Chapter 1. INTRODUCTION - TM-9-4940-549-14-P0033
Figre 1-1. Shop Set, Doors Closed
Figure 1-2. Shop Set, Doors Open.
Figure 1-3. Shop Set, Tent Installed.
DATA.
Tabulated Data. - TM-9-4940-549-14-P0038
Tabulated Data - continued - TM-9-4940-549-14-P0039
Tabulated Data - continued - TM-9-4940-549-14-P0040
Tabulated Data - continued - TM-9-4940-549-14-P0041
Table 1-1. Fits and Tolerance (Engine)
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0043
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0044
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0045
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0046
Table 1-2. Manufacturer's Torque Values National Coarse
Chapter 2. OPERATING INSTRUCTIONS - TM-9-4940-549-14-P0049
Figure 2-1. Hydraulic System Controls.
Figure 2-2. Engine Controls and Instruments.
Manual Shutdown Control
Low Oil Pressure warning Light
Figure 2-3. Air Compressor Drive Motor Control and Air Receiver Tank Pressure Gage.
Figure 2-4. Electrical System Control Panel
Frequency Meter - TM-9-4940-549-14-P0056
240-Volt, 3-Phase, Circuit Breakers
Figure 2-5. Overspeed Safety Switch.
STOPPING THE ENGINE
Figure 2-6. Starting the Shop Set Engine.
Figure 2-7. Stopping the Shop Set Engine.
Operation on External (CITY) Power. - TM-9-4940-549-14-P0062
Figure 2-8. Personnel Heater Controls and Operation.
Operation with Power Selector Switch in OFF Position
Air Compressor Operation.
Drill Press Operation.
Section II. OPERATION OF AUXILIARY MATERIEL USED IN CONJUNCTION WITH THE SHOP SET
OPERATION IN EXTREME HEAT.
OPERATION UNDER RAINY OR HUMID CONDITIONS.
KW FORMULA FOR HIGH ALTITUDES
Chapter 3. OPERATOR/CREW MAINTENANCE INSTRUCTIONS - TM-9-4940-549-14-P0071
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0073
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0074
Section Ill. TROUBLESHOOTING
Table 3-2. Troubleshooting
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0077
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0078
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0079
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0080
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0081
Section IV. OPERATOR/CREW MAINTENANCE
LUBE OIL FILTER.
BODY ENCLOSURE COMPONENTS.
SIDE LIFTING HYDRAULIC SYSTEM.
Chapter 4. GENERAL MAINTENANCE INSTRUCTIONS
Figure 4-1. Shop Set Blocking and Tiedown Instructions.
Figure 4-2. Flatcar With Ramp In Place.
INSTALLATION OF SEPARATELY PACKED COMPONENTS.
Figure 4-3. Batteries, Removal, Installation and Service.
Erecting Tenting. - TM-9-4940-549-14-P0092
Figure 4-4. Raising and Lowering Shop Set Side Doors.
Figure 4-5. Opening Shop Set Rear Doors and Panels.
Figure 4-6. Laying Out Tent Framing.
Figure 4-7. Erecting Tent Framing (Sheet 1 of 2).
Figure 4-7. Erecting Tent Framing (Sheet 2 of 2).
Figure 4-8. Erecting Tenting (Sheet 1 of 3).
Figure 4-8. Erecting Tenting (Sheet 2 of 3).
Figure 4-8. Erecting Tenting (Sheet 3 of 3).
Figure 4-9. External Power Supply, Disconnection and Reconnection.
Figure 4-10. Grounding the Shop Set.
Figure 4-11. Voltage and Frequency Conversion.
Section III. MOVEMENT TO A NEW WORKSITE
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Table 4-1. Quarterly Preventive Maintenance Checks and Services
Table 4-1. Quarterly Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0107
Table 4-1. Quarterly Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0108
Table 4-1. Quarterly Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0109
Table 4-2. Troubleshooting
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0111
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0112
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0113
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0114
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0115
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0116
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0117
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0118
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0119
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0120
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0121
Section VII. GENERAL MAINTENANCE
TESTING OF SUPPRESSION COMPONENTS.
Figure 4-12. Interference Suppression Components, Removal and Installation (Sheet 1 of 2).
Figure 4-12. Interference Suppression Components, Removal and Installation (Sheet 2 of 2).
Chapter 5. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 5-1. Engine Enclosure, Removal and Installation.
ENGINE.
Figure 5-2. Engine and Dynamotor-Welder, R e m o v a l and Installation.
CONTROL CUBICLE.
Figure 5-3. Control Cubicle, Removal and Installation
Legend For FIGURE 5-3
Figure 5-4. S h o p Body, Removal and Installation.
Legend For FIGURE 5-4
Chapter 6. MAINTENANCE OF ELECTRICAL SYSTEM
Figure 6-1. 1 1 0 Volt Electrical Installation (Sheet 1 of 6).
Figure 6-1. 1 1 0 Volt Electrical Installation (Sheet 2 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 3 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 4 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 5 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 6 of 6).
Legend for Figure 6-1
Legend for Figure 6-1 - continued
Figure 6-2. 24 Volt DC Electrical Installation (Sheet 1 of 2).
Figure 6-2. 24 Volt DC Electrical Installation (Sheet 2 of 2).
Legend For Figure 6-2.
Figure 6-3. Service and Blackout Clearance Lights, Removal and Installation.
CONVENIENCE RECEPTACLES, LAMP BASES, AND TOGGLE SWITCHES.
Figure 6-4. Convenience Receptacles, Lamp Bases, and Toggle Switches.
