TM 5-3825-270-23P Engineer Mission Module Water Distribution

TM 5-3825-270-23&P
TECHNICAL MANUAL FIELD MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR
ENGINEER MISSION MODULE - WATER DISTRIBUTOR (EMM - WD) NSN 3825-01-577-2713
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY 30 JUNE 2011
TM 5-3825-270-23&P
WARNING SUMMARY
GENERAL SAFETY CAUTION/WARNING SUMMARY This list summarizes critical warnings. They are repeated here to let you know how important they are. Study these warnings carefully. They can save your life and the lives of personnel you work with. If there is any doubt about handling tools, materials, equipment, and procedures, see TB 43-0216, Safety and Hazard Warnings for Operation and Maintenance of TACOM Equipment.
FOR INFORMATION ON FIRST AID: Reference FM 4-25.11. (WP 0221)
WARNING
MODIFICATION HAZARD Unauthorized modifications to, alterations to, or installations on this equipment are prohibited and are in violation of AR 750-10. Failure to comply may result in injury or death to personnel or damage to equipment.
WARNING
BATTERY To avoid eye injury, eye protection is required 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. Remove all jewelry, such as rings, ID tags, watches and bracelets. If jewelry contacts a battery terminal, a direct short will result in instant heating of tools and/or damage to equipment. Failure to comply may result in injury or death to personnel. Avoid electrolyte contact with skin, eyes, or clothing. If battery electrolyte spills, take immediate action to stop burning effects. External: Immediately flush with cold running water to remove all acid. Eyes: Flush with cold water for at least 15 minutes. Seek immediate medical attention. Internal: Drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek immediate medical attention. Clothing or Vehicle: Wash at once with cold water. Neutralize with baking soda or household ammonia solution. Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent clothing from being damaged. Failure to comply may result in injury or death to personnel.
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WARNING SUMMARY - Continued

WARNING
FIRE EXTINGUISHER Fire extinguisher contents are under pressure. Do not puncture or incinerate. DO NOT store at high temperatures above 120F (49C). Avoid inhaling the extinguishing agent. Avoid inhaling smoke and fumes - all fires release toxic substances that are harmful. DO NOT remain in a closed area after use. Evacuate the area immediately and ventilate thoroughly before re-entering. Although extinguishing agents are non-toxic when properly used, contact with them may cause irritation to eyes, nose, and throat and other allergic symptoms. Failure to comply with the above warnings could result in injury or death to personnel or damage to equipment.
WARNING
SOLVENT CLEANING COMPOUND (DRYCLEANING SOLVENT) Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flashpoint for Type II solvent cleaning compound is 141 to 198F (61 to 92C), and Type III is 200 to 241F (93 to 116C). Improper cleaning methods and use of unauthorized cleaning solvents may result in injury to personnel and/or damage to equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to comply may result in injury or death to personnel. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to comply may result in injury to personnel.
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Eye shields must be worn when cleaning with a wire brush. Failure to comply may result in injury to personnel. If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury or death to personnel.
WARNING
EXTREME HEAT When mission requires the system operator and crew to remain stationary at an area or location in outside temperatures above 90F (32C), operator and crew must observe proper safety precautions to prevent heat stress injury. Refer to FM 21-10, Field Hygiene and Sanitation, and FM 4-25.11, First Aid for Soldiers, for proper precautions and preventive measures. Failure to comply may result in injury or death to personnel.
WARNING
EXTREME COLD DO NOT touch extremely cold metal. Bare skin may freeze to cold metal. Failure to comply may result in injury or death to personnel. Wear gloves when operating or handling metallic equipment that is wet or ice covered. Failure to comply may result in injury or death to personnel. Exercise caution when working on the catwalk where snow or ice exists. Failure to comply may result in injury or death to personnel.
WARNING
LOAD HANDLING SYSTEM OPERATION Check for overhead power lines or other obstructions before attempting LHS operations. LHS reaches a height of 18 ft (5.5 m). Injury or death to personnel could result if LHS contacts power lines. Do not attempt loading or unloading operations on a side slope greater than 5 degrees and/or fore/aft slope greater than 20%. Prior to performing loading or unloading operations on slopes, determine if ground surface conditions permit safe loading or unloading operations. Slopes that contain snow, ice, loose gravel, or sand may not permit safe loading or unloading. Failure to comply may result in injury or death to personnel.
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Check ground conditions for firmness and extreme sideways inclination prior to picking up or off-loading a Water Distributor. Failure to comply may result in damage to equipment and injury or death to personnel. Prior to and during any load or unload cycle, all personnel should stay clear of LHS. Failure to comply may result in damage to equipment and injury or death to personnel.
WARNING
COOLING SYSTEM PRESSURE Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel. Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personal injury.
WARNING
ENGINE STARTING When engine is running during operations, all personnel within 10 ft of the Water Distributor pump operator position are required to wear Army-approved hearing protection devices (HPDs). Failure to comply may result in hearing loss. Before engine is started, always make sure that no personnel are in the danger area (moving parts on engine or machinery). Ensure that all safety guards are in place. Ensure that area is clear from loose parts. Never use any spray starting aids. Failure to comply may result in injury or death to personnel.
WARNING
FUEL Diesel fuel is flammable. Do not perform this procedure near fire, flame or sparks. Failure to comply may result in injury or death to personnel.
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DO NOT smoke or permit any open flame in area of Water Distributor while you are servicing fuel system. Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to comply may result in injury or death to personnel. DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel, or damage to equipment. Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing.
WARNING
HOT ENGINE Engine components become hot during normal operation. Allow engine to cool completely prior to performing this task. If necessary, use insulated pads and gloves. Failure to comply may result in injury or death to personnel.
WARNING
ELECTRICAL SYSTEM Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.
WARNING
HOT EXHAUST Exhaust pipes and muffler can become very hot during engine operation. Allow parts to cool and take care not to touch these parts with bare hands or allow body to contact exhaust pipes or muffler. Failure to comply may result in injury or death to personnel.
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WARNING
LIFTING OPERATIONS This section is applicable to all lifting operations regardless of lifting equipment (crane, LHS, etc.) used. All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury or death to personnel. Never crawl under equipment when performing maintenance unless equipment is securely blocked. Failure to comply may cause injury or death to personnel. Keep clear of equipment when it is being raised or lowered. Failure to comply may cause injury or death to personnel. Do not work on any item supported only by lift jacks or hoist. Always use blocks or proper stands to support the item prior to any work. Failure to comply may result in injury or death to personnel. Do not lift a load greater than the rated load capacity of the crane or materiel handling equipment. Failure to comply may result in injury or death to personnel or damage to equipment. Do not allow heavy components to swing while hanging by lifting device. Failure to comply may cause injury or death to personnel. Any part or component that weighs between 50 lbs (23 kg) and 75 lbs (34 kg) must be removed with the aid of an assistant. Any part or component that weighs over 75 lbs (34 kg) must be removed with the aid of an assistant and a lifting device. Failure to comply may cause injury or death to personnel. Ensure all chains, hooks, and slings are in good condition and are of correct capacity. Ensure hooks are positioned correctly. Failure to comply may result in injury or death to personnel.
WARNING
MOVING MACHINERY Use extreme care when operating or working near moving machinery including running engine, rotating shafts, and other moving parts. Failure to comply may result in injury or death to personnel. Use extreme care when measuring voltage while engine is running around rotating fan blade and hot engine parts. Failure to comply may result in injury or death to personnel.
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WARNING
HEARING PROTECTION Wear single hearing protection (earplugs or equivalent) while working around equipment while it is running. Failure to do so could result in damage to your hearing. Seek medical aid should you suspect a hearing problem.
WARNING
EYE PROTECTION Wear safety goggles and use caution when removing or installing springs, snap ring, retaining rings, and other parts under spring tension. These parts can act as projectiles, resulting in serious injury to personnel. Failure to comply may result in injury or death to personnel.
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TM 5-3825-270-23&P HEADQUARTERS DEPARTMENT OF THE ARMY Washington, DC, 30 JUNE 2011 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST ENGINEER MISSION MODULE - WATER DISTRIBUTOR (EMM - WD) NSN 3825-01-577-2713 Current as of 30 June 2011 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 Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS website will enable us to respond more quickly to your comments and 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, 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.
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 Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. Table 2. List of Abbreviations............................................................................................................. 0001-2 Warning Icons...................................................................................................................... 0001-4
EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Table 1. Equipment Data.................................................................................................................... 0002-1
THEORY OF OPERATION.......................................................................................................................... WP 0003 Chapter 2 - TROUBLESHOOTING PROCEDURES GENERAL TROUBLESHOOTING INSTRUCTIONS................................................................................... WP 0004 TROUBLESHOOTING SYMPTOM INDEX - FIELD MAINTENANCE......................................................... WP 0005 ENGINE DOES NOT CRANK...................................................................................................................... WP 0006 Figure 1. Figure 2. Figure 3. Figure 4. Table 1. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Engine Off/Battery Drain Indicator - Step 1.......................................................................... 0006-2 Battery Voltage Gauge - Step 2........................................................................................... 0006-2 Battery Cables - Step 3........................................................................................................ 0006-3 Battery Terminals - Step 4.................................................................................................... 0006-4 Battery State Of Charge Voltage Table................................................................................ 0006-4 Wire Connections - Step 5................................................................................................... 0006-5 Starter Relay Wire Connections - Step 6............................................................................. 0006-6 Starter Solenoid Positive Terminal - Step 7......................................................................... 0006-7 Starter Motor Ground Wire - Step 8..................................................................................... 0006-8 Starter Solenoid White Wire - Step 9................................................................................... 0006-9 Engine Start//Engine Stop Switch - Step 9........................................................................... 0006-9 Starter Relay Blue Wire - Step 10...................................................................................... 0006-10 Engine Start/Engine Stop Switch - Step 10........................................................................ 0006-10 Starter Relay White Wire - Step 11.................................................................................... 0006-11 Starter Solenoid White Wire - Step 11............................................................................... 0006-12
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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Control Panel Faceplate Screws - Step 12........................................................................ 0006-13 Engine Start/Engine Stop Switch Red Jumper Wires - Step 12......................................... 0006-14 Engine Off/Battery Drain Indicator - Step 12...................................................................... 0006-14 Engine Start/Engine Stop Switch Orange Wire - Step 13.................................................. 0006-15 Interconnect Terminal Strip, Terminal 6 - Step 13.............................................................. 0006-15 Interconnect Terminal Strip - Step 14................................................................................. 0006-16 Governor Controller Harness Connector Pin G2 - Step 14................................................ 0006-16 Governor Controller Harness Connector Pin A2 - Step 15................................................. 0006-17 Starter Relay Blue Wire - Step 15...................................................................................... 0006-17
ENGINE CRANKS BUT DOES NOT START.............................................................................................. WP 0007 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Fuel Tank - Step 1................................................................................................................ 0007-1 Air Filter Restriction Indicator - Step 2.................................................................................. 0007-2 Governor Actuator Harness - Step 3.................................................................................... 0007-3 Engine Timing Sensor Harness Connector - Step 4............................................................ 0007-4 Fuel System Components - Step 5...................................................................................... 0007-5 Flatrack Fuel Lines - Step 6................................................................................................. 0007-6 Engine Injection Pump Banjo-Fitting - Step 7....................................................................... 0007-7 Engine Start/Engine Stop Switch - Step 7............................................................................ 0007-7 Engine Injector Pump Banjo-Fitting - Step 8........................................................................ 0007-8 Fuel/Water Separator Supply Line - Step 8.......................................................................... 0007-9 Engine Start/Engine Stop Switch - Step 8............................................................................ 0007-9
EXCESSIVELY LONG CRANK TIMES....................................................................................................... WP 0008 Figure 1. Table 1. Figure 2. Figure 3. Figure 4. Battery Terminals - Step 3.................................................................................................... 0008-2 Battery State Of Charge Voltage Table................................................................................ 0008-3 Air Filter Restriction Indicator - Step 4.................................................................................. 0008-4 Air Filter - Step 5.................................................................................................................. 0008-4 Fuel System Components - Step 6...................................................................................... 0008-5
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Engine Injection Pump Banjo Fitting - Step 7....................................................................... 0008-6 Engine Start/Engine Stop Switch - Step 7............................................................................ 0008-6 Engine Injection Pump Banjo Fitting - Step 8....................................................................... 0008-7 Fuel/Water Separator Supply Line - Step 8.......................................................................... 0008-8 Engine Start/Engine Stop Switch - Step 8............................................................................ 0008-8
ENGINE STALLS......................................................................................................................................... WP 0009 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Fuel Tank - Step 1................................................................................................................ 0009-2 Engine Oil Pressure Gauge - Step 2.................................................................................... 0009-2 Water Pump Outlet Gauge - Step 3..................................................................................... 0009-3 Engine Temp Gauge - Step 4............................................................................................... 0009-4 Air Filter Restriction Indicator - Step 5.................................................................................. 0009-4 Fuel System Components - Step 6...................................................................................... 0009-5 Engine Injection Pump Banjo-Fitting - Step 7....................................................................... 0009-6 Engine Start/Stop Switch - Step 7........................................................................................ 0009-6 Engine Injection Pump Banjo-Fitting - Step 8....................................................................... 0009-7 Fuel/Water Separator Supply Line - Step 8.......................................................................... 0009-8 Engine Start/Engine Stop Switch - Step 8............................................................................ 0009-8
ENGINE SURGES....................................................................................................................................... WP 0010 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Air Filter Restriction Indicator - Step 1.................................................................................. 0010-1 Air Filter And Air Cleaner - Step 2........................................................................................ 0010-2 Fuel Lines - Step 3............................................................................................................... 0010-3 Fuel System Components - Step 4...................................................................................... 0010-4 Engine Injection Pump Banjo-Fitting - Step 5....................................................................... 0010-5 Engine Start/Engine Stop Switch - Step 5............................................................................ 0010-5 Engine Injection Pump Banjo-Fitting - Step 6....................................................................... 0010-6 Fuel/Water Separator Supply Line - Step 6.......................................................................... 0010-7 Engine Start/Engine Stop Switch - Step 6............................................................................ 0010-7
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Page No. WP Sequence No. ENGINE MISFIRES..................................................................................................................................... WP 0011 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Air Vent Cock - Step 2.......................................................................................................... 0011-2 Engine Injection Pump Banjo-Fitting - Step 2....................................................................... 0011-2 Air Vent Cock (Close) - Step 2............................................................................................. 0011-3 Fuel System Components - Step 3...................................................................................... 0011-3 Engine Injection Pump Banjo-Fitting - Step 4....................................................................... 0011-4 Engine Start/Engine Stop Switch - Step 4............................................................................ 0011-5 Engine Injection Pump Banjo-Fitting - Step 5....................................................................... 0011-6 Fuel/Water Separator Supply Line - Step 5.......................................................................... 0011-7 Engine Start Switch - Step 5................................................................................................ 0011-7
ENGINE WILL NOT INCREASE RPM......................................................................................................... WP 0012 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Engine Speed RPM Switch - Step 1..................................................................................... 0012-1 Control Panel Faceplate Screws - Step 2............................................................................ 0012-3 RPM Switch Red/White Wire - Step 2.................................................................................. 0012-3 Governor Controller Harness Connector Pin E1 - Step 2..................................................... 0012-4 Engine Speed RPM Switch Terminal 1 - Step 3................................................................... 0012-4 Governor Actuator Harness - Step 4.................................................................................... 0012-5 RPM Switch Red/White Wire - Step 5.................................................................................. 0012-6 Interconnect Terminal Strip - Step 5..................................................................................... 0012-6 Interconnect Terminal Strip - Step 6..................................................................................... 0012-7 Governor Controller Harness Connector Pin E1 - Step 6..................................................... 0012-7
EXCESSIVE ENGINE VIBRATION............................................................................................................. WP 0013 Figure 1. Figure 2. Figure 3. Figure 4. Alternator Belt - Step 2......................................................................................................... 0013-2 Alternator Belt And Water Pump Pulley - Step 2.................................................................. 0013-2 Engine Mounts - Step 3........................................................................................................ 0013-3 Cooling Fan - Step 4............................................................................................................ 0013-4
EXCESSIVE ENGINE NOISE...................................................................................................................... WP 0014
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Air Cleaner And Air Filter - Step 2........................................................................................ 0014-2 Alternator Belt - Step 3......................................................................................................... 0014-3 Engine Inlet Assembly Manifold - Step 4.............................................................................. 0014-4 Exhaust Manifold - Step 5.................................................................................................... 0014-4 Cooling Fan - Step 6............................................................................................................ 0014-5
ENGINE OVERHEATS................................................................................................................................ WP 0015 Figure 1. Figure 2. Figure 3. Alternator Belt - Step 2......................................................................................................... 0015-2 Engine Temperature Gauge - Step 7................................................................................... 0015-4 Engine Temperature Gauge - Step 8................................................................................... 0015-5
ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE................................................... WP 0016 Figure 1. Engine Temperature Gauge - Step 2................................................................................... 0016-2
EXCESSIVE ENGINE OIL CONSUMPTION............................................................................................... WP 0017 Figure 1. Engine Oil Sampling Valve - Step 1..................................................................................... 0017-1
EXCESSIVE FUEL CONSUMPTION.......................................................................................................... WP 0018 Figure 1. Figure 2. Figure 3. Figure 4. Tachometer - Test 1............................................................................................................. 0018-1 Air Filter - Step 2.................................................................................................................. 0018-2 Fuel System Components - Step 3...................................................................................... 0018-3 Fuel Lines - Step 4............................................................................................................... 0018-4
ENGINE KNOCK......................................................................................................................................... WP 0019 BLACK/BLUE EXHAUST SMOKE............................................................................................................... WP 0020 Figure 1. Figure 2. Figure 3. Air Filter Restriction Indicator - Step 1.................................................................................. 0020-1 Air Filter - Step 2.................................................................................................................. 0020-2 Exhaust Manifold - Step 3.................................................................................................... 0020-2
WHITE EXHAUST SMOKE......................................................................................................................... WP 0021 WATER PUMP DOES NOT OPERATE....................................................................................................... WP 0022 Figure 1. Figure 2. Pump Drive Coupling - Step 1.............................................................................................. 0022-1 Flex Element - Step 2........................................................................................................... 0022-2
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Page No. WP Sequence No. WATER PRESSURE ERRATIC.................................................................................................................. WP 0023 EXCESSIVE WATER PUMP NOISE........................................................................................................... WP 0024 Figure 1. Figure 2. Figure 3. Figure 4. Water Pump Housing Screws - Step 1................................................................................. 0024-1 Water Pump Isolation Mounts - Step 2................................................................................. 0024-2 Pump Drive Coupling - Step 3.............................................................................................. 0024-2 Flex Element - Step 4........................................................................................................... 0024-3
WORK LIGHTS DO NOT ILLUMINATE....................................................................................................... WP 0025 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Lights Switch - Step 1........................................................................................................... 0025-1 Engine Off/Battery Drain Indicator - Step 2.......................................................................... 0025-2 Work Light Harness Connector Pin 1 - Step 3..................................................................... 0025-3 Work Light Harness Connector Pin 2 - Step 4..................................................................... 0025-4 Control Panel Faceplate Screws - Step 5............................................................................ 0025-5 Light Switch - Step 5............................................................................................................ 0025-5 Light Switch - Step 6............................................................................................................ 0025-6 Positive Terminal Strip - Step 6............................................................................................ 0025-6 Lights Switch - Step 7........................................................................................................... 0025-7
WATER DISTRIBUTOR DOES NOT OPERATE REMOTELY.................................................................... WP 0026 NO POWER TO CONTROL PANEL............................................................................................................ WP 0027 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Table 1. Figure 6. Figure 7. Figure 8. 15-Amp Circuit Breaker - Step 1.......................................................................................... 0027-1 Battery Voltage Gauge - Step 2........................................................................................... 0027-2 Batteries And Battery Terminals - Step 3............................................................................. 0027-3 Batteries And Battery Terminals - Step 4............................................................................. 0027-3 Battery Terminals - Step 5.................................................................................................... 0027-4 Battery State Of Charge Voltage Table - Step 5.................................................................. 0027-4 Control Panel Faceplate Screws - Step 6............................................................................ 0027-6 Emergency Stop Switch, Terminal 1 - Step 6....................................................................... 0027-6 Emergency Stop Switch, Terminal 2- Step 7........................................................................ 0027-7
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Page No. WP Sequence No. Figure 9. Figure 10. Figure 11. Figure 12. Negative Terminal Strip - Step 8.......................................................................................... 0027-8 Negative Battery Terminal - Step 8...................................................................................... 0027-9 15-amp Circuit Breaker Terminal 1 - Step 9....................................................................... 0027-10 15-amp Circuit Breaker Terminal 2 - Step 10..................................................................... 0027-10
BATTERY VOLTAGE GAUGE DOES NOT OPERATE OR READS HIGH................................................. WP 0028 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Off/Battery Drain Indicator - Step 1.......................................................................... 0028-2 Control Panel Faceplate Screws - Step 2............................................................................ 0028-3 Gauge Harness Connector - Step 2..................................................................................... 0028-3 Gauge Harness Connector - Step 3..................................................................................... 0028-4 Negative Terminal Strip - Step 3.......................................................................................... 0028-5 Battery Voltage Gauge - Step 4........................................................................................... 0028-5
BATTERY VOLTAGE GAUGE READS LOW.............................................................................................. WP 0029 Figure 1. Figure 2. Table 1. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Battery Voltage Gauge - Step 2........................................................................................... 0029-2 Battery Terminals - Step 3.................................................................................................... 0029-3 Battery State Of Charge Voltage Table................................................................................ 0029-3 Control Panel Faceplate Screws - Step 4............................................................................ 0029-4 Gauge Harness Connector - Step 4..................................................................................... 0029-5 Positive Terminal Strip - Step 4............................................................................................ 0029-6 Gauge Harness Connector - Step 5..................................................................................... 0029-7 Negative Terminal Strip - Step 5.......................................................................................... 0029-7 Red Wire At Alternator - Step 6............................................................................................ 0029-8 Positive Battery Terminal - Step 6........................................................................................ 0029-9 Battery Voltage Gauge - Step 5........................................................................................... 0029-9
BATTERY VOLTAGE GAUGE READS HIGH............................................................................................. WP 0030 Figure 1. Table 1. Figure 2. Battery Terminals - Step 1.................................................................................................... 0030-2 Battery State Of Charge Voltage Table - Step 1.................................................................. 0030-2 Battery Terminals - Step 2.................................................................................................... 0030-3
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Page No. WP Sequence No. Figure 3. Battery Voltage Gauge - Step 3........................................................................................... 0030-4
ENGINE OFF/BATTERY DRAIN INDICATOR DOES NOT ILLUMINATE.................................................. WP 0031 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Control Panel Faceplate Screws - Step 2............................................................................ 0031-2 Positive Terminal Strip - Step 2............................................................................................ 0031-3 Engine Off/Battery Drain Indicator - Step 3.......................................................................... 0031-4 Governor Controller Harness Connector - Step 3................................................................ 0031-4 Engine Off/Battery Drain Indicator - Step 4.......................................................................... 0031-5 Interconnect Terminal Strip - Step 4..................................................................................... 0031-5 Engine Off/Battery Drain Indicator - Step 5.......................................................................... 0031-6
ENGINE OFF/BATTERY DRAIN INDICATOR STAYS ILLUMINATED....................................................... WP 0032 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Control Panel Faceplate Screws - Step 2............................................................................ 0032-2 Interconnect Terminal Strip - Step 2..................................................................................... 0032-3 Interconnect Terminal Strip - Step 3..................................................................................... 0032-4 Interconnect Terminal Strip Terminals 9 And 10 - Step 3.................................................... 0032-4 Engine Off/Battery Drain Indicator - Step 5.......................................................................... 0032-5
ENGINE OIL PRESSURE GAUGE READS LOW....................................................................................... WP 0033 Figure 1. Figure 2. Engine Oil Pressure Switch - Step 3.................................................................................... 0033-2 Engine Oil Pressure Gauge - Step 5.................................................................................... 0033-3
ENGINE OIL PRESSURE GAUGE READS LOW OR READS HIGH......................................................... WP 0034 Figure 1. Figure 2. Figure 3. Engine Temp Gauge - Step 1............................................................................................... 0034-1 Engine Oil Pressure Gauge - Step 3.................................................................................... 0034-2 Engine Oil Pressure Gauge - Step 3.................................................................................... 0034-3
ENGINE OIL PRESSURE GAUGE INOPERATIVE OR READS HIGH....................................................... WP 0035 Figure 1. Figure 2. Figure 3. Figure 4. Engine Oil Pressure Gauge - Step 1.................................................................................... 0035-1 Control Panel Faceplate Screws - Step 2............................................................................ 0035-2 Gauge Harness Connector - Step 2..................................................................................... 0035-3 Gauge Harness Connector - Step 2..................................................................................... 0035-3
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Gauge Harness Connector - Step 3..................................................................................... 0035-4 Negative Terminal Strip - Step 3.......................................................................................... 0035-5 Gauge Harness Connector - Step 4..................................................................................... 0035-6 Engine Oil Pressure Sending Unit - Step 4.......................................................................... 0035-6 Gauge Harness Connector - Step 5..................................................................................... 0035-7 Interconnect Terminal Strip - Step 5..................................................................................... 0035-7 Engine Oil Pressure Gauge - Step 6.................................................................................... 0035-8
ENGINE TEMPERATURE GAUGE INOPERATIVE OR READS HIGH...................................................... WP 0036 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Engine Temp Gauge - Step 1............................................................................................... 0036-1 Control Panel Faceplate Screws - Step 2............................................................................ 0036-2 Gauge Harness Connector - Step 2..................................................................................... 0036-3 Gauge Harness Connector - Step 2..................................................................................... 0036-3 Gauge Harness Connector - Step 3..................................................................................... 0036-4 Negative Terminal Strip - Step 3.......................................................................................... 0036-5 Gauge Harness Connector - Step 4..................................................................................... 0036-6 Engine Coolant Temperature Sending Unit - Step 4............................................................ 0036-6 Gauge Harness Connector - Step 5..................................................................................... 0036-7 Interconnect Terminal Strip - Step 5..................................................................................... 0036-7 Engine Temperature Gauge - Step 6................................................................................... 0036-8
MAIN CONTROL PANEL TACHOMETER DOES NOT OPERATE............................................................ WP 0037 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Tachometer - Step 1............................................................................................................. 0037-1 Control Panel Faceplate Screws - Step 2............................................................................ 0037-2 Pulse Adjustment Dial - Step 2............................................................................................. 0037-2 Tachometer Red Wire - Step 3............................................................................................. 0037-3 Tachometer Black Wire - Step 4.......................................................................................... 0037-4 Negative Terminal Strip - Step 4.......................................................................................... 0037-5 Alternator And Clear Wire Harness Connector - Step 5....................................................... 0037-5
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Page No. WP Sequence No. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Tachometer Grey Wire - Step 5........................................................................................... 0037-6 Clear Wire Harness Connector - Step 5............................................................................... 0037-6 Tachometer Grey Wire - Step 6........................................................................................... 0037-7 Interconnect Terminal Strip - Step 6..................................................................................... 0037-7 Tachometer - Step 7............................................................................................................. 0037-8
WATER PUMP INLET GAUGE DOES NOT OPERATE............................................................................. WP 0038 Figure 1. Figure 2. Figure 3. Water Pump Inlet Gauge And Hose - Step 1....................................................................... 0038-1 Water Pump Inlet Gauge And Hose - Step 2....................................................................... 0038-2 Water Pump Inlet Gauge - Step 3........................................................................................ 0038-3
WATER PUMP OUTLET GAUGE DOES NOT OPERATE......................................................................... WP 0039 Figure 1. Figure 2. Figure 3. Water Pump Outlet Gauge And Hose - Step 1..................................................................... 0039-1 Water Pump Outlet Gauge And Hose - Step 2..................................................................... 0039-2 Water Pump Outlet Gauge - Step 3..................................................................................... 0039-3
MAIN CONTROL PANEL ENGINE SPEED RESUME/IDLE SWITCH DOES NOT OPERATE.................................................................................................................................................... WP 0040 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Control Panel Faceplate Screws - Step 1............................................................................ 0040-1 Engine Resume/Idle Switch - Step 1.................................................................................... 0040-2 Engine Resume/Idle Switch - Step 2.................................................................................... 0040-3 Governor Controller Harness Connector - Step 2................................................................ 0040-3 Engine Resume/Idle Switch - Step 3.................................................................................... 0040-4 Governor Controller Harness Connector - Step 3................................................................ 0040-4 Engine Resume/Idle Switch - Step 4.................................................................................... 0040-5 Engine Start/Engine Stop Switch - Step 4............................................................................ 0040-6 Engine Resume/Idle Switch - Step 5.................................................................................... 0040-7 Interconnect Terminal Strip - Step 5..................................................................................... 0040-7 Engine Resume/Idle Switch - Step 6.................................................................................... 0040-8 Interconnect Terminal Strip - Step 6..................................................................................... 0040-9
ENGINE SPEED RPM SWITCH DOES NOT OPERATE............................................................................ WP 0041
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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. Control Panel Faceplate Screws - Step 1............................................................................ 0041-1 Engine Speed RPM Switch - Step 1..................................................................................... 0041-2 Engine Speed RPM Switch - Step 2..................................................................................... 0041-3 Governor Controller Harness Connector - Step 2................................................................ 0041-3 Engine Speed RPM Switch - Step 3..................................................................................... 0041-4 Governor Controller Harness Connector - Step 3................................................................ 0041-4 Engine Speed RPM Switch - Step 4..................................................................................... 0041-5 Engine Resume/Idle Switch - Step 4.................................................................................... 0041-5 Engine Speed RPM Switch - Step 5..................................................................................... 0041-6 Interconnect Terminal Strip - Step 5..................................................................................... 0041-6 Engine Speed RPM Switch - Step 6..................................................................................... 0041-7 Interconnect Terminal Strip - Step 6..................................................................................... 0041-7
MAIN CONTROL PANEL ENGINE SPEED SET SWITCH DOES NOT OPERATE................................... WP 0042 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Control Panel Faceplate Screws - Step 1............................................................................ 0042-1 Engine Speed Set Switch - Step 1....................................................................................... 0042-2 Engine Speed Set Switch - Step 2....................................................................................... 0042-3 Governor Controller Harness Connector - Step 2................................................................ 0042-3 Engine Speed Set Switch - Step 3....................................................................................... 0042-4 Engine Speed RPM Switch - Step 3..................................................................................... 0042-4 Engine Speed Set Switch - Step 4....................................................................................... 0042-5 Interconnect Terminal Strip - Step 4..................................................................................... 0042-5
LEFT WATER SPRINKLERS SWITCH DOES NOT OPERATE................................................................. WP 0043 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Left Water Sprinklers Switch - Step 2................................................................................... 0043-2 Left Solenoid Harness Connector - Step 2........................................................................... 0043-2 Control Panel Faceplate Screws - Step 3............................................................................ 0043-3 Negative Terminal Strip - Step 3.......................................................................................... 0043-4 Left Solenoid Harness Connector (Gray) - Step 3................................................................ 0043-4
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Control Panel Faceplate Screws - Step 4............................................................................ 0043-5 Left Water Sprinkler Switch - Step 4.................................................................................... 0043-6 Left Water Sprinklers Switch - Step 5................................................................................... 0043-7 Interconnect Terminal Strip - Step 5..................................................................................... 0043-7
RIGHT WATER SPRINKLERS SWITCH DOES NOT OPERATE............................................................... WP 0044 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Right Water Sprinklers Switch - Step 2................................................................................ 0044-2 Right Solenoid Harness Connector - Step 2........................................................................ 0044-2 Control Panel Faceplate Screws - Step 3............................................................................ 0044-3 Negative Terminal Strip - Step 3.......................................................................................... 0044-4 Right Solenoid Harness Connector - Step 3........................................................................ 0044-4 Control Panel Faceplate Screws - Step 4............................................................................ 0044-5 Right Water Sprinkler Switch - Step 4.................................................................................. 0044-6 Right Water Sprinklers Switch - Step 5................................................................................ 0044-7 Interconnect Terminal Strip - Step 5..................................................................................... 0044-7
WATER LEVEL HIGH INDICATOR DOES NOT ILLUMINATE................................................................... WP 0045 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Water Level Indicator And Magnet - Step 1......................................................................... 0045-1 WATER LEVEL HIGH Indicator - Step 1.............................................................................. 0045-2 Water Level Indicator And Magnet - Step 2......................................................................... 0045-2 Water Level High Indicator - Step 2..................................................................................... 0045-3 Tachometer - Step 3............................................................................................................. 0045-3 Control Panel Faceplate Screws - Step 4............................................................................ 0045-4 Water Level Indicator And Magnet - Step 4......................................................................... 0045-5 WATER LEVEL HIGH Indicator - Step 4.............................................................................. 0045-5 Positive Terminal Strip - Step 5............................................................................................ 0045-6 High Tank Level Switch Harness Connector - Step 5.......................................................... 0045-6 Water Level High Indicator - Step 6..................................................................................... 0045-7 High Tank Level Switch Harness Connector - Step 6.......................................................... 0045-7
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Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Figure 16. Water Level High Indicator - Step 7..................................................................................... 0045-8 Interconnect Terminal Strip - Step 7..................................................................................... 0045-8 Water Level Indicator And Magnet - Step 8......................................................................... 0045-9 WATER LEVEL HIGH Indicator - Step 8.............................................................................. 0045-9
MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR DOES NOT ILLUMINATE.......................... WP 0046 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. Water Level Indicator And Magnet - Step 1......................................................................... 0046-1 Water Level Low Indicator - Step 1...................................................................................... 0046-2 Water Level Indicator And Magnet - Step 2......................................................................... 0046-2 Water Level High Indicator - Step 2..................................................................................... 0046-3 Tachometer - Step 3............................................................................................................. 0046-3 Control Panel Faceplate Screws - Step 4............................................................................ 0046-4 Water Level Indicator And Magnet - Step 4......................................................................... 0046-5 Water Level Low Indicator - Step 4...................................................................................... 0046-5 Positive Terminal Strip - Step 5............................................................................................ 0046-6 Low Tank Level Switch Harness Connector - Step 5........................................................... 0046-6 Water Level Low Indicator - Step 6...................................................................................... 0046-7 Low Tank Level Switch Harness Connector - Step 6........................................................... 0046-7 Water Level Low Indicator - Step 7...................................................................................... 0046-8 Interconnect Terminal Strip - Step 7..................................................................................... 0046-8 Water Level Indicator And Magnet - Step 8......................................................................... 0046-9 Water Level Low Indicator - Step 8...................................................................................... 0046-9
MAIN CONTROL PANEL WATER LEVEL HIGH INDICATOR STAYS ILLUMINATED.............................. WP 0047 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. High Tank Level Switch Harness Connector - Step 1.......................................................... 0047-2 Control Panel Faceplate Screws - Step 2............................................................................ 0047-3 Interconnect Terminal Strip - Step 2..................................................................................... 0047-3 Interconnect Terminal Strip - Step 2..................................................................................... 0047-4 Water Level High Indicator - Step 3..................................................................................... 0047-5
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Page No. WP Sequence No. MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR STAYS ILLUMINATED............................... WP 0048 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Low Tank Level Switch Harness Connector - Step 1........................................................... 0048-2 Control Panel Faceplate Screws - Step 2............................................................................ 0048-3 Interconnect Terminal Strip - Step 2..................................................................................... 0048-3 Interconnect Terminal Strip - Step 2..................................................................................... 0048-4 Water Level Low Indicator - Step 3...................................................................................... 0048-5
MANUAL WATER TURRET DOES NOT OPERATE.................................................................................. WP 0049 Figure 1. Figure 2. Manual Water Turret - Step 1............................................................................................... 0049-1 Water Pump Outlet Gauge - Step 3..................................................................................... 0049-2
MANUAL WATER TURRET PRESSURE LOW.......................................................................................... WP 0050 Figure 1. Figure 2. Figure 3. Figure 4. Manual Water Turret - Step 1............................................................................................... 0050-1 Valve V6 - Step 2................................................................................................................. 0050-2 Valve V5 - Step 3................................................................................................................. 0050-3 Water Pump Outlet Gauge - Step 3..................................................................................... 0050-4
GRAVITY BAR WELDMENT DOES NOT OPERATE................................................................................. WP 0051 Figure 1. Figure 2. Figure 3. Gravity Bar Weldment - Step 1............................................................................................. 0051-1 Closure Cap C2 - Step 2...................................................................................................... 0051-2 Water Tank Sump - Test 3................................................................................................... 0051-3
GRAVITY BAR WELDMENT STREAM LOW.............................................................................................. WP 0052 Figure 1. Figure 2. Figure 3. Gravity Bar Weldment - Step 1............................................................................................. 0052-1 Closure Cap C2 - Step 2...................................................................................................... 0052-2 Water Tank Sump - Test 3................................................................................................... 0052-3
WATER SPRINKLERS DO NOT OPERATE............................................................................................... WP 0053 Figure 1. Figure 2. Figure 3. Figure 4. Water Sprinkler Head - Step 2............................................................................................. 0053-2 Air Hoses - Step 3................................................................................................................ 0053-3 Left And Right Solenoid Valves - Step 4.............................................................................. 0053-4 Air Hoses - Step 7................................................................................................................ 0053-5
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Page No. WP Sequence No. WATER SPRINKLER HEAD PRESSURE LOW.......................................................................................... WP 0054 Figure 1. Figure 2. Figure 3. Air Hoses - Step 3................................................................................................................ 0054-2 Water Sprinkler Head - Step 4............................................................................................. 0054-3 Air Hoses - Step 5................................................................................................................ 0054-3
WATER HOSE INOPERATIVE.................................................................................................................... WP 0055 Figure 1. Figure 2. Water Hose - Step 2............................................................................................................. 0055-1 Water Hose Nozzle - Step 3................................................................................................. 0055-2
WATER HOSE PRESSURE LOW............................................................................................................... WP 0056 Figure 1. Figure 2. Water Hose - Step 1............................................................................................................. 0056-1 Water Hose Nozzle - Step 2................................................................................................. 0056-2
CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR INOPERATIVE................................ WP 0057 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Engine Off/Battery Drain Indicator - Step 1.......................................................................... 0057-1 Cab Control Box - Step 3..................................................................................................... 0057-2 UPIK Air And Electrical Connections - Step 3...................................................................... 0057-3 Cab Control Box Screws - Step 4......................................................................................... 0057-3 Cab Control Box Engine Off/Battery Drain Indicator - Step 4............................................... 0057-4 UPIK Electrical Connection - Step 5..................................................................................... 0057-4 UPIK Harness Connector Pin J - Step 5.............................................................................. 0057-5 Cab Control Box Engine Off/Battery Drain Indicator - Step 6............................................... 0057-6 UPIK Electrical Connection - Step 7..................................................................................... 0057-6 UPIK Harness Connector Pin I - Step 7............................................................................... 0057-7 Cab Control Box Engine Off/Battery Drain Indicator - Step 8............................................... 0057-8
CAB CONTROL BOX LIGHTS SWITCH DOES NOT OPERATE............................................................... WP 0058 Figure 1. Figure 2. Figure 3. Figure 4. Cab Control Box - Step 2..................................................................................................... 0058-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0058-2 Cab Control Box Screws - Step 3......................................................................................... 0058-3 Cab Control Box Lights Switch - Step 3............................................................................... 0058-3
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Cab Control Box Lights Switch - Step 4............................................................................... 0058-4 UPIK Electrical Connection - Step 5..................................................................................... 0058-5 UPIK Harness Connector Pin H - Step 5.............................................................................. 0058-5 Cab Control Box Lights Switch - Step 6............................................................................... 0058-6
CAB CONTROL BOX TACHOMETER DOES NOT OPERATE.................................................................. WP 0059 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Tachometer - Step 1............................................................................................................. 0059-1 Cab Control Box - Step 2..................................................................................................... 0059-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0059-2 Cab Control Box Screws - Step 3......................................................................................... 0059-3 Cab Control Box Tachometer Pulse Adjustment Dial - Step 3............................................. 0059-3 Cab Control Box Tachometer - Step 4................................................................................. 0059-4 Cab Control Box Tachometer - Step 5................................................................................. 0059-5 UPIK Electrical Connection - Step 6..................................................................................... 0059-5 UPIK Harness Connector Pin V - Step 6.............................................................................. 0059-6 UPIK Electrical Connection - Step 7..................................................................................... 0059-7 UPIK Harness Connector Pin U - Step 7.............................................................................. 0059-7 Tachometer - Step 8............................................................................................................. 0059-8
CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH DOES NOT OPERATE........................ WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Cab Control Box - Step 2..................................................................................................... 0060-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0060-2 Cab Control Box Screws - Step 3......................................................................................... 0060-3 Cab Control Box Engine Speed Resume/Idle Switch - Step 3............................................. 0060-3 Cab Control Box Engine Speed Resume/Idle Switch - Step 4............................................. 0060-4 Cab Control Box Engine Speed Resume/Idle Switch - Step 5............................................. 0060-5 UPIK Electrical Connection - Step 6..................................................................................... 0060-6 UPIK Harness Connector Pin C - Step 6.............................................................................. 0060-6 UPIK Electrical Connection - Step 7..................................................................................... 0060-7
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Page No. WP Sequence No. Figure 10. Figure 11. UPIK Harness Connector Pin B - Step 7.............................................................................. 0060-8 Cab Control Box Engine Speed Resume/Idle Switch - Step 8............................................. 0060-8
CAB CONTROL BOX ENGINE SPEED RPM SWITCH DOES NOT OPERATE........................................ WP 0061 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Cab Control Box - Step 2..................................................................................................... 0061-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0061-2 Cab Control Box Screws - Step 3......................................................................................... 0061-3 Cab Control Box Engine Speed RPM Switch - Step 3......................................................... 0061-3 Cab Control Box Engine Speed RPM Switch - Step 4......................................................... 0061-4 Cab Control Box Engine Speed RPM Switch - Step 5......................................................... 0061-5 UPIK Electrical Connection - Step 6..................................................................................... 0061-6 UPIK Harness Connector Pin E - Step 6.............................................................................. 0061-6 UPIK Electrical Connection - Step 7..................................................................................... 0061-7 UPIK Harness Connector Pin D - Step 7.............................................................................. 0061-8 Cab Control Box Engine Speed RPM Switch - Step 8......................................................... 0061-8
CAB CONTROL BOX ENGINE SPEED SET SWITCH DOES NOT OPERATE......................................... WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Control Box - Step 2..................................................................................................... 0062-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0062-2 Cab Control Box Screws - Step 3......................................................................................... 0062-3 Cab Control Box Engine Speed Set Switch - Step 3............................................................ 0062-3 Cab Control Box Engine Speed Set Switch - Step 4............................................................ 0062-4 UPIK Electrical Connection - Step 5..................................................................................... 0062-5 UPIK Harness Connector Pin A - Step 5.............................................................................. 0062-5 Cab Control Box Engine Speed Set Switch - Step 6............................................................ 0062-6
CAB CONTROL BOX WATER SPRINKLER SWITCH (LEFT) INOPERATIVE.......................................... WP 0063 Figure 1. Figure 2. Figure 3. Cab Control Box - Step 2..................................................................................................... 0063-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0063-2 Cab Control Box Screws - Step 3......................................................................................... 0063-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Control Box Left Water Sprinkler Switch - Step 3......................................................... 0063-3 Cab Control Box Left Water Sprinkler Switch - Step 4......................................................... 0063-4 UPIK Electrical Connection - Step 5..................................................................................... 0063-5 UPIK Harness Connector Pin M - Step 5............................................................................. 0063-6 Left Water Sprinkler Switch - Step 6.................................................................................... 0063-6
CAB CONTROL BOX WATER SPRINKLER SWITCH (RIGHT) INOPERATIVE........................................ WP 0064 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Control Box - Step 2..................................................................................................... 0064-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0064-2 Cab Control Box Screws - Step 3......................................................................................... 0064-3 Cab Control Box Right Water Sprinkler Switch - Step 3....................................................... 0064-3 Cab Control Box Right Water Sprinkler Switch - Step 4....................................................... 0064-4 UPIK Electrical Connection - Step 5..................................................................................... 0064-5 UPIK Harness Connector Pin N - Step 5.............................................................................. 0064-5 Right Water Sprinkler Switch - Step 6.................................................................................. 0064-6
CAB CONTROL BOX WATER LEVEL HIGH INDICATOR DOES NOT ILLUMINATE............................... WP 0065 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Water Level Indicator And Magnet - Step 1......................................................................... 0065-1 Water Level High Indicator - Step 1..................................................................................... 0065-2 Cab Control Box - Step 2..................................................................................................... 0065-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0065-3 Cab Control Box Screws - Step 3......................................................................................... 0065-3 Cab Control Box Water Level High Indicator - Step 3.......................................................... 0065-4 UPIK Electrical Connection - Step 4..................................................................................... 0065-4 UPIK Harness Connector Pin K - Step 4.............................................................................. 0065-5 Cab Control Box Water Level High Indicator - Step 5.......................................................... 0065-6 Cab Control Box Water Level High Indicator - Step 6.......................................................... 0065-7 Water Level Indicator And Magnet - Step 7......................................................................... 0065-7 Cab Control Box Water Level High Indicator - Step 7.......................................................... 0065-8
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Page No. WP Sequence No. CAB CONTROL BOX WATER LEVEL LOW INDICATOR DOES NOT ILLUMINATE................................ 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. Water Level Indicator And Magnet - Step 1......................................................................... 0066-1 Water Level Low Indicator - Step 1...................................................................................... 0066-2 Cab Control Box - Step 2..................................................................................................... 0066-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0066-3 Cab Control Box Screws - Step 3......................................................................................... 0066-3 Cab Control Box Water Level Low Indicator - Step 3........................................................... 0066-4 UPIK Electrical Connection - Step 4..................................................................................... 0066-4 UPIK Harness Connector Pin L - Step 4.............................................................................. 0066-5 Cab Control Box Water Level Low Indicator - Step 5........................................................... 0066-6 Cab Control Box Tachometer - Step 5................................................................................. 0066-6 Water Level Indicator And Magnet - Step 6......................................................................... 0066-7 Cab Control Box Water Level Low Indicator - Step 6........................................................... 0066-7
CAB CONTROL BOX ENGINE START/STOP SWITCH DOES NOT OPERATE....................................... WP 0067 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Cab Control Box - Step 2..................................................................................................... 0067-2 UPIK Air And Electrical Connections - Step 2...................................................................... 0067-2 Cab Control Box Screws - Step 3......................................................................................... 0067-3 Cab Control Box Engine Start/Stop Switch - Step 3............................................................. 0067-3 Cab Control Box Engine Start/Stop Switch - Step 4............................................................. 0067-4 Cab Control Box Engine Start/Stop Switch - Step 5............................................................. 0067-5 UPIK Electrical Connection - Step 6..................................................................................... 0067-6 UPIK Harness Connector Pin G - Step 6............................................................................. 0067-6 UPIK Electrical Connection - Step 7..................................................................................... 0067-7 UPIK Harness Connector Pin F - Step 7.............................................................................. 0067-8 Cab Control Box Engine Start/Stop Switch - Step 8............................................................. 0067-8
Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - FIELD LEVEL PREVENTIVE MAINTENANCE............................................................. WP 0068
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Page No. WP Sequence No. FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).................................. WP 0069 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. Figure 13. FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).......... 0069-1 Batteries............................................................................................................................... 0069-2 Engine.................................................................................................................................. 0069-3 Belt....................................................................................................................................... 0069-4 Cooling System.................................................................................................................... 0069-5 Water Tank and Accessories............................................................................................... 0069-6 Hook Bar.............................................................................................................................. 0069-7 Water Tank Mount Screws................................................................................................... 0069-8 Air Lubricator........................................................................................................................ 0069-9 Oil Filter.............................................................................................................................. 0069-10 Air Filter.............................................................................................................................. 0069-11 Water Pump....................................................................................................................... 0069-12 Starter................................................................................................................................. 0069-13 Air Filter.............................................................................................................................. 0069-14
Chapter 4 - MAINTENANCE INSTRUCTIONS COOLANT RESERVOIR REPLACEMENT................................................................................................. WP 0070 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Coolant Reservoir Removal................................................................................................. 0070-1 Coolant Reservoir Removal................................................................................................. 0070-2 Coolant Reservoir Removal................................................................................................. 0070-2 Coolant Reservoir Installation.............................................................................................. 0070-3 Coolant Reservoir Installation.............................................................................................. 0070-3 Coolant Reservoir Installation.............................................................................................. 0070-4
WATER PUMP AND HOUSING REPLACEMENT...................................................................................... WP 0071 Figure 1. Figure 2. Figure 3. Water Pump and Housing Removal..................................................................................... 0071-1 Water Pump and Housing Removal..................................................................................... 0071-2 Water Pump and Housing Removal..................................................................................... 0071-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Water Pump and Housing Removal..................................................................................... 0071-4 Water Pump and Housing Installation.................................................................................. 0071-5 Water Pump and Housing Installation.................................................................................. 0071-6 Water Pump and Housing Installation.................................................................................. 0071-7 Water Pump and Housing Installation.................................................................................. 0071-7
COOLING FAN REPLACEMENT................................................................................................................ WP 0072 Figure 1. Figure 2. Figure 3. Figure 4. Cooling Fan Removal........................................................................................................... 0072-1 Cooling Fan Removal........................................................................................................... 0072-2 Cooling Fan Installation........................................................................................................ 0072-2 Cooling Fan Installation........................................................................................................ 0072-3
UPPER COOLING SYSTEM HOSE REPLACEMENT................................................................................ WP 0073 Figure 1. Figure 2. Upper Cooling System Hose Removal................................................................................. 0073-1 Upper Cooling System Hose Installation.............................................................................. 0073-2
COOLING SYSTEM SERVICING AND TESTING....................................................................................... WP 0074 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. Cooling System Flushing...................................................................................................... 0074-2 Cooling System Flushing...................................................................................................... 0074-3 Cooling System Flushing...................................................................................................... 0074-3 Cooling System Flushing...................................................................................................... 0074-4 Cooling System Flushing...................................................................................................... 0074-4 Cooling System Flushing...................................................................................................... 0074-5 Cooling System Flushing...................................................................................................... 0074-5 Cooling System Flushing...................................................................................................... 0074-6 Cooling System Flushing...................................................................................................... 0074-7 Cooling System Flushing...................................................................................................... 0074-7 Cooling System Flushing...................................................................................................... 0074-8 Cooling System Flushing...................................................................................................... 0074-9 Cooling System Flushing...................................................................................................... 0074-9
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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. Figure 23. Figure 24. Figure 25. Cooling System Flushing.................................................................................................... 0074-10 Cooling System Flushing.................................................................................................... 0074-10 Cooling System Flushing.................................................................................................... 0074-11 Cooling System Flushing.................................................................................................... 0074-12 Cooling System Flushing.................................................................................................... 0074-12 Cooling System Flushing.................................................................................................... 0074-13 Cooling System Pressure Testing...................................................................................... 0074-13 Cooling System Pressure Testing...................................................................................... 0074-14 Cooling System Pressure Testing...................................................................................... 0074-14 Cooling System Pressure Testing...................................................................................... 0074-15 Cooling System Pressure Testing...................................................................................... 0074-16 Cooling System Pressure Testing...................................................................................... 0074-16
RADIATOR DRAIN/FILL.............................................................................................................................. WP 0075 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Radiator Cap Access Door................................................................................................... 0075-1 Radiator Drain Cock............................................................................................................. 0075-2 Radiator Fill Point................................................................................................................. 0075-3 Overflow Tank...................................................................................................................... 0075-3 Radiator Cap Access Door................................................................................................... 0075-4
RADIATOR AND BRACKET REPLACEMENT............................................................................................ WP 0076 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Radiator and Bracket Removal............................................................................................ 0076-1 Radiator and Bracket Removal............................................................................................ 0076-2 Radiator and Bracket Removal............................................................................................ 0076-2 Radiator and Bracket Removal............................................................................................ 0076-3 Radiator and Bracket Removal............................................................................................ 0076-3 Radiator and Bracket Removal............................................................................................ 0076-4 Radiator and Bracket Removal............................................................................................ 0076-4 Radiator and Bracket Removal............................................................................................ 0076-5
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Page No. WP Sequence No. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Radiator and Bracket Installation......................................................................................... 0076-5 Radiator and Bracket Installation......................................................................................... 0076-6 Radiator and Bracket Installation......................................................................................... 0076-6 Radiator and Bracket Installation......................................................................................... 0076-7 Radiator and Bracket Installation......................................................................................... 0076-8 Radiator and Bracket Installation......................................................................................... 0076-8 Radiator and Bracket Installation......................................................................................... 0076-9 Radiator and Bracket Installation......................................................................................... 0076-9
LOWER RADIATOR HOSE REPLACEMENT............................................................................................. WP 0077 Figure 1. Figure 2. Lower Radiator Hose Removal............................................................................................ 0077-1 Lower Radiator Hose Installation......................................................................................... 0077-2
15-AMP CIRCUIT BREAKER REPLACEMENT.......................................................................................... WP 0078 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. 15-amp Circuit Breaker Removal......................................................................................... 0078-1 15-amp Circuit Breaker Removal......................................................................................... 0078-2 15-amp Circuit Breaker Removal......................................................................................... 0078-2 15-amp Circuit Breaker Removal......................................................................................... 0078-3 15-amp Circuit Breaker Installation...................................................................................... 0078-3 15-amp Circuit Breaker Installation...................................................................................... 0078-4 15-amp Circuit Breaker Installation...................................................................................... 0078-5 15-amp Circuit Breaker Installation...................................................................................... 0078-5
ALTERNATOR BELT ADJUSTMENT.......................................................................................................... WP 0079 Figure 1. Figure 2. Figure 3. Alternator Belt Adjustment.................................................................................................... 0079-1 Alternator Belt Adjustment.................................................................................................... 0079-2 Alternator Belt Adjustment.................................................................................................... 0079-2
ALTERNATOR BELT REPLACEMENT....................................................................................................... WP 0080 Figure 1. Figure 2. Alternator Belt Removed...................................................................................................... 0080-1 Alternator Belt Removed...................................................................................................... 0080-2
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Alternator Belt Removed...................................................................................................... 0080-2 Alternator Belt Removed...................................................................................................... 0080-3 Alternator Belt Removed...................................................................................................... 0080-3 Alternator Belt Installation.................................................................................................... 0080-4 Alternator Belt Installation.................................................................................................... 0080-4 Alternator Belt Installation.................................................................................................... 0080-5 Alternator Belt Installation.................................................................................................... 0080-5
ALTERNATOR AND BRACKET REPLACEMENT...................................................................................... WP 0081 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Alternator Removal............................................................................................................... 0081-1 Alternator Removal............................................................................................................... 0081-2 Alternator Removal............................................................................................................... 0081-2 Alternator Removal............................................................................................................... 0081-3 Alternator Installation............................................................................................................ 0081-3 Alternator Installation............................................................................................................ 0081-4 Alternator Installation............................................................................................................ 0081-4 Alternator Installation............................................................................................................ 0081-5
BATTERIES SERVICING AND TESTING................................................................................................... WP 0082 Figure 1. Figure 2. Figure 3. Figure 4. Battery Testing..................................................................................................................... 0082-2 Clean Battery Cables........................................................................................................... 0082-3 Clean Battery Cables........................................................................................................... 0082-3 Battery Service..................................................................................................................... 0082-4
BATTERY BOX REPLACEMENT................................................................................................................ WP 0083 Figure 1. Figure 2. Battery Box Removal............................................................................................................ 0083-2 Battery Box Installation......................................................................................................... 0083-3
BATTERY BOX WIRING REPLACEMENT................................................................................................. WP 0084 Figure 1. Figure 2. Battery Box Wiring Removal................................................................................................ 0084-2 Battery Box Wiring Removal................................................................................................ 0084-2
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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. Figure 16. Battery Box Wiring Removal................................................................................................ 0084-3 Battery Box Wiring Removal................................................................................................ 0084-3 Battery Box Wiring Removal................................................................................................ 0084-4 Battery Box Wiring Removal................................................................................................ 0084-4 Battery Box Wiring Removal................................................................................................ 0084-5 Battery Box Wiring Removal................................................................................................ 0084-6 Battery Box Wiring Installation............................................................................................. 0084-6 Battery Box Wiring Installation............................................................................................. 0084-7 Battery Box Wiring Installation............................................................................................. 0084-8 Battery Box Wiring Installation............................................................................................. 0084-8 Battery Box Wiring Installation............................................................................................. 0084-9 Battery Box Wiring Installation............................................................................................. 0084-9 Battery Box Wiring Installation........................................................................................... 0084-10 Battery Box Wiring Installation........................................................................................... 0084-10
BATTERY DISCONNECT/CONNECTION.................................................................................................. WP 0085 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Disconnect Batteries............................................................................................................ 0085-2 Disconnect Batteries............................................................................................................ 0085-2 Disconnect Batteries............................................................................................................ 0085-3 Connect Batteries................................................................................................................. 0085-4 Connect Batteries................................................................................................................. 0085-5 Connect Batteries................................................................................................................. 0085-5
BATTERY REPLACEMENT........................................................................................................................ WP 0086 Figure 1. Figure 2. Battery Removal................................................................................................................... 0086-2 Battery Installation................................................................................................................ 0086-2
MAIN CONTROL PANEL BATTERY VOLTAGE GAUGE REPLACEMENT............................................... WP 0087 Figure 1. Figure 2. Main Control Panel Battery Voltage Gauge Removal.......................................................... 0087-1 Main Control Panel Battery Voltage Gauge Removal.......................................................... 0087-2
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Main Control Panel Battery Voltage Gauge Removal.......................................................... 0087-2 Main Control Panel Battery Voltage Gauge Installation....................................................... 0087-3 Main Control Panel Battery Voltage Gauge Installation....................................................... 0087-4 Main Control Panel Battery Voltage Gauge Installation....................................................... 0087-4
MAIN CONTROL PANEL EMERGENCY STOP PUSHBUTTON REPLACEMENT.................................... WP 0088 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Main Control Panel Emergency Stop Pushbutton Removal................................................. 0088-1 Main Control Panel Emergency Stop Pushbutton Removal................................................. 0088-2 Main Control Panel Emergency Stop Pushbutton Removal................................................. 0088-2 Main Control Panel Emergency Stop Pushbutton Installation.............................................. 0088-3 Main Control Panel Emergency Stop Pushbutton Installation.............................................. 0088-3 Main Control Panel Emergency Stop Pushbutton Installation.............................................. 0088-4
CONTROL PANEL LIGHT SWITCH REPLACEMENT................................................................................ WP 0089 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Control Panel Light Switch Removal.................................................................................... 0089-1 Control Panel Light Switch Removal.................................................................................... 0089-2 Control Panel Light Switch Removal.................................................................................... 0089-2 Control Panel Light Switch Removal.................................................................................... 0089-3 Control Panel Light Switch Installation................................................................................. 0089-3 Control Panel Light Switch Installation................................................................................. 0089-4 Control Panel Light Switch Installation................................................................................. 0089-4 Control Panel Light Switch Installation................................................................................. 0089-5
MAIN CONTROL PANEL OIL PRESSURE GAUGE REPLACEMENT....................................................... WP 0090 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Main Control Panel Oil Pressure Gauge Removal............................................................... 0090-1 Main Control Panel Oil Pressure Gauge Removal............................................................... 0090-2 Main Control Panel Oil Pressure Gauge Removal............................................................... 0090-2 Main Control Panel Oil Pressure Gauge Installation............................................................ 0090-3 Main Control Panel Oil Pressure Gauge Installation............................................................ 0090-4 Main Control Panel Oil Pressure Gauge Installation............................................................ 0090-4
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Page No. WP Sequence No. MAIN CONTROL PANEL ENGINE START/STOP SWITCH REPLACEMENT........................................... WP 0091 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Main Control Panel Engine Start/Stop Switch Removal....................................................... 0091-1 Main Control Panel Engine Start/Stop Switch Removal....................................................... 0091-2 Main Control Panel Engine Start/Stop Switch Removal....................................................... 0091-2 Main Control Panel Engine Start/Stop Switch Removal....................................................... 0091-3 Main Control Panel Engine Start/Stop Switch Installation.................................................... 0091-3 Main Control Panel Engine Start/Stop Switch Installation.................................................... 0091-4 Main Control Panel Engine Start/Stop Switch Installation.................................................... 0091-4 Main Control Panel Engine Start/Stop Switch Installation.................................................... 0091-5
GOVERNOR CONTROL MODULE REPLACEMENT................................................................................. WP 0092 Figure 1. Figure 2. Figure 3. Figure 4. Governor Control Module Removal...................................................................................... 0092-1 Governor Control Module Removal...................................................................................... 0092-2 Governor Control Module Installation................................................................................... 0092-2 Governor Control Module Installation................................................................................... 0092-3
MAIN CONTROL PANEL ENGINE OFF/BATTERY DRAIN INDICATOR REPLACEMENT....................... WP 0093 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Main Control Panel Engine Off/Battery Drain Indicator Removal......................................... 0093-1 Main Control Panel Engine Off/Battery Drain Indicator Removal......................................... 0093-2 Main Control Panel Engine Off/Battery Drain Indicator Removal......................................... 0093-2 Main Control Panel Engine Off/Battery Drain Indicator Installation...................................... 0093-3 Main Control Panel Engine Off/Battery Drain Indicator Installation...................................... 0093-4 Main Control Panel Engine Off/Battery Drain Indicator Installation...................................... 0093-4
MAIN CONTROL PANEL ENGINE SPEED RESUME/IDLE SWITCH REPLACEMENT............................ WP 0094 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Main Control Panel Engine Speed Resume/Idle Switch Removal....................................... 0094-1 Main Control Panel Engine Speed Resume/Idle Switch Removal....................................... 0094-2 Main Control Panel Engine Speed Resume/Idle Switch Removal....................................... 0094-2 Main Control Panel Engine Speed Resume/Idle Switch Removal....................................... 0094-3 Main Control Panel Engine Speed Resume/Idle Switch Installation.................................... 0094-3
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Main Control Panel Engine Speed Resume/Idle Switch Installation.................................... 0094-4 Main Control Panel Engine Speed Resume/Idle Switch Installation.................................... 0094-5 Main Control Panel Engine Speed Resume/Idle Switch Installation.................................... 0094-5
MAIN CONTROL PANEL ENGINE SPEED RPM SWITCH REPLACEMENT............................................ WP 0095 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Main Control Panel Engine Speed RPM Switch Removal................................................... 0095-1 Main Control Panel Engine Speed RPM Switch Removal................................................... 0095-2 Main Control Panel Engine Speed RPM Switch Removal................................................... 0095-2 Main Control Panel Engine Speed RPM Switch Removal................................................... 0095-3 Main Control Panel Engine Speed RPM Switch Removal................................................... 0095-3 Main Control Panel Engine Speed RPM Switch Installation................................................ 0095-4 Main Control Panel Engine Speed RPM Switch Installation................................................ 0095-5 Main Control Panel Engine Speed RPM Switch Installation................................................ 0095-5
MAIN CONTROL PANEL ENGINE SPEED SET SWITCH REPLACEMENT............................................. WP 0096 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Main Control Panel Engine Speed RPM Switch Removal................................................... 0096-1 Main Control Panel Engine Speed Set Switch Removal...................................................... 0096-2 Main Control Panel Engine Speed Set Switch Removal...................................................... 0096-2 Main Control Panel Engine Speed Set Switch Removal...................................................... 0096-3 Main Control Panel Engine Speed Set Switch Installation................................................... 0096-3 Main Control Panel Engine Speed Set Switch Installation................................................... 0096-4 Main Control Panel Engine Speed Set Switch Installation................................................... 0096-4 Main Control Panel Engine Speed RPM Switch Installation................................................ 0096-5
MAIN CONTROL PANEL ENGINE TEMPERATURE GAUGE REPLACEMENT........................................ WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Main Control Panel Engine Temperature Gauge Removal.................................................. 0097-1 Main Control Panel Engine Temperature Gauge Removal.................................................. 0097-2 Main Control Panel Engine Temperature Gauge Removal.................................................. 0097-2 Main Control Panel Engine Temperature Gauge Installation............................................... 0097-3 Main Control Panel Engine Temperature Gauge Installation............................................... 0097-3
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Page No. WP Sequence No. Figure 6. Main Control Panel Engine Temperature Gauge Installation............................................... 0097-4
ENGINE WIRE HARNESS REPLACEMENT.............................................................................................. WP 0098 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. Engine Wire Harness Removal. .......................................................................................... 0098-1 Engine Wire Harness Removal. .......................................................................................... 0098-2 Engine Wire Harness Removal. .......................................................................................... 0098-2 Engine Wire Harness Removal. .......................................................................................... 0098-3 Engine Wire Harness Removal. .......................................................................................... 0098-3 Engine Wire Harness Removal. .......................................................................................... 0098-4 Engine Wire Harness Removal. .......................................................................................... 0098-4 Engine Wire Harness Removal. .......................................................................................... 0098-5 Engine Wire Harness Removal. .......................................................................................... 0098-5 Engine Wire Harness Removal. .......................................................................................... 0098-6 Engine Wire Harness Removal. .......................................................................................... 0098-7 Engine Wire Harness Installation......................................................................................... 0098-8 Engine Wire Harness Installation......................................................................................... 0098-9 Engine Wire Harness Installation......................................................................................... 0098-9 Engine Wire Harness Installation....................................................................................... 0098-10 Engine Wire Harness Installation....................................................................................... 0098-11 Engine Wire Harness Installation....................................................................................... 0098-11 Engine Wire Harness Installation....................................................................................... 0098-12 Engine Wire Harness Installation....................................................................................... 0098-12 Engine Wire Harness Installation....................................................................................... 0098-13 Engine Wire Harness Installation....................................................................................... 0098-13 Engine Wire Harness Installation....................................................................................... 0098-14
GENERAL WIRE HARNESS REPAIR/JUMPER WIRE FABRICATION..................................................... WP 0099 Figure 1. Figure 2. DT Style Connector Receptacle Repair............................................................................... 0099-2 DT Style Connector Plug Repair.......................................................................................... 0099-3
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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. Figure 16. Figure 17. Figure 18. Spade Connector Repair...................................................................................................... 0099-4 Open Connector Secondary Lock........................................................................................ 0099-4 Connector Breakdown.......................................................................................................... 0099-5 Wire With Seal...................................................................................................................... 0099-5 Wire Seal With Insulation..................................................................................................... 0099-6 Seating Terminal to Connector............................................................................................. 0099-7 Close Connector Secondary Lock........................................................................................ 0099-7 Splicing................................................................................................................................. 0099-8 Splicing With Added Wire..................................................................................................... 0099-8 Before Joint Is Soldered....................................................................................................... 0099-9 Joint With Solder................................................................................................................ 0099-10 Joint With Solder and Heatshrink....................................................................................... 0099-10 Splice Double Joint Soldering............................................................................................ 0099-11 Double Joint With Soldering............................................................................................... 0099-11 Double Joint With Solder and Heatshrink........................................................................... 0099-12 Jumper Wire Fabrication.................................................................................................... 0099-13
MAIN CONTROL BOX REPLACEMENT..................................................................................................... WP 0100 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Engine Wire Harness Removal............................................................................................ 0100-2 Alternator Wire Harness Removal........................................................................................ 0100-3 UPIK Wire Harness Removal............................................................................................... 0100-4 Work Light Wire Harness Removal...................................................................................... 0100-5 Sprinkler Wire Harness Removal......................................................................................... 0100-6 Water Level Wire Harness Removal.................................................................................... 0100-7 Battery Wire Harness Removal............................................................................................ 0100-7 Main Control Box Removal................................................................................................... 0100-8 Main Control Box Removal................................................................................................... 0100-9 Main Control Box Removal................................................................................................... 0100-9
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Page No. WP Sequence No. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Main Control Box Installation.............................................................................................. 0100-10 Main Control Box Installation.............................................................................................. 0100-11 Main Control Box Installation.............................................................................................. 0100-11 Battery Wire Harness Installation....................................................................................... 0100-12 Water Level Wire Harness Installation............................................................................... 0100-13 Sprinkler Wire Harness Installation.................................................................................... 0100-13 Work Light Wire Harness Installation................................................................................. 0100-14 UPIK Wire Harness Installation.......................................................................................... 0100-15 Alternator Wire Harness Installation................................................................................... 0100-16 Engine Wire Harness Installation....................................................................................... 0100-17
NATO SLAVE CONNECTOR REPLACEMENT.......................................................................................... WP 0101 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. NATO Slave Box Removal................................................................................................... 0101-1 NATO Slave Cable Removal................................................................................................ 0101-2 NATO Slave Connector Removal......................................................................................... 0101-2 NATO Slave Cable Removal................................................................................................ 0101-3 NATO Slave Cable Installation............................................................................................. 0101-3 NATO Slave Cable Installation............................................................................................. 0101-4 NATO Slave Connector Installation...................................................................................... 0101-5 NATO Slave Box Installation................................................................................................ 0101-5
MAIN CONTROL PANEL TACHOMETER/HOURMETER REPLACEMENT.............................................. WP 0102 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Main Control Panel Tachometer/Hourmeter Removal......................................................... 0102-1 Main Control Panel Tachometer/Hourmeter Removal......................................................... 0102-2 Main Control Panel Tachometer/Hourmeter Removal......................................................... 0102-2 Main Control Panel Tachometer/Hourmeter Removal......................................................... 0102-3 Main Control Panel Tachometer/Hourmeter Removal......................................................... 0102-3 Main Control Panel Tachometer/Hourmeter Installation...................................................... 0102-4 Main Control Panel Tachometer/Hourmeter Installation...................................................... 0102-5
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Page No. WP Sequence No. Figure 8. Figure 9. Figure 10. Main Control Panel Tachometer/Hourmeter Installation...................................................... 0102-5 Main Control Panel Tachometer/Hourmeter Installation...................................................... 0102-6 Main Control Panel Tachometer/Hourmeter Installation...................................................... 0102-7
MAIN CONTROL PANEL WATER LEVEL HIGH INDICATOR REPLACEMENT........................................ WP 0103 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Main Control Panel Water Level High Indicator Removal.................................................... 0103-1 Main Control Panel Water Level High Indicator Removal.................................................... 0103-2 Main Control Panel Water Level High Indicator Removal.................................................... 0103-2 Main Control Panel Water Level High Indicator Installation................................................. 0103-3 Main Control Panel Water Level High Indicator Installation................................................. 0103-3 Main Control Panel Water Level High Indicator Installation................................................. 0103-4
MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR REPLACEMENT........................................ WP 0104 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Main Control Panel Water Level Low Indicator Removal..................................................... 0104-1 Main Control Panel Water Level Low Indicator Removal..................................................... 0104-2 Main Control Panel Water Level Low Indicator Removal..................................................... 0104-2 Main Control Panel Water Level Low Indicator Installation.................................................. 0104-3 Main Control Panel Water Level Low Indicator Installation.................................................. 0104-3 Main Control Panel Water Level Low Indicator Installation.................................................. 0104-4
MAIN CONTROL PANEL WATER SPRINKLER SWITCH REPLACEMENT.............................................. WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Main Control Panel Water Sprinkler Switch Removal.......................................................... 0105-1 Main Control Panel Water Sprinkler Switch Removal.......................................................... 0105-2 Main Control Panel Water Sprinkler Switch Removal.......................................................... 0105-2 Main Control Panel Water Sprinkler Switch Removal.......................................................... 0105-3 Main Control Panel Water Sprinkler Switch Installation....................................................... 0105-4 Main Control Panel Water Sprinkler Switch Installation....................................................... 0105-4 Main Control Panel Water Sprinkler Switch Installation....................................................... 0105-5 Main Control Panel Water Sprinkler Switch Installation....................................................... 0105-6
WORK LIGHT REPLACEMENT.................................................................................................................. WP 0106
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Work Light Removal............................................................................................................. 0106-2 Work Light Removal............................................................................................................. 0106-3 Work Light Installation.......................................................................................................... 0106-4 Work Light Installation.......................................................................................................... 0106-4
WORK LIGHT WIRE HARNESS REPLACEMENT..................................................................................... WP 0107 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Work Light Wire Harness Removal...................................................................................... 0107-1 Work Light Wire Harness Removal...................................................................................... 0107-2 Work Light Wire Harness Removal...................................................................................... 0107-2 Work Light Wire Harness Removal...................................................................................... 0107-3 Work Light Wire Harness Removal...................................................................................... 0107-3 Work Light Wire Harness Removal...................................................................................... 0107-4 Work Light Wire Harness Installation................................................................................... 0107-4 Work Light Wire Harness Installation................................................................................... 0107-5 Work Light Wire Harness Installation................................................................................... 0107-5 Work Light Wire Harness Installation................................................................................... 0107-6 Work Light Wire Harness Installation................................................................................... 0107-6 Work Light Wire Harness Installation................................................................................... 0107-7
UPIK WIRE HARNESS REPLACEMENT.................................................................................................... WP 0108 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. UPIK Wire Harness Removal............................................................................................... 0108-1 UPIK Wire Harness Removal............................................................................................... 0108-2 UPIK Wire Harness Removal............................................................................................... 0108-2 UPIK Wire Harness Removal............................................................................................... 0108-4 UPIK Wire Harness Removal............................................................................................... 0108-5 UPIK Wire Harness Installation............................................................................................ 0108-6 UPIK Wire Harness Installation............................................................................................ 0108-7 UPIK Wire Harness Installation............................................................................................ 0108-8 UPIK Wire Harness Installation............................................................................................ 0108-9
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Page No. WP Sequence No. Figure 10. UPIK Wire Harness Installation.......................................................................................... 0108-10
AIR HOSE INTAKE REPLACEMENT.......................................................................................................... WP 0109 Figure 1. Figure 2. Air Hose Intake Removal...................................................................................................... 0109-1 Air Hose Intake Installation................................................................................................... 0109-2
CRANKSHAFT PULLEY REPLACEMENT.................................................................................................. WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Crankshaft Pulley Removal.................................................................................................. 0110-1 Crankshaft Pulley Removal.................................................................................................. 0110-2 Crankshaft Pulley Installation............................................................................................... 0110-2 Crankshaft Pulley Installation............................................................................................... 0110-3
ENGINE CRANKSHAFT FRONT SEAL REPLACEMENT.......................................................................... WP 0111 Figure 1. Figure 2. Engine Crankshaft Front Seal Removal............................................................................... 0111-1 Engine Crankshaft Front Seal Installation............................................................................ 0111-2
ENGINE FLYWHEEL REPLACEMENT....................................................................................................... WP 0112 Figure 1. Figure 2. Engine Flywheel Removal.................................................................................................... 0112-2 Engine Flywheel Installation................................................................................................. 0112-2
INJECTION PUMP GEAR COVER PLATE REPLACEMENT..................................................................... WP 0113 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Injection Pump Gear Cover Plate Removal.......................................................................... 0113-1 Injection Pump Gear Cover Plate Removal.......................................................................... 0113-2 Injection Pump Gear Cover Plate Removal.......................................................................... 0113-2 Injection Pump Gear Cover Plate......................................................................................... 0113-3 Injection Pump Gear Cover Plate Removal.......................................................................... 0113-3 Injection Pump Gear Cover Plate Installation....................................................................... 0113-4 Injection Pump Gear Cover Plate Installation....................................................................... 0113-5 Injection Pump Gear Cover Plate Installation....................................................................... 0113-5 Injection Pump Gear Cover Plate Installation....................................................................... 0113-6 Injection Pump Gear Cover Plate Installation....................................................................... 0113-6
ENGINE GEAR ASSEMBLY CASE RELIEF VALVE REPLACEMENT....................................................... WP 0114
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Page No. WP Sequence No. Figure 1. Figure 2. Engine Gear Assembly Case Relief Valve Removal............................................................ 0114-2 Engine Gear Assembly Case Relief Valve Installation......................................................... 0114-3
ENGINE COOLANT TEMPERATURE SENDING UNIT REPLACEMENT.................................................. WP 0115 Figure 1. Figure 2. Engine Coolant Temperature Sending Unit Removal.......................................................... 0115-1 Engine Coolant Temperature Sending Unit Installation....................................................... 0115-2
ENGINE EMERGENCY TEMPERATURE SENDING UNIT REPLACEMENT............................................ WP 0116 Figure 1. Figure 2. Engine Emergency Temperature Sending Unit Removal..................................................... 0116-1 Engine Emergency Temperature Sending Unit Installation.................................................. 0116-2
ENGINE INJECTION PUMP REPLACEMENT............................................................................................ WP 0117 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Injection Pump Removal...................................................................................................... 0117-2 Injection Pump Removal...................................................................................................... 0117-2 Injection Pump Removal...................................................................................................... 0117-3 Injection Pump Removal...................................................................................................... 0117-4 Injection Pump Removal...................................................................................................... 0117-4 Injection Pump Removal...................................................................................................... 0117-5 Injection Pump Removal...................................................................................................... 0117-6 Injection Pump Removal...................................................................................................... 0117-6 Injection Pump Removal...................................................................................................... 0117-7 Injection Pump Removal...................................................................................................... 0117-8
ENGINE NOZZLE TUBES REPLACEMENT............................................................................................... WP 0118 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Engine Nozzle Tubes Removal............................................................................................ 0118-2 Engine Nozzle Tubes Removal............................................................................................ 0118-2 Engine Nozzle Tubes Removal............................................................................................ 0118-3 Engine Nozzle Tubes Installation......................................................................................... 0118-4 Engine Nozzle Tubes Installation......................................................................................... 0118-5 Engine Nozzle Tubes Installation......................................................................................... 0118-5 Engine Nozzle Tubes Installation......................................................................................... 0118-6
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Page No. WP Sequence No. ENGINE INLET ASSEMBLY MANIFOLD REPLACEMENT........................................................................ WP 0119 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Inlet Assembly Manifold Removal........................................................................................ 0119-1 Inlet Assembly Manifold Removal........................................................................................ 0119-2 Inlet Assembly Manifold Removal........................................................................................ 0119-2 Inlet Assembly Manifold Installation..................................................................................... 0119-3 Inlet Assembly Manifold Installation..................................................................................... 0119-3 Inlet Assembly Manifold Installation..................................................................................... 0119-4
ENGINE NOZZLE ASSEMBLY HOLDER (INJECTION NOZZLE) REPLACEMENT.................................. WP 0120 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Injection Nozzle Assembly Removal.................................................................................... 0120-2 Injection Nozzle Assembly Removal.................................................................................... 0120-3 Injection Nozzle Assembly Removal.................................................................................... 0120-3 Injection Nozzle Assembly Removal.................................................................................... 0120-4 Injection Nozzle Assembly Installation................................................................................. 0120-4 Injection Nozzle Assembly Installation................................................................................. 0120-5 Injection Nozzle Assembly Installation................................................................................. 0120-5 Injection Nozzle Assembly Installation................................................................................. 0120-6
OIL PAN REPLACEMENT........................................................................................................................... WP 0121 Figure 1. Figure 2. Figure 3. Figure 4. Oil Pan Removal.................................................................................................................. 0121-1 Oil Pan Sealant Application.................................................................................................. 0121-3 Oil Pan Installation............................................................................................................... 0121-3 Oil Pan Installation............................................................................................................... 0121-4
ENGINE OIL PRESSURE TESTING........................................................................................................... WP 0122 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Engine Oil Pressure Testing................................................................................................. 0122-2 Engine Oil Pressure Testing................................................................................................. 0122-2 Engine Oil Pressure Testing................................................................................................. 0122-3 Engine Oil Pressure Testing................................................................................................. 0122-4 Engine Oil Pressure Testing................................................................................................. 0122-4
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Page No. WP Sequence No. Figure 6. Engine Oil Pressure Testing................................................................................................. 0122-5
ENGINE OIL FILTER REPLACEMENT....................................................................................................... WP 0123 Figure 1. Figure 2. Figure 3. Engine Oil Filter Removal..................................................................................................... 0123-2 Engine Oil Filter Removal..................................................................................................... 0123-2 Engine Oil Filter Installation.................................................................................................. 0123-3
ENGINE OIL SERVICE................................................................................................................................ WP 0124 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Oil Service................................................................................................................ 0124-2 Engine Oil Service................................................................................................................ 0124-2 Engine Oil Service................................................................................................................ 0124-3 Engine Oil Service................................................................................................................ 0124-3 Engine Oil Service................................................................................................................ 0124-4 Engine Oil Service................................................................................................................ 0124-5
ENGINE OIL COOLER AND HOSE REPLACEMENT................................................................................ WP 0125 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Engine Oil Cooler and Hose Removal.................................................................................. 0125-1 Engine Oil Cooler and Hose Removal.................................................................................. 0125-2 Engine Oil Cooler and Hose Removal.................................................................................. 0125-2 Engine Oil Cooler and Hose Removal.................................................................................. 0125-3 Engine Oil Cooler and Hose Installation............................................................................... 0125-3 Engine Oil Cooler and Hose Installation............................................................................... 0125-4 Engine Oil Cooler and Hose Installation............................................................................... 0125-4 Engine Oil Cooler and Hose Installation............................................................................... 0125-5
ENGINE TIMING SENSOR AND COVER REPLACEMENT....................................................................... WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Engine Timing Sensor Removal........................................................................................... 0126-1 Engine Timing Sensor Removal........................................................................................... 0126-2 Engine Timing Sensor Installation........................................................................................ 0126-2 Engine Timing Sensor Installation........................................................................................ 0126-3
ENGINE/PUMP MODULE REPLACEMENT............................................................................................... WP 0127
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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. Engine/Pump Module Removal............................................................................................ 0127-2 Engine/Pump Module Removal............................................................................................ 0127-2 Engine/Pump Module Removal............................................................................................ 0127-3 Engine/Pump Module Removal............................................................................................ 0127-3 Engine/Pump Module Removal............................................................................................ 0127-4 Engine/Pump Module Installation......................................................................................... 0127-5 Engine/Pump Module Installation......................................................................................... 0127-6 Engine/Pump Module Installation......................................................................................... 0127-6 Engine/Pump Module Installation......................................................................................... 0127-7 Engine/Pump Module Installation......................................................................................... 0127-8
ENGINE MODULE REPLACEMENT........................................................................................................... WP 0128 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. Engine Module Removal...................................................................................................... 0128-2 Engine Module Removal...................................................................................................... 0128-3 Engine Module Removal...................................................................................................... 0128-4 Engine Module Removal...................................................................................................... 0128-4 Engine Module Removal...................................................................................................... 0128-5 Engine Module Removal...................................................................................................... 0128-5 Engine Module Removal...................................................................................................... 0128-6 Engine Module Removal...................................................................................................... 0128-6 Engine Module Removal...................................................................................................... 0128-7 Engine Module Removal...................................................................................................... 0128-8 Engine Module Removal...................................................................................................... 0128-8 Engine Module Removal...................................................................................................... 0128-9 Engine Module Removal.................................................................................................... 0128-10 Engine Module Removal.................................................................................................... 0128-10 Engine Module Removal.................................................................................................... 0128-11 Engine Module Removal.................................................................................................... 0128-12
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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. Engine Module Removal.................................................................................................... 0128-12 Engine Module Installation................................................................................................. 0128-13 Engine Module Installation................................................................................................. 0128-13 Engine Module Installation................................................................................................. 0128-14 Engine Module Installation................................................................................................. 0128-15 Engine Module Installation................................................................................................. 0128-15 Engine Module Installation................................................................................................. 0128-16 Engine Module Installation................................................................................................. 0128-16 Engine Module Installation................................................................................................. 0128-17 Engine Module Installation................................................................................................. 0128-17 Engine Module Installation................................................................................................. 0128-18 Engine Module Installation................................................................................................. 0128-19 Engine Module Installation................................................................................................. 0128-20 Engine Module Installation................................................................................................. 0128-20 Engine Module Installation................................................................................................. 0128-21 Engine Module Installation................................................................................................. 0128-22 Engine Module Installation................................................................................................. 0128-22 Engine Module Installation................................................................................................. 0128-23 Engine Module Installation................................................................................................. 0128-24
EXHAUST MANIFOLD REPLACEMENT.................................................................................................... WP 0129 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0129-1 Exhaust Manifold Installation................................................................................................ 0129-2
FRONT ENGINE MOUNT BRACKET REPLACEMENT.............................................................................. WP 0130 Figure 1. Figure 2. Figure 3. Figure 4. Front Engine Mount Bracket Removal................................................................................. 0130-1 Front Engine Mount Bracket Removal................................................................................. 0130-2 Front Engine Mount Bracket Removal................................................................................. 0130-2 Front Engine Mount Bracket Removal................................................................................. 0130-3
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Front Engine Mount Bracket Removal................................................................................. 0130-3 Front Engine Mount Bracket Installation.............................................................................. 0130-4 Front Engine Mount Bracket Installation.............................................................................. 0130-4 Front Engine Mount Bracket Installation.............................................................................. 0130-5 Front Engine Mount Bracket Installation.............................................................................. 0130-5 Front Engine Mount Bracket Installation.............................................................................. 0130-6
GLOW PLUG RELAY REPLACEMENT...................................................................................................... WP 0131 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Glow Plug Relay Removal.................................................................................................... 0131-1 Glow Plug Relay Removal.................................................................................................... 0131-2 Glow Plug Relay Removal.................................................................................................... 0131-3 Glow Plug Relay Installation................................................................................................. 0131-3 Glow Plug Relay Installation................................................................................................. 0131-4 Glow Plug Relay Installation................................................................................................. 0131-5
GLOW PLUG REPLACEMENT................................................................................................................... WP 0132 Figure 1. Figure 2. Glow Plug Removal. ............................................................................................................ 0132-1 Glow Plug Installation. ......................................................................................................... 0132-2
GOVERNOR ACTUATOR REPLACEMENT............................................................................................... WP 0133 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Governor Actuator Removal................................................................................................. 0133-1 Governor Actuator Removal................................................................................................. 0133-2 Governor Actuator Installation.............................................................................................. 0133-2 Governor Actuator Installation.............................................................................................. 0133-3 Governor Actuator Installation.............................................................................................. 0133-3
OIL SAMPLING VALVE REPLACEMENT................................................................................................... WP 0134 Figure 1. Figure 2. Oil Sampling Valve Removal................................................................................................ 0134-1 Oil Sampling Valve Installation............................................................................................. 0134-2
REAR ENGINE MOUNT BRACKET AND BUSHING REPLACEMENT...................................................... WP 0135 Figure 1. Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-2
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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. Figure 13. Figure 14. Figure 15. Figure 16. Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-2 Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-3 Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-3 Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-4 Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-4 Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-5 Rear Engine Mount Bracket and Bushing Removal............................................................. 0135-5 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-6 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-6 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-7 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-7 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-8 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-8 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-9 Rear Engine Mounting Bracket and Bushing Installation..................................................... 0135-9
REAR MAIN SEAL REPLACEMENT........................................................................................................... WP 0136 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Rear Main Seal Removal..................................................................................................... 0136-2 Rear Main Seal Removal..................................................................................................... 0136-2 Rear Main Seal Removal..................................................................................................... 0136-3 Rear Main Seal Removal..................................................................................................... 0136-3 Rear Main Seal Removal..................................................................................................... 0136-4 Rear Main Seal Installation.................................................................................................. 0136-4 Rear Main Seal Installation.................................................................................................. 0136-5 Rear Main Seal Installation.................................................................................................. 0136-6 Rear Main Seal Installation.................................................................................................. 0136-6 Rear Main Seal Installation.................................................................................................. 0136-7 Rear Main Seal Installation.................................................................................................. 0136-7
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Page No. WP Sequence No. OIL PRESSURE SENDING UNIT AND PRESSURE SWITCH REPLACEMENT....................................... WP 0137 Figure 1. Figure 2. Sending Unit Removal.......................................................................................................... 0137-2 Sending Unit Installation....................................................................................................... 0137-4
STARTER RELAY REPLACEMENT........................................................................................................... WP 0138 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Starter Relay Removal. ....................................................................................................... 0138-1 Starter Relay Removal. ....................................................................................................... 0138-2 Starter Relay Removal. ....................................................................................................... 0138-2 Starter Relay Installation. .................................................................................................... 0138-3 Starter Relay Installation. .................................................................................................... 0138-3 Starter Relay Installation. .................................................................................................... 0138-4
STARTER REPLACEMENT........................................................................................................................ WP 0139 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Starter Removal................................................................................................................... 0139-1 Starter Removal................................................................................................................... 0139-2 Starter Removal................................................................................................................... 0139-2 Starter Installation................................................................................................................ 0139-3 Starter Installation................................................................................................................ 0139-3 Starter Installation................................................................................................................ 0139-4
THERMOSTAT AND HOUSING REPLACEMENT...................................................................................... WP 0140 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Thermostat and Housing Removal....................................................................................... 0140-1 Thermostat and Housing Removal....................................................................................... 0140-2 Thermostat and Housing Removal....................................................................................... 0140-2 Thermostat and Housing Removal....................................................................................... 0140-3 Thermostat and Housing Removal....................................................................................... 0140-3 Thermostat and Housing Removal....................................................................................... 0140-4 Thermostat and Housing Removal....................................................................................... 0140-4 Thermostat and Housing Installation.................................................................................... 0140-5 Thermostat and Housing Installation.................................................................................... 0140-6
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Page No. WP Sequence No. Figure 10. Figure 11. Figure 12. Thermostat and Housing Installation.................................................................................... 0140-6 Thermostat and Housing Installation.................................................................................... 0140-7 Thermostat and Housing Installation.................................................................................... 0140-7
VALVE COVER AND GASKET REPLACEMENT....................................................................................... WP 0141 Figure 1. Figure 2. Figure 3. Figure 4. Valve Cover And Gasket Removal....................................................................................... 0141-1 Valve Cover And Gasket Removal....................................................................................... 0141-2 Valve Cover And Gasket Installation.................................................................................... 0141-3 Valve Cover And Gasket Installation.................................................................................... 0141-3
ENGINE COMPARTMENT COVER REPLACEMENT................................................................................ WP 0142 Figure 1. Figure 2. Engine Compartment Cover Removal.................................................................................. 0142-1 Engine Compartment Cover Installation............................................................................... 0142-2
REAR ENCLOSURE PANEL AND SIDE RAIL REPLACEMENT................................................................ WP 0143 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. Rear Enclosure Panel And Side Panel Removal................................................................. 0143-1 Rear Enclosure Panel And Side Panel Removal................................................................. 0143-2 Rear Enclosure Panel And Side Panel Removal................................................................. 0143-2 Rear Enclosure Panel And Side Panel Removal................................................................. 0143-3 Rear Enclosure Panel And Side Panel Removal................................................................. 0143-3 Rear Enclosure Panel And Side Panel Removal................................................................. 0143-4 Rear Enclosure Panel And Side Panel Removal................................................................. 0143-4 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-5 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-5 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-6 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-6 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-7 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-7 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-8 Rear Enclosure Panel And Side Panel Installation.............................................................. 0143-8
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Page No. WP Sequence No. FRONT ENCLOSURE PANEL REPLACEMENT........................................................................................ WP 0144 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Enclosure Panel Removal........................................................................................... 0144-1 Front Enclosure Panel Removal........................................................................................... 0144-2 Front Enclosure Panel Removal........................................................................................... 0144-2 Front Enclosure Panel Installation........................................................................................ 0144-3 Front Enclosure Panel Installation........................................................................................ 0144-3 Front Enclosure Panel Installation........................................................................................ 0144-4
ENGINE CYLINDER HEAD GASKET REPLACEMENT............................................................................. WP 0145 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. Cylinder Head Gasket Removal........................................................................................... 0145-2 Cylinder Head Gasket Removal........................................................................................... 0145-3 Cylinder Head Gasket Removal........................................................................................... 0145-3 Cylinder Head Gasket Removal........................................................................................... 0145-4 Cylinder Head Gasket Removal........................................................................................... 0145-4 Cylinder Head Gasket Removal........................................................................................... 0145-5 Cylinder Head Gasket Removal........................................................................................... 0145-5 Cylinder Head Gasket Removal........................................................................................... 0145-6 Cylinder Head Gasket Removal........................................................................................... 0145-6 Cylinder Head Gasket Removal........................................................................................... 0145-7 Cylinder Head Gasket Removal........................................................................................... 0145-8 Cylinder Head Gasket Inspection......................................................................................... 0145-8 Cylinder Head Gasket Inspection......................................................................................... 0145-9 Cylinder Head Gasket Installation........................................................................................ 0145-9 Cylinder Head Gasket Installation...................................................................................... 0145-10 Cylinder Head Gasket Installation...................................................................................... 0145-11 Cylinder Head Gasket Installation...................................................................................... 0145-12 Cylinder Head Gasket Installation...................................................................................... 0145-12 Cylinder Head Gasket Installation...................................................................................... 0145-13
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Page No. WP Sequence No. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Cylinder Head Gasket Installation...................................................................................... 0145-13 Cylinder Head Gasket Installation...................................................................................... 0145-14 Cylinder Head Gasket Installation...................................................................................... 0145-14 Cylinder Head Gasket Installation...................................................................................... 0145-15 Cylinder Head Gasket Installation...................................................................................... 0145-15
BELT GUARD REPLACEMENT.................................................................................................................. WP 0146 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Belt Guard Removal............................................................................................................. 0146-1 Belt Guard Removal............................................................................................................. 0146-2 Belt Guard Removal............................................................................................................. 0146-2 Belt Guard Installation.......................................................................................................... 0146-3 Belt Guard Installation.......................................................................................................... 0146-3 Belt Guard Installation.......................................................................................................... 0146-4
FLEX ELEMENT REPLACEMENT.............................................................................................................. WP 0147 Figure 1. Figure 2. Flex Element Removal......................................................................................................... 0147-1 Flex Element Installation...................................................................................................... 0147-2
ENGINE OIL PICKUP TUBE REPLACEMENT........................................................................................... WP 0148 Figure 1. Figure 2. Figure 3. Figure 4. Engine Oil Pickup Tube Removal......................................................................................... 0148-1 Engine Oil Pickup Tube Removal......................................................................................... 0148-2 Engine Oil Pickup Tube Installation...................................................................................... 0148-2 Engine Oil Pickup Tube Installation...................................................................................... 0148-3
EXHAUST FLEX PIPE REPLACEMENT..................................................................................................... WP 0149 Figure 1. Figure 2. Exhaust Flex Pipe Removal................................................................................................. 0149-1 Exhaust Flex Pipe Installation.............................................................................................. 0149-2
MUFFLER AND BAND CLAMP REPLACEMENT....................................................................................... WP 0150 Figure 1. Figure 2. Figure 3. Muffler and Band Clamp Removal....................................................................................... 0150-1 Muffler and Band Clamp Removal....................................................................................... 0150-2 Muffler and Band Clamp Removal....................................................................................... 0150-2
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Muffler and Band Clamp Installation.................................................................................... 0150-3 Muffler and Band Clamp Installation.................................................................................... 0150-3 Muffler and Band Clamp Installation.................................................................................... 0150-4
HOSE HOOK WELDMENT REPLACEMENT.............................................................................................. WP 0151 Figure 1. Figure 2. Hose Hook Weldment Removal........................................................................................... 0151-1 Hose Hook Weldment Installation........................................................................................ 0151-2
SPRING MARKER REPLACEMENT........................................................................................................... WP 0152 Figure 1. Figure 2. Spring Marker Removal........................................................................................................ 0152-1 Spring Marker Installation..................................................................................................... 0152-2
ROLLER REPAIR........................................................................................................................................ WP 0153 Figure 1. Figure 2. Roller Disassembly............................................................................................................... 0153-1 Roller Assembly................................................................................................................... 0153-3
STOWAGE BOX REPAIR............................................................................................................................ WP 0154 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Stowage Box Removal......................................................................................................... 0154-1 Stowage Box Disassembly................................................................................................... 0154-2 Stowage Box Disassembly................................................................................................... 0154-2 Stowage Box Disassembly................................................................................................... 0154-3 Stowage Box Assembly........................................................................................................ 0154-4 Stowage Box Assembly........................................................................................................ 0154-4 Stowage Box Assembly........................................................................................................ 0154-5 Stowage Box Installation...................................................................................................... 0154-6
STORAGE BOX REPLACEMENT............................................................................................................... WP 0155 Figure 1. Figure 2. Storage Box Replacement................................................................................................... 0155-1 Storage Box Installation....................................................................................................... 0155-2
WIRE TROUGH CHANNEL REPLACEMENT............................................................................................. WP 0156 Figure 1. Figure 2. Wire Trough Channel Removal............................................................................................ 0156-1 Wire Trough Channel Installation......................................................................................... 0156-2
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Page No. WP Sequence No. DATA PLATE REPLACEMENT................................................................................................................... WP 0157 Figure 1. Figure 2. Data Plate Removal............................................................................................................. 0157-1 Data Plate Installation.......................................................................................................... 0157-2
3" VALVE REPLACEMENT......................................................................................................................... WP 0158 Figure 1. Figure 2. 3" Valve Removal................................................................................................................. 0158-1 3" Valve Installation.............................................................................................................. 0158-2
5" VALVE REPLACEMENT......................................................................................................................... WP 0159 Figure 1. Figure 2. 5" Valve Removal................................................................................................................. 0159-1 5" Valve Installation.............................................................................................................. 0159-2
GRAVITY BAR WELDMENT REPLACEMENT........................................................................................... WP 0160 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Gravity Bar Weldment Removal........................................................................................... 0160-1 Gravity Bar Weldment Removal........................................................................................... 0160-2 Gravity Bar Weldment Removal........................................................................................... 0160-2 Gravity Bar Weldment Installation........................................................................................ 0160-3 Gravity Bar Weldment Installation........................................................................................ 0160-3 Gravity Bar Weldment Installation........................................................................................ 0160-4
HOSE REEL VALVE REPLACEMENT........................................................................................................ WP 0161 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Hose Reel Valve Removal................................................................................................... 0161-1 Hose Reel Valve Removal................................................................................................... 0161-2 Hose Reel Valve Removal................................................................................................... 0161-2 Hose Reel Valve Removal................................................................................................... 0161-3 Hose Reel Valve Installation................................................................................................ 0161-4 Hose Reel Valve Installation................................................................................................ 0161-4 Hose Reel Valve Installation................................................................................................ 0161-5
REAR PLATFORM REPLACEMENT.......................................................................................................... WP 0162 Figure 1. Figure 2. Rear Platform Removal........................................................................................................ 0162-1 Rear Platform Removal........................................................................................................ 0162-2
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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. Rear Platform Removal........................................................................................................ 0162-2 Rear Platform Removal........................................................................................................ 0162-3 Rear Platform Removal........................................................................................................ 0162-4 Rear Platform Installation..................................................................................................... 0162-5 Rear Platform Installation..................................................................................................... 0162-5 Rear Platform Installation..................................................................................................... 0162-6 Rear Platform Installation..................................................................................................... 0162-6 Rear Platform Installation..................................................................................................... 0162-7
MANUAL WATER TURRET AND PIPING REPAIR.................................................................................... 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. Figure 17. Figure 18. Manual Water Turret Replacement...................................................................................... 0163-2 Manual Water Turret Replacement...................................................................................... 0163-2 Manual Water Turret Replacement...................................................................................... 0163-3 Manual Water Turret Replacement...................................................................................... 0163-3 Manual Water Turret Replacement...................................................................................... 0163-4 Water Turret Disassembly. .................................................................................................. 0163-5 Water Turret Disassembly.................................................................................................... 0163-7 Water Turret Disassembly.................................................................................................... 0163-7 Water Turret Assembly....................................................................................................... 0163-10 Water Turret Assembly....................................................................................................... 0163-11 Water Turret Assembly....................................................................................................... 0163-12 Water Turret Assembly....................................................................................................... 0163-13 Manual Water Turret Installation........................................................................................ 0163-14 Manual Water Turret Installation........................................................................................ 0163-14 Manual Water Turret Installation........................................................................................ 0163-15 Manual Water Turret Installation........................................................................................ 0163-15 Manual Water Turret Installation........................................................................................ 0163-16 Manual Water Turret Installation........................................................................................ 0163-16
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Page No. WP Sequence No. AIR VALVE COVER PLATE REPLACEMENT............................................................................................ WP 0164 Figure 1. Figure 2. Air Valve Cover Plate Removal............................................................................................ 0164-1 Air Valve Cover Plate Installation......................................................................................... 0164-2
REAR PLATFORM SCREEN REPLACEMENT.......................................................................................... WP 0165 Figure 1. Figure 2. Rear Platform Screen Removal............................................................................................ 0165-1 Rear Platform Screen Installation......................................................................................... 0165-2
FLUSHER NOZZLE AND AIR ACTUATOR REPLACEMENT..................................................................... WP 0166 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Flusher Nozzle Removal...................................................................................................... 0166-1 Flusher Nozzle Installation................................................................................................... 0166-2 ............................................................................................................................................. 0166-2 Flusher Nozzle and Air Actuator Removal........................................................................... 0166-3 ............................................................................................................................................. 0166-3 Flusher Nozzle Removal...................................................................................................... 0166-4 Flusher Nozzle and Air Actuator Installation........................................................................ 0166-5 ............................................................................................................................................. 0166-5 Flusher Nozzle Installation................................................................................................... 0166-6 Flusher Nozzle Installation................................................................................................... 0166-6 ............................................................................................................................................. 0166-7
FIRE EXTINGUISHER BRACKET REPLACEMENT................................................................................... WP 0167 Figure 1. Figure 2. Figure 3. Figure 4. Fire Extinguisher Bracket Removal...................................................................................... 0167-1 Mounting Bracket Removal.................................................................................................. 0167-2 Mounting Bracket Installation............................................................................................... 0167-2 Fire Extinguisher.................................................................................................................. 0167-3
SOLENOID VALVE REPLACEMENT.......................................................................................................... WP 0168 Figure 1. Figure 2. Figure 3. Solenoid Valve Removal...................................................................................................... 0168-1 Solenoid Valve Removal...................................................................................................... 0168-2 Solenoid Valve Removal...................................................................................................... 0168-2
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Solenoid Valve Removal...................................................................................................... 0168-3 Solenoid Valve Removal...................................................................................................... 0168-3 Solenoid Valve Installation................................................................................................... 0168-4 Solenoid Valve Installation................................................................................................... 0168-5 Solenoid Valve Installation................................................................................................... 0168-5 Solenoid Valve Installation................................................................................................... 0168-6 Solenoid Valve Installation................................................................................................... 0168-7
AIR LINE LUBRICATOR REPLACEMENT.................................................................................................. WP 0169 Figure 1. Figure 2. Figure 3. Figure 4. Air Line Lubricator Removal................................................................................................. 0169-1 Air Line Lubricator Removal................................................................................................. 0169-2 Air Line Lubricator Installation.............................................................................................. 0169-3 Air Line Lubricator Installation.............................................................................................. 0169-4
AIR CLEANER ASSEMBLY REPAIR.......................................................................................................... WP 0170 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Air Cleaner Assembly Removal............................................................................................ 0170-1 Air Cleaner Assembly Removal............................................................................................ 0170-2 Air Cleaner Assembly Removal............................................................................................ 0170-2 Air Cleaner Disassembly...................................................................................................... 0170-3 Air Cleaner Disassembly...................................................................................................... 0170-3 Air Cleaner Assembly........................................................................................................... 0170-4 Air Cleaner Assembly........................................................................................................... 0170-4 Air Cleaner Assembly Installation......................................................................................... 0170-5 Air Cleaner Assembly Installation......................................................................................... 0170-5 Air Cleaner Assembly Installation......................................................................................... 0170-6
AIR HOSE REPLACEMENT........................................................................................................................ WP 0171 Figure 1. Figure 2. Figure 3. Air Hose Removal................................................................................................................ 0171-1 Air Hose Removal................................................................................................................ 0171-2 Air Hose Removal................................................................................................................ 0171-2
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Air Hose Removal................................................................................................................ 0171-3 Air Hose Installation............................................................................................................. 0171-4 Air Hose Installation............................................................................................................. 0171-4 Air Hose Installation............................................................................................................. 0171-5 Air Hose Installation............................................................................................................. 0171-6
FUEL LINE REPLACEMENT....................................................................................................................... WP 0172 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Fuel Line Removal............................................................................................................... 0172-2 Fuel Line Removal............................................................................................................... 0172-3 Fuel Line Removal............................................................................................................... 0172-4 Fuel Line Removal............................................................................................................... 0172-4 Fuel Line Installation............................................................................................................ 0172-5 Fuel Line Installation............................................................................................................ 0172-5 Fuel Line Installation............................................................................................................ 0172-6 Fuel Line Installation............................................................................................................ 0172-7
FUEL PUMP ASSEMBLY REPLACEMENT................................................................................................ WP 0173 Figure 1. Figure 2. Figure 3. Figure 4. Fuel Pump Assembly Removal............................................................................................ 0173-2 Fuel Pump Assembly Removal............................................................................................ 0173-2 Fuel Pump Assembly Installation......................................................................................... 0173-3 Fuel Pump Assembly Installation......................................................................................... 0173-3
FUEL TANK DRAIN/FILL............................................................................................................................. WP 0174 Figure 1. Figure 2. Figure 3. Drain Fuel Tank.................................................................................................................... 0174-1 Drain Fuel Tank.................................................................................................................... 0174-2 Fill Fuel Tank........................................................................................................................ 0174-2
FUEL TANK REPAIR................................................................................................................................... WP 0175 Figure 1. Figure 2. Figure 3. Fuel Tank Removal.............................................................................................................. 0175-1 Fuel Tank Removal.............................................................................................................. 0175-2 Fuel Tank Disassembly........................................................................................................ 0175-3
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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Fuel Tank Disassembly........................................................................................................ 0175-3 Fuel Tank Disassembly........................................................................................................ 0175-4 Fuel Tank Assembly............................................................................................................. 0175-5 Fuel Tank Assembly............................................................................................................. 0175-6 Fuel Tank Assembly............................................................................................................. 0175-6 Fuel Tank Installation........................................................................................................... 0175-7 Fuel Tank Installation........................................................................................................... 0175-8
FUEL/WATER SEPARATOR AND FILTER HEAD REPLACEMENT.......................................................... WP 0176 Figure 1. Figure 2. Fuel/Water Separator and Filter Head Removal.................................................................. 0176-2 Fuel/water Separator and Filter Head Installation................................................................ 0176-3
FUEL/WATER SEPARATOR FILTER REPLACEMENT............................................................................. WP 0177 Figure 1. Figure 2. Fuel/Water Separator Removal............................................................................................ 0177-2 Fuel/Water Separator Installation......................................................................................... 0177-3
WATER PUMP INLET GAUGE AND HOSE REPLACEMENT.................................................................... WP 0178 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Water Pump Inlet Gauge and Hose Removal...................................................................... 0178-1 Water Pump Inlet Gauge and Hose Removal...................................................................... 0178-2 Water Pump Inlet Gauge and Hose Removal...................................................................... 0178-2 Water Pump Inlet Gauge and Hose Removal...................................................................... 0178-3 Water Pump Inlet Gauge and Hose Installation................................................................... 0178-3 Water Pump Inlet Gauge and Hose Installation................................................................... 0178-4 Water Pump Inlet Gauge and Hose Installation................................................................... 0178-5 Water Pump Inlet Gauge and Hose Installation................................................................... 0178-5
WATER PUMP OUTLET GAUGE AND HOSE REPLACEMENT................................................................ WP 0179 Figure 1. Figure 2. Figure 3. Figure 4. Water Pump Outlet Gauge and Hose Removal................................................................... 0179-1 Water Pump Outlet Gauge and Hose Removal................................................................... 0179-2 Water Pump Outlet Gauge and Hose Removal................................................................... 0179-2 Water Pump Outlet Gauge and Hose Removal................................................................... 0179-3
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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Water Pump Outlet Gauge and Hose Installation................................................................ 0179-4 Water Pump Outlet Gauge and Hose Installation................................................................ 0179-5 Water Pump Outlet Gauge and Hose Installation................................................................ 0179-5 Water Pump Outlet Gauge and Hose Installation................................................................ 0179-6
VALVE HANDLE REPLACEMENT.............................................................................................................. WP 0180 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Valve Handle Removal......................................................................................................... 0180-1 Valve Handle Removal......................................................................................................... 0180-2 Valve Handle Removal......................................................................................................... 0180-2 Valve Handle Installation...................................................................................................... 0180-3 Valve Handle Installation...................................................................................................... 0180-3 Valve Handle Installation...................................................................................................... 0180-4
STRAINER ELEMENT REPLACEMENT..................................................................................................... WP 0181 Figure 1. Figure 2. Strainer Element Removal................................................................................................... 0181-1 Strainer Element Installation................................................................................................ 0181-2
STRAINER HOUSING REPLACEMENT..................................................................................................... WP 0182 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Strainer Housing Removal................................................................................................... 0182-1 Strainer Housing Removal................................................................................................... 0182-2 Strainer Housing Removal................................................................................................... 0182-2 Strainer Housing Removal................................................................................................... 0182-3 Strainer Housing Installation................................................................................................ 0182-3 Strainer Housing Installation................................................................................................ 0182-4 Strainer Housing Installation................................................................................................ 0182-4 Strainer Housing Installation................................................................................................ 0182-5 Strainer Housing Installation................................................................................................ 0182-5 Strainer Housing Installation................................................................................................ 0182-6
INLET VALVE AND HOSE REPLACEMENT.............................................................................................. WP 0183 Figure 1. Inlet Valve and Hose Removal............................................................................................. 0183-1
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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Inlet Valve and Hose Removal............................................................................................. 0183-2 Inlet Valve and Hose Removal............................................................................................. 0183-2 Inlet Valve and Hose Installation.......................................................................................... 0183-3 Inlet Valve and Hose Installation.......................................................................................... 0183-3 Inlet Valve and Hose Installation.......................................................................................... 0183-4
DIAL POINTER REPLACEMENT................................................................................................................ WP 0184 Figure 1. Figure 2. Dial Pointer Removal............................................................................................................ 0184-1 Dial Pointer Installation......................................................................................................... 0184-2
FOLDING HAND RAIL ASSEMBLY REPLACEMENT................................................................................ WP 0185 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. Folding Hand Rail Assembly Removal................................................................................. 0185-2 Folding Hand Rail Assembly Removal................................................................................. 0185-2 Folding Hand Rail Disassembly........................................................................................... 0185-3 Folding Hand Rail Disassembly........................................................................................... 0185-3 Folding Hand Rail Disassembly........................................................................................... 0185-4 Folding Hand Rail Disassembly........................................................................................... 0185-4 Folding Hand Rail Disassembly........................................................................................... 0185-5 Folding Hand Rail Assembly................................................................................................ 0185-5 Folding Hand Rail Assembly................................................................................................ 0185-6 Folding Hand Rail Assembly................................................................................................ 0185-6 Folding Hand Rail Assembly................................................................................................ 0185-7 Folding Hand Rail Assembly................................................................................................ 0185-7 Folding Hand Rail Installation............................................................................................... 0185-8 Folding Hand Rail Installation............................................................................................... 0185-9
DIAL POINTER SWITCH REPLACEMENT................................................................................................. WP 0186 Figure 1. Figure 2. Dial Pointer Switch Removal................................................................................................ 0186-1 Dial Pointer Switch Installation............................................................................................. 0186-2
HIGH TANK LEVEL SWITCH REPLACEMENT.......................................................................................... WP 0187
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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. High Tank Level Switch Removal......................................................................................... 0187-1 High Tank Level Switch Removal......................................................................................... 0187-2 High Tank Level Switch Installation...................................................................................... 0187-2 High Tank Level Switch Installation...................................................................................... 0187-3
DIAL AND MOUNTING PLATE REPLACEMENT....................................................................................... WP 0188 Figure 1. Figure 2. Dial and Mounting Plate Removal........................................................................................ 0188-1 Dial and Mounting Plate Installation..................................................................................... 0188-2
LOW TANK LEVEL SWITCH REPLACEMENT .......................................................................................... WP 0189 Figure 1. Figure 2. Figure 3. Figure 4. Low Tank Level Switch Removal......................................................................................... 0189-1 Low Tank Level Switch Removal......................................................................................... 0189-2 Low Tank Level Switch Installation...................................................................................... 0189-2 Low Tank Level Switch Installation...................................................................................... 0189-3
MANHOLE COVER AND BRACKET REPLACEMENT............................................................................... WP 0190 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Manhole Cover and Bracket Removal.................................................................................. 0190-1 Manhole Cover and Bracket Removal.................................................................................. 0190-2 Manhole Cover and Bracket Removal.................................................................................. 0190-2 Manhole Cover and Bracket Removal.................................................................................. 0190-3 Manhole Cover and Bracket Removal.................................................................................. 0190-3 Manhole Cover and Bracket Installation............................................................................... 0190-4 Manhole Cover and Bracket Installation............................................................................... 0190-4 Manhole Cover and Bracket Installation............................................................................... 0190-5 Manhole Cover and Bracket Installation............................................................................... 0190-5 Manhole Cover and Bracket Installation............................................................................... 0190-6
TANK WALKWAY REPLACEMENT............................................................................................................ WP 0191 Figure 1. Figure 2. Tank Walkway Removal....................................................................................................... 0191-1 ............................................................................................................................................. 0191-2
VENT SCREEN REPLACEMENT............................................................................................................... WP 0192
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Page No. WP Sequence No. Figure 1. Figure 2. Vent Screen Removal.......................................................................................................... 0192-1 Vent Screen Installation....................................................................................................... 0192-2
WATER TANK MOUNT BUSHINGS AND SPRING REPLACEMENT........................................................ WP 0193 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. ............................................................................................................................................. 0193-2 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-3 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-3 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-4 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-4 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-5 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-6 Water Tank Mount Bushings and Spring Removal.............................................................. 0193-7 Water Tank Mount Bushings and Spring Installation........................................................... 0193-8 Water Tank Mount Bushings and Spring Installation........................................................... 0193-8 Water Tank Mount Bushings and Spring Installation........................................................... 0193-9 Water Tank Mount Bushings and Spring Installation......................................................... 0193-10 Water Tank Mount Bushings and Spring Installation......................................................... 0193-10 Water Tank Mount Bushings and Spring Installation......................................................... 0193-11 ........................................................................................................................................... 0193-11
VALVE COVER PLATE REPLACEMENT................................................................................................... WP 0194 Figure 1. Figure 2. Valve Cover And Gasket Removal....................................................................................... 0194-1 Valve Cover And Gasket Installation.................................................................................... 0194-2
WATER TANK REPLACEMENT................................................................................................................. WP 0195 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Water Tank Removal............................................................................................................ 0195-2 Water Tank Removal............................................................................................................ 0195-2 Water Tank Removal............................................................................................................ 0195-3 Water Tank Removal............................................................................................................ 0195-3 Water Tank Removal............................................................................................................ 0195-4
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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. Water Tank Removal............................................................................................................ 0195-5 Water Tank Removal............................................................................................................ 0195-5 Water Tank Removal............................................................................................................ 0195-6 Water Tank Removal............................................................................................................ 0195-6 Water Tank Installation......................................................................................................... 0195-7 Water Tank Installation......................................................................................................... 0195-7 Water Tank Installation......................................................................................................... 0195-8 Water Tank Installation......................................................................................................... 0195-9 Water Tank Installation......................................................................................................... 0195-9 Water Tank Installation....................................................................................................... 0195-10 Water Tank Installation....................................................................................................... 0195-10 Water Tank Installation....................................................................................................... 0195-11
WATER PUMP OIL SERVICE..................................................................................................................... WP 0196 Figure 1. Figure 2. Figure 3. Figure 4. Water Pump Oil Service....................................................................................................... 0196-2 Water Pump Oil Service....................................................................................................... 0196-3 Water Pump Oil Service....................................................................................................... 0196-4 Water Pump Oil Service....................................................................................................... 0196-4
DIAL INDICATOR ADJUSTMENT............................................................................................................... WP 0197 Figure 1. Figure 2. Table 1. Dial Indicator Adjustment..................................................................................................... 0197-1 Dial Indicator Adjustment..................................................................................................... 0197-2 Dial Indicator Adjustment..................................................................................................... 0197-2
WATER PUMP ASSEMBLY REPLACEMENT............................................................................................ WP 0198 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Water Pump Assembly Removal.......................................................................................... 0198-1 Water Pump Assembly Removal.......................................................................................... 0198-2 Water Pump Assembly Removal.......................................................................................... 0198-3 Water Pump Assembly Removal.......................................................................................... 0198-3 Water Pump Assembly Removal.......................................................................................... 0198-4
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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Water Pump Assembly Installation....................................................................................... 0198-5 Water Pump Assembly Installation....................................................................................... 0198-6 Water Pump Assembly Installation. ..................................................................................... 0198-7 Water Pump Assembly Installation. ..................................................................................... 0198-8 Water Pump Assembly Installation. ..................................................................................... 0198-9
DISCHARGE TUBE AND PIPE ASSEMBLY PUMP OUTLET HOSE REPLACEMENT............................. WP 0199 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. Discharge Tube and Pipe Assembly Pump Outlet Hose Removal....................................... 0199-1 Discharge Tube and Discharge Tube and Pipe Assembly Pump Outlet Hose Removal............................................................................................................................... 0199-2 Discharge Tube and Pipe Assembly Pump Outlet Hose Removal....................................... 0199-2 Discharge Tube and Pipe Assembly Pump Outlet Hose Removal....................................... 0199-3 Discharge Tube and Pipe Assembly Pump Outlet Hose Removal....................................... 0199-3 Discharge Tube and Pipe Assembly Pump Outlet Hose Removal....................................... 0199-4 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-4 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-5 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-5 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-6 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-7 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-8 Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.................................... 0199-9
PUMP DRIVE COUPLING REPLACEMENT............................................................................................... WP 0200 Figure 1. Figure 2. Figure 3. Figure 4. Pump Drive Coupling Removal............................................................................................ 0200-1 Pump Drive Coupling Removal............................................................................................ 0200-2 Pump Drive Coupling Installation......................................................................................... 0200-2 Pump Drive Coupling Installation......................................................................................... 0200-3
SUCTION TUBE AND HOSE REPLACEMENT.......................................................................................... WP 0201 Figure 1. Figure 2. Suction Tube and Hose Removal......................................................................................... 0201-1 Suction Tube and Hose Removal......................................................................................... 0201-2
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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Suction Tube and Hose Removal......................................................................................... 0201-2 Suction Tube and Hose Installation...................................................................................... 0201-3 Suction Tube and Hose Installation...................................................................................... 0201-3
HOSE REEL REPLACEMENT.................................................................................................................... WP 0202 Figure 1. Figure 2. Figure 3. Figure 4. Hose Reel Removal............................................................................................................. 0202-1 Hose Reel Removal............................................................................................................. 0202-2 Hose Reel Installation.......................................................................................................... 0202-3 Hose Reel Installation.......................................................................................................... 0202-3
HOSE REEL HOSE REPLACEMENT......................................................................................................... WP 0203 Figure 1. Figure 2. Figure 3. Figure 4. Hose Reel Hose Removal.................................................................................................... 0203-1 Hose Reel Hose Removal.................................................................................................... 0203-2 Hose Reel Hose Installation................................................................................................. 0203-2 Hose Reel Hose Installation................................................................................................. 0203-3
HOSE REEL GUIDE ROLLER ASSEMBLY REPLACEMENT.................................................................... WP 0204 Figure 1. Figure 2. Hose Reel Guide Roller Assembly Removal........................................................................ 0204-1 Hose Reel Guide Roller Assembly Installation..................................................................... 0204-2
CAB CONTROL BOX FACEGUARD REPLACEMENT............................................................................... WP 0205 Figure 1. Figure 2. Cab Control Box Faceguard Removal.................................................................................. 0205-1 Cab Control Box Faceguard Replacement........................................................................... 0205-2
CAB CONTROL BOX WIRE HARNESS REPLACEMENT.......................................................................... WP 0206 Figure 1. Figure 2. Figure 3. Figure 4. Cab Control Box Wiring Harness Removal.......................................................................... 0206-1 Cab Control Box Wiring Harness Removal.......................................................................... 0206-2 Cab Control Box Wiring Harness Installation....................................................................... 0206-2 Cab Control Box Wiring Harness Installation....................................................................... 0206-3
DISC MAGNET AND BRACKET REPLACEMENT..................................................................................... WP 0207 Figure 1. Figure 2. Disc Magnet Removal.......................................................................................................... 0207-1 Cab Control Mounting Plate Removal.................................................................................. 0207-2
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Page No. WP Sequence No. Figure 3. Figure 4. Cab Control Mounting Plate Installation............................................................................... 0207-3 Disc Magnet Installation....................................................................................................... 0207-3
CAB CONTROL BOX ENGINE START/STOP SWITCH REPLACEMENT................................................. WP 0208 Figure 1. Figure 2. Cab Control Box Engine Start/Stop Switch Removal........................................................... 0208-1 Cab Control Box Engine Start/Stop Switch Installation........................................................ 0208-2
CAB CONTROL BOX WATER SPRINKLER SWITCH REPLACEMENT.................................................... WP 0209 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cab Control Box Water Sprinkler Switch Removal.............................................................. 0209-1 Cab Control Box Right Water Sprinkler Switch Removal..................................................... 0209-2 Cab Control Box Water Sprinkler Switch Removal.............................................................. 0209-2 Cab Control Box Water Sprinkler Switch Installation........................................................... 0209-3 Cab Control Box Water Sprinkler Switch Installation........................................................... 0209-3 Cab Control Box Water Sprinkler Switch Installation........................................................... 0209-4
CAB CONTROL BOX LIGHT SWITCH REPLACEMENT............................................................................ WP 0210 Figure 1. Figure 2. Cab Control Box Light Switch Removal............................................................................... 0210-1 Cab Control Box Light Switch Installation............................................................................ 0210-2
CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH REPLACEMENT.................................. WP 0211 Figure 1. Figure 2. Figure 3. Figure 4. Cab Control Box Engine Speed Resume/Idle Switch Removal........................................... 0211-1 Cab Control Box Engine Speed Resume/Idle Switch Removal........................................... 0211-2 Cab Control Box Engine Speed Resume/Idle Switch Installation........................................ 0211-2 Cab Control Box Engine Speed Resume/Idle Switch Installation........................................ 0211-3
CAB CONTROL BOX ENGINE SPEED RPM SWITCH REPLACEMENT.................................................. WP 0212 Figure 1. Figure 2. Figure 3. Figure 4. Cab Control Box Engine Speed RPM Switch Removal........................................................ 0212-1 Cab Control Box Engine Speed RPM Switch Removal........................................................ 0212-2 Cab Control Box Engine Speed RPM Switch Installation..................................................... 0212-2 Cab Control Box Engine Speed RPM Switch Removal........................................................ 0212-3
CAB CONTROL BOX ENGINE SPEED SET BUTTON REPLACEMENT................................................... WP 0213 Figure 1. Cab Control Box Engine Speed Set Button Removal.......................................................... 0213-1
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Page No. WP Sequence No. Figure 2. Cab Control Box Engine Speed Set Button Installation....................................................... 0213-2
CAB CONTROL BOX WATER LEVEL INDICATOR REPLACEMENT....................................................... WP 0214 Figure 1. Figure 2. Figure 3. Figure 4. Cab Control Box Water Level Indicator Removal................................................................. 0214-1 Cab Control Box Water Level Indicator Removal................................................................. 0214-2 Cab Control Box Water Level Indicator Installation.............................................................. 0214-3 Cab Control Box Water Level Indicator Installation.............................................................. 0214-3
CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR REPLACEMENT............................. WP 0215 Figure 1. Figure 2. Cab Control Box Engine Off/Battery Drain Indicator Removal............................................. 0215-1 Cab Control Box Engine Off/Battery Drain Indicator Installation.......................................... 0215-2
CAB CONTROL BOX TACHOMETER REPLACEMENT............................................................................ WP 0216 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Cab Control Box Tachometer Removal................................................................................ 0216-1 Cab Control Box Tachometer Removal................................................................................ 0216-2 Cab Control Box Tachometer Removal................................................................................ 0216-2 Cab Control Box Tachometer Removal................................................................................ 0216-3 Cab Control Box Tachometer Removal................................................................................ 0216-4 Cab Control Box Tachometer Installation............................................................................. 0216-5 Cab Control Box Tachometer Installation............................................................................. 0216-6 Cab Control Box Tachometer Installation............................................................................. 0216-7 Cab Control Box Tachometer Installation............................................................................. 0216-7 Cab Control Box Tachometer Installation............................................................................. 0216-8
PREPARATION FOR STORAGE OR SHIPMENT...................................................................................... WP 0217 TORQUE LIMITS......................................................................................................................................... WP 0218 Table 1. Figure 1. Figure 2. Table 2. Table 3. Metal Fasteners.................................................................................................................... 0218-1 Torque Wrench Formula...................................................................................................... 0218-2 Torque Wrench Adapter Setups........................................................................................... 0218-2 Torque Limits - SAE Standard Fasteners............................................................................. 0218-3 Torque Limits - Metric Fasteners.......................................................................................... 0218-5
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Page No. WP Sequence No. Table 4. Figure 3. Figure 4. Thread Classes and Description.......................................................................................... 0218-6 Fastener Size....................................................................................................................... 0218-6 Thread Pattern..................................................................................................................... 0218-6
Chapter 5 - REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST ..................................................... WP 0219 Table 1. Table 2. Table 3. Table 4. Table 5. GROUP 0000 SMR Codes.......................................................................................................................... 0219-1 Source Code 1st and 2nd Positions..................................................................................... 0219-2 Maintenance Code 3rd Position........................................................................................... 0219-3 Maintenance Code 4th Position........................................................................................... 0219-4 Recoverability Code 5th Position......................................................................................... 0219-4 EMM WATER DISTRIBUTOR.......................................................................................... WP 0220
Chapter 6 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0221 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.............................................................. WP 0222 MAINTENANCE ALLOCATION CHART (MAC).......................................................................................... WP 0223 Table 1. Table 2. Table 3. MAINTENANCE ALLOCATION CHART (MAC)................................................................... 0223-1 TOOLS AND TEST EQUIPMENT REQUIREMENTS........................................................ 0223-10 REMARKS.......................................................................................................................... 0223-11
EXPENDABLE/DURABLE ITEMS LIST...................................................................................................... WP 0224 TOOL IDENTIFICATION LIST..................................................................................................................... WP 0225 Table 1. Tool Identification List........................................................................................................... 0225-1
MANDATORY REPLACEMENT PARTS..................................................................................................... WP 0226 Table 1. Mandatory Replacement Parts List...................................................................................... 0226-1
SCHEMATICS............................................................................................................................................. WP 0227 Foldout Figures FO-1. Electrical Schematic........................................................................................................................... FP-1 FO-2. Piping Schematic................................................................................................................................ FP-3
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Page No. WP Sequence No. FO-3. Air Schematic..................................................................................................................................... FP-5
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HOW TO USE THIS MANUAL
GENERAL INFORMATION This manual is designed to help operate and maintain the Water Distributor, NSN 3825-01-577-2713, Part Number 5251894. Listed below are some of the features included in this manual to help locate and use the needed information: Warning, caution and note headings, subject headings and other essential information are printed in bold type, making them easier to see. In addition to text, there are digital photos and some line art illustrations showing how to take a component off and put it back on. Cleaning and inspection criteria are also included where necessary. Chapter 1 of this manual covers General Information, Equipment Description and Theory of Operation. Chapter 2 of this manual provides an Introduction to Troubleshooting and Troubleshooting Procedures. Chapter 3 of this manual covers Preventive Maintenance Checks and Services (PMCS). Chapter 4 of this manual provides Maintenance Instructions. Chapter 5 of this manual covers the Introduction to Repair Parts and Special Tools List (RPSTL) and the Repair Parts and Special Tools List (RPSTL). Chapter 6 of this manual provides Supporting Information, References, and Expendable/Durable Items List. Follow these guidelines when using this manual: Read all WARNINGS, CAUTIONS, and NOTES prior to performing any procedure. Water Distributor TM 5-3825-270-23&P is used in conjunction with Palletized Load System (PLS) TM 9-2320-364 manual series.
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CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
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FIELD MAINTENANCE GENERAL INFORMATION
SCOPE TYPE OF MANUAL This manual contains operation and operator maintenance instructions for the Engineer Mission Module - Water Distributor (EMM - WD). EQUIPMENT NAME AND MODEL NUMBER Engineer Mission Module - Water Distributor (EMM - WD), NSN 3825-01-577-2713, the module is manufactured by E.D. Etnyre and Co. PURPOSE OF EQUIPMENT The EMM - WD's primary mission is to enhance the engineer corps and supported forces in the areas of combat support, combat service support and general construction; this includes the construction of airfields, railways, roads and infrastructure. When mounted on a truck or trailer the Engineer Mission Module - Water Distributor (EMM - WD) shall provide a means of: Spreading measured amounts of water for increasing soil moisture Applying soil stabilization additives Applying dust control chemicals Firefighting support capability MAINTENANCE FORMS AND RECORDS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0221). REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your Engineer Mission Module - Water Distributor (EEM-WD) needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you dont like about your equipment. Let us know why you dont like the design or performance. If you have internet access, the easiest and fastest way to report problem or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the "Submit Quality Deficiency Report" bar). The Internet form lets you choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality Deficiency Report (PQDR) or a Warranty Claim Action (WCA). You may also submit your information using an SF 368 (Product Quality Deficiency Report) (WP 0221) . You can send your SF 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0221). 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 the Engineer Mission Module - Water Distributor (EMM - WD) be reported so that the problem can be corrected and improvements can be made to prevent the problem in the future. While corrosion is typically associated with rusting of metals, corrosion can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. If a corrosion problem is identified, it can be reported using a SF 368 (Product Quality Deficiency Report) (WP 0221) which should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0221)
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DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE Command decision, according to the tactical situation, will determine when the destruction of the Engineer Mission Module - Water Distributor (EMM - WD) will be accomplished. A destruction plan will be prepared by the using organization unless one has been prepared by a higher authority. For general destruction procedures for this equipment, refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-automotive and Armaments Command) (WP 0221). PREPARATION FOR STORAGE OR SHIPMENT For procedures on preparation and storage, refer to Preparation for Storage or Shipment (WP 0217). WARRANTY INFORMATION The Water Distributor is warranted for a period of twelve (12) months from the date of warranty activation. The warranty starts when the Water Distributor's warranty data plate is stamped by the Contractor during the Water Distributor hand-off. Report all defects to your supervisor, who will take appropriate action. For equipment under manufacturer's warranty, hard time oil service intervals shall be followed. Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions, such as longer than usual operating hours, extended idling period, or extreme dust. LIST OF ABBREVIATIONS This list consists of special or unique abbreviations, acronyms, and descriptors not contained in MIL-STD-12, Abbreviations for use on Drawings, and in Specifications, Standards and Technical Documents (WP 0221). Table 1. List of Abbreviations. amp BII C CAGEC COEI CTA DA DC EIR EMM - WD F ft GPM Amperes Basic Issue Item Centigrade Commercial and Government Entity Code Components of End Item Common Table of Allowances Department of the Army Direct Current Equipment Improvement Recommendation Engineer Mission Module - Water Distributor Fahrenheit Foot Gallons per Minute
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LIST OF ABBREVIATIONS - Continued Table 1. List of Abbreviations - Continued. hp in. kg kPa L lb-ft lb-in lb LHS m ml mm Nm NBC NSN PLS PLST PMCS PQDR psi Qt QTY RPSTL rpm SAE Horsepower Inch Kilogram Kilopascal Liter Pound-Foot Pound-Inch Pound Load Handling System Meter Milliliters Millimeter Newton Meter Nuclear, Biological, Chemical National Stock Number Palletized Load System Palletized Load System Trailer Preventive Maintenance Checks and Services Product Quality Deficiency Report Pound-Force Per Square Inch Quart Quantity Repair Parts and Special Tools List Revolutions Per Minute Society of Automotive Engineers
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LIST OF ABBREVIATIONS - Continued Table 1. List of Abbreviations - Continued. STD TAMMS TM U/I U/M vdc WCA SAFETY GENERAL Even though the Engineer Mission Module - Water Distributor (EMM - WD) has no special hazardous or dangerous characteristics during exposure to normal transportation environments, several general safety considerations and precautions are important. Check the entire module to be sure loose items are properly secured. Have fire extinguishers readily available when operating the Engineer Mission Module - Water Distributor (EMM - WD). Make sure only qualified personnel operate the Engineer Mission Module - Water Distributor (EMM - WD). Do not leave the Engineer Mission Module - Water Distributor (EMM - WD) unattended while the engine is running. Do not operate the Engineer Mission Module - Water Distributor (EMM - WD) on public roads without the appropriate safety equipment. Adhere to all local, state, federal, and host-nation safety laws and regulations applying to commercial carriers. WARNING ICONS Table 2. Warning Icons. EAR PROTECTION - headphones over ears shows that noise level will harm ears. Standard The Army Maintenance Management System Technical Manual Unit Of Issue Unit Of Measure Volts Direct Current Warranty Claim Action
ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.
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WARNING ICONS - Continued Table 2. Warning Icons - Continued. ELECTRICAL - electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.
FALLING PARTS - arrow bouncing off human shoulder and head shows that falling parts present a danger to life or limb.
FLYING PARTICLES - arrows bouncing off face shows that particles flying through the air will harm face.
FLYING PARTICLES - arrows bouncing off face with face shield shows that particles flying through the air will harm face.
HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from improper lifting technique.
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.
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WARNING ICONS - Continued Table 2. 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.
HELMET PROTECTION - arrow bouncing off head with helmet shows that falling parts present a danger.
HOT AREA - hand over object radiating heat shows that part is hot and can burn.
LASER LIGHT - laser light hazard symbol indicates extreme danger for eyes from laser beams and reflections.
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.
MOVING PARTS - hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.
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WARNING ICONS - Continued Table 2. Warning Icons - Continued. MOVING PARTS - hand with fingers caught between rollers shows that the moving parts of the equipment present a danger to life or limb.
SHARP OBJECT - pointed object in hand shows that a sharp object presents a danger to limb.
SHARP OBJECT - pointed object in hand shows that a sharp object presents a danger to limb.
SHARP OBJECT - pointed object in foot shows that a sharp object presents a danger to limb.
SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger for falling.
BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.
CHEMICAL - drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.
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WARNING ICONS - Continued Table 2. Warning Icons - Continued. CRYOGENIC - hand in block of ice shows that the material is extremely cold and can injure human skin or tissue.
EXPLOSION - rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition or high pressure.
EYE PROTECTION - person with goggles shows that the material will injure the eyes.
FIRE - flame shows that a material may ignite and cause burns.
POISON - skull and crossbones shows that a material is poisonous or is a danger to life.
RADIATION - three circular wedges shows that the material emits radioactive energy and can injure human tissue.
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WARNING ICONS - Continued Table 2. Warning Icons - Continued. VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.
END OF WORK PACKAGE
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0002
FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA
GENERAL The Engineer Mission Module - Water Distributor (EMM - WD) is a demountable 3000 gallon unit for use with NATO STANAG compatible Load Handling System (LHS) type trucks (e.g., PLS M1075) and associated trailers (e.g., PLST M1076). The Engineer Mission Module Water Distributor (EMM - WD) is compatible for PLS transport, operation and use throughout the mission profile. It can also be powered by an on-board diesel engine. The Engineer Mission Module Water Distributor (EMM - WD) when unloaded from the PLS truck is capable of operating as a wash rack facility. The Water Distributor can be operated from the cab of the PLS vehicle when vehicle is moving or at the rear control station when vehicle is not moving. It is composed of a 3,000 gallon stainless steel water tank mounted on top of a slightly modified M1077 flatrack. Internal baffles in the tank minimize sloshing of material during operations. A 20 inch manhole is located at the rear top of the tank to permit access for inspection or filling. A catwalk and hand rails are provided to allow access to the manhole from the rear control station. An overflow pipe, located at the top of the tank, was incorporated to prevent overfilling and to allow room for expansion of the material. A drain is located in the bottom rear of the tank for complete draining of the unit for service or inspection. Several inlet/outlet ports are provided with a variety of adapters for various connections and operations. EQUIPMENT DATA Refer to the following table for specific equipment data. Table 1. Equipment Data. Item TANK RACK Tank Capacity (usable) NSN Part Number Model Number Length Width Height Weight, Empty Weight, Full WATER PUMP Type Nominal Capacity Self-Priming Centrifugal 600 gpm 3,000 gal 3825-01-577-2713 5251894 WD3000 238.4" 96" 82.1" 8,500 lb 33,500 lb Specification
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EQUIPMENT DATA - Continued Table 1. Equipment Data - Continued. Item Drive Minimum Recommended Operating Speed Maximum Recommended Operating Speed Maximum Discharge Pressure (outlet blocked) ENGINE Type Model Power Maximum Speed Low Idle Speed WATER TURRET Spray Distance Capability Normal Operation Output (shaper nozzle) SPRINKLER NOZZLES Type Spray Width Capability Normal Operation Output (one nozzle) Normal Operation Output (two nozzles) Full Output (two nozzles) HOSE REEL Type Hose Size Normal Operation Output (full open nozzle) Full Output (full open nozzle) Manual Crank 1.5" x 50' 1500 Engine rpm: 50 psi, 65 gpm 2400 Engine rpm: 125 psi, 110 gpm (2) Fan Nozzles-Adjustable Direction Fixed Opening 80' 1800 Engine rpm: 75 psi, 235 gpm 1800 Engine rpm: 65 psi, 420 gpm 2400 Engine rpm: 110 psi, 550 gpm over 175' (shaper nozzle) over 125' (fog nozzle) 2400 Engine rpm: 110psi, 550 gpm Naturally Aspirated Liquid Cooled Diesel Kubota V3600E3B 66.8 HP 2400 rpm 1000 rpm Specification Direct with engine flywheel flex coupling 1500 Engine rpm (continuous) 2400 Engine rpm (continuous) 135 psi at 2400 Engine rpm (30 seconds maximum)
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EQUIPMENT DATA - Continued Table 1. Equipment Data - Continued. Item SHUT-DOWN SYSTEM Engine Overspeed High Engine Coolant Temperature Low Engine Oil Pressure Excessive Pump Discharge Pressure over 2650 rpm over 225 F under 7 psi over 150 psi Specification
END OF WORK PACKAGE
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0003
FIELD MAINTENANCE THEORY OF OPERATION
INTRODUCTION The EMM - WD's primary mission is to enhance the engineer corps and supported forces in the areas of combat support, combat service support and general construction; this includes the construction of airfields, railways, roads and infrastructure. PRINCIPLES OF OPERATION Electrical power is provided to the module by on-board systems. Water distribution is accomplished through the hose reel, sprinkler system, water turret, and gravity bar. OPERATIONAL FEATURES OF COMPONENTS ENGINE The engine, which powers the pump, is mounted within the module unit. It receives its fuel from a 20 gal (76 L) fuel tank mounted to the flatrack on the front left side. Control of the engine is by the control panel as described below. PUMP The pump is coupled directly to the engine. The purpose of the pump is to pump water out of or into the tank. VALVES There are a total of eight valves on the Water Distributor that control different operations. Refer to data plates and decals for location of valves. CONTROL PANEL The control panel controls the starting and stopping of the engine. It also monitors the tank functions as well as the high and low water indicators. The control panel is permanently mounted on the rear platform. TRANSPORTER OPERATION AND FUNCTIONS For transporter operation and functions refer to: TM 9-2320-364-10 for the Palletized Load System (PLS) truck (M1074, M1075). TM 9-2330-385-10 for the PLS trailer (M1076). END OF WORK PACKAGE
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CHAPTER 2 TROUBLESHOOTING PROCEDURES
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0004
FIELD MAINTENANCE GENERAL TROUBLESHOOTING INSTRUCTIONS
GENERAL The troubleshooting included in this manual provides the information needed to isolate, diagnose, and correct malfunctions incurred to the water distributor. Each fault symptom given for an individual component or system is followed by step(s) leading to the cause of the fault and the actions needed to correct it. This manual cannot list all faults that may occur, nor all test, inspections, or corrective actions. If a fault is not listed or is not corrected by listed corrective actions, notify the supervisor. BEFORE TROUBLESHOOTING Before taking any action to correct a possible malfunction, follow these rules: 1. Ensure Operator Troubleshooting has been performed on the vehicle since the fault has occurred. 2. Ensure Operator PMCS was performed prior to, during, and after the mission that incurred the fault. 3. Obtain as much information from the operator as possible about the fault. 4. Check the repair history of the particular piece of equipment with fault. 5. Never overlook the possibility that the problem may be of simple origin and may be repairable with a simple adjustment. 6. Use all of your senses to observe and locate problems. 7. Whenever possible, isolate the system first and then the component causing the fault. 8. Use standard automotive theories and principles when troubleshooting this piece of equipment. TROUBLESHOOTING ELECTRICAL SYSTEMS GENERAL The voltage and current for the electrical system are indicated by a battery gauge located on the main control panel. A circuit breakers located side of the main control panel to protect the main circuits. Electrical power is provided by two 12-volt batteries connected in series. Power is distributed throughout the water distributor by wiring harnesses. The harnesses are interconnected by pin connectors, terminal strips, and/or wire terminals. Use jumper wires when applicable to aid in isolating faults during troubleshooting. Use a standard multimeter to troubleshoot circuits. WHEN TROUBLESHOOTING ELECTRICAL SYSTEMS Look for the following: 1. Inspect wires for loose electrical connections. 2. Inspect connectors for loose, bent, or corroded terminals. 3. Tag and mark wires and connectors prior to removal. 4. When applicable, remove and replace cable ties. 5. When checking for continuity using multimeter, less than 2 ohms represents continuity. When testing through components or through multiple harnesses the allowable resistance tolerance is given in troubleshooting test. 6. When testing wires inside control panel, it may be easier to touch multimeter probes to terminal strip screws. Removal and installation of wires at terminal strips can often be time consuming. 7. Ensure wires at terminal strips are fully seated and not frayed before taking multimeter checks. Unseated or frayed wires can result in improper multimeter readings. TROUBLESHOOTING RULES When performing troubleshooting, follow these rules: 1. Caution must be used when working around the alternator, starter, NATO slave receptacle, or circuit breakers when the battery is connected. These components have 24-volt terminals that will still be live.
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TROUBLESHOOTING RULES - Continued 2. Observe warnings, cautions, and notes. 3. When a link is encountered in the text of a troubleshooting track, the troubleshooting mechanic must proceed to the linked information. The information "linked to" must be reviewed for information as it pertains to the troubleshooting procedures (i.e.: procedures, safety and caution information, component locations, and other necessary information). If this linked information is not reviewed, dangerous situations and/or inaccurate test results may occur. 4. When the information "linked to" is a maintenance task, and you are removing a component, the equipment conditions of the maintenance task must be performed. If the equipment conditions are not performed, dangerous situations and/or inaccurate test results may occur. 5. When the information "linked to" is a maintenance task, and you are installing a component, the follow-on conditions of the maintenance task must be performed. If follow-on conditions are not performed, dangerous situations and/or inaccurate test results may occur. END OF WORK PACKAGE
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0005
FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX - FIELD MAINTENANCE
TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom Troubleshooting Procedure
CAB CONTROL BOX TROUBLESHOOTING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cab Control Box Engine Off/Battery Drain Indicator Inoperative ...................................................... WP 0057 Cab Control Box Engine Speed Resume/Idle Switch Does Not Operate ............................................................................................................................................. WP 0060 Cab Control Box Engine Speed RPM Switch Does Not Operate ...................................................... WP 0061 Cab Control Box Engine Speed Set Switch Does Not Operate ........................................................ WP 0062 Cab Control Box Engine Start/Stop Switch Does Not Operate ......................................................... WP 0067 Cab Control Box Lights Switch Does Not Operate ............................................................................ WP 0058 Cab Control Box Tachometer Does Not Operate .............................................................................. WP 0059 Cab Control Box Water Level High Indicator Does Not Operate ....................................................... WP 0065 Cab Control Box Water Level Low Indicator Does Not Operate ....................................................... WP 0066 Cab Control Box Water Sprinkler Switch (Left) Does Not Operate ................................................... WP 0063 Cab Control Box Water Sprinkler Switch (Right) Does Not Operate ............................................................................................................................................. WP 0064
CONTROL PANEL TROUBLESHOOTING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Engine Off/Battery Drain Indicator Does Not Illuminate .................................................................... WP 0031 Engine Off/Battery Drain Indicator Stays Illuminated ........................................................................ WP 0032 Engine Oil Pressure Gauge Inoperative Or Reads High ................................................................... WP 0035 Engine Oil Pressure Gauge Reads High ........................................................................................... WP 0034 Engine Oil Pressure Gauge Reads Low ............................................................................................ WP 0033 Engine Resume Switch Does Not Operate ....................................................................................... WP 0040 Engine RPM Switch Does Not Operate ............................................................................................. WP 0041 Engine Speed Set Switch Does Not Operate .................................................................................... WP 0042 Engine Temperature Gauge Inoperative Or Reads High .................................................................. WP 0036 Left Water Sprinkler Switch Does Not Operate ................................................................................. WP 0043 Battery Voltage Gauge Does Not Operate Or Reads High ............................................................... WP 0028 Main Control Panel Battery Voltage Gauge Reads High ................................................................... WP 0030 Main Control Panel Battery Voltage Gauge Reads Low ................................................................... WP 0029 Main Control Panel Tachometer Does Not Operate .......................................................................... WP 0037 No Power To Control Panel .............................................................................................................. WP 0027
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TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure
16. 17. 18. 19. 20. 21. 22.
Right Water Sprinkler Switch Does Not Operate ............................................................................... WP 0044 Water Level High Indicator Does Not Illuminate ................................................................................ WP 0045 Water Level High Indicator Stays Illuminated .................................................................................... WP 0047 Water Level Low Indicator Does Not Illuminate ................................................................................ WP 0046 Water Level Low Indicator Stays Illuminated .................................................................................... WP 0048 Water Pump Inlet Gauge Does Not Operate ..................................................................................... WP 0038 Water Pump Outlet Gauge Does Not Operate .................................................................................. WP 0039
ELECTRICAL TROUBLESHOOTING 1. 2. Water Distributor Does Not Operate Remotely ................................................................................. WP 0026 Work Lights Do Not Illuminate ........................................................................................................... WP 0025
ENGINE TROUBLESHOOTING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Engine Cranks But Does Not Start .................................................................................................... WP 0007 Engine Does Not Crank .................................................................................................................... WP 0006 Engine Does Not Reach Normal Operating Temperature ................................................................. WP 0016 Engine Knock .................................................................................................................................... WP 0019 Excessively Long Crank Time ........................................................................................................... WP 0008 Engine Misfires .................................................................................................................................. WP 0011 Engine Overheats ............................................................................................................................. WP 0015 Engine Stalls ..................................................................................................................................... WP 0009 Engine Surges ................................................................................................................................... WP 0010 Engine Will Not Increase RPM .......................................................................................................... WP 0012 Excessive Engine Noise .................................................................................................................... WP 0014 Excessive Engine Vibration ............................................................................................................... WP 0013 Excessive Engine Oil Consumption .................................................................................................. WP 0017 Excessive Fuel Consumption ............................................................................................................ WP 0018
EXHAUST TROUBLESHOOTING 1. 2. Black/Blue Exhaust Smoke ............................................................................................................... WP 0020 White Exhaust Smoke ....................................................................................................................... WP 0021
PUMP TROUBLESHOOTING 1. Excessive Water Pump Noise ........................................................................................................... WP 0024
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TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. Troubleshooting Procedure
Water Pressure Erratic ...................................................................................................................... WP 0023 Water Pump Does Not Operate ........................................................................................................ WP 0022
WATER STATION TROUBLESHOOTING 1. 2. 3. 4. 5. 6. 7. 8. Gravity Bar Weldment Does Not Operate ......................................................................................... WP 0051 Gravity Bar Weldment Stream Low ................................................................................................... WP 0052 Manual Water Turret Does Not Operate ........................................................................................... WP 0049 Manual Water Turret Pressure Low .................................................................................................. WP 0050 Water Hose Does Not Operate ......................................................................................................... WP 0055 Water Hose Pressure Low ................................................................................................................ WP 0056 Water Sprinkler Heads Do Not Operate ............................................................................................ WP 0053 Water Sprinkler Head Pressure Low ................................................................................................. WP 0054
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0006
OPERATOR MAINTENANCE ENGINE DOES NOT CRANK
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Batteries Servicing And Testing (WP 0082) Battery Disconnect/Connection (WP 0085) Battery Replacement (WP 0086) Engine Off/Battery Drain Indicator Does Not Illuminate (WP 0031) Engine Start/Engine Stop Switch And Guard Replacement (WP 0208) References (cont.) General Wire Harness Replacement (WP 0099) Governor Control Module Replacement (WP 0092) Open/Close Engine Access Cover (TM 5-3825-270-10) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Starter Relay Replacement (WP 0138) Starter Replacement (WP 0139) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE DOES NOT CRANK STEP 1 Does ENGINE OFF/BATTERY DRAIN indicator illuminate?
NOTE
Engine will not start and water distributor will not have power if EMERGENCY STOP switch is pushed to off position. 1. 2. 3. Open main control panel cover. (TM 5-3825-270-10) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Observe ENGINE OFF/BATTERY DRAIN light.
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ENGINE OFF / BATTERY DRAIN INDICATOR
Figure 1. Engine Off/Battery Drain Indicator - Step 1. CONDITION/INDICATION Does ENGINE OFF/BATTERY DRAIN indicator illuminate? DECISION No - Go to Engine Off/Battery Drain Indicator Does Not Illuminate. (WP 0031) Yes - Go to step 2. (Step 2 - Does BATTERY VOLTAGE gauge indicate 22 to 28 VDC?) STEP 2 Does BATTERY VOLTAGE gauge indicate 22 to 28 VDC? 1. Ensure EMERGENCY STOP switch is rotated to on position. (TM 5-3825-270-10) 2. Observe BATTERY VOLTAGE gauge.
BATTERY VOLTAGE GAUGE
Figure 2. Battery Voltage Gauge - Step 2. CONDITION/INDICATION Does BATTERY VOLTAGE gauge indicate 22 to 28 VDC? DECISION No - Go to step 3. (Step 3 - Are battery cables properly connected and free of damage and corrosion?) Yes - Go to step 4. (Step 4 - Do batteries measure 24.2 to 25.4 VDC with multimeter?)
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STEP 3 Are battery cables properly connected and free of damage and corrosion? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Open battery box cover. (TM 5-3825-270-10) 3. Visually inspect battery cables and terminals for proper connection, damage, and corrosion. (WP 0085)
BATTERY CABLES
BATTERIES
Figure 3. Battery Cables - Step 3. CONDITION/INDICATION Are battery cables properly connected and free of damage and corrosion? DECISION No - Clean and connect, or replace battery cables. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 4. (Step 4 - Do batteries measure 24.2 to 25.4 VDC with multimeter?) STEP 4 Do batteries measure 24.2 to 25.4 VDC with multimeter?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. Set multimeter to measure voltage.
NOTE
Water distributor is equipped with two 12-volt batteries connected in series. Multimeter measurements must be made from correct battery terminals to obtain 24-volt measurements. 2. 3. Connect red multimeter lead to positive battery terminal. Connect black multimeter lead to negative battery terminal.
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POSITIVE BATTERY TERMINAL
NEGATIVE BATTERY TERMINAL
Figure 4. Battery Terminals - Step 4. 4. Note multimeter reading.
NOTE
The following chart describes battery voltage characteristics when measured with a multimeter. This chart can be used to further isolate and troubleshoot batteries that may be cause of problem. 5. Compare multimeter reading to chart below. Table 1. Battery State Of Charge Voltage Table. Percentage Of Full Charge 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 12 Volt DC System 12.7 12.6 12.5 12.3 12.2 12.1 12.0 11.8 11.7 11.6 24 Volt DC System 25.4 25.2 25 24.6 24.4 24.2 24 23.6 23.4 23.2
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Table 1. Battery State Of Charge Voltage Table - Continued. 0% <=11.6 <=23.2
CONDITION/INDICATION Do batteries measure 24.2 to 25.4 VDC with multimeter? DECISION No - Service batteries (WP 0082) or replace batteries. (WP 0086) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 5. (Step 5 - Are wire connections on starter properly connected and free of damage and corrosion?) STEP 5 Are wire connections on starter properly connected and free of damage and corrosion? 1. Open front engine access cover. (TM 5-3825-270-10) 2. Visually inspect wire connections on starter for proper connection, damage, and corrosion.
WIRE CONNECTIONS
Figure 5. Wire Connections - Step 5. CONDITION/INDICATION Are wire connections on starter properly connected and free of damage and corrosion? DECISION No - Properly clean (WP 0069), connect (WP 0139), and/or replace damaged wiring at starter. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 6. (Step 6 - Are wire connections on starter relay free of damage and corrosion?) STEP 6 Are wire connections on starter relay free of damage and corrosion? 1. Open rear engine access cover. (TM 5-3825-270-10) 2. Visually inspect starter relay wire connections.
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STARTER RELAY CONNECTIONS
Figure 6. Starter Relay Wire Connections - Step 6.
CONDITION/INDICATION Are wire connections on starter relay free of damage and corrosion? DECISION No - Properly clean (WP 0069), connect (WP 0138), and/or replace damaged starter relay wiring. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 7. (Step 7 - Are 22 to 28 VDC present at starter solenoid positive terminal?) STEP 7 Are 22 to 28 VDC present at starter solenoid positive terminal?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. Ensure multimeter is set to measure voltage. Connect red multimeter lead to starter solenoid positive terminal.
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STARTER SOLENOID POSITIVE TERMINAL

