1944 Willys Instruction Driving & Maintenance Manual - PDF DOWNLOAD

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RESTRICTED The Infor",.lIon given In thl. document I. not to be communicated either d l r~tlv or indlr~tly to the prUI or to any per. on not authon,ed to rec eive it

CONTBNTS

• 800'1 'ND PORPOn.............. . . . . . . . . . . . . . .. Pas. 1.

GENERAr. DESCRIPTIO! ••• •••.••••..•••.......

•

8.

OBKBRAL SPECIFIOATION •••••.•••••••••••••• ,

•

7

3.

DRIVBR '8 ROUTIllI I14IN'l'IlfANOB.

•

10

I

•••••• ••••••

10

•••klJ Malntenanoe .•........•••......• ,

• • • •

Ba.l0 Group Maint.nanoe ••..•••.••••••••

•

H

Tra1ler »alntenanoe ••.....•...... ··· ...

•

Deily betore Duty •••••.••••.•.•••.•• · ••

AUSTRALIAN MILITARY FORCES

In.peot Maint.nanoe ••••.•••.••..•.•••••

INSTRUCTION BOOK

Daily atter nut,.._ •....

DRIVING & MAINTENANCE for

eooo

(Inc. Trailers, 2

By AU1horlt y '-'r rk:I.,.LJfO C1rt1f¥'''.''c., A_If f!4h,err,. /#It. NU

10 11 13

"

25

OBNJIIRAL Ol'ERATIIIO IllS'l'IlUOTIOIIS •••••• ,.,.,.

"

26

TranBtor Oaao Operation •..•.••........•

26

I ••••••••••••

" " • •

A. Lubrioation SChednle ................ .

•

B. F.ult F1nding

•••.•••.•••..•••

•

C. Driver YOGhanio OperatiQna •••.....•.

•

D. 'I'spee ot Trailers in uae with Truok t ton .........•..........

"

Towing. , ..

t •••••

1 ••• t • ••

&

•••••••

•••••••••

~ •••••••••••••••••••••

Dr1v1Dg tbrm'sb w.t.r •...•..•...•.....•

Make: Willys·Overland Model MB'(4x4) Ford Model QPW (4 x 4)

Prepa .... d b y Staff of the Ma.ter·General of the Or dnance end I.wed under the direction of the Command r·in,Ohlef, Headquarters Australian Militar y Fo rce.

IO • • • • • • • • • • • • • • • •

Kile Maintenanoe

lor belt-roul,.)

1944

"

Tra.11er Opez:-atlon ••••.•...

II.

Ohart~

26

27 27

SCOPI

AIID

PURPOSB

• '!'be aco.,. 'n d purpo •• or tb1A

lnltruotion Book

11 to

ptoYido tbe

bael0 1n!cc •• tloa 11" ••• &1'1 Cor tbe oorrect and. econ- 'oal. operation ot the •• b1ole conoerned. The tnatruotlortl oo.n~.1n.d 1n tbe .toll ow ina paS" will bl carried out b,. tho drivor 10 oharl' of the •• hlel. in &eoordanoe w1th the _intenanoe routin•• Ind 1n-

terval.1

.t.t~.

Drl.ere will not atte=pt to carry out repair. or .·ke adJulbDlnta beyond their permitted IOOpe, and

.her.

any &4Juabtenta are to be oar ..

r10d out by the driver und.er luporvI.ion, be w111 report to tho appropriate trade.man (d.rlve'l"-meolW\10 or

unit t1tter) and have tl~ benefit ot nil advioo and ••• 1etanOI.

Some adJu.tmonte are to be oarried out by drlyor meohan10' only.

Tho.. aro liltod in tho end ot tile

book: and none ot the •• w111 be att ...ptod b,. the driver.

bo

A11 4rl ••r'a maintenlno. w111 recQ,ded 10 the Vohicle Log Book

AMI 208 ",copt tba drilll nrirrd U not rloordK •

•

•

opeciall,.

GBIIERAL DESCRIPl'ION

• 'l'b.e "hiole de8()rlbed 1n this Instruo t10D BOOk 18 known al tho Truok t ton (U.S.A.). Both tho W1ll,.....

Overland Wodol WB (4 .. 4) and Ford Modol GPW (4 x 4)

are ideDtioal.

purpose

ve~ole

It baa been introduced 88 a general and tIll • • variety at 1"0108.

Per normal roa4 operation, tbo vehicle utilizes t~ two rear driving wheela, tour wbeeled drIve and low .peed range through a transfer case ( ..wtl11a.ry gear box) are prov1ded tor oroa8 countrY' operation or

otoop grad1ents.

-• ~

•

ttl

The power unIt Is the conventional 4 oyl1nder 11de-valvo petrol eagine and with the olutoh, glar

•

t>

~

box, and tranater oase, 1. built into a unit power

plant ~h1ob 1a mounted at tour pointe in the chase18.

Tbo gear box 18 8 8rnchromeah ~ speed tJpe, with

synchronized 8000nd and top speed gears, mounted to whioh 18 the dual range tranater oa80 (auxiliary gear

bOX) which 1ncorporate. the rront axle drive engaging and dieengaging ~ohanla~.

and toot operated brakes are fItted, the tormer beIng meohanioal and aotuating "an external contrao t inS brake band at the rear ot the transter caee, and the latter being hydraulic and operating on all tour wheels.

Bo~h

hand

The body is or tho open type with An open

dri.er ' a compartment. The rolding top oan be removed and atowed, and the wIndshield 'Ilted forward on top or the beod or opened upward and out.Grei. A sparo wheel is mounted on the rear ot the body, and a pintle book 1e provided to hau1 traIled 10ad8 •

•

a >

GENERAL SPECIFICATION

• Engino.

Make •...•••.•••• '. ' • • •••••.. , , ••••••• Ford or Willy a.

Intlation proa.ur •••••••••••••••••••••• 30 lb ••

Type •• • .••••• . •• • •• •• •••••••••••••.• S . l . Si d e Va lv e .

Hor s e power (RAe Ra t ing ) •••••••••••.• 1 5 . 6

Fuol & LubrlcAtlng 011 Capoo1tle. ( l!p' Measure).

Br ake Horse power (at 3600 r. p . m.),o.60

.l'

oy l i nder s •••..•..•.••••. • • 4 F iring Or der • • • •••• • • to • • • • • • • • • • • • • 1- 3-4- 2 ~llmh8 r of

Engine ••••••••••••••••••••••••••••••••• qtl&rt a • Gear Box ••.••••.••••••••••••••••••••••• l pint.

Tr ansfer Ca se •.....•..••••.•• t • • t • • • • • • 2, pinta.

Clutoh.

Ditferenthl ((ront

S1ns l e plate i dry-dbo t ype •••• • •••• 8 rt

t"

&

roar) •••••••••••• 2 pint. '.aob)

Air Cle an e r ••.•••••••••••••••.••••••••• , p1nt

1'r ee ped a l

travel .

F\le 1 TR.I lk •••••••..••.••••.••••••••••••• 121 gall.

Cool ing Sys t em.

Dimenslon ••

Capao ity •• • ••••••.•••.••• • • • •••• t •• • 9-1/4 quar te .

Pump and f an drive • ••• • •• • •••••••• •• One V- be l t (adJustttbl a on geDer ator) • Radlator •••••••••• • ••.• . • • •• • •••••• • Fl n and tabe .

0 The r mos t a t oontr ol •••••••.••••••• • • • Opens 145 - 155 F Fully open l70 o F. Elec t rioa l Equ i pment .

Wheelbaso ............................... 80 1ctl.

Length (ov6rB11) ••••••••.•••••••••••••• 132t ina.

Wldtb ( overa l l ) .•......•••••.•••....••• 62 In •• Haight (overall- t op up) ••••..•••••••••• 691 In •• He l ght (overall-top down) .............. 52 in •• Track ( with

" C o ~b .t ·

tyroe) •••..••••••• 4g in••

Wel g,bt s .

Bat t ery •••.••••••.•••.•••••••••..•• • One 15 plate , 6 vol.t.

Starting System •••••• • •••••• • •••••• • 6 v ol t

Or o, s we i g h t •••••••.•••...••••..••••••• 3125 I bs.

Mo xi mum pa, l oad ••••••••••••••••..••••• 800 Ibe.

