement.Removetarpaulin

ahpbabove.Liftthe completetopbowor

mblies.Removetheeightbolts toseparate

andcornerassemblies.Reversethisproce-

eplacement.Removetheboltsthat

e body,andremovetheseat.Placetheseat

hingebolts.

sframeiscomposedofheavychannel

ycrossmembersand bracketsrivetedto

ensionatthefrontendprovidesa mount-

swellasthe winch,onsomemodels.A

hebackendofframeprovidesforthe

ent.Removethethreebolts that

toframeandfront bumper,andremove

ghookinpositionon frameandbumper,

ment.

DELS.Removethethreetowinghook

movehooks.Removethetwowinchsupport

e headfromthefourbumperto frame

de.Drivetherivets outandremovebumper.

osition,andinstall thetowinghooks

hsupporttobumperbolts. Installbolts,

eretheeightrivets wereremoved.Tighten

rely.

PEDWITHWINCH.Removethethree

ghookandremovehooks.Cuttheheads

tsat eachframemember,driveoutthe

mper.Removethetworivetsthatattach


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


tocenterof bumper,andboltthesupport

ewbumperin position,andinstallthe

allffc-inchbolts,nuts,andlockwashers

eholes,andtightenallattachingboltsand

y.

ment.Removethesixboltsattaching

e,andremovethebumpers.Placethe

rearcornersofframe,andinstallthe six

per.

eplacement

nt(fig.117).Removethecotterpin,

endof pintlehook,andpullthe pintle

thenew pintlehookthroughthebush-

rand nut.Tightenthenutuntil thereis

tohold thebushingstightinframe.In-

rBushings>Replacement.

terpinfromend ofpintlehook,and

g tensionfrompintlehookcrossmember

ssmemberbracebolts.Removepintlehook

race,spring,andbushing.

theshortendofonebushingthrough

withcollaragainstfrontside offrame

dofotherbushing throughpintlehook

atthecollarwill beonrearside ofbrace.

ron rearbushing,andputcrossmember


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

end ofbushingpilotingintospring.Push

gs,andinstallwasherandnut. Tighten

ceboltholes areinposition.Installsix

Loosenpintlenutuntil springtension

meto preventrattle.Installcotterpin.

hookcanbeextendedbackseveralinches

crossmemberbyreversingthe position


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


moval150

allation151

152

ent.'153

consistsoffront fenders,frontfender

models),runningboards,hood,andhood

anufacturingandserviceoperations,the

diatorsupport,fanshroud,frontfenders,

tsareassembledintoa singleunitknown

alassembly.

METALREMOVAL.

thehoodcatches,raisethehood,and

ressionbondstrapsfromthehood.Remove

screws,thehoodhinge pins,andthehood

ohoodsidepanels.

tem.Disconnecttheradiatorbrace

ndcowl,andremovebracerod. Drain

moveradiatordraincock.Disconnectthe

se,andthe steam,relieftube.

onnections.Disconnecttheelectrical

koneachside, andtheblackoutwiresat

movewiringharnessesfromclipsonleft

isconnectwiringharnessfromgenerator.

ressionbondstrapsfromrearend ofeach

ombottomof radiatorsupport.

sembly.Removethefendertorun-

cowlboltsoneachside.Removethebolts

tordiagonalsupportto cabbracket.Re-

adiatoranchoragetoframecrossmember

ers,springs,andbolts.Removethefan

uippedwithafront-mountedwinch.Slide

ssemblyforwarduntil thefanshroud

andlifttheassemblyoff chassis(fig.118).

msofthisassemblyrequirerepairsor

emovedfromtheassemblyveryeasily.

METALINSTALLATION.

mbly.Makesurethelower noseis

toroutlet.Placethesheetmetal.issembly

backintoposition.Makesuretheshroud

mageto thefan,shroud,orradiator.If

ha front-mountedwinchit''illbeneces-


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evrolet)

eetMetalRemoval

esremovedwheninstallingsheetmetal

sin theradiatoranchorage,insulator,

Installthemountingbolts,shims,springs,

ts.Installandtightenthe fendertocowl

dbolts. Installtheboltsattachingthe

ket,andtightenthemsecurely.Installthe

heetmetalreplacement.

pment.Connecttheradiosuppres-

radiatoranchorageandfenderskirts.

stogenerator.Placewiringharnessesin

rtandradiator.Connecttheelectrical

ksandthe bayonetconnectors.

m.Connectandtightenbothradiator

tube.Fill thecoolingsystemandcheckfor


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


noffrontlights.Startthe engineandcheck

alltheradiatorbracerod, butleavethe

hoodsidepanels,andtightenthe

ash evenly.Placethehoodinposition,

pins.Installthehoodbracerod anchor

adiosuppressionbondstraps.

