General Description
LUBRICATION - TM-5-3820-256-24-4_38
Kingpin Bearings
AXLE ADJUSTMENT
Steering Stop Adjustment
AXLE ADJUSTMENT
Adjustment - TM-5-3820-256-24-4_43
STEERABLE DRIVE END DISASSEMBLY - TM-5-3820-256-24-4_44
Brake and Wheel Spindle Disassembly
Spindle Yoke Removal
Inner Axle Shaft Removal
STEERABLE DRIVE END DISASSEMBLY - TM-5-3820-256-24-4_48
CLEANING AND INSPECTION - TM-5-3820-256-24-4_49
STEERABLE DRIVE END ASSEMBLY - TM-5-3820-256-24-4_50
STEERABLE DRIVE END ASSEMBLY - TM-5-3820-256-24-4_51
STEERABLE DRIVE END ASSEMBLY - TM-5-3820-256-24-4_52
Wheel Hub Assembly
Brake Actuator Chamber Installation
DIFFERENTIAL CARRIER
TORQUE SPECIFICATIONS - TM-5-3820-256-24-4_56
SERVICE BULLETIN
SERVICE BULLETIN - cont
Steerable Drive Axle Assembly - TM-5-3820-256-24-4_60
Steerable Drive Axle Assembly - TM-5-3820-256-24-4_61
Steerable Drive End Assembly Disc Style Hub
Steerable Drive End Assembly (Disc Style Hub) - TM-5-3820-256-24-4_63
Steerable Drive End Assembly Disc Style Hub
Steerable Drive End Assembly (Disc Style Hub) - TM-5-3820-256-24-4_65
SUSPENSION ALIGNMENT
Figure 4 - Measure Dimension "B"
SPRING ASSEMBLIES
Figure 5 - Progressive Spring Assembly
SHOCK ABSORBERS
TROUBLESHOOTING - TM-5-3820-256-24-4_73
SPECIFICATIONS - TM-5-3820-256-24-4_74
CODE CONVERSION CHART-SUSPENSIONS (HENDRICKSON TO IH)
DESCRIPTION - TM-5-3820-256-24-4_77
MAINTENANCE - TM-5-3820-256-24-4_78
Figure 4 - Three Piece Adapter Bolt Type Beam End Mounting
CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-4_80
Figure 7 - Removing Equalizer Beam End Bushing
Figure 9 - Ball and Socket Beam Ford
Figure 12 - Installing Center Sleeve and Bearing
Figure 13 - Preparing to Press Bushing Into Torque Rod
Figure 15 - Rubber Cushion Type Suspension
EQUALIZING BEAM SUSPENSION (HENDRICKSON)
Figure 16 - Torque Rod
TORQUE CHART - TM-5-3820-256-24-4_88
TM-5-3820-256-24-4_91
Figure 3 - 4x2 Truck With Initial Split Air System
Figure 4 - 6x4 Truck With Initial Split Air System
Figure 5 - 4x2 Tractor With Initial Split Air System With Separate Spring Brake and Tractor Protection Controls
Figure 6 - 6x4 Tractor With Initial Split Air System With Separate Spring Brake and Tractor Protection Controls
Figure 9 - 6x4 Truck With Refined Split Air System
Figure 10 - 4x2 Tractor With Refined Split Air System and Modular Control Valve For Spring Brake and Tractor Protection Controls
Figure 11 - 6x4 Tractor Refined Split Air System With Steel Spring Suspension and Modular Control Valve For Spring Brake and Tractor Protection Control
Figure 12 - 6x4 Tractor Refined Split Air System With Steel Spring Suspension and Separate Spring Brake and Tractor Protection Controls
AIR BRAKES GENERAL INFORMATION
DIFFERENTIAL POWER DIVIDER LOCK VALVE
AIR BRAKES - GENERAL INFORMATION - cont - TM-5-3820-256-24-4_102
AIR BRAKES - GENERAL INFORMATION - cont - TM-5-3820-256-24-4_103
AIR BRAKES - GENERAL INFORMATION - cont - TM-5-3820-256-24-4_104
OPERATIONAL CHECKS OF SPLIT AIR BRAKE SYSTEM
Modular Control Valve
Modular Control Valve - cont
DIAGNOSIS GUIDES
DIAGNOSIS GUIDES - cont - TM-5-3820-256-24-4_109
DIAGNOSIS GUIDES - cont - TM-5-3820-256-24-4_110
TRACTOR-TRAILER BRAKE ANALYSIS PROCEDURE
Figure 23Air Brake Test Equipment
Figure 25 - Brake Test Data Sheet
Figure 26 - Test Connectlon8 - Single Trailer
Figure 28 - Brake Test Application Pressures
Figure 30Test Connections Multiple Trailers
Figure 31 - Test Instrumentation (In-Cab)
AIR BRAKES-GENERAL INFORMATION
