TM 10-3930-669-34

INTRODUCTION 1-1
TECHNICAL MANUAL
VEHICLE MAINTENANCE 2-1

DIRECT SUPPORT AND ENGINE MAINTENANCE 3-1

GENERAL SUPPORT
MAINTENANCE MANUAL FUEL SYSTEM MAINTENANCE 4-1

EXHAUST SYSTEM MAINTENANCE 5-1

COOLING SYSTEM MAINTENANCE 6-1

ELECTRICAL SYSTEM MAINTENANCE 7-1

TRANSMISSION MAINTENANCE 8-1

FINAL DRIVE MAINTENANCE 9-1

AXLE MAINTENANCE 10-1

BRAKE SYSTEM MAINTENANCE 11-1

STEERING SYSTEM MAINTENANCE 12-1

FRAME MAINTENANCE 13-1

CAB AND BODY MAINTENANCE 14-1

TRUCK, LIFT, FORK, HYDRAULIC SYSTEM MAINTENANCE 15-1

CLEAN BURN DIESEL ,
FRONT/SIDE LOADING REFERENCES A-1

6,000 LB CAPACITY
MODEL R60SL-DC EXPENDABLE/DURABLE SUPPLIES AND
MATERIALS B-1

NSN 3930-01-378-7497 TOOL IDENTIFICATION LIST E-1

Approved for public release; ALPHABETICAL INDEX INDEX-1

distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

JANUARY 1997
 TM 10-3930-669-34

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
No. 10-3930-669-34 Washington, D.C. 21 JANUARY 1997

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE

TRUCK, LIFT, FORK, CLEAN BURN DIESEL,

FRONT/SIDE LOADING,
6,000 LB CAPACITY
MODEL R60SL-DC
NSN 3930-01-378-7497
Approved for public release; distribution is unlimited.

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications
and Blank Forms), or DA Form 2028-2 located at the back of this manual direct to: Commander, US
Army Tank-automotive and Armament Command, ATTN: AMSTA-IM-OPIT, Warren, MI 48397-5000. A
reply will be furnished to you. You may also provide DA Form 2028-2 information to TACOM via datafax
or e-mail. TACOM’s datafax number for AMSTA-IM-OPIT is (810) 574-6323 and the e-mail address is:
amsta-im-opit @cc.tacom-tech-pubs @ cc.tacom.army.mil.

TABLE OF CONTENTS
Page

CHAPTER 1 INTRODUCTION................................................................................................. 1-1

Section I. General Information............................................................................................. 1-2
Section II. Equipment Description and Data......................................................................... 1-5
Section III. Principles of Operation ........................................................................................ 1-6

CHAPTER 2 VEHICLE MAINTENANCE ................................................................................. 2-1

Section I. Repair Parts; Special Tools; Test, Measurement and Diagnostic Equipment
(TMDE); and Support Equipment ........................................................................ 2-2
Section II. Service Upon Receipt.......................................................................................... 2-3
Section III. Troubleshooting................................................................................................... 2-5
Section IV. Maintenance Procedures .................................................................................... 2-88
Section V. Preparation for Storage or Shipment................................................................... 2-95

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TABLE OF CONTENTS (CONT)

Page

CHAPTER 3 ENGINE MAINTENANCE ................................................................................... 3-1

CHAPTER 4 FUEL SYSTEM MAINTENANCE........................................................................ 4-1

CHAPTER 5 EXHAUST SYSTEM MAINTENANCE................................................................ 5-1

CHAPTER 6 COOLING SYSTEM MAINTENANCE ................................................................ 6-1

CHAPTER 7 ELECTRICAL SYSTEM MAINTENANCE .......................................................... 7-1

CHAPTER 8 TRANSMISSION MAINTENANCE ..................................................................... 8-1

CHAPTER 9 FINAL DRIVE MAINTENANCE .......................................................................... 9-1

CHAPTER 10 1 AXLE MAINTENANCE..................................................................................... 10-1

CHAPTER 11 BRAKE SYSTEM MAINTENANCE .................................................................... 11-1

CHAPTER 12 STEERING SYSTEM MAINTENANCE............................................................... 12-1

CHAPTER 13 FRAME MAINTENANCE .................................................................................... 13-1

CHAPTER 14 CAB AND BODY MAINTENANCE..................................................................... 14-1

CHAPTER 15 HYDRAULIC SYSTEM MAINTENANCE............................................................ 15-1

APPENDIXES:

A REFERENCES.................................................................................................... A-1

B EXPENDABLE/DURABLE SUPPLIES AND MATERIALS................................ B-1

C ILLUSTRATED LIST OF MANUFACTURED ITEMS ......................................... C-1

D TORQUE LIMITS ................................................................................................ D-1

E TOOL IDENTIFICATION LIST............................................................................ E-1

ALPHABETICAL INDEX................................................................................................................................. Index-1

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HOW TO USE THIS MANUAL

This manual is designed to help maintain the Truck, Lift, Fork NSN 3930-01-378-7497. Listed below are some special
features included in this manual to help locate and use the needed information:

• A front cover table of contents is provided for quick reference to chapters and sections that will be used often.

• WARNING, CAUTION, and NOTE headings, subject headings, and other essential information are printed in bold
type making them easier to see.

• The maintenance tasks describe what must be done to the forklift before starting the task (Equipment Condition),
and what must be done to return the vehicle to operating condition after the task is finished (Follow-On
Maintenance).

• The Appendixes are located at the end of the manual. They contain a reference guide to other manuals, a list of
expendable supplies and materials, and other material for maintaining the forklift.

• In addition to text, there are exploded-view illustrations showing how to take a component off and put it back on.
Cleaning and inspection procedures are also included as required.

• Chapter 2 of this manual covers Direct Support and General Support level Preventive Maintenance Checks and
Services (PMCS) and basic troubleshooting, as well as general maintenance.

Follow these guidelines when using this manual:

• Read all WARNINGS and CAUTIONS before performing any procedure.

• The equipment conditions found in the maintenance procedures are of a general nature and the mechanic may be
able to perform only certain steps within a procedure to accomplish the equipment condition.

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WARNING

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work
on fuel system when engine is hot. Fuel can be ignited by hot engine. When working with fuel,
post signs that read NO SMOKING WITHIN 50 FEET (15 m).

WARNING

Transmission oil is slippery and can cause falls. To avoid injury, wipe up spilled oil with rags.

WARNING

Engine/Transmission assembly weighs 430 lbs (195 kg). Attach suitable lifting device prior to
removal or installation to prevent possible injury to personnel.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is 138'F (50'C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

WARNING

Use care when removing springs. A compressed spring can act as a projectile when released and
could cause severe injury.

WARNING

Use care when removing snap ring and retaining rings. Snap ring and retaining rings are under
spring tension and can act as projectiles when released and could cause severe eye injury.

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WARNING

Allow engine to cool before performing maintenance on the muffler, exhaust pipe, exhaust
manifold, or turbocharger. If necessary, use insulated pads and gloves.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in well-
ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash
immediately with soap and water.

WARNING

Do not touch hot parts with bare hands; injury to personnel will result.

WARNING

Oil will spray from cylinder barrel ports when rod is moved in or out. Cover ports with two
cleaning cloths to prevent oil from spraying. Failure to comply may result in injury to personnel.

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure
to comply may result in injury or death to personnel.

WARNING

High pressure hydraulics operate this equipment. Refer to vehicle operator and maintenance
manuals for hydraulic oil pressure. Never disconnect any hydraulic line or fitting without first
dropping pressure to zero. A high pressure oil stream can pierce body and cause severe injury to
personnel.

WARNING

All personnel must stand clear during lifting operations. A swinging or shifting load may cause
injury or death to personnel.

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 TM 10-3930-669-34

WARNING

Applying excessive or uneven pressure to cab glass may cause it to crack or break resulting in
injury to personnel and damage to equipment.

WARNING

Hydraulic oil is flammable. Ensure engine is cool to prevent fire. Injury or death to personnel
could result.

WARNING

Use extreme care when removing or installing lock wire. Lock wire is under tension and can act
as a projectile when released suddenly. Ensure proper eye protection is worn to prevent injury to
personnel.

WARNING

Remove rings, bracelets, wristwatches, and neck chains before working on any vehicle. Jewelry
can catch on equipment and cause injury, or may short across an electrical circuit and cause
severe burns or electrical shock.

WARNING

Steam cleaning creates hazardous noise levels and severe burn potential. Eye, skin, and ear
protection are required. Failure to comply may result in injury to personnel.

WARNING

Solvents used with a spray gun must be used in a spray booth with filter. Face shield must be
used by personnel operating spray gun. Failure to comply may result in injury to personnel.

WARNING

On direct contact, uncured silicon sealant irritates eyes. In case of contact, flush eyes with water
and seek medical attention. In case of skin contact, wipe off and flush with water.

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 TM 10-3930-669-34

CHAPTER 1

INTRODUCTION

Para Contents Page

Section I. General Information

1-1 Scope................................................................................................................................. 1-3
1-2 Maintenance Forms, Records, and Reports ...................................................................... 1-4
1-3 Destruction of Army Material to Prevent Enemy Use ........................................................ 1-4
1-4 Preparation for Storage or Shipment ................................................................................. 1-4
1-5 Official Nomenclature, Names, and Designations ............................................................. 1-4
1-6 Reporting Equipment Improvement Recommendations (EIR) .......................................... 1-4
1-7 Warranty Information ......................................................................................................... 1-5
1-8 Corrosion Prevention and Control...................................................................................... 1-5
1-9 Nuclear Hardness .............................................................................................................. 1-5

Section II. Equipment Description and Data

1-10 Equipment Characteristics, Capabilities, and Features ..................................................... 1-5
1-11 Location and Description of Major Components................................................................ 1-5
1-12 Equipment Data ................................................................................................................. 1-5

Section III. Principles of Operation

1-13 Power Train........................................................................................................................ 1-6
1-14 Engine Systems ................................................................................................................. 1-8
1-15 Electrical System ............................................................................................................... 1-11
1-16 Hydraulic System ............................................................................................................... 1-18
1-17 Steering System................................................................................................................. 1-19
1-18 Mast and Pivot/Shift Assembly .......................................................................................... 1-20
1-19 Brake System..................................................................................................................... 1-22
1-20 Wheels and Tires ............................................................................................................... 1-23

1-1
 TM 10-3930-669-34

Section I. GENERAL INFORMATION

1. Mast Assembly 7. Drive Axle

2. Cab 8. Shift Cylinder
3. Cab Door 9. Pivot Cylinder
4. Rear Engine Access Cover 10. Tilt Cylinders
5. Tie Down Points 11. Forks
6. Fuel Tank 12. Carriage Assembly

Figure 1-1. Truck, Lift, Fork (Sheet 1 of 2)

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13. Rear Flood Light 19. Tow Pin

14. Taillight 20. Counterweight
15. Front Flood Light 20. Counterweight
16. Mast Level Indicator 21. Load Rest
17. Engine Panel 22. Exhaust Muffler
18. Steer Axle 23. Battery Box

Figure 1-1. Truck, Lift, Fork (Sheet 2 of 2)

1-1. SCOPE.

a. Type of Manual. This manual is used for direct support and general support maintenance of the Truck, Lift, Fork.

b. Model Number and Equipment Name. Truck, Lift, Fork, NSN 3930-01-378-7497, produced by Drexel Industries,
Inc. of Pennsylvania, Model R60SL-DC. (See Figures 1-1 and 1-2.)

c. Purpose of Equipment. The Truck, Lift, Fork, hereinafter referred to as the forklift, is designed to operate as a
conventional, counterbalanced, front-loading forklift with the additional capability of operating as a side-loading forklift.

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1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS.

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738-
750, The Army Maintenance Management System (TAMMS) (Maintenance Management UPDATE).

1-3. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE.

Command decision, according to the tactical situation, will determine when the destruction of the forklift will be
accomplished. A destruction plan will be prepared by the using organization unless one has been prepared by a higher
authority. For general destruction procedures for this equipment, refer to TM 750-244-6, Procedures for Destruction of
Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive Command).

1-4. PREPARATION FOR STORAGE OR SHIPMENT.

Refer to Chapter 2, Section VI, of this manual for Preparation for Storage or Shipment.

1-5. OFFICIAL NOMENCLATURE, NAMES, AND DESIGNATIONS.

REFERENCE INFORMATION

This listing includes the nomenclature cross-reference list and list of abbreviations used in this manual.

NOMENCLATURE CROSS-REFERENCE LIST

Common List Official Nomenclature

Forklift Truck, Lift, Fork, Clean Burn Diesel,

Front/Side Loading, 6,000 LB. Capacity,
Model R60SL-DC
NSN 3930-01-378-7497

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).

If your 6,000 lb forklift needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us
what you don’t like about our equipment. Let us know why you don’t like the design or performance. Put it on an SF368
(Product Quality Deficiency Report). Mail it to us at: Commander, U S Army Tank-automotive and Armaments Command,
ATTN: AMSTA-TR-E/MPA, Warren, Michigan 483975000. A reply will be furnished to you.

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1-7. WARRANTY INFORMATION.

The warranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defects in material and
workmanship to your supervisor, who will take the appropriate action. Warranty information is listed in TM 10-3930-669-
20.

1-8. CORROSION PREVENTION AND CONTROL.

Corrosion Prevention and Control (CPC) of Army materials is a continuing concern. It is important that any corrosion
problems with the forklift be reported so that the problem can be corrected and improvements can be made to prevent the
problem in the future.

While corrosion is typically associated with rusting of metals, corrosion can also include deterioration of other materials,
such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion
problem.

If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency Report. Use of
key words such as "corrosion, rust, deterioration, and cracking" will ensure that the information is identified as a CPC
problem.

The form should be submitted to the address specified in DA PAM 738-750.

1-9. NUCLEAR HARDNESS.

Is not required for this end item.

Section II. EQUIPMENT DESCRIPTION AND DATA

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

Refer to TM 10-3930-669-10 for Equipment Characteristics, Capabilities, and Features.

1-11. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

Refer to TM 10-3930-669-10 for Location and Description of Major Components.

1-12. EQUIPMENT DATA.

Refer to TM 10-3930-669-10 for Equipment Data.

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 TM 10-3930-669-34

Section III. PRINCIPLES OF OPERATION

1-13. POWER TRAIN.

The forklift is powered by an air-cooled diesel engine (1) coupled directly to a semi-automatic transmission (2). Power
from the transmission is transferred to the drive axle (3) through a short drive shaft (4) with two universal joints.

a. Engine. The forklift is equipped with a KHD Deutz diesel Model F4L912D/W engine rated at 60 HP (44 kilowatt)
at 2,500 RPM. This engine is air cooled.

b. Transmission. The forklift is equipped with a Borg Warner Model PR-2 two-speed, semi-automatic transmission.
Forward low range, forward high range, reverse, and neutral functions are controlled by an electric solenoid-controlled
valve body. Power is transmitted by constant-mesh helical gears and multiple-disc clutch packs.

(1) The transmission control lever located on the steering column operates two switches sending voltage to the
electric solenoids controlling transmission functions.

(a) To select the forward position for the transmission, move the control lever to the forward position.

(b) To select the reverse position for the transmission, move the control lever to the rearward position.

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(c) To select the neutral position for the transmission, move the control lever to the center position.

(2) The high/low range selector switch is located on the right side of instrument panel. The electric control rocker
switch controls a solenoid in the transmission. This solenoid switches the transmission into high range, when energized.
The truck should normally be operated in high range only. Changing from one range to the other is accomplished by
pushing the transmission range control button. The high range light will light on the instrument panel when high range is
selected.

c. Drive Axle. The forklift is equipped with a Clark-Hurth Model 172 drive axle. This drive axle features gear
reduction at the wheel ends and is equipped with wet brake discs that serve as the service brakes.

d. Inching System. The inching system works with both the drivetrain and the brake system. The inching system
permits extremely slow movement for precise load positioning. Light brake application at slow engine speeds activates the
inching solenoid valve. This reduces the hydraulic pressure actuating the hydraulic clutch pack allowing the clutches to
slip and the machine to be inched.

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1-14. ENGINE SYSTEMS.

a. Cooling System. The cooling system protects the engine (1) from excess operating temperatures by removing
heat generated during the combustion process. Air is drawn through the engine oil-to-air cooler (2) and then past the
engine cooling fins (3) by a belt-driven blower (4). A sensor (5) is located on the blower belt tensioner (6). This sensor will
send voltage to a warning buzzer and a warning light on the instrument panel when the blower belt breaks or comes off its
pulleys.

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b. Air Intake System. The air intake system consists of a dry-type filter contained in an air cleaner (1), ducting (2),
and the engine intake manifold (3). Condition of the air filter is monitored using the air filter indicator (4).

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 TM 10-3930-669-34

1-14. ENGINE SYSTEMS (CONT).

c. Fuel System. The fuel system consists of the fuel tank (1), fuel/water separator (2), fuel filter (3), feed pump (4),
injection pump (5), and injectors (6). The fuel tank (1) is located on the LH side of the forklift and has a capacity of 14
gallons. The fuel/water separator (2) removes water and large contaminants from the fuel. Finer contaminants are
removed by the fuel filter (3). The feed pump (4) supplies fuel to the injection pump (5) which distributes the fuel to the
injectors (6). Surplus fuel is returned to the fuel tank (1) through return lines (7).

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 TM 10-3930-669-34

1-15. ELECTRICAL SYSTEM.

a. Electrical System. The forklift is equipped with a 24-volt electrical system. Status of the electrical system can be
monitored by an ammeter gauge (1) located on the dash panel inside the cab. A fuse panel (2) located under the dash
panel protects electrical circuits.

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 TM 10-3930-669-34

1-15. ELECTRICAL SYSTEM (CONT).

b. Battery. The electrical system is equipped with two 12-volt batteries (1). The batteries are contained in a battery
box (2) located on the right-hand side of the forklift under the rear engine access cover (3). This location provides
protection from the environment while allowing convenient access for service.

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 TM 10-3930-669-34

c. Power Storage and Generating. The forklift’s 12-volt batteries (1) have the capability of storing electrical power.
The batteries can power all of the systems for a limited time while the engine is not running, but its primary purpose is to
supply voltage to the engine’s starting system. Once the engine is running, the generating system provides the electrical
power for all systems. The engine-driven alternator (2) generates alternating current (AC) which is passed through a set of
rectifiers that change it into direct current (DC). This direct current is used to charge the battery (1) and is distributed t o
the other systems of the forklift.

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1-15. ELECTRICAL SYSTEM (CONT).

d. Engine Starting and Stopping. The engine starting system consists of a starter motor (1), solenoid (2), neutral
start relay (3), and engine switch (4). Battery voltage is used to operate the starter motor (1). The starter motor (1) is
mounted on the engine and engages the flywheel only when electrically energized. When the engine switch (4) is turned
to the off position, the fuel shutoff solenoid (2) is de-energized causing the injection pump to stop fuel supply to the
injectors.

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e. Service Lighting. The service lighting includes the front and rear flood lights (1 and 2), one taillight (3), and
instrument panel (4) gauge lighting. The front flood light (1), taillight (3), and instrument panel (4) lights are all controlled
by the front flood light rocker switch (5). The rear flood light (2) is controlled by the rear flood light rocker switch (6). The
taillight is equipped with one dual-filament bulb serving as both the running light and the brake light. The brake light
illuminates when it receives voltage from the brake light switch (7) mounted above the brake pedal linkage. Depressing
the brake pedal operates the brake light switch (7) and illuminates the brake light.

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 TM 10-3930-669-34

1-15. ELECTRICAL SYSTEM (CONT).

f. Instruments. All instruments are equipped with individual lamps for illumination and share a common circuit for
power of these lamps. A common ground circuit is also shared for all instrument illumination. All instrumentation is fully
operable when the main power switch and engine switch are on.

• Ammeter(1) receives voltage from the shunt and shares a common ground circuit
with other instruments.
• Hour meter (2) receives voltage from the fuse panel and shares a common ground
circuit with other instruments.
• Fuel level gauge (3) receives voltage from the fuse panel and is grounded at the
sending unit mounted on the fuel tank.
• Engine oil pressure gauge (4) receives voltage from the fuse panel and is
grounded at the sending unit mounted on the engine.
• Engine temperature gauge (5) receives voltage from the fuse panel and is
grounded at the sending unit mounted on the engine.
• Transmission oil temperature gauge (6) receives voltage from the fuse panel and
is grounded at the sending unit mounted on the transmission.
• Air restriction indicator gauge (7) indicates condition of air filter in inches of Hg.
Red button is for resetting indicator.

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g. Warning Lights, Buzzers, and Indicator Lights.

• Broken belt warning light(1) is illuminated when the broken belt sensor (2) closes. The broken belt sensor
(2) will close any time the blower belt tensioner (3) collapses as a result of the blower belt (4) breaking or
coming off its pulleys. The broken belt warning light (1) is on the same electrical circuit as the broken belt
warning buzzer (5).

• Broken belt warning buzzer (5) sounds when the broken belt sensor (2) closes. The broken belt sensor
(2) will close any time the tensioner (3) collapses as a result of the blower belt (4) breaking or coming off its
pulleys. The broken belt warning buzzer (5) is on the same electrical circuit as the broken belt warning light
(1).

• Transmission high range indicator light (6) is illuminated any time the transmission is in high range. The
indicator light (6) receives voltage from the high/low range switch (7).

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1-16. HYDRAULIC SYSTEM.

The hydraulic system supplies hydraulic oil pressure for steering (1) and mast (2) operation any time the engine is running.
A pump (3) mounted on the transmission draws hydraulic fluid from the hydraulic tank (4) mounted on the RH side of the
forklift. A priority valve (5) diverts hydraulic fluid to the mast (2) and steering (1) system by demand. Hydraulic fluid is
filtered by a spin-on filter (6) immediately before returning to the hydraulic tank (4).

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1-17. STEERING SYSTEM.

The steer axle (1) is mounted at the rear of the forklift and is hydraulically assisted any time the engine is running.
Hydraulic oil pressure is provided by a transmission-mounted pump which is shared by the mast, pivot/shift assembly, and
steering system (refer to Para 1-16). No mechanical linkages are used between the steering column (2) and the steer axle
(1) for control of the steer axle (1). A valve (3) is connected to the steering column (2) and controls fluid flow from the
pump to the steer axle (1).

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1-18. MAST AND PIVOT/SHIFT ASSEMBLY.

The mast assembly (1) is mounted to the pivot/shift assembly (2) and is capable of a 90 degree pivot to the right. Two tilt
cylinders (3) make it possible to tilt the mast assembly (1) six degrees forward or back. The frame of the mast assembly
(1) is made up of three separate rails: the inner rail (4), center rail (5), and outer rail (6). The mast assembly (1) is raised
and lowered by the primary lift cylinder (7) and secondary lift cylinders (8) using chains and anchors to synchronize the
movement of the three rails.

The pivot/shift assembly (2) allows side-to-side movement of the mast assembly (1) using one cylinder located behind the
side shift rod (9). Additionally, the pivot cylinder (10) can pivot the mast 90 degrees to the right.

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 TM 10-3930-669-34

All functions of the mast assembly (1) and the pivot/shift assembly (2) are controlled by two joysticks (3) mounted in the
cab. Joysticks (3) are connected by cables (4) to two control valves (5) which direct flow to and from the mast assembly
(1) and pivot/shift assembly (2). Hydraulic oil pressure is provided by a transmission-mounted pump which is shared by
the steering system, mast assembly, and pivot/shift assembly (refer to Para 1-16).

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1-19. BRAKE SYSTEM.

The forklift brakes are located inside the drive axle (1). The steer axle (2) is not equipped with brakes. Braking is
controlled by the brake pedal (3) which is connected to the master cylinder (4) by a linkage. Additionally, the brake pedal
(3) disengages the transmission automatically as the brakes are being applied.

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1-20. WHEELS AND TIRES.

The drive axle is equipped with four wheel-and-tire assemblies (1 and 2), one inner (1) and one outer (2) per side. Inner
and outer wheel-and-tire assemblies are not interchangeable because of a difference in wheel depth. The steer axle is
equipped with two wheel-and-tire assemblies (3), one per side.

a Drive Axle Wheel-and-Tire Assemblies. A wheel-and-tire assembly (1 or 2) consists of one tire and one wheel.
The tire is solid, requiring no air.

b Steer Axle Wheels. A wheel-and-tire assembly (3) consists of one tire and one wheel. The tire is solid,
requiring no air.

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 TM 10-3930-669-34

CHAPTER 2

VEHICLE MAINTENANCE

Para Contents Page

SECTION I - Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support
Equipment
2-1 Common Tools and Equipment ...................................................................................................................... 2-2
2-2 Special Tools, TMDE, and Support Equipment............................................................................................... 2-2
2-3 Repair Parts .................................................................................................................................................... 2-3

SECTION II - Service Upon Receipt

2-4 General Service Instructions ........................................................................................................................... 2-3
2-5 Inspection and Servicing Equipment............................................................................................................... 2-3
2-6 Special Service Instructions ............................................................................................................................ 2-4

SECTION III - Troubleshooting

2-7 Troubleshooting Introduction........................................................................................................................... 2-5
2-8 Troubleshooting Instructions ........................................................................................................................... 2-6
2-9 Troubleshooting Symptoms ............................................................................................................................ 2-8
2-10 Troubleshooting Procedures ........................................................................................................................... 2-9
2-11 Engine System Troubleshooting ..................................................................................................................... 2-9
2-12 Drive Axle Troubleshooting ........................................................................................................................... 2-70

SECTION IV - Maintenance Procedures

2-13 Maintenance Introduction.............................................................................................................................. 2-88
2-14 Ground Handling ........................................................................................................................................... 2-88
2-15 General Removal Instructions....................................................................................................................... 2-88
2-16 General Disassembly Instructions................................................................................................................. 2-89
2-17 General Cleaning Instructions....................................................................................................................... 2-89
2-18 General Inspection Instructions..................................................................................................................... 2-92
2-19 General Repair Instructions .......................................................................................................................... 2-92
2-20 General Assembly Instructions ..................................................................................................................... 2-93
2-21 General Installation Instructions.................................................................................................................... 2-94
2-22 Adjustment .................................................................................................................................................... 2-94
2-23 Placing In Service.......................................................................................................................................... 2-95

SECTION V - Preparation for Storage or Shipment

2-24 Preparation for Shipment .............................................................................................................................. 2-95
2-25 Storage Maintenance Procedures................................................................................................................. 2-95

2-1
 TM 10-3930-669-34

Section I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);
AND SUPPORT EQUIPMENT

2-1. COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA
50-970 or CTA 8-100, as applicable to your unit. Table 2-1 lists tool kits required and authorized for use at the
Direct/General Support Maintenance level. Reference code numbers listed in the first column correspond to those listed in
the same column on the Maintenance Allocation Chart (MAC).

Table 2-1. Authorized Direct/General Support Tool Kits

Tool Or Test
Equipment Maintenance Tool Kit
Ref Code Level Nomenclature Stock Number

1 O,F,H Tool kit, general mechanic’s: automotive 5180-00-177-7033

2 O,F,H Shop equipment, automotive maintenance and 4910-00-754-0654

repair: organizational maintenance common
no. 1, less power

9 O,F,H Shop equipment, automotive maintenance and 4910-00-754-0653

repair: organizational maintenance
supplemental no. 1, less power

5 O,F,H Shop equipment, automotive maintenance and 4910-00-754-0705

repair: field maintenance, basic

7 O,F,H Shop equipment, fuel and electrical system, 4910-00-754-0714

engine: field maintenance, basic

10 O,F,H Shop welding set 3433-00-357-6311

8 F,H Shop equipment, machine shop 3470-00-754-0708

2-2. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.

The Maintenance Allocation Chart (MAC) identifies the authority and responsibility for maintenance tasks listed in this
manual. Tool kits, test equipment, and diagnostic equipment required for performing maintenance tasks are also identified
in the MAC. The forklift Repair Parts and Special Tools List (RPSTL), TM 10-3930-669-24P, lists special tools, TMDE,
and support equipment required to perform maintenance procedures contained in this manual. Appendix E lists the tools
and test equipment required to perform maintenance procedures contained in this manual.

2-2
 TM 10-3930-669-34

2-3. REPAIR PARTS.

Repair parts are listed and illustrated in the Repair Parts and Special Tools List, TM 10-3930-669-24P, for maintenance of
this equipment.

Section II. SERVICE UPON RECEIPT

2-4. GENERAL SERVICE INSTRUCTIONS.

a. Refer to TM 10-3930-669-10 for operating instructions for the forklift.

b. Upon receipt of a new, used, or reconditioned forklift, the receiving organization must see if it has been properly
prepared for service and is in good condition (TM 10-3930-669-10). Inspect all assemblies, subassemblies, and
accessories to be sure they are in proper working order. Secure, clean, correctly adjust, and/or lubricate (LO 10-3930-
669-12) as needed.

c. Follow general procedures for all services and inspections given in TM 10-3930-669-10.

2-5. INSPECTION AND SERVICING EQUIPMENT.

NOTE

If forklift has been driven to the using organization, most or all of the following
work should have been done.

a. When forklift is received, inspect all items for damage that may have occurred during shipping and unloading
operations. Pay close attention to any loose or missing nuts, bolts, screws, access plates, drain plugs, draincocks, oil
plugs, assemblies, subassemblies, or components that may have been lost or broken in transit.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective

goggles and gloves; use only in a well-ventilated area; avoid contact with
skin, eyes, and clothes; and do not breathe vapors. Keep away from heat or
flame. Never smoke when using solvent; the flashpoint for type 1 dry-
cleaning solvent is 100'F (38°C) and for type II is 138'F (50'C). Failure to do so
may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get

fresh air and medical help. If solvent contacts skin or clothes, flush with cold
water. If solvent contacts eyes, immediately flush eyes with water and get
immediate medical attention.

b. Clean all exterior surfaces coated with rust-preventive compound with dry-cleaning solvent.

2-3
 TM 10-3930-669-34

2-5. INSPECTION AND SERVICING EQUIPMENT (CONT).

c. Lubricate specific points shown in LO 10-3930-669-12 regardless of interval. Do not lubricate gear cases or
engine. Check processing tag for gear case and engine oil. If tag states the oil is good for 500 miles (805 km) of
operation and is of the proper grade for local climatic operation, check oil level but do not change oil.

