tm 9-803 willys-overland model mb and ford gpw, 1944

8/22/2019 TM 9-803 WILLYS-OVERLAND MODEL MB AND FORD GPW, 1944

1/243

ICALMANUAL

BRUARY1944

Publ

icDomain,Google-digitized

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CHNICALMANUAL

TB9-803-4,5January1944.ForsupersessionofQuartermasterCorpsIQ-series

ragraph1

EBRUAR Y1944

tPrintingOffice

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3/243

ebruary1944

k(Willys-OverlandModelMBandFord

orthe informationandguidanceofall

r43)]

TARYOFWAR:

ls,seeFM21-6)


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YS-OVERLANDMODEL

W)U

NSTRUCTIONS

..............15-9

ddata..2-3 10-12

ration.. 4-613-20

al

121-27

...12-1628-36

.17-1837-48

owageon

9-2149-51

INTENANCEINSTRUCTIONS

difications........2252

tive

353-67

......24-2668-72

2873

......29-4974-103

ata,

ment

-59104-115

nstallation60-61116-117

......62-69118-125

exhaust

78126-136

........79-86137-143

........87-90144-145

.........91-94146-149


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LANDMODELMB

m....

rsal

ers....

ession

storage


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STRUCTIONS

ispublishedfortheinformationand

personnelchargedwiththe operationand

riel.

ionofthe%-ton4x4Truck(Willys-

ordGPW),thismanualcontainstechnical

eidentification,use,andcareofthe mate-

nto twoparts.PartOne,sectionsI

cleoperatinginstructions.PartTwo,sec-

ntainsvehiclemaintenanceinstructions

rgedwiththe responsibilityofdoing

theirjurisdiction,includingradiosuppres-

porarystorageinformation.

atureoftherepair,modification,or

copeoffacilitiesofthe unit,therespon-

ouldbeinformedsothattrained personnel

pmentmaybeprovided,or properin-

eratingandorganizationalmainte-

efollowingQuartermasterCorps10-series

herwithTM9-1803AandTM9-1803B,

em:

1941.

1941.

942.

15January1943.

ructionswiththemateriel,thistechnicalmanualhas

eofcompletetechnicalreview.Anyerrorsoromissions

esor,if extensive,byanearlyrevision.


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RLANDMODELMB


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S-OVERLANDMODELMB


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YS-OVERLANDMODELMB

LATEDDATA

eneralpurpose,personnel,orcargo

bleforreconnaisanceor.command,and

ruck.Itis afour-wheelvehiclewith

neisa4-cylindergasolineunitlocatedin

nderthehoodatthefront ofthevehicle.

edtransmissionequippedwithatransfer

peedsfortraversingdifficultterrain.The

ithanopendriver'scompartment.The

dandstowed;and,the windshieldtilted

d,oropenedupwardandoutward.Aspare

s mountedontherearofthe body,anda

aul trailedloads.Specificationsofthe

ata"(par.3).Generalphysicalcharacter-

through4.

ufacturer'schassisserialnumberis

he leftframesidememberatthefront end,

g.6).Theengineserialnumberis stamped

nderblock,frontuppercorner.TheU.S.A.

tedonbothsides ofthehood.

9^4in.

0E

r)35 lb

front49in.

dingcrew5


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LATEDDATA

ater2,453Ib

el)2,337Ib

00Ib

in.

tanerating)Gasoline(68min)

bicfeet331

ds(mph)withtransfercasein

1

ds(mph)withtransfercasein

1

pet

right17%ft

1in.

one

930Ib

arhighrange)

verageconditions:....20

tydry5qt

q*

%qt


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YS-OVERLANDMODELMB

ential)1%.qt

ential)1%qt

euniversaljoint%qt

*

t

1qt

rakefluid).%qt

oz

radiooutletboxisprovidedon the

hiclebattery(6-volt currentsupply).This

ebodyside panelattherightfront seat.

OR.A12-volt,55-ampereauxiliarygen-

evehicles.Thegeneratoris drivenbya

offunitonthe rearofthetransfercase.

andcareaccompanythosevehicles.


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OPERATION

4

ntrolsinvehicularoperation5

ARMS

FTLEVER

EVERFRONTAXLEDRIVEAC

EVERAUXILIARYRANGEAD

TAG

OTTLE)

TSWITCH

H(BEAMCONTROL)

SWITCH

Controls

NTROLS.

mmeterontheinstrumentpanel

tflowwhenthe generatorischargingthe

stheamountofcurrentbeingconsumed

fuel gageontheinstrumentpanel


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YS-OVERLANDMODELMB

TDN4 4

DNANCE

MB.

FACTURER

LINE68MIN.

W32 FUSETDWS.A.E.

E 32"FUSE3DS.A.E.

TDTHISVEHICLE

4TON4X4

DNANCEDEPARTMENT

PW

FACTURER

OLINE68 MlN.

32 F.30S.AE.

W32F.10SAE.