LACEMENT.

dandplacepinthroughhole inhood

Disconnectelectrical*wiringatjunction

atbayonetconnectors.Disconnectwiring

nderskirtif leftfenderisbeingremoved.

hoodside panelsfromsideonwhichfender

ethefendertorunningboardandfender

osuppressiongroundstrapfromfender

achingthefendertoradiatorguard. Re-

ssembly.Removetheboltsthat attach

ovelightsfromfender.

htson thefender.Placethefender

der,andinstalltheattachingbolts.Place

ition,andinstall thefendertoradiator

fendertorunning boardbolts.Connectthe

straptofenderskirt. Installthehoodside

ricalwiring,andplacetheharnessesinclips

e operationofallfrontlights.Removepin

rhood.

PLACEMENT.

tachingtherunningboard tofender,

git toeachstephanger.Removetherun-

unningboardin position,andinstallthe


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vrolet)

•155

ff156

ertake-off157

drive158

andearthborerdrive159

auxiliarygear case(fig.30)drivenby

ercase,andprovidesa meansofusing

inches,hoists,earthborers,andother

oncertainvehicles.Duetotherequire-

rtainauxiliaryequipment,severaldifferent

take-offsarerequired.

TAKE-OFF(CentralFibre

smission-mounted,single-drive,one-

ngthepoweroutputshaftatthe rearof

ed intooroutof meshwiththetransmis-

heuseof ashiftleverlocatedjust infront

eftsideof cab.Adriveshaftconnects

stpumpshaft.

tsCo.

mission

zebushings

etscrewthatretainstheuniversal

e-offoutputshaft,and slidetheuniversal

movecotterpinandclevis pinfromcontrol

romtransmission,removethesixpower

,andremovepowertake-offandgasket.

mcngasketbetweenthepowertake-

andinstallthesix capscrews.Lineupthe

universaljointyokewith keyinoutput

ntoshaft.Installthesetscrewthat retains

onnectthecontrolleverlinktoshifter

tocorrectlevel(par. 28).


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RTAKE-OFF(SpicerorGarWood).

ransmission-mounted,single-drive,

ereversespeedpowertake-offshavingthe

ont ofcase.Althoughtheinternalcon-

esvariessomewhat,theoperatingprin-

eyareinterchangeable.Theintermediate

with atransmissioncountershaftgear

speedgearsonthe idlershaft(front

eslidinggearcan beshiftedtothediffer-

onsby useofthepowertake-offcontrol

aftconnectstheoutputshafttothe winch

rse

mission

ngTworollerbearings

woneedlebearings

rbearing

gTwoballbearings

uringCo.

rse

mission

rewinshaftcollar,andslidecollar

crewthatholdstheuniversaljoint onthe

fwinchdriveshaft,andslide thejointoff

eyfromendofshaft.Removethecontrol

tterpinandclevispin.Drain thetrans-

ethesixpowertake-offattachingcapscrews,

e-off.

L,-inchgasketsontheflangeofpower

ake-offinposition,andinstallthesix

allthekeyin winchdriveshaftkeyway.

thkey,and pushjointontoendof shaft.

screwthatattachesjointtoshaft.Slide

htensetscrew.Connectthecontrolrod

tall clevispinandcotterpin.Fill the

vel(par.28),andtest powertake-off

RIVEPOWERTAKE-OFF(Spicer

facturersusethewinchdrivepower

graph156awitha specialcovertoprovide


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vrolet)

overincorporatesahoist driveshaft,hoist

tshifter shaftinadditiontothe standard

anoutputshaft atthefrontforwinch

t therearforhoist drive.

rse,plus

mission

ngTworollerbearings

woneedlebearings

tingRollerbearing

gTwoballbearings

Twobushingsin cover

uringCo.

rse,plus

mission

ngOnerollerbearing

Two needlebearings

tingRollerbearing

ngTwoballbearings

.. Twoneedlebearingsincover

setscrewonwinchdriveshaft,and

ovetheuniversaljointyoketopowertake-

rew,slidethe universaljointoffshaft,and

etheuniversaljointyoketopowertake-off

Slidethe jointoffshaft,andremoveshaft

nsandclevispinsthat attachthecontrol

Drainthetransmissionandpowertake-off

twocapscrewsthatretainthe powertake-

powertake-offattachingcapscrews,and

fandgasket.

gasketonthe flangeofpowertake-

offinposition,andinstallthe sixcapscrews.

raceinposition,andinstallthe tworetain-

rivekeysin thekeywaysinthewinchand

he keywaysinuniversaljointyokeswith

ver shafts,andinstallsetscrews.Slide

oposition,andtightenset screw.Placethe

sontheir respectiveshiftershafts,and

cotterpins.Fillthetransmission(par.28)

fpowertake-off.