CEILING AND BLACKOUT LIGHT.
Figure 6-7. L i g h t Assembly, Removal and Installation.
Figure 6-8. F r o n t Ventilator, Removal and Installation.
REAR VENTILATOR FAN ASSEMBLY.
Figure 6-10. R e a r Ventilators, Disassembly and Removal.
EMERGENCY POWER RECEPTACLE.
Legend For Figure 6-11.
EXTERNAL POWER RECEPTACLE - TM-9-4940-549-14-P0159
CLEARANCE LIGHTS. - TM-9-4940-549-14-P0160
Figure 6-13. Composite Light Assembly, Disassembly and Assembly.
JUNCTION BOX (24 V CIRCUIT).
Legend For Figure 6-14
REAR WIRING TO FLOODLIGHT.
Legend for Figure 6-15
Chapter 7. ENGINE ELECTRICAL SYSTEM
Figure 7-1. Batteries and Battery Box, Removal and Installation.
Table 7-1. State of Charge with Specific Gravity Corrected to 80F.
STARTER ASSEMBLY.
Disassembly - TM-9-4940-549-14-P0171
Figure 7-3. Starter, Disassembly and Assembly.
Legend for Figure 7-3. - TM-9-4940-549-14-P0173
Legend for Figure 7-3. - TM-9-4940-549-14-P0174
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0175
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0176
Assembly - TM-9-4940-549-14-P0177
Figure 7-4. Starter Assembly Motoring Test Circuit.
ALTERNATOR.
Figure 7-5. Alternator, Removal and Installation.
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0181
Legend for Figure 7-5.
Figure 7-6. Alternator, Disassembly and Assembly.
Legend for Figure 7-6.
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0185
Figure 7-7. Rotor Assembly Current Draw Test Circuit.
Assembly. - TM-9-4940-549-14-P0187
Testing - TM-9-4940-549-14-P0188
Figure 7-8. Alternator Test Leads Installation.
figure 7-11. Excitation Voltage Test
Testing - continued
Figure 7-12. Alternator Negative Output Circuit Test.
COOLANT TEMPERATURE TRANSMITTER.
Figure 7-15. Output and Voltage Protection Test.
0IL PRESSURE SENDING UNITS
Figure 7-16. Coolant Thermostat and Sensors, Removal and Installation.
Figure 7-17. Oil Sending Units, Removal and Installation.
Chapter 8. ENGINE FUEL SYSTEM
Figure 8-1. Fuel Tank, Lines, and Fittings, Removal and Installation.
Legend for Figure 8-1.
Fuel Transfer Pump.
Primary Fuel Filter.
Figure 8-3. Primary Fuel Filter, Removal and Installation.
Secondary Fuel Filter.
Figure 8-4. Secondary Fuel Filter, Removal and Installation.
Legend for Figure 8-4
Figure 8-5. F u e l Injection Pump, Removal and Installation.
Disassembly (Refer to figures 8-6 through 8-12).
Disassembly (Refer to figures 8-6 through 8-12) - continued - TM-9-4940-549-14-P0210
Figure 8-6. Fuel Injection Pump Governor.
Legend for Figure 8-6.
Figure 8-7. F u e l Injection Pump Linkage and Control.
Legend for Figure 8-7.
Figure 8-8. F u e l Injection Pump End Plates and Blades.
Figure 8-9. Fuel Injection Pump, Pivot Shaft and Arm Assembly.
Figure 8-10. F u e l Injection Pump Piston and Damper Spring.
Figure 8-11. F u e l Injection Pump Rotor Assembly.
Legend for Figure 8-11.
iFigure 8-12. F u e l Injection Pump Housing and Drive Shafts.
Legend for Figure 8-12.
Disassembly (Refer to figures 8-6 through 8-12) - continued - TM-9-4940-549-14-P0222
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0223
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0224
Assembly. - TM-9-4940-549-14-P0225
Assembly - continued - TM-9-4940-549-14-P0226
Assembly - continued - TM-9-4940-549-14-P0227
Assembly - continued - TM-9-4940-549-14-P0228
Assembly - continued - TM-9-4940-549-14-P0229
Assembly - continued - TM-9-4940-549-14-P0230
Fuel Injection Pump Bench Test.
Table 8-1. Fuel Delivery
Check delivery at 750 rpm
Installation - TM-9-4940-549-14-P0234
Fuel Injection Nozzle Holders and Lines.
Figure 8-14. F u e l Injection Lines and Fittings.
Legend for Figure 8-14.
Figure 8-15. F u e l Nozzle and Holder.
Lines Removal
Testing and Adjustment.
Figure 8-16. Quick Start System.
Chapter 9. ENGINE COOLING SYSTEM
Figure 9-1. Radiator and Support Rods.
Legend for Figure 9-1.
Figure 9-2. Front Support and Tie Rod.
DRAINING, FLUSHING, AND REFILLING THE RADIATOR.
RADIATOR HOSES AND TUBING.
FAN AND WATER PUMP ASSEMBLY.
Figure 9-3. F a n and Water Pump Assembly.
Legend for Figure 9-3.
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0252
Figure 9-4. Checking Impeller to Cover Plate Clearance.
Chapter 10. ENGINE LUBRICATION SYSTEM
Figure 10-1. Oil Filter and Hose Assembly.
Legend for Figure 10-1.
OIL PAN ASSEMBLY.
Figure 10-2. Oil Pan.
Disassembly - TM-9-4940-549-14-P0260
Figure 10-3. Oil Pump Assembly.