TOTHISVEHICLE

/M1O-.

OADSPEEDS

OSITIONS

RCASEIN

NGE

M:OPEN

OCATEOONHOSEFITTINGAT

TORANOCYLINOER

GHTFORWAROSIOEOF


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OPERATION

dicatesthefuel levelinthetank,and

tionswitchis turnedon.

g.5).Theoil pressuregagelocated

dicatestheoil pressurewhentheengine

Thespeedometerontheinstrument

rhour thespeedatwhichthevehicleis

er(inupperpart ofspeedometerface)

ofmiles thevehiclehasbeendriven.A

ofspeedometerface)givesdistance

p indicatorbyturningtheknurledcon-

hbackofthespeedometer.

fig.5).Thetemperaturegageregisters

utionin thecoolingsystem.

GHTSWITCH(fig.5).Theblackout

RIVE)ontheinstrumentpanelcontrols

ocatedontheleft frontfender,tofurnish

koutperiods.Tooperatelight,first pull

uttontothe firstposition,thenpullblack-

b.Toswitchoff thelight,pushinblack-

b.

LY)

SwitchOperatingPositions

TCH(fig.5).Theknobontheinstru-

rolstheentirelighting,system,including

s,blackoutdrivinglight,andstop lights.

e,onthebackofthe switch,openswhen

closeswhenthethermostaticelementcools.

positionpush-pulltypewithasafetylock

nobis pulledouttothefirst position,the

ackoutstopandtaillightsareturnedon.


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YS-OVERLANDMODELMB

avelisautomaticallylockedinthisposition

eventaccidentallyturningonof the

blackoutarea.Toobtainservicelights,

buttonon theleftsideof theswitch,and

condposition.Whenswitchisinthisposi-

rvicestopandtaillightsareturned on,and

nedonbypullingout ontheknob

:Whendrivingduringthe day,press

andpullcontrolknobout tothelastor

only theregularstoplightto function.

ce

fig.5).Thepanellight switchknob

ontheinstrumentpanel,controlsthe

el instrumentsand^controls.Theblackout

bove)must beinservice(brightlight)

ontrolthe panellights.

g.5).Thefireextinguisheris mounted

or emove,pulloutwardontheclamp

xtinguisher,holdbodyinonehand and

to leftone-quarterturn,whichreleases

gactiontoforceliquidon baseoffire.Read

isherplate.


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OPERATION

hehandbrakeis appliedbypulling

enteroftheinstrumentpanel.Pullthe

sitionwhenthevehicleisparked.The

gthe handleone-quarterturn.

NGARMS(fig.5).Thewindshield

ntedoneachendofthe windshieldframe.

nknobsandpushforwardonlower part,

knobs.

(fig.5).Thewindshieldclampsace

f thewindshield.Pulluponboth clamps

hichthewindshieldcanbeloweredon top

okdownthewindshield,usingthehold-

softhe hood.

ig.10).Thegeneratorbracecanbe

non thefanbeltandstop thefanfrom

ginewhencrossingastream.Pull gen-

onas soonaspossiblethereafter,andit

N:Besurefanbelt isonpulleys.

ANDCONTROLS.Otherinstrumentsand

tionaltype,andareshownin figure5.

ANDCONTROLSINVEHICULAR

ce.Performtheservicesinparagraph

artthe engine.

the engineproceedasfollows:

hiftleverin neutralposition(fig.8).

uttonabout1/4inchto1 inch.

theway.NOTE:Chokingisnot

warm.

osition.

disengageclutch,andholdpedal

ed.

o crankagain.Releaseswitchas

lecontrolbuttonsto obtainproper

rmsup,pushchokebuttonall thewayin.

ereading;at idlespeedtheindicator

0 onthegage.

argereading.Checkfuelgagefor

atedafew minutes,checktemperature

ratingtemperatureisbetween160Fand

therrefertoparagraph7.

n.

non servicestoplight(par.4 b(2)).

t-handshiftleverin rearpositionto


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YS-OVERLANDMODELMB

nplacecentershiftleverin forwardposi-

e(fig.8).

ndmovetransmissionshiftlever

rdtoengagelow(1st)gear (fig.8).

brake.

ratortoincreaseenginespeed,andat

seclutchpedal,increasingpressureon

agesandvehiclestartstomove.NOTE:

tionsperformproceduresoutlinedinpara-

oximately10milesper hour,depress

metime releasepressureonaccelerator.

veroutoflow gearintoneutral,andthen

eclutchingisrequired.Releaseclutch

ne.

edaspeed ofapproximately20miles

rocedureasoutlinedabovein orderto

movingthegearshiftleverstraightback.

n Transmission.Shifttoalower

tolabor,as follows:Depressclutchpedal

gear,increaseenginespeed,releaseclutch

ate.Whenshiftingtoalowergearat any

esurethatthe enginespeedissynchronized

clutchisengaged.

rCase(fig. 8).Thetransfercaseis

risapplied tothefrontandrear axles.In

idedbythe transfercasefurtherincreases

idedbythe transmission.Theselectionof

heroad andloadconditions.Shiftgears

ordancewiththeshiftplate(fig.8),and

nthecautionplate(fig.7). Thetransmis-

anywayaffecttheselectionorshiftingof

ehiclemaybedrivenby rearaxle,orbyboth

ont axlecannotbedrivenindependently.

