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RDEPARTMENT
December12,1942
E
D-18)ENGINE(/:
onofthe \ \"~l~lA
.................1-62-27
andtune-up7-22 28-35
einvehicle...23-2436-37
mvehicle.....25-3638-52
...........37-7453-99
bledengine... 75100-104
disassembly,
...76-153105-230
............154-195231-285
vehicle.....196-208286-294
.........209-210295-297
pment........211-214298-302
.......215-216303-304
305-314
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E
D-18)ENGINE
ems4
edutiesbyechelons6
edinthismanualare fortheinformation
chargedwiththemaintenanceandrepairof
mationonthedetailedconstructionofthe
ssemblyprocedure,inspection,maintenance
fourTechnicalManualsofthe1000series,of
seinstructionsaresupplementarytothosein
nualspreparedfortheusing arm.
generaldescriptionof theengine,and
ootingandtune-up,inspection,removal,dis-
nstallationoftheengine.Removal,dis-
arts,repairandrebuildingofenginecom-
ystemstreatedinindividualsectionsare
on(sectionVII).Fits andtolerances,special
eferencesarelikewiseincludedinindividual
llinformationonall engineaccessories
describesthecoolingsystem,thefuel
ystem.
formationonthepowertrain,the track
eatsofthe HeavyTractorMl.
formationonallother equipmentof
,3and 4discussedinthis textare
metotimecertainimprovementshavebeen
etheseimprovementsaffecttheservicingof
llbegivencoveringbothoperations.Major
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E
TD-18)ENGINE
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E
D-18)ENGINE
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derheads,injectionpump,injectionnozzles,
rpump,cylinderlinerswithpistons,cam-
eandinterchangeableonenginesofalllots.
wisewhenviewedfromtheradiatorend.
s appliedtothetransmissionthrough
lywheel.
ineserialnumberis stampedonthe
onamilledsurfacenearthetopof thecrank-
madetohavethe engineserialnumbers
erialnumbers.Engineserialnumbersare
1to TDRM2242,inclusive
6to TDRM3682,inclusive
5to TDRM4067,inclusive
mbers:
DRM4051
DRM5055
DRM4062
DRM4064
DRM4065
8toTDRM4861, inclusive.
Mltractorsisa four-cycle,fullDiesel
fersfromthegasoline engineprincipallyin
ceandignite thefuel.Figure7illustrates
eselenginegoesthroughand comparesthe
thgasolineengineoperation.
TORSYSTEMS.
Waterforthe coolingsystemispro-
galloncapacitywhichislocatedatthefront
s ofthefin-andflat-tubetypeconstruction,
ankswith sideplates.AdoubleV-typefan
vepulley atthecrankshaft,drivesboththe
hefan-drivepulleyruns onballbearingson
ft.The pumpisdrivenfromthe fanpulley
.Thus thepumpshaftassemblyisrelieved
beltload.Whentheengineis cool,water
ineonlybymeansofthe bypass.Asthe
staticallycontrolledvalvesinthehousing
ntofwatertravelingthrough theradiator.
69,70 and71).Theenginehasa front
onnectedbya watermanifold.Eitherthe
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E
TD-18)ENGINE
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E
O-18)ENGINE
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nentsofCoolingSystem
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D-18)ENGINE
emovedindependentlyoftheother.While
ruction,slightmodificationsindesignprevent
heads frombeinginterchangeable.Acylinder
reachhead.Coppergasketrings arelocated
ves.Valveguidesarelocatedintheheads
e,exhaustandstartingvalves,likewiselocated
eplaceable.Theintakemanifoldandthe
eattachedtotherightside ofthecylinderheads.
ecrankcase,whichisthemainstructural
x-like,one-piececastingwhichcontainsthe
ylinderliners.Figure155 showsthecrank-
n.Themain bearingcaps,heldtocrankcase
crankcaseandcannotbereplacedindividually.
ecrankcaseforrubberseal ringstosealthe
ebottomofthecylinderliners.Thecamshaft
ofthecrankcase.
).Cylindersleevescanberemoved
vebeenremoved.Aflangeon thetopofthe
cessin thecrankcase,properlylocatingthe
achsleeveextendsoveritsentirelength.
npinsandrings canbeobtainedinmatched
to thesleevesandshouldneverbeinter-
Themainbearingsare thesteel-backed,
replaceablewithoutremovingthecrank-
psarestamped1,2, 3,etc.,tofacilitate
errespectivepositions,withstampednumber
numberonthesideof thecrankcase.Numbers
eofthe crankcasewheretheoilpanis
ecrankshaftisdrilledfor fullpressure
connectingrodbearings.Crankshaftthrust
the centermain(No.4)bearing.
sboltedtothe endofthecrankshaft
lpins. Oneoftheboltholesis offsetsothat
bledinonlyone position.Thestarterring
heel.
Rods(fig.107).
minumalloyandarefittedwithsix rings.
edoneaboveand onebelowthepistonpin.
relocatedatthetop ofthepistonandone
pperoilcontrolring andthecompressionrings.
efull-floatingtypeandareheldin the
s.An oversizepistonpinisavailableto
epistonandthe connectingrodbushing.
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D-18)ENGINE
illed fromtheconnectingrodcrankshaft
oprovidelubricationatthatpoint.The
pisnotfurnishedseparately.Theupperand
tingrodbearingareidentical.Theyare held
gein thenotchesintheconnectingrodand
nTiming(fig.163).Acompletely
gearsis mountedonthefrontendof the
ardrivesanidlergearwhichin turndrives
njectionpumpdrivegear. Thecamshaft
ssoridler gearwhichinturndrivesthe
Thecamshaftandinjectionpumpdrivegears
f thecrankshaft.Thecrankshaft,idler,
mpdrivegearsaremarkedsothat theengine
enoverhaulingit.
camshaftislocatedinthe right-hand
heldinplacebya thrustplateboltedtothe
.Thecamshaftrunsonfour bearings.These
eand neednoreamingafterbeinginstalled
goilpump isdrivenbythe camshaft.
nism(fig.66).Twovalveleversoneach
ustandintakevalves.Thestartingvalveis
ement.Theentirevalveandshaftassemblies
ovedasa unit.Theexhaustandintakevalve
atedthroughapassagefromtherearcamshaft
hollowvalvelever shaft.Theoildrainsback
hepushrod openings.Thevalvelevershave
solineas aconventionalgasolineengine.
perationitisconvertedtothe Dieselcycle
sel.Acompressionreleaselevermountedon
owstheoperatortoconverttheDieselengine
s donesimplybypullingdownonthe com-
umberofthingswhichwill beexplainedinthe
eplacewhenthisconversionismade.
sdown onthecompressionreleaselever
t operatinglever(A)turnsthecross shaft,
haftjawlever(B),engagingit withthe
ratingjaw(T),througha connectingrod,
nkandshiftsthecarburetorshut-offlever(I),
othe carburetorwhenstartingtheengine.At
perationtakesplace,theoperatingjaw(T)
Q)whichactuatesthestartingvalvecross
gvalveoperatingcrossshaft lever(R)
eratingcrossshaft(C) whichoperatesthe
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ftonwhichthe camrollers(L)aremounted.
wn,theyopenthe startingvalves(D)of
cylinder.Openingthestartingvalve(D)
abovethepiston,exposingthesparkplug(J)
his drawninfromthecarburetor(K).
atingcrossshaftlever (R)alsooperates
whichshifts theairvalve(G)from theseat
eair valveupperseat(H).Asthe airvalve
)makescontact,closingtheprimarycircuit
edistributor.(Theignitioncoilandthe dis-
hisillustration.)
tedtogasolinestarting, airfromtheair
sthemanifoldthroughtheair passage(O)
owsthe whitedottedlinedownthrough
asolineismixedwith it.Thegas-airmixture
r passage(P)tothecylindersthroughthe
ston(M) travelsthroughthecompression
sforcedpast thestartingvalve(D)intothe
reitisignited bythesparkplug(J). The
openat alltimeswhiletheengineis oper-
nvertedtoDieseloperationbyliftingthe
ronthedash,theoperatingjaw(T) isshifted
U) shiftsthewholestartingmechanism.
osedandremainsclosedduringthetime
ngontheDieselcycle.Theswitch(F)breaks
eignitioncoil tothedistributorsothat the
perative.Airisdrawnthrough theairpas-
nerandfollowstheblackarrowdirectlyto
nders.
selfuelflowsfromthe supplytank
oughthe watertrapmountedontheleft
uel supplypump.Thefuelsupplypumppumps
fuelfiltermountedonthecrankcase.The
ter tothefrontend oftheinjectionpump.
ectsthefuel throughpipestothenozzles.
njectionpumpthrougha checkvalveat
umpandisreturnedto thefuelsupplytank.
eddescriptionof thefuelsystem.
ectionpumpistometer thefuelin
oadandspeeddemandsandtodeliverit to
eright time.Thefuelinjectionpumpwith
speedtypegovernorisacompactunit
ginespeedfromthe timinggeartrain.This
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D-18)ENGINE
tside oftheengineinan accessibleposition
dandreplacedasa completeassembly.