Assembly - TM-9-4940-549-14-P0262
Figure 10-4. Oil Pump Assembly Dimension.
Chapter 11. INTAKE AND EXHAUST SYSTEMS
Figure 11-1. Air Cleaner and Tube.
Legend for Figure 11-1.
INTAKE MANIFOLD.
Figure 11-2. Muffler and Cap.
Cleaning and Inspection. - TM-9-4940-549-14-P0270
Figure 11-3. Intake and Exhaust Manifolds.
Chapter 12. ENGINE ASSEMBLY
FLYWHEEL AND FLYWHEEL HOUSING.
Figure 12-1. Flywheel and Housing.
Installation - TM-9-4940-549-14-P0276
Figure 12-2. Checking Flywheel Concentricity and Alignment.
GEAR HOUSING AND COVER.
Figure 12-3. Gear Housing and Cover.
Legend for Figure 12-3.
Installation. - TM-9-4940-549-14-P0281
CYLINDER HEAD AND ROCKER ARM COVER.
Figure 12-4. Cylinder Head and Valve Mechanism.
Legend for Figure 12-4.
Cleaning, Inspection, and Repair - TM-9-4940-549-14-P0285
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0286
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0287
Assembly. - TM-9-4940-549-14-P0288
Figure 12-5. Rocker Arm Mounting Blocks Installation.
Figure 12-6. Rocker Arm Shaft Positioning.
Figure 12-7. Cylinder Head Nut Tightening Sequence.
Installation - TM-9-4940-549-14-P0292
Figure 12-8. Valve Tappet Clearance Adjustment.
Figure 12-9. Camshaft, Exploded View.
Disassembly - TM-9-4940-549-14-P0295
Figure 12-10. Dimensional Inspection of Camshaft.
Assembly - TM-9-4940-549-14-P0297
CRANKSHAFT, CONNECTING RODS, AND PISTONS.
Figure 12-11. Piston and Connecting Rods.
Figure 12-12. Cylinder Block Assembly (Sheet 1 of 2).
Figure 12-12. Cylinder Block Assembly (Sheet 2 of 2).
Legend for Figure 12-12.
Legend for Figure 12-12 - continued
Disassembly. - TM-9-4940-549-14-P0304
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0305
Table 12-1. Undersized Bearing Journals
Assembly. - TM-9-4940-549-14-P0307
Installation. - TM-9-4940-549-14-P0308
Installation - continued - TM-9-4940-549-14-P0309
CYLINDER BLOCK ASSEMBLY.
Assembly and Installation - TM-9-4940-549-14-P0311
Figure 12-13. Clutch and Cover.
Legend for Figure 12-13.
Cleaning, Inspection, and Repair - TM-9-4940-549-14-P0314
Figure 12-14. Clutch Assembly, Removal, Disassembly, Reassembly and Installation
Chapter 13. MAINTENANCE OF DYNAMOTOR-WELDER
END WRAPPERS.
DYNAMOTOR-WELDER BRUSH REPLACEMENT.
Figure 13-3. Dynamotor-Welder Brush Replacement and Tension
Adjustment
Figure 13-4. Overspeed Safety Switch Adjustment.
Figuer 13-5. Overspeed Safety Switch, Exploded View.
Legend for Figure 13-5.
ON-EQUIPMENT ELECTRICAL TESTS.
DYNAMOTOR-WELDER WORK TABLE.
Installation. - TM-9-4940-549-14-P0327
ARMATURE AND BEARINGS.
Testing.
FIELD COILS, POLE SHOES, BRUSH HOLDERS, AND MOUNTING RINGS.
Legend for Figure 13-9 (Sheet 1 of 3)
Figuer 13-9. Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders, and Mounting Rings, Exploded View (Sheet 2 of 3).
Legend for Figure 13-9 (Sheet 2 of 3)
Figuer 13-9. Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders, and Mounting Rings, Exploded View (Sheet 3 of 3).
Legend for Figure 13-9 (Sheet 3 of 3)
TERMINAL BOARDS.
Figure 13-14. Motor Terminal Board, Removal and Installation.
Chapter 14. MAINTENANCE OF AIR COMPRESSOR AND RELATED PARTS
Figure 14-1. Air Compressor and Drive Motor Assembly, Removal and Installation.
INLET AIR FILTER.
Figure 14-2. Inlet Filter, Exploded View.
COMPRESSOR STARTER CONTROL BOX.
PRESSURE SWITCH.
FRAME END COVER.
AIR COMPRESSOR.
Legend for Figure 14-7.
Figure 14-8. Low Pressure Cylinder Piston, Rod, and Rings, Exploded View.
Legend for Figure 14-8.
Figure 14-9.. High Pressure Cylinder, Pistons, Rod, and Rings, Exploded View.
Legend for Figure 14-9.
Figure 14-10. Crankshaft Assembly, Exploded View.
Legend for Figure 14-10.
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0354
Reassembly - TM-9-4940-549-14-P0355
Reassembly - continued - TM-9-4940-549-14-P0356
Reassembly - continued - TM-9-4940-549-14-P0357
BELT GUARD ASSEMBLY.
BELT TIGHTENER AND BASE ASSEMBLY.
Chapter 15. MAINTENANCE OF BODY COMPONENTS
Figure 15-2. Rear Door and Panel, Removal and Installation.
Legend for Figure 15-2.
Figure 15-3. Tent Frame, Removal and Installation.
UTILITY LADDERS
MILLING AND GRINDING ATTACHMENT.
Figuer 15-6. Valve Refacer, Removal and Installation.
Figure 15-7. 17-Ton Press Frame, Removal and Installation.
