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CHAPTER 1 INTRODUCTION - TM-10-4320-344-24_15
1.8 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).
1.14.2 Location and Description of Components.
Table 1-2. Description of Major Components, Model 609-A.
Figure 1-2. Location of Major Components, Model 609-C.
Table 1-3. Description of Major Components, Model 609-C.
Figure 1-3. Location of Major Components, Model US636HCCD-1
Table 1-4. Description of Major Components, Model US636HCCD-1.
1.15.2 Engine.
Figure 1-5. Fuel System Functional Block Diagram
1.15.6 Sound Enclosure.
CHAPTER 2 UNIT MAINTENANCE
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
Figure 2-1. Pumping Assembly with Protective Plywood Cap.
2.4.4 Processing Unpacked Equipment
2.5 INSTALLATION INSTRUCTIONS
2.9 PMCS PROCEDURES
Figure 2-2. PumpingAssembly Model 609-A PMCS Routing Diagram (Sheet 1 of 4).
Figure 2-2. Pumping Assembly Model 609-A PMCS Routing Diagram (sheet 2 of 4).
Figure 2-2. Pumping Assembly Model 609-A PMCS Routing Diagram (Sheet 3 of 4).
Figure 2-2. Pumping Assembly Model 609-A PMCS Routing Diagram (Sheet 4 of 4)
Preventive Maintenance Checks and Services for Pumping Assembly Model 609-A. (Continued) - TM-10-4320-344-24_37
Preventive Maintenance Checks and Services Item No. 9 10 11 12 13 14 15 Interval Semi- annually Semi- annually Semi - annually Semi- annually Semi - annually Semi- annually Semi- annually for Pumping Assembly Model 609-A. (Continued)
Preventive Maintenance Checks and Services for Pumping Assembly Model 609-A. (Continued) - TM-10-4320-344-24_39
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 1 of 5).
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 2 of 5).
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 3 of 5).
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 4 of 5).
Figure 2-3. Pumping Assembly Model 609-C PMCS Routing Diagram (Sheet 5 of 5).
Table 2-2. Preventive Maintenance Checks and Services for Pumping Assembly Model 609-C.
Preventive Maintenance Checks end Services Item No. 7 8 9 10 11 12 Interval Quarterly Semi - annually Semi- annually Semi- annually Semi- annually Semi - annually for Pumping Assembly Model 609-C. (Continued)
Preventive Maintenance Checks and Services for Pumping Assembly Model 609-C. (Continued)
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram (Sheet 1 of 4).
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram (Sheet 2 of 4).
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram (Sheet 3 of 4)
Figure 2-4. Pumping Assembly Model US636HCCD-1 PMCS Routing Diagram (Sheet 4 of 4).
Table 2-3. Preventive Maintenance Checks and Services for Pumping Assembly Model US636HCCD-1
Preventive Maintenance Checks and Services for Pumping Assembly Model US636HCCD-1. (Continued) - TM-10-4320-344-24_53
Preventive Maintenance Checks and Services for pumping Assembly Model US636HCCD-1. (Continued) - TM-10-4320-344-24_54
SECTION IV. TROUBLESHOOTING
Table 2-4. Unit Troubleshooting Table. (Continued)
1. ENGINE MILL NOT CRANK. (Continued)
3. ENGINE STOPS SUDDENLY
3. ENGINE STOPS SUDDENLY. (Continued)
Table 2-4. Unit Troubleshooting Table. (Continued)
6. ENGINE SMOKES
9. ENGINE OVERHEATS. (Models 609-C and US636HCCD-1)
SECTION V. UNIT MAINTENANCE PROCEDURES - TM-10-4320-344-24_63
Figure 2-5. Data Plate Replacement. (Model 609-C Shown)
2.11.2 Stud and Thread Repair.
2.11.2.2 Removing Studs or Screws That Have Not Broken Flush.
2.11.2.5 Oversizing Insert Pilot Holes
Stud and Thread Repair. (Continued)
Figure 2-9. Preparing Threaded Insert for Installation.
Figure 2-10. Installing Threaded Insert.
2.12 SOUND ENCLOSURE ASSEMBLY MAINTENANCE, MODEL 609-C
Figure 2-11. Door Holder Assembly Replacement
2.12.2 Access Cover Assembly Maintenance, Model 609-C.
2.12.2.2 Inspection.
2.12.3 Door Assembly Maintenance. Model 609-C
2.12.3.2 Inspection
2.12.4 Top Panel Assembly Maintenance. Model 609-C.
Figure 2-14. Top Panel Assembly Maintenance. (Sheet 2 of 2)
2.12.4.2 Disassembly.
2.12.4.3 Inspection.
2.12.5 Bulk Head Panel Assembly and Outlet Scoop) Assembly Maintenance, Model 609-C
Figure 2-16. Bulk Head Panel Assembly and Outlet Scoop Assembly Maintenance
2.12.5.3 Inspection.
2.12.6 Right Side Panel Assembly Maintenance. Model 609-C.
2.12.6.2 Inspection.
2.12.7 Control Panel Housing Assembly Maintenance, Model 609-C.
2.12.7.2 Installation.
2.12.8 Left Side Panel Assembly Maintenance, Model 609-C.
Figure 2-19. Left Side Panel Assembly
2.12.9 Left Rear Quarter Panel Assembly Maintenance, Model 609-C.
2.12.9.2 Inspection.
2.12.10 Upper Cover Plate Maintenance. Model 609-C.
2.12.10.2 Inspection.
2.12.11 End Panel Assembly Maintenance, Model 609-C
2.12.11.2 Inspection.
2.12.12 Strap Replacement, Model 609-C.
2.12.13 Baffle Maintenance. Model 609-C.
Figure 2-24. Sound Enclosure Baffles.