2-6. SPECIAL SERVICE INSTRUCTIONS.

a. Forklift Body and Panel Inspection.

(1) Inspect body and panels for evidence of damage during shipment.

(2) Check doors, latches, and hinges on compartments for proper operation.

(3) Check mounting hardware and tighten as necessary.

b. Forklift Cab Inspection.

(1) Inspect cab for evidence of damage during shipment.

(2) Inspect windshields and window glass for cracks or other damage.

(3) Check door latches, hinges, and windows for proper operation.

(4) Check seat and seat belts to ensure they are securely installed and that operator’s seat adjustment controls
are functioning properly.

c. Engine Inspection.

(1) Remove any seals, plugs, or tape used to seal air inlets and ports on the engine during shipping.

(2) Check crankcase oil level with dipstick.

(3) Examine air cleaner element for dirty or restricted condition.

(4) Inspect engine and cooling hose connections for evidence of leakage.

(5) Remove any obstruction of cooling air flow to cooling blower.

d. Transmission Inspection.

(1) Check fluid level with dipstick.

(2) Check external hoses and tubes for evidence of leakage.

2-4
 TM 10-3930-669-34

e. Electrical System Inspection.

(1) Inspect battery cable connections and clean and tighten as necessary.

(2) Check lights for burned out lamps, loose connections, and dirty or broken lenses.

(3) Ensure alternator is charging properly.

(4) Ensure all electrical equipment functions.

f. Steering System Inspection.

(1) Examine steering hoses and connections for evidence of leakage.

(2) Check steering system for proper operation during road test.

g. Tire Inspection.

(1) Inspect tires for serious cuts, bubbles, cracks, bruises, dry-rot, foreign objects, or exposure of internal cords.
Remove foreign objects lodged between treads.

(2) Check all wheel mounting nuts for proper torque (TM 10-3930-669-20).

h. Fuel System Inspection.

(1) Check fuel level and add fuel if necessary.

(2) Inspect fuel hoses, tubes, connections, and filters for evidence of leakage.

i. Hydraulic System Inspection.

(1) Check all hydraulic hoses, tubes, cylinders, and connections for evidence of leakage.

(2) Check mast assembly for proper operation (TM 10-3930-669-10).

Section III. TROUBLESHOOTING

2-7. TROUBLESHOOTING INTRODUCTION.

Troubleshooting contains step-by-step procedures for identifying a specific faulty component that is causing an equipment
malfunction (symptom). Not all possible malfunctions can be covered in the troubleshooting. Troubleshooting covers
malfunctions that are most likely to occur during the life expectancy of the forklift. Obvious mechanical failures and
damage are not covered.

2-5
 TM 10-3930-669-34

2-8. TROUBLESHOOTING INSTRUCTIONS.

NOTE

The troubleshooting makes use of the Simplified Test Equipment for Internal
Combustion Engines-Reprogrammable (STE/ICE-R) and conventional methods for
testing and fault isolation.

a. Simplified Test Equipment for Internal Combustion Engines Reprogrammable (STE/ICE-R). The forklift is
equipped with several STE/ICE-R sensors that are used to support troubleshooting procedures. STE/ICE-R tests,
employing these sensors, are incorporated into the standard troubleshooting test to aid in fault isolation. The STE/ICE-R
acts as a conventional digital multimeter to measure voltage, current, and resistance. It can also measure pressure,
speed, compression unbalance, engine power, and some specialized battery and starter evaluations. The STE/ICE-R is
powered by the forklift battery using an electrical harness called the Diagnostic Connector Assembly (DCA). The complete
system includes a test meter (VTM), cables, transit case, and technical publications. The STE/ICE-R can make TK
measurements while connected to the DCA. STE/ICE-R tests are referenced.

b. General Electrical Troubleshooting Procedures.

WARNING

Remove rings, bracelets, wristwatches, neck chains, etc., before working on any
vehicle. Jewelry can catch on equipment and cause injury, or may short across an
electrical circuit and cause severe burns or electrical shock.

CAUTION

Use proper sized test leads when checking for resistance, continuity, or voltage at
connectors or damage to equipment can result.

NOTE

• Multimeter leads must remain in contact with the circuit being tested for a
minimum of three seconds to obtain a reading.

• If your multimeter does not operate in the way described in the following
steps, learn how it operates before performing troubleshooting.

• The piece of electrical test equipment used will be referred to as the

"multimeter." The multimeter's red test lead will be referred to as the
"positive (+) multimeter lead." The multimeter's black test lead will be referred
to as the "negative (-) multimeter lead."

2-6
 TM 10-3930-669-34

(1) Resistance and Continuity Measurements.

(a) Connect positive (+) multimeter lead to multimeter VOLT-OHM connector. Connect negative (-)
multimeter lead to multimeter COM connector. When the multimeter leads are separated or are measuring a circuit with
no continuity, the multimeter will indicate "OL" (Over Limit) on its display. When multimeter leads are connected together,
multimeter should display "0," indicating a continuous circuit with no (zero) resistance.

(b) Set multimeter function/range switch to the desired ohm position. If the amount of the expected
resistance is not known, set the switch to the highest range, then reduce until a satisfactory reading is obtained. If only
continuity is to be checked, without regard to resistance, set the multimeter function/range switch to the highest ohm
range.

(c) Always turn the main power switch to the OFF position before connecting multimeter leads to a circuit
unless instructed to do otherwise in the troubleshooting procedure.

(d) Connect multimeter leads to the circuit being checked. The multimeter leads must only contact the
point of measurement to ensure an accurate reading.

(e) Read the resistance value displayed on the multimeter.

(f) Disconnect multimeter leads from circuit.

(g) Turn off multimeter.

(2) Voltage Measurements. The forklift is equipped with a 24-volt electrical system. Troubleshooting
procedures will reference 24 vdc measurements; however, these values can vary depending on battery conditions and if
the engine is running or not. If battery voltages are below 20 vdc, charge batteries.

(a) Connect positive (+) multimeter lead to multimeter VOLT-OHM connector. Connect negative (-)
multimeter lead to multimeter COM connector.

(b) Set the function/range switch to the setting closest to, but not below, 24 vdc. If multimeter is equipped
with a DC-AC switch, set the switch to the DC position. (c) Always turn the main power switch to the OFF position before
connecting multimeter leads to a circuit unless instructed to do otherwise in troubleshooting procedure.

(d) Connect the positive (+) multimeter lead to the circuit being tested. Connect the negative (-)
multimeter lead to a known good ground.

(e) Set main power switch to ON position and operate any other controls necessary to energize the circuit
being tested.

(f) Read the voltage value displayed on the multimeter.

(g) Set the main power switch to the OFF position. Return other controls to their "at rest" positions.

(h) Disconnect multimeter leads from circuit.

(i) Turn off multimeter.

2-7
 TM 10-3930-669-34

2-8. TROUBLESHOOTING INSTRUCTIONS (CONT).

(3) General Relay Troubleshooting Procedure. The following general relay troubleshooting procedure applies to
most relays that are pushed into a receptacle and do not require any attaching hardware.

(a) Pull relay out of receptacle just enough for the relay terminals to make contact with receptacle
terminals. Leave about 1/4 to 3/8 in. (6.35 to 9.53 mm) space between the relay and the receptacle to insert a multimeter
lead and make contact with the terminal listed in the troubleshooting test.

(b) Perform necessary test.

(4) General Wiring Harness Short Test. The following procedure applies to any wiring harness suspected of
being shorted. Refer to electrical schematics during this procedure.

(a) Connect positive (+) multimeter lead to multimeter VOLT-OHM connector. Connect negative (-)
multimeter lead to multimeter COM connector. When the multimeter leads are separated or are measuring a circuit with
no continuity, the multimeter will indicate "OL" (Over Limit) on its display. When multimeter leads are connected together,
multimeter should display "0," indicating a continuous circuit with no (zero) resistance. Wires in a harness that are not
purposely joined or connected at a component should not have continuity (multimeter indicates "OL").

(b) Set multimeter function/range switch to the highest OHM range.

(c) Disconnect harness connector.

(d) Connect positive (+) multimeter lead to harness connector terminal of suspected wire.

(e) Connect negative (-) multimeter lead to each of the remaining harness connector terminals. If
multimeter does not display "OL," and is displaying a resistance value of zero or higher, this indicates a continuous circuit.
Refer to the electrical schematic before repairing wires or replacing wiring harness to determine that the wires making a
continuous circuit are not purposely joined or are not connected intentionally at a component.

(f) Disconnect multimeter leads from connector.

(g) Turn off multimeter.

2-9. TROUBLESHOOTING SYMPTOMS.

The Troubleshooting Symptom Index (Table 2-3) lists the most common failure symptoms found during operation of the
forklift. Find the symptom that is closest to the symptom your forklift has and refer to that paragraph for the
troubleshooting procedure.

Table 2-2. Troubleshooting Symptom Index

Para Description Page

2-14 Engine System Troubleshooting.....................................................................................................2-10

2-15 Drive Axle Troubleshooting ............................................................................................................2-70

2-8
 TM 10-3930-669-34

2-10. TROUBLESHOOTING PROCEDURES.

Pages 2-16 through 2-93 contain troubleshooting instructions necessary to identify the faulty component causing the
symptom listed in Tables 2-3 and 2-4. Corrective action for repairing or replacing the faulty component is listed in the
troubleshooting procedure. Unit Maintenance troubleshooting procedures (TM 103930-669-20) should be completed
before performing Direct/General Support Maintenance troubleshooting procedures.

2-11. ENGINE SYSTEM TROUBLESHOOTING.

This paragraph covers Engine System Troubleshooting. The Engine System Fault Index, Table 2-4, lists faults for the
engine system of the forklift.

Table 2-3. Engine System Fault Index

Fault
No. Troubleshooting Procedure Page

1. Engine Cranks But Will Not Run........................................................................................................2-10

2. Low Engine Oil Pressure (Oil Pressure Gauge Continuously Reads Less
Than 30 to 60 psi [207 - 414 kPa] at 625 to 750 rpm) .......................................................................2-24

3. Excessive Engine Oil Consumption and/or Blue Smoke ...................................................................2-32

4. Excessive Black or Gray Smoke........................................................................................................2-38

5. Engine Overheats (Engine Temp Gauge Reads Over 250°F [121°C]) .............................................2-48

6. Engine Runs Rough or Misfires .........................................................................................................2-52

7. Engine Does Not Develop Full Power................................................................................................2-62

2-9
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

1. ENGINE CRANKS BUT WILL NOT RUN.

INITIAL SETUP

Tools and Special Tools Materials/Parts

Tool Kit, General Mechanic’s: Automotive Cap and Plug Set (Item 5, Appendix B)
(Item 1, Appendix E) Tags, Identification (Item 21, Appendix B)
Pressure Test Kit (Item 5, Appendix E) Rings, Retaining (2)
STE(Optional) (Item 14, Appendix E) Gasket
Gauge, Tester, Injection Pump
(Item 5, Appendix E) References
Retainer (Item 13, Appendix E) TM 10-3930-669-10
Hand Pump, High Pressure (Item 30, Appendix E) TM 10-3930-669-20

Equipment Condition
Personnel Required Engine OFF (TM 10-3930-669-10)
Two MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels chocked (TM 10-3930-669-10)

KNOWN INFO TEST OPTIONS

Nothing. Injection pump pressure test.

POSSIBLE PROBLEMS WARNING REASON FOR QUESTION

Read WARNING
Injection pump faulty. on Page 2-11 If injection pump is faulty,
Injection pump timing incorrect, engine will not run
Camshaft gear alignment
incorrect.
Low engine compression.
Cylinder head(s) or gasket(s)
faulty.
Piston crown clearance
incorrect. Replace Injection pump
Cylinder(s) faulty. (Para 4-5). Go to Step
Valve(s) or valve spring(s) 11 of this Fault
faulty.
Piston(s) faulty.
Piston ring(s) faulty.

2-10
 TM 10-3930-669-34

WARNING

• Fuel is very flammable and can explode easily. To avoid serious injury or
death, keep fuel away from open fire and keep fire extinguisher within easy
reach when working with fuel. Do not work on fuel system when engine is
hot. Fuel can be ignited by hot engine. When working with fuel, post signs
that read NO SMOKING WITHIN 50 FEET (15 m).

• Pressure test procedure results in fuel under high pressure. Be sure that
pressure test gauge is connected properly and use safety shield during test.
Failure to do so may result in injury to personnel.

INJECTION PUMP PRESSURE TEST

(1) Remove cab (TM 10-3930-669-20).

(2) Disconnect throttle cable (TM 10-3930-669-20).
(3) Position control lever to maximum position.
(4) Remove pump cover(Para (Para 4-5).
(5) Tag and disconnect injection pump injector lines one
at a time.
(6) Connect injection pump tester gauge to injection
pump port fitting.
(7) Install pressure plug in No. 1 injector line.
(8) Open bleeder valve on back of test gauge.
(9) With aid of an assistant using retainer, turn
crankshaft clockwise until pump element to be
tested is at the bottom of its stroke.
(10) Using pump lever, lift plunger to bleed air from
pressure gauge. Close bleeder valve.
(11) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 2,175 psi (14,997
kPa).
(12) Observe pressure gauge for 60 seconds.
(a) If 145 psi (1,000 kPa) or higher is not
measured, perform Steps (14) and (15)
below and replace injection pump(Para 4-5).
(b) If 145 psi (1,000 kPa) or higher is measured,
go to step (13) below.
(13) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 5,075 psi (34,992
kPa).
(a) If 5,075 psi (34,992 kPa) cannot be measured,
perform Steps (14) and (15) below and
replace injection pump(Para 4-5).
(b) If 5,075 psi (34,992 kPa) can be measured,
repeat steps (5) through (13) above for
remaining elements. If all elements are OK,
perform Steps (14) and (15) below and go to
Step 2 of this Fault.
(14) Remove injection pump tester gauge from pump
port fitting.
(15) Install pump cover.

2-11
 TM 10-3930-669-34

1. ENGINE CRANKS BUT WILL NOT RUN (CONT).

WARNING
Read WARNING
KNOWN INFO on Page 2-13 TEST OPTIONS

Injection pump OK. Injection pump timing check.

POSSIBLE PROBLEMS REASON FOR QUESTION

Injection pump timing incorrect. If injection pump timing is faulty,

Camshaft gear alignment engine will not run.
incorrect.
Low engine compression.
Cylinder head(s) or gasket(s) Adjust Injection pump
faulty. timing (Para 4-4). Go to
Piston crown clearance Step 11 of this Fault
incorrect.
Cylinder(s) faulty.
Valve(s) or valve spring(s)
faulty.
Piston(s) faulty.
Piston ring(s) faulty.

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If camshaft alignment is
Camshaft gear alignment incorrect, engine will not run.
incorrect. Allign camshaft
Low engine compression. (Para 3-16). Go to
Cylinder head(s) or gasket(s) Step 11 of this Fault.
faulty.
Piston crown clearance
incorrect.
Cylinder(s) faulty.
Valve(s) or valve spring(s)
faulty.
Piston(s) faulty.
Piston ring(s) faulty.

2-12
 TM 10-3930-669-34

WARNING

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work
on fuel system when engine is hot. Fuel can be ignited by hot engine. When working with fuel,
post signs that read NO SMOKING WITHIN 50 FEET (15 m).

INJECTION PUMP TIMING CHECK

Check injection pump timing (Para 4-4).

(a) If injection pump timing is incorrect, reset
timing.
(b) If injection pump timing is correct, go to
Step 3 of this Fault.

VISUAL INSPECTION

(1) Remove front cover (Para 3-10).

(2) Check timing marks on camshaft gear and
crankshaft gear.
(a) If timing marks are out of alignment,
match timing marks (Para 3-14).
(b) If timing marks are aligned correctly,
camshaft gear alignment is OK.
(3) Install front cover.

2-13
 TM 10-3930-669-34

1. ENGINE CRANKS BUT WILL NOT RUN (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Compression test.

Injection pump timing OK. STE/ICE-R #50.
Camshaft gear alignment OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If engine compression is low,
Low engine compression. engine will not run.
Cylinder head(s) or gasket(s)
faulty
Piston crown clearance
incorrect.
Cylinder(s) faulty.
Valve(s) or valve spring(s)
faulty.
Piston(s) faulty.
Piston ring(s) faulty.

2-14
 TM 10-3930-669-34

COMPRESSION TEST

(1) Remove one glow plug at a time in sequence (TM

10-3930-669-20).
(2) Connect a compression gauge to cylinder.
(3) With the aid of an assistant using retainer, crank
engine and observe pressure gauge.
(a) If less than 363 psi (2,500 kPa) is measured,
cylinder is faulty. Perform Step (4) and (5)
below and go to Step 5 of this Fault.
(b) If 363 to 435 psi (2,500 - 2,990 kPa) is
measured, repeat Steps (2) and (3) for
remaining cylinders. If all cylinders are OK,
fault not corrected. Perform Steps (4)
through (6) below and notify supervisor.
(4) Remove compression gauge from cylinder.
(5) Install glow plug.
(6) Install cab (TM 10-3930-669-20).

2-15
 TM 10-3930-669-34

1. ENGINE CRANKS BUT WILL NOT RUN (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK Visual inspection.

Injection pump timing OK.
Camshaft gear alignment OK. REASON FOR QUESTION
Engine compression OK.
If cylinder head(s) or gasket(s)
POSSIBLE PROBLEMS Is faulty, engine will not run.

Cylinder head(s) or gasket(s)

faulty. Replace cylinder
Piston crown clearance head(s) or gasket(s)
incorrect. (Para 3-5). Got to
Step 11 of this Fault.
Cylinder(s) faulty.
Valve(s) or valve spring(s)
faulty.
Piston(s) faulty.
Piston ring(s) faulty.

KNOWN INFO TEST OPTIONS

Adjust cylinder (Para
Injection pump OK. 3-7). Go to Step 11 Visual inspection.
Injection pump timing OK. of this Fault.
Camshaft gear alignment OK REASON FOR QUESTION
Engine compression OK.
Cylinder heads and gaskets OK. If piston crown clearance is
incorrect, engine will not run.
POSSIBLE PROBLEMS

Piston crown clearance

incorrect.
Piston(s) faulty.
Cylinder(s) faulty.
Valve(s) or valve spring(s)
faulty.
Piston(s) faulty.
Piston ring(s) faulty.

2-16
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Inspect suspect cylinder head(s).

(a) If leaks or cracks are found, go to Step (2)

below.
(b) If leaks or cracks are not found, perform
Steps (2) and (3) below and go to Step 6 of
this Fault.
(2) Remove cylinder head(s) (Para 3-5).
(3) Inspect cylinder head(s) and gasket(s).
(a) If cylinder head is cracked, replace cylinder
head(s).
(b) If cylinder head gasket(s) is damaged,
replace gasket(s).
(c) If cylinder heads and gaskets are not
cracked or damaged, cylinder heads and
gaskets are OK.

VISUAL INSPECTION

Measure piston crown clearance using a piece of

solder.
(a) If clearance is not 0.0040 to 0.0048 in. (1.0
1.2 mm), shim cylinder(s) to correct
clearance (Para 3-7).
(b) If clearance is 0.0040 to 0.048 in. (1 1.2
mm), piston crown clearance is OK.

2-17
 TM 10-3930-669-34

1. ENGINE CRANKS BUT WILL NOT RUN (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Camshaft gear alignment OK. REASON FOR QUESTION
Engine compression OK.
Cylinder heads and gaskets OK
Piston crown clearance OK. If cylinder(s) is faulty, engine will
not run.
POSSIBLE PROBLEMS
Replace cylinder(s) or
Cylinder(s) faulty.
engine (Para 3-7 of 3-3).
Valve(s) or valve spring(s) Go to Step 11 of this
faulty. Fault.
Piston(s) faulty.
Piston ring(s) faulty.

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Camshaft gear alignment OK. Replace valve(s) or valve REASON FOR QUESTION
Engine compression OK. spring(s) or cylinder head
Cylinder heads and gaskets OK. (Para 3-6 of 3-5). Go to
Cylinders OK. Step 11 of this Fault. If valves or valve springs are
Piston crown clearance OK. faulty, engine will not run.

POSSIBLE PROBLEMS

Valve(s) or valve spring(s)

faulty.
Piston(s) faulty.
Piston ring(s) faulty.

2-18

2-18
 TM 10-3930-669-34

VISUAL INSPECTION

Remove and inspect suspect cylinder(s) (Para 3-7).

(a) If cylinder(s) is cracked or fractured,
cylinder(s) is faulty. Replace cylinder(s) or
engine (Para 3-7 or 3-3).
(b) If cylinders are not damaged, cylinders are
OK.

VISUAL INSPECTION

(1) Remove valves from suspect cylinder

head(s) para 3-6).
(2) Inspect valves and springs for damage.
(a) If valve(s) and/or spring(s) is damaged,
replace valve(s) and/or spring(s) or cylinder
head(s) (Para 3-6 or 3-5).
(b) If valves and springs are not damaged,
valves and springs are OK.

2-19
 TM 10-3930-669-34

1. ENGINE CRANKS BUT WILL NOT RUN (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Camshaft gear alignment OK. REASON FOR QUESTION
Engine compression OK.
Cylinder heads and gaskets OK
Cylinder heads and gaskets OK. If piston(s) is faulty, engine will
Piston crown clearance OK. not run.
Valves and valve springs OK. Replace piston(s) or
engine (Para 3-13 or 3-
3). Go to Step 11 of this
POSSIBLE PROBLEMS Fault.

Piston(s) faulty.
Piston ring(s) faulty.

KNOWN INFO TEST OPTIONS

Replace piston rings or
Injection pump OK. engine (Para 3-13 or 3- Visual inspection.
Injection pump timing OK. 3). Go to Step 11 of
Camshaft gear alignment OK. the Fault. REASON FOR QUESTION
Engine compression OK.
Cylinder heads and gaskets OK.
Cylinders OK. If piston ring(s) is faulty, engine
Piston crown clearance OK will not run.
Valves and valve springs OK.
Pistons OK.-

POSSIBLE PROBLEMS

Piston ring(s) faulty.

2-20
 TM 10-3930-669-34

VISUAL INSPECTION

Inspect suspect piston(s) for damage.

(a) If piston(s) is damaged, replace
piston(s) or engine (Para 3-13 or 3-3).
(b) If pistons are not damaged, pistons
are OK

VISUAL INSPECTION

(1) Inspect inside of suspect cylinder(s) and

engine block for scoring.
(a) If there is scoring, piston rings are
faulty. Replace piston rings (Para 3-
13) and hone engine block and
cylinder(s) (Para 3-7) or replace
engine (Para 3-3).
(b) If there is no scoring, piston rings are
OK.
(2) Install cylinder(s) (Para 3-7).
(3) Install valves and springs (Para 3-6).
(4) Install cylinder head(s) (Para 3-5).
(5) Install engine cowling (TM 10-3930-669-10).
(6) Install cab (TM 10-3930-669-20).

2-21
 TM 10-3930-669-34

1. ENGINE CRANKS BUT WILL NOT RUN (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Verify repair.

Injection pump timing OK.
Camshaft gear alignment OK. REASON FOR QUESTION
Engine compression OK.
Cylinder heads and gaskets OK. If engine runs, fault has been
Cylinders OK. corrected.
Piston crown clearance OK.
Valves and valve springs OK.
Pistons OK.
Piston rings OK.

POSSIBLE PROBLEMS

2-22
 TM 10-3930-669-34

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(a) If engine does not start or is hard to
start, fault not corrected. Perform
Step (2) below and notify supervisor.
(b) If engine starts correctly, fault
corrected.
(2) Shut down engine.

2-23
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

2. LOW ENGINE OIL PRESSURE (OIL PRESSURE GAUGE CONTINUOUSLY READS LESS THAN 30 TO 60 PSI
[207 - 414 KPA] AT 625 TO 750 RPM).

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1, Appendix E)
Equipment Condition
Engine removed (Para 3-3)

KNOWN INFO TEST OPTIONS

Oil level OK. Visual inspection.

POSSIBLE PROBLEMS REASON FOR QUESTION

WARNING Read
WARNING on
Oil suction tube faulty. Page 2-25 If suction tube is faulty, engine
Oil tube faulty. oil pressure will be low.
Oil pump faulty.
Oil pump seal faulty.
Rod and main bearings faulty.
Rifle lines clogged.
Oil pump pressure valve
faulty.

(Para 3-12)

2-24
 TM 10-3930-669-34

Engine retains extreme heat when in operation. Allow time for cooling before performing
troubleshooting procedures. Failure to do so may result in injury to personnel.

VISUAL INSPECTION

(1) Remove oil pan (Para 3-8).

(2) Inspect oil suction tube, tube screen, and
connections.
(a) If oil suction tube is loose, tighten
connections (Para 3-12).
(b) If oil suction tube screen is clogged,
clean oil suction tube.
(c) If oil suction tube is damaged, replace
oil suction tube.
(d) If oil suction tube is secured, clean,
and not damaged, suction tube is OK.

2-25
 TM 10-3930-669-34

2. LOW ENGINE OIL PRESSURE (OIL PRESSURE GAUGE CONTINUOUSLY READS LESS THAN 30 TO 60 PSI
[207 - 414 KPA] AT 625 TO 750 RPM) (CONT).

KNOWN INFO TEST OPTIONS

Oil level OK. Visual inspection.

Oil suction tube OK.

POSSIBLE PROBLEMS REASON FOR QUESTION

Oil tube faulty.

Oil pump faulty. If oil tube is faulty, engine oil
Oil pump seal faulty. pressure will be low.
Rod and main bearings faulty
Rifle lines clogged.
Oil pump pressure valve
(Para 3-12)
faulty

KNOWN INFO TEST OPTIONS

Oil level OK. Visual inspection.

Oil suction tube OK.
Oil tube OK. REASON FOR QUESTION

POSSIBLE PROBLEMS If oil pump is faulty, engine oil

pressure will be low.
Oil pump faulty.
Oil pump seal faulty.
Rod and main bearings faulty.
Rifle lines clogged.
Oil pump pressure valve
faulty.

Replace oil pump or engine

(Para 3-12 or 3-3). Goo to
Step 7 of this Fault

2-26
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove front cover (Para 3-10).

(2) Inspect oil tube for damage and looseness.
(a) If oil tube is loose or damaged. tighten
connections or replace oil tube (Para 3-
12).
(b) If oil tube is not loose or damaged, oil
tube is OK.

VISUAL INSPECTION

(1) Set engine No. 1 piston to TDC (TM 10-3930-

669-20).
(3) Install guage and rotate engine 180’ (TM 10-
393-669-20) and measure oil pump gear
backlash.
(a) If gear backlash is not 0.0039 to 0.0079
in. (0.1-0.2 mm), replace oil pump or
engine (Para 3-12 or 3-3).
(b) If gear backlash is 0.0039 to 0.0079 in.
(0.1-0.2 mm), oil lube pump is OK.

2-27
 TM 10-3930-669-34

2. LOW ENGINE OIL PRESSURE (OIL PRESSURE GAUGE CONTINUOUSLY READS LESS THAN 30 TO 60 PSI
[207 - 414 KPA] AT 625 TO 750 RPM) (CONT).

KNOWN INFO TEST OPTIONS

Oil level OK Visual inspection.

Oil suction tube OK.
Oil tube OK REASON FOR QUESTION
Oil pump OK.
If oil pump seal is faulty. engine
POSSIBLE PROBLEM Soil pressure will below.

Oil pump seal faulty.

Rod and main bearings faulty.
Rifle lines clogged.
Replace oil pump
Oil pump pressure valve (Para 3-12). Go to
faulty. Step 7 of this Fault

KNOWN INFO TEST OPTIONS

Oil level OK. Visual inspection.

Oil suction tube OK.
Oil tube OK. REASON FOR QUESTION
Oil pump OK.
Oil pump seal OK.
If rod or main bearings are
faulty, engine oil pressure will
POSSIBLE PROBLEMS below.

Rod and main bearings faulty.

Rifle lines clogged.
Oil pump pressure valve
Replace faulty
faulty. bearings or
engine(para 3-3).
Go to Step 7 of this
Fault

2-28
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove oil pump (Para 3-12).

(2) Inspect oil pump seal.
(a) If pump seal is damaged, replace pump.
(b) If pump seal is not damaged, pump seal
is OK.

VISUAL INSPECTION

(1) Remove crankshaft (Para 3-14).

(2) Inspect rod and main bearings.
(a) If rod or main bearings are not within
limits, replace damaged bearings or
engine (Para 3-3).
(b) If rod or main bearings are within limits,
rod and main bearings are OK.

2-29
 TM 10-3930-669-34

2. LOW ENGINE OIL PRESSURE (OIL PRESSURE GAUGE CONTINUOUSLY READS LESS THAN 30 TO 60 PSI
[207 - 414 KPA] AT 625 TO 750 RPM) (CONT).

KNOWN INFO TEST OPTIONS

Oil level OK. Visual inspection.

Oil suction tube OK.
Oil tube OK. REASON FOR QUESTION
Oil pump OK.
Oil pump seal OK.
Rod and main bearings OK . If rifle lines are blocked, rifle
lines are faulty. If rifle lines are
POSSIBLE PROBLEMS not blocked, oil pump pressure
valve is faulty.
Rifle lines clogged.
Oil pump pressure valve
faulty.
Clean oil rifle lines
(Para 3-4). Go to
Step 7 of this
Fault.

Replace oil pump

(Para 3-12). Go to
Step 7 of this Fault.
KNOWN INFO TEST OPTIONS

Oil level OK. Verify repair.

Oil suction tube OK.
Oil tube OK. REASON FOR QUESTION
Oil pump OK.
Oil pump seal OK.
Rod and main bearings OK. If oil pressure gauge reads 30
Rifle lines OK. to 60 psi (207 - 414 kPa), fault
Oil pump pressure valve OK. has been corrected.

POSSIBLE PROBLEMS

2-30
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Inspect oil rifle lines in crankshaft, engine

block, and valve train.
(a) If oil rifle lines are clogged, clean all rifle
lines (Para 3-4).
(b) If oil rifle lines are not clogged, replace
oil pump (Para 3-12).
(2) Install crankshaft (Para 3-14).
(3) Install front cover (Para 3-10).
(4) Install oil pan (Para 3-8).

