Chapter 1 Public Works

• Duties and Responsibilities of Supervisory Personnel
• Maintenance and Repair Foreman
• Preventive Maintenance
• Records and Reports
• Preservation, Storage, and Depreservation of Vehicles and Equipment
• Techniques of Scheduling
• Figure 1-4.—Sample Format for Specification for Scheduled Maintenance Inspections and Services.
• Progress Control and Shop Workload
• Figure  1-6.—Order  for  Supplies  or  Services,  DD  Form  1155.
• Contract Maintenance and Repairs
• Figure 1-7.–Quality Deficiency Report, SF 368.
• Figure  1-8.—Report  of  Excess  Personal  Property,  SF  120.
• Technical Assistance

Chapter 2 ALFA Company Shops Supervisor

• Heat, Light, and Ventilations
• The Maintenance Supervisor
• Shop Inspectors
• Electrical  Shop
• Cost-Control Supervisor
• Batallion Maintenance Program
• Organizational Maintenance
• Figure 2-4.—Equipment Repair Order Log Sheet.
• Depot Maintenance
• Figure  2-7.—PM  Schedule.
• Figure 2-9.—Direct Turnover (DTO) Log.
• Equipment Repair Order and Continuation Sheet
• Repair Parts
• COSAL Support
• Figure  2-14.—Single-Line  Item  Release/Receipt  Document,  DD  Form  1348-1.
• Technical Library
• Wrong Parts!
• Batallion Equipment Evaluation Program (BEEP)
• Figure 2-17.—Equipment Evaluation Inspection Guide.
• Figure 2-18.—Equipment Evaluation Inspection Guide—Continued.
• Figure 2-19.—Attachment Evaluation Inspection Guide.
• COMCBPAC/COMCBLANT Responsibilities
• Embarkation
• Storage
• Defense Reulitilization and Marketing Office (DRMO)

Chapter 3 Engine Troubleshooting and Overhaul

• Brake Horsepower
• Graphs and Diagrams
• Timing Diagrams
• Figure  3-5.—Relationship  between  torque  and  horsepower.
• Two-Stroke-Cycle  Engine  Timing
• Figure 3-7.—Timing diagram of a two-stroke-cycle diesel engine.
• Figure 3-8.-Power strokes in one-, four-, six-, and eight-cylinder engines.
• Multiple-Cylinder Engines, Continued
• Engine Troubleshooting
• Engine Testing
• Vacuum Gauge Test
• Cylinder Leakage Test
• Tachometer
• Valves, Valve Mechanisms, and Cylinder Heads Servicing
• Valves in Block
• Valve Removal
• Valve Guide Servicing
• Figure 3-22.—Valve contact correction.
• Valve Seat Insert Replacement
• Valve Lifter Servicing
• Crankshaft Servicing
• Crankshaft Journal Check
• Crankshaft Installation
• Cylinder Servicing
• Cylinder Liners Replacement
• Piston and Rings Servicing
• Piston Pins Fitting
• Operational Testing

Chapter 4 Troubleshooting Electrical Systems

• Rectifiers
• Figure 44.-Typical wiring diagram (transistor regulator).
• Troubleshooting the Charging System with a Voltampere Tester
• Alternator Test
• Excessive Output Test
• Charging System Insulated Circuit Resistant Test
• Charging System Ground Circuit Resistance Test
• Troubleshooting the Alternator Using the Engine Analyzer Screen
• Charging Circuit Diodes
• Troubleshooting the System Using the Battery Starter Test
• Cranking Voltage Test
• Starter Insulated Circuit Resistance Test
• Starter Ground Circuit Resistance Test
• Solenoid Switch Circuit Resistance Test
• Transistor Ignition System
• Capacitor Discharge Ignition System
• Electronic Lean Burn System/Electronic Spark Control
• Unit Ignition System
• Computerized Ignition System
• Distributorless Ignition System
• Troubleshooting
• Transisitor Ignition System
• Table  4-1.-Troubleshooting  Chrysler  Electronic  Ignition
• Troubleshooting Lighitng Systems and Electrical Accessories
• Headlights
• Fuses and Circuit Breakers
• Directional Signals
• References