2.12.14 Cooling Duct Assembly and Outlet Duct Frame Assembly Maintenance, Model 609-C.
Figure 2-25. Cooling Duct Assembly and Screen Assembly Maintenance.
2.12.14.4 Installation.
2.12.15 Bulkhead Panel Assembly and Belt Guard Maintenance, Model 609-C
Figure 2-26. Bulkhead Panel Assembly and Belt Guards Maintenance.
Bulkhead Panel Assembly and Belt Guard Maintenance, Model 609-C. (Continued)
2.12.16 Support Frame Assembly Maintenance, Model 609-C.
Figure 2-27. Support Frame Assembly Maintenance.
2.13 EXHAUST SYSTEM MAINTENANCE.
2.13.1 Muffler Maintenance, Model 609-A. (Continued)
2.13.2 Muffler Maintenance, Model 609-C.
Figure 2-29. Muffler Maintenance, Model 609-c
2.13.2.6 Installation
2.13.3 Muffler Maintenance. Model US636HCCD-1.
Figure 2-30. Muffler Maintenance, Model US636HCCD-1
Muffler Maintenance. Model US636HCCD-1. (Continued)
2.13.4 Exhaust Pipe Assembly Maintenance, Models 609-C and US636HCCD-1.
Figure 2-31. Exhaust Pipe Assembly Maintenance. (Model US636HCCD-1 Shown)
2.14 AIR INTAKE SYSTEM MAINTENANCE
Figure 2-32. Air Cleaner Assembly Maintenance, Model 609-A
2.14.1.4 Service.
Air Cleaner Assembly Maintenance. Model 609-A. (Continued)
2.14.2 Air Cleaner Assembly Maintenance. Model 609-C.
Figure 2-33. Air Cleaner Assembly Maintenance, Model 609-C.
2.14.2.3 Inspection
2.14.2.7 Installation.
2.14.3 Air Cleaner Assembly Maintenance, Model US636HCCD-1.
Figure 2-34. Air Cleaner Maintenance, Model US636HCCD-1.
2.14.3.5 Repair
2.14.4 Air Intake Assembly Maintenance, Model 609-C
Figure 2-35. Air Intake Hose Maintanence, Model 609-C
2.14.5 Air Intake Pipe Assembly Maintenance, Model US636HCCD-1.
Figure 2-36. Air Intake Pipe Assembly Maintenance.
2.15 ELECTRICAL SYSTEM MAINTENANCE.
2.15.1.2 Repair.
2.15.2 Battery Box and Cover Maintenance, Model 609-A.
Figure 2-38. Battery Box and Cover Maintanance, Model 609-A
2.15.2.2 Installation.
2.15.3 Battery Box Assembly Maintenance, Model 609-C.
Figure 2-39. Battery Box Assembly Maintenance, Model 609-C.
2.15.3.2 Installation
2.15.4 Battery Box and Cover Maintenance. Model US63611HCCD-1.
Figure 2-40. Battery Box and Cover Maintenance, Model US636HCCD-1.
2.15.4.2 Installation.
2.15.5 Battery Cable Asssembly Maintenance, Models 609-A and US636HCCD-1
Figure 2-41. Battery Cable Assembly Maintenance, Model 609-A
The step applies to Model 609-A only
2.15.6 Battery Cable Assembly and Power Cable Assembly Maintenance, Model 609-C.
Figure 2-42. Battery Cable Assembly and Power Assembly Maintenance, Model 609-C (Sheet 2 of 2)
2.15.6.2 Testing
2.15.7 Electrical Connector Receptacle Maintenance, Model 609-C.
Figure 2-43. Electrical Connector Receptacle Maintenance
c . Install electrical connector receptacle
2.15.8 Power Control Cable Assembly Maintenance, Model 609-A.
Figure 2-44. Power Control Cable and Manual Throttle Control Cable Assembly
Figure 2-45. Manual Throttle Control Cable and Power Control Cable Assembly Adjustment
Figure 2-47. Power Control Cable Assembly Installation.
2.15.8.3 Adjustment
2.15.9 Limit Switch Assembly Maintenance. Model 509-A.
Figure 2-48. Limit Switch Assembly Maintenance.
2.15.9.3 Installation.
2.15.10 Start Alarm Relay and Start Pilot Relay Maintenance, Models 609-A and 609-C
Figure 2-49. Start alarm Relay Maintenance, Model 609-A.
2.15.10.2 Installation
2.16 CONTROL PANEL ASSEMBLY MAINTENANCE.
2.16.1.2 Disassembly.
Figure 2-51. Control Panel Cover Assembly, Model 609-A.
2.16.2 Control Panel Cover Assembly Maintenance, Model US636HCCD-1.
Figure 2-52. Control Panel Cover Assembly Removal, Model US636HCCD-1
2.16.3 Control Panel Assembly Removal and Installation. Model 609-A.
Figure 2-53. Control Panel Assembly Disconnection, Model 609-A (Sheet 1 of 2).
Figure 2-53. Control Panel Assembly Disconnection, Model 609-A (Sheet 2 of 2)
Figure 2-54. Control Panel Assembly Removal and Installation, Model 609-A.
2.16.3.2 Installation
p. Install manual throttle cable
2.16.4 Control Panel Assembly Removal and Installation, Model 609-C. - TM-10-4320-344-24_174
Figure 2-55. Control Panel Assembly Removal and Installation, Model 609-C.
2.16.4 Control Panel Assembly Removal and Installation, Model 609-C. - TM-10-4320-344-24_176
2.16.5 Control Panel Assembly Removal and Installation. Model US636HCCD-1.
Figure 2-56. Control Panel Assembly, Model US636HCCD-1
2.16.5.2 Installation.
2.16.6 Control Panel Assembly Hiring Maintenance, Models 609-C and US636HCCD-1.
2.16.7 Pump Suction and Discharge Gauge Assemblies Maintenance, Models 609-A and 609-C.
Figure 2-58. 2.16.7.3 Installation. Pump Suction and Discharge Gauge Maintenance, Model 609-A
2.16.8 Pump Suction and Discharge Gauge Maintenance, Model US636HCCD-1.
Figure 2-59. Pump Suction and Discharge Gauge Maintenance, Model US636HCCD-3.