MENT.Frontaxleshouldbeengaged

ion,slipperyroads,steepgrades,orduring

ontaxlewhenoperatingonaverageroads

thTransferCasein "HIGH"Range.

"range,movefrontaxle driveshiftlever

gtheclutchpedalwill facilitateshifting.

ewithTransferCasein "HIGH"

veshiftleverto "OUT"position.Depress

eshifting.

ewhenTransferCaseisin "LOW."

enshifttransfercaselever into

verinto"OUT"position.


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OPERATION

daccelerateenginetodesiredspeed.

CASELOWRANGE.TransfercaseLOW

untilfrontaxledrive isengaged.

(subpar.e (1)above).

ndmovetransfercaseshift leverinto

ndaccelerateengine.

gainandmovetransfercaseshift lever

on.

ndaccelerateenginetodesiredspeed.

CASE"LOW"to"HIGH."Thisshift

vehiclespeed.

ndmovetransfercaseshift leverinto

ndaccelerateenginetodesiredspeed.

movefootfromaccelerator,and

gbrakepedal.

sbeenreducedto engineidlespeed,

movetransmissionshiftleverto"N"

etoa completestop,applyparking

clutchandbrakepedals..

Toshiftintoreversespeed,first bring

top.

tlevertothe leftandforwardinto

owly,andaccelerateasloadispicked

stop theengineturntheignition

OTE:Beforeaneworreconditioned

vice,makerun-intestsasoutlinedinsec-

owvehicleattachthechain,ropeor

ar attheframesiderail gusset(fig.11).

eofthebumper.Toattachtowline, loop

opof bumper,bringtowlineupacross

onoppositeside offrame,thenhookortie.

Placetransfercase(aux.RANGE)

etothe rear("HIGH").Placefrontaxle

orward)position.Depressclutchpedal

nhigh(3rd) speed.Switchignition"ON,"

b(ifengineis cold),pulloutthrottleknob

ng(hand)brake,andtow vehicle.After


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YS-OVERLANDMODELMB

seclutchpedalslowly.Asenginestarts,

econtrolsanddisengageclutch,being

ngtowingvehicleortowline.

e.Whentowingadisabledvehicle

ditionaldamagewilloccur.

ND.

amaged,shifttransmissionandtrans-

onand followsteps(c)and(d)below.

aged,disconnectbothpropellershafts

byremovingtheuniversaljointU-bolts,

e bearingracesandrollers.Securelyfasten

thwireorremovedustcapand pullapart

s.Placebolts, nuts,rollers,andracesin

ntialorpropellershaftisdamaged,

vingflanges.Placefrontaxledriveshift

ositionanddrivevehicleunderown

ntialisdamaged,removetherearaxle

lershaftatrear universaljointU-boltsand

ngsin forwardflange,thendriveout

xledriveshiftleverin "IN"(rear)position

ledrivetopropelvehicleunderown

nlyisdamaged,removeasdescribed

HFRONTORREARWHEELSOFF

towedin thismannerbesurethat transfer

"N"(neutral)positionandfrontaxle

n"OUT"(disengaged)position.


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SUALCONDITIONS

7

EATHER.

utomotiveequipmentatsubzero

oblemsthatdemandspecialprecautionsand

mbothoperationandmaintenanceperson-

ndtotalfunctionalfailureareto beavoided.

ofgasolineis designedtoreducecold

es;therefore,thewintergrademotorfuel

atheroperation.

Gasoline.Dueto condensationof

erwillaccumulateintanks,drums,and

atures,thiswaterwillformicecrystalsthat

buretorjetsiunlessthefollowingprecau-

filterpaper,oranyothertype of

epassageof water.CAUTION:Gasoline

eratesstaticelectricitythatwillresultin a

ovidedtogroundthe electricity.Always

betweenthecontainerandthetank,to

d.

ble.Themorefuelthereisin thetank,

umeofairfromwhichmoisturecanbe

redalcohol,Grade3,tothefueltank

willreducethehazardof iceformationin

nersarethoroughlycleanandfreefrom

them.

ormovingacontainer,allowthefuel

tankfromit.

ntainerstighttopreventsnow,ice,dirt,

omentering.

omdispensingequipmentandfrom

eforeremovingcapto refuelvehicle.

IFFERENTIAL.