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EWINCHDRIVE.

me-mounted,single-driveone-speed

ffhavingtheoutputshaftatrear ofcase.

ransfercasemainshaft.Theinput shaft

thatcanbe shiftedalongtheshaftto

ERSE,"and"FORWARD"speed.The

eofa shiftleverlocatedinthecab tothe

evers.

ndBodyCo.

erse

ackets

haftthrough

and1rollerbearing

llbearings

ng2rollerbearings

erpulleyadjustingbolt,andslide the

emovethewinchdrivechainremovable

movethenutsandlockwashersfromthe

niversaljointtrunnionbearingsin the

ertake-offinputshaft.Removethecotter

achtheshiftershaft.Placeajackunder

efourboltsthatattachthepowertake-off

mebrackets;lowerthejack,andremove

pportchannelsattached.Markthechannels

edintheiroriginalpositions.Removethe

hthesupportchannelsto thepowertake-

pportchannelsonthepowertake-off

emarksmadewhendisassembling,and

Placethepowertake-offassemblyin

tsthat attachthesupportchannelsto

ecttheshiftcontrolrodtothe shiftershaft.

riveshaftinpositionand installtheU-

rivechainoversprockets,andinstallthe

dlerfirmlyagainstthechain,and tighten

unitwithlubricant(par.28),and test

oninallgears.

EWINCHANDEARTHBORER

rshiftpositionsforthis wincharethe

inchdrivepowertake-off,buttheshift

back,engagingtheclutchgear withthe

his drivestheearthboreronly.If the

back,theexternalteethonthesliding

ronthe powershaft,providingdrivefor

arthborer.


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vrolet)

dBodyCo.

e,andearthborerdrive

ackets

haftthrough

ball,oneroller bearing

eball,onerollerbearing

oballbearings

ngTworollerbearings

ainidlerpulleyadjustingboltand

the chain.Removethechainremovable

eU-clampsthatretaintheuniversaljoint

nt yokesonthepowertake-offinputand

theshiftercontrolrodfromtheshifter

ake-offwitharollerj ack,removethefour

bracketattachingscrews,andremove

rtchannels.Markthesupportchannels

edintheiroriginalpositions.Removethe

thesupportchannelstopowertake-off

pportchannelsonthepowertake-off

emarkingsmadewhendisassembling,and

Placethepowertake-offassemblyin

nstall thefourboltsthatattachthe sup-

brackets.Connecttheshiftcontrolrod

stalltheclevispinandcotter pin.Place

aftandearthborer driveshaftuniversal

sonthepowertake-offflanges,andinstall

nchdrivechainoverthesprockets,and

Movetheidlerfirmly againstthechain,

mentlockbolt.Fill thepowertake-off

test thepowertake-offoperation.


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62

er-mountedwinchesarepowerdriven.

able,drum,drumshaft,wormgear,worm,

andmiscellaneouscomponentparts.

NCH.

ejaw-clutchtypepowerwinchis

endedframesiderailsinfront ofthefront

sdrivenfromthepowertake-offby a

e-offprovidestwospeedsforpullingthe

eed(reverse)for payingoutcable.The

hevehicleis standing,ortoassistthe

ydisengagingthejawclutchthecablecan

ughtransmissionpowertake-off

n

MENT(fig.119).Thecorrectdrumbrake

ereissufficientdragon thedrumtopre-

gwhilethe cableisbeingpulledoutwith

s necessarytomakethisadjustment,shift

osition,andengagethe poppetinthehole

thebrakeadjustingscrewchecknut,and

tilthe brakeengagesthedrumflangewith

ntthecablefromlooseningupon drum.

hecknut.

MENT(fig.120).Thewormbrakeis

ontendofthe winchworm.Adjustment

or looseningthespring-loadedadjusting-

f thebrakecase.Loosenthewormbrake

turn theadjustingnut%turn atatime

tlytighttoholdtheload.Whenadjust-

nadjustingnutlocknut.CAUTION:Avoid

justment,oroverheatingwillresult.Itis

Allpartsinterchangeable.


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vrolet)

Adjustment

eatupsomewhat,especiallyinreverse

eckshouldbemadeafteradjustment.If

thehandcannotbeheldon it,thebrake

senedy2turn, andtheoperationre-

ENT(fig.121).Thewinchdrivepro-

ointis attachedtothewormshaftby

ventoverloadingofthewinchand possible

le.Whenthewinchisexcessivelyover-

ff,allowingthejointyoketoturn onthe

singtheloadfromthewinch.Theworm

ndpreventthecablefromunreeling.To

ftheold pinoutofwormshaftand joint

eyokewiththeholein shaft,andinstall

rpin.NOTE:Standardshearpinsmust

donothavecorrecttensilestrengthto pro-

defficiency.

