TM 5-3810-305-23

*TM 5-3810-305-23
TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR
CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON (ROUGH TERRAIN CRANE) LRT 110 TYPE I GENERAL PURPOSE NSN 3810-01-165-0646 TYPE II AIRBORNE/AIRMOBILE NSN 3810-01-165-0647
*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY 14 SEPTEMBER 2012

03/15/2011 Rel(1.8) root(frntcover) wpno(F00001)
TM 5-3810-305-23
WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. FIRST AID For first aid information, refer to FM 4-25.11, First Aid. EXPLANATION OF SAFETY WARNING ICONS
EAR PROTECTION - Headphones over ears shows that noise level will harm ears.
ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.
EYE PROTECTION - Person with goggles shows that the material will injure the eyes.
FLYING PARTICLES - Arrows bouncing off face with face shield show that particles flying through the air will harm face.
HEAVY OBJECT - Human figure stooping under heavy object shows physical injury potential from improper lifting techniques.
HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm.
HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm.
03/15/2011 Rel(1.8) root(warnsum) wpno(F00002)
TM 5-3810-305-23
WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued
HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb.
HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.
HOT AREA - Hand over object radiating heat shows that part is hot and can burn.
MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.
MOVING PARTS - Human figure with an arm caught between gears shows that the moving parts of the equipment present a danger to life or limb.
GENERAL SAFETY WARNING DESCRIPTIONS
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield.
TM 5-3810-305-23

GENERAL SAFETY WARNING DESCRIPTIONS - Continued
WARNING
Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Safety glasses must be used when cleaning parts. Failure to follow this warning may result in injury or death to personnel.
WARNING
Before performing this test, turn the crane power off then on again to ensure that an existing two block warning and/or motion cut has not been overridden. During this test, DO NOT use the cancel alarm button to clear audible warnings or motion cuts. During this test, DO NOT winch the hook block into the boom tip, in case the system does not cut the crane motions. Slowly raise the hook block until it lifts the anti-two block weight and deactivates the antitwo block switch. Failure to follow these warnings may result in damage to equipment or injury or death to personnel.
WARNING
Keep hands out of path of spring-loaded tensioner. Keep fingers from between belt and pulley. Failure to follow these warnings may cause serious injury if tensioner slips.
TM 5-3810-305-23

WARNING
Wear protective gloves when handling hot gear. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of crankshaft is approximately 80 lbs (36 kgs). Use adequate lifting equipment to lift and support crankshaft. Keep hands out of component. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of cylinder head is approximately 80 lbs (36 kgs). Use adequate lifting equipment to lift and support cylinder head. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel.
WARNING
Wear eye protection when driving ring gear from flywheel. Serious injury to personnel may result from flying metal fragments. DO NOT use a steel drift pin.
TM 5-3810-305-23

WARNING
Wear protective gloves when installing ring gear. Serious injury to personnel may result if hot gear contacts skin.
WARNING
Weight of engine and transmission assembly is approximately 1,800 lbs (816 kgs). Use adequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of transmission is approximately 1,100 lbs (499 kgs). Use adequate lifting equipment to lift and support transmission. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of engine is approximately 700 lbs (318 kgs). Use adequate lifting equipment to lift and support engine. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Weight of radiator and oil cooler assembly is approximately 300 lbs (136 kgs). Use adequate lifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of converter assembly is approximately 60 lbs (27 kgs). Use adequate lifting equipment to lift and support converter assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of output disconnect group is approximately 67 lbs (30 kgs). Use adequate lifting equipment to lift and support output disconnect group. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of front cover is approximately 226 lbs (103 kgs). Use adequate lifting equipment to lift and support front cover. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Weight of clutch group is approximately 139 lbs (63 kgs). Use adequate lifting equipment to lift and support clutch group. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Wear protective gloves when handling hot bearing. Serious injury to personnel may result if hot bearing contacts skin.
WARNING
Parts are under spring tension. Serious injury to personnel may result from flying parts. Always wear eye protection.
TM 5-3810-305-23

WARNING
Never reinflate a tire that has been run flat or seriously underinflated without removing and checking for tire tube or rim damage. Never exceed 3 psi (21 kPa) inflation prior to placing tire and wheel assembly into inflation safety cage or mounting on a tire change machine that has a positive lockdown device. Always inflate tires that are mounted on rims with demountable side ring flanges or lock rings in an inflation safety cage. When inflating tires in an inflation cage, always use extension air hose and pneumatic tire inflator-gage. Improperly seated side ring flanges or lock rings may fly off during inflation. Never attempt to seat a side ring flange or lock ring during inflation or after inflation. Never inflate tires over 40 psi (276 kPa) to seat tire beads. If beads do not seat, deflate, demount, and check the tire/rim match. Mount and lubricate according to instructions. When inflating tires mounted on the vehicle, all personnel must remain a minimum of 10 ft (3.1 m) away from tire and not in possible path of lock ring or rim flange. Should they fly off, serious injury or death may result. Failure to follow these warnings may cause injury or death to personnel.
WARNING
Weight of axle assembly is approximately 1,323 lbs (600 kgs). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of differential assembly is approximately 120 lbs (54 kgs). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Heating differential mounting bolts to a temperature of 300F (149C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may cause injury or death to personnel.
WARNING
Wear protective equipment while heating and handling bearing cone. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of pivot and spindle assembly is approximately 69 lbs (30 kgs). Use adequate lifting equipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of housing assembly is approximately 631 lbs (286 kgs). Use adequate lifting equipment to lift and support housing assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. The brake linings contain asbestos. Wear a protective breather respirator when performing maintenance on the brake assembly and brake drum. Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warnings may cause injury or death to personnel.
WARNING
Weight of hub and studs is approximately 79 lbs (36 kgs). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel.
WARNING
Wear protective equipment while heating and handling seal runner. Failure to follow this warning may cause serious injury to personnel.
TM 5-3810-305-23

WARNING
Weight of boom is approximately 3,100 lbs (1,406 kgs). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel.
WARNING
Weight of boom hoist cylinder is approximately 507 lbs (230 kgs). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Heating nut to a temperature of approximately 300F (149C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling parts. Failure to follow this warning may cause injury or death to personnel.
WARNING
Stay clear of boom hoist cylinder rod while extending and retracting to remove air. Serious injury to personnel may result if rod jumps unexpectedly.
TM 5-3810-305-23

WARNING
Weight of hydraulic reservoir is approximately 190 lbs (86 kgs). Use adequate lifting equipment to lift and support hydraulic reservoir. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of outrigger cylinder assembly is approximately 125 lbs (57 kgs). Use adequate lifting equipment to lift and support outrigger cylinder assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of manifold is approximately 200 lbs (91 kgs). Use adequate lifting equipment to lift and support manifold. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of cab is approximately 250 lbs (113 kgs). Use adequate lifting equipment to lift and support cab. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Weight of fender is approximately 99 lbs (45 kgs). Use adequate lifting equipment to support fender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of toolbox is approximately 180 lbs (82 kgs). Use adequate lifting equipment to support toolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of beam is approximately 129 lbs (59 kgs). Use adequate lifting equipment to lift and support beam. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of swing bearing is approximately 187 lbs (85 kgs). Use adequate lifting equipment to lift and support swing bearing. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Weight of swing gearbox is approximately 125 lbs (57 kgs). Use adequate lifting equipment to lift and support swing gearbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of counterweight is approximately 2,200 lbs (998 kgs). Use adequate lifting equipment to lift and support counterweight. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of upperstructure is approximately 6,000 lbs (2,722 kgs). Use adequate lifting equipment to lift and support upperstructure. DO NOT lift over personnel or let personnel walk underneath suspended load. Upperstructure must be properly supported when lowering to ground. Failure to follow these warnings may cause injury or death to personnel.
WARNING
Weight of boom tip section is approximately 1,500 lbs (680 kgs). Use adequate lifting equipment to lift and support boom tip section. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Weight of boom extend cylinder is approximately 415 lbs (188 kgs). Use adequate lifting equipment to lift and support boom extend cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of hook block is approximately 235 lbs (107 kgs). Use adequate lifting equipment to lift and support hook block. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
WARNING
Make sure snapring is seated in groove in splined bore of cam. Snapring will keep brake clutch assembly correctly positioned in center of friction brake pack. Brake may bind or fail if snapring is not correctly installed. Failure to follow this warning may cause injury or death to personnel.
WARNING
Weight of winch is approximately 300 lbs (136 kgs). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow these warnings may result in injury or death to personnel.
WARNING
Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield.
WARNING
DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness may result in serious injury or death if it hits personnel.
WARNING
Safety glasses or face protection must be used when working with compressed air. Failure to follow this warning may result in serious injury to personnel.
TM 5-3810-305-23

WARNING
Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel.
WARNING
If necessary, heat differential mounting bolts to a temperature of 300F (149C) to break down sealant. Hot surface may cause burns or injury. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may result in serious injury to personnel.
WARNING
Wear protective equipment while heating and handling spacer. Failure to follow this warning may result in serious injury to personnel.
WARNING
When deflating tires, always ensure tire is completely deflated before removing from rim. Failure to follow this warning may result in serious injury or death to personnel.
TM 5-3810-305-23

WARNING
When inflating tires, always ensure tires are properly seated. Improperly seated tires can burst with explosive force. DO NOT mix one type of wheel with a different type of tire. Improper seating of these components can cause tire and wheel to fly apart with explosive force. Failure to follow these warnings may result in serious injury or death to personnel.
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Wear protective eye covering. Serious injury to personnel may result from flying metal fragments. Wear protective gloves when handling hot parts. Failure to follow these warnings may result in injury or death to personnel.
WARNING
Keep all personnel away from winch and hook block area. Failure to follow this warning may result in death or serious injury to personnel.
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in injury or death to personnel.
TM 5-3810-305-23

WARNING
Ensure to tag all cables and valve body properly before disconnecting. Failure to follow this warning may result in injury or death to personnel.
WARNING
Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel.
WARNING
Do not use outriggers to support vehicle. Failure to follow this warning may result in serious injury or death to personnel.
WARNING
Do not remove lifting device until hydraulic pressure has been built up. Failure to follow these warnings may result in damage to equipment or injury or death to personnel. EXPLANATION OF HAZARDOUS MATERIALS ICONS
BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria or viruses that present a danger to life or health.
TM 5-3810-305-23

EXPLANATION OF HAZARDOUS MATERIALS ICONS - Continued
CHEMICAL - Drop of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.
FIRE - Flame shows that a material may ignite and cause burns.
HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human hand shows that fluid escaping under great pressure can cause injury or death to personnel.
RADIOACTIVE - Identifies a material that emits radioactive energy and can injure human tissue or organs.
VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.
HAZARDOUS MATERIALS DESCRIPTIONS
WARNING
ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel.
TM 5-3810-305-23

HAZARDOUS MATERIALS DESCRIPTIONS - Continued
WARNING
BATTERIES Battery gases can explode. DO NOT smoke or allow sparks or open flames near batteries. Wear safety glasses or goggles when checking the batteries. To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury or death to personnel. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Seek medical attention in the event of an injury. a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia. Failure to follow these warnings may cause injury or death to personnel.
TM 5-3810-305-23

WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL! Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death to personnel can result from severe exposure. Carbon monoxide occurs in exhaust fumes of internal combustion engines. It also occurs in exhaust fumes of engine coolant heater (arctic vehicle only). Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of crane is operated. 1. 2. 3. 4. DO NOT operate engine in enclosed areas without adequate ventilation. DO NOT idle engine without adequate ventilation. DO NOT drive vehicle with inspection plates or cover plates removed. BE ALERT for exhaust poisoning symptoms. They are: Headache Dizziness Sleepiness Loss of muscular control
5. If you see another person with exhaust poisoning symptoms: Remove person from area. Expose person to fresh air. Keep person warm. DO NOT permit physical exercise. Administer cardiopulmonary resuscitation (CPR), if necessary. Notify a medic.
6. BE AWARE. The field protective mask for Nuclear-Biological-Chemical (NBC) protection will not protect you from carbon monoxide poisoning.
TM 5-3810-305-23

WARNING
CBRN EXPOSURE If Chemical, Biological, Radioactive and Nuclear (CBRN) exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may cause injury or death to personnel. Seek medical attention.
To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083
TM 5-3810-305-23

WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel.
WARNING
If vehicle is parked indoors during performance of Preventive Maintenance Checks and Services (PMCS), DO NOT run engine unless exhaust fumes are vented to the outside. Failure to follow this warning may cause injury or death to personnel due to carbon monoxide poisoning.
WARNING
Diesel fuel and other combustible materials are used in operation and maintenance of this equipment. DO NOT smoke or allow open flames in areas where combustible materials are stored or used. Failure to follow this warning may cause injury or death to personnel.
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.
TM 5-3810-305-23

WARNING
Never perform fan hub bearing end play check with the engine running. Failure to follow this warning may cause death or injury to personnel.
WARNING
Cooling system is pressurized. Use extreme caution and proper protection when removing radiator cap after operating temperature is reached. Steam and hot gases will be escaping through the radiator cap; avoid being burned by these escaping gases. When removing cap, loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed. Failure to follow this warning may cause death or injury to personnel.
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel.
TM 5-3810-305-23

WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities procedures. Eye shields must be worn when cleaning with a wire brush. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. Failure to follow these warnings may result in injury or death to personnel.
WARNING
When servicing equipment, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, or Chemical Agent Resistance Coating (CARC) paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Wear protective eye covering. Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit. Failure to follow these warnings may result in injury or death to personnel.
TM 5-3810-305-23

WARNING
The brake linings contain asbestos. Wear protective breather respirator when performing maintenance on the brake assembly and brake drum. Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warnings may cause injury or death to personnel.
WARNING
Liquid nitrogen is extremely cold, having a temperature of -320F (-195C). Wear protective gloves that will not absorb liquid nitrogen. Excess liquid nitrogen must be disposed of promptly since liquid nitrogen will condense oxygen from the atmosphere. The mixture of liquid nitrogen and liquid oxygen is a powerful oxidizer and may react violently with easily oxidizable substances. Failure to follow this warning may cause injury or death to personnel.
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Hot coolant and alkali contained in cooling system can burn severely. Even with cooling system drained, residual coolant remains in system lines and fittings. Wear protective goggles, face shield, and clothing when handling cooling system components. If coolant contacts eyes, skin, or clothing, flush with large amounts of cold water and seek medical attention, if required. Failure to follow these warnings may result in injury or death to personnel.
aa
TM 5-3810-305-23

WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel.
WARNING
Weight of differential assembly is approximately 120 lbs (54 kgs). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. Failure to follow these warnings may result in serious injury or death to personnel.
ab
TM 5-3810-305-23

WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may result in serious injury or death to personnel.
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TM 5-3810-305-23
LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes. Zero in the "Change No." column indicates an original page or work package. Date of issue for the original manual is: Original 14 September 2012
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 106 AND TOTAL NUMBER OF WORK PACKAGES IS 172 CONSISTING OF THE FOLLOWING: Page/WP No. Front Cover Warning Summary (30 pages) Title Block Page (2 pages) Table of Contents (44 pages) How to Use This Manual (2 pages) Chapter 1 Title Page WP 0001 (4 pages) WP 0002 (18 pages) WP 0003 (2 pages) Chapter 2 Title Page WP 0004 (6 pages) WP 0005 (16 pages) WP 0006 (4 pages) WP 0007 (4 pages) WP 0008 (4 pages) WP 0009 (4 pages) WP 0010 (4 pages) WP 0011 (10 pages) WP 0012 (6 pages) WP 0013 (2 pages) WP 0014 (4 pages) WP 0015 (6 pages) WP 0016 (4 pages) WP 0017 (8 pages) WP 0018 (4 pages) WP 0019 (6 pages) WP 0020 (8 pages) Chapter 3 Title Page WP 0021 (2 pages) WP 0022 (24 pages) Chapter 4 Title Page WP 0023 (4 pages) WP 0024 (28 pages) WP 0025 (2 pages) WP 0026 (2 pages) WP 0027 (6 pages) WP 0028 (2 pages) WP 0029 (8 pages) WP 0030 (6 pages) WP 0031 (8 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0032 (6 pages) WP 0033 (4 pages) WP 0034 (4 pages) WP 0035 (2 pages) WP 0036 (4 pages) WP 0037 (8 pages) WP 0038 (4 pages) WP 0039 (6 pages) WP 0040 (4 pages) WP 0041 (4 pages) WP 0042 (4 pages) WP 0043 (4 pages) WP 0044 (22 pages) WP 0045 (4 pages) WP 0046 (6 pages) WP 0047 (8 pages) WP 0048 (4 pages) WP 0049 (16 pages) WP 0050 (4 pages) WP 0051 (6 pages) WP 0052 (12 pages) WP 0053 (6 pages) WP 0054 (20 pages) WP 0055 (4 pages) WP 0056 (4 pages) WP 0057 (4 pages) WP 0058 (4 pages) WP 0059 (4 pages) WP 0060 (8 pages) WP 0061 (4 pages) WP 0062 (4 pages) WP 0063 (4 pages) WP 0064 (4 pages) WP 0065 (4 pages) WP 0066 (30 pages) WP 0067 (6 pages) WP 0068 (4 pages) WP 0069 (2 pages) WP 0070 (10 pages) WP 0071 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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*TM 5-3810-305-23
HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 14 SEPTEMBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR
CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON (ROUGH TERRAIN CRANE) LRT 110 TYPE I GENERAL PURPOSE NSN 3810-01-165-0646 TYPE II AIRBORNE/AIRMOBILE NSN 3810-01-165-0647
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.
*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.
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TABLE OF CONTENTS
Page No. WP Sequence No. HOW TO USE THIS MANUAL ......................................................................................................................... xlvii Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Figure 2. Figure 3. Figure 4. Table 1. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Major Components............................................................................................................... 0002-2 Major Components............................................................................................................... 0002-4 Major Components............................................................................................................... 0002-5 Major Components............................................................................................................... 0002-6 Gear Range Values............................................................................................................ 0002-13 General Dimensions........................................................................................................... 0002-14 General Dimensions........................................................................................................... 0002-15 Radius from Centerline of Rotation.................................................................................... 0002-16 Crane Working Positions.................................................................................................... 0002-17 Lift Capacity (on Outriggers).............................................................................................. 0002-17 Lift Capacity (on Tires)....................................................................................................... 0002-18 Maximum Permissible Hoist Line Load.............................................................................. 0002-18
THEORY OF OPERATION.......................................................................................................................... WP 0003 Chapter 2 - TROUBLESHOOTING PROCEDURES TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0004 TROUBLESHOOTING PROCEDURES ENGINE........................................................................................ WP 0005 TROUBLESHOOTING PROCEDURES HYDRAULICS.............................................................................. WP 0006 TROUBLESHOOTING PROCEDURES SWING CIRCUIT.......................................................................... WP 0007 TROUBLESHOOTING PROCEDURES BOOM HOIST CIRCUIT............................................................... WP 0008 TROUBLESHOOTING PROCEDURES BOOM EXTEND CIRCUIT........................................................... WP 0009 TROUBLESHOOTING PROCEDURES OUTRIGGER CIRCUIT................................................................ WP 0010 TROUBLESHOOTING PROCEDURES STEERING CIRCUIT................................................................... WP 0011 TROUBLESHOOTING PROCEDURES PUMPS......................................................................................... WP 0012
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Page No. WP Sequence No. TROUBLESHOOTING PROCEDURES RELIEF VALVES.......................................................................... WP 0013 TROUBLESHOOTING PROCEDURES BRAKES....................................................................................... WP 0014 TROUBLESHOOTING PROCEDURES ELECTRICAL SYSTEM............................................................... WP 0015 TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK SYSTEM....................................................... WP 0016 TROUBLESHOOTING PROCEDURES TRANSMISSION.......................................................................... WP 0017 TROUBLESHOOTING PROCEDURES AXLE ASSEMBLY........................................................................ WP 0018 TROUBLESHOOTING PROCEDURES WINCH......................................................................................... WP 0019 MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE...................................................................... WP 0020 Figure 1. Figure 2. Remove Cap from DCA Receptacle..................................................................................... 0020-3 Schematics and Diagrams................................................................................................... 0020-7
Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION............................. WP 0021 Table 1. Leakage Definitions for PMCS............................................................................................. 0021-2
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0022 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Preventive Maintenance Checks and Services (PMCS)...................................................... 0022-2 Winch Lubrication Level Access Plug.................................................................................. 0022-3 Air Cleaner Element Maintenance........................................................................................ 0022-5 Engine Oil and Filter Change............................................................................................... 0022-6 Fuel Tank Drain Plug............................................................................................................ 0022-7 Hydraulic Suction Filter Removal......................................................................................... 0022-9 Transmission Fluid Change................................................................................................ 0022-10 Check Antifreeze Concentration......................................................................................... 0022-11 Check Axle Differential and Hub Oil Levels........................................................................ 0022-12 Check Axle Differential and Hub Oil Levels........................................................................ 0022-12 Check Fan Hub Bearing End Play...................................................................................... 0022-13 Winch Oil Change.............................................................................................................. 0022-14 Add Hydraulic Oil................................................................................................................ 0022-16
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Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Bleed Air from Hydraulic Reservoir.................................................................................... 0022-17 Swing Reduction Unit Oil Change...................................................................................... 0022-18 Differential Oil Filter............................................................................................................ 0022-19 Engine Coolant Change..................................................................................................... 0022-20 Engine Coolant Change..................................................................................................... 0022-21 Check Hydraulic Pressure Relief Valves............................................................................ 0022-22 Relief Valve Adjustment..................................................................................................... 0022-24
Chapter 4 - MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT......................................................................................................................... WP 0023 Figure 1. Vehicle Check Points........................................................................................................... 0023-3
POWER PACK ASSEMBLY MAINTENANCE............................................................................................. WP 0024 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Power Pack Removal........................................................................................................... 0024-2 Power Pack Removal........................................................................................................... 0024-3 Power Pack Removal........................................................................................................... 0024-4 Power Pack Removal........................................................................................................... 0024-4 Power Pack Removal........................................................................................................... 0024-5 Power Pack Removal........................................................................................................... 0024-6 Power Pack Removal........................................................................................................... 0024-7 Power Pack Removal........................................................................................................... 0024-8 Power Pack Removal........................................................................................................... 0024-9 Power Pack Removal........................................................................................................... 0024-9 Power Pack Removal......................................................................................................... 0024-10 Power Pack Removal......................................................................................................... 0024-10 Power Pack Removal......................................................................................................... 0024-11 Power Pack Removal......................................................................................................... 0024-12 Power Pack Removal......................................................................................................... 0024-13 Transmission from Engine Removal.................................................................................. 0024-14
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Page No. WP Sequence No. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Transmission from Engine Removal.................................................................................. 0024-15 Transmission from Engine Removal.................................................................................. 0024-16 Transmission to Engine Installation.................................................................................... 0024-17 Transmission to Engine Installation.................................................................................... 0024-18 Transmission to Engine Installation.................................................................................... 0024-19 Transmission to Engine Installation.................................................................................... 0024-20 Power Pack Installation...................................................................................................... 0024-21 Power Pack Installation...................................................................................................... 0024-22 Power Pack Installation...................................................................................................... 0024-22 Power Pack Installation...................................................................................................... 0024-23 Power Pack Installation...................................................................................................... 0024-23 Power Pack Installation...................................................................................................... 0024-24 Power Pack Installation...................................................................................................... 0024-24 Power Pack Installation...................................................................................................... 0024-25 Power Pack Installation...................................................................................................... 0024-25 Power Pack Installation...................................................................................................... 0024-26 Power Pack Installation...................................................................................................... 0024-26 Power Pack Installation...................................................................................................... 0024-27 Power Pack Installation...................................................................................................... 0024-27 Power Pack Installation...................................................................................................... 0024-28
ENGINE ASSEMBLY MAINTENANCE........................................................................................................ WP 0025 ENGINE MOUNT MAINTENANCE.............................................................................................................. WP 0026 Figure 1. Figure 2. Engine Mount Removal........................................................................................................ 0026-1 Engine Mount Installation..................................................................................................... 0026-2
CYLINDER HEAD MAINTENANCE............................................................................................................. WP 0027 Figure 1. Figure 2. Cylinder Head Removal....................................................................................................... 0027-2 Cylinder Head Removal....................................................................................................... 0027-3
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Page No. WP Sequence No. Figure 3. Figure 4. Cylinder Head Installation.................................................................................................... 0027-4 Cylinder Head Installation.................................................................................................... 0027-5
CRANKSHAFT PULLEY MAINTENANCE................................................................................................... WP 0028 Figure 1. Figure 2. Crankshaft Pulley Removal.................................................................................................. 0028-1 Crankshaft Pulley Installation............................................................................................... 0028-2
FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE........................................................................ WP 0029 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Flywheel Removal................................................................................................................ 0029-1 Flywheel Removal................................................................................................................ 0029-2 Flywheel Installation............................................................................................................. 0029-3 Flywheel Installation............................................................................................................. 0029-3 Flywheel Installation............................................................................................................. 0029-4 Flywheel Installation............................................................................................................. 0029-5 Flywheel Installation............................................................................................................. 0029-6 Flywheel Installation............................................................................................................. 0029-6
REAR CRANKSHAFT SEAL MAINTENANCE............................................................................................ WP 0030 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Rear Seal Removal.............................................................................................................. 0030-2 Rear Seal Removal.............................................................................................................. 0030-2 Rear Seal Removal.............................................................................................................. 0030-3 Rear Seal Installation........................................................................................................... 0030-4 Rear Seal Installation........................................................................................................... 0030-5
ROCKER LEVERS AND PUSH RODS MAINTENANCE............................................................................ WP 0031 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cylinder Head Removal....................................................................................................... 0031-2 Rocker Lever and Push Rods Removal............................................................................... 0031-2 Rocker Lever and Push Rods Disassembly......................................................................... 0031-3 Rocker Lever and Push Rods Disassembly......................................................................... 0031-3 Rocker Lever and Push Rods Inspection............................................................................. 0031-4 Rocker Lever and Push Rods Inspection............................................................................. 0031-4
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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Rocker Lever and Push Rods Inspection............................................................................. 0031-5 Rocker Lever and Push Rods Assembly.............................................................................. 0031-5 Rocker Lever and Push Rods Assembly.............................................................................. 0031-6 Rocker Lever and Push Rods Installation............................................................................ 0031-6 Cylinder Head Installation.................................................................................................... 0031-7
FRONT GEAR COVER AND GASKET MAINTENANCE............................................................................ WP 0032 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Tachometer Drive Removal.................................................................................................. 0032-2 Front Cover Removal........................................................................................................... 0032-3 Front Gear Train Installation................................................................................................. 0032-4 Front Cover Installation........................................................................................................ 0032-5 Tachometer Drive Installation............................................................................................... 0032-6
TIMING PIN ASSEMBLY MAINTENANCE.................................................................................................. WP 0033 Figure 1. Figure 2. Figure 3. Timing Pin Assembly Removal............................................................................................. 0033-1 Timing Pin Assembly Removal............................................................................................. 0033-2 Timing Pin Assembly Installation.......................................................................................... 0033-3
TAPPET COVER AND GASKET MAINTENANCE...................................................................................... WP 0034 Figure 1. Tappet Cover Installation..................................................................................................... 0034-3
VALVE COVERS AND GASKET MAINTENANCE...................................................................................... WP 0035 Figure 1. Figure 2. Valve Covers Removal......................................................................................................... 0035-1 Valve Covers Installation...................................................................................................... 0035-2
FRONT CRANKSHAFT SEAL MAINTENANCE.......................................................................................... WP 0036 Figure 1. Figure 2. Front Seal Removal.............................................................................................................. 0036-2 Front Seal Installation........................................................................................................... 0036-4
LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE.................................................... WP 0037 Figure 1. Figure 2. Figure 3. Lube Oil Cooler Removal..................................................................................................... 0037-2 Lube Oil Cooler Removal..................................................................................................... 0037-2 Lube Oil Cooler Removal..................................................................................................... 0037-3
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Page No. WP Sequence No. Figure 4. Figure 5. Table 1. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Lube Oil Cooler Disassembly............................................................................................... 0037-3 Lube Oil Cooler Disassembly............................................................................................... 0037-4 Pressure Regulator Spring Limits......................................................................................... 0037-4 Lube Oil Cooler Inspection................................................................................................... 0037-5 Lube Oil Cooler Assembly.................................................................................................... 0037-6 Lube Oil Cooler Installation.................................................................................................. 0037-6 Lube Oil Cooler Installation.................................................................................................. 0037-7 Lube Oil Cooler Installation.................................................................................................. 0037-7
LUBE OIL PUMP MAINTENANCE.............................................................................................................. WP 0038 Figure 1. Figure 2. Figure 3. Lube Oil Pump Removal...................................................................................................... 0038-1 Lube Oil Pump Removal...................................................................................................... 0038-2 Lube Oil Pump Installation................................................................................................... 0038-3
OIL PAN AND SUCTION TUBE MAINTENANCE....................................................................................... WP 0039 Figure 1. Figure 2. Figure 3. Figure 4. Oil Pan and Suction Tube Removal..................................................................................... 0039-2 Oil Pan and Suction Tube Removal..................................................................................... 0039-3 Oil Pan and Suction Tube Installation.................................................................................. 0039-5 Oil Pan and Suction Tube Installation.................................................................................. 0039-6
OIL LEVEL GAGE MAINTENANCE............................................................................................................ WP 0040 Figure 1. Figure 2. Figure 3. Oil Level Gage Removal...................................................................................................... 0040-1 Oil Level Gage Removal...................................................................................................... 0040-2 Oil Level Gage Installation................................................................................................... 0040-3
INTAKE MANIFOLD COVER AND GASKET MAINTENANCE................................................................... WP 0041 Figure 1. Figure 2. Manifold Cover Plate Removal............................................................................................. 0041-1 Manifold Cover Plate Installation.......................................................................................... 0041-2
EXHAUST MANIFOLD AND GASKETS MAINTENANCE........................................................................... WP 0042 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0042-1 Exhaust Manifold Removal................................................................................................... 0042-2
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Page No. WP Sequence No. Figure 3. Exhaust Manifold Installation................................................................................................ 0042-2
FUEL INJECTOR MAINTENANCE.............................................................................................................. WP 0043 Figure 1. Figure 2. Figure 3. Figure 4. Injector Nozzles Removal..................................................................................................... 0043-2 Injector Nozzles Removal..................................................................................................... 0043-2 Lube Oil Injector Nozzles Installation................................................................................... 0043-3 Injector Nozzles Installation.................................................................................................. 0043-4
FUEL INJECTION PUMP MAINTENANCE................................................................................................. WP 0044 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Injection Pump Removal...................................................................................................... 0044-2 Injection Pump Removal...................................................................................................... 0044-3 Injection Pump Removal...................................................................................................... 0044-3 Injection Pump Removal...................................................................................................... 0044-4 Injection Pump Removal...................................................................................................... 0044-4 Injection Pump Removal...................................................................................................... 0044-5 Injection Pump Disassembly................................................................................................ 0044-6 Injection Pump Disassembly................................................................................................ 0044-7 Injection Pump Disassembly................................................................................................ 0044-7 Injection Pump Disassembly................................................................................................ 0044-8 Injection Pump Disassembly................................................................................................ 0044-8 Injection Pump Disassembly................................................................................................ 0044-9 Injection Pump Disassembly................................................................................................ 0044-9 Injection Pump Disassembly.............................................................................................. 0044-10 Injection Pump Disassembly.............................................................................................. 0044-11 Injection Pump Disassembly.............................................................................................. 0044-11 Injection Pump Disassembly.............................................................................................. 0044-12 Injection Pump Assembly................................................................................................... 0044-13 Injection Pump Assembly................................................................................................... 0044-14 Injection Pump Assembly................................................................................................... 0044-15
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Page No. WP Sequence No. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Injection Pump Assembly................................................................................................... 0044-15 Injection Pump Assembly................................................................................................... 0044-16 Injection Pump Assembly................................................................................................... 0044-16 Injection Pump Assembly................................................................................................... 0044-17 Injection Pump Assembly................................................................................................... 0044-17 Injection Pump Assembly................................................................................................... 0044-18 Injection Pump Assembly................................................................................................... 0044-18 Injection Pump Assembly................................................................................................... 0044-19 Injection Pump Installation................................................................................................. 0044-19 Injection Pump Installation................................................................................................. 0044-20 Injection Pump Installation................................................................................................. 0044-20 Injection Pump Installation................................................................................................. 0044-21 Injection Pump Installation................................................................................................. 0044-21 Injection Pump Installation................................................................................................. 0044-22
FUEL LIFT PUMP MAINTENANCE............................................................................................................. WP 0045 Figure 1. Figure 2. Lift Pump Removal............................................................................................................... 0045-2 Lift Pump Installation............................................................................................................ 0045-3
AIR CLEANER ASSEMBLY MAINTENANCE............................................................................................. WP 0046 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Air Cleaner Removal............................................................................................................ 0046-2 Air Cleaner Removal............................................................................................................ 0046-3 Air Cleaner Maintenance...................................................................................................... 0046-5 Air Cleaner Installation......................................................................................................... 0046-5 Air Cleaner Installation......................................................................................................... 0046-6
FUEL TANK MAINTENANCE...................................................................................................................... WP 0047 Figure 1. Figure 2. Figure 3. Fuel Tank Removal.............................................................................................................. 0047-1 Fuel Tank Removal.............................................................................................................. 0047-2 Fuel Tank Disassembly........................................................................................................ 0047-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Fuel Tank Disassembly........................................................................................................ 0047-3 Fuel Tank Assembly............................................................................................................. 0047-4 Fuel Tank Assembly............................................................................................................. 0047-5 Fuel Tank Installation........................................................................................................... 0047-6 Fuel Tank Installation........................................................................................................... 0047-7
FUEL LINES MAINTENANCE..................................................................................................................... WP 0048 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Fuel Lines Removal.............................................................................................................. 0048-1 Fuel Lines Removal.............................................................................................................. 0048-2 Fuel Lines Installation........................................................................................................... 0048-3 Fuel Lines Installation........................................................................................................... 0048-3 Fuel Lines Installation........................................................................................................... 0048-4
FUEL INJECTION TUBES MAINTENANCE................................................................................................ WP 0049 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. High-Pressure Tubes Removal............................................................................................ 0049-2 High-Pressure Tubes Removal............................................................................................ 0049-3 High-Pressure Tubes Removal............................................................................................ 0049-4 Low-Pressure Tubes Removal............................................................................................. 0049-5 Low-Pressure Tubes Removal............................................................................................. 0049-6 Low-Pressure Tubes Removal............................................................................................. 0049-7 Fuel Drain Tubes Removal................................................................................................... 0049-8 Fuel Drain Tubes Removal................................................................................................... 0049-9 Fuel Drain Tubes Installation.............................................................................................. 0049-10 Fuel Drain Tubes Installation.............................................................................................. 0049-11 Low-Pressure Tubes Installation........................................................................................ 0049-12 Low-Pressure Tubes Installation........................................................................................ 0049-13 Low-Pressure Tubes Installation........................................................................................ 0049-14 High-Pressure Tubes Installation....................................................................................... 0049-15 High-Pressure Tubes Installation....................................................................................... 0049-16
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Page No. WP Sequence No. FUEL FILTER HEAD ASSEMBLY MAINTENANCE.................................................................................... WP 0050 Figure 1. Figure 2. Figure 3. Fuel Filters and Head Assembly Removal........................................................................... 0050-1 Fuel Filters and Head Assembly Maintenance..................................................................... 0050-2 Fuel Filters and Head Assembly Installation........................................................................ 0050-3
COLD START DEVICE MAINTENANCE..................................................................................................... WP 0051 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cold Start Device Removal.................................................................................................. 0051-1 Cold Start Device Removal.................................................................................................. 0051-2 Cold Start Device Removal.................................................................................................. 0051-2 Cold Start Device Removal.................................................................................................. 0051-3 Cold Start Device Installation............................................................................................... 0051-4 Cold Start Device Installation............................................................................................... 0051-4 Cold Start Device Installation............................................................................................... 0051-5 Cold Start Device Installation............................................................................................... 0051-6
THROTTLE CONTROL MAINTENANCE.................................................................................................... WP 0052 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Throttle Control Removal..................................................................................................... 0052-2 Throttle Control Removal..................................................................................................... 0052-2 Throttle Control Removal..................................................................................................... 0052-3 Throttle Control Removal..................................................................................................... 0052-3 Throttle Control Removal..................................................................................................... 0052-4 Throttle Control Maintenance............................................................................................... 0052-5 Throttle Control Installation.................................................................................................. 0052-6 Throttle Control Installation.................................................................................................. 0052-7 Throttle Control Installation.................................................................................................. 0052-7 Throttle Control Installation.................................................................................................. 0052-8 Throttle Control Installation.................................................................................................. 0052-9 Throttle Control Adjustment................................................................................................ 0052-10
EXHAUST SYSTEM ASSEMBLY MAINTENANCE..................................................................................... WP 0053
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Exhaust System Removal.................................................................................................... 0053-1 Exhaust System Removal.................................................................................................... 0053-2 Exhaust System Maintenance.............................................................................................. 0053-3 Exhaust System Installation................................................................................................. 0053-4 Exhaust System Installation................................................................................................. 0053-5
RADIATOR AND OIL COOLER MAINTENANCE........................................................................................ WP 0054 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Radiator and Oil Cooler Removal......................................................................................... 0054-2 Radiator and Oil Cooler Removal......................................................................................... 0054-3 Radiator and Oil Cooler Removal......................................................................................... 0054-4 Radiator and Oil Cooler Removal......................................................................................... 0054-5 Radiator and Oil Cooler Removal......................................................................................... 0054-6 Radiator and Oil Cooler Removal......................................................................................... 0054-7 Radiator and Oil Cooler Removal......................................................................................... 0054-7 Radiator and Oil Cooler Removal......................................................................................... 0054-8 Radiator and Oil Cooler Removal......................................................................................... 0054-9 Radiator and Air Cooler Assembly..................................................................................... 0054-11 Radiator and Air Cooler Installation.................................................................................... 0054-12 Radiator and Air Cooler Installation.................................................................................... 0054-13 Radiator and Air Cooler Installation.................................................................................... 0054-14 Radiator and Air Cooler Installation.................................................................................... 0054-14 Radiator and Air Cooler Installation.................................................................................... 0054-15 Radiator and Air Cooler Installation.................................................................................... 0054-16 Radiator and Air Cooler Installation.................................................................................... 0054-17 Radiator and Air Cooler Installation.................................................................................... 0054-17 Radiator and Air Cooler Installation.................................................................................... 0054-18
DEFROSTER FAN MAINTENANCE........................................................................................................... WP 0055 Figure 1. Defroster Fan Maintenance.................................................................................................. 0055-3
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Page No. WP Sequence No. THERMOSTAT MAINTENANCE................................................................................................................. WP 0056 Figure 1. Figure 2. Figure 3. Figure 4. Thermostat Removal............................................................................................................ 0056-2 Thermostat Removal............................................................................................................ 0056-2 Thermostat Installation......................................................................................................... 0056-3 Thermostat Installation......................................................................................................... 0056-4
WATER INLET CONNECTION MAINTENANCE........................................................................................ WP 0057 Figure 1. Figure 2. Water Inlet Connection Removal.......................................................................................... 0057-2 Water Inlet Connection Installation....................................................................................... 0057-3
WATER PUMP MAINTENANCE................................................................................................................. WP 0058 Figure 1. Figure 2. Figure 3. Water Pump Removal.......................................................................................................... 0058-1 Water Pump Inspection........................................................................................................ 0058-2 Water Pump Installation....................................................................................................... 0058-3
FAN DRIVE BELT MAINTENANCE ............................................................................................................ WP 0059 Figure 1. Figure 2. Fan Drive Belt Removal....................................................................................................... 0059-2 Fan Drive Belt Installation.................................................................................................... 0059-3
COOLING FAN AND HUB ASSEMBLY MAINTENANCE........................................................................... WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Cooling Fan Removal........................................................................................................... 0060-1 Fan Pulley Removal............................................................................................................. 0060-2 Fan Drive Removal............................................................................................................... 0060-2 Hub Assembly Disassembly................................................................................................. 0060-3 Roller Bearing Disassembly................................................................................................. 0060-3 Roller Bearing Assembly...................................................................................................... 0060-4 Hub Assembly Assembly...................................................................................................... 0060-5 Fan Drive Installation............................................................................................................ 0060-5 Fan Pulley Installation.......................................................................................................... 0060-6 Cooling Fan Installation........................................................................................................ 0060-6
DRIVE BELT TENSIONER AND IDLER MAINTENANCE........................................................................... WP 0061
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Page No. WP Sequence No. Figure 1. Figure 2. Drive Belt Tensioner Removal.............................................................................................. 0061-2 Drive Belt Tensioner Installation........................................................................................... 0061-3
ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE.............................................. WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Alternator and Mounting Bracket Assembly Removal.......................................................... 0062-1 Alternator and Mounting Bracket Assembly Removal.......................................................... 0062-2 Alternator and Mounting Bracket Assembly Installation....................................................... 0062-3 Alternator and Mounting Bracket Assembly Installation....................................................... 0062-3
STARTER MOTOR MAINTENANCE........................................................................................................... WP 0063 Figure 1. Figure 2. Starter Motor Removal......................................................................................................... 0063-1 Starter Motor Assembly........................................................................................................ 0063-2
NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE........................................................................................................................................... WP 0064 Figure 1. Warning Switches Maintenance........................................................................................... 0064-2
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE.......................................................... WP 0065 Figure 1. Fuel Pressure Switch and Transducer Installation............................................................... 0065-3
DASH PANEL GAGES AND SWITCHES MAINTENANCE......................................................................... WP 0066 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Dash Panel Removal............................................................................................................ 0066-2 Dash Panel Removal............................................................................................................ 0066-3 Dash Panel Removal............................................................................................................ 0066-3 Dash Panel Removal............................................................................................................ 0066-4 Dash Panel Removal............................................................................................................ 0066-5 Side Sloping Dash Panel Removal. .................................................................................... 0066-6 Side Sloping Dash Panel Removal...................................................................................... 0066-7 Side Sloping Dash Panel Removal. .................................................................................... 0066-8 Side Sloping Dash Panel Removal...................................................................................... 0066-9 Side Sloping Dash Panel Removal.................................................................................... 0066-10 Circuit Breaker Panel Removal.......................................................................................... 0066-11 Tachometer and Turn Signal Removal............................................................................... 0066-12
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Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Right Console Removal...................................................................................................... 0066-13 Right Console Removal...................................................................................................... 0066-14 Right Console Removal...................................................................................................... 0066-15 Tachometer and Turn Signal Installation............................................................................ 0066-16 Circuit Breaker Panel Installation....................................................................................... 0066-17 Side Sloping Dash Panel Installation................................................................................. 0066-18 Side Sloping Dash Panel Installation................................................................................. 0066-19 Side Sloping Dash Panel Installation................................................................................. 0066-20 Side Sloping Dash Panel Installation................................................................................. 0066-21 Side Sloping Dash Panel Installation................................................................................. 0066-22 Dash Panel Installation....................................................................................................... 0066-23 Dash Panel Installation....................................................................................................... 0066-23 Dash Panel Installation....................................................................................................... 0066-24 Dash Panel Installation....................................................................................................... 0066-25 Dash Panel Installation....................................................................................................... 0066-26 Right Console Installation................................................................................................... 0066-27 Right Console Installation................................................................................................... 0066-28 Right Console Installation................................................................................................... 0066-29
ANTI-TWO BLOCK CONTROL PANEL MAINTENANCE........................................................................... WP 0067 Figure 1. Figure 2. Control Panel Maintenance.................................................................................................. 0067-3 Control Panel Maintenance.................................................................................................. 0067-4
VEHICLE BUBBLE LEVEL MAINTENANCE............................................................................................... WP 0068 Figure 1. Figure 2. Vehicle Bubble Level Removal............................................................................................. 0068-1 Vehicle Bubble Level Installation.......................................................................................... 0068-2
HORN MAINTENANCE............................................................................................................................... WP 0069 Figure 1. Figure 2. Horn Removal...................................................................................................................... 0069-1 Horn Installation................................................................................................................... 0069-2
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Page No. WP Sequence No. ELECTRICAL COLLECTOR RING MAINTENANCE................................................................................... WP 0070 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Electrical Collector Ring Removal........................................................................................ 0070-2 Electrical Collector Ring Removal........................................................................................ 0070-3 Electrical Collector Ring Removal........................................................................................ 0070-4 Electrical Collector Ring Removal........................................................................................ 0070-5 Electrical Collector Ring Installation..................................................................................... 0070-6 Electrical Collector Ring Installation..................................................................................... 0070-7 Electrical Collector Ring Installation..................................................................................... 0070-8 Electrical Collector Ring Installation..................................................................................... 0070-9
REAR LIGHTS MAINTENANCE.................................................................................................................. WP 0071 Figure 1. Rear Lights Maintenance..................................................................................................... 0071-3
FRONT LIGHTS AND BRACKETS MAINTENANCE.................................................................................. WP 0072 Figure 1. Figure 2. Left Front Lights and Bracket Installation............................................................................. 0072-3 Right Front Lights and Bracket Installation........................................................................... 0072-5
WORK LIGHTS MAINTENANCE................................................................................................................. WP 0073 Figure 1. Work Lights Maintenance..................................................................................................... 0073-3
AXLE CENTERING LIGHT SWITCH ASSEMBLY MAINTENANCE........................................................... WP 0074 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Axle Centering Light Switch Assembly Removal.................................................................. 0074-2 Axle Centering Light Switch Assembly Removal.................................................................. 0074-3 Axle Centering Light Switch Assembly Installation............................................................... 0074-4 Axle Centering Light Switch Assembly Installation............................................................... 0074-5 Axle Centering Light Switch Assembly Adjustment.............................................................. 0074-6
TACHOMETER ADJUSTMENT .................................................................................................................. WP 0075 Figure 1. Figure 2. Figure 3. Figure 4. Tachometer Wiring Harness Removal................................................................................. 0075-1 Tachometer Drive Removal.................................................................................................. 0075-2 Tachometer Drive Installation............................................................................................... 0075-3 Tachometer Wiring Harness Installation.............................................................................. 0075-4
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Page No. WP Sequence No. BATTERY ASSEMBLY AND CABLES MAINTENANCE............................................................................. WP 0076 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Battery and Cables Assembly Removal............................................................................... 0076-3 Battery and Cables Assembly Removal............................................................................... 0076-4 Battery and Cables Assembly Removal............................................................................... 0076-5 Battery and Cables Assembly Removal............................................................................... 0076-6 Battery and Cables Assembly Removal............................................................................... 0076-7 Battery and Cables Assembly Removal............................................................................... 0076-7 Battery and Cables Assembly Removal............................................................................... 0076-8 Battery and Cables Assembly Installation............................................................................ 0076-9 Battery and Cables Assembly Installation.......................................................................... 0076-10 Battery and Cables Assembly Installation.......................................................................... 0076-11 Battery and Cables Assembly Installation.......................................................................... 0076-12 Battery and Cables Assembly Installation.......................................................................... 0076-13 Battery and Cables Assembly Installation.......................................................................... 0076-14 Battery and Cables Assembly Installation.......................................................................... 0076-15
BATTERY BOX AND TOOLBOX WITH COVERS MAINTENANCE........................................................... WP 0077 Figure 1. Figure 2. Figure 3. Figure 4. Battery Box and Toolbox Cover Removal............................................................................ 0077-1 Battery Box and Toolbox Removal....................................................................................... 0077-2 Battery Box and Toolbox Installation.................................................................................... 0077-3 Battery Box and Toolbox Cover Installation......................................................................... 0077-4
MAIN ENGINE WIRING HARNESS MAINTENANCE................................................................................. WP 0078 Figure 1. Figure 2. Main Engine Wiring Harness Removal................................................................................. 0078-2 Main Engine Wiring Harness Installation.............................................................................. 0078-3
CAB MAIN HARNESS MAINTENANCE...................................................................................................... WP 0079 Figure 1. Cab Main Harness Maintenance.......................................................................................... 0079-3
BACKUP ALARM MAINTENANCE.............................................................................................................. WP 0080 Figure 1. Back Up Alarm Removal...................................................................................................... 0080-2
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Page No. WP Sequence No. Figure 2. Back Up Alarm Installation................................................................................................... 0080-3
MSD-ICE WIRING HARNESS MAINTENANCE.......................................................................................... WP 0081 Figure 1. Figure 2. Main MSD-ICE Harness Removal........................................................................................ 0081-1 Main MSD-ICE Harness Installation..................................................................................... 0081-2
BOOM WIRING HARNESS MAINTENANCE.............................................................................................. WP 0082 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Boom Wiring Harness Removal........................................................................................... 0082-2 Boom Wiring Harness Removal........................................................................................... 0082-3 Boom Wiring Harness Removal........................................................................................... 0082-4 Boom Wiring Harness Removal........................................................................................... 0082-5 Boom Wiring Harness Removal........................................................................................... 0082-6 Boom Wiring Harness Removal........................................................................................... 0082-7 Boom Wiring Harness Removal........................................................................................... 0082-8 Boom Wiring Harness Removal........................................................................................... 0082-9 Boom Wiring Harness Removal........................................................................................... 0082-9 Boom Wiring Harness Installation...................................................................................... 0082-10 Boom Wiring Harness Installation...................................................................................... 0082-11 Boom Wiring Harness Installation...................................................................................... 0082-11 Boom Wiring Harness Installation...................................................................................... 0082-12 Boom Wiring Harness Installation...................................................................................... 0082-13 Boom Wiring Harness Installation...................................................................................... 0082-14 Boom Wiring Harness Installation...................................................................................... 0082-14 Boom Wiring Harness Installation...................................................................................... 0082-15 Boom Wiring Harness Installation...................................................................................... 0082-15
MSD-ICE DCA CONNECTOR/RESISTOR MODULE MAINTENANCE...................................................... WP 0083 Figure 1. Figure 2. MSD-ICE DCA Connector Resistor/Module Removal.......................................................... 0083-2 MSD-ICE DCA Connector Resistor/Module Installation....................................................... 0083-3
TRANSMISSION DIPSTICK TUBE ASSEMBLY MAINTENANCE.............................................................. WP 0084
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Page No. WP Sequence No. Figure 1. Figure 2. Transmission Dipstick Tube Removal.................................................................................. 0084-2 Transmission Dipstick Tube Installation............................................................................... 0084-3
TRANSMISSION SHIFT CONTROLS MAINTENANCE.............................................................................. WP 0085 Figure 1. Figure 2. Transmission Shift Controls Removal.................................................................................. 0085-3 Transmission Shift Controls Installation............................................................................... 0085-5
TRANSMISSION CABLES MAINTENANCE............................................................................................... WP 0086 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Transmission Cable Removal.............................................................................................. 0086-2 Transmission Cable Removal.............................................................................................. 0086-3 Transmission Cable Removal.............................................................................................. 0086-3 Transmission Cable Removal.............................................................................................. 0086-4 Transmission Cable Removal.............................................................................................. 0086-4 Transmission Cable Removal.............................................................................................. 0086-5 Transmission Cable Installation........................................................................................... 0086-6 Transmission Cable Installation........................................................................................... 0086-7 Transmission Cable Installation........................................................................................... 0086-7 Transmission Cable Installation........................................................................................... 0086-8 Transmission Cable Installation........................................................................................... 0086-8 Transmission Cable Installation........................................................................................... 0086-9
TRANSMISSION CONTROLS MAINTENANCE......................................................................................... WP 0087 Figure 1. Figure 2. Figure 3. Transmission Controls Maintenance.................................................................................... 0087-2 Transmission Controls Maintenance.................................................................................... 0087-3 Transmission Controls Maintenance.................................................................................... 0087-4
TRANSMISSION ASSEMBLY MAINTENANCE.......................................................................................... WP 0088 CHARGE PUMP MAINTENANCE............................................................................................................... WP 0089 Figure 1. Figure 2. Charge Pump Removal........................................................................................................ 0089-2 Charge Pump Installation..................................................................................................... 0089-3
CONTROL VALVE MAINTENANCE............................................................................................................ WP 0090
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Control Valve Disassembly.................................................................................................. 0090-2 Control Valve Disassembly.................................................................................................. 0090-3 Control Valve Disassembly.................................................................................................. 0090-4 Control Valve Disassembly.................................................................................................. 0090-5 Control Valve Disassembly.................................................................................................. 0090-6 Control Valve Disassembly.................................................................................................. 0090-6 Control Valve Disassembly.................................................................................................. 0090-7 Control Valve Disassembly.................................................................................................. 0090-7 Control Valve Assembly..................................................................................................... 0090-10 Control Valve Assembly..................................................................................................... 0090-10 Control Valve Assembly..................................................................................................... 0090-11 Control Valve Assembly..................................................................................................... 0090-12 Control Valve Assembly..................................................................................................... 0090-12 Control Valve Assembly..................................................................................................... 0090-13 Control Valve Assembly..................................................................................................... 0090-13 Control Valve Assembly..................................................................................................... 0090-14 Control Valve Assembly..................................................................................................... 0090-15
TRANSMISSION OIL AND FILTER ELEMENT MAINTENANCE................................................................ WP 0091 Figure 1. Figure 2. Figure 3. Figure 4. Transmission Oil and Filter Element Removal..................................................................... 0091-2 Transmission Oil and Filter Element Removal..................................................................... 0091-3 Transmission Oil and Filter Element Installation.................................................................. 0091-4 Transmission Oil and Filter Element Installation.................................................................. 0091-5
PUMP ADAPTER MAINTENANCE............................................................................................................. WP 0092 Figure 1. Figure 2. Pump Adapter Removal....................................................................................................... 0092-2 Pump Adapter Installation.................................................................................................... 0092-4
FRONT AND REAR DRIVESHAFT MAINTENANCE.................................................................................. WP 0093 Figure 1. Front Driveshaft Removal..................................................................................................... 0093-1
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Front Driveshaft Removal..................................................................................................... 0093-2 Front Driveshaft Disassembly.............................................................................................. 0093-2 Front Driveshaft Disassembly.............................................................................................. 0093-3 Front Driveshaft Assembly................................................................................................... 0093-4 Front Driveshaft Assembly................................................................................................... 0093-4 Front Driveshaft Installation.................................................................................................. 0093-5 Front Driveshaft Installation.................................................................................................. 0093-5 Rear Driveshaft Removal..................................................................................................... 0093-6 Rear Driveshaft Disassembly............................................................................................... 0093-7 Rear Driveshaft Assembly.................................................................................................... 0093-8 Rear Driveshaft Installation.................................................................................................. 0093-9
FRONT AXLE MAINTENANCE................................................................................................................... WP 0094 Figure 1. Figure 2. Front Axle Removal.............................................................................................................. 0094-3 Front Axle Installation........................................................................................................... 0094-5
FRONT DIFFERENTIAL ASSEMBLY MAINTENANCE.............................................................................. WP 0095 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Differential Removal.................................................................................................... 0095-3 Front Differential Removal.................................................................................................... 0095-4 Front Differential Installation................................................................................................. 0095-5 Front Differential Installation................................................................................................. 0095-6 Front Differential Installation................................................................................................. 0095-7
PLANETARY WHEEL END MAINTENANCE.............................................................................................. WP 0096 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Planetary Wheel End Removal............................................................................................ 0096-2 Planetary Wheel End Removal............................................................................................ 0096-3 Planetary Wheel End Removal............................................................................................ 0096-4 Planetary Wheel End Removal............................................................................................ 0096-4 Planetary Wheel End Removal............................................................................................ 0096-5 Planetary Wheel End Disassembly...................................................................................... 0096-5
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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Planetary Wheel End Maintenance...................................................................................... 0096-7 Planetary Wheel End Assembly........................................................................................... 0096-8 Planetary Wheel End Installation......................................................................................... 0096-9 Planetary Wheel End Installation......................................................................................... 0096-9 Planetary Wheel End Installation....................................................................................... 0096-10 Planetary Wheel End Installation....................................................................................... 0096-10 Planetary Wheel End Installation....................................................................................... 0096-11
PIVOT AND SPINDLE ASSEMBLY MAINTENANCE.................................................................................. WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Pivot and Spindle Assembly Removal.................................................................................. 0097-2 Pivot and Spindle Assembly Removal.................................................................................. 0097-3 Pivot and Spindle Assembly Installation............................................................................... 0097-5 Pivot and Spindle Assembly Installation............................................................................... 0097-6 Pivot and Spindle Assembly Installation............................................................................... 0097-7 Pivot and Spindle Assembly Installation............................................................................... 0097-9
PIVOT BEARINGS (TYPE II) MAINTENANCE............................................................................................ WP 0098 Figure 1. Pivot Bearings (Type II) Installation...................................................................................... 0098-3
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE........................................................ WP 0099 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Constant-Velocity Joint and Axle Shaft Removal................................................................. 0099-2 Constant-Velocity Joint and Axle Shaft Removal................................................................. 0099-3 Constant-Velocity Joint and Axle Shaft Maintenance........................................................... 0099-4 Constant-Velocity Joint and Axle Shaft Installation.............................................................. 0099-5 Constant-Velocity Joint and Axle Shaft Installation.............................................................. 0099-7
REAR AXLE MAINTENANCE...................................................................................................................... WP 0100 Figure 1. Figure 2. Rear Axle Removal.............................................................................................................. 0100-3 Rear Axle Installation........................................................................................................... 0100-5
REAR DIFFERENTIAL ASSEMBLY MAINTENANCE................................................................................. WP 0101 Figure 1. Rear Differential Assembly Removal.................................................................................... 0101-3
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Rear Differential Assembly Installation................................................................................. 0101-5 Rear Differential Assembly Installation................................................................................. 0101-5 Rear Differential Assembly Installation................................................................................. 0101-7
PARKING BRAKE MAINTENANCE............................................................................................................ WP 0102 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Parking Brake Removal........................................................................................................ 0102-2 Parking Brake Removal........................................................................................................ 0102-2 Parking Brake Removal........................................................................................................ 0102-3 Parking Brake Removal........................................................................................................ 0102-3 Parking Brake Removal........................................................................................................ 0102-4 Parking Brake Disassembly................................................................................................. 0102-5 Parking Brake Assembly...................................................................................................... 0102-6 Parking Brake Installation..................................................................................................... 0102-7 Parking Brake Installation..................................................................................................... 0102-7 Parking Brake Installation..................................................................................................... 0102-8 Parking Brake Installation..................................................................................................... 0102-8 Parking Brake Installation..................................................................................................... 0102-9 Parking Brake Installation..................................................................................................... 0102-9 Parking Brake Installation................................................................................................... 0102-10
BRAKE ASSEMBLY MAINTENANCE......................................................................................................... WP 0103 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Brake Assembly Removal.................................................................................................... 0103-2 Brake Assembly Removal.................................................................................................... 0103-3 Brake Assembly Removal.................................................................................................... 0103-3 Brake Assembly Installation................................................................................................. 0103-5 Brake Assembly Installation................................................................................................. 0103-5 Brake Assembly Installation................................................................................................. 0103-6 Brake Assembly Installation................................................................................................. 0103-7 Brake Assembly Installation................................................................................................. 0103-7
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Page No. WP Sequence No. BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE........................................................... WP 0104 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Brake Booster Valve/Master Cylinder Removal................................................................... 0104-3 Brake Booster Valve/Master Cylinder Removal................................................................... 0104-3 Brake Booster Valve/Master Cylinder Removal................................................................... 0104-4 Brake Booster Valve/Master Cylinder Disassembly............................................................. 0104-5 Brake Booster Valve Disassembly....................................................................................... 0104-5 Brake Booster Disassembly................................................................................................. 0104-6 Brake Booster Disassembly................................................................................................. 0104-6 Brake Booster Disassembly................................................................................................. 0104-7 Brake Booster Disassembly................................................................................................. 0104-7 Brake Booster Maintenance................................................................................................. 0104-8 Brake Booster Assembly...................................................................................................... 0104-9 Brake Booster Assembly...................................................................................................... 0104-9 Brake Booster Assembly.................................................................................................... 0104-10 Brake Booster Assembly.................................................................................................... 0104-10 Brake Booster Assembly.................................................................................................... 0104-11 Master Cylinder/Brake Booster Assembly.......................................................................... 0104-11 Master Cylinder Installation................................................................................................ 0104-12 Master Cylinder Installation................................................................................................ 0104-13 Brake Booster Valve/Master Cylinder Installation.............................................................. 0104-13
HYDRAULIC BRAKE LINES AND FITTINGS MAINTENANCE.................................................................. WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-3 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-4 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-5 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-6 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-7 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-7
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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-8 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-9 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-10 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-11 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-12 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-13 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-13 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-14 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-15 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-16
BRAKE PEDAL AND LINKAGE MAINTENANCE........................................................................................ WP 0106 Figure 1. Figure 2. Figure 3. Figure 4. Brake Pedal and Linkage Removal...................................................................................... 0106-1 Brake Pedal and Linkage Removal...................................................................................... 0106-2 Brake Pedal and Linkage Installation................................................................................... 0106-3 Brake Pedal and Linkage Installation................................................................................... 0106-4
TIRES AND WHEELS MAINTENANCE...................................................................................................... WP 0107 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Tires and Wheels Removal.................................................................................................. 0107-2 Tires and Wheels Disassembly............................................................................................ 0107-3 Tires and Wheels Assembly................................................................................................. 0107-4 Tires and Wheels Assembly................................................................................................. 0107-5 Tires and Wheels Installation............................................................................................... 0107-5 Tires and Wheels Installation............................................................................................... 0107-6
TIE ROD ASSEMBLY MAINTENANCE....................................................................................................... WP 0108 Figure 1. Figure 2. Figure 3. Tie Rod Assembly Removal................................................................................................. 0108-2 Tie Rod Assembly Installation.............................................................................................. 0108-3 Tie Rod Assembly Adjustment............................................................................................. 0108-4
GROUND DRIVEN STEERING PUMP MAINTENANCE............................................................................ WP 0109
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Ground Driven Steering Pump Removal.............................................................................. 0109-2 Ground Driven Steering Pump Disassembly........................................................................ 0109-3 Ground Driven Steering Pump Disassembly........................................................................ 0109-3 Ground Driven Steering Pump Disassembly........................................................................ 0109-4 Ground Driven Steering Pump Disassembly........................................................................ 0109-4 Ground Driven Steering Pump Disassembly........................................................................ 0109-5 Ground Driven Steering Pump Disassembly........................................................................ 0109-5 Ground Driven Steering Pump Disassembly........................................................................ 0109-6 Ground Driven Steering Pump Assembly............................................................................. 0109-8 Ground Driven Steering Pump Assembly............................................................................. 0109-9 Ground Driven Steering Pump Assembly............................................................................. 0109-9 Ground Driven Steering Pump Assembly........................................................................... 0109-10 Ground Driven Steering Pump Assembly........................................................................... 0109-10 Ground Driven Steering Pump Assembly........................................................................... 0109-11 Ground Driven Steering Pump Assembly........................................................................... 0109-12 Ground Driven Steering Pump Installation......................................................................... 0109-13
STEERING CONTROL UNIT MAINTENANCE........................................................................................... WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Steering Control Removal.................................................................................................... 0110-2 Steering Control Disassembly.............................................................................................. 0110-3 Steering Control Assembly................................................................................................... 0110-5 Steering Control Installation................................................................................................. 0110-6
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE.................................................................... WP 0111 Figure 1. Figure 2. Steering System Hydraulic Hoses Removal......................................................................... 0111-3 Steering System Hydraulic Hoses Installation...................................................................... 0111-5
STEERING CYLINDERS MAINTENANCE.................................................................................................. WP 0112 Figure 1. Figure 2. Steering Cylinders Removal................................................................................................. 0112-3 Steering Cylinders Installation.............................................................................................. 0112-4
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Page No. WP Sequence No. STEERING SELECTOR VALVE MAINTENANCE...................................................................................... WP 0113 Figure 1. Figure 2. Figure 3. Steering Selector Valve Removal......................................................................................... 0113-3 Steering Selector Valve Installation...................................................................................... 0113-5 Steering Selector Valve Installation...................................................................................... 0113-6
FLOW DIVIDER AND STEERING VALVE MAINTENANCE....................................................................... WP 0114 Figure 1. Figure 2. Flow Divider and Steering Valve Removal........................................................................... 0114-3 Flow Divider and Steering Valve Installation........................................................................ 0114-4
HOOK BLOCK TIEBACK MAINTENANCE.................................................................................................. WP 0115 Figure 1. Figure 2. Hook Block Tieback Removal.............................................................................................. 0115-2 Hook Block Tieback Installation........................................................................................... 0115-3
PINTLE HOOK MAINTENANCE.................................................................................................................. WP 0116 Figure 1. Pintle Hook Maintenance..................................................................................................... 0116-3
CAB DOOR MAINTENANCE....................................................................................................................... WP 0117 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Cab Door Removal............................................................................................................... 0117-2 Cab Door Removal............................................................................................................... 0117-3 Cab Door Removal............................................................................................................... 0117-3 Cab Door Removal............................................................................................................... 0117-4 Cab Door Removal............................................................................................................... 0117-4 Cab Door Removal............................................................................................................... 0117-5 Cab Door Installation............................................................................................................ 0117-6 Cab Door Installation............................................................................................................ 0117-6 Cab Door Installation............................................................................................................ 0117-7 Cab Door Installation............................................................................................................ 0117-7 Cab Door Installation............................................................................................................ 0117-8 Cab Door Installation............................................................................................................ 0117-9
ENGINE HOOD AND GRILLE GUARD MAINTENANCE............................................................................ WP 0118 Figure 1. Grille Guard Removal........................................................................................................... 0118-2
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Hood Removal......................................................................................................... 0118-3 Engine Hood Disassembly................................................................................................... 0118-4 Engine Hood Assembly........................................................................................................ 0118-5 Engine Hood Installation...................................................................................................... 0118-6 Grille Guard Installation........................................................................................................ 0118-7
CAB ASSEMBLY MAINTENANCE.............................................................................................................. WP 0119 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Assembly Removal....................................................................................................... 0119-2 Fire Extinguisher Removal................................................................................................... 0119-3 Floormats Removal.............................................................................................................. 0119-4 Cab Assembly Disassembly................................................................................................. 0119-5 Cab Assembly Assembly...................................................................................................... 0119-7 Floormats Installation........................................................................................................... 0119-8 Fire Extinguisher Installation................................................................................................ 0119-9 Cab Assembly Installation.................................................................................................. 0119-10
HOOD SUPPORT MAINTENANCE............................................................................................................. WP 0120 Figure 1. Figure 2. Figure 3. Hood Support Removal........................................................................................................ 0120-2 Hood Support Installation..................................................................................................... 0120-3 Hood Support Installation..................................................................................................... 0120-4
FENDERS MAINTENANCE......................................................................................................................... WP 0121 Figure 1. Fender Maintenance............................................................................................................ 0121-3
DECK PLATES MAINTENANCE................................................................................................................. WP 0122 Figure 1. Deck Plates Maintenance..................................................................................................... 0122-3
OUTRIGGER ASSEMBLY MAINTENANCE................................................................................................ WP 0123 Figure 1. Figure 2. Figure 3. Figure 4. Outrigger Assembly Removal............................................................................................... 0123-3 Outrigger Assembly Assembly............................................................................................. 0123-4 Outrigger Assembly Assembly............................................................................................. 0123-5 Outrigger Assembly Installation............................................................................................ 0123-6
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Page No. WP Sequence No. SEAT AND SEAT BELT MAINTENANCE................................................................................................... WP 0124 Figure 1. Figure 2. Figure 3. Figure 4. Seat Belt Removal................................................................................................................ 0124-2 Seat Removal....................................................................................................................... 0124-3 Seat Installation.................................................................................................................... 0124-4 Seat Belt Installation............................................................................................................. 0124-5
WINCH ASSEMBLY MAINTENANCE......................................................................................................... WP 0125 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Winch Removal.................................................................................................................... 0125-2 Winch Disassembly.............................................................................................................. 0125-3 Hydraulic Hose Disassembly................................................................................................ 0125-4 Motor Disassembly............................................................................................................... 0125-4 Brake Clutch and Cylinder Disassembly.............................................................................. 0125-5 Sun Primary Gear Disassembly........................................................................................... 0125-5 Seal and Ball Bearing Disassembly..................................................................................... 0125-6 Primary Planet Carrier Disassembly.................................................................................... 0125-6 Sun Output Gear Disassembly............................................................................................. 0125-7 Output Planet Carrier Disassembly...................................................................................... 0125-7 Snap Ring Disassembly....................................................................................................... 0125-8 Drum Disassembly............................................................................................................... 0125-9 Seal and Bearing Disassembly.......................................................................................... 0125-10 Base Positioning Assembly................................................................................................ 0125-11 Drum Assembly.................................................................................................................. 0125-12 Drum Assembly.................................................................................................................. 0125-13 Bearing Support Assembly................................................................................................. 0125-13 Bearing Support Fasteners Assembly................................................................................ 0125-14 Snap Ring Assembly.......................................................................................................... 0125-15 Sun Output Gear Assembly................................................................................................ 0125-16 Output Planet Carrier Assembly......................................................................................... 0125-16
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Page No. WP Sequence No. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Primary Planet Carrier Assembly....................................................................................... 0125-17 Bearing and Seal Assembly............................................................................................... 0125-17 Drum Assembly.................................................................................................................. 0125-18 Sun Primary Gear Assembly.............................................................................................. 0125-18 Brake Cylinder Assembly Assembly................................................................................... 0125-19 Brake Cylinder Assembly Assembly................................................................................... 0125-19 Brake Clutch Assembly Assembly...................................................................................... 0125-20 Motor Installation Assembly............................................................................................... 0125-21 Oil Fill Assembly................................................................................................................. 0125-22 Winch Installation............................................................................................................... 0125-23
WINCH MOTOR MAINTENANCE............................................................................................................... WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Winch Motor Disassembly.................................................................................................... 0126-2 Winch Motor Disassembly.................................................................................................... 0126-2 Winch Motor Disassembly.................................................................................................... 0126-3 Winch Motor Disassembly.................................................................................................... 0126-3 Winch Motor Disassembly.................................................................................................... 0126-4 Winch Motor Disassembly.................................................................................................... 0126-4 Winch Motor Disassembly.................................................................................................... 0126-5 Winch Motor Disassembly.................................................................................................... 0126-5 Winch Motor Disassembly.................................................................................................... 0126-6 Winch Motor Disassembly.................................................................................................... 0126-6 Winch Motor Disassembly.................................................................................................... 0126-7 Winch Motor Disassembly.................................................................................................... 0126-7 Winch Motor Disassembly.................................................................................................... 0126-8 Winch Motor Disassembly.................................................................................................... 0126-8 Winch Motor Disassembly.................................................................................................... 0126-9 Winch Motor Assembly....................................................................................................... 0126-10
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Page No. WP Sequence No. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Winch Motor Assembly....................................................................................................... 0126-10 Winch Motor Assembly....................................................................................................... 0126-11 Winch Motor Assembly....................................................................................................... 0126-11 Winch Motor Assembly....................................................................................................... 0126-12 Winch Motor Assembly....................................................................................................... 0126-12 Winch Motor Assembly....................................................................................................... 0126-13 Winch Motor Assembly....................................................................................................... 0126-13 Winch Motor Assembly....................................................................................................... 0126-14 Winch Motor Assembly....................................................................................................... 0126-14 Winch Motor Assembly....................................................................................................... 0126-15 Winch Motor Assembly....................................................................................................... 0126-15 Winch Motor Assembly....................................................................................................... 0126-16 Winch Motor Assembly....................................................................................................... 0126-16 Winch Motor Assembly....................................................................................................... 0126-17
WINCH BRAKE VALVE MAINTENANCE.................................................................................................... WP 0127 Figure 1. Figure 2. Winch Brake Valve Maintenance......................................................................................... 0127-3 Winch Brake Valve Maintenance......................................................................................... 0127-5
WINCH CONTROL VALVE AND FITTINGS MAINTENANCE.................................................................... WP 0128 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Winch Control Valve Installation........................................................................................... 0128-3 Winch Control Valve Test and Adjustment........................................................................... 0128-4 Winch Control Valve Test and Adjustment........................................................................... 0128-5 Winch Control Valve Test and Adjustment........................................................................... 0128-6 Winch Control Valve Test and Adjustment........................................................................... 0128-7 Winch Control Valve Test and Adjustment........................................................................... 0128-7
VALVE CONTROL, BOOM HOIST, EXTEND, AND WINCH CABLES MAINTENANCE............................ WP 0129 Figure 1. Figure 2. Valve Control Cable Removal.............................................................................................. 0129-2 Valve Control Cable Removal.............................................................................................. 0129-3
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Valve Control Cable Removal.............................................................................................. 0129-4 Swing and Outrigger Cable Removal................................................................................... 0129-5 Boom Hoist, Extend, and Winch Cable Removal................................................................. 0129-7 Boom Hoist, Extend, and Winch Cable Installation.............................................................. 0129-8 Swing and Outrigger Cable Installation................................................................................ 0129-9 Valve Control Cables Installation....................................................................................... 0129-10 Valve Control Cables Installation....................................................................................... 0129-11 Valve Control Cables Installation....................................................................................... 0129-12 Cables Adjustment............................................................................................................. 0129-13
MIRROR MAINTENANCE........................................................................................................................... WP 0130 Figure 1. Mirror Maintenance.............................................................................................................. 0130-3
WINDSHIELD WIPER ASSEMBLY MAINTENANCE.................................................................................. WP 0131 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Windshield Wiper Removal.................................................................................................. 0131-2 Windshield Wiper Removal.................................................................................................. 0131-3 Windshield Wiper Removal.................................................................................................. 0131-4 Windshield Wiper Removal.................................................................................................. 0131-5 Windshield Wiper Removal and Installation......................................................................... 0131-7 Windshield Wiper Installation............................................................................................... 0131-8 Windshield Wiper Installation............................................................................................... 0131-9 Windshield Wiper Installation............................................................................................. 0131-10 Windshield Wiper Installation............................................................................................. 0131-11
HEATER MAINTENANCE........................................................................................................................... WP 0132 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Heater Removal................................................................................................................... 0132-3 Heater Removal................................................................................................................... 0132-3 Heater Removal................................................................................................................... 0132-4 Heater Removal................................................................................................................... 0132-4 Heater Removal................................................................................................................... 0132-5
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Heater Removal................................................................................................................... 0132-5 Heater Disassembly............................................................................................................. 0132-6 Heater Disassembly............................................................................................................. 0132-7 Heater Disassembly............................................................................................................. 0132-8 Heater Assembly.................................................................................................................. 0132-9 Heater Assembly................................................................................................................ 0132-10 Heater Installation.............................................................................................................. 0132-10 Heater Installation.............................................................................................................. 0132-11 Heater Installation.............................................................................................................. 0132-11 Heater Installation.............................................................................................................. 0132-12 Heater Installation.............................................................................................................. 0132-12 Heater Installation.............................................................................................................. 0132-13
MARKING DECALS MAINTENANCE.......................................................................................................... WP 0133 MAIN HYDRAULIC PUMP MAINTENANCE................................................................................................ WP 0134 Figure 1. Figure 2. Main Hydraulic Pump Removal............................................................................................ 0134-2 Main Hydraulic Pump Installation......................................................................................... 0134-4
ROTARY MANIFOLD MAINTENANCE....................................................................................................... WP 0135 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Rotary Manifold Removal..................................................................................................... 0135-3 Rotary Manifold Removal..................................................................................................... 0135-4 Rotary Manifold Removal..................................................................................................... 0135-5 Rotary Manifold Removal..................................................................................................... 0135-6 Rotary Manifold Disassembly............................................................................................... 0135-7 Rotary Manifold Assembly.................................................................................................... 0135-9 Rotary Manifold Installation................................................................................................ 0135-10 Rotary Manifold Installation................................................................................................ 0135-11 Rotary Manifold Installation................................................................................................ 0135-12 Rotary Manifold Installation................................................................................................ 0135-13
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Page No. WP Sequence No. Figure 11. Rotary Manifold Installation................................................................................................ 0135-14
OUTRIGGER SOLENOID VALVE MAINTENANCE.................................................................................... WP 0136 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Outrigger Solenoid Valve Removal...................................................................................... 0136-3 Outrigger Solenoid Valve Disassembly................................................................................ 0136-3 Outrigger Solenoid Valve Disassembly................................................................................ 0136-4 Outrigger Solenoid Valve Disassembly................................................................................ 0136-4 Outrigger Solenoid Valve Disassembly................................................................................ 0136-5 Outrigger Solenoid Valve Assembly..................................................................................... 0136-6 Outrigger Solenoid Valve Assembly..................................................................................... 0136-7 Outrigger Solenoid Valve Assembly..................................................................................... 0136-7 Outrigger Solenoid Valve Assembly..................................................................................... 0136-8 Outrigger Solenoid Valve Installation................................................................................... 0136-9
AXLE LOCKOUT VALVE MAINTENANCE.................................................................................................. WP 0137 Figure 1. Figure 2. Figure 3. Axle Lockout Valve Removal................................................................................................ 0137-2 Axle Lockout Valve Installation............................................................................................. 0137-4 Axle Lockout Valve Adjustment............................................................................................ 0137-5
BOOM HOIST, WINCH, AND OUTRIGGER VALVE CONTROLS MAINTENANCE................................... WP 0138 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Boom Hoist, Winch, and Outrigger Valve Controls Removal............................................... 0138-1 Boom Hoist, Winch, and Outrigger Valve Controls Removal............................................... 0138-2 Boom Hoist, Winch, and Outrigger Valve Controls Disassembly......................................... 0138-3 Boom Hoist, Winch, and Outrigger Valve Controls Assembly.............................................. 0138-5 Boom Hoist, Winch, and Outrigger Valve Controls Installation............................................ 0138-6 Boom Hoist, Winch, and Outrigger Valve Controls Installation............................................ 0138-7
SWING/TELESCOPE VALVE CONTROLS MAINTENANCE..................................................................... WP 0139 Figure 1. Figure 2. Figure 3. Swing/Telescope Valve Controls Removal.......................................................................... 0139-2 Swing/Telescope Valve Controls Removal.......................................................................... 0139-3 Swing/Telescope Valve Controls Disassembly.................................................................... 0139-4
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Swing/Telescope Valve Controls Assembly......................................................................... 0139-5 Swing/Telescope Valve Controls Installation....................................................................... 0139-6 Swing/Telescope Valve Controls Installation....................................................................... 0139-7
UPPER HYDRAULICS LINE MAINTENANCE............................................................................................ WP 0140 Figure 1. Figure 2. Upper Hydraulics Line Removal........................................................................................... 0140-3 Upper Hydraulics Line Installation........................................................................................ 0140-5
LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE.......................................... WP 0141 Figure 1. Figure 2. Lower Boom, Swing, and Winch Hydraulic Lines Removal.................................................. 0141-3 Lower Boom, Swing, and Winch Hydraulic Lines Installation............................................... 0141-5
RETURN AND PRESSURE HYDRAULICS MAINTENANCE..................................................................... WP 0142 Figure 1. Figure 2. Return and Pressure Hydraulics Removal........................................................................... 0142-3 Return and Pressure Hydraulics Installation........................................................................ 0142-4
OUTRIGGER HYDRAULICS MAINTENANCE............................................................................................ WP 0143 Figure 1. Figure 2. Outrigger Hydraulics Removal............................................................................................. 0143-3 Outrigger Hydraulics Installation.......................................................................................... 0143-5
SUCTION HYDRAULICS MAINTENANCE................................................................................................. WP 0144 Figure 1. Figure 2. Suction Hydraulics Removal................................................................................................ 0144-3 Suction Hydraulics Installation............................................................................................. 0144-5
ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE................................................ WP 0145 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-3 Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-4 Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-5 Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-6 Rotary Manifold Quick Disconnects (Type II) Installation..................................................... 0145-7 Rotary Manifold Quick Disconnects (Type II) Installation..................................................... 0145-8 Rotary Manifold Quick Disconnects (Type II) Installation..................................................... 0145-9 Rotary Manifold Quick Disconnects (Type II) Installation................................................... 0145-10
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Page No. WP Sequence No. HYDRAULIC SYSTEM VALVE BANK MAINTENANCE.............................................................................. WP 0146 Figure 1. Figure 2. Figure 3. Hydraulic System Valve Bank Removal............................................................................... 0146-2 Hydraulic System Valve Bank Installation............................................................................ 0146-3 Hydraulic System Valve Bank Adjustment........................................................................... 0146-5
RELIEF VALVE MAINTENANCE................................................................................................................. WP 0147 Figure 1. Figure 2. Figure 3. Figure 4. Relief Valve Removal........................................................................................................... 0147-2 Relief Valve Installation........................................................................................................ 0147-3 Relief Valve Adjustment....................................................................................................... 0147-4 Relief Valve Adjustment....................................................................................................... 0147-5
RETURN FILTER MAINTENANCE............................................................................................................. WP 0148 Figure 1. Figure 2. Return Filter Removal.......................................................................................................... 0148-3 Return Filter Installation....................................................................................................... 0148-4
BOOM HOIST CYLINDER MAINTENANCE................................................................................................ WP 0149 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Boom Hoist Cylinder Removal............................................................................................. 0149-2 Boom Hoist Cylinder Removal............................................................................................. 0149-3 Boom Hoist Cylinder Disassembly....................................................................................... 0149-4 Boom Hoist Cylinder Disassembly....................................................................................... 0149-4 Boom Hoist Cylinder Disassembly....................................................................................... 0149-5 Boom Hoist Cylinder Disassembly....................................................................................... 0149-6 Boom Hoist Cylinder Disassembly....................................................................................... 0149-7 Boom Hoist Cylinder Disassembly....................................................................................... 0149-8 Boom Hoist Cylinder Assembly............................................................................................ 0149-9 Boom Hoist Cylinder Assembly.......................................................................................... 0149-10 Boom Hoist Cylinder Assembly.......................................................................................... 0149-11 Boom Hoist Cylinder Assembly.......................................................................................... 0149-11 Boom Hoist Cylinder Installation........................................................................................ 0149-13 Boom Hoist Cylinder Installation........................................................................................ 0149-14
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Page No. WP Sequence No. BOOM EXTEND CYLINDER MAINTENANCE............................................................................................ WP 0150 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Boom Extend Cylinder Disassembly.................................................................................... 0150-1 Boom Extend Cylinder Disassembly.................................................................................... 0150-2 Boom Extend Cylinder Disassembly.................................................................................... 0150-3 Boom Extend Cylinder Disassembly.................................................................................... 0150-4 Boom Extend Cylinder Disassembly.................................................................................... 0150-5 Boom Extend Cylinder Disassembly.................................................................................... 0150-6 Boom Extend Cylinder Disassembly.................................................................................... 0150-6 Boom Extend Cylinder Disassembly.................................................................................... 0150-7 Boom Extend Cylinder Disassembly.................................................................................... 0150-7 Boom Extend Cylinder Disassembly.................................................................................... 0150-8 Boom Extend Cylinder Assembly......................................................................................... 0150-9 Boom Extend Cylinder Assembly....................................................................................... 0150-10 Boom Extend Cylinder Assembly....................................................................................... 0150-10 Boom Extend Cylinder Assembly....................................................................................... 0150-11 Boom Extend Cylinder Assembly....................................................................................... 0150-12 Boom Extend Cylinder Assembly....................................................................................... 0150-13 Boom Extend Cylinder Assembly....................................................................................... 0150-14 Boom Extend Cylinder Assembly....................................................................................... 0150-14
OUTRIGGER CYLINDER ASSEMBLY MAINTENANCE............................................................................ WP 0151 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Outrigger Cylinder Removal................................................................................................. 0151-2 Outrigger Cylinder Removal................................................................................................. 0151-3 Outrigger Cylinder Removal................................................................................................. 0151-4 Outrigger Cylinder Disassembly........................................................................................... 0151-5 Outrigger Cylinder Disassembly........................................................................................... 0151-6 Outrigger Cylinder Disassembly........................................................................................... 0151-7 Outrigger Cylinder Disassembly........................................................................................... 0151-7
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Page No. WP Sequence No. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Outrigger Cylinder Disassembly........................................................................................... 0151-8 Outrigger Cylinder Assembly................................................................................................ 0151-9 Outrigger Cylinder Assembly.............................................................................................. 0151-10 Outrigger Cylinder Assembly.............................................................................................. 0151-11 Outrigger Cylinder Assembly.............................................................................................. 0151-11 Outrigger Cylinder Assembly.............................................................................................. 0151-12 Outrigger Cylinder Installation............................................................................................ 0151-13 Outrigger Cylinder Installation............................................................................................ 0151-14 Outrigger Cylinder Installation............................................................................................ 0151-15
AXLE LOCKOUT CYLINDER MAINTENANCE........................................................................................... WP 0152 Figure 1. Figure 2. Figure 3. Figure 4. Axle Lockout Cylinder Removal........................................................................................... 0152-3 Axle Lockout Cylinder Removal........................................................................................... 0152-4 Axle Lockout Cylinder Installation........................................................................................ 0152-5 Axle Lockout Cylinder Installation........................................................................................ 0152-6
HYDRAULIC RESERVOIR MAINTENANCE............................................................................................... WP 0153 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Hydraulic Reservoir Removal............................................................................................... 0153-2 Hydraulic Reservoir Removal............................................................................................... 0153-3 Hydraulic Reservoir Removal............................................................................................... 0153-3 Hydraulic Reservoir Removal............................................................................................... 0153-4 Hydraulic Reservoir Installation............................................................................................ 0153-5 Hydraulic Reservoir Installation............................................................................................ 0153-6 Hydraulic Reservoir Installation............................................................................................ 0153-7 Hydraulic Reservoir Installation............................................................................................ 0153-7
BOOM ANGLE INDICATOR MAINTENANCE............................................................................................. WP 0154 Figure 1. Figure 2. Boom Angle Indicator Removal............................................................................................ 0154-2 Boom Angle Indicator Installation......................................................................................... 0154-3
HOOK BLOCK MAINTENANCE.................................................................................................................. WP 0155
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Hook Block Disassembly...................................................................................................... 0155-2 Hook Block Disassembly...................................................................................................... 0155-3 Hook Block Assembly........................................................................................................... 0155-5 Hook Block Assembly........................................................................................................... 0155-6
BOOM ASSEMBLY MAINTENANCE.......................................................................................................... WP 0156 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Boom Assembly Removal.................................................................................................... 0156-2 Boom Assembly Removal.................................................................................................... 0156-3 Boom Assembly Removal.................................................................................................... 0156-4 Boom Assembly Removal.................................................................................................... 0156-5 Boom Assembly Removal.................................................................................................... 0156-6 Boom Assembly Disassembly.............................................................................................. 0156-7 Boom Assembly Disassembly.............................................................................................. 0156-7 Boom Assembly Disassembly.............................................................................................. 0156-8 Boom Assembly Disassembly.............................................................................................. 0156-8 Boom Assembly Disassembly.............................................................................................. 0156-9 Boom Assembly Disassembly............................................................................................ 0156-10 Boom Assembly Disassembly............................................................................................ 0156-11 Boom Assembly Disassembly............................................................................................ 0156-11 Boom Assembly Disassembly............................................................................................ 0156-12 Boom Assembly Disassembly............................................................................................ 0156-12 Boom Assembly Disassembly............................................................................................ 0156-13 Boom Assembly Assembly................................................................................................. 0156-15 Boom Assembly Assembly................................................................................................. 0156-15 Boom Assembly Assembly................................................................................................. 0156-16 Boom Assembly Assembly................................................................................................. 0156-17 Boom Assembly Assembly................................................................................................. 0156-18 Boom Assembly Assembly................................................................................................. 0156-19
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Page No. WP Sequence No. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Boom Assembly Assembly................................................................................................. 0156-20 Boom Assembly Assembly................................................................................................. 0156-21 Boom Assembly Assembly................................................................................................. 0156-21 Boom Assembly Assembly................................................................................................. 0156-22 Boom Assembly Assembly................................................................................................. 0156-22 Boom Assembly Installation............................................................................................... 0156-23 Boom Assembly Installation............................................................................................... 0156-24 Boom Assembly Installation............................................................................................... 0156-25 Boom Assembly Installation............................................................................................... 0156-26 Boom Assembly Installation............................................................................................... 0156-27
BOOM WORK LIGHT BRACKET MAINTENANCE..................................................................................... WP 0157 Figure 1. Bracket Maintenance............................................................................................................ 0157-1
UPPERSTRUCTURE MAINTENANCE....................................................................................................... WP 0158 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Upperstructure Removal...................................................................................................... 0158-2 Upperstructure Removal...................................................................................................... 0158-3 Upperstructure Removal...................................................................................................... 0158-5 Swing Bearing Assembly Removal...................................................................................... 0158-6 Swing Bearing Assembly Installation................................................................................... 0158-8 Upperstructure Installation................................................................................................... 0158-9 Upperstructure Installation................................................................................................. 0158-10 Upperstructure Installation................................................................................................. 0158-11 Upperstructure Installation................................................................................................. 0158-12
MAST ASSEMBLY (TYPE II) MAINTENANCE............................................................................................ WP 0159 Figure 1. Mast Assembly Maintenance............................................................................................... 0159-3
SWING MOTOR MAINTENANCE............................................................................................................... WP 0160 Figure 1. Figure 2. Swing Motor Removal.......................................................................................................... 0160-2 Swing Motor Disassembly.................................................................................................... 0160-3
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Swing Motor Disassembly.................................................................................................... 0160-3 Swing Motor Disassembly.................................................................................................... 0160-4 Swing Motor Disassembly.................................................................................................... 0160-4 Swing Motor Disassembly.................................................................................................... 0160-5 Swing Motor Disassembly.................................................................................................... 0160-5 Swing Motor Disassembly.................................................................................................... 0160-6 Swing Motor Assembly......................................................................................................... 0160-7 Swing Motor Assembly......................................................................................................... 0160-8 Swing Motor Assembly......................................................................................................... 0160-8 Swing Motor Assembly......................................................................................................... 0160-9 Swing Motor Assembly....................................................................................................... 0160-10 Swing Motor Assembly....................................................................................................... 0160-11 Swing Motor Installation..................................................................................................... 0160-12
SWING GEARBOX MAINTENANCE........................................................................................................... WP 0161 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Swing Gearbox Removal...................................................................................................... 0161-2 Swing Gearbox Disassembly............................................................................................... 0161-3 Swing Gearbox Cover Disassembly..................................................................................... 0161-4 Swing Gearbox Bearing Retainer Disassembly................................................................... 0161-4 Swing Gearbox Bearing Retainer Disassembly................................................................... 0161-5 Swing Gearbox Disassembly............................................................................................... 0161-6 Swing Gearbox Disassembly............................................................................................... 0161-7 Swing Gearbox Output Shaft Disassembly.......................................................................... 0161-8 Swing Gearbox Bearing Cups Disassembly......................................................................... 0161-9 Swing Gearbox Vent Plug and Grease Fitting Disassembly................................................ 0161-9 Swing Gearbox Vent Plug and Grease Fitting Assembly................................................... 0161-10 Swing Gearbox Bearing Cups Assembly........................................................................... 0161-11 Swing Gearbox Assembly.................................................................................................. 0161-12
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Page No. WP Sequence No. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Swing Gearbox Assembly.................................................................................................. 0161-13 Swing Gearbox Assembly.................................................................................................. 0161-13 Swing Gearbox Assembly.................................................................................................. 0161-14 Swing Gearbox Bearing Retainer Assembly...................................................................... 0161-15 Swing Gearbox Bearing Retainer Assembly...................................................................... 0161-16 Swing Gearbox Cover Assembly........................................................................................ 0161-16 Swing Gearbox Drain Plugs Assembly............................................................................... 0161-17 Swing Gearbox Assembly.................................................................................................. 0161-17 Swing Gearbox Installation................................................................................................. 0161-18
GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0162 GENERAL WIRING HARNESS AND CABLE MAINTENANCE.................................................................. WP 0163 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Electrical Harness Identification........................................................................................... 0163-2 Electrical Harness Identification........................................................................................... 0163-3 Electrical Harness Disassembly........................................................................................... 0163-4 Electrical Harness Disassembly........................................................................................... 0163-5 Electrical Harness Disassembly........................................................................................... 0163-6 Electrical Harness Disassembly........................................................................................... 0163-7 Electrical Harness Disassembly........................................................................................... 0163-8 Electrical Harness Disassembly........................................................................................... 0163-9 Electrical Harness Assembly.............................................................................................. 0163-10 Electrical Harness Assembly.............................................................................................. 0163-11 Electrical Harness Assembly.............................................................................................. 0163-11 Electrical Harness Assembly.............................................................................................. 0163-12 Electrical Harness Assembly.............................................................................................. 0163-13 Electrical Harness Assembly.............................................................................................. 0163-14 Electrical Harness Assembly.............................................................................................. 0163-15 Electrical Harness Assembly.............................................................................................. 0163-16
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Page No. WP Sequence No. Figure 17. Figure 18. Electrical Harness Assembly.............................................................................................. 0163-17 Electrical Harness Assembly.............................................................................................. 0163-18
PREPARATION FOR SHIPMENT AND STORAGE.................................................................................... WP 0164 TORQUE LIMITS......................................................................................................................................... WP 0165 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. English Capscrew Heads. ................................................................................................... 0165-3 English Nut Markings. ......................................................................................................... 0165-3 Metric Fastener Markings..................................................................................................... 0165-4 Fastener Symbol Markings. ................................................................................................. 0165-5 Fastener Indented Markings. ............................................................................................... 0165-6 Metric Capscrew Nomenclature........................................................................................... 0165-6 Engine Fastener Torque Values........................................................................................... 0165-7 Transmission Fastener Torque Values................................................................................ 0165-8 All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values............................................................................................. 0165-10 All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values............................................................................................. 0165-12 Torque Limits for Dry Fasteners......................................................................................... 0165-13 Torque Limits for Wet Fasteners........................................................................................ 0165-14
DIAGRAMS.................................................................................................................................................. WP 0166 Chapter 5 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0167 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.............................................................. WP 0168 MAINTENANCE ALLOCATION CHART (MAC).......................................................................................... WP 0169 Table 1. Table 2. Table 3. Maintenance Allocation Chart (MAC)................................................................................... 0169-1 Tools and Test Equipment................................................................................................. 0169-14 Remarks............................................................................................................................. 0169-14
EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0170 Table 1. Expendable and Durable Items List..................................................................................... 0170-1
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Page No. WP Sequence No. TOOL IDENTIFICATION LIST..................................................................................................................... WP 0171 Table 1. Tool Identification List........................................................................................................... 0171-1
MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0172 Table 1. Foldout Figures FO-1. FO-2. FO-3. FO-4. Index Vehicle Electrical Schematic............................................................................................................. FP-1 Electrical System Identification......................................................................................................... FP-3 MSD/ICE Electrical Schematic......................................................................................................... FP-5 Hydraulic System Schematic............................................................................................................ FP-7 Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton........................ 0172-1
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HOW TO USE THIS MANUAL
INTRODUCTION 1. This manual contains maintenance procedures for the 7 1/2 Ton Crane. 2. This manual is written in work package format: a. Chapters divide the manual into major categories of information (e.g., General Information, Troubleshooting, PMCS, Maintenance Instructions, and Supporting Information). b. Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001, 0002, etc.) located on the upper right-hand corner of each page. The work package page number (e.g., 0001-1, 0001-2, etc.) is located centered at the bottom of each page. c. Read through this manual to become familiar with its organization and contents before attempting to maintain the equipment.
CONTENTS OF THIS MANUAL 1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before maintaining the equipment. 2. A Table of Contents, located in the front of the manual, lists all chapters and work packages in the publication. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual. 3. Chapter 1, General Information, Equipment Description, and Theory of Operation provides general information about the equipment, identifies the major components and systems, and describes how the components and systems work. 4. Chapter 2, Troubleshooting Procedures, describes troubleshooting procedures to locate and correct malfunctions of the equipment. 5. Chapter 3, PMCS covers field level PMCS. 6. Chapter 4 covers maintenance of the major systems on the crane, including (but not limited to) transmission, fuel system, and electrical. 7. Chapter 5, Supporting Information, contains the following: References, Maintenance Allocation Chart (MAC), Expendable and Durable Items List, Tool Identification List, and Foldouts. 8. An alphabetical Index is located at the back of this manual.
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HOW TO USE THIS MANUAL - Continued
FEATURES OF THIS MANUAL 1. This manual contains information on maintaining the crane. 2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid. WARNING indicates a hazard which may result in serious injury or death to personnel. CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment. NOTE is a statement containing information that will make the procedures easier to perform. 3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis. 4. Within a procedural step, reference may be made to another chapter or work package in this manual or to another manual. These references indicate where you should look for more complete information. a. If you are told: "Valve Covers Maintenance (WP 0035)," go to WP 0035 in this manual for instructions on servicing Valve Covers. b. If you are told: For complete information on batteries, refer to TB 9-6140-252-13", go to WP 0168, References for complete information on the referenced technical manual. 5. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art are text or numbers. 6. Numbers located at lower right corner of art are art control numbers and are used for tracking purposes only. Disregard these numbers. 7. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual. 8. Location Terms. The terms left, right, front, or rear are used to describe areas of the equipment. These terms indicate location as seen when facing toward front of crane.
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CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
TM 5-3810-305-23
0001
FIELD MAINTENANCE GENERAL INFORMATION
SCOPE 1. Type of Manual. This manual is for use in performing troubleshooting and maintenance on the 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light. 2. Equipment Name and Model Number. 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light, Type I NSN 3810-01-165-0646 and Type II NSN 3810-01-165-0647. 3. Purpose of Equipment. 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light is a wheel-mounted, selfcontained, two-wheel/four-wheel drive, two-wheel/four-wheel steering crane. It is used to lift heavy equipment, parts, and building supplies throughout a 360 degree rotation at various radii. It can travel over primary or secondary roads in various climates and military conditions worldwide. 7 1/2 Ton Crane design meets all applicable requirements of OSHA, EPA, PCSA Std. #4, ANSI B30.5 and the specified SAE Standards. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for equipment and maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS). REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light needs improvement, let us kno w. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance. All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https ://www.pdrep.csd.disa.mil/. If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the address/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.
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DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE When the tactical situation requires that Army materiel be abandoned, refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use. PREPARATION FOR STORAGE OR SHIPMENT Refer to Preparation for Shipment and Storage (WP 0164) to perform preparation for storage or shipment tasks. NOMENCLATURE CROSS-REFERENCE LIST Nomenclature cross-references used in this manual include the following: Common Name 7 1/2 Ton Crane Type I 7 1/2 Ton Crane Type II Official Nomenclature 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light Type I NSN 3810-01-165-0646 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light Type II NSN 3810-01-165-0647
LIST OF ABBREVIATIONS/ACRONYMS Abbreviation/Acronym ANSI BO C CAGEC CARC CCA cm CPC DCA EDIL EIR EPA F FGC FO ft-lb GP IAW I.D. in-lb IPS IWRC kg km kPa kph kW L lb(s) m MAC MIs mm Nm N Name American National Standards Institute Blackout Celsius Commercial and Government Entity Code Chemical Agent Resistant Coating Cold Cranking Amps Centimeter Corrosion Prevention and Control Diagnostic Connector Assembly Expendable and Durable Items List Equipment Improvement Recommendations Environmental Protection Agency Fahrenheit Functional Group Code Fold Out Foot Pound General Purpose In Accordance With Inner Diameter Inch Pound Improved Plow Steel Independent Wire Rope Core Kilogram Kilometer Kilopascal Kilometers per Hour Kilowatt Liter Pound(s) Meter Maintenance Allocation Chart Modification Instructions Millimeter Newton Meter Neutral
0001-2
TM 5-3810-305-23 LIST OF ABBREVIATIONS/ACRONYMS - Continued Abbreviation/Acronym NSN O.D. OHSA PCSA PM-SKOT PMCS PQDR PR psi qt rpm RPSTL SAE SKO SMR SOP SRA TAMMS TDC TI TIR TK TM TMDE TULSA U/I UOC UUT VID VDC VTM WP XDCR QUALITY OF MATERIAL Name National Stock Number Outer Diameter Occupational Health and Safety Administration Power Crane and Shovel Association Product Manager for Sets, Kits, Outfits and Tools Preventive Maintenance Checks and Services Product Quality Deficiency Report Ply Rating Pounds per Square Inch Quart Revolutions Per Minute Repair Parts and Special Tool List Society of Automotive Engineers Sets, Kits and Outfits Source, Maintenance and Recoverability Standard Operating Procedures Specialized Repair Activity The Army Maintenance Management System Top Dead Center Technical Instruction Total Indicator Reading Transducer Kit Technical Manual Test, Measurement and Diagnostic Equipment TACOM Unique Logistics Support Applications Unit of Issue Usable On Code Unit Under Text Vehicle Identification Volts Direct Current Vehicle Test Meter Work Package Transducer
0001
Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of material requirements are not stated in this manual, the material must meet the requirements for the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment. END OF WORK PACKAGE
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0002
FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES Characteristics The 7 1/2 Ton Crane is a wheel-mounted, self-contained, two-wheel/four-wheel drive, two-wheel/four-wheel steering crane. A diesel engine powers the 7 1/2 Ton Crane, driving through a powershift transmission with tandem pump hydraulic power for operation of the crane, outriggers, fully revolving upperstructure, and steering system. The 7 1/2 Ton Crane design meets all applicable requirements of OSHA, EPA, PCSA Std. #4, ANSI B30.5, and specified SAE Standards. Capabilities The capabilities of the 7 1/2 Ton Crane include: Lifting. 15,000 lb (6,804 kg) at up to a 10 ft (3 m) radius throughout 360 degree rotation with outriggers. 4,000 lb (1,814 kg) at up to a 30 ft (9 m) radius throughout 360 degree rotation with outriggers. 13,600 lb (6,169 kg) straight over the front on tires, no rotation, without use of outriggers. Travel Speeds. Up to 22 mph (35 kph) on level, hard surfaces. Up to 2.5 mph (4.0 kph) carrying a 4,500 lb (2,041 kg) load, with boom extended 20 ft (6.1 m) straight over the front. Rough terrain travel when placed in four-wheel drive. Continuous operation in temperatures up to 120F (49C) or altitudes up to 5,000 ft (1,524 m). Fording up to 30 inches (76 cm) of water. Safe to operate in ammunition and petroleum dumps.
Features The following are features of the 7 1/2 Ton Crane: Upperstructure. Includes counterweight and hydraulic winch. Boom Attachment. Includes crane boom, boom lift cylinder, and hook block. Carrier. Includes chassis, frame, engine, transmission, swing bearing, planetary axles, outriggers, operator cab, fuel tank, hydraulic reservoir, batteries, and tool compartment.
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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
10
9 7 15 14 8 13 12 11 10 9
G0001105
Figure 1. KEY 1 COMPONENT Counterweight
Major Components. DESCRIPTION Located at base of boom; used to stabilize crane during a lift. Located at base of boom; used to raise and lower steel cables. Steel beam that acts as an arm to lift a load. Piston cylinder that extends and retracts to lower and raise boom. Controlled by operator to give audible warning to personnel. Can be reeved three different ways, compensates for different size loads. Used to attach load to cable. Also keeps cable tight when there is no load on it. Includes chassis, frame, engine, transmission, swing bearing, planetary axles, outriggers, operator cab, fuel tank, hydraulic reservoir, batteries, and tool compartment.
Hydraulic Winch
3 4
Boom Boom Hoist
Forward Horn
Cable
Hook Block
Carrier
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0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued KEY 9 COMPONENT Tiedown/Sling Points DESCRIPTION Attachment points for overhead lifting device. There is one lift point on each side of front and rear of carrier. Supports that lower from each side to balance and support crane during lifts. Transfers rotary motion of engine and transmission to wheels. Center point of rotation for boom. Stores fuel being used to operate crane. Powerplant for crane. See Equipment Data in this work package for more information. Provide attachment points for towbar.
10
Outrigger
11
Planetary Axle
12 13 14
Swing Bearing Fuel Tank Engine/Transmission
15
Towing Lugs
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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
2 2
4 3
Figure 2. KEY 1 COMPONENT Stop Lights Major Components. DESCRIPTION Red lights that illuminate when the brakes are applied. Lights that illuminate based on position of vehicle light switch. Used for trailer and tow bar hookups. Audible warning that sounds when transmission is in REVERSE and ignition switch is in ON position.
G0002105
Rear Composite Lights
3 4
Tow Pintle Backup Alarm
0002-4
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0002
4 2
G0010105
3
Figure 3. KEY 1 COMPONENT Hydraulic Reservoir
Major Components. DESCRIPTION Stores hydraulic fluid used in vehicle hydraulic systems. Provides protection for two batteries. Provides on-vehicle storage for tools and equipment. Located on each side of operator cab.
2 3
Battery Compartment Tool Compartment
Rear View Mirror
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0002
3 4 5
Figure 4. KEY 1 COMPONENT Operator Cab
4
Major Components. DESCRIPTION
G0011105
Contains all controls and indicators for operation of crane. One at front of boom and two at back near counterweight. Used when operating in blackout mode. Controlled by vehicle light switch from cab. Controlled by turn signal switch from cab.
Work Lights
3 4 5
Blackout (BO) Drivelight Service Drivelights Front Turn Signals
0002-6
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0002
EQUIPMENT DATA Engine Type Bore and stroke Displacement Maximum gross horsepower Maximum gross torque Net horsepower Air filter Electrical System Alternator Battery Transmission Type Manufacturer Shift controls Powershift Funk Forward/reverse lever, gear speed (1 through 4) select lever, two-wheel/four-wheel drive select lever (See Gear Range Values (Table 1) for gear ranges.) Four speeds forward and reverse 24V, 40 amp 440 cold cranking amps at 24V Cummins 4B3.9 water-cooled, 4-cycle diesel engine 4.02 x 4.72 inches (102 x 120 mm) 239.3 cu inch (3.92 L) 80 hp (60 kW) at 2,800 rpm 184 ft-lb (249 Nm) at 2,800 rpm 60 hp (47 kW) at 2,800 rpm Dry type
Speeds Torque Converter Type
Single-stage, three-element, free-wheel stator (size 11.75 inch, STR-2 9)
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0002
EQUIPMENT DATA - Continued Wheels Type Size Wheel base Tires Tire inflation pressure Axles Type Reduction Brakes Type Suspension Type Driving modes Oscillating rear axle w/automatic lockout Two-wheel, rear drive (For hard surfaces at high speeds.) Four-wheel drive (For rough terrain.) Steering Type Full fluid linked power steering, w/backup steering pump (Auxiliary pump is ground driven off rotation of wheels and provides steering and braking during power loss. Two-wheel steering Four-wheel steering Crab steering Turning radius Two-wheel: 32 ft 2 inches (9.80 m) Four-wheel: 18 ft 4 inches (5.59 m) Hydraulically boosted, dual system with front-to-rear split Soma, planetary, Model 3 19:61:1 Disc 8.25 x 22.5 inches (210 x 572 mm) 108 inches (274 cm) 12 x 22.5, 14 PR radial 115 psi (793 kPa)
Modes
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0002
EQUIPMENT DATA - Continued Hydraulic System Hydraulic pump drive One tandem hydraulic pump driven off transmission at 0.87 x engine rpm
Steering, brake, and swing circuit Pump 21 gal. (79.5 L) per minute, operating at 2,440 rpm and 2,650 psi (18,272 kPa) 10 gal. (37.8 L) per minute at 2,440 rpm and 2,500 psi (17,238 kPa) 18 gal. (68.1 L) per minute, operating at 2,440 rpm and 2,650 psi (18,272 kPa) 21 gal. (79.5 L) per minute, operating at 2,440 rpm and 2,750 psi (18,961 kPa) Four-spool, two-way valve Single-spool, two-way valve Full-flow system with 100 mesh (140 micron) screen and 10 micron return filter
Priority flow
Winch circuit
Boom hoist, telescope, and outrigger circuit
Hydraulic valve bank Winch valve Oil filtration
Swing System Type Speed Drawbar Continuous pull Pintle Hook Towing capacity 40,000 lb (18,144 kg) 10,000 lb (4,536 kg) Hydraulically powered, worm gear reduction unit 3.08 rpm (no load)
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0002
EQUIPMENT DATA - Continued Outriggers Type Flipper, 7 inches (178 mm) lift on 12 x 22.5, 14 PR (standard tires) 4.5 seconds 4.0 seconds
Extend time per outrigger Retract time per outrigger Outrigger cylinders Bore Stroke Rod Boom Type Maximum length Construction Point sheaves
5.0 inches (127 mm) 17.75 inches (451 mm) 3 inches (76 mm)
Standard, two-section 35.75 ft (10.90 m) All welded, box beam Cast, ductile iron, mounted on non-friction bearings, two-sheave boom head To 21.75 ft (6.63 m) (PCSA Standards) 70,000 psi (483 N/mm2) material
Retraction Base and tip sections Boom Cylinders Boom hoist Bore Stroke Rod Hoist time Down time
8.5 inches (216 mm) 39.3 inches (998 mm) 3 inches (76 mm) 28.5 seconds 25.3 seconds
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0002
EQUIPMENT DATA - Continued Boom extend Bore Stroke Rod Extend time Retract time Winch Maximum line speed (no load) First layer Third layer Drum capacity Rope size 177 ft (53.95 m) per minute 216 ft (65.84 m) per minute 350 ft (107 m), five layers 1/2 inch, 6 x 9 Independent Wire Rope Core (IWRC), Improved Plow Steel (IPS), preformed 8.5 inches (216 mm) 12.25 inches (311 mm) 14.56 inches (370 mm) 4.0 inches (102 mm) 167 inches (4.27 m) 3 inches (76 mm) 27.2 seconds 22.7 seconds
Drum diameter Drum length Flange diameter Boom Mounted Work Platform Total weight of platform and adapter Excluding load Maximum load Counterweight Weight
1,005 lb (456 kg) 600 lb (272 kg)
2,200 lb (998 kg)
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0002
EQUIPMENT DATA - Continued Vehicle Weight Distribution Front Type I Type II Rear Type I Type II Hook Block TOTAL Type I Type II Fluid Capacities Cooling system Fuel Crankcase Hydraulic system Hydraulic oil reservoir Transmission Capacity Refill Axle Hub Differential Swing reduction unit Winch 3 qt (2.8 L) 14 qt (13.2 L) 3 qt (2.8 L) 2 qt (1.9 L) 20.5 qt (19.4 L) 12 qt (11.3 L) 28 qt (26.5 L) 44 gal. (166.5 L) 11 qt (10.4 L) 45 gal. (170.3 L) 23.8 gal. (90.1 L) 22,870 lb (10,374 kg) 24,230 lb (10,991 kg) 12,110 lb (5,493 kg) 12,520 lb (5,679 kg) 345 lb (156 kg) 10,760 lb (4,881 kg) 11,710 lb (5,312 kg)
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0002
EQUIPMENT DATA - Continued Table 1. Gear 1 2 3 4 Maximum Speed 3.3 mph (5.3 kph) 6.2 mph (9.9 kph) 11.4 mph (18.3 kph) 22 mph (35.4 kph) Gear Range Values. Gradeability 99.2% 38.8% 19.1% 9.2%
Maximum Tractive Effort 18,830 lb (8,541 kg) 9,930 lb (4,504 kg) 5,400 lb (2,449 kg) 2,900 lb (1,315 kg)
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EQUIPMENT DATA - Continued
1 2 3 5 4
6 7 10 11 12 9 8
G0005105
Figure 5. KEY DESCRIPTION
General Dimensions. DIMENSIONS
NOTE
All dimensions assume boom fully retracted and crane equipped with standard tires. 1 2 3 4 5 6 7 8 9 10 11 Overall length Centerline of rotation to boom end Boom end to front of carrier Tail swing radius Centerline of rotation to boom pivot Height of cab Ground clearance to transmission Ground clearance to outrigger box Centerline of rotation to centerline of rear axle Wheelbase 308.16 inches (782 cm) 212 inches (538 cm) 78.5 inches (199 cm) 93 inches (236 cm) 56.5 inches (144 cm) 74 inches (188 cm) 14.4 inches (37 cm) 15 inches (38 cm) 50.9 inches (129 cm) 108 inches (274 cm)
Centerline of front outrigger box to centerline of rear 172 inches (437 cm) outrigger box Overall length of carrier 229.6 inches (583 cm)
12
0002-14
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0002
3 6 7
G0006105
Figure 6. KEY 1 2 3 4 5 6 7 8 DESCRIPTION Overall travel width Outrigger extension, below Ground clearance to lowest point of axle Track Width of carrier Effective width of outriggers Overall width over floats Overall height
General Dimensions. DIMENSIONS 72 inches (183 cm) 7.3 inches (19 cm) 14 inches (36 cm) 72 inches (183 cm) 82.3 inches (209 cm) 148.9 inches (378 cm) 163.9 inches (416 cm) 92.5 inches (235 cm)
0002-15
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0002
G0007105
Figure 7. Radius from Centerline of Rotation.
0002-16
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G0008105
Figure 8.
Crane Working Positions.
NOTE
Working areas are measured in a circular area around centerline of rotation.
G1305105
Figure 9.
Lift Capacity (on Outriggers).
0002-17
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0002
Figure 10. Lift Capacity (on Tires).
Figure 11. Maximum Permissible Hoist Line Load. END OF WORK PACKAGE
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0003
FIELD MAINTENANCE THEORY OF OPERATION
INTRODUCTION 1. The purpose of this work package is to provide a general description of the 7 1/2 Ton Crane and an overall view of its components and their functions. 2. This section explains how the systems and components of the crane work together. A functional description is provided for each major component and system. GENERAL 1. The 7 1/2 Ton Crane is a self-contained vehicle, featuring 7.5 ton maximum lifting capacity, optional fourwheel drive, outriggers for added stability during lifting operations, and three different steering modes: front wheel steering for normal driving, crab steering for diagonal moves, and four-wheel steering for minimumradius turns. 2. Power originates from an in-line, four-cylinder, diesel engine mounted at the rear of the vehicle. The transmission is mounted directly on the engine and is used to turn driveshafts and to power the tandem hydraulic pump. One-half of the tandem hydraulic pump supplies hydraulic pressure to winch, and other half supplies hydraulic pressure to actuate the boom telescope cylinder, boom hoist cylinder, boom swing motor, outrigger cylinders, axle lockout cylinders, and steering controls. It also provides hydraulic assistance for brake system. BOOM The boom is a two-section telescope-type with rotating boom support. Two large-diameter, double-acting hydraulic cylinders telescope and hoist the boom assembly. A hydraulic swing motor and worm gear rotates the upperstructure. The cable and hook block assembly are operated by hydraulic winch. Hydraulic and electrical systems on the upperstructure are connected to the rest of the vehicle by a hydraulic rotary manifold and electrical collector ring. TRANSMISSION 1. The transmission is capable of four-speed shifting in both forward and reverse. Direction and speed are selected through hydraulically actuated multiple-disc clutches. The clutches are power absorbing, allowing shifts under full engine power in both forward and reverse. The clutches are hydraulically controlled and spring released. Hydraulic control makes the clutches self-adjusting. Each clutch is made of friction plates and polished-steel reaction plates. 2. The transmission receives power from the engine through the torque converter. The torque converter is fluid driven, creating a smooth and shock-free drive. Fluid drive also eliminates engine stalling and lugging when vehicle has a heavy load. With light loads, the torque converter can transmit engine power directly to the transmission at most engine speeds with no torque multiplication. This provides variable and automatic speed ratios, reducing need for shifting gears.
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0003
AXLES The front and rear axles have remote breathers to allow operation in up to 30 inches (762 mm) of water. The rear axle has lockout cylinders to provide increased stability during hoisting. Steering for each axle is enhanced by dualacting hydraulic cylinders that are tied together by a single tie rod, which provides smooth, sharp, synchronized turning with minimum alignment and adjustment requirements. The service brakes are shoe-type hydraulic units and are part of the axle. The front axle has a disc brake that can be used either as a parking brake or an emergency brake. Each axle has its own differential. WINCH 1. The winch consists of four basic assemblies: winch base, hydraulic motor and brake valve, brake cylinder and motor support, and drum assembly. The hydraulic motor turns the gears in the drum assembly, working the cable. 2. The winch has a dual braking system: a dynamic brake and a static brake. These two types of brakes work together to control the speed of the drum assembly. The dynamic brake uses hydraulic pressure to operate the brake valve, which controls the flow of hydraulic oil to the hydraulic motor. The static brake consists of multiple friction discs, a brake clutch assembly, and a hydraulic piston and cylinder. The static brake is automatically applied unless it is released by brake valve pilot pressure at a level lower than that required to open the pilot-operated spool valve. 3. Either brake system does not affect the winch during hoisting operations. When the operator's control is placed in neutral, rollers between the cam and outer race wedge to prevent the drum assembly from turning. The brake valve stops oil flow from the hydraulic motor. For lowering a load slowly, the operator can allow only enough oil to release the brake without engaging the hydraulic motor. The hydraulic oil dissipates heat build-up. For faster lowering, the hydraulic pressure is increased by the operator to both release the brake and engage the hydraulic motor. END OF WORK PACKAGE
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CHAPTER 2 TROUBLESHOOTING PROCEDURES
TM 5-3810-305-23 FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX
0004
GENERAL This section provides information for identifying and correcting issues which may develop when operating or maintaining the 7 1/2 Ton Crane. The index lists common symptoms which may occur and refers you to the proper work package for a troubleshooting procedure. This section cannot list all symptoms that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify your Maintenance Supervisor. When troubleshooting a malfunction: 1. Question the operator to obtain any information that might help determine the cause of the problem. Before continuing, ensure that all applicable operator/crew troubleshooting was performed. 2. Locate the symptom or symptoms in the Troubleshooting Index that best describe the issue. If the appropriate symptom is not listed, notify your Maintenance Supervisor. 3. Go to the work package where the troubleshooting procedures for the symptom in question are described. Headings at the top of each page show how each troubleshooting procedure is organized: Symptom, Malfunction, and Corrective Action. 4. Perform each step in the order listed until the symptom is corrected and the item being inspected is operational. Do not perform any maintenance task unless the troubleshooting procedure tells you to do so. EXPLANATION OF HEADINGS The headings in the troubleshooting procedures are defined as follows: 1. SYMPTOM. A visual or operational indication that something is wrong with the crane. 2. MALFUNCTION. Observable fault in component or system. 3. CORRECTIVE ACTION. A procedure to correct the fault. TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom ENGINE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine Cranks but Will Not Start; No Smoke from Exhaust.............................................................. WP 0005 Engine Will Not Start when Cold Start is Used.................................................................................. WP 0005 Engine Hard to Start/Will Not Start; Smoke from Exhaust................................................................ WP 0005 Engine Starts, but Will Not Keep Running......................................................................................... WP 0005 Engine Will Not Crank....................................................................................................................... WP 0005 Engine Surges at Idle........................................................................................................................ WP 0005 Warm Engine Idles Rough................................................................................................................ WP 0005 Engine Misfires.................................................................................................................................. WP 0005 Engine Runs Hot............................................................................................................................... WP 0005 Low Oil Pressure............................................................................................................................... WP 0005 Engine Running Too Cold................................................................................................................. WP 0005 Troubleshooting Procedure
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TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 12. 13. 14. 15.
0004
Troubleshooting Procedure
Engine RPM Will Not Reach Rated Speed - No Load....................................................................... WP 0005 Low Power........................................................................................................................................ WP 0005 Excessive Smoke Under Load.......................................................................................................... WP 0005 Fuel Knock........................................................................................................................................ WP 0005
HYDRAULICS 1. 2. Control Lever Sticks or Binds............................................................................................................ WP 0006 No Movement of Hydraulic Function(s)............................................................................................. WP 0006
SWING CIRCUIT 1. 2. 3. 4. Upperstructure Will Not Swing.......................................................................................................... WP 0007 Swing Motion Sluggish...................................................................................................................... WP 0007 Swing Motion Erratic......................................................................................................................... WP 0007 Swing Motor Turns in Wrong Direction.............................................................................................. WP 0007
BOOM HOIST CIRCUIT 1. 2. 3. 4. Boom Hoist Cylinder Inoperative or Erratic....................................................................................... WP 0008 Boom Drops Slightly as Raise Control is Released.......................................................................... WP 0008 Boom Hoist, Extend, and Outrigger Cylinders Inoperative or Erratic................................................................................................................................................ WP 0008 Boom Drifts Down............................................................................................................................. WP 0008
BOOM EXTEND CIRCUIT 1. 2. 3. Boom Extend Function Will Not Operate........................................................................................... WP 0009 Boom Extend Cylinder Extends but Will Not Retract......................................................................... WP 0009 Boom Section Retracts Under Load.................................................................................................. WP 0009
OUTRIGGER CIRCUIT 1. 2. 3. 4. All Outriggers Inoperative.................................................................................................................. WP 0010 Individual Outrigger Inoperative........................................................................................................ WP 0010 Outriggers Will Not Lift Vehicle.......................................................................................................... WP 0010 Outrigger Retracts Under Load......................................................................................................... WP 0010
0004-2
TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom STEERING CIRCUIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
0004
Slow Steering, Hard Steering, or Loss of Power Assist.................................................................... WP 0011 Vehicle Wanders - Vehicle Will Not Stay in a Straight Line............................................................... WP 0011 Drift - Vehicle Veers Slowly in One Direction.................................................................................... WP 0011 Slip - Slow Movement of Steering Wheel Fails to Cause Any Movement of Steered Wheels........................................................................................................... WP 0011 Temporary Hard Steering or Hang-up............................................................................................... WP 0011 Erratic Steering................................................................................................................................. WP 0011 Spongy" or Soft Steering.................................................................................................................. WP 0011 Free Wheeling - Steering Wheel Turns With Slight Resistance but Results in Little or No Steered Wheel Action.............................................................................. WP 0011 Excessive Free Play at Steering Wheel............................................................................................ WP 0011 Steering Unit Locks Up..................................................................................................................... WP 0011 Steering Wheel Oscillates or Turns by Itself..................................................................................... WP 0011 Steered Wheels Turn in Wrong Direction When Operator Activates Steering Wheel.................................................................................................................. WP 0011
PUMPS 1. 2. 3. 4. 5. Failure of Hydraulic Pump(s) to Deliver Fluid.................................................................................... WP 0012 Low or No Pressure in System.......................................................................................................... WP 0012 Pump(s) Making Noise...................................................................................................................... WP 0012 External Oil Leakage Around Hydraulic Pump(s).............................................................................. WP 0012 Breakage of Parts Inside Hydraulic Pump Housing(s)...................................................................... WP 0012
RELIEF VALVES 1. 2. 3. 4. Cannot Get Pressure........................................................................................................................ WP 0013 Erratic Pressure................................................................................................................................ WP 0013 Pressure Setting Not Correct............................................................................................................ WP 0013 Leakage............................................................................................................................................ WP 0013
BRAKES 1. 2. 3. 4. Brakes Slow to Release or Drag....................................................................................................... WP 0014 Brakes Do Not Release..................................................................................................................... WP 0014 Brakes Slow to Apply........................................................................................................................ WP 0014 Insufficient Brakes............................................................................................................................. WP 0014 0004-3
TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom
0004
ELECTRICAL SYSTEM 1. 2. 3. 4. 5. Starting Motor Does Not Operate...................................................................................................... WP 0015 Alternator Charging Low or Unsteady............................................................................................... WP 0015 Battery Voltage Low.......................................................................................................................... WP 0015 External Light(s) Not Operating......................................................................................................... WP 0015 Worklights Not Operating.................................................................................................................. WP 0015
ANTI-TWO BLOCK SYSTEM 1. 2. 3. 4. 5. Panel Light and Horn Will Not Come On With Anti-Two Block Counterweight Lifted; Control Disconnects Will Not Engage............................................................ WP 0016 Horn Works but No Light With Anti-Two Block Counterweight Lifted; Control Disconnects Will Not Engage..................................................................................... WP 0016 Light and Horn Are On With Hook Block Not Contacting AntiTwo Block Counterweight; Control Disconnects Will Not Engage..................................................... WP 0016 Light and Horn Are On but Control Disconnects Will Not Disengage......................................................................................................................................... WP 0016 No Light and Horn but Control Disconnects Will Not Engage........................................................... WP 0016
TRANSMISSION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Erratic Transmission Oil Pressure..................................................................................................... WP 0017 Excessive Transmission Oil Pressure at High Speed (RPM)............................................................ WP 0017 Low Transmission Oil Pressure in All Gears..................................................................................... WP 0017 Low Transmission Oil Pressure in One Gear but Alright in Other Gears................................................................................................................................................ WP 0017 Low Converter Pressure................................................................................................................... WP 0017 High Transmission Oil Pressure........................................................................................................ WP 0017 Clutch Selected Pressure Does Not Return to Normal..................................................................... WP 0017 Excessive Noise at Engine Idle......................................................................................................... WP 0017 Excessive Gear Noise at High Speed (RPM).................................................................................... WP 0017 Transmission Oil Blows out of Breather on Top of Transmission...................................................... WP 0017 Transmission Overheating................................................................................................................ WP 0017
AXLE ASSEMBLY 1. Wheels Pull to Right or Left............................................................................................................... WP 0018
0004-4
TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. 4. 5.
0004
Steering is Erratic.............................................................................................................................. WP 0018 Wheel End Leaks Oil......................................................................................................................... WP 0018 Wheels Noisy When Turned to Right or Left..................................................................................... WP 0018 Excessive Noise in Transfer of Power From Engine to Wheels........................................................ WP 0018
WINCH 1. 2. 3. 4. 5. 6. 7. 8. 9. Winch Will Not Develop Maximum Line Pull..................................................................................... WP 0019 Winch Will Lower but Will Not Raise................................................................................................. WP 0019 Winch Will Not Lower Load or Not Lower Load Smoothly................................................................. WP 0019 Hydraulic Oil Leaks From Vent Plug................................................................................................. WP 0019 The Brake Will Not Hold a Load With the Control Lever in Neutral................................................... WP 0019 Winch Will Not Hoist Rated Load...................................................................................................... WP 0019 Winch Runs Hot................................................................................................................................ WP 0019 Winch Chatters" While Raising Rated Load..................................................................................... WP 0019 Wire Rope Does Not Spool Smoothly on Drum................................................................................ WP 0019
END OF WORK PACKAGE
0004-5/6 blank
TM 5-3810-305-23
0005
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES ENGINE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0020 WP 0022 WP 0025 WP 0031 WP 0039 WP 0043 WP 0044 WP 0045 WP 0047 WP 0048 References (cont.) WP 0049 WP 0051 WP 0052 WP 0054 WP 0056 WP 0058 WP 0059 WP 0061 WP 0063 WP 0064 WP 0065 WP 0066 WP 0075 WP 0076 WP 0162
TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE CRANKS BUT WILL NOT START; NO SMOKE FROM EXHAUST MALFUNCTION Out of Fuel. CORRECTIVE ACTION Fill tank. MALFUNCTION MSD-ICE Fuel Switch OFF. CORRECTIVE ACTION 1. 2. Turn switch ON (WP 0020). Replace switch (WP 0065).
0005-1
03/15/2011 Rel(1.8) root(tswp) wpno(T00010)
TM 5-3810-305-23
0005
MALFUNCTION Less Than 22 VDC at Fuel Solenoid. CORRECTIVE ACTION 1. 2. Tighten wire connection on fuel solenoid (WP 0162). Check wire for continuity. Replace if faulty (WP 0162).
MALFUNCTION Fuel Line Plugged. CORRECTIVE ACTION 1. 2. 3. Change fuel filters (WP 0022). Clean out fuel line (WP 0162). Replace fuel line (WP 0048) and (WP 0049).
MALFUNCTION Lift Pump Inoperative. CORRECTIVE ACTION Inspect pump. Replace pump if required (WP 0045). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM ENGINE WILL NOT START WHEN COLD START IS USED MALFUNCTION No Ether Delivered from Cylinder. CORRECTIVE ACTION 1. 2. Check cylinder for tightness and quantity of ether. If empty, replace cylinder (WP 0051).
0005-2
TM 5-3810-305-23
0005
MALFUNCTION Valve Not Dispensing Ether. CORRECTIVE ACTION 1. 2. Disconnect tube at valve and actuate valve. Adjust actuating cable (WP 0051).
MALFUNCTION Obstruction in Tube to Atomizer. CORRECTIVE ACTION Reconnect tube to valve. Actuate valve; if no ether is present, replace tube (WP 0051). MALFUNCTION Obstruction in Atomizer. CORRECTIVE ACTION Remove atomizer. Reconnect tube to atomizer. Actuate valve. If either is not discharged from atomizer, it is clogged. Remove atomizer and clean out or replace (WP 0051). SYMPTOM ENGINE HARD TO START/WILL NOT START; SMOKE FROM EXHAUST MALFUNCTION Cranking Speed Too Low. CORRECTIVE ACTION 1. 2. 3. Tighten battery connection (WP 0076). Service batteries (WP 0076). Replace starting motor (WP 0063).
MALFUNCTION Cold Start Needed. CORRECTIVE ACTION Use cold start device (TM 5-3810-305-10).
0005-3
TM 5-3810-305-23
0005
MALFUNCTION Engine Starting Under Load. CORRECTIVE ACTION Check for properly positioned valve spools, cables, and levers. Repair or replace as required. SYMPTOM ENGINE STARTS, BUT WILL NOT KEEP RUNNING MALFUNCTION Idle Speed Too Low. CORRECTIVE ACTION Adjust low idle screw (WP 0020). MALFUNCTION Engine Starting Under Load. CORRECTIVE ACTION Check for properly positioned valve spools, cables, and levers. Repair or replace as required. MALFUNCTION Contaminated Fuel. CORRECTIVE ACTION Drain fuel and clean fuel system (TM 5-3810-305-10). MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.
0005-4
TM 5-3810-305-23
0005
SYMPTOM ENGINE WILL NOT CRANK MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON. MALFUNCTION Transmission Shift Not in Neutral. CORRECTIVE ACTION 1. 2. Shift into neutral. Replace neutral safety switch (WP 0064).
MALFUNCTION Battery Connections Loose. CORRECTIVE ACTION Tighten battery connections (WP 0076). MALFUNCTION Battery Voltage Low. CORRECTIVE ACTION Service batteries (WP 0076). SYMPTOM ENGINE SURGES AT IDLE MALFUNCTION Idle Speed Set Too Low. CORRECTIVE ACTION Adjust low idle screw (WP 0020). MALFUNCTION Air in Fuel System.
0005-5
TM 5-3810-305-23
0005
CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.
MALFUNCTION Low Fuel Level in Tank. CORRECTIVE ACTION Add fuel (TM 5-3810-305-10). MALFUNCTION Fuel Lines Restricted. CORRECTIVE ACTION 1. 2. Clean out fuel lines. Replace fuel lines (WP 0048) and (WP 0049).
MALFUNCTION Fuel Filters Plugged. CORRECTIVE ACTION Replace fuel filters (WP 0022). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM WARM ENGINE IDLES ROUGH MALFUNCTION Idle Speed Set Too Low. CORRECTIVE ACTION Adjust low idle screw (WP 0020).
0005-6
TM 5-3810-305-23
0005
MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION Drain fuel and clean system (TM 5-3810-305-10). MALFUNCTION Air Cleaner Element Plugged. CORRECTIVE ACTION 1. 2. Clean air cleaner element (TM 5-3810-305-10). Replace air cleaner element (WP 0022).
MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.
MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044).
0005-7
TM 5-3810-305-23
0005
MALFUNCTION Valves Incorrectly Adjusted. CORRECTIVE ACTION Adjust valve clearance (WP 0031). SYMPTOM ENGINE MISFIRES MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION Drain fuel and clean system (WP 0047). MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.
MALFUNCTION Fuel Injection Lines Leaking. CORRECTIVE ACTION 1. 2. Tighten connections. Replace lines (WP 0048) and (WP 0049).
MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzle (WP 0043). MALFUNCTION Valves Adjusted Incorrectly. CORRECTIVE ACTION Adjust valve clearance (WP 0031).
0005-8
TM 5-3810-305-23
0005
SYMPTOM ENGINE RUNS HOT MALFUNCTION Vehicle Overloaded. CORRECTIVE ACTION 1. 2. Reduce load (TM 5-3810-305-10). Use lower gear (TM 5-3810-305-10).
MALFUNCTION Coolant Level Low. CORRECTIVE ACTION 1. 2. Add coolant (TM 5-3810-305-10). Check for leaks and repair.
MALFUNCTION Engine Temperature Gage/Sending Unit Malfunctioning. CORRECTIVE ACTION Replace engine temperature gage/sending unit (WP 0066). MALFUNCTION Fins in Radiator Plugged. CORRECTIVE ACTION Clean out fins (TM 5-3810-305-10). MALFUNCTION Thermostat Inoperative, Incorrect, or Missing. CORRECTIVE ACTION Replace thermostat (WP 0056). MALFUNCTION Collapsed Hose. CORRECTIVE ACTION Replace collapsed hose (WP 0054).
0005-9
TM 5-3810-305-23
0005
MALFUNCTION Loose Belt on Water Pump and Fan. CORRECTIVE ACTION 1. 2. Check belt for correct size (WP 0059). Replace belt tensioner (WP 0061).
MALFUNCTION Pressure Cap Incorrect/Malfunctioning. CORRECTIVE ACTION Replace cap. MALFUNCTION Water Pump Inoperative. CORRECTIVE ACTION Replace water pump (WP 0058). MALFUNCTION Injection Pump Timing Incorrect or Overfueled. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM LOW OIL PRESSURE MALFUNCTION Oil Level Low. CORRECTIVE ACTION 1. 2. Fill to proper level (TM 5-3810-305-10). Check for leaks and repair.
MALFUNCTION Oil Pressure Gage/Sending Unit Malfunctioning. CORRECTIVE ACTION Replace oil pressure gage/sending unit.
0005-10
TM 5-3810-305-23
0005
MALFUNCTION Engine Oil Diluted or Improper Viscosity. CORRECTIVE ACTION 1. 2. Change engine oil (WP 0022). Check for origin of contamination and repair.
MALFUNCTION Engine Oil Filter Plugged. CORRECTIVE ACTION Change engine oil filter (WP 0022). MALFUNCTION Seal on Engine Oil Suction Tube Inoperative. CORRECTIVE ACTION Replace seal (WP 0039). MALFUNCTION Engine Bearing Worn or Damaged. CORRECTIVE ACTION Replace engine (WP 0025). SYMPTOM ENGINE RUNNING TOO COLD MALFUNCTION Engine Temperature Gage/Sending Unit Malfunctioning. CORRECTIVE ACTION Replace engine temperature gage/sending unit. MALFUNCTION Thermostat Inoperative, Incorrect Temperature Set-Point. CORRECTIVE ACTION Replace thermostat (WP 0056).
0005-11
TM 5-3810-305-23
0005
SYMPTOM ENGINE RPM WILL NOT REACH RATED SPEED - NO LOAD MALFUNCTION Throttle Linkage Incorrectly Adjusted. CORRECTIVE ACTION Adjust throttle linkage. MALFUNCTION Tachometer Malfunctioning. CORRECTIVE ACTION Replace tachometer (WP 0075). SYMPTOM LOW POWER MALFUNCTION Vehicle Overloaded. CORRECTIVE ACTION 1. 2. Reduce load (TM 5-3810-305-10). Use lower gear (TM 5-3810-305-10).
MALFUNCTION Air Cleaner Element Plugged. CORRECTIVE ACTION 1. 2. Clean air cleaner element (TM 5-3810-305-10). Replace air cleaner element (WP 0022).
MALFUNCTION Fuel Filters Plugged. CORRECTIVE ACTION Replace fuel filters (WP 0022).
0005-12
TM 5-3810-305-23
0005
MALFUNCTION Poor Quality Fuel. CORRECTIVE ACTION 1. 2. Drain fuel tank (TM 5-3810-305-10). Clean out fuel lines (WP 0162).
MALFUNCTION Throttle Linkage Incorrectly Adjusted. CORRECTIVE ACTION Adjust throttle linkage (WP 0052). MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fitting. Replace damaged fuel system components.
MALFUNCTION Fuel Lines Restricted. CORRECTIVE ACTION 1. 2. Clean out lines (WP 0048) and (WP 0049). Replace lines (WP 0048) and (WP 0049).
MALFUNCTION Fuel Drain Manifold Restricted. CORRECTIVE ACTION 1. 2. Clear restriction. Replace fuel drain manifold (WP 0049).
MALFUNCTION Oil Level High. CORRECTIVE ACTION Drain to proper level (TM 5-3810-305-10).
0005-13
TM 5-3810-305-23
0005
MALFUNCTION Valves Incorrectly Adjusted. CORRECTIVE ACTION Adjust valve clearance (WP 0031). MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM EXCESSIVE SMOKE UNDER LOAD MALFUNCTION Air Cleaner Element Plugged. CORRECTIVE ACTION 1. 2. Clean air cleaner element (TM 5-3810-305-10). Replace air cleaner (WP 0022).
MALFUNCTION Engine Running Too Cold. CORRECTIVE ACTION 1. 2. Warm up engine (TM 5-3810-305-10). Replace thermostat (WP 0056).
MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044).
0005-14
TM 5-3810-305-23
0005
MALFUNCTION More Than One Seal Washer Under Injector Nozzle. CORRECTIVE ACTION Remove extra washers (WP 0043). MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). MALFUNCTION Injection Pump Overfueled. CORRECTIVE ACTION Replace injection pump (WP 0044). MALFUNCTION Poor Quality Fuel. CORRECTIVE ACTION 1. 2. Drain fuel tank (TM 5-3810-305-10). Clean out fuel lines (WP 0162).
MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fitting. Replace damaged fuel system components.
MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044).
0005-15
TM 5-3810-305-23
0005
MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). SYMPTOM FUEL KNOCK MALFUNCTION Poor Quality Fuel. CORRECTIVE ACTION 1. 2. Drain fuel tank (TM 5-3810-305-10). Clean out fuel lines (WP 0162).
MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fitting. Replace damaged fuel system components.
MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044). MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). END OF WORK PACKAGE
0005-16
TM 5-3810-305-23
0006
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES HYDRAULICS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References WP 0012 WP 0013 References (cont.) WP 0019 WP 0129 WP 0138 WP 0139 WP 0146
TROUBLESHOOTING PROCEDURE
NOTE
Hydraulic function" is the general term used for any of the following five hydraulically controlled operations on the crane: boom hoist, boom telescope, upperstructure swing, winch, and outriggers. Before any troubleshooting is attempted, become fully acquainted with the following two basic fundamental facts of a hydraulic system: 1. SPEED - The speed of a hydraulic function is directly related to the system flow. A reduction in speed of a cylinder or motor is caused by an insufficient quantity of oil being delivered to the component. 2. POWER - The power or force of a hydraulic function is related to pressure. If the differences between speed and power of a hydraulic system is understood, then accurate troubleshooting can be accomplished in a minimum of time. Follow these steps to isolate hydraulic malfunctions: 1. Identify hydraulic functions that are malfunctioning. 2. If one function is malfunctioning, check components unique to that function. 3. If more than one function is malfunctioning, refer to hydraulic schematic. Identify components common to all areas malfunctioning. Check those common components first. 4. Check for proper hydraulic oil level in hydraulic reservoir and for obvious leaks. 5. Check for proper hydraulic pressures before any components are replaced.
0006-1
TM 5-3810-305-23
0006
SYMPTOM CONTROL LEVER STICKS OR BINDS MALFUNCTION Control Linkage or Cable Sticking. CORRECTIVE ACTION
NOTE
Binding push-pull cables may simply have too tight a bend at some point in their length. Starting from the control valve end, disconnect the components one at a time until the malfunction is located. Then repair or replace that component. MALFUNCTION Valve Spool Sticking. CORRECTIVE ACTION Replace control valve (WP 0138) and (WP 0139). SYMPTOM NO MOVEMENT OF HYDRAULIC FUNCTION(S) MALFUNCTION Valve Spool Does Not Shift Fully. CORRECTIVE ACTION 1. 2. 3. Adjust linkage. Replace faulty linkage (WP 0129). Replace control valve (WP 0138) and (WP 0139).
MALFUNCTION Valve Spool Shifts Fully.
0006-2
TM 5-3810-305-23
0006
CORRECTIVE ACTION 1. Refer to sections on: a. b. c. 2. Relief Valve Troubleshooting (WP 0013). Winch Troubleshooting (WP 0019). Pump Troubleshooting (WP 0012).
Replace control valve (WP 0146).
END OF WORK PACKAGE
0006-3/4 blank
TM 5-3810-305-23
0007
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES SWING CIRCUIT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0114 References (cont.) WP 0134 WP 0146 WP 0147 WP 0160 WP 0161
TROUBLESHOOTING PROCEDURE SYMPTOM UPPERSTRUCTURE WILL NOT SWING MALFUNCTION Swing Relief Valve Stuck in Open Position. CORRECTIVE ACTION Replace swing relief valve (WP 0147). MALFUNCTION Swing Motor Leaks Internally. CORRECTIVE ACTION 1. 2. Repair swing motor (WP 0160). Replace swing motor (WP 0160).
MALFUNCTION Downstream Blockage. CORRECTIVE ACTION 1. 2. Return additional controls to neutral position. Locate and remove blockage.
0007-1
TM 5-3810-305-23
0007
MALFUNCTION Swing Valve Spool Damaged. CORRECTIVE ACTION Replace main control valve (WP 0146). MALFUNCTION Mechanical Fault in Swing Reducer Gearbox. CORRECTIVE ACTION 1. 2. Repair swing gearbox (WP 0161). Replace swing gearbox (WP 0161).
MALFUNCTION Mechanical Fault in Swing Bearing. CORRECTIVE ACTION Replace swing bearing (WP 0158). MALFUNCTION Main Hydraulic Pump Faulty. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM SWING MOTION SLUGGISH MALFUNCTION Swing Relief Valve Set Too Low. CORRECTIVE ACTION Adjust swing relief valve (WP 0147). MALFUNCTION Fault in Flow Divider Valve. CORRECTIVE ACTION Replace flow divider (WP 0114).
0007-2
TM 5-3810-305-23
0007
MALFUNCTION Swing Motor Leaks Internally. CORRECTIVE ACTION 1. 2. Repair swing motor (WP 0160). Replace swing motor (WP 0160).
MALFUNCTION Main Hydraulic Pump Faulty. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). MALFUNCTION Leakage Around Swing Control Valve Spool. CORRECTIVE ACTION Replace main control valve (WP 0146). SYMPTOM SWING MOTION ERRATIC MALFUNCTION Swing Bearing Not Lubricated Properly. CORRECTIVE ACTION Lubricate swing bearing (TM 5-3810-305-10). MALFUNCTION Swing Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust swing relief valve (WP 0147). Replace swing relief valve (WP 0147).
0007-3
TM 5-3810-305-23
0007
SYMPTOM SWING MOTOR TURNS IN WRONG DIRECTION MALFUNCTION Hose Connections Wrong. CORRECTIVE ACTION Reverse hose connections. MALFUNCTION Swing Motor Assembled Improperly. CORRECTIVE ACTION 1. 2. Repair swing motor (WP 0160). Replace swing motor (WP 0160).
END OF WORK PACKAGE
0007-4
TM 5-3810-305-23
0008
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES BOOM HOIST CIRCUIT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0067 WP 0134 References (cont.) WP 0135 WP 0138 WP 0145 WP 0146 WP 0147 WP 0149 WP 0162
TROUBLESHOOTING PROCEDURE SYMPTOM BOOM HOIST CYLINDER INOPERATIVE OR ERRATIC MALFUNCTION Load is Too Great. CORRECTIVE ACTION Consult capacity chart for maximum loads and reduce as required (TM 5-3810-305-10). MALFUNCTION Anti-Two Block System Malfunctioning. CORRECTIVE ACTION 1. 2. 3. 4. 5. Ensure proper connection of counterweight. Replace relay in anti-two block panel (WP 0067). Repair open circuits in wiring (WP 0162). Lubricate disconnect assemblies (TM 5-3810-305-10). Replace disconnect assemblies (WP 0145).
MALFUNCTION Boom Hoist Hold Valve Malfunctioning. CORRECTIVE ACTION Replace boom hoist hold valve (WP 0138).
0008-1
TM 5-3810-305-23
0008
MALFUNCTION Rotary Manifold Leaking Internally. CORRECTIVE ACTION 1. 2. Repair rotary manifold (WP 0135). Replace swing motor (WP 0135).
MALFUNCTION Downstream Blockage. CORRECTIVE ACTION Locate and remove blockage. MALFUNCTION Boom Hoist Cylinder Binding. CORRECTIVE ACTION Replace boom hoist cylinder (WP 0149). SYMPTOM BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED MALFUNCTION Boom Hoist Hold Valve Free Flow Check Not Seating Properly. CORRECTIVE ACTION Replace boom hoist hold valve (WP 0138). SYMPTOM BOOM HOIST, EXTEND, AND OUTRIGGER CYLINDERS INOPERATIVE OR ERRATIC MALFUNCTION Main Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).
0008-2
TM 5-3810-305-23
0008
MALFUNCTION Main Hydraulic Pump Faulty. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM BOOM DRIFTS DOWN MALFUNCTION Test Boom Hoist Cylinder. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. With hydraulic oil at a working temperature and boom off to one side, elevate boom to 60 degree angle and suspend a 5-ton (4.54 metric ton) load on a two-part line 1 ft (305 mm) off ground. Shut engine OFF. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect hose from adapter on right side of hold valve. Some hydraulic oil will run out, but will stop. Turn ignition switch ON to energize anti-two block solenoid. Push boom hoist lever to lower position and hold. Boom should hold its position. If boom lowers, and no hydraulic oil comes out of adapter, boom hoist hold valve must be replaced. If boom lowers, and hydraulic oil comes out of adapter, boom hoist cylinder is bypassing and should be replaced (WP 0149).
MALFUNCTION Boom Hoist Hold Valve Not Seating Properly. CORRECTIVE ACTION Replace boom hoist hold valve (WP 0138). MALFUNCTION Boom Hoist Cylinder Bypassing Hydraulic Oil. CORRECTIVE ACTION Replace boom hoist cylinder (WP 0149). END OF WORK PACKAGE
0008-3/4 blank
TM 5-3810-305-23
0009
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES BOOM EXTEND CIRCUIT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 References (cont.) WP 0067 WP 0135 WP 0145 WP 0150 WP 0162
TROUBLESHOOTING PROCEDURE SYMPTOM BOOM EXTEND FUNCTION WILL NOT OPERATE MALFUNCTION Load Too Great. CORRECTIVE ACTION Consult capacity chart for maximum load and reduce load as required (TM 5-3810-305-10). MALFUNCTION Anti-Two Block Malfunctioning. CORRECTIVE ACTION 1. 2. 3. 4. 5. Ensure proper connection of counterweight. Replace relay in anti-two block panel (WP 0067). Repair open circuits in wiring (WP 0162). Lubricate disconnect assemblies (TM 5-3810-305-10). Replace disconnect assemblies (WP 0145).
MALFUNCTION Rotary Manifold Leaking Internally. CORRECTIVE ACTION 1. 2. Repair rotary manifold (WP 0135). Replace rotary manifold (WP 0135).
0009-1
TM 5-3810-305-23
0009
MALFUNCTION Boom Extend Cylinder Binding. CORRECTIVE ACTION 1. 2. SYMPTOM BOOM EXTEND CYLINDER EXTENDS BUT WILL NOT RETRACT MALFUNCTION Counterbalance Valve Malfunctioning. CORRECTIVE ACTION Replace counterbalance valve (WP 0150). MALFUNCTION Internal Leakage in Boom Extend Cylinder. CORRECTIVE ACTION 1. 2. SYMPTOM BOOM SECTION RETRACTS UNDER LOAD MALFUNCTION Boom Section Retracts Under Load. CORRECTIVE ACTION 1. 2. 3. 4. With boom off to one side and horizontal, extend boom approximately 6 ft (1.83 m). Mark side of the extended section at end of the boom base. Elevate boom to maximum angle and suspend a 5 ton (4.54 metric ton) load on a two-part line 1 ft (305 mm) off ground. With engine shut off, hold or tie boom extend lever in fully extended position for approximately 15 minutes. Return boom extend lever to neutral position. Start engine and lower boom to horizontal. Re-mark extended section as in Step 1. Measure distance between marks. The difference is the leak-down: Leak-down must not exceed 0.75 inch (19.1 mm) in 15 minutes with hydraulic oil at a working temperature. If leak-down exceeds 0.75 inch (19.1 mm) in 15 minutes, perform Step 5. Reseal boom extend cylinder (WP 0150). Replace boom extend cylinder (WP 0150). Repair boom extend cylinder (WP 0150). Replace boom extend cylinder (WP 0150).
0009-2
TM 5-3810-305-23
0009
CORRECTIVE ACTION - Continued 5. With hydraulic oil at a working temperature, elevate boom to a 60 degree angle and suspend a 5 ton (4.54 metric ton) load on a two-part line 1 ft (305 m) off ground. Extend telescoping section approximately 1/2 of full extension. Shut engine off. Disconnect hose from tube on left side of boom. Extend cylinder at boom base. Some hydraulic oil should run out, but will stop. Pull boom extend lever to the retract position and hold. Boom should hold its position. a. b. If boom retracts and no hydraulic oil comes out of tube, counterbalance valve must be replaced. If boom retracts and hydraulic oil comes out of tube, boom extend cylinder is bypassing and should be replaced (WP 0150).
MALFUNCTION Counterbalance Valve Not Seating Properly. CORRECTIVE ACTION Replace counterbalance valve (WP 0150). MALFUNCTION O-ring Around Counterbalance Valve Damaged. CORRECTIVE ACTION Replace counterbalance valve (WP 0150). MALFUNCTION Boom Extend Cylinder Bypassing. CORRECTIVE ACTION 1. 2. Repair boom extend cylinder (WP 0150). Replace boom extend cylinder (WP 0150).
END OF WORK PACKAGE
0009-3/4 blank
TM 5-3810-305-23
0010
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES OUTRIGGER CIRCUIT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References WP 0134 WP 0136 References (cont.) WP 0138 WP 0146 WP 0147 WP 0151 WP 0162
TROUBLESHOOTING PROCEDURE SYMPTOM ALL OUTRIGGERS INOPERATIVE MALFUNCTION No Electrical Power to Outrigger Valve. CORRECTIVE ACTION Reset circuit breaker (WP 0162). MALFUNCTION Solenoid Valves Connection Loose. CORRECTIVE ACTION Tighten wire harness connection (WP 0162). MALFUNCTION Main Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).
0010-1
TM 5-3810-305-23
0010
MALFUNCTION Main Hydraulic Pump worn or Damaged. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM INDIVIDUAL OUTRIGGER INOPERATIVE MALFUNCTION Wire Connection at Outrigger Solenoid. CORRECTIVE ACTION Connect wire (WP 0162). MALFUNCTION Valve Loose or Disconnected. CORRECTIVE ACTION Repair wire (WP 0162). MALFUNCTION Individual Outrigger Switch Malfunction. CORRECTIVE ACTION Replace bad outrigger switch (WP 0136). MALFUNCTION Outrigger Solenoid Coil Burned Out. CORRECTIVE ACTION Replace outrigger solenoid coil (WP 0136). MALFUNCTION Outrigger Hold Valve on Outrigger Cylinder Not Operating. CORRECTIVE ACTION 1. 2. Repair outrigger hold valve (WP 0138). Replace outrigger hold valve (WP 0138).
0010-2
TM 5-3810-305-23
0010
MALFUNCTION Outrigger Cylinder Leaking Internally. CORRECTIVE ACTION 1. 2. Repair outrigger cylinder (WP 0151). Replace outrigger cylinder (WP 0151).
MALFUNCTION Outrigger Solenoid Valve Spool Damaged. CORRECTIVE ACTION Replace outrigger solenoid valve (WP 0136). SYMPTOM OUTRIGGERS WILL NOT LIFT VEHICLE MALFUNCTION Main Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).
MALFUNCTION Outrigger Cylinder Leaking Internally. CORRECTIVE ACTION 1. 2. Repair outrigger cylinder (WP 0151). Replace outrigger cylinder (WP 0151).
0010-3
TM 5-3810-305-23
0010
SYMPTOM OUTRIGGER RETRACTS UNDER LOAD MALFUNCTION To Determine Malfunction Perform the Following: With Hydraulic Oil at Working Temperature, Start Engine and Set Vehicle on Outriggers. Shut Engine Off. Turn Dipstick Cap 1/4 Turn to Safety Notch to Relieve Pressure. Disconnect Both Hoses from Either Front or Rear Outrigger Cylinders at Tee Located by Outrigger Solenoid Valve. Cap Tee. Some Hydraulic Oil Will Run Out, but Will Stop. Turn Ignition Switch ON to Energize Outrigger Solenoid Valve Switches. Pull Outrigger Control Lever To Raise Position and Hold. Actuate Outrigger Switch Corresponding to Outrigger Cylinder Being Checked. CORRECTIVE ACTION
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. 2. If outrigger cylinder retracts and no hydraulic oil comes out of hose, outrigger hold valve must be replaced/ repaired (WP 0138). If outrigger cylinder retracts and hydraulic oil comes out of hose, outrigger cylinder is bypassing and should be replaced/repaired (WP 0151).
END OF WORK PACKAGE
0010-4
TM 5-3810-305-23
0011
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES STEERING CIRCUIT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0088 WP 0108 WP 0110 References (cont.) WP 0111 WP 0112 WP 0113 WP 0114 WP 0134 WP 0140 WP 0147
TROUBLESHOOTING PROCEDURE SYMPTOM SLOW STEERING, HARD STEERING, OR LOSS OF POWER ASSIST MALFUNCTION Steer Axle Overloaded. CORRECTIVE ACTION Consult capacity chart for maximum load. Reduce load as required (TM 5-3810-305-10). MALFUNCTION Swing Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust swing relief valve (WP 0147). Replace swing relief valve (WP 0147).
MALFUNCTION Flow Divider Sticking. CORRECTIVE ACTION Replace flow divider (WP 0114).
0011-1
TM 5-3810-305-23
0011
MALFUNCTION Main Hydraulic Pump Worn or Malfunctioning. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM VEHICLE WANDERS - VEHICLE WILL NOT STAY IN A STRAIGHT LINE MALFUNCTION Mechanical Linkage Worn. CORRECTIVE ACTION Replace linkage (WP 0140). MALFUNCTION Leaking Fitting on Steering Circuit. CORRECTIVE ACTION 1. 2. Tighten fitting. Replace fitting.
MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leaks in pump suction circuit. MALFUNCTION Steering Cylinder Leaking Internally. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Steering Cylinder Piston Loose. CORRECTIVE ACTION Replace steering cylinder (WP 0112).
0011-2
TM 5-3810-305-23
0011
SYMPTOM DRIFT - VEHICLE VEERS SLOWLY IN ONE DIRECTION MALFUNCTION Steering Linkage Worn or Damaged. CORRECTIVE ACTION Replace steering linkage (WP 0108). MALFUNCTION Steering Cylinder Leaks Internally. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Steering Selector Valve Leaking. CORRECTIVE ACTION Replace steering selector valve (WP 0113). SYMPTOM SLIP - SLOW MOVEMENT OF STEERING WHEEL FAILS TO CAUSE ANY MOVEMENT OF STEERED WHEELS MALFUNCTION Steering Cylinder Leaking Internally. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Steering Control Unit Worn. CORRECTIVE ACTION Replace steering control unit (WP 0110). MALFUNCTION Main Hydraulic Pump Failure. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134).
0011-3
TM 5-3810-305-23
0011
MALFUNCTION Transmission Pump Drive Failure. CORRECTIVE ACTION Replace transmission (WP 0088). MALFUNCTION Blockage in Supply or Output Lines to Main Hydraulic Pump. CORRECTIVE ACTION Replace hydraulic hose (WP 0111). MALFUNCTION Thermal Shock. CORRECTIVE ACTION
CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50F [10C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM TEMPORARY HARD STEERING OR HANG-UP MALFUNCTION Main Hydraulic Pump Failure. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). MALFUNCTION Transmission Pump Drive Failure. CORRECTIVE ACTION Replace transmission (WP 0088).
0011-4
TM 5-3810-305-23
0011
MALFUNCTION Blockage in Supply or Output Lines to Main Hydraulic Pump. CORRECTIVE ACTION Replace hydraulic hose (WP 0111). MALFUNCTION Thermal Shock. CORRECTIVE ACTION
CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50F [10C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM ERRATIC STEERING MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leak in pump suction circuit. MALFUNCTION Leaking Fitting on Steering Circuit. CORRECTIVE ACTION 1. 2. Tighten fitting. Replace fitting.
MALFUNCTION Hose Pinched. CORRECTIVE ACTION Replace hose (WP 0111).
0011-5
TM 5-3810-305-23
0011
MALFUNCTION Flow Divider Sticking. CORRECTIVE ACTION Replace flow divider (WP 0114). MALFUNCTION Steering Cylinder Piston Loose. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Thermal Shock. CORRECTIVE ACTION
CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50F [10C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM SPONGY" OR SOFT STEERING MALFUNCTION Air in Hydraulic Steering Circuit. CORRECTIVE ACTION Turn steering wheel repeatedly from full left to full right while sitting still.
0011-6
TM 5-3810-305-23
0011
SYMPTOM FREE WHEELING - STEERING WHEEL TURNS WITH SLIGHT RESISTANCE BUT RESULTS IN LITTLE OR NO STEERED WHEEL ACTION MALFUNCTION Steering Linkage Malfunctioning. CORRECTIVE ACTION 1. 2. Repair steering linkage (WP 0108). Replace steering linkage (WP 0108).
MALFUNCTION Steering Cylinder Internal Leakage. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Loose Steering Cylinder Piston. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Wear in Steering Control Unit. CORRECTIVE ACTION Replace steering control unit (WP 0110). SYMPTOM EXCESSIVE FREE PLAY AT STEERING WHEEL MALFUNCTION Steering Wheel Nut Loose. CORRECTIVE ACTION Tighten steering wheel nut.
0011-7
TM 5-3810-305-23
0011
MALFUNCTION Steering Column Shaft/Steering Wheel Worn or Damaged. CORRECTIVE ACTION Replace steering control unit/steering wheel (WP 0110). MALFUNCTION Steering Linkage Malfunctioning. CORRECTIVE ACTION 1. 2. Repair steering linkage (WP 0108). Replace steering linkage (WP 0108).
MALFUNCTION Loose Steering Cylinder Piston. CORRECTIVE ACTION Replace steering cylinder (WP 0112). SYMPTOM STEERING UNIT LOCKS UP MALFUNCTION Hydraulic Power Insufficient. CORRECTIVE ACTION Replace steering/swing relief valve and/or flow divider (WP 0114). MALFUNCTION Large Particles in Steering Control Unit. CORRECTIVE ACTION 1. 2. 3. Locate origin of particles and correct. Drain and flush entire hydraulic system. Replace steering control unit (WP 0110).
0011-8
TM 5-3810-305-23
0011
MALFUNCTION Steering Control Unit Worn. CORRECTIVE ACTION Replace steering control unit (WP 0110). MALFUNCTION Thermal Shock. CORRECTIVE ACTION
CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50F [10C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM STEERING WHEEL OSCILLATES OR TURNS BY ITSELF MALFUNCTION Lines Connected to Wrong Cylinder Ports. CORRECTIVE ACTION Reconnect lines correctly. SYMPTOM STEERED WHEELS TURN IN WRONG DIRECTION WHEN OPERATOR ACTIVATES STEERING WHEEL MALFUNCTION Lines Connected to Wrong Cylinder Ports. CORRECTIVE ACTION Reconnect lines correctly. END OF WORK PACKAGE
0011-9/10 blank
TM 5-3810-305-23
0012
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES PUMPS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 References (cont.) WP 0134 WP 0147
TROUBLESHOOTING PROCEDURE SYMPTOM FAILURE OF HYDRAULIC PUMP(S) TO DELIVER FLUID MALFUNCTION Low Hydraulic Oil Level. CORRECTIVE ACTION Add hydraulic oil as required (TM 5-3810-305-10). MALFUNCTION Hydraulic Oil Intake Suction Filter Plugged. CORRECTIVE ACTION Clean hydraulic oil intake suction filter. MALFUNCTION Hydraulic Oil Viscosity Too Heavy to Pick Up Prime. CORRECTIVE ACTION Use lighter viscosity hydraulic oil. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Air Leak in Suction Line, Preventing Priming or Causing Noise and Irregular Action of Control Circuit. CORRECTIVE ACTION Repair leaks.
0012-1
TM 5-3810-305-23
0012
MALFUNCTION Shaft or Parts Broken Inside Hydraulic Pump(s). CORRECTIVE ACTION Replace hydraulic pump(s) (WP 0134). MALFUNCTION Contamination in Pump(s). CORRECTIVE ACTION 1. 2. 3. SYMPTOM LOW OR NO PRESSURE IN SYSTEM MALFUNCTION Engine Rpm Too Low. CORRECTIVE ACTION Adjust low idle rpm. MALFUNCTION Relief Valve Set Too Low. CORRECTIVE ACTION Adjust relief valve setting (WP 0147). MALFUNCTION Hydraulic Oil Leaking. CORRECTIVE ACTION 1. 2. Check hydraulic system for leaks. Repair leaks. Locate origin of contamination and correct. Drain and flush entire hydraulic system. Replace hydraulic pump(s) (WP 0134).
0012-2
TM 5-3810-305-23
0012
MALFUNCTION Hydraulic Oil Viscosity Incorrect. CORRECTIVE ACTION Use proper hydraulic oil. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leak in pump suction circuit. SYMPTOM PUMP(S) MAKING NOISE MALFUNCTION Hydraulic Oil Viscosity Too High. CORRECTIVE ACTION 1. 2. Warm hydraulic oil. Use lower viscosity hydraulic oil. Consult lube chart (TM 5-3810-305-10).
MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leak in pump suction circuit. MALFUNCTION Partially Clogged Intake Line, Intake Filter, or Restricted Intake Pipe. CORRECTIVE ACTION Clean out intake filter screen or eliminate restriction. MALFUNCTION Worn or Broken Parts in Hydraulic Pump(s). CORRECTIVE ACTION Replace hydraulic pump(s) (WP 0134).
0012-3
TM 5-3810-305-23
0012
SYMPTOM EXTERNAL OIL LEAKAGE AROUND HYDRAULIC PUMP(S) MALFUNCTION Loose Fitting on Hydraulic Pump(s). CORRECTIVE ACTION Tighten fitting. MALFUNCTION Damaged O-rings at Split Flange Fittings. CORRECTIVE ACTION Replace o-ring seal (WP 0134). MALFUNCTION Damaged O-ring Seals Between Hydraulic Pump(s) Sections. CORRECTIVE ACTION Replace o-ring seal (WP 0134). SYMPTOM BREAKAGE OF PARTS INSIDE HYDRAULIC PUMP HOUSING(S) MALFUNCTION Seizure Due to Lack of Hydraulic Oil. CORRECTIVE ACTION Fill hydraulic reservoir to proper level, clean hydraulic oil filter, and check for restrictions in suction line. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Excessive Pressure Above Maximum Rating. CORRECTIVE ACTION Adjust relief valve maximum setting(s) (WP 0147).
0012-4
TM 5-3810-305-23
0012
MALFUNCTION Solid Matter Being Wedged in Hydraulic Pump(s). CORRECTIVE ACTION 1. 2. 3. Locate origin of contamination and correct. Drain and flush entire hydraulic system. Replace hydraulic pump(s) (WP 0134).
END OF WORK PACKAGE
0012-5/6 blank
TM 5-3810-305-23
0013
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES RELIEF VALVES
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References WP 0147
TROUBLESHOOTING PROCEDURE SYMPTOM CANNOT GET PRESSURE MALFUNCTION Poppet Stuck Open or Dirt Under Seat. CORRECTIVE ACTION Replace relief valve (WP 0147). SYMPTOM ERRATIC PRESSURE MALFUNCTION Poppet Seat Damaged. CORRECTIVE ACTION Replace relief valve (WP 0147). SYMPTOM PRESSURE SETTING NOT CORRECT MALFUNCTION Locknut and Adjusting Screw Loose. CORRECTIVE ACTION Adjust relief valve (WP 0147).
0013-1
TM 5-3810-305-23
0013
SYMPTOM LEAKAGE MALFUNCTION Damaged Seats or Worn O-rings. CORRECTIVE ACTION Replace relief valve (WP 0147). END OF WORK PACKAGE
0013-2
TM 5-3810-305-23
0014
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES BRAKES
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 References (cont.) WP 0102 WP 0103 WP 0104 WP 0105 WP 0134
TROUBLESHOOTING PROCEDURE SYMPTOM BRAKES SLOW TO RELEASE OR DRAG MALFUNCTION Brake Pedal Adjustment Improper. CORRECTIVE ACTION Adjust pedal free play. MALFUNCTION Brake-shoe Return Springs Weak or Broken. CORRECTIVE ACTION Replace brake-shoe return springs (WP 0103). MALFUNCTION Automatic Adjuster Improperly Assembled. CORRECTIVE ACTION Replace adjuster (WP 0103). MALFUNCTION Parking Brake Caliper Frozen to Mounting Pins. CORRECTIVE ACTION Free up and coat with grease. Consult lube chart (TM 5-3810-305-10).
0014-1
TM 5-3810-305-23
0014
MALFUNCTION Parking Brake Linkage Improperly Assembled or Adjusted. CORRECTIVE ACTION 1. 2. SYMPTOM BRAKES DO NOT RELEASE MALFUNCTION Brake Pedal Sticking. CORRECTIVE ACTION Lubricate clevis and pivot pin with (TM 5-3810-305-10). MALFUNCTION Brake Pedal Adjustment Improper. CORRECTIVE ACTION Adjust pedal free play. MALFUNCTION Brake Booster Defective. CORRECTIVE ACTION Repair or replace brake booster (WP 0104). SYMPTOM BRAKES SLOW TO APPLY MALFUNCTION Piston in Brake Booster Sticking or Damaged. CORRECTIVE ACTION Repair or replace brake booster (WP 0104). Assemble parking brake linkage properly (WP 0102). Adjust parking brake (WP 0102).
0014-2
TM 5-3810-305-23
0014
MALFUNCTION Low Hydraulic Oil Flow. CORRECTIVE ACTION 1. 2. SYMPTOM INSUFFICIENT BRAKES MALFUNCTION Low Brake Fluid Level. CORRECTIVE ACTION 1. 2. Fill to proper level (TM 5-3810-305-10). Bleed brake system (WP 0103). Increase engine rpm. Replace main hydraulic pump (WP 0134).
MALFUNCTION Improper Brake Pedal Adjustment. CORRECTIVE ACTION Adjust brake pedal. MALFUNCTION Automatic Adjuster(s) Inoperative. CORRECTIVE ACTION Replace automatic adjuster(s) (WP 0103). MALFUNCTION Hydraulic Tubing Loose or Damaged. CORRECTIVE ACTION Tighten or replace hydraulic tubing and fittings (WP 0105). MALFUNCTION Brake Hose/Tube Restricted. CORRECTIVE ACTION Replace brake hose/tube (WP 0105).
0014-3
TM 5-3810-305-23
0014
MALFUNCTION Wheel Cylinders Leaking. CORRECTIVE ACTION Replace wheel cylinder (WP 0103). MALFUNCTION Brake Lining or Drum Condition Poor. CORRECTIVE ACTION 1. 2. Replace brake lining (WP 0103). Replace drum (WP 0103).
MALFUNCTION Parking Brake Pads Worn. CORRECTIVE ACTION 1. 2. Adjust parking brake pad clearance (WP 0102). Replace parking brake pad and adjust (WP 0102).
END OF WORK PACKAGE
0014-4
TM 5-3810-305-23
0015
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES ELECTRICAL SYSTEM
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Multimeter (WP 0171, Table 1, Item 29) Tester, Battery, Electrolyte Solution (WP 0171, Table 1, Item 12) References TM 5-3810-305-10 WP 0059 References (cont.) WP 0061 WP 0062 WP 0063 WP 0064 WP 0070 WP 0076 WP 0162 WP 0166
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.
NOTE
Refer to electrical schematic FO-1 (WP 0166) for aid in troubleshooting electrical system. SYMPTOM STARTING MOTOR DOES NOT OPERATE MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON (TM 5-3810-305-10).
0015-1
TM 5-3810-305-23
0015
MALFUNCTION Transmission Not in Neutral. CORRECTIVE ACTION Place transmission in neutral (TM 5-3810-305-10). MALFUNCTION Defective Neutral Safety Switch. CORRECTIVE ACTION Replace neutral safety switch (WP 0064). MALFUNCTION Battery Weak or Dead. CORRECTIVE ACTION 1. 2. Tighten battery terminals (WP 0076). Charge or replace battery (WP 0076).
MALFUNCTION No Voltage at Starting Motor S Terminal. CORRECTIVE ACTION 1. 2. 3. Reset or replace circuit breaker (WP 0162). Charge or replace battery (WP 0076). Repair open circuits (WP 0162).
MALFUNCTION Damaged or Loose Wiring Between Starter Motor and Batteries. CORRECTIVE ACTION 1. 2. Clean and tighten all connections. Replace wiring as needed.
MALFUNCTION Solenoid, Relay, or Starting Switch Defective. CORRECTIVE ACTION Replace failed component.
0015-2
TM 5-3810-305-23
0015
MALFUNCTION Starter Motor Defective. CORRECTIVE ACTION 1. 2. SYMPTOM ALTERNATOR CHARGING LOW OR UNSTEADY MALFUNCTION Fan Belt Loose or Worn. CORRECTIVE ACTION 1. 2. Replace fan belt (WP 0059). Replace belt tensioner (WP 0061). Replace starter motor (WP 0063). Check pinion gear and flywheel ring gear.
MALFUNCTION Alternator Terminals Loose or Corroded. CORRECTIVE ACTION 1. 2. 3. Tighten alternator terminals (WP 0062). Clean alternator terminals (WP 0062). Replace alternator terminals (WP 0062).
MALFUNCTION Brushes Worn. CORRECTIVE ACTION Replace alternator (WP 0062). MALFUNCTION Circuit Open. CORRECTIVE ACTION 1. 2. Repair wire. Replace alternator (WP 0062).
0015-3
TM 5-3810-305-23
0015
MALFUNCTION Diode Panel Defective. CORRECTIVE ACTION Replace alternator (WP 0062). MALFUNCTION Alternator Defective. CORRECTIVE ACTION Replace alternator (WP 0062). SYMPTOM BATTERY VOLTAGE LOW MALFUNCTION Batteries Weak. CORRECTIVE ACTION 1. 2. Charge batteries (WP 0076). Replace batteries (WP 0076).
MALFUNCTION Battery Electrolyte Level Low. CORRECTIVE ACTION Fill battery cells. MALFUNCTION Battery Cables or Terminals Corroded. CORRECTIVE ACTION Clean battery cables, terminals, and battery posts (WP 0076). MALFUNCTION Alternator Defective. CORRECTIVE ACTION Replace alternator (WP 0062).
0015-4
TM 5-3810-305-23
0015
SYMPTOM EXTERNAL LIGHT(S) NOT OPERATING MALFUNCTION Light Switch OFF or in Blackout Mode. CORRECTIVE ACTION Turn on light switch or correct position (TM 5-3810-305-10). MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. Replace circuit breaker.
MALFUNCTION Connection at Light Fixture Corroded or Loose. CORRECTIVE ACTION 1. 2. 3. Tighten connector. Clean connector (WP 0162). Replace connector (WP 0162).
MALFUNCTION Bulb Burned Out in Light Assembly. CORRECTIVE ACTION Replace bulb. MALFUNCTION Light Switch Defective. CORRECTIVE ACTION Replace light switch.
0015-5
TM 5-3810-305-23
0015
MALFUNCTION Lighting Circuit Shorted. CORRECTIVE ACTION Check for shorts and repair (WP 0162). SYMPTOM WORKLIGHTS NOT OPERATING MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. Replace circuit breaker.
MALFUNCTION Vehicle Lights in Blackout Mode. CORRECTIVE ACTION Switch to correct mode (TM 5-3810-305-10). MALFUNCTION Relay Faulty. CORRECTIVE ACTION Replace relay. MALFUNCTION No Circuit Through Electrical Collector Ring. CORRECTIVE ACTION 1. 2. Repair electrical collector ring (WP 0070). Replace electrical collector ring (WP 0070).
END OF WORK PACKAGE
0015-6
TM 5-3810-305-23
0016
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK SYSTEM
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Multimeter (WP 0171, Table 1, Item 29) References TM 5-3810-305-10 References (cont.) WP 0067 WP 0070
TROUBLESHOOTING PROCEDURE SYMPTOM PANEL LIGHT AND HORN WILL NOT COME ON WITH ANTI-TWO BLOCK COUNTERWEIGHT LIFTED; CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON (TM 5-3810-305-10). MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. If problem still occurs, replace circuit breaker.
MALFUNCTION Wire Broken. CORRECTIVE ACTION 1. 2. 3. 4. Check voltage in control panel harness between terminals #0 and #37. If voltage is 0, check between ignition post of ignition switch and ground. If 24 VDC available, wire to control panel is bad. Replace wire (WP 0067).
0016-1
TM 5-3810-305-23
0016
SYMPTOM HORN WORKS BUT NO LIGHT WITH ANTI-TWO BLOCK COUNTERWEIGHT LIFTED; CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Light Bulb Burned Out. CORRECTIVE ACTION Replace panel bulb (WP 0067). SYMPTOM LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT CONTACTING ANTI-TWO BLOCK COUNTERWEIGHT; CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Anti-Two Block Counterweight Chain Broken or Hung Up. CORRECTIVE ACTION Ensure counterweight is attached to chain and hanging freely. MALFUNCTION Electrical Cable Broken or Bad Connection. CORRECTIVE ACTION 1. Check all cables for visible damage, then check plug terminals #37 and #38 at control panel and check for continuity. If circuit is open, check wires inside cable reel, wires from reel to anti-two block switch, and anti-two block switch on boom head. If continuity exists, check relay in panel (WP 0067). Replace faulty component.
2.
MALFUNCTION Anti-Two Block Switch Defective. CORRECTIVE ACTION 1. 2. 3. Check for correct mechanical operation. If correct, remove cover and wires from terminals #1 and #2. With arm pulled down there should be a closed circuit between terminals. With arm up, circuit should be open. If all conditions are not met, replace anti-two block switch (WP 0067).
0016-2
TM 5-3810-305-23
0016
MALFUNCTION Relay in Anti-Two Block Panel Defective. CORRECTIVE ACTION 1. 2. 3. Check for 24 VDC between relay pins #30 (hot) and #86 (ground). If voltage is 0, check for voltage between pin #87a and ground. If 24 VDC, replace relay. (With no electrical power to relay, pins #30 and #87a should show continuity.) With 24 VDC to #85 and #86 grounded, there should be continuity between pins #87 and #30.
MALFUNCTION No Circuit Through Electrical Collector Ring. CORRECTIVE ACTION 1. 2. SYMPTOM LIGHT AND HORN ARE ON BUT CONTROL DISCONNECTS WILL NOT DISENGAGE MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON (TM 5-3810-305-10). MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. If problem still occurs, replace circuit breaker. Replace electrical collector ring (WP 0070). Repair electrical collector ring (WP 0070).
MALFUNCTION Wire Broken. CORRECTIVE ACTION 1. 2. 3. 4. Check voltage in control panel harness between terminals #0 and #37. If voltage is 0, check between ignition post of ignition switch and ground. If 24 VDC available, wire to control panel is bad. Replace wire (WP 0067).
0016-3
TM 5-3810-305-23
0016
SYMPTOM NO LIGHT AND HORN BUT CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Control Disconnect Defective. CORRECTIVE ACTION 1. Check voltage across disconnect terminals. If 24 VDC, check anti-two block BY-PASS switch in anti-two block panel. If voltage is 0, repair or replace disconnect (check other disconnects for condition). To operate crane, solenoid must have 24 VDC supplied to one side and have a good ground on the other side. Under this condition, the disconnect should act as a solid link. With 24 VDC removed, disconnect should allow free motion of control lever in one direction and operate valve spool in other direction.
2.
MALFUNCTION Anti-Two Block BY-PASS Switch Defective. CORRECTIVE ACTION 1. 2. Check to ensure that anti-two block BY-PASS switch is in the OFF position. Check for 24 VDC in anti-two block panel. If present, replace anti-two block BY-PASS switch or anti-two block panel (WP 0067).
MALFUNCTION Wire Broken or Bad Connection. CORRECTIVE ACTION 1. 2. Check voltage across disconnect terminals. If voltage is 0, check voltage across terminals in the anti-two block panel. If 24 VDC, replace wire. If 24 VDC across disconnect, disconnect is defective.
MALFUNCTION Function Disconnect Defective. CORRECTIVE ACTION 1. 2. Check solenoid for function. Applying 24 VDC to disconnect, solenoid should engage with a distinct snap. If not, solenoid must be replaced. If solenoid engages but disconnect breaks" under load, replace disconnect.
END OF WORK PACKAGE
0016-4
TM 5-3810-305-23
0017
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES TRANSMISSION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10
NOTE
If transmission performance is inadequate, install pressure gage(s) on the transmission control valve and check pressures, also check for the following symptoms. SYMPTOM ERRATIC TRANSMISSION OIL PRESSURE MALFUNCTION Transmission Oil Level Low. CORRECTIVE ACTION Add transmission oil to proper level. Consult lube chart (TM 5-3810-305-10). SYMPTOM EXCESSIVE TRANSMISSION OIL PRESSURE AT HIGH SPEED (RPM) MALFUNCTION Main Regulator Valve Sticking. CORRECTIVE ACTION Check main regulator for contamination and clean orifice. MALFUNCTION Main Regulator Valve Spring Faulty. CORRECTIVE ACTION Replace main regulator valve spring.
0017-1
TM 5-3810-305-23
0017
MALFUNCTION Main Regulator Valve Orifice Plugged. CORRECTIVE ACTION Clean main regulator valve orifice. SYMPTOM LOW TRANSMISSION OIL PRESSURE IN ALL GEARS MALFUNCTION Main Regulator Valve Sticking. CORRECTIVE ACTION Check main regulator valve spring. MALFUNCTION Transmission Oil Pressure Set Too Low. CORRECTIVE ACTION 1. 2. Repair control valve. Replace control valve.
MALFUNCTION Main Regulator Valve Spring Faulty. CORRECTIVE ACTION Replace main regulator valve spring. MALFUNCTION Control Valve Body Cracked. CORRECTIVE ACTION Replace control valve body. MALFUNCTION Charge Pump Defective. CORRECTIVE ACTION Replace charge pump.
0017-2
TM 5-3810-305-23
0017
MALFUNCTION O-ring on Charge Pump Mount Defective. CORRECTIVE ACTION Replace o-ring on charge pump. SYMPTOM LOW TRANSMISSION OIL PRESSURE IN ONE GEAR BUT ALRIGHT IN OTHER GEARS MALFUNCTION Broken Seal Ring on Input End of Clutch Weld Assembly Piston Shaft. CORRECTIVE ACTION Replace seal ring. MALFUNCTION Outer or Inner Piston Seal Not Sealing. CORRECTIVE ACTION Replace piston seals. SYMPTOM LOW CONVERTER PRESSURE MALFUNCTION Converter Bypass Valve Defective. CORRECTIVE ACTION Inspect converter bypass valve and replace if necessary. MALFUNCTION Converter Hub Seal Ring Not Sealing. CORRECTIVE ACTION Replace converter hub seal ring.
0017-3
TM 5-3810-305-23
0017
SYMPTOM HIGH TRANSMISSION OIL PRESSURE MALFUNCTION Hose Bends Too Sharp in Routing. CORRECTIVE ACTION Re-route hoses. MALFUNCTION Hose Defective. CORRECTIVE ACTION Replace hose. MALFUNCTION Hoses Not Connected Correctly. CORRECTIVE ACTION Connect hoses correctly. MALFUNCTION Main Regulator Valve Orifice Plugged. CORRECTIVE ACTION Clean main regulator valve orifice. SYMPTOM CLUTCH SELECTED PRESSURE DOES NOT RETURN TO NORMAL MALFUNCTION Main Regulator Valve Spring Weak. CORRECTIVE ACTION Replace main regulator valve spring.
0017-4
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0017
MALFUNCTION Accumulator Spring Too Strong. CORRECTIVE ACTION Replace spring. MALFUNCTION Charge Pump Defective. CORRECTIVE ACTION Replace charge pump. MALFUNCTION Excessive Internal Leakage to Clutch. CORRECTIVE ACTION Replace seals. SYMPTOM EXCESSIVE NOISE AT ENGINE IDLE MALFUNCTION Charge Pump Defective. CORRECTIVE ACTION Replace charge pump. MALFUNCTION Excessive Backlash in Gear Train. CORRECTIVE ACTION Replace bearings and inspect for defective gears. SYMPTOM EXCESSIVE GEAR NOISE AT HIGH SPEED (RPM) MALFUNCTION Main Regulator Valve Orifice Plugged. CORRECTIVE ACTION Clean main regulator valve orifice.
0017-5
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0017
SYMPTOM TRANSMISSION OIL BLOWS OUT OF BREATHER ON TOP OF TRANSMISSION MALFUNCTION Converter Seal Ring Broken. CORRECTIVE ACTION Replace converter hub seal ring. SYMPTOM TRANSMISSION OVERHEATING MALFUNCTION Converter Stalling. CORRECTIVE ACTION Shift to lower gear. MALFUNCTION Transmission Oil Level Too High. CORRECTIVE ACTION Drain to proper level. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Engine Overheating. CORRECTIVE ACTION 1. 2. Add engine coolant if required. Clean radiator.
0017-6
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0017
MALFUNCTION Transmission Oil Cooler Dirty. CORRECTIVE ACTION Flush and clean transmission oil cooler. MALFUNCTION Transmission Oil Level Low. CORRECTIVE ACTION Add transmission oil. Consult lube chart (TM 5-3810-305-10). END OF WORK PACKAGE
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0018
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES AXLE ASSEMBLY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0093 WP 0096 References (cont.) WP 0097 WP 0098 WP 0099 WP 0100 WP 0101 WP 0107 WP 0108
TROUBLESHOOTING PROCEDURE SYMPTOM WHEELS PULL TO RIGHT OR LEFT MALFUNCTION Tires Not Properly Inflated. CORRECTIVE ACTION Inflate tires properly (TM 5-3810-305-10). MALFUNCTION Tires Worn. CORRECTIVE ACTION Check and replace tires (WP 0107). SYMPTOM STEERING IS ERRACTIC MALFUNCTION Tie Rods Out of Adjustment or Worn. CORRECTIVE ACTION Adjust or repair tie rods (WP 0108).
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0018
MALFUNCTION Tires or Wheels Damaged. CORRECTIVE ACTION Replace wheels or tires (WP 0107). MALFUNCTION Wheel Bearings Worn. CORRECTIVE ACTION Replace wheel bearings (WP 0096). MALFUNCTION Worn Pivot and Spindle Assembly Trunnion Bearings. CORRECTIVE ACTION Replace pivot and spindle assembly trunnion bearings (WP 0097) and (WP 0098). SYMPTOM WHEEL END LEAKS OIL MALFUNCTION Hub Seal Defective. CORRECTIVE ACTION Replace hub seal (WP 0096). MALFUNCTION Wheel End Cover O-ring Defective. CORRECTIVE ACTION Replace wheel end cover o-ring (WP 0096). SYMPTOM WHEELS NOISY WHEN TURNED TO RIGHT OR LEFT MALFUNCTION Air Pressure Low or Unevenly Worn Tires. CORRECTIVE ACTION Replace tires (WP 0107).
0018-2
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0018
MALFUNCTION Fluid Level Low in Differential or Wheel End. CORRECTIVE ACTION Service wheel end or differential (WP 0096) and (WP 0100). MALFUNCTION Constant-Velocity Joint Worn. CORRECTIVE ACTION Repair constant-velocity joint (WP 0099). SYMPTOM EXCESSIVE NOISE IN TRANSFER OF POWER FROM ENGINE TO WHEELS MALFUNCTION Driveshaft(s) Defective. CORRECTIVE ACTION 1. 2. Repair driveshaft(s) (WP 0093). Replace driveshaft(s) (WP 0093).
MALFUNCTION Differential Defective. CORRECTIVE ACTION Replace ring and pinion gears (WP 0101). END OF WORK PACKAGE
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0019
FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES WINCH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0016 WP 0125 WP 0126 WP 0128 References (cont.) WP 0129 WP 0134 WP 0135 WP 0142 WP 0146 WP 0147 WP 0158 WP 0165
TROUBLESHOOTING PROCEDURE SYMPTOM WINCH WILL NOT DEVELOP MAXIMUM LINE PULL MALFUNCTION Winch Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. Adjust winch relief valve (WP 0147). Replace winch control valve (WP 0128).
MALFUNCTION Winch Relief Valve Sticking. CORRECTIVE ACTION Replace winch control valve (WP 0128). MALFUNCTION Main Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).
0019-1
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MALFUNCTION Main Relief Valve Sticking. CORRECTIVE ACTION Replace main control valve (WP 0146). MALFUNCTION Winch Motor Worn or Damaged. CORRECTIVE ACTION 1. 2. Repair winch motor (WP 0126). Replace winch motor (WP 0126).
MALFUNCTION Main Hydraulic Pump Worn or Damaged. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). MALFUNCTION Rotary Manifold Leaking. CORRECTIVE ACTION 1. 2. SYMPTOM WINCH WILL LOWER BUT WILL NOT RAISE MALFUNCTION Insufficient Parts of Line Being Lifted. CORRECTIVE ACTION Consult capacity chart for maximum loads. Reduce load as required (TM 5-3810-305-10). MALFUNCTION Anti-Two Block System Malfunction. CORRECTIVE ACTION Refer to Anti-Two Block Troubleshooting (WP 0016). Repair rotary manifold (WP 0135). Replace rotary manifold (WP 0135).
0019-2
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0019
SYMPTOM WINCH WILL NOT LOWER LOAD OR NOT LOWER LOAD SMOOTHLY MALFUNCTION Plugged or Loose Pilot Orifice. Pilot Orifice is a Small Pipe Plug with a Hole Drilled Through It, Located Behind Pilot Port Fitting on Brake Valve. If It Becomes Plugged, It Will Prevent Pilot Pressure from Opening Brake Valve. If It Becomes Loose, It Will Allow an Unregulated Amount of Oil in to Operate Brake Valve, Which Causes Erratic Brake Valve Operation. CORRECTIVE ACTION Remove pilot hose and fitting brake valve, then use a 5/32 inch allen wrench to remove pilot orifice. Diameter of orifice is approximately 0.020 inch (0.51 mm). Clean and install pilot orifice tightly in brake valve (WP 0127). MALFUNCTION Brake Cylinder Seal Leaking. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125).
MALFUNCTION Brake Discs Damaged. CORRECTIVE ACTION 1. 2. SYMPTOM HYDRAULIC OIL LEAKS FROM VENT PLUG MALFUNCTION Brake Cylinder Seal Defective. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125). Repair winch (WP 0125). Replace winch (WP 0125).
0019-3
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0019
MALFUNCTION High Hydraulic System Back Pressure. CORRECTIVE ACTION 1. 2. 3. SYMPTOM THE BRAKE WILL NOT HOLD A LOAD WITH THE CONTROL LEVER IN NEUTRAL MALFUNCTION High Hydraulic System Back Pressure. CORRECTIVE ACTION 1. 2. 3. Clean hydraulic return filter. Clean out hydraulic return lines. Replace pinched hydraulic return lines (WP 0142). Clean hydraulic return filter. Clean out hydraulic return lines. Replace pinched hydraulic return lines (WP 0142).
MALFUNCTION Brake Discs Damaged. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125).
MALFUNCTION Brake Clutch Slipping. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125).
0019-4
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0019
SYMPTOM WINCH WILL NOT HOIST RATED LOAD MALFUNCTION Winch Mounted on an Uneven or Flexible Surface. CORRECTIVE ACTION 1. 2. Inspect upperstructure for cracks or defects (WP 0158). Loosen, then evenly retighten all winch mounting bolts to recommended torque (WP 0165).
MALFUNCTION Winch Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. Adjust winch relief valve (WP 0128). Replace winch control valve (WP 0128).
MALFUNCTION Rigging and Sheaves Not Operating Efficiently. CORRECTIVE ACTION Perform rigging service as recommended (TM 5-3810-305-10). SYMPTOM WINCH RUNS HOT MALFUNCTION Winch Mounted on an Uneven or Flexible Surface. CORRECTIVE ACTION 1. 2. Inspect upperstructure for cracks or defects (WP 0158). Loosen then evenly retighten all winch mounting bolts to recommended torque (WP 0165).
MALFUNCTION Hydraulic Oil Cooler Plugged. CORRECTIVE ACTION Thoroughly clean exterior and flush interior of hydraulic cooler.
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0019
MALFUNCTION Internal Winch Parts Excessively Worn or Damaged. CORRECTIVE ACTION 1. 2. SYMPTOM WINCH "CHATTERS" WHILE RAISING RATED LOAD MALFUNCTION Winch Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. SYMPTOM WIRE ROPE DOES NOT SPOOL SMOOTHLY ON DRUM MALFUNCTION Rope Damaged or Spooled Without Tension. CORRECTIVE ACTION Consult wire rope section (TM 5-3810-305-10). MALFUNCTION Winch May Have Been Overloaded, Causing Permanent Set in Wire Rope. CORRECTIVE ACTION Replace wire rope (WP 0129). END OF WORK PACKAGE Adjust winch relief valve (WP 0128). Replace winch control valve (WP 0128). Repair winch (WP 0125). Replace winch (WP 0125).
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0020
FIELD MAINTENANCE MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Test Set, Electronic Systems (MSD) (WP 0171, Table 1, Item 7) References TM 9-4910-571-12&P WP 0005 WP 0015 WP 0022 WP 0025 WP 0038 References (cont.) WP 0044 WP 0045 WP 0050 WP 0052 WP 0056 WP 0058 WP 0062 WP 0063 WP 0066 WP 0076 WP 0081
GENERAL To troubleshoot a vehicle problem, the technician can use MSD-ICE VTM (Vehicle Test Meter and transducer). DATA ENTRY TESTS For information regarding Data Entry, Cylinder Entry, and Data Display Tests, refer to TM 9-4910-571-12&P. OFFSET TESTS The MSD-ICE VTM performs a test by setting the TEST SELECT switches to the test number and then pressing the TEST button. For some tests, an offset test is required before the test itself can be performed. This is done by selecting the number of the desired test and holding the TEST button down for several seconds. The offset test nulls characteristic differences in the VTM, test leads, and transducer. It zeros the meter. Once the offset is performed, the VTM automatically corrects for the offset before displaying measured values. The displayed offset value should be checked against limits given in the test procedures. If the displayed value is outside these limits, either the transducer or the test cable is faulty and must be replaced. This is a form of a self-test. Perform the offset test when each transducer is connected. The offset test is performed with the test probe cable in TK mode or the DCA plug connected to the VTM. Ensure that no stimulus is applied to the transducer in TK mode. Test probe cable leads should be shorted together. To perform an offset test, dial the test number into the TEST SELECT switches. Press and hold the TEST button, until the prompting message CAL appears on the display. A few seconds after the TEST button is released, a number will appear. This is the measured offset value associated with the test probe cable or transducer and cable.
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CONTROL TESTS These tests are used to change (or control) the way a vehicle test is displayed, or the way it is run. There are four control tests: 1. 2. 3. 4. 01 Interleave (displays rpm with next test) 02 Minimum Value (displays minimum value for next test) 03 Maximum Value (displays maximum value for next test) 04 Peak to Peak Value (displays peak-to-peak value for next test)
(Note: control tests 01, 02, 03, and 04 specify the action to be taken by the next test only. A subsequent test will reset the control.) Interleave (Test 01) This test alternately measures engine speed and a second parameter, such as fuel pressure or alternator voltage. To initiate interleave, dial 01 into the TEST SELECT switches and press and release the TEST button. The prompting message PASS is the signal to dial in the second test number and again press and release the TEST button. Minimum Value (Test 02) This test displays the minimum value display. Dial 02 into the TEST SELECT switches and press and release the TEST button. The minimum value is displayed and updated whenever a lower minimum value is measured. Entering 02 and the test number again will reset the process and a new minimum value will be displayed. Maximum Value (Test 03) This test displays the maximum value measured during a test. To initiate a maximum value display, dial 03 into the TEST SELECT switches and press and release the TEST button. The prompting message PASS is the signal to dial in the desired test number and again press and release the TEST button. The maximum value is displayed and updated whenever a higher maximum value is measured. Entering 03 and the test number again will reset the process and a new maximum value will be displayed. Peak-to-Peak Value (Test 04) This test displays the peak-to-peak measurement. Dial 04 into the TEST SELECT switches and press the TEST button. The prompting message PASS is the signal to dial in one of the four numbers (82, 89, 90, 67) and press the TEST button. MSD-ICE TESTS
NOTE
When using the MSD-ICE, refer to the manufacturer's operating instructions for use. 1. 2. 3. Verify that engine oil, engine coolant, fuel, and batteries are at proper level. Check fan belt installation. Open VTM/XDCR Kit Assembly, MSD-ICE, remove top tray containing TM 9-4910-571-12&P, Simplified Test Equipment For Internal Combustion Engines, and temporarily set aside. Remove DCA cap from DCA receptacle located in right rear of cab. Remove cable W1 from MSD-ICE kit. Attach cable W1 to DCA receptacle.
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0020
MSD-ICE TESTS - Continued
M0835105
Figure 1. Remove Cap from DCA Receptacle.
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0020
MSD-ICE TESTS - Continued 4. 5. Ensure VTM is off. Attach other end of cable W1 to J1 plug on VIM. Turn VTM ON. Change TEST SELECT switches to read 66. Push TEST button. Change TEST SELECT switches to read 99. Push TEST button. VTM will display a series of numbers and then PASS. If display does not read PASS or C, or an incorrect display appears, refer to TM 9-4910-571-12&P. Change TEST SELECT switches to read 60. Push TEST button. VTM will display VEH. Refer to vehicle test card for vehicle identification (VID) number. Change TEST SELECT switches to read VID number. Push TEST button. VTM will display 28. Change TEST SELECT switches to read 61. Push TEST button. VTM will flash VII number. Change TEST SELECT switches to read 58. Push TEST button. VTM will display CYL. Change TEST SELECT switches to read 04. Push TEST button. Change TEST SELECT switches to read 62. Push TEST button. VTM will flash 04. Change TEST SELECT switches to read 67. Push TEST button. VTM will flash battery voltage. Refer to test card for battery voltage test limits. If battery voltage falls outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Start engine. Operate engine at 1,000 to 1,200 rpm. Change TEST SELECT switches to read 01. Push TEST button. VIM will display PASS. Change TEST SELECT switches to read 67. Push TEST button. VTM will alternately flash battery charge voltage and engine rpm. During this test engine speed must be maintained between 1,000 to 1,200 rpm. Refer to test card for battery charge voltage test limits. If battery charge voltage falls outside test limits, refer to Alternator Charging Low or Unsteady (WP 0015). With engine speed at idle, charge TEST SELECT switches to read 10. Push TEST button. VTM will display engine rpm. Refer to test card for engine rpm idle test limits. If engine rpm falls outside test limits, adjust throttle idle speed, refer to Throttle Control Maintenance, (WP 0052). Accelerate engine to full governed speed, no load. Refer to test card for engine rpm governed speed, no load, test limits. If engine rpm falls outside limits, refer to Engine RPM Will Not Reach Rated Speed (WP 0005). Check vehicle engine oil pressure gage reading. Perform TK engine oil pressure test to verify gage (refer to test card and TM 9-4910-571-12&P). If vehicle engine oil pressure gage readings fall outside test limits but TK test is within limits, replace vehicle engine oil pressure gage, refer to Dash Panel Gages and Switches Maintenance (WP 0066). If TK test falls outside test limits, inspect vehicle for oil leaks and change oil filter, refer to PMCS, Change Engine Oil and Oil Filter (WP 0022). Replace lube oil pump, refer to Lube Oil Pump Maintenance (WP 0038). Check air cleaner filter restriction gage. Maximum reading is 25 inches (635 mm) of water. If reading is above 25 inches of water, service air cleaner, refer to PMCS, Service Air Filter (WP 0022). Shut engine OFF. Wait one minute to allow fuel pressure to bleed off. Change TEST SELECT switches to read 24. Push TEST button until VTM displays CAL, then release button. Refer to test card for fuel supply pressure test offset limit. If CAL reading is high, break fuel supply line at tee to release line pressure and retest. Start engine. Accelerate engine to full governed speed. Push TEST button. VTM will display fuel supply pressure. Refer to test card for fuel supply pressure test limits. If fuel supply pressure falls outside test limits, inspect fuel supply lines for leaks or pinched tubes. Service fuel filters, refer to Fuel Filters and Head Assembly Maintenance (WP 0050). Replace fuel pressure transducer, refer to MSD-ICE Wiring Harness Maintenance (WP 0081). Replace fuel lift pump, refer to Fuel Lift Pump Maintenance (WP 0045). Change TEST SELECT switches to read 26. Push TEST button. Accelerate engine to full governed speed. VTM will display either PASS or FAIL. If VTM displays FAIL, service fuel filters, refer to Fuel Filters Head Assembly Maintenance (WP 0050). With engine at idle, change TEST SELECT switches to read 27. Push TEST button. Refer to test card for fuel solenoid voltage test limits. If fuel solenoid voltage falls outside test limits, check wiring at fuel solenoid, refer to MSD-ICE Wiring Harness Maintenance (WP 0081). If fuel solenoid still falls outside test limits, replace fuel solenoid, refer to Fuel Injection Pump Maintenance (WP 0044).
6.
7.
8.
9.
10.
11. 12.
13.
14.
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MSD-ICE TESTS - Continued 15. Operate engine between 1,000 to 1,200 rpm. Change TEST SELECT switches to read 01. Push TEST button. VTM will display PASS. Change TEST SELECT switches to read 82. Push TEST button. Refer to test card for alternator voltage test limits. If alternator voltage falls outside test limits, replace or repair alternator, refer to Alternator and Mounting Assembly Bracket Maintenance (WP 0062). Engine must be within the normal temperature range. With engine at idle, change TEST SELECT switches to read 12. Push TEST button. When VTM displays CIP, push accelerator pedal to floor and hold until VTM displays power test percent full power value. Return engine to idle. Refer to test card for power test percent full power test limits. Shut engine OFF. Turn fuel switch OFF. Change TEST SELECT switches to read 14. Push TEST button. When VTM displays O, crank engine. Stop cranking engine when VTM displays OFF or E013. If the cranking is incorrect, VTM will display E013. If E013 is displayed, batteries could be discharged, cranking speed could be low, or cranking was interrupted during test. Correct problem and repeat test. After VTM displays OFF, it will display either FAIL or the compression unbalance test value. If FAIL appears, the compression unbalance value is too far unbalanced for VTM to measure. Refer to test card for compression unbalance test limits. If compression unbalance test falls outside test limits, replace engine, refer to Engine Assembly Maintenance (WP 0025). Change TEST SELECT switches to read 72. Push TEST button until VTM displays CAL, then release button. Refer to test card for current first peak test offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display amperage value. Refer to test card for current first peak test limits. If amperage falls outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Start engine. Check vehicle engine temperature gage. Refer to test card for engine temperature test limits. If temperature falls outside test limits, replace thermostat, refer to Thermostat Maintenance (WP 0056). If temperature is still outside test limits, replace water pump, refer to Water Pump Maintenance (WP 0058). Shut engine OFF. Turn fuel switch ON. Change TEST SELECT switches to read 01. Push TEST button. VTM will display PASS. Operate engine between 1,000 to 1,200 rpm. Change TEST SELECT switches to read 84. Push TEST button. Refer to test card for alternator negative cable voltage drop test limits. If voltage falls outside test limits, clean and inspect battery and ground connections. Turn fuel switch OFF. Change TEST SELECT switches to read 80. Push TEST button until VTM displays CAL then release button. Refer to TEST card for starter motor current average offset hits. Push TEST button again. Crank engine. Stop cranking engine. VTM will display amperage value. Refer to test card for starter motor current average test limits. If amperage falls outside test limits, clean and inspect battery, starter, and ground connections. Change TEST SELECT switches to read 73. Push TEST button until VTM displays CAL, then release button. Refer to TEST card for battery internal resistance offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display milliohm value. Refer to test card for battery internal resistance test limits. If milliohms fall outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Change TEST SELECT switches to read 74. Push TEST button until VTM displays CAL, then release button. Refer to TEST card for starter current resistance offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display milliohm value. Refer to test card for starter current resistance test limits. If milliohms fall outside test limits, check starter connections. If test limits are still exceeded, replace or repair starter, refer to Starter Motor Maintenance (WP 0063). Change TEST SELECT switches to read 75. Push TEST button until VTM displays CAL, then release button. Refer to TEST card for battery resistance charge offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display milliohm value. Refer to test card for battery resistance charge test limits. If milliohms fall outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076).
16.
17.
18.
19.
20.
21.
22.
23.
24.
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MSD-ICE TESTS - Continued 25. Change TEST SELECT switches to read 70. Push TEST button. Crank engine. VTM will display voltage value while engine is cranking. Stop cranking engine. Refer to test card for starter solenoid voltage test limits. If voltage falls outside test limits, replace or repair starter, refer to Starter Motor Maintenance (WP 0063). Change TEST SELECT switches to read 69. Push TEST button. Crank engine. VTM will display voltage value while engine is cranking. Stop cranking engine. Refer to test card for starter negative cable drop test limits. If voltage falls outside test limits, clean and inspect battery and starter cable connections. Change TEST SELECT switches to read 68. Push TEST button. Crank engine. VTM will display voltage value while engine is cranking. Stop cranking engine. Refer to test card for starter motor voltage test limits. If voltage falls outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Turn fuel switch ON. Start engine. Operate vehicle at proper road speeds. Check vehicle transmission temperature gage. Refer to test card for vehicle transmission temperature limits. If temperature reading falls outside limits, service transmission oil filter. Perform TK return fuel pressure test. Refer to test card (TM 9-4910-571-12&P). If pressure value falls outside test limits, inspect fuel return hoses for kinks or damage. Turn ignition switch OFF. Turn VTM OFF. Disconnect cable W1 from DCA receptacle. Disconnect cable W1 from J1 plug on VTM. Stow VTM in case (TM 9-4910-571-12&P).
26.
27.
28.
29. 30.
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MSD-ICE TESTS - Continued
M0836105
Figure 2. END OF WORK PACKAGE
Schematics and Diagrams.
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CHAPTER 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TM 5-3810-305-23
0021
FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL To ensure that the 7 1/2 Ton Crane is ready for operation at all times, it must be inspected on a regular basis so that defects may be found and corrected before they result in serious damage, equipment failure, or injury to personnel. The PMCS Table in Preventive Maintenance Checks and Services (PMCS) (WP 0022) contains systematic instructions on inspections, adjustments, and corrections to be performed by the operator/crew to keep the equipment in good operating condition and ready for its primary mission. EXPLANATION OF PMCS TABLE ENTRIES 1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E, include the item number for the check/service indicating a fault. Item numbers appear in the order in which you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the procedure column. a. Before procedures must be done immediately before you operate the crane. b. During procedures must be done while you are operating the crane. c. After procedures must be done immediately after you have operated the crane.
d. Weekly procedures must be done once each week. e. Monthly procedures must be done once each month. 3. Location, Item to Check/Service Column. This column provides the location and item to be checked or serviced.
NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. You must observe all WARNINGs to prevent serious injury to yourself and others, and all CAUTIONs to prevent the crane from being damaged. 4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item to Check/Service column to know if the equipment is ready or available for its intended mission. You must perform the procedure at the time stated in the interval column. 5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or reporting equipment failure.
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GENERAL PMCS PROCEDURES 1. Always perform PMCS in the same order so it gets to be a habit. Once you've had some practice, you should be able to spot anything wrong in a hurry. If the crane does not perform as required, refer to the appropriate work package in Troubleshooting Symptom Index (WP 0004). 2. If anything looks wrong and you cant fix it, write it on forms DA Form 2404 or 5988-E. If you find something seriously wrong, IMMEDIATELY report it to your Maintenance Supervisor. 3. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare everything needed to make all the checks. For example, you will always need a rag, or two. a. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use Solvent Cleaning Compound Type III on all metal surfaces. Use soap and water when you clean rubber, plastic, and painted surfaces. b. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and apply a light coat of lubricating oil. Report it to your Maintenance Supervisor. c. Bolts, Nuts and Screws. Check bolts, nuts, and screws for obvious loose, missing, bent, or broken condition. You cannot try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find one is loose, notify your Maintenance Supervisor.
d. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your Maintenance Supervisor. e. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Reconnect loose connectors. Ensure that wires are in good condition. If any damage or looseness is present, notify your Maintenance Supervisor. f. Hoses and Fluid Lines. Look for wear, damage, and signs of leaks. Check for loose clamps and fittings. Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, notify your Maintenance Supervisor. If something is broken or worn out, notify your Maintenance Supervisor.
g. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your crane. The following are definitions of the types/classes of leakage you need to know to determine the status of the crane. Learn and be familiar with them, and remember: when in doubt, notify your Maintenance Supervisor. Table 1. Leakage Definitions for PMCS. Class I Class II Leakage indicated by wetness or discoloration, but not great enough to form drops. Leakage great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected. Leakage great enough to form drops that fall from the item being checked/inspected.
Class III
END OF WORK PACKAGE
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0022
FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Can, Radiator Filling (WP 0171, Table 1, Item 40) Face Shield, Industrial (WP 0171, Table 1, Item 25) Funnel (WP 0171, Table 1, Item 41) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Pump, Lubricant (WP 0171, Table 1, Item 42) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Antifreeze, 1 Gallon Bottle (WP 0170, Table 1, Item 2) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Cloth, Abrasive, Crocus (WP 0170, Table 1, Item 12) Qty: 1 Filter Element (WP 0172, Table 1, Item 27) Qty: 1 Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 O-Ring, 441-70N (WP 0172, Table 1, Item 96) Qty: 1 Plug, with O-Ring (WP 0172, Table 1, Item 115) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0031 References (cont.) WP 0050 WP 0059 WP 0103 WP 0114 WP 0122 WP 0125 WP 0128 WP 0132 WP 0144 WP 0148 WP 0156 WP 0158 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Parking brake engaged (TM 5-3810-305-10) Engine shut down (TM 5-3810-305-10) Wheels chocked (TM 5-3810-305-10) Battery disconnect switch in OFF position (TM 5-3810-305-10) Hydraulic system pressure relieved (TM 5-3810-305-10)
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TM 5-3810-305-23
0022
Table 1. Preventive Maintenance Checks and Services (PMCS).

ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
PROCEDURE
WARNING
If vehicle is parked indoors during performance of Preventive Maintenance Checks and Services (PMCS), DO NOT run engine unless exhaust fumes are vented to the outside. Failure to follow this warning may cause injury or death to personnel due to carbon monoxide poisoning.
NOTE
Review all WARNINGs, CAUTIONs, and NOTEs before performing PMCS on the 7 1/2 Ton Crane. Unless otherwise indicated, perform all lubrication and preventive maintenance with machine parked on level ground, parking brake engaged, transmission in N (Neutral), work tool lowered to the ground, engine shut down, wheels chocked, battery disconnect switch in OFF position, and hydraulic system pressure relieved (TM 5-3810-305-10). Perform Operator PMCS prior to or in conjunction with Field PMCS if: 1. There is a delay between daily operation of the machine and Field PMCS. 2. The regular operator is not assisting. 1 Two Week Check or Every 80 to 100 Hours of Service Swing Reducer Oil Level Refer to Boom Maintenance (WP 0156).
Check Winch Lubrication Level
a. Remove plug. b. If oil is not visible, fill to level of plug.
0022-2
TM 5-3810-305-23
0022
Table 1.
Preventive Maintenance Checks and Services (PMCS) - Continued.

EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
ITEM TO BE CHECKED OR SERVICED
PROCEDURE
PLUG
M0837105
Figure 1. 3 ThreeMonth Check or Every 250 Hours of Service Service Air Filter
Winch Lubrication Level Access Plug.
NOTE
Test drive machine over varied terrain for at least 15 minutes, until fully warmed up.
a. Loosen clamp (Figure 2, Item 1) on air cleaner (Figure 2, Item 2) from underneath carrier. b. Remove cup (Figure 2, Item 5) and baffle (Figure 2, Item 6). c. Separate cup (Figure 2, Item 5) and baffle (Figure 2, Item 6). d. Remove wingnut (Figure 2, Item 4) and element (Figure 2, Item 3).
0022-3
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
WARNING
Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. e. Clean cup (Figure 2, Item 5) with compressed air. f. Clean element (Figure 2, Item 3) with compressed air. Keep air nozzle perpendicular to element pleats while rotating element. g. Inspect element (Figure 2, Item 3) by placing a bright light inside element. If element has thin spots, pin holes or small ruptures, element must be replaced. h. Install element (Figure 2, Item 3) and wingnut (Figure 2, Item 4) on air filter. i. Install baffle (Figure 2, Item 6) in cup (Figure 2, Item 5). j. Install baffle (Figure 2, Item 6) and cup (Figure 2, Item 5) on bottom of air cleaner (Figure 2, Items 2 and 5). k. Tighten clamp (Figure 2, Item 1).
0022-4
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
1 3
4 6 2 5
M0838105
Figure 2. Air Cleaner Element Maintenance. 4 ThreeMonth Check or Every 250 Hours of Service Change Engine Oil and Oil Filter a. Warm engine oil prior to draining.
b. Place a suitable container under oil filter. c. Using a strap wrench, remove oil filter. d. Place a suitable container under engine oil pan and remove drain plug. Engine holds 10 qt (9.46 L). Drain engine oil. e. Install drain plug, torque to 60 ft-lb (81 Nm) and fill with 10 qt (9.46 L) of engine oil (TM 5-3810-305-10). f. Coat oil filter seal with clean engine oil, fill oil filter with oil, and install hand-tight. Oil filter holds 1 qt (0.95 L). g. Start engine and run for approximately 5 minutes. Check for leaks.
0022-5
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
OIL PAN
OIL FILTER
Figure 3. Engine Oil and Filter Change. 5 Four-Month Drain Fuel Tank Check or of Water and Every 500 Sediment Hours of Service a. Change fuel filter elements (WP 0050).
DRAIN PLUG
M0839105
b. Change hydraulic return line filter (WP 0148).
WARNING
Diesel fuel and other combustible materials are used in operation and maintenance of this equipment. DO NOT smoke or allow open flames in areas where combustible materials are stored or used. Failure to follow this warning may cause injury or death to personnel.
NOTE
Vehicle must be level and not operated for approximately one hour to allow fuel and water to separate. c. Place a suitable container under fuel tank. Fuel tank holds 40 gal. (151.4 L).
0022-6
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE d. Loosen plug located at the bottom of fuel tank and drain until fuel runs clearly and no water remains. e. Install drain plug and refill fuel tank.
DRAIN PLUG
M0840105
Figure 4. Fuel Tank Drain Plug. 6 Four-Month Clean Hydraulic Check or Suction Filter Every 500 Hours of Service a. Suction Filter Removal:
(1) Remove deck plates (WP 0122).
WARNING
0022-7
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE (2) Turn dipstick cap 1/4 turn to safety notch to relieve pressure. (3) Remove plug (Figure 5, Item 2), o-ring (Figure 5, Item 3), eight nuts (Figure 5, Item 1), washers (Figure 5, Item 8), cover (Figure 5, Item 4), and o-ring (Figure 5, Item 5). Discard o-rings. (4) Remove filter (Figure 5, Item 6) and o-ring (Figure 5, Item 7) from reservoir. Discard o-rings. b. Suction Filter Cleaning: Clean all parts (WP 0162). c. Suction Filter Inspection: Inspect all parts (WP 0162). d. Suction Filter Installation: (1) Install new o-ring (Figure 5, Item 7) and filter (Figure 5, Item 6). (2) Install new o-ring (Figure 5, Item 5), cover (Figure 5, Item 4), eight washers (Figure 5, Item 8), nuts (Figure 5, Item 1), new o-ring (Figure 5, Item 3), and plug (Figure 5, Item 2). (3) Close dipstick cap. Operate crane at part throttle to slightly pressurize the reservoir. (4) Bleed out all air by loosening plug (Figure 5, Item 2). Tighten plug. (5) Install deck plates (WP 0122).
0022-8
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
3 1 8 2
6 7
Figure 5. 7 Four-Month Check or Every 500 Hours of Service Hydraulic Suction Filter Removal.
M0841105
Change a. Warm transmission oil to operating temperature Transmission Oil prior to draining. and Transmission Oil Filter b. Using a strap wrench, remove transmission oil filter. c. Place a suitable container under transmission. Transmission holds 12 qt (11.36 L). d. Remove drain plug located on the bottom of transmission and drain.
NOTE
New or rebuilt transmission will require 20.5 qt (19.40 L) of transmission oil. e. Install drain plug and fill transmission with 12 qt (11.36 L) of transmission oil (TM 5-3810-305-10). f. Coat transmission oil filter seal with clean transmission oil and install hand-tight. Warm transmission oil and check for leaks and proper level.
0022-9
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
OIL FILL
DRAIN PLUG
Figure 6. 8 Transmission Fluid Change.
M0842105
Four-Month Check Antifreeze a. Using an antifreeze tester, test the antifreeze Check or Concentration. concentration for -34F (-37C). Every 500 Hours of Service b. Maintain a 50/50 mixture of antifreeze to water (TM 5-3810-305-10).
0022-10
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
RADIATOR CAP
DRAIN PLUG
M0843105
Figure 7. 9 Six-Month Check or Every 500 Hours of Service
Check Antifreeze Concentration.
a. Adjust engine valve lash clearance (WP 0031).
b. Change winch oil (WP 0125). c. Check relief valve pressure settings (WP 0147). Tighten swing bearing bolts (WP 0158). 10 Six-Month Check or Every 500 Hours of Service Check Axle Differential and Hub Oil Levels a. Remove axle hub fill check plug.
b. If oil is not visible, fill to level of fill/check plug (TM 5-3810-305-10). Install fill/check plug.
0022-11
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
AXLE HUB FILL/CHECK PLUG AXLE HUB DRAIN PLUG

Figure 8. Check Axle Differential and Hub Oil Levels. c. Remove fill/check plug. d. If oil is not visible, fill to level of fill/check plug (TM 5-3810-305-10). Install fill/check plug.
M0844105
FILL/CHECK PLUG
DRAIN PLUG
Figure 9. Check Axle Differential and Hub Oil Levels.
M0845105
e. Check brake shoes for wear condition (WP 0103). f. Inspect brake shoes for cracks, scoring, grooves, Brake shoe is less than or wear. If brake shoe is less than 0.177 inch (4.50 mm) 0.177 inch (4.50 mm) thick. thick, or if inspection indicates damage, replace.
0022-12
TM 5-3810-305-23
0022
Table 1.

ITEM NO. 11
INTERVAL
PROCEDURE
Six-Month Check Fan Hub Check or Bearing for End Every 1,000 Play Hours of Service
WARNING
Never perform fan hub bearing end play check with the engine running. Failure to follow this warning may cause death or injury to personnel. a. Release tension of fan belt (WP 0059). b. Fan should spin freely. Grasp fan blade and alternately push and pull fan to check for end play.
M0846105
Figure 10. 12 Six-Month Check or Every 1000 Hours of Service Change Winch Oil
Check Fan Hub Bearing End Play.
a. Start engine and rotate winch drum to align drain plug (Figure 11, Item 3) and access hole in base.
b. Insert a length of 1 inch (25.4 mm) I.D. pipe and screw into the larger threads of drain hole. c. Position a suitable container under pipe. d. Remove drain plug (Figure 11, Item 3) and oring (Figure 11, Item 4) and drain. Discard o-ring. e. Install drain plug (Figure 11, Item 3) and new oring (Figure 11, Item 4). Remove pipe and oil level plug (Figure 11, Item 1) and o-ring (Figure 11, Item 2). Discard o-ring.
0022-13
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE f. Add approximately 2 qt (1.89 L) of lubricant.
NOTE
Allow time for lubricant to flow through winch and then check that lubricant level is at bottom of oil level plug threads. g. Install oil level plug (Figure 11, Item 1) and new o-ring (Figure 11, Item 2).
1,2
3,4
Figure 11. 13 TwelveDrain and Clean Month Hydraulic Check or Reservoir Every 1,500 Hours of Service Winch Oil Change.
M0847105
a. Warm hydraulic oil to operating temperature prior to draining.
b. Position a suitable container under hydraulic reservoir. Hydraulic reservoir holds 23.8 gal. (90.09 L).
0022-14
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
WARNING
NOTE
Hydraulic reservoir must be completely drained and flushed to remove any water or sediment. c. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Remove drain plug at bottom of hydraulic reservoir and drain. d. Remove suction filter (WP 0144).
WARNING
Diesel fuel and other combustible materials are used in operation and maintenance of this equipment. DO NOT smoke or allow open flames in areas where combustible materials are stored or used. Failure to follow this warning may cause injury or death to personnel. e. Replace drain plug and fill hydraulic reservoir with 10 gal. (37.9 L) of diesel fuel. Allow fuel to remain in hydraulic reservoir approximately 1 hour to thoroughly clean it. f. Remove drain plug and drain diesel fuel from hydraulic reservoir.
0022-15
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE g. Install drain plug and add 15 gal. (56.8 L) of hydraulic oil (TM 5-3810-305-10).
VENT PLUG
DIPSTICK CAP
DRAIN PLUG
Figure 12. Add Hydraulic Oil.
M0849105
h. Remove drain plug and drain hydraulic oil from reservoir. i. Install drain plug and fill hydraulic reservoir with 23.8 gal. (90.09 L) of hydraulic oil (TM 5-3810-305-10). j. After refilling hydraulic reservoir, it will be necessary to bleed air from system. Open vent plug on suction filter cover and vent until filling is complete. Close vent plug and dipstick cap. Operate crane at part throttle to slightly pressurize hydraulic reservoir. Then bleed out all air by loosening vent plug. Tighten vent plug.
0022-16
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
VENT PLUG
DIPSTICK CAP
DRAIN PLUG
Figure 13. Bleed Air from Hydraulic Reservoir. 14 TwelveDrain and Clean Month Hydraulic Check or Reservoir Every 1,500 to 2,000 Hours of Service a. Remove deck plates (WP 0122).
M0849105
b. Position a suitable container under swing reduction unit. c. Remove drain plugs and fill/check plug to drain oil. d. Install drain plugs. e. Fill with gear oil to level of fill/check plug (TM 5-3810-305-10). f. Install fill/check plug. g. Install deck plates (WP 0122).
0022-17
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
FILL/CHECK PLUG
DRAIN PLUGS
Figure 14. Swing Reduction Unit Oil Change. 15 TwelveDrain and Clean Month Hydraulic Check or Reservoir Every 1,500 to 2,000 Hours of Service a. Position axle hub drain plug at 6 oclock".
M0850105
b. Position a suitable container under axle hub drain plug. Axle hub holds 3 qt (2.84 L). c. Remove axle hub drain plug and drain oil completely. d. Install axle hub drain plug. e. Remove axle hub fill/check plug. f. Fill axle hub with 3 qt (2.84 L) of oil. Oil level should be level of fill plug. If not, add oil to obtain fill plug level. Install sealing washer and axle hub fill plug. g. Repeat Steps a through f for remaining three axle hubs. h. Position a suitable container under differential housing. Remove drain plug at the bottom of differential housing and drain oil completely.
0022-18
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE i. Install drain plug and remove fill/check plug on top rear of differential. Fill with oil and install fill/check plug (TM 5-3810-305-10).
FILL/CHECK PLUG
DRAIN PLUG
Figure 15. Differential Oil Filter. 16 TwelveChange Engine Month Coolant Check or Every 1,500 to 2,000 Hours of Service
M0845105
WARNING
Cooling system is pressurized. Use extreme caution and proper protection when removing radiator cap after operating temperature is reached. Steam and hot gases will be escaping through the radiator cap; avoid being burned by these escaping gases. When removing cap, loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed. Failure to follow this warning may cause death or injury to personnel. a. Remove radiator cap and drain cooling system by opening drain valve on bottom tank of radiator and removing plug in side of engine coolant inlet. Drain radiator into a suitable container. Radiator holds 28 qt (26.50 L). b. Check for damaged coolant hoses and loose or damaged hose clamps. Replace as required. c. To clean system, flush with clean water. If system shows mineral build-up, scale, rust, or oil, use a heavy-
0022-19
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE duty radiator cleaner and follow manufacturers directions.
RADIATOR CAP
DRAIN PLUG
M0843105
Figure 16.
Engine Coolant Change.
d. Replace plug, close drain valve, and refill cooling system with a 50/50 mixture of water and ethylene-glycol type antifreeze. Adequate venting is provided for a fill rate of 32 qt (30.38 L) per minute, so allow time for air to be expelled in order to get a complete fill. e. Install radiator cap and start engine. Check for leaks while running engine for 5 minutes. f. Remove radiator cap, recheck coolant level, and add coolant if necessary.
0022-20
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
RADIATOR CAP
DRAIN PLUG
M0843105
Figure 17. 17 TwelveCheck Hydraulic Month Pressure Relief Check or Valves Every 1,500 to 2,000 Hours of Service
Engine Coolant Change.
NOTE
Hydraulic system has three separate pressure circuits that have protective adjustable relief valves.
a. Main relief valve - set at 2,750 +/- 50 psi (18,960 +/- 345 kPa) at full flow. Controls outriggers, boom hoist, and boom extend. b. Winch relief valve - set at 2,650 +/- 50 psi (18,270 +/- 345 kPa) at full flow. c. Swing relief valve - set at 2,500 +/- 50 psi (17,240 +/- 345 kPa) at full flow.
0022-21
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
M0851105
Figure 18. 18 TwelveCheck Relief Month Valve Check or Adjustments Every 1,500 to 2,000 Hours of Service
Check Hydraulic Pressure Relief Valves.
Setting hydraulic pressure is an extremely intricate operation and should be performed only after satisfying the following conditions:
a. Warm hydraulic oil to operating temperature. b. Be sure to operate at full governed engine speed as relief valve setting will vary with flow rate. c. Use a good quality 4,000 psi (27,580 kPa) gage equipped with a short pressure hose and 1/4 inch female quick disconnect. Be certain to calibrate pressure gage used. Gage calibration can be lost if gage is subjected to rapidly pulsating pressure for a few seconds. Gage must have a proper snubber to read center of pump pressure ripple or erroneous readings will result.
0022-22
TM 5-3810-305-23 Table 1.
ITEM NO.
0022

INTERVAL
PROCEDURE
NOTE
Relief valves used on this crane have screw-type adjustments. If it is determined that a relief valve is out of adjustment, follow this general adjustment procedure. Install a 4,000 psi (27,579 kPa) gage in the designated test port locations and proceed with pressure check and adjustments. If MSD-ICE is available, this version contains a 5,000 psi (34,474 kPa) pressure transducer. This may be substituted for the 4,000 psi gage referenced for checking the hydraulic circuit pressures. By attaching the 1219-879 adapter between the transducer and the 7091272-18 hose, the transducers threaded 1/4-inch pipe connection will adapt to the hose.
4. Remove acorn nut and loosen jam nut. 5. Run engine at full rpm so pump will develop required flow. 6. Operate one plunger of control valve at its extreme position long enough to get a pressure reading on the gage. 7. Turn adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure until desired pressure setting is obtained. 8. Holding adjusting screw, tighten jam nut. Install and tighten acorn nut. 9. Retest to check pressure setting.
NOTE
Results of the above settings will indicate a relatively constant relief valve setting across full engine rpm. 10. Check main relief valve (WP 0147). 11. Check winch relief valve (WP 0128). 12. Check steering/swing control relief valve (WP 0114).
0022-23
TM 5-3810-305-23
0022
Table 1.