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YS-OVERLANDMODELMB

t,SAE80,wherespecifiedonfigure14,

eraturesaslowas 20F.Ifconsistent

nticipated,drainthegearcaseswhile

e75 universalgearlubricant,whichissuit-

mperaturesbelow+32F.IfGrade75

notavailable,SAE80 universalgearlubri-

sed bytheengine,inthe proportionofone

rsalgearlubricant,maybeused.Dilute

oportionbeforeit isaddedtogearcases.

armedup,engageclutch,andmain-

dlefor5minutes,or untilgearscanbe

ninlow(first)gear,and drivevehiclefor

ottostall engine.Thiswillheatgearlubri-

rmaloperationcanbe expected.

catechassispointswithgeneral

ING.Drainhousjng,ifpossible,oruse

muchlubricantas possible.Refillwithuni-

e75,or,if notavailable,SAE80universal

fuelusedin theengine,intheproportion

sSAE80universalgear lubricant.Dilute

oportionbeforeit isaddedtothe housing.

canpointswhereengineoilis pre-

ightlubricating,preservativeoil.

stems.

POUND.Protectthesystemwithanti-

ne-glycoltype)foroperationbelow+32F.

applytouseofnew antifreezecompound.

EM.Beforeaddingantifreezecompound,

andcompletelyfreeitfromrust.If thecool-

edrecently,itmaybe necessaryonlyto

er,andagaindrain. Otherwisethesystem

aningcompound.

tallhoses,andreplaceifdeteriorated.

ugs,andpetcocksandtighten ifnecessary.

foreaddingantifreezecompound.Correct

or airintothecoolingsystem.

MPOUND.Whenthecoolingsystemis

stemwithwatertoaboutone-thirdcapacity.

ound,usingtheproportionofantifreeze

ystemcapacityindicatedbelow.Protect

Fbelowthelowesttemperatureexpectedto

winterseason.


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SUALCONDITIONS

CHART

lingsystem)

teraddingantifreezecompound,fill

wthe fillerneck;thenstartandwarmthe

gtemperature.

LUTION.Stoptheengineandcheckthe

r,addingantifreezecompoundifrequired.

rvice,inspectthecoolantweeklyfor

drainand cleancoolingsystemthor-

onofthe requiredstrength.

stheonlyantifreezematerialauthor-

.

reezesolutionsbekeptclean.Useonly

arefreefromdirt, rust,andoil.

meter.Totestahydrometer,useone

totwopartswater.Thissolutionwill pro-

gof0F.

compoundonpaintedsurfaces.

ANKINGMOTOR.Checkthebrushes,

gs.Seethatthecommutatorsareclean.The

choccurwhenstartinga coldengine

eenbrushesandcommutators.

andtightenallconnections,especially

eshouldbetakenthat noshortcircuitsare

perfunctioningbynotingqualityof

horoughly,andcleanorreplacepoints.

y.Incoldweather,slightlypittedpoints

starting.

ndadjustorreplace,if necessary.Ifit

ne fire,reducethegapto0.005inch less

ornormaloperation(par.67b).This will

veat.-educedvoltageslikelytoprevail.


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YS-OVERLANDMODELMB

y.Careshouldbetakenthatthespark

rretarded.

iesdecreasessharplywithdecreasing

mespracticallynilat 40F.Donottry to

batterywhenithasbeenchilledto tem-

ntilbatteryhasbeen heated,unlessawarm

Seethatthe batteryisalwaysfully

eterreadingbetween1.275and1.300.A

otfreezeat temperatureslikelytobe

cclimates,butafullydischargedbattery

+5F.

atterywhenit hasbeenexposedto

essthebatteryisto bechargedimmediately.

atterynotputon charge,thelayerofwater

ezebeforeithas achancetomixwith

tscarefully.Checkforshortcircuits

aroundsockets.

seethat thesparkplugs,wiring,or

tisfreefromice.

Engine.

OTORMECHANISM.Besurethatno

eenleftonthecrankingmotorthrowout

eordirtisliableto keepthegearsfrombeing

remainin meshaftertheenginestartsrun-

ecrankingmotorandnecessitaterepairs.

okeis necessarytosecuretherich

orcoldweatherstarting.Checkthebutter-

esallthe way,andotherwisefunctions

ELPUMP.Thecarburetor,whichwill

eatnormaltemperatures,isliablenot to

wtemperatures.Besurethefuelpumphas

gm,asthis willpreventthefuelpumpfrom

elrequiredto starttheengineatlow

ngspeedsarereducedto30to 60revolu-

peraturesbelow0Fdonotuseoil in

gealand preventtheeasyflowofair.

ingsolvent,dry,andreplace.Iceandfrost

erscreenscancausean abnormallyhigh

uretorairhornhose,resulting incollapse.

eandcleansedimentbulb,strainers,

anksumpdailyto removewateranddirt.


