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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
/ h t t p : / / w w w . h
a t h i t r u s t . o r g / a c c e s s_
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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
/ h t t p : / / w w w . h
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ecember1943
ck(Chevrolet),ispublishedforthe
ofallconcerned.
TARYOFWAR:
ls,seeFM21-6.)
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/ h t t p : / / w w w . h
a t h i t r u s t . o r g / a c c e s s_
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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
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
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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
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
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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.
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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olet)
on,4x4 Truck
hCab
r
Ton,4x4Truck
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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on,4x4Truck
Winch
Winch
Ton,4x4Truck
Winch
Winch
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/ h t t p : / / w w w . h
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evrolet)
n,4x4Truck
EarthBorer
on/4x4Truck
eMaintenance
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/ h t t p : / / w w w . h
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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.
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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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.
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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LATEDDATA
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vrolet)
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
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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
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)
MSSION
SSION,
NCH
ONTRANSFERCASE
RIVEWHEN
DSURFACEDRDS
ANSFERC«SE
DRIVEWHEN
DSURFACEDRDS
SSION,
ST
MSSION,
ERCASE
EDRIVEWHEN
DSURFACEDRDS.
MSSION,
RFECTIONHOIST
SSION,
HOIST
structionPlates
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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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).
sedwithfour-speedtransmission,
C",fig.10).Usedwith eitherHerculesor
Productspowertake-off.
sedwithfour-speedtransmission,
E",fig.10).Usedwith Perfectionhoistand
wertake-off.
sedwithfour-speedtransmission,
hoist("D",fig.10).Usedwitheither the
theWoodorSpicerpowertake-off.
sedwithfour-speedtransmission,
hoist("F",fig.10).UsedwithPerfection
Spicerpowertake-off.
sedon modelsG-7163Telephone
173TelephoneMaintenancetruck(fig.
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)
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.
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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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
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
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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
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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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
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
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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
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
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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.
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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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
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
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NTROLSANDOPERATION
hpedal;shiftwinchclutchandbrakecontrol
H)position;shifttransmissionto
pedal,andshiftpowertake-offto
nottobeused again,shifttransfer
nnectcablefromload,andtightlywind
his winchisalsousedin connectionwith
poles.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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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,
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
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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.
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
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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-
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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VEMAINTENANCESERVICE
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.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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VEMAINTENANCESERVICE
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-
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
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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.
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
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VEMAINTENANCESERVICE
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
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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VEMAINTENANCESERVICE
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
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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
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VEMAINTENANCESERVICE
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.
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
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
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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,
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
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
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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
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
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
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rolet)
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
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
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
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
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vrolet)
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
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
http://slidepdf.com/reader/full/tm-9-805-chevrolet-15-ton 46/266 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
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
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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
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
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
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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).
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
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
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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)
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
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
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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
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
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
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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.
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
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
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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
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
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
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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.
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
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
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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.
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
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
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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
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
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
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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
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
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
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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-
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
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
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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
/ h t t p : / / w w w . h
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
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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
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
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
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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.
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
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
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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
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
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
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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
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
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
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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
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
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
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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-
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
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
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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).
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
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
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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
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
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
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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
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
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
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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
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
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
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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.
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
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
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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.
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
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
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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.
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
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
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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.
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
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
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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
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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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
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
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TEM.Seeparagraph42a.
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
TEM.Seeparagraph42a.
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).
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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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.
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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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
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
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evrolet)
USTMENT.Adjustcarburetoridling
USTMENT.Adjustcarburetoridling
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
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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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).
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)
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.
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
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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
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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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
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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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.
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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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.
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
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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).
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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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.
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
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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).
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
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
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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-
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
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
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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).
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
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
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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.
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
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
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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.
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
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
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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.
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
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
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rUp. Checkforlackofoilin
s.164b, 165b,or166 b).
Position.
AGENOTADJUSTEDPROPERLY.Adjust
ngth,andrecheckuntilcorrectoperation
.Notifyhigherauthority,orreplace
m(pars.164b, 165b,or166 b).
NING.Checkfordisconnecteddrive
pumpdriveshaft.Makenecessaryrepairs
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
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
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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
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
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
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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
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
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
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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.
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
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
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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
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
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
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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.
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
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
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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
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
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
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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
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
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
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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
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
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
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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.
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
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
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TA,MAINTENANCE,
LE
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
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
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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
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
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
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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
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
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
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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,
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
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
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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.
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
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
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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-
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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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
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
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vrolet)
willreducetheefficiencyoftheventilating
onsofoperationsuchasunusual
theair,or wherethereareothertypes
used,itmaybe necessarytocleanthe
ssemblymoreoften.
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
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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
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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t)
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
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STALLATION
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
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evrolet)
data68
dalTravelAdjustment
BULATEDDATA.
sasingle-plate,dry-disktype,incor-
dhub.Theengagementpressureissupplied
ng.Theclutchis controlledbytheclutch
owoutfork,andthrowoutbearing.
43in.
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
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
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/ h t t p : / / w w w . h
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
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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).
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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).
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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et)
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
a t h i t r u s t . o r g / a c c e s s_
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edData.
