INTRODUCTION - TM-5-3820-256-24-5_25
DIAGNOSTIC ANALYSIS
DIAGNOSTIC ANALYSIS - cont - TM-5-3820-256-24-5_27
DIAGNOSTIC ANALYSIS - cont - TM-5-3820-256-24-5_28
DIAGNOSTIC ANALYSIS - cont
ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_30
ENGINE DIAGNOSTIC TOOLS
ENGINE DIAGNOSTIC TOOLS - CONT
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_33
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_34
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_35
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_36
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_37
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_38
Figure 11. Design Technology Tech-Time Model 3354 Connections
Figure 12. Pressure Test Kit
ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_41
CALIBRATING THE PRESSURE TEST KIT
Figure 14. Smoke Sampling Kit
Figure 15. Orificed Restrictor Tool SE-4039
Figure 16. Orificed Restrictor Tool SE-4146
ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_46
ENGINE PERFORMANCE ANALYSIS GUIDE
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_48
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_49
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_50
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_51
ENGINE DIAGNOSTIC TEST PROCEDURES
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_53
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_54
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_55
Figure 4c. Inner and Outer Throttle Lever Assembly (Without Bellcrank)
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_57
Figure 5a. Version "I" Bellcrank Linkage
LINKAGE ADJUSTMENT - TM-5-3820-256-24-5_59
LINKAGE ADJUSTMENT - TM-5-3820-256-24-5_60
Figure 6. Shutoff Test
ELECTRIC SHUTOFF (AUTOMATIC SHUT-OFF)
Figure 7. Electric Shut-Off Control On Robert Bosch "MW" Pump
Figure 8. S-Series Electric Shut-Off Wiring
Figure 10. Solenoid Resistance Check
Measure Low Idle Speed
Figure 13b. MW Throttle Lever
AIR CLEANER MAXIMUM RESTRICTION
Figure 15. Top View of Dual Element Air Cleaner
Figure 17. Filter Screen
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_71
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_72
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_73
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_74
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_75
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_76
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_77
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_78
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_79
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_80
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_81
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_82
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_83
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_84
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_85
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_86
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_87
CHART D INTERNATIONAL SMOKE NOMOGRAPH
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_89
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_90
PERFORMANCE DATA GUIDELINES - TM-5-3820-256-24-5_91
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_92
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_93
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_94
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_95
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_96
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_97
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_98
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_99
PERFORMANCE DATA GUIDELINES - TM-5-3820-256-24-5_100
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_101
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_102
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_103
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_104
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_105
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_106
METRIC CONVERSION FACTOR CHART
CONVERSION TABLES
SERVICE MANUAL - TM-5-3820-256-24-5_115
ENGINE FEATURES
ENGINE FEATURES- cont
ENGINE FEATURES - cont - TM-5-3820-256-24-5_118
ENGINE FEATURES - cont - TM-5-3820-256-24-5_119
SAFETY SUGGESTIONS
SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_121
SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_122
SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_123
CONVERTION TABLE
TORQUE - TENSION VALUES FOR STANDARD FASTENERS
TORQUE VALUES FOR HOSE CLAMPS
SPECIAL SERVICE TOOL LIST
GENERAL INFORMATION - SEALING COMPOUND USE
APPLICATION
ENGINE APPLICATION CHART
CONSTRUCTION EQUIPMENT
ON HIGHWAY TRUCK
OEM APPLICATIONS
SPECIFICATIONS - TM-5-3820-256-24-5_134
AGRICULTURAL EQUIPMENT
AGRICULTURAL EQUIPMENT (Continued)
AGRICULTURAL EQUIPMENT (Continued)
CONSTRUCTION EQUIPMENT (Continued) - TM-5-3820-256-24-5_138
CONSTRUCTION EQUIPMENT (Continued) - TM-5-3820-256-24-5_139
ON HIGHWAY TRUCK (Continued) - TM-5-3820-256-24-5_140
ON HIGHWAY TRUCK (Continued) - TM-5-3820-256-24-5_141
OEM (Continued) - TM-5-3820-256-24-5_142
OEM (Continued) - TM-5-3820-256-24-5_143
OEM (Continued) - TM-5-3820-256-24-5_144
SPECIAL NUT AND BOLT TORQUE DATA
SPECIAL NUT AND BOLT TORQUE DATA* (Continued)
SERVICE DIAGNOSIS
PRIOR TO DISASSEMBLY OF ENGINE
DURING ENGINE DISASSEMBLY
DURING ENGINE REASSEMBLY
ENGINE START-UP
PROBLEM ANALYSIS GUIDE
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_153
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_154
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_155
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_156
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_157
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_158
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_159
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_160
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_161
MOUNTING ENGINE ON STAND
MOUNTING ENGINE ON STAND - CONT
Figure 1. - Typical Turbocharger and Common Parts
TURBOCHARGERS - TM-5-3820-256-24-5_165
Figure 2. - Turbocharger Core Assembly
Figure 4. - Turbocharger Properly Capped
Figure 5a. - Foreign Material Turbo Damage
TURBOCHARGERS - CONT
Figure 7. - Compressor Housing Installation
Figure 8. -- Center and Turbine Housing Aligned
TURBOCHARGERS - TM-5-3820-256-24-5_173
Figure 1. - Intake and Exhaust Manifold (400 Series Turbocharger for Payline Shown)*
MANIFOLDS
MANIFOLDS - CONT - TM-5-3820-256-24-5_176
MANIFOLDS - CONT - TM-5-3820-256-24-5_177
MANIFOLDS - CONT - TM-5-3820-256-24-5_178
MANIFOLDS - CONT - TM-5-3820-256-24-5_179
MANIFOLDS - CONT - TM-5-3820-256-24-5_180
CYLINDER HEAD & VALVES
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_182
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_183
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_184
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_185
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_186
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_187