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SUALCONDITIONS

.Observethefollowingprecautionsin

tingprocedure(par.5 aandb).

outsideof sparkplugsofdirtand

onpost andcleanpoints.

closesfully.

vertofill carburetorbowl(fig.

rankor useslavebattery.

ureshowsongage.

ndOperation

uptransmissionoil beforeattempting

nforpropercondition(par.13b (22)).

bands,particularlyonnewvehicles,

hentheyare verycold.Alwayshavea

uptheseparts,if theybindpriortomov-

,thevehicle.Parkingthevehiclewith the

temostofthebinding.Precautionmustbe

stances,toblockthewheelsorotherwise

vehicle.


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YS-OVERLANDMODELMB

RATURESONMETALS.Inspectthe

resistanceofmetals,orresistanceagainst

edatextremelylowtemperatures.Operation

groundcausesstrainand joltingwhichwill

ornuts jarringloose.

EDisconnecttheoil-lubricatedspeed-

nd whenoperatingthevehicleattempera-

.Thecablewilloftenfail toworkproperly

dsometimeswillbreak,duetothe excessive

cosityof theoilwithwhichit islubricated.

ATHER.

extremelyhotweatheravoidthe

ratioswheneverpossible.Checkand

uently.Ifa floodedconditionofthe

arting,pullthe throttlecontrolout,push

hecrankingmotor.Whenenginestarts,

stformationoccursmorerapidlydur-

erefore,addrustpreventivesolutiontothe

ndflushthesystemat frequentintervals.

ethevehicleforhotweatheroperation

Checkthebatterysolutionlevelfre-

roperation,andaddwateras requiredto

eplates.Ifhard startingisexperiencedin

kchangesintemperature,drythespark

eandoutside ofdistributorcap.

pressuresindesertterrainif character

aution.Whenoperatinginsanddeep

alowergear,donot exceedthespeed

ateforthe particulargearratio(fig.7).

enstartingthevehiclein sand,

agethefront wheeldrive(par.5e(1)).

ysothewheelswillnot spinand"digin,"

ch-out."

o"jump"or "rock"thevehicleout

oftheclutch,particularlyifa toworwinch

gineusuallycausesthewheelsto "digin"

itorycleanthe carburetoraircleaner

yofcleaningdependsupontheseverityof


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SUALCONDITIONS

ationchecktheradiatorcoolantsupply

eair passagesofthecoredonot become

onontechniqueofoperatingthe

31-25.

NG.

ossibleaftercompletinga landingor

tthevehicleforwaterin thevariousunits.

necrankcaseoil.If waterorsludge

sing amixtureofhalfengineoil SAE10

puttinginnewoil,cleanthe valvechamber,

er,andinstallanew filterelement.

thecarburetorbowl,fuelstrainers,

andlines.Cleanthe aircleanerand

tthefrontandrearaxle housings,

sion,andtransfercaselubricantforpresence

d,renewthelubricantaftercleaningthe

fengineoilSAE10 andhalfkerosene.

aftuniversaljointsandspringshacklesto

mightdamageparts.

vemeasuresagainstchemicalattacks

ertoFM17-59.


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YS-OVERLANDMODELMB

VEMAINTENANCESERVICE

13

14

lyservice16

fficiencyitisnecessarythatthevehicle

edatintervalseachdayitis operated,also

aybediscoveredandcorrectedbeforethey

failure.Certainscheduledmaintenance

atthesedesignatedintervals.Theservices

ethoseperformedbydriverorcrewbefore

on,athalt,andafteroperationandweekly.

enanceservicesarelistedontheback

PreventiveMaintenanceService

8,tocovervehiclesofalltypesand models.

ehicles,butnotlistedon W.D.FormNo.

proceduresundertheitems towhichthey

stedonthe formthatdonotpertainto

minatedfromtheproceduresaswritten

anizationmustthoroughlyschooleach

aintenanceproceduressetforthinmanuals,

ecificallyonW.D.FormNo.48 ornot.

D.FormNo.48thatapplyto this

smanualto providespecificprocedures

einspectionsandservices.Theseservices

spectionandconservethetimeof the

arily,inthe samenumericalorderasshown

temnumbers,however,areidenticalwith

ofeachitemappliesalso toanysup-

ction,andgenerallyincludesachecktosee

odcondition,correctlyassembled,secure,

dcondition"isusuallyan external

minewhethertheunitis damagedbeyond

Theterm"goodcondition"isexplained

otbentor twisted,notchafedorburned,

bareor frayed,notdentedorcollapsed,


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toseethatit is"correctlyassembled"

linspectionto seewhetherornotit isin

tioninthe vehicle.

todetermineifitis "secure"is

examination,ahand-feel,wrench,orpry-

uchaninspectionshouldincludeany

cknuts,lockingwires,orcotterpinsused

beunderstoodtomeanworn,close

mits,andlikelyto resultinfailureif not

cheduledinspection.

ctoryoperatingcharacteristicsbeyond

elontocorrectmustbereportedatthe

designatedindividualinauthority.

