*TM 5-3810-305-23

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON (ROUGH TERRAIN CRANE) LRT 110 TYPE I GENERAL PURPOSE NSN 3810-01-165-0646 TYPE II AIRBORNE/AIRMOBILE NSN 3810-01-165-0647

*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY 14 SEPTEMBER 2012
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WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. FIRST AID For first aid information, refer to FM 4-25.11, First Aid. EXPLANATION OF SAFETY WARNING ICONS

EAR PROTECTION - Headphones over ears shows that noise level will harm ears.

ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

EYE PROTECTION - Person with goggles shows that the material will injure the eyes.

FLYING PARTICLES - Arrows bouncing off face with face shield show that particles flying through the air will harm face.

HEAVY OBJECT - Human figure stooping under heavy object shows physical injury potential from improper lifting techniques.

HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm.

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WARNING SUMMARY - Continued
EXPLANATION OF SAFETY WARNING ICONS - Continued

HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb.

HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.

HOT AREA - Hand over object radiating heat shows that part is hot and can burn.

MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb.

MOVING PARTS - Human figure with an arm caught between gears shows that the moving parts of the equipment present a danger to life or limb.

GENERAL SAFETY WARNING DESCRIPTIONS

WARNING

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield.

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03/15/2011 Rel(1.8) root(warnsum) wpno(F00002)

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Safety glasses must be used when cleaning parts. Failure to follow this warning may result in injury or death to personnel.

WARNING

• Before performing this test, turn the crane power off then on again to ensure that an existing two block warning and/or motion cut has not been overridden. • During this test, DO NOT use the cancel alarm button to clear audible warnings or motion cuts. • During this test, DO NOT winch the hook block into the boom tip, in case the system does not cut the crane motions. • Slowly raise the hook block until it lifts the anti-two block weight and deactivates the antitwo block switch. • Failure to follow these warnings may result in damage to equipment or injury or death to personnel.

WARNING

• Keep hands out of path of spring-loaded tensioner. • Keep fingers from between belt and pulley. • Failure to follow these warnings may cause serious injury if tensioner slips.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Wear protective gloves when handling hot gear. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of crankshaft is approximately 80 lbs (36 kgs). Use adequate lifting equipment to lift and support crankshaft. Keep hands out of component. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of cylinder head is approximately 80 lbs (36 kgs). Use adequate lifting equipment to lift and support cylinder head. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel.

WARNING

Wear eye protection when driving ring gear from flywheel. Serious injury to personnel may result from flying metal fragments. DO NOT use a steel drift pin.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Wear protective gloves when installing ring gear. Serious injury to personnel may result if hot gear contacts skin.

WARNING

Weight of engine and transmission assembly is approximately 1,800 lbs (816 kgs). Use adequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of transmission is approximately 1,100 lbs (499 kgs). Use adequate lifting equipment to lift and support transmission. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of engine is approximately 700 lbs (318 kgs). Use adequate lifting equipment to lift and support engine. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of radiator and oil cooler assembly is approximately 300 lbs (136 kgs). Use adequate lifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of converter assembly is approximately 60 lbs (27 kgs). Use adequate lifting equipment to lift and support converter assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of output disconnect group is approximately 67 lbs (30 kgs). Use adequate lifting equipment to lift and support output disconnect group. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of front cover is approximately 226 lbs (103 kgs). Use adequate lifting equipment to lift and support front cover. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of clutch group is approximately 139 lbs (63 kgs). Use adequate lifting equipment to lift and support clutch group. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Wear protective gloves when handling hot bearing. Serious injury to personnel may result if hot bearing contacts skin.

WARNING

Parts are under spring tension. Serious injury to personnel may result from flying parts. Always wear eye protection.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

• Never reinflate a tire that has been run flat or seriously underinflated without removing and checking for tire tube or rim damage. • Never exceed 3 psi (21 kPa) inflation prior to placing tire and wheel assembly into inflation safety cage or mounting on a tire change machine that has a positive lockdown device. • Always inflate tires that are mounted on rims with demountable side ring flanges or lock rings in an inflation safety cage. • When inflating tires in an inflation cage, always use extension air hose and pneumatic tire inflator-gage. • Improperly seated side ring flanges or lock rings may fly off during inflation. Never attempt to seat a side ring flange or lock ring during inflation or after inflation. • Never inflate tires over 40 psi (276 kPa) to seat tire beads. If beads do not seat, deflate, demount, and check the tire/rim match. Mount and lubricate according to instructions. • When inflating tires mounted on the vehicle, all personnel must remain a minimum of 10 ft (3.1 m) away from tire and not in possible path of lock ring or rim flange. Should they fly off, serious injury or death may result. • Failure to follow these warnings may cause injury or death to personnel.

WARNING

Weight of axle assembly is approximately 1,323 lbs (600 kgs). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of differential assembly is approximately 120 lbs (54 kgs). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Heating differential mounting bolts to a temperature of 300°F (149°C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may cause injury or death to personnel.

WARNING

Wear protective equipment while heating and handling bearing cone. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of pivot and spindle assembly is approximately 69 lbs (30 kgs). Use adequate lifting equipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of housing assembly is approximately 631 lbs (286 kgs). Use adequate lifting equipment to lift and support housing assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

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

WARNING

Weight of hub and studs is approximately 79 lbs (36 kgs). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel.

WARNING

Wear protective equipment while heating and handling seal runner. Failure to follow this warning may cause serious injury to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of boom is approximately 3,100 lbs (1,406 kgs). Use adequate lifting equipment to lift and support boom. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel.

WARNING

Weight of boom hoist cylinder is approximately 507 lbs (230 kgs). Use adequate lifting equipment to lift and support boom hoist cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Heating nut to a temperature of approximately 300°F (149°C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling parts. Failure to follow this warning may cause injury or death to personnel.

WARNING

Stay clear of boom hoist cylinder rod while extending and retracting to remove air. Serious injury to personnel may result if rod jumps unexpectedly.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of hydraulic reservoir is approximately 190 lbs (86 kgs). Use adequate lifting equipment to lift and support hydraulic reservoir. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of outrigger cylinder assembly is approximately 125 lbs (57 kgs). Use adequate lifting equipment to lift and support outrigger cylinder assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of manifold is approximately 200 lbs (91 kgs). Use adequate lifting equipment to lift and support manifold. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of cab is approximately 250 lbs (113 kgs). Use adequate lifting equipment to lift and support cab. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of fender is approximately 99 lbs (45 kgs). Use adequate lifting equipment to support fender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of toolbox is approximately 180 lbs (82 kgs). Use adequate lifting equipment to support toolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of beam is approximately 129 lbs (59 kgs). Use adequate lifting equipment to lift and support beam. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of swing bearing is approximately 187 lbs (85 kgs). Use adequate lifting equipment to lift and support swing bearing. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of swing gearbox is approximately 125 lbs (57 kgs). Use adequate lifting equipment to lift and support swing gearbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of counterweight is approximately 2,200 lbs (998 kgs). Use adequate lifting equipment to lift and support counterweight. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

• Weight of upperstructure is approximately 6,000 lbs (2,722 kgs). Use adequate lifting equipment to lift and support upperstructure. DO NOT lift over personnel or let personnel walk underneath suspended load. • Upperstructure must be properly supported when lowering to ground. • Failure to follow these warnings may cause injury or death to personnel.

WARNING

Weight of boom tip section is approximately 1,500 lbs (680 kgs). Use adequate lifting equipment to lift and support boom tip section. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of boom extend cylinder is approximately 415 lbs (188 kgs). Use adequate lifting equipment to lift and support boom extend cylinder. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of hook block is approximately 235 lbs (107 kgs). Use adequate lifting equipment to lift and support hook block. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

WARNING

Make sure snapring is seated in groove in splined bore of cam. Snapring will keep brake clutch assembly correctly positioned in center of friction brake pack. Brake may bind or fail if snapring is not correctly installed. Failure to follow this warning may cause injury or death to personnel.

WARNING

Weight of winch is approximately 300 lbs (136 kgs). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

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TM 5-3810-305-23

WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow these warnings may result in injury or death to personnel.

WARNING

Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield.

WARNING

DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness may result in serious injury or death if it hits personnel.

WARNING

Safety glasses or face protection must be used when working with compressed air. Failure to follow this warning may result in serious injury to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel.

WARNING

If necessary, heat differential mounting bolts to a temperature of 300°F (149°C) to break down sealant. Hot surface may cause burns or injury. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may result in serious injury to personnel.

WARNING

Wear protective equipment while heating and handling spacer. Failure to follow this warning may result in serious injury to personnel.

WARNING

When deflating tires, always ensure tire is completely deflated before removing from rim. Failure to follow this warning may result in serious injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

• When inflating tires, always ensure tires are properly seated. Improperly seated tires can burst with explosive force. • DO NOT mix one type of wheel with a different type of tire. Improper seating of these components can cause tire and wheel to fly apart with explosive force. • Failure to follow these warnings may result in serious injury or death to personnel.