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_188
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_189
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_190
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_191
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_192
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_193
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_194
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_195
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_196
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_197
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_198
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_199
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_200
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_201
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_202
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_203
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_204
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_205
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_206
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_207
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_208
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_209
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_210
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_211
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_212
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_213
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_214
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_215
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_217
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_218
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_219
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_220
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_221
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_222
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_223
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_224
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_225
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_226
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_227
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_228
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_229
CONNECTING RODS, PISTONS, RINGS & SLEEVES
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_231
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_232
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_233
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_234
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_235
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_236
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_237
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_238
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_239
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_240
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_241
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_242
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_243
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_244
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_245
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_246
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_247
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_248
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_249
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_250
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_251
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_252
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_253
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_254
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_255
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_256
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_257
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_258
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_259
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_261
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_262
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_263
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_264
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_265
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_266
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_267
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_268
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_269
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_270
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_271
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_272
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_273
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_274
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_275
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_276
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_277
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_278
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_279
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_280
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_281
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_282
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_283
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_284
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_285
TIMING, GEAR TRAIN & FRONT COVER
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_287
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_288
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_289
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_290
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_291
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_292
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_293
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_294
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_295
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_296
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_297
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_298
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_299
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_300
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_301
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_302
LUBRICATING OIL PUMP, OIL FILTERS & COOLER
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_304
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_305
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_306
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_307
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_308
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_309
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_310
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_311
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_312