ITEM NO.
INTERVAL
PROCEDURE
M0852105
Figure 19.
Relief Valve Adjustment.
END OF TASK END OF WORK PACKAGE
0022-24
TM 5-3810-305-23
CHAPTER 4 MAINTENANCE INSTRUCTIONS
TM 5-3810-305-23
0023
FIELD MAINTENANCE SERVICE UPON RECEIPT
INITIAL SETUP: References TM 5-3810-305-10
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03/15/2011 Rel(1.8) root(maintwp) wpno(M00028)
TM 5-3810-305-23
0023
GENERAL Conduct the following checks BEFORE putting a new 7 1/2 Ton Crane into operation. 1. Engine. Check oil and coolant level and ensure all clamps on air intake system are tight. Ensure all filters are installed. Look for oil leaks around engine. Oil level is to be maintained between ADD and FULL as indicated on dipstick. Transmission. Check transmission oil level dipstick. Oil level is checked with engine running at idle speed, transmission in NEUTRAL, and oil warm (160 to 190F (71 to 88C)). Oil should be at FULL line on dipstick. Driveshafts. Visually check connecting capscrews and driveshafts for damage. Examine parking brake disc and brake pack. Check brake function. Axles. Visually check all attaching bolts. Check differentials and hub drives for lubricant levels. Visually check steering cylinders and tie rods for damage. Ensure torque on all wheel nuts is 450 to 500 ft-lb (610 to 678 Nm). Visually check tires for damage and verify air pressure. Swing Gearbox. Check lubricant level in swing gearbox. Overall a. Check fuel in fuel tank. b. Check hydraulic components and fittings for oil leaks. c. Check batteries for electrolyte level and ensure all battery connections are tight and not corroded. d. Check brake fluid in brake reservoir. e. Lubricate the crane according to the lubrication chart in PMCS (TM 5-3810-305-10), up to and including two weeks (80 to 100 hours). f. Start engine and check gages while running at low idle rpm. When engine temperature reaches 190F (88C), increase rpm and continue to monitor gages, making sure everything is functioning properly. g. Shut engine OFF. h. If not already on the crane, install cable, hook block, and anti-two block counterweight, according to instructions found in Operation Under Usual Conditions (TM 5-3810-305-10). Perform the following requirements once AFTER indicated hours of service. 8 hours: Torque wheel nuts to 450 to 500 ft-lb (610 to 678 Nm) for two-week period. 20 hours: Drain, change filter, and refill transmission with new fluid. 40 hours: Make initial replacement of hydraulic return line filter. 7. Winch 100 hours: Do the following. a. Drain and change winch lubricant. b. Tighten swing bearing capscrews. Eighteen capscrews in outer race hold upperstructure to bearing. Twenty-two capscrews in inner race hold bearing to carrier. Tighten all 40 capscrews to 722 ft-lb (979 Nm). c. Tighten winch base mounting capscrews to 249 ft-lb (338 Nm). d. Tighten counterweight capscrews to 845 ft-lb (1,146 Nm).
2. 3. 4.
5. 6.
0023-2
TM 5-3810-305-23
0023
M0853105
Figure 1. END OF TASK END OF WORK PACKAGE
Vehicle Check Points.
0023-3/4 blank
TM 5-3810-305-23
0024
FIELD MAINTENANCE POWER PACK ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Indicator, Dial (WP 0171, Table 1, Item 6) Stand, Maintenance, Automotive Engine (WP 0171, Table 1, Item 11) Suitable Lifting Device 2,700-lb (1,225 kgs) Minimum Capacity Test Set, Electronic Systems (MSD) (WP 0171, Table 1, Item 7) Tester, Valve VAC (WP 0171, Table 1, Item 15) Wrench, Torque, Click, 1/2 Inch Drive (345 Nm) (WP 0171, Table 1, Item 35) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 5 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 127) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 11 Personnel Required (Two) References WP 0078 WP 0086 WP 0162 Equipment Condition Upperstructure and boom rotated to an altitude of 90 degrees to carrier frame (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Sliding engine hood removed (WP 0118) Air cleaner removed (WP 0046) Exhaust system removed (WP 0053) Engine oil drained (WP 0022) Transmission fluid drained (WP 0091) Radiator and oil cooler removed (WP 0054)
0024-1
TM 5-3810-305-23
0024
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. REMOVAL Power Pack 1. Remove two bolts (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and exhaust system support bracket (Figure 1, Item 3) from engine (Figure 1, Item 4). Discard lockwashers.
1 2
4
Figure 1. Power Pack Removal.
M0058105
0024-2
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 2. Disconnect all electrical connections from alternator, starter, temperature, and pressure sending units (WP 0078).
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 3. Disconnect two hoses (Figure 2, Items 2 and 4) from charge pump (Figure 2, Item 3) on right hand side of transmission (Figure 2, Item 1). Secure hoses out of way for removal.
3 4
M0059105
Figure 2.
Power Pack Removal.
0024-3
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 4. Disconnect two hoses (Figure 3, Items 1 and 2) from main hydraulic pump (Figure 3, Item 3). Secure hoses out of the way for removal.
3
M0060105
Figure 3. 5.
Power Pack Removal.
Disconnect two hoses (Figure 4, Items 1 and 3) from ground driven steering pump (Figure 4, Item 2). Secure hoses out of the way for removal.
M0061105
Figure 4.
Power Pack Removal.
0024-4
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 6. Remove two cotter pins (Figure 5, Item 1) to disconnect two control cables (Figure 5, Items 2 and 5) from transmission control valve (Figure 5, Item 6). Loosen two jam nuts (Figure 5, Item 4) on each cable and remove cables from mounting bracket (Figure 5, Item 3). Discard cotter pins.
4 6
M0062105
0024-5
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 7. 8. Remove nut (Figure 6, Item 1) and ground strap (Figure 6, Item 2) from top of hydraulic hose (Figure 6, Item 3). Secure ground strap out of way for removal. Remove two oil cooler hoses (Figure 6, Items 3 and 4) from left-hand side of transmission (Figure 6, Item 5). Secure hoses out of way for removal.
5 4
M0063105
Figure 6.
Power Pack Removal.
0024-6
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 9. 10. Disconnect two fuel hoses (Figure 7, Items 3 and 4). Remove nut (Figure 7, Item 1) from injector pump throttle cable (Figure 7, Item 2). Secure injector pump throttle cable out of way for removal.
M0064105
Figure 7.
Power Pack Removal.
0024-7
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 11. 12. Remove two hose clamps (Figure 8, Item 1) from upper radiator hose (Figure 8, Item 3). Disconnect upper radiator hose (Figure 8, Item 3) from engine (Figure 8, Item 4) and radiator (Figure 8, Item 2).
3 4
M0065105
Figure 8.
Power Pack Removal.
0024-8
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 13. 14. Remove two hose clamps (Figure 9, Item 2) from lower radiator hose (Figure 9, Item 3). Disconnect lower radiator hose (Figure 9, Item 3) from engine (Figure 9, Item 1) and radiator.
3
M0066105
Figure 9. 15.
Power Pack Removal.
Remove four bolts (Figure 10, Item 2) from shift bracket (Figure 10, Item 1) and transmission (Figure 10, Item 3).
M0067105
Figure 10.
Power Pack Removal.
0024-9
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 16. Remove cotter pin (Figure 11, Item 1) and straight pin (Figure 11, Item 2) from transmission shift control (Figure 11, Item 3). Discard cotter pin.
3
Figure 11. Power Pack Removal. 17.
M0068105
Remove four capscrews (Figure 12, Item 1) and disconnect front driveshaft (Figure 12, Item 2) from transmission (Figure 12, Item 3). Support front driveshaft with suitable support.
3
M0069105
0024-10
TM 5-3810-305-23
0024
REMOVAL - Continued Power Pack - Continued 18. Remove four capscrews (Figure 13, Item 1) and rear driveshaft (Figure 13, Item 2) from transmission (Figure 13, Item 3).
2 3
M0070105
Figure 13.
Power Pack Removal.
0024-11
TM 5-3810-305-23
0024
NOTE
Engine and transmission assembly is mounted at three points with rubber shock mounts: one at front of engine and two on sides of transmission. 19. Remove two nuts (Figure 14, Item 3), capscrews (Figure 14, Item 1), and spacers (Figure 14, Item 2) from sides of transmission (Figure 14, Item 4).
2 3
4
M0207105
Figure 14. Power Pack Removal. 20. Remove capscrew (Figure 15, Item 3), washer (Figure 15, Item 2), and spacer (Figure 15, Item 1) from front of engine (Figure 15, Item 4).
0024-12
TM 5-3810-305-23
0024
2
M0206105
WARNING
Weight of engine and transmission assembly is approximately 1,800 lb (816 kg). Use adequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
NOTE
Make sure all brackets, electrical connectors, wiring harnesses, hoses, lines and cables have been disconnected or removed from the engine and transmission assembly prior to removal. Use more than one person when removing engine and transmission assembly to make sure engine and transmission DO NOT contact vehicle. 21. Attach hoist and chains to front engine lift eye and rear transmission mounts. Gradually hoist engine and transmission assembly up, guiding it slightly forward to clear main hydraulic pump on rear of transmission. Move engine and transmission assembly away from carrier. Lower engine and transmission assembly onto suitable support stand.
22.
END OF TASK
0024-13
TM 5-3810-305-23
0024
REMOVAL Transmission from Engine
NOTE
Engine flywheel is bolted to transmission converter drive plate with 12 capscrews. Access to 12 capscrews is through engine side of flywheel housing. 1. Remove two capscrews (Figure 16, Item 1), cover plate (Figure 16, Item 4) and plug (Figure 16, Item 3) on right-hand side of flywheel housing (Figure 16, Item 2).
1 2 3 4
M0073105
Figure 16.
Transmission from Engine Removal.
0024-14
TM 5-3810-305-23
0024
REMOVAL - Continued Transmission from Engine - Continued 2. With a barring tool or large screwdriver, rotate flywheel ring gear (Figure 17, Item 1) through plug hole access hole (Figure 17, Item 2) until each capscrew (Figure 17, Item 3) is lined up with access hole (Figure 17, Item 4) and remove 12 capscrews.
4
M0201105
Figure 17.
0024-15
TM 5-3810-305-23
0024
REMOVAL - Continued Transmission from Engine - Continued
WARNING
Weight of transmission is approximately 1,100 lb (499 kg). Use adequate lifting equipment to lift and support transmission. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. 5. Attach hoist and sling around flywheel housing (Figure 18, Item 3) on transmission (Figure 18, Item 4). With transmission (Figure 18, Item 4) supported, remove 12 capscrews (Figure 18, Item 2) and lockwashers (Figure 18, Item 1) from transmission and flywheel housing (Figure 18, Item 3). Discard lockwashers. Pull transmission (Figure 18, Item 4) straight out of flywheel housing (Figure 18, Item 3) and support it on a suitable work stand.
M0202105
Figure 18.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0024-16
TM 5-3810-305-23
0024
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Transmission to Engine 1. Examine 12 capscrews (Figure 19, Item 2) for damaged threads. Check flywheel ring gear (Figure 19, Item 1) for condition before attaching transmission (Figure 19, Item 3).
M0203105
Figure 19. 2. 3. 4.
Transmission to Engine Installation.
Using a dial indicator, check engine crankshaft end play. It should be from 0.005 to 0.010 inch (0.13 to 0.25 mm). Crankshaft end play should be the same after attaching the transmission. Install 3/8-24 x 2 1/4 threaded guide stud, with a screwdriver slot in end, into one of the threaded inserts on converter drive plate from engine side. Rotate flywheel until one of the holes in flywheel is aligned with flywheel access hole.
0024-17
TM 5-3810-305-23
0024
INSTALLATION - Continued Transmission to Engine - Continued
WARNING
Weight of transmission is approximately 1,100 lb (499 kg). Use adequate lifting equipment to lift and support transmission. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. Support and align transmission to flywheel. Align protruding stud from drive plate face with mounting hole in flywheel.
CAUTION
DO NOT force transmission at any time. Forcing transmission into pilot sleeve of flywheel can preload crankshaft and cause engine and transmission damage. 6. 7. Push transmission into engine. Install 12 new lockwashers (Figure 20, Item 1) and capscrews (Figure 20, Item 2) to transmission (Figure 20, Item 4) and flywheel housing (Figure 20, Item 3).
M0202105
Figure 20. Transmission to Engine Installation.
0024-18
TM 5-3810-305-23
0024
INSTALLATION - Continued Transmission to Engine - Continued 8. Check crankshaft end play and compare measurement with what was observed in Step 2. No end play can mean crankshaft has been preloaded. Do not proceed until the reason for preload has been determined and corrected. Remove guide stud. Install 12 capscrews (Figure 21, Item 3) through access hole (Figure 21, Item 4) through flywheel into drive plate. Hand tighten all the way around. Tighten capscrews to 31 +/- 2 ft-lb (42 +/- 3 Nm).
9.
4
M0201105
Figure 21.
Transmission to Engine Installation.
0024-19
TM 5-3810-305-23
0024
INSTALLATION - Continued Transmission to Engine - Continued 10. Recheck crankshaft end play and compare measurement with what was observed in Step 2. No end play can mean crankshaft has been preloaded. Do not proceed until preload has been determined and corrected. When satisfactory, replace cover plate (Figure 22, Item 2), two capscrews (Figure 22, Item 3), and plug (Figure 22, Item 1). The engine and transmission assembly is ready to return to carrier frame.
11.
3 1 2
M0205105
Figure 22. Transmission to Engine Installation.
END OF TASK
0024-20
TM 5-3810-305-23
0024
INSTALLATION Power Pack
WARNING
Weight of engine and transmission assembly is approximately 1,800 lb (816 kg). Use adequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
NOTE
Use more than one person when installing engine and transmission assembly to make sure engine and transmission DO NOT contact vehicle. When reassembled engine and transmission is ready for installation, check rubber shock mounts for deterioration and distortion. Replace if condition warrants. Examine all connecting components to make sure they are in position to install. 1. 2. Attach hoist and chains to front engine lift eye and rear transmission mounts. Gradually lower engine and transmission assembly down, guiding it into position on carrier. Install spacer (Figure 23, Item 1), washer (Figure 23, Item 2), and capscrew (Figure 23, Item 3) on front of engine (Figure 23, Item 4).
2
Figure 23. Power Pack Installation.
M0206105
0024-21
TM 5-3810-305-23
0024
INSTALLATION - Continued 3. Install two spacers (Figure 24, Item 2), capscrews (Figure 24, Item 1), and nuts (Figure 24, Item 3) on sides of transmission (Figure 24, Item 4).
2 3
4
M0207105
Figure 24. 4. 5.
Power Pack Installation.
Install rear driveshaft and four capscrews (Figure 25, Item 4) to transmission (Figure 25, Item 3). Tighten capscrews to 50 ft-lb (68 Nm). Connect front driveshaft (Figure 25, Item 2) and install four capscrews (Figure 25, Item 1) to transmission (Figure 25, Item 3). Tighten four capscrews to 50 ft-lb (68 Nm).
1 4 2
2 3 3
M0208105
0024-22
TM 5-3810-305-23
0024
INSTALLATION - Continued 6. Install four bolts (Figure 26, Item 2) to shift bracket (Figure 26, Item 1) and transmission (Figure 26, Item 3).
M0067105
Figure 26. 7.
Install new cotter pin (Figure 27, Item 1) and straight pin (Figure 27, Item 2) to transmission shift control (Figure 27, Item 3).
3
M0068105
0024-23
TM 5-3810-305-23
0024
INSTALLATION - Continued 8. 9. Install nut (Figure 28, Item 1) to injector pump throttle cable (Figure 28, Item 2). Connect two fuel hoses (Figure 28, Items 3 and 4).
M0064105
Figure 28. 10. 11.
Connect two oil cooler hoses (Figure 29, Items 3 and 4) to left-hand side of transmission (Figure 29, Item 5). Install nut (Figure 29, Item 1) and ground strap (Figure 29, Item 2) to top of oil cooler hose (Figure 29, Item 3).
5 4
M0063105
Figure 29.
0024-24
TM 5-3810-305-23
0024
INSTALLATION - Continued 12. Using two new cotter pins (Figure 30, Item 1) connect two control cables (Figure 30, Items 2 and 5) to transmission control valve (Figure 30, Item 6). Tighten two jam nuts (Figure 30, Item 4) on each cables to mounting bracket (Figure 30, Item 3). Check and adjust cables (WP 0086).
4 6
Figure 30. 13. Power Pack Installation.
M0062105
Connect two hoses (Figure 31, Items 1 and 3) to ground driven steering pump (Figure 31, Item 2).
M0061105
Figure 31.
0024-25
TM 5-3810-305-23
0024
INSTALLATION - Continued 14. Connect two hoses (Figure 32, Items 1 and 2) to main hydraulic pump (Figure 32, Item 3).
3
M0060105
Figure 32. 15.
Connect two hoses (Figure 33, Items 2 and 4) to charge pump (Figure 33, Item 3) on top right hand side of transmission (Figure 33, Item 1).
3 4
M0059105
Figure 33.
0024-26
TM 5-3810-305-23
0024
INSTALLATION - Continued 16. Install two bolts (Figure 34, Item 1), new lockwashers (Figure 34, Item 2), and exhaust system support bracket (Figure 34, Item 3) to engine (Figure 34, Item 4).
1 2
4
Figure 34. 17. 18. 19. Power Pack Installation.
M0058105
Connect all electrical connections to alternator, starter, temperature and pressure sending units (WP 0078). Install two hose clamps (Figure 35, Item 1) to upper radiator hose (Figure 35, Item 3). Connect upper radiator hose (Figure 35, Item 3) to engine (Figure 35, Item 4) and radiator (Figure 35, Item 2).
3 4
M0065105
Figure 35.
0024-27
TM 5-3810-305-23
0024
INSTALLATION - Continued 20. 21. Install two hose clamps (Figure 36, Item 2) to lower radiator hose (Figure 36, Item 3). Connect lower radiator hose (Figure 36, Item 3) to engine (Figure 36, Item 1) and radiator.
3
M0066105
Figure 36. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install radiator and oil cooler (WP 0054). Fill transmission fluid (WP 0091). Fill engine oil (WP 0022). Install exhaust system (WP 0053). Install air cleaner (WP 0046). Install sliding engine hood (WP 0118). Connect battery cables (WP 0076).
Place boom in resting position (TM 5-3810-305-10).
0024-28
TM 5-3810-305-23
0025
FIELD MAINTENANCE ENGINE ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0039 References (cont.) WP 0040 WP 0049 WP 0059 WP 0060 WP 0061 WP 0062 WP 0063 WP 0162 Equipment Condition Power Pack assembly removed (WP 0024)
REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove oil pan and suction tube (WP 0039). Remove oil level gage and tube (WP 0040). Remove starter motor (WP 0063). Remove fan drive belt (WP 0059). Remove cooling fan hub assembly (WP 0060). Remove drive belt tensioner and idler pulley (WP 0061). Remove alternator and mounting bracket (WP 0062). Remove fuel injection tubes (WP 0049).
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0025-1
TM 5-3810-305-23
0025
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install fuel injection tubes (WP 0049). Install alternator and mounting bracket (WP 0062). Install drive belt tensioner and idler pulley (WP 0061). Install cooling fan hub assembly (WP 0060). Install fan drive belt (WP 0059). Install starter motor (WP 0063). Install oil level gage and tube (WP 0040). Install oil pan and suction tube (WP 0039).
END OF TASK FOLLOW-ON MAINTENANCE Install power pack assembly (WP 0024). END OF TASK END OF WORK PACKAGE
0025-2
TM 5-3810-305-23
0026
FIELD MAINTENANCE ENGINE MOUNT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Power pack assembly removed (WP 0024)
REMOVAL Remove four capscrews (Figure 1, Item 1) and engine mount (Figure 1, Item 3) from engine (Figure 1, Item 2).
3 2
M0043105
Figure 1. END OF TASK CLEANING
Engine Mount Removal.
Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0026-1
TM 5-3810-305-23
0026
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Install engine mount (Figure 2, Item 3) and four capscrews (Figure 2, Item 1) to engine (Figure 2, Item 2). Tighten to 57 ft-lb (77 Nm).
3 2
M0043105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install power pack assembly (WP 0024). END OF TASK END OF WORK PACKAGE
Engine Mount Installation.
0026-2
TM 5-3810-305-23
0027
FIELD MAINTENANCE CYLINDER HEAD MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 200-lb (91 kgs) Minimum Capacity Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 145) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Preservative and Break-In (WP 0170, Table 1, Item 45) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Exhaust manifold removed (WP 0042) Fuel injection tubes removed (WP 0049) Valve covers removed (WP 0035) Rocker levers and push rods removed (WP 0031) Manifold cover plate removed (WP 0041)
0027-1
TM 5-3810-305-23
0027
REMOVAL 1. Remove 14 capscrews (Figure 1, Item 1) from cylinder head (Figure 1, Item 2).
WARNING
Weight of the cylinder is approximately 80 lb (36 kg). Use adequate lifting equipment to lift and support cylinder head. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 2. Using a suitable hoist and sling, remove cylinder head (Figure 1, Item 2) from block (Figure 1, Item 3) and place on a suitable work table.
3
M02101045
Figure 1. 3.
Cylinder Head Removal.
Remove gasket (Figure 2, Item 1) from engine block (Figure 2, Item 2). Discard gasket and all gasket material.
0027-2
TM 5-3810-305-23
0027
REMOVAL - Continued
2
Figure 2. END OF TASK CLEANING 1. 2. 3. 4. 5. Clean parts IAW General Maintenance Instructions (WP 0162). Clean carbon from injector nozzle seat with a nylon or brass brush. Wash cylinder head in hot soapy water solution and dry with compressed air. Cylinder Head Removal.
M0211105
Polish gasket surfaces with 400-grit paper. Use an orbital sander or sanding block to maintain a flat surface. Dry parts with compressed air.
END OF TASK INSPECTION 1. Inspect parts IAW General Maintenance Instructions (WP 0162). 2. Inspect all parts for wear, pitting, cracks, or corrosion, and replace if necessary. 3. Inspect cylinder head surface for nicks and erosion. 4. Using a feeler gage and straight edge, check cylinder head for distortion.
Limit Variation: 0.0039 inch (0.099 mm) within 2.00 inch (50.8 mm) diameter area. 0.003 inch (0.08 mm) overall end-to-end or side-to-side.
END OF TASK
0027-3
TM 5-3810-305-23
0027
INSTALLATION
NOTE
Make sure cylinder head and block surfaces are clean and not nicked or gouged. 1. Install new gasket (Figure 3, Item 1) on block (Figure 3, Item 2), aligning gasket with holes on block.
2
Figure 3. Cylinder Head Installation.
M0211105
0027-4
TM 5-3810-305-23
0027
INSTALLATION - Continued
WARNING
Weight of the cylinder is approximately 80 lb (36 kg). Use adequate lifting equipment to lift and support cylinder head. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 2. 3. Using a suitable hoist and sling, install cylinder head (Figure 4, Item 2) carefully on block (Figure 4, Item 3), making sure gasket stays in place. Lubricate and install 14 capscrews (Figure 4, Item 1) on cylinder head (Figure 4, Item 2). Tighten 14 capscrews in sequence three separate times. First time, tighten capscrews to 29 ft-lb (39 Nm). Second time, tighten capscrews to 62 ft-lb (84 Nm). Third time, tighten capscrews to 92 ft-lb (125 Nm).
3
M02101045
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install manifold cover plate (WP 0041).
Cylinder Head Installation.
Install rocker levers and push rods (WP 0031). Install valve covers (WP 0035). Install fuel injection tubes (WP 0049). Install exhaust manifold (WP 0042). Connect battery cables (WP 0076).
0027-5
TM 5-3810-305-23
0027
FOLLOW-ON MAINTENANCE - Continued 7. Place boom in resting position (TM 5-3810-305-10).
0027-6
TM 5-3810-305-23
0028
FIELD MAINTENANCE CRANKSHAFT PULLEY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Cooling fan removed (WP 0060)
REMOVAL 1. 2. Remove plug (Figure 1, Item 1) located at top right of bell housing and use a suitable prybar wedged between flywheel and bell housing to lock flywheel before removing crankshaft pulley (Figure 1, Item 3). Remove four capscrews (Figure 1, Item 2) and crankshaft pulley (Figure 1, Item 3) from vehicle.
M0010105
Figure 1. END OF TASK
Crankshaft Pulley Removal.
0028-1
TM 5-3810-305-23
0028
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Use a suitable prybar in hole of plug wedged between flywheel and bell housing to lock flywheel before installing crankshaft pulley. Install crankshaft pulley (Figure 2, Item 3) and four capscrews (Figure 2, Item 2) in vehicle. Tighten four capscrews to 44 ft-lb (60 Nm). Install plug (Figure 2, Item 1) in bell housing.
M0010105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install cooling fan (WP 0060). END OF TASK END OF WORK PACKAGE
Crankshaft Pulley Installation.
0028-2
TM 5-3810-305-23
0029
FIELD MAINTENANCE FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Indicator, Dial (WP 0171, Table 1, Item 6) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Materials/Parts O-Ring (WP 0172, Table 1, Item 76) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Power pack assembly removed (WP 0024)
REMOVAL 1. Remove eight capscrews (Figure 1, Item 1), washers (Figure 1, Item 2), and flywheel (Figure 1, Item 3) from engine.
3
M0215105
Figure 1.
Flywheel Removal.
0029-1
TM 5-3810-305-23
0029
REMOVAL - Continued 2. Remove eight capscrews (Figure 2, Item 3), flywheel housing (Figure 2, Item 1), and o-ring (Figure 2, Item 2) from engine. Discard o-ring.
3
Figure 2. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK Flywheel Removal.
M0216105
0029-2
TM 5-3810-305-23
0029
INSTALLATION 1. 2. Install new o-ring (Figure 3, Item 2), flywheel housing (Figure 3, Item 1), and eight capscrews (Figure 3, Item 3). Tighten eight capscrews to 57 ft-lb (77 Nm).
3
Figure 3. 3. Flywheel Installation.
M0216105
Attaching a dial indicator to crankshaft, measure vertical and horizontal runout of flywheel housing.
M0219105
Figure 4.
Flywheel Installation.
0029-3
TM 5-3810-305-23
0029
CAUTION
Dial indicator tip must not enter capscrew holes or gage will be damaged.
NOTE
Extension bar for dial indicator must be rigid for an accurate reading. 4. 5. 6. Position dial indicator at 12 oclock position. Adjust dial until needle points to zero. Slowly rotate crankshaft. Record readings obtained at 3 oclock, 6 oclock, and 9 oclock positions. Continue to rotate crankshaft back to 12 oclock position. Check dial indicator to make sure needle points to zero. Determine Total Indicator Reading (TIR). EXAMPLE: 12 oclock = 0.000 inch (0.00 mm) 3 oclock = +0.003 inch (0.08 mm) 6 oclock = -0.002 inch (0.05 mm) 9 oclock = +0.003 inch (0.08 mm) Equals TIR = 0.005 inch (0.13 mm)
M0220105
Figure 5. Flywheel Installation.
0029-4
TM 5-3810-305-23
0029
NOTE
Maximum TIR is determined by diameter of housing bore. Replace housing if out of specification. 7. Specification of bore diameter is 17.625 to 17.630 inches (447.68 to 447.80 mm). TIR maximum is 0.008 inch (0.20 mm).
CAUTION
DO NOT force crankshaft beyond point where bearing clearance has been removed. DO NOT use flywheel housing as a fulcrum. Failure to follow this caution may cause damage to equipment. 8. Determine adjustment for main bearing clearance by raising rear of crankshaft to its upper hit. Use a floormounted support with padded pry bar to raise crankshaft and record reading.
M0221105
Figure 6. 9.
Flywheel Installation.
Calculate bearing clearance adjustment by subtracting one-half of reading obtained in Step 8 from reading obtained at 6 oclock position. EXAMPLE: Total bearing clearance = +0.003 inch (+0.08 mm) One-half bearing clearance = +0.0016 inch (+0.040 mm) 6 oclock position reading = +0.008 inch (+0.20 mm) Adjusted 6 oclock reading = +0.0064 inch (+0.162 mm)
0029-5
TM 5-3810-305-23
0029
INSTALLATION - Continued 10. 11. Lock crankshaft. Install flywheel (Figure 7, Item 3), eight washers (Figure 7, Item 2), and capscrews (Figure 7, Item 1).
3
M0215105
Figure 7. Flywheel Installation. 12. Tighten eight capscrews in sequence shown in (Figure 8) to 101 ft-lb (137 Nm).
C E
H F
G B D
M0222105
Figure 8. Flywheel Installation. END OF TASK
0029-6
TM 5-3810-305-23
0029
FOLLOW-ON MAINTENANCE 1. 2. 3. Install power pack assembly (WP 0024). Connect battery cables (WP 0076). Check for proper operation.
0029-7/8 blank
TM 5-3810-305-23
0030
FIELD MAINTENANCE REAR CRANKSHAFT SEAL MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Drill-Driver, Battery Operated (WP 0171, Table 1, Item 24) Drill Set, Twist (WP 0171, Table 1, Item 23) Wrench, Torque, Dial, 1/4 Inch Drive, 30 in-lb (WP 0171, Table 1, Item 37) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 83) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Seal (WP 0172, Table 1, Item 150) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 Personnel Required (Two) References WP 0029 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0030-1
TM 5-3810-305-23
0030
REMOVAL
NOTE
There are two separate procedures for removing rear seal. One is with flywheel housing installed and one is with flywheel housing removed. Steps 1 through 3 are for removal of rear seal with flywheel housing installed. Steps 4 through 7 are for removal of rear seal with flywheel housing removed. 1. 2. Remove flywheel (Figure 1, Item 1) (WP 0029). Drill two holes 180 degrees apart to relieve tension on rear seal (Figure 1, Item 2).
2
Figure 1. Rear Seal Removal. 3. Remove rear seal (Figure 2, Item 1) from flywheel housing (Figure 2, Item 2).
M0040105
1 2
M0041105
Figure 2. Rear Seal Removal.
0030-2
TM 5-3810-305-23
0030
REMOVAL - Continued 4. 5. 6. 7. Remove flywheel housing (WP 0029). Remove six capscrews (Figure 3, Item 1), rear cover (Figure 3, Item 2), and gasket (Figure 3, Item 4) from block (Figure 3, Item 3). Discard gasket and remove all gasket material from mounting surfaces. Support rear cover (Figure 3, Item 2) on a suitable work stand. Remove rear seal (Figure 3, Item 5) from rear cover (Figure 3, Item 2).
5
4,3
1
M0042105
Rear Seal Removal.
Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0030-3
TM 5-3810-305-23
0030
INSTALLATION
CAUTION
Seal lip and sealing surface on crankshaft must be free from all oil residue to prevent seal leaks. Teflon seals must be installed on dry clean surfaces. Drive rear seal alternately at the 12, 3, 6, and 9 o'clock positions to prevent bending rear cover.
NOTE
Steps 1 through 4 are for installation of rear seal with flywheel housing removed. Use a mild soap on inside diameter of rear seal for easier installation. DO NOT use any kind of sealant on rear seal. 1. 2. 3. Using a seal starter ring, install new real seal (Figure 4, Item 5) in rear cover (Figure 4, Item 2). Install new gasket (Figure 4, Item 4), rear cover (Figure 4, Item 2) and six capscrews (Figure 4, Item 1) to block (Figure 4, Item 3). Tighten capscrews to 7 ft-lb (9 Nm). Using a seal driver, drive rear seal (Figure 4, Item 5) until seal driver bottoms.
4,3
1
M0042105
Figure 4. Rear Seal Installation.
0030-4
TM 5-3810-305-23
0030
INSTALLATION - Continued 4. Install flywheel housing (Figure 5, Item 2) (WP 0029).
CAUTION
Drive rear seal alternately at the 12, 3, 6 and 9 o'clock positions to prevent bending rear cover.
NOTE
Steps 5 through 7 are for installation of rear seal with flywheel housing installed. Use a mild soap on inside diameter of rear seal for easier installation. DO NOT use any kind of sealant on rear seal. 5. 6. 7. Using a seal starter, install rear seal (Figure 5, Item 1) on flywheel housing (Figure 5, Item 2). Using a seal driver, drive rear seal (Figure 5, Item 1) on crankshaft until seal driver bottoms. Install flywheel (WP 0029).
1 2
M0041105
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076).
Rear Seal Installation.
0030-5/6 blank
TM 5-3810-305-23
0031
FIELD MAINTENANCE ROCKER LEVERS AND PUSH RODS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper, Micrometer, Outside (WP 0171, Table 1, Item 21) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Tester, Valve Spring (WP 0171, Table 1, Item 14) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Engine, 15W40 Grade (WP 0170, Table 1, Item 36) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0044 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) High-pressure fuel injection lines removed (WP 0048) Valve covers removed (WP 0035)
0031-1
TM 5-3810-305-23
0031
REMOVAL 1. 2. 3. Loosen eight adjusting nuts (Figure 1, Item 2) and rocker adjustment screws (Figure 1, Item 3) to release spring tension from rocker shaft support assemblies (Figure 1, Item 4). Remove four capscrews (Figure 1, Item 5) from four rocker shaft support assemblies (Figure 1, Item 4). Remove four capscrews (Figure 1, Item 1) and four rocker shaft support assemblies (Figure 1, Item 4) from cylinder head.
1 4 3 5
M0022105
Figure 1. 4. Remove eight push rods (Figure 2, Item 1).
Cylinder Head Removal.
M0023105
Rocker Lever and Push Rods Removal.
0031-2
TM 5-3810-305-23
0031
DISASSEMBLY
NOTE
The following is a maintenance instruction for one rocker shaft support assembly. Maintenance instruction for remaining three rocker shaft support assemblies is identical. Before disassembly of rocker shaft support assemblies, mark on each side of rocker shaft support and rocker levers (I) or (E) for intake or exhaust to aid in assembly. 1. Remove two retaining rings (Figure 3, Item 1), thrust washers (Figure 3, Item 2) and intake and exhaust rocker levers (Figure 3, Item 3) from rocker shaft support assemblies (Figure 3, Item 4).
4
2
3 3
1
M0024105
Figure 3. Rocker Lever and Push Rods Disassembly.
NOTE
DO NOT disassemble rocker shaft support. They are serviced as an assembly. 2. If inspection shows adjusting nuts (Figure 4, Item 1) and rocker adjusting screws (Figure 4, Item 2) are defective, remove and discard from intake and exhaust rocker levers (Figure 4, Item 3).
1 2
3 3
M0025105
Figure 4. Rocker Lever and Push Rods Disassembly. END OF TASK
0031-3
TM 5-3810-305-23
0031
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect rocker levers for cracks and wear in bore and contact surface of valve stem.
M0026105
Figure 5. 3.
Rocker Lever and Push Rods Inspection.
Measure diameter of rocker lever bore. Diameter of bore should measure 0.7480 inch (18.999 mm) minimum and 0.7500 inch (19.050 mm) maximum.
M0027105
Figure 6.
0031-4
TM 5-3810-305-23
0031
INSPECTION - Continued 4. 5. Inspect rocker shaft support assembly for wear on shaft. Measure diameter of shaft. Diameter of shaft should measure 0.7456 inch (18.938 mm) minimum and 0.7470 inch (18.974 mm) maximum. Replace rocker shaft support assembly when shaft measurement is not within minimum/maximum tolerance.
M0028105
Figure 7. END OF TASK ASSEMBLY 1.
If removed, install rocker adjustment screws (Figure 8, Item 2) and adjusting nuts (Figure 8, Item 1) on intake and exhaust rocker levers (Figure 8, Item 3).
1 2
3 3
M0025105
Figure 8. Rocker Lever and Push Rods Assembly.
0031-5
TM 5-3810-305-23
0031
ASSEMBLY - Continued
NOTE
Be sure to assemble intake and exhaust rocker levers in the correct location. 2. Lubricate rocker shaft support assemblies (Figure 9, Item 4) with engine oil and install intake and exhaust rocker levers (Figure 9, Item 3), two thrust washers (Figure 9, Item 2), and retaining rings (Figure 9, Item 1).
4
2
3 3
1
M0024105
Figure 9. Rocker Lever and Push Rods Assembly. END OF TASK INSTALLATION 1. Lubricate with engine oil and install eight push rods (Figure 10, Item 1) in engine.
M0023105
Figure 10. Rocker Lever and Push Rods Installation.
0031-6
TM 5-3810-305-23
0031
INSTALLATION - Continued 2. 3. 4. 5. 6. 7. 8. 9. Install four rocker shaft support assemblies (Figure 11, Item 4). Lubricate with engine oil and install four capscrews (Figure 11, Item 1) to cylinder head. Tighten four capscrews to 92 ft-lb (125 Nm). Lubricate with engine oil and install four capscrews (Figure 11, Item 5) to four rocker shaft support assemblies (Figure 11, Item 4). Tighten four capscrews to 18 ft-lb (24 Nm). To set valve clearance, turn rocker adjustment screws (Figure 11, Item 3) in until they touch push rod sockets. Loosen valve adjustment screws one full turn. Timing pin is designed only to locate Top Dead Center (TDC) for cylinder number 1 and not to lock engine. Locate TDC for cylinder number 1 (WP 0044). Disengage timing pin. Valve stem to rocker lever clearances for intake should measure 0.010 inch (0.25 mm); for exhaust 0.020 inch (0.51 mm). To adjust, turn adjusting screw (Figure 11, Item 3) to obtain correct clearance and hold. Tighten adjusting nut (Figure 11, Item 2) to 18 ft-lb (24 Nm).
1 4 3 5
M0022105
Figure 11. 10. 11. 12. 13.
Cylinder Head Installation.
Perform valve set procedure with cylinder number 1 at TDC; timing pin will engage. Adjust intake and exhaust valves at cylinder number 1, intake at cylinder 2, and exhaust at cylinder 3. Mark crankshaft and front cover and rotate crankshaft 360 degrees. Timing pin will not engage this time. Adjust exhaust and intake valves at cylinder 4, intake at cylinder 3, and exhaust at cylinder 2.
END OF TASK
0031-7
TM 5-3810-305-23
0031
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install valve covers (WP 0035). Install high-pressure fuel injection lines (WP 0048). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0031-8
TM 5-3810-305-23
0032
FIELD MAINTENANCE FRONT GEAR COVER AND GASKET MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 79) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Radiator and oil cooler removed (WP 0054) Drive belt, pulleys, and fan removed (WP 0059)
0032-1
TM 5-3810-305-23
0032
REMOVAL 1. 2. Remove two capscrews (Figure 1, Item 3), washers (Figure 1, Item 4) and tachometer drive (Figure 1, Item 2) from front cover (Figure 1, Item 5). Using a strap wrench, remove access hole cover (Figure 1, Item 1) from front cover (Figure 1, Item 5).
1 2 3 4
M0016105
Figure 1.
Tachometer Drive Removal.
0032-2
TM 5-3810-305-23
0032
REMOVAL - Continued 3. 4. 5. Remove 20 capscrews (Figure 2, Item 1), front cover (Figure 2, Item 2), and gasket (Figure 2, Item 3). Discard gasket. Remove all gasket material from mounting surfaces. Remove seal (Figure 2, Item 4) by driving out of front cover (Figure 2, Item 2).
3 4
M0017105
Front Cover Removal.
0032-3
TM 5-3810-305-23
0032
INSTALLATION 1. Using clean oil, lubricate front gear train (Figure 3, Item 1).
1
Figure 3. Front Gear Train Installation.
M0018105
WARNING
CAUTION
Seal lip and sealing surface on crankshaft must be free from all oil residue to prevent seal leaks. Teflon seals must be installed on dry, clean surfaces.
0032-4
TM 5-3810-305-23
0032
INSTALLATION - Continued 2. 3. 4. 5. 6. 7. Thoroughly clean and dry front seal area of crankshaft. Apply sealant to outside diameter of front seal (Figure 4, Item 4). Install seal (Figure 4, Item 4) in front cover (Figure 4, Item 2). Make sure seal and sealing surface is free of oil residue to prevent leaks. Apply sealant to front cover (Figure 4, Item 2) and gear housing. Install new gasket (Figure 4, Item 3) on gear housing. Install front cover (Figure 4, Item 2) and 20 capscrews (Figure 4, Item 1). Tighten 20 capscrews to 18 ft-lb (24 Nm).
3 4
M0017105
Figure 4.
Front Cover Installation.
0032-5
TM 5-3810-305-23
0032
INSTALLATION - Continued 8. Install access hole cover (Figure 5, Item 1), tachometer drive (Figure 5, Item 2), two washers (Figure 5, Item 4), and capscrews (Figure 5, Item 3) in front cover (Figure 5, Item 5). Tighten two capscrews to 7 ft-lb (9.5 Nm).
1 2 3 4
M0016105
Figure 5. Tachometer Drive Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install drive belt, pulleys, and fan (WP 0059). Install radiator and oil cooler assembly (WP 0054). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Start vehicle, run at operating temperature, and check for leaks (TM 5-3810-305-10).
0032-6
TM 5-3810-305-23
0033
FIELD MAINTENANCE TIMING PIN ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 O-Ring (WP 0172, Table 1, Item 77) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Cylinder head removed (WP 0027) Front gear cover removed (WP 0032)
REMOVAL 1. 2. Remove two screws (Figure 1, Item 3) from timing pin housing (Figure 1, Item 1). Remove timing pin housing (Figure 1, Item 1) from gear housing (Figure 1, Item 2).
M0019105
Figure 1.
Timing Pin Assembly Removal.
0033-1
TM 5-3810-305-23
0033
REMOVAL - Continued 3. Remove o-ring (Figure 2, Item 1) from timing pin housing (Figure 2, Item 2). Discard o-ring.
M0020105
Timing Pin Assembly Removal.
0033-2
TM 5-3810-305-23
0033
INSTALLATION 1. 2. 3. Install new o-ring (Figure 3, Item 3) on timing pin housing (Figure 3, Item 1). Install timing pin housing (Figure 3, Item 1) on gear housing (Figure 3, Item 2). Install two screws (Figure 3, Item 4) to timing pin housing.
2 3
M0021105
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install front gear cover (WP 0032). Install cylinder head (WP 0027). Connect battery cables (WP 0076).
Timing Pin Assembly Installation.
0033-3/4 blank
TM 5-3810-305-23
0034
FIELD MAINTENANCE TAPPET COVER AND GASKET MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper, Micrometer, Outside (WP 0171, Table 1, Item 21) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 46) Qty: 1 Grommet (WP 0172, Table 1, Item 55) Qty: 4 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Fuel filters and head assembly removed (WP 0050) Injection pump removed (WP 0044) Lift pump removed (WP 0045) Manifold cover plate removed (WP 0041)
0034-1
TM 5-3810-305-23
0034
REMOVAL 1. 2. Remove spring hose clamp (Figure 1, Item 4) and hose (Figure 1, Item 5) from tappet cover (Figure 1, Item 3). Remove capscrews (Figure 1, Item 6), four grommets (Figure 1, Item 1), tappet cover (Figure 1, Item 3), and tappet cover gasket (Figure 1, Item 2) from block. Remove all gasket material from mounting surfaces.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION
WARNING
NOTE
Tappet cover gasket has an adhesive back. Pull off protective cover on gasket to expose adhesive surface. 1. 2. 3. Install new tappet cover gasket (Figure 1, Item 2) with adhesive side down on tappet cover (Figure 1, Item 3). Apply sealing compound to top of gasket and block. Install tappet cover (Figure 1, Item 3), four grommets (Figure 1, Item 1), and capscrews (Figure 1, Item 6) on block. Tighten capscrews to 18 ft-lb (24 Nm). Install hose (Figure 1, Item 5) and spring hose clamp (Figure 1, Item 4) on tappet cover (Figure 1, Item 3).
0034-2
TM 5-3810-305-23
0034
2 1 6 3
5
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install manifold cover plate (WP 0041). Install lift pump (WP 0045). Install injection pump (WP 0044). Install fuel filters and head assembly (WP 0050). Place boom in resting position (TM 5-3810-305-10). Tappet Cover Installation.
M0015105
0034-3/4 blank
TM 5-3810-305-23
0035
FIELD MAINTENANCE VALVE COVERS AND GASKET MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 58) Qty: 4 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 75) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Sliding engine hood removed (WP 0118)
REMOVAL Remove four capscrews (Figure 1, Item 2), o-rings (Figure 1, Item 3), valve covers (Figure 1, Item 1), and gaskets (Figure 1, Item 4). Remove all gasket material from mounting surfaces. Discard o-rings and gaskets.
M0014105
Valve Covers Removal.
0035-1
TM 5-3810-305-23
0035
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Install four new gaskets (Figure 2, Item 4), valve covers (Figure 2, Item 1), new o-rings (Figure 2, Item 3), and capscrews (Figure 2, Item 2). Tighten four capscrews to 18 ft-lb (24 Nm).
M0014105
Figure 2. Valve Covers Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install sliding engine hood (WP 0118). Place boom in resting position (TM 5-3810-305-10).
0035-2
TM 5-3810-305-23
0036
FIELD MAINTENANCE FRONT CRANKSHAFT SEAL MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Drill-Driver, Battery Operated (WP 0171, Table 1, Item 24) Drill Set, Twist (WP 0171, Table 1, Item 23) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Seal Driver (WP 0171, Table 1, Item 46) Stand, Maintenance, Automotive Engine (WP 0171, Table 1, Item 11) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Seal (WP 0172, Table 1, Item 62) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 References WP 0028 WP 0029 WP 0032 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0036-1
TM 5-3810-305-23
0036
REMOVAL
NOTE
There are two separate procedures for removing front seal. One is with front cover removed and one is with front cover installed. Step 1 is for removing front seal with front cover removed. 1. Remove front seal (Figure 1, Item 1) from front cover (Figure 1, Item 2) with front cover removed. Refer to Front Gear Cover and Gasket Maintenance (WP 0032).
NOTE
Steps 2 and 3 are for removal of front seal with front cover installed. 2. 3. 4. Remove crankshaft pulley. Refer to Crankshaft Pulley Maintenance (WP 0028). Drill two holes 180 degrees apart to relieve tension on front seal (Figure 1, Item 1). Remove and discard front seal (Figure 1, Item 1) from front cover (Figure 1, Item 2).
2
Figure 1. END OF TASK Front Seal Removal.
M0038105
0036-2
TM 5-3810-305-23
0036
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION
WARNING
CAUTION
Seal lip and sealing surface on crankshaft must be free from all oil residue to prevent seal leaks. Teflon seals must be installed on dry, clean surfaces.
0036-3
TM 5-3810-305-23
0036
NOTE
Steps 1 through 3 are the procedures for installation of new front seal with front cover installed. 1. 2. 3. Apply sealing compound to outside diameter of front seal (Figure 2, Item 1). Using a seal starter ring, install new front seal (Figure 2, Item 1) on front cover (Figure 2, Item 2). Install crankshaft pulley. Refer to Crankshaft Pulley Maintenance (WP 0028).
CAUTION
Drive front seal alternately at the 12, 3, 6, and 9 oclock positions to prevent damage to seal carrier.
NOTE
Steps 4 and 5 are for installation of new front seal with front cover removed. 4. 5. Using a seal driver, install new front seal (Figure 2, Item 1) on front cover (Figure 2, Item 2). Install new front seal (Figure 2, Item 1) in cover (Figure 2, Item 2) with front cover removed. Refer to Front Gear Cover and Gasket Maintenance (WP 0032).
M0039105
Figure 2. Front Seal Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0036-4
TM 5-3810-305-23
0037
FIELD MAINTENANCE LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Tester, Valve Spring (WP 0171, Table 1, Item 14) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 101) Qty: Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0054 WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Oil filter removed (WP 0022)
0037-1
TM 5-3810-305-23
0037
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. Disconnect wires (Figure 1, Items 3 and 4) from oil pressure switch (Figure 1, Item 1) and remove oil pressure switch from engine (Figure 1, Item 2).
M0212105
Figure 1. 2.
Lube Oil Cooler Removal.
Remove 14 capscrews (Figure 2, Item 1) and cover (Figure 2, Item 3) from engine (Figure 2, Item 2).
1 2 3
M0213105
Figure 2. 3.
Lube Oil Cooler Removal.
Remove cooler core (Figure 3, Item 3) and cooler core gasket (Figure 3, Item 2) from engine (Figure 3, Item 1) and discard gasket.
0037-2
TM 5-3810-305-23
0037
REMOVAL - Continued
3 2
Figure 3. END OF TASK DISASSEMBLY 1. 2. Remove plug (Figure 4, Item 1), sealing washer (Figure 4, Item 2), spring (Figure 4, Item 3), and pressure regulator plunger (Figure 4, Item 4) from cooler core cover (Figure 4, Item 5). Inspect pressure regulator plunger (Figure 4, Item 4) bore for nicks or scratches. Pressure regulator plunger must move freely in bore. If pressure regulator plunger does not move freely, replace lube oil cooler assembly. Lube Oil Cooler Removal.
M0214105
5
M2318105
Figure 4.
Lube Oil Cooler Disassembly.
0037-3
TM 5-3810-305-23
0037
DISASSEMBLY - Continued 3. Check spring (Figure 5, Item 1). If spring is out of tolerance, replace spring.
M2319105
Figure 5. Lube Oil Cooler Disassembly. Table 1. Pressure Regulator Spring Limits. Valve Open Height Load END OF TASK Valve Assembled
1.57 inches (39.9 mm) 1.77 inches (44.9 mm) 20.5 lb (91 N) 13.5 lb (60 N)
0037-4
TM 5-3810-305-23
0037
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Soak cooler core (Figure 6, Item 1) in cleaning solvent to remove coolant deposits. Back flush oil passages and dry with compressed air. Inspect soldered joints for corrosion or cracks. Pressurize cooler core (Figure 6, Item 1) to 70 psi (483 kPa), submerge in water and check for leaks.
M2440105
Lube Oil Cooler Inspection.
0037-5
TM 5-3810-305-23
0037
ASSEMBLY Install pressure regulator plunger (Figure 7, Item 4), spring (Figure 7, Item 3), sealing washer (Figure 7, Item 2), and plug (Figure 7, Item 1) on cooler core cover (Figure 7, Item 5). Tighten plug to 74 ft-lb (100 Nm).
5
M2318105
Figure 7. Lube Oil Cooler Assembly. END OF TASK INSTALLATION 1. Install new cooler core gasket (Figure 8, Item 2) and cooler core (Figure 8, Item 3) to engine (Figure 8, Item 1).
3 2
Figure 8. Lube Oil Cooler Installation.
M0214105
0037-6
TM 5-3810-305-23
0037
INSTALLATION - Continued 2. Install cover (Figure 9, Item 3) and 14 capscrews (Figure 9, Item 1) to engine (Figure 9, Item 2). Tighten 14 capscrews to 18 ft-lb (24 Nm).
1 2 3
M0213105
Figure 9. 3. 4.
Lube Oil Cooler Installation.
Install oil pressure switch (Figure 10, Item 1) on engine (Figure 10, Item 2). Connect wires (Figure 10, Items 3 and 4) to oil pressure switch (Figure 10, Item 1).
M0212105
Lube Oil Cooler Installation.
0037-7
TM 5-3810-305-23
0037
FOLLOW-ON MAINTENANCE 1. 2. 3. Install oil filter (WP 0022). Fill with coolant, if required (WP 0054). Connect battery cables (WP 0076).
0037-8
TM 5-3810-305-23
0038
FIELD MAINTENANCE LUBE OIL PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Indicator, Dial (WP 0171, Table 1, Item 6) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Fuel, Diesel Run-In Mobil 4Y17 (WP 0170, Table 1, Item 19) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Front gear cover removed (WP 0032)
REMOVAL
NOTE
Before removing lube oil pump, check backlash of lube oil pump gears. Hold adjoining gear to keep from moving, when checking backlash. Lube oil pump gear and idler gear backlash limit is 0.003 to 0.013 inch (0.08 to 0.33 mm). 1. 2. Using dial indicator on tooth of lube oil pump gear (Figure 1, Item 2), check for excessive backlash. Using dial indicator on tooth of idler gear (Figure 1, Item 1), check for excessive backlash.
1
M0051105
Figure 1.
Lube Oil Pump Removal.
0038-1
TM 5-3810-305-23
0038
REMOVAL - Continued 3. 4. 5. Remove four capscrews (Figure 2, Item 1) from lube oil pump (Figure 2, Item 2). Remove lube oil pump (Figure 2, Item 2) from engine (Figure 2, Item 3). If backlash exceeds limits, replace lube oil pump (Figure 2, Item 2).
2
Figure 2. Lube Oil Pump Removal.
M0052105
0038-2
TM 5-3810-305-23
0038
INSTALLATION
NOTE
Filling lube oil pump before installing will aid in priming during engine startup. 1. 2. 3. Lubricate lube oil pump (Figure 3, Item 2) with clean engine oil. Install lube oil pump (Figure 3, Item 2) to engine (Figure 3, Item 3). Install four capscrews (Figure 3, Item 1) to lube oil pump (Figure 3, Item 2). Tighten capscrews to 18 ft-lb (24 Nm).
2
Figure 3. Lube Oil Pump Installation.
M0052105
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install front gear cover (WP 0032). Run engine and check for correct engine operation (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10).
0038-3/4 blank
TM 5-3810-305-23
0039
FIELD MAINTENANCE OIL PAN AND SUCTION TUBE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 82) Qty: 1 Gasket (WP 0172, Table 1, Item 84) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Engine oil drained (WP 0022) Battery cables disconnected (WP 0076)
0039-1
TM 5-3810-305-23
0039
REMOVAL
NOTE
Engine shown removed in Figure 1 for clarity. 1. Remove 24 capscrews (Figure 1, Item 2), washers (Figure 1, Item 3), and oil pan (Figure 1, Item 1) from engine block (Figure 1, Item 4).
2 3
4
M0056105
Figure 1.
Oil Pan and Suction Tube Removal.
0039-2
TM 5-3810-305-23
0039
REMOVAL - Continued 2. 3. Remove gasket (Figure 2, Item 2) from engine block (Figure 2, Item 1). Discard gasket. Remove all gasket material from mounting surfaces. Remove two capscrews (Figure 2, Item 5), capscrew (Figure 2, Item 3), suction tube (Figure 2, Item 4), and gasket (Figure 2, Item 6) from engine block (Figure 2, Item 1). Discard gasket. Remove all gasket material from mounting surfaces.
5
Figure 2.
4
Oil Pan and Suction Tube Removal.
M0057105
0039-3
TM 5-3810-305-23
0039
INSTALLATION
WARNING
NOTE
Engine shown removed in Figure 2 for clarity. 1. 2. Install new gasket (Figure 3, Item 6), suction tube (Figure 3, Item 4), capscrew (Figure 3, Item 3), and two capscrews (Figure 3, Item 5) on engine block (Figure 3, Item 1). Tighten capscrews to 18 ft-lb (24 Nm). Apply sealing compound to fill joints between oil pan rail, gear housing and rear cover.
NOTE
Oil pan gasket has a print-a-seal surface on one side. 3. Apply sealing compound to both sides of new gasket (Figure 3, Item 2) and position it with print-a-seal surface toward engine block (Figure 3, Item 1).
0039-4
TM 5-3810-305-23
0039
5
Figure 3.
4
Oil Pan and Suction Tube Installation.
M0057105
0039-5
TM 5-3810-305-23
0039
INSTALLATION - Continued 4. Install oil pan (Figure 4, Item 1), 24 washers (Figure 4, Item 3), and capscrews (Figure 4, Item 2) on engine block (Figure 4, Item 4). Tighten 24 capscrews to 18 ft-lb (24 Nm).
2 3
4
M0056105
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.
Oil Pan and Suction Tube Installation.
Fill engine with clean engine oil (WP 0022). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0039-6
TM 5-3810-305-23
0040
FIELD MAINTENANCE OIL LEVEL GAGE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL 1. Remove dipstick (Figure 1, Item 1) from oil gage tube (Figure 1, Item 2).
2
Figure 1. Oil Level Gage Removal.
M0054105
0040-1
TM 5-3810-305-23
0040
REMOVAL - Continued
NOTE
DO NOT remove oil gage tube unless damaged. 2. Remove oil gage tube (Figure 2, Item 2) from block (Figure 2, Item 1) by screwing the oil gage tube counterclockwise.
M0055105
Oil Level Gage Removal.
0040-2
TM 5-3810-305-23
0040
INSTALLATION
WARNING
ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 1. 2. 3. Apply sealing compound to base of oil gage tube (Figure 3, Item 2). Insert a capscrew into top of oil gage tube (Figure 3, Item 2) and install oil gage tube on block. Remove capscrew. Install dipstick (Figure 3, Item 1) into oil gage tube (Figure 3, Item 2).
2
Figure 3. END OF TASK Oil Level Gage Installation.
M0054105
0040-3
TM 5-3810-305-23
0040
FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0040-4
TM 5-3810-305-23
0041
FIELD MAINTENANCE INTAKE MANIFOLD COVER AND GASKET MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 78) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) High-pressure fuel injection lines removed (WP 0048)
REMOVAL Remove eight capscrews (Figure 1, Item 1), cover plate (Figure 1, Item 2), and gasket (Figure 1, Item 3). Discard gasket. Clean all gasket material from mounting surfaces.
1 3
M0053105
Manifold Cover Plate Removal.
0041-1
TM 5-3810-305-23
0041
NOTE
Cover plate must be installed with air inlet on flywheel end. Air inlet must be directly above cold start atomizer inlet. 1. 2. 3. 4. 5. Install new gasket (Figure 2, Item 3) and cover plate (Figure 2, Item 2). Lubricate eight capscrews (Figure 2, Item 1) with threadlock compound and install on cover plate (Figure 2, Item 2). Install high-pressure fuel injection lines (WP 0048). Torque eight capscrews (Figure 2, Item 1) to 18 ft-lb (24 Nm) after high-pressure fuel injection lines are installed. Connect battery cables (WP 0076).
1 3
M0053105
Figure 2. Manifold Cover Plate Installation. END OF TASK
0041-2
TM 5-3810-305-23
0041
FOLLOW-ON MAINTENANCE 1. 2. 3. Install high-pressure fuel injection lines (WP 0048). Battery cables connected (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0041-3/4 blank
TM 5-3810-305-23
0042
FIELD MAINTENANCE EXHAUST MANIFOLD AND GASKETS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 147) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Exhaust pipe removed (WP 0053)
REMOVAL Remove eight capscrews (Figure 1, Item 1), manifold (Figure 1, Item 3), and four gaskets (Figure 1, Item 2) from engine block (Figure 1, Item 4). Remove all gasket material from mounting surfaces. Discard gasket.
M0295105
Exhaust Manifold Removal.
0042-1
TM 5-3810-305-23
0042
INSTALLATION 1. Install four new gaskets (Figure 2, Item 2), manifold (Figure 2, Item 3), and eight capscrews (Figure 2, Item 1) on engine block (Figure 2, Item 4).
M0295105
Figure 2. 2.
Exhaust Manifold Removal.
Torque eight capscrews (Figure 3) to 32 ft-lb (43 Nm) in sequence shown.
3
Figure 3.
2
Exhaust Manifold Installation.
M2301105
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install exhaust pipe (WP 0053). Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Place boom in resting position (TM 5-3810-305-10).
0042-2
TM 5-3810-305-23
0042
FOLLOW-ON MAINTENANCE - Continued 6. Shut down engine (TM 5-3810-305-10).
0042-3/4 blank
TM 5-3810-305-23
0043
FIELD MAINTENANCE FUEL INJECTOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Tester, Diesel Fuel Injector Nozzle (WP 0171, Table 1, Item 13) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Antiseize Compound (WP 0170, Table 1, Item 5) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Gasket (WP 0172, Table 1, Item 56) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Exhaust manifold removed (WP 0042) Fuel injection tubes removed (WP 0049) Battery cables disconnected (WP 0076)
REMOVAL
CAUTION
If rust has formed on hold-down nut, the injector nozzle can turn in bore when nut is loosened. This will cause injector locating ball to cut a groove in bore, severely damaging head.
NOTE
If injectors are rusty, soak hold-down nut with a rust-penetrating solvent for a minimum of three minutes and loosen rust by carefully hitting injector body with drift pin.
0043-1
TM 5-3810-305-23
0043
REMOVAL - Continued 1. Loosen hold-down nut (Figure 1, Item 2) and remove four injector nozzles (Figure 1, Item 3) from cylinder head (Figure 1, Item 1).
2 1 3
M0289105
Figure 1. Injector Nozzles Removal. 2. Remove four injector gaskets (Figure 2, Item 1). Discard gaskets.
M0290105
Figure 2. Injector Nozzles Removal. END OF TASK
0043-2
TM 5-3810-305-23
0043
CLEANING 1. 2. Clean parts IAW General Maintenance Instructions (WP 0162). Dry parts with compressed air.
END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks, or corrosion, and replace if necessary. Inspect oil passages to ensure they are clean and unobstructed. Inspect for corrosion, pitting, and damage. Replace as necessary.
END OF TASK INSTALLATION 1. Apply antiseize compound to threads between injector nozzle hold-down nut and injector body.
NOTE
Protrusion on side of nozzle fits into a notch in head to orient injector. 2. Install four new injector gaskets (Figure 3, Item 1).
M0290105
Figure 3. Lube Oil Injector Nozzles Installation.
0043-3
TM 5-3810-305-23
0043
INSTALLATION - Continued 3. 4. Install four injector nozzles (Figure 4, Item 3) in cylinder head (Figure 4, Item 1). Hold injector body with adjustable wrench and tighten hold-down nut, making sure injector nozzle (Figure 4, Item 3) does not rotate. Torque hold-down nut (Figure 4, Item 2) to 44 ft-lb (60 Nm).
2 1 3
M0289105
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install exhaust manifold (WP 0042). Install fuel injection tubes (WP 0049). Connect battery cables (WP 0076).
Injector Nozzles Installation.
Place boom in resting position (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10).
0043-4
TM 5-3810-305-23
0044
FIELD MAINTENANCE FUEL INJECTION PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Indicator, Dial (WP 0171, Table 1, Item 6) Puller Set, Mechanical (WP 0171, Table 1, Item 38) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, Dial, 1/4 Inch Drive (30 in-lb) (WP 0171, Table 1, Item 37) Materials/Parts Gasket (WP 0172, Table 1, Item 68) Qty: 1 Locknut (WP 0172, Table 1, Item 63) Qty: 2 Locknut (WP 0172, Table 1, Item 65) Qty: 1 O-Ring (WP 0172, Table 1, Item 64) Qty: 1 O-Ring (WP 0172, Table 1, Item 67) Qty: 1 O-Ring (WP 0172, Table 1, Item 71) Qty: 2 O-Ring (WP 0172, Table 1, Item 72) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Copper (WP 0172, Table 1, Item 66) Qty: 1 Materials/Parts (cont.) Washer, Lock 9/16 Reg (WP 0172, Table 1, Item 54) Qty: 1 Washer, Seal (WP 0172, Table 1, Item 18) Qty: 8 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Front cover removed (WP 0032) Fuel injection tubes removed (WP 0049)
0044-1
TM 5-3810-305-23
0044
REMOVAL
NOTE
Hold camshaft gear from moving when checking injection pump drive gear backlash. Gear backlash limit is 0.003 to 0.013 inch (0.08 to 0.33 mm). 1. 2. Use dial indicator on tooth of injection pump drive gear and check for excessive injection pump drive gear backlash. If injection pump drive gear backlash exceeds limit, replace injection pump drive gear and/or camshaft gear.
NOTE
Number 1 cylinder must be at Top Dead Center (TDC) before removing pump. 3. 4. 5. Barring engine, slowly push on engine timing pin (Figure 1, Item 1) until pin engages. Number 1 cylinder is now at TDC. Disengage engine timing pin (Figure 1, Item 1).
1
M0269105
Figure 1.
Injection Pump Removal.
0044-2
TM 5-3810-305-23
0044
REMOVAL - Continued
NOTE
Injection pump driveshaft must be locked before removing injection pump. 6. 7. 8. Loosen injection pump driveshaft lockscrew (Figure 2, Item 2) on fuel injection pump (Figure 2, Item 1). Reposition locked timing seal (Figure 2, Item 3). Tighten injection pump lockscrew (Figure 2, Item 2) to 22 ft-lb (30 Nm).
2
Figure 2. Injection Pump Removal.
M0270105
NOTE
Hold drive gear steady to prevent locked injection pump from rotating during drive gear removal. 9. Remove drive gear mounting nut (Figure 3, Item 2) and lockwasher (Figure 3, Item 3) from injection pump drive gear (Figure 3, Item 1). Discard lockwasher.
1 2 3
M0271105
Figure 3.
0044-3
TM 5-3810-305-23
0044
REMOVAL - Continued 10. 11. Using a puller, remove injection pump drive gear from engine (Figure 4, Item 1). Remove fuel injection pump capscrew (Figure 4, Item 2) from rear bracket (Figure 4, Item 3).
1 2
3
Figure 4. 12. 13. Injection Pump Removal.
M0272105
Align marks (Figure 5, Items 1 and 5) on injection pump mounting flange (Figure 5, Item 2) and gear housing (Figure 5, Item 4). Remove three flange nuts (Figure 5, Item 3) from mounting studs.
1 2
M0273105
Figure 5.
0044-4
TM 5-3810-305-23
0044
REMOVAL - Continued 14. 15. Remove injection pump (Figure 6, Item 2) with drive gear key (Figure 6, Item 1) in place from engine (Figure 6, Item 4). Remove gasket (Figure 6, Item 3) from engine (Figure 6, Item 4). Discard gasket.
2 3
Figure 6. END OF TASK Injection Pump Removal.
M0274105
0044-5
TM 5-3810-305-23
0044
DISASSEMBLY
CAUTION
Rebuild and calibration of pumps must be performed by qualified personnel using the appropriate special equipment. However, there are a number of external repairs that can be performed on injection pump without affecting calibration. Failure to follow this caution may result in damage to equipment.
NOTE
Mark shaft position to housing. 1. Remove driveshaft lockscrew (Figure 7, Item 3) and washer (Figure 7, Item 2) from injection pump (Figure 7, Item 1).
2
M1508105
Figure 7. Injection Pump Disassembly.
0044-6
TM 5-3810-305-23
0044
DISASSEMBLY - Continued 2. Remove o-ring (Figure 8, Item 2) from driveshaft lockscrew (Figure 8, Item 1). Discard o-ring.
M1509105
Figure 8. 3. 4.
Injection Pump Disassembly.
Remove four banjo bolts (Figure 9, Item 1), eight copper washers (Figure 9, Item 3) and four fittings (Figure 9, Item 7) from injection pump (Figure 9, Item 2). Discard copper washers. Remove solenoid with plunger (Figure 9, Item 4), spring (Figure 9, Item 6), and o-ring (Figure 9, Item 5) from injection pump (Figure 9, Item 2). Discard o-ring.
5,6 4
Figure 9.
3
M1510105
0044-7
TM 5-3810-305-23
0044
DISASSEMBLY - Continued 5. 6. Remove orifice bleed fitting (Figure 10, Item 1) and washer (Figure 10, Item 2) from injection pump (Figure 10, Item 5). Remove screw assembly (Figure 10, Item 4) and washer (Figure 10, Item 3) from injection pump (Figure 10, Item 5).
3 4
5
Figure 10. Injection Pump Disassembly. 7.
M1511105
Remove inlet fitting (Figure 11, Item 1), washer (Figure 11, Item 2), and filter (Figure 11, Item 3) from injection pump (Figure 11, Item 4).
2,3
M1512105
0044-8
TM 5-3810-305-23
0044
DISASSEMBLY - Continued 8. Remove locknut (Figure 12, Item 2) and throttle lever kit (Figure 12, Item 1). Discard locknut.
M1513105
Figure 12. 9.
Remove locknut (Figure 13, Item 2), washer (Figure 13, Item 3), shutoff lever (Figure 13, Item 4), spring (Figure 13, Item 5), and guide (Figure 13, Item 1) from injection pump. Discard locknut.
2 3 1 4
M1514105
Figure 13.
0044-9
TM 5-3810-305-23
0044
DISASSEMBLY - Continued 10. Remove plug (Figure 14, Item 7) and washer (Figure 14, Item 1) from spring cap (Figure 14, Item 2) on injection pump (Figure 14, Item 4).
WARNING
Remove cap slowly. Cap is under spring tension. Failure to follow this warning may cause injury or death to personnel.
NOTE
Record the number of shims for use in assembly. 11. Remove spring cap (Figure 14, Item 2) and o-ring (Figure 14, Item 3) slowly and remove spring (Figure 14, Item 5) and shims (Figure 14, Item 6). Discard o-ring.
2 3
5 7 6
Figure 14. Injection Pump Disassembly. 12. Remove pressure end cap (Figure 15, Item 1) and o-ring (Figure 15, Item 2) from timing housing (Figure 15, Item 3). Discard o-ring.
M1515105
0044-10
TM 5-3810-305-23
0044
DISASSEMBLY - Continued
2 3
M1516105
Figure 15. 13. 14. 15.
Remove cap nut (Figure 16, Item 4) and sealing washer (Figure 16, Item 5) from timing housing (Figure 16, Item 8). Remove locating fitting (Figure 16, Item 1), o-rings (Figure 16, Item 2), and ball (Figure 16, Item 3) from timing housing (Figure 16, Item 8). Discard o-rings. Remove timing housing (Figure 16, Item 8) and gasket (Figure 16, Item 7) from injection pump (Figure 16, Item 6). Discard gasket.
3 4
5 2 6
7
M1517105
0044-11
TM 5-3810-305-23
0044
NOTE
Mark position of locknut on idle screw to aid in assembly. 16. 17. 18. Remove screw assembly (Figure 17, Item 4) and washer (Figure 17, Item 5) from injection pump (Figure 17, Item 6). Remove low idle screw (Figure 17, Item 3), washer (Figure 17, Item 2), and locknut (Figure 17, Item 1) from injection pump (Figure 17, Item 6). Discard locknut. Remove return fitting (Figure 17, Item 8) and washer (Figure 17, Item 7) from injection pump (Figure 17, Item 6).
3 4
5 6
Figure 17. Injection Pump Disassembly. END OF TASK
M1518105
0044-12
TM 5-3810-305-23
0044
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. 3. Install return fitting (Figure 18, Item 8) and washer (Figure 18, Item 7) on injection pump (Figure 18, Item 6). Install new locknut (Figure 18, Item 1), washer (Figure 18, Item 2), and idle screw (Figure 18, Item 3). Align marks made during disassembly. Install washer (Figure 18, Item 5) and screw assembly (Figure 18, Item 4) on injection pump (Figure 18, Item 6). Tighten screw assembly to 65 in-lb. (7.3 Nm).
3 4
5 6
Figure 18. Injection Pump Assembly.
M1518105
0044-13
TM 5-3810-305-23
0044
ASSEMBLY - Continued 4. 5. 6. 7. Position new gasket (Figure 19, Item 7) and timing housing (Figure 19, Item 8) on injection pump (Figure 19, Item 6). Install ball (Figure 19, Item 3), new o-rings (Figure 19, Item 2), and locating fitting (Figure 19, Item 1) on injection pump (Figure 19, Item 6). Do not tighten locating fitting at this time. Install cap nut (Figure 19, Item 4) and sealing washer (Figure 19, Item 5) onto timing housing (Figure 19, Item 8). Tighten cap nut (Figure 19, Item 4) and locating fitting (Figure 19, Item 1) alternately and evenly until a torque of 22 ft-lb (30 Nm) is obtained on cap nut and a torque of 29 ft-lb (39 Nm) is obtained on locating fitting.
3 4
5 2 6
7
M1517105
0044-14
TM 5-3810-305-23
0044
ASSEMBLY - Continued 8. Install new o-ring (Figure 20, Item 2) and pressure end cap (Figure 20, Item 1) into timing housing (Figure 20, Item 3). Tighten pressure end cap to 17.5 ft-lb (23.7 Nm).
2 3
M1516105
Figure 20. 9.
Injection Pump Assembly.
Install spring cap (Figure 21, Item 2), new o-ring (Figure 21, Item 3), spring (Figure 21, Item 5), and shims (Figure 21, Item 6) onto timing housing (Figure 21, Item 4), using the number of shims recorded during disassembly. Tighten spring cap to 17.5 ft-lb (23.7 Nm). Install plug (Figure 21, Item 7) into spring cap (Figure 21, Item 2).
10.
2 3
5 7 6
M1515105
0044-15
TM 5-3810-305-23
0044
ASSEMBLY - Continued 11. 12. 13. Install guide (Figure 22, Item 1), spring (Figure 22, Item 5), and shutoff lever (Figure 22, Item 4) on injection pump. Position return spring (Figure 22, Item 5) with one end contacting boss on governor cover. Hook free end around shutoff lever (Figure 22, Item 4). Rotate lever clockwise until it engages flats on shutoff shaft. Install washer (Figure 22, Item 3) and new locknut (Figure 22, Item 2). Tighten locknut to 30 in-lb. (3.4 Nm).
2 3 1 4
M1514105
Figure 22. Injection Pump Assembly. 14. Install throttle lever kit (Figure 23, Item 1) and new locknut (Figure 23, Item 2). Stop arm in lever kit must slide over flats of shaft. Tighten locknut to 30 in-lb. (3.4 Nm).
M1513105
0044-16
TM 5-3810-305-23
0044
ASSEMBLY - Continued 15. Install filter (Figure 24, Item 3), washer (Figure 24, Item 2), and inlet fitting (Figure 24, Item 1) on injection pump (Figure 24, Item 4). Tighten inlet fitting to 38 ft-lb (52 Nm).
2,3
M1512105
Figure 24. 16. 17.
Install washer (Figure 25, Item 2) and orifice bleed fitting (Figure 25, Item 1) on injection pump (Figure 25, Item 5). Tighten orifice bleed fitting to 15 ft-lb (20 Nm). Install washer (Figure 25, Item 4) and screw assembly (Figure 25, Item 3) on injection pump (Figure 25, Item 5). Tighten screw assembly to 40 in-lb. (28 Nm).
3 4
5
M1511105
0044-17
TM 5-3810-305-23
0044
ASSEMBLY - Continued 18. 19. Install new o-ring (Figure 26, Item 6), spring (Figure 26, Item 5), and solenoid with plunger (Figure 26, Item 4) in injection pump (Figure 26, Item 2). Tighten solenoid to 11 ft-lb. (15 Nm). Install four fittings (Figure 26, Item 7), eight new copper washers (Figure 26, Item 3), and four banjo bolts (Figure 26, Item 1) on injection pump (Figure 26, Item 2). Tighten four banjo bolts to 23 ft-lb (31 Nm).
5,6 4
3
M1510105
Figure 26. Injection Pump Assembly. 20. Install new o-ring (Figure 27, Item 2) on driveshaft lockscrew (Figure 27, Item 1).
M1509105
0044-18
TM 5-3810-305-23
0044
ASSEMBLY - Continued 21. Position shaft as marked during disassembly, and install washer (Figure 28, Item 2) and lockscrew (Figure 28, Item 3) into injection pump (Figure 28, Item 1) to lock.
2
M1508105
Figure 28. END OF TASK INSTALLATION
NOTE
Number 1 cylinder must be at Top Dead Center (TDC) before installing injection pump. 1. Barring engine slowly, push in engine timing pin (Figure 29, Item 1) until pin engages.
1
M0269105
Figure 29.
Injection Pump Installation.
0044-19
TM 5-3810-305-23
0044
INSTALLATION - Continued 2. 3. 4. 5. Number 1 cylinder is now at TDC. Disengage engine timing pin. Install new gasket (Figure 30, Item 3) on engine (Figure 30, Item 4). Install timed and locked injection pump (Figure 30, Item 2) with drive gear key (Figure 30, Item 1) on engine (Figure 30, Item 4).
2 3
Figure 30. 6. Injection Pump Installation.
M0274105
Install three flange nuts (Figure 31, Item 1) finger tight on mounting studs.
M0287105
Figure 31.
0044-20
TM 5-3810-305-23
0044
INSTALLATION - Continued 7. 8. 9. Install injection pump drive gear (Figure 32, Item 1) onto driveshaft, aligning keyway in injection pump drive gear with key in shaft and aligning mark on injection pump drive gear with timing mark on camshaft gear. Install new lockwasher (Figure 32, Item 3) and drive gear mounting nut (Figure 32, Item 2) on injection pump drive gear (Figure 32, Item 1). Tighten nut to 11 to 15 ft-lb (15 to 20 Nm).
1 2 3
M0271105
Figure 32. 10. 11.
When installing previously removed injection pump, align matchmarks. When new or rebuilt injection pump is installed, align injection pump mounting flange (Figure 33, Item 1) mark to gear housing (Figure 33, Item 2) mark.
1
M0288105
Figure 33.
0044-21
TM 5-3810-305-23
0044
INSTALLATION - Continued 12. Install fuel injection pump capscrew (Figure 34, Item 2) on fuel injection pump (Figure 34, Item 1) to rear bracket (Figure 34, Item 3).
1 2
3
Figure 34. 13. 14. 15. 16. 17. Injection Pump Installation.
M0272105
Tighten three flange nuts to 18 ft-lb (24 Nm). Tighten rear bracket capscrew to 18 ft-lb (24 Nm). Loosen injection pump driveshaft lockscrew. Reposition locked timing seal to unlocked position. Tighten injection pump driveshaft lockscrew to 7 ft-lb (10 Nm).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install fuel injection tubes (WP 0049). Install front cover (WP 0032). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0044-22
TM 5-3810-305-23
0045
FIELD MAINTENANCE FUEL LIFT PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Gasket (WP 0172, Table 1, Item 85) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0045-1
TM 5-3810-305-23
0045
REMOVAL 1. 2. Disconnect fittings (Figure 1, Items 1 and 2) from lift pump (Figure 1, Item 4). Remove two capscrews (Figure 1, Item 3), lift pump (Figure 1, Item 4), and gasket (Figure 1, Item 5) from engine (Figure 1, Item 6). Remove all gasket material from mounting surfaces. Discard gasket.
4
Figure 1. END OF TASK CLEANING 1. 2.
3
Lift Pump Removal.
M0291105
Clean parts IAW General Maintenance Instructions (WP 0162). Clean parts and surfaces with solvent cleaning compound.
END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect camshaft lever and return spring for wear. Inspect diaphragm by blocking fuel inlet line with finger and operating priming lever. A properly operating pump will have suction that will not bleed down until finger is removed from inlet.
END OF TASK
0045-2
TM 5-3810-305-23
0045
INSTALLATION 1. 2. Install new gasket (Figure 2, Item 5), lift pump (Figure 2, Item 4), and two capscrews (Figure 2, Item 3) to engine (Figure 2, Item 6). Tighten two capscrews to 18 ft-lb (24 Nm). Connect fittings (Figure 2, Items 1 and 2) to lift pump (Figure 2, Item 4).
4
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
3
Lift Pump Installation.
M0291105
0045-3/4 blank
TM 5-3810-305-23
0046
FIELD MAINTENANCE AIR CLEANER ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock M4 (WP 0172, Table 1, Item 168) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0051 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Hood support removed (WP 0120)
0046-1
TM 5-3810-305-23
0046
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. 3. Remove cold start cylinder, if so equipped (WP 0051). Loosen four clamps (Figure 1, Item 4). Remove elbows (Figure 1, Items 1 and 3), four clamps (Figure 1, Item 4), and tube (Figure 1, Item 2) from vehicle.
3 4
M0001105
Figure 1. Air Cleaner Removal.
0046-2
TM 5-3810-305-23
0046
REMOVAL - Continued 4. 5. 6. Remove two screws (Figure 2, Item 3) and nuts (Figure 2, Item 1) to loosen two mounting bands (Figure 2, Item 2). Remove air cleaner (Figure 2, Item 4) from vehicle. Remove two nuts (Figure 2, Item 8) and capscrews (Figure 2, Item 7) to disconnect bracket (Figure 2, Item 6) from bracket (Figure 2, Item 5).
2
3 8
7
5
M0002105
Figure 2.
Air Cleaner Removal.
0046-3
TM 5-3810-305-23
0046
REMOVAL - Continued 7. 8. 9. 10. Remove four nuts (Figure 3, Item 8), lockwashers (Figure 3, Item 9), capscrews (Figure 3, Item 7), and two mounting bands (Figure 3, Item 6) from bracket (Figure 3, Item 3). Discard lockwashers. Remove two nuts (Figure 3, Item 10), capscrews (Figure 3, Item 2), and bracket (Figure 3, Item 11) from vehicle. Remove two capscrews (Figure 3, Item 4), washers (Figure 3, Item 5), and bracket (Figure 3, Item 3) from vehicle. Remove two nuts (Figure 3, Item 1), lockwashers (Figure 3, Item 14), vehicle screws (Figure 3, Item 13), and restriction indicator (Figure 3, Item 12) from hood support. Discard lockwashers.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. Install restriction indicator (Figure 3, Item 12), two vehicle screws (Figure 3, Item 13), new lockwashers (Figure 3, Item 14), and nuts (Figure 3, Item 1) on hood support. Install bracket (Figure 3, Item 3), two washers (Figure 4, Item 5), and capscrews (Figure 3, Item 4) on vehicle. Install bracket (Figure 3, Item 11), two capscrews (Figure 3, Item 2), and nuts (Figure 3, Item 10) on vehicle. Install two mounting bands (Figure 3, Item 6), four capscrews (Figure 3, Item 7), new lockwashers (Figure 3, Item 9), and nuts (Figure 3, Item 8) to bracket (Figure 3, Item 3).
0046-4
TM 5-3810-305-23
0046
2 1 11 10 9 14 8 7 6 13 12
M0003105
Figure 3. 5. 6.
Air Cleaner Maintenance.
Install two capscrews (Figure 4, Item 7) and nuts (Figure 5, Item 8) to connect bracket (Figure 4, Item 6) on bracket (Figure 5, Item 5). Install air cleaner (Figure 4, Item 4) and tighten two mounting bands (Figure 4, Item 2) by installing two nuts (Figure 5, Item 1) and screws (Figure 4, Item 3).
2
3 8
7
5
M0002105
Figure 4.
Air Cleaner Installation.
0046-5
TM 5-3810-305-23
0046
INSTALLATION - Continued 7. 8. 9. Install tube (Figure 5, Item 2), four clamps (Figure 6, Item 4), and elbows (Figure 5, Items 1 and 3). Tighten four clamps (Figure 5, Item 4). Install cold start cylinder, if so equipped (WP 0051).
3 4
M0001105
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install hood support (WP 0120).
Air Cleaner Installation.
0046-6
TM 5-3810-305-23
0047
FIELD MAINTENANCE FUEL TANK MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Gasket (WP 0172, Table 1, Item 2) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 1) Qty: 5 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL 1. 2. Remove drain plug (Figure 1, Item 5) and drain fuel tank (Figure 1, Item 1). Remove four nuts (Figure 1, Item 3), washers (Figure 1, Item 4), capscrews (Figure 1, Item 2), and bracket (Figure 1, Item 6) from fuel tank (Figure 1, Item 1).
1 2
6 3 4
5
Figure 1. Fuel Tank Removal.
M0265105
0047-1
TM 5-3810-305-23
0047
REMOVAL - Continued
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 3. Disconnect fuel lines (Figure 2, Items 1 and 3) from fuel tank (Figure 2, Item 7).
NOTE
Tag all wire assemblies before disconnecting to aid installation. Remove tags following maintenance. 4. 5. Remove nut (Figure 2, Item 10), lockwasher (Figure 2, Item 11), screw (Figure 2, Item 8), lockwasher (Figure 2, Item 9), and disconnect sending unit harness (Figure 2, Item 2). Discard lockwashers. Remove four nuts (Figure 2, Item 4), washers (Figure 2, Item 5), two straps (Figure 2, Item 6), and fuel tank (Figure 2, Item 7) from vehicle.
1 10,11 2
3 8,9 4 5 7
6
Figure 2. Fuel Tank Removal. END OF TASK DISASSEMBLY 1. 2.
M0266105
Remove elbows (Figure 3, Items 1 and 3), bushing (Figure 3, Item 2), and check valve (Figure 3, Item 4) from fuel tank. Remove five machine screws (Figure 3, Item 6), lockwashers (Figure 3, Item 7), sending unit (Figure 3, Item 5) and gasket from fuel tank. Discard lockwashers and gasket.
0047-2
TM 5-3810-305-23
0047
1 2 6,7 3 4
5
M0267105
Figure 3. 3. 4.
Fuel Tank Disassembly.
Unscrew cap (Figure 4, Item 1) and remove fill screen (Figure 4, Item 2) from fuel tank. Unhook chain (Figure 4, Item 3) at clip (Figure 4, Item 4) and remove cap from fuel tank.
2 1
4
3
Fuel Tank Disassembly.
M0268105
0047-3
TM 5-3810-305-23
0047
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. Hook chain (Figure 5, Item 3) on clip (Figure 5, Item 4). Install fill screen (Figure 5, Item 2) and cap (Figure 5, Item 1) on fuel tank.
2 1
4
Figure 5.
3
Fuel Tank Assembly.
M0268105
0047-4
TM 5-3810-305-23
0047
ASSEMBLY - Continued 3. 4. Install sending unit (Figure 6, Item 5), new gasket, four new lockwashers (Figure 6, Item 7), and machine screws (Figure 6, Item 6) on fuel tank. Install check valve (Figure 6, Item 4), bushing (Figure 6, Item 2), and elbows (Figure 6, Items 1 and 3).
1 2 6,7 3 4
5
M0267105
Fuel Tank Assembly.
0047-5
TM 5-3810-305-23
0047
INSTALLATION 1. 2. 3. 4. Position fuel tank (Figure 7, Item 7) and install two straps (Figure 7, Item 6), four washers (Figure 7, Item 5), and nuts (Figure 7, Item 4). Install screw (Figure 7, Item 8) and new lockwasher (Figure 7, Item 9). Position ground wire and install lockwasher and screw. Connect sending unit harness (Figure 7, Item 2) and install new lockwasher (Figure 7, Item 11) and nut (Figure 7, Item 10) on fuel tank (Figure 7, Item 7). Connect fuel lines (Figure 7, Items 1 and 3) on fuel tank (Figure 7, Item 7).
1 10,11 2
3 8,9 4 5 7
6
Figure 7. Fuel Tank Installation.
M0266105
0047-6
TM 5-3810-305-23
0047
INSTALLATION - Continued 5. 6. Install bracket (Figure 8, Item 6), four capscrews (Figure 8, Item 2), washers (Figure 8, Item 4), and nuts (Figure 8, Item 3). Install drain plug (Figure 8, Item 5) and fill fuel tank (Figure 8, Item 1).
1 2
6 3 4
5
Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Fuel Tank Installation.
M0265105
0047-7/8 blank
TM 5-3810-305-23
0048
FIELD MAINTENANCE FUEL LINES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Strap, Tiedown, Electrical Component (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine hood removed (WP 0118)
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. 1. Disconnect fuel lines (Figure 1, Items 1 and 3) at elbows (Figure 1, Item 2) on top of fuel tank (Figure 1, Item 4).
M0260105
Figure 1.
Fuel Lines Removal.
0048-1
TM 5-3810-305-23
0048
REMOVAL - Continued 2. Remove two nuts (Figure 2, Item 1), washers (Figure 2, Item 3), clamps (Figure 2, Items 2 and 4), and tiedown strap (Figure 2, Item 5) from fuel lines. Discard tiedown strap.
3 5
Figure 2. 3. 4.
4
M0261105
Fuel Lines Removal.
Remove fuel line (Figure 3, Item 2) from fuel lift pump (Figure 3, Item 1). Remove clamp (Figure 3, Item 3) from fuel line (Figure 3, Item 5) and fuel return line (Figure 3, Item 4).
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Install clamp (Figure 3, Item 3) to fuel line (Figure 3, Item 5) and fuel return line (Figure 3, Item 4). Install fuel line (Figure 3, Item 2) to fuel lift pump (Figure 3, Item 1).
0048-2
TM 5-3810-305-23
0048
1 2
3 4
5
M0263105
Figure 3. 3.
Fuel Lines Installation.
Install two nuts (Figure 4, Item 1), washers (Figure 4, Item 3), clamps (Figure 4, Items 4 and 2), and new tiedown strap (Figure 4, Item 5) to fuel lines.
3 5
Figure 4.
4
M0261105
Fuel Lines Installation.
0048-3
TM 5-3810-305-23
0048
INSTALLATION - Continued 4. Connect fuel lines (Figure 5, Items 1 and 3) to elbows (Figure 5, Item 2) on top of fuel tank (Figure 5, Item 4).
M0260105
Figure 5. Fuel Lines Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine hood (WP 0118). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0048-4
TM 5-3810-305-23
0049
FIELD MAINTENANCE FUEL INJECTION TUBES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting (WP 0171, Table 1, Item 36) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Seal, Banjo (WP 0172, Table 1, Item 60) Qty: 4 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Seal (WP 0172, Table 1, Item 18) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Throttle cable disconnected (WP 0052) 1
0049-1
TM 5-3810-305-23
0049
REMOVAL High-Pressure Tubes
NOTE
Before removal of fuel injection tubes, have suitable container available. Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. Remove four capscrews (Figure 1, Item 1) and tube clamps (Figure 1, Item 2) from high-pressure tubes (Figure 1, Items 3, 4, 5, and 6) from injection pump (Figure 1, Item 7).
2 1
6
Figure 1. High-Pressure Tubes Removal.
M0252105
0049-2
TM 5-3810-305-23
0049
REMOVAL - Continued High-Pressure Tubes - Continued
NOTE
Mark on four tags, No. 1 cylinder through No. 4 cylinder, to aid in installation. 2. Disconnect four high-pressure tubes (Figure 2, Items 1, 2, 3, and 4) from four injectors (Figure 2, Item 5). Make sure marked tags match proper cylinders.
2 1
M0253105
Figure 2.
High-Pressure Tubes Removal.
0049-3
TM 5-3810-305-23
0049
REMOVAL - Continued High-Pressure Tubes - Continued
CAUTION
Use a wrench on injection pump delivery valves when removing high-pressure tubes to prevent damage to injection pump delivery valves. 3. 4. Remove No. 3 cylinder high-pressure tube (Figure 3, Item 3) and No. 4 cylinder high-pressure tube (Figure 3, Item 2) from injection pump (Figure 3, Item 5). Remove No. 1 cylinder high-pressure tube (Figure 3, Item 4) and No. 2 cylinder high-pressure tube (Figure 3, Item 1) from injection pump (Figure 3, Item 5).
5 3
4
Figure 3. High-Pressure Tubes Removal.
M0254105
0049-4
TM 5-3810-305-23
0049
REMOVAL - Continued
Low-Pressure Tubes
NOTE
Before removal of fuel injection tubes, have suitable container available. Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. Disconnect two fuel pressure sender hoses (Figure 4, Items 6 and 7) from banjo fittings (Figure 4, Items 3 and 5). Remove two banjo screws (Figure 4, Items 8 and 9) and four copper seals (Figure 4, Items 2 and 4) from engine (Figure 4, Item 1). Discard four copper seals.
8
Figure 4.
7
Low-Pressure Tubes Removal.
M0255105
0049-5
TM 5-3810-305-23
0049
REMOVAL - Continued Low-Pressure Tubes - Continued
CAUTION
Use a wrench on lift pump connection while removing low-pressure tube to prevent damage to lift pump connection. 3. Loosen nut (Figure 5, Item 1) and remove low-pressure tube (Figure 5, Item 2) from lift pump (Figure 5, Item 3).
M0256105
Figure 5. Low-Pressure Tubes Removal.
0049-6
TM 5-3810-305-23
0049
REMOVAL - Continued Low-Pressure Tubes - Continued 4. 5. Loosen two nuts (Figure 6, Items 2 and 5) and remove low-pressure tube (Figure 6, Item 4) from injection pump (Figure 6, Item 6) and tee fitting (Figure 6, Item 3). Loosen nut (Figure 6, Item 7) and remove low-pressure tube assembly (Figure 6, Item 1) from injection pump (Figure 6, Item 6).
4 7
6
Figure 6.
5
M0257105
Low-Pressure Tubes Removal.
0049-7
TM 5-3810-305-23
0049
REMOVAL - Continued
Fuel Drain Tubes
NOTE
Before removal of fuel injection tubes, have suitable container available. Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. Remove four banjo connector screws (Figure 7, Item 3) and banjo connector seals (Figure 7, Item 2) from injectors (Figure 7, Item 1). Discard four banjo connector seals.
1
M0258105
Figure 7. Fuel Drain Tubes Removal.
0049-8
TM 5-3810-305-23
0049
REMOVAL - Continued Fuel Drain Tubes - Continued 2. 3. Remove fuel manifold tube (Figure 8, Item 3) from male union tee (Figure 8, Item 4). Remove two capscrews (Figure 8, Item 6) from engine (Figure 8, Item 2).
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. 4. Remove fuel drain hose (Figure 8, Item 1) from rubber hose (Figure 8, Item 5) and injection pump (Figure 8, Item 7). Remove fuel drain hose from vehicle.
7 6
M0259105
Fuel Drain Tubes Removal.
0049-9
TM 5-3810-305-23
0049
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Fuel Drain Tubes 1. 2. 3. Install fuel drain tube (Figure 9, Item 1) to rubber hose (Figure 9, Item 5) and injection pump (Figure 9, Item 7). Install two capscrews (Figure 9, Item 6) to engine (Figure 9, Item 2). Tighten two capscrews to 18 ft-lb (24 Nm). Install fuel manifold tube (Figure 9, Item 3) to male union tee (Figure 9, Item 4).
7 6
Figure 9.
M0259105
Fuel Drain Tubes Installation.
0049-10
TM 5-3810-305-23
0049
INSTALLATION - Continued Fuel Drain Tubes - Continued 4. Install four new banjo connector seals (Figure 10, Item 2) and banjo connector screws (Figure 10, Item 3) to injectors (Figure 10, Item 1). Tighten four banjo connector screws to 6.5 ft-lb (8.8 Nm).
1
M0258105
Figure 10.
Fuel Drain Tubes Installation.
0049-11
TM 5-3810-305-23
0049
Low-Pressure Tubes
CAUTION
Make sure injection pump connection is held securely when tightening low-pressure tubes. Failure to follow this caution may result in damage to equipment. 1. 2. Install low-pressure tube assembly (Figure 11, Item 1) to injection pump (Figure 11, Item 6) and tighten nut (Figure 11, Item 7). Install low-pressure tube (Figure 11, Item 4) to injection pump (Figure 11, Item 6) and tee fitting (Figure 11, Item 3) and tighten two nuts (Figure 11, Items 2 and 5).
4 7
5
M0257105
Figure 11. Low-Pressure Tubes Installation.
0049-12
TM 5-3810-305-23
0049
INSTALLATION - Continued Low-Pressure Tubes - Continued
CAUTION
Make sure lift pump connection is held securely when tightening low-pressure tubes. Failure to follow this caution may result in damage to equipment. 3. Install low-pressure tube (Figure 12, Item 2) to lift pump (Figure 12, Item 3) and tighten nut (Figure 12, Item 1).
M0256105
Figure 12.
Low-Pressure Tubes Installation.
0049-13
TM 5-3810-305-23
0049
INSTALLATION - Continued Low-Pressure Tubes - Continued 4. 5. Install four new copper seals (Figure 13, Items 1 and 3), two banjo fittings (Figure 13, Items 2 and 4), and two banjo screws (Figure 13, Items 7 and 8) to filter head. Tighten two banjo fittings to 18 ft-lb (24 Nm). Connect two fuel pressure sender hoses (Figure 13, Items 5 and 6) to banjo fittings (Figure 13, Items 7 and 8).
M0262105
Figure 13. Low-Pressure Tubes Installation.
0049-14
TM 5-3810-305-23
0049
High-Pressure Tubes
CAUTION
Make sure injection pump connections are held securely when tightening high-pressure tubes. Failure to follow this caution may result in damage to equipment.
NOTE
Make sure high-pressure lines are correct for engine. Check part number tag on tubes. 1. Connect four high-pressure tubes (Figure 14, Items 1, 2, 3, and 4) to four injectors (Figure 14, Item 5). Make sure marked tags match proper cylinders.
2 1
M0253105
Figure 14.
High-Pressure Tubes Installation.
0049-15
TM 5-3810-305-23
0049
INSTALLATION - Continued High-Pressure Tubes - Continued 2. 3. 4. Connect No. 3 cylinder high-pressure tube (Figure 15, Item 5) and No. 4 cylinder high-pressure tube (Figure 15, Item 4) to injection pump (Figure 15, Item 7). Connect No. 1 cylinder high-pressure tube (Figure 15, Item 6) and No. 2 cylinder high-pressure tube (Figure 15, Item 3) to injection pump (Figure 15, Item 7). Install four capscrews (Figure 15, Item 1) and tube clamps (Figure 15, Item 2) to high-pressure tubes.
2 1
6
Figure 15. High-Pressure Tubes Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect throttle cable (WP 0052). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
M0252105
0049-16
TM 5-3810-305-23
0050
FIELD MAINTENANCE FUEL FILTER HEAD ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Oil Filter, Strap (WP 0171, Table 1, Item 32) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Lubricating Oil, Preservative and Break-In (WP 0170, Table 1, Item 45) Qty: 1 O-Ring (WP 0172, Table 1, Item 70) Qty: 1 Materials/Parts (cont.) Packing, Preformed (WP 0172, Table 1, Item 69) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Fuel injection tubes disconnected (WP 0049)
REMOVAL 1. Remove secondary fuel filter (Figure 1, Item 3) and primary fuel filter (Figure 1, Item 2) from fuel filter head (Figure 1, Item 1).
1 2
3
Figure 1. Fuel Filters and Head Assembly Removal.
M0246105
0050-1
TM 5-3810-305-23
0050
REMOVAL - Continued 2. Remove preformed packing (Figure 2, Item 1), hexagon nut (Figure 2, Item 2), fuel filter head (Figure 2, Item 4), and o-ring (Figure 2, Item 3). Discard o-ring and preformed packing.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install new o-ring (Figure 2, Item 3), fuel filter head (Figure 2, Item 4), new preformed packing (Figure 2, Item 1), and hexagon nut (Figure 2, Item 2) to engine. Tighten hexagon nut to 24 ft-lb (33 Nm).
M0247105
Figure 2. Fuel Filters and Head Assembly Maintenance.
0050-2
TM 5-3810-305-23
0050
INSTALLATION - Continued 2. 3. Fill fuel filters with clean fuel and lubricate seal with clean oil. Install primary fuel filter (Figure 3, Item 2) and secondary fuel filter (Figure 3, Item 3) to fuel filter head (Figure 3, Item 1).
1 2
3
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect fuel injection tubes (WP 0049). Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Shut down engine (TM 5-3081-305-10). Place boom in resting position (TM 5-3810-305-10). Fuel Filters and Head Assembly Installation.
M0246105
0050-3/4 blank
TM 5-3810-305-23
0051
FIELD MAINTENANCE COLD START DEVICE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He M6 (WP 0172, Table 1, Item 138) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL 1. 2. 3. 4. 5. 6. Remove cold start cylinder, if equipped. Loosen screw (Figure 1, Item 9) securing cable end. Remove screw (Figure 1, Item 10), clamp (Figure 1, Item 2), and disconnect cable (Figure 1, Item 1). Disconnect tube fitting (Figure 1, Item 8) from elbow (Figure 1, Item 7). Remove elbow (Figure 1, Item 7) from valve (Figure 1, Item 3). Remove two nuts (Figure 1, Item 6), bracket (Figure 1, Item 5), valve (Figure 1, Item 3), and two capscrews (Figure 1, Item 4).
5 10 9
Figure 1.
6 8 7
M0248105
Cold Start Device Removal.
0051-1
TM 5-3810-305-23
0051
REMOVAL - Continued 7. Remove tube (Figure 2, Item 3) and fitting (Figure 2, Item 2) from cylinder head (Figure 2, Item 1).
M0249105
Figure 2. Cold Start Device Removal. 8. 9. Remove two nuts (Figure 3, Item 8), capscrews (Figure 3, Item 7), and bracket (Figure 3, Item 6) from vehicle. Remove two nuts (Figure 3, Item 1), capscrews (Figure 3, Item 3), bracket (Figure 3, Item 2), and clamp (Figure 3, Item 4) from vehicle.
2
3 8
7
5
M0002105
Figure 3. Cold Start Device Removal.
0051-2
TM 5-3810-305-23
0051
REMOVAL - Continued 10. Remove knob (Figure 4, Item 1), locknut (Figure 4, Item 3), washer (Figure 4, Item 4), and cable (Figure 4, Item 2) from vehicle. Discard locknut.
4
2
Cold Start Device Removal.
M0251105
0051-3
TM 5-3810-305-23
0051
INSTALLATION 1. 2. Install cable by positioning through opening on back wall of operator's compartment and through opening on instrument panel. Install washer (Figure 5, Item 4), new locknut (Figure 5, Item 3), and knob (Figure 5, Item 1) to cable (Figure 5, Item 2).
M0251105
Figure 5. Cold Start Device Installation. 3. 4. Install clamp (Figure 6, Item 4), bracket (Figure 6, Item 2), two capscrews (Figure 6, Item 3), and nuts (Figure 6, Item 1) on vehicle. Install bracket (Figure 6, Item 6), two capscrews (Figure 6, Item 7), and nuts (Figure 6, Item 8) on vehicle.
2
3 8
7
5
M0002105
Figure 6. Cold Start Device Installation.
0051-4
TM 5-3810-305-23
0051
NOTE
Atomizer opening at end of fitting must point straight up when installed in cylinder head. 5. Install fitting (Figure 7, Item 2) and tube (Figure 7, Item 3) to cylinder head (Figure 7, Item 1).
M0249105
Figure 7.
Cold Start Device Installation.
0051-5
TM 5-3810-305-23
0051
INSTALLATION - Continued 6. 7. 8. Install valve (Figure 8, Item 3), bracket (Figure 8, Item 5), two capscrews (Figure 8, Item 4), and nuts (Figure 8, Item 6) to bracket. Install elbow (Figure 8, Item 7) to valve (Figure 8, Item 3). Connect tube fitting (Figure 8, Item 8) to elbow (Figure 8, Item 7).
NOTE
Cable knob inside cab must be down when connecting cable to valve. 9. 10. 11. 12. Insert cable end into lever opening on valve (Figure 8, Item 3). Install clamp (Figure 8, Item 2) and screw (Figure 8, Item 10) to secure cable (Figure 8, Item 1). Position lever on valve to up position until just before lever springs back. Tighten screw (Figure 8, Item 9) to secure cable end (Figure 8, Item 1). Check that valve lever can perform full operating stroke.
5 10 9 8 7 6
M0248105
Figure 8. Cold Start Device Installation. 13. Install cold start cylinder, if equipped.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0051-6
TM 5-3810-305-23
0052
FIELD MAINTENANCE THROTTLE CONTROL MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter (WP 0172, Table 1, Item 154) Qty: 2 Pin, Spring (WP 0172, Table 1, Item 152) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Strap, Tiedown, Electrical Component (WP 0170, Table 1, Item 71) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 4 References WP 0054 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0052-1
TM 5-3810-305-23
0052
REMOVAL 1. 2. 3. 4. Slide open engine cover. Remove nut (Figure 1, Item 11) and disconnect throttle cable (Figure 1, Item 1) from fuel injection pump (Figure 1, Item 12). Remove two nuts (Figure 1, Item 8), washers (Figure 1, Item 6), capscrews (Figure 1, Item 4), clamp (Figure 1, Item 3), and shim (Figure 1, Item 5) from throttle cable (Figure 1, Item 1). Remove two nuts (Figure 1, Item 10), lockwashers (Figure 1, Item 9), capscrews (Figure 1, Item 7), and bracket (Figure 1, Item 2) from vehicle. Discard lockwashers.
3 1 2
12 11 5 10 9 8 7 6
M0539105
Figure 1. Throttle Control Removal. 5. Cut and discard tiedown straps (Figure 2, Item 1) as required.
M0540105
Figure 2. Throttle Control Removal.
0052-2
TM 5-3810-305-23
0052
REMOVAL - Continued 6. Remove nut (Figure 3, Item 2), washer (Figure 3, Item 3), clamp (Figure 3, Item 1) and detach throttle cable (Figure 3, Item 4) from vehicle.
2 1 3
4
Figure 3. 7. Throttle Control Removal.
M0541105
Remove two nuts (Figure 4, Item 5), washers (Figure 4, Item 4), lockwashers (Figure 4, Item 3), cover (Figure 4, Item 1), and washers (Figure 4, Item 2) from vehicle. Discard lockwashers.
5 4 3
M0542105
Figure 4.
Throttle Control Removal.
0052-3
TM 5-3810-305-23
0052
REMOVAL - Continued 8. Remove cotter pin (Figure 5, Item 5) and pin (Figure 5, Item 4) from end yoke (Figure 5, Item 3) and bell crank (Figure 5, Item 6). Discard cotter pin.
NOTE
DO NOT remove end yoke from throttle cable unless necessary. If removal is necessary, mark distance from end of cable prior to removal. 9. 10. 11. 12. 13. 14. 15. 16. Loosen nut (Figure 5, Item 2), if necessary, to remove end yoke (Figure 5, Item 3). Loosen nut (Figure 5, Item 22) and disconnect throttle cable (Figure 5, Item 1) from weldment. Pull throttle cable through opening in cab. Remove spring (Figure 5, Item 7) from hook (Figure 5, Item 10) and yoke (Figure 5, Item 3). Remove nut (Figure 5, Item 8), lockwasher (Figure 5, Item 9), and hook (Figure 5, Item 10). Discard lockwasher. Remove two nuts (Figure 5, Item 13), washers (Figure 5, Item 12), and capscrews (Figure 5, Item 11). Remove two nuts (Figure 5, Item 20), washers (Figure 5, Item 19), capscrews (Figure 5, Item 16), bell crank (Figure 5, Item 6), and pedal (Figure 5, Item 21) as an assembly. Remove bearing unit (Figure 5, Item 14) from pedal (Figure 5, Item 21). Remove two roll pins (Figure 5, Item 15), pedal (Figure 5, Item 21), bracket (Figure 5, Item 17), and bushing (Figure 5, Item 16) from bell crank (Figure 5, Item 6). Discard roll pins.
1 21 22
4 5 6
20 19 18 17 16 14 15 12 13 11 8 10 9
M0544105
Figure 5. Throttle Control Removal.
0052-4
TM 5-3810-305-23
0052
REMOVAL - Continued 17. Loosen nut (Figure 6, Item 1) and remove capscrew (Figure 6, Item 2) and nut, only if necessary.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install nut (Figure 6, Item 1) and capscrew (Figure 6, Item 2) and tighten nut to secure, if removed.
2 1
M0545105
Figure 6.
Throttle Control Maintenance.
0052-5
TM 5-3810-305-23
0052
INSTALLATION - Continued 2. 3. 4. 5. 6. 7. 8. 9. 10. Install pedal (Figure 7, Item 21), bushing (Figure 7, Item 16), bracket (Figure 7, Item 17), and two new roll pins (Figure 7, Item 15) on bell crank (Figure 7, Item 6). Install bearing unit (Figure 7, Item 14) on pedal (Figure 5, Item 21). Install bell crank (Figure 7, Item 6) and pedal (Figure 8, Item 21) as an assembly and secure with two capscrews (Figure 8, Item 16), washers (Figure 7, Item 19), and nuts (Figure 7, Item 20). Install two capscrews (Figure 7, Item 11), washers (Figure 7, Item 12), and nuts (Figure 7, Item 13). Install hook (Figure 7, Item 10), new lockwasher (Figure 7, Item 9) and nut (Figure 7, Item 8). Install spring (Figure 7, Item 7) on yoke (Figure 7, Item 3) and hook (Figure 7, Item 10). Install throttle cable (Figure 7, Item 1) and push through opening in cab. Position throttle cable in weldment and tighten nut (Figure 7, Item 22). Install end yoke (Figure 7, Item 3), if removed, and secure with nut (Figure 7, Item 2). Install to distance as marked. Install pin (Figure 7, Item 4) and new cotter pin (Figure 7, Item 5) to attach bell crank (Figure 7, Item 6) and end yoke (Figure 7, Item 3).
1 21 22
4 5 6
20 19 18 17 16
14 15
12 13 11
8 10 9
M0544105
Figure 7. Throttle Control Installation.
0052-6
TM 5-3810-305-23
0052
INSTALLATION - Continued 11. Install two washers (Figure 8, Item 2), cover (Figure 8, Item 1), two new lockwashers (Figure 8, Item 3), washers (Figure 8, Item 4), and nuts (Figure 8, Item 5).
5 4 3
M0542105
Figure 8. 12.
Throttle Control Installation.
Install clamp (Figure 9, Item 3), washer (Figure 9, Item 2), and nut (Figure 9, Item 1) on vehicle.
Figure 9.
0052-7
TM 5-3810-305-23
0052
INSTALLATION - Continued 13. Install new tiedown straps (Figure 10, Item 1) as required.
M0540105
Figure 10. Throttle Control Installation.
0052-8
TM 5-3810-305-23
0052
INSTALLATION - Continued 14. 15. Install bracket (Figure 11, Item 2), two capscrews (Figure 11, Item 7), new lockwashers (Figure 11, Item 9), and nuts (Figure 11, Item 10) on throttle cable (Figure 11, Item 1). Install shim (Figure 11, Item 5), clamp (Figure 11, Item 3), two capscrews (Figure 11, Item 4), washers (Figure 11, Item 6), and nuts (Figure 11, Item 8) to secure throttle cable (Figure 11, Item 1) to bracket (Figure 12, Item 2). Connect throttle cable (Figure 12, Item 1) to fuel injection pump (Figure 12, Item 12). Install nut (Figure 12, Item 11). Check throttle cable adjustment.
16. 17.
3 1 2
12 11 5 10 9 8 7 6
M0539105
0052-9
TM 5-3810-305-23
0052
ADJUSTMENT
NOTE
Throttle control adjustment will require two people to make the adjustment. 1. 2. Release nut (Figure 12, Item 2) on stop capscrew (Figure 12, Item 3) and screw all the way in. Adjust cable (Figure 12, Item 1) and linkage so that engine injection pump lever has full stop to stop travel. If full travel is not obtained, jam nuts on pedal end of cable conduit on cable end fittings must be adjusted to increase travel. Check cable (Figure 12, Item 1) to ensure that threads on cable ends are not entering wiper seals on ends of cable conduit. If one does, ball joint and yoke on cable ends must be readjusted to move threads on cable core further away from that wiper seal. Adjust pedal stop capscrew (Figure 12, Item 3) on floor of cab by loosening the nut (Figure 12, Item 2) and screwing capscrew in or out. Pedal should rest against stop capscrew (Figure 12, Item 3) just as arm on fuel injection pump touches high idle stop. Hold capscrew (Figure 12, Item 3) in position and tighten nut (Figure 12, Item 2). Check cable (Figure 12, Item 1) for free travel. If adjustment of low idle is required, loosen nut (Figure 12, Item 4) and turn capscrew (Figure 12, Item 5) to obtain required rpm. Tighten nut. Slide engine cover closed.
3.
4. 5. 6. 7. 8. 9.
1 2 5 3
4
M0547105
Throttle Control Adjustment.
0052-10
TM 5-3810-305-23
0052
FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0052-11/12 blank
TM 5-3810-305-23
0053
FIELD MAINTENANCE EXHAUST SYSTEM ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 148) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 14) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Engine hood support removed (WP 0118)
REMOVAL 1. Remove four nuts (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and capscrews (Figure 1, Item 5) from bracket (Figure 1, Item 1). Discard lockwashers.
2 3 5
Figure 1.
M0292105
Exhaust System Removal.
0053-1
TM 5-3810-305-23
0053
REMOVAL - Continued 2. 3. 4. 5. Remove four capscrews (Figure 2, Item 2) and exhaust tube (Figure 2, Item 3) from exhaust manifold (Figure 2, Item 5). Remove gasket (Figure 2, Item 4) from exhaust manifold (Figure 2, Item 5). Remove all gasket material from mounting surfaces. Discard gasket. Remove complete exhaust system from vehicle. Remove two nuts (Figure 2, Item 7), capscrews (Figure 2, Item 6), and clamp (Figure 2, Item 8) from muffler (Figure 2, Item 1) and exhaust tube (Figure 2, Item 3).
8 7 6
M0293105
Figure 2. Exhaust System Removal.
0053-2
TM 5-3810-305-23
0053
REMOVAL - Continued 6. Remove two nuts (Figure 3, Item 1), lockwashers (Figure 3, Item 2), clamp (Figure 3, Item 3), and exhaust tube (Figure 3, Item 5) from end of muffler (Figure 3, Item 4). Discard lockwashers.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install exhaust tube (Figure 3, Item 5) to end of muffler (Figure 3, Item 4) with clamp (Figure 3, Item 3), two new lockwashers (Figure 3, Item 2), and nuts (Figure 3, Item 1). Do not tighten at this time.
1,2
M0294105
Figure 3.
Exhaust System Maintenance.
0053-3
TM 5-3810-305-23
0053
INSTALLATION - Continued 2. 3. 4. Install exhaust tube (Figure 4, Item 3) to muffler (Figure 4, Item 1) with clamp (Figure 4, Item 8), two capscrews (Figure 4, Item 6), and nuts (Figure 4, Item 7). Position complete exhaust system on vehicle. Install new gasket (Figure 4, Item 4) between exhaust manifold (Figure 4, Item 5) and exhaust tube (Figure 4, Item 3). Secure with four capscrews (Figure 4, Item 2). Torque capscrews to 32 ft-lb (43 Nm).
8 7
Figure 4.
6
Exhaust System Installation.
M0293105
0053-4
TM 5-3810-305-23
0053
INSTALLATION - Continued 5. Install four capscrews (Figure 5, Item 5), washers (Figure 5, Item 4), new lockwashers (Figure 5, Item 3), and nuts (Figure 5, Item 2) to bracket (Figure 5, Item 1).
2 3 5
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install engine hood support (WP 0118). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).
M0292105
Exhaust System Installation.
0053-5/6 blank
TM 5-3810-305-23
0054
FIELD MAINTENANCE RADIATOR AND OIL COOLER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Antifreeze (WP 0170, Table 1, Item 2) Qty: 1 Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 1/4 Inch (WP 0172, Table 1, Item 110) Qty: 8 References WP 0162 Equipment Condition Upperstructure rotated 90 degrees out of the way (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine sliding hood removed (WP 0118) Drive belt removed (WP 0059) Alternator removed (WP 0062)
0054-1
TM 5-3810-305-23
0054
REMOVAL
WARNING
Cooling system is pressurized. Use extreme caution and proper protection when removing radiator cap after operating temperature is reached. Steam and hot gases will be escaping through the radiator cap; avoid being burned by these escaping gases. When removing cap, loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed. Failure to follow this warning may cause death or injury to personnel. 1. 2. 3. Position drain pan (28 qt [26.50 L] minimum capacity). Remove radiator cap (Figure 1, Item 1) and open drain valve (Figure 1, Item 2). Allow coolant to drain.
M0074105
Figure 1.
Radiator and Oil Cooler Removal.
0054-2
TM 5-3810-305-23
0054
REMOVAL - Continued
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 4. Turn dipstick cap 1/4 turn to safety notch.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all hoses, tubes, and ports to reduce fluid leakage and system contamination. Remove caps, plugs, and tags prior to installation. 5. Disconnect hose (Figure 2, Item 1) and hose (Figure 2, Item 3) on front of oil cooler (Figure 2, Item 2).
3 1
M0075105
Figure 2.
0054-3
TM 5-3810-305-23
0054
REMOVAL - Continued 6. Remove two clamps (Figure 3, Item 1), upper hose (Figure 3, Item 2), two clamps (Figure 3, Item 3), and lower hose (Figure 3, Item 4) from radiator and engine.
1
Figure 3. Radiator and Oil Cooler Removal.
M0076105
0054-4
TM 5-3810-305-23
0054
REMOVAL - Continued 7. 8. Remove overflow hose (Figure 4, Item 1) from clips on shroud (Figure 4, Item 2). Remove eight capscrews (Figure 4, Item 5), lockwashers (Figure 4, Item 4), and washers (Figure 4, Item 3) from shroud (Figure 4, Item 2). Remove and support shroud on engine. Discard lockwashers.
3,4,5
M0079105
Figure 4.
0054-5
TM 5-3810-305-23
0054
REMOVAL - Continued 9. 10. Remove two capscrews (Figure 5, Item 4) that attach rod ends (Figure 5, Item 5) on each side of radiator. Remove two nuts (Figure 5, Item 1), spacers (Figure 5, Item 2), and rod assembly (Figure 5, Item 3).
5 4
2 1
M0080105
0054-6
TM 5-3810-305-23
0054
REMOVAL - Continued 11. Remove two mounts (Figure 6, Item 6), retainers (Figure 6, Item 5), nuts (Figure 6, Item 4), studs (Figure 6, Item 3), and nuts (Figure 6, Item 2) from rod ends (Figure 6, Item 1).
Figure 6. 12.
Remove two nuts (Figure 7, Item 2) and spacers (Figure 7, Item 1) from studs on bottom of radiator under frame.
1
M0082105
0054-7
TM 5-3810-305-23
0054
REMOVAL - Continued
WARNING
Weight of radiator and oil cooler assembly is approximately 300 lb (136 kg). Use adequate lifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury to death to personnel. 13. 14. Install two capscrews (Figure 8, Item 2) in radiator and oil cooler assembly (Figure 8, Item 1). Attach suitable sling to two capscrews (Figure 8, Item 2) and using lifting device, carefully lift radiator and oil cooler assembly (Figure 8, Item 1) upward and away from frame.
M0083105
Figure 8.
0054-8
TM 5-3810-305-23
0054
REMOVAL - Continued 15. Remove shroud (Figure 9, Item 1) and two mounts (Figure 9, Item 2) from engine and frame.
M0084105
0054-9
TM 5-3810-305-23
0054
DISASSEMBLY 1. Position radiator on suitable work surface and remove two capscrews (Figure 10, Item 6), drain valve (Figure 10, Item 5), eight capscrews (Figure 10, Item 8), washers (Figure 10, Item 9), brackets (Figure 10, Items 3 and 7), and oil cooler (Figure 10, Item 1) from radiator. Remove plug (Figure 10, Item 4) and overflow tube (Figure 10, Item 2), if necessary, for repair of radiator.
2.
END OF TASK CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Clean radiator interior and exterior with water and dry with compressed air. Cap oil cooler ports to prevent contamination. Clean exterior with water and dry with compressed air. Clean all other parts.
END OF TASK INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect hoses for deterioration. Inspect radiator for leaks in seams and tubes. Inspect all other parts.
END OF TASK ASSEMBLY 1. 2. If removed, install overflow tube (Figure 10, Item 2) and plug (Figure 10, Item 4) from radiator. Install oil cooler (Figure 10, Item 1), brackets (Figure 10, Items 3 and 7), eight washers (Figure 10, Item 9), capscrews (Figure 10, Item 8), drain valve (Figure 10, Item 5), and two capscrews (Figure 10, Item 6) to radiator.
0054-10
TM 5-3810-305-23
0054
2 3 1
4 8 7 6 5
Figure 10. END OF TASK Radiator and Air Cooler Assembly.
M0085105
0054-11
TM 5-3810-305-23
0054
INSTALLATION 1. Support shroud (Figure 11, Item 1) on engine and install two mounts (Figure 11, Item 2) on frame.
M0084105
Figure 11. Radiator and Air Cooler Installation.
0054-12
TM 5-3810-305-23
0054
WARNING
Weight of radiator and oil cooler assembly is approximately 300 lb (136 kg). Use adequate lifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury to death to personnel. 2. 3. Using suitable hoist and sling, attach sling to two capscrews (Figure 12, Item 1) and carefully position radiator and cooler assembly (Figure 12, Item 2) in frame. Remove sling and two capscrews (Figure 12, Item 2) from radiator and oil cooler assembly (Figure 12, Item 1).
M0083105
Figure 12.
Radiator and Air Cooler Installation.
0054-13
TM 5-3810-305-23
0054
INSTALLATION - Continued 4. Install two spacers (Figure 13, Item 1) and nuts (Figure 14, Item 2) to studs on bottom of radiator.
1
M0082105
5.
Install nut (Figure 14, Item 4), retainer (Figure 14, Item 5), and mounts (Figure 14, Item 6) on one end of stud (Figure 15, Item 3), and nut (Figure 14, Item 2), and rod end (Figure 14, Item 1) on other end of stud.
0054-14
TM 5-3810-305-23
0054
INSTALLATION - Continued 6. 7. Install rod assembly (Figure 15, Item 3) and secure with two spacers (Figure 15, Item 2) and nuts (Figure 15, Item 1). Secure two rod ends (Figure 15, Item 5) to radiator with capscrews (Figure 15, Item 4).
5 4
2 1
M0080105
0054-15
TM 5-3810-305-23
0054
INSTALLATION - Continued 8. 9. Install shroud (Figure 17, Item 2), eight washers (Figure 17, Item 3), new lockwashers (Figure 17, Item 4), and capscrews (Figure 17, Item 5) to radiator. Install overflow hose (Figure 17, Item 1) to clips on shroud.
3,4,5
M0079105
0054-16
TM 5-3810-305-23
0054
INSTALLATION - Continued 10. 11. Install lower hose (Figure 17, Item 4) and secure with two clamps (Figure 17, Item 3). Install upper hose (Figure 17, Item 2) and secure with two clamps (Figure 17, Item 1).
1
Figure 17. 12. Radiator and Air Cooler Installation.
M0076105
Connect hose (Figure 18, Item 3) and hose (Figure 18, Item 1) to front of oil cooler (Figure 18, Item 2).
3 1
M0075105
Figure 18.
Radiator and Air Cooler Installation.
0054-17
TM 5-3810-305-23
0054
INSTALLATION - Continued 13. 14. 15. 16. 17. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Close dipstick cap. Close drain valve (Figure 19, Item 2). Fill radiator with recommended antifreeze solution to proper level. Install radiator cap (Figure 19, Item 1).
M0074105
Figure 19. Radiator and Air Cooler Installation. END OF TASK
0054-18
TM 5-3810-305-23
0054
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install alternator (WP 0062). Install drive belt (WP 0059). Install engine sliding hood (WP 0118). Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Check for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).
0054-19/20 blank
TM 5-3810-305-23
0055
FIELD MAINTENANCE DEFROSTER FAN MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 3 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
0055-1
TM 5-3810-305-23
0055
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. 1. 2. 3. Disconnect wire assembly (Figure 1, Item 4). Remove three bolts (Figure 1, Item 1) and lockwashers (Figure 1, Item 2) from defroster fan assembly (Figure 1, Item 3). Discard lockwashers. Remove defroster fan assembly (Figure 1, Item 3) from vehicle.
NOTE
Install wire as tagged during removal. 1. 2. 3. Install defroster fan assembly (Figure 1, Item 3) on vehicle. Install three new lockwashers (Figure 1, Item 2) and bolts (Figure 1, Item 1) on defroster fan assembly (Figure 1, Item 3). Connect wire assembly (Figure 1, Item 4).
0055-2
TM 5-3810-305-23
0055
1,2
4
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Defroster Fan Maintenance.
M0527105
0055-3/4 blank
TM 5-3810-305-23
0056
FIELD MAINTENANCE THERMOSTAT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 149) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Thermostat, Flow Con (WP 0172, Table 1, Item 81) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Coolant drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Drive belt removed (WP 0059) Alternator removed (WP 0062) Upper radiator hose removed (WP 0054)
0056-1
TM 5-3810-305-23
0056
REMOVAL 1. Remove three capscrews (Figure 1, Item 3), thermostat housing (Figure 1, Item 2), gasket (Figure 1, Item 4), and lifting bracket (Figure 1, Item 1) from engine (Figure 1, Item 5). Remove remaining gasket material from engine. Discard gasket.
2 3
4 5
M0296105
Figure 1. Thermostat Removal. 2. Remove thermostat (Figure 2, Item 2) from thermostat housing (Figure 2, Item 1). Discard thermostat.
1 2
M0297105
Figure 2. Thermostat Removal. END OF TASK
0056-2
TM 5-3810-305-23
0056
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Make sure vent notch is open and free from corrosion.
END OF TASK INSTALLATION 1. Install new thermostat (Figure 3, Item 1) in thermostat housing (Figure 3, Item 2) aligning tang up with notch.
2 1
M0298105
Figure 3.
Thermostat Installation.
0056-3
TM 5-3810-305-23
0056
INSTALLATION - Continued 2. Install lifting bracket (Figure 4, Item 1), new gasket (Figure 4, Item 4), thermostat housing (Figure 4, Item 2), and three capscrews (Figure 4, Item 3). Tighten three capscrews to 18 ft-lb (24 Nm).
2 3
4 5
M0296105
Figure 4. Thermostat Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install upper radiator hose (WP 0054). Install alternator (WP 0062). Install drive belt (WP 0059). Connect battery cables (WP 0076). Fill radiator with coolant (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).
0056-4
TM 5-3810-305-23
0057
FIELD MAINTENANCE WATER INLET CONNECTION MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Packing, Preformed (WP 0172, Table 1, Item 57) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom is horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Coolant drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Drive belt removed (WP 0059) Alternator removed (WP 0062) Lower radiator hose removed (WP 0054)
0057-1
TM 5-3810-305-23
0057
REMOVAL Remove three capscrews (Figure 1, Item 1), water inlet connection (Figure 1, Item 2), and o-ring (Figure 1, Item 3) from engine. Discard o-ring.
3
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK Water Inlet Connection Removal.
M0299105
0057-2
TM 5-3810-305-23
0057
INSTALLATION Install new o-ring (Figure 2, Item 3), water inlet connection (Figure 2, Item 2), and three capscrews (Figure 2, Item 1).
3
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install lower radiator hose (WP 0054). Install alternator (WP 0062). Install drive belt (WP 0059). Connect battery cables (WP 0076). Fill radiator with coolant (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Check for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10). Water Inlet Connection Installation.
M0299105
0057-3/4 blank
TM 5-3810-305-23
0058
FIELD MAINTENANCE WATER PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts O-Ring (WP 0172, Table 1, Item 59) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Coolant drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Drive belt removed (WP 0059)
REMOVAL 1. 2. Remove two capscrews (Figure 1, Item 2), and water pump (Figure 1, Item 3) from engine. Remove o-ring (Figure 1, Item 1) from groove on inside of water pump (Figure 1, Item 3). Discard o-ring.
1 2
3
Figure 1. END OF TASK Water Pump Removal.
M0300105
0058-1
TM 5-3810-305-23
0058
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect impeller blades for wear or corrosion. Inspect for free rotation of water pump. Check weep hole (Figure 2, Item 1) for evidence of a leaky seal. If seal is bad, replace water pump (Figure 2, Item 2)
1 2
M0354105
Water Pump Inspection.
0058-2
TM 5-3810-305-23
0058
INSTALLATION 1. 2. Install new o-ring (Figure 3, Item 1) in groove on water pump (Figure 3, Item 3). Install water pump (Figure 3, Item 3) and two capscrews (Figure 3, Item 2) on engine. Tighten two capscrews to 18 ft-lb (24 Nm).
1 2
3
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Install drive belt (WP 0059). Connect battery cables (WP 0076). Fill with coolant (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Check for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10). Water Pump Installation.
M0300105
0058-3/4 blank
TM 5-3810-305-23
0059
FIELD MAINTENANCE FAN DRIVE BELT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Sliding engine hood removed (WP 0118)
0059-1
TM 5-3810-305-23
0059
REMOVAL
WARNING
Keep hands out of path of spring-loaded tensioner. Keep fingers from between belt and pulley. Failure to follow these warnings may cause serious injury if tensioner slips. 1. 2. Use square hole in belt tensioner (Figure 1, Item 2) to rotate belt tensioner clockwise to release tension on fan drive belt (Figure 1, Item 1). Remove fan drive belt (Figure 1, Item 1) from vehicle.
2 1
M0007105_1
Fan Drive Belt Removal.
0059-2
TM 5-3810-305-23
0059
INSTALLATION 1. 2. Use square hole in belt tensioner (Figure 2, Item 2) and rotate belt tensioner clockwise to permit installation of fan drive belt (Figure 2, Item 1). Install fan drive belt (Figure 2, Item 1) around pulleys and under belt tensioner (Figure 2, Item 2).
2 1
M0007105_1
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install sliding engine hood (WP 0118).
Fan Drive Belt Installation.
0059-3/4 blank
TM 5-3810-305-23
0060
FIELD MAINTENANCE COOLING FAN AND HUB ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Fixture, Arbor Press (WP 0171, Table 1, Item 1) Vise (WP 0171, Table 1, Item 44) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Grease, Molybdenum (WP 0170, Table 1, Item 27) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Solvent Cleaning Compound Type III (WP 0170, Table 1, Item 9) Qty: 1 Washer, Lock M8 (WP 0172, Table 1, Item 126) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Drive belt tensioner and idler removed (hub assembly only) (WP 0061)
REMOVAL 1. Remove four capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 1), and fan (Figure 1, Item 3) from vehicle. Discard lockwashers.
3
M0007105_2
Figure 1.
Cooling Fan Removal.
0060-1
TM 5-3810-305-23
0060
REMOVAL - Continued 2. Remove spacer (Figure 2, Item 1) and fan pulley (Figure 2, Item 2) from vehicle.
2
M0008105
Figure 2. 3.
Fan Pulley Removal.
Remove four capscrews (Figure 3, Item 1) and hub assembly (Figure 3, Item 2) from vehicle.
M0009105
Fan Drive Removal.
0060-2
TM 5-3810-305-23
0060
DISASSEMBLY 1. Secure hub assembly in suitable vise. Remove center bolt (Figure 4, Item 1) and washer (Figure 4, Item 2) from fan hub.
2
M0011105
Figure 4.
Hub Assembly Disassembly.
NOTE
Approximately 6 tons (5.44 metric tons) of pressure are required for the following step. 2. Press roller bearing (Figure 5, Item 1) out of hub housing.
M0012105
Roller Bearing Disassembly.
0060-3
TM 5-3810-305-23
0060
CLEANING 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean roller bearing for leakage of lubricant and make sure hub rotates freely. Clean all other parts IAW General Maintenance Instructions (WP 0162).
END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect roller bearing for leakage of lubricant and make sure hub rotates freely. Inspect all other parts IAW General Maintenance Instructions (WP 0162).
END OF TASK ASSEMBLY 1. Pack roller bearing (Figure 6, Item 1) with grease. Press roller bearing into fan hub housing, flush with front of housing.
M0012105
Figure 6.
Roller Bearing Assembly.
0060-4
TM 5-3810-305-23
0060
ASSEMBLY - Continued 2. Install washer (Figure 7, Item 2) and center bolt (Figure 7, Item 1) in hub assembly. Tighten center bolt to 57 ft-lb (77 Nm).
2
M0011105
Figure 7. END OF TASK INSTALLATION 1.
Hub Assembly Assembly.
Install hub assembly (Figure 8, Item 2) on vehicle with four capscrews (Figure 8, Item 1). Tighten four capscrews to 18 ft-lb (24 Nm).
M0009105
Figure 8.
Fan Drive Installation.
0060-5
TM 5-3810-305-23
0060
INSTALLATION - Continued 2. Install fan pulley (Figure 9, Item 1) and spacer (Figure 9, Item 2) on vehicle.
2
M0008105
Figure 9. Fan Pulley Installation. 3. Install fan (Figure 10, Item 3) on vehicle with four new lockwashers (Figure 10, Item 1), and capscrews (Figure 10, Item 2). Tighten capscrews to 18 ft-lb (24 Nm).
3
M0007105_2
Figure 10. Cooling Fan Installation. END OF TASK
0060-6
TM 5-3810-305-23
0060
FOLLOW-ON MAINTENANCE 1. 2. Install drive belt tensioner and idler (WP 0061). Place boom in resting position (TM 5-3810-305-10).
0060-7/8 blank
TM 5-3810-305-23
0061
FIELD MAINTENANCE DRIVE BELT TENSIONER AND IDLER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) References WP 0162 Equipment Condition Fan drive belt removed (WP 0059)
0061-1
TM 5-3810-305-23
0061
REMOVAL
WARNING
Keep hands out of path of spring-loaded tensioner. Keep fingers from between belt and pulley. Failure to follow these warnings may cause serious injury if tensioner slips. Remove capscrew (Figure 1, Item 2) and drive belt tensioner (Figure 1, Item 1) from engine.
M0007105_3
Drive Belt Tensioner Removal.
0061-2
TM 5-3810-305-23
0061
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Install belt tensioner (Figure 2, Item 1) and capscrew (Figure 2, Item 2) with idler pulley hanging directly below capscrew. Tighten capscrew to 32 ft-lb (43 Nm).
M0007105_3
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install fan drive belt (WP 0059). END OF TASK END OF WORK PACKAGE
Drive Belt Tensioner Installation.
0061-3/4 blank
TM 5-3810-305-23
0062
FIELD MAINTENANCE ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Fan drive belt removed (WP 0059)
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid installation. Remove tags following maintenance. 1. 2. Disconnect wires (Figure 1, Items 1 and 2) from alternator (Figure 1, Item 5). Remove two capscrews (Figure 1, Item 4) and brace (Figure 1, Item 3) from lower end of alternator (Figure 1, Item 5).
2 1 5
M0102105
Figure 1. Alternator and Mounting Bracket Assembly Removal.
0062-1
TM 5-3810-305-23
0062
REMOVAL - Continued 3. 4. Remove mounting capscrew (Figure 2, Item 1), alternator (Figure 2, Item 5), and spacer (Figure 2, Item 4) from support (Figure 2, Item 3). Remove three capscrews (Figure 2, Item 2) and support (Figure 2, Item 3) from engine.
2 3 4
5
M0103105
Figure 2. Alternator and Mounting Bracket Assembly Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0062-2
TM 5-3810-305-23
0062
INSTALLATION 1. 2. Install support (Figure 3, Item 3) and three capscrews (Figure 3, Item 2) on engine. Install spacer (Figure 3, Item 4), alternator (Figure 3, Item 5) and mounting capscrew (Figure 3, Item 1) on support (Figure 3, Item 3). Do not tighten capscrew at this time.
2 3 4
5
M0103105
Figure 3. Alternator and Mounting Bracket Assembly Installation. 3. 4. 5. Install brace (Figure 4, Item 3) and two capscrews (Figure 4, Item 4) at lower end of alternator (Figure 4, Item 5). Tighten two capscrews to 18 ft-lb (24 Nm). Tighten mounting capscrew (Figure 3, Item 1) to 32 ft-lb (43 Nm). Connect wires (Figure 4, Items 1 and 2) to alternator (Figure 4, Item 5).
2 1 5
M0102105
Figure 4. Alternator and Mounting Bracket Assembly Installation. END OF TASK
0062-3
TM 5-3810-305-23
0062
FOLLOW-ON MAINTENANCE 1. 2. 3. Install fan drive belt (WP 0076). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0062-4
TM 5-3810-305-23
0063
FIELD MAINTENANCE STARTER MOTOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL
NOTE
Tag and identify all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect cables and wires from starting motor solenoid (Figure 1, Item 2). Remove three capscrews (Figure 1, Item 4), clip (Figure 1, Item 1) and starting motor (Figure 1, Item 3) from engine.
3 4
Figure 1. END OF TASK Starter Motor Removal.
M0115105
0063-1
TM 5-3810-305-23
0063
CLEANING
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT directed compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Position starting motor (Figure 2, Item 3) on engine and install clip (Figure 2, Item 1) and three capscrews (Figure 2, Item 4). Tighten capscrews to 32 ft-lb (43 Nm). Connect wires and cables to starting motor solenoid (Figure 2, Item 2).
3 4
Figure 2. END OF TASK Starter Motor Assembly.
M0115105
0063-2
TM 5-3810-305-23
0063
FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Check starter operation. Place boom in resting position (TM 5-3810-305-10).
0063-3/4 blank
TM 5-3810-305-23
0064
FIELD MAINTENANCE NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Equipment Condition (cont.) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122)
0064-1
TM 5-3810-305-23
0064
REMOVAL 1. 2. 3. 4. Remove two wires (Figure 1, Items 3 and 6) from neutral safety switch (Figure 1, Item 2). Remove two wires (Figure 1, Items 4 and 5) from reverse warning switch (Figure 1, Item 1). Remove neutral safety switch (Figure 1, Item 2) from transmission. Remove reverse warning switch (Figure 1, Item 1) from transmission.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. Install reverse warning switch (Figure 1, Item 1). Install neutral safety switch (Figure 1, Item 2). Connect wires (Figure 1, Items 4 and 5) to reverse warning switch (Figure 1, Item 1). Connect wires (Figure 1, Items 3 and 6) to neutral safety switch (Figure 1, Item 2).
4 3
M2100105
Figure 1. Warning Switches Maintenance. END OF TASK
0064-2
TM 5-3810-305-23
0064
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (WP 0122). Connect battery cables (WP 0076). Check neutral safety switch and backup reverse warning switch operation (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10).
0064-3/4 blank
TM 5-3810-305-23
0065
FIELD MAINTENANCE FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine hood removed (WP 0118)
0065-1
TM 5-3810-305-23
0065
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid installation. Remove tags following maintenance. 1. Disconnect pressure switch wire (Figure 1, Item 5) and transducer wire (Figure 1, Item 17) from transducer (Figure 1, Item 4).
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect two hose fittings (Figure 1, Items 10 and 18) from elbow adapters (Figure 1, Items 9 and 19) on transducer (Figure 1, Item 4). Disconnect hose fitting (Figure 1, Item 16) from elbow adapter (Figure 1, Item 13) and remove hose (Figure 1, Item 11) from vehicle. Disconnect hose fitting (Figure 1, Item 14) from straight adapter (Figure 1, Item 15) and remove hose (Figure 1, Item 12) from vehicle. Remove two nuts (Figure 1, Item 20), capscrews (Figure 1, Item 3), clamps (Figure 1, Item 7), and transducer (Figure 1, Item 4) from plate (Figure 1, Item 2). Remove two elbow adapters (Figure 1, Items 9 and 19) from transducer (Figure 1, Item 4). Remove pressure switch (Figure 1, Item 6) from tee adapter (Figure 1, Item 8). Remove tee adapter (Figure 1, Item 8) from transducer (Figure 1, Item 4). Remove two capscrews (Figure 1, Item 1) and plate (Figure 1, Item 2) from vehicle.
0065-2
TM 5-3810-305-23
0065
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Install plate (Figure 1, Item 2) and two capscrews (Figure 1, Item 1) on vehicle. Install tee adapter (Figure 1, Item 8) on transducer (Figure 1, Item 4). Install pressure switch (Figure 1, Item 6) on tee adapter (Figure 1, Item 8). Install two elbow adapters (Figure 1, Items 19 and 9) on transducer (Figure 1, Item 4). Install two nuts (Figure 1, Item 20), capscrews (Figure 2, Item 3), clamps (Figure 1, Item 7), and transducer (Figure 1, Item 4) to plate (Figure 1, Item 2). Install hose (Figure 1, Item 12) to vehicle and connect hose fitting (Figure 1, Item 14) to straight adapter (Figure 1, Item 15). Install hose (Figure 1, Item 11) to vehicle and connect hose fitting (Figure 1, Item 16) to elbow adapter (Figure 1, Item 13). Connect two hose fittings (Figure 1, Items 18 and 10) to elbow adapters (Figure 1, Items 9 and 19) on transducer (Figure 2, Item 4). Connect pressure switch wire (Figure 1, Item 5) and transducer wire (Figure 1, Item 17) to transducer.
2 1
10
11 12 19 18 17 16
20
15
14
13
M0264105
Figure 1. Fuel Pressure Switch and Transducer Installation. END OF TASK
0065-3
TM 5-3810-305-23
0065
FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine hood (WP 0118). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0065-4
TM 5-3810-305-23
0066
FIELD MAINTENANCE DASH PANEL GAGES AND SWITCHES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking He M6 (WP 0172, Table 1, Item 138) Qty: 1 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 6 References WP 0015 References (cont.) WP 0068 WP 0124 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL
WARNING
CAUTION
When removing dash, care must be used to avoid damage to electrical wires attached to back of gages.
0066-1
TM 5-3810-305-23
0066
REMOVAL - Continued
Dash Panel 1. 2. 3. 4. 5. Remove six bolts (Figure 1, Item 1), six lockwashers (Figure 1, Item 2) and washers (Figure 1, Item 3) from dash panel (Figure 1, Item 7). Discard lockwashers. Loosen jam nut (Figure 1, Item 5) and remove cold start knob (Figure 1, Item 4) from dash panel (Figure 1, Item 7). Remove jam nut (Figure 1, Item 5) and cable locknut (Figure 1, Item 6). Pull cold start cable out of dash panel (Figure 1, Item 7). Discard locknut. Disconnect two plastic cannon-style electrical connectors under right-hand corner of dash panel (Figure 1, Item 7). Remove screw (Figure 1, Item 9) from turn signal switch mounting band to release ground wire and clamp (Figure 1, Item 8), and remove dash panel (Figure 1, Item 7) assembly to a work bench for further disassembly.
2 1,2,3 3
6 5 7 9 8
M0500105
Figure 1. Dash Panel Removal.
NOTE
Tag wires to aid installation. 6. 7. 8. 9. 10. 11. 12. 13. 14. Disconnect wires (Figure 2, Item 9) from back of gage and light. Remove two nuts (Figure 2, Item 15), washers (Figure 2, Item 14), and bracket (Figure 2, Item 13) from dash panel (Figure 2, Item 1). Pull gage (Figure 2, Item 8) out of dash panel (Figure 2, Item 1). Remove light bulb assembly (Figure 2, Item 12) from gage (Figure 2, Item 8). Remove filter (Figure 2, Item 11) from light bulb (Figure 2, Item 12). Push down and twist light bulb (Figure 2, Item 12) to remove from socket (Figure 2, Item 10). If necessary, use same procedure to remove remaining five gages. Disconnect two wires (Figure 2, Item 7) and remove nut (Figure 2, Item 2) and internal tooth washer (Figure 2, Item 3) from dash panel (Figure 2, Item 1). Pull light socket (Figure 2, Item 6) through dash panel (Figure 2, Item 1).
0066-2
TM 5-3810-305-23
0066
REMOVAL - Continued Dash Panel - Continued 15. 16. Unscrew cover (Figure 2, Item 5), remove filter, and push and turn light bulb (Figure 2, Item 4) to remove from socket (Figure 2, Item 6). Follow same procedure to remove remaining two dash lights, if necessary.
2,3,4,5
8 9
15
14 13 12 11 10
M0501105
Figure 2. 17. 18.
Dash Panel Removal.
Hold socket (Figure 3, Item 2) and remove nut (Figure 3, Item 1). Pull socket through back of dash panel (Figure 3, Item 5) and remove washer (Figure 3, Item 3). Unscrew red lens cap and pull bulb (Figure 3, Item 4) from back of lens cap.
2 1
4 5
M0502105
Figure 3.
Dash Panel Removal.
0066-3
TM 5-3810-305-23
0066
REMOVAL - Continued Dash Panel - Continued 19. Push out through rear of dash panel (Figure 4, Item 1).
NOTE
Tag wires to aid installation. 20. 21. 22. Disconnect wires (Figure 4, Item 2) from back of horn button (Figure 4, Item 4). Loosen nut (Figure 4, Item 3) on back of horn button (Figure 4, Item 4) and unscrew rubber cover (Figure 4, Item 5). Push out through rear of dash panel (Figure 4, Item 1).
5 4 3 2
1
M0503105
Figure 4. Dash Panel Removal.
0066-4
TM 5-3810-305-23
0066
REMOVAL - Continued Dash Panel - Continued
NOTE
Tag wires to aid installation. 23. 24. Unscrew plastic retaining nut (Figure 5, Item 3) and push speedometer alarm (Figure 5, Item 2) through dash panel (Figure 5, Item 5). Disconnect wires (Figure 5, Item 1) from speedometer (Figure 5, Item 4).
2,3 2,3 (HIDDE4 ) N
4
5
1 1
M0504105
Figure 5.
Dash Panel Removal.
0066-5
TM 5-3810-305-23
0066
REMOVAL - Continued
Side Sloping Dash Panel
NOTE
It is not necessary to remove side sloping panel to remove switches. Tag wires to aid installation. 1. 2. 3. Remove screw (Figure 6, Item 2) from knob (Figure 6, Item 3). Pull knob off ignition switch (Figure 6, Item 1) and remove nut (Figure 6, Item 4). Pull ignition switch (Figure 6, Item 1) through back of sloping dash panel (Figure 6, Item 6). Disconnect wires (Figure 6, Item 5) from switch (Figure 6, Item 1).
2 1 3,4,5
6
M0505105
Figure 6.
Side Sloping Dash Panel Removal.
0066-6
TM 5-3810-305-23
0066
REMOVAL - Continued Side Sloping Dash Panel - Continued 4. 5. Pull knob (Figure 7, Item 5) up, remove nut (Figure 7, Item 4), washer (Figure 7, Item 3), and push switch (Figure 7, Item 6) through sloping dash panel (Figure 7, Item 1). Disconnect wires (Figure 7, Item 2) from wiper switch (Figure 7, Item 6).
6 5,4,3,2
M0506105
Figure 7.
0066-7
TM 5-3810-305-23
0066
REMOVAL - Continued Side Sloping Dash Panel - Continued
NOTE
Tag wires to aid installation. 6. 7. 8. Pull switch up through sloping dash panel (Figure 8, Item 4). Disconnect wires (Figure 8, Item 3) from worklight (Figure 8, Item 1) and outrigger switches (Figure 8, Item 2). Follow same procedure to remove remaining outrigger switches and worklights, if necessary.
1,2,3
M0507105
Figure 8.
0066-8
TM 5-3810-305-23
0066
REMOVAL - Continued Side Sloping Dash Panel - Continued
NOTE
Tag wires to aid installation. 9. 10. 11. 12. 13. Remove three screws (Figure 9, Item 4), three levers (Figure 9, Item 5), and four screws (Figure 9, Item 1). Push switch (Figure 9, Item 2) down through sloping dash panel (Figure 9, Item 6). Disconnect wires (Figure 9, Item 3) from master light switch (Figure 9, Item 2). Disconnect wires (Figure 9, Item 8) from back of start button (Figure 9, Item 7). Loosen nut (Figure 9, Item 9) on back of start button (Figure 9, Item 7) and unscrew rubber cover (Figure 9, Item 10). Push start button (Figure 9, Item 7) out through rear of sloping dash panel (Figure 9, Item 6).
7,8,9,10
2,3
4
5
M0508105
Figure 9.
0066-9
TM 5-3810-305-23
0066
REMOVAL - Continued Side Sloping Dash Panel - Continued 14. Remove two nuts (Figure 10, Item 1), capscrew (Figure 10, Item 2), and side sloping dash panel (Figure 10, Item 3) from vehicle.
1 2
M0509105
Figure 10. Side Sloping Dash Panel Removal.
0066-10
TM 5-3810-305-23
0066
REMOVAL - Continued
Circuit Breaker Panel
NOTE
Tag wires to aid installation. 1. 2. 3. 4. Remove four capscrews (Figure 11, Item 4) and washers (Figure 11, Item 3) from circuit breaker panel (Figure 11, Item 1). Lift circuit breaker panel (Figure 11, Item 1) up and out of frame. Remove retaining nut (Figure 11, Item 5) and push circuit breaker (Figure 11, Item 2) through circuit breaker panel (Figure 11, Item 1). Disconnect wires (Figure 11, Item 6) from circuit breakers. If necessary, remove nine remaining circuit breakers using the same procedure.
1 2 3 4
5 6
M0510105
Figure 11.
Circuit Breaker Panel Removal.
0066-11
TM 5-3810-305-23
0066
REMOVAL - Continued
Tachometer and Turn Signal
NOTE
Tag wires to aid installation. 1. 2. 3. 4. Remove two screws (Figure 12, Item 5) and lockwashers (Figure 12, Item 6) from case (Figure 12, Item 3). Slide case down wires (Figure 12, Item 4). Discard lockwashers. Disconnect wires (Figure 12, Item 4) from tachometer (Figure 12, Item 2). Disconnect wires (Figure 12, Item 7) from turn signal (Figure 12, Item 1). Remove two retaining screws and turn signal (Figure 12, Item 1) from vehicle.
2 1
3,4
5
M0511105
Figure 12. Tachometer and Turn Signal Removal.
0066-12
TM 5-3810-305-23
0066
REMOVAL - Continued
Right Console 1. 2. 3. 4. 5. 6. 7. 8. Remove seat (WP 0124). Remove two capscrews, nuts (Figure 13, Item 1), and washers (Figure 13, Item 2) from cover (Figure 13, Item 18). Remove four nuts (Figure 13, Item 14) and washers (Figure 13, Item 13) from cover (Figure 13, Item 18). Remove three nuts (Figure 13, Item 11), capscrews (Figure 13, Item 9), and washers (Figure 13, Item 10) from cover (Figure 13, Item 18). Remove two capscrews (Figure 13, Item 17), lockwasher (Figure 13, Item 16), washers (Figure 13, Item 15), and cover (Figure 13, Item 18) from vehicle. Discard lockwashers. Remove four capscrews (Figure 13, Item 6) and lockwashers (Figure 13, Item 7). Lay circuit breaker panel (Figure 13, Item 8) against back cab wall. Discard lockwashers. Remove two capscrews (Figure 13, Item 3), lockwasher (Figure 13, Item 4), and washer (Figure 13, Item 5) from vehicle. Discard lockwashers. Lift right console (Figure 13, Item 12) and rotate 1/4 turn to allow access to shift control linkage.
6,7 3,4,5 1,2
8 9,10 11
18
12
15,16,17
Figure 13.
13,14
M0512105
Right Console Removal.
0066-13
TM 5-3810-305-23
0066
REMOVAL - Continued Right Console - Continued 9. 10. Remove six nuts (Figure 14, Item 2), lockwashers (Figure 14, Item 3), and capscrews (Figure 14, Item 1). Discard lockwashers. Remove three clamps (Figure 14, Item 4) and shims (Figure 14, Item 5).
NOTE
Tag cable terminals and record holes in shifter to aid in assembly. 11. Remove three cotter pins (Figure 14, Item 7) and pins (Figure 14, Item 8) from cable terminal (Figure 14, Item 6). Discard cotter pins.
2,3 4 5
8 7 8 7 6 7 8 6
Figure 14. Right Console Removal.
M0513105
0066-14
TM 5-3810-305-23
0066
REMOVAL - Continued Right Console - Continued 12. 13. Remove four capscrews (Figure 15, Item 6), lockwashers (Figure 15, Item 5), washer (Figure 15, Item 4), and spacer (Figure 15, Item 3) and remove shifter (Figure 15, Item 1). Discard lockwashers. Remove vehicle bubble level (Figure 15, Item 2), if necessary (WP 0068).
4,5,6
M0514105
Figure 15. END OF TASK CLEAN
Right Console Removal.
0066-15
TM 5-3810-305-23
0066
INSTALLATION Tachometer and Turn Signal 1. 2. 3. 4. 5. Position turn signal (Figure 16, Item 1) on stud and connect wires (Figure 16, Item 6). Install two retaining screws (Figure 16, Item 6) in turn signal strap and turn signal (Figure 16, Item 1). Position and tighten. Install case on wires (Figure 16, Item 3) and connect wires to tachometer (Figure 16, Item 2). Slide case up wires and install tachometer (Figure 16, Item 2) in case. Position tachometer (Figure 16, Item 2) on dash and install two new lockwashers (Figure 16, Item 5) and screws (Figure 16, Item 4).
2 1
3,4
4
M0515105
Figure 16. Tachometer and Turn Signal Installation.
0066-16
TM 5-3810-305-23
0066
Circuit Breaker Panel
NOTE
Install wires as tagged during removal. 1. 2. 3. 4. Connect wires (Figure 17, Item 6) to circuit breaker (Figure 17, Item 2). Push circuit breaker (Figure 17, Item 2) up through circuit breaker panel (Figure 17, Item 1) and install retaining nut (Figure 17, Item 5). Use same procedure to install remaining nine circuit breakers. Position circuit breaker panel and install four washers (Figure 17, Item 3) and capscrews (Figure 17, Item 4).
1 2 3 4
5 6
M0510105
Figure 17.
Circuit Breaker Panel Installation.
0066-17
TM 5-3810-305-23
0066
Side Sloping Dash Panel 1. Install slide sloping dash panel (Figure 18, Item 3), two capscrews (Figure 18, Item 2), and nuts (Figure 18, Item 1) on vehicle.
1 2
M0509105
Figure 18. Side Sloping Dash Panel Installation.
0066-18
TM 5-3810-305-23
0066
INSTALLATION - Continued Side Sloping Dash Panel - Continued
NOTE
Install wires as tagged during removal. 2. 3. 4. 5. 6. 7. Push start button (Figure 19, Item 7) in through rear of sloping dash panel (Figure 19, Item 6). Connect wires (Figure 19, Item 8) to back of start button (Figure 19, Item 7). Screw rubber cover (Figure 19, Item 10) on back of start button (Figure 19, Item 7) and tighten nut (Figure 19, Item 9). Connect wires (Figure 19, Item 3) to master light switch (Figure 19, Item 2). Push master light switch (Figure 19, Item 2) up through panel and install four screws (Figure 19, Item 1). Install three levers (Figure 19, Item 5) on master light switch (Figure 19, Item 2) and install three screws (Figure 19, Item 4) in levers.
7,8,9,10
2,3
4
5
M0508105
Figure 19.
Side Sloping Dash Panel Installation.
0066-19
TM 5-3810-305-23
0066
NOTE
Install wires as tagged during removal. 8. 9. Pull wires (Figure 20, Item 3) up through sloping dash panel (Figure 20, Item 4) and install on worklight or outrigger switches (Figure 20, Item 1). Push switch down through dash panel. Use same procedure to install remaining two outrigger switches (Figure 20, Item 2).
1,2,3
M0507105
0066-20
TM 5-3810-305-23
0066
NOTE
Install wires as tagged during removal. 10. 11. Connect wires (Figure 21, Item 2) to wiper switch (Figure 21, Item 6) and remove tags. Push switch through sloping dash panel (Figure 21, Item 1). Install washer (Figure 21, Item 3), nut (Figure 21, Item 4), and knob (Figure 21, Item 5). Tighten nut.
6 5,4,3,2
M0506105
Figure 21.
Side Sloping Dash Panel Installation.
0066-21
TM 5-3810-305-23
0066
NOTE
Install wires as tagged during removal. 12. 13. Push ignition switch (Figure 22, Item 1) in through back of sloping dash panel (Figure 22, Item 6). Install nut (Figure 22, Item 4), knob (Figure 22, Item 3), and screw (Figure 22, Item 2). Connect wires (Figure 22, Item 5) to ignition switch (Figure 22, Item 1).
2 1 3,4,5
6
M0505105
0066-22
TM 5-3810-305-23
0066
Dash Panel
NOTE
Install wires as tagged during removal. 1. 2. Push speedometer alarm (Figure 23, Item 2) through dash panel (Figure 23, Item 5) and install plastic retaining nut (Figure 23, Item 3) on front of speedometer alarm. Install wires (Figure 23, Item 1) speedometer (Figure 23, Item 4).
2,3 2,3 (HIDDE4 ) N
4
5
1 1
M0504105
Figure 23.
Dash Panel Installation.
NOTE
Install wires as tagged during removal. 3. 4. Connect wires (Figure 24, Item 2) on horn button. Install nut (Figure 24, Item 3) on horn button (Figure 24, Item 4), push horn button through dash panel (Figure 24, Item 1) and install rubber covers (Figure 24, Item 5). Tighten nut.
5 4 3 2
1
M0503105
Figure 24.
0066-23
TM 5-3810-305-23
0066
INSTALLATION - Continued Dash Panel - Continued 5. 6. Install axle centering light bulb (Figure 25, Item 4) in red lens cap and install in socket (Figure 25, Item 2). Install washer (Figure 25, Item 3) and push socket (Figure 25, Item 2) through dash panel (Figure 25, Item 5). Install nut (Figure 25, Item 1).
2 1
4 5
M0502105
Figure 25. Dash Panel Installation.
0066-24
TM 5-3810-305-23
0066
INSTALLATION - Continued Dash Panel - Continued
NOTE
Install wires as tagged during removal. 7. 8. Installation of three dash lights: Install light bulb (Figure 26, Item 4) and filter in socket. Connect wires (Figure 26, Item 7) and push socket (Figure 26, Item 6) through dash panel (Figure 26, Item 1) and install internal tooth washer (Figure 26, Item 3) and nut (Figure 26, Item 2). Install cover (Figure 26, Item 5). Use same procedure to install remaining two dash lights. Install light bulb (Figure 26, Item 12) and filter (Figure 26, Item 11) in socket (Figure 26, Item 10). Push gage (Figure 26, Item 8) through dash panel (Figure 26, Item 1). Install bracket (Figure 26, Item 13), two washers (Figure 26, Item 14) and nuts (Figure 26, Item 15). Connect wires (Figure 26, Item 9) on gage (Figure 26, Item 8).
9. 10. 11. 12.
2,3,4,5
8 9
15
14 13 12 11 10
M0501105
Figure 26.
0066-25
TM 5-3810-305-23
0066
INSTALLATION - Continued Dash Panel - Continued
NOTE
Install wires as tagged during removal. 13. 14. 15. 16. 17. Carefully lift and position dash (Figure 27, Item 7) over mounting holes and install screw (Figure 27, Item 9) to turn signal switch mounting band and secure clamp and ground wire (Figure 27, Item 8). Connect two plastic cannon-style electrical connectors under-hand corner of dash panel (Figure 27, Item 7). Position cold start cable in dash panel (Figure 27, Item 7). Install new cable locknut (Figure 27, Item 6), cold start knob (Figure 27, Item 4), and jam nut (Figure 27, Item 5). Install six washers (Figure 27, Item 3), new lockwashers (Figure 27, Item 2), and six bolts (Figure 27, Item 1). Test speedometer alarm (WP 0015).
2 1,2,3 3
6 5 7 9 8
M0500105
Figure 27. Dash Panel Installation.
0066-26
TM 5-3810-305-23
0066
Right Console 1. 2. 3. Install vehicle bubble level, if removed (WP 0068). Install shifter (Figure 28, Item 1) in right console (Figure 28, Item 2) with four spacers (Figure 28, Item 3), washers (Figure 28, Item 4), new lockwashers (Figure 28, Item 5), and capscrews (Figure 28, Item 6). Position right console (Figure 28, Item 2) in cab to allow access to shift control linkage.
4,5,6
M0514105
Figure 28.
Right Console Installation.
0066-27
TM 5-3810-305-23
0066
INSTALLATION - Continued Right Console - Continued 4. 5. Position cable terminal (Figure 29, Item 6) as recorded during disassembly and install three pins (Figure 29, Item 8) and new cotter pins (Figure 29, Item 7). Install three shims (Figure 29, Item 5), clamps (Figure 29, Item 4), six capscrews (Figure 29, Item 1), new lockwashers (Figure 29, Item 3), and nuts (Figure 29, Item 2).
2,3 4 5
8 7 8 7 6 7 8 6
Figure 29. Right Console Installation.
M0513105
0066-28
TM 5-3810-305-23
0066
INSTALLATION - Continued Right Console - Continued 6. 7. 8. Rotate right console (Figure 30, Item 12) 1/4 turn and position it in cab. Install two washers (Figure 30, Item 5), new lockwasher (Figure 30, Item 4), and capscrew (Figure 30, Item 3) on dash (Figure 30, Item 12). Install but DO NOT TIGHTEN washers (Figure 30, Item 2), capscrews and nuts (Figure 30, Item 1), cover (Figure 30, Item 18), washers (Figure 30, Item 15), new lockwashers (Figure 30, Item 16), capscrews (Figure 30, Item 17), three washers (Figure 30, Item 10), capscrews (Figure 30, Item 9), nuts (Figure 30, Item 11), four washers (Figure 30, Item 13) and nuts (Figure 30, Item 14). Tighten capscrews and nuts (Figure 30, Item 1), capscrews (Figure 30, Item 17), capscrews (Figure 30, Item 9), and nuts (Figure 30, Item 14). Install circuit breaker panel (Figure 30, Item 8), four new lockwashers (Figure 30, Item 7), and capscrews (Figure 30, Item 6). If circuit breaker panel was completely removed, refer to Circuit Breaker Panel in this work package. Install seat (WP 0124).
9. 10.
11.
6,7 3,4,5 1,2
8 9,10 11
18
12
15,16,17
13,14
M0512105
Right Console Installation.
0066-29
TM 5-3810-305-23
0066
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Raise all outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Shut down engine (TM 5-3810-305-10).
0066-30
TM 5-3810-305-23
0067
FIELD MAINTENANCE ANTI-TWO BLOCK CONTROL PANEL MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Soldering Gun (WP 0171, Table 1, Item 31) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Battery cables disconnected (WP 0076)
WARNING
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance.
0067-1
TM 5-3810-305-23
0067
REMOVAL 1. 2. 3. Remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and tubes (Figure 1, Item 3) from control panel (Figure 1, Item 13). Disconnect plug (Figure 1, Item 11) from connector in cab at rear of control panel (Figure 1, Item 13). Remove control panel (Figure 1, Item 13) from vehicle.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove two bolts and disconnect two wires from BY-PASS toggle switch (Figure 1, Item 5). Remove nut, washers, and BY-PASS toggle switch (Figure 1, Item 5) from control panel (Figure 1, Item 13). Disconnect five wires from relay (Figure 1, Item 6). Remove relay from control panel (Figure 1, Item 13). Disconnect two wires from HORN (Figure 1, Item 12). Remove plastic nut and HORN (Figure 1, Item 12) from control panel (Figure 1, Item 13). Disconnect two wires from TEST switch (Figure 1, Item 10). Remove nut, washer, and TEST switch (Figure 1, Item 10) from control panel (Figure 1, Item 4). Disconnect two wires from HORN switch (Figure 1, Item 4). Remove HORN switch (Figure 1, Item 4) by pressing in on spring clips while pushing HORN switch out.
NOTE
DO NOT unsolder connections unless necessary. 10. Remove nut, washer, and WARNING light (Figure 1, Item 14) from control panel (Figure 1, Item 13).
0067-2
TM 5-3810-305-23
0067
2 3 14
5 6 7 8
13 12 10 11
9
M0089105
Control Panel Maintenance.
0067-3
TM 5-3810-305-23
0067
ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install WARNING light (Figure 2, Item 14), washer, and nut to control panel (Figure 2, Item 13). Install HORN switch (Figure 2, Item 4) by pushing HORN switch in hole until spring clips lock. Connect two wires to HORN switch (Figure 2, Item 4). Install TEST switch (Figure 2, Item 10), washer, and nut to control panel (Figure 2, Item 13). Connect two wires to TEST switch (Figure 2, Item 10). Install HORN (Figure 2, Item 12) and plastic nut on control panel (Figure 2, Item 13). Connect two wires to HORN (Figure 2, Item 12). Connect five wires to relay (Figure 2, Item 6). Install BY-PASS toggle switch (Figure 2, Item 5), washers, and nut to control panel (Figure 2, Item 13). Connect two wires to BY-PASS toggle switch (Figure 2, Item 5) with two bolts.
END OF TASK INSTALLATION 1. 2. 3. Connect plug (Figure 2, Item 11) on rear of control panel (Figure 2, Item 13) to connector in cab. Install four tubes (Figure 2, Item 3), washers (Figure 2, Item 2), and bolts (Figure 2, Item 1) to control panel (Figure 2, Item 13). Install control panel (Figure 2, Item 13) to vehicle.
2 3 14
5 6 7 8
13 12 10 11
9
M0089105
Figure 2. Control Panel Maintenance. END OF TASK
0067-4
TM 5-3810-305-23
0067
FOLLOW-ON MAINTENANCE Connect battery cables (WP 0076). END OF TASK END OF WORK PACKAGE
0067-5/6 blank
TM 5-3810-305-23
0068
FIELD MAINTENANCE VEHICLE BUBBLE LEVEL MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 3 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Equipment Condition (cont.) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122) Battery cables disconnected (WP 0076)
REMOVAL Remove three screws (Figure 1, Item 2), lockwashers (Figure 1, Item 3), six nuts (Figure 1, Item 4), and vehicle bubble level (Figure 1, Item 1) from vehicle. Discard lockwashers.
2
M0565105
Vehicle Bubble Level Removal.
0068-1
TM 5-3810-305-23
0068
INSTALLATION
NOTE
Installation of vehicle bubble level is critical to the proper operation of vehicle and must be installed properly. 1. 2. 3. 4. 5. 6. 7. 8. 9. Lower outrigger pads and raise tires off ground. Clean machined surface of frame around swing pinion. Place a vehicle bubble level (Figure 2, Item 1) on the machined surface of frame next to swing pinion. By raising or lowering outrigger pads, level the frame in both side-to-side and front-to-rear directions. Install three screws (Figure 2, Item 2) in vehicle bubble level (Figure 2, Item 1). Install two nuts (Figure 2, Item 4) then one new lockwasher (Figure 2, Item 3) on each screw (Figure 2, Item 2). Tighten two nuts on each screw up to vehicle bubble level (Figure 2, Item 1). Position machined vehicle bubble level (Figure 2, Item 1) and start screws (Figure 2, Item 2) in mounting holes. Adjust three screws (Figure 2, Item 2) until bubble in vehicle bubble level (Figure 2, Item 1) is centered in center circle. Hold screws (Figure 2, Item 2) in place and tighten bottom nut (Figure 2, Item 4) and lockwasher (Figure 2, Item 3) down against panel. Recheck vehicle bubble level on frame and vehicle bubble level (Figure 2, Item 1).
2
M0565105
Vehicle Bubble Level Installation.
0068-2
TM 5-3810-305-23
0068
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Raise all outriggers (TM 5-3810-305-10). Install deck plates (WP 0122). Place boom in resting position (TM 5-3810-305-10).
0068-3/4 blank
TM 5-3810-305-23
0069
FIELD MAINTENANCE HORN MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect electrical wires (Figure 1, Item 5) from horn (Figure 1, Item 4). Remove locknut (Figure 1, Item 1), washer (Figure 1, Item 3), and horn (Figure 1, Item 4) from stud (Figure 1, Item 2). Discard locknut.
1,2,3
5
Figure 1. END OF TASK Horn Removal.
M0124105
0069-1
TM 5-3810-305-23
0069
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Install horn (Figure 2, Item 4), washer (Figure 2, Item 3), and new locknut (Figure 2, Item 1) on stud (Figure 2, Item 2). Connect electrical wires (Figure 2, Item 5) to horn (Figure 2, Item 4).
1,2,3
5
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Horn Installation.
M0124105
0069-2
TM 5-3810-305-23
0070
FIELD MAINTENANCE ELECTRICAL COLLECTOR RING MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Dial, 1/4 Inch Drive, 30 in-lb (WP 0171, Table 1, Item 37) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Tape, Pressure Sensitive Adhesive - Clear (WP 0170, Table 1, Item 69) Qty: 1 References WP 0162 Equipment Condition Boom to 15 degree position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) 1
WARNING
0070-1
TM 5-3810-305-23
0070
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. 3. Disconnect four knife connectors (Figure 1, Item 5) from under carrier at bottom of rotary manifold (Figure 1, Item 4). Disconnect four knife connectors (Figure 1, Item 2) from inside upperstructure near top of collector ring (Figure 1, Item 6). Remove two nuts (Figure 1, Item 1) and washers (Figure 1, Item 3) from cover (Figure 1, Item 7) of collector ring (Figure 1, Item 6). Remove cover.
1 7 6
3 4
5
M0128105
Figure 1. Electrical Collector Ring Removal.
0070-2
TM 5-3810-305-23
0070
REMOVAL - Continued 4. Remove cap nut (Figure 2, Item 1), nylon washer (Figure 2, Item 6), nylon plate (Figure 2, Item 5), capscrew (Figure 2, Item 3), and washer (Figure 2, Item 2) from cover (Figure 2, Item 4).
2 1 3 6
4 5
M0129105
0070-3
TM 5-3810-305-23
0070
REMOVAL - Continued 5. Loosen three setscrews (Figure 3, Item 11) on bottom of collector ring core (Figure 3, Item 12). Lift collector ring base (Figure 3, Item 8) and brush assemblies (Figure 3, Item 7) off as an assembly from mounting column (Figure 3, Item 9). Remove setscrews, if necessary. Remove two of four set collars (Figure 3, Item 1), bearing (Figure 3, Item 4), and remaining two set collars from two studs (Figure 3, Item 3). Push upon lower harness (Figure 3, Item 13) to create slack. Slide collector ring core (Figure 3, Item 12) to one side and remove collector ring core from brush assemblies (Figure 3, Item 7). Remove lower harness (Figure 3, Item 13) from collector ring core (Figure 3, Item 12).
6. 7. 8.
NOTE
Record number of nylon shims used when removing brush assemblies. Also note position of color coded wires when removing brush assemblies. 9. 10. 11. 12. 13. Remove nylon shim(s) (Figure 3, Item 15) and four brush assemblies (Figure 3, Item 7) from two studs (Figure 3, Item 3). Remove four springs (Figure 3, Item 2) from brush assemblies (Figure 3, Item 7). Remove upper harness (Figure 3, Item 5) from brush assemblies (Figure 3, Item 7). Loosen two nuts (Figure 3, Item 6) and remove two studs (Figure 3, Item 3), washers (Figure 3, Item 14), and nuts from collector ring base (Figure 3, Item 8). Remove bearing (Figure 3, Item 10) from collector ring base (Figure 3, Item 8).
1 15 14
3 4 5
6 13 12 11 10 9 8 7
M0130105
0070-4
TM 5-3810-305-23
0070
REMOVAL - Continued 14. 15. Remove three capscrews (Figure 4, Item 3) and mounting column (Figure 4, Item 4) from rotary manifold (Figure 4, Item 5). Remove two capscrews (Figure 4, Item 1), washers (Figure 4, Item 6), and bracket (Figure 4, Item 2) from rotary manifold (Figure 4, Item 5).
4 1 2
M0131105
Electrical Collector Ring Removal.
0070-5
TM 5-3810-305-23
0070
INSTALLATION 1. 2. Install bracket (Figure 5, Item 2), two washers (Figure 5, Item 6), and capscrews (Figure 5, Item 1) on rotary manifold (Figure 5, Item 5). Install mounting column (Figure 5, Item 4) and three capscrews (Figure 5, Item 3).
4 1 2
M0131105
Figure 5.
Electrical Collector Ring Installation.
0070-6
TM 5-3810-305-23
0070
INSTALLATION - Continued 3. 4. 5. 6. Install bearing (Figure 6, Item 10) in collector ring base (Figure 6, Item 8). Install two nuts (Figure 6, Item 6) and washers (Figure 6, Item 14) on two studs (Figure 6, Item 3). Install studs in collector ring base (Figure 6, Item 8). Secure two nuts. Connect upper harness (Figure 6, Item 5) to brush assemblies (Figure 6, Item 7). Install four springs (Figure 6, Item 2) in four brush assemblies (Figure 6, Item 7).
NOTE
Use number of nylon shims recorded in removal for assembling collector ring core. Also, use the placement of color coded wires noted during removal for assembling collector ring core. 7. 8. 9. Install nylon shim(s) (Figure 6, Item 15) and four brush assembly (Figure 6, Item 7) on two studs (Figure 6, Item 3). Connect lower harness (Figure 6, Item 13) to collector ring core (Figure 6, Item 12). Install lower harness (Figure 6, Item 13) and collector ring core (Figure 6, Item 12) through collector ring base (Figure 6, Item 8). Slide collector ring core into brush assemblies (Figure 6, Item 7). Make sure brush assemblies are on correct ring. Install two of four set collars (Figure 6, Item 1), bearing (Figure 6, Item 4), and remaining two set collars on studs (Figure 6, Item 3). Install three setscrews (Figure 6, Item 11), if removed. Install collector ring core (Figure 6, Item 12) and collector ring base (Figure 6, Item 8) as an assembly on mounting column (Figure 6, Item 9). Align hole in collector ring base with bracket (Figure 6, Item 2) on rotary manifold (Figure 5, Item 5). Tighten three setscrews to 45 to 55 in-lb (5.1 to 6.2 Nm).
10. 11.
1 15 14
3 4 5
6 13
Figure 6.
12
11 10
9 8
7
M0130105
0070-7
TM 5-3810-305-23
0070
INSTALLATION - Continued 12. Install washer (Figure 7, Item 2), capscrew (Figure 7, Item 3), nylon plate (Figure 7, Item 5), nylon washer (Figure 7, Item 6), and cap nut (Figure 7, Item 1) on cover (Figure 7, Item 4).
2 1 3 6
4 5
Figure 7. Electrical Collector Ring Installation.
M0129105
0070-8
TM 5-3810-305-23
0070
INSTALLATION - Continued 13. Install cover (Figure 8, Item 7). Make sure upper harness grommet fits in slot on side of cover. Install two washers (Figure 8, Item 3) and nuts (Figure 8, Item 1).
CAUTION
Secure harness so that it does not drop down around electrical collector ring. Damage to harness may result. 14. 15. Connect four knife connectors (Figure 8, Item 2) inside upperstructure. Protect connectors with shrink tubing or electrical tape. Secure harnesses together with tiedown straps. Connect four knife connectors (Figure 8, Item 5) to connector ring (Figure 8, Item 6) under carrier near rotary manifold (Figure 8, Item 4). Protect connectors with shrink tubing or electrical tape. Secure harnesses together with electrical tiedown straps.
1 7 6
3 4
5
M0128105
0070-9
TM 5-3810-305-23
0070
0070-10
TM 5-3810-305-23
0071
FIELD MAINTENANCE REAR LIGHTS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 14) Qty: 4 Washer, Lock Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
0071-1
TM 5-3810-305-23
0071
REMOVAL
NOTE
Tag and identify wires to aid in installation. Following steps apply to both left and right hand rear light assemblies. 1. 2. 3. Disconnect electrical connectors (Figure 1, Item 7). Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), ground wire (Figure 1, Item 6), rear turn signal (Figure 1, Item 2), and washer (Figure 1, Item 3) from mounting bracket (Figure 1, Item 1). Discard lockwasher. Remove two bolts (Figure 1, Item 8), lockwashers (Figure 1, Item 9), ground wires (Figure 1, Item 10), and rear taillight (Figure 1, Item 12) from mounting bracket (Figure 1, Item 11). Discard lockwashers.
NOTE
Install wires as tagged during removal. 1. 2. 3. Install rear taillight (Figure 1, Item 12), two ground wires (Figure 1, Item 10), new lockwashers (Figure 1, Item 9), and bolts (Figure 1, Item 8) on mounting bracket (Figure 1, Item 11). Install washer (Figure 1, Item 3), rear turn signal (Figure 1, Item 2), ground wire (Figure 1, Item 6), new lockwasher (Figure 1, Item 5), and nut (Figure 1, Item 4) on mounting bracket (Figure 1, Item 1). Connect electrical connectors (Figure 1, Item 7).
0071-2
TM 5-3810-305-23
0071
4,5,6
7 12
11
8,9,10
M0151105
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076).
Rear Lights Maintenance.
Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0071-3/4 blank
TM 5-3810-305-23
0072
FIELD MAINTENANCE FRONT LIGHTS AND BRACKETS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 8 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0072-1
TM 5-3810-305-23
0072
REMOVAL Left Front Lights and Bracket
WARNING
NOTE
Tag all wires and electrical connectors to aid in installation. 1. 2. 3. 4. 5. 6. Disconnect electrical connectors (Figure 1, Items 7, 15 and 16) from blackout lamp (Figure 1, Item 3), headlight (Figure 1, Item 19), and turn signal (Figure 1, Item 2). Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), ground wire (Figure 1, Item 6), and blackout lamp (Figure 1, Item 3) from bracket (Figure 1, Item 18). Discard lockwasher. Remove nut (Figure 1, Item 8), lockwasher (Figure 1, Item 9), ground wire (Figure 1, Item 10), turn signal (Figure 1, Item 2), and washer (Figure 1, Item 1) from bracket (Figure 1, Item 18). Discard lockwasher. Remove nut (Figure 1, Item 22) and lockwasher (Figure 1, Item 21) from headlight (Figure 1, Item 19) base. Discard lockwasher. Remove headlight (Figure 1, Item 19) and washer (Figure 1, Item 20) from bracket (Figure 1, Item 18). Remove four nuts (Figure 1, Item 11), lockwashers (Figure 1, Item 12), capscrews (Figure 1, Item 13), and left front bracket (Figure 1, Item 18) from vehicle. Discard lockwashers.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect grommet (Figure 1, Item 14) and rubber bumper (Figure 1, Item 17) IAW General Maintenance Instructions (WP 0162). If damaged, replace.
END OF TASK
0072-2
TM 5-3810-305-23
0072
INSTALLATION Left Front Lights and Bracket
NOTE
Install all wires and electrical connectors as tagged during removal. 1. 2. 3. 4. 5. Install left front bracket (Figure 1, Item 18), four capscrews (Figure 1, Item 15), new lockwashers (Figure 1, Item 12), and nuts (Figure 1, Item 11) on vehicle. Install washer (Figure 1, Item 20), headlight (Figure 1, Item 19), new lockwasher (Figure 1, Item 21), and nut (Figure 1, Item 22) on bracket (Figure 1, Item 18). Install washer (Figure 1, Item 1), turn signal (Figure 1, Item 2), ground wire (Figure 1, Item 10), new lockwasher (Figure 1, Item 9), and nut (Figure 1, Item 8) on bracket (Figure 1, Item 18). Install blackout lamp (Figure 1, Item 3), ground wire (Figure 1, Item 6), new lockwasher (Figure 1, Item 5), and nut (Figure 1, Item 4) on bracket (Figure 1, Item 18). Connect electrical connectors (Figure 1, Items 7, 15, and 16) on blackout lamp (Figure 1, Item 3), headlight (Figure 1, Item 19), and turn signal (Figure 1, Item 2).
2 1
4,5,6
8,9,10 11,12,13
14
15 16 18 17
21,22
20
19
M0149105
Figure 1.
Left Front Lights and Bracket Installation.
END OF TASK
0072-3
TM 5-3810-305-23
0072
END OF TASK REMOVAL Right Front Lights and Bracket
WARNING
NOTE
Tag and identify all wires and electrical connectors to aid in installation. 1. 2. 3. 4. 5. Disconnect electrical connectors (Figure 2, Items 7 and 10) from headlight (Figure 2, Item 16) and turn signal (Figure 2, Item 2). Remove nut (Figure 2, Item 4), lockwasher (Figure 2, Item 5), ground wire (Figure 2, Item 6), turn signal (Figure 2, Item 2), and washer (Figure 2, Item 3) from right front bracket (Figure 2, Item 1). Discard lockwasher. Remove nut (Figure 2, Item 11) and lockwasher (Figure 2, Item 12) from headlight (Figure 2, Item 16) base. Discard lockwasher. Remove headlight (Figure 2, Item 16) and washer (Figure 2, Item 9) from right front bracket (Figure 2, Item 1). Remove four nuts (Figure 2, Item 13), lockwashers (Figure 2, Item 14), capscrews (Figure 2, Item 15), and right front bracket (Figure 2, Item 1) from vehicle. Discard lockwashers.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect grommet and rubber bumper IAW General Maintenance Instructions (WP 0162). If damaged, replace.
END OF TASK
0072-4
TM 5-3810-305-23
0072
INSTALLATION Right Front Lights and Bracket 1. 2. 3. Install right front bracket (Figure 2, Item 1), four capscrews (Figure 2, Item 15), new lockwashers (Figure 2, Item 14), and nuts (Figure 2, Item 13) on vehicles. Install washer (Figure 2, Item 9), headlight (Figure 2, Item 16), new lockwasher (Figure 2, Item 12), and nut (Figure 2, Item 11) on right front bracket (Figure 2, Item 1). Install washer (Figure 2, Item 3), turn signal (Figure 2, Item 2), ground wire (Figure 2, Item 6), new lockwasher (Figure 2, Item 5), and nut (Figure 2, Item 4) on right front bracket (Figure 2, Item 1).
NOTE
Install all wires and electrical connectors as tagged during removal. 4. Connect electrical connectors (Figure 2, Items 7 and 10) on turn signal (Figure 2, Item 2) and headlight (Figure 2, Item 16).
4,5,6 7
16 10 11,12 13,14,15
M0150105
8 9
Figure 2. Right Front Lights and Bracket Installation.
END OF TASK
0072-5
TM 5-3810-305-23
0072
0072-6
TM 5-3810-305-23
0073
FIELD MAINTENANCE WORK LIGHTS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0073-1
TM 5-3810-305-23
0073
WARNING
Wear protective equipment while heating and handling bearing cone. Failure to follow this warning may cause injury or death to personnel. REMOVAL
NOTE
The following is a maintenance procedure for one work light. Maintenance procedure for remaining two work lights is identical. Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect two wires (Figure 1, Item 3) from work light (Figure 1, Item 1). Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), and work light (Figure 1, Item 1) from boom (Figure 1, Item 2). Discard lockwasher.
NOTE
Install wires as tagged during removal. 1. 2. Install work light (Figure 1, Item 1), new lockwasher (Figure 1, Item 5), and nut (Figure 1, Item 4) to boom (Figure 1, Item 2). Connect two wires (Figure 1, Item 3) to work light (Figure 1, Item 1).
0073-2
TM 5-3810-305-23
0073
4,5
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
3
Work Lights Maintenance.
M0126105
0073-3/4 blank
TM 5-3810-305-23
0074
FIELD MAINTENANCE AXLE CENTERING LIGHT SWITCH ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 53) Qty: 2 Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 2 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
0074-1
TM 5-3810-305-23
0074
REMOVAL
NOTE
Tag and identify all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. Disconnect cam switch electrical lead (Figure 1, Item 1).
M0152105
Figure 1. Axle Centering Light Switch Assembly Removal. 2. 3. 4. 5. 6. 7. 8. 9. Remove two capscrews (Figure 2, Item 6), locknuts (Figure 2, Item 7), and washers (Figure 2, Item 8) from cam switch (Figure 2, Item 5). Discard locknuts. Remove switch (Figure 2, Item 5) from vehicle. Remove jam nut (Figure 2, Item 3) and washer (Figure 2, Item 1) from plate (Figure 2, Item 4). Remove two locknuts (Figure 2, Item 9), washers (Figure 2, Item 10), capscrews (Figure 2, Item 13), washers (Figure 2, Item 12), block (Figure 2, Item 11), and rod (Figure 2, Item 14) from vehicle. Discard locknuts. Remove rod (Figure 2, Item 14) from block (Figure 2, Item 11). Loosen jam nut (Figure 2, Item 15) and remove rod (Figure 2, Item 14) from rod end (Figure 2, Item 16). Remove jam nut (Figure 2, Item 15) from rod (Figure 2, Item 14). Remove two capscrews (Figure 2, Item 2) and plate (Figure 2, Item 4) from vehicle.
0074-2
TM 5-3810-305-23
0074
REMOVAL - Continued
3 4 5
6 7,8
10 11
16
12
13 15 14
Figure 2. Axle Centering Light Switch Assembly Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
M0153105
0074-3
TM 5-3810-305-23
0074
INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install plate (Figure 3, Item 4) and two capscrews (Figure 3, Item 2) on vehicle. Install jam nut (Figure 3, Item 15) on rod (Figure 3, Item 14). Install rod (Figure 3, Item 14) into rod end (Figure 3, Item 16). Install rod (Figure 3, Item 14) into the large diameter hole side of block (Figure 3, Item 11). Install block (Figure 3, Item 11) with rod (Figure 3, Item 14), two washers (Figure 3, Item 12), capscrews (Figure 3, Item 13), washers (Figure 3, Item 10), and new locknuts (Figure 3, Item 9) on vehicle. Install rod end (Figure 3, Item 16), washer (Figure 3, Item 1) and jam nut (Figure 3, Item 3) on plate (Figure 3, Item 4). Install switch (Figure 3, Item 5), two capscrews (Figure 3, Item 6), washers (Figure 3, Item 8) and locknuts (Figure 3, Item 7) on vehicle.
3 4 5
6 7,8
10 11
16
12
13 15
Figure 3.
14
Axle Centering Light Switch Assembly Installation.
M0153105
0074-4
TM 5-3810-305-23
0074
INSTALLATION - Continued 8. 9. Connect battery cables (WP 0076). Connect cam switch electrical lead (Figure 4, Item 1).
M0152105
Axle Centering Light Switch Assembly Installation.
0074-5
TM 5-3810-305-23
0074
ADJUSTMENT 1. 2. 3. 4. 5. 6. Rear wheels must be parallel to carrier frame when making any adjustments. Loosen jam nut (Figure 5, Item 2) on rod (Figure 5, Item 4). Thread rod (Figure 5, Item 4) in or out of rod end (Figure 5, Item 1) until cam switch is in the center of groove on rod. Tighten jam nut (Figure 5, Item 2) against rod end (Figure 5, Item 1). Loosen two capscrews (Figure 5, Item 3). Slide cam switch until roller is centered in groove and just rests on rod (Figure 5, Item 4). Tighten two capscrews. Red indicator light should be on while rear axle is being turned right or left. Light should be off when axle is centered.
1 2
4
Figure 5. Axle Centering Light Switch Assembly Adjustment. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
M0154105
0074-6
TM 5-3810-305-23
0075
FIELD MAINTENANCE TACHOMETER ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Gasket (WP 0172, Table 1, Item 61) Qty: 1 O-Ring (WP 0172, Table 1, Item 80) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL 1. 2. Remove male connector (Figure 1, Item 3) of tachometer sensor (Figure 1, Item 2) from female connector (Figure 1, Item 4) of vehicle wiring harness (Figure 1, Item 5). Loosen nut (Figure 1, Item 6) and remove tachometer sensor (Figure 1, Item 2) from tachometer drive (Figure 1, Item 1).
1 2 6 3 4 5
M2106105
Figure 1. Tachometer Wiring Harness Removal.
0075-1
TM 5-3810-305-23
0075
REMOVAL - Continued 3. 4. 5. 6. Remove two screws (Figure 2, Item 1) and two flatwashers (Figure 2, Item 2) securing tachometer drive (Figure 2, Item 8). Remove tachometer drive (Figure 2, Item 8), o-ring (Figure 2, Item 7), cover (Figure 2, Item 3) and gasket (Figure 2, Item 4) from engine as an assembly. Discard gasket. If necessary, remove hub (Figure 2, Item 6) from shaft (Figure 2, Item 5). If necessary, remove tachometer drive (Figure 2, Item 8) and o-ring (Figure 2, Item 7) from cover (Figure 2, Item 3). Discard o-ring.
4 2 1 5 6 7 8
M2107105
Tachometer Drive Removal.
0075-2
TM 5-3810-305-23
0075
INSTALLATION 1. 2. 3. 4. If removed, install hub (Figure 3, Item 6) onto shaft (Figure 3, Item 5). If removed, install drive (Figure 3, Item 8) and new o-ring (Figure 3, Item 7) to cover (Figure 3, Item 3). Position new gasket (Figure 3, Item 4) on cover (Figure 3, Item 3). Install new gasket (Figure 3, Item 4), cover (Figure 3, Item 3), new o-ring (Figure 3, Item 7) and tachometer drive (Figure 3, Item 8) to engine as an assembly, and secure with two flatwashers (Figure 3, Item 2) and screws (Figure 3, Item 1).
4 2 1 5 6 7 8
M2107105
Figure 3.
Tachometer Drive Installation.
0075-3
TM 5-3810-305-23
0075
INSTALLATION - Continued 5. 6. 7. Insert tachometer sensor (Figure 4, Item 2) into tachometer drive (Figure 4, Item 1). Hand-tighten nut (Figure 4, Item 6) on tachometer sensor (Figure 4, Item 2) and then further tighten nut 1/4 to 1/2 additional turn. Insert male connector (Figure 4, Item 3) of tachometer sensor (Figure 4, Item 2) into female connector (Figure 4, Item 4) of vehicle wiring harness (Figure 4, Item 5).
1 2 6 3 4 5
M2106105
Figure 4. Tachometer Wiring Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Verify correct tachometer operation (TM 5-3810-305-10).
0075-4
TM 5-3810-305-23
0076
FIELD MAINTENANCE BATTERY ASSEMBLY AND CABLES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Battery Kit, Service (WP 0171, Table 1, Item 43) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 2 O-Ring Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Soda, Baking (WP 0170, Table 1, Item 67) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 8) Qty: 2 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 92) Qty: 4 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 129) Qty: 1 References TB 9-6140-252-13 TM 5-3810-305-10 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0076-1
TM 5-3810-305-23
0076
REMOVAL
WARNING
BATTERIES Battery gases can explode. DO NOT smoke or allow sparks or open flames near batteries. Wear safety glasses or goggles when checking the batteries. To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury or death to personnel. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Seek medical attention in the event of an injury. a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia. Failure to follow these warnings may cause injury or death to personnel. 1. Open battery compartment cover (TM 5-3810-305-10).
WARNING
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 2. Disconnect ground cable (Figure 1, Item 6) from battery (Figure 1, Item 9). Discard lockwasher.
0076-2
TM 5-3810-305-23
0076
REMOVAL - Continued 3. 4. 5. 6. 7. Disconnect black wire from ground cable (Figure 1, Item 6). Disconnect positive cable (Figure 1, Item 2) from battery (Figure 1, Item 3). Discard lockwasher. Disconnect two white wires and cable (Figure 1, Item 1) from cable (Figure 1, Item 2). Remove jump cable (Figure 1, Item 4) from batteries (Figure 1, Items 3 and 9). Discard lockwasher. Remove four nuts (Figure 1, Item 8), washers (Figure 1, Item 7), and two battery clamps (Figure 1, Item 5) from vehicle.
3 2
9 8
7 5 6
Figure 1. Battery and Cables Assembly Removal.
M0091105
0076-3
TM 5-3810-305-23
0076
REMOVAL - Continued 8. 9. 10. 11. Remove capscrew (Figure 2, Item 2) and lockwasher (Figure 2, Item 3), and disconnect cable (Figure 2, Item 4) from slave receptacle (Figure 2, Item 1). Discard lockwasher. Remove capscrew (Figure 2, Item 2) and lockwasher (Figure 2, Item 3), and disconnect cable (Figure 2, Item 9) from slave receptacle (Figure 2, Item 1). Discard lockwasher. Remove batteries (Figure 2, Items 5 and 6) from battery compartment. Remove four bolts (Figure 2, Item 7) and o-rings (Figure 2, Item 8) from battery compartment. Discard o-rings.
7 2,3 4 5 6
2,3 9
M0092105
0076-4
TM 5-3810-305-23
0076
REMOVAL - Continued 12. 13. Remove capscrew (Figure 3, Item 2) and lockwasher (Figure 3, Item 3), and disconnect cables (Figure 3, Items 5 and 6) from shunt (Figure 3, Item 4). Discard lockwasher. Remove capscrews (Figure 3, Item 2) and lockwasher (Figure 3, Item 3), and disconnect cable (Figure 3, Item 1) from shunt (Figure 3, Item 4). Discard lockwasher.
2,3
2,3
M0093105
Figure 3.
Battery and Cables Assembly Removal.
0076-5
TM 5-3810-305-23
0076
REMOVAL - Continued 14. 15. 16. 17. 18. 19. Remove bolt (Figure 4, Item 5) and lockwasher (Figure 4, Item 6), and disconnect cables (Figure 4, Items 7 and 10). Discard lockwasher. Cut and remove all tiedown straps securing cables (Figure 4, Items 1 and 7). Discard tiedown straps. Remove nut (Figure 4, Items 2 and 3) securing cable (Figure 4, Item 1) to starting motor. Disconnect cable (Figure 4, Items 1 and 4). Install nut (Figure 4, Item 2) and washer (Figure 4, Item 3) on starting motor (Figure 4, Item 4). Follow cable (Figure 4, Item 10) down to frame and remove nut (Figure 4, Item 9), washer (Figure 4, Item 8), and cable. Remove cables (Figure 4, Items 1 and 7) from vehicle.
2,3,4
5,6
10 9,8
M0094105
0076-6
TM 5-3810-305-23
0076
REMOVAL - Continued 20. Remove two locknuts (Figure 5, Item 2), two washers (Figure 5, Item 1), and four clamps (Figure 5, Item 3). Discard locknuts.
1,2
3
M0095105
1,2
Figure 5. 21. Battery and Cables Assembly Removal.
Remove grommet (Figure 6, Item 1) and flexible trim (Figure 6, Item 2).
M0096105
Figure 6.
Battery and Cables Assembly Removal.
0076-7
TM 5-3810-305-23
0076
REMOVAL - Continued 22. 23. 24. Remove two screws (Figure 7, Item 1) and lockwashers (Figure 7, Item 2), and disconnect red and blue wires from shunt (Figure 7, Item 3). Discard lockwashers. Remove two nuts (Figure 7, Item 4), lockwashers (Figure 7, Item 5), bolts (Figure 7, Item 6), and shunt (Figure 7, Item 3) from battery box. Discard lockwashers. Remove four nuts (Figure 7, Item 7), lockwashers (Figure 7, Item 8), bolts (Figure 7, Item 9), and slave receptacle (Figure 7, Item 10) from battery box. Discard lockwashers.
1,2 3
4,5,6
10
7,8,9
M0097105
Figure 7. Battery and Cables Assembly Removal. END OF TASK CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Clean cable terminals with a solution of baking soda and water. Rinse with clean water and wire brush. Clean batteries with a solution of baking soda and water. Rinse with clean water. Clean negative and positive terminal posts with a wire brush. Clean all other parts.
END OF TASK
0076-8
TM 5-3810-305-23
0076
INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect battery cables for broken, cracked, or deteriorated insulation. Inspect battery cable terminal for corroded or damaged condition. Inspect battery case for signs of cracks or electrolyte leakage. Ensure terminal posts are solid. Replace battery cables that have broken wires or damaged insulation. If battery is to be charged, observe all safety precautions. Charge batteries (refer to TB 9-6140-252-13). Inspect all other parts.
END OF TASK INSTALLATION 1. 2. 3. Install slave receptacle (Figure 8, Item 10), four bolts (Figure 8, Item 9), new lockwashers (Figure 8, Item 8), and nuts (Figure 8, Item 7) on battery box. Install shunt (Figure 8, Item 3), two bolts (Figure 8, Item 6), new lockwashers (Figure 8, Item 5), and nuts (Figure 8, Item 4) on battery box. Connect blue and red wires to shunt (Figure 8, Item 3) and install two new lockwashers (Figure 8, Item 2) and screws (Figure 8, Item 1) on shunt.
1,2 3
4,5,6
10
7,8,9
M0097105
Figure 8. Battery and Cables Assembly Installation.
0076-9
TM 5-3810-305-23
0076
INSTALLATION - Continued 4. 5. Install flexible trim (Figure 9, Item 2) and grommet (Figure 9, Item 1) on battery box. Route cables (Figure 9, Items 3 and 4) through flexible trim (Figure 9, Item 2) and grommet (Figure 9, Item 1).
3 4
M0099105
0076-10
TM 5-3810-305-23
0076
INSTALLATION - Continued 6. 7. 8. 9. Connect cable (Figure 10, Item 1) to starting motor (Figure 10, Item 4) and install nut (Figure 10, Item 2) and washer (Figure 10, Item 3). Install cable (Figure 10, Item 10), washer (Figure 10, Item 8), and nut (Figure 10, Item 9). Connect cable (Figure 10, Items 7 and 10) and install new lockwasher (Figure 10, Item 5) and bolt (Figure 10, Item 6). Install new tiedown straps as needed.
2,3,4
5,6
10 9,8
Figure 10.
7
Battery and Cables Assembly Installation.
M0094105
0076-11
TM 5-3810-305-23
0076
INSTALLATION - Continued 10. 11. 12. 13. 14. 15. Connect cable (Figure 11, Item 1) to shunt (Figure 11, Item 4) and install lockwasher (Figure 11, Item 3) and capscrew (Figure 11, Item 2). Install four bolts (Figure 11, Item 12) and new o-rings (Figure 11, Item 13). Install batteries (Figure 11, Items 10 and 11) into battery compartment. Install cables (Figure 11, Items 5 and 14), lockwasher (Figure 11, Item 3), and capscrew (Figure 11, Item 2) to shunt (Figure 11, Item 4). Connect cable (Figure 11, Item 14) and install two lockwashers (Figure 11, Item 8) and capscrew (Figure 11, Item 7) to slave receptacle (Figure 11, Item 6). Connect cable (Figure 11, Item 9) and install two lockwashers (Figure 11, Item 8) and capscrew (Figure 11, Item 7) to slave receptacle (Figure 11, Item 6).
4 1 2,3 2,3 5
7,8 9
10
11
12
13
14
8,9
14
M0100105
0076-12
TM 5-3810-305-23
0076
INSTALLATION - Continued 16. 17. Install two battery clamps (Figure 12, Item 2), four washers (Figure 12, Item 4), and locknuts (Figure 12, Item 5). Connect black wire to ground cable (Figure 12, Item 3) and connect ground cable to battery (Figure 12, Item 1).
4 2 3
M0101105
0076-13
TM 5-3810-305-23
0076
INSTALLATION - Continued 18. Install four clamps (Figure 13, Item 3), two washers (Figure 13, Item 1), and two new locknuts (Figure 13, Item 2).
1,2
3
M0095105
1,2
0076-14
TM 5-3810-305-23
0076
INSTALLATION - Continued 19. 20. 21. Install jumper cable (Figure 14, Item 3) to batteries (Figure 14, Items 4 and 5). Connect cable (Figure 14, Item 1) and two white wires to cable (Figure 14, Item 2). Install cable (Figure 14, Item 2) to battery (Figure 14, Item 5).
3
M0090105
Figure 14. END OF TASK FOLLOW-ON MAINTENANCE
Battery and Cables Assembly Installation.
Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
0076-15/16 blank
TM 5-3810-305-23
0077
FIELD MAINTENANCE BATTERY BOX AND TOOLBOX WITH COVERS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Nut, Self-Locking, He M6 (WP 0172, Table 1, Item 138) Qty: 3 Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 8 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Batteries removed (WP 0076)
REMOVAL 1. 2. 3. 4. Remove four locknuts (Figure 1, Item 5), washers (Figure 1, Item 6), and capscrews (Figure 1, Item 7) from battery cover (Figure 1, Item 8). Discard locknuts. Remove battery cover (Figure 1, Item 8) from vehicle. Remove four locknuts (Figure 1, Item 2), washers (Figure 1, Item 3), and capscrews (Figure 1, Item 4) from toolbox cover (Figure 1, Item 1). Discard locknuts. Remove toolbox cover (Figure 1, Item 1) from toolbox (Figure 1, Item 9).
2,3 4
5,6
9 7
8
Figure 1. Battery Box and Toolbox Cover Removal.
M1250105
0077-1
TM 5-3810-305-23
0077
REMOVAL - Continued 5. 6. Remove three locknuts (Figure 2, Item 5), capscrews (Figure 2, Item 6), and hand pump (Figure 2, Item 7) from inside of toolbox (Figure 2, Item 2). Discard locknuts. Remove all tools and spare parts from toolbox (Figure 2, Item 2).
WARNING
Weight of toolbox is approximately 180 lb (82 kg). Use adequate lifting equipment to support toolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. Support toolbox (Figure 2, Item 2) with suitable blocking or a floor jack. Remove six capscrews (Figure 2, Item 3), washers (Figure 2, Item 4), and toolbox (Figure 2, Item 2) from vehicle (Figure 2, Item 1).
2 1
4 7 6
5
M1251105
Figure 2. Battery Box and Toolbox Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0077-2
TM 5-3810-305-23
0077
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION
WARNING
Weight of toolbox is approximately 180 lb (82 kg). Use adequate lifting equipment to support toolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. 4. Support toolbox (Figure 3, Item 2) in suitable blocking or floor jack. Install toolbox (Figure 3, Item 2), six washers (Figure 3, Item 4) and capscrews (Figure 3, Item 3) on vehicle (Figure 3, Item 1). Install all tools and spare parts removed earlier from toolbox (Figure 3, Item 2). Using three capscrews (Figure 3, Item 6) and new locknuts (Figure 3, Item 5) secure hand pump (Figure 3, Item 7) to inside of toolbox (Figure 3, Item 2).
2 1
4 7 6
5
M1251105
Figure 3.
Battery Box and Toolbox Installation.
0077-3
TM 5-3810-305-23
0077
INSTALLATION - Continued 5. 6. 7. 8. Install toolbox cover (Figure 4, Item 1) on vehicle (Figure 4, Item 9). Install four capscrews (Figure 4, Item 4), washers (Figure 4, Item 3), and new locknuts (Figure 4, Item 2) on toolbox cover (Figure 4, Item 1). Install battery cover (Figure 4, Item 8) on vehicle. Install four capscrews (Figure 4, Item 7), washers (Figure 4, Item 6), and new locknuts (Figure 4, Item 5) on battery cover (Figure 4, Item 8).
2,3 4
5,6
9 7
8
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install batteries (WP 0076). Place boom in resting position (TM 5-3810-305-10). Battery Box and Toolbox Cover Installation.
M1250105
0077-4
TM 5-3810-305-23
0078
FIELD MAINTENANCE MAIN ENGINE WIRING HARNESS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 8 Materials/Parts (cont.) Washer, Lock M8 (WP 0172, Table 1, Item 126) Qty: 26 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance.
0078-1
TM 5-3810-305-23
0078
REMOVAL 1. Disconnect main engine wiring harness (Figure 1, Item 12) from shunt (Figure 1, Item 21), hydraulic valve bank (Figure 1, Item 6), winch valve (Figure 1, Item 10), fuel shutoff toggle switch (Figure 1, Item 8), front outrigger solenoid valve (Figure 1, Item 9), collector ring (Figure 1, Item 5), fuel sender (Figure 1, Item 13), transmission temperature sender (Figure 1, Item 4), axle centering light switch (Figure 1, Item 14), oil pressure sender (Figure 1, Item 17), backup alarm (Figure 1, Item 19), rear outrigger solenoid valve (Figure 1, Item 3), water temperature sender (Figure 1, Item 20), alternator (Figure 1, Item 2), starting motor solenoid and starting motor relay (Figure 1, Item 1), speedometer sender (Figure 1, Item 7), taillights (Figure 1, Item 16), fuel solenoid (Figure 1, Item 18), and turn signals (Figure 1, Item 15). Remove main engine wiring harness mounting clamps (Figure 1, Item 11), lockwashers and tiedown straps. Discard tiedown straps and lockwashers. Remove main engine wiring harness (Figure 1, Item 12).
2. 3.
2 3
19 18
20 21 4 5 6 7 8
17
16
15 14 13 12 11 10 9
M0164105
Main Engine Wiring Harness Removal.
0078-2
TM 5-3810-305-23
0078
INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Repair wire harness, if necessary.
END OF TASK INSTALLATION 1. 2. Position main engine wiring harness (Figure 2, Item 12) in vehicle. Connect main engine wiring harness (Figure 2, Item 12) at shunt (Figure 2, Item 21), hydraulic valve bank (Figure 2, Item 6), winch valve (Figure 2, Item 10), fuel shutoff toggle switch (Figure 2, Item 8), front outrigger solenoid valve (Figure 2, Item 9), collector ring (Figure 2, Item 5), fuel sender (Figure 2, Item 13), transmission temperature sender (Figure 2, Item 4), axle centering light switch (Figure 2, Item 14), oil pressure sender (Figure 2, Item 17), backup alarm (Figure 2, Item 19), rear outrigger solenoid valve (Figure 2, Item 3), water temperature sender (Figure 2, Item 20), alternator (Figure 2, Item 2), starting motor solenoid and starting motor relay (Figure 2, Item 1), speedometer sender (Figure 2, Item 7), taillights (Figure 2, Item 16), fuel solenoid (Figure 2, Item 18), and turn signals (Figure 2, Item 15). Install new tiedown straps, new lockwashers, and clamps to secure main engine wiring harness.
3.
2 3
19 18
20 21 4 5 6 7 8
17
16
15 14 13 12 11 10 9
M0164105
Main Engine Wiring Harness Installation.
0078-3
TM 5-3810-305-23
0078
FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for normal operation.
0078-4
TM 5-3810-305-23
0079
FIELD MAINTENANCE CAB MAIN HARNESS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Tool Kit, Auto Fuel and Electrical System (WP 0171, Table 1, Item 16) Materials/Parts Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Circuit breaker panel and wire assemblies disconnected (WP 0066) Side sloping dash panel and wire assemblies disconnected (WP 0066) Dash panel and wire assemblies disconnected (WP 0066)
0079-1
TM 5-3810-305-23
0079
REMOVAL
NOTE
Tag and identify all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. 3. Disconnect wire harness plugs from receptacles on back wall of cab. Remove two clamps (Figure 1, Item 14) and wire (Figure 1, Item 15) from heater and circuit breaker. Disconnect cab main harness from cab floor ground (Figure 1, Item 12), circuit breaker (Figure 1, Item 11), sloping dash panel (Figure 1, Item 10), horn (Figure 1, Item 7), defroster fan (Figure 1, Item 5), brakelight switch (Figure 1, Item 6), wiper motor (Figure 1, Item 2), turn signal switch (Figure 1, Item 17), speedometer (Figure 1, Item 3), headlights (Figure 1, Item 1), and speedometer alarm (Figure 1, Item 4). Remove cab main harness mounting clamps (Figure 1, Item 13), capscrews (Figure 1, Item 8), nuts (Figure 1, Item 9), and tiedown straps (Figure 1, Item 16). Discard tiedown straps. Remove cab main harness from cab.
4. 5.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Repair cab main harness, if necessary.
END OF TASK
0079-2
TM 5-3810-305-23
0079
INSTALLATION 1. 2. 3. Position cab main harness in cab. Install new tiedown straps (Figure 1, Item 16), nuts (Figure 1, Item 9), capscrews (Figure 1, Item 8), and cab main harness mounting clamps (Figure 1, Item 13) to secure cab main harness. Connect cab main harness to cab floor ground (Figure 1, Item 12), circuit breaker (Figure 1, Item 11), sloping dash panel (Figure 1, Item 10), horn (Figure 1, Item 7), defroster fan (Figure 1, Item 5), brakelight switch (Figure 1, Item 6), wiper motor (Figure 1, Item 2), turn signal switch (Figure 1, Item 17), speedometer (Figure 1, Item 3), headlights (Figure 1, Item 1), and speedometer alarm (Figure 1, Item 4). Install wire (Figure 1, Item 15) and two clamps (Figure 1, Item 14) to heater and circuit breaker.
4.
3 4 7
5 6
17
16 10 13 11 12 9
15
14
Figure 1. Cab Main Harness Maintenance.
M0127105
END OF TASK
0079-3
TM 5-3810-305-23
0079
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect dash panel and wire assemblies (WP 0066). Connect side sloping dash panel and wire assemblies (WP 0066). Connect circuit breaker panel and wire assemblies (WP 0066). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0079-4
TM 5-3810-305-23
0080
FIELD MAINTENANCE BACKUP ALARM MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 93) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
0080-1
TM 5-3810-305-23
0080
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect electrical connections (Figure 1, Item 1). Remove two nuts (Figure 1, Item 2), two washers (Figure 1, Item 3), lockwashers (Figure 1, Item 4), and backup alarm (Figure 1, Item 6) from mounting studs (Figure 1, Item 5). Discard lockwashers.
2,3,4
6
M0125105
Figure 1. Back Up Alarm Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0080-2
TM 5-3810-305-23
0080
INSTALLATION 1. 2. Install backup alarm (Figure 2, Item 6), two new lockwashers (Figure 2, Item 4), washers (Figure 2, Item 3), and two nuts (Figure 2, Item 2) on mounting studs (Figure 2, Item 5). Discard lockwashers. Connect electrical connections (Figure 2, Item 1).
2,3,4
6
M0125105
Back Up Alarm Installation.
0080-3/4 blank
TM 5-3810-305-23
0081
FIELD MAINTENANCE MSD-ICE WIRING HARNESS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. Disconnect main MSD-ICE harness (Figure 1, Item 10) from resistor module (Figure 1, Item 8), tachometer sender (Figure 1, Item 12), fuel pressure transducer (Figure 1, Item 2), alternator (Figure 1, Item 3), starting motor solenoid (Figure 1, Item 5), fuel differential pressure switch (Figure 1, Item 1), shunt (Figure 1, Item 6) batteries (Figure 1, Item 7), starting motor (Figure 1, Item 4), and fuel solenoid (Figure 1, Item 11). Remove main MSD-ICE harness mounting clamps (Figure 1, Item 9) and hardware from main MSD-ICE harness (Figure 1, Item 10). Remove MSD-ICE harness (Figure 1, Item 10) from vehicle.
2. 3.
2 3
12
4 6 7
11 10
M0163105
Main MSD-ICE Harness Removal.
0081-1
TM 5-3810-305-23
0081
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Position main MSD-ICE harness (Figure 2, Item 10) in vehicle. Connect main MSD-ICE harness (Figure 2, Item 10) resistor module (Figure 2, Item 8), tachometer sender (Figure 2, Item 12), fuel pressure transducer (Figure 2, Item 2), alternator (Figure 2, Item 3), starter solenoid (Figure 2, Item 5), fuel pressure differential switch (Figure 2, Item 1), shunt (Figure 2, Item 6), batteries (Figure 2, Item 7), starting motor (Figure 2, Item 4), and fuel solenoid (Figure 2, Item 11). Install DCA and resistor module connectors on rear wall of cab. Install clamps (Figure 2, Item 9) and hardware to secure main MSD-ICE wire harness (Figure 2, Item 10).
3. 4.
2 3
12
4 6 7
11 10 9
M0163105
Figure 2. Main MSD-ICE Harness Installation. END OF TASK
0081-2
TM 5-3810-305-23
0081
FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for normal operation.
0081-3/4 blank
TM 5-3810-305-23
0082
FIELD MAINTENANCE BOOM WIRING HARNESS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 129) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 165) Qty: 2 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0082-1
TM 5-3810-305-23
0082
REMOVAL
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Lift and turn latch (Figure 1, Item 2) on counterweight (Figure 1, Item 1). Split and remove counterweight (Figure 1, Item 1) from around cable (Figure 1, Item 3).
3 3
Figure 1. Boom Wiring Harness Removal.
M0165105
0082-2
TM 5-3810-305-23
0082
REMOVAL - Continued 3. 4. 5. Remove threaded pin from clevis (Figure 2, Item 5). Unlatch lock (Figure 2, Item 2) and disconnect electrical connector (Figure 2, Item 1). Remove pin (Figure 2, Item 3) and switch (Figure 2, Item 4) from mounting bracket (Figure 2, Item 6).
6
M0166105
0082-3
TM 5-3810-305-23
0082
REMOVAL - Continued
CAUTION
Anti-two block switch is serviced only as a complete assembly. DO NOT discard or lose any parts. Failure to follow this caution may result in damage to equipment.
NOTE
Tag wires and note routing to aid in installation. 6. 7. Remove four screws (Figure 3, Item 1) and cover (Figure 3, Item 2) from switch (Figure 3, Item 4). Disconnect wiring harness (Figure 3, Item 3) from switch (Figure 3, Item 4).
1 4
3 2
M0167105
0082-4
TM 5-3810-305-23
0082
REMOVAL - Continued
WARNING
DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness may result in serious injury or death if it hits personnel. 8. 9. Remove four screws (Figure 4, Item 1) and connector (Figure 4, Item 2). Remove cable (Figure 4, Item 4) from strain relief tube (Figure 4, Item 3). Slowly allow cable reel to take up cable.
M0168105
Figure 4.
Boom Wiring Harness Removal.
0082-5
TM 5-3810-305-23
0082
REMOVAL - Continued 10. 11. Remove two capscrews (Figure 5, Item 6), lockwashers (Figure 5, Item 7), and roller bracket (Figure 5, Item 5) from boom. Discard lockwashers. Remove nut (Figure 5, Item 4), roller (Figure 5, Item 3), washer (Figure 5, Item 2), and shoulder screw (Figure 5, Item 1) from roller bracket (Figure 5, Item 5). Repeat for other roller.
2 3 1 7 4
5 6
M0169105
0082-6
TM 5-3810-305-23
0082
REMOVAL - Continued
NOTE
Boom must be raised to highest position to aid in removing wire harness clamps. 12. 13. 14. 15. 16. 17. Connect battery cables (WP 0076). Start engine. Raise boom to highest position (TM 5-3810-305-10). Remove two nuts (Figure 6, Item 1), washers (Figure 6, Item 2), and clamps (Figure 6, Item 3) from vehicle. Install two washers (Figure 6, Item 2) and nuts (Figure 6, Item 1). Remove nut (Figure 6, Item 7), washer (Figure 6, Item 8), and clamp (Figure 6, Item 9) from vehicle. Remove nut (Figure 6, Item 4), washer (Figure 6, Item 5), and clamp (Figure 6, Item 6) from vehicle.
1,2,3
4,5,6
7,8,9 1,2,3
M0170105
0082-7
TM 5-3810-305-23
0082
REMOVAL - Continued 18. 19. 20. 21. Hold anti-two block BY-PASS switch and lower boom. Shut engine OFF. Disconnect battery cables (WP 0076). Disconnect two worklight wires (Figure 7, Item 4) from each of the three worklights (Figure 7, Item 1). Remove three nuts (Figure 7, Item 3), washers (Figure 7, Item 2), worklights (Figure 7, Item 1), and spacers (Figure 7, Item 5) from vehicle.
5 4
M0171105
0082-8
TM 5-3810-305-23
0082
REMOVAL - Continued
NOTE
Tag wires and note routing to aid in installation. 22. 23. Disconnect wire harness (Figure 8, Item 3) from wire harnesses (Figure 8, Items 1 and 2). Remove nut (Figure 8, Item 6), washer (Figure 8, Item 5), and clamp (Figure 8, Item 4) from vehicle.
3 5,6
Figure 8.
M0172105
NOTE
Tag wires and note routing to aid in installation. 24. 25. Disconnect wire harness (Figure 9, Item 1) from collector ring wire harness (Figure 9, Item 2). Remove wire harness (Figure 9, Item 1) from vehicle.
M0173105
0082-9
TM 5-3810-305-23
0082
NOTE
Install wiring harness as tagged during removal. 1. Install wiring harness (Figure 10, Item 1) to collector ring wiring harness (Figure 10, Item 2).
M0173105
Figure 10. Boom Wiring Harness Installation.
0082-10
TM 5-3810-305-23
0082
NOTE
Install wiring harness as tagged during removal. 2. 3. Install clamp (Figure 11, Item 4), washer (Figure 11, Item 5), and nut (Figure 11, Item 6) on vehicle. Connect wiring harnesses (Figure 11, Items 1 and 2) to wiring harness (Figure 11, Item 3).
3 5,6
Figure 11. 4. 5.
M0172105
Boom Wiring Harness Installation.
Install three spacers (Figure 12, Item 5) worklights (Figure 12, Item 1), washers (Figure 12, Item 2), and nuts (Figure 12, Item 3). Connect two worklight wires (Figure 12, Item 4) to each of three worklights (Figure 12, Item 1).
5 4
M0171105
0082-11
TM 5-3810-305-23
0082
NOTE
Boom must be raised to highest position to aid in installing wire harness clamps. 6. 7. 8. 9. 10. 11. Connect battery cables (WP 0076). Start engine. Raise boom to highest position. Install clamp (Figure 13, Item 6), washer (Figure 13, Item 5), and nut (Figure 13, Item 4) on vehicle. Install clamp (Figure 13, Item 8), washer (Figure 13, Item 7), and nut (Figure 13, Item 9) on vehicle. Remove two nuts (Figure 12, Item 1) and washers (Figure 12, Item 2). Install two clamps (Figure 12, Item 3), washers (Figure 12, Item 2), and nuts (Figure 12, Item 1) on vehicle.
1,2,3
4,5,6
7,8,9 1,2,3
M0170105
0082-12
TM 5-3810-305-23
0082
WARNING
DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness may result in serious injury or death if it hits personnel. 12. 13. 14. 15. Hold anti-two block BY-PASS switch and lower boom. Shut engine OFF. Disconnect battery cables (WP 0076). Install shoulder screw (Figure 14, Item 1), washer (Figure 14, Item 2), roller (Figure 14, Item 3), and nut (Figure 14, Item 4) on roller bracket (Figure 14, Item 5). Repeat for other roller. Install roller bracket (Figure 14, Item 5), two new lockwashers (Figure 14, Item 7), and capscrews (Figure 14, Item 6) on boom.
2 3 1 7 4
5 6
M0169105
0082-13
TM 5-3810-305-23
0082
INSTALLATION - Continued 16. 17. Install cable (Figure 15, Item 4) into strain relief tube (Figure 15, Item 3). Install connector (Figure 15, Item 2) and four screws (Figure 15, Item 1) on boom.
M0168105
CAUTION
Anti-two block switch is serviced only as a complete assembly. DO NOT discard or lose any parts. Failure to follow this caution may result in damage to equipment.
NOTE
Install wire harness as tagged during removal. 18. 19. Connect wiring harness (Figure 16, Item 3) on switch (Figure16, Item 4). Install cover (Figure 16, Item 2) and four screws (Figure 16, Item 1) on switch (Figure 16, Item 4).
1 4
3 2
M0167105
0082-14
TM 5-3810-305-23
0082
INSTALLATION - Continued 20. 21. 22. Install switch (Figure 17, Item 4) on mounting bracket (Figure 17, Item 6) with secure pin (Figure 17, Item 3). Connect electrical connector (Figure 17, Item 1). Secure with lock (Figure 17, Item 2). Install threaded pin on clevis (Figure 17, Item 5).
6
Figure 17. 23. 24. Boom Wiring Harness Installation.
M0166105
Close counterweight (Figure 18, Item 1) around cable (Figure 18, Item 3). Turn and lower latch (Figure 18, Item 2) on counterweight (Figure 18, Item 1).
3 3
Figure 18. END OF TASK Boom Wiring Harness Installation.
M0165105
0082-15
TM 5-3810-305-23
0082
FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation (TM 5-3810-305-10).
0082-16
TM 5-3810-305-23
0083
FIELD MAINTENANCE MSD-ICE DCA CONNECTOR/RESISTOR MODULE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Battery cables disconnected (WP 0076) Deck plates removed (TM 5-3810-305-10) (WP 0122)
0083-1
TM 5-3810-305-23
0083
REMOVAL
NOTE
Tag and identify all wires and wiring harnesses to aid in installation. 1. 2. 3. Remove MSD-ICE cap (Figure 1, Item 3), four nuts (Figure 1, Item 6), ground wires (Figure 1, Item 5), screws (Figure 1, Item 4), and MSD-ICE diagnostic connector (Figure 1, Item 7) from inside rear cab wall. Remove resistor cap (Figure 1, Item 1), four nuts (Figure 1, Item 8), screws (Figure 1, Item 2), and resistor module (Figure 1, Item 9) from inside rear cab wall. Remove nut (Figure 1, Item 11), washer (Figure 1, Item 12), and fuel toggle switch (Figure 1, Item 10) from inside rear cab wall.
10 11,12
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK MSD-ICE DCA Connector Resistor/Module Removal.
M0155105
0083-2
TM 5-3810-305-23
0083
INSTALLATION
NOTE
Install all wires and wiring harnesses as tagged during removal. 1. 2. 3. Install fuel toggle switch (Figure 2, Item 10), washer (Figure 2, Item 12), and nut (Figure 2, Item 11) on inside rear cab wall. Install resistor module (Figure 2, Item 9), four screws (Figure 2, Item 2), resistor cap (Figure 2, Item 1), and nuts (Figure 2, Item 8) to inside rear cab wall. Install MSD-ICE diagnostic connector (Figure 2, Item 7), four screws (Figure 2, Item 4), ground wires (Figure 2, Item 5), nuts (Figure 2, Item 6), plug and MSD-ICE cap (Figure 2, Item 3) to inside rear cab wall.
10 11,12
Figure 2. MSD-ICE DCA Connector Resistor/Module Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (WP 0122). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
M0155105
0083-3/4 blank
TM 5-3810-305-23
0084
FIELD MAINTENANCE TRANSMISSION DIPSTICK TUBE ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122) Transmission fluid drained (WP 0091)
0084-1
TM 5-3810-305-23
0084
REMOVAL 1. 2. 3. Remove cap screw (Figure 1, Item 1) and clamp (Figure 1, Item 6) from top rear of transmission (Figure 1, Item 2). From the bottom of vehicle, remove tubing nut (Figure 1, Item 4) and remove dipstick tube (Figure 1, Item 5) from elbow (Figure 1, Item 3). Remove elbow (Figure 1, Item 3) from transmission (Figure 1, Item 2).
1 2 6
5 4
3
M2105105
Figure 1. Transmission Dipstick Tube Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0084-2
TM 5-3810-305-23
0084
INSTALLATION 1. 2. 3. Install elbow (Figure 2, Item 3) on transmission (Figure2, Item 2). From the bottom of vehicle, install dipstick tube (Figure 2, Item 5) and install tubing nut (Figure 2, Item 4) on elbow (Figure 2, Item 3). Install clamp (Figure 2, Item 6) and cap screw (Figure 2, Item 1) on the top rear of transmission (Figure 2, Item 2).
1 2 6
5 4
3
M2105105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Fill transmission fluid (WP 0091). Install deck plates (WP 0122). Connect battery cables (WP 0076).
Transmission Dipstick Tube Installation.
Place boom in resting position (TM 5-3810-305-10). Check proper operation.
0084-3/4 blank
TM 5-3810-305-23
0085
FIELD MAINTENANCE TRANSMISSION SHIFT CONTROLS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 117) Qty: 2 Washer, Split (WP 0172, Table 1, Item 116) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Right console panel removed (WP 0066) Battery cables disconnected (WP 0076)
0085-1
TM 5-3810-305-23
0085
REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove four capscrews (Figure 1, Item 22) and split washers (Figure 1, Item 23) from side housing (Figure 1, Item 8). Discard split washers. Remove two capscrews (Figure 1, Item 25) and lockwashers (Figure 1, Item 7) from side housing (Figure 1, Item 8). Discard lockwashers. Remove two side housings (Figure 1, Items 8 and 9) and extruded spacers (Figure 1, Item 19) from control assembly. Remove two access caps (Figure 1, Item 26) and decals (Figure 1, Item 24) from side housing (Figure 1, Item 8). Remove three ball knobs (Figure 1, Item 4) from shift levers (Figure 1, Items 1, 3, and 5). Remove gate plate (Figure 1, Item 27) from control assembly. Remove position strips (Figure 1, Items 28, 29, and 30) from gate plate (Figure 1, Item 27). Remove two retaining rings (Figure 1, Item 10) and spacers (Figure 1, Item 11) from actuator assembly (Figure 1, Item 21). Remove three time actuator assemblies (Figure 1, Item 21) and two spacers (Figure 1, Item 18) from shaft (Figure 1, Item 20).
NOTE
The following step covers removal for one actuator assembly; removal of remaining actuators is similar. 10. 11. 12. 13. Drive pin spring (Figure 1, Item 17) from actuator assembly (Figure 1, Item 21) and remove shift lever (Figure 1, Item 5). Remove lever detent (Figure 1, Item 6) from actuator assembly (Figure 1, Item 21). Straighten ends of torsion springs (Figure 1, Items 2 and 13) extending through actuator assembly (Figure 1, Item 21). Remove torsion springs (Figure 1, Items 2 and 13) and torsion spring shaft (Figure 1, Item 12) from actuator assembly (Figure 1, Item 21). Remove torsion springs (Figure 1, Items 2 and 13) from torsion spring shaft (Figure 1, Item 12). Remove balls (Figure 1, Item 16), springs (Figure 1, Item 15), and slugs (Figure 1, Item 14) from center actuator assembly (Figure 1, Item 21).
14.
0085-2
TM 5-3810-305-23
0085
REMOVAL - Continued
4 5 4 30 29 28 27 1 3 2
6 7
11
10
12 13
18 26 8 7 25 24 23
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
16 17
15
14
11
21 19 20
22
M0548105
Transmission Shift Controls Removal.
0085-3
TM 5-3810-305-23
0085
INSTALLATION
NOTE
Steps 1, 2, and 3 explain installation for one lever; installation of remaining levers is the same. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install lever detent (Figure 2, Item 6) on shift lever (Figure 2, Item 5). Position shift lever (Figure 2, Item 5) in actuator assembly (Figure 2, Item 21). Install pin spring (Figure 2, Item 17) in actuator assembly (Figure 2, Item 21). Install ball (Figure 2, Item 16), spring (Figure 2, Item 15), and slug (Figure 2, Item 14). Repeat for opposite side of center actuator assembly (Figure 2, Item 21). Install torsion springs (Figure 2, Items 2 and 13) on torsion spring shaft (Figure 2, Item 12). Insert spring ends through mounting holes on actuator assembly (Figure 2, Item 21) and bend over to secure. Install shaft (Figure 2, Item 20), two spacers (Figure 2, Item 18), and three actuator assemblies (Figure 2, Item 21). Install two spacers (Figure 2, Item 11) on each end of shaft (Figure 2, Item 20) and secure each end of shaft (Figure 2, Item 20) with retaining ring (Figure 2, Item 10). Install gate plate (Figure 2, Item 27) on control assembly. Install position strips (Figure 2, Items 28, 29, and 30) on gate plate (Figure 2, Item 27). Install three ball knobs (Figure 2, Item 4) on levers (Figure 2, Items 1, 3, and 5). Install two side housings (Figure 2, Items 8 and 9) and extruded spacers (Figure 2, Item 19). Secure two side housings (Figure 2, Items 9 and 8) with two capscrews (Figure 2, Item 25) and new lockwashers (Figure 2, Item 7). Secure two extruded spacers (Figure 2, Item 19) with four capscrews (Figure 2, Item 22) and new split washers (Figure 2, Item 23). Install two access caps (Figure 2, Item 26) and decals (Figure 2, Item 24).
0085-4
TM 5-3810-305-23
0085
4 5 4 30 29 28 27 1 3 2
6 7
11
10
12 13
18 26 8 7 25 24 23 20 22 11 21 17
16
15
14
19
M0548105
Figure 2. Transmission Shift Controls Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install right console panel (WP 0066). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0085-5/6 blank
TM 5-3810-305-23
0086
FIELD MAINTENANCE TRANSMISSION CABLES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 2 Nut, Self-Locking He 1/4F (WP 0172, Table 1, Item 102) Qty: 2 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 3 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 167) Qty: 3 Washer, Split (WP 0172, Table 1, Item 116) Qty: 5 Personnel Required (Two) References TM 9-254 WP 0162 Equipment Condition Main battery switch in OFF position (TM 5-3810-305-10) Right console panel removed (WP 0066)
0086-1
TM 5-3810-305-23
0086
REMOVAL 1. 2. 3. 4. Remove five nuts (Figure 1, Item 13), lockwashers (Figure 1, Item 12), screws (Figure 1, Item 11), two clamps (Figure 1, Item 14), and shims (Figure 1, Item 9) from lever shim (Figure 1, Item 15). Discard lockwashers. Remove lever shim (Figure 1, Item 15). Remove three nuts (Figure 1, Item 4), lockwashers (Figure 1, Item 5), screws (Figure 1, Item 6), clamp (Figure 1, Item 7), and shim (Figure 1, Item 8) from lever shim (Figure 1, Item 10). Discard lockwashers. Remove left hanger (Figure 1, Item 3) and right hanger (Figure 1, Item 16).
NOTE
Tag all wiring assemblies before disconnecting to aid in installation. Remove tags following maintenance. 5. Release three jam nuts (Figure 1, Item 2) and remove two cable terminals (Figure 1, Item 17) and cable terminal (Figure 1, Item 1).
6 8
15 14
10
17 16
Figure 1.
13
11 12
M2115105
Transmission Cable Removal.
0086-2
TM 5-3810-305-23
0086
REMOVAL - Continued 6. 7. Remove two grommets (Figure 2, Item 4) and grommet (Figure 2, Item 3) from rear cab panel. Push two cables (Figure 2, Item 2) and cable (Figure 2, Item 1) through rear cab panel.
3 2 4 4
M2116105
Figure 2. 8.
Remove nut (Figure 3, Item 6), washer (Figure 3, Item 5), washer (Figure 3, Item 4), and clamp (Figure 3, Item 3) from two cables (Figure 3, Item 1). Cut and remove three wire ties (Figure 3, Item 2) from two cables. Remove two locknuts (Figure 3, Item 9), washers (Figure 3, Item 8), clamps (Figure 3, Item 11), and washers (Figure 3, Item 7) from cable (Figure 3, Item 10). Discard locknuts. Near center of vehicle, cut and remove wire tie (Figure 3, Item 2) from cable (Figure 3, Item 10).
9. 10.
2 1 11
3,4,5,6
8 9 10
M2117105
Figure 3.
0086-3
TM 5-3810-305-23
0086
REMOVAL - Continued 11. Remove two cotter pints (Figure 4, Item 1) and pivots (Figure 4, Item 3) from side transmission shift controls. Remove two pivots (Figure 4, Item 3) from end of cables (Figure 4, Item 3). Discard cotter pins.
3
M2118105
Figure 4. 12. 13. 14.
Remove cotter pin (Figure 5, Item 3) and pin (Figure 5, Item 4) from clevis (Figure 5, Item 10) through cut out in bracket (Figure 5, Item 2). Discard cotter pin. Remove two screws (Figure 5, Item 8) locknuts (Figure 5, Item 7), and clamp (Figure 5, Item 6) from bracket (Figure 5, Item 1). Discard locknuts. Remove clevis (Figure 5, Item 10) from end of cable by loosening jam nut (Figure 5, Item 5) and unscrewing clevis (Figure 5, Item 10). Remove cable (Figure 5, Item 9) from vehicle.
2 1 3 10 8 9 4
5 7
Figure 5.
6
M2119105
0086-4
TM 5-3810-305-23
0086
REMOVAL - Continued 15. 16. 17. 18. Loosen two jam nuts (Figure 6, Item 3) on each cable (Figure 6, Item 1). Disconnect two cables (Figure 6, Item 1) from bulkhead bracket on side of transmission. Remove two cables (Figure 6, Item 1) from vehicle. Remove four nuts (Figure 6, Item 3) and washers (Figure 6, Item 2) from two cables (Figure 6, Item 1).
2,3 1
2,3
M2120105
0086-5
TM 5-3810-305-23
0086
INSTALLATION Transmission Cable
1. 2. 3. 4.
Install jam nut (Figure 7, Item 5) and clevis (Figure 7, Item 10) on cable (Figure 7, Item 9) and tighten jam nut (Figure 7, Item 5) against clevis. Position clamp (Figure 7, Item 6) over cable on bracket (Figure 7, Item 1). Install two screws (Figure 7, Item 8) and locknuts (Figure 7, Item 7) on bracket (Figure 7, Item 1). Position clevis (Figure 7, Item 10) on lever (Figure 7, Item 2) and install pin (Figure 7, Item 4) and new cotter pin (Figure 7, Item 3) through cut out in bracket.
2 1 3 10 8 9 4
5 7
Figure 7.
6
M2119105
Transmission Cable Installation.
0086-6
TM 5-3810-305-23
0086
INSTALLATION - Continued 5. 6. Install nut (Figure 8, Item 3), two washers (Figure 8, Item 2) and nut on each cable (Figure 8, Item 1). Position two cables (Figure 8, Item 1) in bulkhead bracket on side of transmission. Tighten two jam nuts (Figure 8, Item 3) to secure each cable.
2,3 1
2,3
M2120105
Figure 8. 7.
Install two pivots (Figure 9, Item 3) on cables (Figure 9, Item 2). Install two pivots in valve body on side of transmission and install two cotter pins (Figure 9, Item 1) in pivots.
3
M2118105
Figure 9.
0086-7
TM 5-3810-305-23
0086
INSTALLATION - Continued 8. 9. Install three grommets (Figure 10, Items 3 and 4) in rear cab panel. Push two cables (Figure 10, Item 2) and cable (Figure 10, Item 1) through grommets (Figure 10, Items 3 and 4) in rear of cab panel.
3 2 4 4
M2116105
Figure 10. Transmission Cable Installation. 10. 11. 12. Install three jam nuts (Figure 11, Item 2) on cables (Figure 10, Items 1 and 2). Install two cable terminals (Figure 11, Item 16) on cables (Figure 10, Item 2) and cable terminal (Figure 11, Item 1) on cable (Figure 10, Item 1). Install three screws (Figure 11, Item 6), lockwashers (Figure 11, Item 5), nuts (Figure 11, Item 4), clamp (Figure 11, Item 7), shim (Figure 11, Item 8) on lever shim (Figure 11, Item 10) with left hanger (Figure 11, Item 3) and right hanger (Figure 11, Item 15). Install five screws (Figure 11, Item 11), new lockwashers (Figure 11, Item 12), nuts (Figure 11, Item 13), two clamps (Figure 11, Item 14), and two shims (Figure 11, Item 9) on lever shim (Figure 11, Item 17) with right hanger (Figure 11, Item 15) and left hanger (Figure 11, Item 3).
13.
6 8
15 14
10
17 16
13
11 12
M2115105
Figure 11. Transmission Cable Installation.
0086-8
TM 5-3810-305-23
0086
INSTALLATION - Continued 14. 15. 16. Near center of vehicle install tie wrap (Figure 12, Item 2) on cable (Figure 12, Item 10) to secure cable to vehicle. Install two clamps (Figure 12, Item 11), flatwashers (Figure 12, Item 7), washers (Figure 12, Item 8) and locknuts (Figure 12, Item 9) on cable (Figure 12, Item 10). Install clamp (Figure 12, Item 3), washers (Figure 12, Items 4 and 5), nut (Figure 12, Item 6) to secure two cables (Figure 12, Item 1) under vehicle. Install three tie wraps (Figure 12, Item 2) on cables to secure cables to bottom of vehicle.
2 1 11
3,4,5,6
8 9 10
M2117105
Figure 12. END OF TASK ADJUSTMENT Two-Wheel Four-Wheel Cable
1. 2. 3. 4. 5. 6. 7. 8.
Put lever in cab into two-wheel drive position. Pull shaft spool on transmission to full out position. Clamp cable to bracket aligning groove in cable with groove in clamp. Thread yoke jam nut all the way onto rod end. Thread yoke onto rod end and adjust to insert pin. Check lever in cab for full movement from stop to stop. Adjust yoke if lever is not centered between stops. Tighten jam nut on yoke. Insert cotter pin into pin. Check cables (Figure 12, Item 10) and (Figure 12, Item 1) for freedom of movement.
END OF TASK
0086-9
TM 5-3810-305-23
0086
FOLLOW-ON MAINTENANCE Install right console panel (WP 0066). END OF TASK END OF WORK PACKAGE
0086-10
TM 5-3810-305-23
0087
FIELD MAINTENANCE TRANSMISSION CONTROLS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking He 1/4F (WP 0172, Table 1, Item 102) Qty: 2 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 167) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122)
0087-1
TM 5-3810-305-23
0087
REMOVAL 1. 2. 3. 4. 5. Disconnect battery cables (WP 0076). Remove cotter pin (Figure 1, Item 15) and pin (Figure 1, Item 4) from clevis assembly (Figure 1, Item 10) through the cut-out in bracket (Figure 1, Item 3). Discard cotter pin. Remove two screws (Figure 1, Item 9), locknuts (Figure 1, Item 5), and clamp (Figure 1, Item 8) from bracket (Figure 1, Item 3). Discard locknuts. Remove cotter pin (Figure 1, Item 18), pin (Figure 1, Item 20), and two straps (Figure 1, Item 19) from transmission. Discard cotter pin. Remove four capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 1), and bracket (Figure 1, Item 3). Discard lockwashers.
END OF TASK DISASSEMBLY 1. 2. Remove two snaprings (Figure 1, Item 16), pin (Figure 1, Item 17), two spacers (Figure 1, Item 12), and lever (Figure 1, Item 13). Remove cotter pin (Figure 1, Item 14), pin (Figure 1, Item 11), and two straps (Figure 1, Item 19). Discard cotter pin.
1 2 3 4 19 20 5
18 14 17 16
16 15 12 12 13
6 11 10 8 9
M2140105
Figure 1. Transmission Controls Maintenance. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0087-2
TM 5-3810-305-23
0087
ASSEMBLY 1. 2. 3. Position one strap (Figure 2, Item 19) on each side of lever (Figure 2, Item 13) and install pin (Figure 2, Item 11) and new cotter pin (Figure 2, Item 14). Install two spacers (Figure 2, Item 12) on each side of lever (Figure 2, Item 13) and install pin (Figure 2, Item 17) in bracket (Figure 2, Item 3). Install two snaprings (Figure 2, Item 16) on each end of pin (Figure 2, Item 17).
END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. Position bracket (Figure 2, Item 3) over mounting holes in frame and install four new lockwashers (Figure 2, Item 1) and capscrews (Figure 2, Item 2). Install pin (Figure 2, Item 20) through two straps (Figure 2, Item 19) and install new cotter pin (Figure 2, Item 18). Position clamp (Figure 2, Item 8) over cable on bracket (Figure 2, Item 3) and install two screws (Figure 2, Item 9) and new locknuts (Figure 2, Item 5). Position clevis (Figure 2, Item 10) on lever (Figure 2, Item 13) and install pin (Figure 2, Item 4) and new cotter pin (Figure 2, Item 15). Check control for freedom of movement. Connect battery cables (WP 0076).
1 2 3 4 19 20 5
18 14 17 16
16 15 12 12 13
6 11 10 8 9
M2140105
Figure 2. Transmission Controls Maintenance. END OF TASK
0087-3
TM 5-3810-305-23
0087
ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove cotter pin (Figure 3, Item 14) and pin (Figure 3, Item 11). Put lever in cab into two-wheel drive position. Pull shaft spool on transmission to full out position. Thread jam nut (Figure 3, Item 6) all the way onto rod end (Figure 3, Item 7). Thread clevis (Figure 3, Item 10) either up or down rod end (Figure 3, Item 7) to adjust. Position clevis (Figure 3, Item 10) on lever (Figure 3, Item 13). Install pin (Figure 3, Item 11) and new cotter pin (Figure 3, Item 14) through lever (Figure 3, Item 13) and clevis (Figure 3, Item 10). Check lever in cab for full movement from stop to stop. Repeat Steps 1 through 7 if not adjusted correctly. Tighten jam nut (Figure 3, Item 6) to clevis (Figure 3, Item 10).
1 2 3 4 19 20 5
18 14 17 16
16 15 12 12 13
6 11 10 8 9
M2140105
Figure 3. Transmission Controls Maintenance. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (WP 0122). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Outriggers raised and unextended (TM 5-3810-305-10).
0087-4
TM 5-3810-305-23
0088
FIELD MAINTENANCE TRANSMISSION ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) References TM 5 3810-305-10 References (cont.) WP 0089 WP 0109 WP 0134 WP 0162 Equipment Condition Power pack removed (WP 0024)
REMOVAL 1. 2. 3. Remove main hydraulic pump from transmission (WP 0134). Remove charge pump from transmission (WP 0089). Remove ground driven steering pump from transmission (WP 0109).
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Install ground driven steering pump to transmission (WP 0109). Install charge pump to transmission (WP 0089). Install main hydraulic pump to transmission (WP 0134).
END OF TASK
0088-1
TM 5-3810-305-23
0088
FOLLOW-ON MAINTENANCE 1. 2. Install power pack to vehicle (WP 0024). Check transmission for proper operation (TM 5-3810-305-10).
0088-2
TM 5-3810-305-23
0089
FIELD MAINTENANCE CHARGE PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 141) Qty: 4 References TM 9-254 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122)
0089-1
TM 5-3810-305-23
0089
REMOVAL 1. 2. 3. Disconnect hoses (Figure 1, Items 5 and 6) from charge pump (Figure 1, Item 1) on right side of transmission main case (Figure 1, Item 4). Position hoses aside. Remove four cap screws (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from charge pump (Figure 1, Item 1). Discard lockwashers. Remove charge pump (Figure 1, Item 1) from transmission main case (Figure 1, Item 4).
3 2 1
4 6 5
M2104105
Figure 1. Charge Pump Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0089-2
TM 5-3810-305-23
0089
INSTALLATION 1. 2. 3. 4. Install charge pump (Figure 2, Item 1) on transmission main case (Figure 2, Item 4). Install four new lockwashers (Figure 2, Item 3) and capscrews (Figure 2, Item 2) on charge pump. Position hoses (Figure 2, Items 5 and 6) on charge pump (Figure 2, Item 1). Connect hoses (Figure 2, Items 5 and 6) to charge pump (Figure 2, Item 1) on top right side of transmission main case (Figure 2, Item 4).
3 2 1
4 6 5
M2104105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install deck plates (WP 0122). Connect battery cables (WP 0076).
Charge Pump Installation.
0089-3/4 blank
TM 5-3810-305-23
0090
FIELD MAINTENANCE CONTROL VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gage, Pressure, Dial Indicating (WP 0171, Table 1, Item 3) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Tester, Valve Spring (WP 0171, Table 1, Item 14) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket, Valve Body (WP 0172, Table 1, Item 88) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 89) Qty: 3 Packing, Preformed (WP 0172, Table 1, Item 86) Qty: 1 Seal, Plain (WP 0172, Table 1, Item 17) Qty: 2 Solvent, Cleaning Compound Type III (WP 0170, Table 1, Item 9) Qty: 1 References WP 0140 Equipment Condition Battery cables disconnected (WP 0076) Control valve linkages and hoses removed (WP 0140)
0090-1
TM 5-3810-305-23
0090
DISASSEMBLY
CAUTION
Care must be taken not to lose two detent springs and balls when handling control valve. Failure to follow this caution may result in damage to equipment.
NOTE
Record bore location of balls, springs, and rollers to aid installation. 1. 2. Remove two detent springs (Figure 1, Item 3) and balls (Figure 1, Item 4) from control valve (Figure 1, Item 1). Remove rolled needle (Figure 1, Item 5) and roller (Figure 1, Item 2).
1 5
4
M0223105
Figure 1. Control Valve Disassembly.
0090-2
TM 5-3810-305-23
0090
NOTE
Flat surface shown as TOP of control valve will be referred to as "top" for this maintenance procedure. Disassembly is started from bottom bore. 3. 4. 5. Remove neutral safety switch (Figure 2, Item 3). Remove reverse warning switch (Figure 2, Item 5) and elbow (Figure 2, Item 4). Remove four pipe plugs (Figure 2, Item 2) from valve body (Figure 2, Item 1).
TOP 1 2
4 5
M0224105_1
0090-3
TM 5-3810-305-23
0090
DISASSEMBLY - Continued 6. Remove plug (Figure 3, Item 2) and o-ring (Figure 3, Item 1) from control valve. Discard o-ring.
TOP
1 2
M0225105
0090-4
TM 5-3810-305-23
0090
CAUTION
Use care when handling parts. DO NOT scratch the vehicle surface of stems. Failure to follow this caution may cause damage to equipment. 7. 8. Remove plug (Figure 4, Item 5), o-ring (Figure 4, Item 4), seal (Figure 4, Item 6), and stem (Figure 4, Item 7). Discard o-ring and seal. Remove forward/reverse stem (Figure 4, Item 2) and seal (Figure 4, Item 3) from control valve (Figure 4, Item 1). Discard seal.
3 4 5 6
M0226105
Figure 4.
Control Valve Disassembly.
0090-5
TM 5-3810-305-23
0090
DISASSEMBLY - Continued 9. Remove plug (Figure 5, Item 3) and o-ring (Figure 5, Item 2) from control valve (Figure 5, Item 1). Discard o-ring.
TOP
3
M0227105
Figure 5. Control Valve Disassembly. 10. 11. 12. Remove regulator spool (Figure 6, Item 3) from control valve (Figure 6, Item 1). Remove shim (Figure 6, Item 2) from regulator spool (Figure 6, Item 3). Remove orifice plate (Figure 6, Item 4) and snapring (Figure 6, Item 5) from regulator spool (Figure 6, Item 3).
1 TOP
2 3 4 5
M0228105
0090-6
TM 5-3810-305-23
0090
DISASSEMBLY - Continued 13. Remove dump valve plug (Figure 7, Item 4), o-ring (Figure 7, Item 5), dump valve spring (Figure 7, Item 3), and dump valve (Figure 7, Item 2) from control valve (Figure 7, Item 1). Discard o-ring.
2 3 5 4
Figure 7. 14. Control Valve Disassembly.
M0229105
Remove accumulator piston (Figure 8, Item 4), accumulator spring (Figure 8, Item 3), and washer (Figure 8, Item 2) from control valve (Figure 8, Item 1).
TOP
2 3 4
Figure 8. END OF TASK Control Valve Disassembly.
M0230105
0090-7
TM 5-3810-305-23
0090
CLEANING
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Eye shields must be worn when cleaning with a wire brush. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound. Dry parts with compressed air.
END OF TASK
0090-8
TM 5-3810-305-23
0090
INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks, or corrosion, and replace if necessary. Inspect opening in orifice plate. Inside diameter should be 0.02 inch (0.5 mm) and outside diameter should be 0.550 to 0.555 inch (13.97 to 14.10 mm). Inspect flatness of valve body. Inspect dump valve and valve spool for scratches, gouges, and wear. Inspect dump valve and valve spool for freedom of movement in valve body. Inspect all parts for cracks and flaking. Inspect all parts for warpage, wear, scratches, and gouges. Inspect sealing surfaces for any scratches and score marks.
WARNING
Safety glasses or face protection must be used when working with compressed air. Failure to follow this warning may result in serious injury to personnel. 10. 11. 12. Use compressed air to clean and inspect oil passages for leakage. Soak all parts in transmission oil prior to installing. Measure detent springs. Spring specifications should be as follows: LOAD 0 lb (0 kg) 7.00 lb (3.18 kg) 11.00 lb (4.99 kg) SPRING HEIGHT 0.97 inch (24.6 mm) 0.75 inch (19.1 mm) 0.625 inch (15.88 mm)
END OF TASK
0090-9
TM 5-3810-305-23
0090
ASSEMBLY 1. 2. 3. Install shim (Figure 9, Item 2) on regulator spool (Figure 9, Item 3). Install snapring (Figure 9, Item 5) and orifice plate (Figure 9, Item 4) on regulator spool (Figure 9, Item 3). Install regulator spool (Figure 9, Item 3) in control valve (Figure 9, Item 1).
1 TOP
2 3 4 5
M0228105
Figure 9. Control Valve Assembly. 4. 5. Install new o-ring (Figure 10, Item 2) on plug (Figure 10, Item 3). Install plug (Figure 10, Item 3) in control valve (Figure 10, Item 1).
TOP
3
M0231105
Figure 10.
Control Valve Assembly.
0090-10
TM 5-3810-305-23
0090
ASSEMBLY - Continued 6. 7. 8. 9. 10. Install new seal (Figure 11, Item 3) in control valve (Figure 11, Item 1). Install new seal (Figure 11, Item 6) and o-ring (Figure 11, Item 4) on plug (Figure 11, Item 5). Install forward/reverse stem (Figure 11, Item 2) in control valve (Figure 11, Item 1). Install stem (Figure 11, Item 7) in control valve (Figure 11, Item 1). Install plug (Figure 11, Item 5) in control valve (Figure 11, Item 1).
3 4 5 6
M0226105
Figure 11.
0090-11
TM 5-3810-305-23
0090
ASSEMBLY - Continued 11. Install washer (Figure 12, Item 2), accumulator spring (Figure 12, Item 3) and accumulator piston (Figure 12, Item 4) in control valve (Figure 12, Item 1).
TOP
2 3 4
Figure 12. Control Valve Assembly.
M0230105
NOTE
Depress accumulator piston and accumulator spring in order to install roller in back side of valve body. 12. Install rolled needle (Figure 13, Item 2) and roller (Figure 13, Item 3) in back side of control valve (Figure 13, Item 1).
TOP 1 2
M0232105
Figure 13.
0090-12
TM 5-3810-305-23
0090
ASSEMBLY - Continued 13. 14. Install new o-ring (Figure 14, Item 5) on dump valve plug (Figure 14, Item 4). Install dump valve (Figure 14, Item 2), dump valve spring (Figure 14, Item 3), and dump valve plug (Figure 14, Item 4) in control valve (Figure 14, Item 1).
2 3 5 4
Figure 14. 15. 16. Control Valve Assembly.
M0229105
Install pipe plugs (Figure 15, Item 2) on control valve (Figure 15, Item 1). Install elbow (Figure 15, Item 4), reverse warning switch (Figure 15, Item 5), and neutral safety switch (Figure 15, Item 3) in control valve.
TOP 1 2
4 5
Figure 15. Control Valve Assembly.
M0224105_1
0090-13
TM 5-3810-305-23
0090
ASSEMBLY - Continued 17. 18. 19. 20. Install two balls (Figure 16, Item 4) and detent springs (Figure 16, Item 3) in back side of control valve (Figure 16, Item 1). Ensure rolled needle (Figure 16, Item 5) and roller (Figure 16, Item 2) are properly seated. Install control valve linkages and hoses (WP 0139). Connect battery cables (WP 0076).
1 5
4
M0223105
Figure 16. END OF TASK PRESSURE CHECKS
NOTE
Pressure checks must be made with transmission oil temperature at 160F to 190F (71C to 88C). Pressure Regulator Test 1. 2. 3. Install 200 psi (1,379 kPa) gage in port (Figure 17, Item 5). Position forward-neutral-reverse shift lever in neutral and 1-2-3-4 shift lever in 1. Start engine and operate at approximately 2,000 rpm while reading pressure indicated on gage. Pressure must be 155 to 180 psi (1,069 to 1,241 kPa). If pressure is within this range, proceed to Clutch Pressure Test. If pressure is not within this range, proceed to Step 4. Shut engine OFF. Remove plug (Figure 17, Item 4), o-ring (Figure 17, Item 3), regulator spool (Figure 17, Item 2) and shims (Figure 17, Item 1). Discard o-ring. Check o-ring for nicks or damage and regulator spool (Figure 17, Item 2) to ensure that it works freely in valve body. Add or remove shims (Figure 17, Item 1) to increase or decrease pressure.
4. 5. 6. 7.
0090-14
TM 5-3810-305-23
0090
PRESSURE CHECKS - Continued Pressure Regulator Test - Continued 8. 9. 10. Install shims (Figure 17, Item 1), regulator spool (Figure 17, Item 2), o-ring (Figure 17, Item 3), and plug (Figure 17, Item 4). Repeat Step 3. If required pressure range cannot be reached through shimming, replacement of charge pump may be required.
M0233105
Figure 17. Clutch Pressure Test 1. 2. 3. 4. 5. 6. 7.
Record pressure indicated on gage with engine idling. Repeat Step 1 for 2nd, 3rd and 4th gears. Apply brakes, shift forward-neutral-reverse lever to forward position, and record pressure. Shift to reverse and record pressure. Return shift lever to neutral and shut engine OFF. Pressures recorded in Steps 1 through 4 must not vary more than 10 psi (69 kPa). If pressures vary more than this, clutch packs must be rebuilt. Remove gage from port.
END OF TASK FOLLOW-ON MAINTENANCE Check for proper operation. END OF TASK END OF WORK PACKAGE
0090-15/16 blank
TM 5-3810-305-23
0091
FIELD MAINTENANCE TRANSMISSION OIL AND FILTER ELEMENT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Wrench, Oil Filter, Strap (WP 0171, Table 1, Item 32) Materials/Parts Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References TM 9-254 WP 0162 Equipment Condition Transmission oil at operating temperature (TM 5-3810-305-10)
0091-1
TM 5-3810-305-23
0091
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. REMOVAL 1. 2. Place a suitable container under oil filter (Figure 1, Item 2). Remove oil filter (Figure 1, Item 2) from filter base (Figure 1, Item 1).
M0243105
Figure 1. Transmission Oil and Filter Element Removal.
0091-2
TM 5-3810-305-23
0091
REMOVAL - Continued 3. 4. Place a suitable container under transmission (Figure 2, Item 1) and remove drain plug (Figure 2, Item 2). Drain transmission oil from transmission (Figure 2, Item 1).
M0244105
Figure 2. Transmission Oil and Filter Element Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0091-3
TM 5-3810-305-23
0091
INSTALLATION
NOTE
New or rebuilt transmission will require 20.5 qt (19.40 L) of transmission oil. 1. 2. 3. Install drain plug (Figure 2, Item 2) into transmission (Figure 2, Item 1). Coat oil filter (Figure 3, Item 2) seal with clean transmission oil and fill oil filter with new transmission oil. Install oil filter (Figure 3, Item 2) onto filter base (Figure 3, Item 1) and hand tighten.
M0243105
Figure 3.
Transmission Oil and Filter Element Installation.
0091-4
TM 5-3810-305-23
0091
INSTALLATION - Continued 4. 5. 6. 7. Remove transmission fill plug (Figure 4, Item 2) from transmission (Figure 4, Item 3) and fill with 12 qt (11.36 L) of transmission oil. Install transmission fill plug (Figure 4, Item 2) into transmission (Figure 4, Item 3). Check for proper fill level with dipstick (Figure 4, Item 1). Repeat Steps 4 through 6 if not at proper level.
M0245105
Transmission Oil and Filter Element Installation.
0091-5/6 blank
TM 5-3810-305-23
0092
FIELD MAINTENANCE PUMP ADAPTER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 87) Qty: 1 O-Ring (WP 0172, Table 1, Item 143) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock 1/2 Inch Reg (WP 0172, Table 1, Item 142) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Main hydraulic pump removed (WP 0134)
0092-1
TM 5-3810-305-23
0092
REMOVAL 1. 2. Remove four bolts (Figure 1, Item 3) and lockwashers (Figure 1, Item 4). Discard lockwashers. Remove pump adapter (Figure 1, Item 2) from transmission (Figure 1, Item 1).
2 3,4
M0375105
Figure 1. Pump Adapter Removal. END OF TASK
0092-2
TM 5-3810-305-23
0092
CLEANING
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Eye shields must be worn when cleaning with a wire brush. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound. Soak all parts in lubricating oil prior to installation.
END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks or corrosion, and replace if necessary.
END OF TASK
0092-3
TM 5-3810-305-23
0092
INSTALLATION 1. 2. Install pump adapter (Figure 2, Item 2) on transmission (Figure 2, Item 1). Install four bolts (Figure 2, Item 3) and new lockwashers (Figure 2, Item 4).
2 3,4
M0375105
Figure 2. Pump Adapter Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install main hydraulic pump (WP 0134). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).
0092-4
TM 5-3810-305-23
0093
FIELD MAINTENANCE FRONT AND REAR DRIVESHAFT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
REMOVAL Front Driveshaft 1. 2. Support front end of driveshaft assembly (Figure 1, Item 1) with jack stand. Remove four capscrews (Figure 1, Item 3) from front spider bearing assembly (Figure 1, Item 2).
3
M0187105
Figure 1.
Front Driveshaft Removal.
0093-1
TM 5-3810-305-23
0093
REMOVAL - Continued Front Driveshaft - Continued 3. 4. 5. Support rear end of driveshaft assembly (Figure 2, Item 2) with jack stand. Remove four capscrews (Figure 2, Item 3) from rear spider bearing assembly (Figure 2, Item 1). Lower driveshaft assembly (Figure 2, Item 2) and remove from under vehicle.
3
Figure 2. Front Driveshaft Removal.
M0188105
END OF TASK DISASSEMBLY Front Driveshaft 1. 2. Remove four capscrews (Figure 3, Item 4) and rear spider bearing assembly (Figure 3, Item 3) from tube assembly (Figure 3, Item 2). Remove grease fitting (Figure 3, Item 1) from rear spider bearing assembly (Figure 3, Item 3).
4 3
Figure 3.
2
Front Driveshaft Disassembly.
M0189105
0093-2
TM 5-3810-305-23
0093
DISASSEMBLY - Continued Front Driveshaft - Continued 3. 4. 5. 6. 7. 8. Remove four capscrews (Figure 4, Item 8) and front spider bearing assembly (Figure 4, Item 7) from yoke assembly (Figure 4, Item 5). Remove two grease fittings (Figure 4, Item 6) from yoke assembly (Figure 4, Item 5). Loosen dust cap (Figure 4, Item 2). Separate slip yoke assembly (Figure 4, Item 5) from tube assembly (Figure 4, Item 1). Remove washer (Figure 4, Item 3), felt washer (Figure 4, Item 4), and washer (Figure 4, Item 3) from tube assembly (Figure 4, Item 1). Remove dust cap (Figure 4, Item 2) from tube assembly (Figure 4, Item 1).
6 1 2 3 4 5
8 3
Figure 4. Front Driveshaft Disassembly.
M0190105
END OF TASK CLEANING Front Driveshaft Clean parts IAW General Maintenance Instructions (WP 0162).
END OF TASK INSPECTION Front Driveshaft Inspect parts IAW General Maintenance Instructions (WP 0162).
END OF TASK
0093-3
TM 5-3810-305-23
0093
ASSEMBLY Front Driveshaft 1. 2. 3. 4. 5. 6. Install dust cap (Figure 5, Item 2) on tube assembly (Figure 5, Item 1). Install split washer (Figure 5, Item 3), felt washer (Figure 5, Item 4), and split washer (Figure 5, Item 3) on tube assembly (Figure 5, Item 1). Install tube assembly (Figure 5, Item 1) into slip yoke assembly (Figure 5, Item 5). Tighten dust cap (Figure 5, Item 2). Install two grease fittings (Figure 5, Item 6) on yoke (Figure 5, Item 5). Install front spider bearing assembly (Figure 5, Item 7) and four capscrews (Figure 5, Item 8) to yoke assembly (Figure 5, Item 5).
6 1 2 3 4 5
8 3
Figure 5. Front Driveshaft Assembly. 7. 8. 9. Install grease fitting (Figure 6, Item 1) on rear spider bearing assembly (Figure 6, Item 3). Install rear spider bearing assembly (Figure 6, Item 3) and four capscrews (Figure 6, Item 4) to tube assembly (Figure 6, Item 2). Tighten eight capscrews (Figure 6, Item 4 and Figure 4, Item 8) to 50 ft-lb (68 Nm).
M0190105
4 3 2
Figure 6. Front Driveshaft Assembly.
M0189105
END OF TASK
0093-4
TM 5-3810-305-23
0093
INSTALLATION Front Driveshaft 1. 2. Position driveshaft assembly (Figure 7, Item 2). Install four capscrews (Figure 7, Item 3) in rear spider bearing assembly (Figure 7, Item 1).
3
Figure 7. 3. 4. 5. 6. Front Driveshaft Installation.
M0188105
Position front end of driveshaft assembly (Figure 8, Item 1). Install four capscrews (Figure 8, Item 3) in front spider bearing assembly (Figure 8, Item 2). Tighten eight capscrews (Figure 8, Item 3) to 50 ft-lb (68 Nm). Check for proper operation.
3
M0187105
Figure 8.
Front Driveshaft Installation.
0093-5
TM 5-3810-305-23
0093
END OF TASK REMOVAL Rear Driveshaft 1. 2. 3. Remove four capscrews (Figure 9, Item 1) from front spider bearing assembly (Figure 9, Item 2). Remove four capscrews (Figure 9, Item 4) from rear spider bearing assembly (Figure 9, Item 5). Lower driveshaft assembly (Figure 9, Item 3) and remove from under vehicle.
1 2
5
Figure 9.
M0199105
Rear Driveshaft Removal.
END OF TASK DISASSEMBLY Rear Driveshaft 1. 2. 3. 4. 5. 6. 7. Remove four capscrews (Figure 10, Item 1) and front spider bearing assembly (Figure 10, Item 2) from stub yoke (Figure 10, Item 7). Remove four capscrews (Figure 10, Item 1) and rear spider bearing assembly (Figure 10, Item 8) from slip yoke assembly (Figure 10, Item 4). Unscrew dust cap (Figure 10, Item 5). Separate slip yoke assembly (Figure 10, Item 4) from stub yoke (Figure 10, Item 7). Remove washer (Figure 10, Item 6), felt washer (Figure 10, Item 9), and washer (Figure 10, Item 6) from stub yoke assembly (Figure 10, Item 7). Remove dust cap (Figure 10, Item 5) from stub yoke assembly (Figure 10, Item 7). Remove three grease fittings (Figure 10, Item 3) from front spider bearing assembly (Figure 10, Item 2), rear spider bearing assembly (Figure 10, Item 8), and slip yoke assembly (Figure 10, Item 4).
0093-6
TM 5-3810-305-23
0093
DISASSEMBLY - Continued Rear Driveshaft - Continued
2 1 3
4 5 9 6 3 7
8 1
Figure 10.
3
Rear Driveshaft Disassembly.
M0200105
END OF TASK CLEANING Rear Driveshaft Clean parts IAW General Maintenance Instructions (WP 0162).
END OF TASK INSPECTION Rear Driveshaft Inspect parts IAW General Maintenance Instructions (WP 0162).
END OF TASK
0093-7
TM 5-3810-305-23
0093
ASSEMBLY Rear Driveshaft 1. 2. 3. 4. 5. 6. 7. 8. Install three grease fittings (Figure 11, Item 3). Install dust cap (Figure 11, Item 5) on stub yoke assembly (Figure 11, Item 7). Install split washer (Figure 11, Item 6), felt washer (Figure 11, Item 10), and split washer (Figure 11, Item 1) on stub yoke assembly (Figure 11, Item 7). Install stub yoke (Figure 11, Item 7) into slip yoke assembly (Figure 11, Item 3). Tighten dust cap (Figure 11, Item 5). Install rear spider bearing assembly (Figure 11, Item 9) and four capscrews (Figure 11, Item 1) on yoke assembly (Figure 11, Item 4). Install front spider bearing assembly (Figure 11, Item 2) and four capscrews (Figure 11, Item 1) on stub yoke (Figure 11, Item 7). Tighten eight capscrews (Figure 11, Item 1) to 50 ft-lb (68 Nm).
2 1 3
4 5 9 6 3 7
8 1 3
Figure 11. Rear Driveshaft Assembly.
M0200105
END OF TASK
0093-8
TM 5-3810-305-23
0093
INSTALLATION Rear Driveshaft 1. 2. 3. 4. Position driveshaft assembly (Figure 12, Item 3) under vehicle. Install four capscrews (Figure 12, Item 4) in rear spider bearing assembly (Figure 12, Item 5). Install four capscrews (Figure 12, Item 1) in front spider bearing assembly (Figure 12, Item 2). Tighten eight capscrews (Figure 12, Items 1 and 4) to 50 ft-lb (68 Nm).
1 2
5
Figure 12.
M0199105
Rear Driveshaft Installation.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0093-9/10 blank
TM 5-3810-305-23
0094
FIELD MAINTENANCE FRONT AXLE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Gage, Depth, Dial Indicating (WP 0171, Table 1, Item 2) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Materials/Parts Pin, Cotter (WP 0172, Table 1, Item 156) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References TM 5-3810-305-10 WP 0076 WP 0103 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Tire and wheel assemblies removed (WP 0107)
0094-1
TM 5-3810-305-23
0094
REMOVAL
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. Disconnect and cap all hydraulic lines to steering cylinders, brake lines, and breather hose.
WARNING
Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. Remove two cotter pins (Figure 1, Item 3), washers (Figure 1, Item 4), pins (Figure 1, Item 2), and parking brake assembly (Figure 1, Item 10) from front axle (Figure 1, Item 6). Discard two cotter pins. Let parking brake assembly (Figure 1, Item 10) hang by cable (Figure 1, Item 5).
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 5. Disconnect battery negative ground cable (WP 0076).
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 6. Disconnect two wires from speedometer sensor unit.
0094-2
TM 5-3810-305-23
0094
REMOVAL - Continued 7. 8. 9. 10. 11. Using floor jack, support front driveshaft (Figure 1, Item 12). Remove four capscrews (Figure 1, Item 1) to disconnect front axle (Figure 1, Item 6) from front driveshaft spider bearing (Figure 1, Item 11). Using hydraulic floor jacks, support front axle (Figure 1, Item 6). Remove eight nuts (Figure 1, Item 7), washers (Figure 1, Item 8), and capscrews (Figure 1, Item 9). Remove front axle (Figure 1, Item 6) from under vehicle.
2 1
3 4 5
12
11 3 2 4 10
9
M0198105
Front Axle Removal.
0094-3
TM 5-3810-305-23
0094
CAUTION
Copper sealing washers are not reusable. If a previously tightened connection containing copper sealing washer(s) is loosened, the washer(s) must be replaced before retightening. Failure to follow this caution may result in damage to equipment. 1. Transfer steering cylinders, brake connections, vent hose adapter, and other attaching components to new axle before installing on vehicle.
WARNING
Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. 4. 5. Raise front axle (Figure 2, Item 6) in position under vehicle. Install eight capscrews (Figure 2, Item 9), washers (Figure 2, Item 8), and nuts (Figure 2, Item 7). Tighten eight capscrews to 500 ft-lb (678 Nm). Install four capscrews (Figure 2, Item 1) to connect front axle (Figure 2, Item 6) to front driveshaft spider bearing (Figure 2, Item 11). Tighten capscrews to 50 ft-lb (68 Nm). Position parking brake assembly (Figure 2, Item 10) and cable (Figure 2, Item 5) on front axle (Figure 2, Item 6) and install two pins (Figure 2, Item 2), washers (Figure 2, Item 4), and new cotter pins (Figure 2, Item 3).
0094-4
TM 5-3810-305-23
0094
2 1
3 4 5
12
11 3 2 4 10
9
M0198105
Figure 2.
Front Axle Installation.
CAUTION
Speedometer sensor wires must be connected as tagged for speedometer to work properly. Failure to follow this caution may result in damage to equipment. 6. 7. 8. Connect two wires to speedometer sensor unit. Connect all hydraulic lines to breather hose, brake lines, and steering cylinders. Close dipstick cap.
END OF TASK
0094-5
TM 5-3810-305-23
0094
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Bleed front brake system (WP 0103). Be sure outer hub drives and center axle differential have been serviced with lubricant (TM 5-3810-305-10). Install tire and wheel assemblies (WP 0107). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0094-6
TM 5-3810-305-23
0095
FIELD MAINTENANCE FRONT DIFFERENTIAL ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Grease, General Purpose, Lithium Base (WP 0170, Table 1, Item 25) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealing Compound, Silicone (WP 0170, Table 1, Item 62) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Front axle removed (WP 0094) Constant-velocity joint removed (WP 0099) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Tire and wheel assemblies removed (WP 0107)
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0095
REMOVAL
WARNING
Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
CAUTION
Differential assembly may be removed with axle attached to vehicle, but this is not recommended. If differential assembly is removed with axle installed, use extreme care in positioning and hoisting differential assembly. Failure to follow this caution may result in damage to equipment.
NOTE
Removal of differential assembly from axle or axle from vehicle is not required for pinion seal replacement. 1. Position axle with pinion flange on differential assembly (Figure 1, Item 3) in an upward direction.
WARNING
Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. Using an overhead hoist, attach a suitable lifting fixture to input yoke and disc (Figure 1, Item 2). To ease alignment at installation, matchmark differential assembly (Figure 1, Item 3) and axle housing.
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REMOVAL - Continued
WARNING
Heating differential mounting bolts to a temperature of 300F (149C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may cause injury or death to personnel. 4. 5. Unstake and loosen pinion nut (Figure 1, Item 1) to aid in disassembly. Remove 10 differential mounting bolts (Figure 1, Item 4) and washers (Figure 1, Item 5) securing differential assembly (Figure 1, Item 3) to axle housing.
NOTE
A tap with a soft-faced mallet may be required to break seal between differential assembly and axle housing. 6. Apply pressure to hoist and lift differential assembly (Figure 1, Item 3) from axle housing approximately 1 inch (25 mm). Rotate differential assembly 90 degrees to align ring gear with clearance cutouts in axle housing and remove from housing.
1 2
4,5
Figure 1.
3
Front Differential Removal.
M0301105
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0095
REMOVAL - Continued
CAUTION
DO NOT interchange bearings, pinions, or input yoke from other axles. Preload is factory set. Failure to follow this caution may result in damage to equipment. 7. 8. 9. Remove pinion nut (Figure 2, Item 1), input yoke (Figure 2, Item 2), and dust shield (Figure 2, Item 8). Discard pinion nut. Remove trunnion (Figure 2, Item 4) and spacer (Figure 2, Item 3), if necessary. Remove input yoke seal (Figure 2, Item 5).
1 8
5 6
Figure 2. Front Differential Removal. END OF TASK CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Remove sealant IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound IAW General Maintenance Instructions (WP 0162). Dry parts with compressed air.
M0315105
END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
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0095
INSTALLATION
WARNING
Wear protective equipment while heating and handling spacer. Failure to follow this warning may result in serious injury to personnel. 1. 2. 3. Lubricate and install new input yoke seal (Figure 3, Item 5) flush. Heat spacer (Figure 3, Item 3) to approximately 350F (176C). Install spacer (Figure 3, Item 3) and trunnion (Figure 3, Item 4). Install input yoke (Figure 3, Item 2), dust shield (Figure 3, Item 8) and new pinion nut (Figure 3, Item 1). Tighten pinion nut (Figure 3, Item 1) to 405 to 433 ft-lb (549 to 587 Nm). Stake pinion nut (Figure 3, Item 1) in two locations 180 degrees apart.
1 8
5 6
Figure 3. Front Differential Installation.
M0315105
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INSTALLATION - Continued 4. If differential was disassembled, file off washer face of bolts (Figure 4, Item 1) flush with machined surface of bearing cap (Figure 4, Item 2).
M0316105
Figure 4. Front Differential Installation.
WARNING
Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. Failure to follow these warnings may result in serious injury or death to personnel. 5. 6. 7. Install a suitable fixture to input yoke and disc (Figure 5, Item 1) and suspend differential assembly (Figure 5, Item 2) over axle housing opening. Spread a bead of silicone sealant around differential assembly opening. Lower differential assembly (Figure 5, Item 2) into axle housing to approximately 1 inch (25 mm) from seating.
NOTE
Differential assembly must be rotated to align with axle shafts and matchmarks made during removal.
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INSTALLATION - Continued 8. 9. 10. 11. Lower and tap differential assembly (Figure 5, Item 2) with a mallet to seat in axle housing. Remove lifting fixture. Apply thread sealant to 10 differential mounting bolts (Figure 5, Item 3) and install with washers (Figure 5, Item 4). Tighten bolts (Figure 5, Item 3) to 58 ft-lb (79 Nm).
3,4
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Fill differential assembly with oil (TM 5-3810-305-10). Install front axle assembly (WP 0094). Install constant-velocity joints (WP 0099). Install tire and wheel assemblies (WP 0107). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Front Differential Installation.
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0096
FIELD MAINTENANCE PLANETARY WHEEL END MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gage, Depth, Dial Indicating (WP 0171, Table 1, Item 2) Gloves, Leather (WP 0171, Table 1, Item 5) Socket, Wrench, Face Spanner (WP 0171, Table 1, Item 10) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 24) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 O-Ring (WP 0172, Table 1, Item 111) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 25) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Tire and wheel assemblies removed (WP 0107) Battery cables disconnected (WP 0076)
REMOVAL
WARNING
Weight of brake drum is approximately 81 lb (37 kg). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. The brake linings contain asbestos. Wear a protective breather respirator when performing maintenance on the break assembly and brake drum. Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warnings may cause injury or death to personnel.
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REMOVAL - Continued
NOTE
Jacking bolts may be required to remove brake drum. There is no difference in the maintenance procedures for front and rear planetary wheel ends. 1. 2. 3. Remove three assembly screws (Figure 1, Item 3) and brake drum (Figure 1, Item 2) from wheel hub (Figure 1, Item 1). Position a suitable container to accept oil from wheel end. Rotate wheel hub (Figure 1, Item 1) so that drain plug (Figure 1, Item 4) is at 6 oclock position. Remove drain plug.
1 2 3
4
M0308105
Figure 1. Planetary Wheel End Removal.
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REMOVAL - Continued 4. 5. 6. Remove fill plug and washer (Figure 2, Item 5) and eight bolts (Figure 2, Item 4) from wheel end cover (Figure 2, Item 3). Remove wheel end cover (Figure 2, Item 3), thrust plug (Figure 2, Item 6), and o-ring (Figure 2, Item 2) from wheel hub (Figure 2, Item 1) as an assembly. A punch and hammer may be required for this. Remove four sector plates (Figure 2, Item 7).
NOTE
DO NOT remove thrust plug from wheel end cover unless replacement is required. 7. Remove o-ring (Figure 2, Item 2) and, if necessary, thrust plug (Figure 2, Item 6) from wheel end cover (Figure 2, Item 3). Discard o-ring.
1
3
4 7 6 5
M0309105
Figure 2.
Planetary Wheel End Removal.
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REMOVAL - Continued 8. 9. Remove planetary gear carrier assembly (Figure 3, Item 4) from wheel hub (Figure 3, Item 1) by pulling outward. Remove sun gear (Figure 3, Item 3) and coupler (Figure 3, Item 2).
1
2 3 4
M0310105
NOTE
It may be necessary to strike ring gear carrier assembly with a soft-faced mallet to jar centering cone loose before removing. Outer hub bearing assembly comes off when ring gear carrier assembly is removed. 10. Straighten tab on lockwasher (Figure 4, Item 1). Remove spindle nut (Figure 4, Item 2), lockwasher, and centering cone (Figure 4, Item 3). Discard lockwasher.
3
M0311105
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REMOVAL - Continued
WARNING
Weight of hub and studs is approximately 79 lb (36 kg). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 11. Remove ring gear carrier assembly (Figure 5, Item 2) and hub (Figure 5, Item 1) from vehicle.
1
M0312105
Figure 5. END OF TASK DISASSEMBLY
Planetary Wheel End Removal.
NOTE
If there are no visible signs of damage, bearing assemblies or oil seal and runner should not be removed. 1. Remove bearing cone (Figure 6, Item 1), if necessary, from ring gear carrier assembly (Figure 6, Item 2).
2
Figure 6. Planetary Wheel End Disassembly.
M0313105
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0096
NOTE
Hub seal runner remains on pivot and spindle when hub assembly is removed. 2. Remove hub seal runner (Figure 7, Item 1), hub seal (Figure 7, Item 2), and bearing cone (Figure 7, Item 3) from hub (Figure 7, Item 5).
NOTE
Remove hub seal runner only if inspection proves necessary. 3. If hub seal runner (Figure 7, Item 1) is damaged, remove 15 bolts which attach brake assembly to pivot and spindle assembly, and remove brake assembly.
WARNING
Wear protective equipment while heating and handling seal runner. Failure to follow this warning may cause serious injury to personnel. 4. 5. 6. Remove hub seal runner (Figure 7, Item 1), if necessary. Apply moderate heat and use pry bar to remove seal. Discard seal. Remove 10 studs (Figure 7, Item 7), if necessary, from hub (Figure 7, Item 5). Remove two bearing cups (Figure 7, Items 4 and 6) from hub (Figure 7, Item 5) if inspection proves necessary.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. 5. 6. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect ring gear carrier assembly for deformed or scored teeth. Inspect wheel hub and studs for damage. Check inner portion of hub for damaged teeth, rough spots on bearing surface, or cracks. Inspect studs for deformed shanks or damaged threads. Inspect all parts for wear, pitting, cracks, or corrosion. Replace if necessary.
END OF TASK
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ASSEMBLY
WARNING
Wear protective equipment while heating and handling seal runner. Failure to follow this warning may cause serious injury to personnel.
NOTE
Hub seal must be installed in the hub concentric and perpendicular to the axis. 1. 2. 3. 4. 5. 6. Heat hub seal runner (Figure 7, Item 1), if removed, to approximately 176F (80C). Install and secure with threadlock compound. If removed, install brake assembly and 15 bolts, which attach the brakes to pivot and spindle assembly. If removed, install two bearing cups (Figure 7, Items 4 and 6). If removed, install bearing cone (Figure 7, Item 3) in hub (Figure 7, Item 5). Install hub seal (Figure 7, Item 3) into hub (Figure 8, Item 5) against shoulder. If removed, install 10 studs (Figure 7, Item 7) to hub (Figure 7, Item 5).
1 2 3 4 5 6
7
M0314105
Figure 7.
Planetary Wheel End Maintenance.
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ASSEMBLY - Continued 7. If removed, heat bearing cone (Figure 8, Item 1) to approximately 176F (80C) and install on ring gear carrier (Figure 9, Item 2).
2
Figure 8. Planetary Wheel End Assembly. END OF TASK INSTALLATION
M0313105
CAUTION
All parts must be cleaned before installation to prevent damage to gears. 1. Apply grease to hub seal lips and to hub seal runner.
WARNING
Weight of hub and studs is approximately 79 lb (36 kg). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 2. 3. Position hub (Figure 9, Item 1) onto pivot and spindle. Install ring gear carrier assembly (Figure 9, Item 2).
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1
M0312105
Figure 9. 4.
Planetary Wheel End Installation.
Install centering cone (Figure 10, Item 3), new lockwasher (Figure 10, Item 1), and spindle nut (Figure 10, Item 2). Tighten spindle nut according to procedures in Steps a, b, and c below: a. b. c. Tighten spindle nut (Figure 10, Item 2) while rotating hub to correctly position all components (bearings and spindle cone). Tighten spindle nut to 258 to 295 ft-lb (350 to 400 Nm). Apply 15.8 lb (70 N) tangential force to wheel stud. Adjust spindle nut (Figure 10, Item 2) by loosening until rotation of hub is obtained. Secure spindle nut (Figure 10, Item 2) by bending tab on lockwasher (Figure 10, Item 1).
3
M0311105
Figure 10.
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0096
INSTALLATION - Continued 5. 6. Install coupler (Figure 11, Item 2) and sun gear (Figure 12, Item 3) to wheel hub (Figure 11, Item 1). Install planetary carrier assembly (Figure 11, Item 4).
1
2 3 4
M0310105
Figure 11. 7. 8. 9. 10. 11.
Install four sector plates (Figure 12, Item 7) onto wheel hub (Figure 12, Item 1). Lubricate new o-ring (Figure 12, Item 2) and install onto wheel end cover (Figure 12, Item 3). If removed, install thrust plug (Figure 12, Item 6) into wheel end cover. Install wheel end cover (Figure 12, Item 3) with eight bolts (Figure 12, Item 4) and tighten to 58 ft-lb (79 Nm). Install washer and fill plug (Figure 12, Item 5) on wheel end cover (Figure 12, Item 3).
1
3
4 7 6 5
M0309105
Figure 12.
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INSTALLATION - Continued 12. Install drain plug (Figure 14, Item 4) on wheel hub (Figure 14, Item 1).
WARNING
Weight of brake drum is approximately 81 lb (37 kg). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel. 13. Install brake drum (Figure 13, Item 2) and three assembly screws (Figure 13, Item 3) on wheel hub (Figure 13, Item 1). Tighten screws to 14 to 18 ft-lb (19 to 24 Nm).
1 2 3
4
M0308105
Figure 13. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5.
Install tire and wheel assemblies (WP 0107). Fill with oil (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
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0097
FIELD MAINTENANCE PIVOT AND SPINDLE ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 100-lb (46 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Trunnion Seal (WP 0172, Table 1, Item 23) Qty: 2 Personnel Required (Two) References WP 0096 WP 0103 WP 0108 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Tires and wheels removed (WP 0107)
REMOVAL
NOTE
There is no difference in the maintenance procedures for front and rear pivot and spindle assemblies. 1. Remove tie rod assembly, if necessary (WP 0108).
NOTE
It is not necessary to remove planetary wheel end or brake assembly from pivot and spindle assembly to remove constant-velocity joint or differential assembly. 2. Remove planetary wheel end (WP 0096).
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all parts. Remove caps, plugs, and tags following maintenance. 3. 4. Disconnect and cap brake lines, if necessary. Remove brake assembly (WP 0103).
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REMOVAL - Continued
WARNING
Weight of pivot and spindle assembly is approximately 69 lb (30 kg). Use adequate lifting equipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. 6. 7. Position hoist above pivot and spindle assembly (Figure 1, Item 3). Support pivot and spindle assembly with sling. Remove eight bolts (Figure 1, Item 1), pivot cap (Figure 1, Item 2), and tie rod lever (Figure 1, Item 4) from spindle assembly (Figure 1, Item 3). Remove and measure shim packs (Figure 1, Item 5) from spindle assembly (Figure 1, Item 3). Record measurements and locations of shims.
5 3
5 4 1
M0303105
Figure 1.
Pivot and Spindle Assembly Removal.
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REMOVAL - Continued 8. 9. 10. 11. Remove and tag trunnions (Figure 2, Item 1) from spindle assembly (Figure 2, Item 5). Remove upper and lower bearings (Figure 2, Item 4) from trunnions (Figure 2, Item 1), if necessary. Pull pivot and spindle assembly (Figure 2, Item 5) horizontally outward from spindle assembly. If necessary, pull out bearing cups (Figure 2, Item 3).
NOTE
Pivot and spindle assembly consists of a thrust ring on splined end, a shaft bushing on other end, and pivot and spindle. 12. 13. 14. If necessary, remove thrust ring (Figure 2, Item 6) and shaft bushing (Figure 2, Item 8) from pivot and spindle assembly (Figure 2, Item 5). Remove and discard trunnion seals (Figure 2, Item 2) from spindle assembly (Figure 2, Item 5). Remove mid-shaft (Figure 2, Item 7) from spindle assembly (Figure 2, Item 5).
1 2 3 4 5
4 4 2 3 1
M0304105
Pivot and Spindle Assembly Removal.
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0097
NOTE
If bearings, trunnions, main housing, or pivot spindle have not been replaced, use shim pack thickness recorded during removal in this work package, and go to Step 2. 1. Perform the following steps to determine required lower shimming:
NOTE
Lower shims to ensure alignment of pivot, axle housing sphere, and axle shaft. a. b. c. d. e. Read pivot dimension X (distance from lower machined surface to center of pivot) on lower face of pivot and spindle assembly. Measure height of trunnion hearing assembly and call it Y. Read axle housing measurement Z (distance from bearing cup seat to center line of axle housing) as stamped in bottom of lower trunnion cavity. To calculate thickness of required lower shim, substitute dimensions in the following equation: Lower shim = X - (Y+ Z).
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Z X AXLE HOUSING MEASUREMENT-Z Y
PIVOT DIMENSION-X
Figure 3. Pivot and Spindle Assembly Installation.
M0305105
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0097
WARNING
Weight of housing assembly is approximately 631 lb (286 kg). Use adequate lifting equipment to lift and support housing assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
NOTE
Place axle housing with input yoke in an upward direction. This will ease installation of trunnion/bearing assemblies. 2. Install mid-shaft (Figure 4, Item 2) in pivot and spindle assembly (Figure 4, Item 1).
2
M0306105
Figure 4. Pivot and Spindle Assembly Installation. 3. 4. If removed, install thrust ring (Figure 5, Item 6) in splined end and shaft bushing (Figure 5, Item 7) on spindle assembly (Figure 5, Item 5). Grease center bore of pivot and spindle assembly (Figure 5, Item 5).
NOTE
If bearing cups were removed, install them at this time using a bearing installing tool. Apply grease to trunnion bore in axle housing. 5. 6. Pack trunnion bearings (Figure 5, Item 4) with grease. Install new trunnion seals (Figure 5, Item 2) and bearing cups (Figure 5, Item 3) onto trunnions (Figure 5, Item 1).
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WARNING
Weight of pivot and spindle assembly is approximately 69 lb (30 kg). Use adequate lifting equipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. 9. Install pivot and spindle assembly (Figure 5, Item 5) onto axle housing. Lubricate trunnion bores in pivot and spindle assembly (Figure 5, Item 5). Insert trunnions (Figure 5, Item 1) into axle housing through pivot and spindle assembly (Figure 5, Item 5).
1 2 3 4 7 5
6 4 4 3 2 1
M0307105
Figure 5. Pivot and Spindle Assembly Installation.
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0097
NOTE
Ensure correct shim packs are with trunnion and bearing assemblies. 10. Install lower shim packs (Figure 6, Item 5).
CAUTION
DO NOT tighten bolts at this time. Damage to axle could result. 11. Install tie rod lever (Figure 6, Item 4) and four bolts (Figure 6, Item 1) to pivot and spindle assembly (Figure 6, Item 3).
NOTE
If axle housing, pivot and spindle assembly, or trunnion assemblies have been replaced, shimming must be checked and a preload check must be made. If not, go to Step 13. 12. Perform the following procedures to determine the required upper shimming: a. b. Install all shims (Figure 6, Item 5) supplied in shim kit. Install pivot cap (Figure 6, Item 2) and bolts (Figure 6, Item 1). Tighten bolts in diagonal pattern to 30 ft-lb (41 Nm), then retighten them in the same pattern, increasing the torque in 2 ft-lb (2.7 Nm) increments until all have been tightened to 35 ft-lb (47 Nm). Move pivot cup (Figure 6, Item 2) through 5 to 10 complete turns to seat bearing. Using the procedure from Step b, re-tighten bolts (Figure 6, Item 1) to 35 ft-lb (47 Nm). Using a feeler gage, measure the gap between pivot and spindle assembly (Figure 6, Item 3) and pivot cap (Figure 6, Item 2) on all four sides. The average of the gaps is the amount to be subtracted from shim kit to obtain upper shim pack (Figure 6, Item 5). Remove bolts (Figure 6, Item 1), pivot cap (Figure 6, Item 2), and shim (Figure 6, Item 5).
c. d. e. f. g. 13. 14. 15. 16.
Install shim pack (Figure 6, Item 5) onto upper trunnion/bearing assembly. Apply grease to bore of pivot cap (Figure 6, Item 2) and snug pivot cap to pivot and spindle assembly (Figure 6, Item 3) with bolts (Figure 6, Item 1). Tighten all bolts (Figure 6, Item 1) to 542 ft-lb (735 Nm). Install pivot and spindle assembly (Figure 6, Item 3).
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5 3
5 4 1
M0303105
Figure 6. Pivot and Spindle Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install tires and wheels (WP 0107). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
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0098
FIELD MAINTENANCE PIVOT BEARINGS (TYPE II) MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Puller Set, Mechanical (WP 0171, Table 1, Item 38) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Materials/Parts Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 242 (WP 0170, Table 1, Item 56) Qty: 1 References WP 0162 Equipment Condition Perform sectionalization of equipment (TM 5-3810-305-10)
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REMOVAL
NOTE
Do not disassemble unless pivot is not turning freely. 1. 2. 3. 4. Remove two capscrews (Figure 1, Item 1), washers (Figure 1, Item 2), cap (Figure 1, Item 3), and shims (Figure 1, Item 4) from housing assembly (Figure 1, Item 7). Using a bearing puller, remove housing assembly (Figure 1, Item 7) from frame spud (Figure 1, Item 8). Remove cone (Figure 1, Item 5) and two cups (Figure 1, Item 6) from housing assembly (Figure 1, Item 7). Remove cone (Figure 1, Item 5) from spud (Figure 1, Item 8).
CAUTION
There is a limit to which gaging material will compress, thus resulting in a false measurement. If 0.12 inch (3.0 mm) material crushes to below 0.05 inch (1.3 mm), remeasure using 0.06 inch (1.5 mm) material.
NOTE
If using new parts, before installing cap and capscrews, place one piece of either 0.12 inch(3.0 mm) or 0.06 inch x 2.00 inch (1.5 x 50.8 mm) gaging material across end of spud. Install cap and capscrews and evenly torque until no end play is felt in bearing, and slight resistance is felt in bearing rotation. Remove capscrew, cap and gaging material. Measure, using a micrometer, to find proper shim pack equal to or up to 0.002 inch (0.05 mm) thicker than measurement. 1. 2. 3. 4. 5. 6. 7. Pack bearings with grease. Install two cups (Figure 1, Item 5) and one cone (Figure 2, Item 6) into housing assembly (Figure 1, Item 7). Install housing assembly (Figure 1, Item 7) onto spud (Figure 1, Item 8). Install one cone (Figure 1, Item 6) onto spud (Figure 2, Item 8). Apply sealant compound on threads of two capscrews (Figure 1, Item 1). Install shims (Figure 1, Item 4), cap (Figure 1, Item 3), two washers (Figure 1, Item 2), and capscrews (Figure 1, Item 1) to housing assembly (Figure 1, Item 7). Tighten two capscrews (Figure 1, Item 1) to 74 ft-lb (100 Nm).
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1 2 3 4 5
7 5 6
M2300105
Pivot Bearings (Type II) Installation.
Perform sectionalization of equipment (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
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TM 5-3810-305-23 FIELD MAINTENANCE CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE
0099
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, 1/2 inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Materials/Parts Grease, Automotive and Artillery Qty: 1 (WP 0170, Table 1, Item 20) Grease, Ball and Roller Bearing Qty: 1 (WP 0170, Table 1, Item 31) Parts Kit, Steering Qty: 1 (WP 0172, Table 1, Item 22) Materials/Parts (cont.) Rag, Wiping Qty: 1 (WP 0170, Table 1, Item 52) Sealing Compound, Silicone Qty: 1 (WP 0170, Table 1, Item 62) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Pivot and spindle assembly removed (WP 0097)
0099-1
TM 5-3810-305-23
0099
REMOVAL
NOTE
1. 2. There is no difference in the maintenance procedures for front and rear constantvelocity joint and axleshaft. Pivot and spindle assembly must be removed to remove constant-velocity joint and shaft assembly.
Remove nut (Figure 1, Item 7) and seal assembly (Figure 1, Item 8) from bowl (Figure 1, Item 3). Remove face seal (Figure 1, Item 6) and o-ring (Figure 1, Item 4) from bowl (Figure 1, Item 3). Discard o-ring.
CAUTION
If a slide hammer or pry bar is used, extreme care must be exercised to prevent damage to bowl.
NOTE
It may be necessary to use a pry bar or slide hammer and ring to remove bowl. 3. Remove bowl (Figure 1, Item 3), guide bushing (Figure 1, Item 2), and o-ring (Figure 1, Item 1) from axle housing (Figure 1, Item 5). Discard o-ring.
8 1 7 6 5 4 3 2
M0195105
Figure 1. 4. 5.
Constant-Velocity Joint and Axle Shaft Removal.
Remove constant-velocity joint (Figure 2, Item 2) and axle shaft (Figure 2, Item 4) from axle housing (Figure 2, Item 3). Remove oil baffle (Figure 2, Item 1) only if there is visible damage.
0099-2
TM 5-3810-305-23 REMOVAL - Continued
0099
4 3
Figure 2.
2
Constant-Velocity Joint and Axle Shaft Removal.
M0196105
NOTE
Left and right axle shafts are different lengths. It may be necessary to place axle shaft into a soft-faced vise to separate it from constant-velocity joint. Once it is secure in the vise, use a brass drift to remove joint from shaft. A C" ring mounted on the shaft will compress into a groove to slip through joint. It will expand when shaft is out of joint. 6. Separate axle shaft (Figure 3, Item 1) from constant-velocity joint (Figure 3, Item 2).
CAUTION
All parts must be clean before installation to prevent damage to constant-velocity joint.
0099-3
TM 5-3810-305-23 INSTALLATION - Continued
0099
NOTE
Make sure axle shaft has a C" ring installed in the groove before assembling constantvelocity joint and shaft. C" ring will be compressed as it goes through joint and will expand to hold assembly when compression is released. 1. Insert end of axle shaft (Figure 3, Item 1) into constant-velocity joint (Figure 3, Item 2).
1 2
M0197105
Figure 3. 2. 3. 4.
Constant-Velocity Joint and Axle Shaft Maintenance.
Lubricate constant-velocity joint (Figure 4, Item 2) and inner surface of axle housing (Figure 4, Item 3). Install oil baffle (Figure 4, Item 1), if removed. Insert axle shaft (Figure 4, Item 4) and constant-velocity joint (Figure 4, Item 2) into axle housing (Figure 4, Item 3).
4 3
Figure 4.
M0196105
Constant-Velocity Joint and Axle Shaft Installation.
0099-4
TM 5-3810-305-23 INSTALLATION - Continued 5. 6.
0099
Place guide bushing (Figure 5, Item 2) over small end of bowl (Figure 5, Item 3) and push to large portion of bowl. Lubricate new o-ring (Figure 5, Item 4) and face seal (Figure 5, Item 6) with ball and roller bearing grease and install on bowl (Figure 5, Item 3).
NOTE
Make sure o-ring is on rear of guide bushing. 7. Lubricate with ball and roller bearing grease and install new o-ring (Figure 5, Item 1), guide bushing (Figure 5, Item 2), bowl (Figure 6, Item 3), new o-ring (Figure 5, Item 4), and face seal (Figure 6, Item 6) as an assembly into axle housing (Figure 5, Item 5). Using ball and roller bearing grease, lubricate seal assembly (Figure 5, Item 8) and install on bowl. Fill free intervals between parts with grease.
8.
WARNING
ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 9. 10. Apply a bead of silicone sealant around threaded portion of nut (Figure 5, Item 7). Install nut (Figure 5, Item 7). Turn nut in counterclockwise direction to engage the leading thread. Tighten nut in clockwise direction to 100 ft-lb (136 Nm).
0099-5
TM 5-3810-305-23 INSTALLATION - Continued
0099
8 1 7 6 5 4 3 2
M0195105
Constant-Velocity Joint and Axle Shaft Installation.
Install pivot and spindle assembly (WP 0097). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0099-6
TM 5-3810-305-23
0100
FIELD MAINTENANCE REAR AXLE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References WP 0074 References (cont.) WP 0103 WP 0152 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Tire and wheel assemblies removed (WP 0107) Tie rod assembly removed (WP 0108) Steering cylinder removed (WP 0112)
0100-1
TM 5-3810-305-23
0100
REMOVAL 1. 2. Use outriggers or jack to raise tires off ground. Support frame with jack stands.
NOTE
Tag all wire assemblies for disconnecting to aid in installation. 3. Disconnect axle centering indicator electrical wire (WP 0074).
WARNING
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. 5. 6. 7. 8. 9. 10. Disconnect and cap all hydraulic lines to steering cylinders, brake lines, and breather hose. Disconnect and remove rear axle lockout cylinders retaining pins (WP 0152). Remove four capscrews (Figure 1, Item 2) to disconnect rear axle (Figure 1, Item 6) from rear driveshaft spider bearing assembly (Figure 1, Item 3). Using hydraulic floor jacks, support rear axle (Figure 1, Item 6). Matchmark two caps (Figure 1, Item 5) and bushings (Figure 1, Item 4). Remove eight capscrews (Figure 1, Item 7), washers (Figure 1, Item 8), two caps (Figure 1, Item 5), and grease fitting (Figure 1, Item 1).
0100-2
TM 5-3810-305-23
0100
REMOVAL - Continued
8 7 6 5 4 3 2
M0318105
Rear Axle Removal.
0100-3
TM 5-3810-305-23
0100
INSTALLATION
CAUTION
Copper sealing washers are not reusable. If a previously tightened connection containing copper sealing washer(s) is loosened, washer(s) must be replaced before retightening. Failure to follow this procedure may result in damage to equipment. 1. Transfer steering cylinders, brake connections, vent hose adapter and other attaching components to new axle before installing on vehicle.
WARNING
Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. 4. 5. 6. 7. 8. 9. 10. Apply threadlock compound to the outside diameter of bushing (Figure 2, Item 4) and install. Raise rear axle (Figure 2, Item 6) in position under vehicle. Install grease fittings (Figure 2, Item 1), capscrews (Figure 2, Item 5), eight washers (Figure 2, Item 8), and capscrews (Figure 2, Item 7). Tighten eight capscrews (Figure 2, Item 5) to 100 ft-lb (136 Nm). Install four capscrews (Figure 2, Item 2) to connect rear axle (Figure 2, Item 6) to driveshaft spider bearing assembly (Figure 2, Item 3). Install lockout cylinder retaining pins (WP 0152). Connect all brake lines, breather hose and hydraulic lines. Connect axle centering indicator electrical wire (WP 0074). Bleed rear brake system (WP 0103). Ensure outer hub drives and center axle differential have been serviced with lubricant, and bushings (Figure 2, Item 4) greased.
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TM 5-3810-305-23
0100
8 7 6 5 4 3 2
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Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install steering cylinder (WP 0112). Install tie rod assembly (WP 0108). Install tire and wheel assemblies (WP 0107). Close dipstick cap.
Rear Axle Installation.
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TM 5-3810-305-23
0101
FIELD MAINTENANCE REAR DIFFERENTIAL ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Indicator, Dial (WP 0171, Table 1, Item 6) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 lbft (WP 0171, Table 1, Item 34) Materials/Parts Gasket (WP 0172, Table 1, Item 112) Qty: 1 Nut (WP 0172, Table 1, Item 21) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Personnel Required (Two) References WP 0095 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Oil from differential removed (TM 5-3810-305-10) Tires and wheels removed (WP 0107) Constant-velocity joint removed (WP 0099) Rear axle removed (WP 0100)
0101-1
TM 5-3810-305-23
0101
REMOVAL
WARNING
Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
CAUTION
Differential assembly may be removed with axle attached to vehicle, but this is not recommended. If differential assembly is removed with axle installed, be careful when positioning and hoisting differential assembly. Failure to follow this caution may result in damage to equipment.
NOTE
Removal of differential assembly from axle or axle from vehicle is not required for pinion seal replacement. 1. Position axle with pinion flange on differential assembly (Figure 1, Item 7) in an upward direction.
WARNING
Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. Using an overhead hoist, attach a suitable lifting fixture to input yoke (Figure 1, Item 2) and disc. To ease alignment at installation, matchmark differential assembly (Figure 1, Item 7) and axle housing.
WARNING
Heating differential mounting bolts to a temperature of 300F (149C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may cause injury or death to personnel. 4. Unstake and loosen pinion nut (Figure 1, Item 1) to aid in disassembly of differential assembly (Figure 1, Item 7).
0101-2
TM 5-3810-305-23
0101
REMOVAL - Continued 5. Remove 10 differential mounting bolts (Figure 1, Item 6) and washers securing differential assembly (Figure 1, Item 7) to axle housing.
NOTE
A tap with a soft-faced mallet may be required to break seal between differential assembly and axle housing. 6. Apply pressure to hoist and lift differential assembly (Figure 1, Item 7) from axle housing approximately 1 inch (25 mm). Rotate differential 90 degrees to align ring gear with clearance cutouts in axle housing and remove from housing.
CAUTION
DO NOT interchange bearings, pinions, or input yoke from other axles. Preload is factory set. Failure to follow this caution may result in damage to equipment. 7. 8. 9. Remove pinion nut (Figure 1, Item 1), input yoke (Figure 1, Item 2), and dust shield (Figure 1, Item 8). Discard pinion nut. Remove trunnion (Figure 1, Item 4) and spacer (Figure 1, Item 3), if necessary. Remove input yoke seal (Figure 1, Item 5).
1 8
5 6
Figure 1. END OF TASK Rear Differential Assembly Removal.
M0315105
0101-3
TM 5-3810-305-23
0101
CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Remove sealant IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound IAW General Maintenance Instructions (WP 0162). Dry parts with compressed air.
END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION
WARNING
Wear protective equipment while heating and handling spacer. Failure to follow this warning may result in serious injury to personnel. 1. 2. Lubricate and install new input yoke seal (Figure 2, Item 5) flush. Heat spacer (Figure 2, Item 3) to approximately 350F (176C). Install spacer and trunnion (Figure 2, Item 4).
0101-4
TM 5-3810-305-23
0101
INSTALLATION - Continued 3. Install input yoke (Figure 2, Item 2), dust shield (Figure 2, Item 8) and new pinion nut (Figure 2, Item 1). Tighten pinion nut to 405 to 433 ft-lb (549 to 587 Nm). Stake pinion nut in two locations 180 degrees apart.
1 8
5 6
Figure 2. 4. Rear Differential Assembly Installation.
M0315105
If differential was disassembled, file off washer face of bolts (Figure 3, Item 1) flush with machined surface of bearing cap (Figure 3, Item 2).
M0316105
Figure 3.
Rear Differential Assembly Installation.
0101-5
TM 5-3810-305-23
0101
WARNING
Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. Failure to follow these warnings may result in serious injury or death to personnel. 5. 6. 7. Install a suitable lifting fixture to input yoke (Figure 4, Item 3) and disc and suspend differential assembly (Figure 4, Item 5) over axle housing opening. Spread a bead of silicone sealant around differential assembly opening. Lower differential assembly (Figure 4, Item 5) into axle housing to approximately 1 inch (25 mm) from seating.
NOTE
Differential assembly must be rotated to align with axle shafts and marks made during removal. 8. 9. 10. 11. Lower and tap differential assembly (Figure 4, Item 5) with a mallet to seat in axle housing. Remove lifting fixture. Apply threadlock compound to 10 mounting bolts (Figure 3, Item 4) and install to secure differential assembly (Figure 4, Item 5) to axle housing. Tighten 10 mounting bolts (Figure 4, Item 4) to 58 ft-lb (79 Nm).
0101-6
TM 5-3810-305-23
0101
4
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install rear axle (WP 0100). Fill differential assembly with oil (TM 5-3810-305-10). Install constant-velocity joints (WP 0099). Install tire and wheel assemblies (WP 0107). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Rear Differential Assembly Installation.
M0317105
0101-7/8 blank
TM 5-3810-305-23
0102
FIELD MAINTENANCE PARKING BRAKE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Pin, Cotter 3/32X1 Inch (WP 0172, Table 1, Item 122) Qty: 1 Pin, Cotter 3X30 (WP 0172, Table 1, Item 156) Qty: 4 Pin, Cotter (WP 0172, Table 1, Item 158) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Washer, Lock 3/8 Inch (WP 0172, Table 1, Item 12) Qty: 2 Materials/Parts (cont.) Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 16) Qty: 4 Washer, Split (WP 0172, Table 1, Item 95) Qty: 6 References WP 0076 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Constant-velocity joint removed (WP 0099) Battery cables disconnected (WP 0076)
0102-1
TM 5-3810-305-23
0102
REMOVAL 1. 2. 3. 4. Remove cotter pin (Figure 1, Item 2) and pin (Figure 1, Item 1) from caliper assembly (Figure 1, Item 3). Discard cotter pin. Remove yoke (Figure 1, Item 13), nut (Figure 1, Item 11), lockwasher (Figure 1, Item 12), and spring (Figure 1, Item 10) from end of cable (Figure 1, Item 7). Discard lockwasher. Remove two nuts (Figure 1, Item 5), lockwashers (Figure 1, Item 4), capscrews (Figure 1, Item 9), and clamp (Figure 1, Item 8) from cable (Figure 1, Item 7). Discard lockwashers. Remove cable (Figure 1, Item 7) from bracket (Figure 1, Item 6).
2 1 13 12 11 10 4 5 6 9 8
M0528105
Figure 1. Parking Brake Removal. 5. 6. Remove four cotter pins (Figure 2, Item 2), washers (Figure 2, Item 3), and two mounting pins (Figure 2, Item 1) from caliper assembly (Figure 2, Item 4) on front axle. Discard cotter pins. Remove caliper assembly (Figure 2, Item 4) from front axle for further disassembly.
2 1
3
M0534105
Figure 2. Parking Brake Removal.
0102-2
TM 5-3810-305-23
0102
REMOVAL - Continued
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 7. 8. Disconnect wiring harness on sensor (Figure 3, Item 3). Remove jam nut (Figure 3, Item 1) and sensor (Figure 3, Item 3) from bracket (Figure 3, Item 2).
2 3
M0530105
Figure 3. 9.
Parking Brake Removal.
Remove four locknuts (Figure 4, Item 3), washers (Figure 4, Item 2), washers (Figure 4, Item 1), and clamps (Figure 4, Item 4) to release cable (Figure 4, Item 5) from vehicle frame. Discard locknuts.
1 5
2 3 4
M0531105
Figure 4.
Parking Brake Removal.
0102-3
TM 5-3810-305-23
0102
REMOVAL - Continued 10. Remove two nuts (Figure 5, Item 3), lockwashers (Figure 5, Item 4), capscrews (Figure 5, Item 9), spacer (Figure 5, Item 2), clamp (Figure 5, Item 12), and two spacers (Figure 5, Item 13) from cable (Figure 5, Item 1) mounted to lever (Figure 5, Item 6). Discard lockwashers. Remove cotter pin (Figure 5, Item 5) and pin (Figure 5, Item 7) to release cable (Figure 5, Item 1) from lever (Figure 5, Item 6). Discard cotter pin. Remove cable (Figure 5, Item 1) by pulling out of cab. Remove four nuts (Figure 5, Item 11) and lockwashers (Figure 5, Item 10) from rear of cab. Discard lockwashers. Remove four capscrews (Figure 5, Item 8) inside cab to remove lever (Figure 5, Item 6).
11. 12. 13. 14.
2 1
3 4 5 6
13 12 11 10 9 8 7
M0532105
Figure 5. Parking Brake Removal. END OF TASK DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Remove cotter pin (Figure 6, Item 13), castle nut (Figure 6, Item 12), and washer (Figure 6, Item 14) from stud in cam side casting (Figure 6, Item 5). Discard cotter pin. Remove operating cam (Figure 6, Item 11) from stud in cam side casting (Figure 6, Item 5). Remove two springs (Figure 6, Item 4) and spring (Figure 6, Item 7) from side casting (Figure 6, Item 5) and carrier casting (Figure 6, Item 6). Remove two pad holder assemblies (Figure 6, Item 8) from side casting (Figure 6, Item 5) and carrier casting (Figure 6, Item 6). Remove two bolts (Figure 6, Item 1), washers (Figure 6, Item 2), and bracket (Figure 6, Item 3) from side casting (Figure 6, Item 5). Remove bolt (Figure 6, Item 15) and washer (Figure 6, Item 9) to separate cam side casting (Figure 6, Item 5) and carrier casting (Figure 6, Item 6). Remove two push pins (Figure 6, Item 10) from cam side casting (Figure 6, Item 5).
0102-4
TM 5-3810-305-23
0102
5 3 2 1 8 14 13 12
15 10 11 9
M0533105
Parking Brake Disassembly.
0102-5
TM 5-3810-305-23
0102
ASSEMBLY
NOTE
Lightly lubricate all moving parts except friction plates. Stamped on the back of each pad holder is a code number. The first or first and second numbers specify the friction material type. The new friction pad material must be the same as the pads being replaced. 1. 2. 3. 4. 5. 6. 7. Position two pad holder assemblies (Figure 7, Item 8) on cam side casting (Figure 7, Item 5) and carrier casting (Figure 7, Item 6). Install two springs (Figure 7, Item 4) and spring (Figure 7, Item 7) holding pad holder assemblies (Figure 7, Item 8) in place. Position cam side casting (Figure 7, Item 5) and carrier casting (Figure 7, Item 6) together. Install washer (Figure 7, Item 9) and bolt (Figure 7, Item 15). Tighten bolt to 32 ft-lb (43 Nm). Install bracket (Figure 7, Item 3) with two washers (Figure 7, Item 2) and bolts (Figure 7, Item 1). Tighten bolts to 32 ft-lb (43 Nm). Install two push pins (Figure 7, Item 10) in cam side casting (Figure 7, Item 5). Install operating cam (Figure 7, Item 11) on stud in cam side casting (Figure 7, Item 5). Install washer (Figure 7, Item 14) and castle nut (Figure 7, Item 12) on stud in cam side casting (Figure 7, Item 5). Do not install cotter pin (Figure 7, Item 13) at this time. See Installation, Step 14 in this work package. All sliding parts must move freely.
8.
5 3 2 1 8 14 13 12 11
M0533105
15 10 9
Figure 7. Parking Brake Assembly. END OF TASK
0102-6
TM 5-3810-305-23
0102
INSTALLATION 1. 2. 3. 4. Install four capscrews (Figure 8, Item 8), new lockwashers (Figure 8, Item 10), and nuts (Figure 8, Item 11) securing lever (Figure 8, Item 6) to rear of cab. Push cable (Figure 8, Item 1) through rear of cab. Install pin (Figure 8, Item 7) and new cotter pin (Figure 8, Item 5), attaching end of cable (Figure 8, Item 1) to lever (Figure 8, Item 6). Install two spacers (Figure 8, Item 13), clamp (Figure 8, Item 12), spacer (Figure 8, Item 2), two capscrews (Figure 8, Item 9), new lockwashers (Figure 8, Item 4), nuts (Figure 8, Item 3) and mounting cable (Figure 8, Item 1) to lever (Figure 8, Item 6).
2 1
3 4 5 6
13 12 11 10 9 8 7
M0532105
Figure 8. 5.
Parking Brake Installation.
Install four clamps (Figure 9, Item 4), washers (Figure 9, Item 1), new lockwashers (Figure 9, Item 2), and nuts (Figure 9, Item 3) to secure cable (Figure 9, Item 5) to vehicle frame.
1 5
2 3 4
M0531105
Figure 9.
0102-7
TM 5-3810-305-23
0102
INSTALLATION - Continued 6. 7. Install sensor (Figure 10, Item 3) on bracket (Figure 10, Item 2) with jam nut (Figure 10, Item 1). Adjust sensor. Connect wiring harness to sensor (Figure 10, Item 3). Note tag from removal.
2 3
M0530105
Figure 10. Parking Brake Installation. 8. 9. Position caliper assembly (Figure 11, Item 4) on front axle. Apply grease to two mounting pins (Figure 11, Item 1). Install mounting pins, four washers (Figure 11, Item 3), and new cotter pins (Figure 11, Item 2), securing caliper assembly (Figure 11, Item 4) to front axle.
2 1
3
M0534105
Figure 11. Parking Brake Installation. 10. 11. 12. 13. Install clamp (Figure 12, Item 8), two capscrews (Figure 12, Item 9), new lockwashers (Figure 12, Item 4), and nuts (Figure 12, Item 5) to secure cable (Figure 12, Item 7) to bracket (Figure 12, Item 6). Install spring (Figure 12, Item 10), new lockwasher (Figure 12, Item 12), nut (Figure 12, Item 11), and yoke (Figure 12, Item 13) on end of cable (Figure 12, Item 7). Install pin (Figure 12, Item 1) and new cotter pin (Figure 12, Item 2) in caliper assembly (Figure 12, Item 3). Check cable (Figure 12, Item 7) for correct adjustment and ease of movement.
0102-8
TM 5-3810-305-23
0102
2 1 13 12 11 10 4 5 6 9 8
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Figure 12. 14. 15.
With lever in cab in UP position, pins (Figure 13, Item 2) should rest in bottom of groove in cam (Figure 13, Item 3). Adjust two pad holder assemblies (Figure 13, Item 1) clearance to 0.010 to 0.020 inch (0.25 to 0.51 mm) by turning castle nut (Figure 13, Item 4) in or out until proper clearance has been obtained. Install new cotter pin (Figure 13, Item 5).
2 5 4
Figure 13. Parking Brake Installation.
3
M0535105
0102-9
TM 5-3810-305-23
0102
INSTALLATION - Continued 16. 17. 18. 19. Additional adjustment can be made on lever. Turn lever handle right to tighten cable, or left to loosen cable. Loosen jam nut (Figure 14, Item 1) on sensor (Figure 14, Item 2). Using a feeler gage, adjust sensor so the gap between sensor and parking brake disc measures 0.025 to 0.040 inch (0.64 to 1.02 mm). Tighten jam nut. Inspect actuator linkage for adequate freedom of movement for positive brake operation. Fill and bleed brake system (WP 0103).
M0536105
Figure 14. Parking Brake Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Connect battery cables (WP 0076). Install constant-velocity joints (WP 0099). Raise and retract outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0102-10
TM 5-3810-305-23
0103
FIELD MAINTENANCE BRAKE ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Brake Fluid, Automotive (WP 0170, Table 1, Item 6) Qty: 1 Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealant, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Planetary wheel end removed (WP 0096) Battery cables disconnected (WP 0076)
WARNING
The brake linings contain asbestos. Wear protective breather respirator when performing maintenance on the brake assembly and brake drum. Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warning may cause injury to death to personnel.
0103-1
TM 5-3810-305-23
0103
REMOVAL
CAUTION
When brake linings have worn down to a thickness of 0.177 inch (4.50 mm) they must be replaced. Failure to follow this caution may result in damage to brake drum.
NOTE
Replacement of parts other than brake drum, brake shoes, springs, banjo fitting, bleeder screw, or automatic adjuster will require disassembly of planetary wheel end. Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. 3. Disconnect and cap brake lines. Remove bolt (Figure 1, Item 4) from spring retainer plate (Figure 1, Item 3) and relieve tension on springs (Figure 1, Item 1). Remove bolt (Figure 1, Item 2), spring retainer plate (Figure 1, Item 3), springs (Figure 1, Item 1), spring retainer (Figure 1, Item 7), spring (Figure 1, Item 9), lockplate (Figure 1, Item 8), brake shoes (Figure 1, Item 5), and spring (Figure 1, Item 10) from wheel (Figure 1, Item 6).
2 1
3 4 5
7 8 10 9
Figure 1. Brake Assembly Removal. 4. 5. 6. Unscrew bolt (Figure 2, Item 5) from rear of automatic adjuster (Figure 2, Item 3). Remove automatic adjuster (Figure 2, Item 3) from brake spider assembly (Figure 2, Item 1). Remove 15 bolts (Figure 2, Item 2), brake spider assembly (Figure 2, Item 1), bolt (Figure 2, Item 5), and two washers from wheel (Figure 2, Item 4).
M0191105
0103-2
TM 5-3810-305-23
0103
REMOVAL - Continued
5 4
Figure 2. 7. 8.
3
Brake Assembly Removal.
M0192105
Remove banjo fitting assembly (Figure 3, Item 5), six bolts and washers (Figure 3, Item 3), and dust shield (Figure 3, Item 1) from brake spider assembly (Figure 3, Item 6). Remove two bolts (Figure 3, Item 4) and wheel cylinder (Figure 3, Item 2) from brake spider assembly (Figure 3, Item 6).
2 1 3
5 6
M0193105
Brake Assembly Removal.
0103-3
TM 5-3810-305-23
0103
INSPECTION 1. Inspect parts IAW General Maintenance Instructions (WP 0162).
WARNING
The brake linings contain asbestos. Wear protective breather respirator when performing maintenance on the brake assembly and brake drum. Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warning may cause injury to death to personnel. 2. Inspect all parts for wear, pitting, cracks, or corrosion and replace if necessary.
END OF TASK INSTALLATION 1. Install wheel cylinder (Figure 4, Item 2) and two bolts (Figure 4, Item 4) on brake spider assembly (Figure 4, Item 6).
CAUTION
Copper sealing washers are not reusable. If previously tightened connection containing copper sealing washer(s) is loosened, washer(s) must be replaced before retightening. Failure to follow this caution may result in damage to equipment. 2. Install dust shield (Figure 4, Item 1), six bolts and washers (Figure 4, Item 3), and banjo fitting assembly (Figure 4, Item 5) on brake spider assembly (Figure 4, Item 6). Do not tighten until brake lines have been connected.
0103-4
TM 5-3810-305-23
0103
2 1 3
5 6
M0193105
Figure 4. 3. 4.
Brake Assembly Installation.
Install automatic adjuster (Figure 5, Item 3), two washers (Figure 5, Item 4), and bolt (Figure 5, Item 5) on brake spider assembly (Figure 5, Item 1) roughly centered. Hand tighten only. Apply threadlock compound to bolt (Figure 5, Item 2) threads. Install brake spider assembly (Figure 5, Item 1) and 15 bolts onto wheel. Tighten bolts to 252 ft-lb (342 Nm).
5 4
Figure 5.
3
M0192105
0103-5
TM 5-3810-305-23
0103
NOTE
Clearance between adjusting plate and star wheel is set at 0.070 inch (1.78 mm) per side. Brake adjuster is designed to work with a total of 0.140 inch (3.56 mm). The maximum clearance on one side is 0.080 inch (2.03 mm). Replace adjuster if clearance is outside specified range. 5. Turn adjustment screws (Figure 6, Item 1) until distance between slots is 4.00 inch (101.6 mm) and both slots have the same distance (Figure 6, Item 2) to star wheel on each side. By following this procedure, brake shoes will be properly centered.
2 4.00 IN. (101.6 MM)
2
M0194105
Figure 6. 6.
Install brake shoes (Figure 7, Item 5), lockplate (Figure 7, Item 8), springs (Figure 7, Item 9), spring retainers (Figure 7, Item 7), spring (Figure 7, Item 10), springs (Figure 7, Item 1), spring retainer plate (Figure 7, Item 3), and bolt (Figure 7, Item 2) on wheel (Figure 7, Item 6). Using spring retainer plate, tension springs (Figure 7, Item 1) and install bolt (Figure 7, Item 4). Tighten bolts (Figure 7, Items 2 and 4) to 18 ft-lb (24 Nm). After brake shoes (Figure 7, Item 5) have been installed, check diameter of brake. Diameter must be 0.010 to 0.020 inch (0.25 to 0.51 mm) less than inside diameter of brake drum.
7.
0103-6
TM 5-3810-305-23
0103
2 1
3 4 5
7 8 10
Figure 7. 8. 9. 10.
9
M0191105
Loosen bolt (Figure 8, Item 5) to allow automatic adjuster (Figure 8, Item 3) to move back and forth. Using a feeler gage through the inspection holes, center the brake assembly so there is an equal amount of clearance at each side. With brake centered, tighten bolt (Figure 8, Item 5) to 60 ft-lb (82 Nm).
5 4
Figure 8.
3
M0192105
0103-7
TM 5-3810-305-23
0103
INSTALLATION - Continued 11. 12. Check clearance between brake and drum. Clearance should be between 0.010 to 0.020 inch (0.25 to 0.51 mm). If necessary, adjust clearance by turning star wheels with a brake adjusting tool through openings provided in dust shield.
END OF TASK BRAKE BLEEDING
CAUTION
Never reuse fluid that has been drained from the system. Be sure a high level of fluid is maintained in reservoir during and after the entire bleeding process. Use only hydraulic brake fluid MIL-B-46176. Make sure master cylinder is mounted securely, all fittings are tight, and reservoir is full with proper fluid. DO NOT depress pedal and connect pressure bleeder into reservoir adapter. Recommended bleeding pressure is 30 psi (207 kPa) maximum. Failure to follow these cautions may result in damage to equipment. 1. 2. 3. 4. 5. Open wheel cylinder bleeder screw furthest from master cylinder. Most of air contained in system will escape by this route. Close bleeder screw. Continue to next furthest bleeder screw. At each point when air bubbles disappear, close bleeder screw. Open bleeder screw at master cylinder. Actuate cylinder to remove any residual air. Tighten bleeder screw before permitting pedal to return. Remove pressure bleeder. Actuate pedal several times. If pedal is spongy, check for system leaks and repeat bleeding process.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install planetary wheel end (WP 0096). Connect battery cables (WP 0076). Place boom in resting position (TM 9-3810-305-10). Check for proper operation.
0103-8
TM 5-3810-305-23
0104
FIELD MAINTENANCE BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Cotter Pin 1/8X1 Inch (WP 0172, Table 1, Item 118) Qty: 1 Lubricating Oil, Hydraulic (WP 0170, Table 1, Item 42) Qty: 1 Parts Kit, Hydraulic (WP 0172, Table 1, Item 4) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 47) Qty: 3 Materials/Parts (cont.) Washer, Lock 7/16 (WP 0172, Table 1, Item 166) Qty: 4 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0146 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Lower dash panel removed (WP 0066)
0104-1
TM 5-3810-305-23
0104
REMOVAL
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. 2. 3. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Position oil drain pan under master cylinder and brake booster valve (Figure 1, Item 2). Remove brake relief valve (WP 0146).
WARNING
When servicing equipment, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, or Chemical Agent Resistant Coating (CARC) paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Wear protective eye covering. Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit. Failure to follow these warnings may result in injury or death to personnel.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 4. Disconnect two brake lines (Figure 1, Item 5) and hoses (Figure 1, Items 1 and 2) from brake master cylinder (Figure 1, Item 3). Drain fluid from system into container and discard.
WARNING
0104-2
TM 5-3810-305-23
0104
REMOVAL - Continued
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 5. 6. Disconnect two brake light wires (Figure 1, Item 7) from brake light switch (Figure 1, Item 6) on master cylinder (Figure 1, Item 3). Remove brake light switch (Figure 1, Item 6) and elbow (Figure 1, Item 4) from master cylinder (Figure 1, Item 3).
2 1
7 4 6
Figure 1. 7.
3 5
M0488105
Brake Booster Valve/Master Cylinder Removal.
Remove four capscrews (Figure 2, Item 2) and lockwashers (Figure 2, Item 1). Lower steering assembly so that steering wheel rests on instrument panel. Discard lockwashers.
2
Figure 2.
1
M0489105
0104-3
TM 5-3810-305-23
0104
REMOVAL - Continued 8. 9. Remove cotter pin (Figure 3, Item 21) from pin on yoke (Figure 3, Item 18). Discard cotter pin. Remove pin (Figure 3, Item 17) from yoke (Figure 3, Item 18) connecting brake booster valve to brake pedal (Figure 3, Item 8).
NOTE
Brake pedal stop bracket will be removed along with brake booster mounting brackets. 10. 11. Remove four capscrews (Figure 3, Item 6) and lockwashers (Figure 3, Item 7) holding brake booster valve and pedal stop bracket to mounting bracket (Figure 3, Item 27). Discard lockwashers. Lower and remove brake booster valve from under dash.
NOTE
Before removing yoke, measure and retain distance between locking nuts to aid in assembly. 12. 13. Remove yoke (Figure 3, Item 18) and push rod (Figure 3, Item 5) by loosening jam nuts (Figure 3, Item 28) and unscrewing from brake booster valve, if required. Remove two elbows (Figure 3, Item 26) and o-rings (Figure 3, Item 25) from master cylinder. Discard o-rings.
2 1
3 4 5 6 7 8
13 9 12 11 10 34 32 31 33 17 14 15 16
28
18
19 20
27
30 23 22 29 25 26 24 21
M0490105
0104-4
TM 5-3810-305-23
0104
DISASSEMBLY 1. 2. Mark across ends of brake booster valve (Figure 4, Item 2) and master cylinder (Figure 4, Item 1) where they attach. Remove three capscrews (Figure 4, Item 4) and lockwashers (Figure 4, Item 3) from master cylinder (Figure 4, Item 1). Separate booster valve (Figure 4, Item 2) and master cylinder. Discard lockwashers.
M0491105
Figure 4. Brake Booster Valve/Master Cylinder Disassembly.
NOTE
Drain fluid from booster assembly before disassembling. 3. Remove push rod (Figure 5, Item 1) and boot (Figure 5, Item 2) from brake booster valve (Figure 5, Item 3). Discard boot.
2 3
Figure 5. Brake Booster Valve Disassembly.
M0492105
0104-5
TM 5-3810-305-23
0104
DISASSEMBLY - Continued 4. 5. 6. Loosen end plug (Figure 6, Item 4) with spanner wrench and remove piston assembly (Figure 6, Item 5) from brake booster valve (Figure 6, Item 3) housing. Remove spring (Figure 6, Item 2) and retainer (Figure 6, Item 1) from internal assembly. Remove end plug (Figure 6, Item 4) from piston assembly (Figure 6, Item 5).
5 4
Figure 6. 7. 8.
3
Brake Booster Disassembly.
M0493105
Remove o-ring (Figure 7, Item 2) from end plug (Figure 7, Item 1). Discard o-ring. Remove cup (Figure 7, Item 3) and back-up ring (Figure 7, Item 4) from bore of end plug (Figure 7, Item 1).
CAUTION
Care should be taken when removing piston ring. Failure to follow this caution may result in damage to equipment.
NOTE
Record position of piston from piston assembly to aid in assembly. 9. Remove piston assembly (Figure 7, Item 7) from piston (Figure 7, Item 5) and remove piston ring (Figure 7, Item 6) from piston. Discard piston ring.
3,4 2 1 5 6 7
M0494105
Figure 7.
0104-6
TM 5-3810-305-23
0104
DISASSEMBLY - Continued 10. Remove retaining ring (Figure 8, Item 1) from piston assembly (Figure 8, Item 6). Retaining ring is under tension of spring (Figure 8, Item 5).
CAUTION
Care should be taken so as not to scratch bore of piston when removing cup and back-up ring. Failure to follow this caution may result in damage to equipment. 11. 12. 13. Remove piston (Figure 8, Item 2) from piston assembly (Figure 8, Item 6). Remove cup (Figure 8, Item 3) and back-up ring (Figure 8, Item 4) from bore of piston (Figure 8, Item 2). Remove spring (Figure 8, Item 5) from piston assembly.
3 1 2
M0495105
Figure 8.
CAUTION
Care should be taken so as not to scratch housing bore when removing cup and back-up ring. Failure to follow this caution may result in damage to equipment. 14. Remove cup (Figure 9, Item 2) and back-up ring (Figure 9, Item 3) from brake booster valve housing (Figure 9, Item 1).
1 2
M0496105
Figure 9.
0104-7
TM 5-3810-305-23
0104
DISASSEMBLY - Continued 15. Remove plug (Figure 10, Item 6) and o-ring (Figure 10, Item 5) from plug. Discard o-ring.
NOTE
Record number of shims when removed. 16. Remove spring (Figure 10, Item 4), shims (Figure 10, Item 3), and piston (Figure 10, Item 2) from brake booster valve housing (Figure 10, Item 1).
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY
CAUTION
Use only clean hydraulic oil to lubricate. Failure to follow this caution may result in damage to equipment. 1. 2. 3. Lubricate all parts with hydraulic oil before assembling. Install piston (Figure 10, Item 2) and shims (Figure 10, Item 3) as recorded, and spring (Figure 10, Item 4) in brake booster valve housing (Figure 10, Item 1). Piston must be free to move in housing. Install new o-ring (Figure 10, Item 5) and plug (Figure 10, Item 6).
3 1 2
M0497105
Figure 10.
Brake Booster Maintenance.
0104-8
TM 5-3810-305-23
0104
CAUTION
Two lips of U-cup must point toward inside of brake booster. Use care to avoid nicking or scratching seal lips. 4. Install back-up ring (Figure 11, Item 3) and cup (Figure 11, Item 2) and in brake booster valve housing (Figure 11, Item 1).
1 2
M0496105
Figure 11. 5.
Brake Booster Assembly.
Install spring (Figure 12, Item 5) on piston assembly (Figure 12, Item 6).
NOTE
Two lips of U-cup must be away from piston. Use care to avoid nicking or scratching seal lips. 6. 7. 8. Install back-up ring (Figure 12, Item 4) and cup (Figure 12, Item 3) in piston (Figure 12, Item 2). Do not mar piston bore. Install piston (Figure 12, Item 2) over spring (Figure 12, Item 5) and piston assembly (Figure 12, Item 6). Install retaining ring (Figure 12, Item 1) on piston assembly (Figure 12, Item 6).
3 1 2
M0495105
Figure 12.
Brake Booster Assembly.
0104-9
TM 5-3810-305-23
0104
CAUTION
DO NOT allow the piston seal to twist" in the seal groove. The piston seal can be made pliable to aid in installation by soaking in approximately 300F (149C) oil. Failure to follow this caution may result in damage to equipment. 9. 10. 11. 12. 13. Install new piston ring (Figure 13, Item 6) on piston (Figure 13, Item 5). Caution should be taken when installing piston ring (Figure 13, Item 6). Install piston assembly (Figure 13, Item 7) on piston assembly (Figure 13, Item 5). Note direction of piston (Figure 13, Item 6) as recorded during disassembly. Install back-up ring (Figure 13, Item 4) and cup (Figure 13, Item 3) in bore of end plug (Figure 13, Item 1). Install new o-ring (Figure 13, Item 2) on end plug (Figure 13, Item 1). Install end plug (Figure 13, Item 1) on piston assembly.
3,4 2 1 5 6 7
M0494105
Figure 13. Brake Booster Assembly. 14. 15. Install retainer (Figure 14, Item 1) and spring (Figure 14, Item 2) over piston assembly (Figure 14, Item 5). Install piston assembly (Figure 14, Item 5) into brake booster valve housing bore (Figure 14, Item 3). Use a spanner wrench to tighten end plug (Figure 13, Item 4).
5 4
M0493105
Figure 14. Brake Booster Assembly.
0104-10
TM 5-3810-305-23
0104
ASSEMBLY - Continued 16. Install new boot (Figure 15, Item 2) and push rod (Figure 15, Item 1) into booster valve housing (Figure 15, Item 3).
2 3
Figure 15. 17. Brake Booster Assembly.
M0492105
Align marks on brake booster valve (Figure 16, Item 2) and master cylinder (Figure 16, Item 1). Install three new lockwashers (Figure 16, Item 3) and capscrews (Figure 16, Item 4).
M0491105
Figure 16. Master Cylinder/Brake Booster Assembly. END OF TASK
0104-11
TM 5-3810-305-23
0104
INSTALLATION
NOTE
If yoke was disassembled, use measurement taken in disassembly to assemble yoke to rod. 1. 2. 3. 4. 5. 6. Install two new o-rings (Figure 17, Item 25) and elbows (Figure 17, Item 26) to master cylinder. Install yoke (Figure 17, Item 18), push rod (Figure 17, Item 5), and tighten jam nuts (Figure 17, Item 28). Position brake booster valve, master cylinder, and brake pedal stop bracket under dash on mounting bracket (Figure 17, Item 27). Install four new lockwashers (Figure 17, Item 7) and capscrews (Figure 17, Item 6). Attach yoke (Figure 17, Item 18) to brake pedal (Figure 17, Item 8) using pin (Figure 18, Item 17). Install new cotter pin (Figure 17, Item 21) in pin (Figure 17, Item 17).
2 1
3 4 5 6 7 8
13 9 12 11 10 34 32 31 33 17 14 15 16
28
18
19 20
27
30 23 22 29 25 26 24 21
M0490105
Figure 17. Master Cylinder Installation. 7. Install four new lockwashers (Figure 18, Item 1) and capscrews (Figure 18, Item 2) in steering wheel pump.
0104-12
TM 5-3810-305-23
0104
1
M0489105
Figure 18. 8. 9. 10. 11. 12.
Master Cylinder Installation.
Connect hoses (Figure 19, Items 1 and 2) and two brake lines (Figure 19, Item 5) to master cylinder (Figure 19, Item 3). Install elbow (Figure 19, Item 4) and brake light switch (Figure 19, Item 6) to master cylinder (Figure 19, Item 3). Install two brake light wires (Figure 19, Item 7) to brake light switch (Figure 19, Item 6) on master cylinder (Figure 19, Item 3). Install brake relief valve (WP 0146). Fill and bleed brake system (WP 0103).
2 1
7 4 6 5
3
M0488105
Figure 19. Brake Booster Valve/Master Cylinder Installation.. END OF TASK
0104-13
TM 5-3810-305-23
0104
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install lower dash panel (WP 0110). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0104-14
TM 5-3810-305-23
0105
FIELD MAINTENANCE HYDRAULIC BRAKE LINES AND FITTINGS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 37) Qty: 4 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 7 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 2 References WP 0103 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0105-1
TM 5-3810-305-23
0105
REMOVAL
WARNING
CAUTION
Wipe area clean around all connections to be opened during removal. Cap lines and hoses. Plug openings after removing lines. Contamination of system could result in premature failure.
NOTE
Tag hoses prior to removal to ensure correct installation. 1. 2. 3. 4. Disconnect hoses (Figure 1, Items 7 and 11) from master cylinder reservoir (Figure 1, Items 1 and 6). Disconnect hoses (Figure 1, Items 7 and 11) from master cylinder (Figure 1, Item 8). Disconnect tubes (Figure 1, Items 9 and 10) from master cylinder (Figure 1, Item 8). Remove two capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), nuts (Figure 1, Item 5), and master cylinder reservoir (Figure 1, Items 1 and 6) from vehicle. Discard lockwashers.
0105-2
TM 5-3810-305-23
0105
REMOVAL - Continued
2,3,4,5 1 6
11 7 10
8 9
M0326105
Figure 1.
Hydraulic Brake Lines and Fittings Removal.
0105-3
TM 5-3810-305-23
0105
REMOVAL - Continued 5. 6. 7. 8. Disconnect tube (Figure 2, Items 2 and 4) from coupling (Figure 2, Item 3). Disconnect tube (Figure 2, Items 1 and 9) from coupling (Figure 2, Item 10). Remove tube (Figure 2, Items 1 and 2) from vehicle. Remove capscrew (Figure 2, Item 5), nut (Figure 2, Item 6), washer (Figure 2, Item 7), and clamp (Figure 2, Item 8).
3 4
5,6,7,8
10
Figure 2. Hydraulic Brake Lines and Fittings Removal.
M0327105
0105-4
TM 5-3810-305-23
0105
REMOVAL - Continued 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Disconnect tube (Figure 3, Item 7) from reducer (Figure 3, Item 8). Remove tube (Figure 3, Item 7) from vehicle. Disconnect reducer (Figure 3, Item 8) from tee (Figure 3, Item 9). Disconnect tube (Figure 3, Item 10) from tee (Figure 3, Item 9). Disconnect tube (Figure 3, Item 11) from tee (Figure 3, Item 9). Disconnect tube (Figure 3, Item 3) from coupling (Figure 3, Item 2). Disconnect tube (Figure 3, Item 1) from coupling (Figure 3, Item 2). Remove nut (Figure 3, Item 4), washer (Figure 3, Item 5), and clamp (Figure 3, Item 6) from tube (Figure 3, Item 3). Remove tube (Figure 3, Item 3) from vehicle. Remove nut (Figure 3, Item 14), washer (Figure 3, Item 13), and clamp (Figure 3, Item 12) from tube (Figure 3, Item 1).
4,5,6
12, 13, 14
11
Figure 3.
11
10
8
M0335105
0105-5
TM 5-3810-305-23
0105
REMOVAL - Continued
NOTE
Steps 19 and 20 are removal procedures for one outer axle area. The removal procedures for the other three outer axle areas are identical. 19. 20. Remove capscrew (Figure 4, Item 4), bracket (Figure 4, Item 3), spring (Figure 4, Item 2), and clamp (Figure 4, Item 1) from vehicle. Disconnect hose (Figure 4, Item 6) from axle (Figure 4, Item 5).
6 5
Figure 4. 21. 22. 23. 24. 25. 26. 27. 28. Hydraulic Brake Lines and Fittings Removal.
M0329105
Remove nut (Figure 5, Item 1), washer (Figure 5, Item 2), and clamp (Figure 5, Item 3) from tube (Figure 5, Item 6). Disconnect tube (Figure 5, Item 5) from coupling (Figure 5, Item 4). Remove tube (Figure 5, Item 5) from vehicle. Disconnect tube (Figure 5, Item 6) from coupling (Figure 5, Item 4). Disconnect tube (Figure 5, Item 6) from coupling (Figure 5, Item 11). Remove nut (Figure 5, Item 7), washer (Figure 5, Item 8), and clamp (Figure 5, Item 9) from tube (Figure 5, Item 6). Remove tube (Figure 5, Item 6) from vehicle. Disconnect hose (Figure 5, Item 10) from coupling (Figure 5, Item 11).
0105-6
TM 5-3810-305-23
0105
REMOVAL - Continued
1,2,3
6 4 5
7,8,9
10
11
M0330105
Figure 5. 29. 30. 31. 32.
Disconnect hose (Figure 6, Item 1) from tee (Figure 6, Item 2). Disconnect tubes (Figure 6, Items 3 and 7) from tee (Figure 6, Item 2). Remove capscrew (Figure 6, Item 6), washer (Figure 6, Item 5), and nut (Figure 6, Item 4). Remove tee (Figure 6, Item 2) from vehicle.
2 3
7
Figure 6.
4,5,6
M0331105
0105-7
TM 5-3810-305-23
0105
REMOVAL - Continued 33. 34. 35. 36. Disconnect left rear hose (Figure 7, Item 1) from coupler (Figure 7, Item 2). Remove hose from vehicle. Disconnect left rear tube (Figure 7, Item 3) from coupler (Figure 7, Item 2). Remove tube from vehicle. Disconnect right rear hose (Figure 7, Item 6) from coupler (Figure 7, Item 5). Remove hose from vehicle. Disconnect right rear tube (Figure 7, Item 4) from coupler (Figure 7, Item 5). Remove tube from vehicle.
6
M0332105
Figure 7. 37. 38. 39. 40.
Disconnect left front hose (Figure 8, Item 4) from coupler (Figure 8, Item 3). Remove hose from vehicle. Disconnect left front tube (Figure 8, Item 2) from coupler (Figure 8, Item 3). Remove tube from vehicle. Disconnect right front hose (Figure 8, Item 1) from coupler (Figure 8, Item 6). Remove hose from vehicle. Disconnect right front tube (Figure 8, Item 5) from coupler (Figure 8, Item 6). Remove tube from vehicle.
0105-8
TM 5-3810-305-23
0105
REMOVAL - Continued
0105-9
TM 5-3810-305-23
0105
INSTALLATION 1. 2. 3. 4. Install right front tube (Figure 9, Item 5) on vehicle and connect to coupler (Figure 9, Item 6). Install right front hose (Figure 9, Item 1) and connect to coupler (Figure 9, Item 6). Install left front tube (Figure 9, Item 2) on vehicle and connect to coupler (Figure 9, Item 3). Install left front hose (Figure 9, Item 4) and connect to coupler (Figure 9, Item 3).
Figure 9.
Hydraulic Brake Lines and Fittings Installation.
0105-10
TM 5-3810-305-23
0105
INSTALLATION - Continued 5. 6. 7. 8. Install right rear tube (Figure 10, Item 4) on vehicle and connect to coupler (Figure 10, Item 5). Install right rear hose (Figure 10, Item 6) and connect to coupler (Figure 10, Item 5). Install left rear tube (Figure 10, Item 3) on vehicle and connect to coupler (Figure 10, Item 2). Install left rear hose (Figure 10, Item 1) and connect to coupler (Figure 10, Item 2).
6
M0332105
Figure 10. Hydraulic Brake Lines and Fittings Installation.
0105-11
TM 5-3810-305-23
0105
INSTALLATION - Continued 9. 10. 11. 12. Place tee (Figure 11, Item 2) on vehicle. Install nut (Figure 11, Item 4), washer (Figure 11, Item 5), and capscrew (Figure 11, Item 6). Connect tube (Figure 11, Items 3 and 7) to tee (Figure 11, Item 2). Connect hose (Figure 11, Item 1) to tee (Figure 11, Item 2).
2 3
4,5,6
M0331105
Figure 11. Hydraulic Brake Lines and Fittings Installation. 13. 14. 15. 16. 17. 18. 19. 20. Connect hose (Figure 12, Item 10) to coupling (Figure 12, Item 11). Install tube (Figure 12, Item 6) on vehicle. Connect tube (Figure 12, Item 6) to coupling (Figure 12, Item 11). Install clamp (Figure 12, Item 9), washer (Figure 12, Item 8), and nut (Figure 12, Item 7) on tube (Figure 12, Item 6). Connect tube (Figure 12, Item 6) to coupling (Figure 12, Item 4). Install tube (Figure 12, Item 5) on vehicle. Connect tube (Figure 12, Item 5) to coupling (Figure 12, Item 4). Install clamp (Figure 12, Item 3), washer (Figure 12, Item 2), and nut (Figure 12, Item 1) on tube (Figure 12, Item 6).
0105-12
TM 5-3810-305-23
0105
1,2,3
6 4 5
7,8,9
10
11
M0330105
Figure 12. Hydraulic Brake Lines and Fittings Installation. 21. 22. Install capscrew (Figure 13, Item 4), bracket (Figure 13, Item 3), spring (Figure 13, Item 2), and clamp (Figure 13, Item 1). Connect hose (Figure 13, Item 6) to axle (Figure 13, Item 5).
6 5
M0329105
0105-13
TM 5-3810-305-23
0105
INSTALLATION - Continued 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. Install nut (Figure 14, Item 14), washer (Figure 14, Item 13), and clamp (Figure 14, Item 12) on tube (Figure 14, Item 1). Install tube (Figure 14, Item 3) on vehicle. Install nut (Figure 14, Item 4), washer (Figure 14, Item 5), and clamp (Figure 14, Item 6) on tube (Figure 14, Item 3). Connect tube (Figure 14, Item 1) to coupling (Figure 14, Item 2). Connect tube (Figure 14, Item 3) to coupling (Figure 14, Item 2). Connect tube (Figure 14, Item 11) to tee (Figure 14, Item 9). Connect tube (Figure 14, Item 10) to tee (Figure 14, Item 9). Connect reducer (Figure 14, Item 8) to tee (Figure 14, Item 9). Install tube (Figure 14, Item 7) on vehicle. Connect tube (Figure 14, Item 7) to reducer (Figure 14, Item 8).
4,5,6
12, 13, 14
11
11
10
8
M0335105
0105-14
TM 5-3810-305-23
0105
INSTALLATION - Continued 33. 34. 35. 36. Install clamp (Figure 15, Item 8), washer (Figure 15, Item 7), nut (Figure 15, Item 6), and capscrew (Figure 15, Item 5). Install tube (Figure 15, Items 1 and 2) on vehicle. Connect tube (Figure 15, Items 2 and 4) to coupling (Figure 15, Item 3). Connect tube (Figure 15, Items 1 and 9) to coupling (Figure 15, Item 10).
3 4
5,6,7,8
10
M0327105
0105-15
TM 5-3810-305-23
0105
INSTALLATION - Continued 37. 38. 39. 40. 41. Install nuts (Figure 16, Item 5), washers (Figure 16, Item 4), new lockwashers (Figure 16, Item 3), and two capscrews (Figure 16, Item 2) to master cylinder reservoir (Figure 16, Items 1 and 6) on vehicle. Connect hoses (Figure 16, Items 7 and 11) to master cylinder reservoir (Figure 16, Items 1 and 6). Connect hoses (Figure 16, Items 7 and 11) to master cylinder (Figure 16, Item 8). Connect tubes (Figure 16, Items 9 and 10) to master cylinder (Figure 16, Item 8). Bleed brakes (WP 0103).
2,3,4,5 1 6
11 7 10
8 9
M0326105
Figure 16. Hydraulic Brake Lines and Fittings Installation. END OF TASK
0105-16
TM 5-3810-305-23
0105
0105-17/18 blank
TM 5-3810-305-23
0106
FIELD MAINTENANCE BRAKE PEDAL AND LINKAGE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Jelly, Petroleum (WP 0170, Table 1, Item 32) Qty: 1 Nut, Self-Locking, He 3/4 Inch (WP 0172, Table 1, Item 10) Qty: 1 Pin, Cotter 1/8X1 Inch (WP 0172, Table 1, Item 118) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 49) Qty: 4 Materials/Parts (cont.) Washer, Lock 7/16 (WP 0172, Table 1, Item 166) Qty: 4 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Lower dash panel removed (WP 0110) Battery cables disconnected (WP 0076)
REMOVAL 1. Remove four capscrews (Figure 1, Item 3) and lockwashers (Figure 1, Item 2) from steering assembly (Figure 1, Item 1). Discard lockwashers.
1 3 2
M0498105
Figure 1.
Brake Pedal and Linkage Removal.
0106-1
TM 5-3810-305-23
0106
REMOVAL - Continued 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove cotter pin (Figure 2, Item 10) and pin (Figure 2, Item 8) from booster valve (Figure 2, Item 9). Discard cotter pin. Remove locknut (Figure 2, Item 19), bushing (Figure 2, Item 20), washer (Figure 2, Item 21), and bolt (Figure 2, Item 3) from bracket (Figure 2, Item 11). Discard locknut. Remove pedal (Figure 2, Item 2), bushing (Figure 2, Item 1), and rubber pedal (Figure 2, Item 14) as an assembly from bracket (Figure 2, Item 11). Remove bushing (Figure 2, Item 1) from pedal (Figure 2, Item 2), if necessary. Remove rubber pedal (Figure 2, Item 14) from pedal (Figure 2, Item 2). Remove four capscrews (Figure 2, Item 17) and lockwashers (Figure 2, Item 16) from booster valve (Figure 2, Item 9). Discard lockwashers. Remove bracket (Figure 2, Item 12), capscrew (Figure 2, Item 15), nut (Figure 2, Item 13), bumper (Figure 2, Item 18), and screw (Figure 2, Item 4) from bracket (Figure 2, Item 11) as an assembly. Remove screw (Figure 2, Item 4), bumper (Figure 2, Item 18), nut (Figure 2, Item 13), and capscrew (Figure 2, Item 15) from bracket (Figure 2, Item 12). Remove four nuts (Figure 2, Item 7), lockwashers (Figure 2, Item 6), capscrews (Figure 2, Item 5), and bracket (Figure 2, Item 11). Discard lockwashers.
1 2 21 3 4 19 20 5 6 7 17 16 15 11 10 8 9
18
14
13
12
M0499105
Brake Pedal and Linkage Removal.
0106-2
TM 5-3810-305-23
0106
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Install bracket (Figure 3, Item 11), four capscrews (Figure 3, Item 5), new lockwashers (Figure 3, Item 6), and nuts (Figure 3, Item 7). Install capscrew (Figure 3, Item 15) and nut (Figure 3, Item 13) to bracket (Figure 3, Item 12). Install bumper (Figure 3, Item 18) and screw (Figure 3, Item 4) to capscrew (Figure 3, Item 15). Position bracket (Figure 3, Item 12) on bracket (Figure 3, Item 11). Install four new lockwashers (Figure 3, Item 16) and capscrews (Figure 3, Item 17) through bracket (Figure 3, Item 11) into booster valve (Figure 3, Item 9). Heat rubber pedal (Figure 3, Item 14) in hot water and install on pedal (Figure 3, Item 2). Install bushing (Figure 3, Item 1), if removed. Position pedal (Figure 3, Item 2) against bracket (Figure 3, Item 11). Apply a coat of petroleum jelly on bolt (Figure 3, Item 3). Install shoulder bolt (Figure 3, Item 3), washer (Figure 3, Item 21), bushing (Figure 3, Item 20) to new locknut (Figure 3, Item 19) and install. Position booster valve clevis to pedal (Figure 3, Item 2). Install pin (Figure 3, Item 8) and new cotter pin (Figure 3, Item 10) in booster valve (Figure 3, Item 9).
1 2 21 3 4 19 20 5 6 7 17 16 15 11 10 8 9
18
14
Figure 3.
13
12
M0499105
Brake Pedal and Linkage Installation.
0106-3
TM 5-3810-305-23
0106
INSTALLATION - Continued 13. Install four new lockwashers (Figure 4, Item 2) and capscrews (Figure 4, Item 3) in steering assembly (Figure 4, Item 1).
1 3 2
M0498105
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Connect battery cables (WP 0076). Install lower dash panel (WP 0066).
Brake Pedal and Linkage Installation.
Raise and retract outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0106-4
TM 5-3810-305-23
0107
FIELD MAINTENANCE TIRES AND WHEELS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Materials/Parts Lubricant, Tire and Rim (WP 0170, Table 1, Item 33) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0103 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
WARNING
Never reinflate a tire that has been run flat or seriously underinflated without removing and checking for tire tube or rim damage. Never exceed 3 psi (21 kPa) inflation prior to placing tire and wheel assembly into inflation safety cage or mounting on a tire change machine that has a positive lockdown device. Always inflate tires that are mounted on rims with demountable side ring flanges or lock rings in an inflation safety cage. When inflating tires in an inflation cage, always use extension are hose and pneumatic tire inflator-gage. Improperly seated side ring flanges or lock rings may fly off during inflation. Never attempt to seat a side ring flange or lock ring during inflation or after inflation. Never inflate tires over 40 psi (276 kPa) to seat tire beads. If beads do not seat, deflate, demount, and check the tire/rim match. Mount and lubricate according to instructions. When inflating tires mounted on the vehicle, all personnel must remain a minimum of 10 ft (3.1 m) away from tire and not in possible path of lock ring or rim flange. Should they fly off, serious injury or death may result. Failure to follow these warnings may cause injury or death to personnel.
0107-1
TM 5-3810-305-23
0107
REMOVAL 1. 2. 3. 4. Use outriggers or jack to raise affected tire off ground. Support frame with jack stands. Remove 10 lug nuts (Figure 1, Item 1) from tire and wheel assembly (Figure 1, Item 3). Remove tire and wheel assembly (Figure 1, Item 3) from axle hub (Figure 1, Item 2).
3
M0181105
Figure 1. Tires and Wheels Removal. END OF TASK DISASSEMBLY
WARNING
When deflating tires, always ensure tire is completely deflated before removing from rim. Failure to follow this warning may result in serious injury or death to personnel. 1. 2. 3. Remove valve stem cap (Figure 2, Item 1) and completely deflate tire (Figure 2, Item 3). Dismount deflated tire (Figure 2, Item 3) from wheel using tire irons. Discard tire. Remove valve stem (Figure 2, Item 2). Discard valve stem.
0107-2
TM 5-3810-305-23
0107
2 1
M0182105
Tires and Wheels Disassembly.
Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect valve stem for wear, cracks or leaks. Discard if worn or leaking.
END OF TASK
0107-3
TM 5-3810-305-23
0107
ASSEMBLY
WARNING
When inflating tires, always ensure tires are properly seated. Improperly seated tires can burst with explosive force. DO NOT mix one type of wheel with a different type of tire. Improper seating of these components can cause tire and wheel to fly apart with explosive force. Failure to follow these warnings may result in serious injury or death to personnel. 1. 2. 3. 4. 5. Install new valve stem (Figure 3, Item 2). Apply lubricant to both beads of tire and wheel rim. Position wheel flat on floor with valve stem (Figure 3, Item 2) up. Place tire and wheel assembly (Figure 3, Item 3) into safety cage. Inflate tire. Recommended tire pressure for the 12.00 x 22.5, 14 PR tire is 115 psi (793 kPa).
2 1
M0182105
Figure 3. Tires and Wheels Assembly. 6. Install valve stem cap (Figure 4, Item 1).
0107-4
TM 5-3810-305-23
0107
1
M0184105
Tires and Wheels Assembly.
NOTE
DO NOT lubricate lug nuts. Tire tread is directional. Refer to travel direction arrow on sidewall of tire. 1. Install inflated tire and wheel assembly (Figure 5, Item 3) on axle hub (Figure 5, Item 2). Install 10 lug nuts (Figure 5, Item 1) on hub studs on the tire and wheel assembly.
3
M0181105
Figure 5.
Tires and Wheels Installation.
0107-5
TM 5-3810-305-23
0107
INSTALLATION - Continued 2. 3. 4. 5. Tighten 10 lug nuts (Figure 6, Item 1) to 450 to 500 ft-lb (610 to 678 Nm) in sequence. Remove jack stands. Raise outriggers or remove jack. Recheck after 8 hours of operation.
M0185105
Figure 6. Tires and Wheels Installation. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
0107-6
TM 5-3810-305-23
0108
FIELD MAINTENANCE TIE ROD ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, 1/2 Inch Drive Ratcheting (250 ftlb) (WP 0171, Table 1, Item 33) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive (75 ft-lb) (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Pin, Cotter 6.3 X 56MM (WP 0172, Table 1, Item 159) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0108-1
TM 5-3810-305-23
0108
REMOVAL
NOTE
The following is a maintenance procedure for rear tie rod. The maintenance procedure for front tie rod is identical. 1. 2. Measure and record distance between two tie rod ends (Figure 1, Item 6) to aid in installation. Loosen clamp assemblies (Figure 1, Item 7).
NOTE
Remove tie rod ends only if necessary. 3. 4. 5. 6. 7. 8. 9. Remove cotter pins (Figure 1, Item 3) from tie rod ends (Figure 1, Item 6). Discard cotter pins. Remove tie rod end nuts (Figure 1, Item 2) from tie rod ends (Figure 1, Item 6). Separate tie rod ends (Figure 1, Item 6) from tie rod levers (Figure 1, Item 4). Remove dust shields (Figure 1, Item 5) from tie rod levers (Figure 1, Item 4). Unscrew tie rod ends (Figure 1, Item 6) from tie rod (Figure 1, Item 8). Remove clamp assemblies (Figure 1, Item 7) from tie rod (Figure 1, Item 8). Remove grease fittings (Figure 1, Item 1) from tie rod ends (Figure 1, Item 6).
8 7
2 6 5 4 3
M0186105
Figure 1. Tie Rod Assembly Removal. END OF TASK CLEANING 1. 2. Clean parts IAW General Maintenance Instructions (WP 0162). Clean parts and surfaces with cleaning compound solvent.
END OF TASK
0108-2
TM 5-3810-305-23
0108
INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect dust shields (Figure 1, Item 5) for wear, tears, and deformation. Inspect all parts for wear, pitting, cracks, or corrosion. Replace if necessary.
END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install grease fittings (Figure 2, Item 1) on tie rod ends (Figure 2, Item 6). Slide clamp assemblies (Figure 2, Item 7) onto tie rod (Figure 2, Item 8). Screw tie rod ends (Figure 2, Item 6) onto tie rod (Figure 2, Item 8), using measurement recorded in removal. Install dust shields (Figure 2, Item 5) on tie rod levers (Figure 2, Item 4). Install tie rod ends (Figure 2, Item 6) into tie rod levers (Figure 2, Item 4). Install tie rod end nuts (Figure 2, Item 2) on to tie rod ends (Figure 2, Item 6). Tighten tie rod end nuts to 180 ft-lb (244 Nm) and advance to next castellation. Install new cotter pins (Figure 2, Item 3) on tie rod ends (Figure 2, Item 6). Secure clamp assemblies (Figure 2, Item 7).
8 7
2 6 5 4 3
M0186105
Tie Rod Assembly Installation.
0108-3
TM 5-3810-305-23
0108
ADJUSTMENT 1. 2. 3. Position wheels straight ahead. Loosen clamp assemblies. Measure distance between outside edges of tread shoulders at axle height on front side of tires. Repeat measurement on back side of tires. When adjustment is correct, back side measurement will be 0.125 to 0.250 inch (3.18 to 6.35 mm) greater than front side measurement. Turn tie rod (Figure 3, Item 8) until measurements fall within tolerance found in Step 3. Tighten clamp assembly to 33 ft-lb (45 Nm). Perform Steps 1 through 5 for other axle, if necessary. Check for proper operation.
4. 5. 6. 7.
8 7
2 6 5 4 3
M0186105
Tie Rod Assembly Adjustment.
0108-4
TM 5-3810-305-23
0109
FIELD MAINTENANCE GROUND DRIVEN STEERING PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click Ratcheting 3/8 Inch Drive (75 ft-lb) (WP 0171, Table 1, Item 36) Materials/Parts Adhesive, 1 Pint Can (WP 0170, Table 1, Item 1) Qty: 1 Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 O-Ring (WP 0172, Table 1, Item 163) Qty: 1 Parts Kit, Seal Repl (WP 0172, Table 1, Item 26) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 515 (WP 0170, Table 1, Item 58) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 7/16 Inch Regular (WP 0172, Table 1, Item 51) Qty: 4 References Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine hood removed (WP 0120) Hydraulic reservoir drained (WP 0153)
WARNING
0109-1
TM 5-3810-305-23
0109
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. Use a suitable container to catch hydraulic oil when hoses are removed from pump. 1. 2. 3. 4. 5. 6. Loosen clamp (Figure 1, Item 7) and remove hose (Figure 1, Item 6) from adapter (Figure 1, Item 10). Remove four capscrews (Figure 1, Item 8) and lockwashers (Figure 1, Item 9) from pump (Figure 1, Item 12). Discard lockwashers. Remove adapter (Figure 1, Item 10) and o-ring (Figure 1, Item 11) from pump (Figure 1, Item 12). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 2). Remove two capscrews (Figure 1, Item 4) and washers (Figure 1, Item 5) from pump (Figure 1, Item 12). Remove pump (Figure 1, Item 12) from transmission (Figure 1, Item 3).
1 12
11 10 8,9 4,5
7 6
M0437105
Figure 1. END OF TASK DISASSEMBLY
Ground Driven Steering Pump Removal.
NOTE
Matchmark pump sections before disassembly. 1. Remove elbow (Figure 2, Item 4) and o-ring (Figure 2, Item 3). Discard o-ring.
0109-2
TM 5-3810-305-23
0109
DISASSEMBLY - Continued 2. 3. Remove four capscrews (Figure 2, Item 5) and washers (Figure 2, Item 6) from pump. Separate rear flange plate (Figure 2, Item 1) from gear plate (Figure 2, Item 2).
5,6 3
M0438105
Figure 2. Ground Driven Steering Pump Disassembly. 4. Remove o-ring (Figure 3, Item 4), back-up ring (Figure 3, Item 3), and o-ring (Figure 3, Item 2) from rear flange plate (Figure 3, Item 1). Discard o-rings and back-up rings.
2
M0439105
Figure 3. Ground Driven Steering Pump Disassembly.
0109-3
TM 5-3810-305-23
0109
DISASSEMBLY - Continued 5. Remove thrust plate (Figure 4, Item 2) from gear plate (Figure 4, Item 1).
M0440105
Figure 4. Ground Driven Steering Pump Disassembly. 6. Remove idler gear (Figure 5, Item 2) and drive gear (Figure 5, Item 3) from gear plate (Figure 5, Item 1).
2 3
M0441105
NOTE
Matchmark position of thrust plate before removal.
0109-4
TM 5-3810-305-23
0109
DISASSEMBLY - Continued 7. 8. 9. Separate gear plate (Figure 6, Item 1) from front flange plate (Figure 6, Item 4). Remove thrust plate (Figure 6, Item 3). Remove eight dowel pins (Figure 6, Item 2) from gear plate (Figure 6, Item 1).
1 2 4
M0442105
Figure 6. Ground Driven Steering Pump Disassembly. 10. Remove o-ring (Figure 7, Item 2), back-up ring (Figure 7, Item 4), and o-ring (Figure 7, Item 3) from front flange plate (Figure 7, Item 1). Discard o-rings and back-up ring.
2 1 3 4
M0443105
0109-5
TM 5-3810-305-23
0109
DISASSEMBLY - Continued 11. Remove plug (Figure 8, Item 5), seal (Figure 8, Item 1), snapring (Figure 8, Item 2), and seal (Figure 8, Item 3) from front flange plate (Figure 8, Item 4). Discard seals.
1 2 3
4
Figure 8. Ground Driven Steering Pump Disassembly. END OF TASK
M0444105
0109-6
TM 5-3810-305-23
0109
CLEANING
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Eye shields must be worn when cleaning with a wire brush. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound. Dry parts with compressed air.
END OF TASK INSPECTION 1. 2. 3. 4. 5. 6. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect wear plates. A smooth wear pattern on the plate face mat is slightly heavier on the inlet side is normal. If surface is severely scored or discolored, plate must be replaced. Inspect gears. Check journals and faces of each gear. They must be smooth and free from nicks or burrs. If any surfaces are discolored, gear must be replaced. Inspect bearing. Bearing interior should be smooth. A light contact pattern is normal. If severe wear or roughness is apparent, the part that bearing is housed in must be replaced. Bearing cannot be replaced. Gear plate pockets should be free from any large grooves around the inside diameter. A gear wipe pattern on this diameter on inlet side is normal and necessary for proper pump operation. Inspect all other parts.
END OF TASK
0109-7
TM 5-3810-305-23
0109
ASSEMBLY 1. Install new seal (Figure 9, Item 3), snapring (Figure 9, Item 2), new seal (Figure 9, Item 1), and plug (Figure 9, Item 5) on front flange plate (Figure 9, Item 4).
1 2 3
4
Figure 9. Ground Driven Steering Pump Assembly. 2.
M0444105
Install new o-ring (Figure 10, Item 3), back-up ring (Figure 10, Item 4), and new o-ring (Figure 10, Item 2) in front flange plate (Figure 10, Item 1).
0109-8
TM 5-3810-305-23
0109
2 1 3 4
M0443105
Figure 10. Ground Driven Steering Pump Assembly. 3. 4. 5. Install eight dowel pins (Figure 11, Item 3) in gear plate (Figure 11, Item 2). Align matchmarks and install gear plate (Figure 11, Item 2) on cover plate (Figure 11, Item 1). Align matchmarks and install thrust plate (Figure 11, Item 4).
1 2 4
M0442105
Figure 11. Ground Driven Steering Pump Assembly.
0109-9
TM 5-3810-305-23
0109
ASSEMBLY - Continued 6. Install drive gear (Figure 12, Item 3) and idler gear (Figure 12, Item 2) in gear plate (Figure 12, Item 1).
2 3
M0441105
Figure 12. Ground Driven Steering Pump Assembly. 7. Align matchmarks and install thrust plate (Figure 13, Item 1) in gear plate (Figure 13, Item 2).
M0440105
0109-10
TM 5-3810-305-23
0109
ASSEMBLY - Continued 8. Install new o-ring (Figure 14, Item 2), back-up ring (Figure 14, Item 3), and o-ring (Figure 14, Item 4) in rear flange plate (Figure 14, Item 1).
2
M0439105
0109-11
TM 5-3810-305-23
0109
ASSEMBLY - Continued 9. 10. 11. 12. Align matchmarks and install rear flange plate (Figure 15, Item 7) on gear plate (Figure 15, Item 1). Install four washers (Figure 15, Item 6) and capscrews (Figure 15, Item 5) on pump. Torque capscrews to 35 ft-lb (47 Nm). Install new o-ring (Figure 15, Item 3) and elbow (Figure 15, Item 4). Coat splines of pump (Figure 15, Item 2) with antiseize thread compound.
5,6 3
M0438105
Figure 15. Ground Driven Steering Pump Assembly. END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. Apply threadlock compound to pump mounting flange. Apply threadlock compound to two capscrews (Figure 16, Item 4). Position pump (Figure 16, Item 12) on transmission (Figure 16, Item 3) and install two new lockwashers (Figure 16, Item 5) and capscrews (Figure 16, Item 4). Install hose (Figure 16, Item 1) on elbow (Figure 16, Item 2). Install new o-ring (Figure 16, Item 11) on adapter (Figure 16, Item 10). Position adapter (Figure 16, Item 10) on pump (Figure 16, Item 12) and install four new lockwashers (Figure 16, Item 9) and capscrews (Figure 16, Item 8). Install hose (Figure 16, Item 6) on adapter (Figure 16, Item 10) and tighten clamp (Figure 16, Item 7).
0109-12
TM 5-3810-305-23
0109
1 12
11 10 8,9 4,5
7 6
M0437105
Figure 16. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill hydraulic reservoir (WP 0153). Connect battery cables (WP 0076). Install engine hood (WP 0120).
Ground Driven Steering Pump Installation.
0109-13/14 blank
TM 5-3810-305-23
0110
FIELD MAINTENANCE STEERING CONTROL UNIT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Fixture, Arbor Press (WP 0171, Table 1, Item 1) Materials/Parts Cap Set, Protective, Dust And Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Parts Kit, Steering (WP 0172, Table 1, Item 19) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 129) Qty: 4 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Lower dash panel removed (WP 0066) 1
WARNING
0110-1
TM 5-3810-305-23
0110
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all port. Remove all caps, plugs, and tags following maintenance. 1. 2. 3. 4. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Remove steering wheel cap (Figure 1, Item 1), nut (Figure 1, Item 2), and steering wheel (Figure 1, Item 3) from control unit (Figure 1, Item 7). Disconnect five hoses (Figure 1, Item 6) from control unit (Figure 1, Item 7). Remove four capscrews (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and control unit (Figure 1, Item 7) from under dash. Discard lockwashers.
1 2 3
7 6 5
4
M0406105
Figure 1. Steering Control Removal. END OF TASK DISASSEMBLY 1. 2. Remove dirt seal (Figure 2, Item 1) from control unit (Figure 2, Item 3). Discard dirt seal. Remove retaining ring (Figure 2, Item 2) from control unit (Figure 2, Item 3).
NOTE
Remove seal package using one of the two following methods. 3. If control unit (Figure 2, Item 3) has not been removed from vehicle and five hoses (Figure 2, Item 4) have not been disconnected, with engine running, rotate shaft of control unit in counterclockwise direction to pressurize control unit and force seal package (Figure 2, Item 5) out. Discard seal package.
0110-2
TM 5-3810-305-23
0110
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT directed compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. 4. If control unit (Figure 2, Item 3) has been removed from vehicle, plug three of four ports in control unit and attach air hose to remaining port. With air pressure, force seal package (Figure 2, Item 5) out. Discard seal package.
1 5
1 2
3 3 4
M0407105
Steering Control Disassembly.
0110-3
TM 5-3810-305-23
0110
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY
CAUTION
Keep new seal package free of particles of lint, felt, and dirt. Failure to follow this caution can cause new seal package to leak, damaging equipment.
NOTE
Clean input shaft of control unit and upper cover seal bore to remove particles of dirt, felt and lint with a clean, lint-free rag. 1. 2. 3. 4. 5. 6. 7. Cover control unit (Figure 3, Item 3) shaft with cellophane tape to protect new seal package (Figure 3, Item 5). Lubricate new seal package (Figure 3, Item 5) with hydraulic oil and install and control unit (Figure 3, Item 3) shaft lip side first. Remove cellophane tape. Install new seal package (Figure 3, Item 5) with small end first on control unit (Figure 3, Item 3) shaft. Using deep-well socket push new seal package (Figure 3, Item 5) washer down into upper cover of control unit (Figure 3, Item 3). Install retaining ring (Figure 3, Item 2) on control unit (Figure 3, Item 3) shaft and push down into upper groove in control unit cover. Install new dirt seal (Figure 3, Item 1) on control unit (Figure 3, Item 3) shaft and press down into control unit upper cover.
0110-4
TM 5-3810-305-23
0110
1 5
1 2
3 3 4
M0407105
Steering Control Assembly.
0110-5
TM 5-3810-305-23
0110
INSTALLATION 1. 2. 3. 4. 5. Position control unit (Figure 4, Item 7) under dash and align mounting holes. Install four new lockwashers (Figure 4, Item 4) and capscrews (Figure 4, Item 5). Connect five hoses (Figure 4, Item 6) on control unit (Figure 4, Item 7). Install steering wheel (Figure 4, Item 3), nut (Figure 4, Item 2), and cap (Figure 4, Item 1) on control unit (Figure 4, Item 7). Close dipstick cap.
1 2 3
7 6
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install lower dash panel (WP 0110).
4 5
Steering Control Installation.
M0406105
Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0110-6
TM 5-3810-305-23
0111
FIELD MAINTENANCE STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 19 O-Ring (WP 0172, Table 1, Item 49) Qty: 12 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 49) Qty: 8 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0111-1
TM 5-3810-305-23
0111
REMOVAL
WARNING
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove all caps, plugs and tags following maintenance. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect hose (Figure 1, Item 21) from steering valve and tee (Figure 1, Item 23). Disconnect hose (Figure 1, Item 20) from steering valve and elbow (Figure 1, Item 17). Remove five clamps (Figure 1, Item 8) and clamp (Figure 1, Item 4). Remove hose (Figure 1, Item 12) from elbow (Figure 1, Item 17) and tee (Figure 1, Item 24). Remove tiedown straps (Figure 1, Item 10) as required, six clamps (Figure 1, Item 8), and four clamps (Figure 1, Item 4). Discard tiedown straps. Remove hose (Figure 1, Item 25) from adapter (Figure 1, Item 19) and tee (Figure 1, Item 24). Remove tiedown straps (Figure 1, Item 10), four clamps (Figure 1, Item 4), and three clamps (Figure 1, Item 8). Discard tiedown straps. Remove hose (Figure 1, Item 11) from tee (Figure 1, Item 23) and adapter (Figure 1, Item 19). Remove two clamps (Figure 1, Item 8). Remove hose (Figure 1, Item 3) from elbow (Figure 1, Item 2) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 24) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove two clamps (Figure 1, Item 22). Remove hose (Figure 1, Item 25) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 24) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 25) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23).
0111-2
TM 5-3810-305-23
0111
REMOVAL - Continued
3 8 23 1 3 23 24 1 2 2 3
2
14 13 5 6 7 8 4 11 9 10 2 3 1 2 12 4 8 25 4
1
4 24 2
23 24
15 16 17 2 17 15 16 18
2
12 2 21 2
24 2 3 2 2 3 2
23
22 8 20
18
19
M0413105
Figure 1. Steering System Hydraulic Hoses Removal. END OF TASK
0111-3
TM 5-3810-305-23
0111
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Install hose (Figure 2, Item 1) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 25) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hoses (Figure 2, Item 24) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 1) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 1) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 25) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 24) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install two clamps (Figure 2, Item 22). Install hose (Figure 2, Item 3) on elbow (Figure 2, Item 2) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 11) on tee (Figure 2, Item 23) and adapter (Figure 2, Item 19). Install two clamps (Figure 2, Item 8). Install hose (Figure 2, Item 25) on tee (Figure 2, Item 24) and adapter (Figure 2, Item 19). Install three clamps (Figure 2, Item 8), four clamps (Figure 2, Item 4), and new tiedown straps (Figure 2, Item 10). Install hose (Figure 2, Item 12) on elbow (Figure 2, Item 17) and tee (Figure 2, Item 24). Install six clamps (Figure 2, Item 8), four clamps (Figure 2, Item 4), and new tiedown straps (Figure 2, Item 10) as required. Install hose (Figure 2, Item 20) on tee (Figure 2, Item 17) and steering valve. Install hose (Figure 2, Item 21) on tee (Figure 2, Item 23) and steering valve. Install clamp (Figure 2, Item 4) and five clamps (Figure 2, Item 8). Close dipstick cap.
0111-4
TM 5-3810-305-23
0111
3 8 23 1 3 23 24 1 2 2 3
2
14 13 5 6 7 8 4 11 9 10 2 3 1 2 12 4 8 25 4
1
4 24 2
23 24
15 16 17 2 17 15 16 18
2
12 2 21 2
24 2 3 2 2 3 2
23
22 8 20
18
19
M0413105
Figure 2. Steering System Hydraulic Hoses Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Check for leaks. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0111-5/6 blank
TM 5-3810-305-23
0112
FIELD MAINTENANCE STEERING CYLINDERS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealant Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0112-1
TM 5-3810-305-23
0112
REMOVAL
WARNING
NOTE
The following is a maintenance procedure for one steering cylinder assembly. The maintenance procedure for the remaining three steering cylinders is identical. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. 5. 6. Disconnect two hydraulic lines (Figure 1, Item 6) from elbows (Figure 1, Item 4). Remove two elbows (Figure 1, Item 4) and o-rings (Figure 1, Item 5) from steering cylinder assembly (Figure 1, Item 8). Discard o-rings. Remove two capscrews (Figure 1, Item 3) and washers (Figure 1, Item 2) from steering cylinder assembly (Figure 1, Item 8). Drive out two pins (Figure 1, Item 1) from steering cylinder assembly (Figure 1, Item 8). Remove four washers (Figure 1, Item 7) and steering cylinder (Figure 1, Item 8) from vehicle.
0112-2
TM 5-3810-305-23
0112
REMOVAL - Continued
6 4 1 2,3 4 5 5 1
2,3
8 7
Figure 1. Steering Cylinders Removal.
M0459105
0112-3
TM 5-3810-305-23
0112
INSTALLATION 1. 2. 3. 4. 5. 6. Install steering cylinder (Figure 2, Item 8) and four washers (Figure 2, Item 7) on vehicle. Install two pins (Figure 2, Item 1) on steering cylinder assembly (Figure 2, Item 8). Install two washers (Figure 2, Item 2) and capscrews (Figure 2, Item 3) on steering cylinder assembly (Figure 2, Item 8). Install two new o-rings (Figure 2, Item 5) and elbows (Figure 2, Item 4) on steering cylinder assembly (Figure 2, Item 8). Connect two hydraulic lines (Figure 2, Item 6) to elbows (Figure 2, Item 4). Close dipstick cap.
6 4 1 2,3 4 5 5 1
2,3
8 7
Figure 2. Steering Cylinders Installation.
M0459105
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0112-4
TM 5-3810-305-23
0113
FIELD MAINTENANCE STEERING SELECTOR VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 49) Qty: 4 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0113-1
TM 5-3810-305-23
0113
REMOVAL
WARNING
NOTE
Matchmark knob and vehicle body, noting position of arrow. 2. Remove setscrew (Figure 1, Item 1) and knob (Figure 1, Item 4) from vehicle.
NOTE
Matchmark cap and underside of vehicle. 3. Remove four capscrews (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from vehicle. Discard lockwashers.
0113-2
TM 5-3810-305-23
0113
REMOVAL - Continued
3
M0408105
Figure 1.
Steering Selector Valve Removal.
0113-3
TM 5-3810-305-23
0113
REMOVAL - Continued
WARNING
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. A container will be necessary to catch hydraulic oil remaining in hose and tube assemblies after disconnecting. 4. 5. 6. From underside of vehicle, disconnect hoses (Figure 2, Items 1, 3, 5, and 6) from steering selector valve (Figure 2, Item 8). Remove steering selector valve (Figure 2, Item 8) from vehicle. Remove two elbows (Figure 2, Item 7), adapters (Figure 2, Item 4), and four o-rings (Figure 2, Item 2) from steering selector valve (Figure 2, Item 8). Discard o-rings.
0113-4
TM 5-3810-305-23
0113
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Install four new o-rings (Figure 3, Item 2), two adapters (Figure 3, Item 4), and elbows (Figure 3, Item 7) on steering selector valve (Figure 3, Item 8). Install valve (Figure 3, Item 8) aligning matchmark on cap with matchmark on underside of vehicle. Connect hoses (Figure 3, Items 1, 3, 5, and 6) to elbows (Figure 3, Item 7) and adapters (Figure 3, Item 4).
7
Figure 2.
M0409105
Steering Selector Valve Installation.
0113-5
TM 5-3810-305-23
0113
INSTALLATION - Continued 4. From inside cab, install four new lockwashers (Figure 4, Item 3) and capscrews (Figure 4, Item 2) on vehicle.
NOTE
Align matchmark on knob with matchmark on vehicle body. 5. 6. Install knob (Figure 4, Item 4) and setscrew (Figure 4, Item 1) on vehicle. Close dipstick cap.
3
M0408105
Steering Selector Valve Installation.
0113-6
TM 5-3810-305-23
0113
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0113-7/8 blank
TM 5-3810-305-23
0114
FIELD MAINTENANCE FLOW DIVIDER AND STEERING VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 28) Qty: 1 O-Ring (WP 0172, Table 1, Item 120) Qty: 4 O-Ring (WP 0172, Table 1, Item 146) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 93) Qty: 2 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (TM 5-3810-305-10) Battery cables disconnected (WP 0076) 1
0114-1
TM 5-3810-305-23
0114
REMOVAL
WARNING
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect hoses (Figure 1, Item 7) from flow divider (Figure 1, Item 1) and steering valve (Figure 1, Item 12). Remove two nuts (Figure 1, Item 13), lockwashers (Figure 1, Item 14), and capscrews (Figure 1, Item 6) from steering valve (Figure 1, Item 12). Discard lockwashers. Remove flow divider (Figure 1, Item 1) and steering valve (Figure 1, Item 12) as a unit from its frame location. Remove flow divider (Figure 1, Item 1) from adapter (Figure 1, Item 4). Remove adapter (Figure 1, Item 4) and two o-rings (Figure 1, Item 5) from steering valve (Figure 1, Item 12). Discard o-rings. Remove two elbows (Figure 1, Item 10) and o-rings (Figure 1, Item 11) from steering valve (Figure 1, Item 12). Discard o-rings. Remove adapter (Figure 1, Item 8) and o-ring (Figure 1, Item 9) from steering valve (Figure 1, Item 12). Discard o-ring. Remove elbow (Figure 1, Item 2), o-ring (Figure 1, Item 3), adapter (Figure 1, Item 8), and o-ring (Figure 1, Item 15) from flow divider (Figure 1, Item 1). Discard o-rings.
0114-2
TM 5-3810-305-23
0114
REMOVAL - Continued
8,15
2,3
4 5 14 6 13
10,11
12
10,11
8,9
M0324105
Figure 1. Flow Divider and Steering Valve Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0114-3
TM 5-3810-305-23
0114
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install new o-ring (Figure 2, Item 15) and adapter (Figure 2, Item 8) on flow divider (Figure 2, Item 1). Install new o-ring (Figure 2, Item 3) and elbow (Figure 2, Item 2) on flow divider (Figure 2, Item 1). Install adapter (Figure 2, Item 8) and new o-ring (Figure 2, Item 9) on flow divider (Figure 2, Item 1). Install two elbows (Figure 2, Item 10) and new o-rings (Figure 2, Item 11) on flow divider (Figure 2, Item 1). Install two new o-rings (Figure 2, Item 5) and adapter (Figure 2, Item 4). Install flow divider (Figure 2, Item 1) onto steering valve (Figure 2, Item 12). Install flow divider (Figure 2, Item 1) and steering valve (Figure 2, Item 12) as a unit in the frame. Install two capscrews (Figure 2, Item 6), new lockwashers (Figure 2, Item 14), and nuts (Figure 2, Item 13) on steering valve (Figure 2, Item 12). Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Close dipstick cap.
8,15
2,3
4 5 14 6 13
10,11
12
10,11
8,9
M0324105
Figure 2. Flow Divider and Steering Valve Installation. END OF TASK
0114-4
TM 5-3810-305-23
0114
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install deck plate (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0114-5/6 blank
TM 5-3810-305-23
0115
FIELD MAINTENANCE HOOK BLOCK TIEBACK MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Shop Equipment, Welding (WP 0171, Table 1, Item 9) Grinder (WP 0171, Table 1, Item 45) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (91W) (91L) Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Wear protective eye covering. Serious injury to personnel may result from flying metal fragments. Wear protective gloves when handling hot parts. Failure to follow these warnings may result in injury or death to personnel.
0115-1
TM 5-3810-305-23
0115
REMOVAL 1. 2. 3. Burn off hook block tieback approximately 0.25 inch (6.4 mm) from surface of mounting plate. Grind mounting plate smooth. Ensure all carbon residue from air arc has been removed by grinding.
M0593105
Figure 1. Hook Block Tieback Removal. END OF TASK
0115-2
TM 5-3810-305-23
0115
INSTALLATION
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Wear protective eye covering. Serious injury to personnel may result from flying metal fragments. Wear protective gloves when handling hot parts. Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Position hook block tieback on mounting plate as shown. Tack weld in place. Weld in place with 0.25 inch (6.4 mm) fillet weld and groove weld as shown. Use the following American Welding Society procedures: SMAW (Shielded Metal Arc Welding) - Use AWS E7018 or El 1018 electrode. GMAW (Gas Metal Arc Welding) - Use AWS E70T-1 Flux Core electrode or E70S-3, E70S-6 Type Solid electrode. FCAW (Flux Core Arc Welding) - Use AWS E70T-1 Flux Core electrode or E70S-3, E70S-6 Type Solid electrode.
M0593105
Hook Block Tieback Installation.
0115-3
TM 5-3810-305-23
0115
FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
0115-4
TM 5-3810-305-23
0116
FIELD MAINTENANCE PINTLE HOOK MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter 1/4 X 3 (WP 0172, Table 1, Item 160) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Equipment Condition (cont.) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Grille guard removed (WP 0118) Battery cables disconnected (WP 0076)
0116-1
TM 5-3810-305-23
0116
REMOVAL 1. 2. 3. Remove cotter pin (Figure 1, Item 1) from nut (Figure 1, Item 2). Discard cotter pin. Remove nut (Figure 1, Item 2) and bushing (Figure 1, Item 3) from pintle hook (Figure 1, Item 5). Remove pintle hook (Figure 1, Item 5) from vehicle.
END OF TASK DISASSEMBLY Remove three grease fittings (Figure 1, Item 4) from pintle hook (Figure 1, Item 5). END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY Install three grease fittings (Figure 1, Item 4) onto pintle hook (Figure 1, Item 5). END OF TASK INSTALLATION 1. 2. 3. Install pintle hook (Figure 1, Item 5) onto vehicle. Install bushing (Figure 1, Item 3) and nut (Figure 1, Item 2) onto pintle hook (Figure 1, Item 5). Install new cotter pin (Figure 1, Item 1) onto nut (Figure 1, Item 2).
0116-2
TM 5-3810-305-23
0116
2 3 1
4 5
M0594105
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install grille guard (WP 0118).
Pintle Hook Maintenance.
0116-3/4 blank
TM 5-3810-305-23
0117
FIELD MAINTENANCE CAB DOOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Locknut Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 11) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock 3/8 Inch (WP 0172, Table 1, Item 12) Qty: 4 Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 1 Materials/Parts (cont.) Washer, Lock M8 (WP 0172, Table 1, Item 126) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0117-1
TM 5-3810-305-23
0117
REMOVAL 1. Open door (Figure 1, Item 3) and lift door off of pins on hinges (Figure 1, Item 4).
NOTE
Top and bottom hinges are removed using the same procedure outlined in Step 2. 2. Remove two nuts (Figure 1, Item 7), washers (Figure 1, Item 6), lockwashers (Figure 1, Item 2), capscrews (Figure 1, Item 1), hinges (Figure 1, Item 4), and spacer plate (Figure 1, Item 5) from doorway. Discard lockwashers.
1 7 7 2 6 5 4 1 4 6
4
Figure 1. Cab Door Removal.
M0574105
0117-2
TM 5-3810-305-23
0117
REMOVAL - Continued 3. 4. Drive out roll pin (Figure 2, Item 3) from inside handle (Figure 2, Item 5). Remove inside handle (Figure 2, Item 5), four screws (Figure 2, Item 2), inside latch (Figure 2, Item 1), and spacer plate (Figure 2, Item 6) from door (Figure 2, Item 4).
3 2 1 4
6 5
Figure 2. 5. Cab Door Removal.
M0575105
Remove two screws (Figure 3, Item 1) and outside handle (Figure 3, Item 3) from door (Figure 3, Item 2).
3
M0576105
Figure 3.
Cab Door Removal.
0117-3
TM 5-3810-305-23
0117
REMOVAL - Continued 6. Remove two capscrews (Figure 4, Item 5), lockwashers (Figure 4, Item 4), washers (Figure 4, Item 3), striker (Figure 4, Item 2), and spacer plate (Figure 4, Item 1) from cab. Discard lockwashers.
1 2
5
Figure 4. Cab Door Removal.
M0577105
NOTE
It may be necessary to cut or peel back insulation on door to gain access to nut securing door latch. 7. Remove four nuts (Figure 5, Item 2), four lockwashers (Figure 5, Item 3) screws (Figure 5, Item 4), and door latch (Figure 5, Item 5) from door (Figure 5, Item 1).
2,3 1 4
M0578105
Figure 5.
Cab Door Removal.
0117-4
TM 5-3810-305-23
0117
REMOVAL - Continued 8. 9. 10. Remove four nuts (Figure 6, Item 8), washers (Figure 6, Item 7), screws (Figure 6, Item 6), and door latch plate (Figure 6, Item 5) from bracket (Figure 6, Item 2). Remove nut (Figure 6, Item 3) and bumper (Figure 6, Item 4) from bracket (Figure 6, Item 2). Remove two locknuts (Figure 6, Item 11), washers (Figure 6, Item 10), bolts (Figure 6, Item 9), plate (Figure 6, Item 1), and bracket (Figure 6, Item 2) from cab. Discard locknuts.
1 11 10
2 3
9 8 7
4
M0579105
Cab Door Removal.
0117-5
TM 5-3810-305-23
0117
INSTALLATION 1. 2. 3. Install bracket (Figure 7, Item 2), plate (Figure 7, Item 1), two bolts (Figure 7, Item 9), washers (Figure 7, Item 10), and locknuts (Figure 7, Item 11) on cab. Install bumper (Figure 7, Item 4) and nut (Figure 7, Item 3) on bracket (Figure 7, Item 2). Install door latch plate (Figure 7, Item 5), four screws (Figure 7, Item 6), washers (Figure 7, Item 7), and nuts (Figure 7, Item 8) on bracket (Figure 7, Item 2).
1 11 10
2 3
9 8 7
Figure 7. 4.
4
M0579105
Cab Door Installation.
Install door latch (Figure 8, Item 5), four screws (Figure 8, Item 4), lockwashers (Figure 8, Item 3), and nuts (Figure 8, Item 2) on door (Figure 8, Item 1).
2,3 1 4
M0578105
Figure 8.
0117-6
TM 5-3810-305-23
0117
INSTALLATION - Continued 5. Install spacer plate (Figure 9, Item 1), striker (Figure 9, Item 2), two washers (Figure 9, Item 3), new lockwashers (Figure 9, Item 4), and capscrews (Figure 9, Item 5) on cab.
1 2
5
Figure 9. 6. Cab Door Installation.
M0577105
Install outside handle (Figure 10, Item 3) and two screws (Figure 10, Item 1) on door (Figure 10, Item 2).
3
M0576105
Figure 10.
0117-7
TM 5-3810-305-23
0117
INSTALLATION - Continued 7. 8. Install spacer plate (Figure 11, Item 6), inside latch (Figure 11, Item 1), four screws (Figure 11, Item 2), and inside handle (Figure 11, Item 5) on door (Figure 11, Item 4). Install roll pin (Figure 11, Item 3) to secure inside handle (Figure 11, Item 5).
3 2 1 4
6 5
Figure 11. Cab Door Installation. 9. 10. Install spacer plate (Figure 12, Item 5), hinges (Figure 12, Item 4), two capscrews (Figure 11, Item 1), new lockwashers (Figure 11, Item 2), washers (Figure 11, Item 6), and nuts (Figure 11, Item 7) on doorway. Lift door (Figure 12, Item 3) over pins on hinges (Figure 12, Item 4) and align hinges. Lower door (Figure 11, Item 1) onto hinge pins.
M0575105
0117-8
TM 5-3810-305-23
0117
1 7 7 2 6 5 4 1 4 6
4
Figure 12. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE Cab Door Installation.
M0574105
0117-9/10 blank
TM 5-3810-305-23
0118
FIELD MAINTENANCE ENGINE HOOD AND GRILLE GUARD MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 2 Nut, Self-Locking (WP 0172, Table 1, Item 137) Qty: 4 Nut, Self-Locking (WP 0172, Table 1, Item 140) Qty: 2 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock M16 (WP 0172, Table 1, Item 130) Qty: 2 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0118-1
TM 5-3810-305-23
0118
REMOVAL Grille Guard 1. Remove two locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), washers (Figure 1, Item 3), bosses (Figure 1, Item 4), washers (Figure 1, Item 11), and capscrews (Figure 1, Item 10) from grille guard (Figure 1, Item 9). Remove two locknuts (Figure 1, Item 8), washers (Figure 1, Item 7), grille guard (Figure 1, Item 9), and two bosses (Figure 1, Item 6) from engine hood (Figure 1, Item 5).
2.
4 5 1,2,3
11
6 10 9 8
Figure 1. Grille Guard Removal.
7
M0582105
0118-2
TM 5-3810-305-23
0118
REMOVAL - Continued
Engine Hood 1. 2. 3. 4. 5. 6. Disconnect engine hood (Figure 2, Item 2) by unlatching lower latches (Figure 2, Item 6). Pull engine hood (Figure 2, Item 2) approximately half way out. Push inward on side of engine hood (Figure 2, Item 2) just above cam follower (Figure 2, Item 4) and lift engine hood to position cam follower on top of guide rail (Figure 2, Item 5). Repeat for other cam follower (Figure 2, Item 4) and lift engine hood (Figure 2, Item 2) up and off frame. Remove four capscrews (Figure 2, Item 3) and two lower latches (Figure 2, Item 6) from guide rail (Figure 2, Item 5). Remove four screws (Figure 2, Item 1) and two blocks (Figure 2, Item 7) from vehicle.
4 1 3
6
M0583105
Engine Hood Removal.
0118-3
TM 5-3810-305-23
0118
DISASSEMBLY 1. 2. 3. 4. Remove four locknuts (Figure 3, Item 6), washers (Figure 3, Item 5), capscrews (Figure 3, Item 4), and two upper latches (Figure 3, Item 3) from engine hood (Figure 3, Item 1). Discard locknuts. Remove two cam followers (Figure 3, Item 7) and lockwashers (Figure 3, Item 8) from engine hood (Figure 3, Item 1). Discard lockwashers. Remove two grease fittings (Figure 3, Item 9) from engine hood (Figure 3, Item 1). Remove reflective tape (Figure 3, Item 2) and two reflective tapes (Figure 3, Item 10) from engine hood(Figure 3, Item 1).
1 2
3 4 10
9 8 7 6 5
M0584105
Figure 3. Engine Hood Disassembly. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0118-4
TM 5-3810-305-23
0118
ASSEMBLY 1. 2. 3. 4. Install two reflective tapes (Figure 4, Item 10) and reflective tape (Figure 4, Item 2) on engine hood (Figure 4, Item 1). Install two grease fittings (Figure 4, Item 9) on engine hood (Figure 4, Item 1). Install two new lockwashers (Figure 4, Item 8) and cam followers (Figure 4, Item 7) on engine hood (Figure 4, Item 1). Install two upper latches (Figure 4, Item 3), four capscrews (Figure 4, Item 4), washers (Figure 4, Item 5), and new locknuts (Figure 4, Item 6) on engine hood (Figure 4, Item 1).
1 2
3 4 10
9 8 7
M0584105
Engine Hood Assembly.
0118-5
TM 5-3810-305-23
0118
INSTALLATION Engine Hood 1. 2. 3. 4. 5. Install two blocks (Figure 5, Item 7) and four screws (Figure 5, Item 1) on vehicle. Install two lower latches (Figure 5, Item 6) and four capscrews (Figure 5, Item 3) on guide rail (Figure 5, Item 5). Position engine hood (Figure 5, Item 2) onto top of guide rails (Figure 5, Item 5) past hood on radiator. Push inward on side of engine hood (Figure 5, Item 2) just above cam follower (Figure 5, Item 4) and position cam follower under guide rails (Figure 5, Item 5). Push engine hood (Figure 5, Item 2) back and latch in place with lower latches (Figure 5, Item 6).
4 1 3
6
M0583105
Figure 5.
Engine Hood Installation.
0118-6
TM 5-3810-305-23
0118
Grille Guard 1. 2. 3. 4. Install two bosses (Figure 6, Item 6) and grille guards (Figure 6, Item 9) on engine hood (Figure 6, Item 5). Install two washers (Figure 6, Item 7) and new locknuts (Figure 6, Item 8). Install two capscrews (Figure 6, Item 10), washers (Figure 6, Item 11), grille guard (Figure 6, Item 9), and two bosses (Figure 6, Item 6). Install two washers (Figure 6, Item 3), washers (Figure 6, Item 2), and new locknuts (Figure 6, Item 1).
4 5 1,2,3
11
6 10 9 8
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Grille Guard Installation.
7
M0582105
0118-7/8 blank
TM 5-3810-305-23
0119
FIELD MAINTENANCE CAB ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Adhesive (WP 0170, Table 1, Item 1) Qty: 1 Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 18 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Silicone (WP 0170, Table 1, Item 62) Qty: 1 Seal, Non-Metallic (WP 0172, Table 1, Item 106) Qty: 2 Seal, Non-Metallic (WP 0172, Table 1, Item 107) Qty: 1 Seal, Non-Metallic (WP 0172, Table 1, Item 108) Qty: 2 Materials/Parts (cont.) Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 4 Weather Stripping (WP 0172, Table 1, Item 169) Qty: 1 Personnel Required (Two) References WP 0066 WP 0079 WP 0148 WP 0162 Equipment Condition Vehicle parked on level ground Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Cab door removed (WP 0117) Windshield wiper removed (WP 0131) Mirrors removed (WP 0130) Defroster fan removed (WP 0055) Seat removed (WP 0124) Seat belt removed (WP 0124)
0119-1
TM 5-3810-305-23
0119
REMOVAL 1. 2. Remove two nuts (Figure 1, Item 1), capscrews (Figure 1, Item 8), and clamps (Figure 1, Item 7) releasing defroster fan harness (Figure 1, Item 6) from cab (Figure 1, Item 2). Remove 18 locknuts (Figure 1, Item 3) and washers (Figure 1, Item 4) from cab (Figure 1, Item 2). Discard locknuts.
WARNING
Weight of cab is approximately 250 lb (113 kg). Use adequate lifting equipment to lift and support cab. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. 5. Attach hoist with sling through door and window openings in cab (Figure 1, Item 2). Using hoist and sling, lift cab (Figure 1, Item 2) off of frame. Remove seals (Figure 1, Item 5). Discard seals.
8 7 7 4 8 7 6 5
M0587105
Figure 1. Cab Assembly Removal.
0119-2
TM 5-3810-305-23
0119
REMOVAL - Continued 6. Remove fire extinguisher (Figure 2, Item 3), four capscrews (Figure 2, Item 5), lockwashers (Figure 2, Item 4), and bracket (Figure 2, Item 1) from cab (Figure 2, Item 2). Discard lockwashers.
4 3
M0588105
Figure 2.
Fire Extinguisher Removal.
0119-3
TM 5-3810-305-23
0119
REMOVAL - Continued
NOTE
Floormats are held in place with adhesive and should not be removed unless inspection indicates replacement is necessary. 7. 8. 9. Inspect floormats (WP 0162). If necessary, remove two wingnuts (Figure 3, Item 4), washers (Figure 3, Item 3), and floormat (Figure 3, Item 5) from cab (Figure 3, Item 1). Remove all adhesive from cab floor. Remove floormats (Figure 3, Items 2 and 6), if replacement is necessary from cab floor.
1 2
3 6
M0589105
Figure 3.
Floormats Removal.
NOTE
Insulation pads are held in place with adhesive and should not be removed unless inspection indicates replacement is necessary. 10. 11. 12. 13. Inspect insulation pads (WP 0162). If left front or right side insulation pad replacement is necessary, remove cab main harness (WP 0079). If lower right insulation pad replacement is necessary, remove panel (WP 0066). If necessary, remove eight insulation pads. Remove all adhesive from cab wall.
END OF TASK
0119-4
TM 5-3810-305-23
0119
DISASSEMBLY
NOTE
DO NOT remove glass panels or weather strips unless inspection indicates replacement is necessary. 1. 2. 3. Inspect glass panels and weather strip (WP 0162). Remove glass panels (Figure 4, Items 1, 4, and 5) from cab (Figure 4, Item 3). Remove weather strips (Figure 4, Item 2). Discard weather strips.
1 2 3
2 4 5
2 4 2 5 2
M0590105
Cab Assembly Disassembly.
0119-5
TM 5-3810-305-23
0119
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. Apply a bead of silicone sealant in both cab (Figure 5, Item 3) and glass channels of weather strips (Figure 5, Item 2). Install glass panels (Figure 5, Item 5).
WARNING
ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 3. Apply a bead of silicone sealant in window frame channel of weather strips (Figure 5, Item 2) for glass panels (Figure 5, Item 1).
0119-6
TM 5-3810-305-23
0119
ASSEMBLY - Continued 4. 5. 6. Install glass panels (Figure 5, Item 1). Install new weather strips (Figure 5, Item 2). Install remaining glass panels (Figure 5, Item 4) in weather strips (Figure 5, Item 2). Seal joints with silicone sealant, as required.
1 2 3
2 4 5
2 4 2 5 2
M0590105
Cab Assembly Assembly.
0119-7
TM 5-3810-305-23
0119
INSTALLATION
WARNING
ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 1. 2. 3. 4. If removed, apply adhesive to cab walls and install eight insulation pads. If removed, install right console panel (WP 0066). If removed, install cab main harness (WP 0079). If removed, install floormats (Figure 6, Items 1 and 5). Apply adhesive to mating surfaces and install floormat (Figure 6, Item 4), two washers (Figure 6, Item 2), and wingnuts (Figure 6, Item 3) to cab floor.
1 2
3 6
M0589105
Figure 6. Floormats Installation.
0119-8
TM 5-3810-305-23
0119
INSTALLATION - Continued 5. Install bracket (Figure 7, Item 1), four new lockwashers (Figure 7, Item 3), capscrews (Figure 7, Item 4), and fire extinguisher (Figure 7, Item 2).
4 3
M0588105
Figure 7.
Fire Extinguisher Installation.
0119-9
TM 5-3810-305-23
0119
INSTALLATION - Continued 6. If removed, install new seals (Figure 8, Item 5). Seal ends of seals together with silicone sealant.
WARNING
Weight of cab is approximately 250 lb (113 kg). Use adequate lifting equipment to lift and support cab. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. 9. Using a hoist with sling through door and window openings, position cab (Figure 8, Item 2) mounting holes over studs in frame and install cab to vehicle. Secure defroster fan harness (Figure 8, Item 6) to cab (Figure 8, Item 2) with two clamps (Figure 8, Item 7), capscrews (Figure 8, Item 8), and nuts (Figure 8, Item 1). Install 18 washers (Figure 8, Item 4) and new locknuts (Figure 8, Item 3) to cab (Figure 8, Item 2).
8 7 7 4 8 7 6 5
M0587105
Figure 8. Cab Assembly Installation. END OF TASK
0119-10
TM 5-3810-305-23
0119
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install seat (WP 0124). Install seat belts (WP 0124). Install defroster fan (WP 0055). Install mirrors (WP 0130). Install windshield wiper (WP 0131). Install cab door (WP 0117). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0119-11/12 blank
TM 5-3810-305-23
0120
FIELD MAINTENANCE HOOD SUPPORT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 6 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock M4 (WP 0172, Table 1, Item 168) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Vehicle parked on level ground (TM 5-3810-305-10)
0120-1
TM 5-3810-305-23
0120
REMOVAL 1. 2. 3. 4. 5. Start engine. Rotate boom to right side of carrier. Shut engine OFF. Remove nut (Figure 1, Item 13), capscrew (Figure 1, Item 4), plate (Figure 1, Item 1), spacer (Figure 1, Item 3), and two clamps (Figure 1, Item 2) from hoses (Figure 1, Items 11 and 12). Remove two nuts (Figure 1, Item 6) and U-bolt (Figure 1, Item 7) from hood support. Loosen nut (Figure 1, Item 10) on T-bolt clamp (Figure 1, Item 9). Remove T-bolt clamp, 90 degree elbow (Figure 1, Item 8), and stack cap (Figure 1, Item 5) as an assembly from vehicle. Disconnect restriction indicator hose (Figure 1, Item 15) from restriction indicator (Figure 1, Item 14).
1 12 13
2 3 4 5
6 11 14 15 7
8 10
M0581105
Figure 1.
Hood Support Removal.
0120-2
TM 5-3810-305-23
0120
REMOVAL - Continued 6. Remove six locknuts (Figure 2, Item 2), washers (Figure 2, Item 3), and hood support (Figure 2, Item 1) from frame. Discard locknuts.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install hood support (Figure 2, Item 1), six washers (Figure 2, Item 3), and locknuts (Figure 2, Item 2) on frame.
1 2 3 2 3
M2312105
Figure 2.
Hood Support Installation.
0120-3
TM 5-3810-305-23
0120
INSTALLATION - Continued 2. 3. 4. 5. Connect restriction indicator hose (Figure 3, Item 15) to restriction indicator (Figure 3, Item 14). Install stack cap (Figure 3, Item 5), 90 degree elbow (Figure 3, Item 8), and T-bolt clamp (Figure 3, Item 9) as an assembly and tighten nut (Figure 3, Item 10) on T-bolt clamp. Install U-bolt (Figure 3, Item 7) and two new locknuts (Figure 3, Item 6) on hood support. Install two clamps (Figure 3, Item 2), spacer (Figure 3, Item 3), plate (Figure 3, Item 1), capscrew (Figure 3, Item 4), and nut (Figure 3, Item 13) on hoses (Figure 3, Items 11 and 12).
1 12 13
2 3 4 5
6 11 14 15 7
8 10
M0581105
Hood Support Installation.
0120-4
TM 5-3810-305-23
0120
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Start engine (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Shut down engine (TM 5-3810-305-10).
0120-5/6 blank
TM 5-3810-305-23
0121
FIELD MAINTENANCE FENDERS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device 150-lb (69 kgs) Minimum Capacity Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 131) Qty: 24 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0121-1
TM 5-3810-305-23
0121
REMOVAL
NOTE
The following is a maintenance procedure for one fender. The maintenance procedure for the remaining fenders is identical. 1. Remove six locknuts (Figure 1, Items 2 and 5) and washers (Figure 1, Items 3 and 4) from studs on frame. Discard locknuts.
WARNING
Weight of fender is approximately 99 lb (45 kg). Use adequate lifting equipment to support fender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. Remove fender (Figure 1, Item 1) from frame.
0121-2
TM 5-3810-305-23
0121
INSTALLATION
WARNING
Weight of fender is approximately 99 lb (45 kg). Use adequate lifting equipment to support fender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. Install fender (Figure 1, Item 1) on frame. Install six washers (Figure 1, Items 3 and 4) and new locknuts (Figure 1, Items 2 and 5) to studs on frame.
1 2 3
5
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE Return upper structure and boom rotated to resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE Fender Maintenance.
M0641105
0121-3/4 blank
TM 5-3810-305-23
0122
FIELD MAINTENANCE DECK PLATES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0122-1
TM 5-3810-305-23
0122
REMOVAL
WARNING
Weight of brake drum is approximately 81 lb (37 kg). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel. 1. 2. 3. Remove five capscrews (Figure 1, Item 6), washers (Figure 1, Item 5), deck plate (Figure 1, Item 4), and five clips (Figure 1, Item 7) from vehicle. Remove three locknuts (Figure 1, Item 8), four washers (Figure 1, Item 3), and capscrew (Figure 1, Item 2) from pinion cover (Figure 1, Item 1). Discard locknuts. Remove pinion cover (Figure 1, Item 1) from vehicle.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Position pinion cover (Figure 1, Item 1) on vehicle. Install four washer (Figure 1, Item 3), capscrew (Figure 1, Item 2), and three new locknuts (Figure 1, Item 8) on pinion cover (Figure 1, Item 1). Install five clips (Figure 1, Item 7), deck plate (Figure 1, Item 4), five washers (Figure 1, Item 5), and capscrews (Figure 1, Item 6) on vehicle.
0122-2
TM 5-3810-305-23
0122
VIEWED FROM TOP 1 2 2
3 3 5 3 8
4 6 5
8 7
6 7
M0642105
Deck Plates Maintenance.
0122-3/4 blank
TM 5-3810-305-23
0123
FIELD MAINTENANCE OUTRIGGER ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper, Micrometer, Outside (WP 0171, Table 1, Item 21) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Fixture, Arbor Press (WP 0171, Table 1, Item 1) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Bearing Sleeve (WP 0172, Table 1, Item 109) Qty: 16 Nitrogen, Liquid, Industrial Grade (WP 0170, Table 1, Item 49) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Materials/Parts (cont.) Washer, Lock M16 (WP 0172, Table 1, Item 130) Qty: 8 Washer, Lock M25 (WP 0172, Table 1, Item 7) Qty: 4 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0123-1
TM 5-3810-305-23
0123
REMOVAL 1. Fully extend and lower all outriggers without putting any pressure on outrigger pads (TM 5-3810-305-10).
WARNING
Weight of beam is approximately 129 lb (59 kg). Use adequate lifting equipment to lift and support beam. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
NOTE
The following is a maintenance procedure for one outrigger assembly. The maintenance procedure for the remaining outrigger assemblies is identical. 2. 3. 4. 5. 6. 7. Support cylinder and beam (Figure 1, Item 1) with suitable lifting device. Remove pin (Figure 1, Item 3) from pin (Figure 1, Item 2). Remove pin (Figure 1, Item 2) from beam (Figure 1, Item 1). Remove capscrew (Figure 1, Item 7), lockwasher (Figure 1, Item 6), and rod end (Figure 1, Item 9). Discard lockwasher. Remove pin (Figure 1, Item 8) from beam (Figure 1, Item 1). Remove beam (Figure 1, Item 1) from frame.
0123-2
TM 5-3810-305-23
0123
REMOVAL - Continued
3 2 1 14 13
4 5 8 6 10 5 3 2 5 10 13 1 14
M0585105
9 8 10 12 11 12 11
Figure 1. END OF TASK DISASSEMBLY 1. 2. 3.
Outrigger Assembly Removal.
Remove nut (Figure 1, Item 14), washer (Figure 1, Item 13), bolt (Figure 1, Item 12), and pad (Figure 1, Item 11) from beam (Figure 1, Item 1). Remove two grease fittings (Figure 1, Item 4) and two grease fittings (Figure 1, Item 5) from beam (Figure 1, Item 1). Using a press, remove four bushings (Figure 1, Item 10) from beam (Figure 1, Item 1).
0123-3
TM 5-3810-305-23
0123
INSPECTION 1. 2. 3. 4. 5. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect beam bushings. Maximum I.D. is 2.03 inch (51.64 mm). If I.D. is greater than limit, replace bushings. Inspect outrigger beam pins. Minimum O.D. is 1.964 inch (49.89 mm). If O.D. is less than limit, replace pins. Inspect pad pivot bolt. Minimum O.D. is 1.230 inch (31.24 mm). If O.D. is less than limit, replace bolt. Inspect pivot bolt bushing. Maximum I.D. is 1.275 inch (32.39 mm). If I.D. is greater than limit, replace outrigger beam.
END OF TASK ASSEMBLY
WARNING
NOTE
Cool bushings to -320F (-195C) submerging bushings in liquid nitrogen. 1. 2. 3. Submerge four bushings (Figure 3, Item 10), in liquid nitrogen to cool them. Apply threadlock sealant to outrigger bushing beam bore. Using a press, install four chilled bushings (Figure 3, Item 10) in beam (Figure 3, Item 1). Stake beam as indicated in Figure 2.
PUNCH 3 PLACES AROUND BUSHINGS BUSHING OUTRIGGER
OUTSIDE ONLY BOTH SIDES OF BEAM