Genera t ing System .. .. ............. . . . 6 volt

Maxlmum tr a lled l oad (lnol. traller) ••• 1330 lb ••

Li ghting System •.•... . •. ••• •• • ••••• • 6 vo l t

Performanoe.

Gear Box.

Type ••••••.•••.••••••••••.••••..•••• Se l flo tlve . sync hrome sh 2nd and top

gear .

Speeds ••• • •• • ••• •• .•• •• • •••• • . • • • • • • 3 .forward - 1 reveree , Trans f er 0 & 19 8 (auxiliary gear box) •• High and l ow r ange.

Front axle dr1ve en ga ge lev e r .

Tyr e e .

S i ze •••••••••• 11

•

•

•••• •• •

•

••• •

•••••••

6 . 00 x 16

Jt' Q

ply ,

non- dlroet1ona1,

Speed at maximum r.p.m •••••••••.••••••• 65 m.p.h.

MAx'nn,m grado tllcenc11ns ability •••••••• 30 0 Minlmum turn1ns rad lu. (loft) •••••••••• 17'6" Minlmum turn1 ns rad l u a (rlght) .••.••.•• 17' 6 · Maxlmum t or d1ns doptb (ran operat l ns) •• 21· Maxlmu~

t or d l ns d e pt h (fan

d lao o nn.ot~

Road c l e aranc e •••..••••••••••••••.. , •.• 8i"

•

b ar t read .

( Comb at tyre s may bu 1cl~ ntlr 1 ed 8S

splIt r1m typo) .

7

27"

B

OnrVEll 's ROUTINE MAINTENANCE

• DAILY BEFORE DUTY (Not ·rooordod in Log Book) Cheok:.

Level of tuel In tank; no leaks; tIller oap aeoure.

Level or 011 In sump; DO leaks; tIller cap •• cure.

Level ot water In radiatorj no leaks; tiller cap and rubber ••• t a.oure. rue! tank sump drain COTers correctl, titted.

Start engine; run at fsst idling speed: Checkl

u1I pressure gauge registers; pre.aure

nor~.l.

Ammeter workingJ reading normal.

Fuel gellga registers correctly.

Horn &nd wind.oreeD wiper tor operation.

All light. (Inol. blaok out lights) tor corroot

OOli'l'ROLS

IlISTR1JIIEliTS

olJoration.

Tyros! Inolud1ng .pare, for correct prossure (uno gBUgO J valve duet oape titted.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Windsoreen wipere Horn button Steering wbeel Hand tm'ottle Ignition Switoh Choke oontrol Rear vision mirror Blaokout driving light switoh Blaokout light ewitoh Headlight root switch (beam oontrol) Sarety strap Clutch pedal InstrllIMut panel light switoh Brake pedal Fuel gauge Oil pressure gauge

23.

24.

25.

26.

27.

28.

29.

30.

31.

Aooelerator pedal Sp&edometer Aooelerator root rest Temperature gauge Starting switoh Transrer caae shirt lever Front axle engage lever Gear shift lever Gear shift diagram Vehicle name plate Warning plate Hand brake lever Windsoreen olamps Ammeter Wind.creen adjusting arms.

9

Urake

opor~tlng

n01 '117; pedal firm and no oxoe.-

elve treyol.

All tools and equipment securely stowed. lJrher carrles 02, OIl, 013, 014, 017, &nd S . O.O. '.; Log Book carried 1n vehicle.

• NOTEI 0 11 pre,eure and temperature gauge must be c onatantl1 checked during running.

IS:.i p r;t: 'f .llAINT t: HANCE.

( Rot recorded Lp Log Book)

Cheok: I

Fuel level In tAnk. 011 layel in Bump.

AIr e leanur, oheok 011 leyol, drain and rofill uoool\l!Iliry.

10

K8

Water level ln radlator (partloular att entlon to tillor oap.)

Radiator, holea, water

Radlator and bo ••• tor leak ••

Tyroe tor damagl

!'yrea tor d'='se or """.1' intlation, 'ntlate a. neo •• sar1J cheok oar.rully tor naUa 1D treada.

tD t,.re., and intiat. a. neo •• ear,..

1Ibeel .tud. and ria bolt nut. - do not over-tigbten .

BJdraull0 brake lIn •• tor 4a"S8 or chating .

Bow a •• embly and oover tor •• ourlty inolud1ng wing nut. and tront braoke t ••

Wl ne!.ore.n tor • • ourity, tighten lal.urled and wing nut •• 71ghten Spring

&Dr

100 •• nut. and bolta.

le •• e., ollp. and "U" bolt. tor damage.

7001e and equi_nt oarried externally one! load tor

leak ••

MIke Any minor adjultmsnt. . b.70od Or! vert. .oope .

Report any deteate

oute and correct pr •• .ure (no

nal1., in t r.ad.!, valve oap. tlt ted, r.port d.-og"

Tlghten up any loo.e nut. and bolt •• M,ke an,. m'nor adjustment •• St •• r'Dg Group •

Obaokl Steering box and linkage for .eourlty, plR7 nor.al.

Sbaokle Group Cheokl Shaokle and _pring anohorag•• IIndam'g04.

Cheokl

·U·

Sprlng leave . and oontr. bolt. unbroken bolta tor .ign. ot movement and unbroken. Cllp••• oure.

Brak. Group

Olaan Vehiola I

Cbaok .

Obaokl

Hydraull0 brake pipes and tlexlble bo.e. tor leak.

Ley.l at ruel in tank, replenieh it necoeeary _

and 4ap" 80'

Puel

Pedal firm, no

tenk end

pipe I ror leakl; fue l tank lump

oorreotl y fltted, drain au.p atter tord1ng operatione .

BOOT Group

Sump , 011 plpe. , val ve oover and tllter t or leo.ke .

Cbeokl

.kid plate sooure and not damaged (no oracks

weld.)

e~oeallve

t ravel.

Ha.e brake. &4Juated br a trade.-,n i t not tullr etteoUve.

L... el of 011 ln ''''llP1 replenlob 1.t n.oe .. arn drain and retill 1t due ror ol~ ohenge .

1D

and englne blook tor

SF ing Group

•• ourlty.

S~

p~

Jlo t1ttinga or pe rt. mlaa.1ng, hood aeoure

.00

undac

aged.

Ckar box, tran.ter 0 ... 0 and 41fterent!..l. t or 011

leak • •

Exhaust pipe and. w ,rrior aeoure and

un~ a.magod.

Level or •• ter in radiator, re plenish it neoe.eary.

(Report any aigna ot 011 ln water) .

11

Tool. and equipment oorr.otlr .towed.

Wheel Alignment and Tyr. Group Oheok.

No obv1ous miaal1gn$ent, rima not damagedJ rim and wbeel nut. tight; s tud threads not ru.t, or damlSed.

RaPOR'l'

.urr

DKl'BO'l'S Oft

BBrOJl])

'8

800PB ON 0.17.

Obe. k bra.at and tipt ... i t n ........, .

* in.pe.tion.

S.t out toolo 0lid .qui_nt tor ....1<1, Rlport dlLloto or "t>ortas"".

ROD!

&rIJ

(Oarried OIlt _tbor tb• .,.b1.l. 10 in Il.e or not)

Azq

other perlod1.al . . intln'nol tallina dillon . _ do,. w111 be .arrled out ln add1tion t. the abo.,..

(a) 8attl17' ft ....... tlatte.., !rom oarrled and .l.an e"t.rnall,..

Check b.tt~ t.r~n'l. ror oorroatoD, i t oorroded, olean tborough'y_ Obo.k batte.., .barge .. ltb IIJdrometer, report i t r . .ding bolo.. 1.200. (Do not te.t dir •• tl,. after

All OrollP ..... t be

w.tor On17_

Obo.k tl11er .ap.

bloakaso.

tor s •• urltJ and air vent. tor

Obo.k batt • .., top tor oraok •• l.ok.. and t.rminal po.t. tor ".urlt1.

IfOTB!

d01.

menta

Batt • .., 011 botb "1' .l.an.r aa.' ~lJ .

0 .... bo" •••• 1' pllto in 41'1. .1'• .ollpart... nt .

0 .... box .kid plat •• .bo •• • 111 be ... pa.04 .hen the approprlat.