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_313
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_314
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_315
WATER PUMP, THERMOSTAT & IDLER PULLEYS
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_317
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_318
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_319
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_320
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_321
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_322
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_323
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_324
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_325
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_326
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_327
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_328
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_329
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_330
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_331
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_332
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_333
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_334
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_335
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_336
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_337
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_338
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_339
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_340
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_341
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_342
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_343
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_344
ROBERT BOSCH MODEL MW INJECTION PUMP
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_346
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_347
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_348
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_349
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_350
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_351
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_352
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_353
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_354
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_355
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_356
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_357
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_358
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_359
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_360
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_361
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_362
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_363
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_364
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_365
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_366
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_367
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_368
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_369
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_370
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_371
NOZZLES - TM-5-3820-256-24-5_372
NOZZLES - CONT - TM-5-3820-256-24-5_373
NOZZLES - CONT - TM-5-3820-256-24-5_374
NOZZLES - CONT - TM-5-3820-256-24-5_375
FORWARD - TM-5-3820-256-24-5_377
INTRODUCTION - TM-5-3820-256-24-5_378
Figure 1. Robert Bosch Model MW Fuel Injection Pump
Figure 3. Four Principle Plunger Positions of Injection Cycle
Figure 4. Fuel System Flow
Figure 5. Helix and Charging Port Metering Positions
Figure 7. Cut-Away View of Governor Assembly
Figure 8. Exploded View of Fuel Injection Nozzle and Holder Assembly
PUMP SPECIFICATIONS
TOOLS
GENERAL
Figure 9. Torque
Figure 1. Injection Pump Mounted in Holding Fixture
Figure 4. Exploded View of Pump Housing
Legend for Figure 57
Figure 5. Exploded View of Governor
Legend for Figure 58
Figure 7. Aneroid Assembly
Figure 9. Removing Guide Pin
Figure 13. Removing Guide Bushing
Figure 19. Removing Side Plugs
Figure 23. Installing Tappet Holder
Figure 24. Camshaft Removal
Figure 28. Rack Positioning
Figure 32. Exploded View of Aneroid
Figure 33. Exploded View of Fuel Supply Pump
CLEANING AND INSPECTION - TM-5-3820-256-24-5_404
Figure 2. Checking Flyweight Trail Build-Up
Figure 3. Exploded View of Flyweight Springs
Figure 7. Old vs. New Fuel Return Hose with Orifice Fitting
Figure 3. Install Plunger Retainers
Figure 4. Control Sleeve Ball Positioning
Figure 7. Tappet Positioning
Figure 9. Install Drive End Bearing Plate
Figure 10. Installing Flyweight Assembly
Figure 13. Basic Setting of S-Plate
Figure 16. Accelerator Lever Assembly
Figure 18. Rack Link and Stop Shackle in Excess Fuel
INJECTION PUMP CALIBRATION
Figure 2. Installing Dial Indicator (Rack Gauge)
Figure 4. Inserting Adjusting Spacers
Figure 6. Making Preliminary Governor Cut-Off Adjustment
Figure 7. Adjusting Hi-Idle Rack Position
Figure 8. Adjusting Lo-ldle Position
Figure 10. Adjusting Aneroid Cutback
Figure 11. Adjusting External Stop Bracket
Check Start Fuel Quantity
INJECTION PUMP AND ENGINE TEST DATA
CALIBRATION DATA
Fig. 2. Air Being Forced Into Engine
Fig. 4. Turbocharger Cycle
Fig. 5. Air and Exhaust Flow In Turbocharged Engine
GENERAL MAINTENANCE AND CLEANING PROCEDURES
Fig. 7. DT-466 Turbocharger (Exploded View)
Fig. 8. Checking Axial End Play
Fig. 11. Related Positions of Parts
Fig. 13. Removing Center Housing From Turbine Housing
Fig. 16. Separating Compressor Wheel From Turbine Shaft
SERVICE MANUAL - TM-5-3820-256-24-5_447
TURBINE WHEEL AND SHAFT
DT-466 TURBOCHARGER
DT-466 TURBOCHARGER - CONT
SPECIFICATIONS - TM-5-3820-256-24-5_451
TORQUE CHART - TM-5-3820-256-24-5_452
TROUBLE SHOOTING - TM-5-3820-256-24-5_453
COOLING SYSTEM - TM-5-3820-256-24-5_456
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_457
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_458
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_459
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_460
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_461
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_462
Figure 5. - Using Hydrometer to Test Anti-freeze Solution
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_464
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_465
SPECIFICATIONS - TM-5-3820-256-24-5_468
Driver Instructions
Transmission Lubrication
General Precautions for Disassembly
Remote Control
SHIFTER HOUSING
SHIFTER HOUSING - CONT - TM-5-3820-256-24-5_474
SHIFTER HOUSING - CONT - TM-5-3820-256-24-5_475
CASE
GEAR & CASE - TM-5-3820-256-24-5_477
GEAR & CASE - CONT - TM-5-3820-256-24-5_478
GEARS & RELATED PARTS
MAINSHAFT
MAINSHAFT - CONT - TM-5-3820-256-24-5_481
MAINSHAFT - CONT - TM-5-3820-256-24-5_482
MAINSHAFT - CONT - TM-5-3820-256-24-5_483
MAINSHAFT - CONT - TM-5-3820-256-24-5_484