ERVICE.

eisdesignedprimarilyasa checkto

t beentamperedwithorsabotagedsince

ewasperformed.Variouscombatcondi-

hevehicleunsafeforoperation,andit is

eterminewhetherornotthe vehicleisin

missionto whichitisassigned.This

yomitted,evenin extremetactical

erationServiceconsistsofinspecting

ngtotheproceduredescribed,andcorrect-

ncies.Uponcompletionoftheservice,

promptlytothe designatedindividualin

DDAMAGE.Examineexteriorof

rakes,andsteeringcontrolfordamageby

botage,orcollision.If wet,drytheignition

g.

SHER.Besurefireextinguisheris full,

ngssecure.

WATER.Checkfueltank,crankcase,

ampering.Addfuel,oil,orwateras

freezechecked.If,duringperiodwhen

mesnecessarytoreplenisha considerable

usuallosses.

ANDDRIVES.,Inspectcarburetor,gener-

motor,andwaterpumpforlooseconnec-

tings.Inspectcarburetorandwaterpump

AL.Lookongroundundervehiclefor

er,brakefluid,orgear oilleaks.Trace

ctorreportto higherauthority.


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YS-OVERLANDMODELMB

UP.Startengine,observecranking

sualnoise,andnotecrankingspeed.Idle

run smoothly.Proceedimmediatelywith

ngineiswarmingup.

newarms,pushin chokeasrequired

topreventoildilution.

S.

ouldindicateapproximateamount

maloil pressureshouldnotbebelow

hould rangefrom40to50 atrunning

ngtemperature).Ifgagefailsto register

gine,andcorrectorreport tohigher

.Temperatureshouldriseslowlydur-

atingtemperaturerangeis160Fto185F.

ouldshowhighchargeforshortperiod

plus)readingabove12 to15milesper

soriesoff.Zeroreadingis normalwith

NDSHIELDWIPERS.Soundhorn,tacti-

rproperoperationandtone.Checkboth

entandnormalfullcontactoperation

EARVIEWMIRROR.Cleanwindshield

spectfor cracked,discolored,orbroken

REFLECTORS.Tryswitchesineach

espond.Lightsandwarningreflectorsmust

an,andingoodcondition.Testfootcontrol

FLANGENUTS.Observewhetherornot

e presentandtight.

epermits,testtireswithgage,includ-

eis35 poundswithtirescold.Inspecttread

uises.Removeimbeddedobjectsfrom

DSUSPENSION.Inspectspringsfor

hiftedleaves,andlooseor missingrebound

NKAGE.Examinesteeringgearcase,

anarmforsecurityandgoodcondition.

andfreemotionofsteeringwheel.

DBUMPERS.Examinefendersand

tingandserviceablecondition.


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NNECTIONS.Examinepintlehookfor

ceablecondition.Besurepintlelatches

y.

OAD.Examinebodyandload(if any)

s acaponfrontdrain holeunderfuel

le capisavailableinglovecompartment.

capshouldbeinstalledwhenaboutto

NATOR.Examinedecontaminatorfor

untings.

EQUIPMENT.Seethattoolsandequip-

erlystowed,andserviceable.

RMITANDFORM26.Drivermusthave

person.Seethatvehiclemanuals,Lubri-

(accidentreport)andW.D.AGOForm

nitAssemblyReplacementRecord)are

erlystowed.

RATION.Accelerateengineandobserve

ngcompressionorexhaustleaks;worn,

equatelylubricatedpartsormisfiring.

ERATIONSERVICE.BegintheDuring-

atelyafterthevehicleisputinmotion.

ERVICE.

on,listenforanysoundssuchas rattles,

hatmayindicatetrouble.Lookforindi-

gsystem,andsmokefromany partofthe

detectanyodorofoverheatedcomponents

r,brakes,orclutch;checkforfuelvapor

,exhaustgas,orothersignsoftrouble.

ed,gears shifted,orvehicleturned,con-

eanyunsatisfactoryorunusualperform-

ntsfrequently.Noticepromptlyanyun-

nthatmaysignifypossibletroublein

mentapplies.

erationServiceconsistsofobserving

ngtotheproceduresfollowingeachitem,

cationsofserioustrouble.Noticeminor

edorreportedatearliestopportunity,usually

NDBRAKES.Footbrakesmuststop

sidepullandwithinreasonabledistance.

sreservebrakepedaltravelandy2-inch

stsecurelyholdvehicleonreasonable

hettravel.Theremustbe 54-inchclear-

elaycrankandlowerendof handbrake


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YS-OVERLANDMODELMB

chmustoperatesmoothlywithout

ng.Freeclutchpedaltravelofthree-

N.Gearshiftmechanismmustoperate

utofmesh.

ASE.Gearshiftmechanismmustoperate

tofmesh.

ONTROLS.Observewhetherornot

s,andhasmaximumpullingpowerwithout

isfiring,overheatingorunusualexhaust

portedduringoperationofthevehicle,the

heradiooperatorin locatingtheinter-

78.

S.Duringoperationobservetheread-

uentlyto seeiftheyareindicating

ustregister approximateamountof

ressuregage shouldregister10with

0to 50atoperatingspeeds.