DATA INTERPRETATION AND CORRECTIVE MEASURES
GLOSSARY OF BRAKE TERMINOLOGY
TM-5-3820-256-24-4_121
SERVICE MANUAL - TM-5-3820-256-24-4_122
Figure 2 - Cutaway View of Air Compressor
OPERATION COMPRESSION
TROUBLESHOOTING GUIDE (Continued)
Figure 3 - Unloader Cover Removal
Figure 4 - Unloader Components
Figure 7 - Cross Section of Piston Assembly
Figure 10 - Checking Connecting Rod Side Clearance
CRANKSHAFT BEARING CAPS
Figure 11 - Piston and Connecting Rod Assembly
Figure 13 - Cylinder Head Bolt Tightening Sequence
SPECIFICATIONS - TM-5-3820-256-24-4_133
TORQUE CHART - TM-5-3820-256-24-4_134
GENERAL INSTRUCTIONS - TM-5-3820-256-24-4_138
Fig. 2 Sectional View of Type D-2 Governor
LEAKAGE TESTS
REASSEMBLY, ADJUST AND TEST
RESERVOIR
SAFETY VALVE
LOW PRESSURE INDICATOR;(LP-3 TYPE)
Leakage Test - TM-5-3820-256-24-4_148
RESERVOIR AUTOMATIC DRAIN VALVE
MAINTENANCE - TM-5-3820-256-24-4_150
Fig. 12 Sectional View of Reservoir Automatic Drain Valve
Fig. 1 Cross Sectional View of One- Way Check Valve
DOUBLE CHECK VALVE
Fig. 4 Pressure Protection Valve
Fig. 6 Pressure Limiting Valve
Fig. 7 Cross Section of Pressure Limiting Valve
Fig. 9 Crow Section of Emergency Relay Valve
LEAKAGE TEST - TM-5-3820-256-24-4_160
Fig. 1 Treadle Type Brake Valve
Fig. 3 Brake Valve Applied - Normal Operation
Fig. 6 Broke Valve In Balanced Position
Fig. 7 Brake Valve Releasing
REINSTALL
Fig. 8 Sectional View of E6 Brake Valve
DISASSEMBLY - TM-5-3820-256-24-4_169
Fig. 9 Sectional View of E7 Brake Valve
MIDLAND-ROSS
Release of Primary Section
MAINTENANCE - TM-5-3820-256-24-4_173
CLEANING AND INSPECTION - TM-5-3820-256-24-4_174
REASSEMBLY - TM-5-3820-256-24-4_175
QUICK RELEASE VALVES AND DIFFERENTIAL QUICK RELEASE VALVE
Figure 3 - Midland Differential Quick Release Valve
SERVICE CHECKS OPERATION TEST
MIDLAND-ROSS RELAY VALVE
MAINTENANCE - TM-5-3820-256-24-4_183
ASSEMBLY - TM-5-3820-256-24-4_184
Fig. 1 Inversion Valve, Type SR-1
Fig. 5 Normal Broke Application, Primary and Secondary Systems Charged
Fig. 7 Brake Application, Loss of Air In Primary System
SERVICE CHECKS Operation Test
CLEANING AND INSPECTION - TM-5-3820-256-24-4_191
Fig. 1 Spring Brake Control Valve
Operation Test
Fig. 3 Lover-Operated Two-Way Control Valve
Fig. 4 Modular Control Valve
Fig. 5 Typical Air System Schematic with Modular Control Valve
Fig. 8 Normal Operating Position
REMOVE
Fig. 10 Cross Section of Dual Circuit Supply
REASSEMBLY - TM-5-3820-256-24-4_203
MIDLAND-ROSS TRACTOR PROTECTION VALVE
Fig. 2 Tractor Protection Valve
DISASSEMBLY - TM-5-3820-256-24-4_209
MIDLAND-ROSS MANIFOLDED TRACTOR PROTECTION VALVE
MAINTENANCE - TM-5-3820-256-24-4_211
Fig. 4 Midland-Ross Manifolded Tractor Protection Valve
Operation Tests
CLEANING AND INSPECTION - TM-5-3820-256-24-4_214
Fig. 1 Flexible Hose Fitting
HOSE ASSEMBLY SPECIAL INSTRUCTIONS
Fig. 6 Nylon Tubing Assembly
TRAILER BRAKE HOSE COUPLING AND DUMMY COUPLING
MAINTENANCE - TM-5-3820-256-24-4_221
Fig. 1 AE-1 Alcohol Evaporator
Fig. 3 Cutaway View of AE-1 Alcohol Evaporator
Fig. 5 Standard Kit (AE-1 Alcohol Evaporator Illustrated)
Supercharged Compressor Induction
TROUBLE SHOOTING GUIDE - TM-5-3820-256-24-4_229
TROUBLE SHOOTING GUIDE - cont
BENDIX AD1 & AD2 TYPES
Fig. 3 Sectional View of AD-1 Air Dryer
Fig. 5 AD-2 Operational Charge Cycle
REMOVAL OF DESICCANT CARTRIDGE AD-1 & AD-2
REPLACING DESICCANT CARTRIDGE
Fig. 10 Installing Felt Cloth In Cartridg
Fig. 14 Installing Second Perforated Plate
REBUILDING AD-1 END COVER ASSEMBLY