Figure 7. Starter Solenoid Positive Terminal - Step 7. 3. 4. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC present at starter solenoid positive terminal? DECISION No - Repair or replace red wire from battery positive terminal to starter solenoid positive terminal. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 8. (Step 8 - Are less than 200 ohms present from starter ground wire to a known good ground?) STEP 8 Are less than 200 ohms present from starter ground wire to a known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to starter ground wire.
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STARTER GROUND WIRE
Figure 8. Starter Motor Ground Wire - Step 8. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms present from starter ground wire to a known good ground? DECISION No - Repair or replace starter ground wire. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 9. (Step 9 - Are 22 to 28 VDC present at starter solenoid white wire with ENGINE START/ ENGINE STOP switch in ENGINE START position?) STEP 9 Are 22 to 28 VDC present at starter solenoid white wire with ENGINE START/ENGINE STOP switch in ENGINE START position?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. Connect batteries. (WP 0085) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Set multimeter to measure voltage. Connect red multimeter lead to starter solenoid white wire.
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STARTER SOLENOID WHITE WIRE
Figure 9. Starter Solenoid White Wire - Step 9. 5. 6. Connect black multimeter lead to a known good ground. With the aid of an assistant, place ENGINE START/ENGINE STOP switch to ENGINE START position and hold.
ENGINE START/ENGINE STOP SWITCH
Figure 10. Engine Start//Engine Stop Switch - Step 9. 7. 8. Note multimeter reading. Release ENGINE START/ENGINE STOP switch.
CONDITION/INDICATION Are 22 to 28 VDC present at starter solenoid white wire with ENGINE START/ENGINE STOP switch in ENGINE START position? DECISION No - Go to step 10. (Step 10 - Are 22 to 28 VDC present at starter relay blue wire with ENGINE START/ENGINE STOP switch in ENGINE START position?) Yes - Replace starter. (WP 0139) Verify problem is solved. (Step 16 - Does engine crank?) STEP 10
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0006
Are 22 to 28 VDC present at starter relay blue wire with ENGINE START/ENGINE STOP switch in ENGINE START position?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. Connect red multimeter lead to starter relay blue wire.
STARTER RELAY BLUE WIRE

Figure 11. Starter Relay Blue Wire - Step 10. 2. 3. Connect black multimeter lead to a known good ground. With the aid of an assistant, place ENGINE START/ENGINE STOP switch to ENGINE START position and hold.
Figure 12. Engine Start/Engine Stop Switch - Step 10. 4. Note multimeter reading.
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0006
5.
Release ENGINE START/ENGINE STOP switch.
CONDITION/INDICATION Are 22 to 28 VDC present at starter relay blue wire with ENGINE START/ENGINE STOP switch in ENGINE START position? DECISION No - Go to step 12. (Step 12 - Are less than 200 ohms present on red jumper wire from ENGINE START/ENGINE STOP switch to ENGINE OFF/BATTERY DRAIN indicator?) Yes - Go to step 11. (Step 11 - Are less than 200 ohms present on white wire from starter relay to starter solenoid?) STEP 11 Are less than 200 ohms present on white wire from starter relay to starter solenoid? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) (WP 0221) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to white wire at starter relay.
STARTER RELAY WHITE WIRE
Figure 13. Starter Relay White Wire - Step 11. 5. Connect black multimeter lead to white wire at starter solenoid.
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STARTER SOLENOID WHITE WIRE
Figure 14. Starter Solenoid White Wire - Step 11. 6. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms present on white wire from starter relay to starter solenoid? DECISION No - Repair or replace white wire between starter relay and starter solenoid. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Replace starter relay. (WP 0138) Verify problem is solved. (Step 16 - Does engine crank?) STEP 12 Are less than 200 ohms present on red jumper wire from ENGINE START/ENGINE STOP switch to ENGINE OFF/BATTERY DRAIN indicator? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Remove six control panel faceplate screws.
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CONTROL PANEL FACEPLATE SCREWS
Figure 15. Control Panel Faceplate Screws - Step 12. 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to red jumper wires at ENGINE START/ENGINE STOP switch.
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0006
ENGINE START/ENGINE STOP SWITCH ORANGE/RED WIRE
RED JUMPER WIRES
ORANGE/BLACK WIRE
Figure 16. Engine Start/Engine Stop Switch Red Jumper Wires - Step 12. 5. Connect black multimeter lead to red jumper wire at ENGINE OFF/BATTERY DRAIN indicator.
WHITE / BLACK WIRE
RED JUMPER WIRE
BACK OF CONTROL PANEL
WHITE / RED WIRE

Figure 17. Engine Off/Battery Drain Indicator - Step 12.
6.
Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms present on red jumper wire from ENGINE START/ENGINE STOP switch to ENGINE OFF/BATTERY DRAIN indicator? DECISION No - Repair or replace red jumper wire between ENGINE START/ENGINE STOP switch and ENGINE DRAIN indicator. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 13. (Step 13 - Are less than 200 ohms present on orange/black wire from ENGINE START/ ENGINE STOP switch to interconnect terminal strip, terminal 6?) STEP 13
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0006
Are less than 200 ohms present on orange/black wire from ENGINE START/ENGINE STOP switch to interconnect terminal strip, terminal 6? 1. Connect red multimeter lead to orange/black wire at ENGINE START/ENGINE STOP switch.
RED JUMPER WIRES
ORANGE/BLACK WIRE
Figure 18. Engine Start/Engine Stop Switch Orange Wire - Step 13. 2. Connect black multimeter lead to interconnect terminal strip, terminal 6.
INSIDE OF CONTROL PANEL
15-AMP CIRCUIT BREAKER
20
15
10
10
10
EMERGENCY STOP SWITCH
15
15
20
20
POSITIVE TERMINAL STRIP
NEGATIVE TERMINAL STRIP
INTERCONNECT TERMINAL STRIP
Figure 19. Interconnect Terminal Strip, Terminal 6 - Step 13. 3. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms present on orange/black wire from ENGINE START/ENGINE STOP switch to interconnect terminal strip, terminal 6?
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DECISION No - Repair or replace orange/black wire between ENGINE START/ENGINE STOP switch and interconnect terminal strip, terminal 6. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 14. (Step 14 - Are less than 200 ohms present on black wire between interconnect terminal strip, terminal 6 and governor controller harness connector pin G2?) STEP 14 Are less than 200 ohms present on black wire between interconnect terminal strip, terminal 6 and governor controller harness connector pin G2? 1. Disconnect governor controller harness connector. (WP 0092) 2. Connect red multimeter lead to black wire at interconnect terminal strip, terminal 6.
20
15
10
10
10
15
15
20
20
Figure 20. Interconnect Terminal Strip - Step 14. 3. With the aid of an assistant, connect black multimeter lead to governor controller harness connector pin G2.
GOVERNOR CONTROLLER
GOVERNOR CONTROLLER HARNESS CONNECTOR A 3 2 1 E F K 3 2 1
Figure 21. Governor Controller Harness Connector Pin G2 - Step 14. 4. Note multimeter reading.
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CONDITION/INDICATION Are less than 200 ohms present on black wire between interconnect terminal strip, terminal 6 and governor controller harness connector pin G2? DECISION No - Repair or replace black wire between interconnect terminal strip, terminal 6 and governor controller harness connector pin G2. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Go to step 15. (Step 15 - Are less than 200 ohms present on blue wire from governor controller harness connect pin A2 to starter relay?) STEP 15 Are less than 200 ohms present on blue wire from governor controller harness connect pin A2 to starter relay? 1. Connect red multimeter lead to governor controller harness connector pin A2.
GOVERNOR CONTROLLER
Figure 22. Governor Controller Harness Connector Pin A2 - Step 15. 2. Connect black multimeter lead to blue wire at starter relay.
STARTER RELAY BLUE WIRE

Figure 23. Starter Relay Blue Wire - Step 15.
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3.
CONDITION/INDICATION Are less than 200 ohms present on blue wire from governor controller harness connect pin A2 to starter relay? DECISION No - Repair or replace blue wire between governor controller harness connector pin A2 and starter relay. (WP 0099) Verify problem is solved. (Step 16 - Does engine crank?) Yes - Replace ENGINE START/ENGINE STOP switch. (WP 0208) Verify problem is solved. (Step 16 - Does engine crank?) STEP 16 Does engine crank? 1. If disconnected, connect batteries. (WP 0085) 2. Attempt to start engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine crank? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0007
FIELD MAINTENANCE ENGINE CRANKS BUT DOES NOT START
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Batteries Servicing And Testing (WP 0082) Battery Replacement (WP 0086) Engine Injection Pump Replacement (WP 0117) Engine Timing Sensor And Cover Replacement (WP 0126) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) References (cont.) Fuel Line Replacement (WP 0172) Fuel Pump Replacement (WP 0173) Fuel/Water Separator And Filter Head Replacement (WP 0176) Governor Actuator Replacement (WP 0133) Open/Close Engine Access Cover (TM 5-3825-270-10) Starter Relay Replacement (WP 0138) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE CRANKS BUT DOES NOT START STEP 1 Does water distributor have sufficient fuel? Visually inspect inside fuel tank for presence of fuel. (TM 5-3825-270-10)
FUEL TANK
Figure 1. Fuel Tank - Step 1.
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CONDITION/INDICATION Does water distributor have sufficient fuel? DECISION No - Fill fuel tank with sufficient fuel to start engine. (TM 5-3825-270-10) Verify problem is solved. (Step 9 - Does engine start?) Yes - Go to step 2. (Step 2 - Does air filter restriction indicator indicate restriction?) STEP 2 Does air filter restriction indicator indicate restriction?
NOTE
Sight glass on air restriction gauge will be red in color if restriction is present. Visually inspect air filter restriction indicator.
AIR FILTER RESTRICTION INDICATOR
Figure 2. Air Filter Restriction Indicator - Step 2. CONDITION/INDICATION Does air filter restriction indicator indicate restriction? DECISION No - Go to step 3. (Step 3 - Is governor actuator harness connector properly connected to governor actuator and free of damage?) Yes - Check for and remove air restriction. Reset air restriction gauge after removal of debris. Verify problem is solved. (Step 9 - Does engine start?) STEP 3 Is governor actuator harness connector properly connected to governor actuator and free of damage? 1. Open rear engine access cover. (TM 5-3825-270-10) 2. Visually inspect governor actuator harness for damage.
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0007
GOVERNOR ACTUATOR
GOVERNOR ACTUATOR HARNESS
Figure 3. Governor Actuator Harness - Step 3. 3. Ensure governor actuator harness is properly connected to governor actuator. (WP 0133)
CONDITION/INDICATION Is governor actuator harness connector properly connected to governor actuator and free of damage? DECISION No - If disconnected, properly connect governor actuator harness connector to governor actuator. (WP 0133) If damaged, repair or replace governor actuator harness and/or connector. (WP 0099) Verify problem is solved. (Step 9 - Does engine start?) Yes - Go to step 4. (Step 4 - Is engine timing sensor harness connector properly connected to engine timing sensor?) STEP 4 Is engine timing sensor harness connector properly connected to engine timing sensor? Ensure engine timing sensor harness connector is properly connected to engine timing sensor. (WP 0126)
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0007
ENGINE TIMING SENSOR HARNESS CONNECTOR
ENGINE TIMING SENSOR HARNESS CONNECTOR
Figure 4. Engine Timing Sensor Harness Connector - Step 4. CONDITION/INDICATION Is engine timing sensor harness connector properly connected to engine timing sensor? DECISION No - Properly connect engine timing sensor harness connector to engine timing sensor. (WP 0126) Verify problem is solved. (Step 9 - Does engine start?) Yes - Go to step 5. (Step 5 - Are fuel system components free from leaks and damage?) STEP 5 Are fuel system components free from leaks and damage? Visually inspect the following fuel system components for damage and leakage. (WP 0069) Fuel lines and fittings Fuel pump, lines, and fittings Fuel/water separator, lines, and fittings Engine injector pump, lines, and fittings
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ENGINE INJECTOR PUMP
FUEL/WATER SEPARATOR FUEL PUMP
FUEL LINES
Figure 5. Fuel System Components - Step 5. CONDITION/INDICATION Are fuel system components free from leaks and damage? DECISION No - If damaged, repair or replace fuel lines or fittings (WP 0172), fuel pump (WP 0173), engine injector pump (WP 0117), or fuel/water separator filter. (WP 0177) Verify problem is solved. (Step 9 - Does engine start?) Yes - Go to step 6. (Step 6 - Are flatrack fuel lines free from damage and leakage?) STEP 6 Are flatrack fuel lines free from damage and leakage? Visually inspect flatrack fuel lines.
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FLATRACK FUEL LINES
(WATER TANK NOT SHOWN FOR CLARITY)

Figure 6. Flatrack Fuel Lines - Step 6.
CONDITION/INDICATION Are flatrack fuel lines free from damage and leakage? DECISION No - Replace flatrack fuel line(s). (WP 0172) Verify problem is solved. (Step 9 - Does engine start?) Yes - Go to step 7. (Step 7 - Is fuel pressurized at fuel supply hose on engine injection pump?) STEP 7 Is fuel pressurized at fuel supply hose on engine injection pump? 1. Place container suitable for holding fuel beneath engine.
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 2. Disconnect fuel supply hose from engine injection pump banjo-fitting.
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ENGINE INJECTION PUMP BANJO-FITTING
Figure 7. Engine Injection Pump Banjo-Fitting - Step 7. 3. 4. Hold and direct fuel supply hose into container suitable to hold fuel. With the aid of an assistant, move ENGINE START/ENGINE STOP switch to ENGINE START position and hold.
Figure 8. Engine Start/Engine Stop Switch - Step 7.
NOTE
Fuel supply at fuel injection pump is normally pressurized. 5. 6. Visually observe fuel stream to verify if fuel supply is pressurized. Release ENGINE START/ENGINE STOP switch.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on engine injection pump?
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DECISION No - Go to step 8. (Step 8 - Is fuel pressurized at fuel supply hose on fuel/water separator?) Yes - Replace engine injection pump. (WP 0117) Verify problem is solved. (Step 9 - Does engine start?) STEP 8 Is fuel pressurized at fuel supply hose on fuel/water separator? 1. Reconnect fuel supply hose to engine injection pump banjo-fitting.
Figure 9. Engine Injector Pump Banjo-Fitting - Step 8.
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 2. Disconnect fuel supply hose from fuel/water separator.
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FUEL/WATER SEPARATOR
FUEL SUPPLY HOSE
Figure 10. Fuel/Water Separator Supply Line - Step 8. 3. 4. Hold and direct fuel supply hose into container suitable to hold fuel. With the aid of an assistant, move ENGINE START/ENGINE STOP switch to ENGINE START position and hold.
NOTE
Fuel supply line at fuel/water separator is normally pressurized.
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5. 6.
Visually observe fuel stream to verify if fuel supply is pressurized. Release ENGINE START/ENGINE STOP switch.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on fuel/water separator? DECISION No - Replace fuel pump. (WP 0173) Verify problem is solved. (Step 9 - Does engine start?) Yes - Replace fuel/water separator filter. (WP 0177) Verify problem is solved. (Step 9 - Does engine start?) STEP 9 Does engine start? Attempt to start engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine start? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0008
FIELD MAINTENANCE EXCESSIVELY LONG CRANK TIMES
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Multimeter (WP 0225, Table 1, Item 4) Personnel Required Construction Equipment Repairer 91L (2) References Air Cleaner Assembly Repair (WP 0170) Batteries Servicing And Testing (WP 0082) Battery Replacement (WP 0086) Engine Injection Pump Replacement (WP 0117) References (cont.) Engine Nozzle Assembly Holder (Injection Nozzle) Replacement (WP 0120) Fuel Line Replacement (WP 0172) Fuel Pump Replacement (WP 0173) Fuel/Water Separator And Filter Head Replacement (WP 0176) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE EXCESSIVELY LONG CRANK TIMES STEP 1 Is ambient air below 32F (0C)?
NOTE
The water distributor is equipped with engine glow plugs to help warm the engine for starting. If the ambient temperature is or has recently been approximately 32F (0C), multiple attempts at starting the engine may be necessary. Note recent and current ambient temperature. CONDITION/INDICATION Is ambient air below 32F (0C)? DECISION No - Go to step 2. (Step 2 - Has water distributor been started recently?) Yes - Do not operate. Store water distributor (TM 5-3825-270-10), and resume operation when temperature reaches 33F (0.5C) or more. STEP 2 Has water distributor been started recently?
CAUTION
Continuous cranking of water distributor engine can cause starter to overheat. If water distributor engine does not start after 10 seconds, release ENGINE START/ENGINE STOP switch and allow starter to cool for one minute before additional starting attempts. Failure to comply may result in damage to equipment.
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0008
Verify if water distributor has been started recently (within past 30 days). CONDITION/INDICATION Has water distributor been started recently? DECISION No - Attempt to start engine by holding ENGINE START/ENGINE STOP switch to ENGINE START position for no longer than 10 seconds at a time. (TM 5-3825-270-10) If engine starts and continues to start normally thereafter, problem is solved. If problem persists, go to test 3. (Step 3 - Are water distributor batteries at 70% or more of full charge?) (Step 2 - Has water distributor been started recently?) Yes - Go to step 3. (Step 3 - Are water distributor batteries at 70% or more of full charge?) STEP 3 Are water distributor batteries at 70% or more of full charge?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) Open battery box cover. (TM 5-3825-270-10) Set multimeter to measure voltage.
NOTE
Water distributor is equipped with two, 12-volt batteries connected in series. Multimeter measurements must be made from correct battery terminals to obtain 24 volt measurements. 4. 5. Connect red multimeter probe to positive battery terminal. Connect black multimeter probe to negative battery terminal.
POSITIVE BATTERY TERMINAL NEGATIVE BATTERY TERMINAL
Figure 1. Battery Terminals - Step 3.
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0008
NOTE
The following chart describes battery voltage characteristics when measured with a multimeter. This chart can be used to further isolate and troubleshoot batteries that may be cause of problem. 6. Note and compare multimeter reading to chart. Table 1. Battery State Of Charge Voltage Table. Percentage Of Full Charge 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 12 Volt DC System 12.7 12.6 12.5 12.3 12.2 12.1 12.0 11.8 11.7 11.6 <=11.6 24 Volt DC System 25.4 25.2 25 24.6 24.4 24.2 24 23.6 23.4 23.2 <=23.2
CONDITION/INDICATION Are water distributor batteries at 70% or more of full charge? DECISION No - Service (WP 0082), or replace batteries. (WP 0086) Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) Yes - Go to step 4. (Step 4 - Does air filter restriction indicator indicate restriction?) STEP 4 Does air filter restriction indicator indicate restriction?
NOTE
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Figure 2. Air Filter Restriction Indicator - Step 4. CONDITION/INDICATION Does air filter restriction indicator indicate restriction? DECISION No - Go to step 5. (Step 5 - Is air filter clean and serviceable?) Yes - Check for and remove air restriction. Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) STEP 5 Is air filter clean and serviceable? 1. Remove air filter. (WP 0170) 2. Visually inspect air filter for cleanliness and serviceability.
AIR CLEANER
AIR FILTER
Figure 3. Air Filter - Step 5.
CONDITION/INDICATION Is air filter clean and serviceable? DECISION No - Clean or replace air filter. (WP 0170) Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) Yes - Go to step 6. (Step 6 - Are fuel system components free from leaks and damage?) STEP 6
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0008
Are fuel system components free from leaks and damage? Visually inspect the following fuel system components for damage and leakage. (WP 0069) Fuel lines and fittings Fuel pump, lines, and fittings Fuel/water separator, lines, and fittings Engine injector pump, lines, and fittings
FUEL LINES
Figure 4. Fuel System Components - Step 6. CONDITION/INDICATION Are fuel system components free from leaks and damage? DECISION No - If damaged, repair or replace fuel lines or fittings (WP 0172), fuel pump (WP 0173), or fuel/water separator. (WP 0176) Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) Yes - Go to step 7. (Step 7 - Is fuel pressurized at fuel supply hose on engine injection pump banjo-fitting?) STEP 7 Is fuel pressurized at fuel supply hose on engine injection pump banjo-fitting? 1. Place container suitable for holding fuel beneath engine.
WARNING
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Figure 5. Engine Injection Pump Banjo Fitting - Step 7. 3. 4. 5. Hold and direct fuel supply hose into container suitable to hold fuel. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) With the aid of an assistant, move ENGINE START/ENGINE STOP switch to ENGINE START position and hold.
NOTE
Fuel supply pressure at fuel injection pump is approximately 8 to 12 psi (55 to 83 kPa). 6. 7. Visually observe fuel stream to verify if fuel supply is pressurized. Release ENGINE START/ENGINE STOP switch.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on engine injection pump banjo-fitting?
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0008
DECISION No - Go to step 8. (Step 8 - Is fuel pressurized at fuel supply hose on fuel/water separator?) Yes - Replace engine injection pump. (WP 0117) Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) STEP 8 Is fuel pressurized at fuel supply hose on fuel/water separator? 1. Reconnect fuel supply hose to engine injection pump banjo-fitting.
Figure 7. Engine Injection Pump Banjo Fitting - Step 8.
WARNING
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FUEL SUPPLY HOSE
NOTE
Fuel supply pressure at fuel injection pump is approximately 8 to 12 psi (55 to 83 kPa).
0008-8
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0008
5. 6.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on fuel/water separator? DECISION No - Reconnect fuel supply hose to fuel/water separator (WP 0176) and replace fuel pump. (WP 0173) Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) Yes - Replace fuel/water separator. (WP 0176) Verify problem is solved. (Step 9 - Is engine crank time normal during engine starts?) STEP 9 Is engine crank time normal during engine starts? Start engine while observing crank time. (TM 5-3825-270-10) CONDITION/INDICATION Is engine crank time normal during engine starts? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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TM 5-3825-270-23&P
0009
FIELD MAINTENANCE ENGINE STALLS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Air Cleaner Assembly Repair (WP 0170) Battery Replacement (WP 0086) Batteries Servicing And Testing (WP 0082) Engine Off/Battery Drain Light Illuminates (WP 0032) Engine Overheats (WP 0015) Engine Injection Pump Assembly Replacement (WP 0117) Engine Injection Nozzle Tubes Replacement (WP 0118) References (cont.) Engine Nozzle Assembly Holder (Injection Nozzle) Replacement (WP 0120) Engine Oil Pressure Gauge Reads Low (WP 0033) Fuel Line Replacement (WP 0172) Fuel Pump Replacement (WP 0173) Fuel Tank Drain/Fill (WP 0174) Fuel/Water Separator And Filter Head Replacement (WP 0176) Open/Close Engine Access Cover (TM 5-3825-270-10) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE STALLS STEP 1 Does water distributor have sufficient fuel? Visually inspect inside fuel tank for presence of fuel. (TM 5-3825-270-10)
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FUEL TANK
Figure 1. Fuel Tank - Step 1. CONDITION/INDICATION Does water distributor have sufficient fuel? DECISION No - Fill with sufficient fuel to start engine. (TM 5-3825-270-10) Verify problem is solved. (Step 9 - Does engine run normally?) Yes - Go to step 2. (Step 2 - Does engine oil pressure reach and/or maintain 8 psi (55 kPa) or greater at engine start up?) STEP 2 Does engine oil pressure reach and/or maintain 8 psi (55 kPa) or greater at engine start up?
NOTE
Water distributor is equipped with engine protection functions. If engine oil pressure is 7 psi (48 KPa) or less at idle speed or falls below 20 psi (140 kPa) at rated speed, the electronic governor controller will command engine to shut down. 1. Observe OIL PRESSURE gauge while starting engine.
ENGINE OIL PRESSURE GAUGE
Figure 2. Engine Oil Pressure Gauge - Step 2.
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2.
If engine does not stall immediately, monitor engine oil pressure for approximately one minute while continuing with troubleshooting.
CONDITION/INDICATION Does engine oil pressure reach and/or maintain 8 psi (55 kPa) or greater at engine start up? DECISION No - Go to Engine Oil Pressure Gauge Reads Low. (WP 0033) Yes - Go to step 3. (Step 3 - Does WATER PUMP OUTLET gauge reach or exceed 150 psi (1,034 kPa) or greater?) STEP 3 Does WATER PUMP OUTLET gauge reach or exceed 150 psi (1,034 kPa) or greater?
NOTE
Water distributor is equipped with engine protection functions. If water pump outlet pressure exceeds 150 psi (1,034 kPa), the electronic governor controller will command engine to shut down. 1. 2. Raise engine speed to 2000 RPM. (TM 5-3825-270-10) Observe WATER PUMP OUTLET gauge.
WATER PUMP OUTLET GAUGE
Figure 3. Water Pump Outlet Gauge - Step 3. 3. If WATER PUMP OUTLET gauge does not reach or exceed 150 psi (1,034 kPa), do not shutdown engine. Continue with troubleshooting.
CONDITION/INDICATION Does WATER PUMP OUTLET gauge reach or exceed 150 psi (1,034 kPa) or greater? DECISION No - Go to step 4. (Step 4 - Does ENGINE TEMP gauge read 230F (99C) or higher?) Yes - Shutdown engine. (TM 5-3825-270-10) Go to Excessive Water Pressure. STEP 4 Does ENGINE TEMP gauge read 230F (99C) or higher?
NOTE
Water distributor is equipped with engine protection functions. If engine coolant temperature exceeds 230F (99C), the electronic governor controller will command engine to shut down.
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0009
Observe ENGINE TEMP gauge.
ENGINE TEMP GAUGE
Figure 4. Engine Temp Gauge - Step 4.
CONDITION/INDICATION Does ENGINE TEMP gauge read 230F (99C) or higher? DECISION No - Go to step 5. (Step 5 - Does air filter restriction indicator indicate restriction?) Yes - Go to Engine Overheats troubleshooting procedure. (WP 0015) STEP 5 Does air filter restriction indicator indicate restriction?
NOTE
Figure 5. Air Filter Restriction Indicator - Step 5. CONDITION/INDICATION Does air filter restriction indicator indicate restriction?
0009-4
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0009
DECISION No - Go to step 6. (Step 6 - Are fuel system components free from leaks and damage?) Yes - Ensure air filter is clean and serviceable and check for air restrictions. After removal of restriction and/or cleaning of air filter, reset air restriction indicator. Verify problem is solved. (Step 9 - Does engine run normally?) STEP 6 Are fuel system components free from leaks and damage? 1. Remove rear engine access cover. (TM 5-3825-270-10) 2. Visually inspect the following fuel system components for damage and leakage. (WP 0069) Fuel lines and fittings Fuel pump, lines, and fittings Fuel/water separator, lines, and fittings Engine injector pump, lines, and fittings
FUEL LINES
Figure 6. Fuel System Components - Step 6. CONDITION/INDICATION Are fuel system components free from leaks and damage? DECISION No - If damaged, repair or replace fuel lines or fittings (WP 0172), fuel pump (WP 0173), engine injector pump (WP 0117), or fuel/water separator. (WP 0176) Verify problem is solved. (Step 9 - Does engine run normally?) Yes - Go to step 7. (Step 7 - Is fuel pressurized at fuel supply hose on engine injection pump?) STEP 7 Is fuel pressurized at fuel supply hose on engine injection pump?
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system
0009-5
TM 5-3825-270-23&P
0009
when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 1. 2. 3. Shutdown engine. (TM 5-3825-270-10) Place container suitable for holding fuel beneath engine. Disconnect fuel supply hose from engine injection pump banjo-fitting.
Figure 7. Engine Injection Pump Banjo-Fitting - Step 7. 4. 5. Hold and direct fuel supply hose into container suitable to hold fuel. With the aid of an assistant, move ENGINE START/STOP switch to ENGINE START position and hold.
Figure 8. Engine Start/Stop Switch - Step 7.
NOTE
Fuel supply at fuel injection pump is normally pressurized. 6. 7. Visually observe fuel stream to verify if fuel supply is pressurized. Release ENGINE START/STOP switch.
0009-6
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0009
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on engine injection pump? DECISION No - Go to step 8. (Step 8 - Is fuel pressurized at fuel supply hose on fuel/water separator?) Yes - Replace engine injection pump. (WP 0117) Verify problem is solved. (Step 9 - Does engine run normally?) STEP 8 Is fuel pressurized at fuel supply hose on fuel/water separator? 1. Reconnect fuel supply hose to engine injection pump banjo-fitting.
Figure 9. Engine Injection Pump Banjo-Fitting - Step 8.
WARNING
0009-7
TM 5-3825-270-23&P
0009
FUEL SUPPLY HOSE
NOTE
0009-8
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0009
5. 6.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on fuel/water separator? DECISION No - Reconnect fuel supply hose to fuel/water separator (WP 0176) and replace fuel pump. (WP 0173) Verify problem is solved. (Step 9 - Does engine run normally?) Yes - Replace fuel/water separator filter. (WP 0177) Verify problem is solved. (Step 9 - Does engine run normally?) STEP 9 Does engine run normally? Start engine and observe engine performance. (TM 5-3825-270-10) CONDITION/INDICATION Does engine run normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
0009-9/10 blank
TM 5-3825-270-23&P
0010
FIELD MAINTENANCE ENGINE SURGES
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References Air Cleaner Assembly Replacement (WP 0170) Engine Injector Tubes Replacement Fuel Line Replacement (WP 0172) Fuel Pump Replacement (WP 0173) References (cont.) Fuel/Water Separator And Filter Head Replacement (WP 0176) Open/Close Engine Access Cover (TM 5-3825-270-10) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE SURGES STEP 1 Does air filter restriction indicator indicate restriction?
NOTE
0010-1
TM 5-3825-270-23&P
0010
DECISION No - Go to step 2. (Step 2 - Is air filter clean and serviceable?) Yes - Remove air filter restrictions and clean air filter. After removal of restriction and cleaning of air filter, reset air restriction indicator. Verify problem is solved. (Step 7 - Does engine run normally?) STEP 2 Is air filter clean and serviceable? 1. Remove air filter. (WP 0170) 2. Visually inspect air filter for cleanliness and serviceability.
AIR CLEANER
AIR FILTER
Figure 2. Air Filter And Air Cleaner - Step 2.
CONDITION/INDICATION Is air filter clean and serviceable? DECISION No - Clean or replace air filter. (WP 0170) Verify problem is solved. (Step 7 - Does engine run normally?) Yes - Go to step 3. (Step 3 - Are fuel lines free from restriction and leakage?) STEP 3 Are fuel lines free from restriction and leakage? Visually inspect fuel lines for restrictions and leakage.
0010-2
TM 5-3825-270-23&P
0010
FLATRACK FUEL LINES

Figure 3. Fuel Lines - Step 3.
CONDITION/INDICATION Are fuel lines free from restriction and leakage? DECISION No - Resolve restriction problem and/or replace fuel lines. (WP 0172) Verify problem is solved. (Step 7 - Does engine run normally?) Yes - Go to step 4. (Step 4 - Are fuel system components free from leaks and damage?) STEP 4 Are fuel system components free from leaks and damage? 1. Remove rear engine access cover. (TM 5-3825-270-10) 2. Start engine. (TM 5-3825-270-10) 3. Visually inspect the following fuel system components for damage and leakage. (WP 0069) Fuel lines and fittings Fuel pump, lines, and fittings Fuel/water separator, lines, and fittings Engine injector pump, lines, and fittings
0010-3
TM 5-3825-270-23&P
0010
FUEL LINES
4.
Figure 4. Fuel System Components - Step 4. Shutdown engine. (TM 5-3825-270-10) (WP 0221)
CONDITION/INDICATION Are fuel system components free from leaks and damage? DECISION No - If damaged, repair or replace fuel lines or fittings (WP 0172), fuel pump (WP 0173), engine injector pump (WP 0117), or fuel/water separator. (WP 0176) Verify problem is solved. (Step 7 - Does engine run normally?) Yes - Go to step 5. (Step 5 - Is fuel pressurized at fuel supply hose on engine injection pump?) STEP 5 Is fuel pressurized at fuel supply hose on engine injection pump? 1. Place container suitable for holding fuel beneath engine.
WARNING
0010-4
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0010
NOTE
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on engine injection pump?
0010-5
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0010
DECISION No - Go to step 6. (Step 6 - Is fuel pressurized at fuel supply hose on fuel/water separator?) Yes - Replace engine injection pump. (WP 0117) Verify problem is solved. (Step 7 - Does engine run normally?) STEP 6 Is fuel pressurized at fuel supply hose on fuel/water separator? 1. Reconnect fuel supply hose to engine injection pump banjo-fitting.
WARNING
0010-6
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0010
FUEL SUPPLY HOSE
NOTE
0010-7
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0010
5. 6. 7.
Visually observe fuel stream to verify if fuel supply is pressurized. Release ENGINE START/ENGINE STOP switch. Reconnect fuel supply hose at fuel/water separator.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on fuel/water separator? DECISION No - Reconnect fuel supply hose to fuel/water separator (WP 0176) and replace fuel pump. (WP 0173) Verify problem is solved. (Step 7 - Does engine run normally?) Yes - Replace fuel/water separator filter. (WP 0177) Verify problem is solved. (Step 7 - Does engine run normally?) STEP 7 Does engine run normally? Start engine and observe engine performance. (TM 5-3825-270-10) CONDITION/INDICATION Does engine run normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
0010-8
TM 5-3825-270-23&P
0011
FIELD MAINTENANCE ENGINE MISFIRES
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Engine Injection Pump Replacement (WP 0117) Engine Injection Tubes Replacement (WP 0118) Engine Nozzle Assembly Holder (Injection Nozzle) Replacement (WP 0119) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) References (cont.) Fuel Line Replacement (WP 0172) Fuel Pump Replacement (WP 0173) Fuel/Water Separator And Filter Head Replacement (WP 0176) Open/Close Engine Access Cover (TM 5-3825-270-10) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE MISFIRES STEP 1 Is engine operation normal after draining fuel/water separator? 1. Drain fuel/water separator. (TM 5-3825-270-10) 2. Operate engine while observing engine performance. (TM 5-3825-270-10) CONDITION/INDICATION Is engine operation normal after draining fuel/water separator? DECISION No - Go to step 2. (Step 2 - Is engine operation normal after bleeding fuel system?) Yes - Problem solved. STEP 2 Is engine operation normal after bleeding fuel system? 1. Remove rear engine access cover. (TM 5-3825-270-10) 2. Place drain pan suitable for holding fuel beneath engine.
WARNING
Diesel fuel is flammable. Do not perform this procedure near fire, flame or sparks. Failure to comply may result in injury or death to personnel.
0011-1
TM 5-3825-270-23&P
0011
3.
Open air vent cock on top of injection pump.
AIR VENT COCK
Figure 1. Air Vent Cock - Step 2. 4. 5. With the aid of an assistant, start engine. (TM 5-3825-270-10) With engine running, loosen engine injection pump banjo-fitting in 1/2 turn increments until fuel begins to leak out of fitting in a steady flow.
Figure 2. Engine Injection Pump Banjo-Fitting - Step 2. 6. 7. 8. 9. 10. For a minimum of 30 seconds, visually inspect fuel stream for disrupted flow indicating air pockets. If fuel stream is consistent and air pockets are not suspected, tighten engine injection pump banjo-fitting and air vent cock. If air pockets are suspected, allow fuel to continue to drain until fuel stream is constant and free from air pockets. When fuel stream is consistent and no signs of air pockets are present, tighten engine injection pump banjofitting. Close air vent cock.
0011-2
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0011
AIR VENT COCK
Figure 3. Air Vent Cock (Close) - Step 2. 11. Operate engine while observing engine performance. (TM 5-3825-270-10)
CONDITION/INDICATION Is engine operation normal after bleeding fuel system? DECISION No - Go to step 3. (Step 3 - Are fuel system components free from leaks and damage?) Yes - Problem solved. STEP 3 Are fuel system components free from leaks and damage? Visually inspect the following fuel system components for damage and leakage. (WP 0069) Fuel lines and fittings Fuel pump, lines, and fittings Fuel/water separator, lines, and fittings Engine injector pump, lines, and fittings
FUEL LINES
Figure 4. Fuel System Components - Step 3.
0011-3
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0011
CONDITION/INDICATION Are fuel system components free from leaks and damage? DECISION No - If damaged, repair or replace fuel lines or fittings (WP 0172), fuel pump (WP 0173), engine injector pump (WP 0117), or fuel/water separator. (WP 0176) Verify problem is solved. (Step 6 - Does engine run normally?) Yes - Go to step 4. (Step 4 - Is fuel pressurized at fuel supply hose on engine injection pump banjo-fitting?) STEP 4 Is fuel pressurized at fuel supply hose on engine injection pump banjo-fitting? 1. Shutdown engine. (TM 5-3825-270-10)
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open fire and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 2. 3. Place container suitable for holding fuel beneath engine. Disconnect fuel supply hose from engine injection pump banjo-fitting.
0011-4
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0011
NOTE
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on engine injection pump banjo-fitting? DECISION No - Go to step 5. (Step 5 - Is fuel pressurized at fuel supply hose on water separator?) Yes - Replace engine injection pump. (WP 0117) Verify problem is solved. (Step 6 - Does engine run normally?) STEP 5 Is fuel pressurized at fuel supply hose on water separator? Reconnect fuel supply hose to engine injection pump banjo-fitting. 1.
0011-5
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0011
WARNING
0011-6
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0011
FUEL SUPPLY HOSE
Figure 9. Engine Start Switch - Step 5.
NOTE
0011-7
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0011
5. 6.
CONDITION/INDICATION Is fuel pressurized at fuel supply hose on water separator? DECISION No - Replace fuel pump. (WP 0173) Verify problem is solved. (Step 6 - Does engine run normally?) Yes - Replace fuel/water separator filter. (WP 0177) Verify problem is solved. (Step 6 - Does engine run normally?) STEP 6 Does engine run normally? Start engine and observe engine performance. (TM 5-3825-270-10) CONDITION/INDICATION Does engine run normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
0011-8
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0012
FIELD MAINTENANCE ENGINE WILL NOT INCREASE RPM
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) Open/Close Engine Access Cover (TM 5-3825-270-10) Main Control Panel Engine Speed RPM Switch Replacement (WP 0095) References (cont.) Engine Wire Harness Replacement (WP 0098) General Wire Harness Replacement (WP 0099) Governor Control Module Replacement (WP 0092) Governor Actuator Module Replacement (WP 0133) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE WILL NOT INCREASE RPM STEP 1 Is problem with engine speed present when using main control panel? 1. Start engine. (TM 5-3825-270-10) 2. Using main control panel, attempt to increase engine speed with engine speed RPM switch. (TM 5-3825-270-10)
ENGINE SPEED RPM SWITCH
Figure 1. Engine Speed RPM Switch - Step 1. 3. 4. Observe engine performance. Shutdown engine. (TM 5-3825-270-10)
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0012
CONDITION/INDICATION Is problem with engine speed present when using main control panel? DECISION No - Cab control box or universal power interface kit (UPIK) harness may be faulty. Go to Cab Control Box Engine Speed RPM Switch Does Not Operate. (WP 0061) Yes - Go to step 2. (Step 2 - Are less than 200 ohms measured from red/white wire at engine speed RPM switch to governor controller harness connector pin E1?) STEP 2 Are less than 200 ohms measured from red/white wire at engine speed RPM switch to governor controller harness connector pin E1?
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. Disconnect batteries. (WP 0085) Remove rear engine access cover. (TM 5-3825-270-10) Disconnect governor controller harness connector. (WP 0092)
CAUTION
Ensure to support weight of control panel faceplate when lowering for troubleshooting/ maintenance purposes. Failure to comply may result in damage to equipment. 4. Remove six control panel faceplate screws.
0012-2
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0012
Figure 2. Control Panel Faceplate Screws - Step 2. 5. 6. Set multimeter to measure continuity. Connect red multimeter probe to red/white wire at engine speed RPM switch.
RED/GREEN WIRE RED JUMPER WIRE ENGINE SPEED RPM SWITCH BACK OF CONTROL PANEL
RED/WHITE WIRE
Figure 3. RPM Switch Red/White Wire - Step 2. 7. With the aid of an assistant, connect black multimeter probe to governor controller harness connector pin E1.
0012-3
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0012
GOVERNOR CONTROLLER
Figure 4. Governor Controller Harness Connector Pin E1 - Step 2. 8. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from red/white wire at engine speed RPM switch to governor controller harness connector pin E1? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured from red/white wire at engine speed RPM switch to interconnect terminal strip, terminal 4?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured across engine speed RPM switch terminals 1 and 2, while switch is in '+' position?) STEP 3 Are less than 200 ohms measured across engine speed RPM switch terminals 1 and 2, while switch is in '+' position? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to engine speed RPM switch, terminal 1.
TERMINAL 1 TERMINAL 2 TERMINAL 3
BACK OF RPM SWITCH
Figure 5. Engine Speed RPM Switch Terminal 1 - Step 3. 3. 4. 5. 6. Connect black multimeter probe to engine speed RPM switch, terminal 2. Place engine speed RPM switch to '+' position and hold. Note multimeter reading. Release engine speed RPM switch.
CONDITION/INDICATION Are less than 200 ohms measured across engine speed RPM switch terminals 1 and 2, while switch is in '+' position?
0012-4
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0012
DECISION No - Replace engine speed RPM switch. (WP 0095) Verify problem is solved. (Step 7 - Does engine increase RPM normally?) Yes - Go to step 4. (Step 4 - Is wiring between governor controller and governor actuator free of damage and connected properly?) STEP 4 Is wiring between governor controller and governor actuator free of damage and connected properly? 1. Remove front engine access cover. (TM 5-3825-270-10) 2. Visually inspect wiring between governor controller and governor actuator to ensure wiring is connected properly and free of damage.
GOVERNOR ACTUATOR HARNESS
GOVERNOR ACTUATOR
Figure 6. Governor Actuator Harness - Step 4. CONDITION/INDICATION Is wiring between governor controller and governor actuator free of damage and connected properly? DECISION No - Properly connect harness connector and/or replace wiring between governor controller and governor actuator. (WP 0132) Verify problem is solved. (Step 7 - Does engine increase RPM normally?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to test 1. (Step 1 - Is problem with engine speed present when using main control panel?) If problem still exists after all troubleshooting test have been accomplished, replace governor controller. (WP 0092) STEP 5 Are less than 200 ohms measured from red/white wire at engine speed RPM switch to interconnect terminal strip, terminal 4? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red/white wire at engine speed RPM switch.
0012-5
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0012
RED/GREEN WIRE RED JUMPER WIRE
BACK OF CONTROL PANEL ENGINE SPEED RPM SWITCH
RED/WHITE WIRE
Figure 7. RPM Switch Red/White Wire - Step 5. 3. Connect black multimeter probe to terminal 4 at interconnect terminal strip.
20
15
10
10
10
15
15
20
20
Figure 8. Interconnect Terminal Strip - Step 5. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from red/white wire at engine speed RPM switch to interconnect terminal strip, terminal 4? DECISION No - Ensure wire is correctly seated in terminal post. If wiring is correctly seated in terminal, repair or replace red/white wire from interconnect terminal strip to engine speed RPM switch. (WP 0099) Verify problem is solved. (Step 7 - Does engine increase RPM normally?) Yes - Go to step 6. (Step 6 - Are less than 200 ohms measured on black wire from interconnect terminal strip, terminal 4 to governor controller harness connector, pin E1?) STEP 6
0012-6
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0012
Are less than 200 ohms measured on black wire from interconnect terminal strip, terminal 4 to governor controller harness connector, pin E1? 1. Connect red multimeter probe to terminal 4 at interconnect terminal strip.
20
15
10
10
10
15
15
20
20
Figure 9. Interconnect Terminal Strip - Step 6. 2. Connect black multimeter probe to governor controller harness connector pin E1.
GOVERNOR CONTROLLER
Figure 10. Governor Controller Harness Connector Pin E1 - Step 6. 3. 4. Note multimeter reading. Connect governor controller harness to governor controller. (WP 0092)
CONDITION/INDICATION Are less than 200 ohms measured on black wire from interconnect terminal strip, terminal 4 to governor controller harness connector, pin E1?
0012-7
TM 5-3825-270-23&P
0012
DECISION No - Ensure wire is correctly seated in terminal post. If wiring is correctly seated in terminal, repair or replace black wire from terminal strip, terminal 4 to governor controller harness connector pin E1. (WP 0099) Verify problem is solved. (Step 7 - Does engine increase RPM normally?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to test 1. (Step 1 - Is problem with engine speed present when using main control panel?) If problem still exists after all troubleshooting test have been accomplished, replace governor controller. (WP 0092) STEP 7 Does engine increase RPM normally? Start engine and attempt to increase engine RPM while observing engine performance. (TM 5-3825-270-10) CONDITION/INDICATION Does engine increase RPM normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
0012-8
TM 5-3825-270-23&P
0013
FIELD MAINTENANCE EXCESSIVE ENGINE VIBRATION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Alternator Belt Adjustment (WP 0079) Water Pump And Housing Replacement (WP 0071) Water Fan Replacement (WP 0072) Engine Compartment Cover Replacement (WP 0142) Engine Crankshaft Shaft Front Seal Replacement (WP 0111) Engine Surges (WP 0010) References (cont.) Engine Misfires (WP 0011) Front Engine Mount Bracket Replacement (WP 0130) Open/Close Engine Access Cover (TM 5-3825-270-10) Rear Engine Mount Bracket And Bushing Replacement (WP 0135) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE EXCESSIVE ENGINE VIBRATION STEP 1 Does engine surge or misfire? 1. Remove front and rear engine access covers. (TM 5-3825-270-10) 2. Start engine. (TM 5-3825-270-10) 3. Monitor engine performance for surges and misfires. 4. Do not shutdown engine if engine does not surge or misfire. CONDITION/INDICATION Does engine surge or misfire? DECISION No - Go to step 2. (Step 2 - Is alternator belt tight and free of damage?) Yes - If engine surges, go to Engine Surges (WP 0010), or if engine misfires, go to Engine Misfires. (WP 0011) STEP 2 Is alternator belt tight and free of damage?
WARNING
Stay clear of moving engine components while working in or near engine bay with engine running. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. Shutdown engine. (TM 5-3825-270-10) Remove engine compartment cover. (WP 0142) Check alternator belt for excessive play and other damage. (WP 0079) Start engine. (TM 5-3825-270-10) With engine running, visually inspect alternator belt for signs of loose fit.
0013-1
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0013
ALTERNATOR
ALTERNATOR BELT
Figure 1. Alternator Belt - Step 2. 6. 7. Shutdown engine. (TM 5-3825-270-10) Visually inspect alternator belt for damage.
COOLANT PUMP PULLEY ALTERNATOR BELT
Figure 2. Alternator Belt And Water Pump Pulley - Step 2.
CONDITION/INDICATION Is alternator belt tight and free of damage? DECISION No - Tighten and or replace alternator belt. (WP 0079) Verify problem is solved. (Step 5 - Does engine exhibit excessive vibration?) Yes - Go to step 3. (Step 3 - Are engine mounts and brackets free from damage and loose hardware?) STEP 3 Are engine mounts and brackets free from damage and loose hardware? Visually inspect engine mounts and brackets for damage and loose hardware.
0013-2
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0013
DRIVER SIDE FRONT PASSENGER SIDE FRONT DRIVER SIDE REAR PASSENGER SIDE REAR
Figure 3. Engine Mounts - Step 3. CONDITION/INDICATION Are engine mounts and brackets free from damage and loose hardware? DECISION No - Replace front engine mount/bracket(s) (WP 0130), and/or rear engine mount/bracket(s) if damaged. Verify problem is solved. (Step 5 - Does engine exhibit excessive vibration?) Yes - Go to step 4. (Step 4 - Is cooling fan free from missing and damaged fan blades?) STEP 4 Is cooling fan free from missing and damaged fan blades? Visually inspect engine fan for missing and damaged fan blades.
0013-3
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0013
COOLING FAN
COOLING FAN GUARD NOT SHOWN FOR CLARITY
Figure 4. Cooling Fan - Step 4.
CONDITION/INDICATION Is cooling fan free from missing and damaged fan blades? DECISION No - Replace cooling fan. (WP 0072) Verify problem is solved. (Step 5 - Does engine exhibit excessive vibration?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to test 1. (Step 1 - Does engine surge or misfire?) If problem still exists after all troubleshooting test have been accomplished, notify supervisor. STEP 5 Does engine exhibit excessive vibration? Start engine and check for excessive engine vibration. (TM 5-3825-270-10) CONDITION/INDICATION Does engine exhibit excessive vibration? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
0013-4
TM 5-3825-270-23&P
0014
FIELD MAINTENANCE EXCESSIVE ENGINE NOISE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Air Cleaner Assembly Repair (WP 0170) Alternator Belt Adjustment (WP 0079) Alternator Belt Replacement (WP 0080) Water Pump And Housing Replacement (WP 0071) Cooling Fan Replacement (WP 0072) Engine Compartment Cover Replacement (WP 0142) References (cont.) Exhaust Manifold Replacement (WP 0129) Engine Inlet Assembly Manifold Replacement (WP 0119) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE EXCESSIVE ENGINE NOISE STEP 1 Does engine have appropriate level of engine oil? Check engine oil level. (WP 0069) CONDITION/INDICATION Does engine have appropriate level of engine oil? DECISION No - Fill or drain engine to appropriate level. (WP 0069) Verify problem is solved. (Step 7 - Does engine exhibit excessive noise?) Yes - Go to step 2. (Step 2 - Is air cleaner assembly free of debris and obstructions that may cause excessive noise?) STEP 2 Is air cleaner assembly free of debris and obstructions that may cause excessive noise? 1. Remove air cleaner assembly. (WP 0170) 2. Remove air filter. (TM 5-3825-270-10) 3. Inspect air cleaner assembly for debris and obstructions that may cause excessive noise.
0014-1
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0014
AIR CLEANER
AIR FILTER
Figure 1. Air Cleaner And Air Filter - Step 2.
CONDITION/INDICATION Is air cleaner assembly free of debris and obstructions that may cause excessive noise? DECISION No - Remove air restriction. Reset air restriction gauge after removal of debris. Verify problem is solved. (Step 7 - Does engine exhibit excessive noise?) Yes - Go to step 3. (Step 3 - Is alternator belt tight and free of damage?) STEP 3 Is alternator belt tight and free of damage?
WARNING
Stay clear of moving engine components while working in or near engine bay with engine running. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. 6. 7. Remove engine compartment cover. (WP 0142) Check alternator belt for excessive play and other damage. (WP 0079) Install engine compartment cover. (WP 0142) Install air cleaner assembly. (WP 0170) Remove front and rear engine access covers. (TM 5-3825-270-10) Start engine. (TM 5-3825-270-10) Visually inspect alternator belt for signs of loose fit while engine is running.
0014-2
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0014
ALTERNATOR
ALTERNATOR BELT
Figure 2. Alternator Belt - Step 3. 8. Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Is alternator belt tight and free of damage? DECISION No - Tighten alternator belt (WP 0079) or replace alternator belt if damaged. (WP 0080) Verify problem is solved. (Step 7 - Does engine exhibit excessive noise?) Yes - Go to step 4. (Step 4 - Is engine inlet assembly manifold and surrounding area free from damage and leaks?) STEP 4 Is engine inlet assembly manifold and surrounding area free from damage and leaks?
WARNING
Engine components become hot during normal operation. Allow engine to cool completely prior to performing this task. If necessary, use insulated pads and gloves. Failure to comply may result in injury or death to personnel. 1. 2. Remove engine compartment cover. (WP 0142) Visually inspect engine inlet assembly manifold and surrounding area for damage and leaks.
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ENGINE INLET ASSEMBLY MANIFOLD
Figure 3. Engine Inlet Assembly Manifold - Step 4. CONDITION/INDICATION Is engine inlet assembly manifold and surrounding area free from damage and leaks? DECISION No - Replace engine inlet assembly manifold. (WP 0119) Verify problem is solved. (Step 7 - Does engine exhibit excessive noise?) Yes - Go to step 5. (Step 5 - Is exhaust manifold free from damage and leaks?) STEP 5 Is exhaust manifold free from damage and leaks? Visually inspect exhaust manifold for damage and leaks.
EXHAUST MANIFOLD
Figure 4. Exhaust Manifold - Step 5.
CONDITION/INDICATION Is exhaust manifold free from damage and leaks? DECISION No - Replace engine exhaust manifold and/or gasket. (WP 0129) Verify problem is solved. (Step 7 - Does engine exhibit excessive noise?) Yes - Go to step 6. (Step 6 - Is cooling fan free from missing and damaged fan blades?) STEP 6
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0014
Is cooling fan free from missing and damaged fan blades? Visually inspect engine fan for missing and damaged fan blades.
COOLING FAN
COOLING FAN GUARD NOT SHOWN FOR CLARITY
Figure 5. Cooling Fan - Step 6.
CONDITION/INDICATION Is cooling fan free from missing and damaged fan blades? DECISION No - Replace cooling fan. (WP 0072) Verify problem is solved. (Step 7 - Does engine exhibit excessive noise?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to test 1. (Step 1 - Does engine have appropriate level of engine oil?) If problem still exists after all troubleshooting test have been accomplished, notify supervisor. STEP 7 Does engine exhibit excessive noise? Start engine and check for excessive engine noise. (TM 5-3825-270-10) CONDITION/INDICATION Does engine exhibit excessive noise? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0015
FIELD MAINTENANCE ENGINE OVERHEATS
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Tester, Pressure Gage (WP 0225, Table 1, Item 11) References Alternator Belt Adjustment (WP 0079) Alternator Belt Replacement (WP 0080) Water Pump And Housing Replacement (WP 0071) Upper Cooling System Hose Replacement (WP 0073) Coolant System Servicing And Testing (WP 0074) Engine Compartment Cover Replacement (WP 0142) References (cont.) Engine Cylinder Head And Gasket Replacement (WP 0145) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Open/Close Engine Access Cover (TM 5-3825-270-10) Radiator And Bracket Replacement (WP 0076) Radiator Drain/Fill (WP 0075) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE OVERHEATS STEP 1 Is engine filled with adequate amount of coolant? Check engine coolant level. (TM 5-3825-270-10) CONDITION/INDICATION Is engine filled with adequate amount of coolant? DECISION No - Fill engine to appropriate level with coolant. (WP 0069) Verify problem is solved. (Step 8 - Does engine overheat?) Yes - Go to step 2. (Step 2 - Is alternator belt tight and fan rotation normal?) STEP 2 Is alternator belt tight and fan rotation normal?
WARNING
Stay clear of moving engine components while working in or near engine bay with engine running. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. Open front and rear engine access covers. (TM 5-3825-270-10) Check alternator belt for excessive play and other damage. (WP 0079) Start engine. (TM 5-3825-270-10) Visually inspect alternator belt for signs of loose fit while engine is running.
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0015
ALTERNATOR
ALTERNATOR BELT
Figure 1. Alternator Belt - Step 2.
NOTE
Water pump and cooling fan are mechanically linked through same pulley that is rotated by alternator belt. Abnormal cooling fan rotation due to loose alternator belt may also affect water pump rotation and cause overheating. 5. 6. Visually check fan operation for free-rotation (binding), adequate fan speed, and abnormal noise. Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Is alternator belt tight and fan rotation normal? DECISION No - Tighten alternator belt (WP 0079) or replace alternator belt if damaged. (WP 0080) Replace water pump/ cooling fan pulley if damaged or binding. (WP 0071) Verify problem is solved. (Step 8 - Does engine overheat?) Yes - Go to step 3. (Step 3 - Is engine oil at appropriate level and free of contamination?) STEP 3 Is engine oil at appropriate level and free of contamination?
WARNING
Engine components become hot during normal operation. Allow engine to cool completely prior to performing this task. If necessary, use insulated pads and gloves. Failure to comply may result in injury or death to personnel.
NOTE
Milky and/or abnormally smelling engine oil are signs of engine coolant contamination in engine oil. 1. 2. Check engine oil level. (WP 0069) Obtain engine oil sample and inspect for signs of contamination. (TM 5-3825-270-10)
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CONDITION/INDICATION Is engine oil at appropriate level and free of contamination? DECISION No - Replace engine cylinder head gasket. (WP 0145) Verify problem is solved. (Step 8 - Does engine overheat?) Yes - Go to step 4. (Step 4 - Are radiator and radiator cap free of leaks and damage?) STEP 4 Are radiator and radiator cap free of leaks and damage? Perform cooling system pressure test on radiator and radiator cap. (WP 0074) CONDITION/INDICATION Are radiator and radiator cap free of leaks and damage? DECISION No - Replace leaking radiator and/or radiator cap. (WP 0076) Verify problem is solved. (Step 8 - Does engine overheat?) Yes - Go to step 5. (Step 5 - Is engine free from coolant leaks?) STEP 5 Is engine free from coolant leaks? 1. Remove engine compartment cover. (WP 0142) 2. Visually inspect engine for coolant leaks. (WP 0069) CONDITION/INDICATION Is engine free from coolant leaks? DECISION No - Replace leaking cooling system hose (WP 0073) or water pump. (WP 0071) Verify problem is solved. (Step 8 - Does engine overheat?) Yes - Go to step 6. (Step 6 - Is exhaust white or have abnormal odor?) STEP 6 Is exhaust white or have abnormal odor? 1. Install engine compartment cover. (WP 0142) 2. Start engine and visually check for white exhaust. (TM 5-3825-270-10) 3. Smell engine exhaust for abnormal odor. 4. Shutdown engine. (TM 5-3825-270-10) CONDITION/INDICATION Is exhaust white or have abnormal odor? DECISION No - Go to step 7. (Step 7 - Is problem solved after flushing coolant system?) Yes - Replace engine cylinder head gasket. (WP 0145) Verify problem is solved. (Step 8 - Does engine overheat?) STEP 7
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Is problem solved after flushing coolant system?
WARNING
Engine components become hot during normal operation. Allow engine to cool completely prior to performing this task. If necessary, use insulated pads and gloves. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. 5. Drain cooling system. (WP 0075) Flush cooling system. (WP 0074) Fill cooling system. (WP 0075) Start engine. (TM 5-3825-270-10) Monitor ENGINE TEMP gauge and engine performance for overheating.
ENGINE TEMP GAUGE
Figure 2. Engine Temperature Gauge - Step 7. 6. Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Is problem solved after flushing coolant system? DECISION No - Replace water pump. (WP 0071) Verify problem is solved. (Step 8 - Does engine overheat?) Yes - Problem solved. STEP 8 Does engine overheat? 1. Start engine. (TM 5-3825-270-10) 2. Monitor ENGINE TEMP gauge and engine performance for overheating.
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ENGINE TEMP GAUGE
CONDITION/INDICATION Does engine overheat? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0016
FIELD MAINTENANCE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Main Control Panel Engine Temperature Gauge Replacement (WP 0097) Radiator Drain/Fill (WP 0075) References (cont.) Thermostat And Housing Replacement (WP 0140) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE STEP 1 Is radiator coolant circulating through radiator at engine startup?
WARNING
DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Wear effective eye, glove, and skin protection when handling coolants. Failure to comply may result in damage to equipment, death, or serious injury to personnel.
NOTE
Ensure engine has not been running for at least six hours to ensure engine cooling system is not pressurized. 1. Remove radiator cap. (WP 0075)
NOTE
Ensure not to run engine for more than 1 minute with radiator cap removed. 2. 3. 4. Start engine. (TM 5-3825-270-10) Visually inspect inside of radiator to check for coolant circulation. Shutdown engine. (TM 5-3825-270-10)
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CONDITION/INDICATION Is radiator coolant circulating through radiator at engine startup? DECISION No - Replace ENGINE TEMP gauge. (WP 0097) Verify problem is solved. (Step 2 - Does engine reach normal operating temperature?) Yes - Replace thermostat. (WP 0140) Verify problem is solved. (Step 2 - Does engine reach normal operating temperature?) STEP 2 Does engine reach normal operating temperature? 1. If removed, install radiator cap. (WP 0075) 2. Start engine. (TM 5-3825-270-10) 3. Run engine for 15 minutes and ensure ENGINE TEMP gauge reads normal operating temperature.
ENGINE TEMP GAUGE
CONDITION/INDICATION Does engine reach normal operating temperature? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0017
FIELD MAINTENANCE EXCESSIVE ENGINE OIL CONSUMPTION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Engine Compartment Cover Replacement (WP 0142) Cylinder Head And Gasket Replacement (WP 0145) Engine Oil Pan Replacement (WP 0121) Engine Oil Filter Replacement (WP 0123) Engine Oil Service (WP 0124) Engine Module Replacement (WP 0128) References (cont.) Oil Drain Sampling Valve Replacement (WP 0134) Open/Close Engine Access Cover (TM 5-3825-270-10) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE EXCESSIVE ENGINE OIL CONSUMPTION STEP 1 Is engine oil sampling valve leaking? 1. Open rear engine access cover. (TM 5-3825-270-10) 2. Inspect engine oil sampling valve for leakage.
ENGINE OIL SAMPLING VALVE
Figure 1. Engine Oil Sampling Valve - Step 1. CONDITION/INDICATION Is engine oil sampling valve leaking? DECISION No - Go to step 2. (Step 2 - Is engine bay free from signs of oil leakage?) Yes - Tighten or replace engine oil sampling valve. (WP 0134) Verify problem is solved. (Step 4 - Does engine exhibit excessive oil consumption?)
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STEP 2 Is engine bay free from signs of oil leakage? 1. Remove engine compartment cover. (WP 0142) 2. Inspect engine bay and engine components for signs of oil leakage: (WP 0069) Oil pan Oil pan drain plug Oil filter CONDITION/INDICATION Is engine bay free from signs of oil leakage? DECISION No - Go to step 3. (Step 3 - Has unit been previously troubleshot for excessive oil consumption?) Yes - Replace damaged or leaking oil pan (WP 0121), oil pan drain plug (WP 0124), or oil filter if leaking. (WP 0123) If engine has leak that can not be readily sealed, replace engine. (WP 0128) Verify problem is solved. (Step 4 - Does engine exhibit excessive oil consumption?) STEP 3 Has unit been previously troubleshot for excessive oil consumption? Review maintenance records to ensure particular unit has not had maintenance previously for excessive oil consumption. CONDITION/INDICATION Has unit been previously troubleshot for excessive oil consumption? DECISION No - Properly change oil and oil filter ensuring to service engine to correct level of engine oil. (WP 0124) Verify problem is solved. (Step 4 - Does engine exhibit excessive oil consumption?) Yes - If troubleshooting has been accomplished before on particular unit for excessive oil consumption, replace engine. (WP 0128) STEP 4 Does engine exhibit excessive oil consumption? 1. If engine maintenance was performed for an external oil leak, start engine and monitor for oil leakage. (TM 5-3825-270-10) 2. If no leaks were present and oil and filters were changed, annotate maintenance records and return to service. CONDITION/INDICATION Does engine exhibit excessive oil consumption? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0018
FIELD MAINTENANCE EXCESSIVE FUEL CONSUMPTION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Air Filter Replacement (TM 5-3825-270-10) Air Cleaner Assembly Repair (WP 0170) Engine Injection Nozzle Tubes Replacement (WP 0118) Engine Nozzle Assembly Holder (Injection Nozzle) Replacement (WP 0120) Engine Injection Pump Replacement (WP 0117) Engine Module Replacement (WP 0128) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) References (cont.) Fuel Line Replacement (WP 0172) Fuel Pump Replacement (WP 0173) Fuel/Water Separator And Filter Head Replacement (WP 0176) Governor Control Module Replacement (WP 0092) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE EXCESSIVE FUEL CONSUMPTION STEP 1 Is engine idle 900 to 1100 rpm? 1. Start engine. (TM 5-3825-270-10)
NOTE
Engine speed may vary at normal engine idle and no load is present. Normal engine idle should range from 900 to 1100 rpm with no load present. 2. Observe tachometer.
TACHOMETER
Figure 1. Tachometer - Test 1.
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0018
3.
Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Is engine idle 900 to 1100 rpm? DECISION No - Replace governor control module. (WP 0092) Verify problem is solved. (Step 6 - Is engine fuel consumption normal?) Yes - Go to step 2. (Step 2 - Is air filter clean and serviceable?) STEP 2 Is air filter clean and serviceable? 1. Remove air filter. (WP 0170) 2. Visually inspect air filter for cleanliness and serviceability.
AIR CLEANER
AIR FILTER
CONDITION/INDICATION Is air filter clean and serviceable? DECISION No - Replace air filter. (WP 0170) Verify problem is solved. (Step 6 - Is engine fuel consumption normal?) Yes - Go to step 3. (Step 3 - Are fuel system components free from leaks and damage?) STEP 3 Are fuel system components free from leaks and damage? 1. Install air filter. (TM 5-3825-270-10) 2. Open rear engine access cover. (TM 5-3825-270-10) 3. Visually inspect the following fuel system components for damage and leakage. (WP 0069) Fuel lines and fittings Fuel pump, lines, and fittings Fuel/water separator, lines, and fittings Engine injector pump, lines, and fittings
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FUEL LINES
Figure 3. Fuel System Components - Step 3. CONDITION/INDICATION Are fuel system components free from leaks and damage? DECISION No - If damaged, repair or replace fuel lines or fittings (WP 0172), fuel pump (WP 0173), or fuel/water separator. (WP 0176) Verify problem is solved. (Step 6 - Is engine fuel consumption normal?) Yes - Go to step 4. (Step 4 - Are flatrack fuel lines free from leaks?) STEP 4 Are flatrack fuel lines free from leaks? Inspect flatrack fuel lines for leakage.
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FLATRACK FUEL LINES

Figure 4. Fuel Lines - Step 4.
CONDITION/INDICATION Are flatrack fuel lines free from leaks? DECISION No - Replace fuel line(s). (WP 0172) Verify problem is solved. (Step 6 - Is engine fuel consumption normal?) Yes - Go to step 5. (Step 5 - Are engine injection nozzles free from deposits, cracks and other signs of damage?) STEP 5 Are engine injection nozzles free from deposits, cracks and other signs of damage? 1. Remove engine injection nozzles. (WP 0120) 2. Inspect engine injector nozzles for following conditions: Burned on combustion deposits Rough surfaces and erosion around nozzle tip Damaged injection nozzle gaskets Cracks Additional or missing sealing washers Abnormal nozzle color (dark yellow and tan, or blue depending on temperature of overheat) CONDITION/INDICATION Are engine injection nozzles free from deposits, cracks and other signs of damage? DECISION No - Replace damaged engine injection nozzle tube (WP 0118), and/or engine nozzle assembly. (WP 0120) Verify problem is solved. (Step 6 - Is engine fuel consumption normal?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to test 1. (Step 1 - Is engine idle 900 to 1100 rpm?) If problem still exists after all troubleshooting test have been accomplished, notify supervisor.
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STEP 6 Is engine fuel consumption normal? Run engine and monitor for excessive fuel consumption. (TM 5-3825-270-10) CONDITION/INDICATION Is engine fuel consumption normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. If problem persists, replace engine. (WP 0128) Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0019
FIELD MAINTENANCE ENGINE KNOCK
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Engine Oil Pressure Testing (WP 0122) Engine Module Replacement (WP 0128) Engine Oil Service (WP 0124) Engine Valve Cover And Gasket Replacement (WP 0141) Fuel Tank Drain/Fill (WP 0174) References (cont.) Fuel/Water Separator And Filter Head Replacement (WP 0176) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE KNOCK STEP 1 Does engine have appropriate level of engine oil? Check engine oil level. (WP 0069) CONDITION/INDICATION Does engine have appropriate level of engine oil? DECISION No - Fill or drain engine to appropriate level with engine oil. (WP 0069) Verify problem is solved. (Step 5 - Does engine knock?) Yes - Go to step 2. (Step 2 - Does fuel exhibit excessive amount of water?) STEP 2 Does fuel exhibit excessive amount of water? 1. Drain fuel/water separator and retain for inspection. (WP 0069) 2. Inspect fuel sample for excessive water. CONDITION/INDICATION Does fuel exhibit excessive amount of water? DECISION No - Go to step 3. (Step 3 - Does engine pass engine oil pressure test?) Yes - Drain, purge, and refill fuel system with good fuel. (WP 0174) Verify problem is solved. (Step 5 - Does engine knock?) STEP 3 Does engine pass engine oil pressure test? Perform engine oil pressure test. (WP 0122)
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CONDITION/INDICATION Does engine pass engine oil pressure test? DECISION No - Replace engine. (WP 0128) Verify problem is solved. (Step 5 - Does engine knock?) Yes - Go to step 4. (Step 4 - Is engine oil free from contaminants?) STEP 4 Is engine oil free from contaminants? 1. Retrieve oil sample from oil sampling valve. (WP 0124) 2. Inspect engine oil for contaminants. CONDITION/INDICATION Is engine oil free from contaminants? DECISION No - Change engine oil. (WP 0124) Verify problem is solved. (Step 5 - Does engine knock?) Yes - Replace engine. (WP 0128) Verify problem is solved. (Step 5 - Does engine knock?) STEP 5 Does engine knock? 1. Start engine. (TM 5-3825-270-10) 2. Monitor engine for engine knock. 3. Shutdown engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine knock? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0020
FIELD MAINTENANCE BLACK/BLUE EXHAUST SMOKE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Air Cleaner Assembly Repair (WP 0170) Engine Compartment Cover Replacement (WP 0142) Engine Injector Pump Replacement (WP 0117) Engine Nozzle Tubes Replacement (WP 0118) Engine Nozzle Assembly Holder (Injection Nozzle) Replacement (WP 0120) References (cont.) Engine Replacement (WP 0128) Engine Valve Cover And Gasket Replacement (WP 0141) Exhaust Manifold Replacement (WP 0129) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE BLACK/BLUE EXHAUST SMOKE STEP 1 Does air filter restriction indicator indicate restriction?
NOTE
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DECISION No - Go to step 2. (Step 2 - Is air filter clean and serviceable?) Yes - Ensure air filter is clean and serviceable and check for air restrictions. After removal of restriction and/or cleaning of air filter, reset air restriction indicator. Verify problem is solved. (Step 5 - Is engine exhaust normal?) STEP 2 Is air filter clean and serviceable? 1. Remove air filter. (WP 0170) 2. Visually inspect air filter for cleanliness and serviceability.
AIR CLEANER
AIR FILTER
CONDITION/INDICATION Is air filter clean and serviceable? DECISION No - Replace air filter. (WP 0170) Verify problem is solved. (Step 5 - Is engine exhaust normal?) Yes - Go to step 3. (Step 3 - Is exhaust manifold free of damage and leaks?) STEP 3 Is exhaust manifold free of damage and leaks? 1. Remove engine compartment cover. (WP 0142) 2. Visually inspect around exhaust manifold for signs of leaks.
EXHAUST MANIFOLD
Figure 3. Exhaust Manifold - Step 3.
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3.
Visually inspect exhaust manifold for damage and cracks.
CONDITION/INDICATION Is exhaust manifold free of damage and leaks? DECISION No - Replace exhaust manifold. (WP 0129) Verify problem is solved. (Step 5 - Is engine exhaust normal?) Yes - Go to step 4. (Step 4 - Are engine injection nozzles free from deposits, cracks and other signs of damage?) STEP 4 Are engine injection nozzles free from deposits, cracks and other signs of damage? 1. Remove engine injection nozzles. (WP 0120) 2. Inspect engine injection nozzles for following conditions: Burned on combustion deposits Rough surfaces and erosion around nozzle tip Damaged injector nozzle gaskets Cracks Additional or missing sealing washers Abnormal nozzle color (dark yellow and tan, or blue depending on temperature of overheat) CONDITION/INDICATION Are engine injection nozzles free from deposits, cracks and other signs of damage? DECISION No - Replace damaged engine nozzle assembly. (WP 0120) Verify problem is solved. (Step 5 - Is engine exhaust normal?) Yes - Replace engine. (WP 0128) Verify problem is solved. (Step 5 - Is engine exhaust normal?) STEP 5 Is engine exhaust normal? Start engine and observe engine exhaust. (TM 5-3825-270-10) CONDITION/INDICATION Is engine exhaust normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0021
FIELD MAINTENANCE WHITE EXHAUST SMOKE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Cleaning Compound, Solvent (WP 0224, Table 1, Item 10, 11, 12, 13, 14, 15) Rag, Wiping (WP 0224, Table 1, Item 52) References Cylinder Head And Gasket Replacement (WP 0145) Engine Does Not Reach Normal Operating Temperature (WP 0016) References (cont.) Engine Module Replacement (WP 0128) Engine Misfires (WP 0011) Engine Overheats (WP 0015) Engine Surges (WP 0010) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Fuel Tank Drain/Fill (WP 0174) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WHITE EXHAUST SMOKE STEP 1 Does white exhaust smoke appear to be caused by fuel or coolant?
NOTE
White exhaust smoke is caused by condensing liquid in the exhaust system. The liquid is typically diesel fuel or coolant. Unburned diesel fuel in the exhaust has a strong diesel fuel odor and causes a severe burning sensation in the eyes. Unburned diesel fuel is caused by a misfire or incomplete combustion. Too low of a coolant temperature may result in white smoke due to incomplete combustion. Poor quality fuel or fuel not blended for the operating conditions may also cause incomplete combustion. Coolant in the exhaust causes white smoke, along with an odor that can be described as sweet. White smoke accompanied with coolant loss and overheating indicates that the white smoke is likely due to coolant in the exhaust. 1. 2. 3. Start engine and observe engine exhaust. (TM 5-3825-270-10) Determine if cause of white exhaust smoke is likely from fuel or coolant. Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Does white exhaust smoke appear to be caused by fuel or coolant? DECISION Coolant - Go to step 5. (Step 5 - Is engine filled with adequate amount of coolant?) Fuel - Go to step 2. (Step 2 - Is fuel determined to be adequate for operation?)
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0021
STEP 2 Is fuel determined to be adequate for operation?
NOTE
If water distributor is filled with incorrect fuel or not properly prepared for storage (TM 5-3825-270-10), fuel may cause white exhaust. Verify if water distributor has been stored for an extended period of time, and/or incorrect fuel may have been used for operation of equipment. CONDITION/INDICATION Is fuel determined to be adequate for operation? DECISION No - Drain and refill water distributor with correct fuel. (WP 0174) Verify problem is solved. (Step 6 - Does engine exhibit white exhaust?) Yes - Go to step 3. (Step 3 - Does engine exhibit any other abnormal conditions?) STEP 3 Does engine exhibit any other abnormal conditions? 1. Start engine and observe engine performance for following conditions: (TM 5-3825-270-10) Engine overheats Engine misfire Engine surge Engine does not reach normal operating temperature 2. Shutdown engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine exhibit any other abnormal conditions? DECISION No - Go to step 4. (Step 4 - Is engine oil and/or coolant level low?) Yes - If engine overheats go to Engine Overheats. (WP 0015) If engine misfires go to Engine Misfires. (WP 0011) If engine surges go to Engine Surges. (WP 0010) If engine does not reach normal operating temperature, go to Engine Does Not Reach Normal Operating Temperature. (WP 0016) STEP 4 Is engine oil and/or coolant level low? 1. Check engine coolant level. (TM 5-3825-270-10) 2. Check engine oil level. (TM 5-3825-270-10) CONDITION/INDICATION Is engine oil and/or coolant level low? DECISION No - If engine oil and coolant levels are normal, replace engine. (WP 0128) Verify problem is solved. (Step 6 Does engine exhibit white exhaust?) Yes - If engine oil level is low, replace engine. (WP 0128) If engine coolant level is low, replace engine cylinder head gasket. (WP 0145) Verify problem is solved. (Step 6 - Does engine exhibit white exhaust?) STEP 5 Is engine filled with adequate amount of coolant? Check engine coolant level. (TM 5-3825-270-10)
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CONDITION/INDICATION Is engine filled with adequate amount of coolant? DECISION No - If engine coolant level is low, replace engine cylinder head gasket. (WP 0145) Verify problem is solved. (Step 6 - Does engine exhibit white exhaust?) Yes - White exhaust may be caused by fuel, go to step 2. (Step 2 - Is fuel determined to be adequate for operation?) STEP 6 Does engine exhibit white exhaust? Start engine and observe engine exhaust. (TM 5-3825-270-10) CONDITION/INDICATION Does engine exhibit white exhaust? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0022
FIELD MAINTENANCE WATER PUMP DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Engine Module Replacement (WP 0128) Pump Drive Coupling Replacement (WP 0200) Flex Element Replacement (WP 0147) References (cont.) Water Pump Assembly Replacement (WP 0198) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER PUMP DOES NOT OPERATE STEP 1 Is pump drive coupling installed correctly and free of damage? 1. Remove engine. (WP 0128) 2. Ensure pump drive coupling is installed correctly and free of damage. (WP 0200)
PUMP DRIVE COUPLING
Figure 1. Pump Drive Coupling - Step 1.
CONDITION/INDICATION Is pump drive coupling installed correctly and free of damage? DECISION No - Properly install or replace pump drive coupling. (WP 0200) Verify problem is solved. (Step 3 - Does water pump operate?) Yes - Go to step 2. (Step 2 - Is flex element installed correctly and free of damage?) STEP 2
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0022
Is flex element installed correctly and free of damage? Ensure flex element is installed correctly and free of damage. (WP 0147)
FLEX ELEMENT
Figure 2. Flex Element - Step 2. CONDITION/INDICATION Is flex element installed correctly and free of damage? DECISION No - Properly install or replace pump drive coupling. (WP 0200) Verify problem is solved. (Step 3 - Does water pump operate?) Yes - Replace water pump assembly. (WP 0198) Verify problem is solved. (Step 3 - Does water pump operate?) STEP 3 Does water pump operate? 1. Install engine. (WP 0128) 2. Start engine and ensure water pump operates. (TM 5-3825-270-10) CONDITION/INDICATION Does water pump operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0023
FIELD MAINTENANCE WATER PRESSURE ERRATIC
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Engine Surges (WP 0010) Excessive Pump Noise (WP 0024) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Inlet Valve And Hose Replacement (WP 0183) References (cont.) Strainer Housing Replacement (WP 0182) Suction Tube And Hose Replacement (WP 0201) Water Pump Assembly Replacement (WP 0198) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER PRESSURE ERRATIC STEP 1 Are all water pump hoses tightly connected and free of leaks? 1. Ensure all water pump hose clamps are tight and properly installed. (WP 0069) 2. Visually inspect all water pump hoses for damage. (WP 0069) 3. Start engine and inspect hoses for leaks. (TM 5-3825-270-10) 4. Shutdown engine. (TM 5-3825-270-10) CONDITION/INDICATION Are all water pump hoses tightly connected and free of leaks? DECISION No - Properly install or tighten hose clamps, and/or replace damaged hoses. (WP 0069) Verify problem is solved. (Step 5 - Is water pressure erratic?) Yes - Go to step 2. (Step 2 - Are water system components free from damage and blockage?) STEP 2 Are water system components free from damage and blockage? Inspect following components for damage and blockage: Inlet valve and hose (WP 0183) Strainer (WP 0182) Suction tube and hose (WP 0201) CONDITION/INDICATION Are water system components free from damage and blockage? DECISION No - Remove blockage or replace inlet valve (WP 0183), suction tube (WP 0201), and/or strainer. (WP 0182) Verify problem is solved. (Step 5 - Is water pressure erratic?) Yes - Go to step 3. (Step 3 - Is engine speed erratic when set to 1500 rpm?) STEP 3
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Is engine speed erratic when set to 1500 rpm?
NOTE
When normally discharging from a water station, engine rpm should be increased and set to a minimum of 1500 rpm to alleviate erratic engine speed. 1. 2. 3. 4. Start engine. (TM 5-3825-270-10) Operate engine at 1500 rpm. (TM 5-3825-270-10) Monitor engine performance while discharging from water hose or other water station. If engine speed is normal, do not shut down engine.
CONDITION/INDICATION Is engine speed erratic when set to 1500 rpm? DECISION No - Go to step 4. (Step 4 - Does water pump exhibit excessive noise?) Yes - Go to Engine Surges. (WP 0010) STEP 4 Does water pump exhibit excessive noise? 1. Monitor water pump for excessive noise. 2. Shut down engine. (TM 5-3825-270-10) CONDITION/INDICATION Does water pump exhibit excessive noise? DECISION No - Replace water pump assembly. (WP 0198) Verify problem is solved. (Step 5 - Is water pressure erratic?) Yes - Go to Excessive Pump Noise. (WP 0024) STEP 5 Is water pressure erratic? Start engine and ensure pump pressure is normal. (TM 5-3825-270-10) CONDITION/INDICATION Is water pressure erratic? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0024
FIELD MAINTENANCE EXCESSIVE WATER PUMP NOISE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Engine Module Replacement (WP 0128) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Pump Drive Coupling Replacement (WP 0200) References (cont.) Flex Element Replacement (WP 0147) Water Distributor Operator Manual (TM 5-3825-270-10) Water Pump Assembly Replacement (WP 0198) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE EXCESSIVE WATER PUMP NOISE STEP 1 Are all water pump housing screws installed and tight? Ensure all water pump housing screws are installed and tight. (WP 0069)
WATER PUMP HOUSING SCREWS
WATER PUMP HOUSING SCREWS
Figure 1. Water Pump Housing Screws - Step 1. CONDITION/INDICATION Are all water pump housing screws installed and tight? DECISION No - Properly install and/or tighten all water pump housing screws. (WP 0128) Verify problem is solved. (Step 5 - Is there excessive water pump noise?) Yes - Go to step 2. (Step 2 - Are water pump isolation mounts tight and free of damage?) STEP 2
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Are water pump isolation mounts tight and free of damage? Ensure water pump isolation mounts are tight and free of damage.
MOUNTING SCREWS WATER PUMP ISOLATION MOUNTS
Figure 2. Water Pump Isolation Mounts - Step 2.
CONDITION/INDICATION Are water pump isolation mounts tight and free of damage? DECISION No - Tighten isolation mounting screws if loose or replace isolation mounts if damaged. (WP 0198) Verify problem is solved. (Step 5 - Is there excessive water pump noise?) Yes - Go to step 3. (Step 3 - Is pump drive coupling tightly fastened and free of damage?) STEP 3 Is pump drive coupling tightly fastened and free of damage? 1. Remove engine module. (WP 0128) 2. Ensure pump drive coupling is tightly fastened and free of damage. (WP 0200)
PUMP DRIVE COUPLING
Figure 3. Pump Drive Coupling - Step 3.
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CONDITION/INDICATION Is pump drive coupling tightly fastened and free of damage? DECISION No - Tighten loose fasteners or replace pump drive coupling. (WP 0200) Verify problem is solved. (Step 5 - Is there excessive water pump noise?) Yes - Go to step 4. (Step 4 - Is flex element tightly fastened and free of damage?) STEP 4 Is flex element tightly fastened and free of damage? Ensure flex element is tightly fastened and free of damage. (WP 0147)
FLEX ELEMENT
Figure 4. Flex Element - Step 4. CONDITION/INDICATION Is flex element tightly fastened and free of damage? DECISION No - Tighten loose fasteners or replace damaged flex element. (WP 0147) Verify problem is solved. (Step 5 - Is there excessive water pump noise?) Yes - Replace water pump assembly. (WP 0198) Verify problem is solved. (Step 5 - Is there excessive water pump noise?) STEP 5 Is there excessive water pump noise? 1. If removed, install engine module. (WP 0128) 2. Start engine and verify water pump noise. (TM 5-3825-270-10) CONDITION/INDICATION Is there excessive water pump noise? DECISION No - Your original problem has been resolved. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0025
FIELD MAINTENANCE WORK LIGHTS DO NOT ILLUMINATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) References Battery Disconnect/Connection (WP 0085) Control Panel Light Switch Replacement (WP 0089) General Wire Harness Replacement (WP 0099) References (cont.) Work Light Harness Replacement (WP 0107) Work Light Replacement (WP 0106) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) No Power To Control Panel (WP 0027) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WORK LIGHTS DO NOT ILLUMINATE STEP 1 Are both work lights inoperative, or just one? 1. Open control panel cover. (TM 5-3825-270-10) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. Move LIGHTS switch to ON position.
LIGHTS SWITCH
Figure 1. Lights Switch - Step 1. 4. Verify if one or both work lights do not illuminate.
CONDITION/INDICATION Are both work lights inoperative, or just one?
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DECISION Both inoperative - Go to step 2. (Step 2 - Does ENGINE OFF/BATTERY DRAIN indicator illuminate?) One inoperative - Replace work light. (WP 0106) Verify problem is solved. (Step 7 - Do work lights illuminate?) STEP 2 Does ENGINE OFF/BATTERY DRAIN indicator illuminate?
NOTE
The ENGINE OFF/BATTERY DRAIN indicator and work lights share some of the same circuitry. The following test is used for further isolation of work light malfunction. Observe ENGINE OFF/BATTERY DRAIN indicator.
CONDITION/INDICATION Does ENGINE OFF/BATTERY DRAIN indicator illuminate? DECISION No - Go to No Power To Control Panel. (WP 0027) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at work light harness connector pin 1?) STEP 3 Are 22 to 28 VDC measured at work light harness connector pin 1? 1. Disconnect work light harness connector. (WP 0106) 2. Set multimeter to measure voltage.
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Place red multimeter probe to work light harness connector pin 1.
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WORK LIGHT HARNESS CONNECTOR
PIN 1 (RED WIRE)
PIN 2 (BLACK WIRE)
Figure 3. Work Light Harness Connector Pin 1 - Step 3. 4. 5. Place black multimeter probe to know good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at work light harness connector pin 1? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured across LIGHTS switch terminal 1 and terminal 2 with switch in ON position?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured at work light harness connector pin 2 to known good ground?) STEP 4 Are less than 200 ohms measured at work light harness connector pin 2 to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) Set multimeter to measure continuity. 3.
CAUTION
Ensure electrical power is off prior to working on all electrical connections. Failure to comply may result in damage to equipment. 4. Place red multimeter probe to work light harness connector pin 2.
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WORK LIGHT HARNESS CONNECTOR
PIN 1 (RED WIRE)
PIN 2 (BLACK WIRE)
Figure 4. Work Light Harness Connector Pin 2 - Step 4. 5. 6. Place black multimeter probe to know good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at work light harness connector pin 2 to known good ground? DECISION No - Repair or replace black wire from work light harness connector pin 2 to control panel negative terminal strip. (WP 0099) Verify problem is solved. (Step 7 - Do work lights illuminate?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to step 1. (Step 1 - Are both work lights inoperative, or just one?) If problem still exists after all troubleshooting test have been accomplished, notify supervisor. STEP 5 Are less than 200 ohms measured across LIGHTS switch terminal 1 and terminal 2 with switch in ON position? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) Remove six control panel faceplate screws. 3.
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CAUTION
Ensure electrical power is off prior to working on all electrical connections. Failure to comply may result in damage to equipment. 5. Place red multimeter probe to LIGHTS switch terminal 1.
TERMINAL 1
TERMINAL 2
BACK OF CONTROL PANEL LIGHT SWITCH
Figure 6. Light Switch - Step 5. 6. 7. 8. Place black multimeter probe to LIGHTS switch terminal 2. While holding multimeter probes on terminals, place LIGHTS switch to ON position. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured across LIGHTS switch terminal 1 and terminal 2 with switch in ON position?
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DECISION No - Replace LIGHTS switch. (WP 0089) Verify problem is solved. (Step 7 - Do work lights illuminate?) Yes - Go to step 6. (Step 6 - Are less than 200 ohms measured on yellow wire from LIGHTS switch, terminal 2 to positive terminal strip, terminal 6?) STEP 6 Are less than 200 ohms measured on yellow wire from LIGHTS switch, terminal 2 to positive terminal strip, terminal 6? 1. Place red multimeter probe to yellow wire on LIGHTS switch terminal 2.
TERMINAL 1
TERMINAL 2
BACK OF CONTROL PANEL LIGHT SWITCH
Figure 7. Light Switch - Step 6. 2. Place black multimeter probe to positive terminal strip, terminal 6.
20
15
10
10
10
15
15
20
20
Figure 8. Positive Terminal Strip - Step 6. 3. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on yellow wire from LIGHTS switch, terminal 2 to positive terminal strip, terminal 6?
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DECISION No - Repair or replace yellow wire from LIGHTS switch to positive terminal strip. (WP 0099) Verify problem is solved. (Step 7 - Do work lights illuminate?) Yes - Replace work light wiring harness. (WP 0107) Verify problem is solved. (Step 7 - Do work lights illuminate?) STEP 7 Do work lights illuminate? 1. If disconnected, connect work light harness connector. (WP 0106) 2. If disconnected, connect batteries. (WP 0085) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Move LIGHTS switch to ON position.
LIGHTS SWITCH
Figure 9. Lights Switch - Step 7. 5. Verify if work lights illuminate.
CONDITION/INDICATION Do work lights illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0026
FIELD MAINTENANCE WATER DISTRIBUTOR DOES NOT OPERATE REMOTELY
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Personnel Required Construction Equipment Repairer 91L (2) References Engine Cranks But Does Not Start (WP 0007) References (cont.) General Wire Harness Replacement (WP 0099) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER DISTRIBUTOR DOES NOT OPERATE REMOTELY STEP 1 Are all control panel switches in correct positions for cab control operation? Ensure LIGHTS and WATER SPRINKLERS switches are in CAB CONTROL position. (TM 5-3825-270-10) CONDITION/INDICATION Are all control panel switches in correct positions for cab control operation? DECISION No - Place switches to CAB CONTROL position. (TM 5-3825-270-10) Verify problem is solved. (Step 3 - Does water distributor operate using cab control box?) Yes - Go to step 2. (Step 2 - Does engine start using cab control box?) STEP 2 Does engine start using cab control box? Attempt to start water distributor using cab control box. (TM 5-3825-270-10) CONDITION/INDICATION Does engine start using cab control box? DECISION No - Go to Cab Control Box Engine Start/Stop Switch Does Not Operate (WP 0067) Yes - Cab control box is properly connected to water distributor. If engine speed switches, water sprinkler switches, or tachometer on cab control box do not operate, see Cab Control Box Troubleshooting section in table of contents for applicable troubleshooting work package. STEP 3 Does water distributor operate using cab control box? Attempt to operate water distributor using cab control box. (TM 5-3825-270-10) CONDITION/INDICATION Does water distributor operate using cab control box?
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DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0027
FIELD MAINTENANCE NO POWER TO CONTROL PANEL
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) Batteries Servicing And Testing (WP 0082) Battery Replacement (WP 0086) References (cont.) Engine Off/Battery Drain Indicator Does Not Illuminate (WP 0031) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) General Wire Harness Replacement (WP 0099) Main Control Panel Emergency Stop Pushbutton Replacement (WP 0088) Water Distributor Operator Manual (TM 5-3825-270-10) 15 Amp Circuit Breaker Replacement (WP 0078) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE NO POWER TO CONTROL PANEL STEP 1 Is 15-amp circuit breaker tripped?
NOTE
The 15-amp circuit breaker works in conjunction with the emergency stop switch to control power to the control panel. If a power surge is detected, the 15-amp circuit breaker will trip prohibiting the emergency stop switch to supply power to the control panel and engine. Verify 15-amp circuit breaker position.
Figure 1. 15-Amp Circuit Breaker - Step 1.
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CONDITION/INDICATION Is 15-amp circuit breaker tripped? DECISION No - Go to step 2. (Step 2 - Does BATTERY VOLTAGE gauge read 22 to 28 VDC?) Yes - Reset 15-amp circuit breaker. Verify problem is solved. (Step 11 - Does control panel have power?) If 15amp circuit breaker trips again after reset, do not attempt to reset. Notify maintenance personnel 15-amp circuit breaker is tripped. STEP 2 Does BATTERY VOLTAGE gauge read 22 to 28 VDC? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Observe BATTERY VOLTAGE gauge.
Figure 2. Battery Voltage Gauge - Step 2. CONDITION/INDICATION Does BATTERY VOLTAGE gauge read 22 to 28 VDC? DECISION No - Go to step 3. (Step 3 - Are batteries properly connected?) Yes - Control panel has power. Go to Engine Off/Battery Drain Indicator Does Not Illuminate. (WP 0031) STEP 3 Are batteries properly connected? 1. Open battery box cover. (TM 5-3825-270-10) 2. Visually inspect batteries for proper connection.
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BATTERY TERMINALS
BATTERIES
Figure 3. Batteries And Battery Terminals - Step 3.
CONDITION/INDICATION Are batteries properly connected? DECISION No - Properly connect batteries. (WP 0085) Verify problem is solved. (Step 11 - Does control panel have power?) Yes - Go to step 4. (Step 4 - Are battery terminals corroded?) STEP 4 Are battery terminals corroded? Visually inspect battery terminals for corrosion.
BATTERY TERMINALS
BATTERIES
Figure 4. Batteries And Battery Terminals - Step 4.
CONDITION/INDICATION Are battery terminals corroded? DECISION No - Go to step 5. (Step 5 - Do batteries read 24.2 to 25.4 volts with multimeter?) Yes - Clean battery terminals. (WP 0069) Verify problem is solved. (Step 11 - Does control panel have power?)
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STEP 5 Do batteries read 24.2 to 25.4 volts with multimeter?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. Set multimeter to measure voltage.
NOTE
Water distributor is equipped with two 12-volt batteries connected in series. Multimeter measurements must be made from correct battery terminals to obtain 24-volt measurements. 2. 3. Connect red multimeter probe to positive battery terminal. Connect black multimeter lead to negative battery terminal.
NOTE
The following chart describes battery voltage characteristics when measured with a multimeter. This chart can be used to further isolate and troubleshoot batteries that may be cause of problem. 5. Compare multimeter reading to chart. Table 1. Battery State Of Charge Voltage Table - Step 5. Percentage Of Full Charge 100% 12 Volt DC System 12.7 24 Volt DC System 25.4
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Table 1. Battery State Of Charge Voltage Table - Step 5 - Continued. 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 12.6 12.5 12.3 12.2 12.1 12.0 11.8 11.7 11.6 <=11.6 25.2 25 24.6 24.4 24.2 24 23.6 23.4 23.2 <=23.2
CONDITION/INDICATION Do batteries read 24.2 to 25.4 volts with multimeter? DECISION No - Service (WP 0082), or replace batteries. (WP 0086) Verify problem is solved. (Step 11 - Does control panel have power?) Yes - Go to step 6. (Step 6 - Are 22 to 28 VDC present at emergency stop switch, terminal 1?) STEP 6 Are 22 to 28 VDC present at emergency stop switch, terminal 1? 1. Remove six control panel faceplate screws.
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Figure 6. Control Panel Faceplate Screws - Step 6. 2. Ensure multimeter is set to measure voltage.
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter probe to EMERGENCY STOP switch, terminal 1.
BACK OF CONTROL PANEL EMERGENCY STOP SWITCH TERMINAL 1
EMERGENCY STOP SWITCH TERMINAL 2
Figure 7. Emergency Stop Switch, Terminal 1 - Step 6. 4. 5. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC present at emergency stop switch, terminal 1?
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DECISION No - Go to step 9. (Step 9 - Are 22 to 28 VDC present at 15-amp circuit breaker terminal 1?) Yes - Go to step 7. (Step 7 - Are 22 to 28 VDC present at emergency stop switch, terminal 2?) STEP 7 Are 22 to 28 VDC present at emergency stop switch, terminal 2? 1. Ensure multimeter is setup to measure voltage. 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10)
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter probe to EMERGENCY STOP switch, terminal 2.
BACK OF CONTROL PANEL EMERGENCY STOP SWITCH TERMINAL 1
EMERGENCY STOP SWITCH TERMINAL 2
Figure 8. Emergency Stop Switch, Terminal 2- Step 7. 4. 5. 6. Connect black multimeter probe to known good ground. Note multimeter reading. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
CONDITION/INDICATION Are 22 to 28 VDC present at emergency stop switch, terminal 2? DECISION No - Replace EMERGENCY STOP switch. (WP 0088) Verify problem is solved. (Step 11 - Does control panel have power?) Yes - Go to step 8. (Step 8 - Are less than 200 ohms measured from negative terminal strip, terminal 6 to negative battery terminal?) STEP 8 Are less than 200 ohms measured from negative terminal strip, terminal 6 to negative battery terminal? 1. Setup multimeter to check for continuity.
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WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 2. Connect red multimeter probe to negative terminal strip, terminal 6.
20
15
10
10
10
15
15
20
20
Figure 9. Negative Terminal Strip - Step 8. 3. With the aid of an assistant, connect black multimeter lead to negative battery terminal.
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Figure 10. Negative Battery Terminal - Step 8. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from negative terminal strip, terminal 6 to negative battery terminal? DECISION No - Replace black wire between negative terminal strip, terminal 6 and negative battery terminal. (WP 0099) Verify problem is solved. (Step 11 - Does control panel have power?) Yes - Replace red wire between EMERGENCY STOP switch, terminal 2 and positive terminal strip, terminal 10. (WP 0099) Verify problem is solved. (Step 11 - Does control panel have power?) STEP 9 Are 22 to 28 VDC present at 15-amp circuit breaker terminal 1?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. Ensure multimeter is setup to measure voltage. Connect red multimeter probe to 15-amp circuit breaker terminal 1.
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15-AMP CIRCUIT BREAKER TERMINAL 2
Figure 11. 15-amp Circuit Breaker Terminal 1 - Step 9. 3. 4. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC present at 15-amp circuit breaker terminal 1? DECISION No - Repair or replace clear wire from 15-amp circuit breaker, terminal 1 positive battery terminal. (WP 0099) Verify problem is solved. (Step 11 - Does control panel have power?) Yes - Go to step 10. (Step 10 - Are 22 to 28 VDC present at 15-amp circuit breaker terminal 2?) STEP 10 Are 22 to 28 VDC present at 15-amp circuit breaker terminal 2?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. Ensure multimeter is setup to measure voltage. Connect red multimeter probe to 15-amp circuit breaker terminal 2.
Figure 12. 15-amp Circuit Breaker Terminal 2 - Step 10. 3. Connect black multimeter probe to known good ground.
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4.
CONDITION/INDICATION Are 22 to 28 VDC present at 15-amp circuit breaker terminal 2? DECISION No - Replace 15-amp circuit breaker. (WP 0078) Verify problem is solved. (Step 11 - Does control panel have power?) Yes - Repair or replace red wire from 15-amp circuit breaker, terminal 2 to EMERGENCY STOP switch. (WP 0099) Verify problem is solved. (Step 11 - Does control panel have power?) STEP 11 Does control panel have power? Attempt to apply power to control panel. (TM 5-3825-270-10) CONDITION/INDICATION Does control panel have power? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0028
FIELD MAINTENANCE BATTERY VOLTAGE GAUGE DOES NOT OPERATE OR READS HIGH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Materials/Parts Tie Wraps (WP 0224, Table 1, Item 56) Personnel Required Construction Equipment Repairer 91L (2) References Control Panel Battery Voltage Gauge Replacement (WP 0087) References (cont.) General Wire Harness Replacement (WP 0099) No Power To Control Panel (WP 0027) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE BATTERY VOLTAGE GAUGE DOES NOT OPERATE OR READS HIGH STEP 1 Does ENGINE OFF/BATTERY DRAIN light illuminate?
NOTE
Engine will not start and water distributor will not have power if emergency stop switch is in off position. 1. 2. 3. Open control panel cover. (TM 5-3825-270-10) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Observe ENGINE OFF/BATTERY DRAIN indicator.
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Figure 1. Engine Off/Battery Drain Indicator - Step 1. CONDITION/INDICATION Does ENGINE OFF/BATTERY DRAIN light illuminate? DECISION No - Go to No Power To Control Panel. (WP 0027) Yes - Go to step 2. (Step 2 - Are 22 to 28 VDC present at BATTERY VOLTAGE gauge harness connector, pin 6?) STEP 2 Are 22 to 28 VDC present at BATTERY VOLTAGE gauge harness connector, pin 6?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) Remove six control panel faceplate screws.
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Figure 2. Control Panel Faceplate Screws - Step 2. 3. 4. 5. 6. Set multimeter to measure voltage. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Disconnect harness connector from BATTERY VOLTAGE gauge. (WP 0087) Connect red multimeter probe to BATTERY VOLTAGE harness connector, pin 6.
GAUGE HARNESS CONNECTOR 1 4 2 5 3 6
Figure 3. Gauge Harness Connector - Step 2. 7. 8. 9. Connect black multimeter probe to known good ground. Note multimeter reading. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
CONDITION/INDICATION Are 22 to 28 VDC present at BATTERY VOLTAGE gauge harness connector, pin 6?
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DECISION No - Replace red wire between BATTERY VOLTAGE gauge harness connector pin 6 and positive terminal strip. (WP 0099) Verify problem is solved. (Step 4 - Does BATTERY VOLTAGE gauge operate?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured from BATTERY VOLTAGE gauge harness connector pin 5 and negative terminal strip terminal 17?) STEP 3 Are less than 200 ohms measured from BATTERY VOLTAGE gauge harness connector pin 5 and negative terminal strip terminal 17? 1. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 2. Connect red multimeter probe to BATTERY VOLTAGE harness connector, pin 5.
Figure 4. Gauge Harness Connector - Step 3. 3. Connect black multimeter probe to negative terminal strip, terminal 17.
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Figure 5. Negative Terminal Strip - Step 3. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from BATTERY VOLTAGE gauge harness connector pin 5 and negative terminal strip terminal 17? DECISION No - Replace black wire between BATTERY VOLTAGE gauge harness connector, pin 5 and negative terminal strip. (WP 0099) Verify problem is solved. (Step 4 - Does BATTERY VOLTAGE gauge operate?) Yes - Replace BATTERY VOLTAGE gauge. (WP 0087) Verify problem is solved. (Step 4 - Does BATTERY VOLTAGE gauge operate?) STEP 4 Does BATTERY VOLTAGE gauge operate? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Observe BATTERY VOLTAGE gauge.
Figure 6. Battery Voltage Gauge - Step 4.
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CONDITION/INDICATION Does BATTERY VOLTAGE gauge operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0029
FIELD MAINTENANCE BATTERY VOLTAGE GAUGE READS LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Alternator And Bracket Replacement (WP 0081) Battery Disconnect/Connection (WP 0085) Batteries Servicing And Testing (WP 0082) References (cont.) Battery Replacement (WP 0086) Main Control Panel Battery Voltage Gauge Replacement (WP 0087) Engine Does Not Crank (WP 0006) General Wire Harness Replacement (WP 0099) Open/Close Battery Box Cover (TM 5-3825-270-10) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE BATTERY VOLTAGE GAUGE READS LOW STEP 1 Does engine crank?
NOTE
Engine will not start if batteries are drained or not charged to adequate level. Battery voltage gauge may not be faulty. This test aides in troubleshooting isolation. Attempt to start engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine crank? DECISION No - Go to Engine Does Not Crank. (WP 0006) Yes - Go to step 2. (Step 2 - Does BATTERY VOLTAGE gauge read 26 to 28 VDC with engine running?) STEP 2 Does BATTERY VOLTAGE gauge read 26 to 28 VDC with engine running?
NOTE
Normal operating voltage is 26 to 28 VDC. 1. Observe BATTERY VOLTAGE gauge.
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Figure 1. Battery Voltage Gauge - Step 2. 2. Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Does BATTERY VOLTAGE gauge read 26 to 28 VDC with engine running? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured on red wire at alternator to positive terminal on battery?) Yes - Go to step 3. (Step 3 - Do batteries read 24.2 to 25.4 VDC with multimeter?) STEP 3 Do batteries read 24.2 to 25.4 VDC with multimeter?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. Open battery box cover. (TM 5-3825-270-10) Set multimeter to measure voltage.
NOTE
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NOTE
The following chart describes battery voltage characteristics when measured with a multimeter. This chart can be used to further isolate and troubleshoot batteries that may be cause of problem. 6. Compare multimeter reading to chart. Table 1. Battery State Of Charge Voltage Table. Percentage Of Full Charge 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 12 Volt DC System 12.7 12.6 12.5 12.3 12.2 12.1 12.0 11.8 11.7 11.6 24 Volt DC System 25.4 25.2 25 24.6 24.4 24.2 24 23.6 23.4 23.2
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Table 1. Battery State Of Charge Voltage Table - Continued. 0% <=11.6 <=23.2
CONDITION/INDICATION Do batteries read 24.2 to 25.4 VDC with multimeter? DECISION No - Service (WP 0082) or replace batteries. (WP 0086) Verify problem is solved. (Step 7 - Does BATTERY VOLTAGE gauge read normal?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on red wire from BATTERY VOLTAGE gauge harness connector pin, 6 to positive terminal strip, terminal 19?) STEP 4 Are less than 200 ohms measured on red wire from BATTERY VOLTAGE gauge harness connector pin, 6 to positive terminal strip, terminal 19?
NOTE
This test is checking for high resistance within a wire. High resistance may cause gauge readings to read inaccurately or abnormally. 1. 2. 3. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) Disconnect batteries. (WP 0085) Remove six control panel faceplate screws.
Figure 3. Control Panel Faceplate Screws - Step 4.
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WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. 5. 6. Disconnect harness connector from BATTERY VOLTAGE gauge. (WP 0087) Set multimeter to measure resistance. Connect red multimeter probe to BATTERY VOLTAGE gauge harness connector, pin 6.
Figure 4. Gauge Harness Connector - Step 4. 7. Connect black multimeter probe to positive terminal strip, terminal 19.
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Figure 5. Positive Terminal Strip - Step 4. 8. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on red wire from BATTERY VOLTAGE gauge harness connector pin, 6 to positive terminal strip, terminal 19? DECISION No - Replace red wire between BATTERY VOLTAGE gauge harness connector, pin 6 and positive terminal strip, terminal 19. (WP 0099) Verify problem is solved. (Step 7 - Does BATTERY VOLTAGE gauge read normal?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured on black wire from BATTERY VOLTAGE gauge harness connector, pin 5 to negative terminal strip, terminal 17?) STEP 5 Are less than 200 ohms measured on black wire from BATTERY VOLTAGE gauge harness connector, pin 5 to negative terminal strip, terminal 17?
NOTE
This test is checking for high resistance within a wire. High resistance may cause gauge readings to read inaccurately or abnormally. 1. Connect red multimeter probe to BATTERY VOLTAGE gauge harness connector, pin 5.
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CONDITION/INDICATION Are less than 200 ohms measured on black wire from BATTERY VOLTAGE gauge harness connector, pin 5 to negative terminal strip, terminal 17? DECISION No - Replace black wire between BATTERY VOLTAGE gauge harness connector, pin 5 and negative terminal strip, terminal 17. (WP 0099) Verify problem is solved. (Step 7 - Does BATTERY VOLTAGE gauge read normal?) Yes - Replace BATTERY VOLTAGE gauge. (WP 0087) Verify problem is solved. (Step 7 - Does BATTERY VOLTAGE gauge read normal?)
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STEP 6 Are less than 200 ohms measured on red wire at alternator to positive terminal on battery? 1. Disconnect batteries. (WP 0085) 2. Open front engine access cover. 3. Set multimeter to measure voltage.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter probe to red wire at alternator.
ALTERNATOR
RED WIRE
Figure 8. Red Wire At Alternator - Step 6. 5. With the aid of assistant using jumper wire, connect black multimeter probe to positive battery terminal.
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Figure 9. Positive Battery Terminal - Step 6. 6. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on red wire at alternator to positive terminal on battery? DECISION No - Repair or replace red wire from alternator to starter. (WP 0099) Verify problem is solved. (Step 7 - Does BATTERY VOLTAGE gauge read normal?) Yes - Replace alternator. (WP 0081) Verify problem is solved. (Step 7 - Does BATTERY VOLTAGE gauge read normal?) STEP 7 Does BATTERY VOLTAGE gauge read normal? 1. If batteries are disconnected, connect batteries. (WP 0085) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. Observe BATTERY VOLTAGE gauge.
Figure 10. Battery Voltage Gauge - Step 5.
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CONDITION/INDICATION Does BATTERY VOLTAGE gauge read normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0030
FIELD MAINTENANCE BATTERY VOLTAGE GAUGE READS HIGH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Personnel Required Construction Equipment Repairer 91L (2) References Alternator And Bracket Replacement (WP 0081) Batteries Servicing And Testing (WP 0082) Battery Replacement (WP 0086) References (cont.) Control Panel Battery Voltage Gauge Replacement (WP 0087) Engine Does Not Crank (WP 0006) General Wire Harness Repair (WP 0099) Open/Close Battery Box Cover (TM 5-3825-270-10) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE BATTERY VOLTAGE GAUGE READS HIGH STEP 1 Are 24.2 to 25.4 VDC measured at batteries with multimeter?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. Open battery box cover. (TM 5-3825-270-10) Setup multimeter to measure voltage.
NOTE
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NOTE
The following chart describes battery voltage characteristics when measured with a multimeter. This chart can be used to further isolate and troubleshoot batteries. 6. Compare multimeter reading to chart. Table 1. Battery State Of Charge Voltage Table - Step 1. Percentage Of Full Charge 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 12 Volt DC System 12.7 12.6 12.5 12.3 12.2 12.1 12.0 11.8 11.7 11.6 <=11.6 24 Volt DC System 25.4 25.2 25 24.6 24.4 24.2 24 23.6 23.4 23.2 <=23.2
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CONDITION/INDICATION Are 24.2 to 25.4 VDC measured at batteries with multimeter? DECISION No - Service (WP 0082) or replace batteries. (WP 0086) Verify problem is solved. (Step 3 - Does BATTERY VOLTAGE gauge read normal?) Yes - Go to step 2. (Step 2 - Do batteries read more than 28 VDC with multimeter while engine is running?) STEP 2 Do batteries read more than 28 VDC with multimeter while engine is running?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. Start engine. (TM 5-3825-270-10) Ensure multimeter is set to measure voltage. Connect red multimeter probe to positive battery terminal. Connect black multimeter probe to negative battery terminal.
CONDITION/INDICATION Do batteries read more than 28 VDC with multimeter while engine is running? DECISION No - Replace battery voltage gauge. (WP 0087) Verify problem is solved. (Step 3 - Does BATTERY VOLTAGE gauge read normal?) Yes - Alternator is overcharging batteries. Replace alternator. (WP 0081) Verify problem is solved. (Step 3 Does BATTERY VOLTAGE gauge read normal?)
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STEP 3 Does BATTERY VOLTAGE gauge read normal? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Observe BATTERY VOLTAGE gauge.
Figure 3. Battery Voltage Gauge - Step 3. CONDITION/INDICATION Does BATTERY VOLTAGE gauge read normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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FIELD MAINTENANCE ENGINE OFF/BATTERY DRAIN INDICATOR DOES NOT ILLUMINATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) References (cont.) Main Control Panel Engine Off/Battery Drain Indicator Replacement (WP 0093) General Wire Harness Repair (WP 0099) Governor Control Module Replacement (WP 0092) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE OFF/BATTERY DRAIN INDICATOR DOES NOT ILLUMINATE STEP 1 Does engine start?
NOTE
ENGINE OFF/BATTERY DRAIN indicator is wired in series with the ENGINE START/ ENGINE STOP switch. If engine starts, fault is with ENGINE OFF/BATTERY DRAIN indicator. Attempt to start engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine start? DECISION No - Go to step 2. (Step 2 - Are less than 200 ohms measured from positive terminal strip, terminal 15 to interconnect terminal strip, terminal 9?) Yes - Replace ENGINE OFF/BATTERY DRAIN indicator. (WP 0093) Verify problem is solved. (Step 5 - Does ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 2 Are less than 200 ohms measured from positive terminal strip, terminal 15 to interconnect terminal strip, terminal 9? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
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Figure 1. Control Panel Faceplate Screws - Step 2. 4. Set multimeter to measure continuity. (WP 0004)
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter lead to positive terminal strip, terminal 15.
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Figure 2. Positive Terminal Strip - Step 2. 6. 7. Connect black multimeter lead to interconnect terminal strip, terminal 9. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from positive terminal strip, terminal 15 to interconnect terminal strip, terminal 9? DECISION No - Repair or replace red wire from positive terminal strip, terminal 15 to interconnect terminal strip, terminal 9. (WP 0099) Verify problem is solved. (Step 5 - Does ENGINE OFF/BATTERY DRAIN indicator illuminate?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured on white/red stripe wire from ENGINE OFF/ BATTERY DRAIN indicator to governor controller harness connector, pin B3?) STEP 3 Are less than 200 ohms measured on white/red stripe wire from ENGINE OFF/BATTERY DRAIN indicator to governor controller harness connector, pin B3? 1. Disconnect governor controller harness connector from governor controller. (WP 0092) 2. Set multimeter to measure continuity. 3. Connect red multimeter lead to white/red stripe wire on ENGINE OFF/BATTERY DRAIN indicator.
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WHITE / BLACK WIRE
RED JUMPER WIRE
WHITE / RED WIRE