2.16.8.3 Installation.
2.16.9 Low Oil Pressure Cutoff Switch Test. Model US636HCCD-1.
Figure 2-60. Low Oil Pressure Cutoff Switch Test
2.16.10 Oil Pressure Gauge and Hose Assembly Maintenance, Models 609-A and US636HCCD-1.
Figure 2-61. 0il Pressure Gauge Maintenance, Model US636HCCD-1.
2.16.11 Engine Coolant Temperature Gauge Assembly Maintenance. Model 609-A.
Figure 2-62. Engine Coolant Temperature Gauge Replacement.
2.16.11.2 Repair
2.16.12 Meter Assembly Maintenance.
Figure 2-63. Oil Pressure. Gauge Maintenance, Model 609-c
2.16.13 Tachometer/HoumeterAssemblyMaintenance. Models 609-A and US636HCCD-1
Figure 2-64. Tachometer/Hourmeter Assembly Replacement
2.16.14 Indicator Maintenance, Models 609-C and US636HCCD-l.
Figure 2-65. Indicator Maintenance.
2.16.15 Engine Alarm Assembly Replacement, Model 609-A
Figure 2-66. Engine Alarm Replacement.
2.16.16 Horn Replacement, Model US636HCCD-1.
Figure 2-67. Horn Replacement.
2.16.17 Engine Alarm Reset Assembly Replacement, Model 609-A.
Figure 2-68. Engine Alarm Reset Replacement.
2.16.18 Toggle Switch Maintenance.
Figure 2-69. Toggle Switch Maintenance.
2.16.19 Start Switch Maintenance, Model US636HCCD-1.
Figure 2-70. Start Switch Maintenance.
2.16.20 Start/Stop Switch Maintenance, Model US636HCCD-1.
Figure 2-71. Start/Stop Switch Maintenance
2.16.21 Fuse Holder Replacement, Model US636HCCD-1.
2.16.21.2 Installation.
2.16.22 Rheostat Replacement, Models 609-C and US636HCCD-1.
Figure 2-73. Rheostat Maintenance
2.16.23 Resistor Replacement, Model 609-C.
Figure 2-74. Resistor Replacement, Model 609-C.
2.16.24 Control Panel Lights Maintenance. Model 609-C.
Figure 2-75. Control Panel Light Maintenance.
2.16.25 Manual Throttle Control Cable Replacement, Model 609-A.
Figure 2-76. Manual Throttle Control Cable Replacement
b . Secure manual throttle control cable
2.16.26 Manual Throttle Control Cable Maintenance, Model 609-C.
Figure 2-77. Manual Throttle Control Cable Assembly Replacement, Model 609-C.
2.16.27 Fuel Rack Cable Replacement, Model 609-A.
Figure 2-78. Fuel Rack Cable Replacement.
2.16.27.2 Installation
2.16.28 Auto Defeat Cable Maintenance, Model 609-C.
Figure 2-79. Auto Defeat Cable Maintenance.
2.16.29 Cold Start Aid Cable Replacement, Model 609-C.
Figure 2-80. Cold Start Aid Cable Replacement.
2.16.30 Pressure Regulator Maintenance, Model 609-A.
Figure 2-81. Pressure Regulator Replacement, Model 609-A.
2.16.30.2 Repair.
2.16.33 Control Module Maintenance. Models 609-C and US636HCCD-1.
Figure 2-82. Pressure Control Module Replacement.
Figure 2-83. Location of Engine Protection System Module.
Figure 2-84. Location of Controlling Device, Model US636HCCD-1.
2.16.32 Governor Control Module Maintenance, Model 609-C
Figure 2-85. Governor Control Module Maintenance.
Figure 2-86. Governor Control Module Cover Removal.
Figure 2-87. Governor Control Module Adjustment With Cover Removed
Governor Control Module Maintenance, Unit 609-C. (Continued)
2.16.33 Process Control Device Maintenance, Unit US636HCCD-1.
Figure 2-89. Process Control Device.
2.16.33.4 Installation.
2.16.34 Terminal Board Replacement, Model US636HCCD-1.
2.16.34.3 Installation.
2.16.35 Pressure Gauge Hose Assembly Maintenance.
Figure 2-91. Pressure Gauge Hose Assembly Diagram, Model 609-A.
Figure 2-92. Pressure Gauge Hose Assembly Diagram, Model 609-C.
Figure 2-93. Pressure Gauge Hose Assembly Diagram, Model US636HCCD-1.
2.16.36 Control Panel Maintenance, Model 609-A.
2.16.36.2 Repair.
2.16.37 Control Panel Maintenance, Model US636HCCD-1.
Figure 2-95. Control Panel Maintenance, Model US636HCCD-1.
2.16.38 Control Panel Frame Maintenance, Model 609-A.
2.16.39 Control Enclosure Assembly Maintenance, Model 609-C.
Figure 2-97. Control Enclosure Assembly.
2.16.40 Base Weldment Maintenance, Model US636HCCD-1.
2.17 ENGINE WIRING HARNESS MAINTENANCE.
2.17.1.4 Repair.
2.18 PUMPING ASSEMBLY MAINTENANCE.
Figure 2-99. Drain Plug and Primer Port Nipple Maintenance.
2.18.2 Suction Elbow and Discharge Elbows Replacement.
2.18.2.2 Installation.
2.19 HOOD, REAR PANEL, AND SHIELD ASSEMBLY MAINTENANCE.
Figure 2-101. Hood Assembly Maintenance, Model 609-A.