Figure 15-9. Vise, Removal and Installation.
LATHE BELT.
LATHE STAND.
Figure 15-12. Lathe Stand, Removal and Installation.
HINGED TABLE.
CABINET ASSEMBLY.
TRACK AND TROLLEY ASSEMBLY.
MISCELLANEOUS VAN BODY COMPONENTS.
Chpater 16. MAINTENANCE OF PERSONNEL HEATER
Legend for Figure 16-1.
Figure 6-2. Tent Curtains.
Chapter 17. MAINTENANCE OF SIDE LIFTING HYDRAULIC SYSTEM
Figure 17-1. Hydraulic Pump, Removal and Installation.
Installation - TM-9-4940-549-14-P0383
Figure 17-2. Side Lifting Cylinder and Hydraulic Hose, Removal and Installation.
SIDE LIFTING CYLINDERS AND HYDRAULIC LINES.
Figure 17-3. Side Lifting Cylinder, Exploded view.
SIDE LIFTING HYDRAULIC PUMP.
Legend for Figure 17-4.
Chapter 18. MAINTENANCE OF CONTROL CUBICLE
Legend for Figure 18-1.
GENERATOR OUTPUT CONTACTOR.
Figure 18-3. Generator Output Contactor, Exploded view.
Legend for Figure 18-3.
OVERLOAD SWITCH.
RESISTOR AND RELAY MOUNTING PANEL AND EMERGENCY POWER PANEL
Figure 18-5. Resistor and Relay Mounting Panel, and Emergency Power Panel.
Legend for Figure 18-5.
EXCITER BOOSTER.
Figure 18-6. Dynamotor - Welder Control Panel.
DYNAMOTOR SWITCH.
FREQUENCY METER.
RECEPTACLES.
POLARITY SWITCH.
AC VOLTAGE ADJUSTING RHEOSTAT.
Legend for 18-7. Upper Control panel
Figure 18-8. Lower Control Panel.
Figure 18-9. C o n t r o l Box and Coil Assembly, Removal and Installation.
Legend for Figure 18-9.
ENGINE INSTRUMENTS AND CONTROLS.
Legend for Figure 18-10.
Figure 18-11. Engine Control Panel, Left Hand.
Legend for Figure 18-11.
Chapter 19. TRAILER CHASSIS AND COMPONENTS
Figure 19-1. Tire and Rim.
TIRES AND WHEELS MAINTENANCE.
HUB BREAKDOWN AND WHEEL BEARINGS.
Figure 19-2. Hub and Drum.
Legend for Figure 19-2.
BRAKE ADJUSTMENT.
Figure 19-3. Brake Adjustment.
EMERGENCY RELAY VALVE.
Figure 19-4. Air Reservoir and Relay Valve.
BRAKE AIR LINES AND FITTINGS.
Figure 19-5. Front Air Brake Lines and Air Filter.
Legend for Figure 19-5.
Figure 19-6. Rear Air Brake Lines.
Legend for Figure 19-6.
Figure 19-7. Brake Air Chamber and Master Cylinder.
Legend for Figure 19-7.
BRAKE SHOES
Figure 19-8. Brake Shield and Shoe.
Legend for Figure 19-8.
BRAKE LINING REPLACEMENT.
Figure 19-9. Axle Assembly.
Legend for Figure 19-9.
TORQUE RODS.
Figure 19-10. Pivot Axle.
Legend for Figure 19-10.
LANDING GEAR.
Figure 19-11. Landing Gear, Removal and Installation.
Figure 19-12. Landing Gear.
Legend for Figure 19-12.
ENGINE ENCLOSURE.
Figure 19-13. Compartment Panels and Access Doors.
Legend for Figure 19-13.
Figure 19-14. Compartment Doors.
Legend for Figure 19-14.
Figure 19-15. Compartment Panel Brackets and Seal Assembly.
FRAME BRACKETS.
Figure 19-16. Frame and Brackets.
Legend for Figure 19-16.
Figure 19-17. Towing Pintle.
Legend for Figure 19-17.
Figure 19-18. Front Ladder.
Legend for Figure 19-18
Figure 19-19. Frame and Wiring.
Appendix A. REFERENCES - TM-9-4940-549-14-P0457
Appendix A. REFERENCES - continued - TM-9-4940-549-14-P0458
Appendix A. REFERENCES - continued - TM-9-4940-549-14-P0459
Appendix B. SHOP SET TOOL LOCATION LOADING AND PACKING LIST
Shop Set Contents
Shop Set Contents - continued - TM-9-4940-549-14-P0463
Shop Set Contents - continued - TM-9-4940-549-14-P0464
Shop Set Contents - continued - TM-9-4940-549-14-P0465
Shop Set Contents - continued - TM-9-4940-549-14-P0466
Shop Set Contents - continued - TM-9-4940-549-14-P0467
Shop Set Contents - continued - TM-9-4940-549-14-P0468
Shop Set Contents - continued - TM-9-4940-549-14-P0469
Appendix C. EXPENDABLE/CONSUMABLE MAINTENANCE SUPPLIES AND MATERIALS
TM-9-4940-549-14-P Shop Equipment General Purpose Semitrailer Mounted Model: SGPRSMD (NSN 4940-01-006-3229) Manual
Figre 1-1. Shop Set, Doors Closed
Figure 1-2. Shop Set, Doors Open.
Figure 1-3. Shop Set, Tent Installed.
DATA.