4.
With the aid of an assistant using jumper wire, connect black multimeter lead to governor controller harness connector, pin B3.
GOVERNOR CONTROLLER
Figure 4. Governor Controller Harness Connector - Step 3. 5. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on white/red stripe wire from ENGINE OFF/BATTERY DRAIN indicator to governor controller harness connector, pin B3? DECISION No - Go to step 4. (Step 4 - Are less than 200 ohms measured on white/red stripe wire on ENGINE OFF/ BATTERY DRAIN indicator to interconnect terminal strip, terminal 10?) Yes - Repair or replace white/black stripe wire from interconnect terminal strip, terminal 9 to ENGINE OFF/ BATTERY DRAIN indicator. (WP 0099) Verify problem is solved. (Step 5 - Does ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 4 Are less than 200 ohms measured on white/red stripe wire on ENGINE OFF/BATTERY DRAIN indicator to interconnect terminal strip, terminal 10? 1. Ensure multimeter is set to measure continuity.
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2.
Connect red multimeter lead to white/red stripe wire on ENGINE OFF/BATTERY DRAIN indicator.
WHITE / BLACK WIRE
RED JUMPER WIRE
WHITE / RED WIRE

3.
Connect black multimeter lead to interconnect terminal strip, terminal 10?.
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CONDITION/INDICATION Are less than 200 ohms measured on white/red stripe wire on ENGINE OFF/BATTERY DRAIN indicator to interconnect terminal strip, terminal 10?
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DECISION No - Repair or replace white/red stripe wire from ENGINE OFF/BATTERY DRAIN indicator to interconnect terminal strip, terminal 10. (WP 0099) Verify problem is solved. (Step 5 - Does ENGINE OFF/BATTERY DRAIN indicator illuminate?) Yes - Repair or replace black wire from interconnect terminal strip, terminal 10 to governor controller harness connector pin B3. (WP 0099) Verify problem is solved. (Step 5 - Does ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 5 Does ENGINE OFF/BATTERY DRAIN indicator illuminate? 1. If disconnected, connect batteries. (WP 0085) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. Observe ENGINE OFF/BATTERY DRAIN indicator.
Figure 7. Engine Off/Battery Drain Indicator - Step 5. CONDITION/INDICATION Does ENGINE OFF/BATTERY DRAIN indicator illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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FIELD MAINTENANCE ENGINE OFF/BATTERY DRAIN INDICATOR STAYS ILLUMINATED
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) References Battery Disconnect/Connection (WP 0085) Engine Cranks But Does Not Start (WP 0007) General Wire Harness Replacement (WP 0099) References (cont.) Governor Controller Module Replacement (WP 0092) Open/Close Battery Box Cover (TM 5-3825-270-10) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE OFF/BATTERY DRAIN INDICATOR STAYS ILLUMINATED STEP 1 Does engine start? Attempt to start engine. (TM 5-3825-270-10) CONDITION/INDICATION Does engine start? DECISION No - Go to Engine Cranks But Does Not Start. (WP 0007) Yes - Go to step 2. (Step 2 - Are greater than 10,000 ohms measured on black wire from interconnect terminal strip, terminal 10 to known good ground?) STEP 2 Are greater than 10,000 ohms measured on black wire from interconnect terminal strip, terminal 10 to known good ground?
NOTE
This test is checking for a short to ground condition. Wire isolation may be necessary to isolate fault. 1. 2. 3. 4. Shutdown engine. (TM 5-3825-270-10) Disconnect batteries. (WP 0085) Disconnect governor controller harness connector from governor controller. (WP 0092) Remove six control panel faceplate screws.
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WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Disconnect black wire at interconnect terminal strip, terminal 10. (WP 0099)
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Figure 2. Interconnect Terminal Strip - Step 2. 6. Set multimeter to measure continuity.
NOTE
This test is checking for a short in the wiring harness. Continuity should not be present on wire(s) being tested to ground. If continuity is present, a short to ground condition exists. 7. 8. 9. Connect red multimeter probe to disconnected black wire at interconnect terminal strip, terminal 10. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are greater than 10,000 ohms measured on black wire from interconnect terminal strip, terminal 10 to known good ground? DECISION No - Repair or replace black wire from interconnect terminal strip, terminal 10 to governor controller harness connector, pin B3. (WP 0099) Verify problem is solved. (Step 4 - Does ENGINE OFF/BATTERY DRAIN indicator turn off normally?) Yes - Go to step 3. (Step 3 - Are greater than 10,000 ohms measured on white/red wire at interconnect terminal strip, terminal 10 to known good ground?) STEP 3 Are greater than 10,000 ohms measured on white/red wire at interconnect terminal strip, terminal 10 to known good ground? 1. Reconnect governor controller harness connector to governor controller. (WP 0092) 2. Reconnect black wire to interconnect terminal strip terminal 10.
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Figure 3. Interconnect Terminal Strip - Step 3. 3. 4. 5. Disconnect white/black wire at interconnect terminal strip terminal 9. Disconnect white/red wire at interconnect terminal strip terminal 10. Set multimeter to measure continuity.
NOTE
This test is checking for a short. Continuity should not be present on wire(s) being tested to ground. If continuity is present a short to ground condition exists. 6. Connect red multimeter probe to disconnected white/red wire at interconnect terminal strip, terminal 10.
Figure 4. Interconnect Terminal Strip Terminals 9 And 10 - Step 3. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading.
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CONDITION/INDICATION Are greater than 10,000 ohms measured on white/red wire at interconnect terminal strip, terminal 10 to known good ground? DECISION No - Repair or replace white/red wire at interconnect terminal strip, terminal 10 to ENGINE OFF/BATTERY DRAIN indicator. (WP 0099) Verify problem is solved. (Step 4 - Does ENGINE OFF/BATTERY DRAIN indicator turn off normally?) Yes - Replace governor controller. (WP 0092) Verify problem is solved. (Step 4 - Does ENGINE OFF/BATTERY DRAIN indicator turn off normally?) STEP 4 Does ENGINE OFF/BATTERY DRAIN indicator turn off normally? 1. Start engine. (TM 5-3825-270-10) 2. Observe ENGINE OFF/BATTERY DRAIN indicator.
Figure 5. Engine Off/Battery Drain Indicator - Step 5. 3. Shutdown engine. (TM 5-3825-270-10)
CONDITION/INDICATION Does ENGINE OFF/BATTERY DRAIN indicator turn off normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0033
FIELD MAINTENANCE ENGINE OIL PRESSURE GAUGE READS LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: AutomotiveTool Kit, General Mechanic's: Automotive Multimeter (WP 0225, Table 1, Item 4) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) Engine Oil Pressure Testing (WP 0122) References (cont.) Engine Module Replacement (WP 0128) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Oil Pressure Sending Unit And Pressure Switch Unit Replacement (WP 0137) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE OIL PRESSURE GAUGE READS LOW STEP 1 Is engine filled to appropriate level with engine oil? Check engine oil level. (WP 0069) CONDITION/INDICATION Is engine filled to appropriate level with engine oil? DECISION No - Fill to correct level with engine oil. (WP 0069) Verify problem is solved. (Step 5 - Does engine oil pressure gauge read normal?) Yes - Go to step 2. (Step 2 - Does engine stall?) STEP 2 Does engine stall?
NOTE
Water distributor is equipped with engine protection functions. If engine oil pressure is 7 psi (48 kPa) or less at idle speed or falls below 20 psi (138 kPa) at rated speed the electronic governor controller will command engine to shut down. Start and observe engine for a minimum of three to five minutes. (TM 5-3825-270-10) If engine stalls, do not turn off power to control panel. CONDITION/INDICATION Does engine stall? DECISION No - Go to step 4. (Step 4 - Does engine pass engine oil pressure test?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured from violet wire at engine oil pressure switch to known good ground?)
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STEP 3 Are less than 200 ohms measured from violet wire at engine oil pressure switch to known good ground? 1. Disconnect batteries. (WP 0085) 2. Remove front engine access cover. (TM 5-3825-270-10) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Place red multimeter probe to violet wire at engine oil pressure switch.
VIOLET WIRE ENGINE OIL PRESSURE SWITCH
RED WIRE
Figure 1. Engine Oil Pressure Switch - Step 3. 5. 6. Place black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from violet wire at engine oil pressure switch to known good ground? DECISION No - Go to step 4. (Step 4 - Does engine pass engine oil pressure test?) Yes - Replace engine oil pressure switch. (WP 0137) Verify problem is solved. (Step 5 - Does engine oil pressure gauge read normal?) STEP 4
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Does engine pass engine oil pressure test? 1. Connect batteries. (WP 0085) 2. Perform engine oil pressure test. (WP 0122) CONDITION/INDICATION Does engine pass engine oil pressure test? DECISION No - Replace engine. (WP 0128) Verify problem is solved. (Step 5 - Does engine oil pressure gauge read normal?) Yes - Replace engine oil pressure sending unit. (WP 0137) Verify problem is solved. (Step 5 - Does engine oil pressure gauge read normal?) STEP 5 Does engine oil pressure gauge read normal? 1. If disconnected, connect batteries. (WP 0085) 2. Start engine and observe engine oil pressure gauge for a minimum of three to five minutes. (TM 5-3825-270-10)
Figure 2. Engine Oil Pressure Gauge - Step 5. CONDITION/INDICATION Does engine oil pressure gauge read normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0034
FIELD MAINTENANCE ENGINE OIL PRESSURE GAUGE READS LOW OR READS HIGH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Main Control Panel Engine Oil Pressure Gauge Replacement (WP 0090) Engine Oil Pressure Testing (WP 0122) Engine Replacement (WP 0128) References (cont.) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE OIL PRESSURE GAUGE READS LOW OR READS HIGH STEP 1 Is engine oil pressure high with engine at normal operating temperature?
NOTE
Engine pressure may read high when engine is cold or not warmed to normal operating temperature. Normal engine operating temperature is 160 to 180F (71 to 82 C). Normal engine oil pressure is 29-56 psi (199-386 kPa). 1. 2. Start engine and allow to warm to normal operating temperature. (TM 5-3825-270-10) Observe ENGINE TEMP gauge.
ENGINE TEMP GAUGE
Figure 1. Engine Temp Gauge - Step 1. 3. Observe ENGINE OIL PRESSURE gauge.
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Figure 2. Engine Oil Pressure Gauge - Step 3. CONDITION/INDICATION Is engine oil pressure high with engine at normal operating temperature? DECISION No - Your original problem has been resolved. Yes - Go to step 2. (Step 2 - Is engine oil pressure high after performing engine oil pressure test?) STEP 2 Is engine oil pressure high after performing engine oil pressure test? Test engine for high oil pressure. (WP 0122) CONDITION/INDICATION Is engine oil pressure high after performing engine oil pressure test? DECISION No - If engine tested normal for oil pressure, replace ENGINE OIL PRESSURE gauge. (WP 0090) Verify problem is solved. (Step 3 - Does ENGINE OIL PRESSURE gauge read normal?) Yes - Replace engine. (WP 0128) Verify problem is solved. (Step 3 - Does ENGINE OIL PRESSURE gauge read normal?) STEP 3 Does ENGINE OIL PRESSURE gauge read normal? Start engine and observe ENGINE OIL PRESSURE gauge at normal engine operating temperature. (TM 5-3825-270-10)
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Figure 3. Engine Oil Pressure Gauge - Step 3. CONDITION/INDICATION Does ENGINE OIL PRESSURE gauge read normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0035
FIELD MAINTENANCE ENGINE OIL PRESSURE GAUGE INOPERATIVE OR READS HIGH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Main Control Panel Engine Oil Pressure Gauge Replacement (WP 0090) References (cont.) General Wire Harness Repair (WP 0099) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Oil Pressure Sending Unit And Pressure Switch Replacement (WP 0137) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE OIL PRESSURE GAUGE INOPERATIVE OR READS HIGH STEP 1 Does ENGINE OIL PRESSURE gauge light illuminate? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Place LIGHTS switch to ON position. (TM 5-3825-270-10) 3. Observe ENGINE OIL PRESSURE gauge and verify if gauge is illuminated.
Figure 1. Engine Oil Pressure Gauge - Step 1. 4. Place LIGHTS switch to OFF position. (TM 5-3825-270-10)
CONDITION/INDICATION Does ENGINE OIL PRESSURE gauge light illuminate?
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DECISION No - Replace ENGINE OIL PRESSURE gauge. (WP 0090) Verify problem is solved. (Step 6 - Does ENGINE OIL PRESSURE gauge read normal?) Yes - Go to step 2. (Step 2 - Are 22 to 28 VDC present at engine OIL PRESSURE gauge harness connector, pin 6?) STEP 2 Are 22 to 28 VDC present at engine OIL PRESSURE gauge harness connector, pin 6?
WARNING
NOTE
Engine oil pressure, coolant temperature, and battery voltage control panel gauges have identical harness connectors. Only one is shown for reference. 3. Disconnect ENGINE OIL PRESSURE gauge harness connector. (WP 0090)
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Figure 3. Gauge Harness Connector - Step 2. 4. 5. 6. Set multimeter to measure voltage. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Connect red multimeter probe to ENGINE OIL PRESSURE gauge harness connector, pin 6.
Figure 4. Gauge Harness Connector - Step 2. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC present at engine OIL PRESSURE gauge harness connector, pin 6? DECISION No - Replace red wire from ENGINE OIL PRESSURE gauge harness connector, pin 6 to positive terminal strip. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE OIL PRESSURE gauge read normal?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured on black wire from ENGINE OIL PRESSURE gauge harness connector, pin 5 to negative terminal strip, terminal 16.) STEP 3
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Are less than 200 ohms measured on black wire from ENGINE OIL PRESSURE gauge harness connector, pin 5 to negative terminal strip, terminal 16. 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter probe to ENGINE OIL PRESSURE gauge harness connector, pin 5.
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Figure 6. Negative Terminal Strip - Step 3. 6. Note reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire from ENGINE OIL PRESSURE gauge harness connector, pin 5 to negative terminal strip, terminal 16. DECISION No - Replace black wire from ENGINE OIL PRESSURE gauge harness connector, pin 5 to negative terminal strip, terminal 16. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE OIL PRESSURE gauge read normal?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured from engine OIL PRESSURE gauge harness connector pin 3 to engine oil pressure sending unit?) STEP 4 Are less than 200 ohms measured from engine OIL PRESSURE gauge harness connector pin 3 to engine oil pressure sending unit? 1. Remove front engine access cover. (TM 5-3825-270-10) 2. Ensure multimeter is set to measure continuity. 3. Connect red multimeter probe to ENGINE OIL PRESSURE gauge harness connector, pin 3.
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Figure 7. Gauge Harness Connector - Step 4. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to white wire on engine oil pressure sending unit.
ENGINE OIL PRESSURE SENDING UNIT
WHITE WIRE
Figure 8. Engine Oil Pressure Sending Unit - Step 4. 5. Note reading.
CONDITION/INDICATION Are less than 200 ohms measured from engine OIL PRESSURE gauge harness connector pin 3 to engine oil pressure sending unit? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured from ENGINE OIL PRESSURE gauge harness connector, pin 3 to interconnect harness connector, terminal 20?) Yes - Replace engine oil pressure sending unit. (WP 0137) Verify problem is solved. (Step 6 - Does ENGINE OIL PRESSURE gauge read normal?) STEP 5
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Are less than 200 ohms measured from ENGINE OIL PRESSURE gauge harness connector, pin 3 to interconnect harness connector, terminal 20? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to ENGINE OIL PRESSURE gauge harness connector, pin 3.
Figure 9. Gauge Harness Connector - Step 5. 3. Connect black multimeter probe to interconnect terminal strip, terminal 20.
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CONDITION/INDICATION Are less than 200 ohms measured from ENGINE OIL PRESSURE gauge harness connector, pin 3 to interconnect harness connector, terminal 20?
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DECISION No - Replace blue wire from ENGINE OIL PRESSURE gauge harness connector, pin 3 to interconnect terminal strip, terminal 20. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE OIL PRESSURE gauge read normal?) Yes - Replace white wire from interconnect terminal strip, terminal 20 to engine oil pressure sending unit. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE OIL PRESSURE gauge read normal?) STEP 6 Does ENGINE OIL PRESSURE gauge read normal? Start engine and observe ENGINE OIL PRESSURE gauge at normal engine operating temperature. (TM 5-3825-270-10)
Figure 11. Engine Oil Pressure Gauge - Step 6. CONDITION/INDICATION Does ENGINE OIL PRESSURE gauge read normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0036
FIELD MAINTENANCE ENGINE TEMPERATURE GAUGE INOPERATIVE OR READS HIGH
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) Engine Coolant Temperature Sending Unit Replacement (WP 0115) References (cont.) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) General Wire Harness Repair (WP 0099) Main Control Panel Engine Temperature Gauge Replacement (WP 0097) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE TEMPERATURE GAUGE INOPERATIVE OR READS HIGH STEP 1 Does ENGINE TEMP gauge light illuminate? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Place LIGHTS switch to ON position. (TM 5-3825-270-10) 3. Observe ENGINE TEMP gauge and verify if gauge is illuminated.
ENGINE TEMP GAUGE
Figure 1. Engine Temp Gauge - Step 1. 4. Place LIGHTS switch to OFF position. (TM 5-3825-270-10)
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CONDITION/INDICATION Does ENGINE TEMP gauge light illuminate? DECISION No - Replace ENGINE TEMP gauge. (WP 0097) Verify problem is solved. (Step 6 - Does ENGINE TEMP gauge operate normally?) Yes - Go to step 2. (Step 2 - Are 22 to 28 VDC present at ENGINE TEMP gauge harness connector, pin 6?) STEP 2 Are 22 to 28 VDC present at ENGINE TEMP gauge harness connector, pin 6?
WARNING
NOTE
Engine oil pressure, coolant temperature, and battery voltage control panel gauges have identical harness connectors. Only one is shown for reference. 3. Disconnect ENGINE TEMP gauge harness connector. (WP 0097)
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Figure 3. Gauge Harness Connector - Step 2. 4. 5. 6. Set multimeter to measure voltage. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Connect red multimeter probe to ENGINE TEMP gauge harness connector, pin 6.
Figure 4. Gauge Harness Connector - Step 2. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC present at ENGINE TEMP gauge harness connector, pin 6? DECISION No - Replace red wire from ENGINE TEMP gauge harness connector, pin 7 to positive terminal strip. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE TEMP gauge operate normally?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured on black wire from ENGINE TEMP gauge harness connector, pin 5 to negative terminal strip, terminal 15.) STEP 3
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Are less than 200 ohms measured on black wire from ENGINE TEMP gauge harness connector, pin 5 to negative terminal strip, terminal 15. 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter probe to ENGINE TEMP gauge harness connector, pin 5.
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CONDITION/INDICATION Are less than 200 ohms measured on black wire from ENGINE TEMP gauge harness connector, pin 5 to negative terminal strip, terminal 15. DECISION No - Replace black wire from ENGINE TEMP gauge harness connector, pin 5 to negative terminal strip, terminal 15. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE TEMP gauge operate normally?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured from ENGINE TEMP gauge harness connector, pin 3 to engine coolant temperature sending unit?) STEP 4 Are less than 200 ohms measured from ENGINE TEMP gauge harness connector, pin 3 to engine coolant temperature sending unit? 1. Remove front engine access cover. (TM 5-3825-270-10) 2. Ensure multimeter is set to measure continuity. 3. Connect red multimeter probe to ENGINE TEMP gauge harness connector, pin 3.
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Figure 7. Gauge Harness Connector - Step 4. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to black wire on engine coolant temperature sending unit.
ENGINE COOLANT TEMPERATURE SENDING UNIT
BLACK WIRE
Figure 8. Engine Coolant Temperature Sending Unit - Step 4. 5. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from ENGINE TEMP gauge harness connector, pin 3 to engine coolant temperature sending unit? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured from ENGINE TEMP gauge harness connector, pin 3 to interconnect harness connector, terminal 19?) Yes - Replace engine coolant temperature sending unit. (WP 0115) Verify problem is solved. (Step 6 - Does ENGINE TEMP gauge operate normally?)
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STEP 5 Are less than 200 ohms measured from ENGINE TEMP gauge harness connector, pin 3 to interconnect harness connector, terminal 19? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to ENGINE TEMP gauge harness connector, pin 3.
Figure 9. Gauge Harness Connector - Step 5. 3. Connect black multimeter probe to interconnect terminal strip, terminal 19.
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CONDITION/INDICATION Are less than 200 ohms measured from ENGINE TEMP gauge harness connector, pin 3 to interconnect harness connector, terminal 19?
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DECISION No - Replace blue wire from ENGINE TEMP gauge harness connector, pin 3 to interconnect terminal strip, terminal 19. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE TEMP gauge operate normally?) Yes - Replace black wire from interconnect terminal, strip terminal 19 to engine coolant temperature sending unit. (WP 0099) Verify problem is solved. (Step 6 - Does ENGINE TEMP gauge operate normally?) STEP 6 Does ENGINE TEMP gauge operate normally? Start engine and observe ENGINE TEMP gauge while warming to normal operating temperature. (TM 5-3825-270-10)
ENGINE TEMP GAUGE
Figure 11. Engine Temperature Gauge - Step 6. CONDITION/INDICATION Does ENGINE TEMP gauge operate normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0037
FIELD MAINTENANCE MAIN CONTROL PANEL TACHOMETER DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Alternator And Bracket Replacement (WP 0081) References (cont.) Battery Disconnect/Connection (WP 0085) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) General Wire Harness Repair (WP 0099) Tachometer/Hourmeter Replacement (WP 0102) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MAIN CONTROL PANEL TACHOMETER DOES NOT OPERATE STEP 1 Does tachometer light illuminate? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Place LIGHTS switch to ON position. (TM 5-3825-270-10) 3. Verify if tachometer is illuminated.
TACHOMETER
Figure 1. Tachometer - Step 1. 4. Place LIGHTS switch to OFF position. (TM 5-3825-270-10)
CONDITION/INDICATION Does tachometer light illuminate?
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DECISION No - Replace tachometer. (WP 0102) Verify problem is solved. (Step 7 - Does tachometer operate normally?) Yes - Go to step 2. (Step 2 - Is tachometer pulse adjustment dial set to pulse 5?) STEP 2 Is tachometer pulse adjustment dial set to pulse 5?
NOTE
The tachometer receives its engine speed signal from the alternator. If the tachometer is not set to proper setting, incorrect engine speed or no engine speed may be observed from gauge. 1. 2. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) Remove six control panel faceplate screws.
Figure 2. Control Panel Faceplate Screws - Step 2. 3. Check tachometer pulse adjustment dial.
GREY WIRE RED WIRE BLACK WIRE PULSE ADJUSTMENT DIAL
Figure 3. Pulse Adjustment Dial - Step 2.
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CONDITION/INDICATION Is tachometer pulse adjustment dial set to pulse 5? DECISION No - Place tachometer pulse adjustment dial to pulse 5. Verify problem is solved. (Step 7 - Does tachometer operate normally?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC present at red wire on tachometer?) STEP 3 Are 22 to 28 VDC present at red wire on tachometer?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. Set multimeter to measure voltage. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Connect red multimeter probe to red wire at tachometer.
Figure 4. Tachometer Red Wire - Step 3. 4. 5. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC present at red wire on tachometer? DECISION No - Replace red wire from tachometer to positive terminal strip terminal. (WP 0099) Verify problem is solved. (Step 7 - Does tachometer operate normally?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire from tachometer to negative terminal strip, terminal 13.) STEP 4 Are less than 200 ohms measured on black wire from tachometer to negative terminal strip, terminal 13. 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
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2. 3.
Disconnect batteries. (WP 0085) Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter probe to black wire on tachometer.
Figure 5. Tachometer Black Wire - Step 4. 5. Connect black multimeter probe to negative terminal strip, terminal 13.
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CONDITION/INDICATION Are less than 200 ohms measured on black wire from tachometer to negative terminal strip, terminal 13. DECISION No - Replace black wire from tachometer to negative terminal strip terminal 13. (WP 0099) Verify problem is solved. (Step 7 - Does tachometer operate normally?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured between grey wire on tachometer and clear wire on alternator?) STEP 5 Are less than 200 ohms measured between grey wire on tachometer and clear wire on alternator? 1. Remove front engine access cover. (TM 5-3825-270-10) 2. Disconnect clear wire harness connector on alternator.
ALTERNATOR
CLEAR WIRE HARNESS CONNECTOR
Figure 7. Alternator And Clear Wire Harness Connector - Step 5. 3. Ensure multimeter is set to measure continuity.
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4.
Connect red multimeter probe to grey wire on tachometer.

Figure 8. Tachometer Grey Wire - Step 5. 5. With the aid of an assistant using jumper wire, connect black multimeter probe to clear wire harness connector on alternator.
ALTERNATOR
CLEAR WIRE HARNESS CONNECTOR
Figure 9. Clear Wire Harness Connector - Step 5. 6. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured between grey wire on tachometer and clear wire on alternator? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured from grey wire on tachometer to interconnect terminal strip terminal 17?) Yes - Replace tachometer. (WP 0102) If problem persist, replace alternator. (WP 0081) Verify problem is solved. (Step 7 - Does tachometer operate normally?) STEP 6 Are less than 200 ohms measured from grey wire on tachometer to interconnect terminal strip terminal 17? 1. Ensure multimeter is set to measure continuity.
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2.
Connect red multimeter probe to grey wire on tachometer.

Figure 10. Tachometer Grey Wire - Step 6. 3. Connect black multimeter probe to interconnect terminal strip, terminal 17.
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CONDITION/INDICATION Are less than 200 ohms measured from grey wire on tachometer to interconnect terminal strip terminal 17? DECISION No - Replace clear wire from interconnect terminal strip terminal 17 to alternator. (WP 0099) Verify problem is solved. (Step 7 - Does tachometer operate normally?) Yes - Replace grey wire from tachometer to interconnect terminal strip, terminal 17 (WP 0099) Verify problem is solved. (Step 7 - Does tachometer operate normally?) STEP 7
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Does tachometer operate normally? 1. If disconnected, connect batteries. (WP 0085) 2. Start engine and observe tachometer. (TM 5-3825-270-10)
TACHOMETER
Figure 12. Tachometer - Step 7. CONDITION/INDICATION Does tachometer operate normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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FIELD MAINTENANCE WATER PUMP INLET GAUGE DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Water Pump Inlet Gauge And Hose Replacement (WP 0178) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER PUMP INLET GAUGE DOES NOT OPERATE STEP 1 Is hose from WATER PUMP INLET gauge to water pump free of leaks and damage? Visually inspect hose from WATER PUMP INLET gauge to water pump for leaks and damage.
HOSE
WATER PUMP
WATER PUMP INLET GAUGE
HOSE
Figure 1. Water Pump Inlet Gauge And Hose - Step 1. CONDITION/INDICATION Is hose from WATER PUMP INLET gauge to water pump free of leaks and damage?
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DECISION No - Replace hose. (WP 0178) Verify problem is solved. (Step 3 - Does WATER PUMP INLET gauge operate?) Yes - Go to step 2. (Step 2 - Is hose from WATER PUMP INLET gauge to water pump free of restriction?) STEP 2 Is hose from WATER PUMP INLET gauge to water pump free of restriction? 1. Remove hose between WATER PUMP INLET gauge and water pump. (WP 0178)
HOSE
WATER PUMP
HOSE
Figure 2. Water Pump Inlet Gauge And Hose - Step 2. 2. Ensure hose is free of restriction.
CONDITION/INDICATION Is hose from WATER PUMP INLET gauge to water pump free of restriction? DECISION No - Remove restriction or replace hose. (WP 0178) Verify problem is solved. (Step 3 - Does WATER PUMP INLET gauge operate?) Yes - Replace WATER PUMP INLET gauge. (WP 0178) Verify problem is solved. (Step 3 - Does WATER PUMP INLET gauge operate?) STEP 3 Does WATER PUMP INLET gauge operate? 1. Operate water hose. (TM 5-3825-270-10) 2. Observe WATER PUMP INLET gauge.
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Figure 3. Water Pump Inlet Gauge - Step 3. CONDITION/INDICATION Does WATER PUMP INLET gauge operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0039
FIELD MAINTENANCE WATER PUMP OUTLET GAUGE DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Water Pump Outlet Gauge And Hose Replacement (WP 0179) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER PUMP OUTLET GAUGE DOES NOT OPERATE STEP 1 Is hose from WATER PUMP OUTLET gauge to water pump leaking or damaged? Visually inspect hose from WATER PUMP OUTLET gauge to water pump for leaks and damage.
HOSE
HOSE
WATER PUMP
Figure 1. Water Pump Outlet Gauge And Hose - Step 1. CONDITION/INDICATION Is hose from WATER PUMP OUTLET gauge to water pump leaking or damaged?
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DECISION No - Go to step 2. (Step 2 - Is hose from WATER PUMP OUTLET gauge to water pump restricted?) Yes - Replace hose. (WP 0179) Verify problem is solved. (Step 3 - Does WATER PUMP OUTLET gauge operate?) STEP 2 Is hose from WATER PUMP OUTLET gauge to water pump restricted? 1. Remove hose between WATER PUMP OUTLET gauge and water pump. (WP 0179)
HOSE
HOSE
WATER PUMP
Figure 2. Water Pump Outlet Gauge And Hose - Step 2. 2. Ensure hose is free of restriction.
CONDITION/INDICATION Is hose from WATER PUMP OUTLET gauge to water pump restricted? DECISION No - Replace WATER PUMP OUTLET gauge. (WP 0179) Verify problem is solved. (Step 3 - Does WATER PUMP OUTLET gauge operate?) Yes - Remove restriction or replace hose. (WP 0179) Verify problem is solved. (Step 3 - Does WATER PUMP OUTLET gauge operate?) STEP 3 Does WATER PUMP OUTLET gauge operate? 1. Operate water hose. (TM 5-3825-270-10) 2. Observe WATER PUMP OUTLET gauge.
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Figure 3. Water Pump Outlet Gauge - Step 3. CONDITION/INDICATION Does WATER PUMP OUTLET gauge operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0040
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE SPEED RESUME/IDLE SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) General Wire Harness Repair (WP 0099) References (cont.) Governor Control Module Replacement (WP 0092) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Main Control Panel Engine Speed Resume/Idle Switch Replacement (WP 0094) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MAIN CONTROL PANEL ENGINE SPEED RESUME/IDLE SWITCH DOES NOT OPERATE STEP 1 Are less than 200 ohms measured across engine RESUME/IDLE switch terminals with switch in RESUME and IDLE positions? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
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0040
4.
Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter probe to terminal 2 on engine RESUME/IDLE switch.
BACK OF PANEL
ENGINE RED/BLACK RESUME/IDLE WIRE SWITCH (TERMINAL 1)
RED WIRE TERMINAL 1 TERMINAL 2 TERMINAL 3 BACK OF RESUME/IDLE SWITCH BLACK/RED WIRE (TERMINAL 3)
Figure 2. Engine Resume/Idle Switch - Step 1. 6. 7. 8. 9. 10. 11. Connect black multimeter probe to terminal 1 on engine RESUME/IDLE switch. While holding multimeter probes to terminals, place engine RESUME/IDLE switch to IDLE position. Note multimeter reading. Move black multimeter probe to terminal 3 on engine RESUME/IDLE switch. While holding multimeter probes to terminals, place engine RESUME/IDLE switch to RESUME position. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured across engine RESUME/IDLE switch terminals with switch in RESUME and IDLE positions? DECISION No - Replace engine RESUME/IDLE switch. (WP 0094) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) Yes - Go to step 2. (Step 2 - Are less than 200 ohms measured from black/red wire on engine RESUME/IDLE switch to governor controller harness connector, pin B1?)
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STEP 2 Are less than 200 ohms measured from black/red wire on engine RESUME/IDLE switch to governor controller harness connector, pin B1? 1. Disconnect governor controller harness connector. (WP 0092) 2. Ensure multimeter is set to measure continuity. 3. Connect red multimeter probe to black/red wire on engine RESUME/IDLE switch.
BACK OF PANEL RED/BLACK WIRE
ENGINE RESUME/IDLE SWITCH RED WIRE BLACK/RED WIRE
Figure 3. Engine Resume/Idle Switch - Step 2. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to governor controller harness connector, pin B1.
GOVERNOR CONTROLLER
CONDITION/INDICATION Are less than 200 ohms measured from black/red wire on engine RESUME/IDLE switch to governor controller harness connector, pin B1?
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DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured from black/red wire on engine RESUME/IDLE switch to interconnect terminal strip, terminal 2?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured from red/black wire on engine RESUME/IDLE switch to governor controller harness connector pin C3?) STEP 3 Are less than 200 ohms measured from red/black wire on engine RESUME/IDLE switch to governor controller harness connector pin C3? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red/black wire on engine RESUME/IDLE switch.
Figure 5. Engine Resume/Idle Switch - Step 3. 3. With the aid of an assistant using jumper wire, connect black multimeter probe to governor controller harness connector, pin C3.
GOVERNOR CONTROLLER
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CONDITION/INDICATION Are less than 200 ohms measured from red/black wire on engine RESUME/IDLE switch to governor controller harness connector pin C3? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured from red/black wire on engine RESUME/IDLE switch to interconnect terminal strip, terminal 3?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on red jumper wire between engine RESUME/ IDLE switch and ENGINE START switch?) STEP 4 Are less than 200 ohms measured on red jumper wire between engine RESUME/IDLE switch and ENGINE START switch? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red jumper wire at engine RESUME/IDLE switch.
Figure 7. Engine Resume/Idle Switch - Step 4. 3. Connect black multimeter probe to red jumper wire at ENGINE START/ENGINE STOP switch.
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RED JUMPER WIRES
ORANGE/BLACK WIRE
Figure 8. Engine Start/Engine Stop Switch - Step 4. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on red jumper wire between engine RESUME/IDLE switch and ENGINE START switch? DECISION No - Repair or replace red jumper wire between engine RESUME/IDLE switch and ENGINE START/ENGINE STOP switch. (WP 0099) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) Yes - Replace governor controller. (WP 0092) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) STEP 5 Are less than 200 ohms measured from black/red wire on engine RESUME/IDLE switch to interconnect terminal strip, terminal 2? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to black/red wire on engine RESUME/IDLE switch.
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BACK OF PANEL
RED/BLACK WIRE
Figure 9. Engine Resume/Idle Switch - Step 5. 3. Connect black multimeter probe to interconnect terminal strip, terminal 2.
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CONDITION/INDICATION Are less than 200 ohms measured from black/red wire on engine RESUME/IDLE switch to interconnect terminal strip, terminal 2?
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DECISION No - Repair or replace black/red wire between engine RESUME/IDLE switch and interconnect terminal strip, terminal 2. (WP 0099) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) Yes - Repair or replace black wire from interconnect terminal strip, terminal 2 to governor controller harness connector, pin B1. (WP 0099) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) STEP 6 Are less than 200 ohms measured from red/black wire on engine RESUME/IDLE switch to interconnect terminal strip, terminal 3? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red/black wire on engine RESUME/IDLE switch.
Figure 11. Engine Resume/Idle Switch - Step 6. 3. Connect black multimeter probe to interconnect terminal strip, terminal 3.
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CONDITION/INDICATION Are less than 200 ohms measured from red/black wire on engine RESUME/IDLE switch to interconnect terminal strip, terminal 3? DECISION No - Repair or replace red/black wire between engine RESUME/IDLE switch and interconnect terminal strip, terminal 3. (WP 0099) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) Yes - Repair or replace white wire from interconnect terminal strip, terminal 3 to governor controller harness connector, pin C3. (WP 0099) Verify problem is solved. (Step 7 - Does engine RESUME/IDLE switch operate normally?) STEP 7 Does engine RESUME/IDLE switch operate normally? 1. If disconnected, connect batteries. (WP 0085) 2. Start engine and increase RPM. (TM 5-3825-270-10) 3. Verify engine RPM resumes previous engine speed when engine RESUME/IDLE switch is positioned to RESUME. (TM 5-3825-270-10) CONDITION/INDICATION Does engine RESUME/IDLE switch operate normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0041
FIELD MAINTENANCE ENGINE SPEED RPM SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) General Wire Harness Repair (WP 0099) References (cont.) Governor Control Module Replacement (WP 0092) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Main Control Panel Engine Speed RPM Switch Replacement (WP 0095) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE ENGINE SPEED RPM SWITCH DOES NOT OPERATE STEP 1 Are less than 200 ohms measured across engine speed RPM switch terminals with switch in '+' and '' positions? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
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0041
4.
Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter probe to terminal 2 on engine speed RPM switch.
BACK OF RED/GREEN CONTROL PANEL WIRE RED JUMPER WIRE
RED/WHITE WIRE TERMINAL 1 TERMINAL 2 TERMINAL 3 BACK OF ENGINE SPEED RPM SWITCH
ENGINE SPEED RPM SWITCH
Figure 2. Engine Speed RPM Switch - Step 1. 6. 7. 8. 9. 10. 11. Connect black multimeter probe to terminal 1 on engine speed RPM switch. While holding multimeter probes to terminals, place engine speed RPM switch to '' position. Note multimeter reading. Move black multimeter probe to terminal 3 on engine speed RPM switch. While holding multimeter probes to terminals, place engine speed RPM switch to '+' position. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured across engine speed RPM switch terminals with switch in '+' and '' positions? DECISION No - Replace engine speed RPM switch. (WP 0095) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?) Yes - Go to step 2. (Step 2 - Are less than 200 ohms measured from red/white wire on engine speed RPM switch to governor controller harness connector, pin E1?) STEP 2
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0041
Are less than 200 ohms measured from red/white wire on engine speed RPM switch to governor controller harness connector, pin E1? 1. Disconnect governor controller harness connector. (WP 0092) 2. Ensure multimeter is set to measure continuity. 3. Connect red multimeter probe to red/white wire on engine speed RPM switch.
RED/WHITE WIRE
Figure 3. Engine Speed RPM Switch - Step 2. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to governor controller harness connector, pin E1.
GOVERNOR CONTROLLER
CONDITION/INDICATION Are less than 200 ohms measured from red/white wire on engine speed RPM switch to governor controller harness connector, pin E1? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured from red/white wire on engine speed RPM switch to interconnect terminal strip, terminal 4?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured from red/green wire on engine speed RPM switch to governor controller harness connector, pin C1?) STEP 3
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Are less than 200 ohms measured from red/green wire on engine speed RPM switch to governor controller harness connector, pin C1? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red/green wire on engine speed RPM switch.
RED/WHITE WIRE
Figure 5. Engine Speed RPM Switch - Step 3. 3. With the aid of an assistant using jumper wire, connect black multimeter probe to governor controller harness connector, pin C1.
GOVERNOR CONTROLLER
CONDITION/INDICATION Are less than 200 ohms measured from red/green wire on engine speed RPM switch to governor controller harness connector, pin C1? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured from red/green wire on engine speed RPM switch to interconnect terminal strip terminal 5?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on red jumper wire between engine speed RPM switch and engine RESUME/IDLE switch?) STEP 4
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Are less than 200 ohms measured on red jumper wire between engine speed RPM switch and engine RESUME/IDLE switch? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red jumper wire at engine speed RPM switch.
RED/WHITE WIRE
Figure 7. Engine Speed RPM Switch - Step 4. 3. Connect black multimeter probe to red jumper wire at engine RESUME/IDLE switch.
Figure 8. Engine Resume/Idle Switch - Step 4. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on red jumper wire between engine speed RPM switch and engine RESUME/ IDLE switch? DECISION No - Repair or replace red jumper wire between engine speed RPM switch and engine RESUME/IDLE switch. (WP 0099) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?) Yes - Replace governor controller. (WP 0092) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?)
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STEP 5 Are less than 200 ohms measured from red/white wire on engine speed RPM switch to interconnect terminal strip, terminal 4? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red/white wire on engine speed RPM switch.
RED/WHITE WIRE
Figure 9. Engine Speed RPM Switch - Step 5. 3. Connect black multimeter probe to interconnect terminal strip, terminal 4.
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CONDITION/INDICATION Are less than 200 ohms measured from red/white wire on engine speed RPM switch to interconnect terminal strip, terminal 4?
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DECISION No - Repair or replace red/white wire between engine speed RPM switch and interconnect terminal strip, terminal 4. (WP 0099) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?) Yes - Repair or replace black wire from interconnect terminal strip, terminal 4 to governor controller harness connector, pin E1. (WP 0099) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?) STEP 6 Are less than 200 ohms measured from red/green wire on engine speed RPM switch to interconnect terminal strip terminal 5? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red/green wire on engine speed RPM switch.
RED/WHITE WIRE
Figure 11. Engine Speed RPM Switch - Step 6. 3. Connect black multimeter probe to interconnect terminal strip, terminal 5.
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CONDITION/INDICATION Are less than 200 ohms measured from red/green wire on engine speed RPM switch to interconnect terminal strip terminal 5? DECISION No - Repair or replace red/green wire between engine speed RPM switch and interconnect terminal strip, terminal 5. (WP 0099) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?) Yes - Repair or replace white wire from interconnect terminal strip, terminal 5 to governor controller harness connector, pin C1. (WP 0099) Verify problem is solved. (Step 7 - Does engine speed RPM switch operate?) STEP 7 Does engine speed RPM switch operate? 1. Start engine. (TM 5-3825-270-10) 2. Increase and decrease engine speed using engine speed RPM switch. (TM 5-3825-270-10) CONDITION/INDICATION Does engine speed RPM switch operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0042
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE SPEED SET SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) General Wire Harness Repair (WP 0099) References (cont.) Governor Control Module Replacement (WP 0092) Field Level Preventive Maintenance Checks And Services (PMCS) (WP 0069) Main Control Panel Engine Speed Set Switch Replacement (WP 0096) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MAIN CONTROL PANEL ENGINE SPEED SET SWITCH DOES NOT OPERATE STEP 1 Are less than 200 ohms measured across engine speed SET switch terminal 1 and terminal 2 when switch is pressed? 1. Ensure EMERGENCY STOP switch is in off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
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4. 5.
Set multimeter to measure continuity. Connect red multimeter probe to terminal 1 on engine speed SET switch.
ENGINE SPEED SET SWITCH BACK OF CONTROL PANEL
RED JUMPER WIRE
TERMINAL 1 TERMINAL 2
BLACK/WHITE WIRE
Figure 2. Engine Speed Set Switch - Step 1. 6. 7. 8. Connect black multimeter probe to terminal 2 on engine speed SET switch. While holding multimeter probes to terminals, press engine speed SET switch. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured across engine speed SET switch terminal 1 and terminal 2 when switch is pressed? DECISION No - Replace engine speed SET switch. (WP 0096) Verify problem is solved. (Step 5 - Does engine speed SET switch operate normally?) Yes - Go to step 2. (Step 2 - Are less than 200 ohms measured from black/white wire on engine speed SET switch to governor controller harness connector, pin E2?) STEP 2 Are less than 200 ohms measured from black/white wire on engine speed SET switch to governor controller harness connector, pin E2? 1. Disconnect governor controller harness connector. (WP 0092) 2. Ensure multimeter is set to measure continuity. 3. Connect red multimeter probe to black/white wire at engine speed SET switch.
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RED JUMPER WIRE
BLACK/WHITE WIRE
Figure 3. Engine Speed Set Switch - Step 2. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to governor controller harness connector, pin E2.
GOVERNOR CONTROLLER
CONDITION/INDICATION Are less than 200 ohms measured from black/white wire on engine speed SET switch to governor controller harness connector, pin E2? DECISION No - Go to step 4. (Step 4 - Are less than 200 ohms measured from black/white wire on engine speed SET switch to interconnect terminal strip, terminal 1?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured on red jumper wire between engine speed SET switch and engine speed RPM switch?) STEP 3 Are less than 200 ohms measured on red jumper wire between engine speed SET switch and engine speed RPM switch? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to red jumper wire at engine speed SET switch.
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RED JUMPER WIRE
BLACK/WHITE WIRE
Figure 5. Engine Speed Set Switch - Step 3. 3. Connect black multimeter probe to red jumper wire at engine speed RPM switch.
RED/WHITE WIRE
Figure 6. Engine Speed RPM Switch - Step 3. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on red jumper wire between engine speed SET switch and engine speed RPM switch? DECISION No - Repair or replace red jumper wire between engine speed SET switch and engine speed RPM switch. (WP 0099) Verify problem is solved. (Step 5 - Does engine speed SET switch operate normally?) Yes - Replace governor controller. (WP 0092) Verify problem is solved. (Step 5 - Does engine speed SET switch operate normally?) STEP 4 Are less than 200 ohms measured from black/white wire on engine speed SET switch to interconnect terminal strip, terminal 1? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to black/white wire on engine speed SET switch.
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RED JUMPER WIRE
BLACK/WHITE WIRE
Figure 7. Engine Speed Set Switch - Step 4. 3. Connect black multimeter probe to interconnect terminal strip, terminal 1.
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CONDITION/INDICATION Are less than 200 ohms measured from black/white wire on engine speed SET switch to interconnect terminal strip, terminal 1? DECISION No - Repair or replace black/white wire between engine speed SET switch and interconnect terminal strip, terminal 1. (WP 0099) Verify problem is solved. (Step 5 - Does engine speed SET switch operate normally?) Yes - Repair or replace black wire from interconnect terminal strip, terminal 1 to governor controller harness connector, pin E2. (WP 0099) Verify problem is solved. (Step 5 - Does engine speed SET switch operate normally?) STEP 5
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Does engine speed SET switch operate normally? 1. Start engine. (TM 5-3825-270-10) 2. Increase and decrease engine speed and ensure engine speed SET switch operates normally. (TM 5-3825-270-10) CONDITION/INDICATION Does engine speed SET switch operate normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0043
FIELD MAINTENANCE LEFT WATER SPRINKLERS SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) References (cont.) General Wire Harness Repair (WP 0099) Main Control Panel Tachometer Does Not Operate (WP 0037) Main Control Panel Water Sprinklers Switch Replacement (WP 0105) Solenoid Valve Replacement (WP 0168) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE LEFT WATER SPRINKLERS SWITCH DOES NOT OPERATE STEP 1 Does RIGHT WATER SPRINKLERS switch operate? Verify if the RIGHT WATER SPRINKLERS switch operates. (TM 5-3825-270-10) CONDITION/INDICATION Does RIGHT WATER SPRINKLERS switch operate? DECISION No - Go to step 6. (Step 6 - Does tachometer operate?) Yes - Go to step 2. (Step 2 - Are 22 to 28 VDC measured at pin 1 (red wire) on left solenoid harness connector?) STEP 2 Are 22 to 28 VDC measured at pin 1 (red wire) on left solenoid harness connector?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. Disconnect left solenoid harness connector from left solenoid valve. (WP 0168) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Move LEFT WATER SPRINKLERS switch to ON position.
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LEFT WATER SPRINKERS SWITCH

Figure 1. Left Water Sprinklers Switch - Step 2. 4. 5. Set multimeter to measure voltage. Connect red multimeter probe to pin 1 (red wire) on left solenoid harness connector.
LEFT SOLENOID VALVE LEFT SOLENOID HARNESS CONNECTOR (GRAY)
PIN 1 (RED WIRE)
PIN 2 (BLACK WIRE)
Figure 2. Left Solenoid Harness Connector - Step 2. 6. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
CONDITION/INDICATION Are 22 to 28 VDC measured at pin 1 (red wire) on left solenoid harness connector? DECISION No - Go to step 4. (Step 4 - Are less than 200 ohms measured across LEFT WATER SPRINKLERS switch terminals with switch in ON position?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured from pin 2 (black wire) on left solenoid harness connector to negative terminal strip, terminal 9?)
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STEP 3 Are less than 200 ohms measured from pin 2 (black wire) on left solenoid harness connector to negative terminal strip, terminal 9? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
WARNING
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Figure 4. Negative Terminal Strip - Step 3. 6. With the aid of an assistant using jumper wire, connect black multimeter probe to pin 2 (black wire) on left solenoid harness connector.
LEFT SOLENOID VALVE LEFT SOLENOID HARNESS CONNECTOR (GRAY)
PIN 1 (RED WIRE)
PIN 2 (BLACK WIRE)
Figure 5. Left Solenoid Harness Connector (Gray) - Step 3. 7. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from pin 2 (black wire) on left solenoid harness connector to negative terminal strip, terminal 9?
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DECISION No - Replace black wire from left solenoid harness connector to negative terminal strip, terminal 9. (WP 0099) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) Yes - Replace left solenoid valve. (WP 0168) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) STEP 4 Are less than 200 ohms measured across LEFT WATER SPRINKLERS switch terminals with switch in ON position? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter probe to terminal 2 on LEFT WATER SPRINKLERS switch.
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WHITE JUMPER BLUE/WHITE WIRE WIRE
BLUE/BLACK WIRE TERMINAL 1 TERMINAL 2 TERMINAL 3 BACK OF WATER SPRINKLER SWITCH LEFT WATER SPRINKLER SWITCH
Figure 7. Left Water Sprinkler Switch - Step 4. 6. 7. 8. Connect black multimeter probe to terminal 1 on LEFT WATER SPRINKLERS switch While holding multimeter probes to terminals, move LEFT WATER SPRINKLERS switch to ON position. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured across LEFT WATER SPRINKLERS switch terminals with switch in ON position? DECISION No - Replace LEFT WATER SPRINKLERS switch. (WP 0105) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) Yes - Go to step 5. (Step 5 - Are 22 to 28 VDC measured on blue/black wire at interconnect terminal strip, terminal 13?) STEP 5 Are 22 to 28 VDC measured on blue/black wire at interconnect terminal strip, terminal 13?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. Connect batteries. (WP 0085) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Move LEFT WATER SPRINKLERS switch to ON position.
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LEFT WATER SPRINKERS SWITCH

Figure 8. Left Water Sprinklers Switch - Step 5. 4. 5. Set multimeter to measure voltage. Connect red multimeter probe to blue/black wire at interconnect terminal strip terminal 13.
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Figure 9. Interconnect Terminal Strip - Step 5. 6. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
CONDITION/INDICATION Are 22 to 28 VDC measured on blue/black wire at interconnect terminal strip, terminal 13? DECISION No - Repair or replace blue/black wire from interconnect terminal strip, terminal 13 to LEFT WATER SPRINKLER switch. (WP 0099) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) Yes - Repair or replace red wire from interconnect terminal strip, terminal 13 to left solenoid harness connector. (WP 0099) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) STEP 6
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Does tachometer operate?
NOTE
Water sprinkler switches and tachometer share the same wires for power source. This test is to isolate possible fault with power to water sprinkler switches. Verify if tachometer operates. (TM 5-3825-270-10) CONDITION/INDICATION Does tachometer operate? DECISION No - Go to Tachometer Does Not Operate. (WP 0037) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) Yes - Repair or replace white jumper wire from tachometer to RIGHT WATER SPRINKLERS switch. (WP 0099) Verify problem is solved. (Step 7 - Does LEFT WATER SPRINKLERS switch operate?) STEP 7 Does LEFT WATER SPRINKLERS switch operate? Verify LEFT WATER SPRINKLERS switch operates. (TM 5-3825-270-10) CONDITION/INDICATION Does LEFT WATER SPRINKLERS switch operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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FIELD MAINTENANCE RIGHT WATER SPRINKLERS SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Battery Disconnect/Connection (WP 0085) References (cont.) General Wire Harness Repair (WP 0099) Main Control Panel Tachometer Does Not Operate (WP 0037) Main Control Panel Water Sprinklers Switch Replacement (WP 0105) Solenoid Valve Replacement (WP 0168) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE RIGHT WATER SPRINKLERS SWITCH DOES NOT OPERATE STEP 1 Does LEFT WATER SPRINKLERS switch operate? Verify if the LEFT WATER SPRINKLERS switch operates. (TM 5-3825-270-10) CONDITION/INDICATION Does LEFT WATER SPRINKLERS switch operate? DECISION No - Go to step 6. (Step 6 - Does tachometer operate?) Yes - Go to step 2. (Step 2 - Are 22 to 28 VDC present at pin 1 (white wire) on right solenoid harness connector?) STEP 2 Are 22 to 28 VDC present at pin 1 (white wire) on right solenoid harness connector?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. 2. 3. Disconnect right solenoid harness connector from right solenoid valve. (WP 0168) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Move RIGHT WATER SPRINKLERS switch to ON position.
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RIGHT WATER SPRINKERS SWITCH

Figure 1. Right Water Sprinklers Switch - Step 2. 4. 5. Set multimeter to measure voltage. Connect red multimeter probe to pin 1 (white wire) on right solenoid harness connector.
RIGHT SOLENOID HARNESS CONNECTOR (BLACK) RIGHT SOLENOID VALVE
PIN 2 (GREEN WIRE)
PIN 1 (WHITE WIRE)
Figure 2. Right Solenoid Harness Connector - Step 2. 6. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
CONDITION/INDICATION Are 22 to 28 VDC present at pin 1 (white wire) on right solenoid harness connector? DECISION No - Go to step 4. (Step 4 - Are less than 200 ohms measured across RIGHT WATER SPRINKLERS switch terminals with switch in ON position?) Yes - Go to step 3. (Step 3 - Are less than 200 ohms measured from pin 2 (green wire) on right solenoid harness connector to negative terminal strip, terminal 8?)
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STEP 3 Are less than 200 ohms measured from pin 2 (green wire) on right solenoid harness connector to negative terminal strip, terminal 8? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
WARNING
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Figure 4. Negative Terminal Strip - Step 3. 6. With the aid of an assistant using jumper wire, connect black multimeter probe to pin 2 (green wire) on right solenoid harness connector.
RIGHT SOLENOID HARNESS CONNECTOR (BLACK) RIGHT SOLENOID VALVE
PIN 2 (GREEN WIRE)
PIN 1 (WHITE WIRE)
Figure 5. Right Solenoid Harness Connector - Step 3. 7. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from pin 2 (green wire) on right solenoid harness connector to negative terminal strip, terminal 8?
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DECISION No - Replace green wire from right solenoid harness connector to negative terminal strip, terminal 8. (WP 0099) Verify problem is solved. (Step 7 - Does RIGHT WATER SPRINKLERS switch operate?) Yes - Replace right solenoid valve. (WP 0168) Verify problem is solved. (Step 7 - Does RIGHT WATER SPRINKLERS switch operate?) STEP 4 Are less than 200 ohms measured across RIGHT WATER SPRINKLERS switch terminals with switch in ON position? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Remove six control panel faceplate screws.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter probe to terminal 2 on RIGHT WATER SPRINKLERS switch.
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WHITE WIRE BLUE/RED WIRE VIOLET WIRE RIGHT WATER SPINKLER SWITCH BACK OF WATER SPRINKLER SWITCH
TERMINAL 1 TERMINAL 2 TERMINAL 3
Figure 7. Right Water Sprinkler Switch - Step 4. 6. 7. 8. Connect black multimeter probe to terminal 1 on RIGHT WATER SPRINKLERS switch While holding multimeter probes to terminals, move RIGHT WATER SPRINKLERS switch to ON position. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured across RIGHT WATER SPRINKLERS switch terminals with switch in ON position? DECISION No - Replace RIGHT WATER SPRINKLERS switch. (WP 0105) Verify problem is solved. (Step 7 - Does RIGHT WATER SPRINKLERS switch operate?) Yes - Go to step 5. (Step 5 - Are 22 to 28 VDC present on blue/red wire at interconnect terminal strip, terminal 15?) STEP 5 Are 22 to 28 VDC present on blue/red wire at interconnect terminal strip, terminal 15? 1. Connect batteries. (WP 0085) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10)
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Move RIGHT WATER SPRINKLERS switch to ON position.
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RIGHT WATER SPRINKERS SWITCH

Figure 8. Right Water Sprinklers Switch - Step 5. 4. 5. Set multimeter to measure voltage. Connect red multimeter probe to blue/red wire at interconnect terminal strip, terminal 15.
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Figure 9. Interconnect Terminal Strip - Step 5. 6. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10)
CONDITION/INDICATION Are 22 to 28 VDC present on blue/red wire at interconnect terminal strip, terminal 15? DECISION No - Repair or replace blue/red wire from interconnect terminal strip, terminal 15 to RIGHT WATER SPRINKLERS switch. (WP 0099) Verify problem is solved. (Step 7 - Does RIGHT WATER SPRINKLERS switch operate?) Yes - Repair or replace white wire from interconnect terminal strip, terminal 15 to right solenoid harness connector. (WP 0099) Verify problem is solved. (Step 7 - Does RIGHT WATER SPRINKLERS switch operate?)
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STEP 6 Does tachometer operate?
NOTE
Water sprinkler switches and tachometer share the same wires for power source. This test is to isolate possible fault with power to water sprinkler switches. Verify if tachometer operates. (TM 5-3825-270-10) CONDITION/INDICATION Does tachometer operate? DECISION No - Go to Main Control Panel Tachometer Does Not Operate. (WP 0037) Verify problem is solved. (Step 7 Does RIGHT WATER SPRINKLERS switch operate?) Yes - Repair or replace white jumper wire from tachometer to RIGHT WATER SPRINKLERS switch. (WP 0099) Verify problem is solved. (Step 7 - Does RIGHT WATER SPRINKLERS switch operate?) STEP 7 Does RIGHT WATER SPRINKLERS switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Verify RIGHT WATER SPRINKLERS switch operates. (TM 5-3825-270-10) CONDITION/INDICATION Does RIGHT WATER SPRINKLERS switch operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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FIELD MAINTENANCE WATER LEVEL HIGH INDICATOR DOES NOT ILLUMINATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Main control Panel Tachometer Does Not Operate (WP 0037) References (cont.) General Wire Harness Repair (WP 0099) High Tank Level Switch Replacement (WP 0187) Dial Pointer Replacement (WP 0184) Main Control Panel Water Level High Indicator Replacement (WP 0103) Main Control Panel Water Level Low Indicator Replacement (WP 0104) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER LEVEL HIGH INDICATOR DOES NOT ILLUMINATE STEP 1 Does WATER LEVEL HIGH indicator illuminate with water level indicator magnet directly positioned over high tank level switch? 1. Open control panel cover. (TM 5-3825-270-10) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. With the aid of an assistant, move water level indicator magnet directly over high tank level switch.
LOW TANK LEVEL SWITCH
HIGH TANK LEVEL SWITCH WATER LEVEL INDICATOR AND MAGNET
Figure 1. Water Level Indicator And Magnet - Step 1. 4. Observe WATER LEVEL HIGH indicator.
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WATER LEVEL HIGH INDICATOR
Figure 2. WATER LEVEL HIGH Indicator - Step 1.
CONDITION/INDICATION Does WATER LEVEL HIGH indicator illuminate with water level indicator magnet directly positioned over high tank level switch? DECISION No - Go to step 2. (Step 2 - Does WATER LEVEL LOW indicator illuminate?) Yes - Properly install or adjust dial pointer and/or magnet. (WP 0184) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) STEP 2 Does WATER LEVEL LOW indicator illuminate? 1. With the aid of an assistant, move water level indicator magnet directly over low tank level switch.
Figure 3. Water Level Indicator And Magnet - Step 2. 2. Observe WATER LEVEL LOW indicator.
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WATER LEVEL LOW INDICATOR
Figure 4. Water Level High Indicator - Step 2.
CONDITION/INDICATION Does WATER LEVEL LOW indicator illuminate? DECISION No - Go to step 3. (Step 3 - Does tachometer operate?) Yes - Go to step 4. (Step 4 - Does WATER LEVEL HIGH indicator illuminate after swapping with WATER LEVEL LOW indicator?) STEP 3 Does tachometer operate?
NOTE
Tachometer provides the ground source for the water level indicators. If both water level indicators do not illuminate, fault may be isolated by verifying if tachometer operates. 1. 2. Start engine. (TM 5-3825-270-10) Observe tachometer.
TACHOMETER
Figure 5. Tachometer - Step 3. 3. Shutdown engine. (TM 5-3825-270-10)
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CONDITION/INDICATION Does tachometer operate? DECISION No - Go to Main Control Panel Tachometer Does Not Operate. (WP 0037) Verify problem is solved. (Step 8 Does WATER LEVEL HIGH indicator illuminate?) Yes - Repair or replace black wire from tachometer to WATER LEVEL LOW indicator. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) STEP 4 Does WATER LEVEL HIGH indicator illuminate after swapping with WATER LEVEL LOW indicator? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Remove six control panel faceplate screws.
Figure 6. Control Panel Faceplate Screws - Step 4. 3. 4. 5. 6. 7. Remove WATER LEVEL HIGH indicator. (WP 0103) Remove WATER LEVEL LOW indicator. (WP 0104) Install WATER LEVEL LOW indicator where WATER LEVEL HIGH indicator was removed. (WP 0103) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) With the aid of an assistant, move water level indicator magnet directly over high tank level switch.
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CONDITION/INDICATION Does WATER LEVEL HIGH indicator illuminate after swapping with WATER LEVEL LOW indicator? DECISION No - Install WATER LEVEL LOW indicator (WP 0104) and go to step 5. (Step 5 - Are less than 200 ohms measured on white wire from positive terminal strip, terminal 16 to high tank level switch?) Yes - Original WATER LEVEL HIGH indicator is faulty. Replace original WATER LEVEL HIGH indicator. (WP 0103) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) STEP 5 Are less than 200 ohms measured on white wire from positive terminal strip, terminal 16 to high tank level switch? 1. Disconnect high tank level harness connector from high tank level switch. (WP 0187) 2. Set multimeter to measure continuity. Connect red multimeter probe to white wire at positive terminal strip, terminal 16. 3.
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Figure 9. Positive Terminal Strip - Step 5. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to pin 1 (white wire) at high tank level switch harness connector.
PIN 1 (WHITE WIRE) PIN 2 (GREEN WIRE)
Figure 10. High Tank Level Switch Harness Connector - Step 5. 5. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on white wire from positive terminal strip, terminal 16 to high tank level switch? DECISION No - Repair or replace white wire from positive terminal strip, terminal 16 to high tank level switch harness connector. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) Yes - Go to step 6. (Step 6 - Are less than 200 ohms measured on green wire from high tank level switch harness connector, to green/black wire at WATER LEVEL HIGH indicator?)
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STEP 6 Are less than 200 ohms measured on green wire from high tank level switch harness connector, to green/ black wire at WATER LEVEL HIGH indicator? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to green/black wire at WATER LEVEL HIGH indicator.
BLACK WIRE
WATER LEVEL HIGH LIGHT
GREEN / BLACK WIRE
Figure 11. Water Level High Indicator - Step 6. 3. With the aid of an assistant using jumper wire, connect black multimeter probe to pin 2 (green wire) at high tank level switch harness connector.
PIN 1 (WHITE WIRE) PIN 2 (GREEN WIRE)
Figure 12. High Tank Level Switch Harness Connector - Step 6. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on green wire from high tank level switch harness connector, to green/black wire at WATER LEVEL HIGH indicator?
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DECISION No - Go to step 7. (Step 7 - Are less than 200 ohms measured on green/black wire from WATER LEVEL HIGH indicator to interconnect terminal strip, terminal 11?) Yes - Replace high tank level switch. (WP 0187) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) STEP 7 Are less than 200 ohms measured on green/black wire from WATER LEVEL HIGH indicator to interconnect terminal strip, terminal 11? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to green/black wire at WATER LEVEL HIGH indicator.
BLACK WIRE
WATER LEVEL HIGH LIGHT
GREEN / BLACK WIRE
Figure 13. Water Level High Indicator - Step 7. 3. Connect black multimeter probe to white wire at interconnect terminal strip, terminal 11.
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CONDITION/INDICATION Are less than 200 ohms measured on green/black wire from WATER LEVEL HIGH indicator to interconnect terminal strip, terminal 11? DECISION No - Repair or replace green/black wire from interconnect terminal strip, terminal 11 to WATER LEVEL HIGH indicator. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) Yes - Repair or replace green wire from interconnect terminal strip, terminal 11 to high tank level switch harness connector. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL HIGH indicator illuminate?) STEP 8 Does WATER LEVEL HIGH indicator illuminate? 1. If disconnected, connect batteries. (WP 0085) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. With the aid of an assistant, move water level indicator magnet directly over high tank level switch.
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CONDITION/INDICATION Does WATER LEVEL HIGH indicator illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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FIELD MAINTENANCE MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR DOES NOT ILLUMINATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Personnel Required Construction Equipment Repairer 91L (2) References Dial Pointer Replacement (WP 0184) References (cont.) General Wire Harness Repair (WP 0099) Low Tank Level Switch (WP 0189) Main control Panel Tachometer Does Not Operate (WP 0037) Water Level Low Indicator Replacement (WP 0104) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR DOES NOT ILLUMINATE STEP 1 Does WATER LEVEL LOW indicator illuminate with water level indicator magnet directly positioned over low tank level switch? 1. Open control panel cover. (TM 5-3825-270-10) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. With the aid of an assistant, move water level indicator magnet directly over low tank level switch.
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Figure 2. Water Level Low Indicator - Step 1.
CONDITION/INDICATION Does WATER LEVEL LOW indicator illuminate with water level indicator magnet directly positioned over low tank level switch? DECISION No - Go to step 2. (Step 2 - Does WATER LEVEL HIGH indicator illuminate?) Yes - Properly install or adjust dial pointer and/or magnet. (WP 0184) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) STEP 2 Does WATER LEVEL HIGH indicator illuminate? 1. With the aid of an assistant, move water level indicator magnet directly over high tank level switch.
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CONDITION/INDICATION Does WATER LEVEL HIGH indicator illuminate? DECISION No - Go to step 3. (Step 3 - Does tachometer operate?) Yes - Go to step 4. (Step 4 - Does WATER LEVEL HIGH indicator illuminate after swapping with WATER LEVEL LOW indicator?) STEP 3 Does tachometer operate?
NOTE
Tachometer provides the ground source for the water level indicators. If both water level indicators do not illuminate, fault may be isolated by verifying if tachometer operates. 1. 2. Start engine. (TM 5-3825-270-10) Observe tachometer.
TACHOMETER
Figure 5. Tachometer - Step 3. 3. Shutdown engine. (TM 5-3825-270-10)
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CONDITION/INDICATION Does tachometer operate? DECISION No - Go to Main Control Panel Tachometer Does Not Operate. (WP 0037) Verify problem is solved. (Step 8 Does WATER LEVEL LOW indicator illuminate?) Yes - Repair or replace black wire from WATER LEVEL LOW indicator to tachometer. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) STEP 4 Does WATER LEVEL HIGH indicator illuminate after swapping with WATER LEVEL LOW indicator? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Remove six control panel faceplate screws.
Figure 6. Control Panel Faceplate Screws - Step 4. 3. 4. 5. 6. 7. Remove WATER LEVEL LOW indicator. (WP 0104) Remove WATER LEVEL HIGH indicator. (WP 0103) Install WATER LEVEL HIGH indicator where WATER LEVEL LOW indicator was removed. (WP 0103) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) With the aid of an assistant, move water level indicator magnet directly over low tank level switch.
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CONDITION/INDICATION Does WATER LEVEL HIGH indicator illuminate after swapping with WATER LEVEL LOW indicator? DECISION No - Install WATER LEVEL HIGH indicator (WP 0103) and go to step 5. (Step 5 - Are less than 200 ohms measured on red wire from positive terminal strip, terminal 17 to low tank level switch?) Yes - Original WATER LEVEL LOW indicator is faulty. Replace original WATER LEVEL LOW indicator. (WP 0104) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) STEP 5 Are less than 200 ohms measured on red wire from positive terminal strip, terminal 17 to low tank level switch? 1. Disconnect low tank level harness connector from low tank level switch. (WP 0187) 2. Set multimeter to measure continuity. 3. Connect red multimeter probe to red wire at positive terminal strip, terminal 17.
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Figure 9. Positive Terminal Strip - Step 5. 4. With the aid of an assistant using jumper wire, connect black multimeter probe to pin 1 (red wire) at low tank level switch harness connector.
PIN 2 (BLACK WIRE) PIN 1 (RED WIRE)
Figure 10. Low Tank Level Switch Harness Connector - Step 5. 5. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on red wire from positive terminal strip, terminal 17 to low tank level switch? DECISION No - Repair or replace red wire from positive terminal strip, terminal 17 to low tank level switch harness connector. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) Yes - Go to step 6. (Step 6 - Are less than 200 ohms measured on green/white wire from low tank level switch harness connector to WATER LEVEL LOW indicator?)
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STEP 6 Are less than 200 ohms measured on green/white wire from low tank level switch harness connector to WATER LEVEL LOW indicator? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to green/white wire at WATER LEVEL LOW indicator.
GREEN/WHITE WIRE BLACK JUMPER WIRES
Figure 11. Water Level Low Indicator - Step 6. 3. With the aid of an assistant using jumper wire, connect black multimeter probe to black wire at low tank level switch harness connector.
PIN 2 (BLACK WIRE) PIN 1 (RED WIRE)
Figure 12. Low Tank Level Switch Harness Connector - Step 6. 4. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on green/white wire from low tank level switch harness connector to WATER LEVEL LOW indicator?
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DECISION No - Go to step 7. (Step 7 - Are less than 200 ohms measured on green/white wire from WATER LEVEL LOW indicator to interconnect terminal strip, terminal 12?) Yes - Replace low tank level switch. (WP 0189) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) STEP 7 Are less than 200 ohms measured on green/white wire from WATER LEVEL LOW indicator to interconnect terminal strip, terminal 12? 1. Ensure multimeter is set to measure continuity. 2. Connect red multimeter probe to green/white wire at WATER LEVEL LOW indicator.
GREEN/WHITE WIRE BLACK JUMPER WIRES
Figure 13. Water Level Low Indicator - Step 7. 3. Connect black multimeter probe to green/white wire at interconnect terminal strip, terminal 12.
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Figure 14. Interconnect Terminal Strip - Step 7.
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4.
CONDITION/INDICATION Are less than 200 ohms measured on green/white wire from WATER LEVEL LOW indicator to interconnect terminal strip, terminal 12? DECISION No - Repair or replace green/white wire from interconnect terminal strip, terminal 11 to WATER LEVEL LOW indicator. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) Yes - Repair or replace black wire from interconnect terminal strip, terminal 12 to low tank level switch harness connector. (WP 0099) Verify problem is solved. (Step 8 - Does WATER LEVEL LOW indicator illuminate?) STEP 8 Does WATER LEVEL LOW indicator illuminate? 1. If disconnected, connect batteries. (WP 0085) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. With the aid of an assistant, move water level indicator magnet directly over low tank level switch.
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CONDITION/INDICATION Does WATER LEVEL LOW indicator illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0047
FIELD MAINTENANCE MAIN CONTROL PANEL WATER LEVEL HIGH INDICATOR STAYS ILLUMINATED
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) References Battery Disconnect/Connection (WP 0085) References (cont.) General Wire Harness Repair (WP 0099) High Tank Level Switch Replacement (WP 0187) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MAIN CONTROL PANEL WATER LEVEL HIGH INDICATOR STAYS ILLUMINATED STEP 1 Are less than 200 ohms measured between pin 1 (black wire) and pin 2 (white wire) on high tank level switch harness connector? 1. Disconnect batteries. (WP 0085) 2. Disconnect high tank level harness connector from high tank level switch. (WP 0187) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter probe to pin 2 (black wire) on high tank level switch.
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PIN 1 (WHITE WIRE)
PIN 2 (BLACK WIRE)
HIGH TANK LEVEL SWITCH HARNESS CONNECTOR
Figure 1. High Tank Level Switch Harness Connector - Step 1. 5. 6. Connect black multimeter probe to pin 1 (white wire) on high tank level switch. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured between pin 1 (black wire) and pin 2 (white wire) on high tank level switch harness connector? DECISION No - Go to step 2. (Step 2 - Are 22 to 28 VDC measured on green wire at interconnect terminal strip, terminal 11?) Yes - High tank level switch is stuck in closed position. Replace high tank level switch. (WP 0187) Verify problem is solved. (Step 3 - Does WATER LEVEL HIGH indicator stay illuminated?) STEP 2 Are 22 to 28 VDC measured on green wire at interconnect terminal strip, terminal 11?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.
NOTE
This test is checking for a short to power in the WATER LEVEL LOW indicator circuit. Wire isolation may be necessary to detect and locate short in wiring. 1. Remove six control panel faceplate screws.
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Figure 2. Control Panel Faceplate Screws - Step 2. 2. Disconnect green/black wire from interconnect terminal strip, terminal 11.
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Figure 3. Interconnect Terminal Strip - Step 2. 3. 4. 5. 6. Connect batteries. (WP 0085) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Set multimeter to measure voltage. Connect red multimeter probe to green wire at interconnect terminal strip, terminal 11.
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Figure 4. Interconnect Terminal Strip - Step 2. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured on green wire at interconnect terminal strip, terminal 11? DECISION No - Short to power condition exist between interconnect terminal strip and WATER LEVEL HIGH indicator. Repair or replace green/black wire from interconnect terminal strip, terminal 11 to WATER LEVEL HIGH indicator. (WP 0099) Verify problem is solved. (Step 3 - Does WATER LEVEL HIGH indicator stay illuminated?) Yes - Short to power condition exist between high tank level switch and interconnect terminal strip. Repair or replace green wire from interconnect terminal strip, terminal 11 to high tank level switch harness connector. (WP 0099) Verify problem is solved. (Step 3 - Does WATER LEVEL HIGH indicator stay illuminated?) STEP 3 Does WATER LEVEL HIGH indicator stay illuminated? 1. If disconnected, connect batteries. (WP 0085) 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. Observe WATER LEVEL HIGH indicator.
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CONDITION/INDICATION Does WATER LEVEL HIGH indicator stay illuminated? DECISION No - Problem solved. Restore water distributor to original operating condition. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0048
FIELD MAINTENANCE MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR STAYS ILLUMINATED
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) References Battery Disconnect/Connection (WP 0085) References (cont.) General Wire Harness Repair (WP 0099) Low Tank Level Switch Replacement (WP 0189) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR STAYS ILLUMINATED STEP 1 Are less than 200 ohms measured between pin 1 and pin 2 on low tank level switch harness connector? 1. Disconnect batteries. (WP 0085) 2. Disconnect low tank level switch harness connector from low tank level switch. (WP 0189) 3. Set multimeter to check for continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter probe to pin 1 on low tank level switch harness connector.
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PIN 2
LOW TANK LEVEL SWITCH HARNESS CONNECTOR
PIN 1
Figure 1. Low Tank Level Switch Harness Connector - Step 1. 5. 6. 7. Connect black multimeter probe to pin 2 on low tank level switch harness connector. Note multimeter reading. Reconnect low tank level switch harness connector to low tank level switch. (WP 0189)
CONDITION/INDICATION Are less than 200 ohms measured between pin 1 and pin 2 on low tank level switch harness connector? DECISION No - Go to step 2. (Step 2 - Are 22 to 28 VDC measured on black wire at interconnect terminal strip, terminal 12?) Yes - Low tank level switch is stuck in closed position. Replace low tank level switch. (WP 0189) Verify problem is solved. (Step 3 - Does WATER LEVEL LOW indicator stay illuminated?) STEP 2 Are 22 to 28 VDC measured on black wire at interconnect terminal strip, terminal 12?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.
NOTE
This test is checking for a short to power in the WATER LEVEL LOW indicator circuit. Wire isolation may be necessary to detect and locate short in wiring. 1. Remove six control panel faceplate screws.
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Figure 2. Control Panel Faceplate Screws - Step 2. 2. Disconnect green/white wire from interconnect terminal strip, terminal 12.
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Figure 3. Interconnect Terminal Strip - Step 2. 3. 4. 5. 6. Connect batteries. (WP 0085) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Set multimeter to measure voltage. Connect red multimeter probe to black wire at interconnect terminal strip, terminal 12.
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Figure 4. Interconnect Terminal Strip - Step 2. 7. 8. Connect black multimeter probe to known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured on black wire at interconnect terminal strip, terminal 12? DECISION No - Short to power condition exist between interconnect terminal strip and WATER LEVEL LOW indicator. Repair or replace green/white wire from interconnect terminal strip, terminal 12 to WATER LEVEL LOW indicator. (WP 0099) Verify problem is solved. (Step 3 - Does WATER LEVEL LOW indicator stay illuminated?) Yes - Short to power condition exist between low tank level switch and interconnect terminal strip. Repair or replace black wire from interconnect terminal strip, terminal 12 to low tank level switch harness connector. (WP 0099) Verify problem is solved. (Step 3 - Does WATER LEVEL LOW indicator stay illuminated?) STEP 3 Does WATER LEVEL LOW indicator stay illuminated? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Observe WATER LEVEL LOW indicator.
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CONDITION/INDICATION Does WATER LEVEL LOW indicator stay illuminated? DECISION No - Problem solved. Restore water distributor to original operating condition. Yes - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. END OF WORK PACKAGE
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0049
FIELD MAINTENANCE MANUAL WATER TURRET DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Manual Water Turret Replacement (WP 0163) Valve Handle Replacement (WP 0180) Water Distributor Operator Manual (TM 5-3825-270-10) References (cont.) Water Pressure Erratic (WP 0023) Water Pump Does Not Operate (WP 0022) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MANUAL WATER TURRET DOES NOT OPERATE STEP 1 Is manual water turret free from restriction and damage? Visually inspect manual water turret for restriction and damage.
MANUAL WATER TURRET
Figure 1. Manual Water Turret - Step 1. CONDITION/INDICATION Is manual water turret free from restriction and damage? DECISION No - Remove restriction or replace manual water turret if damaged. (WP 0163) Verify problem is solved. (Step 4 - Does manual water turret operate?) Yes - Go to step 2. (Step 2 - Does water hose operate?)
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STEP 2 Does water hose operate? Operate water distributor water hose. (TM 5-3825-270-10) CONDITION/INDICATION Does water hose operate? DECISION No - Go to Water Pump Does Not Operate. (WP 0022) Yes - Go to step 3. (Step 3 - Does WATER PUMP OUTLET gauge read normal?) STEP 3 Does WATER PUMP OUTLET gauge read normal? 1. Start engine. (TM 5-3825-270-10) 2. Observe WATER PUMP OUTLET gauge.
Figure 2. Water Pump Outlet Gauge - Step 3. CONDITION/INDICATION Does WATER PUMP OUTLET gauge read normal? DECISION No - Go to Water Pressure Erratic. (WP 0023) Yes - Replace valve V6. (WP 0180) Verify problem is solved. (Step 4 - Does manual water turret operate?) STEP 4 Does manual water turret operate? Operate manual water turret. (TM 5-3825-270-10) CONDITION/INDICATION Does manual water turret operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0050
FIELD MAINTENANCE MANUAL WATER TURRET PRESSURE LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Manual Water Turret Replacement (WP 0163) Valve Handle Replacement (WP 0180) References (cont.) Water Distributor Operator Manual (TM 5-3825-270-10) Water Pump Does Not Operate (WP 0022) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE MANUAL WATER TURRET PRESSURE LOW STEP 1 Is manual water turret free from restriction and damage? Visually inspect manual water turret for restriction and damage.
MANUAL WATER TURRET
Figure 1. Manual Water Turret - Step 1. CONDITION/INDICATION Is manual water turret free from restriction and damage? DECISION No - Remove restriction or replace manual water turret if damaged. (WP 0163) Verify problem is solved. (Step 5 - Does manual water turret operate?) Yes - Go to step 2. (Step 2 - Does valve V6 open and close completely?) STEP 2
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Does valve V6 open and close completely? 1. Remove manual water turret. (WP 0163) 2. Visually inspect valve V6 while opening and closing valve to ensure it opens and closes completely.
VALVE V6
Figure 2. Valve V6 - Step 2. CONDITION/INDICATION Does valve V6 open and close completely? DECISION No - Replace valve V6. (WP 0180) Verify problem is solved. (Step 5 - Does manual water turret operate?) Yes - Go to step 3. (Step 3 - Is valve V5 completely closed?) STEP 3 Is valve V5 completely closed? Verify valve V5 position.
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VALVE V5
Figure 3. Valve V5 - Step 3. CONDITION/INDICATION Is valve V5 completely closed? DECISION No - Fully close valve V5. (TM 5-3825-270-10) Verify problem is solved. (Step 5 - Does manual water turret operate?) Yes - Go to step 4. (Step 4 - Does WATER PUMP OUTLET gauge read normal?) STEP 4 Does WATER PUMP OUTLET gauge read normal? 1. Start engine. (TM 5-3825-270-10) 2. Read WATER PUMP OUTLET gauge while operating turret.
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Figure 4. Water Pump Outlet Gauge - Step 3. CONDITION/INDICATION Does WATER PUMP OUTLET gauge read normal? DECISION No - Go to Water Pump Does Not Operate. (WP 0022) Yes - Replace valve V6. (WP 0180) Verify problem is solved. (Step 5 - Does manual water turret operate?) STEP 5 Does manual water turret operate? Operate manual water turret. (TM 5-3825-270-10) CONDITION/INDICATION Does manual water turret operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0051
FIELD MAINTENANCE GRAVITY BAR WELDMENT DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Gravity Bar Weldment Replacement (WP 0160) Valve Handle Replacement (WP 0180) References (cont.) Water Tank Replacement (WP 0195) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE GRAVITY BAR WELDMENT DOES NOT OPERATE STEP 1 Is gravity bar weldment free of damage? Visually inspect gravity bar weldment for damage?
GRAVITY BAR WELDMENT

Figure 1. Gravity Bar Weldment - Step 1.
CONDITION/INDICATION Is gravity bar weldment free of damage? DECISION No - Replace gravity bar weldment. (WP 0160) Verify problem is solved. (Step 4 - Does gravity bar weldment operate?) Yes - Go to step 2. (Step 2 - Is water present at closure cap C2 when valve V2 is opened?) STEP 2 Is water present at closure cap C2 when valve V2 is opened? 1. Remove closure cap C2. (TM 5-3825-270-10)
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VALVE V2
CLOSURE CAP C2
Figure 2. Closure Cap C2 - Step 2. 2. 3. 4. Open valve V2. (TM 5-3825-270-10) Verify if water is present at closure cap C2. Close valve V2 and install closure cap C2. (TM 5-3825-270-10)
CONDITION/INDICATION Is water present at closure cap C2 when valve V2 is opened? DECISION No - Go to step 3. (Step 3 - Is water tank sump free of restriction?) Yes - Replace valve V8. (WP 0180) Verify problem is solved. (Step 4 - Does gravity bar weldment operate?) STEP 3 Is water tank sump free of restriction? 1. Drain water tank. (TM 5-3825-270-10) 2. Open manhole cover. (TM 5-3825-270-10) 3. Visually inspect water tank sump for restriction.
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WATER TANK SUMP
Figure 3. Water Tank Sump - Test 3. CONDITION/INDICATION Is water tank sump free of restriction? DECISION No - Remove restriction or replace water tank. Verify problem is solved. (Step 4 - Does gravity bar weldment operate?) Yes - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to step 1. (Step 1 - Is gravity bar weldment free of damage?) If problem still exists after all troubleshooting test have been performed, notify supervisor. STEP 4 Does gravity bar weldment operate? Operate gravity bar weldment. (TM 5-3825-270-10) CONDITION/INDICATION Does gravity bar weldment operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0052
FIELD MAINTENANCE GRAVITY BAR WELDMENT STREAM LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Gravity Bar Weldment Replacement (WP 0160) Valve Handle Replacement (WP 0180) References (cont.) Water Distributor Operator Manual (TM 5-3825-270-10) Water Tank Replacement (WP 0195) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE GRAVITY BAR WELDMENT STREAM LOW STEP 1 Is gravity bar weldment damaged? Visually inspect gravity bar weldment for damage?
GRAVITY BAR WELDMENT

Figure 1. Gravity Bar Weldment - Step 1.
CONDITION/INDICATION Is gravity bar weldment damaged? DECISION No - Go to step 2. (Step 2 - Is water stream normal at closure cap C2 when valve V2 is opened?) Yes - Replace gravity bar weldment. (WP 0160) Verify problem is solved. (Step 4 - Is gravity bar weldment stream normal?) STEP 2 Is water stream normal at closure cap C2 when valve V2 is opened? 1. Remove closure cap C2. (TM 5-3825-270-10)
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VALVE V2
CLOSURE CAP C2
Figure 2. Closure Cap C2 - Step 2. 2. 3. 4. Open valve V2. (TM 5-3825-270-10) Verify if water stream is normal at closure cap C2. Close valve V2 and install closure cap C2. (TM 5-3825-270-10)
CONDITION/INDICATION Is water stream normal at closure cap C2 when valve V2 is opened? DECISION No - Go to step 3. (Step 3 - Is water tank sump restricted?) Yes - Replace valve V8. (WP 0180) Verify problem is solved. (Step 4 - Is gravity bar weldment stream normal?) STEP 3 Is water tank sump restricted? 1. Drain water tank. (TM 5-3825-270-10) 2. Visually inspect water tank sump for restriction.
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WATER TANK SUMP
Figure 3. Water Tank Sump - Test 3. CONDITION/INDICATION Is water tank sump restricted? DECISION No - Problem not found and may have been missed or overlooked. Repeat all previous steps in this troubleshooting procedure. Go to step 1. (Step 1 - Is gravity bar weldment damaged?) If problem still exists after all troubleshooting test have been performed, notify supervisor. Yes - Remove restriction or replace water tank. (WP 0195) Verify problem is solved. (Step 4 - Is gravity bar weldment stream normal?) STEP 4 Is gravity bar weldment stream normal? Operate gravity bar weldment. (TM 5-3825-270-10) CONDITION/INDICATION Is gravity bar weldment stream normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0053
FIELD MAINTENANCE WATER SPRINKLERS DO NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Air Hose Replacement (WP 0171) Air Valve Cover Plate Replacement (WP 0164) Flusher Nozzle And Air Actuator Replacement (WP 0166) References (cont.) Air Line Lubricator Replacement (WP 0169) Solenoid Valve Replacement (WP 0168) Water Hose Does Not Operate (WP 0055) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER SPRINKLERS DO NOT OPERATE STEP 1 Are one or both water sprinklers inoperative?
NOTE
When valve V5 is open, water sprinklers may have lower pressure than when fully closed. Attempt to operate water sprinklers. (TM 5-3825-270-10) CONDITION/INDICATION Are one or both water sprinklers inoperative? DECISION Both Inoperative - Go to step 5. (Step 5 - Is prime mover air supply functioning properly?) One Inoperative - Go to step 2. (Step 2 - Is inoperative water sprinkler head damaged or restricted?) STEP 2 Is inoperative water sprinkler head damaged or restricted? Visually inspect water sprinkler head for damage and restriction.
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WATER SPRINKLER HEAD
Figure 1. Water Sprinkler Head - Step 2. CONDITION/INDICATION Is inoperative water sprinkler head damaged or restricted? DECISION No - Go to step 3. (Step 3 - Are air hoses and fittings free of leaks and damage?) Yes - Replace or clean water sprinkler head. (WP 0166) Verify problem is solved. (Step 8 - Do water sprinklers operate?) STEP 3 Are air hoses and fittings free of leaks and damage? Visually inspect air hoses and fittings for leaks and damage.
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AIR HOSES
AIR HOSES
Figure 2. Air Hoses - Step 3. CONDITION/INDICATION Are air hoses and fittings free of leaks and damage? DECISION No - Replace damaged or leaking air hoses and/or fittings. Verify problem is solved. (Step 8 - Do water sprinklers operate?) Yes - Go to step 4. (Step 4 - Does fault switch to other water sprinkler when solenoid valves are swapped?) STEP 4 Does fault switch to other water sprinkler when solenoid valves are swapped?
NOTE
Air hoses are not long enough to swap air lines without removing and reinstalling solenoid valves. 1. Swap solenoid valve of inoperative sprinkler head, with functioning solenoid valve. (WP 0168)
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LEFT SOLENOID VALVE
RIGHT SOLENOID VALVE
LEFT SOLENOID HARNESS CONNECTOR (GRAY) RIGHT SOLENOID HARNESS CONNECTOR (BLACK)
Figure 3. Left And Right Solenoid Valves - Step 4. 2. Operate water sprinklers. (TM 5-3825-270-10)
CONDITION/INDICATION Does fault switch to other water sprinkler when solenoid valves are swapped? DECISION No - If the left sprinkler does not operate, go to Left Water Sprinkler Switch Does Not Operate. (WP 0043) If the right sprinkler does not operate, go to Right Water Sprinkler Switch Does Not Operate. (WP 0043) If problem persist after troubleshooting right or left sprinkler switch, replace air actuator. (WP 0166) Verify problem is solved. (Step 8 - Do water sprinklers operate?) Yes - Replace inoperative solenoid valve. (WP 0168) Verify problem is solved. (Step 8 - Do water sprinklers operate?) STEP 5 Is prime mover air supply functioning properly? Refer to prime mover manual and ensure air pressure is adequate for operation. (TM 9-2320-319-10) CONDITION/INDICATION Is prime mover air supply functioning properly? DECISION No - Replace prime mover. Verify problem is solved. (Step 8 - Do water sprinklers operate?) Yes - Go to test 6. (Step 6 - Does water hose operate?) STEP 6 Does water hose operate? Attempt to operate water hose. (TM 5-3825-270-10) CONDITION/INDICATION Does water hose operate? DECISION No - Go to Water Hose Does Not Operate. (WP 0055) Yes - Go to step 7. (Step 7 - Are air hoses and fittings free of leaks and damage?)
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STEP 7 Are air hoses and fittings free of leaks and damage? 1. Remove air valve cover plate. (WP 0164) 2. Visually inspect air hoses and fittings for leaks and damage.
SOLENOID VALVES
AIR HOSES
Figure 4. Air Hoses - Step 7. CONDITION/INDICATION Are air hoses and fittings free of leaks and damage? DECISION No - Replace damaged or leaking air hoses and/or fittings. Verify problem is solved. (Step 8 - Do water sprinklers operate?) Yes - Replace air line lubricator. (WP 0169) Verify problem is solved. (Step 8 - Do water sprinklers operate?) STEP 8 Do water sprinklers operate? Operate water sprinklers. (TM 5-3825-270-10) CONDITION/INDICATION Do water sprinklers operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
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0054
FIELD MAINTENANCE WATER SPRINKLER HEAD PRESSURE LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Air Line Lubricator Replacement (WP 0169) Air Hose Replacement (WP 0171) Air Valve Cover Plate Replacement (WP 0164) References (cont.) Flusher Nozzle And Air Actuator Replacement (WP 0166) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER SPRINKLER HEAD PRESSURE LOW STEP 1 Are one or both water sprinkler pressures low?
NOTE
When valve V5 is open, water sprinklers may have lower pressure than when fully closed. Operate water sprinklers. (TM 5-3825-270-10) CONDITION/INDICATION Are one or both water sprinkler pressures low? DECISION Both low - Go to step 2. (Step 2 - Is prime mover air supply functioning properly?) One low - Go to step 4. (Step 4 - Is sprinkler head damaged or restricted?) STEP 2 Is prime mover air supply functioning properly? Refer to prime mover manual and ensure air supply is functioning properly. (TM 9-2320-319-10) CONDITION/INDICATION Is prime mover air supply functioning properly? DECISION No - Replace prime mover. Verify problem is solved. (Step 6 - Is water sprinkler pressure normal?) Yes - Go to step 3. (Step 3 - Are air hoses and fittings free of leaks and damage?) STEP 3 Are air hoses and fittings free of leaks and damage? Visually inspect air hoses and fittings for leaks and damage.
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0054
AIR HOSES
AIR HOSES
Figure 1. Air Hoses - Step 3. CONDITION/INDICATION Are air hoses and fittings free of leaks and damage? DECISION No - Replace damaged or leaking air hose(s) and/or fitting(s). Verify problem is solved. (Step 6 - Is water sprinkler pressure normal?) Yes - Replace air line lubricator. (WP 0169) Verify problem is solved. (Step 6 - Is water sprinkler pressure normal?) STEP 4 Is sprinkler head damaged or restricted? Visually inspect sprinkler head for damage and restriction.
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0054
Figure 2. Water Sprinkler Head - Step 4. CONDITION/INDICATION Is sprinkler head damaged or restricted? DECISION No - Go to step 5. (Step 5 - Are air hoses and fittings free of leaks and damage?) Yes - Replace or clean sprinkler head. (WP 0166) Verify problem is solved. (Step 6 - Is water sprinkler pressure normal?) STEP 5 Are air hoses and fittings free of leaks and damage? 1. Remove air valve cover plate. (WP 0164) 2. Visually inspect all hoses and fittings for leaks and damage.
SOLENOID VALVES
AIR HOSES
Figure 3. Air Hoses - Step 5.
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0054
CONDITION/INDICATION Are air hoses and fittings free of leaks and damage? DECISION No - Replace damaged or leaking air hose(s) and/or fitting(s). Verify problem is solved. (Step 6 - Is water sprinkler pressure normal?) Yes - Replace air actuator. (WP 0166) Verify problem is solved. (Step 6 - Is water sprinkler pressure normal?) STEP 6 Is water sprinkler pressure normal? 1. Operate water sprinklers. (TM 5-3825-270-10) 2. Verify if water sprinkler pressure is normal. CONDITION/INDICATION Is water sprinkler pressure normal? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. Restore water distributor to original operating condition. END OF WORK PACKAGE
0054-4
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0055
FIELD MAINTENANCE WATER HOSE INOPERATIVE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Hose Reel Replacement (WP 0202) Hose Reel Valve Replacement (WP 0161) References (cont.) Manual Water Turret Does Not Operate (WP 0049) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER HOSE INOPERATIVE STEP 1 Does manual water turret operate? Operate manual water turret. (TM 5-3825-270-10) CONDITION/INDICATION Does manual water turret operate? DECISION No - Go to Manual Water Turret Does Not Operate. (WP 0049) Yes - Go to step 2. (Step 2 - Is water hose pinched, damaged, or kinked?) STEP 2 Is water hose pinched, damaged, or kinked? Visually inspect water hose for pinches, damage, and kinks.
WATER HOSE
Figure 1. Water Hose - Step 2.
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0055
CONDITION/INDICATION Is water hose pinched, damaged, or kinked? DECISION No - Go to step 3. (Step 3 - Is water hose nozzle plugged with debris?) Yes - If capable, remove kink and/or pinch . Replace hose reel if necessary. (WP 0202) Verify problem is solved. (Step 4 - Does water hose operate?) STEP 3 Is water hose nozzle plugged with debris? Visually inspect hose reel nozzle for debris.
WATER HOSE NOZZLE
Figure 2. Water Hose Nozzle - Step 3. CONDITION/INDICATION Is water hose nozzle plugged with debris? DECISION No - Replace hose reel valve. (WP 0161) Verify problem is solved. (Step 4 - Does water hose operate?) Yes - Clean water hose nozzle or replace hose reel. (WP 0202) Verify problem is solved. (Step 4 - Does water hose operate?) STEP 4 Does water hose operate? Operate water hose. (TM 5-3825-270-10) CONDITION/INDICATION Does water hose operate?
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0055
DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. END OF WORK PACKAGE
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0056
FIELD MAINTENANCE WATER HOSE PRESSURE LOW
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Hose Reel Replacement (WP 0202) References (cont.) Hose Reel Valve Replacement (WP 0161) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE WATER HOSE PRESSURE LOW STEP 1 Is water hose pinched, damaged, or kinked? Visually inspect water hose for pinches, damage, and kinks.
WATER HOSE
Figure 1. Water Hose - Step 1. CONDITION/INDICATION Is water hose pinched, damaged, or kinked? DECISION No - Go to step 2. (Step 2 - Is water hose nozzle restricted or damaged?) Yes - If capable, remove kink and/or pinch. Replace hose reel if necessary. (WP 0202) Verify problem is solved. STEP 2 Is water hose nozzle restricted or damaged?
NOTE
When valve V5 is open, water hose may have lower pressure than when fully closed.
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0056
Visually inspect water hose nozzle for restriction and damage.
WATER HOSE NOZZLE
Figure 2. Water Hose Nozzle - Step 2. CONDITION/INDICATION Is water hose nozzle restricted or damaged? DECISION No - Replace hose reel valve. (WP 0161) Verify problem is solved. Yes - Clean water hose nozzle or replace hose reel. (WP 0202) Verify problem is solved. STEP 3 Is water hose pressure low? Operate water hose. (TM 5-3825-270-10) CONDITION/INDICATION Is water hose pressure low? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Problem solved. END OF WORK PACKAGE
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0057
FIELD MAINTENANCE CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR INOPERATIVE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Engine Off/Battery Drain Indicator Replacement (WP 0215) Cab Control Box Wiring Harness Replacement (WP 0206) Engine Off/Battery Drain Indicator Does Not Illuminate (WP 0031) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR INOPERATIVE STEP 1 Does main control panel ENGINE OFF/BATTERY DRAIN indicator illuminate?
NOTE
If ENGINE OFF/BATTERY DRAIN indicator illuminates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. 1. 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Observe ENGINE OFF/BATTERY DRAIN indicator.
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0057
CONDITION/INDICATION Does main control panel ENGINE OFF/BATTERY DRAIN indicator illuminate? DECISION No - Go to Engine Off/Battery Drain Indicator Does Not Illuminate. (WP 0031) Yes - Go to step 2. (Step 2 - Do work lights illuminate using cab control box LIGHTS switch?) STEP 2 Do work lights illuminate using cab control box LIGHTS switch?
NOTE
Cab control box LIGHTS switch and ENGINE OFF/BATTERY DRAIN indicator share positive and ground wiring. If work lights operate using cab control box, fault can be isolated to cab control box ENGINE OFF/BATTERY DRAIN indicator. Attempt to operate work lights using cab control box LIGHTS switch. (TM 5-3825-270-10) CONDITION/INDICATION Do work lights illuminate using cab control box LIGHTS switch? DECISION No - Go to step 3. (Step 3 - Are cab control box and water distributor harnesses connected properly to prime mover?) Yes - Replace cab control box ENGINE OFF/BATTERY DRAIN indicator. (WP 0215) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 3 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
CAB CONTROL BOX ELECTRICAL CONNECTOR
Figure 2. Cab Control Box - Step 3. 3. Check prime mover UPIK air and electrical connections.
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0057
UPIK AIR CONNECTION
UPIK ELECTRICAL CONNECTION
Figure 3. UPIK Air And Electrical Connections - Step 3.
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) Yes - Go to step 4. (Step 4 - Are 22 to 28 VDC measured at white wire on cab control box ENGINE OFF/ BATTERY DRAIN indicator?) STEP 4 Are 22 to 28 VDC measured at white wire on cab control box ENGINE OFF/BATTERY DRAIN indicator? 1. Remove six screws from cab control box.
CAB CONTROL BOX SCREWS

Figure 4. Cab Control Box Screws - Step 4. 2. 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Ensure multimeter is set to measure voltage.
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0057
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to white wire on cab control box ENGINE OFF/BATTERY DRAIN indicator.
BACK OF CAB CONTROL BOX RED WIRE/WHITE WIRE CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR
BLACK WIRE
Figure 5. Cab Control Box Engine Off/Battery Drain Indicator - Step 4. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at white wire on cab control box ENGINE OFF/BATTERY DRAIN indicator? DECISION No - Go to step 5. (Step 5 - Are 22 to 28 VDC measured at UPIK harness connector pin J?) Yes - Go to step 6. (Step 6 - Are less than 200 ohms measured on black wire at cab control box ENGINE OFF/ BATTERY DRAIN indicator to known good ground?) STEP 5 Are 22 to 28 VDC measured at UPIK harness connector pin J? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
Figure 6. UPIK Electrical Connection - Step 5. 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10)
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0057
4.
Ensure multimeter is set to measure voltage.
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter lead to UPIK harness connector pin J.
UPIK HARNESS CONNECTOR
PIN J
Figure 7. UPIK Harness Connector Pin J - Step 5. 6. 7. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at UPIK harness connector pin J? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 6 Are less than 200 ohms measured on black wire at cab control box ENGINE OFF/BATTERY DRAIN indicator to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) Set multimeter to measure continuity. 3.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel.
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0057
Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to black wire at cab control box ENGINE OFF/BATTERY DRAIN indicator.
BACK OF CAB CONTROL BOX RED WIRE/WHITE WIRE CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR
BLACK WIRE
Figure 8. Cab Control Box Engine Off/Battery Drain Indicator - Step 6. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box ENGINE OFF/BATTERY DRAIN indicator to known good ground? DECISION No - Go to step 7. (Step 7 - Are less than 200 ohms measured at UPIK harness connector pin I to known good ground?) Yes - Replace cab control box ENGINE OFF/BATTERY DRAIN indicator. (WP 0215) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 7 Are less than 200 ohms measured at UPIK harness connector pin I to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
Figure 9. UPIK Electrical Connection - Step 7. 2. Ensure multimeter is set to measure continuity.
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0057
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin I.
PIN I
Figure 10. UPIK Harness Connector Pin I - Step 7. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin I to known good ground? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate?) STEP 8 Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. 4. Observe cab control box ENGINE OFF/BATTERY DRAIN indicator.
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CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR
Figure 11. Cab Control Box Engine Off/Battery Drain Indicator - Step 8. CONDITION/INDICATION Does cab control box ENGINE OFF/BATTERY DRAIN indicator illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0058
FIELD MAINTENANCE CAB CONTROL BOX LIGHTS SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Lights Replacement (WP 0210) Cab Control Box Wiring Harness Replacement (WP 0206) Work Lights Do Not Operate (WP 0025) General Wire Harness Repair (WP 0099) References (cont.) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX LIGHTS SWITCH DOES NOT OPERATE STEP 1 Do work lights operate using LIGHTS switch on main control panel?
NOTE
If work lights operate using main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to operate work lights using main control panel. (TM 5-3825-270-10) CONDITION/INDICATION Do work lights operate using LIGHTS switch on main control panel? DECISION No - Go to Work Lights Does Not Operate. (WP 0025) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0058
CAB CONTROL BOX
ELECTRICAL CONNECTOR
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 6 - Does cab control box LIGHTS switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at red wire on cab control box LIGHTS switch?) STEP 3 Are 22 to 28 VDC measured at red wire on cab control box LIGHTS switch? 1. Remove six screws from cab control box.
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0058

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to red wire on cab control box LIGHTS switch.
RED WIRE CAB CONTROL BOX LIGHTS SWITCH BLACK WIRE BACK OF CAB CONTROL BOX
Figure 4. Cab Control Box Lights Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at red wire on cab control box LIGHTS switch?
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DECISION No - Replace red wire between LIGHTS switch and ENGINE OFF/BATTERY DRAIN indicator. (WP 0099) Verify problem is solved. (Step 6 - Does cab control box LIGHTS switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire at cab control box LIGHTS switch to known good ground?) STEP 4 Are less than 200 ohms measured on black wire at cab control box LIGHTS switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity. 4. Connect red multimeter lead to black wire at cab control box LIGHTS switch.
RED WIRE CAB CONTROL BOX LIGHTS SWITCH BLACK WIRE BACK OF CAB CONTROL BOX
Figure 5. Cab Control Box Lights Switch - Step 4. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box LIGHTS switch to known good ground? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured at UPIK harness connector pin H to known good ground?) Yes - Replace cab control box LIGHTS switch. (WP 0210) Verify problem is solved. (Step 6 - Does cab control box LIGHTS switch operate?) STEP 5 Are less than 200 ohms measured at UPIK harness connector pin H to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
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0058
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin H.
PIN H
Figure 7. UPIK Harness Connector Pin H - Step 5. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin H to known good ground?
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0058
DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 6 - Does cab control box LIGHTS switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 6 - Does cab control box LIGHTS switch operate?) STEP 6 Does cab control box LIGHTS switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Operate work lights using cab control box LIGHTS switch.
CAB CONTROL BOX LIGHTS SWITCH
Figure 8. Cab Control Box Lights Switch - Step 6. CONDITION/INDICATION Does cab control box LIGHTS switch operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0059
FIELD MAINTENANCE CAB CONTROL BOX TACHOMETER DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Tachometer Replacement (WP 0216) Cab Control Box Wiring Harness Replacement (WP 0206) General Wire Harness Repair (WP 0099) Main Control Panel Tachometer Does Not Operate (WP 0037) References (cont.) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX TACHOMETER DOES NOT OPERATE STEP 1 Does main control panel tachometer operate?
NOTE
If tachometer operates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Start engine and ensure main control panel tachometer is operational. (TM 5-3825-270-10)
TACHOMETER
Figure 1. Tachometer - Step 1.
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CONDITION/INDICATION Does main control panel tachometer operate? DECISION No - Go to Main Control Panel Tachometer Does Not Operate. (WP 0037) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor cables connected properly to prime mover?) STEP 2 Are cab control box and water distributor cables connected properly to prime mover? 1. Shut down engine. (TM 5-3825-270-10) 2. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 3. Check cab control box electrical connector.
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor cables connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?) Yes - Go to step 3. (Step 3 - Is cab control box tachometer pulse adjustment dial set to pulse 5?)
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STEP 3 Is cab control box tachometer pulse adjustment dial set to pulse 5?
NOTE
The tachometer receives its engine speed signal from the alternator. If the tachometer is not set to proper setting, incorrect engine speed or no engine speed may be observed from gauge. 1. Remove six screws from cab control box.

Figure 4. Cab Control Box Screws - Step 3. 2. Check tachometer pulse adjustment dial.
PULSE ADJUSTMENT DIAL
BACK OF CAB CONTROL BOX
CAB CONTROL BOX TACHOMETER
Figure 5. Cab Control Box Tachometer Pulse Adjustment Dial - Step 3.
CONDITION/INDICATION Is cab control box tachometer pulse adjustment dial set to pulse 5?
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DECISION No - Place tachometer pulse adjustment dial to pulse 5. Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?) Yes - Go to step 4. (Step 4 - Are 22 to 28 VDC measured at white wire on cab control box tachometer?) STEP 4 Are 22 to 28 VDC measured at white wire on cab control box tachometer? 1. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 2. Ensure multimeter is set to measure voltage.
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to white wire on cab control box tachometer.
CAB CONTROL BOX TACHOMETER WHITE WIRE(S) BLACK WIRE(S) BACK OF CAB CONTROL BOX
Figure 6. Cab Control Box Tachometer - Step 4. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at white wire on cab control box tachometer? DECISION No - Go to step 7. (Step 7 - Are 22 to 28 VDC measured at UPIK harness connector pin U?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured on black wire at cab control box tachometer to known good ground?) STEP 5 Are less than 200 ohms measured on black wire at cab control box tachometer to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity. 4. Connect red multimeter lead to black wire at cab control box tachometer.
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Figure 7. Cab Control Box Tachometer - Step 5. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box tachometer to known good ground? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured at UPIK harness connector pin V to known good ground?) Yes - Replace cab control box tachometer. (WP 0216) Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?) STEP 6 Are less than 200 ohms measured at UPIK harness connector pin V to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
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WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin V.
PIN V
Figure 9. UPIK Harness Connector Pin V - Step 6. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin V to known good ground? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?) STEP 7 Are 22 to 28 VDC measured at UPIK harness connector pin U? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Disconnect water distributor UPIK electrical harness from prime mover.
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UPIK AIR CONNECTION
Figure 10. UPIK Electrical Connection - Step 7. 3. 4. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Ensure multimeter is set to measure voltage.
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter lead to UPIK harness connector pin U.
PIN U
Figure 11. UPIK Harness Connector Pin U - Step 7. 6. 7. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at UPIK harness connector pin U? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box tachometer operate normally?)
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STEP 8 Does cab control box tachometer operate normally? 1. If disconnected, connect batteries. (WP 0085) 2. Start engine and observe cab control box tachometer. (TM 5-3825-270-10)
CAB CONTROL BOX TACHOMETER
Figure 12. Tachometer - Step 8. CONDITION/INDICATION Does cab control box tachometer operate normally? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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FIELD MAINTENANCE CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Engine Speed Resume/Idle Switch Replacement (WP 0211) Cab Control Box Wiring Harness Replacement (WP 0206) General Wire Harness Repair (WP 0099) Main Control Panel Engine Speed Resume/Idle Switch Does Not Operate (WP 0040) References (cont.) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH DOES NOT OPERATE STEP 1 Does main control panel engine speed RESUME/IDLE switch operate?
NOTE
If engine speed resume/idle switch operates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to operate engine using main control panel engine speed RESUME/IDLE switch. (TM 5-3825-270-10) CONDITION/INDICATION Does main control panel engine speed RESUME/IDLE switch operate? DECISION No - Go to Main Control Panel Engine Speed Resume Switch Does Not Operate. (WP 0040) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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CAB CONTROL BOX
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at red wire on cab control box engine speed RESUME/ IDLE switch?) STEP 3 Are 22 to 28 VDC measured at red wire on cab control box engine speed RESUME/IDLE switch? 1. Remove six screws from cab control box.
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0060

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to red wire on cab control box engine speed RESUME/IDLE switch.
BACK OF CAB CONTROL BOX CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH
WHITE WIRE RED JUMPER WIRES BLACK WIRE
Figure 4. Cab Control Box Engine Speed Resume/Idle Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at red wire on cab control box engine speed RESUME/IDLE switch?
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DECISION No - Replace red wire between engine speed RESUME/IDLE switch and cab control box LIGHTS switch. (WP 0099) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire at cab control box engine speed RESUME/IDLE switch to known good ground?) STEP 4 Are less than 200 ohms measured on black wire at cab control box engine speed RESUME/IDLE switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to black wire at cab control box engine speed RESUME/IDLE switch.
Figure 5. Cab Control Box Engine Speed Resume/Idle Switch - Step 4. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box engine speed RESUME/IDLE switch to known good ground?
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DECISION No - Go to step 7. (Step 7 - Are less than 200 ohms measured at UPIK harness connector pin B to known good ground?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured on white wire at cab control box engine speed RESUME/IDLE switch to known good ground?) STEP 5 Are less than 200 ohms measured on white wire at cab control box engine speed RESUME/IDLE switch to known good ground? 1. Ensure multimeter is set to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 2. Connect red multimeter lead to white wire at cab control box engine speed RESUME/IDLE switch.
Figure 6. Cab Control Box Engine Speed Resume/Idle Switch - Step 5. 3. 4. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on white wire at cab control box engine speed RESUME/IDLE switch to known good ground? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured at UPIK harness connector pin C to known good ground?) Yes - Replace cab control box engine speed RESUME/IDLE switch. (WP 0211) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) STEP 6
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Are less than 200 ohms measured at UPIK harness connector pin C to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin C.
PIN C
Figure 8. UPIK Harness Connector Pin C - Step 6. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
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CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin C to known good ground? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) STEP 7 Are less than 200 ohms measured at UPIK harness connector pin B to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin B.
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PIN B
Figure 10. UPIK Harness Connector Pin B - Step 7. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin B to known good ground? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box engine speed RESUME/IDLE switch operate?) STEP 8 Does cab control box engine speed RESUME/IDLE switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Operate engine using cab control box engine speed RESUME/IDLE switch.
CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH
Figure 11. Cab Control Box Engine Speed Resume/Idle Switch - Step 8. CONDITION/INDICATION Does cab control box engine speed RESUME/IDLE switch operate?
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0061
FIELD MAINTENANCE CAB CONTROL BOX ENGINE SPEED RPM SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Engine Speed RPM Switch Replacement (WP 0212) Cab Control Box Wiring Harness Replacement (WP 0206) General Wire Harness Repair (WP 0099) Main Control Panel Engine Speed RPM Switch Does Not Operate (WP 0041) References (cont.) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX ENGINE SPEED RPM SWITCH DOES NOT OPERATE STEP 1 Does main control panel engine speed RPM switch operate?
NOTE
If engine speed RPM switch operates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to operate engine using main control panel engine speed RPM switch. (TM 5-3825-270-10) CONDITION/INDICATION Does main control panel engine speed RPM switch operate? DECISION No - Go to Main Control Panel Engine Speed RPM Switch Does Not Operate. (WP 0041) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0061
CAB CONTROL BOX
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at red wire on cab control box engine speed RPM switch?) STEP 3 Are 22 to 28 VDC measured at red wire on cab control box engine speed RPM switch? 1. Remove six screws from cab control box.
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0061

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to red wire on cab control box engine speed RPM switch.
CAB CONTROL BOX ENGINE SPEED RPM SWITCH
Figure 4. Cab Control Box Engine Speed RPM Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at red wire on cab control box engine speed RPM switch?
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DECISION No - Replace red wire between engine speed RPM switch and engine RESUME/IDLE switch. (WP 0099) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire at cab control box engine speed RPM switch to known good ground?) STEP 4 Are less than 200 ohms measured on black wire at cab control box engine speed RPM switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to black wire at cab control box engine speed RPM switch.
Figure 5. Cab Control Box Engine Speed RPM Switch - Step 4. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box engine speed RPM switch to known good ground? DECISION No - Go to step 7. (Step 7 - Are less than 200 ohms measured at UPIK harness connector pin D to known good ground?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured on white wire at cab control box engine speed RPM switch to known good ground?)
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STEP 5 Are less than 200 ohms measured on white wire at cab control box engine speed RPM switch to known good ground? 1. Ensure multimeter is set to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 2. Connect red multimeter lead to white wire at cab control box engine speed RPM switch.
Figure 6. Cab Control Box Engine Speed RPM Switch - Step 5. 3. 4. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on white wire at cab control box engine speed RPM switch to known good ground? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured at UPIK harness connector pin E to known good ground?) Yes - Replace cab control box engine speed RPM switch. (WP 0211) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) STEP 6 Are less than 200 ohms measured at UPIK harness connector pin E to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
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UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin E.
PIN E
Figure 8. UPIK Harness Connector Pin E - Step 6. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin E to known good ground?
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DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) STEP 7 Are less than 200 ohms measured at UPIK harness connector pin D to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin D.
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PIN D
Figure 10. UPIK Harness Connector Pin D - Step 7. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin D to known good ground? DECISION No - Wiring in water distributor UPIK harness is faulty. Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box engine speed RPM switch operate?) STEP 8 Does cab control box engine speed RPM switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Operate engine using cab control box engine speed RPM switch.
Figure 11. Cab Control Box Engine Speed RPM Switch - Step 8. CONDITION/INDICATION Does cab control box engine speed RPM switch operate?
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0062
FIELD MAINTENANCE CAB CONTROL BOX ENGINE SPEED SET SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Engine Speed Set Button Replacement (WP 0213) Cab Control Box Wiring Harness Replacement (WP 0206) Main Control Panel Engine Speed Set Switch Does Not Operate (WP 0042) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX ENGINE SPEED SET SWITCH DOES NOT OPERATE STEP 1 Does main control panel engine speed SET switch operate?
NOTE
If engine speed SET switch operates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to operate engine using main control panel engine speed SET switch. (TM 5-3825-270-10) CONDITION/INDICATION Does main control panel engine speed SET switch operate? DECISION No - Go to Main Control Panel Engine Speed Set Switch Does Not Operate. (WP 0042) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0062
CAB CONTROL BOX
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 6 - Does cab control box engine speed SET switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at red wire on cab control box engine speed SET switch?) STEP 3 Are 22 to 28 VDC measured at red wire on cab control box engine speed SET switch? 1. Remove six screws from cab control box.
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0062

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to red wire on cab control box engine speed SET switch.
BACK OF CAB CONTROL BOX RED WIRE CAB CONTROL BOX ENGINE SPEED SET SWITCH BLACK WIRE
Figure 4. Cab Control Box Engine Speed Set Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at red wire on cab control box engine speed SET switch?
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DECISION No - Replace red wire between engine speed SET switch and engine speed RPM switch. (WP 0099) Verify problem is solved. (Step 6 - Does cab control box engine speed SET switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire at cab control box engine speed SET switch to known good ground?) STEP 4 Are less than 200 ohms measured on black wire at cab control box engine speed SET switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity. 4. Connect red multimeter lead to black wire at cab control box engine speed SET switch.
BACK OF CAB CONTROL BOX RED WIRE CAB CONTROL BOX ENGINE SPEED SET SWITCH BLACK WIRE
Figure 5. Cab Control Box Engine Speed Set Switch - Step 4. Connect black multimeter lead to known good ground. Note multimeter reading.
5. 6.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box engine speed SET switch to known good ground? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured at UPIK harness connector pin A to known good ground?) Yes - Replace cab control box engine speed SET switch. (WP 0211) Verify problem is solved. (Step 6 - Does cab control box engine speed SET switch operate?) STEP 5 Are less than 200 ohms measured at UPIK harness connector pin A to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
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UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin A.
PIN A
Figure 7. UPIK Harness Connector Pin A - Step 5. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin A to known good ground?
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DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 6 - Does cab control box engine speed SET switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 6 - Does cab control box engine speed SET switch operate?) STEP 6 Does cab control box engine speed SET switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Operate engine using cab control box engine speed SET switch.
CAB CONTROL BOX ENGINE SPEED SET SWITCH
Figure 8. Cab Control Box Engine Speed Set Switch - Step 6. CONDITION/INDICATION Does cab control box engine speed SET switch operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0063
FIELD MAINTENANCE CAB CONTROL BOX WATER SPRINKLER SWITCH (LEFT) INOPERATIVE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Engine Water Sprinkler Switch Replacement (WP 0209) Cab Control Box Wiring Harness Replacement (WP 0206) Water Sprinkler Switch (Left) Inoperative (WP 0043) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX WATER SPRINKLER SWITCH (LEFT) INOPERATIVE STEP 1 Does main control panel LEFT WATER SPRINKLER switch operate?
NOTE
If LEFT WATER SPRINKLER switch operates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to operate left water sprinkler using main control panel LEFT WATER SPRINKLER switch. (TM 5-3825-270-10) CONDITION/INDICATION Does main control panel LEFT WATER SPRINKLER switch operate? DECISION No - Go to Left Water Sprinklers Switch Does Not Operate. (WP 0043) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0063
CAB CONTROL BOX
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 6 - Does cab control box LEFT WATER SPRINKLER switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at white wire on LEFT WATER SPRINKLER switch?) STEP 3 Are 22 to 28 VDC measured at white wire on LEFT WATER SPRINKLER switch? 1. Remove six screws from cab control box.
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0063

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to white wire on cab control box LEFT WATER SPRINKLER switch.
WHITE WIRE LEFT WATER SPRINKLER SWITCH BLACK WIRE
Figure 4. Cab Control Box Left Water Sprinkler Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at white wire on LEFT WATER SPRINKLER switch?
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0063
DECISION No - Replace white wire between LEFT WATER SPRINKLER switch and RIGHT WATER SPRINKLER switch. (WP 0099) Verify problem is solved. (Step 6 - Does cab control box LEFT WATER SPRINKLER switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire at cab control box LEFT WATER SPRINKLER switch to known good ground?) STEP 4 Are less than 200 ohms measured on black wire at cab control box LEFT WATER SPRINKLER switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to black wire at cab control box engine speed SET switch.
WHITE WIRE LEFT WATER SPRINKLER SWITCH BLACK WIRE
Figure 5. Cab Control Box Left Water Sprinkler Switch - Step 4. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box LEFT WATER SPRINKLER switch to known good ground?
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0063
DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured at UPIK harness connector pin M to known good ground?) Yes - Replace cab control box LEFT WATER SPRINKLER switch. (WP 0209) Verify problem is solved. (Step 6 - Does cab control box LEFT WATER SPRINKLER switch operate?) STEP 5 Are less than 200 ohms measured at UPIK harness connector pin M to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin M.
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0063
PIN M
Figure 7. UPIK Harness Connector Pin M - Step 5. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin M to known good ground? DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 6 - Does cab control box LEFT WATER SPRINKLER switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 6 - Does cab control box LEFT WATER SPRINKLER switch operate?) STEP 6 Does cab control box LEFT WATER SPRINKLER switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Operate water sprinklers using cab control box LEFT WATER SPRINKLER switch.
LEFT WATER SPRINKLERS SWITCH
Figure 8. Left Water Sprinkler Switch - Step 6. CONDITION/INDICATION Does cab control box LEFT WATER SPRINKLER switch operate?
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0063
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0064
FIELD MAINTENANCE CAB CONTROL BOX WATER SPRINKLER SWITCH (RIGHT) INOPERATIVE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Water Sprinkler Switch Replacement (WP 0209) Cab Control Box Wiring Harness Replacement (WP 0206) Water Sprinkler Switch (Right) Inoperative (WP 0044) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX WATER SPRINKLER SWITCH (RIGHT) INOPERATIVE STEP 1 Does main control panel RIGHT WATER SPRINKLER switch operate?
NOTE
If RIGHT WATER SPRINKLER switch operates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to operate right water sprinkler using main control panel RIGHT WATER SPRINKLER switch. (TM 5-3825-270-10) CONDITION/INDICATION Does main control panel RIGHT WATER SPRINKLER switch operate? DECISION No - Go to Right Water Sprinklers Switch Does Not Operate. (WP 0044) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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TM 5-3825-270-23&P
0064
CAB CONTROL BOX
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 6 - Does cab control box RIGHT WATER SPRINKLER switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at white wire on RIGHT WATER SPRINKLER switch?) STEP 3 Are 22 to 28 VDC measured at white wire on RIGHT WATER SPRINKLER switch? 1. Remove six screws from cab control box.
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0064

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to white wire on cab control box RIGHT WATER SPRINKLER switch.
BACK OF CAB CONTROL BOX WHITE JUMPER WIRES RIGHT WATER SPRINKLER SWITCH WHITE WIRE
Figure 4. Cab Control Box Right Water Sprinkler Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at white wire on RIGHT WATER SPRINKLER switch?
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0064
DECISION No - Replace white wire between RIGHT WATER SPRINKLER switch and cab control box tachometer. (WP 0099) Verify problem is solved. (Step 6 - Does cab control box RIGHT WATER SPRINKLER switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on white wire at cab control box RIGHT WATER SPRINKLER switch to known good ground?) STEP 4 Are less than 200 ohms measured on white wire at cab control box RIGHT WATER SPRINKLER switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity. 4. Connect red multimeter lead to white wire at cab control box RIGHT WATER SPRINKLER switch.
BACK OF CAB CONTROL BOX WHITE JUMPER WIRES RIGHT WATER SPRINKLER SWITCH WHITE WIRE
Figure 5. Cab Control Box Right Water Sprinkler Switch - Step 4. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on white wire at cab control box RIGHT WATER SPRINKLER switch to known good ground? DECISION No - Go to step 5. (Step 5 - Are less than 200 ohms measured at UPIK harness connector pin N to known good ground?) Yes - Replace cab control box RIGHT WATER SPRINKLER switch. (WP 0209) Verify problem is solved. (Step 6 - Does cab control box RIGHT WATER SPRINKLER switch operate?) STEP 5 Are less than 200 ohms measured at UPIK harness connector pin N to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
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0064
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin N.
PIN N
Figure 7. UPIK Harness Connector Pin N - Step 5. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin N to known good ground?
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0064
DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 6 - Does cab control box RIGHT WATER SPRINKLER switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 6 - Does cab control box RIGHT WATER SPRINKLER switch operate?) STEP 6 Does cab control box RIGHT WATER SPRINKLER switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. Operate water sprinklers using cab control box RIGHT WATER SPRINKLER switch.
RIGHT WATER SPRINKLERS SWITCH
Figure 8. Right Water Sprinkler Switch - Step 6. CONDITION/INDICATION Does cab control box RIGHT WATER SPRINKLER switch operate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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TM 5-3825-270-23&P
0065
FIELD MAINTENANCE CAB CONTROL BOX WATER LEVEL HIGH INDICATOR DOES NOT ILLUMINATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Water Level Indicator Replacement (WP 0214) Cab Control Box Wiring Harness Replacement (WP 0206) Water Level High Indicator Does Not Illuminate (WP 0045) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX WATER LEVEL HIGH INDICATOR DOES NOT ILLUMINATE STEP 1 Does main control panel WATER LEVEL HIGH indicator illuminate?
NOTE
If WATER LEVEL HIGH indicator illuminates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. 1. 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) With the aid of an assistant, move water level indicator magnet directly over high tank level switch.
Figure 1. Water Level Indicator And Magnet - Step 1.
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0065
3.
Verify main control panel WATER LEVEL HIGH indicator illuminates.

Figure 2. Water Level High Indicator - Step 1. CONDITION/INDICATION Does main control panel WATER LEVEL HIGH indicator illuminate? DECISION No - Go to Water Level High Indicator Does Not illuminate. (WP 0045) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0065
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 7 - Does cab control box WATER LEVEL HIGH indicator illuminate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at black wire on WATER LEVEL HIGH indicator?) STEP 3 Are 22 to 28 VDC measured at black wire on WATER LEVEL HIGH indicator? 1. Remove six screws from cab control box.

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0065
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to black wire on cab control box WATER LEVEL HIGH indicator.
CAB CONTROL BOX WATER LEVEL HIGH INDICATOR BLACK JUMPER WIRE BLACK WIRE BACK OF CAB CONTROL BOX
Figure 6. Cab Control Box Water Level High Indicator - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at black wire on WATER LEVEL HIGH indicator? DECISION No - Go to step 4. (Step 4 - Are 22 to 28 VDC measured at UPIK harness connector pin K?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured on black wire at cab control box WATER LEVEL HIGH indicator to known good ground?) STEP 4 Are 22 to 28 VDC measured at UPIK harness connector pin K? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
Figure 7. UPIK Electrical Connection - Step 4.
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0065
3. 4.
Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) Ensure multimeter is set to measure voltage.
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter lead to UPIK harness connector pin K.
PIN K
Figure 8. UPIK Harness Connector Pin K - Step 4. 6. 7. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at UPIK harness connector pin K? DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 7 - Does cab control box WATER LEVEL HIGH indicator illuminate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 7 - Does cab control box WATER LEVEL HIGH indicator illuminate?) STEP 5 Are less than 200 ohms measured on black wire at cab control box WATER LEVEL HIGH indicator to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) Set multimeter to measure continuity. 3. 4. Connect red multimeter lead to black wire at cab control box WATER LEVEL HIGH indicator.
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0065
Figure 9. Cab Control Box Water Level High Indicator - Step 5. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box WATER LEVEL HIGH indicator to known good ground? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured from black wire at WATER LEVEL HIGH indicator to black wire at WATER LEVEL LOW indicator?) Yes - Replace cab control box WATER LEVEL HIGH indicator. (WP 0214) Verify problem is solved. (Step 7 Does cab control box WATER LEVEL HIGH indicator illuminate?) STEP 6 Are less than 200 ohms measured from black wire at WATER LEVEL HIGH indicator to black wire at WATER LEVEL LOW indicator?
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. Connect red multimeter lead to black wire at cab control box WATER LEVEL HIGH indicator.
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0065
Figure 10. Cab Control Box Water Level High Indicator - Step 6. 2. 3. Connect black multimeter lead to black wire at WATER LEVEL LOW indicator. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from black wire at WATER LEVEL HIGH indicator to black wire at WATER LEVEL LOW indicator? DECISION No - Replace black wire between WATER LEVEL HIGH indicator and WATER LEVEL LOW indicator. (WP 0099) Verify problem is solved. (Step 7 - Does cab control box WATER LEVEL HIGH indicator illuminate?) Yes - Replace cab control box WATER LEVEL HIGH indicator. (WP 0214) Verify problem is solved. (Step 7 Does cab control box WATER LEVEL HIGH indicator illuminate?) STEP 7 Does cab control box WATER LEVEL HIGH indicator illuminate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. With the aid of an assistant, move water level indicator magnet directly over high tank level switch.
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0065
5.
Verify WATER LEVEL HIGH indicator illuminates.
CAB CONTROL BOX WATER LEVEL HIGH INDICATOR
Figure 12. Cab Control Box Water Level High Indicator - Step 7. CONDITION/INDICATION Does cab control box WATER LEVEL HIGH indicator illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
0065-8
TM 5-3825-270-23&P
0066
FIELD MAINTENANCE CAB CONTROL BOX WATER LEVEL LOW INDICATOR DOES NOT ILLUMINATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Water Level Indicator Replacement (WP 0214) Cab Control Box Wiring Harness Replacement (WP 0206) Water Level Low Indicator Does Not Illuminate (WP 0046) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX WATER LEVEL LOW INDICATOR DOES NOT ILLUMINATE STEP 1 Does main control panel WATER LEVEL LOW indicator illuminate?
NOTE
If WATER LEVEL LOW indicator illuminates on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. 1. 2. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) With the aid of an assistant, move water level indicator magnet directly over low tank level switch.
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0066
3.
Verify main control panel WATER LEVEL LOW indicator illuminates.

Figure 2. Water Level Low Indicator - Step 1. CONDITION/INDICATION Does main control panel WATER LEVEL LOW indicator illuminate? DECISION No - Go to Water Level Low Indicator Does Not illuminate. (WP 0046) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0066
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 6 - Does cab control box WATER LEVEL LOW indicator illuminate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at white wire on WATER LEVEL LOW indicator?) STEP 3 Are 22 to 28 VDC measured at white wire on WATER LEVEL LOW indicator? 1. Remove six screws from cab control box.