Fig. 19 Purge Valve Assembly Disassembled
CR BRAKEMASTER 62 & 68 MODELS
DISASSEMBLY AND REASSEMBLY
Fig. 23 Cross Section of CR Brakemaster Heat Exchanger
Fig. 24 Contents of Unloader Valve Kit
Servicing Deflector Assembly - TM-5-3820-256-24-4_246
Servicing Deflector Assembly - TM-5-3820-256-24-4_247
Servicing Thermostatically Controlled Cartridge Type Heater
Servicing The Wrap-Around Strap Type Heater
Fig. 28 Exploded View of CR Brakemaster Heat Exchanger
TROUBLE SHOOTING THE CR BRAKEMASTER UNIT
TROUBLE SHOOTING THE CR BRAKEMASTER UNIT - cont
DESCRIPTION - TM-5-3820-256-24-4_255
MANUAL SLACK ADJUSTER OPERATION TEST
Fig. 4 Using Wheel Dolly to Remove Wheel, Hub and Drum Assembly
Fig. 5 Removing Outboard Mounted Drum
Fig. 7 Typical Brake Group with Fixed Anchor Pins
Fig. 8 Typical Brake Group with Removable Anchor Pins
Fig. 11 Removing Lower Cam Roller
Fig. 13 Removing Upper Cam Roller
Fig. 14 Remove Shoe Return Spring
Anchor Pins
Fig. 19 Right Wheel Rotation (Arrow)
Brake Groups with Spiders
CAMSHAFT, BUSHINGS AND SEALS
Fig. 23 Brake Chamber (Cross Sectional View)
Fig. 24 Section View of Slack Adjuster
TORQUE CHARTS
TORQUE CHART - TM-5-3820-256-24-4_272
DRUM BRAKES
Figure 6 - Checking Drum Runout on Brake Drum Lathe
Figure 8 - Reconditioning Drum on Brake Drum Lathe
Figure 11 - Checking for Out-of-Square Lining
igure 14 - Sequence In Securing Brake Lining to Shoe
Fig. 1 - Double Diaphragm Spring rake Chamber
PARKING BRAKE APPLICATION
MANUAL SET OF SPRING BRAKE
REPLACE SPRING BRAKE DIAPHRAGMS
REPLACE SPRING BRAKE DIAPHRAGMS - cont
REPLACE SPRING BRAKE SUSPECTED DEFECTIVE PUSH ROD SEAL
SERVICE SPRING BRAKE UNIT WITH SUSPECTED DEFECTIVE POWER SPRING OR DEFECTIVE RELEASE MECHANISM
Fig. 1 Eaton Heavy Duty Roll Vane Pump
DIAGNOSTIC INFORMATION
DIAGNOSTIC CHARTS
DIAGNOSTIC CHARTS - cont
Fig. 2 SE-2780 Power Steering Analyzer
Gear Driven Pump
Fig. 4. Pump Components
OIL FILTER REPLACEMENT
Fig. 10 Removing Shaft Seal
Fig. 11 Installing Shaft Seal
Fig. 14 Mark Fitting Location
Fig. 17 Valve Components
Fig. 21 Remove Gasket
Fig. 23 Installing Shaft Seal
Fig. 26 End Plate Identification
Fig. 29 Installing Front End Plate
Fig. 33 Proper Carrier Orientation
Fig. 37 Retainer Ring In Housing
Fig. 40 Positioning Discharge Fitting
Fig. 44 Filter Element Components
TORQUE CHART - TM-5-3820-256-24-4_310
STEERING COLUMN ASSEMBLY S-SERIES
Figure 2 - Stationary Steering Column -Conventional Cab
STEERING COLUMN - CONVENTIONAL CAB
Figure 8 - Pitman Arm and Drag Link Installation
Figure 10 - Snap Ring Removal
Figure 14 - Press Bearings Into Yoke
SPECIFICATIONS TORQUE CHART
FORWARD - TM-5-3820-256-24-4_324
Fig. 1 Typical Parts Identification
CONSTRUCTION - TM-5-3820-256-24-4_326
Fig. 2 Slip Joint
Fig. 3 Permanent Joint
Fig. 6 Short Couple Joint
Fig. 9 Universal Joint Seals
UNIVERSAL JOINTS IN THE VEHICLE OR APPLICATION
SERVICE INSTRUCTIONS
REMOVAL OF THE SLIP JOINT
ASSEMBLING UNIVERSAL JOINT
DISASSEMBLING UNIVERSAL JOINT
CLEANING AND INSPECTION - TM-5-3820-256-24-4_337
FAILURE ANALYSIS
REBUILDING DRIVESHAFTS
INSTALLATION - TM-5-3820-256-24-4_340
INSTALLING PROPELLER SHAFT
UNIVERSAL JOINT PHASING
INSTALLING DRIVESHAFT
TORQUE ARM SHIMMING
CENTER BEARING
IDENTIFICATION CHART
PREVENTIVE MAINTENANCE - TM-5-3820-256-24-4_351
VOLTAGE REGULATOR ADJUSTMENT
Figure 6 - Removing Regulator
Figure 9 - Removing Regulator Housing.
Figure 13 - Removing Drive End Housing From Rotor Shaft.
Figure 16 - Negative Heat Sink Tests.