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Observe engine oil pressure gauge.
(a) If engine oil pressure is not 30 to 60 psi
(207 - 414 kPa), fault not corrected.
Perform Step (3) below and notify
supervisor.
(b) If engine oil pressure is 30 and 60 psi
(207 - 414 kPa), fault corrected.
(3) Shut down engine.

2-31
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

3. EXCESSIVE ENGINE OIL CONSUMPTION AND/OR BLUE SMOKE.

INITIAL SETUP

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1, Appendix E) TM 10-3930-669-20

Equipment Condition
Engine OFF (TM 10-3930-669-10)
MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels chocked (TM 10-3930-669-10)

KNOWN INFO TEST OPTIONS

WARNING
Nothing. ReadPage
WARNING
2-33
Visual inspection.
on Page 2-33
POSSIBLE PROBLEMS REASON FOR QUESTION

Missing oil plugs. If oil plugs are missing, oil

Cylinder head components leakage will result in excessive 4
faulty. engine oil consumption.
Piston oil control ring(s) faulty.
Front and/or rear oil seal(s)
faulty.

Install oil plug(s)

(Para 3-4). Go to
Step 5 of this Fault.

2-32
 TM 10-3930-669-34

Engine retains extreme heat when in operation. Allow time for cooling before performing
troubleshooting procedures. Failure to do so may result in injury to personnel.

VISUAL INSPECTION

Inspect engine for missing oil plug.

(a) If oil plug is missing, replace oil plug (Para 3-
4).
(b) If oil plug is not missing, oil plug is OK.

2-33
 TM 10-3930-669-34

3. EXCESSIVE ENGINE OIL CONSUMPTION AND/OR BLUE SMOKE (CONT).

KNOWN INFO TEST OPTIONS

Missing oil plugs Visual inspection.

POSSIBLE PROBLEMS REASON FOR QUESTION

Cylinder head components If cylinder head, valve, valve

faulty. guide or seals are faulty, oil
Piston oil control ring(s) faulty leakage will result in excessive
Front and/or rear oil seal(s) engine oil consumption.
faulty.

(Para 3-3).

KNOWN INFO TEST OPTIONS

Missing oil plugs. Visual inspection.

Cylinder head components OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If piston oil control ring is faulty,
Piston oil control ring(s) faulty. oil leakage will result in
Front and/or rear oil seal(s) excessive engine oil
faulty. consumption.

(Para 3-13 or 3-3).

2-34
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove intake and exhaust manifolds (Para 4-

2 and 5-2).
(2) Check inside of exhaust manifolds for leaking
oil.
(a) If there is oil present inside the exhaust
manifolds, go to Step (3) below.
(b) If there is no oil inside the exhaust
manifold, go to Step 4 of this Fault.
(3) Remove cylinder head (Para 3-5).
(4) Check cylinder head, valve, valve guides, and
seals for cracks and damage.
(a) If cylinder head components are
damaged, replace engine (Para 3-3).
(b) If cylinder head components are not
damaged, components are OK.

VISUAL INSPECTION

(1) Check for oil leakage past cylinder ports or

piston rings.
(a) If oil is leaking past cylinder ports or
piston rings, replace engine
(Para 3-3).
(b) If oil is not leaking past cylinder ports or
piston rings, perform Step (2) below and
go to Step 4 of this Fault.
(2) Install intake and exhaust manifolds
(Para 4-2 and 5-2).

2-35
 TM 10-3930-669-34

3. EXCESSIVE ENGINE OIL CONSUMPTION AND/OR BLUE SMOKE (CONT).

KNOWN INFO TEST OPTIONS

Missing oil plugs. Visual inspection.

Cylinder head components OK.
Piston oil control rings OK. REASON FOR QUESTION

POSSIBLE PROBLEMS If front and/or rear oil seal(s) is

faulty, oil leakage will result in
Front and/or rear oil seal(s) excessive engine oil
faulty. consumption.

Replace rear oil seal

(Para 3-14). Go to
Step 5 of this Fault

KNOWN INFO TEST OPTIONS

Missing oil plugs. Verify repair.

Cylinder head components OK.
Piston oil control rings OK. REASON FOR QUESTION
Front and rear oil seals OK.
If engine oil consumption is
POSSIBLE PROBLEMS normal, fault has been
corrected.

2-36
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Open left side rear access cover (TM 10-3930-

669-10).
(2) Inspect front crankshaft cover for oil leakage.
(a) If oil leakage is present, replace engine
(Para 3-3).
(b) If oil leakage is not present, go to Step
(3) below.
(3) Close left side rear access cover.
(4) Remove fuel/water separator bracket (TM 10-
3930-669-20).
(5) Inspect inside of flywheel housing for oil
leakage.
(a) If oil leakage is present, replace rear oil
seal (Para 3-14).
(b) If oil leakage is not present, rear oil seal
is OK.
(6) Install fuel/water separator bracket.

VERIFY REPAIR

Operate engine over the period of time specified in the

lubrication order (LO 10-3930-669-12).
(a) If engine oil consumption exceeds 10 quarts
per 250 hours of operation and/or blue smoke
is excessive, fault not corrected.
Notify supervisor.
(b) If engine oil consumption does not exceed 10
quarts per 250 hours of operation and blue
smoke is not excessive, fault corrected.

2-37
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

4. EXCESSIVE BLACK OR GREY SMOKE.

INITIAL SETUP

Tools and Special Tools Materials/Parts

Tool Kit, General Mechanic’s: Automotive Cap and Plug Set (Item 5, Appendix B)
(Item 1, Appendix E) Tag, Identification (Item 21, Appendix B)
Pressure Test Kit (Item 5, Appendix E)
STE/ICE-R (Optional) (Item 14, Appendix E) References
Gauge, Tester, Injection Pump TM 10-3930-669-10
(Item 5, Appendix E) TM 10-3930-669-20
Retainer (Item 13, Appendix E)

Equipment Condition
Personnel Required Engine OFF (TM 10-3930-669-10)
Two MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels chocked (TM 10-3930-669-10)

KNOWN INFO TEST OPTIONS

Page 2-39.
Nothing. Injection pump pressure test.

POSSIBLE PROBLEMS REASON FOR QUESTION

Injection pump faulty. If injection pump is faulty,

Injection pump timing incorrect. engine will exhaust black or 4
Low engine compression. grey smoke excessively.
Valves or valve springs faulty.
Piston ring(s) faulty.
(Para 4-5).

2-38
 TM 10-3930-669-34

• Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel.
Do not work on fuel system when engine is hot. Fuel can be ignited by hot engine. When
working with fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

• Pressure test procedure results in fuel under high pressure Be sure that pressure test
gauge is connected properly and use safety shield during test. Failure to do so may result
in injury to personnel.

INJECTION PUMP PRESSURE TEST

(1)Remove cab (TM 10-3930-669-20).

(2)Disconnect throttle cable (TM 10-3930-669-
20).
(3) Position control lever to maximum position.
(4) Remove pump cover (Para 4-5).
(5) Tag and disconnect injection pump injector line
one at a time.
(6) Connect injection pump tester gauge to
injection pump port fitting.
(7) Install pressure plug in No. 1 injector line.
(8) Open bleeder valve on back of test gauge.
(9) With aid of an assistant using retainer, turn
crankshaft clockwise until pump element to be
tested is at the bottom of its stroke.
(10) Using pump lever, lift plunger to bleed air from
pressure gauge. Close bleeder valve.
(11) Hold shutoff solenoid in open position and
pump lever until pressure gauge reads 2,175
psi (14,997 kPa).
(12) Observe pressure gauge for 60 seconds.
(a) If 145 psi (1,000 kPa) or higher is not
measured, perform Steps (14) and (15)
below and replace injection pump (Para 4-
5).
(b) If 145 psi (1,000 kPa) or higher is measured,
go to step (13) below.
(13) Hold shutoff solenoid in open position and
pump lever until pressure gauge reads 5,075
psi (34,992 kPa).
(a) If 5,075 psi (34,992 kPa) cannot be
measured, perform Steps (14) and (15)
below and replace injection pump (Para 4-
5).
(b) If 5,075 psi (34,992 kPa) can be measured,
repeat steps (5) through (13) above for
remaining elements. If all elements are OK,
perform Steps (14) and (15) below and go to
Step 2 of this Fault.
(14) Remove injection pump tester gauge from
pump port fitting.
(15) Install pump cover.

2-39
 TM 10-3930-669-34

4. EXCESSIVE BLACK OR GREY SMOKE (CONT).

KNOWN INFO TEST OPTIONS

Page 2-41.

Injection pump OK. Injection pump timing check.

POSSIBLE PROBLEMS REASON FOR QUESTION

Injection pump timing incorrect. If injection pump timing is fault y,

Low engine compression. engine will exhaust black or
Valves or valve springs faulty. grey smoke excessively.
Piston ring(s) faulty.

(Para 4-4).

2-40
 TM 10-3930-669-34

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work
on fuel system when engine is hot. Fuel can be ignited by hot engine. When working with fuel,
post signs that read NO SMOKING WITHIN 50 FEET (15 m).

INJECTION PUMP TIMING CHECK

Check injection pump timing

(Para 4-4).
(a) If injection pump timing is incorrect, reset
timing.
(b) If injection pump timing is correct, go to Step 3
of this Fault.

2-41
 TM 10-3930-669-34

4. EXCESSIVE BLACK OR GREY SMOKE (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Compression test.

Injection pump timing OK. STE/ICE-R #50.

POSSIBLE PROBLEMS REASON FOR QUESTION

Low engine compression. If engine compression is low,

Valves or valve springs faulty. engine will exhaust black or
Piston ring(s) faulty. grey smoke excessively.

2-42
 TM 10-3930-669-34

COMPRESSION TEST

(1) Remove engine blower ducting (Para 6-2).

(2) Disconnect fuel shutoff solenoid connector P
10.
(3) Remove glow plug from each cylinder in
sequence to perform compression test (TM 10-
3930-669-20).
(4) Install compression test gauge in each cylinder
in sequence to perform test.
(5) With the aid of an assistant, crank engine and
observe compression test gauge installed in
each cylinder in sequence.
(a) If less than 363 psi (2,500 kPa) is
measured, cylinder is faulty. Perform
Steps (6) through (8) below and go to
Step 4 of this Fault.
(b) If 363 psi (2,500 kPa) or greater is
measured, perform Steps (6) through
(8) below and go to Step 5 of this Fault.
(6) Remove compression test gauge from cylinder
when test is complete.
(7) Install engine glow plugs (TM 10-3930-669-
20).
(8) Connect fuel shutoff solenoid connector P10.

2-43
 TM 10-3930-669-34

4. EXCESSIVE BLACK OR GREY SMOKE (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Engine compression OK. REASON FOR QUESTION

POSSIBLE PROBLEMS If valves or valve springs are

faulty, engine will exhaust black
Valves or valve springs faulty. or grey smoke excessively.
Piston ring(s) faulty.

(Para 3-6 or 3-5).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Engine compression OK. REASON FOR QUESTION
Valves and valve springs OK.
If piston ring(s) is faulty, engine
Possible problems will exhaust black or grey smoke
. excessively.
Piston ring(s) faulty.

(Para 3-7 and

3-13 or 3-13

2-44
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove valves from suspect cylinder head(s)

(Para 3-6).
(2) Inspect valves and springs for damage.
(a) If valve(s) and/or spring(s) is
damaged, replace valve(s) and/or
spring(s) or cylinder head(s) (Para
3-6 or 3-5).
(b) If valves and springs are not
damaged, valves and springs are
OK.

VISUAL INSPECTION

(1) Inspect inside of suspect cylinder(s) and engine

block for scoring.
(a) If there is scoring, piston rings faulty.
Replace piston rings (Para 3-13) and
cylinder(s) (Para 3-17) or replace
engine (Para 3-3).
(b) If there is no scoring, go to Step (2)
below.
(2) Measure trapezoidal, taper-faced, and oil control
rings (Table 3-1).
(a) If piston ring(s) is not within limits,
replace piston ring(s).
(b) If piston rings are within limits,
piston rings are OK.
(3) Install cylinder(s) (Para 3-7).
(4) Install valves and springs (Para 3-6).
(5) Install cylinder head(s) (Para 3-5).
(6) Install engine blower ducting (Para 6-2).
(7) Install cab (TM 10-3930-669-20).

2-45
 TM 10-3930-669-34

4. EXCESSIVE BLACK OR GREY SMOKE (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Verify repair.

injection pump timing OK.
Engine compression OK. REASON FOR QUESTION
Valves and valve springs OK.
Piston ring(s) OK.
If engine does not exhaust black or
gray smoke excessively, fault has
POSSIBLE PROBLEMS been corrected.

2-46
 TM 10-3930-669-34

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(a) If exhaust smoke is excessive and
black or gray in color, fault not
corrected. Perform Step (2) below
and notify supervisor.
(b) If exhaust smoke is normal in
quantity and color, fault has been
corrected
(2) Shut down engine.

2-47
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

5. ENGINE OVERHEATS (ENGINE TEMP GAUGE READS OVER 250°F [121°C]).

INITIAL SETUP

Tools and Special Tools Materials/Parts

Tool Kit, General Mechanic’s: Automotive Tags, Identification (Item 21, Appendix B)
(Item 1, Appendix E)
Pressure Test Kit (Item 5, Appendix E) References
Gauge, Tester, Injection Pump TM 10-3930-669-10
(Item 5, Appendix E) TM 10-3930-669-20
Retainer (Item 13, Appendix E)
STE/ICE-R (Optional) (Item 14, Appendix E)
Equipment Condition
Personnel Required Engine OFF (TM 10-3930-669-10)
Two MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels chocked (TM 10-3930-669-10)

KNOWN INFO
WARNING
Read WARNING TEST OPTIONS
Engine oil level OK. on Page 2-49
Injection pump pressure test.
POSSIBLE PROBLEMS
REASON FOR QUESTION

Injection pump faulty.

Injection pump timing incorrect. If injection pump is faulty,
engine will overheat.
Replace
injection(Para 4-5).
Go to Step 3 of this
Fault

2-48
 TM 10-3930-669-34

WARNING

• Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel. Do
not work on fuel system when engine is hot. Fuel can be ignited by hot engine. When
working with fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

• Pressure test procedure results in fuel under high pressure. Be sure that pressure test
gauge is connected properly and use safety shield during test. Failure to do so may result in
injury to personnel.

INJECTION PUMP PRESSURE TEST

(1) Remove cab (TM 10-3930-669-20).

(2) Disconnect throttle cable (TM 10-3930-669-20).
(3) Position control lever to maximum position (4)
Remove pump cover (Para 4-5).
(5) Tag and disconnect injection pump injector line
one at a time.
(6) Connect injection pump tester gauge to injection
pump port fitting.
(7) Install pressure plug in No. 1 injector line.
(8) Open bleeder valve on back of test gauge.
(9) With aid of an assistant using retainer, turn
crankshaft clockwise until pump element to be tested is
at the bottom of its stroke.
(10) Using pump lever, lift plunger to bleed air from
pressure gauge. Close bleeder valve.
(11) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 2,175 psi (14,997 kPa).
(12) Observe pressure gauge for 60 seconds.
(a) If 145 psi (1,000 kPa) or higher is
not measured, perform Steps (14)
and (15) below and replace
injection pump (Para 4-5).
(b) If 145 psi (1,000 kPa) or higher is
measured, go to step (13) below.
(13) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 5,075 psi (34,992 kPa).
(a) If 5,075 psi (34,992 kPa) cannot be
measured, perform Steps (14) and
(15) below and replace injection
pump (Para 4-5).
(b) If 5,075 psi (34,992 kPa) can be
measured, repeat steps (5) through
(13) above for remaining elements.
If all elements are OK, perform
Steps (14) and (15) below and go
to Step 2 of this Fault.
(14) Remove injection pump tester gauge from pump
port fitting.
(15) Install pump cover.

2-49
 TM 10-3930-669-34

5. ENGINE OVERHEATS (ENGINE TEMP GAUGE READS OVER 250°F [121°C]) (CONT).

KNOWN INFO WARNING TEST OPTIONS

Read WARNING
on Page 2-51
Engine oil level OK Injection pump timing check.
Injection pump OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If Injection pump timing is faulty,
Injection pump timing incorrect. engine will overheat.

Adjust injection
pump timing (Para
4-4). Go to Step of
this Fault

KNOWN INFO TEST OPTIONS

Engine oil level OK. Verify repair.

Injection pump OK. REASON FOR QUESTION
Injection pump timing OK
If engine does not overheat,
POSSIBLE PROBLEMS fault has been corrected.

2-50
 TM 10-3930-669-34

WARNING

Fuel is very flammable and can

explode easily. To avoid serious
injury or death, keep fuel away from
open fire and keep fire extinguisher
within easy reach when working with
fuel. Do not work on fuel system
when engine is hot. Fuel can be
ignited by hot engine. When working
with fuel, post signs that read NO
SMOKING WITHIN 50 FEET (15 m).

INJECTION PUMP TIMING CHECK

Check injection pump timing (Para 4-4).

(a) If injection pump timing is incorrect, reset timing.
(b) If injection pump timing is correct, go to Step 3 of
this Fault.

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Operate forklift and observe engine temperature
gauge.
(a) If engine temperature does not go
over 250’F (121’C), fault corrected.
Perform Step (3) below.
(b) If engine temperature goes over
250’F (121 ’C), fault not corrected.
Perform Step (3) below and notify
supervisor.
(3) Shut down engine.

2-51
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

6. ENGINE RUNS ROUGH OR MISFIRES.

INITIAL SETUP

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1, Appendix E) TM 10-3930-669-20
Pressure Test Kit (Item 5, Appendix E)
STE(Optional) (Item 14, Appendix E)
Retainer (Item 13, Appendix E) Equipment Condition
Engine OFF (TM 10-3930-669-10)
MAIN POWER switch OFF (TM 10-3930-669-10)
Personnel Required Parking brake applied (TM 10-3930-669-10)
Two Wheels chocked (TM 10-3930-669-10)

Materials/Parts
Cap and Plug Set (Item 5, Appendix B)
Tags, Identification (Item 21, Appendix B)

KNOWN INFO TEST OPTIONS

WARNING
Read WARNING
Nothing. on Page 2-53 Injection pump pressure test.

POSSIBLE PROBLEMS REASON FOR QUESTION

Injection pump faulty. If injection pump is faulty,

Injection pump timing incorrect. engine will run rough or misfire
Low engine compression.
Cylinder head(s) or gasket(s)
faulty.
Camshaft faulty.
Replace injection
(Para 4-5). Go to
Step 5 of this Fault

2-52
 TM 10-3930-669-34

WARNING

• Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel. Do
not work on fuel system when engine is hot. Fuel can be ignited by hot engine. When
working with fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

• Pressure test procedure results in fuel under high pressure. Be sure that pressure test
gauge is connected properly and use safety shield during test. Failure to do so may result in
injury to personnel.

INJECTION PUMP PRESSURE TEST

(1) Remove cab (TM 10-3930-669-20).

(2) Disconnect throttle cable (TM 10-3930-669-20).
(3) Position control lever to maximum position.
(4) Remove pump cover (Para 4-5).
(5) Tag and disconnect injection pump injector line
one at a time.
(6) Connect injection pump tester gauge to injection
pump port fitting.
(7) Install pressure plug in No. 1 injector line.
(8) Open bleeder valve on back of test gauge.
(9) With aid of an assistant using retainer, turn
crankshaft clockwise until pump element to be tested is
at the bottom of its stroke.
(10) Using pump lever, lift plunger to bleed air from
pressure gauge. Close bleeder valve.
(11) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 2,175 psi (14,997 kPa).
(12) Observe pressure gauge for 60 seconds.
(a) If 145 psi (1,000 kPa) or higher is
not measured, perform Steps (14)
and (15) below and replace
injection pump (Para 4-5).
(b) If 145 psi (1,000 kPa) or higher is
measured, go to step (13) below.
(13) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 5,075 psi (34,992 kPa).
(a) If 5,075 psi (34,992 kPa) cannot be
measured, perform Steps (14) and
(15) below and replace injection
pump (Para 4-5).
(b) If 5,075 psi (34,992 kPa) can be
measured, repeat steps (5) through
(13) above for remaining elements.
If all elements are OK, perform
Steps (14) and (15) below and go
to Step 2 of this Fault,
(14) Remove injection pump tester gauge from pump
port fitting.
(15) Install pump cover.

2-53
 TM 10-3930-669-34

6. ENGINE RUNS ROUGH OR MISFIRES (CONT).

KNOWN INFO WARNING TEST OPTIONS

Read WARNING
Injection pump OK. on Page 2-55 Injection pump timing check.

POSSIBLE PROBLEMS REASON FOR QUESTION

Injection pump timing incorrect. If injection pump timing is faulty,

Low engine compression. engine will run rough or misfire.
Cylinder head(s) or gasket(s)
faulty.
Camshaft faulty.
Adjust injection
(Para 4-4). Go to
Step 6 of this Fault

2-54
 TM 10-3930-669-34

WARNING

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work
on fuel system when engine is hot. Fuel can be ignited by hot engine. When working with fuel,
post signs that read NO SMOKING WITHIN 50 FEET (15 m).

INJECTION PUMP TIMING CHECK

Check injection pump timing (Para 4-4).

(a) If injection pump timing is incorrect, reset timing.
(b) If injection pump timing is correct, go to Step 3 of
this Fault.

2-55
 TM 10-3930-669-34

6. ENGINE RUNS ROUGH OR MISFIRES (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Compression test.

Injection pump timing OK. STE/ICE-R #50.

POSSIBLE PROBLEMS REASON FOR QUESTION

Low engine compression. If engine compression is low,

Cylinder head(s) or gasket(s) engine will run rough or misfire.
faulty.
Camshaft faulty.

2-56
 TM 10-3930-669-34

COMPRESSION TEST

(1) Remove one glow plug at a time in sequence

(TM 10-3930-669-20).
(2) Connect a compression gauge to cylinder.
(3) With the aid of an assistant using retainer, crank
engine and observe pressure gauge.
(a) If less than 363 psi (2,500 kPa) is
measured, cylinder is faulty.
Perform Step (4) and (5) below and
go to Step 4 of this Fault.
(b) If 363 to 435 psi (2,500 - 2,990
kPa) is measured, repeat Steps (2)
through (4) for remaining cylinders.
If all cylinders are OK, fault not
corrected. Perform Steps (4)
through (6) below and notify
supervisor.
(4) Remove compression gauge from cylinder.
(5) Install glow plug.
(6) Install cab (TM 10-3930-669-20).

2-57
 TM 10-3930-669-34

6. ENGINE RUNS ROUGH OR MISFIRES (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Engine compression OK. REASON FOR QUESTION

POSSIBLE PROBLEMS If cylinder head(s) or gasket(s)

is faulty, engine will not run.
Cylinder head(s) or gasket(s)
faulty.
Replace cylinder
Camshaft faulty, head(s) or gasket(s)
(Para 3-5). Go to
Step 6 of this Fault.

2-58
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Inspect suspect cylinder head(s).

(a) If leaks or cracks are found, go to
Step (2) below.
(b) If leaks or cracks are not found,
perform Steps (2) and (3) below
and go to Step 6 of this Fault.
(2) Remove cylinder head (s) (Para 3-5).
(3) Inspect cylinder head(s) and gasket(s).
(a) If cylinder head is cracked, replace
cylinder head(s).
(b) If cylinder head gasket(s) is
damaged, replace gasket(s).
(c) If cylinder heads and gaskets are not cracked or
damaged, cylinder heads and gaskets are OK.

2-59
 TM 10-3930-669-34

6. ENGINE RUNS ROUGH OR MISFIRES (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Injection pump timing OK.
Engine compression OK. REASON FOR QUESTION
Cylinder head(s) or gasket(s)
OK. If camshaft alignment is
incorrect or faulty, engine will
POSSIBLE PROBLEMS run rough or misfire

Camshaft faulty. Align or replace

camshaft or replace
engine (Para 3-16
or 3-3). Go to Step 6
of this Fault.

KNOWN INFO TEST OPTIONS

Injection pump OK. Verify repair.

Injection pump timing OK.
Engine compression OK. REASON FOR QUESTION
Cylinder head(s) and gasket(s)
OK.
Camshaft OK. If engine does not run rough or
misfire, fault has been
corrected.
POSSIBLE PROBLEMS

2-60
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove engine front cover (Para 3-10).

(2) Check timing marks on camshaft gear and
crankshaft gear.
(a) If timing marks are out of alignment,
match timing marks (Para 3-16).
(b) If timing marks are aligned correctly,
go to Step (3) below.
(3) Measure camshaft limits
(a) If camshaft is not within limits, replace
camshaft or engine (Para 3-16 or 3-3).
(b) If camshaft is within limits,
camshaft is OK.
(4) Install engine front cover.

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Operate forklift and listen to engine operation.
(a) If engine does not run rough or
misfire, fault not corrected.
Perform Step (3) below.
(b) If engine runs rough or misfires,
fault not corrected. Perform Step
(3) below and notify supervisor (3)
Shut down engine.

2-61
 TM 10-3930-669-34

2-11. ENGINE SYSTEM TROUBLESHOOTING (CONT).

7. ENGINE DOES NOT DEVELOP FULL POWER.

INITIAL SETUP

Tools and Special Tools Materials/Parts

Tool Kit, General Mechanic’s: Automotive Cap and Plug Set (Item 5, Appendix B)
(Item 1, Appendix E) Tags, Identification (Item 21, Appendix B)
Pressure Test Kit (Item 5, Appendix E)
Gauge, Tester, Injection Pump References
(Item 5, Appendix E) TM 10-3930-669-10
STE(Optional) (Item 14, Appendix E) TM 10-3930-669-20

Personnel Required
Two Equipment Condition
Engine OFF (TM 10-3930-669-10)
MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels chocked (TM 10-3930-669-10)

KNOWN INFO TEST OPTIONS

WARNING
Nothing. Read WARNING Injection pump pressure test.
on Page 2-63

POSSIBLE PROBLEMS REASON FOR QUESTION

Injection pump faulty. If injection pump is faulty

Low engine compression. engine will not develop full
Cylinder head(s) or gasket(s) power.
faulty.
Valves or valve springs faulty.

Replace injection(Para 4-5).

Go to Step 5 of this Fault

2-62
 TM 10-3930-669-34

WARNING

• Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel Do
not work on fuel system when engine is hot. Fuel can be ignited by hot engine When
working with fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

• Pressure test procedure results in fuel under high pressure Be sure that pressure test gauge
is connected properly and use safety shield during test. Failure to do so may result in injury
to personnel

INJECTION PUMP PRESSURE TEST

(1) Remove cab (TM 10-3930-669-20)

(2) Disconnect throttle cable (TM 10-3930-669-20).
(3) Position control lever to maximum position
(4) Remove pump cover (Para 4-5)
(5) Tag and disconnect injection pump injector line
one at a time.
(6) Connect injection pump tester gauge to injection
pump port fitting.
(7) Install pressure plug in No. 1 injector line.
(8) Open bleeder valve on back of test gauge.
(9) With aid of an assistant using retainer, turn
crankshaft clockwise until pump element to be tested is
at the bottom of its stroke.
(10) Using pump lever, lift plunger to bleed air from
pressure gauge. Close bleeder valve.
(11) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 2,175 psi (14,997 kPa).
(12) Observe pressure gauge for 60 seconds.
(a) If 145 psi (1,000 kPa) or higher is
not measured, perform Steps (14)
and (15) below and replace
injection pump (Para 4-5).
(b) If 145 psi (1,000 kPa) or higher is
measured, go to step (13) below.
(13) Hold shutoff solenoid in open position and pump
lever until pressure gauge reads 5,075 psi (34,992 kPa).
(a) If 5,075 psi (34,992 kPa) cannot be
measured, perform Steps (14) and
(15) below and replace injection
pump (Para 4-5).
(b) If 5,075 psi (34,992 kPa) can be
measured, repeat steps (5) through
(13) above for remaining elements.
If all elements are OK, perform
Steps (14) and (15) below and go
to Step 2 of this Fault
(14) Remove injection pump tester gauge from pump
port fitting.
(15) Install pump cover.

2-63
 TM 10-3930-669-34

7. ENGINE DOES NOT DEVELOP FULL POWER (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Compression test.

STE/ICE-R #50.
POSSIBLE PROBLEMS
REASON FOR QUESTION
Low engine compression.
Cylinder head(s) or gasket(s) If engine compression is low,
faulty. engine will not develop full
Valves or valve springs faulty. power.

2-64
 TM 10-3930-669-34

COMPRESSION TEST

(1) Remove one glow plug at a time in sequence

(TM 10-3930-669-20).
(2) Connect a compression gauge to cylinder.
(3) With the aid of an assistant using retainer, crank
engine and observe pressure gauge.
(a) If less than 363 psi (2,500 kPa) is
measured, cylinder is faulty.
Perform Step (4) and (5) below and
go to Step 3 of this Fault.
(b) If 363 to 435 psi (2,500 - 2,990
kPa) is measured, repeat Steps (2)
through (4) for remaining cylinders.
If all cylinders are OK, fault not
corrected. Perform Steps (4)
through (6) below and notify
supervisor.
(4) Remove compression gauge from cylinder.
(5) Install glow plug.
(6) Install cab (TM 10-3930-669-20).

2-65
 TM 10-3930-669-34

7. ENGINE DOES NOT DEVELOP FULL POWER (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK. Visual inspection.

Engine compression OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If cylinder head(s) or gasket(s)
Cylinder head(s) or gasket(s) is faulty, engine will not run.
faulty.
Valves or valve springs faulty. Replace cylinder
head(s) or gasket(s)
(Para 3-5). Go to
Step 5 of this Fault

2-66
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Inspect suspect cylinder head(s).

(a) If leaks or cracks are found, go to
Step (2) below.
(b) If leaks or cracks are not found,
perform Steps (2) and (3) below
and go to Step 6 of this Fault.
(2) Remove cylinder head(s) Para 3-5(Para 3-5).
(3) Inspect cylinder head(s) and gasket(s).
(a) If cylinder head is cracked, replace
cylinder head(s).
(b) If cylinder head gasket(s) is
damaged, replace gasket(s).
(c) If cylinder heads and gaskets are
not cracked or damaged, cylinder
heads and gaskets are OK.