Figure 2. Outrigger Assembly Assembly.
M0586105
0123-4
TM 5-3810-305-23
0123
ASSEMBLY - Continued 4. 5. Install two grease fittings (Figure 3, Item 5) and two grease fittings (Figure 3, Item 4) in beam (Figure 3, Item 1). Install pad (Figure 3, Item 11), bolt (Figure 3, Item 12), washer (Figure 3, Item 13), and nut (Figure 3, Item 14) in beam (Figure 3, Item 1).
3 2 1 14 13
4 5 8 6 10 5 3 2 5 10 13 1 14
M0585105
9 8 10 12 11 12 11
Outrigger Assembly Assembly.
0123-5
TM 5-3810-305-23
0123
INSTALLATION
WARNING
Weight of beam is approximately 129 lb (59 kg). Use adequate lifting equipment to lift and support beam. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. 4. 5. Install beam (Figure 4, Item 1) in frame, aligning holes in beam with holes in frame. Support with lifting device. Install pin (Figure 4, Item 8) into beam (Figure 4, Item 1). Install rod end (Figure 4, Item 9), new lockwasher (Figure 4, Item 6), and capscrew (Figure 4, Item 7). Install pin (Figure 4, Item 2) into beam (Figure 4, Item 1) and cylinder rod eye. Install new pin flush with rod end on cylinder. Remove lifting device supporting beam (Figure 4, Item 1) and cylinder.
3 2 1 14 13
4 5 8 6 10 5 3 2 5 10 13 1 14
M0585105
9 8 10 12 11 12 11
Figure 4. Outrigger Assembly Installation. END OF TASK
0123-6
TM 5-3810-305-23
0123
FOLLOW-ON MAINTENANCE 1. 2. 3. Raise all outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0123-7/8 blank
TM 5-3810-305-23
0124
FIELD MAINTENANCE SEAT AND SEAT BELT MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 4 Nut, Self-Locking, He M12 (WP 0172, Table 1, Item 133) Qty: 2 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0124-1
TM 5-3810-305-23
0124
REMOVAL Seat Belt 1. 2. Tilt seat (Figure 1, Item 2). Remove two locknuts (Figure 1, Item 3), washers (Figure 1, Item 6), and capscrews (Figure 1, Item 5) from seat belt halves (Figure 1, Items 1 and 4). Discard locknuts.. Remove two seat belt halves (Figure 1, Items 1 and 4) from seat bracket (Figure 1, Item 7).
3 4 7
5 6
Figure 1. Seat Belt Removal.
M0638105
0124-2
TM 5-3810-305-23
0124
REMOVAL - Continued
Seat 1. 2. 3. 4. Tilt seat (Figure 2, Item 1), remove capscrews (Figure 2, Item 6) and washers (Figure 2, Item 3) from slide assembly (Figure 2, Item 2). Remove seat (Figure 2, Item 1) from vehicle. Remove four locknuts (Figure 2, Item 4) and washers (Figure 2, Item 3) from under cab. Remove four capscrews (Figure 2, Item 5) from inside cab on slide assembly. Discard locknuts. Remove slide assembly (Figure 2, Item 2) from inside of cab.
3 6 5 3 4
M0639105
Seat Removal.
0124-3
TM 5-3810-305-23
0124
INSTALLATION Seat 1. 2. 3. 4. Install slide assembly (Figure 3, Item 2) inside of cab with four capscrews (Figure 3, Item 5). Install four washers (Figure 3, Item 3) and new locknuts (Figure 3, Item 4) under cab. Install seat (Figure 3, Item 1) in vehicle. Tilt seat (Figure 3, Item 1), and install on slide assembly (Figure 2, Item 2) with four capscrews (Figure 3, Item 6) and washers (Figure 3, Item 3).
3 6 5 3 4
M0639105
Figure 3.
Seat Installation.
0124-4
TM 5-3810-305-23
0124
Seat Belt 1. 2. 3. Position two seat belt halves (Figure 4, Items 1 and 4) into slide assembly (Figure 4, Item 7). Install two locknuts (Figure 4, Item 3), washers (Figure 4, Item 6), capscrews (Figure 4, Item 5), into seat belt halves (Figure 4, Items 1 and 4). Tilt seat (Figure 4, Item 2) into upright position.
3 4 7
5 6
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Seat Belt Installation.
M0638105
0124-5/6 blank
TM 5-3810-305-23
0125
FIELD MAINTENANCE WINCH ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking, He M16 (WP 0172, Table 1, Item 6) Qty: 4 Parts Kit, Seal Repl (WP 0172, Table 1, Item 105) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 9) Qty: 12 Washer, Lock 3/8 Reg (WP 0172, Table 1, Item 41) Qty: 6 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Drum cable removed (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
0125-1
TM 5-3810-305-23
0125
REMOVAL 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. Disconnect two hydraulic hoses (Figure 1, Item 5) from two elbows (Figure 1, Item 6). Remove two elbows (Figure 1, Item 6) from brake valve assembly (Figure 1, Item 7). Remove four locknuts (Figure 1, Item 3), washers (Figure 1, Item 2), and capscrews (Figure 1, Item 1) from winch base (Figure 1, Item 4). Discard locknuts.
WARNING
Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. Attach hoist and sling to winch base (Figure 1, Item 4) and remove from vehicle. Lower onto flat surface.
2,3 1
4 5
M0648105
Winch Removal.
0125-2
TM 5-3810-305-23
0125
DISASSEMBLY
CAUTION
Work should be done in a clean, dust-free area. Cleanliness is of the utmost importance when servicing hydraulic equipment. Failure to follow this caution may result in damage to equipment.
NOTE
It may be necessary to insert a bar into anchor pocket and manually rotate drum in the direction to hoist a load until drain holes are aligned. 1. Remove drain plug (Figure 2, Item 3) and o-ring (Figure 2, Item 4) from winch (Figure 2, Item 2). O-ring is part of plug. If o-ring is damaged replace plug.
NOTE
DO NOT remove relief valve unless inspection indicates replacement is necessary. 2. 3. Inspect relief valve (WP 0162). Remove relief valve (Figure 2, Item 1) from winch (Figure 2, Item 2), if inspection proves necessary.
WARNING
Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 4. Remove oil level plug (Figure 2, Item 5), o-ring (Figure 2, Item 6), and stand winch on bearing support end. O-ring is part of plug. If o-ring is damaged replace plug.
6 3,4 5
M0649105
Figure 2.
Winch Disassembly.
0125-3
TM 5-3810-305-23
0125
DISASSEMBLY - Continued 5. Disconnect hydraulic hose (Figure 3, Item 1) from winch (Figure 3, Item 2).
M0650105
Figure 3. Hydraulic Hose Disassembly. 6. Remove two capscrews (Figure 4, Item 2), lockwashers (Figure 4, Item 3), motor (Figure 4, Item 1), and o-ring (Figure 4, Item 4) from motor support (Figure 4, Item 5). Discard o-ring and lockwashers.
5
Figure 4.
2,3
M0651105
Motor Disassembly.
CAUTION
Avoid damaging sealing or bearing surfaces while removing brake cylinder assembly. Failure to follow this caution may result in damage to equipment. 7. 8. Remove brake clutch assembly (Figure 5, Item 1) from motor support. Remove six capscrews (Figure 5, Item 2) and lockwashers (Figure 5, Item 3), and brake cylinder assembly (Figure 5, Item 5) from winch (Figure 5, Item 4). Discard lockwashers.
0125-4
TM 5-3810-305-23
0125
1 2,3
4 5
M0652105
Figure 5. 9.
Brake Clutch and Cylinder Disassembly.
Remove sun primary gear (Figure 6, Item 1) snapring (Figure 6, Item 5), drum closure (Figure 6, Item 3), and o-ring (Figure 6, Item 4) from drum (Figure 6, Item 2). Discard o-ring.
1 5
3 4
Figure 6. Sun Primary Gear Disassembly.
M0635105
0125-5
TM 5-3810-305-23
0125
DISASSEMBLY - Continued 10. Remove seal (Figure 7, Item 1) and ball bearing (Figure 7, Item 2) from inside of drum closure (Figure 7, Item 3). Discard seal.
2 1
3
M0654105
Figure 7. Seal and Ball Bearing Disassembly. 11. Remove thrust ring (Figure 8, Item 1) and primary planet carrier (Figure 8, Item 2) from drum (Figure 8, Item 3).
M0655105
Figure 8. Primary Planet Carrier Disassembly.
0125-6
TM 5-3810-305-23
0125
DISASSEMBLY - Continued 12. Remove thrust washer (Figure 9, Item 1) and sun output gear (Figure 9, Item 2) from output planet carrier (Figure 9, Item 3).
M0656105
Figure 9. 13.
Sun Output Gear Disassembly.
Remove output planet carrier (Figure 10, Item 1) from drum (Figure 10, Item 2).
2
M0657105
Figure 10.
Output Planet Carrier Disassembly.
0125-7
TM 5-3810-305-23
0125
WARNING
Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 14. Remove snapring (Figure 11, Item 2) from bearing support (Figure 11, Item 1) and stand winch on motor end with bearing support up.
1 2
M0658105
Figure 11.
Snap Ring Disassembly.
0125-8
TM 5-3810-305-23
0125
CAUTION
Use care when removing drum. Failure to follow this warning may result in damage to sealing or bearing surfaces. 15. 16. Remove six capscrews (Figure 12, Item 1), six lockwashers (Figure 12, Item 2), and bearing support (Figure 12, Item 3) from drum (Figure 12, Item 4). Discard lockwashers. Remove drum (Figure 12, Item 4) from base (Figure 12, Item 5).
3 1,2
M0659105
Figure 12.
Drum Disassembly.
0125-9
TM 5-3810-305-23
0125
DISASSEMBLY - Continued 17. Remove seal (Figure 13, Item 1) and bearing (Figure 13, Item 2) from support end of drum (Figure 13, Item 3). Discard seal.
M0660105
Figure 13. Seal and Bearing Disassembly. END OF TASK
0125-10
TM 5-3810-305-23
0125
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. Place base (Figure 14, Item 1) on side with bearing support end up.
M0661105
Figure 14.
Base Positioning Assembly.
0125-11
TM 5-3810-305-23
0125
NOTE
Lubricate all o-rings and oil seals with lubricating oil, prior to installation. Use a sealing compound on outside surface of oil seals and a light coat of thread sealing compound on pipe threads. Avoid getting thread compound inside parts or passages which conduct lubricating oil. 2. 3. 4. Install bearing (Figure 15, Item 4) and new seal (Figure 15, Item 3) in drum (Figure 15, Item 5). Install new seal (Figure 15, Item 3) with spring side of seal away from bearing, and press into drum (Figure 15, Item 5). Install o-ring (Figure 15, Item 2) and drain plug (Figure 15, Item 1) securely in drum (Figure 15, Item 5).
3,4 5 1,2
M0662105
Figure 15.
Drum Assembly.
WARNING
Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. Install drum (Figure 16, Item 1) into opening of base (Figure 16, Item 2).
0125-12
TM 5-3810-305-23
0125
M0663105
Figure 16. 6. 7. 8.
Drum Assembly.
Install relief valve (Figure 17, Item 1) on bearing support (Figure 17, Item 2), if removed. Lubricate bearing support (Figure 17, Item 2) with lubricating oil. Install bearing support (Figure 17, Item 2) on base (Figure 17, Item 4) in drum (Figure 17, Item 3).
M0664105
Figure 17.
Bearing Support Assembly.
0125-13
TM 5-3810-305-23
0125
CAUTION
Be sure relief valve is located above the horizontal centerline for the intended application. Oil leakage may occur if vent is positioned incorrectly. 9. Install six new lockwashers (Figure 18, Item 2) and capscrews (Figure 18, Item 1) on bearing support (Figure 18, Item 3).
3 1,2
M0665105
Figure 18.
Bearing Support Fasteners Assembly.
WARNING
Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
CAUTION
Snapring will keep output planet carrier correctly positioned in winch. Gear train damage may occur if snapring is omitted. 10. Stand winch on bearing support end and install snapring (Figure 19, Item 2) in bearing support (Figure 19, Item 1).
0125-14
TM 5-3810-305-23
0125
1 2
M0666105
Figure 19.
Snap Ring Assembly.
0125-15
TM 5-3810-305-23
0125
ASSEMBLY - Continued 11. Install sun output gear (Figure 20, Item 1) and thrust washer (Figure 20, Item 2) into output planet carrier (Figure 20, Item 3).
M0667105
Figure 20. 12.
Sun Output Gear Assembly.
Install output planet carrier (Figure 21, Item 2) into drum (Figure 21, Item 3) while meshing planet gears with ring gear and planet carrier with bearing support (Figure 21, Item 1).
3
Figure 21. Output Planet Carrier Assembly.
M0668105
0125-16
TM 5-3810-305-23
0125
ASSEMBLY - Continued 13. 14. Install thrust ring (Figure 22, Item 2) on primary planet carrier (Figure 22, Item 1). Install primary planet carrier (Figure 22, Item 1) into drum (Figure 22, Item 3) while meshing planet gears with ring gear and planet carrier with output gear.
3
Figure 22. 15. Primary Planet Carrier Assembly.
M0669105
Install bearing (Figure 23, Item 2) and new seal (Figure 23, Item 1) in drum closure (Figure 23, Item 3). Install new seal with spring side of seal away from bearing.
1,2 3
M0670105
Figure 23.
Bearing and Seal Assembly.
0125-17
TM 5-3810-305-23
0125
ASSEMBLY - Continued 16. 17. 18. Install new o-ring (Figure 24, Item 3) in drum (Figure 24, Item 1). Lubricate new o-ring (Figure 24, Item 3) and drum (Figure 24, Item 1) opening with lubricating oil. Install drum closure (Figure 24, Item 4) and snapring (Figure 24, Item 2) into drum (Figure 24, Item 1).
M0671105
Figure 24. 19.
Drum Assembly.
Install sun primary gear (Figure 25, Item 2) into primary planet carrier (Figure 25, Item 1) while meshing sun primary gear with planet gears.
2 1
M0672105
Figure 25.
Sun Primary Gear Assembly.
0125-18
TM 5-3810-305-23
0125
ASSEMBLY - Continued 20. 21. Apply lubricating oil to new seal and bearing surfaces of brake cylinder assembly (Figure 26, Item 1). Install brake cylinder assembly (Figure 26, Item 1) into base (Figure 26, Item 3) and drum (Figure 26, Item 2).
1 2
M0673105
Figure 26. 22.
Brake Cylinder Assembly Assembly.
Install six new lockwashers (Figure 27, Item 2) and capscrews (Figure 27, Item 1) on brake cylinder assembly (Figure 27, Item 3).
1,2
M0674105
Figure 27.
Brake Cylinder Assembly Assembly.
0125-19
TM 5-3810-305-23
0125
CAUTION
Be certain snapring is seated in groove in splined bore of cam. Snapring will keep brake clutch assembly correctly positioned in center of friction brake pack. Binding of brake or brake failure may occur if snapring is omitted.
NOTE
When installed correctly, cam should turn freely in opposite direction drum turns to pull wire rope in. An easy way to check rotation is to hold outer race in one hand, and rotate cam. If brake discs are misaligned, preventing installation of clutch, use a hand pump to apply 750 to 1,000 psi (5,171 to 6,895 kPa) to brake release port adapter. Brake discs will move freely with brake released, permitting alignment of discs, brake clutch and sun primary gear. 23. Install brake clutch assembly (Figure 28, Item 1) into drum (Figure 28, Item 2).
2
Figure 28. Brake Clutch Assembly Assembly.
M0675105
0125-20
TM 5-3810-305-23
0125
ASSEMBLY - Continued 24. 25. 26. 27. 28. Lubricate new o-ring (Figure 29, Item 1) with lubricating oil. Install new o-ring (Figure 29, Item 1) on pilot of motor (Figure 29, Item 6). Install motor, engaging motor shaft with brake clutch cam and lower motor into drum. Install two new lockwashers (Figure 29, Item 4) and capscrews (Figure 29, Item 3). Connect hose (Figure 29, Item 2) to winch (Figure 29, Item 5).
2 1 3,4
5
M0676105
Figure 29.
Motor Installation Assembly.
0125-21
TM 5-3810-305-23
0125
ASSEMBLY - Continued 29. 30. 31. Check all capscrews and fittings to make certain they have been tightened correctly. Refill winch assembly with lubricating oil. Install o-ring (Figure 30, Item 2) and oil level plug (Figure 30, Item 1) on winch (Figure 30, Item 3).
1,2
M0677105
Oil Fill Assembly.
WARNING
Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. 4. 5. Attach hoist and sling to winch base (Figure 31, Item 4) and install on vehicle. Install four capscrews (Figure 31, Item 1) washers (Figure 31, Item 2) and new locknuts (Figure 31, Item 3) to secure winch base (Figure 31, Item 4). Install two elbows (Figure 31, Item 6) on brake valve assembly (Figure 31, Item 7). Connect two hydraulic hoses (Figure 31, Item 5) to brake valve assembly (Figure 31, Item 7). Close dipstick cap.
0125-22
TM 5-3810-305-23
0125
2,3 1
4 5
M0678105
Figure 31. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect battery cables (WP 0076). Install cable on drum (TM 5-3810-305-10).
Winch Installation.
Run engine until normal operating temperature is reached (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Shut down engine (TM 5-3810-305-10).
0125-23/24 blank
TM 5-3810-305-23
0126
FIELD MAINTENANCE WINCH MOTOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Adapter (WP 0172, Table 1, Item 39) Qty: 1 Adapter (WP 0172, Table 1, Item 45) Qty: 1 Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Elbow (WP 0172, Table 1, Item 36) Qty: 2 O-Ring (WP 0172, Table 1, Item 38) Qty: 2 Parts Kit, Seal Repl (WP 0172, Table 1, Item 73) Qty: 1 Materials/Parts (cont.) Plug (WP 0172, Table 1, Item 115) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Tee (WP 0172, Table 1, Item 40) Qty: 1 References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Winch removed (WP 0125)
WARNING
0126-1
TM 5-3810-305-23
0126
DISASSEMBLY
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. Disconnect hose (Figure 1, Item 1) and elbow with o-ring from winch brake valve assembly (Figure 1, Item 2). Discard elbow with o-ring.
2
Figure 1. 2. Winch Motor Disassembly.
M0623105
Remove two hoses (Figure 2, Item 3) and tee with o-ring (Figure 2, Item 2) from motor (Figure 2, Item 1). Discard tee with o-ring.
2 3
Figure 2. Winch Motor Disassembly.
M0624105
0126-2
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 3. 4. Disconnect hose (Figure 3, Item 1) and elbow with o-ring from winch brake valve assembly (Figure 3, Item 3). Discard elbow with o-ring. Remove hose (Figure 3, Item 1) from motor (Figure 3, Item 2).
2 1
3
M0625105
NOTE
Matchmark brake valve assembly and winch motor gear housing prior to disassembly. 5. Remove four allen screws (Figure 4, Item 3), winch brake valve assembly (Figure 4, Item 2), and o-ring (Figure 4, Item 1) from motor (Figure 4, Item 4). Discard o-ring.
2 3
4
M0626105
0126-3
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 6. Remove four allen screws (Figure 5, Item 1), split flange adapter (Figure 5, Item 2), and o-ring (Figure 5, Item 4) from motor (Figure 5, Item 3). Discard o-ring.
1 2 3
4
M0627105
Figure 5. 7.
Winch Motor Disassembly.
Remove seal (Figure 6, Item 1) from split flange adapter (Figure 6, Item 2). Discard seal.
2
M0628105
Figure 6.
0126-4
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 8. Remove drain plug and o-ring (Figure 7, Item 3) to drain hydraulic oil. Discard plug and o-ring.
NOTE
Matchmark gear housing to shaft end cover and port end cover 9. Remove four capscrews (Figure 7, Item 1) and washers (Figure 7, Item 2).
2 1 3
M0629105
Figure 7. 10.
Remove shaft end cover (Figure 8, Item 1) from motor (Figure 8, Item 2).
1 2
M0630105
Figure 8.
0126-5
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 11. 12. 13. Remove six pocket seals (Figure 9, Item 3) and gasket seal (Figure 9, Item 2) from gear housing (Figure 9, Item 4). Discard pocket seals and gasket seals. Remove port end cover (Figure 9, Item 1) from gear housing (Figure 9, Item 4). Remove remaining six pocket seals (Figure 9, Item 3) and gasket seal (Figure 9, Item 2) from gear housing (Figure 9, Item 4). Discard pocket seals and gasket seals.
1 2 3
2 3
M0631105
Figure 9.
NOTE
Matchmark thrust plates to gear housing. 14. 15. Remove two thrust plates (Figure 10, Item 1) by tapping on shafts (Figure 10, Item 3) to unseat thrust plates. Remove two shafts (Figure 10, Item 3) from gear housing (Figure 10, Item 2).
1
M0632105
Figure 10. Winch Motor Disassembly. 16. Inspect four dowel pins (WP 0162).
0126-6
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 17. Remove four dowel pins (Figure 11, Item 1) from port end cover (Figure 11, Item 2), if inspection proves necessary.
M0633105
Figure 11. 18. 19.
Remove two bearings (Figure 12, Item 1) and ring seal (Figure 12, Item 4) from port end cover (Figure 12, Item 2). Remove adapter with o-ring (Figure 12, Item 3) from port end cover (Figure 12, Item 2). Discard adapter with o-ring.
1 2
3 4
M0634105
Figure 12.
0126-7
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 20. Remove two bearings (Figure 13, Item 1) and ring seal (Figure 13, Item 3) from shaft end cover(Figure 13, Item 2).
M0635105
Figure 13. Winch Motor Disassembly. 21. Remove two check assemblies (Figure 14, Item 1) and adapter with o-ring (Figure 14, Item 2). Discard adapter with o-ring.
2
M0636105
0126-8
TM 5-3810-305-23
0126
DISASSEMBLY - Continued 22. Remove snapring (Figure 15, Item 5), spacer (Figure 15, Item 4), seal retainer (Figure 15, Item 3), and lip seal (Figure 15, Item 1) from shaft end cover (Figure 15, Item 2). Discard lip seal.
2 1
3 4 5
M0637105
0126-9
TM 5-3810-305-23
0126
ASSEMBLY 1. Install snapring (Figure 16, Item 5), spacer (Figure 16, Item 4), seal retainer (Figure 16, Item 3), and new lip seal (Figure 16, Item 1) onto shaft end cover (Figure 16, Item 2).
2 1
3 4 5
M0637105
Figure 16. Winch Motor Assembly. 2. Install two check assemblies (Figure 17, Item 1) and adapter with o-ring (Figure 17, Item 2).
2
Figure 17. Winch Motor Assembly.
M0636105
0126-10
TM 5-3810-305-23
0126
ASSEMBLY - Continued 3. Install new ring seal (Figure 18, Item 3) and two bearings (Figure 18, Item 1) in shaft end cover (Figure 18, Item 2).
M0635105
Figure 18. 4. 5.
Winch Motor Assembly.
Install new adapter and o-ring (Figure 19, Item 3) in port end cover (Figure 19, Item 2). Install new ring seals (Figure 19, Item 4) and two bearings (Figure 19, Item 1) in port end cover (Figure 19, Item 2).
1 2
3 4
M0634105
Figure 19.
0126-11
TM 5-3810-305-23
0126
ASSEMBLY - Continued 6. Install four dowel pins (Figure 20, Item 1) in port end cover (Figure 20, Item 2), if removed.
M0633105
Figure 20. Winch Motor Assembly. 7. 8. Install thrust plate (Figure 21, Item 1) as matchmarked in gear housing (Figure 21, Item 2). Thrust plate is installed flush with gear housing. Install two shafts (Figure 21, Item 3) in gear housing (Figure 21, Item 2).
1
M0632105
0126-12
TM 5-3810-305-23
0126
ASSEMBLY - Continued 9. 10. 11. 12. Install new gasket seal (Figure 22, Item 2) and six new pocket seals (Figure 22, Item 3) in gear housing (Figure 22, Item 4). Install port end cover (Figure 22, Item 1) on gear housing (Figure 22, Item 4) as matchmarked during disassembly. Install remaining thrust plate (Figure 22, Item 4) as matchmarked in gear housing (Figure 22, Item 4). Thrust plate is installed flush with gear housing. Install new gasket seal (Figure 22, Item 2) and remaining six new pocket seals (Figure 22, Item 3) in gear housing (Figure 21, Item 4).
1 2 3
2 3
M0631105
Figure 22. 13.
Install shaft end cover (Figure 23, Item 1) as matchmarked on motor (Figure 23, Item 2).
1 2
M0630105
Figure 23.
0126-13
TM 5-3810-305-23
0126
ASSEMBLY - Continued 14. Install four washers (Figure 24, Item 2), capscrews (Figure 24, Item 1), new o-ring and drain plug (Figure 24, Item 3) to motor (Figure 24, Item 2).
2 1 3
M0629105
Figure 24. Winch Motor Assembly. 15. Install new seal (Figure 25, Item 1) onto split flange adapter (Figure 25, Item 2).
2
M0628105
0126-14
TM 5-3810-305-23
0126
ASSEMBLY - Continued 16. Install new o-ring (Figure 26, Item 4) and split flange adapter (Figure 26, Item 2) on motor (Figure 26, Item 3) with four allen screws (Figure 26, Item 1).
1 2 3
4
M0627105
Figure 26. 17.
Install new o-ring (Figure 27, Item 1), winch brake valve assembly (Figure 27, Item 2), and four allen screws (Figure 27, Item 3) on motor (Figure 27, Item 4).
2 3
4
M0626105
0126-15
TM 5-3810-305-23
0126
ASSEMBLY - Continued 18. Install hose (Figure 28, Item 1) with new elbow and o-ring on motor (Figure 28, Item 2) and winch brake valve assembly (Figure 28, Item 3).
2 1
3
Figure 28. Winch Motor Assembly. 19.
M0645105
Install new tee with o-ring (Figure 29, Item 2) and two hoses (Figure 29, Item 3) on motor (Figure 29, Item 1).
2 3
M0646105
0126-16
TM 5-3810-305-23
0126
ASSEMBLY - Continued 20. Connect hose (Figure 30, Item 1) and new elbow with o-ring to winch brake valve assembly (Figure 30, Item 2).
2
Figure 30. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Install winch (WP 0125). Check for proper operation. Winch Motor Assembly.
M0647105
0126-17/18 blank
TM 5-3810-305-23
0127
FIELD MAINTENANCE WINCH BRAKE VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Elbow (WP 0172, Table 1, Item 36) Qty: 2 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 29) Qty: 1 O-Ring (WP 0172, Table 1, Item 30) Qty: 1 O-Ring (WP 0172, Table 1, Item 31) Qty: 1 O-Ring (WP 0172, Table 1, Item 32) Qty: 1 O-Ring (WP 0172, Table 1, Item 33) Qty: 1 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 34) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Winch disassembled (WP 0125) Separate winch valve from winch motor (WP 0127)
0127-1
TM 5-3810-305-23
0127
REMOVAL
NOTE
Elbows come with o-rings installed. 1. 2. 3. 4. 5. 6. 7. 8. Remove elbow (Figure 1, Item 11), o-ring (Figure 1, Item 10), ball (Figure 1, Item 9), and spring (Figure 1, Item 8) from housing (Figure 1, Item 23). Discard elbow and o-ring. Remove elbow (Figure 1, Item 14), o-ring (Figure 1, Item 13), and pilot orifice (Figure 1, Item 12) from housing (Figure 1, Item 23). Discard elbow and o-ring. Remove spring retainer (Figure 1, Item 4), o-ring (Figure 1, Item 5), and spring (Figure 1, Item 6) from housing (Figure 1, Item 23). Discard o-ring. Remove cap plug (Figure 1, Item 18), damper piston (Figure 1, Item 7), and spool (Figure 1, Item 15) as a unit from housing (Figure 1, Item 23). Remove back-up ring (Figure 1, Item 17) and o-ring (Figure 1, Item 16) from spool (Figure 1, Item 15). Discard o-ring. Separate damper piston (Figure 1, Item 7) from spool (Figure 1, Item 15). Remove back-up ring (Figure 1, Item 2) and o-ring (Figure 1, Item 3) from damper piston (Figure 1, Item 7). Discard o-ring. Remove spring retainer (Figure 1, Item 19), o-ring (Figure 1, Item 20), spring (Figure 1, Item 21), check valve poppet (Figure 1, Item 22), and plug (Figure 1, Item 1) from housing (Figure 1, Item 23). Discard o-ring.
0127-2
TM 5-3810-305-23
0127
REMOVAL - Continued
5 6 7 1 2 3 9 8 13,14 12 10,11
23
22 15 21 20 17 8 19 18
M0622105
16
Winch Brake Valve Maintenance.
0127-3
TM 5-3810-305-23
0127
NOTE
Coat all parts with clean lubricating oil prior to assembly. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install plug (Figure 2, Item 1), check valve poppet (Figure 2, Item 22), spring (Figure 2, Item 21), new o-ring (Figure 2, Item 20), and spring retainer (Figure 2, Item 19) in housing (Figure 2, Item 23). Install new o-ring (Figure 2, Item 3) and back-up ring (Figure 2, Item 2) on damper piston (Figure 2, Item 7). Install damper piston (Figure 2, Item 7) into spool (Figure 2, Item 15). Install new o-ring (Figure 2, Item 16) and back-up ring (Figure 2, Item 17) on spool (Figure 2, Item 15). Install spool (Figure 2, Item 15) and damper piston (Figure 2, Item 7) as a unit in housing (Figure 2, Item 23). Center unit in housing while installing. Install cap plug (Figure 2, Item 18) in housing (Figure 2, Item 23). Install spring (Figure 2, Item 6), new o-ring (Figure 2, Item 5), and spring retainer (Figure 2, Item 4) in housing (Figure 2, Item 23). Install pilot orifice (Figure 2, Item 12), new elbow with o-ring (Figure 2, Item 14) in housing (Figure 2, Item 23). Install spring (Figure 2, Item 8), ball (Figure 2, Item 9), new elbow with o-ring (Figure 2, Item 11) in housing (Figure 2, Item 23). Ball should rest on spring. Install brake clutch assembly.
0127-4
TM 5-3810-305-23
0127
5 6 7 1 2 3 9 8 13,14 12 10,11
23
22 15 21 20 17 8 19 18
M0622105
16
Winch Brake Valve Maintenance.
0127-5
TM 5-3810-305-23
0127
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Assemble winch (WP 0125). Install winch valve to winch motor (WP 0126). Connect battery (WP 0076). Check for proper operation.
0127-6
TM 5-3810-305-23
0128
FIELD MAINTENANCE WINCH CONTROL VALVE AND FITTINGS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gage, Pressure, Dial Indicating (WP 0171, Table 1, Item 3) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 O-Ring (WP 0172, Table 1, Item 120) Qty: 18 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 3 References WP 0076 WP 0129 WP 0145 WP 0162 Equipment Condition Deck plates removed (WP 0122)
0128-1
TM 5-3810-305-23
0128
REMOVAL
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. 2. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect battery cables (WP 0076). Disconnect winch control cable (WP 0129).
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 3. 4. 5. Disconnect all attaching hoses (Figure 1, Item 1), fittings and o-rings (Figure 1, Item 2) from winch control valve (Figure 1, Item 3). Discard o-rings. Remove three nuts (Figure 1, Item 4) and lockwashers (Figure 1, Item 5) from winch control valve (Figure 1, Item 3). Discard lockwashers. Remove winch control valve (Figure 1, Item 3) and three washers (Figure 1, Item 6) from frame location.
0128-2
TM 5-3810-305-23
0128
INSTALLATION 1. 2. 3. Install three washers (Figure 1, Item 6) and winch control valve (Figure 1, Item 3) on frame. Install three new lockwashers (Figure 1, Item 5) and nuts (Figure 1, Item 4). Connect all hoses (Figure 1, Item 1), fittings and new o-rings (Figure 1, Item 2) to winch control valve (Figure 1, Item 3).
2 4 2
3 1 1 2 6 2 2 1 2 5 4 2 1 2
M0478105
4,5,6
Figure 1.
Winch Control Valve Installation.
0128-3
TM 5-3810-305-23
0128
INSTALLATION - Continued 4. Connect winch control cable (WP 0129).
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. 5. 6. Close dipstick cap. Connect battery cables (WP 0076). Start engine (TM 5-3810-305-10) and operate winch control lever. Make sure components operate correctly. Check for leaks. Check hydraulic oil level. Fill to proper level as necessary (TM 5-3810-305-10).
END OF TASK ADJUSTMENT 1. Disconnect brake release hose (Figure 2, Item 1) attached to winch motor, lower port and cap tee before checking pressure. Vent hose to atmosphere.
M0479105
Figure 2.
Winch Control Valve Test and Adjustment.
0128-4
TM 5-3810-305-23
0128
ADJUSTMENT - Continued 2. Remove dust cap (Figure 3, Item 1) from test port located on inlet end of main control valve.
M0480105
Figure 3.
0128-5
TM 5-3810-305-23
0128
ADJUSTMENT - Continued 3. 4. Install a 0 to 4,000 psi (0 to 27,580 kPa) gage equipped with short pressure hose and 1/4 inch female quick disconnect. Remove acorn nut (Figure 4, Item 1) from relief on winch valve.
WARNING
Keep all personnel away from winch and hook block area. Failure to follow this warning may result in death or serious injury to personnel. 5. Run engine at full rpm, operate winch lever in lowering mode and hold long enough to get a pressure reading.
NOTE
Winch control valve is set at 2,650 (+50, -0) psi (18,272 [+345, -0] kPa). 6. 7. Hold adjusting screw (Figure 4, Item 3) and loosen jam nut (Figure 4, Item 2). Turn adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure, until desired pressure setting is obtained. Hold adjusting screw (Figure 4, Item 3) and tighten jam nut (Figure 4, Item 2). Install and tighten acorn nut (Figure 4, Item 1).
2 1
M0481105
Figure 4.
0128-6
TM 5-3810-305-23
0128
ADJUSTMENT - Continued 8. Remove pressure gage from test port and install dust cap (Figure 5, Item 1).
M0482105
Figure 5. 9.
Remove cap from tee and connect brake release hose (Figure 7, Item 1).
M0483105
0128-7
TM 5-3810-305-23
0128
FOLLOW-ON MAINTENANCE 1. 2. Install deck plates (WP 0122). Check for proper operation.
0128-8
TM 5-3810-305-23
0129
FIELD MAINTENANCE VALVE CONTROL, BOOM HOIST, EXTEND, AND WINCH CABLES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter (WP 0172, Table 1, Item 155) Qty: 3 Pin, Cotter (WP 0172, Table 1, Item 156) Qty: 4 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 4 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 6 Materials/Parts (cont.) Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 8 Washer, Split M8 (WP 0172, Table 1, Item 95) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Outriggers lowered and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122)
WARNING
Ensure to tag all cables and valve body properly before disconnecting. Failure to follow this warning may result in injury or death to personnel.
0129-1
TM 5-3810-305-23
0129
REMOVAL Control Valve Cable
NOTE
The following is a procedure for removal of one operator's end of valve control cable. The procedure for removal of the operator's end of the remaining valve control cables is identical. 1. Remove six capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 1), and front dash panel (Figure 1, Item 3) from vehicle. Discard lockwashers.
1 2 3
M0558105
Figure 1. Valve Control Cable Removal.
0129-2
TM 5-3810-305-23
0129
REMOVAL - Continued Control Valve Cable - Continued 2. 3. 4. 5. Remove cotter pin (Figure 2, Item 7), pin (Figure 2, Item 2), and yoke (Figure 2, Item 3) from lever assembly (Figure 2, Item 1). Discard cotter pin. Remove jam nut (Figure 2, Item 4) and remove yoke (Figure 2, Item 3) from vehicle. Loosen locking nuts (Figure 2, Item 5) and pull cable (Figure 2, Item 9) from bracket (Figure 2, Item 8). Remove two locking nuts (Figure 2, Item 5) and washers (Figure 2, Item 6) from cable (Figure 2, Item 9).
3 4 2 5 1 8 7 6 9
M0559105
Figure 2.
Valve Control Cable Removal.
0129-3
TM 5-3810-305-23
0129
REMOVAL - Continued Control Valve Cable - Continued 6. 7. 8. 9. 10. 11. Remove two nuts (Figure 3, Item 2), lockwashers (Figure 3, Item 3), and capscrews (Figure 3, Item 4) from bracket (Figure 3, Item 5). Discard lockwashers. Remove two locknuts (Figure 3, Item 1) and washers (Figure 3, Items 8 and 9) from clamps (Figure 3, Items 7 and 10). Discard locknuts. Spread two clamps (Figure 3, Items 7 and 10) apart and remove cable (Figure 3, Item 6) from vehicle. Remove two locknuts (Figure 3, Item 11) and washers (Figure 3, Items 8 and 9) from two clamps (Figure 3, Item 12). Discard locknuts. Spread two clamps (Figure 3, Item 12) apart and remove cable (Figure 3, Item 6). Pull cable through operator's cab access hole.
1 2, 3, 4 5
9 8 7
8 12 9 11
10
M0560105
Figure 3. Valve Control Cable Removal.
0129-4
TM 5-3810-305-23
0129
REMOVAL - Continued
Swing And Outrigger Cable
NOTE
The valve end of boom hoist, extend and winch cables are different from outrigger and swing cable. The end of each cable group must be removed using the correct procedure. 1. 2. 3. 4. 5. Remove cotter pin (Figure 4, Item 2) and pin (Figure 4, Item 10) from clevis (Figure 4, Item 9). Discard cotter pin. Remove two jam nuts (Figure 4, Item 1) and clevis (Figure 4, Item 9). Loosen two locking nuts (Figure 4, Item 3) and pull cable from bracket. Remove two locking nuts (Figure 4, Item 5) and washers (Figure 4, Items 6 and 8) from clamps (Figure 4, Item 7). Carefully pull cable (Figure 4, Item 4) out of vehicle.
2 1
10 9 3 4
5 6 7 8
Figure 4. Swing and Outrigger Cable Removal.
M0561105
0129-5
TM 5-3810-305-23
0129
REMOVAL - Continued
Boom Hoist, Extend, And Winch Cable 1. Remove cotter pin (Figure 5, Item 2) and pin (Figure 5, Item 9) from clevis (Figure 5, Item 3). Discard cotter pin.
NOTE
Clevis is not removed from disconnect assembly on winch cable. Disconnect assembly and clevis are removed as an unit. Use Steps 3, 4, 5, and 6 for winch cable removal. 2. Remove capscrew (Figure 5, Item 1) and clevis (Figure 5, Item 3) from disconnect assembly (Figure 5, Item 8).
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 3. 4. 5. 6. 7. Disconnect two wires from disconnect assembly (Figure 5, Item 8). Loosen jam nut (Figure 5, Item 10) and remove disconnect assembly (Figure 5, Item 8) from vehicle. Remove jam nut (Figure 5, Item 10) from cable (Figure 5, Item 5). Loosen two locking nuts (Figure 5, Item 4) and lift cable assembly (Figure 5, Item 5) from bracket (Figure 5, Item 6). Remove locking nuts and washers (Figure 5, Item 7) from cable. Remove cable (Figure 5, Item 5) from carrier.
0129-6
TM 5-3810-305-23
0129
REMOVAL - Continued Boom Hoist, Extend, And Winch Cable - Continued
1 9 8 10
2 3
4 7 5 6
2 10 7 9 8
M0562105
Boom Hoist, Extend, and Winch Cable Removal.
0129-7
TM 5-3810-305-23
0129
INSTALLATION Boom Hoist, Extend, And Winch Cable
NOTE
Before tightening jam nut, see adjustment procedure. 1. 2. 3. 4. 5. 6. 7. Install clevis (Figure 6, Item 3) and capscrew (Figure 6, Item 1) on end of disconnect assembly (Figure 6, Item 8), telescope and boom hoist cable only. Install jam nut (Figure 6, Item 10) and disconnect assembly (Figure 6, Item 8) on cable end. Tighten jam nut securing disconnect assembly (Figure 6, Item 8) on cable end. Connect two wires on disconnect assembly (Figure 6, Item 8). Note tag from removal. Position cable (Figure 6, Item 5) in place and install pin (Figure 6, Item 9) and new cotter pin (Figure 6, Item 2) on clevis (Figure 6, Item 3). Install washers (Figure 6, Item 7) and new locking nuts (Figure 6, Item 4) on cable (Figure 6, Item 5). Tighten two new locking nuts (Figure 6, Item 4) securing cable (Figure 6, Item 5) in bracket (Figure 6, Item 6). Check cable (Figure 6, Item 5) operation for correct adjustment and movement.
1 9 8 10
2 3
4 7 5 6
2 10 7 9 8
M0562105
Figure 6. Boom Hoist, Extend, and Winch Cable Installation.
0129-8
TM 5-3810-305-23
0129
INSTALLATION - Continued Swing And Outrigger Cable
NOTE
The valve end of boom hoist, extend and winch cables are different from outrigger and swing cable. The end of each cable group must be installed using the correct procedure. 1. 2. 3. 4. 5. Carefully position cable (Figure 7, Item 4) in place on vehicle. Install two clamps (Figure 7, Item 7), washers (Figure 7, Items 6 and 8), and locking nuts (Figure 7, Item 5) on cable. Tighten two locking nuts (Figure 7, Item 3) to hold cable in place on bracket. Install two jam nuts (Figure 7, Item 1) and clevis (Figure 7, Item 9) on end of cable. Thread two jam nuts and clevis to full threaded engagement. Tighten rear jam nut to lock clevis in place. Position cable (Figure 7, Item 4) in place and install pin (Figure 7, Item 10) and cotter pin (Figure 7, Item 2).
2 1
10 9 3 4
5 6 7 8
Figure 7. Swing and Outrigger Cable Installation.
M0561105
0129-9
TM 5-3810-305-23
0129
Valve Control Cables
NOTE
The following is a procedure for installation of the operator's end of one valve control cable. The procedure for installation of the operator's end of the remaining valve control cables is identical. 1. 2. 3. 4. Pull cable (Figure 8, Item 8) through access hole in rear cab panel. Install two locking nuts (Figure 8, Item 5) and washers (Figure 8, Item 6) on cable (Figure 8, Item 8). Install jam nut (Figure 8, Item 4) and yoke (Figure 8, Item 3) on cable (Figure 8, Item 8). Install yoke (Figure 8, Item 3), pin (Figure 8, Item 2), and new cotter pin (Figure 8, Item 7) on lever assembly (Figure 5, Item 1).
3 4 2 5 1 7 6 8
M0563105
Figure 8. Valve Control Cables Installation.
0129-10
TM 5-3810-305-23
0129
INSTALLATION - Continued Valve Control Cables - Continued 5. 6. 7. 8. Install bracket (Figure 9, Item 5) with two capscrews (Figure 9, Item 4), new lockwashers (Figure 9, Item 3) and nuts (Figure 9, Item 2). Tighten locking nuts (Figure 9, Item 2) and washers (Figure 9, Item 3) on bracket (Figure 9, Item 8). Position cable (Figure 9, Item 9) through clamps (Figure 9, Item 12) and install washer (Figure 9, Items 8 and 9), and locknuts (Figure 9, Item 11). Position cable (Figure 9, Item 6) through clamps (Figure 9, Items 7 and 10) and install washers (Figure 9, Items 8 and 9) and two new locknuts (Figure 9, Item 1).
1 2, 3, 4 5
9 8 7
8 12
Figure 9.
10 9 11
M0560105
Valve Control Cables Installation.
0129-11
TM 5-3810-305-23
0129
INSTALLATION - Continued Valve Control Cables - Continued 9. Install front panel (Figure 10, Item 3) with six new lockwashers (Figure 10, Item 1) and capscrews (Figure 10, Item 2).
1 2 3
M0558105
Figure 10. Valve Control Cables Installation. END OF TASK ADJUSTMENT 1. Adjustment on hoist, winch, and telescope cables are made by installing disconnect assemblies (Figure 11, Item 3) until they bottom on cable ends. Turn out two turns and tighten jam nuts (Figure 11, Item 2). Adjustment for hoist winch and telescope levers are made with electrical power disconnected. Push levers to full forward position (full rearward for winch). Adjust yoke (Figure 11, Item 1) so that no movement to valve bank piston is made. Reposition locking nuts on cable if further adjustment is necessary. Return levers to neutral position. Adjust yoke (Figure 11, Item 1) on remaining levers in alignment with hoist and telescope levers. Tighten jam nuts on all five cables for operator's safety.
2.
3. 4.
0129-12
TM 5-3810-305-23
0129
ADJUSTMENT - Continued
1 3 2
M0564105
Figure 11. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install deck plates (WP 0122).
Cables Adjustment.
0129-13/14 blank
TM 5-3810-305-23
0130
FIELD MAINTENANCE MIRROR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Locknut (WP 0172, Table 1, Item 151) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Split M8 (WP 0172, Table 1, Item 95) Qty: 4 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0130-1
TM 5-3810-305-23
0130
REMOVAL
NOTE
The following is a maintenance procedure for left mirror. The maintenance procedure for right mirror is identical. Remove two nuts (Figure 1, Item 9), lockwashers (Figure 1, Item 8), capscrews (Figure 1, Item 1), and mirror (Figure 1, Item 10) from vehicle. Discard lockwashers. END OF TASK DISASSEMBLY Remove two nuts (Figure 1, Item 5), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and brackets (Figure 1, Items 7 and 11) from mirror (Figure 1, Item 10). Discard lockwashers. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY Install two brackets (Figure 1, Items 7 and 11), washers (Figure 1, Item 4), new lockwashers (Figure 1, Item 3), and nuts (Figure 1, Item 5) on mirror (Figure 1, Item 10). END OF TASK INSTALLATION Install mirror (Figure 1, Item 10), two capscrews (Figure 1, Item 1), new lockwashers (Figure 1, Item 8), and nuts (Figure 1, Item 9) on vehicle.
0130-2
TM 5-3810-305-23
0130
2 1 3 4 5
11 10
6 2 3 4 8 9 1 5 7 6
8 9
M0572105
Mirror Maintenance.
0130-3/4 blank
TM 5-3810-305-23
0131
FIELD MAINTENANCE WINDSHIELD WIPER ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Gasket (WP 0172, Table 1, Item 144) Qty: 1 Locknut (WP 0172, Table 1, Item 151) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 13) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 173) Qty: 1 References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Lower dash panel removed (WP 0066)
0131-1
TM 5-3810-305-23
0131
REMOVAL
WARNING
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Remove screw (Figure 1, Item 1), clamp (Figure 1, Item 4), and wire (Figure 1, Item 5) from wiper motor (Figure 1, Item 3). Disconnect electrical connector (Figure 1, Item 2) from wiper motor (Figure 1, Item 3).
4
Figure 1. Windshield Wiper Removal.
M0566105
0131-2
TM 5-3810-305-23
0131
REMOVAL - Continued 3. Remove two nuts (Figure 2, Items 1 and 3), lockwashers (Figure 2, Items 2 and 4), and wiper arm (Figure 2, Item 6) from adapter (Figure 2, Item 5). Discard lockwashers.
6
M0567105
0131-3
TM 5-3810-305-23
0131
REMOVAL - Continued 4. Remove knurled driver nut (Figure 3, Item 1) and plastic insert (Figure 3, Item 2) from adapter (Figure 3, Item 3).
M0568105
0131-4
TM 5-3810-305-23
0131
REMOVAL - Continued 5. 6. Remove rubber cap (Figure 4, Item 1), nut (Figure 4, Item 2), and two washers (Figure 4, Items 3 and 8) from adapter (Figure 4, Item 4). Remove two capscrews (Figure 4, Item 5), washers (Figure 4, Item 6), adapter (Figure 4, Item 4), and gasket (Figure 4, Item 7) from vehicle. Discard gasket.
8
Figure 4.
5,6
M0569105
Windshield Wiper Removal.
0131-5
TM 5-3810-305-23
0131
REMOVAL - Continued 7. 8. 9. 10. 11. Remove nut (Figure 5, Item 2) and washer (Figure 5, Item 3) from pivot shaft (Figure 5, Item 7) on wiper motor (Figure 5, Item 6). Remove pivot shaft link (Figure 5, Item 4) from pivot shaft (Figure 5, Item 7). Remove three bolts (Figure 5, Item 5) from bracket (Figure 5, Item 1) and wiper motor (Figure 5, Item 6). Remove wiper motor (Figure 5, Item 6) from vehicle. Remove bracket (Figure 5, Item 1) from vehicle.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect plastic insert and replace, if necessary.
END OF TASK INSTALLATION 1. 2. 3. 4. 5. Position bracket (Figure 5, Item 1) on vehicle. Position wiper motor (Figure 5, Item 6) on vehicle. Install three bolts (Figure 5, Item 5) to bracket (Figure 5, Item 1) and wiper motor. Tighten bolts. Install pivot shaft link (Figure 5, Item 4) to pivot shaft (Figure 5, Item 7). Install washer (Figure 5, Items 3 and 8) and nut (Figure 5, Item 2) to pivot shaft (Figure 5, Item 7). Tighten nut.
0131-6
TM 5-3810-305-23
0131
7
M0570105
Figure 5. Windshield Wiper Removal and Installation.
0131-7
TM 5-3810-305-23
0131
INSTALLATION - Continued 6. 7. Install two capscrews (Figure 6, Item 5), washers (Figure 6, Item 6), adapter (Figure 6, Item 4), and new gasket on vehicle. Tighten two capscrews. Install rubber cap (Figure 6, Item 1), nut (Figure 6, Item 2), and two washers (Figure 6, Item 3) on adapter. Tighten nut.
5,6
M0569105
Figure 6. Windshield Wiper Installation.
0131-8
TM 5-3810-305-23
0131
INSTALLATION - Continued 8. Install plastic insert (Figure 7, Item 2) and knurled driver nut (Figure 7, Item 1) on adapter (Figure 7, Item 3). Tighten nut.
M0568105
Figure 7.
Windshield Wiper Installation.
0131-9
TM 5-3810-305-23
0131
INSTALLATION - Continued 9. Install two nuts (Figure 9, Items 1 and 3), new lockwashers (Figure 9, Items 2 and 3), and wiper arm (Figure 9, Item 5) on adapter (Figure 9, Item 4). Tighten nuts.
5
Figure 8. Windshield Wiper Installation.
M0570105
0131-10
TM 5-3810-305-23
0131
INSTALLATION - Continued 10. 11. Install screw (Figure 9, Item 1), clamp (Figure 9, Item 4), and wire (Figure 9, Item 5) on wiper motor (Figure 9, Item 3). Connect electrical connector (Figure 9, Item 2) to wiper motor (Figure 9, Item 3).
5
Figure 9. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install lower dash panel (WP 0066). Connect battery cables (WP 0076). Check for proper operation.
4
Windshield Wiper Installation.
M0566105
0131-11/12 blank
TM 5-3810-305-23
0132
FIELD MAINTENANCE HEATER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 5 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Coolant drained from radiator to a level below heater (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0132-1
TM 5-3810-305-23
0132
REMOVAL
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Hot coolant and alkali contained in cooling system can burn severely. Even with cooling system drained, residual coolant remains in system lines and fittings. Wear protective goggles, face shield, and clothing when handling cooling system components. If coolant contacts eyes, skin, or clothing, flush with large amounts of cold water and seek medical attention, if required. Failure to follow these warnings may result in injury or death to personnel.
NOTE
Use suitable container to catch draining coolant. Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. Loosen two clamps (Figure 1, Item 8) and disconnect hoses (Figure 1, Items 9 and 13) from heater assembly (Figure 1, Item 14). Remove two clamps (Figure 1, Item 8) from hoses (Figure 1, Items 9 and 13).
NOTE
Remove all tiedown straps from heater hoses to aid in removal. Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 3. 4. 5. 6. 7. 8. 9. Remove nut (Figure 1, Item 3), washer (Figure 1, Item 4), and wire assembly (Figure 1, Item 5) from heater assembly (Figure 1, Item 14). Disconnect wire assembly (Figure 1, Item 6) from wire assembly (Figure 1, Item 7). Remove three nuts (Figure 1, Item 1) and washers (Figure 1, Item 2) from heater (Figure 1, Item 14). Remove heater assembly (Figure 1, Item 14) from vehicle. Remove clamp (Figure 1, Item 11) and remove hose (Figure 1, Item 9) from valve (Figure 1, Item 10). Remove grommet (Figure 1, Item 12) from vehicle. Remove valve (Figure 1, Item 10) from vehicle.
0132-2
TM 5-3810-305-23
0132
REMOVAL - Continued
3,4,5
14
6,7
8 9 13 10 12
Figure 1.
11
Heater Removal.
M0518105
10. 11. 12.
From outside rear of cab, loosen clamp (Figure 2, Item 2), and disconnect hose (Figure 2, Item 1) from 90 degree elbow (Figure 2, Item 3). Remove 90 degree elbow (Figure 2, Item 3) from vehicle. Remove clamp (Figure 2, Item 2) from disconnect hose (Figure 2, Item 1).
3 2
M0519105
Figure 2.
Heater Removal.
0132-3
TM 5-3810-305-23
0132
REMOVAL - Continued 13. From under right frame, remove two bolts (Figure 3, Item 4), washers (Figure 3, Item 3), clamps (Figure 3, Items 5 and 7), bars (Figure 3, Item 2), and four clamps (Figure 3, Item 1) from hose (Figure 3, Items 6 and 8).
1 2
3, 4 5 8 6
7
M0520105
Figure 3. 14. 15. 16.
Heater Removal.
Remove nut (Figure 4, Item 1), washer (Figure 4, Item 2), clamp (Figure 4, Item 3), and washer (Figure 4, Item 4) from right frame. From rear axle and right frame, remove two nuts (Figure 4, Item 12), washers (Figure 4, Item 11), two clamps (Figure 4, Item 10), and washers (Figure 4, Item 9). From rear axle and left frame, remove three nuts (Figure 4, Item 5), washers (Figure 4, Item 6), clamps (Figure 4, Item 7), and washers (Figure 4, Item 8).
5,6,7,8 1,2,3,4
9,10,11,12
Figure 4. Heater Removal.
M0521105
0132-4
TM 5-3810-305-23
0132
REMOVAL - Continued 17. 18. 19. Loosen clamp (Figure 5, Item 3) and disconnect hose (Figure 5, Item 4) from 90 degree elbow (Figure 5, Item 1). Remove clamp (Figure 5, Item 8) and hose (Figure 5, Item 4) from vehicle. Remove 90 degree elbow (Figure 5, Item 1) and bushing (Figure 5, Item 2) from vehicle.
1 2
M0522105
Figure 5. 20. 21. 22.
Heater Removal.
Loosen clamp (Figure 6, Item 1) and disconnect hose (Figure 6, Item 5) from 90 degree elbow (Figure 6, Item 2). Remove clamp (Figure 6, Item 1) and hose (Figure 6, Item 5) from 90 degree elbow (Figure 6, Item 2). Remove 90 degree elbow (Figure 6, Item 2) and bushing (Figure 6, Item 3) from inlet connection (Figure 6, Item 4).
2 1
5
M0523105
Heater Removal.
0132-5
TM 5-3810-305-23
0132
DISASSEMBLY 1. Remove four screws (Figure 7, Item 1) and cover assembly (Figure 7, Item 2).
M0524105
Figure 7.
Heater Disassembly.
0132-6
TM 5-3810-305-23
0132
DISASSEMBLY - Continued 2. 3. 4. 5. Remove two heater cores (Figure 8, Item 7), clamps (Figure 8, Item 3), pads (Figure 8, Item 6), and hose (Figure 8, Item 4) as an assembly. Remove two pads (Figure 8, Item 6), clamps (Figure 8, Item 3), and hose (Figure 8, Item 4) from two heater cores (Figure 8, Item 7). Loosen setscrew securing fan and remove fan (Figure 8, Item 8) from motor support (Figure 8, Item 9). Disconnect wire assembly (Figure 8, Item 11).
13 3 4 2
12
11
10 9 2 8 5 7 6
M0525105
Figure 8.
Heater Disassembly.
0132-7
TM 5-3810-305-23
0132
DISASSEMBLY - Continued 6. 7. 8. 9. Remove two screws (Figure 9, Item 2) from motor support (Figure 9, Item 9). Remove motor (Figure 9, Item 10) and motor support (Figure 9, Item 9) as an assembly from casing (Figure 9, Item 12). Remove two nuts securing motor (Figure 9, Item 10) from motor support (Figure 9, Item 9). Pull knob (Figure 9, Item 1) off of switch assembly (Figure 9, Item 13) and remove nut. Remove switch assembly from casing (Figure 9, Item 12).
2 1
7 6 5 3 4
Figure 9. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK Heater Disassembly.
M0525105
0132-8
TM 5-3810-305-23
0132
ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. Install switch assembly (Figure 10, Item 13) in casing assembly (Figure 10, Item 12) and secure with nut. Install knob (Figure 10, Item 1) on switch assembly. Install motor (Figure 10, Item 10) and two nuts on motor support (Figure 10, Item 9). Install motor (Figure 10, Item 10) and motor support (Figure 10, Item 9) as an assembly to casing (Figure 10, Item 12). Install two screws (Figure 10, Item 2) on motor support (Figure 10, Item 9). Connect wire assembly (Figure 10, Item 11). Install fan (Figure 10, Item 8) and align setscrew with flat side of motor support (Figure 10, Item 9). Tighten setscrew. Install hose (Figure 10, Item 4) and two clamps (Figure 10, Item 3) to two heater cores (Figure 10, Item 7). Install two pads (Figure 10, Item 6) on heater cores (Figure 10, Item 7). Install hose (Figure 10, Item 4), pads (Figure 10, Item 6), clamps (Figure 10, Item 3), and two heater cores (Figure 10, Item 7) as an assembly.
13 3 4 2
12
11
10 9 2 8 5 7 6
M0525105
Figure 10.
Heater Assembly.
0132-9
TM 5-3810-305-23
0132
ASSEMBLY - Continued 10. Install cover assembly (Figure 11, Item 2) and four screws (Figure 11, Item 1).
M0524105
Figure 11. END OF TASK INSTALLATION 1. 2.
Heater Assembly.
Install bushing (Figure 12, Item 2) and 90 degree elbow (Figure 12, Item 1) on water inlet connection (Figure 12, Item 3). Install hose (Figure 12, Item 4) and clamp (Figure 12, Item 5) on 90 degree elbow (Figure 12, Item 1).
2 1
5
M0523105
Figure 12. 3. 4.
Heater Installation.
Install bushing (Figure 13, Item 2) and 90 degree elbow (Figure 13, Item 1) on vehicle. Install hose (Figure 13, Item 4) and clamp (Figure 13, Item 3) on vehicle.
0132-10
TM 5-3810-305-23
0132
1 2
M0522105
Figure 13.
NOTE
Position heater hoses on rear axle, right frame, left frame, and to cab to aid in installing clamps. 5. 6. 7. Install three washers (Figure 14, Item 8), clamps (Figure 14, Item 7), washers (Figure 14, Item 6), and nuts (Figure 14, Item 5) on rear axle and left frame. Install two washer (Figure 14, Item 9), clamps (Figure 14, Item 10), washers (Figure 14, Item 11), and nuts (Figure 14, Item 12) on rear axle and right frame. Install washer (Figure 14, Item 4), clamp (Figure 14, Item 3), washer (Figure 14, Item 2), and nut (Figure 14, Item 1) on right frame.
5,6,7,8 1,2,3,4
9,10,11,12
Figure 14. Heater Installation.
M0521105
0132-11
TM 5-3810-305-23
0132
INSTALLATION - Continued 8. Install four clamps (Figure 15, Item 1), two bars (Figure 15, Item 2), clamps (Figure 15, Items 5 and 7), washers (Figure 15, Item 3), and bolts (Figure 15, Item 4) on hoses (Figure 15, Items 6 and 8).
1 2
3, 4 5 8 6
7
M0520105
Figure 15. 9. 10. 11.
Install clamp (Figure 16, Item 2) on disconnect hose (Figure 16, Item 1). Install 90 degree elbow (Figure 16, Item 3) on vehicle. Secure hose (Figure 16, Item 1) to 90 degree elbow (Figure 16, Item 3) with clamp (Figure 16, Item 2).
3 2
M0519105
Figure 16.
NOTE
Install wire assembly as tagged during removal. 12. Install valve (Figure 17, Item 10) on vehicle.
0132-12
TM 5-3810-305-23
0132
INSTALLATION - Continued 13. 14. 15. 16. 17. 18. 19. 20. Install grommet (Figure 17, Item 12) on vehicle. Install hose (Figure 17, Item 9) and clamp (Figure 17, Item 11) on valve (Figure 17, Item 10). Install heater assembly (Figure 17, Item 14), washers (Figure 17, Item 2), and nuts (Figure 17, Item 1) on vehicle. Connect wire assembly (Figure 17, Item 7) to wire assembly (Figure 17, Item 6). Install wire assembly (Figure 17, Item 5), washer (Figure 17, Item 4), and nut (Figure 17, Item 3). Install two clamps (Figure 17, Item 8), one on hoses (Figure 17, Items 9 and 13). Connect hoses (Figure 17, Items 9 and 13) to heater assembly (Figure 17, Item 14) and secure with clamps (Figure 17, Item 8). Install tiedown straps where necessary to keep hoses from sagging.
3,4,5
14
6,7
8 9 13 10 12
Figure 17.
11
M0518105
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill radiator to proper coolant level (TM 5-3810-305-10). Connect battery negative ground cable (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0132-13/14 blank
TM 5-3810-305-23
0133
FIELD MAINTENANCE MARKING DECALS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Drill Set, Twist (WP 0171, Table 1, Item 23) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Hand Riveter (WP 0171, Table 1, Item 28) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Rivet, Solid (WP 0170, Table 1, Item 53) Qty: 1 References TM 5-3810-305-10 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
0133-1
TM 5-3810-305-23
0133
REMOVAL
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel.
NOTE
For location of decals and data plates refer to TM 5-3810-305-10. Decals are notes that are strategically placed on the vehicle for your convenience and protection. Pay attention to what they say. END OF TASK Removing and Installing Sticky Backed Marking Decals When replacing sticky backed marking decals, scrape off all remnants of old decal. Clean all dust and dirt from the mounting surface. Remove any preservative compounds with cleaning solvent. When the mounting surface is clean and dry, apply decal by pressing firmly in place. END OF TASK Removing and Installing Riveted Marking Decals When replacing riveted marking decals, drill out and discard rivets. Clean all dust and dirt from the mounting surface. When the mounting surface is clean and dry, hold marking decals while installing rivets. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
0133-2
TM 5-3810-305-23
0134
FIELD MAINTENANCE MAIN HYDRAULIC PUMP MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Antiseize Compound (WP 0170, Table 1, Item 5) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 O-Ring (WP 0172, Table 1, Item 120) Qty: 3 O-Ring (WP 0172, Table 1, Item 162) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Materials/Parts (cont.) Sealing Compound, Loctite 515 (WP 0170, Table 1, Item 58) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 1/2 Inch Regular (WP 0172, Table 1, Item 50) Qty: 4 References WP 0162 Equipment Condition Engine hood opened and hood support removed (WP 0118) Battery cables disconnected (WP 0076) Main hydraulic pump hoses removed (WP 0142)
WARNING
0134-1
TM 5-3810-305-23
0134
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. 1. 2. 3. 4. 5. Remove two elbows (Figure 1, Item 1), o-rings (Figure 1, Item 2), and washers (Figure 1, Item 3) from main hydraulic pump (Figure 1, Item 11). Discard o-rings. Remove four socket head capscrews (Figure 1, Item 7) and lockwashers (Figure 1, Item 8). Discard lockwashers. Remove supply hose adapter (Figure 1, Item 9) and o-ring (Figure 1, Item 10) from main hydraulic pump (Figure 1, Item 11). Discard o-ring. Remove two capscrews (Figure 1, Item 5) and washers (Figure 1, Item 6). Remove main hydraulic pump (Figure 1, Item 11) from transmission (Figure 1, Item 4).
2,3
5,6
11
7,8
10
M0445105
Figure 1. Main Hydraulic Pump Removal. END OF TASK
0134-2
TM 5-3810-305-23
0134
CLEANING
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel. 1. 2. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound.
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT directed compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. 3. Dry parts with compressed air.
END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0134-3
TM 5-3810-305-23
0134
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Coat hydraulic pump (Figure 2, Item 11) splines with antiseize thread compound. Apply threadlock compound to pump mounting flange. Position pump (Figure 2, Item 11) and align mounting holes on transmission (Figure 2, Item 4). Apply threadlock compound to threads of two capscrews (Figure 2, Item 5). Install two capscrews (Figure 2, Item 5) and washers (Figure 2, Item 6). Install new o-ring (Figure 2, Item 10) on supply hose adapter (Figure 2, Item 9). Install supply hose adapter (Figure 2, Item 9) with four capscrews (Figure 2, Item 7) and new lockwashers (Figure 2, Item 8) on pump. Install two new o-rings (Figure 2, Item 2) on elbows. Install two elbows (Figure 2, Item 1) and washers (Figure 2, Item 3) on main hydraulic pump (Figure 2, Item 11).
2,3
5,6
11
7,8
10
M0445105
Figure 2. Main Hydraulic Pump Installation. END OF TASK
0134-4
TM 5-3810-305-23
0134
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install main hydraulic pump hoses (WP 0142). Connect battery cables (WP 0076). Install engine hood and support (WP 0118). Check for proper operation.
0134-5/6 blank
TM 5-3810-305-23
0135
FIELD MAINTENANCE ROTARY MANIFOLD MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Gasket (WP 0172, Table 1, Item 98) Qty: 7 Gasket (WP 0172, Table 1, Item 99) Qty: 7 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 15) Qty: 1 O-Ring (WP 0172, Table 1, Item 43) Qty: 4 O-Ring (WP 0172, Table 1, Item 119) Qty: 2 O-Ring (WP 0172, Table 1, Item 120) Qty: 4 O-Ring (WP 0172, Table 1, Item 146) Qty: 8 Packing, Retainer (WP 0172, Table 1, Item 113) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Retainer, Packing (WP 0172, Table 1, Item 97) Qty: 2 Spacer, Ring (WP 0172, Table 1, Item 100) Qty: 2 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 1/2 Inch (WP 0172, Table 1, Item 48) Qty: 1 Personnel Required (Two) References WP 0070 WP 0076 WP 0137 WP 0162 Equipment Condition Deck plates removed (WP 0122)
0135-1
TM 5-3810-305-23
0135
REMOVAL 1. Start engine and raise boom to a height suitable to provide access to inside of upperstructure frame.
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. 4. Use a lifting device to support boom. Shut engine OFF. Relieve all line pressure by operating control levers for boom, hoist, extend, and winch in Operators compartment. Disconnect battery cables (WP 0076).
WARNING
0135-2
TM 5-3810-305-23
0135
REMOVAL - Continued
NOTE
Remove lower hoses first and, using suitable container, catch hydraulic oil that drains from manifold and hoses. Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. Record port number stamped on manifold and type of adapter in each port before disconnecting hoses. 6. 7. Disconnect six hoses (Figure 1, Item 2) from bottom of manifold (Figure 1, Item 1). Remove six adapters (Figure 1, Item 3) and o-rings (Figure 1, Item 4) from manifold (Figure 1, Item 1). Discard o-rings.
3
Rotary Manifold Removal.
M0454105
Figure 1.
0135-3
TM 5-3810-305-23
0135
REMOVAL - Continued 8. Disconnect six hoses (Figure 2, Item 2) from side of manifold (Figure 2, Item 7).
NOTE
Record port number stamped on manifold and type of elbow in each port before removal. 9. 10. Remove six elbows (Figure 2, Item 3) and o-rings (Figure 2, Item 1) from side of manifold (Figure 2, Item 7). Discard o-rings. Remove stop pin (Figure 2, Item 5) and lockwasher (Figure 2, Item 6) from stop pin ear (Figure 2, Item 4) attached to side of upperstructure. Discard lockwasher.
7 6 5 4
M0455105
Figure 2. Rotary Manifold Removal.
0135-4
TM 5-3810-305-23
0135
REMOVAL - Continued
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 11. 12. Remove electrical collector ring (WP 0070). Remove three capscrews (Figure 3, Item 2) and washers (Figure 3, Item 3) from bottom of manifold (Figure 3, Item 1).
1 3
M0456105
Figure 3.
Rotary Manifold Removal.
0135-5
TM 5-3810-305-23
0135
REMOVAL - Continued 13. 14. Loosen axle lockout valve mounting nuts (Figure 4, Item 3). Using a hoist and sling, remove manifold (Figure 4, Item 1) by lifting and turning to clear stop pin ear (Figure 4, Item 2) on upperstructure as manifold is removed from vehicle.
3 2
Figure 4. Rotary Manifold Removal. END OF TASK DISASSEMBLY
M0457105
NOTE
Match mark spool to case to aid in assembly. 1. 2. 3. 4. Remove four capscrews (Figure 5, Item 1), plate (Figure 5, Item 2), o-ring (Figure 5, Item 3), and thrust washer (Figure 5, Item 4) from case (Figure 5, Item 13). Discard o-ring and thrust washer. Remove spool (Figure 5, Item 12) from case (Figure 5, Item 13). Remove back-up ring (Figure 5, Item 6) and o-ring (Figure 5, Item 10) from spool (Figure 5, Item 12). Discard o-ring. Remove two retainer packings (Figure 5, Item 11), seven gaskets (Figure 5, Item 8), and gaskets (Figure 5, Item 9) from spool (Figure 5, Item 12). Discard retainer packings and gaskets.
0135-6
TM 5-3810-305-23
0135
DISASSEMBLY - Continued 5. 6. Remove o-ring (Figure 5, Item 7) and back-up ring (Figure 5, Item 6) from spool (Figure 5, Item 12). Discard o-ring. Remove thrust washer (Figure 5, Item 5) from spool (Figure 5, Item 12). Discard thrust washer.
1 2 3 4
13
5 6
12
7 8 9
11
10 6
M0458105
Rotary Manifold Disassembly.
0135-7
TM 5-3810-305-23
0135
INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect bore of case for scoring or deep scratches that would indicate a contaminated hydraulic system. Inspect spool for wear or damage. Inspect hydraulic hose ports for contamination and crossed or stripped threads.
END OF TASK ASSEMBLY
CAUTION
When replacing seals, caution must be used to prevent stretching, cutting, or nicking seals. Seals must be walked on one side at a time. Before starting assembly, coat entire spool and bore of case with hydraulic oil. 1. 2. Install new thrust washer (Figure 6, Item 5) on spool (Figure 6, Item 12). Install back-up ring (Figure 6, Item 6) and new o-ring (Figure 6, Item 7) on spool (Figure 6, Item 12).
CAUTION
DO NOT allow rectangular rings to twist" in seal groove. Seals can be made pliable to aid in installation by soaking in 300F (149C) oil. Failure to follow this caution may result in damage to equipment.
NOTE
Compress teflon seals while they cool so that seals return to their original shape. 3. 4. 5. 6. Install seven new gaskets (Figure 6, Item 9), new gaskets (Figure 6, Item 8), and two new retainer packings (Figure 6, Item 11) on spool (Figure 6, Item 12). Install new o-ring (Figure 6, Item 10) and back-up ring (Figure 6, Item 6) on spool (Figure 6, Item 12). Carefully install spool (Figure 6, Item 12) by pushing spool into case (Figure 6, Item 13) from bottom. Align match marks and seat spool firmly. Install new thrust washer (Figure 6, Item 4), new o-ring (Figure 6, Item 3), plate (Figure 6, Item 2), and four capscrews (Figure 6, Item 1) in case (Figure 6, Item 13).
0135-8
TM 5-3810-305-23
0135
1 2 3 4
13
5 6
12
7 8 9
11
10 6
M0458105
Rotary Manifold Assembly.
0135-9
TM 5-3810-305-23
0135
INSTALLATION
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. Use lifting device to support beam.
WARNING
Weight of manifold is approximately 200 lb (91 kg). Use adequate lifting equipment to lift and support manifold. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. Using hoist and sling, install rotary manifold (Figure 7, Item 1) by lifting manifold over opening in carrier and lowering straight down and turning manifold to avoid stop pin ear (Figure 7, Item 2) located on upperstructure. Tighten axle lockout valve mounting nuts (Figure 7, Item 3).
3 2
Figure 7. Rotary Manifold Installation.
M0457105
0135-10
TM 5-3810-305-23
0135
INSTALLATION - Continued 4. Install three washers (Figure 8, Item 3) and capscrews (Figure 8, Item 2) through frame and into bottom of manifold (Figure 8, Item 1).
1 3
M0456105
Figure 8.
Rotary Manifold Installation.
0135-11
TM 5-3810-305-23
0135
NOTE
Install all wire assemblies as tagged during removal. 5. 6. 7. Install electrical collector ring (WP 0070). Align ear on side of manifold (Figure 9, Item 7) to hole in stop pin ear (Figure 9, Item 4). Install new lockwasher (Figure 9, Item 6) and stop pin (Figure 9, Item 5) into manifold (Figure 9, Item 7).
7 6 5 4
M0455105
Figure 9. Rotary Manifold Installation.
0135-12
TM 5-3810-305-23
0135
NOTE
Install elbows as tagged during removal. 8. 9. Install six new o-rings (Figure 10, Item 1) and elbows (Figure 10, Item 3) to side of manifold (Figure 10, Item 7). Connect six hoses (Figure 10, Item 2) to side of manifold (Figure 10, Item 7).
7 6
Figure 10.
M0455105
Rotary Manifold Installation.
0135-13
TM 5-3810-305-23
0135
INSTALLATION - Continued 10. 11. 12. 13. 14. Install six new o-rings (Figure 11, Item 4) and adapters (Figure 11, Item 3) to bottom of manifold (Figure 11, Item 1), as recorded. Connect six hoses (Figure 11, Item 2) to bottom of manifold (Figure 11, Item 1). Close dipstick cap. Install battery cables (WP 0076). Remove lifting device from boom.
M0454105
Figure 11. Rotary Manifold Installation. END OF TASK
0135-14
TM 5-3810-305-23
0135
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Adjust axle lockout valve (WP 0137). Install deck plates (WP 0122). Start engine and operate control levers for boom hoist, telescope and winch several times to remove any air trapped in system. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).
0135-15/16 blank
TM 5-3810-305-23
0136
FIELD MAINTENANCE OUTRIGGER SOLENOID VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 4 O-Ring (WP 0172, Table 1, Item 42) Qty: 2 O-Ring (WP 0172, Table 1, Item 44) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Seal Kit (WP 0172, Table 1, Item 20) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0136-1
TM 5-3810-305-23
0136
REMOVAL
WARNING
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 2. Disconnect four electric wires connected to outrigger solenoid valve (Figure 1, Item 4).
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. 3. Disconnect three hoses (Figure 1, Item 1), remove three elbows (Figure 1, Item 2), and o-rings (Figure 1, Item 3) from outrigger solenoid valve (Figure 1, Item 4). Cap hoses and plug holes in outrigger solenoid valve. Discard o-rings. Remove four nuts (Figure 1, Item 7), washers (Figure 1, Item 8), and capscrews (Figure 1, Item 6) from mounting brackets (Figure 1, Item 5). Remove outrigger solenoid valve (Figure 1, Item 4) from outrigger box.
4.
0136-2
TM 5-3810-305-23
0136
REMOVAL - Continued
5 7,8 6
M0087105
Figure 1. END OF TASK DISASSEMBLY 1. 2.
Outrigger Solenoid Valve Removal.
Remove eight capscrews (Figure 2, Item 1) from case and tube assemblies (Figure 2, Item 3). Remove two solenoid coils (Figure 2, Item 2) from case and tube assemblies (Figure 2, Item 3).
1 2 3
M0088105
Figure 2. Outrigger Solenoid Valve Disassembly.
0136-3
TM 5-3810-305-23
0136
DISASSEMBLY - Continued 3. Remove two spring retainers (Figure 3, Item 1), springs (Figure 3, Item 2), and spring retainers (Figure 3, Item 3) from tubes (Figure 3, Item 4).
2 3 4
M0104105
Figure 3. Outrigger Solenoid Valve Disassembly. 4. 5. Remove two tubes (Figure 4, Item 1) and springs (Figure 4, Item 3) from body (Figure 4, Item 4). Remove four seals (Figure 4, Item 2) from tubes (Figure 4, Item 1). Discard seals.
1 2 3 4
M0105105
0136-4
TM 5-3810-305-23
0136
DISASSEMBLY - Continued 6. Remove two retaining washers (Figure 5, Item 1) and spool (Figure 5, Item 3) from body (Figure 5, Item 2).
3 1
M0106105
0136-5
TM 5-3810-305-23
0136
DISASSEMBLY - Continued 7. Remove two brackets (Figure 6, Item 3), if damaged, remove two capscrews (Figure 6, Item 2), nuts (Figure 6, Item 4), and brackets (Figure 6, Item 3) from body.
END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. If removed, install two brackets (Figure 6, Item 3), two capscrews (Figure 6, Item 2), and nuts (Figure 6, Item 4) to body (Figure 6, Item 1).
2 1
3 4
Figure 6. Outrigger Solenoid Valve Assembly.
M0107105
0136-6
TM 5-3810-305-23
0136
ASSEMBLY - Continued 2. 3. 4. Coat spool (Figure 5, Item 3) with clean hydraulic oil and install spool and two retaining washers (Figure 5, Item 1) to body (Figure 6, Item 1). Install four new seals (Figure 7, Item 2) on two tubes (Figure 7, Item 1). Install two springs (Figure 7, Item 3) and tubes (Figure 7, Item 1) to body (Figure 7, Item 4).
1 2 3 4
M0105105
Figure 7. 5.
Outrigger Solenoid Valve Assembly.
Install springs (Figure 8, Item 2), two spring retainers (Figure 8, Item 3), and tubes (Figure 8, Item 4) to spring retainers (Figure 8, Item 1).
2 3 4
M0104105
Figure 8.
0136-7
TM 5-3810-305-23
0136
ASSEMBLY - Continued 6. 7. Install two solenoid coils (Figure 9, Item 2) to case and tube assemblies (Figure 9, Item 3). Install eight cap screws (Figure 9, Item 1) to case and tube assemblies (Figure 9, Item 3).
1 2 3
M0088105
0136-8
TM 5-3810-305-23
0136
INSTALLATION 1. Position outrigger solenoid valve (Figure 10, Item 4) over mounting holes in outrigger box and install four capscrews (Figure 10, Item 6), washers (Figure 10, Item 8), and nuts (Figure 10, Item 7) on mounting bracket (Figure 10, Item 5). Install three elbows (Figure 10, Item 2) and new o-rings (Figure 10, Item 3) on outrigger solenoid valve (Figure 10, Item 4). Connect three hoses (Figure 10, Item 1) on elbows (Figure 10, Item 2). Connect four electric wires to outrigger solenoid valve (Figure 10, Item 4). Close dipstick cap.
2. 3. 4. 5.
5 7,8 6
M0087105
Figure 10. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Outrigger Solenoid Valve Installation.
Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cable (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0136-9/10 blank
TM 5-3810-305-23
0137
FIELD MAINTENANCE AXLE LOCKOUT VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking He M6 (WP 0172, Table 1, Item 138) Qty: 2 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 114) Qty: 4 O-Ring (WP 0172, Table 1, Item 121) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)
WARNING
0137-1
TM 5-3810-305-23
0137
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. 3. 4. 5. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect hoses (Figure 1, Items 4, 5, and 8) from axle lockout valve (Figure 1, Item , Item 9). Remove two locknuts (Figure 1, Item 7), washers (Figure 1, Item 6), and capscrews (Figure 1, Item 1). Discard locknuts. Remove axle lockout valve (Figure 1, Item 9) from vehicle. Remove adapter (Figure 1, Item 10), two elbows (Figure 1, Item 2), and three o-rings (Figure 1, Item 3) from axle lockout valve (Figure 1, Item 9). Discard o-rings.
1 2,3
3,10 2,3
4 9 8 7
M0322105
Axle Lockout Valve Removal.
0137-2
TM 5-3810-305-23
0137
CLEANING
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel. 1. 2. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound IAW General Maintenance Instructions (WP 0162).
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT directed compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. 3. Dry parts with compressed air.
END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Replace worn or damaged parts. Polish metal surfaces having minor blemishes with fine crocus cloth. Coat all parts with clean hydraulic oil.
END OF TASK
0137-3
TM 5-3810-305-23
0137
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install three new o-rings (Figure 2, Item 3), two elbows (Figure 2, Item 2), and adapter (Figure 2, Item 10) in axle lockout valve (Figure 2, Item 9). Install elbows (Figure 2, Item 2) pointing down. Install axle lockout valve (Figure 2, Item 9) in vehicle. Install two capscrews (Figure 2, Item 1), washers (Figure 2, Item 6), and new locknuts (Figure 2, Item 7). Do not tighten capscrews (Figure 2, Item 1) at this time. Install hoses (Figure 2, Items 4, 5, and 8) on axle lockout valve (Figure 2, Item 9). Close dipstick cap. Start engine. Rotate upperstructure to the travel position and check for leaks. Open bleed screws on axle lockout cylinders until all air escapes. Tighten bleed screws. Shut OFF engine. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Adjust axle lockout valve (Figure 2, Item 9).
1 2,3
3,10 2,3
4 9 8 7
M0322105
Figure 2. Axle Lockout Valve Installation. END OF TASK
0137-4
TM 5-3810-305-23
0137
ADJUSTMENT 1. 2. Start engine and rotate upperstructure approximately 45 degrees. Shut engine OFF (TM 5-3810-305-10). Insert 0.010 inch (0.25 mm) gage between axle lockout valve rollers and high area of cam surface on rotary manifold. Slide axle lockout valve toward rotary manifold until axle lockout valve spring is fully compressed and hold in that position while tightening capscrews (Figure 2, Item 1). Remove 0.010 inch (0.25 mm) gage.
3.
M0323105
Axle Lockout Valve Adjustment.
Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0137-5/6 blank
TM 5-3810-305-23
0138
FIELD MAINTENANCE BOOM HOIST, WINCH, AND OUTRIGGER VALVE CONTROLS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter M2X12MM (WP 0172, Table 1, Item 155) Qty: 3 Pin, Cotter 3X30 (WP 0172, Table 1, Item 156) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Split M8 (WP 0172, Table 1, Item 95) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Dash panels removed (WP 0066) Battery cables disconnected (WP 0076)
REMOVAL 1. Remove three cotter pins (Figure 1, Item 3) and pins (Figure 1, Item 4) to disengage yokes (Figure 1, Item 1) from handles (Figure 1, Item 2). Discard cotter pins.
2 1
3
M0484105
Figure 1. Boom Hoist, Winch, and Outrigger Valve Controls Removal.
0138-1
TM 5-3810-305-23
0138
REMOVAL - Continued 2. 3. Remove three jam nuts (Figure 2, Item 2) and knobs (Figure 2, Item 1) from handle. Remove two capscrews (Figure 2, Item 5), lockwashers (Figure 2, Item 4), and bracket (Figure 2, Item 3) from vehicle. Discard lockwashers.
1 2
4 5
M2311105
Figure 2. Boom Hoist, Winch, and Outrigger Valve Controls Removal. END OF TASK
0138-2
TM 5-3810-305-23
0138
DISASSEMBLY 1. Remove three cotter pins (Figure 3, Item 2) from pin (Figure 3, Item 8). Discard cotter pins.
NOTE
Record number of washers removed to aid in assembly. 2. 3. 4. 5. Carefully pull pin (Figure 3, Item 8) out of bracket assembly (Figure 3, Item 5). Remove 12 washers (Figure 3, Item 6), three handles (Figure 3, Item 1), and two tubes (Figure 3, Items 3 and 7) from pin (Figure 3, Item 8). Remove two bushings (Figure 3, Item 4) from bracket assembly (Figure 3, Item 5). Remove bushings (Figure 3, Item 9) from handles (Figure 3, Item 1).
2 1
3 9
5 7 6
2
M0486105
Boom Hoist, Winch, and Outrigger Valve Controls Disassembly.
0138-3
TM 5-3810-305-23
0138
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. 3. 4. 5. 6. Install bushings (Figure 4, Item 9) in handles (Figure 4, Item 1). Install two bushings (Figure 4, Item 4) in bracket assembly (Figure 4, Item 5). Install pin (Figure 4, Item 8) by pushing through bushing (Figure 4, Item 4) and bracket assembly (Figure 4, Item 5). Install two washers (Figure 4, Item 6) on pin (Figure 4, Item 8). Install handle (Figure 4, Item 1) and washer (Figure 4, Item 6). Continue pushing pin (Figure 4, Item 8) and install tube (Figure 4, Item 7), washer (Figure 4, Item 6), handle (Figure 4, Item 1), washer, tube, two washers, and handle.
NOTE
Add washers as required to minimize end play in handles without causing binding. 7. Secure pin (Figure 4, Item 8) in place with washers (Figure 4, Item 6) and new cotter pins (Figure 4, Item 2).
0138-4
TM 5-3810-305-23
0138
2 1
3 9
5 7 6
2
M0486105
Figure 4. Boom Hoist, Winch, and Outrigger Valve Controls Assembly. END OF TASK
0138-5
TM 5-3810-305-23
0138
INSTALLATION 1. 2. 3. Position bracket assembly (Figure 5, Item 3) under dash panel. Install two new lockwashers (Figure 5, Item 4) and two capscrews (Figure 5, Item 5). Install three jam nuts (Figure 5, Item 2) and knobs (Figure 5, Item 1) on handle and lock in place with jam nuts.
1 2
4 5
M2311105
Figure 5. Boom Hoist, Winch, and Outrigger Valve Controls Installation.
0138-6
TM 5-3810-305-23
0138
INSTALLATION - Continued 4. 5. Position three yokes (Figure 6, Item 1) on end of handles (Figure 6, Item 2). Install three pins (Figure 6, Item 4) and new cotter pins (Figure 6, Item 3).
2 1
3
M0484105
Figure 6. Boom Hoist, Winch, and Outrigger Valve Controls Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Connect battery cables (WP 0076). Install dash panels (WP 0066). Place boom in resting position (TM 5-3810-305-10). Outriggers retracted and raised (TM 5-3810-305-10). Check for proper operation.
0138-7/8 blank
TM 5-3810-305-23
0139
FIELD MAINTENANCE SWING/TELESCOPE VALVE CONTROLS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter M2X12MM (WP 0172, Table 1, Item 155) Qty: 2 Pin, Cotter 3X30 (WP 0172, Table 1, Item 156) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 2 Washer, Split M8 (WP 0172, Table 1, Item 95) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Lower dash panels removed (WP 0066) Battery cables disconnected (WP 0076)
0139-1
TM 5-3810-305-23
0139
REMOVAL
NOTE
Step 1 shows the removal for one of the two handles. 1. Remove two cotter pins (Figure 1, Item 4) and pins (Figure 1, Item 2) to disengage yokes (Figure 1, Item 3) from handles (Figure 1, Item 1). Discard cotter pins.
2 4
M0537105
Figure 1.
Swing/Telescope Valve Controls Removal.
0139-2
TM 5-3810-305-23
0139
REMOVAL - Continued 2. 3. Loosen two jam nuts (Figure 2, Item 2) to remove knobs (Figure 2, Item 1) and jam nuts. Remove two capscrews (Figure 2, Item 5), lockwashers (Figure 2, Item 4), and bracket assembly (Figure 2, Item 3). Discard lockwashers.
1 2 5 4
M0538105
Swing/Telescope Valve Controls Removal.
0139-3
TM 5-3810-305-23
0139
DISASSEMBLY 1. Remove two cotter pins (Figure 3, Item 7).
NOTE
Record number of washers removal to aid in assembly. 2. 3. 4. Carefully pull pin (Figure 3, Item 6) out of bracket assembly (Figure 3, Item 10). As pin is removed, washers (Figure 3, Item 8), two handles (Figure 3, Item 1) and tube (Figure 3, Item 5) will slide off pin. Remove two bushings (Figure 3, Item 9) from bracket assembly (Figure 3, Item 10). Remove bushings (Figure 3, Item 4) from handles (Figure 3, Item 1).
1 7 4 12 11 5 6 12 11 9 3 2 3 2
10
8
M2313105
Figure 3. Swing/Telescope Valve Controls Disassembly. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0139-4
TM 5-3810-305-23
0139
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. 3. Install bushings (Figure 4, Item 4) in handles (Figure 4, Item 1). Install two bushings (Figure 4, Item 9) in bracket assembly (Figure 4, Item 10). While pushing pin (Figure 4, Item 6) through bushing (Figure 4, Item 9), install washer (Figure 4, Item 8), handle (Figure 4, Item 1), washer, tube (Figure 4, Item 5), washer, handle, and washer.
NOTE
Add washers as required to minimize end play in handles without causing binding. 4. Secure pin (Figure 4, Item 6) in place with washers (Figure 4, Item 8), as required, and two cotter pins (Figure 3, Item 7).
1 7 4 12 11 5 6 12 11 9 3 2 3 2
10
8
M2313105
Figure 4. Swing/Telescope Valve Controls Assembly. END OF TASK
0139-5
TM 5-3810-305-23
0139
INSTALLATION 1. 2. 3. Position bracket assembly (Figure 5, Item 3) under dash panel. Install two new lockwashers (Figure 5, Item 4) and capscrews (Figure 5, Item 5) on bracket assembly (Figure 5, Item 3). Install three jam nuts (Figure 5, Item 2) and knobs (Figure 5, Item 1) and lock in place with jam nuts.
1 2 5 4
M0538105
Figure 5. Swing/Telescope Valve Controls Installation.
0139-6
TM 5-3810-305-23
0139
INSTALLATION - Continued 4. 5. Position two yokes (Figure 6, Item 3) on end of handles (Figure 6, Item 1). Install two pins (Figure 6, Item 2) and new cotter pins (Figure 6, Item 4).
2 4
M0537105
Figure 6. Swing/Telescope Valve Controls Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install dash panels (WP 0066). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0139-7/8 blank
TM 5-3810-305-23
0140
FIELD MAINTENANCE UPPER HYDRAULICS LINE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 8 O-Ring (WP 0172, Table 1, Item 43) Qty: 4 O-Ring (WP 0172, Table 1, Item 120) Qty: 2 O-Ring (WP 0172, Table 1, Item 146) Qty: 4 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10)
REMOVAL 1. Start engine. Raise boom to a height suitable to provide access to inside of upperstructure frame. Shut engine OFF.
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. Use a lifting device to support boom.
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 3. 4. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Relieve all line pressure by operating control levers for boom hoist extend and winch in Operators compartment.
0140-1
TM 5-3810-305-23
0140
REMOVAL - Continued
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Disconnect hoses (Figure 1, Items 11 and 12) from winch. Disconnect and remove hoses (Figure 1, Items 11 and 12) from two tubes (Figure 1, Item 10). Remove six capscrews (Figure 1, Item 18), two plates (Figure 1, Item 17), and eight clamps (Figure 1, Item 16). Disconnect two tubes (Figure 1, Item 10) from rotary manifold. Disconnect two hoses (Figure 1, Item 9) from rotary manifold. Remove two locknuts (Figure 1, Item 8), two washers (Figure 1, Items 6 and 7), and two clamps (Figure 1, Item 4) from hose (Figure 1, Item 9). Discard locknuts. Remove two hoses (Figure 1, Item 9) with flex trim (Figure 1, Item 14) from tubes (Figure 1, Item 1). Remove two tubes (Figure 1, Item 1) from elbows. Disconnect two hoses (Figure 1, Item 13) from rotary manifold. Remove five locknuts (Figure 1, Item 8), five washers (Figure 1, Items 3 and 15), and five clamps (Figure 1, Item 2). Discard locknuts. Remove two hoses (Figure 1, Item 13) with flex trim (Figure 1, Item 14) and adapters (Figure 1, Item 5) from vehicle.
0140-2
TM 5-3810-305-23
0140
REMOVAL - Continued
3 4 5 4 6 7
12 11 14 15
8 9
8 14 18 17 16 13 2 12 11
10 9
M0415105
Upper Hydraulics Line Removal.
0140-3
TM 5-3810-305-23
0140
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install two adapters (Figure 2, Item 5) and hoses (Figure 2, Item 13) with flex trim (Figure 2, Item 14). Connect two hoses (Figure 2, Item 13) to rotary manifold. Install five clamps (Figure 2, Item 2), five washers (Figure 2, Items 3 and 15), and five new locknuts (Figure 2, Item 8). Install two tubes (Figure 2, Item 1) to elbows. Install two hoses (Figure 2, Item 9) with flex trim (Figure 2, Item 14) to tubes (Figure 2, Item 1). Connect two hoses (Figure 2, Item 9) to rotary manifold. Install two clamps (Figure 2, Item 4), two washers (Figure 2, Items 6 and 7), and two new locknuts (Figure 2, Item 7) to hose (Figure 2, Item 9). Install two tubes (Figure 2, Item 10) to rotary manifold. Connect hoses (Figure 2, Items 11 and 12) to two tubes (Figure 2, Item 10). Connect hoses (Figure 2, Items 11 and 12) to winch. Install eight clamps (Figure 2, Item 7), two plates (Figure 2, Item 15), and six capscrews (Figure 2, Item 18).
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 12. Return boom to travel position (TM 5-3810-305-10).
0140-4
TM 5-3810-305-23
0140
3 4 5 4 6 7
12 11 14 15
8 9
8 14 18 17 16 13 2 12 11
10 9
M0415105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.
Upper Hydraulics Line Installation.
0140-5/6 blank
TM 5-3810-305-23
0141
FIELD MAINTENANCE LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 7 Nut, Self-Locking He M12 (WP 0172, Table 1, Item 133) Qty: 1 O-Ring (WP 0172, Table 1, Item 42) Qty: 8 O-Ring (WP 0172, Table 1, Item 43) Qty: 2 O-Ring (WP 0172, Table 1, Item 120) Qty: 6 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 146) Qty: 6 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122) Battery cables disconnected (WP 0076)
0141-1
TM 5-3810-305-23
0141
REMOVAL
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. Turn dipstick 1/4 turn to safety notch to relieve pressure.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. Position suitable container under vehicle to catch hydraulic oil that will run from hoses when disconnected. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect hoses (Figure 1, Items 6 and 7) from swing motor. Remove hoses (Figure 1, Items 6 and 7) from main control valve. Remove hoses (Figure 1, Items 6 and 7) from vehicle. Remove five locknuts (Figure 1, Item 16), washers (Figure 1, Item 15), capscrews (Figure 1, Item 3), and horn cushion (Figure 1, Item 17). Discard locknuts. Remove horn cushion top half (Figure 1, Item 17) from hoses (Figure 1, Items 8, 9, 10, 11, 19, and 20). Remove two locknuts (Figure 1, Item 5), washers (Figure 1, Item 4), and capscrews (Figure 1, Item 3) from horn cushion top half (Figure 1, Item 17). Discard locknuts. Remove plate (Figure 1, Item 14) and bottom half of cushion (Figure 1, Item 17) from hoses (Figure 1, Items 8, 9, 10, 11, 19, and 20). Remove locknut (Figure 1, Item 1), washer (Figure 1, Item 2), capscrew (Figure 1, Item 12), plate (Figure 1, Item 13), and top half of cushion (Figure 1, Item 18) from bottom cushion (Figure 1, Item 17). Discard locknuts. Disconnect hoses (Figure 1, Items 19 and 20) from rotary manifold. Disconnect hoses (Figure 1, Items 19 and 20) from winch valve. Remove hoses (Figure 1, Items 19 and 20) from vehicle. Disconnect hoses (Figure 1, Items 8, 9, 10, and 11) from rotary manifold. Disconnect hoses (Figure 1, Items 8, 9, 10, and 11) from main control valve. Remove hoses (Figure 1, Items 8, 9, 10, and 11) from vehicle.
10. 11. 12. 13. 14. 15.
0141-2
TM 5-3810-305-23
0141
REMOVAL - Continued
1,2
4,5 6 7 8 9 20 19
10
11
18 17 16 15 14 12
M0342105
13
Lower Boom, Swing, and Winch Hydraulic Lines Removal.
0141-3
TM 5-3810-305-23
0141
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Position hoses (Figure 2, Items 8, 9, 10 and 11) on vehicle. Route hoses from rotary manifold to main control valve. Connect hoses (Figure 2, Items 8, 9, 10 and 11) to main control valve. Connect hoses (Figure 2, Items 8, 9, 10 and 11) on rotary manifold. Position hoses (Figure 2, Items 19 and 20) on vehicle. Route hose from rotary manifold to winch valve. Connect hoses (Figure 2, Items 19 and 20) to winch valve. Connect hoses (Figure 2, Items 19 and 20) on rotary manifold. Install top half of cushion top half (Figure 2, Item 17), plate (Figure 2, Item 13), capscrew (Figure 2, Item 12), washer (Figure 2, Item 2), and new locknut (Figure 2, Item 1) in bottom cushion (Figure 2, Item 18). Position hoses (Figure 2, Items 8, 9, 10, 11, 19 and 20) in cushion top half (Figure 2, Item 17). Install bottom half of cushion (Figure 2, Item 17) and plate (Figure 2, Item 14) in cushion top half. Install two capscrews (Figure 2, Item 3), washers (Figure 2, Item 4), and new locknuts (Figure 2, Item 5). Install five capscrews (Figure 2, Item 3), washers (Figure 2, Item 15), and new locknuts (Figure 2, Item 16) in cushion (Figure 2, Item 17). Connect hoses (Figure 2, Items 6 and 7) on main control valve. Connect hoses (Figure 2, Items 6 and 7) on swing motor. Close dipstick cap.
0141-4
TM 5-3810-305-23
0141
1,2
4,5 6 7 8 9 20 19
10
11
18 17 16 15 14 12
M0342105
13
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5.
Lower Boom, Swing, and Winch Hydraulic Lines Installation.
Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Install deck plates (WP 0122). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0141-5/6 blank
TM 5-3810-305-23
0142
FIELD MAINTENANCE RETURN AND PRESSURE HYDRAULICS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 37) Qty: 2 Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 8 O-Ring (WP 0172, Table 1, Item 42) Qty: 8 O-Ring (WP 0172, Table 1, Item 43) Qty: 4 O-Ring (WP 0172, Table 1, Item 44) Qty: 14 O-Ring (WP 0172, Table 1, Item 120) Qty: 14 O-Ring (WP 0172, Table 1, Item 146) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Strap, Tiedown Electrical (WP 0170, Table 1, Item 71) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine covers removed (TM 5-3810-305-10) Deck plates removed (WP 0122)
0142-1
TM 5-3810-305-23
0142
REMOVAL
WARNING
CAUTION
Wipe area clean around all connections to be opened during removal. Cap lines and hoses and plug openings after removing lines. Contamination of system could result in premature failure.
NOTE
Tag hoses prior to removal to ensure correct installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Turn dipstick cap 1/4 turn to safety notch to relieve hydraulic pressure. Disconnect hoses (Figure 1, Items 1 and 2) from oil cooler. Remove 14 capscrews (Figure 1, Item 25), seven half clamps (Figure 1, Item 24), and seven cover plates (Figure 1, Item 23) from hoses (Figure 1, Items 1 and 2). Disconnect hoses (Figure 1, Items 3, 4, and 5) from main hydraulic pump and ground driven steering pump. Remove four capscrews (Figure 1, Item 22), two cushions (Figure 1, Item 21), and two plate covers (Figure 1, Item 20) from hoses (Figure 1, Items 3 and 4). Remove hoses (Figure 1, Items 3 and 5) from steering valve. Disconnect hoses (Figure 1, Items 6, 7, and 16) from steering valve and flow divider. Remove hoses (Figure 1, Items 1 and 4) from winch control valve. Disconnect hoses (Figure 1, Items 8, 10, 11, and 19) from winch control valve. Remove tiedown strap (Figure 1, Items 18) and hoses (Figure 1, Items 6, 8, and 19) from valve bank. Disconnect hose (Figure 1, Item 12) from valve bank. Remove clamp (Figure 1, Item 9) and hoses (Figure 1, Items 2, 7, and 10) from return filter. Remove three clamps (Figure 1, Item 17), three clamps (Figure 1, Item 14), and hoses
0142-2
TM 5-3810-305-23
0142
REMOVAL - Continued (Figure 1, Items 11 and 16) from pressure valve on booster valve. 14. 15. Disconnect hoses (Figure 1, Items 13 and 15) from pressure valve. Remove six clamps (Figure 1, Item 14) and hoses (Figure 1, Items 12, 13, and 15) from steering control unit.
3 1 2 4 5 25 24 23 22 21 20 10 16 14 19 14 18 14 12 17 14 16
M0110105
12
2 11 11
13 14 15
Return and Pressure Hydraulics Removal.
0142-3
TM 5-3810-305-23
0142
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Install hoses (Figure 2, Items 12, 13, and 15) and six clamps (Figure 2, Item 14) to steering control unit. Connect hoses (Figure 2, Items 13 and 15) to pressure valve on booster valve. Install hoses (Figure 2, Items 11 and 16), three clamps (Figure 2, Item 17), and three clamps (Figure 2, Item 14) to pressure valve. Install hoses (Figure 2, Items 2, 7, and 10) and clamp (Figure 2, Item 9) to return filter. Connect hose (Figure 2, Item 12) to valve bank. Install hoses (Figure 2, Items 6, 8, and 19) and tiedown strap (Figure 2, Item 18) to valve bank. Connect hoses (Figure 2, Items 8, 10, 11 and 19) to winch control valve. Install hoses (Figure 2, Items 1 and 4) to winch control valve. Connect hoses (Figure 2, Items 6, 7, and 16) to flow divider and steering valve. Install hoses (Figure 2, Items 3 and 5) to steering valve. Install two plate covers (Figure 2, Item 20), two cushions (Figure 2, Item 21), and four capscrews (Figure 2, Item 22) to hoses (Figure 2, Items 3 and 4). Connect hoses (Figure 2, Items 3, 4, and 5) to main hydraulic pump and ground driven steering pump. Install seven cover plates (Figure 2, Item 23), seven half clamps (Figure 2, Item 24), and 14 capscrews (Figure 2, Item 25) to hoses (Figure 2, Items 1 and 2). Connect hoses (Figure 2, Items 1 and 2) to oil cooler. Close dipstick cap.
3 1 2 4 5 25 24 23 22 21 20 10 16 14 19 14 18 14 12 17 14 16
M0110105
12
2 11 11
13 14 15
Return and Pressure Hydraulics Installation.
0142-4
TM 5-3810-305-23
0142
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Check hydraulic oil level. Fill to proper level, if necessary. Install deck plates (WP 0122). Engine covers installed (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0142-5/6 blank
TM 5-3810-305-23
0143
FIELD MAINTENANCE OUTRIGGER HYDRAULICS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 18 O-Ring (WP 0172, Table 1, Item 42) Qty: 18 O-Ring (WP 0172, Table 1, Item 44) Qty: 6 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Strap, Tiedown Electrical (WP 0172, Table 1, Item 164) Qty: 2 References WP 0151 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL
WARNING
0143-1
TM 5-3810-305-23
0143
REMOVAL - Continued 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Remove right front outrigger hold valve (WP 0151). Remove hoses (Figure 1, Items 18 and 21) from outrigger hold valve, solenoid, and elbow (Figure 1, Item 24). Remove left front outrigger hold valve (WP 0151). Remove locknuts (Figure 1, Item 6), washers (Figure 1, Items 7 and 30), and clamps (Figure 1, Items 5, 8, 17, and 34). Discard locknuts. Remove hoses (Figure 1, Items 19 and 20), elbow (Figure 1, Item 24), and tee (Figure 1, Item 16) from outrigger hold valve. Disconnect hose (Figure 1, Item 23) from elbow (Figure 1, Item 22). Remove two tiedown straps (Figure 1, Item 9) and seven clamps (Figure 1, Items 3, 8, 14, 25, 26, 27, and 28). Discard tiedown straps. Remove hose (Figure 1, Item 23) from elbow (Figure 1, Item 10). Remove elbow (Figure 1, Item 24) from tee (Figure 1, Item 16). Remove adapter (Figure 1, Item 15) from tee (Figure 1, Item 16) and remove adapter from hose (Figure 1, Item 13). Remove hose (Figure 1, Item 13) from tee (Figure 1, Item 12). Remove right rear outrigger hold valve (WP 0151). Remove hoses (Figure 1, Items 35 and 38) from outrigger hold valve, solenoid, and elbow (Figure 1, Item 33). Remove left rear outrigger hold valve (WP 0151). Remove hoses (Figure 1, Items 36 and 37), elbow (Figure 1, Item 33), and tee (Figure 1, Item 32) from outrigger hold valve. Disconnect hose (Figure 1, Item 4) from elbow (Figure 1, Item 1). Remove hose (Figure 1, Item 4) from tee (Figure 1, Item 29). Disconnect hose (Figure 1, Item 31) from elbow (Figure 1, Item 11). Remove hose (Figure 1, Item 31) from adapter (Figure 1, Item 3). Remove adapter (Figure 1, Item 2) and elbow (Figure 1, Item 33) from tee (Figure 1, Item 32). Remove elbow (Figure 1, Item 10) from tee (Figure 1, Item 29). Remove elbow (Figure 1, Item 11) from tee (Figure 1, Item 12).
0143-2
TM 5-3810-305-23
0143
REMOVAL - Continued
3 2
6 8
7 9 10
31 32 33 34 38 37 36 35
30 29
11 12 13
14 15 16
17 18 19 20
28 27 26 25 24 23 21 22
M0086105
Outrigger Hydraulics Removal.
0143-3
TM 5-3810-305-23
0143
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Install elbow (Figure 2, Item 11) on tee (Figure 2, Item 12). Install elbow (Figure 2, Item 10) on tee (Figure 2, Item 29). Install adapter (Figure 2, Item 2) an elbow (Figure 2, Item 33) on tee (Figure 2, Item 32). Install hose (Figure 2, Item 31) on adapter (Figure 2, Item 2). Connect hoses (Figure 2, Item 31) to elbow (Figure 2, Item 1). Install hose (Figure 2, Item 4) on elbow (Figure 2, Item 1). Install hose (Figure 2, Item 4) to tee (Figure 2, Item 29). Install left rear outrigger hold valve (WP 0151). Install hoses (Figure 2, Items 36 and 37) and tee (Figure 2, Item 32) to outrigger hold valve. Install right rear outrigger hold valve (WP 0151). Install hoses (Figure 2, Items 35 and 38) to outrigger hold valve, solenoid, and elbow. Install hose (Figure 2, Item 13) to tee (Figure 2, Item 12). Install adapter (Figure 2, Item 15) to hose (Figure 2, Item 13) and install adapter to tee (Figure 2, Item 16). Install elbow (Figure 2, Item 24) to tee (Figure 2, Item 16) Install hose (Figure 2, Item 23) to elbow (Figure 2, Item 10). Install new tiedown straps (Figure 2, Item 9) and seven clamps (Figure 2, Items 3, 8, 14, 25, 26, 27, and 28). Connect hose (Figure 2, Item 23) to elbow (Figure 2, Item 22). Install left front outrigger hold valve (WP 0151). Install hoses (Figure 2, Items 19 and 20), elbow (Figure 2, Item 24), and tee (Figure 2, Item 16) to outrigger hold valve. Install new locknuts (Figure 2, Items 6), washers (Figure 2, Items 7 and 30), and clamps (Figure 2, Items 5, 8, 17 and 34). Install right front outrigger hold valve (WP 0151). Install hoses (Figure 2, Items 18 and 21) to outrigger hold valve, solenoid and elbow (Figure 2, Item 24). Close dipstick cap.
0143-4
TM 5-3810-305-23
0143
3 2
6 8
7 9 10
31 32 33 34 38 37 36 35
30 29
11 12 13
14 15 16
17 18 19 20
28 27 26 25 24 23 21 22
M0086105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.
Outrigger Hydraulics Installation.
Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0143-5/6 blank
TM 5-3810-305-23
0144
FIELD MAINTENANCE SUCTION HYDRAULICS MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 133) Qty: 4 O-Ring (WP 0172, Table 1, Item 162) Qty: 1 O-Ring (WP 0172, Table 1, Item 163) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 50) Qty: 4 Washer, Lock (WP 0172, Table 1, Item 51) Qty: 4 References WP 0076 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Hydraulic reservoir drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
WARNING
0144-1
TM 5-3810-305-23
0144
REMOVAL
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Drain hydraulic reservoir.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. 5. 6. 7. 8. 9. 10. Loosen four clamps (Figure 1, Item 7) and remove hose (Figure 1, Item 8) from suction tube (Figure 1, Item 9). Remove four clamps (Figure 1, Item 7) from hose (Figure 1, Item 8). Remove four capscrews (Figure 1, Item 10), two cover plates (Figure 1, Item 11), and half clamps (Figure 1, Item 12) from suction tube (Figure 1, Item 9). Loosen two T-bolt clamps (Figure 1, Item 13) and remove pump suction tube (Figure 1, Item 9) from vehicle. Loosen two T-bolt clamps (Figure 1, Item 5) and remove hoses (Figure 1, Items 6 and 14). Remove T-bolt clamps (Figure 1, Item 5) from hoses. Remove four capscrews (Figure 1, Item 15), lockwashers (Figure 1, Item 16), and beaded insert (Figure 1, Item 17) from vehicle. Discard lockwashers. Remove o-ring (Figure 1, Item 18) from inside beaded insert (Figure 1, Item 17). Discard o-ring. Remove four capscrews (Figure 1, Item 4), lockwashers (Figure 1, Item 3), and beaded insert (Figure 1, Item 2) from vehicle. Discard lockwashers. Remove o-ring (Figure 1, Item 1) from inside beaded insert (Figure 1, Item 2). Discard o-ring.
0144-2
TM 5-3810-305-23
0144
REMOVAL - Continued
4 5 6 7
13 5 12 13 14 11 17 16 15 18
10 9 8 7
M0414105
Suction Hydraulics Removal.
0144-3
TM 5-3810-305-23
0144
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Install new o-ring (Figure 2, Item 1) in beaded insert (Figure 2, Item 2). Position beaded insert (Figure 2, Item 2) on vehicle and install capscrews (Figure 2, Item 4) and four new lockwashers (Figure 2, Item 3). Install new o-ring (Figure 2, Item 18) in beaded insert (Figure 2, Item 17). Position beaded insert (Figure 2, Item 17) on vehicle. Install four capscrews (Figure 2, Item 15) and four new lockwashers (Figure 2, Item 16). Position T-bolt clamp (Figure 2, Item 5) on hose (Figure 2, Item 6). Install hose (Figure 2, Item 6) on beaded insert (Figure 2, Item 2) and tighten T-bolt clamp (Figure 2, Item 5). Install T-bolt clamp (Figure 2, Item 5) on hose (Figure 2, Item 14). Install hose (Figure 2, Item 14) on beaded insert (Figure 2, Item 17) and tighten T-bolt clamp (Figure 2, Item 5). Install two T-bolt clamps (Figure 2, Item 13) on hoses (Figure 2, Items 6 and 14). Install pump suction tube (Figure 2, Item 9) in hoses (Figure 2, Items 6 and 14) and tighten two T-bolt clamps (Figure 2, Item 13). Position pump suction tube (Figure 2, Item 9) and install two half clamps (Figure 2, Item 12), two cover plates (Figure 2, Item 11), and four capscrews (Figure 2, Item 10). Install four clamps (Figure 2, Item 7) on hose (Figure 2, Item 8). Install hose (Figure 2, Item 8) on suction hose (Figure 2, Item 9) and tighten four clamps (Figure 2, Item 7). Fill hydraulic reservoir (TM 5-3810-305-10). Close dipstick cap.
0144-4
TM 5-3810-305-23
0144
4 5 6 7
13 5 12 13 14 11 17 16 15 18
10 9 8 7
M0414105
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables IAW (WP 0076).
Suction Hydraulics Installation.
Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0144-5/6 blank
TM 5-3810-305-23
0145
FIELD MAINTENANCE ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Suitable Lifting Device 5,000-lb (2,268 kgs) Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 28) Qty: 2 O-Ring (WP 0172, Table 1, Item 43) Qty: 6 O-Ring (WP 0172, Table 1, Item 120) Qty: 6 O-Ring (WP 0172, Table 1, Item 146) Qty: 6 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 48) Qty: 3 References WP 0076 WP 0138 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Deck plates removed (WP 0122)
REMOVAL 1. Start engine and raise boom to a height suitable to provide access to the inside of upperstructure frame (TM 5-3810-305-10).
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. Use lifting device to support boom. Shut engine OFF.
0145-1
TM 5-3810-305-23
0145
REMOVAL - Continued
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 4. 5. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Release all line pressure by turning ignition switch ON and operating control levers for boom, hoist extend and winch in the operators compartment. Turn ignition switch OFF. Disconnect battery cables.
WARNING
NOTE
Remove lower hoses first and using a suitable container, catch oil that drains from manifold and lines. Tag all hose assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. Record port number stamped on manifold and type of adapter in each port before removing hose.
0145-2
TM 5-3810-305-23
0145
REMOVAL - Continued 6. Disconnect six hoses (Figure 1, Item 12) from bottom of manifold (Figure 1, Item 1). Remove six adapters (Figure 1, Item 14) and o-rings (Figure 1, Item 13) from bottom of manifold. Discard o-rings.
NOTE
Record port number stamped on manifold and type of quick disconnect in each port before removal. 7. 8. 9. Disconnect six hoses and remove quick disconnects (Figure 1, Items 2, 8 and 18) from fittings (Figure 1, Items 3 and 9) on side of manifold (Figure 1, Item 1). Remove o-rings (Figure 1, Items 7 and 15 ) from elbows (Figure 1, Items 6 and 16). Discard o-rings. Remove o-rings (Figure 1, Items 5, 11 and 15 ) from fittings (Figure 1, Items 4, 10 and 19). Discard o-rings.
1 2 2 3 7 14 13 12 5 6 7 9 4 3 4 5 6
11 10 11 16 17 18 20 15 19 15 10
9 8
M2111105
Figure 1.
Rotary Manifold Quick Disconnects (Type II) Removal.
0145-3
TM 5-3810-305-23
0145
REMOVAL - Continued 10. 11. Remove stop pin (Figure 2, Item 3) and lockwasher (Figure 2, Item 4) from ear (Figure 2, Item 5) attached to side of upperstructure. Discard lockwasher. Disconnect electrical connector (Figure 2, Item 2) that is attached to electrical collector ring.
2 3 4 5 6
1
M2112105
Figure 2.
0145-4
TM 5-3810-305-23
0145
REMOVAL - Continued
NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 12. 13. 14. Disconnect electrical connectors (Figure 3, Item 3) on bottom of manifold (Figure 3, Item 4). Remove three capscrews (Figure 3, Item 2) and washers (Figure 3, Item 1) from bottom of manifold (Figure 3, Item 4). Loosen axle lockout valve mounting nuts (Figure 3, Item 3).
1 4 2
M2113105
Figure 3.
0145-5
TM 5-3810-305-23
0145
REMOVAL - Continued
WARNING
Weight of manifold is approximately 200 lb (91 kg). Use adequate lifting equipment to lift and support manifold. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 15. Using hoist and sling, remove manifold (Figure 4, Item 7) by lifting and turning it at the same time to clear stop pin ear (Figure 4, Item 4) on upperstructure as manifold is removed from vehicle.
7 6
M0455105
0145-6
TM 5-3810-305-23
0145
INSTALLATION
WARNING
Weight of manifold is approximately 200 lb (91 kg). Use adequate lifting equipment to lift and support manifold. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. Using hoist and sling, install rotary manifold (Figure 5, Item 7) by lifting manifold over opening in carrier and lowering down and turning manifold to avoid stop pin ear (Figure 5, Item 4) located on upperstructure. Align ear on side of manifold (Figure 5, Item 7) to the hole in stop pin ear (Figure 5, Item 4). Install stop pin (Figure 5, Item 5) and new lockwasher (Figure 5, Item 6) through stop pin ear into manifold.
7 6 5 4
M0455105
Figure 5. Rotary Manifold Quick Disconnects (Type II) Installation.
0145-7
TM 5-3810-305-23
0145
INSTALLATION - Continued 3. 4. 5. Install and tighten axle lockout valve mounting nuts (Figure 6, Item 3). Install three washers (Figure 6, Item 1) and three capscrews (Figure 6, Item 2) through frame and into bottom of manifold (Figure 6, Item 4). Connect electrical connectors (Figure 6, Item 3) to bottom of manifold (Figure 6, Item 4).
1 2 2 3 7 14 13 12 5 6 7 9 4 3 4 5 6
11 10 11 16 17 18 20 15 19 15 10
9 8
M2111105
0145-8
TM 5-3810-305-23
0145
INSTALLATION - Continued 6. 7. Connect electrical connector (Figure 7, Item 2) that is attached to electrical collector ring. Install stop pin (Figure 7, Item 3) and new lockwasher (Figure 7, Item 4) on ear (Figure 7, Item 5) attached to side of upperstructure.
2 3 4 5 6
1
M2112105
0145-9
TM 5-3810-305-23
0145
INSTALLATION - Continued 8. 9. 10. 11. Install new o-rings (Figure 8, Items 5, 11 and 15) onto fittings (Figure 8, Items 4, 10 and 19). Install new o-rings (Figure 8, Items 7 and 15) onto elbows (Figure 8, Items 6 and 16). Install six quick disconnects (Figure 8, Items 2, 8, and 18) and fittings (Figure 8, Items 3 and 9) to six hoses on side of manifold (Figure 8, Item 1). Install six adapters (Figure 8, Item 14) and o-rings (Figure 8, Item 13) to bottom of manifold (Figure 8, Item 1). Connect Six hoses (Figure 8, Item 12) to bottom of manifold.
1 2 2 3 7 14 13 12 5 6 7 9 4 3 4 5 6
11 10 11 16 17 18 20 15 19 15 10
9 8
M2111105
0145-10
TM 5-3810-305-23
0145
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 12. 13. 14. Remove lifting device from boom. Adjust axle lockout valve (WP 0137). Connect battery cables (WP 0076).
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. 15. Close dipstick cap. Start engine and operate control levers for boom hoist, extend and winch several times to remove any air trapped in the system. Check hydraulic oil level. Fill to proper level, if necessary refer to (TM 5-3810-305-10).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install deck plates (WP 0122). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0145-11/12 blank
TM 5-3810-305-23
0146
FIELD MAINTENANCE HYDRAULIC SYSTEM VALVE BANK MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gage, Pressure, Dial Indicating (WP 0171, Table 1, Item 3) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 42) Qty: 6 O-Ring (WP 0172, Table 1, Item 44) Qty: 1 O-Ring (WP 0172, Table 1, Item 146) Qty: 4 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Split (WP 0172, Table 1, Item 95) Qty: 3 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122) Battery cables disconnected (WP 0076)
REMOVAL
WARNING
0146-1
TM 5-3810-305-23
0146
REMOVAL - Continued
CAUTION
NOTE
Tag hoses prior to removal to ensure correct installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. 1. 2. 3. 4. 5. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect 14 hoses and fittings (Figure 1, Item 2) from control valve (Figure 1, Item 1). Disconnect four control cables and disconnect assemblies (Figure 1, Item 3) from control valve (Figure 1, Item 1). Remove three nuts (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and capscrews (Figure 1, Item 6). Discard lockwashers. Remove control valve (Figure 1, Item 1) from vehicle.
4,5,6
LRT110-2378 LRT110-2378 M0340105
Figure 1. Hydraulic System Valve Bank Removal. END OF TASK
0146-2
TM 5-3810-305-23
0146
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. Position control valve (Figure 2, Item 1) on frame location. Install three capscrews (Figure 2, Item 4), new lockwashers (Figure 2, Item 5) and nuts (Figure 2, Item 6) on control valve (Figure 2, Item 1). Connect four control cables and disconnect assemblies (Figure 2, Item 3). Install 14 fittings and connect hoses (Figure 2, Item 2) to control valve (Figure 2, Item 1).
4,5,6
LRT110-2378 LRT110-2378 M0340105
Figure 2. Hydraulic System Valve Bank Installation. END OF TASK
0146-3
TM 5-3810-305-23
0146
OTHER MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Install deck plates plate (WP 0122). Check hydraulic oil level. Fill to proper level. If necessary refer to (TM 5-3810-305-10).
END OF TASK ADJUSTMENT 1. 2. 3. 4. Remove acorn nut (Figure 3, Item 3) from relief valve located on middle inlet of main control valve (Figure 3, Item 1). Remove dust cap and install a 0 to 4,000 psi (0 to 27,580 kPa) gage onto test port (Figure 3, Item 2) at end of main control valve (Figure 3, Item 1). Run engine at full rpm so pump will develop required flow. Operate boom retract spool control valve to its extreme position long enough to get a pressure reading on gage.
NOTE
Main control valve should be set at 2,750 +/- 50 psi (18,961 +/- 345 kPa) at full flow. 5. 6. 7. 8. Hold adjusting screw (Figure 3, Item 5) and loosen jam nut (Figure 3, Item 4). Turn adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure, until desired pressure setting is obtained. Hold adjusting screw (Figure 3, Item 5) and tighten jam nut (Figure 3, Item 4). Install and tighten acorn nut (Figure 3, Item 3). Remove pressure gage from test port (Figure 3, Item 2) and install dust cap.
0146-4
TM 5-3810-305-23
0146
4,5
3
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Hydraulic System Valve Bank Adjustment.
M0341105
0146-5/6 blank
TM 5-3810-305-23
0147
FIELD MAINTENANCE RELIEF VALVE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gage, Pressure, Dial Indicating (WP 0171, Table 1, Item 3) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 1 O-Ring (WP 0172, Table 1, Item 146) Qty: 4 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122) Battery cables disconnected (WP 0076)
REMOVAL
WARNING
CAUTION
0147-1
TM 5-3810-305-23
0147
REMOVAL - Continued
NOTE
Tag hoses prior to removal to ensure correct installation. 1. 2. 3. 4. 5. 6. 7. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Remove lower dash panel. Remove hoses (Figure 1, Items 6, 8, and 11). Remove elbow (Figure 1, Item 10) and o-ring (Figure 1, Item 9). Discard o-ring. Remove tee (Figure 1, Item 7) from adapter (Figure 1, Item 5). Remove nipple (Figure 1, Item 1), o-ring (Figure 1, Item 2), and dust cap (Figure 1, Item 3) from relief valve (Figure 1, Item 4). Discard o-ring. Remove relief valve (Figure 1, Item 4) from brake booster.
1,2,3
8 9 11
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK
10
M0108105
Relief Valve Removal.
0147-2
TM 5-3810-305-23
0147
INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. 5. Install relief valve (Figure 2, Item 4) onto brake booster. Install dust cap (Figure 2, Item 3), new o-ring (Figure 2, Item 2), and nipple (Figure 2, Item 1). Install tee (Figure 2, Item 7) to relief valve (Figure 2, Item 4). Install elbow (Figure 2, Item 10) and new o-ring (Figure 2, Item 9) to relief valve (Figure 2, Item 4). Install hoses (Figure 2, Items 6, 8, and 11).
1,2,3
8 9 11
Figure 2. END OF TASK OTHER MAINTENANCE 1. 2. 3. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Check for proper operation (TM 5-3810-305-10).
10
M0108105
Relief Valve Installation.
END OF TASK
0147-3
TM 5-3810-305-23
0147
ADJUSTMENT 1. 2. 3. Remove dust cap (Figure 3, Item 1). Install a 0 to 4,000 psi (0 to 27,580 kPa) pressure gage on test port. Start engine. Run engine at full rpm (TM 5-3810-305-10).
M1551105
Figure 3. Relief Valve Adjustment.
NOTE
Valve setting is 2,500 +/- 50 psi (17,238 +/- 345 kPa) at full rpm. 4. 5. 6. 7. 8. 9. 10. 11. 12. Hold steering wheel in full turn position long enough to get pressure reading. If pressure reading is correct, go to Step 11. If not, continue procedure. Hold adjusting screw (Figure 4, Item 1) and loosen jam nut (Figure 4, Item 2). Hold steering wheel in full position and turn adjusting screw (Figure 4, Item 1) clockwise to increase pressure or counterclockwise to decrease pressure until desired pressure setting is obtained. Hold adjusting screw (Figure 4, Item 1) and tighten jam nut (Figure 4, Item 2). Repeat Step 5. Shut engine OFF (TM 5-3810-305-10). Remove pressure gage from test port. Install dust cap on adjusting screw (Figure 4, Item 1). Install lower dash panel (WP 0110).
0147-4
TM 5-3810-305-23
0147
M1552105
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install deck plates (WP 0122).
Relief Valve Adjustment.
Place boom in resting position (TM 5-3810-305-10). Return vehicle to normal operation.
0147-5/6 blank
TM 5-3810-305-23
0148
FIELD MAINTENANCE RETURN FILTER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Wrench, Oil Filter, Strap (WP 0171, Table 1, Item 32) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Filter, Oil (WP 0172, Table 1, Item 103) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 43) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 2 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 120) Qty: 3 O-Ring (WP 0172, Table 1, Item 162) Qty: 2 Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 50) Qty: 4 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122)
REMOVAL
WARNING
0148-1
TM 5-3810-305-23
0148
REMOVAL - Continued
CAUTION
NOTE
Tag hoses prior to removal to ensure correct installation. 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Remove spin-on filter element (Figure 1, Item 22) from filter head (Figure 1, Item 3), letting oil drain into container. Remove hose (Figure 1, Item 10), elbow (Figure 1, Item 11), and o-ring (Figure 1, Item 12). Discard o-ring. Remove hose (Figure 1, Item 13), elbow (Figure 1, Item 14), and o-ring (Figure 1, Item 15). Discard o-ring. Remove hose (Figure 1, Item 19), elbow (Figure 1, Item 20), and o-ring (Figure 1, Item 21). Discard o-ring. Remove check valve (Figure 1, Item 16), adapter (Figure 1, Item 17), and o-ring (Figure 1, Item 18) from manifold (Figure 1, Item 7). Discard o-ring. Remove dust cap (Figure 1, Item 5) and nipple (Figure 1, Item 6). Remove four capscrews (Figure 1, Item 8), lockwashers (Figure 1, Item 9), manifold (Figure 1, Item 7), and o-ring (Figure 1, Item 4) from filter head (Figure 1, Item 3). Discard lockwashers and o-ring. Remove four capscrews (Figure 1, Item 1), o-ring (Figure 1, Item 2), and filter head (Figure 1, Item 3) from manifold (Figure 1, Item 23). Discard o-ring.
0148-2
TM 5-3810-305-23
0148
REMOVAL - Continued
5 6 1 2 3 4 5,6 7 8,9 10,11,12 2 23 4 22 12 11 16,17,18 22 19,20,21