EMENT.

movecotterpinandshearpin from

oke,loosensocketheadsetscrewin

-offendofshaft, andslidethedriveshaft


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Adjustment

wormshaft.Removethesetscrewthat

ljointrearyoketo thepowertake-off

ovethedriveshaftassembly.

earyokeof thesplinedjointonthe

hdriveshaftandinstall thesetscrewthat

Placethedriveshaftinposition,and line

ntjoint frontyokewiththeshearpin

nstallthe shearpinandcotterpin.Posi-

edriveshaft%m°h fromthefrontend

e,andtighten thesetscrew.

vecotterpinandshearpinfromfront

Loosensetscrewinthrust collarondrive

,and slidethefrontuniversaljoint offthe

roundwinchdrum,attachsling toachain

draisejust enoughtosupportthewinch.

embercapscrewsandboltatrear ofwinch.

derailattachingboltsandnuts, remove

tsatbumper,andremovebrackets.Lower

omvehicle.Removeslingfromwinch.


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et)

ation

tedWinch


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


nchBrakePressurePlate

ewinchunderfrontofframe,place

ha chainhoistorcranetosling, andraise

e.Installthe capscrewsandboltthat

mberatrearof winch,theboltsthatattach

rackettoframesiderail,and thebolts

brackettofrontbumper.Tightenall

Disconnectthechainhoistfromwinchand

chdriveshaftfront universalonworm

nholeinuniversalyokewith theholein

arpin andcotterpin.Positionthethrust

fromsplinedyokeofrearuniversal,and

ear casetocorrectlevelwithlubricant,

yaccordingtolubricationinstructions

INCH.

hecenter-mountedwinchisusedonly

elephoneservice.Thewinchassemblywith

onthe framejustbackofthecab.The

aframe-mountedpowertake-offthatis

througha shortdriveshaft.Thepower

dandareversegear.


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et)

tStopPin

ughtransfercase

ab

MENT(fig.123).Thewinchworm

t endofthewormshaft.Adjustmentis

gortighteningthesixpressureplateadjust-

pliedby endmovementofthewormbrake

ormbrakenutforward(towardthe pres-

s)as farasitwill go.Thewormhasa

amaximumof%-inchendmovement.

ardwinchuntilpinhits stop(fig.124).

npressureplateandbrakeliningplateto

eoffrom^2tol/lf,inch.This isaccom-

xadjustingbolt locknuts,andturning

headjustmentis completed,tightenthe

EMENT(fig.125).Loosentheidler

he pulleyawayfromchain.Remove

ovablelinkpins,andremovelink from

rthesprockets,installtheremovablelink,

n thelinkpins.Pushthe idlerfirmly

tenthelockbolt.


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hainAdjustment

ntheidlerpulleyadjustingbolt,and

the chain(fig.125).Removethecotter

nlink,andremovethelink.Disconnectthe

ntrolrodfromclutchshifteryokeand

rod.Removethefourmountingsillto

ceaslingaroundthewinchdrum,and

hoistorcrane;slidethehoist totheright

endofwinch,andworkit upandtothe

rssideofbody.Lowerthechainhoist,

dremoveslingfromwinch.

easlingaroundthe winch,andraise

ershaftendofwinchfirst,andthread end

side ofbodyaswinchis loweredinto

l toframemountingboltholes;install

ely.Installcotterpins. Disconnecthoist

ewinchclutchandbrakecontrolrodin

insand cotterpins.Placedrivechain

ovablelink,linkplate,andcotterpins.

stthe chain,andtightenthelockbolt.

rrectlevel withlubricant,andlubricate


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evrolet)

lichoistisusedon trucksequipped

yis mountedonasubframe,andhinged

ismountedinthesubframeand hydrau-

f bodysothattheload canbedumped

hingedtail gateatrear.Thehydraulic

fromatransmission-mountedpowertake-

's compartmentarerequiredtooperate

epowertake-offtodrivethe hoistpump,

valvefor raising,holding,orloweringthe

econtrolvalvethehydraulicfluid can

er,eitherin frontofthepiston,or back

a meansofforcingthepistontotravel

onis connectedtothedumpbodyby

orlowerthebodyas thepistonisforced

der.Dumpbodytrucksmaybeequipped

ectionhoists.Theremoval,installation,

arysomewhatforthedifferentmakes;

tical.

ucts

echassisframe

take-off

CSYSTEM.Whenthebodyfailsto

e,it indicateslackofoilinthe hydraulic

pumpslowly.Setthehoistvalvecontrol

")position.Removefillerholecoveron

hSAE10engineoil.Lowerbodyslowly

henraisebody slowlytotopoftravel,

and gasket.Recheckthehoistoperation.

oldweatherasmallamountofkerosene

mprovehydraulicoperation.Thisshould

installed,whenweatherpermits.