Thediaphragm-typefuelpumpis
oftheenginecrankcase,andisoperated
shaft.Thefloatcontrolledneedlevalve
heamountoffuel flow,andacoilspring
stantpressureinpump tocarburetorfuel
providesameansofprimingthe pumpand
torBowl
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
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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t)
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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evrolet)
data79
83
BULATEDDATA.
ecoolingsystemconsistsofa radi-
mostat,centrifugalwaterpump,fanbelt,
m
7/4^
gal
manentlysealedandlubricated
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
a t h i t r u s t . o r g / a c c e s s_
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ator
at140° to147°F
Removal
Approximatelyly^in.
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
a t h i t r u s t . o r g / a c c e s s_
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et)
UMP
emoval
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
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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
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
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
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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
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
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
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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.
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
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
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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
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
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
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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
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
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
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)
AS
3—
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
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
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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
/ h t t p : / / w w w . h
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
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et)
K
Timing
tallation
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
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
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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
/ h t t p : / / w w w . h
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
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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
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
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
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RUMENTSANDGAGES
TER
ROVAC
EGAGE
E
ACUUMLINE
HECKVALVE
ECKVALVE
CTIONBLOCK
ator(CoverRemoved)
rising above40amperes,therebypre-
hebatteryor generator.
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
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
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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.
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
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
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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
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
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
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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.
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
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
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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
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
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
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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.
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
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
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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
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
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
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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
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
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
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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
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
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
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evrolet)
nnectionTable(fig.59).
t
er
WiringHarnessConnections
nnectionTable(fig.60).
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
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
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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.
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
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
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vrolet)
NECTIONTABLE
struction
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
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
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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
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
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
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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
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
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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
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
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
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et)
DistributorFilter,andCranking
randCondenser
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
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
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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
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
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
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et)
er
nBonding
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
a t h i t r u s t . o r g / a c c e s s_
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RUMENTSANDGAGES
dLocations
derandHood
ters mentionedinsubparagraph(3)above.
crewsandterminalsmustbekepttight.
ccomplishedbytheuseof13 flexible
enweldedatthe hoodsidepanellouvers,
s,nuts,andtoothedlockwashers.The
eepallmetalpartsat acommonpotential.
the flexiblemetalstrapsisillustratedin
are locatedatthefollowingpoints:
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
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
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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
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
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
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RUMENTSANDGAGES
densers
Y
L
dingParts
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
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
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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
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
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
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
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Removal
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
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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
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/ h t t p : / / w w w . h
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
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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
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
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
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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).
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
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
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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-
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
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
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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
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
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
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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
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
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
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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
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
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
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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
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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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
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
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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)).
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
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
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/ h t t p : / / w w w . h
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
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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
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
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
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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).
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
a t h i t r u s t . o r g / a c c e s s_
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t)
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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es,FrontWheel
kes/RearWheel
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
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
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rolet)
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
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
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/ h t t p : / / w w w . h
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
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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,
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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).
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
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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ESHOE
HOE
uction,RearWheel
ylinderClamp
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
a t h i t r u s t . o r g / a c c e s s_
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vrolet)
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
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
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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
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
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
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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
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
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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
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
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
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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)
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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
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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
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
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
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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
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
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
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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.
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
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
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S,HUBS,AND TIRES
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
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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).
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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SORBERS
BOLTPLATE
er,Rear
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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evrolet)
nstalltheshockabsorberin thereverse
maroundfillerplug,andremovethe
ll shockabsorberfulloffluid.Work
ddownwhilefilling toeliminatetrapped
tity(about2 tablespoonfuls)offluid
fteritis fulltoprovideexpansionspace.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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,
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
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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
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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evrolet)
end ofbushingpilotingintospring.Push
gs,andinstallwasherandnut. Tighten
ceboltholes areinposition.Installsix
Loosenpintlenutuntil springtension
meto preventrattle.Installcotterpin.
hookcanbeextendedbackseveralinches
crossmemberbyreversingthe position
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
a t h i t r u s t . o r g / a c c e s s_
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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-
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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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).
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
a t h i t r u s t . o r g / a c c e s s_
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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
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)
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.
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
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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.
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
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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.
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
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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.
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
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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
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
a t h i t r u s t . o r g / a c c e s s_
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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.
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
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et)
ation
tedWinch
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
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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.
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
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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.
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
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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
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
a t h i t r u s t . o r g / a c c e s s_
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et)
Hoist
fkeyinpumpdrive shaft;pushthedrive
npumpdriveshaft, andlockitinplace
rew.Connectvalvecontrolrodto valve
vispin andcotterpin.Removechainhoist
thehoist withoilfollowingtheinstruc-
ove.NOTE:Donot removetheblocking
ylinderis filled,andthebodyis tobe
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
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
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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.
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
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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
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
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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.
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
a t h i t r u s t . o r g / a c c e s s_
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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
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
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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
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
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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.
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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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
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
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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-
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
a t h i t r u s t . o r g / a c c e s s_
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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
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)
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.
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
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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
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
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evrolet)
CTPOINT-
uirementsforSecuringWheeled
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
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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.
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
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
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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
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
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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
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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evrolet)
rolsand
peration.25
n24
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ent199
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196
ol
ent200
)...223
y
ody
ulin
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park
6
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ch
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tion
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ollever.
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er
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ents,and
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otor..
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vrolet)
cover
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yservice
l
t
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
k......17
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y
s
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ons
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258
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vrolet)
Cont'd
onditions
quipment
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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vemainte-
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ystorage
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ageon
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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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evrolet)
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e92
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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