WARNING

• Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. • Wear protective eye covering. Serious injury to personnel may result from flying metal fragments. • Wear protective gloves when handling hot parts. • Failure to follow these warnings may result in injury or death to personnel.

WARNING

Keep all personnel away from winch and hook block area. Failure to follow this warning may result in death or serious injury to personnel.

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in injury or death to personnel.

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WARNING SUMMARY - Continued
GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

Ensure to tag all cables and valve body properly before disconnecting. Failure to follow this warning may result in injury or death to personnel.

WARNING

Weight of brake drum is approximately 81 lbs (37 kgs). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel.

WARNING

Do not use outriggers to support vehicle. Failure to follow this warning may result in serious injury or death to personnel.

WARNING

Do not remove lifting device until hydraulic pressure has been built up. Failure to follow these warnings may result in damage to equipment or injury or death to personnel. EXPLANATION OF HAZARDOUS MATERIALS ICONS

BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria or viruses that present a danger to life or health.

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WARNING SUMMARY - Continued
EXPLANATION OF HAZARDOUS MATERIALS ICONS - Continued

CHEMICAL - Drop of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

FIRE - Flame shows that a material may ignite and cause burns.

HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human hand shows that fluid escaping under great pressure can cause injury or death to personnel.

RADIOACTIVE - Identifies a material that emits radioactive energy and can injure human tissue or organs.

VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.

HAZARDOUS MATERIALS DESCRIPTIONS

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

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

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL! • Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death to personnel can result from severe exposure. Carbon monoxide occurs in exhaust fumes of internal combustion engines. It also occurs in exhaust fumes of engine coolant heater (arctic vehicle only). Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of crane is operated. 1. 2. 3. 4. DO NOT operate engine in enclosed areas without adequate ventilation. DO NOT idle engine without adequate ventilation. DO NOT drive vehicle with inspection plates or cover plates removed. BE ALERT for exhaust poisoning symptoms. They are: • • • • Headache Dizziness Sleepiness Loss of muscular control

5. If you see another person with exhaust poisoning symptoms: • • • • • • Remove person from area. Expose person to fresh air. Keep person warm. DO NOT permit physical exercise. Administer cardiopulmonary resuscitation (CPR), if necessary. Notify a medic.

6. BE AWARE. The field protective mask for Nuclear-Biological-Chemical (NBC) protection will not protect you from carbon monoxide poisoning.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

CBRN EXPOSURE If Chemical, Biological, Radioactive and Nuclear (CBRN) exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may cause injury or death to personnel. Seek medical attention.

To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel.

WARNING

If vehicle is parked indoors during performance of Preventive Maintenance Checks and Services (PMCS), DO NOT run engine unless exhaust fumes are vented to the outside. Failure to follow this warning may cause injury or death to personnel due to carbon monoxide poisoning.

WARNING

Diesel fuel and other combustible materials are used in operation and maintenance of this equipment. DO NOT smoke or allow open flames in areas where combustible materials are stored or used. Failure to follow this warning may cause injury or death to personnel.

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

Never perform fan hub bearing end play check with the engine running. Failure to follow this warning may cause death or injury to personnel.

WARNING

Cooling system is pressurized. Use extreme caution and proper protection when removing radiator cap after operating temperature is reached. Steam and hot gases will be escaping through the radiator cap; avoid being burned by these escaping gases. When removing cap, loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed. Failure to follow this warning may cause death or injury to personnel.

WARNING

DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering. Avoid sudden movement of vehicle. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Failure to follow these warnings may result in injury or death to personnel.

• • • • •

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities’ procedures. Eye shields must be worn when cleaning with a wire brush. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. Failure to follow these warnings may result in injury or death to personnel.

• • • • •

WARNING

When servicing equipment, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, or Chemical Agent Resistance Coating (CARC) paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Wear protective eye covering. Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit. Failure to follow these warnings may result in injury or death to personnel.

• • •

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

• •

The brake linings contain asbestos. Wear protective breather respirator when performing maintenance on the brake assembly and brake drum. Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. DO NOT use compressed air to dry the brake assembly. Let it air dry. Failure to follow these warnings may cause injury or death to personnel.

• •

WARNING

Liquid nitrogen is extremely cold, having a temperature of -320°F (-195°C). Wear protective gloves that will not absorb liquid nitrogen. Excess liquid nitrogen must be disposed of promptly since liquid nitrogen will condense oxygen from the atmosphere. The mixture of liquid nitrogen and liquid oxygen is a powerful oxidizer and may react violently with easily oxidizable substances. Failure to follow this warning may cause injury or death to personnel.

WARNING

• •

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Hot coolant and alkali contained in cooling system can burn severely. Even with cooling system drained, residual coolant remains in system lines and fittings. Wear protective goggles, face shield, and clothing when handling cooling system components. If coolant contacts eyes, skin, or clothing, flush with large amounts of cold water and seek medical attention, if required. Failure to follow these warnings may result in injury or death to personnel.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury to personnel.

WARNING

Weight of differential assembly is approximately 120 lbs (54 kgs). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. Failure to follow these warnings may result in serious injury or death to personnel.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may result in serious injury or death to personnel.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE: This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes. Zero in the "Change No." column indicates an original page or work package. Date of issue for the original manual is: Original 14 September 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 106 AND TOTAL NUMBER OF WORK PACKAGES IS 172 CONSISTING OF THE FOLLOWING: Page/WP No. Front Cover Warning Summary (30 pages) Title Block Page (2 pages) Table of Contents (44 pages) How to Use This Manual (2 pages) Chapter 1 Title Page WP 0001 (4 pages) WP 0002 (18 pages) WP 0003 (2 pages) Chapter 2 Title Page WP 0004 (6 pages) WP 0005 (16 pages) WP 0006 (4 pages) WP 0007 (4 pages) WP 0008 (4 pages) WP 0009 (4 pages) WP 0010 (4 pages) WP 0011 (10 pages) WP 0012 (6 pages) WP 0013 (2 pages) WP 0014 (4 pages) WP 0015 (6 pages) WP 0016 (4 pages) WP 0017 (8 pages) WP 0018 (4 pages) WP 0019 (6 pages) WP 0020 (8 pages) Chapter 3 Title Page WP 0021 (2 pages) WP 0022 (24 pages) Chapter 4 Title Page WP 0023 (4 pages) WP 0024 (28 pages) WP 0025 (2 pages) WP 0026 (2 pages) WP 0027 (6 pages) WP 0028 (2 pages) WP 0029 (8 pages) WP 0030 (6 pages) WP 0031 (8 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0032 (6 pages) WP 0033 (4 pages) WP 0034 (4 pages) WP 0035 (2 pages) WP 0036 (4 pages) WP 0037 (8 pages) WP 0038 (4 pages) WP 0039 (6 pages) WP 0040 (4 pages) WP 0041 (4 pages) WP 0042 (4 pages) WP 0043 (4 pages) WP 0044 (22 pages) WP 0045 (4 pages) WP 0046 (6 pages) WP 0047 (8 pages) WP 0048 (4 pages) WP 0049 (16 pages) WP 0050 (4 pages) WP 0051 (6 pages) WP 0052 (12 pages) WP 0053 (6 pages) WP 0054 (20 pages) WP 0055 (4 pages) WP 0056 (4 pages) WP 0057 (4 pages) WP 0058 (4 pages) WP 0059 (4 pages) WP 0060 (8 pages) WP 0061 (4 pages) WP 0062 (4 pages) WP 0063 (4 pages) WP 0064 (4 pages) WP 0065 (4 pages) WP 0066 (30 pages) WP 0067 (6 pages) WP 0068 (4 pages) WP 0069 (2 pages) WP 0070 (10 pages) WP 0071 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued
Page/WP No. WP 0072 (6 pages) WP 0073 (4 pages) WP 0074 (6 pages) WP 0075 (4 pages) WP 0076 (16 pages) WP 0077 (4 pages) WP 0078 (4 pages) WP 0079 (4 pages) WP 0080 (4 pages) WP 0081 (4 pages) WP 0082 (16 pages) WP 0083 (4 pages) WP 0084 (4 pages) WP 0085 (6 pages) WP 0086 (10 pages) WP 0087 (4 pages) WP 0088 (2 pages) WP 0089 (4 pages) WP 0090 (16 pages) WP 0091 (6 pages) WP 0092 (4 pages) WP 0093 (10 pages) WP 0094 (6 pages) WP 0095 (8 pages) WP 0096 (12 pages) WP 0097 (10 pages) WP 0098 (4 pages) WP 0099 (6 pages) WP 0100 (6 pages) WP 0101 (8 pages) WP 0102 (10 pages) WP 0103 (8 pages) WP 0104 (14 pages) WP 0105 (18 pages) WP 0106 (4 pages) WP 0107 (6 pages) WP 0108 (4 pages) WP 0109 (14 pages) WP 0110 (6 pages) WP 0111 (6 pages) WP 0112 (4 pages) WP 0113 (8 pages) WP 0114 (6 pages) WP 0115 (4 pages) WP 0116 (4 pages) WP 0117 (10 pages) WP 0118 (8 pages) WP 0119 (12 pages) WP 0120 (6 pages) WP 0121 (4 pages) WP 0122 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0123 (8 pages) WP 0124 (6 pages) WP 0125 (24 pages) WP 0126 (18 pages) WP 0127 (6 pages) WP 0128 (8 pages) WP 0129 (14 pages) WP 0130 (4 pages) WP 0131 (12 pages) WP 0132 (14 pages) WP 0133 (2 pages) WP 0134 (6 pages) WP 0135 (16 pages) WP 0136 (10 pages) WP 0137 (6 pages) WP 0138 (8 pages) WP 0139 (8 pages) WP 0140 (6 pages) WP 0141 (6 pages) WP 0142 (6 pages) WP 0143 (6 pages) WP 0144 (6 pages) WP 0145 (12 pages) WP 0146 (6 pages) WP 0147 (6 pages) WP 0148 (6 pages) WP 0149 (16 pages) WP 0150 (16 pages) WP 0151 (16 pages) WP 0152 (8 pages) WP 0153 (8 pages) WP 0154 (4 pages) WP 0155 (6 pages) WP 0156 (28 pages) WP 0157 (2 pages) WP 0158 (12 pages) WP 0159 (4 pages) WP 0160 (12 pages) WP 0161 (20 pages) WP 0162 (10 pages) WP 0163 (18 pages) WP 0164 (6 pages) WP 0165 (16 pages) WP 0166 (2 pages) Chapter 5 Title Page WP 0167 (2 pages) WP 0168 (4 pages) WP 0169 (14 pages) WP 0170 (6 pages) WP 0171 (4 pages) WP 0172 (10 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued
Page/WP No. Index (6 pages) Foldouts Change No. 0 0 Page/WP No. Back Cover Change No. 0