Chapter 5 Fuel System Overhaul

• Reassembly and Adjustment
• Gasoline Fuel Injection Systems
• Figure 5-1.-Mechanical-timed injection.
• Figure 5-2.-Electronic-timed injection.
• Continuous Fuel Injection Systems
• Servicing and Precautions
• Diesel Fuel Injection Systems
• Troubleshooting
• Compact  Fuel  System
• Figure  5-11.-Precombustion  chamber  and  fuel  injection  valve.
• Sleeve Metering Fuel System
• ROOSA Master Fuel Injection Pump
• Table 5-1.-Troubleshooting Chart for Roosa Master Fuel System
• Figure 5-16.-Gauge installed for checking transfer pump pressure.
• American Bosch Fuel Injection Pump
• Figure  5-19.-Metering  and  distributing  fuel  pump  assembly–left  sectional  view.
• Figure 5-21.-Fuel intake flow diagram.
• Troubleshooting
• Table  5-2.-Troubleshooting  Bosch  System
• Nozzle Operation
• Troubleshooting
• Valve Opening/Pressure Test
• High-Pressure Test
• Injector Disassembly, Cleaning and Inspecting, and  Reassembly
• Cummins Pressure Time Fuel Injection System
• Pump Cleaning and Inspection
• Pump  Reassembly
• Injector Maintenance and Testing
• Air Induction System
• Blower  Removal  and  Disassembly
• Superchargers
• Turbochargers
• Removal,  Disassembly,  and  Cleaning
• Cold Starting Devices
• Figure  5-40.-Typical  diesel  engine  glow  plug.
• Ether

Chapter 6 Inspecting and Troubleshooting Brake Systems

• Figure 6-3.-Using a drum micrometer to measure the drum.
• Brakes Drag
• Table 6-1.-Troubleshooting Chart for Hydraulic Brakes (Standard)
• Table  6-1.—Troubleshooting  Chart  for  Hydraulic  Brakes  (Standard)–Continued
• Table  6-1.—Troubleshooting  Chart  for  Hydraulic  Brakes  (Standard)–Continued
• Table  6-1.—Troubleshooting  Chart  for  Hydraulic  Brakes  (Standard)-–Continued
• Table  6-1.—Troubleshooting  Chart  for  Hydraulic  Brakes  (Standard)–Continued
• Car Pulls to One Side
• Troubleshooting Vacuum-Assisted Hydraulic Brakes (Power) Systems
• Table  6-2.—Troubleshootiug  Chart  for  Vacuum-Assisted  Hydraulic  Brakes  (Power)
• Hydroboost Troubleshooting
• Troubleshooting Air Brake Systems
• Figure 6-11.—Air reservoir with air drain cock.
• Table 6-3. Air Brake System Troubleshooting Chart
• Air-Over-Hydraulic
• Parking/Emergency Brakes
• Figure 6-14.—Automotive type emergency/parking brake axle mounted.
• Antilock Brakes
• References

Chapter 7 Clutches and Automatic Transmissions

• Figure 7-2.—Friction disk clutch with flexible center.
• Figure 7-4.—Clutch operation.
• Figure 7-7.—Hydraulic clutch operating system.
• Clutch Malfunctions
• Slipping
• Clutch Pedal Pulsation
• Table 7-1.—Clutch Assembly Troubleshooting Chart
• Turbo Hydra-matic Model 400
• Planetary  Gears
• Coupling ((Torque Converter Operation)
• Figure 7-15.—Torque converter, partial cutaway view.
• Figure 7-16.—Torque converter in fluid coupling stage.
• Hydraulic  System  Operation
• Figure 7-21.—Internal gear type of pump assembly.
• Preventive Maintenance
• Linkage and Band Adjustment
• Refilling  the  Transmission
• Transmission Overhaul
• Table 7-2.-Turbo Hydra-Matic Model 400 Troubleshooting List
• Table 7-2.—Turbo Hydra-Matic Model 400 Troublesbooting List–Contiued
• Figure 7-26.—Removing the control valve assembly.
• Figure 7-32.—Removing the pump assembly.
• Figure 7-37.—Removing the center support snap ring.
• References

Chapter 8 Air Compressor Overhaul

• Types of Air Compressors
• Reciprocating Compressor
• Screw Type of Compressor
• Components of Compressors
• Pressure Control System
• Air Intake System
• Figure 8-12.—Cleaning an air filter with low pressure air.
• The Air Receiver
• Intercoolers
• Lubrication System
• Figure  8-19.-Rotary  vane  air  compressor  lubrication  system.
• Table 8-1.-Air Compressor Troubleshooting Chart
• Air Compressor Troubleshooting
• Figure  8-20.-Removing  vanes  for  inspection  and  replacement.
• References

