NVI
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
MAINTENANCE MANUAL
GRADER, ROAD, MOTORIZED: DIESEL ENGINE
DRIVEN; 13,300 LB. PRESSURE AT BLADE; 12
FT. BLADE; 6 WHEELS, 4 DRIVING, 2 STEERABLE;
LEANING FRONT WHEELS; W SCARIFIER
(LETOURNEAU-WESTINGHOUSE MODEL 440HA)
FSN 3805-931-7881
This copy is a reprint which includes current
pages from Change 6
HEADQUARTERS, DEPARTMENT OF THE ARMY
MARCH 1967
SAFETY PRECAUTIONS
OPERATION
Before driving motor grader from the trans-
porter, be sure there is enough ground clear-
ance when negotiating the ramp.
Do not store acid-type batteries near stacks
of tires; the acid fumes have a harmful effect
on rubber.
Use care when removing blocking and straps
so as not to damage motor grader.
When motor grader is to be used only in
warm climates, remove container from cold
weather starting aid. Inadvertent injection
of the highly volatile fluid into the air intake
of a warm engine could result in serious
damage to the engine when started.
DURING OPERATION
If changing direction of travel, bring motor
grader to complete stop before shifting.
When using cold weather starting aid, do
not pull primer knob until cranking action
starts. Serious damage to the engine could
result.
AFTER OPERATION
Before servicing any part of the motor
grader electrical system, make certain that the
battery disconnect switch is disengaged.
When removing battery cables, disconnect
the ground cable first. When installing battery
cables, connect the ground cable last. Any
short circuit of the batteries can cause painful
burns to personnel and damage to tools. A
short circuited battery may explode and spray
hot acid over the surrounding area.
Change in force: C 6
TM 5-3805-237-12
*CG
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D. c.,Ji Mai/ 1974
Operator and Organizational Maintenance Manual
GRADER, ROAD, MOTORIZED: DIESEL ENGINE DRIVEN;
13,300 LE. PRESSURE AT BLADE; 12 FT. BLADE;
6 WHEELS, 4 DRIVING, 2 STEERABLE;
LEANING FRONT WHEELS; W/SCARIFIER
(LeTOURNEAU-WESTINGHOUSE MODEL 440HA)
FSN 3805-931-7881
TM 5-3805-237-12, 16 March 1967, is changed as
follows:
Page 1-1. Paragraph 1-1 is superseded as follows:
1-1. Scope, a. This manual contains instructions
for the use of operator and organizational person-
nel maintaining the motorized road grader as
allocated by the Maintenance Allocation Chart. It-
provides information on the operation, lubrica-
tion, preventive maintenance checks and services
and maintenance of the equipment, accessories
and components. This manual also includes
instructions on shipment.
b. You can help to improve this manual by
calling attention to errors and by recommending
improvements. Your letter or DA Form 2028
(Recommended Changes to Publications and
Blank Forms) should be mailed direct to: Com-
mander, US Army Troop Support Commander
attn: AMSTS-MPP, 4300 Goodfellow Blvd, ST
Louis, MO 63120. A reply will be furnished direct to
you.
Page 1-4. Paragraph b (3)OV is added after/; (
(j) Hydraulic
Pumps
Manufacture. 1 ! 1
Typo
Ro.lief valve pressure
(high idle)
Steering
Moldbourd
Hydroco
(Jour typo,
ur driven
1150 to 1200 psi
1200 psi
Page 1-5. Figure 1-3 is superseded as follows:
"This change supersedes C 1, 15 March 1%H, (' 2, 7 January- 1969, (' 3, 19 January 1970, (' 4, f> May 1971 and C 5, 9 May 1972.
A
Page 2-6. Figure 2-2 is superseded as follows:
' V,l. iT HANOI I
'AM.': f- ; ON HO! p'
f A { . ; ,')*( K. O*i'
. A !
Controls awl ituttrumcntH -~ continued.
Page 2-8. Paragraph 2-146 (4). Delete the first word
"slowly" and add the following after the last
sentence of the note: "Do not ride the clutch
pedal".
Page 3-1. Paragraph S-4c is superseded as follows:
c. Points of Imbrication. Follow the detailed
lubrication given on the current lubrication order,
LO 5-3805-237-12. Always apply lubricants
specified on the current lubrication order.
Paragraph 3-4d is superseded as follows:
d. Refer to LO &-3805-237-12 for localized
lubrication points.
Page 3-2 through page 3-13. Figure 3-2 (1) through
3-2 (12) is rescinded.
Page 3-14. Paragraph 3-4# is superseded as
follows:
g. Air cleaner service. Refer to figure 3-5 and
service the air cleaner. To clean, blow out
cartridge from clean air side with a jet of low
pressure, clean, dry, compressed air.
Add the following note after paragraph 3-4/i:
NOTE
Keep the air cleaner under close surveil-
lance, especially under adverse condi-
tions as the air cleaner cartridge can
become clogged within four hours.
Page 3-14. Figure 3-5 is superseded as follows:
MM...* i. .iU'jT cut . .MS ! . <L: 5 A*. ciiP
A? ;D r.-'.'jf f.T BY AIPM.O Cl.lAti V.ITH
CiOTM. CHLO AI-: n.r\r-u.;: r .:MC:AT'..;%
!f- 'f;!> IMJFJN 'MStiS I* ; I M' .. ! K.DICA-
TG- 1 , -U-Fl ACi: fll T; :: ^ C A"! - ! [iGf , ^.MOVI
DUST CUP, : 'EMv/. E THT'/B SC : -t.'.S AND
CAi-.-T'MnGE E 1 . P-'Y 250 HOURS, REGARD-
Figure 3-5. Air cleaner service.
Page 3-19. Figure 3-8 (1) is superseded as follows:
PREVENTIVE MAINTENANCE SERVICES
QUARTERLY
TM 5-3805-237-12
LETOURNEAU-WESTINGHOUSE MODEL 440HA
(is;
MOTOR GRADER
LUBRICATE IN ACCORDANCE WITH CURRENT LUBRICATION ORDER
ITEM
PAR REF
FUEL FILTER AND STRAINER. Inspect filter and strainer far insecure mounting and leaks at connecHons.
Check fuel lines for leaks and damage. Drain water and sediment from shells. Install new filter and
strainer elements .
EUEl TANK. Check for loose mounting and tighten if necessary. Check for leaking tank and replace if
necessary. Check cap and vent. Replace cap gasket if necessary. Clean cap vent. Inspect fuel lines
for leaks and damage. Clean fuel strainer at tank outlet.
AIR CLEANER. Check the air cleaner for serviceable condition. Replace defective air
cleaner.
M E C H A N j C A L _Q_QV Ejtj^l OJjj_. Check governor linkage for free movement and correct operation. Oil
linkage at joints .
CRANKCASE O|L LV|L QAGJL Check oil level. Add oil as necessary. Reference current L.O.
.t Check oil lines for leaks and damage.
FUJEL PUMP . Check fuel lines for leaks and damage. Check fuel pump for loose mounting and damage.
Check fuel flow .
3-9
3-41
3-4
3-43
3-4
3-4
3-40
ML 3805-237-12 3-8 (T) C6
,7-tf (1). Quarterly /wwrtiw inaintcmnifc n
Page 3-20. Figure 3-8 (2) is superseded as follows:
ITEM
F
AR REF
8
INJECTOR NOZZLE AND HOLDER ASSEMBLIES. Check nozzle and holder and lines for leaks and
3-40
damage .
9
WATER PUMP. Inspect pump for leaks and loose mounting.
3-50
10
RADIATOR. Check for proper coolant level. Replace cracked or frayed hose. Replace leaking radi-
ator. Clean air passages. Tighten all mountings and leaking connections . Check radiator cap far
proper pressure .
3-48
11
CLUTCH. Check clutch pedal and linkage operation. Adjust if necessary. Free play
should be approximately 2 inches.
3-39
12
FAN BELT. Check fan belt deflection. Correct deflection is 1/2 to 3/4-inch midway between pulleys.
3-10
Adjust if necessary. Replace worn or stretched belts.
13
GENERATOR. Tighten loose mounting and electrical connections. Check regulator mounting and
3-51
connections. Replace defective generator or regulator.
14
STARTER. Tighten loose mounting and electrical connections. Replace defective starter.
3-53
15
LIGHTS. Check runninq lights and floodlights for loose connections and damage. Replace defective
3-56
lamp units or lights .
BATTERIES.. Tiahten loose cables and mounting. Clean corrosion from cables and
16
batteries. Clean vent holes in filler caps. Perform a hydrometer test. Replace a
weak, cracked, or ieakmq battery.
3-58
17
TIRES. Inspect tires for leaks and damage. Replace damaged tires.
3-67
18
BREATHERS. Clean breathers or replace damaged breathers.
3-62
19
BRAKE CYLINDERS. Inspect lines and cylinders for leaks. Replace defective cylinders and lines.
3-66
20
HYDRAULIC RESERVOIR. Inspect reservoii for leaks, damage and loose mounting. Tighten loose con-
3-68
nections and mountings. Replace defective reservoir and lines. Replace filter elements.
21
GEAR BOXES. Inspect gear boxes and shafts for leaks and damage. Inspect control levers for damage.
T-74
Replace defective shafts or control levers.
22
TIE-ROD ENDS. Inspect tie-rod ball ends for correct adjustment.
23
EXHAUST SYSTEM. Check exhaust system for leaks and damage. Replace damaged or defective parts.
3-45
24
CONTROLS. Start engine and operate all vehicle controls. Check, for proper operation. Adjust if
9 10
necessary.
25
INSTRUMENTS. Inspect instruments for damage and insecure mounting. Replace defective instruments.
Normal operating ranges for instruments are as follows:
Ammeter Charge range
Oil Pressure 30-60 psi
Coolant Temperature 160-185F
NOTE 1 . OPERATIONAL TEST. During operation observe for any unusual noises or vibrations.
NOTE 2. ADJUSTMENTS. Make all adjustments during operational test .
^Blf
ME 3805-237- 1 2/3-8 @ C 6
f
-}-x < ,'). Quartivlii prcwntirc imiiiitciunice .wrw
(Cont'd).
Page 3-21. Figure 3-9 is superseded as follows:
NOTE- DRAIN WATER ANI* SEDIMENT ROM Hilt- ANL'; ,I- Ai'tf;.-
DAII y.
STEP i . D R A. l N F I L T R O R S T fc A i N H .
STEP 2. REMOVE COVER SCREW.
STEP 3. REMOVE SHELL FROM FILTER COVER. REMOVE GAS* I T I- v
COVER .
STEP 4, REMOVE FILTER OR STAINEK ELEMENT *WOM SHEU .
STEP 5. CLEAN SHfi l AtTH AN APPROVED ClfANlNG SCIVENT ..',::
CIEAN Clt -TH.
STEP 6. AFTER INSTALLATION OF NEV^ ELEMENTS, PRIME FiiTE^ AM[>
STRAINER BY FILLING SHEll WITH CLEAN FuFt.
STEP /. INSTALL SHELL AND COVER GASKET IN COVES ANI; SCC-.-t'l
WITH COVES! SCREW.
NOTE- CHANGE FILTER AND STRAINER ELEMENTS EVE*Y 250 HOURS
OF OPERATION.
Mt .?e'.^-:;
Figure S-9. Fuel filter and strainer service.
Page 3-22, paragraph 3-U. "(para 3-43)" is changed defective water pump is changed to read: "Replace
to read "(para 344)". water pump (para 3-50)".
Page 3-2S, paragraph 3-21. Possible remedy for Paragraph 3-24. Line 7, "(para 3-77) is
changed to read "(para 3-79)".
Paragraph 3-25. Possible remedy for ball
joints connecting to moldboard loose, change
"(para 3-80)" to read "(para 3-79)".
Page 3-24, paragraph 3-30. Possible remedy for
Hydraulic Lines leaking, change "(para 3-64)" to
read "(para 3-66)".
Paragraph 3-31 is superseded as follows:
3-31. Parking Brake Does Not Hold Vehicle
I',tllH,IJr C.I.ST />,,W,/, I!: ,,[,!
Brake or linkage out of Adjust parking brake (para 3-<>fi).
Page 3-25.
follows:
Paragraph 3-39/> is superseded as
Brake lining worn.
Brake drum or shoes
damaged.
.
Report this condition to direct
suppoit maintenance.
Replace brake drum or shoe.
Page 3-24. Paragraph 3-32 is superseded as
follows:
3-32. Anti-Coast Brakes Do Not Function Properly
Brake Iming worn.
Brake damaged or
defective.
Replace brake band assembly
(para 3-70).
Replace damaged or defective
brake parts (Para 3-76).
h. Free Pedal Travel Adjustment.
(1) Loosen locknuts (1, fig. 3-12) at each end of
adjusting coupling (2).
(2) Turn rod (3) in direction necessary to bring
upper hole (A) in clutch pedal flush with top of
floor plate at end of free pedal travel.
(3) Tighten locknuts and jamnuts (1) to hold
adjustment.
(4) Adjust tension on spring (4) by loosening or
tightening adjusting nut (5) at bracket (6) until
distance between spring anchor hole in eyebolt
and spring anchor hole in lever is 13 inches.
(5) Loosen screws holding angle bracket (6)
and move bracket up or down until pedal can be
positioned at the top or bottom of its free travel
with approximately 5 pounds pressure. Tighten
bracket screws. Spring stud hole (B) in bracket
should be approximately in line with pivot points
(C and D).
Page 3-26. Figure 3-12 is superseded as follows:
ME 3805-237-12/3-12 C6
1. LOCKNUT 8.
2. ADJUSTING COUPLING 9.
3. PULL ROD 10.
4. SPRING 11.
5. ADJUSTING NUT 12.
6. ANGLE BRACKET 13.
7. PEDAL LEVER PAD 14.
SWIVEL
ADJUSTING NUT
SPRING
JAM NUT
SPRING STUD
JAM NUT
ADJUSTING NUT
Figure 3-12. Clutch Adjustment.
Page 3-26. Paragraph 3-39e is superseded as
follows:
c. Clutch Brake Adjustment. With engine run-
ning, clutch brake must stop clutch in not less
than three seconds after pedal has been fully
depressed. Stopping the clutch greatly aids in
shifting transmission without damage to gears.
(1) Loosen jamnut (11, fig. 3-12). Move adjust-
ing nut (9) until spring behind nut is compressed to
5/8 inch in length when pedal is fully depressed.
(2) Tighten jamnut (11) against adjusting nut
(9) to hold adjustment.
(3) Loosen jamnut (13) and tighten adjusting
nut ( 14) against swivel finger to prevent rattle and
looseness in linkage. Tighten jamnut (13).
(4) Check operation of brake and clutch under
load to be sure adjustment is correct.
Page. 3-27. Paragraph 3-42.1 is added after para-
graphe 3-42 as follows:
3-42.1. Fuel Injectors, a. General.
(1) Four fuel injectors supply fuel to the
cylinders. The injectors build pressure and meter
the fuel without use of a fuel injection pump.
(2) The timing of the injector rack controls the
amount of fuel mete red and injected into the
cylinder.
(3) Type HV8 injectors (80-mm) are operated
by rocker arms to inject fuel into the cylinders.
h. Kent ova I.
(1) Refer to figure 3-21 and remove the engine
hood.
(2) Loosen the two cover bolts and remove the
rocker arm cover and gasket. Remove the cover
studs if they are in the way.
(3) Disconnect and remove the fuel lines from
the injectors. Be careful not to bend the lines.
Install caps on the fuel injector inlet and outlet to
prevent entrance of dirt.
(4) Bar the engine over to relieve rocker arm
pressure on the injector and valve push rods of the
injector to be removed.
(5) Remove two rocker shaft bracket bolts (fig.
3-14.1 (A)) and swing rocker arms away from
injector and valves.
(6) Remove screw and washer securing injec-
tor clamp.
(7) Loosen inner and outer adjusting screws
on injector rack control lever and slide lever away
from injector.
(8) Remove injector from cylinder head with
injector removal tool. Cover or plug hole to
prevent foreign matter entering cylinder.
P(t(/c 3-27. Figure 3-14.1 (A) is added as follows:
ADJUSTING
SCREWS
^jr t 'mmausmsmimS
CROCKER ARM
Figure S-U..1 (A). Fuel injector removal and installation.
10
c. Installation.
NOTE
Prior to installation, check injector tube
in cylinder head. Ream out carbon if
necessary.
(1) Install injector in cylinder head with dowel
pin in locating hole in cylinder head. Move inj-ctor
lever to aline with injector control rack.
(2) Install injector clamp and secure with
screw and washer. Check placement of clamp so
clamp does not interfere with valve or injector
springs. Tighten screw to 20-25 foot-pounds tor-
que.
NOTE
Check injector control .rack for free
movement.
(3) Move speed governor control over to
maximum speed position, adjust inner and outer
adjusting screws for full fuel rack position. When
control lever is released, injector rack should be
returned to its original position.
(4) Install rocker arm brackets and tighten
bolts to 90 to 100 foot-pounds torque.
(5) Install fuel lines. Torque inlet lines to 12 to
15 foot-pounds. Do not tighten outlet lines.
(6) Set injector control rack in NO FUEL
position (all the way out). Crank engine briefly to
bleed any air from injector. Tighten outlet line to
injector and torque to 12 to 15 foot-pounds.
CAUTION
Do not exceed torque specification, as
excessive torque could twist or crack
flared end of fuel line and result in fuel
leaking into the crankcase.
d. Adjustment and Timing.
(1) Place engine governor speed control level
in NO FUEL position.
(2) Rotate the crankshaft until injector fol
lower on the exhaust valve is fully depressed on
the cylinder being adjusted.
(3) Loosen the push rod locknut. Place
0.013-inch feeler gage between the valve stem and
the rocker arm. Adjust the push rod to obtain a
smooth "pull" on the feeler gage (fig. 3-14.1 (B)),
Hold the push rod with the wrench and tighten
locknut. Recheck the clearance. An 0.011-inch
feeler gage should pass freely between the valve
stem and rocker arm, but the 0.013-inch gage will
not pass through.
(4) Place the small end of the injector timing
gage (General Motors Part No. 72-582 J 1853) in the
hole in the top of the injector body with the flat oi
the gage toward the injector follower (fig. 3-14.]
(C)).
(5) Loosen injector push rod locknut. Turr
push rod and adjust injector rocker arm until
extended part of gage will just pass over the top oi
the injector follower. Hold push rod with wrench
and tighten locknut. Recheck adjustment.
(6) Start the engine and bring up to normal
operating temperature (160 -185F.). Recheck ex-
haust valve clearance with an 0.008-inch feeler
gage which should pass through, but an 0.010-inch
gage should not pass between the valve stem and
the rocker arm.
(7) Install rocker arm cover and gasket and
secure with cover bolts. Install engine hood.
Page 3-27. Figure 3-14.1 (B) is added as follows:
ME 3805-237-12 3-14.1 (B) C6
Figure 3-U.l (B). Continued.
12
Figure 3-14.1 (C) is added as follows:
Figure 3-14.1 (C). Continued.
13
Page 3-28. Paragraph 3-436 is rescinded.
Page 3-31. Figure 3-18 is superseded as follows:
v.umt'
NOTE: SHUTOFF ENGINE AND
ALLOW EXHAUST SYSTEM
TO COOL OFF BEFORE
ATTEMPTING TO REMOVE
COMPONENTS.
STEP 1. LOOSEN CLAMP AND REMOVE
MUFFLER FROM EXHAUST
FLANGE.
STEP 2. REMOVE FOUR SCREWS AND
LOCKWASHERS AND REMOVE
EXHAUST FLANGE FROM
MANIFOLD,
STEP 3. REMOVE AND INSPECT EX-
HAUST FLANGE GASKET.
DISCARD GASKET IF
DAMAGED OR LEAKAGE !S
EVIDENT.
Page 3-39, paragraph 3-51. Subparagraph e is
added after subparagraph d as follows:
e. On Vehicle Generator and Voltage Regulator
Test.
(1) If ammeter shows high charging rate,
operate engine at half throttle and disconnect
field lead "B". If output remains high, generator
or wiring is defective and must be replaced (fig.
3-26). If output drops, regulator is defective and
must be replaced (fig. 3-27).
(2) If ammeter shows low charging rate,
connect field lead "B" to ground. Slowly increase
engine speed. If charging rate does not increase,
generator is defective.
NOTE
After generator or voltage regulator
replacement, before starting engine,
momentarily connect a jumper between
armature terminal "A" lead and battery
terminal of regulator to polarize
generator.
Paragraph 3-52. Subparagraph c is added as
follows:
c. On Vehicle Test. Refer to paragraph 3-51.
Paragraph 3-53. Subparagraph c is rescinded.
Paragraph 3-53. Subparagraph d is added as
follows:
d. On Vehicle Test (fig. 3-28).
(1) Remove solenoid to starter connector and
connect voltmeter between the two terminals of
solenoid. If voltage is indicated, solenoid is
defective. Replace solenoid.
(2) Install solenoid to starter connector. Con-
nect voltmeter to same terminals as listed in (1)
above. If battery voltage does not show, starter is
defective. Replace starter.
Page 3-4.1. Figure 3-29 is rescinded.
Page 3-47. Figure 3-36 is superseded as follows:
ME 3805-237.1? "3.18 C6
Figure 3-18. Exhaust system removal and installation.
Page 3-53. Figure 342 is superseded as follows:
T. \
i
Figure 3-86. Batteries, removal and installation.
Page S-54, paragraph 3-66. Subparagraph c is
rescinded.
Subparagraph d (3) is added as follows:
(3) Removal Shift transmission into gear. Drill
out all staking on shaft locknut and remove nut.
Remove brak^ drum. Remove shoe holddown
LEAN
A HEEL GEAR
JUSf.NG
STEP I. REMOVE FOUR SCREWS AND LOCK-
.VASHERS AND REMOVE CAPS FROM TWO
BEARING SUPPORTS ; FIG. 3-40 < SUPPORT-
ING FRONT LEAN WHEEL CONTROL
SHAFT.
STEP ?. REMOVE SCREWS, NUTS, AND PINS AND
DISCONNECT THREE YOKES (FIG. 3-40,
FROM. CONTROL SHAFT AND POWER
CONTROL BOX.
STEP 3. REMOVE TWO SCREV.S AND LOCK-
WASHERS AND REMOVE CAP FROM
BEARING SUPPORT.
STEP 4. REMOVE SCREWS AND NUTS AND DIS-
CONNECT YOKES FROM CONTROL
SHAFT AND FRONT LEAN V.HEEL GEAR
HOUSING.
vi ; 3"5O"'-':; '"-4: re
Figure 3-42. Front leaning wheel control shaft, removal
and installation,
springs and pins, anchor to shoe springs. Discon-
nect cable from lever and remove shoes, adjusting
screw, and strut. Install in reverse order. Torque
locknut to 550-575 foot-pounds. Restake nut. Shift
transmission to neutral.
Page 3-58. Figure 3-47 is superseded as follows:
15
iUT
STEP
NOTE-
NOTE:
REMOVE EIGHT NUTS AND i-MM
CLAMPS.
ON RONT '.'.'HEELS, REMOVE THPFE
SO1Y.S AND LOCK WASHES AND
fiEMO/E H!JB CAP. REMOVE SCHEV.-
AND LOCK NUT AND ; T.MOVE
-VHEEL NUT FROM AXLE .
FRONT '.'/HEELS CAN BE REMOVED
WITHOUT USE OF PULLER SCREWS.
WE: 38Cj.:37.i: 2.4? C6
Figure 3-47. Wheels, removal and installation.
Paragraph 3-69 is superseded as follows:
3-69. Hydraulic Pump. a. General The steering
hydraulic pump and the moldboard shift hy-
draulic pump are driven by a gear on the power
box horizontal drive shaft.
b. Removal and Installation. Refer to figure 3-48.
Page 3-61. Paragraph 3-76, subparagraph a (2) is
superseded and subparagraphs 6 and c are added
as follows:
(2) If adjustment does not correct operation,
replace brake band assembly.
b. Removal. Remove upper and lower strap,
adjusting hut, bolt, and compression spring. Slide
brake band off drum.
c. Installation. Install in reverse order.
Paragraph 3-80 is superseded as follows:
3-80. Circle Reverse Assembly, a. Gear Assembly.
Inspect gear assembly for leakage and damage.
Inspect large circle reverse gear for damaged
teeth. Operate controls and move circle reverse
through entire length of travel. Check operation of
gear assembly and reversing pinion. Check retain-
ing plates and shims at three points of suspension
on drawbar.
b. Adjustment. For proper operation and a
minimum of wear on the plates, the wear and
retaining plates can be adjusted through the use
of shims. Clearance must be maintained between
the upper or wear plate and the top of the
moldboard circle flange.
(1) Raise the moldboard clear of the ground
with the moldboard circle in a horizontal position.
(2) Check clearance between wear plate and
top of the flange. Verticle clearance should be 1/16
inch at all three points.
(3) If clearance is not 1/16 inch, lower
moldboard to ground and remove retaining plate
(fig. 3-51.1 (A)). Add or remove shims between
lower or retaining plate and adjusting plate to
provide required clearance. See note.
NOTE
When it is possible to achieve this
clearance by removing shims, reverse
position of retaining plate (place unworn
side against circle) and ?.dd shims as
necessary to provide clearance.
(4) Install plates and adjust for horizontal
clearance. This can be adjusted with the wedges.
In adjusting for horizontal clearance, the mesh of
the ring gear with the drive gear must be also
adjusted.
(5) Set the adjusting plates at all three points
so the circle can be rotated.
(6) Note point at which drive gear meshes
deepest with ring gear. Loosen jam nut on front
and left adjusting plates. Move wedges with
adjusting nut until adjusting plates contact the
circle. Check clearance between drive gear teeth
and ring gear. Minimum clearance is 3/16 inch
between the top of the drive gear teeth and the
bottom of the teeth in the ring gear.
(7) Use a 3/16-inch rod with two right angle
bends. Place one end of rod at top of teeth and
other end at bottom. Adjust plates by moving
wedges to obtain this clearance (fig. 3-51.1 (B)).
(8) Check clearance between ring gear teeth
and left side of circle reverse gear assembly. This
clearance must be at least 1/8 inch.
(9) This adjustment is accomplished with the
two rear adjusting plates. Loosen the wedges on
the right rear block. Tighten wedges on left rear
block to push circle out. Check adjustment and
tighten wedge jam nuts.
(10) Check clearance between top of driving
gear teeth and bottom of ring gear teeth. If
adjustments have changed, adjust with front % and
left plates as in (6) above to get this clearance.
16
CAUTION
The clearance between the top of the
drive gear teeth and the bottom of the
ring gear teeth must be 3/16 inch
minimum to 3/8 inch maximum. Do not
operate moldboard circle under load
when clearance is more than 3/8 inch.
Damage to circle reverse gear assembly
could result.
(11) Tighten all wedge nuts and plate mount-
ing nuts securely.
c. Reverxiny Pinion. Check reversing pinion
clearance with circle gear. Note any wear spots on
circle gear teeth. Wear should be even all around
circle. If wear shows in certain areas, circle is out
of alignment and three retaining plates and shims
must be adjusted to aline circle with reversing
pinion.
Page -i-fil. Figure 3-51.1 is added as follows:
STKP 1. REMOVE THREE JAM NUTS, LOCK .VASHS-.--:, r^T',,
AND SCREWS. MOVl SIX -JVEDGfcS,
STFP ?, REMOVE NINE COTTER PINS, SLGTTiL N-..; 1 ,, MAT
WASHERS, AND SCREWS.
STEP 3, REMOVE THREE RETAINING PLATES, ADj; ;-,7!f,G
PLATIS, SHJMS, AND WEAR PLATB l-'w.*,t ;, - A.VBA*;
Figure 3-51.1 (A). Moldboard circle adjustment.
'i. ;-.<;. i;
6
18
t
*
RETAINING
PLATE
CIRCLE REVERSE
GEAR ASSEMBLY
HOUSING
RING GEAR
CLEARANCE
MUST BE
1/8 INCH
CLEARANCE MUST BE
MINIMUM 3/16 INCH TO
MAXIMUM 3/8 INCH
BETWEEN TOP OF EACH
DRIVE GEAR TOOTH AND
THE BOTTOM OF RING
GEAR TOOTH.
ME 3805-237-12/3-51.1 C6
.J-Gt.l (B). -Continued.
Page 3-63. Figure 3-53 is superseded as follows:
SHj.MS
MOUNTING
SCEWS ?
ST? 1. REMOVE TWO SCREWS, LOCKWASHERS,
AND NUTS AND KEMOVI SOCKET CAP,
STEP 2, iEMGVI OR JNSTAU SHJMS AS NEC-
ESSARY TO PKQVIDg FR MOV6MNT
WtTHOlfT WNOING Ot TOO MUCH
Page 3-63, paragraph 3-85. Note is superseded as
follows:
NOTE
Always adjust end thrust bearing before
adjusting clutch anti-coast brakes. Prior
to adjusting thrust bearings, have all
pressure on worm gear toward gear
housing.
Page A.-1. Appendix A is superseded as follows:
ifirure 5-55. I^/i Kn/c sAi?9is, removal and installation.
20
APPENDIX A
REFERENCES
1. Fire Protection
TB 5-4200-200-10 Hand Portable Fire Extinguishers Approved For Army Users
2. Lubrication
C9100-IL Identification List for Fuels, Lubricants, Oils and Waxes
LO 5-3805-237-12-1 Grader, Road, Motorized: Diesel Engine Driven; 13,300 Lb Pressure at Blade
12 Ft Blade 6 Wheels; 4 Driving, 2 Steerable, Leaning Front Wheels;
W/Engine GM Model 4057.
LO 5-3805-237-12-2 Grader, Road, Motorized: Diesel Engine Driven 13,300 Lb. Pressure at Blade:
12 Ft Blade 6 Wheels 4 Driving, 2 Steerable, Leaning Front Wheels
W/Scarifier (LeTourneau-Westinghouse Model 440HA) W/Engine GM
Model 4057.
LO 5-3805-237-12-3 Grader, Road Motorized, Diesel Engine Driven 13,300 Lb Pressure at Blade;
12 Ft Blade 6 Wheels 4 Driving, 2 Steerable Leaning Front Wheels
W/Scarifier (LeTourneau-Westinghouse Model 440HA) W/Engine GM
Model 40.57.
3. Painting
TM 9-213 Painting Instructions for Field Use
4. Radio Suppression
TM 11-483 Radio Interference Suppression
5. Maintenance
TB 750-651 Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling
Systems
TM 5-3805-237-20P Organizational Maintenance Repair Parts and Special Tools List: Grader,
Road Motorized ded, 15,000 Lb Pressure at Blade, 12 Ft Blade, 6 Wheels 4
Driving, 2 Steerable Leaning Front Wheels W/Scarifier (LeTourneau-
Westinghouse Model 440HA) FSN 3805-931-7881.