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0066
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to white wire on cab control box WATER LEVEL LOW indicator.
CAB CONTROL BOX WATER LEVEL LOW INDICATOR
BLACK WIRE WHITE WIRE BACK OF CAB CONTROL BOX
Figure 6. Cab Control Box Water Level Low Indicator - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at white wire on WATER LEVEL LOW indicator? DECISION No - Go to step 4. (Step 4 - Are 22 to 28 VDC measured at UPIK harness connector pin L?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured from black wire at WATER LEVEL LOW indicator to black wire at cab control box tachometer?) STEP 4 Are 22 to 28 VDC measured at UPIK harness connector pin L? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
Figure 7. UPIK Electrical Connection - Step 4. 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10)
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0066
4.
Ensure multimeter is set to measure voltage.
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 5. Connect red multimeter lead to UPIK harness connector pin L.
PIN L UPIK HARNESS CONNECTOR
Figure 8. UPIK Harness Connector Pin L - Step 4. 6. 7. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at UPIK harness connector pin L? DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 6 - Does cab control box WATER LEVEL LOW indicator illuminate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 6 - Does cab control box WATER LEVEL LOW indicator illuminate?) STEP 5 Are less than 200 ohms measured from black wire at WATER LEVEL LOW indicator to black wire at cab control box tachometer?
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 1. Connect red multimeter lead to black wire at cab control box WATER LEVEL LOW indicator.
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0066
BLACK WIRE WHITE WIRE BACK OF CAB CONTROL BOX
Figure 9. Cab Control Box Water Level Low Indicator - Step 5. 2. Connect black multimeter lead to black wire at cab control box tachometer.
Figure 10. Cab Control Box Tachometer - Step 5. 3. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured from black wire at WATER LEVEL LOW indicator to black wire at cab control box tachometer? DECISION No - Replace black wire between WATER LEVEL LOW indicator and cab control box tachometer. (WP 0099) Verify problem is solved. (Step 6 - Does cab control box WATER LEVEL LOW indicator illuminate?) Yes - Replace cab control box WATER LEVEL LOW indicator. (WP 0214) Verify problem is solved. (Step 6 Does cab control box WATER LEVEL LOW indicator illuminate?) STEP 6 Does cab control box WATER LEVEL LOW indicator illuminate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) 3. Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 4. With the aid of an assistant, move water level indicator magnet directly over low tank level switch.
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0066
Figure 11. Water Level Indicator And Magnet - Step 6. 5. Verify WATER LEVEL LOW indicator illuminates.
Figure 12. Cab Control Box Water Level Low Indicator - Step 6. CONDITION/INDICATION Does cab control box WATER LEVEL LOW indicator illuminate? DECISION No - If the problem still exists, it is possible that another fault exists or that another troubleshooting procedure applies. If this was the first time through the task, restart the same symptom troubleshooting fault task. Yes - Your original problem has been resolved. END OF WORK PACKAGE
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0067
FIELD MAINTENANCE CAB CONTROL BOX ENGINE START/STOP SWITCH DOES NOT OPERATE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Multimeter (WP 0225, Table 1, Item 4) References Battery Disconnect/Connection (WP 0085) Cab Control Box Engine Start/Stop Switch Replacement (WP 0208) Cab Control Box Wiring Harness Replacement (WP 0206) Engine Does Not Crank (WP 0006) References (cont.) General Wire Harness Repair (WP 0099) Universal Power Interface Kit (UPIK) Wire Harness Replacement (WP 0108) Water Distributor Operator Manual (TM 5-3825-270-10) Equipment Condition Engine OFF. (TM 5-3825-270-10) Universal Power Interface Kit (UPIK) harness connected to prime mover. (TM 5-3825-270-10)
TROUBLESHOOTING PROCEDURE CAB CONTROL BOX ENGINE START/STOP SWITCH DOES NOT OPERATE STEP 1 Does engine start using main control panel ENGINE START/STOP switch?
NOTE
If engine starts using ENGINE START/STOP switch on main control panel, fault can be isolated to cab control box or universal power interface kit (UPIK) harness. Attempt to start engine using main control panel ENGINE START/STOP switch. (TM 5-3825-270-10) CONDITION/INDICATION Does engine start using main control panel ENGINE START/STOP switch? DECISION No - Go to Engine Does Not Crank. (WP 0006) Yes - Go to step 2. (Step 2 - Are cab control box and water distributor harnesses connected properly to prime mover?) STEP 2 Are cab control box and water distributor harnesses connected properly to prime mover? 1. Push EMERGENCY STOP switch in to off position. (TM 5-3825-270-10) 2. Check cab control box electrical connector.
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0067
CAB CONTROL BOX
UPIK AIR CONNECTION
CONDITION/INDICATION Are cab control box and water distributor harnesses connected properly to prime mover? DECISION No - Properly connect cab control box and/or harness connections to prime mover. (TM 5-3825-270-10) Verify problem is solved. (Step 8 - Does cab control box ENGINE START/STOP switch operate?) Yes - Go to step 3. (Step 3 - Are 22 to 28 VDC measured at red wire on cab control box ENGINE START/STOP switch?) STEP 3 Are 22 to 28 VDC measured at red wire on cab control box ENGINE START/STOP switch? 1. Remove six screws from cab control box.
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0067

WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 4. Connect red multimeter lead to red wire on cab control box ENGINE START/STOP switch.
CAB CONTROL BOX ENGINE START/STOP SWITCH
WHITE WIRE
RED WIRE BLACK WIRE
Figure 4. Cab Control Box Engine Start/Stop Switch - Step 3. 5. 6. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are 22 to 28 VDC measured at red wire on cab control box ENGINE START/STOP switch?
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DECISION No - Replace red wire between ENGINE START/STOP switch and cab control box LIGHTS switch. (WP 0099) Verify problem is solved. (Step 8 - Does cab control box ENGINE START/STOP switch operate?) Yes - Go to step 4. (Step 4 - Are less than 200 ohms measured on black wire at cab control box ENGINE START/ STOP switch to known good ground?) STEP 4 Are less than 200 ohms measured on black wire at cab control box ENGINE START/STOP switch to known good ground? 1. Push in EMERGENCY STOP switch to off position. (TM 5-3825-270-10) 2. Disconnect batteries. (WP 0085) 3. Set multimeter to measure continuity. 4. Connect red multimeter lead to black wire at cab control box ENGINE START/STOP switch.
WHITE WIRE
RED WIRE BLACK WIRE
Figure 5. Cab Control Box Engine Start/Stop Switch - Step 4. 5. 6. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on black wire at cab control box ENGINE START/STOP switch to known good ground? DECISION No - Go to step 7. (Step 7 - Are less than 200 ohms measured at UPIK harness connector pin F to known good ground?) Yes - Go to step 5. (Step 5 - Are less than 200 ohms measured on white wire at cab control box ENGINE START/ STOP switch to known good ground?) STEP 5 Are less than 200 ohms measured on white wire at cab control box ENGINE START/STOP switch to known good ground? 1. Ensure multimeter is set to measure continuity.
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WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 2. Connect red multimeter lead to white wire at cab control box ENGINE START/STOP switch.
WHITE WIRE
RED WIRE BLACK WIRE
Figure 6. Cab Control Box Engine Start/Stop Switch - Step 5. 3. 4. Connect black multimeter lead to known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured on white wire at cab control box ENGINE START/STOP switch to known good ground? DECISION No - Go to step 6. (Step 6 - Are less than 200 ohms measured at UPIK harness connector pin G to known good ground?) Yes - Replace cab control box ENGINE START/STOP switch. (WP 0211) Verify problem is solved. (Step 8 Does cab control box ENGINE START/STOP switch operate?) STEP 6 Are less than 200 ohms measured at UPIK harness connector pin G to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
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0067
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin G.
PIN G
Figure 8. UPIK Harness Connector Pin G - Step 6. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin G to known good ground?
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DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box ENGINE START/ STOP switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box ENGINE START/STOP switch operate?) STEP 7 Are less than 200 ohms measured at UPIK harness connector pin F to known good ground? 1. Disconnect water distributor UPIK electrical harness from prime mover.
UPIK AIR CONNECTION
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. 3. Connect red multimeter lead to UPIK harness connector pin F.
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PIN F
Figure 10. UPIK Harness Connector Pin F - Step 7. 4. 5. Connect black multimeter lead to a known good ground. Note multimeter reading.
CONDITION/INDICATION Are less than 200 ohms measured at UPIK harness connector pin F to known good ground? DECISION No - Replace UPIK harness. (WP 0108) Verify problem is solved. (Step 8 - Does cab control box ENGINE START/ STOP switch operate?) Yes - Wiring in cab control box harness is faulty. Replace cab control box wiring harness. (WP 0206) Verify problem is solved. (Step 8 - Does cab control box ENGINE START/STOP switch operate?) STEP 8 Does cab control box ENGINE START/STOP switch operate? 1. If disconnected, connect batteries. (WP 0085) 2. Ensure water distributor is set up to be operated using cab control box. (TM 5-3825-270-10) Rotate EMERGENCY STOP switch to on position. (TM 5-3825-270-10) 3. 4. Operate engine using cab control box ENGINE START/STOP switch.
Figure 11. Cab Control Box Engine Start/Stop Switch - Step 8. CONDITION/INDICATION Does cab control box ENGINE START/STOP switch operate?
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TM 5-3825-270-23&P
CHAPTER 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TM 5-3825-270-23&P
0068
FIELD MAINTENANCE INTRODUCTION - FIELD LEVEL PREVENTIVE MAINTENANCE
PMCS INTRODUCTION This section contains Preventive Maintenance Checks and Services (PMCS) requirements for the Engineer Mission Module-Water Distributor (EMM - WD). The PMCS tables contain checks and services necessary to ensure that the Water Distributor is ready for operation. Using PMCS tables, perform maintenance at specified intervals. Operator Preventive Checks and Services must be completed before doing Field Level Preventive Checks and Services. MAINTENANCE FORMS AND RECORDS Every mission begins and ends with paperwork. There is not much of it, but it must be kept up. The filled out forms and records have several uses; they are a permanent record of services, repairs, and modifications made on the Water Distributor; they are reports to unit maintenance and to your Commander; and they serve as a checklist to find out what is wrong with the equipment after its last use, and whether those faults have been fixed. For more information on forms and records, refer to DA PAM 750-8. GENERAL MAINTENANCE PROCEDURE Cleanliness: Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Use solvent cleaning compound on all metal surfaces and soapy water on rubber. Bolts, Nuts, and Screws: Check bolts, nuts, and screws for obvious looseness, missing, bent, or broken condition and tighten or replace as necessary. They cannot all be checked with a tool, of course, but look for chipped paint, bare metal, or rust around bolt heads. Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is found, have it repaired. Electric Wires and Connectors: Look for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors and make sure wires are in good shape. Hydraulic Lines and Fittings: Look for wear, damage, and leaks, and make sure clamps and fittings are tight. Wet spots show leaks, of course, but a stain around a fitting or connector can indicate a leak. If a connector or fitting is loose, tighten it. If something is broken or worn out, repair or replace per applicable procedure.
FLUID LEAKAGE
NOTE
Equipment operation is allowable with minor leakage (Class I or II). Consideration must be given to the fluid capacity in the item/system being checked/inspected. When in doubt, notify the supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS. Class III leaks should be repaired per applicable procedure. Fluid leakage affects the operational status of fuel, oil, coolant, and the hydraulic systems. The following are definitions of types/classes of leakage necessary to know in order to determine the status of the vehicle: Class I :Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. Class II: Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected. Class III: Leakage of fluid great enough to form drops that fall from the item being checked/inspected. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Complete SEMI-ANNUAL PREVENTIVE MAINTENANCE (WP 0069) once every 6 months and/or every 50 hours, whichever comes first.
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PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued Complete ANNUAL PREVENTIVE MAINTENANCE once each year and/or every 250 hours, whichever comes first. Complete BIENNIAL PREVENTIVE MAINTENANCE once every 2 years and/or every 500 hours, whichever comes first. Always complete PREVENTIVE MAINTENANCE in the same order, every time, until it becomes habit. Once PREVENTIVE MAINTENANCE is mastered, it should allow you to spot any discrepancies, even in a rushed situation. If something does not work, troubleshoot per instructions in the troubleshooting section of this publication. If anything looks wrong and is not fixed immediately upon discovery, complete either a DA Form 2404 or DA FORM 5988E. When completing PREVENTIVE MAINTENANCE, always take along the tools needed to make all the required checks (including one or two clean rags).
END OF WORK PACKAGE
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0069
FIELD MAINTENANCE FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INITIAL SETUP: Not Applicable
Table 1. FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
ITEM TO BE CHECKED OR SERVICED
PROCEDURE
WARNING
BATTERIES To avoid shock when disconnecting the batteries, ensure that the negative terminal is disconnected first and the system power is turned off. Failure to comply may result in serious injury or death to personnel and/or damage to equipment.
50 Hours/ SemiAnnual
Batteries
Remove battery box cover (TM 5-3825-270-10). Clean and inspect tops of both batteries for obvious signs of damage.
Batteries have damage that will impair operation.
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0069
Table 1. FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued EQUIPMENT NOT READY/ AVAILABLE IF:
ITEM NO.
INTERVAL
PROCEDURE
BATTERY BOX
BATTERIES
Figure 1. Batteries. Check electrolyte level (WP 0082). Specific gravity on maintainable batteries. Install battery box cover (TM 5-3825-270-10). 2 250 Hours/ SemiAnnual Engine Oil
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with
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0069
ITEM NO.
INTERVAL
PROCEDURE lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. Remove rear engine access cover (TM 5-3825-270-10). Drain and refill engine oil. (WP 0124)
ENGINE
Figure 2. Engine. Install rear engine access cover (TM 5-3825-270-10). 3 250 Hours/ SemiAnnual Belt Remove engine compartment cover (WP 0142).
Inspect engine drive belt for looseness, wear, or obvious signs of damage.
Belt has damage that will impair operation.
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0069
ITEM NO.
INTERVAL
PROCEDURE
DRIVE BELT
Figure 3. Belt. Adjust (WP 0079) or install new belt (WP 0080) as necessary. Install engine compartment cover. (WP 0142) 4 250 Hours/ SemiAnnual Cooling System
WARNING
Cooling systems are hot and under pressure. Allow engine to completely cool prior to handling any cooling system component or hose. Be sure to wear proper eye protection. Failure to comply
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0069
ITEM NO.
INTERVAL
PROCEDURE may result in injury or death to personnel. Remove engine compartment cover (WP 0142) and rear engine access cover (TM 5-3825-270-10). Check antifreeze level and that protection rating is -50 F (-46 C) or lower. Replace antifreeze (WP 0075) or flush cooling system (WP 0074) as required. Check the following components for leaks and obvious signs of damage: a. Radiator b. Hoses c. Clamps
Class III leak is evident. Radiator, hoses or clamps have damage that will impair operation.
CLAMP ANTIFREEZE RADIATOR
HOSES
Figure 4. Cooling System. Install engine compartment cover (WP 0142) and rear engine access cover (TM 5-3825-270-10).
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0069
Table 1. FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued EQUIPMENT NOT READY/ AVAILABLE IF: Class III leak is evident. Water tank, valves, hoses, clamps, or water pump has damage that will impair operation.
ITEM NO. 5
INTERVAL 250 Hours/ SemiAnnual
ITEM TO BE CHECKED OR SERVICED Water Tank and Accessories
PROCEDURE Check water tank and the following for leaks or obvious signs of damage: a. Valves b. Hoses c. Clamps d. Water Pump
WATER CLAMPS PUMP
WATER TANK
VALVES
HOSE
HOSE
CLAMP
Figure 5. Water Tank and Accessories. 6 250 Hours/ SemiAnnual Hook Bar Check hook bar for cracks, gouges, or other obvious signs of damage. If wear at lower back side of hook bar is greater than 0.25 in. (6.4 mm) or greater than 0.125 (3.18 mm) at bottom of hook bar, notify supervisor. Wear at lower back side is greater than 0.25 in. (6.4 mm) or greater than 0.125 in. (3.18 mm) at bottom of hook bar. Hook bar has damage
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0069
Table 1. FIELD LEVEL PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - Continued EQUIPMENT NOT READY/ AVAILABLE IF: that will impair operation.
ITEM NO.
INTERVAL
PROCEDURE
0.25 IN. MAX (6.4 MM)
0.125 IN. MAX (3.18 MM)
Figure 6. Hook Bar. 7 250 Hours/ SemiAnnual Water Tank Mount Screws Check and re-torque the following water tank mount screws: a. Re-torque 16 isolator mount screws to 400 lb-ft (542 Nm). b. Re-torque four rear mount screws to 220 lb-ft (298 Nm).
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ITEM NO.
INTERVAL
PROCEDURE
ISOLATOR MOUNT SCREWS
REAR MOUNT SCREWS
Figure 7. Water Tank Mount Screws. 8 250 Hours/ SemiAnnual Air Lubricator
WARNING
Air line lubricator is under high pressure. Use protective gloves and goggles when servicing system. Remove fill plug slowly to allow depressurization of system. Failure to comply may result in injury or death to personnel. Drain and refill air lubricator oil (WP 0169).
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ITEM NO.
INTERVAL
PROCEDURE
AIR LUBRICATOR
Figure 8. Air Lubricator. 9 500 Hours/ Annual Oil Filter Remove rear engine access cover (TM 5-3825-270-10. Replace engine oil filter (WP 0123).
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0069
ITEM NO.
INTERVAL
PROCEDURE
OIL FILTER
Figure 9. Oil Filter. Install rear engine access cover (TM 5-3825-270-10). 10 500 Hours/ Annual Air Filter Replace inner air filter element (WP 0170).
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0069
ITEM NO.
INTERVAL
PROCEDURE
INNER AIR FILTER
Figure 10. Air Filter. 11 500 Hours/ Annual Water Pump Oil
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. Drain and refill water pump oil (WP 0196).
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ITEM NO.
INTERVAL
PROCEDURE
WATER PUMP
Figure 11. Water Pump. 12 500 Hours/ Biennial Starter Remove front engine access cover (TM 5-3825-270-10). Inspect starter and the following for any signs of burning, corrosion, or obvious damage: a. Wiring b. Electrical connectors Starter, wiring, or electrical connectors have damage that will impair operation.
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0069
ITEM NO.
INTERVAL
PROCEDURE
CONNECTORS
STARTER
WIRES
Figure 12. Starter. Install front engine access cover (TM 5-3825-270-10). 13 500 Hours/ Annual Fuel/Water Separator Replace fuel/water separator (WP 0177).
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0069
ITEM NO.
INTERVAL
PROCEDURE
Figure 13. Air Filter.
END OF TASK END OF WORK PACKAGE
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CHAPTER 4 MAINTENANCE INSTRUCTIONS
TM 5-3825-270-23&P
0070
FIELD MAINTENANCE COOLANT RESERVOIR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Materials/Parts Lockwasher (WP 0226, Table 1, Item 7) Qty: 2 References Parts Manual (WP 0220) Figure 4022 Equipment Condition Rear access door removed. (TM 5-3825-270-10)
REMOVAL 1. Loosen clamp (Figure 1, Item 4) and remove hose (Figure 1, Item 5) from bottom of coolant reservoir (Figure 1, Item 1) and drain coolant into drain pan.
1 2 3
Figure 1. Coolant Reservoir Removal. 2. 3. Remove hose (Figure 1, Item 3) from coolant reservoir cap (Figure 1, Item 2). Lift coolant reservoir (Figure 2, Item 1) up and remove from bracket (Figure 2, Item 6).
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REMOVAL - Continued
1 6
Figure 2. Coolant Reservoir Removal. 4. Remove four nuts (Figure 3, Item 8) and bracket (Figure 3, Item 6) from bracket (Figure 3, Item 7).
10
11
Figure 3. Coolant Reservoir Removal. 5. Remove two screws (Figure 3, Item 10), lockwashers (Figure 3, Item 11), and bracket (Figure 3, Item 7), from intake manifold (Figure 3, Item 9). Discard lockwashers.
END OF TASK INSTALLATION 1. Install bracket (Figure 4, Item 7) on intake manifold (Figure 4, Item 9) with two screws (Figure 4, Item 10) and lockwashers (Figure 4, Item 11).
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INSTALLATION - Continued
10
11
Figure 4. Coolant Reservoir Installation. 2. 3. Install bracket (Figure 4, Item 6) onto bracket (Figure 4, Item 7) with four nuts (Figure 4, Item 8). Install coolant reservoir (Figure 5, Item 1) onto bracket (Figure 5, Item 6).
1 6
Figure 5. Coolant Reservoir Installation. 4. Install hose (Figure 6, Item 3) on coolant reservoir cap (Figure 6, Item 2).
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1 2 3
Figure 6. Coolant Reservoir Installation. 5. Install hose (Figure 6, Item 5) onto bottom of coolant reservoir (Figure 6, Item 1) with hose clamp (Figure 6, Item 4).
END OF TASK FOLLOW-ON MAINTENANCE Install rear access door. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
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0071
FIELD MAINTENANCE WATER PUMP AND HOUSING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Materials/Parts (cont.) Gasket (WP 0226, Table 1, Item 25) Qty: 1 Packing, Preformed (WP 0226, Table 1, Item 5) Qty: 1 References Parts Manual (WP 0220) Figure 4036 Equipment Condition Engine cooling fan removed. (WP 0072)
REMOVAL 1. Remove cooling fan pulley (Figure 1, Item 1) from water pump (Figure 1, Item 2).
1 2
Figure 1. Water Pump and Housing Removal. 2. Remove two screws (Figure 2, Item 4) from water pump (Figure 2, Item 2) and water pump housing (Figure 2, Item 3).
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REMOVAL - Continued
3 4
2, 5
Figure 2. Water Pump and Housing Removal. 3. 4. 5. Remove four screws (Figure 2, Item 6), from water pump (Figure 2, Item 2), water pump housing (Figure 2, Item 3), and engine block (Figure 2, Item 7). Remove water pump (Figure 2, Item 2) and gasket (Figure 2, Item 5) from water pump housing (Figure 2, Item 3). Discard gasket. Loosen clamp (Figure 3, Item 10) and remove coolant hose (Figure 3, Item 11) from fitting (Figure 3, Item 12).
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REMOVAL - Continued
10
11
12 8 9
3
Figure 3. Water Pump and Housing Removal. 6. 7. Loosen clamp (Figure 3, Item 9) and remove water pump housing (Figure 3, Item 3) from coolant hose (Figure 3, Item 8). Removed preformed packing (Figure 4, Item 15) from water pump housing (Figure 4, Item 3). Discard preformed packing.
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REMOVAL - Continued
3 13
15
14
Figure 4. Water Pump and Housing Removal.
NOTE
Perform Step (8) if plug or fittings are damaged. 8. Remove fitting (Figure 4, Item 14) and plug (Figure 4, Item 13) from water pump housing (Figure 4, Item 3).
END OF TASK INSTALLATION
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Apply sealing compound to threads of plug (Figure 5, Item 13).
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3 13
15
14
Figure 5. Water Pump and Housing Installation. 2. Install plug (Figure 5, Item 13) on water pump housing (Figure 5, Item 3).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 3. 4. 5. 6. Apply pipe thread sealant to threads of fitting (Figure 5, Item 14). Install fitting (Figure 5, Item 14) on water pump housing (Figure 5, Item 3). Install preformed packing (Figure 5, Item 15) in water pump housing (Figure 5, Item 3). Install water pump housing (Figure 6, Item 3) on coolant hose (Figure 6, Item 8) with clamp (Figure 6, Item 9).
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10
11
12 8 9
3
Figure 6. Water Pump and Housing Installation. 7. 8. Install coolant hose (Figure 6, Item 11) and clamp (Figure 6, Item 10) on fitting (Figure 6, Item 12). Install water pump housing (Figure 7, Item 3), gasket (Figure 7, Item 5), and water pump (Figure 7, Item 2) on engine block (Figure 7, Item 7) with four screws (Figure 7, Item 6).
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3 4
2, 5
Figure 7. Water Pump and Housing Installation. 9. 10. Install two screws (Figure 7, Item 4) in water pump (Figure 7, Item 2). Install cooling fan pulley (Figure 8, Item 1) on water pump (Figure 8, Item 2).
1 2
Figure 8. Water Pump and Housing Installation. END OF TASK FOLLOW-ON MAINTENANCE Install engine cooling fan. (WP 0072) END OF TASK END OF WORK PACKAGE
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0072
FIELD MAINTENANCE COOLING FAN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4038 Equipment Condition Alternator belt removed. (WP 0080) Radiator and bracket removed. (WP 0076)
REMOVAL 1. Remove four screws (Figure 1, Item 1) and cooling fan (Figure 1, Item 3) from water pump pulley (Figure 1, Item 2).
1 2 3
Figure 1. Cooling Fan Removal. 2. Remove two spacers (Figure 2, Item 4) from water pump pulley (Figure 2, Item 2).
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0072
REMOVAL - Continued
Figure 2. Cooling Fan Removal. END OF TASK INSTALLATION 1. Install two spacers (Figure 3, Item 4) on water pump pulley (Figure 3, Item 2).
Figure 3. Cooling Fan Installation. 2. Install cooling fan (Figure 4, Item 3) on water pump pulley (Figure 4, Item 2) with four screws (Figure 4, Item 1).
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1 2 3
Figure 4. Cooling Fan Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install radiator and bracket. (WP 0076) Install alternator bracket. (WP 0080)
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TM 5-3825-270-23&P
0073
FIELD MAINTENANCE UPPER COOLING SYSTEM HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4027 Equipment Condition Engine compartment cover removed. (WP 0142) Cooling system drained. (WP 0075)
REMOVAL Loosen two hose clamps (Figure 1, Item 2) and remove radiator hose (Figure 1, Item 1) from radiator (Figure 1, Item 3) and thermostat housing (Figure 1, Item 4).
4 3
Figure 1. Upper Cooling System Hose Removal. END OF TASK INSTALLATION Install radiator hose (Figure 2, Item 1) on thermostat housing (Figure 2, Item 4) and radiator (Figure 2, Item 3) with two hose clamps (Figure 2, Item 2).
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4 3
Figure 2. Upper Cooling System Hose Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill cooling system. (WP 0075) Install engine compartment cover. (WP 0142)
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0074
FIELD MAINTENANCE COOLING SYSTEM SERVICING AND TESTING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Tester, Electrolyte and Antifreeze (WP 0225, Table 1, Item 2) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Test Kit, Radiator (WP 0225, Table 1, Item 2) Materials/Parts Antifreeze, Ethylene Glycol, Inhibited (WP 0224, Table 1, Item 1, 2, 3) Materials/Parts (cont.) Cleaning Compound, Solvent (WP 0224, Table 1, Item 10, 11, 12, 13, 14, 15) Rag, Wiping (WP 0224, Table 1, Item 52) Distilled Water, Reagent (WP 0224, Table 1, Item 27) References Parts Manual (WP 0220) Figure 4027
FLUSHING
WARNING
DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Wear effective eye, glove, and skin protection when handling coolants. Failure to comply may result in damage to equipment, death, or serious injury to personnel. 1. Loosen two screws (Figure 1, Item 1) and open access door (Figure 1, Item 2).
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0074
FLUSHING - Continued
1 2 1
Figure 1. Cooling System Flushing.
WARNING
Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel. Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personnel injury. 2. Remove radiator cap (Figure 2, Item 4) from radiator (Figure 2, Item 3) by pressing down and rotating counterclockwise.
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Figure 2. Cooling System Flushing. 3. Position drain pan under drain cock (Figure 3, Item 5) on bottom of radiator (Figure 3, Item 3).
3
4. 5.
Open drain cock (Figure 3, Item 5) on bottom of radiator (Figure 3, Item 3) by rotating counterclockwise and allow fluid to drain into drain pan. Drain enough engine radiator coolant to accept entire contents of a bottle of cleaning compound in radiator filler neck (Figure 4, Item 6).
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0074
3 6
Figure 4. Cooling System Flushing. 6. Close drain cock (Figure 5, Item 5) on bottom of radiator (Figure 5, Item 3) by rotating clockwise. Tighten drain cock.
3
7. 8.
Shake bottle of cleaning compound. Pour entire contents of a bottle of cleaning compound into radiator filler neck (Figure 6, Item 6).
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0074
3 6
Figure 6. Cooling System Flushing. 9. Install radiator cap (Figure 7, Item 4) on radiator (Figure 7, Item 3) by pressing down and rotating clockwise.
Figure 7. Cooling System Flushing. 10. 11. 12. 13. Start engine. (TM 5-3825-270-10) Allow engine to warm up to operating temperature, and then run for an additional 5 to 10 minutes with cleaning compound in cooling system. Shut OFF engine. (TM 5-3825-270-10) Allow radiator (Figure 7, Item 3) to cool.
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0074
WARNING
Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel. Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personnel injury. 14. 15. Remove radiator cap (Figure 7, Item 4) from radiator (Figure 7, Item 3) by pressing down and rotating counterclockwise. Open drain cock (Figure 8, Item 5) on bottom of radiator (Figure 8, Item 3) by rotating counterclockwise and allow cleaning compound and coolant to drain into drain pan.
3
16. 17. 18.
Close drain cock (Figure 8, Item 5) on bottom of radiator (Figure 8, Item 3) by rotating clockwise. Tighten drain cock. Remove drain pan and dispose of contents IAW local procedures. Pour clean water in radiator filler neck (Figure 9, Item 6) until full.
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0074
3 6
Figure 10. Cooling System Flushing. 20. 21. 22. 23. Start engine. (TM 5-3825-270-10) Allow engine to warm up to operating temperature, and then run for an additional 5 to 10 minutes. Shut OFF engine. (TM 5-3825-270-10) Allow radiator (Figure 10, Item 4) to cool.
0074-7
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0074
WARNING
Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel. Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personnel injury. 24. 25. Remove radiator cap (Figure 10, Item 4) from radiator (Figure 10, Item 3) by pressing down and rotating counterclockwise. Position drain pan under drain cock (Figure 11, Item 5) on bottom of engine (Figure 11, Item 3).
3
26. 27. 28. 29. 30.
Open drain cock (Figure 11, Item 5) on bottom of radiator (Figure 11, Item 3) by rotating counterclockwise and allow water to drain into drain pain. Close drain cock (Figure 11, Item 5) on bottom of radiator (Figure 11, Item 3) by rotating clockwise. Tighten drain cock. Remove drain pan and dispose of contents IAW local procedures. Prepare approximately 2.38 gal (9 L) of a solution made up of 60% antifreeze and 40% distilled water. Pour solution into radiator filler neck (Figure 12, Item 6) until full.
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0074
3 6
Figure 13. Cooling System Flushing. 32. Add coolant to overflow tank (Figure 14, Item 7) until half full.
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0074
7
Figure 14. Cooling System Flushing. 33. 34. 35. 36. 37. Start engine. (TM 5-3825-270-10) Allow engine to warm to operating temperature, and then run for an additional 5 to 10 minutes. Check cooling system for leaks. Shut OFF engine. (TM 5-3825-270-10) Allow radiator (Figure 15, Item 3) to cool.
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0074
WARNING
Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel. Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personnel injury. 38. 39. Remove radiator cap (Figure 15, Item 4) from radiator (Figure 15, Item 3) by pressing down and rotating counterclockwise. Check coolant level in radiator filler neck (Figure 16, Item 6) of radiator (Figure 16, Item 3).
3 6
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0074
Figure 17. Cooling System Flushing. 41. Check coolant level in overflow tank (Figure 18, Item 7). Add coolant as necessary to fill system.
7
Figure 18. Cooling System Flushing. 42. 43. Clean up spilled fluid with cleaning cloth and dispose of waste IAW local procedures. Close access cover (Figure 19, Item 2) and secure with two screws (Figure 19, Item 1).
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0074
1 2 1
Figure 19. Cooling System Flushing. END OF TASK PRESSURE TESTING 1. Loosen two screws (Figure 20, Item 1) and open access door (Figure 20, Item 2).
Figure 20. Cooling System Pressure Testing.
WARNING
Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel.
0074-13
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0074
PRESSURE TESTING - Continued Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personnel injury. 2. Remove radiator cap (Figure 21, Item 4) from radiator (Figure 21, Item 3) by pressing down and rotating counterclockwise.
Figure 21. Cooling System Pressure Testing. 3. Install radiator test kit pressure tester on radiator (Figure 22, Item 3).
RADIATOR TEST KIT
Figure 22. Cooling System Pressure Testing.
CAUTION
Do not exceed 15 psi (103 kPa). Failure to comply could result in a rupture in the cooling system or other damage to equipment. 4. Using radiator test kit pressure tester, pressurize cooling system to 13 psi (89.6 kPa).
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0074
PRESSURE TESTING - Continued 5. 6. 7. 8. 9. Observe system pressure on radiator test kit pressure tester for 30 seconds. If a measurable pressure drop is detected, examine entire cooling system for possible external or internal leaks. Repair as necessary. Release pressure. Remove radiator test kit pressure tester from radiator (Figure 22, Item 3). Install radiator cap adapter on pressure tester.
PRESSURE TESTER CAP ADAPTER
Figure 23. Cooling System Pressure Testing. 10. 11. Install radiator cap (Figure 23, Item 4) on radiator cap adapter. Apply 13 psi (89.6 kPa) to radiator cap (Figure 23, Item 4) and hold for 10 seconds.
NOTE
If the cap releases early or late, the cap must be replaced. 12. 13. 14. Observe that radiator cap (Figure 23, Item 4) releases pressure at 13 to 14 psi (89.6 to 96.5 kPa). Remove pressure tester and cap adapter from radiator cap (Figure 23, Item 4). Install radiator cap (Figure 24, Item 4) on radiator (Figure 24, Item 3) by pressing down and rotating clockwise.
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0074
PRESSURE TESTING - Continued
Figure 24. Cooling System Pressure Testing. 15. Close access door (Figure 25, Item 2) and secure with two screws (Figure 25, Item 1).
1 2 1
Figure 25. Cooling System Pressure Testing. END OF TASK END OF WORK PACKAGE
0074-16
TM 5-3825-270-23&P
0075
FIELD MAINTENANCE RADIATOR DRAIN/FILL
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 2) Materials/Parts Antifreeze, Ethylene Glycol, Inhibited (WP 0224, Table 1, Item 1, 2, 3) Rag, Wiping (WP 0224, Table 1, Item 52) References Parts Manual (WP 0220) Figure 4027 Equipment Condition Engine OFF. (TM 5-3825-270-10)
DRAIN
WARNING
Use extreme care when removing radiator pressure cap. Sudden release of pressure can cause steam flash. Slowly loosen cap to the first stop to relieve pressure prior to removing cap completely. Failure to comply may result in injury or death to personnel. Use clean, thick waste cloth or like material to remove radiator pressure cap. Avoid using gloves, hot water soaks through gloves. Failure to comply may result in injury or death to personnel. Wear suitable eye protection when working on vehicle cooling systems to avoid personnel injury. 1. Loosen two screws (Figure 1, Item 1) and open access door (Figure 1, Item 3).
Figure 1. Radiator Cap Access Door. 2. Push down on radiator cap (Figure 1, Item 2) and slowly turn turn counterclockwise to relieve pressure.
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0075
DRAIN - Continued 3. 4. Remove radiator cap (Figure 1, Item 2). Position drain pan under drain cock (Figure 2, Item 4).
Figure 2. Radiator Drain Cock. 5. 6. Open drain cock (Figure 2, Item 4) and allow coolant to drain. Close drain cock (Figure 2, Item 4) after coolant stops draining.
END OF TASK FILL 1. Prepare 14 quarts of coolant mixture. Mixture is 60% antifreeze to 40% water.
NOTE
Cooling system capacity is 14 quart of antifreeze mix. 2. Fill radiator (Figure 3, Item 5) with coolant until full.
0075-2
TM 5-3825-270-23&P
0075
FILL - Continued
5
Figure 3. Radiator Fill Point. 3. Add coolant to overflow tank (Figure 4, Item 6) until half full.
6
Figure 4. Overflow Tank. 4. 5. 6. 7. 8. Start engine (TM 5-3825-270-10) and run until normal operating temperature is reached. Shut off engine. (TM 5-3825-270-10) Check that coolant is visible in radiator (Figure 3, Item 5) and overflow tank (Figure 4, Item 6). Add coolant as necessary to fill system. Install radiator cap (Figure 5, Item 2).
0075-3
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0075
FILL - Continued
Figure 5. Radiator Cap Access Door. 9. Close access door (Figure 5, Item 3) and tighten two screws (Figure 5, Item 1).
0075-4
TM 5-3825-270-23&P
0076
FIELD MAINTENANCE RADIATOR AND BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) References Parts Manual (WP 0220) Figure 4027 Equipment Condition Radiator drained. (WP 0075) Front enclosure panel removed. (WP 0144) Belt guard removed. (WP 0146)
REMOVAL 1. Loosen hose clamp (Figure 1, Item 2) and remove upper radiator hose (Figure 1, Item 1) from radiator assembly (Figure 1, Item 3).
3
Figure 1. Radiator and Bracket Removal. 2.
Loosen hose clamp (Figure 2, Item 5) and remove lower radiator hose (Figure 2, Item 4) from radiator assembly (Figure 2, Item 3).
0076-1
TM 5-3825-270-23&P
0076
REMOVAL - Continued
4 5 3
Figure 2. Radiator and Bracket Removal.
CAUTION
Support radiator when removing screws to prevent damage to radiator. 3. Remove two screws (Figure 3, Item 9), washers (Figure 3, Item 7), and radiator assembly (Figure 3, Item 3) from lower radiator support (Figure 3, Item 6).
3
7, 8
9 10
11
Figure 3. Radiator and Bracket Removal. 4. 5. Remove upper isolators (Figure 3, Item 10), sleeves (Figure 3, Item 11), and lower isolators (Figure 3, Item 8) from lower radiator support (Figure 3, Item 6). Remove six plugs (Figure 4, Item 12), hex screws (Figure 4, Item 13) and fan shroud (Figure 4, Item 14) from radiator (Figure 4, Item 15).
0076-2
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0076
REMOVAL - Continued
12, 13 14 15
Figure 4. Radiator and Bracket Removal. 6. Remove drain cock (Figure 5, Item 17) and two plugs (Figure 5, Item 16) from radiator (Figure 5, Item 15).
15
16 17
Figure 5. Radiator and Bracket Removal.
NOTE
Perform Steps (7) through (9) if upper radiator support brackets are damaged. 7. Remove screw (Figure 6, Item 18) and upper radiator support bracket (Figure 6, Item 19) from isolator (Figure 6, Item 17).
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0076
REMOVAL - Continued
17 18
19
Figure 6. Radiator and Bracket Removal. 8. Remove nut (Figure 7, Item 20) and isolator (Figure 7, Item 17) from bracket (Figure 7, Item 21).
20
21 17
Figure 7. Radiator and Bracket Removal. 9. Remove two screws (Figure 8, Item 23) and bracket (Figure 8, Item 21) from thermostat housing (Figure 8, Item 22).
0076-4
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0076
REMOVAL - Continued
21 22
23
Figure 8. Radiator and Bracket Removal. END OF TASK INSTALLATION
NOTE
Perform Steps (1) through (3) if upper radiator brackets were removed. 1. Install bracket (Figure 9, Item 21) on thermostat housing (Figure 9, Item 22) with two screws (Figure 9, Item 23).
21 22
23
Figure 9. Radiator and Bracket Installation. 2. Install isolator (Figure 10, Item 17) on bracket (Figure 10, Item 21) with nut (Figure 10, Item 20).
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0076
20
21 17
Figure 10. Radiator and Bracket Installation. 3. Install upper radiator support bracket (Figure 11, Item 19) on isolator (Figure 11, Item 17) with screw (Figure 11, Item 18).
17 18
19
Figure 11. Radiator and Bracket Installation.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 4. Coat threads of drain cock (Figure 12, Item 17) with sealing compound.
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0076
15
16 17
Figure 12. Radiator and Bracket Installation. 5. Install drain cock (Figure 12, Item 17) on radiator (Figure 12, Item 15).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 6. 7. 8. Coat threads of two plugs (Figure 12, Item 16) with sealing compound. Install plugs (Figure 12, Item 16) on radiator (Figure 12, Item 15). Install fan shroud (Figure 13, Item 14) on radiator (Figure 13, Item 15) with six hex screws (Figure 13, Item 13).
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12, 13 14 15
Figure 13. Radiator and Bracket Installation. 9. 10. Install six plugs (Figure 13, Item 12) in holes for hex screws (Figure 13, Item 13). Install two upper isolators (Figure 14, Item 10), sleeves (Figure 14, Item 11), and lower isolators (Figure 14, Item 8) on lower radiator support (Figure 14, Item 6).
3
7, 8
9 10
11
Figure 14. Radiator and Bracket Installation. 11. 12. Install radiator assembly (Figure 14, Item 3) on lower radiator support (Figure 14, Item 6) with two washers (Figure 14, Item 7) and screws (Figure 14, Item 9). Install lower radiator hose (Figure 15, Item 4) on radiator assembly (Figure 15, Item 3) with hose clamp (Figure 15, Item 5).
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0076
4 5 3
Figure 15. Radiator and Bracket Installation. 13. Install upper radiator hose (Figure 16, Item 1) on radiator assembly (Figure 16, Item 3) with hose clamp (Figure 16, Item 2).
3
Figure 16. Radiator and Bracket Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install belt guard. (WP 0146) Install front enclosure panel. (WP 0144) Fill radiator. (WP 0075)
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0077
FIELD MAINTENANCE LOWER RADIATOR HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4027 Equipment Condition Radiator drained. (WP 0075) Rear access door removed. (TM 5-3825-270-10)
REMOVAL Loosen two clamps (Figure 1, Item 2) and remove lower radiator hose (Figure 1, Item 1) from radiator (Figure 1, Item 3) and water pump housing (Figure 1, Item 4).
1 1 2 4
Figure 1. Lower Radiator Hose Removal. END OF TASK INSTALLATION Install lower radiator hose (Figure 2, Item 1) on radiator (Figure 2, Item 3) and water pump housing (Figure 2, Item 4) with two hose clamps (Figure 2, Item 2).
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0077
1 1 2 4
Figure 2. Lower Radiator Hose Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill radiator. (WP 0075) Install rear access door. (TM 5-3825-270-10).
0077-2
TM 5-3825-270-23&P
0078
FIELD MAINTENANCE 15-AMP CIRCUIT BREAKER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Tags, Identification, White (WP 0224, Table 1, Item 54) References Parts Manual (WP 0220) Figure 4018 Equipment Condition Batteries disconnected. (WP 0085)
REMOVAL 1. Open control panel cover (Figure 1, Item 1) by releasing rubber T-handle (Figure 1, Item 2).
1 2
Figure 1. 15-amp Circuit Breaker Removal.
CAUTION
Do not allow control panel to hang by wires. Failure to comply may result in damage to equipment. 2. Remove six screws (Figure 2, Item 3) and washers (Figure 2, Item 4) from main control box (Figure 2, Item 5) and control panel (Figure 2, Item 6).
0078-1
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0078
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove clear wire (Figure 3, Item 11) from terminal one (Figure 3, Item 10) on 15-amp circuit breaker (Figure 3, Item 9).
11
Figure 3. 15-amp Circuit Breaker Removal. 4. 5.
10
Remove red wire (Figure 3, Item 7) from terminal two (Figure 3, Item 8) on 15-amp circuit breaker (Figure 3, Item 9). Remove protective cover (Figure 4, Item 13) from 15 amp circuit breaker (Figure 4, Item 9).
0078-2
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0078
REMOVAL - Continued
12
9, 13
NOTE
Note position of 15-amp circuit breaker prior to removal to ensure proper installation. 6. Remove nut (Figure 4, Item 12) and 15-amp circuit breaker (Figure 4, Item 9) from main control box (Figure 4, Item 5).
NOTE
Install 15-amp circuit breaker as noted prior to removal. 1. Install 15-amp breaker (Figure 5, Item 9) on control box (Figure 5, Item 5) with nut (Figure 5, Item 12).
12
9, 13
Figure 5. 15-amp Circuit Breaker Installation. 2. Install protective cover (Figure 5, Item 13) on 15-amp circuit breaker (Figure 5, Item 9).
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0078
NOTE
Install wires as noted prior to removal. 3. Install red wire (Figure 6, Item 7) on terminal two (Figure 6, Item 8) of 15-amp circuit breaker (Figure 6, Item 9).
11
Figure 6. 15-amp Circuit Breaker Installation. 4.
10
Install clear wire (Figure 6, Item 11) on terminal one (Figure 6, Item 10) of 15-amp circuit breaker (Figure 6, Item 9).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 5. Apply sealing compound to the threads of six screws (Figure 7, Item 3).
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0078
3, 4
Figure 7. 15-amp Circuit Breaker Installation. 6. 7. Install six washers (Figure 7, Item 4) and screws (Figure 7, Item 3) on main control box (Figure 7, Item 5) and control panel (Figure 7, Item 6). Tighten six screws securely. Close control panel cover (Figure 8, Item 1) and secure with rubber T-handle (Figure 8, Item 2).
1 2
Figure 8. 15-amp Circuit Breaker Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
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0079
FIELD MAINTENANCE ALTERNATOR BELT ADJUSTMENT
INITIAL SETUP: Tools and Special Tools Pry Bar (WP 0225, Table 1, Item 12) Tensionmeter, Dial Indicating (WP 0225, Table 1, Item 10) Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4043 Equipment Condition Engine compartment cover removed. (WP 0142) Equipment Condition (cont.) Batteries disconnected. (WP 0085) Belt guard removed. (WP 0146)
ADJUSTMENT 1. Loosen screw (Figure 1, Item 3) from adjusting bracket (Figure 1, Item 2) and alternator (Figure 1, Item 1).
Figure 1. Alternator Belt Adjustment. 2. Loosen screw (Figure 2, Item 5) and nut (Figure 2, Item 6) from alternator (Figure 2, Item 1) and timing cover (Figure 2, Item 4).
0079-1
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0079
ADJUSTMENT - Continued
4 5, 6 1
Figure 2. Alternator Belt Adjustment. 3. Position pry bar between engine (Figure 3, Item 8) and alternator (Figure 3, Item 1).
10
PRYBAR 1 7
5, 6
Figure 3. Alternator Belt Adjustment. 4. 5. 6. Apply moderate pressure to alternator (Figure 3, Item 1) with pry bar, removing slack from belt (Figure 3, Item 9). While maintaining pressure, and with the aid of an assistant, tighten screw (Figure 3, Item 3), screw (Figure 3, Item 5) and nut (Figure 3, Item 6). Check belt deflection by pressing down in the center of belt (Figure 3, Item 9) halfway between alternator pulley (Figure 3, Item 7) and coolant pump pulley (Figure 3, Item 10) with a specified force of 98 N (10 kgf, 22 lbf). Belt tension should be between 10 and 12 mm. If belt adjustment does not meet these specifications, repeat Steps (1) through (6).
7.
END OF TASK
0079-2
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0079
FOLLOW ON MAINTENANCE 1. 2. 3. Install belt guard. (WP 0146) Install engine compartment cover. (WP 0142) Connect batteries. (WP 0085)
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0080
FIELD MAINTENANCE ALTERNATOR BELT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Tensionmeter, Dial Indicating (WP 0225, Table 1, Item 10) References Parts Manual (WP 0220) Figure 4043 Equipment Condition Belt guard removed. (WP 0146)
REMOVAL 1. Loosen screw (Figure 1, Item 3) on adjusting bracket (Figure 1, Item 2) and alternator (Figure 1, Item 1).
Figure 1. Alternator Belt Removed. 2. Loosen screw (Figure 2, Item 5) on adjusting bracket (Figure 2, Item 2) and thermostat housing (Figure 2, Item 4).
0080-1
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0080
REMOVAL - Continued
4 5 2
Figure 2. Alternator Belt Removed. 3. Loosen screw (Figure 3, Item 7) and nut (Figure 3, Item 8) on alternator (Figure 3, Item 1) and timing cover (Figure 3, Item 6).
6 7, 8 1
Figure 3. Alternator Belt Removed. 4. Rotate alternator (Figure 4, Item 1) toward engine (Figure 4, Item 10) to relieve tension on belt (Figure 4, Item 9).
0080-2
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0080
REMOVAL - Continued
1 9 10
Figure 4. Alternator Belt Removed. 5. Remove belt (Figure 5, Item 9) from alternator pulley (Figure 5, Item 12), water pump pulley (Figure 5, Item 11), crankshaft pulley (Figure 5, Item 14) and from around cooling fan (Figure 5, Item 13).
11 9
12
14
13
Figure 5. Alternator Belt Removed. END OF TASK INSTALLATION 1. Position belt (Figure 6, Item 9) around cooling fan (Figure 6, Item 13) and on crankshaft pulley (Figure 6, Item 14), water pump pulley (Figure 6, Item 11), and alternator pulley (Figure 6, Item 12).
0080-3
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0080
11
12
14
13
Figure 6. Alternator Belt Installation.
2.
Position prybar between engine (Figure 7, Item 10) and alternator (Figure 7, Item 1).
9 3
10
PRYBAR
7, 8
Figure 7. Alternator Belt Installation. 3. 4. 5. Apply moderate pressure to alternator (Figure 7, Item 1) with prybar, removing slack from belt (Figure 7, Item 9). While maintaining pressure, and with the aid of an assistant, tighten screw (Figure 7, Item 3), screw (Figure 7, Item 7) and nut (Figure 7, Item 8). Tighten screw (Figure 8, Item 5) on adjusting bracket (Figure 8, Item 2) and thermostat housing (Figure 8, Item 4).
0080-4
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0080
4 5 2
Figure 8. Alternator Belt Installation. 6. Check belt deflection by pressing down in the center of belt (Figure 9, Item 9) halfway between alternator pulley (Figure 9, Item 12) and water pump pulley (Figure 9, Item 11) with a specified force of 22 lbf (98 Nm). Belt travel should be between 10 and 12 mm.
11
12
Figure 9. Alternator Belt Installation. 7. If belt adjustment does not meet these specifications, repeat Steps (1) through (6).
END OF TASK FOLLOW-ON MAINTENANCE Install belt guard. (WP 0146) END OF TASK END OF WORK PACKAGE
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0081
FIELD MAINTENANCE ALTERNATOR AND BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Lockwasher (WP 0226, Table 1, Item 59) Qty: 1 References Parts Manual (WP 0220) Figure 4043 Equipment Condition Batteries disconnected. (WP 0085) Alternator belt removed. (WP 0080)
REMOVAL 1. Disconnect connector (Figure 1, Item 4) from alternator (Figure 1, Item 3).
1 2
6 5 4
Figure 1. Alternator Removal. 2. 3. 4. Disconnect connector (Figure 1, Item 2) from alternator (Figure 1, Item 3). Remove nut (Figure 1, Item 6), lockwasher (Figure 1, Item 1), and red wire (Figure 1, Item 5) from alternator (Figure 1, Item 3). Discard lockwasher. Remove screw (Figure 2, Item 7) and washer (Figure 2, Item 8) from alternator (Figure 2, Item 3) and adjusting bracket (Figure 2, Item 9).
0081-1
TM 5-3825-270-23&P
0081
REMOVAL - Continued
Figure 2. Alternator Removal. 5. Remove nut (Figure 3, Item 11), screw (Figure 3, Item 10), spacer (Figure 3, Item 13) and alternator (Figure 3, Item 3) from timing cover (Figure 3, Item 12).
10
12
10
Figure 3. Alternator Removal.
13
12
11
NOTE
Perform Step (6) if adjusting bracket is damaged. 6. Remove screw (Figure 4, Item 15) and adjusting bracket (Figure 4, Item 9) from thermostat housing (Figure 4, Item 14).
0081-2
TM 5-3825-270-23&P
0081
REMOVAL - Continued
14 15 9
Figure 4. Alternator Removal. END OF TASK INSTALLATION
NOTE
Perform Step (1) if adjusting bracket was removed. 1. Install adjusting bracket (Figure 5, Item 9) on thermostat housing (Figure 5, Item 14) with screw (Figure 5, Item 15).
14 15 9
Figure 5. Alternator Installation. 2. Install alternator (Figure 6, Item 3) on timing cover (Figure 6, Item 12) with screw (Figure 6, Item 10), spacer (Figure 6, Item 13), and nut (Figure 6, Item 11).
0081-3
TM 5-3825-270-23&P
0081
10
12
10
Figure 6. Alternator Installation.
13
12
11
3.
Install alternator (Figure 7, Item 3) on adjusting bracket (Figure 7, Item 9) with screw (Figure 7, Item 7) and washer (Figure 7, Item 8).
Figure 7. Alternator Installation. 4. Install red wire (Figure 8, Item 5) on alternator (Figure 8, Item 3) with lockwasher (Figure 8, Item 1) and nut (Figure 8, Item 6).
0081-4
TM 5-3825-270-23&P
0081
1 2
6 5 4
Figure 8. Alternator Installation. 5. 6. Connect connector (Figure 8, Item 2) to alternator (Figure 8, Item 3). Connect connector (Figure 8, Item 4) to alternator (Figure 8, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install alternator belt. (WP 0085) Connect batteries. (WP 0085)
0081-5/6 blank
TM 5-3825-270-23&P
0082
FIELD MAINTENANCE BATTERIES SERVICING AND TESTING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Brush, Battery Terminal, Cleaner, Battery Post (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Apron, Rubber (WP 0225, Table 1, Item 2) Tester, Electrolyte and Antifreeze (WP 0225, Table 1, Item 2) Materials/Parts Distilled Water, Reagent (WP 0224, Table 1, Item 27) Materials/Parts (cont.) Grease, Automotive and Artillery (GAA) (WP 0224, Table 1, Item 35, 36, 37, 38, 39) Sodium Bicarbonate Injection (WP 0224, Table 1, Item 53) References Parts Manual (WP 0220) Figure 4009 Equipment Condition Battery box opened. (TM 5-3825-270-10)
BATTERY TESTING
WARNING
Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and do not smoke when performing maintenance on batteries. Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent clothing from being damaged. Failure to comply may result in injury or death to personnel. 1. Remove 12 battery cell caps (Figure 1, Item 1) from two batteries (Figure 1, Item 2).
0082-1
TM 5-3825-270-23&P
0082
BATTERY TESTING - Continued
ELECTROLYTE AND ANTIFREEZE TESTER

Figure 1. Battery Testing.
2. 3.
Using electrolyte and antifreeze tester, check specific gravity on all cells of batteries (Figure 1, Item 2). Install battery cell caps (Figure 1, Item 1) on batteries (Figure 1, Item 2).
END OF TASK CLEAN BATTERY CABLES
WARNING
Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and do not smoke when performing maintenance on batteries. Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent clothing from being damaged. Failure to comply may result in injury or death to personnel.
NOTE
All battery cables are cleaned the same way. 1. 2. Disconnect batteries. (WP 0085) Using battery brush, clean battery terminals (Figure 2, Item 4) and posts (Figure 2, Items 3) with sodium bicarbonate (baking soda) and water to remove any corrosion.
0082-2
TM 5-3825-270-23&P
0082
CLEAN BATTERY CABLES - Continued
4
Figure 2. Clean Battery Cables. 3. 4. 5. Allow battery terminals (Figure 2, Item 4) and posts (Figure 2, Item 3) to completely dry. Connect batteries. (WP 0085) Apply a coat of grease to battery terminals (Figure 3, Item 4) and posts (Figure 3, Item 3).
3
Figure 3. Clean Battery Cables. END OF TASK
0082-3
TM 5-3825-270-23&P
0082
SERVICE BATTERIES
WARNING
Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and do not smoke when performing maintenance on batteries. Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent clothing from being damaged. Failure to comply may result in injury or death to personnel. 1. Remove battery cell caps (Figure 4, Item 1).
ELECTROLYTE AND ANTIFREEZE TESTER

Figure 4. Battery Service.
2. 3.
Using distilled water, fill all cells of batteries (Figure 4, Item 2) so level of electrolyte covers tops of plates inside batteries. Install twelve battery cell caps (Figure 4, Item 1) on two batteries (Figure 4, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE Close battery box. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0082-4
TM 5-3825-270-23&P
0083
FIELD MAINTENANCE BATTERY BOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 76) Qty: 4 References Parts Manual (WP 0220) Figure 4009 Equipment Condition Batteries removed. (WP 0086) NATO slave connector removed. (WP 0101)
REMOVAL
CAUTION
Use caution when removing battery cables from battery box. Cables may be damaged if forced through battery box. Failure to comply may result in damage to equipment.
NOTE
Position boot on positive battery cable back and through battery box before removing cable. 1. Remove positive battery cable (Figure 1, Item 1) and negative battery cable (Figure 1, Item 2) from battery box (Figure 1, Item 3).
0083-1
TM 5-3825-270-23&P
0083
REMOVAL - Continued
4, 5, 6
Figure 1. Battery Box Removal. 2. Remove four locknuts (Figure 1, Item 4), washers (Figure 1, Item 5), screws (Figure 1, Item 6) and battery box (Figure 1, Item 3) from flatrack (Figure 1, Item 7). Discard locknuts.
END OF TASK INSTALLATION 1. Install battery box (Figure 2, Item 3) on flatrack (Figure 2, Item 7) with four screws (Figure 2, Item 6), washers (Figure 2, Item 5) and locknuts (Figure 2, Item 4).
0083-2
TM 5-3825-270-23&P
0083
4, 5, 6
Figure 2. Battery Box Installation.
CAUTION
Use caution when installing battery cables in battery box. Cables may be damaged if forced through battery box. Failure to comply may result in damage to equipment.
NOTE
Install boot on positive battery cable through battery box before cable. 2. Install negative battery cable (Figure 2, Item 2) and positive battery cable (Figure 2, Item 1) on battery box (Figure 2, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install NATO slave connector. (WP 0101) Install batteries. (WP 0086)
0083-3/4 blank
TM 5-3825-270-23&P
0084
FIELD MAINTENANCE BATTERY BOX WIRING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Cable Ties (WP 0224, Table 1, Item 9) Tags, Identification, White (WP 0224, Table 1, Item 54) References Parts Manual (WP 0220) Figure 4009 References (cont.) Parts Manual (WP 0220) Figure 4018 Parts Manual (WP 0220) Figure 4037 Equipment Condition Battery box removed. (WP 0083) Access panels removed. (TM 5-3825-270-10)
REMOVAL
NOTE
Tag and mark all wires prior to removal to ensure proper installation. Remove cable ties and retainers as required. Perform Steps (1) through (4) for starter wire harness removal. Perform Steps (3) through (11) for battery box wire harness removal. Note routing of wiring to ensure proper installation. 1. Remove nut (Figure 1, Item 5), positive battery cable (Figure 1, Item 1), red wire (Figure 1, Item 2), red wire (Figure 1, Item 3), and red wire (Figure 1, Item 4) from starter (Figure 1, Item 6).
0084-1
TM 5-3825-270-23&P
0084
REMOVAL - Continued
2 3 4
Figure 1. Battery Box Wiring Removal. 2. Remove nut (Figure 2, Item 7), black wire (Figure 2, Item 8), and negative battery cable (Figure 2, Item 9) from starter (Figure 2, Item 6).
7 8 9
Figure 2. Battery Box Wiring Removal. 3. Remove nut (Figure 3, Item 10), negative battery cable (Figure 3, Item 11), black wire (Figure 3, Item 12), negative battery cable (Figure 3, Item 13), and screw (Figure 3, Item 14) from terminal (Figure 3, Item 16) and battery box (Figure 3, Item 15).
0084-2
TM 5-3825-270-23&P
0084
REMOVAL - Continued
10
11
12
13
14
15
16
Figure 3. Battery Box Wiring Removal. 4. Remove nut (Figure 4, Item 17), screw (Figure 4, Item 21), positive battery cable (Figure 4, Item 18), clear wire (Figure 4, Item 19), and positive battery cable (Figure 4, Item 20) from terminal (Figure 4, Item 22) and battery box (Figure 4, Item 15).
17 18 19 20 21 15
22
Figure 4. Battery Box Wiring Removal. 5. Open control panel cover (Figure 5, Item 23) by releasing rubber t-handle (Figure 5, Item 24).
0084-3
TM 5-3825-270-23&P
0084
REMOVAL - Continued
23 24
Figure 5. Battery Box Wiring Removal.
CAUTION
25, 26 27
28
Figure 6. Battery Box Wiring Removal. 7. Disconnect clear wire (Figure 7, Item 31) from 15 amp breaker (Figure 7, Item 32).
0084-4
TM 5-3825-270-23&P
0084
REMOVAL - Continued
31 32
29
30
27
33
34
35
36
Figure 7. Battery Box Wiring Removal. 8. 9. 10. Remove nut (Figure 7, Item 35), washer (Figure 7, Item 34), and ground wire (Figure 7, Item 33) from ground post (Figure 7, Item 36) and main control box (Figure 7, Item 27). Remove black wire (Figure 7, Item 30) from negative terminal strip (Figure 7, Item 29) socket 6. Remove fitting (Figure 8, Item 37) and wire harness (Figure 8, Item 38) from main control box (Figure 8, Item 27).
0084-5
TM 5-3825-270-23&P
0084
REMOVAL - Continued
27 37
38
Figure 8. Battery Box Wiring Removal. 11. Remove wire harness (Figure 8, Item 38) from water distributor.
NOTE
Perform Steps (1) through (8) for battery box wire harness installation. Perform Steps (7) through (9) for starter wire harness installation. Route wiring as noted prior to removal. Install cable ties and retainers as required. Install wiring as noted prior to removal to ensure proper installation. 1. Install wiring harness (Figure 9, Item 38) through opening in control box (Figure 9, Item 27) with fitting (Figure 9, Item 37).
27 37
38
Figure 9. Battery Box Wiring Installation. 2. Install black wire (Figure 10, Item 30) on negative terminal strip (Figure 10, Item 29) socket 6.
0084-6
TM 5-3825-270-23&P
0084
31 32
29
30
27
33
34
35
36
Figure 10. Battery Box Wiring Installation. 3. 4. Install ground wire (Figure 10, Item 33), washer (Figure 10, Item 34), and nut (Figure 10, Item 35) on ground stud (Figure 10, Item 36) and main control box (Figure 10, Item 27). Connect clear wire (Figure 10, Item 31) to 15 amp breaker (Figure 10, Item 32).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 5. Apply sealant to the threads of six screws (Figure 11, Item 25).
0084-7
TM 5-3825-270-23&P
0084
25, 26 27
28
Figure 11. Battery Box Wiring Installation. 6. 7. Install six washers (Figure 7, Item 26) and screws (Figure 7, Item 25) on main control box (Figure 7, Item 27) and control panel (Figure 7, Item 28). Tighten six screws securely. Close control box cover (Figure 12, Item 23) and secure with rubber t-handle (Figure 12, Item 24).
23 24
Figure 12. Battery Box Wiring Installation. 8. Install positive battery cable (Figure 13, Item 20), clear wire (Figure 13, Item 19), and positive battery cable (Figure 13, Item 18) in battery box (Figure 13, Item 15) and on terminal (Figure 13, Item 22) with screw (Figure 13, Item 21) and nut (Figure 13, Item 17).
0084-8
TM 5-3825-270-23&P
0084
17 18 19 20 21 15
22
Figure 13. Battery Box Wiring Installation. 9. Install negative battery cable (Figure 14, Item 13), black wire (Figure 14, Item 12), and negative battery cable (Figure 14, Item 11) in battery box (Figure 14, Item 15) and on terminal (Figure 14, Item 16) with screw (Figure 14, Item 14) and nut (Figure 14, Item 10).
10
11
12
13
14
15
16
Figure 14. Battery Box Wiring Installation. 10. Install negative battery cable (Figure 15, Item 9) and black wire (Figure 15, Item 8) on starter (Figure 15, Item 6) with nut (Figure 15, Item 7).
0084-9
TM 5-3825-270-23&P
0084
7 8 9
Figure 15. Battery Box Wiring Installation. 11. Install red wire (Figure 16, Item 4), red wire (Figure 16, Item 3), red wire (Figure 16, Item 2), and positive battery cable (Figure 16, Item 1) on starter (Figure 16, Item 6) with nut (figure 16, Item 5).
2 3 4
Figure 16. Battery Box Wiring Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. Install battery box. (WP 0083)
0084-10
TM 5-3825-270-23&P
0084
FOLLOW-ON MAINTENANCE - Continued 2. Install access panels. (TM 5-3825-270-10)
0084-11/12 blank
TM 5-3825-270-23&P
0085
FIELD MAINTENANCE BATTERY DISCONNECT/CONNECTION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Goggles, Industrial (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Apron, Rubber (WP 0225, Table 1, Item 2) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) References Parts Manual (WP 0220) Figure 4009 Equipment Condition Battery box cover removed. (TM 5-3825-270-10)
DISCONNECT
WARNING
Upon removal of terminal clamps, ensure no contact is made with battery terminals. Secure terminal clamps, cables, and wires away from battery terminals with cable ties as required. Failure to comply may result in injury or death to personnel.
WARNING
WARNING
Remove all jewelry such as rings, ID tags, bracelets, etc. prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.
NOTE
Main negative terminal should always be disconnected first and reconnected last.
0085-1
TM 5-3825-270-23&P
0085
DISCONNECT - Continued Note location of cables prior to removal to ensure proper installation. 1. Loosen nut (Figure 1, Item 4) and remove terminal (Figure 1, Item 2) from negative battery post (Figure 1, Item 1) of battery (Figure 1, Item 3).
3
Figure 1. Disconnect Batteries.
2.
Pull back terminal cover (Figure 2, Item 6), loosen nut (Figure 2, Item 5) and remove terminal (Figure 2, Item 13) from negative battery post (Figure 2, Item 14) of battery (Figure 2, Item 12).
14
13 12
11
10
Figure 2. Disconnect Batteries. 3. 4. Pull back terminal cover (Figure 2, Item 7) and loosen nut (Figure 2, Item 9). Remove terminal (Figure 2, Item 10) and jumper cable (Figure 2, Item 11) from positive post (Figure 2, Item 8) of battery (Figure 2, Item 3).
0085-2
TM 5-3825-270-23&P
0085
DISCONNECT - Continued 5. Loosen nut (Figure 3, Item 15) and remove terminal (Figure 3, Item 17) from positive post (Figure 3, Item 16) of battery (Figure 3, Item 12).
15
16
12
17
Figure 3. Disconnect Batteries. END OF TASK CONNECT
WARNING
WARNING
0085-3
TM 5-3825-270-23&P
0085
CONNECT - Continued
WARNING
NOTE
Install cables as noted prior to removal. Main negative terminal should always be disconnected first and reconnected last. 1. Install terminal (Figure 4, Item 17) on positive post (Figure 4, Item 16) of battery (Figure 4, Item 12).
15
16
12
17
Figure 4. Connect Batteries. 2. 3. Tighten nut (Figure 4, Item 15) to 84 to 96 lb-in (9 to 11 Nm). Install jumper cable (Figure 5, Item 11) and terminal (Figure 5, Item 10) on positive post (Figure 5, Item 8) of battery (Figure 5, Item 3).
0085-4
TM 5-3825-270-23&P
0085
CONNECT - Continued
14
13 12
11
10
Figure 5. Connect Batteries. 4. 5. 6. 7. 8. 9. Tighten nut (Figure 5, Item 9) to 84 to 96 lb-in (9 to 11 Nm). Pull terminal cover (Figure 5, Item 7) over terminal (Figure 5, Item 10). Install terminal (Figure 5, Item 13) on negative post (Figure 5, Item 14) of battery (Figure 5, Item 12). Tighten nut (Figure 5, Item 5) to 84 to 96 lb-in (9 to 11 Nm). Pull terminal cover (Figure 5, Item 6) over terminal (Figure 5, Item 13). Install terminal (Figure 6, Item 2) on negative post (Figure 6, Item 1) of battery (Figure 6, Item 3).
4
Figure 6. Connect Batteries. 10. Tighten nut (Figure 6, Item 4) to 84 to 96 lb-in (9 to 11 Nm).
END OF TASK
0085-5
TM 5-3825-270-23&P
0085
FOLLOW-ON MAINTENANCE Install battery box cover. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0085-6
TM 5-3825-270-23&P
0086
FIELD MAINTENANCE BATTERY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Goggles, Industrial (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Apron, Rubber (WP 0225, Table 1, Item 2) References Parts Manual (WP 0220) Figure 4009 Equipment Condition Batteries disconnected. (WP 0085)
REMOVAL
WARNING
WARNING
WARNING
NOTE
Note position of batteries prior to removal to ensure proper installation. 1. Remove two nuts (Figure 1, Item 1), screws (Figure 1, Item 3), washers (Figure 1, Item 4), and hold down bracket (Figure 1, Item 2) from two batteries (Figure 1, Item 5) and battery box (Figure 1, Item 6).
0086-1
TM 5-3825-270-23&P
0086
REMOVAL - Continued
3, 4
Figure 1. Battery Removal. 2. Remove two batteries (Figure 1, Item 5) from battery box (Figure 1, Item 6).
NOTE
Install batteries as noted prior to removal to ensure proper installation. 1. Install two batteries (Figure 2, Item 5) in battery box (Figure 2, Item 6).
3, 4
Figure 2. Battery Installation.
0086-2
TM 5-3825-270-23&P
0086
INSTALLATION - Continued 2. Install hold down bracket (Figure 2, Item 2) on two batteries (Figure 2, Item 5) and battery box (Figure 2, Item 6) with two screws (Figure 2, Item 3), washers (Figure 2, Item 4), and nuts (Figure 2, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0086-3/4 blank
TM 5-3825-270-23&P
0087
FIELD MAINTENANCE MAIN CONTROL PANEL BATTERY VOLTAGE GAUGE REPLACEMENT
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Open control panel cover (Figure 1, Item 1) by releasing rubber t-handle (Figure 1, Item 2).
1 2
Figure 1. Main Control Panel Battery Voltage Gauge Removal. 2. Remove six screws (Figure 2, Item 3) and washers (Figure 2, Item 4) from main control box (Figure 2, Item 5) and control panel (Figure 2, Item 6).
0087-1
TM 5-3825-270-23&P
0087
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Battery Voltage Gauge Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove wire connector (Figure 3, Item 9) from main control panel battery voltmeter gauge (Figure 3, Item 8).
6 7 8
Figure 3. Main Control Panel Battery Voltage Gauge Removal.
NOTE
Note position of main control panel battery voltmeter gauge prior to removal to ensure proper installation. 4. Remove nut (Figure 3, Item 7) and main control panel battery voltmeter gauge (Figure 3, Item 8) from control panel (Figure 3, Item 6).
NOTE
Install main control panel battery voltmeter gauge noted prior to removal.
0087-2
TM 5-3825-270-23&P
0087
INSTALLATION - Continued 1. Install main control panel battery voltmeter gauge (Figure 4, Item 8) and nut (Figure 4, Item 7) on control panel (Figure 4, Item 6).
6 7 8
Figure 4. Main Control Panel Battery Voltage Gauge Installation.
NOTE
Install wires as noted prior to removal. 2. Install wire connector (Figure 4, Item 9) on main control panel battery voltmeter gauge (Figure 4, Item 8).
WARNING
0087-3
TM 5-3825-270-23&P
0087
3, 4
Figure 5. Main Control Panel Battery Voltage Gauge Installation. 4. 5. Install six washers (Figure 5, Item 4) and screws (Figure 5, Item 3) on main control box (Figure 5, Item 5) and control panel (Figure 5, Item 6). Tighten six screws securely. Close control panel cover (Figure 6, Item 1) and secure with rubber t-handle (Figure 6, Item 2).
1 2
Figure 6. Main Control Panel Battery Voltage Gauge Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0087-4
TM 5-3825-270-23&P
0088
FIELD MAINTENANCE MAIN CONTROL PANEL EMERGENCY STOP PUSHBUTTON REPLACEMENT
REMOVAL 1. Open control panel cover (Figure 1, Item 1) by releasing rubber t-handle (Figure 1, Item 2).
1 2
Figure 1. Main Control Panel Emergency Stop Pushbutton Removal.
CAUTION
0088-1
TM 5-3825-270-23&P
0088
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Emergency Stop Pushbutton Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove two screws (Figure 3, Item 8) and red wires (Figure 3, Item 7) from main control panel emergency stop pushbutton (Figure 3, Item 10).
10
Figure 3. Main Control Panel Emergency Stop Pushbutton Removal. 4. Remove nut (Figure 3, Item 9) and main control panel emergency stop pushbutton (Figure 3, Item 10) from main control box (Figure 3, Item 5).
END OF TASK INSTALLATION 1. Install main control panel emergency stop pushbutton (Figure 4, Item 10) and nut (Figure 4, Item 9) on main control box (Figure 4, Item 5).
0088-2
TM 5-3825-270-23&P
0088
10
Figure 4. Main Control Panel Emergency Stop Pushbutton Installation.
NOTE
Install wires as noted prior to removal. 2. Install two red wires (Figure 4, Item 7) with screws (Figure 4, Item 8) on main control panel emergency stop pushbutton (Figure 4, Item 10).
WARNING
3, 4
Figure 5. Main Control Panel Emergency Stop Pushbutton Installation.
0088-3
TM 5-3825-270-23&P
0088
INSTALLATION - Continued 4. 5. Install six washers (Figure 5, Item 4) and screws (Figure 5, Item 3) on main control box (Figure 5, Item 5) and control panel (Figure 5, Item 6). Tighten six screws securely. Close control panel cover (Figure 6, Item 1) and secure with rubber t-handle (Figure 6, Item 2).
1 2
Figure 6. Main Control Panel Emergency Stop Pushbutton Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0088-4
TM 5-3825-270-23&P
0089
FIELD MAINTENANCE CONTROL PANEL LIGHT SWITCH REPLACEMENT
1 2
Figure 1. Control Panel Light Switch Removal.
CAUTION
0089-1
TM 5-3825-270-23&P
0089
REMOVAL - Continued
3, 4
Figure 2. Control Panel Light Switch Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Loosen screw (Figure 3, Item 7) and remove orange wire (Figure 3, Item 8) from control panel light switch (Figure 3, Item 9).
7, 8
12, 13
10, 11
Figure 3. Control Panel Light Switch Removal. 4. 5. 6. Loosen screw (Figure 3, Item 12) and remove yellow wire (Figure 3, Item 13) from control panel light switch (Figure 3, Item 9). Loosen screw (Figure 3, Item 10) and remove two red wires (Figure 3, Item 11) from control panel light switch (Figure 3, Item 9). Remove toggle switch seal (Figure 4, Item 14) from control panel light switch (Figure 4, Item 9).
0089-2
TM 5-3825-270-23&P
0089
REMOVAL - Continued
9, 14
15
6
Figure 4. Control Panel Light Switch Removal. 7. Remove nut (Figure 4, Item 15) and control panel light switch (Figure 4, Item 9) from control panel (Figure 4, Item 6).
END OF TASK INSTALLATION 1. Install control panel light switch (Figure 5, Item 9) on control panel (Figure 5, Item 6) with nut (Figure 5, Item 15).
9, 14
15
6
Figure 5. Control Panel Light Switch Installation. 2. Install toggle switch seal (Figure 5, Item 14) on control panel light switch (Figure 5, Item 9).
NOTE
Install wires as noted prior to removal. 3. Install two red wires (Figure 6, Item 10) on control panel light switch (Figure 6, Item 5) and tighten screw (Figure 6, Item 9).
0089-3
TM 5-3825-270-23&P
0089
7, 8
12, 13
10, 11
Figure 6. Control Panel Light Switch Installation. 4. 5. Install yellow wire (Figure 6, Item 13) on control panel light switch (Figure 6, Item 9) and tighten screw (Figure 6, Item 12). Install orange wire with green stripe (Figure 6, Item 8) on control panel light switch (Figure 6, Item 9) and tighten screw (Figure 6, Item 7).
WARNING
3, 4
Figure 7. Control Panel Light Switch Installation.
0089-4
TM 5-3825-270-23&P
0089
1 2
Figure 8. Control Panel Light Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0089-5/6 blank
TM 5-3825-270-23&P
0090
FIELD MAINTENANCE MAIN CONTROL PANEL OIL PRESSURE GAUGE REPLACEMENT
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Open control panel cover (Figure 1, Item 1) by releasing rubber t-handle (Figure 1, Item 2).
1 2
Figure 1. Main Control Panel Oil Pressure Gauge Removal.
CAUTION
0090-1
TM 5-3825-270-23&P
0090
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove wire connector (Figure 3, Item 9) from main control panel oil pressure gauge (Figure 3, Item 8).
NOTE
Note position of main control panel oil pressure gauge prior to removal to ensure proper installation. 4. Remove nut (Figure 3, Item 7) and main control panel oil pressure gauge (Figure 3, Item 8) from control panel (Figure 3, Item 6).
NOTE
Install main control panel oil pressure gauge as noted prior to removal.
0090-2
TM 5-3825-270-23&P
0090
INSTALLATION - Continued 1. Install main control panel oil pressure gauge (Figure 4, Item 8) and nut (Figure 4, Item 7) on control panel (Figure 4, Item 6).
Figure 4. Main Control Panel Oil Pressure Gauge Installation.
NOTE
Install wires as noted prior to removal. 2. Install wire connector (Figure 4, Item 9) on main control panel oil pressure gauge (Figure 4, Item 8).
WARNING
0090-3
TM 5-3825-270-23&P
0090
3, 4
Figure 5. Main Control Panel Oil Pressure Gauge Installation. 4. 5. Install six washers (Figure 5, Item 4) and screws (Figure 5, Item 3) on main control box (Figure 5, Item 5) and control panel (Figure 5, Item 6). Tighten six screws securely. Close control panel cover (Figure 6, Item 1) and secure with rubber t-handle (Figure 6, Item 2).
1 2
Figure 6. Main Control Panel Oil Pressure Gauge Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0090-4
TM 5-3825-270-23&P
0091
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE START/STOP SWITCH REPLACEMENT
1 2
Figure 1. Main Control Panel Engine Start/Stop Switch Removal.
CAUTION
0091-1
TM 5-3825-270-23&P
0091
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove orange wire (Figure 3, Item 7) from main control panel engine start/stop switch (Figure 3, Item 8).
10
Figure 3. Main Control Panel Engine Start/Stop Switch Removal. 4. 5. 6. Remove two red wires (Figure 3, Item 9) from main control panel engine start/stop switch (Figure 3, Item 8). Remove orange wire with black stripe (Figure 3, Item 10) from main control panel engine start/stop switch (Figure 3, Item 8). Remove toggle switch seal (Figure 4, Item 12) from main control panel engine start/stop switch (Figure 4, Item 8).
0091-2
TM 5-3825-270-23&P
0091
REMOVAL - Continued
11
8, 12
NOTE
Note position of main control panel engine start/stop switch prior to removal to ensure proper installation. 7. Remove nut (Figure 4, Item 11) and main control panel engine start/stop switch (Figure 4, Item 8) from control panel (Figure 4, Item 6).
NOTE
Install main control panel engine start/stop switch as noted prior to removal. 1. Install main control panel engine start/stop switch (Figure 5, Item 8) on control panel (Figure 5, Item 6) with nut (Figure 5, Item 11).
11
8, 12
Figure 5. Main Control Panel Engine Start/Stop Switch Installation. 2. Install toggle switch seal (Figure 5, Item 12) on main control panel engine start/stop switch (Figure 5, Item 8).
0091-3
TM 5-3825-270-23&P
0091
NOTE
Install wires as noted prior to removal. 3. Install orange wire with black stripe (Figure 6, Item 10) on main control panel engine start/stop switch (Figure 6, Item 8).
10
Figure 6. Main Control Panel Engine Start/Stop Switch Installation. 4. 5. Install two red wires (Figure 6, Item 9) on main control panel engine start/stop switch (Figure 6, Item 8). Install orange wire (Figure 6, Item 7) on main control panel engine start/stop switch (Figure 6, Item 8).
WARNING
3, 4
Figure 7. Main Control Panel Engine Start/Stop Switch Installation.
0091-4
TM 5-3825-270-23&P
0091
1 2
Figure 8. Main Control Panel Engine Start/Stop Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0091-5/6 blank
TM 5-3825-270-23&P
0092
FIELD MAINTENANCE GOVERNOR CONTROL MODULE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 58) Qty: 4 Lockwasher (WP 0226, Table 1, Item 37) Qty: 4 References Parts Manual (WP 0220) Figure 4026 Equipment Condition Engine OFF. (TM 5-3825-270-10) Equipment Condition (cont.) Batteries disconnected. (WP 0085) Rear engine access cover removed. (TM 5-3825-270-10)
REMOVAL 1. Loosen screw (Figure 1, Item 2) and disconnect connector (Figure 1, Item 3) from governor control module (Figure 1, Item 1).
1
3 2
Figure 1. Governor Control Module Removal. 2. Remove four locknuts (Figure 2, Item 4), lockwashers (Figure 2, Item 5), washers (Figure 2, Item 6), screws (Figure 2, Item 7) and governor control module (Figure 2, Item 1) from mounting surface (Figure 2, Item 8). Discard locknuts and lockwashers.
0092-1
TM 5-3825-270-23&P
0092
REMOVAL - Continued
4, 5, 6, 7
Figure 2. Governor Control Module Removal. END OF TASK INSTALLATION 1. Install governor control module (Figure 3, Item 1) on mounting surface (Figure 3, Item 8) with four screws (Figure 3, Item 7), washers (Figure 3, Item 6), lockwashers (Figure 3, Item 5), and locknuts (Figure 3, Item 4).
4, 5, 6, 7
Figure 3. Governor Control Module Installation. 2. Connect connector (Figure 4, Item 3) to governor control module (Figure 4, Item 1) with screw (Figure 4, item 2).
0092-2
TM 5-3825-270-23&P
0092
1
3 2
Figure 4. Governor Control Module Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install rear engine access cover. (TM 5-3825-270-10) Connect batteries. (WP 0085)
0092-3/4 blank
TM 5-3825-270-23&P
0093
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE OFF/BATTERY DRAIN INDICATOR REPLACEMENT
1 2
Figure 1. Main Control Panel Engine Off/Battery Drain Indicator Removal.
CAUTION
0093-1
TM 5-3825-270-23&P
0093
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Engine Off/Battery Drain Indicator Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Disconnect red wire (Figure 3, Item 8) and white wire with black stripe (Figure 3, Item 7) from main control panel engine off/battery drain indicator (Figure 3, Item 10).
8 7 9
10
11, 12
Figure 3. Main Control Panel Engine Off/Battery Drain Indicator Removal. 4. 5. Disconnect white wire with red stripe (Figure 3, Item 9) from main control panel engine off/battery drain indicator (Figure 3, item 10). Remove nut (Figure 3, Item 11), washer (Figure 3, item 12) and main control panel engine off/battery drain indicator (Figure 3, Item 10) from control panel (Figure 3, Item 6).
END OF TASK INSTALLATION 1. Install main control panel engine off/battery drain indicator (Figure 4, Item 10) in control panel (Figure 4, Item 6) with washer (Figure 4, Item 12) and nut (Figure 4, Item 11).
0093-2
TM 5-3825-270-23&P
0093
8 7 9
10
11, 12
Figure 4. Main Control Panel Engine Off/Battery Drain Indicator Installation.
NOTE
Install wires as noted prior to removal. 2. 3. Connect white wire with black stripe (Figure 4, Item 7) and red wire (Figure 4, Item 8) to main control panel engine off/battery drain indicator (Figure 4, Item 10). Connect white wire with red stripe (Figure 4, Item 9) to main control panel engine off/battery drain indicator (Figure 4, Item 10).
WARNING
0093-3
TM 5-3825-270-23&P
0093
3, 4
Figure 5. Main Control Panel Engine Off/Battery Drain Indicator Installation. 5. 6. Install six washers (Figure 5, Item 4) and screws (Figure 5, Item 3) on main control box (Figure 5, Item 5) and control panel (Figure 5, Item 6). Tighten six screws securely. Close control panel cover (Figure 6, Item 1) and secure with rubber t-handle (Figure 6, Item 2).
1 2
Figure 6. Main Control Panel Engine Off/Battery Drain Indicator Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0093-4
TM 5-3825-270-23&P
0094
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE SPEED RESUME/IDLE SWITCH REPLACEMENT
1 2
Figure 1. Main Control Panel Engine Speed Resume/Idle Switch Removal.
CAUTION
0094-1
TM 5-3825-270-23&P
0094
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove red wire with black stripe (Figure 3, Item 7) from main control panel engine speed resume/idle switch (Figure 3, Item 10).
7 8 9
10
Figure 3. Main Control Panel Engine Speed Resume/Idle Switch Removal. 4. 5. 6. Remove two red wires (Figure 3, Item 8) from main control panel engine speed resume/idle switch (Figure 3, Item 10). Remove black wire with red stripe (Figure 3, Item 9) from main control panel engine speed resume/idle switch (Figure 3, Item 10). Remove toggle switch seal (Figure 4, Item 12) from main control panel engine speed resume/idle switch (Figure 4, Item 10).
0094-2
TM 5-3825-270-23&P
0094
REMOVAL - Continued
11 10, 12 6
NOTE
Note position of main control panel engine speed resume/idle switch prior to removal to ensure proper installation. 7. Remove nut (Figure 4, Item 11) and main control panel engine speed resume/idle switch (Figure 4, Item 10) from control panel (Figure 4, Item 6).
NOTE
Install main control panel engine speed resume/idle switch as noted prior to removal. 1. Install main control panel engine speed resume/idle switch (Figure 5, Item 10) on control panel (Figure 5, Item 6) with nut (Figure 5, Item 11).
11 10, 12 6
Figure 5. Main Control Panel Engine Speed Resume/Idle Switch Installation. 2. Install toggle switch seal (Figure 5, Item 12) on main control panel engine speed resume/idle switch (Figure 5, Item 10).
0094-3
TM 5-3825-270-23&P
0094
NOTE
Install wires as noted prior to removal. 3. Install black wire with red stripe (Figure 6, Item 9) on main control panel engine speed resume/idle switch (Figure 6, Item 10).
7 8 9
10
Figure 6. Main Control Panel Engine Speed Resume/Idle Switch Installation. 4. 5. Install two red wires (Figure 6, Item 8) on main control panel engine speed resume/idle switch (Figure 6, Item 10). Install red wire with black stripe (Figure 6, Item 7) on main control panel engine speed resume/idle switch (Figure 6, Item 10).
WARNING
0094-4
TM 5-3825-270-23&P
0094
3, 4
Figure 7. Main Control Panel Engine Speed Resume/Idle Switch Installation. 7. 8. Install six washers (Figure 7, Item 4) and screws (Figure 7, Item 3) on main control box (Figure 7, Item 5) and control panel (Figure 7, Item 6). Tighten six screws securely. Close control panel cover (Figure 8, Item 1) and secure with rubber t-handle (Figure 8, Item 2).
1 2
Figure 8. Main Control Panel Engine Speed Resume/Idle Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0094-5/6 blank
TM 5-3825-270-23&P
0095
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE SPEED RPM SWITCH REPLACEMENT
1 2
Figure 1. Main Control Panel Engine Speed RPM Switch Removal.
CAUTION
0095-1
TM 5-3825-270-23&P
0095
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove red wire with green stripe (Figure 3, Item 10) from main control panel engine speed RPM switch (Figure 3, Item 7).
10
Figure 3. Main Control Panel Engine Speed RPM Switch Removal. 4. 5. 6. Remove two red wires (Figure 3, Item 9) from main control panel engine speed RPM switch (Figure 3, Item 7). Remove red wire with white stripe (Figure 3, Item 8) from main control panel engine speed RPM switch (Figure 3, Item 7). Remove toggle switch seal (Figure 4, Item 12) from main control panel engine speed RPM switch (Figure 4, Item 7).
0095-2
TM 5-3825-270-23&P
0095
REMOVAL - Continued
7, 12 11
6
NOTE
Note position of main control panel engine speed RPM switch prior to removal to ensure proper installation. 7. Remove nut (Figure 4, Item 11) and main control panel engine speed RPM switch (Figure 4, Item 7) from control panel (Figure 4, Item 6).
NOTE
Install main control panel engine speed RPM switch as noted prior to removal. 1. Install main control panel engine speed RPM switch (Figure 5, Item 7) on control panel (Figure 5, Item 6) with nut (Figure 5, Item 11).
7, 12 11
6
Figure 5. Main Control Panel Engine Speed RPM Switch Removal. 2. Install toggle switch seal (Figure 5, Item 12) on main control panel engine speed RPM switch (Figure 5, Item 7).
0095-3
TM 5-3825-270-23&P
0095
NOTE
Install wires as noted prior to removal. 3. Install red wire with white stripe (Figure 6, Item 8) on main control panel engine speed RPM switch (Figure 6, Item 7).
10
Figure 6. Main Control Panel Engine Speed RPM Switch Installation. 4. 5. Install two red wires (Figure 6, Item 9) on main control panel engine speed RPM switch (Figure 6, Item 7). Install red wire with green stripe (Figure 6, Item 10) on main control panel engine speed RPM switch (Figure 6, Item 7).
WARNING
0095-4
TM 5-3825-270-23&P
0095
3, 4
Figure 7. Main Control Panel Engine Speed RPM Switch Installation. 7. 8. Install six washers (Figure 7, Item 4) and screws (Figure 7, Item 3) on main control box (Figure 7, Item 5) and control panel (Figure 7, Item 6). Tighten six screws securely. Close control panel cover (Figure 8, Item 1) and secure with rubber t-handle (Figure 8, Item 2).
1 2
Figure 8. Main Control Panel Engine Speed RPM Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0095-5/6 blank
TM 5-3825-270-23&P
0096
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE SPEED SET SWITCH REPLACEMENT
1 2
CAUTION
0096-1
TM 5-3825-270-23&P
0096
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Engine Speed Set Switch Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Loosen screw (Figure 3, Item 8) and remove black wire with white stripe (Figure 3, Item 7) from main control panel engine speed set switch (Figure 3, Item 9).
6 10, 11 9 7, 8
Figure 3. Main Control Panel Engine Speed Set Switch Removal. 4. 5. Loosen screw (Figure 3, Item 11) and remove red wire (Figure 3, Item 10) from main control panel engine speed set switch (Figure 3, Item 9). Remove toggle switch seal (Figure 4, Item 13) from main control panel engine speed set switch (Figure 4, Item 9).
0096-2
TM 5-3825-270-23&P
0096
REMOVAL - Continued
12
9, 13
6
Figure 4. Main Control Panel Engine Speed Set Switch Removal.
NOTE
Note position of main control panel engine speed set switch prior to removal to ensure proper installation. 6. Remove nut (Figure 4, Item 12) and main control panel engine speed set switch (Figure 4, Item 9) from control panel (Figure 4, Item 6).
NOTE
Install main control panel engine speed set switch prior to removal. 1. Install main control panel engine speed set switch (Figure 5, Item 9) on control panel (Figure 5, Item 6) with nut (Figure 5, Item 12).
12
9, 13
6
Figure 5. Main Control Panel Engine Speed Set Switch Installation. 2. Install toggle switch seal (Figure 5, Item 13) on main control panel engine speed set switch (Figure 5, Item 9).
0096-3
TM 5-3825-270-23&P
0096
NOTE
Install wires as noted prior to removal. 3. Install red wire (Figure 6, Item 10) on main control panel engine speed set switch (Figure 6, Item 9) and tighten screw (Figure 6, Item 11).
6 10, 11 9 7, 8
Figure 6. Main Control Panel Engine Speed Set Switch Installation. 4. Install black wire with white stripe (Figure 6, Item 7) on main control panel engine speed set switch (Figure 6, Item 9) and tighten screw (Figure 6, Item 8).
WARNING
3, 4
Figure 7. Main Control Panel Engine Speed Set Switch Installation.
0096-4
TM 5-3825-270-23&P
0096
1 2
Figure 8. Main Control Panel Engine Speed RPM Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0096-5/6 blank
TM 5-3825-270-23&P
0097
FIELD MAINTENANCE MAIN CONTROL PANEL ENGINE TEMPERATURE GAUGE REPLACEMENT
1 2
Figure 1. Main Control Panel Engine Temperature Gauge Removal.
CAUTION
0097-1
TM 5-3825-270-23&P
0097
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove wire connector (Figure 3, Item 9) from main control panel engine temperature gauge (Figure 3, Item 8).
7 8 9 6
NOTE
Note position of main control panel engine temperature gauge prior to removal to ensure proper installation. 4. Remove nut (Figure 3, Item 7) and main control panel engine temperature gauge (Figure 3, Item 8) from control panel (Figure 3, Item 6).
NOTE
Install main control panel engine temperature gauge as noted prior to removal.
0097-2
TM 5-3825-270-23&P
0097
INSTALLATION - Continued 1. Install main control panel engine temperature gauge (Figure 4, Item 8) and nut (Figure 4, Item 7) on control panel (Figure 4, Item 6).
7 8 9 6
Figure 4. Main Control Panel Engine Temperature Gauge Installation.
NOTE
Install wires as noted prior to removal. 2. Install wire connector (Figure 4, Item 9) on main control panel engine temperature gauge (Figure 4, Item 8).
WARNING
3, 4
Figure 5. Main Control Panel Engine Temperature Gauge Installation.
0097-3
TM 5-3825-270-23&P
0097
1 2
Figure 6. Main Control Panel Engine Temperature Gauge Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0097-4
TM 5-3825-270-23&P
0098
FIELD MAINTENANCE ENGINE WIRE HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Materials/Parts Tags, Identification (WP 0224, Table 1, Item 54) Ties, Cable (WP 0224, Table 1, Item 9) Lockwasher (WP 0226, Table 1, Item 37) Qty: 4 Lockwasher (WP 0226, Table 1, Item 62) Qty: 1 Lockwasher (WP 0226, Table 1, Item 61) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4026 Equipment Condition Batteries disconnected. (WP 0085) Engine compartment cover removed. (WP 0142)
REMOVAL
NOTE
Tag and mark all wires prior to removal. Note routing of harness prior to removal to ensure proper installation. Remove cable ties and cushion clips as required. 1. Disconnect governor actuator harness connector (Figure 1, Item 1) from engine wire harness connector (Figure 1, Item 2).
Figure 1. Engine Wire Harness Removal. 2. Remove nut (Figure 2, Item 3), lockwasher (Figure 2, Item 4), washers (Figure 2, Items 5 and 6), and wire (Figure 2, Item 7), from temperature sensor (Figure 2, Item 8). Discard lockwasher.
0098-1
TM 5-3825-270-23&P
0098
REMOVAL - Continued
3, 4
5, 6
Figure 2. Engine Wire Harness Removal. 3. Disconnect wire (Figure 3, Item 10) from temperature sending unit (Figure 3, Item 9).
10
Figure 3. Engine Wire Harness Removal. 4. Remove nut (Figure 4, Item 12), washer (Figure 4, Item 13), and wire (Figure 4, Item 11) from oil pressure sending unit (Figure 4, Item 14).
0098-2
TM 5-3825-270-23&P
0098
REMOVAL - Continued
11 12, 13 14
17 15, 16
Figure 4. Engine Wire Harness Removal. 5. 6. Remove screw (Figure 4, Item 15), lockwasher (Figure 4, Item 16), and wire (Figure 4, Item 17) from oil pressure sending unit (Figure 4, Item 14). Discard lockwasher. Loosen screw (Figure 5, Item 20) and remove connector (Figure 5, Item 21) from governor control unit (Figure 5, Item 19).
18
19
23, 24
22
20, 21
Figure 5. Engine Wire Harness Removal.
0098-3
TM 5-3825-270-23&P
0098
REMOVAL - Continued 7. 8. Remove nut (Figure 5, Item 23), lockwasher (Figure 5, Item 24) and wire eyelet (Figure 5, Item 22) from rear enclosure panel (Figure 5, Item 18). Discard lockwasher. Disconnect engine timing sensor harness connector (Figure 6, Item 26) from engine wire harness connector (Figure 6, Item 25).
25
26
Figure 6. Engine Wire Harness Removal. 9. Remove nut (Figure 7, Item 28), lockwasher (Figure 7, Item 29), and yellow wire eyelet (Figure 7, Item 30) from glow plug relay (Figure 7, Item 27). Discard lockwasher.
27
28, 29
30
31, 32
33
0098-4
TM 5-3825-270-23&P
0098
REMOVAL - Continued 10. 11. Remove nut (Figure 7, Item 31), lockwasher (Figure 7, Item 32), and white wire eyelet (Figure 7, Item 33) from glow plug relay (Figure 7, Item 27). Discard lockwasher. Remove nut (Figure 8, Item 39), lockwasher (Figure 8, Item 40), and white wire eyelet (Figure 8, Item 38) from starter relay (Figure 8, Item 34). Discard lockwasher.
34
39, 40
38
37
35, 36
Figure 8. Engine Wire Harness Removal. 12. 13. Remove nut (Figure 8, Item 35), lockwasher (Figure 8, Item 36), and blue wire eyelet (Figure 8, Item 37) from starter relay (Figure 8, Item 34). Discard lockwasher. Open control panel cover (Figure 9, Item 42) by releasing T-handle (Figure 9, Item 41).
41 42
0098-5
TM 5-3825-270-23&P
0098
REMOVAL - Continued
CAUTION
Control panel and cover must be supported after removal. Allowing cover to hang from wiring may result in damage to equipment. 14. Remove six screws (Figure 10, Item 43), washers (Figure 10, Item 44), and control panel (Figure 10, Item 45) from main control box (Figure 10, Item 46).
43, 44
45
46
NOTE
Note routing of harness prior to removal to ensure proper installation. Tag and mark wires prior to removal to ensure proper installation. Remove cable ties and cushion clips as required. All wires are removed from terminal strips the same way. 15. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 1.
0098-6
TM 5-3825-270-23&P
0098
REMOVAL - Continued
47 48 WIRE 49
10
10
10
WIRE
5 15 15
20
20
46
51
50
WIRE
Figure 11. Engine Wire Harness Removal. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 2. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 4. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 6. Remove black wire from positive terminal strip (Figure 11, Item 47) socket 19. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 10. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 11. Remove black wire from interconnect terminal strip (Figure 11, Item 49) socket 14. Remove white wire from interconnect terminal strip (Figure 11, Item 49) socket 3. Remove white wire from interconnect terminal strip (Figure 11, Item 49) socket 5. Remove white wire from interconnect terminal strip (Figure 11, Item 49) socket 7. Remove white wire from negative terminal strip (Figure 11, Item 48) socket 11. Remove white wire from positive terminal strip (Figure 11, Item 47) socket 10. Remove white wire from interconnect terminal strip (Figure 11, Item 49) socket 20. Remove retaining nut (Figure 11, Item 51) and engine wire harness (Figure 11, Item 50) from control box (Figure 11, Item 46).
NOTE
All wires are installed on terminal strips the same way.
0098-7
TM 5-3825-270-23&P
0098
INSTALLATION - Continued Install cable tie and cushion clips as required. Install wires as noted prior to removal to ensure proper installation. Route harness as noted prior to removal to ensure proper installation. 1. Install engine wiring harness (Figure 12, Item 50) in main control box (Figure 12, Item 46) with retaining nut (Figure 12, Item 51).
47 48 WIRE 49
10
10
10
WIRE
5 15 15
20
20
46
51
50
WIRE
Figure 12. Engine Wire Harness Installation. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Install white wire on interconnect terminal strip (Figure 12, Item 49) socket 20. Install white wire on positive terminal strip (Figure 12, Item 47) socket 10. Install white wire on negative terminal strip (Figure 12, Item 48) socket 11. Install white wire on interconnect terminal strip (Figure 12, Item 49) socket 7. Install white wire on interconnect terminal strip (Figure 12, Item 49) socket 5. Install white wire on interconnect terminal strip (Figure 12, Item 49) socket 3. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 14. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 11. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 10. Install black wire on positive terminal strip (Figure 12, Item 47) socket 19. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 6. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 4. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 2. Install black wire on interconnect terminal strip (Figure 12, Item 49) socket 1.
0098-8
TM 5-3825-270-23&P
0098
WARNING
43, 44
45
46
Figure 13. Engine Wire Harness Installation. 17. 18. Install six washers (Figure 13, Item 44) and screws (Figure 13, Item 43) on main control box (Figure 13, Item 45) and control panel (Figure 13, Item 46). Tighten six screws securely. Close and secure control panel cover (Figure 14, Item 42) with T-handle (Figure 14, Item 41).
41 42
Figure 14. Engine Wire Harness Installation. 19. Install blue wire eyelet (Figure 15, Item 37) on starter relay (Figure 15, Item 34) with lockwasher (Figure 15, Item 36) and nut (Figure 15, Item 35).
0098-9
TM 5-3825-270-23&P
0098
34
39, 40
38
37
35, 36
Figure 15. Engine Wire Harness Installation. 20. 21. Install white wire eyelet (Figure 15, Item 38) on starter relay (Figure 15, Item 34) with lockwasher (Figure 15, Item 40) and nut (Figure 15, Item 39). Install white wire eyelet (Figure 16, Item 33) on glow plug relay (Figure 16, Item 27) with lockwasher (Figure 16, Item 32) and nut (Figure 16, Item 31).
0098-10
TM 5-3825-270-23&P
0098
27
28, 29
30
31, 32
33
Figure 16. Engine Wire Harness Installation. 22. 23. Install yellow wire eyelet (Figure 16, Item 30) on glow plug relay (Figure 16, Item 27) with lockwasher (Figure 16, Item 29) and nut (Figure 16, Item 28). Connect engine timing sensor harness connector (Figure 17, Item 26) to engine wire harness connector (Figure 17, Item 25).
25
26
Figure 17. Engine Wire Harness Installation. 24. Install wire eyelet (Figure 18, Item 22) on rear panel (Figure 18, Item 18) with lockwasher (Figure 18, Item 24) and nut (Figure 18, Item 23).
0098-11
TM 5-3825-270-23&P
0098
18
19
23, 24
22
20, 21
Figure 18. Engine Wire Harness Installation. 25. 26. Install connector (Figure 18, Item 21) into governor control unit (Figure 18, Item 19) with screw (Figure 18, Item 20). Install wire (Figure 19, Item 17) on oil pressure sending unit (Figure 19, Item 14) with lockwasher (Figure 19, Item 16) and screw (Figure 19, Item 15).
11 12, 13 14
17 15, 16
Figure 19. Engine Wire Harness Installation.
0098-12
TM 5-3825-270-23&P
0098
INSTALLATION - Continued 27. 28. Install wire (Figure 19, Item 11) on oil pressure sending unit (Figure 19, Item 14) with washer (Figure 19, Item 13) and nut (Figure 19, Item 12). Connect wire (Figure 20, Item 10) to temperature sending unit (Figure 20, Item 9).
10
Figure 20. Engine Wire Harness Installation. 29. Install wire (Figure 21, Item 7), on temperature sensor (Figure 21, Item 8) with two washers (Figure 21, Items 6 and 5), lockwasher (Figure 21, Item 4), and nut (Figure 21, Item 3).
3, 4
5, 6
Figure 21. Engine Wire Harness Installation. 30. Connect governor actuator harness connector (Figure 22, Item 1) to engine wire harness connector (Figure 22, Item 2).
0098-13
TM 5-3825-270-23&P
0098
Figure 22. Engine Wire Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install engine compartment cover. (WP 0142) Connect batteries. (WP 0085)
0098-14
TM 5-3825-270-23&P
0099
FIELD MAINTENANCE GENERAL WIRE HARNESS REPAIR/JUMPER WIRE FABRICATION
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Terminal Kit (WP 0225, Table 1, Item 2) Crimping Tool, Terminal, Hand, Weatherpack Goggles, Industrial (WP 0225, Table 1, Item 2) Torch Kit, Soldering (WP 0225, Table 1, Item 2) Tool Kit, Electric (WP 0225, Table 1, Item 2) Tool, Terminal Remover (Weatherpack), Electrical Materials/Parts Heatshrink (WP 0224, Table 1, Item 40) Tags, Identification, White (WP 0224, Table 1, Item 54) Materials/Parts (cont.) Tie Wraps (WP 0224, Table 1, Item 56) Wire (WP 0224, Table 1, Item 57) Personnel Required Construction Equipment Repairer 91L (2) Equipment Condition Engine OFF (TM 5-3825-270-10). Negative battery cable disconnected. (WP 0085)
DT STYLE CONNECTOR RECEPTACLE REPAIR
WARNING
Ensure electrical power is off prior to working on all electrical systems. Failure to comply may result in injury or death to personnel. Remove all jewelry, such as rings, ID tags, bracelets, etc., prior to working on or around equipment. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.
CAUTION
Terminals come in different styles and sizes. Use only exact replacement. Do not attempt to modify terminal to fit. Failure to comply may cause damage to equipment.
NOTE
Tag and mark wires, connectors, and harnesses prior to removal to ensure proper installation. 1. Remove wedge lock (Figure 1, Item 2) from receptacle (Figure 1, Item 1).
0099-1
TM 5-3825-270-23&P
0099
DT STYLE CONNECTOR RECEPTACLE REPAIR - Continued

1
5 4 3
Figure 1. DT Style Connector Receptacle Repair.
NOTE
Hold rear grommet when pulling terminal and wire out, to prevent displacing rear grommet. 2. 3. 4. Move locking finger (Figure 1, Item 6) away from terminal (Figure 1, Item 4) to release terminal while gently pulling wire (Figure 1, Item 3) backwards. Remove terminal (Figure 1, Item 4) and wire (Figure 1, Item 3 ) from receptacle rear grommet (Figure 1, Item 5). Cut wire behind old terminal (Figure 1, Item 4) and strip wire (Figure 1, Item 3).
NOTE
Ensure all wire strands are in crimp barrel and visible in terminal inspection hole. 5. 6. 7. 8. Insert and crimp wire (Figure 1, Item 3) to new terminal (Figure 1, Item 4). Insert wire (Figure 1, Item 3) and terminal (Figure 1, Item 4) into receptacle (Figure 1, Item 1) through rear grommet (Figure 1, Item 5) until a click is felt. Slightly tug wire (Figure 1, Item 3) to verify terminal (Figure 1, Item 4) is properly locked in place. Install wedge lock (Figure 1, Item 2) into connector (Figure 1, Item 1) until it snaps into place.
END OF TASK DT STYLE CONNECTOR PLUG REPAIR
NOTE
Tag and mark wires, connectors, and harnesses prior to removal to insure proper installation. 1. Remove wedge lock (Figure 2, Item 3) from plug (Figure 2, Item 1).
0099-2
TM 5-3825-270-23&P
0099
DT STYLE CONNECTOR PLUG REPAIR - Continued
1 2 3 1 6 5 4 4 5
7
Figure 2. DT Style Connector Plug Repair.
NOTE
Hold rear grommet when pulling terminal and wire out, to prevent displacing rear grommet. 2. 3. 4. Move locking finger (Figure 2, Item 7) away from terminal (Figure 2, Item 5) to release terminal while gently pulling wire (Figure 2, Item 4) backwards. Remove terminal (Figure 2, Item 5) and wire (Figure 2, Item 4) from rear grommet (Figure 2, Item 6). Cut wire behind old terminal (Figure 2, Item 6) and strip wire (Figure 2, Item 4).
NOTE
Make sure all wire strands are in crimp barrel and visible in terminal inspection hole. 5. 6. 7. 8. 9. Insert and crimp wire (Figure 2, Item 4) to new terminal (Figure 2, Item 5). Insert wire (Figure 2, Item 4) and terminal (Figure 2, Item 5) into plug (Figure 2, Item 1) through rear grommet (Figure 2, Item 6) until a click is felt. Slightly tug wire (Figure 2, Item 4) to verify terminal (Figure 2, Item 5) is properly locked in place. Verify seal (Figure 2, Item 2) is in place on plug (Figure 2, Item 1). Install wedge lock (Figure 2, Item 3) to plug (Figure 2, Item 1) until it snaps into place.
END OF TASK SPADE CONNECTOR REPAIR
NOTE
Make cut directly behind damaged terminal. 1. Cut and remove terminal (Figure 3, Item 3) from wire (Figure 3, Item 1).
0099-3
TM 5-3825-270-23&P
0099
SPADE CONNECTOR REPAIR - Continued
A 1
Figure 3. Spade Connector Repair. 2. Remove insulation (Figure 3, Item 2) from end of wire (Figure 3, Item 1) equal to dimension A.
NOTE
Ensure all strands of wire are inside terminal when installing. 3. Install new terminal (Figure 3, Item 3) to wire (Figure 3, Item 1) and crimp.
END OF TASK WEATHERPACK CONNECTOR REPAIR
NOTE
Connectors are repaired in a similar way. Number of wires in connector may vary. 1. Unlatch and open secondary lock (Figure 4, Item 2) on connectors (Figure 4, Item 1), and (Figure 4, Item 3) to be repaired.
1 2
Figure 4. Open Connector Secondary Lock.
0099-4
TM 5-3825-270-23&P
0099
WEATHERPACK CONNECTOR REPAIR - Continued
WARNING
Tip of removal tool is very sharp. Use care when using removal tool. Failure to comply may result in injury or death to personnel. 2. Insert terminal remover (Figure 5, Item 5) into cavity (Figure 5, Item 4) on connector (Figure 5, Item 1), and (Figure 5, Item 3) until seated.
5 4 3 1 2
6 7 8
Figure 5. Connector Breakdown. 3. Pull wire (Figure 5, Item 8), terminal (Figure 5, Item 6), and wire seal (Figure 5, Item 7) back through connectors (Figure 5, Item 1), and (Figure 5, Item 3) and remove terminal remover (Figure 5, Item 5).
NOTE
Make cut directly behind damaged terminal. 4. 5. Cut and remove terminal (Figure 5, Item 6) and wire seal (Figure 5, Item 7) from wire (Figure 5, Item 8). Insert 1 in. (25 mm) of wire (Figure 6, Item 8) through wire seal (Figure 6, Item 7).
8 7
Figure 6. Wire With Seal.
0099-5
TM 5-3825-270-23&P
0099
CAUTION
Strip wire after placing it through seal. Failure to comply may cause damage to equipment. 6. Strip end of wire (Figure 7, Item 8), leaving 1/4 in. (6 mm) of bare wire.
7 8
Figure 7. Wire Seal With Insulation. 7. 8. Insert terminal (Figure 7, Item 6) in locating hole of weatherpack crimper (Figure 7, Item 9) using proper hole according to the gauge of wire (Figure 7, Item 8). Slide wire seal (Figure 7, Item 7) down to end of insulation on wire (Figure 7, Item 8).
NOTE
Wire and seal should be positioned so larger wings of terminal will crimp around seal, and smaller wings will crimp around exposed bare wire. Ensure all strands of wire are inside terminal when installing. 9. 10. Position wire (Figure 7, Item 8) on terminal (Figure 7, Item 6). Press handles of weatherpack crimper (Figure 8, Item 9) together until ratchet releases and crimp is complete.
0099-6
TM 5-3825-270-23&P
0099
3 1
6 7 8
Figure 8. Seating Terminal to Connector. 11. 12. Push terminal (Figure 8, Item 6), wire seal (Figure 8, Item 7), and wire (Figure 8, Item 8) through connectors (Figure 8, Item 1), and (Figure 8, Item 3) until seated. Close secondary lock (Figure 9, Item 2) on connector (Figure 9, Item 1), and (Figure 9, Item 3).
1 2
Figure 9. Close Connector Secondary Lock. END OF TASK WIRE REPAIR
NOTE
If 30 percent or more of wiring harness wires have been repaired or replaced, replace complete harness. 1. Access damaged wire (Figure 10, Item 1).
0099-7
TM 5-3825-270-23&P
0099
WIRE REPAIR - Continued
3 2
Figure 10. Splicing. 2. Remove insulation (Figure 10, Item 2) from end of both wires (Figure 10, Item 1) equal to dimension A.
NOTE
Ensure all strands of wire are inside terminal when installing. 3. 4. 5. Install butt connector (Figure 10, Item 3) over bare ends of wire (Figure 10, Item 1) and crimp. Inspect wire splice to ensure no bare wire is visible. Install two butt connectors (Figure 11, Item 5), one on each bare end of wire (Figure 11, Item 4).
7
Figure 11. Splicing With Added Wire. 6. 7. 8. 9. 10. 11.
Crimp one end of both butt connectors (Figure 11, Item 5) securely over wire (Figure 11, Item 4). Measure distance between open ends of butt connectors (Figure 11, Item 5). Cut section of wire (Figure 11, Item 6) 1 in. (25 mm) longer than distance measured in Step 7. Remove insulation (Figure 11, Item 7) from both ends of wire (Figure 11, Item 6) equal to dimension A. Install bare ends of wire (Figure 11, Item 6) in butt connectors (Figure 11, Item 5) and crimp. Inspect splice to ensure no bare wire (Figure 11, Item 4), and (Figure 11, Item 6) is visible.
END OF TASK
0099-8
TM 5-3825-270-23&P
0099
WIRE SOLDER REPAIR
WARNING
Avoid breathing fumes generated from soldering. Various metals have potential to generate hazardous atmospheres. Good ventilation is required. Eye protection is required. Failure to comply may result in injury or death to personnel.
WARNING
Allow solder to cool prior to handling. Failure to comply may result in injury or death to personnel.
NOTE
This method produces a stronger, more permanent repair. Use this method when possible. 1. Remove damaged wire (Figure 12, Item 1) if necessary.
1 2
1 3
Figure 12. Before Joint Is Soldered. 2. 3. Remove 3/4 in. (19 mm) of insulation (Figure 12, Item 3) from end of both wires (Figure 12, Item 1). Slide 3 in. (76 mm) piece of heatshrink tubing (Figure 12, Item 2) over end of one wire (Figure 12, Item 1).
WARNING
0099-9
TM 5-3825-270-23&P
0099
WIRE SOLDER REPAIR - Continued
NOTE
Ensure solder flows evenly on both ends of wire. 4. Twist two ends of wire (Figure 13, Item 1) together and solder.
APPLY SOLDER 2 1
Figure 13. Joint With Solder. 5. Slide heatshrink tubing (Figure 13, Item 2) over solder joint.
WARNING
Never use open flame to apply heat to heatshrink tubing. Allow heatshrink tubing to cool prior to handling. Failure to comply may result in injury or death to personnel.
CAUTION
Do not overheat tubing. Failure to comply may cause damage to wire.
NOTE
Ensure solder joint is centered in heatshrink tubing. 6. Apply heat to heatshrink tubing (Figure 14, Item 2). Allow tubing to shrink until tight on solder joint and insulation of wire (Figure 14, Item 1).
1 2 1
Figure 14. Joint With Solder and Heatshrink. 7. Measure distance between ends of wire (Figure 15, Item 4).
0099-10
TM 5-3825-270-23&P
0099
4 5 6 5 4
7 7
Figure 15. Splice Double Joint Soldering. 8. 9. 10. Cut section of wire (Figure 15, Item 6) 2 in. (50 mm) longer than distance measured in Step 7. Remove 3/4 in. (19 mm) of insulation (Figure 15, Item 7) from both ends of wire (Figure 15, Item 6). Slide two 3 in. (76 mm) pieces of heatshrink tubing (Figure 15, Item 5) over ends of wires (Figure 15, Item 4).
WARNING
NOTE
Ensure solder flows evenly on both ends of wire. 11. Twist bare ends of wires (Figure 16, Item 4) and (Figure 16, Item 6) together and solder.
5 4 APPLY SOLDER 5 4 6
Figure 16. Double Joint With Soldering. 12. Slide heatshrink tubing (Figure 17, Item 5) over solder joint.
0099-11
TM 5-3825-270-23&P
0099

4 5 6 5 4
Figure 17. Double Joint With Solder and Heatshrink.
WARNING
Never use open flame to apply heat to heatshrink tubing. Allow heatshrink tubing to cool prior to handling. Failure to comply may result in injury or death to personnel.
CAUTION
Do not overheat tubing. Failure to comply may cause damage to wire.
NOTE
Ensure solder joint is centered in heatshrink tubing. 13. 14. Apply heat to heatshrink tubing (Figure 17, Item 5). Allow tubing to shrink until tight on solder joint and insulation of wires (Figure 17, Item 4) and (Figure 17, Item 6). Repeat Steps 11 thru 13 for other soldered joint.
END OF TASK JUMPER WIRE FABRICATION Strip approximately 1 in. (25 mm) off each end of wire (Figure 18, Item 1).
0099-12
TM 5-3825-270-23&P
0099
JUMPER WIRE FABRICATION - Continued