Figure 19 - Rotor Coil Resistance Test
Figure 22 - Removing Slip Ring Assembly
Figure 24 - Using Pin to Hold Brush Springs Depressed
BATTERY - TM-5-3820-256-24-4_362
Figure 2 - Maintenance Free Type Battery
ELECTROLYTE AND SPECIFIC GRAVITY
Figure 5 - Relationship of Specific Gravity to Transfer of Sulphate From Electrolyte to Plates
Figure 7 - Specific Gravity Temperature Correction Valves
Figure 8 - Battery Maintenance Inspection
Figure 9 - Proper Jumper Cable Connections
Figure 10 - Removing Vent Manifold to Gain Access to Cells
Figure 12a - Testing Specific Gravity
Figure 13 -- Battery Tester
Figure 14 - Charging Battery
TABLE 6 BATTERY CHARGING GUIDE
INSTALLATION - TM-5-3820-256-24-4_374
STORAGE INSTRUCTIONS
SPECIFICATIONS LOW MAINTENANCE BATTERIES
SPECIFICATIONS MAINTENANCE FREE BATTERIES
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_381
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_382
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_383
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_384
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_385
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_386
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_387
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_388
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_389
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_390
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_391
FUSE BLOCK
BULB CHART
S-SERIES LEFT HAND DRIVE ELECTRICAL CIRCUIT DIAGRAMS
CIRCUIT DIAGRAM INDEX
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_397
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_398
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_399
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_400
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_401
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_402
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_403
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_404
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_405
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_406
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_407
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_408
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_409
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_410
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_411
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_412
INTRODUCTION - TM-5-3820-256-24-4_416
SEALED BEAM UNIT REPLACEMENT
Fig. 6 Disconnecting Headlight Retainer Spring
LIGHT ASSEMBLY REPLACEMENT - TM-5-3820-256-24-4_419
Fig. 11 Instrument Cluster Light Locations (As viewed from front of vehicle)
Fig. 12 Removing Bulb from face of Cluster
BULB REPLACEMENT
LIGHT ASSEMBLY REPLACEMENT - TM-5-3820-256-24-4_423
Fig. 18 Ashtray Light
CONTROL IDENTIFICATION OR WARNING LIGHTS
LIGHT BULB CHART
Figure 1 S-Series Instruments (Typical)
Figure 2-Removing Instrument Cluster
Figure 6 Removing Instrument Cluster Bezel
Figure 11 Removing Bulb and Bulb Socket From Rear of Cluster
SPEEDOMETER AND TACHOMETER SPEEDOMETER
CABLE SERVICE
GAUGES
GAUGE QUICK CHECKS
WATER TEMPERATURE GAUGE
Figure 19 - Water Temperature Gauge Circuit Diagram
Figure 20 - Servicing Auxiliary Gauge
AIR PRESSURE GAUGE
VOLTMETER (BATTERY/CHARGING SYSTEM GAUGE)
Testing - TM-5-3820-256-24-4_442
Fig. 1 Heavy Duty Starting Motor with Enclosed Shift
Fig. 2. Sectional View of Starting Motor with International Duty Clutch
Fig. 3. Sectional View of Starting Motor with Heavy Duty Sprag Clutch
Fig. 4. Sectional View of Starting Motor with DR-250 Heavy Duty Drive
Fig. 5. Cranking Voltage test
Fig. 6. Starting Motor Circuit
Fig. 7. Cranking Circuit Test
Fig. 8. Control Circuit Test
Fig. 9. No Load Test Hookup
Fig. 10. Removing retainer from Snap Ring
Fig. 11. Testing Armature for CG-6685 Short Circuits
Fig. 12. Testing Armature for Grounds
Fig. 13. Installing Snap Ring
Fig. 14. Installation of Retainer
Fig. 15. Pinion Drive Clearance Check Hookup
Fig. 16. Checking Pinion Clearance on Motors with the Intermediate Duty Clutch