2.19.2 Rear Panel Assembly Maintenance. Model 609-A
2.19.2.2 Repair.
2.19.3 Shield Assembly Maintenance, Model 609-A.
2.19.3.2 Repair.
2.20 RADIATOR ASSEMBLY MAINTENANCE.
Figure 2-104. Radiator Shall Assembly Removal, Model 609-A.
Figure 2-105. Radiator Shell Assembly
2.20.2 Cooling System Hoses Maintenance, Model 609-A
Figure 2-106. Cooling System Hoses Maintenance, Model 609-A.
2.20.3 Radiator Service. Model 609-A
2.20.3.2 Flushing Radiator
Antifreeze
2.20.4 Radiator and Fan Shroud Replacement, Model 609-A.
2.20.4.2 Repair.
2.20.5 Radiator Support Brackets Repair, Model 609-A.
2.20.5.2 Repair.
2.21 ENGINE ASSEMBLY MAINTENANCE
Figure 2-110. Fuel System Bleeding (Models 609-C and US636HCCD-1 Shown).
2.21.1.2 Bleeding Fuel Injection Lines
2.21.2 Fuel and Oil Lines. Hoses. and Fittings Maintenance.
Figure 2-111. Fuel Lines, Oil Lines, and Fittings, Model 609-A.
Figure 2-112. Fuel Line and Fittings, Model 609-C.
Figure 2-113. Fuel Lines, Oil Lines, and Fittings, Model US636HCCD-1
2.21.2.3 Assembly.
2.21.3 Fuel Solenoid Replacement, Model 609-C
2.21.3.2 Installation.
2.21.4 Fuel Filter and Base Assembly Maintenance. Model 609-A.
Figure 2-115. Fuel Filter and Base Assembly Maintenance, Model 609-A.
2.21.4.4 Installation.
2.21.5 Fuel Filter and Base Assembly Maintenance, Models 609-C and US636HCCD-1.
Figure 2-116. Fuel Filter and Base Assembly Maintenance, Models 609-C and US636HCCD-1.
2.21.5.3 Repair.
2.21.6 Fuel Transfer Pump Assembly Maintenance.
2.21.6.2 Test.
2.21.6.3 Removal.
2.21.7 Fuel Injection Lines and Fuel Leakoff Manifold Assembly Maintenance.
Figure 2-120. d. Inspect all e . Replace all Fuel Injection Lines and Fuel Leakoff Manifold Line Connections.
2.21.8 Fuel Injection Nozzle and Holder Assembly Maintenance. Model 609-A
2.21.8.2 Test.
2.21.9 Fuel Injection Nozzle Maintenance. Models 609-C and US636HCCD-I
Figure 2-122. Fuel Injection Nozzle Removel, Model 609-C and US636HCCD-1.
2.21.9.3 Installation.
2.21.10 Cold Starting Aid Maintenance. Model 609-C.
Figure 2-124. Cold Starting Aid Maintenance, Model 609-C.
2.21.10.3 Installation.
2.21.11 V-Belt Guard and Mounting Supports Maintenance, Model US636HCCD-1.
Figure 2-125. V-Belt Guard Maintenance, Model US636HCCD-1.
h. Position V-belt guard
2.21.12 V-Belt Replacement, Models 609-C and US636HCCD-1
2.21.12.2 Installation.
2.21.13 Alternator Belt Maintenance.
2.21.13.2 Removal.
2.21.14 Alternator Cover Maintenance, Model US636HCCD-1.
2.21.14.5 Installation.
2.21.15 Generator Capacitor Replacement, Model 609-C.
Figure 2-129. Generator Capacitor Replacement, Model 609-C.
2.21.16 Alternator Maintenance.
2.21.16.2 Removal.
2.21.16.4 Installation.
2.21.17 Starter Rectifier Replacement, Models 609-A and 609-C.
Figure 2-132. Starter Rectifier Replacement, Models 609-A and 609-C.
2.21.18 Starter Assembly Replacement.
2.21.18 Starter Assembly Replacement. (Continued)
2.21.19 V-Belt Contact Switch Maintenance, Models 609-C and US636HCCD-1.
Figure 2-134. V-Belt Contact Switch Maintenance.
c . Secure wiring harness
2.21.20 Engine Switch and Transmitter Replacement, Model 609-C.
2.21.20.2 Installation.
2.21.21 Exhaust Pipe Elbow Assembly Maintenance, Model 609-A.
2.21.21.2 Repair.
2.21.22 Air Intake Pipe Assembly Maintenance. Model 609-A.
2.21.22.2 Repair.
2.21.23 Oil Inlet Tube Assembly Replacesment
Figure 2-138. Oil Inlet Tube Assembly Raplacement.
2.21.24 Oil Drain Tube Assembly Maintenance.
Figure 2-139. Oil Drain Tube Assembly Replacemmt.
2.21.25 0i1 Bypass Line Rpair, Model US636HCCD-1.
Figure 2-140. Oi1 Bypass Line Replacement, Model US636HCCD-1.
2.21.26 Oil Filter and Base Assembly Replacement. Mel 609-A.
2.21.26.2 Repair.
2.21.27 Oil Filter and Base Assembly Replacement, Models 609-C and US636HCCD-1.
Figure 2-142. Oil Filter and Base Assembly Replacement, Models 609-C and US636HCCD-1.
2.21.27.3 Installation.
2.21.28 Oil Cooler Replacement, Model 609-A.
2.21.28.2 Repair
2.21.29 Oil Cooler Replacement, Model 609-C.
Figure 2-144. Oil Cooler Replacement, Model 609-C.
2.21.30 Oil Cooler Replacement, Model US636HCCD-1.
Figure 2-145. Oil Cooler Replacement, Model US636HCCD-1.