OrOllp 10 .Olllll.ted. llben r.fitting tbo .kid plat., .... e must b e tak.n to .n.ur. tbot thl bolt bead. are te. tb. ollhld• • 'l'be

Wipe all grea•• nippl.. ollan betor. and aftl!' lubrioation .

• Steering

Rlplao. battlr1 In oarrler, mlk•• e.ur. but do not o•• rtlght.n, I.' tbat botb ••• uring .trap. or. prOperl, po.ltlon.d.

Jaok up tront ,xle.

• Lub r1cate:

• 1

•

eat.guard againat oorro.ion.

Ob8ok earth ,trap to tra.me •• oure

and

'.'7

onto block. to pro'flde aoo ••• to oo.pona-nta. onc! tbe t.ll.wing obollld b. "'110'004 b.tor • • o_no ..

Ollan 0"'1'1.1' ot .0.... 0.10n and ruat wbere .plllage ha. o.ourr04, b1 Dllltrall.atlon. It n.o ••• ..., tou.b up .1tb paint.

Tighten teralnal 011pa and a.e ... w1th m1neral jell,

... b 500 all...

* plat04Wher.

Bao1o OrollP IIdnten.MI 1.• to b • • __ in an, ooe the .. biol• •bould b ...a1o ld

adding dl.tl1l.d wat.r. It too 10.. to te.t. top IlP ond t •• t att.r a run bo. mIxed ele.trol,t. ....nl,.)

Obe.k 1.... 1 ot .l •• tro l ,.tl in e. ob 0.11. ~t low brlng 1••• 1 to i" abo ... plate. b1 adding dl.tl11ed

oo~l.ted

Report &nJ mie.lng or damaS.4 nlppl •• • ~aup

Clean

e~terlor

Dr.g 11nk ••• •••• •••• ••

or

oo~neDt

••

2 n1ppl.,.

Bell orank •••••••••••.•••.••••••••••••• l ni pple .

Traok rods •••.••.••••.•.••••••••••••••• " nipple •.

I t I"'"

1.11 •••••

und 'mpge4.

Cheok!

(b) Tool!

Oheok all i t . . . tor oo~l.t.n.e. and •• rv1oeablllt1' trl.do. trom ru.t or deterioratlon.

(.)

i,re.

• port an1 lign. ot

S\lering look .top • • I.ur., .Ild inta.t.

Stelrlng wbool tor 1".leet ... b.a oltlub, boldina bolt •• cur • • Sh.rlng •• lllm b.... a t ... url to dub board, .lamp bolt ........ .

S.I tbat tir. l"tlngu1abor 11 full and r.ad1 tor '-mediate u.a. Plaoe tbum o ...r ttl outlet. turJ:l beMle to th. lett -"" operate the plllDser JU." .n.ugh to teel tbat pr. . .url 1. being appli04.

Lo.1< handl. b1 turning to t!i. right •

Steering box •• our. to tr-•• ) no .ov... nt. plat. bolt. tight, box not l.aking.

Drop ....... uring bolt tlg»l;, w.ah.r iotaot.

Coyer

Linkage and traok rod ends tor seourlty and movement; all spllt-p1ns lntaot.

no~l

Pedal not toullng d..,trloal o.ble ,'''''".. toe board.

Pedal .top p.d ao.... eot17 poaltloned.

Lever anchor bolts secure.

pullout oabl. and Joke !etr elgn. ot damage, oabJ..

Steering knuokle flange nuts eeoure.

not rusted - ... ar wltb 011.

Nuts seour1ng lower epindle pin oap tight.

Brake Group

Front wheel bearinga and p1vot pine tor exoe.,ive play.

Lub rloat., Brake peeta] .het.t •••••••••••••.•.•.••• 1 Nipple.

Pu.h rod plYot •••••••••••••••••••••••• 011 Oan. Band brake aotuating joint. (. pointe) 011 Can. Band brake Gontrol l ever .11de, l~r oable ••••••••••••••••••••••••••••••••• 011 Oan • •

Shaokle Group Clean extertor of componente.

Lubrioatel Front aprins .haokle ••••••••••••••••• 6 n1pplee.

Rear ,pr1ng shaakles ••••••••.••••••.• 6 nlppl ••• Torque reaotion .pring bolt •••••.•••• I n1ppl •• ( on left tront spr1ng).

Eno ure gre.o. goo, throuahJ report any .eized, loooe or worn .hackle ••••

Claan extarlor at oomponent ••

Cbaok.

Br.ke pedal .eourlng nut., ol.vi. p1n. and return .prinS. Ma,ter o711nder •• our. to obaa.ie.

Cheal"

Brake lInea and flexible hoe •• tor leak' or

Shaokles and apring anchoragee tor aeo urity, .elding not orooked.

Spring Group

~am·8.

line mountings and olampa .eoure.

Ke.ter 07l!nder .. e.er.oir tor tluid 1 ...11 repl.nlob i t neoe .. u7 to witb!n t " ot top witb B.B.l".

Cleon exterior ot components.

Ped , l rroe travel b7 bend ,-

Cbeck.

Pedal .top pad. oorr.ot17 poaltloned.

Spring lea ves and centre b olt. not d 1s placed or broken. Exa m1 ne end ot ~in and torque reaction lea vee for crucke.

I.;ook wire on heM brake mounting to transter oue.

"U" bolts tor s1gns ot movement; spr1ng cli ps f o r

Lool! wire on bend brake lDOuntlng to plvot adJuat-

ment.

aecur1ty and oorr&ct positioning; nuts and lock nute tlght.

Cla.l. plna in bInd brake llnk.SI, nut. and 'pllt pine aeoure.

Arrestor pad a sooure to tramo.

Clutoh Group

Clean exterior ot component.

Lubrioatel

"haft..................

Clutch pedal 1 nipple.

Linkage Jointe •••.••••••••••••••..•• 0 11 c on.

*

NOTll On completion or maintenanoe or 1mm1 11 atel.7 att ... any adJu.t •• nt or brakl., oarry out .. oad t •• t tor brake equallt7 and .topplng power. Teat b.nd brake tar holding power on .teep inoline. a.va brake. adju.tod by work.bop. i t not tully err.otlve.

Olean exterior ot oomponent •.

Chock: Pedal troo travel til; adjust 1t necessary (under su pervision of driver meohanio).

Secur1ty ot pedal .ecuring nute, s plit pine, and return :Jprlng.

15

LUbrl0.te.

Propellor .bott .plln•• (tront and rl~•• 2 Nlpple •• Rear propellor abatt nnivereal Joint.

(Speoial gr •••• gun . d.ptar) ••••••••••••• 2 Nlppla~ PI'Ont propel l or Ih. r t lIn1".ereal j oint .

(Special greAle gun adaptor) ••••••••••••• 2 NIpple •• 16

Tran.t.r Caae . bitt l'ver .h·tt ••...• l Nipple Front ·xle o o ~ tant weloolt7 joint • •• Level pl uS'

Obeok.

011 gauSe, • .ngine " n't.

011 tl1t er plpe eeour1ty to eQ8ine.

0 1~

All apll n • • and 'mi ....r.al jointa tor e.xcI.al •• RIA

P"", houling •• oure and DO l . ·k••

Cranko • • e vent l lation pipel .loure11 8Ount ed.

Seourlt1 at uni .ereal joint nuta and bolte; P01 p'rti oular at tention to nut. 1mmedlatel , rear or h&n4 brake dru ...

Seourlt, ot exh·u.t and int'ke men' told, 011

Seourit1 at . plined .hott .eal. , tront end r ear .

W.ter pump dr.Sn bole tr •••

PrOllt axle oonatant velool ty joint hou.tns. tor

Pan bl. Oe ri •• t. tor .eourlt7.

1 .......

Inll1ne

tUtor mount ing. ,

Puel Line Gr oup

Orou p

Clean exterlor at oo"",onents .

Ind

bond .trapping.

Olean e xt.rior ot oom.ponent ••

RelDOve.

IA1brlo ate.

Carbur.ttor band and toot oontr ol• •••• 011 Can.

S·nd oontrol .l14••• •••••••••••• • •• • •• 01L Can .

Dl .tr1butor .batt b.ar 1n g ••••••• •••• •• 2 drop. tllrouSb oUer. Start.r ~tor ••• •• • • •.•••••• •••••• •••• Ol1 Can .

Obotok .

Air ole. ner) oheng. all, •••b ti~t.r element in petrol and r.-oU. Clean 1nelde ot oontainer boior.

replaCing.