INSPECTION PROCEDURES & TORQUE SPECIFICATIONS
INPUT GEAR
GEAR & CASE - TM-5-3820-256-24-5_487
GEAR & CASE - CONT - TM-5-3820-256-24-5_488
TROUBLESHOOTING - TM-5-3820-256-24-5_489
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_490
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_491
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_492
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_493
OPERATING INSTRUCTIONS
LUBRICATION - TM-5-3820-256-24-5_501
Recommended Lubricants
TRANSFER CASE REMOVAL & INSTALLATION
TRANSFER CASE DISASSEMBLY
Shift Shaft Disassembly
Input Shaft Disassembly
Front Output Shaft Removal
CLEANING AND INSPECTION - TM-5-3820-256-24-5_508
TRANSFER CASE ASSEMBLY
Assembly of Front Output Shaft
Installation of Rear Output Shaft
Installation of the Intermediate Shaft
Installation of the Intermediate Shaft - CONT - TM-5-3820-256-24-5_513
Installation of the Intermediate Shaft - cont - TM-5-3820-256-24-5_514
Input Shaft Assembly
Air Shifter Shaft Installation
Air Shifter Shaft Installation - cont
Manual Shifter Shaft Installation
Assembly of PTO Unit
Assembly of PTO Unit - cont
Final Assembly
TORQUE SPECIFICATIONS - TM-5-3820-256-24-5_522
PARTS MANUAL
Shafts, Gear, Bearings, Spacers, Seals, Carriers and Caps
FRONT OUTPUT SHAFT
REAR OUTPUT SHAFT
INTERMEDIATE SHAFT
INPUT SHAFT
AIR OPERATED H-U AND H-N-U
H-U Air Shift
MANUAL H-N-U SHIFT
AIR OPERATED FRONT DRIVE DECLUTCH
MANUAL FRONT DRIVE DECLUTCH
PTO
AIR OPERATED PTO SHIFT
MANUAL PTO SHIFT
Oil Lines & Fittings - PTO
Fig. 1. IH Single Reduction Tandem Rear Axle
Fig. 2. Power Divider and Diff Carrier In Rebuild Stand
Fig. 4. Removing Inter-Axle Diff
Fig. 7. Removing Inter-Axle Differential From Cover
Fig. 11. Removing Clutch Shift Collar
Fig. 13. Removing Idler Shaft and Gear
Fig. 15. Removing Differential Bearing Caps
Fig. 19. Drive Gear Rivet Removal
Fig. 22. Removing Pinion End Nut (Rear Rear Shown)
Fig. 23. Forward Rear Axle (Exploded View)
SERVICE MANUAL - TM-5-3820-256-24-5_552
Fig. 24. Rear Rear Axle (Exploded View)
CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-5_554
Preload Pinion Bearing
Fig. 30. Installing Step Plate
Fig. 32. Installing Drive Gear to Diff Case
Fig. 33. Setting Gear Lash
Fig. 36. Tooth Contact Impressions
Fig. 37. Installing Bushing In Rear Half of Diff Case
Fig. 40. Cross-Section Showing Shims Used To Control Inter-Axle Diff End Play
Fig. 42. Installing Inter-Axle Diff Cover oil Seal
Fig. 44. Cross Section Of Idler Shaft Installation
Fig. 46. Installing Clutch Shift Collar
Fig. 48. Installing Intermediate Case To Diff Carrier
ELECTRIC SHIFT SYSTEM
LUBRICATION - TM-5-3820-256-24-5_567
TROUBLE SHOOTING - TM-5-3820-256-24-5_568
SPECIFICATIONS - TM-5-3820-256-24-5_569
TORQUE CHART - TM-5-3820-256-24-5_570
Fig. 1. S-Series Conventional Cab
Fig. 2. S-Series Cab Interior View (Typical)
SERIAL NUMBER LOCATIONS
Fig. 4. Hood Hinge Types For 200 Cm (80 Inch) Wide Cabs
Fig. 5. Custom Trimmed Door
Fig. 6. Door Hardware, Trim and Internal Components - Exploded View
Fig. 7. Door and Hinge Details
Fig. 12. Removing Rear Run Channel
Fig. 13. Removing or Installing Window Glass
Fig. 16. Door Glass Inner Seal
Fig. 19. Door Glass Regulator and Latch Details
Fig. 21. Removing Remote Control Assembly
Fig. 22. Removing Latch Assembly
Fig. 24. Removing Door Outer Handle
Fig. 26. Removing or Installing Door Striker Pin
Fig. 27. Location for Door Adjustments at Hinge Pillar
Fig. 29. Individual Drivers Seat - Custom Trim Exploded View
Fig. 30. Removing Windshield Wiper Arm
Fig. 33. Details of Windshleld Division Bar (230 cm or 90 Inch Cob Only)
Fig. 35. S-Series Cab Panels
Fig. 36. Components of Side Panel Assembly
Fig. 38 Location of MIG Weld Seams
Fig. 42. Filler Panel to Dash Panel Spot Welds
Fig. 46. Side Panel to Roof Inner Panel Spot Welds
Fig. 48. Using MIG Welder For Plug Welds
Fig. 51. Fastening Roof Panel To New Side Panel
Fig. 53. Cab Front Mounting Bracket (Left Front View)
Fig. 55. Cab Rear Mounting (230 cm - 90 inch Wide Cab)
Fig. 57. Stay Rod Details for 230 x 230 cm (90 x 90 Inch) Cob
CAB REMOVAL
TORQUE CHART - TM-5-3820-256-24-5_606
REPAIR INSTRUCTIONS USING FIBER GLASS MATERIAL
Figure 2. - Fiber Glass Mat
Figure 6. - Body Fillers
Figure 10. - Masking Undamaged Area
Figure 15. - Sanding Surface
Figure 20. - Large Fractures
Figure 21. - Opening Cracked Area
Figure 26. - Covering Repair Area with Separating Film
Figure 30. - Mat Lay-Up
Figure 35. - Sanding Backing Patch
Figure 40. - Filler Mat Lay-Up
Figure 45. - Applying Adhesive
Figure 48. - fiber Glass Mat and Cloth Patch Installation
Figure 53. - Applying Body Filler
Figure 56. - Applying Glazing Putt
S-SERIES AIR CONDITIONING- HEATER SYSTEM
Figure 5. - Heater (Only) Unit Heater Core - Exploded View
Figure 6. - Blower and Resistor
Control Unit, Switch and Cables
Figure 13. - Heater (Only) Control Unit
S-SERIES AIR CONDITIONING -- HEATER SYSTEM - cont
Figure 18. - Control Cable Adjustment - Heater Only Models
Figure 20. - Heater Core Removal - Heater Only Models
S-SERIES AIR CONDITIONING -- HEATER SYSTEM
Figure 22. - Hot Water Flow Control Valve Connections
Figure 24. - Control Assembly and Cables
BLOWER MOTOR ASSEMBLY AND FAN
Figure 27. - Blower Motor Removal
Figure 30. - Removing Relay
CONTROL CABLE REPLACEMENT - HEATER ONLY
CONTROL CABLE REPLACEMENT - HEATER ONLY - cont
TORQUE CHART - TM-5-3820-256-24-5_646
Fig. 7. Exploded View of Cam Actuated Parking Type Motor (American Bosch)
Fig. 8. Electric Windshield Wiper Motor (External View)
CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-5_652
Fig. 11. Windshield Wiper Motor Wiring Schematic
TROUBLE SHOOTING - TM-5-3820-256-24-5_654
TROUBLE SHOOTING - cont
SPECIFICATIONS - TM-5-3820-256-24-5_656
Fig. 1. Electric Windshield Wiper Components
Fig. 3. Removing Cowl Cover Panel
Fig. 4. Removing Windshield Wiper Linkage
Fig. 7. Removing Wiper Switch
SPECIFICATIONS - TM-5-3820-256-24-5_664
TROUBLE SHOOTING (ELECTRIC)
Fig. 1. Windshield Washer Installation (80" Wide Cab Shown)
Fig. 2. Pump, Motor Reservoir Assembly
TROUBLE SHOOTING - TM-5-3820-256-24-5_671
Figure 2. - Disc Front Wheel
Figure 5. - Cross Section of Inboard and Outboard Mounted Drum
Figure 9. - Disc Rear Wheel Assembly
WHEEL BEARING ADJUSTMENT
Figure 14. - Wheel Seals Used With Grease Lubricated Wheel Bearings
Figure 17. - Unitized Scot or National Seal
Figure 18. - Unitized Barrier Seal
Figure 20. - Installing Wiper Ring on Axle Shoulder
Unitized Barrier Seal
Figure 26. - Improper Installation of Guardian Oil Seal
WHEELS, RIMS AND TIRES
OIL LUBRICATED
WHEEL BEARING SEAL AND BEARING CAP DIAGNOSTIC CHART
WHEEL BEARING SEAL AND BEARING CAP DIAGNOSTIC CHART - cont
RIM, WHEELS AND TIRES
Figure 35. - Dual Disc Wheel Installation
INSTALLATION, TIGHTENING AND ALIGNMENT OF DISC WHEELS AND RIMS
Figure 40. - Disc Wheel Tightening Sequence
WHEEL AND TIRE BALANCING
BIAS AND RADIAL TIRE LOAD AND INFLATION CHART
LOW PROFILE RADIAL TIRE LOADS AND INFLATIONS
TIRE LOAD AND INFLATION CHART (MICHELIN)
TIRE LOAD AND INFLATION CHART (MICHELIN) CONTINUED
TIRE AND RIM COMBINATIONS
TORQUE CHART - TM-5-3820-256-24-5_698