2.21.31 Oil Breather Assembly Replacement, Models 609-C and US636HCCD-1.
2.21.31.1 Removal.
2.21.32 Oil Drain Assembly Replacement.
Figure 2-147. 0il Drain Assembly Replacement.
2.21.33 Turbocharger Assembly Replacement, Model 609-A.
2.21.33.2 Repair.
2.21.34 Turbocharger Assembly and Air Shield Maintenance. Models 609-C and US636HCCD-1.
Figure 2-149. Turbocharger Assembly and Air Shield Replacement, Models 609-C and US636HCCD-1.
b . Insert turbocharger assembly
2.21.35 Air Outlet Frame Maintenance. Model 509-C
Figure 2-150. Air Outlet Frame Replacement, Model 609-C.
2.21.36 Exhaust and Intake Manifold Maintenance, Model 609-A.
Figure 2-151. Manifold Maintenance (Exhaust Manifold Shown).
2.21.37 Exhaust Manifold Pipes Maintenance, Models 609-C and US636HCCD-1.
2.21.37.2 Disassembly.
2.21.38 Intake Manifold Maintenance. Models 609-C and US636HCCD-1.
2.21.38.2 Disassembly.
2.21.39 Cooling Air Blower Replacement, Models 609-C and US636HCCD-1.
2.21.39.2 Installation.
2.21.40 Cowling Assembly Maintenance, Models 609-C and US636HCCD-1.
Figure 2-155. Cowling Assembly Maintenance, Models 609-C and US636HCCD-1.
2.21.40.3 Assembly.
2.21.41 Thermostat Maintenance. Model 609-A.
2.21.41.2 Repair.
2.21.42 Fan Replacement, Model 609-A.
2.21.43 Water Pump Assembly Maintenance, Model 609-A.
2.21.43.2 Installation.
2.21.44 Tachometer Cable Replacement, Models 609-A and US636HCCD-1.
2.21.44.2 Installation.
2.21.45 Tachometer Angle Drive Maintenance, Models 609-A and US636HCCD-1.
2.21.45.2 Repair.
2.21.46 Breather Cap Maintenance, Model 609-A.
2.21.46.3 Repair.
2.21.47 Cylinder Head Cover Maintenance. Model 609-A
2.21.47.2 Repair.
2.21.48 Cylinder Head Cover Maintenance. Models 609-C and US636HCCCD-1.
2.21.48.2 Repair.
2.21.49 Rocker Arm (Valve) Adjustment, Model 609-A.
2.21.49.2 Warm Engine Valve Adjustment.
2.21.50 Rocker Arm (Valve) Adjustment, Models 609-C and US636HCCD-1.
b. Adjust intake
2.22 FUEL TANK ASSEMBLY MAINTENANCE.
2.22.1.2 Repair.
2.22.2 Fuel Tank Maintenance.
Figure 2-167. Fuel Tank Maintenance.
Fuel Tank Maintenance. (Continued)
2.23 WHEEL MOUNTED FRAME ASSEMBLY MAINTENANCE
2.23.1.2 Installation.
2.23.2 Hub and Wheel Bearing Maintenance.
2.23.2.2 Repair.
2.23.3 Tongue Jack and Tripod Assembly Maintenance.
Figure 2-170. Front Tripod Assembly Manintenance.
2.23.3.4 Assembly.
2.23.4 Rear Jack Assembly Maintenance
2.23.4.2 Installation.
2.23.5 Brake System Servicing.
Periodically check fluid level
2.23.6 Master Cylinder and Brake Line Maintenance.
Figure 2-173. Master Cylinder and Brake Line Maintenamce.
2.23.6.2 Repair
2.23.7 Brake Actuator Maintenance. Models 609-A and 609-C.
Figure 2-174. Brake Actuator Maintenance, Models 609-A and 609-C
2.23.7.4 Assembly.
2.23.8 Brake Actuator Maintenance. Model US636tlCC0-1.
2.23.8.3 Repair.
2.23.8.4 Assembly.
2.23.9 Wheel Cylinder and Brake Shoes Replacement.
Figure 2-176. Wheel Cylinder end Brake Shoe Maintenance (Model 609-A Shown)
2.23.9.3 Assembly.
2.23.10 Handbrake Assembly Maintenance. - TM-10-4320-344-24_426
2.23.10.3 Assembly.
2.23.10 Handbrake Assembly Maintenance. - TM-10-4320-344-24_428
2.23.11 Intervehicular Cable Maintenance.
2.23.11.2 Repair.
2.23.12 Trailer Wiring Harness Maintenance
Figure 2-180. Trailer Wiring Harness Maintenance
2.23.12.3 Installation.
2.23.13 Lights Miantenance.
Figure 2-182. Lights Maintenance.
Lights Maintenance. (Continued)
2.23.14 Reflector Replacement.
2.23.14.1 Removal.
2.23.15 Shock Absorber Maintenance, Models 609-A and 609-C.
2.23.15.2 Repair.
2.23.16 Axle Maintenance.
2.23.16.4 Assembly
2.23.17 Forklift Pocket Maintenance. Model 609-C
2.23.17.2 Repair.
SECTION VI. PREPARATION FOR SHIPMENT AND STORAGE - TM-10-4320-344-24_445
Figure 2-188. Securing Air Cleaner and Exhaust Muffler on Model 609-A
Figure 2-189. Install Protective Plywood Cap on Model 609-A
Components/Materials
Figure 2-191. Securing Air Cleaner and Exhaust Muffler on Model US636HCCD-1.
Figure 2-192. Install Protective Plywood Cap on Model US636HCCD-1.