TM 9-2610-200-20 Organizational care, maintenance and repair of pneumatic tires and inner
tubes.
TM 9-6140-200-14 Operator, Organizational, Direct Support, and General Support Mainte-
nance Manual Storage Batteries Lead- Acid Type
TM 38-750 The Army Maintenance Management Systems (TMMS)
6. Shipment and Storage
TM 740-90-1 Administrative Storage of Equipment
7. Destruction to Prevent Enemy Use
TM 750-244-3 Procedures for Destruction of Equipment to Pi-event Enemy Use (Mobility
Equipment Command)
Page B-l. Appendix B is superseded as follows:
21
APPENDIX B
BASIC ISSUE ITEMS LIST AND ITEMS
TROOP INSTALLED OR AUTHORIZED
Section I. INTRODUCTION
B-l. Scope. This appendix lists items required by
the operator for operation of the grader.
B-2. General. This list is divided into the following
sections:
a. Ba^ic /s,me Itonn Lint -Section II. Not
applicable.
6. Itetnn Troop Installed or Authorized
List -Section III. A list of items in alphabetical
sequence, which at the discretion of the unit
commander may accompany the grader. These
items are NOT subject to turn-in with the grader
when evacuated.
B-3. Explanation of Columns. The following pro-
vides an explanation of columns in the tabular list
of Basic Issue Items List, Section II, and Items
Troop Installed or Authorized, Section III.
a. Source, Mavitenct)ice, and Recoverability Code
(s) (SMR).
(1) Source Code. Indicates the source for the
listed item. Source codes are:
fWr /;,/'/<"<"'<
P . . . Repair pails, special tools and test equipment
supplied from GSA/DSA or Army supply system and
authorized for use at indicated maintenance levels.
P2 . . . Repair parts, special tools and test equipment which
are procured and stocked for insurance purposes
because the combat or military essentiality of the end
item dictates that a minimum quantity he available in
the supply system.
(2) Maintenance Code. Indicates the lowest
level of maintenance authorized to install the
listed item. The maintenance level code is:
C Crew/Operator
(3) Recoverability Code. Indicates whether
unserviceable items should be returned for recov-
ery or salvage. Items not coded are non-
recoverable. Recoverability codes are:
R . . . Applied to repair parts (assemblies and components),
special tools and test equipment which are considered
economically reparable at direct and general support
maintenance levels.
S . . . Repair parts, special tools, test equipment and
assemblies which are economically reparable at DSU
and GSU activities and which nomially are furnished
by supply on an exchange basis.
b. Federal Stock Number. This column indicates
the Federal stock number assigned to the item
and will be used for requisitioning purposes.
c. Description. This column indicates the Fed-
eral item name and any additional description of
the item required.
d. Unit of Measure (UIM). A 2 character
alphabetic abbreviation indicating the amount or
quantity of the item upon which the allowances
are based, e.g., ft, ea, pr, etc.
e. Quantity Furnished With Equipment (BIIL).
Not applicable.
/. Quajitity Authorized (Itenix Troop Installed or
Authorized). This column indicates the quantity of
the item authorized to be used with the equip-
ment.
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
Federal
stock
nunilwr
Dcscripliuii
I'M
CJty
Aulh
7520-559-9618
CASE, Maintenance and Operation Manuals
EA
1
4210-889-2221
EXTINGUISHERS, Fire
EA
1
4910-922-6921
KIT, Tubeless Tire Repair
EA
1
7240408-3985
MEASURE, 1 Qt. Flex. Extension
EA
1
5120-595-9162
WRENCH, Allen, 9/16 In.
EA
1
5120-203-4804
WRENCH, Open End, 1 1/2 In.
EA
1
Page C-l. Appendix C is superseded as follows:
22
APPENDIX C
MAINTENANCE ALLOCATION CHART
Section L INTRODUCTION
1. General, a. This section provides a general
explanation of all maintenance and repair func-
tions authorized at various maintenance levels.
6. Section II designates overall responsibility for
the performance of maintenance functions on the
identified end item or component. The implemen-
tation of the maintenance functions upon the end
item or component will be consistent with the
assigned maintenance functions.
c. Section III lists the special tools and test
equipment required for each maintenance func-
tion as referenced from Section II.
d. Section IV contains supplemental instruc-
tions, explanatory notes and/or illustrations re-
quired for a particular maintenance function.
2. Explanation of Columns in Section II. a. Group
Number, Column (1). The functional group is a
numerical group set up on a functional basis. The
applicable functional grouping indexes (obtained
from TB 750-93-1, Functional Grouping Codes) are
listed on the MAC in the appropriate numerical
sequence. These indexes normally are set up in
accordance with their function and proximity to
each other.
b. Functional Group, Column (2). This column
contains a brief description of the components of
each functional group.
c. Maintenance Functio}i8, Column (3). This
column lists the various maintenance functions (A
through K) and indicates the lowest maintenance
category authorized to perform these functions.
The symbol designations for the various mainte-
nance categories are as follows:
C Operator or crew
Organizational maintenance
F Direct support maintenance
H General support maintenance
D Depot maintenance
The maintenance functions are defined as follows:
A INSPECT. To determine serviceability
of an item by comparing its physical, mechanical,
and electrical characteristics with established
standards.
B TEST. To verify serviceability and to
detect electrical or mechanical failure by use of
test equipment.
C SERVICE. To clean, to preserve, to
charge, to paint, and to add fuel, libricants, cooling
agents, and air.
D ADJUST. To rectify to the extent neces-
sary to bring into proper operating range.
E ALINE. To adjust specified variable
elements of an item to bring to optimum perfor-
mance.
F CALIBRATE. To determine the correc-
tions to be made in the readings of instruments or
test equipment used in precise measurement.
Consists of the comparisons of two instruments,
one of which is a certified standard of known
accuracy, to detect and adjust any discrepancy in
the accuracy of the instrument being compared
with the certified standard.
G INSTALL. To set up for use in an
operation environment such as an emplacement,
site, or vehicle.
H REPLACE. To replace unserviceable
items with serviceable assemblies, subassemblies,
or parts.
I REPAIR. To restore an item to service-
able condition. This includes, but is not limited to,
inspection, cleaning, preserving, adjusting, replac-
ing, welding, riveting, and strengthening.
J OVERHAUL. To restore an item to a
completely serviceable condition as prescribed by
maintenance serviceability standards using the
Inspect and Repair Only as Necessary (IROAN)
technique.
K REBUILD. To restore an item to a
standard as nearly as possible to original or new
condition in appearance, performance, and life
expectancy. This is accomplished through com-
plete disassembly of the item, inspection of all
parts or components, repair or replacement of
worn or unserviceable elements (items) using
original manufacturing tolerances and specifica-
tions, and subsequent reassembly of the item.
d. Tools and Equipment, Column (4). This
column is provided for referencing by code the
special tools and test equipment (Section III),
required to perform the maintenance functions
(Section II).
e. Remarks, Column (5). This column is provided
for referencing by code the remarks (Section IV)
pertinent to the maintenance functions.
3. Explanation of Columns in Section III. a.
Reference Code. This column consists of a number
and a letter separated by a dash. The number
references the tools and equipment requirements
23
column on the MAC. The letter represents the
specific maintenance function the item is to be
used with. The letter is representative of columns
A through K on the MAC.
b. Maintenance Level. This column shows the
lowest level of maintenance authorized to use the
special tool or test equipment.
c. Nomenclature. This column lists the name or
identification of the tool or test equipment.
d. Tool Number. This column lists the
manufacturer's code and part number, or Federal
stock number of tools and test equipment.
4. Explanation of Columns in Section IV. a.
Reference Code. This column consists of two
letters separated by a dash, both of which are
references to Section II. The first letter references
column 5 and the second letter references a
maintenance function, column 3, A through K.
b. Remarks. This column lists information
pertinent to the maintenance function being
performed, as indicated on the MAC, section II.
Section II MAINTENANCE ALLOCATION CHART
ll 1
i2i
,;,,
n.
if),
Maiiuciiiincc fu u-lion.s
A
B
c
D
K
K
G
H
i
j
K
Group No.
.Assembly Group
Tools a mi
1
-
c(j mpmrnt
^
r
~
~-
_
r;
_
2
3
r
ft.
f.
\
.2,
|
|
2
i
.
1
5
G
01
0100
ENGINE
Engine Assembly Engine
C
0.5
F
1.5
C
0.5
!
12.3
F
1.0
D
85.0
A-B
0101
Crankcase, Block, Cylindei
Head
Head, cylinder
F
H
3.0
2.0
0102
Crankshaft Pulley
F
F
5.5
3.0
0103
Flywheel Assembly
Flywheel, housing,
H
H
ring gear
3.0
1.0
0105
Valves, Camshafts, and
Timing System
Arm, rocker
F
F
1.0
3.0
3.0
Tappets
!
H
1.5
3.0
Valves, Seats
H
H
5.5
3.0
0106
Engine Lubricating Systeiv
Breather
C
O
0.4
0.1
Pump, oil
H
H
0.6
1.5
02
CLUTCH
0200
Clutch Assembly
Clutch assembly
F
0.5
Disk, plates
H
5.0
0202
Clutch Release Mechanism
Bearings, shaft, yoke
H
0.5
5.0
Pedal, linkage
O
0.5
1.5
0206
Clutch. Brake
Hub. plate
!
11
0.5
2.0
24
Ill
<2l
13)
14)
iSi
Maintenance functions
A
B
c
D
E
F
G
H
I
j
K
Group No.
Assembly Group
Tools and
je
!_
cc
o
u
a
o
Cj
V.
"5
2
quipment
E
u
Cl
o
M
c
u
a
7J
c
'3
a
-*
>
.2,
y
_t
"5. .
a.
o
o
c
a
H
HI
CX3
a
<
<
3
U3
o
a:
6
o
ai
03
0301
FUEL SYSTEM
Fuel Injector
Injector, fuel
F
O
O
H
0.5
0.3
2.5
1.5
0302
Fuel Pumps
Pump, fuel transfer
o
O
F
1.3
0.8
1.5
0304
Air Cleaner
Cleaner, air, cartridge
c
0.5
1.0
0305
Blower
F
H
8.8
4.8
0306
Tanks, Lines, Fittings
Cap, fittings, lines
O
1.0
0.5
Tank
c
c
o
F
0.2
0.3
2.0
1.0
0308
Engine Speed Governor
and Controls
Governor
F
F
D
1.5
1.5
3.0
0309
Fuel Filters
Filter, fuel
C
O
0.5
0.5
0311
Starting Aid
C
0.3
0.4
05
COOLING SYSTEM
0501
Radiator
Core, tanks
F
F
5.0
4.0
Radiator
C
C
O
F
O.I
0.5
3.5
2.0
0504
Water Pump
Pump, water
O
F
1.5
1.5
0505
Fan Assembly
Belt, vee
c
C
O
0.1
0.2
0.5
Tightener, belt
C
O
0.1
0.3
06
ELECTRICAL SYSTEM
0601
Generator
Belt, vee
c
C
O
0.1
0.2
1.0
Generator
O
c
o
F'
0.5
0.2
0.7
3.0
0602
Generator Regulator
Regulator generator
O
0.3
O
0.4
0.5
0603
Starting Motor
Starter
O
O
F'
0.2
0.8
3.0
0607
Instrument or Engine
Control Panel
Wiring
O
1.0
0608
Miscellaneous Items
O
o
Wiring
1.0
0.5
25
. 1 1
,._,,
. :( ,
, 1 1
..',,
Miiintrn.ancr fu \i-tions
A
H
c
i)
K
K
c;
H
i
.1
K
C'.nnip No.
\ssi"iili|y Crcmji
~
-=
ools ;m<i
If
at"
*
r
5
zl
S
\
~L
i-
~
|
-
jr.
061 1
Horn
Wiring
0.5
o
0.5
0612
Batteries
Batteries
C
O
0.4
0.5
0.6
Cables
O
1.0
0.5
0613
Chassis Wiring Harness
Harness, wiring
F
1.5
0.5
0615
Radio Interference sup-
pression Components
0.5
1.0
07
TRANSMISSION
0700
Transmission Assembly
Transmission
C
C
H
H
0.2
0.5
5.0
20.0
09
PROPELLER AND
PROPELLER SHAFTS
0900
Propeller Shafts
Shaft, clutch drive
F
F
1.0
1.5
Shaft, power control box
drive
1.0
1.5
10
AXLE
1000
Front Axle Assembly
Axle assembly, front
C
F
F
0.3
3.0
5.0
1004
Steering and Leaning
Wheel Mechanism
Gear box assembly
C
C
F
0.5
0.4
3.0
6.0
Knuckles, arms, shafts
bearings, seals, flanges.
pins; gear case, gears
F
F
0.5
3.0
Shafts, bushings
C
C
0.5
3.5
Shafts, control joints
universal
2.5
3.0
11
REAR AXLE
1103
Final Drive
Final drive assembly
C
H
H
0.5
18.5
21.0
1105
Tandem Drive Assembly
Carrier axle assembly
C
H
H
0.5
16.5
18.0
Chain, drive
-!
F
V
10.0
4.0
1108
Walking Beams, Stud
Axles and Parts
Axle drive assembly
C
H
H
0.5
7.0
5.0
1201
Hand Brakes
o
F
Drum
2.5
4.0
26
Ill
i 2 I
i:ii
Ma ink- nance functions
A
H
C
n
K
K
G
H
I
j
K
Group No.
Assembly (Irmip
Tools and
j:
3
ciiuipmon
2
^
?j
~
_
^
_
-.
2
r
s.
7
'>
^
g.
~.
2
5
?
H
.
C
(/3
(J
1
6
-
1201
Hand Brakes (Cont'd)
Levers, linkage
C
0.4
O
1.5
Shoe assembly
O
O
F
0.5
2.5
~> <
1202
Service Brakes
*"
Brakes, service
O
F
F
0.4
4.0
1.0
Shoe assembly
F
F
5.0
6.0
1204
Hydraulic Brakes System
Cylinder, master
C
C
O
F
0.2
0.3
2.5
3.0
Cylinder, wheel
V
F
6.5
8.0
1206
Mechanical Brake Controls
Pedal, brackets, linkage,
rods
O
0.5
2.5
13
WHEELS
1311
Wheel Assembly
Bearings, seals (front)
C
O
O
2.0
1.0
4.0
Drums
F
F'
2.0
5.5
1313
Tires
Tires
C
O
O
0.5
2.0
0.5
14
STEERING
1401
Steering Assembly
Shafts, draglinks, arm
C
O
0.6
2.5
3.0
Steering gear assembly
C
F
F
0.3
3.5
4.0
1410
Hydraulic Pump
Pump, hydraulic
O
F
0.4
1.5
4.0
1414
Steering System Valves
Valve assemblies
O
F
1.5
3.0
15
FRAME, TOWING ATTACH-
MENTS
1503
Pintles and Towing
Attachments
/
Hook, pintle
C
O
O
0.1
1.0
1.0
20
POWER CONTROL UNIT
2002
Power Control Unit
Assembly
Brake band
C
o
Control assembly
C
C
0.5
2.0
F
F
Shaft, Propeller
0.1
0.3
c
1.5
2.0
\^
O
O
0.1
1.0
1.5
27
11 1
,2!
,:i,
14 i
ifti
MiUiilcn;! net 1 functions
A
K
C
i)
K
F
G
H
i
j
K
Group No.
Assembly Group
Tools and
|
r
w
\
j.
|
-a
rquipmrn
=
c.
_
>
i
=
=
*~
.2
'3
F
5
^
S5
^
T
^;
5
cT
"
r^
~
v
O
43
HYDRAULIC SYSTEM
4301.
Filters, Hoses, Fittings
Tubing
Filter, hydraulic oil
C
c
0.5
0.5
Junction assembly
C
0.5
0.5
4302
Pump and Pump Prives
F
0.2
4.9
3.0
4305
Control Valves
Valves
F
1.0
2.0
4307
Hydraulic Cylinders
Cylinder, hydraulic
F
F
1.5
3.0
74
EARTH MOVING EQUIP-
MENT COMPONENTS
7435
Moldboard Assembly
Blade assembly
F
1.0
2.5
Moldboard assembly
C
o
F
0.2
1.0
1.5
7436
Lift, Arms and Pivot
Assemblies
Bar, links, arms
C
c
0.1
1.0
3.0
7438
Circle and Drawbar Assem-
bly
Circle, drawbar
c
o
F
F
0.1
0.4
2.5
4.0
7439
Circle Reverse Drawbar
Shift & Lift Mechanism
Gear box assembly
c
C
O
F
0.1
0.1
2.0
3.0
Joints, universal
O
1.5
2.0
7440
Scarifier Assembly
Drawbar, rods, bushings,
angle adjustments,
shanks
C
O
0.3
3.0
1-H
Teeth
C
C
0.5
0.5
7441
Scarifier Actuating
c
C
O
F
0.1
0.1
1.0
1.5
Gear box assembly
c
C
o
F
0.2
0.2
3.0
5.0
Joints, universal
C
c:
O
O
0.1
0.1
1.5
2.0
Shafts, arms, bushings
c
O
0.1
2.0
76
FIRE FIGHTING EQUIPMENT
7603
Fire Extinguishers
Extinguisher, fire
c
C
0.5
0.1
Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT REQUIREMENTS
Reference
code
Maintenance
level
Nomenclature
Tool
numlx;r
I-H
c
Remover, scarifier point
429581 (35311)
Section IV. REMARKS
Reference
code
Remarks
A-B
Test includes engine operation and compression.
By Order of the Secretary of the Army:
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
CREIGHTON W. ABRAMS
General, United States Army
Chief of Staff
Distribution:
To be distributed in accordance with DA Form 12-25B (qty rqr block no. 394), Organizational maintenance requirements for
Earth Moving Equipment: Graders.
29
I
TECHNICAL MANUAL i
i
NO. 5-3805-237-12 !
TM 5-3805-237-12
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 16 March 1967
OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL
GRADER, ROAD, MOTORIZED: DIESEL ENGINE DRIVEN; 13,300 LB
PRESSURE AT BLADE; 12 FT. BLADE; 6 WHEELS, 4 DRIVING 2 ST EERABLE;
LEANING FRONT WHEELS; W/SCARIFIER (LeTOURNEAU-WEST-
INGHOUSE MODEL 440HA
FSN 3805-931-7881
I
I
I
Paragraph Page
CHAPTER I. INTRODUCTION
Section I. General 1-1,1-2 1-1,1-2
II. Description and tabulated
data 1-3,1-4 1-3
CHAPTER 2, INSTALLATION AND OPERATION
INSTRUCTIONS
Section I. Service upon receipt of
equipment 2-1 2-6 2-1 2-2
II. Movement to a new worksite 2-7,2-8 2-
III. Controls and! instrumentE 2-9,2-10 2-3
IV. Operation of equipment 2-11 2-20 2-3 2-19
V. Operation of auxiliary
materiel used in conjunction
with the equipment, 2-21,2-2? 2-20
CHAPTER S. OPERATOR AND ORGANIZATIONAL
MAINTENANCE INSTRUCTIONS
Section I. Operator and organizational
maintenance tools and
equipment .. 3-1,3-2 31
II. Lubrication 3-3,3-4 3-1
III. Preventive maintenance
services 3-5 3-7 3-16
IV. Operator's maintenance 3-8 3-10 3-16
V. Troubleshooting 3-11 S-33 3-163-24
VI. Radio interference suppression 3-34 3-37 3-24
VII. Clutch assembly 3-38,3-39 3-25
VIII. Fuel system 3_40_3-43 3-26 3-2&
IX. Exhaust system 3-44,3-45 3-303-32
X. Cooling system ._ 3-463-50 3-323-37
XL Electrical system 3-51 3-5 3-38 3-41
XII. Transmission assembly 3-59,3-60 3-46
XIII. Front axle and steering
system 3-61 3-64 3-46 3-6S
XIV. Tandem drives and brakes 3-65 3-67 3-53 3_56
Paraxrapn Page
XV. Hydraulic system 3-68,3-69 3-58
XVI. Hood and cab assembly 3-703-72 3-58
XVII. Power control box 3-733-76 3-59,3-60
XVIII. Moldboard 3-77,3-78 3-61
XIX. Circle reverse mechanism 3-793-81 3-61
XX. Scarifier 3-823-84 3-62,3-63
XXI. Adjustment 3-85,3-86 3-63
APPENDIX A. REFERENCES A-l
B. BASIC ISSUE ITEMS LIST
AND MAINTENANCE AND OPERATING SUPPLIES B-l
C. MAINTENANCE ALLOCATION CHART C-l
INDEX 1-1
INTRODUCTION
Section 1. GENERAL
1-1. Scope
a. These instructions are published for use
of personnel to whom the motorized road grader
(figs. 1-1 and 1-2) is issued. They provide
information on the operation and organizational
maintenance of the equipment! Also included
are descriptions of main units and their func-
tions in relationship to other components.
8 9 10
20 19 18
17 16 15 14 13
1 Main frame
2 Steering gear
3 Scarifier housing
4 Lift housing
5 Lateral housing
6 Power control box
7 Upper transmission
8 Fuel tank
SHIPPING DIMENSIONS
LENGTH 309 INCHES
WIDTH 92 INCHES
HEIGHT 92 INCHES
WEIGHT 26,500 POUNDS
9 Air cleaner
10 Engine
11 Battery box
12 Tandem drive
13 Clutch
14 Lower transmission
15 Headlight
16 Moldboard
MEC 3805-237-12/1-1
17 Circle
18 Blackout headlight
19 Floodlight
20 Scarifier block
21 Front axle
22 Leaning wheel housing
Figure 1-1. Model UOHA motor grader, left front, three-quarter view with shipping dimensions.
1-1
8 7
MEC 3805-237-1 2/1 -2
1 Reflector
2 Engine hood
3 Muffler
4 Steering wheel
5 Lift housing
6 Front wheel
7 Scarifier
8 Moldboard
9 Transmission shift levers
10 Tool box
11 Radiator
12 Taillight
13 Floodlight
14 Towing pintle
Figure 1-2. Model 440HA motor grader, right rear, three-quarter view.
b. Appendix A contains a list of publications
applicable to this manual. Appendix B con-
tains the list of basic issue items authorized
the operator of this equipment and the list of
maintenance and operating supplies required
for initial operation. Appendix C contains
the maintenance allocation chart.
c. Numbers in parentheses following nomen-
clature callouts on illustrations indicate quan-
tity; numbers preceding callouts indicate
preferred maintenance sequence.
d. DA Form 2028 (Recommended changes
to DA Publications) will be used for reporting
discrepancies and recommendations for im-
proving this equipment publication. This form
will be completed by the individual using the
manual and forwarded direct to Commanding
General, U.S. Army Mobility Equipment Com-
mand, ATTN : AMSME-MPD, 4300 Goodfellow
Blvd., St. Louis, Mo., 63120.
e. Report all equipment improvement recom-
mendations as prescribed by TM 38-750.
1-2. Record and Report Forms
a. DA Form 2258 ^Depreservation Guide
for Vehicles and Equipment).
6. For other record and report forms applic-
able to the operator, crew and organizational
maintenance, refer to TM 38-750.
Note. Applicable forms, excluding Standard Form
46 (United States Government Motor Vehicles Oper-
ator's Identification Card) which is carried by the
operator, will be kept in a canvas bag mounted on the
equipment.
1-2
Section ii. DESCRIPTION AND TABULATED DATA
1-3. Description (4) Grader identification plate. This
a' Motor Grader. The motor grader is a plate identifies the motor grader by
self-propelled grader operated by one man. The model serial, and registration num-
model 440HA motor grader moldboard (16, ^ ers ; ' dentlfles th ? f vernment con-
i i x . V j r 4.j j v tract it was manufactured under, and
fig. 1-1) is hydraulic operated and can be . . , . , . , ,.
, . , , , . , . , . . , , , , vehicle weight and dimensions.
adjusted to every position relative to the work e
to be performed. b. Tabulated Data.
b. Engine, The engine used to power the (1) Motor grader.
motor grader is a 2 cycle, naturally aspirated, Manufacturer ------------ Westinghouse Air Brake
four cylinder diesel engine. The engine (10, Company Construction
fig. 1-1 is mounted in a housing at the rear of M , . A^*** ^^^
,, , . Model ------------------- 44UrIA
the operator's seat. Drive for the rear wheels Type ___________________ Self-propelled road grader
is provided through a clutch to the, two trans- Serial numbers __________ 440HAGM001 thru
missions and to the driving axles. The engine 440HAGM520
also drives two hydraulic pumps through the (2) Engine.
power control box. Manufacturer ----------- General Motors
c. Clutch. Power from the engine crankshaft Ty P e -------------------- 4 c y linder in - line
is connected to the grader drive shaft through Model 5 c
.bore ____________________ 4.4OU inches
a dry-plate clutch. The clutch is controlled stroke __________________ 5 inches
by the clutch pedal and clutch brake. The Fuel ____________________ Diesel
clutch brake will stop clutch rotation three to Piston displacement ------ 284 cubic inches
four seconds after pedal is depressed to make Compression ----- ..17 to 1
shifting and power operation faster. Main bearing bore (ID) 3.8120 to 3.8130 inches
fe * * c Number of main bearings .5
i A u M.'f M.' j f i i i M . Firing order ------------- 1-3-4-2
1-4. Identification and Tabulated Data Governed speed __________ 1975 rpm
a. Identification. The motor grader has four High idle ---------------- 2140 rpm
major identification plates. The information (3) Engine accessories.
contained on the plates is listed below. (a) Generator,
(1) Engine plate. The engine plate lists Manufacturer ----------- Delco-Remy (1105993)
the engine model, unit number, rated P * rt number -------------- MS13823-1
, ' , Voltage _________________ 24 volts
horsepower, continuous horsepower, Amperage _______________ 18 arnp8
and maximum revolutions per minute ,^ starter
With no load. Manufacturer ______ '____. Delco-Remy
(2) Transmission instruction plate. The p ar t number ____________ 1113842
transmission instruction plate illu- ( c ) ^ r cleaner.
strates the shifting diagram for the Manufacturer ___________ Donaldson
upper and lower transmissions and Part number -------------- MS39247-6
details lever positions for the six for- (d) Fuel filter.
ward speeds and three reverse speeds Manufacturer ----------- AC Spark Plug
delivered by the transmissions. Part number ------------- 5571256
(3) Grader transportation data plate. The ^ Fuel pump.
vehicle transportation data plate illu- Manufacturer ----------- Detroit Diesel
. , ..,, , ,. , . .,.,. ,, Part number _____________ 5184532
strates lift and tiedown facilities of (f\ F I t '
the motor grader. This plate also ... . \ . ' , ,,,
& * Manufacturer ___________ AC Spark Plug
gives moldboard blade and scarifier Part num b er _____________ 5571218
positions for shipping. Loads on the (g) Vo i tage regulator.
tandem axle and front axle are also Manufacturer ___________ Delco-Remy
detailed. Part number _____________ 1118644
1-3
( h ) Transmission.
Manufacturer Westinghouse Air Brake
Company Construction
jfiquipment Division
Type Mechanical, 6 speed for-
ward, 3 speed reverse
Part number 493566
(i) Clutch.
Manufacturer Rockford
Type 16 inch, dry
(4) Capacities.
Fuel tank 52 gallons
Engine crankcase (less 3.5 gallons
filter).
Cooling system 15 gallons
Tandem drive 4 gallons
Upper transmission and 3 gallons
shifter housing.
Master cylinder 2.5 pints
Lateral shift housing 15.5 pints
Lateral shift reduction 3.5 pints
housing.
Lift housing 3 pints
Lift reduction housings 3.5 pints
Circle reverse housing 5 pints
Front lean wheel housing 8 pints
Scarifier lift housing 24.5 pints
Scarifier lift reduction 1.5 pints
housing.
Power box housing 7 pints
Power drive housing 7.75 pints
(with adapter).
Lower transmission 15.75 gallons
Hydraulic reservoir 32.6 quarts
(5) Nut and bolt torque data.
Item Torque ft-lb
Cylinder head studs 75
Main bearing stud 35-75
Hand hole cover 10-15
Standard torques (engine bolts and nuts)
%-20 7-9
^4-28 _. 8-10
5/16-18 13-17
5/16-24 15-19
%-16 30-35
%-24 35-39
7/16-14 46-50
7/16-20 57-61
%-13 71-75
H-30 83-93
9/16-12 90-100
9/16-18 107-117
%-ll 137-147
%-18 168-178
%-10 240-250
%-16 290-300
%-9 410-420
%-14 475-485
1-8 580-590
1-14 685-695
(6) Adjustment data.
Exhaust valves
Valve clearance (cold) 0.012 inch
Valve clearance (hot) 0.009 inch
Valve guide clearance 0.002 inch
Clutch
Free travel 2 inches
Clutch spring extension . 13 inches
(7) Dimensions and weight (fig. 1-1).
Length 309 inches
Width 92 inches
Height 92 inches
Weight 26,500 pounds
(8) Wiring diagram. Refer to figure 1-3
for a schematic wiring diagram of
the motor grader electrical circuits.
1-4
8
00
n
U
UJ
I
.1
I2N
a: X
1-5
CHAFfil 1
INSTALLATION AND OPiftATION MITIUCTSONS
Section I. SERVICE UPON HiCiiFf Of EQUIPMENT
2-1. Unloading Equipment
a. The motor graders are normally shipped
to their destination on railroad cars and are
blocked and tied down as shown in figure 2-1.
6. Remove all straps, tiedowns and blocking
to free motor grader.
Caution: Use care when removing blocking
and straps so as not to damage motor grader.
c. The motor grader is equipped with lifting
eyes (fig. 2-1). When an adequate crane is
available, lift motor grader from transporter
with suitable slings or cables.
d. If a ramp is available to allow removal
of the motor grader, the grader can be driven
from the transporter. Prepare the motor
grader for operation (para 2-8) before at-
tempting to move grader.
Caution: Before driving grader from the
transporter be sure there is sufficient ground
Figure 2-1, Motor grader shipping and unloading details.
2-1
I
clearance when negotiating the ramp.
^__2. Unpacking Equipment
The motor grader is shipped assembled with
tlie overpack kit. Check contents of overpack
kit for completeness and condition. Remove
all protective strapping, tape, and any pro-
tective coverings applied to the motor grader.