DIAGNOSTIC ANALYSIS
DIAGNOSTIC ANALYSIS - cont - TM-5-3820-256-24-5_27
DIAGNOSTIC ANALYSIS - cont - TM-5-3820-256-24-5_28
DIAGNOSTIC ANALYSIS - cont
ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_30
ENGINE DIAGNOSTIC TOOLS
ENGINE DIAGNOSTIC TOOLS - CONT
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_33
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_34
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_35
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_36
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_37
ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_38
Figure 11. Design Technology Tech-Time Model 3354 Connections
Figure 12. Pressure Test Kit
ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_41
CALIBRATING THE PRESSURE TEST KIT
Figure 14. Smoke Sampling Kit
Figure 15. Orificed Restrictor Tool SE-4039
Figure 16. Orificed Restrictor Tool SE-4146
ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_46
ENGINE PERFORMANCE ANALYSIS GUIDE
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_48
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_49
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_50
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_51
ENGINE DIAGNOSTIC TEST PROCEDURES
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_53
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_54
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_55
Figure 4c. Inner and Outer Throttle Lever Assembly (Without Bellcrank)
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_57
Figure 5a. Version "I" Bellcrank Linkage
LINKAGE ADJUSTMENT - TM-5-3820-256-24-5_59
LINKAGE ADJUSTMENT - TM-5-3820-256-24-5_60
Figure 6. Shutoff Test
ELECTRIC SHUTOFF (AUTOMATIC SHUT-OFF)
Figure 7. Electric Shut-Off Control On Robert Bosch "MW" Pump
Figure 8. S-Series Electric Shut-Off Wiring
Figure 10. Solenoid Resistance Check
Measure Low Idle Speed
Figure 13b. MW Throttle Lever
AIR CLEANER MAXIMUM RESTRICTION
Figure 15. Top View of Dual Element Air Cleaner
Figure 17. Filter Screen
ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_71
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_72
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_73
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_74
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_75
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_76
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_77
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_78
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_79
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_80
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_81
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_82
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_83
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_84
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_85
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_86
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_87
CHART D INTERNATIONAL SMOKE NOMOGRAPH
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_89
ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_90
PERFORMANCE DATA GUIDELINES - TM-5-3820-256-24-5_91
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_92
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_93
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_94
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_95
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_96
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_97
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_98
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_99
PERFORMANCE DATA GUIDELINES - TM-5-3820-256-24-5_100
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_101
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_102
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_103
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_104
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_105
PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_106
METRIC CONVERSION FACTOR CHART
CONVERSION TABLES
SERVICE MANUAL - TM-5-3820-256-24-5_115
ENGINE FEATURES
ENGINE FEATURES- cont
ENGINE FEATURES - cont - TM-5-3820-256-24-5_118
ENGINE FEATURES - cont - TM-5-3820-256-24-5_119
SAFETY SUGGESTIONS
SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_121
SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_122
SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_123
CONVERTION TABLE
TORQUE - TENSION VALUES FOR STANDARD FASTENERS
TORQUE VALUES FOR HOSE CLAMPS
SPECIAL SERVICE TOOL LIST
GENERAL INFORMATION - SEALING COMPOUND USE
APPLICATION
ENGINE APPLICATION CHART
CONSTRUCTION EQUIPMENT
ON HIGHWAY TRUCK
OEM APPLICATIONS
SPECIFICATIONS - TM-5-3820-256-24-5_134
AGRICULTURAL EQUIPMENT
AGRICULTURAL EQUIPMENT (Continued)
AGRICULTURAL EQUIPMENT (Continued)
CONSTRUCTION EQUIPMENT (Continued) - TM-5-3820-256-24-5_138
CONSTRUCTION EQUIPMENT (Continued) - TM-5-3820-256-24-5_139
ON HIGHWAY TRUCK (Continued) - TM-5-3820-256-24-5_140
ON HIGHWAY TRUCK (Continued) - TM-5-3820-256-24-5_141
OEM (Continued) - TM-5-3820-256-24-5_142
OEM (Continued) - TM-5-3820-256-24-5_143
OEM (Continued) - TM-5-3820-256-24-5_144
SPECIAL NUT AND BOLT TORQUE DATA
SPECIAL NUT AND BOLT TORQUE DATA* (Continued)
SERVICE DIAGNOSIS
PRIOR TO DISASSEMBLY OF ENGINE
DURING ENGINE DISASSEMBLY
DURING ENGINE REASSEMBLY
ENGINE START-UP
PROBLEM ANALYSIS GUIDE
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_153
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_154
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_155
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_156
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_157
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_158
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_159
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_160
PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_161
MOUNTING ENGINE ON STAND
MOUNTING ENGINE ON STAND - CONT
Figure 1. - Typical Turbocharger and Common Parts
TURBOCHARGERS - TM-5-3820-256-24-5_165
Figure 2. - Turbocharger Core Assembly
Figure 4. - Turbocharger Properly Capped
Figure 5a. - Foreign Material Turbo Damage
TURBOCHARGERS - CONT
Figure 7. - Compressor Housing Installation
Figure 8. -- Center and Turbine Housing Aligned
TURBOCHARGERS - TM-5-3820-256-24-5_173
Figure 1. - Intake and Exhaust Manifold (400 Series Turbocharger for Payline Shown)*
MANIFOLDS
MANIFOLDS - CONT - TM-5-3820-256-24-5_176
MANIFOLDS - CONT - TM-5-3820-256-24-5_177
MANIFOLDS - CONT - TM-5-3820-256-24-5_178
MANIFOLDS - CONT - TM-5-3820-256-24-5_179
MANIFOLDS - CONT - TM-5-3820-256-24-5_180
CYLINDER HEAD & VALVES
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_182
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_183
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_184
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_185
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_186
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_187