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*TM 5-3810-305-23

HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 14 SEPTEMBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

CRANE, WHEEL MOUNTED, HYDRAULIC, LIGHT, 7 1/2 TON (ROUGH TERRAIN CRANE) LRT 110 TYPE I GENERAL PURPOSE NSN 3810-01-165-0646 TYPE II AIRBORNE/AIRMOBILE NSN 3810-01-165-0647
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

*SUPERSEDURE NOTICE - This manual supersedes TM 5-3810-305-24 dated 3 December 1991 including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS
Page No. WP Sequence No. HOW TO USE THIS MANUAL ......................................................................................................................... xlvii Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Figure 2. Figure 3. Figure 4. Table 1. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Major Components............................................................................................................... 0002-2 Major Components............................................................................................................... 0002-4 Major Components............................................................................................................... 0002-5 Major Components............................................................................................................... 0002-6 Gear Range Values............................................................................................................ 0002-13 General Dimensions........................................................................................................... 0002-14 General Dimensions........................................................................................................... 0002-15 Radius from Centerline of Rotation.................................................................................... 0002-16 Crane Working Positions.................................................................................................... 0002-17 Lift Capacity (on Outriggers).............................................................................................. 0002-17 Lift Capacity (on Tires)....................................................................................................... 0002-18 Maximum Permissible Hoist Line Load.............................................................................. 0002-18

THEORY OF OPERATION.......................................................................................................................... WP 0003 Chapter 2 - TROUBLESHOOTING PROCEDURES TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0004 TROUBLESHOOTING PROCEDURES ENGINE........................................................................................ WP 0005 TROUBLESHOOTING PROCEDURES HYDRAULICS.............................................................................. WP 0006 TROUBLESHOOTING PROCEDURES SWING CIRCUIT.......................................................................... WP 0007 TROUBLESHOOTING PROCEDURES BOOM HOIST CIRCUIT............................................................... WP 0008 TROUBLESHOOTING PROCEDURES BOOM EXTEND CIRCUIT........................................................... WP 0009 TROUBLESHOOTING PROCEDURES OUTRIGGER CIRCUIT................................................................ WP 0010 TROUBLESHOOTING PROCEDURES STEERING CIRCUIT................................................................... WP 0011 TROUBLESHOOTING PROCEDURES PUMPS......................................................................................... WP 0012

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. TROUBLESHOOTING PROCEDURES RELIEF VALVES.......................................................................... WP 0013 TROUBLESHOOTING PROCEDURES BRAKES....................................................................................... WP 0014 TROUBLESHOOTING PROCEDURES ELECTRICAL SYSTEM............................................................... WP 0015 TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK SYSTEM....................................................... WP 0016 TROUBLESHOOTING PROCEDURES TRANSMISSION.......................................................................... WP 0017 TROUBLESHOOTING PROCEDURES AXLE ASSEMBLY........................................................................ WP 0018 TROUBLESHOOTING PROCEDURES WINCH......................................................................................... WP 0019 MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE...................................................................... WP 0020 Figure 1. Figure 2. Remove Cap from DCA Receptacle..................................................................................... 0020-3 Schematics and Diagrams................................................................................................... 0020-7

Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION............................. WP 0021 Table 1. Leakage Definitions for PMCS............................................................................................. 0021-2

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0022 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Preventive Maintenance Checks and Services (PMCS)...................................................... 0022-2 Winch Lubrication Level Access Plug.................................................................................. 0022-3 Air Cleaner Element Maintenance........................................................................................ 0022-5 Engine Oil and Filter Change............................................................................................... 0022-6 Fuel Tank Drain Plug............................................................................................................ 0022-7 Hydraulic Suction Filter Removal......................................................................................... 0022-9 Transmission Fluid Change................................................................................................ 0022-10 Check Antifreeze Concentration......................................................................................... 0022-11 Check Axle Differential and Hub Oil Levels........................................................................ 0022-12 Check Axle Differential and Hub Oil Levels........................................................................ 0022-12 Check Fan Hub Bearing End Play...................................................................................... 0022-13 Winch Oil Change.............................................................................................................. 0022-14 Add Hydraulic Oil................................................................................................................ 0022-16

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Bleed Air from Hydraulic Reservoir.................................................................................... 0022-17 Swing Reduction Unit Oil Change...................................................................................... 0022-18 Differential Oil Filter............................................................................................................ 0022-19 Engine Coolant Change..................................................................................................... 0022-20 Engine Coolant Change..................................................................................................... 0022-21 Check Hydraulic Pressure Relief Valves............................................................................ 0022-22 Relief Valve Adjustment..................................................................................................... 0022-24

Chapter 4 - MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT......................................................................................................................... WP 0023 Figure 1. Vehicle Check Points........................................................................................................... 0023-3

POWER PACK ASSEMBLY MAINTENANCE............................................................................................. WP 0024 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Power Pack Removal........................................................................................................... 0024-2 Power Pack Removal........................................................................................................... 0024-3 Power Pack Removal........................................................................................................... 0024-4 Power Pack Removal........................................................................................................... 0024-4 Power Pack Removal........................................................................................................... 0024-5 Power Pack Removal........................................................................................................... 0024-6 Power Pack Removal........................................................................................................... 0024-7 Power Pack Removal........................................................................................................... 0024-8 Power Pack Removal........................................................................................................... 0024-9 Power Pack Removal........................................................................................................... 0024-9 Power Pack Removal......................................................................................................... 0024-10 Power Pack Removal......................................................................................................... 0024-10 Power Pack Removal......................................................................................................... 0024-11 Power Pack Removal......................................................................................................... 0024-12 Power Pack Removal......................................................................................................... 0024-13 Transmission from Engine Removal.................................................................................. 0024-14

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Transmission from Engine Removal.................................................................................. 0024-15 Transmission from Engine Removal.................................................................................. 0024-16 Transmission to Engine Installation.................................................................................... 0024-17 Transmission to Engine Installation.................................................................................... 0024-18 Transmission to Engine Installation.................................................................................... 0024-19 Transmission to Engine Installation.................................................................................... 0024-20 Power Pack Installation...................................................................................................... 0024-21 Power Pack Installation...................................................................................................... 0024-22 Power Pack Installation...................................................................................................... 0024-22 Power Pack Installation...................................................................................................... 0024-23 Power Pack Installation...................................................................................................... 0024-23 Power Pack Installation...................................................................................................... 0024-24 Power Pack Installation...................................................................................................... 0024-24 Power Pack Installation...................................................................................................... 0024-25 Power Pack Installation...................................................................................................... 0024-25 Power Pack Installation...................................................................................................... 0024-26 Power Pack Installation...................................................................................................... 0024-26 Power Pack Installation...................................................................................................... 0024-27 Power Pack Installation...................................................................................................... 0024-27 Power Pack Installation...................................................................................................... 0024-28