M0111105
5 6 7 3 23 8 18 17 16 9
13,14,15
Return Filter Removal.
0148-3
TM 5-3810-305-23
0148
INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install new o-ring (Figure 2, Item 2) and filter head (Figure 2, Item 3) on manifold (Figure 2, Item 23). Install four capscrews (Figure 2, Item 1) in manifold (Figure 2, Item 23) and tighten. Install new o-ring (Figure 2, Item 4) and manifold (Figure 2, Item 7) on filter head (Figure 2, Item 3). Install four capscrews (Figure 2, Item 8) and new lockwashers (Figure 2, Item 9) in manifold (Figure 2, Item 7) and tighten. Install dust cap (Figure 2, Item 5) and nipple (Figure 2, Item 6) on manifold (Figure 2, Item 7). Install new o-ring (Figure 2, Item 18), adapter (Figure 2, Item 17), and check valve (Figure 2, Item 16) on manifold (Figure 2, Item 7). Install new o-ring (Figure 2, Item 21), elbow (Figure 2, Item 20), and hose (Figure 2, Item 19). Install new o-ring (Figure 2, Item 15), elbow (Figure 2, Item 14), and hose (Figure 2, Item 13). Install new o-ring (Figure 2, Item 12), elbow (Figure 2, Item 11), and hose (Figure 2, Item 10). Apply film of oil on filter seal and install new spin-on filter element (Figure 2, Item 22) on filter head (Figure 2, Item 3).
5 6 1 2 3 4 5,6 7 8,9 10,11,12 2 23 4 22 12 11 16,17,18 22 19,20,21

