Chevrolet HM80 Series User manual

HEAVY DUTY TRUCK
SUPPLEMENT

1972
CHEVROLET
HEAVY DUTY TRUCK
(SERIES 70, 80, and 90)
SHOP MANUAL
SUPPLEMENT
FOREWORD
This supplement has been prepared for use with the
1970 Heavy Duty Truck hop Manual and the 1971
Heavy Duty Truck hop Manual upplement. It covers
additional service information peculiar to 1972 Chev
rolet Heavy Duty Trucks.
ummaries of new or revised pecifications for
truck components are included at the end of each major
section.
All information, illustrations and specifications
contained in this literature are based on the latest prod
uct information available at the time of publication
approval. The right is reserved to make changes at any
time without notice.
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, MICHIGAN
SERVICE SECTION INDEX
6A
6 C
6D
6K
6 M
6T
6Y
8
10
11
12
13
© 1 72
General Motors Corporation rinted in U.S.A.
LUBRICATION
CABS AND
BODY MOUNTINGS
FRAME
FRONT SUS ENSION
REAR SUS ENSION
.BRAKES
GASOLINE ENGINES
SERIES 5^ and 71
DIESEL ENGINES
ENGINE MOUNTINGS
ENGINE COOLING SYSTEM
ENGINE FUEL SY5TEM
AIR COM RESSOR
AND GOVERNOR
ENGINE ELECTRICAL
TRANSMISSIONS
AND CLUTCHES
FUEL TANK & EXHAUST
STEERING SYSTEM
WHEELS & TIRES
SHEET METAL
CHASSIS ELECTRICAL
AND INSTRUMENTS
RADIATOR AND
SURGE TANK
S ECIAL TOOLS
£
; :'^Vv;v*' ■

INTRODUCTION
Information in this Supplement, when used in conjunction with 1970
Heavy uty Truck Manual ST135-70 and the 1971 Heavy uty Truck Shop
Manual Supplement ST332-71 provided coverage for all 70 thru 90 Series
trucks listed on Model ata Chart on pages ii and iii.
The information in this Supplement is arranged in the same section
sequence as in 1970 Heavy uty Truck Service Manual ST135-70.
IMPORTANT: Refer to the applicable section in this Supplement
(see Index below) to determine whether there is supplementary information
before servicing any unit or system on 70 thru 90 Series trucks.
SECTION IN EX
SECTION PAGE
0 Lubrication................................................................................... 1
1 Cab and Body Mountings ............................................................ 13
2 Fram e............................................................................................ 21
3 Front Suspension.......................................................................... 23
4 Rear Suspension.......................................................................... 33
5 Brakes............................................................................................ 45
6A Gasoline Engines.......................................................................... 53
6C etroit iesel Engines (53 & 71 Series)................................... 61
6 Engine Mountings........................................................................ 81
6K Engine Cooling System ............................................................ 87
6M Engine Fuel System..................................................................... 95
6T Air Compressor and Governor................................................... I ll
6Y Engine Electrical.......................................................................... 113
7 Transmission and Clutches.......................................................... 151
8 Fuel Tank and Exhaust............................................................... 173
9 Steering System .......................................................................... 177
10 Wheels and Tires.......................................................................... 187
11 Sheet Metal................................................................................... 207
12 Chassis Electrical and Instruments .......................................... 209
13 Radiator and Surge Tank............................................................ 229
Special Tools................................................................................. 235
CHEVROLET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL SUPPLEMENT

MODEL DATA
TRUCK
SERIES
ENGINE CLUTCH FRONT AXLE REAR AXLE TRANSMISSION
STD. OPT. STD. OPT. STD. OPT. STD. OPT. STD. OPT.
HM80 401M 478M 13-2 13-2*
14-2 F070 F090 F120 17121 17221 18121 18221 19221 285V 282V 387V
5652 5752C
MT40 AT540
HV70 6V-53N -14-2 -F070 F090 F120 17221 18221 19121
19221 5752C MT41
JM80 401M 478M 13-2 13-2*
14-2 F090 F120 FL901 30DSC 34DSC SLHD SQHD 5652/w 6041 Aux. 401V 7041 Aux. MT40
JV70 6V-53N —14-2 -F090 F120
FL901 34DSC SLHD 385V/W
7041 Aux. MT41
RM80 401M 478M 13-2 13-2*
14-2 F090 -H162 H361 L162 L362 285V 325V MT42
HM80 478SN -- - F160 F161 U
200 -MT42 -
TM80 401M 478M 13-2 13-2*
14-2 F070 F090 F120 17121 17221 18121
18221 19221 285V 282V 387V
5652 5752C
WIT40 AT540
TV70 6V-53N -14-2 - F070 F090 F120 17221 19121 19221 5752C MT41
WM80 401M - 13-2 13-2* F090 F120 34DSC SLHD 5652/w
6041 Aux. -
WV70 6V-53N - - -FL901 -34DSC - MT41 -
WW90 6V-71N -14-2 -F120 -SLHD -RT910 -
HC90 NHCT270 NTC335 14-2** 15!/2-2** F090 F120 19121 R170 RT910 RT09513
HE90 637 - 14-2 -F090 F120 18221 19221 408V -
HH90 8V-71N -14-2 14-2**
lWz-2**
F090 F120 19121 R170 RT910 RT09513
HI90 6-71N - 14-2 14-2**
m - 2 * *
F090 F120 18221 19121 19221
R170 6852S 6853C RT910
HN90 NHC250 NH230 14-2 14-2**
1514-2** F090 F120 18221 19121 19221
R170 7452E RT910 RT09513
JB90 8V-903 -14-2** -F120 -SLHD -RT910 -
JC90 NHCT270 NTC335 14-2**
m - 2 * * F090 F I20 FL901 SLHD SQHD RT910 RT09513
CHEVROLET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL SUPPLEMENT