ENGINE ASSEMBLY MAINTENANCE........................................................................................................ WP 0025 ENGINE MOUNT MAINTENANCE.............................................................................................................. WP 0026 Figure 1. Figure 2. Engine Mount Removal........................................................................................................ 0026-1 Engine Mount Installation..................................................................................................... 0026-2

CYLINDER HEAD MAINTENANCE............................................................................................................. WP 0027 Figure 1. Figure 2. Cylinder Head Removal....................................................................................................... 0027-2 Cylinder Head Removal....................................................................................................... 0027-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Figure 4. Cylinder Head Installation.................................................................................................... 0027-4 Cylinder Head Installation.................................................................................................... 0027-5

CRANKSHAFT PULLEY MAINTENANCE................................................................................................... WP 0028 Figure 1. Figure 2. Crankshaft Pulley Removal.................................................................................................. 0028-1 Crankshaft Pulley Installation............................................................................................... 0028-2

FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE........................................................................ WP 0029 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Flywheel Removal................................................................................................................ 0029-1 Flywheel Removal................................................................................................................ 0029-2 Flywheel Installation............................................................................................................. 0029-3 Flywheel Installation............................................................................................................. 0029-3 Flywheel Installation............................................................................................................. 0029-4 Flywheel Installation............................................................................................................. 0029-5 Flywheel Installation............................................................................................................. 0029-6 Flywheel Installation............................................................................................................. 0029-6

REAR CRANKSHAFT SEAL MAINTENANCE............................................................................................ WP 0030 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Rear Seal Removal.............................................................................................................. 0030-2 Rear Seal Removal.............................................................................................................. 0030-2 Rear Seal Removal.............................................................................................................. 0030-3 Rear Seal Installation........................................................................................................... 0030-4 Rear Seal Installation........................................................................................................... 0030-5

ROCKER LEVERS AND PUSH RODS MAINTENANCE............................................................................ WP 0031 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cylinder Head Removal....................................................................................................... 0031-2 Rocker Lever and Push Rods Removal............................................................................... 0031-2 Rocker Lever and Push Rods Disassembly......................................................................... 0031-3 Rocker Lever and Push Rods Disassembly......................................................................... 0031-3 Rocker Lever and Push Rods Inspection............................................................................. 0031-4 Rocker Lever and Push Rods Inspection............................................................................. 0031-4

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Rocker Lever and Push Rods Inspection............................................................................. 0031-5 Rocker Lever and Push Rods Assembly.............................................................................. 0031-5 Rocker Lever and Push Rods Assembly.............................................................................. 0031-6 Rocker Lever and Push Rods Installation............................................................................ 0031-6 Cylinder Head Installation.................................................................................................... 0031-7

FRONT GEAR COVER AND GASKET MAINTENANCE............................................................................ WP 0032 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Tachometer Drive Removal.................................................................................................. 0032-2 Front Cover Removal........................................................................................................... 0032-3 Front Gear Train Installation................................................................................................. 0032-4 Front Cover Installation........................................................................................................ 0032-5 Tachometer Drive Installation............................................................................................... 0032-6

TIMING PIN ASSEMBLY MAINTENANCE.................................................................................................. WP 0033 Figure 1. Figure 2. Figure 3. Timing Pin Assembly Removal............................................................................................. 0033-1 Timing Pin Assembly Removal............................................................................................. 0033-2 Timing Pin Assembly Installation.......................................................................................... 0033-3

TAPPET COVER AND GASKET MAINTENANCE...................................................................................... WP 0034 Figure 1. Tappet Cover Installation..................................................................................................... 0034-3

VALVE COVERS AND GASKET MAINTENANCE...................................................................................... WP 0035 Figure 1. Figure 2. Valve Covers Removal......................................................................................................... 0035-1 Valve Covers Installation...................................................................................................... 0035-2

FRONT CRANKSHAFT SEAL MAINTENANCE.......................................................................................... WP 0036 Figure 1. Figure 2. Front Seal Removal.............................................................................................................. 0036-2 Front Seal Installation........................................................................................................... 0036-4

LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE.................................................... WP 0037 Figure 1. Figure 2. Figure 3. Lube Oil Cooler Removal..................................................................................................... 0037-2 Lube Oil Cooler Removal..................................................................................................... 0037-2 Lube Oil Cooler Removal..................................................................................................... 0037-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 4. Figure 5. Table 1. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Lube Oil Cooler Disassembly............................................................................................... 0037-3 Lube Oil Cooler Disassembly............................................................................................... 0037-4 Pressure Regulator Spring Limits......................................................................................... 0037-4 Lube Oil Cooler Inspection................................................................................................... 0037-5 Lube Oil Cooler Assembly.................................................................................................... 0037-6 Lube Oil Cooler Installation.................................................................................................. 0037-6 Lube Oil Cooler Installation.................................................................................................. 0037-7 Lube Oil Cooler Installation.................................................................................................. 0037-7

LUBE OIL PUMP MAINTENANCE.............................................................................................................. WP 0038 Figure 1. Figure 2. Figure 3. Lube Oil Pump Removal...................................................................................................... 0038-1 Lube Oil Pump Removal...................................................................................................... 0038-2 Lube Oil Pump Installation................................................................................................... 0038-3

OIL PAN AND SUCTION TUBE MAINTENANCE....................................................................................... WP 0039 Figure 1. Figure 2. Figure 3. Figure 4. Oil Pan and Suction Tube Removal..................................................................................... 0039-2 Oil Pan and Suction Tube Removal..................................................................................... 0039-3 Oil Pan and Suction Tube Installation.................................................................................. 0039-5 Oil Pan and Suction Tube Installation.................................................................................. 0039-6

OIL LEVEL GAGE MAINTENANCE............................................................................................................ WP 0040 Figure 1. Figure 2. Figure 3. Oil Level Gage Removal...................................................................................................... 0040-1 Oil Level Gage Removal...................................................................................................... 0040-2 Oil Level Gage Installation................................................................................................... 0040-3

INTAKE MANIFOLD COVER AND GASKET MAINTENANCE................................................................... WP 0041 Figure 1. Figure 2. Manifold Cover Plate Removal............................................................................................. 0041-1 Manifold Cover Plate Installation.......................................................................................... 0041-2

EXHAUST MANIFOLD AND GASKETS MAINTENANCE........................................................................... WP 0042 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0042-1 Exhaust Manifold Removal................................................................................................... 0042-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Exhaust Manifold Installation................................................................................................ 0042-2

FUEL INJECTOR MAINTENANCE.............................................................................................................. WP 0043 Figure 1. Figure 2. Figure 3. Figure 4. Injector Nozzles Removal..................................................................................................... 0043-2 Injector Nozzles Removal..................................................................................................... 0043-2 Lube Oil Injector Nozzles Installation................................................................................... 0043-3 Injector Nozzles Installation.................................................................................................. 0043-4

FUEL INJECTION PUMP MAINTENANCE................................................................................................. WP 0044 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Injection Pump Removal...................................................................................................... 0044-2 Injection Pump Removal...................................................................................................... 0044-3 Injection Pump Removal...................................................................................................... 0044-3 Injection Pump Removal...................................................................................................... 0044-4 Injection Pump Removal...................................................................................................... 0044-4 Injection Pump Removal...................................................................................................... 0044-5 Injection Pump Disassembly................................................................................................ 0044-6 Injection Pump Disassembly................................................................................................ 0044-7 Injection Pump Disassembly................................................................................................ 0044-7 Injection Pump Disassembly................................................................................................ 0044-8 Injection Pump Disassembly................................................................................................ 0044-8 Injection Pump Disassembly................................................................................................ 0044-9 Injection Pump Disassembly................................................................................................ 0044-9 Injection Pump Disassembly.............................................................................................. 0044-10 Injection Pump Disassembly.............................................................................................. 0044-11 Injection Pump Disassembly.............................................................................................. 0044-11 Injection Pump Disassembly.............................................................................................. 0044-12 Injection Pump Assembly................................................................................................... 0044-13 Injection Pump Assembly................................................................................................... 0044-14 Injection Pump Assembly................................................................................................... 0044-15

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Injection Pump Assembly................................................................................................... 0044-15 Injection Pump Assembly................................................................................................... 0044-16 Injection Pump Assembly................................................................................................... 0044-16 Injection Pump Assembly................................................................................................... 0044-17 Injection Pump Assembly................................................................................................... 0044-17 Injection Pump Assembly................................................................................................... 0044-18 Injection Pump Assembly................................................................................................... 0044-18 Injection Pump Assembly................................................................................................... 0044-19 Injection Pump Installation................................................................................................. 0044-19 Injection Pump Installation................................................................................................. 0044-20 Injection Pump Installation................................................................................................. 0044-20 Injection Pump Installation................................................................................................. 0044-21 Injection Pump Installation................................................................................................. 0044-21 Injection Pump Installation................................................................................................. 0044-22