23. Inspecting and Servicing Equipment
a. Inspect identification plates on the grader
for serial number and other information and
compare with data contained on accompanying
invoice or packing slip to insure receipt of
proper equipment.
b. Inspect entire motor grader for evidence
of damage during transit. Inspect the unit
for loose connections, broken lines, tightness
of attachments and fittings. Check all parts
for secure mounting.
c. Perform the daily preventive maintenance
services described in paragraph 3-6.
d. Lubricate the motor grader in accordance
with current lubrication order and paragraph
3-4.
Note. Engine crankcase is filled with a light break-
in oil. Do not operate motor grader under full load
until a reasonable engine running time has been
accumulated. Drain crankcase and refill with proper oil.
e. Service engine cooling system by closing
drain cocks in cylinder block and radiator.
Remove radiator filler cap and fill radiator
with proper coolant for expected ambient
temperature. See table 2-1.
/. If the motor grader is to be put into
operation in cold weather (below 20F), check
lubrication chart for proper lubricants and
change if necessary. Check coolant in radiator
Table 2-1. Freezing Points, Composition, and
Specific Gravities of Military
Anti-freeze Materials
Lowest
expected
ambient
temp,
F
Pints of
inhibited
glyeol per
peal, of coolant 1
Compound, anti-freeze
arcMc"
Ethylene Rlycol
coolant solution
specific ptravity
at eS-F"
+20
1%
Issued full strength and ready mixed for
1.022
+ 10
2
to 65 F temperatures for both
1.036
2%
initial installation and replenishment of
1.047
-10
3%
losses.
1.062
-20
3%
1.062
-30
4
1.067
-40
4%
1.073
_50
Arctic anti-
DO NOT DILUTE WITH WATER
-60
freeze pre-
OR ANY OTHER SUBSTANCE
-75
ferred
Maximum protection is obtained at 60 percent by volume (4.8 pints of ethylene glycol per gallons of solution).
2 Military Specification MIL-C-11765 Arctic type, nonvolatile anti-freeze compound is intended for use in the cooling system of
liquid-cooled internal combustion engines. It is used for protection against freezing primarily in Arctic regions where the ambient temper-
ature remains for extended periods close to 40F or drops below, to as low as 90
"Use an accurate hydrometer. To test hydrometer, use 1 part ethylene glycol anti-freeze to 2 parts water. This should produce a
hydrometer reading of 0F.
Note. Fasten tag near radiator filler cap indicating the type anti-freeze.
and replace with anti-freeze to protect cooling
system. Refer to table 2-1 for Military anti-
freeze materials.
g. Batteries are shipped dry. Fill batteries
with electrolyte solution.
2-4. Installation of Separately Packed
Components
The unit is shipped completely assembled
and is ready to operate after services listed
in paragraph 2-3 have been performed. No
installation of separately packed components
is required.
2-2
25. Installation or Setting yp instryefions
No installation or setting up instructions are
required to prepare the motor grader for
operation.
2~o. Equipment Conversion
Various operations of the motor grader can
be performed without any conversion of the
equipment. All necessary details are included
in the operation section of this chapter. The
only modification that may be required is ad-
justment of scarifier teeth and is considered a
normal operating function.
Section II. TO A WORKSITi
2-7. Dismantling for Movement
a. The motor grader does not require dis-
mantling before moving to a new worksite.
b. Movement of the motor grader to a new
worksite can normally be accomplished by
moving the motor grader over the road under
its own power. Care should be observed to
provide clearance for other traffic when travel-
ing on public roads. The motor grader is wider
than normal vehicles and the moldboard should
be placed in line with the frame as much as
possible to avoid extension to either side and
increasing width of grader.
c. Long distance moving of the grader should
be accomplished with transportation equipment
of a suitable type. Flat bed truck-drawn trail-
ers or railroad flat cars are the most suitable.
Depending upon length of journey and type of
terrain to be traversed, tiedown and block
motor grader securely. See figure 2-1.
2-8, ReinsfoISotion after Movement
No reinstallation after movement is required.
Depending on length and type of movement,
inspect and service motor grader as detailed
in paragraph 2-3 if necessary.
2-9. General
Section III. CONTROLS AND INSTRUMENTS
proper operation of the motor grader.
This section describes, locates, illustrates and
furnishes operator, crew, or organizational
maintenance personnel sufficient information
about various controls and instruments for
210. Controls and Instruments
The purpose of controls and instruments and
their normal and maximum reading are illu-
strated in figure 2-2.
Section IV. OPERATION OF EQUIPMENT
2-1 1. General
a. Instructions in this section are published
for information and guidance of personnel
responsible for operation of the motor grader.
6. The operator must know how to perform
every operation of which the motor grader is
capable. This section gives instructions on
starting and stopping the motor grader, basic
motions of the motor grader, and coordinating
basic motions to perform specific tasks for
which the equipment is designed. Since nearly
every job presents a different problem, the
operator may have to vary given procedures to
fit the individual job.
2-12. Starting
a. Preparation for Starting.
(1) Perform necessary daily preventive
maintenance services (para 3-6).
(2) Turn handle of battery disconnect
switch (fig. 2-2) clockwise and push
handle in to connect batteries.
b. Starting. Refer to f.gure 2-3 and start
the motor grader.
2-13. Stopping
a. Center moldboard under grader and lower
to ground.
6. Refer to figure 2-4 and stop the motor
grader.
c. Perform the necessary daily preventive
maintenance services.
2-3
PANEL LIGHT.
LIGHTS UP PANEL
FOR NIGHT OPERATION.
STARTER SWITCH.
DEPRESS TO
CRANK ENGINE.
OIL PRESSURE GAGE.
INDICATES PRESSURE
OF ENGINE
LUBRICATING OIL.
WHEN ENGINE IS AT
OPERATING TEMPERATURE,
NORMAL OIL PRESSURE
IS FROM 30 TO 60
POUNDS PER SQUARE
INCH.
FRONT FLOODLIGHT
SWITCH. LIFT LEVER
UP TO OPERATE
FRONT FLOODLIGHTS.
HORN BUTTON.
DEPRESS TO
SOUND HORN.
AMMETER. INDICATES
CHARGE OR DISCHARGE
RATE OF GENERATOR
AND BATTERIES.
SHOULD BE IN THE
CHARGE RANGE WHEN
ENGINE IS OPERATING
AT NORMAL SPEEDS.
COOLANT TEMPERATURE
GAGE. INDICATES
SK ENGINE COOLANT
TEMPERATURE. NORMAL
OPERATING TEMPERATURE
IS FROM 160 TO 180
FAHRENHEIT.
LIGHT SWITCH. CONTROLS OPERATION OF
VEHICLE LIGHTS AS FOLLOWS:
REAR FLOODLIGHT
SWITCH. LIFT LEVER
UP TO OPERATE
REAR FLOODLIGHT.
1. PLACE UPPER LEVER IN POSITION RE-
QUIRED. B.O. DRIVE AND B.O. MARKER
POSITIONS OPERATE BLACKOUT LIGHTS.
STOP LIGHT POSITION OPERATES STOP
LIGHT. SER. DRIVE POSITION OPERATES
HEAD AND TAlLLIGHTS.
2. TO PLACE UPPER LEVER IN SER. DRIVE
POSITION, RAISE UNLOCK LEVER. SWITCH
MUST BE IN SER. DRIVE POSITION TO
OPERATE FLOODLIGHTS.
3. LOWER LEVER CONTROLS PANEL LIGHT
AND PARKING LIGHTS.
A. INSTRUMENT PANEL
MEC 3805-237-12/2-2
Figure 2-2 . Controls and instruments.
2-4
CIRCLE REVERSE LEVER.
PULL LEVER BACK TO
ROTATE MOLDBOARD
CLOCKWISE. PUSH LEVER
FORWARD TO ROTATE MOLD-
' BOARD COUNTERCLOCKWISE.
LATERAL SHIFT LEVER.
PULL LEVER BACK TO
SHIFT MOLDBOARD CIRCLE
TO RIGHT. PUSH LEVER
FORWARD TO SHIFT
MOLDBOARD CIRCLE TO
LEFT,
FRONT WHEEL LEAN LEVER,
PUSH LEVER FORWARD TO
LEAN WHEELS TO RIGHT.
PULL BACK ON LEVER TO
LEAN WHEELS TO LEFT.
LEFT MOLDBOARD
LI FT LEVER.
PULL LEVER BACK
TO LI FT MOLDBOARD.
PUSH LEVER FORWARD
TO LOWER MOLDBOARD
STEERING WHEEL.
TURN WHEEL IN
DIRECTION OF
TRAVEL TO STEER
MOTOR GRADER.
WHEEL OPERATES
POWER STEERING
CLUTCH PEDAL.
DEPRESS TO '
DISENGAGE
CLUTCH.
SCARIFIER LIFT LEVER.
PULL BACK ON LEVER
TO RAISE SCARIFIER.
PUSH FORWARD ON
LEVER TO LOWER
SCARIFIER.
RIGHT MOLDBOARD
LIFT LEVER. PULL
LEVER BACK TO LIFT
MOLDBOARD. PUSH
LEVER FORWARD TO
LOWER MOLDBOARD.
POWER SHIFT LEVER.
PULL LEVER TO
LEFT TO SHIFT
MOLDBOARD TO
LEFT. PULL LEVER
TO RIGHT TO SHIFT
MOLDBOARO TO RIGHT,
BRAKE PEDAL.
DEPRESS TO
STOP GRADER.
GOVERNOR CONTROL
LEVER. PULLING
BACK ON LEVER
INCREASES ENGINE
SPEED.
PARKING BRAKE
LEVER. ROTATE
LEVER AND PULL
UP TO SET PARKING
BRAKE.
ACCELERATOR. DEPRESS
TO INCREASE ENGINE
SPEED.
LOWER TRANSMISSION
SHIFT LEVER. CONTROLS
OPERATION OF LOWER
TRANSMISSION.
UPPER TRANSMISSION
SHIFT LEVER. CONTROLS
OPERATION OF UPPER
TRANSMISSION.
DECELERATOR. DEPRESS
TO DECREASE ENGINE
SPEED WHILE SHIFTING
OR OPERATING
MOLDBOARD.
B. OPERATOR'S CONTROLS
MEC 3805-237-12/2-2
Figure 2-2 .-
214. Operation under Usual Conditions
a. Start Motor Grader. Refer to paragraph
2-12 and start motor grader.
b. Placing Grader in Motion.
(1) With engine running at operating
temperature depress the clutch pedal
(fig. 2-5).
(2) Release parking brake lever (fig.
-continued.
2-5).
(3) Place governor control lever at 14
throttle and move transmission shifter
levers (fig. 2-5) in position to provide
power requirements for the work to be
performed. Refer to figure 2-6 and
table 2-2 for suggested transmission
speeds.
2-5
COLO WEATHER
;START!NG AID PRIMER
!KNOB. PULL KfNOB
(OUT FOR ONE TO TWO
j SECONDS TO INJECT
STARTING FLUID IN
NG(NE.
IATTERY DISCONNECT
SWITCH. PULL UP AND
TURN HANDLE ONE-
QUARTER TURN TO
DISCONNECT BATTERIES
FROM GRADER CIRCUITS.
ENGINE SHUTOFF LEVER.
PULL OUT ON KNOB TO
SHUTOFF ENGINE IN
NORMAL OPERATION.
SEAT ADJUSTMENT HANDLE.
DEPRESS HANDLES ON BOTH
SIDE TO RAISE, LOWER, OR
REMOVE SEAT.
1
C. STARTING CONTROLS.
ENGINE EMERGENCY SHLJTOFF
LEVER. TO STOP ENGINE
IN AN EMERGENCY, PULL OUT
LEVER AND HOLD UNTIL
ENGINE STOPS.
D. ENGINE SHUT OFF CONTROLS.
I ENGINE HOUPMt'.TER
; REGISTLRS ELAPSLD
; RUNNING TIME O',-
ENGINE.
B.VntKY CHARGING RECEPTACLE
kl'MOVE CAP AND PLUG IN
CABLH TO CHAR OF. BATTERY
AND AID IN STARTING GRADER
OR OI'RATING ELECTRICAL
EQUIPMENT.
L
E. HOUK'MLTI'.R.
MF.C 3805-?37- 12/2-2(3)
Figure 2-2 .-- -continued.
2-6
GOVERNOR
y CONTP.OI.
wHwr^ntvwTr"*" ~\ ,r* "fTA , "' X"' ^*'f"
UPPER
TRANSMISSION
LEVER
ENGINE OIL ;/!
PRESSURE
AGE
LOWER ,
TRANSMISSION
LEVER
U PUCE ALL CONTROL AND TRANSMISSION LEVliRS IN ^UTRAL POSITION .
Tfc> a. PLACE GOVERNOR CONTROL LEVER AT APPROXIMATELY 1/4 THROTTLE ,
* D-EPR6SS CLUTCH PEDAL.
, PRISS STARTER SWITCH UNTIL ENGINE STARTS.
00 NOT CRANK: ENGINE MORE THAN 30 SECONDS CONTINUOUSLY WITHOUT
AtlOWlNG A TWO MINUTE C6OLING OFF PERIOD, IF ENGINE DOES NOT
. JtART AFTER A FEW TRIES, STOP CRANKING AND DETERMINE CASUE. CORRECT
OR REPORT CONDITION TO ORGANIZATIONAL MAINTENANCE.
AFTO ENGINE STARTS, CHECK ENGINE OIL PRESSURE . NORMAL PRESSURE
(30 TO 60 PSO SHOULD BE INDICATED .
RILEASE CLUTCH PEDAL .
*lySW GOVERNOR CONTROL LEVER IN TO IDLE POSITION.
AiLOW ENGINE TO WARM UP AT APPROXIMATELY IDLE SPEED . OPERATING
flMPERATURE RANGE IS 160 TO 180 F.
MEC 3805-237-12/2-3
$Tff $4
6
> 7,
Figure 2-3. Starting the motor grader.
2-7
Table 2-2. Transmission Lever Positions
Work
Upper transmission lever
position
Lower transmission lever
position
Forward speed
Miles per hour
Bank sloping
L
1
1st
2.2
Clearing
L
1
1st
2.2
Ditching
L
1
1st
2.2
Leveling
L
1
1st
3.2
Scarifying
L
1
1st
2.2
Inslope finishing
L
1
1st
2.2
Snow plowing
L
2
3rd
4.4
Terracing
H
1
2nd
3.2
Spreading
H
1
2nd
3.2
Finish
L
1
1st
2.2
Light dozing
H
1
2nd
3.2
Highway travel
H
3
6th
22.5
Shoulder grading
H
1
2nd
3.2
Surface grading
H
1
2nd
3.2
ide filling
H
1
2nd
3.2
Nate, Speeds and gear ranges shown in table are suggested and are at the discretion of the operator in the interests of safety and
the power requirements of the job.
Note. The upper transmission lever controls high (H) and low (L) ranges and reverse gear (R).
(4) Slowly release clutch pedal until
grader begins to move. Continue to
release clutch pedal while simultane-
ously depressing accelerator (fig. 2-5)
or pulling back on governor control
lever to increase engine speed.
Note. Avoid spinning the tandem tires
when starting out. Spinning damages road
surfaces and causes excessive tire wear.
(5) With clutch pedal fully released, con-
trol speed of grader with governor
control lever or accelerator.
c. Shifting Transmission While in Motion.
Note. Always start motor grader in transmission
speed that will permit completion of work or cut with-
out requiring further shifting.
(1) Depress clutch pedal and depress de-
celerator pedal (fig. 2-5) to decrease
engine speed. Do not depress clutch
pedal all the way to avoid setting
clutch brake.
Caution: If changing direction of
travel, bring grader to a complete stop
before shifting.
(2) Shift transmission shifter levers as
required to provide correct transmis-
sion speed.
(3) Release clutch pedal smoothly and in-
crease engine speed to maintain mo-
mentum.
d. Steering. Steer the motor grader with the
steering wheel (fig. 2-5). Movement of the
steering wheel operates the power steering sys-
tem. A hydraulic cylinder assists in moving the
front wheels in the direction of the turn. Turn
wheel in opposite direction to center wheels
after completion of turn. Front wheels also
have a leaning feature to prevent drifting or
side-skidding of front wheels due to the force
of the load on the moldboard.
e. Moldboard Operation. The basic function
of the motor grader is grading with the mold-
board. Many types of grading can be accom-
plished. The moldboard is power operated and
can be positioned to perform all grading opera-
tions.
Note. Before placing machine into operation, engine
must be running at operating temperature (para
2-12).
(1) Raising moldboard. Pull back on lift
control levers (fig. 2-7) to raise mold-
board.
Note. Remove scarifier teeth when not
using scarifier to keep them from filling with
dirt and debris.
(2) Lowering moldboard. Push forward
on lift control levers on lower mold-
board.
(3) Lateral shift of moldboard. The mold-
board can be shifted laterally to either
side by moving the lateral shift lever
2-8
GOVERNOR
CONTROL
LEVER
UPPER .
TRANSMISSION
LEVER
LOWER
TRANSMISSION
LEVER
STEP1. DEPRESS CLUTCH PEDAL.
STEP 2. PLACE ALL CONTROL AND TRANSMISSION LEVERS fN NEUTRAL
POSITION.
STEP 3 . RELEASE CLUTCH PEDAL .
STEP 4, SET PARKING BRAKE.
STEP 5, PLACE GOVERNOR CONTROL LEVER IN IDLE POSITION.
STEP 6. ALLOW ENGINE TO OPERATE AT IDLE SPEED FOR 4 OR 5 MINUTES .
STEP 7. PULL OUT ON ENGINE SHUTOFF LEVER (FIG. 2-2) AND HOLD
OUT UNTIL ENGINE STOPS.
MEC 3805-237-12/2-4
Figure 2-4. Stopping ike motor grader.
(fig. 2-7) . To move the moldboard to
the right, pull back on the lever. Push-
ing forward on the lever will move
the moldboard to the left. In shifting
the moldboard laterally in this man-
ner the entire circle is shifted.
(4) Shifting moldboard. The moldboard
can be shifted laterally as above with
the lateral shift levers. Model 440HA
motor graders are equipped with a
power shift moldboard which permits
lateral shifting of moldboard either to
2-9
GOVERNOR
CONTROL
LEVER
!"' STEERING/ *
WHEEL
' ACCELERATOR TRANSMISSION '*
^ijm*JwJr '^ySfr LEVER
/._._..
MEC 3805-237-12/2-5
DECELERATQR
Figure 2-5. Placing grader in motion.
the right or left without shifting the
circle. The power shift moldboard is
controlled by the power shift lever
(fig. 2-7). Moving power shift lever
to the left will move moldboard to the
left. Moving lever to the right will
shift moldboard to the right.
(5) Angling moldboard. To provide for
delivery of material either to the right
or left of machine while grading mold-
board is to be rotated until desired
angle has been obtained. For delivery
of material to left of grader, pull back
on circle reverse lever (fig. 2-7). To
angle moldboard in opposite direction
for delivery of material to right of
grader, push circle reverse lever for-
ward.
/. Moldboard Link Adjustments. In addition
to the moldboard movements listed above,
range of the movements can be supplemented
by moving the link adjustments.
(1) Lift link adjustment. The right and
left hand lift links (fig. 2-8) have five
adjustments to provide greater or less
height to moldboard lift. To adjust
links, loosen clamp bolts (A). Lower
moldboard to ground to take weight
off locking pins (B). Remove cotter
pins and remove locking pins. Operate
left control levers to raise or lower
lift link tubes to desired position. In-
2-10
*J
Vjr
R H 2
!|| Ip Ifl FORWARD
REVERSE
1ST L-l
1ST R-l
2ND H-l
2ND R-2
3RD L-2
3RD R-3
' x
4TH H-2
5TH L-3
6TH H-3
1
M
(V
L 3
.. _ (r\
MEC 3305-237-12/2-6
Figure 2-6. Transmission shifting diagram.
stall locking pin through holes and
secure with cotter pin. Tighten clamp
bolts.
Note. Both lift links must be adjusted.
For normal operation, locking pin should
be in hole 3 or 4 (fig. 2-8) in right hand
link and in hole 3 in left hand link.
(2) Lateral link adjustment. The lateral
link adjustment (fig. 2-9) allows the
operator to fully extend the moldboard
to either side or to shorten the lateral
shift of the moldboard. To adjust
lateral link, remove cotter pin and
locking pin. Shift moldboard, using
lateral shift lever (fig. 2-7) to slide
adjusting link to desired position. In-
stall locking pin in proper hole and
secure with cotter pin.
Note. Figure 2-9 illustrates the lateral link
connected to the left side of the circle draw-
bar. When moldboard operation is to be on
the right side of the grader the lateral link
should be in this position. If moldboard op-
eration is to be on the left side of the grader,
disconnect link from ball on drawbar by
loosening bolts holding cap to ball and connect
link to ball on right side of circle drawbar.
Tighten screws securely.
g. Pitching Moldboard. As grader moves and
material slides along moldboard, moldboard
must be pitched properly for correct discharge
of material. To adjust moldboard pitch proceed
as follows.
(1) Lower moldboard to the ground, with
moldboard at right angles to wheels.
(2) Remove cotter pins from pivot bolts
(fig. 2-10) on plates at both ends of
moldboard.
(3) Loosen nuts on locking plates (fig.
2-10) until locking plate is free of
notches.
(4) Move motor grader forward or back-
ward until desired pitch of moldboard
is obtained.
(5) Install lock plates in notches and
tighten nuts. Tighten pivot bolt nuts
and secure with cotter pins.
h. Grading. Normal grader operation con-
sists of spreading, finishing, or bulldozing with
the moldboard. To perform the grading oper* 1 -
tion proceed as follows:
(1) tart grader engine (para 2-12).
(2) Position scarifier block, using scarifier
lever (fig. 2-7) , to provide clearance
between scarifier block and circle
drawbar during operation.
(3) Adjust front wheels to a vertical posi-
tion by moving front wheel lean lever
(fig. 2-7) as necessary.
(4) Lower moldboard with moldboard lift
levers (fig. 2-7).
(5) Angle moldboard, using circle reverse
lever (fig. 2-7), to proper angle.
Note. Moldboard must be positioned to dis-
charge dirt either inside or outside of rear
wheels. Cut cannot be kept .straight if whels
run over discharged dirt.
(6) To properly position moldboard dur-
ing various operations, it may be
necessary to operate moldboard lift
levers, circle reverse lever, and lateral
shift lever in sequence or simultane-
ously. All levers aid in positioning the
moldboard to extent desired, the lat-
eral link may have to be adjusted
(Para / above) . The power shift lever
may be utilized to extend the mold-
board.
(7) With moldboard positioned, place
grader in motion (b above) . As grader
moves forward, check grader for side
2-11
w
LATERAL SHIFT 1 CIRCLE REVERSE
LEVER i LEVER
FRONT WHEEL
LEAN LEVER
SCARIFIER
LIFT LEVER
RIGHT MOLDBOARD
LIFT LEVER
LEFT MOLDBOARD
LIFT LEVER
- ** " ,'' 'VmRf-,'^' awsrT ""sBis*
-POWER SHIFT
MEC 3805-237-12/2-7
Figure 2-7. Moldboard operation levers.
thrust caused by load on moldboard.
(8) If grader is shifting to the side, lean
front wheels in opposite direction, us-
ing front wheel lean lever (fig. 2-7)
to offset side thrust of blade and keep
grader in straight line.
Raise or lower moldboard as neces-
(9)
sary to accomplish amount of grading
necessary to produce result desired.
i. Ditching. The motor grader can be used
to form flat bottom ditches by operating in a
series of steps as described below.
(1) To maintain a straight ditch, set a
line of stakes to follow before making
first cut.
(2) Set moldboard as described above,
with point of moldboard positioned
directly behind front wheel (fig.
2-11).
(3) As motor grader moves forward, point
of moldboard blade is pushed into
ground. Point is positioned directly
behind front wheel to hold proper
alignment. In succeeding cuts (fig.
2-12) front and rear wheels should
track in previous cut.
(4) Lean front wheels slightly away from
ditch to overcome side thrust.
(5) At completion of first cut (fig. 2-12),
position motor grader as shown in sec-
2-12
2-8
I
Fiyure 2-8. Lift link adjustment.
Figure 2-9. Lateral link adjustment.
PIVOT
BOLT
MG1.DBGARD
Figure 2-10. Pitching moldboard.
ond operation. Point of moldboard
should be approximately 1 foot away
from first cut, with wheels on cutting
side of grader riding in first cut and
wheels on opposite side on top of
ground (fig. 2-12).
(6) For third cut, position grader as
shown in third operation (fig. 2-12)
and complete cut.
(7) To finish ditch, shift moldboard to
position it outside of wheel as shown
in fourth operation (fig. 2-12) and
clean bottom of ditch. Last illustration
(fig. 2-12) shows finished ditch.
y. Bank Sloping. The moldboard, through use
of lateral shift lever, lift levers, circle reverse
lever, and changing lateral link and lift link
adjustments, can be set at any desired position
for bank sloping. Bank sloping is accomplished
by swinging and raising the moldboard to the
side of the grader at the angle of the desired
slope and moving the grader alnog the slope
with the moldboard cutting at the desired depth.
(1) Figure 2-13 illustrates moldboard and
link settings for right hand bank slop-
ing.
2-13
MEC 3805-237-1 2/2- 11
Figure 2-11. Preparing to start ditch cut.
(2) When bank sloping, operate front
wheel lean lever (fig. 2-7) to lean
wheels toward bank to counteract side
shift of motor grader.
Note. When bank sloping at a 90 angle
as shown in figure 2-13, heel of moldboard
blade must extend beyond wheels.
(3) To prepare for bank sloping on left
side of motor grader reverse position
of lift link pins and position of lateral
link.
k. Scarifier Operation.
(1) A scarifier is used to rip material
which is too hard to cut with the mold-
board. To reshape the surface of a
gravel or stone road or runway, lower
scarifier block until teeth penetrate far
enough to get below bottom of chuck
holes. If greater penetration is de-
sired, teeth can be lowered by re-
positioning shanks in block or
lowering scarifier lift link tubes.
When operating in extremely hard
materials it is recommended that
scarifier teeth be positioned up into
block as far as adjustment permits.
2-14
A. FIRST OPERATION
I
B. SECOND OPERATION
C. THIRD OPERATION
D. FOURTH OPERATION
E. FLAT BOTTOM DITCH
Figure 2-12. Ditching operation.
MEC 3805-237-12/2-1 2
Note. During scarifier operation, block
must be parallel with ground.
(2) If scarifier, is to be used to break up
a crusted or asphalt surface, teeth
must be lowered and pitched at such a
degree to permit penetration beneath
hard surface and result in a lifting
action as machine is moved forward.
This will result in breaking up ma-
terial to permit its removal.
2-15
A. MOLDBOARD POSITIONS FOR BANKSLOPINO
A,B,C
D,E,F
B. LEFT HAND LINK
C. LATERAL LINK
D. RIGHT HAND LINK
MEC 3805-237-12/2-13
Figure 2 IS. Moldboard and link positions for bank sloping.
(3) At end of scarifying operation, raise
scarifier and remove scarifier shanks
and teeth (fig. 2-14) . Store teeth and
shanks in tool box.
(4) Position scarifier block in such a man-
ner to assure there will be no inter-
ference with circle drawbar during
moldboard operations.
2-16
I Installing scarifier teeth and shanks.
(1) Insert shank up through slot in bot-
tom of scarifier block and secure with
key (fig- 2-14).
(2) Desired extension of tooth and shank
is determined by positioning of
notches in shank opposite upper plate
of block.
n. Adjusting pitch of scarifier.
(1) Pitch of scarifier determines the
amount of tooth penetration. Three
(3) adjustments may be made at the
scarifier block and two (2) on the
scarifier lift link tubes.
PITCH
ADJUSTING
HOLES
SCARIFIER
TOOTH .
MEC 3805-237- 12/2-1 4
Figure 2-14. Installation or removal of scarifier
shank and tooth.
m. Removal of scarifier teeth and shanks.
(1) Push forward on lower portion of
tooth shank to permit removal of key.
(2) Lower shank until it clears block.
(3) If removal of tooth only is desired,
place end of tool (fig. 3-1) against
top of tooth body and strike with ham-
mer until tooth drops from shank.
Note. Scarifier teeth must be kept sharp to
obtain best results during operation.
MEC 3805-237-12/2-15
Figure 2-15. Adjusting pitch of scarifier.
(2) To adjust at block, first lower scarifier
to ground. Remove pitch adjusti
bolt (fig. 2-15) Raise or lower scar.
fier lift links by using control level
(fig 2-7) until block is positioned at
desired pitch. Install bolt, nut and
cotter key.
(3) To adjust at lift link tubes, first lower
scarifier to ground. Remove cotter pins
from locking pins at upper end of
tubes and drive out pins. Raise or
lower tubes depending on desired posi-
tion of scarifier using scarifier control
lever until pin hole in tube is aligned
with that in lift link. Install locking
pin and cotter pin.
o. Parking the Grader.
(1) Move motor grader to parking posi-
tion.
(2) Depress clutch pedal and move trans-
mission levers to neutral position.
(3) Depress brake pedal and bring motor
grader to a stop.
(4) Engage parking brake.
(5) Refer to paragraph 2-13 (fig. 2-4)
and stop motor grader engine.
-15. Operation in Extreme Cold (Below
F)
a. General If the motor grader is to be oper-
ted in extreme cold weather temperatures,
jrtain precautions must be taken to assure
>ntinued normal operations. The following
aragraphs detail checks to be made to be cer-
lin the grader is capable of operating at these
imperatures.
b. Cooling System. Check cooling system for
Drrect antifreeze solution for lowest tempera-
ire expected (table 2-1). Carefully inspect
ooling system and correct or report any leaks.
c. Batteries. Keep batteries fully charged to
revent freezing. If water is added to batteries,
un engine for at least one hour to mix
lectrolyte solution.
d. Fuel System. Keep fuel tank full at all
Lines. Drain condensate from fuel tank before
nd after operation. Drain and service fuel
liters (par 3-4).
e. Lubrication. Lubricate entire motor
;rader according to the current lubrication
>rder.
/. Operation. Start engine and allow it to
each normal operating temperature before ap-
ilying load.
(1) Operate hydraulic units with care
until units have reached a tempera-
ture to enable them to operate nor-
mally.
(2) Check all moldboard and grader oper-
ations with operating levers to be sure
they are in operating condition.
g. Parking.
(1) Park grader on high dry ground if
possible. Prepare a footing of planks
or brush if necessary to keep grader
wheels from freezing in ground. Chock
wheels and release parking brake.
Place blocks under moldboard to pre-
vent blade from freezing to ground.
(2) Clean all mud, snow, and ice from
grader to prevent freezing. Park
grader under cover or cover with a
tarpaulin if possible. Keep ends of
tarpaulin from freezing to ground.