singcontainsoneplunger-typeinjection
er,allplungersbeing operatedinproper
gonball bearingsinthelowerpartof the
f-regulating,piston-typesupplypump
of theinjectionpumphousingandisactu-
camshaft.Thesupplypumpdrawsfuel
underpressurethroughalargedouble
onchambersump,whichrunsthe full
p.Atone endofthesumpis anoverflow
pipingtothefuel tank.Thisvalveissetto
ureintheinjectionpump.
vernoristoserveas ameansforpre-
thincloseregulationanydesiredengine
dlingandnominalmaximumspeedrange.It
ineload.In addition,thegovernorcontrols
preventstallingandcontrolsthemaximum
enclosedunitrigidlymountedtoone
mp.A largegearismountedon theendof
aftwhichextendsintothegovernorhousing
connectedtothegovernorshaft.Through
theshaftis causedtotravelata higherspeed
mshaft.Thecentrifugalforceexertedbythe
amovementofthegovernorsleeveassembly.
dbythecompressionofthegovernorsprings.
ertedbythe governorspringsisregulated
edash.Thegovernorisinternallyconnected
rolrod.
aircleaneris locatedimmediatelyin
centerofthedashand cowlassembly.A
ppreventsflyingleaves,etc.,fromentering
oughtheair pipeassemblyandthebody
embly,whereheavyparticlesofdust and
l cup.Theairthenpassesupwardthrough
mbly,thehousedscreenandthe cleaning
retheoil-impregnatedelementremoves
mthe air.Theaircontinuesthroughthe
ntair cleanerpipetotheintakemanifold
anerwillbeservicedbytheusing arm
g.26).Theair compressorisdriven
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ewhichin turnisdrivenby thegeartrain
Thecrankshaftgeardrivesanidlergear
tgear.Thecamshaftgeardrivestheair com-
turndrivestheaircompressordrivegear.
haftandthe aircompressorcouplingflange
ubbercouplingand acouplingcover.Should
essary,theair compressordrivecanbe
whiletheengineis installedinthevehicle.
-voltstoragebatteries,locatedunder
seriesto maintainthevoltageoftheelectrical
teriesare chargedbya12-voltDelco-Remy
dontherightside oftheengineblockand
entheengineisrunning.Thegenerator
toplights,headlights,andblackoutlights;
rankingmotorandthe ignitionsystem(used
-1777Bfor detaileddescriptionsofthe
calandstarting(ignition)systems.
em(fig.10).
dwithafullpressurelubricatingsystem.
nkcasedelivertheoil tothebearingsand
lubricated.Noexternallinesareusedexcept
lpressuregage mountedonthedash.
bricatingoilfor themainlubricating
pump(O) fromtherearofthe crankcase
P) fromthefrontofthe crankcasedeliver
ractorisoperatingat extremeanglesoftilt.
mp(N) receivesthisoilthroughafloat (R)
thesurfaceoftheoil levelinthecrankcase
throughtheoilpassage(D) fromlubricating
(C)inthe crankcase.
)mountedin thebodyofthelubri-
esthe pressureandbypassesthesurplus
s.Partof theoilfromthe oilheader(C)in
ubricatingoilfilter (E).Aftertheoilis
tingoilfilter (E),itisreturned directlyto
ypartofthe oilthatis pumpedbythelubri-
ubricatedthroughoil passages(A)
hecrankcasetothemainbearings.Oil
ages(L)in thecrankshafttotheconnecting
sare lubricatedthroughtheoilpassages
dbearingstothe pistonpins.
arelubricatedthroughtheoil passages
header(C)tothemainbearing andcam-
camshaftbearingjournal(B)thereisa slot
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TD-18)ENGINE
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D-18)ENGINE
switheachrevolutionofthecamshaft
othe-camshaftandmainbearingstothe
sup throughtheoilpassage(I) fromthe
hevalveleverassemblyto theoilpassage
bricatedthroughtheoilpassage(K)to
alTD-18
691
62
nkendClockwise
1,350
fullloadrpm1,350
noload,"A"seriesrpm1,465
noload,"K"seriesrpm1,500
1,350rpm103*
at650rpm
el14.2to1
line6.7to1
"(updraft)
co-Remy
ettype
ENANCEDUTIESBYECHELONS.
dwordsasusedin thislistofmainte-
nedasfollows:
neorganizationregiments,battalions,com-
helons).
ancelightmaintenancecompanies,ord-
ncecompanies,ordnancedivisionalmaintenance
ceshops.
rdnanceheavymaintenancecompanies
ops.
ometricpressure(29.92in.ofmercury)and60 F,
ngcode.
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ancebaseregiments,ordnancebases,
ers'plants.
ventivemaintenance)(par.23a.(1)
1942):Consistsofservicing,cleaning,lubri-
dnutsandmakingexternaladjustmentsof
iesandcontrol.
AR850-15.Oct.6, 1942):Consistsof
emblyorassemblyfromthevehiclesandre-
conditionedorrebuiltpart,subassemblyor
casemaybe.
and(5)inpart. AR850-15):Consists
acementof,thepart, subassemblyor
omplishedwithoutcompletelydisassembling
blies,anddoesnotrequireheavy.welding,or
gand/orbalancing.
in partand(6)AR850-15):Consists
ingandreplacinginserviceableconditionany
semblyorassemblyofthevehicle,including
ng,fitting,alining,balancing,assemblingand
BLY
adjust)X
EX
X
(recondition)E
aceX
irX
eviceandreplaceX
ace.'....X
irX
ildEX
S
replaceEX
repairX
rebuildEX
aceX
airX
uild(recondition)EX
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eorreplaceX
g,electricalreplaceX
ricalrepairEX
eplaceX
(inserts)replaceEEX
erts)replaceEEX
service(adjust)andreplaceX
sassemblyrebuild(recon-
t)andreplaceX
eplaceX
laceX
airX
ondition)EX
blyreplaceX
pairX
buildX
ce* X
X
dEX
ndreplaceX
n)andreplaceX
)andreplaceX
aceX
ud(recondition)EX
manifoldandoilpanreplaceX
aceX
viceandreplace^... X
pair~...X
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buildX
vice(adjust),replaceorrepairX
uildEX
replaceX
repairX
rebuildEX
ceX
rX
dEX
(external)replaceX
(external)repairEX
(internal)replaceorrepairX
ke,assembliesreplace....X
ke,assembliesrepair....X
ke,assembliesrebuild(re-
replaceX
repairX
rebuildX
ce(clean)andreplaceX
rX
eEEX
an)andreplaceX
repairX
replaceX
erviceandreplaceX
pairX
buildX
aceEX
airX
uildX
serviceandreplaceX
repairX
rebuildX
lyreplaceEEX
EE X
(adjust)X
X
eX
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dioxideCO.,)replace...X
dioxideCO2) service
dioxideCO2) rebuild....EX
tetrachlorideCCl.^)
X
tetrachlorideCC14)
tetrachlorideCC14)
esreplaceX
tsreplaceX
tsrepairX
tsrebuildEX
ts,truckframereplaceX
ts,truckframerepairX
eplaceX
epairX
ebuildEX
ngservice(adjust)
ngrepairX
ngrebuildEX
mbliesreplaceX
mbliesrepairX
mbliesrebuildEX
yreplaceX
yrepairX
yrebuildEX
ceorrepair. ...X
dEX
replaceX
repairX
rebuildEX
s,airservice(clean)
s,airrepairX
elservice(clean)
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)
elrepairEX
ervice(clean)
epairX
AMEASSEMBLY
tchservice(adjust)
tchrepair(reline)X
emblyreplaceX
emblyrepairX
emblyrebuildX
ereplaceX
erepairX
esservice(adjust)X
esreplaceorrepairX
esrebuildEX
rnal)replaceX
rnal)repairX
nal)replaceorrepair....X
aceX
airX
ervice(adjust)
eX
X
aceX
irX
eX
X
d,EX
X
sreplaceorrepairX
srebuildEX
ES
eplaceX
epairX
ebuildEX
eplaceX
epairX
ebuildEX
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ES(Continued)
paceX
pirX
bildEX
olreplaceX
olrepairX
bliesreplaceX
bliesrepairX
X
t,assemblyreplaceX
t,assemblyrepairX
ceX
rX
IHC)-serviceX
IHC)-rebuild(with
E
RAKE-CONTROL,AIR
yserviceandreplaceX
yrepairX
yrebuildEX
laceX
airX
semblyservice(adjust)
semblyrepairX
semblyrebuildEX
replaceorrepairX
aceX
airX
esreplaceX
esrepairX
esrebuild(recondition)...EX
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C
mblyreplaceX
mblyrepairX
mblyrebuildX
assemblyreplaceX
assemblyrepairX
replaceX
repairX
X
vice(adjust)andreplaceX
air(reline)X
placeX
replaceX
repairX
ceX
rX
laceX
airX
aceX
airX
replace.-X
repairX
rebuild(recondition)EX
X
X
EX
tedwillnormallybeperformedintheechelonindi-
eechelonsasindicatedby"E"maybeaccomplished
sinemergenciesonly.
thorizedtoremoveandreinstallengineand transmission
controlleddifferentialassemblyandotheritemsmarked
enitisnecessarytoreplacean itemmarkedbyanasterisk
subassemblyorunitassembly,theassemblymarkedby
dfromthe vehiclebythesecondechelonuntil
romahigherechelon.