FUEL LIFT PUMP MAINTENANCE............................................................................................................. WP 0045 Figure 1. Figure 2. Lift Pump Removal............................................................................................................... 0045-2 Lift Pump Installation............................................................................................................ 0045-3

AIR CLEANER ASSEMBLY MAINTENANCE............................................................................................. WP 0046 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Air Cleaner Removal............................................................................................................ 0046-2 Air Cleaner Removal............................................................................................................ 0046-3 Air Cleaner Maintenance...................................................................................................... 0046-5 Air Cleaner Installation......................................................................................................... 0046-5 Air Cleaner Installation......................................................................................................... 0046-6

FUEL TANK MAINTENANCE...................................................................................................................... WP 0047 Figure 1. Figure 2. Figure 3. Fuel Tank Removal.............................................................................................................. 0047-1 Fuel Tank Removal.............................................................................................................. 0047-2 Fuel Tank Disassembly........................................................................................................ 0047-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Fuel Tank Disassembly........................................................................................................ 0047-3 Fuel Tank Assembly............................................................................................................. 0047-4 Fuel Tank Assembly............................................................................................................. 0047-5 Fuel Tank Installation........................................................................................................... 0047-6 Fuel Tank Installation........................................................................................................... 0047-7

FUEL LINES MAINTENANCE..................................................................................................................... WP 0048 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Fuel Lines Removal.............................................................................................................. 0048-1 Fuel Lines Removal.............................................................................................................. 0048-2 Fuel Lines Installation........................................................................................................... 0048-3 Fuel Lines Installation........................................................................................................... 0048-3 Fuel Lines Installation........................................................................................................... 0048-4

FUEL INJECTION TUBES MAINTENANCE................................................................................................ WP 0049 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. High-Pressure Tubes Removal............................................................................................ 0049-2 High-Pressure Tubes Removal............................................................................................ 0049-3 High-Pressure Tubes Removal............................................................................................ 0049-4 Low-Pressure Tubes Removal............................................................................................. 0049-5 Low-Pressure Tubes Removal............................................................................................. 0049-6 Low-Pressure Tubes Removal............................................................................................. 0049-7 Fuel Drain Tubes Removal................................................................................................... 0049-8 Fuel Drain Tubes Removal................................................................................................... 0049-9 Fuel Drain Tubes Installation.............................................................................................. 0049-10 Fuel Drain Tubes Installation.............................................................................................. 0049-11 Low-Pressure Tubes Installation........................................................................................ 0049-12 Low-Pressure Tubes Installation........................................................................................ 0049-13 Low-Pressure Tubes Installation........................................................................................ 0049-14 High-Pressure Tubes Installation....................................................................................... 0049-15 High-Pressure Tubes Installation....................................................................................... 0049-16

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Page No. WP Sequence No. FUEL FILTER HEAD ASSEMBLY MAINTENANCE.................................................................................... WP 0050 Figure 1. Figure 2. Figure 3. Fuel Filters and Head Assembly Removal........................................................................... 0050-1 Fuel Filters and Head Assembly Maintenance..................................................................... 0050-2 Fuel Filters and Head Assembly Installation........................................................................ 0050-3

COLD START DEVICE MAINTENANCE..................................................................................................... WP 0051 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cold Start Device Removal.................................................................................................. 0051-1 Cold Start Device Removal.................................................................................................. 0051-2 Cold Start Device Removal.................................................................................................. 0051-2 Cold Start Device Removal.................................................................................................. 0051-3 Cold Start Device Installation............................................................................................... 0051-4 Cold Start Device Installation............................................................................................... 0051-4 Cold Start Device Installation............................................................................................... 0051-5 Cold Start Device Installation............................................................................................... 0051-6

THROTTLE CONTROL MAINTENANCE.................................................................................................... WP 0052 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Throttle Control Removal..................................................................................................... 0052-2 Throttle Control Removal..................................................................................................... 0052-2 Throttle Control Removal..................................................................................................... 0052-3 Throttle Control Removal..................................................................................................... 0052-3 Throttle Control Removal..................................................................................................... 0052-4 Throttle Control Maintenance............................................................................................... 0052-5 Throttle Control Installation.................................................................................................. 0052-6 Throttle Control Installation.................................................................................................. 0052-7 Throttle Control Installation.................................................................................................. 0052-7 Throttle Control Installation.................................................................................................. 0052-8 Throttle Control Installation.................................................................................................. 0052-9 Throttle Control Adjustment................................................................................................ 0052-10

EXHAUST SYSTEM ASSEMBLY MAINTENANCE..................................................................................... WP 0053

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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Exhaust System Removal.................................................................................................... 0053-1 Exhaust System Removal.................................................................................................... 0053-2 Exhaust System Maintenance.............................................................................................. 0053-3 Exhaust System Installation................................................................................................. 0053-4 Exhaust System Installation................................................................................................. 0053-5

RADIATOR AND OIL COOLER MAINTENANCE........................................................................................ WP 0054 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Radiator and Oil Cooler Removal......................................................................................... 0054-2 Radiator and Oil Cooler Removal......................................................................................... 0054-3 Radiator and Oil Cooler Removal......................................................................................... 0054-4 Radiator and Oil Cooler Removal......................................................................................... 0054-5 Radiator and Oil Cooler Removal......................................................................................... 0054-6 Radiator and Oil Cooler Removal......................................................................................... 0054-7 Radiator and Oil Cooler Removal......................................................................................... 0054-7 Radiator and Oil Cooler Removal......................................................................................... 0054-8 Radiator and Oil Cooler Removal......................................................................................... 0054-9 Radiator and Air Cooler Assembly..................................................................................... 0054-11 Radiator and Air Cooler Installation.................................................................................... 0054-12 Radiator and Air Cooler Installation.................................................................................... 0054-13 Radiator and Air Cooler Installation.................................................................................... 0054-14 Radiator and Air Cooler Installation.................................................................................... 0054-14 Radiator and Air Cooler Installation.................................................................................... 0054-15 Radiator and Air Cooler Installation.................................................................................... 0054-16 Radiator and Air Cooler Installation.................................................................................... 0054-17 Radiator and Air Cooler Installation.................................................................................... 0054-17 Radiator and Air Cooler Installation.................................................................................... 0054-18

DEFROSTER FAN MAINTENANCE........................................................................................................... WP 0055 Figure 1. Defroster Fan Maintenance.................................................................................................. 0055-3

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Page No. WP Sequence No. THERMOSTAT MAINTENANCE................................................................................................................. WP 0056 Figure 1. Figure 2. Figure 3. Figure 4. Thermostat Removal............................................................................................................ 0056-2 Thermostat Removal............................................................................................................ 0056-2 Thermostat Installation......................................................................................................... 0056-3 Thermostat Installation......................................................................................................... 0056-4

WATER INLET CONNECTION MAINTENANCE........................................................................................ WP 0057 Figure 1. Figure 2. Water Inlet Connection Removal.......................................................................................... 0057-2 Water Inlet Connection Installation....................................................................................... 0057-3

WATER PUMP MAINTENANCE................................................................................................................. WP 0058 Figure 1. Figure 2. Figure 3. Water Pump Removal.......................................................................................................... 0058-1 Water Pump Inspection........................................................................................................ 0058-2 Water Pump Installation....................................................................................................... 0058-3

FAN DRIVE BELT MAINTENANCE ............................................................................................................ WP 0059 Figure 1. Figure 2. Fan Drive Belt Removal....................................................................................................... 0059-2 Fan Drive Belt Installation.................................................................................................... 0059-3

COOLING FAN AND HUB ASSEMBLY MAINTENANCE........................................................................... WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Cooling Fan Removal........................................................................................................... 0060-1 Fan Pulley Removal............................................................................................................. 0060-2 Fan Drive Removal............................................................................................................... 0060-2 Hub Assembly Disassembly................................................................................................. 0060-3 Roller Bearing Disassembly................................................................................................. 0060-3 Roller Bearing Assembly...................................................................................................... 0060-4 Hub Assembly Assembly...................................................................................................... 0060-5 Fan Drive Installation............................................................................................................ 0060-5 Fan Pulley Installation.......................................................................................................... 0060-6 Cooling Fan Installation........................................................................................................ 0060-6

DRIVE BELT TENSIONER AND IDLER MAINTENANCE........................................................................... WP 0061

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Page No. WP Sequence No. Figure 1. Figure 2. Drive Belt Tensioner Removal.............................................................................................. 0061-2 Drive Belt Tensioner Installation........................................................................................... 0061-3

ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE.............................................. WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Alternator and Mounting Bracket Assembly Removal.......................................................... 0062-1 Alternator and Mounting Bracket Assembly Removal.......................................................... 0062-2 Alternator and Mounting Bracket Assembly Installation....................................................... 0062-3 Alternator and Mounting Bracket Assembly Installation....................................................... 0062-3

STARTER MOTOR MAINTENANCE........................................................................................................... WP 0063 Figure 1. Figure 2. Starter Motor Removal......................................................................................................... 0063-1 Starter Motor Assembly........................................................................................................ 0063-2

NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE........................................................................................................................................... WP 0064 Figure 1. Warning Switches Maintenance........................................................................................... 0064-2

FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE.......................................................... WP 0065 Figure 1. Fuel Pressure Switch and Transducer Installation............................................................... 0065-3

DASH PANEL GAGES AND SWITCHES MAINTENANCE......................................................................... WP 0066 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Dash Panel Removal............................................................................................................ 0066-2 Dash Panel Removal............................................................................................................ 0066-3 Dash Panel Removal............................................................................................................ 0066-3 Dash Panel Removal............................................................................................................ 0066-4 Dash Panel Removal............................................................................................................ 0066-5 Side Sloping Dash Panel Removal. .................................................................................... 0066-6 Side Sloping Dash Panel Removal...................................................................................... 0066-7 Side Sloping Dash Panel Removal. .................................................................................... 0066-8 Side Sloping Dash Panel Removal...................................................................................... 0066-9 Side Sloping Dash Panel Removal.................................................................................... 0066-10 Circuit Breaker Panel Removal.......................................................................................... 0066-11 Tachometer and Turn Signal Removal............................................................................... 0066-12

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Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Right Console Removal...................................................................................................... 0066-13 Right Console Removal...................................................................................................... 0066-14 Right Console Removal...................................................................................................... 0066-15 Tachometer and Turn Signal Installation............................................................................ 0066-16 Circuit Breaker Panel Installation....................................................................................... 0066-17 Side Sloping Dash Panel Installation................................................................................. 0066-18 Side Sloping Dash Panel Installation................................................................................. 0066-19 Side Sloping Dash Panel Installation................................................................................. 0066-20 Side Sloping Dash Panel Installation................................................................................. 0066-21 Side Sloping Dash Panel Installation................................................................................. 0066-22 Dash Panel Installation....................................................................................................... 0066-23 Dash Panel Installation....................................................................................................... 0066-23 Dash Panel Installation....................................................................................................... 0066-24 Dash Panel Installation....................................................................................................... 0066-25 Dash Panel Installation....................................................................................................... 0066-26 Right Console Installation................................................................................................... 0066-27 Right Console Installation................................................................................................... 0066-28 Right Console Installation................................................................................................... 0066-29

ANTI-TWO BLOCK CONTROL PANEL MAINTENANCE........................................................................... WP 0067 Figure 1. Figure 2. Control Panel Maintenance.................................................................................................. 0067-3 Control Panel Maintenance.................................................................................................. 0067-4

VEHICLE BUBBLE LEVEL MAINTENANCE............................................................................................... WP 0068 Figure 1. Figure 2. Vehicle Bubble Level Removal............................................................................................. 0068-1 Vehicle Bubble Level Installation.......................................................................................... 0068-2

HORN MAINTENANCE............................................................................................................................... WP 0069 Figure 1. Figure 2. Horn Removal...................................................................................................................... 0069-1 Horn Installation................................................................................................................... 0069-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. ELECTRICAL COLLECTOR RING MAINTENANCE................................................................................... WP 0070 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Electrical Collector Ring Removal........................................................................................ 0070-2 Electrical Collector Ring Removal........................................................................................ 0070-3 Electrical Collector Ring Removal........................................................................................ 0070-4 Electrical Collector Ring Removal........................................................................................ 0070-5 Electrical Collector Ring Installation..................................................................................... 0070-6 Electrical Collector Ring Installation..................................................................................... 0070-7 Electrical Collector Ring Installation..................................................................................... 0070-8 Electrical Collector Ring Installation..................................................................................... 0070-9

REAR LIGHTS MAINTENANCE.................................................................................................................. WP 0071 Figure 1. Rear Lights Maintenance..................................................................................................... 0071-3

FRONT LIGHTS AND BRACKETS MAINTENANCE.................................................................................. WP 0072 Figure 1. Figure 2. Left Front Lights and Bracket Installation............................................................................. 0072-3 Right Front Lights and Bracket Installation........................................................................... 0072-5

WORK LIGHTS MAINTENANCE................................................................................................................. WP 0073 Figure 1. Work Lights Maintenance..................................................................................................... 0073-3

AXLE CENTERING LIGHT SWITCH ASSEMBLY MAINTENANCE........................................................... WP 0074 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Axle Centering Light Switch Assembly Removal.................................................................. 0074-2 Axle Centering Light Switch Assembly Removal.................................................................. 0074-3 Axle Centering Light Switch Assembly Installation............................................................... 0074-4 Axle Centering Light Switch Assembly Installation............................................................... 0074-5 Axle Centering Light Switch Assembly Adjustment.............................................................. 0074-6

TACHOMETER ADJUSTMENT .................................................................................................................. WP 0075 Figure 1. Figure 2. Figure 3. Figure 4. Tachometer Wiring Harness Removal................................................................................. 0075-1 Tachometer Drive Removal.................................................................................................. 0075-2 Tachometer Drive Installation............................................................................................... 0075-3 Tachometer Wiring Harness Installation.............................................................................. 0075-4

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Page No. WP Sequence No. BATTERY ASSEMBLY AND CABLES MAINTENANCE............................................................................. WP 0076 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Battery and Cables Assembly Removal............................................................................... 0076-3 Battery and Cables Assembly Removal............................................................................... 0076-4 Battery and Cables Assembly Removal............................................................................... 0076-5 Battery and Cables Assembly Removal............................................................................... 0076-6 Battery and Cables Assembly Removal............................................................................... 0076-7 Battery and Cables Assembly Removal............................................................................... 0076-7 Battery and Cables Assembly Removal............................................................................... 0076-8 Battery and Cables Assembly Installation............................................................................ 0076-9 Battery and Cables Assembly Installation.......................................................................... 0076-10 Battery and Cables Assembly Installation.......................................................................... 0076-11 Battery and Cables Assembly Installation.......................................................................... 0076-12 Battery and Cables Assembly Installation.......................................................................... 0076-13 Battery and Cables Assembly Installation.......................................................................... 0076-14 Battery and Cables Assembly Installation.......................................................................... 0076-15

BATTERY BOX AND TOOLBOX WITH COVERS MAINTENANCE........................................................... WP 0077 Figure 1. Figure 2. Figure 3. Figure 4. Battery Box and Toolbox Cover Removal............................................................................ 0077-1 Battery Box and Toolbox Removal....................................................................................... 0077-2 Battery Box and Toolbox Installation.................................................................................... 0077-3 Battery Box and Toolbox Cover Installation......................................................................... 0077-4

MAIN ENGINE WIRING HARNESS MAINTENANCE................................................................................. WP 0078 Figure 1. Figure 2. Main Engine Wiring Harness Removal................................................................................. 0078-2 Main Engine Wiring Harness Installation.............................................................................. 0078-3

CAB MAIN HARNESS MAINTENANCE...................................................................................................... WP 0079 Figure 1. Cab Main Harness Maintenance.......................................................................................... 0079-3

BACKUP ALARM MAINTENANCE.............................................................................................................. WP 0080 Figure 1. Back Up Alarm Removal...................................................................................................... 0080-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 2. Back Up Alarm Installation................................................................................................... 0080-3

MSD-ICE WIRING HARNESS MAINTENANCE.......................................................................................... WP 0081 Figure 1. Figure 2. Main MSD-ICE Harness Removal........................................................................................ 0081-1 Main MSD-ICE Harness Installation..................................................................................... 0081-2

BOOM WIRING HARNESS MAINTENANCE.............................................................................................. WP 0082 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Boom Wiring Harness Removal........................................................................................... 0082-2 Boom Wiring Harness Removal........................................................................................... 0082-3 Boom Wiring Harness Removal........................................................................................... 0082-4 Boom Wiring Harness Removal........................................................................................... 0082-5 Boom Wiring Harness Removal........................................................................................... 0082-6 Boom Wiring Harness Removal........................................................................................... 0082-7 Boom Wiring Harness Removal........................................................................................... 0082-8 Boom Wiring Harness Removal........................................................................................... 0082-9 Boom Wiring Harness Removal........................................................................................... 0082-9 Boom Wiring Harness Installation...................................................................................... 0082-10 Boom Wiring Harness Installation...................................................................................... 0082-11 Boom Wiring Harness Installation...................................................................................... 0082-11 Boom Wiring Harness Installation...................................................................................... 0082-12 Boom Wiring Harness Installation...................................................................................... 0082-13 Boom Wiring Harness Installation...................................................................................... 0082-14 Boom Wiring Harness Installation...................................................................................... 0082-14 Boom Wiring Harness Installation...................................................................................... 0082-15 Boom Wiring Harness Installation...................................................................................... 0082-15

MSD-ICE DCA CONNECTOR/RESISTOR MODULE MAINTENANCE...................................................... WP 0083 Figure 1. Figure 2. MSD-ICE DCA Connector Resistor/Module Removal.......................................................... 0083-2 MSD-ICE DCA Connector Resistor/Module Installation....................................................... 0083-3