2-16. Operation in Extreme Heat
a. General. Continuous heavy operation of
the motor grader in high temperatures may
cause the grader to overheat. Avoid continuous
low gear operation if possible. Continuously
observe engine temperature and halt grader
for a cooling-off period whenever necessary.
6. Cooling System. Make frequent inspec-
tions and servicings of the fan and radiator.
Keep coolant level to top of radiator. Check
grilles and radiator fins for accumulation of
dust, sand, and insects which could block cool-
ing passages.
(1) Formation of scale and rust in cooling
system occurs more rapidly in ex-
tremely high temperatures. Change
anti-f reeze each year to keep corrosion
inhibitor at full strength.
(2) If necessary, flush cooling system per-
iodically to keep passages clear. Avoid
use of water with a high alkali con-
tent which increases scale and rust
formations.
c. Batteries. Check level of electrolyte daily.
Keep electrolyte above plates to prevent dam-
age to batteries. Use a slightly weaker elect-
rolyte in hot climates. Dilute 1.280 specific
gravity electrolyte as issued to 1.200 to 1.240
specific gravity reading at full charge. Recharge
batteries at 1.160 specific gravity. Batteries
self-discharge at a higher rate if left standing
for long periods at high temperatures. If
grader is to stand for several days, remove
batteries and store in a cool place.
Caution: Do not store acid-type storage bat-
teries near stacks of tires ; the acid
fumes have a harmful effect on
rubber.
d. Fuel System. Service fuel system as di-
rected in the preventive maintenance (paras.
3-6 and 3-7) . Check fuel for water content be-
fore filling tank. High temperatures and cool-
ing off cause condensation in drums.
e. Lubrication. Lubricate as specified in cur-
rent lubrication order (para 3-2).
/. Parking.
(1) Do not park grader in sun for long
periods of time. When practical park
grader under cover to protect it from
sun, sand and dust.
(2) Cover inactive grader with tarpaulins
if no suitable shelter is available. Pro-
tect power plant compartment against
entry of sand.
(3) In hot, damp climates, corrosive action
will occur on all parts of the grader
and will be accelerated during the
rainy season. Rust and paint blisters
will appear on metal surfaces and
fungus growth on other surfaces.
(4) Protect all unfinished exposed metal
surfaces with a film of preservative
lubricating oil, medium (P10). Pro-
ject cables and terminals with igni-
tion-insulation compound. Apply paint
or suitable ru:-,t preventive to damaged
surfaces to protect from rust and cor-
rosion.
2-17. Operation in Dusty or Sandy Areas
a. General. Operation of the grader will
cause dust in almost any area. However, when
operating in predominantly dusty or sandy
areas additional precautions must be taken.
b. Cooling System. Keep cooling system radi-
ator fins and cooling areas clean. Blow out with
compressed air, if possible, as often as neces-
sary.
c. Fuel System. Use care when servicing fuel
system to prevent dust sand from entering
tank or filters.
d. Air System. Service air cleaner at fre-
quent intervals, checking it every few hours
and keeping dust cup clean. Avoid allowing
dust and sand to get into engine parts as much
as possible.
e. Lubrication. Lubricate grader according to
current lubrication order (fig. 3-2). Clean all
lubrication fittings thoroughly before applying
lubricant. Sand mixed with lubricant becomes
very abrasive and speeds wear on parts, there-
fore, lubricate and perform services at much
shorter intervals than normal.
/. Parking. Protect grader from dust and
sand as much as possible. Park grader under
cover or protect with tarpaulins to keep dust
and sand from damaging vehicle.
218. Operation under Rainy or Hufttid
Conditions
a. General. Operation under rainy or humid
conditions is similar to that in extreme heat.
b. Preservation. Keep all exposed surfaces
coated with preservative lubricating oil (PT
medium). Pay particular attention to damaged
painted surfaces. Cover all paint cracks and
chip marks as soon as possible to avoid corro-
sive effects.
219. Operation in Salt Water Areas
a. General. The corrosive effect of salt water
and salt water spray is very extensive. When
operating in salt water areas observe the fol-
lowing precautions.
b. Preservation.
(1) When exposed to salt water, dry
grader thoroughly and rinse as soon
as possible.
(2) Keep all exposed surfaces coated with
preservative lubricating oil (PT me-
dium) .
(3) Keep all painted surfaces in good re-
pair.
(4) Lubricate vehicle as prescribed in cur-
rent lubrication order (fig. 3-2).
Shorten lubricating intervals for parts
subject to exposure to salt water.
2-20. Operation at High Altitudes
a. Normally, operation of the motor grader
at high altitudes will be as outlined in para-
graph 2-15, operation in extreme cold.
bl Check engine operating temperature to
insure against overheating. The pressure cap
on the radiator must make a perfect seal to
maintain radiator pressure.
c. The operating efficiency of the grader en-
gine should not be affected. A blower assembly
on the engine maintains a sufficient supply of
air for the cylinders.
2-19
Section V. OPERATION OF AUXILIARY MATERIEL USED IN
CONJUNCTION WITH THE EQUIPMENT
2-21. General
a. This section contains detailed instructions
on the operation of auxiliary equipment issued
with the motor grader.
b. An ether cartridge type cold weather
starting aid is supplied to aid in starting the
grader engine in cold weather.
2-22. Cold Weather Starting Aid
a. General. The cold weather starting aid
used on the grader is of the ether primer type.
Figure 2-1 G. Cold loc.athcr starling aid.
Highly volatile fuel (ether) is injected into the
air intake system to assist in igniting fuel at
low temperatures. The fluid is contained in cap-
sules. The starting aid (fig. 2-16) is mounted
on the rear wall of the engine compartment,
with the primer knob (fig. 2-2) mounted on
the left side of the operator's compartment.
Tubing connects the starting aid to the air in-
take on the engine.
b. Operation.
(1) Remove cap (fig. 2-16) and install
container in top of valve. Secure con-
tainer with latch.
(2) Set governor control lever to 1/2 '%
speed. Pull out on primer knob (fig.
2-2) mounted in cab and hold out for
1 to 2 seconds (with engine turning
over). Push knob in to inject fluid
into air intake.
Caution: Do not pull primer knob
until cranking action starts. Serious
damage to the engine could result.
(3) If engine fails to start, wait 1 second
and repeat step (2) .
(4) When engine starts be sure primer is
pushed all the way down.
c. Precautions.
(1) Use starting aid only for starting en-
gine in cold weather.
(2) When motor grader is to be used only
in warm climates where starting aid
may not be required, remove container
(fig. 2-16) from valve and install cap
(fig. 2-16) on valve.
Caution: The above action will pre-
vent inadvertent injection of the
highly volatile fluid into the air intake
and resulting damage to the engine
when started.
2-20
CHAPTER 3
OPERATOR AND ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I. OPERATOR AND ORGANIZATIONAL MAINTENANCE TOOLS AND EQUIPMENT
3-1. Special Tools and Equipment
Table 3-1 lists the special tools applicable to
Table 8-1. Special Tools
operator and organizational maintenance of the
motor grader.
Item
FSN or
Part No,
Reference
Use
Fiprure
Paragraph
Tool, scarifier
tooth removing 1
429581
3-1
2-14fc
Removing tooth from
scarifier shank
MEG 3805-237-12/3-1
Figure S-l. Special tools.
32. Basic Issue Tools and Equipment
Tools and repair parts issued with or autho-
rized for use with the motor grader are listed
in the Basic Issue Items List, Appendix B of
this manual.
Section II. LUBRICATION
3-3. General Lubrication Information
a. This section contains a reproduction of the
lubrication order and lubrication instructions
which are supplemental to, and not specifically
covered in the lubrication order.
3-4. Detailed Lubrication Information
a. General. Keep all lubricants in closed con-
tainers and store in a clean dry place away
from external heat. Allow no dust, dirt, or
other foreign material to mix with the lubri-
cants.
6. Cleaning. Clean lubricant from all ex-
ternal parts not requiring lubrication. Before
lubricating the equipment, wipe all lubrication
points free of dirt and grease. Clean all lubri-
cation points after lubricating to prevent ac-
cumulation of foreign matter.
c. Points of Lubrication. Service the points
of lubrication at proper intervals as illustrated
in figure 3-2.
d. Localized Lubrication Points. Refer to
figure 3-2 for localized lubrication points. All
grease fittings are circled and should be lubri-
cated with grease (GAA), using a pressure
grease gun every 10 hours or daily.
e. Crankcase Oil Level.
(1) Crankcase oil level must be checked
frequently. Refer to figure 3-3 for oil
level gage.
(2) Oil may require changing more fre-
quently than usual because of con-
3-1
LUBRICATION CHART
__
GRADER, ROAD, MOTORIZED: DI1SIL DRIVEN; 12 fT
MOLDBOARD (WABCO-CSD MODEL 44OHA)
W/ENG1NE GM MODEL 4057
Intervals are based on normal hours of operation. Reduce
to compensate for abnormal operation and severe condi-
tions. During inactive periods, sufficient lubrication must
be performed for adequate preservation.
Clean fittings before lubricating.
A dotted circle indicates a drain below.
LUBRICANT INTERVAL
Steering Gear
(Lubricated by
Hydraulic Oil.)
-Scarifier Lift GO
Housing Fill
Plug (See key.)
Scarifier Lift
Housing Drain
(Drain and refill.)
-Scarifier Lift
Housing Level
(Check Level .)
1000
so
-Lift Housing
and Level Plug
(See key.)
(Check Level.)
.Lift Housing
Drain
(Drain and refill.)
Scarifier Control
Shaft
(1 Fitting, 2 uni-
versal joints.)
oo so
1000
OAA 10
Relubricate after washing or fording.
Clean parts with SOLVENT, dry-cleaning, or with OIL, fuel,
Diesel. Dry before lubricating.
Lubricate points indicated by dotted arrow shafts on both
sides of equipment.
Drain gear cases only when hot after operation; replenish and
check level when cool .
INTERVAL LUBRICANT
GO Front Wheel Lean-
Housing Fill
Plug (See key.)
1000
50
Front Wheel Lean -
Housing Drain
(Drain and refill. )
Front Wheel Lean '
Housing Level
(Check Level.)
10 OAA Blade Lift Link
10 OAA Front Wheel Lean -
Control Shaft
(2 Fittings, 3 uni-
versal joints.)
10 OAA Lift Control Shaft -
(2 Fittings, 3 uni-
versal joints.)
Ol Power Control
Box Fill Plug
(See key. )
1000 Power Control
Box Drain
(Drain and refill.)
-10
SO
Power Control
Box Level
(Check Level.)
-N
-12
13
14
15
16
FRONT END VIEW
CONTINUED ON
FOLLOWING PAGE
MEC 3805-237- 12/3-2 M
LUBRICANT INTERVAL
'Vibrating Bar Fittings GAA 1O
(6 Fittings.)
Spindle Bushings GAA 10
and Drag Links
(3 Fittings ea. side. )
Scarifier Lift Link GAA 10
(2 Fittings ea. side. )
CONTINUED FROM
PRECEDING PAGE
Circle Reverse
Housing Fill
Plug (See key.)
Circle Reverse
Housing Drain
(Drain and refill. )
Circle Reverse
Housing Level
(Check Level.)
Circle Reverse
Transfer Housing
Fill Plug (See key.)
Circle Reverse
GO
100
50
Transfer Housing
Drain
(Drain and refill. )
Circle Reverie
Transfer Housing
Level (Check Level.)
1000
50
INTERVAL LUBRICANT
10 GAADrawbar
Sail and Socket
(2 Fittings.)
10 GAATie Rods
(2 Fittings.)
10 GAA Steering Arm
(2 Fittings.)
10 OAAMoldboard
Shift Cylinder
(2 Fittings.)
10 OAAMoldboard
Slide
(2 Fittings.)
OO Lateral Shift
Housing Fill
Plug (See key.1
1000
50
Lateral Shift
Housing Drain
(Drain and refill.
Lateral Shift
Housing Level
(Check Level.)
FRONT END VIEW
-KEY-
LUBRICANTS
CAPACITY
EXPECTED TEMPERATURES
INTERVALS
Above *32F
40F to -IOF
0f 10 -t>Sf
OE-OIL, Engine, Heavy Duty
OE30
OE 10
OES
Power Control Box
7 pit.
Oil Can Points
OES-OIL, Engine, Sub-Zero
GO-LUBRICATING OIL, Geor
GO 90
GO BO
COS
Intervals given
ore in hours of
normal opera-
tion.
Circle Reverse Transfer Housing
0.66 prs,
Scarifier Lift Housing
24.5 pts.
Lift Houslnp
3 pis. ea.
Front Wheel Leon Homing
8 prt.
Circle Reverie Housing
5 pts.
Lateral Shaft Housing
15,5 pti,
Lateral Shift Gear Reduction Hauling
3.5 pts.
GOS-LUBRICATING OIL, Gear, Sub-Zero
GAA-GREASE, Automotive and Artillery
ALL TEMPERATURES
NOTES:
1. FOR OPERATION OF EQUIPMENT IN PROTRACTED COLD. TEM-
PERATURES BELOW -)0F. Remove lubricants prescribed in the key
for temperatures above -10F. Clean parts with SOLVENT, dry-
cleaning. Relubricate with lubricants specified in the key for tem-
peratures below -10F.
2. OIL CAN POINTS. Every 50 hours, lubricate linkage pins,
clevises, and all exposed threads with OE.
3. UNIVERSAL JOINTS, Al disassembly, repack with GAA.
MEC 3805-237- 12/3-2
'4 mire, ft 9, fa f~!r>nt.inued.
LUBRICATION
GRADER, ROAD, MOTORIZED: DIESEL DRIVEN; 12 FT
MOLDiOARD (WABCO-CiD MODEL 44OHA)
W/ENGINE OM MODEL 4057
Relubricate after washing or fording.
Clean parts with SOLVENT, dry-cleaning, or with OIL, fuel
Diesel. Dry before lubricating.
34-
35
36
37
Intervals are based on normal hours of operation. Reduce
to compensate for abnormal operation and severe condi-
tions. During inactive periods, sufficient lubrication must
be performed for adequate preservation.
Clean fittings before lubricating.
A dotted circle indicates a drain below.
LUBRICANT INTERVAL
Scarifier Gear Reduction GO
Housing Fill Plug
(See key.)
Lubricate points indicated by dotted arrow shafts on both
sides of equipment.
Drain gear cases only when hot after operation; replenish and
c:heck level when cool .
INTERVAL LUBRICANT
Scarifier Gear
Reduction Housing
Drain
(Drain and refill.)
Scarifier Gear
Reduction Level
(Check Level.)
1000
50
Lift Gear GO
38
39
40
Reduction Housing
Fill Plug
(See key.)
Lift Gear
Reduction Housing
Drain
(Drain and refill.)
Lift Gear
Reduction Housing
Level (Check Level.)
-Lateral Shift
Link
(2 Fittings.)
1000
50
10 OAA Steering Control
Shaft
(2 Fittings, 2 uni-
versal joints. )
10 OO Circle Flange
(See note 3.)
10 OAA Circle Reverse
Control Shaft
(3 Fittings, 4 uni-
versal joints.)
41
OAA Lateral Shift
Control Shaft
(2 Universal joints. )|
GO Power Control Box
Vertical Drive
Housing Fill Plug
(See key.)
1000 Power Control Bo>* --46
Vertical Drive
Housing Drain
(Drain and refij-'l . )
50 Power Control Box -~47
Vertical Drive
Housing Level
(Check Level.)
CONTINUED ON
FOLLOWING PAGE
MEC 3805-237-12/3-2
Figure S-2 . Continued.
3-4
48
49-
50-
51
52
53-
54
LUBRICANT INTERVAL
CONTINUED FROM
PRECEDING PAGE
INTERVAL LUBRICANT
Lateral Shift OO
Gear Re'duclion
Housing Fill
Plug (See key.)
Lateral Shift
Gear Reduction
Housirtg Drain
(Drain and refill.)
Lateral Shift
Gear Reduction
Housing Level
(Check Level.)
100
50
Hydraulic Reservoir
Level (Check Level.)
50
50
-Reservoir Breather
(Remove Breather,
Clean, Reoil,
Install.)
Hydraulic Reservoir Fill Of 500
and Filter (See key.)
(See note 4.)
Hydraulic Reservoir
Drain (Drain and
Refill.)
1000
1000
50
OO Upper Transmission"
and Shifter Housing
Fill Plug (See key.)
Upper Transmission -
and Shifter Housing
Drain (Drain and
refill.)
Upper Transmission
Level (Check Level.)
50 OO Lower Transmission-
Fill and Level
Plug (See key.)
(Check Level.)
1000
Lower Transmission'
Drain
(Drain and refil.l.)
10 GAA Wheel Bearings-
(Sparingly)
(See note 5.)
REAR END VIEW
-KEY-
250 GAA Pintle Hook-
(3 Fittings.)
LUBRICANTS
CAPACITY
EXPECTED TEMPERATURES
INTERVALS
Above +32F
tOF to -IOF
0F lo -65F
OE-OIL, Engine, Heovy Duty
OE 20
OE 10
OES
Intervals given
are in hours of
normal opera-
tion.
Hydraulic System
32.5 pts.
Oil Con Point!
OE 30
OE 10
OES
OES-OlL, Engine, Sub-Zero
GO-LUBRICATING OIL, Gcor
GO 90
GO 80
GOS
Scarifier Gear Reduction Housing
I.Spts.
Lift Gear Reduction Housing
3. 5 pts. eo.
Power Box Vertical Drive Shaft Housing
7.75 pis.
Lateral Shift Gear Reduction Housing
3.5 pis.
Upper Transmission
12 pts.
Lower Transmission
63 pts.
GOS-LUBRICATING OIL, Gear, Sub-Zero
GAA-GREASE, Automotive and Artillery
ALL TEMPERATURES
NOTES:
1. FOR OPERATION OF EQUIPMENT IN PROTRACTED COLD TEM-
PERATURES BELOW -IOF. Remove lubricants prescribed in the key
for temperatures above -IOF. Clean parts with SOLVENT, dry-
cleaning. Re lubricate with lubricants specified in key for tempera-
tures below -10F.
2. OIL CAN POINTS. Every 50 hours, lubricate linkage, pins,
clevises, and all exposed threads w.ith OE.
3. CIRCLE FLANGE. Flush circle flange and apply coat of GO.
4. HYDRAULIC RESERVOIR AND FILTER. Fill reservoir lo full
mark. Start engine and operate all hydraulic controls.
Check level and bring to full mark. Change filler elements
every 500 hours.
5. WHEEL BEARINGS. Every 1000 hours remove, clean, in-
spect and lubricate and reassemble.
6. UNIVERSAL JOINTS. At disassembly, repack with GAA.
MEC 3805-237-12/3-2 (7)
Figure S-2 . Continued.
LUBRICATION CHART
GRADIR, ROAD, MOTORIZED: DIESEL DRIVEN; 12 FT
MOLDBOARD (WAiCO-CID MODEL 44OHA)
W/iNGINi GM MOD1L 4057
REFERENCE:
C9100-1L
62
63-
64-
Intervals are based on normal hours of operation. Reduce
to compensate for abnormal operation and severe condi-
tions. During inactive periods, sufficient lubrication must
be performed for adequate preservation.
Clean fittings before lubricating.
A dotted circle indicates a drain below.
LUBRICANT INTERVAL
-Master Cylinder HSA 10
Fill and Level
(See key.)
(Check Level.)
Relubricate after washing or fording.
Clean parts with SOLVENT, dry-cleaning, or with OIL, fuel,
Diesel. Dry before lubricating.
Lubricate points indicated by dotted arrow shafts on both
sides of equipment.
Drain gear cases only when hot after operation; replenish and
check level when cool.
INTERVAL LUBRICANT
Fuel Filter and
Strainer (Change
Elements.)
Engine Oil
Level Gage
(Check Level.)
250
10
Engine Crankcase OI
(See key.)
Axle Bearings OAA 10
(2 Fiftingi
ea. side.)
Engine Oil
Filter (Change
Elements.)
(See note 4.)
too
10 OAA Throttle Linkage-
(6 Fittings.)
10 OAA Brake Linkage
(5 Fittings.)
10 OAA Drive Shaft
10
10
50
Universal Joint
(2 Universal jolnti.)
OAA Clutch Bearings
(2 Fittings.)
OAA Outboard and
Inboard Bearings
Tandem Drive-
Level (Check Level.)
1000
100
Ol Tandem Drive
Fill (See key.)
Tandem Drive
Drain (See not- 3.)
(Drain and refill.)
Engine Oil
Drain
(Drain and refill.)
REAR END VIEW
CONTINUED ON
FOLLOWING PAGE
70
71
72
-73
-74
MEC 3805-237-12/3-2(5
75
CONTINUED FROM
PRECEDING PAGE
-KEY-
LUBRICANTS
CAPACITY
EXPECTED TEMPERATURES
INTERVALS
Above +32F
+40F to -10F
0F to -65F
OE- OIL, Engine, Heavy Duty
OE 30
OE 10
OES
Intervals
given are
in hours of
norma 1
operation
Engine Crankcase
12qts.
Tandems
32 pts. ea .
Oil Can Points
OES- OIL, Engine, Sub- Zero
NBA- HYDRAULIC FLUID, Non-Petroleum
ALL TEMPERATURES
Master Cylinder
1.25qh.
GAA- GREASE, Automotive and Artillery
NOTES:
1. FOR OPERATION OF EQUIPMENT IN PROTRACTED
COLD TEMPERATURES BELOW -10F. Remove lubricants
prescribed in key for temperatures above -10F. Clean
parts with SOLVENT, dry-cleaning. Relubricate with
lubricants specified in key for temperatures below -10F.
2. OILCAN POINTS. Every 50 hours, lubricate linkage
pins, clevises and all exposed threads with OE.
3. TANDEM DRAIN. Every 1000 hours drain tandems.
Place tandems in uphill position and remove tandem level
and drain plug.
4. ENGINE OIL FILTER. After installing new element,
fill crankcase, operate engine 5 minutes, check filter
housing for leaks, check crankcase oil level and fill to
proper level .
5. UNIVERSAL JOINTS. At disassembly repack with GAA.
MEC 3805-237-12/3-2
Figure S-2 . Continued.
3-7
REF. 1. STEERING GEAR
REF. 12, FRONT LEAN WHEEL CONTROL SHAFT
REF, 19. SCARIFIER LIFT LINK
REF. 5. LIFT HOUSING FILL AND LEVEL PLUG
REF. 6. LIFT HOUSING DRAIN
REF. 37, GEAR REDUCTION HOUSING FILL PLUG
REF. 38. GEAR REDUCTION HOUSING DRAIN
REF. 39. GEAR REDUCTION HOUSING LEVEL
2. SCARIFIER LIFT HOUSING FILL PLUG
3. SCARIFIER LIFT HOUSING DRAIN
A, SCARIFIER LIFT HOUSING LEVEL
34. GEAR REDUCTION HOUSING FILL PLUG
35. GEAR REDUCTION HOUSING DRAIN
REF. 36. GEAR REDUCTION HOUSING LEVEL
REF
REF
REF
REF
REF
REF. 8. FRONT WHEEL LEAN HOUSING FILL PLUG
REF. 9, FRONT WHEEL LEAN HOUSING DRAIN
REF. 10. FRONT WHEEL LEAN HOUSING LEVEL
REF. 17. VIBRATING BAR FITTINGS
REF. 11. BLADE LIFT LINK
REF. 40. LATERAL SHIFT LINK
MEC 3805-237-12/3-2 (7
Figure 3-2 . Continued.
^
REF.7. SCARIFIER CONTROL SHAFT
REF. 12. FRONT WHEEL LEAN CONTROL SHAFT
REF. 13. LIFT CONTROL SHAFT
REF, 41. STEERING CONTROL SHAFT
REF. 43. CIRCLE REVERSE CONTROL SHAFT
REF. 44. LATERAL SHIFT CONTROL SHAFT
REF. 14. POWER CONTROL BOX FILL PLUG
REF. 15. POWER CONTROL BOX DRAIN
REF. 16. POWER CONTROL BOX LEVEL
REF. 45. VERTICAL DRIVE HOUSING FILL PLUG
REF. 47. VERTICAL DRIVE HOUSING LEVEL
REF. 17. VIBRATING BAR FITTINGS
REF. 18. SPINDLE BUSHINGS AND DRAG LINKS
MEC 3805-237-12/3-2
Figure 3-2 . Continued.
REF. 20. CIRCLE REVERSE HOUSING FILL PLUG
REF. 21. CIRCLE REVERSE HOUSING DRAIN
REF. 22. CIRCLE REVERSE HOUSING LEVEL
REF. 23. CIRCLE REVERSE TRANSITS HOUSING
FILL PLUG
REF. 24. CIRCLE REVERSE TRANSFER HOUSING
DRAIN
REF. 25. CIRCLE REVERSE TRANSFER HOUSING
LEVEL
REF. 42. CIRCLE REVERSE FLANGE
REF. 26. DRAWBAR BALL AND SOCKET
REF. 29. MOLDBOARD SHIFT CYLINDER
REF. 30, MOLDBOARD SLIDE
REF. 17. VIBRATING BAR FITTINGS
REF. 26. DRAWBAR BALL AND SOCKET
REF. 27. TIE RODS
REF. 28. STEERING ARM
REF,
REF,
REF.
REF.
REF,
REF.
31.
32.
33.
48.
49.
50.
LATERAL SHIFT HOUSING FILL PLUG
LATERAL SHIFT HOUSING DRAIN
LATERAL SHIFT HOUSING LEVEL
GEAR REDUCTION HOUSING FILL PLUG
GEAR REDUCTION HOUSING DRAIN
GEAR REDUCTION HOUSING LEVEL
MEC 3805-237- 12/3-2 (9)
Figure S~2 . Continued.
REF. "46. VfR'HOM DKIVT HOUSING DRAIN
REF. 69. IHMVi- SHAM UNIVERSAL JOINT
NOTE: REFERENCE 54 . TO DRAIN
DISCONNECT HOSE AT
BOTTOM OF RESERVOIR.
REF. 51. HYDRAULIC RESERVOIR LEVEL
REF. 52. RESERVOIR BREATHER
REF. 53. HYDRAULIC RESERVOIR FILL
AND FILTER
REF. 54. HYDRAULIC RESERVOIR DRAIN
REF. 55. UPPI R if'/U ISMIYJIt iM At ID SHIFTER
HOUSING 1 II I. I'l in,
REF. 56. UPPER TRANSMISSION DRAIN
REF. 56. SHIFTER HOUSING DRAIN
REF. 57. UPHER TKANSMISSIQN LEVEL
REF. 58. LOWEER TRANSMISSION FILL AND
LEVEL PLUG
MEC 3805-237-12/3-2 MOj
Figure 3-2 . Continued.
3-11
REF, 59. LOWER TRANSMISSION DRAIN
REF. 60. WHEEL BEARINGS
REF. 61. PINTLE HOOK
REF. 62. MASTER CYLINDER
REF. 68. BRAKE LINKAGE
REF, 63, FUEL FILTER AND STRAINER
REF. 64. ENGINE OIL LEVEL GAGE
REF. '65. ENGINE CRANKCASE FILL
REF. 66. AXLE BEARINGS
REF, 71 . INBOARD AND OUTBOARD BEARINGS
REF. 73. TANDEM DRIVE FILL
REF. 74. TANDEM DRIVE DRAIN
MEC 3805-237-12/3-2 (Tf)
Figure S-2 >. Continued.
3-12
REF. 67. ENGINE OIL FILTER
REF. 70. CLUTCH BEARINGS
REF. 68. THROTTLE LINKAGE
REF. 72. TANDEM DRIVE LEVEL
REF. 75. ENGINE OIL DRAIN
MEC 3805-237-12/3-2
Figure S-t . Continued.
tamination by dilution. Sludge forma-
tion will increase under cold weather
operating conditions.
/. Oil Filter Service. Refer to figure 3-4 and
service the engine oil filter.
AIR INTAKE
REMOVE CLAMP AND
REMOVE DUST CUP.
CHECK CUP GASKET
REPLACE GASKET
IF WORN OR DAMAGED,
CLAMP
Figure 3-3. Oil level gage and filler cap.
iNOTE: STOP ENGINE BEFORE
SERVICING THE OIL
REMOVE FILTER
CAP AND DIS-
CARD GASKET
AIR CLEANER
INDICATOR
REMOVE ELEMENT
FROM HOUSING
AND DISCARD.
DRAIN FILTER
BEFORE SERVICING
NOTE; SERVICE AFTER EACH 100 HOURS
OF OPERATION. CLEAN CAP
AND BOUSING. WITH AN AP-
PROVED CLEANING SOLVENT
AND A CLEAN CLOTH .
MEC 3805-237- 12/3-4
Figure 3-4- Oil filter service.
NOTE: REMOVE DUST CUP DAILY. CLEAN CUP
AND GASKET BY WIPING CLEAN WITH
CLOTH. CHECK AIR CLEANER INDICATOR -
IF RED PISTON RISES TO TOP OF INDICA-
TOR, REPLACE FILTER CARTRIDGE. REMOVE
DUST CUP , REMOVE THUMB SCREWS AND
REMOVE CARTRIDGE. CLEAN OR REPLACE
CARTRIDGE EVERY 1000 HOURS, REGARD-
LESS OF INDICATOR POSITION.
MEC 3805-237-12/3-5
Figure 3-5. Air cleaner service.
g. Air Cleaner Service. Refer to figure 3-5
and service the air cleaner.
h. Hydraulic Reservoir Filter. Refer to
figure 3-6 and service the hydraulic reservoir
filter. The reservoir filter is mounted in the
hydraulic reservoir.
3-14
COVER
RETAINING
RING
RETAINER
WASHER
OIL
RESERVOIR
IN FUEL
TANK
ELEMENT
5 LB.
RELIEF
VALVE
GASKET
STEP 1 . REMOVE DIPSTICK AND
CAP NUT.
STEP 2. REMOVE COVER AND
GASKET.
STEP 3. REMOVE RETAINING
RING, SPRING, UPPER
ELEMENT, WASHER,
AND GASKET.
STEP 4. REMOVE LOWER ELE-
MENT AND GASKET.
NOTE: CHANGE FILTER ELEMENT
EVERY 500 HOURS OF
OPERATION. CHECK AND
CLEAN BREATHER EVERY
100 HOURS OF OPERATION.
MEC 3805-237-12/3-6
Figure 3-6. Hydraulic reservoir filter service.
