INTRODUCTION - TM-5-3820-256-24-5_25DIAGNOSTIC ANALYSISDIAGNOSTIC ANALYSIS - cont - TM-5-3820-256-24-5_27DIAGNOSTIC ANALYSIS - cont - TM-5-3820-256-24-5_28DIAGNOSTIC ANALYSIS - cont ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_30ENGINE DIAGNOSTIC TOOLS ENGINE DIAGNOSTIC TOOLS - CONT ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_33ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_34ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_35ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_36ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_37ENGINE DIAGNOSTIC TOOLS - CONT - TM-5-3820-256-24-5_38Figure 11. Design Technology Tech-Time Model 3354 ConnectionsFigure 12. Pressure Test KitENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_41CALIBRATING THE PRESSURE TEST KITFigure 14. Smoke Sampling KitFigure 15. Orificed Restrictor Tool SE-4039Figure 16. Orificed Restrictor Tool SE-4146ENGINE DIAGNOSTIC TOOLS - TM-5-3820-256-24-5_46ENGINE PERFORMANCE ANALYSIS GUIDEENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_48ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_49ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_50ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_51ENGINE DIAGNOSTIC TEST PROCEDURES ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_53ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_54ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_55Figure 4c. Inner and Outer Throttle Lever Assembly (Without Bellcrank)ENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_57Figure 5a. Version "I" Bellcrank LinkageLINKAGE ADJUSTMENT - TM-5-3820-256-24-5_59LINKAGE ADJUSTMENT - TM-5-3820-256-24-5_60Figure 6. Shutoff TestELECTRIC SHUTOFF (AUTOMATIC SHUT-OFF)Figure 7. Electric Shut-Off Control On Robert Bosch "MW" PumpFigure 8. S-Series Electric Shut-Off WiringFigure 10. Solenoid Resistance CheckMeasure Low Idle SpeedFigure 13b. MW Throttle LeverAIR CLEANER MAXIMUM RESTRICTIONFigure 15. Top View of Dual Element Air CleanerFigure 17. Filter ScreenENGINE DIAGNOSTIC TEST PROCEDURES - TM-5-3820-256-24-5_71ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_72ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_73ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_74ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_75ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_76ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_77ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_78ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_79ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_80ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_81ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_82ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_83ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_84ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_85ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_86ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_87CHART D INTERNATIONAL SMOKE NOMOGRAPHENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_89ENGINE DIAGNOSTIC TEST PROCEDURES - cont - TM-5-3820-256-24-5_90PERFORMANCE DATA GUIDELINES - TM-5-3820-256-24-5_91PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_92PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_93PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_94PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_95PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_96PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_97PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_98PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_99PERFORMANCE DATA GUIDELINES - TM-5-3820-256-24-5_100PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_101PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_102PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_103PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_104PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_105PERFORMANCE DATA GUIDELINES - cont - TM-5-3820-256-24-5_106METRIC CONVERSION FACTOR CHARTCONVERSION TABLESSERVICE MANUAL - TM-5-3820-256-24-5_115ENGINE FEATURES ENGINE FEATURES- cont ENGINE FEATURES - cont - TM-5-3820-256-24-5_118ENGINE FEATURES - cont - TM-5-3820-256-24-5_119SAFETY SUGGESTIONSSAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_121SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_122SAFETY SUGGESTIONS - cont - TM-5-3820-256-24-5_123CONVERTION TABLETORQUE - TENSION VALUES FOR STANDARD FASTENERSTORQUE VALUES FOR HOSE CLAMPSSPECIAL SERVICE TOOL LISTGENERAL INFORMATION - SEALING COMPOUND USEAPPLICATIONENGINE