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aulicHoist

Thehydraulichoistcylinderandpump

dregularlyforoilleaks.Oilleaks atthe

packing,valvepistonpacking,cylinder

manifoldstuds,pumpshaft packing,or

sedbylooseboltsor packingglands.If

correcttheleak,hewpackingsmustbe

eplaced.

mpbodyandsecurelyblockitin the

ctthevalvecontrolrodfromtheshifter

eadsetscrewinrear yokeofrearuniversal

veshaft.Placeaslingaroundthe hoist

nhoist, andraisethechainhoistenough

ecotterpinfrom hoistcrossheadshaft,

oist cylinderandpumpassembly,and

aroundhoist andraisetheassembly

e assemblyintopositioninthehoist

ndershaft,andlockit inplacewithanew

shead shaft,andlockitinplacewith the


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

Hoist

fkeyinpumpdrive shaft;pushthedrive

npumpdriveshaft, andlockitinplace

rew.Connectvalvecontrolrodto valve

vispin andcotterpin.Removechainhoist

thehoist withoilfollowingtheinstruc-

ove.NOTE:Donot removetheblocking

ylinderis filled,andthebodyis tobe


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vechassisframe

take-off

CSYSTEM.Runthebodyuphalfway,

entandfiller plug.Pouroilinthrough this

unning slowlyandthevalveisin the

yraisestofullheight. Addaboutl/2

dy slowlywithpumprunning.Raise

nd installthespecial54-inchventand

ection(par.28)for correctgradeofoil.

beforeloweringandraisingthe hoist,

seaton thesills.Theoil maybethinned

oseneto providebetteroperationinex-

inandrefillwithfreshoil againassoon

Thehydraulichoistcylinderandpump

dregularlyforoilleaks.Oilleaks atthe

acking,pumpsupportbracket,control

tpacking,pumpgearendplate,orpump

ausedbylooseboltsor packingglands.If

correcttheleaks,newpackingsmustbe

eplaced.

otterpinsfromthehoistliftinglink

thepins.Removethecotterpinsfrom

ge pins,anddriveoutthe pins.Attach

y,and liftitoffthe hoistunit.Remove

attachingcontrolrodtovalveoperating

ewfromdriveshaftrearuniversaljoint

versaljoint offthepumpdriveshaft.

st cylinder,andattachittochainhoist

ameleverpin,cylinderpivotpin lock

cylinderandpumpassemblyoutof

ylinderandpumpassemblyinposi-

hachainhoist.Install cylinderpivotpin

ckthemsecurely.Install Woodruffkey

stall theuniversaljoint,andtightenthe

nnectvalvecontrolrodtovalvecontrolbell

ntplugfromcylinderhead;fillthecylinder

he plugloosely.Placethebodyinposi-

stallbodyhingepins;lineup liftinglink

dy,andinstallthepins.Fill thehydraulic

ctionsinsubparagraphbabove.


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et)

draulicHoist

yCo.

echassisframe

take-off

CSYSTEM.Removefillerplug;raise

ylinderfull,and installfillerplug.See

8)forcorrectlubricants.Loosen(donot

f cylinderandlowerbody.Thisaction

oilfromthecylinder.Afterbodyis com-

ebodyandtightenplug.Recheckhoist

hinnedwithkeroseneto providebetter

dclimates.Drainandrefillwithfresh oil

s.

Thehoisthydraulicsystemshouldbe

aks.Oilleaksatthe cylinderhead,piston

controlvalvepackings,orpumpcovers,

boltsor packingglands.Ifpropertighten-

ks,newpackingsmustbe installed,or


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otterpinsfromthetwoliftlink to

y hingepins.Removethefourpins;

andlift bodyfromhoistunit.Disconnect

trolvalvecontrollever.Removesetscrew

rsaljoint rearyoke,andslideuniversal

aft.Removethefour hoistunittochassis

guidebolts.Lift thehoistunitfrom

oist.

oistassemblyonthe chassisframe.

andthefourU-bolts.Placedriveshaft

pdrive gearshaft.Installandtighten

versaljointtopump gearshaft.Placethe

ntrolvalvecontrollever,and installclevis

andfill cylinderwithengineoil;install

ebodyon thehoistframe,andinstall

fttobodypins.Fill andbleedthehydraulic

ctionsinsubparagraphbabove.


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evrolet)

T

168

69

tionedvehicleisfirstreceivedatthe

essaryforsecondechelonpersonnelto

hevehiclewilloperatesatisfactorilywhen

urpose,inspectallaccessories,sub-

ools,andequipmenttoseethattheyarein

ed.Inaddition,theywillperforma run-in

directedin AR850-15,paragraph25,table

inparagraph169below.