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NGANDTUNE-UP
tarting(gasolinecycle)9
solinecycle)10
eseloperation11
or morecylinders12
operation14
rly(Diesel) 21
cedureoutlinedinthis sectioncovers
tem,coolingsystem,fuelsystemandelectrical
hparagraphinthissectiontreats acondition
iblecausesandnecessarycorrectivemeas-
inesenginetune-upprocedure.
cedureoutlinedinthis sectionshould
telyassembledtractor,beforeanypartshave
hicleortheengine.
DHARDSTARTING(GASOLINE
termineifthereissufficientgasolinein
ndsa shortdistanceupinsidethegasoline
sarythattherebesufficientfuelin thetank
e.
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NGANDTUNE-UP
HINGCARBURETOR.Removegasoline
vegasolinelineandclean.Removescreen
system,TM9-1777B)andclean.
Drainfuelandwatermixturefrom
estrainer.Draincarburetorfuelbowlby
fbowl.Fill gasolinetankwithgasoline.
ecktiming(electricalsystem,TM
NG.Seeifcarburetorfloatvalveisshutting
roubleisgasolinedrippingfrom thedrip
veseatorwornvalveseat willcauseflood-
assemblydisconnectfuellineatthe carbu-
assemblyandcheckasoutlinedinfuelsystem
H.Checkfloatlevelandadjustasout-
,TM9-1777B.
OKEDTOOMUCH.Removesparkplugs,
rythem.
TIONING.Removecoveronintakemani-
ompressionreleaselevertocheckoperation
maryCircuit.
TDUETOLOOSECONNECTIONS,DEFEC-
NTACTPOINTS,DEFECTIVEIGNITIONSWITCH
DPARTLYOPENIGNITIONCOILPRIMARY
amgiveninTM 9-777andcheckthecir-
nitioncoilswitchandignitioncoilif
CRCUITEDLowINSULATIONRESISTANCE,
E.Replacecondenser.
IES.Installfullychargedbatteries.
CIRCUITANDCOILWIRINGORDIS-
ckthewiringcircuitforgroundedcondition.
WITCH.Checkswitchforbrokencon-
ary.
aryCircuit.
IONWIRING.Checkwiringforbroken
IONSINHIGHTENSIONCIRCUIT.Check
heyare tightandclean.
OROUTSIDEOFDISTRIBUTORCAP.Re-
leancloth.
D,CRACKEDOROUTOFADJUSTMENT.
entofsparkplugs.
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E
D-18)ENGINE
GEACROSSCOILHEAD,DISTRIBUTOR
LUGPORCELAIN.Cleanallpointswhereleak-
OIL.Checkcoilforshortedprimaryor
enorgroundedsecondarycoil.
RING(GASOLINECYCLE).
graph42.
Draingasolineandwatermixturefrom
ine.
Manifold.Tightenmanifoldstudnuts.
emovedistributorcapanddry it.
hecksparkplugcablesforcorrect
ndat distributor.
OVERTODIESELOPERATION.
tDeliverFuel.
TANKSHUT-OFFVALVECLOSED.Refill
esure valveisopen.
AIRBOUND.Bleedsystem.SeeTM
ULED,DAMAGEDORLEAKING.Clean
eplacedamagedlines.Tightenallconnections.
.Drainentiresystemand tankandrefill
msystem.
GED.Removefilterandthoroughlyclean.
CLOGGED.Removewatertrap,glass
PUMP.Openventcocksonthewater
nnozzlesto bleedairfromsystem.
ESNOTDELIVERFUEL.Removesupply
utlinedin fuelsystemsection,TM9-1777B.
OGOVERNORLEVERLOOSEORBROKEN.
ryrepairs.
PBROKENORKEYONSHAFTSHEARED
mpshaftwillturn whenengineisstopped.
nismNotFunctioning.
LDNOTFUNCTIONING.Removehousing
controlmechanismtoseeifair valveis
TCLOSING.Removevalvehousingcover
tartingvalves.Checkclearancebetweencam
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NGANDTUNE-UP
LINKAGEBROKENOROUTOFADJUSTMENT.
parts,missingcotterkeysandpins.Check
aragraph186.
ARPED.Removecylinderheadsandreplace
ONONEORMORECYLINDERS.
UENTLY.
h14fortroubleshooting.
UNEVENOPERATION.
usesOutlinedinParagraph11.
YORSTICKING.Removedeliveryvalves,
n fuelsystemsection,TM9-1777B.
NGBROKEN.Replacesprings(TM
NGINE.Cleanairintakecapscreenand
leanerisclean.Cleanoil cupandrefillwith
).
GRAPH10TODETERMINELossOFPOWER.
BROKEN.Replacespringsasoutlinedin
ING.SeeTM9-1777C.
GRETARDED.SeeTM9-1777B.
GINE.Seeparagraph18.
E.
theoil levelisupto specifiedmarkon
eandLine.Removeoilgageand re-
curacytobesurethe oilgageisfunctioning.
tingRodBearingsforExcessiveWear.
bearingwearasoutlinedin paragraphs98,
e.Removelubricatingoilpumpand
101).
gulatingValveSpringBrokenor
utlinedinparagraph102and check.Replace
ecttension.
oilpumpanddisassembleas outlined
kforwear.
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E
D-18)ENGINE
nExcessively.Removecamshaftfrom
llnewbearings.See paragraph158.
ON.
.Valveleversholdvalvesopenslightly,
sion.Ifsettingclearance(par.193)doesnot
dvalves.
dcarbononvalvestemsandin valve
fromclosingproperly.Removecylinderheads.
ms(par.80).Grind orlapvalvesif necessary.
PistonRingsandStickingPiston
embliesandcheckwearon,pistons,piston
estickingrings.Replacewornsleeves.
orinNeedof Grinding.Remove
raph79.Replacewarpedvalvesandvalves
heretheycanbe ground.Seeparagraph85.
.Removecylinderheadsandreplace
Usefuel asspecifiedinTM9-777.
tlyTimedtoEngine.Checktiming
nctioningProperly.
properly adjustedororificeinnozzle
venozzleandtestas outlinedinTM9-1777B.
AKS.Removeandtestfor leakingasout-
RodStopPlateAdjustmentIncorrect.
tadjustment.
olingSystem.Checkwaterleveland
AUTION:Donotputcoldwaterin ahot
engine isrunning.
ktensiononfanbelt andadjustas
section,TM9-1777B.
d.Flushoutradiatorandengine.
deofRadiator.Cleanalldirtand
diatortubefins withairorwaterpressure.
netimingis advancedexcessively',
tlinedinTM 9-1777B.
e.Removeandtestthermostatsasout-
tion,TM9-1777B.
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NGANDTUNE-UP
Filloilpan withtherequiredamount
gshavenotbeenburnedor thecylinderscored
ON.
an.
dbracket.
arendsof crankshaft.Ifoilsealatrear
befoundin clutchcompartment.
seatendofcamshaft.Ifthisplugleaks,
owntherearsupportplateof theengine.
ves,PistonsandStickyPistonRings.
fromthebreatherpipeontheside ofthe
nexcessiveamountofoilisbeingused.Check
ndreplaceif necessary.Oilcontrolrings
essivewearintheintakeandexhaust
hoil consumption.Checkforwearbetween
msandreplaceif necessary.
FENGINE.
istedinparagraph11.
Low.Checkthermostats.Remove
coolingsystemsection,TM9-1777B.
.Seeelectricalsystemsection,TM
EPROPERLY(DIESEL).
y,SluggishorStuck.Removegovernor
ntrolrod.
Replaceplungerspring(TM9-1777B).
ndedinBarrel.Removeandfree
9-1777B.
SleeveDamagedDuetoBroken
onorreplacesleeveasoutlinedinTM
veryValves.Removedeliveryvalves,
edin TM9-1777B.
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E
D-18)ENGINE
ingScrewLoose.Alinemarkontoothed
trolsleeveandtightenscrewsecurely.See
netheoperationswhichshouldbe
-up.Thesestepspointout thevariousparts
ed,cleaned,timedorrepaired,as needed.
umpfromtheengine,placeit oninjec-
alibrationtestonthepump.Test thefuel
TM 9-1777B.
injectionpump(TM9-1777B).
injectionnozzlesforleaksandopening
rasoutlinedin TM9-1777B.
cersandinspectforpitted orburned
etsandreplacespacersifnecessary.SeeTM
FDIESELTHROTTLECONTROL.Adjust
y.Checktheoperationofthe springsonthe
TM9-1777B.
nceonintake,exhaustandstartingvalves.
nedinparagraph186.
heaircleanerandconnectionsforpos-
semblyon aircleanerandscreenonair
catingoilfilterelements,cleaningtheoil
ughly.Cleanandinspectthemetalandcloth
eplacethecloth elementiftorn.SeeTM
ewatertrap.Cleanthoroughlyandinspect
M9-1777B.