Oheok.

Seourit7 ot air ole.ner quiok rele.a. lSnks and

oontain.rl tl.x1bl. booe not d'c'ged, alr lntAke

Radlator ho •• ol1p. tor aoourltYI hooo. tor ol gn. ot ~.terlor a tion or d.m·ge. (t.el hOI. tor int.rnal br . ,ke).

Radiator oore tor OOI'M" t l onJ r.DOY. &n1

dS rt,

in"ot, or d.br1, .

to carbur.ttor, DO leake.

Oarburettor mounting bolt •• SeourU, ot tual 1""'" mounttns bolta. Olean 1"'." tl1ter .ore.n and ••dill.nt trapI obeok sa.ket sorviceable on replaoement.

Radiator 8OUDtina' and br acing

.to,1

tor .eourity .

Pu.l .linea to pr'mary tllter; no l.aka or

Operation ot t bor moltatl it oorreot , engine ohould

R.mo.... and ol.an pri"r1 tilter . l ement •

'an bllt t or oondltlon end oorreot t.n. lon l repllo. or adjust •• neo ••• ary (undor wporvl11on or drlT..

Fuel l 1n., to t·nk) no leaks or d· .. S"

• ar. up quiokly , then water lhoul d oiroulate tro.ly .

_ obanio) .

Dratn cooks tor freedoD ot oper,tton.

Seouritr

or

t1JolnS

0"0

coyer .

Fuel

tenk

dJla1D plug not ruated. up _

ruel tank sump

tor ~ •• ag••

Fuel tonk stra pptns, tlllor oap and puge unit tor .eo\.ll"lt7.

Bnglne moun t ing Ituc1a , !'ront and roar ,

Ignition Or o'Y' Clean ext.rior ot o,,",ponants.

Operation ot g.n.rator qui ck rel •••• mech e n1 •• ,

Lubrio ate.

freedOll or aoUonl return OJll'ing I""operly pollUoned. oonerator and starter motor mounting • •

lDr1,.r _ ob· nJ o .

Cam pr otl1 •••••••• Llgbtlr om.lr) Under aupervl,lon Rotor .iok •••••••• Two drop. at Br. aker AN piTOt. On.e drop

Temporature gaus. , engine unlt .

17

~"'g••

18

Oboakl

No Citting. or part e mioal"!!.

Oent.a' br.anr pol,n t. rar 0 0111 lot IUp8I''Y'1 .1on ot drl.er meohanio).

sap

(tI"".r

Hood secure and undamaged.

Toole and

BlOT. Lead., capI 'nd .uppr••• orl •• ouroS not tl'..,.ad, oraoked or Uable to obort oirouit.

S"'lI1'lq. at dlotrlbutar and ooU IIIOUlltl.ngo,

equl~nt

oorreotly ,to•• d.

Cl.oan II xtorlor ot oom ponont ••

Cheak l

L.'f. lAi&d1 not "able to abort oiroult.

Inelde wall ot tront tyro. tor

No obviou. milallgnment or whe.la untrue.

Remove and ollan Ipnrk pluSl, re.et gape to .03011' nooeeeary (under .uperv1.10D at driver meohaniol.

011 Level Group

d~ag••

Tyre. tor abnorrul wear.

REPORT an,. ligna or

undue •• ar.

Olean exterior at oomponent ••

T,l". not oreeping.

Obook and repleniOb .. neoe.earyl

Tyros valve.

8t•• r1.ng box, Gear box. ifrlnator Ca •••

Rim rlang•• not da".ged.

undamaged and valvo oape ritt.d.

Wboel and detaohabl. rim stud nut. tigbt and. threads not rust,.

rront d11'tereDtto.l.

R.... d11'terentio.l.

Hub oap•• ecure.

Rear •• 1• • batt Clang• • tud. tight.

Oheokl Br.ather oap. tor oleanUno •• and eeolU'1t7'

Withdrawal etude not d1.tortlng tlange.

All plug. tor loourlt7, no le.ks.

Chonge over t,.r •• i t due aooord1,,!! to ow-rent DMB Technical Instructiona.

* '°1/1, 011 w 1] be ob'nged ( er auper.lI1on) at 1.nterT&l.1 ,toted 1n hlbrlcatloD Sohsdule Appe"cUx 1

•••• B?4l Group

1Ind

Olean exterior ot oomponent ••

nut. palnt.c1 Warning Red • • , W1rJns and Light1ng Oroup Clean exterior Eleotrioo.l ftias

or

Oheokl

Lubr10atel

Expo.ed .leotrioal wir1ng lnlulation tor oraok., kSnks, fra,., and fouling or movtna pert ••

Bonnet and windeoreen b1nge., t •• tener. olip. ond p'l Yot ........................... , ............ 011 Oan. Se&4 lamp. bing•••••••••••••••••••••••••• Oil Can. P•••• na.r .eat btng••••••••••••••.••••••• Oil Oan .

Term1na.ls olean and tight.

• ,pc1.ore.n w1per abatta .••••••••••.•••••• 011 Can. PlDtla book •••••••••••••••••••••••••••••• 011 Can . ifool and equipment ol&IDps, bInges, and w'l.Jl8 nuts ................................. 011 Can.

Lempa

Bod, mounting bolta tor .eourity to aba_als.

Spe.re .bael carrier seour ••

looker. tor oleanllne •• and operation ot

locka.

1'01" seourity or . mounting, lena08 and 1"'" and we.t~rproot. All lampo tor oorreot

tir" operat1on and blaok-out mad1tloat1on. a. ord.red tram t1me to time.

Oheokl

~ool

oomponenta.

*

Voltage Regulator eeo\U'8 to bod,. - •••1. intact.

NOTS: Ma.l.ntena.noe Redto Suppres .ion Equll4lilnt.

All 8s.ombli •• eaploy.d in tbo rad10 auppre •• ion systom must be 1nspeated b1 the driv. r evory 500

milea Wld attention payed to the tollowing pointa.lG

20

at F1ltere.

WIll'! 1lA1HtBkAJICB

Cheok to see that filter mounting screws are drawn up tlght, and that oonnectlng wlres are tlBbt and in good oondltlon.

~

lOTS! The tollowing noto. on trall.r .. inbor~oo are pro.ided onl7 a • • gu1d., and m&7 bo app11ed to a.1 1 tlp81 ot trailors 2 wbeel, 8 owt.

b. Condensers!

0&117 Botoro Dutl'

Check eaoh oondeneer mount1ng and terminal oonneot10n and s.. that the7 are olean and tlght.

Obook.

Operation of l1g1>to l Gobl. and .ooket p1

a. Supprossorll.

•• ourltl'

Chook olloh opark plug ouppro •• or tor oraoked or brokon boueing and meke cortain that none are missing. See that auppresllors are properly sorewed into wiroe in oablos. Snap-on tormina1s must be tree trom oorrosion and dirt and must b. tlght, to make a SCad oontaot with plug.

Brake cable and l ln k ·ge.

for

Band brake Cor oorreo t operat1on .

TI l" •• fc:r oor r lot Intlatlon pr •••UI"e ( 30 l b ll) ,u••

gauge.

d. Bonding.

To.1ng .,e oorroot17 po.Itlon.d in pintle book. sar.t" ohai n. in plaoe .

Inspoot all points ot bond strap attachment to b. eure that they are clean and that all bolts and 8hakoproot wa8hers are drawn up tight.

Parking eupport seourol" olaaped ln ·Up· pooit10n.

REPORT ANY DEFECTS OR ADJUSTIIENTS B.I!YOND DRIVER '5 SCOPE ON O.l?

•

Load tor lI.ouritl, tarpaulIn oorrootl,

1.II~d

down.

Oal11 Att.r Dut1 ' Cheolu

Towing .,. and pint le hook tor .e.uri t7

,n'

"'-II.'

Tyree tor ~.77 g ., out. , and oorreot prell.ure .alve oape fitted .

Shaokle Illd .pring anaboras •• "neSem'Sed.

Spring l a ••• e .cd OIDkr, bolt. 'mbrokenJ ·0· bolt. tor .1gn. ot .ove~n t, olip • • eour ••

Bod, bolt . tlghtJ tarpaa1in oorroot17 laoh.d do.n.

e•• ic

Group Ka1nt,nanc.