CIENCIES.

uringthecourseoftherun-intest will

eswithinthescopeofthemaintenance

zationbeforethevehicleis placedin

ondthescopeofthemaintenance

zationtoa higherechelonforcorrection.

riousnaturetothe attentionofthe

DURES,

eethatportableextinguisherispresent

tit momentarilyforproperoperation,and

R.Fillfueltank.Checkcrankcaseoil

andcoolantas necessarytobringto

forexpansioninfueltankand radiator.

estvalueofantifreezeandadd asneces-

temagainstfreezing.CAUTION://there

aporsteeringwheelconcerningengineoil

ctionsontagbeforedrivingthevehicle.

uelfilterforleaks,damage,andsecure

ns.Drainfiltersedimentbowl.Ifanyappre-

irt ispresent,removebowl,andclean

eaningsolvent.Alsodrainaccumulated

f fueltank.Drainonlyuntilfuel runs


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T

meterandvoltagetestofbattery,and

ectrolyteH mcr»aboveplates.

EATHERCAP.Examinecarburetorand

thercaptoseeiftheyare ingoodcondition

entsfrombothunits,andwashthoroughly

lreservoirstobeadlevelwith freshoil,

ureallgasketsare ingoodcondition,and

nnectionsaretight.

LT.Seethataccessoriessuchascar-

tor,crankingmotor,distributor,water

e securelymounted.Makesurethatfan

ingoodcondition,andadjustedtohave

eflection.

Examineallaccessiblewiringandcon-

oodcondition,securelyconnected,and

s,includingspare,areproperlyinflated

msare incorrectposition;allvalvecaps

spectfordamage,andremoveobjects

ssesandbetweenduals.

UTS.Seethatallwheelmountingand

tand secure.

ER.Examinefendersandfrontbumper

.

ONS.Inspectalltowingshackles,pintle

reused),forloosenessordamage.See

onnectingmechanismoperatesproperly,

INS.Inspectcabandbodyforlooseness

ttachmentsanditemsof specialequip-

.Oncargobodiesbe suretailgateoper-

andthattarpaulinis ingoodcondition;

hedtobodyhooks.Inspectendcurtains

enings.Ondumpbodiestesthoist for

eraisedexaminemechanismforloose-

s.Besurebodywhen loweredisguided

framesill,and thattailgatelatching

panelbodiesbesurereardoors fit,close,

odytypes examinedoorandwindshield

ift mechanismandallhardwareisin

andsecure.Inspectdrivers'and/ortroop

,skidstrips,andstowagecompartments,

tassembly,andsecuremounting.Ontele-

arth-borerequippedvehicleseethat

equipmentis inproperpositioninvehicle,

ndattached,andthatalllooseitemsare


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

hfordamage,securemounting,andoil

echanismforproperoperation.Testdrag

mfromspinningas cableisunwound;

e,andadequatelubrication.Testwinch

gvehicleattopofsteepincline andattach-

eatbottom.Whiledrawingtowedvehicle

ch;iftowedvehiclebacksdownhill, brake

weringvehicledownhillwithwinch;throw

vehicledoesnotstop ordriftsmorethan

sadjustment.Seeparagraphs161and162.

enlyandtightlyondrum andaswinding,

ndapplyafilmofengine oil.Ifwinchis

rivechainandsprocketstosee thatthey

ot excessivelyworn.Chainidlershould

o slack.

acompletelubricationofthevehicle,

ordingtotheinstructionsontheLubrica-

exceptgearcases,wheelbearings,and

edingprocedures.Checkallgearcaseoil

rytobring tocorrectlevel.Changeonly

he necessity,orifgearoilis notof

tmospherictemperature.NOTE:Perform

ubrication.

NSIONS.Inspectfrontandrearsprings

eyare ingoodcondition,correctlyassem-

hingsandshacklepinsare notexcessively

Seethatallsteeringarms,rods,and

onditionandsecure;andthatgear caseis

leakingexcessively.

nspectallshaftsanduniversaljointsto

condition,correctlyassembled,alined,

cessively.

RVENTS.Seethataxlehousingand

sent,ingoodcondition,andnot clogged.

ketobesureit opensandclosesfully

chokebutton.

artengineandnoteifcrankingmotor

enginehasanytendencytowarddifficult

orun engineatfastidleduring warm-up.

okebuttonsothatenginewill runsmoothly,

gandoildilution.

mediatelyafterenginestarts,observe

ory.(Normaloperatingpressure,hot,at

7Ib;atidle, 5Ib).Stopengineif pressure

onds.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


T

ouldshowslightpositive(+) charge.

teduntilgeneratorrestoresto batterythe

ginetemperatureshouldrisegradu-

dtonormaloperatingrange,140°Fto

ouldregister "FULL"iftankhas

Observeifenginerespondsproperlyto

eratewithoutexcessiveloosenessorbinding.

ELDWIPERS.Seethattheseitemsarein

e.Iftacticalsituationpermits,testhorn

ne.Seeif wiperarmswilloperatethrough

ladecontactsglassevenlyandfirmly.

