1-3 ORDNANC MAINTNANC-POWR PLANT, CLUTCH, AND LCTRICAL SYSTM-_) AND lt TON VHICLS (DODG) CHAPTR 1 INTRODUCTION Paragraph Purpose and scope... 1 References... 2 Arrangement of manual... 3 Distinguishing characteristics of materiel... 4 Organization maintenance... 5 Tool equipment... 6 1. PURPOS AND SCOP a. This manual is published for the information and guidance of Ordnance maintenance personnel. It contains maintenance information on the engine assembly, clutch and electrical system (fig. 1) of the Dodge J/i ton 4 x 4 and 1 i/z ton 6 x 6 basic vehicles. Maintenance instructions are supplementary to those contained in the Operator s Manua!s TM 9-808, TM 9-750A and TM 9-8 10 published for the using arma. b. In addition to the instructions contained in this manual on carburetors, maintenance information is also contained in TM 9-1826A for the Carter carburetor and TM 9-1826C for the Zenith carburetor. c. Another manual, TM 9-1808B, contains maintenance information on the power train and chassis of these vehicles. 2. RFRNCS a, Standard nomenclature lists and other publications applicable to the materiel described in this manual are listed in Chapter IV. 3. ARRANGMNT OF MANUAL a. The manual is arranged as follows: ( 1) CHAPTR 1. Contains information to help identify the matenel on which maintenance information is given. It also contains general information on maintenance terms used and tool equipment specified for servicing, repairing and rebuilding the materiel. (2 ) CHAPTR 2. Concerns the engine and components (including the clutch), beginning with general description and function of parts and specifications and data. ngine trouble shooting and repairs which may be made with the engine in the truck are treated next, followed by removal and complete disassembly of the engine and components. Inspection and repair of engine components, reassembly and installation of the engine in the truck, and finally a chart of engine fits and tolerances completes Chapter 2. 4
3-4 INTRODUCTION (3) CHAPTR 3. Concerns the electrical system which is divided into sections containing information on the starting system, generating system and ignition system. It contains electrical trouble shooting information, rebuilding instructions and a table of fits and tolerances for electrical units. Wiring circuit diagrams show all electrical circuits of the vehicles. MO maintenance information is given covering the lighting system, replacement of wiring, or miscellaneous eiectrical equipment, as these subjects are treated fully in TM 9-808 and TM 9:8I0. U.S.A. RGISTRATION NUMBR AND ON TH RAR OF SOM BODIS Figure 2-U. 5. A. Registration Numbers RA PD 53212 (4) CHAPTR 4. Contains a list of special tools. Chapter 4 is followed by a list of references to other publications applicable to the materiel described. (5) CARTR CARBURTOR SUPPLMNT. A supplement has been added to the back of this manual containing maintenance instructions on the Carter TW 1 carburetor with which later model vehicles are equipped. 4. DISTINGUISHING CHARACTRISTICS OF MATRIL a. General. The 3/4 ton, 4 x 4 basic vehicles are manufactured in different models for various tactical uses. The electrical systems of the various models differ insofar as the voltage output is concerned, however, to provide for the installation of radio equipment in certain body styles. The 1% ton, 6 x 6 vehicle is manufactured in one body!i
4 ORDNANC MAINTNANC-POWR PLANT, CLUTCH, AND LCTRICAL SYSTM-~ AND 13 TON VHICLS (DODG) style with a 6-volt electrical system identical to that used in 3/4 ton 4 x 4 models equipped with t-volt systems. The electrical system is explained in paragraphs 79 through 85. The stripped engine and components is identical in all 3/4 ton, 4 x 4 and 1 r/z ton, 6 x 6 models. b. U. S. A. Registration hmbere (fig. 2 ). The following tabulation of U. S. A. registration numbers is given to help identify the materiel described in this manual. Operator s Manuals TM Q-808, TM 9-720A and TM 9-810 contain pictures of the various models listed below: Model Body Style