A1J groupe aut ba oO.lll,pleted • • ob SOO Il1le ••

Shlokl.o Group

Clean e xt.rlor ot oocaponent ••

Lubrioate.

Spr lna .haokle ••••••••••••••• ,......... 6 nlp'p le II. Ensur. gr .... goo 8 througbJ r.port &n7

IIleE64, 100. . or worn ahaokl •••

Oh.Ok. Shackle. and s pring anohorog •• tor .eourlt1J 21

22

... 141ng not craoked.

SF1J¥ (h;oup

01.....xt.rlor ot O_Dent ••

Wheel and detaob'ble rim .tud nut. tight ODd tbr.ad. not ru, t1J bub oap' ,.oure.

Chango over t,r•• i t duo (Se. in.truotlon. lole log book AAB 2OB).

Oheok.

Spring 1.........d oentro bolt. not dbplooed or broken.

• U" bolh tor olgo. ot _ n t • •prlng cUp. aeoure, nuts end bolts t1ght.

Shook ab.orbor. tor ....urlt,-.

Clean ext.rior ot oomponont ••

Lubrloat ••

Ohook' Brake oabl•• and ltnkage tor .eourlty_ Br'k•• tor oorreat operat1on.

Choak.

.ulna

tor chated or broOD .1rea .

Ret.Sn1ng ol1p. and grwamot. ror a .ourlt1'

All oonn.otlon. tor tlgbtn ••••

• INDEX

Olean exter10r at oomponente.

Lubrloate.

Towing er. ewIv.l •...........••..•...• 1Hlpple.

Park'ng ,upport hInge ••.•••••••••••••• Ol1 Can .

Oh.ok.

B0d7 lDOunt1n,g bolt. tor .eourlt,-.

Draw bar mounting bolt. tigbt.

Towing 01. a •• ombl, tor •• ourlt7.

Bo tlttlog. or part. mi.elng.

All bod, bolt. t1gbt.

Tarpaulin

.n'!

la.hing. oomplete and ••rvlaeable.

Olean exterIor at oomponent ••

Oh.ak.

Wheel and axle alignment.

'!'Jr.'

tor abnorml .. ear; report an,. Wldue wear, rim

flange. not damaged, tyro .alve. undamaged and valve

aape tltted.

23

Veh-

Olean exterIor ot oOJ!U)Onent ••

OperatloD or all l1gbt ••

Band braD lonr abatt and I1nngo ••..• 011 CaD. Plexibl. brake oable, dl.mantl. and gr •••• b, herd.

10

2.

OPl!lUTIllG IH:trRICrICIII

..,11 be ollM'h4 out b7 wptnll1oQ, .btl, tb. nhlol. 1. 1D

•

( ..... tollow1n&

!!!I'ine Ol'oup

.,.t..

Dr"l.. radiator and 07UDdtl' 1>100.. II1II tlu'b thol

oooltns

Dr.'n poiDt.

IInd.r

I..N

pr.'IUJ"'.

poI.1tlor::t4 •• toll0."

1. Low.r l . t i bend oarn.r of reAl_tor. e. Right tront lower .orn.r ot .71ind.1' blo.", C.paolty

or

.ooling .:ret•• -

et

.... , a fthi.l. baa b.en .pael-U7 deolgDed w'-'b , wba.l bllo .... b'sh ratio It •• rlng, to 'o'bl. oegot.1&t. d.1ttloult oOUDtrr_ Tn,sptJI"l.Doe4

it drh.r., or tbo .. new to tbe fthiola, ... t DOt .tteep, to u •• It. hIgh .peed o.pebll1tl•• OD good ro.d., .. under the.e .0Ddltlono, tbe t •• tOI" mentloDed Ibo•• tend to _lie tbe yehiol. owing ob.rp17.

Tran.ter C. . . Opel'au,OII.

qu... t. .

.xl.

"'.1 Mne lb'Ollp

Tranal.r •••• -1 be oparated in .1tber Mlh 01' low .pe.d rlnS' whln tront eyl. 4rl•• 18 .".... d.

II....... drain, 'M .l.an tIl.l tenlt - .be ... tor l •• k ••

Ol.en out tuel ton"

'WOJI.

r.pe.l nt i t n.o ......7.

AU , LeY'l Oroup

Pront

0 ••• •

rnr 41tr.rent1a1l .

b'·'n. draining • • ar'r-;~tln!0r ..di. . nt and .. Col parti.l ••• report i t "" unuouol touM.

!ht.l Alia,.ent and TIle Or oup R.., •••blela I'rH •• biol.•

Clean bub tao •• , brAke In.lde ot tyru .

ax1.

oan b. drl... 1a

To dl .... g.8. tront .xle drl•• , 1'.1•••••••• ler.t· or and ,hltt 11••1' to lorward po.ltlon.

bOlt. oM

HIlS' wbeD trnnt

0'"

to re ... pooltlon.

5teerln8 box,

Tran.ter

Tile tran.t.r

To engage t'rODt ·xl • c2rlY•• u)JJ"'" olut6h pede', r.l•••• aooelerator .,,,, . ,.... trOll" ....'. '"Pst' ~.w

Dr.in end r.tlll,

a,ar

0."

ID.truotlona tor .bltting go .... in tr....t.1' ... goa-nt ot tbe Ilont drift ...... 101lowII

,04

tpol' fro. -.beell.

~. ~.l.

and r'"

and

P.int .1tb ou1table punt .11 r al, .11 Wheel. where J'\l8ty or ohipped .

Chenp m •• r on"" . . .Hreote4.

In V.hiol. Lo, Boo.. AlB 80111 .

(a..

8hifting bOIl bilb to low .p ••d r.nge obcnlld bOt b • •t"IIPCed UGlpt when tbe nhiol. 11 being oper.ted .t 10• •pee40 01' .t • • hDd .tUl. The troDt driv. muat be ensase4 tor th' • •b1tt. B.l.· •• aoolleratol' and depre •• olutoh pedal; 110.' tront axle ea,... lenl' to rear pool tion. engaging troDt wheel drlY.,

ax'.

thlD move tranlt.r 0 ••• obenge lpeed lever, to

po.ltion.

Shlrtlng trom 10. to higb lpeed I'.ng. P'7 b.

• •• 000p11lbed at '1\1 ciM, regard1e .. ot nhi.l• • peed.

R.t. ••• aocelerator .04 depre •• olutob pIOa',ah1tt tr1n.t• .r 0 ••• chAnge .peed lever into rear polit1oo,

Inacruotlaal

.ben Dlo •• earl to tow the veb101e,tbe to. oheSn, rope

•

8S

t Wiard

01'

cable, .hoUld

bl

bar Ind Irent old. I'ul

attaohed to the !'ront b l1 m.per ~ ••• t

•

Loop ohain or rope OYer top or b _ .M true ~I .. t, brining i t uP aoro.. tooe or 1>Ulllper .Dd b •• k on oppo.lte aide or tr.n, tben book or tho Do not tow tr<a the .'''41,. ~ tt» m'-rar,

26

th. look h

Pri.ins fbrougb Water When dri.1n8 throusb .at.r, •• e tbat tb. o.p i .

on tho trout draJD bole u""er the t'uel tank, AD .xtra oap oarri.d in the Slov. ooap'rtacmt sbould be in.tal-

l.d on th. r ..... dra1n bol.. Rnan tbi. oap .... ...turn it to tba glo •• oo~t..ut atte.. pa.oing tbrousb the wat.... Alt.r operatlona 1n ,w&,IQ)' .nd .tr••··, tnap.ot tor .at.r in engine, ,.arbox, traner.r oa •• , tront and rear Ixl,., .beel bearing. and tront unl.... roal Jo1nta.