35. General
To insure that the motor grader is ready for
operation at all times, it must be inspected
systemtically so that defects may be discovered
and corrected before they result in serious dam-
age or failure. The necessary preventive main-
tenance services to be performed are listed and
described in paragraphs 3-6 and 3-7. Item
numbers indicate the minimum inspection re-
quirements. Defects discovered during opera-
tion of the unit shall be noted for future
correction, to be made as soon as operation has
ceased. Stop operation immediately if deficiency
is noticed which would damage equipment if
operation were continued. All deficiencies and
short comings will be recorded together with
the corrective action taken on DA Form 2404
(Equipment Inspection and Maintenance Work-
sheet) at the earliest possible opportunity.
3-6. Daily Preventive Maintenance
This paragraph contains an illustrated tabu-
lated listing of preventive maintenance ser-
vices which must be performed by the operator.
The item numbers are listed consecutively and
indicate the sequence of minimum require-
ments. Refer to figure 3-7 for the daily pre-
ventive maintenance services.
3-7. Quarterly Preventive Maintenance
Services
a. This paragraph contains an illustrated
tabulated listing of preventive maintenance
services which must be performed by organiza-
tional maintenance personnel at quarterly in-
tervals. A quarterly interval is equal to 3
calendar months, or 250 hours of operation
whichever occurs first.
b. The item numbers are listed consecutively
and indicate the sequence of minimum require-
ments. Refer to figure 3-8 for the quarterly
preventive maintenance services.
Section IV. OPERATOR'S MAINTENANCE
3-8. General
Instructions in this section are published for
the information and guidance of the operator
to maintain the road grader.
3-9. Fuel Filter and Strainer Service
Refer to figure 3-8 and 3-9 and service the
fuel filter and strainer.
3-10. Fan Belt Adjustment
a. Stop vehicle engine.
b. Refer to figure 3-10 and adjust fan belt
tension.
Section V. TROUBLESHOOTING
3-11. General
This section provides information useful in
diagnosing and correcting unsatisfactory oper-
ation or failure of the motor grader and its
components. Each trouble symptom stated is
followed by a list of probable causes. The pos-
sible remedy is described opposite the probable
cause. Any trouble beyond the scope of organi-
zational maintenance shall be reported to direct
support maintenance.
3-12. Engine Fails to Start
Probable cense
Battery disconnect
switch not engaged.
Defective batteres
Loose or defective
wiring.
Defective starter .
No fuel
Defective fuel system __
Engage battery disconnect
switch (para 2-12).
Replace defective batteries
(para 3-58).
Tighten connections or re-
place defective wiring.
Replace starter (para 3-53).
Fill fuel tank. Prime fuel
filters (para 3-9).
Check fuel system and cor-
rect (para 3-40).
3-16
DAILY
TM 5-3805-237- 12
LETOURNEAU-WESTINGHOUSE MODEL 440HA
MOTOR GRADER-
LUBRICATE IN ACCORDANCE WITH CURRENT LUBRICATION ORDER
ITEM
PAR REF
FUEL FILTER AND STRAINER. Drain 1/4 pint of fuel from filter and strainer to remove water and sediment.
3-9
FUEL TANK. Add fuel as required. Drain condensation from tank before and after each days operation.
3-41
;RANKCASE OIL LEVEL GAGE. Check oil level and add oil as necessary. Reference current L.O.
3-4
TIRES. Check tires for damage. Check tire pressures. Tires require 30 psi air pressure.
3-67
RADIATOR. Fill to proper level.
3-48
FAN BELT. 'Check deflection. Proper deflection is 1/2 \o 3/4-inch midway between pulleys. (Check
adjustment weekly.)
3-10
A|R CLEANER. Clean dust cup and service air cleaner.
3-4
BATTERIES. Check for loose cables and mountings. Tighten if necessary. Remove corrosion. Check
level of electrolyte . Fill to 3/8-inch above plates. In freezing weather run engine for minimum of
one hour after adding water. Clean vent holes in filler caps (weekly).
3-58
MEC 3805-237-12/3-7 (7)
Figure 3-7 . Daily preventive maintenance services.
3-17
IGHTS. Check operation of running lighhond floodlights
all controls and instruments for damage and
%%ff$%3ZZ^ **r: operotion
formal operating ranges for instruments are
Ammeter
Oil Pressure
ioolant Temperoture
NOTE 1 - OPERATION. During operation observe for any unusual noise or vibration.
NOTE 2 OPERATION After the first 10 hours of operation, retorque the tandem
"" " nuts to 600 ft. Ibs.
MEC 3805-237-12/3-7 (2
Figure 3-7 . Continued.
3-18
TM 5-3805-237- 1 2
PREVENTIVE MAINTENANCE SERVICES
QUARTERLY
* -
LETOURNEAU-WESTINGHOUSE MODEL 440HA
1?) (20:
MOTOR GRADER
LUBRICATE IN ACCORDANCE WITH CURRENT LUBRICATION ORDER
ITEM
PAR REF
FILJER AND STRAjNER, Inspect filter and strainer for insecure mounting and leaks at connections.
Check fuel lines for leaks and damage. Drain water and sediment from shells. Install new filter and
strainer elements.
PUEL TANK, i Check for loose mounting and tighten if necessary. Check for leaking tank and replace if
necessary. Check cap and vent. Replace cap gasket if necessary. Clean cap vent. Inspect fuel lines
for leaks and damage. Clean fuel strainer at tank outlet.
3-9
3-41
MECHANICAL GOVERNOR, Check governor linkage for free movement and correct operation. Oil
linkage at joints.
3-43
CRANKCASE OIL LEVEL GAGE, Check oil level. Add oil as necessary. Reference current L.O.
3-4
ENGINE OIL FILTER, Check oil lines for leaks and damage.
3-4
FUEL PUMP. Check fuel lines for leaks and damage. Check fuel pump for loose mounting and damage,
Check fuel flow.
3-40
MEC 3805-237-12/3-8 (T)
Figure 3-8 . Quarterly preventive maintenance services.
3-19
ITEM PAR REF
7
NJECTOR LINES AND HOLDER ASSEMBLIES. Check holder and lines for leaks and
3-40
damage .
8
WATER PUMP, Inspect pump for leaks and loose mounting.
3-50
9
RADIATOR. Check for proper coolant level. Replace cracked or frayed hose. Replace leaking radi-
3-48
ator. Clean air passages. Tighten all mountings and leaking connections. Check radiator cap for
sroper pressure .
10
CLUTCH. Check clutch pedal and linkage operation. Adjust if necessary.
3-39
U
FAN BELT. Check fan belt deflection. Correct deflection is 1/2 to 3/4-inch midway between pulleys.
3-10
Adjust if necessary. Replace worn or stretched belts.
12
GENERATOR. Tighten loose mounting and electrical connections. Check regulator mounting and
3-51
connections. Replace defective generator or regulator.
13
STARTER. Tighten loose mounting and electrical connections. Replace defective starter.
3-53
14
LIGHTS. Check running lights and floodlights for loose connections and damage. Replace defective
lamp units or lights.
3-56
15
BATTERIES. Tighten loose cables and mounting. Clean corrosion from cables and batteries. Clean vent
3-58
holes in filler caps. Replace a weak, cracked, or leaking battery.
16
TIRES. Inspect Hres for leaks and damage. Replace damaged tires.
3-67
17
BREATHERS. Clean breathers or replace damaged breathers.
18
BRAKE CYLINDERS. Inspect lines and cylinders for leaks. Replace defective cylinders and lines.
3-66
19
HYDRAULIC RESERVOIR. Inspect reservoir for leaks, damage and loose mounting. Tighten loose con-
3-68
nections and mountings. Replace defective reservoir and lines. Replace filter elements.
20
GEAR BOXES. Inspect gear boxes and shafts for teaks and damage. Inspect control levers for damage.
3-74
3-75
Replace defective shafts or control levers.
21
EXHAUST SYSTEM. Check exhaust system for leaks and damage. Replace damaged or defective parts.
3-45
22
CONTROLS. Start engine and operate all vehicle controls. Check for proper operation. Adjust if
2-10
necessary.
23
INSTRUMENTS. Inspect instruments for damage and insecure mounting. Replace defective instruments.
Normal operating ranges for instruments are as follows:
Ammeter Charge range
Oil Pressure 30-60 psi
Coolant Temperature 160-185 F
NOTE 1 . OPERATIONAL TEST. During operation observe for any unusual noises or vibrations.
NOTE 2. ADJUSTMENTS. Make all adjustments during operational test.
MEC 3805-237-12/3-8 (2
Figure 3-8 . Continued.
3-20
NOTE: DRAIN WATER AND SEDIMENT FROM FILTER AND STRAINER
DAILY.
STEP 1 . DRAIN FILTER OR STRAINER.
STEP 2. REMOVE COVER SCREW. .
STEP 3. REMOVE SHELL FROM FILTER COVER. REMOVE GASKET FROM
COVER.
STEP 4. REMOVE FILTER OR STRAINER ELEMENT FROM SHELL.
STEP 5. CLEAN SHELL WITH AN APPROVED CLEANING SOLVENT AND
CLEAN CLOTH,
STEP 6. AFTER INSTALLATION OF NEW ELEMENTS, PRIME FILTER AND
STRAINER BY FILLING SHELL WITH CLEAN FUEL.
STEP 7. INSTALL SHELL AND COVER GASKET IN COVER AND SECURE
WITH COVER SCREW.
NOTE: CHANGE FILTER AND STRAINER ELEMENTS EVERY 300 HOURS
' OF OPERATION.
MEC 3805-237-12/3-9
Figure 3-9. Fuel filter and strainer service.
Probable cusc Possible remedy
Fuel filters not primed ... Prime fuel filters (para
Defective air system
3-9).
Check air system and cor-
rect (para 3-6).
3A13. Engine Overheats
Probable ro.se Possible remedy
coolant level Inspect coolant level and re-
low. fill if necessary.
Fan beltXproken, loose, Adjust or replace fan belt
or slipping^ (para 3-10).
3-21
--tf,
J ,
TRUSTING j* MOUNTING f I
*'*${? | SCREW SCREWS f 4^ M
ffic-V - - -" '
STEP 1. LOOSEN FOUR MOUNTING SCREWS.
STEP 2. TURN ADJUSTING SCREW CLOCKWISE TO
TIGHTEN BELTS AND COUNTERCLOCKWISE
TO LOOSEN BELTS.
STEP 3. CORRECT FAN BELT ADJUSTMENT 151/2 TO
3/4 INCH DEFLECTION MIDWAY BETWEEN
PULLEYS.
STEP 4. TIGHTEN MOUNTING SCREWS SECURELY.
MEC 3805-237-12/3-10
Figure 3-10. Fan belt adjustment.
Probable cause
Defective thermostat
Possible remedy
- Replace defective thermostat
(para 3-49).
Clean radiator and grille.
Replace gage (para 3-54).
Radiator openings
clogged.
Defective coolant tem-
perature gage.
Operating machine in too Use proper gear (Table
low gear range. 2-2).
3-14. Engine Power Low
Possible remedy
Service air cleaner and hoses
Probable cause
Restricted air intake
system. (para 3-6).
Defective fuel system Check fuel system and cor-
rect (para 3-40).
Restricted exhaust Check exhaust system and
system. correct (para 3-43).
3-15. Engine Oil Pressure Low
Probable cause Possible remedy
Crankcase oil level low __ Replenish oil to bring to cor-
rect level on gage. Refer
to current lubrication
order.
External oil leak Check oil lines and correct
if possible.
Defective oil pressure Replace oil pressure gage
gage. (para 3-54).
Defective oil pump Report this condition to di-
rect support maintenance.
3-16. Engine Oil Consumption Excessive
F'robable cause Possible remedy
External oil leak Check oil lines and correct if
possible.
Improper oil viscosity Drain and refill with oil of
proper viscosity. Reference
current lubrication order.
3-17. Electrical System not Providing Power
Probable raitse
Possible remedy
Batteries
tive.
Loose or
ground
Defective
Defective
low or defec- Charge batteries or replace
batteries (para 3-58).
defective Tighten ground cable or re-
cable, place ground cable (para
3-58).
generator Replace defective generator
(para 3-51).
regulator Replace defective regulator
(para 3-52).
3-18. Fuel System not Operating Properly
Probable cause.
Clogged fuel tank
strainer.
Leaking or clogged
fuel lines.
Dirty or defective fuel
niters.
Contaminated fuel
Possible remedy
Clean or replace strainer
(para 3-41).
Tighten connection or re-
place fuel line.
Service fuel filters (para
3-9).
Drain and clean fuel tank.
Fill tank with clean fuel.
Prime fuel niters (para
3-9).
Defective fuel pump Replace defective fuel pump
(para 3-40).
Fuel injection system Report this condition to di-
not properly adjusted rect support maintenance,
or defective injectors.
3-19. Air Intake System not Operating
Properly
Probable cause
Possible remedy
Clogged or defective air Service air cleaner (para
cleaner. 3-6).
Defective air cleaner Replace defective hose (para
hose. 3-6).
3-22
3-20. Exhaust System not Operating
Properly
Probable cause ' Possible remedy
Defective or restricted Replace defective parts
exhaust muffler or (para 3-45).
pipe.
Loose or defective mani- Tighten clamps.
fold or exhaust pipe
clamps.
3-21. Engine Cooling System not Operating
Property
Probable cause Possible remedy
Coolant level low Add coolant to radiator.
Leaking or defective Tighten connections or re-
radiator hoses or hose place hoses (para 3-48).
connections.
Loose or defective fan Service fan belt (para 3-10).
belt.
Clogged cooling system Refer to TM 9-2858 to test
systems arid determine
cause and corrective
action. Clean and flush
system. Replace compon-
ents (para 3-48) if
necessary.
Defective thermostat Replace defective thermostat
(para 3-49).
Clean grille and radiator or
replace (para 3-48).
Replace defective parts.
Clogged or defective
radiator or grille.
Defective water tem-
perature gage, sending
unit, or wiring.
Defective water pump _.
Report this condition to di-
rect support maintenance.
3-22. Grader will
Probable cause
Parking brake engaged
Clutch not adjusted
properly.
Clutch defective
Transmission defective
not Move
Possible remedy
Release brake.
Adjust clutch (para 3-39).
._. Report this condition to di-
rect support maintenance.
Report this condition to di-
rect support maintenance.
3-23. Grader does not Steer Properly
Probable cause
Hydraulic oil level low _
Defective hydraulic
pump.
Air in hydraulic lines __
Front wheels not proper-
ly adjusted.
Possible remedy
.Refill hydraulic oil reservoir.
Reference lubrication
order ( fig. 3-2).
Replace defective pump
(para 3-69).
_ Bleed steering hydraulic sys-
tem (para 3-69).
Check camber and castor ad-
justment (para 3-63).
Probable cause Possible remedy
Front leaning wheels not Refer to Section IV, Opera-
operated properly ac- tion of Equipment,
cording to function
performed.
Front wheels shimmy Tighten steering connections.
If not corrected, report
this condition to direct
support maintenance.
324. Moldboard does not Lift or Lower
Probable cause Possible remedy
Shear bolt on propeller Replace shear bolt (para
shaft broken. 3-75).
Defective propeller Replace shaft (para 3-75).
shaft.
Lift link pin out Install lift link pin (para
3-77).
3-25. Moldboard does not Angle Properly
Probable cause
Possible remedy
Circle binds
Check circle operation. If
circle is bent report this
condition to direct support
maintenance.
Circle guide plates loose ..Adjust guide plates (para
3-80).
Adjust ball joints (para
3-80).
Adjust end thrust bearing
(para 3-85).
Ball joints connecting to
moldboard loose.
Circle reverse housing
end thrust bearing not
adjusted properly.
Anti-coast brake not ad-
justed properly.
Scarifter interfering with
blade.
Adjust anti-coast brake
(para 3-76).
Lift scarifier out of way
(para 2-14).
3-26. Moldboard does not Shift Properly
Probable cause
Possible remedy
Lateral shift end thrust Adjust end thrust bearing
bearing not adjusted (para 3-76).
properly.
Lateral shift anti-coast Adjust anti-coast brake
brake not adjusted (para 3-76).
properly.
Lateral shift links not Adjust lateral shift links
adjusted properly, (para 3-79).
3-27. Moldboard does not Power Shift
Properly
Probable cause Possible remedy
Hydraulic fluid low Refill hydraulic reservoir.
Reference lubrication
order (fig. 3-2).
Hydraulic lines leaking Tighten connections or re-
or damaged. place hydraulic lines (para
3-68) .
Hydraulic pump defec- Replace pump (para 3-69).
tive.
3-23
3-28. Scarifier does not Operate Properly
Probable cause Possible remedy
Defective scarifier teeth ..Replace defective teeth (para
2-14).
Improper operation Refer to Section IV. Opera-
tion of Equipment, Opera-
tion of Scarifier.
Requires adjustment Refer to figure 2-15.
suitable to job re-
quirement.
3-29. Clutch Brake does not Function
Properly
Probable cause Pomtible remain
Brake not adjusted Adjust brake (para 3-39).
properly.
Pedal does not travel far Adjust pedal travel (para
enough to engage 3-39).
brake.
3-30. Wheel Brakes do not Operate
Properly
Probalilf reuse Possible re > ed'r
Brake not adjusted Adjust brakes (para 3-66).
correctly.
Brake fluid low Add fluid to master cylinder.
Hydraulic lines leaking __ Tighten lines or replace de-
fective lines (para 3-64).
Air in brake system Bleed brake system (para
3-66).
Brake master cylinder Replace master cylinder
defective. (para 3-66).
Probable ratine Possible rcitipHi/
Brake wheel cylinders Replace brake wheel cylinder
leaking or defective. (para 3-66).
Brake linings worn Report this condition to di-
rect support maintenance.
3-31. Parking Brake does not Hold Vehicle
Probable rauxe
Brake or linkage out
adjustment.
Brake lever bent or
jammed.
Brake lining worn
Brake drum or shoes
damaged.
Possible reinc'iu
of Adjust parking brake (para
3-66).
Report this condition to di-
rect support maintenance.
Report this condition to di-
rect support maintenance.
Report this condition to di-
rect support maintenance.
3-32. Anti-Coast Brakes do not Function
Properly
Probable rouse Pnsitible rcwHi/
Anti-coast brake out of Adjust brakes (para 3-70'
adjustment.
Brake lining worn _________ Report this condition to di-
dect support maintenance.
Brake damaged or defec- Report this condition to di-
tive. rect support maintenance.
3-33. Tandem Drive Inoperative
Probable rnnxi'
Worn chains or
sprockets.
Broken chain.
I'oxsible rfnieiiii
Report this condition to di-
rect support maintenance.
Report this condition to di-
rect support maintenance.
Section VI. RADIO INTERFERENCE SUPPRESSION
334. Definitions
a. Interference. The term "interference" as
used herein applies to electrical disturbances
in the radio frequency range which are gen-
erated by the motor grader and which may
interfere with the proper operation of radio
receivers or other electronic equipment, or en-
able the enemy to locate the equipment.
b. Interference Suppression. The term "in-
terference suppression" as used herein applies
to the methods used to eliminate or effectively
reduce radio interference generated by the
motor grader.
3-35. General Methods used to Attain
Proper Suppression
Essentially, suppression is attained by pro-
viding a low resistance path to ground stary
currents. Methods used include shielding the
ignition and high frequency wires, grounding
the frame with bonding straps, and using cap-
acitors and resistors.
3-36. Interference Suppression Components
a. General. The motor grader is equipped
with a diesel engine and has no high frequency
ignition wires. A generator supplies current to
charge the vehicle batteries.
b. Primary Interference Components. The
primary components are those whose primary
function is to suppress radio interference.
These components are described and located
in figure 3-11.
3-37, Replacement of Interference
Components
Refer to figure 3-11 and replace the radio
interference components.
3-24
^mfmammmL^
DISCONNECT SHIELDED CABLE FROM
VOLTAGE REGULATOR AND GEN-
ERATOR (FIG. 3-26K REMOVE CLAMP
SECURING CABLE TO SIDE OF EN-
GINE AND REMOVE CABLE.
iMEC 3805-237-1 2/3- 11
Figure 3-11. Radio interference components,
removal and installation.
Section VII. CLUTCH ASSEMBLY
3-38. General
The clutch is a 16 inch dry plate clutch manu-
factured by Rockford Clutch, splined directly
to the crankshaft. The clutch is connected to
the upper transmission by a drive shaft.
3-39. Clutch Pedal Adjustment
a. Clutch Pedal Travel.
(1) Clutch pedal must have approximately
2 inches of free pedal travel to engage
the clutch.
(2) Adjust for maximum travel with the
upper hole on pedal arm (A, fig. 3-12)
flush with floor plate.
(3) Minimum travel is shown when lower
hole is clutch arm is flush with floor
plate. When this condition exists, ad-
justment must be made before serious
damage to the clutch results.
b. Free Pedal Travel Adjustment.
(1) Loosen locknut (1, fig. 3-12).
(2) Move adjusting nut (2) until upper
hole in clutch arm (A) is flush with
floor plate at end of free pedal travel,
when pedal is depressed.
(3) Tighten locknut (1) to hold adjust-
ment.
(4) Disconnect clutch return spring (7).
(5) Depress clutch pedal until upper hole
(A) is flush with floor plate.
(6) Tighten or loosen stud nut (10) until
outside loops of spring (11) are
stretched approximately 13 inches
apart.
(7) Loosen screws holding angle bracket
(12) and adjust angle bracket up or
down until pedal can be positioned at
the top or bottom of its free travel
with approximately five pounds pres-
sure. Tighten bracket screws. Spring
stud hole (B) in bracket should be
approximately in line with pivot
points (C and D).
(8) Return spring (7) must return and
hold clutch pedal pad against bottom
of floor plate. To adjust, insert a pry
3-25
10
3 4
6 5
MEC 3805-237-12/3-12
1 JLocknut
2 Adjusting nut
3 Locknut
4 Adjusting nut
6 Locknut
6 Adjusting nut
1 Eeturn spring
8 Anchor bolt
9 Pry holes in arm
10 Stud nut
11 Brake spring
12 Angle bracket
Figure 8-12. Clutch adjustment.
bar in one of the holes (9). Use bar
as a pry point, loosen anchor bolt nut
and pry anchor bolt (8) forward until
spring tension holds pedal pad against
floor. Tighten /anchor bolt nut.
c. Clutch Brake Adjustment. With engine
running, clutch brake must stop clutch in not
less than three seconds and not more than four
seconds after pedal has been fully depressed.
Stopping the clutch greatly aids in shifting
transmission without damage to gears.
(1) Loosen locknut (3, fig. 3-12). Move
adjusting nut (4) until spring behind
nut (4) is compressed y^-mch when
pedal is fully depressed.
(2) Tighten locknut (3) to hold adjust-
ment.
(3) Loosen locknut (5) and tighten ad-
justing nut (6) against swivel finger
to prevent rattle and looseness in link-
age. Tighten locknut (5).
(4) Check operation of brake and clutch
under load to be .sure adjustment is
correct.
Section VIII. FUEL SYSTEM
3-40. Fuel Pump
a. Inspection. Check fuel pump (fig. 3-13)
for secure mounting. Tighten mounting bolts,
if necessary. Check fuel tubes for leaks and
tighten or replace tubes.
3^26
FUEL PUMP-TO-FUEL
FILTER TUBE
Figure. S-1S. Fuel pump service and testing.
b. Tcatittf/. Test fuel flow through as follows.
(1) Disconnect fuel return tube (fig.
3-13) from hose to fuel tank. Connect
a hose to fuel return tube and hold
hose in convenient receptacle.
(2) Start the engine and run at 1200 re-
volutions per minute.
(3) Measure fuel flow from tube for one
minute.
(4) A minimum of one-half gallon of
fuel should flow in one minute.
(5) If flow is leas than one-half gallon,
check fuel filters and service as de-
scribed in paragraph 3-9.
(6) Check fuel flow again (3 and 4 above) .
If flow is still below minimum, replace
fuel pump.
3-41. Fuel Tank.
a. Inspection. Check fuel tank and fuel lines
for evidence of leakage. If fuel has shown signs
of water or other contamination, drain fuel
tank and refill with clean fuel. Tighten fuel
connections if necessary. Inspect fuel tank cap
for good condition. Replace cap if defective. If
fuel tank is defective, notify direct support
maintenance to replace tank.
b. Fuel Strainer. A fuel strainer is placed in
STEP 1 . REMOVE CAP AND CHECK GASKET,
STEP 2. CHECK OVERFLOW TUBE FOR DAMAGE.
STEP 3. INSPECT FUEL TANK FOR LEAKS AND
DAMAGE.
MEC 3805-237-12/3-14
Figure 3-14- Fuel tank service.
the tank outlet to filter large particles before
they reach the fuel filter. Check and clean
strainer, if necessary, by disconnecting fuel line
and removing drain valve at bottom of tank.
3-42. Cold Weather Starting Aid
a. Inspection. Check fuel primer (fig. 3-15)
for damage. Operate priming knob in opera-
tor's compartment and check primer for correct
operation.
6. Removal and Installation.
(1) Disconnect cable (fig. 3-15) from
priming pump.
(2) Disconnect tube to engine from prim-
ing pump.
(3) Remove four screws securing starting
aid to engine compartment and remove
starting aid.
(4) Install new starting aid in reverse
order of removal.
MOUNTING
SCREWS (4i i
Figure 3-15. Cold weather starting aid service.
3-43. Governor and Throttle Linkage
a. Governor Linkage. Check governor lever
(fig. 3-16) and shut off rod for damage and
smooth operation. Pull ball in operator's com-
partment to check lever and rod operation.
Lever must move enough to completely close
governor to stop engine. If lever or rod is
damaged, replace defective parts.
b. Removal and Installation
(1) Remove ball from shutoff rod in oper-
ator's compartment. Remove retaining
ring and insulating bushing.
(2) Remove cotter pin (fig. 3-16) and
washer and remove shutoff rod from
lever.
(3) Remove shoulder bolt (fig. 3-16),
lockwasher and nut securing lever to
bracket.
(4) Disconnect lever from ball joint (fig.
3-16) and remove lever.
(5) Remove ball joint from governor rod
3-28
(fig. 3-16) and remove rod from gov-
ernor lever.
(6) Install new governor rod (fig. 3-16)
in governor lever and connect ball
joint to rod.
(7) Install lever (fig. 3-16) on bracket
and secure with shoulder bolt, lock-
washer and nut.
(8) Connect ball joint to lever.
(9) Slide new shutoff rod (fig. 3-16) into
operator's compartment through in-
sulating bushing and secure with re-
taining ring. Install ball on rod.
(10) Install shutoff rod through hole in
lever and secure with cotter pin (fig.
3-17) and washer.
(11) Operate rod from operator's compart-
ment to check operation.
c. Throttle Linkage. The foot throttle or
pedals (accelerator and decelerator) (fig. 3-17)
are mounted through holes in the floor of the
operator's compartment. The front pedal is the
accelerator. The rear or round pedal is the
decelerator pedal. A hand throttle or governor
control lever is mounted on the right side of
the operator's compartment.
d. Inspection. Check operation of throttle
linkage by depressing both foot pedals and
moving governor control lever through com-
plete travel. Linkage should operate smoothly
and completely control governor. Governor con-
trol lever should stop and hold in any position,
due to friction bearings in shaft. Check rods
for bent condition or damage. Replace dam-
aged parts in linkage. Lubricate seven lubrica-
tion fittings with grease (GAA) using a
pressure grease gun every 250 hours.
e. Removal. Refer to figure 3-17 and remove
the throttle linkage.
/. Installation. Refer to figure 3-17 and in-
stall the throttle linkage.
g. Adjustment.
(1) On installation, locate accelerator and
governor control lever halfway be-
tween their stops for high and low
speed.
(2) Install all vertical linkage rods as
nearly vertical as possible and all hori-
zontal rods as horizontal as possible.
COLD WEATHER
STARTING AID
BALL
GOVERNOR
ROD
BALL JOINT
BUSHING AND
RETAINING RING
SHOULDER
BOLT
LEVER
COTTER PIN
'AND WASHER
MEC 3805-237-12/3-16
Figure 3-16. Governor lever and linkage, removal and installation.
(3) With engine off, place governor con-
trol lever (fig. 3-17) against full speed
stop (all the way back). Adjust rod,
attached to lever through floor plate,
until accelerator decelerator rod is
pulled out of its housing 3/16 (0.1875)
to Vi (0.250) inch. When governor
control lever is against low speed stop,
rod should be pushed into housing the
same distance.
(4) After making above adjustments, ad-
just length of rod from pedal support
to accelerator decelerator to prevent
either pedal from striking floor plate.
(5) After all adjustments, hook a spring
scale to governor control lever as close
to ball as possible. A pull of 8 to 25
pounds should be required to move
lever through full range of travel.
3-29
GOVERNOR
CONTROL -
LEVER
ACCELERATOR
6.
DECELERATOR
\
REMOVE COTTER PIN
AND STRAIGHT PIN
AND REMOVE ROD
AND CLEVIS
5. REMOVE COTTER PIN
AND WASHER
REMOVE
COTTER PIN
AND STRAIGHT
PIN
3. REMOVE ACCELERATOR-
DECELERATOR
2. REMOVE TWO COTTER
PINS, WASHERS, AND
STRAIGHT PIN
.4. REMOVE BALL JOINT AND
ROD FROM LEVER
MEC 3805-237- 12/3- 17
Figure S-17. Throttle linkage, removal and installation.
Section IX. EXHAUST SYSTEM
3-44. Inspection
a. Check exhaust pipe and flange for evi-
dence of leakage, cracks and other damage.
b. Inspect flange gasket and exhaust mani-
fold and gasket for evidence of leakage.
c. Replace defective parts.
3-30
MUFFLER
CLAMP
EXHAUST
r MANIFOLD
EXHAUST
FLANGE
NOTE: SHUTOFF ENGINE AND
ALLOW EXHAUST SYSTEM
TO COOL OFF BEFORE
ATTEMPTING TO REMOVE
COMPONENTS.
STEP 1 . LOOSEN CLAMP AND REMOVE
MUFFLER FROM EXHAUST
FLANGE.
STEP 2. REMOVE FOUR SCREWS AND
L OC K WA S H E R S A h 1 D R E M OV E .
EXHAUST I1ANGE FROM
MANlFOt D.
STEP 3. REMOVE AND INSPECT EX-
HAUST FLANGE GASKET.
DISCARD GASKET IF
DAMAGED OR LEAKAGE IS
EVIPFNT.
MtC 3805-237-12/3-18
Figure 8-18. Exhaust system, removal and installation.
3-31
345. Muffler and Exhaust Flange
a. Removal. Refer to figure 3-18 and remove
muffler and and exhaust flange.
b. Installation. Refer to figure 3-18 and in-
stall the muffler and exhaust flange.