MODEL DATA (continued)
T R U C K
S E R IE S EN G IN E CLU T CH FR O N T A XLE REAR A X LE TRA N SM ISSIO N
STD . O PT. STD . OPT. STD . OPT. ST D . O PT. STD . O PT.
JE90 637 -14-2 -F090 F120
FL901 SLHD 34D3C RT910 6852 K
JH90 8V-71N -14-2 14-2**
15‘/2-2** F090 F120 FL901 SLHD SQHD RT910 RT09513 T905A
8341C Aux.
JI90 6-71N -14-2 14-2**
m - 2 * *
F090 F120
FL901 SLHD SQHD 34D3C RT910 RT09513 6852K
JN90 NHC250 NH230 14-2 151/2-2** F090 F120
FL901 34DSC SLHD SQHD
34D3C RT910 RT09513 7352B 8552A 8341C Aux.
MB90 8V-903 -14-2** -F120 -SLHD - RT910 -
MC90 NTC350 -
m - 2 * * -F120 -SLHD -RT910 -
MH90 8V-71N -14-2
m - 2 ** F090 F120
FL901 SLHD SQHD 34D3C RT910 RT09513
8716-3B
TE90 637 -14-2
-
F090 F120 18221 19221 408V -
FB90 8V-903 -14-2** - F120 - 19121 -RT910 -
FC90 NHCT270 NTC335 14-2 14-2**
15!/2-2** F120 -19121 R170 RT910 RT09513
FH90 8V-71N -14-2 151/2-2** F120 -19121 R170 RT910 RT09513
FI90 6-71N -14-2 -F120 -18221 19121 19221
R170 6852S 7452E RT910 RT09513
FN90 NHC250 NH230 14-2 14-2**
15!/2-2** F120 -18221 19121 19221
R170 RT910 -
DB90 8V-903 -14-2** -F120 -SLHD -RT09513 -
DC90 NHCT270 NTC335 14-2 14-2**
15i/2-2** F120 FL901 SLHD SQHD SSHD RT910 RT09513
DH90 8V-71N -14-2 15i/2.2** F120 FL901 SLHD SQHD SSHD
34DSC 34D3C RT910 RT09513
8716-3B
DI90 6-71N -14-2 -F120 -34D3C 34DSC SLHD
SQHD 7352B RT910 RT09513
DN90 NHC250 N H230 14-2 151/2-2**
14-2** F120 34D3C 34DSC SLHD
SQHD RT910 RT09513
DP90 12V-71 —
m - 2 * *
F120 SQHD RT01213 -
♦Equipped with Cerametalix Clutch Discs. **Spicer Clutch.
CHEVROLET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL' SUPPLEMENT