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_188
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_189
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_190
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_191
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_192
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_193
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_194
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_195
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_196
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_197
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_198
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_199
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_200
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_201
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_202
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_203
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_204
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_205
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_206
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_207
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_208
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_209
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_210
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_211
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_212
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_213
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_214
CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_215
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_217
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_218
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_219
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_220
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_221
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_222
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_223
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_224
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_225
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_226
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_227
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_228
VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_229
CONNECTING RODS, PISTONS, RINGS & SLEEVES
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_231
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_232
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_233
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_234
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_235
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_236
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_237
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_238
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_239
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_240
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_241
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_242
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_243
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_244
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_245
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_246
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_247
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_248
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_249
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_250
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_251
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_252
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_253
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_254
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_255
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_256
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_257
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_258
CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_259
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_261
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_262
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_263
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_264
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_265
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_266
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_267
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_268
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_269
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_270
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_271
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_272
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_273
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_274
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_275
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_276
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_277
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_278
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_279
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_280
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_281
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_282
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_283
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_284
CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_285
TIMING, GEAR TRAIN & FRONT COVER
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_287
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_288
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_289
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_290
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_291
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_292
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_293
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_294
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_295
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_296
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_297
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_298
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_299
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_300
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_301
TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_302
LUBRICATING OIL PUMP, OIL FILTERS & COOLER
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_304
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_305
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_306
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_307
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_308
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_309
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_310
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_311
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_312