When tbero i. a pooaibi11t,. or .at.r b.inS tbrown 0.... tho engin. b,. ran aotion 1n oro •• ing .t.... ·., ~l up on bandl. or tb. g.n.rato.. b.. &o., tbaD r'lIOn tboo ran b.lt. ~ ••111 .top tba r.... Aa aOon .. po ..ibl. tb. b.lt .bould b ....plao"", tboo" ~l out on th. g.ne ... to... The gan.. ato.. will look 1n plaoe b7 aprins aotion ot the brao •• '!'raUer Operation

(Se. Illuatration "'!'raJ,l... Oeupl1n8")

tb. us. or a two wh••l t .. ailer, 1t i. i_port... t to properl,. diotribut. tb. 10"" tor bal...o•• T) .... ahoUld be 1ntlat.d to ~ pr •• IIUl'I. Du oare lbould be Ixerol.ed .ben ooupltag or UDooupltas tbe trailer rr ... tboo •• biol. eo tbat It .111 not lI.t out ot control. Sat tba b''''' bNk. _ parldng tboo ~

PO"""

tr&11er.

couple up trall... , Uft up tbe p1nUa book look on tboo truok aM rai.. tba lItob, Bo.l. Rai .. tbe tra'1 ........ plio. trail... dr. . b.... C&' (X..... tt.

1I:ye) 1n booll:. 010.. th. Jl1ntl. book ...d b. aura that To

de on 1n plao ••

•• xt, book lIP tboo .at.t,. cbtl"., 40 not oro .. the.. tn •• rt the book, h-oa ttM und 'r 114e at th' .,.a No.a, 00 tbat tba boon will not jUIIIP out 1n go1n8 0•• 1' rou&b ground, Oon-.ot lIP tb. al.otrloal o,.at.. b,. raio1nB tboo 00.'1' on tbe oo~pl1ns oookot 1n tboo l.tt rear .l.4a or tbo h'uok bod,., No.lI, turn1n8 tbe oatle plUS poaltioning lUS to line UJ) with 8 1 ' 1n .ook.t an4 J>lah tboo plus ••U rorward lnto tbe looket.

PIlll out on tboo OI\Pport leg plllng.r, No •• and raia. l.g to bor1.ontal po.it10n, U•• one ren to .a•• the v.hlol. and another to

b.ndl. the oouJ)linS .hon the tr.ilor 10 ho.vil,. loadod or tber. i. a poaoibilit,. ot tbo trail.r g.tting out ot oontrol. ~ ouoh In.tano.o, b.ok tb. v.biol. to tb. trail.r and rol.... the brakol •• tbe lalt operation.

To l1DOOQple t~ tranor, pull tbo o.bl. plUS out ot .ookot and b.ng ov.r book on bod,. Unhook the obe1na aM hook tbell over tbIo obain attlo_nt link on tbo tral1l r, drop tb. support 10, b1 pulling out on tbe plunger handl.. Bo lure the support !~ looko in Oo.n pOlitlon. Unlook tbe pintle book unooupl. tho trail.r, When tb. tral1er is ooupled to tb. truok, t.il and .top 11ghts .... oontrolled b,. oper.tion or tb. lighting .yatom or brako appll0.tlon in drlving tho vebiola. Wben the maln lighting .w1toh 10 obona.d to blaokout po.itlon, lt i. noool ••ry to turn th • • • itob provid.d on the tral10r bolo. tbo bind brake 10."', otb.rwl.e th. tral10r a.rvloo tall and .top lightl will oontlnua to 1\IMtion. Puob uld. the oovo .. on tho "Uoh, and, uling tba oor ko,. or a loro. drivor, turn tb. I.ltob t turn to tbo right .id. ot the traile.. Cor blaokout 11gbta anO to tbe lott tor ••rvioo l1sbta.

DO NOT FORGBT TO

MOVING OFF.

RBI,R~SB

TRAu.m BRAXB III,PORS

'!'be bod,. 10 .atorproor and doalpd ao tl».t tbe ••hl010 .111 rlo.t oarryine a load ot 600 poundo. '!'be

loaded .ater 11ne 10 12 inoba' above tbe tloor.

A tarpaul1n oov.r la prov 1dod and 10 ...U,. inatallod b,. tak1n8 • b.lt bitob 1n the ..opa. ero"''' tboo boot..

OO'U'L1iO

*

NQt!!!

Tho abon not .. are .... itt.n tor tbe Aeurioan t)pa ot trail.r, but _,. bo appli.d in seneral , tor all t), ••• 28

Al'PEIIDII "A"

•

LUBRICATION SCHEDULE

Dr1vors w111 regard a recondIt1oned engine, gear box, transfer asaomb17 and w111 drive, lubricate and maintain accordingly_ must b. caretully exam1ned tor signe ot water, sed1ment, sludge, metal particl•• , nuts or

pins ar parts

~h&l'eot.

Report anything unU!IlUll !'om'd and keep drain1.ne1l tor turther eXAmination. ' I t DOl'mal, draining. must be preserved separately and handed in tar salvage in

acoordance wIth current L.H.Q. Instructions.

'"<0

Lubrioant

Assembly

lot Obango

SUb.equent Ching••

at

evert .000

Engine crankcase Engin. 011 tl1.ter

0E-30

Gear Box

00-90

1000

•

,

1000

•

6000

1000

6000

•

•

1000

•

6000

Change elecont OVOl'Y 8000 miles.

Transfer Case

D1tterent18.1s (tront and Rear) Steer1ng Box

NOTE;

250

ever}'

6000

UDder severe conditione, the engine crankOase oIl, and 011 fIlter element w11l be changed at more .t"roquont intervals •

."lBI.lI 2 - GROUP LUBRICATION

T,pc ot ••• embly

~lbrlofJ]t

Lubr1aator

110.

~

Pointe

Period Daily

or

Lubrication 500 111], ••

.•

DrI.6 TJnk Bell arank Traak rod.

CII-l(Mo)

••

2 1 4.

--

Front .pring ohl.Okl •• Rear spring .heakl•• Torque reaction .pr1Dg bolt.

CII-l(Mo)

6

e

--

Grease OWl Oreaee Gtm Gre.e. Gun

Olutah pe1" .h'tt Link.ge joint.

CII-l(AL) 0B-30

Hipple 011 Can

1

-

--

Grease gun Pew Drope

Brake pedal -bett CII-1UL) }\JIb rod Il1wt 0E-3D • Send Brake aatuating Jointa Contro~ le.er .11de inner c· bJe

\I1ppl.

011 Can

1 1

Reservoir

1 1

••

,

B7draul1c .,..tem

H.B.P.

1

•,

,

---

, •

Grea"e Gun

Grease Gun Fe. drop.

• • • •

a.pleutah

...

,

-1.7

Lo"rlc.aDt

!'". or

Ko. ot

J. :abri.oator

Point.

Hipples

2

hr104 ot I. "'rloat.1OD &00 IIU ••

D1117

I~ FlOP _ ,hert apl'n •• e.tront end re'r) Universal joint. (tront ."" rear) Transfer 0 •• ' 1 ....1' 'h' r ,t .

Pront 'x l , C.V. Jointa.

CO-1.(AL)

• • •

•

• •

Level P1UC'

1.

2

a•• enoir

1

011 Can 011 Can

-1

--

are""

0Im

• • •

• • •

ERGm !l80vP

Cr,"lcca'l

011-30

toot Gontz 01.

Distr1butor ,he tt 'b. ar1D.a Starter .,tazo

0:&-30

Bend

en4

~30

•

•

1

OMok 1 •••1 & replen1.b

--

01 , 30

cll.ner

Puol. pi '''1' rUt... • :rleo •• '1 . . .10 trag PrblllrJ' rl1 tv

end

-

-

--

-

-

Lubrloator

I;~in~

SM ... b7

1

•

1 1

Lubrioant 'l'J'pe or

A••• llbl.,.

1

R"arTo1:"

I~ 1111-2

protll••

I ~otor w10k Breaker arm pl.at

0:&-30

•

hen d 0110an

OIL UYJQ,gnOyP

...

'"

00-90

St.wrlng bolt alar bolt

Transter

0& • •

D1.tterlntlala (.tront

&. rear)

• • •

R•••rvo1.r

• • •

1 1 1 2

Dr,'n rlulh

Lt neC.leary_

&; r l t 11 1

-P~riod

Do.117

-

---

replenilh J •• drop.

Two 4rop. f oo drop.

I~

.'1'

Ob.ok 1 .... 1 &

Dr-' n tlueb rl.tl11 or"n

end

•

•

,ntI

ele'n

•

ot Lubrioation Kl.l••

300

Sme ...

two drape.

Ooe drop

R.~l"'hh

• • •

--

BOIlY OI\OUP

Bonnet and windler_en bing. . and .r •• tenere t.amp hinges Seat binges WladsoreeD wiper .hatt.