Fig. 17. Checking Pinion Clearance on Motors with the heavy Duty Sprag Clutch
ENGINE DIVISION SERVICE MANUAL - TM-5-3820-256-24-4_461
ENGINE DIVISION SERVICE MANUAL - TM-5-3820-256-24-4_462
LUBRICATION - TM-5-3820-256-24-4_466
OIL VISCOSITY
ENGINE MAINTENANCE SCHEDULE CHARTS
COOLING SYSTEM - TM-5-3820-256-24-4_470
Figure 1 - Lubrication Points - Typical 6x4 Vehicle with Single Rear Axle Options Illustrated
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_473
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_474
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_475
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_476
SPECIAL INSTRUCTIONS
SPECIAL INSTRUCTIONS - cont - TM-5-3820-256-24-4_478
SPECIAL INSTRUCTIONS - cont - TM-5-3820-256-24-4_479
STAMPED ANGLE SPRING CLUTCH - TM-5-3820-256-24-4_482
SPACER RING & INTERMEDIATE PLATE ASSEMBLY
RECOMMENDED OPERATION AND MAINTENANCE FOR LONG CLUTCH LIFE
TRANSMISSION REMOVAL
STAMPED ANGLE SPRING CLUTCH - TM-5-3820-256-24-4_486
INSPECTION OF FLYWHEEL/ENGINE HOUSING
INSPECTION OF FLYWHEEL/ENGINE HOUSING - cont
INSTALLATION OF SAS-1402 (Two Plate)
INSTALLATION OF SAS-1402 (Two Plate) - cont
TRANSMISSION INSTALLATION
LUBRICATION - TM-5-3820-256-24-4_492
ADJUSTMENT PROCEDURE FOR STAMPED ANGLE-SPRING PULL CLUTCHES
ADJUSTMENT PROCEDURE FOR STAMPED ANGLE-SPRING PULL CLUTCHES - cont
SPECIFICATIONS - TM-5-3820-256-24-4_495
TROUBLE SHOOTING - TM-5-3820-256-24-4_496
STAMPED ANGLE SPRING CLUTCH - TM-5-3820-256-24-4_497
DESCRIPTION - TM-5-3820-256-24-4_500
Fig. 4 Checking Release Bearing Adjustment
ADJUSTMENT - TM-5-3820-256-24-4_503
Fig. 11 Release Bearing-to-Release Shaft Yoke Clearance
CLUTCH PEDAL SHAFT BUSHING REPLACEMENT
Fig. 16 Clutch Pedal Shaft Details
Vehicles Except 2200 Series
Fig. 18 Relay Shaft Details (Vehicles Except 2200 Series) (Typical)
TROUBLE SHOOTING GUIDE - TM-5-3820-256-24-4_511
SPECIFICATIONS - TM-5-3820-256-24-4_512
LUBRICATION - TM-5-3820-256-24-4_38
Kingpin Bearings
AXLE ADJUSTMENT
Steering Stop Adjustment
AXLE ADJUSTMENT
Adjustment - TM-5-3820-256-24-4_43
STEERABLE DRIVE END DISASSEMBLY - TM-5-3820-256-24-4_44
Brake and Wheel Spindle Disassembly
Spindle Yoke Removal
Inner Axle Shaft Removal
STEERABLE DRIVE END DISASSEMBLY - TM-5-3820-256-24-4_48
CLEANING AND INSPECTION - TM-5-3820-256-24-4_49
STEERABLE DRIVE END ASSEMBLY - TM-5-3820-256-24-4_50
STEERABLE DRIVE END ASSEMBLY - TM-5-3820-256-24-4_51
STEERABLE DRIVE END ASSEMBLY - TM-5-3820-256-24-4_52
Wheel Hub Assembly
Brake Actuator Chamber Installation
DIFFERENTIAL CARRIER
TORQUE SPECIFICATIONS - TM-5-3820-256-24-4_56
SERVICE BULLETIN
SERVICE BULLETIN - cont
Steerable Drive Axle Assembly - TM-5-3820-256-24-4_60
Steerable Drive Axle Assembly - TM-5-3820-256-24-4_61
Steerable Drive End Assembly Disc Style Hub
Steerable Drive End Assembly (Disc Style Hub) - TM-5-3820-256-24-4_63
Steerable Drive End Assembly Disc Style Hub
Steerable Drive End Assembly (Disc Style Hub) - TM-5-3820-256-24-4_65
SUSPENSION ALIGNMENT
Figure 4 - Measure Dimension "B"
SPRING ASSEMBLIES
Figure 5 - Progressive Spring Assembly
SHOCK ABSORBERS
TROUBLESHOOTING - TM-5-3820-256-24-4_73
SPECIFICATIONS - TM-5-3820-256-24-4_74
CODE CONVERSION CHART-SUSPENSIONS (HENDRICKSON TO IH)
DESCRIPTION - TM-5-3820-256-24-4_77
MAINTENANCE - TM-5-3820-256-24-4_78
Figure 4 - Three Piece Adapter Bolt Type Beam End Mounting
CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-4_80
Figure 7 - Removing Equalizer Beam End Bushing
Figure 9 - Ball and Socket Beam Ford
Figure 12 - Installing Center Sleeve and Bearing
Figure 13 - Preparing to Press Bushing Into Torque Rod
Figure 15 - Rubber Cushion Type Suspension
EQUALIZING BEAM SUSPENSION (HENDRICKSON)
Figure 16 - Torque Rod
TORQUE CHART - TM-5-3820-256-24-4_88
TM-5-3820-256-24-4_91
Figure 3 - 4x2 Truck With Initial Split Air System
Figure 4 - 6x4 Truck With Initial Split Air System
Figure 5 - 4x2 Tractor With Initial Split Air System With Separate Spring Brake and Tractor Protection Controls
Figure 6 - 6x4 Tractor With Initial Split Air System With Separate Spring Brake and Tractor Protection Controls