Tabulated Data. - TM-9-4940-549-14-P0038
Tabulated Data - continued - TM-9-4940-549-14-P0039
Tabulated Data - continued - TM-9-4940-549-14-P0040
Tabulated Data - continued - TM-9-4940-549-14-P0041
Table 1-1. Fits and Tolerance (Engine)
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0043
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0044
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0045
Table 1-1. Fits and Tolerance (Engine) - continued - TM-9-4940-549-14-P0046
Table 1-2. Manufacturer's Torque Values National Coarse
Chapter 2. OPERATING INSTRUCTIONS - TM-9-4940-549-14-P0049
Figure 2-1. Hydraulic System Controls.
Figure 2-2. Engine Controls and Instruments.
Manual Shutdown Control
Low Oil Pressure warning Light
Figure 2-3. Air Compressor Drive Motor Control and Air Receiver Tank Pressure Gage.
Figure 2-4. Electrical System Control Panel
Frequency Meter - TM-9-4940-549-14-P0056
240-Volt, 3-Phase, Circuit Breakers
Figure 2-5. Overspeed Safety Switch.
STOPPING THE ENGINE
Figure 2-6. Starting the Shop Set Engine.
Figure 2-7. Stopping the Shop Set Engine.
Operation on External (CITY) Power. - TM-9-4940-549-14-P0062
Figure 2-8. Personnel Heater Controls and Operation.
Operation with Power Selector Switch in OFF Position
Air Compressor Operation.
Drill Press Operation.
Section II. OPERATION OF AUXILIARY MATERIEL USED IN CONJUNCTION WITH THE SHOP SET
OPERATION IN EXTREME HEAT.
OPERATION UNDER RAINY OR HUMID CONDITIONS.
KW FORMULA FOR HIGH ALTITUDES
Chapter 3. OPERATOR/CREW MAINTENANCE INSTRUCTIONS - TM-9-4940-549-14-P0071
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0073
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0074
Section Ill. TROUBLESHOOTING
Table 3-2. Troubleshooting
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0077
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0078
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0079
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0080
Table 3-2. Troubleshooting - continued - TM-9-4940-549-14-P0081
Section IV. OPERATOR/CREW MAINTENANCE
LUBE OIL FILTER.
BODY ENCLOSURE COMPONENTS.
SIDE LIFTING HYDRAULIC SYSTEM.
Chapter 4. GENERAL MAINTENANCE INSTRUCTIONS
Figure 4-1. Shop Set Blocking and Tiedown Instructions.
Figure 4-2. Flatcar With Ramp In Place.
INSTALLATION OF SEPARATELY PACKED COMPONENTS.
Figure 4-3. Batteries, Removal, Installation and Service.
Erecting Tenting. - TM-9-4940-549-14-P0092
Figure 4-4. Raising and Lowering Shop Set Side Doors.
Figure 4-5. Opening Shop Set Rear Doors and Panels.
Figure 4-6. Laying Out Tent Framing.
Figure 4-7. Erecting Tent Framing (Sheet 1 of 2).
Figure 4-7. Erecting Tent Framing (Sheet 2 of 2).
Figure 4-8. Erecting Tenting (Sheet 1 of 3).
Figure 4-8. Erecting Tenting (Sheet 2 of 3).
Figure 4-8. Erecting Tenting (Sheet 3 of 3).
Figure 4-9. External Power Supply, Disconnection and Reconnection.
Figure 4-10. Grounding the Shop Set.
Figure 4-11. Voltage and Frequency Conversion.
Section III. MOVEMENT TO A NEW WORKSITE
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
Table 4-1. Quarterly Preventive Maintenance Checks and Services
Table 4-1. Quarterly Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0107
Table 4-1. Quarterly Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0108
Table 4-1. Quarterly Preventive Maintenance Checks and Services - continued - TM-9-4940-549-14-P0109
Table 4-2. Troubleshooting
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0111
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0112
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0113
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0114
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0115
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0116
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0117
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0118
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0119
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0120
Table 4-2. Troubleshooting - continued - TM-9-4940-549-14-P0121
Section VII. GENERAL MAINTENANCE
TESTING OF SUPPRESSION COMPONENTS.
Figure 4-12. Interference Suppression Components, Removal and Installation (Sheet 1 of 2).
Figure 4-12. Interference Suppression Components, Removal and Installation (Sheet 2 of 2).
Chapter 5. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 5-1. Engine Enclosure, Removal and Installation.
ENGINE.
Figure 5-2. Engine and Dynamotor-Welder, R e m o v a l and Installation.
CONTROL CUBICLE.
Figure 5-3. Control Cubicle, Removal and Installation
Legend For FIGURE 5-3
Figure 5-4. S h o p Body, Removal and Installation.
Legend For FIGURE 5-4
Chapter 6. MAINTENANCE OF ELECTRICAL SYSTEM
Figure 6-1. 1 1 0 Volt Electrical Installation (Sheet 1 of 6).
Figure 6-1. 1 1 0 Volt Electrical Installation (Sheet 2 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 3 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 4 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 5 of 6).
Figure 6-1. 110 Volt Electrical Installation (Sheet 6 of 6).
Legend for Figure 6-1
Legend for Figure 6-1 - continued
Figure 6-2. 24 Volt DC Electrical Installation (Sheet 1 of 2).
Figure 6-2. 24 Volt DC Electrical Installation (Sheet 2 of 2).
Legend For Figure 6-2.
Figure 6-3. Service and Blackout Clearance Lights, Removal and Installation.
CONVENIENCE RECEPTACLES, LAMP BASES, AND TOGGLE SWITCHES.