CHAPTER 3 DIRECT SUPPORT MAINTENANCE
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-10-4320-344-24_452
Table 3-1. Direct Support Troubleshooting Table
5. IMPROPER GOVERNOR SYSTEM OPERATION. (Model 609-C)
6. IMPROPER GOVERNOR OPERATION. (Model US636HCCD-1)
7. NO OR LOW SUCTION OR DISCHARGE PRESSURE. (Continued) - TM-10-4320-344-24_456
7. NO OR LOW SUCTION OR DISCHARGE PRESSURE. (Continued) - TM-10-4320-344-24_457
SECTION III. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-10-4320-344-24_458
3.6 PIMPING ASSEMBLY MAINTENANCE.
Figure 3-1. Pump Assembly Replacement.
Figure 3-2. S-Bolt Removal From Flywheel.
Pump Assembly Replacement. (Continued)
3.6.2 Intermediate Bracket Assembly Replacement.
Figure 3-3. Intermediate Bracket Assembly Replacement.
3.6.3 Pump Casing Assembly Repair, Models 609-A and 609-C.
Figure 3-4. Pump Assembly Repair, Models 609-A and 609-c
3.6.4 Pump Casing Assembly Repair, Model US636HCCD-1.
3.6.4.2 Repair.
3.6.5 Flexible Coupling Assembly Repair, Model 609-A.
3.6.5.2 Repair.
3.6.6 Flexible Coupling Repair, Models 609-C and US636HCCD-1.
3.6.6 Flexible Coupling Repair. Models 609-C and US636HCCD-1
3.6.7 Impeller Maintenance
3.6.7.2 Repair.
Figure 3-9. Impeller and Seal Assembly Removal, Models 609-A and 609-C.
Impeller Maintenance. (Continued)
Figure 3-10. Centering Impeller, Models 609-A and 609-c.
3.6.8 Impeller Shaft and Bearings Maintenance, Models 609-A and 609-C.
Figure 3-11. Rotating Assembly Maintenance, Mosels 609-A and 609-c.
3.6.8.2 Repair.
3.6.9 Impeller Shaft and Bearings Maintenance. Model US636HCCD-1.
3.6.9.2 Repair
3.6.10 Pump Mount Isolators Replacement, Model 609-C
3.6.11 Pump Support Maintenance, Model US636HCCD-1.
3.6.11.3 Installation.
3.7 RADIATOR ASSEMBLY MAINTENANCE
3.8 ENGINE ASSEMBLY MAINTENANCE.
3.8.1 Engine Replacement. (Continued)
For Model 609-C
3.8.1.2 Installation
3.8.2 Front Engine Support Replacement. Model 609-A.
3.8.3 Engine Support Replacement, Models 609-C and US636HCCD-1
Figure 3-17. Engine Supports Replacement, Models 609-c and US636HCCD-1
3.8.4 Engine Mount Isolators Replacement, Model 609-C.
3.8.5 Magnetic Pickup Replacement.
3.8.5.2 Installation.
3.8.6 Governor Maintenance, Model 609-A.
Figure 3-20. Governor, Model 609-A.
3.8.6.4 Calibration and Adjustment.
Governor Maintenance. Model 609-A. (Continued)
Changing the adjustments
3.8.7 Governor Actuator Assembly Maintenance, Model 609-C.
Figure 3-22. Governor Actuator Assembly, Model 609-C
3.8.7.3 Installation.
3.8.8 Governor Maintenance. Model US636HCCD-1.
3.8.8.2 Repair.
The GAIN= potentiometer
3.8.9 Fuel Injection Pump Assembly Maintenance, Model 609-A.
Figure 3-24. Fuel Injection Pump Assembly Removal, Model 609-A.
3.8.9.2 Repair
Do not rotate FIP drive shaft backwards
3.8.10 Fuel Injection Pump Assembly Test and Adjustment, Model 609-A.
Transfer pump
Fuel Injection Pump Assembly Test and Adjustment, Model 609-A. (Continued)
3.8.11 Fuel Injection Pump Assembly Maintenance, Models 609-C and US636HCCD-1.
Figure 3-25. Internal Leakage Test Setup.
3.8.11.2 Start-of-Delivery Test.
Figure 3-27. Pointer and Graduation Magnet Installation.
3.8.11.3 Adjustment.
Figure Removal. 3-28. Fuel Injection Pump Assembly Adjustment.
3.8.11.6 Installation.
3.8.12 0il Pan Assembly Maintenance.
Figure 3-30. 0il Pan Assembly Replacement.
3.8.12.3 Installation.
3.8.13 Suction Pipe Replacement, Models 609-C and US636HCCD-1.
3.8.13.2 Repair.
3.8.14 Oil Pump Assembly Maintenance. Model 609-A.
3.8.15 Oil Nozzle Replacement, Model US636HCCD-1.
3.8.15.2 Installation.
3.8.16 V-Belt Tensioner Maintenance. Models 609-C and US636HCCD-1.
Figure 3-34. V-Belt Tensioner Maintenance, Models 609-C and US636HCCD-1.
3.8.17 Rocker Ann Assembly Maintenance, Model 609-A.
Figure 3-35. Rocker Arm Assembly Removal, Model 609-A.
Figure 3-36. Rocker 3.8.17.3 Repair. Arm Disassembly, Model 609-A.
Table 3-2. Rocker Arm Shaft Dimensions, Model 609-A.
3.8.17.5 Installation.
Figure 3-38. Rocker Arm Assembly Bolt Tightening Pattern, Model 609-A.
3.8.18 Rocker Arm Assembly Maintenance, Models 609-C and US636HCCD-1.
3.8.18.2 Disassembly.
3.8.18.4 Assembly.
3.8.19 Cylinder Head Assembly Replacement, Model 609-A.
Figure 3-40. Cylinder Head Assembly Removal, Model 609-A.
Figure 3-41. Cylinder Head Assembly Bolt Tightening Pattern, Model 609-A.