ARKPLUGS.Replacebrokenplugs.See
.Cleanandadjustdistributorpoints.See
NITIONCOIL.Checkcondenserandreplace
oncoil,replacingifnecessary.SeeTM9-1777B.
TIONS.Checkallelectricalconnections
ndlowtensioncircuitsofthe ignitionsystem.
SOLINECYCLE.Seeelectricalsystem
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NGANDTUNE-UP
ONTROLANDLINKAGE.Checktheentire
em.Seeparagraph186.Checkstartingvalve
186.
vethescreenretainerandcleanit.Remove
evel.Adjustif necessary.Checkthefloat
e.SeeTM9-1777B.
ushradiatorwithcleanwater,drainand
ilable.Checkwaterpumppacking,adjust
ackingas needed.Checkthefanbeltsfor
ary.Checkfanbelttension.Seecooling
7B.
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CE
O-18)ENGINE
NEINVEHICLE
neinthevehicle24
NS.
veninTM 9-777forthefollowinginspec-
TION.
.Procedureisoutlinedforinspections
400hoursofoperation.
LLEDENGINEINTHEVEHICLE.
leOperatingonGasolineCycle.
onsperminutewithatachometerplacedon
.Seeparagraph14ifrevolutionsperminute
leOperatingonDieselCycle.Change
ionand allowittooperatefor fourorfive
ree-quarteropenthrottle.
NS.Listenforanyunusualnoises,such
heengine.Thismayindicatethata connecting
burnedout.Piston slapalsoproducesasimilar
utlinedinparagraph16andchecktolocate
kingnoiseindicatesthat thepistonpins
heconnectingrodbushingsandpistons.Re-
outlinedinparagraph107and inspectforwear.
oiseatthefront oftheengineindicates
wornexcessively.Removefrontcrankcase
aphs131and 132andinspectforwear.
ngnoiseindicatesinadequatelubrication
eneratorbearingsandbushingsforwearas
oilpressureatfullthrottle.If low,see
dicatorneedleshouldbein whiteareawhen
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NEINVEHICLE
ationofthemotorindicatesstickingvalves.
rear cylinderheads,orboth,asindicated
linderheadasoutlinedin paragraphs78,79,
see thattheyarenotsticking.
Whitesmokeattheexhaustwhenengine
gunderload indicatesthatthenozzleis
owopeningpressure.Openbleedervalvesone
ozzlestolocatethedefectivenozzle.
achometertocheckthemaximumand
ttheyconformwithspecifications.
Observetensiononthethrottlecontrol
holdthe throttleleverinpositionselected.
kforexcessivesmokeattheoutletofthe
andrear sideofthecrankcase.Excessive
ngs,pistonsandsleevesare wornorpiston
ongrooves,orthatopeningsinoil controlrings
onassembliesasoutlinedinparagraph107
veontheammeterthechargingratewhen
highandlowpositions.If thegeneratoris
pecified,seeTM9-1777B.
rviceandblackoutswitchinallpositions
efunctioning.Replaceanyburned-outbulbs.
ckoutstoplights.
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E
D-18)ENGINE
OMVEHICLE
engine30
31
movalwithengine32
emoval33
tion?34
e35
portandplacingofengine36
ovedfromthe vehicle,anadequatesup-
othe enginecanbereadilyworkedupon.An
supportcanbebuiltasoutlined inparagraph
re removedassembliesundercovershould
ONS.
movedfromthe tractorexceptforcom-
sor replacementswhichcannotbemade
din thevehicle.
Diesel fueltanksisclosed.
estrainer isshutoff.
emis drainedbeforeremovingradiator.
n,TM9-1777B.
efrombatteries.Batteriesarelocated
beforeremoval.Itisimportantthat the
andalldirtremovedfromall exteriorparts
eengineisremovedfromthetractor.This not
perationsbutpreventsdirtfromcomingin
ingsubsequentoperations.
movalofwinchasoutlinedin TM
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OMVEHICLE
m.
ndcapscrewwhichholdmufflerclamp
fmuffler.Removesecondmufflerinsame
moval
AL(fig.11).
open-end,s/8-in.
n.
LLERCAP.Fillercapis locatedatleft
beremovedbyhand.
SFROMTopOFHOODSHEET.
n.
w.Therearefourcapscrewsatrear of
nt.Eachcapscrewhasflatwasherandlock
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E
TD-18)ENGINE
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OMVEHICLE
OTTEDSCREWS.
open-end,s/s-in.
rews,lockwashersandnutswhichsecure
ners.
ORFROMENGINE.
edincoolingsystemsection,TM9-1777B.
REMOVAL(fig.12).
,l5/16-in.,
dle
GUARDONJACK.
owerisavailabletolowercrankcase
rankcaseguardonjacksothat guardwillnot
ts areremoved.
DLOCKWASHERSFROMEACHSIDEOF
,l5/16-in.,
ut bolts.
UARD.Lowerjacksothatcrankcase
orfloor.
dbecarefultobe outofwaywhen
L(fig.95).
NCH,box,^-in.
magneticdrainplugs.
UTCHFORREMOVALWITH
heengine,the engineisremovedwith
d.Theclutchisthenremovedfromtheengine.
RINGFROMTRANSMISSIONFLANGE.Fol-
chprocedureinTM9-177 7C,untilclutch
ransmissionflange.
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E
TO-18)ENGINE
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OMVEHICLE
FT.
dlockwasherwhichhold theclutch
ft.Thenremovethe clutchlever.Removethe
ofthe shaft.
GINEFORREMOVAL.
nd,%6-in.
open-end,5^-in.
RENCH,open-end,"/^-in.
m.WRENCH,open-end,^-in.
G-in.WRENCH,ratchet,with
n.socket
SWHICHSECUREDASHANDCOWL
NDERHEAD.
m.
sandlockwashersfromdriver'sside
y.Thenremovespacerbetweendashand
OIR.SeeTM9-1777D.
CONTROLRODFROMBELLCRANKAT
iftrod fromtopholeofbell crank.Push
GRODFROMBELLCRANKATREAROF
3).
thenremoverod frombellcrank.Push
NGSWITCHTOSTARTINGMOTORCABLE
ig.13).
m.WRENCH,ratchet,reversible,
asherwhichholdcableto starter.Re-
washerwhichholdcableclipandcranking
ort.
COILTOIGNITIONSWITCH)(fig.13).
n.
asherwhichholdcableto coil.
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E
D-18)ENGINE
MPRESSORTOGOVERNOR)(fig.13).
n.
eachendoftube.Thenremovetube.
LEANERPIPE(fig.13).
6-in.WRENCH,open-end,%6-in.
seclip.Removefourcapscrewsandlock
etointakemanifoldhousing.Removepipe
CABLE(AMMETERTOVOLTAGESHIELD,
RACER)REGULATOR-BLACKANDREDTRACER),HEAT
gCablesfromGenerator
SERVICESWITCHTOGENERATOR)FROM
open-end,%6-in.
leybrace.Pushgeneratortowardengine
nd thenremovefanbeltsfromidlerpulley.
bleswithoutremovingheatshield,pull
ne.Removenutholdingserviceswitchto
cer).Removeammetertovoltageregulator
ckandredtracer).
removecable.
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OMVEHICLE
/PIPE,FUEL
UELSUPPLY
nsorLeftRearofEngine
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E
D-18)ENGINE
ATORPLUGFROMREARCYLINDERHEAD
n.
enremoveplug.
RESSIONRELEASERODFROMCROSSSHAFT
5).
rodfromlever andmoverodupward,
N
SCREW,CAP"* >13779
welBoltfromRearEngineSupport
CONTROLROD(fig.15).
chholdsrodto governorcontrollever.
vecotterpinfrompinwhichholdsadjusting
orcontrollever.Thenremoverod.
CATINGOILINDICATORPIPE(fig.15).
.WRENCH,open-end,%-in.
eachendofpipe.Removecapscrewand
pecliptocrankcase.
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MVEHICLE
NPIPE(fig.15).
eachendof pipe.
YPIPE(fig.15).
n.
eachendof pipe.
CONNECTION,
%-in.,
R-in.withspinnertypehandle
arEngineSupportCap
ngine
NGINESUPPORTFROMMAINFRAMESIDE
in.WRENCH,socket,T/8-in.,
sed),nut andlockwasherfromeach
t.Holdnuts withopen-endwrenchwhile
twrench.
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E
D-18)ENGINE
NT
0
eSlingonLeftSide ofEngine
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OMVEHICLE
PULLEY,FANDRIVE
eSlingonRightSide ofEngine
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E
D-18)ENGINE
GINESUPPORTFROMMAINFRAME(figs.
%-m.,
tswhichlineup engineandclutchwith
ssideofdashandcowlassembly,removenut
elboltin leftsideofrearengine support.
ebolt,lockwasherand nutfromcorrespond-
frearenginesupport.This boltalsoholds
ltprevioustoTDR-3752dowelpinswere
s foraliningtheengineto themainframe.
AMERAPD1Z782
nginefromVehicle
enuton dowelpinandtightenasfar asit
acewashersunderit andagaintightennut.
welpinhasbeenremoved.
wsandlockwashersfromrearengine
screwsmustberemovedfromdriver's side
y(fig.17).