Figure 6-4. Convenience Receptacles, Lamp Bases, and Toggle Switches.
CEILING AND BLACKOUT LIGHT.
Figure 6-7. L i g h t Assembly, Removal and Installation.
Figure 6-8. F r o n t Ventilator, Removal and Installation.
REAR VENTILATOR FAN ASSEMBLY.
Figure 6-10. R e a r Ventilators, Disassembly and Removal.
EMERGENCY POWER RECEPTACLE.
Legend For Figure 6-11.
EXTERNAL POWER RECEPTACLE - TM-9-4940-549-14-P0159
CLEARANCE LIGHTS. - TM-9-4940-549-14-P0160
Figure 6-13. Composite Light Assembly, Disassembly and Assembly.
JUNCTION BOX (24 V CIRCUIT).
Legend For Figure 6-14
REAR WIRING TO FLOODLIGHT.
Legend for Figure 6-15
Chapter 7. ENGINE ELECTRICAL SYSTEM
Figure 7-1. Batteries and Battery Box, Removal and Installation.
Table 7-1. State of Charge with Specific Gravity Corrected to 80F.
STARTER ASSEMBLY.
Disassembly - TM-9-4940-549-14-P0171
Figure 7-3. Starter, Disassembly and Assembly.
Legend for Figure 7-3. - TM-9-4940-549-14-P0173
Legend for Figure 7-3. - TM-9-4940-549-14-P0174
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0175
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0176
Assembly - TM-9-4940-549-14-P0177
Figure 7-4. Starter Assembly Motoring Test Circuit.
ALTERNATOR.
Figure 7-5. Alternator, Removal and Installation.
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0181
Legend for Figure 7-5.
Figure 7-6. Alternator, Disassembly and Assembly.
Legend for Figure 7-6.
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0185
Figure 7-7. Rotor Assembly Current Draw Test Circuit.
Assembly. - TM-9-4940-549-14-P0187
Testing - TM-9-4940-549-14-P0188
Figure 7-8. Alternator Test Leads Installation.
figure 7-11. Excitation Voltage Test
Testing - continued
Figure 7-12. Alternator Negative Output Circuit Test.
COOLANT TEMPERATURE TRANSMITTER.
Figure 7-15. Output and Voltage Protection Test.
0IL PRESSURE SENDING UNITS
Figure 7-16. Coolant Thermostat and Sensors, Removal and Installation.
Figure 7-17. Oil Sending Units, Removal and Installation.
Chapter 8. ENGINE FUEL SYSTEM
Figure 8-1. Fuel Tank, Lines, and Fittings, Removal and Installation.
Legend for Figure 8-1.
Fuel Transfer Pump.
Primary Fuel Filter.
Figure 8-3. Primary Fuel Filter, Removal and Installation.
Secondary Fuel Filter.
Figure 8-4. Secondary Fuel Filter, Removal and Installation.
Legend for Figure 8-4
Figure 8-5. F u e l Injection Pump, Removal and Installation.
Disassembly (Refer to figures 8-6 through 8-12).
Disassembly (Refer to figures 8-6 through 8-12) - continued - TM-9-4940-549-14-P0210
Figure 8-6. Fuel Injection Pump Governor.
Legend for Figure 8-6.
Figure 8-7. F u e l Injection Pump Linkage and Control.
Legend for Figure 8-7.
Figure 8-8. F u e l Injection Pump End Plates and Blades.
Figure 8-9. Fuel Injection Pump, Pivot Shaft and Arm Assembly.
Figure 8-10. F u e l Injection Pump Piston and Damper Spring.
Figure 8-11. F u e l Injection Pump Rotor Assembly.
Legend for Figure 8-11.
iFigure 8-12. F u e l Injection Pump Housing and Drive Shafts.
Legend for Figure 8-12.
Disassembly (Refer to figures 8-6 through 8-12) - continued - TM-9-4940-549-14-P0222
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0223
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0224
Assembly. - TM-9-4940-549-14-P0225
Assembly - continued - TM-9-4940-549-14-P0226
Assembly - continued - TM-9-4940-549-14-P0227
Assembly - continued - TM-9-4940-549-14-P0228
Assembly - continued - TM-9-4940-549-14-P0229
Assembly - continued - TM-9-4940-549-14-P0230
Fuel Injection Pump Bench Test.
Table 8-1. Fuel Delivery
Check delivery at 750 rpm
Installation - TM-9-4940-549-14-P0234
Fuel Injection Nozzle Holders and Lines.
Figure 8-14. F u e l Injection Lines and Fittings.
Legend for Figure 8-14.
Figure 8-15. F u e l Nozzle and Holder.
Lines Removal
Testing and Adjustment.
Figure 8-16. Quick Start System.
Chapter 9. ENGINE COOLING SYSTEM
Figure 9-1. Radiator and Support Rods.
Legend for Figure 9-1.
Figure 9-2. Front Support and Tie Rod.
DRAINING, FLUSHING, AND REFILLING THE RADIATOR.
RADIATOR HOSES AND TUBING.
FAN AND WATER PUMP ASSEMBLY.
Figure 9-3. F a n and Water Pump Assembly.
Legend for Figure 9-3.
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0252
Figure 9-4. Checking Impeller to Cover Plate Clearance.
Chapter 10. ENGINE LUBRICATION SYSTEM
Figure 10-1. Oil Filter and Hose Assembly.
Legend for Figure 10-1.
OIL PAN ASSEMBLY.
Figure 10-2. Oil Pan.
Disassembly - TM-9-4940-549-14-P0260
Figure 10-3. Oil Pump Assembly.