1
Figure 18. Jumper Wire Fabrication. END OF TASK FOLLOW-ON MAINTENANCE Connect negative battery cable. (WP 0085) END OF TASK END OF WORK PACKAGE
0099-13/14 blank
TM 5-3825-270-23&P
0100
FIELD MAINTENANCE MAIN CONTROL BOX REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Locknut (WP 0226, Table 1, Item 38) Qty: 5 References Parts Manual (WP 0220) Figure 4018 Equipment Condition Batteries disconnected. (WP 0085) Main control panel battery voltage gauge removed. (WP 0087) Main control panel emergency stop pushbutton removed. (WP 0088) Main control panel light switch removed. (WP 0089) Main control panel engine oil pressure gauge removed. (WP 0090) Main control panel engine start/stop switch removed. (WP 0091) Equipment Condition (cont.) Main control panel engine OFF/battery drain indicator removed. (WP 0093) Main control panel engine speed resume/idle switch removed. (WP 0094) Main control panel engine speed RPM switch removed. (WP 0095) Main control panel engine speed set switch removed. (WP 0096) Main control panel engine temperature gauge removed. (WP 0097) Main control panel tachometer/hourmeter removed. (WP 0102) Main control panel water level high indicator removed. (WP 0103) Main control panel water level low indicator removed. (WP 0104) Main control panel water sprinkler switches removed. (WP 0105) Main control panel 15 AMP circuit breaker removed. (WP 0078) Water pump inlet gauge and hose removed. (WP 0178) Water pump outlet gauge and hose removed. (WP 0179)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. Note position and location of wire harness through bottom of control panel. All wires are removed from terminal strips the same way. Some sockets may have two wires twisted together. Tag both wires to ensure proper installation. Perform Steps (1) through (14) for engine wire harness. 1. Remove retaining nut (Figure 1, Item 6) and slightly lower engine wiring harness (Figure 1, Item 5) from main control box (Figure 1, Item 4).
0100-1
TM 5-3825-270-23&P
0100
REMOVAL - Continued
1 2 WIRE 3
10
10
10
WIRE
5 15 15
20
20
WIRE
Figure 1. Engine Wire Harness Removal. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 1 and feed through bottom of panel. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 2 and feed through bottom of panel. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 4 and feed through bottom of panel. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 6 and feed through bottom of panel. Remove black wire from positive terminal strip (Figure 1, Item 1) socket 19 and feed through bottom of panel. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 10 and feed through bottom of panel. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 11 and feed through bottom of panel. Remove black wire from interconnect terminal strip (Figure 1, Item 3) socket 14 and feed through bottom of panel. Remove white wire from interconnect terminal strip (Figure 1, Item 3) socket 3 and feed through bottom of panel. Remove white wire from interconnect terminal strip (Figure 1, Item 3) socket 5 and feed through bottom of panel. Remove white wire from interconnect terminal strip (Figure 1, Item 3) socket 7 and feed through bottom of panel. Remove white wire from negative terminal strip (Figure 1, Item 2) socket 10 and feed through bottom of panel. Remove white wire from interconnect terminal strip (Figure 1, Item 3) socket 20 and feed through bottom of panel.
0100-2
TM 5-3825-270-23&P
0100
REMOVAL - Continued 15. Remove white wire from positive terminal strip (Figure 1, Item 1) socket 10 and feed through bottom of panel.
NOTE
Perform Steps (16) through (19) for alternator wiring harness. 16. Remove red wire from positive terminal strip (Figure 2, Item 1) socket 11 and feed through bottom of panel.
1 WIRE 7, 8, 9 3
10
10
10
WIRE
15
15
20
20
11
10
WIRE
Figure 2. Alternator Wire Harness Removal. 17. 18. 19. Remove clear wire from interconnect terminal strip (Figure 2, Item 3) socket 17. Remove nut (Figure 2, Item 7), washer (Figure 2, Item 8), and black wire from screw (Figure 2, Item 9). Remove retaining nut (Figure 2, Item 11) and slightly lower alternator wiring harness (Figure 2, Item 10) from main control box (Figure 2, Item 4).
NOTE
Perform Steps (20) through (37) for UPIK wire harness. 20. Remove retaining nut (Figure 3, Item 13) and slightly lower UPIK wire harness (Figure 3, Item 12) from main control box (Figure 3, Item 4).
0100-3
TM 5-3825-270-23&P
0100
REMOVAL - Continued
WIRE
WIRE
10
10
10
WIRE
5 15 15
20
20
12
13
Figure 3. UPIK Wire Harness Removal. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 2. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 3. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 4. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 5. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 6. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 7. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 8. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 9. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 10. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 11. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 12. Remove black wire from interconnect terminal strip (Figure 3, Item 3) socket 14. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 15. Remove white wire from interconnect terminal strip (Figure 3, Item 3) socket 16. Remove white wire from positive terminal strip (Figure 3, Item 1) socket 7. Remove white wire from positive terminal strip (Figure 3, Item 1) socket 18. Remove black wire from negative terminal strip (Figure 3, Item 2) socket 13.
NOTE
Perform Steps (38) through (40) for work light wire harness.
0100-4
TM 5-3825-270-23&P
0100
REMOVAL - Continued 38. Remove retaining nut (Figure 4, Item 14) and slightly lower work light wire harness (Figure 4, Item 15) from main control box (Figure 4, Item 4).
WIRE
WIRE
10 10 10
15
15
20
20
14
15
Figure 4. Work Light Wire Harness Removal. 39. 40. Remove black wire from negative terminal strip (Figure 4, Item 2) socket 7. Remove red wire from positive terminal strip (Figure 4, Item 1) socket 8.
NOTE
Perform Steps (41) through (45) for sprinkler wire harness. 41. Remove retaining nut (Figure 5, Item 17) and slightly lower sprinkler wire harness (Figure 5, Item 16) from main control box (Figure 5, Item 4).
0100-5
TM 5-3825-270-23&P
0100
REMOVAL - Continued
2 WIRE 3 WIRE
10
10
10
15
15
20
20
17
16
Figure 5. Sprinkler Wire Harness Removal. 42. 43. 44. 45. Remove red wire from interconnect terminal strip (Figure 5, Item 3) socket 13. Remove black wire from negative terminal strip (Figure 5, Item 2) socket 9. Remove white wire from interconnect terminal strip (Figure 5, Item 3) socket 15. Remove green wire from negative terminal strip (Figure 5, Item 2) socket 8.
NOTE
Perform Steps (46) through (48) for water level harness. 46. Remove retaining nut (Figure 6, Item 18) and slightly lower water level harness (Figure 6, Item 19) from main control box (Figure 6, Item 4).
0100-6
TM 5-3825-270-23&P
0100
REMOVAL - Continued
1 WIRE 3
10
10
10
15
15
20
20
WIRE 4
18 19
Figure 6. Water Level Wire Harness Removal. 47. 48. Remove red wire from positive terminal strip (Figure 6, Item 1) socket 17. Remove green wire from interconnect terminal strip (Figure 6, Item 3) socket 11.
NOTE
Perform Steps (49) and (50) for battery wire harness. 49. Remove retaining nut (Figure 7, Item 20) and slightly lower battery wire harness (Figure 7, Item 21) from main control box (Figure 7, Item 4).
2
10
10
10
15
15
20
20
WIRE
21
20
Figure 7. Battery Wire Harness Removal.
0100-7
TM 5-3825-270-23&P
0100
REMOVAL - Continued 50. 51. Remove black wire from negative terminal strip (Figure 7, Item 2) socket 6. Remove two locknuts (Figure 8, Item 23), four washers (Figure 8, Item 24), and two screws (Figure 8, Item 25) from main control box (Figure 8, Item 4) and frame (Figure 8, Item 22). Discard locknuts.
22 23, 24, 25
Figure 8. Main Control Box Removal. 52. Remove three locknuts (Figure 9, Item 23), six washers (Figure 9, Item 24), three screws (Figure 9, Item 25) and main control box (Figure 9, Item 4) from frame (Figure 9, Item 22). Discard locknuts.
0100-8
TM 5-3825-270-23&P
0100
REMOVAL - Continued
22
23, 24, 25
Figure 9. Main Control Box Removal.
NOTE
Note position and location of terminal strips prior to removal to ensure proper installation. Faceplate harness may remain on terminal strips when removing terminal strips from main control box. All terminal strips are removed from main control box the same way. 53. Remove two nuts (Figure 10, Item 26), screws (Figure 10, Item 27), washers (Figure 10, Item 28), lockwashers (Figure 9, Item 29), and positive terminal strip (Figure 10, Item 1) from main control box (Figure 10, Item 4). Discard lockwashers.
1 26, 27, 28, 29
10
10
10
15
15
20
20
Figure 10. Main Control Box Removal.
0100-9
TM 5-3825-270-23&P
0100
REMOVAL - Continued 54. Repeat Step (53) for removal of negative terminal strip (Figure 10, Item 2) and interconnect terminal strip (Figure 10, Item 3).
NOTE
Install terminal strips as noted prior to removal. Faceplate harness may remain on terminal strips when installing terminal strips from main control box. All terminal strips are installed from main control box the same way. 1. Install positive terminal strip (Figure 11, Item 26) on main control box (Figure 11, Item 4) using two screws (Figure 10, Item 27), washers (Figure 10, Item 28), lockwashers (Figure 11, Item 29), and nuts (Figure 10, Item 26).
1 26, 27, 28, 29
10
10
10
15
15
20
20
Figure 11. Main Control Box Installation. 2. 3. Repeat Step (1) for installation of negative terminal strip (Figure 11, Item 2) and interconnect terminal strip (Figure 11, Item 3). Install main control box (Figure 12, Item 4) on frame (Figure 12, Item 22) using three screws (Figure 12, Item 25), six washers (Figure 12, Item 24) and three locknuts (Figure 12, Item 23).
0100-10
TM 5-3825-270-23&P
0100
22
23, 24, 25
Figure 12. Main Control Box Installation. 4. Secure main control box (Figure 13 Item 4) on frame (Figure 13, Item 22) using two screws (Figure 13, Item 25), four washers (Figure 13, Item 24) and two locknuts (Figure 13, Item 23).
22 23, 24, 25
Figure 13. Main Control Box Installation.
0100-11
TM 5-3825-270-23&P
0100
NOTE
Perform Steps (5) through (6) for battery wire harness. 5. Install battery wire harness (Figure 14, Item 21) in main control box (Figure 14, Item 4) with retaining nut (Figure 14, Item 20).
2
10
10
10
15
15
20
20
WIRE
21
20
Figure 14. Battery Wire Harness Installation. 6. Install black wire on negative terminal strip (Figure 14, Item 2) socket 6.
NOTE
Perform Steps (7) through (9) for water level wire harness. 7. Install water level wire harness (Figure 15, Item 19) in main control box (Figure 15, Item 4) with retaining nut (Figure 15, Item 18).
0100-12
TM 5-3825-270-23&P
0100
1 WIRE 3
10
10
10
15
15
20
20
WIRE 4
18 19
Figure 15. Water Level Wire Harness Installation. 8. 9. Install green wire on interconnect terminal strip (Figure 15, Item 3) socket 11. Install red wire on positive terminal strip (Figure 15, Item 1) socket 17.
NOTE
Perform Steps (10) through (14) for sprinkler wire harness. 10. Install sprinkler wire harness (Figure 16, Item 16) in main control box (Figure 16, Item 4) with retaining nut (Figure 16, Item 17).
2 WIRE 3 WIRE
10
10
10
15
15
20
20
17
16
Figure 16. Sprinkler Wire Harness Installation.
0100-13
TM 5-3825-270-23&P
0100
INSTALLATION - Continued 11. 12. 13. 14. Install green wire on negative terminal strip (Figure 16, Item 2) socket 8. Install white wire on interconnect terminal strip (Figure 16, Item 3) socket 15. Install black wire on negative terminal strip (Figure 16, Item 2) socket 9. Install red wire on interconnect terminal strip (Figure 16 , Item 3) socket 13.
NOTE
Perform Steps (15) through (17) work light harness. 15. Install work light harness (Figure 17, Item 15) in main control box (Figure 17, Item 4) with retaining nut (Figure 17, Item 14).
WIRE
WIRE
10 10 10
15
15
20
20
14
15
Figure 17. Work Light Wire Harness Installation. 16. 17. Install red wire on positive terminal strip (Figure 17, Item 1) socket 8. Install black wire on negative terminal strip (Figure 17, Item 2) socket 7.
NOTE
Perform Steps (18) through (36) for UPIK wire harness. 18. Install UPIK wire harness (Figure 18, Item 12) in main control box (Figure 18, Item 4) with retaining nut (Figure 18, Item 13).
0100-14
TM 5-3825-270-23&P
0100
WIRE
WIRE
10
10
10
WIRE
5 15 15
20
20
12
13
Figure 18. UPIK Wire Harness Installation. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. Install black wire on negative terminal strip (Figure 18, Item 2) socket 13. Install white wire on positive terminal strip (Figure 18, Item 1) socket 18. Install white wire on positive terminal strip (Figure 18, Item 1) socket 7. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 16. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 15. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 14. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 12. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 11. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 10. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 9. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 8. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 7. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 6. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 5. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 4. Install white wire on interconnect terminal strip (Figure 18, Item 3) socket 3. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 2. Install black wire on interconnect terminal strip (Figure 18, Item 3) socket 1.
NOTE
Perform Step (37) through (40) for alternator wire harness.
0100-15
TM 5-3825-270-23&P
0100
INSTALLATION - Continued 37. Install alternator wire harness (Figure 19, Item 10) in main control box (Figure 19, Item 4) with retaining nut (Figure 19, Item 11).
1 WIRE 7, 8, 9 3
10
10
10
WIRE
15
15
20
20
11
10
WIRE
Figure 19. Alternator Wire Harness Installation. 38. 39. 40. Install black wire on screw (Figure 19, Item 9) with washer (Figure 19, Item 8) and nut (Figure 19, Item 7). Install clear wire on interconnect terminal strip (Figure 19, Item 3) socket 17. Install red wire on positive terminal strip (Figure 19, Item 1) socket 11.
NOTE
Perform Steps (41) through (55) for engine wire harness. 41. Install engine wire harness (Figure 20, Item 5) in main control box (Figure 20, Item 4) with retaining nut (Figure 20, Item 6).
0100-16
TM 5-3825-270-23&P
0100
1 2 WIRE 3
10
10
10
WIRE
5 15 15
20
20
WIRE
Figure 20. Engine Wire Harness Installation. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. Install white wire on interconnect terminal strip (Figure 20, Item 3) socket 20. Remove white wire on negative terminal strip (Figure 20, Item 2) socket 10. Remove white wire on interconnect terminal strip (Figure 20, Item 3) socket 7. Remove white wire on interconnect terminal strip (Figure 20, Item 3) socket 5. Remove white wire on interconnect terminal strip (Figure 20, Item 3) socket 3. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 14. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 11. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 10. Remove black wire on positive terminal strip (Figure 20, Item 1) socket 19. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 6. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 4. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 2. Remove black wire on interconnect terminal strip (Figure 20, Item 3) socket 1. Install white wire on positive terminal strip (Figure 20, Item 1) socket 10.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install water pump outlet gauge and hose. (WP 0179) Install water pump inlet gauge and hose. (WP 0178) Install main control panel 15 AMP circuit breaker. (WP 0078)
0100-17
TM 5-3825-270-23&P
0100
FOLLOW-ON MAINTENANCE - Continued 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Install main control panel water sprinkler switches. (WP 0105) Install main control panel water level low indicator. (WP 0104) Install main control panel water level high indicator. (WP 0103) Install main control panel tachometer/hourmeter. (WP 0102) Install main control panel engine temperature gauge. (WP 0097). Install main control panel engine speed set switch. (WP 0096) Install main control panel engine speed RPM switch. (WP 0095) Install main control panel engine speed resume/idle switch. (WP 0094) Install main control panel engine OFF/battery drain indicator. (WP 0093) Install main control panel engine start/stop switch. (WP 0091) Install main control panel engine oil pressure gauge. (WP 0090) Install main control panel light switch. (WP 0089) Install main control panel emergency stop pushbutton. (WP 0088) Install main control panel battery voltage gauge. (WP 0087) Connect batteries. (WP 0085)
0100-18
TM 5-3825-270-23&P
0101
FIELD MAINTENANCE NATO SLAVE CONNECTOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 77) Qty: 4 Materials/Parts (cont.) Lockwasher (WP 0226, Table 1, Item 75) Qty: 2 Locknut (WP 0226, Table 1, Item 63) Qty: 4 References Parts Manual (WP 0220) Figure 4009 Equipment Condition Batteries removed. (WP 0086)
REMOVAL 1. Remove four locknuts (Figure 1, Item 4), screws (Figure 1, Item 2), washers (Figure 1, Item 3), and NATO slave box (Figure 1, Item 5) from battery box (Figure 1, Item 1). Discard locknuts.
1 2, 3, 4
Figure 1. NATO Slave Box Removal. 2. Remove screw (Figure 2, Item 7), lockwasher (Figure 2, Item 8), and negative battery cable (Figure 2, Item 6) from NATO slave receptacle (Figure 2, Item 9). Discard lockwasher.
0101-1
TM 5-3825-270-23&P
0101
REMOVAL - Continued
6 7
Figure 2. NATO Slave Cable Removal. 3. Remove four locknuts (Figure 3, Item 11), screws (Figure 3, Item 10), lanyard (Figure 3, Item 14), cover (Figure 3, Item 12), and NATO slave receptacle (Figure 3, Item 9) from NATO slave box (Figure 3, Item 5). Discard locknuts.
9 10, 11
12 5
14
Figure 3. NATO Slave Connector Removal. 4. Rotate NATO slave box (Figure 4, Item 5) around NATO slave receptacle (Figure 4, Item 9) so that positive battery cable (Figure 4 Item 18) is visible.
0101-2
TM 5-3825-270-23&P
0101
REMOVAL - Continued
15 16
17 18 19
Figure 4. NATO Slave Cable Removal. 5. 6. 7. Pull back protective cover (Figure 4, Item 19) on positive battery cable (Figure 4, Item 18) to expose screw (Figure 4, Item 17). Remove screw (Figure 4, Item 17), lockwasher (Figure 4, Item 16), and positive battery cable (Figure 4, Item 18) from NATO slave receptacle (Figure 4, Item 9). Discard lockwasher. Remove NATO slave receptacle (Figure 4, Item 9), gasket (Figure 4, Item 15), and NATO slave box (Figure 4, Item 5) from positive battery cable (Figure 4, Item 18) and negative battery cable (Figure 4, Item 6).
END OF TASK INSTALLATION 1. Install NATO slave box (Figure 5, Item 5) over positive battery cable (Figure 5, Item 18) and negative battery cable (Figure 5, Item 6).
15 16
17 18 19
Figure 5. NATO Slave Cable Installation. 2. Install gasket (Figure 5, Item 15) and NATO slave receptacle (Figure 5, Item 9) on NATO slave box (Figure 5, Item 5). Do not install screws.
0101-3
TM 5-3825-270-23&P
0101
NOTE
Battery cables and slave receptacle are marked + (Positive) and (Negative) to ensure proper installation. 3. 4. 5. Install positive battery cable (Figure 5, Item 18) on NATO slave receptacle (Figure 5 Item 9) with screw (Figure 5, Item 17) and lockwasher (Figure 5, Item 16). Install protective cover (Figure 5, Item 19) on positive battery cable (Figure 5, Item 18). Rotate NATO slave box (Figure 6, Item 5) around NATO slave receptacle (Figure 6, Item 9) so that negative battery cable (Figure 6, Item 6) is visible.
6 7
Figure 6. NATO Slave Cable Installation. 6. 7. Install negative battery cable (Figure 6, Item 6) on NATO slave receptacle (Figure 6, Item 9) with screw (Figure 6, Item 7) and lockwasher (Figure 6, Item 8). Install lanyard (Figure 7, Item 14), cover (Figure 7, Item 12), and NATO slave receptacle (Figure 7, Item 9) on NATO slave box (Figure 7, Item 5) with four screws (Figure 7, Item 10) and locknuts (Figure 7, Item 11).
0101-4
TM 5-3825-270-23&P
0101
9 10, 11
12 5
14
Figure 7. NATO Slave Connector Installation. 8. Install NATO slave box (Figure 8, Item 5) onto battery box (Figure 8, Item 1) with four screws (Figure 8, Item 2), washers (Figure 8, Item 3), and locknuts (Figure 8, Item 4).
1 2, 3, 4
Figure 8. NATO Slave Box Installation. END OF TASK
0101-5
TM 5-3825-270-23&P
0101
FOLLOW-ON MAINTENANCE Install batteries. (WP 0086) END OF TASK END OF WORK PACKAGE
0101-6
TM 5-3825-270-23&P
0102
FIELD MAINTENANCE MAIN CONTROL PANEL TACHOMETER/HOURMETER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Materials/Parts (cont.) Tags, Identification, White (WP 0224, Table 1, Item 54) Lockwasher (WP 0226, Table 1, Item 7) Qty: 1 References Parts Manual (WP 0220) Figure 4018 Equipment Condition Batteries disconnected. (WP 0085)
1 2
Figure 1. Main Control Panel Tachometer/Hourmeter Removal.
CAUTION
0102-1
TM 5-3825-270-23&P
0102
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Tachometer/Hourmeter Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove nut (Figure 3, Item 15), washer (Figure 3, Item 16), and two black wires (Figure 3, Item 13) from ground stud (Figure 3, Item 14).
7 8 9 10 11, 12
15, 16 14
13
Figure 3. Main Control Panel Tachometer/Hourmeter Removal. 4. 5. 6. Remove nut (Figure 3, Item 7), white wire (Figure 3, Item 9), and red wire (Figure 3, Item 10) from +24 vdc stud (Figure 3, Item 8). Disconnect yellow wire (Figure 3, Item 11) from terminal (Figure 3, Item 12). Remove nut (Figure 4, Item 22), lockwasher (Figure 4, Item 23), washer (Figure 4, Item 24), and grey wire (Figure 4, Item 17) from stud (Figure 4, Item 21). Discard lockwasher.
0102-2
TM 5-3825-270-23&P
0102
REMOVAL - Continued
17 14 18 19 20
21 22, 23, 24
Figure 4. Main Control Panel Tachometer/Hourmeter Removal. 7. 8. Remove two nuts (Figure 4, Item 18) and circuit board (Figure 4, Item 20) from stud (Figure 4, Item 14) and stud (Figure 4, Item 19). Remove two lockwashers (Figure 5, Item 29) from stud (Figure 5, Item 14) and stud (Figure 5, Item 19).
25
26, 27, 28
21
14
29
19
30, 31, 33
33 34
36
35
Figure 5. Main Control Panel Tachometer/Hourmeter Removal. 9. 10. 11. Remove nut (Figure 5, Item 33) from stud (Figure 5, Item 14). Remove nut (Figure 5, Item 34) from stud (Figure 5, Item 21). Remove nut (Figure 5, Item 30), lockwasher (Figure 5, Item 31), and washer (Figure 5, Item 32) from stud (Figure 5, Item 19).
0102-3
TM 5-3825-270-23&P
0102
REMOVAL - Continued 12. Remove nut (Figure 5, Item 26), lockwasher (Figure 5, Item 27), and washer (Figure 5, Item 28) from stud (Figure 5, Item 25).
NOTE
Note position of tachometer/hourmeter prior to removal to ensure proper installation. 13. Remove retainer (Figure 5, Item 35) and tachometer/hourmeter (Figure 5, Item 36) from control panel (Figure 5, Item 6).
NOTE
Install tachometer/hourmeter as noted prior to removal. 1. Position tachometer/hourmeter (Figure 6, Item 36) in control panel (Figure 6, Item 6).
25
26, 27, 28
21
14
29
19
30, 31, 33
33 34
36
35
Figure 6. Main Control Panel Tachometer/Hourmeter Installation. 2. 3. 4. 5. 6. 7. Position retainer (Figure 6, Item 35) on tachometer/hourmeter (Figure 6, Item 36). Install retainer (Figure 6, Item 35) on stud (Figure 6, Item 25) with washer (Figure 6, Item 28), lockwasher (Figure 6, Item 27), and nut (Figure 6, Item 26). Install retainer (Figure 6, Item 35) on stud (Figure 6, Item 19) with washer (Figure 6, Item 32), lockwasher (Figure 6, Item 31), and nut (Figure 6, Item 30). Install nut (Figure 6, Item 34) on stud (Figure 6, Item 21). Install nut (Figure 6, Item 33) on stud (Figure 6, Item 14). Tighten nut until it is parallel with nut (Figure 6, Item 30). Position lockwashers (Figure 6, Item 29) on stud (Figure 6, Item 19) and stud (Figure 6, Item 14).
0102-4
TM 5-3825-270-23&P
0102
CAUTION
Do not over-tighten nuts on circuit board. Failure to comply will result in damage to equipment. 8. Install circuit board (Figure 7, Item 20) on stud (Figure 7, Item 19) and stud (Figure 7, Item 14) with two nuts (Figure 7, Item 18).
17 14 18 19 20
21 22, 23, 24
Figure 7. Main Control Panel Tachometer/Hourmeter Installation.
NOTE
Install wires as noted prior to removal. 9. 10. Install grey wire (Figure 7, Item 17) on stud (Figure 7, Item 21) with washer (Figure 7, Item 24), lockwasher (Figure 7, Item 23), and nut (Figure 7, Item 22). Connect yellow wire (Figure 8, Item 11) to terminal (Figure 8, Item 12).
7 8 9 10 11, 12
15, 16 14
13
Figure 8. Main Control Panel Tachometer/Hourmeter Installation.
0102-5
TM 5-3825-270-23&P
0102
CAUTION
Do not over-tighten nuts on circuit board. Failure to comply will result in damage to equipment. 11. 12. Install white wire (Figure 8, Item 9) and red wire (Figure 8, Item 10) on +24 vdc stud (Figure 8, Item 8) with nut (Figure 8, Item 7). Install two black wires (Figure 8, Item 13) on ground stud (Figure 8, Item 14) with washer (Figure 8, Item 16) and nut (Figure 8, Item 15).
WARNING
3, 4
Figure 9. Main Control Panel Tachometer/Hourmeter Installation. 14. 15. Install six washers (Figure 9, Item 4) and screws (Figure 9, Item 3) on main control box (Figure 9, Item 5) and control panel (Figure 9, Item 6). Tighten six screws securely. Close control panel cover (Figure 10, Item 1) and secure with rubber t-handle (Figure 10, Item 2).
0102-6
TM 5-3825-270-23&P
0102
1 2
Figure 10. Main Control Panel Tachometer/Hourmeter Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0102-7/8 blank
TM 5-3825-270-23&P
0103
FIELD MAINTENANCE MAIN CONTROL PANEL WATER LEVEL HIGH INDICATOR REPLACEMENT
1 2
Figure 1. Main Control Panel Water Level High Indicator Removal.
CAUTION
0103-1
TM 5-3825-270-23&P
0103
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Water Level High Indicator Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Disconnect green wire (Figure 3, Item 11) from water high level indicator (Figure 3, Item 8).
9, 10
11 5
Figure 3. Main Control Panel Water Level High Indicator Removal. 4. 5. Disconnect black wire (Figure 3, Item 7) from water high level indicator (Figure 3, Item 8). Remove nut (Figure 3, Item 9), washer (Figure 3, Item 10), and water high level indicator (Figure 3, Item 8) from control panel (Figure 3, Item 5).
END OF TASK INSTALLATION 1. Install water high level indicator (Figure 4, Item 8) in control panel (Figure 4, Item 5) with washer (Figure 4, Item 10) and nut (Figure 4, Item 9).
0103-2
TM 5-3825-270-23&P
0103
9, 10
11 5
Figure 4. Main Control Panel Water Level High Indicator Installation.
NOTE
Install wires as noted prior to removal. 2. 3. Connect black wire (Figure 4, Item 7) to water high level indicator (Figure 4, Item 8). Connect green wire (Figure 4, Item 11) to water high level indicator (Figure 4, Item 8).
WARNING
3, 4
Figure 5. Main Control Panel Water Level High Indicator Installation.
0103-3
TM 5-3825-270-23&P
0103
1 2
Figure 6. Main Control Panel Water Level High Indicator Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0103-4
TM 5-3825-270-23&P
0104
FIELD MAINTENANCE MAIN CONTROL PANEL WATER LEVEL LOW INDICATOR REPLACEMENT
1 2
Figure 1. Main Control Panel Water Level Low Indicator Removal.
CAUTION
0104-1
TM 5-3825-270-23&P
0104
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Water Level Low Indicator Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Disconnect green wire with white stripe (Figure 3, Item 7) from water level low indicator (Figure 3, Item 8).
11 9, 10 6
Figure 3. Main Control Panel Water Level Low Indicator Removal. 4. 5. Disconnect black wire (Figure 3, Item 11) from water level low indicator (Figure 3, Item 8). Remove nut (Figure 3, Item 9), washer (Figure 3, Item 10), and water level low indicator (Figure 3, Item 8) from control panel (Figure 3, Item 6).
END OF TASK INSTALLATION 1. Install water level low indicator (Figure 4, Item 8) on control panel (Figure 4, Item 6) with washer (Figure 4, Item 10) and nut (Figure 4, Item 9).
0104-2
TM 5-3825-270-23&P
0104
11 9, 10 6
Figure 4. Main Control Panel Water Level Low Indicator Installation.
NOTE
Install wires as noted prior to removal. 2. 3. Connect black wire (Figure 4, Item 11) to water level low indicator (Figure 4, Item 8). Connect green wire with white stripe (Figure 4, Item 7) to water level low indicator (Figure 4, Item 8).
WARNING
3, 4
Figure 5. Main Control Panel Water Level Low Indicator Installation.
0104-3
TM 5-3825-270-23&P
0104
1 2
Figure 6. Main Control Panel Water Level Low Indicator Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0104-4
TM 5-3825-270-23&P
0105
FIELD MAINTENANCE MAIN CONTROL PANEL WATER SPRINKLER SWITCH REPLACEMENT
REMOVAL
NOTE
Both left water sprinkler switch and right water sprinkler switch are removed the same way except where noted. 1. Open control panel cover (Figure 1, Item 1) by releasing rubber t-handle (Figure 1, Item 2).
1 2
Figure 1. Main Control Panel Water Sprinkler Switch Removal.
CAUTION
0105-1
TM 5-3825-270-23&P
0105
REMOVAL - Continued
3, 4
Figure 2. Main Control Panel Water Sprinkler Switch Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. Perform Steps (3) through (5) for main control panel right water sprinkler switch. 3. Loosen screw (Figure 3, Item 7) and remove purple wire (Figure 3, Item 8) from main control panel water sprinkler switch (Figure 3, Item 15).
7, 8
9, 10 11, 12 15 13, 14
18, 19
16, 17
15
Figure 3. Main Control Panel Water Sprinkler Switch Removal. 4. 5. Loosen screw (Figure 3, Item 16) and remove blue wire with red stripe (Figure 3, Item 17) from main control panel water sprinkler switch (Figure 3, Item 15). Loosen screw (Figure 3, Item 18) and remove two white wires (Figure 3, Item 19) from main control panel water sprinkler switch (Figure 3, Item 15).
NOTE
Tag and mark wires prior to removal to ensure proper installation. Perform Steps (6) through (8) for main control panel left water sprinkler switch.
0105-2
TM 5-3825-270-23&P
0105
REMOVAL - Continued 6. 7. 8. 9. Loosen screw (Figure 3, Item 9) and remove blue wire with white stripe (Figure 3, Item 10) from main control panel water sprinkler switch (Figure 3, Item 15). Loosen screw (Figure 3, Item 11) and remove blue wire with black stripe (Figure 3, Item 12) from main control panel water sprinkler switch (Figure 3, Item 15). Loosen screw (Figure 3, Item 13) and remove white wire (Figure 3, Item 14) from main control panel water sprinkler switch (Figure 3, Item 15). Remove toggle switch seal (Figure 4, Item 21) from main control panel water sprinkler switch (Figure 4, Item 15).
20 20
15, 21
15, 21
Figure 4. Main Control Panel Water Sprinkler Switch Removal. 10. Remove nut (Figure 4, Item 20) and main control panel water sprinkler switch (Figure 4, Item 15) from control panel (Figure 4, Item 6).
END OF TASK INSTALLATION 1. Install main control panel water sprinkler switch (Figure 5, Item 15) on control panel (Figure 5, Item 6) with nut (Figure 6, Item 20).
0105-3
TM 5-3825-270-23&P
0105
20 20
15, 21
15, 21
Figure 5. Main Control Panel Water Sprinkler Switch Installation. 2. Install toggle switch seal (Figure 5, Item 21) on main control panel water sprinkler switch (Figure 5, Item 15).
NOTE
Install wires as noted prior to removal. Perform Steps (3) through (5) for main control panel left water sprinkler switch. 3. Install white wire (Figure 6, Item 14) on main control panel water sprinkler switch (Figure 6, Item 15) and tighten screw (Figure 6, Item 13).
7, 8
9, 10 11, 12 15 13, 14
18, 19
16, 17
15
Figure 6. Main Control Panel Water Sprinkler Switch Installation. 4. 5. Install blue wire with black stripe (Figure 6, Item 12) on main control panel water sprinkler switch (Figure 6, Item 15) and tighten screw (Figure 6, Item 11). Install blue wire with white stripe (Figure 6, Item 10) on main control panel water sprinkler switch (Figure 6, Item 15) and tighten screw (Figure 6, Item 9).
NOTE
Install wires as noted prior to removal.
0105-4
TM 5-3825-270-23&P
0105
INSTALLATION - Continued Perform Steps (6) through (8) for main control panel right water sprinkler switch. 6. 7. 8. Install two white wires (Figure 6, Item 19) on main control panel water sprinkler switch (Figure 6, Item 15) and tighten screw (Figure 6, Item 18). Install blue wire with red stripe (Figure 6, Item 17) on main control panel water sprinkler switch (Figure 6, Item 15) and tighten screw (Figure 6, Item 16). Install purple wire (Figure 6, Item 8) on main control panel water sprinkler switch (Figure 6, Item 15) and tighten screw (Figure 6, Item 7).
WARNING
3, 4
Figure 7. Main Control Panel Water Sprinkler Switch Installation. 10. 11. Install six washers (Figure 7, Item 4) and screws (Figure 7, Item 3) on main control box (Figure 7, Item 5) and control panel (Figure 7, Item 6). Tighten six screws securely. Close control panel cover (Figure 8, Item 1) and secure with rubber t-handle (Figure 8, Item 2).
0105-5
TM 5-3825-270-23&P
0105
1 2
Figure 8. Main Control Panel Water Sprinkler Switch Installation. END OF TASK FOLLOW-ON MAINTENANCE Connect batteries. (WP 0085) END OF TASK END OF WORK PACKAGE
0105-6
TM 5-3825-270-23&P
0106
FIELD MAINTENANCE WORK LIGHT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Cable Ties (WP 0224, Table 1, Item 9) Materials/Parts (cont.) Locknut (WP 0226, Table 1, Item 65) Qty: 1 Lockwasher (WP 0226, Table 1, Item 60) Qty: 1 References Parts Manual (WP 0220) Figure 4013 Equipment Condition Batteries disconnected. (WP 0085)
REMOVAL
NOTE
Right and left work lights are removed the same way. Right side shown. Remove cable ties as required. 1. Disconnect connector (Figure 1, Item 6) from connector (Figure 1, Item 7).
0106-1
TM 5-3825-270-23&P
0106
REMOVAL - Continued
4 5
Figure 1. Work Light Removal. 2. 3. Remove locknut (Figure 1, Item 4), lockwasher (Figure 1, Item 2), and washer (Figure 1, Item 1) from work light (Figure 1, Item 5) and flatrack (Figure 1, Item 3). Discard locknut and lockwasher. Remove work light (Figure 2, Item 5) and base (Figure 2, Item 8) from flatrack (Figure 2, Item 3).
0106-2
TM 5-3825-270-23&P
0106
REMOVAL - Continued
Figure 2. Work Light Removal. 4. Repeat Steps (1) thru (3) for left side.
NOTE
Right and left side work lights are installed the same way. Right side shown. Install cable ties as required. 1. Install base (Figure 3, Item 8) and work light (Figure 3, Item 5) on flatrack (Figure 3, Item 3).
0106-3
TM 5-3825-270-23&P
0106
Figure 3. Work Light Installation. 2. Install washer (Figure 4, Item 1), lockwasher (Figure 4, Item 2), and locknut (Figure 4, Item 4), on work light (Figure 4, Item 5) and flatrack (Figure 4, Item 3).
4 5
Figure 4. Work Light Installation.
0106-4
TM 5-3825-270-23&P
0106
INSTALLATION - Continued 3. 4. Connect connector (Figure 4, Item 7) to connector (Figure 4, Item 6). Repeat Steps (1) thru (3) for left side.
0106-5/6 blank
TM 5-3825-270-23&P
0107
FIELD MAINTENANCE WORK LIGHT WIRE HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Materials/Parts (cont.) Cable Ties (WP 0224, Table 1, Item 9) Tags, Identification, White (WP 0224, Table 1, Item 54) References Parts Manual (WP 0220) Figure 4018 Equipment Condition Batteries disconnected. (WP 0085) Air valve cover plate removed. (WP 0164)
REMOVAL
NOTE
Remove cable ties as required. 1. Open control panel cover (Figure 1, Item 1) by releasing rubber t-handle (Figure 1, Item 2).
1 2
Figure 1. Work Light Wire Harness Removal.
CAUTION
0107-1
TM 5-3825-270-23&P
0107
REMOVAL - Continued
3, 4
Figure 2. Work Light Wire Harness Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove black wire (Figure 3, Item 9) from terminal B (Figure 3, Item 8).
7 8
9, 10
Figure 3. Work Light Wire Harness Removal. 4. 5. Remove red wire (Figure 3, Item 10) from terminal C (Figure 3, Item 7). Loosen nut (Figure 4, Item 11) and remove wire harness (Figure 4, Item 12) from main control box (Figure 4, Item 5).
0107-2
TM 5-3825-270-23&P
0107
REMOVAL - Continued
11
12
Figure 4. Work Light Wire Harness Removal. 6. Disconnect wire connector (Figure 5, Item 14) from left work light (Figure 5, Item 13).
13
14
Figure 5. Work Light Wire Harness Removal. 7. Remove eight nuts (Figure 7, Item 15), eight screws (Figure 7, Item 16), and eight clips (Figure 7, Item 17) from main frame (Figure 7, Item 18) and remove wire harness (Figure 7, Item 12).
0107-3
TM 5-3825-270-23&P
0107
REMOVAL - Continued
15, 16, 17 18 12
Figure 6. Work Light Wire Harness Removal. END OF TASK INSTALLATION
NOTE
Install cable ties as required. 1. Install wire harness (Figure 7, Item 12) on main frame (Figure 7, Item 18) with eight clips (Figure 7, Item 17), eight screws (Figure 7, Item 16), and eight nuts (Figure 7, Item 15).
15, 16, 17 18 12
Figure 7. Work Light Wire Harness Installation. 2. Connect wire connector (Figure 8, Item 14) on left work light (Figure 8, Item 13).
0107-4
TM 5-3825-270-23&P
0107
13
14
Figure 8. Work Light Wire Harness Installation. 3. Install wire harness (Figure 9, Item 12) in main control box (Figure 9, Item 5) and tighten two nuts (Figure 9, Item 11).
11
12
Figure 9. Work Light Wire Harness Installation.
NOTE
Install wires as noted prior to removal. 4. Install red wire (Figure 10, Item 10) on terminal C (Figure 10, Item 7).
0107-5
TM 5-3825-270-23&P
0107
7 8
9, 10
Figure 10. Work Light Wire Harness Installation. 5. Install black wire (Figure 10, Item 9) on terminal B (Figure 10, Item 8).
WARNING
3, 4
Figure 11. Work Light Wire Harness Installation. 7. 8. Install six washers (Figure 11, Item 4) and screws (Figure 11, Item 3) on main control box (Figure 11, Item 5) and control panel (Figure 11, Item 6). Tighten six screws securely. Close control panel cover (Figure 12, Item 1) and secure with rubber t-handle (Figure 12, Item 2).
0107-6
TM 5-3825-270-23&P
0107
1 2
Figure 12. Work Light Wire Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install air valve cover plate. (WP 0164) Connect batteries. (WP 0085)
0107-7/8 blank
TM 5-3825-270-23&P
0108
FIELD MAINTENANCE UPIK WIRE HARNESS REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Jack, Hyd, 20 Ton Cap (WP 0225, Table 1, Item 2) Block, Filler Wood, 3 in. Thick (WP 0225, Table 1, Item 2) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Materials/Parts (cont.) Cable Ties (WP 0224, Table 1, Item 9) Tags, Identification, White (WP 0224, Table 1, Item 54) Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4018 Equipment Condition Batteries disconnected. (WP 0085) Water tank drained. (TM 5382527010) Hoses unstowed. (TM 5-3825-270-10) Floating strainer unstowed. (TM 5-3825-270-10)
1 2
Figure 1. UPIK Wire Harness Removal.
CAUTION
0108-1
TM 5-3825-270-23&P
0108
REMOVAL - Continued
3, 4
NOTE
Tag and mark wires prior to removal to ensure proper installation. All wires are removed from terminal strips the same way. 3. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 1.
6 7 8 9
WIRE
WIRE
WIRE
10 11
Figure 3. UPIK Wire Harness Removal. 4. 5. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 2. Remove white wire from interconnect terminal strip (Figure 3, Item 9) socket 3.
0108-2
TM 5-3825-270-23&P
0108
REMOVAL - Continued 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 4. Remove white wire from interconnect terminal strip (Figure 3, Item 9) socket 5. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 6. Remove white wire from interconnect terminal strip (Figure 3, Item 9) socket 7. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 8. Remove white wire from interconnect terminal strip (Figure 3, Item 8) socket 9. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 10. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 11. Remove white wire from interconnect terminal strip (Figure 3, Item 9) socket 12. Remove black wire from interconnect terminal strip (Figure 3, Item 9) socket 14. Remove white wire from interconnect terminal strip (Figure 3, Item 9) socket 15. Remove white wire from interconnect terminal strip (Figure 3, Item 9) socket 16. Remove white wire from positive terminal strip (Figure 3, Item 7) socket 7. Remove white wire from positive terminal strip (Figure 3, Item 7) socket 18. Remove black wire from negative terminal strip (Figure 3, Item 8) socket 13. Remove retaining nut (Figure 3, Item 10) and UPIK wire harness (Figure 3, Item 11) from main control box (Figure 3, Item 6).
WARNING
Water Distributor weighs in excess of 8,500 lbs (3,856 kg). Ensure that personnel are clear during lifting operations. Failure to comply may result in injury or death to personnel. 22. Using jack, raise and support front of water distributor (Figure 4, Item 12) with wood blocks.
0108-3
TM 5-3825-270-23&P
0108
REMOVAL - Continued
12
NOTE
Note position and remove cable ties as required. Note position and remove cushion clips as required. Note routing of wire harness prior to removal to ensure proper installation. 23. Remove UPIK wire harness (Figure 5, Item 11) from water distributor (Figure 5, Item 12).
0108-4
TM 5-3825-270-23&P
0108
REMOVAL - Continued
12
11
Figure 5. UPIK Wire Harness Removal. END OF TASK INSTALLATION
NOTE
Route wiring harness as noted prior to removal. Install cushion clips as noted prior to removal. Install cable ties as required. 1. Install UPIK wire harness (Figure 6, Item 11) on water distributor (Figure 6, Item 12).
0108-5
TM 5-3825-270-23&P
0108
12
11
Figure 6. UPIK Wire Harness Installation.
WARNING
Water Distributor weighs in excess of 8,500 lbs (3,856 kg). Ensure that personnel are clear during lifting operations. Failure to comply may result in injury or death to personnel. 2. Remove wood blocks and lower water distributor (Figure 7, Item 12) with jack.
0108-6
TM 5-3825-270-23&P
0108
12
Figure 7. UPIK Wire Harness Installation. 3. Install UPIK wire harness (Figure 8, Item 11) in main control box (Figure 8, Item 6) with retaining nut (Figure 8, Item 10).
0108-7
TM 5-3825-270-23&P
0108
6 7 8 9
WIRE
WIRE
WIRE
10 11
Figure 8. UPIK Wire Harness Installation.
NOTE
Install wires as noted prior to removal. All wires are installed on terminal strips the same way. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Install white wire on interconnect terminal strip (Figure 8, Item 9) socket 16. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 15. Install white wire on interconnect terminal strip (Figure 8, Item 9) socket 12. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 11. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 10. Install white wire on interconnect terminal strip (Figure 8, Item 9) socket 9. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 8. Install white wire on interconnect terminal strip (Figure 8, Item 9) socket 7. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 6. Install white wire on interconnect terminal strip (Figure 8, Item 9) socket 5. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 4. Install white wire on interconnect terminal strip (Figure 8, Item 9) socket 3. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 2. Install black wire on interconnect terminal strip (Figure 8, Item 9) socket 1. Install black wire on negative terminal strip (Figure 8, Item 8) socket 13.
0108-8
TM 5-3825-270-23&P
0108
INSTALLATION - Continued 19. 20. Install white wire on positive terminal strip (Figure 8, Item 7) socket 18. Install white wire on positive terminal strip (Figure 8, Item 7) socket 7.
WARNING
3, 4
Figure 9. UPIK Wire Harness Installation. 22. 23. Install six washers (Figure 9, Item 4) and screws (Figure 9, Item 3) on main control box (Figure 9, Item 5) and control panel (Figure 9, Item 6). Tighten six screws securely. Close control panel cover (Figure 10, Item 2) and secure with rubber t-handle (Figure 10, Item 1).
0108-9
TM 5-3825-270-23&P
0108
1 2
Figure 10. UPIK Wire Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Stow floating strainer. (TM 5-3825-270-10) Stow fill hoses. (TM 5-3825-270-10) Connect batteries. (WP 0085)
0108-10
TM 5-3825-270-23&P
0109
FIELD MAINTENANCE AIR HOSE INTAKE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4021 Equipment Condition Engine compartment cover removed. (WP 0142)
REMOVAL
WARNING
Engine components become hot during normal operation. Allow engine to cool completely prior to performing this task. If necessary, use insulated pads and gloves. Failure to comply may result in injury or death to personnel. Loosen clamp (Figure 1, Item 1) and remove air hose intake (Figure 1, Item 2) from intake manifold (Figure 1, Item 3).
3
Figure 1. Air Hose Intake Removal. END OF TASK
0109-1
TM 5-3825-270-23&P
0109
INSTALLATION Install air hose intake (Figure 2, Item 2) onto intake manifold (Figure 2, Item 3) with clamp (Figure 2, Item 1).
3
Figure 2. Air Hose Intake Installation. END OF TASK FOLLOW-ON MAINTENANCE Install engine compartment cover. (WP 0142) END OF TASK END OF WORK PACKAGE
0109-2
TM 5-3825-270-23&P
0110
FIELD MAINTENANCE CRANKSHAFT PULLEY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive (WP 0225, Table 1, Item 15) References Parts Manual (WP 0220) Figure 4043 Equipment Condition Alternator belt removed. (WP 0080) Radiator removed. (WP 0076)
REMOVAL
NOTE
Pulley must be held when removing screw. 1. Remove screw (Figure 1, Item 2) from crankshaft pulley (Figure 1, Item 1).
1 2
Figure 1. Crankshaft Pulley Removal. 2. Remove crankshaft pulley (Figure 2, Item 1) from crankshaft (Figure 2, Item 3).
0110-1
TM 5-3825-270-23&P
0110
REMOVAL - Continued
Figure 2. Crankshaft Pulley Removal. END OF TASK INSTALLATION 1. Install crankshaft pulley (Figure 3, Item 1) on crankshaft (Figure 3, Item 3).
Figure 3. Crankshaft Pulley Installation.
NOTE
Pulley must be held when tightening screw. 2. Install screw (Figure 4, Item 2) on crankshaft pulley (Figure 4, Item 1). Tighten screw to 188-202 lb ft (255-274 Nm).
0110-2
TM 5-3825-270-23&P
0110
1 2
Figure 4. Crankshaft Pulley Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install alternator belt. (WP 0080) Install radiator. (WP 0076)
0110-3/4 blank
TM 5-3825-270-23&P
0111
FIELD MAINTENANCE ENGINE CRANKSHAFT FRONT SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Seal Installer (WP 0225, Table 1, Item 6) Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Oil, Lubricating,OE/HDO 10 (MIL-PRF-2104) (WP 0224, Table 1, Item 46, 47, 48) Seal (WP 0226, Table 1, Item 28) Qty: 1 References Parts Manual (WP 0220) Figure 4029 Equipment Condition Crankshaft pulley removed. (WP 0110)
REMOVAL Remove crankshaft oil seal (Figure 1, Item 1) from engine gear assembly case (Figure 1, Item 2). Discard seal.
Figure 1. Engine Crankshaft Front Seal Removal. END OF TASK
0111-1
TM 5-3825-270-23&P
0111
INSTALLATION
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 1. Lightly lubricate crankshaft oil seal (Figure 2, Item 1) with clean oil.
1 OIL SEAL INSTALLER 2
Figure 2. Engine Crankshaft Front Seal Installation. 2. 3. Using seal installer and crankshaft pulley screw (Figure 2, Item 3), install crankshaft oil seal (Figure 2, Item 1) into engine gear assembly case (Figure 2, Item 2). Remove crankshaft pulley screw (Figure 2, Item 3) and seal installer from crankshaft oil seal (Figure 2, Item 1) and engine gear assembly case (Figure 2, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE Install crankshaft pulley. (WP 0110) END OF TASK END OF WORK PACKAGE
0111-2
TM 5-3825-270-23&P
0112
FIELD MAINTENANCE ENGINE FLYWHEEL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive (WP 0225, Table 1, Item 15) Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4033 Equipment Condition Engine module removed. (WP 0128) Flex element removed. (WP 0147)
REMOVAL
WARNING
Flywheel weighs 75 lbs (34 kg). Do not attempt to lift or move or lift flywheel without the aid of an assistant. Failure to comply may result in injury or death to personnel.
CAUTION
Do not use impact wrench on flywheel at anytime. Failure to comply may result in damage to equipment.
NOTE
Flywheel bolt pattern is offset and can only be installed one way. Match mark flywheel and flywheel housing prior to removal to ensure proper installation. Remove seven screws (Figure 1, Item 1) and flywheel (Figure 1, Item 2) from crankshaft (Figure 1, Item 3).
0112-1
TM 5-3825-270-23&P
0112
REMOVAL - Continued
3
Figure 1. Engine Flywheel Removal. END OF TASK INSTALLATION
NOTE
Install flywheel as noted prior to removal. Install flywheel (Figure 2, Item 2) on crankshaft (Figure 2, Item 3) with seven screws (Figure 2, Item 1). Tighten screws to 72 to 79 lb-ft (98 to 107 Nm).
3
Figure 2. Engine Flywheel Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. Install flex element. (WP 0147)
0112-2
TM 5-3825-270-23&P
0112
FOLLOW-ON MAINTENANCE - Continued 2. Install engine module. (WP 0128)
0112-3/4 blank
TM 5-3825-270-23&P
0113
FIELD MAINTENANCE INJECTION PUMP GEAR COVER PLATE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Materials/Parts (cont.) Gasket (WP 0226, Table 1, Item 30) Qty: 2 Gasket (WP 0226, Table 1, Item 22) Qty: 1 References Parts Manual (WP 0220) Figure 4029 Equipment Condition Cooling fan removed. (WP 0072)
REMOVAL 1. Remove screw (Figure 1, Item 1) and gasket (Figure 1, Item 2) from oil line (Figure 1, Item 3) and fitting (Figure 1, Item 4). Discard gasket.
1, 2
Figure 1. Injection Pump Gear Cover Plate Removal. 2. Remove screw (Figure 2, Item 6) and gasket (Figure 2, Item 7) from oil line (Figure 2, Item 3) and injection pump gear cover plate (Figure 2, Item 5). Discard gasket.
0113-1
TM 5-3825-270-23&P
0113
REMOVAL - Continued
5
6, 7
Figure 2. Injection Pump Gear Cover Plate Removal. 3. Remove nut (Figure 3, Item 9) and oil line (Figure 3, Item 3) from screw (Figure 3, Item 8) and injection pump mounting plate (Figure 3, Item 10).
10
3
Figure 3. Injection Pump Gear Cover Plate Removal.
NOTE
Perform Step (4) if fitting is damaged. 4. Remove fitting (Figure 4, Item 4) from engine block (Figure 4, Item 11).
0113-2
TM 5-3825-270-23&P
0113
REMOVAL - Continued
11
Figure 4. Injection Pump Gear Cover Plate. 5. Remove screw (Figure 5, Item 8) from injection pump gear cover plate (Figure 5, Item 5) and injection pump mounting plate (Figure 5, Item 10).
12
5, 13
12
12 12 14
15, 10
Figure 5. Injection Pump Gear Cover Plate Removal. 6. 7. Remove four screws (Figure 5, Item 12) from injection pump gear cover plate (Figure 5, Item 5) and injection pump mounting plate (Figure 5, Item 10). Remove screw (Figure 5, Item 14), injection pump gear cover plate (Figure 5, Item 5), and gasket (Figure 5, Item 13) from engine gear assembly case (Figure 5, Item 15). Discard gasket.
END OF TASK INSTALLATION 1. Install injection pump gear cover plate (Figure 6, Item 5) and gasket (Figure 6, Item 13) on engine gear assembly case (Figure 6, Item 15) with screw (Figure 6, Item 14).
0113-3
TM 5-3825-270-23&P
0113
12
5, 13
12
12 12 14
15, 10
Figure 6. Injection Pump Gear Cover Plate Installation. 2. 3. Install four screws (Figure 6, Item 12) into injection pump gear cover plate (Figure 6, Item 5) and engine gear assembly case (Figure 6, Item 15). Install screw (Figure 6, Item 8) into injection pump gear cover plate (Figure 6, Item 5) and injection pump mounting plate (Figure 6, Item 10).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel.
NOTE
Perform Steps (4) and (5) if fitting was removed. 4. Apply sealant to the threads of fitting (Figure 7, Item 4).
0113-4
TM 5-3825-270-23&P
0113
11
Figure 7. Injection Pump Gear Cover Plate Installation. 5. 6. Install fitting (Figure 7, Item 4) into engine block (Figure 7, Item 11). Install oil line (Figure 8, Item 3) onto screw (Figure 8, Item 8) and injection pump mounting plate (Figure 8, Item 10) with nut (Figure 8, Item 9).
10
3
Figure 8. Injection Pump Gear Cover Plate Installation. 7. Install oil line (Figure 9, Item 3) onto injection pump gear cover plate (Figure 9, Item 5) with gasket (Figure 9, Item 7) and screw (Figure 9, Item 6).
0113-5
TM 5-3825-270-23&P
0113
5
6, 7
Figure 9. Injection Pump Gear Cover Plate Installation. 8. Install oil line (Figure 10, Item 3) onto fitting (Figure 10, Item 4) with gasket (Figure 10, Item 2) and screw (Figure 10, Item 1).
1, 2
Figure 10. Injection Pump Gear Cover Plate Installation. END OF TASK FOLLOW-ON MAINTENANCE Install cooling fan. (WP 0072) END OF TASK END OF WORK PACKAGE
0113-6
TM 5-3825-270-23&P
0114
FIELD MAINTENANCE ENGINE GEAR ASSEMBLY CASE RELIEF VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Oil, Lubricating, OE/HDO 10 (MIL-PRF-2104) (WP 0224, Table 1, Item 46, 47, 48) Packing, Preformed (WP 0226, Table 1, Item 10) Qty: 1 References Parts Manual (WP 0220) Figure 4029 Equipment Condition Engine OFF. (TM 5-3825-270-10)
REMOVAL
WARNING
Use care when replacing valve plug. Spring behind plug is under tension. Wear proper eye protection. Failure to comply may result in injury or death to personnel. 1. Remove plug (Figure 1, Item 5) from engine gear assembly case (Figure 1, Item 1).
0114-1
TM 5-3825-270-23&P
0114
REMOVAL - Continued
RADIATOR SHOWN REMOVED FOR CLARITY
2 3 4 5
Figure 1. Engine Gear Assembly Case Relief Valve Removal. 2. 3. 4. Remove preformed packing (Figure 1, Item 4) from plug (Figure 1, Item 5). Discard preformed packing. Remove spring (Figure 1, Item 3) from engine gear assembly case (Figure 1, Item 1). Remove gear assembly case relief valve (Figure 1, Item 2) from engine gear assembly case (Figure 1, Item 1).
WARNING
Use care when replacing valve plug. Spring behind plug is under tension. Wear proper eye protection. Failure to comply may result in injury or death to personnel. 1. Lightly lubricate preformed packing (Figure 2, Item 4) with clean oil.
0114-2
TM 5-3825-270-23&P
0114
RADIATOR SHOWN REMOVED FOR CLARITY
2 3 4 5
Figure 2. Engine Gear Assembly Case Relief Valve Installation. 2. 3. 4. 5. Install preformed packing (Figure 2, Item 4) on plug (Figure 2, Item 5). Install gear assembly case relief valve (Figure 2, Item 2) in engine gear assembly case (Figure 2, Item 1). Install spring (Figure 2, Item 3) in engine gear assembly case (Figure 2, Item 1). Install plug (Figure 2, Item 5) in engine gear assembly case (Figure 2, Item 1).
0114-3/4 blank
TM 5-3825-270-23&P
0115
FIELD MAINTENANCE ENGINE COOLANT TEMPERATURE SENDING UNIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Lockwasher (WP 0226, Table 1, Item 37) Qty: 1 References Parts Manual (WP 0220) Figure 4026 Equipment Condition Rear engine access cover removed. (TM 5-3825-270-10) Coolant drained. (WP 0075)
REMOVAL
WARNING
Spilled coolant is slippery and can cause falls. To avoid injury, wipe up spilled coolant with a clean cloth. Failure to comply may result in injury or death to personnel. 1. Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), washer (Figure 1, Item 6), fiber washer (Figure 1, Item 7), and wire (Figure 1, Item 8) from engine coolant temperature sending unit (Figure 1, Item 1). Discard lockwasher.
4, 5, 6, 7
Figure 1. Engine Coolant Temperature Sending Unit Removal.
2.
Remove engine coolant temperature sending unit (Figure 1, Item 1) from fitting (Figure 1, Item 2).
0115-1
TM 5-3825-270-23&P
0115
REMOVAL - Continued 3. Remove fitting (Figure 1, Item 2) from thermostat housing (Figure 1, Item 3).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Coat threads of fitting (Figure 2, Item 2) with pipe thread sealant.
4, 5, 6, 7
Figure 2. Engine Coolant Temperature Sending Unit Installation.
2. 3. 4. 5.
Install fitting (Figure 2, Item 2) on thermostat housing (Figure 2, Item 3). Coat threads of engine coolant temperature sending unit (Figure 2, Item 1) with pipe thread sealant. Install engine coolant temperature sending unit (Figure 2, Item 1) in fitting (Figure 2, Item 2). Install wire (Figure 2, Item 8) on engine coolant temperature sending unit (Figure 2, Item 1) with fiber washer (Figure 2, Item 7), washer (Figure 2, Item 6), lockwasher (Figure 2, Item 5), and nut (Figure 2, Item 4).
END OF TASK FOLLOW-ON MAINTENANCE 1. Fill coolant reservoir. (WP 0075)
0115-2
TM 5-3825-270-23&P
0115
FOLLOW-ON MAINTENANCE - Continued 2. Install rear engine access cover. (TM 5-3825-270-10)
0115-3/4 blank
TM 5-3825-270-23&P
0116
FIELD MAINTENANCE ENGINE EMERGENCY TEMPERATURE SENDING UNIT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) References Parts Manual (WP 0220) Figure 4026 Equipment Condition Engine compartment cover removed. (WP 0142) Coolant drained. (WP 0075)
REMOVAL
WARNING
Spilled coolant is slippery and can cause falls. To avoid injury, wipe up spilled coolant with a clean cloth. Failure to comply may result in injury or death to personnel. 1. Disconnect wire (Figure 1, Item 2) from engine emergency temperature sending unit (Figure 1, Item 3).
1
Figure 1. Engine Emergency Temperature Sending Unit Removal. 2. Remove engine emergency temperature sending unit (Figure 1, Item 3) from thermostat housing (Figure 1, Item 1).
END OF TASK
0116-1
TM 5-3825-270-23&P
0116
INSTALLATION
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Coat threads of engine emergency temperature sending unit (Figure 2, Item 3) with pipe thread sealant.
1
Figure 2. Engine Emergency Temperature Sending Unit Installation. 2. 3. Install engine emergency temperature sending unit (Figure 2, Item 3) in thermostat housing (Figure 2, Item 1). Connect wire (Figure 2, Item 2) to engine emergency temperature sending unit (Figure 2, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill coolant reservoir. (WP 0075) Install engine compartment cover. (WP 0142)
0116-2
TM 5-3825-270-23&P
0117
FIELD MAINTENANCE ENGINE INJECTION PUMP REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Cap and Plug Set (WP 0225, Table 1, Item 2) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 13) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Tags, Identification, White (WP 0224, Table 1, Item 54) Cable Ties (WP 0224, Table 1, Item 9) Materials/Parts (cont.) Locknut (WP 0226, Table 1, Item 26) Qty: 1 Shim (WP 0226, Table 1, Item 23) Qty: 1 Gasket (WP 0226, Table 1, Item 9) Qty: 2 References Parts Manual (WP 0220) Figure 4029 Equipment Condition Rear engine access cover removed. (TM 5-3825-270-10) Coolant reservoir removed. (WP 0070) Engine nozzle tubes removed. (WP 0118) Governor actuator removed. (WP 0133)
REMOVAL
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel.
NOTE
Cap and plug fuel hoses upon removal. Tag and mark hoses prior to removal to ensure proper installation. 1. Loosen clamp (Figure 1, Item 3) and remove fuel hose (Figure 1, Item 2) from fuel pump (Figure 1, Item 1).
0117-1
TM 5-3825-270-23&P
0117
REMOVAL - Continued
1 2 3
Figure 1. Injection Pump Removal. 2. Loosen clamp (Figure 2, Item 5) and remove fuel hose (Figure 2, Item 4) from bleeder valve (Figure 2, Item 6).
Figure 2. Injection Pump Removal. 3. Loosen clamp (Figure 3, Item 8) and remove fuel hose (Figure 3, Item 7) from fitting (Figure 3, Item 9).
0117-2
TM 5-3825-270-23&P
0117
REMOVAL - Continued
7 8 9 6
14
13
12
10, 11
Figure 3. Injection Pump Removal. 4. 5. Remove plug (Figure 3, Item 12) from injection pump housing (Figure 3, Item 13). Remove bleeder valve (Figure 3, Item 6) from injection pump (Figure 3, Item 14).
NOTE
Note position of gaskets prior to removal to ensure proper installation. 6. Remove screw (Figure 3, Item 10), fitting (Figure 3, Item 9), and two gaskets (Figure 3, Item 11) from injection pump (Figure 3, Item 14). Discard gaskets.
CAUTION
Spring must not be allowed to retract into injection pump when removed from stud. Small cable tie may be attached to end of spring to prevent losing spring. Failure to comply may result in damage to equipment. 7. Attach cable tie to spring (Figure 4, Item 19).
0117-3
TM 5-3825-270-23&P
0117
REMOVAL - Continued
15
16
17
CABLE TIE
19
18
Figure 4. Injection Pump Removal. 8. 9. 10. 11. Remove spring (Figure 4, Item 19) from stud (Figure 4, Item 18). Remove locknut (Figure 4, Item 15) from stud (Figure 4, Item 18). Discard locknut. Remove linkage (Figure 4, Item 16) from injection pump linkage (Figure 4, Item 17). Remove three nuts (Figure 5, Item 20) from injection pump (Figure 5, Item 14).
20
21
22
14
13
Figure 5. Injection Pump Removal. 12. Loosen three screws (Figure 5, Item 21) evenly from injection pump (Figure 5, Item 14) and injection pump housing (Figure 5, Item 13).
NOTE
Linkage must be aligned with grove in housing when removing injection pump. 13. Remove three screws (Figure 5, Item 21), injection pump (Figure 5, Item 14), and shim (Figure 5, Item 22) from injection pump housing (Figure 5, Item 13).
0117-4
TM 5-3825-270-23&P
0117
REMOVAL - Continued 14. Remove shim (Figure 5, Item 22) from injection pump (Figure 5, Item 14). Discard shim.
NOTE
Linkage must be aligned with grove in housing when installing injection pump. 1. Position injection pump (Figure 6, Item 14) on injection pump housing (Figure 6, Item 13) with shim (Figure 6, Item 22) and three screws (Figure 6, Item 21). Hand tighten screws.
20
21
22
14
13
Figure 6. Injection Pump Removal.
CAUTION
Ensure linkage is clear of injection pump while tightening screws. Failure to comply may result in damage to equipment. 2. 3. 4. 5. 6. Tighten three screws (Figure 6, Item 21) evenly until injection pump (Figure 6, Item 14) is evenly seated on injection pump housing (Figure 6, Item 13). Install three nuts (Figure 6, Item 20) on injection pump (Figure 6, Item 14). Tighten screws (Figure 6, Item 21) to 17.33 to 20.22 lb ft (23.54 to 27.46 Nm). Tighten nuts (Figure 6, Item 20) to 20 lb ft (27 Nm). Position linkage (Figure 7, Item 16) on injection pump linkage (Figure 7, Item 17).
0117-5
TM 5-3825-270-23&P
0117
15
16
17
CABLE TIE
19
18
Figure 7. Injection Pump Removal. 7. 8. 9. 10. Install locknut (Figure 7, Item 15) on stud (Figure 7, Item 18). Tighten locknut to 25 to 35 lb-in (3 to 4 Nm). Install spring (Figure 7, Item 19) on stud (Figure 7, Item 18). Remove cable tie from spring (Figure 7, Item 19). Install plug (Figure 8, Item 12) in injection pump housing (Figure 8, Item 13).
7 8 9 6
14
13
12
10, 11
Figure 8. Injection Pump Removal. 11. Install fitting (Figure 8, Item 9) and two gaskets (Figure 8, Item 11) on injection pump (Figure 8, Item 14) with screw (Figure 8, Item 10).
0117-6
TM 5-3825-270-23&P
0117
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 12. 13. Apply sealing compound to threads of bleeder valve (Figure 8, Item 6). Install bleeder valve (Figure 8, Item 6) on injection pump (Figure 8, Item 14).
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 14. 15. Install fuel hose (Figure 8, Item 7) on fitting (Figure 8, Item 9) with clamp (Figure 8, Item 8). Install fuel hose (Figure 9, Item 4) on bleeder valve (Figure 9, Item 6) with clamp (Figure 9, Item 5).
Figure 9. Injection Pump Removal. 16. Install fuel hose (Figure 10, Item 2) on fuel pump (Figure 10, Item 1) with clamp (Figure 10, Item 3).
0117-7
TM 5-3825-270-23&P
0117
1 2 3
Figure 10. Injection Pump Removal. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install governor actuator. (WP 0133) Install engine nozzle tubes. (WP 0118) Install coolant reservoir. (WP 0070) Install rear engine access cover. (TM 5-3825-270-10)
0117-8
TM 5-3825-270-23&P
0118
FIELD MAINTENANCE ENGINE NOZZLE TUBES REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4046 Equipment Condition Engine access panel open. (TM 5-3825-270-10) Coolant reservoir and bracket removed. (WP 0070)
REMOVAL
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 1. Loosen four fittings (Figure 1, Item 5) and remove nozzle tubes (Figure 1, Items 1, 2, 3, and 4) from injection pump (Figure 1, Item 6).
0118-1
TM 5-3825-270-23&P
0118
REMOVAL - Continued
6
Figure 1. Engine Nozzle Tubes Removal. 2. Loosen four fittings (Figure 2, Item 7) and remove nozzle tubes (Figure 2, Items 1, 2, 3, and 4) from injection nozzles (Figure 2, Item 8).
8
Figure 2. Engine Nozzle Tubes Removal.
0118-2
TM 5-3825-270-23&P
0118
REMOVAL - Continued
NOTE
Note position of tube clamps prior to removal to ensure proper installation. Note position of nozzle tubes prior to removal to ensure proper installation. All tube clamps are removed the same way. 3. Remove screw (Figure 3, Item 9), lockwasher (Figure 3, Item 10), and tube clamps (Figure 3, Items 11 and 12) from nozzle tubes (Figure 3, Items 1 and 2).
9, 10
11, 12
13, 14
15, 16
17, 18
19, 20
Figure 3. Engine Nozzle Tubes Removal. 4. 5. Remove screw (Figure 3, Item 13), lockwasher (Figure 3, Item 14), and tube clamps (Figure 3, Items 15 and 16) from nozzle tubes (Figure 3, Items 2 and 3). Remove screw (Figure 3, Item 17), lockwasher (Figure 3, Item 18), and tube clamps (Figure 3, Items 19 and 20) from nozzle tubes (Figure 3, Items 3 and 4).
NOTE
Assemble tube clamps as noted prior to removal. 1. Loosely install tube clamps (Figure 4, Items 19 and 20) on nozzle tubes (Figure 4, Items 3 and 4) with lockwasher (Figure 4, Item 18) and screw (Figure 4, Item 17).
0118-3
TM 5-3825-270-23&P
0118
9, 10
11, 12
13, 14
15, 16
17, 18
19, 20
Figure 4. Engine Nozzle Tubes Installation. 2. 3. Loosely install tube clamps (Figure 4, Items 15 and 16) on nozzle tubes (Figure 4, Items 2 and 3) with lockwasher (Figure 4, Item 14) and screw (Figure 4, Item 13). Loosely install tube clamps (Figure 4, Items 11 and 12) on nozzle tubes (Figure 4, Items 1 and 2) with lockwasher (Figure 4, Item 10) and screw (Figure 4, Item 9).
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 4. Install four nozzle tubes (Figure 5, Items 1, 2, 3, and 4) on injection nozzles (Figure 5, Item 8) with four fittings (Figure 5, Item 7).
0118-4
TM 5-3825-270-23&P
0118
8
Figure 5. Engine Nozzle Tubes Installation. 5. Install four nozzle tubes (Figure 6, Items 1, 2, 3, and 4) on injection pump (Figure 6, Item 6) with four fittings (Figure 6, Item 5).
6
Figure 6. Engine Nozzle Tubes Installation.
0118-5
TM 5-3825-270-23&P
0118
INSTALLATION - Continued 6. Tighten screws (Figure 7, Items 9, 13, and 17).
13
17
Figure 7. Engine Nozzle Tubes Installation.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install coolant reservoir and bracket. (WP 0070) Close engine access panel. (TM 5-3825-270-10)
0118-6
TM 5-3825-270-23&P
0119
FIELD MAINTENANCE ENGINE INLET ASSEMBLY MANIFOLD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Gasket (WP 0226, Table 1, Item 19) Qty: 1 References Parts Manual (WP 0220) Figure 4039 Equipment Condition Fuel/water separator and filter head removed. (WP 0176) Equipment Condition (cont.) Engine nozzle tubes removed. (WP 0118) Air hose intake removed. (WP 0109) Cylinder head removed. (WP 0145)
REMOVAL 1. Remove two nuts (Figure 1, Item 4), screws (Figure 1, Item 2), and bracket (Figure 1, Item 3) from engine block (Figure 1, Item 1) and injection pump assembly (Figure 1, Item 5).
1 2 3 4 5
Figure 1. Inlet Assembly Manifold Removal. 2. Loosen clamp (Figure 2, Item 7) and remove vent hose (Figure 2, Item 6) from inlet assembly manifold (Figure 2, Item 8).
0119-1
TM 5-3825-270-23&P
0119
REMOVAL - Continued
6 7
Figure 2. Inlet Assembly Manifold Removal. 3. Remove three screws (Figure 3, Item 10) and bracket (Figure 3, Item 11) from inlet assembly manifold (Figure 3, Item 8).
8, 9
10
11
13
12
Figure 3. Inlet Assembly Manifold Removal. 4. Remove five screws (Figure 3, Item 12), inlet assembly manifold (Figure 3, Item 8), and gasket (Figure 3, Item 9) from cylinder head (Figure 3, Item 13). Discard gasket.
END OF TASK INSTALLATION 1. Install gasket (Figure 4, Item 9) and inlet assembly manifold (Figure 4, Item 8) on cylinder head (Figure 4, Item 13) with five screws (Figure 4, Item 12).
0119-2
TM 5-3825-270-23&P
0119
8, 9
10
11
13
12
Figure 4. Inlet Assembly Manifold Installation. 2. 3. Install bracket (Figure 4, Item 11) and three screws (Figure 4, Item 10) on inlet assembly manifold (Figure 4, Item 8). Install vent hose (Figure 5, Item 6) on inlet assembly manifold (Figure 5, Item 8) with clamp (Figure 5, Item 7).
6 7
Figure 5. Inlet Assembly Manifold Installation. 4. Install bracket (Figure 6, Item 3) on injection pump assembly (Figure 6, Item 5) and engine block (Figure 6, Item 1) with two nuts (Figure 6, Item 4) and screws (Figure 6, Item 2).
0119-3
TM 5-3825-270-23&P
0119
1 2 3 4 5
Figure 6. Inlet Assembly Manifold Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install cylinder head. (WP 0145) Install air hose intake. (WP 0109) Install engine nozzle tubes. (WP 0118) Install fuel/water separator and filter head. (WP 0176)
0119-4
TM 5-3825-270-23&P
0120
FIELD MAINTENANCE ENGINE NOZZLE ASSEMBLY HOLDER (INJECTION NOZZLE) REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 13) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Packing, Preformed (WP 0226, Table 1, Item 12) Qty: 4 Seal, Plain, Encased (WP 0226, Table 1, Item 16) Qty: 4 References Parts Manual (WP 0220) Figure 4046 Equipment Condition Engine nozzle tubes removed. (WP 0118)
REMOVAL
WARNING
Keep fingers away from pinch points. Fingers may be pinched. Failure to comply may result in injury or death to personnel. 1. Loosen clamp (Figure 1, Item 1) and remove hose (Figure 1, Item 2) from fuel tube (Figure 1, Item 3).
0120-1
TM 5-3825-270-23&P
0120
REMOVAL - Continued
3
2 1 4 5 6 3
Figure 1. Injection Nozzle Assembly Removal. 2. 3. Loosen clamp (Figure 1, Item 5) and remove hose (Figure 1, Item 4) from fuel tube (Figure 1, Item 3). Remove four nuts (Figure 1, Item 6) and fuel tube (Figure 1, Item 3) from four injection nozzle assemblies (Figure 1, Item 7).
CAUTION
Passage into cylinder is exposed when nozzle assemblies are removed. Ensure that no foreign materials are allowed to enter cylinder. Failure to comply may result in damage to equipment. 4. Remove four injection nozzle assemblies (Figure 2, Item 9) from cylinder head (Figure 2, Item 8).
0120-2
TM 5-3825-270-23&P
0120
REMOVAL - Continued
9
Figure 2. Injection Nozzle Assembly Removal. 5. Remove four preformed packings (Figure 3, Item 10) from cylinder head (Figure 3, Item 8). Discard preformed packings.
8 10
Figure 3. Injection Nozzle Assembly Removal. 6. Remove four encased plain seals (Figure 4, Item 11) from cylinder head (Figure 4, Item 8). Discard encased plain seals.
0120-3
TM 5-3825-270-23&P
0120
REMOVAL - Continued
11
Figure 4. Injection Nozzle Assembly Removal. END OF TASK INSTALLATION 1. Install four encased plain seals (Figure 5, Item 11) in cylinder head (Figure 5, Item 8).
11
Figure 5. Injection Nozzle Assembly Installation. 2. Install four preformed packings (Figure 6, Item 10) in cylinder head (Figure 6, Item 8).
0120-4
TM 5-3825-270-23&P
0120
8 10
Figure 6. Injection Nozzle Assembly Installation. 3. Install four injection nozzle assemblies (Figure 7, Item 9) in cylinder head (Figure 7, Item 8). Tighten to 37 to 50 ft-lb (50 to 68 Nm).
9
Figure 7. Injection Nozzle Assembly Installation. 4. Install fuel tube (Figure 8, Item 3) on four injection nozzle assemblies (Figure 8, Item 7) with nuts (Figure 8, Item 6). Tighten to 15 in-lb (20 Nm).
0120-5
TM 5-3825-270-23&P
0120
3
2 1 4 5 6 3
Figure 8. Injection Nozzle Assembly Installation. 5. 6. Install hose (Figure 8, Item 4) on fuel tube (Figure 8, Item 3) with clamp (Figure 8, Item 5). Install hose (Figure 8, Item 2) on fuel tube (Figure 8, Item 3) with clamp (Figure 8, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE Install engine nozzle tubes. (WP 0118) END OF TASK END OF WORK PACKAGE
0120-6
TM 5-3825-270-23&P
0121
FIELD MAINTENANCE OIL PAN REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Gun, Air Blow (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 12) Materials/Parts Gasket, Silicon (WP 0224, Table 1, Item 34) Cleaning Compound, Solvent (WP 0224, Table 1, Item 10, 11, 12, 13, 14, 15) References Parts Manual (WP 0220) Figure 4034 Equipment Condition Engine module removed. (WP 0128) Oil drained. (WP 0124)
REMOVAL
NOTE
Pry bar may be necessary to separate oil pan from engine block. Note location of long oil pan screws during removal to ensure proper installation. 1. Remove 20 screws (Figure 1, Item 1) from oil pan (Figure 1, Item 4) and engine block (Figure 1, Item 3).
4
Figure 1. Oil Pan Removal.
0121-1
TM 5-3825-270-23&P
0121
REMOVAL - Continued 2. Remove four screws (Figure 1, Item 2) and oil pan (Figure 1, Item 4) from engine block (Figure 1, Item 3).
END OF TASK CLEANING/INSPECTION
WARNING
SOLVENT CLEANING COMPOUND (DRYCLEANING SOLVENT) Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flashpoint for Type II solvent cleaning compound is 141 to 198F (61 to 92C), and Type III is 200 to 241F (93 to 116C). Improper cleaning methods and use of unauthorized cleaning solvents may result in injury to personnel and/or damage to equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to comply may result in injury or death to personnel. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to comply may result in injury to personnel. Eye shields must be worn when cleaning with a wire brush. Failure to comply may result in injury to personnel. If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury or death to personnel. 1. Clean oil pan and all mating surfaces with solvent cleaning compound. Mating surface must be free of dirt, oil, and old sealant material.
0121-2
TM 5-3825-270-23&P
0121
CLEANING/INSPECTION - Continued
WARNING
Compressed air used for cleaning and drying purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and proper protective equipment (goggles, shield, gloves, etc.). Failure to comply may result in injury or death to personnel. 2. 3. Blow parts dry. Inspect mating surfaces for cracks, burrs, or pitting.
END OF TASK INSTALLATION 1. Apply -inch bead of silicone sealant (Figure 2, Item 5) to oil pan mating surface (Figure 2, Item 6).
Figure 2. Oil Pan Sealant Application. 2. Install oil pan (Figure 3, Item 4) on engine block (Figure 3, Item 3) with four screws (Figure 3, Item 1). Tighten screws finger tight.
2, 3
4
Figure 3. Oil Pan Installation.
0121-3
TM 5-3825-270-23&P
0121
INSTALLATION - Continued 3. 4. Install 20 screws (Figure 3, Item 2) in oil pan (Figure 3, Item 4) and engine block (Figure 3, Item 3). Tighten screws finger tight. Tighten screws in sequence shown.
21 17 9 1 3 11 19 23
16 8 6 14
13 5 7 15
24
20
12
10
18
22
TIGHTENING SEQUENCE DIAGRAM
Figure 4. Oil Pan Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Fill oil. (WP 0124) Install engine module. (WP 0128)
0121-4
TM 5-3825-270-23&P
0122
FIELD MAINTENANCE ENGINE OIL PRESSURE TESTING
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Tester, Pressure Gage (WP 0225, Table 1, Item 11) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Equipment Condition Engine OFF. (TM 5-3825-270-10)
TESTING
WARNING
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel.
NOTE
Position drain pan under engine oil pressure sending unit prior to removal. Refer to local policies and regulations for disposal of contaminated oil, rags, and oil filter. 1. Remove nut (Figure 1, Item 2), washer (Figure 1, Item 3), and wire (Figure 1, Item 4) from oil pressure sending unit (Figure 1, Item 1).
0122-1
TM 5-3825-270-23&P
0122
TESTING - Continued
1 2, 3 4
Figure 1. Engine Oil Pressure Testing. 2. 3. Remove oil pressure sending unit (Figure 1, Item 1) from fitting (Figure 1, Item 5). Install test kit adapter (Figure 2, Item 6) on fitting (Figure 2, Item 5).
6
Figure 2. Engine Oil Pressure Testing. 4. Install oil pressure tester (Figure 3, Item 7) on test kit adapter (Figure 3, Item 6).
0122-2
TM 5-3825-270-23&P
0122
TESTING - Continued
6, 7
Figure 3. Engine Oil Pressure Testing.
WARNING
Keep hands and test equipment clear of engine drive belts and cooling fan while observing engine oil pressure. Failure to comply may result in damage to equipment, death, or serious injury to personnel. 5. Start engine. (TM 5-3825-270-10)
NOTE
Minimum allowable oil pressure at idle speed is 7 psi (49 kPa). 6. With engine at idle speed of 900 to 1100 rpm, note gauge reading. Verify oil pressure shows approximately 14 psi (98 kPa).
NOTE
Minimum allowable oil pressure at maximum speed is 21.3 psi (147.1 kPa). 7. 8. 9. Increase engine to maximum speed of 2,400 rpm, note gauge reading. Verify oil pressure is 28 to 57 psi (196 to 393 kPa). Return engine to idle speed and shut engine OFF. (TM 5-3825-270-10) Remove engine oil pressure tester (Figure 4, Item 7) from test kit adapter (Figure 4, Item 6).
0122-3
TM 5-3825-270-23&P
0122
TESTING - Continued
6, 7
Figure 4. Engine Oil Pressure Testing. 10. Remove test kit adapter (Figure 5, Item 6) from fitting (Figure 5, Item 5).
6
Figure 5. Engine Oil Pressure Testing.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 11. Coat threads of engine oil pressure sending unit (Figure 6, Item 1) with sealing compound.
0122-4
TM 5-3825-270-23&P
0122
TESTING - Continued
1 2, 3 4
Figure 6. Engine Oil Pressure Testing. 12. 13. Install engine oil pressure sending unit (Figure 6, Item 1) on fitting (Figure 6, Item 5). Install wire (Figure 6, Item 4) on engine oil pressure sending unit (Figure 6, Item 1) with washer (Figure 6, Item 3) and nut (Figure 6, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE Check engine oil level. (WP 0124) END OF TASK END OF WORK PACKAGE
0122-5/6 blank
TM 5-3825-270-23&P
0123
FIELD MAINTENANCE ENGINE OIL FILTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Wrench, Universal Chain (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Materials/Parts Oil, Lubricating, Engine, OE/HDO 15W40 (WP 0224, Table 1, Item 42, 43, 44, 45) Rag, Wiping (WP 0224, Table 1, Item 54) References Parts Manual (WP 0220) Figure 4044 Equipment Condition Engine OFF. (TM 5-3825-270-10) Oil drained. (WP 0124)
REMOVAL
WARNING
WARNING
NOTE
Position drain pan under oil filter prior to removal. Refer to local policies and regulations for disposal of contaminated oil, rags, and oil filter. Universal chain wrench may be necessary for removing oil filter. 1. Using universal chain wrench, remove oil filter (Figure 1, Item 2) from oil cooler assembly (Figure 1, Item 1) by turning counter-clockwise.
0123-1
TM 5-3825-270-23&P
0123
REMOVAL - Continued
5
Figure 1. Engine Oil Filter Removal. 2. Wipe mating surface (Figure 2, Item 3) clean on oil cooler assembly (Figure 2, Item 1), making sure to remove any old gasket material.
Figure 2. Engine Oil Filter Removal. END OF TASK INSTALLATION 1. Lightly lubricate gasket (Figure 3, Item 4) on new oil filter (Figure 3, Item 2) with clean oil.
0123-2
TM 5-3825-270-23&P
0123
4 5 7
Figure 3. Engine Oil Filter Installation.
CAUTION
Do not use universal chain wrench to tighten oil filter on oil assembly cooler. Failure to comply may result in damage to equipment. 2. Install oil filter (Figure 3, Item 2) on oil cooler assembly (Figure 3, Item 1) until gasket contacts oil cooler assembly. Tighten oil filter another -turn by hand.
END OF TASK FOLLOW-ON MAINTENANCE Fill oil. (WP 0124) END OF TASK END OF WORK PACKAGE
0123-3/4 blank
TM 5-3825-270-23&P
0124
FIELD MAINTENANCE ENGINE OIL SERVICE
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal. Cap (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Funnel, Rigid Spout (WP 0225, Table 1, Item 2) Wrench, Universal Chain (WP 0225, Table 1, Item 2) Materials/Parts Oil, Lubricating, Engine, OE/HDO 15W40 (WP 0224, Table 1, Item 42, 43, 44, 45) Materials/Parts (cont.) Rag, Wiping (WP 0224, Table 1, Item 52) Gasket (WP 0226, Table 1, Item 14) Qty: 1 Cartridge, Oil Filter (WP 0226, Table 1, Item 72) Qty: 1 References Parts Manual (WP 0220) Figure 4034 Equipment Condition Rear access door removed. (TM 5-3825-270-10)
DRAIN
WARNING
Do not drain engine oil while engine is hot. Failure to comply may result in injury to personnel.
WARNING
NOTE
Dispose of used oil, contaminated rags, and drain pan contents IAW local procedures. 1. Position drain pan under drain plug (Figure 1, Item 1).
0124-1
TM 5-3825-270-23&P
0124
DRAIN - Continued
1,2
Figure 1. Engine Oil Service. 2. Remove drain plug (Figure 1, Item 1) and gasket (Figure 1, Item 2) from oil pan (Figure 1, Item 3) and allow oil to drain until flow stops.
NOTE
Position drain pan under oil filter prior to removal. Universal chain wrench may be necessary for removing oil filter. 3. Using universal chain wrench, remove oil filter (Figure 2, Item 4) from oil cooler assembly (Figure 2, Item 5) by turning counter-clockwise. Discard oil filter.
5
Figure 2. Engine Oil Service. 4. Wipe mating surface (Figure 3, Item 6) clean on oil cooler assembly (Figure 3, Item 4), making sure to remove any old gasket material.
0124-2
TM 5-3825-270-23&P
0124
DRAIN - Continued
Figure 3. Engine Oil Service. 5. Remove gasket (Figure 1, Item 2) from drain plug (Figure 1, Item 1). Discard gasket.
1,2
Figure 4. Engine Oil Service. 6. Install drain plug (Figure 1, Item 1) and new gasket (Figure 1, Item 2) in oil pan (Figure 1, Item 3). Tighten drain plug.
END OF TASK
0124-3
TM 5-3825-270-23&P
0124
FILL
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 1. Lightly lubricate gasket (Figure 5, Item 4) on new oil filter (Figure 5, Item 2) with clean oil.
4 5 7
Figure 5. Engine Oil Service.
CAUTION
Do not use universal chain wrench to tighten oil filter on oil assembly cooler. Failure to comply may result in damage to equipment. 2. Install oil filter (Figure 5, Item 2) on oil cooler assembly (Figure 5, Item 1) until gasket contacts oil cooler assembly. Tighten oil filter another -turn by hand.
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 3. Remove oil fill cap (Figure 6, Item 8) from engine block (Figure 6, Item 10).
0124-4
TM 5-3825-270-23&P
0124
FILL - Continued
8 7
9, 10 11
HIGH MARK
LOW MARK
Figure 6. Engine Oil Service.
NOTE
Engine oil capacity is 3.49 gal. (13.25 L). 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Add 14 quarts of lubricating oil through opening (Figure 6, Item 9) in engine block (Figure 6, Item 10) using funnel. Remove engine oil dipstick (Figure 6, Item 7) from engine block (Figure 6, Item 10) and wipe end with clean rag. Install engine oil dipstick (Figure 6, Item 7) in engine block (Figure 6, Item 10). Remove engine oil dipstick (Figure 6, Item 7) from engine block (Figure 6, Item 10) to verify oil level is between high and low marks. Reinstall engine oil dipstick (Figure 6, Item 7) in engine block (Figure 6, Item 10). Install oil cap (Figure 6, Item 8) in opening (Figure 6, Item 9) in engine block (Figure 6, Item 10). Clean any spilled oil with clean rag. Start engine. (TM 5-3825-270-10) Run engine for approximately 30 seconds. Shut OFF engine. (TM 5-3825-270-10) Remove engine oil dipstick (Figure 6, Item 7) from engine block (Figure 6, Item 10) and wipe end clean with clean rag. Reinstall engine oil dipstick (Figure 6, Item 7) in engine block (Figure 6, Item 10). Remove engine oil dipstick (Figure 6, Item 7) from engine block (Figure 6, Item 10) and verify oil level is between high and low marks.
CAUTION
Do not overfill oil. Failure to comply may result in damage to equipment.
0124-5
TM 5-3825-270-23&P
0124
FILL - Continued 17. If required, add oil until full mark is reached on engine oil dipstick (Figure 6, Item 7).
END OF TASK FOLLOW-ON MAINTENANCE Install rear access door. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0124-6
TM 5-3825-270-23&P
0125
FIELD MAINTENANCE ENGINE OIL COOLER AND HOSE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Gloves, Rubber (WP 0225, Table 1, Item 2) Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Goggles, Industrial (WP 0225, Table 1, Item 2) Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 13) Materials/Parts Rag, Wiping (WP 0224, Table 1, Item 54) Gasket, Oil Cooler (WP 0226, Table 1, Item 11) Qty: 1 References Parts Manual (WP 0220) Figure 4044 Equipment Condition Radiator drained. (WP 0075) Oil filter removed. (WP 0123)
REMOVAL
WARNING
Cooling systems are hot and under pressure. Allow engine to completely cool prior to handling any cooling system component or hose. Be sure to wear proper eye protection. Failure to comply may result in injury or death to personnel. 1. Remove fitting (Figure 1, Item 3) from engine oil cooler (Figure 1, Item 2) and engine block (Figure 1, Item 1).
1 2
Figure 1. Engine Oil Cooler and Hose Removal. 2. Loosen two clamps (Figure 2, Item 5) and reposition to center of hose (Figure 2, Item 4).
0125-1
TM 5-3825-270-23&P
0125
REMOVAL - Continued
Figure 2. Engine Oil Cooler and Hose Removal. 3. 4. Loosen two clamps (Figure 2, Item 6) and reposition to center of hose (Figure 2, Item 7). Remove hose (Figure 3, Item 4) from fitting (Figure 3, Item 8).
4 8
7
Figure 3. Engine Oil Cooler and Hose Removal. 5. 6.
Remove oil cooler (Figure 3, Item 2) and hose (Figure 3, Item 7) from tube (Figure 3, Item 9). Remove oil cooler gasket (Figure 4, Item 10) from oil cooler (Figure 4, Item 2). Discard oil cooler gasket.
0125-2
TM 5-3825-270-23&P
0125
REMOVAL - Continued
10
Figure 4. Engine Oil Cooler and Hose Removal. 7. 8. 9. 10. Remove hose (Figure 4, Item 4) from oil cooler (Figure 4, Item 2). Remove hose (Figure 4, Item 7) from oil cooler (Figure 4, Item 2). Remove two clamps (Figure 4, Item 5) from hose (Figure 4, Item 4). Remove two clamps (Figure 4, Item 6) from hose (Figure 4, Item 7).
END OF TASK INSTALLATION 1. Install two clamps (Figure 5, Item 6) onto center of hose (Figure 5, Item 7).
10
Figure 5. Engine Oil Cooler and Hose Installation. 2. 3. 4. Install two clamps (Figure 5, Item 5) onto center of hose (Figure 5, Item 4). Install hose (Figure 5, Item 7) on oil cooler (Figure 5, Item 2). Install hose (Figure 5, Item 4) on oil cooler (Figure 5, Item 2).
0125-3
TM 5-3825-270-23&P
0125
INSTALLATION - Continued 5. 6. Install oil cooler gasket (Figure 5, Item 10) on oil cooler (Figure 5, Item 2). Install hose (Figure 6, Item 7) and oil cooler (Figure 6, Item 2) onto tube (Figure 6, Item 9).
4 8
7
Figure 6. Engine Oil Cooler and Hose Installation. 7. 8. Install hose (Figure 6, Item 4) onto fitting (Figure 6, Item 8). Loosen two clamps (Figure 7, Item 6) and slide to ends of hose (Figure 7, Item 7).
Figure 7. Engine Oil Cooler and Hose Installation. 9. 10. Loosen two clamps (Figure 7, Item 5) and slide to ends of hose (Figure 7, Item 4). Install oil cooler (Figure 8, Item 2) on engine block (Figure 8, Item 1) with fitting (Figure 8, Item 3).
0125-4
TM 5-3825-270-23&P
0125
1 2
Figure 8. Engine Oil Cooler and Hose Installation. 11. Tighten fitting (Figure 8, Item 3) to 29 to 32 ft-lb (39 to 43 Nm).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install oil filter. (WP 0123) Fill radiator. (WP 0075)
0125-5/6 blank
TM 5-3825-270-23&P
0126
FIELD MAINTENANCE ENGINE TIMING SENSOR AND COVER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Lockwasher (WP 0226, Table 1, Item 37) Qty: 2 References Parts Manual (WP 0220) Figure 4026 Equipment Condition Engine OFF. (TM 5-3825-270-10) Engine access cover removed. (TM 5-3825-270-10)
REMOVAL
NOTE
Remove cushion clips as required. 1. Disconnect connector (Figure 1, Item 1) from harness connector (Figure 1, Item 2).
Figure 1. Engine Timing Sensor Removal. 2. Loosen jam nut (Figure 2, Item 5) and remove engine timing sensor (Figure 2, Item 6) from cover plate (Figure 2, Item 7).
0126-1
TM 5-3825-270-23&P
0126
REMOVAL - Continued
3, 4
5 6
8
Figure 2. Engine Timing Sensor Removal.
3, 4
NOTE
Perform Step (3) only if cover plate is damaged. 3. Remove two screws (Figure 2, Item 3), lockwashers (Figure 2, Item 4), and cover plate (Figure 2, Item 7) from flywheel housing (Figure 2, Item 8). Discard lockwashers.
NOTE
Perform Step (1) only if cover plate was removed. 1. Install cover plate (Figure 3, Item 7) on flywheel housing (Figure 3, Item 8) with two lockwashers (Figure 3, Item 4) and screws (Figure 3, Item 3).
3, 4
5 6
3, 4
Figure 3. Engine Timing Sensor Installation. 2. Install engine timing sensor (Figure 3, Item 6) in cover plate (Figure 3, Item 7) until it makes contact with flywheel.
0126-2
TM 5-3825-270-23&P
0126
INSTALLATION - Continued 3. 4. 5. Unscrew engine timing sensor (Figure 3, Item 6) one-half turn. Tighten jam nut (Figure 3, Item 5) on engine timing sensor (Figure 3, Item 6). Connect connector (Figure 4, Item 1) to harness connector (Figure 4, Item 2).
Figure 4. Engine Timing Sensor Installation. END OF TASK FOLLOW ON MAINTENANCE Install engine access cover. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0126-3/4 blank
TM 5-3825-270-23&P
0127
FIELD MAINTENANCE ENGINE/PUMP MODULE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Cap and Plug Set (WP 0225, Table 1, Item 2) Sling (2) (WP 0225, Table 1, Item 9) Multi-Leg Nylon Sling (WP 0225, Table 1, Item 3) Lifting Device 2,300 lb (1043.30 kg) capacity Materials/Parts Locknut (WP 0226, Table 1, Item 2) Qty: 8 Locknut (WP 0226, Table 1, Item 66) Qty: 2 Personnel Required Construction Equipment Repairer 91L (3) References Parts Manual (WP 0220) Figure 4007 References (cont.) Parts Manual (WP 0220) Figure 4010 Parts Manual (WP 0220) Figure 4014 Parts Manual (WP 0220) Figure 4016 Equipment Condition Batteries disconnected. (WP 0085) Strainer housing removed. (WP 0182) Main control box removed. (WP 0100) Air valve cover plate removed. (WP 0164) Fire extinguisher bracket removed. (WP 0167) Work lights removed. (WP 0106) Inlet valve and hose removed. (WP 0183) Folding hand rail removed. (WP 0185) Rear platform screen removed. (WP 0165) Gravity sprinkler bar removed. (WP 0160)
REMOVAL
NOTE
Remove cable ties and cushion clips as required. Cap and plug hoses upon removal. 1. Loosen clamp (Figure 1, Item 3) and remove air line (Figure 1, Item 2) from oiler (Figure 1, Item 1).
0127-1
TM 5-3825-270-23&P
0127
REMOVAL - Continued
Figure 1. Engine/Pump Module Removal. 2. Disconnect two air valve switch connectors (Figure 2, Item 4) from air valve switch harness connectors (Figure 2, Item 8).
5
Figure 2. Engine/Pump Module Removal.
NOTE
Note wiring harness routing prior to removal to ensure proper installation. Remove cable ties and cushion clips as required. 3. 4. Remove work light wire harness (Figure 2, Item 7) and air valve switch wire harness (Figure 2, Item 6) from engine/pump module (Figure 2, Item 5). Loosen clamp (Figure 3, Item 11) from hose (Figure 3, Item 10), and union (Figure 3, Item 9).
0127-2
TM 5-3825-270-23&P
0127
REMOVAL - Continued
9
13, 14
12
11
10
Figure 3. Engine/Pump Module Removal. 5. Remove two locknuts (Figure 3, Item 13), washers (Figure 3, Item 14), and union (Figure 3, Item 9), from flatrack (Figure 3, Item 12), and hose (Figure 3, Item 10). Discard locknuts.
NOTE
Note position of hardware prior to removal to ensure proper installation. 6. Remove eight nuts (Figure 4, Item 17), screws (Figure 4, Item 16), and washers (Figure 4, Item 15) from engine/ pump module (Figure 4, Item 5) and flatrack (Figure 4, Item 12).
16 5 15
17
12
0127-3
TM 5-3825-270-23&P
0127
REMOVAL - Continued 7. Remove eight locknuts (Figure 5, Item 20), eight screws (Figure 5, Item 18), and twenty-four washers (Figure 5, Item 19) from engine/pump module (Figure 5, Item 5) and flatrack (Figure 5, Item 12).
LIFTING DEVICE
18 5 19
12
19 20
WARNING
Engine/pump module weighs 2,300 lbs (1043 kg). Do not attempt to lift or move module without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 8. 9. Attach suitable lifting device to engine/pump module (Figure 5, Item 5). With the aid of an assistant and lifting device, remove engine/pump module (Figure 5, Item 5) from flatrack (Figure 5, Item 12).
END OF TASK
0127-4
TM 5-3825-270-23&P
0127
INSTALLATION
WARNING
Engine/pump module weighs 2,300 lbs (1043 kg). Do not attempt to lift or move module without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 1. Attach suitable lifting device to engine/pump module (Figure 6, Item 5).
LIFTING DEVICE
18 5 19
12
19 20
Figure 6. Engine/Pump Module Installation. 2. With the aid of an assistant and lifting device, position engine/pump module (Figure 6, Item 5) on flatrack (Figure 6, Item 12).
NOTE
Install hardware as noted prior to removal to ensure proper installation. 3. Secure engine/pump module (Figure 6, Item 5) to flatrack (Figure 6, Item 12) with eight screws (Figure 6, Item 18), twenty four washers (Figure 6, Item 19), and eight locknuts (Figure 6, Item 20).
0127-5
TM 5-3825-270-23&P
0127
INSTALLATION - Continued 4. Secure engine/pump module (Figure 7, Item 5) to flatrack (Figure 7, Item 12) with eight screws (Figure 7, Item 16), washers (Figure 7, Item 15), and eight nuts (Figure 7, Item 17).
16 5 15
17
12
Figure 7. Engine/Pump Module Installation. 5. Install union (Figure 8, Item 9) in hose (Figure 8, Item 10) with clamp (Figure 8, Item 11). Do not tighten clamp.
9
13, 14
12
11
10
Figure 8. Engine/Pump Module Installation. 6. 7. Install union (Figure 8, Item 9) on flatrack (Figure 8, Item 12), with two washers (Figure 8, Item 14), and locknuts (Figure 8, Item 13). Tighten clamp (Figure 8, Item 11) to 70 lbs-in (7.9 Nm).
0127-6
TM 5-3825-270-23&P
0127
NOTE
Install wire ties and cushion clips as required. Route wire harnesses as noted prior to removal to ensure proper installation. 8. Install air valve switch wire harness (Figure 9, Item 6) and work light wire harness (Figure 9, Item 7) on engine/ pump module (Figure 9, Item 5).
5
Figure 9. Engine/Pump Module Installation.
9.
Connect two air valve switch connectors (Figure 9, Item 4) to two air valve switch harness connectors (Figure 9, Item 8).
NOTE
Install cable ties and cushion clips as required. 10. Install air line (Figure 10, Item 2) on oiler (Figure 10, Item 1) with clamp (Figure 10, Item 3).
0127-7
TM 5-3825-270-23&P
0127
Figure 10. Engine/Pump Module Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install gravity sprinkler bar. (WP 0160) Install rear platform screen. (WP 0165) install folding handrail. (WP 0185) Install inlet valve and hose. (WP 0183) Install work lights. (WP 0106) Install air valve cover plate. (WP 0164) Install main control box. (WP 0100) Install fire extinguisher bracket. (WP 0167) Install strainer housing. (WP 0182) Connect batteries. (WP 0085)
0127-8
TM 5-3825-270-23&P
0128
FIELD MAINTENANCE ENGINE MODULE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Jack, Hyd Hand Bottle, Type 20 Ton Cap (WP 0225, Table 1, Item 2) Multi-Leg Nylon Sling (WP 0225, Table 1, Item 3) Shakle (2) (WP 0225, Table 1, Item 7) Lifting Device, Minimum Capacity 800 lbs Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive (WP 0225, Table 1, Item 15) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Tap & Die Set (Screwdriver) (WP 0225, Table 1, Item 2) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Cable Ties (WP 0224, Table 1, Item 9) Lumber, Softwood, Dimension (WP 0224, Table 1, Item 41) Materials/Parts (cont.) Isolator Mounts (WP 0226, Table 1, Item 49) Qty: 4 Locknut (WP 0226, Table 1, Item 41) Qty: 4 Locknut (WP 0226, Table 1, Item 66) Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4007 Parts Manual (WP 0220) Figure 4020 Parts Manual (WP 0220) Figure 4024 Parts Manual (WP 0220) Figure 4037 Equipment Condition Batteries disconnected. (WP 0085) Engine compartment cover removed. (WP 0142)
REMOVAL
NOTE
Remove cable ties and retainers as required. Tag and mark wires prior to removal to ensure proper installation. Note wire harness routing prior to removal to ensure proper installation. Only positive battery cable needs to be removed from starter, all other wires remain on starter. 1. Remove nut (Figure 1, Item 1) and positive battery cable (Figure 1, Item 6) from starter (Figure 1, Item 2).
0128-1
TM 5-3825-270-23&P
0128
REMOVAL - Continued
6
Figure 1. Engine Module Removal. 2. Remove nut (Figure 1, Item 3), black wire (Figure 1, Item 5), and negative battery cable (Figure 1, Item 4) from starter (Figure 1, Item 2).
NOTE
Only red wire needs to be removed from pressure switch, purple wire remains on pressure switch. 3. Remove screw (Figure 2, Item 8), lockwasher (Figure 2, Item 9), and red wire (Figure 2, Item 10) from pressure switch (Figure 2, Item 7). Discard lockwasher.
0128-2
TM 5-3825-270-23&P
0128
REMOVAL - Continued
8, 9 10
Figure 2. Engine Module Removal.
WARNING
NOTE
Cap and plug hoses upon removal. 4. Loosen clamp (Figure 3, Item 13) and remove fuel hose (Figure 3, Item 12) from fitting (Figure 3, Item 11).
0128-3
TM 5-3825-270-23&P
0128
REMOVAL - Continued
11
12 13
Figure 3. Engine Module Removal. 5. Loosen clamp (Figure 4, Item 15) and remove fuel hose (Figure 4, Item 16) from fuel pump (Figure 4, Item 14).
14
15
16
Figure 4. Engine Module Removal. 6. Loosen two clamps (Figure 5, Item 20) from hoses (Figure 5, Items 17 and 19) and union (Figure 5, Item 18).
0128-4
TM 5-3825-270-23&P
0128
REMOVAL - Continued
18 17 20 20 19
23
21, 22
Figure 5. Engine Module Removal. 7. 8. Remove two locknuts (Figure 5, Item 21), washers (Figure 5, Item 22), and union (Figure 5, Item 18), from flatrack (Figure 5, Item 23) and hoses (Figure 5, Item 17 and Item 19). Discard locknuts. Open control panel cover (Figure 6, Item 25) by releasing T-handle (Figure 6, Item 24).
28 29
CAUTION
Control panel and cover must be supported after removal. Allowing cover to hang from wiring may result in damage to equipment. 9. Remove six screws (Figure 7, Item 26) and control panel (Figure 7, Item 27) from main control box (Figure 7, Item 28).
0128-5
TM 5-3825-270-23&P
0128
REMOVAL - Continued
26
27, 28
NOTE
Note routing of harness prior to removal to ensure proper installation. Tag and mark wires prior to removal to ensure proper installation. All wires are removed from terminal strips the same way. 10. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 1.
29 30 31
10
10
10
WIRE WIRE
5 15 15
20
20
WIRE 28
33
32
Figure 8. Engine Module Removal. 11. 12. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 2. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 4.
0128-6
TM 5-3825-270-23&P
0128
REMOVAL - Continued 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 6. Remove black wire from positive terminal strip (Figure 8, Item 29) socket 19. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 10. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 11. Remove black wire from interconnect terminal strip (Figure 8, Item 31) socket 14. Remove white wire from interconnect terminal strip (Figure 8, Item 31) socket 3. Remove white wire from interconnect terminal strip (Figure 8, Item 31) socket 5. Remove white wire from interconnect terminal strip (Figure 8, Item 31) socket 7. Remove white wire from negative terminal strip (Figure 8, Item 30) socket 11. Remove white wire from positive terminal strip (Figure 8, Item 29) socket 10. Remove white wire from interconnect terminal strip (Figure 8, Item 31) socket 20. Remove retaining nut (Figure 8, Item 33) and engine wiring harness (Figure 8, Item 32) from control box (Figure 8, Item 28). Remove red wire from positive terminal strip (Figure 9, Item 31) socket 11.
29 34, 35, 36 31
10
10
10
WIRE
15
15
WIRE
20
20
WIRE
28
38
37
Figure 9. Engine Module Removal. 26. 27. 28. Remove clear wire from interconnect terminal strip (Figure 9, Item 31) socket 17. Remove nut (Figure 9, Item 34), washer (Figure 9, Item 35), and black wire from screw (Figure 9, Item 36). Remove retaining nut (Figure 9, Item 38) and alternator wiring harness (Figure 9, Item 37) from control box (Figure 9, Item 28).
NOTE
Both front engine mount bracket bushings are removed the same way. Right side shown.
0128-7
TM 5-3825-270-23&P
0128
REMOVAL - Continued 29. Remove locknut (Figure 10, Item 42), upper snubbing washer (Figure 10, Item 39), upper isolator mount (Figure 10, Item 45), screw (Figure 10, Item 40), and washer (Figure 10, Item 41) from front engine mount bracket (Figure 10, Item 43) and frame (Figure 10, Item 44). Discard locknut.
40, 41 39
42
45 43
44
Figure 10. Engine Module Removal. 30. Repeat Step (29) for other side.
NOTE
Both rear engine mount bracket bushings are removed the same way. Right side shown. 31. Remove locknut (Figure 11, Item 47), upper snubbing washer (Figure 11, Item 46), upper isolator mount (Figure 11, Item 51), screw (Figure 11, Item 48), and washer (Figure 11, Item 49) from rear engine mount bracket (Figure 11, Item 50) and frame (Figure 11, Item 44). Discard locknut.
46 44 50 47 48, 49
51
Figure 11. Engine Module Removal. 32. 33. Repeat Step (31) for left side. Remove ten screws (Figure 12 Item 53) and washers (Figure 12, Item 54) from water pump assembly (Figure 12, Item 52) and flywheel housing (Figure 12, Item 55).
0128-8
TM 5-3825-270-23&P
0128
REMOVAL - Continued
ENGINE AND PUMP SHOWN REMOVED FOR CLARITY
55 53, 54
52
56, 57 58
Figure 12. Engine Module Removal. 34. Remove two screws (Figure 12, Item 56) and washers (Figure 12, Item 57) from discharge tube support bracket (Figure 12, Item 58), water pump assembly (Figure 12, Item 52), and flywheel housing (Figure 12, Item 55).
WARNING
Engine module weighs 800 lbs (363 kg). Do not attempt to move or lift without the aid of an assistant and lifting device.
NOTE
Water pump assembly must be supported during removal to ensure proper alignment during installation. Failure to comply may cause damage to equipment 35. Attach suitable lifting device to engine module (Figure 13, Item 59).
0128-9
TM 5-3825-270-23&P
0128
REMOVAL - Continued
LIFTING DEVICE
59
CAUTION
Ensure all wiring, fuel hoses, and components are clear when removing engine module. Failure to comply may result in damage to equipment. 36. With the aid of an assistant and lifting device, remove engine module (Figure 14, Item 59) from water pump assembly (Figure 14, Item 52) and frame (Figure 14, Item 44).
ENGINE / PUMP MODULE SHOWN REMOVED FOR CLARITY
59
52 44
Figure 14. Engine Module Removal. 37. Remove two lower isolator mounts (Figure 15, Item 61) from front engine mount brackets (Figure 15, Item 43). Discard isolator mounts.
0128-10
TM 5-3825-270-23&P
0128
REMOVAL - Continued
50
60 43 61
Figure 15. Engine Module Removal. 38. 39. Remove two lower isolator mounts (Figure 15, Item 60) from rear engine mount brackets (Figure 15, Item 50). Discard isolator mounts. Place engine module on level surface.
NOTE
Lower snubbing washers may be on lower isolator mounts. 40. Collect four lower snubbing washers (Figure 16, Item 62) from frame (Figure 16, Item 44).
0128-11
TM 5-3825-270-23&P
0128
REMOVAL - Continued
TANK SHOWN REMOVED FOR CLARITY 44
62
Figure 16. Engine Module Removal. 41. Remove lifting device from engine module (Figure 17, Item 59).
LIFTING DEVICE
59
Figure 17. Engine Module Removal. END OF TASK INSTALLATION
WARNING
Engine module weighs 800 lbs (363 kg). Do not attempt to move or lift without the aid of an assistant and lifting device. 1. Attach suitable lifting device to engine module (Figure 18, Item 59).
0128-12
TM 5-3825-270-23&P
0128
LIFTING DEVICE
59
Figure 18. Engine Module Installation. 2. Install two lower isolator mounts (Figure 19, Item 60) on rear engine mount brackets (Figure 19, Item 50).
50
60 43 61
Figure 19. Engine Module Installation. 3. 4. Install two lower isolator mounts (Figure 19, Item 61) on front engine mount brackets (Figure 19, Item 43). With the aid of an assistant and lifting device, align flex element (Figure 20, Item 63) with pump drive coupling (Figure 20, Item 64) and position engine module (Figure 20, Item 59) on water pump assembly (Figure 20, Item 52) and frame (Figure 20, Item 44).
0128-13
TM 5-3825-270-23&P
0128
63 59 64 52
52 59
44
Figure 20. Engine Module Installation. 5. Secure flywheel housing (Figure 21, Item 55) on water pump assembly (Figure 21, Item 52) with ten washers (Figure 21, Item 54) and screws (Figure 21, Item 53).
0128-14
TM 5-3825-270-23&P
0128
ENGINE AND PUMP SHOWN REMOVED FOR CLARITY
55 53, 54
52
56, 57 58
Figure 21. Engine Module Installation. 6. 7. Install two screws (Figure 21, Item 56) and washers (Figure 21, Item 57) in discharge tube support bracket (Figure 21, Item 58), water pump assembly (Figure 21, Item 52), and flywheel housing (Figure 21, Item 55). Position bottle jack and lumber beneath front of oil pan (Figure 22, Item 65).
65
LUMBER
BOTTLE JACK
Figure 22. Engine Module Installation.
CAUTION
Do not jack engine module up too high. Only raise engine module in small increments until snubbing washers can be installed. Failure to comply may result in damage to equipment. 8. Using bottle jack and lumber, raise engine module (Figure 23, Item 59) until four lower snubbing washers (Figure 23, Item 62) can be installed between lower isolator mounts (Figure 23, Items 60 and 61) and frame (Figure 23, Item 44).
0128-15
TM 5-3825-270-23&P
0128
59
60 61 44 62 62
Figure 23. Engine Module Installation. 9. Lower bottle jack from front of oil pan (Figure 24, Item 65).
65
LUMBER
BOTTLE JACK
Figure 24. Engine Module Installation. 10. Remove lumber and bottle jack from beneath oil pan (Figure 24, Item 65).
0128-16
TM 5-3825-270-23&P
0128
INSTALLATION - Continued 11. Secure rear engine mount bracket (Figure 25, Item 50) to frame (Figure 25, Item 44) with washer (Figure 25, Item 49), screw (Figure 25, Item 48), upper isolator mount (Figure 25, Item 51), upper snubbing washer (Figure 25, Item 46), and locknut (Figure 25, Item 47). Tighten locknut to 150 lb-ft (203 NM).
46 44 50 47 48, 49
51
Figure 25. Engine Module Installation. 12. Repeat Step (11) for other side.
NOTE
Both front engine mount bracket bushings are installed the same way. Right side shown. 13. Secure front engine mount bracket (Figure 26, Item 43) to frame (Figure 26, Item 44) with washer (Figure 26, Item 41), screw (Figure 26, Item 40), upper isolator mount (Figure 26, Item 45), upper snubbing washer (Figure 26, Item 39), and locknut (Figure 26, Item 42). Tighten locknut to 150 lb-ft (203 Nm).
40, 41 39
42
45 43
44
Figure 26. Engine Module Installation. 14. Repeat Step (13) for left side.
NOTE
Route wiring as noted prior to removal.
0128-17
TM 5-3825-270-23&P
0128
INSTALLATION - Continued Install wiring as noted prior to removal. All wiring is installed onto terminal strips the same way. 15. Install alternator wiring harness (Figure 27, Item 37) in control box (Figure 27, Item 28) with retaining nut (Figure 27, Item 38).
29 34, 35, 36 31
10
10
10
WIRE
15
15
WIRE
20
20
WIRE
28
38
37
Figure 27. Engine Module Installation. 16. 17. 18. 19. Install black wire on screw (Figure 27, Item 36) with washer (Figure 27, Item 35) and nut (Figure 27, Item 34). Install clear wire on interconnect terminal strip (Figure 27, Item 31) socket 17. Install red wire on positive terminal strip (Figure 27, Item 31) socket 11. Install engine wiring harness (Figure 28, Item 32) in main control box (Figure 28, Item 28) with retaining nut (Figure 28, Item 33).
0128-18
TM 5-3825-270-23&P
0128
29 30 31
10
10
10
WIRE WIRE
5 15 15
20
20
WIRE 28
33
32
Figure 28. Engine Module Installation. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. Install white wire on interconnect terminal strip (Figure 28, Item 31) socket 20. Install white wire on positive terminal strip (Figure 28, Item 29) socket 10. Install white wire on negative terminal strip (Figure 28, Item 30) socket 11. Install white wire on interconnect terminal strip (Figure 28, Item 31) socket 7. Install white wire on interconnect terminal strip (Figure 28, Item 31) socket 5. Install white wire on interconnect terminal strip (Figure 28, Item 31) socket 3. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 14. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 11. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 10. Install black wire on positive terminal strip (Figure 28, Item 29) socket 19. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 6. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 4. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 2. Install black wire on interconnect terminal strip (Figure 28, Item 31) socket 1. Install control panel (Figure 29, Item 27) on main control box (Figure 29, Item 28) with six screws (Figure 29, Item 26).
0128-19
TM 5-3825-270-23&P
0128
26
27, 28
Figure 29. Engine Module Installation. 35. Close and secure control panel cover (Figure 30, Item 25) with T-handle (Figure 30, Item 24).
28 29
Figure 30. Engine Module Installation. 36. Install union (Figure 31, Item 18) in hoses (Figure 31, Item 19 and 17) with two clamps (Figure 31, Item 20). Do not tighten clamps.
0128-20
TM 5-3825-270-23&P
0128
18 17 20 20 19
23
21, 22
Figure 31. Engine Module Installation. 37. 38. Install union (Figure 31, Item 18) on flatrack (Figure 31, Item 23) with two washers (Figure 31, Item 22) and locknuts (Figure 31, Item 21). Tighten clamps (Figure 31, Item 20) to 70 lbs-in (7.9 Nm).
WARNING
NOTE
Route wiring harness and hoses as noted prior to removal. Install cable ties and retainers as required. 39. Install fuel hose (Figure 32, Item 16) on fuel pump (Figure 32, Item 14) with clamp (Figure 32, Item 15).
0128-21
TM 5-3825-270-23&P
0128
14
15
16
Figure 32. Engine Module Installation. 40. Install fuel hose (Figure 33, Item 12) on fitting (Figure 33, Item 11) with clamp (Figure 33, Item 13).
11
12 13
Figure 33. Engine Module Installation. 41. Install red wire (Figure 34, Item 10) on pressure switch (Figure 34, Item 7) with lockwasher (Figure 34, Item 9) and screw (Figure 34, Item 8).
0128-22
TM 5-3825-270-23&P
0128
8, 9 10
Figure 34. Engine Module Installation. 42. Install negative battery cable (Figure 35, Item 4) and black wire (Figure 35, Item 5) on starter (Figure 35, Item 2) with nut (Figure 35, Item 3).
0128-23
TM 5-3825-270-23&P
0128
6
Figure 35. Engine Module Installation. 43. Install positive battery cable (Figure 35, Item 6) on starter (Figure 35, Item 2) with nut (Figure 35, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install engine compartment cover. (WP 0142) Connect batteries. (WP 0085)
0128-24
TM 5-3825-270-23&P
0129
FIELD MAINTENANCE EXHAUST MANIFOLD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Gasket, Manifold (WP 0226, Table 1, Item 20) Qty: 1 References Parts Manual (WP 0220) Figure 4040 Equipment Condition Exhaust flex pipe removed. (WP 0149)
REMOVAL
WARNING
Exhaust pipes and muffler can become very hot during engine operation. Allow parts to cool and take care not to touch these parts with bare hands or allow body to contact exhaust pipes or muffler. Failure to comply may result in injury or death to personnel. 1. Remove four nuts (Figure 1, Item 5) from exhaust manifold (Figure 1, Item 3) and cylinder head (Figure 1, Item 1).
1
2 3 4
Figure 1. Exhaust Manifold Removal.
0129-1
TM 5-3825-270-23&P
0129
REMOVAL - Continued 2. Remove four screws (Figure 1, Item 4), exhaust manifold (Figure 1, Item 3), and manifold gasket (Figure 1, Item 2) from cylinder head (Figure 1, Item 1). Discard manifold gasket.
END OF TASK INSTALLATION 1. Install manifold gasket (Figure 2, Item 2) and exhaust manifold (Figure 2, Item 3) on cylinder head (Figure 2, Item 1) with four screws (Figure 2, Item 4).
1
2 3 4
Figure 2. Exhaust Manifold Installation. 2. Install four nuts (Figure 2, Item 5) onto exhaust manifold (Figure 2, Item 3) and cylinder head (Figure 2, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE Install exhaust flex pipe. (WP 0149) END OF TASK END OF WORK PACKAGE
0129-2
TM 5-3825-270-23&P
0130
FIELD MAINTENANCE FRONT ENGINE MOUNT BRACKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Jack, Hydraulic Hand Bottle Type, 20 Ton Cap (WP 0225, Table 1, Item 2) Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive (WP 0225, Table 1, Item 15) Materials/Parts Lumber, Softwood, Dimension (WP 0224, Table 1, Item 41) Locknut (WP 0226, Table 1, Item 41) Qty: 2 Materials/Parts (cont.) Isolator Mount (WP 0226, Table 1, Item 49) Qty: 2 Lockwasher (WP 0226, Table 1, Item 43) Qty: 8 References Parts Manual (WP 0220) Figure 4020 Parts Manual (WP 0220) Figure 4025 Equipment Condition Radiator and bracket removed. (WP 0076)
REMOVAL
NOTE
Both front engine mounts are removed the same way. Right engine mount shown. 1. Position bottle jack and lumber beneath front of oil pan (Figure 1, Item 1).
LUMBER 1
BOTTLE JACK
Figure 1. Front Engine Mount Bracket Removal. 2. 3. Using jack and lumber, apply light pressure to oil pan (Figure 1, Item 1). Remove locknut (Figure 2, Item 3), screw (Figure 2, Item 4), washer (Figure 2, Item 5), two snubbing washers (Figure 2, Item 2), and isolator mount (Figure 2, Item 7) from engine mount bracket (Figure 2, Item 6) and frame (Figure 2, Item 8). Discard locknut.
0130-1
TM 5-3825-270-23&P
0130
REMOVAL - Continued
4, 5
Figure 2. Front Engine Mount Bracket Removal. 4. Lift radiator support (Figure 3, Item 9) from front engine mount bracket (Figure 3, Item 6).
9 6
Figure 3. Front Engine Mount Bracket Removal. 5. Remove four screws (Figure 4, Item 10), lockwashers (Figure 4, Item 11), washers (Figure 4, Item 12), and front engine mounting bracket (Figure 4, Item 6) from engine block (Figure 4, Item 13). Discard lockwashers.
0130-2
TM 5-3825-270-23&P
0130
REMOVAL - Continued
6 10 11 12
13
Figure 4. Front Engine Mount Bracket Removal. 6. Remove isolator mount (Figure 5, Item 14) from engine mount bracket (Figure 5, Item 6). Discard isolator mounts.
14
Figure 5. Front Engine Mount Bracket Removal. END OF TASK INSTALLATION
NOTE
Both front engine mounts are installed the same way. Right engine mount shown. 1. Install isolator mount (Figure 6, Item 14) onto engine mount bracket (Figure 6, Item 6).
0130-3
TM 5-3825-270-23&P
0130
14
Figure 6. Front Engine Mount Bracket Installation. 2. Install engine mount bracket (Figure 7, Item 6) onto engine block (Figure 7, Item 13) with four washers (Figure 7, Item 12), lockwashers (Figure 7, Item 11), and screws (Figure 7, Item 10).
6 10 11 12
13
Figure 7. Front Engine Mount Bracket Installation. 3. Align dowel and position radiator support (Figure 8, Item 9) onto front engine mount bracket (Figure 8, Item 6).
0130-4
TM 5-3825-270-23&P
0130
9 6
Figure 8. Front Engine Mount Bracket Installation. 4. Install engine mount bracket (Figure 9, Item 6) onto frame (Figure 9, Item 8) with isolator mount (Figure 9, Item 7), two snubbing washers (Figure 9, Item 2), washer (Figure 9, Item 5), screw (Figure 9, Item 4), and locknut (Figure 9, Item 3). Tighten locknut to 150 lb-ft (203 Nm).
4, 5
Figure 9. Front Engine Mount Bracket Installation. 5. Lower bottle jack.
0130-5
TM 5-3825-270-23&P
0130
LUMBER 1
BOTTLE JACK
Figure 10. Front Engine Mount Bracket Installation. 6. Remove lumber and bottle jack from beneath oil pan (Figure 10, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE Install radiator and bracket. (WP 0076) END OF TASK END OF WORK PACKAGE
0130-6
TM 5-3825-270-23&P
0131
FIELD MAINTENANCE GLOW PLUG RELAY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Lockwasher (WP 0226, Table 1, Item 75) Qty: 3 Materials/Parts (cont.) Lockwasher (WP 0226, Table 1, Item 37) Qty: 1 Lockwasher (WP 0226, Table 1, Item 59) Qty: 4 References Parts Manual (WP 0220) Figure 4026 Equipment Condition Batteries disconnected. (WP 0085) Rear enclosure panel removed. (WP 0143)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. Note position of wires prior to removal to ensure proper installation. 1. Remove nut (Figure 1, Item 5), lockwasher (Figure 1, Item 6), and white wire (Figure 1, Item 8) from stud (Figure 1, Item 7). Discard lockwasher.
1 2, 3, 4 10, 11, 12
5, 6, 7
Figure 1. Glow Plug Relay Removal.
0131-1
TM 5-3825-270-23&P
0131
REMOVAL - Continued 2. 3. 4. Remove nut (Figure 1, Item 10), lockwasher (Figure 1, Item 11), and yellow wire (Figure 1, Item 9) from stud (Figure 1, Item 12). Discard lockwasher. Remove nut (Figure 1, Item 2), lockwasher (Figure 1, Item 3), and red wire (Figure 1, Item 1) from stud (Figure 1, Item 4). Discard lockwasher. Remove nut (Figure 2, Item 18), lockwasher (Figure 2, Item 19), and blue wire (Figure 2, Item 17) from stud (Figure 2, Item 20). Discard lockwasher.
13, 14, 15
16
18, 19, 20
17
Figure 2. Glow Plug Relay Removal. 5. Remove two nuts (Figure 2, Item 13), lockwashers (Figure 2, Item 14), and glow plug relay (Figure 2, Item 16) from isolators (Figure 2, Item 15). Discard lockwashers.
NOTE
Perform Step (6) if isolators are damaged. All isolators are removed the same way. Top isolator shown. 6. Remove screw (Figure 3, Item 21), lockwasher (Figure 3, Item 22), and isolator (Figure 3, Item 15) from mounting surface (Figure 3, Item 23). Discard lockwasher.
0131-2
TM 5-3825-270-23&P
0131
REMOVAL - Continued
15
21, 22
23
Figure 3. Glow Plug Relay Removal. END OF TASK INSTALLATION
NOTE
Perform Step (1) if isolators were removed. All isolators are installed the same way. Top isolator shown. 1. Install isolator (Figure 4, Item 15) on mounting surface (Figure 4, Item 23) with lockwasher (Figure 4, Item 22) and screw (Figure 4, Item 21).
15
21, 22
23
Figure 4. Glow Plug Relay Installation. 2. Install glow plug relay (Figure 5, Item 16) on isolators (Figure 5, Item 15) with lockwashers (Figure 5, Item 14) and nuts (Figure 3, Item 13).
0131-3
TM 5-3825-270-23&P
0131
13, 14, 15
16
18, 19, 20
17
Figure 5. Glow Plug Relay Installation.
NOTE
Install wires as noted prior to removal. 3. 4. Install blue wire (Figure 5, Item 17) on stud (Figure 5, Item 20) with lockwasher (Figure 5, Item 19) and nut (Figure 5, Item 18). Install red wire (Figure 6, Item 1) on stud (Figure 6, Item 4) with lockwasher (Figure 6, Item 3) and nut (Figure 6, Item 2).
0131-4
TM 5-3825-270-23&P
0131
1 2, 3, 4 10, 11, 12
5, 6, 7
Figure 6. Glow Plug Relay Installation. 5. 6. Install yellow wire (Figure 6, Item 9) on stud (Figure 6, Item 12) with lockwasher (Figure 6, Item 11) and nut (Figure 6, Item 10). Install white wire (Figure 6, Item 8) on stud (Figure 6, Item 7) with lockwasher (Figure 6, Item 6) and nut (Figure 6, Item 5).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install rear enclosure panel. (WP 0143) Connect batteries. (WP 0085)
0131-5/6 blank
TM 5-3825-270-23&P
0132
FIELD MAINTENANCE GLOW PLUG REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) References Parts Manual (WP 0220) Figure 4046 Equipment Condition Engine OFF. (TM 5-3825-270-10) Equipment Condition (cont.) Batteries disconnected. (WP 0085) Engine compartment cover removed. (WP 0142)
REMOVAL
NOTE
All glow plugs are removed the same way. 1. Remove four nuts (Figure 1, Item 2), blue wire (Figure 1, Item 1), and cord (Figure 1, Item 3) from glow plugs (Figure 1, Item 4).
2
5 4
Figure 1. Glow Plug Removal.
NOTE
Ensure area around glow plugs is clean and free of debris. Failure to comply may result in damage to equipment. 2. Remove glow plug (Figure 1, Item 4) from cylinder head (Figure 1, Item 5).
END OF TASK
0132-1
TM 5-3825-270-23&P
0132
INSTALLATION
NOTE
All glow plugs are installed the same way. 1. Install glow plug (Figure 2, Item 4) in cylinder head (Figure 2, Item 5).
2
5 4
Figure 2. Glow Plug Installation. 2. 3. Tighten glow plug (Figure 2, Item 4) to 180 in-lb (20 Nm). Install cord (Figure 2, Item 3) and blue wire (Figure 2, Item 1) on glow plugs (Figure 2, Item 4) with four nuts (Figure 2, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install engine compartment cover. (WP 0142) Connect batteries. (WP 0085)
0132-2
TM 5-3825-270-23&P
0133
FIELD MAINTENANCE GOVERNOR ACTUATOR REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing (WP 0224, Table 1, Item 18) References Parts Manual (WP 0220) Figure 4026 Equipment Condition Batteries disconnected. (WP 0085) Rear access panel removed. (TM 5-3825-270-10).
REMOVAL 1. Disconnect connector (Figure 1, Item 1) from connector (Figure 1, Item 2).
1 2
Figure 1. Governor Actuator Removal.
CAUTION
Do not allow dirt, or debris fall into injection pump when removing governor actuator. Failure to comply may result in damage to equipment. 2. Remove two hex screws (Figure 2, Item 5) and governor actuator (Figure 2, Item 3) from injection pump (Figure 2, Item 4).
0133-1
TM 5-3825-270-23&P
0133
REMOVAL - Continued
3
Figure 2. Governor Actuator Removal. END OF TASK INSTALLATION
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Apply sealing compound to bottom mating surface of governor actuator (Figure 3, Item 4).
Figure 3. Governor Actuator Installation.
NOTE
Ensure solenoid pin seats on shutoff lever.
0133-2
TM 5-3825-270-23&P
0133
INSTALLATION - Continued 2. Install governor actuator (Figure 4, Item 3) on injection pump (Figure 4, Item 4) with two hex screws (Figure 4, Item 5).
3
Figure 4. Governor Actuator Installation. 3. Connect connector (Figure 5, Item 2) to connector (Figure 5, Item 1).
1 2
Figure 5. Governor Actuator Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install rear access panel. (TM 5-3825-270-10) Connect batteries. (WP 0085)
0133-3/4 blank
TM 5-3825-270-23&P
0134
FIELD MAINTENANCE OIL SAMPLING VALVE REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Materials/Parts (cont.) Oil, Lubricating, Engine, OE/HDO 15W40 (WP 0224, Table 1, Item 42, 43, 44, 45) Gasket (WP 0226, Table 1, Item 14) Qty: 1 References Parts Manual (WP 0220) Figure 4034 Equipment Condition Engine oil drained. (WP 0124)
REMOVAL 1. Remove oil sampling valve (Figure 1, Item 4), drain plug (Figure 1, Item 2) and gasket (Figure 1, Item 3) from oil pan (Figure 1, Item 1). Discard gasket.
2, 3
Figure 1. Oil Sampling Valve Removal. 2. Remove oil sampling valve (Figure 1, Item 4) from drain plug (Figure 1, Item 2).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated
0134-1
TM 5-3825-270-23&P
0134
INSTALLATION - Continued area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Apply sealing compound to threads of oil sampling valve (Figure 2, Item 4).
2, 3
Figure 2. Oil Sampling Valve Installation. 2. 3. Install oil sampling valve (Figure 2, Item 4) on drain plug (Figure 2, Item 2). Install oil sampling valve (Figure 2, Item 4), drain plug (Figure 2, Item 2), and gasket (Figure 2, Item 3) onto oil pan (Figure 2, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE Fill engine oil. (WP 0124) END OF TASK END OF WORK PACKAGE
0134-2
TM 5-3825-270-23&P
0135
FIELD MAINTENANCE REAR ENGINE MOUNT BRACKET AND BUSHING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Jack, Hydraulic Hand Bottle Type, 20 Ton Cap (WP 0225, Table 1, Item 2) Materials/Parts Lumber, Softwood, Dimension (WP 0224, Table 1, Item 41) Locknut (WP 0226, Table 1, Item 41) Qty: 4 Isolation Mount (WP 0226, Table 1, Item 49) Qty: 1 Lockwasher (WP 0226, Table 1, Item 55) Qty: 1 Materials/Parts (cont.) Lockwasher (WP 0226, Table 1, Item 43) Qty: 4 Isolation Mount (WP 0226, Table 1, Item 69) Qty: 2 References Parts Manual (WP 0220) Figure 4020 Parts Manual (WP 0220) Figure 4023 Parts Manual (WP 0220) Figure 4024 Equipment Condition Rear access panel removed. (TM 5-3825-270-10)
REMOVAL
WARNING
Engine assembly must be supported prior to removing mounting bracket hardware. Failure to comply may result in injury or death to personal.
NOTE
Both rear engine mount brackets are removed the same way. Right side shown. 1. Remove locknut (Figure 1, Item 2), upper snubbing washer (Figure 1, Item 1), upper isolator mount (Figure 1, Item 6), screw (Figure 1, Item 3), and washer (Figure 1, Item 4) from engine mount bracket (Figure 1, Item 5) and frame (Figure 1, Item 7). Discard locknut and isolator mount.
0135-1
TM 5-3825-270-23&P
0135
REMOVAL - Continued
1 2 3, 4 5
Figure 1. Rear Engine Mount Bracket and Bushing Removal. 2. Remove nut (Figure 2, Item 9), lockwasher (Figure 2, Item 11), washer (Figure 2, Item 10), screw (Figure 2, Item 12), and washer (Figure 2, Item 13) from engine compartment side rail (Figure 2, Item 14) and support bracket (Figure 2, Item 8). Discard lockwasher.
9 8 10
11
14
12, 13
Figure 2. Rear Engine Mount Bracket and Bushing Removal. 3. Remove two screws (Figure 3, Item 16), lockwashers (Figure 3, Item 15), and support bracket (Figure 3, Item 8) from engine mount bracket (Figure 3, Item 5) and flywheel housing (Figure 3, Item 17). Discard lockwashers.
0135-2
TM 5-3825-270-23&P
0135
REMOVAL - Continued
8 5 15 16
17
Figure 3. Rear Engine Mount Bracket and Bushing Removal.
NOTE
Perform Step (4) if isolator mount is damaged. 4. Remove isolator mount (Figure 4, Item 18) from support bracket (Figure 4, Item 8). Discard isolator mount.
8 18
Figure 4. Rear Engine Mount Bracket and Bushing Removal. 5. Position jack and lumber under flywheel housing (Figure 5, Item 17).
0135-3
TM 5-3825-270-23&P
0135
REMOVAL - Continued
LUMBER
17
JACK
Figure 5. Rear Engine Mount Bracket and Bushing Removal. 6. 7. Using jack and lumber, apply light pressure to flywheel housing (Figure 5, Item 17). Remove two screws (Figure 6, Item 20), lockwashers (Figure 6, Item 19), and engine mount bracket (Figure 6, Item 5) from flywheel housing (Figure 6, Item 17). Discard lockwashers.
17
19
20
Figure 6. Rear Engine Mount Bracket and Bushing Removal. 8. Remove lower snubbing washer (Figure 7, Item 21) from frame (Figure 7, Item 7).
0135-4
TM 5-3825-270-23&P
0135
REMOVAL - Continued
7 21
Figure 7. Rear Engine Mount Bracket and Bushing Removal. 9. Remove lower isolator mount (Figure 8, Item 22) from engine mount bracket (Figure 8, Item 5). Discard isolator mount.
5
22
Figure 8. Rear Engine Mount Bracket and Bushing Removal. END OF TASK INSTALLATION
NOTE
Both rear engine mount brackets are installed the same way. Right side shown. 1. Install lower isolator mount (Figure 9, Item 22) on engine mount bracket (Figure 9, Item 5).
0135-5
TM 5-3825-270-23&P
0135
5
22
Figure 9. Rear Engine Mounting Bracket and Bushing Installation. 2. Position lower snubbing washer (Figure 10, Item 21) on frame (Figure 10, Item 7).
7 21
Figure 10. Rear Engine Mounting Bracket and Bushing Installation. 3. Install engine mount bracket (Figure 11, Item 5) on flywheel housing (Figure 11, Item 17) with two lockwashers (Figure 11, Item 19) and screws (Figure 11, Item 20).
0135-6
TM 5-3825-270-23&P
0135
17
19
20
Figure 11. Rear Engine Mounting Bracket and Bushing Installation.
NOTE
Perform Step (4) if isolator bushing was removed. 4. Install bushing (Figure 12, Item 18) on support bracket (Figure 12, Item 8).
8 18
Figure 12. Rear Engine Mounting Bracket and Bushing Installation. 5. Install support bracket (Figure 13, Item 8) on engine mount bracket (Figure 13, Item 5) and flywheel housing (Figure 13, Item 17) with two screws (Figure 13, Item 16) and lockwashers (Figure 13, Item 15).
0135-7
TM 5-3825-270-23&P
0135
8 5 15 16
17
Figure 13. Rear Engine Mounting Bracket and Bushing Installation. 6. Install engine compartment side rail (Figure 14, Item 14) on support bracket (Figure 14, Item 8) with washer (Figure 14, Item 13), screw (Figure 14, Item 12), washer (Figure 14, Item 10), lockwasher (Figure 14, Item 11), and nut (Figure 14, Item 9).
9 8 10
11
14
12, 13
Figure 14. Rear Engine Mounting Bracket and Bushing Installation. 7. Secure engine mount bracket (Figure 15, Item 5) on frame (Figure 15, Item 7) with upper isolator mount (Figure 15, Item 6), upper snubbing washer (Figure 15, Item 1), washer (Figure 15, Item 4), screw (Figure 15, Item 3), and locknut (Figure 15, Item 2). Tighten locknut to 150 lb-ft (203 Nm).
0135-8
TM 5-3825-270-23&P
0135
1 2 3, 4 5
Figure 15. Rear Engine Mounting Bracket and Bushing Installation. 8. Relive pressure on flywheel housing (Figure 16, Item 17) by lowering jack.
LUMBER
17
JACK
Figure 16. Rear Engine Mounting Bracket and Bushing Installation. 9. Remove jack and lumber from under flywheel housing (Figure 15, Item 17).
END OF TASK FOLLOW-ON MAINTENANCE Install rear access panel. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0135-9/10 blank
TM 5-3825-270-23&P
0136
FIELD MAINTENANCE REAR MAIN SEAL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Press, Arbor, Hand Operated (WP 0225, Table 1, Item 5) Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 13) Materials/Parts Gasket, Silicon (WP 0224, Table 1, Item 34) Oil, Lubricating, Engine, OE/HDO 15W40 (WP 0224, Table 1, Item 42, 43, 44, 45) References Parts Manual (WP 0220) Figure 4041 Equipment Condition Engine module removed. (WP 0128) Engine flywheel removed. (WP 0112)
REMOVAL
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 1. Remove eight screws (Figure 1, Item 3) securing rear main seal housing assembly (Figure 1, Item 2) to engine block (Figure 1, Item 1).
0136-1
TM 5-3825-270-23&P
0136
REMOVAL - Continued
4
Figure 1. Rear Main Seal Removal. 2. 3. Install two screws (Figure 1, Item 3) in jack screw holes (Figure 1, Item 4) on rear main seal housing assembly (Figure 1, Item 2). Tighten two screws (Figure 2, Item 3) in jack screw holes (Figure 2, Item 4) one half-turn at a time until rear main seal housing assembly (Figure 2, Item 2) is removed from engine block (Figure 2, Item 1).
3, 4
Figure 2. Rear Main Seal Removal. 4. Remove two screws (Figure 3, Item 3) from jack screw holes (Figure 3, Item 4) on rear main seal housing assembly (Figure 3, Item 2).
0136-2
TM 5-3825-270-23&P
0136
REMOVAL - Continued
3, 4
Figure 3. Rear Main Seal Removal. 5. Remove all gasket material from engine block (Figure 4, Item 1) and mating surface of rear main seal housing (Figure 4, Item 2).
1 2 MATING SURFACE
MATING SURFACE
Figure 4. Rear Main Seal Removal. 6. Place rear main seal housing assembly (Figure 5, Item 2) in hand operated arbor press with mating surface down.
0136-3
TM 5-3825-270-23&P
0136
REMOVAL - Continued
ARBOR PRESS
Figure 5. Rear Main Seal Removal. 7. Remove rear main seal (Figure 5, Item 5) from rear main seal housing assembly (Figure 5, Item 2) by pressing out with hand operated arbor press.
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 1. Lightly coat outer mounting surface of rear main seal (Figure 6, Item 5) with clean oil.
OUTER MOUNTING SURFACE 5
Figure 6. Rear Main Seal Installation.
0136-4
TM 5-3825-270-23&P
0136
INSTALLATION - Continued 2. Place rear main seal housing (Figure 7, Item 6) on hand operated arbor press with mating surface up.
ARBOR PRESS 5 6
Figure 7. Rear Main Seal Installation. 3. Press rear main seal (Figure 7, Item 5) in rear main seal housing (Figure 7, Item 6) with hand operated arbor press.
WARNING
CAUTION
Once sealant has been applied, the rear main seal housing assembly must be installed within 10 minutes. Failure to comply may result in an oil leak and damage to equipment. 4. Apply sealant to mating surface of rear main seal housing assembly (Figure 8, Item 2).
0136-5
TM 5-3825-270-23&P
0136
SEALANT
Figure 8. Rear Main Seal Installation. 5. Lightly lubricate inner mounting surface of rear main seal (Figure 9, Item 5) with clean oil.
INNER MOUNTING SURFACE
Figure 9. Rear Main Seal Installation. 6. Install rear main seal housing assembly (Figure 10, Item 2) on engine block (Figure 10, Item 1) with eight screws (Figure 10, Item 3).
0136-6
TM 5-3825-270-23&P
0136
1 2 3
Figure 10. Rear Main Seal Installation.
CAUTION
Rear main seal housing assembly screws must be tightened evenly, in sequence shown. Failure to comply may result in an oil leak and damage to equipment. 7. Torque screws to 18-20 lb ft (24-27 Nm).
3 5
6 4 TIGHTENING SEQUENCE DIAGRAM
Figure 11. Rear Main Seal Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install engine flywheel. (WP 0112) Install engine module. (WP 0128)
0136-7/8 blank
TM 5-3825-270-23&P
0137
FIELD MAINTENANCE OIL PRESSURE SENDING UNIT AND PRESSURE SWITCH REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Lockwasher (WP 0226, Table 1, Item 62) Qty: 1 References Parts Manual (WP 0220) Figure 4026 Equipment Condition Batteries disconnected. (WP 0085) Engine access panel removed. (TM 5-3825-270-10)
REMOVAL
WARNING
WARNING
NOTE
Position drain pan under sending unit prior to removal. Clean up any oil spills immediately. Refer to local policies and regulations for disposal of contaminated oil and rags. 1. Remove nut (Figure 1, Item 2), washer (Figure 1, Item 3), and wire (Figure 1, Item 4) from sending unit (Figure 1, Item 1).
0137-1
TM 5-3825-270-23&P
0137
REMOVAL - Continued
2, 3
5, 6 7 8
12
11
10
Figure 1. Sending Unit Removal. 2. 3. 4. Remove screw (Figure 1, Item 5), lockwasher (Figure 1, Item 6), purple wire (Figure 1, Item 8), and red wire (Figure 1, Item 7) from pressure switch (Figure 1, Item 9). Discard lockwasher. Remove sending unit (Figure 1, Item 1) from fitting (Figure 1, Item 10). Remove pressure switch (Figure 1, Item 9) from fitting (Figure 1, Item 10).
NOTE
Note position of fittings prior to removal to ensure proper installation. 5. 6. Remove fitting (Figure 1, Item 10) from fitting (Figure 1, Item 12). Remove fitting (Figure 1, Item 12) from engine block (Figure 1, Item 11).
END OF TASK
0137-2
TM 5-3825-270-23&P
0137
INSTALLATION
WARNING
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 1. Apply pipe thread sealant to threads of fitting (Figure 2, Item 12).
0137-3
TM 5-3825-270-23&P
0137
2, 3
5, 6 7 8
12
11
10
Figure 2. Sending Unit Installation.
NOTE
Install fittings as noted prior to removal. 2. 3. Install fitting (Figure 2, Item 12) on engine block (Figure 2, Item 11). Apply pipe thread sealant to threads of fitting (Figure 2, Item 10).
NOTE
Install fittings as noted prior to removal. 4. 5. 6. 7. 8. 9. Install fitting (Figure 2, Item 10) on fitting (Figure 2, Item 12). Apply pipe thread sealant to threads of pressure switch (Figure 2, Item 9). Install pressure switch (Figure 2, Item 9) on fitting (Figure 2, Item 10). Apply pipe thread sealant to threads of sending unit (Figure 2, Item 1). Install sending unit (Figure 2, Item 1) on fitting (Figure 2, Item 10). Install red wire (Figure 2, item 7) and purple wire (Figure 2, Item 8) on pressure switch (Figure 2, Item 9) with lockwasher (Figure 2, Item 6) and screw (Figure 2, Item 5).
0137-4
TM 5-3825-270-23&P
0137
INSTALLATION - Continued 10. Install wire (Figure 2, Item 4) on sending unit (Figure 2, Item 1) with washer (Figure 2, Item 3) and nut (Figure 2, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install engine access panel. (TM 5-3825-270-10) Connect batteries. (WP 0085)
0137-5/6 blank
TM 5-3825-270-23&P
0138
FIELD MAINTENANCE STARTER RELAY REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Lockwasher (WP 0226, Table 1, Item 75) Qty: 3 Materials/Parts (cont.) Lockwasher (WP 0226, Table 1, Item 37) Qty: 1 Lockwasher (WP 0226, Table 1, Item 59) Qty: 4 References Parts Manual (WP 0220) Figure 4026 Equipment Condition Batteries disconnected. (WP 0085) Rear enclosure panel removed. (WP 0143)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. Note position of wires prior to removal to ensure proper installation. 1. Remove nut (Figure 1, Item 8), lockwasher (Figure 1, Item 9), and blue wire (Figure 1, item 11) from stud (Figure 1, Item 10). Discard lockwasher.
1, 2, 3
4, 5, 6
12
11
8, 9, 10
Figure 1. Starter Relay Removal. 2. Remove nut (Figure 1, Item 1), lockwasher (Figure 1, Item 2), and white wire (Figure 1, Item 12) from stud (Figure 1, Item 3). Discard lockwasher.
0138-1
TM 5-3825-270-23&P
0138
REMOVAL - Continued 3. 4. Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), and white wire (Figure 1, Item 7) from stud (Figure 1, Item 6). Discard lockwasher. Remove nut (Figure 2, Item 18), lockwasher (Figure 2, Item 19), and red wire (Figure 2, Item 17) from stud (Figure 2, Item 20). Discard lockwasher.
13 14, 15, 16
18, 19, 20
17
Figure 2. Starter Relay Removal. 5. Remove two nuts (Figure 2, Item 14), lockwashers (Figure 2, Item 15), and starter relay (Figure 2, Item 13) from two isolators (Figure 2, Item 16). Discard lockwashers.
NOTE
Perform Step (6) if isolator is damaged. All isolators are removed the same way. Top isolator shown. 6. Remove screw (Figure 3, Item 21), lockwasher (Figure 3, Item 22), and isolator (Figure 3, Item 16) from mounting surface (Figure 3, Item 23). Discard lockwasher.
16 21, 22
23
Figure 3. Starter Relay Removal. END OF TASK
0138-2
TM 5-3825-270-23&P
0138
INSTALLATION
NOTE
Perform Step (1) if isolator was removed. All isolators are installed the same way. Top isolator shown. 1. Install isolator (Figure 4, Item 16) on mounting surface (Figure 4, Item 23) with lockwasher (Figure 4, Item 22) and screw (Figure 4, Item 21).
16 21, 22
23
Figure 4. Starter Relay Installation. 2. Install starter relay (Figure 5, Item 13) on two isolators (Figure 5, Item 16) with lockwashers (Figure 5, Item 15) and nuts (Figure 3, Item 14).
13 14, 15, 16
18, 19, 20
17
Figure 5. Starter Relay Installation.
NOTE
Route and install wires as noted prior to removal. 3. 4. Install red wire (Figure 5, Item 17) on stud (Figure 5, Item 20) with lockwasher (Figure 5, Item 19) and nut (Figure 5, Item 18). Install white wire (Figure 6, Item 7) on stud (Figure 6, Item 6) with lockwasher (Figure 6, Item 5) and nut (Figure 6, Item 4).
0138-3
TM 5-3825-270-23&P
0138
1, 2, 3
4, 5, 6
12
11
8, 9, 10
Figure 6. Starter Relay Installation. 5. 6. Install white wire (Figure 6, Item 12) on stud (Figure 6, Item 3) with lockwasher (Figure 6, Item 2) and nut (Figure 6, Item 1). Install blue wire (Figure 6, Item 11) on stud (Figure 6, Item 10) with lockwasher (Figure 6, Item 9) and nut (Figure 6, Item 8).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install rear enclosure panel. (WP 0143) Connect batteries. (WP 0085)
0138-4
TM 5-3825-270-23&P
0139
FIELD MAINTENANCE STARTER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) References Parts Manual (WP 0220) Figure 4037 Equipment Condition Batteries disconnected. (WP 0085) Front engine access cover removed. (TM 5-3825-27-10)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Disconnect white wire (Figure 1, Item 5) from starter (Figure 1, Item 6).
1 2 3 4
7, 8
Figure 1. Starter Removal. 2. 3. Remove nut (Figure 1, Item 7), lockwasher (Figure 1, Item 8) positive battery cable (Figure 1, Item 1), red wire (Figure 1, Item 2), red wire (Figure 1, Item 3), and red wire (Figure 1, Item 4) from starter (Figure 1, Item 6). Remove nut (Figure 2, Item 9), black wire (Figure 2, Item 11), and negative battery cable (Figure 2, Item 10) from starter (Figure 2, Item 6).
0139-1
TM 5-3825-270-23&P
0139
REMOVAL - Continued
9 10
11
Figure 2. Starter Removal. 4. Remove screw (Figure 3, Item 13) and starter (Figure 3, Item 6) from flywheel housing (Figure 3, Item 12).
13
12
Figure 3. Starter Removal. END OF TASK INSTALLATION 1. Install red wire (Figure 6, Item 4), red wire (Figure 6, Item 3), red wire (Figure 6, Item 2), and positive battery cable (Figure 6, Item 1) on starter (Figure 6, Item 6) with lockwasher (Figure 6, Item 8) and nut (Figure 6, Item 7).
0139-2
TM 5-3825-270-23&P
0139
1 2 3 4
7, 8
Figure 4. Starter Installation. 2. Install starter (Figure 5, Item 6) on flywheel housing (Figure 5, Item 12) with screw (Figure 5, Item 13).
12
11
Figure 5. Starter Installation. 3. Install negative battery cable (Figure 4, Item 10) and black wire (Figure 4, Item 11) on starter (Figure 4, Item 6) with nut (Figure 4, Item 9).
0139-3
TM 5-3825-270-23&P
0139
10
11
Figure 6. Starter Installation.
4.
Connect white wire (Figure 6, Item 5) to starter (Figure 6, Item 6).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install front engine access cover. (TM 5382527010) Connect batteries. (WP 0085)
0139-4
TM 5-3825-270-23&P
0140
FIELD MAINTENANCE THERMOSTAT AND HOUSING REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Gasket (WP 0226, Table 1, Item 29) Qty: 1 Gasket (WP 0226, Table 1, Item 24) Qty: 1 Gasket (WP 0226, Table 1, Item 33) Qty: 1 References Parts Manual (WP 0220) Figure 4045 Equipment Condition Upper radiator hose removed. (WP 0073) Equipment Condition (cont.) Water pump and housing removed. (WP 0071) Radiator and bracket removed. (WP 0076) Engine coolant temperature sending unit removed. (WP 0115) Engine emergency temperature sending unit removed. (WP 0116)
REMOVAL 1. Remove three screws (Figure 1, Item 4), thermostat cover (Figure 1, Item 1), and gasket (Figure 1, Item 2) from thermostat housing (Figure 1, Item 3). Discard gasket.
1, 2
3
Figure 1. Thermostat and Housing Removal.
2. 3.
Remove any remaining gasket material from thermostat cover (Figure 1, Item 1). Remove thermostat (Figure 2, Item 5) from thermostat housing (Figure 2, Item 3).
0140-1
TM 5-3825-270-23&P
0140
REMOVAL - Continued
Figure 2. Thermostat and Housing Removal. 4. Remove any remaining gasket material from thermostat housing mating surface (Figure 2, Item 6).
NOTE
Perform Steps (4) through (12) if thermostat housing needs to be replaced. 5. Loosen clamp (Figure 3, Item 7) and remove hose (Figure 3, Item 8) from fitting (Figure 3, Item 9).
9
Figure 3. Thermostat and Housing Removal. 6. Remove screw (Figure 4, Item 10) from bracket (Figure 4, Item 11), thermostat housing (Figure 4, Item 3), and cylinder head (Figure 4, Item 12).
0140-2
TM 5-3825-270-23&P
0140
REMOVAL - Continued
10
11
12
Figure 4. Thermostat and Housing Removal. 7. Loosen screw (Figure 5, Item 13) from alternator (Figure 5, Item 14) and bracket (Figure 5, Item 11).
13 11 14
Figure 5. Thermostat and Housing Removal. 8. Position bracket (Figure 6, Item 11) aside.
0140-3
TM 5-3825-270-23&P
0140
REMOVAL - Continued
15
3, 16
11
12
15
15
Figure 6. Thermostat and Housing Removal. 9. 10. Remove three screws (Figure 6, Item 15), thermostat housing (Figure 6, Item 3), and gasket (Figure 6, Item 16) from cylinder head (Figure 6, Item 12). Discard gasket. Remove any remaining gasket material from mating surface (Figure 7, Item 17) on cylinder head (Figure 7, Item 12).
17
12
Figure 7. Thermostat and Housing Removal. END OF TASK
0140-4
TM 5-3825-270-23&P
0140
INSTALLATION
NOTE
Perform Steps (1) through (5) if thermostat housing was removed. 1. Install thermostat housing (Figure 8, Item 3) and gasket (Figure 8, Item 16) on cylinder head (Figure 8, Item 12) with three screws (Figure 8, Item 15).
15
3, 16
11
12
15
15
Figure 8. Thermostat and Housing Installation. 2. Install bracket (Figure 9, Item 11) on thermostat housing (Figure 9, Item 3) and cylinder head (Figure 10, Item 12) with screw (Figure 9, Item 10).
0140-5
TM 5-3825-270-23&P
0140
10
11
12
Figure 9. Thermostat and Housing Installation. 3. 4. Adjust alternator belt. (WP 0079) Install hose (Figure 10, Item 8) on fitting (Figure 10, Item 9) with clamp (Figure 10, Item 7).
9
Figure 10. Thermostat and Housing Installation. 5. Install thermostat (Figure 11, Item 5) in thermostat housing (Figure 11, Item 3).
0140-6
TM 5-3825-270-23&P
0140
3
Figure 11. Thermostat and Housing Installation. 6. Install thermostat cover (Figure 12, Item 1) and gasket (Figure 12, Item 2) on thermostat housing (Figure 12, Item 3) with three screws (Figure 12, Item 4).
1, 2
3
Figure 12. Thermostat and Housing Installation.
END OF TASK FOLLOW-ON MAINTENANCE 1. Install engine emergency temperature sending unit. (WP 0116)
0140-7
TM 5-3825-270-23&P
0140
FOLLOW-ON MAINTENANCE - Continued 2. 3. 4. 5. Install engine coolant temperature sending unit. (WP 0115) Install water pump and housing. (WP 0071) Install upper radiator hose. (WP 0073) Install radiator and bracket. (WP 0076)
0140-8
TM 5-3825-270-23&P
0141
FIELD MAINTENANCE VALVE COVER AND GASKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Gasket (WP 0226, Table 1, Item 21) Qty: 1 References Parts Manual (WP 0220) Figure 4030 Equipment Condition Engine compartment cover removed. (WP 0142)
REMOVAL 1. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 3) from valve cover (Figure 1, Item 1).
1 2 3
Figure 1. Valve Cover And Gasket Removal. 2. Remove 10 screws (Figure 2, Item 4), valve cover (Figure 2, Item 1), and gasket (Figure 2, Item 5) from cylinder head (Figure 2, Item 6). Discard gasket.
0141-1
TM 5-3825-270-23&P
0141
REMOVAL - Continued
4 1, 5
Figure 2. Valve Cover And Gasket Removal. END OF TASK INSTALLATION 1. Install valve cover (Figure 3, Item 1) and gasket (Figure 3, Item 5) on cylinder head (Figure 3, Item 6) with 10 screws (Figure 3, Item 4).
0141-2
TM 5-3825-270-23&P
0141
4 1, 5
Figure 3. Valve Cover And Gasket Installation. 2. 3. Tighten 10 screws (Figure 3, Item 4) to 61 to 97 lb-in (7 to 11 Nm). Install hose (Figure 4, Item 3) on valve cover (Figure 4, Item 1) with clamp (Figure 4, Item 2).
1 2 3
Figure 4. Valve Cover And Gasket Installation. END OF TASK
0141-3
TM 5-3825-270-23&P
0141
FOLLOW-ON MAINTENANCE Install engine compartment cover. (WP 0142) END OF TASK END OF WORK PACKAGE
0141-4
TM 5-3825-270-23&P
0142
FIELD MAINTENANCE ENGINE COMPARTMENT COVER REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4023 Equipment Condition Muffler and bracket removed. (WP 0150) Equipment Condition (cont.) Air cleaner assembly removed. (WP 0170) Front engine access cover removed. (TM-5-3825-270-10) Rear engine access cover removed. (TM-5-3825-270-10)
REMOVAL Remove twelve screws (Figure 1, Item 1) and engine cover (Figure 1, Item 2) from engine compartment (Figure 1, Item 3).
3 3
Figure 1. Engine Compartment Cover Removal. END OF TASK INSTALLATION Install engine cover (Figure 2, Item 2) on engine compartment (Figure 2, Item 3) with twelve screws (Figure 2, Item 1).
0142-1
TM 5-3825-270-23&P
0142
3 3
Figure 2. Engine Compartment Cover Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install air cleaner assembly. (WP 0170) Install muffler and bracket assembly. (WP 0150) Install rear engine access cover. (TM-5-3825-270-10) Install front engine access cover. (TM-5-3825-270-10)
0142-2
TM 5-3825-270-23&P
0143
FIELD MAINTENANCE REAR ENCLOSURE PANEL AND SIDE RAIL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Foam Gasket (WP 0226, Table 1, Item 71) Qty: 1 Lockwasher (WP 0226, Table 1, Item 61) Qty: 1 Lockwasher (WP 0226, Table 1, Item 55) Qty: 4 Isolator Mount (WP 0226, Table 1, Item 69) Qty: 4 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4023 Equipment Condition Radiator and bracket removed. (WP 0076) Glow plug relay removed. (WP 0131) Starter relay removed. (WP 0138) Governor control module removed. (WP 0092) Data plate removed. (WP 0157)
REMOVAL
NOTE
Remove cushion clips as required. 1. Remove nut (Figure 1, Item 1), lockwasher (Figure 1, Item 2), and wire eyelet (Figure 1, Item 3) from rear enclosure panel (Figure 1, Item 4). Discard lockwasher.
1, 2, 3
Figure 1. Rear Enclosure Panel And Side Panel Removal.
NOTE
Plate supports are not interchangeable. Tag and mark plate supports prior to removal to ensure proper installation. 2. Remove six screws (Figure 2, Item 5), plate support (Figure 2, Item 7), plate support (Figure 2, Item 8) and rear enclosure panel (Figure 2, Item 4) from two side rails (Figure 2, Item 6).
0143-1
TM 5-3825-270-23&P
0143
REMOVAL - Continued
NOTE
Perform Step (3) if foam gasket is damaged. 3. Remove foam gasket (Figure 3, Item 9) from rear enclosure panel (Figure 3, Item 4). Discard gasket.
NOTE
Both side rails are removed the same way. Right side shown.
0143-2
TM 5-3825-270-23&P
0143
REMOVAL - Continued 4. Remove nut (Figure 4, Item 15), lockwasher (Figure 4, Item 14), washer (Figure 4, Item 13), screw (Figure 4, Item 10), washer (Figure 4, Item 11), and side rail (Figure 4, Item 6) from support bracket (Figure 4, Item 12). Discard lockwasher.
6 10, 11 12
15
14
13
Figure 4. Rear Enclosure Panel And Side Panel Removal. 5. Remove nut (Figure 5, Item 19), lockwasher (Figure 5, Item 20), washer (Figure 5, Item 21), screw (Figure 5, Item 16), washer (Figure 5, Item 17), and side rail (Figure 4, Item 6) from radiator support (Figure 5, Item 18). Discard lockwasher.
6 16, 17
21
20
19
18
Figure 5. Rear Enclosure Panel And Side Panel Removal. 6. Remove radiator support (Figure 6, Item 18) from two front engine mount brackets (Figure 6, Item 23).
0143-3
TM 5-3825-270-23&P
0143
REMOVAL - Continued
22
23
18
NOTE
Perform Step (7) if isolator mounts on radiator support are damaged. 7. Remove two isolator mounts (Figure 6, Item 22) from radiator support (Figure 6, Item 18). Discard isolator mounts.
NOTE
Perform Step (8) if isolator mounts on side panel support bracket are damaged. 8. Remove isolator mount (Figure 7, Item 24) from side panel support bracket (Figure 7, Item 12). Discard isolator mounts.
12
24
Figure 7. Rear Enclosure Panel And Side Panel Removal. END OF TASK INSTALLATION
NOTE
Perform Step (1) if isolator mount on side panel support bracket was removed.
0143-4
TM 5-3825-270-23&P
0143
INSTALLATION - Continued 1. Install isolator mount (Figure 8, Item 24) on side panel support bracket (Figure 8, Item 12).
12
24
Figure 8. Rear Enclosure Panel And Side Panel Installation. 2. Align dowels and position radiator support (Figure 9, Item 18) on two front engine mount brackets (Figure 9, Item 23).
18
23
Figure 9. Rear Enclosure Panel And Side Panel Installation.
NOTE
Perform Step (3) if isolator mount on radiator support was removed. 3. Install isolator mount (Figure 10, Item 22) on radiator support (Figure 10, Item 18) and two front engine mount brackets (Figure 10, Item 23).
0143-5
TM 5-3825-270-23&P
0143
22
23
18
NOTE
Both side rails are installed the same way. Right side shown. 4. Install side rail (Figure 11, Item 6) on radiator support (Figure 11, Item 18) with washer (Figure 11, Item 17), screw (Figure 11, Item 16), washer (Figure 11, Item 21), lockwasher (Figure 11, Item 20), and nut (Figure 11, Item 19).
6 16, 17
21
20
19
18
Figure 11. Rear Enclosure Panel And Side Panel Installation. 5. Install side rail (Figure 12, Item 6) on support bracket (Figure 12, Item 12) with washer (Figure 12, Item 11), screw (Figure 12, Item 10), washer (Figure 12, Item 13), lockwasher (Figure 12, Item 14), and nut (Figure 12, Item 15).
0143-6
TM 5-3825-270-23&P
0143
6 10, 11 12
15
14
13
NOTE
Perform Step (6) if foam gasket was removed. 6. Install foam gasket (Figure 13, Item 9) on rear enclosure panel (Figure 13, Item 4).
NOTE
Install plate supports as noted prior to removal. 7. Install rear enclosure panel (Figure 14, Item 4) on two side rails (Figure 14, Item 6) with plate support (Figure 14, Item 8), plate support (Figure 14, Item 7), and six screws (Figure 14, Item 5).
0143-7
TM 5-3825-270-23&P
0143
NOTE
Install cushion clips as required. 8. Install wire eyelet (Figure 15, Item 3) on rear enclosure panel (Figure 15, Item 4) with lockwasher (Figure 15, Item 2) and nut (Figure 15, Item 1).
1, 2, 3
Figure 15. Rear Enclosure Panel And Side Panel Installation. END OF TASK
0143-8
TM 5-3825-270-23&P
0143
FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install data plate. (WP 0157) Install governor control module. (WP 0092) Install starter relay. (WP 0138) Install glow plug relay. (WP 0131) Install radiator and bracket. (WP 0076)
0143-9/10 blank
TM 5-3825-270-23&P
0144
FIELD MAINTENANCE FRONT ENCLOSURE PANEL REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Gasket, Foam (WP 0226, Table 1, Item 71) Qty: 1 Foam, Barrier (WP 0226, Table 1, Item 70) Qty: 2 References Parts Manual (WP 0220) Figure 4023 Equipment Condition Engine compartment cover removed. (WP 0142)
REMOVAL
NOTE
Plate supports are not interchangeable. Tag and mark plate supports prior to removal to ensure proper installation. 1. Remove six screws (Figure 1, Item 4), plate support (Figure 1, Item 2), plate support (Figure 1, Item 5), and front enclosure panel (Figure 1, Item 3) from two side rails (Figure 1, Item 1).
1 3
1 5
Figure 1. Front Enclosure Panel Removal.
NOTE
Perform Steps (2) and (3) if foam gaskets are damaged. Note position of foam gaskets prior to removal to ensure proper installation. 2. Remove foam gasket (Figure 2, Item 6) from front enclosure panel (Figure 2, Item 3). Discard foam gasket.
0144-1
TM 5-3825-270-23&P
0144
REMOVAL - Continued
6
Figure 2. Front Enclosure Panel Removal. 3. Remove four foam barriers (Figure 3, Item 7) from front enclosure panel (Figure 3, Item 3). Discard foam barriers.
3
Figure 3. Front Enclosure Panel Removal. END OF TASK INSTALLATION
NOTE
Perform Steps (1) and (2) if foam gaskets were removed. Install foam gaskets as noted prior to removal. 1. Install four foam barriers (Figure 4, Item 7) on front enclosure panel (Figure 4, Item 3).
0144-2
TM 5-3825-270-23&P
0144
3
Figure 4. Front Enclosure Panel Installation. 2. Install foam gasket (Figure 5, Item 6) on front enclosure panel (Figure 5, Item 3).
6
Figure 5. Front Enclosure Panel Installation.
NOTE
Install plate supports as noted prior to removal. 3. Install front enclosure panel (Figure 6, Item 3) on two side rails (Figure 6, Item 1) with plate support (Figure 6, Item 5), plate support (Figure 6, Item 2), and six screws (Figure 6, Item 4).
0144-3
TM 5-3825-270-23&P
0144
1 3
1 5
Figure 6. Front Enclosure Panel Installation. END OF TASK FOLLOW-ON MAINTENANCE Install engine compartment cover. (WP 0142) END OF TASK END OF WORK PACKAGE
0144-4
TM 5-3825-270-23&P
0145
FIELD MAINTENANCE ENGINE CYLINDER HEAD GASKET REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Shakle (WP 0225, Table 1, Item 7) Multi-Leg Nylon Sling (WP 0225, Table 1, Item 3) Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 13) Materials/Parts Lubricating Oil, Engine, OE/HDO 15W40 (WP 0224, Table 1, Item 42, 43, 44, 45) Qty: 1 Screw, Cylinder Head (WP 0226, Table 1, Item 18) Qty: 18 Gasket, Cylinder Head (WP 0226, Table 1, Item 27) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4031 Equipment Condition Radiator drained. (WP 0075) Rear access door opened. (TM 5-3825-270-10) Engine compartment cover removed. (WP 0142) Coolant reservoir removed. (WP 0070) Engine nozzle tubes removed. (WP 0118) Valve cover and gasket removed. (WP 0141)
REMOVAL
CAUTION
Fuel/water separator filter must be supported when removed. Failure to comply may result in damage to equipment. 1. Remove two screws (Figure 1, Item 1) and fuel/water separator filter assembly (Figure 1, Item 3) from inlet assembly (Figure 1, Item 2).
0145-1
TM 5-3825-270-23&P
0145
REMOVAL - Continued
Figure 1. Cylinder Head Gasket Removal.
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 2. Remove fuel hoses (Figure 2, Item 4) from bracket (Figure 2, Item 5).
0145-2
TM 5-3825-270-23&P
0145
REMOVAL - Continued
Figure 2. Cylinder Head Gasket Removal. 3. Disconnect wire (Figure 3, Item 7) from temperature sensor (Figure 3, Item 6).
6 7
Figure 3. Cylinder Head Gasket Removal. 4. Remove nut (Figure 4, Item 8), lockwasher (Figure 4, Item 9), washer (Figure 4, Item 10), washer (Figure 4, Item 11), and wire (Figure 4, Item 12) from temperature sensor (Figure 4, Item 13).
0145-3
TM 5-3825-270-23&P
0145
REMOVAL - Continued
8, 9, 10, 11 12 13
Figure 4. Cylinder Head Gasket Removal. 5. Disconnect governor actuator connector (Figure 5, Item 14) from harness connector (Figure 5, Item 15).
14
15
Figure 5. Cylinder Head Gasket Removal. 6. Loosen clamp (Figure 6, Item 17) and remove hose (Figure 6, Item 16) from fuel tube (Figure 6, Item 18).
0145-4
TM 5-3825-270-23&P
0145
REMOVAL - Continued
16
17
18
Figure 6. Cylinder Head Gasket Removal. 7. Loosen clamp (Figure 7, Item 20) and remove hose (Figure 7, Item 19) from fuel tube (Figure 7, Item 18).
19
20
18
Figure 7. Cylinder Head Gasket Removal. 8. Remove four nuts (Figure 8, Item 21), blue wire (Figure 8, Item 23), four washers (Figure 8, Item 22), and cord (Figure 8, Item 25) from glow plugs (Figure 8, Item 24).
0145-5
TM 5-3825-270-23&P
0145
REMOVAL - Continued
21, 22 23
25 24
Figure 8. Cylinder Head Gasket Removal. 9. Remove four screws (Figure 9, Item 27) and rocker arm assembly (Figure 9, Item 26) from cylinder head assembly (Figure 9, Item 28) and push rods (Figure 9, Item 30).
26 27 5 1 13 9 10 2 6 17 18 14 16 12 11 15 8 4 3 GEARCASE END
FLYWHEEL END
31
30
28, 29
Figure 9. Cylinder Head Gasket Removal.
CAUTION
Tag and mark pushrod location prior to removal to ensure proper installation. Failure to comply may result in damage to equipment. 10. 11. 12. Remove push rods (Figure 9, Item 30) from lifters (Figure 9, Item 29) and cylinder head assembly (Figure 9, Item 28). Loosen 18 screws (Figure 9, Item 31) from cylinder head assembly (Figure 9, Item 28) in sequence shown. Remove 18 screws (Figure 9, Item 31) from cylinder head assembly (Figure 9, Item 28). Discard screws.
0145-6
TM 5-3825-270-23&P
0145
REMOVAL - Continued
WARNING
Cylinder head assembly weighs 95 lbs. Do not attempt to lift or move without the aid of an assistant and suitable lifting device. Failure to comply may result in damage to equipment and death or serious injury to personnel. 13. Attach suitable lifting device to cylinder head assembly (Figure 10, Item 28).
LIFTING DEVICE 28
32
Figure 10. Cylinder Head Gasket Removal. 14. With the aid of an assistant and suitable lifting device, remove cylinder head assembly (Figure 10, Item 28) from engine block (Figure 10, Item 32).
NOTE
Note position of cylinder head gasket prior to removal to ensure proper installation. 15. Remove cylinder head gasket (Figure 11, Item 33) from engine block (Figure 11, Item 32). Discard cylinder head gasket.
0145-7
TM 5-3825-270-23&P
0145
REMOVAL - Continued
33
32
Figure 11. Cylinder Head Gasket Removal. END OF TASK INSPECTION 1. Clean any contamination or remaining gasket material from mating surface of engine block (Figure 12, Item 32). Inspect for cracks between cylinders, pitting, rust, or abnormal wear.
MATING SURFACE
32
Figure 12. Cylinder Head Gasket Inspection. 2. With the aid of an assistant, turn cylinder head (Figure 13, Item 28) over to access its mating surface. Clean contamination or remaining gasket material from the mating surface of the cylinder head (Figure 13, Item 28). Inspect for cracks between combustion chambers, pitting, rust, or abnormal wear.
0145-8
TM 5-3825-270-23&P
0145
INSPECTION - Continued
MATING SURFACE
28
Figure 13. Cylinder Head Gasket Inspection. END OF TASK INSTALLATION
NOTE
Install cylinder head gasket as noted prior to removal. 1. Position cylinder head gasket (Figure 14, Item 33) on engine block (Figure 14, Item 32).
33
32
Figure 14. Cylinder Head Gasket Installation. 2. With the aid of an assistant and suitable lifting device, position cylinder head assembly (Figure 15, Item 28) on engine block (Figure 15, Item 32).
0145-9
TM 5-3825-270-23&P
0145
LIFTING DEVICE 28
32
Figure 15. Cylinder Head Gasket Installation.
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 3. Apply engine lubricating oil to threads of 18 cylinder head screws (Figure 16, Item 31).
0145-10
TM 5-3825-270-23&P
0145
26 27 14 18 10 9 17 13 6 2 1 5 3 7 8 4 11 15 16 GEARCASE END
12
31
30
28, 29
Figure 16. Cylinder Head Gasket Installation. 4. 5. 6. 7. Install 18 screws (Figure 16, Item 31) in cylinder head (Figure 16, Item 28). Hand tighten screws. Torque 18 screws (Figure 16, Item 31) in sequence shown to 25 lb-ft (33.9 Nm). Torque 18 screws (Figure 16, Item 31) in sequence shown to 50 lb-ft (67.8 Nm). Torque 18 screws (Figure 16, Item 31) in sequence shown to 72.4 to 79.5 lb-ft (98.1 to 107 Nm).
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 8. Coat push rods (Figure 16, Item 30) with engine lubricating oil.
CAUTION
Install pushrods as noted prior to removal. Failure to comply may result in damage to equipment. 9. 10. Install push rods (Figure 16, Item 30) on lifters (Figure 16, Item 29) and in cylinder head (Figure 16, Item 28). Install rocker arm assembly (Figure 16, Item 26) on cylinder head (Figure 16, Item 28) and push rods (Figure 16, Item 30) with four screws (Figure 16, Item 31). Torque screws (Figure 16, Item 27) to 37 to 41 lb-ft (49 to 55 Nm). Install cord (Figure 17, Item 25) and blue wire (Figure 17, Item 23) on glow plugs (Figure 17, Item 24) with four washers (Figure 17, Item 22) and nuts (Figure 17, Item 21).
11.
0145-11
TM 5-3825-270-23&P
0145
21, 22 23
25 24
Figure 17. Cylinder Head Gasket Installation. 12. Install hose (Figure 18, Item 19) on tube (Figure 18, Item 18) with clamp (Figure 18, Item 20).
19
20
18
Figure 18. Cylinder Head Gasket Installation. 13. Install hose (Figure 19, Item 16) on tube (Figure 19, Item 18) with clamp (Figure 19, Item 17).
0145-12
TM 5-3825-270-23&P
0145
16
17
18
Figure 19. Cylinder Head Gasket Installation. 14. Connect governor actuator connector (Figure 20, Item 14) to harness connector (Figure 20, Item 15).
14
15
Figure 20. Cylinder Head Gasket Installation. 15. Install wire (Figure 22, Item 12) on temperature sensor (Figure 21, Item 13) with washer (Figure 21, Item 11), washer (Figure 21, Item 10), lockwasher (Figure 21, Item 9), and nut (Figure 21, Item 8).
0145-13
TM 5-3825-270-23&P
0145
8, 9, 10, 11 12 13
Figure 21. Cylinder Head Gasket Installation. 16. Connect wire (Figure 22, Item 7) to temperature sensor (Figure 22, Item 6).
6 7
Figure 22. Cylinder Head Gasket Installation. 17. Secure fuel hoses (Figure 23, Item 4) with bracket (Figure 23, Item 5).
0145-14
TM 5-3825-270-23&P
0145
Figure 23. Cylinder Head Gasket Installation. 18. Install fuel/water separator filter assembly (Figure 24, Item 3) on inlet assembly (Figure 24, Item 2) with two screws (Figure 24, Item 1).
Figure 24. Cylinder Head Gasket Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install valve cover and gasket. (WP 0141) Install engine nozzle tubes. (WP 0118) Install coolant reservoir. (WP 0070) Install engine compartment cover. (WP 0142)
0145-15
TM 5-3825-270-23&P
0145
FOLLOW-ON MAINTENANCE - Continued 5. 6. Install rear access door. (TM 5-3825-270-10) Fill radiator. (WP 0075)
0145-16
TM 5-3825-270-23&P
0146
FIELD MAINTENANCE BELT GUARD REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Cable Ties (WP 0224, Table 1, Item 9) Lockwasher (WP 0226, Table 1, Item 55) Qty: 2 References Parts Manual (WP 0220) Figure 4027 Equipment Condition Front engine access panel removed. (TM 5-3825-270-10) Equipment Condition (cont.) Rear engine access panel removed. (TM 5-3825-270-10) Engine compartment cover removed. (WP 0142)
REMOVAL 1. Remove two screws (Figure 1, Item 1) from bracket (Figure 1, Item 3).
1 2 3 4
Figure 1. Belt Guard Removal.
NOTE
Remove cable ties as required. 2. Remove overflow tube (Figure 1, Item 5) from belt guard (Figure 1, Item 2), belt guard (Figure 1, Item 4) and radiator (Figure 1, Item 6).
0146-1
TM 5-3825-270-23&P
0146
REMOVAL - Continued
NOTE
Both side rails are removed the same. Right side rail shown. 3. Remove two nuts (Figure 2, Item 9), lockwashers (Figure 2, Item 10), washers (Figure 2, Item 11), screws (Figure 2, Item 7), and washers (Figure 2, Item 8) from side rails (Figure 2, Item 13) and radiator support (Figure 2, Item 12). Discard lockwashers.
7, 8
10
11
13
Figure 2. Belt Guard Removal. 4.
12
Remove twelve screws (Figure 3, Item 14), belt guard (Figure 3, Item 2), and belt guard (Figure 3, Item 4) from radiator assembly (Figure 3, Item 6).
6
14
Figure 3. Belt Guard Removal. END OF TASK INSTALLATION 1. Install belt guard (Figure 4, Item 4) and belt guard (Figure 4, Item 2) on radiator assembly (Figure 4, Item 6) with twelve screws (Figure 4, Item 14).
0146-2
TM 5-3825-270-23&P
0146
6
14
Figure 4. Belt Guard Installation. 2. Install side rails (Figure 5, Item 13) on radiator support (Figure 5, Item 12) with two screws (Figure 5, Item 7), washers (Figure 5, Item 8), washers (Figure 5, Item 11), lockwashers (Figure 5, Item 10), and nuts (Figure 5, Item 9).
7, 8
10
11
13
Figure 5. Belt Guard Installation.
12
NOTE
Install cable ties as required. 3. Install overflow tube (Figure 6, Item 5) on belt guard (Figure 6, Item 2), belt guard (Figure 6, Item 4), and radiator (Figure 6, Item 6) with cable ties.
0146-3
TM 5-3825-270-23&P
0146
1 2 3 4
Figure 6. Belt Guard Installation. 4. Install bracket (Figure 6, Item 3) on radiator assembly (Figure 6, Item 6) with two screws (Figure 6, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine compartment cover. (WP 0142) Install rear engine access panel. (TM 5-3825-270-10) Install front engine access panel. (TM 5-3825-270-10)
0146-4
TM 5-3825-270-23&P
0147
FIELD MAINTENANCE FLEX ELEMENT REPLACEMENT
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 13) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) References Parts Manual (WP 0220) Figure 4011 Equipment Condition Engine/pump module removed. (WP 0127)
REMOVAL Remove eight screws (Figure 1, Item 2) and flex element (Figure 1, Item 3) from flywheel (Figure 1, Item 1).
1 2 3
Figure 1. Flex Element Removal. END OF TASK
0147-1
TM 5-3825-270-23&P
0147
INSTALLATION
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Apply sealing compound to threads of eight screws (Figure 2, Item 2).
1 2 3
Figure 2. Flex Element Installation. 2. Install flex element (Figure 2, Item 3) on flywheel (Figure 2, Item 1) with eight screws (Figure 2, Item 2). Tighten screws to 45 lb-ft (61 Nm).
END OF TASK FOLLOW-ON MAINTENANCE Install engine/pump module. (WP 0128) END OF TASK END OF WORK PACKAGE
0147-2
TM 5-3825-270-23&P FIELD MAINTENANCE ENGINE OIL PICKUP TUBE REPLACEMENT
0148
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Oil, Lubricating, Engine, OE/HDO 15W40 (WP 0224, Table 1, Item 42, 43, 44, 45) Packing, Preformed (WP 0226, Table 1, Item 4) Qty: 1 References Parts Manual (WP 0220) Figure 4034 Equipment Condition Oil pan removed. (WP 0121)
REMOVAL 1. Remove two screws (Figure 1, Item 3) and engine oil pickup tube (Figure 1, Item 1) from engine block (Figure 1, Item 2).
3
Figure 1. Engine Oil Pickup Tube Removal. 2. Remove preformed packing (Figure 2, Item 4) from engine oil pickup tube (Figure 2, Item 1). Discard preformed packing.
0148-1
TM 5-3825-270-23&P REMOVAL - Continued