WC-5 1 Weapon carrier (3/ ton,4x4) WC-52 Weapon carrier with winch (3/4 ton, 4 x 4) WC-53 Command field sedan (3$ ton, 4 x 4) WC-53 Carryall ( 3/4 ton, 4 x 4) WC-54 Ambulance (Vi ton, 4 x 4) WC-S5 37mm. gun motor carriage M6 (3/4 ton,4x4) WC-56 Command ( 3/4 ton, 4 x 4) WC-57 Command with winch (j/4 ton,4x4) WC-58 Radio (a/4 ton, 4 x 4) WC-59 Telephone maintenance (L.I.U. body) (% ton, 4 x 4) 6 U. 5. A. Registration Numbers 252293 to 254792 (in&) 259135 to 289212 (incl.) 291910 to 291992 (incl.) 293685 to 294209 (incl,) 2110000 to 2125113 (in&) 2232075 to 2233424 (incl.) 245845 to 246394 (incl.) 289213 to 291384 (incl.) 291993 to 292512 (incl,) 2160419 to 2179292 (incl.) 2180276 to 2199555 (incl.) 2092777 to 2092778 (incl.) 2072128 to 2073327 (incl.) 20163146 to 20167956 (incl.) 2089952 to 2091083 (incl.) 2089 176 to 2089947 (incl.) 2080156 to 2089175 (incl.) 20260793 to 20261257 (in&) 77841 to 79999 (in&) 710000 to 719045 (incl.) 750068 to 750083 (incl.) 721000 to 732635 (in&) 6016072 to 6021066 (incl). 6022453 to 6022837 (in&) 20167957 to 20182608 (in&) 2091084 to 2091983 (incl.) 20184953 to 20185868 (incl.) 2092119 to 2092618 (incl.) 20291158 to 20295751 (in&) 20182690 to 20184952 (incl.) 0015366 to 0015914 (in&)
TM 9.1808A 4-5 Model Body Style WC-60 mergency (3/4 ton, 4 x 4) repair chassis WC-6 1 Telephone maintenance (body model 4551) (3/s ton, 4 x 4) WC-62 Personnel and cargo (1% ton, 6 x 6) JNTRODUCTION U. 5. A. Registration Numbers 0015915 to 0015986 (incl.) 0026383 to 0026606 (incl.) 0051312 to 0051369 (incl.) 3297503 to 3328846 (incl.) WC-63 Personnel and cargo with 3328847 to 3342502 (in&) winch ( 1 r/2 ton, 6 x 6) 5. MAINTNANC ALLOCATION. a. Scope. The scope of maintenance and repair by the crew and other units of the using arms is determined by the availability of suitable tools, availability of necessary parts, capabilities of the mechanics, time available, and the tactical situation. All of these are variable and no exact system of procedure can be prescribed. h. Allocation of Maintenancre. Indicated below are the maintenance duties for which tools and parts have been provided for the.using arm and ordnance maintenance personnel. Replacements and repairs which are the responsibility of ordnance maintenance personnel may be performed by using arm personnel when circumstances permit, within the discretion of the commander concerned. chelons and words as used in this list of maintenance allocations are defined as follows: Line organization regiments, battalions, companies, detachments, and separate companies. THIRDCHLON: FOURTH CHLON: FIFTH CHLON: SRVIC (including preventive maintenance) : Refer to AR 850-15, paragraph 23 a ( 1) and (2). Ordnance light maintenance companies, ordnance medium maintenance companies, ordnance divisional maintenance battalions, and post ordnance shops. Ordnance heavy maintenance companies, and service command shops. Ordnance base regiments, ordnance bases, arsenals, and manufacturers plants. Consists of servicing, cleaning, lubricating, tightening bolts and nuts, and making external adjustments of subassemblies or assemblies and controls. 7
5 ORDNANC MAINTNANC-POWR PLANT, CLUTCH, AND LCTRICAL SYSTM-O AND 14 TON VHICLS (PODG) RPLAC: Refer to Consists of removing the part, sub- AR 8.50-15, paragraph assembly or assembly from the vehi- 23 a (4). cles and replacing it with a new or reconditioned or rebuilt part, subassembly or assembly, whichever the case may be. RPAIR: Refer to Consists of making repairs to, or re- AR 850-15, paragraph placement of the part, subassembly or 23 a (3) and (S), in assembly that can be accomplished part. without completely disassembling the subassembly or assemblies, and does not require heavy welding, or riveting, machining, fitting and/or alining or balancing. RBUILD: Refer to Consists of completely reconditioning AR 850-15, paragraph and replacing in serviceable condition 23 a (5) in part, any unserviceable part, subassembly and (6). or assembly of the vehicle, including welding, riveting, machining, fitting, alining, balancing, assembling