M0111105
5 6 7 3 23 8 18 17 16 9
13,14,15
Return Filter Installation.
0148-4
TM 5-3810-305-23
0148
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Install deck plates (WP 0122). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0148-5/6 blank
TM 5-3810-305-23
0149
FIELD MAINTENANCE BOOM HOIST CYLINDER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Liquid Nitrogen (WP 0170, Table 1, Item 49) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 90) Qty: 2 Packing (WP 0172, Table 1, Item 91) Qty: 1 Parts Kit, Linear AC (WP 0172, Table 1, Item 124) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 242 (WP 0170, Table 1, Item 56) Qty: 1 Materials/Parts (cont.) Sealing Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Sealing Compound, Loctite 515 (WP 0170, Table 1, Item 58) Qty: 1 Sealing Compound, Loctite RC 680 (WP 0170, Table 1, Item 61) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 4 Washer, Lock (WP 0172, Table 1, Item 128) Qty: 2 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
REMOVAL 1. Start engine. Elevate boom to 30 degrees to allow for removal of hoist cylinder rod end at boom attachment point.
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. Use suitable lifting device to support boom weight.
0149-1
TM 5-3810-305-23
0149
REMOVAL - Continued
WARNING
Weight of boom hoist cylinder is approximately 507 lb (230 kg). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. Secure boom hoist cylinder (Figure 1, Item 4) in lifting device. Remove capscrew (Figure 1, Item 1), lockwasher (Figure 1, Item 2), rod eye (Figure 1, Item 3). and pin (Figure 1, Item 5) from rod end of boom hoist cylinder. Discard lockwasher.
1,2
5 4
M0427105
Figure 1. Boom Hoist Cylinder Removal. 4. Retract boom hoist cylinder (Figure 1, Item 4) by pushing boom hoist lever and retracting boom hoist cylinder approximately 6 inch (152 mm). Shut engine OFF.
WARNING
0149-2
TM 5-3810-305-23
0149
REMOVAL - Continued 5. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 6. 7. Disconnect two boom hoist cylinder hoses (Figure 2, Item 2) from adapters (Figure 2, Item 3) on boom hoist cylinder (Figure 2, Item 1). Remove capscrew (Figure 2, Item 4), lockwasher (Figure 2, Item 5), rod (Figure 2, Item 6), and pin (Figure 2, Item 7). Boom hoist cylinder (Figure 2, Item 1) is now free. Carefully lift out of upperstructure and move to work area. Discard lockwasher. Lower boom to horizontal position and block. Remove four capscrews (Figure 2, Item 8), lockwashers (Figure 2, Item 9), hold valve and o-rings (Figure 2, Item 10), two adapters (Figure 2, Item 3), and o-rings (Figure 2, Item 11). Discard o-rings and lockwashers.
8. 9.
1 4,5 6 2 3 10 7 8,9
3,11
M0428105
Boom Hoist Cylinder Removal.
0149-3
TM 5-3810-305-23
0149
DISASSEMBLY 1. Place boom hoist cylinder (Figure 3, Item 1) in appropriate holding device or fixture.
M0429105
Figure 3. 2. 3.
Boom Hoist Cylinder Disassembly.
Using spanner wrench, unscrew gland (Figure 4, Item 1) from cylinder tube (Figure 4, Item 3). Position suitable container under cylinder hold valve and gland areas. Pull rod assembly (Figure 4, Item 2) out of cylinder tube (Figure 4, Item 3).
2 3
M0430105
Figure 4.
0149-4
TM 5-3810-305-23
0149
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may result in serious injury or death to personnel. 4. Remove nut (Figure 5, Item 3), piston (Figure 5, Item 2), and gland (Figure 5, Item 4) on rod assembly (Figure 5, Item 1).
1 2
M0431105
Figure 5.
0149-5
TM 5-3810-305-23
0149
NOTE
Piston seal and expander ring should be cut to ease in disassembly. 5. 6. 7. Remove piston seal (Figure 6, Item 5) and square expander ring (Figure 6, Item 2). Discard piston seal. Remove two wear rings (Figure 6, Item 1) from outside diameter of piston (Figure 6, Item 3). Discard wear rings. Remove o-ring (Figure 6, Item 4) from inside diameter of piston (Figure 6, Item 3). Discard o-ring.
M0431105
Figure 6.
0149-6
TM 5-3810-305-23
0149
DISASSEMBLY - Continued 8. 9. Remove o-ring (Figure 7, Item 1) and back-up ring (Figure 7, Item 2) from outside diameter of gland (Figure 7, Item 3). Discard o-ring and back-up ring. Remove rod wiper (Figure 7, Item 5) and rod seal (Figure 7, Item 4) from inside of gland (Figure 7, Item 3). Discard rod wiper and rod seal.
3 4 5
M0433105
Figure 7. 10. 11.
Inspect bushings IAW General Maintenance Instructions (WP 0162). Inspect grease fittings IAW General Maintenance Instructions (WP 0162). Replace if necessary.
0149-7
TM 5-3810-305-23
0149
CAUTION
Removal of bushings may cause destruction of bushings. Remove bushings only if inspection indicates replacement is necessary. 12. Remove four bushings (Figure 8, Item 1) if inspection deems necessary.
M0434105
Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. 5. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks, or corrosion and replace if necessary. Inspect boom hoist cylinder bushing. Maximum I.D. is 2.543 inch (64.59 mm). If I.D. is more than limit, replace boom hoist cylinder bushing. Inspect boom hoist cylinder base pin. Minimum O.D. is 2.474 inch (62.84 mm). If O.D. is less than limit, replace boom hoist cylinder base pin. Inspect all other parts.
END OF TASK
0149-8
TM 5-3810-305-23
0149
ASSEMBLY
WARNING
NOTE
Cool bushings to -320F (-195C) by submerging bushings in liquid nitrogen. 1. If removed, submerge four bushings (Figure 8, Item 1), in liquid nitrogen to cool them. Apply threadlock sealant and install four bushings.
CAUTION
Rod seal is installed with open end and lips toward the interior of cylinder. Rod wiper is installed with lip toward the outside of cylinder. Use care to avoid nicking or scratching seal lips. Failure to follow this caution may result in damage to equipment.
NOTE
Coat all internal parts with clean hydraulic oil before assembling. 2. 3. Install new rod seal (Figure 9, Item 4) and new rod wiper (Figure 9, Item 5) inside gland (Figure 9, Item 3). Install new back-up ring (Figure 9, Item 2) and new o-ring (Figure 9, Item 1) on outside diameter of gland (Figure 9, Item 3).
3 4 5
M0433105
Figure 9.
Boom Hoist Cylinder Assembly.
0149-9
TM 5-3810-305-23
0149
ASSEMBLY - Continued 4. Install new o-ring (Figure 10, Item 4) on inside diameter of piston (Figure 10, Item 3).
CAUTION
DO NOT allow piston seal to twist in seal groove. Failure to follow this caution may result in damage to equipment. 5. Install two new wear rings (Figure 10, Item 1), square expander ring (Figure 10, Item 2), and new piston seal (Figure 10, Item 5) on outside diameter of piston.
M0431105
Figure 10. 6. 7.
Install gland (Figure 11, Item 4) and piston (Figure 11, Item 2) on rod assembly (Figure 11, Item 1). Apply threadlock sealant to threads on rod assembly (Figure 11, Item 1). Install nut (Figure 11, Item 3) and tighten to 250 ft-lb (339 Nm).
0149-10
TM 5-3810-305-23
0149
1 2
M0431105
Figure 11. 8. 9.
Install assembled rod assembly (Figure 12, Item 2) in cylinder tube (Figure 12, Item 3). Screw gland (Figure 12, Item 1) in cylinder tube. Tighten with spanner wrench. Push rod assembly (Figure 12, Item 2) all the way into cylinder tube (Figure 12, Item 3).
2 3
M0430105
0149-11
TM 5-3810-305-23
0149
INSTALLATION 1. Install two new o-rings (Figure 13, Item 11) on adapters (Figure 13, Item 3). Position hold valve and four new o-rings (Figure 13, Item 10) on boom hoist cylinder (Figure 13, Item 2) and install four new lockwashers (Figure 13, Item 9), capscrews (Figure 13, Item 8), and two adapters.
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. Raise boom to 30 degrees using suitable lifting equipment.
WARNING
Weight of boom hoist cylinder is approximately 507 lb (230 kg). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. 5. 6. Secure boom cylinder (Figure 13, Item 1) in suitable lifting device. Lift and position boom hoist cylinder in upperstructure. Install pin (Figure 13, Item 7), rod (Figure 13, Item 6), new lockwasher (Figure 13, Item 5), and capscrew (Figure 13, Item 4) cylinder end of boom hoist cylinder (Figure 13, Item 1). Apply threadlock sealant to hoses (Figure 13, Item 2) and adapters (Figure 13, Item 3). Install hoses (Figure 13, Item 2) to adapters (Figure 13, Item 3) at a 50 degree angle up from the long axis of the boom hoist cylinder (Figure 13, Item 1).
0149-12
TM 5-3810-305-23
0149
1 4,5 6 2 3 10 7 8,9
3,11
M0428105
Figure 13.
Boom Hoist Cylinder Installation.
0149-13
TM 5-3810-305-23
0149
WARNING
Stay clear of boom hoist cylinder rod while extending and retracting to remove air. Serious injury to personnel may result if rod jumps unexpectedly. 7. 8. 9. Close dipstick cap. Start engine and slowly extend boom hoist cylinder (Figure 14, Item 4) rod two times to remove air trapped in cylinder. Then extend boom hoist cylinder rod to attachment point and shut engine OFF. Install pin (Figure 14, Item 5), rod eye (Figure 14, Item 3), new lockwasher (Figure 14, Item 2), and capscrew (Figure 14, Item 1) to secure rod end boom hoist cylinder (Figure 14, Item 4). Remove supports from boom hoist cylinder (Figure 14, Item 4).
1,2
5 4
M0427105
Boom Hoist Cylinder Installation.
0149-14
TM 5-3810-305-23
0149
0149-15/16 blank
TM 5-3810-305-23
0150
FIELD MAINTENANCE BOOM EXTEND CYLINDER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Packing Assortment (WP 0172, Table 1, Item 172) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom removed and disassembled (WP 0156) Battery cables disconnected (WP 0076)
DISASSEMBLY 1. 2. Remove grease fitting (Figure 1, Item 1). Position suitable container under counterbalance valve (Figure 1, Item 2) area and remove counterbalance valve and plug (Figure 1, Item 3).
1 2
3
M0416105
Figure 1.
Boom Extend Cylinder Disassembly.
0150-1
TM 5-3810-305-23
0150
DISASSEMBLY - Continued 3. 4. Pull rod assembly (Figure 2, Item 4) half way out of cylinder case (Figure 2, Item 1). Place support under outer end of rod assembly (Figure 2, Item 4).
CAUTION
Head gland should unscrew freely. If, after several turns, a bind is noticed, STOP: DO NOT FORCE THREADS. Place a C" clamp over threaded end of cylinder case in line with port tube. Gradually draw down C" clamp until head gland can be unscrewed easily. The reason for an occasional bind is due to the fact that heat generated from welding of port tube to cylinder case may cause a slight cylinder case eccentricity. This most generally occurs when boom extend cylinder has been in service for only a short period of time. Extended service stress relieves the weld and improves concentricity. This caution can be used in reassembly if a bind occurs when installing head gland. Failure to follow this caution may result in damage to equipment. 5. 6. Remove setscrew (Figure 2, Item 2) from cylinder case (Figure 2, Item 1). Remove head gland (Figure 2, Item 3) from cylinder case (Figure 2, Item 1).
NOTE
Be sure head gland threads are fully disengaged from cylinder case threads. 7. Pull assembled rod assembly (Figure 2, Item 4) out, gently bumping head gland (Figure 2, Item 3), forcing head gland out of cylinder case (Figure 2, Item 1).
2 3
M0417105
Figure 2.
0150-2
TM 5-3810-305-23
0150
CAUTION
Once head gland has cleared cylinder case mouth, rod assembly must be supported close to cylinder case prior to piston being pulled past cylinder case threads to avoid damage to cylinder case threads and/or piston seals. 8. 9. 10. Pull rod assembly (Figure 3, Item 4) completely out of cylinder case (Figure 3, Item 3). Remove two setscrews (Figure 3, Item 1) from buttress ring nut (Figure 3, Item 2). Remove buttress ring nut (Figure 3, Item 2).
1 2
M0418105
Figure 3.
0150-3
TM 5-3810-305-23
0150
DISASSEMBLY - Continued 11. Remove piston (Figure 4, Item 1) from rod assembly (Figure 4, Item 2).
2
M0419105
Figure 4.
0150-4
TM 5-3810-305-23
0150
NOTE
Piston seal and o-ring should be cut to ease disassembly. 12. Remove wear ring (Figure 5, Item 2), o-ring (Figure 5, Item 4), piston seal (Figure 5, Item 3), and piston ring (Figure 5, Item 5) from piston (Figure 5, Item 1). Discard wear ring, o-ring, and piston seal.
1 2 3 4 5
M0420105
Figure 5.
0150-5
TM 5-3810-305-23
0150
DISASSEMBLY - Continued 13. Remove two back-up rings (Figure 6, Item 2) and o-ring (Figure 6, Item 3) from piston (Figure 6, Item 1). Discard o-ring and back-up rings.
1 2
3
M0421105
Figure 6. 14.
Remove spacer (Figure 7, Item 1) from rod assembly (Figure 7, Item 2).
2 1
M0422105
Figure 7.
0150-6
TM 5-3810-305-23
0150
DISASSEMBLY - Continued 15. Remove head gland (Figure 8, Item 1) from rod assembly (Figure 8, Item 2).
M0423105
Figure 8. 16.
Remove back-up ring (Figure 9, Item 2) and o-ring (Figure 9, Item 1) from head gland (Figure 9, Item 3). Discard back-up ring and o-ring.
2 3
M0424105
Figure 9.
0150-7
TM 5-3810-305-23
0150
DISASSEMBLY - Continued 17. Remove wiper (Figure 10, Item 3) and U-cup seal (Figure 10, Item 2) from head gland (Figure 10, Item 1). Discard wiper and U-cup seal.
1 2 3
M0425105
Figure 10. Boom Extend Cylinder Disassembly. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0150-8
TM 5-3810-305-23
0150
ASSEMBLY
CAUTION
Two seal lips of U-cup seal must point toward inside of cylinder case, and wiper seal lips must point toward outside of cylinder case. Use care to avoid nicking or scratching seal lips. Failure to follow this caution may result in damage to equipment.
NOTE
Lubricate all parts with clean hydraulic oil. 1. 2. 3. Install new U-cup seal (Figure 10, Item 2) and wiper (Figure 10, Item 3) in head gland (Figure 10, Item 1). Install new back-up ring (Figure 11, Item 4) and new o-ring (Figure 11, Item 3) on head gland (Figure 11, Item 1) with new o-ring towards inside of cylinder case. Install head gland (Figure 11, Item 1) as an assembly on rod assembly (Figure 11, Item 2).
4 5
M0426105
Figure 11.
Boom Extend Cylinder Assembly.
0150-9
TM 5-3810-305-23
0150
ASSEMBLY - Continued 4. Install spacer (Figure 12, Item 1) on rod assembly (Figure 12, Item 2).
2 1
M0422105
Figure 12. Boom Extend Cylinder Assembly. 5. Install new o-ring (Figure 13, Item 3) and two new back-up rings (Figure 13, Item 2) in piston (Figure 13, Item 1).
1 2
3
M0421105
Figure 13. Boom Extend Cylinder Assembly.
0150-10
TM 5-3810-305-23
0150
CAUTION
DO NOT allow piston seal to twist" in seal groove. Failure to follow this caution may result in damage. 6. 7. Install new o-ring (Figure 14, Item 4) and new piston seal (Figure 14, Item 3) on piston (Figure 14, Item 1). Install new piston ring (Figure 14, Item 5) and new wear ring (Figure 14, Item 2) on piston (Figure 14, Item 1).
1 2 3 4 5
M0420105
Figure 14.
0150-11
TM 5-3810-305-23
0150
ASSEMBLY - Continued 8. Install piston (Figure 15, Item 1) as an assembly on rod assembly (Figure 15, Item 2).
2
M0419105
Figure 15. Boom Extend Cylinder Assembly.
0150-12
TM 5-3810-305-23
0150
ASSEMBLY - Continued 9. 10. Install and tighten buttress ring nut (Figure 16, Item 2) on rod assembly (Figure 16, Item 4). Install two setscrews (Figure 16, Item 1) on buttress ring nut (Figure 16, Item 2).
CAUTION
Use extreme caution in slipping piston and piston rings past cylinder mouth threads to avoid damage to piston seals or case threads. Make sure the outer end of cylinder threads are properly lubricated before attempting to screw head gland into cylinder case. Use caution to avoid cutting o-ring on head gland as it is slipped past threads and rod assembly in cylinder case. After boom cylinder extend has been assembled, rod assembly should be pushed all the way in (fully retracted) prior to the installation of counterbalance valve. Failure to follow these cautions may result in damage to equipment.
NOTE
Before attempting to start piston into cylinder case, carefully oil cylinder threaded area and piston. The mouth of cylinder case is chamfered immediately behind the threaded area to compress piston rings during assembly. It may be necessary to oscillate the outer end of cylinder rod to cause rings to compress as they enter the chamfered portion of cylinder case. 11. Install assembled rod assembly (Figure 16, Item 4) in cylinder case (Figure 16, Item 3).
1 2
M0418105
Figure 16.
0150-13
TM 5-3810-305-23
0150
ASSEMBLY - Continued 12. 13. Install head gland (Figure 17, Item 3) in cylinder case (Figure 17, Item 1). Tighten setscrew (Figure 17, Item 2) in cylinder case (Figure 17, Item 1).
2 3
M0417105
Figure 17. Boom Extend Cylinder Assembly. 14. 15. Install plug (Figure 18, Item 3) and counterbalance valve (Figure 18, Item 2). Install grease fitting (Figure 18, Item 1).
1 2
3
M0416105
Figure 18. Boom Extend Cylinder Assembly. END OF TASK
0150-14
TM 5-3810-305-23
0150
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Assemble and install boom (WP 0156). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0150-15/16 blank
TM 5-3810-305-23
0151
FIELD MAINTENANCE OUTRIGGER CYLINDER ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 17) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Wrench, Torque, 3/4 Inch Drive Ratcheting (600 ftlb) (WP 0171, Table 1, Item 34) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Liquid Nitrogen (WP 0170, Table 1, Item 49) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 2 Parts Kit, Seal Repl (WP 0172, Table 1, Item 123) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealant, Loctite 515 (WP 0170, Table 1, Item 58) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 165) Qty: 2 Washer, Lock M16 (WP 0172, Table 1, Item 130) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0151-1
TM 5-3810-305-23
0151
REMOVAL
WARNING
Do not use outriggers to support vehicle. Failure to follow this warning may result in serious injury or death to personnel.
NOTE
The following is a maintenance procedure for one outrigger cylinder assembly. The maintenance procedure for the remaining outrigger cylinder assemblies is identical. 1. 2. 3. 4. Support outrigger beam (Figure 1, Item 1) and outrigger cylinder assembly (Figure 1, Item 4) with suitable lifting device. Using a punch, remove pin (Figure 1, Item 3) by driving through pin (Figure 1, Item 2). Remove pin (Figure 1, Item 3) by driving pin through beam (Figure 1, Item 1). Start engine. Retract outrigger cylinder rod into outrigger cylinder assembly (Figure 1, Item 4). Shut engine OFF.
3 2
M0446105
Figure 1. Outrigger Cylinder Removal.
0151-2
TM 5-3810-305-23
0151
REMOVAL - Continued
WARNING
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 6. Remove two capscrews (Figure 2, Item 5), lockwashers (Figure 2, Item 4), hold valve (Figure 2, Item 3), and two o-rings (Figure 2, Item 2) from outrigger cylinder (Figure 2, Item 1). Discard lockwashers and o-rings.
3 4 5
4
M0447105
Figure 2.
Outrigger Cylinder Removal.
0151-3
TM 5-3810-305-23
0151
REMOVAL - Continued 7. 8. Remove capscrew (Figure 3, Item 2), lockwasher (Figure 3, Item 3), and rod end (Figure 3, Item 4). Discard lockwasher. Using a brass drift pin, remove pin (Figure 3, Item 5) by driving pin through frame, inside cab.
WARNING
Weight of outrigger cylinder assembly is approximately 125 lb (57 kg). Use adequate lifting equipment to lift and support outrigger cylinder assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 9. Using hoist and sling, remove outrigger cylinder assembly (Figure 3, Item 1).
4 3
2
M0448105
Figure 3. Outrigger Cylinder Removal. END OF TASK
0151-4
TM 5-3810-305-23
0151
DISASSEMBLY 1. 2. Remove gland (Figure 4, Item 2) from cylinder barrel (Figure 4, Item 3). Position containers under hold-valve mounting block and cylinder mouth to catch oil and slowly remove assembled rod (Figure 4, Item 1).
2 1 3
M0449105
Figure 4.
Outrigger Cylinder Disassembly.
0151-5
TM 5-3810-305-23
0151
WARNING
Heating nut to a temperature of approximately 300F (149C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling parts. Failure to follow this warning may cause injury to death to personnel. 3. 4. Remove retaining nut (Figure 5, Item 2). Remove piston (Figure 5, Item 3) and gland (Figure 5, Item 4) from rod (Figure 5, Item 1).
4
Figure 5.
M0450105
NOTE
Piston seal and expander ring should be cut to ease disassembly. 5. 6. Remove seal (Figure 6, Item 3), expander ring (Figure 6, Item 2), and two wear rings (Figure 6, Items 1 and 6) from outside of piston (Figure 6, Item 4). Discard seal and wear rings. Remove o-ring (Figure 6, Item 5) from inside of piston (Figure 6, Item 4). Discard o-rings.
0151-6
TM 5-3810-305-23
0151
M0451105
Figure 6. 7. 8.
Remove o-ring (Figure 7, Item 5) and back-up ring (Figure 7, Item 4) from outside of gland (Figure 7, Item 3). Discard o-ring and back-up ring. Remove rod wiper (Figure 7, Item 1) and poly-pak seal (Figure 7, Item 2) from inside of gland (Figure 7, Item 3). Discard rod wiper and poly-pak seal.
M0452105
Figure 7.
0151-7
TM 5-3810-305-23
0151
CAUTION
Removal of bushings may cause destruction of bushings. Remove bushings only if inspection indicates replacement is necessary. 9. 10. Inspect bushings. Replace if deemed necessary. Remove two bushings (Figure 8, Item 1) from base end of cylinder barrel (Figure 8, Item 2).
M0453105
Clean all parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect all parts IAW General Maintenance Instructions (WP 0162). END OF TASK
0151-8
TM 5-3810-305-23
0151
ASSEMBLY
NOTE
Coat all internal parts with clean hydraulic oil before assembly. 1. 2. Install new poly-pak seal (Figure 9, Item 2), with lips toward inside of cylinder and new rod wiper (Figure 9, Item 1), and with lip toward outside of cylinder, in gland (Figure 9, Item 3). Install back-up ring (Figure 9, Item 4) and new o-ring (Figure 9, Item 5) to outside of gland (Figure 9, Item 3).
M0452105
Figure 9.
Outrigger Cylinder Assembly.
0151-9
TM 5-3810-305-23
0151
CAUTION
DO NOT allow seal to twist" in seal groove. Failure to follow this caution may result in damage to equipment. 3. 4. Install two new wear rings (Figure 10, Items 1 and 6), expander ring (Figure 10, Item 2) and new seal (Figure 10, Item 3) to outside of piston (Figure 10, Item 4). Install new o-ring (Figure 10, Item 5) on inside of piston (Figure 10, Item 4).
M0451105
Figure 10.
0151-10
TM 5-3810-305-23
0151
ASSEMBLY - Continued 5. Install gland (Figure 11, Item 4), piston (Figure 11, Item 3), and retaining nut (Figure 11, Item 2) on rod (Figure 11, Item 1). Tighten nut to 400 ft-lb (542 Nm).
4
Figure 11. 6.
M0450105
Install assembled rod (Figure 12, Item 1) in cylinder barrel (Figure 12, Item 3) and secure gland (Figure 12, Item 2).
2 1 3
M0449105
Figure 12.
0151-11
TM 5-3810-305-23
0151
WARNING
NOTE
Cool bushings to -320F (-195C) by submerging bushings in liquid nitrogen before installing. 7. Submerge two bushings (Figure 13, Item 1), if removed, in liquid nitrogen to cool them.
M0453105
0151-12
TM 5-3810-305-23
0151
INSTALLATION
WARNING
Weight of outrigger cylinder assembly is approximately 125 lb (57 kg). Use adequate lifting equipment to lift and support outrigger cylinder assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. Using hoist and sling, install outrigger cylinder assembly (Figure 14, Item 1). Install pin (Figure 14, Item 5) through frame and outrigger cylinder assembly (Figure 14, Item 1). Install rod end (Figure 14, Item 4), new lockwasher (Figure 14, Item 3), and capscrew (Figure 14, Item 2).
4 3
2
M0448105
Figure 14.
Outrigger Cylinder Installation.
0151-13
TM 5-3810-305-23
0151
INSTALLATION - Continued 4. Position two new o-rings (Figure 15, Item 2) on hold valve (Figure 15, Item 3) and install with two new lockwashers (Figure 15, Item 4) and capscrews (Figure 15, Item 5) on outrigger cylinder (Figure 15, Item 1).
3 4 5
4
M0447105
Figure 15. 5. 6. 7.
Start engine. Extend outrigger cylinder rod to align outrigger cylinder rod end with beam. Check for leaks. Shut engine OFF. Install pin (Figure 16, Item 3) into pin (Figure 16, Item 2). Install pin (Figure 16, Item 2) and drive pin into beam (Figure 16, Item 1).
WARNING
Do not remove lifting device until hydraulic pressure has been built up. Failure to follow these warnings may result in damage to equipment or injury or death to personnel. 8. 9. Remove suitable lifting device supporting outrigger beam (Figure 16, Item 1) and outrigger cylinder assembly (Figure 16, Item 4). Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10).
0151-14
TM 5-3810-305-23
0151
3 2
M0446105
0151-15/16 blank
TM 5-3810-305-23
0152
FIELD MAINTENANCE AXLE LOCKOUT CYLINDER MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Leather (WP 0171, Table 1, Item 5) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 8 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0076 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10)
WARNING
0152-1
TM 5-3810-305-23
0152
REMOVAL
NOTE
The following is a maintenance procedure for one axle lockout cylinder assembly. The maintenance procedure for the remaining axle lockout cylinders assemblies is identical. 1. 2. 3. 4. Start engine, center boom over cab (TM 5-3810-305-10). Using outrigger, raise rear of carrier up until tire is off ground. Place jack stands under axle. Shut engine OFF (TM 5-3810-305-10). Disconnect battery cables (WP 0076). Open engine housing for access to cylinder hose fittings (TM 5-3810-305-10).
WARNING
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 5. 6. 7. 8. 9. 10. 11. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect and cap hydraulic hoses (Figure 1, Item 8) from elbows (Figure 1, Item 9). Support cylinder (Figure 1, Item 6). Remove two capscrews (Figure 1, Item 5) and washers (Figure 1, Item 4) from two pins (Figure 1, Item 3). Drive out top pin (Figure 1, Item 3). Remove two washers (Figure 1, Item 2) from each pin (Figure 1, Item 3). Remove cylinder (Figure 1, Item 6) from carrier (Figure 1, Item 7). Remove two elbows (Figure 1, Item 9) and two o-rings (Figure 1, Item 1) from cylinder (Figure 1, Item 6). Discard o-rings.
0152-2
TM 5-3810-305-23
0152
REMOVAL - Continued
1 2 3 4 5
6 9 8 7 2
3 4 5
M0319105
Figure 1.
Axle Lockout Cylinder Removal.
0152-3
TM 5-3810-305-23
0152
REMOVAL - Continued 12. Remove two grease fittings (Figure 2, Item 1) from barrel assembly (Figure 2, Item 2).
1 2
M2310105
Axle Lockout Cylinder Removal.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and lowtoxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel. 1. Clean all parts and surfaces with solvent cleaning compound IAW General Maintenance Instructions (WP 0162).
0152-4
TM 5-3810-305-23
0152
CLEANING - Continued
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. Failure to follow this warning may result in injury to personnel. 2. Dry parts with compressed air.
END OF TASK INSPECTION 1. 2. 3. Inspect parts for wear, burrs, nicks, and corrosion IAW General Maintenance Instructions (WP 0162). Replace worn or damaged parts. Polish metal surfaces having minor blemishes with fine crocus cloth. Coat all parts with clean hydraulic oil.
END OF TASK INSTALLATION 1. Install two grease fittings (Figure 3, Item 1) into barrel assembly (Figure 3, Item 2).
1 2
M2310105
Figure 3.
Axle Lockout Cylinder Installation.
0152-5
TM 5-3810-305-23
0152
INSTALLATION - Continued 2. 3. 4. Install two new o-rings (Figure 4, Item 1) and two elbows (Figure 4, Item 10) on cylinder (Figure 4, Item 7). Set cylinder (Figure 4, Item 7) into position onto carrier (Figure 4, Item 8). Align cylinder (Figure 4, Item 7) bottom mounting holes with carrier (Figure 4, Item 8). Install one of two washers (Figure 4, Item 3), pin (Figure 4, Item 4), and remaining washer. Secure pin with washer (Figure 4, Item 5) and capscrew (Figure 4, Item 6). Align remaining cylinder (Figure 4, Item 7) mounting hole with carrier. Install one washer (Figure 4, Item 3), pin (Figure 4, Item 4), and remaining washer. Secure with washer and capscrew (Figure 4, Item 6). Connect hydraulic hoses (Figure 4, Item 9). Close dipstick cap and start engine. Slightly open bleeder screw (Figure 4, Item 2) to bleed air from axle lockout cylinders. Check for leaks.
5. 6. 7.
4 5 6
10 9 3 8
6
M0321105
Figure 4.
Axle Lockout Cylinder Installation.
0152-6
TM 5-3810-305-23
0152
WARNING
Do not remove lifting device until hydraulic pressure has been built up. Failure to follow these warnings may result in damage to equipment or injury or death to personnel. 8. 9. 10. Remove jack stands supporting axle and lower carrier to ground using outrigger. Shut engine OFF (TM 5-3810-305-10). Check hydraulic oil level. If necessary, fill to proper level (TM 5-3810-305-10). Check for proper operation.
0152-7/8 blank
TM 5-3810-305-23
0153
FIELD MAINTENANCE HYDRAULIC RESERVOIR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Filter Element (WP 0172, Table 1, Item 27) Qty: 1 Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 8 Nut, Self-Locking He M12 (WP 0172, Table 1, Item 133) Qty: 4 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 35) Qty: 1 O-Ring (WP 0172, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 2 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 96) Qty: 1 O-Ring (WP 0172, Table 1, Item 120) Qty: 1 O-Ring (WP 0172, Table 1, Item 121) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References WP 0144 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom on right side of carrier (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Deck plate removed (TM 5-3810-305-10) Return filter assembly removed (WP 0148) Hydraulic system valve bank removed (WP 0146)
REMOVAL
WARNING
0153-1
TM 5-3810-305-23
0153
REMOVAL - Continued
CAUTION
NOTE
Tag hoses prior to removal to ensure correct installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Hydraulic reservoir capacity is 23.8 gal. (90.1 L). 1. 2. 3. 4. Turn dipstick cap 1/4 turn to safety to relieve pressure. Remove drain plug (Figure 1, Item 2) and o-ring (Figure 1, Item 3). Discard o-ring. Drain hydraulic reservoir (Figure 1, Item 4) into suitable container. Remove two clamps (Figure 1, Item 1) and hose (Figure 1, Item 5) from hydraulic reservoir (Figure 1, Item 4) and drain any hydraulic fluid in hose into suitable container.
2,3
4 5
M0336105
Figure 1. Hydraulic Reservoir Removal. 5. 6. 7. Disconnect hose (Figure 2, Item 11), elbow (Figure 2, Item 10), and o-ring (Figure 2, Item 9). Discard o-ring. Remove nipple (Figure 2, Item 4), o-rings (Figure 2, Item 5), and dust cap (Figure 2, Item 6). Discard o-rings. Remove four locknuts (Figure 2, Item 8), washers (Figure 2, Item 7), two capscrews (Figure 2, Item 1), and washers (Figure 2, Item 2) on reservoir (Figure 2, Item 3).
0153-2
TM 5-3810-305-23
0153
REMOVAL - Continued
1,2
4,5,6
9,10,11
7,8
M0337105
Figure 2. 8.
Hydraulic Reservoir Removal.
Remove nipple (Figure 3, Item 1), o-ring (Figure 3, Item 2), dust cap (Figure 3, Item 3), and dipstick cap (Figure 3, Item 4) from reservoir. Discard o-ring.
1,2,3
M0338105
Figure 3.
Hydraulic Reservoir Removal.
0153-3
TM 5-3810-305-23
0153
REMOVAL - Continued 9. Remove eight locknuts (Figure 4, Item 1), washers (Figure 4, Item 2), plug (Figure 4, Item 3), o-ring (Figure 4, Item 4), cover (Figure 4, Item 5), o-ring (Figure 4, Item 6), filter (Figure 4, Item 7), and o-ring (Figure 4, Item 8) from reservoir (Figure 4, Item 1). Discard o-rings.
3,4 1,2
7,8
M0339105
Figure 4. Hydraulic Reservoir Removal.
WARNING
NOTE
Weight of hydraulic reservoir is approximately 190 lb (86 kg). 10. Using suitable hoist and sling, lift hydraulic reservoir (Figure 5, Item 4) from vehicle and place on a suitable surface.
0153-4
TM 5-3810-305-23
0153
WARNING
NOTE
Weight of hydraulic reservoir is approximately 190 lb (86 kg). 1. 2. Using suitable hoist and sling, lift and position hydraulic reservoir (Figure 5, Item 4) in carrier. Install eight locknuts (Figure 5, Item 1), washers (Figure 5, Item 2), plug (Figure 5, Item 3), new o-ring (Figure 5, Item 4), cover (Figure 5, Item 5), new o-ring (Figure 5, Item 6), filter (Figure 5, Item 7), and new o-ring (Figure 5, Item 8) from reservoir.
3,4 1,2
7,8
M0339105
Figure 5.
Hydraulic Reservoir Installation.
0153-5
TM 5-3810-305-23
0153
INSTALLATION - Continued 3. Install nipple (Figure 6, Item 1), new o-ring (Figure 6, Item 2), dust cap (Figure 6, Item 3), and dipstick cap (Figure 6, Item 4) on reservoir.
1,2,3
M0338105
Figure 6. 4. 5. 6.
Install washers (Figure 7, Item 2), two capscrews (Figure 7, Item 1), washers (Figure 7, Item 7), and four locknuts (Figure 7, Item 8) from reservoir (Figure 7, Item 3). Install nipple (Figure 7, Item 4), new o-ring (Figure 7, Item 5), and dust cap (Figure 7, Item 6). Install hose (Figure 7, Item 11), elbow (Figure 7, Item 10), and new o-ring (Figure 7, Item 9).
0153-6
TM 5-3810-305-23
0153
1,2
4,5,6
9,10,11
7,8
M0337105
Figure 7. 7. 8. 9.
Install two clamps (Figure 8, Item 1) and hose (Figure 8, Item 5) onto hydraulic reservoir (Figure 8, Item 4). Install drain plug (Figure 8, Item 2) and new o-ring (Figure 8, Item 3). Install dipstick cap.
2,3
4 5
M0336105
0153-7
TM 5-3810-305-23
0153
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install hydraulic system valve bank (WP 0146). Install return filter assembly (WP 0148). Install deck plates (TM 5-3810-305-10). Connect battery cables (WP 0076). Fill reservoir to proper level (TM 5-3810-305-10). Bleed air from suction filter housing (WP 0144). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0153-8
TM 5-3810-305-23
0154
FIELD MAINTENANCE BOOM ANGLE INDICATOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, 1/2 Inch Drive (345 Nm) (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 37) Qty: 1 Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 4 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite RC 680 (WP 0170, Table 1, Item 61) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)
0154-1
TM 5-3810-305-23
0154
REMOVAL 1. Remove locknut (Figure 1, Item 3), pendulum (Item 1, Figure 5), and spacer (Figure 1, Item 4) from bracket (Figure 1, Item 6). Discard locknut.
NOTE
Do not remove cam follower unless damaged. 2. 3. 4. Inspect cam follower (Figure 1, Item 7), if damaged, remove and replace. If necessary, remove cam follower (Figure 1, Item 7) by pressing it out of bracket (Figure 1, Item 6). Remove four locknuts (Figure 1, Item 2), bracket (Figure 1, Item 6), and strip (Figure 1, Item 1) from boom. Discard locknuts.
5 6
M0595105
Boom Angle Indicator Removal.
0154-2
TM 5-3810-305-23
0154
INSTALLATION 1. 2. 3. Install strip (Figure 2, Item 1), bracket (Figure 2, Item 6), and four new locknuts (Figure 2, Item 2) onto boom. If removed, apply threadlock compound to cam follower (Figure 2, Item 7) and press into bracket (Figure 2, Item 6) until the stud end of cam follower is 0.03 inch (0.8 mm) below the surface of bracket. Install spacer (Figure 2, Item 4), pendulum (Figure 2, Item 5), and new locknut (Figure 2, Item 3) on bracket (Figure 2, Item 6). Tighten locknut to 21 ft-lb (28 Nm).
5 6
M0595105
Boom Angle Indicator Installation.
Place boom in resting position (TM 5-3810-305-10) Check for proper operation.
0154-3/4 blank
TM 5-3810-305-23
0155
FIELD MAINTENANCE HOOK BLOCK MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Wrench, Torque, Click, 1/2 Inch Drive (345 Nm) (WP 0171, Table 1, Item 35) Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 134) Qty: 3 Nut, Self-Locking He (WP 0172, Table 1, Item 52) Qty: 1 Pin, Cotter (WP 0172, Table 1, Item 161) Qty: 1 Materials/Parts (cont.) Primer, Sealing Compound Loctite 7471 (WP 0170, Table 1, Item 51) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Hook block removed (TM 5-3810-305-10)
0155-1
TM 5-3810-305-23
0155
DISASSEMBLY
WARNING
Weight of hook block is approximately 235 lb (107 kg). Use adequate lifting equipment to lift and support hook block. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. Remove three locknuts (Figure 1, Item 4), cotter pin (Figure 1, Item 1) from cable side plate (Figure 1, Item 5). Discard cotter pin and locknuts. Separate cable side plate (Figure 1, Item 2) from cable side plate (Figure 1, Item 5). Remove three tubes (Figure 1, Item 3) from cable side plate (Figure 1, Item 5).
4
M0620105
Figure 1. Hook Block Disassembly.
0155-2
TM 5-3810-305-23
0155
DISASSEMBLY - Continued 4. 5. 6. 7. 8. 9. 10. Remove two spacers (Figure 2, Item 11), washers (Figure 2, Item 12), sheaves (Figure 2, Item 13), and shaft (Figure 2, Item 2) from cable side plate (Figure 2, Item 1). Remove grease fitting (Figure 2, Item 14) from sheave (Figure 2, Item 13). Press bushing (Figure 2, Item 10) out of sheave (Figure 2, Item 13), if necessary. Remove locknut (Figure 2, Item 4), thrust bearing (Figure 2, Item 5), trunnion (Figure 2, Item 7), grease fitting (Figure 2, Item 8), and latch kit (Figure 2, Item 9) from hook (Figure 2, Item 10). Discard locknut. Remove trunnion (Figure 2, Item 7) and hook (Figure 2, Item 10) as an assembly. Press bushing (Figure 2, Item 6) out of trunnion (Figure 2, Item 7), if necessary. Remove three capscrews (Figure 2, Item 3) from cable side plate (Figure 2, Item 1).
2 12 13 10 12 11 4 5 6 10 7 8 9
M0621105
11 3
14
Hook Block Disassembly.
0155-3
TM 5-3810-305-23
0155
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY
WARNING
Weight of hook block is approximately 235 lb (107 kg). Use adequate lifting equipment to lift and support hook block. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. Clean bushing (Figure 3, Item 6) and trunnion (Figure 3, Item 7) with primer compound and allow to dry. Apply threadlock compound and press bushing into trunnion.
CAUTION
Thrust bearing must be installed with sheet metal cover down against trunnion. Failure to follow this caution may result in damage to equipment. 2. 3. Install latch kit (Figure 3, Item 9), grease fitting (Figure 3, Item 8), trunnion (Figure 3, Item 7), and thrust bearing (Figure 3, Item 5) on hook (Figure 3, Item 10). Apply primer compound to hook (Figure 3, Item 10) and locknut (Figure 3, Item 4) threads and allow to dry. Apply threadlock compound to hook threads and install new locknut on hook. Tighten new locknut until the machined shoulder on hook is approximately 0.12 inch (3.0 mm) away from bottom of trunnion (Figure 3, Item 7). Do not pull hook tight against trunnion. Install three capscrews (Figure 3, Item 3) in cable side plate (Figure 3, Item 1). Install trunnion (Figure 3, Item 7) and hook (Figure 3, Item 10) as an assembly. Install bushing (Figure 3, Item 10) and grease fitting (Figure 3, Item 14) in sheave (Figure 3, Item 13). Install shaft (Figure 3, Item 2), two spacers (Figure 3, Item 11), washers (Figure 3, Item 12), and sheaves (Figure 3, Item 13) on cable side plate (Figure 3, Item 1).
4. 5. 6. 7.
0155-4
TM 5-3810-305-23
0155
2 12 13 10 12 11 4 5 6 10 7 8 9
M0621105
11 3
14
Figure 3.
Hook Block Assembly.
0155-5
TM 5-3810-305-23
0155
ASSEMBLY - Continued 8. 9. Install three tubes (Figure 4, Item 3) on cable side plate (Figure 4, Item 2). Install cable side plate (Figure 4, Item 5), new cotter pin (Figure 4, Item 1) and three new locknuts (Figure 4, Item 4) to cable side plate (Figure 4, Item 2). Torque nuts to 50 ft-lb (68 Nm).
4
M0620105
Figure 4. Hook Block Assembly. END OF TASK FOLLOW-ON MAINTENANCE Install hook block (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
0155-6
TM 5-3810-305-23
0156
FIELD MAINTENANCE BOOM ASSEMBLY MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Liquid Nitrogen (WP 0170, Table 1, Item 49) Nut, Self-Locking, He M30 (WP 0172, Table 1, Item 135) Qty: 2 O-Ring Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Tag, Marker (WP 0170, Table 1, Item 68) Materials/Parts (cont.) Washer, Lock 24M (WP 0172, Table 1, Item 128) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 1 Personnel Required (Two) References TM 5-3810-305-10 WP 0076 WP 0082 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Hook block assembly removed (WP 0155)
0156-1
TM 5-3810-305-23
0156
REMOVAL
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. 4. 5. Start engine. Take up cable on winch, maintaining tension on cable at all times. Place carrier upon outriggers. Shut engine OFF (TM 5-3810-305-10). Disconnect battery negative ground cable (WP 0076). Tag and disconnect electrical wiring (Figure 1, Item 1) from boom base, and insulate electrical connectors. Connect battery negative ground cable (WP 0076).
M0616105
Figure 1. Boom Assembly Removal.
WARNING
0156-2
TM 5-3810-305-23
0156
REMOVAL - Continued 7. 8. Turn ignition switch ON. Bleed pressure from boom extend cylinder by operating boom telescope lever. Disconnect two hydraulic hoses (Figure 2, Item 1) from boom extend cylinder.
M0617105
Figure 2. 9.
Boom Assembly Removal.
Close dipstick cap. Start engine. Elevate boom to 10 degrees to allow for placement of suitable bracing material under boom hoist cylinder.
WARNING
Weight of boom hoist cylinder is approximately 507 lb (230 kg). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
0156-3
TM 5-3810-305-23
0156
REMOVAL - Continued 10. Place suitable bracing material to support boom hoist cylinder. Hold anti-two block BY-PASS switch down and lower boom hoist cylinder onto suitable bracing material. Shut engine OFF (TM 5-3810-305-10).
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
CAUTION
Use webbing or wire mesh slings to prevent damage of boom. If chain or cables are used, boom must be protected. Failure to follow this caution may result in damage to equipment. 11. Attach lifting device to boom, making sure slings are placed for equal weight distribution. Take up slack.
M2314105
Figure 3.
0156-4
TM 5-3810-305-23
0156
REMOVAL - Continued 12. Remove capscrew (Figure 4, Item 1) lockwasher (Figure 4, Item 2), rod (Figure 4, Item 4), and pin (Figure 4, Item 5) from boom hoist cylinder (Figure 4, Item 3) at boom. Discard lockwasher.
5 4 3
M0618105
Figure 4.
0156-5
TM 5-3810-305-23
0156
REMOVAL - Continued 13. Start engine. Retract boom hoist cylinder rod by pushing boom hoist lever and holding anti-two block BY-PASS switch. Cylinder rod must clear attachment point on boom. Shut engine OFF (TM 5-3810-305-10).
NOTE
Record number of shims during removal to aid in installation. 14. 15. Remove capscrew (Figure 5, Item 1), lockwasher (Figure 5, Item 6), rod (Figure 5, Item 4), boom base pin (Figure 5, Item 3), and shims (Figure 5, Item 2). Discard lockwasher. Lift boom (Figure 5, Item 5) off carrier with lifting device and lower onto support.
2 1 3 4
M0619105
Figure 5. Boom Assembly Removal. END OF TASK
0156-6
TM 5-3810-305-23
0156
DISASSEMBLY 1. 2. Remove boom electrical (WP 0002). Remove four locknuts (Figure 6, Item 1) and boom angle indicator and strip (Figure 6, Item 2).
2
M2430105
Figure 6. 3.
Boom Assembly Disassembly.
Remove capscrew (Figure 7, Item 1), rod end (Figure 7, Item 2), and pin (Figure 7, Item 3) from upperstructure (base) end of boom extend cylinder.
2 3
M2431105
Figure 7.
0156-7
TM 5-3810-305-23
0156
WARNING
Weight of boom tip section is approximately 1,500 lb (680 kg). Use adequate lifting equipment to lift and support boom tip section. Do not lift over personnel or let personnel walk underneath suspended load. Failure to follow this procedure could cause DEATH or serious injury. 4. 5. Slide boom tip section with boom extend cylinder out of boom base section. Remove snap ring (Figure 8, Item 1) and pin (Figure 8, Item 2).
2 1
M2432105
Figure 8. 6.
Remove two capscrews (Figure 9, Item 1) and wear bar (Figure 9, Item 2).
2
M2433105
Figure 9.
0156-8
TM 5-3810-305-23
0156
WARNING
Weight of boom extend cylinder is approximately 415 lb (188 kg). Use adequate lifting equipment to lift and support boom extend cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. Remove boom extend cylinder (Figure 10, Item 3) from rear of boom tip section. Remove two grease fittings (Figure 10, Item 2) and two bushings (Figure 10, Item 1) from boom base section, if inspection proves necessary.
1 2 2
3
Figure 10. Boom Assembly Disassembly.
M2434105
0156-9
TM 5-3810-305-23
0156
NOTE
Record the number of shims removed to aid in assembly. 9. Remove 10 capscrews (Figure 11, Item 2), six capscrews (Figure 11, Item 5), 16 washers (Figure 11, Item 4), shims (Figure 11, Item 1), five small pads (Figure 11, Item 3) and two large wear pads (Figure 11, Item 6) from end of boom tip. Inspect pads (Figure 11, Items 3 and 6) and replace if worn.
2 1
6 5 4 1
3
4 2 1
M2435105
0156-10
TM 5-3810-305-23
0156
DISASSEMBLY - Continued 10. Remove eight capscrews (Figure 12, Item 6), six capscrews (Figure 12, Item 3), 14 washers (Figure 12, Item 2), shims (Figure 12, Item 5), four spacers (Figure 12, Item 7), small pads (Figure 12, Item 1) and two large wear pads (Figure 12, Item 4) from front end of boom base. Inspect pads (Figure 12, Items 1 and 4) and replace if worn.
6 2
2
M2436105
Figure 12. 11.
Remove four capscrews (Figure 13, Item 1), washers (Figure 13, Item 3) and two small pads (Figure 13, Item 2) from boom extend cylinder.
1 2 3
M2437105
Figure 13.
0156-11
TM 5-3810-305-23
0156
DISASSEMBLY - Continued 12. 13. Remove six hair pin cotters (Figure 14, Item 4) and three cable retaining pins (Figure 14, Item 5) from boom tip. Remove four grease fittings (Figure 14, Item 3), two lock nuts (Figure 14, Item 1), boom pins (Figure 14, Item 2), three sheaves (Figure 14, Item 6), two spacer washers (Figure 14, Item 7) and tube (Figure 14, Item 8) from boom tip.
7,8 6
5 4
M2438105
Figure 14. Boom Assembly Disassembly. 14. Remove two cotter pins (Figure 15, Item 2), two plain washers (Figure 15, Item 3) and bracket (Figure 15, Item 1) from top of boom base section.
M2439105
0156-12
TM 5-3810-305-23
0156
DISASSEMBLY - Continued 15. Remove two tubes (Figure 16, Item 1) and elbows and o-rings (Figure 16, Item 2) from boom extend cylinder.
2
M2410105
0156-13
TM 5-3810-305-23
0156
INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect boom pads. Minimum thickness is 0.31 inches (7.9 mm). Inspect wear bar. If wear bar is worn more than 0.25 inches (6.4 mm), replace wear bar. Inspect boom hoist cylinder pin. Minimum O.D. is 2.474 inches (62.84 mm). If O.D. is less than limit, replace pin. Inspect boom hoist cylinder pin bushing. Maximum I.D. is 2.543 inches (64.59 mm). If I.D. is greater than limit, replace bushing. Inspect relax boom extend cylinder pin. Minimum O.D. is 1.700 inches (43.18 mm). If O.D. is less than limit, replace pin. Inspect front boom extend cylinder pin. Minimum O.D. is 1.450 inches (36.83 mm). If O.D. is less than limit, replace pin. Inspect boom base pin. Minimum O.D. is 2.738 inches. (69.55 mm). If O.D. is less than limit replace pin. Inspect boom sheave pins. Minimum O.D. is 1.174 inches. (37.44 mm). If O.D. is less than limit replace pins. Inspect boom tip sheave bushing. Maximum I.D. is 1.519 inches. (38.58 mm). If I.D. is greater than limit, replace bushing. lnspect boom base pin bushing. Maximum I.D. is 2.784 inches. (70.71 mm). If I.D. is greater than limit, replace bushing.
END OF TASK ASSEMBLY 1. 2. Install bracket (Figure 17, Item 1), two washers (Figure 17, Item 3) and cotter pins (Figure 17, Item 2) on top of boom tip section. Install tube (Figure 17, Item 8), two spacer washers (Figure 17, Item 7), three sheaves (Figure 17, Item 6), two boom pins (Figure 17, Item 2), lock nuts (Figure 17, Item 1) and four grease fittings (Figure 17, Item 3) on boom tip. Install three cable retaining pins (Figure 17, Item 5) and six hair pin cotters (Figure 17, Item 4) in boom tip.
3.
0156-14
TM 5-3810-305-23
0156
7,8 6
5 4
M2438105
Figure 17. 4.
Boom Assembly Assembly.
Install two small pads (Figure 18, Item 2), four washers (Figure 18, Item 3) and capscrews (Figure 18, Item 1) to boom extend cylinder.
1 2 3
M2437105
Figure 18.
0156-15
TM 5-3810-305-23
0156
NOTE
Install same number of shims recorded in disassembly. 5. Install two large wear pads (Figure 19, Item 4), four small pads (Figure 19, Item 1), spacers (Figure 19, Item 7), shims (Figure 19, Item 5), 14 washers (Figure 19, Item 2), six capscrews (Figure 19, Item 3) and eight capscrews (Figure 19, Item 6) to front end of boom base.
6 2
2
M2436105
Figure 19. Boom Assembly Assembly.
0156-16
TM 5-3810-305-23
0156
ASSEMBLY - Continued 6. Install two large wear pads (Figure 20, Item 6), five small pads (Figure 20, Item 3), shims (Figure 20, Item 1), 16 washers (Figure 20, Item 4), six capscrews (Figure 20, Item 5) and 10 capscrews (Figure 20, Item 2).
2 1
6 5 4 1
3
4 2 1
M2435105
Figure 20.
0156-17
TM 5-3810-305-23
0156
WARNING
NOTE
Cool bushings to -320F (-195C) by submerging bushings in liquid nitrogen. 7. Submerge two bushings (Figure 21, Item 1) in liquid nitrogen to cool them.
1 2 2
3
M2434105
0156-18
TM 5-3810-305-23
0156
ASSEMBLY - Continued 8. 9. 10. If removed, using a press, install two bushings (Figure 22, Item 1) in base boom section. Install two grease fittings (Figure 22, Item 2). Install two o-rings and elbows (Figure 22, Item 4) and tubes (Figure 22, Item 1) on boom extend cylinder.
2
M2411105
Figure 22.
0156-19
TM 5-3810-305-23
0156
WARNING
Weight of boom extend cylinder is approximately 415 lb (188 kg). Use adequate lifting equipment to lift and support boom extend cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 11. Install boom extend cylinder (Figure 23, Item 3) in boom tip section.
1 2 2
3
Figure 23. Boom Assembly Assembly. 12. Install wear bar (Figure 24, Item 3) and two capscrews (Figure 24, Item 2).
M2434105
0156-20
TM 5-3810-305-23
0156
2
M2411105
Figure 24. 13.
Install pin (Figure 25, Item 2) and snap ring (Figure 25, Item 1).
M2412105
Figure 25.
0156-21
TM 5-3810-305-23
0156
WARNING
Weight of boom tip section is approximately 1,500 lb (680 kg). Use adequate lifting equipment to lift and support boom tip section. Do not lift over personnel or let personnel walk underneath suspended load. Failure to follow this procedure could cause DEATH or serious injury. 14. 15. Slide boom tip section with boom extend cylinder into boom base section. Install pin (Figure 26, Item 2), rod end (Figure 26, Item 3) and capscrew (Figure 26, Item 1).
M2413105
Figure 26. Boom Assembly Assembly. 16. Install boom angle indicator (Figure 27, Item 2) and four lock nuts (Figure 27, Item 1).
2
M2414105
0156-22
TM 5-3810-305-23
0156
ASSEMBLY - Continued 17. Install boom electrical (WP 0082).
END OF TASK INSTALLATION
WARNING
Weight of boom is approximately 3,100 lb (1,406 kg). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. Attach lifting device to boom making certain slings are placed for equal weight distribution. Take up slack and raise boom to upperstructure.
M2314105
Figure 28.
Boom Assembly Installation.
0156-23
TM 5-3810-305-23
0156
INSTALLATION - Continued 2. Align boom (Figure 29, Item 5) so that pivot holes match pivot holes in upperstructure. Install shims (Figure 29, Item 2), boom base pin (Figure 29, Item 3), rod (Figure 29, Item 4), new lockwasher (Figure 29, Item 6), and capscrew (Figure 29, Item 1).
2 1 3 4
M0619105
Figure 29. Boom Assembly Installation.
WARNING
Weight of boom hoist cylinder is approximately 507 lb (230 kg). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. Start engine. Extend boom hoist cylinder rod by pulling boom hoist lever. Align rod end with attachment point on boom. Shut engine OFF (TM 5-3810-305-10). Install pin (Figure 30, Item 5), rod (Figure 30, Item 4), new lockwasher (Figure 30, Item 2), and capscrew (Figure 30, Item 1) on boom hoist cylinder (Figure 30, Item 3).
0156-24
TM 5-3810-305-23
0156
3
Figure 30. 5. Boom Assembly Installation.
M0644105
Start engine. Raise boom 10 degrees and remove suitable bracing material. Hold anti-two block BY-PASS switch and lower boom. Shut engine OFF (TM 5-3810-305-10).
WARNING
0156-25
TM 5-3810-305-23
0156
INSTALLATION - Continued 7. Remove caps from hydraulic hoses and cylinder tubes. Install two hydraulic hoses (Figure 31, Item 1) to boom extend cylinder.
M0617105
Figure 31. Boom Assembly Installation. 8. Close dipstick cap.
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 9. Disconnect battery cables (WP 0076).
0156-26
TM 5-3810-305-23
0156
INSTALLATION - Continued 10. Connect electrical wiring (Figure 32, Item 1) to boom.
M0616105
Figure 32. 11. 12. 13. Connect battery cables (WP 0076).
Boom Assembly Installation.
Start engine. Take carrier off of outriggers (TM 5-3810-305-10). Push winch control lever and pay out cable over boom sheaves (TM 5-3810-305-10), maintaining tension on cable at all times. Shut engine OFF (TM 5-3810-305-10).
END OF TASK OTHER MAINTENANCE 1. 2. 3. 4. 5. Connect hook block assembly (WP 0155). Start engine (TM 5-3810-305-10). Check for hydraulic oil leaks. Shut engine OFF (TM 5-3810-305-10). Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10).
END OF TASK
0156-27
TM 5-3810-305-23
0156
ADJUSTMENT 1. 2. Level carrier using outriggers. Reeve cable on single part line over boom tip sheaves (TM 5-3810-305-10). Start engine. Fully extend boom and raise boom to the fully raised position. Lower hook block so that it is 5 ft (1.5 m) off the ground.
NOTE
This procedure may require a load. Use approximately 500 lb (227 kg). 3. Check hook block alignment. Adjust boom pads on sides of sections at front of lower section and rear of tip section so that cable is hanging within the width of lower boom section by adding or subtracting shims under pads. Lower boom fully. Stand at rear of boom and swing boom from side to side. Watch for side play between boom base section and boom tip section. If there is an appreciable amount of play between sections, boom tip will have to be reshimmed.
4.
NOTE
See Steps 9 through 11 in Disassembly for locations of pads. 5. If reshimming is required, check pad sets by measuring the gap between side wear pads and surface where pad slides on. Add the gaps on both sides of boom together for each set of pads which are directly opposite each other; the total gap should be 0.06 to 0.09 inch (1.5 to 2.3 mm) per set. Pad sets on front of boom base can be replaced without disassembling boom. To replace pad sets on boom extend cylinder and boom tip section, disassemble boom.
6. 7.
END OF TASK FOLLOW-ON-MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE
0156-28
TM 5-3810-305-23
0157
FIELD MAINTENANCE BOOM WORK LIGHT BRACKET MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Washer, Lock M10 Qty: 1
REMOVAL Remove a capscrew (Figure 1, Item 1), lockwasher (Figure 1, Item 2) and bracket (Figure 1, Item 3). Discard lockwasher. END OF TASK INSTALLATION Install bracket (Figure 1, Item 3), new lockwasher (Figure 1, Item 2) and capscrew (Figure 1, Item 1).
3 2 1
M2110105
Bracket Maintenance.
0157-1/2 blank
TM 5-3810-305-23
0158
FIELD MAINTENANCE UPPERSTRUCTURE MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Multiplier, Torque Wrench (WP 0171, Table 1, Item 30) Suitable Lifting Device, 10,000-lb (4,536 kgs) Minimum Capacity Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 136) Qty: 2 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 8 O-Ring (WP 0172, Table 1, Item 43) Qty: 4 O-Ring (WP 0172, Table 1, Item 120) Qty: 5 O-Ring (WP 0172, Table 1, Item 146) Qty: 5 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Strap, Tie Down Electrical (WP 0172, Table 1, Item 164) Qty: 2 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 48) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 128) Qty: 3 Personnel Required (Two) References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Boom removed (WP 0156)
REMOVAL Upperstructure
WARNING
Weight of hub and studs is approximately 79 lb (36 kg). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 1. Use a lifting device to raise boom hoist cylinder and hold it in vertical position.
0158-1
TM 5-3810-305-23
0158
REMOVAL - Continued Upperstructure - Continued
WARNING
Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 2. 3. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Tag and disconnect two boom extend cylinder hoses (Figure 1, Item 1) and boom hoist cylinder hoses from rotary manifold (Figure 1, Item 2). Plug hoses and cap manifold port elbows.
2
M0611105
Figure 1. 4.
Upperstructure Removal.
Tag and disconnect two winch hydraulic tubes (Figure 2, Item 1) from rotary manifold (Figure 2, Item 8). Plug tubes and cap manifold port elbows.
0158-2
TM 5-3810-305-23
0158
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 5. 6. 7. Remove and discard tiedown straps and tag and disconnect collector ring wiring harness (Figure 2, Item 9) from top of rotary manifold (Figure 2, Item 8). Remove stop pin (Figure 2, Item 6) and lockwasher (Figure 2, Item 7) from torque arm bracket (Figure 2, Item 5). Discard lockwasher. Remove 10 capscrews (Figure 2, Item 3) and 20 washers (Figure 2, Item 4) from inside of upperstructure (Figure 2, Item 2).
3 9 8 4 5 7 6
M0612105
Figure 2.
Upperstructure Removal.
0158-3
TM 5-3810-305-23
0158
CAUTION
Block boom hoist cylinder with suitable bracing material to prevent hoist cylinder from contacting rotary manifold. Failure to follow this caution may result in damage to equipment. 8. Lower boom hoist cylinder (Figure 3, Item 1) onto suitable bracing material.
WARNING
Weight of upperstructure is approximately 6,000 lb (2,722 kg). Use adequate lifting equipment to lift and support upperstructure. DO NOT lift over personnel or let personnel walk underneath suspended load. Upperstructure must be properly supported when lowering to ground. Failure to follow these warnings may cause injury or death to personnel. 9. Use a lifting device on upperstructure (Figure 3, Item 4) to support the weight. Remove eight capscrews (Figure 3, Item 6) and 16 washers (Figure 3, Item 5) on outside of upperstructure.
WARNING
Weight of upperstructure is approximately 6,000 lb (2,722 kg). Use adequate lifting equipment to lift and support upperstructure. DO NOT lift over personnel or let personnel walk underneath suspended load. Upperstructure must be properly supported when lowering to ground. Failure to follow these warnings may cause injury or death to personnel. 10. Raise upperstucture (Figure 3, Item 4) to a height sufficient to clear rotary manifold (Figure 3, Item 3) and electrical collector ring (Figure 3, Item 2). Lower to a suitable location.
0158-4
TM 5-3810-305-23
0158
2 3 4
6 5
Figure 3. Upperstructure Removal.
M0613105
END OF TASK REMOVAL Swing Bearing Assembly 1. 2. Disconnect lubrication hose (Figure 4, Item 3) from fitting (Figure 4, Item 4). Remove fitting (Figure 4, Item 4) from inside swing bearing (Figure 4, Item 2).
NOTE
Mark position of swing bearing inspection plug retaining pin relative to carrier frame. 3. Remove 22 capscrews (Figure 4, Item 1) from swing bearing (Figure 4, Item 2).
0158-5
TM 5-3810-305-23
0158
REMOVAL - Continued Swing Bearing Assembly - Continued
WARNING
Weight of swing bearing is approximately 187 lb (85 kg). Use adequate lifting equipment to lift and support swing bearing. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 4. Install two lifting eye bolts in swing bearing (Figure 4, Item 2) 180 degrees apart. Attach lifting device and lift swing bearing over rotary manifold and electrical collector ring.
1 4 3 2
M0596105
Figure 4.
Swing Bearing Assembly Removal.
END OF TASK
0158-6
TM 5-3810-305-23
0158
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Swing Bearing Assembly
WARNING
Weight of swing bearing is approximately 187 lb (85 kg). Use adequate lifting equipment to lift and support swing bearing. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. Install two lifting eye bolts in swing bearing 180 degrees apart. Attach lifting device and lift swing bearing (Figure 5, Item 2) over rotary manifold and electrical collector ring. Locate mark made during removal and line up swing bearing inspection plug retaining pin with mark. Install 22 capscrews (Figure 5, Item 1) to swing bearing (Figure 5, Item 2) and tighten to 722 ft-lb (979 Nm) in sequence shown in Figure 5. Install fitting (Figure 5, Item 4) to inside swing bearing (Figure 5, Item 2). Connect lubrication hose (Figure 5, Item 3) to fitting (Figure 5, Item 4).
2. 3. 4.
0158-7
TM 5-3810-305-23
0158
INSTALLATION - Continued Swing Bearing Assembly - Continued
1 4 3 2
OUTER
M0597105
Figure 5.
Swing Bearing Assembly Installation.
END OF TASK INSTALLATION Upperstructure
WARNING
Weight of upperstructure is approximately 6,000 lb (2,722 kg). Use adequate lifting equipment to lift and support upperstructure. DO NOT lift over personnel or let personnel walk underneath suspended load. Upperstructure must be properly supported when lowering to ground. Failure to follow these warnings may cause injury or death to personnel.
0158-8
TM 5-3810-305-23
0158
INSTALLATION - Continued Upperstructure - Continued
CAUTION
Block boom hoist cylinder with suitable bracing material to prevent boom hoist cylinder from contacting rotary manifold. Failure to follow this caution may result in damage to equipment. 1. Use a lifting device to lift upperstructure (Figure 6, Item 4) to a height sufficient to clear rotary manifold (Figure 6, Item 3) and electrical collector ring (Figure 6, Item 2). Lower onto frame. Use suitable bracing material under boom hoist cylinder (Figure 6, Item 1) to protect electrical collector ring and rotary manifold. Install eight capscrews (Figure 6, Item 6) and 16 washers (Figure 6, Item 5) on outside of upperstructure (Figure 6, Item 4).
2.
2 3 4
6 5
Figure 6. Upperstructure Installation.
M0613105
WARNING
Weight of boom hoist cylinder is approximately 507 lb (230 kg). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. Use lifting device to raise boom hoist cylinder and hold it in a vertical position.
0158-9
TM 5-3810-305-23
0158
INSTALLATION - Continued Upperstructure - Continued 4. Install 20 washers (Figure 7, Item 3) and 10 capscrews (Figure 7, Item 2) on upperstructure (Figure 7, Item 1). Tighten both inside and outside capscrews to 722 ft-lb (979 Nm) in sequence shown in Figure 7.
INNER
2 3
M0614105
Figure 7.
Upperstructure Installation.
CAUTION
Torque arm on rotary manifold must be aligned with torque arm bracket on upperstructure before stop pin is installed. Failure to follow this caution may result in damage to equipment.
NOTE
If necessary, rotate upperstructure manually to align torque arm brackets. 5. 6. 7. Install new lockwasher (Figure 8, Item 4) and stop pin (Figure 8, Item 3) in torque arm bracket (Figure 8, Item 2). Connect collector ring wiring harness (Figure 8, Item 6) to electrical collector ring. Install plastic tubes and secure with new tiedown straps. Connect two winch hydraulic tubes (Figure 8, Item 1) to rotary manifold (Figure 8, Item 5) elbows.
0158-10
TM 5-3810-305-23
0158
3 9 8 4 5 7 6
M0612105
Figure 8. 8.
Connect two boom extend cylinder hoses and boom hoist cylinder hoses (Figure 9, Item 1) to rotary manifold (Figure 9, Item 2) elbows.
0158-11
TM 5-3810-305-23
0158
2
M0611105
Figure 9. 9. 10.
Lower boom hoist cylinder onto suitable lifting device. Tighten dipstick cap.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install boom (WP 0156). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0158-12
TM 5-3810-305-23
0159
FIELD MAINTENANCE MAST ASSEMBLY (TYPE II) MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Puller Set, Mechanical (WP 0171, Table 1, Item 38) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 References WP 0162
0159-1
TM 5-3810-305-23
0159
REMOVAL 1. Inspect mast assembly. Repair if necessary.
NOTE
Do not disassemble unless mast assembly is not turning freely. 2. 3. 4. 5. 6. Remove four capscrews (Figure 1, Item 1), washers (Figure 1, Item 4), cap (Figure 1, Item 10), spacer (Figure 1, Item 9), and shims (Figure 1, Item 8) from swivel (Figure 1, Item 7). Remove swivel (Figure 1, Item 7) and spud (Figure 1, Item 2) from mast (Figure 1, Item 3). Using a bearing puller, separate swivel (Figure 1, Item 7) from spud (Figure 1, Item 2). Remove one cone (Figure 1, Item 5) and two cups (Figure 1, Item 6) from swivel (Figure 1, Item 7). Remove one cone (Figure 1, Item 5) from spud (Figure 1, Item 2).
CAUTION
There is a limit to which gaging material will compress, thus resulting in a false measurement. If 0.12 inch (3.0 mm) material crushes to below 0.05 inch (1.3 mm), remeasuring using 0.06 inch (1.5 mm) material.
NOTE
If using new parts, before installing cap and capscrews, place one piece of either 0.12 inch (3.0 mm) or 0.06 inch x 2.00 inch (1.5 x 50.8 mm) gaging material across end of spud. Install cap and capscrews and evenly torque until no end play is felt in bearing, and slight resistance is felt in bearing rotation. Remove capscrew, cap and gaging material. Measure, using a micrometer, to find proper shim pack requirement. Build up shim pack equal to or up to 0.002 inch (0.05 mm) thicker than measurement. 1. 2. 3. 4. 5. Install spud (Figure 1, Item 2) to mast (Figure 1, Item 3). Pack cups (Figure 1, Item 6) with grease. Install two cups (Figure 1, Item 6) and cones (Figure 1, Item 5) into swivel (Figure 1, Item 7). Press and install swivel (Figure 1, Item 7) onto spud (Figure 1, Item 2). Install shims (Figure 1, Item 8), spacer (Figure 1, Item 9), cap (Figure 1, Item 10), four washers (Figure 1, Item 4), and capscrews (Figure 1, Item 1) to cap. Torque capscrews to 74 ft-lb (100 Nm).
0159-2
TM 5-3810-305-23
0159
1 10 9 5 6 7 6 5 8 4 2 3
M2108105
Mast Assembly Maintenance.
0159-3/4 blank
TM 5-3810-305-23
0160
FIELD MAINTENANCE SWING MOTOR MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Vise (WP 0171, Table 1, Item 42) Wrench, Torque, Click, Ratcheting 3/8 inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Antiseize Compound (WP 0170, Table 1, Item 5) Qty: 1 Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Grease, Molybdenum Disulfide (WP 0170, Table 1, Item 27) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 146) Qty: 4 Parts Kit, Bearing R (WP 0172, Table 1, Item 171) Qty: 1 Materials/Parts (cont.) Parts Kit, Seal Repl (WP 0172, Table 1, Item 170) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Sealing Compound, Loctite 515 (WP 0170, Table 1, Item 58) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Deck plates removed (TM 5-3810-305-10)
WARNING
0160-1
TM 5-3810-305-23
0160
REMOVAL
NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. 3. 4. 5. 6. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect hydraulic hoses (Figure 1, Items 4 and 5) from two adapters (Figure 1, Item 3). Remove two adapters (Figure 1, Item 3) from swing motor (Figure 1, Item 2). Remove two o-rings (Figure 1, Item 6) from adapters (Figure 1, Item 3). Discard o-rings. Remove two capscrews (Figure 1, Item 1) from swing motor (Figure 1, Item 2). Remove swing motor (Figure 1, Item 2) from case.
4
M0460105
Figure 1. Swing Motor Removal. END OF TASK DISASSEMBLY
CAUTION
DO NOT clamp housing port area between vise jaws as it might distort housing around commutator preventing disassembly of commutator. Failure to comply may result in damage to equipment. 1. 2. 3. Remove seven bolts (Figure 2, Item 1) from end cover (Figure 2, Item 2). Remove end cover (Figure 2, Item 2) and seal ring (Figure 2, Item 3) from housing (Figure 2, Item 5). Discard seal ring. Remove drive link spacer/washer (Figure 2, Item 4) from housing (Figure 2, Item 5).
0160-2
TM 5-3810-305-23
0160
2 3 4
M0461105
Figure 2. 4.
Swing Motor Disassembly.
Remove rotor assembly (Figure 3, Item 1) and seal ring (Figure 3, Item 2) from housing (Figure 3, Item 3). Discard seal ring.
1 2 3
M0462105
Figure 3.
0160-3
TM 5-3810-305-23
0160
DISASSEMBLY - Continued 5. Remove wear plate (Figure 4, Item 1), drive link (Figure 4, Item 3), and seal ring (Figure 4, Item 2) from housing (Figure 4, Item 4). Discard seal ring.
1 2 3 4
M0463105
Figure 4. Swing Motor Disassembly. 6. 7. Remove commutator (Figure 5, Item 1) from housing (Figure 5, Item 3). Inspect drive pin, replace if necessary. If necessary, remove drive pin (Figure 5, Item 2) from commutator (Figure 5, Item 1) only if it must be replaced.
M0464105
Figure 5. Swing Motor Disassembly.
0160-4
TM 5-3810-305-23
0160
NOTE
A damaged thrust bearing would be indicated by a roughness felt or heard when removing coupling shaft and drive link. Replacement of thrust washer and bearing will be required if roughness is detected. 8. Remove coupling shaft (Figure 6, Item 1) from housing (Figure 6, Item 2).
1 2
M0465105
Figure 6. 9.
Remove and discard water seal (Figure 7, Item 2) from housing (Figure 7, Item 1).
M0466105
Figure 7.
0160-5
TM 5-3810-305-23
0160
CAUTION
Use care when removing bearing; DO NOT damage bore of commutator. Failure to follow this caution may result in damage to equipment. 10. Remove inner bearing (Figure 8, Item 1), thrust washer (Figure 8, Item 2), thrust bearing (Figure 8, Item 3), thrust washer (Figure 8, Item 4), inner seal (Figure 8, Item 5), and back-up washer (Figure 8, Item 6) from housing (Figure 8, Item 8). Discard inner bearing and inner seal. Remove retaining ring (Figure 8, Item 7) from housing (Figure 8, Item 8). Remove and discard bearing (Figure 8, Item 9).
11. 12.
4 5 6 7 8
M0467105
Figure 8. Swing Motor Disassembly. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect bolt head recesses for damage that would prevent bolt heads from sealing properly. If inspection reveals damage to rotor assembly, set commutator, or housing, swing motor should be replaced as an assembly. Time parts are all matched to each other and are not serviced separately.
END OF TASK
0160-6
TM 5-3810-305-23
0160
ASSEMBLY
NOTE
Coat all internal parts with hydraulic oil before assembling. 1. 2. Install retaining ring (Figure 9, Item 7) with rounded surface of ring facing in toward larger housing (Figure 9, Item 8) cavity. Install back-up washer (Figure 9, Item 6) and new inner seal (Figure 9, Item 5). Inner seal must be installed flush against back-up ring with seal lip facing out toward thrust washer.
NOTE
Use a bearing and press when installing bearings. 3. Install thrust washer (Figure 9, Item 4), thrust bearing (Figure 9, Item 3), thrust washer (Figure 9, Item 2), and new inner bearing (Figure 9, Item 1). Press inner bearing into a depth of 0.125 to 0.135 inches (3.18 to 3.43 mm). Apply molybdenum grease to new bearing (Figure 9, Item 9) rollers. Turn housing (Figure 9, Item 8) over and install new bearing to a depth of 1.598 to 1.618 inches (40.59 to 41.10 mm). Make sure new bearing is not cocked and is square to housing.
4.
4 5 6 7 8
M0467105
Figure 9.
Swing Motor Assembly.
0160-7
TM 5-3810-305-23
0160
ASSEMBLY - Continued 5. Apply molybdenum grease to seal lip and install dirt and new water seal (Figure 10, Item 2) in housing (Figure 10, Item 1). Seat dirt and water seal against bearing, with seal lip facing bearing.
M0466105
Figure 10. Swing Motor Assembly. 6. 7. Place swing motor in a soft-jawed vise with mounting flange down, and clamp vise jaws against edges of mounting flange. Install coupling shaft (Figure 11, Item 1) into housing (Figure 11, Item 3) seating it against thrust washer (Figure 11, Item 2). Coupling shaft must rotate smoothly on thrust bearing package.
M0468105
Figure 11. Swing Motor Assembly.
0160-8
TM 5-3810-305-23
0160
ASSEMBLY - Continued 8. Install new drive pin (Figure 12, Item 2), if removed, into commutator (Figure 12, Item 1) drive pin hole until it bottoms out.
CAUTION
DO NOT force commutator into bore. It is a close slip fit and must rotate. Failure to follow this caution may result in damage to equipment. 9. Install commutator (Figure 12, Item 1) assembly into housing (Figure 12, Item 4) commutator bore. Commutator must not be cocked as it enters the bore. Drive pin (Figure 12, Item 2) must be in line with coupling shaft (Figure 12, Item 3) drive pin slot indicated by timing mark. Engage drive pin end that protrudes from commutator into coupling shaft drive pin slot, rotating coupling shaft if necessary. Commutator will be below housing wear plate surface when correctly seated.
NOTE
Commutator drive pin and coupling shaft drive pin slot at this point in the assembly are visible through commutator center cavity for coupling pin engagement purposes. 10. Install either end of drive link (Figure 12, Item 5) through commutator (Figure 12, Item 1) cavity and engage lower drive link spines into mesh with internal spines in coupling shaft (Figure 12, Item 3). A spline valley on both ends of the drive link will now be in line with commutator drive pin (Figure 12, Item 2) and the timing mark.
2 3 4
M0469105
Figure 12.
0160-9
TM 5-3810-305-23
0160
ASSEMBLY - Continued 11. 12. 13. Install new seal ring (Figure 13, Item 2) in seal groove of housing (Figure 13, Item 3). Place wear plate with either side up onto rotor assembly set (Figure 13, Item 1) and align wear plate bolt holes with rotor assembly set bolt slots. Install new seal ring (Figure 13, Item 2) into seal ring groove in rotor assembly set (Figure 13, Item 1).
CAUTION
Be careful not to disengage rotor, drive link or coupling shaft while aligning bolt holes as this could affect the timing that was just achieved. The meshing of the precise rotor teeth with the precise drive link splines and valleys as described is absolutely crucial to a correctly timed and functional motor. Misalignment by one spline tooth will be indicated by the timing mark on coupling shaft being 45 degrees from the specified rotor lobe. Failure to follow this caution may result in damage to equipment. 14. 15. 16. Locate on rotor assembly set (Figure 13, Item 1) the only two spline teeth that are on same center line with two rotor lobes. Take rotor assembly set (Figure 13, Item 1), seal ring (Figure 13, Item 2), and wear plate as a unit and align rotor spline teeth from Step 14 with drive link (Figure 13, Item 3) spline valley identified in Step 10. Install drive link spacer/washer (Figure 13, Item 3) into rotor spline cavity onto end of drive link (Figure 13, Item 3).
1 2 3 4
M0463105
Figure 13. Swing Motor Assembly.
0160-10
TM 5-3810-305-23
0160
ASSEMBLY - Continued 17. 18. 19. Apply a small amount of grease to seal ring (Figure 14, Item 3) and insert seal ring into end cover (Figure 14, Item 2) seal ring groove. Install end cover (Figure 14, Item 2) assembly onto housing (Figure 14, Item 5) with seal ring (Figure 14, Item 3) against housing and align end cover bolt holes with housing bolt holes. Install seven bolts (Figure 14, Item 1) finger tight. Tighten seven bolts to 22 to 26 ft-lb (30 to 35 Nm).
2 3 4
M0461105
0160-11
TM 5-3810-305-23
0160
INSTALLATION 1. 2. 3. 4. Coat motor spline with antiseize thread compound. Apply threadlock sealant to motor mounting flange. Install swing motor (Figure 15, Item 2) to case. Apply threadlock sealant to threads of two capscrews (Figure 15, Item 1) and install capscrews in swing motor (Figure 15, Item 2). Install two new o-rings (Figure 15, Item 6) and adapters (Figure 15, Item 3) and connect hydraulic hoses (Figure 15, Items 4 and 5) to adapters (Figure 15, Item 3).
6
Figure 15. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
4
M0460105
Swing Motor Installation.
0160-12
TM 5-3810-305-23
0161
FIELD MAINTENANCE SWING GEARBOX MAINTENANCE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Puller Set, Mechanical (WP 0171, Table 1, Item 38) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Wrench, Torque, Click, 1/2 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 35) Materials/Parts Antiseize Compound (WP 0170, Table 1, Item 5) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Parts Kit, Bearing R (WP 0172, Table 1, Item 171) Qty: 1 Materials/Parts (cont.) Parts Kit, Seal Repl (WP 0172, Table 1, Item 3) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 166) Qty: 10 Personnel Required (Two) References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Deck plates removed (WP 0122) Swing motor removed (WP 0160)
WARNING
Weight of swing gearbox is approximately 125 lb (57 kg). Use adequate lifting equipment to lift and support swing gearbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.
0161-1
TM 5-3810-305-23
0161
REMOVAL 1. 2. Rotate upperstructure to the right. With adequate hoist and sling, support swing gearbox (Figure 1, Item 1).
NOTE
It will be necessary to rotate upperstructure by hand to access rear hardware. 3. 4. 5. Attach a wrench to protruding shaft of swing box drive. Turn swing box drive clockwise to swing upperstructure to the right and counterclockwise to swing upperstructure to the left. Remove four nuts (Figure 1, Item 2), washers (Figure 1, Item 3), spacers (Figure 1, Item 4), and capscrews (Figure 1, Item 5). Lower swing gearbox (Figure 1, Item 1) out of pilot hole and remove from vehicle.
5 4 3 2
Figure 1. END OF TASK Swing Gearbox Removal.
M0598105
0161-2
TM 5-3810-305-23
0161
DISASSEMBLY
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. 4. 5. Remove two drain plugs (Figure 2, Item 2) from cover (Figure 2, Item 1). Remove pipe plug (Figure 2, Item 6) from housing (Figure 2, Item 5). Drain oil into suitable container. Remove six capscrews (Figure 2, Item 4) and lockwashers (Figure 2, Item 3) from horn cover (Figure 2, Item 1). Discard lockwashers. Remove cover (Figure 2, Item 1) from housing (Figure 2, Item 5).
2 3 1 4
M0599105
Figure 2.
Swing Gearbox Disassembly.
0161-3
TM 5-3810-305-23
0161
DISASSEMBLY - Continued 6. 7. Remove o-ring (Figure 3, Item 3) from cover (Figure 3, Item 2). Discard o-ring. Remove bushing (Figure 3, Item 1) from cover (Figure 3, Item 2), if necessary.
1 3 2
M0600105
Figure 3. Swing Gearbox Cover Disassembly. 8. 9. 10. Remove four capscrews (Figure 4, Item 6) and lockwashers (Figure 4, Item 5) from bearing retainer (Figure 4, Item 4). Discard lockwashers. Remove bearing retainer (Figure 4, Item 4) from housing (Figure 4, Item 1). Remove o-ring (Figure 4, Item 2) and seal (Figure 4, Item 3) from bearing retainer (Figure 4, Item 4). Discard o-ring and seal.
6 4 3 1 2 5
M0601105
Figure 4. Swing Gearbox Bearing Retainer Disassembly.
0161-4
TM 5-3810-305-23
0161
DISASSEMBLY - Continued 11. 12. Remove four capscrews (Figure 5, Item 1) from bearing retainer (Figure 5, Item 2). Remove bearing retainer (Figure 5, Item 2), o-ring (Figure 5, Item 3), and shim (Figure 5, Item 4) from housing (Figure 5, Item 5). Discard o-ring.
2 1
M0602105
Figure 5. Swing Gearbox Bearing Retainer Disassembly.
0161-5
TM 5-3810-305-23
0161
NOTE
Record number of shim(s) removed to aid in assembly. 13. 14. 15. 16. Remove two bearing cups (Figure 6, Item 1). This will allow worm gear (Figure 6, Item 3) to drop for aid in removal. Rotate worm gear (Figure 6, Item 3) out to one end of housing (Figure 6, Item 2) and remove one of two bearing cones (Figure 6, Item 1). Remove worm gear (Figure 6, Item 3) from opposite end of housing (Figure 6, Item 2). Remove remaining bearing cone (Figure 6, Item 4) from worm gear (Figure 6, Item 3).
1 3 4
M0603105
Figure 6.
0161-6
TM 5-3810-305-23
0161
DISASSEMBLY - Continued 17. Remove capscrew (Figure 7, Item 5) and nut (Figure 7, Item 4) from housing (Figure 7, Item 2).
NOTE
Gear puller is required to remove worm gear from output shaft, utilizing two 1/2-13 NC tapped holes in worm gear. 18. 19. Remove worm gear (Figure 7, Item 6) from output shaft (Figure 7, Item 1). Remove two keys (Figure 7, Item 3) from output shaft (Figure 7, Item 1).
2 1
5 1 4 3
M0604105
Figure 7.
0161-7
TM 5-3810-305-23
0161
NOTE
It is not recommended to remove spacer from output shaft. If worn, replace output shaft, spacer, and o-ring. 20. 21. 22. Press output shaft (Figure 8, Item 4) out of housing (Figure 8, Item 1). Remove seal (Figure 8, Item 2) and one bearing cone (Figure 8, Item 3) from housing (Figure 8, Item 1). Discard seal. Remove cone (Figure 8, Item 3) from housing (Figure 8, Item 1).
2,3 4
M0605105
Figure 8. Swing Gearbox Output Shaft Disassembly.
0161-8
TM 5-3810-305-23
0161
DISASSEMBLY - Continued 23. Remove two bearing cups (Figure 9, Item 1) from housing (Figure 9, Item 2).
1
M0606105
Figure 9. 24.
Swing Gearbox Bearing Cups Disassembly.
Remove vent plug (Figure 10, Item 2) and grease fitting (Figure 10, Item 3) from housing (Figure 10, Item 1).
1 2
3
M0607105
Swing Gearbox Vent Plug and Grease Fitting Disassembly.
0161-9
TM 5-3810-305-23
0161
CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY
WARNING
Weight of counterweight is approximately 2,200 lb (998 kg). Use adequate lifting equipment to lift and support counterweight. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. Install vent plug (Figure 11, Item 2) and grease fitting (Figure 11, Item 3) to housing (Figure 11, Item 1).
1 2
3
M0607105
Figure 11. Swing Gearbox Vent Plug and Grease Fitting Assembly.
0161-10
TM 5-3810-305-23
0161
ASSEMBLY - Continued 2. Install two bearing cups (Figure 12, Item 1) in housing (Figure 12, Item 2).
1
M0606105
Figure 12. Swing Gearbox Bearing Cups Assembly.
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NOTE
Install new seal with sealant on outer diameter of seal. Lubricate seal lip with antiseize compound. 3. 4. 5. Install one of two bearing cones (Figure 13, Item 3) and new seal (Figure 13, Item 2) on housing (Figure 13, Item 1). Install output shaft (Figure 13, Item 4) in housing (Figure 13, Item 1). Turn housing (Figure 13, Item 1) over and install remaining bearing cone (Figure 13, Item 3). Press completely onto shaft (Figure 13, Item 4).
2,3 4
M0605105
Figure 13. Swing Gearbox Assembly.
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ASSEMBLY - Continued 6. Install keys (Figure 14, Item 2) on output shaft (Figure 14, Item 1).
1 2
M0608105
Figure 14.
Swing Gearbox Assembly.
NOTE
When pressing worm gear onto shaft, position worm gear so not to damage bronze worm gear. 7. 8. 9. Press worm gear (Figure 15, Item 4) onto output shaft (Figure 15, Item 1) with gear hub facing up. Install nut (Figure 15, Item 2). Tighten nut to approximately 5 ft-lb (6.8 Nm). Install capscrew (Figure 15, Item 3). Tighten capscrew to 15 ft-lb (20 Nm).
1 4
2
M0609105
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ASSEMBLY - Continued 10. 11. 12. 13. Press one of two bearing cones (Figure 16, Item 4) on worm gear (Figure 16, Item 2). Install worm gear (Figure 16, Item 2) and bearing cone (Figure 16, Item 1) in housing (Figure 15, Item 3). Press remaining bearing cone (Figure 16, Item 4) on worm gear (Figure 16, Item 2). Press two bearing cups (Figure 16, Item 4) in housing (Figure 16, Item 3).
1 3 4
M0603105
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NOTE
If any part(s) on worm gear axis have been replaced, shim thickness must be recalculated to give 0 to 0.005 inch (0 to 0.13 mm) end play on worm gear. 14. 15. Install new o-ring (Figure 17, Item 3) and shim(s) (Figure 17, Item 4) on bearing retainer (Figure 17, Item 2). Install four capscrews (Figure 17, Item 1) and bearing retainer (Figure 17, Item 2) on housing (Figure 17, Item 5). Tighten four capscrews to 58 ft-lb (79 Nm).
2 1
M0602105
Figure 17. Swing Gearbox Bearing Retainer Assembly.
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NOTE
Install seal with sealant on outer diameter of seal. Lubricate seal lip with antiseize thread compound. 16. 17. Install new seal (Figure 18, Item 3) and new o-ring (Figure 18, Item 2) on bearing retainer (Figure 18, Item 4). Install bearing retainer (Figure 18, Item 4) with four new lockwashers (Figure 18, Item 5) and capscrews (Figure 18, Item 6) into housing (Figure 18, Item 1). Tighten capscrews to 58 ft-lb (79 Nm). Worm gear should rotate freely by hand.
6 4 3 1 2 5
M0601105
Figure 18. Swing Gearbox Bearing Retainer Assembly. 18. Install bushing (Figure 19, Item 1) and new o-ring (Figure 19, Item 3) on cover (Figure 19, Item 2).
1 3 2
M0600105
Figure 19. Swing Gearbox Cover Assembly.
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ASSEMBLY - Continued 19. 20. 21. Install cover (Figure 20, Item 1), six new lockwashers (Figure 20, Item 3) and capscrews (Figure 20, Item 4). Tighten capscrews to 58 ft-lb (79 Nm). Install two drain plugs (Figure 20, Item 2) in cover (Figure 20, Item 1). With pinion up and swing gearbox level, fill with gear oil per lubrication chart (TM 5-3810-305-10), or until oil runs out of fill level hole. Install fill pipe plug (Figure 20, Item 6).
2 3 1 4
M0599105
Figure 20. 22.
Swing Gearbox Drain Plugs Assembly.
Grease bearings through fitting (Figure 21, Item 2) located under pinion gear in housing (Figure 21, Item 1).
2
M0610105
Swing Gearbox Assembly.
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INSTALLATION 1. 2. Using adequate hoist and sling, support swing gearbox (Figure 21, Item 1). Position swing gearbox (Figure 22, Item 1) in place.
NOTE
It will be necessary to rotate upperstructure by hand to access rear hardware. 3. 4. Attach a wrench to protruding shaft of swing box drive. Turn swing box drive clockwise to swing upperstructure to the right and counterclockwise to swing to the left. Install four capscrews (Figure 22, Item 5), spacers (Figure 22, Item 4), washers (Figure 22, Item 3), and nuts (Figure 22, Item 2). Tighten capscrews to 344 ft-lb (466 Nm).
5 4 3 2
Figure 22. Swing Gearbox Installation. END OF TASK
M0598105
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FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install swing motor (WP 0160). Install deck plates (WP 0122). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
0161-19/20 blank
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0162
FIELD MAINTENANCE GENERAL MAINTENANCE INSTRUCTIONS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Apron, Utility (WP 0171, Table 1, Item 20) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Multimeter (WP 0171, Table 1, Item 29) Soldering Gun (WP 0171, Table 1, Item 31) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Cloth, Abrasive, Crocus (WP 0170, Table 1, Item 12) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Soap GP, Liquid, A (WP 0170, Table 1, Item 66) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References TM 9-214 TM 43-0139 WP 0165
SCOPE These general maintenance instructions contain general shop practices and specific methods you must be familiar with to properly maintain the 7 1/2 Ton Crane. You should read and understand these practices and methods before starting maintenance tasks on the crane. WORK SAFETY 1. 2. 3. 4. 5. Before starting a task, think about the risks and hazards to your safety as well as that of others. Wear protective gear such as safety goggles or lenses, safety shoes, rubber apron, or gloves. Protect yourself against injury. Observe all WARNINGs, CAUTIONs and NOTEs. When lifting heavy parts, have someone help you. Make sure lifting equipment is working properly, suitable for the task assigned, of sufficient load capacity, and secured against slipping. Always use power tools carefully. Before beginning a procedure, ensure the following conditions have been observed, unless otherwise specified: a. b. c. d. e. f. The crane must be parked on level ground with parking brake engaged. Transmission must be in N (Neutral). Engine must be off. Components that are hot at operating temperatures (i.e., cooling, exhaust, and hydraulic systems) must cool down before they are removed. Components must, however, be at operating temperature to be tested. Battery disconnect switch must be in OFF position and/or batteries disconnected when performing electrical system maintenance.
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WORK SAFETY - Continued g. Hydraulic system pressure must be relieved before disconnecting any hydraulic system line or fitting. Refer to Relieving Hydraulic System Pressure in this work package.
END OF TASK RELIEVING HYDRAULIC SYSTEM PRESSURE
WARNING
DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel. 1. Relieving Hydraulic System Pressure. a. b. c. d. e. f. 2. Park the crane on a smooth, level surface. Engage parking brake. Shut down engine. In superstructure cab, turn engine start switch to ON position without starting engine. Move joystick control lever through all positions. This will relieve any pressure that is present in hydraulic system. Slowly loosen hydraulic tank filler cap and allow any pressure to escape.
Relieving Brake Hydraulic System Pressure. a. b. c. d. e. f. Park the crane on a smooth, level surface. Shut down engine. Engage parking brake. In chassis cab, turn engine start switch to ON position. Depress brake pedal 30 times, pausing two seconds between each application. Turn engine start switch to OFF position.
END OF TASK
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GENERAL INFORMATION 1. Before beginning a task, find out how much repair, modification, or replacement is needed to fix the equipment as described in this manual. Sometimes the reason for equipment failure can be seen right away and complete teardown is not necessary. Disassemble the equipment only as far as necessary to repair or replace damaged or broken parts. All tags and forms attached to the equipment must be checked to learn the reason for removal from service. Check all Modification Instructions (MIs) and Technical Instructions (TIs) for equipment changes and updates. In some cases, a part may be damaged by removal. If the part appears to be good, and other parts behind it are not defective, leave it on and continue the procedure. Here are a few simple rules: a. b. c. Do not remove dowel pins or studs unless loose, bent, broken, or otherwise damaged. Do not pull bearings or bushings unless damaged. If you must get at parts behind them, pull out bearings or bushings carefully. Replace all gaskets, seals, preformed packings, o-rings, cotter pins, spring pins, self-locking nuts, and lockwashers.
2. 3.
END OF TASK CLEANING INSTRUCTIONS
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Eye shields must be worn when cleaning with a wire brush. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. Failure to follow these warnings may result in injury or death to personnel. 1. 2. Cleaning instructions are the same for the majority of the parts and components of the crane. The importance of cleaning must be thoroughly understood by maintenance personnel. Great care and effort are required in cleaning. Dirt and foreign material are a constant threat to satisfactory maintenance. The following should apply to all cleaning, inspection, repair, and assembly operations: a. Clean all parts before inspection, after repair, and before assembly.
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CLEANING INSTRUCTIONS - Continued b. c. 3. To prevent contamination, hands should be kept free of any accumulation of grease, which can collect dust, dirt, or grit. After cleaning, all parts should be covered or wrapped to protect them from dust and dirt. Parts that are subject to rust should be lightly oiled.
External Engine Cleaning. a. b. c. d. Protect all electrical equipment that could be damaged by steam or moisture before steam cleaning. Cover all openings before steam cleaning. After cleaning, dry and apply a light coat of oil to all parts subject to rust. Clear out all tapped (threaded) holes with compressed air to remove dirt and cleaning fluid.
4.
Cleaning Disassembled Parts. a. b. c. d. e. Place all disassembled parts in wire baskets for cleaning. Dry and cover all cleaned parts. Place parts on or in racks" and hold for inspection or repair. All parts subject to rusting must be lightly oiled and wrapped. Keep all related parts and components together. Do not mix parts.
5.
Castings. a. b. c. Clean inner and outer surfaces of castings and all areas subject to grease and oil with solvent cleaning compound. Use a stiff brush to remove sludge and gum deposits. Clear out all tapped (threaded) holes with compressed air to remove dirt and cleaning solvent.
6.
Oil Passages. Particular attention must be given to all oil passages in castings and machined parts. Oil passages must be clean and free of any obstructions. a. b. c. Clean passages with wire probes to break up any sludge or gum deposits. Wash passages by flushing with solvent cleaning compound. Dry passages with compressed air.
CAUTION
Washing flexible hoses and oil seals with solvent cleaning compound or mineral spirits will cause serious damage or destroy the material. 7. Oil Seals and Flexible Hoses. a. b. 8. 9. Wash flexible hoses with a mild solution of soap and water. Wipe dry. Oil seals are generally damaged during removal; cleaning will not be necessary since new seals will be used in assembly.
Bearings. Refer to TM 9-214, Inspection, Care, and Maintenance of Antifriction Bearings for complete instructions. Machined Surfaces. a. b. Clean machined surfaces with solvent cleaning compound. Dry surfaces with compressed air.
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CLEANING INSTRUCTIONS - Continued 10. Mated Surfaces. a. b. 11. 12. 13. 14. 15. Remove old gasket and/or sealing compound using a wire brush and solvent cleaning compound. Lightly coat with oil and wrap all parts subject to rust before storing.
Rusted Surfaces. Clean all rusted surfaces using wire brush and crocus cloth. Oil-Bathed Internal Parts. Wipe oil-bathed internal parts clean with a lint-free cloth. Air-Actuated Internal Parts. Wash air-actuated internal parts clean with a lint-free cloth. Externally Exposed Parts. Wash externally exposed parts with soap and water. Rinse thoroughly and air dry. Hydraulic Cylinders. a. b. c. Care in handling of parts and hydraulic system cleanliness cannot be over stressed. Use ONLY the oil type and viscosity ranges specified under Lubricants and Capacities". Wash all metal parts including cylinder in solvent. Dry all parts with filtered compressed air. Protect components with a light film of oil. Flush cylinder with oil to remove all traces of solvent and protect cylinder walls from oxidation. Check cylinder bore and rod surface for scratches and/or abrasions that may have been caused by grit deposits in the cylinder packings. Carefully remove small rough or sharp surfaces with a fine-grained stone. The closer these surfaces are to a mirror finish, the more efficiently the new packing will operate.
d.
END OF TASK INSPECTION INSTRUCTIONS 1. 2. General. All components and parts must be carefully checked to determine if they are serviceable for reuse, if they can be repaired, or if they must be scrapped. Hydraulic Cylinders. a. Inspect all surfaces for burrs, scratches, nicks, scores and other abrasions. Stone or lap all burrs. If scoring is deep enough to produce excessive leakage, replace valve assembly. Stone or use crocus cloth on small scores. All parts with sliding fit must move freely in their bores. All grooves and passages must be free of foreign matter. Replace springs if they are broken or distorted. Replace all o-rings, seal rings, and gaskets. Listed below are instructions that must be followed to ensure correct installation and effective sealing of o-rings. (1) (2) (3) (4) (5) Seal counterbores must be thoroughly cleaned. o-rings, plungers, and counterbores must be lubricated on assembly. o-rings must be free of molding defects and handling damage. o-rings must not be stretched beyond the yield point. Extreme care must be taken to avoid rolling" the o-ring into the counterbore. (A twisted o-ring is not likely to straighten itself after installation and is almost certain to leak.)
b. c. d. e. f.
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INSPECTION INSTRUCTIONS - Continued (6) (7) 3. Care in handling of parts and hydraulic system cleanliness cannot be over stressed. Use ONLY the oil type and viscosity ranges specified under Lubricants and Capacities".
Drilled and Tapped (Threaded) Holes. a. b. c. Inspect for wear, distortion (stretching), cracks, or any other damage in or around holes. Inspect threaded areas for wear, distortion, or evidence of cross-threading. Mark all damaged areas for repair or replacement.
4.
Metal Lines, Flexible Lines (Hoses), and Fittings. a. b. c. d. Inspect lines for sharp kinks, cracks, bends, or dents. Inspect flexible lines for fraying, evidence of leakage, or loose fittings or connectors. Check all fittings and connectors for thread damage. Check for hex heads that are worn or rounded by poorly fitting wrenches. Mark all damaged material for repair or replacement.
5.
Castings. a. Inspect all ferrous and nonferrous castings for cracks using a magnifying glass and strong light. Particularly check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace all cracked castings. Inspect machined surfaces for nicks, burrs, or raised metal. Mark damaged areas for repair or replacement. Inspect all pipe plugs, pipe plug openings, screws, and screw openings for damaged or stripped threads. Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straightedge or surface plate. Inspect mating flanges for discoloration that may indicate persistent oil leakage.
b. c. d. 6. 7.
Bearings. Refer to TM 9-214, Inspection, Care, and Maintenance of Antifriction Bearings, for inspection of bearings. Damaged bearings must be replaced. Studs, Bolts, and Screws. Replace if threads are damaged, bent, loose, or stretched.
NOTE
When gear teeth wear limits are not established, good judgment is required to determine if gear replacement is necessary. 8. Gears. a. b. c. 9. Inspect all gears for cracks using a magnifying glass and strong light. No cracks are permissible. Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces. Check keyway slots for wear or damage. If keyways are worn, damaged, or elongated, replace gear.
Bushing and Bushing-Type Bearings. a. b. Check all bushings and bushing-type bearings for secure fit, evidence of overheating, wear, burrs, nicks, and out-of-round condition. Replace as necessary. Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage.
10. 11.
Oil Seals. Oil seals are mandatory replacement items. Core Hole Expansion Plugs. Inspect for leakage. Replace plugs when leakage is present.
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INSPECTION INSTRUCTIONS - Continued 12. 13. 14. 15. 16. 17. 18. 19. Machine-Tooled Parts. Inspect for cracks, breaks, elongated holes, wear, and chips. Replace any damaged parts. Machined Surfaces. Inspect for cracks, evidence of wear, galled or pitted surface, burrs, nicks, and scratches. Mating Surfaces. Inspect for remains of old gasket, seal, secure fit, pitting, and evidence of leakage. Rusted Surfaces. Inspect for pitting, holes, and severe damage. Oil-Bathed Internal Parts. Inspect for cracks, nicks, burrs, evidence of overheating, and wear. Internal Parts. Inspect for cracks, nicks, burrs, evidence of overheating, and wear. Externally Exposed Parts. Inspect for breaks, cracks, rust damage, and wear. Springs. Inspect for broken, collapsed, and twisted coils.
END OF TASK REPAIR INSTRUCTIONS
CAUTION
Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from entering working parts of the vehicle. Failure to comply may result in damage to equipment. 1. General. a. b. 2. Any repair procedure peculiar to a specific part or component is covered in the work package relating to that item. After repair, clean all parts thoroughly to prevent dirt, metal chips, or other foreign material from entering any working parts.
Castings. a. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and scratches with: (1) (2) (3) b. c. Fine-mill file. Crocus cloth dipped in solvent cleaning compound. Lapping across a surface plate.
Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted. Replace castings. Repair damaged threaded pipe plug or screw threads with a tap or die. Repair oversized holes with threaded inserts.
3.
Studs. a. b. Repair minor thread damage with a thread die. Replace studs having stripped or damaged threads as described below: (1) (2) (3) Remove using a stud remover. Back studs out slowly to avoid heat buildup and seizure that can cause stud to break off. If studs break off too short to use a stud remover, use a stud extractor to remove or use welding method": weld bar stock or a nut to stud and remove with a wrench. Install replacement stud slowly to prevent heat buildup and break-off.
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REPAIR INSTRUCTIONS - Continued 4. Gears. a. b. Remove gears using pullers. Only minor repairs to gears are permitted. Remove minor nicks, burrs, or scratches on gear teeth with: (1) (2) 5. Fine-mill file. Crocus cloth dipped in solvent cleaning compound.
Bushings and Bushing Type Bearings. a. b. When bushings and bushing type bearings seize to a shaft and spin in the bore, associated parts must also be replaced. It may be necessary to heat bearings to aid in installation.
6.
Oil Seals. a. b. Remove oil seals by pressing or prying out, being careful not to damage casting or adapter bore. Always install new seal in bore using proper seal installation tool.
7.
Painting. Upon installation, restored parts must be painted in accordance with Army TM 43-0139, Painting Instructions for Field Use.
END OF TASK LUBRICATION INSTRUCTIONS Refer to Lubrication Instructions (TM 5-3810-305-10) for detailed, illustrated instructions on proper lubrication. The following are some general practices to remember: a. b. c. d. Use correct lubricant. Keep lubricants clean. Clean all fittings and area around fill and drain points before lubrication. Lubricate clean disassembled and new parts to prevent rust.
END OF TASK STANDARD TOOL REQUIREMENTS 1. The following are general practices regarding the use of tools: a. b. c. d. e. f. 2. Always use proper tool kit and tools for procedure being performed. Ensure tools are clean and lubricated to reduce wear and to prevent rust. Keep track of tools. Do not be careless with them. Return tools to toolbox when finished with repair or maintenance. Return toolboxes and tools to tool storage when not in use. Inventory tools before and after each use.
Some maintenance tasks may require special or fabricated tools. The Initial Setup" of the work package will specify any special or fabricated tools needed to perform that procedure. Use these special tools only for the
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STANDARD TOOL REQUIREMENTS - Continued maintenance instructions for which they are designed or called out. If you are unfamiliar with a required tool, see your Maintenance Supervisor. END OF TASK APPLYING TORQUE 1. 2. When tightening fasteners, use torque value as specified in Torque Limits (WP 0165). If a unique torque value is required, it will be provided in a procedural step in the task.
END OF TASK TAGGING INSTRUCTIONS 1. Use marker tags to identify all electrical wires, fuel, oil, coolant, hydraulic lines, and any other parts that may be hard to identify or replace later. Fasten tags to parts during removal by wrapping wire fasteners around or through parts and twisting ends together. Position tags to be out of the way during cleaning, inspection, and repair. Mark tags with a pencil, pen, or marker. Whenever possible, identify electrical wires with the number of the terminal or wire to which they connect. If no markings can be found, tag both wires or wire and terminal, and use the same identifying mark for both. If you cannot tag a wire because it must fit through a small hole or you cannot reach it, write down a description of the wire and the point to which it connects, or draw a simple diagram on paper. Be sure to write down enough information for you to properly connect the wires during assembly. If you need to identify a loose wire, look for an identifying number near the end of the wire, stamped on a permanent metal tag. Compare the number to wire numbers on the appropriate electrical schematic. Identify fuel, oil, coolant, and hydraulic lines when you are taking off more than one line at the same time. Mark tags with points to which lines and hoses must be connected. If it is not obvious which end of a line goes where, tag each end of the line. Identify and tag other parts by name and installed location as required.
2.
3.
4.
END OF TASK LINES AND PORTS To keep dirt from contaminating fluid systems when removing and installing fuel, oil, coolant, and hydraulic lines, perform these steps: a. b. Clean fittings and surrounding area before disconnecting lines. Cover, cap, plug, or tape lines and ports after disconnecting lines. When these specialized covers are not available, use plastic bags and rubber bands, clean rags, duct tape, or other similar materials to prevent dirt from entering system. Ensure new and used parts are clean before installing. Replace all removed tiedown straps. Wait to remove covers, caps, plugs, or tape from lines and ports until just before installing lines.
c. d. e.
END OF TASK
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FLUID DISPOSAL
WARNING
When servicing equipment, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, or Chemical Agent Resistant Coating (CARC) paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Wear protective eye covering. Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit. Failure to follow these warnings may result in injury or death to personnel. END OF TASK END OF WORK PACKAGE
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FIELD MAINTENANCE GENERAL WIRING HARNESS AND CABLE MAINTENANCE
INITIAL SETUP: References TB SIG 222 WP 0076
This work package contains instruction on repair of wiring harnesses and cables (leads). Repair of wiring harnesses and cables consists of replacement of defective connectors, shells, and terminals, or taping cut or worn insulation and exposed wire conductors. Exploded views of typical harness and cable connectors used on the vehicle and given procedures for disassembly and assembly of connecters. When soldering is required, procedures in TB SIG 222 must be followed. If multiple pin connectors are disassembled, tag or label all wires and cables to ensure that correct connections are made at time of assembly. The following procedures are contained in this work package: Typical Panel Mounting Receptacle: Disassembly and Assembly Typical Plug Disassembly and Assembly Terminal-type Cable Connectors Replacement Male Cable Connector Replacement Female Cable Connector (with Washer) Replacement Female Cable Connector Electrical Harness Identification Female-Type Panel Mounting Receptacle Disassembly and Assembly Male-Type Panel Mounting Receptacle Disassembly and Assembly Female-Type Panel Mounting Receptacle with Ridged Locking Nut Disassembly and Assembly Male-Type Panel Mounting Receptacle with Ridged Locking Nut Disassembly and Assembly Female-Type Plug with Ridged Locking Nut Male-Type Plug with Ridged Locking Nut Cable Connectors
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IDENTIFICATION
NOTE
When removing more than one wire from a multiple wire harness, record which line was removed from which pin hole. 1. 2. Cable identifiers (Figure 1, Item 1) are aluminum tags attached to cables. These tags are embossed with cable identification number. Wire identifiers (Figure 1, Item 2) are embossed with same individual wire number. Wire identifier numbers are shown on wiring diagram.
M0132105
Figure 1. Electrical Harness Identification.
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IDENTIFICATION - Continued 3. 4. If cables or wires are replaced, remove tags from old wire and place them on new wire. All pins (male connectors) and sockets (female connectors) in receptacles and plugs are identified by alphabetical code. Coded identification starts at the connector key (Figure 2, Item 2) or groove (Figure 2, Item 1). Male connectors identifying letters run clockwise and female connectors identifying letters run counterclockwise.
M0133105
Electrical Harness Identification.
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DISASSEMBLY Female-Type Panel Mounting Receptacle
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. Push socket contacts (Figure 3, Item 2) out through rear of insert (Figure 3, Item 3) with pin extractor. Unsolder cable leads (Figure 3, Item 1) from solder wells on socket contacts (Figure 3, Item 2). Slide insert (Figure 3, Item 3) out through rear of shell (Figure 3, Item 4).
4 3 2 1
M0134105
Figure 3. Electrical Harness Disassembly.
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Male-Type Panel Mounting Receptacle
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. Push pin contacts (Figure 4, Item 2) out through rear of insert (Figure 4, Item 3) with pin extractor. Unsolder cable leads (Figure 4, Item 1) from solder wells on pin contacts (Figure 4, Item 2). Slide insert (Figure 4, Item 3) out through rear of shell (Figure 4, Item 4).
4 2 3
M0135105
Figure 4.
Electrical Harness Disassembly.
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Female-Type Panel Mounting Receptacle with Ridged Locking Nut
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. 4. 5. Unscrew nut (Figure 5, Item 5) from shell assembly and slide back on cable. Slide grommet (Figure 5, Item 4) back on cable leads (Figure 5, Item 6). Push socket contacts (Figure 5, Item 3) out through front of insert (Figure 5, Item 2) with pin extractor. Push insert (Figure 5, Item 2) out through rear of shell (Figure 5, Item 1). Unsolder cable leads (Figure 5, Item 6) from socket contacts (Figure 5, Item 3).
4 1 2 3
M0136105
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Male-Type Panel Mounting Receptacle with Ridged Locking Nut
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. 4. 5. Unscrew nut (Figure 6, Item 2) from shell assembly and slide back on cable. Push grommet (Figure 6, Item 3) back on cable leads (Figure 6, Item 1). Push pin contacts (Figure 6, Item 4) out through rear of insert (Figure 6, Item 5) with pin extractor. Push insert (Figure 6, Item 5) out through rear of shell (Figure 6, Item 6). Unsolder leads (Figure 6, Item 1) from pin contacts (Figure 6, Item 4).
5 3 2 1
M0137105
Figure 6.
0163-7
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0163
Female-Type Plug with Ridged Locking Nut
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. 4. 5. 6. Unscrew nut (Figure 7, Item 2) from shell assembly and slide back on cable. Push grommet (Figure 7, Item 3) back on cable leads (Figure 7, Item 1). Push coupling nut (Figure 7, Item 4) off shell (Figure 7, Item 7). Push socket contacts (Figure 7, Item 5) out through rear of insert (Figure 7, Item 6) with pin extractor. Push insert (Figure 7, Item 6) out through rear of shell (Figure 7, Item 7). Unsolder leads (Figure 7, Item 1) from pin contacts (Figure 7, Item 5).
1 2 3 4 5 6 7
M0138105
0163-8
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0163
Male-Type Plug with Ridged Locking Nut
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. 4. 5. 6. Unscrew nut (Figure 8, Item 2) from shell cables, assembly and slide back on cable. Push grommet (Figure 8, Item 3) back on cable leads (Figure 8, Item 1). Push coupling nut (Figure 8, Item 4) off shell assembly. Drive pin contacts (Figure 8, Item 5) out through rear of insert (Figure 8, Item 6) with pin extractor. Push insert (Figure 8, Item 6) out through rear of shell (Figure 8, Item 7). Unsolder cable leads (Figure 8, Item 1) from pin contacts (Figure 8, Item 5).
4 2 1 3
M0139105
Figure 8.
0163-9
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0163
Cable Connectors
WARNING
Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. Cut and discard connectors for terminal-type cables, female cables with washers or sleeves, and male cables with washers. END OF TASK ASSEMBLY Terminal-Type Cable Connector 1. 2. 3. 4. 5. Strip cable insulation equal to depth of well. Slide insulator (Figure 9, Item 2) over cable (Figure 9, Item 1). Insert cable (Figure 9, Item 1) into terminal (Figure 9, Item 3) well and crimp. Slide insulator (Figure 9, Item 2) over crimped end of terminal (Figure 9, Item 3). Connect battery cables (WP 0076).
3 2 1
M0140105
Figure 9.
Electrical Harness Assembly.
0163-10
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0163
Female Cable Connector with Washer 1. 2. 3. 4. 5. Strip cable insulation approximately 0.125 inches (3.2 mm). Slide shell (Figure 10, Item 2) and washer (Figure 10, Item 3) over cable (Figure 10, Item 1). Place cable (Figure 10, Item 1) in cylinder end of terminal and crimp. Slide shell (Figure 10, Item 2) and washer (Figure 10, Item 3) over terminal (Figure 11, Item 4). Connect battery cables (WP 0076).
1 2 3 4
M0353105
Figure 10. Male Cable Connector with Washer 1. 2. 3. 4. 5.
Strip cable insulation equal to depth of ferrule well. Slide shell (Figure 11, Item 2) over cable (Figure 11, Item 1). Insert cable (Figure 11, Item 1) into terminal (Figure 11, Item 4) well and crimp. Place C-washer (Figure 11, Item 3) over cable (Figure 11, Item 1) at crimped junction and slide shell (Figure 11, Item 2) over C-washer and terminal (Figure 11, Item 4). Connect battery cables (WP 0076).
2 3 4
M0141105
Figure 11.
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ASSEMBLY - Continued Female Cable Connector with Sleeve 1. 2. 3. 4. 5. Strip cable insulation approximately 0.125 inches (3.2 mm). Slide shell (Figure 12, Item 1) and sleeve (Figure 12, Item 2) over cable (Figure 12, Item 4). Place cable (Figure 12, Item 4) in cylinder end of terminal (Figure 12, Item 1) and crimp. Slide shell (Figure 12, Item 3) and sleeve (Figure 12, Item 2) over terminal (Figure 12, Item 1). Connect battery cables (WP 0076).
4 3 1 2
M0142105
Figure 12. Electrical Harness Assembly. Male-Type Plug with Ridged Locking Nut 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Strip cable of insulation equal to depth of solder wells of pin contacts (Figure 13, Item 5). Slide nut (Figure 13, Item 2) over cable leads (Figure 13, Item 1). Slide grommet (Figure 13, Item 3) over cable leads (Figure 13, Item 1). Insert cable leads (Figure 13, Item 1) into solder wells of pin contacts (Figure 13, Item 5) and solder (use rosin core solder only). Push insert (Figure 13, Item 6) into shell (Figure 13, Item 7) from rear until seated. Groove in insert must be aligned with guide in shell to ensure proper fit. Push pin contacts (Figure 13, Item 5) into insert (Figure 13, Item 6) from rear until seated. Slide coupling nut (Figure 13, Item 4) onto shell assembly. Push grommet (Figure 13, Item 3) down cable leads (Figure 13, Item 1) over solder wells of pin contacts (Figure 13, Item 5). Screw nut (Figure 13, Item 2) onto shell assembly. Tape cable leads as required. Connect battery cables (WP 0076).
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0163
ASSEMBLY - Continued Male-Type Plug with Ridged Locking Nut - Continued
4 2 1 3
M0143105
Figure 13.
0163-13
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0163
Female-Type Plug with Ridged Locking Nut 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Strip cable insulation equal to depth of solder wells of socket contacts (Figure 14, Item 5). Slide nut (Figure 14, Item 2) over cable leads (Figure 14, Item 1). Slide grommet (Figure 14, Item 3) over cable leads (Figure 14, Item 1). Insert cable leads (Figure 14, Item 1) into solder wells of socket contacts (Figure 14, Item 5) and solder (use rosin core solder only). Push insert (Figure 14, Item 6) into shell assembly (Figure 14, Item 7) from rear until seated. Groove in insert must be aligned with guide in shell to ensure proper fit. Push socket contacts (Figure 14, Item 5) into insert (Figure 14, Item 6) from rear until seated. Slide coupling nut (Figure 14, Item 4) onto shell assembly (Figure 14, Item 7). Push grommet (Figure 14, Item 3) down cable leads (Figure 14, Item 1) over solder wells of socket contacts (Figure 14, Item 5) Screw nut (Figure 14, Item 2) onto shell assembly. Tape cable leads as required. Connect battery cables (WP 0076).
1 2 3 4 5 6 7
Figure 14. Electrical Harness Assembly.
M0144105
0163-14
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Male-Type Panel Mounting Receptacle with Ridged Locking Nut 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Strip cable insulation equal to depth of solder wells of pin contacts (Figure 15, Item 4). Slide nut (Figure 15, Item 2) over cable leads (Figure 15, Item 1). Slide grommet (Figure 15, Item 3) over cable leads (Figure 15, Item 1). Insert cable leads (Figure 15, Item 1) into solder wells of pin contacts (Figure 15, Item 4) and solder (use rosin core solder only). Push insert (Figure 15, Item 5) into shell (Figure 15, Item 6) from rear until seated. Groove in insert must be aligned with guide in shell to ensure proper fit. Push pin contacts (Figure 15, Item 4) into insert (Figure 15, Item 5) from rear until seated. Push grommet (Figure 15, Item 3) down cable leads (Figure 15, Item 1) and over solder wells of pin contacts (Figure 15, Item 5) Screw nut (Figure 15, Item 2) onto shell assembly. Tape cable leads as required. Connect battery cables (WP 0076).
5 3 2 1
M0145105
Figure 15.
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Female-Type Panel Mounting Receptacle with Ridged Locking Nut 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Strip cable insulation equal to depth of solder wells of socket contacts (Figure 16, Item 3). Slide nut (Figure 16, Item 5) over cable leads (Figure 16, Item 6). Slide grommet (Figure 16, Item 4) over cable leads (Figure 16, Item 6). Insert cable leads (Figure 16, Item 6) into solder wells of socket contacts (Figure 16, Item 3) and solder (use rosin core solder only). Push insert (Figure 16, Item 2) into shell (Figure 16, Item 1) from rear until seated. Groove in insert must be aligned with guide in shell to ensure proper fit. Push socket contacts (Figure 16, Item 3) into insert (Figure 16, Item 2) from rear until seated. Push grommet (Figure 16, Item 4) down cable leads (Figure 16, Item 6) and over solder wells of socket contacts (Figure 16, Item 3). Screw nut (Figure 16, Item 5) onto shell assembly. Tape cable leads as required. Connect battery cables (WP 0076).
4 1 2 3
M0146105
Figure 16. Electrical Harness Assembly.
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Male-Type Panel Mounting Receptacle 1. 2. 3. 4. 5. 6. Strip cable insulation equal to depth of solder wells of pin contacts (Figure 17, Item 2). Insert cable leads (Figure 17, Item 1) into solder wells of pin contacts (Figure 17, Item 2) and solder (use rosin core solder only). Push insert (Figure 17, Item 3) into shell (Figure 17, Item 4) from rear until seated. Groove in insert must be aligned with guide in shell to ensure proper fit. Push pin contacts (Figure 17, Item 2) into insert (Figure 17, Item 3) from rear until seated. Tape cable leads as required. Connect battery cables (WP 0076).
4 2 3
M0147105
Figure 17.
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Female-Type Panel Mounting Receptacle 1. 2. 3. 4. 5. 6. Strip cable insulation equal to depth of solder wells of pin contacts (Figure 18, Item 2). Insert cable leads (Figure 18, Item 1) into solder wells of socket contacts (Figure 18, Item 2) and solder (use rosin core solder only). Push insert (Figure 18, Item 3) into shell (Figure 18, Item 4) from rear until seated. Groove in insert must be aligned with guide in shell to ensure proper fit. Push socket contacts (Figure 18, Item 2) into insert (Figure 18, Item 3) from rear until seated. Tape cable leads as required. Connect battery cables (WP 0076).
3 2 1
M0148105
Figure 18. Electrical Harness Assembly. END OF TASK END OF WORK PACKAGE
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FIELD MAINTENANCE PREPARATION FOR SHIPMENT AND STORAGE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Oil Filter, Strap (WP 0171, Table 1, Item 32) Materials/Parts Antifreeze, (WP 0170, Table 1, Item 2) Qty: 2 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Lubricating Oil, Hydraulic (WP 0170, Table 1, Item 42) Qty: 1 Lubricating Oil, Preservative and Break-In (WP 0170, Table 1, Item 45) Qty: 1 Materials/Parts (cont.) Motorstor (WP 0170, Table 1, Item 48) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Soda, Baking (WP 0170, Table 1, Item 67) Qty: 1 Tape, Pressure Sensitive Adhesive (WP 0170, Table 1, Item 69) Qty: 1 References TM 5-3810-305-10 WP 0022 WP 0046 WP 0076 WP 0152 WP 0153 WP 0162
Vehicles being placed in storage must be adequately protected from deterioration during the period of idleness. This will ensure that they can be restored to active service with a minimum effort. Determine the amount of time that the vehicle will be in storage. This will determine which procedure will be followed in preparing the crane. Storage procedures for 30 days or less will be found under Short Term Storage (30 Days or Less). Storage procedures for more than 30 days will be found under Long Term Storage (More Than 30 Days), both of which can be found in this work package. SHORT TERM STORAGE (30 DAYS OR LESS) The crane should be thoroughly cleaned, lubricated, and painted surfaces retouched anywhere paint has deteriorated. Exposed portions of all hydraulic cylinder rods should be coated with multipurpose grease. Coat unpainted metal surfaces with multipurpose grease after removing any rust accumulation. When an engine is to be stored or removed from operation for a period of time, special precautions should be taken to protect the interior and exterior of the engine, transmission, and other parts from rust accumulation and corrosion. The parts requiring attention and the recommended preparations are given below. It will be necessary to remove all rust or corrosion completely from any exposed part before applying a rust-preventive compound. Therefore, it is recommended that the engine be processed for storage as soon as possible after removal from operation. 1. 2. 3. Drain the engine crankcase of oil (WP 0022). Fill the crankcase to the proper level with the recommended viscosity and grade of oil. Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two minutes at 1,200 rpm and no load.
NOTE
DO NOT drain the fuel system or the crankcase after this run.
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SHORT TERM STORAGE (30 DAYS OR LESS) - Continued 4. 5. 6. 7. Check the air cleaner and service it if necessary. If freezing weather is expected during the storage period, check the antifreeze for the low freeze point capability. Clean the entire exterior of the engine (except the electrical system) with fuel oil and dry it with compressed air. Seal all of the engine openings. The material used for this purpose must be waterproof, vaporproof, and possess sufficient physical strength to resist puncture and damage from the expansion of entrapped air.
The following procedures will prepare a transmission for a storage period of 30 days or less: 1. 2. 3. Drain the transmission oil and remove the transmission oil filter element. Install the drain plugs and new oil filter element. Refill to operating level with lubricating oil.
CAUTION
DO NOT allow temperature to exceed 250F (121C). Failure to follow this caution may result in damage to equipment. 4. Operate the unit for at least 5 minutes at a minimum of 1,000 rpm. Shift the transmission slowly through all selector positions to thoroughly distribute the oil, then stall the converter to raise the oil temperature to 225F (107C). As soon as the unit is cool enough to touch, seal all openings and breathers with moisture-proof tape. Coat all exposed, unpainted surfaces with a good grade of preservative grease.
5. 6.
END OF TASK LONG TERM STORAGE (MORE THAN 30 DAYS)
NOTE
Long-term storage requires greater preparation than short-term storage and must be undertaken with greater care. The crane should be prepared as follows: 1. 2. 3. 4. Perform the short-term vehicle storage preparation, making certain that all points with grease fittings are liberally lubricated in this work package. Drain and refill the swing reducer, winch, axle differentials, planetary hubs, and hydraulic reservoir. Distribute new hydraulic oil to all parts of the system by operating all functions. Clean the batteries and battery cables with a baking soda solution and rinse them with fresh water. Do not allow the soda solution to enter the battery. Add distilled water to the electrolyte, if necessary, and fully charge the batteries. Coat the external ring gear of the swing bearing with open gear lubricant. Fill the hydraulic reservoir to the top after the vehicle is parked in its storage spot. Coat wire rope with lubricant (TM 5-3810-305-10). Coat exposed cylinder rods with grease.
5. 6. 7. 8.
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0164
LONG TERM STORAGE (MORE THAN 30 DAYS) - Continued Prepare the engine for long-term storage as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Drain and thoroughly flush the cooling system with clean, soft water. Refill the cooling system with clean, soft water. Add a rust inhibitor to the cooling system. Remove, check, and recondition the injectors, if necessary, to ensure they will be ready to operate when the engine is restored to service. Reinstall the injectors in the engine, time them, and adjust the valve clearance. Circulate the coolant through the entire system by operating the engine until normal operating temperature is reached (160 to 185F [71 to 85C]). Stop the engine. Remove the drain plug and completely drain the engine crankcase. Reinstall and tighten the drain plug. Install new lubricating oil filter to elements and gaskets. Fill the crankcase to the proper level with a 30-weight preservative lubricating oil. Drain the engine fuel tank. Refill the fuel tank with enough rust-preventive fuel oil to enable the engine to operate 10 minutes. Drain the fuel filter and strainer. Remove the retaining bolts, shells, and elements. Discard the used elements and gaskets. Wash the shells in clean fuel oil and insert new elements. Fill the cavity between the element and shell about two-thirds full of the same rust-preventive compound as used in the fuel tank and reinstall the shell. Operate the engine for 5 minutes to circulate the rust-preventive compound throughout the engine. Service the air cleaner. Apply a non-friction, rust-preventive compound to all exposed parts. If it is convenient, apply the rust-preventive compound to the engine flywheel. Drain the engine cooling system (tag cap). The oil may be drained from the engine crankcase if so desired. If the oil is drained, reinstall and tighten the drain plug (tag cap). Clean the batteries and battery cables with a baking soda solution and rinse them with fresh water. Insert heavy paper strips between the pulleys and belts to prevent sticking. Seal all of the openings in the engine, including the exhaust outlet, with moisture-resistant tape. Use cardboard, plywood, or metal covers where practical. Clean and dry the exterior painted surfaces of the engine. Spray the surfaces with a suitable liquid automobile body wax, a synthetic resin varnish, or a rust-preventive compound. Cover the engine with a good weather-resistant tarpaulin or other cover if it must be stored outdoors. A clear plastic cover is recommended for indoor storage.
13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
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LONG TERM STORAGE (MORE THAN 30 DAYS) - Continued The stored engine should be inspected periodically. If there are any indications of rust or corrosion, corrective steps must be taken to prevent damage to the engine parts. Perform a complete inspection at the end of one year and apply additional treatment as required. There are two methods of preparing the transmission for long-term storage: without oil and with oil. Long-term storage without oil: 1. 2. 3. 4. 5. Drain oil. Seal all openings and breathers, except oil drain hole, with moisture-proof tape. Coat all exposed, unpainted surfaces with a good grade of preservative grease. Atomize or spray 2 ounces (59 ml) of rust-preventative mixture into the transmission through the oil drain hole. Install the drain plug. If additional storage time is required, Steps 3 and 4 above should be repeated at yearly intervals.
Long-term storage with oil: 1. 2. 3. Drain oil and remove the transmission oil filter element(s). Install the drain plugs and new filter element(s). Fill the transmission to operating level with a mixture of 30 parts hydraulic transmission oil preservative.
CAUTION
DO NOT allow temperature to exceed 250F (121C). Failure to follow this caution may result in damage to equipment. 4. Operate the unit for approximately 5 minutes at a minimum of 1,000 rpm. Shift the transmission slowly through all selector positions to thoroughly distribute the oil, then stall the converter to raise the oil temperature to 225F (107C). As soon as the unit is cool enough to touch, seal all openings and breathers with moisture-proof tape. Coat all exposed, unpainted surfaces with a good grade of preservative grease. If additional storage time is required, Steps 3 through 6 above should be repeated at yearly intervals, except it is not necessary to drain the transmission each year - just add rust-preventative mixture.
5. 6. 7.
END OF TASK RESTORATION TO SERVICE Remove the crane from storage using the following procedure: 1. 2. 3. 4. Remove preservative lubricants from all surfaces (WP 0162). Check all fluid levels, adding or draining as required. Lubricate the vehicle according to lubrication instructions, making certain that all points with grease fittings are lubricated. Make a thorough visual inspection of the entire vehicle, placing special emphasis on the condition of all hydraulic hoses.
END OF TASK
0164-4
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RESTORING ENGINE TO SERVICE 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the covers and tape from all the openings of the engine, fuel tank, and electrical equipment. Do not overlook the exhaust outlet. Wash the exterior of the engine with fuel oil to remove the rust-preventive compound. Remove the paper strips from between the pulleys and belts. Check the crankcase oil level. Fill the crankcase to the proper level with the recommended lubricating oil (WP 0022). Fill the fuel tank with the fuel specified. Close the drain cock and fill the engine cooling system with a clean antifreeze solution of 50% Base/50% water. Install and connect the battery (WP 0076). Service the air cleaner (WP 0046). The small amount of rust-preventive compound which remains in the fuel system will cause a smoky exhaust for a few minutes.
END OF TASK RESTORING TRANSMISSION TO SERVICE
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel. If rust-preventative mixture was used in preparing the transmission for storage, use the following procedure to restore the unit to service: 1. 2. 3. Remove the tape from all openings and breathers. Wash off all the external grease with solvent. Add hydraulic transmission oil to proper level (WP 0153).
NOTE
It is not necessary to drain oil to remove the rust-preventive compound mixture from the transmission. If rust-preventative mixture was not used in preparing the transmission for storage, use the following procedure to restore the unit to service: 1. 2. 3. 4. Remove the tape from all openings and breathers. Wash off all the external grease with solvent. Drain oil (WP 0022). Install new oil filter elements (WP 0022).
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RESTORING TRANSMISSION TO SERVICE - Continued 5. Refill transmission with hydraulic transmission oil to proper level (WP 0152).
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FIELD MAINTENANCE TORQUE LIMITS
0165-1
03/15/2011 Rel(1.8) root(torquewp) wpno(M00183)
TM 5-3810-305-23
0165
SCOPE This work package provides general torque limits for screws and nuts used on the 7 1/2 Ton Crane. Special torque limits are indicated in the maintenance procedures for applicable components. General torque limits in this work package shall be used when special torque limits are not indicated in the maintenance procedures. TORQUE LIMITS Table 1 lists dry torque limits. Dry torque limits are used on screws that have not had lubricants applied to the threads. Table 2 lists wet torque limits. Wet torque limits are used on screws that have had lubricants applied to the threads. Unless the maintenance procedure indicated otherwise, lubricate threads of screws with oil (OE/HDO-10 or OEA). When tightening screws to torque limits of 30 ft-lb (41 Nm) and above, use the torque sequence for the component specified in the maintenance procedures or the general circular or straight sequences. Tighten screws to 70 percent of their final value, then repeat the pattern until the final value is reached. HOW TO USE TORQUE LIMIT TABLES 1. Measure the diameter of the screw being installed. 2. Count the number of threads in 1 inch (2.5 cm) of screw length. 3. Under the SIZE heading in Tables 1 or 2, look down the left-hand column to find the diameter of the screw being installed, measure in Step 1. There are usually two listings. 4. In the right-hand column under the SIZE heading, find the number of threads per inch counted in Step 2. 5. To find the grade of screw being installed, match the marking on the head of the screw being installed with the correct picture in SCREW MARKINGS on Tables 1 and 2. 6. Look down the SAE GRADE column in the TORQUE column in Tables 1 or 2 to find the correct torque limit for the screw being installed.
FASTENER IDENTIFICATION
CAUTION
When installing capscrews, always ensure they are replaced in their proper locations. When replacing capscrews or nuts, always use a new capscrew or nut of the same size and strength. DO NOT use standard torque chart values if a specific torque is referenced in the procedure. All torque values listed in this manual are dry torques. Dry hardware is defined as hardware as received from supply without additional lubricants being applied. Failure to follow these cautions may result in damage to equipment.
NOTE
The 7 1/2 Ton Crane uses both English and Metric Dimensions.
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FASTENER IDENTIFICATION - Continued
GRADE 2
GRADE 5
GRADE 8
M0680105
Figure 1.
English Capscrew Heads.
GRADE 2 NO MARKING
GRADE 5 3 MARKS 120 DEGREES APART ON CORNERS
GRADE 8 6 MARKS
M0681105
Figure 2.
English Nut Markings.
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FASTENER IDENTIFICATION - Continued Then, measure the length of the torque wrench. Measure the wrench from the center of the handle to the center of the connecting point with the socket or adapter. Calculate what the dial indicator or clicker setting should be using the following formula:
Dial indicator or = Clicker Setting For Metric Measurement Fasteners
Torque Wrench Length x Torque Desired Torque Wrench Length + Extension Length
Markings on capscrews, screws, and studs should be obligatory for property classes equal to or higher than 8.8, preferably on top of the head by indenting or embossing on the side of the head. Marking is required for socket head capscrews with a nominal diameter greater than M5. Studs must be marked at nut end.
CAPSCREWS
SCREWS
STUDS
M0470105
Figure 3. Metric Fastener Markings.
0165-4
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How Adapters Affect Torque Limits Torque wrenches have built-in devices (i.e. dials or clicks) which indicate to a mechanic when the desired torque limit has been reached. However, when adapters or extensions are used on the torque wrench that increase the length of the wrench, the torque applied will be greater than the dial reading, or preset torque limit. Some quick mathematics will help the mechanic decide what the dial reading or preset torque limit should be to obtain the desired torque limit when an adapter or extension is used. First, measure the length of the extension from the center of the connecting point with the torque wrench to the center of the socket. For example: A 6 inch extension is used on 18 inch torque wrench. The torque desired on the screw is 300 ft-lb (407 Nm). Using the formula, the dial indicator reading or clicker setting can be determined.
18 x 300 = 18 + 6
5400 = 24 225 ft-lb (305 Nm)
Therefore, a dial indicator reading of 225 ft-lb (305 Nm), or a clicker setting of the same level will result in the desired torque of 300 ft-lb (407 Nm) being applied. In most cases, adapters that add 1 inch (2.5 cm) or less to the torque wrench length do not require recalculating torque. Only if the desired torque has an exceedingly tight tolerance should the new torque be calculated. Be careful when deciding the length of the adapter. In the example above, the extension will not affect the torque reading.
M0471105
Figure 4.
Fastener Symbol Markings.
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FASTENER IDENTIFICATION - Continued In the example above, the adapter will affect the torque. But use only the distance the wrench is extended by the adapter (B), no the actual length of the adapter, when calculating the new torque.
M0472105
Figure 5.
Fastener Indented Markings.
M0473105
Figure 6.
Metric Capscrew Nomenclature.
0165-6
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0165
FASTENER IDENTIFICATION - Continued FASTENER TORQUE VALUES Table 1. Engine Fastener Torque Values. TORQUE SIZE THREAD DIAMETER MM 5 6 7 10 12 14 16 18 5 7 10 18 32 57 94 144 190 CLASS 8.8 CLASS 10.9 CLASS 12.9
FT-LB 7 9 14 24 43 77 127 195 258
Nm 6 10 15 25 47 83 133 196 265
FT-LB 8 14 20 34 64 113 180 266 359
Nm 6 10 20 28 57 101 159 235 325
FT-LB 8 14 27 38 77 137 216 319 441
Nm
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CAUTION
DO NOT use standard torque chart values if a specific torque is referenced in the procedure. Failure to follow this caution may result in damage to equipment. Table 2. Transmission Fastener Torque Values. TORQUE SIZE SAE GRADE 5 DIAMETER (INCHES) 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 25.40 22.23 19.05 15.58 14.29 12.70 11.11 9.53 7.94 THREADS PER INCH (MILLIMETERS) 6.35 8 10 17 19 30 35 50 55 75 85 110 120 150 170 270 300 400 440 580 640 FT-LB 11 14 23 26 41 47 68 73 102 115 149 163 203 230 366 407 542 597 786 868 Nm
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FASTENER IDENTIFICATION - Continued Table 2. Transmission Fastener Torque Values - Continued. TORQUE SIZE SAE GRADE 5 DIAMETER (INCHES) 1-1/8 1-1/8 1-1/4 1-1/4 1-3/8 1-3/8 1-1/2 1-1/2 7 12 7 12 6 12 6 12 38.10 34.93 31.75 THREADS PER INCH (MILLIMETERS) 28.58 800 880 1120 1240 1470 1680 1940 2200 FT-LB 1085 1193 1519 1681 1980 2278 2631 2983 Nm
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NOTE
Torque values are to be within +/- 5 percent. Table 3. All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values. TORQUE SIZE DIAMETER MM 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 1 1-1/8 1-1/4 4 6 7* 12 12 * 20 20 35 30 50 45 75 60 100 110 180 175 265 375 530 SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
FT-LB 5 8 9* 16 16 * 27 27 * 47 41 * 68 61 * 102 81 * 136 149 * 244 237 359 580 719
Nm 8
FT-LB 11
Nm 12
FT-LB 16
Nm
20
27
25
34
30
41
45
61
50
68
75
102
80
108
110
149
115
156
160
217
160
217
2215
305
280
380
400
542
450 680 840 1,200
610 922 1,139 1,627
640 970 1,380 1,930
868 1,315 1,871 2,617
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FASTENER IDENTIFICATION - Continued Table 3. All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values Continued. TORQUE SIZE 1-3/8 1-1/2 1-3/4 2 2-1/4 2-1/2 700 930 1,460 2,200 3,200 4,400 SAE GRADE 2 949 1,261 1,979 2,983 4,339 5,966 1,570 2,080 2,430 3,200 5,350 7,300 SAE GRADE 5 2,129 2,820 3,295 4,339 7,254 9,897 2,540 3,380 5,300 7,990 11,690 15,990 SAE GRADE 8 3,444 4,583 7,186 10,833 15,849 21,679
Torque values for bolts and screws longer than 6 in. (152 mm).
0165-11
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0165
NOTE
The values result in 75 percent use of the screw yield point with a coefficient of friction total 0.20. The compliance with the tightening torques is controlled by torque wrenches. Table 4. All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values. TORQUE SIZE DIAMETER MM M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 N127 M30 2.5 5 8 20 41 71 113 17 243 344 468 594 940 1,307 GRADE 8.8 GRADE 10.9 GRADE 12.9
FT-LB 3.4 7 11 27 56 96 153 239 329 466 635 805
Nm 3.5 7 12 29 57 100 160 249 343 486 661 840
FT-LB 4.7 9 16 39 77 136 217 338 465 659 896
Nm 4 8 14 34 68 119 189 294 405 574 781 993
FT-LB 5.4 11 19 46 92 161 256 399 549 778
Nm
1,059 1,346 2,127 2,960
1,139 1,801 2,504
1,274 1,772
1,328 1,847
1,569 2,183
CAUTION
DO NOT use standard torque chart values if a specific torque is referenced in the procedure. Failure to follow this caution may result in damage to equipment.
0165-12
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0165
FASTENER IDENTIFICATION - Continued Table 5. Torque Limits for Dry Fasteners. TORQUE SIZE SAE GRADE 2 Nm 7 9 15 16 27 31 41 47 68 75 88 102 122 136 149 169 190 210 298 325 407 461 SAE GRADE 5 FT-LB 8 10 17 19 30 35 50 55 75 90 110 120 150 180 260 300 400 440 580 640 800 880 Nm 11 14 23 26 41 47 68 73 102 122 149 163 203 244 353 407 542 597 786 868 1085 1193 SAE GRADE 6 OR 7 FT-LB 10 12 21 24 40 45 60 70 95 100 135 150 190 210 320 360 520 580 800 860 1120 1260 Nm 14 16 28 33 54 61 81 95 129 136 183 203 238 285 434 488 705 786 1085 1166 1519 1709 SAE GRADE 8 FT-LB 12 14 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 1280 1440 Nm 16 19 34 34 61 65 95 105 149 163 203 231 298 325 515 597 814 895 1220 1356 1736 1953
DIAMETER THREADS (MILLIMETERS) FT-LB (INCHES) PER INCH 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/8 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 28.58 25.40 22.23 19.05 15.58 14.29 12.70 11.11 9.53 7.94 6.35 5 6 11 12 20 23 30 35 50 55 65 75 90 100 110 125 140 155 220 240 300 340
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FASTENER IDENTIFICATION - Continued Table 5. Torque Limits for Dry Fasteners - Continued. TORQUE SIZE SAE GRADE 2 Nm 570 624 759 868 1003 1139 SAE GRADE 5 FT-LB 1120 1240 1470 1680 1940 2200 Nm 1519 1681 1980 2278 2631 2983 SAE GRADE 6 OR 7 FT-LB 1580 1760 2080 2380 2780 3100 Nm 2142 2387 2820 3227 3770 4204 SAE GRADE 8 FT-LB 1820 2000 2380 2720 3160 3560 Nm 2468 2712 3227 3688 4285 4827
DIAMETER THREADS (MILLIMETERS) FT-LB (INCHES) PER INCH 1-1/4 1-1/4 1-3/8 1-3/8 1-1/2 1-1/2 7 12 6 12 6 12 38.10 34.93 31.75 420 460 560 640 750 840
Table 6. Torque Limits for Wet Fasteners. TORQUE SIZE SAE GRADE 2 Nm 6 7 11 12 20 23 33 34 47 54 SAE GRADE 5 FT-LB 6 7 13 14 23 25 35 40 55 65 Nm 8 9 18 19 31 34 47 54 75 88 SAE GRADE 6 OR 7 FT-LB 8 9 16 18 30 30 45 50 70 80 Nm 11 12 22 24 41 41 61 63 95 108 SAE GRADE 8 FT-LB 9 10 18 20 35 35 55 60 80 90 Nm 12 14 24 28 47 47 75 81 108 123
DIAMETER THREADS (MILLIMETERS) FT-LB (INCHES) PER INCH 1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 20 28 18 24 16 24 14 20 13 20 12.70 11.11 9.53 7.94 6.35 4 5 8 9 15 17 24 25 35 40
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FASTENER IDENTIFICATION - Continued Table 6. Torque Limits for Wet Fasteners - Continued. TORQUE SIZE SAE GRADE 2 Nm 60 75 95 108 122 136 149 163 217 231 298 353 434 488 570 624 760 841 SAE GRADE 5 FT-LB 80 90 110 130 200 220 300 320 440 480 600 660 840 920 1103 1260 1460 1640 Nm 108 122 149 176 271 298 407 434 597 651 814 893 1139 1248 1492 1709 1980 2224 SAE GRADE 6 OR 7 FT-LB 100 110 140 160 240 280 400 440 600 660 540 940 1100 1320 1560 1780 2080 2320 Nm 136 149 190 217 325 380 542 597 814 895 1139 1275 1492 1790 2115 2414 2820 3146 SAE GRADE 8 FT-LB 110 130 170 180 280 320 460 500 680 740 960 1080 1360 1500 1760 2040 2360 2660 Nm 149 170 231 273 378 434 624 678 922 1003 1302 1464 1844 2034 2414 2760 3288 3607
DIAMETER THREADS (MILLIMETERS) FT-LB (INCHES) PER INCH 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/8 1-1/4 1-1/4 1-3/8 1-3/8 1-1/2 1-1/2 END OF TASK END OF WORK PACKAGE 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 38.10 34.93 31.75 25.58 25.40 22.23 19.05 15.88 14.29 50 55 70 80 90 100 110 120 160 170 220 260 320 360 420 460 560 620
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FIELD MAINTENANCE DIAGRAMS
INITIAL SETUP: Not Applicable
SCHEMATICS Vehicle Electrical Schematic. (FO-1) Electrical System Identification. (FO-2) MSD/ICE Electrical Schematic. (FO-3) Hydraulic System Schematic. (FO-4)
END OF WORK PACKAGE
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CHAPTER 5 SUPPORTING INFORMATION
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FIELD MAINTENANCE REFERENCES
SCOPE This work package lists all forms, field manuals, technical manuals, and other publications referenced in this manual and which apply to the operation of the 7 1/2 Ton Crane.
FORMS Refer to DA PAM 750-8, The Army Maintenance Management System (TAMMS) User's Manual, for instructions on the use of maintenance forms pertaining to the vehicle. DA Form 2028 DA Form 2404 DA Form 5988-E Recommended Changes to Publications and Blank Forms Lubrication Record Recommended Changes to Publications and Blank Forms
PUBLICATION INDEXES DA PAM 25-30 Consolidated Index of Army Publications and Blank Forms
PUBLICATION REFERENCES General CTA 8-100 CTA 50-970 DA PAM 750-8 FM 4-25.11 FM 9-207 FM 21-60 FM 31-70 FM 31-71 SF 368 TM 43-0139 TM 9-214 Army Medical Department Expendable/Durable Items Expendable/Durable Items (Except Medical, Class V. Repair Parts, and Heraldic Items) The Army Maintenance Management System (TAMMS) User's Manual First Aid Operation and Maintenance of Army Materiel in Extreme Cold Weather 0 to -65F (TO 36-1-40) Visual Signals Basic Cold Weather Manual Northern Operations Product Quality Deficiency Report Painting Instructions for Field Use Inspection, Care, and Maintenance of Antifriction Bearings
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Vehicle NAVSEA S9074-AQ-GIB-010/248 TM 5-3810-305-10 Requirements for Welding, Metal Arc and Gas Crane, Wheel Mounted, Hydraulic, Light, 7 1/2 Ton (Rough Terrain Crane) LRT 110 Type 1 General Purpose Type (NSN 3810-01-165-0646) II Airborne/Airmobile (NSN 3810-01-165-0647) Simplified Test Equipment For Internal Combustion Engines Technical Manual for Recharging Procedures for Automotive Valve Regulated Lead-Acid Batteries Transportability Guidance For The Crane, 7 1/2 Ton, Rough Terrain, Type 1, (NSN 3810-01-165-0646), Type 2 (NSN 3810-01-165-0647). Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems Solder and Soldering
TM 9-4910-571-12&P TB 9-6140-252-13 TM 55-3810-01-165-14
TB 750-651 TB SIG-222 END OF WORK PACKAGE
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0168
FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
The Army Maintenance System MAC This introduction provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two-Level Maintenance System concept. This MAC (immediately following the introduction) designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component shall be consistent with the capacities and capabilities of the designated maintenance levels, which are shown on the MAC in Column (4) as: Field (includes two subcolumns): C - Crew and F - Maintainer. Sustainment (includes two subcolumns): H - Below Depot and D - Depot. The maintenance to be performed at field and sustainment levels is described as follows: 1. Crew maintenance. The responsibility of a using organization to perform maintenance on its assigned equipment. It normally consists of inspecting, servicing, lubricating, adjusting, and replacing parts, minor assemblies, and subassemblies. The replace function for this level of maintenance is indicated by the letter C" in the third position of the SMR code. A C" appearing in the fourth position of the SMR code indicates complete repair is possible at the crew maintenance level. 2. Maintainer maintenance. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter F" appearing in the third position of the SMR code. An F" appearing in the fourth position of the SMR code indicates complete repair is possible at the field maintenance level. Items are returned to the user after maintenance is performed at this level. 3. Below depot sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter H" appearing in the third position of the SMR code. An H" appearing in the fourth position of the SMR code indicates complete repair is possible at the below depot sustainment maintenance level. Items are returned to the supply system after maintenance is performed at this level. 4. Depot sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly, plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of maintenance is indicated by the letter D" or K" appearing in the third position of the SMR code. Depot sustainment maintenance can be performed by either depot personnel or contractor personnel. A D" or K" appearing in the fourth position of the SMR code indicates complete repair is possible at the depot sustainment maintenance level. Items are returned to the supply systems after maintenance is performed at this level. The tools and test equipment requirements table (immediately following the MAC) lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from the MAC. The remarks table (immediately following the tools and test equipment requirements) contains supplemental instructions and explanatory notes for a particular maintenance function. MAINTENANCE FUNCTIONS Maintenance functions are limited to and defined as follows: 1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel). This includes scheduled inspection and gagings and evaluation of cannon tubes.
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The Army Maintenance System MAC - Continued 2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift devices and hydrostatic testing of pressure hoses. 3. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases. This includes scheduled exercising and purging of recoil mechanisms. The following are examples of service functions: a. Unpack. To remove from packing box for service or when required for the performance of maintenance operations. b. Repack. To return item to packing box after service and other maintenance operations. c. Clean. To rid the item of contamination. d. Touch up. To spot paint scratched or blistered surfaces. e. Mark. To restore obliterated identification. 4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters. 5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. 6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared. 7. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Installation may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system. 8. Paint (ammunition only). To prepare and spray color coats of paint so that the ammunition can be identified and protected. The color indicating primary use is applied, preferably, to the entire exterior surface as the background color of the item. Other markings are to be repainted as original so as to retain ammunition identification. 9. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. Replacement is authorized by the MAC and the assigned maintenance level is shown as the third position code of the Source, Maintenance and Recoverability (SMR) code. 10. Repair. Repair is the application of maintenance services, including fault location/troubleshooting, removal/ installation, disassembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system.
NOTE
The following definitions are applicable to the repair" maintenance function: Services. Inspect, test, service, adjust, align, calibrate, and/or replace. Fault location/troubleshooting. The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT). Disassembly/assembly. The step-by-step breakdown (taking apart) of a spare/ functional group coded item to the level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e., identified as maintenance significant). Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing. 11. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army.
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The Army Maintenance System MAC - Continued Overhaul does not normally return an item to like new condition. 12. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (e.g., hours/miles) considered in classifying Army equipment/components. EXPLANATION OF COLUMNS IN THE MAC Column (1) Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher Assembly (NHA). Column (2) Component/Assembly. Column (2) contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column (3) Maintenance Function. Column (3) lists the functions to be performed on the item listed in column (2). (For a detailed explanation of these functions refer to Maintenance Functions" outlined above). Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals) in the appropriate subcolumn. This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various maintenance levels are as follows: Field: C - Crew Maintenance and F - Maintainer Maintenance. Sustainment: L - Specialized Repair Activity (SRA), H - Below Depot Maintenance, and D - Depot Maintenance.
NOTE
The L" maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance are identified by a work time figure in the H" column of column (4), and an associated reference code is used in the REMARKS column (6). This code is keyed to the remarks and the SRA complete repair application is explained there. Column (5) Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE and special support equipment required to perform the designated function. Codes are keyed to the entries in the tools and test equipment table. Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the remarks table entries. EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS Column (1) Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a code used in column (5) of the MAC. Column (2) Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. Column (3) Nomenclature. Name or identification of the tool or test equipment. Column (4) National Stock Number (NSN). The NSN of the tool or test equipment.
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The Army Maintenance System MAC - Continued Column (5) Tool Number. The manufacturers part number. EXPLANATION OF COLUMNS IN THE REMARKS Column (1) Remarks Code. The code recorded in column (6) of the MAC. Column (2) Remarks. This column lists information pertinent to the maintenance function being performed as listed in the MAC. END OF WORK PACKAGE
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FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC)
Table 1.
(1) (2) (3)
Maintenance Allocation Chart (MAC).