TRANSMISSION DIPSTICK TUBE ASSEMBLY MAINTENANCE.............................................................. WP 0084

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Figure 2. Transmission Dipstick Tube Removal.................................................................................. 0084-2 Transmission Dipstick Tube Installation............................................................................... 0084-3

TRANSMISSION SHIFT CONTROLS MAINTENANCE.............................................................................. WP 0085 Figure 1. Figure 2. Transmission Shift Controls Removal.................................................................................. 0085-3 Transmission Shift Controls Installation............................................................................... 0085-5

TRANSMISSION CABLES MAINTENANCE............................................................................................... WP 0086 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Transmission Cable Removal.............................................................................................. 0086-2 Transmission Cable Removal.............................................................................................. 0086-3 Transmission Cable Removal.............................................................................................. 0086-3 Transmission Cable Removal.............................................................................................. 0086-4 Transmission Cable Removal.............................................................................................. 0086-4 Transmission Cable Removal.............................................................................................. 0086-5 Transmission Cable Installation........................................................................................... 0086-6 Transmission Cable Installation........................................................................................... 0086-7 Transmission Cable Installation........................................................................................... 0086-7 Transmission Cable Installation........................................................................................... 0086-8 Transmission Cable Installation........................................................................................... 0086-8 Transmission Cable Installation........................................................................................... 0086-9

TRANSMISSION CONTROLS MAINTENANCE......................................................................................... WP 0087 Figure 1. Figure 2. Figure 3. Transmission Controls Maintenance.................................................................................... 0087-2 Transmission Controls Maintenance.................................................................................... 0087-3 Transmission Controls Maintenance.................................................................................... 0087-4

TRANSMISSION ASSEMBLY MAINTENANCE.......................................................................................... WP 0088 CHARGE PUMP MAINTENANCE............................................................................................................... WP 0089 Figure 1. Figure 2. Charge Pump Removal........................................................................................................ 0089-2 Charge Pump Installation..................................................................................................... 0089-3

CONTROL VALVE MAINTENANCE............................................................................................................ WP 0090

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Control Valve Disassembly.................................................................................................. 0090-2 Control Valve Disassembly.................................................................................................. 0090-3 Control Valve Disassembly.................................................................................................. 0090-4 Control Valve Disassembly.................................................................................................. 0090-5 Control Valve Disassembly.................................................................................................. 0090-6 Control Valve Disassembly.................................................................................................. 0090-6 Control Valve Disassembly.................................................................................................. 0090-7 Control Valve Disassembly.................................................................................................. 0090-7 Control Valve Assembly..................................................................................................... 0090-10 Control Valve Assembly..................................................................................................... 0090-10 Control Valve Assembly..................................................................................................... 0090-11 Control Valve Assembly..................................................................................................... 0090-12 Control Valve Assembly..................................................................................................... 0090-12 Control Valve Assembly..................................................................................................... 0090-13 Control Valve Assembly..................................................................................................... 0090-13 Control Valve Assembly..................................................................................................... 0090-14 Control Valve Assembly..................................................................................................... 0090-15

TRANSMISSION OIL AND FILTER ELEMENT MAINTENANCE................................................................ WP 0091 Figure 1. Figure 2. Figure 3. Figure 4. Transmission Oil and Filter Element Removal..................................................................... 0091-2 Transmission Oil and Filter Element Removal..................................................................... 0091-3 Transmission Oil and Filter Element Installation.................................................................. 0091-4 Transmission Oil and Filter Element Installation.................................................................. 0091-5

PUMP ADAPTER MAINTENANCE............................................................................................................. WP 0092 Figure 1. Figure 2. Pump Adapter Removal....................................................................................................... 0092-2 Pump Adapter Installation.................................................................................................... 0092-4

FRONT AND REAR DRIVESHAFT MAINTENANCE.................................................................................. WP 0093 Figure 1. Front Driveshaft Removal..................................................................................................... 0093-1

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Front Driveshaft Removal..................................................................................................... 0093-2 Front Driveshaft Disassembly.............................................................................................. 0093-2 Front Driveshaft Disassembly.............................................................................................. 0093-3 Front Driveshaft Assembly................................................................................................... 0093-4 Front Driveshaft Assembly................................................................................................... 0093-4 Front Driveshaft Installation.................................................................................................. 0093-5 Front Driveshaft Installation.................................................................................................. 0093-5 Rear Driveshaft Removal..................................................................................................... 0093-6 Rear Driveshaft Disassembly............................................................................................... 0093-7 Rear Driveshaft Assembly.................................................................................................... 0093-8 Rear Driveshaft Installation.................................................................................................. 0093-9

FRONT AXLE MAINTENANCE................................................................................................................... WP 0094 Figure 1. Figure 2. Front Axle Removal.............................................................................................................. 0094-3 Front Axle Installation........................................................................................................... 0094-5

FRONT DIFFERENTIAL ASSEMBLY MAINTENANCE.............................................................................. WP 0095 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Differential Removal.................................................................................................... 0095-3 Front Differential Removal.................................................................................................... 0095-4 Front Differential Installation................................................................................................. 0095-5 Front Differential Installation................................................................................................. 0095-6 Front Differential Installation................................................................................................. 0095-7

PLANETARY WHEEL END MAINTENANCE.............................................................................................. WP 0096 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Planetary Wheel End Removal............................................................................................ 0096-2 Planetary Wheel End Removal............................................................................................ 0096-3 Planetary Wheel End Removal............................................................................................ 0096-4 Planetary Wheel End Removal............................................................................................ 0096-4 Planetary Wheel End Removal............................................................................................ 0096-5 Planetary Wheel End Disassembly...................................................................................... 0096-5

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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Planetary Wheel End Maintenance...................................................................................... 0096-7 Planetary Wheel End Assembly........................................................................................... 0096-8 Planetary Wheel End Installation......................................................................................... 0096-9 Planetary Wheel End Installation......................................................................................... 0096-9 Planetary Wheel End Installation....................................................................................... 0096-10 Planetary Wheel End Installation....................................................................................... 0096-10 Planetary Wheel End Installation....................................................................................... 0096-11

PIVOT AND SPINDLE ASSEMBLY MAINTENANCE.................................................................................. WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Pivot and Spindle Assembly Removal.................................................................................. 0097-2 Pivot and Spindle Assembly Removal.................................................................................. 0097-3 Pivot and Spindle Assembly Installation............................................................................... 0097-5 Pivot and Spindle Assembly Installation............................................................................... 0097-6 Pivot and Spindle Assembly Installation............................................................................... 0097-7 Pivot and Spindle Assembly Installation............................................................................... 0097-9

PIVOT BEARINGS (TYPE II) MAINTENANCE............................................................................................ WP 0098 Figure 1. Pivot Bearings (Type II) Installation...................................................................................... 0098-3

CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE........................................................ WP 0099 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Constant-Velocity Joint and Axle Shaft Removal................................................................. 0099-2 Constant-Velocity Joint and Axle Shaft Removal................................................................. 0099-3 Constant-Velocity Joint and Axle Shaft Maintenance........................................................... 0099-4 Constant-Velocity Joint and Axle Shaft Installation.............................................................. 0099-5 Constant-Velocity Joint and Axle Shaft Installation.............................................................. 0099-7

REAR AXLE MAINTENANCE...................................................................................................................... WP 0100 Figure 1. Figure 2. Rear Axle Removal.............................................................................................................. 0100-3 Rear Axle Installation........................................................................................................... 0100-5

REAR DIFFERENTIAL ASSEMBLY MAINTENANCE................................................................................. WP 0101 Figure 1. Rear Differential Assembly Removal.................................................................................... 0101-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Rear Differential Assembly Installation................................................................................. 0101-5 Rear Differential Assembly Installation................................................................................. 0101-5 Rear Differential Assembly Installation................................................................................. 0101-7

PARKING BRAKE MAINTENANCE............................................................................................................ WP 0102 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Parking Brake Removal........................................................................................................ 0102-2 Parking Brake Removal........................................................................................................ 0102-2 Parking Brake Removal........................................................................................................ 0102-3 Parking Brake Removal........................................................................................................ 0102-3 Parking Brake Removal........................................................................................................ 0102-4 Parking Brake Disassembly................................................................................................. 0102-5 Parking Brake Assembly...................................................................................................... 0102-6 Parking Brake Installation..................................................................................................... 0102-7 Parking Brake Installation..................................................................................................... 0102-7 Parking Brake Installation..................................................................................................... 0102-8 Parking Brake Installation..................................................................................................... 0102-8 Parking Brake Installation..................................................................................................... 0102-9 Parking Brake Installation..................................................................................................... 0102-9 Parking Brake Installation................................................................................................... 0102-10