VEHICLE MODEL IDENTIFICATION
In order that a vehicle may be specifically identified as to manufacturer,
chassis type, engine type, GVW range, cab/axle dimension, continuous model,
plant code, and sequential number, refer to the chart below.
CHASSIS TYPE SYMBOL
C-Conv. Cab (96" BBC) (4x2)
D -T ilt Cab (54" 74", and 86"
Alum.) (6x4,6x2)
F -T ilt Cab (54", 74", 86" Alum.) (4 x 2)
H-Short Conv. Cab (92" BBC) (4 x 2)
J-Short Conv. Cab (92" BBC) (6 x 4; 6 x 2)
M -Conv. Cab (96"-114" BBC) (6 x 4; 6 x 2)
R-Fw d. Control, W /Rear Engine
T -T ilt Cab (72" Steel) (4 x 2)
W -T ilt Cab (72" Steel) (6 x 4; 6 x 2)
GVW ANGE CONTINUOUS SEQUENTIAL
NUMBE MODEL NUMBE
\
CCM58 OVOOOOOO
\
ENGINE TY E SYMBOL
B -8 cyl.—V903 Cummins Diesel
C - 6 cyl. 270 or 335 Cummins Turbo-Chg. Diesel
E-V -8 Gasoline
H—8V-71—8 cyl. "V” Detroit Diesel
1-6-7 1-6 cyl. In Line Detroit Diesel
M -V-6 Gasoline
N -6 cyl. 230 or 250 Cummins Diesel
—12V-71—12 cyl. “V” Detroit Diesel
V—6V-53—6 cyl. “V” Detroit Diesel
W—6V-71—6 cyl. “V” Detroit Diesel
ASSY.
PLANT
CODE
V - o n t ia c
C A B /A X LE
DIM ENSION
Location of Vehicle Identifi
cation Number on GVW plate—
which is affixed to cab or body.
O GENERAL MOTORS CORPORATION O
WARRANTY MAY BE VOIDED IF WEIGHT
EXCEEDS ANY OF THE RATINGS SHOWN.
GROSS VEHICLE WEIGHT INCLUDES WEIGHT OF
BASE TRUCK. ALL ADDED EQUIPMENT, DRIVER
AND PASSENGERS, AND ALL PROPERTY LOADED
INTO TRUCK.
♦ REFER TO OWNER'S MANUAL FOR EQUIP
MENT REQUIRED FOR INTERMEDIATE OR
MAXIMUM GVW RATINGS. AND FOR OTHER
LOADING INFORMATION, INCLUDING TIRE
INFLATION.
1 RATINGS IN POUNDS
GROSS VEHICLE WEIGHT
FOR THIS VEHICLE
MAXIMUM FRONT END
WEIGHT AT GROUND
MAXIMUM REAR END
WEIGHT AT GROUND
^VEHICLE
IDENTIFICATION NO. \~
C .
AS MANU
FACTURED ♦MAXIMUM
CAPABILITY
sc: o
iv
CHEVROIET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL SUPPLEMENT

SECTION 0
J l u M u x i t i a n
All information contained in the 1970 Heavy uty Truck Service Manual
ST135-70 under LUBRICATION (SEC. 0) will apply to vehicles covered by this
publication. The following information will also apply.
AIR CLEANERS
Air cleaner should be inspected and serviced
at intervals specified in Emission Control System
booklet, or more often under severe dust condi
tions, also whenever dirt is visible in element or
oil.
TRANSMISSION CA ACITIES
The lubricant capacities for transmissions
AT540, RT09513, and RT012513 are as follows:
REAR AXLE CA ACITY
(AXLE MODEL E30DSC)
The Imperial capacity of lubricant for this
axle rear unit is 22% pints instead of 20% pints as
specified in 1970 Heavy uty Truck Service Manual
ST135-70, page 0-10.
TWO AND THREE-S EED
AXLE SHIFT UNIT
Lubricant for axle shift unit should be a re
frigeration machine type oil which is a highly re
fined straight mineral petroleum oil. Formerly,
regular engine oil was specified for this purpose.
The identification symbol on all future lubri
cation charts will be S7 for this type lubricant.
Apply oil to level of filler hole opening at
12,000 mile intervals.
OIL AND FILTER RE LACEMENT
(AUTOMATIC TRANSMISSIONS)
RAINING AN FILLING
When new or after overhaul, drain fluid and
change filter element after 3000 miles; thereafter
at 24,000-mile intervals (12,000 m iles under severe
conditions for MT Series only). rain while fluid is
at operating temperature (160°F. minimum).
MT Series Transmission
1. Remove bolt, nut, and strap which secure
filter cover to oil pan.
2. Carefully remove filter cover to prevent
oil "gushing" out. When drainage is complete, re
move cover and filter element.
3. Install new element, retainer seal ring, and
cover seal ring. Secure cover to oil pan with strap.
Tighten strap retaining bolt to 11-14 foot-pounds.
Pour 18 pints of specified oil into transm ission.
4. Start engine and check fluid level. O NOT
OVERFILL.
AT475 and AT540 Transmissions
1. Remove dipstick and filler tube to drain
fluid (AT540 only). Remove oil pan (both models).
2. Remove single bolt which retains filter ele
ment to valve body. Remove element.
3. Install new element using new O-ring at
top of oil intake pipe; torque attaching bolt to 10
to 13 foot-pounds, then install oil pan using new
gasket.
4. Install filler tube (AT540), then pour ap
proximately 22 pints (AT540) or 10 pints (AT475),
of specified oil into transmission.
5. Check fluid level.
CLUTCH IDLER LEVER
(ALL CONVENTIONAL CAB MODELS
EXCE T HE AND JE)
These vehicles are equipped with mechanical
type clutch controls. The only component of link
age arrangement which requires lubricant is the
linkage idler lever and shaft, bracket-mounted to
frame rail.
Apply "MPG" lubricant to single fitting at
6,000 mile intervals.
LUBRICATION CHARTS
All lube charts have been updated.
Jints
Transmission U.S. Imperial
AT540 22 18%
RT09513 27 22%
RT012513 27 22%
CHEVROLET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL SUPPLEMENT