3.8.20 Cylinder Head Assembly Replacement, Models 609-C and US636HCCD-1.
Figure 3-42. Cylinder Head Assembly Removal, Models 609-C and US636HCCD-1
3.8.20.2 Adjustment.
l. Slowly remove spring tensioning tool
3.8.21 Crankshaft Pulley and Vibration Damper Replacement, Model 609-A
d. Position vibration damper
3.8.22 Crankshaft Pulley and Vibration Damper Replacement. Models 609-C and US636HCCD-1.
Figure 3-44. Vibration Damper Crankshaft Pulley Maintenance, Models 609-C and US636HCCD-1 .
3.9 FUEL TANK MAINTENANCE.
3.10 WHEEL MOUNTED FRAME ASSEMBLY.
3.10.2 Wheel Mounted Frame Assembly Repair.
3.10.3 Brake Line Repair.
3.10.4 Safety Chains Maintenance.
3.10.4.2 Repair.
CHAPTER 4 GENERAL SUPPORT MAINTENANCE
SECTION I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT - TM-10-4320-344-24_560
SECTION II. GENERAL SUPPORT MAINTENANCE PROCEDURES
Figure 4-1. Cylinder Head Assembly Disassembly, Model 609-A.
Table 4-1. Valve Spring Data
4.4.1.3 Assembly
f . Pour solvent into intake manifold openings
4.4.2 Cylinder Head Assembly, Intake Valve, and Exhaust Valve Repair, Models 609-C and US636HCCD-l.
Figure 4-2. Cylinder Head c . Inspect valves (6 and 7) 4-4 and 4-5. For intake valves on Model values given in Table 4-4. Assembly Disassembly, Models 609-C and US636HCCD-1.
Table 4-4. Intake Valve Fits and Tolerances, Models 609-C and US636HCCD-1. (continued)
Figure 4-3. Chocking Cylinder Head Seating Surface, Models 609-C and US636HCCD-1
Figure 4-5. Valve Seat Drilling, Models 609-C and US636HCCD-1
j . Remove valve seat
4.4.2.3 Assembly.
4.4.3 Cylinder Maintenance. Models 609-C and US636HCCD-1
4.4.3.2 Repair.
4.4.3.3 Installation.
4.4.4 Gear Housing Cover Maintenance, Model 609-A
Figure 4-8. Gear Housing Cover Maintenance, Model 609-A.
4.4.4 Gear Housing Cover Maintenance, Model 609-A.
4.4.5 Crankcase Front Cover Maintenance. Models 609-C and US5636HCCD-1.
Figure 4-9. Crankcase Front c . Press shaft seal (16) from (16). d. Remove oil filler cap (17) Discard gasket (18). Cover Maintenance, Models 609-C and US636HCCD-1
4.4.5.3 Repair.
4.4.6 Idler Gear and Bearing Maintenance. Model 609-A.
4.4.6.2 Repair.
4.4.7 Oil Pump Assembly and Oil Pipe Maintenance. Models 609-C and US636HCCD-1,
4.4.7.4 Assembly.
4.4.8 Idler Gear Maintenance, Models 609-C and US636HCCD-1.
4.4.8.2 Repair.
4.4.9 Flywheel Maintenance, Model 609-A.
Figure 4-14. Flywheel Removal, Model 609-A
4.4.9.3 Installation.
4.4.10 Flywheel Maintenance, Models 609-C and US636HCCD-1.
4.4.10.3 Installation.
4.4.11 Bellhousing Maintenance. Model 609-A.
Figure 4-16. Bellhousing Maintenance.
4.4.11.3 Installation.
4.4.12 Flywheel Cover Maintenance, Models 609-C and US636HCCD-1.
4.4.12.2 Repair
4.4.13 Crankcase Rear Cover Maintenance, Models 609-C and US636HCCD-1.
4.4.13.2 Repair.
4.4.14 Piston and Connecting Rod Assembly Maintenance, Model 609-A.
Figure 4-19. Piston and Connecting Rod Assembly, Model 609-A
4.4.14 Piston and Connecting Rod Assembly Maintenance, Model 609-A. (Continued)
4.4.14.3 Repair.
able 4-7. Piston Dimensions, Model 609-A. (Continued)
4.4.14.4 Assembly.
4.4.14.5 Installation.
Figure 4-23. Boaring Clearance Measurement, Model 609-A.
4.4.15 Piston and Connecting Rod Assembly Maintenance, Models 609-C and US636HCCD-1.
Figure 4-25. Piston and Connecting Rod Assembly, Models 609-C and US636HCCD-1.
4.4.15.2 Repair.
Figure 4-27. Piston Pin Measuring Locations, Models 609-C and US636HCCD-1.
4.4.15.3 Installation.
4.4.16 Camshaft Maintenance, Model 609-A.
Figure 4-28. Camshaft Maintenance, Model 609-A.
4.4.16.2 Repair.
4.4.16.3 Installation.
Figure 4-30. Installed Camshaft Assembly, Model 609-A.
4.4.17 Camshaft Maintenance, Models 609-C and US636HCCD-1.
Figure 4-31. Camshaft Maintenance, Models 609-C and US636HCCD-1.
4.4.17.3 Installation
Carefully remove camshaft assembly
4.4.18 Gear Housing Maintenance, Model 609-A.
4.4.18.2 Repair.
4.4.19 Crankshaft Assembly Maintenance, Model 609-A.
4.4.19.2 Repair.
Table 4-13. Crankshaft Dimensions, Model 609-A.
Table 4-14. Torque Values.
Figure 4-35. Crankshaft End Thrust, Models 699-A.
4.4.20 Crankshaft Assembly Maintenance, Models 609-C and US636HCCD-1.
4.4.20.2 Repair.
Table 4-15. Crankshaft Dimensions, Models 609-C and US636HCCD-1.
4.4.20.3 Installation.
4.4.21 Engine Block Maintenance. Model 609-A.
Figure 4-38. Engine Block Repair, Model 609-A.