.Temperatureindicatorshouldshow

185Fafter warm-upundernormalcon-

metershouldshowspeedofvehicle

nofindicatorneedle.Odometershould

andtotalmileage.

ouldshowzeroreadingwithlightson,

gewith lightsoff,andslightlyhigher

horttimeimmediatelyafterstarting.

AR.Observesteeringforexcessivepull-

e,wandering,orshimmy.

enforunusualnoises fromwheelor

vebodyforsaggingsprings,looseor

er,if inuse.

egardedasthe minimummainte-

uldbeperformedunderalltacticalcondi-

xtensivemaintenanceservicesmustbe

her.

viceconsistsofinvestigatingany

operation,inspectingitemslistedbelow

esfollowingtheitems,andcorrectingany

enciesnotcorrectedshouldbereported

dindividualinauthority.


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DWATER.Checkfuelsupply,oil,and

forcompleteoperationofvehicletothe

ngperiodwhenantifreezeis used,an

risrequiredto refillradiator,havecoolant

ndaddantifreezeifrequired.

ES.Feeleachbrakedrumandwheel

ercase,andfrontandrearaxlesfor over-

sesforexcessiveoilleaks.

ANSFERCASEVENTS.Observewhether

tsarepresent,and seethattheyarenot

HAFT.Inspectpropellershaftforloose-

kforbrokenspringleaves orloose

KAGE.Examinesteeringcontrol

ordamageorlooseness.Investigateany

operation.

LANGENUTS.Observewhetherornot

uts arepresentand-tight.

cttires,includingspare,for flatsor

eignmaterialimbeddedin tread.

RAL.Checkaroundengineandon

eforexcessiveleaks.Tracetosource,and

igherauthority.

ESANDBELTS.Seethatfan,waterpump

ymounted,thatfanbeltis adjustedto

otbadlyfrayed.Ifradio noiseduring

sobserved,examineallradionoise sup-

l,ignitionandstartingswitches,generator,

nalbox;suppressorsatsparkplugs and

apsfor damage,andloosemountingsor

R.Ifdustyor sandyconditionshave

neoilsumpforexcessivedirt.Serviceif

tapplyoiltoelementaftercleaning.

DBUMPERS.Inspectfendersand

amage.

NNECTIONS.Inspectpintlehookand

ceability.

ANDTARPAULIN.Inspectvehicleand

fting;seethat tarpaulinsareproperly

.

EANDGLASS.Cleanwindshield,mirror,

ehiclefordamage.


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YS-OVERLANDMODELMB

DWEEKLYSERVICE.

eisparticularlyimportantbecauseat

shis vehicletodetectanydeficienciesthat

correctsthoseheispermittedto handle.

,tothedesignatedindividualin authority,

on.Ifthisscheduleisperformedthoroughly,

yto rollagainonshortnotice.TheBefore-

ewexceptions,isthennecessaryonlyto

icleisinthe sameconditioninwhichitwas

eAfter-operationService.TheAfter-

everbeentirelyomitted,eveninextreme

ybereduced,ifnecessary,tothebare

inedfortheAt-haltService.

ormingtheAfter-operationServicethe

dconsideranyirregularitiesnoticedduring

eration,During-operation,andAt-haltServ-

Serviceconsistsofinspectingandservicing

itemsoftheAfter-operationServicethat

*) requireadditionalWeeklyService,the

ndicatedinstep(b) ofeachapplicable

DWATER.Checkcoolantandoil

Fillfuel tank.Refillsparecans.During

sed,havehydrometertestmadeof coolant

rcausehasbeenconsiderable.Addanti-

d.

ATION.Listenformiss,backfire,noise,

catewornparts,loose mountings,faulty

on.

S.Inspectallinstrumentstoseethat

ed,andnotdamaged.

NDSHIELDWIPERS.Testhornfor

permits.Seethathornis securelymounted

Operatebothwindshieldwipers.Seethat

fectivelythroughoutfullstroke.

EARVIEWMIRROR.Cleanglassof

mirror.Examineforsecuremountingand

EFLECTORS.Observewhetherornot

htheswitchin "ON"positions,andgoout

tstop lightoperatesproperly.Cleanlenses

ISHER.Besurefireextinguisheris

t extinguisherismountedsecurely.

ATOR.Examinedecontaminatorfor

emounting.


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an,securelymounted,andnotleaking.

whichshouldbe54mchaboveplateswith

en.Cleancablesas required.

ttery.Removebatterycaps,andadd

es.(Use distilledwaterifavailable;ifnot

r.)CAUTION:Donotoverfill.Cleanposts

andapplylightcoat ofgrease.Tighten

tenhold-downassembly.Cleanbattery

IESANDBELTS.

tionof1inch.Examinebeltforgood

yed.Timinghole covermustbeclosed

essoriessuchascarburetor,gener-

motor,fan,waterpump,andhoseconnec-

fraying,wear,cracking,orpresenceofoil.