APPLICATION CHARTCONSTRUCTION EQUIPMENTON HIGHWAY TRUCKOEM APPLICATIONSSPECIFICATIONS - TM-5-3820-256-24-5_134AGRICULTURAL EQUIPMENTAGRICULTURAL EQUIPMENT (Continued)AGRICULTURAL EQUIPMENT (Continued)CONSTRUCTION EQUIPMENT (Continued) - TM-5-3820-256-24-5_138CONSTRUCTION EQUIPMENT (Continued) - TM-5-3820-256-24-5_139ON HIGHWAY TRUCK (Continued) - TM-5-3820-256-24-5_140ON HIGHWAY TRUCK (Continued) - TM-5-3820-256-24-5_141OEM (Continued) - TM-5-3820-256-24-5_142OEM (Continued) - TM-5-3820-256-24-5_143OEM (Continued) - TM-5-3820-256-24-5_144SPECIAL NUT AND BOLT TORQUE DATASPECIAL NUT AND BOLT TORQUE DATA* (Continued)SERVICE DIAGNOSISPRIOR TO DISASSEMBLY OF ENGINEDURING ENGINE DISASSEMBLYDURING ENGINE REASSEMBLYENGINE START-UPPROBLEM ANALYSIS GUIDEPROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_153PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_154PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_155PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_156PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_157PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_158PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_159PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_160PROBLEM ANALYSIS GUIDE - CONT - TM-5-3820-256-24-5_161MOUNTING ENGINE ON STANDMOUNTING ENGINE ON STAND - CONT Figure 1. - Typical Turbocharger and Common PartsTURBOCHARGERS - TM-5-3820-256-24-5_165Figure 2. - Turbocharger Core AssemblyFigure 4. - Turbocharger Properly CappedFigure 5a. - Foreign Material Turbo DamageTURBOCHARGERS - CONT Figure 7. - Compressor Housing InstallationFigure 8. -- Center and Turbine Housing AlignedTURBOCHARGERS - TM-5-3820-256-24-5_173Figure 1. - Intake and Exhaust Manifold (400 Series Turbocharger for Payline Shown)*MANIFOLDSMANIFOLDS - CONT - TM-5-3820-256-24-5_176MANIFOLDS - CONT - TM-5-3820-256-24-5_177MANIFOLDS - CONT - TM-5-3820-256-24-5_178MANIFOLDS - CONT - TM-5-3820-256-24-5_179MANIFOLDS - CONT - TM-5-3820-256-24-5_180CYLINDER HEAD & VALVESCYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_182CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_183CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_184CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_185CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_186CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_187CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_188CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_189CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_190CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_191CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_192CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_193CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_194CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_195CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_196CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_197CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_198CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_199CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_200CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_201CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_202CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_203CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_204CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_205CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_206CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_207CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_208CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_209CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_210CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_211CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_212CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_213CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_214CYLINDER HEAD & VALVES - CONT - TM-5-3820-256-24-5_215VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODSVALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_217VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_218VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_219VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_220VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_221VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_222VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_223VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_224VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_225VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_226VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_227VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_228VALVE