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OMVEHICLE
edonBlocks
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E
D-18)ENGINE
VEHICLE.
size,
ENGINE(figs.18and19).
g
Frontloop ofropeshouldbeplaced
tto frontenginesupport,withloopinfront
d Dieselfueloilfilter onleftsideofengine.
nt loopshouldrunbetweenidlerpulleyand
ouldbeplacedbackofNo. 6nozzleonleft
oilpan,nexttorear enginesupport.Onright
ould bebackofrearexhaustmanifold.Tie
e inpositionsothatweightof engine
TION:Ropeshouldbeattachedtohoistno
p ofengine.
0).
weightofengineis offmainframeside
lcompleteclutchclearsmainframe.
yfrom vehicle,placingengineonblocks
6.
GINESUPPORTANDPLACINGOF
in.BLOCKS,wooden,2x4x12 in.
nona 2by4by 12-inchwoodenblock
eavyblockoruponequivalentbaseofplanks.
rton heavyblockoruponequivalentbase
ertsmallblocksunderoilpanflanges at
erJo.keepenginewith accessoriesinarigid
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E
removal39
dwithcarburetorattached40
1
l42
kplugremoval44
removal46
7
val48
elfilter removal50
ateroutletremoval52
val53
ywithvibrationdamperattached....54
oval55
56
7
ontrolremoval59
l60
val61
removal62
3
val64
ngremoval65
mblyremoval66
emoval68
oval70
spartsfromsidesofcrankcase71
al72
al73
4
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E
D-18)ENGINE
shouldbeavailablefor thedisassembly
edpartsmustbeprotectedfromthe elements
ybecoveredandprotectedfromdust and
ovedfromthe tractorandsupportedon
dinsectionIV.
altoolslistedinsectionXI,a complete
dbe available.Allthetoolsneededforeach
atthe beginningofeachparagraph.The
hparagrapharelikewiselistedatthebeginning
ssarytomovetheengineto thevariousposi-
time intheprocessofdisassembly.
ONS.
yofenginesubassembliesandsubsequent
derlinessandcleanlinessshouldbemain-
eengine.
embletheengine,it shouldbecarefully
rt,oilorother accumulationshavebeen
removalofenginefromtractor,sectionIV,
theenginebe thoroughlysteam-cleaned
xtremecareto protectinteriorofassemblies
ovedfromtheengine.
hnewones.Alltracesof oldgasketsshould
sketsareinstalled.
atedto removeallpartshavingatight
ould notbepriedoffwith screwdriversor
cted.
ersmoothworkingsurfaceswithcare,
orpossiblescoring.
edvalves,pistonsand connectingrods.
mallpartsin receptacles.Tosimplify
embledpartsinorder.
RCLEANERREMOVAL(fig.22).
open-end,^-in.
ANERFROMINTAKEMANIFOLD.
.
sandlockwasherswhichsecureair
manifold.
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E
D-18)ENGINE
PRESSORAIRCLEANERFROMAIRCOM-
clampofair compressorinletpipelower
efromair compressorairinletelbowand
inlet pipeandtwohosesattached.NOTE:
mpressoraircleanerisfasteneddirectlyto
oslottedscrews.Usea screwdrivertoremove.
MANIFOLDWITHCARBURETOR
l3/1G-in.,
.withspeeder
.
VECONTROLROD(fig.136).
mpinwhichconnectsairvalvecontrol
ollever.Removepinand removerodfrom
ASSEMBLYFROMIGNITIONCUT-OUTSWITCH
g.136).
n.
rewsandlockwashersfromcoveratfront
emovecoverandgasket.
tswitchtodistributor)andcable(coil
enut,lockwasherandflatwasherwhich
tchterminalwithinhousing.Pull cablesout
NEPIPEFROMCARBURETOR(fig.22).
n.
utwhichholdsgasolinepipetocarburetor.
RETORCONTROLRODFROMCARBURETOR
chholdscontrolrodto leveratcar-
FOLD(fig.22).
n.,withspeeder
chholdintakemanifoldtocylinderhead.
hendofmanifoldandfourat center.Liftoff
ttached.Removethreegaskets.
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E
SCREW.CAPMOTOR,CRANKING
orRemoval
EMOVAL(fig.23).
NCH,socket,9/16-m.,
IPE(fig.22).
ndspeeder
sandlockwasherswhichholdbreather
vepipeandgasket.
OTORANDCRANKINGMOTORCABLECLIP.
wsandlockwasherswhichholdcrank-
upport.Liftoffcrankingmotor.
REMOVAL.
n.,andspeeder
STMANIFOLD(fig.22).
ndspeeder
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E
D-18)ENGINE
hsecurerearexhaustmanifoldto
anifoldandtwocoppergaskets.
AUSTMANIFOLD(fig.22).
n..andspeeder
eoutlinedinstep(1) above.
TAGNUTCOIL,GNITION
moval
VAL(fig.24).
m.WRENCH,open-end,%6-in.
DISTRIBUTORCABLEASSEMBLYFROM
fromcoil.
NCOILTOCUT-OUTSWITCHCABLEFROM
m.
scabletocoil terminal(+).Aftercable
elockwasherandnutonterminal.Also,
dof cabletofacilitatecorrectinstallation.
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D-18)ENGINE
LWITHBRACKETFROMCRANKCASE.
6-in.
sandlockwasherswhichsecureignition
Thenremovecoilwithbracketattached.
NDSPARKPLUGREMOVAL
n.WRENCH,sparkplug(IHC
o.32941-Dorequivalent)
CABLES.
n.WRENCH,socket,%6-in.,
xsparkplugs,turningcableterminal
counterclockwisedirection.Replacenutson
veruseplierstoremoveortighten spark
ugporcelainmaybecomebroken.
o.1and No.2sparkplugcablesto
screwandlockwasher.
scable(ignitioncut-outswitchtodis-
movecablefromdistributor.
esandignitioncoilcablefromdis-
S(fig.25).
No.32941-Dorequivalent)
wrenchto loosensixsparkplugs,asout-
ection,TM9-1777B.
VAL(fig.25).
box,%6-in.
WHICHSECURESDISTRIBUTORBRACKET
,box,9/16-in.
ngnut.Thenusescrewdrivertoloosen
fromdistributorbracket.
R.Liftdistributor,withbracketattached,
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ERATORREMOVAL(fig.25).
ENCH,socket,%6-in.,
.WRENCH,socket,34-in.,
PE.
ndspeeder
lockwasherwhichsecureheatshield
nkcase.Removegasolinepipe.
LET,
SSORAIRCOMPRESSORCONNECTOR
SCREW,
AP
sorRemove/
.
.WRENCH,socket,3^-in.,
lockwasherwhichholdidlerpulley
lockwasherwhichholdheatshieldand
Removeheatshield.
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TO-18)ENGINE
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n.WRENCH,socket,3/4-in.,
n.andspeeder
ckwasherwhichholdidler bracket
Holdnutwithopen-endwrenchandremove
ckwasherwhichholdgeneratorat
racket.Holdnutwith open-endwrenchand
open-endwrench.Liftoutgenerator,idler
MOVAL(fig.26).
-in.WRENCH,socket,%-in.,
speeder
m.
SSORWATERINLETTUBE.
.
eachendoftube.Thenremovetube.
SSOROUTLETTUBE.
.
eachendoftube.Thenremovetube.
SSORDRIVECOUPLINGCOVER.
n.
washersandlockwasherswhichhold
ngoncouplingflangegearanddriveshaft
SSORWITHBRACKETATTACHED.
wsandlockwasherswhichholdair com-
ase.Liftaircompressorwithbracketattached
eaircompressorbracketgasket.
REMOVAL(fig.27).
nd,s/8-m.
open-end,^-in.
n.
NJECTIONPUMPTONOZZLES).
n.WRENCH,open-end,3/4-'m.
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D-18)ENGINE
dNo.1and No.6pipesto cylinder
sateachendofsixpipes.RemoveNo.1
4,5and 6insequence.
veholderwithcaporwith tapeassoon
portantthatholdersbe coveredsothat
ctionpump.
ELFILTERTOINJECTIONPUMP).
m.
eachendofpipe.
ELSUPPLYPUMPTOFUELFILTER).
m.
eachendofpipe.
ATERTRAPTOFUELSUPPLYPUMP).
m
eachendofpipe.
NORCONTROLRODFROMGOVERNOROPER-
enremovepinandcontrolrod from
SPACER.
coversspacerbetweenadjusterand
ONPUMP.
.
wsandlockwasherswhichholdfuelinjec-
kcase.Thenliftoffpumpand bracket
AL(fig.27).
ndspeeder
ocapscrewsandlockwasherswhich
crankcase.Liftoffwatertrapwith bracket
TERSANDFUELFILTER
ndspinnertypehandle
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rcapscrewsandlockwasherswhichhold
ftofffilterbase withfiltersattached.Then
AL(fig.27).
NCH,open-end,7/16-in.
capscrews.
R.