1
0148
Figure 2. Engine Oil Pickup Tube Removal. END OF TASK INSTALLATION
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 1. Lightly lubricate preformed packing (Figure 3, Item 4) with clean oil and install on engine oil pickup tube (Figure 3, Item 1).
1
Figure 3. Engine Oil Pickup Tube Installation.
0148-2
TM 5-3825-270-23&P INSTALLATION - Continued 2.
0148
Install engine oil pickup tube (Figure 4, Item 1) onto engine block (Figure 4, Item 2) with two screws (Figure 4, Item 3).
3
Figure 4. Engine Oil Pickup Tube Installation. END OF TASK FOLLOW-ON MAINTENANCE Install oil pan. (WP 0121) END OF TASK END OF WORK PACKAGE
0148-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE EXHAUST FLEX PIPE REPLACEMENT
0149
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Antiseize Compound (WP 0224, Table 1, Item 4) Lockwasher (WP 0226, Table 1, Item 3) Qty: 4 Materials/Parts (cont.) Gasket, Manifold (WP 0226, Table 1, Item 17) Qty: 1 Stud (WP 0226, Table 1, Item 1) Qty: 4 References Parts Manual (WP 0220) Figure 4025 Parts Manual (WP 0220) Figure 4040 Equipment Condition Engine compartment cover removed. (WP 0142)
REMOVAL
WARNING
Exhaust pipes and muffler can become very hot during engine operation. Allow parts to cool and take care not to touch these parts with bare hands or allow body to contact exhaust pipes or muffler. Failure to comply may result in injury or death to personnel. 1. Remove four nuts (Figure 1, Item 4) and lockwashers (Figure 1, Item 5) from exhaust flex pipe (Figure 1, Item 1). Discard lockwashers.
4, 5
1, 2
Figure 1. Exhaust Flex Pipe Removal.
0149-1
TM 5-3825-270-23&P REMOVAL - Continued 2.
0149
Remove exhaust flex pipe (Figure 1, Item 1) and gasket (Figure 1, Item 2) from exhaust manifold (Figure 1, Item 3). Discard gasket.
NOTE
Perform Step (3) if studs are damaged. 3. Remove four studs (Figure 1, Item 6) from exhaust manifold (Figure 1, Item 3).
NOTE
Perform Steps (1) and (2) if studs were removed. 1. Apply anti seize to threads of four studs (Figure 2, Item 6).
4, 5
1, 2
Figure 2. Exhaust Flex Pipe Installation. 2. 3. Install four studs (Figure 2, Item 6) onto exhaust manifold (Figure 2, Item 3). Install exhaust flex pipe (Figure 2, Item 1) and gasket (Figure 2, Item 2) on exhaust manifold (Figure 2, Item 3) with four lockwashers (Figure 2, Item 5) and nuts (Figure 2, Item 4).
END OF TASK FOLLOW-ON MAINTENANCE Install engine compartment cover. (WP 0142) END OF TASK END OF WORK PACKAGE
0149-2
TM 5-3825-270-23&P FIELD MAINTENANCE MUFFLER AND BAND CLAMP REPLACEMENT
0150
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4025 Equipment Condition Rear access panel removed. (TM 5-3825-270-10)
REMOVAL
WARNING
Exhaust pipes and muffler can become very hot during engine operation. Allow parts to cool and take care not to touch these parts with bare hands or allow body to contact exhaust pipes or muffler. Failure to comply may result in injury or death to personnel. 1. Loosen exhaust clamp (Figure 1, Item 1) and remove exhaust pipe (Figure 1, Item 2) from muffler (Figure 1, Item 3).
1 2
Figure 1. Muffler and Band Clamp Removal. 2. Loosen exhaust clamp (Figure 2, Item 4) on muffler (Figure 2, Item 3) and flex pipe (Figure 2, Item 5).
0150-1
0150
4 6 3 5
Figure 2. Muffler and Band Clamp Removal. 3. Remove two screws (Figure 2, Item 6), four bushings (Figure 2, Item 8), and muffler (Figure 2, Item 3) from two band clamps (Figure 2, Item 7).
NOTE
Perform Step (4) if band clamp is damaged. Left and right band clamps are removed the same way. Right side is shown. 4. Remove two nuts (Figure 3, Item 9), screws (Figure 3, Item 10), and band clamp (Figure 3, Item 7) from engine compartment cover (Figure 3, Item 11).
11
9, 10
Figure 3. Muffler and Band Clamp Removal. END OF TASK INSTALLATION
CAUTION
Do not over-tighten muffler clamps. Doing so will cause damage to pipes. Failure to comply may cause damage to equipment.
0150-2
TM 5-3825-270-23&P INSTALLATION - Continued
0150
NOTE
Perform Step (1) if brackets are damaged. Left and Right band clamps are installed the same way. Right side is shown. 1. Install band clamp (Figure 4, Item 7) on engine compartment cover (Figure 4, Item 11) with two screws (Figure 4, Item 10) and nuts (Figure 4, Item 9).
11
9, 10
Figure 4. Muffler and Band Clamp Installation. 2. Position muffler (Figure 5, Item 3) in two band clamps (Figure 5, Item 7) and on flex pipe (Figure 5, Item 5).
4 6 3 5
Figure 5. Muffler and Band Clamp Installation. 3. 4. 5. Secure band clamps (Figure 5, Item 7) on muffler (Figure 5, Item 3) with four bushings (Figure 5, Item 8) and two screws (Figure 5, Item 6). Install exhaust clamp (Figure 5, Item 4) on muffler (Figure 5, Item 3) and flex pipe (Figure 5, Item 5). Install exhaust pipe (Figure 6, Item 2) on muffler (Figure 6, Item 3) with exhaust clamp (Figure 6, Item 1).
0150-3
0150
1 2
Figure 6. Muffler and Band Clamp Installation. END OF TASK FOLLOW-ON MAINTENANCE Install rear access panel. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0150-4
TM 5-3825-270-23&P FIELD MAINTENANCE HOSE HOOK WELDMENT REPLACEMENT
0151
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 38) Qty: 2 References Parts Manual (WP 0220) Figure 4004 Equipment Condition Fill hoses removed. (TM 5-3825-270-10)
REMOVAL
NOTE
All four hose hook weldments are removed the same way. Front corner hose hook weldment shown. Remove two locknuts (Figure 1, Item 1), screws (Figure 1, Item 2), and hose hook weldment (Figure 1, Item 3) from frame rail (Figure 1, Item 4). Discard locknuts.
1,2 4
Figure 1. Hose Hook Weldment Removal END OF TASK INSTALLATION
NOTE
All four hose hook weldments are installed the same way. Front corner hose hook weldment shown.
0151-1
0151
Install hose hook weldment (Figure 2, Item 3) on frame rail (Figure 2, Item 4) with two screws (Figure 2, Item 2) and locknuts (Figure 1, Item 2).
1,2 4
Figure 2. Hose Hook Weldment Installation END OF TASK FOLLOW-ON MAINTENANCE Stow fill hoses. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0151-2
TM 5-3825-270-23&P FIELD MAINTENANCE SPRING MARKER REPLACEMENT
0152
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4003
REMOVAL Remove screw (Figure 1, Item 1), washer (Figure 1, Item 2), and spring (Figure 1, Item 3) from flatrack (Figure 1, Item 4).
2 4
Figure 1. Spring Marker Removal. END OF TASK INSTALLATION Install spring (Figure 2, Item 3) on flatrack (Figure 2, Item 4) with washer (Figure 2, Item 2) and screw (Figure 2, Item 1).
0152-1
0152
2 4
Figure 2. Spring Marker Installation. END OF TASK END OF WORK PACKAGE
0152-2
TM 5-3825-270-23&P FIELD MAINTENANCE ROLLER REPAIR
0153
INITIAL SETUP: Tools and Special Tools Compressor Unit, Air (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 12) Gun, Air Blow (WP 0225, Table 1, Item 2) Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Cloth, Cleaning, Low-Lint (WP 0224, Table 1, Item 16, 17) Materials/Parts (cont.) Cleaning Compound, Solvent (WP 0224, Table 1, Item 10, 11, 12, 13, 14, 15) Pin, Cotter (WP 0226, Table 1, Item 15) Qty: 1 References Parts Manual (WP 0220) Figure 4003 Equipment Condition Roller removed. (TM 5-3825-270-10)
DISASSEMBLY
NOTE
Both left and right rollers are repaired the same way. Right side shown. Note and tag location of roll pin and collar prior to removal to ensure proper installation. 1. Remove cotter pin (Figure 1, Item 1) from collar (Figure 1, Item 7). Discard cotter pin.
3 1 4
5 7
Figure 1. Roller Disassembly. 2. Remove collar (Figure 1, Item 7), roller shaft (Figure 1, Item 5), and roller (Figure 1, Item 6) from bracket (Figure 1, Item 2).
NOTE
Perform Step (3) if retaining pins are damaged.
0153-1
TM 5-3825-270-23&P DISASSEMBLY - Continued 3. Disconnect retaining pins (Figure 1, Item 4) from holding pins (Figure 1, Item 3).
0153
END OF TASK CLEANING/INSPECTION
WARNING
SOLVENT CLEANING COMPOUND (DRYCLEANING SOLVENT) Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flashpoint for Type II solvent cleaning compound is 141 to 198F (61 to 92C), and Type III is 200 to 241F (93 to 116C). Improper cleaning methods and use of unauthorized cleaning solvents may result in injury to personnel and/or damage to equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to comply may result in injury or death to personnel. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to comply may result in injury to personnel. Eye shields must be worn when cleaning with a wire brush. Failure to comply may result in injury to personnel. If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury or death to personnel. 1. Visually inspect all components for dirt or other contamination and clean with a cleaning cloth and solvent cleaning compound.
0153-2
TM 5-3825-270-23&P CLEANING/INSPECTION - Continued
0153
WARNING
Compressed air used for cleaning and drying purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and proper protective equipment (goggles, shield, gloves, etc.). Failure to comply may result in injury or death to personnel. 2. 3. 4. Dry components with compressed air. Inspect lockwires and retaining rings for damage. If necessary, replace lockwires. Inspect roller for damage that would interfere with rotation.
END OF TASK ASSEMBLY
NOTE
Perform Step (1) if retaining pins were removed. 1. Install retaining pins (Figure 2, Item 4) on holding pins (Figure 2, Item 3).
3 1 4
5 7
Figure 2. Roller Assembly. 2. 3. 4. Install roller (Figure 2, Item 6) in bracket (Figure 2, Item 2) and secure with roller shaft (Figure 2, Item 5). Install collar (Figure 2, Item 7) on roller shaft (Figure 2, Item 5). Secure collar (Figure 2, Item 7) on roller shaft (Figure 2, Item 5) with cotter pin (Figure 2, Item 1).
END OF TASK
0153-3
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE Install roller. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0153
0153-4
TM 5-3825-270-23&P FIELD MAINTENANCE STOWAGE BOX REPAIR
0154
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Drill, Hand, VSR, Elec. (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 2) Drill Bit Set Standard (WP 0225, Table 1, Item 2) Tool Kit, Blind Rivets (WP 0225, Table 1, Item 2) Materials/Parts Rivet, Pop (WP 0226, Table 1, Item 44) Qty: 22 Seal, Toolbox (WP 0226, Table 1, Item 47) Qty: 94 in. (2,388 mm) Materials/Parts (cont.) Cable, Door Stop (WP 0226, Table 1, Item 46) Qty: 15 in. (381 mm) Stop, Sleeve (WP 0226, Table 1, Item 42) Qty: 4 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4006
REMOVAL 1. Unlatch two draw latches (Figure 1, Item 2) and open stowage box door (Figure 1, Item 4).
1 2
5, 6, 7
Figure 1. Stowage Box Removal. 2. Remove six nuts (Figure 1, Item 5), twelve washers (Figure 1, Item 6), six screws (Figure 1, Item 7), and stowage box (Figure 1, Item 1) from flat rack (Figure 1, Item 3).
END OF TASK DISASSEMBLY 1. Starting at seam, remove stowage box door seal (Figure 2, Item 5) from stowage box (Figure 2, Item 1). Discard seal.
0154-1
TM 5-3825-270-23&P DISASSEMBLY - Continued

2, 3 1 1
0154
6, 7
Figure 2. Stowage Box Disassembly.
WARNING
Wear safety goggles when drilling to prevent injury to eyes. Failure to comply may result in injury or death to personnel. 2. 3. 4. Remove four screws (Figure 2, Item 3) and two draw latches (Figure 2, Item 2) from stowage box (Figure 2, Item 1). Using drill, drill out four rivets (Figure 2, Item 6) and remove two latches (Figure 2, Item 7) from stowage box door (Figure 2, Item 4). Remove two sleeve stops (Figure 3, Item 8) from door stop cable (Figure 3, Item 9). Discard sleeve stops.
1
9 8
0154-2
TM 5-3825-270-23&P DISASSEMBLY - Continued 5. 6.
0154
Remove stowage box door stop cable (Figure 3, Item 9) from stowage box (Figure 3, Item 1) and stowage box door (Figure 3, Item 4). Discard door stop cable. Turn stowage box (Figure 4, Item 1) over to access stowage box door rivets (Figure 4, Item 10).
10
11
WARNING
Wear safety goggles when drilling to prevent injury to eyes. Failure to comply may result in injury or death to personnel. 7. Using drill, drill out 18 rivets (Figure 4, Item 10) and remove door hinge (Figure 4, Item 11) from stowage box door (Figure 4, Item 4) and stowage box (Figure 4, Item 1). Discard rivets.
END OF TASK ASSEMBLY 1. Using nine rivets (Figure 5, Item 10), install stowage box door hinge (Figure 5, Item 11) on stowage box (Figure 5, Item 1).
0154-3
TM 5-3825-270-23&P ASSEMBLY - Continued
0154
10
11
Figure 5. Stowage Box Assembly. 2. 3. 4.
Using nine rivets (Figure 5, Item 10) install stowage box door (Figure 5, Item 4) on stowage box (Figure 5, Item 1). Turn stowage box (Figure 5, Item 1) over. Install stowage box door stop cable (Figure 6, Item 9) on stowage box (Figure 6, Item 1) and stowage box door (Figure 6, Item 4) with two sleeve stops (Figure 6, Item 8).
1
9 8
Figure 6. Stowage Box Assembly. 0154-4
TM 5-3825-270-23&P ASSEMBLY - Continued 5.
0154
Using four rivets (Figure 7, Item 6), install two latches (Figure 7, Item 7) on stowage box door (Figure 7, Item 4).
2, 3 1 1
6, 7
Figure 7. Stowage Box Assembly. 6. Using four screws (Figure 7, Item 3), install two draw latches (Figure 7, Item 2) on stowage box (Figure 7, Item 1).
WARNING
NOTE
Install stowage box door seal so that seam of seal is on bottom side of stowage box assembly. 7. 8. Apply adhesive compound to mounting edges of stowage box door seal (Figure 7, Item 5). Starting at bottom center, install stowage box door seal (Figure 7, Item 5) on stowage box (Figure 7, Item 1).
END OF TASK INSTALLATION 1. Install stowage box (Figure 8, Item 1) on flat rack (Figure 8, Item 3) with six screws (Figure 8, Item 7), twelve washers (Figure 8, Item 6), and nuts (Figure 8, Item 5).
0154-5

1 2
0154
5, 6, 7
Figure 8. Stowage Box Installation. 2. Close stowage box door (Figure 8, Item 4) and latch two draw latches (Figure 8, Item 2).
0154-6
TM 5-3825-270-23&P FIELD MAINTENANCE STORAGE BOX REPLACEMENT
0155
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 40) Qty: 4 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4006 Equipment Condition Ladder removed. (TM 5-3825-270-10) UPIK wire harness unstowed. (TM 5-3825-270-10)
REMOVAL 1. With the aid of an assistant, remove four locknuts (Figure 1, Item 4), washers (Figure 1, Item 3), washers (Figure 1, Item 2), and screws (Figure 1, Item 1) from storage box (Figure 1, Item 5). Discard locknuts.
1, 2, 3, 4
5
Figure 1. Storage Box Replacement.
2.
Remove storage box (Figure 1, Item 5) from frame (Figure 1, Item 6).
END OF TASK INSTALLATION 1. Place storage box (Figure 1, Item 5) on frame (Figure 1, Item 6).
0155-1
0155
1, 2, 3, 4
5
Figure 2. Storage Box Installation.
2.
With the aid of an assistant, install storage box (Figure 1, Item 5) to frame (Figure 1, Item 6) with four screws (Figure 1, Item 1), washers (Figure 1, Item 2), washers (Figure 1, Item 3), and locknuts (Figure 1, Item 4).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Stow ladder. (TM 5-3825-270-10) Stow UPIK wire harness. (TM 5-3825-270-10)
0155-2
TM 5-3825-270-23&P FIELD MAINTENANCE WIRE TROUGH CHANNEL REPLACEMENT
0156
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 39) Qty: 5 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4003
REMOVAL
NOTE
All four trough wire channels are removed the same way. Rear trough wire channel shown. Remove five locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), and wire trough channel (Figure 1, Item 4 ) from studs (Figure 1, Item 3) and frame (Figure 1, Item 5). Discard locknuts.
1, 2, 3
Figure 1. Wire Trough Channel Removal. END OF TASK INSTALLATION
NOTE
All four trough wire channels are installed the same way. Rear trough wire channel shown. Install wire trough channel (Figure 2, Item 4) on frame (Figure 2, Item 5) and studs (Figure 2, Item 3) with five washers (Figure 2, Item 2) and locknuts (Figure 2, Item 1).
0156-1

1, 2, 3
0156
Figure 2. Wire Trough Channel Installation. END OF TASK END OF WORK PACKAGE
0156-2
TM 5-3825-270-23&P FIELD MAINTENANCE DATA PLATE REPLACEMENT
0157
INITIAL SETUP: Tools and Special Tools Drill, Electric, Portable (WP 0225, Table 1, Item 2) Drill, Set, Twist (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 2) Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Rivet (WP 0226, Table 1, Item 68) Qty: 12 References Parts Manual (WP 0220) Figure 4050
REMOVAL
WARNING
Wear safety goggles when drilling to prevent injury to eyes. Failure to comply may result in injury or death to personnel.
NOTE
All data plates are removed the same way. One is shown. Number of rivets may vary from each data plate. Using a 1/8 in. drill bit, remove four rivets (Figure 1, Item 1) and data plate (Figure 1, Item 2) from water distributor (Figure 1, Item 3). Discard rivets.
1 2 3
Figure 1. Data Plate Removal. END OF TASK
0157-1
TM 5-3825-270-23&P INSTALLATION
0157
NOTE
All data plates are installed the same way. One is shown. Install data plate (Figure 2, Item 2) on water distributor (Figure 2, Item 3) with four rivets (Figure 2, Item 1).
1 2 3
Figure 2. Data Plate Installation. END OF TASK END OF WORK PACKAGE
0157-2
TM 5-3825-270-23&P FIELD MAINTENANCE 3" VALVE REPLACEMENT
0158
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 64) Qty: 8 Gasket (WP 0226, Table 1, Item 35) Qty: 2 References Parts Manual (WP 0220) Figure 4007 Equipment Condition Valve handle removed. (WP 0180)
REMOVAL
NOTE
All 3" valves are removed the same way. Valve V4 shown. Some valves may have other components that have to be removed or supported during valve replacement. Remove or support other components as necessary. Note position of valve assembly prior to removal, to ensure proper installation. Remove eight locknuts (Figure 1, Item 4), adapter pipe (Figure 1, Item 6), gasket (Figure 1, Item 1), valve (Figure 1, Item 2), gasket (Figure 1, Item 1), and screws (Figure 1, Item 5) from water tank assembly (Figure 1, Item 3). Discard locknuts.
4, 5
6
Figure 1. 3" Valve Removal. END OF TASK
0158-1
0158
NOTE
All 3" valves are installed the same way. Valve V4 shown. Some valves may have other components that have to be removed or supported during valve replacement. Remove or support other components as necessary. Install valve assembly as noted prior to removal. 1. Install gasket (Figure 2, Item 1), valve (Figure 2, Item 2), gasket (Figure 2, Item 1), and adapter pipe (Figure 2, Item 6) on water tank assembly (Figure 2, Item 3) with eight screws (Figure 2, Item 5) and locknuts (Figure 2, Item 4).
1 2 3 4, 5
TIGHTENING SEQUENCE
Figure 2. 3" Valve Installation. 2. Tighten locknuts (Figure 2, Item 4) in sequence shown.
END OF TASK FOLLOW-ON MAINTENANCE Install valve handle. (WP 0180) END OF TASK END OF WORK PACKAGE
0158-2
TM 5-3825-270-23&P FIELD MAINTENANCE 5" VALVE REPLACEMENT
0159
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 64) Qty: 8 Gasket (WP 0226, Table 1, Item 35) Qty: 2 References Parts Manual (WP 0220) Figure 4007 Equipment Condition Valve handle removed. (WP 0180)
REMOVAL
NOTE
All 5" valves are removed the same way. Valve V2 shown. Some valves may have other components that have to be removed or supported during valve replacement. Remove or support other components as necessary. Note position of valve assembly prior to removal, to ensure proper installation. Remove eight locknuts (Figure 1, Item 5), adapter pipe (Figure 1, Item 4), gasket (Figure 1, Item 1), valve (Figure 1, Item 3), gasket (Figure 1, Item 1), and screws (Figure 1, Item 6) from water tank assembly (Figure 1, Item 2). Discard locknuts.
1 2 3
5, 6
Figure 1. 5" Valve Removal. END OF TASK
0159-1
0159
NOTE
All 5" valves are installed the same way. Valve V2 shown. Some valves may have other components that have to be removed or supported during valve replacement. Remove or support other components as necessary. Position as noted prior to removal. 1. Install gasket (Figure 2, Item 1), valve (Figure 2, Item 3), gasket (Figure 2, Item 1), and adapter pipe (Figure 2, Item 4) on water tank assembly (Figure 2, Item 2) with eight screws (Figure 2, Item 6) and locknuts (Figure 2, Item 5).
1 2 3
5 5, 6 4 7 2
TIGHTENING SEQUENCE
Figure 2. 5" Valve Installation. 2. Tighten locknuts (Figure 2, Item 5) in sequence shown.
END OF TASK FOLLOW-ON MAINTENANCE Install valve handle. (WP 0180) END OF TASK END OF WORK PACKAGE
0159-2
TM 5-3825-270-23&P FIELD MAINTENANCE GRAVITY BAR WELDMENT REPLACEMENT
0160
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 76) Qty: 2 References Parts Manual (WP 0220) Figure 4014
REMOVAL 1. Remove pin (Figure 1, Item 2) holding hose reel (Figure 1, Item 3) on gravity bar (Figure 1, Item 1).
1
Figure 1. Gravity Bar Weldment Removal.
2.
Loosen clamp (Figure 2, Item 4) from water hose (Figure 2, Item 5).
0160-1
0160
Figure 2. Gravity Bar Weldment Removal. 3. Remove two locknuts (Figure 3, Item 8), four washers (Figure 3, Item 7), two screws (Figure 2, Item 6), and gravity bar weldment (Figure 3, Item 1) from power unit frame (Figure 3, Item 9). Discard locknuts.
6, 7, 8
6, 7, 8
Figure 3. Gravity Bar Weldment Removal. END OF TASK INSTALLATION 1. Install gravity bar weldment (Figure 4, Item 1) on power unit frame (Figure 4, Item 9) with two screws (Figure 4, Item 6), four washers (Figure 4, Item 7), and two locknuts (Figure 4, Item 8).
0160-2
0160
6, 7, 8
6, 7, 8
Figure 4. Gravity Bar Weldment Installation. 2. Tighten clamp (Figure 5, Item 4) on water hose (Figure 5, Item 5).
Figure 5. Gravity Bar Weldment Installation. 3. Install hose reel (Figure 6, Item 3) on gravity bar (Figure 6, Item 1) with pin (Figure 6, Item 2).
0160-3
0160
1
Figure 6. Gravity Bar Weldment Installation.
0160-4
TM 5-3825-270-23&P FIELD MAINTENANCE HOSE REEL VALVE REPLACEMENT
0161
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pipe Wrench (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) References Parts Manual (WP 0220) Figure 4047
REMOVAL 1. Loosen two clamps (Figure 1, Item 1) and remove hose reel supply hose (Figure 1, Item 2) from fitting (Figure 1, Item 3).
1 2
Figure 1. Hose Reel Valve Removal. 2. Remove nut (Figure 2, Item 11), flange nut (Figure 2, Item 12), and valve handle (Figure 2, Item 10) from hose reel valve (Figure 2, Item 13).
0161-1

4 5 6
0161
2, 13
7, 8, 9
10 12 11
Figure 2. Hose Reel Valve Removal. 3. Remove two nuts (Figure 2, Item 7) and u-bolt (Figure 2, Item 8) from bracket (Figure 2, Item 9) and pump prime hose (Figure 2, Item 6).
NOTE
Note position of valve prior to removal to ensure proper installation. 4. Remove hose reel valve (Figure 2, Item 13) and hose reel supply hose (Figure 2, Item 2) from fitting (Figure 2, Item 4).
NOTE
Note position of fitting prior to removal to ensure proper installation. 5. 6. Remove fitting (Figure 2, Item 4) from water turret assembly (Figure 2, Item 5). Loosen two clamps (Figure 3, Item 14) and remove hose reel supply hose (Figure 3, Item 2) from fitting (Figure 3, Item 15).
13
15
14
Figure 3. Hose Reel Valve Removal.
0161-2
TM 5-3825-270-23&P REMOVAL - Continued 7. With the aid of an assistant, remove fitting (Figure 3, Item 15) from hose reel valve (Figure 3, Item 13).
0161
END OF TASK INSTALLATION 1. Install hose reel supply hose (Figure 4, Item 2) on fitting (Figure 4, Item 15) with two clamps (Figure 4, Item 14).
13
15
14
Figure 4. Hose Reel Valve Removal.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 2. 3. 4. Apply sealing compound to threads of fitting (Figure 4, Item 15). Install fitting (Figure 4, Item 15) in hose reel valve (Figure 4, Item 13). Apply sealing compound to threads of water turret assembly (Figure 5, Item 5).
0161-3

5
0161
Figure 5. Hose Reel Valve Installation.
NOTE
Install fitting as noted prior to removal. 5. 6. 7. Install fitting (Figure 5, Item 4) on water turret assembly (Figure 5, Item 5). Apply sealant to threads of fitting (Figure 5, Item 4). Install hose reel supply hose (Figure 6, Item 2) and hose reel valve (Figure 6, Item 13) on fitting (Figure 6, Item 4).
4 6
2, 13
7, 8, 9
10 12 11
Figure 6. Hose Reel Valve Installation. 8. 9. 10. Install valve handle (Figure 6, Item 10) on hose reel valve (Figure 6, Item 13) with flange nut (Figure 6, Item 12) and nut (Figure 6, Item 11). Install u-bolt (Figure 6, Item 8) on pump prime hose (Figure 6, Item 6) and bracket (Figure 6, Item 9) with two nuts (Figure 6, Item 7). Install hose reel supply hose (Figure 7, Item 2) on fitting (Figure 7, Item 3) with two clamps (Figure 7, Item 1).
0161-4

1 2
0161
Figure 7. Hose Reel Valve Installation. END OF TASK END OF WORK PACKAGE
0161-5/6 blank
TM 5-3825-270-23&P FIELD MAINTENANCE REAR PLATFORM REPLACEMENT
0162
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Sling (WP 0225, Table 1, Item 9) Lifting Device, 150 lbs capacity Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Cable Ties (WP 0224, Table 1, Item 9) Tape, Duct (WP 0224, Table 1, Item 55) Locknut (WP 0226, Table 1, Item 54) Qty: 6 Locknut (WP 0226, Table 1, Item 40) Qty: 5 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4016 Parts Manual (WP 0220) Figure 4018 Equipment Condition Batteries disconnected. (WP 0085) Inlet valve and hose removed. (WP 0183) Rear platform screen removed. (WP 0165) Flusher nozzles and air actuators removed. (WP 0166) Folding hand rail assembly removed. (WP 0185) Valve V7 handle removed. (WP 0180) Valve V6 handle removed. (WP 0180) Manual water turret removed. (WP 0163)
REMOVAL 1. Open control panel cover (Figure 1, Item 1) by releasing rubber T-handle (Figure 1, Item 2).
1 2
Figure 1. Rear Platform Removal.
CAUTION
0162-1
0162
3, 4
CAUTION
After removing main control panel and box and during removal of platform secure in a position where it will not be damaged. Failure to comply may cause damage to equipment. 3. Remove five locknuts (Figure 3, Item 9), ten washers (Figure 3, Item 8), five screws (Figure 3, Item 7), and main control box (Figure 3, Item 5) from rear platform (Figure 3, Item 10). Discard locknuts.
7, 8, 9
10
Figure 3. Rear Platform Removal. 4. Remove six locknuts (Figure 4, Item 13), screws (Figure 4, Item 12), and twelve washers (Figure 4, Item 14) from rear platform (Figure 4, Item 10) and frame (Figure 4, Item 11). Discard locknuts.
0162-2
0162
11
12, 13
14
10
WARNING
Main platform weighs in excess of 125 lbs. Personnel should stay clear of lifting operation and suspended load. Attention should be paid to overhead obstacles during lifting. Failure to comply may result in death or serious injury to personnel. 5. Attach suitable lifting device to rear platform (Figure 5, Item 10).
0162-3
0162
LIFTING DEVICE 10
11
Figure 5. Rear Platform Removal. 6. With the aid of an assistant and suitable lifting device, remove rear platform (Figure 5, Item 10) from frame (Figure 5, Item 11).
WARNING
Main platform weighs in excess of 125 lbs. Personnel should stay clear of lifting operation and suspended load. Attention should be paid to overhead obstacles during lifting. Failure to comply may result in death or serious injury to personnel.
CAUTION
Ensure main control panel is secured and box are a position where it and its wiring will not be damaged during rear platform installation. Failure to comply may result in damage to equipment. 1. Attach suitable lifting device to rear platform (Figure 6, Item 10).
0162-4
0162
LIFTING DEVICE 10
11
Figure 6. Rear Platform Installation. 2. 3. With the aid of an assistant and lifting device, position rear platform (Figure 6, Item 10) on frame (Figure 6, Item 11). Secure rear platform (Figure 7, Item 10) to frame (Figure 7, Item 11) with six screws (Figure 7, Item 12), twelve washers (Figure 7, Item 14), and six locknuts (Figure 7, Item 13).
11
12, 13
14
10
Figure 7. Rear Platform Installation. 4. Install main control box (Figure 8, Item 5) on rear platform (Figure 8, Item 10) with five screws (Figure 8, Item 7), ten washers (Figure 8, Item 8), and five locknuts (Figure 8, Item 9).
0162-5
0162
7, 8, 9
10
Figure 8. Rear Platform Installation.
WARNING
3, 4
Figure 9. Rear Platform Installation. 6. 7. Install six washers (Figure 9, Item 4) and screws (Figure 9, Item 3) on main control box (Figure 9, Item 5) and control panel (Figure 9, Item 6). Tighten six screws securely. Close control panel cover (Figure 10, Item 1) and secure with rubber T-handle (Figure 10, Item 2).
0162-6

1 2
0162
Figure 10. Rear Platform Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install flusher nozzles and air actuators. (WP 0166) Install rear platform screen. (WP 0165) Install inlet valve and hose. (WP 0183) Install folding hand rail assembly. (WP 0185) Install valve V7 handle. (WP 0180) Install valve V6 handle. (WP 0180) Install manual water turret. (WP 0163) Connect batteries. (WP 0085)
0162-7/8 blank
TM 5-3825-270-23&P FIELD MAINTENANCE MANUAL WATER TURRET AND PIPING REPAIR
0163
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Goggles, Industrial (WP 0225, Table 1, Item 2) Gloves, Rubber (WP 0225, Table 1, Item 2) Gun, Air Blow (WP 0225, Table 1, Item 2) Gun, Grease (WP 0225, Table 1, Item 2) Pliers Kit, Retaining Ring (WP 0225, Table 1, Item 2) Wrench, Hydrant Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Compound, Sealing (WP 0224, Table 1, Item 18) Rag, Wiping (WP 0224, Table 1, Item 52) Swivel Kit (WP 0226, Table 1, Item 6) Qty: 1 Materials/Parts (cont.) Locknut (WP 0226, Table 1, Item 64) Qty: 24 Gasket (WP 0226, Table 1, Item 35) Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4014 Equipment Condition Air valve cover plate removed. (WP 0164) Flusher nozzles and air actuators removed. (WP 0166) Hose reel valve removed. (WP 0161)
REMOVAL
WARNING
Manual water turret components are heavy. Use the aid of an assistant when removing. Failure to comply will result in damage to equipment, death, or serious injury to personnel.
NOTE
Note position of water turret prior to removal to ensure proper installation. 1. Using hydrant wrench (Figure 1, Item 2), remove water turret (Figure 1, Item 1) from pipe (Figure 1, Item 3).
0163-1

1 2
0163
Figure 1. Manual Water Turret Replacement.
NOTE
Perform Steps (2) through (5) if piping is damaged. 2. Remove eight locknuts (Figure 2, Item 5), screws (Figure 2, Item 4), two gaskets (Figure 2, Item 6), valve V6 (Figure 2, Item 8), and pipe (Figure 2, Item 3) from cross pipe (Figure 2, Item 7). Discard locknuts and gaskets.
4, 5 3
7
Figure 2. Manual Water Turret Replacement. 3. Remove eight locknuts (Figure 3, Item 10), screws (Figure 3, Item 9), gasket (Figure 3, Item 12), and flange (Figure 3, Item 11) from cross pipe (Figure 3, Item 7). Discard locknuts.
0163-2

7
0163
9, 10
11, 12
Figure 3. Manual Water Turret Replacement. 4. Remove four locknuts (Figure 4, Item 13), washers (Figure 4, Item 14), and two u-bolts (Figure 4, Item 16) from cross pipe (Figure 4, Item 7) and weldment (Figure 4, Item 15). Discard locknuts.
7 13, 14
15 16
Figure 4. Manual Water Turret Replacement. 5. Remove six locknuts (Figure 5, Item 17), washers (Figure 5, Item 18), three u-bolts (Figure 5, Item 19), and cross pipe (Figure 5, Item 7) from weldment (Figure 5, Item 15). Discard locknuts.
0163-3

7
0163
17, 18, 19
15
Figure 5. Manual Water Turret Replacement. END OF TASK DISASSEMBLY 1. Remove sealant from two holes (Figure 6, Item 2) in upper water turret tube (Figure 6, Item 1).
0163-4
0163
2, 3
12 11
10
4, 5 6 7
8 7 6
Figure 6. Water Turret Disassembly.
WARNING
Wear proper eye protection and use care when removing and installing retaining rings. Retaining rings are under spring tension and can act as projectiles when released. Failure to comply may result in injury or death to personnel. 2. 3. 4. Remove two retaining rings (Figure 6, Item 9) from two holes (Figure 6, Item 2) in upper water turret tube (Figure 6, Item 1). Discard retaining rings. Remove two ball bearing retaining plugs (Figure 6, Item 10) from upper water turret tube (Figure 6, Item 1). Discard ball bearing retaining plugs. Remove lock handle (Figure 6, Item 8) and four washers (Figure 6, Items 6 and 7) from adjusting bracket (Figure 6, Item 4) and bracket (Figure 6, Item 5).
0163-5
0163
WARNING
SOLVENT CLEANING COMPOUND (DRYCLEANING SOLVENT) Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flashpoint for Type II solvent cleaning compound is 141 to 198F (61 to 92C), and Type III is 200 to 241F (93 to 116C). Improper cleaning methods and use of unauthorized cleaning solvents may result in injury to personnel and/or damage to equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to comply may result in injury or death to personnel. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to comply may result in injury to personnel. Eye shields must be worn when cleaning with a wire brush. Failure to comply may result in injury to personnel. If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury or death to personnel.
NOTE
Grease may not allow balls to roll out of races. Solvent may be used to free balls from races. Upper water turret tube may only be disassembled after all ball bearings have been removed from swivel joint. 5. 6. 7. Rotate upper water turret tube (Figure 6, Item 1) around lower water turret tube (Figure 6, Item 12) to allow 84 ball bearings (Figure 6, Item 11) to roll out of two races (Figure 6, Items 3). Discard ball bearings. Remove upper water turret tube (Figure 6, Item 1) from lower water turret tube (Figure 6, Item 12). Remove dust seal (Figure 7, Item 14) from upper water turret tube (Figure 7, Item 1). Discard seal.
0163-6
0163
14 13
Figure 7. Water Turret Disassembly. 8. 9. Remove pressure seal (Figure 7, Item 13) from upper water turret tube (Figure 7, Item 1). Discard seal. Remove sealant from two holes (Figure 8, Item 19) in lower water turret tube (Figure 8, Item 12).
18 19, 20 12 17 16 15 21 22 23
Figure 8. Water Turret Disassembly. 10. 11. Remove two retaining rings (Figure 8, Item 23) from two holes (Figure 8, Item 19) in lower water turret tube (Figure 8, Item 12). Discard retaining rings. Remove two ball bearing retaining plugs (Figure 8, Item 22) from lower water turret tube (Figure 8, Item 12). Discard retaining plugs.
0163-7
TM 5-3825-270-23&P DISASSEMBLY - Continued 12. Loosen lock knob (Figure 8, Item 18) from lower water turret tube (Figure 8, Item 12).
0163
WARNING
SOLVENT CLEANING COMPOUND (DRYCLEANING SOLVENT) Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flashpoint for Type II solvent cleaning compound is 141 to 198F (61 to 92C), and Type III is 200 to 241F (93 to 116C). Improper cleaning methods and use of unauthorized cleaning solvents may result in injury to personnel and/or damage to equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to comply may result in injury or death to personnel. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to comply may result in injury to personnel. Eye shields must be worn when cleaning with a wire brush. Failure to comply may result in injury to personnel. If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury or death to personnel.
NOTE
Grease may not allow balls to roll out of races. Solvent may be used to free balls from races. 13. 14. 15. 16. Rotate fitting (Figure 8, Item 15) to allow 84 ball bearings (Figure 8, Item 21) to roll out of two races (Figure 8, Item 20). Discard ball bearings. Remove fitting (Figure 8, Item 15) from lower water turret tube (Figure 8, Item 12). Remove dust seal (Figure 8, Item 16) from lower water turret tube (Figure 8, Item 12). Discard seal. Remove pressure seal (Figure 8, Item 17) from lower water turret tube (Figure 8, Item 12). Discard seal.
END OF TASK
0163-8
TM 5-3825-270-23&P CLEANING/INSPECTION
0163
WARNING
SOLVENT CLEANING COMPOUND (DRYCLEANING SOLVENT) Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in a well-ventilated area. Use respirator as needed. Accidental ingestion can cause irritation of digestive tract and respiratory tract, may cause lung and central nervous system damage. Can be fatal if swallowed. Inhalation of high/massive concentrations can cause coma or be fatal. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flashpoint for Type II solvent cleaning compound is 141 to 198F (61 to 92C), and Type III is 200 to 241F (93 to 116C). Improper cleaning methods and use of unauthorized cleaning solvents may result in injury to personnel and/or damage to equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Failure to comply may result in injury or death to personnel. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. Failure to comply may result in injury to personnel. Eye shields must be worn when cleaning with a wire brush. Failure to comply may result in injury to personnel. If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. Failure to comply may result in injury or death to personnel. 1. 2. 3. 4. Clean all grease from upper and lower water turret tubes using solvent. Blow parts dry. Inspect upper and lower water turret tubes for cracking or pitting around swivel joint and bearing races. Replace assembly if damage is found.
CAUTION
Pressure seal must be installed with lip facing away from races. Failure to comply may result in damage to equipment. 1. Apply light coat of grease to pressure seal (Figure 9, Item 17).
0163-9
0163
18 19, 20 12 17 16 15 21 22 23
Figure 9. Water Turret Assembly. 2. 3. 4. 5. 6. 7. 8. Install pressure seal (Figure 9, Item 7) in lower water turret tube (Figure 9, Item 12). Apply light coat of grease to dust seal (Figure 9, Item 16). Install dust seal (Figure 9, Item 16) in lower water turret tube (Figure 9, Item 12). Install fitting (Figure 9, Item 15) in lower water turret tube (Figure 9, Item 12). Install 84 ball bearings (Figure 9 Item 21) into two races (Figure 9, Item 20). Tighten lock knob (Figure 9, Item 18). Install two ball bearing retainer plugs (Figure 9, Item 22) in holes (Figure 9, Item 19).
WARNING
Wear proper eye protection and use care when removing and installing retaining rings. Retaining rings are under spring tension and can act as projectiles when released. Failure to comply may result in injury or death to personnel. 9. Install two retaining rings (Figure 9, Item 23) into holes (Figure 9, Item 19).
WARNING
On direct contact, uncured silicone sealant irritates eyes. Wear proper eye protection and gloves. If silicone sealant gets in your eyes, flush eyes with water and seek immediate medical attention. In case of skin contact, wipe off skin and flush with water. Failure to comply may result in injury or death to personnel.
0163-10
TM 5-3825-270-23&P ASSEMBLY - Continued 10. 11. 12. Fill two holes (Figure 9, Item 19) with sealant. Loosen lock knob (Figure 9, Item 18). Apply light coat of grease to pressure seal (Figure 10, Item 13).
0163
14 13
Figure 10. Water Turret Assembly. 13. 14. 15. 16. Install pressure seal (Figure 10, Item 13) in upper water turret tube (Figure 10, Item 1). Apply light coat of grease to dust seal (Figure 10, Item 14). Install dust seal (Figure 10, Item 14) in upper water turret tube (Figure 10, Item 1). Install upper water turret tube (Figure 11, Item 1) on lower water turret tube (Figure 11, Item 12).
0163-11
0163
2, 3
12 11
10
4, 5 6 7
8 7 6
Figure 11. Water Turret Assembly. 17. 18. 19. 20. 21. Loosely install lock handle (Figure 11, Item 8) with four washers (Figure 11, Items 6 and 7) on adjusting bracket (Figure 11, Item 5) and bracket (Figure 11, Item 4). Install 84 ball bearings (Figure 11, Item 11) into two races (Figure 11, Item 3). Install two ball bearing plugs (Figure 11, Item 10) in two holes (Figure 11, Item 2). Install two retaining rings (Figure 11, Item 9) in holes (Figure 11, Item 2). Fill holes (Figure 11, Item 2) with sealant.
CAUTION
Do not over grease swivel joints. Excessive grease can cause leakage and/or difficult rotation. Failure to comply may result in damage to equipment.
NOTE
Zerk fittings are required to be greased a total of three times. 22. Lubricate two zerk fittings (Figure 12, Item 26) with small amount of grease.
0163-12
0163
24
26
25
Figure 12. Water Turret Assembly. 23. 24. Rotate two swivel joints (Figure 12, Items 24 and 25) and repeat Step (21). Repeat Step (22).
WARNING
Manual water turret components are heavy. Use the aid of an assistant when removing. Failure to comply will result in damage to equipment, death, or serious injury to personnel.
NOTE
Perform Steps (1) through (5) if piping was removed. 1. Install cross pipe (Figure 13, Item 7) on weldment (Figure 13, Item 15) with three u-bolts (Figure 13, Item 19), six washers (Figure 13, Item 18), and locknuts (Figure 13, Item 17).
0163-13

7
0163
17, 18, 19
15
Figure 13. Manual Water Turret Installation. 2. Secure cross pipe (Figure 14, Item 7) to weldment (Figure 14, Item 15) with two u-bolts (Figure 14, Item 16), four washers (Figure 14, Item 14), and locknuts (Figure 14, Item 13).
7 13, 14
15 16
Figure 14. Manual Water Turret Installation. 3. Install gasket (Figure 15, Item 12) and flange (Figure 15, Item 11) on cross pipe (Figure 15, Item 7) with eight screws (Figure 15, Item 9) and locknuts (Figure 15, Item 10).
0163-14

7
0163
9, 10
11, 12
Figure 15. Manual Water Turret Installation. 4. Install gasket (Figure 16, Item 6), valve V6 (Figure 16, Item 8), gasket (Figure 16, Item 6), and pipe (Figure 16, Item 3) on cross pipe (Figure 16, Item 7) with eight screws (Figure 16, Item 4) and locknuts (Figure 16, Item 5).
4, 5 3
7
Figure 16. Manual Water Turret Installation.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 5. Apply pipe thread sealant to threads of pipe (Figure 17, Item 3).
0163-15
0163
Figure 17. Manual Water Turret Installation.
NOTE
Install water turret as noted prior to removal. 6. Install manual water turret (Figure 18, Item 1) on pipe (Figure 18, Item 3) using hydrant wrench (Figure 18, Item 2).
1 2
Figure 18. Manual Water Turret Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install hose reel valve. (WP 0161) Install flusher nozzles and air actuators. (WP 0166)
0163-16
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE - Continued 3. Install air valve cover plate. (WP 0164)
0163
0163-17/18 blank
TM 5-3825-270-23&P FIELD MAINTENANCE AIR VALVE COVER PLATE REPLACEMENT
0164
REMOVAL Remove two locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), screws (Figure 1, Item 3), and air valve cover plate (Figure 1, Item 4) from bracket (Figure 1, Item 5). Discard locknuts.
1, 2, 3
Figure 1. Air Valve Cover Plate Removal. END OF TASK INSTALLATION Install air valve cover plate (Figure 2, Item 4) on bracket (Figure 2, Item 5) with two screws (Figure 2, Item 3), washers (Figure 2, Item 2), and locknuts (Figure 2, Item 1).
0164-1
0164
1, 2, 3
Figure 2. Air Valve Cover Plate Installation. END OF TASK END OF WORK PACKAGE
0164-2
TM 5-3825-270-23&P FIELD MAINTENANCE REAR PLATFORM SCREEN REPLACEMENT
0165
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 57) Qty: 5 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4016
REMOVAL Remove five locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), screws (Figure 1, Item 3), washers (Figure 1, Item 4), and rear platform screen (Figure 1, Item 5) from rear module (Figure 1, Item 6). Discard locknuts.
1, 2, 3, 4
Figure 1. Rear Platform Screen Removal. END OF TASK INSTALLATION Install rear platform screen (Figure 2, Item 5) on rear module (Figure 2, Item 6) with five washers (Figure 2, Item 4), screws (Figure 2, Item 3), washers (Figure 2, Item 2), and locknuts (Figure 2, Item 1).
0165-1
0165
1, 2, 3, 4
Figure 2. Rear Platform Screen Installation. END OF TASK END OF WORK PACKAGE
0165-2
TM 5-3825-270-23&P FIELD MAINTENANCE FLUSHER NOZZLE AND AIR ACTUATOR REPLACEMENT
0166
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 76) Qty: 18 Gasket (WP 0226, Table 1, Item 34) Qty: 2 References Parts Manual (WP 0220) Figure 4014 Equipment Condition Air valve cover plate removed. (WP 0164)
REMOVAL
NOTE
Both right and left flusher nozzles are replaced the same way. Left side shown. 1. Loosen six set screws (Figure 1, Item 3) and three collars (Figure 1, Item 2).
2 3 4
Figure 1. Flusher Nozzle Removal. 2. 3. 4. Remove nozzle (Figure 1, Item 4) from elbow (Figure 1, Item 1). Remove elbow (Figure 1, Item 1) from elbow (Figure 1, Item 6). Remove four locknuts (Figure 2, Item 8), washers (Figure 2, Item 9), and two u-bolts (Figure 2, Item 10) from manual water turret assembly (Figure 2, Item 7) and module (Figure 2, Item 11). Discard locknuts.
0166-1

7
0166
8, 9, 10
11
Figure 2. Flusher Nozzle Installation. 5. Remove six locknuts (Figure 3, Item 13), washers (Figure 3, Item 14), and three u-bolts (Figure 3, Item 12) from manual water turret assembly (Figure 3, Item 7) and module (Figure 3, Item 11). Discard locknuts.
12 13 14
11
Figure 3. 6. Shift manual water turret assembly (Figure 4, Item 7) forward to gain access to screws (Figure 4, Item 15).
0166-2
0166
15
Figure 4. Flusher Nozzle and Air Actuator Removal. 7. Remove elbow (Figure 5, Item 6) from tube (Figure 5, Item 5).
5
Figure 5. 8. Loosen clamp (Figure 6, Item 17) and remove air line (Figure 6, Item 19) from fitting (Figure 6, Item 18).
0166-3
0166
16
17, 18
19
20, 21 15, 22
5
Figure 6. Flusher Nozzle Removal.
NOTE
Note position of gaskets prior to removal to ensure proper installation. 9. Remove eight locknuts (Figure 6, Item 22), tube (Figure 6, Item 5), gasket (Figure 6, Item 20), air actuator (Figure 6, Item 16), gasket (Figure 6, Item 21), and screws (Figure 6, Item 15) from manual water turret assembly (figure 6, Item 7). Discard gaskets and locknuts. Repeat Steps (1) through (9) for right side.
10.
NOTE
Install gaskets as noted prior to removal. 1. Install air actuator (Figure 7, Item 16) and tube (Figure 7, Item 5) on manual water turret assembly (Figure 7, item 7) with gasket (Figure 7, Item 21), gasket (Figure 7, Item 20), eight screws (Figure 7, Item 15), and locknuts (Figure 7, Item 22). Tighten screws in sequence shown.
0166-4
0166
16
17, 18
19
7 1 8
20, 21 7 15, 22 TIGHTENING SEQUENCE 2
5
Figure 7. Flusher Nozzle and Air Actuator Installation. 2. 3. Install air line (Figure 7, Item 19) on fitting (Figure 7, Item 18) with clamp (Figure 7, Item 8). Install elbow (Figure 8, Item 6) on tube (Figure 8, Item 5).
5
Figure 8. 4. Reposition manual water turret assembly (Figure 9, Item 7). Install three u-bolts (Figure 9, Item 12), six washers (Figure 9, Item 14), and locknuts (Figure 9, Item 13) on module (Figure 9, Item 11).
0166-5

12 13 14
0166
11
Figure 9. Flusher Nozzle Installation. 5. Install two u-bolts (Figure 9, Item 10), four washers (Figure 9, Item 9), and locknuts (Figure 9, Item 8) on manual water turret assembly (Figure 9, Item 7) and module (Figure 9, Item 11).
7
8, 9, 10
11
Figure 10. Flusher Nozzle Installation. 6. Install elbow (Figure 11, Item 1) on elbow (Figure 11, Item 6).
0166-6

2 3 4
0166
Figure 11. 7. 8. 9. Install nozzle (Figure 11, Item 4) on elbow (Figure 11, Item 1). Tighten three collars (Figure 11, Item 2) and six set screws (Figure 11, Item 3). Repeat Steps (1) through (8) for right side.
END OF TASK FOLLOW-ON MAINTENANCE Install air valve cover plate. (WP 0164) END OF TASK END OF WORK PACKAGE
0166-7/8 blank
TM 5-3825-270-23&P FIELD MAINTENANCE FIRE EXTINGUISHER BRACKET REPLACEMENT
0167
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 56) Qty: 4 Locknut (WP 0226, Table 1, Item 76) Qty: 3 References Parts Manual (WP 0220) Figure 4017 Equipment Condition Fire extinguisher removed. (TM 5-3825-270-10)
REMOVAL 1. Remove four locknuts (Figure 1, Item 1), four washers (Figure 1, Item 2), four screws (Figure 1, Item 3), and fire extinguisher bracket (Figure 1, Item 4) from mounting bracket (Figure 1, Item 5). Discard locknuts.
1, 2, 3
Figure 1. Fire Extinguisher Bracket Removal.
NOTE
Perform Step (2) if mounting bracket is damaged. 2. Remove three locknuts (Figure 2, Item 6), six washers (Figure 2, Item 7), three screws (Figure 2, Item 8), and mounting bracket (Figure 2, Item 5) from hose reel (Figure 2, Item 9). Discard locknuts.
0167-1
0167
6, 7, 8
Figure 2. Mounting Bracket Removal. END OF TASK INSTALLATION
NOTE
Perform Step (1) if mounting bracket was removed. 1. Install mounting bracket (Figure 3, Item 5) on hose reel (Figure 3, Item 9) with six washers (Figure 3, Item 7), three screws (Figure 3, Item 8), and locknuts (Figure 3, Item 6).
6, 7, 8
Figure 3. Mounting Bracket Installation. 2. Install fire extinguisher bracket (Figure 4, Item 4) on mounting bracket (Figure 4, Item 5) with four screws (Figure 4, Item 3), four washers (Figure 4, Item 2), and four locknuts (Figure 4, Item 1).
0167-2
0167
1, 2, 3
Figure 4. Fire Extinguisher. END OF TASK FOLLOW-ON MAINTENANCE Install fire extinguisher. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0167-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE SOLENOID VALVE REPLACEMENT
0168
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Tags, Identification, White (WP 0224, Table 1, Item 54) Materials/Parts (cont.) Screw (WP 0226, Table 1, Item 48) Qty: 4 Locknut (WP 0226, Table 1, Item 8) Qty: 4 References Parts Manual (WP 0220) Figure 4014 Equipment Condition Batteries disconnected. (WP 0085) Air valve cover plate removed. (WP 0164)
REMOVAL
NOTE
Tag and mark all hoses and wires prior to removal to ensure proper installation. Perform Steps (1) through (8) if removing right solenoid valve. Perform Steps (9) through (13) if removing left solenoid valve. 1. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 1) from fitting (Figure 1, Item 3).
2 1 3 4
Figure 1. Solenoid Valve Removal. 2. 3. 4. 5. Loosen clamp (Figure 1, Item 5) and remove hose (Figure 1, Item 6) from fitting (Figure 1, Item 7). Remove fitting (Figure 1, Item 7) from fitting (Figure 1, Item 3). Remove fitting (Figure 1, Item 3) from fitting (Figure 1, Item 4). Disconnect right solenoid valve connector lead (Figure 2, Item 9) from harness connector (Figure 2, Item 8).
0168-1

8 9
0168
Figure 2. Solenoid Valve Removal. 6. Loosen clamp (Figure 3, Item 13) and remove hose (Figure 3, Item 14) from fitting (Figure 3, Item 12).
10
11 12
13 14
15, 16
18
Figure 3. Solenoid Valve Removal. 7. 8. 9. 10.
17
15, 16
Loosen clamp (Figure 3, Item 18) and remove hose (Figure 3, Item 6) from fitting (Figure 3, Item 17). Remove two locknuts (Figure 3, Item 16), screws (Figure 3, Item 15), and right solenoid valve (Figure 3, Item 11) from frame (Figure 3, Item 10). Discard locknuts and screws. Remove fitting (Figure 3, Item 12) and fitting (Figure 3, Item 17) from right solenoid valve (Figure 3, Item 11). Disconnect left solenoid valve connector lead (Figure 4, Item 19) from harness connector (Figure 4, Item 20).
0168-2
0168
20
19
Figure 4. Solenoid Valve Removal. 11. Loosen clamp (Figure 5, Item 22) and remove hose (Figure 5, Item 21) from fitting (Figure 5, Item 23).
21
22
23 24, 25
10
24, 25
28
27
26
Figure 5. Solenoid Valve Removal. 12. 13. 14. Loosen clamp (Figure 5, Item 28) and remove hose (Figure 5, Item 1) from fitting (Figure 5, Item 27). Remove two locknuts (Figure 5, Item 25), screws (Figure 5, Item 24), and left solenoid valve (Figure 5, Item 26) from frame (Figure 5, Item 10). Discard locknuts and screws. Remove fitting (Figure 5, Item 23) and fitting (Figure 5, Item 27) from left solenoid valve (Figure 5, Item 26).
END OF TASK
0168-3
0168
WARNING
NOTE
Install hoses and wires as noted prior to removal. Perform Steps (1) through (8) if left solenoid valve was removed. Perform Steps (9) through (20) if right solenoid valve was removed. 1. Coat threads of fitting (Figure 6, Item 27) with pipe thread sealant.
21
22
23 24, 25
10
24, 25
28
27
26
Figure 6. Solenoid Valve Installation. 2. 3. 4. 5. 6. 7. 8. Install fitting (Figure 6, Item 27) on left solenoid valve (Figure 6, Item 26). Coat threads of fitting (Figure 6, Item 23) with pipe thread sealant. Install fitting (Figure 6, Item 24) on left solenoid valve (Figure 6, Item 26). Install left solenoid valve (Figure 6, Item 26) on frame (Figure 6, Item 10) with two screws (Figure 6, Item 24) and locknuts (Figure 6, Item 25). Install hose (Figure 6, Item 1) on fitting (Figure 6, Item 27) with clamp (Figure 6, Item 28). Install hose (Figure 6, Item 21) on fitting (Figure 6, Item 23) with clamp (Figure 6, Item 22). Connect left solenoid valve connector lead (Figure 7, Item 19) to harness connector (Figure 7, Item 20).
0168-4
0168
20
19
Figure 7. Solenoid Valve Installation.
WARNING
10
11 12
13 14
15, 16
18
Figure 8. Solenoid Valve Installation. 10. Install fitting (Figure 8, Item 17) on right solenoid valve (Figure 8, Item 11).
17
15, 16
0168-5
TM 5-3825-270-23&P INSTALLATION - Continued 11. 12. 13. 14. 15. 16. Coat threads of fitting (Figure 8, Item 12) with pipe thread sealant. Install fitting (Figure 8, Item 12) on right solenoid valve (Figure 8, Item 11).
0168
Install right solenoid valve (Figure 8, Item 11) on frame (Figure 8, Item 10) with two screws (Figure 8, Item 15) and locknuts (Figure 8, Item 16). Install hose (Figure 8, Item 6) on fitting (Figure 8, Item 17) with clamp (Figure 8, Item 18). Install hose (Figure 8, Item 14) on fitting (Figure 8, Item 12) with clamp (Figure 8, Item 13). Connect right solenoid valve connector lead (Figure 9, Item 9) to harness connector (Figure 9, Item 8).
8 9
Figure 9. Solenoid Valve Installation.
WARNING
0168-6

2 1 3 4
0168
Figure 10. Solenoid Valve Installation. 18. 19. 20. 21. 22. Install fitting (Figure 10, Item 3) on fitting (Figure 10, Item 4). Coat threads of fitting (Figure 10, Item 7) with pipe thread sealant. Install fitting (Figure 10, Item 7) on fitting (Figure 10, Item 3). Install hose (Figure 10, Item 6) on fitting (Figure 10, Item 7) with clamp (Figure 10, Item 5). Install hose (Figure 10, Item 1) on fitting (Figure 10, Item 3) with clamp (Figure 10, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install air valve cover plate (WP 0164) Connect batteries. (WP 0085)
0168-7/8 blank
TM 5-3825-270-23&P FIELD MAINTENANCE AIR LINE LUBRICATOR REPLACEMENT
0169
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Gloves, Rubber (WP 0225, Table 1, Item 2) Goggles, Industrial (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Oil, Lubricating, OE/HDO 10 (MIL-PRF-2104) (WP 0224, Table 1, Item 46, 47, 48) References Parts Manual (WP 0220) Figure 4014 Equipment Condition Air valve cover plate removed. (WP 0164)
REMOVAL
WARNING
Air line lubricator is under high pressure. Use protective gloves and goggles when servicing system. Remove fill plug slowly to allow depressurization of system. Failure to comply may result in injury or death to personnel. 1. Remove fill plug (Figure 1, Item 3) from air line lubricator (Figure 1, Item 2).
1 2 3 4 5
Figure 1. Air Line Lubricator Removal.
0169-1
0169
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 2. 3. Remove fluid bowl (Figure 1, Item 7) from air line lubricator (Figure 1, Item 2). Loosen clamp (Figure 1, Item 6) and remove air hose (Figure 1, Item 5) from fitting (Figure 1, Item 4).
NOTE
Note position of air line lubricator prior to removal to ensure proper installation. 4. 5. Rotate air line lubricator (Figure 1, Item 2) counterclockwise and remove from fitting (Figure 1, Item 1). Remove fitting (Figure 2, Item 4) from air line lubricator (Figure 2, Item 2).
2 4
Figure 2. Air Line Lubricator Removal. END OF TASK
0169-2
0169
WARNING
NOTE
Install air line lubricator as noted prior to removal. 1. Apply sealing compound to threads of fitting (Figure 3, Item 4).
2 4
Figure 3. Air Line Lubricator Installation. 2. 3. Install fitting (Figure 3, Item 4) on air line lubricator (Figure 3, Item 2). Apply sealing compound to threads of fitting (Figure 4, Item 1).
0169-3

1 2 3 4 5
0169
Figure 4. Air Line Lubricator Installation. 4. 5. Install air line lubricator (Figure 4, Item 2) on fitting (Figure 4, Item 1). Install air hose (Figure 4, Item 5) on fitting (Figure 4, Item 4) with clamp (Figure 4, Item 6).
WARNING
Prolonged contact with lubricating oil may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with lubricating oil. Keep area well-ventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 6. 7. Fill fluid bowl (Figure 4, Item 7) with clean oil and install on air line lubricator (Figure 4, Item 2). Install fill plug (Figure 4, Item 3) on air line lubricator (Figure 4, Item 2).
0169-4
TM 5-3825-270-23&P FIELD MAINTENANCE AIR CLEANER ASSEMBLY REPAIR
0170
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 51) Qty: 2 Spring (WP 0226, Table 1, Item 50) Qty: 2 References Parts Manual (WP 0220) Figure 4021 Equipment Condition Rear engine access cover removed. (TM 5-3825-270-10) Outer air filter element removed. (TM 5-3825-270-10)
REMOVAL 1. Remove inner air filter element (Figure 1, Item 1) from air cleaner assembly (Figure 1, Item 2).
2 3, 4, 5
Figure 1. Air Cleaner Assembly Removal. 2. Remove two locknuts (Figure 1, Item 3), springs (Figure 1, Item 4), and screws (Figure 1, Item 5) from bracket (Figure 1, Item 6). Discard locknuts and springs.
0170-1
0170
Loosen clamp (Figure 2, Item 7) and remove air cleaner assembly (Figure 2, Item 2) from fitting (Figure 2, Item 8).
2 7
10
Figure 2. Air Cleaner Assembly Removal. 4. Loosen clamp (Figure 2, Item 9) and remove fitting (Figure 2, Item 8) from hose (Figure 2, Item 10).
NOTE
Perform Step (5) if bracket is damaged. Note position of bracket prior to removal to ensure proper installation. 5. Remove two nuts (Figure 3, Item 13), screws (Figure 3, Item 11), and bracket (Figure 3, Item 6) from engine compartment cover (Figure 3, Item 12).
6 ENGINE COMPARTMENT COVER SHOWN REMOVED FOR CLARITY
11 12
13
Figure 3. Air Cleaner Assembly Removal. END OF TASK DISASSEMBLY 1. Loosen clamp (Figure 4, Item 1) and remove air pre cleaner (Figure 4, Item 2) and reducer (Figure 4, Item 3) from air cleaner assembly (Figure 4, Item 4).
0170-2

2
0170
Figure 4. Air Cleaner Disassembly. 2. Remove air filter restriction indicator (Figure 5, Item 5) from air cleaner assembly (Figure 5, Item 4).
5
Figure 5. Air Cleaner Disassembly. END OF TASK ASSEMBLY 1. Install air filter restriction indicator (Figure 6, Item 5) on air cleaner assembly (Figure 6, Item 4).
0170-3
0170
5
Figure 6. Air Cleaner Assembly. 2. Install clamp (Figure 7, Item 1), reducer (Figure 7, Item 3), and air pre cleaner (Figure 7, Item 2) on air cleaner assembly (Figure 7, Item 4).
2
Figure 7. Air Cleaner Assembly. END OF TASK INSTALLATION
NOTE
Perform Step (1) if bracket was removed. Install bracket as noted prior to removal. 1. Install bracket (Figure 8, Item 6) on engine compartment cover (Figure 8, Item 12) with two screws (Figure 8, Item 11) and nuts (Figure 8, Item 13).
0170-4
0170
6 ENGINE COMPARTMENT COVER SHOWN REMOVED FOR CLARITY
11 12
13
Figure 8. Air Cleaner Assembly Installation. 2. Install fitting (Figure 9, Item 8) on hose (Figure 9, Item 10) with clamp (Figure 9, Item 9).
2 7
10
Figure 9. Air Cleaner Assembly Installation. 3. 4. Install air cleaner assembly (Figure 9, Item 2) on fitting (Figure 9, Item 8) with clamp (Figure 9, Item 7). Install two screws, (Figure 10, Item 5), springs (Figure 10, Item 4), and locknuts (Figure 10, Item 3) in bracket (Figure 10, Item 6).
0170-5
0170
2 3, 4, 5
Figure 10. Air Cleaner Assembly Installation. 5. Install inner air filter element (Figure 10, Item 1) in air cleaner assembly (Figure 10, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install outer air filter element. (TM 5-3825-270-10) Install rear engine access cover. (TM 5-3825-270-10)
0170-6
TM 5-3825-270-23&P FIELD MAINTENANCE AIR HOSE REPLACEMENT
0171
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) References Parts Manual (WP 0220) Figure 4014 Equipment Condition Air valve cover plate removed. (WP 0164)
REMOVAL 1. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 4) from fitting (Figure 1, Item 3).
1 2 3
Figure 1. Air Hose Removal. 2. 3. Loosen clamp (Figure 1, Item 5) and remove hose (Figure 1, Item 4) from solenoid valve (Figure 1, Item 1). Loosen clamp (Figure 2, Item 10) and remove hose (Figure 2, Item 9) from solenoid valve (Figure 2, Item 1).
0171-1
0171
10
Figure 2. Air Hose Removal. 4. Loosen clamp (Figure 2, Item 8) and remove hose (Figure 2, Item 9) from fitting (Figure 2, Item 7).
NOTE
Perform Step (5) if fitting is damaged. 5. 6. Remove fitting (Figure 2, Item 7) from actuator (Figure 2, Item 6). Loosen clamp (Figure 3, Item 12) and remove hose (Figure 3, Item 13) from fitting (Figure 3, Item 3).
11
14
Figure 3. Air Hose Removal. 0171-2
13
12
TM 5-3825-270-23&P REMOVAL - Continued 7. 8.
0171
Loosen clamp (Figure 3, Item 14) and remove hose (Figure 3, Item 13) from solenoid valve (Figure 3, Item 11). Loosen clamp (Figure 4, Item 15) and remove hose (Figure 4, Item 16) from solenoid valve (Figure 4, Item 11).
11
15
16
16
17
18
19
Figure 4. Air Hose Removal. 9. Loosen clamp (Figure 4, Item 17) and remove hose (Figure 4, Item 16) from fitting (Figure 4, Item 18).
NOTE
Perform Step (10) if fitting is damaged. 10. Remove fitting (Figure 4, Item 18) from air actuator (Figure 4, Item 19).
WARNING
NOTE
Perform Steps (1) and (2) if fitting was removed. 1. Coat threads of fitting (Figure 5, Item 18) with pipe thread sealant.
0171-3
0171
11
15
16
16
17
18
19
Figure 5. Air Hose Installation. 2. 3. 4. 5. Install fitting (Figure 5, Item 18) on air actuator (Figure 5, Item 19). Install hose (Figure 5, Item 16) on fitting (Figure 5, Item 18) with clamp (Figure 5, Item 17). Install hose (Figure 5, Item 16) on solenoid valve (Figure 5, Item 11) with clamp (Figure 5, Item 15). Install hose (Figure 6, Item 13) on solenoid valve (Figure 6, Item 11) with clamp (Figure 6, Item 14).
11
14
Figure 6. Air Hose Installation. 6.
13
12
Install hose (Figure 6, Item 13) on fitting (Figure 6, Item 3) with clamp (Figure 6, Item 12).
0171-4
0171
WARNING
NOTE
Perform Steps (7) and (8) if fitting was removed. 7. Coat threads of fitting (Figure 7, Item 7) with pipe thread sealant.
10
Figure 7. Air Hose Installation. 8. 9. 10. 11. Install fitting (Figure 7, Item 7) on air actuator (Figure 7, Item 6). Install hose (Figure 7, Item 9) on fitting (Figure 7, Item 7) with clamp (Figure 7, Item 8). Install hose (Figure 7, Item 9) on solenoid valve (Figure 7, Item 1) with clamp (Figure 7, Item 10). Install hose (Figure 8, Item 4) on solenoid valve (Figure 8, Item 1) with clamp (Figure 8, Item 5).
0171-5

1 2 3
0171
Figure 8. Air Hose Installation. 12. Install hose (Figure 8, Item 4) on fitting (Figure 8, Item 3) with clamp (Figure 8, Item 2).
0171-6
TM 5-3825-270-23&P FIELD MAINTENANCE FUEL LINE REPLACEMENT
0172
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Materials/Parts Locknut Qty: 8 References Parts Manual (WP 0220) Figure 4005 Equipment Condition Engine compartment cover removed. (WP 0142)
REMOVAL
WARNING
NOTE
Water tank shown removed for clarity. Remove cable ties as required. Note location and position of cushion clips and fuel line routing prior to removal to ensure proper installation. Use a drain pan where appropriate to catch any spilled fuel. Dispose of drain pan contents IAW local procedures. Both fuel supply line and fuel return lines are removed the same way, except where noted. Perform Step (1) if fuel supply line is damaged. 1. Loosen clamp (Figure 1, Item 3) and remove fuel supply line (Figure 1, Item 1) from fuel tank (Figure 1, Item 4).
0172-1
0172
2 1
5 5 6, 7 1 2
6, 7
2 3
4 3
Figure 1. Fuel Line Removal.
NOTE
Perform Step (2) if 5/16 inch fuel return line is damaged. 2. 3. Loosen clamp (Figure 1, Item 3) and remove 5/16 inch fuel return line (Figure 1, Item 2) from fuel tank (Figure 1, Item 4). Remove eight locknuts (Figure 1, Item 6), screws (Figure 1, Item 7), and cushion clips (Figure 1, Item 5) from flatrack (Figure 1, Item 8), fuel supply line (Figure 1, Item 1), and 5/16 inch fuel return line (Figure 1, Item 2). Discard locknuts.
NOTE
Perform Step (4) if fuel supply line is damaged. 4. Loosen clamp (Figure 2, Item 16) and remove fuel supply line (Figure 2, Item 1) from fuel pump (Figure 2, Item 17).
0172-2
0172
14 15
16 1 17 10 9 10
11
12 2
13
NOTE
Perform Step (5) if 5/16 inch fuel return line is damaged. 5. Loosen clamp (Figure 2, Item 13) and remove 5/16 inch fuel return line (Figure 2, Item 2) from fitting (Figure 2, Item 12).
NOTE
Perform Steps (6) and (7) if 1/4 inch fuel return line is damaged. 6. 7. Loosen clamp (Figure 2, Item 9) and remove 1/4 inch fuel return line (Figure 2, Item 10) from fitting (Figure 2, Item 11). Loosen clamp (Figure 2, Item 15) and remove 1/4 inch fuel return line (Figure 2, Item 10) from fitting (Figure 2, Item 14).
NOTE
If fuel line from fuel pump to fuel filter housing is damaged, perform Steps (8) and (9). 8. Loosen clamp (Figure 3, Item 19) and remove fuel line (Figure 3, Item 18) from fuel pump (Figure 3, Item 17).
0172-3

20 18 19 17
0172
21
18
Figure 3. Fuel Line Removal. 9. Loosen clamp (Figure 3, Item 21) and remove fuel line (Figure 3, Item 18) from fitting (Figure 3, Item 20).
NOTE
If fuel line from fuel filter housing to fuel injection pump is damaged, perform Steps (10) and (11). 10. 11. Loosen clamp (Figure 4, Item 23) and remove fuel line (Figure 4, Item 22) from fitting (Figure 4, Item 24). Loosen clamp (Figure 4, Item 25) and remove fuel line (Figure 4, Item 22) from fitting (Figure 4, Item 26).
26
22
23
24
25
22
END OF TASK
0172-4
0172
NOTE
If fuel line from fuel filter housing to fuel injection pump was removed, perform Steps (1) and (2). 1. Install fuel line (Figure 5, Item 22) on fitting (Figure 5, Item 26) with clamp (Figure 5, Item 25).
26
22
23
24
25
22
Figure 5. Fuel Line Installation.
2.
Install fuel line (Figure 5, Item 22) on fitting (Figure 5, Item 24) with clamp (Figure 5, Item 23).
NOTE
If fuel line from fuel pump to fuel filter housing was removed, perform Steps (3) and (4). 3. Install fuel line (Figure 6, Item 18) on fitting (Figure 6, Item 20) with clamp (Figure 6, Item 21).
20 18 19 17
21
18
Figure 6. Fuel Line Installation. 4. Install fuel line (Figure 6, Item 18) on fuel pump (Figure 6, Item 17) with clamp (Figure 6, Item 19).
0172-5
0172
NOTE
If 1/4 inch fuel return line was removed, perform Steps (5) and (6). 5. Install 1/4 inch fuel return line (Figure 7, Item 10) on fitting (Figure 7, Item 14) with clamp (Figure 7, Item 15).
14 15
16 1 17 10 9 10
11
12 2
13
Figure 7. Fuel Line Installation. 6. Install 1/4 inch fuel return line (Figure 7, Item 10) on fitting (Figure 7, Item 11) with clamp (Figure 7, Item 9).
NOTE
If 5/16 inch fuel return line was removed, perform Step (7). 7. Install 5/16 inch fuel return line (Figure 7, Item 2) on fitting (Figure 7, Item 12) with clamp (Figure 7, Item 13).
NOTE
If fuel supply line was removed, perform Step (8). 8. 9. Install fuel supply line (Figure 7, Item 1) on fuel pump (Figure 7, Item 17) with clamp (Figure 7, Item 16). Install fuel supply line (Figure 8, Item 1) and 5/16 inch fuel return line (Figure 8, Item 2) on flatrack (Figure 8, Item 8) with eight cushion clips (Figure 8, Item 5), screws (Figure 8, Item 7), and locknuts (Figure 8, Item 6).
0172-6
0172
2 1
5 5 6, 7 1 2
6, 7
2 3
4 3
Figure 8. Fuel Line Installation.
NOTE
If 5/16 inch fuel return line was removed, perform Step (10). 10. Install 5/16 inch fuel return line (Figure 8, Item 2) on fuel tank (Figure 8, Item 4) with clamp (Figure 8, Item 3).
NOTE
If fuel supply line was removed, perform Step (11). 11. Install fuel supply line (Figure 8, Item 1) on fuel tank (Figure 8, Item 4) with clamp (Figure 8, Item 3).
END OF TASK FOLLOW-ON MAINTENANCE Install engine compartment cover. (WP 0142) END OF TASK END OF WORK PACKAGE 0172-7/8 blank
TM 5-3825-270-23&P FIELD MAINTENANCE FUEL PUMP ASSEMBLY REPLACEMENT
0173
INITIAL SETUP: Tools and Special Tools Cap and Plug Set (WP 0225, Table 1, Item 2) Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Gasket (WP 0226, Table 1, Item 13) Qty: 1 References Parts Manual (WP 0220) Figure 4035 Equipment Condition Rear access door removed. (TM 5-3825-270-10)
REMOVAL
WARNING
NOTE
Cap and plug fuel hoses as required. 1. Remove clamp (Figure 1, Item 1) and fuel hose (Figure 1, Item 2) from fuel pump assembly (Figure 1, Item 7).
0173-1

1 7 2 3
0173
Figure 1. Fuel Pump Assembly Removal. 2. 3. 4. Remove clamp (Figure 1, Item 3) and fuel hose (Figure 1, Item 4) from fuel pump assembly (Figure 1, Item 7). Remove two nuts (Figure 1, Item 5) and fuel pump assembly (Figure 1, Item 7) from injection pump (Figure 1, Item 6). Remove gasket (Figure 2, Item 8) from injection pump (Figure 2, Item 6). Discard gasket.
Figure 2. Fuel Pump Assembly Removal. END OF TASK INSTALLATION 1. Install gasket (Figure 3, Item 8) on injection pump (Figure 3, Item 6).
0173-2
0173
Figure 3. Fuel Pump Assembly Installation. 2. Install fuel pump assembly (Figure 4, Item 7) on injection pump (Figure 4, Item 6) with two nuts (Figure 4, Item 5).
1 7 2 3
Figure 4. Fuel Pump Assembly Installation.
NOTE
Remove caps and plugs from fuel hoses as required. 3. 4. Install fuel hose (Figure 4, Item 4) on fuel pump assembly (Figure 4, Item 7) with clamp (Figure 4, Item 3). Install fuel hose (Figure 4, Item 1) on fuel pump assembly (Figure 4, Item 7) with clamp (Figure 4, Item 2).
END OF TASK
0173-3
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE Install rear access door. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0173
0173-4
TM 5-3825-270-23&P FIELD MAINTENANCE FUEL TANK DRAIN/FILL
0174
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Drain, Pan, 5 Gal Cap (WP 0225, Table 1, Item 2) References Parts Manual (WP 0220) Figure 4005 Equipment Condition Batteries disconnected. (WP 0085)
DRAIN
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 1. Ensure fuel cap (Figure 1, Item 1) is closed on fuel tank (Figure 1, Item 2).
1 2
Figure 1. Drain Fuel Tank. 2. Position drain pan under fuel tank (Figure 2, Item 2) and drain cock (Figure 2, Item 3).
0174-1
TM 5-3825-270-23&P DRAIN - Continued

2
0174
Figure 2. Drain Fuel Tank. 3. 4. 5. 6. Open drain cock (Figure 2, Item 3) by turning counterclockwise. Close drain cock (Figure 2, Item 3) by turning clockwise when fuel tank (Figure 2, Item 2) is empty or drain pan is full. Dispose of fuel IAW local SOP. Repeat steps (1) through (5) as necessary.
END OF TASK FILL 1. Remove fuel cap (Figure 3, Item 1) from fuel tank (Figure 3, Item 2).
1 2
Figure 3. Fill Fuel Tank. 2. Use fuel container with funnel to fill fuel tank (Figure 3, Item 2).
0174-2
TM 5-3825-270-23&P FILL - Continued 3. 4. Fill with fuel until fuel tank (Figure 3, Item 2) is full. Install fuel cap (Figure 3, Item 1) on fuel tank (Figure 3, Item 2).
0174
0174-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE FUEL TANK REPAIR
0175
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Tags, Identification, White (WP 0224, Table 1, Item 54) Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4005 Equipment Condition Fuel tank drained. (WP 0174)
REMOVAL
NOTE
Clean up and dispose of spilled fuel IAW local procedures. 1. Position drain pan under fuel lines (Figure 1, Item 2) prior to removal.
1 2 1 2 3
Figure 1. Fuel Tank Removal.
WARNING
0175-1
0175
NOTE
Tag and mark fuel lines prior to removal to ensure proper installation. 2. 3. Loosen two clamps (Figure 1, Item 1) and remove fuel lines (Figure 1, Item 2) from fuel tank (Figure 1, Item 3). Remove four nuts (Figure 2, Item 5), four washers (Figure 2, Item 6), and four screws (Figure 2, Item 7) from fuel tank (Figure 2, Item 3) and flatrack (Figure 2, Item 4).
5, 6, 7
Figure 2. Fuel Tank Removal. 4. With the aid of an assistant, remove fuel tank (Figure 2, Item 3) from flatrack (Figure 2, Item 4).
END OF TASK DISASSEMBLY 1. Remove liquid level gauge (Figure 3, Item 8) from fuel tank (Figure 3, Item 3) by unscrewing counterclockwise.
0175-2
0175
Figure 3. Fuel Tank Disassembly. 2. Remove drain cock (Figure 4, Item 9) from fuel tank (Figure 4, Item 3).
Figure 4. Fuel Tank Disassembly. 3. Remove fitting (Figure 5, Item 11) from fitting (Figure 5, Item 10).
0175-3
0175
11 10
12 13
15 14
Figure 5. Fuel Tank Disassembly. 4. 5. 6. Remove fitting (Figure 5, Item 12) from fitting (Figure 5, Item 13). Remove fitting (Figure 5, Item 10) from fuel tank fitting (Figure 5, Item 15). Remove fitting (Figure 5, Item 13) from fuel tank fitting (Figure 5, Item 14).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Apply pipe thread sealant to threads of fuel tank fitting (Figure 6, Item 14).
0175-4
0175
11 10
12 13
15 14
Figure 6. Fuel Tank Assembly. 2. 3. 4. 5. 6. 7. 8. 9. Install fitting (Figure 6, Item 13) on fuel tank fitting (Figure 6, Item 14). Apply pipe thread sealant to threads of fuel tank fitting (Figure 6, Item 15). Install fitting (Figure 6, Item 10) on fuel tank fitting (Figure 6, Item 15). Apply pipe thread sealant to threads of fitting (Figure 6, Item 12). Install fitting (Figure 6, Item 12) in fitting (Figure 6, Item 13). Apply pipe thread sealant to threads of fitting (Figure 6, Item 11). Install fitting (Figure 6, Item 11) in fitting (Figure 6, Item 10). Apply pipe thread sealant to threads of drain cock (Figure 7, Item 9).
0175-5
0175
Figure 7. Fuel Tank Assembly. 10. 11. Install drain cock (Figure 7, Item 9) on fuel tank (Figure 7, Item 3). Apply pipe thread sealant to threads of fuel tank (Figure 8, Item 3).
Figure 8. Fuel Tank Assembly. 12. Install liquid level gauge (Figure 8, Item 8) on fuel tank (Figure 8, Item 3).
END OF TASK
0175-6
0175
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 1. With the aid of an assistant, position fuel tank (Figure 9, Item 3) on flatrack (Figure 9, Item 4).
5, 6, 7
Figure 9. Fuel Tank Installation. 2. Install fuel tank (Figure 9, Item 3) on flatrack (Figure 9, Item 4) with four screws (Figure 9, Item 7), four washers (Figure 9, Item 6), and four nuts (Figure 7, Item 5).
NOTE
Install fuel lines as noted prior to removal. 3. Install two fuel lines (Figure 10, Item 2) on fuel tank (Figure 10, Item 3) with two clamps (Figure 10, Item 1).
0175-7

1 2 1 2 3
0175
Figure 10. Fuel Tank Installation. END OF TASK FOLLOW-ON MAINTENANCE Fill fuel tank. (WP 0174) END OF TASK END OF WORK PACKAGE
0175-8
TM 5-3825-270-23&P FIELD MAINTENANCE FUEL/WATER SEPARATOR AND FILTER HEAD REPLACEMENT
0176
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Drain, Pan, 5 Gal Cap (WP 0225, Table 1, Item 2) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Packing, Preformed (WP 0226, Table 1, Item 8) Qty: 1 References Parts Manual (WP 0220) Figure 4032 Equipment Condition Batteries disconnected. (WP 0085) Fuel/water separator filter removed. (WP 0177)
REMOVAL
WARNING
NOTE
Tag and mark all hoses prior to removal to ensure proper installation. 1. Loosen clamp (Figure 1, Item 7) and remove fuel hose (Figure 1, Item 6) from filter head (Figure 1, Item 5).
0176-1

1, 2 3 4
0176
Figure 1. Fuel/Water Separator and Filter Head Removal. 2. 3. 4. Loosen clamp (Figure 1, Item 9) and remove fuel hose (Figure 1, Item 8) from filter head (Figure 1, Item 5). Remove two screws (Figure 1, Item 3) and filter head (Figure 1, Item 5) from intake manifold (Figure 1, Item 4). Remove screw (Figure 1, Item 1) and preformed packing (Figure 1, Item 2) from filter head (Figure 1, Item 5). Discard preformed packing.
WARNING
Fuel is very flammable and can explode easily. Keep fuel away from open flame and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited when engine is hot. When working with fuel, post signs that read NO SMOKING WITHIN 50 FEET OF VEHICLE. Failure to comply may result in injury or death to personnel. 1. Install preformed packing (Figure 2, Item 2) and screw (Figure 2, Item 1) on filter head (Figure 2, Item 5).
0176-2

1, 2 3 4
0176
Figure 2. Fuel/water Separator and Filter Head Installation. 2. Install filter head (Figure 2, Item 5) on intake manifold (Figure 2, Item 4) with two screws (Figure 2, Item 3).
NOTE
Install hoses as noted prior to removal. 3. 4. Install hose (Figure 2, Item 8) on filter head (Figure 2, Item 5) with clamp (Figure 2, Item 9). Install hose (Figure 2, Item 6) on filter head (Figure 2, Item 5) with clamp (Figure 2, Item 7).
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install fuel/water separator filter. (WP 0177) Connect batteries. (WP 0085)
0176-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE FUEL/WATER SEPARATOR FILTER REPLACEMENT
0177
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Universal Chain (WP 0225, Table 1, Item 2) Drain, Pan, 5 Gal Cap (WP 0225, Table 1, Item 2) Materials/Parts Fuel (WP 0224, Table 1, Item 28, 29, 30, 31, 32, 33) Materials/Parts (cont.) Gasket (WP 0226, Table 1, Item 31) Qty: 1 Packing, Preformed (WP 0226, Table 1, Item 8) Qty: 1 References Parts Manual (WP 0220) Figure 4032 Equipment Condition Rear access cover removed. (TM 5-3825-270-10) (WP 0221)
REMOVAL
WARNING
NOTE
Position drain pan under fuel/water separator during removal to catch any spilled fuel. Clean up and dispose of spilled fuel and any contaminated rags IAW local procedures. 1. Open drain cock (Figure 1, Item 5) and drain fuel from fuel filter cartridge (Figure 1, Item 2).
0177-1
0177
2, 3
5, 6
4
Figure 1. Fuel/Water Separator Removal.
2. 3. 4.
Using chain wrench, remove fuel filter cartridge (Figure 1, Item 2) and gasket (Figure 1, Item 3) from filter head (Figure 1, Item 1). Discard gasket. Remove water separator (Figure 1, Item 4) from fuel filter cartridge (Figure 1, Item 2). Remove drain cock (Figure 1, Item 5) and preformed packing (Figure 1, Item 6) from water separator (Figure 1, Item 4). Discard preformed packing.
WARNING
0177-2
0177
Install drain cock (Figure 2, Item 5) on water separator (Figure 2, Item 4) with preformed packing (Figure 2, Item 6).
8 2, 3
5, 6
4
Figure 2. Fuel/Water Separator Installation.
2. 3.
Install water separator (Figure 2, Item 4) on fuel filter cartridge (Figure 2, Item 2). Fill fuel filter cartridge (Figure 2, Item 2) with clean fuel.
WARNING
Prolonged contact with fuel may cause skin rash. Immediately wash skin and clothing thoroughly and remove saturated clothing that comes in contact with fuel. Keep area wellventilated to keep fumes at a minimum. Failure to comply may result in injury or death to personnel. 4. 5. 6. Lightly lubricate gasket (Figure 2, Item 3) with clean fuel. Install fuel filter cartridge (Figure 2, Item 2) on filter head (Figure 2, Item 1) until it contacts, then tighten another three-quarter turn by hand. Loosen air vent screw (Figure 2, Item 8) and allow air to escape.
0177-3
TM 5-3825-270-23&P INSTALLATION - Continued 7. 8. 9. 10. Pump primer plunger (Figure 2, Item 7) until a solid stream of fuel is present. Tighten air vent screw (Figure 2, Item 8). Pump primer plunger (Figure 2, Item 7) until firm. Start engine and allow to run. (TM 5-3825-270-10)
0177
NOTE
If engine stalls, perform Steps (11) through (15). 11. 12. 13. 14. 15. Loosen air vent screw (Figure 2, Item 8). Crank engine and observe air escaping from air vent screw (Figure 2, Item 8). Tighten air vent screw (Figure 2, Item 8). Pump primer plunger (Figure 2, Item 7) until firm. Start engine and allow to run. (TM 5-3825-270-10)
NOTE
If engine continues to stall, repeat Steps (11) through (15). 16. Shut off engine (TM 5-3825-270-10) and check for fuel leaks.
END OF TASK FOLLOW-ON MAINTENANCE Install rear access cover. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0177-4
TM 5-3825-270-23&P FIELD MAINTENANCE WATER PUMP INLET GAUGE AND HOSE REPLACEMENT
0178
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) References Parts Manual (WP 0220) Figure 4018 Equipment Condition Engine OFF. (TM 5-3825-270-10)
1 2
Figure 1. Water Pump Inlet Gauge and Hose Removal. 2. Loosen clamp (Figure 2, Item 5) and remove hose (Figure 2, Item 6) from fitting (Figure 2, Item 4).
0178-1

3 4 5
0178
Figure 2. Water Pump Inlet Gauge and Hose Removal. 3. Remove two nuts (Figure 2, Item 8), brackets (Figure 2, Item 7), and gauge (Figure 2, Item 9) from control panel (Figure 2, Item 3).
NOTE
Perform Step (4) if fitting is damaged. 4. Remove fitting (Figure 3, Item 4) from gauge (Figure 3, Item 9).
4
Figure 3. Water Pump Inlet Gauge and Hose Removal.
NOTE
Perform Step (5) if hose is damaged. Note position of cushion clips prior to removal to ensure proper installation.
0178-2
TM 5-3825-270-23&P REMOVAL - Continued Note routing of hose prior to removal to ensure proper installation. 5. Loosen clamp (Figure 4, Item 10) and remove hose (Figure 4, Item 6) from fitting (Figure 4, Item 11).
0178
10
11
Figure 4. Water Pump Inlet Gauge and Hose Removal. END OF TASK INSTALLATION
NOTE
Perform Step (1) if hose was removed. Route and install hose as noted prior to removal. Install cushion clips as noted prior to removal. 1. Install hose (Figure 5, Item 6) on fitting (Figure 5, Item 11) with clamp (Figure 5, Item 10).
10
11
Figure 5. Water Pump Inlet Gauge and Hose Installation.
0178-3
0178
WARNING
NOTE
Perform Step (2) if fitting was removed. 2. Apply sealing compound to threads of fitting (Figure 6, Item 4) and install on gauge (Figure 6, Item 9).
4
Figure 6. Water Pump Inlet Gauge and Hose Installation. 3. Install gauge (Figure 7, Item 9) on control panel (Figure 7, Item 3) with two brackets (Figure 7, Item 7) and nuts (Figure 7, Item 8).
0178-4

3 4 5
0178
Figure 7. Water Pump Inlet Gauge and Hose Installation. 4. 5. Install hose (Figure 7, Item 6) on fitting (Figure 7, Item 4) with clamp (Figure 7, Item 5). Close control panel cover (Figure 8, Item 1) and secure with rubber t-handle (Figure 8, Item 2).
1 2
Figure 8. Water Pump Inlet Gauge and Hose Installation. END OF TASK END OF WORK PACKAGE
0178-5/6 blank
TM 5-3825-270-23&P FIELD MAINTENANCE WATER PUMP OUTLET GAUGE AND HOSE REPLACEMENT
0179
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) References Parts Manual (WP 0220) Figure 4018 Equipment Condition Engine OFF. (TM 5-3825-270-10)
1 2
Figure 1. Water Pump Outlet Gauge and Hose Removal. 2. Loosen clamp (Figure 2, Item 8) and remove hose (Figure 2, Item 9) from fitting (Figure 2, Item 7).
0179-1
0179
7 8 9
Figure 2. Water Pump Outlet Gauge and Hose Removal. 3. Remove two nuts (Figure 2, Item 4), brackets (Figure 2, Item 5), and gauge (Figure 2, Item 6) from control panel (Figure 2, Item 3).
NOTE
Perform Step (4) if fitting is damaged. 4. Remove fitting (Figure 3, Item 7) from gauge (Figure 3, Item 6).
6
Figure 3. Water Pump Outlet Gauge and Hose Removal.
NOTE
Perform Step (5) if hose is damaged. Note position of cushion clips prior to removal to ensure proper installation.
0179-2
TM 5-3825-270-23&P REMOVAL - Continued Note routing of hose prior to removal to ensure proper installation. 5. Loosen clamp (Figure 4, Item 10) and remove hose (Figure 4, Item 9) from fitting (Figure 4, Item 11).
0179
11
10
Figure 4. Water Pump Outlet Gauge and Hose Removal. END OF TASK INSTALLATION
NOTE
Perform Step (1) if hose was removed. Route and install hose as noted prior to removal. Install cushion clips as noted prior to removal. 1. Install hose (Figure 5, Item 9) on fitting (Figure 5, Item 11) with clamp (Figure 5, Item 10).
0179-3
0179
11
10
Figure 5. Water Pump Outlet Gauge and Hose Installation.
WARNING
NOTE
Perform Step (2) if fitting was removed. 2. Apply sealing compound to threads of fitting (Figure 6, Item 7) and install on gauge (Figure 6, Item 6).
0179-4

6
0179
Figure 6. Water Pump Outlet Gauge and Hose Installation. 3. Install gauge (Figure 7, Item 6) on control panel (Figure 7, Item 3) with two brackets (Figure 7, Item 5) and nuts (Figure 7, Item 4).
7 8 9
Figure 7. Water Pump Outlet Gauge and Hose Installation. 4. 5. Install hose (Figure 7, Item 9) on fitting (Figure 7, Item 7) using clamp (Figure 7, Item 8). Close control panel cover (Figure 8, Item 1) and secure with rubber t-handle (Figure 8, Item 2).
0179-5

1 2
0179
Figure 8. Water Pump Outlet Gauge and Hose Installation. END OF TASK END OF WORK PACKAGE
0179-6
TM 5-3825-270-23&P FIELD MAINTENANCE VALVE HANDLE REPLACEMENT
0180
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) References Parts Manual (WP 0220) Figure 4007 Parts Manual (WP 0220) Figure 4014
REMOVAL
NOTE
If ratcheting valve handle is damaged, perform Steps (1) and (2). All ratcheting valve handles are removed the same. Valve V6 is shown. Note position of handle prior to removal to ensure proper installation. 1. Remove nut (Figure 1, Item 1) and screw (Figure 1, Item 5) from ratcheting valve handle (Figure 1, Item 2).
1 2 3
Figure 1. Valve Handle Removal. 2. While squeezing release handle (Figure 1, Item 3), remove ratcheting valve handle (Figure 1, Item 2) from ratcheting valve (Figure 1, Item 4).
NOTE
If butterfly valve handle is damaged, perform Steps (3) and (4). All butterfly valve handles are removed the same. Valve V4 shown. Note position of handle prior to removal to ensure proper installation. 3. Remove nut (Figure 2, Item 8) and screw (Figure 2, Item 9) from butterfly valve handle (Figure 2, Item 6).
0180-1

6 7 8
0180
Figure 2. Valve Handle Removal. 4. Remove butterfly valve handle (Figure 2, Item 6) from butterfly valve (Figure 2, Item 7).
NOTE
If ball valve handle is damaged, perform Step (5). Note position of handle prior to removal to ensure proper installation. 5. Remove flange nut (Figure 3, Item 12) and ball valve handle (Figure 3, Item 10) from ball valve (Figure 3, Item 11). Discard lockwasher.
10
12
11
Figure 3. Valve Handle Removal.
NOTE
If ball valve handle was removed, perform Step (1). Install ball valve handle as noted prior to removal.
0180-2
0180
Install ball valve handle (Figure 4, Item 10) on ball valve (Figure 4, Item 11) with flange nut (Figure 4, Item 12).
10
12
11
Figure 4. Valve Handle Installation.
NOTE
If butterfly valve handle was removed, perform Step (2). Install butterfly valve handle as noted prior to removal. 2. Install butterfly valve handle (Figure 5, Item 6) on butterfly valve (Figure 5, Item 7) with screw (Figure 5, Item 9) and nut (Figure 5, Item 8).
6 7 8
Figure 5. Valve Handle Installation.
NOTE
If ratcheting valve handle was removed, perform Steps (3) and (4). Install ratcheting valve handle as noted prior to removal. 3. Install ratcheting valve handle (Figure 6, Item 2) on ratcheting valve (Figure 6, Item 4) while squeezing release handle (Figure 6, Item 3) and secure with screw (Figure 6, Item 5) and nut (Figure 6, Item 1).
0180-3

1 2 3
0180
Figure 6. Valve Handle Installation. END OF TASK END OF WORK PACKAGE
0180-4
TM 5-3825-270-23&P FIELD MAINTENANCE STRAINER ELEMENT REPLACEMENT
0181
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 64) Qty: 8 Gasket (WP 0226, Table 1, Item 35) Qty: 1 References Parts Manual (WP 0220) Figure 4007 Equipment Condition Water tank completely drained. (TM 5-3825 270-10)
REMOVAL Remove eight locknuts (Figure 1, Item 1), screws (Figure 1, Item 2), cover plate (Figure 1, Item 3), gasket (Figure 1, Item 4), and strainer element (Figure 1, Item 5) from strainer housing (Figure 1, Item 6). Discard locknuts and gasket.
1, 2 5
3, 4, 5
Figure 1. Strainer Element Removal. END OF TASK INSTALLATION Install strainer element (Figure 2, Item 5), gasket (Figure 2, Item 4), and cover (Figure 2, Item 3) on strainer housing (Figure 2, Item 6) with eight screws (Figure 2, Item 2) and locknuts (Figure 2, Item 1).
0181-1
0181
1, 2 5
3, 4, 5
Figure 2. Strainer Element Installation. END OF TASK END OF WORK PACKAGE
0181-2
TM 5-3825-270-23&P FIELD MAINTENANCE STRAINER HOUSING REPLACEMENT
0182
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Locknut (WP 0226, Table 1, Item 64) Qty: 20 Gasket (WP 0226, Table 1, Item 34) Qty: 2 Gasket (WP 0226, Table 1, Item 34) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4007 Equipment Condition Water tank completely drained. (TM 5-3825 270-10)
REMOVAL 1. Remove eight locknuts (Figure 1, Item 5), screws (Figure 1, Item 6), two gaskets (Figure 1, Item 2), and valve V1 (Figure 1, Item 3) from water tank assembly (Figure 1, Item 1) and strainer housing (Figure 1, Item 4). Discard locknuts and gaskets.
1 2, 3 4
5, 6
Figure 1. Strainer Housing Removal. 2. Remove eight locknuts (Figure 2, Item 8), cap (Figure 2, Item 11), hose adapter (Figure 2, Item 10), gasket (Figure 2, Item 9), and screws (Figure 2, Item 7) from strainer housing (Figure 2, Item 4). Discard locknuts and gasket.
0182-1

4 7, 8 9, 10, 11
0182
Figure 2. Strainer Housing Removal. 3. Remove two locknuts (Figure 3, Item 12), two screws (Figure 3, Item 14), and four flat washers (Figure 3, Item 13) from mounting bracket (Figure 3, Item 15) and strainer housing (Figure 3, Item 4). Discard locknuts.
12, 13, 14
15
16, 17, 18
Figure 3. Strainer Housing Removal.
NOTE
Perform Step (4) if mounting bracket is damaged. 4. Remove two locknuts (Figure 3, Item 16), two screws (Figure 3, Item 18), and four flat washers (Figure 3, Item 17) from mounting bracket (Figure 3, Item 15) and water tank assembly (Figure 3, Item 1). Discard locknuts.
0182-2
0182
Loosen two hose clamps (Figure 4, Item 20) and remove strainer housing (Figure 4, Item 4) from tube (Figure 4, Item 19).
24
25
Figure 4. Strainer Housing Removal. END OF TASK INSTALLATION 1. Install strainer housing (Figure 5, Item 4) in tube (Figure 5, Item 19) with two hose clamps (Figure 5, Item 20). Tighten clamps to 70 in-lbs (7.9 Nm).
24
25
Figure 5. Strainer Housing Installation.
NOTE
Perform Step (2) if mounting bracket was removed. 2. Install mounting bracket (Figure 6, Item 15) on water tank assembly (Figure 6, Item 1) with two screws (Figure 6, Item 18), four flat washers (Figure 6, Item 17), and two locknuts (Figure 6, Item 16). Do not tighten locknuts.
0182-3
0182
15
18, 17, 16
Figure 6. Strainer Housing Installation. 3. Install gasket (Figure 7, Item 9), hose adapter (Figure 7, Item 10), and cap (Figure 7, Item 11) on strainer housing (Figure 7, Item 4) with eight screws (Figure 7, Item 7) and locknuts (Figure 7, Item 8).
7, 8
9, 10, 11 1 8
3 6
TIGHTENING SEQUENCE
Figure 7. Strainer Housing Installation. 4. 5. Tighten locknuts (Figure 7, Item 8) as shown in sequence. Install valve V1 (Figure 8, Item 3) on water tank assembly (Figure 8, Item 1) and strainer housing (Figure 8, Item 4) with two gaskets (Figure 8, Item 2), eight screws (Figure 8, Item 6), and locknuts (Figure 8, Item 5). Do not tighten screws and locknuts.
0182-4

1 2, 3 4
0182
5, 6
Figure 8. Strainer Housing Installation. 6. Install strainer housing (Figure 6, Item 4) on mounting bracket (Figure 6, Item 15) with two screws (Figure 6, Item 14), four flat washers (Figure 6, Item 13), and two locknuts (Figure 6, Item 12).
12, 13, 14
15
16
Figure 9. Strainer Housing Installation. 7. 8. Tighten two locknuts (Figure 6, Item 16) on mounting bracket (Figure 6, Item 15). Tighten eight screws (Figure 9, Item 6) and locknuts (Figure 9, Item 5) on valve V1 (Figure 9, Item 3) in sequence shown.
0182-5

3 1 8
0182
3 6
2 5, 6
TIGHTENING SEQUENCE
Figure 10. Strainer Housing Installation. END OF TASK END OF WORK PACKAGE
0182-6
TM 5-3825-270-23&P FIELD MAINTENANCE INLET VALVE AND HOSE REPLACEMENT
0183
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Locknut (WP 0226, Table 1, Item 76) Qty: 8 Gasket (WP 0226, Table 1, Item 34) Qty: 2 References Parts Manual (WP 0220) Figure 4014 Equipment Condition Rear platform screen removed. (WP 0165)
REMOVAL 1. Loosen two clamps (Figure 1, Item 2) from inlet hose (Figure 1, Item 1) and discharge tube (Figure 1 Item 3).
1 2 3
Figure 1. Inlet Valve and Hose Removal. 2. Loosen two clamps (Figure 2, Item 6) on inlet hose (Figure 2, Item 1) and inlet elbow (Figure 2, Item 5).
0183-1

4
0183
6 11 10 9 7, 8 1
Figure 2. Inlet Valve and Hose Removal. 3. Remove eight locknuts (Figure 2, Item 7), screws (Figure 2, Item 8), inlet elbow (Figure 2, Item 5), gasket (Figure 2, Item 9), inlet valve (Figure 2, Item 10), and gasket (Figure 2, Item 11) from tank (Figure 2, Item 4). Discard locknuts and gaskets. Remove inlet elbow (Figure 2, Item 5) from inlet hose (Figure 2, Item 1). Remove inlet hose (Figure 3, Item 1) from discharge tube (Figure 3, Item 3).
4. 5.
Figure 3. Inlet Valve and Hose Removal. END OF TASK INSTALLATION 1. Install inlet hose (Figure 4, Item 1) onto discharge tube (Figure 4, Item 3) with two clamps (Figure 4, Item 2). Do not tighten clamps.
0183-2