(4) MAINTENANCE LEVEL FIELD CREW C MAINTAINER F 8.0 SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 6, 7, 11, 15, 17, 18 (6)
GROUP COMPONENT/ MAINTENANCE NUMBER ASSEMBLY FUNCTION
REMARKS CODE
0100-00
ENGINE AND TRANSMISSION ASSEMBLY ENGINE MOUNT CYLINDER HEAD CRANKSHAFT PULLEY FLYWHEEL AND FLYWHEEL HOUSING CRANKSHAFT SEAL REAR ROCKER LEVERS AND PUSHRODS FRONT GEAR COVER AND GASKET TIMING PIN ASSEMBLY TAPPET COVER AND GASKET VALVE COVER(S)
Replace
0100-01
Replace
1.0
17, 18
0101-01
Replace
6.0
2, 17, 18
0102-01
Replace
1.0
17, 18
0103-00
Repair
14.0
6, 11, 17, 18
0103-01
Replace
15.0
17, 18
0105-00
Repair
6.0
14, 17, 18
0105-02
Replace
3.5
17, 18
0105-03
Replace
14.0
17, 18
0105-04
Replace
6.0
17, 18
0105-05
Replace
1.0
17, 18
0169-1
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0169
Table 1.
(1) (2) (3)
Maintenance Allocation Chart (MAC) - Continued.