Pintle book

011-30

• • • •

Oll can

• •• •

~I Whe.l bearincs

WB -2

Pack b7

b.'....

--•

---

P.w drop.

• • • •

• • • •

Worklbope every 6000 .:11e.

"CO

APPENDIX "B"

•

• The tollow-1ng oplratlonl .nd adJust_nt. wl11 be oarried out b7 drl.er .-ohenioa 0017_

Pan. (Set oontrol. and tr7 agltn)

Gaus" tunot10n i Obeok tnel turned 00 i Obeok air nnt in Cap I Cbeok .park a~ plug.

Gaugee do not tnnot10n I Oheok battery and .01en01d terminale. Conneotion. tight and olean. Wir1ns to .ntoh.

I Obaok .tate ot ollarge ot batter).

10 .park at plug.

Sp'rk at plug.

I Oheok prlmary wlrlna

I

Obeole fuel at oarburottOl'

D1.trlbutor unlt, to .ntoh, to battery.

I

Obaok oonden.er eeourlty

I di.trlbutor

Cheok oap .eourlty H.T. Lead. to Plug',

I

Work.hop.

'l'bere .hould alw&1' be at leut

travel betore the push rod o06ag.. the pia tone

Thi. adjuotmoot 1. aooompll.hed by the abortenlns or lensthonlns ot tho brake ma.ter oylindor oy" bolt. Thi. 1. done eo tbo pr1aary oup wl11 olear tho port, wben tbe platon 18 In the ott poaltlon, otherwlae the Dompensating aotlon at the master oylinder will be d.ltroyed and aau.. the brakes to drag.

WIlen the brake l1o1ns beoom... worn, as indioated by toot pedal g01l>8 almost to the tloor board, nooe.eary adju.tment oan readlly be mad. a. dooorlbod ln the rollowlng paragraph, Mike oertaln tbat thor. 1. ." tree brake pedal tranl.

Jaok up tbe wheel. to olear the ground.

oarbur.ttor

I

Workshop.

10 ruol at Carburottor.

I Oheok t"ol lin.. tor leak•• toppag .. and

Adju.t>-

ment Ie made by rotatIng t~ brake ahoe eaaentria.

WIth a wrenoh, looaen the eaoentrio look Dut on the torward brake ahoe. Hold tbe look nut, ana wIth another wrenoh, turn the eaoentrio towards the tront ot ~he vehiole until t~ brake shoe binds on the drum.

Turn the whoel with 000 hend and rolease the eooentria

untl1 tho ibeel turn. freely.

Bold tho oooentrio and

tIghten the look nut. To adjust the rear s hoe, repeat the above ' operation exoept to turn tbe ecoentrio toward

the roar ot the vehiole. ruel at

i" tree pedal

In the event

Repeat tor all wbe.l ••

ot tho minor adJu.tment not g1v1l>8

looa. "Diona.

adequate brakes, it will b. neo •• sary to reeet the anohor pln.. The brake adJuot..nto ohould be mode a. tollow ••

Puel 11n•• ol.ar I

Loo.en the anobor pln look nut. on the rear ot tho baok1l>8 plato. AdJuatment 1 ••• 1. bj turning the

I

pump trouble lndloated

I

Cheok d.~cm... oap .Oroen Drain Plug Oaaket.

I

Workshop.

eooentrio anohor pine toward. eaob other and down, until the ahooa are .et to ttHt proper olearance, ae determ'ned by teeler gaugea. The reoommended aboe setting Is .005" ·olearanoe at the heel (lower end) and .OOB" at tho to. (upper end) ot the brake .hoe

11ning.

A ~lot 1. provided ln the brake drum tor

cheoking these clearanoe ••

Xllu.traUon "U.nd-br&lc. a4J".t."t") •

(s. .

I. .ppll.d to tbe 1'0' 1' propell.r .bert .t tb. tran.t.r 0.... !be oper.tlon at tbe br&lc. 11 poilU.. t.beoup .. oable OOM.oUon. To adJI.. t \b. hand brake tbe tollodna opeutIon •• hould b. plrto~dl

B...

tbe band brake on tho d ...h In tbe r.l.o.ed po.ltlon. Und.r tbe v.hlol., ••• tbet tho br.k. oabl. hal rol ••••d tbe brak. and that tho 1'.1.., or ..nk 1. in tho rullT r.l .... ed po.ltlon. Ad~U.t tho anohOr '01".

No . 1, .0 that tbo. . .111 b • • 008 - .010" ol.orano . b.t ••• n tbe band and tb. 4rUM .t tho '01". ' TIgbt.n nut No.1 until tbe band 1. broulbt tight, .s.ln.t thl Adja-t bolt 10.:1 .0 tbet tbe bea4 Ju.t rllto on thl upp.r halt ot tbe band Ind tbe 100ktns nut I •• Slln.t tbe

41'....

"nAir

,14,

or braokat.

B.ok ott t.o turn. on tbe I4ju.t1ns nut wo. e. Tbi. will I i " tb. bra .... bind "PIlI'O'" I ... t.l, . 010" 01.",,anoo trolD thl 4rum.

Du. att.ntlon .hould b. alvon to tbo oable Ind l1nk&,. to ••• tbet th., 40 no. bind. '!'h. l 'nstb ot tbe o.ble tro. tbe band 8l'lp to tbe HAND BRAD AnrullTIIINf brak. 1"'1'1 1. 01 • pred.t.rmln.d 1.nstb and oannot b. obanaed. (tood 1I04ltlo.tl4n Wo.ltg7 ...k•• pro.lalon tor l.nsth ot oabl. to b. a4J~at.d).

At r.sul"" period., It 1. ad.laabl. to at•• 4r0pe ot oil in tho upper .nd ot tbe oonduU tllb...t tho .able to k.. p IttI'II to .11d••lthin tbe oondult.

Thl. br&lc. 1. dll1&ned onlT tor hOldl na tbe .. blol. 1fb1l. parked, and .bould not b. ulld wbU.,

pu'

t~

•• b101a

1. in mot1on.

.u.'

The b,4r ..ull0 brake .,.t•• b. bled WhenfluId 11n. hi. bOln dlooonnaoted, or air f'U into tbe .,.t... A l.ak In tbe 'Tot ......1 .o•• t . . .

".1' ..

b. ..ld.no.d tbrouab tho pr •••no. ot • 'PODIT brak, pedal. Air trapped In tho 'T.t •• 1. oompr ••• lbl. and dOli not peNlt prllour. app11.d to tbe br&lc. podol to b. tran.attt.d .011411 throuSb to tho brak, ••

Tbe .,.hll ..... t b. ab.olutel, tr .. trOll air at all U..... Who" bleodlns tbo br.kll It 11 .d.lI.blo' tbet tbe 10nSllt flu14 Uno tro. tbe ..... tor o,Undor b. blod tlr.t. '1'bo propo.r "qu."o. ot ble 11 rlgbt r.&p, rlSht troat, l.tt 1'0"", l.,t tront.

1ns tbe bl ••d1ns oper.tion tbe ... tu o,Undor ..at b. kept at lout t tull ot bJ4rlull0 brake flu14.

To bloed tbe bralcll. thot o"""tullJ 010 .....u dirt tr_ ....... ., tbe _.tor o,lIndar tUlu plus.

Rer'" tbe tll10r plns .nd tu~ tbe _.tor 0T11 ....r to tbe 1"".1' ed,. at tb' tlllor nook. 01..... ott all bl•• d.~ oonneotion. at all tour tit',l 0J1Snder •• .t.tt;aob bloed.r boe..... tLet ..... to rl&bt roar whlel o71t ndcr bl'~,~ .or,., and plao, the ,DA or tbl tub.

1.n a .'." jar, end "".rpd 1D fioht.

OPl6 tb, bloed.r .al. . . to t of .. ti!Fll. the .toot p.e"a' b'b~:nd, a.UOWSns 1t to retw'u .10w17' OODthm. ~1.D& Utl0D to .toro. tbe auld thrc)Ulb thl ltn. aM OUt: tb e b1-•• der bo •• whioh Darri •• w1tb 1t 8n7 .S. 1D the ......Dtpr •••

.'l'7

.,.t••.