Section X. COOLING SYSTEM
3-46. General
a. The motor grader cooling system consists
of a fan, radiator, shroud, water pump, ther-
mostat, hoses, and pipes.
b. Coolant pumped through the system by the
water pump passes through the block around
the pistons to cool the engine. It also flows
through the oil cooler, cooling the oil before it
returns to the engine.
3-47. Fan
a. Removal. Refer to figure 3-19 to remove
the fan, fan shroud, fan spacer and fan brac-
ket.
6. Installation. Refer to figure 3-19 to install
the fan and its components.
3-48. Radiator
a. Inspection. Inspect radiator and hoses for
leaks and deterioration. Check all hose con-
nections and drain for leaks. Inspect radiator
cap, cap spring, and cap gasket for damage.
Replace defective parts.
b. Removal.
(1) Remove plug (fig. 3-20) beneath radi-
ator grille and drain coolant from
radiator. Open drain (fig. 3-22) at
bottom of oil cooler to drain cooler.
(2) Refer to figure 3-21 and remove en-
gine hood.
(3) Loosen clamp (fig. 3-22) and remove
radiator outlet and inlet hoses from
radiator, oil cooler and thermostat
housing.
(4) Remove six screws and lockwashers
securing radiator to frame and remove
radiator as shown in figure 3-23.
(5) Refer to paragraph 3-56 and remove
blackout light, reflectors and floodlight
from radiator.
(6) Remove seven mounting screws (fig.
3-23) and lockwashers from each side
and remove radiator shell (fig. 3-23)
from radiator.
3-32
(7) Remove four screws and lockwashers
and remove grille from radiator shell.
c. Installation.
(1) Install radiator grille on radiator shell
and secure with four screws and lock-
washers.
(2) Install radiator shell and secure with
fourteen screws (fig. 3-23) and lock-
washers.
<3) Install reflectors and lights (para
3-56).
(4) Refer to figure 3-23 and install the
radiator. Secure radiator with six
screws and lockwashers.
(5) Refer to figure 3-22 and install the
radiator inlet and outlet hoses.
(6) Refer to figure 3-21 and install engine
hood.
(7) Install plug (fig. 3-20) in radiator.
Close drain (fig. 3-22) at bottom of oil
cooler.
(8) Remove plug at top of thermostat
housing. Fill radiator with coolant un-
til all air is forced from engine
through plug hole. Install plug and
complete filling of radiator.
3-49. Thermostat Housing and Thermostat
a. Removal.
(1) Drain cooling system (para 3-486).
(2) Loosen clamps (fig. 3-22) and remove
radiator inlet hose from radiator and
thermostat housing.
(3) Refer to figure 3-24 and remove ther-
mostat housing and outlet elbow.
b. Testing.
(1) Hook a wire to thermostat and lower
thermostat into a container of water.
Immerse an accurate thermometer,
reading up to 200 F, in the water.
(2) Heat water container. As water tem-
perature reaches 170 F the thermo-
stat should start to open. At 185F
NOTE: LOOSEN CLAMPS AT THERMOSTAT HOUSING
AND RADIATOR AND REMOVE RADIATOR
INLET HOSE FROM TOP OF RADIATOR.
REMOVE
CLAMP
RADIATOR
DRAIN PLUG
LOOSEN
CLAMPS
AT COOLER
AND RADIATOR
OIL COOLER
DRAIN
; . JjMEC 3805-237-12 3-20
RADIATOR
OUTLET
HOSE
REMOVE HOSE
MEC 3805-237-12/3-22i
Figure 3-20. Radiator drain plug.
Figure 3-22. Radiator hoses, removal and installatioji.
REMOVE MUFFLER
(PAR. 3-45\
REMOVE SCREWS (61
LOCKWASHERS (6)
AND NUTS
REMOVE SCREWS (2),
LOCKWASHERS (2),
AND NUTS (2) AND
REMOVE BAR
/ . DISENGAGE HOOK
. BOLTS
i * '"lft|'i|i, <4\ REMOVE
' > . VHk V**ig HOOD
3805-237-12/3-21
.)
Figure 3-21. Engine hood, removal and installation.
3-34
PLACE CHAIN AROUND
RADIATOR AND LIFT FROM
MOUNTS, USING A SUIT-
ABLE HOIST
NOTE: RADIATOR CAN BE
REMOVED AS SHOWN
BY SEPARATING FAN
GUARD FROM SHROUD
(FIG. 3-19) AND RE-
MOVING SHROUD
WITH RADIATOR.
REMOVE SCREWS (6) AND
LOCKWASHERS (6) SECURING
RADIATOR TO MOUNTS
RADIATOR SHELL
MOUNTING SCREWS
MEC 3805-237-12/3-23
Figure S-2S. Radiator, removal and installation.
the thermostat should be completely
open.
(3) If thermostat does not test as above,
replace thermostat.
c. Installation.
(1) Clean thermostat seat in housing.
(2) Refer to figure 3-24 and install ther-
mostat housing and thermostat. In-
stall new gaskets between housing and
3-35
NOTE:
WHEN INSTALLING WATER
PUMP, USE NEW GASKET,
PACKING, AND SEAL.
REMOVE SCREWS (3) AND
LOCKWASHERS (3) AND
REMOVE WATER PUMP
FROM BLOWER HOUSING
REMOVE GASKET.
LOOSEN CLAMPS (2) AND
SLIDE HOSE BACK ON
WATER BY-PASS ELBOW.
REMOVE BY-PASS ELBOW
I AND HOSE FROM WATER
PUMP COVER.
DRAIN WATER
PUMP.
REMOVE CLAMP FROM
WATER PUMP COVER
AND OIL COOLER OUT-
LET. REMOVE SEAL.
REMOVE SCREWS (2) AND
LOCKWASHERS (2^ SECUR-
ING WATER PUMP OUTLET
FLANGE TO CYLINDER
BLOCK. REMOVE FLANGE
AND PREFORMED PACKING
MEC 3805-237-12/3-25
Figure 3-25. Water pump, removal and installation.
water manifold and housing and out-
let elbow.
(3) Install hose between radiator and
thermostat (para 3-48c).
Fill radiator with coolant (para
(4)
3-48c) .
3-50. Water Pump
a. Removal.
(1) Drain cooling system (para 3-48b).
(2) Refer to figure 3-25 and remove
water pump.
b. Installation. Refer to figure 3-25 and in-
stall water pump. Install new gaskets and
packing when installing water pump.
3-37
Section XI. ELECTRICAL SYSTEM
3-51. Generator
a. Belt Adjustment
(1) Loosen two generator mounting
screws (fig. 3-26). Loosen generator
adjusting screw.
(2) Move generator towards engine to
loosen belt and away from engine to
tighten belt.
(3) Belt should have a deflection of V 2 to
3/4 inches midway between the pulleys.
(4) Tighten adjusting screw and moun-
ting screws.
REMOVE GENERATOR ADJUSTING
SCREW, LOCKWASHERS, AND
NUT.
DISCONNECT SHIELDED
CABLE FROM GENERATOR,
TO REPLACE GENERATOR
BEIT r fcfMOVE FAN
(PAH, 3-4?) AND PAH
BEITS*
ADJUST1N0 SCWSfl
PUSH
EHOfHl
REMOVE GENERATOR
REMOVE GENERATOR
MOUNTING SCREWS (2),
REPLACE
USHES ,
NUTS(2) '
Figure 3-26. Generator, adjustment, removal and installation.
3-38
b. Removal.
(1) Place battery disconnect switch in dis-
engaged position.
(2) Refer to figure 3-26 and remove the
generator.
c. Inspection and Repair.
(1) Inspect generator for damage and
for evidence of arcing.
(2) Refer to figure 3-26 and replace gen-
erator brushes if necessary.
d. Installation. Refer to figure 3-26 and in-
stall generator.
3-52. Voltage Regulator
a. Removal.
(1) Place battery disconnect switch in the
disengaged position.
(2) Refer to figure 3-27 and remove volt-
age regulator.
STEP 1. DISCONNECT POWER CABLE FROM
VOLTAGE REGULATOR,
STEP 2. DISCONNECT SHIELDED GENERATOR
CABLE FROM VOLTAGE REGULATOR.
STEP 3. REMOVE FOUR SCREWS AND LOCK-
WASHERS AND REMOVE VOLTAGE
REGULATOR.
MEC 3805-237-12/3-27
Figure 3-27. Voltage regulator, removal and
installation.
b. Installation. Refer to figure 3-27 and in-
stall the voltage regulator.
3-53. Starter
a. Removal.
(1) Place battery disconnect switch in the
disengaged position.
(2) Refer to figure 3-28 and remove the
starter.
b. Starter Solenoid.
(1) Removal. Disconnect wires and con-
nector from solenoid terminals. Re-
move four screws and remove solenoid
(fig. 3-28).
(2) Installation. Install solenoid on
starter and secure with four screws.
Connect wires and connector to sole-
noid terminals.
Note. Install solenoid carefully to pre-
vent damage to boot. Boot must fit in lever
housing around solenoid plunger.
c. Brushes. Replace starter brushes if neces-
sary.
(1) Removal. Refer to figure 3-29 and
remove starter brushes.
(2) Installation. Refer to figure 3-29
and install starter brushes.
d. Installation. Refer to figure 3-28 and
install the starter.
3-54. Instrument Panel Gages and Light
a. Removal.
(1) Place battery disconnect switch in
disengaged position.
(2) Refer to figure 3-30 and remove gages
and light from instrument panel.
6. Inspection. Inspect instrument panel wir-
ing and connections. Repair wiring if neces-
sary.
c. Installation. Refer to figure 3-30 and in-
stall gages and lights in instrument panel.
3-55. Battery Charging Receptacle and
Hourmeter
a. Removal.
(1) Place battery disconnect switch in
disengaged position.
(2) Refer to figure 3-31 and remove bat-
tery charging receptacle and hour-
meter.
b. Installation. Refer to figure 3-31 and
install the battery charging receptacle and
hourmeter.
3-39
i'..
E: REFER TO FIGURE 3-36 AND ,;-:,
MOVE BATTERY BOX AWAY '";
FROM STARTER.
DISCONNECT CABLES FROM
STARTER SOLENOID.
REMOVE MOUNTING SCREWS
AND LOCKWASHERS AND
REMOVE STARTER.
DISCONNECT CABLES
TERMINAL STUD.
SOLENOID
MOUNTING
SCREWS (4)
MEC 3805-237-12/3-28
Figure 3-28. Starter, removal and installation.
3-56. Vehicle Lights
Caution: Do not attempt to service or remove
any vehicle lights without placing the battery
disconnect switch in the disengaged position.
a. Floodlights.
(1) Removal. Refer to figure 3-32 and
remove the floodlight.
(2) Installation. Refer to figure 3-32 and
install the floodlight.
6. Headlights.
(1) Removal. Refer to figure 3-33 and
remove the headlights.
(2) Installation. Refer to figure 3-33 and
install the headlights.
c. Blackout Light and Taillight.
(1) Removal. Refer to "figure 3-34 and
remove blackout light and taillight.
(2) Installation. Refer to figure 3-34 and
install blackout light and taillight.
3-40
REMOVE SCREWS (8) AND
WASHERS (4) AND REMOVE
EIGHT BRUSHES
REMOVE SCREWS (4)
AND LOCKWASHERS (4)
REMOVE COMMUTATOR
END PLATE ASSEMBLY
REMOVE AND DISCARD
PREFORMED PACKING
MEC 3805-237-12/3-29
Figure 3-29. Starter brushes, removal and installation.
357. Horn
a. Removal. Refer to figure 3-35 and re-
move the horn.
b. Installation. Refer to figure 3-35 and
install the horn.
358. Batteries
a,. Service.
(1) Specific gravity test. The state of
charge of each battery cell is de-
termined by checking the specific
gravity of the electrolyte (battery
fluid) . A corrected specific gravity
reading of 1.285 in each cell indicates
a fully charged battery. A reading
of 1.225 or less in each cell indicates
that the battery must be recharged or
replaced.
(2) Adding water. The water in the
electrolyte solution will evaporate at
high temperature or with excessive
charging rates. Check the electrolyte
level and add distilled water or clean
water when necessary to bring the
electrolyte level the three-fourths of
an inch above the separators.
(3) Cleaning. The tops of the batteries
must be kept clean. Tighten vent
plugs and clean batteries with a
brushed dipped in an alkaline solution
such as ammonia or a solution of bi-
carbonate of soda and water. After
foaming stops, flush top of batteries
with clean water. If terminals and
cable clamps are corroded, disconnect
cables and clean with the same solu-
tion. Connect cables to battery.
Waterproof battery terminals by
packing with heavy asbestos grease
(GK).
3-41
TO GAIN ACCESS T<
" iNsr-MiMtiNT r-v in. ,
MOVL !"WG SCr.LV/S AMI)
'CKWASHCRS. IIP PANES
PANFL. IS HINGFD
BOTTOM.
FE: TO REMOVE GAGES AND
SWITCHES .REMOVE MOUNT-
ING SCREWS AND WASHERS
AND DISCONNECT WIRES OR
TUBES FROM GAGES AND
SWITCHES.
3805-237-1 ?/3-30l
Figure S~SO. Gages and light, removal and installation.
Warning: When removing battery
cables, disconnect the ground cable
first. When installing battery cables,
connect the ground cable last. Acci-
dental contact of a cable replacing tool
with the vehicle causes a direct short
resulting in arcing and instant heating
of the tool to red hoal. This can cause
painful burns on hands and serious
damage to tools, vehicle and batteries.
A shorted battery may explode and
spray hot acid over the surrounding
area.
b. Removal.
(1) Place battery disconnect switch in
disengaged position.
(2) Refer to figure 3-36 and remove
batteries.
c. Installation. Refer to figure 3-36 and in-
stall the batteries.
STEP 1. KlIMOVl; THREE SCREWS. DISCONNECT
WIRFS AT RCAR OF HOURMETER.
STEP 2. k'CMOVE HOURMETLR AND RESILIENT
MOUNT.
STEP ;j. REMOVE HOUK SCREWS, LOCKWASHF.RS
AND NUTS.
STEP 4. DISCONNECT WIRES AT REAR Of BATTERY
CHARGING RECEPTACLE AND REMOVE
RECEPTACLE.
MEC 3805-237- 12/3 -3 I
Figure S-SJ. Battery charging receptacle and
hourmcter, removal and installation.
REAR
FLOODLIGHT
CLAMP (2)
MOUNTING
SCREWS (2)
STEP 1 . DISCONNECT WIRE FROM REAR
TERMINAL.
STEP 2. REMOVE TWO MOUNTING SCREWS
AND LOCKWASHERS.
STEP 3. REMOVE FLOODLIGHT. REMOVE
NUT AND REMOVE FLOODLIGHT
FROM MOUNT.
STEP 4. TO REPLACE LAMP UNIT IN
FLOODLIGHT, REMOVE CLAMPS.
REMOVE LAMP UNIT (SEALED
BEAM) AND INSTALL NEW LAMP
UNIT.
NOTE: FRONT AND REAR FLOODLIGHTS '
ARE SERVICED IN THE SAME
MANNER.
MEC 3805-237- 12/3-32
Figure 3-S2. Floodlight, removal and installation.
3-43
LENS
SCREW (3)
BLACKOUT
HEADLIGHT
MOUNTING SCREW
..;
? j
TERMINAL
MOUNTING SCREW (2)
BLACKOUT HEADLIGHT
STEP \. DISCONNECT WIRE AT CONNECTOR
STEP 2. REMOVE MOUNTING SCREW AND
REMOVE BLACKOUT HEADLIGHT.
STEP 3. TO REPLACE LAMPS, REMOVE THREE
LENS SCREWS. REMOVE LENS AND
REMOVE LAMPS.
HEADLIGHT
STEP K DISCONNECT WIRE FROM REAR
TERMINAL.
STEP 2. REMOVE TWO MOUNTING SCREWS,
LOCK WASHERS, AND NUTS.
STEP 3. REMOVE HEADLIGHT-
STEP 4. TO REPLACE LAMP UNIT IN HEAD-
LIGHT, REMOVE CLAMPS. REMOVE
LAMP UNIT (SEALED BEAM) AND
INSTALL NEW LAMP UNIT.
MEC 3805-237-12/3-33
Figure 3-33. Headlights, removal a?ui installation.
TAILLIGHT
LENS MOUNTING
SCREWS (6)
LENS MOUNTING
SCREW (6)
TAILLIGHT
MOUNTING
SCREWS (2)
BLACKOUT
LIGHT
MOUNTING
SCREWS (2)
1
BLACKOUT
LIGHT
BLACKOUT LIGHT
STEP 1. DISCONNECT WIRE AT CONNECTOR
AND PULL WIRE THROUGH GROMMET.
STEP 2. REMOVE TWO MOUNTING SCREWS
AND LOCKWASHERS AT REAR OF
LIGHT AND REMOVE BLACKOUT
LIGHT.
STEP 3. TO REPLACE LAMPS IN BLACKOUT
LIGHT, REMOVE SIX LENS MOUNT-
ING SCREWS, REMOVE LENS, AND
REMOVE LAMPS FROM SOCKETS.
TAILLIGHT
STEP 1. DISCONNECT WIRE AT CONNECTOR.
STEP 2. REMOVE TWO MOUNTING SCREWS
AND LOCKWASHERS AT REAR OF
TAILLIGHT AND REMOVE TAILLIGHT.
STEP 3. TO REPLACE LAMPS IN TAILLIGHT,
REMOVE SIX LENS MOUNTING
SCREWS, REMOVE LENS, AND RE-
MOVE LAMPS FROM SOCKETS.
MEC 3805-237-12/3-34
Figure 3-34. Blackout light and taillight, removal and installation.
3-45
Section X81. TRANSMISSION
19. Transmission
',. Inspection. Inspect both transmissions
evidence of leaking or damage. Move
fter levers through all gear ranges to check
ration. Notify direct support maintenance
ransmission,is damaged or does not operate
iperly.
'. Lubrication. Check level of oil in trans-
ision and fill to correct level if necessary.
a. Removal. Refer to figure 3-37 and re-
move the transmission levers. Protect open-
ings in transmission while levers are removed
to prevent dirt or debris from entering trans-
mission.
b. Installation. Refer to figure 3-37 and in-
stall transmission levers.
Section XIII. FRONT AXLE AND
51. Front Axle
i. Service. Perform lubrication of front
e as described in current lubrication order.
3ck condition of lubricating fittings and re-
ce if damaged.
). Inspection. Inspect front axle for dam-
j. Inspect spindles and spindle forks for
ications of wear. Inspect sleeve bearings
axle for wear and excessive movement pivot
.s in bearings. Notify direct support main-
ance if parts require replacement.
62. Steering
i. Inspection. Inspect steering gear assem-
for leakage and damage. Start engine and
irate steering to check for. proper operation,
ipect steering wheel and control shaft for
nage and proper operation. Lubricate shaft
required. Refer to current lubrication order.
?. Steering Arm.
(1) Removal.
(a) Turn moldboard straight across
under frame. Lower moldboard
until wheels leave the ground. Place
blocks or jacks beneath axle to help
support grader.
(b) Scribe a mark on the power steer-
ing shaft and on steering arm to
aid in correct location at assembly.
(c) Refer to figure 3-38 and remove
steering arm.
(2) Installation.
(a) Aline scribe marks on steering arm
and power steering shaft.
(b) Refer to figure 3-38 and install
steering arm.
46
STEP 1 . DISCONNECT WIRES AT CONNECTOR.
STEP 2. REMOVE TWO HORN MOUNTING
SCREWS, LOCKWASHERS, AND NUTS.
STEP 3. REMOVE HORN FROM HORN
BRACKET.
MEC 3805-237-12/3-35
Figure 3-35. Horn, removal and installation.
c. Steering Wheel and Shaft.
(1) Removal.
(a) Refer to figure 3-39 and remove
the steering wheel.
(b) Refer to figure 3-40 and remove
steering wheel shaft.
(2) Installation.
Mrl GROUND
1 CABLE
STEP 1. OPEN BATTERY BOX COVER.
STEP 2. LIFT LEVERS AND DISCONNECT GROUND
CABLE. DISCONNECT GROUND CABLE
FROM BATTERY DISCONNECT SWITCH
UNDER OPERATOR'S CAB. REMOVE
CABLE ,
STEP 3. DISCONNECT AND REMOVE JUMPER
CABLE .
STEP 4. DISCONNECT POWER CABLE FROM
BATTERIES AND STARTER SOLENOID
AND REMOVE CABLE.
STEP 5, LOOSEN 10 WING NUTS AND REMOVE
BATTERY HOLDDOWN BRACKETS.
STEP 6. REMOVE FOUR BATTERIES FROM
BATTERY BOX,
STEP 7. REMOVE FOUR SCREWS AND WASHERS
AT BOTTOM OF BATTERY BOX AND
REMOVE BATTERY BOX.
MEC 3805-237-12/3-36
Figure S-S6. Batteries, removal and installation.
3-47
TRANSMISSION
LEVER
STEP 1. REMOVE FIVE CARRIAGE BOLTS, LOCK-
WASHERS, AND NUTS AND LIFT PLATE
FROM FLOOR OF OPERATOR'S COM-
PARTMENT.
STEP 2. REMOVE CLAMPS AND REMOVE RUB-
BER COVER FROM LEVERS AND SHIFTER
HOUSING.
STEP 3. REMOVE FOUR SCREWS AND LOCK-
WASHERS SECURING BALL CAP TO
SHIFTER HOUSING.
STEP 4. REMOVE TRANSMISSION LEVER UP
THROUGH FLOOR. REMOVE SHIMS.
STEP 5. REMOVE CLAMPS AND REMOVE BOOT
FROM LEVER.
STEP 6. REMOVE SPRING, SEAL , AND BALL
CAP FROM LEVER.
MEC 3805-237-12/3-37
Figure S-87. Transmission levers, removal and installation.
3-48
SLOTTED
NUT
DRAG
LINK
SLOTTED
NUT
BOOT
MOUNTING
SCREWS (4)
A. STEERING ARM
STEP 1. SCRIBE A LINE ON
STEERING ARM AND
SPLINED STEERING
SHAFT.
STEP 2. REMOVE LACES AND
REMOVE BOOT.
STEP 3. REMOVE FOUR SCREWS,
LOCKWASHERS, AND
NUTS SECURING TIE
RODS TO STEERING
ARM. REMOVE AND
COUNT NUMBER OF
SHIMS.
STEP 4. REMOVE NUT AND
LOCKWASHER SECUR-
ING STEERING ARM
TO STEERING SHAFT
AND REMOVE STEER-
ING ARM.
B. TIE RODS
STEP 1 . REMOVE LACES AND
REMOVE BOOT.
STEP 2. REMOVE FOUR SCREWS,
LOCKWASHERS, AND
NUTS SECURING TIE
RODS TO STEERING
ARM. REMOVE AND
COUNT NUMBER OF
SHIMS.
STEP 3. REMOVE COTTER PIN
AND SLOTTED NUT
SECURING TIE ROD TO
DRAG LINK.
STEP 4. REMOVE TIE ROD.
NOTE: WHEN INSTALLING TIE
RODS ON STEERING
ARM BALL, INSTALL
CORRECT AMOUNT OF
SHIMS TO PROVIDEA
FREE, BUT SNUG, FIT.
C. DRAG LINK
STEP 1 . REMOVE COTTER PIN
AND SLOTTED NUT
FROM BOTH ENDS OF
DRAG LINK.
STEP 2. REMOVE DRAG LINK
FROM TIE ROD AND
SPINDLE.
MEC 3805-237-12/3-38
Figure 3-38. Steering arm, tie rods, and drag links, removal and installation.
3-49
(a) Refer to figure 3-40 and install the
steering wheel shaft.
(b) Refer to figure 3-39 and install the
steering wheel.
d. Tie Rods and Drag Links.
(1) Removal
(a) Refer to figure 3-38 and remove
tie rods from steering arm.
.(b) Refer to figure 3-38 and remove
drag links.
(2) Installation.
(a) Refer to figure 3-38 and install the
drag links.
(b) Refer to figure 3-38 and install the
tie rods. Refer to" paragraph 3-63<2
and adjust wheel toe-in.
3-63. Wheel Adjustment
a. General. Wheel alinement and steering
STEERING
CONTROL
SHAFT
STEP 1 . REMOVE CAP NUT AND LOCKWASHER .
STEP 2. USING A SUITABLE PULLER, REMOVE
STEERING WHEEL FROM STEERING
CONTROL SHAFT.
MEC 3805-237-12/3-39
Figure S-S9. Steering wheel, removal and
installation.
(2)
(3)
performance is based on wheel camber, wheel
caster and wheel toe-in.
(1) Wheel camber. Camber means the
wheels are closer together at bottom
than at the top. This positive camber
offsets wear in axle parts, spindle
hearings, sleeve bearings and wheel
bearings. This wear is caused by
sagging and wheel deflection.
Wheel caster. Caster defines the
placement of the spindle forks. Posi-
tive caster means the top of the
spindle fork is closer to the rear of
the machine than the bottom. Caster,
along with toe-in and camber centers
the weight of the machine oil center
of tires and splines.
Toe-in. Toe-in of wheels means the
front of the tires are closer to the
machine than the rear of the tires.
A leaning wheel tries to turn outward
and toe-in overcomes this tendency
and reduces drag and wear on tires.
6. Wheel Caster Adjustment. Caster ad-
justment is built into the machine and cannot
be adjusted by relation of the axle pivot pin to
front bolster. Replaceable bearings are pro-
vided at these points and should be replaced
if badly worn. Ease of steering is not affected
by small changes in caster. Notify direct sup-
port maintenance if axle pivot pin and front
bolster bearings require replacement.
c. Wheel Camber Adjustment.
Note. Before attempting to correct camber or toe-in,
check spindles and spindle forks to determine if bear-
ings or sleeve bearings require replacement. Notify
direct support maintenance if bearings have to be
replaced.
(1) Camber must be one degree of posi-
tive camber on each wheel ; top of
wheel must lean outward.
(2) Refer to figure 3--41 for wheel camber
and toe-in adjustment. These set-
tings are shown with weight of grader
on wheels.
Operate leaning wheel control so that
one wheel leans outward one degree.
Opposite wheel must lean outward the
same.
Notify direct support maintenance to
(3)
(4)
repair or replace spindle forks, front
axle, vibrating link, or bearings as
3-50
SCARIFIER
CONTROL
SHAFT
BEARING
SUPPORT
BEARING
SUPPORT
BEARING
SCREWS
UNIVERSAL
JOINT
FRONT LEAN
WHEEL CON
TROL SHAFT
STEERING.
WHEEL
BEARING i
SUPPORT
CAP
BEARING
CAP SCREWS (2)
STEP 1 . REMOVE TWO SCREV/S AND LOCKWASHERS AND
REMOVE REAR BEARING SUPPORT CAP.
STEP 2. REMOVE THREE SCREWS AND LOCKWASHERS AND
REMOVE FRONT BEARING SUPPORT CAP.
STEP 3. REMOVE COTTER PIN AND STRAIGHT PIN AMD
DISCONNECT SHAFT AT UNIVERSAL JOINT.
STEP 4. REMOVE COTTER PIN AND STRAIGHT PIN AND
DISCONNECT SHAFT FROM STEERING GEAR AT
FRONT OF MOTOR GRADER.
Figure 3-40. Steering wheel shaft, removal and installation.
MEC 3805-237- 12/3-40
3-51
D
\
TIE RODS
A. TOE IN (TOP VIEW)
\
B. CAMBER (REAR VIEW)
MEC 3805-237-12/3-41
Figure 3-41- Wheels camber and toe-in adjustment.
3-52
FRONT LEAN
WHEEL GEAR
HOUSING
STEP 1. REMOVE FOUR SCREWS AND LOCK-
WASHERS AND REMOVE CAPS FROM TWO
BEARING SUPPORTS (FIG. 3-41) SUPPORT-
ING FRONT LEAN WHEEL CONTROL
SHAFT.
STEP 2. REMOVE SCREWS, NUTS, AND PINS AND
DISCONNECT THREE YOKES (FIG. 3-41)
FROM CONTROL SHAFT AND POWER
CONTROL BOX.
STEP 3. REMOVE TWO SCREWS AND LOCK-
WASHERS AND REMOVE CAP FROM
BEARING SUPPORT.
STEP 4. REMOVE SCREWS AND NUTS AND DIS-
CONNECT YOKES FROM CONTROL
SHAFT AND FRONT LEAN WHEEL GEAR
HOUSING.
MEC 3805-237-12/3-42
Figure 842. Front leaning wheel control shaft,
removal and installation.
necessary to correct camber, if re-
quired.
d. Wheel Toe-In Adjustment.
(1) Lower moldhoard to ground far
enough to raise front wheels.
(2) Hold a piece of chalk at the center
of each front tire and rotate wheel
to place a chalk mark all around tire.
(3) Lower wheels to ground. Loosen
locking nuts and adjust length of each
tie rod until distance (A, fig. 3-41)
between chalk line is i/ 8 to i/i inch
longer at rear of tire than at front of
tire. Tighten tie rod locking nut.
3-64. Front Leaning Wheel Assembly
a. Gear Assembly. Inspect gear assembly
for leaks and damage. Notify direct support
maintenance if gear assembly requires replace-
ment. Fill gear housing with correct lubricant,
if necessary. Refer to current lubrication
order.
b. Vibration Bar and Gear Rack. Inspect
vibrating bar, vibrating link, and gear rack
for damage. Operate leaning wheel controls
and check operation. Operation should be
smooth and positive. Notify direct support
maintenance if repair or replacement is re-
quired.
c. Front Leaning Wheel Control Shaft.
(1) Removal. Refer to figure 3-42 and
remove front leaning wheel control
shaft.
(2) Installation. Refer to figure 3-42
and install front leaning wheel con-
trol shaft.
Section XIV. TANDEM DRIVES AND BRAKES
365. Tandem Drives
a. General. The two tandem drives operate
both rear wheels. The lower transmission and
final drive rotate the driving sprocket at the
center of the tandem drive. Front and rear
driving axles are driven by chains from the
driving sprocket. The four rear wheels drive
the motor grader and the two front tandem
wheels are equipped with service brakes.
b. Inspection. Inspect tandem drives for
leaks and damage. Remove upper covers and
inspect chains and sprockets for wear. Notify
direct support maintenance if repair or replace-
3-53
ment of tandem drive components is required.
3-66. Brake System
a. General. The service brakes on the motor
grader are hydraulically actuated. Pressure
on the brake pedal actuates the master cylinder.