4.4.21.2 Repair. - TM-10-4320-344-24_635
Figure 4-39. Engine Block Stud Location, Model 609-A
4.4.21.3 Installation
4.4.22 Crankcase Maintenance, Models 609-C and US636HCCD-1.
4.4.21.2 Repair. - TM-10-4320-344-24_639
4.4.22.3 Installation.
c . Position deflector plate
APPENDIX A REFERENCES - TM-10-4320-344-24_643
A.5 MISCELLANEOUS PUBLICATIONS.
APPENDIX B MAINTENANCE ALLOCATION CHART (MAC) - TM-10-4320-344-24_645
B.3 EXPLANATION OF COLWNS IN TNE MAC
B.4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQIPMENT REQUIREMENTS
SECTION II. MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER)
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_649
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_650
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_651
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_652
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_653
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_654
MAINTENANCE ALLOCATION CHART FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER) (continued) - TM-10-4320-344-24_655
SECTION III . TOOL AND TEST EQUIPMENT REQUIREMENTS FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER)
SECTION IV. REMARKS FOR PUMPING ASSEMBLY, 600 GALLONS PER MINUTE, PUMP (WATER)
APPENDIX C EXPENDABLE AND DURABLE ITEMS LIST
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST
EXPENDABLE AND DURABLE ITEMS LIST (Continued)
A P P E N D I X D ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure D-1. Sound Enclosure Assembly Insulation Material, Model 609-C.
Figure D-2. Battery Cable Assembly, Model 609-A.
Figure D-3. Battery Cable Assembly, Model US636HCCD-1.
Figure D-4. Control Panel Wiring Harness Assembly, Model 609-c. - TM-10-4320-344-24_667
Figure D-4. Control Panel Wiring Harness Assembly, Model 609-c. - TM-10-4320-344-24_668
Table D-5. Control Panel Wire Run List, Model 609-C.
Control Panel Wire Run List, Model 609-C. (Continued) - TM-10-4320-344-24_670
Control Panel Wire Run List, Model 609-C. (Continued) - TM-10-4320-344-24_671
Figure D-5. Main Wiring Harness Assembly, Model 609-C.
Table D-6. Parts List for Main Wiring Harness, Model 609-C.
Table D-7. Main Wiring Harness Wire Run List, Model 609-C. - TM-10-4320-344-24_674
Main Wiring Harness Wire Run List, Model 609-C. (Continued)
Table D-7. Main Wiring Harness Wire Run List, Model 609-C. - TM-10-4320-344-24_676
Figure D-6. Control Panel Wiring Harness Assembly, Model US636HCCD-1
Table D-8. Parts List for Control Panel Wiring Harness Assembly, Model US636HCCD-1. - TM-10-4320-344-24_678
Table D-8. Parts List for Control Panel Wiring Harness Assembly, Model US636HCCD-1. - TM-10-4320-344-24_679
Table D-9. Control Panel Wire Run List, Model US636HCCD-1. (Continued)
Figure D-7. Main Wiring Harness Assembly, Model US636HCCD-1.
Table D-10. Parts List for Main Wiring Harness Assembly, Model US636HCCD-1.
Main Wiring Harness Run List, Model US636HCCD-1. (continued)
Figure D-8. Fuel, Oil, Suction, and Discharge Hose Assemblies, Models 609-C and US636HCCD-1.
Figure D-9. Brake Line Assemblies, Model 609-A.
Figure D-10. Chain.
APPENDIX E TORQUE LIMITS
APPENDIX F SCHEMATICS AND WIRING DIAGRAMS
Figure F-1. Schematic diagram Model 609-A.
Table F-1. Wire Run List, Model 609-A.
Figure F-2. Control Panel Schematic Diagram, Model 609 -C
Table F-2. Control Panel Wire Run List, Model 609-C.
Figure F-3. Main Wiring Harness Wiring Diagram, Model 609-C.
Table F-3. Main Wiring Harness Wire Run List, Model 609-C.
Figure F-4. Control Pared Schamatic Diagram, Model US636HCCD-1. (Sheet 1 of 2)
Figure F-4. Control Pared Schamatic Diagram, Model US636HCCD-1. (Sheet 2 of 2)
Table F-4. Control Panel Wire Run List, Model US636HCCD-1.
Figure F-5. Main Wiring Harness Wiring Diagram, Model US636HCCD-1
Table F-5. Main Wiring Harness Wire Run List, Model US636HCCD-1.
GLOSSARY SECTION I. ABBREVIATIONS - TM-10-4320-344-24_701
SECTION II. DEFINITION OF UNUSUAL TERMS - TM-10-4320-344-24_702
INDEX - TM-10-4320-344-24_703
INDEX (Continued) - TM-10-4320-344-24_704
INDEX (Continued) - TM-10-4320-344-24_705
INDEX (Continued) - TM-10-4320-344-24_706
INDEX (Continued) - TM-10-4320-344-24_707
INDEX (Continued) - TM-10-4320-344-24_708
INDEX (Continued) - TM-10-4320-344-24_709
INDEX (Continued) - TM-10-4320-344-24_710
INDEX (Continued) - TM-10-4320-344-24_711
INDEX (Continued) - TM-10-4320-344-24_712
INDEX (Continued) - TM-10-4320-344-24_713
INDEX (Continued) - TM-10-4320-344-24_714
INDEX (Continued) - TM-10-4320-344-24_715
INDEX (Continued) - TM-10-4320-344-24_716
INDEX (Continued) - TM-10-4320-344-24_717
INDEX (Continued) - TM-10-4320-344-24_718
INDEX (Continued) - TM-10-4320-344-24_719
INDEX (Continued) - TM-10-4320-344-24_720
INDEX (Continued) - TM-10-4320-344-24_721
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