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_313
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_314
LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_315
WATER PUMP, THERMOSTAT & IDLER PULLEYS
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_317
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_318
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_319
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_320
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_321
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_322
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_323
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_324
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_325
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_326
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_327
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_328
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_329
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_330
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_331
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_332
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_333
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_334
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_335
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_336
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_337
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_338
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_339
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_340
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_341
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_342
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_343
WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_344
ROBERT BOSCH MODEL MW INJECTION PUMP
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_346
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_347
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_348
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_349
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_350
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_351
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_352
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_353
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_354
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_355
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_356
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_357
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_358
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_359
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_360
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_361
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_362
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_363
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_364
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_365
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_366
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_367
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_368
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_369
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_370
ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_371
NOZZLES - TM-5-3820-256-24-5_372
NOZZLES - CONT - TM-5-3820-256-24-5_373
NOZZLES - CONT - TM-5-3820-256-24-5_374
NOZZLES - CONT - TM-5-3820-256-24-5_375
FORWARD - TM-5-3820-256-24-5_377
INTRODUCTION - TM-5-3820-256-24-5_378
Figure 1. Robert Bosch Model MW Fuel Injection Pump
Figure 3. Four Principle Plunger Positions of Injection Cycle
Figure 4. Fuel System Flow
Figure 5. Helix and Charging Port Metering Positions
Figure 7. Cut-Away View of Governor Assembly
Figure 8. Exploded View of Fuel Injection Nozzle and Holder Assembly
PUMP SPECIFICATIONS
TOOLS
GENERAL
Figure 9. Torque
Figure 1. Injection Pump Mounted in Holding Fixture
Figure 4. Exploded View of Pump Housing
Legend for Figure 57
Figure 5. Exploded View of Governor
Legend for Figure 58
Figure 7. Aneroid Assembly
Figure 9. Removing Guide Pin
Figure 13. Removing Guide Bushing
Figure 19. Removing Side Plugs
Figure 23. Installing Tappet Holder
Figure 24. Camshaft Removal
Figure 28. Rack Positioning
Figure 32. Exploded View of Aneroid
Figure 33. Exploded View of Fuel Supply Pump
CLEANING AND INSPECTION - TM-5-3820-256-24-5_404
Figure 2. Checking Flyweight Trail Build-Up
Figure 3. Exploded View of Flyweight Springs
Figure 7. Old vs. New Fuel Return Hose with Orifice Fitting
Figure 3. Install Plunger Retainers
Figure 4. Control Sleeve Ball Positioning
Figure 7. Tappet Positioning
Figure 9. Install Drive End Bearing Plate
Figure 10. Installing Flyweight Assembly
Figure 13. Basic Setting of S-Plate
Figure 16. Accelerator Lever Assembly
Figure 18. Rack Link and Stop Shackle in Excess Fuel
INJECTION PUMP CALIBRATION
Figure 2. Installing Dial Indicator (Rack Gauge)
Figure 4. Inserting Adjusting Spacers
Figure 6. Making Preliminary Governor Cut-Off Adjustment
Figure 7. Adjusting Hi-Idle Rack Position
Figure 8. Adjusting Lo-ldle Position
Figure 10. Adjusting Aneroid Cutback
Figure 11. Adjusting External Stop Bracket
Check Start Fuel Quantity
INJECTION PUMP AND ENGINE TEST DATA
CALIBRATION DATA
Fig. 2. Air Being Forced Into Engine
Fig. 4. Turbocharger Cycle
Fig. 5. Air and Exhaust Flow In Turbocharged Engine
GENERAL MAINTENANCE AND CLEANING PROCEDURES
Fig. 7. DT-466 Turbocharger (Exploded View)
Fig. 8. Checking Axial End Play
Fig. 11. Related Positions of Parts
Fig. 13. Removing Center Housing From Turbine Housing
Fig. 16. Separating Compressor Wheel From Turbine Shaft
SERVICE MANUAL - TM-5-3820-256-24-5_447
TURBINE WHEEL AND SHAFT
DT-466 TURBOCHARGER
DT-466 TURBOCHARGER - CONT
SPECIFICATIONS - TM-5-3820-256-24-5_451
TORQUE CHART - TM-5-3820-256-24-5_452
TROUBLE SHOOTING - TM-5-3820-256-24-5_453
COOLING SYSTEM - TM-5-3820-256-24-5_456
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_457
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_458
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_459
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_460
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_461
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_462
Figure 5. - Using Hydrometer to Test Anti-freeze Solution
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_464
COOLING SYSTEM - CONT - TM-5-3820-256-24-5_465
SPECIFICATIONS - TM-5-3820-256-24-5_468
Driver Instructions
Transmission Lubrication
General Precautions for Disassembly
Remote Control
SHIFTER HOUSING
SHIFTER HOUSING - CONT - TM-5-3820-256-24-5_474
SHIFTER HOUSING - CONT - TM-5-3820-256-24-5_475
CASE
GEAR & CASE - TM-5-3820-256-24-5_477
GEAR & CASE - CONT - TM-5-3820-256-24-5_478
GEARS & RELATED PARTS
MAINSHAFT
MAINSHAFT - CONT - TM-5-3820-256-24-5_481
MAINSHAFT - CONT - TM-5-3820-256-24-5_482
MAINSHAFT - CONT - TM-5-3820-256-24-5_483
MAINSHAFT - CONT - TM-5-3820-256-24-5_484
INSPECTION PROCEDURES & TORQUE SPECIFICATIONS
INPUT GEAR
