Figure 1-1. Military Standard Engine.
CHAPTER 1 INTRODUCTION - TM-9-2805-259-140021
Section II. EQUIPMENT DESCRIPTION AND DATA - TM-9-2805-259-140022
Location and Description of Major Components (Models 4A084-2, -3 and -4)
Figure 1-2. Location and Description of Major Components Models 2A042-2 and -3.
Equipment Data. - TM-9-2805-259-140025
Section III. PRINCIPLES OF OPERATION - TM-9-2805-259-140026
Detailed Principles of Operation.
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-2805-259-140029
Operator's Control and lndicators
Figure 2-1. Operator's Controls and Indicators. - TM-9-2805-259-140031
Section Il. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-2805-259-140032
Special Instructions - TM-9-2805-259-140033
Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS).
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-2805-259-140035
Operation in Rainy, Humid, or Salt Air Conditions
CHAPTER 3 OPERATOR'S MAINTENANCE INSTRUCTIONS - TM-9-2805-259-140037
SYMPTOM INDEX - TM-9-2805-259-140038
Section III. OPERATOR'S MAINTENANCE
CHAPTER 4 UNIT MAINTENANCE - TM-9-2805-259-140041
Section II. SERVICE UPON RECEIPT - TM-9-2805-259-140042
Section IV. UNIT TROUBLESHOOTING - TM-9-2805-259-140043
ENGINE FAILS TO START.
ENGINE STARTS BUT FAILS TO KEEP RUNNING.
ENGINE OVERHEATS.
Section V. UNIT MAINTENANCE PROCEDURES - TM-9-2805-259-140047
General. - TM-9-2805-259-140048
Figure 4-1. Fuel Filter, Service.
Air Cleaner Element.
Figure 4-2. Air Cleaner Element, Service.
Air Cleaner Element
Figure 4-3. Air Cleaner Element, Replacement.
Air Cleaner Support Bracket and Restriction Indicator.
Figure 4-4. Air Cleaner, Support Bracket and Restriction Indicator, Removal and Installation.
Clamps and Hoses.
Figure 4-5. Clamps and Hose, Removal and Installation.
Air Cleaner Elbow.
Figure 4-6. Air Cleaner Elbow, Removal and Installation.
Breather Tube.
Figure 4-7. Breather Tube, Removal and Installation.
Oil Filter Element.
Figure 4-8. Oil Filter Element, Replacement
Oil Filter Element
Figure 4-9. Oil Filter, Replacement.
Oil Filter Cover and Studs.
Figure 4-10. Oil Filter Cover and Studs, Removal and Installation.
Top Cover, Right and Left Shrouds and Cylinder Baffles.
Figure 4-11. Top Cover, Right and Left Shrouds and Cylinder Baffles, Removal.
Top Cover, Right and Left Shrouds and Cylinder Baffles
Figure 4-12. Top Cover, Right and Left Shrouds and Cylinder Baffles, Installation.
Oil Pan Cover, Shroud and Baffle Plate.
Figure 4-13. Oil Pan Cover, Shroud and Baffle Plate, Removal and Installation.
Oil Pan Baffle, Control Rod, Positioner and Front Engine Mount.
Figure 4-14. Oil Pan Baffle Control Rod, Positioner and Front Engine Mount, Removal and Installation.
Oil Lines and Fittings.
Figure 4-15. Oil Lines and Fittings, Removal and Installation.
Rocker Box Hose and Fittings
Figure 4-16. Rocker Box Hose and Fittings, Removal and Installation.
Pressure Regulator Valve.
Figure 4-17. Pressure Regulator Valve, Removal and installation.
Crankcase Breather.
Figure 4-18. Crankcase Breather, Removal and Installation.
Low Oil Pressure Shutdown Switch and "T" Connector.
Figure 4-19. Low Oil Pressure Shutdown Switch and T Connector, Removal and Installation.
Oil Pressure Transmitter.
Figure 4-20. Oil Pressure Transmitter, Removal and Installation.
Choke Solenoid and Bracket - TM-9-2805-259-140088
Figure 4-21. Choke Solenoid and Bracket, Adjustment.
Choke Solenoid and Bracket - TM-9-2805-259-140090
Figure 4-22. Choke Solenoid and Bracket, Removal and Installation.
Preheater.
Figure 4-23. Preheater, Removal and Installation.
Magneto and Gear.
Figure 4-24. Magneto and Gear, Removal.
Magneto and Gear
Figure 4-25. Magneto and Gear, Installation.
Ignition Timing.
Figure 4-26. Ignition Timing, Adjustment.