6-in.
ousingandWaterOutletRemoval
sandlockwasherswhichsecurehour
ear housing.Thenremovehourmeterand
RDRIVENGEARASSEMBLY.Liftassembly
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D-18)ENGINE
NGANDWATEROUTLETREMOVAL
box,^-in.
OUTLETHOSEFROMWATERPUMP.
mp.
AHOUSINGANDWATEROUTLET.
wsandlockwasherswhichholdwater
movehousingwithwateroutletattached.
gasket.
PREMOVAL(fig.28).
PUMPFROMCRANKCASE.
ngcapscrewsandlockwasherswhich
rankcase.Thenremovewaterpumpand
PBODYGASKETANDTwoWATERPUMP
VEPULLEYWITHVIBRATION
ket,2%-in.,and
bspinnertypehandle
UT.
ket,2}i-in.,
spinnertypehandle
ginefromturning overwhenstarting
ovestartingnutin samemannershownin
artingnutlockwasher.
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ULLEYWITHVIBRATIONDAMPER
b
dvibrationdamperfromcrankshaft.
ORTREMOVAL.
bWRENCH,open-end,7/16-in.
OMCRANKCASEFRONTCOVER.
b
port.
blyRemoval
6-in.
mfrontenginesupport.
MOVAL(fig.29).
ndspinnertypehandle
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D-18)ENGINE
BACKPLATEFROMFLYWHEEL.
andspinnertypehandle
wsandlockwasherswhichholdclutch
LUTCH.Liftcompleteclutchfromflywheel.
eelRemoval
MOVAL(fig.30).
nd
nd
OCKS.
cksfromheadsofcapscrews.These
insin place.
SWHICHSECUREFLYWHEELTOCRANK-
nd
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don outsideofflywheel,tokeepfly-
apscrewsarebeingremoved.Removesix
vethreecapscrewlocks.
eelfromCrankshaft
WITHRINGGEARATTACHED.
%-in.,and
crewsintopuller holes.Thentighten
eachoneaquarterturn atatime,untilfly-
shaft.CAUTION:Becauseofweightof
usedto liftitawayfromengine.Otherwise,
kenwhenliftingtheflywheelby hand.
OVAL,
.
and
nd
SINGCOVER(fig.63).
.
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TD-18)ENGINE
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opperwasherswhichholdcoverto
er;removegasketandfelt.
SHAFTOPERATINGRODFROMCROSSSHAFT
mpinwhichholdsadjusting yoketo
pin.
TSPRING(fig.32).
onnectsinnerlevertospringanchor
RSHAFTBRACKETSTUDNUTS(fig.32).
.
centerstudswhichholdend andinter-
derheads.
ROMRIGHTSIDEOFVALVESHAFT
dspinnertypehandle
SFROMSTUDSWHICHHOLDHOUSING
ndspinnertypehandle
SFROMCROSSSHAFTANDFRONTCENTER
ndspinner typehandle
wsfromcrossshaftbracketandfourcap
rackets.Thesecapscrewsholdbracketsto
THVALVELEVERASSEMBLIES(fig.32).
offcylinderheads.Removehousinggasket.
FOLD(fig.32).
n.
sandlockwasherswhichholdmanifold
Removewatermanifoldandgasket.
(fig.67).Liftpushrodsfromcrankcase
HHOLDCYLINDERHEADSTOCRANKCASE
ndspinnertypehandlewithextension
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TD-18)ENGINE
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securecylinderheadstocrankcasestuds.
oneachsideof cylinderheadsandalsoa
twocylinderheadshasflatwasherbetweennut
EADS(fig.69).
rearstudorcap screwoffrontcylinder
dsused.Thenlift cylinderheadupward
eadinsamemanner.
gasketsandgasketrings.
ERATING
eratingLeverRemoval
OVERNORCONTROLREMOVAL
.
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D-18)ENGINE
TOPERATINGLEVER.
in.
eremovenutandlockwasherfrom
vertocross shaft.
pin.
DCONTROLLEVER.
ndspinnertypehandle
wsandlockwasherswhichholdbracket
ase.Thenliftoffbracketandcontrollever
moval
T(fig.35).Fromrightsideofcrankcase,
peratingrodandconnectingpartsattached.
G(fig.35).
g.35).
.*
Thenliftoff latch.
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KET(fig.35).
ndspeeder
asherwhichholdlatchbracketto crank-
hbracket.
NTf^y,(CRANKCASE
N.x 3FT.~~~RAPD17IO4
einHorizontalPosition
REMOVAL.
SLING,rope
9/16-in.,
ypehandle
CASEANDATTACHEDPARTSONITSLEFT
PLANK,2-in.
romleft sideofcrankcase.
attachedpartsonhoistby meansofrope
dedforusewhenremovingenginefromvehicle.
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D-18)ENGINE
er rearofoilpan andanotherloopunder
enblocksapproximately12-inchby12-
t,asa base,andcoverthemwith2-inch
ttachedpartsonplank,pushingassembly
cksunderupperpartof crankcaseto
horizontalposition.
PumpRemoval
ILPAN.
ndspinnertypehandle
,remove32capscrewsandlockwashers
old oilpantocrankcase.Therearethree
onein front.Removeoilpan.
ILPANGASKET.Takegasketoffoilpan.
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MPREMOVAL.
nd,%G-in.
ox,WRENCH,open-end,^-in.
ETURNPIPE(fig.96).
d,WRENCH,open-end,%G-in.
lockwasherwhichholdpipebracket
pipefromoilpumpcover,removingtwocap
Liftofffrontoilreturn pipeandremove
TURNPIPE(fig.96).
d,WRENCH,open-end,%6-in.
odBearingCapRemoval
lockwasherwhichholdpipebracketto
ectpipefromlubricatingoil pumpupper
pscrewsandlockwashers.Liftoutpipe
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D-18)ENGINE
OILPUMP(fig.37).
nd,54-in.
ksdrilledcapscrewsthatholdpump
pscrewsandlockwashers,thenlowerpump
TINGRODREMOVAL,
CH,socket,54-in.,
andle
nnectingRodandPiston
CTINGRODBEARINGCAP(fig.38).
CH,socket,^-in.,
andle
chlockfourconnectingrodboltnuts.
ngrodboltnuts.
dbearingcapwithlowerconnectingrod
sary,tapcaplightlywithrawhidehammer.
NECTINGRODANDUPPERCONNECTING
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onnectingrodbearingjournalis inup-
providemaximumclearanceforremovalof
.Toturnovercrankshaft,firstinstall inend
rewswhichwereusedtohold flywheeltoend
shaftbyplacingbarbetweentwocapscrews.
and piston,takingcarenottodamage
ISTONSANDCONNECTINGRODSBYFOL-
E.
E-SE-654
vePullerToolInstallation
MOVAL.
pen-end,
HC
EEVEPULLERTOOL(fig.40).
e-WRENCH,open-end,
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TO-18)ENGINE
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uller.First,run pullernuttotop of
ugendofrod intocylindersothatlugcan
eeve.Legsof tool"spider"shouldreston
er,sothattoolnutisin centerofcylinder.Then
EEVE(fig.41).Continuetighteningnut
fromcrankcase.Liftouttoolandcylinder
eRingRemoval
EEVERING(fig.42).
free andthenremovering.Ringis
erwall.
SLEEVESINSAMEMANNER.Whenremov-
t isimportanttomarkor systematically
eplacementincounterboresfromwhich
ed.Whensamesleeveistobe installedagainin
eincrankcaseshouldalsobemarkedsothat
s originalposition.
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D-18)ENGINE
nvertedPosition
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RTREMOVAL.
ENCH,socket,9/16-in.,
1-in.,
typehandle
NDATTACHEDPARTSININVERTEDPOSI-
ST
o.3andNo.4 cylinderbores,tying
hhoistto ropeslingatcrankshaftsideof
asefromitssupport.
SealRetainerP/ateRemoval
by12-inchby3-footwoodenblocks(or
used)paralleltocrankcaseandlowercrank-
etweenblocks,withblockssupportingeach
rdsacrosseachendofblocksas aprecaution
goutofposition.
ndspeeder
ewsandlockwasherswhichholddust
arengine support.Thenremovedustseal
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D-18)ENGINE
ESUPPORT.
dspinnertypehandle
ockwasherswhichholdrear engine
supportloosefromcrankcaseandthen
AINBEARINGREMOVAL.
in.
nd
KET,FRONTCOVERBOLT
ontCoverRemoval
OILSEALRETAINERPLATE(fig.44).
wsandlockwasherswhichholdoil seal
eallowerretainer.Thenremoveplategasket
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AINER.
n.
s,lockwashersandflatwasherswhich
ankcase.Alsoremovetwocapscrews,lock
whichholdupperandlower retainerstogether.
sections,twopiecesofoilseal felt,tworetainer
.
RONTCOVER(fig.45).
box,orsocket,
sandlockwashersandeight bolts,nuts
oldcrankcasecovertocrankcase.
ankcase.Thenliftoffcoverand remove
ruffkeysandoilflinger fromtheendof
inBearingCapRemoval
MAINBEARINGCAPSANDLOWERMAIN
,1-in.,and
e,
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TD-18)ENGINE
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mtwonutswhichsecuremainbearing
studs.
oosenthem.Thenliftoffcapwithlower
bearingcapsandlowermainbearingsin
rnutsmustbe removedtoremoveinter-
.