GEAR & CASE - TM-5-3820-256-24-5_487
GEAR & CASE - CONT - TM-5-3820-256-24-5_488
TROUBLESHOOTING - TM-5-3820-256-24-5_489
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_490
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_491
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_492
TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_493
OPERATING INSTRUCTIONS
LUBRICATION - TM-5-3820-256-24-5_501
Recommended Lubricants
TRANSFER CASE REMOVAL & INSTALLATION
TRANSFER CASE DISASSEMBLY
Shift Shaft Disassembly
Input Shaft Disassembly
Front Output Shaft Removal
CLEANING AND INSPECTION - TM-5-3820-256-24-5_508
TRANSFER CASE ASSEMBLY
Assembly of Front Output Shaft
Installation of Rear Output Shaft
Installation of the Intermediate Shaft
Installation of the Intermediate Shaft - CONT - TM-5-3820-256-24-5_513
Installation of the Intermediate Shaft - cont - TM-5-3820-256-24-5_514
Input Shaft Assembly
Air Shifter Shaft Installation
Air Shifter Shaft Installation - cont
Manual Shifter Shaft Installation
Assembly of PTO Unit
Assembly of PTO Unit - cont
Final Assembly
TORQUE SPECIFICATIONS - TM-5-3820-256-24-5_522
PARTS MANUAL
Shafts, Gear, Bearings, Spacers, Seals, Carriers and Caps
FRONT OUTPUT SHAFT
REAR OUTPUT SHAFT
INTERMEDIATE SHAFT
INPUT SHAFT
AIR OPERATED H-U AND H-N-U
H-U Air Shift
MANUAL H-N-U SHIFT
AIR OPERATED FRONT DRIVE DECLUTCH
MANUAL FRONT DRIVE DECLUTCH
PTO
AIR OPERATED PTO SHIFT
MANUAL PTO SHIFT
Oil Lines & Fittings - PTO
Fig. 1. IH Single Reduction Tandem Rear Axle
Fig. 2. Power Divider and Diff Carrier In Rebuild Stand
Fig. 4. Removing Inter-Axle Diff
Fig. 7. Removing Inter-Axle Differential From Cover
Fig. 11. Removing Clutch Shift Collar
Fig. 13. Removing Idler Shaft and Gear
Fig. 15. Removing Differential Bearing Caps
Fig. 19. Drive Gear Rivet Removal
Fig. 22. Removing Pinion End Nut (Rear Rear Shown)
Fig. 23. Forward Rear Axle (Exploded View)
SERVICE MANUAL - TM-5-3820-256-24-5_552
Fig. 24. Rear Rear Axle (Exploded View)
CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-5_554
Preload Pinion Bearing
Fig. 30. Installing Step Plate
Fig. 32. Installing Drive Gear to Diff Case
Fig. 33. Setting Gear Lash
Fig. 36. Tooth Contact Impressions
Fig. 37. Installing Bushing In Rear Half of Diff Case
Fig. 40. Cross-Section Showing Shims Used To Control Inter-Axle Diff End Play
Fig. 42. Installing Inter-Axle Diff Cover oil Seal
Fig. 44. Cross Section Of Idler Shaft Installation
Fig. 46. Installing Clutch Shift Collar
Fig. 48. Installing Intermediate Case To Diff Carrier
ELECTRIC SHIFT SYSTEM
LUBRICATION - TM-5-3820-256-24-5_567
TROUBLE SHOOTING - TM-5-3820-256-24-5_568
SPECIFICATIONS - TM-5-3820-256-24-5_569
TORQUE CHART - TM-5-3820-256-24-5_570
Fig. 1. S-Series Conventional Cab
Fig. 2. S-Series Cab Interior View (Typical)
SERIAL NUMBER LOCATIONS
Fig. 4. Hood Hinge Types For 200 Cm (80 Inch) Wide Cabs
Fig. 5. Custom Trimmed Door
Fig. 6. Door Hardware, Trim and Internal Components - Exploded View
Fig. 7. Door and Hinge Details
Fig. 12. Removing Rear Run Channel
Fig. 13. Removing or Installing Window Glass
Fig. 16. Door Glass Inner Seal
Fig. 19. Door Glass Regulator and Latch Details
Fig. 21. Removing Remote Control Assembly
Fig. 22. Removing Latch Assembly
Fig. 24. Removing Door Outer Handle
Fig. 26. Removing or Installing Door Striker Pin
Fig. 27. Location for Door Adjustments at Hinge Pillar
Fig. 29. Individual Drivers Seat - Custom Trim Exploded View
Fig. 30. Removing Windshield Wiper Arm
Fig. 33. Details of Windshleld Division Bar (230 cm or 90 Inch Cob Only)
Fig. 35. S-Series Cab Panels
Fig. 36. Components of Side Panel Assembly
Fig. 38 Location of MIG Weld Seams
Fig. 42. Filler Panel to Dash Panel Spot Welds
Fig. 46. Side Panel to Roof Inner Panel Spot Welds
Fig. 48. Using MIG Welder For Plug Welds
Fig. 51. Fastening Roof Panel To New Side Panel
Fig. 53. Cab Front Mounting Bracket (Left Front View)
Fig. 55. Cab Rear Mounting (230 cm - 90 inch Wide Cab)
Fig. 57. Stay Rod Details for 230 x 230 cm (90 x 90 Inch) Cob
CAB REMOVAL
TORQUE CHART - TM-5-3820-256-24-5_606
REPAIR INSTRUCTIONS USING FIBER GLASS MATERIAL
Figure 2. - Fiber Glass Mat
Figure 6. - Body Fillers
Figure 10. - Masking Undamaged Area
Figure 15. - Sanding Surface
Figure 20. - Large Fractures
Figure 21. - Opening Cracked Area
Figure 26. - Covering Repair Area with Separating Film
Figure 30. - Mat Lay-Up
Figure 35. - Sanding Backing Patch
Figure 40. - Filler Mat Lay-Up
Figure 45. - Applying Adhesive
Figure 48. - fiber Glass Mat and Cloth Patch Installation
Figure 53. - Applying Body Filler
Figure 56. - Applying Glazing Putt
S-SERIES AIR CONDITIONING- HEATER SYSTEM
Figure 5. - Heater (Only) Unit Heater Core - Exploded View
Figure 6. - Blower and Resistor
Control Unit, Switch and Cables
Figure 13. - Heater (Only) Control Unit
S-SERIES AIR CONDITIONING -- HEATER SYSTEM - cont
Figure 18. - Control Cable Adjustment - Heater Only Models
Figure 20. - Heater Core Removal - Heater Only Models
S-SERIES AIR CONDITIONING -- HEATER SYSTEM
Figure 22. - Hot Water Flow Control Valve Connections
Figure 24. - Control Assembly and Cables
BLOWER MOTOR ASSEMBLY AND FAN
Figure 27. - Blower Motor Removal
Figure 30. - Removing Relay
CONTROL CABLE REPLACEMENT - HEATER ONLY
CONTROL CABLE REPLACEMENT - HEATER ONLY - cont
TORQUE CHART - TM-5-3820-256-24-5_646
Fig. 7. Exploded View of Cam Actuated Parking Type Motor (American Bosch)
Fig. 8. Electric Windshield Wiper Motor (External View)
CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-5_652
Fig. 11. Windshield Wiper Motor Wiring Schematic
TROUBLE SHOOTING - TM-5-3820-256-24-5_654
TROUBLE SHOOTING - cont
SPECIFICATIONS - TM-5-3820-256-24-5_656
Fig. 1. Electric Windshield Wiper Components
Fig. 3. Removing Cowl Cover Panel
Fig. 4. Removing Windshield Wiper Linkage
Fig. 7. Removing Wiper Switch
SPECIFICATIONS - TM-5-3820-256-24-5_664
TROUBLE SHOOTING (ELECTRIC)
Fig. 1. Windshield Washer Installation (80" Wide Cab Shown)
Fig. 2. Pump, Motor Reservoir Assembly
TROUBLE SHOOTING - TM-5-3820-256-24-5_671
Figure 2. - Disc Front Wheel
Figure 5. - Cross Section of Inboard and Outboard Mounted Drum
Figure 9. - Disc Rear Wheel Assembly
WHEEL BEARING ADJUSTMENT
Figure 14. - Wheel Seals Used With Grease Lubricated Wheel Bearings
Figure 17. - Unitized Scot or National Seal
Figure 18. - Unitized Barrier Seal
Figure 20. - Installing Wiper Ring on Axle Shoulder
Unitized Barrier Seal
Figure 26. - Improper Installation of Guardian Oil Seal
WHEELS, RIMS AND TIRES
OIL LUBRICATED
WHEEL BEARING SEAL AND BEARING CAP DIAGNOSTIC CHART
WHEEL BEARING SEAL AND BEARING CAP DIAGNOSTIC CHART - cont
RIM, WHEELS AND TIRES
Figure 35. - Dual Disc Wheel Installation
INSTALLATION, TIGHTENING AND ALIGNMENT OF DISC WHEELS AND RIMS
Figure 40. - Disc Wheel Tightening Sequence
WHEEL AND TIRE BALANCING
BIAS AND RADIAL TIRE LOAD AND INFLATION CHART
LOW PROFILE RADIAL TIRE LOADS AND INFLATIONS
TIRE LOAD AND INFLATION CHART (MICHELIN)
TIRE LOAD AND INFLATION CHART (MICHELIN) CONTINUED
TIRE AND RIM COMBINATIONS
TORQUE CHART - TM-5-3820-256-24-5_698
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