2-67
 TM 10-3930-669-34

7. ENGINE DOES NOT DEVELOP FULL POWER (CONT).

KNOWN INFO TEST OPTIONS

Injection pump OK Visual inspection.

Engine compression OK.
Cylinder heads and gaskets OK. REASON FOR QUESTION

POSSIBLE PROBLEMS If valve(s) or valve Spring(s) are

faulty, engine will not develop
Valves or valve springs faulty. full power.

Replace valve(s) or
valve spring(s)
or cylinder head
(Para 3-6 or 3-5).
Go to Step 5 of this
Fault.

KNOWN INFO TEST OPTIONS

Injection pump OK. CAUTION Verify repair.

Engine compression OK. Read CAUTION STE/ICE-R #12.
Cylinder heads and gaskets OK. on Page 2-69.
Valves and valve springs OK REASON FOR QUESTION

POSSIBLE PROBLEMS If engine develops full power.

fault has been corrected.

2-68
 TM 10-3930-669-34
CAUTION

Engine idle speed must be checked prior to performing power test. If idle speed is not within
limits specified for vehicle:

• Adjust idle speed to be within proper limits.

• Do not run power test if idle speed cannot be properly adjusted.

• To prevent damage to equipment, allow engine to idle at least two minutes after performing power test.

.
VISUAL INSPECTION

(1) Remove valves from suspect cylinder head(s)

(Para 3-6).
(2) Inspect valves and springs for damage.
(a) If valve(s) and or spring(s) is damaged,
replace valve(s) and/or spring(s) or
cylinder head(s) (Para 3-6 or 3-5).
(b) If valves and springs are not damaged,
valves and springs are OK.

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Operate forklift with a standard load and observe
operation.
(a) If engine does not develop full power, fault
not corrected. Perform Step (3) below and
notify supervisor.
(b) If engine develops full power, fault corrected.
Perform Step (3) below.
(3) Shut down engine

2-69
 TM 10-3930-669-34

2-12. DRIVE AXLE TROUBLESHOOTING.

This paragraph covers the Drive Axle Troubleshooting. The Drive Axle Fault Index, Table 2-5, lists faults for the drive axle
of the forklift.

Table 2-5. Drive Axle Fault Index

Fault Page
Number Troubleshooting Procedure Number

1. Drive Axle Noise Same Under Power And Coast.............................................................. 2-72

2. Drive Axle Noise Greater Under Power Than During Coast ... ......... ............................... 2-76

3. Drive Axle Noise Greater During Coast Than Under Power ............ ................................ 2-80

4. Drive Axle Engaging Harshly When Switching Direction .................................................. 2-84

2-70
 TM 10-3930-669-34

THIS SPACE INTENTIONALLY LEFT BLANK

2-71
 TM 10-3930-669-34

2-12. DRIVE AXLE TROUBLESHOOTING (CONT.).

1. DRIVE AXLE NOISE SAME UNDER POWER AND COAST.

INITIAL SETUP

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1, Appendix E)
Equipment Condition
Engine OFF (TM 10-3930-669-10)
MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels choked (TM 10-3930-669-10)

KNOWN INFO TEST OPTIONS

Visual inspection.
Nothing. REASON FOR QUESTION
If wheel bearing are faulty, drive axle
POSSIBLE PROBLEMS will be unusually noisy under power
and during coasting.
Wheel bearing faulty.

(Para 9-2).

2-72
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove wheel hub (Para(Para 9-2). 9-2)

(2) Remove wheel bearings and races.
(3) Inspect wheel bearings for pitting and wear.
Inspect races for nicks and cracks.
(a) If bearings or races are damaged, replace
bearings.
(b) If bearings and races are not damaged,
fault not corrected. Perform Step (4) below
and notify supervisor.
(4) Install wheel hub.

2-73
 TM 10-3930-669-34

1. DRIVE AXLE NOISE SAME UNDER POWER AND COAST (CONT.).

TEST OPTIONS
KNOWN INFO
Wheel bearing OK. Verify repair.
POSSIBLE PROBLEMS
REASON FOR QUESTION
If drive axle is not unusually noisy under
power and during coasting fault has
been corrected.

(Para 10-2).

2-74
 TM 10-3930-669-34

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Operate forklift and listen for unusual noise from drive
axle.
(a) If drive axle is unusually noisy under power and
during coasting, fault not corrected. Perform Step
(3) below and replace drive axle (Para 10-2).
(b) If drive axle is not unusually noisy under power and
during coasting, fault corrected.
(3) Shut down engine.

2-75
 TM 10-3930-669-34

2-12. DRIVE AXLE TROUBLESHOOTING (CONT.).

2. DRIVE AXLE NOISE GREATER UNDER POWER THAN DURING COAST.

INITIAL SETUP

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1, Appendix E)
Equipment Condition
Engine OFF (TM 10-3930-669-10)
MAIN POWER switch OFF (TM 10-3930-669-10)
Parking brake applied (TM 10-3930-669-10)
Wheels choked (TM 10-3930-669-10)

TEST OPTIONS
KNOWN INFO.
Visual inspection.
Nothing.
REASON FOR QUESTION
POSSIBLE PROBLEMS

Ring gear and pinion assembly faulty. If ring gear is faulty, drive axle will be
Planetary gears and/ or bearing faulty. noisier under power than during coasting.

(Para 10-2).
(Para
(para 10-
10-2).

2-76
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove differential housing cover (Para 10-4).

(2) Inspect ring gear for cracks, chips, and uneven
wear.
(a) If ring gear is damaged, replace drive axle
(Para 10-2).
(b) If ring gear is not damaged, ring gear and
pinion assembly is OK.
(3) Install differential housing cover.

2-77
 TM 10-3930-669-34

2. DRIVE AXLE NOISE GREATER UNDER POWER THAN DURING COAST (CONT.).

TEST OPTIONS
KNOWN INFO
Visual inspection.
Ring gear and pinion assembly OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
Planetary gears and/ or bearing faulty If planetary gears for bearings are
faulty drive axle will be nosier
under power than during coasting.

(Para 10-2).
(para 10-2).

KNOWN INFO
TEST OPTIONS
Ring gear and pinion assembly OK.
Planetary gear and bearings OK. Verify repair.

POSSIBLE PROBLEMS REASON FOR QUESTION

If drive axle is not noisier under power

than during coasting, fault has been
corrected.

(Para 10-2).

(Para 10-2).

2-78
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove planetary gears (Para 9-2).

(2) Inspect planetary gears and bearings for chips,
cracks, and uneven wear.
(a) If gears or bearings are damaged,
replace Drive axle (Para 10-2).
(b) If gears and bearings are not damaged,
fault not corrected Perform Step (3)
below and notify supervisor.
(3) Install planetary gears.

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Operate forklift and listen for unusual noise from
drive axle.
(a) If drive axle is noisier under power, fault not
corrected. Perform Step (3) below and
replace drive axle (Para 10-2).
(b) If drive axle is not noisier under power, fault
corrected.
(3) Shut down engine.

2-79
 TM 10-3930-669-34

2-12. DRIVE AXLE TROUBLESHOOTING (CONT.).

3. DRIVE AXLE NOISE GREATER DURING COAST THAN UNDER POWER.

INITIAL SETUP

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1, Appendix E)
Wrench, Torque (O to 600 Ib-ft [0-814 N.m]) Equipment Condition
(Item 5, Appendix E) Drive axle removed (Para 10-2)

KNOWN INFO
TEST OPTIONS
Nothing.
Ring nut check.
POSSIBLE PROBLEMS
REASON FOR QUESTION
Pinion ring nut loose. Ring gear and
pinion assembly faulty. If pinion ring is loose drive axle will
be noisier during coasting than
under power.

2-80
 TM 10-3930-669-34

RING NUT CHECK

(1) Remove pinion gear flange (Para 10-4).

(2) Check torque on pinion ring nut.
(a) If torque is not 443 to 516 Ib-ft (600-700
N.m), torque nut.
(b) If torque is 443 to 516 Ib-ft (600-700 N-
m), ring nut torque is OK.
(3) Install pinion gear flange.

2-81
 TM 10-3930-669-34

3. DRIVE AXLE NOISE GREATER DURING COAST THAN UNDER POWER (CONT.).

TEST OPTIONS
KNOWN INFO
Visual inspection.
Pinion nut torque OK.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If ring gear is faulty drive axle will be
Ring gear and pinion assembly noisier during coasting than under
faulty. power.

(Para 10-4).

KNOWN INFO

Pinion ring nut torque OK

Ring gear and pinion assembly OK. TEST OPTIONS

POSSIBLE PROBLEMS Verify repair.

REASON FOR QUESTION

If drive axle is nit noisier during

coating than under power, fault has
been corrected.

(Para 10-2).

2-82
 TM 10-3930-669-34

VISUAL INSPECTION

(1) Remove differential housing cover (Para 10-4).

(2) Inspect ring gear for cracks, chips, and uneven
wear.
(a) If ring gear is damaged, replace drive axle
(Para 10-2).
(b) If ring gear is not damaged, fault not
corrected. Perform Step (3) below and
replace drive axle (Para 10-2).
(3) Install differential housing cover.

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10).

(2) Operate forklift and listen for unusual noise from
drive axle.
(a) If drive axle is noisier during coasting, fault
not corrected. Perform Step (3) below and
replace drive axle (Para 10-2).
(b) If drive axle is not noisier under power, fault
corrected.
(3) Shut down engine.

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2-12. DRIVE AXLE TROUBLESHOOTING (CONT.).

4. DRIVE AXLE ENGAGING HARSHLY WHEN SWITCHING DIRECTION.

INITIAL SETUP

Tools and Special Tools References

Tool Kit, General Mechanic’s: Automotive TM 10-3930-669-10
(Item 1. Appendix E)
Equipment Condition
Drive axle removed (Para 10-2)

TEST OPTIONS
KNOWN INFO
Visual Inspection.
Nothing.
REASON FOR QUESTION
POSSIBLE PROBLEMS
If differential case pins are faulty,
drive axle will engage harshly when
Differential case pins faulty. switching direction.
Differential case and / or side gear
washers faulty.

(Para 10-2).
(para 10-2).

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VISUAL INSPECTION

(1) Remove differential cover and side gear

(Para 10-4).
(2) Inspect differential case pins for looseness and
damage.
(a) If differential case pins are missing, loose,
or damaged, replace drive axle (Para 10-2).
(b) If differential case pins are not missing,
loose, or damaged, pins are OK

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4 DRIVE AXLE ENGAGING HARSHLY WHEN SWITCHING DIRECTION (CONT.).

KNOWN INFO
TEST OPTIONS
Differential case pins OK.
Visual Inspection.
POSSIBLE PROBLEMS
REASON FOR QUESTION
Differential case and side gear
washers faulty. If differential case shaft retainer,
pinion(s) washer(s) and / or side
gear washers are faulty, drive axle
will engage harshly when switching
direction.
(Para 10-2).

KNOWN INFO TEST OPTIONS

Differential case pins OK. Verify repair.

Differential case and side gear washers
OK. REASON FOR QUESTION

POSSIBLE PROBLEMS If drive axle does not engage harshly when

switching direction, fault has been corrected.

(Para 10-2).

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VISUAL INSPECTION

(1) Remove differential case pins, shaft retainer,

pinions, and washers (Para 10-4).
(2) Inspect washers, shaft retainer, and pinions for
cracks and signs of wear
(a) If washer(s), shaft retainer, and/or pinion(s)
are damaged, replace drive axle
(Para 10-2).
(b) If washers, shaft retainer, and pinions are
not damaged, fault not corrected. Perform
Steps (3) and (4) below and replace drive
axle (Para 10-2).
(3) Install washers, shaft retainer, pinions and pins.
(4) Install side gear, washer, and differential cover.

VERIFY REPAIR

(1) Start engine (TM 10-3930-669-10)

(2) Operate forklift forward and reverse and observe
drive axle engagement.
(a) If drive axle engagement is not smooth,
fault not corrected. Perform Step (3) below
and replace drive axle (Para 10-2).
(b) If drive axle engagement is smooth, fault
corrected
(3) Shut down engine.

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Section IV. MAINTENANCE PROCEDURES

2-13. MAINTENANCE INTRODUCTION.

This section provides general maintenance procedures for Direct/General Support Maintenance as specified in the
Maintenance Allocation Chart (MAC). When a special procedure is necessary, the detailed procedure will be in the section
covering that component.

2-14. GROUND HANDLING.

For Ground Handling information refer to TM 10-3930-669-10.

2-15. GENERAL REMOVAL INSTRUCTIONS.

a. Work Required. Remove parts for repair or replacement as required. Do not disassemble a component any
further than needed.

b. Preparation. Before removal of any electrical components, disconnect battery ground cable to ensure that circuits
and components are not energized. Before removal of any hydraulic components, relieve hydraulic system pressure.
Before removal of fasteners (nuts, screws), remove any paint on threads to ease removal and installation.

c. Identification. To ease assembly and installation, tag and mark shims, connectors, wires, and mating ends of
lines before disconnecting them. Identify similar parts to ensure correct assembly.

d. Position of Valves. Before removing valve handles, mark or diagram their positions when opened or closed.
This will help during assembly.

e. Tire Removal. Before removing any tires, position wooden blocks under frame. This will secure the forklift for
safe tire removal.

f. Location. Before removing cable ties, cushioned clamps, hoses, tubing, wiring, etc., note the location, position,
and routing to ensure correct assembly.
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2-16. GENERAL DISASSEMBLY INSTRUCTIONS.

a. Cleanliness. Work area must be as clean as possible to prevent contamination of components. Hydraulic
components, engines, transmissions, and axles require extremely clean work area when disassembled.

b. Locking Parts. Replace all lock wire, lock washers, cotter pins, and lock nuts at time of disassembly. Self-locking
fasteners that are loosened must be replaced, when loosened or removed.

c. Expendable Parts. All gaskets, packings, and seals removed during repair must be discarded and replaced with
new parts.

d. Removing Seals. Be sure all traces of oil, gaskets, and sealants are removed from components. When possible,
use wood or plastic probes and scrapers to prevent damage to machined surfaces.

CAUTION

Do not use tape to close off fuel or oil openings. Sticky surface of tape can mix with fuel and oil
and cause engine malfunctions.

e. Parts Protection. To keep dust, moisture, and other objects out of internal parts of the system or components,
cap or tape over tubes, hoses, air lines, fittings, and component openings as soon as part is removed. Wrap all removed
parts in clean paper or dip parts in preservation oil.

2-17. GENERAL CLEANING INSTRUCTIONS.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and
gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and
do not breathe vapors. Keep away from heat or flame. Never smoke when using solvent;
the flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is 138'F (50'C).
Failure to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and
medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts
eyes, immediately flush eyes with water and get immediate medical attention.

• Never use fuel to clean parts. Fuel is highly flammable. Serious personal injury could
result if fuel ignites during cleaning.

a. Cleaning Solvents. Use only approved cleaning solvents to clean parts. Dry-cleaning solvent P-D-680 is
commonly used. Always work in a well-ventilated area.

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2-17. GENERAL CLEANING INSTRUCTIONS (CONT.).

WARNING

Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

b. Removing Deposits. Soak parts in dry-cleaning solvent and wash away deposits by flushing or spraying. When
necessary, brush with a soft-bristle brush (not wire) moistened in solvent. Use compressed air to dry parts, except
bearings, after cleaning. Bearings must drip and air dry.

c. Tools. Do not use wire brushes, abrasive wheels, or compounds to clean parts unless specifically approved in the
detailed procedures. Parts may be scratched or altered and may be weakened.

d. Ball and Roller Bearings. When cleaning ball or roller bearings, place them in a basket and suspend them in a
container of dry-cleaning solvent. If needed, use a brush to remove caked grease, chips, etc. Avoid rotating bearing
before solid particles are removed to prevent damage to precision bearing surfaces. When bearings have been cleaned,
coat them lightly with lubricating oil to remove solvent.

CAUTION

Do not clean tires, lubricant seals, rubber hoses, or electrical components with solvent mixture.

e. Rubber Parts. Do not clean preformed packings or rubber parts in dry-cleaning solvent. Wipe parts clean with a
dry, cleaning cloth.

WARNING

Steam cleaning creates hazardous noise levels and severe burn potential. Eye, skin, and ear
protection are required. Failure to comply may result in injury to personnel.

f. Exterior Parts. Steam clean all exterior parts thoroughly before removing. This will make inspection and
disassembly easier.

WARNING

Solvents used with a spray gun must be used in a spray booth with filter. Face shield must be
used by personnel operating spray gun. Failure to comply may result in injury to personnel.

g. Engine, Cab, and Body. Use a spray gun and solvent mixture for cleaning exterior of engine, cab, and body.
Allow mixture to remain on item for ten minutes before rinsing. Rinse with hot water under 80 to 120 pounds of pressure, if
available. An ordinary garden hose with nozzle may be used if other equipment is not available. Rinse thoroughly.

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 TM 10-3930-669-34

CAUTION

To prevent corrosion, parts should be dipped in rust preventive within two hours of degreasing .

h. Degreasing Machine. A degreasing machine may be used to remove heavy grease and oil from metal parts.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and
gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and
do not breathe vapors. Keep away from heat or flame. Never smoke when using solvent;
the flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is 138'F (50'C).
Failure to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and
medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts
eyes, immediately flush eyes with water and get immediate medical attention.

• Never use fuel to clean parts. Fuel is highly flammable. Serious personal injury could
result if fuel ignites during cleaning.

i. Passages. After degreasing, check all oil passages and cavities for dirt or blockage before coating with
lubricating oil. Run a thin, flexible wire through oil passages to make sure they are not clogged. Use a pressure spray gun
and dry-cleaning solvent to clean dirty passages.
j. Electrical Parts. Electrical parts, such as coils, junction blocks, and switches, should not be soaked or sprayed
with dry-cleaning solutions. Clean these parts with a cleaning cloth moistened with dry-cleaning solvent.

CAUTION

Do not use soap or alkalies for cleaning tank interiors.

k. Oil and Fuel Tanks. Pay special attention to all warnings and cautions when working on forklift fuel tank. Oil
tanks and fuel tanks should be flushed, using a spray gun and dry-cleaning solvent.

I. Battery. Exterior surfaces of the electrical system and battery should be cleaned with a weak solution of baking
soda and water. Apply solution with a bristle brush to remove corrosion. Pay special attention to all warnings and cautions
when working on the battery.

m. Hydraulic System. When cleaning hydraulic system parts, use dry-cleaning solvent P-D-680. Clean and dry
parts thoroughly to make sure no solvent residue remains. If a coating preservative is required before assembly, apply a
light film of lubricant. This lubricant must be of the same type used in the forklift’s system.

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 TM 10-3930-669-34

2-18. GENERAL INSPECTION INSTRUCTIONS.

a. Cleaning. Clean all parts before inspection. Check for defects such as physical distortion, wear, cracks, and
burrs. If any defect is found, correct it before assembly.

b. Sealing Surfaces. Inspect all surfaces in contact with grease, packings, or seals for nicks and burrs. If , any
defect is found, correct it before assembly.

c. Bearings. Inspect bearings for rusting, pitting, rolling, peening, scoring, burning, brinnelling, and fatigue cracking.

d. Gear and Splined Shafts. Inspect gears and splined shafts for wear, pitting, rolling, peening, scoring, burning,
brinnelling, and fatigue cracking.

e. Tubing and Hoses. Inspect all hose surfaces for broken or frayed fabric. Check for breaks caused by sharp
kinks or contact with other parts of the forklift. Inspect copper tubing lines for kinks. Inspect fitting threads for damage.
Replace any defective parts. After assembly and during initial forklift operation period, check for leaks.

f. Electrical Parts. Inspect all wiring harnesses for broken, chafed, or burned wiring. Inspect all terminal
connectors for loose or broken parts.

g. Metal Parts. Visually inspect all castings and weldments for cracks. Parts that carry a great load should receive
magnetic particle inspection. Critical non-ferrous parts may be inspected with fluorescent penetrate.

h. Drain Plugs. When removing drain plugs from transmission, engine, hydraulic system components, or axle
differential and planetary hubs, check amount of sediment on plugs. Accumulations of grit or fine metal particles may
indicate actual or potential component failure. A few fine particles are normal. This inspection helps to determine if there
are defective parts prior to internal inspection of the component and to predict degradation of the equipment.

2-19. GENERAL REPAIR INSTRUCTIONS.

a. Burrs. Remove burrs from surface with a fine-cut file or crocus cloth.

b. Exterior Parts. Chassis and exterior painted parts may be resurfaced when paint is damaged or where parts
have been repaired.

NOTE
Polished or machined steel parts not protected by cadmium, tin, copper, or other plating or
surface treatments require protection. Bare metal surfaces must be free of moisture when
protective coating is applied.

c. Protecting Parts. Protect bare steel surfaces from rust when not actually undergoing repair work. Dip parts in, or
spray them with, corrosion preventive compound. Aluminum parts may require protection in atmospheres having a high
salt content.

2-92
 TM 10-3930-669-34

d. Screws, Nuts, and Fittings. Replace any screw, nut, or fitting with damaged threads. Inspect tapped holes for
thread damage. If cross-threading is evident, retap the hole for the next oversize screw or stud. If the retapping will
weaken the part, or if the cost of the part makes retapping impractical, replace the part.
Chasing the threads with proper size tap or die may be adequate.

e. Stud Installation. When installing studs, use a proper driver. A worn stud driver may damage the end thread
and a chasing die must be used before a nut can be installed. This procedure will remove cadmium plating and allow
corrosion. Before installing a stud, inspect the hole for chips. Blow out foreign matter and start stud by hand. Before
installation, coat thread with a film of antiseize compound. Install stud to proper "setting height", which is the total
projecting length.

f. Dents. Straighten minor body dents by bumping with a soft-faced hammer while using a wooden block backing.

g. Sheet Metal Repair. Repair minor skin cracks by installing patches.

2-20. GENERAL ASSEMBLY INSTRUCTIONS.

a. Preparation. Remove protective grease coatings from new parts before installation.

b. Preformed Packing Installation. Clean groove that preformed packing is to be installed in before installation.
Lubricate preformed packing, prior to installation, with a clean lubricant. This lubricant must be of the same type used in
the component the preformed packing is to be installed in. Do not over-stretch preformed packing during installation. Use
care not to cut preformed packing during installation.

c. Pipe Joints and Fittings. Use non-hardening sealing compound or Teflon pipe sealant to join piping and fittings.

d. Oil Seals. Coat oil seals with clean lubricant before installing. This lubricant must be of the same type used in the
component the oil seal is to be installed in. Wipe all excess lubricant from side of oil seal that is on the outside of the
component (away from lubricant). Install oil seals with seal lip facing toward lubricant, applying an even force to the outer
edge of the seal. If oil seals are to be installed over keyed or splined shafts, use a guide to prevent sharp edge of keyway
or splines from cutting the seal. Construct guides of very thin gauge sheet metal and shape to the required diameter.
Make certain guide edges are not sharp and are bent slightly inward so they do not cut the seal.

e. Bearings and Shafts. When mounting bearings on shafts, always apply force to the inner races. When
mounting bearings into housing, always apply the force to the outer race.

f. Bearing Lubrication. Lubricate bearings, before assembly, with clean lubricant. This lubricant must be of the
same type used in the component the bearing is to be installed in.

2-93
 TM 10-3930-669-34

2-20. GENERAL ASSEMBLY INSTRUCTIONS (CONT).

WARNING

On direct contact, uncured silicon sealant irritates eyes. In case of contact, flush eyes with water and
seek medical attention. In case of skin contact, wipe off and flush with water.

g. Silicone Sealant. Silicone sealant is often used instead of a gasket to seal mating parts. The mating parts must
be clean, dry, and free of oil or grease for proper adhesion. After silicon sealant has been applied, the mating parts must
be assembled immediately. Silicone sealant starts to set-up in 15 minutes and takes 24 hours to completely set. Excess
silicone sealant should be removed after assembling the mating parts.

h. Gaskets. Remove all traces of previous gasket and sealant before installing new gasket.

2-21. GENERAL INSTALLATION INSTRUCTIONS.

a. Preparation. When unpacking items, remove all packing material, barrier paper, tape, plastic, plastic bags,
protective caps, and protective grease coatings. Handle and store removed components carefully.

CAUTION,

Use sealing compound sparingly and only on threads. Do not apply compound to hose
connections. Damage to equipment may result.

b. Sealing Compounds. Use sealing compounds as required in each maintenance task.

c. Torquing. Tighten screws as required in Appendix D or in each maintenance task.

d. identification Tags. Use identification tags and other identifying markings to ensure hoses, tubes, lines, and
electrical wiring are installed and connected correctly.

e. Hoses, Air Lines, and Wiring. After installing hoses, air lines, and wiring, ensure that they do not contact moving
parts or components edges. Secure in place, out of the way, with cable ties and cushion clips.

2-22. ADJUSTMENT.

Make changes to equipment pressures, settings, and positions only as required in each maintenance task. Adjustments
will bring equipment into proper operating condition.

2-94
 TM 10-3930-669-34

2-23. PLACING IN SERVICE.

For information on Placing In Service refer to TM 10-3930-669-20.

Section V. PREPARATION FOR STORAGE OR SHIPMENT

2-24. PREPARATION FOR SHIPMENT.

For information about Preparation For Shipment refer to TM 10-3930-669-20.

2-25. STORAGE MAINTENANCE PROCEDURES.

For information about Storage Maintenance Procedures refer to TM 10-3930-669-20.

2-95/(2-96 blank)
 TM 10-3930-669-34

CHAPTER 3

ENGINE MAINTENANCE

Para Contents Page

3-1 Introduction ..................................................................................................................................... 3-1

3-2 Wear Limits, Fits, and Tolerances .................................................................................................. 3-2
3-3 Engine/Transmission Assembly Replacement................................................................................ 3-8
3-4 Crankcase Repair ........................................................................................................................... 3-27
3-5 Cylinder Head Assembly Replacement........................................................................................... 3-36
3-6 Cylinder Head Repair...................................................................................................................... 3-42
3-7 Cylinder Replacement..................................................................................................................... 3-50
3-8 Engine Oil Pan Replacement .......................................................................................................... 3-52
3-9 Crankshaft Pulley/Vibration Damper Replacement......................................................................... 3-54
3-10 Engine Front Cover Replacement/Repair ....................................................................................... 3-55
3-11 Idler Gear Replacement/Repair ...................................................................................................... 3-59
3-12 Oil Pump Replacement ................................................................................................................... 3-62
3-13 Piston and Connecting Rod Assembly Replacement/Repair.......................................................... 3-66
3-14 Crankshaft Replacement/Repair ..................................................................................................... 3-73
3-15 Rocker Arm and Pushrod Replacement/Repair.............................................................................. 3-82
3-16 Camshaft Replacement .................................................................................................................. 3-86
3-17 Injection Pump Timing Gear Replacement ..................................................................................... 3-89
3-18 Flywheel Housing Replacement...................................................................................................... 3-92

3-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, repairing, installing, adjusting, and testing engine
components authorized by the Maintenance Allocation Chart (MAC) at the Direct Support and General Support
Maintenance level.

3-1
 TM 10-3930-669-34

3-2. WEAR LIMITS, FITS, AND TOLERANCES.

Refer to Table 3-1 for wear limits, fits, and tolerances for use throughout this chapter.

Table 3-1. Wear Limits, Fits, and Tolerances

Component Minimum Maximum

Intake Valves:

Head Diameter 1.689 in. 1.697 in.

(42.900 mm) (43.100 mm)

Stem Diameter 0.3128 in. 0.3134 in.

(7.9450 mm) (7.9600 mm)

Stem-to-guide normal clearance 0.0016 in. 0.0028 in.

(0.0400 mm) (0.0700 mm)

Stem-to-guide maximum clearance 0.0059 in.

(0.1500 mm)

Seat bore diameter in head nominal 1.7913 in. 1.7923 in.

(45.5000 mm) (45.5250 mm)

Seat outside diameter 1.7969 in. 1.7976 in.

(45.6400 mm) (45.6600 mm)

Valve seat width 0.0591 in. 0.0787 in.

(1.5000 mm) (2.0000 mm)

Seat angle 45°

Valve rim thickness 0.0197 in. 0.0394 in.

(0.7000 mm) (1.0000 mm)

Valve recessed below cylinder head seating surface 0.2000 in. 0.2205 in.
(5.0800 mm) (5.6000 mm)
Exhaust Valves:

Head diameter 1.4527 in. 1.4606 in.

(36.9000 mm) (37.1000 mm)

Stem diameter 0.3118 in. 0.3125 in.

(7.9200 mm) (7.9400 mm)

Stem-to-guide normal clearance 0.0023 in. 0.0037 in.

(0.0600 mm) (0.0950 mm)

Stem-to-guide maximum clearance 0.0079 in.

(0.2000 mm)

3-2
 TM 10-3930-669-34

Table 3-1. Wear Limits, Fits, and Tolerances

Component Minimum Maximum

Exhaust Valves - continued:

Seat bore diameter in head nominal 1.5748 in. 1.5757 in.

(40.0000 mm) (40.0250 mm)

Seat outside diameter 1.5803 in. 1.5811 in.

(40.1400 mm) (40.1600 mm)

Valve seat width 0.0591 in. 0.0787 in.

(1.5000 mm) (2.0000 mm)

Seat angle 45°

Valve rim thickness 0.0197 in. 0.0591 in.

(0.5000 mm) (1.5000 mm)

Valve recessed below cylinder head seating surface 0.2000 in. 0.2205 in.
(5.0800 mm) (5.6000 mm)

Valve Guides:

Outside diameter - nominal 0.5923 in. 0.5927 in.

(15.0450 mm) (15.0560 mm)

Bore in cylinder head diameter 0.5905 in. 0.5909 in.

(15.0000 mm) (15.0110 mm)

Pressed in inside diameter 0.3149 in. 0.3155 in.

(8.0000 mm) (8.0150 mm)

Valve springs:

Total coils 7

Normal length 2.3230 in. 2.3976 in.

(59.0000 mm) (60.9000 mm)

Minimum length 2.2047 in.

(56.0000 mm)

Cylinder Head:

Distance between cylinder head bottom and 0.2323 in. 0.2519 in.
cylinder head joint w/ shim bolts. (5.9000 mm) (6.4000 mm)

Stud nominal length 8.2870 in. 8.3268 in.