Chapter 9 The Shop Inspector

• The Public Works Shop Inspector
• Acceptance Inspections
• Figure 9-3.-DoD Property Record Card, DD Form 1342 (front).
• The Batallion Maintenance Shop Inspector
• Embarkation Inspections
• Preservation Inspections
• Deadline Inspections
• Figure  9-7.-Crane  condition  inspection  record.
• Figure  9-7.-Crane  condition  inspection  record–Continued.
• Final Inspections

Chapter 10 Hydraulic Systems

• Pascal's Law
• Components
• Rotary  Pumps
• Figure 10-4.-Lobe type of pump.
• Vane Pump
• Reciprocating  Pumps
• Variable Volume Piston Pump
• Hand Pumps
• Actuators
• Figure 10-13.-Example of piston type of cylinder.
• Motors
• Figure  10-15.-Typical  vane  type  of  hydraulic  motor.
• Valves
• Pressure Regulator Valves
• Selector  Valves
• Check Valves
• Reservoirs
• Accumulators  
• Application
• Filters
• Micronic Filter
• Filter Classifications
• Figure  10-31.-Full-flow,  porous  metal,  bypass  electrical-indicating  hydraulic  filter.
• Hydraulic Systems
• Types of Hydraulic Systems
• Hydrauoic System Troubleshooting and Maintenance
• Troubleshooting
• Maintenance
• Hydraulic System Contamination
• Control of Contamination
• Figure 10-37.—One example of a hydraulic liquid contamination test kit.
• Flushing the System
• References

Chapter 11 Troubleshooting Transmissions, Transfer Cases, and Differentials

• Troubleshooting Transmissions
• Table  11-1.—Troubleshooting  Transmissions  (5-ton  military)
• Inspecting the Transmission
• Figure 11-5.—Transmission gears and shafts-exploded view.
• Testing Transmission for Malfunctions
• Testing Transmission for Malfunctions, Continued
• Overhaul of the Transmission
• Troubleshooting Transfer Cases
• Figure 11-10.—Transfer case to the transmission.
• Table 11-2.—Transfer Case Troubleshooting Chart
• Figure 11-13.—Transfer shafts, bearing, and gears–exploded view–legend.
• Figure 11-14.—Front axle engagement air control diagram–legend.
• Troubleshotting the Power Takeoff
• Troubleshooting the Differential
• Figure 11-17.—Typical differential and axle assembly with ring and pinion.
• Figure 11-19.—No spin differential-exploded view.
• Axles, Wheels and Tracks
• Full-Floating  Axles
• Service and Maintenance
• References

Chapter 12 Wheel and Track Alignment

• Figure 12-2.—Caster angle.
• Figure  12-3.—Kingpin  inclination.
• Figure 12-6.—Difference of radii between inner and outer wheels.
• Adjusting Wheel Alignment
• Alignment Procedures
• Figure  12-11.—Mechanical  toe-measuring  gauge.
• Figure  12-14.—Ball  joint  wear  indication.
• Figure 12-16.—Various locations of caster-camber adjustment points.
• Caster/Camber Adjustments
• Toe-In and Steering Wheel Adjustment
• Nonadjustable Angles
• Track Alignment
• Track Roller Frame Alignment with Sprocket
• References

Chapter 13 Air-Conditioning Systems

• Figure 13-1.—The closed circuit refrigeration cycle.
• Figure 13-2.—Warming the refrigerant by using hot water.
• Refrigeration Cycle
• Components of the Air-Conditioning System
• Expansion  Valve
• The Evaporator
• Thermostatic  Switch
• Figure 13-9.—Suction throttling valve.
• The Compressor
• Figure  13-11.—Compressor  components.
• Figure 13-12.—Compressor superheat switch.
• Figure 13-13.—Two-cylinder reciprocating compressor.
• Figure 13-14.—Four-cylinder radial compressor.
• Four-Cylinder Radial Compressor
• Malfunctions of Components in the Air-Conditioning System
• Inspecting the Air-Conditioning System for Leaks
• Propane Torch Detector
• Purging the Air-Conditioning System
• Adding Refrigerant to the Air-Conditioning System
• Functional Testing of the Air-Conditioning System
• Other Refrigerants

References, Continued

Index

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