WMIRRORS.Cleanallbodyglassand

senessanddamage.Adjustrearview

REFLECTORS.Cleanlensesandinspect

damage.Iftacticalsituationpermits,open

to seeiflampsrespondproperly.

okundervehicle,andwithinengine

onsoffuel,oil,coolant,andbrakefluid

ndtosource,andcorrectorreport them

ENT.Checktoolsandonvehiclestow-

32, tobesureall itemsarepresent,and

ble,andproperlymountedorstowed.

efollowingprocedures,items(1)to

oadtest ofthevehicle.Onvehicleswhich

or moreinthecourseof deliveryfromthe

nization,reducethelengthof theroad

ecessarytomakeobservationslistedbelow.

ationofthevehicleat speedsapproach-

edonthecautionplateshouldbe avoided

NDGAGES.Donotmovevehicleuntil

hes135°F.Maximumsafeoperatingtem-

ereadingsofammeter,oil,temperature,

heyareindicatingtheproper function

apply.Alsoseethatspeedometerregisters

todometerregistersaccumulatingmileage.

AND.Testservicebrakestoseeifthey

ithoutsidepull,chatter,orsquealing;and

beforemeetingresistanceis \l/2inches.

vehicleonareasonableincline,withl/3

ble.Observeifhydrovacbrakebooster

inservicebrakeapplication.CAUTION:

rakesuntilshoesbecomeevenlyseated


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


et)

tchoperatessmoothlywithoutgrab,

gement,orslippage(underload)when

dalhasl'-inchfree travelbeforemeeting

otride clutchpedalatanytime,anddo

enewclutchseverelyorunnecessarily,until

vebecomeproperlywornin.

RANSFER.Gearshiftmechanismshould

ly,andgearsshouldoperatequietly,and

rontaxledeclutching,andpowertake-off

oequipped)forproperoperation.

eeringactionforbindingorlooseness;

lltoone side,wander,shimmy,orwheel

racket,andwheelaresecure.

rtforanyabnormalengineoperating

noise,suchaslackofpullingpoweror

isfiring,stalling,overheating,orexcessive

fenginerespondsproperlytoallcontrols.

nthealertthroughoutroadtest forany

ndattachments,runninggear,suspensions,

atelooseness,damage,wear,inadequate

tedtires.

MILEINTERVALSFORSERVICESIN

.

RATION.Listenatthehydrovacair

asthebrakepedal isappliedandreleased

st todetermineifsystemisoperating.

utiouslyhand-feeleachbrakedrumand

mperatures.Examinetransmission,trans-

ousingsforindicationsofoverheatingand

atseals,gaskets,orvents.NOTE:Transfer

rmallyhigherthanothergearcases.

nning,andfuel,engineoil, andcooling

ookwithinenginecompartmentandunder

aks.

intest,correctorreportany deficien-

conditionofvehicletodesignatedindi-


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ARYSTORAGE

ystorageordomesticshipment171

ailshipment172

IONS.

cshipmentofthevehicleisthe same

arystorageorbivouac.Preparationfor

structionsforloadingand unloadingthe

rytosecurethevehicleonfreightcars,

ghtcar,clearance,weight,andotherinfor-

erlypreparethevehicleforrail shipment.

tion,andforpreparationforindefinite

8.

EMPORARYSTORAGEOR

fortemporarystorageor domestic

orimmediateservice,butnotused for

lesaretobeindefinitelystoredaftership-

reparedforsuchstorageattheir desti-

temporarilystoredorbivouacked,

ions:

ethevehiclecompletely(par.28).

eezingtemperaturemaynormallybe

dstorageorshipmentperiod,test the

randaddtheproper quantityofanti-

dprotectionfromfreezingatthelowest

duringthestorageorshippingperiod.Com-

systemforleaks.

eryandterminalsforcorrosionandif

oughlyservicebattery(par.94).

andproperlyinflatealltires. Replace

resrequiringretreadingor repairing.Do

,cinders,orother surfaceswhichare

Washoff immediatelyanyoil,grease,gaso-

mesincontactwiththetires underany

rationforlimitedstoragewillinclude

es,after thebattery,coolingsystem,lubri-

ocheckongeneralconditionofthe vehicle.

inthevehicleoperation,beforethevehicle


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

attachedtothesteering wheel,stating

cribingtheconditionpresent.Awritten

henbemadetothe officerincharge.

otnecessarytoremovethefuelfrom

hintheUnited States,nortolabelthe

mmerceCommissionRegulations.Leave

enstoring inlocationswhereFireOrdi-

lations,requireremovalofallgasoline

E.Removerustappearingonany part

flintpaper.Repaintpainted surfaces

otectwoodormetalfromdeterioration.

rfaceswhicharesusceptibletorust,such

nd,inthecaseof track-layingvehicles,

atedwithaprotective,medium-grade

yallcabdoors,windows,andwindshields.

en-typecabswithcollapsibletopswill

rtainsi nplace,andthewindshieldclosed.