D.... to appear at ble.d.r bo.. , Upto" tb. bloed.r .al. . . nd ~b

bubble.

the end o.t the ra.....

the boe ••

Attor th' bloedlns op.ratlon ha. bO.D 00.p10ted ..t III tour wboo1., till tho ~.tor oTllnd.r 1'0.01'.011' and roplao. tho tll10r plug, It 1. not Id.l ...ble to ro-u.o tbo t1u14 wblob ha. bo.n r ......d troll tbe linll tbrough thl b1.. ,lns pro.....

OLll'lCB gRQDP

. , tbe olutch .tao1Dsa •• ar, t!»

rr..

p'"., al

tray.l 1, 4'·'nt.~d. Wboa the o1utoh pl1 r •• t. a!:,nat tho toe board 1t 1. D.O"'&r7 to adJuet th. o tob oable. Le.n.gtb.n1q or ebortentna ttl ol.utoh oontrol l.yer e."1. gonrlW ol.ar ano • ot ttl

tb. olutob rol.... bear·1 ns to the ol"tClb tlns.r. 1fb1ob

.boul4 b •• dntl'n.d .t 1/16", ~. repr..."t. a/." rr.. pldal tra.l.l . 'fbt. al.ao 41,.nsase' ttl olll'oh rel.a.e b..ariDa and pt' •• ente "nD80",&1"'7 •• ar .", " thl engSae 1. r nnn'nSt

too ..n tbe olutob 00l1tro1 lnor oabl. I4juot1ns Toke loolaNt. Wltb" .....nob, un.or.w tbe oabl. to tbe dllh.d pollUon, tt.n t 19bt.n looknut.

BIlOW GROVP

Val •• AdJu.tllOnt (Tb1. 1. I t ••por..,., 4dju.tlDOnt and

moot bo r.port.d to workebope at tho Llr.t opportunity).

clear the noor.

Remove the valve epr1ns oover.

2.

Witb hand., toot old.way. mo.ement or the wheel.

It bearing_ are correotly adjusted, _hoke ot wbeel wll1 be ju.t peroeptible and wheel will tutU treely wi th no drag. I t boaring adju.t_t 10 too tight. the rollers may break: or beoome overheated. Loose bearings may cause excessive woar and possibly no1se.

Adjuet th. o.lr 10ok1ng oold to .01. inch.

t.pp.~

sorewe Whil. they are

Set the tapp.t eor ••, (etarting w1th Bo.l oylind.r on oompr.eeion etrok. at top o.ntr.), then adjuet valv•• ~ oylinder rlrlng order, turning the orankshaft on8halt turn tor .aoh oylind.r (Bot., The valve tappet. wIll then be on the heel ot the cam.

Atter adJust1ng, replace the valve sprIng oover.

Pan B.lt

Adju.boe~t

To inetall the tan b.lt, loos.n th. olamp bolt on the .lotted braoket at tho gon.rator and mova generator toward. the engine. 811do the belt over the orank.bltt pull.,., up through the tan 'tl1s4e a ••• ,,': ly and over tho ran pull.y, t .b en over genorator pulley.

Adjuet the tan bolt by br1nging tho gon.rator away rrom the .n§in. to a point where the tan b.lt oan b. d.pr •••• d 1 midway betw.en tho tan pulley and the generator pulley_ The drive or the tan and generator 1. on tho ald •• 01' the "v ft belt, theretol" it 18 not nooe.sery to have the tan belt tight whioh might cause exelaeive .ear on the generator and tho water pumP boar ingo.

FUEL LIIIE OROUP

The Idle adjustment aore. Ie the only service adjustment provided on ' the carburettor. To obta1n the approximate correct setting, turn the adjuatment acrew to tho r1ght and all tbo way tn, but do not jam tb. aorew against the eeat} than, baok out adjustment aorew betweon one and two turns. To mako the tinal adjustIIIOnt warm up tbe engine, and adjust the Bor.w until the engine runs .moothly. Set the throttlo . top oorew .0 the .ngine will idlo at 600 r.volutions per minute (vehiole opeod, 8 mph).

It this t.ot indio ate. adjuetmant i. n.o ••• ary, prooeed as followat .ldju.tlllOnt 1.

Witb wheels. tlll on jaok, remove the hub oap, axle ahatt nut, waaher &Dd driving flAnge. Wheel bearlng adjustment will then b.' aoo •• sible.

Bend the lip ot tbe nut look ao that tho adjustment looknut and look can be removed.

2.

Tighten tho adjusting nut until tbe wb.el binds at the same time rotating the wbeel to make sure all surfaoes are 1"n proper oontact.

3.

4.

Then baok ott the nut about ~ 6 turn or more if neo •• sary making sure the wbeel rotat.a iraely.

S. Replaoe the look md do not taU to bend over the looknut.

6.

Cheok adjuat... nt and re ....,.,l. tha driving flange. When the Eront bub is oompletely assembled, test the wbeel sbAke before remov1ng jaok.

Rear

Wheo~

Bearings.

Raiee the wbeel on whiob the adjustment i. to b. made by plaoing jaok under the axle housing. Test the wheel ror loose bear1ng. If adjustment 18 neoessary proceed as follow., Adjustment 1.

Remove the axle abaft flange oap aoreW8 and axle ahaft.

Who.l B.aring Adju.tmont

2.

Bend the lip ot tba nut look so that tho nut can be removed.

Whoel bear1ng. oannot be ohooked tor ad ju.tment properl3' unless brakes are tree from dragglng on brake d.ru m " and are in tully released pl)Isition.

3.

Tighten the inner adjusting nut until tho whuel binds, 'at the eame time rotate the wheel to make sure that all aurtaoee are soating properly.

Front Whe.l Bearinge

4.

1.

Raise tront end of vehiole with jaok 110 that 37

loo~

Back off the nut 1/6 turn or more i t neoessary

until the wheel turn8 freely.

38

o. nop1&oo the nut look and th. 100knut and be aure to bend the look over.

APPENDIX "D"

•

e.

Replaoo tb. axle lbAtt wltb S.lket, and lnlta1l tbe oap lor ••••

•

T"llokl,

t

ot Trailar. u.od with ton (U.S.A.) 111&7 be rO&dil7 ldont1tied, the

In ordor thet the t7POI

following d •• oription. are provided:

Tr.,lera,

e Wheeled

8 Cwt. (Ault.) No.2.

Coneieto at a lIght oboll.. ateo1 bod1 wlth proviolon tor oarr7il1& otandard ArMS .trotohea.

A waterprooted can..o O&nOPT 10 Pl'O'f1dod ond the trailer i. tltted wlth 1-~/8' oq. oteel oxle, and 6.00 x 16 oonvention" t,-r... !'b1. 1m! t 1. oap'blA ot bo1ns ~okl7 dismantled tor trlo.port.

Trailer., 2 Wheeled 8 awt. (Auot.)

No.~.

Conelete at • watertlght ateel bod1 or welded oonstruotion D)unted on a o ,b onnel irOD ohl,.ie. It 1. fitted with epr"ng towing 070, h1ns.ed puleSng .upport, 1-3/8- aCluar. ate.l axll, 8.00 x 16 oODventional tread tyro. and waterprooted oanv.s oover.

Trailert. 2 Wheoled The

e

Owt. (Auot.) No.3A,

bod7 or th1. trailer 1. Identioal wltb

(Auet.) Ro,&, but baa tmported wbeela,

huba,

bralce

~

and boartnsa whiob are tnterobangeable witb Tl'uc)ca, 1/. ton. Tbe ·,Je 1. ot tubular ateel and 18 100a111 1JtPnufactured; The t1l". are 6.00 x 16 non-

dlreotional Bar Tread Identiool wltb thoee fltted to TI'uoko, l/4-ton. 110 braku are fitted.

Trailero, 2 Wheeled 8 Cwt.(U.8.A.) Tb1s trailer 1.

or

overa ••• 5s°utaotur. and

oonllote of • watertl8ht Ite.l bo47 at wold.d oonltruotion, ZDO\mted on .. ohlnnel iron oba.ai... banns a sprung towlll8

.J.,

a hinged· pErk'ng IQPPOrt,

6.00 x 16 nOD-dlreotionu Bar Tread

tubular

trr...

8")8 and

Th1e trailer

1. allO rltted with eleotrioal oonneotlonl, abook absorber. , .aret,. oh'Sna and band brake. Tbo .heala, bearing. , ahook ab ll orber., brake 4ru.ma &ad t1r •• are

interohangeable wltb Trucko, l/4-ton •

•