TM-9-2320-260-34-1
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 1 OF 2
JULY 1994
TM-9-2320-260-34-1 - Page 628 of 657
TM 9-2320-260-34-1
11-5. AIR COMPRESSOR REPAIR (Contd)
c. Inspection and Repair
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inspect narrow part of unloader cap (1) for scoring and excessive wear. Inspect unloader cap (1)
seating surface for distortion, pitting, and excessive wear. Replace unloaded cap (1) if scored,
distorted, pitted, or excessively worn.
Inspect unloader valve spring (2) for wear. Measure unloader valve spring (2). Refer to table 11-3,
Air Compressor Spring Wear Limits, for measurements. Replace unloader valve spring (2) if worn
past limits.
Inspect intake valve spring (3) for wear. Measure intake valve spring (3). Refer to table 11-3,
Air Compressor Spring Wear Limits, for measurements. Replace intake valve spring (3) if worn
past limits.
Inspect cylinder head cover (4) and cylinder head (6) for cracks, breaks, and bends. Replace cylinder
head cover (4) and/or cylinder head (6) if cracked, broken, or bent.
Inspect exhaust valve seat (5) for bends, cracks, breaks, and wear. Measure exhaust valve seat (5)
height. Refer to table 11-2, Air Compressor Wear Limits, for measurements. Replace exhaust valve
seat (5) if bent, cracked, broken, or worn past limits.
Inspect exhaust valve spring (7) for wear. Measure exhaust valve spring (7). Refer to table 11-3,
Air Compressor Spring Wear Limits, for measurements. Replace exhaust valve spring (7) if worn
past limits.
Inspect intake valve seat (8) for bends, cracks, breaks, and wear. Measure intake valve seat (8)
height and surface. Refer to table 11-2, Air Compressor Wear Limits, for measurements. Replace
intake valve seat (8) if bent, cracked, broken, or worn past limits.
Inspect crankshaft (12) for scratches, scoring, and excessive wear. Replace crankshaft (12) if
scratched, scored, or excessively worn.
Inspect crankshaft journals (9), (10), and (11) for wear. Measure crankshaft journals (9), (10),
and (11). Refer to table 11-2, Air Compressor Wear Limits, for measurements. Replace crank-
shaft (12) if any journal (9), (10), or (11) is worn past limits.
Table 11-2. Air Compressor Wear Limits.
ITEM
WEAR LIMITS/TOLERANCES
NO.
ITEM/POINT Of MEASUREMENT
INCHES
MILLIMETERS
5
Exhaust valve seat height - minimum
0.485
12.32
8
Intake valve seat
Height - minimum
0.270
6.86
Surface
0.001
0.03
9
Crankshaft journal - minimum
1.871
47.52
10
Crankshaft journal – minimum
1.871
47.52
11
Crankshaft journal - minimum
1.933
49.10
Table 11-3. Air Compressor Spring Wear Limits.
ITEM
WEAR LIMITS/TOLERANCES
NO.
ITEM/POINT Of MEASUREMENT
INCHES
MILLIMETERS
2
Unloader valve spring - minimum
12.00
304.8
3
Intake valve spring-minimum
0.55
14.0
6
Exhaust valve spring - minimum
8.00
203.2
11-16
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