TRAIN - CAMSHAFT, TAPPETS & PUSH RODS - CONT - TM-5-3820-256-24-5_229CONNECTING RODS, PISTONS, RINGS & SLEEVESCONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_231CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_232CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_233CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_234CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_235CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_236CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_237CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_238CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_239CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_240CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_241CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_242CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_243CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_244CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_245CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_246CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_247CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_248CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_249CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_250CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_251CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_252CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_253CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_254CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_255CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_256CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_257CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_258CONNECTING RODS, PISTONS, RINGS & SLEEVES - CONT - TM-5-3820-256-24-5_259CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASECRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_261CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_262CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_263CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_264CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_265CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_266CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_267CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_268CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_269CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_270CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_271CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_272CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_273CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_274CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_275CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_276CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_277CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_278CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_279CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_280CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_281CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_282CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_283CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_284CRANKSHAFT, MAIN BEARINGS, FLYWHEEL & CRANKCASE - CONT - TM-5-3820-256-24-5_285TIMING, GEAR TRAIN & FRONT COVERTIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_287TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_288TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_289TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_290TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_291TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_292TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_293TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_294TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_295TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_296TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_297TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_298TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_299TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_300TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_301TIMING, GEAR TRAIN & FRONT COVER - CONT - TM-5-3820-256-24-5_302LUBRICATING OIL PUMP, OIL FILTERS & COOLERLUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_304LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_305LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_306LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_307LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_308LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_309LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_310LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_311LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_312LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_313LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_314LUBRICATING OIL PUMP, OIL FILTERS & COOLER - CONT - TM-5-3820-256-24-5_315WATER PUMP, THERMOSTAT & IDLER PULLEYSWATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_317WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_318WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_319WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_320WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_321WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_322WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_323WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_324WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_325WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_326WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_327WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_328WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_329WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_330WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_331WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_332WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_333WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_334WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_335WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_336WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_337WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_338WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_339WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_340WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_341WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_342WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_343WATER PUMP, THERMOSTAT & IDLER PULLEYS - CONT - TM-5-3820-256-24-5_344ROBERT BOSCH MODEL MW INJECTION PUMPROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_346ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_347ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_348ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_349ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_350ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_351ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_352ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_353ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_354ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_355ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_356ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_357ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_358ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_359ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_360ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_361ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_362ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_363ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_364ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_365ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_366ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_367ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_368ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_369ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_370ROBERT BOSCH MODEL MW INJECTION PUMP - CONT - TM-5-3820-256-24-5_371NOZZLES - TM-5-3820-256-24-5_372NOZZLES - CONT - TM-5-3820-256-24-5_373NOZZLES - CONT - TM-5-3820-256-24-5_374NOZZLES - CONT - TM-5-3820-256-24-5_375FORWARD - TM-5-3820-256-24-5_377INTRODUCTION - TM-5-3820-256-24-5_378Figure 1. Robert Bosch Model MW Fuel Injection PumpFigure 3. Four Principle Plunger Positions of Injection CycleFigure 4. Fuel System FlowFigure 5. Helix and Charging Port Metering PositionsFigure 7. Cut-Away View of Governor AssemblyFigure 8. Exploded View of Fuel Injection Nozzle and Holder AssemblyPUMP SPECIFICATIONSTOOLSGENERALFigure 9. TorqueFigure 1. Injection Pump Mounted in Holding FixtureFigure 4. Exploded View of Pump HousingLegend for Figure 57Figure 5. Exploded View of GovernorLegend for Figure 58Figure 7. Aneroid AssemblyFigure 9. Removing Guide PinFigure 13. Removing Guide BushingFigure 19. Removing Side PlugsFigure 23. Installing Tappet HolderFigure 24. Camshaft