Assembly - TM-9-4940-549-14-P0262
Figure 10-4. Oil Pump Assembly Dimension.
Chapter 11. INTAKE AND EXHAUST SYSTEMS
Figure 11-1. Air Cleaner and Tube.
Legend for Figure 11-1.
INTAKE MANIFOLD.
Figure 11-2. Muffler and Cap.
Cleaning and Inspection. - TM-9-4940-549-14-P0270
Figure 11-3. Intake and Exhaust Manifolds.
Chapter 12. ENGINE ASSEMBLY
FLYWHEEL AND FLYWHEEL HOUSING.
Figure 12-1. Flywheel and Housing.
Installation - TM-9-4940-549-14-P0276
Figure 12-2. Checking Flywheel Concentricity and Alignment.
GEAR HOUSING AND COVER.
Figure 12-3. Gear Housing and Cover.
Legend for Figure 12-3.
Installation. - TM-9-4940-549-14-P0281
CYLINDER HEAD AND ROCKER ARM COVER.
Figure 12-4. Cylinder Head and Valve Mechanism.
Legend for Figure 12-4.
Cleaning, Inspection, and Repair - TM-9-4940-549-14-P0285
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0286
Cleaning, Inspection, and Repair - continued - TM-9-4940-549-14-P0287
Assembly. - TM-9-4940-549-14-P0288
Figure 12-5. Rocker Arm Mounting Blocks Installation.
Figure 12-6. Rocker Arm Shaft Positioning.
Figure 12-7. Cylinder Head Nut Tightening Sequence.
Installation - TM-9-4940-549-14-P0292
Figure 12-8. Valve Tappet Clearance Adjustment.
Figure 12-9. Camshaft, Exploded View.
Disassembly - TM-9-4940-549-14-P0295
Figure 12-10. Dimensional Inspection of Camshaft.
Assembly - TM-9-4940-549-14-P0297
CRANKSHAFT, CONNECTING RODS, AND PISTONS.
Figure 12-11. Piston and Connecting Rods.
Figure 12-12. Cylinder Block Assembly (Sheet 1 of 2).
Figure 12-12. Cylinder Block Assembly (Sheet 2 of 2).
Legend for Figure 12-12.
Legend for Figure 12-12 - continued
Disassembly. - TM-9-4940-549-14-P0304
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0305
Table 12-1. Undersized Bearing Journals
Assembly. - TM-9-4940-549-14-P0307
Installation. - TM-9-4940-549-14-P0308
Installation - continued - TM-9-4940-549-14-P0309
CYLINDER BLOCK ASSEMBLY.
Assembly and Installation - TM-9-4940-549-14-P0311
Figure 12-13. Clutch and Cover.
Legend for Figure 12-13.
Cleaning, Inspection, and Repair - TM-9-4940-549-14-P0314
Figure 12-14. Clutch Assembly, Removal, Disassembly, Reassembly and Installation
Chapter 13. MAINTENANCE OF DYNAMOTOR-WELDER
END WRAPPERS.
DYNAMOTOR-WELDER BRUSH REPLACEMENT.
Figure 13-3. Dynamotor-Welder Brush Replacement and Tension
Adjustment
Figure 13-4. Overspeed Safety Switch Adjustment.
Figuer 13-5. Overspeed Safety Switch, Exploded View.
Legend for Figure 13-5.
ON-EQUIPMENT ELECTRICAL TESTS.
DYNAMOTOR-WELDER WORK TABLE.
Installation. - TM-9-4940-549-14-P0327
ARMATURE AND BEARINGS.
Testing.
FIELD COILS, POLE SHOES, BRUSH HOLDERS, AND MOUNTING RINGS.
Legend for Figure 13-9 (Sheet 1 of 3)
Figuer 13-9. Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders, and Mounting Rings, Exploded View (Sheet 2 of 3).
Legend for Figure 13-9 (Sheet 2 of 3)
Figuer 13-9. Dynamotor-Welder Frames, Field Coils, Pole Shoes, Brush Holders, and Mounting Rings, Exploded View (Sheet 3 of 3).
Legend for Figure 13-9 (Sheet 3 of 3)
TERMINAL BOARDS.
Figure 13-14. Motor Terminal Board, Removal and Installation.
Chapter 14. MAINTENANCE OF AIR COMPRESSOR AND RELATED PARTS
Figure 14-1. Air Compressor and Drive Motor Assembly, Removal and Installation.
INLET AIR FILTER.
Figure 14-2. Inlet Filter, Exploded View.
COMPRESSOR STARTER CONTROL BOX.
PRESSURE SWITCH.
FRAME END COVER.
AIR COMPRESSOR.
Legend for Figure 14-7.
Figure 14-8. Low Pressure Cylinder Piston, Rod, and Rings, Exploded View.
Legend for Figure 14-8.
Figure 14-9.. High Pressure Cylinder, Pistons, Rod, and Rings, Exploded View.
Legend for Figure 14-9.
Figure 14-10. Crankshaft Assembly, Exploded View.
Legend for Figure 14-10.
Cleaning, Inspection, and Repair. - TM-9-4940-549-14-P0354
Reassembly - TM-9-4940-549-14-P0355
Reassembly - continued - TM-9-4940-549-14-P0356
Reassembly - continued - TM-9-4940-549-14-P0357
BELT GUARD ASSEMBLY.
BELT TIGHTENER AND BASE ASSEMBLY.
Chapter 15. MAINTENANCE OF BODY COMPONENTS
Figure 15-2. Rear Door and Panel, Removal and Installation.