1 2 3
0183
Figure 4. Inlet Valve and Hose Installation. 2. Install inlet elbow (Figure 5, Item 5) into inlet hose (Figure 5, Item 1) with two clamps (Figure 5, Item 6). Do not tighten clamps.
4
6 11 10 9 7, 8 1
Figure 5. Inlet Valve and Hose Installation. 3. Install inlet elbow (Figure 5 Item 5), gasket (Figure 5, Item 11), inlet valve (Figure 5, Item 10), and gasket (Figure 5, Item 9) on tank (Figure 5, Item 4) with eight screws (Figure 5, Item 8) and locknuts (Figure 5, Item 7). Install two clamps (Figure 5, Item 6) onto inlet hose (Figure 5, Item 1) and inlet valve (Figure 5, Item 5). Tighten two clamps to 70 lb-in (8 Nm). Install two clamps (Figure 6, Item 2) onto inlet hose (Figure 6, Item 1) and discharge tube (Figure 6, Item 3). Tighten two clamps to 70 lb-in (8 Nm).
4. 5.
0183-3

1 2 3
0183
Figure 6. Inlet Valve and Hose Installation. END OF TASK FOLLOW-ON MAINTENANCE Install rear platform screen. (WP 0165) END OF TASK END OF WORK PACKAGE
0183-4
TM 5-3825-270-23&P FIELD MAINTENANCE DIAL POINTER REPLACEMENT
0184
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 39) Qty: 1 References Parts Manual (WP 0220) Figure 4002 Equipment Condition Dial pointer switch removed. (WP 0186)
REMOVAL Remove locknut (Figure 1, Item 4), screw (Figure 1, Item 3), two washers (Figure 1, Item 2), and dial pointer (Figure 1, Item 1) from shaft (Figure 1, Item 5). Discard locknut.
3, 4
Figure 1. Dial Pointer Removal. END OF TASK INSTALLATION Install dial pointer (Figure 2, Item 1) on shaft (Figure 2, Item 5) with screw (Figure 2, Item 3), two washers (Figure 2, Item 2), and locknut (Figure 2, Item 4).
0184-1
0184
3, 4
Figure 2. Dial Pointer Installation. END OF TASK FOLLOW-ON MAINTENANCE Install dial pointer switch. (WP 0186) END OF TASK END OF WORK PACKAGE
0184-2
TM 5-3825-270-23&P FIELD MAINTENANCE FOLDING HAND RAIL ASSEMBLY REPLACEMENT
0185
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 54) Qty: 12 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4049 Equipment Condition Folding hand rail in stowed position. (TM 5-3825-270-10)
REMOVAL
WARNING
Hand rail components are heavy. Use the aid of an assistant when moving and supporting assembly during removal and installation. Joints between hand rail components create a pinch point hazard. Take care not to catch fingers or hands in joints. Failure to comply may result in serious injury or death of personnel.
NOTE
Both sides of folding hand rail assembly removed in the same way. Left side shown. 1. Remove two locknuts (Figure 1, Item 4), six washers (Figure 1, Item 3), two screws (Figure 1, Item 1), and two bearing sleeves (Figure 1, Item 2) from folding handrail assembly (Figure 1, Item 5) and upper walkway assembly (Figure 1, Item 6). Discard locknuts.
0185-1
0185
1, 2
Figure 1. Folding Hand Rail Assembly Removal. 2. Remove two locknuts (Figure 2, Item 7), six washers (Figure 2, Item 8), two screws (Figure 2, Item 10), and two bearing sleeves (Figure 2, Item 9) from folding handrail assembly (Figure 2, Item 5) and rear platform (Figure 2, Item 11). Discard locknuts.
9 8 10
11
Figure 2. Folding Hand Rail Assembly Removal. 3. With the aid of an assistant, remove folding handrail assembly (Figure 2, Item 5) from upper walkway (Figure 2, Item 6) and rear platform (Figure 2, Item 11).
END OF TASK DISASSEMBLY
NOTE
Both sides of folding handrail assembly are disassembled the same way. Left side shown.
0185-2
TM 5-3825-270-23&P DISASSEMBLY - Continued 1.
0185
Remove two locknuts (Figure 3, Item 14), six washers (Figure 3, Item 13), and two screws (Figure 3, Item 12) from walkway pivoting rail (Figure 3, Item 15) and midrail plate (Figure 3, Item 16). Discard locknuts.
13 13 12 14
15 16
Figure 3. Folding Hand Rail Disassembly. 2. Remove two locknuts (Figure 4, Item 17), six washers (Figure 4, Item 18), two bearing sleeves (Figure 4, Item 19), and two screws (Figure 4, Item 20) from walkway pivoting rail (Figure 4, Item 15) and upper rail (Figure 4, Item 21). Discard locknuts.
15 17
18
19
18 20
21
Figure 4. Folding Hand Rail Disassembly. 3. 4. Remove upper rail (Figure 4, Item 21) from walkway pivoting rail (Figure 4, Item 15). Remove two snap pins (Figure 5, Item 22) from rear upright rails (Figure 5, Item 23).
0185-3
0185
22
23
Figure 5. Folding Hand Rail Disassembly. 5. Remove two locknuts (Figure 6, Item 28), two screws (Figure 6, Item 24), two snap pin lanyards (Figure 6, Item 25), six washers (Figure 6, Item 27), two bearing sleeves (Figure 6, Item 26), and two midrail plates (Figure 6, Item 16) from two rear upright rails (Figure 6, Item 23). Discard locknuts.
24, 25, 26
27
28
16 23
Figure 6. Folding Hand Rail Disassembly. 6. Remove two locknuts (Figure 7, Item 29), two screws (Figure 7, Item 31), two bearing sleeves (Figure 7, Item 32), eight washers (Figure 7, Item 30), and two rear upright rails (Figure 7, Item 23) from upper rail (Figure 7, Item 21). Discard locknuts.
0185-4
0185
21
31, 32 23 30 30 29
Figure 7. Folding Hand Rail Disassembly. END OF TASK ASSEMBLY
NOTE
Both sides of folding handrail assembly are assembled the same way. Left side shown. 1. Install two rear upright rails (Figure 8, Item 23) on upper rail (Figure 8, Item 21) with two screws (Figure 8, Item 31), two bearing sleeves (Figure 8, Item 32), eight washers (Figure 8, Item 30), and two locknuts (Figure 8, Item 29).
21
31, 32 23 30 30 29
Figure 8. Folding Hand Rail Assembly.
0185-5
TM 5-3825-270-23&P ASSEMBLY - Continued 2.
0185
Install two midrail plates (Figure 9, Item 16) on two rear upright rails (Figure 9, Item 23) with two bearing sleeves (Figure 9, Item 26), six washers (Figure 9, Item 27), two snap pin lanyards (Figure 9, Item 25), two screws (Figure 9, Item 24), and two locknuts (Figure 9, Item 28).
24, 25, 26
27
28
16 23
Figure 9. Folding Hand Rail Assembly. 3. Install two snap pins (Figure 10, Item 22) in two rear upright rails (Figure 10, Item 23).
22
23
Figure 10. Folding Hand Rail Assembly. 4. Install upper rail (Figure 11, Item 21) on walkway pivoting rail (Figure 11, Item 15) with two bearing sleeves (Figure 11, Item 19), six washers (Figure 11, Item 18), two screws (Figure 11, Item 20), and two locknuts (Figure 11, Item 17).
0185-6
0185
15 17
18
19
18 20
21
Figure 11. Folding Hand Rail Assembly. 5. Install midrail plate (Figure 12, Item 16) on walkway pivoting rail (Figure 12, Item 15) with six washers (Figure 12, Item 13), two screws (Figure 12, Item 12), and two locknuts (Figure 12, Item 14).
13 13 12 14
15 16
Figure 12. Folding Hand Rail Assembly. END OF TASK
0185-7
0185
WARNING
Hand rail components are heavy. Use the aid of an assistant when moving and supporting assembly during removal and installation. Joints between hand rail components create a pinch point hazard. Take care not to catch fingers or hands in joints. Failure to comply may result in serious injury or death of personnel.
NOTE
Both sides of folding hand rail assembly are installed the same way. Left side shown. 1. With the aid of an assistant, position folding handrail assembly (Figure 13, Item 5) on upper walkway (Figure 13, Item 6) and main platform (Figure 13, Item 11).
9 8 10
11
Figure 13. Folding Hand Rail Installation. 2. Install folding handrail assembly (Figure 13, Item 5) on rear platform (Figure 13, Item 11) with two screws (Figure 13, Item 10), six washers (Figure 13, Item 8), two bearing sleeves (Figure 13, Item 9), and two locknuts (Figure 13, Item 7). Install folding handrail assembly (Figure 14, Item 5) to upper walkway assembly (Figure 14, Item 6) with two screws (Figure 14, Item 1), six washers (Figure 14, Item 3), two bearing sleeves (Figure 14, Item 2), and two locknuts (Figure 14, Item 4).
3.
0185-8
0185
1, 2
Figure 14. Folding Hand Rail Installation. END OF TASK END OF WORK PACKAGE
0185-9/10 blank
TM 5-3825-270-23&P FIELD MAINTENANCE DIAL POINTER SWITCH REPLACEMENT
0186
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Lockwasher (WP 0226, Table 1, Item 59) Qty: 2 References Parts Manual (WP 0220) Figure 4002
REMOVAL
NOTE
Note position of switch prior to removal to ensure proper installation. Remove two nuts (Figure 1, Item 3), lockwashers (Figure 1, Item 4), screws (Figure 1, Item 6), retaining brackets (Figure 1, Item 2), and switch (Figure 1, Item 1) from dial pointer (Figure 1, Item 5). Discard lockwashers.
Figure 1. Dial Pointer Switch Removal. END OF TASK INSTALLATION
NOTE
Install switch as noted prior to removal. Install switch (Figure 2, Item 1) on dial pointer (Figure 2, Item 5) with two retaining brackets (Figure 2, Item 2), screws (Figure 2, Item 6), lockwashers (Figure 2, Item 4), and nuts (Figure 2, Item 3).
0186-1
0186
Figure 2. Dial Pointer Switch Installation. END OF TASK END OF WORK PACKAGE
0186-2
TM 5-3825-270-23&P FIELD MAINTENANCE HIGH TANK LEVEL SWITCH REPLACEMENT
0187
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 56) Qty: 2 Lockwasher (WP 0226, Table 1, Item 59) Qty: 2 References Parts Manual (WP 0220) Figure 4002
REMOVAL 1. Disconnect switch harness connector (Figure 1, Item 1) from harness connector (Figure 1, Item 6).
1 2 3 4
Figure 1. High Tank Level Switch Removal. 2. 3. Remove two locknuts (Figure 1, Item 3), retainer clips (Figure 1, Item 4), and switch harness (Figure 1, Item 5) from two studs (Figure 1, Item 2). Discard locknuts. Remove two nuts (Figure 2, Item 10), lockwashers (Figure 2, Item 9), screws (Figure 2, Item 8), retaining brackets (Figure 2, Item 7), and high tank level switch (Figure 2, Item 6) from backing plate (Figure 2, Item 11). Discard lockwashers.
0187-1
0187
7 8, 9, 10 11
Figure 2. High Tank Level Switch Removal. END OF TASK INSTALLATION 1. Install high tank level switch (Figure 3, Item 6) on backing plate (Figure 3, Item 11) with retaining brackets (Figure 3, Item 7), screws (Figure 3, Item 8), lockwashers (Figure 3, Item 9), and nuts (Figure 3, Item 10).
7 8, 9, 10 11
Figure 3. High Tank Level Switch Installation. 2. Install switch harness (Figure 4, Item 5) on two studs (Figure 4, Item 2) with retaining clips (Figure 4, Item 4) and locknuts (Figure 4, Item 3).
0187-2

1 2 3 4
0187
Figure 4. High Tank Level Switch Installation. 3. Connect switch harness connector (Figure 4, Item 6) to harness connector (Figure 4, Item 1).
0187-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE DIAL AND MOUNTING PLATE REPLACEMENT
0188
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 56) Qty: 2 References Parts Manual (WP 0220) Figure 4002 Equipment Condition High tank level switch removed. (WP 0187) Low tank level switch removed. (WP 0189)
REMOVAL Remove two locknuts (Figure 1, Item 6), screws (Figure 1, Item 5), four washers (Figure 1, Item 4), mounting plate (Figure 1, Item 3), and dial (Figure 1, Item 2) from tank (Figure 1, Item 1). Discard locknuts.
5, 6
Figure 1. Dial and Mounting Plate Removal. END OF TASK INSTALLATION
Install dial (Figure 2, Item 2) and mounting plate (Figure 2, Item 3) on tank (Figure 2, Item 1) with two screws (Figure 2, Item 5), four washers (Figure 2, Item 4), and two locknuts (Figure 2, Item 6).
0188-1
0188
5, 6
Figure 2. Dial and Mounting Plate Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install low tank level switch. (WP 0189) Install high tank level sensor switch. (WP 0187)
0188-2
TM 5-3825-270-23&P FIELD MAINTENANCE LOW TANK LEVEL SWITCH REPLACEMENT
0189
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 56) Qty: 2 Lockwasher (WP 0226, Table 1, Item 59) Qty: 2 References Parts Manual (WP 0220) Figure 4002
REMOVAL
NOTE
Note position of low tank level switch prior to removal to ensure proper installation. Note position of connectors prior to removal to ensure proper installation. 1. Disconnect switch harness connector (Figure 1, Item 1) from harness connector (Figure 1, Item 2).
Figure 1. Low Tank Level Switch Removal. 2. 3. Remove two locknuts (Figure 1, Item 4), retainer clips (Figure 1, Item 5), and switch harness (Figure 1, Item 6) from two studs (Figure 1, Item 3). Discard locknuts. Remove two nuts (Figure 2, Item 11), lockwashers (Figure 2, Item 10), screws (Figure 2, Item 9), retaining brackets (Figure 2, Item 7), and low level switch (Figure 2, Item 8) from bracket (Figure 2, Item 12). Discard lockwashers.
0189-1
0189
9, 10, 11
12
Figure 2. Low Tank Level Switch Removal. END OF TASK INSTALLATION
NOTE
Install connectors as noted prior to removal. Install low tank level switch as noted prior to removal. 1. Install low tank level switch (Figure 3, Item 8) on bracket (Figure 3, Item 12) with retaining brackets (Figure 3, Item 7), screws (Figure 3, Item 9), lockwashers (Figure 3, Item 10), and nuts (Figure 3, Item 11).
9, 10, 11
12
Figure 3. Low Tank Level Switch Installation. 2. Install switch harness (Figure 4, Item 6) on two studs (Figure 4, Item 3) with retaining clips (Figure 4, Item 5) and locknuts (Figure 4, Item 4).
0189-2
0189
Figure 4. Low Tank Level Switch Installation. 3. Connect switch harness connector (Figure 4, Item 2) to harness connector (Figure 4, Item 1).
0189-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE MANHOLE COVER AND BRACKET REPLACEMENT
0190
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 57) Qty: 2 Pin Cotter (WP 0226, Table 1, Item 74) Qty: 1 Gasket (WP 0226, Table 1, Item 32) Qty: 1 References Parts Manual (WP 0220) Figure 4002 Equipment Condition Folding hand rail assembly in unstowed position. (TM 5-3825-270-10)
REMOVAL 1. Loosen and remove manhole cover hold down assembly (Figure 1, Item 4) from manhole cover bracket (Figure 1, Item 3).
1 2 3
Figure 1. Manhole Cover and Bracket Removal. 2. 3. Remove locknut (Figure 1, Item 2) and manhole cover bracket (Figure 1, Item 3) from manhole cover (Figure 1, Item 1). Discard locknut. Remove reinforcer plate (Figure 2, Item 5) from manhole cover (Figure 2, Item 1).
0190-1

1 5 6
0190
Figure 2. Manhole Cover and Bracket Removal. 4. Remove manhole cover (Figure 2, Item 1) from tank (Figure 2, Item 6).
NOTE
Perform Step (5) if manhole cover gasket is damaged. 5. Remove gasket (Figure 3, Item 7) from manhole cover (Figure 3, Item 1). Discard gasket.
Figure 3. Manhole Cover and Bracket Removal. 6. Remove cotter pin (Figure 4, Item 8) from shaft hinge (Figure 4, Item 9). Discard cotter pin.
0190-2
0190
10
Figure 4. Manhole Cover and Bracket Removal.
NOTE
Note position of hinge prior to removal. 7. Remove shaft hinge (Figure 4, Item 9) and manhole cover bracket (Figure 4, Item 3) from two brackets (Figure 4, Item 10).
NOTE
Perform Step (8) if manhole cover hold down assembly is damaged. 8. Remove locknut (Figure 5, Item 13), screw (Figure 5, Item 11), and manhole cover hold down assembly (Figure 5, Item 4) from two brackets (Figure 5, Item 12). Discard locknut.
11
12
13
4
Figure 5. Manhole Cover and Bracket Removal. END OF TASK
0190-3
TM 5-3825-270-23&P
0190
INSTALLATION
NOTE
Perform Step (1) if manhole cover hold down assembly was removed. 1. Install manhole cover hold down assembly (Figure 6, Item 4) on two brackets (Figure 6, Item 12) with screw (Figure 6, Item 11) and locknut (Figure 6, Item 13).
11
12
13
4
Figure 6. Manhole Cover and Bracket Installation. 2. Install manhole cover bracket (Figure 7, Item 3) on two brackets (Figure 7, Item 10) with shaft hinge (Figure 7, Item 9).
10
Figure 7. Manhole Cover and Bracket Installation. 3. Install cotter pin (Figure 7, Item 8) in shaft hinge (Figure 7, Item 9).
NOTE
Perform Step (4) if manhole cover gasket was removed. 4. Install gasket (Figure 8, Item 7) on manhole cover (Figure 8, Item 1).
0190-4
0190
Figure 8. Manhole Cover and Bracket Installation. 5. Position manhole cover (Figure 9, Item 1) on tank (Figure 9, Item 6).
1 5 6
Figure 9. Manhole Cover and Bracket Installation. 6. 7. Position reinforcer plate (Figure 9, Item 5) on manhole cover (Figure 9, Item 1). Install manhole cover bracket (Figure 10, Item 3) on manhole cover (Figure 10, Item 1) with locknut (Figure 10, Item 2).
0190-5

1 2 3
0190
Figure 10. Manhole Cover and Bracket Installation. 8. Install manhole cover hold down assembly (Figure 10, Item 4) on manhole cover (Figure 10, Item 1). Hand tighten hold down assembly.
0190-6
TM 5-3825-270-23&P FIELD MAINTENANCE TANK WALKWAY REPLACEMENT
0191
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 40) Qty: 5 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4049 Equipment Condition Folding hand rail assembly removed. (WP 0185)
REMOVAL 1. Remove four locknuts (Figure 1, Item 4), screws (Figure 1, Item 2), and washers (Figure 1, Item 3) from upper walkway (Figure 1, Item 1) and weldment (Figure 1, Item 5). Discard locknuts.
1
2, 3, 4
Figure 1. Tank Walkway Removal. 2. Remove nut (Figure 1, Item 7), screw (Figure 1, Item 8), and washer (Figure 1, Item 6) from upper walkway (Figure 1, Item 1) and weldment (Figure 1, Item 9).
0191-1
0191
WARNING
Hand rail components are heavy. Use the aid of an assistant when moving and supporting assembly during removal and installation. Failure to comply may result in serious injury or death of personnel. 3. With the aid of an assistant, remove upper walkway (Figure 1, Item 1) from weldments (Figure 1, Item 5) and (Figure 1, Item 9).
WARNING
Hand rail components are heavy. Use the aid of an assistant when moving and supporting assembly during removal and installation. Failure to comply may result in serious injury or death of personnel. 1. With the aid of an assistant, position upper walkway (Figure 2, Item 1) on weldments (Figure 2, Item 5) and (Figure 2, Item 9).
1
2, 3, 4
Figure 2. 2. Install four screws (Figure 2, Item 2), washers (Figure 2, Item 3), and locknuts (Figure 2, Item 4) onto upper walkway (Figure 2, Item 1) and weldment (Figure 2, Item 5).
0191-2
0191
Install screw (Figure 2, Item 8), washer (Figure 2, Item 6), and nut (Figure 2, Item 7) on upper walkway (Figure , Item 1) and weldment (Figure 2, Item 9).
END OF TASK FOLLOW-ON MAINTENANCE Install folding hand rail assembly. (WP 0185) END OF TASK END OF WORK PACKAGE
0191-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE VENT SCREEN REPLACEMENT
0192
REMOVAL Remove four screws (Figure 1, item 2), locknuts (Figure 1, item 3), and vent screen (Figure 1, item 4) from vent tube (Figure 1, item 1). Discard locknuts.
1 2, 3 4
Figure 1. Vent Screen Removal. END OF TASK INSTALLATION 1. Install vent cover (Figure 2, item 4) on vent tube (Figure 2, item 1) with four screws (Figure 2, item 2) and locknuts (Figure 2, item 3).
0192-1

1 2, 3 4
0192
Figure 2. Vent Screen Installation. END OF TASK END OF WORK PACKAGE
0192-2
TM 5-3825-270-23&P FIELD MAINTENANCE WATER TANK MOUNT BUSHINGS AND SPRING REPLACEMENT
0193
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Bit, Screwdriver 3/4 in (19mm) (WP 0225, Table 1, Item 1) Bag, Air Lifting (WP 0225, Table 1, Item 2) Block, Filler, Wood, 3 in. Thick (WP 0225, Table 1, Item 2) Lifting Device, Capacity 8,500 lbs (3,855 kg) Sling (WP 0225, Table 1, Item 9) Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive (WP 0225, Table 1, Item 15) Wrench, Torque, 90-600 lb-ft (122-813 Nm), 3/4 in. Drive (WP 0225, Table 1, Item 16) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Locknut (WP 0226, Table 1, Item 56) Qty: 2 Locknut (WP 0226, Table 1, Item 67) Qty: 24 Materials/Parts (cont.) Kit, Tank Install Rubber Mount (WP 0226, Table 1, Item 53) Qty: 1 Kit, Tank Install Springs (WP 0226, Table 1, Item 52) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4002 Equipment Condition Water tank drained. (TM 5-3825-270-10) Strainer housing removed. (WP 0182) Inlet valve and hose removed. (WP 0183) Stowage box removed. (WP 0154) Battery box removed. (WP 0083) Valve V1 removed. (WP 0158) Valve V8 removed. (WP 0159) Folding hand rail assembly removed. (WP 0185) Rear platform removed. (WP 0162)
REMOVAL 1. Remove two locknuts (Figure 1, Item 1) and wire harness (Figure 1, Item 4) from water tank (Figure 1, Item 3).
0193-1

1 2 3
0193
Figure 1.
NOTE
Tag and mark connectors prior to removal to ensure proper installation. 2. Disconnect two switch harness connectors (Figure 1, Item 2) from wire harness (Figure 1, Item 4).
WARNING
Water Distributor weighs in excess of 8,500 lbs (3,856 kg). Ensure that personnel are clear during lifting operations. Failure to comply may result in injury or death to personnel. 3. Using air lifting bag, lift and support flatrack (Figure 2, Item 5) on wood blocks.
0193-2

5
0193
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 2. Water Tank Mount Bushings and Spring Removal. 4. Remove four locknuts (Figure 3, Item 6), washers (Figure 3, Item 7), and springs (Figure 3, Item 8) from studs (Figure 3, Item 9). Discard locknuts and springs.
8, 9
10
Figure 3. Water Tank Mount Bushings and Spring Removal. 5. 6. 7. Remove stud (Figure 2, Item 9) from mounting plate (Figure 2, Item 10) and flatrack (Figure 2, Item 5). Repeat Steps (4) and (5) for five remaining studs. Using air lifting bag, lift flatrack (Figure 4, Item 5) and remove wood blocks.
0193-3

5
0193
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 4. Water Tank Mount Bushings and Spring Removal. 8. 9. Lower flatrack (Figure 4, Item 5) to ground. Remove four locknuts (Figure 5, Item 12), eight washers (Figure 5, Item 13), and four screws (Figure 5, Item 14) from mounting plate (Figure 5, Item 11) and flatrack (Figure 5, Item 5). Discard locknuts.
11 12, 13, 14
Figure 5. Water Tank Mount Bushings and Spring Removal.
WARNING
Empty tank weighs 2,425 lbs (1,100 kg). Do not attempt to lift or move tank without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 10. Position lifting straps around water tank (Figure 6, Item 3).
0193-4
0193
LIFTING STRAP
5
WARNING
Before lifting water tank, attach guidelines to ensure control of water tank is maintained during lifting operations. All lifting should be done with the aid of assistants using guidelines and acting as spotters. All personnel should stand clear of supported load. All lifting should be done slowly. Failure to comply may result in damage to equipment, death, or serious injury to personnel. 11. 12. With the aid of an assistant and suitable lifting device, remove water tank (Figure 6, Item 3) from flatrack (Figure 6, Item 5). Position wood blocks under water tank (Figure 7, Item 3).
0193-5

3
0193
WOOD BLOCKS
WARNING
The water tank weighs 2,425 lbs (1,100 kg) empty. Water tank must be securely supported with suitable lifting device and blocks while removing isolator mounts. Failure to comply will cause damage to equipment, and death or serious injury to personnel. 13. 14. Lower water tank (Figure 7, Item 3) on wood blocks . Remove locknut (Figure 8, Item 16), snubbing washer (Figure 8, Item 17), isolator mount bushing (Figure 8, Item 18), screw (Figure 8, Item 15), sleeve (Figure 8, Item 19), isolator mount bushing (Figure 8, Item 20), and mounting plate (Figure 8, Item 10) from water tank (Figure 8, Item 3). Discard locknuts and isolator mounts.
0193-6

15 16 17 18
0193
19
10
20
20
Figure 8. Water Tank Mount Bushings and Spring Removal. END OF TASK INSTALLATION 1. Install mounting plate (Figure 9, Item 10), isolator mount (Figure 9, Item 20), sleeve (Figure 9, Item 19), isolator mount (Figure 9, Item 18), and snubbing washer (Figure 9, Item 17) on water tank (Figure 9, Item 3) with screw (Figure 9, Item 15) and locknut (Figure 9, Item 16). Tighten locknut to 400 ft lb (542 Nm).
0193-7

15 16 17 18
0193
19
10
20
20
Figure 9. Water Tank Mount Bushings and Spring Installation. 2. Position lifting straps around water tank (Figure 10, Item 3).
LIFTING STRAP
5
Figure 10. Water Tank Mount Bushings and Spring Installation.
WARNING
Prior to lifting water tank, attach guide lines to ensure control of water tank is maintained during lifting operations. All lifting should be done with the aid of assistants using guidelines and acting as spotters. All personnel should stand clear of supported load. All lifting should be done slowly. Failure to comply may result in damage to equipment, death, or serious injury to personnel.
0193-8
TM 5-3825-270-23&P INSTALLATION - Continued 3. 4. 5.
0193
With the aid of an assistant and suitable lifting device, position water tank (Figure 10, Item 3) on flatrack (Figure 10, Item 5). Remove lifting straps from water tank (Figure 11, Item 3). Install mounting plate (Figure 11, Item 11) on flatrack (Figure 11, Item 5) with eight washers (Figure 11, Item 13), four screws (Figure 11, Item 14), and locknuts (Figure 11, Item 12). Tighten four screws to 220 lb ft (298 Nm).
11 12, 13, 14
Figure 11. Water Tank Mount Bushings and Spring Installation.
WARNING
Empty tank weighs 2,425 lbs (1,100 kg). Do not attempt to lift or move tank without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 6. Using air lifting bag, lift flatrack (Figure 12, Item 5) and securely support on wood blocks.
0193-9

5
0193
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 12. Water Tank Mount Bushings and Spring Installation. 7. Install mounting plate (Figure 13, Item 10) on flatrack (Figure 13, Item 5) with 2 studs (Figure 13, Item 9), springs (Figure 13, Item 8), washers (Figure 13, Item 7), and four locknuts (Figure 13, Item 6).
8, 9
10
Figure 13. Water Tank Mount Bushings and Spring Installation. 8. 9. Repeat Steps (6) and (7) for remaining studs. Using air lifting bag, lift flatrack (Figure 14, Item 5) and remove wood blocks.
0193-10

5
0193
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 14. Water Tank Mount Bushings and Spring Installation. 10. Lower flatrack (Figure 14, Item 5) to ground.
NOTE
Install connectors as noted prior to removal. 11. Connect two switch harness connectors (Figure 15, Item 2) to wire harness (Figure 15, Item 4).
1 2 3
Figure 15. 12. Install wire harness (Figure 15, Item 4) on water tank (Figure 15, Item 3) with two locknuts (Figure 15, Item 1).
END OF TASK FOLLOW-ON MAINTENANCE 1. Install rear platform. (WP 0162)
0193-11
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE - Continued 2. 3. 4. 5. 6. 7. 8. Install folding hand rail assembly. (WP 0185) Install valve V8. (WP 0159) Install valve V1. (WP 0158) Install battery box. (WP 0083) Install stowage box. (WP 0154) Install inlet valve and hose. (WP 0183) Install strainer housing. (WP 0182)
0193
0193-12
TM 5-3825-270-23&P FIELD MAINTENANCE VALVE COVER PLATE REPLACEMENT
0194
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Gasket (WP 0226, Table 1, Item 45) Qty: 1 Lockwasher (WP 0226, Table 1, Item 73) Qty: 4 References Parts Manual (WP 0220) Figure 4011
REMOVAL Remove four nuts (Figure 1, Item 5), lockwashers (Figure 1, Item 4), valve cover plate (Figure 1, Item 3), and gasket (Figure 1, Item 2) from water pump (Figure 1, Item 1).
4 5
3
Figure 1. Valve Cover And Gasket Removal. END OF TASK INSTALLATION Install valve cover plate (Figure 2, Item 3) onto water pump (Figure 2, Item 1) with gasket (Figure 2, Item 2), four lockwashers (Figure 2, Item 4), and nuts (Figure 2, Item 5).
0194-1
0194
4 5
3
Figure 2. Valve Cover And Gasket Installation. END OF TASK END OF WORK PACKAGE
0194-2
TM 5-3825-270-23&P FIELD MAINTENANCE WATER TANK REPLACEMENT
0195
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Bit, Screwdriver 3/4 in (19mm) (WP 0225, Table 1, Item 1) Block, Filler, Wood, 3 in. Thick (WP 0225, Table 1, Item 2) Sling (WP 0225, Table 1, Item 9) Lifting Device, Capacity 8,500 lbs (3,855 kg) Lifting Straps, Capacity 2,500 lbs (1,134 kg) Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive (WP 0225, Table 1, Item 15) Wrench, Torque, 90-600 lb-ft (122-813 Nm), 3/4 in. Drive (WP 0225, Table 1, Item 16) Materials/Parts Locknut (WP 0226, Table 1, Item 67) Qty: 24 Kit, Tank Install Rubber Mount (WP 0226, Table 1, Item 53) Qty: 1 Kit, Tank Install Springs (WP 0226, Table 1, Item 52) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4002 Equipment Condition Water tank drained. (TM 5-3825-270-10) Strainer housing removed. (WP 0182) Inlet valve and hose removed. (WP 0183) Stowage box removed. (WP 0154) Battery box removed. (WP 0083) Valve V1 removed. (WP 0158) Valve V2 removed. (WP 0159) Valve V3 removed. (WP 0158) Valve V4 removed. (WP 0158) Valve V8 removed. (WP 0160) Folding hand rail assembly removed. (WP 0185) Tank walkway removed. (WP 0191) Rear platform removed. (WP 0162) Dial pointer removed. (WP 0184) Dial and bracket removed. (WP 0188) High tank level switch removed. (WP 0187) Low tank level switch removed. (WP 0189)
REMOVAL
WARNING
Water Distributor weighs in excess of 8,500 lbs (3,856 kg). Ensure that personnel are clear during lifting operations. Failure to comply may result in injury or death to personnel.
NOTE
Both sides of the water distributor must be lifted and supported to remove spring mount studs. Water distributor should only be raised and supported one side at a time. Left side shown lifted. Some components may need to be removed to reach certain spring mounts and mount bolts. Remove components as necessary. 1. Using air lifting bag, lift and support flatrack (Figure 1, Item 1) with wood blocks.
0195-1

1
0195
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 1. Water Tank Removal. 2. Remove 24 locknuts (Figure 2, Item 2), 12 washers (Figure 2, Item 3), springs (Figure 2, Item 4), and studs (Figure 2, Item 5) from mounting plates (Figure 2, Item 6) and flatrack (Figure 2, Item 1). Discard locknuts and springs.
4, 5
6
Figure 2. Water Tank Removal. 3. Using air lifting bag, lift flatrack (Figure 3, Item 1) and remove wood blocks.
0195-2

1
0195
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 3. Water Tank Removal. 4. 5. Lower flatrack (Figure 3, Item 1) to ground and remove air lifting bag. Remove four locknuts (Figure 4, Item 9), eight washers (Figure 4, Item 8), and four screws (Figure 4, Item 7) from mounting plates (Figure 4, Item 6) and flatrack (Figure 4, Item 1). Discard locknuts.
6 7, 8, 9
Figure 4. Water Tank Removal.
WARNING
Empty tank weighs 2,425 lbs (1,100 kg). Do not attempt to lift or move tank without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 6. Position lifting straps (Figure 5, Item 10) around water tank (Figure 5, Item 11).
0195-3
0195
10
11
1
Figure 5. Water Tank Removal.
WARNING
Before lifting water tank, attach guidelines to ensure control of water tank is maintained during lifting operations. All lifting should be done with the aid of assistants using guidelines and acting as spotters. All personnel should stand clear of supported load. All lifting should be done slowly. Failure to comply may result in damage to equipment, death, or serious injury to personnel. 7. With the aid of an assistant and suitable lifting device, remove water tank (Figure 5, Item 11) from flatrack (Figure 5, Item 1).
WARNING
The water tank weighs 2,425 lbs (1,100 kg) empty. Water tank must be securely supported with suitable lifting device and blocks while removing isolator mounts. Failure to comply will cause damage to equipment, and death or serious injury to personnel. 8. Position wood blocks under water tank (Figure 6, Item 11), and lower water tank.
0195-4

11
0195
WOOD BLOCKS
Figure 6. Water Tank Removal. 9. Remove locknut (Figure 7, Item 13), screw (Figure 7, Item 12), snubbing washer (Figure 7, Item 14), isolator mounts (Figure 7, Item 15), sleeve (Figure 7, Item 16), and mounting plate (Figure 7, Item 6) from water tank (Figure 7, Item 11).
12 13 14 15
16
15
11
15
11
Figure 7. Water Tank Removal. 10. Lift water tank (Figure 8, Item 11) and remove wood blocks.
0195-5

11
0195
WOOD BLOCKS
Figure 8. Water Tank Removal. 11. 12. Lower water tank (Figure 8, Item 11) to ground. Remove lifting straps (Figure 9, Item 10) from water tank (Figure 9, Item 11).
10 11
Figure 9. Water Tank Removal. END OF TASK INSTALLATION 1. Position lifting straps (Figure 10, Item 10) on water tank (Figure 10, Item 11).
0195-6

10 11
0195
Figure 10. Water Tank Installation. 2. With the aid of an assistant and suitable lifting device, position water tank (Figure 11, Item 11) on wood blocks.
11
WOOD BLOCKS
Figure 11. Water Tank Installation. 3. Install isolator mounts (Figure 12, Item 15), sleeve (Figure 12, Item 16), snubbing washer (Figure 12, Item 14), mounting plate (Figure 12, Item 6), screw (Figure 12, Item 12), and locknut (Figure 12, Item 13) on water tank (Figure 12, Item 11). Tighten locknuts to 400 ft lb (542 Nm).
0195-7

12 13 14 15
0195
16
15
11
15
11
Figure 12. Water Tank Installation.
WARNING
Before lifting water tank, attach guidelines to ensure control of water tank is maintained during lifting operations. All lifting should be done with the aid of assistants using guidelines and acting as spotters. All personnel should stand clear of supported load. All lifting should be done slowly. Failure to comply may result in damage to equipment, death, or serious injury to personnel.
WARNING
Empty tank weighs 2,425 lbs (1,100 kg). Do not attempt to lift or move tank without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 4. With the aid of an assistant and suitable lifting device, position water tank (Figure 13, Item 11) on flatrack (Figure 13, Item 1).
0195-8
0195
10
11
1
Figure 13. Water Tank Installation. 5. 6. Remove lifting straps (Figure 13, Item 10) from water tank (Figure 13, Item 11). Install mounting plates (Figure 14, Item 6) on flatrack (Figure 14, Item 1) with eight washers (Figure 14, Item 8), four screws (Figure 14, Item 7), and locknuts (Figure 14, Item 9). Tighten four screws to 220 lb ft (298 Nm).
6 7, 8, 9
Figure 14. Water Tank Installation.
WARNING
Water Distributor weighs in excess of 8,500 lbs (3,856 kg). Ensure that personnel are clear during lifting operations. Failure to comply may result in injury or death to personnel.
0195-9
0195
NOTE
Both sides of the water distributor must be lifted and supported to install spring mount studs. Water distributor should only be raised and supported one side at a time. Left side shown. 7. Using air lifting bag , lift and support flatrack (Figure 15, Item 1) on wood blocks.
1
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 15. Water Tank Installation. 8. Install 12 studs (Figure 16, Item 5), springs (Figure 16, Item 4), washers (Figure 16, Item 3), and 24 locknuts (Figure 16, Item 2) on mounting plates (Figure 16, Item 6) and flatrack (Figure 16, Item 1).
4, 5
6
Figure 16. Water Tank Installation. 9. Using air lifting bag, lift flatrack (Figure 17, Item 1) and remove wood blocks.
0195-10

1
0195
WOOD BLOCKS
AIR LIFTING BAG
WOOD BLOCKS
Figure 17. Water Tank Installation. 10. Lower flatrack (Figure 17, Item 1) and remove air lifting bag.
END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Install low tank level switch. (WP 0189) Install high tank level switch. (WP 0187) Install dial and bracket. (WP 0188) Install dial pointer. (WP 0184) Install rear platform. (WP 0162) Install tank walkway. (WP 0191) Install folding hand rail assembly. (WP 0185) Install valve V8. (WP 0160) Install valve V4. (WP 0158) Install valve V3. (WP 0159) Install valve V2. (WP 0159) Install valve V1. (WP 0158) Install battery box. (WP 0083) Install stowage box. (WP 0154) Install inlet valve and hose. (WP 0183) Install strainer housing. (WP 0182)
0195-11/12 blank
TM 5-3825-270-23&P FIELD MAINTENANCE WATER PUMP OIL SERVICE
0196
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pan, Drain, 5 Gal Cap (WP 0225, Table 1, Item 2) Funnel, Rigid Spout, 2 QT Cap (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Oil, SAE-30 (WP 0224, Table 1, Item 49, 50, 51) References Parts Manual (WP 0220) Figure 4011 Equipment Condition Engine OFF. (TM 5-3825-270-10)
DRAIN
WARNING
NOTE
Dispose of used oil, contaminated rags, and drain pan contents IAW local procedures. 1. Position drain pan under water pump drain plug (Figure 1, Item 1).
0196-1
TM 5-3825-270-23&P DRAIN - Continued

1 2
0196
Figure 1. Water Pump Oil Service. 2. Remove water pump drain plug (Figure 1, Item 1) from water pump assembly (Figure 1, Item 2) and allow oil to drain until flow stops.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 3. 4. 5. Apply pipe thread sealing to threads of drain plug (Figure 1, Item 1). Install water pump drain plug (Figure 1, Item 1) in water pump (Figure 1, Item 2). Remove drain pan and dispose of used oil IAW local procedures.
END OF TASK FILL 1. Remove water pump air vent (Figure 2, Item 3) from water pump assembly (Figure 2, Item 2).
0196-2
TM 5-3825-270-23&P FILL - Continued

2 3, 4
0196
Figure 2. Water Pump Oil Service.
WARNING
CAUTION
Do not over fill water pump oil. Over-filling can cause the bearings to overheat. Failure to comply may result in damage to equipment. 2. 3. Using 2 QT funnel, add approximately 3 oz of lubricating oil through air vent hole (Figure 2, Item 4). Verify oil level though water pump oil level sight gauge (Figure 3, Item 5) on water pump assembly (Figure 3, Item 2). Oil level should be level with center of oil level sight gauge.
0196-3
TM 5-3825-270-23&P FILL - Continued
0196
Figure 3. Water Pump Oil Service.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 4. Apply pipe thread sealant to threads of air vent (Figure 4, Item 3).
2 3, 4
Figure 4. Water Pump Oil Service. 5. Install air vent (Figure 4, Item 3) in air vent hole (Figure 4, Item 4) on water pump assembly (Figure 4, Item 2).
END OF TASK END OF WORK PACKAGE 0196-4
TM 5-3825-270-23&P FIELD MAINTENANCE DIAL INDICATOR ADJUSTMENT
0197
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Equipment Condition Water Distributor on Level Surface. (TM 5-3825-270-10)
ADJUSTMENT
CAUTION
Water distributor must be on level ground to get an accurate reading. Failure to comply may result in false readings and damage to equipment may occur. 1. 2. Open manhole cover. (TM 5-3825-270-10) Using a tape measurer, measure from top of water surface to top edge of manhole. Record measurement.
Read Number at top edge of manhole, then refer to chart to determine water volume in tank.
End of tape touches top of water.
Figure 1. Dial Indicator Adjustment. 3. Loosen hex head screw (Figure 2, Item 2) and locknut (Figure 2, Item 3).
0197-1
TM 5-3825-270-23&P ADJUSTMENT - Continued
0197
2, 3
Figure 2. Dial Indicator Adjustment. 4. Using measurement from Step 2 and Table 1 set dial indicator (Figure 2, Item 1) to correct water level. Table 1. Dial Indicator Adjustment. GALLONS 0 50 100 150 200 250 300 350 400 450 TOP OF MANHOLE TO WATER SURFACE 55 1/4 in (140 cm) 52 11/16 in (133 cm) 51 3/16 in (130 cm) 50 in (126 cm) 49 in (124 cm) 48 in (121 cm) 47 in (118 cm) 46 in (116 cm) 45 in (114 cm) 44 1/4 in (112 cm)
0197-2
TM 5-3825-270-23&P ADJUSTMENT - Continued Table 1. Dial Indicator Adjustment - Continued. 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700 43 3/8 in (110 cm) 42 9/16 in (108 cm) 41 1/2 in (106 cm) 41 in (104 cm) 40 1/4 in (102 cm) 39 9/16 in (100 cm) 38 3/4 in (98 cm) 38 1/8 in (96 cm) 37 1/2 in (94 cm) 36 11/16 in (93 cm) 36 in (91 cm) 35 5/16 in (89 cm) 34 5/8 in (87 cm) 33 15/16 in (86 cm) 33 1/4 in (84 cm) 32 1/2 in (82 cm) 32 in (81 cm) 31 1/4 in (79 cm) 30 9/16 in (77 cm) 29 7/8 in (76 cm) 29 1/4 in (74 cm) 28 9/16 in (72 cm) 27 7/8 in (70 cm) 27 1/4 in (69 cm) 26 1/2 in (67 cm)
0197
0197-3
TM 5-3825-270-23&P ADJUSTMENT - Continued Table 1. Dial Indicator Adjustment - Continued. 1750 1800 1850 1900 1950 2000 2050 2100 2150 2200 2250 2300 2350 2400 2450 2500 2550 2600 2650 2700 2750 2800 2850 2900 2950 25 7/8 in (65 cm) 25 3/16 in (64 cm) 24 1/2 in (62 cm) 23 3/4 in (60 cm) 23 1/4 in (58 cm) 22 1/5 in (57 cm) 21 3/4 in (55 cm) 21 in (53 cm) 20 3/8 in (51 cm) 19 11/16 in (49 cm) 18 3/4 in (48 cm) 18 1/4 in (46 cm) 17 1/2 in (44 cm) 16 3/4 in (42 cm) 16 in (40 cm) 15 1/4 in (38 cm) 14 1/2 in (36 cm) 13 11/16 in (34 cm) 12 7/8 in (32 cm) 12 in (30 cm) 11 1/8 in (28 cm) 10 1/8 in (25 cm) 9 1/8 in (23 cm) 8 1/16 in (20 cm) 6 7/8 in (17 cm)
0197
0197-4
TM 5-3825-270-23&P ADJUSTMENT - Continued Table 1. Dial Indicator Adjustment - Continued. 3000 5. 6. 5 1/2 in (14 cm)
0197
Once proper adjustments have been made, tighten hex head screw (Figure 2, Item 2) and locknut (Figure 2, Item 3). Close manhole cover. (TM 5-3825-270-10)
0197-5/6 blank
TM 5-3825-270-23&P FIELD MAINTENANCE WATER PUMP ASSEMBLY REPLACEMENT
0198
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Sling 36 INCH (WP 0225, Table 1, Item 8) Lifting Device, 300 lbs (136 kg) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) Locknut (WP 0226, Table 1, Item 41) Qty: 6 Isolator Mount (WP 0226, Table 1, Item 49) Qty: 2 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4011 Equipment Condition Engine module removed. (WP 0128) Pump drive coupling removed. (WP 0200) Water pump oil drained. (WP 0196) Water pump drained. (TM 5-3825-270-10) Discharge tube and pipe assembly pump outlet hose removed. (WP 0199) Suction tube and hose removed. (WP 0201)
REMOVAL 1. Loosen two clamps (Figure 1, Item 2) and remove pump prime hose (Figure 1, Item 1) from adapter (Figure 1, Item 3).
3 2 1
Figure 1. Water Pump Assembly Removal.
CAUTION
Support pump when removing hardware. Failure to comply may result in damage to equipment. 2. Remove two locknuts (Figure 2, Item 6), screws (Figure 2, Item 10), washers (Figure 2, Item 9), snubbing washers (Figure 2, Item 7), and upper isolator mounts (Figure 2, Item 8) from outer bracket (Figure 2, Item 4) and frame (Figure 2, Item 11). Discard locknuts.
0198-1

LIFTING DEVICE
0198
6 4 7 8
12 11
9 10
Figure 2. Water Pump Assembly Removal. 3. Attach suitable lifting device to water pump assembly (Figure 2, Item 5).
WARNING
Water pump weighs 210 lbs (95 kg). Do not attempt to lift or move pump without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 4. 5. With the aid of an assistant and suitable lifting device, remove water pump assembly (Figure 2, Item 5) and lower snubbing washer (Figure 2, Item 12) from frame (Figure 2, Item 11). Remove two lower isolator mounts (Figure 3, Item 19) from outer bracket (Figure 3, Item 4). Discard isolator mount.
0198-2

5
0198
15 13 4 14 20 14 16 17
18
19
Figure 3. Water Pump Assembly Removal. 6. 7. 8. Remove two locknuts (Figure 3, Item 15), screws (Figure 3, Item 20), four washers (Figure 3, Item 14), and outer bracket (Figure 3, Item 4) from inner bracket (Figure 3, Item 13). Discard locknuts. Remove two locknuts (Figure 3, Item 16), screws (Figure 3, Item 18), washers (Figure 3, Item 17), and inner bracket (Figure 3, Item 13) from water pump assembly (Figure 3, Item 5). Discard locknuts. Remove adapter (Figure 4, Item 3) from fitting (Figure 4, Item 21).
3 21
22 5
Figure 4. Water Pump Assembly Removal.
0198-3
TM 5-3825-270-23&P REMOVAL - Continued 9. 10. 11. Remove fitting (Figure 4, Item 21) from fitting (Figure 4, Item 22). Remove fitting (Figure 4, Item 22) from pump assembly (Figure 4, Item 5). Remove drain cock (Figure 5, Item 23) from pump assembly (Figure 5, Item 5).
0198
23
Figure 5. Water Pump Assembly Removal. END OF TASK INSTALLATION
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 1. Apply sealing compound to threads of drain cock (Figure 6, Item 23).
0198-4
0198
23
Figure 6. Water Pump Assembly Installation. 2. Install drain cock (Figure 6, Item 23) into water pump assembly (Figure 6, Item 5).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 3. Apply sealing compound to threads of fitting (Figure 7, Item 22).
0198-5
0198
3 21
22 5
Figure 7. Water Pump Assembly Installation. 4. 5. 6. 7. 8. 9. Install fitting (Figure 7, Item 22) into water pump assembly (Figure 7, Item 5). Apply sealing compound to threads of fitting (Figure 7, Item 21). Install fitting (Figure 7, Item 21) onto fitting (Figure 7, Item 22). Apply sealing compound to threads of adapter (Figure 7, Item 3). Install adapter (Figure 7, Item 3) onto fitting (Figure 7, Item 21). Install inner bracket (Figure 8, Item 13) on water pump assembly (Figure 8, Item 5) with two screws (Figure 8, Item 18), washers (Figure 8, Item 17), and locknuts (Figure 8, Item 16).
0198-6

5
0198
15 13 4 14 20 14 16 17
18
19
Figure 8. Water Pump Assembly Installation. 10. 11. 12. Install outer bracket (Figure 8, Item 4) on inner bracket (Figure 8, Item 13) with two screws (Figure 8, Item 20), four washers (Figure 8, Item 14), and two locknuts (Figure 8, Item 15). Install two lower isolator mounts (Figure 8, Item 19) on outer bracket (Figure 8, Item 4). Attach suitable lifting device to water pump assembly (Figure 9, Item 5).
0198-7

LIFTING DEVICE
0198
6 4 7 8
12 11
9 10
Figure 9. Water Pump Assembly Installation. 13. With the aid of an assistant and suitable lifting device, secure water pump assembly (Figure 9, Item 5) to frame (Figure 9, Item 11) and outer bracket (Figure 9, Item 4) with two screws (Figure 9, Item 10), washers (Figure 9, Item 9), lower isolator mounts (Figure 9, Item 12), upper isolator mounts (Figure 9, Item 8), upper snubbing washers (Figure 9, Item 7), and locknuts (Figure 9, Item 6). Install water pump prime hose (figure 10, item 1) on adapter (figure 10, item 3) with two clamps (Figure 10, Item 2).
14.
0198-8
0198
3 2 1
Figure 10. Water Pump Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install suction tube and hose. (WP 0201) Install discharge tube and pipe assembly pump outlet hose. (WP 0199) Install pump drive coupling. (WP 0200) Install engine module. (WP 0128) Fill water pump oil. (WP 0196)
0198-9/10 blank
TM 5-3825-270-23&P FIELD MAINTENANCE DISCHARGE TUBE AND PIPE ASSEMBLY PUMP OUTLET HOSE REPLACEMENT
0199
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Locknut (WP 0226, Table 1, Item 76) Qty: 12 Locknut (WP 0226, Table 1, Item 64) Qty: 8 Materials/Parts (cont.) Gasket (WP 0226, Table 1, Item 34) Qty: 1 Gasket (WP 0226, Table 1, Item 34) Qty: 1 References Parts Manual (WP 0220) Figure 4014 Equipment Condition Rear platform screen removed. (WP 0165) Inlet valve and hose removed. (WP 0183)
REMOVAL 1. Disconnect connector (Figure 1, Item 2) from harness connector (Figure 1 Item 1).
1 2
Figure 1. Discharge Tube and Pipe Assembly Pump Outlet Hose Removal. 2. Loosen clamp (Figure 2, Item 6) and remove water hose (Figure 2, Item 5) from fitting (Figure 2, Item 7).
0199-1
0199
Figure 2. Discharge Tube and Discharge Tube and Pipe Assembly Pump Outlet Hose Removal.
NOTE
Note position of pressure sensor prior to removal to ensure proper installation. 3. 4. Remove pressure sending unit assembly (Figure 2, Item 3) from discharge tube (Figure 2, Item 4). Remove drain cock (Figure 3, Item 8) from discharge tube (Figure 3, Item 4).
4 8
Figure 3. Discharge Tube and Pipe Assembly Pump Outlet Hose Removal. 5. Remove four locknuts (Figure 4, Item 11), washers (Figure 4, Item 10), and two u-bolts (Figure 4, Item 12) from discharge tube (Figure 4, Item 4) and bracket (Figure 4, Item 16). Discard locknuts.
0199-2
0199
10
11
12
13, 14 15
16
Figure 4. Discharge Tube and Pipe Assembly Pump Outlet Hose Removal. 6. 7. Remove two screws (Figure 4, Item 13), washers (Figure 4, Item 14), and support bracket (Figure 4, Item 16) from water pump (Figure 4, Item 9) and flywheel housing (Figure 4, Item 15). Remove eight locknuts (Figure 5, Item 26) and two flange reinforcement plates (Figure 5, Item 25) from water pump (Figure 5, Item 9) and discharge tube (Figure 5, Item 4). Discard locknuts.
17 18, 19 20 4
21, 22
23 24 27 26 25 9
Figure 5. Discharge Tube and Pipe Assembly Pump Outlet Hose Removal. 8. 9. 10. 11. 12. Remove eight locknuts (Figure 5, Item 19), screws (Figure 5, Item 18), gasket (Figure 5, Item 22) and flange (Figure 5, Item 21) from cross pipe (Figure 5, Item 20). Discard locknuts and gasket. Loosen two clamps (Figure 5, Item 23) and remove water hose (Figure 5, Item 24) from discharge tube (Figure 5, Item 4). Loosen two clamps (Figure 5, Item 17) and remove water hose (Figure 5, Item 24) from flange (Figure 5, Item 20). Remove discharge tube (Figure 5, Item 4) and gasket (Figure 5, Item 27) from water pump (Figure 5, Item 9). Remove fitting (Figure 6, Item 7) from fitting (Figure 6, Item 29).
0199-3
0199
28
30
29
Figure 6. Discharge Tube and Pipe Assembly Pump Outlet Hose Removal. 13. 14. Remove pressure sending unit (Figure 6, Item 28) from fitting (Figure 6, Item 29). Remove fitting (Figure 6, Item 30) from fitting (Figure 6, Item 29).
END OF TASK INSTALLATION 1. Install discharge tube (Figure 7, Item 4) on water pump (Figure 7, Item 9) with gasket (Figure 7, Item 27), two flange reinforcement plates (Figure 7, Item 25) and eight locknuts (Figure 7, Item 26).
4
27
26
25
Figure 7. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation. 2. Install support bracket (Figure 8, Item 16) on water pump (Figure 8, Item 9) and flywheel housing (Figure 8, Item 15) with two washers (Figure 8, Item 14) and screws (Figure 8, Item 13).
0199-4
0199
10
11
12
13, 14 15
16
Figure 8. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation. 3. 4. Install two u-bolts (Figure 8, Item 12) onto support bracket (Figure 8, Item 16) and discharge tube (Figure 8, Item 4) with four washers (Figure 8, Item 10) and locknuts (Figure 8, Item 11). Install water hose (Figure 9, Item 24) on discharge tube (Figure 9, Item 4) with two clamps (Figure 9, Item 23). Tighten two clamps to 70 lb-in (8 Nm).
17 18, 19 20
21, 22
24
23
Figure 9. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.
0199-5
TM 5-3825-270-23&P INSTALLATION - Continued 5. 6.
0199
Install water hose (Figure 9, Item 24) on flange (Figure 9, Item 21) with two clamps (Figure 9, Item 17). Tighten two clamps to 70 lb-in (8 Nm). Install flange (Figure 9, Item 21) on cross pipe (Figure 9, Item 20) with gasket (Figure 9, Item 22), eight screws (Figure 9, Item 18) and locknuts (Figure 9, Item 19).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 7. Coat threads of drain cock (Figure 10, Item 8) with sealant.
4 8
Figure 10. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation. 8. Install drain cock (Figure 10, Item 8) on discharge tube (Figure 10, Item 4).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 9. Coat threads of fitting (Figure 11, Item 30) with sealant.
0199-6
0199
28
30
29
Figure 11. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation. 10. Install fitting (Figure 11, Item 30) on fitting (Figure 11, Item 29).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 11. 12. Coat threads of pressure sending unit (Figure 11, Item 28) with sealant. Install pressure sending unit (Figure 11, Item 28) on fitting (Figure 11, Item 29).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 13. 14. Coat threads of fitting (Figure 11, Item 7) with sealant. Install fitting (Figure 11, Item 7) on fitting (Figure 11, Item 29).
0199-7
0199
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 15. Coat threads of pressure sending unit assembly (Figure 12, Item 3) with sealant.
Figure 12. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation.
NOTE
Install pressure sending unit as noted prior to removal to ensure proper installation. 16. 17. 18. Install pressure sending unit assembly (Figure 12, Item 3) on discharge tube (Figure 12, Item 4). Install water hose (Figure 12, Item 5) on fitting (Figure 12, Item 7) with clamp (Figure 12, Item 6). Connect connector (Figure 13, Item 2) to harness connector (Figure 13, Item 1).
0199-8

1 2
0199
Figure 13. Discharge Tube and Pipe Assembly Pump Outlet Hose Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install inlet valve and hose. (WP 0183) Install rear platform screen. (WP 0165)
0199-9/10 blank
TM 5-3825-270-23&P FIELD MAINTENANCE PUMP DRIVE COUPLING REPLACEMENT
0200
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Lockwasher (WP 0226, Table 1, Item 76) Qty: 6 Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) References Parts Manual (WP 0220) Figure 4011 Equipment Condition Engine module removed. (WP 0128)
REMOVAL 1. Remove six screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), plate (Figure 1, Item 4), and pump drive coupling (Figure 1, Item 3) from pump (Figure 1, Item 5). Discard lockwashers.
1, 2 3 4 5
Figure 1. Pump Drive Coupling Removal 2. Remove six sleeves (Figure 2, Item 6) from pump drive coupling (Figure 2, Item 3).
0200-1
0200
Figure 2. Pump Drive Coupling Removal END OF TASK INSTALLATION 1. Install six sleeves (Figure 3, Item 6) in pump drive coupling (Figure 3, Item 3).
Figure 3. Pump Drive Coupling Installation
WARNING
0200-2

1, 2 3 4 5
0200
Figure 4. Pump Drive Coupling Installation 3. 4. Install pump drive coupling (Figure 4, Item 3) on pump (Figure 4, Item 5) with plate (Figure 4, Item 4), six lockwashers (Figure 4, Item 2), and screws (Figure 4, Item 1). Torque six screws (Figure 4, Item 1) to 108 lb-in (12 Nm).
END OF TASK FOLLOW-ON MAINTENANCE Install engine module. (WP 0128) END OF TASK END OF WORK PACKAGE
0200-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE SUCTION TUBE AND HOSE REPLACEMENT
0201
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive (WP 0225, Table 1, Item 14) Materials/Parts Locknut (WP 0226, Table 1, Item 76) Qty: 8 Gasket (WP 0226, Table 1, Item 34) Qty: 1 References Parts Manual (WP 0220) Figure 4014 Equipment Condition Strainer housing removed. (WP 0182)
REMOVAL 1. Loosen two clamps (Figure 1, Item 1) on suction hose (Figure 1, Item 3) and suction tube (Figure 1, Item 2).
1 2
Figure 1. Suction Tube and Hose Removal. 2. Loosen clamp (Figure 2, Item 9) and remove water hose (Figure 2, Item 10) from fitting (Figure 2, Item 8).
0201-1

4 5 6 7
0201
10
Figure 2. Suction Tube and Hose Removal. 3. 4. Remove eight locknuts (Figure 2, Item 5), two flange reinforcement plates (Figure 2, Item 7), suction tube (Figure 2, Item 2), and gasket (Figure 2, Item 6) from pump (Figure 2, Item 4). Discard locknuts and gasket. Remove suction tube (Figure 3, Item 2) and clamps (Figure 3, Item 1) from suction hose (Figure 3, Item 3).
1 2
Figure 3. Suction Tube and Hose Removal. END OF TASK INSTALLATION 1. Install suction tube (Figure 4, Item 2) on water pump (Figure 4, Item 4) with gasket (Figure 4, Item 6), two flange reinforcement plates (Figure 4, Item 7), and eight locknuts (Figure 4, Item 5).
0201-2

4 5 6 7
0201
10
Figure 4. Suction Tube and Hose Installation. 2. 3. Install water hose (Figure 4, Item 10) on fitting (Figure 4, Item 8) with clamp (Figure 4, Item 9). Install two clamps (Figure 5, Item 1) on suction hose (Figure 5, Item 3) and suction tube (Figure 5, Item 2). Tighten two clamps to 70 lb-in (8 Nm).
1 2
Figure 5. Suction Tube and Hose Installation. END OF TASK FOLLOW-ON MAINTENANCE Install strainer housing. (WP 0182) END OF TASK END OF WORK PACKAGE
0201-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE HOSE REEL REPLACEMENT
0202
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Locknut (WP 0226, Table 1, Item 76) Qty: 12 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4047 Equipment Condition Rear platform removed. (WP 0162) Fire extinguisher bracket removed. (WP 0167) Hose reel hose removed. (WP 0204) Unstow hose reel crank handle. (TM 5-3825-270-10)
REMOVAL 1. Loosen two hose clamps (Figure 1, Item 1) and remove hose reel supply hose (Figure 1, Item 2) from hose reel (Figure 1, Item 3).
2
Figure 1. Hose Reel Removal. 2. Attach lifting device to hose reel (Figure 2, Item 3).
0202-1

4, 5, 6 7 3
0202
Figure 2. Hose Reel Removal. 3. Remove 12 locknuts (Figure 2, Item 4), screws (Figure 2, Item 5), and 24 washers (Figure 2, Item 6) from hose reel (Figure 2, Item 3) and module (Figure 2, Item 7). Discard locknuts.
WARNING
Hose reel weighs in excess 100 lbs (45 kg). Do not attempt to lift or move hose reel without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 4. With the aid of an assistant and lifting device, remove hose reel (Figure 2, Item 3) from module (Figure 2, Item 7).
WARNING
Hose reel weighs in excess 100 lbs (45 kg). Do not attempt to lift or move hose reel without the aid of an assistant and a lifting device. Failure to comply may result in injury or death to personnel. 1. With the aid of an assistant, install hose reel (Figure 3, Item 3) onto module (Figure 3, Item 7) with 12 screws (Figure 3, Item 5), 24 washers (Figure 3, Item 6), and 12 locknuts (Figure 3, Item 4).
0202-2

4, 5, 6 7 3
0202
Figure 3. Hose Reel Installation. 2. Install hose reel supply hose (Figure 4, Item 2) on hose reel (Figure 4, Item 3) with two clamps (Figure 4, Item 1).
2
Figure 4. Hose Reel Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Stow reel crank handle. (TM 5-3825-270-10) Install hose reel hose. (WP 0204) Install fire extinguisher bracket. (WP 0167)
0202-3
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE - Continued 4. Install rear platform. (WP 0162)
0202
0202-4
TM 5-3825-270-23&P FIELD MAINTENANCE HOSE REEL HOSE REPLACEMENT
0203
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Pipe Wrench (WP 0225, Table 1, Item 2) Materials/Parts Compound, Sealing, Pipe Thread, Loctite 567 (WP 0224, Table 1, Item 23, 24, 25, 26) Gasket (WP 0226, Table 1, Item 36) Qty: 1 Personnel Required Construction Equipment Repairer 91L (2) References Parts Manual (WP 0220) Figure 4047 Equipment Condition Unstow hose reel hose. (TM 5-3825-270-10)
REMOVAL 1. Remove fitting (Figure 1, Item 1) from elbow (Figure 1, Item 2).
Figure 1. Hose Reel Hose Removal. 2. Remove nozzle (Figure 2, Item 3) and gasket (Figure 2, Item 4) from hose (Figure 2, Item 5). Discard gasket.
0203-1
0203
Figure 2. Hose Reel Hose Removal. END OF TASK INSTALLATION 1. Install nozzle (Figure 3, Item 3) and gasket (Figure 3, Item 4) on hose (Figure 3, Item 5).
Figure 3. Hose Reel Hose Installation.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to skin and clothing. Keep away from open fire and use in well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water. Failure to comply may result in injury or death to personnel. 2. Apply sealing compound to threads of fitting (Figure 4, Item 1).
0203-2
0203
Figure 4. Hose Reel Hose Installation. 3. Install fitting (Figure 4, Item 1) on elbow (Figure 4, Item 2).
END OF TASK FOLLOW-ON MAINTENANCE Stow hose reel hose. (TM 5-3825-270-10) END OF TASK END OF WORK PACKAGE
0203-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE HOSE REEL GUIDE ROLLER ASSEMBLY REPLACEMENT
0204
REMOVAL Remove four locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), screws (Figure 1, Item 5), retaining blocks (Figure 1, Item 4), rollers (Figure 1, Item 3), and eight pins (Figure 1, Item 6) from weldment (Figure 1, Item 7). Discard locknuts.
5 6
Figure 1. Hose Reel Guide Roller Assembly Removal. END OF TASK INSTALLATION Install eight pins (Figure 2, Item 6), four rollers (Figure 2, Item 3), retaining blocks (Figure 2, Item 4), screws (Figure 2, Item 5), washers (Figure 2, Item 2), and locknuts (Figure 2, Item 1) to weldment (Figure 2, Item 7).
0204-1
0204
5 6
Figure 2. Hose Reel Guide Roller Assembly Installation. END OF TASK END OF WORK PACKAGE
0204-2
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX FACEGUARD REPLACEMENT
0205
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Compound, Sealing, Loctite 242 (WP 0224, Table 1, Item 19, 20, 21, 22) References Parts Manual (WP 0220) Figure 4008
REMOVAL Remove six screws (Figure 1, Item 1), washers (Figure 1, Item 2), application rate lanyard (Figure 1, Item 6), six spacers (Figure 1, Item 3), and faceguard (Figure 1, Item 4) from cab control box (Figure 1, Item 5).
1, 2 3 4 5
Figure 1. Cab Control Box Faceguard Removal. END OF TASK
0205-1
0205
WARNING
1, 2 3 4 5
Figure 2. Cab Control Box Faceguard Replacement. 2. Install faceguard (Figure 2, Item 4) on cab control box (Figure 2, Item 5) with six spacers (Figure 2, Item 3), application rate lanyard (Figure 2, Item 6), washers (Figure 2, Item 2), and six screws (Figure 2, Item 1). Tighten six screws securely.
0205-2
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX WIRE HARNESS REPLACEMENT
0206
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Lockwasher (WP 0226, Table 1, Item 61) Qty: 2 References Parts Manual (WP 0220) Figure 4008 Equipment Condition Cab control box faceguard removed. (WP 0205) Cab control box engine start/stop switch disconnected. (WP 0208) Equipment Condition (cont.) Cab control box water sprinkler switches disconnected. (WP 0209) Cab control box light switch disconnected. (WP 0210) Cab control box engine speed resume/idle switch disconnected. (WP 0211) Cab control box engine speed RPM disconnected. (WP 0212) Cab control box engine speed set button disconnected. (WP 0213) Cab control box water level indicators disconnected. (WP 0214) Cab control box engine off/battery drain indicator disconnected. (WP 0215) Cab control box tachometer disconnected. (WP 0216)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove nut (Figure 1, Item 3), two lockwashers (Figure 1, Item 4), two black wires (Figure 1, Item 2), and screw (Figure 1, Item 5) from cab control box (Figure 1, Item 1).
1 1
3, 4, 5
Figure 1. Cab Control Box Wiring Harness Removal.
0206-1
0206
Remove retaining nut (Figure 2, Item 7) and wiring harness (Figure 2, Item 6) from cab control box (Figure 2, Item 1).
1 6 7
1
Figure 2. Cab Control Box Wiring Harness Removal. END OF TASK INSTALLATION 1. Install wiring harness (Figure 3, Item 6) in cab control box (Figure 3, Item 1) with retaining nut (Figure 3, Item 7).
1 6 7
1
Figure 3. Cab Control Box Wiring Harness Installation. 2. Install two black wires (Figure 4, Item 2) on cab control box (Figure 4, Item 1) with screw (Figure 4, Item 5) two lockwashers (Figure 4, Item 4) and nut (Figure 4, Item 3).
0206-2
0206
1 1
3, 4, 5
Figure 4. Cab Control Box Wiring Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Connect cab control box engine start/stop switch. (WP 0208) Connect cab control box water sprinkler switches. (WP 0209) Connect cab control box light switch. (WP 0210) Connect cab control box engine speed resume/idle switch. (WP 0211) Connect cab control box engine speed RPM. (WP 0212) Connect cab control box engine speed set button (WP 0213) Connect cab control box water level indicators. (WP 0214) Connect cab control box engine off/battery drain indicator. (WP 0215) Connect cab control box tachometer. (WP 0216) Install cab control box faceguard. (WP 0205)
0206-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE DISC MAGNET AND BRACKET REPLACEMENT
0207
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Materials/Parts (cont.) Lockwasher (WP 0226, Table 1, Item 59) Qty: 3 Lockwasher (WP 0226, Table 1, Item 61) Qty: 2 References Parts Manual (WP 0220) Figure 4008 Equipment Condition Cab control box faceguard removed. (WP 0205)
REMOVAL
NOTE
Both disc magnets are removed the same way. Right side disc magnet shown. 1. Remove nut (Figure 1, Item 1), lockwasher (Figure 1, Item 2), screw (Figure 1, Item 5), and disc magnet (Figure 1, Item 4) from cab control mounting plate (Figure 1, Item 3). Discard lockwasher.
5 4 1, 2 3
Figure 1. Disc Magnet Removal. 2. Remove two nuts (Figure 2, Item 9), lockwashers (Figure 2, Item 10), and screws (Figure 2, Item 6) from cab control box (Figure 2, Item 8) and cab control mounting plate (Figure 2, Item 3). Discard lockwashers.
0207-1
0207
9, 10
9, 10
12, 13
11
Figure 2. Cab Control Mounting Plate Removal.
NOTE
Tag and mark wires prior to removal to ensure proper installation. 3. Remove nut (Figure 2, Item 12), two lockwashers (Figure 2, Item 13), two black wires (Figure 2, Item 11), screw (Figure 2, Item 7), and cab control box mounting plate (Figure 2, Item 3) from cab control box (Figure 2, Item 8).
NOTE
Install wires as noted prior to removal. 1. Install cab control box mounting plate (Figure 3, Item 3) on cab control box (Figure 3, Item 8) with screw (Figure 3, Item 7), two black wires (Figure 3, Item 11), two lockwashers (Figure 3, Item 13), and nut (Figure 3, Item 12).
0207-2
0207
9, 10
9, 10
12, 13
11
Figure 3. Cab Control Mounting Plate Installation. 2. Install two screws (Figure 3, Item 6), lockwashers (Figure 3, Item 10), and nuts (Figure 3, Item 9) on cab control box (Figure 3, Item 8) and cab control mounting plate (Figure 3, Item 3).
NOTE
Both disc magnets are installed the same way. Right side disc magnet shown. 3. Install disc magnet (Figure 4, Item 4) on cab control mount plate (Figure 4, Item 3) with screw (Figure 4, Item 5), lockwasher (Figure 4, Item 2), and nut (Figure 4, Item 1).
5 4 1, 2 3
Figure 4. Disc Magnet Installation. END OF TASK
0207-3
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE Install cab control box faceguard. (WP 0205) END OF TASK END OF WORK PACKAGE
0207
0207-4
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX ENGINE START/STOP SWITCH REPLACEMENT
0208
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) References Parts Manual (WP 0220) Figure 4008 Equipment Condition Cab control box faceguard removed. (WP 0205)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove white wire No. 4 (Figure 1, Item 5) from engine start/stop switch (Figure 1, Item 4).
5 1 2 3 4
Figure 1. Cab Control Box Engine Start/Stop Switch Removal. 2. 3. Remove red wire (Figure 1, Item 6) from engine start/stop switch (Figure 1, Item 4). Remove black wire No. 4 (Figure 1, Item 7) from engine start/stop switch (Figure 1, Item 4).
NOTE
Note position of engine start/stop switch and switch guard prior to removal to ensure proper installation.
0208-1
0208
Remove nut (Figure 1, Item 3), switch guard (Figure 1, Item 2), and engine start/stop switch (Figure 1, Item 4) from cab control box cover (Figure 1, Item 1).
NOTE
Install engine start/stop switch and switch guard as noted prior to removal. 1. Install engine start/stop switch (Figure 2, Item 4) and switch guard (Figure 2, Item 2) on cab control box cover (Figure 2, Item 1) with nut (Figure 2, Item 3).
5 1 2 3 4
Figure 2. Cab Control Box Engine Start/Stop Switch Installation.
NOTE
Install wires as noted prior to removal. 2. 3. 4. Install black wire No. 4 (Figure 2, Item 7) on engine start/stop switch (Figure 2, Item 4). Install red wire (Figure 2, Item 6) on engine start/stop switch (Figure 2, Item 4). Install white wire No. 4 (Figure 2, Item 5) on engine start/stop switch (Figure 2, Item 4).
END OF TASK FOLLOW-ON MAINTENANCE Install cab control box faceguard. (WP 0205) END OF TASK END OF WORK PACKAGE
0208-2
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX WATER SPRINKLER SWITCH REPLACEMENT
0209
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. Both left water sprinkler switch and right water sprinkler switch are removed the same way except where noted. 1. Remove screw (Figure 1, Item 5) and white wire (Figure 1, Item 1) from cab control box water sprinkler switch (Figure 1, Item 4).
Figure 1. Cab Control Box Water Sprinkler Switch Removal.
NOTE
Perform Step (2) for cab control box left water sprinkler switch. 2. Remove screw (Figure 1, Item 3) and black wire (Figure 1, Item 2) from cab control box water sprinkler switch (Figure 1, Item 4).
NOTE
Perform Step (3) for cab control box right water sprinkler switch.
0209-1
0209
Remove screw (Figure 2, Item 7) and white wire No. 8 (Figure 2, Item 6) from cab control box water sprinkler switch (Figure 2, Item 4).
Figure 2. Cab Control Box Right Water Sprinkler Switch Removal. 4. Remove nut (Figure 3, Item 8) and cab control box water sprinkler switch (Figure 3, Item 4) from cab control box cover (Figure 3, Item 9).
9
Figure 3. Cab Control Box Water Sprinkler Switch Removal. END OF TASK INSTALLATION
NOTE
Both left cab control box water sprinkler switch and right cab control box water sprinkler switch are installed the same way except where noted. 1. Install cab control box water sprinkler switch (Figure 4, Item 4) on cab control box cover (Figure 4, Item 9) with nut (Figure 4, Item 8).
0209-2
0209
9
Figure 4. Cab Control Box Water Sprinkler Switch Installation.
NOTE
Install wires as noted prior to removal. Perform Step (2) for cab control box right water sprinkler switch. 2. Install white wire No. 8 (Figure 5, Item 6) on cab control box water sprinkler switch (Figure 5, Item 4) with screw (Figure 5, Item 7).
Figure 5. Cab Control Box Water Sprinkler Switch Installation.
NOTE
Install wires as noted prior to removal. Perform Step (3) for cab control box left water sprinkler switch. 3. Install black wire (Figure 6, Item 2) on cab control box water sprinkler switch (Figure 6, Item 4) with screw (Figure 6, Item 3).
0209-3
0209
Figure 6. Cab Control Box Water Sprinkler Switch Installation. 4. Install white wire (Figure 6, Item 1) on cab control box water sprinkler switch (Figure 6, Item 4) with screw (Figure 6, Item 5).
0209-4
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX LIGHT SWITCH REPLACEMENT
0210
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove screw (Figure 1, Item 4) and two red wires (Figure 1, Item 5) from cab control box light switch (Figure 1, Item 1).
Figure 1. Cab Control Box Light Switch Removal. 2. 3. Remove screw (Figure 1, Item 7) and black wire No. 5 (Figure 1, Item 6) from cab control box light switch (Figure 1, Item 1). Remove nut (Figure 1, Item 2) and cab control box light switch (Figure 1, Item 1) from cab control box cover (Figure 1, Item 3).
END OF TASK
0210-1
0210
NOTE
Install wires as noted prior to removal. 1. Install cab control box light switch (Figure 2, Item 1) on cab control box cover (Figure 2, Item 3) with nut (Figure 2, Item 2).
Figure 2. Cab Control Box Light Switch Installation. 2. 3. Install black wire No. 5 (Figure 2, Item 6) on cab control box light switch (Figure 2, Item 1) with screw (Figure 2, Item 7). Install two red wires (Figure 2, Item 5) on cab control box light switch (Figure 2, Item 1) with screw (Figure 2, Item 4).
0210-2
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX ENGINE SPEED RESUME/IDLE SWITCH REPLACEMENT
0211
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove white wire No. 2 (Figure 1, Item 1) from engine speed resume/idle switch (Figure 1, Item 4).
1 2 3
Figure 1. Cab Control Box Engine Speed Resume/Idle Switch Removal. 2. 3. Remove black wire (Figure 1, Item 3) from engine speed resume/idle switch (Figure 1, Item 4). Remove two red wires (Figure 1, Item 2) from engine speed resume/idle switch (Figure 1, Item 4).
NOTE
Note position of engine speed resume/idle switch prior to removal to ensure proper installation.
0211-1
0211
Remove nut (Figure 2, Item 5) and engine speed resume/idle switch (Figure 2, Item 4) from cab control box cover (Figure 2, Item 6).
5
Figure 2. Cab Control Box Engine Speed Resume/Idle Switch Removal. END OF TASK INSTALLATION
NOTE
Install engine speed resume/idle switch as noted prior to removal. 1. Install engine speed resume/idle switch (Figure 3, Item 4) on cab control box cover (Figure 3, Item 6) with nut (Figure 3, Item 5).
5
Figure 3. Cab Control Box Engine Speed Resume/Idle Switch Installation.
0211-2
0211
NOTE
Install wires as noted prior to removal. 2. Install two red wires (Figure 4, Item 2) on engine speed resume/idle switch (Figure 4, Item 4).
1 2 3
Figure 4. Cab Control Box Engine Speed Resume/Idle Switch Installation. 3. 4. Install black wire (Figure 4, Item 3) on engine speed resume/idle switch (Figure 4, Item 4). Install white wire No. 2 (Figure 4, Item 1) on engine speed resume/idle switch (Figure 4, Item 4).
0211-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX ENGINE SPEED RPM SWITCH REPLACEMENT
0212
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove white wire No. 3 (Figure 1, Item 1) from engine speed RPM switch (Figure 1, Item 4).
1 2 3
Figure 1. Cab Control Box Engine Speed RPM Switch Removal. 2. 3. 4. Remove two red wires (Figure 1, Item 2) from engine speed RPM switch (Figure 1, Item 4). Remove black wire (Figure 1, Item 3) from engine speed RPM switch (Figure 1, Item 4). Remove nut (Figure 2, Item 5) and engine speed RPM switch (Figure 2, Item 4) from cab control box cover (Figure 2, Item 6).
0212-1
0212
Figure 2. Cab Control Box Engine Speed RPM Switch Removal. END OF TASK INSTALLATION 1. Install engine speed RPM switch (Figure 3, Item 4) on cab control box cover (Figure 3, Item 6) with nut (Figure 3, Item 5).
Figure 3. Cab Control Box Engine Speed RPM Switch Installation.
NOTE
Install wires as noted prior to removal. 2. Install black wire (Figure 4, Item 3) on engine speed RPM switch (Figure 4, Item 4).
0212-2

1 2 3
0212
Figure 4. Cab Control Box Engine Speed RPM Switch Removal. 3. 4. Install two red wires (Figure 4, Item 2) on engine speed RPM switch (Figure 4, Item 4). Install white wire No. 3 (Figure 4, Item 1) on engine speed RPM switch (Figure 4, Item 4).
0212-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX ENGINE SPEED SET BUTTON REPLACEMENT
0213
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove screw (Figure 1, Item 4) and red wire (Figure 1, Item 5) from engine speed set button (Figure 1, Item 1).
1 7 6
Figure 1. Cab Control Box Engine Speed Set Button Removal. 2. Remove screw (Figure 1, Item 7) and black wire No. 1 (Figure 1, Item 6) from engine speed set button (Figure 1, Item 1).
NOTE
Note position of engine speed set button prior to removal to ensure proper installation.
0213-1
0213
Remove nut (Figure 1, Item 2) and engine speed set button (Figure 1, Item 1) from cab control box cover (Figure 1, Item 3).
NOTE
Install engine speed set button as noted prior to removal. 1. Install engine speed set button (Figure 2, Item 1) on cab control box cover (Figure 2, Item 3) with nut (Figure 2, Item 2).
1 7 6
Figure 2. Cab Control Box Engine Speed Set Button Installation.
NOTE
Install wires as noted prior to removal. 2. 3. Install black wire No. 1 (Figure 2, Item 6) on engine speed set button (Figure 2, Item 1) with screw (Figure 2, Item 7). Install red wire (Figure 2, Item 5) on engine speed set button (Figure 2, Item 1) with screw (Figure 2, Item 4).
0213-2
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX WATER LEVEL INDICATOR REPLACEMENT
0214
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. Both water level indicators are removed the same way, except where noted. 1. Remove black wire (Figure 1, Item 1) from water level indicator (Figure 1, Item 3).
2 1
Figure 1. Cab Control Box Water Level Indicator Removal.
NOTE
Perform Step (2) if removing high water level indicator. 2. Remove black wire (Figure 1, Item 2) from water level indicator (Figure 1, Item 3).
NOTE
Perform Step (3) if removing low water level indicator. 3. Remove white wire No. 7 (Figure 2, Item 7) from water level indicator (Figure 2, Item 3).
0214-1
0214
4, 5
Figure 2. Cab Control Box Water Level Indicator Removal.
NOTE
Note position of water level indicator prior to removal to ensure proper installation. 4. Remove nut (Figure 2, Item 4), star washer (Figure 2, Item 5), and water level indicator (Figure 2, Item 3) from cab control box cover (Figure 2, Item 6).
NOTE
Install water level indicator as noted prior to removal. 1. Install water level indicator (Figure 3, Item 3) on cab control box cover (Figure 3, Item 6) with star washer (Figure 3, Item 5) and nut (Figure 3, Item 4).
0214-2
0214
4, 5
Figure 3. Cab Control Box Water Level Indicator Installation.
NOTE
Install wires as noted prior to removal. Perform Step (2) if installing low water level indicator. 2. Install white wire No. 7 (Figure 3, Item 7) on water level indicator (Figure 3, Item 3).
NOTE
Perform Step (3) if installing high water level indicator. 3. Install black wire (Figure 4, Item 2) on water level indicator (Figure 4, Item 3).
2 1
Figure 4. Cab Control Box Water Level Indicator Installation.
0214-3
TM 5-3825-270-23&P INSTALLATION - Continued 4. Install black wire (Figure 4, Item 1) on water level indicator (Figure 4, Item 3).
0214
0214-4
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX ENGINE OFF/BATTERY DRAIN INDICATOR REPLACEMENT
0215
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove two red wires (Figure 1, Item 1) from engine off/battery drain indicator (Figure 1, Item 4).
5, 6
Figure 1. Cab Control Box Engine Off/Battery Drain Indicator Removal. 2. 3. Remove white wire No. 6 (Figure 1, Item 2) from engine off/battery drain indicator (Figure 1, Item 4). Remove black wire (Figure 1, Item 3) from engine off/battery drain indicator (Figure 1, Item 4).
0215-1
0215
NOTE
Note position of engine off/battery drain indicator prior to removal to ensure proper installation. 4. Remove nut (Figure 1, Item 5), star washer (Figure 1, Item 6), and engine off/battery drain indicator (Figure 1, Item 4) from cab control box cover (Figure 1, Item 7).
NOTE
Install engine off/battery drain indicator as noted prior to removal. 1. Install engine off/battery drain indicator (Figure 2, Item 4) on cab control box cover (Figure 2, Item 7) with star washer (Figure 2, Item 6) and nut (Figure 2, Item 5).
5, 6
Figure 2. Cab Control Box Engine Off/Battery Drain Indicator Installation.
NOTE
Install wires as noted prior to removal. 2. 3. 4. Install black wire (Figure 2, Item 3) on engine off/battery drain indicator (Figure 2, Item 4). Install white wire No. 6 (Figure 2, Item 2) on engine off/battery drain indicator (Figure 2, Item 4). Install two red wires (Figure 2, Item 1) on engine off/battery drain indicator (Figure 2, Item 4).
END OF TASK
0215-2
TM 5-3825-270-23&P FOLLOW-ON MAINTENANCE Install cab control box faceguard. (WP 0205) END OF TASK END OF WORK PACKAGE
0215
0215-3/4 blank
TM 5-3825-270-23&P FIELD MAINTENANCE CAB CONTROL BOX TACHOMETER REPLACEMENT
0216
INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12) Materials/Parts Tags, Identification, White (WP 0224, Table 1, Item 54) Lockwasher Qty: 1 References Parts Manual (WP 0220) Figure 4008 Equipment Condition Cab control box faceguard removed. (WP 0205)
REMOVAL
NOTE
Tag and mark wires prior to removal to ensure proper installation. 1. Remove nut (Figure 1, Item 2) and two black wires (Figure 1, Item 1) from ground stud (Figure 1, Item 3).
1 2 3 4
Figure 1. Cab Control Box Tachometer Removal. 2. 3. 4. Remove nut (Figure 1, Item 5), white wire No. 9 (Figure 1, Item 7), and white jumper wire (Figure 1, Item 6) from +24vdc stud (Figure 1, Item 4). Disconnect white wire No. 5 (Figure 1, Item 9) from terminal (Figure 1, Item 8). Remove nut (Figure 2, Item 10), lockwasher (Figure 2, Item 11), washer (Figure 2, Item 12), and white wire No. 10 (Figure 2, Item 14) from stud (Figure 2, Item 13). Discard lockwasher.
0216-1

10, 11, 12 13
0216
14
Figure 2. Cab Control Box Tachometer Removal. 5. Remove two nuts (Figure 3, Item 15) and circuit board (Figure 3, Item 17) from stud (Figure 3, Item 16) and stud (Figure 3, Item 3).
15
16
17
3
Figure 3. Cab Control Box Tachometer Removal. 6. Remove two lockwashers (Figure 4, Item 18) from stud (Figure 4 , Item 3) and stud (Figure 4, Item 16).
0216-2
0216
13
18
16
20
19
Figure 4. Cab Control Box Tachometer Removal.
NOTE
Count number of threads between nut and top of stud prior to removal to ensure proper installation. 7. 8. 9. Remove nut (Figure 4, Item 19) from stud (Figure 4, Item 3). Remove nut (Figure 4, Item 20) from stud (Figure 4, Item 13). Remove nut (Figure 5, Item 21), lockwasher (Figure 5, Item 22), and washer (Figure 5, Item 23) from stud (Figure 5, Item 24).
0216-3

21, 22, 23 24 16
0216
25, 26,27
30
29
28
Figure 5. Cab Control Box Tachometer Removal. 10. Remove nut (Figure 5, Item 25), lockwasher (Figure 5, Item 26), and washer (Figure 5, Item 27) from stud (Figure 5, Item 16).
NOTE
Note position of tachometer prior to removal to ensure proper installation. 11. Remove retainer (Figure 5, Item 28), and tachometer (Figure 5, Item 29) from cab control box cover (Figure 5, Item 30).
NOTE
Install tachometer as noted prior to removal. 1. Position tachometer (Figure 6, Item 29) in cab control box cover (Figure 6, Item 30).
0216-4

21, 22, 23 24 16
0216
25, 26,27
30
29
28
Figure 6. Cab Control Box Tachometer Installation. 2. 3. 4. 5. Install retainer (Figure 6, Item 28) on tachometer (Figure 6, Item 29). Install retainer (Figure 6, Item 28) on stud (Figure 6, Item 24) with washer (Figure 6, Item 23), lockwasher (Figure 6, Item 22), and nut (Figure 6, Item 21). Install washer (Figure 6, Item 27), lockwasher (Figure 6, Item 26), and nut (Figure 6, Item 25) on stud (Figure 6, Item 16). Install nut (Figure 7, Item 20) on stud (Figure 7, Item 13).
0216-5

13 3 18 16
0216
20
19
25
Figure 7. Cab Control Box Tachometer Installation.
NOTE
Install nut and ensure threads showing are same as noted prior to removal. 6. Install nut (Figure 7, Item 19) on stud (Figure 7, Item 3).
NOTE
Install wires as noted prior to removal. 7. Install lockwashers (Figure 7, Item 18) on stud (Figure 7, Item 3) and stud (Figure 7, Item 16).
CAUTION
Do not over-tighten nuts on circuit board. Failure to comply will result in damage to equipment. 8. Install circuit board (Figure 8, Item 17) on stud (Figure 8, Item 3) and stud (Figure 8, Item 16) with nuts (Figure 8, Item 15).
0216-6
0216
15
16
17
3
Figure 8. Cab Control Box Tachometer Installation. 9. Install white wire No. 10 (Figure 9, Item 14) on stud (Figure 9, Item 13) with washer (Figure 9, Item 12), lockwasher (Figure 9, Item 11), and nut (Figure 9, Item 10).
10, 11, 12 13
14
Figure 9. Cab Control Box Tachometer Installation. 10. Connect white wire No. 5 (Figure 10, Item 9) to terminal (Figure 10, Item 8).
0216-7

1 2 3
0216
Figure 10. Cab Control Box Tachometer Installation.
CAUTION
Do not over-tighten nuts on circuit board. Failure to comply will result in damage to equipment. 11. 12. Install white jumper wire (Figure 10, Item 6) and white wire No. 9 (Figure 10, Item 7) on +24vdc stud (Figure 10, Item 4) with nut (Figure 10, Item 5). Install two black wires (Figure 10, Item 1) on ground stud (Figure 10, Item 3) with nut (Figure 10, Item 2).
0216-8
TM 5-3825-270-23&P FIELD MAINTENANCE PREPARATION FOR STORAGE OR SHIPMENT
0217
INITIAL SETUP: Not Applicable
PREPARATION FOR STORAGE INTRODUCTION 1. The storage instructions apply to water distributors being taken out of service for a period of up to one year with exercise. If water distributors are inactive for more than one year, they will use extended storage (water distributor inactive) procedures within this file. Proper preservation of a water distributor and its individual parts for storage or shipment to a repair/rework facility is vital to the life of that equipment. Instructions pertaining to security procedures are covered in TB 9-2300-422-20 (WP 0221).
2. 3.
END OF TASK PREPARATION FOR STORAGE
NOTE
Prior to water distributor storage and shipment, perform the following. 1. 2. 3. 4. 5. Perform all Field Preventive Maintenance Checks and Services (WP 0069) (PMCS). Correct all deficiencies noted during inspection if facilities are available. If repairs required are beyond the scope of Field Maintenance, refer the deficiencies to Sustainment Maintenance. Place all Basic Issue Items (BII) into storage. Remove rust and corrosion, and scrape any flaked and peeling paint. Dry all surfaces to be painted and coat with preservatives. Refer to TM 9-247 (WP 0221). Repaint surface, as required, to prevent against deterioration. Instructions pertaining to security procedures are covered in TB 43-0209 (WP 0221).
END OF TASK STORAGE 1. Before placing a water distributor in storage, perform the following tasks: a. b. c. d. e. Fully drain water distributor. (TM 5-3825-270-10) Clean the engine, and frame. (TM 5-3825-270-10) Conduct a visual inspection of the water distributor. Check lubricant levels. Correct any discrepancies. Completely lubricate the water distributor and all ancillary equipment in accordance with LO-5-3825-270-13 (WP 0221). Check the coolant level. Test the coolant to ensure that the cooling system is protected against corrosion and temperatures down to -50F (-46C). Add antifreeze or corrosion inhibitors compatible with ethylene glycol base antifreeze if cooling system is not adequately protected. Refer to TB 750-651 (WP 0221).
0217-1
TM 5-3825-270-23&P STORAGE - Continued f.
0217
Ensure the fuel tank contains at least 4 gal (15 L) of treated fuel. The fuel should be treated with a fuel fungus inhibitor (WP 0224, Table 1, Item 5, 6, 7, 8). The addition of 1/4 teaspoons (4 ml) of fuel fungus inhibitor (WP 0224, Table 1, Item 5, 6, 7, 8) to 4 gal (15 L) of fuel will provide adequate protection against fungus growth. When storing a water distributor in freezing conditions, the addition of 1/4 ounces (0.74 ml) of isopropyl alcohol to 4 gal (15 L) of fuel will help prevent fuel line freeze up. Check condition of engine air filter elements. Service (WP 0170) if necessary. Coat all exposed, unpainted surfaces with grease to prevent against deterioration.
g. h.
CAUTION
Do not allow baking soda solution to enter batteries. Failure to comply may result in damage to equipment. i. Clean batteries (WP 0082) and battery cables with a baking soda solution and rinse with fresh water. Add water to battery electrolyte if necessary. Check the specific gravity of the batteries regularly. Keep the batteries fully charged and clean according to TM 5-3825-270-23&P (WP 0221). If possible, store water distributors close together, out of direct sunlight, and away from electrical or generating equipment. Position water distributor to allow access for inspection, maintenance, and exercising.
j. k.
CAUTION
The alternator drains the batteries at all times. Batteries will discharge during storage if not disconnected. l. 2. Disconnect batteries (WP 0085).
While water distributor is in storage, perform the following tasks monthly: a. b. Connect batteries (WP 0085). If engine is run every 30 days or less, use lubricating oil OE/HDO 15W40 (MIL-L-2104). If engine is not run every 30 days or less, use lubricating oil (MIL-L-21260C, Grade 2) and change oil filter or warranty will not be maintained. Conduct visual inspection of the water distributor. Check for fluid leaks, lubricant levels, battery electrolyte, and coolant level. Correct any deficiencies. Fill water distributor. (TM 5-3825-270-10) with 300 gallons (1135 L) or more. Start engine and idle for 5 minutes. After 5 minutes of engine idle, circulate water (TM 5-3825-270-10) for 5 minutes at 1500 rpm, or until the engine temperature reaches 180 F (82 C). Check grease coating on all unpainted surfaces. If grease was wiped away inadvertently, recoat these surfaces. Fully drain water distributor. (TM 5-3825-270-10) Disconnect batteries (WP 0085). If batteries are not going to be charged for over 30 days, remove batteries (WP 0086) from water distributor and keep fully charged according to TM 5-3825-270-23&P (WP 0221).
c. d. e. f. g. h.
3.
While water distributor is in storage, perform the following tasks quarterly: Perform all monthly Preventive Maintenance Checks and Services (PMCS).
4.
While water distributor is in storage, perform the following tasks yearly: a. Perform all quarterly tasks.
0217-2
TM 5-3825-270-23&P STORAGE - Continued b. Clean the engine and frame.
0217
CAUTION
Do not allow baking soda solution to enter batteries. Failure to comply may result in damage to equipment. c. Clean batteries and battery cables with a baking soda solution and rinse with fresh water. Add water (WP 0082) to battery electrolyte if necessary. Check the specific gravity of the batteries regularly. Keep the batteries fully charged and clean according to TM 5-3825-270-23&P (WP 0221). Lubricate all lube points in accordance with lubrication table LO-5-3825-270-13 (WP 0221). Check the coolant level. Test the coolant to ensure that the cooling system is protected against corrosion and temperatures down to -50F (-46C). Add antifreeze or corrosion inhibitors compatible with ethylene glycol base antifreeze if cooling system is not adequately protected. Refer to TB 750-651 (WP 0221). Change the engine oil and oil filter (WP 0124) and change the fuel/water separator filter (WP 0177).
d. e.
f. 5.
Extended storage (water distributor inactive).
CAUTION
When water distributor is to remain inactive for more than 12 months, extended storage procedures must be performed to prevent damage due to rust, corrosion, or organic growth in the fluids.
NOTE
When water distributor is to remain inactive for more than 12 months, extended storage procedures must be performed to maintain the water distributor warranty. Lubricate all lube points in accordance with lubrication table LO-5-3825-270-13 (WP 0221). 6. Fuel system extended storage. a. b. c. Drain fuel tank (WP 0174). Replace fuel/water separator filter (WP 0177). Ensure the fuel tank contains at least 4 gal (15 L) of treated fuel. The fuel should be treated with a fuel fungus inhibitor (WP 0224, Table 1, Item 5, 6, 7, 8) or equivalent as a fungus inhibitor. The addition of 1/4 teaspoons (4 ml) of fuel fungus inhibitor (WP 0224, Table 1, Item 5, 6, 7, 8) to 4 gal (15 L) of fuel will provide adequate protection against fungus growth. When storing a vehicle in freezing conditions, the addition of 1/4 ounce (0.74 ml) of isopropyl alcohol to 4 gal (15 L) of fuel will help prevent fuel line freeze up. Prime engine pump.
d.
CAUTION
Do not let engine pump run more than 5 minutes without circulating water through pump. Failure to comply may result in damage to equipment. e. f. 7. Start engine and let run 5 minutes to circulate clean treated fuel throughout the fuel system. All fuel that is added to the vehicle during storage must be treated. While in storage, there must always be at least 4 gal (15 L) of treated fuel in the water distributors fuel tank.
Engine extended storage. Change the engine oil and oil filter. Add preservative lubricating oil (MIL-L-21260C, Grade 2).
0217-3
TM 5-3825-270-23&P STORAGE - Continued 8. 9.
0217
Battery extended storage (more than 30 days with no charging). Remove batteries (WP 0086) from water distributor and keep fully charged. Check the coolant level. Test the coolant to ensure that the cooling system is protected against corrosion and temperatures down to -50F (-46C). Add antifreeze or corrosion inhibitors compatible with ethylene glycol base antifreeze if cooling system is not adequately protected. Refer to TB 750-651 (WP 0221). When removing water distributor from storage, perform the following tasks: a. b. c. d. Install batteries (WP 0086). Change oil and filter (WP 0123). Conduct a visual inspection of the water distributor. Check lubricant levels, and correct any discrepancies. Lubricate all lube points in accordance with lubrication table LO-5-3825-270-13 (WP 0221).
10.
0217-4
TM 5-3825-270-23&P FIELD MAINTENANCE TORQUE LIMITS
0218
SCOPE This work package lists standard torque values and provides general information for applying torque. Special torque values and tightening sequences are indicated in the maintenance procedures for applicable components. GENERAL 1. Always use torque values listed in Tables 2 and 3 when a maintenance procedure does not give a specific torque value. 1. Table 2 provides torque limits for SAE standard fasteners. 2. Table 3 provides torque limits for metric fasteners. 2. Unless otherwise indicated, standard torque tolerance shall be 10 percent. 3. Torque values listed are based on clean, dry threads. Reduce torque by 10 percent when engine oil is used as a lubricant. Reduce torque by 20 percent if new plated capscrews are used. TIGHTENING METAL FASTENERS
NOTE
If replacement capscrews are of higher grade than originally supplied, use torque specifications for the original. This will prevent equipment damage due to overtorquing When torquing a fastener, select a wrench whose range fits the required torque value. A torque wrench is most accurate from 25 to 75 percent of its stated range. A wrench with a stated range of 0 to 100 Ib-ft (0 to 136 Nm) will be most accurate from 25 to 75 Ib-ft (34 to 102 Nm). The accuracy of readings will decrease as you approach 0 lbft or 100 lb-ft (136 Nm). Ranges in Table 1 are based on this principle. Table 1. Metal Fasteners. STATED RANGE 0 to 200 Ib-in. 0 to 600 lb-ft 0 to 170 lb-ft 15 to 75 lb-ft (0 to 23 Nm) (0 to 813 Nm) (0 to 230 Nm) (20 to 102 Nm) MOST EFFECTIVE RANGE 50 to 150 Ib-in. 50 to 450 lb-ft 44 to 131 lb-ft 30 to 30 lb-ft (6 to 17 Nm) (68 to 610 Nm) (60 to 178 Nm) (41 to 81 Nm)
0218-1
TM 5-3825-270-23&P SCOPE - Continued
0218
Figure 1. Torque Wrench Formula.
Figure 2. Torque Wrench Adapter Setups. INSTALLATION AND TORQUING 1. Matching Nuts. Matching nuts require a minimum height equal to the basic diameter of the bolt. The same is true of tapped holes. In tapped softer materials, the depth of the tapped hole should be 1-1/2 times the basic diameter of the bolt. 2. Threaded Protrusion. In all installations, bolts, studs, and screws must extend through the nut at least a length equivalent to two complete threads. This applies to both self-locking and plain nuts. 3. Torquing Self-Locking Nuts. To obtain the correct recommended torque value on self-locking nuts, the nut must be tightened until it is one turn from the beginning of seating. At this point, if the torque is less than 1/3 of the
0218-2
TM 5-3825-270-23&P SCOPE - Continued
0218
recommended torque, it should be disregarded and the nut tightened to the recommended torque value. If the torque is 113 or more of the recommended torque, it should be added to the recommended torque. Example: The recommended torque is 50 to 70 Ib-in. (6 to 8 Nm). The torque at one turn from seating is 30 lb-in. (3 Nm). The correct torque wrench reading would be 80 to 100 Ib-in. (9 to 11 Nm). 4. Retorquing Fasteners. Procedures intended for installing metal fasteners can cause incorrect readings when used to check or retorque already installed fasteners during maintenance. Before checking or retorquing an already installed threaded fastener, first mark the fastener and its companion components so the marks are in line. Second, back it off a 1/4 turn to loosen it. Torque it to the specification with an even steady pull on the torque wrench. The marks should be in line; if not, the marks will indicate the fastener was under- or over-torqued. 5. Standard Torque Charts. Standard torque charts have been established for dry and wet torque conditions. Surface variations such as thread roughness, scale paint, lubrication (oil, grease, etc.), hardening, and plating may alter these values considerably. Tables 2 and 3 are standard torque charts. 6. To find the grade of the screw that is to be installed, match the markings on the head to the correct picture of CAPSCREW HEAD MARKINGS in Tables 2 and 3. Manufacturer's marks may vary. Table 2. Torque Limits - SAE Standard Fasteners. QUALITY OF MATERIAL SAE Grade Number Capscrew Head Markings Manufacturer's Marks May Vary These are all SAE Grade 5 (3 line) CAPSCREW BODY SIZE IN. THREAD 1/4 20 28 18 24 16 24 14 20 INDETERMINAT E 1 or 2 MINIMUM COMMERCIAL 5 MEDIUM COMMERCIAL 6 or 7 BEST COMMERCIAL 8
TORQUE LB-FT (NM) 5 6 11 13 18 20 28 30 (7) (8) (15) (18) (24) (27) (38) (41)
TORQUE LB-FT (NM) 8 10 17 19 31 35 49 55 (11) (14) (23) (26) (42) (47) (66) (75)
TORQUE LB-FT (NM) 10 (14)
TORQUE LB-FT (NM) 12 14 24 27 44 49 70 78 (16) (19) (33) (37) (60) (66) (95) (106)
5/16
19
(26)
3/8
34
(46)
7/16
55
(75)
0218-3
TM 5-3825-270-23&P SCOPE - Continued Table 2. Torque Limits - SAE Standard Fasteners - Continued. QUALITY OF MATERIAL SAE Grade Number Capscrew Head Markings Manufacturer's Marks May Vary These are all SAE Grade 5 (3 line) CAPSCREW BODY SIZE IN. THREAD 1/2 13 20 12 18 10 16 10 16 9 14 8 14 INDETERMINAT E 1 or 2 MINIMUM COMMERCIAL 5 MEDIUM COMMERCIAL 6 or 7 BEST COMMERCIAL 8
0218
TORQUE LB-FT (NM) 39 41 51 55 83 95 105 115 160 175 235 250 (53) (56) (69) (75) (113) (129) (142) (156) (217) (237) (319) (339)
TORQUE LB-FT (NM) 75 85 110 120 150 170 270 295 395 435 590 660 (102) (115) (149) (163) (203) (231) (366) (400) (536) (590) (800) (895)
TORQUE LB-FT (NM) 85 (115)
TORQUE LB-FT (NM) 105 120 155 170 210 240 375 420 605 675 910 990 (142) (163) (210) (231) (285) (325) (508) (569) (820) (915) (1,234) (1,342)
9/16
120
(163)
5/8
167
(226)
3/4
280
(380)
7/8
440
(597)
660
(895)
0218-4
TM 5-3825-270-23&P SCOPE - Continued Table 3. Torque Limits - Metric Fasteners. Torque values for metric thread fasteners with lubricated* or plated threads
0218
Thread Diameter-Pitch
TORQUE: LB-FT (Nm) M6 M8 M8 x 1 M10 M10 x 1.25 M12 M12 x 1.5 M14 M14 x 1.5 M16 M16 x 1.5 M18 M18 x 1.5 M20 M20 x 1.5 M22 M22 x 1.5 M24 M24 x 2 M27 M27 x 2 M30 M30 x 2 5 (7) 12 (16) 13 (18) 24 (33) 27 (37) 42 (57) 43 (58) 66 (89) 72 (98) 103 (140) 110 (149) 147 (199) 165 (224) 208 (282) 213 (313) 283 (384) 315 (427) 360 (488) 392 (531) 527 (715) 569 (771) 715 (969) 792 (1,074)
TORQUE: LB-FT (Nm) 7 (9) 17 (23) 18 (24) 34 (46) 38 (52) 60 (81) 62 (84) 94 (129) 103 (140) 148 (201) 157 (213) 203 (275) 229 (310) 288 (390) 320 (434) 392 (531) 431 (584) 498 (675) 542 (735) 729 (988) 788 (1,068) 990 (1,342) 1,096 (1,486)
* All plated and unplated fasteners should be coated with oil before installation. Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed).
0218-5
TM 5-3825-270-23&P SCOPE - Continued FASTENER SIZE AND THREAD PATTERN
0218
Threaded fasteners are categorized according to diameter of the fastener shank. Thread styles are divided into broad groups, the two most common being coarse (Unified Course-UNC) and fine (Unified Fine-UNF). These groups are defined by the number of threads per inch in the bolt shanks. In addition, threads are categorized by thread class, which is a measure of the degree between threads of the bolt or screws (external threads) and threads of attaching nut or tapped hole (internal threads of attaching nut or tapped hole) (internal threads). The most common thread class for bolts and screws is Class 2. Table 4. Thread Classes and Description. EXTERNAL 1A 2A 3A INTERNAL 1B 2B 3B INTERNAL LOOSE FIT MEDIUM FIT CLOSE FIT
Figure 3. Fastener Size.
NOTE
Unless followed with "LH" (e.g., 3/4-10 UNC-2A-LH), threads are right-hand.
Figure 4. Thread Pattern.
0218-6
TM 5-3825-270-23&P
0218
0218-7/8 blank
TM 5-3825-270-23&P
CHAPTER 5 REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)
TM 5-3825-270-23&P FIELD MAINTENANCE FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
0219
INTRODUCTION SCOPE This Repair Parts and Special Tools List (RPSTL) lists and authorizes spares and repair parts; special tools; special test, measurement, diagnostic equipment (TMDE); and other special support equipment required for performance of field and sustainment maintenance. It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes. GENERAL In addition to the Introduction, this RPSTL is divided into the following sections: Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. The lists also include parts which must be removed for replacement of authorized parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number sequence. Bulk materials are listed by item name in FIG. BULK at the end of the RPSTL. Repair parts kits are listed separately in their own functional group at the end of the RPSTL. Special Tools List. A list of special tools, special TMDE, and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE column) for the performance of maintenance. EXPLANATION OF COLUMNS Item No. Indicates the number used to identify items called out in the illustration. SMR Code. The Source, Maintenance, and Recoverability (SMR) code is a 5-position code containing supply/ requisitioning information, maintenance category authorization criteria, and disposition instruction as shown in the following breakout. Table 1. SMR Codes Source Code xx Maintenance Code xx Recoverability Code xx
1st two positions: How 3rd position: Who can 4th position: Who can Last two positions: Who do you get an item install, replace, use the do complete repair* on determines disposition item the item action on an unserviceable item *Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the "Repair" function in a use/user environment in order to restore serviceability to a failed item. Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul on an end item/equipment. Explanation of source codes follows:
0219-1
TM 5-3825-270-23&P EXPLANATION OF COLUMNS - Continued Table 2. Source Code 1st and 2nd Positions Code PA PB PC** PD PE PF PG KD KF KB MO (Made at Service level) MF (Made at Field level) MH (Made at Below Depot level) ML (Made at Specialized Repair Activity SRA)) MD (Made at Depot) AO (Assembled by Service level) AF (Assembled by Field level) AH (Assembled by Below Depot level) AL (Assembled by SRA) AD (Assembled by Depot) XA Items with these codes are not to be requested/ requisitioned individually. They are part of a kit which is authorized to the maintenance category in the 3rd position of the SMR code. The complete kit must be requisitioned and applied. Items with these codes are not to be requested/ requisitioned individually. They must be made from bulk material which is identified by the part number in the DESCRIPTION AND USABLE ON CODE (UOC) column and listed in the Bulk Material group of the repair parts list in this RPSTL. If the item is authorized to you by the 3rd position of the SMR code, but the source code indicates it is made at a higher level, order the item from the higher level of maintenance. Items with these codes are not to be requested/ requisitioned individually. The parts that make up the assembled item must be requisitioned or fabricated and assembled at the level of maintenance indicated by the source code. If the 3rd position code of the SMR code authorizes you to replace the item, but the source code indicates the item is assembled at a higher level, order the item from the higher level of maintenance. Do not requisition an "XA" coded item. Order its next higher assembly. If an "XB" item is not available from salvage, order it using the CAGEC and part number given. Application/Explanation Stocked items; use the applicable NSN to request/requisition items with these source codes. They are authorized to the category indicated by the code entered in the 3rd position of the SMR code.
0219
XB***
0219-2
TM 5-3825-270-23&P EXPLANATION OF COLUMNS - Continued Table 2. Source Code 1st and 2nd Positions - Continued Code XC*** Application/Explanation Installation drawing, diagram, instruction sheet, field service drawing, that is identified by manufacturer's part number. Item is not stocked. Order an "XD" coded item through normal supply channels using the CAGEC and part number given, if no NSN is available.
0219
XD***
**NOTE: Items coded PC are subject to deterioration. ***NOTE: Cannibalization or controlled exchange, when authorized, may be used as a source of supply for items with this source code. Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to USE and REPAIR support items. The maintenance codes are entered in the 3rd and 4th positions of the SMR code as follows: Third Position. The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to the following levels of maintenance: Table 3. Maintenance Code 3rd Position Code C Application/Explanation Crew or operator maintenance done within Service level. Service level can remove, replace, and use the item. Field Support level can remove, replace, and use the item. Below Depot level can remove, replace, and use the item. Specialized repair activity can remove, replace, and use the item. Depot level can remove, replace, and use the item.
The maintenance code entered in the 4th position tells whether or not the item is to be repaired and identifies the lowest maintenance level with the capability to do complete repair (i.e., perform all authorized repair functions). (NOTE: Some limited repair may be done on the item at a lower level of maintenance, if authorized by the Maintenance Allocation Chart (MAC) and SMR codes.) This position will contain one of the following maintenance codes:
0219-3
TM 5-3825-270-23&P EXPLANATION OF COLUMNS - Continued Table 4. Maintenance Code 4th Position Code O Application/Explanation Service is the lowest level that can do complete repair of the item. Field level is the lowest level that can do complete repair of the item. Below Depot level is the lowest level that can do complete repair of the item. Depot is the lowest level that can do complete repair of the item. Nonrepairable. No repair is authorized. No repair is authorized. (No parts or special tools are authorized for the maintenance of a "B" coded item). However, the item may be reconditioned by adjusting, lubricating, etc., at the user level.
0219
Z B
Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on unserviceable items. The recoverability code is entered in the 5th position of the SMR Code as follows: Table 5. Recoverability Code 5th Position Code Z Application/Explanation Nonrepairable item. When unserviceable, condemn and dispose of the item at the level of maintenance shown in the 3rd position of SMR Code. Reparable item. When uneconomically reparable, condemn and dispose of the item at Service level. Reparable item. When uneconomically reparable, condemn and dispose of the item at Field level. Reparable item. When uneconomically reparable, condemn and dispose of the item at Below Depot Sustainment level. Reparable item. When beyond lower level repair capability, return to depot. Condemnation and disposal of item not authorized below Depot level. Reparable item. Condemnation and disposal of item not authorized below SRA.
0219-4
TM 5-3825-270-23&P EXPLANATION OF COLUMNS - Continued Table 5. Recoverability Code 5th Position - Continued Code A Application/Explanation Item requires special handling or condemnation procedures because of specific reasons (e.g., precious metal content, high dollar value, critical material, or hazardous material). Refer to appropriate manuals/directives for specific instructions.
0219
NSN. The National Stock Number (NSN) identifies the stock number of the item to be used for requisitioning purposes. CAGEC. The Commercial and Government Entity Code (CAGEC) is a 5-digit alphanumeric code which is used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item. Part No. 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, specification standards, and inspection requirements to identify an item or range of items. NOTE: When you use an NSN to requisition an item, the item received may have a different part number from the part ordered. Description. The Federal item name and, when required, a minimum description to identify the item. The physical security classification of the item is indicated by the parenthetical entry (none). Items that are included in kits and sets are listed below the name of the kit or set. Spare/repair parts that make up an assembled item are listed immediately following the assembled item line entry. Part numbers for bulk material are referenced in the line entry for the item to be manufactured/fabricated. When the item is not used with all serial numbers of the same model, the effective serial numbers are shown on the last line(s) of the description. UOC. The Usable on Code (UOC) identifies which models each part is applicable to. UPA. The Units Per Assembly (UPA) indicates the quantity of the item used in the breakout shown on the illustration figure, which is prepared for a functional group, subfunctional group, or an assembly. A "V" in the UPA in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application. SPECIAL INFORMATION Fabrication Instructions. Bulk materials required to manufacture items are listed in the Bulk Material Functional Group of this RPSTL. Part numbers for bulk materials are also referenced in the description of the line item entry for the item to be manufactured/fabricated. Detailed fabrication instructions for items source coded to be manufactured or fabricated are found in the Illustrated List of Manufactured Items in the Appendices of the maintenance manuals in this IETM. Assembly Instructions. Detailed assembly instructions for items source coded to be assembled from component spare/repair parts are found in the maintenance manuals of this IETM. Items that make up the assembly are listed immediately following the assembly item entry or reference is made to an applicable figure. Kits. Line item entry for repair parts kits appear in a group at the end of the RPSTL. END OF WORK PACKAGE
0219-5/6 blank
TM 5-3825-270-23&P FIELD MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST
0220
0220-1
TM 5-3825-270-23&P
0220
7 8 1 2 THROUGH 27 5 4 10 11 3 9
10 11
2
12
25 26
27
18
13
19 17 20 24
21
13
14
16 15
23
Figure 4002. Water Tank. (Sheet 1 of 3)
0220-2
TM 5-3825-270-23&P
0220
36
37 THROUGH 42
28 29
30
28 29 35 33
31 31 32 31
28 29
33 34
33
31
33
33 28 29
31
43
39 33 40 33
41 42
38 40
28 29
31 22
37 38
0220-3
TM 5-3825-270-23&P
0220
48 44 45 46 47 52 48 49 50 51
53 54
49 50
52 54
44
51
55
0220-4
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4002. WATER TANK. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PAFFF XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5315-00-234-1627 5315-01-540-8683 5310-01-588-6037 2590-01-588-7262 5310-01-591-0903 5340-01-540-8821 5340-01-540-9318 5340-01-588-6465 5330-01-540-9730 5305-01-134-0726 5310-01-591-0900 5340-01-588-6112 5306-00-537-8198 6680-01-588-5046 5305-01-588-6012 4510-01-082-9687 4730-01-588-7699 6680-01-588-5043 5331-01-588-6531 5310-01-588-6040 5340-01-588-6436 5330-01-588-6462 5310-00-935-9021 4730-01-588-7508 5305-01-529-4402 5310-00-761-6882 5310-01-357-8844 5340-01-588-6364 80195 80195 80205 80195 39428 80195 39428 80195 80195 80195 80195 39428 39428 80195 80063 80195 80195 80195 39428 80195 8L582 39428 80195 80195 96906 80195 2V507 96906 39428 80195 5251998 5251758 MS24665-391 2700233 90134A036 5252141 90040A137 2700243 2700241 5251959 2700248 92240A540 90047A029 5251979 490832Z26L 5251966 6100487 6600335 4638K822 5251791 OR-012-2885-633 92217A545 5251978 5251974 MS51943-35 5252157 92865A540 MS51967-2 91102A029 5252153
0220
(7) QTY
TANK ASSEMBLY .......................................... 1 . TANK,3000 GALLON .................................... 1 . PIN,COTTER ................................................. 2 . PIN,STRAIGHT HEADLESS ......................... 1 . WASHER,SPRING TENSION ....................... 2 . BRACKET,VEHICULAR COMPONENTS,KIT ........................................ 1 . NUT,SELF-LOCKING HEXAGON,1/2 ........... 2 . WINGNUT ..................................................... 1 . WASHER,SPACER ....................................... 1 . COVER,ACCESS .......................................... 1 . . GASKET,MANHOLE COVER ..................... 1 . SCREW,CAP,HEXAGON HEAD,1/4-20 X 1/2 ................................................................... 2 . NUT,SELF-LOCKING .................................... 5 . CLAMP,BLOCK ............................................. 2 . BOLT,MACHINE ........................................... 1 . FLOAT,SIGHT INDICATOR .......................... 1 . SCREW,CAP,HEXAGON HEAD,1/4-20 X 3/4 ................................................................... 3 . FLOAT,VALVE .............................................. 1 . PLUG-PIPE ................................................... 1 . SHAFT,FLOAT ARM ..................................... 1 . O-RING ......................................................... 1 . WASHER,FLAT 1/2 ....................................... 2 . CAP ............................................................... 1 . GASKET,TANK GAGE .................................. 1 . NUT,SELF-LOCKING HEXAGON,3/8-16 ..... 1 . SCREEN ....................................................... 1 . SCREW,CAP,HEXAGON HEAD,1/4-20 X 3/4 ................................................................... 1 NUT,PLAIN,HEXAGON 1/4-20 ....................... 6 WASHER,LOCK 1/4 ........................................ 6 PLATE,MOUNTING ........................................ 1
0220-5
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 31 32 33 34 35 36 37 38 39 40 41 42 43 44 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ 5355-01-588-6456 5310-01-563-4510 5340-01-588-7698 5305-01-566-1317 5340-01-588-7700 (3) NSN 5340-01-589-5099 5930-01-588-7240 5306-01-577-7639 5930-01-588-4569 5355-01-588-7477 5355-01-588-7637 5306-01-290-1676 (4) CAGEC 75272 80195 39428 80195 80195 80195 39428 80195 80195 3A054 80195 3A054 80195 80195 (5) PART NUMBER COV090921 5252137 92865A541 5252136 5252277 5251975 91257A583 0446363 5251976 95615A170 5251977 90128A587 6704032 9413948 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
CLAMP ............................................................ 8 SWITCH,MAGNETIC ...................................... 1 BOLT,MACHINE 1/4-20 X 7/8 ......................... 2 SWITCH,MAGNETIC ...................................... 1 DIAL,ENGRAVED ........................................... 1 DIAL POINTER ............................................... 1 . BOLT,MACHINE 5/16-18 X 1 ........................ 1 . WASHER,FLAT ............................................. 2 . DIAL POINTER 1/4 X 7/8 .............................. 1 . NUT,SELF-LOCKING HEXAGON ................. 2 . CLAMP-TANK GA.,POINTER ....................... 1 . SCREW,CAP,SOCKET HEAD,5/16-18 X 1 1/2 ................................................................... 1 MAGNET ......................................................... 1 NUT,SELF-LOCKING PART OF KIT P/N 7050803 5/8, PART OF KIT P/N 7050803 (80195) .......................................................... 48 WASHER,FLAT PART OF KIT P/N 7050803 5/8, PART OF KIT P/N COV1913Z1 (75272) ....... 24 STUD,TIEDOWN PART OF KIT P/N 7050803 PART OF KIT P/N 7050803 (80195) ............. 12 SPRING,HELICAL PART OF KIT P/N 7050803 COMPRESSION, PART OF KIT P/N 7050803 (80195) .......................................................... 12 NUT,SELF-LOCKING PART OF KIT P/N 7050804 HEXAGON, .875NC, PART OF KIT P/ N 7050804 (80195) ....................................... 16 WASHER,SNUB PART OF KIT P/N 7050804 PART OF KIT P/N 7050804 (80195) ............. 16 BUSHING ASSEMBLY PART OF KIT P/N 7050804 RING, PART OF KIT P/N 7050804 (80195) .......................................................... 16 BOLT PART OF KIT P/N 7050804 PART OF KIT P/N 7050804 (80195) .................................... 16 BAR,FLAT,ATTACH ........................................ 8 SCREW,CAP,HEXAGON HEAD,5/8-11 X 2 1/2 ................................................................... 4 WASHER,FLAT ............................................... 8 NUT,SELF-LOCKING HEXAGON 5/8 ............ 4
45 46 47
KFFZZ KFFZZ KFFZZ
5310-01-481-2060
19204 80195
RIA149111-4 3311945 6001225
5360-01-540-8782
80195
48
KFFZZ
5310-01-466-7854
39428
95615A290
49 50
KFFZZ KFFZZ 5365-01-541-2220
80195 80195
3311944 6420212
51 52 53 54 55
KFFZZ PFFZZ PAFZZ PAFZZ PAFZZ 5340-01-588-6312 5305-01-516-6272 5310-01-481-2060 5310-01-553-3078
80195 80195 39428 19204 0Y3H3
9421730 3311663 91257A804 RIA149111-4 0167012
END OF FIGURE
0220-6/7 blank
TM 5-3825-270-23&P
0220
4 5 15 16 THROUGH 21 6
1 2 3 7
22
1 8
9 10 11
14 21 20
13 5
19 18 17 16 10 12
Figure 4003. Flatrack.
0220-8
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4003. FLATRACK. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PBFHH PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5975-01-588-4599 5305-01-533-1178 5310-01-351-7793 5360-01-588-6485 3990-01-590-4391 5340-01-588-7602 5305-01-504-8288 5310-01-083-1540 2540-01-588-6106 5310-01-222-9097 5305-01-533-5700 5310-01-588-6075 3990-01-588-5068 3040-01-372-8553 3120-01-372-3618 3040-01-372-7046 5315-01-372-2507 5315-01-372-2508 5340-01-372-3866 5340-01-588-6495 5310-01-537-3529 0Y3H3 80195 80195 3A054 10988 80195 80195 75272 2V507 39428 80195 0Y3H3 39428 39428 80195 45152 45152 45152 45152 45152 45152 0HBT5 37262 0446363 5251832 92865A794 496-21053 6001509 5251793 COV1913Z1 92865A622 98026A031 5252333 37264 92865A714 98233A400 5250126 3HD598 1726860W 2HL808 1726740 1726750 2HL806 GOCB1515 8X24
0220
(7) QTY
NUT,PLAIN,HEXAGON ................................ 34 WASHER,FLAT ............................................. 20 TROUGH,WIRE .............................................. 4 SCREW,CAP,HEXAGON HEAD,5/8-11 X 1 ...................................................................... 2 WASHER,FLAT 1/2 ......................................... 2 MARKER,SPRING .......................................... 2 FLAT RACK ASSEMBLY ................................ 1 CLAMP,LOOP ............................................... 14 SCREW,CAP,HEXAGON HEAD,3/8-16 X 3/4 ................................................................... 2 WASHER,FLAT 3/8 ......................................... 4 SHIELD,MUD .................................................. 1 NUT,SELF-LOCKING HEXAGON,3/8-16 ....... 2 SCREW,CAP,HEXAGON HEAD,1/2-13 X 1 1/4 ................................................................... 8 NUT,FLANGED LOCKING,1/2-13 .................. 8 ROLLER ASSEMBLY ..................................... 2 . SHAFT,SHOULDERED ................................. 1 . ROLLER LINEAR-ROTARY MOTION .......... 1 . COLLAR,SHAFT ........................................... 1 . PIN,COTTER ................................................. 1 . PIN,QUICK RELEASE .................................. 1 . BRACKET SET,ANGLE ................................ 1 STRAP,NYLON ............................................... 2
END OF FIGURE
0220-9
TM 5-3825-270-23&P
0220
3 2 1 2 THROUGH 5 3 2 4 5
6 1 1
8 10 11 AND 12 7
13 5 5 12 11 10 4 4 6 7 8
Figure 4004. Hoses.
0220-10
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4004. HOSES. 1 2 3 4 5 6 7 8 9 10 11 12 13 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5315-01-457-2385 5310-01-557-0564 4730-01-588-8849 4730-00-929-0790 5330-01-577-5197 5340-01-588-6495 4720-01-588-9647 5330-01-577-5197 4730-00-929-0790 4730-00-929-0787 5330-01-577-5197 5306-01-577-7639 80195 72661 58536 96906 72661 39428 80195 39428 0Y3H3 80195 58536 72661 0HBT5 5251829 300-G-BU AA59326X1 MS27028-15 300-G-BU 92865A541 5252350 98497A661 37260 5251841 AA59326X1 300-G-BU GOCB1515 8X24
0220
(7) QTY
HOSE ASSEMBLY .......................................... 2 . GASKET ........................................................ 2 . PLUG,QUICK DISCONNECT ....................... 2 . CAP,QUICK ................................................... 2 . . GASKET ...................................................... 1 BOLT,MACHINE 1/4-20 X 7/8 ......................... 8 HOOK ASSEMBLY,HOSE .............................. 4 . PIN,QUICK RELEASE .................................. 4 NUT,SELF-LOCKING HEXAGON,3/8-16 ....... 8 STRAINER,FLOATING ................................... 1 . PLUG,QUICK DISCONNECT ....................... 1 . GASKET ........................................................ 1 STRAP,NYLON ............................................... 1
END OF FIGURE
0220-11
TM 5-3825-270-23&P
0220
2 THROUGH 11
12
8 7 9 3 10
12 11
8
13
4 8 7 6
12 12
8 7 6
14 15
16 5
Figure 4005. Fuel Tank.
0220-12
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4005. FUEL TANK. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ MFFZZ MFFZZ PAFZZ PAFZZ PAFZZ 5310-01-588-5831 5310-01-346-9434 5305-01-533-1178 4730-01-017-5119 2910-01-588-7684 2910-01-588-7517 5340-01-540-9792 6680-01-588-5064 4820-00-849-1220 4730-01-588-7557 4730-01-588-8617 4730-01-549-7172 4730-01-588-7504 80195 80195 10203 23224 58536 80195 80195 0SUA9 80195 39428 29510 80195 80195 0Y3H3 39428 3A054 5251876 5251818 5343-15 200328 A-A-59440/1-005 0105413 6603377 04HC 0105409 4638K651 343544R91 5252301 5252302 110166992 90108A035 92865A794
0220
(7) QTY
TANK,FUEL ASSEMBLY ................................ 1 . TANK,FUEL ................................................... 1 . CAP,FILLER OPENING ................................ 1 . GAUGE,FUEL ............................................... 1 . COCK,DRAIN ................................................ 1 . ELBOW,PIPE ................................................ 2 . ADAPTER,HOSE .......................................... 3 . CLAMP,HOSE ............................................... 4 . COUPLING,PIPE .......................................... 1 . BUSHING,PIPE ............................................. 1 . ADAPTER,HOSE .......................................... 1 HOSE MAKE FROM P/N 5633K22 (39428),300 INCHES ........................................................... 2 FUEL HOSE MAKE FROM P/N 7187-191 (81300),12 INCHES ........................................ 1 NUT,LOCK FLANGE ....................................... 4 WASHER,FLAT 5/8 ......................................... 4 SCREW,CAP,HEXAGON HEAD,5/8-11 X 1 ...................................................................... 4 END OF FIGURE
0220-13/14 blank
TM 5-3825-270-23&P
0220
5 THROUGH 18
3 2 2 1
5 6
7 8 9
10
18
11 12
14 15 16 14
16
17
13
Figure 4006. Stowage Box. (Sheet 1 of 2)
0220-15
TM 5-3825-270-23&P
0220
19
20
21 22 23
Figure 4006. Stowage Box. (Sheet 2 of 2)
0220-16
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4006. STOWAGE BOX. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ MFFZZ PAFZZ MFFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-222-9097 5306-01-346-3686 2540-01-588-7278 5310-01-487-6360 3120-01-588-5497 5320-01-588-6008 5340-01-591-0861 5310-01-273-1640 5310-01-583-5824 5310-01-553-3107 5340-01-588-6430 5320-01-580-0869 5310-01-082-8578 5310-01-481-2060 5305-01-533-1178 2540-01-588-7299 0Y3H3 19204 3A054 80195 39428 39428 39428 0Y3H3 0Y3H3 80195 3A054 80195 80195 0Y3H3 80195 39428 80195 80195 39428 80195 39428 80195 0Y3H3 37350 RIA149111-4 92865A794 5251877 90283A148 1864A11 90126A007 1133610 36020 5251984 97525A485 5252387 5252217 41418 5251983 3936T14 5251953 5251878 92356A624 5252226 90108A033 0446363 37264
0220
(7) QTY
NUT,PLAIN,HEXAGON 5/8 ............................ 6 WASHER,FLAT 5/8 ....................................... 12 SCREW,CAP,HEXAGON HEAD,5/8-11 X 1 ...................................................................... 6 BOX,ACCESSORIES STOWAGE .................. 1 . SCREW,MACHINE #6-32 X 1/2 .................... 4 . DRAW,LATCH ............................................... 2 . WASHER,FLAT #6 ........................................ 4 . WASHER,LOCK ............................................ 4 . NUT,PLAIN,HEXAGON #6-32 ...................... 4 . HINGE,DOOR ............................................... 1 . RIVET,POP ................................................... 4 . LATCH ........................................................... 2 . DOOR ............................................................ 1 . RIVET,POP ................................................. 18 . SEAL,TOOLBOX MAKE FROM P/N 6320883 (80195),94 INCHES ........................................ 1 . SLEEVE,STOP .............................................. 4 . CABLE,DOOR STOP MAKE FROM P/N 6001705 (80195),15 INCHES ......................... 2 . TOOLBOX ASSEMBLY ................................. 1 BOLT,SQUARE NECK .................................... 4 BOX,STORAGE .............................................. 1 WASHER,FLAT 1/2 ......................................... 4 WASHER,FLAT ............................................... 4 NUT,SELF-LOCKING HEXAGON,3/8-16 ....... 4
END OF FIGURE
0220-17/18 blank
TM 5-3825-270-23&P
0220
4 THROUGH 6
18
19 THROUGH 23
24
25 AND 26
25
26
10 THROUGH 12
22
23 4 5
29
30 THROUGH 32
10
11
1 2
40
41 THROUGH 43
1 13 14 THROUGH 17
3 2 7
31 32 28
8
10 12 11 29 30 14
2 40 43 42 39 41 37 8 2 1
28 27 15 25 26 23 8 22 17
16
21 38 20 37 19
36
33
34
35
Figure 4007. Pipes. (Sheet 1 of 4)
0220-19
TM 5-3825-270-23&P
0220
40
41 THROUGH 43
43
42 2
41 2
40
44
37
0220-20
TM 5-3825-270-23&P
0220
4 THROUGH 6
13
14 THROUGH 17
10 THROUGH 12
10
11
4 5 6 2
3 2
7
10 12 11 14
8 15 17
16
0220-21
TM 5-3825-270-23&P
0220
45
45
29
30 THROUGH 32
46 46 50 32 31 30 28 8 29 61 28 2 49 8 51 50 52
56
51
47
46
48 56 8 57 THROUGH 61
46
53
55 57
60
59
58
54
0220-22
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4007. PIPES. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 4730-01-588-8488 4730-01-588-8488 4730-01-589-0655 4010-01-204-1128 4010-01-589-7391 4010-01-204-1128 4010-01-589-7391 4730-01-589-0676 5330-01-588-5783 4710-01-589-7812 5310-01-588-6031 4730-01-588-8781 5310-01-588-5799 5305-00-782-9489 5330-01-588-6325 80204 3HMC9 13226 13226 13226 13226 80195 39428 80195 20266 72661 20266 80195 20266 80195 39428 80195 80195 39428 80195 80195 80195 20266 80195 20266
0220
(7) QTY
B1821BH038C200N SCREW,CAP,HEXAGON HEAD .................. 40 32491 WD301ALVB162 9Q5808 25884EY 9Q5818 5251901 91837A031 6201055 103099004 250-G-BU 62726000 5252353 00093001 6100740 8947T14 6001991 5252352 8947T14 6001991 6100740 6201054 33179000 6201053 11148001 W/ 62721000 STRAINER 62721000 5251911 32492 WD401ALVB162 9Q5818 GASKET .......................................................... 9 VALVE,BUTTERFLY 3 INCH DETENT .......... 2 . NUT,HEXAGON HEAD ................................. 2 . HANDLE ........................................................ 2 . SCREW,CAP,HEXAGON HEAD ................... 2 SIDE PIPE 3 INCH .......................................... 2 NUT,SELF-LOCKING 3/8 COARSE ............. 52 SUCTION ADAPTER (W/STRAINER) 3.0 NPT X 2.5 NST ........................................................... 2 . ADAPTER ..................................................... 2 . . GASKET ...................................................... 2 . STRAINER 2 1/2 INCH ................................. 2 CAP ASSEMBLY 2 1/2 INCH .......................... 2 . PLUG,PIPE 2 1/2 INCH ................................. 2 . SCREW,CAP,SOCKET #8 X 3/16 ................ 2 . LOOP,QUICK RELEASE .............................. 2 . LANYARD ..................................................... 2 CAP ASSEMBLY 5 INCH ................................ 1 . LOOP,QUICK RELEASE .............................. 1 . LANYARD ..................................................... 1 . SCREW,CAP,SOCKET #8 X 3/16 ................ 1 . HOSE CAP 5 INCH ....................................... 1 . . GASKET ...................................................... 1 SUCTION,ADAPTER ASSEMBLY .................. 1 . ADAPTER 4 INCH TO 5 INCH ...................... 1
26 27 28 29 30
PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ
4730-01-588-8620 4710-01-588-7562 5330-01-589-4078
20266 80195 3HMC9 13226 13226
. . STRAINER-SUCTION 5 INCH .................... 1 SIDE PIPE ASSEMBLY 4 INCH ..................... 1 GASKET .......................................................... 4 VALVE,BUTTERFLY 4 INCH DETENT .......... 2 . SCREW,CAP,HEXAGON HEAD ................... 2
0220-23
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-588-6031 5305-01-532-9137 5330-01-589-4078 4730-01-588-8514 4730-01-589-7672 4710-01-588-9535 4730-00-929-0787 5330-01-577-5197 4720-01-588-7513 5305-01-589-4136 5310-01-588-5799 5340-01-504-7309 4730-01-589-7635 5305-01-504-8288 5310-01-357-0876 5340-01-588-6421 5305-01-532-9137 4720-01-588-8624 4730-01-588-7583 5310-01-591-0897 4820-00-849-1220 4710-01-588-7551 5310-01-588-5799 (3) NSN (4) CAGEC 13226 13226 80195 39428 58536 80195 0JPJ8 80195 80195 13226 13226 13226 13226 80195 2V507 39428 80195 39428 1VMA4 96906 72661 80195 0JPJ8 55822 80195 80195 3HMC9 3HMC9 80195 39428 39428 (5) PART NUMBER 25884EY 9Q5808 0446363 90040A030 A-A-59440/1-005 5251904 HTBC350 5252117 5251927 WD304ALVB162 9Q5897 9Q5808 26284AL 5251913 92865A622 90108A031 5252012 92865A624 300-ALT-AL MS27028-15 300-G-BU 5252113 HTBC450 100228-12 6603986 5251895 S20152H 32492 7050806 91837A031 92865A624 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
. HANDLE ........................................................ 2 . NUT,HEXAGON HEAD ................................. 2 WASHER,FLAT 5/16 ....................................... 2 NUT,SELF-LOCKING HEXAGON,5/16-18 ..... 2 COCK,DRAIN .................................................. 1 PIPE ASSEMBLY METALLIC ......................... 1 CLAMP,HOSE 3 1/2 INCH .............................. 4 HOSE,NONMETALLIC ................................... 1 FLANGE 3 INCH ............................................. 1 VALVE,BUTTERFLY 3 INCH METER ............ 2 . SCREW,CAP,HEXAGON HEAD ................... 2 . NUT,HEXAGON HEAD ................................. 2 . HANDLE,RATCHETING, VALVE .................. 2 ELBOW 3 INCH .............................................. 1 SCREW,CAP,HEXAGON HEAD,3/8-16 X 3/4 ................................................................... 4 WASHER,FLAT ............................................... 8 PLATE SUPPORT CONNECT ........................ 1 SCREW,CAP,HEXAGON HEAD .................... 8 ADAPTOR-CAM TYPE 3 INCH ...................... 1 CAP,QUICK .................................................... 1 . GASKET ........................................................ 1 HOSE,WATER 4 INCH ................................... 1 CLAMP,HOSE 4 1/2 INCH .............................. 2 NOZZLE-SHAPERTIP .................................... 1 FOG NOZZLE-MANUAL ................................. 1 PIPE,STRAINER INTAKE ............................... 1 . STRAINER .................................................... 1 . GASKET ........................................................ 1 . CAP,STRAINER ............................................ 1 . NUT,SELF-LOCKING 3/8 COARSE ............. 1 . SCREW,CAP,HEXAGON HEAD ................... 8
END OF FIGURE
0220-24
TM 5-3825-270-23&P
0220
2 THROUGH 29 2
3 4 5 4 6 8 9 7 7 10 10 11 12 4 5
22
13 14 21 20 19 16 17 16 15
18
Figure 4008. Cab Control Box. (Sheet 1 of 2)
0220-25
TM 5-3825-270-23&P
0220
23
24 THROUGH 29
25
24
26
25 27 28 29 26 25 26 25
Figure 4008. Cab Control Box. (Sheet 2 of 2)
0220-26
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4008. CAB CONTROL BOX. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5325-01-590-0340 5310-00-761-6882 5310-01-357-8844 5310-01-357-8845 5305-00-068-7837 5340-01-589-9989 5340-01-588-3188 5930-01-084-2371 5930-01-321-4987 5930-01-589-1230 5340-01-589-9976 5340-01-589-9529 6680-01-589-8438 6220-01-589-0724 5930-01-589-0833 6695-01-545-5915 5305-01-590-9693 5310-01-572-2443 5365-01-097-5770 5940-00-276-0678 6150-01-589-8277 5940-00-276-0678 5940-00-813-0698 5940-00-436-1632 5940-00-143-4771 5940-00-557-1629 5940-00-230-0515 2510-01-590-8348 80195 80195 78276 96906 39428 39428 80204 80195 39428 80195 73559 5P209 80195 80195 03479 51054 80195 80195 39428 3A054 80195 00779 80195 00779 81343 56501 81343 81343 81343 5252004 5251999 AKS3T-832-80 MS51967-2 91102A029 91114A029
0220
(7) QTY
CAB CONTROL BOX ...................................... 1 . BOX,CAB CONTROL .................................... 1 . INSERT ......................................................... 6 . NUT,PLAIN,HEXAGON 1/4-20 ..................... 5 . WASHER,LOCK 1/4 ...................................... 4 . WASHER,LOCK ............................................ 2
B1821BH025C063N . SCREW,CAP,HEXAGON HEAD,1/4-20 X 5/8 ................................................................... 5 5252003 5685K39 6700255 6GM5M-68 0100-0001 5252001 5252002 ATA-30-24 651342042620 5252142 3361256 92210A203 98466A009 3360315 61765-2 5252008 61765-2 MS25036-101 RA257 MS25036-103 MS25036-149 MS25035-154 . PLATE,MOUNTING ...................................... 1 . MAGNET,PERMANENT ............................... 2 . SWITCH,TOGGLE 2 WAY ............................ 3 . SWITCH,TOGGLE MOMENTARY ................ 3 . SWITCH,PUSH BUTTON ............................. 1 . FACEPLATE,CAB CONTROL,EMM WD ...... 1 . OVERLAY,CAB CONTROL .......................... 1 . TACHOMETER,3000 RPM ........................... 1 . LIGHT,PILOT ................................................ 3 . GUARD,SWITCH .......................................... 1 . GUARD,CONTROL BOX .............................. 1 . SCREW,FLATHEAD ..................................... 6 . WASHER,COUNTERSUNK M8 .................... 6 . SPACER,SLEEVE ......................................... 6 . TERMINAL,QUICK DISCONNECT ............... 1 . HARNESS,CAB REMOTE CONTROL .......... 1 . . TERMINAL,QUICK DISCONNECT ............. 1 . . TERMINAL,LUG .......................................... 4 . . TERMINAL,QUICK DISCONNECT ........... 11 . . TERMINAL,STUD ....................................... 2 . . TERMINAL,LUG .......................................... 1 . . TERMINAL,LUG .......................................... 1
END OF FIGURE
0220-27
TM 5-3825-270-23&P
0220
5 6 1 3 2 7 4 7 8
12 11 16 15 13 9
10
11 11
6 5
14 27 19 24
7
17
20
23 25 18 26 22 18 19
20 21
Figure 4009. Battery Box Assembly.
0220-28
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4009. BATTERY BOX ASSEMBLY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PBFZZ PAFZZ PAFZZ PAFZZ PBFZZ PAFZZ PBFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-588-6075 2590-01-587-7205 6160-01-588-5051 5305-00-068-7837 5306-00-050-1237 5310-00-407-9566 6150-01-588-4894 5935-01-097-9974 5340-01-059-0114 5305-01-567-2506 6150-01-588-5022 5310-01-463-4929 6150-01-588-5026 5940-01-089-7066 5310-01-357-8844 5310-00-761-6882 5940-00-549-6581 6140-01-446-9506 5320-01-588-6336 5340-01-588-6478 6160-01-588-5056 5305-01-491-0478 5310-01-487-6360 5305-01-504-8288 5310-01-503-8765 5310-01-570-3917 6160-01-588-5036 39428 80195 80195 80204 80204 96906 80195 19207 19207 0KVE6 80195 39428 80195 45152 39428 96906 58536 19207 94222 80195 80195 0Y3H3 39428 2V507 1YHH8 0Y3H3 80195 98233A400 5251249 5251988
0220
(7) QTY
NUT,FLANGED LOCKING,1/2-13 .................. 2 BRACKET ....................................................... 1 BOX,NATO ...................................................... 1
B1821BH025C063N SCREW,CAP,HEXAGON HEAD,1/4-20 X 5/8 ................................................................... 4 B1821BH031F063N BOLT,MACHINE ............................................. 2 MS35338-45 5252132 11674728 11675004 92200A245 5252133 91831A011 5252131 117585A 91102A029 MS51967-2 A52425-1 6TMF/TYPEII 38-106-06-16 6001161 5251811 12233 90108A033 92865A622 8307110 1137264 5251940 WASHER,LOCK .............................................. 2 CABLE,NATO POS ......................................... 1 CONNECTOR RECEPTACLE,ELECTRICAL ......................... 1 CAP,PROTECTIVE DUST AND MOISTURE SEAL ............................................................... 1 SCREW,CAP,SOCKET HEAD ........................ 4 CABLE,NATO NEG ......................................... 1 NUT,SELF-LOCKING HEXAGON .................. 4 CABLE,JUMPER ............................................. 1 ADAPTER,BATTERY TERMINAL,NEG .......... 1 WASHER,LOCK 1/4 ........................................ 4 NUT,PLAIN,HEXAGON 1/4-20 ....................... 4 ADAPTER,BATTERY TERMINAL,POS .......... 1 BATTERY,STORAGE ..................................... 2 RIVET .............................................................. 8 LATCH ............................................................ 2 BATTERY BOX COVER ................................. 1 SCREW,CAP,HEXAGON HEAD,1/2-13 X 10 .................................................................... 2 WASHER,FLAT 1/2 ......................................... 2 SCREW,CAP,HEXAGON HEAD,3/8-16 X 3/4 ................................................................... 4 WASHER,FLAT 3/8 ......................................... 4 NUT,SELF-LOCKING HEXAGON .................. 4 BATTERY BOX,FLOOR ASSEMBLY ............. 1
END OF FIGURE
0220-29
TM 5-3825-270-23&P
0220
Figure 4010. Engine Pump Module.
0220-30
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4010. ENGINE PUMP MODULE. 1 PBFHH 2815-01-590-7072 80195 5252080
0220
(7) QTY
ENGINE PUMP MODULE ............................... 1
END OF FIGURE
0220-31
TM 5-3825-270-23&P
0220
8 THROUGH 22 3 4 21 5 22
18
19 AND 20
20 6 1 7 2 6 5 3 4 8 23 8 17 9
10
19
11
5 26
29
24 25
12
24 25
24
15 16
14
13
27
28
27 28 27 28 31 34 31 35 33
28
33
30
32
Figure 4011. Engine - Water Pump.
0220-32
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4011. ENGINE - WATER PUMP. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PBFHH PAFZZ PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5307-01-549-4029 5307-00-080-2016 5340-01-502-8758 5340-01-533-3344 4730-00-010-3867 5330-00-063-2437 4320-01-536-0845 5310-01-533-4987 5310-00-725-9479 5315-01-533-2469 3010-01-533-7689 5365-01-549-5606 3010-01-548-9543 5310-01-549-4033 5305-01-533-5619 5305-01-590-9670 5310-01-083-1540 5305-01-590-9673 5305-01-504-8942 5310-01-530-1545 5310-01-481-2060 4820-00-849-1220 5340-01-588-6475 5340-01-588-6358 5330-01-589-4078 4730-01-589-0721 4730-01-588-7549 5310-01-222-9097 80195 80195 0Y3H3 80195 80195 3HMC9 80195 25567 25567 15567 1CC55 81348 25567 1CC55 25567 25567 1CC55 25567 25567 1CC55 25567 1CC55 39428 39428 39428 39428 0Y3H3 19204 58536 80195 L238009 0179402 37264 0446363 5252086 32492 6602671 C0606-1/2 C0608 S1703 38818-020
0220
(7) QTY
ELBOW,PIPE .................................................. 1 ADAPTER,PIPE FITTING ............................... 1 NUT,SELF-LOCKING HEXAGON,3/8-16 ..... 16 WASHER,FLAT ............................................. 16 PLATE,FLANGE ............................................. 4 GASKET .......................................................... 2 PUMP .............................................................. 1 . STUD,PLAIN ............................................... 13 . STUD ............................................................. 3 . PLUG,VENT .................................................. 1 . PLATE,MOUNTING ...................................... 1
WW-P-471AASBUC . PLUG,PIPE ................................................... 1 4635GA 4635 J06-17000 D06 N0609 24391-101 24391-002 24391-003 24391-010 24391-011 91247A633 98026A031 91180A635 92865A626 37272 RIA149111-4 A-A-59440/1-005 5251938 . GASKET ........................................................ 1 . VALVE PLATE HYDRAULIC MOTORPUMP .............................................................. 1 . WASHER,LOCK ............................................ 4 . NUT,PLAIN,HEXAGON ................................. 4 . KEY,WOODRUFF ......................................... 1 . COUPLING HALF,SHAFT ............................. 1 . . CONNECTOR RING ................................... 1 . . FLEX ELEMENT ......................................... 1 . WASHER,LOCK ............................................ 6 . SCREW,CAP,HEXAGON .............................. 6 SCREW,CAP,HEXAGON HEAD,3/8-16 X 2 1/4 ................................................................... 8 WASHER,FLAT 3/8 ....................................... 12 SCREW,CAP,HEXAGON HEAD,M10 X 35MM .............................................................. 2 SCREW,CAP,HEXAGON HEAD,M10 X 30MM ............................................................ 10 NUT,SELF-LOCKING HEXAGON,5/8 ............ 6 WASHER,FLAT 5/8 ......................................... 8 COCK,DRAIN .................................................. 1 BRACKET ....................................................... 1
0220-33
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 31 32 33 34 35 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ (3) NSN 5306-01-533-5601 5305-01-572-0149 5365-01-588-6487 5340-01-383-4648 5340-01-588-6469 (4) CAGEC 39428 3A054 80195 81860 80195 (5) PART NUMBER 92865A589 91247A810 6400630 22003-12 5251937 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
BOLT,MACHINE HEAD,5/8 X 1 3/4 ................ 4 SCREW,CAP,HEXAGON HEAD,5/8-11 X 4 ...................................................................... 2 WASHER,SNUBBING ..................................... 2 MOUNT,RESILIENT GENERAL PURPOSE ....................................................... 2 BRACKET ....................................................... 1
END OF FIGURE
0220-34/35 blank
TM 5-3825-270-23&P
0220
2 THROUGH 7
1 1 7 2 7 3 4 6 4 3 6 2
5 3 4
5 3 4
Figure 4013. Engine - Pump Lights.
0220-36
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4013. ENGINE - PUMP LIGHTS. 1 2 3 4 5 6 7 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XAFZZ PAFZZ 5305-01-552-4533 6220-01-590-6280 5306-01-552-8677 5310-01-524-7656 5310-01-524-7436 5310-01-555-9058 80195 39428 39428 39428 39428 80195 39428 6704066 90185A583 91102A755 95462A030 98025A030 81250XA1 92865A591
0220
(7) QTY
LIGHT ASSEMBLY WORK, 24 VOLT ............. 2 . BOLT,SQUARE NECK 5/16-18 X 1 .............. 1 . WASHER,LOCK 5/16 .................................... 2 . NUT,PLAIN,HEXAGON 5/16-18 ................... 2 . WASHER,FLAT 5/16 ..................................... 1 . BRACKET ..................................................... 1 . SCREW,CAP,HEXAGON HEAD,5/16-18 X 2 ...................................................................... 1 END OF FIGURE
0220-37
TM 5-3825-270-23&P
0220
2 THROUGH 11
3 THROUGH 6 14
15 THROUGH 24
16
17 THROUGH 20
25
26 AND 27
6 7 5
4 3 7
7 8 10 8 7 11 13 7 12 13 12 18 17 15 21 21 21 31
12
19
20
21
22
23
25
26
22
29 30 24 22 28
27 13
30 12 25
26
21
28
32 13 27
Figure 4014. Engine - Pump Rear Piping. (Sheet 1 of 5)
0220-38
TM 5-3825-270-23&P
0220
34 42 43 AND 44 33 34 33
51
35 33 36
33 48 36 49 50
37 38
39 40 47 36 33 33 54
AU TI O N
41 48 49 36 33 51 47 36 42 50 43 44
51
55
53
56 55 54
52 36 33 51
CA UT IO N
46 45
0220-39
TM 5-3825-270-23&P
0220
57
58 59
60 71 70 58 12 65 62 64 63 61
29
68 60 58 67 30 12 66 30 12
0220-40
TM 5-3825-270-23&P
0220
72 73 74 THROUGH 90
77 78
92
93 THROUGH 95
74
75
76 79 80
81 87 88 89 79 80 87 88 90 89 86 85 84 32 91 85 86 81 76 82 83
13
93 94 95 96 92 97
12
13 12 30 12
98 99
69
0220-41
TM 5-3825-270-23&P
0220
100 101 60
102
104 100 103