Hydraulic pressure from the master cylinder,
through the hydraulic brake lines, actuates the
wheel cylinders. The wheel cylinders force
the brake linings against the brake drums,
stopping the grader. The parking brake is
actuated by pulling the parking brake lever in
STEP 1. DISCONNECT STOP LIGHT SWITCH
FROM MASTER CYLINDER.
STEP 2. DRAIN MASTER CYLINDER.
STEP 3. DISCONNECT HYDRAULIC LINES FROM
MASTER CYLINDER,
STEP 4* : . REMOVE COTTER PIN AND REMOVE
CLEVIS PIN FROM CLEVIS AND LEVER.
STEP 5. REMOVE THREE MOUNTING SCREWS,
LOCKWASHERS, AND NUTS AND
REMOVE MASTER CYLINDER.
NOTE? AFTER INSTALLATION OF MASTER
CYLINDER AND REPLACING HY-
DRAULIC FL\JID, BLEED HYDRAULIC
SYSTEM BEFORE OPERATING MOTOR
GRADER. "
MEC 3805-237-12/3-43
Figure S-43. Brake master cylinder, removal and
installation.
the operator's compartment. This action will
set the parking brake and hold the motor
grader in position while parked.
b. Master Cylinder.
(1) Removal. Refer to figure 3-43 and
remove the master cylinder and hy-
draulic lines.
(2) Installation. Refer to figure 3-43 and
install the brake master cylinder.
(3) Bleed brake system.
(a) Fill master cylinder with brake
fluid (fig. 3-2).
(b) Refer to figure 3-44 and bleed both
front tandem wheels to bleed the
brake system.
c. Wheel Cylinders.
(1) Removal.
(a) Remove wheel and brake drum
from grader (para 3-67).
(6) Disconnect hydraulic line (fig.
3-44) from wheel cylinder fitting.
(c) Remove two wheel cylinder screws
(fig. 3-44) and lockwashers.
(d) Remove wheel cylinder and links
from brake assembly.
(2) Installation.
(a) Install links in wheel cylinder.
Move shoes outward to permit in-
stallation of cylinder between brake
shoes. Slots in links must be in-
stalled over edge of brake shoes.
(b) Secure wheel cylinder with two
screws (fig. 3-44) and lockwashers.
(c) Connect hydraulic line (fig. 344)
to wheel cylinder fitting.
(d) Install wheel and brake drum on
grader (para 3-67) .
(e) Bleed the brake hydraulic system
(fig. 3-44) .
d. Parking Brake. The parking brake is
mounted on the lower transmission assembly
countershaft. A hand lever, mounted in the
operator's compartment, sets the parking brake,
through a linkage, when the vehicle is parked.
Adjust parking brake linkage as follows:
(1) Refer to figure 3-45 and adjust park-
ing brake linkage.
(2) Operate hand lever and check func-
tion of linkage and brake.
e. Wheel Brake Adjustment. The motor
grader wheel brakes have an automatic ad-
3-54
FRONT TANDEM
WHEEL BRAKE
,*1 TANDEM
HOUSING
WHEEL
CYLINDER
SCREWS (2)
STEP1. CONNECT TUBE TO BLEEDER PLUG
FITTING. ALLOW TUBE TO HANG INTO
RECEPTACLE SUCH AS A CLEAN GLASS
JAR.
STEP 2. REMOVE MASTER CYLINDER FILL PLUG
(FIG. 3-43) AND KEEP CYLINDER FILLED
WITH FLUID WHILE BLEEDING LINES.
STEP 3. OPEN BLEEDER PLUG 3/4 TURN.
STEP 4. DEPRESS BRAKE PEDAL (FIG. 2-2) HALF
WAY; CLOSE BLEEDER PLUG AND RE- <
LEASE BRAKE PEDAL.
STEP 5, REPEAT STEPS 3 AND 4 TO FORCE FLUID
OUT OF SYSTEM. KEEP END OF TUBE
BELOW SURFACE OF FLUID IN JAR.
STEP 6. WHEN ALL AIR BUBBLES CEASE TO AP-
PEAR IN JAR, CLOSE BLEEDER PLUG
. AND REMOVE TUBE. /
NOTE; REPEAT BLEEDING OPERATION AT BRAKE
ON OTHER SIDE OF GRADER. /
3805-237-12/3-44
Figure 3-44. Bleeding brake hydraulic system.
3-55
STEP 1. REMOVE COTTER PIN AND REMOVE
TURNBUCKLE PIN AND WASHERS.
STEP 2. SHORTEN OR LENGHTEN CABLE BY
ROTATING TURNBUCKLE UNTIL
PARKING BRAKE IS APPLIED WHEN
PARKING BRAKE LEVER (FIG. 2-2)
REACHES HALF THE LENGTH OF
TRAVEL.
STEP 3. CONNECT TURNBUCKLE TO BELL-
CRANK AND SECURE WITH TURN-
BUCKLE PIN, WASHERS, AND
COTTER P!N.
MEC 3805-237- 12/3-45
Figure 3-45. Parking brake linkage adjustment.
justment built into the brake assembly.
Through a cable and spring arrangement the
brake adjusting screw is rotated to adjust the
brake shoes as they wear. Initial brake adjust-
ment must be made when new linings are in-
stalled. If brake joinings require replacement,
notify direct support maintenance. To obtain
automatic adjustment, move grader in reverse
a short distance and apply brakes. Repeat
procedure two or three times.
/. Brake Pedal and Linkage.
(1) Removal. Refer to figure 3-46 and
remove the brake pedal and linkage.
(2) Installation. Refer to figure 3-46
and install brake pedal and linkage.
(3) Adjustment. Refer to figure 3-46
and adjust brake pedal linkage as
follows.
(a) With brake pedal seal pad (10)
against floor plate, remove cotter
pin and remove pin (2).
(b) Loosen locknuts (4) and adjust
length of threaded rod (5) until
holes in clevis (3) are 1/32 to 1/16
inch too short to aline with hole in
lever (1).
(c) Pull rod to aline holes and install
pin (2) in clevis and lever and
secure with cotter pin.
(d) Depress brake pedal (7) and release
several times.
(e) Remove cotter pin and remove pin
(2) from clevis (3) and lever (1).
(/) Check distance detailed in (b)
above. If distance hasn't changed,
install pin (2) and secure with
cotter pin. If necessary, repeat ad-
justment procedure.
3-67. Wheels and Tires
a. Wheels.
(1) Removal.
Note. All six wheels on the motor grader
are mounted the same. The only difference
in the wheels are the brake drums on the
two front tandem wheels.
(a) Jack or raise frame or axle of
motor grader to elevate wheels from
ground.
(b) Refer to figure 3-47 and remove
wheel and tire from grader.
(2) Installation.
(a) Refer to figure 3-47 and install
wheel and tire on grader.
(b) Lower motor grader to ground.
b. Tires. The tires on the motor grader are
of the tubeless type.
Warning: Care must be observed to install
a protective device or chain around tire before
attempting to inflate tire.
(1) Removal.
(a) Remove wheel (a above).
(b) Rest wheel on a support to keep
wheel off ground.
(c) Deflate tire by removing valve core.
(d) Use a hammer and a pry bar to
loosen lockring.
(e) Remove preformed packing from
wheel.
3-56
1C
NOTE:
SPRING (12) IS ATTACHED
TO ANGLE ON BOTTOM
OF FLOOR PLATE .
1
2
3
4
5
6
7
8
9
10
11
12
LEVER
PIN
CLEVIS
LOCKNUT (2 rqr)
THREADED ROD
MASTER CYLINDER
BRAKE PEDAL
SCREW
PEDAL ARM
SEAL PAD
SCREW
SPRING
MEC 3805-237-12/3-46
Figure 3-46. Brake pedal and linkage adjustment, removal and replacement.
(/) Remove large flange from wheel.
Remove tubeless tire from rim.
(r/) Remove valve from wheel rim.
(2) Installation.
(a) Install valve in wheel rim.
(6) Install tire on wheel.
(c) Install flange on rim. Depress
flange and install preformed pack-
ing in lower groove in rim base.
(d) Install lockring in base. Start one
3-57
SLOTTED
NUT
STEP 1 . REMOVE EIGHT NUTS AND RIM
CLAMPS.
STEP 2. REMOVE COTTER PiN AND REMOVE
SLOTTED NUT FROM AXLE.
NOTE: ON FRONT WHEELS, REMOVE THREE
SCREWS AND LOCKWASHERS AND
REMOVE HUB CAP. REMOVE SCREW
AND LOCK NUT AND REMOVE
WHEEL NUT FROM AXLE .
STEP 3. INSTALL TWO 7/8-9 PULLER SCREWS
IN PULLER SCREW HOLES ATTACHING
SUITABLE PULLER. TURN PULLER
SCREW IN AGAINST END OF AXLE
UNTIL WHEEL IS FREE,
NOTE: FRONT WHEELS CAN BE REMOVED
WITHOUT USE OF PULLER SCREWS.
MEC 3805-237-12/3-47
Figure S-47. Wheels, removal and installation.
end of lockring in upper groove of
rim. Work ring into .place gradu-
ally until it is firmly locked.
(3) Inflation.
(a) Install protective device or chain
on tire.
(b) Inflate tire with, enough air pres-
sure to seat tire solidly on rim and
flange.
(c) After tire is seated and sealed, re-
duce pressure to normal limits. On
Model 440HA motor graders with
1300 X 24 10-ply tires, inflate to
30 pounds.
Section XV. HYDRAULIC SYSTEM
3-68. Hydraulic Reservoir
a. Inspection. Inspect hydraulic reservoir
and lines for leakage and damage. Replace
any defective lines. Notify direct support
maintenance if reservoir requires replacement.
b. Reservoir Cap. Remove cap and check
cap for secure fit and for damage. Inspect
gage for damage. Replace defective parts.
c. Hydraulic Reservoir Filter. Refer to
paragraph 3-4 for service of the filter.
3-69. Steering Hydraulic Pump
a. General. The hydraulic pump is mounted
on the front of the power box and is driven by
the power box vertical drive shaft.
b. Removal. Refer to figure 3-48 and re-
move hydraulic pump.
c. Installation. Refer to figure 3-48 and in-
stall hydraulic pump.
Section XVI. HOOD AND CAB ASSEMBLY
3-70. Engine Hood
a. Removal. Refer to figure 3-21 and remove
engine hood.
b. Installation. Refer to figure 3-21 and
install engine hood and panels.
3-71. Cab
a. Removal. Refer to figure 2-2 and remove
seat and cab components.
b. Installation. Refer to figure 2-2 and in-
stall seat and cab components.
3-72. Tool Box
a. Removal.
(1) Open tool box and remove tools.
(2) Remove four screws and washers
securing tool box to brackets and re-
move tool box.
b. Installation.
(1) Install tool box on right rear brackets
alongside of engine and secure with
four screws and washers.
(2) Place tools in tool box and secure
cover.
3-58
CONTROL VALVE
HYDRAULIC LINE
CROSSOVER
HYDRAULIC
,' f if .'< S\ >!hV
! I ! 11 f , M N r
MOUNTING
SCREWS (4}
MOLDBOARD SHIFT
HYDRAULIC PUMP
STLLRING
HYDRAULIC
PUMP
LINE TO
HYDRAULIC
RESERVOIR
STEP I . DISCONNECT HYDRAULIC LINES FROM PUMP.
STEP 2. RKMOVE FOUR MOUNTING SCREWS AND LOCKWASHERS
STEP 3. RF-:MOVE PUMP AND ADAPTER FROM VERTICAL DRIVE
HOUSING, REMOVE GASKET.
STEP 4. REMOVE FITTINGS FROM PUMP.
NOTE: REMOVAL IS IDENTICAL FOR BOTH HYDRAULIC PUMPS.
INSTALL NEW GASKET WHEN INSTALLING PUMP.
MEC 3805-237-12/3-48
Figure 3~4S. Hydraulic pump, removal and installation.
Section XVII. POWER CONTROL BOX
3-73. Control Box age and damage. Operate controls and check
a. Inspection. Inspect control box for leak- operation of control box. All controls should
3-59
shift smoothly and response to control should
be immediate. Notify direct support mainte-
nance if control box is defective.
b. Service. Replenish oil in control box if
necessary. Refer to current lubrication order.
3-74. Control Box Levers
a. Removal. Refer to figure 3-49 and re-
move control box levers.
Note. All control box levers are removed in the
same manner.
STEP \ , REMOVE BALI FROM TOP OF LEVER.
STEP 2. REMOVE TWO SCREWS AND LOCK-
WASHERS.
STEP 3. REMOVE CONTROL LEVER AND BALL
CAP FROM POWER CONTROL BOX,
STEP 4. COUNT AND REMOVE SHIMS BE-
TWEEN BALL CAP AND CONTROL
BOX.
STEP 5. REMOVE BALL CAP AND BALL SEAT
FROM LEVER.
NOTE: ALL CONTROL LEVERS ARE REMOVED
IN THE SAME MANNER.
MEC 3805-237-1 2/3-49
Figure 3-4.9. Control box levers, removal and
installation.
b. Installation. Refer to figure 3-49 and in-
stall the control box levers.
3-75. Propeller Shalt
a. Removal. Refer to figure 3-50 and
remove propeller shaft.
Note. The propeller shaft has a shear bolt coupling.
Refer to figure 3-50 for replacement of the shear bolt.
b. Installation. Refer to figure 3-50 and
install propeller shaft.
3-76. Clutch Anti-Coast Brakes
a. General. Each power box clutch that
drives a control shaft is equipped with an anti-
coast brake. This brake prevents coasting of
moldboard, scarifier, circle reverse and lateral
shift when a load is placed on it.
Note. Before adjusting the clutch anti-coast brake,
adjust the worm gear end thrust bearing in the gear
housings (para 3-85).
STEP 1 . REMOVE NUT AND TWO LOCKWASHERS
AND REMOVE SHEAR BOLT FROM
COUPLING.
STEP 2. REMOVE FOUR YOKE SCRF.WS AND LOCK
PLATE AND REMOVE YOKE FROM
PROPELLER SHAFT.
STEP 3. REMOVE YOKE SCREWS AND DISCON-
NECT PROPELLER SHAFT FROM TRANS-
MISSION.
MEC 3805-237- 12/3-50
Figure S-50. Propeller shaft and shear bolt, removal
and installation.
3-60
(1) Adjust brake by tightening adjusting
nut (fig. 3~5i) on particular brake
until coasting is eliminated. Take up
on adjustment and check operation.
It may be necessary to vary the ad-
CLUTCH
CONTROL
SHAFT
Figure 3~51. Clutch anti-coast brake adjustment.
justment to get the best results.
(2) If adjustment does not correct opera-
tion, notify direct support mainte-
nance.
Section XVIII. MOLDBOARD
3-77. Moldboard Blade
a. Removal.
(1) Lift moldboard from ground and sup-
port blade.
(2) Refer to figure 3-52 and remove mold-
board blade and edges.
b. Installation. Refer to figure 3-52 and
install moldboard blade and edges.
3-78. Power Shift Moldboard
a. General. Hydraulic oil pressure in a
cylinder moves the moldboard to either side.
A separate hydraulic pump supplies pressure
for the power shaft.
b. Inspection. Inspect hydraulic cylinder
(fig. 3-52) and lines for leakage and damage.
Replace damaged lines. Inspect slides and
clean and lubricate. Refer to current lubrica-
tion order.
Section XIX. CIRCLE REVERSE MECHANISM
3-79. Lateral Shift and Lift Gear Assemblies
a. Inspection. Inspect gear assemblies for
leakage and damage. Check control shaft and
universal joints for looseness. .Inspect pins in
left and lateral shift links for wear and -dam-
age. Operate lateral shift and lift controls
and check operation. Tilt and lift blade to
check movement of circle and drawbar pivot.
b. Adjustment. If ball and sockets are loose,
adjust as follows.
(1) Lower moldboard to the ground.
(2) Remove shims in lift links as shown in
figure 3-53.
(3) Remove shims from lateral shift link
as shown in figure 3-54.
3-80. Circle Reverse Assembly
a. Gear Assembly. Inspect gear assembly
for leakage and damage. Inspect large circle
reverse gear for damaged teeth. Operate con-
trols and move circle reverse through entire
length of travel. Check operation of gear
assembly and reversing pinion. Check retain-
ing plates and shims at three points of suspen-
sion on drawbar. If plates need adjustment,
notify direct support maintenance.
b. Reversing Pinion. Check reversing pinion
clearance with circle gear. Note any wear
spots on circle gear teeth. Wear should be
even all around circle. If wear shows in cer-
tain areas, circle is out of alinement and three
retaining plates and shims must be adjusted to
aline circle with reversing pinion.
3-81. Drawbar
a. General The drawbar supports the
circle, moldboard and reversing gear assem-
bly. A ball at the front end of the drawbar
pivots in the front of the main frame, allow-
ing the circle and moldboard to be raised to
3-61
HYDRAULIC
YLINOER
MOUNTING
BOLTS (A)
MOLD BOARD
BLADE
MOLD BOARD
SLIDE
MOUNTING
BOLTS (16)
STEP 1. REMOVE FOUR MOUNTING BOLTS AND FOUR SCREWS FROM BOTH ENDS OF
MOLDBOARD AND REMOVE TWO BLADE EDGES.
STEP 2. REMOVE 16 MOUNTING BOLTS AND NUTS AND REMOVE TWO MOLDBOARD
BLADES AND TWO BOOTS.
MEC 3805-237-12/3-52
Figure S52. Moldboard blade, removal and installation.
the sides of the frame and to change the blade
angle for all types of operations.
6. Inspection. Check drawbar and circle
mountings for damage. Operate circle and
check drawbar pivot in frame. If drawbar
ball is loose in frame, notify direct support
maintenance.
Section XX. SCARIFIER
3-82. Scarifier Gear Assembly
a. Inspection. Inspect scarifier gear assem-
bly for leakage and damage. Check universal
joints and shaft connections for looseness and
damage. Operate scarifier controls and check
operation. Move scarifier up and down as
necessary to check controls. If gear assembly
is defective, notify direct support maintenance.
b. Service. Lubricate gear assembly as
necessary. Refer to the current lubrication
order. Adjust end thrust bearing (para 3-85)
if necessary.
3-83. Scarifier Lift Arms
a. Removal. Refer to figure 3-55 and re-
move scarifier lift arms.
b. Installation. Refer to figure 3-55 and
install scarifier lift arms.
3-62
SHIMS
Mv UNITING
SCREWS 1 2'!
STEP 1. REMOVE TWO SCREWS, LOCKWASHERS,
AND NUTS AND REMOVE SOCKET CAP.
STEP 2. REMOVE OR INSTALL SHIMS AS NEC-
ESSARY TO PROVIDE FREE MOVEMENT
WITHOUT BINDING OR TOO MUCH
FREE PLAY.
MEC 3805-237- 12. '3 -53
Figure 3-53. Lift link shims, removal or installation.
3-84. Scarifier Control Shaft
a. Removal. Remove scarifier control shaft
(fig. 3-40) in the same manner as steering
control shaft and front lean wheel control shaft.
b. Installation. Install scarifier control shaft
(fig. 3-40) in the same manner as steering con-
trol shaft and front lean wheel control shaft.
Section XXI. ADJUSTMENT
3-85. Worm Gear End Thrust Bearing
a. General. The end thrust bearings in the
STEP 1. REMOVE TWO SCREWS AND LOCK'AASHERS AND PEVO'-
SOCKET CAP.
STEP 2. REMOVE OR INSTALL SHIMS A5 NECESSARY TO PROVnE
FREE MOVEMENT WITHOUT BINDING OR TOO MUCH "
FREE PLAY !N UNk
MEC 38lb-?j!?-i?-3-54
Figure S-54. Lateral shift link shims, removal and
installation.
control gear boxes of the motor grader aid the
clutch anti-coast brake in stopping motion when
control lever is disengaged. The thrust bear-
ing should be adjusted periodically, or when
coasting of the motion becomes noticeable.
Note. Always adjust and thrust bearings before
adjusting clutch anti-coast brakes.
b. Adjustment.
(1) Refer to figure 3-56 and loosen the
locknut.
(2) Tighten adjusting screw (fig. 3-56)
with alien wrench. Back off screw
1/16 to i/s of a revolution. Tighten
locknut.
(3) Operate control lever and check for
coasting. Tighten screw again if
necessary.
(4) Adjust anti-coast brakes (para 3-76)
as necessary to aid in prevention of
coasting by grader motion.
3-86. Power Shift Moldboard
a. General. The power shift moldboard is
incorporated on the model 440HA motor grad-
ers. It is hydraulically actuated, enabling the
operator to shift the moldboard to either side
3-63
SOCKET
CAP
SHIMS
SCARIFIER
LIFT ARM
with a control lever mounted in the operator's
compartment. The ball and socket on the hy-
draulic ram may become worn. Shims must
be added or removed to adjust and compensate
for wear.
b. Adjustment.
(1) Remove ball socket cap (fig. 3-52).
(2) Add or remove shims to adjust for
wear.
(3) Install ball socket cap. Ball and
socket should be snug, but operate
freely, without binding.
W
THRUST
ADJUSTING BEARING
SCREW /
WORM
GEAR
Figure 355. Scarifier lift arms, removal and
installation.
MEC 3805-237-12/3-56
Figure 8-56. End thrust bearing, adjustment,.
3-64
wIP
APPENDIX A
REFERENCES
A-l. Fire Protection
TB 5-4200-200-10
TM 5-687
A-2. Lubrication
FS C9100-1L
Hand Portable Fire Extinguishers Approved for Army Users.
Repairs and Utilities : Fire Protection Equipment and Appliances ;
Inspection, Operation, and Preventive Maintenance.
Petroleum, Petroleum-Base Products and Related Materials.
A-3. Preventive Maintenance
TB ENG 347
TM 9-1870-1
TM 9-2858
TM 9-6140-200-15
TM 38-750
Winterization Techniques for Engineer Equipment.
Care and Maintenance of Pneumatic Tires.
Cooling Systems : Vehicles and Powered Ground Equipment.
Storage Batteries, Lead-Acid Type.
Army Equipment Record Procedures.
A-l
APPENDIX B
BASIC ISSUE ITEMS LIST AND MAINTENANCE
AND OPERATING SUPPLIES
Section 1. INTRODUCTION
B1. General
Section II lists the accessories, tools, and pub-
lications required for maintenance and opera-
tion by the operator which are initially issued
with, or authorized for use with the motor
grader. Section III lists the maintenance and
operating supplies required for initial opera-
tion.
B~2. Explanation of Columns Contained in
Section 81
a. Source Codes. The information provided
in each column is as follows:
(1) Materiel This column is left blank.
For identification of agencies assigned
supply responsibility for parts, refer
to appropriate Federal and Depart-
ment of Army supply catalogs.
(2) Source. The selection status and
source of supply for each part are
indicated by one of the following code
symbols.
(a) p applied to high-mortality repair
parts which are stocked in or sup-
plied from the army supply system,
and authorized for use at indicated
maintenance categories.
(b) pi applied to repair parts which
are low-mortality parts, stocked in
or supplied from supply service de-
pota, and authorized for installation
at indicated maintenance level.
(c) M applied to repair parts which
are not procured or stocked but are
to be manufactured at indicated
maintenance level.
(d) X2 applied to repair parts which
are not stocked. The indicated
maintenance level requiring such
parts will attempt to obtain them
through cannibalization ; if not ob-
tainable through cannibalization,
such repair parts will be requisi-
tioned with supporting justification
through normal supply channels.
(3) Maintenance. The lowest mainte-
nance level authorized to use, stock,
install, or manufacture the part is
indicated by the following code sym-
bol.
Organizational maintenance
(4) Recover ability. _Bepair parts and/or
tool and equipment items that are
recoverable are indicated by one of
the following code symbols :
(a) R applied to repair parts and as-
semblies which are economically re-
pairable at direct and general sup-
port maintenance activities and
normally are furnished by supply
on an exchange basis.
(b) T applied to high-dollar value re-
coverable repair parts which are
subject to special handling and are
issued on an exchange basis. Such
repair parts normally are repaired
or overhauled at depot maintenance
facilities.
(c) U applied to repair parts specific-
ally selected for salvage by reclama-
tion units because of precious metal
content, critical materials, high-
dollar value reusable casings, cast-
ings, and the like.
Note. When no code is shown in the
recoverability column the part is con-
sidered expendable.
b. Federal Stock Number. When a Federal
stock number is available for a part, it will be
B-1
shown in this column, and will be used for
requisitioning purposes.
c. Description.
(1) The item name and a brief description
of the part are shown.
(2) A five-digit Federal supply code for
manufacturer's and/or other supply
services is shown in parentheses fol-
lowed by the manfacturer's part num-
ber. This number shall be used for
requisitioning purposes when no Fed-
eral stock number is indicated in the
Federal stock number column.
Example: (08645) 86453
d. Unit of Issue. If no abbreviation is
shown in this column, the unit of issue is
"each".
e. Quantity Authorized. This column lists
the quantities of repair parts, accessories, tools,
or publications authorized for issue to the
equipment operator or crew as required.
/. Quantity Issued with Equipment. This
column lists the quantities of repair parts, ac-
cessories, tools, or publications that are initially
issued with each item of equipment. Those in-
dicated by an asterisk are to be requisitioned
through normal supply channels as required.
g. Illustrations. This column is subdivided
into two columns which provide the following
information :
(1) Figure number. Provides the identi-
fying number of the illustration.
(2) Item number. Provides the reference
number for the parts shown in the
illustration.
B-3. Explanation of Columns Contained in
Section 839
a. Item. This column contains numerical
sequenced item numbers, assigned to each
component application, to facilitate reference.
b. Component Application. This column
identifies the component application of each
maintenance or operating supply item.
c. Source of Supply. This column is left
blank. For identification of agencies assigned
supply responsibility for parts, refer to appro-
priate Federal and Department of Army sup-
ply catalogs.
d. Federal Stock Number. The Federal
stock number will be shown in this column and
will be used for requisitioning purposes.
e. Description. The item and a brief de-
scription are shown.
/. Quantity Required for Initial Operation.
This column lists the quantity of each mainte-
nance or operating supply item required for
initial operation of the equipment.
g. Quantity Required for 8 Hours Operation.
Quantities listed represent the estimated re-
quirements for an average eight hours of
operation.
h. Notes. This column contains informative
notes keyed to data appearing in the preceding
column.
B-2
Section II. BASIC iSSUi LIST
Source codes
Illustration
Federal
f4
1
Sc
c
3
Stock
Description
1
3
g
Figure
Index
tl
Number
-3
no.
g
g
a
$
*s
+3
3 J
of
i
3
i
"a
|
5
a
&
a
D
<
Of"?
GROUP 31 BASIC ISSUE ITEMS,
MANUFACTURER
INSTALLED
3100 BASIC ISSUE ITEMS, MANU-
FACTURER OR DEPOT IN-
STALLED
p
6140-067-2664
BATTERY: storage dry-charged, Type 6TN
4
4
3-36
(36311-485040)
9
p
7610-889-3494
BINDER: loose-leaf, U. S. Army Equip-
1
1
ment Log Book
9
p
7520-669-9618
CASE: operation & maintenance publica-
1
1
tions, cotton duck, water repellent, mil-
dew resistant, MIL-B-11743B
DEPARTMENT OR THE ARMY OPERA-
1
1
TOR & ORGANIZATION MAINTE-
NANCE MANUAL TM 5-3805-237-12
6810-264-9063
SULPHURIC ACID: electrolyte (35311-
GAL
7
7
488141)
TOOL, SCARIFIER TOOTH REMOVING
1
1
3-1
p
6120-595-9162
WRENCH: alien 9/16 in.
1
*
p
6120-203-4804
WRENCH: open end 1% in.
1
*
GROUP 32 BASIC ISSUE ITEMS
TROOP INSTALLED
3200 BASIC ISSUE ITEMS TROOP IN-
STALLED OR AUTHORIZED
p
7240-408-3985
MEASURE: liquid, steel zinc coated, 1 qt.
EA
1
1
funnel spout w/flex extension
p
4910-922-6921
KIT, REPAIR: tubeless tire
EA
1
1
B-3
>
GL
a.
O
1
LU
a.
O
o
u
<
ui
C
o
I
U)
53 .S
-d
3 1?
s-g
n '43
QJ 4J
TJ C
2
M 6
60 -s
w C Q
<u -S -P
j|-
g
SJ^Sg
3 S d | 5
'w
.g
s :
o"S
H ^
p
$ ^
|-|1|
nJ
l!
^ g-
3*
O t3
g 4
A
4J T3
S c
CU CU M
^ DO o
tt
P, M S rt _.
l l-a a
.S
DO
1
00
" : 3 .
"3 0> $
^ . G <3
s s
OS gj
O
w ?
fa-S S
J31
Jl ,z ~)
C g
55 ss
fc e
30.
5 -43 J
OS 03
0) cj >
a; {^
M u^
||
l{
a " s -s "
8 - 2 .52
5 ~ c
111 1 !
f-t t* C
"eS
bo
x-s 0) 'S
rH
S ft
s & -s
" OS ^i
C3 4^
O <H CU O
,-+. G T) w
us
co
K,"
fill
CO
/*, ^
CO CO
O' o o
4J
40 "ft
^V ^-N
^-s ^-^ '-s
^*> ^* x^^
S- > ^-N X-v
^
*-X x-s
*
C 1
o 1 o*
us" us us"
CO
cc rt
CO CO CO
CO CO CO
CO CO CO
CO
CO CO
rH
rH rH
s_, v_^ s_x
v ~'
*^^ *^^
^^ v--
111 I
CO
CO CO
c -a '2 "S
. 1 r F 1
13
'3 73
p^, ,
^"^
*~s ^~t
Itil
'S
bo
cd K)
bo bo
rt OS oj
bo bo bo
bo
bo bo
bo bo bo
p< ft ft
P, & ft
"3
bO
'a 'ca
bo bo
o o o
T-T*
r^j f-i*
CO CO CO
CO
CO CO
co CD co
CO
CO CO
rH rH rH
^ "* ""
rj< -* ^
00
oo oo
w
1
W
W
O
CJ
o ..
m
w
0}
CO
>
m
09
E
.2
O ^3
g ..
-H O
O S
t3|
0-3
I-H
o
ti o
o ~
Vj o
O^S
&
H
W S
s
H
aTj
H
"C
O M
sl__ Q
^r W
M C3
o
g
S
L_ DO
Z 03
C5 g
55 rt
BRICATI
gal pail
OE-30
o
*~ l r>
W W
ri ^ ^ s r
O rt *? 7 1
g ~ Q Q Q
^*
r. vl
PQ
o
00
2 '3 o o
(3 bo 9 O O
1
Ills
H ra
<j ca o o
O i r OT
y -a O O O
g boO O
M
<=>
< ft co
-. r(
I-H 73 w
boO
m
o
{3 us
j-j PQ
H-% LO
J-, US
1
P *>
D us
c7
c?e?