and testing. e. The following chart indicates maintenance allocation for only those components of the vehicle, the maintenance of which is covered in this manual. For a complete chart of the maintenance duties for a specific vehicle, refer to the pertinent 100-series Technical Manual. CHLONS CLUTCH 2nd 3rd 4th 5th Clutch-replace.,. Clutch-repair. _. Clutch-rebuild.,.,.. Controls and linkage-service and;or replace. Controls and linkage-repair,., Housing, ciutch-replace, Housing. clutch-rebuild, NOT: Operations allocated will normally be performed in the echelon indicated by. Operations allocated to the echelons as indicated by may be accomplished by the respective echelons in emergencies only. NOT: < The second echelon is authorized to remove and reinstall items marked by an asterisk. However. when it is necessary to replace an item marked by an asterisk with a new or rebuilt part, sub-assembly or unit assembly, the assembly marked by an asterisk may be removed from the vehicle by the second echelon only after authority has been obtained from a high echelon of maintenance. s
COOLING IN IRODUCTION GROUP Connections-replace... Radiator assembly-replace... Radiator assembly-repair... Radiator assembly-rebuild... System, cooling-service... Tank, surge--replace... Tank, surge--repair..... i; P x_ 2 nd x., CHLON: 7 ii - 4th G - LCTRICAL GROUP Battery -service, recharge and/or replace... Battery-tepair... Battery-rebuild... Cables, battery--replace and/or repair... Coil, ignition-replace... Horn assembly-service and/or replace... Horn assembly-repair... Lamp assemblies-service and/:or replace... Lamp assemblies-repair... Regulator, current and voltage-replace... Regulator, current and voltage-service and/or repair... Regulator, current and voltage-rebuild... Switch assemblies-replace... Switch assemblies-repair... Wiring-replace... I. */ * NGIN Bearings, connecting rod (inserts)-replace... kearings, crankshaft (inserts)-replace... *. Belt-service and /or replace.... Block, cylinder-rebuild (recondition)... * Carburetor assembly-service and/or replace _ I. Carburetor assembly-repair... Carburetor assembly-rebuild... Chain, timing-replace... Cleaner, air-service and/or replace... Cleaner, air-repair... Condenser, distributor--replace... Controls and linkage-service and/or replace. Controls and linkage-repair... Crankshaft-rebuild (recondition)... Distributor assembly-service and/or replace Distributor assembly-repair... Distributor assembly-rebuild... 9 *. *.../. *.. *
5 ORDNANC MAINTNANC-POWR PLANT, CLUTCH, AND LCTRICAL SYSTM-3 AND if TON VHICLS (DODG) r - CHLONS -!nd G z- - -iftx *ngine assembly-replace... ngine assembly-repair... ngine assembly-rebuild... Fan assembly-replace... Fan assembly-repair... Fan assembly-rebuild... Filter assembly, oii-service or replace cartridge Filter assembly, oil-replace... Filter assembly, oil-repair... Flywheel assembly-replace and/or repair... Flywheel assembly-rebuild (recondition)... Gaskets, cylinder head, manifold and oil panreplace... Generator assembly-replace... Generator assembly-repair... Generator assembly-rebuild... Governor assembly-adjust and/or replace... Governor assembly-rebuild... Head, cylinder-replace and/or repair... Lines and connections, oil (external)-replace and/or repair... Lines and connections, oil (internal)-replace and/or repair... Manifolds-replace... Manifolds-rebuild... Motor assembly, starting-replace... Motor assembly, starting-repair... Motor assembly, starting-rebuild... Pan assembly, oil-service and replace gaskets. Pan assembly, oil-replace and/or repair... Pistons and rings-replace... Plugs, spark-service and/or replace... Plugs, spark (two piece)-repair... Points, breaker, distributor-replace... Pump assembly, fuel-service and/or replace. Pump assembly, fuel-repair... Pump assembly, fuel-rebuild... Pump assembly, oil-replace and/or repair... Pump assembly, oil-rebuild... Pump assembly, water-replace... Pump assembly, water-repair... Pump assembly, water-rebuild....- *See Note on Page 8. IO - -I 1 ah