Legend for Figure 15-2.
Figure 15-3. Tent Frame, Removal and Installation.
UTILITY LADDERS
MILLING AND GRINDING ATTACHMENT.
Figuer 15-6. Valve Refacer, Removal and Installation.
Figure 15-7. 17-Ton Press Frame, Removal and Installation.
Figure 15-9. Vise, Removal and Installation.
LATHE BELT.
LATHE STAND.
Figure 15-12. Lathe Stand, Removal and Installation.
HINGED TABLE.
CABINET ASSEMBLY.
TRACK AND TROLLEY ASSEMBLY.
MISCELLANEOUS VAN BODY COMPONENTS.
Chpater 16. MAINTENANCE OF PERSONNEL HEATER
Legend for Figure 16-1.
Figure 6-2. Tent Curtains.
Chapter 17. MAINTENANCE OF SIDE LIFTING HYDRAULIC SYSTEM
Figure 17-1. Hydraulic Pump, Removal and Installation.
Installation - TM-9-4940-549-14-P0383
Figure 17-2. Side Lifting Cylinder and Hydraulic Hose, Removal and Installation.
SIDE LIFTING CYLINDERS AND HYDRAULIC LINES.
Figure 17-3. Side Lifting Cylinder, Exploded view.
SIDE LIFTING HYDRAULIC PUMP.
Legend for Figure 17-4.
Chapter 18. MAINTENANCE OF CONTROL CUBICLE
Legend for Figure 18-1.
GENERATOR OUTPUT CONTACTOR.
Figure 18-3. Generator Output Contactor, Exploded view.
Legend for Figure 18-3.
OVERLOAD SWITCH.
RESISTOR AND RELAY MOUNTING PANEL AND EMERGENCY POWER PANEL
Figure 18-5. Resistor and Relay Mounting Panel, and Emergency Power Panel.
Legend for Figure 18-5.
EXCITER BOOSTER.
Figure 18-6. Dynamotor - Welder Control Panel.
DYNAMOTOR SWITCH.
FREQUENCY METER.
RECEPTACLES.
POLARITY SWITCH.
AC VOLTAGE ADJUSTING RHEOSTAT.
Legend for 18-7. Upper Control panel
Figure 18-8. Lower Control Panel.
Figure 18-9. C o n t r o l Box and Coil Assembly, Removal and Installation.
Legend for Figure 18-9.
ENGINE INSTRUMENTS AND CONTROLS.
Legend for Figure 18-10.
Figure 18-11. Engine Control Panel, Left Hand.
Legend for Figure 18-11.
Chapter 19. TRAILER CHASSIS AND COMPONENTS
Figure 19-1. Tire and Rim.
TIRES AND WHEELS MAINTENANCE.
HUB BREAKDOWN AND WHEEL BEARINGS.
Figure 19-2. Hub and Drum.
Legend for Figure 19-2.
BRAKE ADJUSTMENT.
Figure 19-3. Brake Adjustment.
EMERGENCY RELAY VALVE.
Figure 19-4. Air Reservoir and Relay Valve.
BRAKE AIR LINES AND FITTINGS.
Figure 19-5. Front Air Brake Lines and Air Filter.
Legend for Figure 19-5.
Figure 19-6. Rear Air Brake Lines.
Legend for Figure 19-6.
Figure 19-7. Brake Air Chamber and Master Cylinder.
Legend for Figure 19-7.
BRAKE SHOES
Figure 19-8. Brake Shield and Shoe.
Legend for Figure 19-8.
BRAKE LINING REPLACEMENT.
Figure 19-9. Axle Assembly.
Legend for Figure 19-9.
TORQUE RODS.
Figure 19-10. Pivot Axle.
Legend for Figure 19-10.
LANDING GEAR.
Figure 19-11. Landing Gear, Removal and Installation.
Figure 19-12. Landing Gear.
Legend for Figure 19-12.
ENGINE ENCLOSURE.
Figure 19-13. Compartment Panels and Access Doors.
Legend for Figure 19-13.
Figure 19-14. Compartment Doors.
Legend for Figure 19-14.
Figure 19-15. Compartment Panel Brackets and Seal Assembly.
FRAME BRACKETS.
Figure 19-16. Frame and Brackets.
Legend for Figure 19-16.
Figure 19-17. Towing Pintle.
Legend for Figure 19-17.
Figure 19-18. Front Ladder.
Legend for Figure 19-18
Figure 19-19. Frame and Wiring.
Appendix A. REFERENCES - TM-9-4940-549-14-P0457
Appendix A. REFERENCES - continued - TM-9-4940-549-14-P0458
Appendix A. REFERENCES - continued - TM-9-4940-549-14-P0459
Appendix B. SHOP SET TOOL LOCATION LOADING AND PACKING LIST
Shop Set Contents
Shop Set Contents - continued - TM-9-4940-549-14-P0463
Shop Set Contents - continued - TM-9-4940-549-14-P0464
Shop Set Contents - continued - TM-9-4940-549-14-P0465
Shop Set Contents - continued - TM-9-4940-549-14-P0466
Shop Set Contents - continued - TM-9-4940-549-14-P0467
Shop Set Contents - continued - TM-9-4940-549-14-P0468
Shop Set Contents - continued - TM-9-4940-549-14-P0469
Appendix C. EXPENDABLE/CONSUMABLE MAINTENANCE SUPPLIES AND MATERIALS
TM-9-4940-549-14-P Shop Equipment General Purpose Semitrailer Mounted Model: SGPRSMD (NSN 4940-01-006-3229) Manual