LWIRING.

ingandaccessiblelowvoltagewiring

correctlyandsecurelyassembledand

sewiringconnectionsorelectrical

ularattentiontoradionoisesuppression

bondstraps,andsparkplug anddistributor

ER.

neroilcuptoseethat itisat proper

dirty.Cleanelementandrefilloil cupas

tapplyoiltoelementaftercleaning.

n,anddryaircleanerelementandoil

level(approximatelyfiqt).Donot

eaning.

RS.

aks.

rombottomofdash-mountedfuel

menttodrainout. Besureplugis replaced

TROLS.Examineenginecontrolsfor

age.

rabnormaltreadwear;removeforeign

o35 poundswhentiresarecold.

ywornorotherwiseunserviceabletires.

,brokenor shiftedleaves,looseor

hackles.

andtightenU-boltsandshacklesas


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YS-OVERLANDMODELMB

NKAGE.Examinesteeringwheel

narm,draglink,tierod,and steeringarm

se,orinadequatelylubricated.

SHAFT.Inspectpropellershaftand

onnections,lubricationleaks,ordamage.

RANSFERVENTS.

sfercaseventsareingood condition,

n,andreplacevents.

ERAL.Checkunderhoodandbeneath

offuel,oil,water,or brakefluidleaks.

VELS.Afterunitshavecooled,inspect

ndtransferunitlubricantlevels.Lubricant

mof fillerhole.Observegearcasesfor

DBUMPERS.Fendersandbumpers

nd secure.

NNECTIONS.

towed-loadconnectionsforlooseness

hookmountingbolts,andlubricate

ARPAULINS.Inspectbody,top,and

geandproperstowage.Makesurerear

pen,andthatcapisin glovecompartment.

el,axledriveflange,and springU-bolt

icleassemblyormountingnutsor

catesrequiretightening.

EASNEEDED.

esandsteeringlinkage,iflubrication

tsindicatedoncurrentvehicleLubri-

eeklyattention,alsopointsthatexperi--

ionsindicateneedlubrication.Observe

es.

INEANDVEHICLE.

ominsideofbody.Keepsumpunder

d water.Removeexcessivedirtorgrease

.

fpossible.Ifnot possible,wipeoff

EQUIPMENT.Checktoseethatalltools

ovehiclearepresentandsecure.


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ctions18

ationGuideNo.501(figs.13and 14)

ntenanceforthe14-ton4x4truck.

acedon orisissuedwith eachvehicle

atall times.Intheeventthevehicleis

theusingarmshall immediatelyrequisi-

eCommandingOfficer,FortWayneOrd-

ich.

sontheGuidearebindingon all

andthereshallbenodeviationsfromthese

edontheGuideare fornormaloper-

heseintervalsunderextremeconditions

rlowtemperatures,prolongedperiodsof

erationinsandordust, immersioninwater,

nyoneof whichmayquicklydestroythe

ubricantandrequireservicingin order

ordamagetothemateriel.

edinthe"Key"in accordancewith

;above+32F,+32Fto0F,andbelow

changegradesoflubricantsby maintain-

tionof thevehicleduringtheapproachto

particularlyobservantwhenstartingthe

sanindicationof thickenedlubricantsand

adesprescribedforthenextlowertempera-

be necessarytochangegradesoflubri-

raturesareconsistentlyinthe nexthigher

functioningoccurssoonerduetolubricants

y.

ONINSTRUCTIONS.

Eachpieceofmaterielissupplied

tadequatetomaintainthemateriel.Be

ntbothbefore andafteruse.Operate

andinsuchmannerasto insureaproper

t.

glubricationfittings,greasecups,

hemreadilyidentifiableonthevehicle.

rsandthesurroundingsurfacebeforelubri-


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YS-OVERLANDMODELMB


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S-OVERLANDMODELMB


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YS-OVERLANDMODELMB

erpipe.Checklevelotleostdoily.Keep

fivequorts;refillfourquorts.

AINING

.Atleost

element.Aftercompleting

nd refillcronkcosetoFULL

esfour.Useoilconforoilerond

dpost;greosecomlightly.

n,pushasideoil holecover.Oilond

ationPoints


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ALSHAFTCG

ugstwo(filleronddroin).Usegeor oil

ottomoffillerplughole.Copocity

ugstwo(filleronddroin). Usegeor

bottomoffillerplughole.Copocity

fittings one.Usepressureguni

RSALJOINTSCG

fittingsfour.Usepressuregun (hond)

onotusehighpressuregreasegun

s.

NTCG

stwo.Usepressure gunonfittings

ndPowerTrainLubricationPoints


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YS-OVERLANDMODELMB

geor

seight.Usebeoringlubricotororho

eoseolsooroundoutsideofcogeo

b,inspectbeoringroces,putthree oun

tm 9-803 willys-overland model mb and ford gpw, 1944

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