0220-42
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4014. ENGINE - PUMP REAR PIPING. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PAFFF PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5305-00-782-9489 5306-01-321-8721 5310-01-083-1540 4710-01-590-8014 5305-01-590-0065 4710-01-590-8072 4730-01-322-6697 3825-01-323-0121 5330-01-322-6056 5305-01-564-2905 4730-01-328-5539 5305-01-590-9684 5365-01-228-4013 4730-01-590-8003 4710-01-590-8064 5310-01-222-9097 5330-01-588-6325 4730-01-590-8111 4730-01-322-6697 3825-01-323-0121 5330-01-322-6056 5305-01-564-2905 4730-01-328-5539 5305-01-590-9684 5365-01-228-4013 4730-01-590-8003 80195 80195 80195 80195 39428 80195 39428 80195 80195 39428 80195 0Y3H3 3HMC9 80195 80195 80195 80195 80195 39428 80195 39428 80195 80195 39428 13226 13226 13226 80204 80195 39428 80195 5251917 2940006 2940008 2940009 92240A539 2940007 92311A537 2940005 T204829 4638K151 5251914 37264 32491 5251918 5251919 2940006 2940008 2940009 92240A539 2940007 92311A537 2940005 T204829 4638K151 WD319ALVB162 9Q5856 46504AL
0220
(7) QTY
NOZZLE ASSEMBLY LEFT HAND ................. 1 . NOZZLE ASSEMBLY FLUSHER .................. 1 . . PLATE,BOTTOM FLUSHER NOZZLE ........ 1 . . GASKET ...................................................... 1 . . SCREW,CAP,HEXAGON HEAD ................. 8 . . NOZZLE,SPRAY FLUID EMULSION .......... 1 . SCREW,SET ................................................. 6 . RING,LOCKING ............................................ 3 . ELBOW,PIPE,90 ........................................... 1 . ELBOW,PIPE,90 ........................................... 1 . PIPE,WELDMENT LEFT HAND SPRAY ...... 1 NUT,SELF-LOCKING HEXAGON,3/8-16 ..... 40 GASKET 3 INCH ............................................. 6 NOZZLE ASSEMBLY RIGHT HAND .............. 1 . PIPE WELDMENT RIGHT HAND SPRAY .... 1 . NOZZLE ASSEMBLY .................................... 1 . . PLATE,BOTTOM FLUSHER NOZZLE ........ 1 . . GASKET ...................................................... 1 . . SCREW,CAP,HEXAGON HEAD ................. 8 . . NOZZLE,SPRAY FLUID-EMULSION .......... 1 . SCREW,SET ................................................. 6 . RING,LOCKING ............................................ 3 . ELBOW,PIPE,90 ........................................... 1 . ELBOW,PIPE,90 ........................................... 1 VALVE,BUTTERFLY 3 INCH .......................... 2 . SCREW,CAP,HEXAGON HEAD ................... 4 . ACTUATOR ................................................... 2
B1821BH038C200N SCREW,CAP,HEXAGON HEAD .................. 24 2990003 98026A031 5251922 U-BOLT,PIPE 4 INCH ..................................... 5 WASHER,FLAT 3/8 ......................................... 8 PIPE WELDMENT CANON ............................ 1
0220-43
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 PAFZZ PAFZZ PAFZZ MFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ MFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 4720-01-590-8103 5930-01-589-1217 4730-01-322-9122 4710-01-590-8065 5340-01-589-9972 4720-01-588-7513 4730-01-590-8077 5305-00-068-7837 5320-01-591-0920 4730-00-196-1464 5340-01-543-5018 4730-00-011-8831 4820-01-590-8060 5305-01-589-9552 5331-01-590-0077 4730-01-017-5119 5340-01-589-9517 5310-01-589-6059 5310-00-761-6882 5310-01-357-8844 4730-01-038-0435 4930-01-083-6045 (3) NSN 5305-01-504-8288 4730-01-569-0826 4730-01-590-8007 (4) CAGEC 2V507 1QNZ3 80195 80195 29510 80195 39428 96906 39428 62727 80195 98963 98963 39428 81346 72661 92878 80195 80195 80195 80195 80204 8J942 39428 80195 80195 0JPJ8 80195 0JPJ8 80195 85814 80195 (5) PART NUMBER 92865A622 62002 6602242 5252218 343544R91 5252119 93825A110 MS51967-2 91102A029 5404-04-04 6600137 LRP-96-736 GRP-96-710 4638K651 A733S-1CFG ASP-1BV 13336 5252120 6001943 5252219 0105416 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
SCREW,CAP,HEXAGON HEAD,3/8-16 X 3/4 ................................................................. 16 CLAMP,HOSE ................................................. 8 FITTING,ADAPTER ........................................ 2 HOSE,AIR MAKE FROM P/N 7187-191 (81300), 17 INCHES ...................................................... 1 ADAPTER,HOSE ............................................ 4 BRACKET,MOUNTING ................................... 1 NUT,CAPTIVE WASHER ................................ 4 NUT,PLAIN,HEXAGON 1/4-20 ....................... 2 WASHER,LOCK 1/4 ........................................ 2 NIPPLE,PIPE .................................................. 2 LUBRICATOR,AIRLINE .................................. 1 . BOWL,FLUID ................................................ 2 . O-RING ......................................................... 2 BUSHING,PIPE ............................................... 2 NIPPLE,PIPE .................................................. 2 VENT,BREATHER .......................................... 2 PLUG .............................................................. 2 VALVE,SOLENOID ......................................... 2 SCREW,MACHINE 3 MM ............................... 4 HOSE,AIR MAKE FROM P/N 7187-191 (81300), 13 INCHES ...................................................... 3 FITTING,TEE .................................................. 2
B1821BH025C063N SCREW,CAP,HEXAGON HEAD,1/4-20 X 5/8 ................................................................... 2 SD 53 BS 5252388 5252290 5252113 HTBC450 5251928 HTBC350 5252116 LM-T1A-150R/WD 6200292 RIVET .............................................................. 8 PLACARD-CAUTION ...................................... 2 PLATE,AIR VALVE ......................................... 1 HOSE,WATER 4 INCH ................................... 1 CLAMP,HOSE 4 1/2 INCH .............................. 6 PIPE ASSEMBLY PUMP INLET ..................... 1 CLAMP,HOSE 3 1/2 INCH .............................. 6 HOSE,WATER 3 INCH ................................... 1 SWITCH,PRESSURE ..................................... 1 NIPPLE,PIPE .................................................. 1
0220-44
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PBFFF PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ KFFZZ KFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ KFFZZ KFFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ 5305-01-589-4136 5340-01-504-7309 4710-01-590-8067 4730-00-172-0010 5310-01-589-9913 5310-01-475-9244 5340-01-589-9903 5310-01-589-9920 5310-01-589-9922 5340-01-589-9901 5305-01-237-6733 5355-01-589-9528 4730-01-590-8114 5330-01-589-4078 (3) NSN 4730-01-590-8074 4730-00-200-0531 4710-01-590-8063 5340-01-589-9514 4720-01-590-8097 (4) CAGEC 80195 93061 80195 80195 80195 80195 80195 3HMC9 72661 13189 13189 80195 13189 13189 39428 13189 13189 17576 13189 39428 13189 13189 13189 13189 13189 13189 13189 80195 13226 13226 13226 (5) PART NUMBER 0144083 125HBL-4-4 5251930 5252196 5252114 6602358 5251926 32492 PFC250F 925250-51 102537-1 5252355 925250-51ZA1 100287-21 92240A626 100127-742 103803-2 AN944-101 101715-38C 91831A127 103815-11 103817-11 105448-11 100083-16 103661-1 101497-50H 802090-91 5251920 WD304ALVB162 9Q5897 26284AL (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
TEE,PIPE 1/4 NPT .......................................... 1 ADAPTER PIPE TO HOSE ............................. 1 PIPE ASSEMBLY PUMP OUTLET ................. 1 BRACKET OUTLET CLAMP ........................... 1 HOSE,WATER 4 INCH ................................... 1 U-BOLT,PIPE 3 INCH ..................................... 2 FLANGE,WELDMENT 4 INCH ....................... 1 GASKET 4 INCH ............................................. 1 DUST CAP ...................................................... 1 TURRET ASSEMBLY ..................................... 1 . LOCK,KNOB ................................................. 1 . NUT,JAM ....................................................... 1 . PIPING,TURRET ........................................... 1 . HANDLE,TURRET ASSEMBLY,REMOVABLE,CIRCULAR .......... 1 . SCREW,MACHINE ....................................... 3 . SEAL,DIRT PART OF KIT P/N 103829-1 ..... 2 . SEAL,PRESSURE PART OF KIT P/N 103829-1 ......................................................... 2 . FITTING,ZERK PART OF KIT P/N 103829-1 ......................................................... 2 . WASHER,FLAT .390 ID X .62 OD X .063 THK ................................................................. 3 . NUT,SELF-LOCKING HEXAGON ................. 3 . LOCK HANDLE WELDMENT ....................... 1 . WASHER,FLAT ............................................. 2 . WASHER,FLAT ............................................. 2 . BEARING,BALL PART OF KIT P/N 103829-1 ..................................................... 168 . PLUG,BALL RETAINER PART OF KIT P/N 103829-1 ......................................................... 4 . RING,RETAINING PART OF KIT P/N 103829-1 ......................................................... 4 . INTAKE,BASE ............................................... 1 PIPE,WELDMENT TURRET ASSEMBLY ...... 1 VALVE,BUTTERFLY 3 INCH METER ............ 1 . SCREW,CAP,HEXAGON .............................. 1 . HANDLE,RATCHETING, VALVE .................. 1
0220-45
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 95 96 97 98 99 100 101 102 103 104 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5305-01-504-8942 5310-01-503-8765 5310-01-570-3917 4720-01-590-8107 4730-01-588-7549 (3) NSN 5310-01-588-5799 4730-01-590-8113 (4) CAGEC 13226 80195 1BMA4 80195 80195 1YHH8 0Y3H3 80195 80195 39428 (5) PART NUMBER 9Q5808 6601093 AL-A-200 0179402 6100731 8307110 1137264 5252112 5252106 92865A626 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
. NUT,HEXAGON HEAD ................................. 1 CAP,DUST 2 INCH ......................................... 1 ADAPTER,TYPE A 2 INCH ALUMINUM ........ 1 ADAPTER,PIPE .............................................. 1 BOLT,U 2 INCH .............................................. 1 WASHER,FLAT 3/8 ......................................... 4 NUT,SELF-LOCKING HEXAGON 3/8 ............ 2 HOSE,WATER 3 INCH ................................... 1 GRAVITY SPRAY BAR WELDMENT ............. 1 SCREW,CAP,HEXAGON HEAD,M10 X 30MM .............................................................. 2 END OF FIGURE
0220-46/47 blank
TM 5-3825-270-23&P
0220
3 2 4
6 7 12 6 8 8 6
6 7 6 7
9 10
9 10
11
11
Figure 4016. Engine - Pump Frame.
0220-48
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4016. ENGINE - PUMP FRAME. 1 2 3 4 5 6 7 8 9 10 11 12 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5340-01-588-6495 5310-01-508-8932 5310-01-591-0903 5305-01-533-5700 5306-01-485-8162 5310-01-346-9434 5310-01-553-3078 2510-01-588-7499 2510-01-588-7570 5310-01-588-6342 5305-01-325-8388 80195 80195 80205 80195 0HBT5 39428 39428 39428 39428 39428 0Y3H3 80195 5252077 5252085 MS90725-113 5252065 GOCB1515 8X24 90126A033 90040A137 92865A714 92865A802 90108A035 0167012 5252036
0220
(7) QTY
SCREEN,PLATFORM REAR .......................... 1 WASHER,FLAT ............................................... 4 SCREW,CAP,HEX HD HEAD,1/2-13 X 1 1/2 INCH ............................................................... 4 PLATFORM,MAIN ........................................... 1 STRAP,NYLON ............................................... 1 WASHER,FLAT 1/2 ....................................... 16 NUT,SELF-LOCKING HEXAGON,1/2 ............ 4 SCREW,CAP,HEXAGON HEAD,1/2-13 X 1 1/4 ................................................................... 6 BOLT,MACHINE 5/8-11 X 2 ............................ 8 WASHER,FLAT HEXAGON,5/8-11 .............. 16 NUT,SELF-LOCKING HEXAGON 5/8 ............ 8 FRAME,POWER UNIT .................................... 1
END OF FIGURE
0220-49
TM 5-3825-270-23&P
0220
6 AND 7
1 3 2
2 4 10 9
Figure 4017. Fire Extinguiser.
0220-50
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4017. FIRE EXTINGUISER. 1 2 3 4 5 6 7 8 9 10 PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 4210-01-541-0695 5305-00-068-7837 5310-01-357-8844 5310-01-557-0564 5305-01-532-9137 4210-00-775-0127 5310-01-559-7985 1KE74 80195 80195 39428 80244 03670 03670 80204 39428 0Y3H3 0129152 0446363 5251838 92865A624 AA393-A2B 429008 429146
0220
(7) QTY
NUT,PLAIN,EXTENDED WASHER,HEXAGON, 3/8-16 .............................................................. 3 WASHER,FLAT ............................................... 6 BRACKET,FIRE EXTINGUISHER .................. 1 SCREW,CAP,HEXAGON HEAD .................... 3 EXTINGUISHER,FIRE .................................... 1 . FIRE EXTINGUISHER HAND PORTABLE ..................................................... 1 . BRACKET,FIRE EXTINGUISHER ................ 1
B1821BH025C063N SCREW,CAP,HEXAGON HEAD,1/4-20 X 5/8 ................................................................... 4 91102A029 37260 WASHER,LOCK 1/4 ........................................ 4 NUT,SELF-LOCKING HEXAGON,3/8-16 ....... 4
END OF FIGURE
0220-51
TM 5-3825-270-23&P
0220
2 5 6 5 7 8 3 4 62 61 59 58 60 10 11 43 57 56 13 25 4 55 44 54 48 49 42 39 32 38 28 52 53 36 22 34 45 46 47 45 46 49 51 50 51 49 50 48 22 48 21 35 29 33 30 31 41 32 28 29 3 40 22 23 12 21 24 26 27 18 19 20 9 15 14 37 16 19 17 19 38 AND 39 6 7 1 2 THROUGH 65
Figure 4018. Engine - Pump Control Box. (Sheet 1 of 3)
0220-52
TM 5-3825-270-23&P
0220
2 THROUGH 65
63
64
65
0220-53
TM 5-3825-270-23&P
0220
68
69 AND 70
66
67
69
70
0220-54
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4018. ENGINE - PUMP CONTROL BOX. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 2510-01-590-8346 5340-01-589-9962 5310-01-533-1805 5310-01-357-8846 5310-01-550-0961 5340-01-589-9505 5305-01-589-6031 5320-01-591-0922 5365-01-590-8019 5340-01-589-9990 5930-01-589-0833 6680-01-589-8445 5975-01-589-1234 5310-01-583-5824 5310-01-273-1640 5310-01-553-3107 6150-01-590-5980 6150-01-589-8375 5940-01-461-2813 6150-01-589-8459 5310-00-761-6882 5310-01-357-8844 5940-00-113-8184 5925-01-441-6891 2530-01-460-5505 7690-01-589-9561 5930-01-589-2371 5310-01-590-0059 5935-01-589-1168 5310-01-589-9577 5935-01-589-0935 80195 80195 39428 39428 3A054 80195 0Y3H3 39428 80195 80195 80195 1ST83 80195 0Y3H3 39428 0Y3H3 80195 80195 08118 80195 96906 39428 81343 3XXE0 97539 80195 60886 80195 28520 80195 28520 5252096 5252095 90480A195 91102A011 90126A011 6001854 27554 97525A645 5252099 6703277 5252142 ATHA-30-24 5252094 1133610 90126A007 36020 5252103 5252101 8459-1 5252104 MS51967-2 91102A029 MS25036-150 716031 NC30307/16-28 6703409 HW1E-BV4F02-R 6704004 4531 6704005 4536
0220
(7) QTY
CONTROL BOX,MAIN .................................... 1 . COVER,CONTROL PANEL .......................... 1 . NUT,PLAIN,HEXAGON ................................. 6 . WASHER,LOCK ............................................ 6 . WASHER,FLAT ............................................. 4 . BUMPER ....................................................... 4 . SCREW,MACHINE ....................................... 4 . RIVET,BLIND ................................................ 2 . BUSHING ...................................................... 2 . COVER,DUST AND MOISTURE .................. 6 . GUARD,SWITCH .......................................... 1 . TACHOMETER W/HOUR ............................. 1 . OVERLAY ..................................................... 1 . WASHER,LOCK ............................................ 6 . WASHER,FLAT #6 ........................................ 6 . NUT,PLAIN,HEXAGON #6-32 ...................... 6 . JUMPER ........................................................ 1 . JUMPER ........................................................ 1 . STRIP,TERMINAL ......................................... 3 . JUMPER ........................................................ 1 . NUT,PLAIN,HEXAGON 1/4-20 ..................... 2 . WASHER,LOCK 1/4 ...................................... 6 . TERMINAL,LUG ............................................ 4 . CIRCUIT BREAKER ...................................... 1 . COVER,DUST AND MOISTURE .................. 1 . DECAL .......................................................... 1 . SWITCH,STOP ............................................. 1 . NUT,LOCK .................................................... 4 . CORD,GRIP ELECTRICAL ........................... 4 . NUT,LOCK .................................................... 1 . CORD,GRIP ELECTRICAL ........................... 1
0220-55
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ MFFZZ MFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 4320-01-086-2873 5975-01-589-1164 5305-00-068-7837 6625-01-590-6261 5310-01-572-2443 5305-01-590-9682 6685-01-590-6255 6685-01-590-6272 6220-01-589-0724 5320-01-584-6190 7690-01-588-7608 6150-01-590-5987 6150-01-590-5977 4730-00-200-0531 5930-01-589-1230 5930-01-321-4987 5930-00-615-9376 5325-01-590-0340 5340-01-588-6478 5305-01-455-1291 6685-01-590-6620 5930-01-097-9929 5940-00-276-0678 (3) NSN 5310-01-589-9576 5935-01-589-2364 5935-01-589-0971 5305-01-451-9220 5305-01-589-6035 6695-01-590-6262 (4) CAGEC 80195 28520 28520 39428 0Y3H3 80195 80195 78276 80195 39428 1ST83 81349 00779 39428 93061 5P209 73559 96906 80195 80195 1ST83 80195 80204 80195 3A054 39428 80195 80195 51054 39428 80195 80195 80195 (5) PART NUMBER 6704006 4548 4547 92865A542 27328 5252092 5252091 AKS3T-832-80 6001161 90276A829 6210000 M5423/07-03 61765-2 440605K121 125HBL-4-4 0100-0001 6GM5M-68 MS35059-21 5252098 5252097 SM50100 5252093 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
. NUT,LOCK .................................................... 2 . CORD,GRIP ELECTRICAL ........................... 1 . CORD,GRIP ELECTRICAL ........................... 1 . SCREW,CAP,HEXAGON HEAD ................... 1 . SCREW,MACHINE ....................................... 6 . BOX,CONTROL ............................................ 1 . . BOX,MAIN CONTROL WELDMENT ........... 1 . . INSERT ....................................................... 6 . LATCH ........................................................... 1 . SCREW,MACHINE ....................................... 4 . GAUGE,PRESSURE ..................................... 1 . COVER,SWITCH .......................................... 1 . TERMINAL,QUICK DISCONNECT ............... 1 . ELBOW ......................................................... 2 . ADAPTER ..................................................... 2 . SWITCH,PUSH BUTTON ............................. 1 . SWITCH,TOGGLE MOMENTARY ................ 3 . SWITCH,TOGGLE 3 WAY ............................ 3 . SEAL MAKE FROM P/N 93625K54(39428),6 1/2 INCHES ..................................................... 1 . SEAL MAKE FROM P/N 93625K54(39428),14 5/16 INCHES ................................................... 1 . GAUGE,PRESSURE ..................................... 1 . FACEPLATE ................................................. 1
B1821BH025C063N . SCREW,CAP,HEXAGON HEAD,1/4-20 X 5/8 ................................................................... 1 5252162 98466A009 92210A199 5252163 5252164 651342042620 97525A615 5252222 5252127 5252125 . GAUGE,VOLTAGE ....................................... 1 . WASHER,COUNTERSUNK M8 .................... 6 . SCREW,MACHINE M8-32 X 1 ...................... 6 . GAUGE,OIL PRESS ..................................... 1 . GAUGE,ENGINE TEMP ................................ 1 . LIGHT,PILOT ................................................ 3 . RIVET ............................................................ 6 . PLACARD-VALVE CONTROL,EMM - WD . . . 1 . HARNESS,WORK LIGHTS ........................... 1 . HARNESS,AIR VALVES ............................... 1
0220-56
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 65 66 67 68 69 70 PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ (3) NSN 6150-01-590-5976 6150-01-589-8213 6150-01-589-8198 6150-01-589-8458 5940-00-276-0678 5940-01-564-1378 (4) CAGEC 80195 80195 80195 80195 00779 39428 (5) PART NUMBER 5252130 5252129 5252128 5252124 61765-2 7113K825 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
. WIRE,GROUNDING ...................................... 1 HARNESS,TANK LEVEL ................................ 1 WIRE HARNESS,SYSTEM POWER .............. 1 WIRE HARNESS,MAIN CONTROL ................ 1 . TERMINAL,QUICK DISCONNECT ............... 1 . TERMINAL,LUG ............................................ 1
END OF FIGURE
0220-57/58 blank
TM 5-3825-270-23&P
0220
Figure 4020. Engine Assembly. (Sheet 1 of 2)
0220-59
TM 5-3825-270-23&P
0220
2 3 4
2 3 4
3 5 6 3 5 6
Figure 4020. Engine Assembly. (Sheet 2 of 2)
0220-60
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4020. ENGINE ASSEMBLY. 1 2 3 4 5 6 PBFHH PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 2815-01-590-7080 5310-01-530-1545 5365-01-588-6487 5340-01-383-4648 5310-01-481-2060 5305-01-572-0149 80195 0Y3H3 80195 81860 19204 3A054 6400626 37272 6400630 22003-12 RIA149111-4 91247A810
0220
(7) QTY
MODULE,ENGINE .......................................... 1 NUT,SELF-LOCKING HEXAGON,5/8 ............ 4 WASHER,SNUBBING ..................................... 8 MOUNT,RESILIENT GENERAL PURPOSE ....................................................... 4 WASHER,FLAT 5/8 ......................................... 6 SCREW,CAP,HEXAGON HEAD .................... 4
END OF FIGURE
0220-61
TM 5-3825-270-23&P
0220
2 THROUGH 12 7
7 THROUGH 9 8 9 2 3 4 6
10 13
5 21
11
14 15 16
20
17 18
12
17
19
17
Figure 4021. Air cleaner.
0220-62
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4021. AIR CLEANER. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-579-4031 5306-01-588-5842 2940-01-589-2068 2940-01-589-2059 2940-01-588-7559 2940-01-589-1648 4730-01-588-8557 4730-01-565-0170 2940-01-588-7612 4730-01-273-3672 4730-01-588-7564 2940-01-588-6088 4730-01-588-8542 4730-01-588-7524 2940-01-588-7701 4320-01-588-7419 5340-01-588-7543 62797 62797 62797 62797 62797 62797 62797 62797 62797 62797 62797 62797 5X475 62797 0Y3H3 62797 58536 62797 5X475 39428 0Y3H3 2.5-FO-2 68214 68215 68132-1 68213 68238 68715 68710 68717 68315 68355 68132-2 61513 33025 62022 DLOF20 A-A-52506-F-44 2.5-MF90 EW 10844 92501A030 1119916
0220
(7) QTY
FILTER ASSEMBLY,AIR ................................ 1 . CLAMP .......................................................... 2 . CLAMP,HINGE .............................................. 2 . CAP,FILTER .................................................. 1 . EJECTOR,INTERNAL ................................... 1 . BRACKET,CLAMP ........................................ 1 . . NUT,M6 ....................................................... 2 . . SPRING ....................................................... 2 . . BOLT,M6 ..................................................... 2 . ELEMENT,PRIMARY .................................... 1 . ELEMENT,SAFETY ...................................... 1 . BODY,FILTER ............................................... 1 PRECLEANER,AIR ......................................... 1 REDUCER,SLEEVE ....................................... 1 CLAMP,HOSE ................................................. 1 INDICATOR,DUST LOAD ............................... 1 CLAMP,HOSE ................................................. 3 ELBOW ........................................................... 1 HOSE,INTAKE,AIR ......................................... 1 NUT,SELF-LOCKING HEXAGON .................. 2 BOLT,FLANGE ............................................... 2
END OF FIGURE
0220-63
TM 5-3825-270-23&P
0220
2 3
Figure 4022. Coolant Recovery Tank.
0220-64
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4022. COOLANT RECOVERY TANK. 1 2 3 4 5 6 7 PAFZZ PAFZZ MFFZZ PAFZZ PAFZZ MFFZZ PAFZZ 5310-01-588-5825 2815-01-588-7539 4730-01-524-7708 5305-01-572-8716 5340-01-588-6658 39428 5X475 39428 5X475 39428 39428 0Y3H3 91180A626 EW 10813 5633K22-45 81500001 5388K14 5633K22-25 0160517
0220
(7) QTY
SCREW,FLANGE M10 - 1.25 X 20 ................. 2 SUPPORT ....................................................... 1 HOSE MAKE FROM P/N 5633K22 (39428),45 INCHES ........................................................... 1 TANK COOLANT RECOVERY ....................... 1 CLAMP,HOSE ................................................. 1 HOSE MAKE FROM P/N 5633K22 (39428),25 INCHES ........................................................... 1 NUT,FLANGE 5/16-18 .................................... 4
END OF FIGURE
0220-65
TM 5-3825-270-23&P
0220
5 4
3 2
10 13 14 15 12
13 14 15
7 3
16 17 18 19
11 12
16
10
20
18 19
Figure 4023. Engine Enclosure.
0220-66
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4023. ENGINE ENCLOSURE. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PAFZZ PAFZZ MFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PCFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-588-2727 5310-01-588-6023 5310-01-588-6019 5342-01-332-3586 5340-01-588-6656 5365-01-589-7523 5305-00-226-4832 5340-01-588-6653 5340-01-588-6648 5340-01-588-6644 5305-01-588-5801 2930-01-588-7581 5340-01-588-6618 2930-01-588-7615 9330-01-588-7632 5306-01-589-2418 5340-01-588-6650 0Y3H3 5X475 5X475 5X475 5X475 5X475 5X475 5X475 5X475 5X475 5X475 5X475 0Y3H3 0Y3H3 0Y3H3 76005 5X475 5X475 80204 5X475 19916 EW 11352 EW 11380-27.25 EW 11358 BF ST-2710 EW 11359 EW 11428 EW 11356 EW 10777 EW 11643 EW 11357 EW 11642 70712 78067 71017 CB-1120-10 EW 11318 PPI14727
0220
(7) QTY
SCREW,CAP,HEXAGON HEAD,5/16-18 X 3/4 ................................................................. 24 ENCLOSURE,REAR ASSY ............................ 1 GASKET,FOAM MAKE FROM P/N EW 11380 (5X475),27 1/4 INCHES .................................. 2 ENCLOSURE,TOP ......................................... 1 SCREW,THUMB 5/16 X 5/8 ............................ 2 COVER,RADIATOR CAP ............................... 1 PANEL,SIDE ASSEMBLY ............................... 2 ENCLOSURE,FRONT .................................... 1 FOAM,BARRIER ............................................. 4 SUPPORT,PLATE .......................................... 2 RAIL,SIDE ....................................................... 2 SUPPORT,PLATE .......................................... 2 NUT,HEX ........................................................ 4 WASHER,LOCK .............................................. 4 WASHER,FLAT ............................................... 4 MOUNT,ISOLATOR ........................................ 4 SUPPORT,LH ................................................. 1 WASHER,SPACER ......................................... 4
B1821BH031C175N BOLT,MACHINE HEAD,3/8-16 X 1 3/4 ........... 4 EW 11319 SUPPORT,RH ................................................. 1
END OF FIGURE
0220-67
TM 5-3825-270-23&P
0220
4 5 6
2
10
1 7 8
3 4
12
11
5 6
10
8 9
Figure 4024. Engine and Mounts.
0220-68
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4024. ENGINE AND MOUNTS. 1 2 3 4 5 6 7 8 9 10 11 12 PBFHH PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 2815-01-590-7339 2510-01-588-7335 5310-01-588-2718 5305-00-071-2069 5310-01-508-8995 5306-01-513-8491 2510-01-588-7330 5310-01-557-0524 5310-01-564-3336 5305-01-588-6001 2510-01-588-6114 2510-01-588-6116 5X475 5X475 0Y3H3 80204 2V507 1YHH8 5X475 0Y3H3 0Y3H3 0Y3H3 5X475 5X475 1J405-34000 EW 11315 78071
0220
(7) QTY
ENGINE,BASIC ............................................... 1 MOUNT,ENGINE REAR LH ............................ 1 WASHER,LOCK 1/2 ........................................ 4
B1821BH050C150N SCREW,CAP,HEXAGON 1/2-13 X 1 1/2 ........ 4 91102A033 8303625 EW 11313 40359 40254 38727 EW 11314 EW 11316 WASHER,LOCK 1/2 ........................................ 4 BOLT,CLOSE TOLERANCE,1/2-13 X 1 1/4 ................................................................... 4 MOUNT,ENGINE FRONT LH ......................... 1 WASHER,FLAT M12 ....................................... 8 WASHER,LOCK M12 ...................................... 8 SCREW,CAP,HEXAGON HEAD,M12-1.25 X 30 .................................................................... 8 MOUNT,ENGINE FRONT RH ......................... 1 MOUNT,ENGINE REAR RH ........................... 1
END OF FIGURE
0220-69
TM 5-3825-270-23&P
0220
5 4
7 8 9
10
Figure 4025. Exhaust Muffler.
0220-70
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4025. EXHAUST MUFFLER. 1 2 3 4 5 6 7 8 9 10 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 2990-01-588-7403 5306-01-588-5995 2990-01-588-7397 5305-01-588-6057 5340-01-588-7610 5310-01-588-5825 2990-01-588-7601 5310-01-500-2378 5310-01-500-2376 5330-01-533-7589 3HGG0 39428 80195 39428 3HGG0 0Y3H3 5X475 0XWR1 0XWR1 3H244 M065044 3042T92 5252121 92979A249 M002118 0160517 EW 11228 02176-50100 04512-60100 19258-12230
0220
(7) QTY
MUFFLER,EXHAUST ..................................... 1 CLAMP,EXHAUST 2 1/2 INCH ID .................. 2 PIPE,EXHAUST .............................................. 1 SCREW,FLANGE HEAD 5/16-18 X 3/4 .......... 4 CLAMP,BAND ................................................. 2 NUT,FLANGE 5/16-18 .................................... 4 TUBE,FLEX,EXHAUST ................................... 1 NUT,PLAIN,HEXAGON .................................. 4 WASHER,LOCK .............................................. 4 GASKET .......................................................... 1
END OF FIGURE
0220-71/72 blank
TM 5-3825-270-23&P
0220
6 THROUGH 9
1 2 4
1 2 3
7 6
15 10 18 10 5 5 2 10 15 2
9 10
11
17
14 16 2 10 13 12
Figure 4026. Intruments and Controls. (Sheet 1 of 4)
0220-73
TM 5-3825-270-23&P
0220
25
26 AND 27
20 19 22 21
23
24
33 13 25
32
26 27 28 31 30
29
0220-74
TM 5-3825-270-23&P
0220
34
35
36
37
38
39
40
41
0220-75
TM 5-3825-270-23&P
0220
42
0220-76
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4026. INTRUMENTS AND CONTROLS. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-559-7078 5930-01-578-0722 5306-01-533-3783 5310-01-357-8844 5305-01-451-9220 5305-01-589-6044 2920-01-590-4085 5310-00-407-9566 5310-01-589-6053 5310-01-533-1805 5310-01-530-1515 5310-00-761-6882 2990-01-590-4370 5310-01-290-2196 5310-01-530-1515 5310-01-550-0961 5342-01-235-7666 5340-01-322-7104 5305-01-529-4402 5310-01-357-8845 5306-01-533-7420 2910-01-590-4371 5306-01-533-2070 5310-01-533-3780 5340-01-590-0076 6680-01-590-6640 6685-01-551-8544 39428 39428 39428 39428 SH703 80205 39428 39428 0Y3H3 96906 5DR61 39428 0Y3H3 3A054 19200 06721 2V507 39428 1Q0C4 5DR61 1Q0C4 39428 5X475 5X475 03479 1Q0C4 39428 5X475 0Y3H3 1Q094 92865A537 91102A029 92865A542 90283A245 SAS-4410 MS35338-45 90480A225 90480A195 33614 MS51967-2 9493 90631A011 33614 90126A011 9360009 1511-5 92865A540 91114A029 0131-10616 9494-24 01774-51018 91202A242 EP-10769 11210-210 ESP-100 15841-39010XA1 91202A226 15841-39010 69955 19484-95981
0220
(7) QTY
SCREW,CAP,HEXAGON HEAD,1/4 X 1/2 ..... 4 WASHER,LOCK 1/4 ...................................... 11 SCREW,CAP,HEXAGON HEAD,1/4 X 1 INCH ............................................................... 1 SCREW,MACHINE ......................................... 4 RELAY,STARTER ........................................... 2 . WASHER,LOCK 5/16 .................................... 4 . NUT,MACHINE 5/16-24 ................................ 4 . NUT,PLAIN,HEXAGON 10-30 ...................... 4 . WASHER,LOCK 10 ....................................... 4 NUT,PLAIN,HEXAGON 1/4-20 ....................... 9 GOVERNOR CONTROL MODULE ................ 1 NUT,SELF-LOCKING HEXAGON .................. 4 WASHER,LOCK 10 ......................................... 4 WASHER,FLAT ............................................... 4 ISOLATOR ...................................................... 4 CLAMP ............................................................ 3 SCREW,CAP,HEXAGON HEAD,1/4-20 X 3/4 ................................................................... 3 WASHER,LOCK 1/4 ........................................ 1 BOLT,MACHINE ............................................. 2 ACTUATOR,24V ............................................. 1 BOLT,MACHINE ............................................. 2 WASHER,LOCK .............................................. 2 PLATE,MOUNT,PICKUP ................................ 1 SWITCH,MAGNETIC ...................................... 1 SENDING UNIT .............................................. 1 . SCREW,MACHINE ....................................... 1 . WASHER,LOCK M4 ...................................... 1 SWITCH,PRESSURE ..................................... 1 FITTING,TEE .................................................. 1 ELBOW ........................................................... 1
0220-77
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE 31 32 33 34 35 36 37 38 39 40 41 42 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ (3) NSN 5930-01-589-2484 5930-01-589-2385 5310-01-533-1805 6150-01-590-5995 6150-01-590-6008 6150-01-590-6084 6150-01-590-6165 6150-01-590-6110 6150-01-590-6100 6150-01-590-6070 6150-01-590-6065 6150-01-590-6171 (4) CAGEC 1Q094 03479 39428 80195 80195 80195 80195 80195 80195 80195 80195 80195 (5) PART NUMBER 51601-37671 EST-250/300-5/8 90480A195 5252190 5252193 5252194 5252191 5252189 5252126 5252135 5252134 5252187 (6) DESCRIPTION AND USABLE ON CODE (UOC)
0220
(7) QTY
SWITCH,TEMPERATURE .............................. 1 SWITCH,TEMPERATURE .............................. 1 NUT,PLAIN,HEXAGON 10-30 ........................ 1 WIRE,SOLENOID ........................................... 1 WIRE,GLOW RELAY ...................................... 1 WIRE,STARTER ............................................. 1 WIRE,GLOWPLUG ......................................... 1 WIRE,ALTERNATOR ...................................... 1 HARNESS,PRESSURE SWITCH ................... 1 CABLE,GROUND ........................................... 1 CABLE,POSITIVE ........................................... 1 HARNESS,ENGINE ........................................ 1
END OF FIGURE
0220-78/79 blank
TM 5-3825-270-23&P
0220
2 THROUGH 12
13 14
15
16 17
3 THROUGH 5
4 18 3 5 6
4 12
7 24 23 8
23
23
11 21
22
10
21 25 20 19
Figure 4027. Radiator.
23
0220-80
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4027. RADIATOR. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PFFFF XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PFFZZ PAFZZ PBFZZ PBFZZ 5340-01-589-7404 5310-01-555-4988 2930-01-589-1630 5340-01-588-7579 5306-01-535-8160 2930-01-589-1641 5305-01-588-6050 5305-00-071-2074 5365-01-588-5833 5340-01-588-6183 2930-01-588-5911 4730-00-204-3491 2930-01-588-6135 5305-01-589-4144 2930-01-588-6129 5305-01-559-0882 2930-01-588-7604 2930-01-588-5900 2930-01-589-1619 5X475 5X475 5X475 39428 5X475 39428 5X475 5X475 5X475 39428 5X475 39428 0Y3H3 5X475 5X475 0Y3H3 5X475 39428 80204 0Y3H3 5X475 5X475 58536 5X475 5X475 79000625 99600046 89600399 98093A312 89600398 92316A536 89100402 69300001 69000625 4513K322 63500250 8087K14 37340 EW 10652 TPC 51328 0161881 EW 10651 92979A245
0220
(7) QTY
RADIATOR ASSEMBLY ................................. 1 . GUARD,FAN ASSEMBLY ............................. 1 . . SHROUD,FAN RH ...................................... 1 . . BOLT ......................................................... 10 . . SHROUD,FAN LH ....................................... 1 . SCREW,CAP,HEXAGON HEAD ................... 6 . SHROUD,FAN ............................................... 1 . CAP,RADIATOR ........................................... 1 . RADIATOR .................................................... 1 . PLUG ............................................................. 1 . DRAIN ........................................................... 1 . PLUG ............................................................. 6 NUT,PLAIN,HEXAGON .................................. 1 SUPPORT,RADIATOR UPPER ...................... 1 ISOLATOR 5/16M X F STUD MOUNT ........... 1 BOLT,MACHINE HEAD,M8-1.25 X 20 ............ 4 SUPPORT,RADIATOR UPPER ...................... 1 HEX FLANGE BOLT 5/16-18 X 5/8 ................ 1
B1821BH050C275N SCREW,CAP,HEXAGON HEAD,1/2-13 X 2 3/4 ................................................................... 2 11101280 60270-2 EW 11536 A-A-52506-F-32 68900652 68900653 WASHER,SPACER 1/2 X 2 X 1/8 ................... 2 WASHER,SPACER ......................................... 2 SUPPORT,RADIATOR LOWER ..................... 1 CLAMP,HOSE ................................................. 4 HOSE,PREFORMED RADIATOR,UPPER ..... 1 HOSE,PREFORMED LOWER ........................ 1
END OF FIGURE
0220-81/82 blank
TM 5-3825-270-23&P
0220
15
16 THROUGH 18
2 2
4 6
18
17
16
14
13 12
11
10 9 8 7
Figure 4029. Pump Housing. (Sheet 1 of 2)
0220-83
TM 5-3825-270-23&P
0220
19
20 AND 21
23
21 20 22
26
12
19
25
24
Figure 4029. Pump Housing. (Sheet 2 of 2)
0220-84
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4029. PUMP HOUSING. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XCFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5331-01-533-7418 4730-01-533-2896 5306-01-358-9526 2910-01-524-9666 4730-01-588-7625 5330-01-588-5791 5310-01-533-2080 5310-01-589-5778 5365-01-533-2987 5310-01-533-9486 2815-01-536-0879 4710-01-588-7644 4730-01-588-7621 5330-01-588-5747 4730-01-588-8518 2910-01-588-7590 5330-01-533-4948 4730-01-533-2846 5330-01-506-5021 5360-01-533-4688 4820-01-583-4853 5330-01-524-7393 5306-01-588-5732 5306-01-533-8062 5306-01-588-5761 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 5X475 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 0MR83 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1G596-3331-3 1C020-9581-0 1C020-9673-0 1G596-3328-0 1G574-5165-0 1C010-5166-0 1C010-3696-0 15451-9667-0 1C010-3695-0 1C010-3692-2 1C010-0414-0 01754-50825 01754-50875 1G596-9101-0 1C020-0401-0 19202-9683-0 1C010-3288-0 01754-50820 1C010-5101-0 1C010-5132-0 15401-9665-0 15401-9569-0 1C010-9202-0 1C010-5211-0 02751-50080 14311-6050-4
0220
(7) QTY
PIPE,LUBE ...................................................... 1 BOLT,BANJO .................................................. 2 GASKET .......................................................... 2 LINE,INJECTOR PUMP LUBE ....................... 1 COVER,INJECTOR PUMP ............................. 1 GASKET,COVER ............................................ 1 PLUG .............................................................. 1 GASKET .......................................................... 1 SPRING .......................................................... 1 VALVE,RELIEF ............................................... 1 SEAL,PLAIN .................................................... 1 BOLT,FLANGE ............................................... 4 BOLT,MACHINE ............................................. 4 BOLT,FLANGE ............................................... 1 ASSEMBLY,CASE GEAR ............................... 1 . O-RING ......................................................... 1 . CAP,LUBRICATION FITTING, PROTECTIVE ................................................. 1 . BOLT,MACHINE ........................................... 4 INJECTOR ASSEMBLY FUEL ........................ 1 . SCREW,HOLLOW ........................................ 1 . GASKET ........................................................ 2 JOINT,EYE ...................................................... 1 NUT,SELF-LOCKING HEXAGON .................. 1 SHIM ............................................................... 1 NUT,PLAIN,PLATE ......................................... 3 JET START COCK .......................................... 1
END OF FIGURE
0220-85
TM 5-3825-270-23&P
0220
4 THROUGH 14
4 1 2 1 14 13 12 8 5 6 7
7 11
9 10
Figure 4030. Head Cover.
0220-86
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4030. HEAD COVER. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ XAFZZ XAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5305-01-533-2067 5330-01-524-7680 5306-01-533-2940 5331-01-583-5360 5365-01-589-3941 4730-01-588-8046 4720-01-534-0036 2815-01-588-7417 5305-01-533-2472 4820-01-533-3294 4820-01-536-0898 4730-01-533-2129 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 03798 1Q0C4 16241-3351-0 1C010-0551-0 1C010-1450-6 03054-50508 1C010-0512-0 1C010-0520-0 06311-85016 1C010-1450-A 1J510-0537-0 03054-50408 1C010-1452-0 1C010-9102-0 53120 1C010-3308-0
0220
(7) QTY
CLAMP,HOSE ................................................. 2 HOSE,NONMETALLIC ................................... 1 COVER ASSEMBLY VALVE .......................... 1 . SCREW,TAPPING ........................................ 6 . CAP,VALVE .................................................. 1 . VALVE,PRESSURE EQUALIZING, GASEOUS PRODUCTS .................................................... 1 . PLUG,TUBE FITTING THREADED .............. 2 . COVER,CYLINDER HEAD ........................... 1 . SHIELD,OIL BREATHER .............................. 3 . SCREW,TAPPING ........................................ 6 . GASKET ........................................................ 1 . BOLT,MACHINE ......................................... 10 . O-RING ......................................................... 1 . PLUG ASSEMBLY ........................................ 1
END OF FIGURE
0220-87
TM 5-3825-270-23&P
0220
6 5 7 3
Figure 4031. Cylinder Head.
0220-88
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4031. CYLINDER HEAD. 1 2 3 4 5 6 7 8 PAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5306-01-588-5730 5340-01-533-3726 2815-01-536-0830 5307-01-533-2948 5310-01-533-9486 5330-01-588-5749 5306-01-533-9220 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1C010-0345-0
0220
(7) QTY
BOLT,MACHINE ........................................... 18
1K011-006-10NHAC ROCKER ARM ASSEMBLY ........................... 1 01754-50814 12234-6758-0 15471-0174-0 15221-9153-0 02751-50080 1C020-0331-0 BOLT,FLANGE ............................................... 3 BRACKET,ANGLE .......................................... 1 ENGINE HOOK ............................................... 2 STUD .............................................................. 1 NUT,PLAIN,PLATE ......................................... 1 GASKET,CYLINDER HEAD ........................... 1
END OF FIGURE
0220-89
TM 5-3825-270-23&P
0220
2 THROUGH 10
7 AND 8 2
4 5
13
11
11 8
11
12
9
11 10
Figure 4032. Fuel Filter.
0220-90
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4032. FUEL FILTER. 1 2 3 4 5 6 7 8 9 10 11 12 13 PAFZZ PAFZZ PAFZZ PAFZZ XAFZZ PAFZZ XAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5365-10-588-5751 4820-01-588-8536 4730-01-359-4772 4720-01-588-7449 4720-01-588-8838 2910-01-524-7650 2910-01-588-7627 5306-01-588-5739 5365-01-588-5754 5331-01-588-5793 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 98255 1Q0C4 1Q0C4 1K011-4301-0 01774-51030 1K011-4328-0 14301-4329-0 1K011-4301-30 1K011-43060 1K011-4314-0 1K011-4306-10 1K011-4389-0 1K011-4327-0 14911-4275-0 09661-70500 09661-70625
0220
(7) QTY
FUEL FILTER ASSEMBLY ............................. 1 . BOLT,FLANGE .............................................. 2 . PLUG ............................................................. 1 . O-RING ......................................................... 1 . FILTER HEAD ............................................... 1 . KIT,ELEMENT ............................................... 1 . . GASKET ...................................................... 1 . . FILTER,FUEL .............................................. 1 . PLUG ............................................................. 1 . ASSEMBLY,COCK,DRAIN ........................... 1 CLAMP,HOSE ................................................. 4 HOSE,NONMETALLIC ................................... 1 HOSE,NONMETALLIC ................................... 1
END OF FIGURE
0220-91
TM 5-3825-270-23&P
0220
1 2 3
9 6
8 7
Figure 4033. Flywheel Assembly.
0220-92
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4033. FLYWHEEL ASSEMBLY. 1 2 3 4 5 6 7 8 9 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5306-01-500-4266 5340-01-536-0877 5340-01-533-3336 5306-01-533-2933 5305-01-533-2597 2815-01-536-0874 5306-01-588-5757 2815-01-588-7421 5306-01-588-5769 0XWR1 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 01123-60816 15521-0468-0 15521-0479-0 01779-51445 15471-2516-2 1G521-2501-0 1G772-9103-2 1G521-0461-0 1G521-9103-0
0220
(7) QTY
BOLT,MACHINE ............................................. 2 COVER,ACCESS ............................................ 1 GASKET,COVER ............................................ 1 BOLT,MACHINE ............................................. 2 SCREW,CAP,HEXAGON HEAD .................... 7 FLYWHEEL,ENGINE ...................................... 1 BOLT,FLANGE ............................................... 6 HOUSING,FLYWHEEL ................................... 1 BOLT,FLANGE ............................................... 2
END OF FIGURE
0220-93
TM 5-3825-270-23&P
0220
1 2 3
6 5 4 7 3
8 9
10
Figure 4034. Engine Oil Pan.
0220-94
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4034. ENGINE OIL PAN. 1 2 3 4 5 6 7 8 9 10 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 4820-01-393-5272 5365-01-588-6371 5330-01-583-5351 5306-01-588-5730 2910-01-585-2110 5331-01-533-2921 5365-01-506-5046 5306-01-533-4120 2815-01-588-6058 5306-01-588-5774 01276 80195 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 FD15-1026-04 5252220 16265-9667-0 01754-50814 1C010-3211-0 04814-00220 15707-33750 01774-51004 1C010-0150-3 1C010-9110-0
0220
(7) QTY
VALVE,OIL SAMPLE HYDRAULIC SYSTEM ......................................................... 1 PLUG,DRAIN .................................................. 1 GASKET .......................................................... 2 BOLT,FLANGE ............................................... 2 TUBE,OIL PICKUP ......................................... 1 O-RING ........................................................... 1 PLUG,DRAIN .................................................. 1 BOLT,FLANGE ............................................... 4 PAN,OIL .......................................................... 1 BOLT,MACHINE ........................................... 20
END OF FIGURE
0220-95
TM 5-3825-270-23&P
0220
2 3
Figure 4035. Fuel Pump.
0220-96
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4035. FUEL PUMP. 1 2 3 PAFZZ PAFZZ PAFZZ 5310-01-500-2374 2910-01-524-7918 5330-01-478-6336 0XWR1 1Q0C4 0XWR1 02751-50060 1C010-52033 16264-52140
0220
(7) QTY
NUT,PLAIN,PLATE ......................................... 2 PUMP,FUEL,CAM ACTUATED ...................... 1 GASKET .......................................................... 1
END OF FIGURE
0220-97
TM 5-3825-270-23&P
0220
4 5 3 2 1 6
Figure 4036. Water Pump.
0220-98
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4036. WATER PUMP. 1 2 3 4 5 6 7 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5306-01-588-5735 2930-01-588-7406 5330-01-524-7431 2930-01-588-7667 2930-01-533-7027 5331-01-533-6875 5306-01-357-3765 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 S4532 01754-50830 1C010-7303-2 1C010-7343-0 1C010-7306-8 1C010-3711-0 04814-00420 01754-50880
0220
(7) QTY
BOLT,FLANGE ............................................... 2 WATER PUMP ASSEMBLY ........................... 1 GASKET .......................................................... 1 HOUSING,WATER PUMP .............................. 1 . NIPPLE,WATER OUTLET ............................ 1 O-RING ........................................................... 1 BOLT,MACHINE ............................................. 4
END OF FIGURE
0220-99
TM 5-3825-270-23&P
0220
2 1 3
6 5
4
Figure 4037. Starter.
0220-100
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4037. STARTER. 1 2 3 4 5 6 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 2920-01-524-7906 5310-01-533-3364 5307-01-588-5741 5306-01-320-7032 5310-01-137-4829 5310-00-407-9566 1Q0C4 1Q0C4 1Q0C4 S4532 72741 80205 1K011-63010 02771-60100 01517-61030 01774-51035 430-008 MS35338-45
0220
(7) QTY
STARTER,ENGINE ELECTRICAL ................. 1 NUT,PLAIN,PLATE ......................................... 1 STUD .............................................................. 1 BOLT,MACHINE ............................................. 1 NUT,PLAIN,HEXAGON 8MM ......................... 1 WASHER,LOCK 5/16 ...................................... 1
END OF FIGURE
0220-101
TM 5-3825-270-23&P
0220
4 2 3
Figure 4038. Engine Fan.
0220-102
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4038. ENGINE FAN. 1 2 3 4 PAFZZ PAFZZ PAFZZ PAFZZ 5306-01-358-9526 4140-01-583-0198 5365-01-588-5794 3020-01-588-6661 0MR83 1QC04 1QC04 1QC04 01754-50820 1K011-74110 3A111-16231 1G541-74250
0220
(7) QTY
BOLT,MACHINE ............................................. 4 FAN,COOLING ............................................... 1 SPACER ......................................................... 2 PULLEY,WATER PUMP ................................. 1
END OF FIGURE
0220-103
TM 5-3825-270-23&P
2
0220
Figure 4039. Inlet Manifold.
0220-104
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4039. INLET MANIFOLD. 1 2 3 4 5 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5330-01-533-9117 5306-01-358-9526 5306-01-533-3807 5340-01-533-3726 1Q0C4 1Q0C4 0MR83 1Q0C4 1Q0C4 1C010-1177-0 1C010-1182-0 01754-50820 01754-50865 12234-6758-0
0220
(7) QTY
MANIFOLD,INTAKE ........................................ 1 GASKET .......................................................... 1 BOLT,MACHINE ............................................. 5 BOLT,MACHINE ............................................. 3 BRACKET,ANGLE .......................................... 1
END OF FIGURE
0220-105
TM 5-3825-270-23&P
0220
4 3
5 6
Figure 4040. Exhaust Manifold.
0220-106
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4040. EXHAUST MANIFOLD. 1 2 3 4 5 6 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5307-01-533-2948 5330-01-533-5751 2815-01-588-7386 5307-01-588-5741 5306-01-358-9526 5310-01-533-9486 1Q0C4 1Q0C4 1Q0C4 1Q0C4 0MR83 1Q0C4 15221-9153-0 1C010-12352 1J510-1231-0 01517-61030 01754-50820 02751-50080
0220
(7) QTY
STUD .............................................................. 4 GASKET MANIFOLD ...................................... 1 EXHAUST MANIFOLD .................................... 1 STUD .............................................................. 4 BOLT,MACHINE ............................................. 4 NUT,PLAIN,PLATE ......................................... 4
END OF FIGURE
0220-107
TM 5-3825-270-23&P
0220
1 3
Figure 4041. Main Bearing Case.
0220-108
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4041. MAIN BEARING CASE. 1 2 3 PAFZZ PAFZZ PAFZZ 3130-01-533-2489 5330-01-524-8043 5306-01-588-5735 1Q0C4 1Q0C4 1Q0C4 1C010-0430-0 1C010-0446-0 01754-50830
0220
(7) QTY
CAP,PILLOW BLOCK ..................................... 1 . SEAL,PLAIN .................................................. 1 BOLT,FLANGE ............................................... 8
END OF FIGURE
0220-109
TM 5-3825-270-23&P
0220
2 3
Figure 4042. Dipstick Assembly.
0220-110
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4042. DIPSTICK ASSEMBLY. 1 2 3 PAFZZ PAFZZ PAFZZ 6680-01-534-1062 5365-01-588-5756 4730-01-533-1441 1Q0C4 1Q0C4 1Q0C4 1C010-3641-2 1G513-3655-0 1C010-3642-2
0220
(7) QTY
GAGE ROD LIQUID LEVEL ............................ 1 PLUG,OIL GAUGE .......................................... 1 TUBE,DIPSTICK DISCONNECT .................... 2
END OF FIGURE
0220-111
TM 5-3825-270-23&P
0220
3 4
10 6 7 8 9
Figure 4043. Alternator and Pulley.
0220-112
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4043. ALTERNATOR AND PULLEY. 1 2 3 4 5 6 7 8 9 10 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PBFZZ PAFZZ PAFZZ PAFZZ 3030-01-588-7609 5310-01-533-3364 5342-01-588-5422 5310-01-500-2384 5306-01-588-5732 5310-01-466-8446 2920-01-588-5917 5306-01-588-5738 5306-01-588-5765 3020-01-588-7567 1Q0C4 1Q0C4 1Q0C4 0XWR1 1Q0C4 39428 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1C010-97010 02771-60100 1C010-64420 04015-60080 01754-50825 90591A151 1K011-64010 01774-51065 1C010-91010 1C010-74282
0220
(7) QTY
BELT,V ............................................................ 1 NUT,PLAIN,PLATE ......................................... 1 BRACKET,ALTERNATOR .............................. 1 WASHER,FLAT ............................................... 1 BOLT,FLANGE ............................................... 1 NUT,HEXAGON 6MM ..................................... 1 ALTERNATOR ASSEMBLY ............................ 1 BOLT,FLANGE ............................................... 1 BOLT ............................................................... 1 PULLEY,CRANKSHAFT ................................. 1
END OF FIGURE
0220-113
TM 5-3825-270-23&P
0220
6 AND 7
9 1 3 4 2 13
12
6 7 4 8 9
4
11
4 4
4
10
Figure 4044. Oil Cooler.
0220-114
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4044. OIL COOLER. 1 2 3 4 5 6 7 8 9 10 11 12 13 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 2910-01-524-7660 2815-01-588-7652 4720-01-524-7615 4730-01-478-7123 5365-01-589-3941 5365-01-542-6383 5331-01-583-5360 2935-01-536-0882 5330-01-583-5452 4710-01-588-7633 4720-01-524-7591 4710-01-533-6260 5306-01-588-5730 1Q0C4 1Q0C4 1Q0C4 0XWR1 1Q0C4 S8029 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 HH1C0-32430 1C010-3229-2 1C010-3715-0 09318-88200 1C010-3308-0 E9151-33140 04817-50300 1C010-3701-0 15484-3707-0 1C010-3717-2 1C010-3718-2 1C010-3716-0 01754-50814
0220
(7) QTY
CARTRIDGE,OIL FILTER ............................... 1 STEM,FILLER ADAPTER ............................... 1 HOSE,PREFORMED ...................................... 1 CLAMP,HOSE ................................................. 6 PLUG ASSEMBLY OIL FILLER ...................... 1 . PLUG,OIL FILLER ......................................... 1 . O-RING ......................................................... 1 COOLER,OIL .................................................. 1 . GASKET,OIL COOLER ................................. 1 HOSE,PREFORMED ...................................... 1 HOSE,PREFORMED ...................................... 1 TUBE,METALLIC ............................................ 1 BOLT,FLANGE ............................................... 1
END OF FIGURE
0220-115
TM 5-3825-270-23&P
0220
7 THROUGH 13
1 13 15 16 12 7
5 15 11 10 14 4 9 8
Figure 4045. Water Flange and Thermostat.
0220-116
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4045. WATER FLANGE AND THERMOSTAT. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5365-01-533-9254 5365-01-533-6239 5330-01-438-8809 5365-01-533-9254 2930-01-533-7027 5365-01-506-8257 5306-01-533-5746 4730-01-478-7123 4720-01-588-8481 6685-01-585-2190 5330-01-583-5376 5340-01-588-5750 5306-01-588-5732 5330-01-533-6252 3040-01-588-7405 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 1Q0C4 67271 1Q0C4 1Q0C4 5X475 1Q0C4 0XWR1 1Q0C4 1C011-7301-0 1C020-7327-2 1C020-7326-0 01754-50825 1C010-7282-0 1G516-7280-2 1G516-7270-2 1G521-9601-0 15109-3363-0 322539 1G521-9601-0 1C010-3711-0 16241-9602-0 01754-50850 09318-88200 1C010-7335-2
0220
(7) QTY
THERMOSTAT,COOLANT ............................. 1 GASKET .......................................................... 1 HOUSING,THERMOSTAT, UPPER ............... 1 BOLT,FLANGE ............................................... 6 GASKET .......................................................... 1 THERMOSTAT,HOUSING ASSEMBLY ......... 1 . THERMOSTAT,HOUSING ............................ 1 . PLUG,MACHINE THREAD ........................... 1 . PLUG,MACHINE THREAD ........................... 1 . GASKET ........................................................ 1 . PLUG,MACHINE THREAD ........................... 1 . NIPPLE,WATER OUTLET ............................ 1 . PLUG,MACHINE THREAD ........................... 1 BOLT,MACHINE ............................................. 1 CLAMP,HOSE ................................................. 2 HOSE,PREFORMED ...................................... 1
END OF FIGURE
0220-117
TM 5-3825-270-23&P
0220
10 AND 11
13
14 AND 15 1 2 1
3 3 3
18 17
4 5
16
10 11 7 13 14 10 15 13 14 15 8 13 14 15
10 11
13 14 15
10 12
Figure 4046. Nozzle Holder and Glow Plug.
0220-118
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4046. NOZZLE HOLDER AND GLOW PLUG. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5310-01-440-6749 2920-01-536-0883 2920-01-524-7911 5305-01-533-3695 4730-01-434-3361 4710-01-533-3318 4730-01-434-3360 4710-01-533-9215 4710-01-533-4676 4730-01-359-4773 4720-01-533-5594 4730-01-589-1226 4820-01-524-7610 5331-01-431-3621 5330-01-431-3620 4710-01-533-2057 4710-01-533-6287 4710-01-533-5407 S4532 1Q0C4 1Q0C4 1Q0C4 67271 1Q0C4 67271 1Q0C4 1Q0C4 98255 1Q0C4 1Q0C4 1Q0C4 0XWR1 31013 1Q0C4 1Q0C4 1Q0C4 02761-5004-0 1C010-6556-0 16665-65510 03024-50520 322136 1C010-5371-0 322135 1C010-4250-0 1C010-4240-0 10244-4232-0 09661-40170 17490-4236-0 1C010-5390-0 15841-53622 19077-5365-0 1C010-5372-0 1C010-5373-0 1C010-5374-0
0220
(7) QTY
NUT,SLEEVE .................................................. 4 COVER,GLOW PLUG ..................................... 1 GLOW PLUG .................................................. 4 SCREW,ASSEMBLED WASHER ................... 3 CLAMP,HOSE SPECIAL-SHAPED ................ 3 TUBE ASSEMBLY,METAL ............................. 1 CLAMP,HOSE SPECIAL-SHAPED ................ 2 PIPE ASSEMBLY METAL ............................... 1 PIPE ASSEMBLY METAL ............................... 2 . CLAMP,HOSE ............................................... 4 . HOSE,NONMETALLIC .................................. 2 CONNECTOR,HOSE ...................................... 1 NOZZLE,VALVE ............................................. 4 . O-RING ......................................................... 1 . SEAL,PLAIN,ENCASED ............................... 1 TUBE ASSEMBLY,METAL ............................. 1 TUBE ASSEMBLY,METAL ............................. 1 TUBE ASSEMBLY,METAL ............................. 1
END OF FIGURE
0220-119/120 blank
TM 5-3825-270-23&P
0220
5 THROUGH 7
8 23
10 AND 11
22
1 2 1 3 4 5 6 7
12
10
11
9
13
14 13 13 12
15
18
13 12
3 20 19 17 16
23 21 22
19
Figure 4047. Engine - Pump Reel. (Sheet 1 of 2)
0220-121
TM 5-3825-270-23&P
0220
24
3 2
25
Figure 4047. Engine - Pump Reel. (Sheet 2 of 2)
0220-122
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4047. ENGINE - PUMP REEL. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PBFZZ PAFZZ PAFZZ PAFZZ 3130-01-588-8249 5305-01-504-8942 4720-01-588-8868 4730-01-588-8433 4210-01-131-3290 5360-01-149-7230 3040-01-130-4541 4730-01-589-0721 4820-01-098-7881 5310-01-466-8127 3040-01-211-1048 4730-00-621-8357 4730-00-909-8627 4720-01-588-8860 4720-01-589-7611 4820-00-849-1220 4730-01-589-7577 5340-01-590-7525 5305-01-532-9137 5310-01-083-1540 5310-00-935-9021 39428 39428 96906 80195 92858 92858 92858 80195 72219 39428 72219 72661 58536 80195 80195 58536 80195 80195 3DHZ7 92858 80195 20266 20266 92858 39428 92865A624 98026A031 MS51943-35 6001919 9914.0433 9914.0451 9914.0413 L238009 76-107-01 93776A461 W6365700 STC-20 AA52506-F-36 5252115 5252167 A-A-59440/1-005 5252161 6001131 SNAP-375-2500R A55A-00080 6603996 00649L01 33074-A
0220
(7) QTY
SCREW,CAP,HEXAGON HEAD .................. 15 WASHER,FLAT 3/8 ....................................... 19 NUT,SELF-LOCKING HEXAGON HEAD ..... 19 REEL,HOSE .................................................... 1 . PAD,BRAKE,HOSE REEL ............................ 1 . SPRING,HELICAL COMPRESSION ............. 1 . BRAKE,WHEEL ............................................ 1 ELBOW,PIPE .................................................. 1 VALVE,BALL ................................................... 1 . NUT,SELF-LOCKING .................................... 1 . LEVER ........................................................... 1 ADAPTER,STRAIGHT .................................... 3 CLAMP,HOSE ................................................. 8 HOSE,NONMETALLIC ................................... 1 HOSE,NONMETALLIC ................................... 1 COCK,DRAIN .................................................. 1 ELBOW,PIPE .................................................. 1 CLAMP,LOOP ................................................. 3 PIN,SNAP ....................................................... 2 HANDLE,HOSE REEL .................................... 1 HOSE ASSEMBLY NONMETALLIC ............... 1 NOZZLE .......................................................... 1 . GASKET ........................................................ 1
9939.0062 X18,Y12 GUIDE,ROLLER ASSEMBLY ......................... 1 92865A626 SCREW,CAP,HEXAGON HEAD,M10 X 30MM .............................................................. 4 END OF FIGURE
0220-123/124 blank
TM 5-3825-270-23&P
0220
2 THROUGH 14
14 3 4
4 3
4 13 3 4
13 10
15 7 6
10
6 17 16 15
12
11
7 4
5 11 18
12
9 8 4 4 7 4 3 20
3 4 7 4 9
23 22 22 21
4
19 15
8 17 16 15 15 18
19 15
Figure 4049. Walkway. (Sheet 1 of 2)
0220-125
TM 5-3825-270-23&P
0220
25
24
Figure 4049. Walkway. (Sheet 2 of 2)
0220-126
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4049. WALKWAY. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ MFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 5305-01-532-9137 5340-01-588-6495 5440-01-588-7703 5305-01-325-8388 2510-01-588-7529 5310-01-508-8932 5310-01-539-5111 3120-01-588-7631 5310-01-591-0903 5305-01-533-5700 2510-01-588-7577 5310-01-222-9097 2510-01-588-7507 2510-01-588-7573 5310-01-591-0903 5310-01-508-8932 5340-01-588-6350 5310-01-539-5111 3120-01-588-7631 5305-00-071-2075 2510-01-588-7525 3120-01-588-5497 80195 80195 39428 39428 80195 39428 70901 80204 80195 39428 3DHZ7 80195 80205 80195 39428 39428 70901 39428 39428 80195 0Y3H3 80195 39428 0HBT5 80195 5252035 5252025 90040A137 90126A033 5252032 90126A036 SOA-744-5
0220
(7) QTY
RAIL,FOLDING ASSY ..................................... 1 . RAIL,FOLDING ASSEMBLY ......................... 1 . NUT,SELF-LOCKING HEXAGON ................. 8 . WASHER,FLAT 1/2 ..................................... 20 . PLATE,MID RAIL .......................................... 2 . WASHER,FLAT 3/4 ....................................... 4 . BEARING ...................................................... 8
B1821BH050C300N . SCREW,CAP,HEXAGON 1/2-13 X 3 ............ 4 5252034 3936T14 SNAP-375-2500R 5252293 MS90725-113 5252031 90126A033 90126A036 SOA-744-5 90040A137 92865A714 5252327 37264 0446363 92865A624 GOCB1515 8X24 5252087 . RAIL,REAR UPRIGHT .................................. 2 . SLEEVE,STOP .............................................. 4 . PIN,SNAP ...................................................... 2 . LANYARD MAKE FROM P/N 8908T32 (3A054) 20 INCHES ...................................................... 2 . SCREW,CAP,HEX HD HEAD,1/2-13 X 1 1/2 INCH ............................................................... 4 . RAIL,UPPER ................................................. 1 WASHER,FLAT 1/2 ....................................... 12 WASHER,FLAT 3/4 ......................................... 4 BEARING ........................................................ 4 NUT,SELF-LOCKING HEXAGON,1/2 ............ 4 SCREW,CAP,HEXAGON HEAD,1/2-13 X 1 1/4 ................................................................... 4 CATWALK ....................................................... 1 NUT,SELF-LOCKING HEXAGON,3/8-16 ....... 4 WASHER,FLAT ............................................... 8 SCREW,CAP,HEXAGON HEAD .................... 4 STRAP,NYLON ............................................... 1 STEP ASSEMBLY .......................................... 1
END OF FIGURE
0220-127
TM 5-3825-270-23&P
0220
3 1 2
2 4
Figure 4050. Dataplates.
0220-128
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. 4050. DATAPLATES. 1 2 3 4 PAFZZ PAFZZ PAFZZ PAFZZ 7690-01-588-7639 5320-01-584-6190 7690-01-588-7608 7690-01-588-7605 80195 39428 80195 80195 5252188 97525A615 5252222 5252223
0220
(7) QTY
PLATE-ID/LIFT DATA ..................................... 1 RIVET ............................................................ 18 PLACARD-VALVE CONTROL,EMM - WD ..... 2 PLACARD-WATER DRAIN, EMM - WD ......... 1
END OF FIGURE
0220-129
TM 5-3825-270-23&P
0220
FIGURE ILLUSTRATION NOT REQUIRED

Figure BULK. Bulk Items.
0220-130
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. BULK. BULK ITEMS. 1 2 3 4 5 6 7 PAFZZ PAFZZ PCFZZ PAFZZ PAFZZ PAFZZ PCFZZ 4010-01-572-0869 5330-01-588-6616 4720-01-588-7676 4720-01-468-1971 5330-01-589-6076 5330-01-588-6015 39428 81300 39428 80195 80195 3A054 5X475 5633K22 7187-191 93625K54 6320883 6001705 8908T32 EW 11380
0220
(7) QTY
HOSE,NONMETALLIC ................................... 1 HOSE,NONMETALLIC ................................... 1 FOAM .............................................................. 1 TRIM SEAL ..................................................... 1 CABLE,SS ....................................................... 1 LANYARD ....................................................... 1 GASKET,FOAM .............................................. 1
END OF FIGURE
0220-131
TM 5-3825-270-23&P
0220
FIGURE ILLUSTRATION NOT REQUIRED

Figure KITS. Repair Kits.
0220-132
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. KITS. REPAIR KITS. 1 PAFZZ 80195 7050803
0220
(7) QTY
KIT,TANK INSTALL SPRINGS ....................... 1 NUT,SELF-LOCKING (048) 4002-44 (024) 4002-45 WASHER,FLAT STUD,TIEDOWN SPRING,HELICAL (012) (012) 4002-46 4002-47
PAFZZ
80195
7050804
KIT,TANK INSTALL RUBBER MOUNT ........ 16 NUT,SELF-LOCKING (016) 4002-48 (016) 4002-49 WASHER,SNUB BUSHING ASSEMBLY(016) (016) BOLT 4002-50 4002-51
PAFZZ
13189
103829-1
. KIT,SWIVEL .................................................. 2 (002) 4014-79 SEAL,DIRT SEAL,PRESSURE FITTING,ZERK BEARING,BALL PLUG,BALL RETAINER RING,RETAINING END OF FIGURE (002) (002) (168) (004) (004) 4014-80 4014-81 4014-87 4014-88 4014-89
0220-133
TM 5-3825-270-23&P
0220
2 THROUGH 10
3 2
4 5
7 6
10 9
Figure TOOL. Special Tools.
0220-134
TM 5-3825-270-23&P
(1) (2) ITEM NO. SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) GROUP 0000 EMM WATER DISTRIBUTOR FIG. TOOL. SPECIAL TOOLS. 1 2 3 4 5 6 7 8 9 10 PEFHH PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ 3940-01-591-0865 4030-01-423-0946 3940-01-591-0868 5120-01-437-3788 6635-01-093-3710 6685-01-582-6563 2590-01-590-8219 80195 80195 33287 0XWR1 39428 55719 0HBT5 39428 39428 39428 5252430 5252311 6673 07916-32032 2444A73 LAW124E 2-TLL-N-24 3383T105 3558T49 8864T81
0220
(7) QTY
KIT-SPECIAL TOOLS EMM - WD .................. 1 . SEAL INSTALLER ......................................... 1 . TENSIOMETER,DIAL INDICATING .............. 1 . TESTER,PRESSURE GAGE ........................ 1 . PRESS,ARBOR HAND OPERATED,2 TON ................................................................. 1 . SCREWDRIVER ATTACHMENT,SOCKET WRENCH,3/4 .................................................. 1 . SLING 24 FT ................................................. 2 . SLING 36 INCH ............................................. 2 . SHACKLE 5/8 PIN DIAMETER ..................... 2 . SLING,TWO-LEG NYLON 1 INCH X 3 FT WITH OBLONG LINKS ............................................. 1 END OF FIGURE
END OF WORK PACKAGE
0220-135/136 blank
TM 5-3825-270-23&P
CHAPTER 6 SUPPORTING INFORMATION
TM 5-3825-270-23&P FIELD MAINTENANCE REFERENCES
0221
SCOPE This work package lists all the pamphlets, forms, field manuals, technical manuals, and other publications referred to in this manual. Also, those publications that should be consulted for additional information about water distributor operations are listed. DEPARTMENT OF ARMY PAMPHLETS MILITARY PUBLICATION INDEXES DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual
FORMS DA Form 2028 DA Form 2404 DA Form 2407 DD Form 314 DD Form 1397 SF 368 DA Form 5988-E SF 364 Recommended Changes to Publications and Blank Forms Equipment Inspection and Maintenance Worksheet Maintenance Request Preventive Maintenance Schedule and Record Processing and Deprocessing Record for Shipment, Storage, and Issue of Vehicles and Spare Engines Quality Deficiency Report Equipment Inspection/Maintenance Worksheet (EGA) Supply Discrepancy Report
FIELD MANUALS FM 21-10 Field Hygiene and Sanitation
TECHNICAL MANUALS TM 5-3825-270-10 TM 5-3825-270-23&P Water Distributor Operator Manual Field Maintenance Manual Including Sustainment Maintenance Repair Parts and Special Tools List for EMM Water Distributor Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive Command) Operator's Manual for Truck, Tractor, M1074 and M1075 Palletized Load System (PLS)
TM 750-244-6 TM 9-2320-364-10
0221-1
TM 5-3825-270-23&P
0221
TECHNICAL MANUALS - Continued TM 9-2320-364-14&P TM 9-247 Interactive Electronic Technical Manual for Palletzied Load System (PLS) M1074, M1075, M1076, M1077 Material used for Cleaning, Preserving, Abrading, and Cementing Ordnance Material and Related Material including Chemicals.
MISCELLANEOUS PUBLICATIONS TB 43-0209 LO-5-3825-270-13 TB 750-651 CTA 50-970 SF 368 END OF WORK PACKAGE Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment, and Materials handling Equipment Lubrication Order for EMM Water Distributor Use of Antifreeze Multi-Engine Type Cleaning Compounds and Test Kit in Engine Cooling System Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Item) Product Quality Deficiency Report
0221-2
TM 5-3825-270-23&P FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
0222
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 standard 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 as: Field includes three subcolumns, Crew maintenance (C), Service maintenance (O), and Field maintenance (F). Sustainment includes two subcolumns, Below Depot (H) and Depot (D). 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 system 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:
0222-1
TM 5-3825-270-23&P The Army Maintenance System MAC - Continued INSPECT
0222
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 gaugings and evaluation of cannon tubes. 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, e.g., load testing of lift devices and hydrostatic testing of pressure hoses. 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: UNPACK To remove from packing box for service or when required for the performance of maintenance operations. REPACK To return item to packing box after service and other maintenance operations. CLEAN To rid the item of contamination. TOUCH UP To spot paint scratched or blistered surfaces. MARK To restore obliterated identification. ADJUST To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters. ALIGN To adjust specified variable elements of an item to bring about optimum or desired performance. 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.
0222-2
TM 5-3825-270-23&P The Army Maintenance System MAC - Continued REMOVE/INSTALL
0222
To remove and install the same item when required to perform service or other maintenance functions. Install 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 equipment or system. REPLACE To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is authorized by the MAC and assigned maintenance level is shown as the third position code of the Source, Maintenance, and Recoverability (SMR) code. REPAIR 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 malfunction; 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. 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. Overhaul does not normally return an item to like-new condition. 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.
0222-3
TM 5-3825-270-23&P The Army Maintenance System MAC - Continued EXPLANATION OF ENTRIES IN THE MAC COLUMN (1) GROUP NUMBER
0222
Entry 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 Entry contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized. COLUMN (3) MAINTENANCE FUNCTION Entry 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 Entry 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 Operator or Crew maintenance, O Service maintenance, and F Field maintenance. SUSTAINMENT: L Specialized Repair Activity, H below Depot maintenance, and D Depot maintenance.
NOTE
The "L" maintenance level is not included in column (4) of the MAC. Functions at 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 Entry 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 entry contains a letter code, in alphabetical order, which is keyed to the remarks table entries.
0222-4
TM 5-3825-270-23&P The Army Maintenance System MAC - Continued 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. COLUMN (5) TOOL NUMBER The manufacturer's part number. EXPLANATION OF COLUMNS IN THE REMARKS COLUMN (1) REMARKS CODE The code recorded in Column (6) of the MAC. COLUMN (2) REMARKS The column lists information pertinent to the maintenance function being performed as indicated in the MAC. END OF WORK PACKAGE
0222
0222-5/6 blank
TM 5-3825-270-23&P FIELD MAINTENANCE MAINTENANCE ALLOCATION CHART (MAC)
0223
Table 1. MAINTENANCE ALLOCATION CHART (MAC)

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O F H D (5) (6)
CREW GROUP NUMBER 0000 COMPONENT/ ASSEMBLY EMM Water Distributor Storage Box Water Tank Replace Replace MAINTENANCE FUNCTION C
TOOLS AND EQUIPMENT REF CODE
REMARKS CODE
0.3 5.0
12 1, 2, 9, 12, 15, 16 12 A
Manhole Cover and Bracket Vent Screen Dial and Bracket
Replace
0.4
Replace Replace
0.1 0.6 0.2 0.2 0.2 0.1 2.0
12 12 12 12 12 12 1, 2, 12, 15, 16 A
High Tank Level Switch Replace Low Tank Level Switch Dial Pointer Dial Pointer Sensor Water Tank Mount Bushings and Spring Wire Trough Spring Marker Roller Replace Replace Replace Replace
Replace Replace Repair
0.1 0.1 0.4 1.5 0.1
12 12 2, 12 2, 12 12
Suction Tube and Hose Replace Hose Hook Weldment Replace
0223-1
TM 5-3825-270-23&P
0223
Table 1. MAINTENANCE ALLOCATION CHART (MAC) - Continued

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O 1.4 0.4 2.0 F H D (5) (6)
CREW GROUP NUMBER COMPONENT/ ASSEMBLY Fuel Tank Stowage Box Flusher Nozzle and Air Actuator Inlet Valve and Hose Valve Handle Discharge Tube and Pipe Assembly Pump Outlet Hose 5" Valve and Adapter Strainer Element 3" Valve and Adapter Air Hose Disc Magnet and Bracket MAINTENANCE FUNCTION Repair Repair Replace C
TOOLS AND EQUIPMENT REF CODE 12 2, 12 12
REMARKS CODE
Replace Replace Replace
1.1 0.1 2.0
2, 12, 14 12 12, 14
Replace Replace Replace Replace Replace
0.4 0.1 0.4 0.6 0.3
12 12 12 12 12
Cab Control Box Engine Replace Start/Stop Switch Cab Control Box Water Sprinkler Switch Cab Control Box Light Switch Replace
0.3
12
0.4
12
Replace
0.2
12
Cab Control Box Engine Replace Speed RPM Cab Control Box Faceguard Replace
0.2
12
0.1
12
0223-2
TM 5-3825-270-23&P
0223

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O 0.2 F H D (5) (6)
CREW GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION C
TOOLS AND EQUIPMENT REF CODE 12
REMARKS CODE
Cab Control Box Engine Replace Speed Set Button Main Control Panel Engine Speed Set Switch Cab Control Box Tachometer Cab Control Box Water Level Indicator Replace
0.3
12
Replace
0.6
12
Replace
0.3
12
Cab Control Box Engine Replace OFF/Battery Drain Indicator Cab Control Box Wire Harness Replace
0.3
12
2.4
12
Cab Control Box Engine Replace Speed Resume/Idle Switch Battery Box Battery Disconnect/ Connection Replace Replace
0.2
12
0.8 0.2
12 2, 12, 14 A
NATO Slave Connector Replace Battery Batteries Engine/Pump Module Water Pump Assembly Valve Cover Plate Replace Service Replace Replace Replace
0.6 0.4 0.6 8.6 7.9 0.2
12 12 2, 12 2, 9, 12 2, 8, 12 12, 14 A
0223-3
TM 5-3825-270-23&P
0223

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O 5.7 0.2 0.4 0.1 0.8 2.4 1.0 0.2 F H D (5) (6)
CREW GROUP NUMBER COMPONENT/ ASSEMBLY Pump Drive Coupling Work Light Air Line Lubricator Air Valve Cover Plate Solenoid Valve Manual Turret Hose Reel Valve MAINTENANCE FUNCTION Replace Replace Replace Replace Replace Replace Replace C
TOOLS AND EQUIPMENT REF CODE 2, 12, 14 12 2, 12 12 12 2, 12 12 12
REMARKS CODE A
Hose Reel Guide Roller Replace Assembly Hose Reel Hose Gravity Bar Weldment Rear Platform Screen Rear Platform Main Control Box Water Pump Inlet Gauge and Hose Water Pump Outlet Gauge and Hose Control Panel Light Switch Main Control Panel Engine Start/Stop Switch Replace Replace Replace Replace Replace Replace
0.2 0.3 0.2 6.2 4.0 0.2
12 12 12 9, 12 12 12
Replace
0.3
12
Replace
0.3
12
Replace
0.3
12
0223-4
TM 5-3825-270-23&P
0223

CREW GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION C
REMARKS CODE
Main Control Panel Replace Engine Speed Resume/ Idle Switch Main Control Panel Engine Speed RPM Switch Main Control Panel Water Sprinkler Switch Main Control Panel Battery Voltage Gauge Main Control Panel Engine Temperature Gauge Main Control Panel Oil Pressure Gauge Main Control Panel Tachometer/Hourmeter Main Control Panel Engine OFF/Battery Drain Indicator Main Control Panel Water Level High Indicator Main Control Panel Water Level Low Indicator 15AMP Circuit Breaker Main Control Panel Emergency Stop Pushbutton Work Light Wire Harness Replace
0.3
12
Replace
0.6
12
Replace
0.2
12
Replace
0.3
12
Replace
0.2
12
Replace
0.5
12
Replace
0.3
12
Replace
0.3
12
Replace
0.3
12
Replace Replace
0.4 0.2
12 12
Replace
1.3
12
0223-5
TM 5-3825-270-23&P
0223

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O 3.0 5.5 F H D (5) (6)
CREW GROUP NUMBER COMPONENT/ ASSEMBLY UPIK Wire Harness Engine Module MAINTENANCE FUNCTION Replace Replace C
TOOLS AND EQUIPMENT REF CODE 2, 12 2, 3, 7, 12, 14, 15 12 2, 12 12
REMARKS CODE
Air Cleaner Assembly Coolant Reservoir Rear Enclosure Panel and Side Rail Engine Compartment Cover Front Enclosure Panel Rear Engine Mount Bracket and Bushing Front Engine Mount Bracket
Repair Replace Replace
0.4 0.4 3.6
Replace
1.2
12
Replace Replace
0.8 1.1
12 2, 12
Replace
2.6
2, 12, 15
Muffler and Band Clamp Replace Exhaust Flex Pipe Governor Control Module Governor Actuator Engine Timing Sensor and Cover Oil Pressure Sending Unit and Pressure Switch Unit Replace Replace
0.4 0.8 0.5
12 12 12
Replace Replace
0.4 0.3
12 12
Replace
0.7
2, 12
0223-6
TM 5-3825-270-23&P
0223

CREW GROUP NUMBER COMPONENT/ ASSEMBLY Engine Coolant Temperature Sending Unit Engine Emergency Temperature Sensor Engine Flywheel Battery Box Wiring Glow Plug Relay Starter Relay Upper Cooling System Hose Engine Wire Harness Injection Pump Gear Cover Plate Engine Crankshaft Front Seal Engine Injection Pump Air Hose Intake Valve Cover and Gasket Engine Cylinder Head Gasket Fuel/Water Separator and Filter Head Fuel/Water Separator Filter MAINTENANCE FUNCTION Replace C
REMARKS CODE
Replace
1.2
12
5.4 2.2 1.0 0.9 1.7
2, 12, 15 12 12 12 12
Replace Replace
1.9 1.3
12 12
Replace
3.2
6, 12
Replace Replace Replace
1.6 0.7 0.8
2, 12, 13, 14 12 2, 12
Replace
4.1
2, 12, 13
Replace
*0.4
2, 12
Replace
0.2
2, 12
0223-7
TM 5-3825-270-23&P
0223

CREW GROUP NUMBER COMPONENT/ ASSEMBLY Oil Drain Sampling Valve Engine Oil Filter/ Strainer Engine Oil Pan MAINTENANCE FUNCTION Replace C
REMARKS CODE
Replace
0.4
2, 12
Replace
5.4 5.6 0.2 0.4
2, 12 12 12 12
Engine Oil Pickup Tube Replace Fuel Pump Water Pump and Housing Strainer Housing Starter Cooling Fan Engine Inlet Assembly Manifold Rear Main Seal Exhaust Manifold Alternator Belts Alternator and Bracket Crankshaft Pulley Replace Replace
Replace Replace Replace Replace
0.4 0.9 0.9 1.0
2, 12, 14 12 12 12
6.2 0.4 0.8 1.1 3.1 0.9 2.7
5, 12, 13 12 10, 12 12 2, 12, 15 2, 12, 13 12
A A
Engine Oil Cooler Hose Replace Thermostat and Housing Replace
0223-8
TM 5-3825-270-23&P
0223

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O 1.0 1.2 F H D (5) (6)
CREW GROUP NUMBER COMPONENT/ ASSEMBLY Glow Plug Engine Nozzle Assembly Holder (Injection Nozzle) Engine Nozzle Tubes MAINTENANCE FUNCTION Replace Replace C
TOOLS AND EQUIPMENT REF CODE 2, 12, 14 12, 13, 14
REMARKS CODE A A
Replace
0.6 * * 2.2 0.6 1.2 0.8 0.2
12 12, 14 12 12 2, 12 12 12 12 A
Suction Tube and Hose Replace Hose Reel Radiator and Bracket Radiator Drain Fill Belt Guard Lower Radiator Hose Fire Extinguisher Bracket Folding Rail Assembly Tank Walkway Data Plate Coolant System Flushing Alternator Belts Engine Gear Assembly Case Relief Valve Engine Oil Pressure Replace Replace Service Replace Replace Replace
Replace Replace Replace Service
0.7 1.0 0.1 4.1
12 12 2, 12 2, 12
Adjust Replace
1.5 0.1
10, 12 12
Test
0.6
2, 11, 12
0223-9
TM 5-3825-270-23&P
0223

(1) (2) (3) (4) MAINTENANCE LEVEL FIELD SUSTAINMENT BELOW SERVICE FIELD DEPOT DEPOT O 0.3 8.8 1.0 0.2 F H D (5) (6)
CREW GROUP NUMBER COMPONENT/ ASSEMBLY Engine Oil Flex Element Fuel Tank Water Pump Oil MAINTENANCE FUNCTION Service Replace Service Service C
TOOLS AND EQUIPMENT REF CODE 2, 12 2, 12, 13 2, 12 2, 12
REMARKS CODE
Table 2. TOOLS AND TEST EQUIPMENT REQUIREMENTS

TOOL OR TEST EQUIPMENT REF CODE 1 2 3 4 5 6 7 8 9 10 11 12 13 MAINTENANCE CATEGORY F F F F F F F F F F F F F NATIONAL/NATO STOCK NUMBER 5120-01-437-3788 4940-01-463-7940
NOMENCLATURE Bit, Screwdriver 3/4" Forward Repair System (FRS) Multi-Leg Nylon Web Sling Multimeter Press, Arbor, Hand Operated Seal Installer Shackle Sling 36 INCH Sling Tensionmeter, Dial Indicating Tester, Pressure Gage Tool Kit, General Mechanics: Automotive Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive
TOOL NUMBER LAW124E SC4940-95-E41 8864T81
6625-01-336-3372
77-4BN 2444A73 5252311
4030-01-423-0946 3940-01-591-0865
3558T49 3383T105 2-TLL-N-24'
6635-01-093-3710 6685-01-582-6563 5180-01-483-0249 5120-01-426-7580
6673 07916-32032 12B470000-1 1002MFR
14
5120-01-092-3278
2002MR
0223-10
TM 5-3825-270-23&P
0223
Table 2. TOOLS AND TEST EQUIPMENT REQUIREMENTS - Continued

TOOL OR TEST EQUIPMENT REF CODE 15 MAINTENANCE CATEGORY F NATIONAL/NATO STOCK NUMBER 5120-01-426-7585
NOMENCLATURE Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive Wrench, Torque, 90-600 lb-ft (122-813 Nm), 3/4 in. Drive
TOOL NUMBER 2503MFR
16
5120-01-400-0319
6020AB
Table 3. REMARKS
REMARK CODE REMARKS
Torque wrench specified is FRS (item 2) component.
END OF WORK PACKAGE
0223-11/12 blank
TM 5-3825-270-23&P FIELD MAINTENANCE EXPENDABLE/DURABLE ITEMS LIST
0224
Introduction Scope This work package lists expendable and durable items that you will need to operate and maintain the Water Distributor. This list 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), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns 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 brake fluid (WP 0098, item 5)). Column (2) - Level This column identifies the lowest level of maintenance that requires the listed item. C -- Operator/Crew O -- Service F -- Field H -- Below Depot D -- Depot Column (3) - National Stock Number (NSN) This is the NSN assigned to the item which you can use to requisition it. Column (4) - Item Name, Description, Part Number/(CAGEC) This column provides the other information you need to identify the item. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (5) - Unit of Issue (U/I) Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.
0224-1
TM 5-3825-270-23&P
0224
Table 1. Expendable/Durable Supplies and Materials List (1) ITEM NO. (2) LEVEL (3) NATIONAL STOCK NUMBER (NSN) (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) (5) U/I
Antifreeze, Ethylene Glycol (60%), Inhibited Type IA recycled (A-A-52624 Type 1B) 1 2 3 F F F 6850-01-441-3234 6850-01-441-3240 6850-01-441-3248 Antifreeze, Ethylene Glycol (60%), Type IB 1-gallon can A-A-52624 Type 1B 58536 Antifreeze, Ethylene Glycol (60%), Type IB 5-gallon can A-A-52624 Type 1B 58536 Antifreeze, Ethylene Glycol (60%), Type IB 55-gallon drum A-A-52624 Type 1B 58536 Antiseize Compound 4 F 8030-00-155-6444 Antiseize Compound 12 or 16 oz aerosol can 76759 05972 Biocide, Fuel Preservation 5 6 7 8 F F F F 6840-00-300-6373 6840-01-531-4088 6810-00-300-6373 6840-01-173-6940 Biocide, Fuel Preservation 1-quart bottle KATHON FP 1.5/QT 40161 Biocide, Fuel Preservation 16 oz. Bottle BB16EZ12US 0U7J1 Biocide, Fuel Preservation 1-quart bottle KATHON FP 1.5/QT 40161 Biocide, Fuel Preservation 5-gallon can KETHON FP 1.5 QT 40161 Cable Ties 9 F 4310-01-115-2297 Cable Ties TY525MX 56501 Cleaning Compound, Solvent 10 11 12 13 14 15 F F F F F F 6850-01-474-2319 6850-01-474-2317 6850-01-474-2316 6850-01-474-2318 6850-01-474-2320 6850-01-474-2321 Cleaning Compound, Solvent 1 gallon can MIL-PRF-680 81349 Cleaning Compound, Solvent 5 gallon can MIL-PRF-680 81349 Cleaning Compound, Solvent 55 gallon drum MIL-PRF-680 81349 Cleaning Compound, Solvent MIL-PRF-680 81349 Cleaning Compound, Solvent MIL-PRF-680 81349 Cleaning Compound, Solvent MIL-PRF-680 81349 GL CO DR GL BX DR EA QT BT QT CN CN GL GL DR
Cloth, Cleaning, Low-Lint; Type 1 16 F 7920-00-044-9281 Cloth, Cleaning, Low-lint; Type 1 10-pound box 12" X 16" A-A-59323 58536 BX
0224-2
TM 5-3825-270-23&P
0224
Table 1. Expendable/Durable Supplies and Materials List - Continued (1) ITEM NO. 17 (2) LEVEL F (3) NATIONAL STOCK NUMBER (NSN) 7920-00-165-7195 (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Cloth, Cleaning, Low-lint; Type 1 10-pound box 15" X 15" E00 05 03 01 AP 03 U4756 Compound, Sealing 18 F 5330-01-100-5218 Compound, Sealing 03342100 61080 TU (5) U/I BX
Compound, Sealing, Loctite 242, Type 2, Grade N 19 F 8030-01-104-5392 Compound, Sealing, Loctite 242, Type 2, Grade N Ten 10-Cubic Centimeter Bottles MIL-S-46163 81349 Compound, Sealing, Loctite 242, Type 2, Grade N 50cubic centimeter bottle MIL-S-46163 81349 Sealing Compound 250-cubic centimeter bottle MIL-S-46163 81349 Adhesive, Thread Locking, Locktite 242 50-ml 242 05972 BX
20
8030-01-014-5869
BT
21 22
F F
8030-01-025-1692 8040-01-250-3969
BT BT
Compound, Sealing, Pipe Thread, Loctite 567 23 F 8030-01-054-0740 Compound, Sealing, Pipe Thread, Loctite 567, Six 50 cubic centimeter bottles 59231 05972 Compound, Sealing, Pipe Thread, Loctite 567, 6 millileter tube 567 05972 Compound, Sealing, Pipe Thread, Loctite 567,250 millileter tube 56765 05972 Compound, Sealing, Pipe Thread, Loctite 567, 250 millileter tube 56747 05972 Distilled Water, Reagent 27 F 6550-01-310-1677 Distilled Water, Reagent (4 GAL) 1 Gallon Bottle 9801 1CNC5 Fuel 28 29 30 F F F 9130-01-031-5816 9140-01-412-1311 9140-00-286-5294 Fuel, JP8 Bulk MIL-T-83133 GR JP8 81349 Fuel, DF-2, Regular Bulk A-A-52557 58536 Fuel, DF-2, Regular Bulk AA52557-2 58536 GL GL GL BT BX
24
8030-01-431-3582
TU
25
8030-01-517-1616
TU
26
8030-01-166-0675
TU
0224-3
TM 5-3825-270-23&P
0224
Table 1. Expendable/Durable Supplies and Materials List - Continued (1) ITEM NO. 31 32 33 (2) LEVEL F F F (3) NATIONAL STOCK NUMBER (NSN) 9140-00-286-5295 9140-00-286-5296 9140-00-286-5297 (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Fuel, DF-2, Regular 5-gal can AA52557-2 58536 Fuel, DF-2, Regular 55gallon drum, 16 gauge AA52557-7 58536 Fuel, DF-2 Regular AA52557-2 58536 Gasket, Silicon 34 F 5330-01-100-5218 Gasket 3.35 oz. tube 03342100 61080 TU (5) U/I CN DR DR
Grease, Automotive and Artillery (GAA) (MIL-PRF-10924) 35 F 9150-01-197-7688 Grease, Automotive and Artillery (GAA) (MILPRF-10924) 2 1/4-ounce tube M-10924-A 81349 Grease, Automotive and Artillery (GAA) (MILPRF-10924) 14-ounce cartridge M-10924-B 81349 Grease, Automotive and Artillery (GAA) (MILPRF-10924) 6 1/2-pound can M-10924-D 81349 Grease, Automotive and Artillery (GAA) (MILPRF-10924) 35-pound can M-19024-E 81349 Grease, Automotive and Artillery (GAA) (MILPRF-10924) 120-pound drum M-10924-F 81349 Heatshrink 40 F 5970-01-342-1742 Heatshrink Heatshrink 603314-4 00779 Lumber, Softwood, Dimension 41 F 5510-00-220-6178 Lumber, Softwood, Dimension MM-L-751 81348 EA EA TU
36
9150-01-197-7693
CA
37
9150-01-197-7689
CN
38
9150-01-197-7692
CN
39
9150-01-197-7691
DR
Oil, Lubricating, Engine, OE/HDO 15W40 (MIL-PRF-2104) 42 F 9150-01-152-4117 Oil, Lubricating, Internal Combustion Engine, Tactical Service OE/HDO 15W40 (MIL-PRF-2104) 1-quart can M2104-1-15W40 81349 Oil, Lubricating, Internal Combustion Engine, Tactical Service OE/HDO 15W40 (MIL-PRF-2104) 24-quart box MIL-PRF-2104 81349 QT
43
9150-01-421-1427
QT
0224-4
TM 5-3825-270-23&P
0224
Table 1. Expendable/Durable Supplies and Materials List - Continued (1) ITEM NO. 44 (2) LEVEL F (3) NATIONAL STOCK NUMBER (NSN) 9150-01-421-1424 (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Oil, Lubricating, Internal Combustion Engine, Tactical Service OE/HDO 15W40 (MIL-PRF-2104) 5-gallon can MIL-PRF-2104 81349 Oil, Lubricating, Internal Combustion Engine, Tactical Service OE/HDO 15W40 (MIL-PRF-2104) 55-gallon drum MIL-PRF-2104 81349 (5) U/I CN
45
9150-01-421-1432
DR
Oil, Lubricating, OE/HDO 10 (MIL-PRF-2104) 46 47 48 F F F 9150-00-189-6727 9150-00-186-6668 9150-00-191-2772 Oil, Lubricating, OE/HDO 10 1-quart can MIL-PRF-2104 81349 Oil, Lubricating, OE/HDO 10 5-gallon can MIL-PRF-2104 81349 Oil, Lubricating, OE/HDO 10 55-gallon drum MIL-PRF-2104 81349 QT CN DR
Oil, Lubricating, OE/HDO-30 (MIL-PRF-2104) 49 F 9150-01-433-7988 Oil, Lubricating, OE/HDO-30 (MIL-PRF-2104) 1-quart can MIL-PRF-2104 81349 Oil, Lubricating, OE/HDO-30 (MIL-PRF-2104) 5-gallon can MIL-PRF-2104 81349 Oil, Lubricating, OE/HDO-30 (MIL-PRF-2104) 55-gallon drum MIL-PRF-2104 81349 Rag, Wiping 52 F 7920-00-205-1711 Rag, Wiping 50 pound bale 7920-00-205-1711 80244 Sodium Bicarbonate Injection 53 F 6505-01-053-2634 Sodium Bicarbonate Injection 50.000 Millilters NDC00517-0639-25 32288 Tags, Identification, White 54 F 9905-00-720-5377 Tags, Identification White 12-105 16956 Tape, Duct 55 F 5640-00-103-2254 Tap, Duct 60 yard roll 1791K70 39428 Tie Wraps 56 F 5975-00-984-6582 Tie Wraps Tie Wraps, 1 Carton MS3367-1-0 96906 HD EA EA BX BE QT
50
9150-00-188-9858
CN
51
9150-00-189-6729
DR
0224-5
TM 5-3825-270-23&P
0224
Table 1. Expendable/Durable Supplies and Materials List - Continued (1) ITEM NO. 57 (2) LEVEL F (3) NATIONAL STOCK NUMBER (NSN) (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Wire Wire Single - Conductor Stranded Wire Assortment, 18 Gauge, 15 Amps, Black, 25'L 6808K828 07BY4 RL (5) U/I
END OF WORK PACKAGE
0224-6
TM 5-3825-270-23&P FIELD MAINTENANCE TOOL IDENTIFICATION LIST
0225
SCOPE This work package is a list of tools, both common and special, test equipment, and tool kits used to repair the Water Distributor. This list is arranged alphabetically and shows the nomenclature, part number (P/N), National Stock Number (NSN) when applicable. Explanation Of Columns Column (1) Item Number. This number is assigned to the entry in the list and is referenced in the initial setup box to identify the material (e.g., Tool Kit, General Mechanic's: Automotive (WP 0225, Table 1, Item 12)). Column (2) Item Name. Indicates the federal item name and, if required, a description to identify the item. Column (3) National Stock Number. This is the National Stock Number assigned to the item; use it to requisition the item. Column (4) Part Number/(CAGEC). This is the vendor number assigned to the item. Column (5) Reference. This column identifies the authorizing supply catalog or RPSTL for items listed in this work package. Table 1. Tool Identification List. (1) (2) (3) NATIONAL STOCK NUMBER (NSN) 5120-01-437-3788 (4) PART NUMBER /(CAGEC) LAW124E (55719) SC4940-95E41 (19204) 8864T81 (39428) 77-4BN (4U744) 2444A73 (39428) 5252311 (80195) 3558T49 (39428) 3383T105 (39428) 2-TLL-N-24 (5)
ITEM NO. 1
ITEM NAME Bit, Screwdriver 3/4"
REFERENCE TM 5-3825-270-23&P SC 4940-95-E42
Forward Repair System (FRS)
4940-01-463-7940
Multi-Leg Nylon Web Sling
TM 5-3825-270-23&P SC 4940-95-E42
Multimeter
6625-01-336-3372
Press, Arbor, Hand Operated
TM 5-3825-270-23&P TM 5-3825-270-23&P TM 5-3825-270-23&P TM 5-3825-270-23&P TM 5-3825-270-23&P
Seal Installer
Shackle
4030-01-423-0946
Sling 36 INCH
Sling
0225-1
TM 5-3825-270-23&P
0225
Table 1. Tool Identification List - Continued. (1) (2) (3) NATIONAL STOCK NUMBER (NSN) (4) PART NUMBER /(CAGEC) (0HBT5) 10 Tensionmeter, Dial Indicating 6635-01-093-3710 6673 (33287) 07916-32032 (0XWR1) 12B470000-1 (59678) 1002MFR (08194) 2002MR (08194) 2503MFR (08194) 6020AB (1CV05) TM 5-3825-270-23&P TM 5-3825-270-23&P SC 5180-95-B48 (5)
ITEM NO.
ITEM NAME
REFERENCE
11
Tester, Pressure Gage
6685-01-582-6563
12
Tool Kit, General Mechanic's: Automotive Wrench, Torque, 20-100 lb-ft (27-136 Nm), 3/8 in. Drive Wrench, Torque, 40-200 lb-in (6-23 Nm), 3/8 in. Drive Wrench, Torque, 50-250 lb-ft (68-339 Nm), 1/2 in. Drive Wrench, Torque, 90-600 lb-ft (122-813 Nm), 3/4 in. Drive
5180-01-483-0249
13
5120-01-426-7580
SC 4940-95-E42
14
5120-01-092-3278
SC 4940-95-E42
15
5120-01-426-7585
SC 4940-95-E42
16
5120-01-400-0319
SC 4940-95-E42
END OF WORK PACKAGE
0225-2
TM 5-3825-270-23&P FIELD MAINTENANCE MANDATORY REPLACEMENT PARTS
0226
GENERAL. This work package is a cross-reference of item numbers to part numbers and is included for that purpose only. EXPLANATION OF COLUMNS. The five table columns of have the following headings: Column (1) - Item Number. This number is assigned to the entry in Table1 for cross-referencing to the part number. The item number appears in the "Materials/Parts" listing of each maintenance procedure. Column (2) - Part Number/(CAGEC). This is the primary number used by the manufacturer, 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. Column (3) - National Stock Number. When available, the National Stock Number is listed. Column (4) - Nomenclature. This is the name given to the item in the "Materials/Parts" listing and in the text of the maintenance procedure. Column (5) - Quantity. Refer to the Materials/Parts section in the Initial Setup of the Maintenance Task for required quantities of item needed. Table 1. Mandatory Replacement Parts List.
ITEM NO. 1 PART NUMBER /(CAGEC) 01517-61030 (1Q04C) 0167012 (0Y3H3) 04512-60100 (0XWR1) 04814-00220 (1Q0C4) 04814-00420 (1Q0C4) NATIONAL STOCK NUMBER (NSN) 5307-01-588-5741 STUD NOMENCLATURE QTY 4
5310-01-553-3078
LOCKNUT
5310-01-500-2376
LOCKWASHER
5331-01-533-2921
PACKING, PREFORMED
5331-01-533-6875
PACKING, PREFORMED
0226-1
TM 5-3825-270-23&P
0226
Table 1. Mandatory Replacement Parts List - Continued.

ITEM NO. 6 PART NUMBER /(CAGEC) 103829-1 (13189) 1133620 (0Y3H3) 14301-4329-0 (1Q0C4) 15401-9665-0 (1Q0C4) 15451-9667-0 (5X475) 15484-3707-0 (1Q0C4) 15841-5362-2 (0XWR1) 16264-52140 (0XWR1) 16265-9667-0 (1Q0C4) 1726740 (45152) 19077-5365-0 (31013) 19258-12230 (3H244) 1C010-0345-0 (1Q0C4) 1C010-1182-0 (1Q0C4) 1C010-12352 (1Q0C4) 1C010-1452-0 (1Q0C4) 1C010-5166-0 (1Q0C4) NATIONAL STOCK NUMBER (NSN) SWIVEL KIT NOMENCLATURE QTY 1
5310-01-583-5810
LOCKWASHER
5331-01-588-5793
PACKING, PREFORMED
5330-01-588-5791
GASKET
10
5330-01-506-5021
PACKING, PREFORMED
11
5330-01-583-5452
GASKET, OIL COOLER
12
5331-01-431-3621
PACKING, PREFORMED
13
5330-01-478-6366
GASKET
14
5330-01-583-5351
GASKET
15
5315-01-372-2507
PIN, COTTER
16
5330-01-431-3620
SEAL, PLAIN, ENCASED
17
5330-01-533-7589
GASKET
18
5306-01-533-9220
SCREW, CYLINDER HEAD
18
19
5330-01-533-9117
GASKET
20
5330-01-5335751
GASKET, MANIFOLD
21
5330-01-524-7680
GASKET
22
5330-01-533-4948
GASKET
0226-2
TM 5-3825-270-23&P
0226

ITEM NO. 23 PART NUMBER /(CAGEC) 1C010-5211-0 (1Q0C4) 1C010-7282-0 (1Q0C4) 1C010-7343-0 (1Q0C4) 1C010-9202-0 (1Q0C4) 1C020-0331-0 (1Q0C4) 1C020-0414-0 (1Q0C4) 1C020-7327-2 (1Q0C4) 1C020-9673-0 (1Q0C4) 1K011-4314-0 (1Q0C4) 2700248 (80195) 322539 (67271) 32491 (3HMC9) 32492 (3HMC9) 33074-A (20266) 33614 (0Y3H3) 37260 (0Y3H3) 37262 (0Y3H3) NATIONAL STOCK NUMBER (NSN) 5365-01-533-2987 SHIM NOMENCLATURE QTY 1
24
5330-01-533-6252
GASKET
25
5330-01-524-7431
GASKET
26
5310-01-589-5778
LOCKNUT
27
5330-01-588-5749
GASKET, CYLINDER HEAD
28
5330-01-524-7393
SEAL
29
5330-01-583-5376
GASKET
30
5330-01-588-5747
GASKET
31
GASKET
32
5330-01-540-9730
GASKET
33
5330-01-438-8809
GASKET
34
5330-01-588-6325
GASKET
35
5330-01-589-4078
GASKET
10
36
GASKET
37
5310-01-530-1515
LOCKWASHER
13
38
5310-00-557-0564
LOCKNUT
39
5310-01-537-3529
LOCKNUT
0226-3
TM 5-3825-270-23&P
0226

ITEM NO. 40 PART NUMBER /(CAGEC) 37264 (0Y3H3) 37272 (0Y3H3) 3936T14 (39428) 40254 (0Y3H3) 41418 (0Y3H3) 4635GA (25567) 5251953 (80195) 5251983 (80195) 6001943 (80195) 6400630 (80195) 68710 (62797) 68715 (62797) 7050803 (80195) 7050804 (80195) 77864 (49181) 78067 (0Y3H3) 90040A029 (80195) NATIONAL STOCK NUMBER (NSN) 5310-01-222-9097 LOCKNUT NOMENCLATURE QTY 13
41
5310-01-530-1545
LOCKNUT
16
42
3120-01-588-5497
STOP, SLEEVE
43
5310-01-564-3336
LOCKWASHER
12
44
5320-01-588-6008
RIVET, POP
22
45
5330-00-063-2437
GASKET
46
CABLE, DOOR STOP
47
SEAL, TOOLBOX
48
5305-01-589-9552
SCREW
49
5365-01-588-6487
ISOLATOR MOUNT
50
SPRING
51
LOCKNUT
52
KIT, TANK INSTALL SPRINGS
53
KIT, TANK INSTALL RUBBER MOUNT
54
5310-01-424-8423
LOCKNUT
19
55
LOCKWASHER
56
5310-01-563-1902
LOCKNUT
14
0226-4
TM 5-3825-270-23&P
0226

ITEM NO. 57 PART NUMBER /(CAGEC) 90040A137 (39428) 90631A011 (39428) 91102A029 (39428) 91102A755 (39428) 91114A029 (39428) 91202A226 (39428) 91831A011 (39428) 91837A031 (39428) 95462A030 (39428) 95615A170 (3A054) 95615A290 (39428) 97525A615 (39428) CB-1120-10 (76005) EW 10777 (5X475) EW 11380-27.25 (5X475) HH1C0-32430 (1Q0C4) J06-17000 (25567) NATIONAL STOCK NUMBER (NSN) 5310-01-557-0714 LOCKNUT NOMENCLATURE QTY 7
58
5310-01-290-2196
LOCKNUT
59
5310-01-357-8844
LOCKWASHER
15
60
5310-01-524-7656
LOCKWASHER
61
5310-01-357-8845
LOCKWASHER
62
5310-01-559-7078
LOCKWASHER
63
5310-01-463-4929
LOCKNUT
64
5310-01-588-6031
LOCKNUT
76
65
5310-01-524-7436
LOCKNUT
66
5310-01-563-4510
LOCKNUT
67
5310-01-466-7854
LOCKNUT
48
68
5320-01-584-6190
RIVET
12
69
5342-01-332-3586
ISOLATOR MOUNT
70
9330-01-588-7632
FOAM, BARRIER
71
GASKET, FOAM
72
2910-01-524-7660
CARTRIDGE, OIL FILTER
73
5310-01-533-4987
LOCKWASHER
0226-5
TM 5-3825-270-23&P
0226

ITEM NO. 74 PART NUMBER /(CAGEC) MS24665-391 (80205) MS35338-45 (96906) MS51943-35 (96906) MS51967-2 (96906) NATIONAL STOCK NUMBER (NSN) 5315-00-234-1627 NOMENCLATURE PIN, COTTER QTY 1
75
5310-00-407-9566
LOCKWASHER
76
5310-00-935-9021
LOCKNUT
78
77
5310-00-761-6882
LOCKNUT
END OF WORK PACKAGE
0226-6
TM 5-3825-270-23&P FIELD MAINTENANCE SCHEMATICS
0227
SCHEMATICS The following schematics are for the Electrical System, Piping System, and Air System for the EMM - WD. Electrical Schematic. (FO-1) Piping Schematic. (FO-2) Air Schematic. (FO-3) END OF WORK PACKAGE
0227-1/2 blank
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
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 (MS 727) 6501 E. 11 Mile Road, Warren, MI 48397-5000
FROM: (Activity and location) (Include ZIP Code)
Your mailing address
PUBLICATION/FORM NUMBER
PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS DATE TITLE
TM 5-3825-270-23&P
ITEM PAGE NO. PARAGRAPH LINE NO.* FIGURE NO. TABLE NO.
30 June 2011
Engineer Mission Module - Water Distributor, WD3000, Field Maintenance Manual & RPSTL
RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).
0004-1
Wrong POC is listed.
TYPED NAME, GRADE OR TITLE
SA
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE
Your name
DA FORM 2028, FEB 1974
M PL
Your telephone number Your signature
Page 1 of 2
APD PE v4.01ES
REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.
TO: (Forward direct to addressee listed in publication)
DATE
PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TM 5-3825-270-23&P
30 June 2011
NATIONAL STOCK NUMBER REFERENCE NO. FIGURE NO. ITEM NO.
Engineer Mission Module - Water Distributor, WD3000, Field Maintenance Manual & RPSTL
TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION
PAGE NO.
COLM NO.
LINE NO.
SA
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
M PL
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
Your telephone number
E
SIGNATURE
Your signature
Page 2 of 2

DATE
TM 5-3825-270-23&P
30 June 2011
Engineer Mission Module - Water Distributor, M7, Field Maintenance Manual & RPSTL
SIGNATURE
Page 1 of 2
APD PE v4.01ES
DATE
TM 5-3825-270-23&P
30 June 2011
PAGE NO.
COLM NO.
LINE NO.
SIGNATURE
Page 2 of 2

DATE
TM 5-3825-270-23&P
30 June 2011
SIGNATURE
Page 1 of 2
APD PE v4.01ES
DATE
TM 5-3825-270-23&P
30 June 2011
PAGE NO.
COLM NO.
LINE NO.
SIGNATURE
Page 2 of 2

DATE
TM 5-3825-270-23&P
30 June 2011
SIGNATURE
Page 1 of 2
APD PE v4.01ES
DATE
TM 5-3825-270-23&P
30 June 2011
PAGE NO.
COLM NO.
LINE NO.
SIGNATURE
Page 2 of 2

DATE
TM 5-3825-270-23&P
30 June 2011
SIGNATURE
Page 1 of 2
APD PE v4.01ES
DATE
TM 5-3825-270-23&P
30 June 2011
PAGE NO.
COLM NO.
LINE NO.
SIGNATURE
Page 2 of 2
By Order of the Secretary of the Army: MARTIN E. DEMPSEY General, United States Army Chief of Staff Official:
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1113103
DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 257875, requirements for TM 5-3825-270-23&P.
FO-1. Electrical Schematic
FP-1/FP-2 blank
FP-3/FP-4 blank
FO-2. Piping Schematic
SPRINKLER SWITCH SA
SPRINKLER SWITCH SB
24 VOLT DC AIR VALVE
24 VOLT DC AIR VALVE
AIR-ACTUATED WATER VALVE
AIR-ACTUATED WATER VALVE
LH SPRINKLER NOZZLE DA
AIR LUBRICATOR
RH SPRINKLER NOZZLE DA
PLS TRUCK UPIK

FO-3. Air Schematic
FP-5/FP-6 blank
086822-000

TM 5-3825-270-23P Engineer Mission Module Water Distribution

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TM 5-3825-270-23P Engineer Mission Module Water Distribution

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TM 5-3825-270-23&P

ENGINEER MISSION MODULE - WATER DISTRIBUTOR (EMM - WD) NSN 3825-01-577-2713

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY 30 JUNE 2011

FOR INFORMATION ON FIRST AID: Reference FM 4-25.11. (WP 0221)

WARNING SUMMARY - Continued

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

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DISTRIBUTION STATEMENT A - Approved for public release: distribution is unlimited.

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Table 1. Equipment Data.................................................................................................................... 0002-1

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EXCESSIVE ENGINE NOISE...................................................................................................................... WP 0014

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ENGINE SPEED RPM SWITCH DOES NOT OPERATE............................................................................ WP 0041

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WORK LIGHT REPLACEMENT.................................................................................................................. WP 0106

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ENGINE GEAR ASSEMBLY CASE RELIEF VALVE REPLACEMENT....................................................... WP 0114

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ENGINE/PUMP MODULE REPLACEMENT............................................................................................... WP 0127

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