OMCRANKCASE(fig.47).
ndandfifthcrankshaftconnectingrod
opetohoistandlift outcrankshaft.
BEARINGS.Aftercrankshafthasbeenre-
inbearingsfromcrankcase,slidingthemin
AUTION:Identifyorarrangebearingssothey
orrectpositions,ifnewbearingsarenot
ORDRIVE
rDriveRemoval
IVEASSEMBLYREMOVAL,
%-in
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D-18)ENGINE
PRESSORDRIVEHOUSINGFROMENGINE
sandcopperwasherswhichholdhousing
ewalsoholds cliptoplate.
SSORDRIVEWITHGASKETANDDOWEL
menginefrontplate andliftoffassem-
SHAFTGEAR,CAMSHAFTSCREW,CAP
gCamshaftPlatefromCrankcase
4-in.socket.
AFTPLATEFROMCRANKCASE(fig.49).
^-'m.socket
siontoremovetwocapscrewsand lock
haftplatetocrankcase.Itisnecessaryto
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CamshaftGearRemoval
ANKCASE
emoval
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D-18)ENGINE
atwrenchcanbeinsertedthrough gearholes
fig.50).Pulloutcamshaftwithcamshaft
ETS(fig.51).Withcamshaftremovedand
tion,valvetappetscannowbeliftedoutfrom
petguidesareto beremovedwithoutfully
eoftheengine,theymayberemovedat this
eonitsside.Guides canthenbetappedout
(fig.58).
PumpShaftGearHutRemoval
DRIVEREMOVAL.
ocket,1^-in.,
ertypehandle
fig.49).
box,^-in.
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kandthen removetwocapscrewswhich
rshaft.Thenliftidler gearfromshaft.
ONPUMPDRIVESHAFTGEAR(fig.52).
-in.,
typehandle
hat shaftwillnotturnwhengear nutis
sgeartoshaft.
fromendofshaft.
UMP;ASSEMBLYHOUSING,
NT
PumpDriveAssemb/yRemoval
ONPUMPDRIVEASSEMBLY(fig.53).
box,3/4-in.
wocapscrews.Then,removetwocap
gtocrankcasefrontplate.Alsoremovehousing
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D-18)ENGINE
rGearShaftfromCrankcase
MOVAL,
socket,1^-in.,
removenut.
SHAFT.
RENCH,box,yA-in.
eror improvisedmeansofpullingshaft,
mplemethod,asillustrated,isto usepieceof
slong,placingitoverendof shaftand
ewashersand%-inchNationalFineby
ythreaded,screwingcapscrewintoendof
ewuntilshaftis pulledfromcrankcase.
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ATEREMOVAL.
^-in.
LOCKSFROMCAPSCREWS(fig.55).
dsof fivecapscrews.
S.
swhichsecurefrontplatetocrankcase.
E.
omcrankcase.Thenliftoffplateand
.
ontPlateRemoval
LANEOUSPARTSFROMSIDESOF
n.
G-in.
e
nd
and
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TD-18)ENGINE
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EELBOW(fig.56).
6-in.
htsideof crankcase.
BRACKET.
ndspeeder
sandlockwasherswhichholdbracketto
movebracket.
ASESIDEPLATES.
ndspeeder
emovetwocapscrewsandlockwashers
ankcase.Thenremovetwosideplatesand
IDECOVER.
ndspeeder
mrightsideof crankcase,removingfour
ers.Thenremovesidecovergasket.
ELBOWANDCOCK.
e
htsideof crankcase.
AGESLEEVE(fig.57).
oving(steelbar)
movingtoolofasizewhichwill fitover
o crankcaseanddriveoutsleeve.
OILGAGEPIPEELBOW(fig.57).
n.
ftsideof crankcase.
TCONTROLDISKPIN(fig.57).
e
de ofcrankcase.
ETURNPIPE(fig.57).
e
pipe frominsideofcrankcase.
MFRONTENDOFCRANKCASE(fig.57).
sandlockwasherswhichholdplateto
moveplateandgasket.
REMOVAL(fig.58).
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O-18)ENGINE
ATESCREW,CAP
GageSleeve
HAFTBEARING
GuideRemoval
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NITSSIDE.
hsecondand fifthcylinderbores,use
asefromitsbaseandlowercrankcaseagain,
eforeremovinghoistandrope,blockup
evelposition.
ETGUIDES.
ofcrankcaseandtap12guidesloose.
ofcrankcase.
REMOVAL.
fcamshaftbearings,asoutlinedinpara-
forreplacementofoneor morecamshaft
beremovedfromcrankcase.
cold
AMSHAFTBEARINGPLUG(fig.58).
aringisto beremoved,itisnecessaryto
haftbearingplug.Thisstep isnotrequiredfor
tbearings.Toremoveplug,insertsteelbar
andtapplugout ofcrankcase.
.59).
earingandtapchiseluntil onesideof
ntapedgeof bearinguntilbearingisremoved.
erberemovedunlesstheyare tobereplaced,
issible.CAUTION:Donotallowchiselto
CRANKSHAFTBEARINGSINSAMEMANNER
OVE.
MOVAL.
,itshouldnot benecessarytoremove
ceptwhencrankcaseinspectiondisclosesbroken
ds.Inabsenceofstandardstudremovers,
forremovalofmainbearingstudcanalso be
ercrankcasestuds,providingnutswhich
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D-18)ENGINE
tBearingRemoval
StudRemove/
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n.
mainbearingstud,proceedasfollows:
ARINGSTUDNUTSTOSTUDWHICHIsTO
n.
dthreadastightas possible.Then
f firstoneassecurelyas possible.
m.
ud nut,pullingincounterclockwisedirec-
.
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D-18)ENGINE
MBLEDENGINE
ssemblies75
ESUBASSEMBLIES.
nshouldbemadebeforethesubassemblies
mustbethoroughlycleanedin suitable
dshouldbeinspectedforwear,galling or
smustbereplacedandallmovingpartscovered
foreassemblytoprovideinitiallubrication.
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MBLEDENGINE
-
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D-18)ENGINE
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MBLEDENGINE
-
t
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D-18)ENGINE
pectbearings
ectdrive
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DISASSEMBLY,REPAIRAND
EMBLIES
n77
y79
fdisassembledcylinderheadparts...80
s85
eforeinstallation86
87
rassembliesandhousing88
veleverassemblies89
sembliesandhousing90
rassembliesandhousing91
fvalveleverassembliesandhousing
semblies93
erassemblies94
elever housing95
ssembliesandhousing96
nkcaseoilpan97
l98
gandinspection99
ion100
val101
sembly102
ction103
haul104
pump105
lation106
removal107
disassembly108
nspection109
overhaul110
onnectingrods^ 111
ectingrodassembliesbefore
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D-18)ENGINE
nstallation113
moval114
spection115
stallation116
18
19
20
n121
arfromthecrankshaft122
nkshaft124
5
ndtappetguideremoval126
7
etappetandtappetguideinspection..128
ndtappetguideinstallation129
ondamperoverhaul130
moval131
erhaul132
tallation133
oval134
sembly135
linginspection136
faircompressordriveparts137
ordrive138
ordrivebeforeinstallation139
lation140
erhaul141
42
bly143
andhousingparts144
fintakemanifoldandhousingparts... 145
old146
n147
l148
oldinspection149
ion150
on151
l152
ion153
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DISASSEMBLY,REPAIRAND
EMBLIES
ginewhicharenot majorcomponentsof
ng,electricalandstartingsystemsaretreated
mponents,refertofuel, lubrication,cooling,
emsections,TM9-1777B.
ovalfromengine,disassembly,cleaning
assemblyandinstallationonengine,asmay
nentsincluded.
vinganycomponentsfromtheenginein
nginedisassemblyiscoveredinsectionV.
orinstallinganycomponentintheprocess
blyiscoveredinsectionVIII.
STRUCTION.
chcoveringthreecylindersareusedin
elyboltedtothe crankcaseandarejoined
e watermanifold.Cylinderheadsarede-
uelinjectionnozzlesand precombustion
ntakeandexhaustvalvesarepairedto
mentandimprovegaspassage.
OVAL.
bliesdonothavetobe removedfromthe
valvespring.See paragraph90.
%6-'m.,
andle
6-in.WRENCH,socket,1-in.,
6-in.andspinnertypehandle
.WRENCH,sparkplug
.(No.32941-D,orequivalent)
T.Seeparagraph29.
FOLD.Seeparagraph142.
ANIFOLDS.Seeparagraph148.
NWIRESFROMSPARKPLUGS.
S.
32941-D,orequivalent)
rench,toremoveplugs.
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DISASSEMBLY,REPAIRAND
EMBLIES
SHAFTOPERATINGRODFROMCROSSSHAFT
mpinwhichholdsadjusting yoketocross
OSTATHOUSINGANDWATEROUTLET
.
wsandlockwasherswhichholdwater
teroutletgasketshouldbe removedwhen
ONPUMPTONOZZLEPIPES.