Federal
stock number
0-265-9435 (
0-265-9428 i
0-242-76031
* ^ co
OS CO 00
N CNI CO
US US UP
N CD CO
US 00 00
222
00
t-
us
ci
0-577-5841
0-257-5440
X*J rH O
00 00 <#
US US US
C- t- US
332
>0-577-5844
0-577-5841
0-257-5440
** rH O
^( Xj* ""^*
00 00 ^
up up up
32ti
t- fr- US
up us co
2ci<i
0-265-9435
0-265-9428
0-242-7603
us
us us
"^* *^( Tj*
UP
us us
us us us
U3 US US
us us us
us
US US
rH
rH rH
rH r-( rH
rH rH
rH rH rH
rH T-I rH
rH rH rH
TH
rH rH
OS OS
OS
O> OS
OS OS OS
OS OS OS
OS OS OS
OS
OS OS
aajnog
H
M
125
fc
Component
application
101 CRANKCAS
(1)
CD
CO
700 UPPER
TRANSMISSIO
700 LOWER
TRANSMISSIO
AND FINAL
DRIVE
701 TRANSMIS-
SIGN SHIFTE
HOUSING
004 FRONT
LEANING
WHEEL
HOUSING
105 TANDEM
DRIVE HOUS-
ING
o
o
o
o
o
ri
H
1
iH
CO
CO
,
up
CD
t>
B-4
I
I
CO CO CO
13 IS 13 O^ .L2 ft ft ft
HJJ bO bfi bO ftftft vjji5jis^
ft "ft "ft
ft 'ft ft
CO CO CO
ft ft ft
"ft ft "ft
N OOOOOO t- t- t- t- t- O
in m m
W O3 <M
in m m
rH rH rH
CO CO CO
PH
w
W
M
H
H
o ..
o ..
<3 ..
O
B 2 J S 1 S HH
M P "o -l I s HH o
ta
Dl
(A
CO
J
T n< O^3 OS O TO
o|
Sa
1 ( o
O s
o 3
r .S **H
H
o
o
*H
" "H c5 O **"* O
O ^
O **
o g S 3 g $ g <a
J5 S
HH
J5 ot
^ w
CH rt
55
ij. H^3 IH rJ E-i ~
3S <| "" S -5 3 ^J00
EH r^J
^ oj o o
E-< 13
^ ^ OT 00
t
^HO^ O (a<C ? r l < CO Q p<C T r Tw O \ ? W
S *> S a is w H w a is w w w a ^ o o o
pftW &000 g^OOO gbflOOO
O ^ T ? W
H 13 O O O
g ooO O O
HH -3 O O O
g 8>u o o
M -TJ O O O
g So o o
>rj 13 O O O
g too a o
^^ iM |j to *^ IO I"***) ^O
p m
& w
p to
p ^
W HJ KH J
HH
rH
J
J
eoi inpoco mooco -^THO
"^ rH O
^ rH O
^Jt rH O
Tf rH O
CO CO, CN O CO CN O *^H *di *cr
00 00 ^
00 00 ^
00 00 ^f
o OT 05 c~ abcnt~ minin
ci> ininN inincj t- t- t-
222
222
t- t- t>
m in m
t- t- in
t> t- in
t- t> in
t- t- m
rH COCHIN WNCM lOinCjl
f^ ci c? cb ci ci cb cb ci) cis
222
222
222
in in d
in ininm intoio mmm
in m in
in in in
in in in
tn in w
rH rHrHrH rHrHrH r-trHrH
rH rH rH
rH rH rH
rH rH rH
rH rH rH
Ot o>o>o) ocncn ocno
O) O) O^
O5 O O
Ol O5 O
O5 O4 OS
A
So 3 o gw
PH
hH
j
{2J H^ W P
S3 wJg riS g
SB l i| lls fc g
pij i*^tj WJHC/J wCHJ^HHp^
PQ W WOT ^J^P ^ H 5'-io^^
-J.&3 S^ oO Oo3vkDQ
^* r CO*^ CM^tH Cfl r^ 51J X }r ""j
OH itCO oOW o ^ f- 1 I-H PH ^J
W rh
^ S
O r , 55
ggg
tf P
_ W O
S > W
j W W o
w oj o
^ H W
<
C5
w 2
H\
, r. HH
<< r w
J & P
M O
Oi JJJ HH
co W W
w w S
c<i 5* o o
*^p
xj<
x*
rji
iH rH M M
c-
^
t~
t~
0-5
s
Q.
a.
u>
O
1
UJ
o.
O
UJ
U
1
O
55
Quantity
required
for 8 hours
operation
COCQ04 OOCOCO COCOCO
*~* s-* **~^
CO CO CO
00 *J
o & a
at S>
10
Quantity
required
for initial
operation
* ** 4J
-M 43 43 ft Pi ft
Pi ft Pi
43 "** ** ^ ^ ^!
ft ft ft iP#^! CO(M(M
r "P*"P.
rl
01
COOOCO OOCOCO rHrHrH
rH >
PH OH PH
WWW
W
H
o o d
O
r*
" OQ
g
S? C fe
O O f O^
HH g
s|
s
S3
H H ^
o
o 3
P,
rn ^^
'C
S5 S Sz: a 55
\>yr TO
M *
P C
H^ HH HH
E-< ^U H rd EH ^3
glss},, gl^s Sa^s
5^oo
S ^Jw
*
H ^ <j
tJ'SOOO tl'rfOOO S'eSOOO
gaooo gooooa gboooo
H T8
g So o o
W^
p 10 J3 us {3 us
P U5
W ***
K4 J iJ
^
O
Ju.
^IrHO -tJtr-lO Tl<rHO
-JI rH O
m
X
^4^ ^1 ^4 ^4t ^M xi* TT ^^f "^
T}* xf* ^i*
o
"21
00 00 ^* OO 00 *V 00 00 ""Cf*
t- t- c-
a>
3
|V *^
t-t-U5 t*t-VD 1>1>U5
t- t- IA
o>
1
222 222 222
222
3
Loiaus iAioLo lousia
IA kA IA
ia
O) O} OS O) O) ^^ O) O^ O)
rH rH rH
Cs O Oi
o>
aoanog
Component
application
tf O
< fi*
wg S5
^ &g
S SS
S CO S p M S _
rf J l 8 g
|w w 513
441 SCARIFIER
GEAR REDUC-
TION HOUSING
.UBRICATION
FITTINGS
t- t- ?
t-
M
1
t- 00
o>
O
3
M
rH rH rH
rH
<N
B-6
APPENDIX C
MAINTENANCE ALLOCATION CHART
Section i. INTRODUCTION
C-l. General
a. Section I provides a general explanation
of all maintenance and repair functions author-
ized at various maintenance levels.
b. Section II designates overall responsi-
bility for the performance of maintenance
operations on the identified and item or com-
ponent. The implementation of the mainten-
ance tasks upon the end item or component will
be consistent with the assigned maintenance
operations.
c. Section III lists the special tools and test
equipment required for each maintenance op-
eration as referenced from Section II.
d. Section IV contains supplemental instruc-
tions, explanatory notes and/or illustrations re-
quired for a particular maintenance function.
C 2. Explanation of Columns in Section II
a. Functional Group Number. The function-
al group is a numerical group set up on a
functional basis. The applicable functional
grouping indexes (obtained from TB 750-93-1
Functional Grouping Codes) are listed on the
MAC (Maintenance Allocation Chart) in the
appropriate numerical sequence. These in-
dexes are normally set up in accordance with
their function and proximity to each other.
/;. Component Assembly Nomenclature. This
column contains a brief description of the com-
ponents of each functional group.
c. Maintenance Operations and Maintenance
Levels. This column lists the various mainte-
nance operations (A through J) and indicates
the lowest maintenance level authorized to per-
form these operations. The symbol designation
for the various maintenance levels are as fol-
lows:
0/C Operator or crew
Organizational maintenance
F Direct support maintenance
H General support maintenance
D Depot maintenance
The Maintenance Operations are denned as
follows :
A Service : Operations required periodically
to keep the item in proper operating con-
dition, i.e., to clean, preserve, drain,
paint and replenish fuel, lubricants,
hydraulic and deicing fluids, or com-
pressed air supplies.
B Adjust: Regulate periodically to prevent
malfunction. Adjustments will be made
commensurate with adjustment proce-
dures and associated equipment specifica-
tions.
C Aline: Adjust two or more components
of an electrical or mechanical system so
that their functions are properly syn-
chronized or adjusted.
D Calibrate: Determine, check, or rectify
the graduation of an instrument, weap-
on, or weapons system or components
of a weapons system.
E Inspect : Verify serviceability and detect
incipient electrical or mechanical failure
by close visual examination.
F Test: Verify serviceability and detect
incipient electrical or mechanical failure
by measuring the mechanical or electri-
cal characteristics of the item and
comparing those characteristics with
authorized standards. Tests will be
made commensurate with test procedures
and with calibrated tools and/or test
equipment referred in the MAC.
G Replace: Substitute serviceable compon-
ents, assemblies and subassemblies for
unserviceable counterparts or remove
and install the same item when required
for the performance of other mainte-
nance operations.
C-H
H Repair: Restore to a serviceable condi-
tion by replacing unserviceable parts or
by any other action required using avail-
able tools, equipment and skills to
include welding, grinding, riveting,
straightening, adjusting and facing.
I Overhaul: Restore an item to a com-
pletely serviceable condition (as pre-
scribed by serviceability standards de-
veloped and published by the commodity
commands) by employing techniques of
"Inspect and Repair Only as Necessary"
(IROAN). Maximum use of diagnostic
and test equipment is combined with
minimum disassembly during overhaul.
"Overhaul" may be assigned to any level
of maintenance except organizational,
provided the time, tools, equipment, re-
pair parts authorization, and technical
skills are available at that level. Nor-
mally, overhaul as applied to end items,
is limited to depot maintenance level.
J Rebuild : Restore to a condition compar-
able to new by disassembling to deter-
mine the condition of each component
part and reassembling using serviceable,
rebuilt, or new assemblies, subassemblies,
and parts.
d. Reference Note. This column, subdivided
into columns K and L, is provided for refer-
encing the SPECIAL TOOL AND TEST
EQUIPMENT REQUIREMENTS (sec. Ill)
and REMARKS (sec. IV) that may be associ-
ated with maintenance operations (sec. II).
C 3. Explanation of Columns in Section III
a. Reference Code. This column consists of
a number and a letter separated by a dash. The
number references the T & TE requirements
column on the MAC. The letter represents the
specific maintenance operation the item is to
be used with. The letter is representative of
columns A through J on the MAC.
6. Maintenance Level. This column shows
the lowest level of maintenance authorized to
use the special tool or test equipment.
c. Nomenclature. This column lists the
name or identification of the tool or test equip-
ment.
d. Tool Number. This column lists the man-
ufacturer's code and part number, or Federal
stock number, of tools and test equipment.
C-4. Explanation of Columns in Section IV
a. Reference Code. This column consists of
two letters separated by a dash, both of which
are references to section II. The first letter
references column L and the second letter ref-
erences a maintenance operation, column A
through J.
b. Remarks. This column lists information
pertinent to the maintenance operation being
performed, as indicated on the MAC, section II.
C-2
Section II. MAINTENANCE ALLOCATION CHART
Functional
group
number
Component Assembly Nomenclature
~ ~ -
Maintenance
operations
Maintenance
^____^ levels
Note
ref
A
B
c
D
E
F
G
H
i
j
K
L
Essentiality
Service
40
00
3
o
o>
<
Calibrate
4J
I
8
Replace
5
a
&
Overhaul
Rebuild
4->
1
W
h
a
t*
Remarks
Component Assembly Nomenclature
01
0100
0101
0102
0103
0104
0105
0106
0108
0109
ENGINE
Engine Assembly:
Engine _ _
O/C
o/c
F
F
F
H
H
H
H
F
F
H
H
F
H
H
H
H
H
D
H
H
A
B
C
Crankcase, Block, Cylinder
Head:
Block
Head, cylinder _ _
F
Crankshaft :
Bearings, main
Crankshaft
Damper, pulley
Flywheel Assembly:
Cover
Flywheel, housing,
ring gear
Pistons, Connecting Rods:
Bearings, pistons, pins,
retainers
Hods connecting rings
Valves, Camshafts, and
Timing System:
F
Bearings, camshaft, cover,
Gear ?ears timincr chain
Guides, springs, retainers
. H
. H
. F
.
.
-O/C
. F
.
F
H
H
H
Engine Lubricating System:
O/C
Cap, filler, fittings, hose,
Lines pipes
___
---
--
Manifolds :
Accessory Driving
Mechanisms:
1
C-3
Section II. Maintenance Allocation Chart Continued
Functional
group
number
FOR:
"~"~ - _____^_^^ Maintenance
- _______^^ levels
laintenance ~ ~ ^____^
perationa _____^
Note
ref
A
c
D
E I
G ]
1
I
J
K
L
Essentiality
1
Service
'
j
Calibrate
Inspect
.u
h
Replace
a
a
V
Overhaul
Rebuild
e
H
S
3
%
Component Assembly Nomenclature
02
0200
0202
0206
03
0301
0302
0304
0306
0308
0309
0312
04
0401
05
0501
0502
CLUTCH
Clutch Assembly:
F
H
D
. F
F
F
F
H
H
F
D
Clutch Release Mechanism:
o
T^*i/lnl linlfA&p
__.
.
Clutch Brake:
FUEL SYSTEM
Fuel Injector:
Tyiia/itm* -fiipl
. F
..
F
-
_
Fuel Pumps :
o/c
c
AIR CLEANER:
o/c
Tanks, Lines, Fittings:
-o
_
Tank
. o/c
_ O/C
Engine Speed Governor
& Controls:
._ F
Fuel Filters:
TPilfpr flip]
. o/c
._
Accelerator, Throttle:
o
EXHAUST SYSTEM
Muffler and Pipes:
Muffler, pipes,
T
COOLING SYSTEM:
Radiator :
n*m
o/c
Core tanks
.. F
.
fi-rillp
Radiator
. o/
0/(
J __
Shroud :
..
4 T "
lip
IBf
C-4
Section II. Maintenance Allocation Chart Continued
Functional
group
number
FOR:
I
Maintenance
operations
____^ Maintenance
""" levels
_
Note
ref
A
B
C
)
E
F
G
H
i
J
K
L
1
Service
1
3
0)
.5
Calibrate
Inspect
|
Replace
kl
I
Overhaul
Rebuild
\
W
EH
Remarks
Component Assembly Nomenclature 1
0503
050'4
0505
06
0601
0602
0603
0607
0608
0609
0611
0612
0613
Thermostats & Housing
Gaskets :
Hoses, pipes, clamps,
lines, Fittings
o
o
.
.
.
.
o
F
F
F
F
Housing L
Thermostat L
Water pump:
Pump, water - L
Fan Assembly:
Belt V L
O/C
Fan guard L
Tightener belt L
O/C
ELECTRICAL SYSTEM
Generator :
Belt V -L
o/c
Brushes 1-
Generator +
o/c
o
Generator Regulator:
Regulator generator - 1
Starting Motor:
o/c
Instrument or Engine
Control Panel:
Gages, switches, lamp,
Miscellaneous Items:
Lights :
o/c
o
Horn :
Wiring
Batteries :
o/c
Box, battery
o
Cables
Chassis Wiring Harness:
T
Harness wiring -j-
I
i
C-5
Section II. Maintenance Allocation Chart Continued
Functional
group
number
FOR:
Essentiality
" ^____^ Maintenance
" , levels
Maintenance ~~~ ___^
operations ~~~~ ~___^__^
Note
ref
A
B
c
D
E
F
G
H
I
J
K
XL.
Service
m
l-
n
<
01
<!
Calibrate
Inspect
m
(a
H
ia
u
"ft
<u
k,
'3
j
Overhaul
Rebuild
I
a
u
W
EH
s
1
M
Component Assembly Nomenclature
0615
07
0700
0701
0702
0704
0710
0721
LO
1000
1004
1
1100
Radio Interference
Suppression :
Components _ _
- H
o
E3
1^
TRANSMISSION:
Transmission Assembly:
Case, transmission
Cover _ _ _ .
Transmission _ _
0/C
. o/c
- H
H
. H
H
H
F
F
O
F
H
Transmission Shafts:
Shafts, gears, bearings,
seals
Opposed Output:
Shafts, gears, bearings,
retainers
Transmission Top Cover
Assembly:
Levers, linkage _
Shifter, forks, shafts,
seals
Transmission Assembly:
(hydraulic)
Bearings, covers, gaskets,
gears planetary units,
plugs & shafts _
Lubricating Components :
Filter, oil, breather __
o/c
Pitting, tube _ _ _
Line, fittings
Pump, oil __ _
F
F
F
FRONT AXLE
Front Axle Assembly:
Axle assembly front _
0/C
o/c
Steering & Wheel Leaning
Mechanism :
Gear box assembly
.
o/c
Knuckles, arms, shafts,
bearings seals, flanges,
pins gear case, gears _
Shafts, bushings
0/C
Shafts, control joints,
universal
REAR AXLE
Rear Axle Assembly:
Chain _ _ _ j
Shafts, sprockets, bearings,
Seals, retainers, spacers,
gears _ __ _
~~^
C-*
Section II. Maintenance Allocation Chart Continued
Functional
group
number
FOR :
1
" Maintenance
~" ___^ levels
Maintenance ~ ' .
operations " - .
Note
ref
A
B
c
D
E F
G
H
i
J
K
L
1 &
1 -S
1
Service
*
.
T?
<
V
_c
<
Calibrate
1 8
5 hi
Replace
L.
'3
s
Overhaul
Rebuild
1
W
H
<8
H
Remarks
Component Assembly Nomenclature
1105
12
1201
1202
1204
1206
13
1311
1313
14
1401
1410
1411
1412
1413
1414
15
1501
Tandem Drive Assembly:
Case J
._ H
._
.. F
._ F
._
__ F
.-
..
F
F
F
F
F
F
F
F
F
H
Covers, breather _ _J_
---
_ O/C _
Drive, tandem J
0/0
BRAKES
Hand Brakes:
Band, brake J
Drum _ - J
Levers linkage J
o/c
Service Brakes:
Brakes service J
Hydraulic Brakes System:
Cylinder master -1
o/c
O/C
Cylinder wheel 1
Lines hose fittings J
1
._
.-
_.
_.
-.0
_.
...
... o
__.
....
__.
Mechanical Brake Controls:
Pedal, brackets, linkage,
WHEELS
Wheel Assembly:
o/c
AJVlt*Al vim <*f*ft1fi flt.uds L
Tires :
TIT-PS L
o/c
o/c
o/c
STEERING
Steering Assembly:
Steering gear assembly __.L_
"Whepl L
.
Hydraulic Pump:
. __
Hose, Lines, Fittings:
Hydraulic Cylinders:
_ . F
Tanks :
__.o/c
L/ap t-
o/c
-
Steering System Valves:
... o
FRAME, TOWING
ATTACHMENTS
Frame Assembly:
Frame assembly -I
i
C-7
Section II. Maintenance Allocation Chart Continued
Functional
srroup
number
FOR:
Maintenance
- ^_ levels
Maintenance " ~~ ________^^
operations ~ ______
Note
ref
A
B
C
D
E
F
G
H
i
J
K
L
Essentiality
Service
1
3
<
.5
<
Calibrate
4->
!
s
M
*>
1
Replace
*
'3
o,
A
Overhaul
Rebuild
z
H
H
g
Remarks
Component Assembly Nomenclature
1503
18
1801
1805
1806
1808
20
2002
22
2210
43
4301
4305
4307
47
Pintles & Towing
Attachments :
O/C
o
F
F
C!VioMrftfk
. o
. o
_ o
.
L
. o/c
F
CAB, HOOD
Cab, Hood:
Hood
Floors :
Seats:
Seat
Boxes :
POWER CONTROL UNIT
Power Control Unit
Assembly:
Control assembly
o/c
o/c
Slin'ff irrn'DAllp'r
o/c
ACCESSORY ITEMS
Data Plates:
F
Plates, instruction &
HYDRAULIC SYSTEM
Filters^ Hoses, Fittings,
Tubing:
Filter, hydraulic oil
Hoses tubes fittings
. o/c
o/c
Control Valves:
Hydraulic Cylinders;
1
GAGES AND MEASURING
DEVICES
c-e
Section II. Maintenance Allocation Chart Continued
Functional
srroup
number
FOR:
' ^_^_^ Maintenance
' _^____^ . levels
Maintenance " ' ^_^___^
operations ' ________^
Note
ref
A
B
c
D
E
F
G
H
I
J
K
L
>>
5
5
Service
I
5
41
% G
<
Calibrate
Inspect
I
Replace
i*
1
Overhaul
Rebuild
4-
1
W
H
8
H
Remarks
Component Assembly Nomenclature
4702
4703
74
7435
7436
7438
7439
7440
7441
76
7603
Gages, mountings, lines, &
fittings :
Gages __ _.
Gage, fuel
Hourmeter:
Hourmeter _ _ .
EARTH MOVING EQUIP-
MENT COMPONENTS
Moldboard Assembly:
Blade assembly
edges, bits
0/C
F
F
0/C
F
Lift Arms and Pivot
Assemblies :
Bar, links, arms
0/C
0/C
Circle and Drawbar
Assembly:
Circle, drawbar
Shims
Circle Reverse Drawbar Side
Shift & Lift Mechanism:
Cases, gears, shafts, seals,
bearings
Gear box assembly
0/C
0/C
Joints, universal
Pins
Scarifier Assembly:
Drawbar, rods, bushings,
angle adjustments, shanks -
Teeth
Scarifier Actuating:
Gear box assembly
0/C
0/C
Joints universal
Shafts arms bushings
Shafts, gear cases, gears,
bearings seals
FIRE FIGHTING
EQUIPMENT
Fire Extinguishers:
Extinguisher fire
o/c
0/C
Section gii. SP1CIAL TOOL AND SPECIAL TEST EQUIPMENT
Reference
code
Maintenance
level
Nomenclature
Tool
number
4
o/c
Eemover, scarifier
point
429581(35311)
Section IV. REMARKS
Reference
code
A-F
B-H
C-G
D-F
E-G
F-G
Remarks
Test includes engine operation and
compression
Repair includes metalizing, grinding
and alining
Camshaft removal necessary
Test for proper fuel pressure
Internal
External
C-10
INDEX
Paragraph Page
Adjustments :
Fan belt 3-10 3-16
Clutch pedal 3-39 S-25
Clutch anti-coast brakes 3-76 3-60
Governor and throttle linkage 3-43 3-28
Power shift moldboard 3-86 3-63
Wheel 3-63 3-50
Worm gear end thrust bearing 3-85 3-63
Air cleaner service 34 3-1
Air intake system not operating
properly 3-19 3_2
Anti-coast brakes do not function
properly 3-32 3-24
Basic issue tools and equipment 3-2 3-1
Batteries, removal 3-58 3-41
Brake system 3-66 3-54
Cab components 3-71 3-58
Cold weather starting aid :
Operation 3-22 3-23
Service 3-42 3-27
Controls and instruments 2-10 2-3
Control box service 3-73 3-59
Control box levers, removal 3-74 3-60
Cooling system:
Fan 3-47 3-32
Radiator 3-48 3-32
Thermostat 3-49 3-32
Water pump 3-50 3-37
Circle reverse assembly service 3-80 3-61
Clutch anti-coast brakes:
Adjustment 3-76 3-60
Troubleshooting 3-32 3-24
Clutch pedal adjustment 3-39 3-25
Clutch brake does not function
properly 3-29 3-24
Daily preventive maintenance
services 3-6 3-16
Data:
Identification and tabulated 1-4 1-3
Definitions ___ 3-34 3-24
Description 1-3 1-3
Dismantling for movement 2-7 2-3
Drawbar inspection 3-81 3-61
Electrical system:
Batteries 3-58 3-41
Generator 3-51 3-38
Interference suppression 3-36 3-24
Instrument panel gages and light .._ 3-54 3-39
Starter 3-53 3-39
Troubleshooting 3-17 3-22
Vehicle lights 3-56 3-40
Paragraph
Voltage regulator 3-52
Engine hood, removal 3-70
Equipment:
Basic issue tools and 3-2
Conversion 2-6
Inspecting and servicing 2-3
Special tools and 3-1
Unloading 2-1
Unpacking 2-2
Exhaust system:
Inspection 3-44
Muffler and exhaust flange 3-45
Fan belt adjustment 3-10
Fan, removal 3-47
Front axle, inspection 3-61
Front leaning wheel assembly 3-64
Fuel system:
Fuel filter and strainer service 3-9
Fuel tank service 341
Fuel pump service 3-40
Governor and throttle linkage 3-43
General lubrication information 3-3
General methods used to attain
proper suppression 3-35
Generator, service 3-51
Governor and throttle linkage,
adjustment and service 3-43
Horn, removal 3-57
Hydraulic reservoir:
Service 3-4
Inspection 3-68
Identification and tabulated data 14
Inspection 3-44
Inspection and servicing equipment 2-3
Installation of separately packed
components 2-4
Installation and setting up
instructions : 2-5
Interference suppression:
General methods used to attain
proper suppression 3-35
Interference suppression
components 3-36
Replacement of interference
components 3-37
Instrument panel gages and lights 3-54
Lateral shift and lift gear
assemblies 3-79
l^r
Paragraph
Lubrication :
Detailed information 3-4
General information 3-3
Moldboard blade, removal 3-77
Muffler and exhaust flange 3-45
Operation :
At high altitudes 2-20
In dusty or sandy areas . 2-17
In extreme cold 2-15
In extreme heat 2-16
In salt water areas 2-19
Under rainy or humid conditions 2-18
Under usual conditions 2-14
Preventive maintenance services :
Daily 3-6
Quarterly 3-7
Propeller shaft 3-75
Power shift moldboard:
Adjustment 3-86
Removal 3-78
Quarterly preventive maintenance
services
3-7
Radiator, removal 3-48
Record and report forms 1-2
Reinstallation after movement 2-8
Replacement of interference
components 3-37
Scarifier control shaft, removal 3-84
Scarifier gear assembly, service 3-82
Scarifier lift arms, removal 3-83
Scope 1-1
Special tools and equipment 3-1
Steering 3-62
Steering hydraulic pump 3-69
Starter, removal 3-53
Starting 2-12
Stopping 2-13
Page
3-1
3-1
3-61
3-32
2-19
2-19
2-18
2-18
2-19
2-19
2-5
3-16
3-16
3-60
3-63
3-61
3-16
3-32
1-2
2-3
3-24
3-63
3-62
3-62
1-1
3-1
3-46
3-58
3-39
2-3
2-3
Paragraph Page
Tandem drives, service 3-65 3-53
Thermostat housing and thermostat 3-49 3-32
Tool box 3-72 3-58
Transmission :
Levers 3-60 3-46
Service 3-59 3-46
Troubleshooting :
Air intake system 3-19 3-22
Anti-coast brakes 3-32 3-24
Cooling system 3-21 3-23
Clutch brake 3-29 3-24
Electrical system 3-17 3-22
Engine overheating 3-13 3-21
Excessive oil consumption 3-16 3-22
Exhaust system 3-20 3-23
Fuel system 3-18 3-22
Grader will not move 3-22 3-23
Low oil pressure 3-15 3-22
Low power 3-14 3-22
Moldboard angle 3-25 3-23
Moldboard lift 3-24 3-23
Moldboard shift 3-27 3-23
Moldboard power shift 3-26 3-23
Parking brake 3-31 3_24
Scarifier system 3-28 3-24
Starting system 3-12 3-16
Steering system 3-23 3-23
Tandem drives 3-33 3-24
Wheel brakes 3_3Q 3-24
Unloading equipment 2-1 2-1
Unpacking equipment 2-2 2-2
Vehicle lights, removal 3-56 3-40
Voltage regulator, removal 3-52 3-39
Water pump, removal 3-50 3-37
Wheel adjustment 3-63 3-50
Wheels and tires, service 3-67 3-56
Worm gear end thrust bearing
adjustment 3-85 3-63
1-2
By Order of the Secretary of the Army
Official :
KENNETH G. WICKHAM,
Major General, United States Army,
The Adjutant General.
HAROLD K. JOHNSO
General, United States .
Chief of Staff.
Distribution :
Active Army:
USASA (2)
ACSI (1)
DCSLOG (1)
CNGB (1)
TSG (1)
CofEngrs (3)
OCC-E (1)
Dir/Trans (1)
CofSptS (1)
USAMB (1)
USA Arty Bd (2)
USA Armor Bd (2)
USAIB (2)
USARADBD (2)
USAAESWBD (2)
USAAVNTBD (2)
USCONARC (3)
OS Maj Comd (5) except
USASETAF (2)
USARJ (1)
USAMC (1)
MDW (1)
Armies (2)
Corps (2)
Div (2)
Engr Bde (1)
Svc Colleges (2)
JBr Svc Sch (2)
USACDCEC (10)
USMA (2) I
GENDEP (10 1 )
Engr Dep (10)
Army Dep (2) except
TOAD (3)
USA Tml Comd (2)
Army Tml (1)
Div Engr (2)
Engr Dist (2)
USAERDL (3)
USAMEC (46)
Engr Cen (5)
USAREUR Engr Proc Cen (2)
USAREUR Engr Sup Con Agcy (1
Engr FLDMS (2)
Fort Knox FLDMS (10)
Fid Comd, DASA (8)
AMS (3)
USAREURCOMZ (2)
USAC (1)
MAAG (1)
JBUSMC (1)
Units org under f ol TOE :
(2 copies UNOINDC)
5-15
5-16
5-35
5-36
5-38
5-45
5-46
5-48
5-54
5-107
5-115
5-117
5-118
5-127
5-145
5-146
5-155
5-156
5-237 (5)
5-262 (5)
5-267 (1)
5-278 (5)
5-279
5-405
5-408
5-420
5-425
5-427
5-500 (EA,
5-600
5-625
5-627
7-100
17-100
29-16
29-17
29-26
29-27
29-36
29-79
37-100
39-51
39-61
77-100
NG: State AG (3)
USAR: Same as active Army except allowance is one (1) copy for each unit.
For explanation of abbreviations used, see AR 320-50.
ft U.S. GOVERNMENT PRINTING OFFICE: 1988201-421/80162 Region No. 2
Live Music Archive
Librivox Free Audio
Metropolitan Museum
Cleveland Museum of Art
Internet Arcade
Console Living Room
Books to Borrow
Open Library
TV News
Understanding 9/11