Figure 9 - 6x4 Truck With Refined Split Air System
Figure 10 - 4x2 Tractor With Refined Split Air System and Modular Control Valve For Spring Brake and Tractor Protection Controls
Figure 11 - 6x4 Tractor Refined Split Air System With Steel Spring Suspension and Modular Control Valve For Spring Brake and Tractor Protection Control
Figure 12 - 6x4 Tractor Refined Split Air System With Steel Spring Suspension and Separate Spring Brake and Tractor Protection Controls
AIR BRAKES GENERAL INFORMATION
DIFFERENTIAL POWER DIVIDER LOCK VALVE
AIR BRAKES - GENERAL INFORMATION - cont - TM-5-3820-256-24-4_102
AIR BRAKES - GENERAL INFORMATION - cont - TM-5-3820-256-24-4_103
AIR BRAKES - GENERAL INFORMATION - cont - TM-5-3820-256-24-4_104
OPERATIONAL CHECKS OF SPLIT AIR BRAKE SYSTEM
Modular Control Valve
Modular Control Valve - cont
DIAGNOSIS GUIDES
DIAGNOSIS GUIDES - cont - TM-5-3820-256-24-4_109
DIAGNOSIS GUIDES - cont - TM-5-3820-256-24-4_110
TRACTOR-TRAILER BRAKE ANALYSIS PROCEDURE
Figure 23Air Brake Test Equipment
Figure 25 - Brake Test Data Sheet
Figure 26 - Test Connectlon8 - Single Trailer
Figure 28 - Brake Test Application Pressures
Figure 30Test Connections Multiple Trailers
Figure 31 - Test Instrumentation (In-Cab)
AIR BRAKES-GENERAL INFORMATION
DATA INTERPRETATION AND CORRECTIVE MEASURES
GLOSSARY OF BRAKE TERMINOLOGY
TM-5-3820-256-24-4_121
SERVICE MANUAL - TM-5-3820-256-24-4_122
Figure 2 - Cutaway View of Air Compressor
OPERATION COMPRESSION
TROUBLESHOOTING GUIDE (Continued)
Figure 3 - Unloader Cover Removal
Figure 4 - Unloader Components
Figure 7 - Cross Section of Piston Assembly
Figure 10 - Checking Connecting Rod Side Clearance
CRANKSHAFT BEARING CAPS
Figure 11 - Piston and Connecting Rod Assembly
Figure 13 - Cylinder Head Bolt Tightening Sequence
SPECIFICATIONS - TM-5-3820-256-24-4_133
TORQUE CHART - TM-5-3820-256-24-4_134
GENERAL INSTRUCTIONS - TM-5-3820-256-24-4_138
Fig. 2 Sectional View of Type D-2 Governor
LEAKAGE TESTS
REASSEMBLY, ADJUST AND TEST
RESERVOIR
SAFETY VALVE
LOW PRESSURE INDICATOR;(LP-3 TYPE)
Leakage Test - TM-5-3820-256-24-4_148
RESERVOIR AUTOMATIC DRAIN VALVE
MAINTENANCE - TM-5-3820-256-24-4_150
Fig. 12 Sectional View of Reservoir Automatic Drain Valve
Fig. 1 Cross Sectional View of One- Way Check Valve
DOUBLE CHECK VALVE
Fig. 4 Pressure Protection Valve
Fig. 6 Pressure Limiting Valve
Fig. 7 Cross Section of Pressure Limiting Valve
Fig. 9 Crow Section of Emergency Relay Valve
LEAKAGE TEST - TM-5-3820-256-24-4_160
Fig. 1 Treadle Type Brake Valve
Fig. 3 Brake Valve Applied - Normal Operation
Fig. 6 Broke Valve In Balanced Position
Fig. 7 Brake Valve Releasing
REINSTALL
Fig. 8 Sectional View of E6 Brake Valve
DISASSEMBLY - TM-5-3820-256-24-4_169
Fig. 9 Sectional View of E7 Brake Valve
MIDLAND-ROSS
Release of Primary Section
MAINTENANCE - TM-5-3820-256-24-4_173
CLEANING AND INSPECTION - TM-5-3820-256-24-4_174
REASSEMBLY - TM-5-3820-256-24-4_175
QUICK RELEASE VALVES AND DIFFERENTIAL QUICK RELEASE VALVE
Figure 3 - Midland Differential Quick Release Valve
SERVICE CHECKS OPERATION TEST
MIDLAND-ROSS RELAY VALVE
MAINTENANCE - TM-5-3820-256-24-4_183
ASSEMBLY - TM-5-3820-256-24-4_184
Fig. 1 Inversion Valve, Type SR-1
Fig. 5 Normal Broke Application, Primary and Secondary Systems Charged
Fig. 7 Brake Application, Loss of Air In Primary System
SERVICE CHECKS Operation Test
CLEANING AND INSPECTION - TM-5-3820-256-24-4_191
Fig. 1 Spring Brake Control Valve
Operation Test
Fig. 3 Lover-Operated Two-Way Control Valve
Fig. 4 Modular Control Valve
Fig. 5 Typical Air System Schematic with Modular Control Valve
Fig. 8 Normal Operating Position
REMOVE
Fig. 10 Cross Section of Dual Circuit Supply
REASSEMBLY - TM-5-3820-256-24-4_203
MIDLAND-ROSS TRACTOR PROTECTION VALVE
Fig. 2 Tractor Protection Valve
DISASSEMBLY - TM-5-3820-256-24-4_209
MIDLAND-ROSS MANIFOLDED TRACTOR PROTECTION VALVE
MAINTENANCE - TM-5-3820-256-24-4_211
Fig. 4 Midland-Ross Manifolded Tractor Protection Valve
Operation Tests
CLEANING AND INSPECTION - TM-5-3820-256-24-4_214
Fig. 1 Flexible Hose Fitting
HOSE ASSEMBLY SPECIAL INSTRUCTIONS