Magneto Contacts and Rotor Button.
Figure 4-27. Magneto Contacts, Adjustment.
Magneto Contacts
Figure 4-28. Magneto Contacts and Rotor Button, Removal and Installation.
Condenser.
Figure 4-29. Condenser, Removal and Installation.
High Tension Cables.
Figure 4-30. High Tension Cable, Removal and Installation.
Spark Plugs.
Figure 4-31. Spark Plug, Removal and Installation.
Starter.
Figure 4-32. Starter, Removal and Installation.
Regulator-Rectifier.
Figure 4-33. Regulator-Rectifier, Removal and Installation.
Governor/Carburetor Control.
Figure 4-34. Governor/Carburetor Control, Removal and Installation.
Governor Control Rod.
Figure 4-35. Governor Control Rod, Adjustment.
Governor Control Rod
Figure 4-36. Governor Control Rod, Removal and Installation.
Governor Oil Tube.
Figure 4-37. Governor Oil Tube, Removal and Installation.
Governor.
Figure 4-38. Governor, Adjustment.
Governor
Figure 4-39. Governor, Removal and Installation.
Exhaust Manifold and Exhaust Pipe.
Figure 4-40. Exhaust Manifold and Exhaust Pipe, Removal and Installation.
Manual Choke. - TM-9-2805-259-140128
Manual Choke. - TM-9-2805-259-140129
Carburetor.
Figure 4-42. Carburetor, Adjustment.
Carburetor - TM-9-2805-259-140132
Figure 4-43. Carburetor, Removal and Installation.
Fuel Line and Fittings.
Figure 4-44. Fuel Line and Fittings, Removal and Installation.
Fuel Pump.
Figure 4-45. Fuel Pump, Test.
Fuel Pump - TM-9-2805-259-140138
Figure 4-46. Fuel Pump, Removal and Installation.
Intake Manifold Assembly.
Figure 4-47. Intake Manifold Assembly, Removal and Installation.
Rocker Box Cover.
Figure 4-48. Rocker Box Cover, Removal and Installation.
Alternator.
Figure 4-49. Alternator, Removal and Installation.
Wiring Harness. - TM-9-2805-259-140146
Figure 4-50. Wiring Harness, Test, Removal and Installation.
Tachometer Adapter.
Figure 4-51. Tachometer Adapter, Replacement.
Air Breather Reed and Support.
Figure 4-52. Air Breather Reed and Support, Removal and Installation.
Compression Test.
Figure 4-53. Compression, Test.
Figure 4-54. Wiring Diagram.
Section VI. PREPARATION FOR SHIPMENT OR STORAGE
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-2805-259-140157
SYMPTOM INDEX - TM-9-2805-259-140158
ENGINE LACKS POWER.
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURE.
Installation - TM-9-2805-259-140161
Fan Housing.
Figure 5-2. Fan Housing, Removal and Installation.
Oil Pump Gears, Spacer and Oil Pump Cover.
Figure 5-3. Oil Pump Gears, Spacer and Oil Pump Cover, Removal and Installation.
Oil Filler Tube and Gage.
Figure 5-4. Oil Filler Tube and Gage, Replacement.
Starter Assembly.
Figure 5-5. Starter Assembly, Repair.
Carburetor.
Figure 5-6. Carburetor, Repair.
Timing Gear Cover.
Figure 5-7. Timing Gear Cover, Removal and Installation.
Timing Gear Cover Oil Seal.
Figure 5-8. Timing Gear Cover Oil Seal, Replacement.
Oil Pan.
Figure 5-9. Oil Pan, Removal and Installation.
Check Valve. - TM-9-2805-259-140178
Figure 5-10. Check Valve, Removal and Installation.
Cylinder Head Assembly.
Figure 5-11. Cylinder Head Assembly, Removal.
Cylinder Head Assembly
Figure 5-12. Cylinder Head Assembly, Repair.
Cylinder Head Assembly
Figure 5-13. Cylinder Head Assembly, Installation.
Rockers.
Figure 5-14. Rockers, Removal.
Figure 5-15. Rockers, Inspection/Repair.
Figure 5-16. Rockers, Installation.
Intake and Exhaust Valves.
Figure 5-17 Intake and Exhaust Valves, Removal and Installation.
Valve Tappets.
Figure 5-18. Valve Tappets, Removal and Installation.
Rear Oil Seal.
Figure 5-19. Rear Oil Seal, Replacement.
Table 5-2. Engine Repair and Replacements Limits.
Table 5-2. Engine Repair and Replacements Limits (cont).
CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-2805-259-140199
SYMPTOM INDEX - TM-9-2805-259-140200
ENGINE OIL CONSUMPTION EXCESSIVE.
Piston and Connecting Rod.
Figure 6-1. Piston and Connecting Rod, Removal.
Piston and Connecting Rod
Figure 6-2. Piston and Connecting Rod, Repair.
Piston and Connecting Rod - TM-9-2805-259-140206
Figure 6-3. Piston and Connecting Rod, Installation.
Cylinder.
Figure 6-4. Cylinder, Removal and Installation.
Camshaft, Camshaft Gear, and Bearing.
Figure 6-5. Camshaft, Camshaft Gear and Bearing, Removal and Installation.
Crankshaft.
Figure 6-6. Crankshaft, Removal.
Crankshaft
Figure 6-7. Crankshaft, Installation.
Crankcase.
Figure 6-8. Crankcase, Repair.
Table 6-2. Engine Repair and Replacements Limits.
Table 6-2. Engine Repair and Replacements Limits (cont). - TM-9-2805-259-140219
Table 6-2. Engine Repair and Replacements Limits (cont). - TM-9-2805-259-140220
APPENDIX A REFERENCES - TM-9-2805-259-140221
Technical Bulletins. - TM-9-2805-259-140222
MAINTENANCE ALLOCATION CHART - TM-9-2805-259-140223
Explanation of Columns in the MAC, Section Il. - TM-9-2805-259-140224
Explanation of Columns in the MAC, Section III. - TM-9-2805-259-140225
Section Il. MAINTENANCE ALLOCATION CHART - TM-9-2805-259-140226
Section II. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140227
Section Il. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140228
Section II. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140229
Section II. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140230
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR 10 HP MILITARY STANDARD ENGINE
APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS - TM-9-2805-259-140233
Section II. COMPONENTS OF END ITEMS
APPENDIX C EXPENDABLE/DURABLE SUPPLIES MATERIALS
Section Il. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST - TM-9-2805-259-140236
APPENDIX E TORQUE LIMITS - TM-9-2805-259-140237
APPENDIX F ADDITIONAL AUTHORIZATION LIST (AAL)
TM-9-2805-259-14 Engine Gasoline 20 HP Military Standard Models (MODEL 4A084-2 MODEL 4A084-3 MODEL 4A084-4 Manual
CHAPTER 1 INTRODUCTION - TM-9-2805-259-140021
Section II. EQUIPMENT DESCRIPTION AND DATA - TM-9-2805-259-140022
Location and Description of Major Components (Models 4A084-2, -3 and -4)
Figure 1-2. Location and Description of Major Components Models 2A042-2 and -3.
Equipment Data. - TM-9-2805-259-140025
Section III. PRINCIPLES OF OPERATION - TM-9-2805-259-140026
Detailed Principles of Operation.
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-2805-259-140029
Operator's Control and lndicators
Figure 2-1. Operator's Controls and Indicators. - TM-9-2805-259-140031
Section Il. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-2805-259-140032
Special Instructions - TM-9-2805-259-140033
Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS).
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-2805-259-140035
Operation in Rainy, Humid, or Salt Air Conditions
CHAPTER 3 OPERATOR'S MAINTENANCE INSTRUCTIONS - TM-9-2805-259-140037
SYMPTOM INDEX - TM-9-2805-259-140038
Section III. OPERATOR'S MAINTENANCE
CHAPTER 4 UNIT MAINTENANCE - TM-9-2805-259-140041
Section II. SERVICE UPON RECEIPT - TM-9-2805-259-140042
Section IV. UNIT TROUBLESHOOTING - TM-9-2805-259-140043
ENGINE FAILS TO START.
ENGINE STARTS BUT FAILS TO KEEP RUNNING.
ENGINE OVERHEATS.
Section V. UNIT MAINTENANCE PROCEDURES - TM-9-2805-259-140047
General. - TM-9-2805-259-140048
Figure 4-1. Fuel Filter, Service.
Air Cleaner Element.
Figure 4-2. Air Cleaner Element, Service.
Air Cleaner Element
Figure 4-3. Air Cleaner Element, Replacement.
Air Cleaner Support Bracket and Restriction Indicator.
Figure 4-4. Air Cleaner, Support Bracket and Restriction Indicator, Removal and Installation.
Clamps and Hoses.
Figure 4-5. Clamps and Hose, Removal and Installation.
Air Cleaner Elbow.
Figure 4-6. Air Cleaner Elbow, Removal and Installation.
Breather Tube.
Figure 4-7. Breather Tube, Removal and Installation.
Oil Filter Element.