Sec. 0-2
LUBRICATION
Figure 1—Lubrication Chart (Conventional Cab Models)

Sec. 0-3
LUBRICATION
LUBRICATION DATA
(CHART ON O OSITE AGE)
Item
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
Ji&u Item Remarks Svmbol Miles(c)
1 Spring Shackles & Brackets ( d ) ...............
. . MPG 6,000
1 fitting each bracket (if used) . .. . . MPG 6,000
2Spring Slip Pads (d) .................................... , . . MPG 6,000
3Steering Knuckles
. ...................................... . . . MPG 6,000
4 Steering Tie Rod Ends .............................. 6,000
5Steering rag Link Ends ........................... . . . MPG 6,000
6Power Steering Cylinder Ends (d) . . . . , . . MPG 6,000
7Auxiliary Transmission Shift Tower (d)., . . . 1 fitting................................................. . . MPG 6,000
8 Prop. Shaft "U" J o in ts................................. , . . MPG 6,000
9Prop. Shaft Slip Joint.................................... , . . MPG 6,000
10 Steering Column "U" Joint ..................... , . . MPG 6,000
11 Steering Column Slip Joint (d )
..................
6,000
12 Clutch Release Cross Shaft (d)
..................
, . . MPG 6,000
13 Clutch Release Bearing (d ) ........................ . . . S27 6,000
14 Tru-Stop Brake (d) .................................... 6,000
15 Speedometer Adapter (d)
.............................. 6,000
16 Brake Camshaft (d )....................................... , . . MPG 6,000
17 Clutch Master Cylinder (d ) ........................ . . . S12 6,000
18 Steering Gear H ousing................................. , . . SG 6,000
19 Battery Terminals (Except "ST" Type) . . . . Keep co ated......................................., . . S3 6,000(i)
20 Electric Shift Unit (2 or 3 spd.) (d) . . . . . . . S7 12.000
21 Transmission (NP & GMC) (d ).................. , . . MPO 6,000
rain and refill ........................... ..
. . . MPO 12,000
21 Transmission (Clark & Fuller) (d) . . . . . . . GO 6,000
rain and refill .............................. , . . GO 12,000
21 Transmission (Spicer) (d)
........................ . . . ES 6,000
rain and refill ............................... . . ES 12,000
21 Transmission - Auxiliary (d)..................... , . . ES 6,000
rain and refill .............................., . . ES 12,000
21 Transmission - Automatic ( d )
..................
, . . S19 6,000
rain and refill ..............................
, . . S19 12,000
22 Rear Axle ...................................................... . . . MPO 6,000(b)
rain and refill ..............................
12,000
23 Front Wheel Bearings ( g )
........................... , . . MPG 20,000
20,000(a)
24 Rear Wheel Bearings (h) ........................... , . . MPG
25 Brake Cam Roller Pins ( e ) ........................■ • • • Apply ................................................
..
20.000(a)
26 Steering Idler Lever ( d ) .............................. . . . MPG 6,000
27 Brake and Axle Cylinder Air Cleaner(d) . . . Clean and reinstall
........................
6,000
28 Brake Master Cylinder ( f )
.......................
. . . S12 3,000(])
29 Hood Latch Mechanism, Pivot Points
and Hinges ................................................... . . S17 6,000(k)
30 Clutch Idler Levers (Note: Two clutch
idler levers on MC & MB Models) . . 6,000
31 Speedometer rive Adapter(d)
...............
, , MPG 6,000
(a) Or once a year, whichever occurs first.
(b) Or every 6 months, whichever occurs first.
(c) When "MPG" (Multi-Purpose Grease) is specified, lubricate every 6,000 miles or 60 days.
If used.
Air cam brakes only.
Hydraulic brakes only.
Optional oil lubricated front wheel bearings use "GO" type oil.
No periodic servicing with oil lubricated bearings (Stemco seals).
No lube required on side terminal type battery.
Or every 30 days, whichever occurs first.
Or every 4 months, whichever occurs first.
CHEVROLET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL SUPPLEMENT

Sec. 0-4
LUBRICATION
CHEVROLET SERIES 70 90 HEAVY DUTY TRUCK SHOP MANUAL SUPPLEMENT