RemovalFigure 28. Rack PositioningFigure 32. Exploded View of AneroidFigure 33. Exploded View of Fuel Supply PumpCLEANING AND INSPECTION - TM-5-3820-256-24-5_404Figure 2. Checking Flyweight Trail Build-UpFigure 3. Exploded View of Flyweight SpringsFigure 7. Old vs. New Fuel Return Hose with Orifice FittingFigure 3. Install Plunger RetainersFigure 4. Control Sleeve Ball PositioningFigure 7. Tappet PositioningFigure 9. Install Drive End Bearing PlateFigure 10. Installing Flyweight AssemblyFigure 13. Basic Setting of S-PlateFigure 16. Accelerator Lever AssemblyFigure 18. Rack Link and Stop Shackle in Excess FuelINJECTION PUMP CALIBRATIONFigure 2. Installing Dial Indicator (Rack Gauge)Figure 4. Inserting Adjusting SpacersFigure 6. Making Preliminary Governor Cut-Off AdjustmentFigure 7. Adjusting Hi-Idle Rack PositionFigure 8. Adjusting Lo-ldle PositionFigure 10. Adjusting Aneroid CutbackFigure 11. Adjusting External Stop BracketCheck Start Fuel QuantityINJECTION PUMP AND ENGINE TEST DATACALIBRATION DATAFig. 2. Air Being Forced Into EngineFig. 4. Turbocharger CycleFig. 5. Air and Exhaust Flow In Turbocharged EngineGENERAL MAINTENANCE AND CLEANING PROCEDURESFig. 7. DT-466 Turbocharger (Exploded View)Fig. 8. Checking Axial End PlayFig. 11. Related Positions of PartsFig. 13. Removing Center Housing From Turbine HousingFig. 16. Separating Compressor Wheel From Turbine ShaftSERVICE MANUAL - TM-5-3820-256-24-5_447TURBINE WHEEL AND SHAFTDT-466 TURBOCHARGERDT-466 TURBOCHARGER - CONT SPECIFICATIONS - TM-5-3820-256-24-5_451TORQUE CHART - TM-5-3820-256-24-5_452TROUBLE SHOOTING - TM-5-3820-256-24-5_453COOLING SYSTEM - TM-5-3820-256-24-5_456COOLING SYSTEM - CONT - TM-5-3820-256-24-5_457COOLING SYSTEM - CONT - TM-5-3820-256-24-5_458COOLING SYSTEM - CONT - TM-5-3820-256-24-5_459COOLING SYSTEM - CONT - TM-5-3820-256-24-5_460COOLING SYSTEM - CONT - TM-5-3820-256-24-5_461COOLING SYSTEM - CONT - TM-5-3820-256-24-5_462Figure 5. - Using Hydrometer to Test Anti-freeze SolutionCOOLING SYSTEM - CONT - TM-5-3820-256-24-5_464COOLING SYSTEM - CONT - TM-5-3820-256-24-5_465SPECIFICATIONS - TM-5-3820-256-24-5_468Driver InstructionsTransmission LubricationGeneral Precautions for DisassemblyRemote ControlSHIFTER HOUSINGSHIFTER HOUSING - CONT - TM-5-3820-256-24-5_474SHIFTER HOUSING - CONT - TM-5-3820-256-24-5_475CASEGEAR & CASE - TM-5-3820-256-24-5_477GEAR & CASE - CONT - TM-5-3820-256-24-5_478GEARS & RELATED PARTSMAINSHAFTMAINSHAFT - CONT - TM-5-3820-256-24-5_481MAINSHAFT - CONT - TM-5-3820-256-24-5_482MAINSHAFT - CONT - TM-5-3820-256-24-5_483MAINSHAFT - CONT - TM-5-3820-256-24-5_484INSPECTION PROCEDURES & TORQUE SPECIFICATIONSINPUT GEARGEAR & CASE - TM-5-3820-256-24-5_487GEAR & CASE - CONT - TM-5-3820-256-24-5_488TROUBLESHOOTING - TM-5-3820-256-24-5_489TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_490TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_491TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_492TROUBLESHOOTING - CONT - TM-5-3820-256-24-5_493OPERATING INSTRUCTIONSLUBRICATION - TM-5-3820-256-24-5_501Recommended LubricantsTRANSFER CASE REMOVAL & INSTALLATIONTRANSFER CASE DISASSEMBLYShift Shaft DisassemblyInput Shaft DisassemblyFront Output Shaft RemovalCLEANING AND INSPECTION - TM-5-3820-256-24-5_508TRANSFER CASE ASSEMBLYAssembly of Front Output ShaftInstallation of Rear Output ShaftInstallation of the Intermediate ShaftInstallation of the Intermediate Shaft - CONT - TM-5-3820-256-24-5_513Installation of the Intermediate Shaft - cont - TM-5-3820-256-24-5_514Input Shaft AssemblyAir Shifter Shaft InstallationAir Shifter Shaft Installation - cont Manual Shifter Shaft InstallationAssembly of PTO UnitAssembly of PTO Unit - cont Final AssemblyTORQUE SPECIFICATIONS - TM-5-3820-256-24-5_522PARTS MANUALShafts, Gear, Bearings, Spacers, Seals, Carriers and Caps FRONT OUTPUT SHAFTREAR OUTPUT SHAFTINTERMEDIATE SHAFTINPUT SHAFTAIR OPERATED H-U AND H-N-UH-U Air ShiftMANUAL H-N-U SHIFTAIR OPERATED FRONT DRIVE DECLUTCHMANUAL FRONT DRIVE DECLUTCHPTOAIR OPERATED PTO SHIFTMANUAL PTO SHIFTOil Lines & Fittings - PTOFig. 1. IH Single Reduction Tandem Rear AxleFig. 2. Power Divider and Diff Carrier In Rebuild StandFig. 4. Removing Inter-Axle DiffFig. 7. Removing Inter-Axle Differential From CoverFig. 11. Removing Clutch Shift CollarFig. 13. Removing Idler Shaft and GearFig. 15. Removing Differential Bearing CapsFig. 19. Drive Gear Rivet RemovalFig. 22. Removing Pinion End Nut (Rear Rear Shown)Fig. 23. Forward Rear Axle (Exploded View)SERVICE MANUAL - TM-5-3820-256-24-5_552Fig. 24. Rear Rear Axle (Exploded View)CLEANING, INSPECTION AND REPAIR - TM-5-3820-256-24-5_554Preload Pinion BearingFig. 