This copy is a reprint which includes current pages from Change 1. TM 9-8000 TECHNICAL MANUAL PRINCIPLES OF AUTOMOTIVE VEHICLES DEPARTMENT OF THE ARMY 25 OCTOBER 1985 TM 9-8000 C 1 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY NO. 1 WASHINGTON,D.C., 14 NOVEMBER 1988 TECHNICAL MANUAL PRINCIPLES OF AUTOMOTIVE VEHICLES TM 9-8000, 25 October 1985, is changed as follows: 1. Remove old pages and insert new pages as indicated below. 2. New or changed material is indicated by a vertical bar in the margin of the page. Remove Pages Insert Pages 2-3 and 2-4 2-3 and 2-4 2-33 and 2-34 2-33 and 2-34 2-35 and 2-36 2-35 and 2-36 4-21 and 4-22 4-21 and 4-22 5-1 and 5-2 5-1 and 5-2 5-3 and 5-4 5-3 and 5-4 8-5 and 8-6 8-5 and 8-6 None 8-6.1 (8-6.2 Blank) 11-1 and 11-2 11-1 and 11-2 11-7 and 11-8 11-7 and 11-8 12-11 (12-12 Blank) 12-11 (12-12 Blank) 14-9 and 14-10 14-9 and 14-10 14-11 (14-12 Blank) 14-11 (14-12 Blank) 22-1 and 22-2 22-1 and 22-2 33-1 and 33-2 33-1 and 33-2 A-1 and A-2 A-1 and A-2 A-3 and A-4 A-3 and A-4 File this change sheet in front of the publication for reference purposes. TM 9-8000 By Order of the Secretary of the Army: CARLE.E. VUONO General, United States Army Official: Chief of Staff WILLIAM J. MEEHAN II Brigadier General, United States Army The Adjutant General Distribution: To be distributed in accordance with DA Form 12-37, Operator, Organizational, Direct and General Support Maintenance requirements for Carrier, Personnel, M113A1, Command Post, M577A1, Mortar, M06A1; Mortar, M125A1; Flame Thrower, M132A1; Gun, M741; Recovery Vehicle, XM1059. Also, to be distributed in accordance with DA Form 12-38, Operator, Organizational, Direct and General Support Maintenance requirements for Truck, Utility, ¼-ton, 4x4, M151-sees. TM 9-8000 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY NO. 9-8000} WASHINGTON, DC 25 October 1985 PRINCIPLES OF AUTOMOTIVE VEHICLES REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes, or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Tank-Automotive Command, ATTN: AMSTA-MB, Warren, MI 48397-5000. A reply will be sent to you. TABLE OF CONTENTS Page PART ONE INTRODUCTION...................................................................................................... 1-1 CHAPTER 1 GENERAL INFORMATION...................................................................................... 1-1 Section I. Purpose of Manual ................................................................................................... 1-1 Section II. Organization of the Manual ...................................................................................... 1-1 Section III. History of Military Vehicles ....................................................................................... 1-2 Section IV. Characteristics of Military Vehicles........................................................................... 1-2 Section V. Military Vehicle Categories....................................................................................... 1-3 Section VI. Classification of Vehicles.......................................................................................... 1-4 PART TWO ENGINES ................................................................................................................. 2-1 CHAPTER 2. PISTON ENGINE CHARACTERISTICS .................................................................. 2-1 Section I. Engine Operation ..................................................................................................... 2-1 Section II. Comparison of Engine Types................................................................................... 2-8 Section III. Classification of Piston Engines ............................................................................... 2-22 Section IV. Engine Measurements ............................................................................................. 2-27 Section V. Timing....................................................................................................................... 2-32 Section VI. Engine Output .......................................................................................................... 2-37 Section VII. Engine Efficiency...................................................................................................... 2-42 CHAPTER 3. CONVENTIONAL ENGINE CONSTRUCTION ........................................................ 3-1 Section I. Cylinder Blocks, Heads, and Crankcases ................ ................................................ 3-1 Section II. Rotating and Reciprocating Parts............................................................................. 3-8 Section III. Valves and Operating Mechanisms ......................................................................... 3-27 CHAPTER 4. GASOLINE FUEL SYSTEMS................................................................................... 4-1 Section I. Components and Their Purposes ............................................................................ 4-1 Section II. Principles of Carburetion.......................................................................................... 4-13 Section III. Construction of the Basic Carburetor ....................................................................... 4-15 Section IV. Systems of the Carburetor ....................................................................................... 4-17 Section V. Fuel Injection Systems for Gasoline Engines........................................................... 4-40 *This publication supersedes TM9-8000, dated 27 January 1956 i TM 9-8000 TABLE OF CONTENTS - CONTINUED Page Section VI. Turbochargers and Supercharges ........................................................................... 4-45 Section VII. Governors................................................................................................................. 4-48 Section VIII. Characteristics of Gasoline ...................................................................................... 4-52 CHAPTER 5. DIESEL FUEL SYSTEMS ........................................................................................ 5-1 Section I. Characteristics of Diesel Fuels................................................................................. 5-1 Section II. Combustion Chamber Design .................................................................................. 5-3 Section III. Injection Systems ..................................................................................................... 5-8 Section IV. Fuel Supply Pumps .................................................................................................. 5-28 Section V. Governors................................................................................................................. 5-30 Section VI. Timing Device........................................................................................................... 5-33 Section VII. Cold Weather Starting Aids...................................................................................... 5-35 Section VIII. Fuel Filters................................................................................................................ 5-37 Section IX. Engine Retarder System .......................................................................................... 5-39 CHAPTER 6. PROPANE FUEL SYSTEMS ................................................................................... 6-1 Section I. Characteristics.......................................................................................................... 6-1 Section II. Basic System............................................................................................................ 6-1 CHAPTER 7. EXHAUST AND EMISSION CONTROL SYSTEMS ................................................ 7-1 Section I. Exhaust System ....................................................................................................... 7-1 Section II. Emission Control System ......................................................................................... 7-2 CHAPTER 8. LUBRICATION SYSTEM ......................................................................................... 8-1 Section I. Purpose .................................................................................................................... 8-1 Section II. Engine Oils............................................................................................................... 8-2 Section III. Oil Pumps................................................................................................................. 8-5 Section IV. Types of Lubrication Systems .................................................................................. 8-12 CHAPTER 9. ENGINE COOLING SYSEMS.................................................................................. 9-1 Section I. Cooling Essentials.................................................................................................... 9-1 Section II. Liquid Cooling Systems............................................................................................ 9-1 Section III. Air Cooling Systems................................................................................................. 9-11 CHAPTER