(210.5000 mm) (211.5000 mm)

3-3
 TM 10-3930-669-34

Table 3-1. Wear Limits, Fits, and Tolerances

Component Minimum Maximum

Cylinder Head - continued:

Stud maximum length 8.3661 in.

(212.5000 mm)

Cylinders:

Bore diameter - normal 3.9370 in. 3.9378 in.

(100.0000 mm) (100.0220 mm)

Bore wear - maximum 0.0004 in.

(0.1000 mm)

Pistons:

Diameter - normal 3.9331 in. 3.9338 in.

(99.9010 mm) (99.9190 mm)

Diameter of bore for connecting rod pin 1.3779 in. 1.3782 in.
(35.0000 mm) (35.0060 mm)

Connecting rod pin diameter 1.3777 in. 1.3779 in.

(34.9940 mm) (35.0000 mm)

2nd ring groove width 0.0984 in. 0.1020 in.

(2.5000 mm) (2.6100 mm)

3rd ring groove width 0.0984 in. 0.1020 in.

(2.5000 mm) (2.5900 mm)

4th ring groove width 0.1969 in. 0.1980 in.

(5.0000 mm) (5.0300 mm)

Piston Rings:

2nd ring clearance in groove 0.0039 in. 0.0052 in.

(0.1000 mm) (0.1320 mm)

2nd ring maximum clearance in groove 0.0118 in.

(0.3000 mm)

3rd ring clearance in groove 0.0039 in. 0.0052 in.

(0.1000 mm) (0.1320 mm)

3rd ring maximum clearance in groove 0.0118 in.

(0.3000 mm)

3-4
 TM 10-3930-669-34

Table 3-1. Wear Limits, Fits, and Tolerances

Component Minimum Maximum

Piston Rings - continued:

4th ring clearance in groove 0.0015 in 0.0028 in.

(0.0400 mm) (0.0720 mm)

4th ring maximum clearance in groove 0.0059 in.

(0.15 mm)

Gap: 1st ring - normal 0.0137 in 0.0216 in.

(0.3500 mm) (0.5500 mm)

Gap: 2nd ring - normal 0.0079 in 0.0177 in.

(0.2000 mm) (0.4500 mm)

Gap: 3rd ring - normal 0.0098 in 0.0197 in.

(0.2500 mm) (0.5000 mm)

Gap: 4th ring - normal 0.0098 in 0.0157 in.

(0.2500 mm) (0.4000 mm)

Gap: 1st, 2nd, 3rd, and 4th rings - maximum 0.0315 in.
(0.8000 mm)

Connecting Rods:

Hole for connecting rod pin bushing 1.4961 in 1.4966 in.

(38.0000 mm) (38.0160 mm)

Rod bearing bore diameter, less bearing 2.5196 in 2.5204 in.

(64.0000 mm) (64.0190 mm)

Rod bearing inside diameter 2.3622 in 2.3637 in.

(60.0000 mm) (60.0390 mm)

Rod pin bushing outside diameter 1.4980 in 1.4992 in.

(38.0500 mm) (38.0800 mm)

Rod pin bushing inside diameter - pressed in 1.3795 in 1.3813 in.

(35.0400 mm) (35.0860 mm)

Rod pin-to-bushing clearance 0.0015 in 0.0035 in.

(0.0400 mm) (0.0910 mm)

Rod pin-to-bushing maximum clearance 0.0059 in.

(0.1500 mm)

Rod bearing width 0.9763 in 0.9842 in.

(24.8000 mm) (25.0000 mm)

3-5
 TM 10-3930-669-34

Table 3-1. Wear Limits, Fits, and Tolerances

Component Minimum Maximum

Connecting Rods - continued:

Rod width 1.3172 in. 1.3228 in.

(33.5200 mm) (33.6000 mm)

Rod bearing-to-crankshaft clearance 0.0015 in. 0.0038 in.

(0.0400 mm) (0.0980 mm)

Rod bearing-to-crankshaft maximum clearance 0.0059 in.

(0.1500 mm)

Idler Gear and Journal:

Bearing bushing internal diameter - pressed in 1.5748 in. 1.5757 in.

(40.0000 mm) (40.0250 mm)

Journal diameter 1.5744 in. 1.5748 in.

(39.9910 mm) (40.0000 mm)

Journal clearance in bushing 0.0013 in. 0.0026 in.

(0.0340 mm) (0.0660 mm)

Journal-to-bushing maximum clearance 0.0039 in.

(0.10 mm)

Camshaft:

Camshaft-to-bushing maximum clearance 0.0079 in.

(0.20 mm)

Camshaft bushing inside diameter - nominal 1.8890 in. 1.8911 in.

(47.9800 mm) (48.0340 mm)

Crankshaft:

Connecting rod journal diameter - nominal 2.3606 in. 2.3610 in.

(59.9410 mm) (59.9700 mm)

Connecting rod journal out-of-round maximum 0.0004 in.

(0.0100 mm)

Main bearing journal diameter - normal 2.7555 in. 2.7556 in.

(69.9700 mm) (70.0000 mm)

3-6
 TM 10-3930-669-34

Table 3-1. Wear Limits, Fits, and Tolerances

Component Minimum Maximum

Crankshaft - continued:

Main bearing journal out-of-round 0.001 in.

(0.020 mm)

Main bearing journal width 1.4567 in. 1.4606 in.

(37.0000 mm) (37.1000 mm)

Main bearings, numbers 2, 3, and 4:

Main bearing bore diameter - less bearings 2.9330 in. 2.9334 in.
(74.5000 mm) (74.5080 mm)

Main bearing inside diameter - normal 2.7574 in. 2.7582 in.

(70.0400 mm) (70.0600 mm)

Main bearing inside diameter - minimum 2.6984 in. 2.7001 in.

(68.5400 mm) (68.5830 mm)

Main bearing to crankshaft journal clearance - normal 0.0019 in. 0.0043 in.
(0.0500 mm) (0.1100 mm)

Main bearing to crankshaft journal clearance - maximum 0.0059 in.

(0.1500 mm)

Thrust bearings with stop rings:

Outside distance of stop rings - nominal 1.4453 in. 1.4508 in

(36.7110 mm) (36.8500 mm)

Outside distance of stop rings - maximum 1.5241 in. 1.5295 in.

(38.7110 mm) (38.8500 mm)

Thrust bearing-to-journal - normal clearance 0.0059 in. 0.0123 in.

(0.1500 mm) (0.3140 mm)

Thrust bearing-to-journal - maximum clearance 0.0157 in.

(0.4000 mm)

3-7
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT.

This task covers:

a. TDC Equipment Setup c. Removal e. TDC Equipment Removal

b. TDC Adjustment d. Installation

INITIAL SETUP

Tools and Special Tools

Tool Kit, General Mechanic’s: Automotive Equipment Condition
(Item 1, Appendix E) Wheels chocked (TM 10-3930-669-10)
Lifting Eye (2) (Item 16, Appendix E) Mast pivoted 90 degrees (TM 10-3930-669-10)
Engine Stand (Item 5 Appendix E) Cab removed (TM 10-3930-669-20)
Engine oil drained (LO 10-3930-669-12)
Materials/Parts Transmission oil drained
Cap and Plug Set (Item 5, Appendix B) (LO 10-3930-669-12)
Rags, Wiping (Item 19, Appendix B) Air cleaner assembly removed
Tags, Identification (Item 21, Appendix B) (TM 10-3930-669-20)
Washer, Lock (2) Throttle cable removed (TM 10-3930-669-20)
Engine ground strap removed
Personnel Required (TM 10-3930-669-20)
Two Engine wire harness removed (Para 7-5)

3-8
 TM 10-3930-669-34

a. TDC Equipment Setup.

WARNING

BURN HAZARD
Allow engine to cool before performing maintenance on the muffler, exhaust pipe, exhaust
manifold, or turbocharger. If necessary, use insulated pads and gloves.

NOTE

Cylinder number designation starts with No. 1 cylinder closest to transmission.

(1) Remove screw (1), washer (2), washer (3), valve cover (4), and gasket (5) from engine (6) cylinder No. 1.
Discard gasket.

NOTE

• All turning of engine will be done with

retainer at crankshaft pulley.

• All turning of engine will be described as if

looking at the crankshaft pulley end of
engine.

(2) Using retainer to turn pulley (7), turn engine (6)

to the right.

3-9
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT).

NOTE

Valve overlapping is when exhaust

valve is about to close and inlet valve
is about to open. Both pushrods will
not rotate.

(3) As described in Step (2), continue turning engine

(6) to the right until exhaust valve pushrod (8)
overlaps intake valve pushrod (9).

(4) Loosen screw (10) and washer (11) on engine

(6).

(5) Mount pointer on engine (6) with screw (10) and

washer (11).

(6) Loosen pointer handle and adjust pointer to middle of two index marks (12) on pulley (7).

(7) Using retainer, turn pulley (7) 180 degrees to the right.

3-10
 TM 10-3930-669-34

NOTE

Headless screw is part of adjusting

device.

(8) Mount headless screw in rocker bracket (13).

NOTE
Ensure pressure screw is screwed
out so it does not contact engine
during adjusting device installation.

(9) Install mounting handle on headless screw until

adjusting device is firmly seated on engine (6).

(10) Tighten pressure screw of adjusting device until

exhaust rocker arm (14) is depressed .20 to .23
in. (5-6 mm).

3-11
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT).

NOTE

Preload is when the plunger of the

dial gauge contacts the internal
plunger of the pressure screw.

(11) Install the dial gauge in the pressure screw of

the adjusting device until the dial gauge pointer moves.
Tighten the compression nut.

b. TDC Adjustment.

(1) Using retainer, turn pulley (7) to the right until dial gauge needle begins to move.

(2) Using retainer, continue turning pulley (7) slowly until dial gauge pointer stops moving in one direction and starts to
move in the opposite direction.

3-12
 TM 10-3930-669-34

(3) Loosen bezel lock.

(4) Turn bezel until zero is aligned with pointer.

Tighten bezel lock.

(5) Place mark (15) on pulley (7) at the point indicated by the pointer.

(6) Using retainer, turn pulley (7) to the right one half rotation.

(7) Using retainer, turn pulley (7) to the left until the dial gauge pointer begins to move.

3-13
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT). |’

(8) Using retainer, continue turning pulley (7) slowly

until dial gauge pointer again stops moving in
one direction and starts to move in the opposite
direction.

(9) Place second mark (16) on pulley (7) at point indicated by the pointer.

NOTE

The point halfway between the two pulley marks is top dead center (TDC). If the two pulley marks
are the same position, that position becomes top dead center (TDC).

(10) Determine the point halfway between two marks (15 and 16). Mark this point as top dead center (TDC).

3-14
 TM 10-3930-669-34
c. Removal

(1) Remove two clamps (1) and hose (2) from blower (3) and plate (4).

WARNING

Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work
on fuel system when engine is hot. Fuel can be ignited by hot engine. When working with fuel,
post signs that read NO SMOKING WITHIN 50 FEET (15 m).

NOTE

• Inspect all hoses and fittings for

cracks, bends, nicks, dents, stripped
threads, and cuts.
Replace all damaged parts.

• Tag and mark each hose prior to

removal.

• Cap and plug all hoses and fittings

after removal.

(2) Remove two clamps (5) and hoses (6) from

fittings (7).

3-15
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT).

(3) Remove clamp (8) and hose (9) from banjo fitting
(10).

(4) Remove clamp (11) and overflow hose (12) from

fitting (13).

(5) Remove clamp (14) and fuel return hose (15) from fitting (16).

3-16
 TM 10-3930-669-34

(6) Remove two screws (17), lock washers (18), and

brackets (19) from engine (20). Discard lock washers.

(7) Remove two hoses (21) from fittings (22).

3-17
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT)

WARNING

• Engine/Transmission assembly weighs 430 lbs (195 kg). Attach suitable lifting device prior to
removal or installation to prevent possible injury to personnel.

• Exercise extreme caution when working near a cable or chain under tension. A snapped cable
or a shifting or swinging load may result in injury or death to personnel.

(8) Remove two nuts (23), washers (24), screws (25), and washers (26) from engine (20) and front engine mounts
(27).

(9) Remove two nuts (28), washers (29), washers (30) from two screws (31), and nuts (32) on rear engine mounts
(33).

3-18
 TM 10-3930-669-34

(10) Install two lifting eyes in engine/transmission assembly (34).

WARNING

Engine/Transmission assembly weighs 430 lbs (195.05 kg). Attach suitable lifting device prior to
removal or installation to prevent possible injury to personnel.

(11) With the aid of an assistant, use lifting device to raise engine/transmission assembly (34) 2 ft from engine mounts.
(12) Position wiping rags under hoses to catch excess oil.
(13) Disconnect engine drain hose (35) from elbow (36).

NOTE

• Drive shaft spline must be removed from transmission during removal of engine/transmission
assembly.
• Transmission yoke will slide out of transmission.

(14) Disconnect transmission drain hose (37) from tee (38).

(15) With the aid of an assistant, use lifting device to remove engine/transmission assembly (34) from forklift.

3-19
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT).

d. Installation.

NOTE

Drive shaft spline must be installed prior to installing engine/transmission assembly.

(1) With the aid of an assistant, use lifting device to position engine/transmission assembly (34) on forklift 2 ft. above
engine mounts.
(2) Connect transmission drain hose (37) on tee (38).
(3) Connect engine drain hose (35) on elbow (36).

3-20
 TM 10-3930-669-34

(4) With the aid of an assistant, use lifting device to position engine/transmission assembly (34) on screws (31) and
nuts (32) of rear engine mounts (33) and front engine mounts (27).

(5) Install two washers (30) and washers (29) on screws (31) and nuts (32) with two nuts (28) Tighten nuts 45 lb-ft (61
N•m).

(6) Install two washers (26), screws (25), washers (24), and nuts (23) on front engine mounts (27) Tighten nuts 45 lb-
ft (61 N•m).

3-21
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT)@@@

(7) Install two hoses (21) on fittings (22).

(8) Remove lifting device and two lifting eyes.

(9) Install two brackets (19) on engine (20) with two

lock washers (18) and screws (17).

3-22
 TM 10-3930-669-34

(10) Install fuel return hose (15) on fitting (16) with clamp (14).

(11) Install overflow hose (12) on fitting (13) with

clamp (11).

(12) Install hose (9) on banjo fitting (10) with clamp

(8).

3-23
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT).

(13) Install two hoses (6) on fittings (7) with clamps

(5).

(14) Install hose (2) on blower (3) and plate (4) with
two clamps (1).

3-24
 TM 10-3930-669-34

e. TDC Equipment Removal.

(1) Loosen compression nut on pressure screw of

adjusting device.

(2) Remove dial gauge from pressure screw on

adjusting device.

(3) Turn pressure screw to the left to remove

pressure from exhaust rocker arm (14).

(4) Remove mounting handle and adjusting device

from headless screw.

(5) Remove headless screw from rocker bracket

(13).

3-25
 TM 10-3930-669-34

3-3. ENGINE/TRANSMISSION ASSEMBLY REPLACEMENT (CONT).

(6) Loosen screw (10) and washer (11) from

engine (6) and remove pointer.

(7) Tighten screw (10) to 18 lb-ft (25 N•m).

(8) Install gasket (5), washer (2), washer (3), and

valve cover (4) on engine (6) with screw (1).
Tighten screw 5 to 11 lb-ft (7-15 N•m).

NOTE

Follow-on Maintenance:

• Install engine wire harness (Para 7-5).

• Install engine ground strap (TM 10-3930-669-

20).

• Install throttle cable (TM 10-3930-669-20).

• Install cab (TM 10-3930-669-20).

• Install air cleaner assembly (TM 10-3930-669-

20).

• Fill transmission with oil (LO 10-3930-669-

12).

• Fill engine with oil (LO 10-3930-669-12).

• Remove wheel chocks (TM 10-3930-669-10).

• Mast pivoted closed (TM 10-3930-669-10).

END OF TASK
3-26
 TM 10-3930-669-34

3-4. CRANKCASE REPAIR.

This task covers:

a. Disassembly c. Repair
b. Cleaning/Inspection d. Assembly

INITIAL SETUP

Tools and Special Tools Materials/Parts - Continued

Tool Kit, General Mechanic’s: Automotive Nozzles, Oil (4)
(Item 1, Appendix E) Packing, Preformed (4)
Gauge, Dial, Bore, Cylinder Plug
(Item 5, Appendix E) Plug (2)
Gauge, Tightening (Item 22, Appendix E) Plug (3)
Inserter and Remover (Item 32, Appendix E) Plug (5)
Installing Tool, Oil Nozzle Washer
(Item 33, Appendix E)
Micrometer (Item 5, Appendix E) Equipment Condition
Refacing Device (Item 5, Appendix E) Cylinders removed (Para 3-7)
C-Clamp (Item 5, Appendix E) Oil pan removed (Para 3-8)
Oil pump removed (Para 3-12)
Materials/Parts Idler gear removed (Para 3-11)
Compound, Sealing (Item 24, Appendix B) Pistons and connecting rods removed
Rags, Wiping (Item 19, Appendix B) (Para 3-13)
Solvent, Drycleaning (Item 20, Appendix B) Crankshaft removed (Para 3-14)
Ink, Marking Camshaft removed (Para 3-16)

a. Disassembly.

(1) Remove four oil nozzles (1) and preformed

packings (2) from crankcase (3) as follow:

(a) Using a 10-inch "C" clamp, position clamp

through cylinder port and external
crankcase. Turn screw press to slowly
remove each oil nozzle and preformed
packing.

(b) Discard oil nozzles and preformed

packings.

3-27
 TM 10-3930-669-34

3-4. CRANKCASE REPAIR (CONT).

(2) Remove two screws (4), washers (5) from

crankcase (3). Discard plugs.

(3) Remove five screws (6) and washers (7) from

crankcase (3).

(4) Remove three plugs (8, 9, and 10) from

crankcase (3). Discard plugs.

(5) Using inserter and remover, remove bearing

bushings (11) from crankcase (3).

(6) Remove plug (12) and washer (13) from

crankcase (3). Discard plug and washer.

(7) Remove two dowel sleeves (14), plate (15), and

two pins (16) from crankcase (3).

3-28
 TM 10-3930-669-34

b. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles

and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and
clothes; and do not breathe vapors. Keep away from heat or flame. Never smoke
when using solvent; the flashpoint for type I dry-cleaning solvent is 100°F (38°C)
and for type II is 138°F (50°C). Failure to do so may result in injury or death to
personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air
and medical help. If solvent contacts skin or clothes, flush with cold water. If
solvent contacts eyes, immediately flush eyes with water and get immediate
medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.). Failure to comply may result in injury or death to
personnel.

(1) Clean all parts with dry-cleaning solvent.

Thoroughly wash out oil ways. Dry with
compressed air.

(2) Clean tapped holes for lifting eyes and cylinder

head screws in crankcase by running down a
tap. A greased tap should be used for blind
holes.

(3) Inspect crankcase for cracks. Replace cracked

crankcase.

(4) Blow clean compressed air through oil nozzle

and bushing oil holes.

(5) Clean all tapped holes in crankcase by running down a tap. A greased tap should be used for blind holes.

(6) Inspect bearing bushings for galling or excessive wear. Replace defective bushings.

3-29
 TM 10-3930-669-34

3-4. CRANKCASE REPAIR (CONT).

c. Repair.
NOTE

Main bearings are of thin-shell type. Their proper installation requires that webs in
crankcase be in alignment and for bearing bores to be preloaded. No attempt should be
made to adjust or recondition bearing shells.

(1) Check preloading of bearing bores as follows:

(a) Position and install main bearing caps,

washers, and screws making sure that their
identification numbers match with those
stamped in crankcase. Using a tightening
gauge, torque screws in accordance with
instructions given in Appendix D, Table D-1.

(b) Using a precision gauge, set gauge to

2.933 inches (74.50 mm).

(c) Measure each main bearing bore at points

1 and 2 in plane "a," and in plane "b" offset
by 90 degrees.

(d) If main bearing bore measurement is

between 2.933 inches (74.50 mm) and
2.934 inches (74.519 mm), respective
bearing is in acceptable condition and
required preload will be obtained when
bearing halves are installed.

(e) If main bearing bore measurement is not

between 2.933 inches (74.50 mm) and
2.934 inches (74.519 mm), repeat
measurements with new bearing halves
installed.

(f) Insert new main bearings.

3-30
 TM 10-3930-669-34

(g) Position and install main bearing caps,

washers, and screws. Preload and torque
screws in accordance with instructions
given in Appendix D, Table D-1.

(h) Using a precision gauge, set gauge to

nominal inside diameter of crankshaft main
bearing bore (2.7574 inches (70.0400
mm)).

(i) Measure each main bearing bore at points

1 and 2 in vertical and horizontal positions
"a" and "b."

(j) If main bearing bore measurements are

between 2.7574 inches (70.0400 mm) and
2.7582 inches (70.0600 mm), crankcase is
acceptable for further use. If not, notify
supervisor.

(2) Check main bearing housing for alignment as

follows:

(a) Remove main bearing screws, washers,

and caps.

(b) Coat main crankshaft journals with marking

ink.

(c) Position crankshaft in crankcase and install

main bearing caps, washers, and screws
according to numbering. Torque screws in
accordance with instructions given in
Appendix D, Table D-1.

3-31
 TM 10-3930-669-34

3-4. CRANKCASE REPAIR (CONT).

NOTE

• If all bearings have a uniform

contact pattern, bearings are in
alignment.

• Do not bore out individual

bearings.

(d) Rotate crankshaft. Remove screws,

washers, bearing caps, and crankshaft. If
bearing bores are in alignment, there will be
an even pattern of marking by crankshaft in
all bearing bores. If bearing bores require
alignment, bores must be line-bored.

(3) Using an inside micrometer, measure camshaft

bearing bores of crankcase. Bore should be 1.8890
to 1.8911 in. (47.9800-48.0340 mm). If bores are
more than 1.8890 to 1.8911 in. (47.9800-48.0340
mm), replace camshaft bearings as follows:

(a) Install shorter, small-diameter thrust piece

(part of inserter and remover) on front end
of camshaft bore.

(b) Install end support (part of inserter and

remover) at next camshaft bore.

(c) Pull bearing bushing out towards flywheel

end.

CAUTION

Failure to align bearing/bushing oil holes with crankcase oil hole will result in
severe damage.

(d) Align new camshaft bearing bushing so oil holes in bushing coincide with those in crankcase.

(e) Using inserter and remover, press new bearing bushing into crankcase. Install bushing flush with front end of
crankcase.

(f) Clean crankcase thoroughly.

3-32
 TM 10-3930-669-34

(4) Check cylinder liner seating on crankcase

surface and feel for any evidence of roughness.
Seating surface must be level and free from
grooves. If cylinder liner seat is not level and
free of grooves, repair liner(s) as follows:

(a) Using a wiping rag, clean seating area and

remove paint residues.

(b) Center refacing device and tighten screws

(18).

(c) Withdraw centering finger and slide tool

holder (19) out to diameter of cylinder
seating face.

CAUTION

• DO NOT turn spindle counterclockwise when reworking surface or refacing

device will be damaged.

• Adjust feed carefully. A full turn (360°) of knurled nut feeds tool holder 0.059
inch (1.5 mm).

(d) Using knurled nut (20), turn spindle of turning device clockwise and adjust tool holder (19) specified amount
of liner face to be reworked.

(e) Move tool holder (19) toward middle of bore.

(f) Using knurled nut (20), set tool over and slightly beyond distance "A" to permit satisfactory refacing.

(g) After adjusting tool, tighten setscrew (21).

NOTE

• Selected cutting depth should not exceed 0.008 inch (0.2 mm). This feed
corresponds to a 1/8th turn (45°) of knurled nut. Less feed per cut will
produce a better surface.

• Resurfacing cut should not exceed the cylinder height of 5.405 in. (137.7
mm).

(h) Turn spindle (22) to rework seating area until smooth and/or flush with top of crankcase surface.

(i) Set back tool holder and remove refacing device.

(j) Clean crankcase thoroughly.

3-33
 TM 10-3930-669-34

3-4. CRANKCASE REPAIR (CONT).

d. Assembly.

(1) Install plate (15) in crankcase (3) with two pins

(16).

(2) Install two dowel sleeves (14) in crankcase (3).

(3) Install washer (13) and plug (12) in crankcase

(3).

(4) If bearing bushings (11) were not replaced,

install bushings in crankcase (3) using inserter
and remover tool.

(5) Install plugs (8, 9, and 10) in crankcase (3).

Plugs may require using a pressing device.

(6) Install five washers (7) and screws (6) in

crankcase (3).

(7) Install two washers (5) and plugs (4) in

crankcase (3).

3-34
 TM 10-3930-669-34

(8) Apply sealing compound to preformed packings

(2).

NOTE

When installing oil nozzles, ensure

key pin is facing in the up position.

(9) Install four oil nozzles (1) and preformed

packings (2) in crankcase (3).

NOTE

Follow-on Maintenance:

• Install camshaft (Para 3-16).

• Install crankshaft (Para 3-14).

• Install pistons and connecting rods (Para 3-

13).

• Install idler gear (Para 3-11).

• Install oil pump (Para 3-12).

• Install oil pan (Para 3-8).

• Install cylinders (Para 3-7).

END OF TASK

3-35
 TM 10-3930-669-34

3-5. CYLINDER HEAD ASSEMBLY REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanics: Automotive Engine OFF (TM 10-3930-669-10)
(Item 1, Appendix E) Parking brake applied (TM 10-3930-669-10)
Spring, Compressor (Item 21, Appendix E) Wheels chocked (TM 10-3930-669-10)
Wrench, Torque (0-60 N•S) Blower ducting removed (Para 6-2)
(Item 5, Appendix E)
Materials/Parts Muffler removed (TM 10-3930-669-20)
Wrench, Torque (0 to 175 lb-ft [0-237 N•S]) Exhaust manifold removed (Para 5-2)
(Item 5, Appendix E) Intake manifold removed (Para 4-2)
Gage Tightening (Item 22, Appendix E) Fuel return lines removed (TM 10-3930-669-20)

Fuel lines removed

Compound, Sealing (Item 24, Appendix B) (TM 10-3930-669-20)
Grease, Automotive and Artillery, Injector removed (TM 10-3930-669-20)
(Item 13, Appendix B) Glow plug removed (TM 10-3930-669-20)
Lubricating Oil (Item 15, Appendix B)
Intermediate Ring
Packing, Preformed (2)
Packing, Preformed (4)

a. Removal

NOTE

Cylinder No. 1 is shown. All cylinders are removed the same way.

(1) Remove screw (1), washer (2), washer (3), rocker cover (4), and gasket (5) from cylinder head (6). Discard
gasket.

3-36
 TM 10-3930-669-34

(2) Remove three nuts (7) and rocker arm assembly

(8) from cylinder head (6).

(3) Remove two pushrods (9) from cylinder head

(6).

(4) Remove two plugs (10) and preformed packings

(11) from cylinder head (6). Discard preformed
packings.

(5) Remove four screws (12) and washers (13) from

cylinder head (6).

3-37
 TM 10-3930-669-34

3-5. CYLINDER HEAD ASSEMBLY REPLACEMENT (CONT).

WARNING

Use care when removing springs. A

compressed spring can act as a
projectile when released and could
cause severe injury.

CAUTION

Remove cylinder head slowly to

prevent damage to pushrod cover
tubes.

(6) Remove cylinder head (6), intermediate ring

(14), two pushrod cover tubes (15), compression
springs (16), four preformed packings (17), and
two caps (18) from cylinder (19). Discard
intermediate ring and preformed packings.

3-38
 TM 10-3930-669-34

b. Installation.

(1) Apply a light coat of grease to intermediate ring

(14) and position on cylinder head (6).

(2) Position cylinder head (6) on cylinder (19).

(3) Apply a light coat of oil to threads of four screws

(12) and install screws and washers (13) in
cylinder head (6). Preload four screws to 30 lb-ft
(40 N•m). Tighten screws (see Appendix D).

(4) Install two preformed packings (11) and plugs

(10) in cylinder head (6). Tighten plugs to 59 to
66 lb-ft (80-90 N•m).

3-39
 TM 10-3930-669-34

3-5. CYLINDER HEAD ASSEMBLY REPLACEMENT (CONT).

WARNING

Use care when installing springs.

Springs are under compression
tension and can act as projectiles
when released and could cause sever
injury.

NOTE

Pushrod cover tubes are installed

one at a time. Both are installed the
same way.

(5) Position compression spring (16) on pushrod

cover tube (15) and compress spring with spring
compressor.

(6) Position two preformed packings (17) and cap

(18) on pushrod cover tube (15).

NOTE

Position pushrod cover tube into the

crankcase first, then into the cylinder
head for easy installation.

(7) Install pushrod cover tube (15) in cylinder head

(6) and remove spring compressor.

3-40
 TM 10-3930-669-34

NOTE

Ensure pushrods are properly seated

upon installation.

(8) Position pushrods (9) in cylinder head (6).

NOTE

After rocker arm assembly is

installed, adjust valve clearance (TM-
10-3930-669-20), then continue with
Step (10) of cylinder head assembly
in this paragraph.

(9) Install rocker arm assembly (8) with three nuts

(7) on cylinder head (6). Tighten nuts to 21 lb-ft
(28 N•m).

(10) Apply sealing compound to gasket (5) and

position on cylinder head (6).

(11) Install rocker cover (4) and gasket (5) on

cylinder head (6) with washer (3), washer (2),
and screw (1). Tighten screw 7 lb-ft (10 N•m).

NOTE

Follow-on Maintenance:

• Install fuel lines (TM-10-3930-669-20).

• Install fuel return lines (TM-10-3930-669-20).

* Install intake manifold (Para 4-2).

• Install exhaust manifold (Para 5-2).

• Install muffler (TM-10-3930-669-20).

• Install blower ducting (Para 6-2).

• Install injector (TM 10-3930-669-20).

• Install glow plug (TM 10-3930-669-20).

• Remove wheel chocks (TM- 10-3930-669-10).

END OF TASK
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 TM 10-3930-669-34

3-6. CYLINDER HEAD REPAIR.