.
ctorsateachendofeachofsix pipes.To
pes,itisnecessaryto removeclipwhich
head.Removecapscrewwhichholdseach
ecapsortape oninjectionfuelpumpde-
TORCABLEANDELEMENTFROMLEFT
HEAD(fig.62).
6-in.WRENCH,open-end,/8-in.
ch,useanotherwrenchto removecon-
ent.
NIFOLD(fig.62).
ndspinnertypehandle
sandlockwasherswhichholdwater
erhead.Removewatermanifoldandgasket.
SSHAFTTHRUSTBRACKETFROMREAR
.
sandlockwasherswhichsecurebracket
YLINDERHEADFROMDASHANDCOWL
.
sandlockwashersfromdriver'ssideof
Thesecapscrewsholdcylinderheadtodash
vespacersbetweendashandhead.Second
espondingpositiononotherside ofaircleaner.
SINGCOVER(fig.63).
.
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TO-18)ENGINE
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DISASSEMBLY,REPAIRAND
MBLIES
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TO-18)ENGINE
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DISASSEMBLY,REPAIRAND
EMBLIES
opperwasherswhichholdcoverto
erandremovegasketandfelt.
ERSHAFTBRACKETSTUDNUTS(fig.64).
m.
terstudswhichholdend andintermediate
s.
FTSPRING(fig.64).
pringwhichconnectsinnerlevertospring
FROMRIGHTSIDEOFVALVESHAFT
ndspinnertypehandle
emovefivenuts.
OMSTUDSWHICHHOLDHOUSINGIN
ndspinnertypehandle
emovenuts.
WSFROMCROSSSHAFTANDFRONTCENTER
ndspinnertypehandle
typehandlewrenchto removefourcap
acketsandfourcapscrewsfromfrontcenter
wsholdbracketstocylinderheads.
ITHVALVESHAFTANDLEVERASSEMBLIES
wardandoffcylinderheads.
ODS(fig.67).Pushrodscanbe liftedout
esandhousinghavebeenremoved.
HHOLDCYLINDERHEADSTOCRANKCASE
ndspinnertypehandle
uredtocrankcasewithnutson 31crank-
w ofstudsoneachsideof cylinderheadsand
weentwocylinderheadshas flatwasher
uts.
EADS(fig.69).
rearstudoffront cylinderhead,re-
Thenlift cylinderheadupwardandoff
eadinsamemanner.
gaskets.
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TD-18)ENGINE
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DISASSEMBLY,REPAIRAND
MBLIES
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TD-18)ENGINE
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DISASSEMBLY,REPAIRAND
EMBLIES
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TD-18)ENGINE
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DISASSEMBLY,REPAIRAND
MBLIES
YLINDER"APD12894
ValveSpringswithValveLifter
VALVE
keandExhaustValveandRelatedParts
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D-18)ENGINE
SSEMBLY.
PUNCH,center
ENCH,open-end,%-in.
EXHAUSTVALVESFROMFRONTCYLINDER
PUNCH,center
Removal
fterVL-500,orequivalent,placeclamp
tofonevalve.Thenturncrankof tooluntil
ollarkeys.Releasethevalvelifterand
eat.
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DISASSEMBLY,REPAIRAND
EMBLIES
valve.
erneathsideofcylinderhead.
muppersideof cylinderhead.
akeandexhaustvalvesinsamemanner.
numberofdotsonfaceofeachvalveto
epositioninwhichit wasoriginallyinstalled.
takeValveGuide
ALVES(fig.72).
moneofspring retainerswhichlocksre-
fstartingvalve.Thenunscrewspringre-
espring.Valvecanthen beliftedoutfrom
erhead.
rtingvalvesinsamemanner.
EXHAUSTVALVEGUIDES(fig.73).
ntil theyhavebeencleanedasinpara-
edforwear.Removeonlythoseguidesthat
ylinderheadinarborpress,or anothersuit-
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D-18)ENGINE
bar ofslightlysmallerdiameterthanguide
dethroughheadby pressingsleeveandguide
Removeremainingintakeandexhaustvalve
ALVEGUIDES(fig.73).Followsamepro-
emovestartingvalveguides.
ZZLEBODYANDNOZZLEBODYRETAINER
.
zzle,Nozz/eBodyand
ad
hholdbodyretainerto cylinderhead
zzlebodyandnozzlebodyretainerwithdust
t,spacerandsecondspacergasket.NOTE:
enozzlebodyandnozzlebodyretainerseals.
zzlesandrelatedpartsin samemanner.
NSIONPLUGS(fig.75).
xpansionplugsin nozzlesideofeach
ansionplugatone endofeachcylinderhead.
emovedexceptin rareinstanceswhenfreez-
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DISASSEMBLY,REPAIRAND
EMBLIES
ld blowoutorloosenplugswithoutcracking
es,plugcanbe removedwithpunch.
ULDNOTBEREMOVED.
EDURETODISASSEMBLEREARCYLINDER
.
epsoutlinedaboveindisassemblingthe
eoperatingcrossshaftthrustbracket.Itis
erheadby twocapscrewsandlockwashers.
2901
onfromCylinderHead
ONOFDISASSEMBLEDCYL-
lve
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D-18)ENGINE
MCYLINDERHEADS(fig.75).
KNIFE,putty
pecarbonfrombottomfacesofcylinder
hin electricdrilltocleancarbonthoroughly
roundvalveseatsand frominsideofexhaust
aretoseethatfaceof headisthoroughlyclean
sthatgasketringsrest (fig.75).
RTIONSOFCYLINDERHEADS.
ning
D12908
derHeadwithWater
ovealltracesofoldgasketand dirt
ad.UseSOLVENT,dry-cleaning,andbrush
omofcylinderhead.
DWITHWATER(fig.76).
sagesandwaterjacketsofcylinder
rhead,usingcompressedair,if available.
ry-cleaning
ncarbonfromvalves.Thenwashthem
ry-cleaning.
S,SEATSANDCOLLARKEYS.
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DISASSEMBLY,REPAIRAND
EMBLIES
inSOLVENT,dry-cleaning.
AD.
forcracks,particularlybetweenexhaust,
penings.
GUIDES.
ectric,portable,
n.
IGHT
eValveGuide
erin electricdrill.Expandtoolcleaner
guidesizeby adjustinghexagonnutonend
debymovingcleanerupand downinside
hatguidesare shinywhenoperationiscom-
y shiningflashlightintovalveguidefrom
.
RESSURE(fig.78).
alveandclutch(IHCNo.SE-1057
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D-18)ENGINE
SpringPressure
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DISASSEMBLY,REPAIRAND
EMBLIES
yforrustand pits.Pitsinvalvesprings
see.soextremecaremustbegivenininspect-
gevidenceofpittingmustbereplaced.
inspecialvalve andclutchspringtester,
Placespringonplatformas nearcenteras
heel,compressingspringtodesiredheight,
ide ofplatform.Thisscalereadsfrombottom
edtodesiredheight,moveoneof knurled
ro toreleaseanyfrictionthatmayexist
rmovinghandle,recheckheightonscaleat
collardirectlybelowhandwheelmaythenbe
tingsnugly,andthe thumbscrewincollar
maythenbe removedandotherspringstested
eeluntilstopcollarcomesup againstbody
edureisthenfollowedinbreakingfrictionand
chintakeandexhaustvalvespringshould
compressed,with50to56poundspressure.
asure1%inchwhencompressedwith26^
g doesnotmeetstandards,itshouldbe re-
ength ofexhaustandintakevalvespring
s.Freelengthofstartingvalvespring should
ever,afteritisout,spring may"set"andbe
ssible,providingspringmeetscompression
takeandexhaustvalvespringshavebeen
typemeasures3V16inches,freelength, and
dswhencompressedto2l/2inches.
prings.
respectiveguideandcheckforexcessive
atvalveguidesshouldbe replaced,providing
dition.
ringfrommovementinguidesand re-
ceofvalveforpitting.Alsoexaminevalve
headforpitting.
n, inchuckofvalverefacinggrinder
rue,otherwiseit iswarpedandshouldbe
RHAUL,
stable,tee
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D-18)ENGINE
LINDERHEAD.Followprocedureoutlined
LLPARTS.Followprocedureoutlinedin
(fig.77).Seeparagraph80b (7).
VEGUIDES(figs.79and80).
eVa/veGuideintoCylinderHead
nedinparagraph80,disclosesneedfor
ouldbepressedinto topofcylinderhead.
chamferedendout.Placebrassdriftof
hanguideoverguideand pressguideinto
veguidesshouldbe pressedintocylinder
topof guidetotopofcylinderhead meas-
veguidesshouldbe pressedbelowthesurface
mtop endofguidetotop surfaceof
16inch.
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DISASSEMBLY,REPAIRAND
EMBLIES
ES(fig.81).
WRENCH,adjustable,tee
dle
or replacementservicearefurnished
alveguide hasbeeninstalledinthe head,it
meterinsidethe valveguidehasbeen
ereit setsinthecylinderhead.Usea reamer
starttakingacutwhenit isrunthrougha
GVALVERAPD12906
itionofStartingValve
en installedintheengine.Insertthe reamer
Recommended