(4) MAINTENANCE LEVEL FIELD CREW C MAINTAINER F SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D (6)
REMARKS CODE
AND GASKET(S) 0105-06 CRANKSHAFT SEAL FRONT Replace 1.5 17
0106-00
LUBE OIL Replace COOLER AND FILTER HEAD ASSEMBLY LUBE OIL PUMP OIL PAN AND SUCTION TUBE OIL LEVEL GAGE INTAKE MANIFOLD COVER AND GASKET EXHAUST MANIFOLD AND GASKETS FRONT GEAR TRAIN ACCESSORY DRIVE FUEL INJECTOR INJECTION PUMP FUEL LIFT PUMP Replace
4.0
14, 17, 18
0106-01
17.5
6, 17, 18
0106-02
Replace
9.0
17, 18
0106-03
Replace
1.0
17, 18
0108-00
Replace
4.0
17, 18
0108-01
Replace
4.0
17, 18
0109-00
Replace
16.0
17, 18
0301-00
Replace
2.0
13, 17, 18
0302-00
Replace
4.0
6, 17, 18
0302-01
Replace
0.8
17, 18
0169-2
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0169
Table 1.
(1) (2) (3)

(4) MAINTENANCE LEVEL FIELD CREW C MAINTAINER F 0.5 SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 17, 18 (6)
REMARKS CODE
0304-00
AIR CLEANER Repair ASSEMBLY FUEL TANK FUEL LINES FUEL INJECTION TUBES FUEL FILTER HEAD ASSEMBLY COLD START DEVICE THROTTLE CONTROL ~ EXHAUST SYSTEM ASSEMBLY RADIATOR AND OIL COOLER DEFROSTER FAN Repair Replace Replace
0306-00 0306-01 0306-02
2.0 0.5 1.6
17, 18 17, 18 17, 18
0309-00
Replace
0.5
18
0311-00
Replace
0.5
17, 18
0312-00
Adjust
1.0
17
~ 0401-00
Repair Repair
1.0 0.5
17, 18 17, 18
0501-00
Repair
4.0
17, 18
0501-01
Replace
0.3
17, 18
0503-00
THERMOSTA- Replace T WATER INLET Replace CONNECTION WATER PUMP Replace
1.0
17, 18
0503-01
0.8
17, 18
0504-00
1.0
17, 18
0169-3
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0169
Table 1.
(1) (2) (3)

REMARKS CODE
0505-00
FAN DRIVE BELT
Replace
0505-01
COOLING Repair FAN AND HUB ASSEMBLY DRIVE BELT TENSIONER AND IDLER Replace
1.0
17, 18
0505-02
0.5
17, 18
0601-00
ALTERNATOR Replace AND MOUNTING BRACKET STARTER MOTOR NEUTRAL SAFETY SWITCH AND BACK UP REVERSE WARNING SWITCH FUEL PRESSURE SWITCH AND TRANSDUCER DASH PANEL,GAGES AND SWITCHES ANTI-TWOBLOCK CONTROL PANEL VEHICLE LEVEL HORN Replace
2.0
17, 18
0603-00
3.0
17, 18
0606-00
Replace
1.0
17
0606-01
Replace
0.5
17, 18
0607-00
Replace
2.0
17, 18
0607-01
Repair
1.0
17, 18
0607-02
Replace
0.5
17
0607-03
Replace
0.5
17, 18
0169-4
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0169
Table 1.
(1) (2) (3)

REMARKS CODE
0608-00
ELECTRICAL COLLECTOR RING
Repair
0609-00 0609-01
REAR LIGHTS Replace FRONT LIGHTS AND BRACKETS WORK LIGHTS AXLE CENTERING LIGHT SWITCH ASSEMBLY Replace
0.5 0.5
17, 18 17, 18
0609-02
Replace
0.5
17, 18
0610-00
Repair
1.0
17, 18
0610-01
TACHOMETE- Adjust R SENDER BATTERY ASSEMBLY AND CABLES BATTERY BOX AND TOOLBOX COVERS Replace
1.5
17
0612-00
2.5
12, 17, 18
0612-01
Replace
2.0
17, 18
0613-00
MAIN ENGINE Replace WIRING HARNESS CAB MAIN HARNESS BACKUP ALARM MSD/ICE WIRING HARNESS Replace
3.0
17, 18
0613-01
3.0
16, 17, 18
0613-02
Replace
0.5
17, 18
0613-03
Replace
1.0
17, 18
0169-5
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0169
Table 1.
(1) (2) (3)

REMARKS CODE
0613-04
BOOM WIRING HARNESS
Replace
0613-05
MSD/ICE DCA Replace CONNECTOR/ RESISTOR MODULE TRANSMISSION DIPSTICK TUBE ASSEMBLY TRANSMISSION SHIFT CONTROLS TRANSMISSION CABLES Replace
1.0
17, 18
0700-00
0.5
17
0705-00
Repair
2.0
17, 18
0705-01
Repair
0.3
17, 18
0705-02
TRANSMISSI- Repair ON CONTROL CHARGE PUMP CONTROL VALVE Replace
1.5
17, 18
0710-03
3.0
17, 18
0714-00
Repair
3.0
4, 14, 17, 18
0721-00
TRANSMISSI- Replace ON HOSES,LINES ,AND FITTINGS TRANSMISSION FILTER ELEMENT AND BREATHER VENT PUMP ADAPTER Replace
2.0
17
0721-01
1.0
17, 18
0721-02
Replace
2.0
17, 18
0169-6
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0169
Table 1.
(1) (2) (3)

REMARKS CODE
0900-00
FRONT AND REARDRIVE SHAFT ~ FRONT AXLE FRONT DIFFERENTIA -L ASSEMBLY
Replace
~ 1000-00 1002-00
Repair Repair Replace
2.0 6.0 8.0
17, 18 6, 17, 18 6, 17, 18 A A
1003-00
PLANETARY Repair WHEEL ENDS PIVOT AND SPINDLE ASSEMBLY PIVOT BEARINGS (TYPE II) CONSTANTVELOCITY JOINT AND AXLE SHAFT REAR AXLE REAR DIFFERENTIA -L ASSEMBLY AXLE LOCKOUT SYSTEM PARKING BRAKE ~ Replace
8.0
10, 17, 18
1004-00
8.0
17, 18
1004-01
Repair
0.5
17, 18
1004-02
Replace
8.0
17, 18
1100-00 1102-00
Repair Replace
6.0 8.0
17, 18 6, 17, 18
A A
1104-00
Replace
2.0
17
1201-00
Adjust
0.2
17, 18
Repair
1.5
17, 18
0169-7
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0169
Table 1.
(1) (2) (3)

REMARKS CODE
1202-00
BRAKE ASSEMBLY BRAKE BOOSTER VALVE/ MASTER CYLINDER HYDRAULIC BRAKE LINES AND FITTINGS BRAKE RELIEF VALVE BRAKE PEDAL AND LINKAGE TIRES AND WHEELS TIE ROD ASSEMBLY ~ TIE ROD END GROUND DRIVEN STEERING PUMP STEERING CONTROL UNIT STEERING SYSTEM HYDRAULIC/ HOSES
Repair
1204-00
Repair
3.5
17, 18
1204-01
Replace
3.5
17, 18
1204-02
Replace
1.0
17, 18
1206-00
Replace
0.5
17, 18
1313-00
Repair
2.0
17, 18
1401-00
Adjust
0.5
17, 18
~ 1401-01 1410-00
Repair Replace Repair
2.0 2.0 5.0
17, 18 17, 18 17, 18
1410-01
Repair
1.0
17, 18
1411-00
Replace
1.0
17, 18
0169-8
TM 5-3810-305-23
0169
Table 1.
(1) (2) (3)

REMARKS CODE
1412-00
STEERING CYLINDERS STEERING SELECTOR VALVE FLOW DIVIDER AND STEERING VALVE
Replace
1414-00
Replace
5.0
17, 18
1414-01
Replace
2.0
17, 18
1501-00
HOOK BLOCK Replace TIEBACK PINTLE HOOK Repair CAB DOOR ENGINE HOOD AND GRILLE GUARD CAB ASSEMBLY HOOD SUPPORT CAB INSULATION FENDERS DECK PLATES CAB GLASS ASSEMBLY OUTRIGGER ASSEMBLY Repair Repair
1.0
5, 9, 17, 18
1503-00 1801-00 1801-01
0.5 2.5 1.5
17, 18 17, 18 17, 18
1801-02
Repair
10.0
17, 18
A, B
1801-03
Replace
0.5
17, 18
1801-04
Repair
2.0
17
1802-00 1802-01
Replace Replace
1.5 0.5
17, 18 17, 18
A A
1802-02
Replace
1.0
17, 18
1802-03
Repair
3.0
17, 18
0169-9
TM 5-3810-305-23
0169
Table 1.
(1) (2) (3)

REMARKS CODE
1802-04
TOOL BOX WITH COVERS SEAT AND SEAT BELTS WINCH ASSEMBLY ~ WINCH BRAKE VALVE WINCH MOTOR WINCH CONTROL VALVE AND FITTINGS WINCH CABLE MIRROR WINDSHIELD WIPER ASSEMBLY HEATER ASSEMBLY MARKING DECALS MAIN HYDRAULIC PUMP ~
Replace
1806-00
Repair
0.5
17, 18
2001-00
Replace
2.0
17, 18
~ 2001-01
Repair Repair
10.0 1.0
17, 18 17, 18
2001-02
Repair
1.1
17, 18
2001-03
Replace
2.0
3, 17, 18
2001-04
Replace
17, 18
2202-00 2202-01
Repair Repair
0.5 0.5
17, 18 17, 18
2202-02
Repair
2.5
17, 18
2210-00
Replace
0.5
17, 18
2401-00
Replace
5.0
17, 18
Repair
12.0
17, 18
0169-10
TM 5-3810-305-23
0169
Table 1.
(1) (2) (3)

REMARKS CODE
2402-00
ROTARY MANIFOLD ~ OUTRIGGER SOLENOID VALVE AXLE LOCKOUT VALVE HOLD VALVES
Replace
~ 2402-01
Repair Repair
8.0 2.0
17, 18 17, 18
2402-02
Replace
1.0
17, 18
2402-03
Replace
2.0
17
2403-00
BOOM HOIST, Replace WINCH, OUTRIGGER VALVE CONTROLS SWING/ TELESCOPE VALVE CONTROLS VALVE CONTROL CABLES UPPER HYDRAULIC LINES LOWER BOOM, SWING AND WINCH HYDRAULIC LINES RETURN AND PRESSURE HYDRAULICS Replace
3.0
17, 18
2403-01
2.0
17, 18
2403-02
Replace
2.0
17, 18
2406-00
Replace
1.0
17, 18
2406-01
Replace
2.0
17, 18
2406-02
Replace
1.0
17, 18
0169-11
TM 5-3810-305-23
0169
Table 1.
(1) (2) (3)

REMARKS CODE
2406-03
OUTRIGGER HYDRAULICS SUCTION HYDRAULICS
Replace
2406-04
Replace
2.0
17, 18
2406-05
ROTARY Replace MANIFOLD QUICK DISCONNECT -S (TYPE II) HYDRAULIC SYSTEM VALVE BANK ~ RETURN FILTER BOOM HOIST CYLINDER BOOM EXTEND CYLINDER ~ OUTRIGGER CYLINDER ~ AXLE LOCKOUT CYLINDER HYDRAULIC RESERVOIR Adjust
1.0
17, 18
2406-06
1.5
3, 17, 18
~ 2406-07
Replace Replace
2.0 1.0
3, 17, 18 17, 18
2407-00
Replace
2.0
17, 18
2407-01
Replace
2.0
17, 18
~ 2407-02
Repair Replace
6.0 2.3
17, 18 17, 18
A A
~ 2407-03
Repair Replace
6.0 1.5
17, 18 17, 18
2408-00
Repair
3.5
17, 18
7411-00
BOOM ANGLE Repair INDICATOR
0.8
17, 18
0169-12
TM 5-3810-305-23
0169
Table 1.
(1) (2) (3)

(4) MAINTENANCE LEVEL FIELD CREW C MAINTAINER F 1.0 3.0 SUSTAINMENT (5) TOOLS AND EQUIPMENT BELOW DEPOT DEPOT REFERENCE CODE H D 17, 18 17, 18 (6)
REMARKS CODE
7411-01 7411-02
HOOK BLOCK Repair BOOM ASSEMBLY BOOM WORK LIGHT BRACKET ANTI TWOBLOCK ASSEMBLY UPPERSTRU CTURE MAST ASSEMBLY (TYPE II) SWING BEARING ASSEMBLY SWING MOTOR SWING GEAR BOX Replace
A A
7411-03
Replace
0.5
17
7411-04
Repair
1.0
17, 18
7411-05
Replace
6.0
17, 18
7411-06
Repair
0.5
17, 18
7419-00
Repair
4.0
17, 18
7419-01
Repair
2.0
1, 17, 18
7419-02
Repair
2.0
17, 18
0169-13
TM 5-3810-305-23
0169
Table 2.
TOOL OR TEST EQUIPMENT REF CODE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MAINTENANCE CATEGORY F F F F F F F F F F F F F F F F F F
Tools and Test Equipment.

NATIONAL/NATO STOCK NUMBER 3465-00-015-4289 5210-00-309-9192 6685-00-972-1372 6685-01-050-7026 8415-01-394-0208 5210-01-192-9432 6625-01-493-8968 5210-00-007-8229 4940-01-454-9877 5120-01-290-0760 4910-01-374-2140 6630-00-171-5126 4910-00-255-8641 4910-01-142-4929 4910-01-128-2691 5180-00-754-0655 5180-01-548-7634 4910-01-490-6453
NOMENCLATURE Fixture, Arbor Press Gage, Depth, Dial Indicating Gage, Pressure, Dial Indicating Gage, Pressure, Dial Indicating Gloves, Leather Indicator, Dial Test Set, Electronic Systems Plumb Bob Shop Equipment, Welding Socket, Wrench, Face Spanner Stand, Maintenance, Automotive Engine Tester, Battery Electrolyte Solution Tester, Diesel Fuel Injector Nozzle Tester, Valve Spring Tester, Valve Vac Tool Kit, Auto Fuel and Electrical System Tool Kit, General Mechanic's Tool Set, SATS, Base
TOOL NUMBER 3S60014-101 S640GZ 0870404000 25.400-200 6170-5 CM6400 13580880 PD5210-00-007-8229 DFP 419 709 4398 G1-29-9099-001 6630-00-171-5126 7551255 3375182 3824277 SC5180-95-CL-B08 PD484 SC 4910-95-A81
Table 3.
REMARK CODE
Remarks.
REMARKS
Weight of component is too heavy for one person. Use proper lifting device and two or more people to properly support and lift component. Failure to follow this procedure could cause death or serious injury to personnel. Includes all general maintenance to cab such as replacement of seals, panels, etc. Refer to TM 5-3810-305-10 for instruction.
B C
END OF WORK PACKAGE
0169-14
TM 5-3810-305-23
0170
FIELD MAINTENANCE EXPENDABLE AND DURABLE ITEMS LIST
INTRODUCTION Scope This work package lists expendable and durable items you will need to maintain the 7 1/2 Ton Crane. This listing is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/ Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns in the Expendable/Durable Items List Column (1) - Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item [e.g., Use Abrasive Pad (ED001, A00248)]. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item. F- Direct Support Maintenance H- General Support Maintenance Column (3) - National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it. Column (4) - Description, Item Name, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). This provides the other information you need to identify the item. Column (5) - Unit of Issue (U/I). This code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc. Table 1. (1) ITEM NO. 1 2 3 4 5 6 (2) LEVEL F C C C F F (3) NATIONAL STOCK NUMBER (NSN) 8040-00-273-8717 6850-01-464-9125 6850-00-181-7933 6850-01-441-3223 8030-00-251-3980 9150-01-102-9455 Expendable and Durable Items List. (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Adhesive, 1 Pint Can 1300 (52152) Antifreeze, 1 Gallon Bottle A-A-52624 (58536) Antifreeze, 5 Gallon Can MILA46153 (81349) Antifreeze, 55 Gallon Drum A-A-52624 (58536) Antiseize Compound, 1 Pound Can MIL-A-907 (81349) Brake Fluid, Automotive 1 Gallon Bottle MIL-B-46176 (81349) (5) U/I PT GL GL GL LB GL
0170-1
03/15/2011 Rel(1.8) root(explistwp) wpno(S00188)
TM 5-3810-305-23
0170
Table 1. (1) ITEM NO. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 (2) LEVEL F F F F F F C C C C C C F C C C C F F F F F (3)
Expendable and Durable Items List - Continued. (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Cap Set, Protective Dust and Moisture Seal 10935405 (19207) Caulking Compound 1050 (1E7M3) Cleaning Compound, Solvent, Type III 1 Gallon Can MIL-PRF-680 (81349) Cleaning Compound, Solvent, Type III 5 Gallon Can MIL-PRF-680 (81349) Cleaning Compound, Solvent, Type III 55 Gallon Drum MIL-PRF-680 (81349) Cloth, Abrasive, Crocus A-A-1206 (58536) Fuel, Diesel, DF-1 Grade, Winter, Bulk ASTM D 975 81346 Fuel, Diesel, DF-1 Grade, Winter, Bulk 5 Gallon Can Fuel, Diesel, DF-1 Grade, Winter, Bulk 55 Gallon Drum Fuel, Diesel, DF-2 Grade, Bulk ASTM D 975 (81346) Fuel, Diesel, DF-2 Grade, Bulk 5 Gallon Can Fuel, Diesel, DF-2 Grade, Bulk 55 Gallon Drum Fuel, Diesel Run-In Mobil 4Y17 (5) U/I EA KT GAL. BX DR EA GL GL DR GL GL GL
NATIONAL STOCK NUMBER (NSN) 5340-00-450-5718 8030-00-682-6745 6850-01-474-2318 6850-01-474-2320 6850-01-474-2321 5350-00-221-0872 9140-00-286-5286 9140-00-286-5287 9140-00-286-5288 9140-00-286-5294 9140-00-286-5295 9140-00-286-5296
9150-01-197-7688 9150-01-197-7693 9150-01-197-7690 9150-01-197-7692 9150-01-117-2928 9150-01-028-9360 9150-00-735-1800 9150-01-302-7377 9150-00-754-2595
Grease, Automotive and Artillery, 2-1/4 oz Tube MIL-G-10924 (81349) Grease, Automotive and Artillery, 14 oz cartridge MIL-G-10924 (81349) Grease, Automotive and Artillery, 1-3/4 Pound Can MIL-G-10924 (81349) Grease, Automotive and Artillery, 35 Pound Can MIL-G-10924 (81349) Grease, Ball and Roller Bearing, 6-1/2 Pound Can DOD-G-24508 (81349) Grease, General Purpose, 38 Pound Can BEARINGGARD (82250) Grease, Graphite 1 Pound Can G-392 (01139) Grease, Molybdenum Disulfide, 500 Gram Container MOLYKOTE3402C (94499) Grease, Molybdenum Disulfide, 1.75 Lb Can MIL-M-7866 (81349)
OZ OZ LB LB CN LB LB CO LB
0170-2
TM 5-3810-305-23 Table 1. (1) ITEM NO. 29 30 31 32 33 34 35 36 37 38 39 40 41 42 (2) LEVEL F F C C F F F C C C F F F C (3) NATIONAL STOCK NUMBER (NSN) 9150-00-223-4044 9150-00-965-2003 9150-01-095-5512 9150-00-250-0933 2540-00-256-5526 2540-00-256-5527 2540-00-256-5529 9150-01-518-9477 9150-01-421-1424 9150-01-421-1432 9150-01-035-5392 9150-00-001-9395 9150-01-035-5394 9150-00-189-6727 Expendable and Durable Items List - Continued. (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Grease, Molybdenum Disulfide, 6.5 Lb Can MIL-M-7866 (81349) Grease, Molybdenum Disulfide, 35 Lb Can MIL-M-7866 (81349) Grease, Ball and Roller Bearing L0189.001 (73219) Jelly, Petroleum VV-P-236 (81348) Lubricant, Tire and Rim, 1 Quart Can AA17 (96980) Lubricant, Tire and Rim, 1 Gallon Can AA18 (96980) Lubricant, Tire and Rim, 5 Gallon Can AA20 (96980) Lubricating Oil, Engine, 15W40 Grade, 1 Gallon Can MIL-PRF-2104 (81349) Lubricating Oil, Engine, 15W40 Grade, 5 Gallon Can MIL-PRF-2104 (81349) Lubricating Oil, Engine, 15W40 Grade, 55 Gallon Drum MIL-PRF-2104 (81349) Lubricating Oil, Gear, 80W-90 Grade, 1 Gallon Can MIL-PRF-2105 (81349) Lubricating Oil, Gear, 80W-90 Grade, 5 Gallon Can MIL-PRF-2105 (81349) Lubricating Oil, Gear, 80W-90 Grade, 55 Gallon Can MIL-PRF-2105 (81349) Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 Gallon Can MIL-PRF-2104 81349 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 5 Gallon Can MIL-PRF-2104 (81349) Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 55 Gallon Drum MIL-PRF-2104 (81349) Lubricating Oil, Preservative and Break-In 1 Quart Can (81349) Lubricating Oil, Preservative and Break-In, 5 Gallon Can (81349)
0170
(5) U/I LB LB
LB QT GL GL QT CN DR QT CN DR QT
43
9150-00-186-6668
CN
44
9150-00-191-2772
DR
45 46
C C
9150-00-153-0207 9150-00-111-0209
QT CN
0170-3
TM 5-3810-305-23
0170
Table 1. (1) ITEM NO. 47 (2) LEVEL C (3)
Expendable and Durable Items List - Continued. (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Lubricating Oil, Preservative and Break-In, 55 Gallon Drum (81349) Motorstor MIL-L 46002 (ORD) MIL-I-23310 (5) U/I DR
NATIONAL STOCK NUMBER (NSN) 9150-00-111-0210
48 49 50 51 52 53 54 55 56
F F F F C F F F F 8030-01-069-3046 8030-01-014-5869 6830-01-526-5162 9150-00-710-1797 8030-00-082-2508 7920-00-205-1711 5320-01-267-2011
Nitrogen, Liquid, Industrial Grade AWS A5.32 (52838) Petrolatum, Liquid, Technical 1 Gallon MIL-C-11796 (15958) Primer, Sealing Compound Loctite 7471 (05972) Rag, Wiping 7920-00-205-1711 (64607) Rivet, Solid 1212-48 (81495) Sandpaper, 400 Grit Sealing Compound, Loctite 222 (50 ml Bottle) 22231 (05972) Sealing Compound, Loctite 242 MIL-S-46163 Type II Grade N MIL-S-46163 TY2GRN (80244) Sealing Compound, Loctite 271 MIL-S-46163 Type I Grade L 50 ml Bottle 27131 (80244) Sealing Compound, Loctite 515 51580 (05972) Sealing Compound, Loctite 549 50 cc Tube 549-31 (05972) Sealing Compound, Loctite RC 640 RC640 (05972) Sealing Compound, Loctite RC 680 680 (05972) Sealing Compound, Silicone 5477K12 (39428) Sealing Compound, Fuel Resistant MIL-S-7916 (81349) Sealing Compound, High Pressure MIL-S-15204 (81349) Sealing Compound, Thread Locking ASTM D5363 (81349) BT TU BT TUBE BT BT OZ BE EA GL
57
8030-01-158-6070
BT
58 59 60 61 62 63 64 65
F F F F F F F F
5330-01-172-1895 8030-01-024-9290 8030-01-416-5798 8030-01-429-8188 8030-01-513-0319 8030-00-543-4384 8030-00-246-0931 8030-01-088-8140
0170-4
TM 5-3810-305-23
0170
Table 1. (1) ITEM NO. 66 67 68 69 70 71 (2) LEVEL F C F F C C (3)
Expendable and Durable Items List - Continued. (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Soap GP, Liquid, A MIL-S-46163 (81349) Soda, Baking O-S-576 (81348) Tag, Marker MIL-T-12755 (81349) Tape, Pressure Sensitive Adhesive, Clear 351 (52170) Strap, Tiedown Electrical Components MS3367-3-9 (81343) Strap, Tiedown Electrical Components 5975009846582 (SCY13) HD (5) U/I GL OZ EA RL
NATIONAL STOCK NUMBER (NSN) 7930-00-282-9699 6810-00-264-6618 9905-00-537-8954 7510-00-663-3732 5975-00-451-5001 5975-00-984-6582
END OF WORK PACKAGE
0170-5/6 blank
TM 5-3810-305-23
0171
FIELD MAINTENANCE TOOL IDENTIFICATION LIST
INTRODUCTION Scope This work package lists all common tools and supplements and special tools/fixtures needed to maintain the 7 1/2 Ton Crane. Most PM-SKOT products have lifetime warranties and replacement capabilities and are supported world-wide through PM-SKOT. The PM-SKOT implemented a Web-based tool replacement and warranty program in May 2005 for tools authorized in SKO. User may access the online program by first accessing the PM-SKOT Web site at https://pmskot.army.mil and clicking on the Tool Replacement/Warranty banner. EXPLANATION OF COLUMNS Column (1) - Item No. This number is assigned to the entry in the list and is referenced in the initial setup to identify the item (e.g., Extractor (WP 0090, Item 32)). Column (2) - Item Name. This column lists the item by noun nomenclature and other descriptive features (e.g., Gage, belt tension). Column (3) - National Stock Number (NSN). This is the National Stock Number (NSN) assigned to the item: use it to requisition the item. Column (4) - Part Number/(CAGEC). Indicates the primary number used by the manufacturer (individual, company, firm, corporation, or Government activity) which controls the design and characteristics of the item by means of its engineering drawings, specifications, standards, and inspection requirements to identify an item or range of items. The manufacturer's Commercial and Government Entity Code (CAGEC) is also included. Column (5) - Reference. This column identifies the authorizing supply catalog or RPSTL for items listed in this work package. Table 1. (1) (2) Tool Identification List. (3) NATIONAL STOCK NUMBER (NSN) 3465-00-015-4289 (4) PART NUMBER /(CAGEC) 3S60014-101 (98897) S640GZ (57163) 0870404000 (26337) 25.400-200 (62091) 6170-5 (04024) (5)
ITEM NO. 1
ITEM NAME Fixture, Arbor Press
REFERENCE TM 5-3810-305-24P
Gage, Depth, Dial Indicating
5210-00-309-9192
TM 5-3810-305-24P
Gage, Pressure, Dial Indicating
6685-00-972-1372
TM 5-3810-305-24P
Gage, Pressure, Dial Indicating
6685-01-050-7026
TM 5-3810-305-24P
Gloves, Leather
8415-01-394-0208
TM 5-3810-305-24P
0171-1
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TM 5-3810-305-23
0171
Table 1. (1) (2)
Tool Identification List - Continued. (3) NATIONAL STOCK NUMBER (NSN) 5210-01-192-9432 (4) PART NUMBER /(CAGEC) CM6400 (55719) 13580880 (18876) PD5210-00-0 07-8229 (80244) DFP 419 (59678) 709 4398 (81495) G1-29-9099-0 01 (55827) 6630-00-1715126 (93489) 7551255 (19204) 3375182 (15434) 3824277 (15434) SC5180-95CL-B08 (19204) PD484 (19200) SC 4910-95A81 (59678) KTC S5801 (00NS2) SATS CL 4910-95A81 (5)
ITEM NO. 6
ITEM NAME Indicator, Dial
REFERENCE TM 5-3810-305-24P
Test Set, Electronic Systems (MSD)
6625-01-493-8968
TM 5-3810-305-24P
Plumb Bob
5210-00-007-8229
TM 5-3810-305-24P
Shop Equipment, Welding
4940-01-454-9877
TM 5-3810-305-24P
10
Socket, Wrench, Face Spanner
5120-01-290-0760
TM 5-3810-305-24P
11
Stand, Maintenance, Automotive Engine
4910-01-374-2140
TM 5-3810-305-24P
12
Tester, Battery, Electrolyte Solution
6630-00-171-5126
TM 5-3810-305-24P
13
Tester, Diesel Fuel Injector Nozzle
4910-00-255-8641
TM 5-3810-305-24P
14
Tester, Valve Spring
4910-01-142-4929
TM 5-3810-305-24P
15
Tester, Valve VAC
4910-01-128-2691
TM 5-3810-305-24P
16
Tool Kit, Auto Fuel and Electrical System
5180-00-754-0655
TM 5-3810-305-24P
17
Tool Kit, General Mechanic's
5180-01-548-7634
CL 5-3810-95-B48
18
Tool Set, SATS, Base
4910-01-490-6453
19
10 Ton Jack Stand
4910-01-490-6453
0171-2
TM 5-3810-305-23
0171
Table 1. Tool Identification List - Continued. (1) (2) (3) NATIONAL STOCK NUMBER (NSN) 4910-01-490-6453 (4) PART NUMBER /(CAGEC) KTC S0126 (00NS2) KTC S0999 (00NS2) KTC S0998 (00NS2) KTC S0194 (00NS2) KTC S0188 (00NS2) KTC S0209 (00NS2) KTC S0208 (00NS2) KTC S0209 (00NS2) KTC S0700 (00NS2) KTC S0252 (00NS2) KTC S0253 (00NS2) KTC S0695 (00NS2) KTC S0982 (00NS2) KTC S0991 (00NS2) KTC S1490 (00NS2) KTC S0990 (00NS2) (5)
ITEM NO. 20
ITEM NAME Apron, Utility
REFERENCE SATS CL 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81
21
Caliper, Micrometer, Outside
4910-01-490-6453
22
Caliper Set, Micrometer, Inside
4910-01-490-6453
23
Drill Set, Twist
4910-01-490-6453
24
Drill-Driver, Battery Operated
4910-01-490-6453
25
Face Shield, Industrial
4910-01-490-6453
26
Gloves, Rubber
4910-01-490-6453
27
Goggles, Industrial
4910-01-490-6453
28
Hand Riveter
4910-01-490-6453
29
Multimeter
4910-01-490-6453
30
Multiplier, Torque Wrench
4910-01-490-6453
31
Soldering Gun
4910-01-490-6453
32
Wrench, Oil Filter, Strap
4910-01-490-6453
33
Wrench, Torque, 1/2 Inch Drive, Ratcheting (250 ft-lb) Wrench, Torque, 3/4 Inch Drive Ratcheting (600 ft-lb) Wrench, Torque, Click, 1/2 Inch Drive (345 Nm)
4910-01-490-6453
34
4910-01-490-6453
35
4910-01-490-6453
0171-3
TM 5-3810-305-23
0171
Table 1. (1) (2)
Tool Identification List - Continued. (3) NATIONAL STOCK NUMBER (NSN) 4910-01-490-6453 (4) PART NUMBER /(CAGEC) KTC S0989 (00NS2) KTC S1492 (00NS2) KTC S0269 (00NS2) KTC S0255 (00NS2) KTC S0152 (00NS2) KTC S0207 (00NS2) KTC S0272 (00NS2) KTC S0132 (00NS2) KTC S0725 (00NS2) KTC S0132 (00NS2) 3164659 (0B8S3) (5)
ITEM NO. 36
ITEM NAME Wrench, Torque, Click, Ratcheting 3/8 Inch Drive (75 ft-lb) Wrench, Torque, Dial, 1/4 Inch Drive (30 in-lb) Puller Set, Mechanical
REFERENCE SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81 SATS SC 4910-95A81
37
4910-01-490-6453
38
4910-01-490-6453
39
Pan, Drain
4910-01-490-6453
40
Can, Radiator Filling
4910-01-490-6453
41
Funnel
4910-01-490-6453
42
Pump, Lubricant
4910-01-490-6453
43
Battery Kit, Service
4910-01-490-6453
44
Vise
4910-01-490-6453
45
Grinder
4910-01-490-6453
46
Seal Driver (Oil Seal Replacer Kit, Front)
4920-01-559-1764
END OF WORK PACKAGE
0171-4
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0172
FIELD MAINTENANCE MANDATORY REPLACEMENT PARTS LIST
INTRODUCTION This work package includes a list of all mandatory replacement parts referenced in the task initial setups and procedures. These are items that must be replaced during maintenance whether they have failed or not. This includes items based on usage intervals such as miles, time, rounds fired, etc.
Table 1.
ITEM NO. 1 2 3 010-80003-2 (59187) 02-400-076 (82865) 068025 (77640) 081 316 21 (81495) 085 125 44 (81495) 085 306 12 (155226) 11026 (08302) 1129E02 ITEM 35 (90099) 1205-35 (81495) 1209-4 (81495) 1210-14 (0MKW7) 1210-20 (0MKW7) 1218-52 (0MKW7)
Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton
NATIONAL STOCK NUMBER (NSN) 5310-01-137-4508 5330-01-290-2621 5330-01-285-2911 Washer, Lock Gasket Parts Kit, Seal Repl NOMENCLATURE QTY 5 1 1
PART NUMBER /(CAGEC)
2530-01-105-7503
Parts Kit, Hydraulic
3110-01-264-0111
Inner Bearing (Part of Kit P/N SK000013)
5310-01-281-0906
Nut, Self-Locking, He M16
5310-01-271-2452
Washer, Lock M25
Washer, Lock
5310-01-049-1647
Washer, Lock
10
5310-00-027-2022
Nut, Self-Locking, He 3/4 Inch
11
5310-01-268-7001
Nut, Self-Locking
12
5310-01-271-1844
Washer, Lock 3/8 Inch
13
5310-01-322-5039
Washer, Lock
14
5310-01-269-1426
Washer, Lock
15
5331-01-207-3034
O-Ring
0172-1
03/15/2011 Rel(1.8) root(mrplwp) wpno(S00190)
TM 5-3810-305-23
0172
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
ITEM NO. 16 PART NUMBER /(CAGEC) 1459-254 (72452) 18Z2585D4 (81495) 205257 (81495) 206609 (81495) 206610 (81405) 206809 (81495) 206814 (81495) 206828 (81495) 206847 (81495) 206854 (81495) 207720 (81495) 2103 (31844) 22617-12 (01276) 23601 (08302) 24186 (08302) 24193 (08302) 24194 (08302) 24195 (08302) 24196 NATIONAL STOCK NUMBER (NSN) 5310-00-171-1734 NOMENCLATURE Washer, Lock 5/16 Inch Regular QTY 2
17
5330-01-268-2611
Seal, Plain
18
5310-01-340-8469
Washer, Seal Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 Parts Kit, Steering
10
19
2530-01-281-7919
20
5330-01-271-5725
Seal Kit
21
5310-01-263-0803
Nut M28X1.5/23/41/54-6H-10
22
2530-01-332-7675
Parts Kit, Steering
23
Seal, Trunnion Part of Kit P/N 206814
24
5330-01-263-4252
Gasket
25
5310-01-263-0823
Washer, Lock
26
4320-01-268-0248
Parts Kit, Seal Repl
27
4330-01-261-6523
Filter Element
28
5331-00-228-7196
O-Ring
29
5331-01-269-4373
O-Ring
30
5331-01-269-8579
O-Ring
31
5331-01-269-6301
O-Ring
32
5331-01-268-5810
O-Ring
33
5331-01-268-5811
O-Ring
34
5331-01-269-6148
O-Ring
0172-2
TM 5-3810-305-23
0172
ITEM NO. PART NUMBER /(CAGEC) (08302) 35 2507294-79 (02697) 25302 (08302) 2533408PC11 (10001) 25366 (08302) 26001 (08302) 26002 (08302) 27152 (08302) 3-908N552-90 (02697) 3-916N552-90 (83259) 3-96-N-552-90 (57760) 31284 (08302) 328376700 (15434) 33-125-007 (92865) 331-V2200 (81495) 332 1800 (81495) 332 2200 (81495) 332V2100 (0MKW7) 340 4613 (81495) 5331-01-031-8239 O-Ring 1 NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
36
4730-01-266-1334
Elbow With O-Ring
37
5310-00-010-8415
Nut, Self-Locking
38
5331-01-268-5812
O-Ring Part of Kit P/N 61690
39
4730-01-284-8913
Adapter Straight Including O-Ring
40
4730-01-266-1668
Tee, With O-Ring
41
5310-01-067-1506
Washer, Lock 3/8 Reg
42
5331-00-929-8171
O-Ring
27
43
5331-01-125-6268
O-Ring
24
44
5331-01-263-4244
O-Ring
69
45
4730-01-284-8992
Adapter Straight Including O-Ring
46
5330-01-266-3297
Gasket Pushrod Cover Part Of Kit P/N 3802019
47
5310-01-160-1898
Washer, Lock
48
5310-01-267-9213
49
5310-01-270-2660
Washer, Lock 5/16 Inch Regular
20
50
5310-01-270-8401
16
51
5310-01-263-0824
52
5310-01-285-5931
Nut, Self-Locking, He
0172-3
TM 5-3810-305-23
0172
ITEM NO. 53 PART NUMBER /(CAGEC) 340V0000 (81495) 34810S2 (57526) 3900267 (15434) 3900808 (15434) 3901460 (15434) 3902666 (15434) 3903297 (15434) 3903380 (15434) 3903475 (15434) 3904353 (15434) 3904634 (15434) 3904635 (15434) 3904639 (15434) 3904644 (15434) 3904780 (15434) 3905685 (15434) 3906694 (15434) 3906695 (15434) 3907489 NATIONAL STOCK NUMBER (NSN) 5310-01-297-8867 NOMENCLATURE Nut, Self-Locking QTY 2
54
5310-00-011-6122
Washer, Lock 9/16 Reg
55
5325-01-194-4354
Grommet Part Of Kit P/N 3802019
56
5130-01-317-1831
Gasket
57
Packing, Preformed
58
5330-01-190-7443
Gasket Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 O-Ring
59
5331-01-190-7434
60
5330-01-195-5268
Seal, Banjo Connect Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 Gasket
61
5330-01-191-8047
62
5330-01-191-4513
Seal Part Of Kit P/N 3802019
63
5310-01-234-1403
Locknut
64
5331-01-234-7615
O-Ring
65
5310-01-234-1405
Locknut
66
5310-01-291-5673
Washer, Copper
67
5330-01-236-6141
O-Ring
68
5330-01-306-8642
Gasket Part Of Kit P/N 3802019
69
5330-01-267-2981
Packing, Preformed Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 O-Ring Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 O-Ring
70
5331-01-281-8998
71
5331-01-266-3283
0172-4
TM 5-3810-305-23
0172
ITEM NO. PART NUMBER /(CAGEC) (15434) 72 3907491 (15434) 391-1801-032 (13829) 391-2883-119 (82338) 3910824 (15434) 3912473 (15434) 3913994 (15434) 3914028 (15434) 3914385 (15434) 3915800 (15434) 39173240 (15434) 3938157 (15434) 3938159 (15434) 3938162 (15434) 393925800 (15434) 4001218 (96105) 4001468 (96105) 4001910 (96105) 40392071 (96105) 5331-01-267-2983 O-Ring 1 NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
73
2520-01-265-2614
74
5330-01-236-0469
Seal, Plain Encased Part Of Kit P/N 391-1801-032 O-Ring Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 O-Ring
75
5331-01-281-8997
76
5330-01-271-9375
77
5330-01-291-6537
O-Ring
78
5330-01-193-0182
Gasket Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 Gasket
79
5330-01-191-7322
80
5330-01-270-8144
O-Ring, Part Of Kit P/N 3802019
81
6685-01-343-1572
Thermostat, Flow Con
82
5330-01-453-7145
83
5330-01-304-7807
Gasket
84
5330-01-305-9414
Gasket Oil Pan Part Of Kit P/N 3802019
85
5330-01-467-2130
86
5330-00-477-2476
Packing, Preformed
87
5331-01-270-1757
O-Ring 242-75N
88
5330-01-268-6826
Gasket, Valve Body
89
5331-01-270-1262
O-Ring
0172-5
TM 5-3810-305-23
0172
ITEM NO. 90 PART NUMBER /(CAGEC) 406518 (77521) 406579 (10129) 435-005 (72741) 435-006 (72741) 435-006 (72741) 435-008 (72741) 460V0436 (0MKW7) 49125 (81495) 49126 (81495) 49127 (81495) 49128 (81495) 4932124 (K4843) 50908-066 (62809) 51759 (79396) 53775-004020 (62410) 61690 (08302) 709 1134 (81495) 709 1135 (81495) 709 1136 NATIONAL STOCK NUMBER (NSN) 5331-01-073-2547 O-Ring NOMENCLATURE QTY 2
91
5330-00-152-3039
Packing
92
5310-01-137-4508
Washer, Lock M5
16
93
5310-01-138-3289
Washer, Lock
46
94
5310-01-138-2389
Lockwasher
95
5310-01-357-6467
Washer, Split M8
22
96
5331-01-269-9251
O-Ring 441-70N
97
5330-01-194-4844
Retainer, Packing
98
5330-01-193-0202
Gasket
99
5330-01-199-3443
Gasket
100
5365-01-195-5402
Spacer, Ring
101
5330-01-191-2965
Gasket Part Of Kit P/N 3802019 0.8MM Thick, Natural Aspiration Nut, Self-Locking, He 1/4F
102
5310-01-135-6786
103
2940-01-163-7326
Filter, Oil
104
Ring, Piston Part of Kit P/N 130435
105
4320-01-275-5257
106
5330-01-272-7484
Seal, Non-Metallic
107
5330-01-263-6194
Seal, Non-Metallic
108
5330-01-263-6193
Seal, Non-Metallic
0172-6
TM 5-3810-305-23
0172
ITEM NO. PART NUMBER /(CAGEC) (81495) 109 709 1634 (81495) 73704 (17285) 75 500 346 (81495) 75 503 031 (9J891) 8-439N300-90 (83259) 853181952 (09605) 900598-6S (01276) A50801-309 (62809) A50806-016 (62809) AN380-4-4 (80059) ARP568-439SAEJ200 (81343) AS568-912 (81343) ASTM D2000 M6BG910 (81346) C10 (69266) DH24-111 (67089) DH24-112 (67089) DH3-187 (67089) 3120-01-287-6314 Bearing Sleeve With Bearing 16 NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
110
5310-01-271-9498
111
5331-01-263-6097
O-Ring 196.44X3.53
112
5330-01-263-6100
Gasket
113
5330-01-065-0735
Retainer, Packing
114
5331-01-155-4277
O-Ring
115
5365-00-382-6713
Plug With O-Ring
116
5310-01-176-8078
Washer, Split
117
5310-01-019-2096
Washer, Lock
118
5315-00-839-5822
Pin, Cotter 1/8X1 Inch
119
5331-01-206-9697
O-Ring
120
5331-01-057-3127
O-Ring
58
121
5331-01-049-1292
O-Ring
122
5315-00-816-1794
Pin, Cotter 3/32X1 Inch
123
4320-01-262-7598
124
3040-01-262-7594
Parts Kit, Linear AC
125
5330-01-278-1860
Retainer, Packing
0172-7
TM 5-3810-305-23
0172
ITEM NO. 126 PART NUMBER /(CAGEC) DIN 127B ST 8 -A4C (15526) DIN125A-M12-A4C (15526) DIN127-24-A4C (15526) DIN127B-M12-A4C (15526) DIN127B-M16-A4C (15526) DIN9021-10-A4C (15526) DIN985-M10-A4C (15526) DIN985-M12-A4C (D8286) DIN985-M20-6/8-A4C (15526) DIN985-M30-6/8-A4C (15526) DIN985-M36-84C (D8286) DIN985-M4-8-A4C (D8286) DIN985-M6-6/8-A4C (15526) DIN985-M8-A4C (15526) E6 BS 518P (04866) F15003 (96105) F16204 (96105) F37030254 (96105) GA721006 NATIONAL STOCK NUMBER (NSN) 5310-01-365-9692 NOMENCLATURE Washer, Lock M8 QTY 32
127
5310-01-267-8511
Washer, Lock
128
5310-01-281-1830
Washer, Lock 24M
129
5310-01-264-9409
Washer, Lock M10
56
130
5310-01-266-5040
Washer, Lock M16
131
5310-01-286-8004
Nut, Self-Locking
24
132
5310-01-264-1640
16
133
5310-01-264-1641
11
134
5310-01-276-1650
Nut, Self-Locking
135
5310-01-282-0905
136
5310-01-274-2906
Nut, Self Locking
137
5310-01-287-5790
Nut, Self-Locking
138
5310-01-263-6166
139
5310-01-264-9404
Nut, Self-Locking, He
145
140
5310-01-094-8046
Nut, Self-Locking
141
5310-01-268-2634
Washer, Lock
142
5310-01-176-9719
143
5331-01-270-1756
O-Ring
144
5330-01-106-1161
Gasket
0172-8
TM 5-3810-305-23
0172
ITEM NO. PART NUMBER /(CAGEC) (24956) 145 J282999 (10988) J515CH246X0191H (81343) J905443 (10988) J912220 (10988) J923331 (10988) J934486 (10988) M45913/1-4CS3 (81349) MS16562-38 (80205) MS17825-3 (96906) MS24665-132 (80205) MS24665-208 (80205) MS24665-210 (80205) MS24665-281 (80205) MS24665-360 (80205) MS24665-625 (80205) MS24665-628 (80205) MS24665-752 (80205) MS28775-225 (81343) 5330-01-311-5981 Gasket 1 NATIONAL STOCK NUMBER (NSN) NOMENCLATURE QTY
146
5331-01-115-8223
O-Ring
41
147
5330-01-218-1201
Gasket Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 Manifold Gasket Part Of Kit P/N 408964800 Flanged For 2.50 Inch Pipe Gasket Part Of Kit P/N 408964800, Part Of Kit P/N 3802017 Seal
148
5330-01-243-9455
149
5330-01-190-1904
150
5330-01-192-2037
151
5310-00-929-1807
Locknut
152
5315-00-810-3702
Pin, Spring 1/8X1 Inch
153
5310-00-785-1755
Locknut
154
5315-00-839-2325
Pin, Cotter 1/16X1/2 Inch
155
5315-00-829-1480
Pin, Cotter M2X12MM
11
156
5315-00-059-0157
Pin, Cotter 3X30
13
157
5315-00-839-2326
Pin, Cotter
13
158
5315-00-298-1499
Pin, Cotter
159
5315-00-209-7273
Pin, Cotter 6.3 X 56MM
160
5315-00-846-0126
Pin, Cotter 1/4 X 3
161
5315-00-846-4297
Pin, Cotter
162
5331-00-579-7927
O-Ring
0172-9
TM 5-3810-305-23
0172
ITEM NO. 163 PART NUMBER /(CAGEC) MS29513-222 (81343) MS3367-3-9 (81343) MS35338-45 (80205) MS35338-47 (80205) MS51848-10 (96906) N0120043 (D9134) OF250-125 (22601) SK000012 x (77640) SK000013 (77640) SKSH-064013 (62410) WA721033 (24956) NATIONAL STOCK NUMBER (NSN) 5331-00-599-2766 O-Ring NOMENCLATURE QTY 1
164
5975-00-451-5001
Strap, Tiedown Electrical Components
165
5310-00-407-9566
Washer, Lock
166
5310-00-209-0965
Washer, Lock 7/16
18
167
5310-00-143-6272
Washer, Lock
168
5310-12-142-0656
Washer, Lock M4
169
9390-01-302-9669
Weather Stripping
170
4320-01-270-4970
171
Parts Kit, Bearing R
172
5330-01-269-4417
Packing Assortment
173
5310-01-035-0869
Washer, Lock
END OF WORK PACKAGE
0172-10
TM 5-3810-305-23
INDEX
Subject WP Sequence No.-Page No.
A
AIR CLEANER ASSEMBLY MAINTENANCE......................................................................... ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE.......................... ANTI-TWO BLOCK CONTROL PANEL MAINTENANCE....................................................... AXLE CENTERING LIGHT SWITCH ASSEMBLY MAINTENANCE....................................... AXLE LOCKOUT CYLINDER MAINTENANCE....................................................................... AXLE LOCKOUT VALVE MAINTENANCE............................................................................. WP 0046-1 WP 0062-1 WP 0067-1 WP 0074-1 WP 0152-1 WP 0137-1
B
BACKUP ALARM MAINTENANCE......................................................................................... BATTERY ASSEMBLY AND CABLES MAINTENANCE......................................................... BATTERY BOX AND TOOLBOX WITH COVERS MAINTENANCE....................................... BOOM ANGLE INDICATOR MAINTENANCE........................................................................ BOOM ASSEMBLY MAINTENANCE...................................................................................... BOOM EXTEND CYLINDER MAINTENANCE........................................................................ BOOM HOIST CYLINDER MAINTENANCE........................................................................... BOOM HOIST, WINCH, AND OUTRIGGER VALVE CONTROLS MAINTENANCE.............. BOOM WIRING HARNESS MAINTENANCE.......................................................................... BOOM WORK LIGHT BRACKET MAINTENANCE................................................................. BRAKE ASSEMBLY MAINTENANCE..................................................................................... BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE....................................... BRAKE PEDAL AND LINKAGE MAINTENANCE................................................................... WP 0080-1 WP 0076-1 WP 0077-1 WP 0154-1 WP 0156-1 WP 0150-1 WP 0149-1 WP 0138-1 WP 0082-1 WP 0157-1 WP 0103-1 WP 0104-1 WP 0106-1
C
CAB ASSEMBLY MAINTENANCE.......................................................................................... CAB DOOR MAINTENANCE.................................................................................................. CAB MAIN HARNESS MAINTENANCE.................................................................................. CHARGE PUMP MAINTENANCE........................................................................................... COLD START DEVICE MAINTENANCE................................................................................ CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE.................................... CONTROL VALVE MAINTENANCE....................................................................................... COOLING FAN AND HUB ASSEMBLY MAINTENANCE....................................................... CRANKSHAFT PULLEY MAINTENANCE.............................................................................. CYLINDER HEAD MAINTENANCE........................................................................................ WP 0119-1 WP 0117-1 WP 0079-1 WP 0089-1 WP 0051-1 WP 0099-1 WP 0090-1 WP 0060-1 WP 0028-1 WP 0027-1
D
DASH PANEL GAGES AND SWITCHES MAINTENANCE.................................................... DECK PLATES MAINTENANCE............................................................................................. DEFROSTER FAN MAINTENANCE....................................................................................... DIAGRAMS............................................................................................................................. DRIVE BELT TENSIONER AND IDLER MAINTENANCE...................................................... WP 0066-1 WP 0122-1 WP 0055-1 WP 0166-1 WP 0061-1
E
ELECTRICAL COLLECTOR RING MAINTENANCE.............................................................. ENGINE ASSEMBLY MAINTENANCE................................................................................... ENGINE HOOD AND GRILLE GUARD MAINTENANCE....................................................... ENGINE MOUNT MAINTENANCE......................................................................................... EQUIPMENT DESCRIPTION AND DATA.............................................................................. EXHAUST MANIFOLD AND GASKETS MAINTENANCE...................................................... WP 0070-1 WP 0025-1 WP 0118-1 WP 0026-1 WP 0002-1 WP 0042-1
Index-1
03/15/2011 Rel(1.8) root(aindx) wpno(Paper_Index)
TM 5-3810-305-23
INDEX - Continued
E
EXHAUST SYSTEM ASSEMBLY MAINTENANCE................................................................ EXPENDABLE AND DURABLE ITEMS LIST......................................................................... WP 0053-1 WP 0170-1
F
FAN DRIVE BELT MAINTENANCE ....................................................................................... FENDERS MAINTENANCE.................................................................................................... FLOW DIVIDER AND STEERING VALVE MAINTENANCE................................................... FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE................................................... FRONT AND REAR DRIVESHAFT MAINTENANCE.............................................................. FRONT AXLE MAINTENANCE............................................................................................... FRONT CRANKSHAFT SEAL MAINTENANCE..................................................................... FRONT DIFFERENTIAL ASSEMBLY MAINTENANCE.......................................................... FRONT GEAR COVER AND GASKET MAINTENANCE........................................................ FRONT LIGHTS AND BRACKETS MAINTENANCE.............................................................. FUEL FILTER HEAD ASSEMBLY MAINTENANCE............................................................... FUEL INJECTION PUMP MAINTENANCE............................................................................. FUEL INJECTION TUBES MAINTENANCE........................................................................... FUEL INJECTOR MAINTENANCE......................................................................................... FUEL LIFT PUMP MAINTENANCE........................................................................................ FUEL LINES MAINTENANCE................................................................................................. FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE...................................... FUEL TANK MAINTENANCE.................................................................................................. WP 0059-1 WP 0121-1 WP 0114-1 WP 0029-1 WP 0093-1 WP 0094-1 WP 0036-1 WP 0095-1 WP 0032-1 WP 0072-1 WP 0050-1 WP 0044-1 WP 0049-1 WP 0043-1 WP 0045-1 WP 0048-1 WP 0065-1 WP 0047-1
G
GENERAL INFORMATION..................................................................................................... GENERAL MAINTENANCE INSTRUCTIONS........................................................................ GENERAL WIRING HARNESS AND CABLE MAINTENANCE.............................................. GROUND DRIVEN STEERING PUMP MAINTENANCE........................................................ WP 0001-1 WP 0162-1 WP 0163-1 WP 0109-1
H
HEATER MAINTENANCE....................................................................................................... HOOD SUPPORT MAINTENANCE........................................................................................ HOOK BLOCK MAINTENANCE.............................................................................................. HOOK BLOCK TIEBACK MAINTENANCE............................................................................. HORN MAINTENANCE........................................................................................................... HYDRAULIC BRAKE LINES AND FITTINGS MAINTENANCE.............................................. HYDRAULIC RESERVOIR MAINTENANCE.......................................................................... HYDRAULIC SYSTEM VALVE BANK MAINTENANCE......................................................... WP 0132-1 WP 0120-1 WP 0155-1 WP 0115-1 WP 0069-1 WP 0105-1 WP 0153-1 WP 0146-1
I
INTAKE MANIFOLD COVER AND GASKET MAINTENANCE............................................... WP 0041-1
L
LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE...................... LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE................................ LUBE OIL PUMP MAINTENANCE.......................................................................................... WP 0141-1 WP 0037-1 WP 0038-1
Index-2
TM 5-3810-305-23
INDEX - Continued
M
MAIN ENGINE WIRING HARNESS MAINTENANCE............................................................. MAIN HYDRAULIC PUMP MAINTENANCE........................................................................... MAINTENANCE ALLOCATION CHART (MAC)...................................................................... MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION......................................... MANDATORY REPLACEMENT PARTS LIST........................................................................ MARKING DECALS MAINTENANCE..................................................................................... MAST ASSEMBLY (TYPE II) MAINTENANCE....................................................................... MIRROR MAINTENANCE....................................................................................................... MSD-ICE DCA CONNECTOR/RESISTOR MODULE MAINTENANCE.................................. MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE................................................. MSD-ICE WIRING HARNESS MAINTENANCE..................................................................... WP 0078-1 WP 0134-1 WP 0169-1 WP 0168-1 WP 0172-1 WP 0133-1 WP 0159-1 WP 0130-1 WP 0083-1 WP 0020-1 WP 0081-1
N
NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE...................................................................................................................... WP 0064-1
O
OIL LEVEL GAGE MAINTENANCE........................................................................................ OIL PAN AND SUCTION TUBE MAINTENANCE................................................................... OUTRIGGER ASSEMBLY MAINTENANCE........................................................................... OUTRIGGER CYLINDER ASSEMBLY MAINTENANCE........................................................ OUTRIGGER HYDRAULICS MAINTENANCE....................................................................... OUTRIGGER SOLENOID VALVE MAINTENANCE............................................................... WP 0040-1 WP 0039-1 WP 0123-1 WP 0151-1 WP 0143-1 WP 0136-1
P
PARKING BRAKE MAINTENANCE........................................................................................ PINTLE HOOK MAINTENANCE............................................................................................. PIVOT AND SPINDLE ASSEMBLY MAINTENANCE............................................................. PIVOT BEARINGS (TYPE II) MAINTENANCE....................................................................... PLANETARY WHEEL END MAINTENANCE.......................................................................... POWER PACK ASSEMBLY MAINTENANCE......................................................................... PREPARATION FOR SHIPMENT AND STORAGE............................................................... PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)..................................... PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION........ PUMP ADAPTER MAINTENANCE......................................................................................... WP 0102-1 WP 0116-1 WP 0097-1 WP 0098-1 WP 0096-1 WP 0024-1 WP 0164-1 WP 0022-1 WP 0021-1 WP 0092-1
R
RADIATOR AND OIL COOLER MAINTENANCE................................................................... REAR AXLE MAINTENANCE................................................................................................. REAR CRANKSHAFT SEAL MAINTENANCE........................................................................ REAR DIFFERENTIAL ASSEMBLY MAINTENANCE............................................................ REAR LIGHTS MAINTENANCE............................................................................................. REFERENCES........................................................................................................................ RELIEF VALVE MAINTENANCE............................................................................................ RETURN AND PRESSURE HYDRAULICS MAINTENANCE................................................. RETURN FILTER MAINTENANCE......................................................................................... ROCKER LEVERS AND PUSH RODS MAINTENANCE........................................................ ROTARY MANIFOLD MAINTENANCE................................................................................... WP 0054-1 WP 0100-1 WP 0030-1 WP 0101-1 WP 0071-1 WP 0167-1 WP 0147-1 WP 0142-1 WP 0148-1 WP 0031-1 WP 0135-1
Index-3
TM 5-3810-305-23
INDEX - Continued
R
ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE........................... WP 0145-1
S
SEAT AND SEAT BELT MAINTENANCE............................................................................... SERVICE UPON RECEIPT..................................................................................................... STARTER MOTOR MAINTENANCE...................................................................................... STEERING CONTROL UNIT MAINTENANCE....................................................................... STEERING CYLINDERS MAINTENANCE............................................................................. STEERING SELECTOR VALVE MAINTENANCE.................................................................. STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE................................................ SUCTION HYDRAULICS MAINTENANCE............................................................................. SWING GEARBOX MAINTENANCE...................................................................................... SWING MOTOR MAINTENANCE........................................................................................... SWING/TELESCOPE VALVE CONTROLS MAINTENANCE................................................. WP 0124-1 WP 0023-1 WP 0063-1 WP 0110-1 WP 0112-1 WP 0113-1 WP 0111-1 WP 0144-1 WP 0161-1 WP 0160-1 WP 0139-1
T
TACHOMETER ADJUSTMENT ............................................................................................. TAPPET COVER AND GASKET MAINTENANCE................................................................. THEORY OF OPERATION..................................................................................................... THERMOSTAT MAINTENANCE............................................................................................. THROTTLE CONTROL MAINTENANCE................................................................................ TIE ROD ASSEMBLY MAINTENANCE.................................................................................. TIMING PIN ASSEMBLY MAINTENANCE............................................................................. TIRES AND WHEELS MAINTENANCE.................................................................................. TOOL IDENTIFICATION LIST................................................................................................. TORQUE LIMITS..................................................................................................................... TRANSMISSION ASSEMBLY MAINTENANCE...................................................................... TRANSMISSION CABLES MAINTENANCE........................................................................... TRANSMISSION CONTROLS MAINTENANCE..................................................................... TRANSMISSION DIPSTICK TUBE ASSEMBLY MAINTENANCE......................................... TRANSMISSION OIL AND FILTER ELEMENT MAINTENANCE........................................... TRANSMISSION SHIFT CONTROLS MAINTENANCE.......................................................... TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK SYSTEM.................................. TROUBLESHOOTING PROCEDURES AXLE ASSEMBLY................................................... TROUBLESHOOTING PROCEDURES BOOM HOIST CIRCUIT.......................................... TROUBLESHOOTING PROCEDURES BRAKES.................................................................. TROUBLESHOOTING PROCEDURES ELECTRICAL SYSTEM........................................... TROUBLESHOOTING PROCEDURES ENGINE................................................................... TROUBLESHOOTING PROCEDURES HYDRAULICS.......................................................... TROUBLESHOOTING PROCEDURES OUTRIGGER CIRCUIT............................................ TROUBLESHOOTING PROCEDURES PUMPS.................................................................... TROUBLESHOOTING PROCEDURES RELIEF VALVES..................................................... TROUBLESHOOTING PROCEDURES STEERING CIRCUIT............................................... TROUBLESHOOTING PROCEDURES SWING CIRCUIT..................................................... TROUBLESHOOTING PROCEDURES TRANSMISSION...................................................... TROUBLESHOOTING PROCEDURES WINCH..................................................................... TROUBLESHOOTING PROCEDURES BOOM EXTEND CIRCUIT....................................... TROUBLESHOOTING SYMPTOM INDEX............................................................................. WP 0075-1 WP 0034-1 WP 0003-1 WP 0056-1 WP 0052-1 WP 0108-1 WP 0033-1 WP 0107-1 WP 0171-1 WP 0165-1 WP 0088-1 WP 0086-1 WP 0087-1 WP 0084-1 WP 0091-1 WP 0085-1 WP 0016-1 WP 0018-1 WP 0008-1 WP 0014-1 WP 0015-1 WP 0005-1 WP 0006-1 WP 0010-1 WP 0012-1 WP 0013-1 WP 0011-1 WP 0007-1 WP 0017-1 WP 0019-1 WP 0009-1 WP 0004-1
Index-4
TM 5-3810-305-23
INDEX - Continued
U
UPPER HYDRAULICS LINE MAINTENANCE........................................................................ UPPERSTRUCTURE MAINTENANCE................................................................................... WP 0140-1 WP 0158-1
V
VALVE CONTROL, BOOM HOIST, EXTEND, AND WINCH CABLES MAINTENANCE........ VALVE COVERS AND GASKET MAINTENANCE................................................................. VEHICLE BUBBLE LEVEL MAINTENANCE........................................................................... WP 0129-1 WP 0035-1 WP 0068-1
W
WATER INLET CONNECTION MAINTENANCE.................................................................... WATER PUMP MAINTENANCE............................................................................................. WINCH ASSEMBLY MAINTENANCE..................................................................................... WINCH BRAKE VALVE MAINTENANCE............................................................................... WINCH CONTROL VALVE AND FITTINGS MAINTENANCE................................................ WINCH MOTOR MAINTENANCE........................................................................................... WINDSHIELD WIPER ASSEMBLY MAINTENANCE.............................................................. WORK LIGHTS MAINTENANCE............................................................................................ WP 0057-1 WP 0058-1 WP 0125-1 WP 0127-1 WP 0128-1 WP 0126-1 WP 0131-1 WP 0073-1
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RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.
Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).
DATE Date you filled out this form.
TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
FROM (Activity and location) (Include ZIP Code)
Your mailing address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE
TM Number
ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO.
Date of the TM
Title of the TM
RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)
0007-3
Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).
0018-2
SAMPLE
TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
SIGNATURE
Your Name
DA FORM 2028, FEB 74
Your Phone Number
Your Signature
APD V4.00
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS
DATE Date you filled out this form
Your Address
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE
TM Number
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER
Date of the TM
Title of the TM
RECOMMENDED ACTION
TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED
SAMPLE
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
Your Name
TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION
Your Phone Number
Your Signature
APD V4.00

For use of this form, see AR 25-30; the proponent agency is OAASA
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Crane, Wheel Mounted, 14 September 2012 TM 5-3810-305-23 Hydraulic, Light, (Rough Terrain Crane) Model LRT 110 7 1/2 Ton PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Crane, Wheel Mounted, 14 September 2012 TM 5-3810-305-23 Hydraulic, Light, (Rough Terrain Crane) Model LRT 110 7 1/2 Ton PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Field Maintenance Manual for Crane, Wheel Mounted, 14 September 2012 TM 5-3810-305-23 Hydraulic, Light, (Rough Terrain Crane) Model LRT 110 7 1/2 Ton ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO. RECOMMENDED CHANGES AND REASON
SIGNATURE
APD V4.00
DATE
PART III REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00

DATE
SIGNATURE
APD V4.00
DATE
PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)
APD V4.00
By Order of the Secretary of the Army: RAYMOND T. ODIERNO General, United States Army Chief of Staff
Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1221630
Distribution: To be distributed in accordance with the initial distribution number (IDN) 255758 requirements for TM 5-3810-305-23.
M0474105
FO-1.
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FO-2.
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MSD/ICE Electrical Schematic.
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FO-4.
Hydraulic System Schematic. FP-7/FP-8 blank
THE METRIC SYSTEM AND EQUIVALENTS

Linear Measure 1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles Weights 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 9/5 C +32 = F 5/9 (F - 32) = C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32.2 Celsius 32 Fahrenheit is equivalent to 0 Celsius Square Measure 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles Cubic Measure 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature
APPROXIMATE CONVERSION FACTORS

To Change Inches Feet Yards Miles Sq Inches Sq Feet Sq Yards Sq Miles Acres Cubic Feet Cubic Yards Fluid Ounces Pints Quarts Gallons Ounces Pounds Short Tons Pound-Feet Pounds per Sq Inch Miles per Gallon Miles per Hour To Centimeters Meters Meters Kilometers Sq Centimeters Sq Meters Sq Meters Sq Kilometers Sq Hectometers Cubic Meters Cubic Meters Milliliters Liters Liters Liters Grams Kilograms Metric Tons Newton-Meters Kilopascals Multiply By 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 To Change Centimeters Meters Meters Kilometers Sq Centimeters Sq Meters Sq Meters Sq Kilometers Sq Hectometers Cubic Meters Cubic Meters Milliliters Liters Liters Liters Grams Kilograms Metric Tons Newton-Meters Kilopascals To Inches Feet Yards Miles Sq Inches Sq Feet Sq Yards Sq Miles Acres Cubic Feet Cubic Yards Fluid Ounces Pints Quarts Gallons Ounces Pounds Short Tons Pound-Feet Pounds per Sq Inch Miles per Gallon Miles per Hour Multiply By 0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145
Kilometers per Liter Kilometers per Hour
0.425 1.609
Kilometers per Liter Kilometers per Hour
2.354 0.621
PIN: 087187-000

TM 5-3810-305-23

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TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

HEADQUARTERS, DEPARTMENT OF THE ARMY 14 SEPTEMBER 2012

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HAZARDOUS MATERIALS DESCRIPTIONS

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

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