This task covers:

a. Disassembly c. Repair
b. Cleaning/Inspection d. Assembly

INITIAL SETUP

Tools and Special Tools Tools and Special Tools - Continued

Tool Kit, General Mechanics: Automotive Cutter, Valve Seat (Item 26, Appendix E)
(Item 1, Appendix E) Reamer, Hand (Item 27, Appendix E)
Compressor, Valve Spring Reamer, Hand (Item 28, Appendix E)
(Item 23, Appendix E) Punch Valve Guide (Item 29, Appendix E)
Depth Gauge (Item 5, Appendix E)
Drill (Item 5, Appendix E) Material/Parts
Fixture, Lathe (Item 5, Appendix E) Rags, Wiping (Item 19, Appendix B)
Micrometer (Item 5, Appendix E) Solvent, Dry-cleaning (Item 20, Appendix B)
Stud Remover (Item 5, Appendix E) Seals, Valve Stem (2)
Stone, Abrasive (Item 5, Appendix E)
Mandrel, Exhaust (Item 24, Appendix E) Equipment Condition
Mandrel, Intake (Item 25, Appendix E) Cylinder head removed (Para 3-5)

a. Disassembly.

(1) Place cylinder head (1) on clean surface.

(2) Using valve spring compressor, remove two

valve spring keepers (2), spring caps (3), springs
(4), valve stem seals (5), valve rotators (6), and
inlet and exhaust valves (7 and 8) from cylinder
head (1). Discard valve stem seals.

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 TM 10-3930-669-34

(3) Remove three studs (9) from cylinder head (1).

(4) Remove four studs (10) from cylinder head (1).

b. Cleaning/Inspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean parts in dry-cleaning solvent. Dry parts using clean wiping rag.

(2) Inspect cylinder head for external damage or cracks. Replace cylinder head if damaged or cracked.

(3) Inspect cylinder head parts for defects. Replace defective parts.

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 TM 10-3930-669-34

3-6. CYLINDER HEAD REPAIR (CONT).

c. Repair.
CAUTION

Perform all inspections before beginning repairs. Do not reheat cylinder head. Too much heating
may warp head.

NOTE

• Use the following procedure to make sure cylinder head seating surface is flat and
square.

• Remove as little material as possible to achieve a perfect sealing surface.

(1) Check cylinder head seating surface (11).

Surface must be flat and square. Minor damage
to seating surface can be removed by grinding
cylinder head on cylinder with abrasive stone.

(2) If cylinder head seating surface (11) is more

severely damaged, replace cylinder head (Para
3-5).

NOTE

• Use the following procedure to make sure valve springs, valve rotators, spring caps,
valves, and valve seats are within specification.

• Measurement must be made with intermediate ring inserted.

(3) Inspect intermediate ring (12). Replace if damaged.

(4) After refacing cylinder head seating surface (11), measure clearance between cylinder head bottom and cylinder
head seating surface. If measured value is not between 0.2323 in. (5.9000 mm) and 0.2519 in. (6.4000 mm),
replace valve seats (13).

(5) Inspect valve seats (13). Measure distance between crown of valve and cylinder head seating surface (11). If
measured distance is not between 0.2000 in. (5.0800 mm) and 0.2205 in. (5.6000 mm), replace valve seats.

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 TM 10-3930-669-34

(6) Fit valve stem seals (5) and, using a

micrometer, measure valve spring (4) length. If
measured value is not between 2.2047 inch
(56.0000 mm) and 2.3976 inch (60.9000 mm),
replace valve springs.

(7) Inspect valve rotators (6) and spring caps (3)

for damage. Make sure valve rotators work
freely. Replace valve rotators and spring caps
if damaged.

(8) Inspect inlet and exhaust valves (7 and 8) for

cracks and pits. Replace as required. Reface
valves if required and inspect to tolerances
specified in Table 3-1.

(9) Check clearance of valve stems (14) in valve

guides (15) of inlet and exhaust valves (7 and
8). If clearance exceeds 0.0059 in. (0.1500
mm) for inlet valve or 0.0079 in. (0.2000 mm)
for exhaust valve, replace guides.

(10) Check inner diameter clearance of valve guides

(15) (pressed in). If inner diameter clearance
exceeds 0.3155 in. (8.0150 mm), replace valve
guides.

3-45
 TM 10-3930-669-34

3-6. CYLINDER HEAD REPAIR (CONT).

NOTE

• Use the following procedure to replace valve seats and valve guides.

• Mandrels come in two sizes; one to fit exhaust valve seat and the other to fit intake valve
seat.

(11) Place mandrel on valve seat (13) and insert

guide through mandrel into valve guide (15).
Tighten guide so that mandrel is firmly in place.

CAUTION

Do not drill into cylinder head.

Damage to equipment may result.

(12) Insert drill into mandrel and drill through valve

seat (13) at two positions 180 degrees apart.

(13) Remove guide and mandrel.

(14) Carefully remove and discard drilled seat (13)

from cylinder head (1).

(15) Measure diameter of valve seat bore (16) in

cylinder head (1).

NOTE

Intake valve seat has a larger outside

diameter than exhaust valve seat.

(16) Measure outside diameter of new valve seat

(13). Subtract diameter of bore (16) from
diameter of seat. Difference must not be less
than 0.003 inch (0.076 mm).

CAUTION

Heating cylinder head for longer than 30 minutes or at a higher temperature than
430°F (220° C) may cause head to warp.

(17) Heat cylinder head (1) in oven uniformly to a temperature of 430° F (220° C). Do not heat for more than 30
minutes.

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 TM 10-3930-669-34

WARNING

Exercise care when working around

hot cylinder head. Wear gloves.
Severe burns can result if protective
measures are not taken.

(18) Remove cylinder head (1) from oven.

NOTE
Replace valve guides in need of
replacement at this time.

(19) Insert punch into chamber side of valve guide

(15) and drive guide out of cylinder head (1).

(20) Place new valve seat (13) on drift with

chamfered side up and drive seat into recess of
cylinder head (1). Ensure that seat is fully
inserted.

(21) Position new locating ring on valve guide (15)

and drive longer end of guide into bore from
rocker arm side. Drive in until locating ring seats
in guide bore.

(22) After head cools, ream valve guides (15) using

special 8.0000 mm (0.3149 in.) reamer.

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 TM 10-3930-669-34

3-6. CYLINDER HEAD REPAIR (CONT).

d. Assembly.

(1) Install four studs (10) in cylinder head (1).

(2) Install three studs (9) in cylinder head (1).

(3) Position inlet and exhaust valves (7 and

8), two valve rotators (6), valve stem seals
(5), springs (4), and spring caps (3) in
cylinder head (1).

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 TM 10-3930-669-34

(4) Using valve spring compressor, install two

valve spring keepers (2) in spring caps (3)
to lock in valve stems (14).

NOTE

Follow-on Maintenance:

• Install cylinder head (Para 3-5).

END OF TASK

3-49
 TM 10-3930-669-34

3-7. CYLINDER REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Cylinder head removed (Para 3-5)
(Item 1, Appendix E)
Compressor, Piston Ring
(Item 20, Appendix E)

Materials /Parts
Grease, Automotive and Artillery
(Item 13, Appendix B)
Lubricating Oil (Item 15, Appendix B)
Shim (3)

a. Removal.

CAUTION

Ensure that piston will not tilt over

and hit engine block after removal of
cylinder, or damage to piston may
occur.

NOTE

All four cylinders are removed the

same way. No. 1 cylinder shown.

(1) Remove cylinder (1) from engine block (2),

and place two wooden blocks under piston
(3).

(2) Remove shims (4) from cylinder

(1).Discard shims.

3-50
 TM 10-3930-669-34

b. Installation.

NOTE

• Piston crown clearance is 0.0398

to 0.0472 (1 to 1.2 mm).

• Adjust clearance by shims, 0.2

mm, 0.5 mm, 0.8 mm, or 1.0 mm.
Keep the number of shims in the
stack to an absolute minimum.

(1) Apply light coat of grease to shims (4), and

install on cylinder (1).

(2) Apply light coat of oil on piston rings (5).

(3) Position ring compressor over piston rings (5) on

piston (3) and compress rings.

NOTE

Be sure to align cylinder on the

engine block so recessed fins on
cylinder align with tappet bores.

(4) Position cylinder (1) on piston (3). Remove ring

compressor.

NOTE
After installation of cylinder, be sure
to align with adjacent cylinders.

(5) Remove two wooden blocks from under piston

(3) and install cylinder (1) in engine block (2).

NOTE

Follow-on Maintenance:

• Install cylinder head (Para 3-5).

END OF TASK

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 TM 10-3930-669-34

3-8. ENGINE OIL PAN REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Transmission removed (Para 8-3)
(Item 1, Appendix E)

Materials/Parts
Compound, Sealing (Item 24, Appendix B)
Solvent, Dry-cleaning (Item 20, Appendix B)
Gasket
Gasket

a. Removal.

NOTE

Engine must be attached to stand

prior to performing procedure.

(1) Rotate engine (1) until oil pan (2) is on top.

(2) Remove twenty-one screws (3) and washers (4)

from oil pan (2).

(3) Remove oil pan (2), gasket (5), intermediate

plate (6), and gasket (7) from engine (1).
Discard gaskets.

3-52
 TM 10-3930-669-34

b. Cleaning/Inspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and
gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and
do not breathe vapors. Keep away from heat or flame. Never smoke when using
solvent; the flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is
138°F (50°C). Failure to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and
medical help. If solvent contacts skin or clothes, flush with cold water. If solvent
contacts eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal protective equipment (goggles/shield, gloves,
etc.). Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with dry-cleaning solvent.

(2) Inspect all parts for cracks or damage.

(3) Replace all damaged parts.

c. Installation.

WARNING

Adhesive sealant MIL-S-46163 can damage your eyes. Wear safety goggles/glasses
when using; avoid contact with eyes. If sealant contacts eyes, flush eyes with
water and get immediate medical attention.

(1) Apply sealing compound to all gasket mating

surfaces and position gasket (7), intermediate
plate (6) and gasket (5) on engine (1).
(2) Install oil pan (2) on engine (1) with twenty-one
washers (4) and screws (3).
(3) Rotate engine (1) until oil pan (2) is on bottom.

NOTE

Follow-on Maintenance:

• Install transmission (Para 8-3).

END OF TASK

3-53
 TM 10-3930-669-34

3-9. CRANKSHAFT PULLEYNIBRATION DAMPER REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit General Mechanic’s: Automotive Engine/Transmission assembly removed
(Item 1 Appendix E) (Para 3-3)
Wrench, Torque (0-60 N.m) Blower belt tensioner removed
(Item 5, Appendix E) (TM 10-3930-669-20)
Retainer (Item 13, Appendix E) Alternator belts removed (TM 3930-669-20)

a. Removal

NOTE
Crankshaft pulley screw has left-hand threads.

(1) Install retainer No. 030 1107 on crankshaft pulley (1) and remove screw (2) and washer (3).

(2) Remove crankshaft pulley (1) from front cover (4).

(3) Remove eight screws (5), washers (6), and vibration damper (7) from crankshaft pulley (1).

b. Installation.

(1) Install vibration damper (7) on crankshaft pulley (1) with eight washers (6) and screws (5).

(2) Install crankshaft pulley (1) on front cover (4) with washer (3) and screw (2). Preload screw 36.9 lb-ft (50 N-
m). Tighten screw (see Appendix D).

NOTE

Follow-on Maintenance:

• Install engine/transmission assembly

(Para 3-3).

• Install blower belt tensioner

(TM 10-3930-669-20).

• Install alternator belts

(TM 3930-669-20).

END OF TASK

3-54
 TM 10-3930-669-34

3-10. ENGINE FRONT COVER REPLACEMENT/REPAIR.

This task covers:

a. Removal c. Cleaning/Inspection e. Installation
b. Disassembly d. Assembly

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Alternator removed (TM-10-3930-669-20)
(Item 1, Appendix E) Alternator bracket removed
(TM- 10-3930-669-20)
Materials/Parts Blower removed (TM-10-3930-669-20)
Solvent, Dry-cleaning (Item 20, Appendix B) Crankshaft pulley removed (Para 3-9)
Compound, Sealing (Item 24, Appendix B) Injection pump removed (Para 4-5)
Gasket
Packing, Preformed
Packing, Preformed
Packing, Preformed
Packing, Preformed
Washer, Lock (4)
Washer, Lock (4)
Washer, Lock

a. Removal.

(1) Remove screw (1) and washer (2) from front

cover (3).

(2) Remove four screws (4) and lock washers (5)

from front cover (3). Discard lock washers.

(3) Remove four screws (6), lock washers (7), and

sixteen spacers (8) from front cover (3). Discard
lock washers.

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 TM 10-3930-669-34

3-10. ENGINE FRONT COVER REPLACEMENT/REPAIR (CONT).

(4) Remove screw (9) and washer (10) from front

cover (3).
(5) Remove front cover (3) and gasket (11) from
crankcase (12). Discard gasket.

b. Disassembly.

(1) Remove filler cap (13) and spacer ring

(14) from front cover (3).

(2) Remove screw (15) and preformed

packing (16) from front cover (3). Discard
preformed packing.

(3) Remove body (17) from angle drive (18).

(4) Remove tach drive nut (19) and shaft (20)

from body (17).

(5) Remove angle drive (18), adapter (21) and

lock nut (22) from front cover (3).

(6) Remove screw (23), lock washer (24),

cover (25), and preformed packing (26)
from front cover (3). Discard lock washer
and preformed packing.

(7) Remove two studs (27 and 28) from front

cover (3).

(8) Remove preformed packing (29) from

front cover (3). Discard preformed
packing.

(9) Remove plate (30), three screws (31) and

gasket (32) from front cover (3).

3-56
 TM 10-3930-669-34

c. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles

and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and
clothes; and do not breathe vapors. Keep away from heat or flame. Never smoke
when using solvent; the flashpoint for type I dry-cleaning solvent is 100°F (38°C)
and for type II is 138°F (50°C). Failure to do so may result in injury or death to
personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air
and medical help. If solvent contacts skin or clothes, flush with cold water. If
solvent contacts eyes, immediately flush eyes with water and get immediate
medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.). Failure to comply may result in injury or death to
personnel.

(1) Clean all metal parts with dry-cleaning

solvent.

(2) Inspect all parts for cracks or damage.

(3) Replace all damaged parts.

d. Assembly.

(1) Install gasket (32) and plate (30) on front

cover (3) with three screws (31).

(2) Install preformed packing (29), and two

studs (27 and 28) in front cover (3).

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 TM 10-3930-669-34

3-10. ENGINE FRONT COVER REPLACEMENT/REPAIR (CONT).

(3) Install preformed packing (26) and cover

(25) on front cover (3) with lock washer
(24) and screw (23).

(4) Install lock nut (22), adapter (21), and

angle drive (18) in front cover (3).

(5) Install body (17) on angle drive

(18).Tighten body.

(6) Install tach drive nut (19) and shaft (20) on

body (17).

(7) Install preformed packing (16) and screw

(15) in front cover (3).

(8) Install filler cap (13) and spacer ring (14) in

front cover (3).

e. Installation.

(1) Apply sealing compound to gasket (11)

and position on front cover (3).

(2) Install front cover (3) on crankcase (12)

with two washers (10) and screws (9).

(3) Install sixteen spacers (8), four lock

washers (7), and screws (6) on front cover
(3).

(4) Install four lock washers (5) and screws

(4).

(5) Install washer (2) and screw (1).

NOTE

Follow-on Maintenance:

• Install crankshaft pulley (Para 3-9).

• Install injection pump (Para 4-5).

• Install blower (TM-10-3930-669-20).

• Install alternator bracket (TM- 10-3930-

669-20).

• Install alternator (TM-10-3930-669-20).

END OF TASK
3-58
 TM 10-3930-669-34

3-11. IDLER GEAR REPLACEMENT/REPAIR.

This task covers:

a. Removal c. Cleaning/Inspection e. Installation
b. Disassembly d. Assembly

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Front cover removed (Para 3-10)
(Item 1, Appendix E) Oil pump removed (Para 3-12)
Press, 60 Ton (Item 5, Appendix E) No. 1 piston at top dead center (TDC)
Wrench, Torque (0-60 N.m) (Para 3-3)
(Item 5, Appendix E)

Materials/Parts
Solvent, Dry-cleaning (Item 20, Appendix B)
Gaskets (2)

a. Removal

(1) Remove screw (1) and yoke spring (2)

from idler gear (3).

(2) Matchmark gear timing marks.

(3) Remove idler gear (3), journal (4), and

bushing (5) from crankcase (6).

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 TM 10-3930-669-34

3-11. IDLER GEAR REPLACEMENT/REPAIR (CONT).

b. Disassembly. Using press, remove bushing (7)

from idler gear (3).

c. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and
gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and clothes;
and do not breathe vapors. Keep away from heat or flame. Never smoke when using
solvent; the flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is
138°F (50°C). Failure to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and
medical help. If solvent contacts skin or clothes, flush with cold water. If solvent
contacts eyes, immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal protective equipment (goggles/shield,
gloves, etc.). Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with dry-cleaning solvent. Dry with compressed air.

(2) Inspect all parts for cracks or damage.

(3) Replace all damaged parts.

3-60
 TM 10-3930-669-34

d. Assembly. Using press, install bushing (7) in

idler gear (3).

e. Installation.

(1) Align gear timing marks.

(2) Install bushing (5), journal (4), and idler

gear (3) in crankcase (6) with yoke spring
(2) and screw (1). Preload screw (1) to 22
lb-ft (30 N.m). Tighten screw (see
Appendix D).

NOTE

Follow-on Maintenance:

• Install oil pump (Para 3-12).

• Install front cover (Para 3-10).

END OF TASK

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 TM 10-3930-669-34

3-12. OIL PUMP REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation

INITIAL SETUP

Tools and Special Tools Materials Parts

Tool Kit, General Mechanic’s: Automotive Solvent, Dry-cleaning (Item 20, Appendix B)
(Item 1, Appendix E) Gasket (2)
Wrench, Torque (0 - 60 N.m) Sleeve, Coupling
(Item 5, Appendix E) Washer, Lock (2)
Wrench, Torque (0 to 175 lb-ft [0-237 N-m]) Washer, Lock (2)
(Item 5, Appendix E) Washer, Lock (2)

Equipment Condition
Front cover removed (Para 3-10)
Oil pan removed (Para 3-8)

a. Removal

(1) Remove two nuts (1), lock washers (2),

and screws (3) from pipe brackets (4 and
5). Discard lock washers.

(2) Loosen ferrule nut (6) and remove suction

pipe (7) and coupling sleeve (8) from oil
pump (9). Discard coupling sleeve.

(3) Remove two screws (10), lock washers

(11), and pipe brackets (4 and 5) from
crankcase (12). Discard lock washers.

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 TM 10-3930-669-34

(4) Remove screw (13), yoke spring (14), tube (15),

and two gaskets (16) from oil pump (9) and
crankcase (12). Discard gaskets.

(5) Remove two screws (17), lock washers (18),

baffle (19), and oil pump (9) from crankcase
(12). Discard lock washers.

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 TM 10-3930-669-34

3-12. OIL PUMP REPLACEMENT (CONT).

b. Cleaning/Inspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective

goggles and gloves; use only in a well-ventilated area; avoid contact with skin,
eyes, and clothes; and do not breathe vapors. Keep away from heat or flame.
Never smoke when using solvent; the flashpoint for type I dry-cleaning solvent
is 100°F (38°C) and for type II is 138°F (50°C). Failure to do so may result in
injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh
air and medical help. If solvent contacts skin or clothes, flush with cold water.
If solvent contacts eyes, immediately flush eyes with water and get immediate
medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa).
Use only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.). Failure to comply may result in injury or death to
personnel.

(1) Clean all metal parts with dry-cleaning solvent. Dry with compressed air.

(2) Inspect all parts for cracks or damage.

(3) Replace all damaged parts.

c. Installation.

(1) Install oil pump (9) and baffle (19) on

crankcase (12) with two lock washers (18)
and screws (17). Tighten screws to 26 lb-
ft (35 N.m).

3-64
 TM 10-3930-669-34

(2) Install yoke spring (14), tube (15), and two

gaskets (16) on oil pump (9) and crankcase (12)
with screw (13). Preload screw to 22 lb-ft (30
N.m). Tighten screw (see Appendix D).

(3) Install pipe brackets (4 and 5) on crankcase (12)

with two lock washers (11) and screws (10).

(4) Position suction pipe (7) between pipe brackets

(4 and 5) and install coupling sleeve (8), ferrule
nut (6), and suction pipe (7) on oil pump (9).
Tighten ferrule nut to 59 to 74 lb-ft (80-100 N.m).

(5) Install two screws (3), lock washers (2), and nuts
(1) on pipe brackets (4 and 5).

NOTE

Follow-on Maintenance:

• Install oil pan (Para 3-8).

• Install front cover (Para 3-10).

END OF TASK

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 TM 10-3930-669-34

3-13. PISTON AND CONNECTING ROD ASSEMBLY REPLACEMENT/REPAIR.

This task covers:

a. Removal c. Inspection e. Installation
b. Disassembly d. Assembly

INITIAL SETUP

Tools and Special Tools Materials Parts

Tool Kit, General Mechanic’s: Automotive Lubricating Oil (Item 15, Appendix B)
(Item 1, Appendix E) Rags, Wiping (Item 19, Appendix B)
Gauge, Dial, Bore, Cylinder Solvent, Dry-cleaning
(Item 5, Appendix E) (Item 20, Appendix B)
Wrench, Torque (0-60 N.m) Washer, Lock (2)
(Item 5, Appendix E) Washer, Lock (2)
Heater (Item 5, Appendix E)
Press, 60 Ton (Item 5, Appendix E) Equipment Condition
Pliers, Snap ring (Item 5, Appendix E) Cylinders removed (Para 3-7)
Gage, Tightening (Item 22, Appendix E) Oil pump removed (Para 3-12)

a. Removal.

NOTE
• All piston and connecting rod
assemblies are removed the
same way. Piston and
connecting rod assembly No. 4
is shown.

• Do not miss match connecting

rod bearing caps.

(1) Remove two screws (1) and connecting rod

bearing cap (2) from piston and connecting rod
assembly (3).

(2) Remove bearing half (4) from connecting rod

bearing cap (2).

3-66
 TM 10-3930-669-34

(3) Remove piston and connecting rod

assembly (3) from crankcase (5).

(4) Remove bearing half (6) from piston and

connecting rod assembly (3).

b. Disassembly.

WARNING

Use care when removing snap

ring and retaining rings. Snap
ring and retaining rings are
under spring tension and can
act as projectiles when released
and could cause severe eye
injury.

(1) Remove two retaining rings (7), pin (8),

and connecting rod (9) from piston (10).

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 TM 10-3930-669-34

3-13. PISTON AND CONNECTING ROD ASSEMBLY REPLACEMENT/REPAIR (CONT).

(2) Remove locating pin (11) and sleeve bushing

(12) from connecting rod (9).

(3) Remove trapezoidal ring (13), two taper-faced

rings (14), and oil control ring (15) from piston
(10).

3-68
 TM 10-3930-669-34

c. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles

and gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and
clothes; and do not breathe vapors. Keep away from heat or flame. Never smoke
when using solvent; the flashpoint for type I dry-cleaning solvent is 100°F (38°C)
and for type II is 138°F (50°C). Failure to do so may result in injury or death to
personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air
and medical help. If solvent contacts skin or clothes, flush with cold water. If
solvent contacts eyes, immediately flush eyes with water and get immediate
medical attention.

(1) Clean parts in dry-cleaning solvent. Dry all parts using a clean shop rag.

NOTE
All measurements are according to Table 3-1.

(2) Inspect piston (10) for damage or visible

wear, including bosses. Measure
diameter of piston at position A. Normal
diameter is between 3.9331 in. (99.9010
mm) to 3.9338 in. (99. mm). If not in
range, replace piston.

(3) Measure outside diameter of pin (8) at

position B. Normal diameter is between
1.3777 in. (34.9940 mm) to 1.3779 in.
(35.0000 mm). If not in range, replace pin.

(4) Measure ring grooves on piston (Table 3-

1).
(5) Measure trapezoidal ring (13), taperfaced
rings (14), and oil control ring (15) at
position C (Table 3-1). Insert each piston
ring (one at a time) into cylinder and press
down with piston to a distance of 30 mm
from cylinder head contacting surface.
Measure gap of piston ring and compare
with gap clearance in Table 3-1. If
measurement is wrong, replace ring.

(6) Make all necessary measurements of

piston (10) and connecting rod (9)
assemblies according to Table 3-1.

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 TM 10-3930-669-34

3-13. PISTON AND CONNECTING ROD ASSEMBLY REPLACEMENT/REPAIR (CONT).

(7) Inspect cylinder liner as follows:

NOTE

If cylinder liner and or piston is worn

beyond limits, replace cylinder and
piston as a set.

(a) Set precision gauge to 3.937 in. (100.000

mm).

(b) Gauge cylinder bore at levels i to 4 of

engine centerline "a" as well as crossline
"b."

(c) Compare readings with above dimensions.

If not within plus 0.0079 in. (0.2200 mm),
replace cylinder and piston as a set.

(8) Check that cylinder top and bottom joint faces

are flat. Replace cylinders as needed.

d. Assembly.

NOTE
Ring gaps should be positioned at
90° intervals.

(1) Install oil control ring (15) on piston (10).

(2) Install two taper-faced rings (14) on piston (10)

with face marked "Top" toward top of piston.

(3) Install trapezoidal ring (13) on piston (10) with

face marked "Top" toward top of piston.

3-70
 TM 10-3930-669-34

(4) Install sleeve bushing (12) and locating pin (11)

in connecting rod (9).

Use care when installing snap ring

and retaining rings. Snap ring and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(5) Install one retaining ring (7) in piston (10).

Use care when working around hot

pistons. Gloves must be worn.
Severe burns can result if protective
measures are not taken.

NOTE

Step (6) below may not be necessary.

Try to perform step (7) below first.

(6) Using piston heater, heat piston (10) to

approximately 176°F (80'C).

(7) Apply a light coat of oil to pin (8) and install

connecting rod (9) in piston (10) with pin (8).

(8) Install other retaining ring (7) in piston (10).

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 TM 10-3930-669-34

3-13. PISTON AND CONNECTING ROD ASSEMBLY REPLACEMENT/REPAIR (CONT).

e. Installation.

(1) Install bearing half (6) in piston and

connecting rod assembly (3).

(2) Position piston and connecting rod

assembly (3) in crankcase (5).

(3) Install bearing half (4) in connecting rod

bearing cap (2).

(4) Install connecting rod bearing cap (2) on

piston and connecting rod assembly (3)
with two screws (1). Preload screw to 22
lb-ft (30 N•m). Tighten screws (see
Appendix D)

NOTE

Follow-on Maintenance:

• Install oil pump (Para 3-12).

• Install cylinders (Para 3-7).

END OF TASK

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 TM 10-3930-669-34

3-14. CRANKSHAFT REPLACEMENT/REPAIR.

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly

INITIAL SETUP

Tools and Special Tools Materials/Parts - Continued

Tool Kit, General Mechanic’s: Automotive Solvent, Dry-cleaning
(Item 1, Appendix E) (Item 34, Appendix B)
Drill (Item 5, Appendix E) Magnaflux Penetrant (Item 28, Appendix C)
Micrometer (Item 5, Appendix E) Gasket
Gauge, Dial, Bore, Cylinder Plugs (4)
(Item 5, Appendix E) Seal
Press, 60 Ton (Item 5, Appendix E) Washers (4)
Puller, Bearing (Item 5, Appendix E)
Wrench, Torque (0-60 N•m) Equipment Condition
(Item 5, Appendix E) Flywheel removed (Para 8-9)
Piston and connecting rod assemblies
Materials /Parts removed (Para 3-13)
Grease, Automotive and Artillery
(Item 13, Appendix B)
Lubricating Oil (Item 15, Appendix B)

a. Removal.

(1) Remove eight screws (1), washers (2),

cover (3), and gasket (4) from crankcase
(5). Discard gasket.

(2) Remove seal (6) from cover (3). Discard

seal.

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 TM 10-3930-669-34

3-14. CRANKSHAFT REPLACEMENT/REPAIR (CONT).

NOTE

Matchmark main bearing cap and

screws for ease of ’installation.

(3) Remove ten bolts (7), washers (8), four

bearing caps (9), and bearing cap (10)
from crankcase (5).

NOTE

Note location and position of stop

rings.

(4) Remove five bearing halves (11), ten

dowel bushings (12), and stop rings (13)
from bearing caps (9 and 10).

Crankshaft assembly weighs 79 lb (36

kg). Remove with aid of assistant to
prevent possible injury to personnel.

(5) With aid of assistant, remove crankshaft

assembly (14), five bearing halves (15),
and stop rings (16) from crankcase (5).

3-74
 TM 10-3930-669-34

b. Disassembly.

NOTE

Mark position of balancing weights

prior to removal.

(1) Remove eight screws (17), washers (18),

and four balancing weights (19) from
crankshaft (20).

(2) Using puller, remove gear (21) and pin (22) from crankshaft (20).

(3) Remove pin (23) from crankshaft (20).

(4) Using a drill, remove four plugs (24) and washers (25) from crankshaft (20). Discard plugs and washers.

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 TM 10-3930-669-34

3-14. CRANKSHAFT REPLACEMENT/REPAIR (CONT)

c. Cleaning/lnspection.

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38'C) and for type II is 138°F (50°C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi. Use only with effective
chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

(1) Clean all metal parts in dry-cleaning solvent. Dry thoroughly.

(2) Inspect stop rings for defects. Replace if defective.

(3) Check locating pin in crankshaft gearwheel. It should project 0.67 inch (17mm) from side opposite that
bearing identification mark. If necessary, install a new locating pin.

(4) Using magnaflux penetrate, check crankshaft for cracks. Replace crankshaft if cracked.

3-76
 TM 10-3930-669-34

(5) Measure crankshaft as follows:

(a) Support crankshaft at outer main journals on prism-shaped blocks.

(b) Measure outside diameter of each bearing journal at points "1" and "2," in the vertical and horizontal, as indicated
by "a" and "b."

(c) Measure width "3" for a loading bearing.