Figure 4-8. Oil Filter Element, Replacement
Oil Filter Element
Figure 4-9. Oil Filter, Replacement.
Oil Filter Cover and Studs.
Figure 4-10. Oil Filter Cover and Studs, Removal and Installation.
Top Cover, Right and Left Shrouds and Cylinder Baffles.
Figure 4-11. Top Cover, Right and Left Shrouds and Cylinder Baffles, Removal.
Top Cover, Right and Left Shrouds and Cylinder Baffles
Figure 4-12. Top Cover, Right and Left Shrouds and Cylinder Baffles, Installation.
Oil Pan Cover, Shroud and Baffle Plate.
Figure 4-13. Oil Pan Cover, Shroud and Baffle Plate, Removal and Installation.
Oil Pan Baffle, Control Rod, Positioner and Front Engine Mount.
Figure 4-14. Oil Pan Baffle Control Rod, Positioner and Front Engine Mount, Removal and Installation.
Oil Lines and Fittings.
Figure 4-15. Oil Lines and Fittings, Removal and Installation.
Rocker Box Hose and Fittings
Figure 4-16. Rocker Box Hose and Fittings, Removal and Installation.
Pressure Regulator Valve.
Figure 4-17. Pressure Regulator Valve, Removal and installation.
Crankcase Breather.
Figure 4-18. Crankcase Breather, Removal and Installation.
Low Oil Pressure Shutdown Switch and "T" Connector.
Figure 4-19. Low Oil Pressure Shutdown Switch and T Connector, Removal and Installation.
Oil Pressure Transmitter.
Figure 4-20. Oil Pressure Transmitter, Removal and Installation.
Choke Solenoid and Bracket - TM-9-2805-259-140088
Figure 4-21. Choke Solenoid and Bracket, Adjustment.
Choke Solenoid and Bracket - TM-9-2805-259-140090
Figure 4-22. Choke Solenoid and Bracket, Removal and Installation.
Preheater.
Figure 4-23. Preheater, Removal and Installation.
Magneto and Gear.
Figure 4-24. Magneto and Gear, Removal.
Magneto and Gear
Figure 4-25. Magneto and Gear, Installation.
Ignition Timing.
Figure 4-26. Ignition Timing, Adjustment.
Magneto Contacts and Rotor Button.
Figure 4-27. Magneto Contacts, Adjustment.
Magneto Contacts
Figure 4-28. Magneto Contacts and Rotor Button, Removal and Installation.
Condenser.
Figure 4-29. Condenser, Removal and Installation.
High Tension Cables.
Figure 4-30. High Tension Cable, Removal and Installation.
Spark Plugs.
Figure 4-31. Spark Plug, Removal and Installation.
Starter.
Figure 4-32. Starter, Removal and Installation.
Regulator-Rectifier.
Figure 4-33. Regulator-Rectifier, Removal and Installation.
Governor/Carburetor Control.
Figure 4-34. Governor/Carburetor Control, Removal and Installation.
Governor Control Rod.
Figure 4-35. Governor Control Rod, Adjustment.
Governor Control Rod
Figure 4-36. Governor Control Rod, Removal and Installation.
Governor Oil Tube.
Figure 4-37. Governor Oil Tube, Removal and Installation.
Governor.
Figure 4-38. Governor, Adjustment.
Governor
Figure 4-39. Governor, Removal and Installation.
Exhaust Manifold and Exhaust Pipe.
Figure 4-40. Exhaust Manifold and Exhaust Pipe, Removal and Installation.
Manual Choke. - TM-9-2805-259-140128
Manual Choke. - TM-9-2805-259-140129
Carburetor.
Figure 4-42. Carburetor, Adjustment.
Carburetor - TM-9-2805-259-140132
Figure 4-43. Carburetor, Removal and Installation.
Fuel Line and Fittings.
Figure 4-44. Fuel Line and Fittings, Removal and Installation.
Fuel Pump.
Figure 4-45. Fuel Pump, Test.
Fuel Pump - TM-9-2805-259-140138
Figure 4-46. Fuel Pump, Removal and Installation.
Intake Manifold Assembly.
Figure 4-47. Intake Manifold Assembly, Removal and Installation.
Rocker Box Cover.
Figure 4-48. Rocker Box Cover, Removal and Installation.
Alternator.
Figure 4-49. Alternator, Removal and Installation.
Wiring Harness. - TM-9-2805-259-140146
Figure 4-50. Wiring Harness, Test, Removal and Installation.
Tachometer Adapter.
Figure 4-51. Tachometer Adapter, Replacement.
Air Breather Reed and Support.