30. Installing Step PlateFig. 32. Installing Drive Gear to Diff CaseFig. 33. Setting Gear LashFig. 36. Tooth Contact ImpressionsFig. 37. Installing Bushing In Rear Half of Diff CaseFig. 40. Cross-Section Showing Shims Used To Control Inter-Axle Diff End PlayFig. 42. Installing Inter-Axle Diff Cover oil SealFig. 44. Cross Section Of Idler Shaft InstallationFig. 46. Installing Clutch Shift CollarFig. 48. Installing Intermediate Case To Diff CarrierELECTRIC SHIFT SYSTEMLUBRICATION - TM-5-3820-256-24-5_567TROUBLE SHOOTING - TM-5-3820-256-24-5_568SPECIFICATIONS - TM-5-3820-256-24-5_569TORQUE CHART - TM-5-3820-256-24-5_570Fig. 1. S-Series Conventional CabFig. 2. S-Series Cab Interior View (Typical)SERIAL NUMBER LOCATIONSFig. 4. Hood Hinge Types For 200 Cm (80 Inch) Wide CabsFig. 5. Custom Trimmed DoorFig. 6. Door Hardware, Trim and Internal Components - Exploded ViewFig. 7. Door and Hinge DetailsFig. 12. Removing Rear Run ChannelFig. 13. Removing or Installing Window GlassFig. 16. Door Glass Inner SealFig. 19. Door Glass Regulator and Latch DetailsFig. 21. Removing Remote Control AssemblyFig. 22. Removing Latch AssemblyFig. 24. Removing Door Outer HandleFig. 26. Removing or Installing Door Striker PinFig. 27. Location for Door Adjustments at Hinge PillarFig. 29. Individual Drivers Seat - Custom Trim Exploded ViewFig. 30. Removing Windshield Wiper ArmFig. 33. Details of Windshleld Division Bar (230 cm or 90 Inch Cob Only)Fig. 35. S-Series Cab PanelsFig. 36. Components of Side Panel AssemblyFig. 38 Location of MIG Weld SeamsFig. 42. Filler Panel to Dash Panel Spot WeldsFig. 46. Side Panel to Roof Inner Panel Spot WeldsFig. 48. Using MIG Welder For Plug WeldsFig. 51. Fastening Roof Panel To New Side PanelFig. 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) CobCAB REMOVALTORQUE CHART - TM-5-3820-256-24-5_606REPAIR INSTRUCTIONS USING FIBER GLASS MATERIALFigure 2. - Fiber Glass MatFigure 6. - Body FillersFigure 10. - Masking Undamaged AreaFigure 15. - Sanding SurfaceFigure 20. - Large FracturesFigure 21. - Opening Cracked AreaFigure 26. - Covering Repair Area with Separating FilmFigure 30. - Mat Lay-UpFigure 35. - Sanding Backing PatchFigure 40. - Filler Mat Lay-UpFigure 45. - Applying AdhesiveFigure 48. - fiber Glass Mat and Cloth Patch InstallationFigure 53. - Applying Body FillerFigure 56. - Applying Glazing PuttS-SERIES AIR CONDITIONING- HEATER SYSTEMFigure 5. - Heater (Only) Unit Heater Core - Exploded ViewFigure 6. - Blower and ResistorControl Unit, Switch and CablesFigure 13. - Heater (Only) Control UnitS-SERIES AIR CONDITIONING -- HEATER SYSTEM - cont Figure 18. - Control Cable Adjustment - Heater Only ModelsFigure 20. - Heater Core Removal - Heater Only ModelsS-SERIES AIR CONDITIONING -- HEATER SYSTEMFigure 22. - Hot Water Flow Control Valve ConnectionsFigure 24. - Control Assembly and CablesBLOWER MOTOR ASSEMBLY AND FANFigure 27. - Blower Motor RemovalFigure 30. - Removing RelayCONTROL CABLE REPLACEMENT - HEATER ONLYCONTROL CABLE REPLACEMENT - HEATER ONLY - contTORQUE CHART - TM-5-3820-256-24-5_646Fig. 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_652Fig. 11. Windshield Wiper Motor Wiring SchematicTROUBLE SHOOTING - TM-5-3820-256-24-5_654TROUBLE SHOOTING - cont SPECIFICATIONS - TM-5-3820-256-24-5_656Fig. 1. Electric Windshield Wiper ComponentsFig. 3. Removing Cowl Cover PanelFig. 4. Removing Windshield Wiper LinkageFig. 7. Removing Wiper SwitchSPECIFICATIONS - TM-5-3820-256-24-5_664TROUBLE SHOOTING (ELECTRIC)Fig. 1. Windshield Washer Installation (80" Wide Cab Shown)Fig. 2. Pump, Motor Reservoir AssemblyTROUBLE SHOOTING - TM-5-3820-256-24-5_671Figure 2. - Disc Front WheelFigure 5. - Cross Section of Inboard and Outboard Mounted DrumFigure 9. - Disc Rear Wheel AssemblyWHEEL BEARING ADJUSTMENTFigure 14. - Wheel Seals Used With Grease Lubricated Wheel BearingsFigure 17. - Unitized Scot or National SealFigure 18. - Unitized Barrier SealFigure 20. - Installing Wiper Ring on Axle ShoulderUnitized Barrier SealFigure 26. - Improper Installation of Guardian Oil SealWHEELS, RIMS AND TIRESOIL LUBRICATEDWHEEL BEARING SEAL AND BEARING CAP DIAGNOSTIC CHARTWHEEL BEARING SEAL AND BEARING CAP DIAGNOSTIC CHART - cont RIM, WHEELS AND TIRESFigure 35. - Dual Disc Wheel InstallationINSTALLATION, TIGHTENING AND ALIGNMENT OF DISC WHEELS AND RIMSFigure 40. - Disc Wheel Tightening SequenceWHEEL AND TIRE BALANCINGBIAS AND RADIAL TIRE LOAD AND INFLATION CHARTLOW PROFILE RADIAL TIRE LOADS AND INFLATIONSTIRE LOAD AND INFLATION CHART (MICHELIN)TIRE LOAD AND INFLATION CHART (MICHELIN) CONTINUEDTIRE AND RIM COMBINATIONSTORQUE CHART - TM-5-3820-256-24-5_698