(d) Note measurements and compare with the following:

1 Crankshaft bearing diameter: 2.75 inches (70 mm) maximum.

2 Crankshaft center locating bearing: 2.75 inches (70 mm).

3 Length of journal: 1.46 inches (37 mm) minimum.

(e) Wear limit for ovality is 0.0008 inch (0.01 mm).

(f) Using a micrometer, check other journals for out-of-round. Refer to Table 3-1 for tolerances.

(g) Check working surface of radial packing ring on flywheel flange. Replace crankshaft if it is defective.

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 TM 10-3930-669-34

3-14. CRANKSHAFT REPLACEMENT/REPAIR (CONT).

The main bearings are of thin-shell type. Their proper installation requires that webs in crankcase
be in alinement and for bearing bores to be preloaded. No attempt should be made to adjust or
recondition bearing shells. Severe engine damage may result.

(6) Check preloading of bearing bores as follows:

(a) Position bearing caps, making sure that their identification number match with those stamped in crankcase.
Torque bolt in accordance instructions given in Table 3-1.

(b) Using a micrometer and precision gauge, set gauge to 2.93 inches (74.5 mm).

(c) Measure each main bearing bore at points 1 and 2 in plane "a," then in the same manner in plane "b" offset
by 90 degrees.

(d) If the recorded value is between 2.933 inches (74.50 mm) and 2.9334 inches (74.508 mm), respective
bearing is in acceptable condition and required preload will be obtained when bearing halves are installed.

(e) If recorded bearing bore diameters differ from the specified values given above, repeat measurements with
new bearing halves installed.

d. Assembly.

(1) Using a press, install pin (23) in crankshaft

(20).

3-78
 TM 10-3930-669-34

(2) Install four washers (25) and plugs (24) in

crankshaft (20).

(3) Using press, install pin (22) and gear (21) with
face bearing identification mark directed away
from crankshaft.

(4) Install four balancing weights (19) on crankshaft

(20) with eight washers (18) and screws (17).
Preload screws to 22 lb-ft (30 N•m). Tighten
screws (Appendix D).

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 TM 10-3930-669-34

3-14. CRANKSHAFT REPLACEMENT/REPAIR (CONT).

e. Installation.

(1) Apply grease on stop rings (16) and install

in matchmarked locations in crankcase
(5).

(2) Install five bearing halves (15) in

crankcase (5), making sure that
matchmark locations are correct.

(3) Using oil, lubricate crankshaft assembly

(14) journals and install with crankshaft
gear (21) matchmark positioned properly.

(4) Apply grease on stop rings (13) and install

in matchmarked locations.

(5) Install ten dowel bushings (12).

(6) Install five bearing halves (11) in

matchmarked locations of bearing caps (9
and 10) making sure they are seated
properly.

NOTE

Start by tightening middle bearing

caps and finish with bearing caps at
ends. The crankshaft must be able to
rotate freely.

(7) Install bearing caps (9 and 10), with their

matchmarked locations corresponding to
that of crankcase (5), install ten washers
(8) and ten screws (7). Preload screws
(7) to 22 lb-ft (30 N•m). Tighten screw
(see Appendix D).

3-80
 TM 10-3930-669-34

(8) Using dial indicator, measure the float of the

crankshaft.

NOTE

If crankshaft end float requires

additional shimming, repeat
replacement procedures.

(9) Crankshaft end float is 0.006 to 0.012 in. (0.15-

0.314 mm). Add or subtract shims as required.

(10) Press seal (6) into cover (3).

(11) Install gasket (4) and cover (3) and secure with
eight washers (2) and eight screws (1).

NOTE

Follow-on Maintenance:

• Install flywheel (Para 8-9).

• Install piston and connecting rod assemblies

(Para 3-13).

END OF TASK

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 TM 10-3930-669-34

3-15. ROCKER ARM AND PUSHROD REPLACEMENT/REPAIR.

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly

INITIAL SETUP

Tools and Special Tools Materials/Parts

Tool Kit, General Mechanic’s: Automotive Compound, Sealing (Item 24, Appendix B)
(Item 1, Appendix E) Gasket
Wrench, Torque (0-60 N.m)
(Item 5, Appendix E) Equipment Condition
Pliers, Snap Ring (Item 5, Appendix E) Cab removed (TM 10-3930-669-20)

a. Removal

NOTE

All rocker arms and pushrods are removed the same. Cylinder No. 1 is shown.

(1) Remove screw (1), washer (2), washer (3), valve cover (4), and gasket (5) from cylinder head (6). Discard
gasket.

3-82
 TM 10-3930-669-34

(2) Remove three nuts (7) and rocker arm

assembly (8) from cylinder head (6).

(3) Remove two pushrods (9) from cylinder

head (6).

b. Disassembly.

Use care when removing snap rings.

Snap rings are under compression
tension and can act as projectiles
when released which could cause
severe injury.

(1) Remove two retaining rings (10), two

washers (11), and two rocker arms (12)
from rocker bracket (13).

(2) Remove nut (14) and screw (15) from two

rocker arms (12).

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 TM 10-3930-669-34

3-15. ROCKER ARM AND PUSHROD REPLACEMENT/REPAIR (CONT).

c. Cleaning/lnspection.

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38"C) and for type II is 138°F (50°C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
Failure to comply may result in injury or death to personnel.

(1) Clean all metal parts with dry-cleaning solvent. Dry with compressed air.

(2) Inspect all parts for cracks or damage.

(3) Replace all damaged parts.

d. Assembly.

Use care when installing snap rings.

Snap rings are under compression
tension and can act as projectiles
when released which could cause
severe injury.

(1) Install screw (15) and nut (14) on two

rocker arms (12).

(2) Install two rocker arms (12), two washers

(11), and two retaining rings (10) on rocker
bracket (13).

3-84
 TM 10-3930-669-34

e. Installation.

(1) Install two pushrods (9) in cylinder head

(6).

(2) Install rocker arm assembly (8) on cylinder

head (6) with three nuts (7). Tighten nuts
to 21 lb-ft (28 N•m).

(3) Adjust rocker arms. Refer to (TM 10-

3930-669-20) for adjustment.

(4) Apply sealing compound to gasket (5) and

position on cylinder head (6).

(5) Install washer (2), washer (3), and valve

cover (4) on cylinder head (6) with screw
(1). Tighten screw to 7 lb-ft (10 N•m)

NOTE

Follow-on Maintenance:

• Install cab (TM 10-3930-669-20).

END OF TASK

3-85
 TM 10-3930-669-34

3-16. CAMSHAFT REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Oil pump removed (Para 3-12)
(Item 1 Appendix E) Idler gear removed (Para 3-11)
Pistons and connecting rods removed
Materials/Parts (Para 3-13)
Lubricating Oil (Item 15, Appendix B)
Solvent, Dry-cleaning (Item 20, Appendix B)

a. Removal

(1) Remove cap (1) and spring (2) from

camshaft (3).

NOTE

• Use care when removing

camshaft. If camshaft lobes
contact crankcase, damage to
camshaft could result.

• Turn engine upside down before

attempting to remove camshaft.
Rotate camshaft to clear tappets
during removal of camshaft.

(2) Remove camshaft (3), washer (4), and

eight tappets (5) from crankcase (6).

3-86
 TM 10-3930-669-34

b. Cleaning/lnspection.

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38'C) and for type II is 138°F (50'C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts in dry-cleaning solvent. Dry thoroughly.

(2) Check tappets for excessive wear (contacting face must be convex) and oil hole not obstructed.

(3) Inspect camshaft for cracks and scores using the magnetic particle method. Replace if defective.

(4) Measure camshaft bearing journal outside diameter. Record journal diameter.

(5) Measure inside diameter of bearing. Subtract journal diameter from its bearing inside diameter. Replace
bearing if difference (clearance) is more than 0.0079 inch (0.20mm).

3-87
 TM 10-3930-669-34

3-16. CAMSHAFT REPLACEMENT (CONT).

c. Installation.

(1) Lubricate eight tappets (5) with oil and

install in crankcase (6).

(2) Install washer (4) on camshaft (3).

NOTE

Use care when installing camshaft. If

camshaft lobes contact crankcase,
damage to camshaft could result.

(3) Lubricate camshaft (3) with oil and install

with camshaft gear positioned as shown.

(4) Check camshaft gear lineup carefully.

Dots and characters must match
illustration.

(5) Install spring (2) and cap (1) on camshaft

(3) end.

NOTE

Follow-on Maintenance:

• Install idler gear (Para 3-11).

• Install oil pump (Para 3-12).

• Install piston and connecting rod

assemblies (Para 3-13).

END OF TASK

3-88
 TM 10-3930-669-34

3-17. INJECTION PUMP TIMING GEAR REPLACEMENT/REPAIR.

This task covers:

a. Removal c. Cleaning/Inspection e. Installation

b. Disassembly d. Assembly

INITIAL SETUP

Tools and Special Tools Materials /Parts

Tool Kit, General Mechanic’s: Automotive Cloth, Lint-free (Item 6, Appendix B)
(Item 1, Appendix E) Solvent, Dry-cleaning (Item 20, Appendix B)
Wrench, Torque (0 to 175 lb-ft [0-237 N.m])
(Item 5, Appendix E) Equipment Condition
Puller, Injector Timing Gear No. 1 piston at top dead center (TDC)
(Item 32, Appendix E) (TM 10-3930-669-20)
Front cover removed (Para 3-10)

a. Removal

NOTE

Ensure that engine timing marks are

aligned prior to removal of timing
gear.

(1) Remove gear retaining nut (1) from

injection pump shaft (2) in crankcase (3).

Use care in removing timing gear.

Gear could fall and be damaged.

(2) Using a gear puller, remove timing gear

(4) from injection pump shaft (2).

(3) Remove key (5) from injection pump shaft

(2).

b. Disassembly. Remove three screws (6), spring

washers (7), washers (8), and hub (9) from
timing gear (4).

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 TM 10-3930-669-34

3-17. INJECTION PUMP TIMING GEAR REPLACEMENT/REPAIR (CONT).

c. Cleaning/lnspection.

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38'C) and for type II is 138°F (50'C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
Failure to comply may result in injury or death to personnel.

(1) Clean timing gear with dry-cleaning

solvent.

(2) Inspect timing gear for cracks, wear, or

damage.

(3) Replace damaged timing gear.

d. Assembly. Install hub (9) on timing gear (4)

with three washers (8), spring washers (7) and
screws (6).

e. Installation.

(1) Install key (5) in fuel injection pump shaft

(2) keyway in crankcase (3).

3-90
 TM 10-3930-669-34

(4) Check timing gear lineup carefully. Dots

and characters must match illustration.

(5) Align timing gear (4) keyway with pump

shaft key and gear/crankcase position
mark Install gear.

(6) Install gear retaining nut (1) on injection

pump shaft (2). Tighten nut to 44 to 52 lb-
ft (60-70 N•m).

NOTE

Follow-on Maintenance:

• Install front cover (Para 3-10).

• Adjust fuel injection pump timing

(Para 4-4).

END OF TASK

3-91
 TM 10-3930-669-34

3-18. FLYWHEEL HOUSING REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation

INITIAL SETUP

Tools and Special Tools Materials /Parts

Tool Kit, General Mechanic’s: Automotive Cloth, Lint-free (Item 6, Appendix B)
(Item 1, Appendix E) Solvent, Dry-cleaning (Item 20, Appendix B)
Wrench, Torque (0 to 175 lb-ft [0-237 N.m])
(Item 5, Appendix E) Equipment Condition
Engine/transmission assembly removed
Personnel Required (Para 3-3)
Two Transmission removed (Para 8-3)
Torque converter removed (Para 8-8)
Flywheel removed (Para 8-9)

a. Removal

(1) Remove four screws (1), four lock

washers (2), and cover (3) from housing
(4).

(2) Remove three screws (5), three lock

washers (6), and plate (7) from housing
(4).

Flywheel housing weighs 46 lbs (21

kg). Use the aid of an assistant when
removing flywheel housing or injury
to personnel can result.

(3) Remove nine screws (8), nine

lockwashers (9), screw (10), lockwasher
(11), and housing (4) from crankcase (12).

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 TM 10-3930-669-34

3-18. FLYWHEEL HOUSING REPLACEMENT (CONT).

b. Cleaning/inspection.

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).
Failure to comply may result in injury or death to personnel.

(1) Clean flywheel housing with drycleaning

solvent.

(2) Inspect flywheel housing for cracks, wear,

or damage.

(3) Replace damaged flywheel housing.

c. Installation.

(1) Install housing (4) on crankcase (12) with

lockwasher (11), screw (10), nine
lockwashers (9), and nine screws (8).

(2) Install plate (7) on housing (4) with three

lockwashers (6), and three screws (5).

(3) Install cover (3) on housing (4) with four

lockwashers (2) and four screws (1).

NOTE

Follow-on Maintenance:

• Install flywheel (Para 8-9).

• Install torque converter (Para 8-8).
• Install front cover (Para 3-10).

END OF TASK

3-93/(3-94 blank)
 TM 10-3930-669-34

CHAPTER 4

FUEL SYSTEM MAINTENANCE

Para Contents Page

4-1 Introduction............................................................................................................................ 4-1

4-2 Intake Manifold Replacement................................................................................................ 4-2
4-3 Fuel Tank Replacement ........................................................................................................ 4-4
4-4 Injection Pump Adjustment ................................................................................................... 4-6
4-5 Injection Pump Replacement ................................................................................................ 4-17

4-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing, repairing, and testing fuel components
authorized by the Maintenance Allocation Chart (MAC) at the Direct Support and General Support Maintenance level.

4-1
 TM 10-3930-669-34

4-2. INTAKE MANIFOLD REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Engine OFF (TM 10-3930-669-10)
(Item 1, Appendix E) Parking brake applied (TM 10-3930-669-10)
Wheels chocked (TM 10-3930-669-10)
Materials/Parts Right-hand engine access cover open
Gasket (4) (TM 10-3930-669-10)
Washer, Lock Batteries disconnected (TM 10-3930-669-20)
Washer, Lock (6) Blower ducting removed (Para 6-2)

a. Removal.

(1) Remove clamp (1) and tube (2) from

manifold (3).

(2) Remove screw (4), lock washer (5),

washer (6), connector (7), and bracket (8)
from manifold ducting (9). Discard lock
washer.

(3) Remove six screws (10), lock washers

(11), and washers (12) from manifold
ducting (9). Discard lock washers.

(4) Remove manifold ducting (9) from engine

(13).

(5) Remove four extension nuts (14).

4-2
 TM 10-3930-669-34

(6) Remove eight nuts (15), washers (16), and

manifold (3) from engine (13).

(7) Remove four gaskets (17) from engine (13).

Discard gaskets.

b. Installation.

(1) Position four gaskets (17) on engine (13).

(2) Install manifold (3), eight washers (16), and nuts

(15) on engine (13).

(3) Install four extension nuts (14).

(4) Install manifold ducting (9) on engine (13) with

six screws (10), lock washers (11), and washers
(12).

(5) Install bracket (8) and connector (7) to manifold

ducting (9) with screw (4), lock washer (5), and
washer (6).

(6) Install tube (2) on manifold (3) with two clamps

(1).

NOTE
Follow-on Maintenance:

• Connect batteries (TM 10-3930-669-20).

• Close right-hand engine access cover
(TM 10-3930-669-10).
• Remove wheel chocks (TM 10-3930-
669-10).
• Install blower ducting (Para 6-2).

END OF TASK

END OF TASK

4-3
 TM 10-3930-669-34

4-3. FUEL TANK REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP:

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Wheel chocked (TM 10-3930-669-10)
(Item 1, Appendix E) Fuel drained (LO 10-3930-669-12)
Fuel filler tube removed (TM 10-3930-669-20)
Materials/Parts Fuel sender removed (TM 10-3930-669-20)
Fuel Oil, Diesel (Item 9, Appendix B) Engine/transmission assembly removed
Tags, Identification (Item 21, Appendix B) (Para 3-3)
Counterweight removed (Para 13-4)
Personnel Required
Two

a. Removal.

WARNING
Fuel is very flammable and can
explode easily. To avoid serious
injury or death, keep fuel away from
open fire and keep a B-C fire
extinguisher within easy reach when
working with fuel. Do not work on
fuel system when engine is hot. Fuel
can be ignited by hot engine. When
working with fuel, post signs that
read NO SMOKING WITHIN 50 FEET
(15 m).

NOTE
Tag and mark all hoses prior to
removal.

(1) Loosen two clamp screws (1) and remove two

hoses (2) from two fittings (3).

(2) Remove extension tube (4) from fuel tank (5).

(3) Remove four screws (6) and washers (7) from

fuel tank (5).

(4) With the aid of an assistant, remove fuel tank (5)

from forklift (8).

4-4
 TM 10-3930-669-34

b. Installation.

WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away
from open fire and keep a B-C fire extinguisher within easy reach when working with fuel. Do not
work on fuel system when engine is hot. Fuel can be ignited by hot engine. When working with
fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

(1) With the aid of an assistant, install fuel tank (5)

on forklift (8) with four washers (7) and screws
(6).

(2) Install extension tube (4) on fuel tank (5).

(3) Install tube (2) on manifold (3) with clamp (1).

NOTE
Follow-on Maintenance:

• Install counterweight (Para 13-4).

• Install engine/transmission assembly

(para 3-3).

• Install fuel filler tube (TM 10-3930-669-

20).

• Install fuel sender (TM 10-3930-669-20).

• Install cab (TM 10-3930-669-20).

• Refill fuel tank (TM 10-3930-669-10).

• Remove wheel chocks (TM 10-3930-

669-10).

END OF TASK

4-5
 TM 10-3930-669-34

4-4. INJECTION PUMP ADJUSTMENT.

This task covers:

a. Removal b. Adjustment c. Removal

INITIAL SETUP:

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Engine OFF (TM 10-3930-669-10)
(Item 1, Appendix E) Wheels chocked (TM 10-3930-669-10)
Pointer, Dial (Item 5, Appendix E) No. 1 piston at top dead center (TDC)
Wrench, Torque (0 to 175 lb-ft [0-237 N•m]) (TM 10-3930-669-20)
(Item 5, Appendix E) Engine/transmission removed (Para 3-3)
High Pressure Pump (Item 30, Appendix E) Blower belt tensioner removed
(TM 10-39930-669-20)
Materials /Parts
Fuel Oil, Diesel (Item 9, Appendix B)
Rags, Wiping (Item 19, Appendix B)
Wire (Item 27, Appendix B)
Washer (7)

a. Installation.

NOTE
The left mark on the crankshaft pulley is the top dead center mark (TDC) and the right mark is the
timing mark (18 degrees BTDC).

(1) Position crankshaft pulley (1) with Top Dead Center (TDC) mark (2) at pointer.

4-6
 TM 10-3930-669-34

NOTE
All directions of engine rotation will
be stated as looking at the crankshaft
pulley end of the engine.

(2) Using retainer, rotate crankshaft pulley (1) one

half turn counter-clockwise.

WARNING

• Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel. Do
not work on fuel system when engine is hot. Fuel can be ignited by hot engine. When working
with fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

• Fuel and oil are slippery and can cause falls. To avoid injury, wipe up spilled fuel or oil with
rags.

(3) Remove screw (3), fuel line (4), and two washers
(5) from injection pump (6). Discard washers.

(4) Remove screw (7), overflow line (8), and two

washers (5) from injection pump (6). Discard
washers.

4-7
 TM 10-3930-669-34

4-4. INJECTION PUMP ADJUSTMENT (CONT).

(5) Install plug (9) and washer (5) in overflow port

(10) of injection pump (6).

(6) Position control lever (11) to maximum position

and attach wire to hold that position.

(7) Remove retaining clip (12) and plunger (13) from

fuel shutoff lever (14).

(8) Lift fuel shutoff lever (14) to maximum open

position.

4-8
 TM 10-3930-669-34

WARNING

• Fuel is very flammable and can NOTE

explode easily. To avoid serious High pressure hand feed pump must
injury or death, keep fuel away be assembled prior to installation.
from open fire and keep fire
extinguisher within easy reach
when working with fuel. Do not
work on fuel system when engine
is hot. Fuel can be ignited by hot
engine. When working with fuel,
post signs that read NO
SMOKING WITHIN 50 FEET (15
m).

• Fuel and oil are slippery and can

cause falls. To avoid injury, wipe
up spilled fuel or oil with rags.

(9) Install high pressure feed line in fuel line port

(15) of injection pump (6) with two washers (5)
and screw (16).

(10) Remove No. 1 injector line (17) from fitting (18)

of injection pump (6).

4-9
 TM 10-3930-669-34

4-4. INJECTION PUMP ADJUSTMENT (CONT).

(11) Install adapter (19) on fitting (18) of injection

pump (6).

(12) Install reservoir line on adapter (19).

(13) Install high pressure hand feed pump supply line

on fitting (20) of reservoir tank cover.

(14) Install reservoir line on fitting (21) of reservoir

tank cover.

(15) Fill reservoir tank with clean fuel.

(16) Install reservoir tank cover on reservoir tank.

4-10
 TM 10-3930-669-34

b. Adjustment.

WARNING
• Fuel is very flammable and can
explode easily. To avoid serious
injury or death, keep fuel away
from open fire and keep fire
extinguisher within easy reach
when working with fuel. Do not
work on fuel system when engine
is hot. Fuel can be ignited by hot
engine. When working with fuel,
post signs that read NO
SMOKING WITHIN 50 FEET (15
m).

• Fuel and oil are slippery and can

cause falls. To avoid injury, wipe
up spilled fuel or oil with rags.

NOTE
Air must be bled from system prior to
adjusting injection pump.

(1) Loosen plug (9) slightly.

(2) While holding a container under plug (9), operate

high pressure hand feed pump until fuel flows
past plug (9).

(3) Tighten plug (9).

(4) Actuate high pressure hand feed pump and

observe fuel flow from adapter (19).

4-11
 TM 10-3930-669-34

4-4. INJECTION PUMP ADJUSTMENT (CONT).

(5) With the aid of an assistant and using retainer, rotate pulley (1) slowly clockwise until fuel flow is reduced to
droplets.

NOTE
• If the pointer is not pointing at right-hand mark on pulley, proceed to step (6).
• If the pointer is pointing at the right-hand mark on pulley, proceed to removal step (1).

(6) Using retainer, rotate pulley (1) clockwise or counter-clockwise until pointer aligns with right-hand mark on pulley.

4-12
 TM 10-3930-669-34

CAUTION
Do not remove timing device
adjustment screws. Screws can
easily fall inside engine resulting in
damage to equipment or major
engine disassembly.

(7) Loosen three screws (22) on timing device (23).

Do not remove screws.

(8) With the aid of an assistant, perform adjustment

steps (1) through (4).

(9) Rotate clamping nut (24) until fuel flow is

reduced to droplets.

(10) Tighten three screws (22) on timing device (23).

(11) Repeat step (4) to verify adjustment.

c. Removal.

WARNING

• Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel
away from open fire and keep fire extinguisher within easy reach when working with fuel. Do
not work on fuel system when engine is hot. Fuel can be ignited by hot engine. When working
with fuel, post signs that read NO SMOKING WITHIN 50 FEET (15 m).

• Fuel and oil are slippery and can cause falls. To avoid injury, wipe up spilled fuel or oil with
rags.

NOTE
Use wiping rag to wipe up any spilled
fuel during removal of adjustment
equipment.

(1) Remove reservoir line from adapter (19).

(2) Remove adapter (19) from fitting (18) of injection

pump (6).

4-13
 TM 10-3930-669-34

4-4. INJECTION PUMP ADJUSTMENT (CONT).

(3) Install No. 1 injector line (17) on fitting (18) of

injection pump (6).

(4) Remove screw (16), high pressure feed line, and

two washers (5) from fuel line port (15) of
injection pump (6). Discard washers.

(5) Install plunger (13) in fuel shutoff lever (14) with

retaining clip (12).

4-14
 TM 10-3930-669-34

(6) Remove wire from control lever (11). Discard

wire.

WARNING

• Fuel is very flammable and can

explode easily. To avoid serious
injury or death, keep fuel away
from open fire and keep fire
extinguisher within easy reach
when working with fuel. Do not
work on fuel system when engine
is hot. Fuel can be ignited by hot
engine. When working with fuel,
post signs that read NO
SMOKING WITHIN 50 FEET (15
m).

• Fuel and oil are slippery and can

cause falls. To avoid injury, wipe
up spilled fuel or oil with rags.

(7) Remove plug (9) and washer (5) from overflow

port (10) of injection pump (6). Discard washer.

(8) Install overflow line (8) on injection pump (6) with

two washers (5) and screw (7).

(9) Install fuel line (4) on injection pump (6) with two
washers (5) and screw (3).

4-15
 TM 10-3930-669-34

4-4. INJECTION PUMP ADJUSTMENT (CONT).

(10) Remove screw (25), washer (26), and pointer

from engine (27).

(11) Install washer (26) and screw (25) in engine

(27). Tighten to 18 lb-ft (25 N•m).

NOTE
Follow-on Maintenance:

• Install blower belt tensioner (TM 10-

3930-669-20).
• Install engine/transmission (Para 3-3).
• Remove wheel chocks (TM 10-3930-
669-10).

END OF TASK

4-16
 TM 10-3930-669-34

4-5. INJECTION PUMP REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation

INITIAL SETUP:

Tools and Special Tools Materials/Parts - Continued

Tool Kit, General Mechanic’s: Automotive Seal (2)
(Item 1, Appendix E) Seal (4)
Wrench, Torque (0-60 N•m) Seal (4)
(Item 5, Appendix E) Washer, Lock (3)
Wrench, Torque (0 to 175 lb-ft [0-237 N•m])
(Item 5, Appendix E) Equipment Condition
Engine OFF (TM 10-3930-669-10)
Materials/Parts Wheels chocked (TM 10-3930-669-10)
Cap and Plug Set (Item 5, Appendix B) Engine/transmission removed (Para 3-3)
Rags, Wiping (Item 19, Appendix B) No. 1 piston at top dead center (TDC)
Solvent, Dry-cleaning (Item 20, Appendix B) (TM 10-3930-669-20)
Tags, Identification (Item 21, Appendix B) Fuel pipes removed (TM 10-3930-669-20)
Gasket Fuel shutoff solenoid removed
Packing, Preformed (TM 10-3930-669-20)
Seal V-Belt tensioner removed
(TM 10-3930-669-20)

a. Removal.

WARNING

BURN HAZARD
Allow engine to cool before performing maintenance on the muffler, exhaust pipe, exhaust
manifold, or turbocharger. If necessary, use insulated pads and gloves.

NOTE
• Tag and mark all lines and fittings prior to removal.
• Cap and plug all lines and fittings when disconnected.

(1) Remove two screws (1), fuel lines (2), and four seals (3) from fuel supply pump (4). Discard seals.

4-17
 TM 10-3930-669-34

4-5. INJECTION PUMP REPLACEMENT (CONT).

(2) Remove cable (5) from ball screw (6).

(3) Remove nut (7), washer (8), and ball screw (6)
from lever (9).

(4) Remove screw (10), two seals (11), and oil line
(12) from engine block (13). Discard seals.

(5) Remove screw (14), two seals (15), and fuel line
(16) from injection pump (17). Discard seals.

(6) Remove clamping nut (18) from timing device

(19) at the fan belt tensioner position (20) of front
engine cover (21).

4-18
 TM 10-3930-669-34

(7) Remove four nuts (22) and washers (23) from

injection pump (17) and front engine cover (21).

CAUTION

Injection pump may suddenly come

free when device is used to press
injection pump shaft from timing
device. Failure to support injection
pump could result in damage to
equipment.

(8) Install puller device in timing device (19).

(9) Using puller device, remove injection pump shaft

(24) from timing device (19).

(10) Remove injection pump (17) and gasket (25)

from engine block (13). Discard gasket.

(11) Remove key (26) from injection pump shaft (24).

(12) Place injection pump (17) on clean work surface.

4-19
 TM 10-3930-669-34

4-5. INJECTION PUMP REPLACEMENT (CONT).

(13) Remove screw (27), two seals (11), and oil line
(12) from injection pump (17). Discard seals.

(14) Remove three nuts (28), lock washers (29), fuel

supply pump (4), and seal (30) from injection
pump (17). Discard three lock washers and
seal.

b. Cleaning/Inspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves;
use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not
breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for type I dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure
to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with dry-cleaning solvent and wipe dry with wiping rag.

(2) Inspect all parts for breaks, cracks, burrs, and sharp edges.

(3) Replace all damaged parts.

c. Installation.

(1) Remove two screws (31), preformed packing

(32), pump cover (33), and seal (34) from
injection pump (17). Discard seal and preformed
packings.

(2) Turn injection pump shaft (24) counter-clockwise

until cylinder number one plunger (35) lifts.

(3) Install pump cover (33) on injection pump (17)

with seal (34), two preformed packings (32), and
screws (31). Tighten screws to 7 Ib-ft (10 N•m).

4-20
 TM 10-3930-669-34

(4) Install seal (30) and fuel supply pump (4) on

injection pump (17) with three lock washers (29)
and nuts (28). Tighten nuts to 7 lb-ft (10 N•m).

(5) Install oil line (12) on injection pump (17) with

two seals (11) and screw (27).

(6) Install key (26) in injection pump shaft (24).

(7) Position gasket (25) on engine block (13).

NOTE
Prior to mounting injection pump,
align groove in timing device with key
on injection pump shaft.

(8) Mount injection pump (17) on engine block (13)

by inserting shaft (24) and key (26) in timing
device (19).

(9) Position injection pump (17) on front engine

cover (21) with four washers (23) and nuts (22).

(10) Turn injection pump, as required, until four

washers (23) and nuts (22) are centered in
elongated holes (37) of injection pump (17).
Tighten nuts 36 lb-ft (49 N•m).

4-21
 TM 10-3930-669-34

4-5. INJECTION PUMP REPLACEMENT (CONT).

(11) Install clamping nut (18) at timing device (19).

Tighten clamping nut to 44-52 lb-ft (60-70 N•m).

(12) Install fuel line (16) on injection pump (17) with

two seals (15) and screw (14).

4-22
 TM 10-3930-669--34

(13) Install oil line (12) on engine block (13) with two
seals (11) and screw (10).

(14) Install ball screw (6), washer (8), and nut (7) on
lever (9).

(15) Install cable (5) on ball screw (6).