Figure 4-52. Air Breather Reed and Support, Removal and Installation.
Compression Test.
Figure 4-53. Compression, Test.
Figure 4-54. Wiring Diagram.
Section VI. PREPARATION FOR SHIPMENT OR STORAGE
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-2805-259-140157
SYMPTOM INDEX - TM-9-2805-259-140158
ENGINE LACKS POWER.
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURE.
Installation - TM-9-2805-259-140161
Fan Housing.
Figure 5-2. Fan Housing, Removal and Installation.
Oil Pump Gears, Spacer and Oil Pump Cover.
Figure 5-3. Oil Pump Gears, Spacer and Oil Pump Cover, Removal and Installation.
Oil Filler Tube and Gage.
Figure 5-4. Oil Filler Tube and Gage, Replacement.
Starter Assembly.
Figure 5-5. Starter Assembly, Repair.
Carburetor.
Figure 5-6. Carburetor, Repair.
Timing Gear Cover.
Figure 5-7. Timing Gear Cover, Removal and Installation.
Timing Gear Cover Oil Seal.
Figure 5-8. Timing Gear Cover Oil Seal, Replacement.
Oil Pan.
Figure 5-9. Oil Pan, Removal and Installation.
Check Valve. - TM-9-2805-259-140178
Figure 5-10. Check Valve, Removal and Installation.
Cylinder Head Assembly.
Figure 5-11. Cylinder Head Assembly, Removal.
Cylinder Head Assembly
Figure 5-12. Cylinder Head Assembly, Repair.
Cylinder Head Assembly
Figure 5-13. Cylinder Head Assembly, Installation.
Rockers.
Figure 5-14. Rockers, Removal.
Figure 5-15. Rockers, Inspection/Repair.
Figure 5-16. Rockers, Installation.
Intake and Exhaust Valves.
Figure 5-17 Intake and Exhaust Valves, Removal and Installation.
Valve Tappets.
Figure 5-18. Valve Tappets, Removal and Installation.
Rear Oil Seal.
Figure 5-19. Rear Oil Seal, Replacement.
Table 5-2. Engine Repair and Replacements Limits.
Table 5-2. Engine Repair and Replacements Limits (cont).
CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-2805-259-140199
SYMPTOM INDEX - TM-9-2805-259-140200
ENGINE OIL CONSUMPTION EXCESSIVE.
Piston and Connecting Rod.
Figure 6-1. Piston and Connecting Rod, Removal.
Piston and Connecting Rod
Figure 6-2. Piston and Connecting Rod, Repair.
Piston and Connecting Rod - TM-9-2805-259-140206
Figure 6-3. Piston and Connecting Rod, Installation.
Cylinder.
Figure 6-4. Cylinder, Removal and Installation.
Camshaft, Camshaft Gear, and Bearing.
Figure 6-5. Camshaft, Camshaft Gear and Bearing, Removal and Installation.
Crankshaft.
Figure 6-6. Crankshaft, Removal.
Crankshaft
Figure 6-7. Crankshaft, Installation.
Crankcase.
Figure 6-8. Crankcase, Repair.
Table 6-2. Engine Repair and Replacements Limits.
Table 6-2. Engine Repair and Replacements Limits (cont). - TM-9-2805-259-140219
Table 6-2. Engine Repair and Replacements Limits (cont). - TM-9-2805-259-140220
APPENDIX A REFERENCES - TM-9-2805-259-140221
Technical Bulletins. - TM-9-2805-259-140222
MAINTENANCE ALLOCATION CHART - TM-9-2805-259-140223
Explanation of Columns in the MAC, Section Il. - TM-9-2805-259-140224
Explanation of Columns in the MAC, Section III. - TM-9-2805-259-140225
Section Il. MAINTENANCE ALLOCATION CHART - TM-9-2805-259-140226
Section II. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140227
Section Il. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140228
Section II. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140229
Section II. MAINTENANCE ALLOCATION CHART (cont) - TM-9-2805-259-140230
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR 10 HP MILITARY STANDARD ENGINE
APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS - TM-9-2805-259-140233
Section II. COMPONENTS OF END ITEMS
APPENDIX C EXPENDABLE/DURABLE SUPPLIES MATERIALS
Section Il. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST - TM-9-2805-259-140236
APPENDIX E TORQUE LIMITS - TM-9-2805-259-140237
APPENDIX F ADDITIONAL AUTHORIZATION LIST (AAL)
TM-9-2805-259-14 Engine Gasoline 20 HP Military Standard Models (MODEL 4A084-2 MODEL 4A084-3 MODEL 4A084-4 Manual