Fig. 6 Nylon Tubing Assembly
TRAILER BRAKE HOSE COUPLING AND DUMMY COUPLING
MAINTENANCE - TM-5-3820-256-24-4_221
Fig. 1 AE-1 Alcohol Evaporator
Fig. 3 Cutaway View of AE-1 Alcohol Evaporator
Fig. 5 Standard Kit (AE-1 Alcohol Evaporator Illustrated)
Supercharged Compressor Induction
TROUBLE SHOOTING GUIDE - TM-5-3820-256-24-4_229
TROUBLE SHOOTING GUIDE - cont
BENDIX AD1 & AD2 TYPES
Fig. 3 Sectional View of AD-1 Air Dryer
Fig. 5 AD-2 Operational Charge Cycle
REMOVAL OF DESICCANT CARTRIDGE AD-1 & AD-2
REPLACING DESICCANT CARTRIDGE
Fig. 10 Installing Felt Cloth In Cartridg
Fig. 14 Installing Second Perforated Plate
REBUILDING AD-1 END COVER ASSEMBLY
Fig. 19 Purge Valve Assembly Disassembled
CR BRAKEMASTER 62 & 68 MODELS
DISASSEMBLY AND REASSEMBLY
Fig. 23 Cross Section of CR Brakemaster Heat Exchanger
Fig. 24 Contents of Unloader Valve Kit
Servicing Deflector Assembly - TM-5-3820-256-24-4_246
Servicing Deflector Assembly - TM-5-3820-256-24-4_247
Servicing Thermostatically Controlled Cartridge Type Heater
Servicing The Wrap-Around Strap Type Heater
Fig. 28 Exploded View of CR Brakemaster Heat Exchanger
TROUBLE SHOOTING THE CR BRAKEMASTER UNIT
TROUBLE SHOOTING THE CR BRAKEMASTER UNIT - cont
DESCRIPTION - TM-5-3820-256-24-4_255
MANUAL SLACK ADJUSTER OPERATION TEST
Fig. 4 Using Wheel Dolly to Remove Wheel, Hub and Drum Assembly
Fig. 5 Removing Outboard Mounted Drum
Fig. 7 Typical Brake Group with Fixed Anchor Pins
Fig. 8 Typical Brake Group with Removable Anchor Pins
Fig. 11 Removing Lower Cam Roller
Fig. 13 Removing Upper Cam Roller
Fig. 14 Remove Shoe Return Spring
Anchor Pins
Fig. 19 Right Wheel Rotation (Arrow)
Brake Groups with Spiders
CAMSHAFT, BUSHINGS AND SEALS
Fig. 23 Brake Chamber (Cross Sectional View)
Fig. 24 Section View of Slack Adjuster
TORQUE CHARTS
TORQUE CHART - TM-5-3820-256-24-4_272
DRUM BRAKES
Figure 6 - Checking Drum Runout on Brake Drum Lathe
Figure 8 - Reconditioning Drum on Brake Drum Lathe
Figure 11 - Checking for Out-of-Square Lining
igure 14 - Sequence In Securing Brake Lining to Shoe
Fig. 1 - Double Diaphragm Spring rake Chamber
PARKING BRAKE APPLICATION
MANUAL SET OF SPRING BRAKE
REPLACE SPRING BRAKE DIAPHRAGMS
REPLACE SPRING BRAKE DIAPHRAGMS - cont
REPLACE SPRING BRAKE SUSPECTED DEFECTIVE PUSH ROD SEAL
SERVICE SPRING BRAKE UNIT WITH SUSPECTED DEFECTIVE POWER SPRING OR DEFECTIVE RELEASE MECHANISM
Fig. 1 Eaton Heavy Duty Roll Vane Pump
DIAGNOSTIC INFORMATION
DIAGNOSTIC CHARTS
DIAGNOSTIC CHARTS - cont
Fig. 2 SE-2780 Power Steering Analyzer
Gear Driven Pump
Fig. 4. Pump Components
OIL FILTER REPLACEMENT
Fig. 10 Removing Shaft Seal
Fig. 11 Installing Shaft Seal
Fig. 14 Mark Fitting Location
Fig. 17 Valve Components
Fig. 21 Remove Gasket
Fig. 23 Installing Shaft Seal
Fig. 26 End Plate Identification
Fig. 29 Installing Front End Plate
Fig. 33 Proper Carrier Orientation
Fig. 37 Retainer Ring In Housing
Fig. 40 Positioning Discharge Fitting
Fig. 44 Filter Element Components
TORQUE CHART - TM-5-3820-256-24-4_310
STEERING COLUMN ASSEMBLY S-SERIES
Figure 2 - Stationary Steering Column -Conventional Cab
STEERING COLUMN - CONVENTIONAL CAB
Figure 8 - Pitman Arm and Drag Link Installation
Figure 10 - Snap Ring Removal
Figure 14 - Press Bearings Into Yoke
SPECIFICATIONS TORQUE CHART
FORWARD - TM-5-3820-256-24-4_324
Fig. 1 Typical Parts Identification
CONSTRUCTION - TM-5-3820-256-24-4_326
Fig. 2 Slip Joint
Fig. 3 Permanent Joint
Fig. 6 Short Couple Joint
Fig. 9 Universal Joint Seals
UNIVERSAL JOINTS IN THE VEHICLE OR APPLICATION
SERVICE INSTRUCTIONS
REMOVAL OF THE SLIP JOINT
ASSEMBLING UNIVERSAL JOINT
DISASSEMBLING UNIVERSAL JOINT
CLEANING AND INSPECTION - TM-5-3820-256-24-4_337
FAILURE ANALYSIS
REBUILDING DRIVESHAFTS
INSTALLATION - TM-5-3820-256-24-4_340
INSTALLING PROPELLER SHAFT
UNIVERSAL JOINT PHASING
INSTALLING DRIVESHAFT
TORQUE ARM SHIMMING
CENTER BEARING
IDENTIFICATION CHART
PREVENTIVE MAINTENANCE - TM-5-3820-256-24-4_351
VOLTAGE REGULATOR ADJUSTMENT
Figure 6 - Removing Regulator
Figure 9 - Removing Regulator Housing.
Figure 13 - Removing Drive End Housing From Rotor Shaft.
Figure 16 - Negative Heat Sink Tests.