(16) Install two fuel lines (2), as tagged and marked

during removal, on fuel supply pump (4) with four
seals (3) and two screws (1).

NOTE
Follow-on Maintenance:

• Install V-belt tensioner (TM 10-3930-

669-20).
• Install fuel pipes (TM 10-3930-669-20).
• Install fuel shutoff solenoid (TM 10-
3930-669-20).
• Check and adjust injection pump (Para
4-4).
• Install engine/transmission (Para 3-3).

END OF TASK

4-23/(4-24 blank)
 TM 10-3930-669-34

CHAPTER 5

EXHAUST SYSTEM MAINTENANCE

Para Contents Page

5-1 Introduction ..................................................................................................................... 5-1

5-2 Exhaust Manifold Replacement ...................................................................................... 5-2

5-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing, repairing, and testing exhaust
components authorized by the Maintenance Allocation Chart (MAC) at the Direct Support and General Support
Maintenance level.

5-1
 TM 10-3930-669-34

5-2. EXHAUST MANIFOLD REPLACEMENT. ’

This task covers:

a. Removal b. Installation

INITIAL SETUP:

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Engine OFF (TM 10-3930-669-10)
(Item 1, Appendix E) Parking brake applied (TM 10-3930-669-1C)
Wheels chocked (TM 10-3930-669-10)
Materials/Parts Right-hand engine access cover open
Gasket (TM 10-3930-669-10)
Gasket (8) Batteries disconnected (TM 10-3930-669-20)
Blower ducting removed (Para 6-2)

a. Removal.

WARNING

• Allow engine to cool before performing maintenance on the muffler, exhaust pipe, exhaust
manifold, or turbocharger. If necessary, use insulated pads and gloves.

• Do not touch hot exhaust system with bare hands; injury to personnel will result.

(1) Remove three nuts (1), washers (2), and screws (3) from exhaust pipe (4).

(2) Remove exhaust pipe (4) and gasket (5) from manifold (6). Discard gasket.

5-2
 TM 10-3930-669-34

(3) Remove eight nuts (7), washers (8), and

manifold (6) from engine (9).

(4) Remove eight gaskets (10) and four spacers

(11) from engine (9). Discard gaskets.

b. Installation.

(1) Install eight gaskets (10) and four spacers (11)

on engine (9).

(2) Install manifold (6) on engine (9) with eight

washers (8) and nuts (7).

(3) Position gasket (5) and exhaust pipe (4) on

manifold (6) and install with three screws (3),
washers (2), and nuts (1). Tighten nuts only until
gasket is seated.

NOTE
Follow-on Maintenance:
• Install blower ducting (Para 6-2).

• Connect batteries (TM 10-3930-669-20).

• Close right-hand engine access cover

(TM 10-3930-669-10).

• Remove wheel chocks (TM 10-3930-

669-10).

END OF TASK

5-3/(5-4 blank)
 TM 10-3930-669-34

CHAPTER 6

COOLING SYSTEM MAINTENANCE

Para Contents Page

6-1 Introduction...................................................................................................................................6-1
6-2 Blower Ducting Replacement .......................................................................................................6-2
6-3 Blower Repair...............................................................................................................................6-10

6-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, replacing, installing, repairing, and testing cooling
components authorized by the Maintenance Allocation Chart (MAC) at the Direct Support and General Support
Maintenance level.

6-1
 TM 10-3930-669-34

6-2. BLOWER DUCTING REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation
INITIAL SETUP:

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Wheels chocked (TM 10-3930-669-10)
(Item 1, Appendix E) Cab removed (TM 10-3930-669-20)
Fuel pipes removed (TM 10-3930-669-20)
Materials/Parts Blower removed (TM 10-3930-669-20)
Cable Ties (Item 4, Appendix B) Engine oil breather removed
Rags, Wiping (Item 19, Appendix B) (TM 10-3930-669-20)
Solvent, Dry-cleaning (Item 20, Appendix B) Engine oil cooler removed
Washer, Lock (2) (TM 10-3930-669-20)
Washer, Lock (2) Transmission oil cooler removed
Washer, Lock (2) (TM 10-3930-669-20)
Washer, Lock (3)
Washer, Lock (6)
Washer, Lock (11)

a. Removal.

(1) Remove two screws (1), lock washers (2), and washers (3) from plate (4). Discard lock washers.

(2) Remove screw (5), lock washer (6), washer (7), and plate (4) from engine (8). Discard lock washer.

(3) Remove grommet (9) from plate (4).

6-2
 TM 10-3930-669-34

(4) Remove screw (10), lock washer (11), and

washer (12) from guide rail (13). Discard lock
washer.

(5) Remove seven screws (14), lock washers (15),

and guide rail (13) from engine (8). Discard lock
washers.

(6) Remove two screws (16), washers (17), and

bracket (18) from cover (19).

(7) Remove two screws (20), washer (21), and

cover (19) from hood (22).

(8) Remove screw (23) and lock washer (24) from

hood (22). Discard lock washer.

(9) Remove screw (25), lock washer (26), and

washer (27) from plate (28). Discard lock
washer.

(10) Remove two nuts (29), lock washers (30),

washers (31), and screws (32) from hood (22)
and plate (28). Discard lock washers.

6-3
 TM 10-3930-669-34

6-2. BLOWER DUCTING REPLACEMENT (CONT).

(11) Remove screw (33) and washer (34) from hood

(22).

(12) Remove screw (35), washer (36), and bracket

(37) from hood (22).

(13) Remove screw (38), washer (39), and hood (22)

from transmission oil cooler (40).

(14) Remove grommet (41) from hood (22).

(15) Remove nut (42), lock washer (43), washer (44),

and screw (45) from plate (28) and base ducting
(46). Discard lock washer.

(16) Remove base ducting (46) from engine (8).

(17) Remove screw (47) and washer (48) from oil

cooler duct (49).

(18) Remove screw (50), washer (51), and bracket

(52) from oil cooler duct (49).

(19) Remove screw (53) and oil cooler duct (49) from
transmission oil cooler (40).

6-4
 TM 10-3930-669-34

(20) Remove screw (54), lock washer (55), washer

(56), and bracket (57) from engine (8).

(21) Remove six screws (59), lock washers (60), and

washers (61) from manifold ducting (58).
Discard lock washers.

(22) Remove manifold ducting (58) from engine (8).

(23) Remove baffle (62) from engine (8).

(24) Remove three screws (63), lock washers (64),

and washers (65) from plate (28). Discard lock
washers.

(25) Remove screw (66), washer (67), and plate (28)

from engine (8).

6-5
 TM 10-3930-669-34

6-2. BLOWER DUCTING REPLACEMENT (CONT).

b. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves; use
only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not breathe
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for
type I dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure to do so may
result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with dry-cleaning solvent.

(2) Dry all parts with wiping rags.

(3) Inspect all parts for breaks, cracks, burrs, and

sharp edges.
(4) Replace all damaged parts.

c. Installation.

(1) Install plate (28) on engine (8) with washer (67)

and screw (66).

(2) Install three washers (65), lock washers (64),

and screws (63) in plate (28).

6-6
 TM 10-3930-669-34

(3) Position baffle (62) on engine (8).

(4) Install manifold ducting (58) on engine (8) with

six washers (61), lock washers (60), and screws
(59).

(5) Install bracket (57) on manifold ducting (58) with

washer (56), lock washer (55), and screw (54).

(6) Install oil cooler duct (49) on transmission oil

cooler (40) with screw (53).

(7) Install bracket (52) on oil cooler duct (49) with

washer (51) and screw (50).

(8) Install washer (48) and screw (47) in oil cooler

duct (49).

(9) Position base ducting (46) on engine (8).

(10) Install screw (45), washer (44), lock washer (43),

and nut (42) in base ducting (46) and plate (28).

6-7
 TM 10-3930-669-34

6-2. BLOWER DUCTING REPLACEMENT (CONT).

(11) Install grommet (41) in hood (22).

(12) Install hood (22) on transmission oil cooler (40)

with washer (39) and screw (38).

(13) Install bracket (37) on hood (22) with washer

(36) and screw (35).

(14) Install washer (34) and screw (33) in hood (22).

(15) Install two screws (32), washers (31), lock

washers (30), and nuts (29) in hood (22) and
plate (28).

(16) Install washer (27), lock washer (26), and screw

(25) in plate (28).

(17) Install lock washer (24) and screw (23) in hood

(22).

(18) Install cover (19) on hood (22) with two washers

(21) and screws (20).

(19) Install bracket (18) on cover (19) with two

washers (17) and screws (16).

6-8
 TM 10-3930-669-34

(20) Install guide rail (13) on engine (8) with seven

lock washers (15) and screws (14).

(21) Install washers (12), lock washer (11), and screw

(10) in guide rail (13).

(22) Install grommet (9) in plate (4).

(23) Install plate (4) on engine (8) with washer (7),

lock washer (6), and screw (5).

(24) Install two washers (3), lock washers (2), and

screws (1) in plate (4)

NOTE
Follow-on Maintenance:

• Install engine oil cooler

(TM 10-3930-669-20).

• Install engine oil breather

(TM 10-3930-669-20).

• Install blower
(TM 10-3930-669-20).

• Install fuel pipes

(TM 10-3930-669-20).

• Install cab
(TM 10-3930-669-20).

• Remove wheel chocks

(TM 10-3930-669-10).

• Install transmission oil cooler

(TM 10-3930-669-20).

END OF TASK

6-9
 TM 10-3930-669-34

6-3. BLOWER REPAIR.

This task covers:

a. Removal b. Cleaning/Inspection c. Assembly
INITIAL SETUP:

Tools and Special Tools Materials/Parts - Continued

Tool Kit, General Mechanic’s: Automotive Washer, Lock
(Item 1, Appendix E) Washer, Lock
Press, 60 Ton (Item 5, Appendix E) Washer, Lock (2)

Materials/Parts Equipment Condition

Rags, Wiping (Item 19, Appendix B) Blower removed (TM 10-3930-669-20)
Solvent, Dry-cleaning (Item 20, Appendix B)

a. Disassembly.

(1) Remove nut (1), screw (2), and impeller (3) from
blower (4).

(2) Remove pulley (5) from blower (4).

WARNING

Use care when removing or installing

snap and retaining rings. Snap and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(3) Remove snap ring (6) and shaft (7) from blower
(4).

6-10
 TM 10-3930-669-34

(4) Using a press, remove two bearings (8) and

bushing (9) from blower (4).

b. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves; use
only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not breathe
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for
type I dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure to do so may
result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with dry-cleaning solvent.

(2) Dry all parts with wiping rags.

(3) Inspect all parts for breaks, cracks, burrs, and sharp edges.

(4) Replace all damaged parts.

6-11
 TM 10-3930-669-34

6-3. BLOWER REPAIR (CONT).

c. Assembly.

(1) Using press, install two bearings (8) and bushing

(9) in blower (4).

WARNING

Use care when removing or installing

snap and retaining rings. Snap and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(2) Install shaft (7) and snap ring (6) in blower (4).

6-12
 TM 10-3930-669-34

(3) Install pulley (5) on blower (4).

(4) Install impeller (3), screw (2), and nut (1) in

blower (4).

NOTE
Follow-on Maintenance:

• Install blower (TM 10-3930-669-20).

END OF TASK

6-13/(6-14 blank)
 TM 10-3930-669-34

CHAPTER 7

ELECTRICAL SYSTEM MAINTENANCE

Para Contents Page

7-1 Introduction................................................................................................................................................ 7-1

7-2 Alternator Repair ....................................................................................................................................... 7-2
7-3 Starter Repair ............................................................................................................................................ 7-15
7-4 Cab Wire Harness Replacement............................................................................................................... 7-31
7-5 Engine Wire Harness Replacement .......................................................................................................... 7-44

7-1. INTRODUCTION.

This chapter contains maintenance instructions for removing, repairing, installing, and replacing electrical system
components as authorized by the Maintenance Allocation Chart (MAC) at the Direct and General Support Maintenance
level.

7-1
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR.

This task covers:

a. Removal b. Cleaning/Inspection c. Assembly

INITIAL SETUP

Tools and Special Tools Materials/Parts - Continued

Tool Kit, General Mechanic’s: Automotive Washer, Lock (5)
(Item 1, Appendix E) Washer, Lock (5)
Gun, Soldering (Item 5, Appendix E) Washer, Plastic
Press, 60 Ton (Item 5, Appendix E) Washer, Plastic (2)
Test Stand, Automotive Generator and Washer, Plastic (3)
Starter (Item 6, Appendix E)
Personnel Required
Materials /Parts Two
Solvent, Dry-cleaning (Item 20, Appendix B)
Tags, Identification (Item 21, Appendix B) Equipment Condition
Nut, Lock Alternator removed
Nut, Lock (2) (TM 10-3930-669-20)
Nut, Lock (2) Regulator removed (TM 10-3930-669-20)
Nut, Lock (3) Relay removed (TM 10-3930-669-20)
Nut, Lock (3)

a. Disassembly.

(1) Remove lock nut (1), washer (2), and pulley

assembly (3) from rotor assembly shaft (4).
Discard lock nut.

(2) Remove key (5) from rotor assembly shaft (4).

7-2
 TM 10-3930-669-34

NOTE
Tag and mark all wires prior to
removal.

(3) Remove five screws (6), lock washers (7), and

six wires (8) from five terminals (9). Discard lock
washers.

(4) Remove three screws (10), plastic washers (11),

heat sink (12), and insulator (13) from forgings
and field coil assembly (14). Discard plastic
washers.

(5) Turn alternator (15) over and place on wooden

blocks.

7-3
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR (CONT).

(6) Remove three lock nuts (16) and end cover (17)
from alternator (15). Discard lock nuts.

(7) Remove three nuts (18) from screw shafts (19)

in forging and field coil assembly (14).

(8) Separate forging and field coil assembly (14)

and stator and shell assembly (20) until soldered
connection (21) can be accessed.

(9) Using a soldering gun, disconnect soldered

connection (21).

(10) Remove three screw shafts (19) from forging

and field coil assembly (14).

7-4
 TM 10-3930-669-34

(11) Remove lock nut (22), washer (23), and strap

(24) from stud (25) and stud (26). Discard lock
nut.

(12) Remove lock nut (27), washer (28), connector

(29), plastic washer (30), and insulator (31) from
stud (25). Discard lock nut and plastic washer.

(13) Remove stud (25) and collar (32) from stator and
shell assembly (20).

(14) Remove lock nut (33), washer (34),connector

(35) plastic washer (36), and insulator (37)from
screw (38). Discard lock nut and plastic washer.

(15) Remove screw (38) and collar (39) from stator

and shell assembly (20)

7-5
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR (CONT).

(16) Remove lock nut (40), washer (41), connector

(42), plastic washer (43), and insulator (44) from
screw (45). Discard lock nut and plastic washer.

(17) Remove screw (45) and collar (46) from stator

and shell assembly (20).

WARNING

Use care when removing or installing

snap and retaining rings. Snap and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(18) Remove retaining ring (47) from forging and field

coil assembly (14).

7-6
 TM 10-3930-669-34

(19) Using a press, remove rotor assembly shaft (4)

from outer bearing (48) in forging and field coil
assembly (14).

WARNING
Use care when removing or installing
snap and retaining rings. Snap and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(20) Remove retaining cup (49) and retaining ring

(50) from rotor assembly shaft (4).

(21) Using a press, remove rotor assembly shaft (4)

from inner bearing (51).

7-7
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR (CONT).

(22) Using a press, remove outer bearing (48) from

forging and field coil assembly (14).

b. Cleaning/lnspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves; use
only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not breathe
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for type I
dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure to do so may result in
injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with dry-cleaning solvent.

(2) Do not allow dry-cleaning solvent to come in contact with rubber wire insulation.

(3) Inspect all parts for breaks, cracks, burrs, and sharp edges.

(4) Inspect rotor, refer to TM 9-2920-225-34.

(5) Replace all damaged parts.

7-8
 TM 10-3930-669-34

c. Assembly.

(1) Using a press, install outer bearing (48) in

forging and field coil assembly (14).

(2) Using a press, install inner bearing (51) on rotor

assembly shaft (4).

WARNING

Use care when removing or installing

snap and retaining rings. Snap and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(3) Install retaining ring (50) and retaining cup (49)

on rotor assembly shaft (4).

7-9
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR (CONT).

NOTE

Use suitable spacer to ensure bearing

is fully seated in forging and field coil
assembly.

(4) Using a press, install inner bearing (51) in

forging and field coil assembly (14) and rotor
assembly (4) shaft in outer bearing (48).

WARNING

Use care when removing or installing

snap and retaining rings. Snap and
retaining rings are under spring
tension and can act as projectiles
when released and could cause
severe eye injury.

(5) Install retaining ring (47) in forging and field coil

assembly (14).

7-10
 TM 10-3930-669-34

(6) Position screw (45) in collar (46).

(7) Position collar (46) in stator and shell assembly

(20).

(8) Install insulator (44), plastic washer (43),

connector (42), and washer (41) on screw (45)
with lock nut (40).

(9) Position screw (38) in collar (39).

(10) Position collar (39) in stator and shell assembly

(20).

(11) Install insulator (37), plastic washer (36),

connector (35), and washer (34) on screw (38)
with lock nut (33).

7-11
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR (CONT).

(12) Position screw (25) in collar (32).

(13) Position collar (32) in stator and shell assembly

(20).

(14) Install insulator (31), plastic washer (30),

connector (29), and washer (28) on screw (25)
with lock nut (27).

(15) Position strap (24) on studs (26 and 25).

(16) Install strap (24) on stud (25) with washer (23)

and lock nut (22).

(17) Position forging and field coil assembly (14) on

wooden blocks.

(18) Install three screw shafts (19) in forging and field

coil assembly (14).

(19) Using a soldering gun and solder, form

connection (21) with wires tagged and marked
during Disassembly.

(20) Install stator and shell assembly (20) on three

screw shafts (19) and forging and field coil
assembly (14) with three nuts (18).

7-12
 TM 10-3930-669-34

(21) Install end cover (17) on alternator (15)

with three lock nuts (16).

(22) Turn alternator (15) over and remove

wooden blocks.

(23) Install insulator (13) and heat sink (12) on

forging and field coil assembly (14) with
three plastic washers (11) and screws (10)
in alternator (15).

7-13
 TM 10-3930-669-34

7-2. ALTERNATOR REPAIR (CONT).

(24) Install six wires (8) on five terminals (9) as

tagged and marked during Disassembly,
with five lock washers (7) and screws (6).

(25) Install key (5) on rotor assembly shaft (4).

(26) Install pulley assembly (3) on rotor

assembly shaft (4) with washer (2) and
lock nut (1).

(27) Using test stand, test alternator for proper

AMPS and Voltage out-put. With
alternator working properly the amps
should be LOW to 0 and volts should be
27.0 (36.0 kw) to 29.6 (39.2 kw).

NOTE

Follow-on Maintenance:

• Install regulator (TM 10-3930-669-20)

• Install relay (TM 10-3930-669-20)

• Install alternator (TM 10-3930-669-20)

END OF TASK

7-14
 TM 10-3930-669-34

7-3. STARTER REPAIR.

This task covers:

a. Disassembly b. Cleaning/Inspection c. Assembly

INITIAL SETUP
Tools and Special Tools Materials/Parts - Continued
Tool Kit, General Mechanic’s: Automotive Washer, Lock
(Item 1, Appendix E) Washer, Lock
Gun, Soldering (Item 5, Appendix E) Washer, Lock
Press, 60 Ton (Item 5, Appendix E) Washer, Lock
Test Stand, Automotive Generator and Washer, Lock
Starter (Item 6, Appendix E) Washer, Lock
Test Set, Armature (Item 6, Appendix E) Washer, Lock (2)
Washer, Lock (2)
Materials/Parts Washer, Lock (3)
Solvent, Dry-cleaning (Item 20, Appendix B)
Tags, Identification (Item 21, Appendix B) Equipment Condition
Grommets (2) Starter removed (TM 10-3930-669-20)
Nut, Lock
Packing, Preformed
Seal
Washer, Lock

a. Disassembly.

(1) Remove two screws (1), lock washers (2),

grommet covers (3), grommets (4), and
cover (5) from studs (6). Discard lock
washers and grommets.

(2) Remove preformed packing (7) from

commutator (8). Discard preformed
packing.

7-15
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

NOTE

Tag and mark all wires and cables

prior to removal.

(3) Disconnect two wires (9 and 10) from

magnet (11).

(4) Remove two screws (12), lock washers

(13), and wire (14) from commutator (8).
Discard lock washers.

(5) Remove screw (15), lock washer (16), and

wire (17) from switch (18). Discard lock
washer.

(6) Using soldering iron, remove two wires (19

and 20) from commutator (8).

(7) Remove two studs (6), washers (21), and

magnet (11) from commutator (8).

(8) Disconnect wire (22) from switch (18).

(9) Remove screw (23), lock washer (24), and

washer (25) from rail bar (26) and switch
(18). Discard lock washer.

7-16
 TM 10-3930-669-34

(10) Remove two screws (27), lock washers

(28), washers (29), and copper wires (30)
from switch (18). Discard lock washers.

(11) Remove two screws (31), lock washers

(32), and switch (18) from commutator (8).
Discard lock washers.

(12) Remove nut (33), lock washer (34),

washer (35), screw (36), and spacer (37)
from commutator (8). Discard lock
washer.

(13) Remove nut (38), lock washer (39),

washer (40), bushing (41), and screw (42)
from commutator (8). Discard lock
washer.

(14) Remove nut (43), lock washer (44),

washer (45), mount (46), rail bar (26),
washer (47), and spacer (48) from
commutator (8). Discard lock washer.

7-17
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

(15) Remove screw (49), lock washer (50),

brush wire (51), and wire (9) from
commutator (8). Discard lock washer.

(16) Remove screw (52), lock washer (53), and

brush wire (54) from commutator (8).
Discard lock washer.

(17) Lift four retainers (55) and remove

brushes (56) from commutator (8).

(18) Remove four nuts (57), washers (58), and

commutator (8) from starter housing (59).

7-18
 TM 10-3930-669-34

(19) Remove lock nut (60) and nut (61) from pinion (62). Discard lock nut.

(20) Remove pinion (62) and parallel key (63) from axle (64).

(21) Remove drive bearing (65) from starter housing (59).

(22) Remove four stud bolts (66) from drive

bearing (65).

(23) Remove bushing (67), bearing (68), seal

(69), and spring (70) from drive bearing
(65). Discard seal.

7-19
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

(24) Remove shim (71) and armature (72) from

starter housing (59).

(25) Remove four screws (73) and bearing cap

(74) from armature (72).

(26) Remove clutch pack (75) from armature

(72).

7-20
 TM 10-3930-669-34

(27) Remove two spacers (76) and washer (77) from armature (72).

WARNING

• Use care when removing or installing snap and retaining rings. Snap and retaining rings are
under spring tension and can act as projectiles when released and could cause severe eye injury.

• Use care when removing or installing springs. Springs are under spring tension and can act as
projectiles when released and could cause severe eye injury.

(28) Remove retaining ring (78), eleven balls

(79), stop bush (80), compression spring
(81), and ring (82) from axle (64).

(29) Remove axle (64) from armature (72).

7-21
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

(30) Remove needle roller bearing (83) from armature (72).

(31) Remove four screws (84) from starter housing (59).

7-22
 TM 10-3930-669-34

b. Cleaning/Inspection.

WARNING

• Dry-cleaning solvent (P-D-680) is TOXIC and flammable. Wear protective goggles and gloves; use
only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and do not breathe
vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for type I
dry-cleaning solvent is 100°F (38°C) and for type II is 138°F (50°C). Failure to do so may result in
injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.

(1) Clean all metal parts with dry-cleaning solvent.

(2) Do not allow dry-cleaning solvent to come in contact with rubber wire insulation.

(3) Inspect all parts for breaks, cracks, burrs, and sharp edges.

(4) Replace all damaged parts.

7-23
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

c. Assembly.

(1) Install four screws (84) in stater housing (59). Tighten screws.

(2) Install needle roller bearing (83) in armature (72).

7-24
 TM 10-3930-669-34

(3) Install axle (64) in armature (72).

WARNING

• Use care when removing or installing snap and retaining rings. Snap and retaining rings are
under spring tension and can act as projectiles when released and could cause severe eye injury.

• Use care when removing or installing springs. Springs are under spring tension and can act as
projectiles when released and could cause severe eye injury.

(4) Install ring (82), compression spring (81),

stop bush (80), eleven balls (79), and
retaining ring (78) on axle (64).

(5) Install two spacers (76) and washer (77) in

armature (72).

(6) Install clutch pack (75) in armature (72).

(7) Install bearing cap (74) on armature (72)

with four screws (73).

7-25
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

(8) Install armature (72) and shim (71) in

starter housing (59).

(9) Install spring (70), seal (69) bearing (68),

and bushing (67) in drive bearing
(65).

(10) Install four stud bolts (66) in drive bearing

(65).

7-26
 TM 10-3930-669-34

(11) Install drive bearing (65) in starter housing

(59).

(12) Install parallel key (63) and pinion (62) on

axle (64).

(13) Install nut (61) and lock nut (60) on pinion

(62).

(14) Install commutator (8) on starter housing

(59) with four washers (58) and nuts (57).

7-27
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

(15) Lift four retainers (55) and install four

brushes (56) in commutator (8).

(16) Install brush wire (54) on commutator (8)

with lock washer (53) and screw (52).

(17) Install wire (9) and brush wire (51) on

commutator (8) with lock washer (50) and
screw (49).

(18) Install spacer (48), washer (47), rail bar

(26), and mount (46) on commutator (8)
with washer (45), lock washer (44), and
nut (43).

(19) Install screw (42) and bushing (41) on

commutator (8) with washer (40), lock
washer (39), and nut (38).

(20) Install spacer (37) and screw (36) on

commutator (8) with washer (35), lock
washer (34), and nut (33).

7-28
 TM 10-3930-669-34

(21) Install switch (18) on commutator (8) with

two lock washers (32) and screws (31).

(22) Install copper wires (30) on switch (18)

with two washers (29), lock washers (28),
and screws (27).

(23) Install rail bar (26) on switch (18) with

washer (25), lock washer (24), and screw
(23).

(24) Connect wire (22) on switch (18).

(25) Install magnet (11) on commutator (8) with

two washers (21) and studs (6).

(26) Using soldering iron, connect two wires

(19 and 20) on commutator (8).

7-29
 TM 10-3930-669-34

7-3. STARTER REPAIR (CONT).

(27) Install wire (17) on switch (18) with two

lock washers (16) and screws (15).

(28) Install wire (14) on commutator (8) with

two lock washers (13) and screws (12).

(29) Connect two wires (9 and 10) on magnet

(11).

(30) Install preformed packing (7) on

commutator (8).

(31) Install cover (5) on studs (6) with two

grommets (4), grommet covers (3), lock
washers (2), and screws (1).

(32) Using test stand, test starter for voltage

loss. Voltage loss must not be higher than
1.6 volts.

NOTE

Follow-on Maintenance:

• Install starter (TM 10-3930-669-20)

END OF TASK

7-30
 TM 10-3930-669-34

7-4. CAB WIRE HARNESS REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s: Automotive Engine OFF (TM 10-3930-669-10)
(Item 1, Appendix E) Parking brake applied (TM 10-3930-669-10)
Tool, Spade Terminal, Removal Wheels chocked (TM 10-3930-669-10)
(Item 5, Appendix E)

Materials/Parts
Cable Ties (Item 4, Appendix B)
Tags, Identification (Item 21, Appendix B)

a. Removal.

NOTE

• Tag and mark all wires before disconnecting.

• Remove plastic ties as necessary.

(1) Remove five screws (1), washers (2), and lower dash panel (3) from dash frame (4).

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7-4. CAB WIRE HARNESS REPLACEMENT (CONT).

(2) Disconnect connectors P7 (5) and P6 (6)

from connectors J7 (7) and J6 (8).

(3) Disconnect connector J9 (9) from

connector P9 (10).

(4) Disconnect connector J13 (11) from

connector P13 (12).

(5) Disconnect connector J8 (13) from

connector P8 (14).

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(6) Disconnect three wires (15, 16, and 17)

from top wiper motor assembly (18).

(7) Remove three EMI filters (19) from three

wires (15, 16, and 17).

(8) Disconnect connector (20) from front worklight connector (21).

(9) Using terminal removal tool, remove two wires (22 and 23) from connector (20).

(10) Remove conduit (24) from two wires (22 and 23).

(11) If damaged, remove grommet (25) from cab (26).

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7-4. CAB WIRE HARNESS REPLACEMENT (CONT).

(12) Disconnect three wires (27, 28, and 29)

from front wiper motor assembly (30).

(13) Remove three EMI filters (31) from wires

(27, 28, and 29).

(14) Disconnect connector (32) from front fan

motor connector (33).

(15) Remove cab harness (34) from dash

frame (4).

(16) Remove nut (35), washer (36), and six

wires (37) from cab shunt (38).

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(17) Remove four screws (39) and heater temperature control (40) from cab (26).

(18) Remove switch (41) from cab (26).

(19) Disconnect three wires (42, 43, and 44) from switch (41).

(20) Remove seven screws (45) and cover (46) from heater housing (47).

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7-4. CAB WIRE HARNESS REPLACEMENT (CONT).

(21) Disconnect two wires (48 and 49) from heater (50).

(22) Remove screw (51) and two wires (52 and 53) from heater (50).

(23) Disconnect connector (54) from rear worklight connector (55).

(24) Using terminal removal tool, remove two wires (56 and 57) from connector (54).

(25) Remove conduit (58) from two wires (56 and 57).

(26) If damaged, remove grommet (59) from cab (26).

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NOTE

Repeat steps (27) and (28) for

remaining interior light.

(27) Remove light (60) from bracket (61).

(28) Disconnect two wires (62 and 63) from

light (60).

(29) Disconnect three wires (64, 65, and 66)

from rear wiper motor assembly (67).

(30) Remove three EMI filters (68) from wires

(64, 65, and 66).

(31) Disconnect rear fan motor connector (69)

from connector (70).

(32) Remove cab harness (34) from cab (26).

b. Installation.

(1) Position cab harness (34) in cab (26).

(2) Connect connector (70) to rear fan motor

connector (69).

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