windowcurtainsarein placeandfirmly

ts,suchasfloormats,whereprovided,in

floor,andnotrolledor curledup.Equip-

trucktools,tire chains,andfireextin-

cein thevehicle.

ystematicinspectionjustbeforeship-

e,toinsurethatall abovestepshavebeen

cleisreadyfor operationoncall.Make

ageditems,andattachit tothesteering

erationService(par.23).

enginefor storage,removetheair

or.Starttheengine,and-setthethrottle

dle.Pour1 pintofmedium-grade,pre-

OrdnanceDepartmentSpecificationAXS-

effect,intothecarburetorthroat,being

gine.Turnoff theignitionswitchas

eoil hasbeenpouredintothecarburetor.

openthe throttlewide,andturnthe

lutionsbymeansofthecrankingmotor.

ed bythecrankingmotorwiththeswitch

onnectthehigh-tensionleadandground

eby meansofthecrankingmotor.Then

kesandchockthewheelsortracks.

orage.Vehiclesinlimitedstorage

orconditionoftiresand battery.Ifwater

atherisanticipated,rechargethebattery

removethebatteryfor charging.Donot

erybyrunningthe engine.


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ARYSTORAGE

KINGFORRAILSHIPMENT.

tothe preparationdescribedinpara-

evehiclesarepreparedfordomesticship-

rationsandprecautionswillbetaken:

odyofthevehiclewitha canvascover

ictiresfrom5to 10poundsabove

thebatterytopreventitsdischarge

Thismaybeaccomplishedbydisconnecting

eend ofthelead,andtyingit backaway

ustbeappliedandthe transmission

e vehiclehasbeenplacedinpositionwith

fatleast6 inches("A",fig.129).The

thecar insuchamanneras toprevent

balancedload.

ancevehiclesmustbeplacarded

ybeshippedonflatcars,end-doorbox

rdrop-endgondolacars,whichevertype

.

heneverpossible,loadandunload

dertheirownpower,usingpermanentend

orms.Movementfromoneflatcarto

fthe trainismadepossibleby cross-over

ms.Ifnopermanentend rampisavailable,

emadefromrailroadties. Vehiclesmay

withoutdrop endsbyusingacrane.In

oorboxcars,use adolly-typejacktofit

ithinthecar.

curingorblockingavehicle,three

wise,andbouncing),mustbeprevented.

ethodsofblockingthevehiclesonfreight

Whenblockingdualwheels,allblocking

outsidewheelof thedual.

ocateeightblocks"B",oneto the

ofeachwheel.Nailtheheel ofeachblock

40-pennynailstoeachblock.Thatportion

d willbetoe-nailedtothe carfloorwith

block.Locatetwoblocks"D"against

heel.Nailthe lowerblocktothecarfloor

andthetop blocktothelowerblockwith

fourstrands,twowrappings,ofNo.8

e"C"throughtheholesin thewheels,and

kets.Tightenthewiresenoughto remove

sed,thisstrappingmustbeappliedin a


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

CTPOINT-

uirementsforSecuringWheeled


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ARYSTORAGE

edtothefloorby theuseofblockingor

ngisnotrequired whengondolacarsare

acefourblocks"G",one tothefront

hsetof wheels.Theseblocksaretobeat

e over-allwidthofthevehicleatthe car

ocatetwoagainstblocks"G"to the

oagainstblocks"G"to therearofeach

wowrappings,ofNo.8 gage,black

theholesin thewheels,andsecureas

ve.


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

RELISTS.

vrolet)SNLG-506

lubricatingmaterials,re-

miscellaneousrelated

eldingmaterials,gases,

t:.SNLN-19

oforganizationalspecial

SNLG-19

clatureListsarelisted

fSNL'sis maintained

Publications"OFSB1-1

NS.

ningFM21-6

-565

10-580

missionunitsTM10-585

nitsTM10-560

0

M1-455

0-550

850-15

ectricalequipment

A

arburetors(Carter)TM9-1826A

acuumpowerbrakesys-

27B

ehiclesTM9-2800

ngineTM10-570

10

M10-540

icating,andweldingma-

suedby theOrdnance


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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ctionsforOrdnance

sFM5-25

andpreventivemainte-

neumatictiresand

nmaterialsandequip-

redforcevehiclesFM17-59

attackFM21-40

emicalagentsTM3-215

clesAR850-10

quipmentAR850-18

gofmechanizedand

nt;also,majorcaliber

Armyand Navy,on

shedbyOperations

mentofAssociationof


/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


evrolet)

rolsand

peration.25

n24

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ody

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t224

25

hing

225

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cement.224

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/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


park

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/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


vrolet)

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/ h t t p : / / w w w . h



7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


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/ h t t p : / / w w w . h



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7/28/2019 Tm 9-805 CHEVROLET 1.5 TON


ructions—

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Tm 9-805 CHEVROLET 1.5 TON