Figure 19 - Rotor Coil Resistance Test
Figure 22 - Removing Slip Ring Assembly
Figure 24 - Using Pin to Hold Brush Springs Depressed
BATTERY - TM-5-3820-256-24-4_362
Figure 2 - Maintenance Free Type Battery
ELECTROLYTE AND SPECIFIC GRAVITY
Figure 5 - Relationship of Specific Gravity to Transfer of Sulphate From Electrolyte to Plates
Figure 7 - Specific Gravity Temperature Correction Valves
Figure 8 - Battery Maintenance Inspection
Figure 9 - Proper Jumper Cable Connections
Figure 10 - Removing Vent Manifold to Gain Access to Cells
Figure 12a - Testing Specific Gravity
Figure 13 -- Battery Tester
Figure 14 - Charging Battery
TABLE 6 BATTERY CHARGING GUIDE
INSTALLATION - TM-5-3820-256-24-4_374
STORAGE INSTRUCTIONS
SPECIFICATIONS LOW MAINTENANCE BATTERIES
SPECIFICATIONS MAINTENANCE FREE BATTERIES
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_381
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_382
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_383
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_384
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_385
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_386
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_387
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_388
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_389
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_390
CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_391
FUSE BLOCK
BULB CHART
S-SERIES LEFT HAND DRIVE ELECTRICAL CIRCUIT DIAGRAMS
CIRCUIT DIAGRAM INDEX
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_397
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_398
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_399
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_400
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_401
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_402
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_403
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_404
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_405
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_406
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_407
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_408
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_409
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_410
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_411
S-SERIES LH DR ELECTRICAL CIRCUIT DIAGRAMS - TM-5-3820-256-24-4_412
INTRODUCTION - TM-5-3820-256-24-4_416
SEALED BEAM UNIT REPLACEMENT
Fig. 6 Disconnecting Headlight Retainer Spring
LIGHT ASSEMBLY REPLACEMENT - TM-5-3820-256-24-4_419
Fig. 11 Instrument Cluster Light Locations (As viewed from front of vehicle)
Fig. 12 Removing Bulb from face of Cluster
BULB REPLACEMENT
LIGHT ASSEMBLY REPLACEMENT - TM-5-3820-256-24-4_423
Fig. 18 Ashtray Light
CONTROL IDENTIFICATION OR WARNING LIGHTS
LIGHT BULB CHART
Figure 1 S-Series Instruments (Typical)
Figure 2-Removing Instrument Cluster
Figure 6 Removing Instrument Cluster Bezel
Figure 11 Removing Bulb and Bulb Socket From Rear of Cluster
SPEEDOMETER AND TACHOMETER SPEEDOMETER
CABLE SERVICE
GAUGES
GAUGE QUICK CHECKS
WATER TEMPERATURE GAUGE
Figure 19 - Water Temperature Gauge Circuit Diagram
Figure 20 - Servicing Auxiliary Gauge
AIR PRESSURE GAUGE
VOLTMETER (BATTERY/CHARGING SYSTEM GAUGE)
Testing - TM-5-3820-256-24-4_442
Fig. 1 Heavy Duty Starting Motor with Enclosed Shift
Fig. 2. Sectional View of Starting Motor with International Duty Clutch
Fig. 3. Sectional View of Starting Motor with Heavy Duty Sprag Clutch
Fig. 4. Sectional View of Starting Motor with DR-250 Heavy Duty Drive
Fig. 5. Cranking Voltage test
Fig. 6. Starting Motor Circuit
Fig. 7. Cranking Circuit Test
Fig. 8. Control Circuit Test
Fig. 9. No Load Test Hookup
Fig. 10. Removing retainer from Snap Ring
Fig. 11. Testing Armature for CG-6685 Short Circuits
Fig. 12. Testing Armature for Grounds
Fig. 13. Installing Snap Ring
Fig. 14. Installation of Retainer
Fig. 15. Pinion Drive Clearance Check Hookup
Fig. 16. Checking Pinion Clearance on Motors with the Intermediate Duty Clutch
Fig. 17. Checking Pinion Clearance on Motors with the heavy Duty Sprag Clutch
ENGINE DIVISION SERVICE MANUAL - TM-5-3820-256-24-4_461
ENGINE DIVISION SERVICE MANUAL - TM-5-3820-256-24-4_462
LUBRICATION - TM-5-3820-256-24-4_466
OIL VISCOSITY
ENGINE MAINTENANCE SCHEDULE CHARTS
COOLING SYSTEM - TM-5-3820-256-24-4_470
Figure 1 - Lubrication Points - Typical 6x4 Vehicle with Single Rear Axle Options Illustrated
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_473
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_474
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_475
LUBRICATION - MAINTENANCE GUIDE INTERVALS - TM-5-3820-256-24-4_476
SPECIAL INSTRUCTIONS
SPECIAL INSTRUCTIONS - cont - TM-5-3820-256-24-4_478
SPECIAL INSTRUCTIONS - cont - TM-5-3820-256-24-4_479
STAMPED ANGLE SPRING CLUTCH - TM-5-3820-256-24-4_482
SPACER RING & INTERMEDIATE PLATE ASSEMBLY
RECOMMENDED OPERATION AND MAINTENANCE FOR LONG CLUTCH LIFE
TRANSMISSION REMOVAL
STAMPED ANGLE SPRING CLUTCH - TM-5-3820-256-24-4_486
INSPECTION OF FLYWHEEL/ENGINE HOUSING
INSPECTION OF FLYWHEEL/ENGINE HOUSING - cont
INSTALLATION OF SAS-1402 (Two Plate)
INSTALLATION OF SAS-1402 (Two Plate) - cont
TRANSMISSION INSTALLATION
LUBRICATION - TM-5-3820-256-24-4_492
ADJUSTMENT PROCEDURE FOR STAMPED ANGLE-SPRING PULL CLUTCHES
ADJUSTMENT PROCEDURE FOR STAMPED ANGLE-SPRING PULL CLUTCHES - cont
SPECIFICATIONS - TM-5-3820-256-24-4_495
TROUBLE SHOOTING - TM-5-3820-256-24-4_496
STAMPED ANGLE SPRING CLUTCH - TM-5-3820-256-24-4_497
DESCRIPTION - TM-5-3820-256-24-4_500
Fig. 4 Checking Release Bearing Adjustment
ADJUSTMENT - TM-5-3820-256-24-4_503
Fig. 11 Release Bearing-to-Release Shaft Yoke Clearance
CLUTCH PEDAL SHAFT BUSHING REPLACEMENT
Fig. 16 Clutch Pedal Shaft Details
Vehicles Except 2200 Series
Fig. 18 Relay Shaft Details (Vehicles Except 2200 Series) (Typical)
TROUBLE SHOOTING GUIDE - TM-5-3820-256-24-4_511
SPECIFICATIONS - TM-5-3820-256-24-4_512