BRAKE ASSEMBLY MAINTENANCE......................................................................................................... WP 0103 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Brake Assembly Removal.................................................................................................... 0103-2 Brake Assembly Removal.................................................................................................... 0103-3 Brake Assembly Removal.................................................................................................... 0103-3 Brake Assembly Installation................................................................................................. 0103-5 Brake Assembly Installation................................................................................................. 0103-5 Brake Assembly Installation................................................................................................. 0103-6 Brake Assembly Installation................................................................................................. 0103-7 Brake Assembly Installation................................................................................................. 0103-7

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE........................................................... WP 0104 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Brake Booster Valve/Master Cylinder Removal................................................................... 0104-3 Brake Booster Valve/Master Cylinder Removal................................................................... 0104-3 Brake Booster Valve/Master Cylinder Removal................................................................... 0104-4 Brake Booster Valve/Master Cylinder Disassembly............................................................. 0104-5 Brake Booster Valve Disassembly....................................................................................... 0104-5 Brake Booster Disassembly................................................................................................. 0104-6 Brake Booster Disassembly................................................................................................. 0104-6 Brake Booster Disassembly................................................................................................. 0104-7 Brake Booster Disassembly................................................................................................. 0104-7 Brake Booster Maintenance................................................................................................. 0104-8 Brake Booster Assembly...................................................................................................... 0104-9 Brake Booster Assembly...................................................................................................... 0104-9 Brake Booster Assembly.................................................................................................... 0104-10 Brake Booster Assembly.................................................................................................... 0104-10 Brake Booster Assembly.................................................................................................... 0104-11 Master Cylinder/Brake Booster Assembly.......................................................................... 0104-11 Master Cylinder Installation................................................................................................ 0104-12 Master Cylinder Installation................................................................................................ 0104-13 Brake Booster Valve/Master Cylinder Installation.............................................................. 0104-13

HYDRAULIC BRAKE LINES AND FITTINGS MAINTENANCE.................................................................. WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-3 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-4 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-5 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-6 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-7 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-7

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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-8 Hydraulic Brake Lines and Fittings Removal........................................................................ 0105-9 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-10 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-11 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-12 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-13 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-13 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-14 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-15 Hydraulic Brake Lines and Fittings Installation................................................................... 0105-16

BRAKE PEDAL AND LINKAGE MAINTENANCE........................................................................................ WP 0106 Figure 1. Figure 2. Figure 3. Figure 4. Brake Pedal and Linkage Removal...................................................................................... 0106-1 Brake Pedal and Linkage Removal...................................................................................... 0106-2 Brake Pedal and Linkage Installation................................................................................... 0106-3 Brake Pedal and Linkage Installation................................................................................... 0106-4

TIRES AND WHEELS MAINTENANCE...................................................................................................... WP 0107 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Tires and Wheels Removal.................................................................................................. 0107-2 Tires and Wheels Disassembly............................................................................................ 0107-3 Tires and Wheels Assembly................................................................................................. 0107-4 Tires and Wheels Assembly................................................................................................. 0107-5 Tires and Wheels Installation............................................................................................... 0107-5 Tires and Wheels Installation............................................................................................... 0107-6

TIE ROD ASSEMBLY MAINTENANCE....................................................................................................... WP 0108 Figure 1. Figure 2. Figure 3. Tie Rod Assembly Removal................................................................................................. 0108-2 Tie Rod Assembly Installation.............................................................................................. 0108-3 Tie Rod Assembly Adjustment............................................................................................. 0108-4

GROUND DRIVEN STEERING PUMP MAINTENANCE............................................................................ WP 0109

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Ground Driven Steering Pump Removal.............................................................................. 0109-2 Ground Driven Steering Pump Disassembly........................................................................ 0109-3 Ground Driven Steering Pump Disassembly........................................................................ 0109-3 Ground Driven Steering Pump Disassembly........................................................................ 0109-4 Ground Driven Steering Pump Disassembly........................................................................ 0109-4 Ground Driven Steering Pump Disassembly........................................................................ 0109-5 Ground Driven Steering Pump Disassembly........................................................................ 0109-5 Ground Driven Steering Pump Disassembly........................................................................ 0109-6 Ground Driven Steering Pump Assembly............................................................................. 0109-8 Ground Driven Steering Pump Assembly............................................................................. 0109-9 Ground Driven Steering Pump Assembly............................................................................. 0109-9 Ground Driven Steering Pump Assembly........................................................................... 0109-10 Ground Driven Steering Pump Assembly........................................................................... 0109-10 Ground Driven Steering Pump Assembly........................................................................... 0109-11 Ground Driven Steering Pump Assembly........................................................................... 0109-12 Ground Driven Steering Pump Installation......................................................................... 0109-13

STEERING CONTROL UNIT MAINTENANCE........................................................................................... WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Steering Control Removal.................................................................................................... 0110-2 Steering Control Disassembly.............................................................................................. 0110-3 Steering Control Assembly................................................................................................... 0110-5 Steering Control Installation................................................................................................. 0110-6

STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE.................................................................... WP 0111 Figure 1. Figure 2. Steering System Hydraulic Hoses Removal......................................................................... 0111-3 Steering System Hydraulic Hoses Installation...................................................................... 0111-5

STEERING CYLINDERS MAINTENANCE.................................................................................................. WP 0112 Figure 1. Figure 2. Steering Cylinders Removal................................................................................................. 0112-3 Steering Cylinders Installation.............................................................................................. 0112-4

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Page No. WP Sequence No. STEERING SELECTOR VALVE MAINTENANCE...................................................................................... WP 0113 Figure 1. Figure 2. Figure 3. Steering Selector Valve Removal......................................................................................... 0113-3 Steering Selector Valve Installation...................................................................................... 0113-5 Steering Selector Valve Installation...................................................................................... 0113-6

FLOW DIVIDER AND STEERING VALVE MAINTENANCE....................................................................... WP 0114 Figure 1. Figure 2. Flow Divider and Steering Valve Removal........................................................................... 0114-3 Flow Divider and Steering Valve Installation........................................................................ 0114-4

HOOK BLOCK TIEBACK MAINTENANCE.................................................................................................. WP 0115 Figure 1. Figure 2. Hook Block Tieback Removal.............................................................................................. 0115-2 Hook Block Tieback Installation........................................................................................... 0115-3

PINTLE HOOK MAINTENANCE.................................................................................................................. WP 0116 Figure 1. Pintle Hook Maintenance..................................................................................................... 0116-3

CAB DOOR MAINTENANCE....................................................................................................................... WP 0117 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Cab Door Removal............................................................................................................... 0117-2 Cab Door Removal............................................................................................................... 0117-3 Cab Door Removal............................................................................................................... 0117-3 Cab Door Removal............................................................................................................... 0117-4 Cab Door Removal............................................................................................................... 0117-4 Cab Door Removal............................................................................................................... 0117-5 Cab Door Installation............................................................................................................ 0117-6 Cab Door Installation............................................................................................................ 0117-6 Cab Door Installation............................................................................................................ 0117-7 Cab Door Installation............................................................................................................ 0117-7 Cab Door Installation............................................................................................................ 0117-8 Cab Door Installation............................................................................................................ 0117-9

ENGINE HOOD AND GRILLE GUARD MAINTENANCE............................................................................ WP 0118 Figure 1. Grille Guard Removal........................................................................................................... 0118-2

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Engine Hood Removal......................................................................................................... 0118-3 Engine Hood Disassembly................................................................................................... 0118-4 Engine Hood Assembly........................................................................................................ 0118-5 Engine Hood Installation...................................................................................................... 0118-6 Grille Guard Installation........................................................................................................ 0118-7

CAB ASSEMBLY MAINTENANCE.............................................................................................................. WP 0119 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Assembly Removal....................................................................................................... 0119-2 Fire Extinguisher Removal................................................................................................... 0119-3 Floormats Removal.............................................................................................................. 0119-4 Cab Assembly Disassembly................................................................................................. 0119-5 Cab Assembly Assembly...................................................................................................... 0119-7 Floormats Installation........................................................................................................... 0119-8 Fire Extinguisher Installation................................................................................................ 0119-9 Cab Assembly Installation.................................................................................................. 0119-10

HOOD SUPPORT MAINTENANCE............................................................................................................. WP 0120 Figure 1. Figure 2. Figure 3. Hood Support Removal........................................................................................................ 0120-2 Hood Support Installation..................................................................................................... 0120-3 Hood Support Installation..................................................................................................... 0120-4

FENDERS MAINTENANCE......................................................................................................................... WP 0121 Figure 1. Fender Maintenance............................................................................................................ 0121-3

DECK PLATES MAINTENANCE................................................................................................................. WP 0122 Figure 1. Deck Plates Maintenance..................................................................................................... 0122-3

OUTRIGGER ASSEMBLY MAINTENANCE................................................................................................ WP 0123 Figure 1. Figure 2. Figure 3. Figure 4. Outrigger Assembly Removal............................................................................................... 0123-3 Outrigger Assembly Assembly............................................................................................. 0123-4 Outrigger Assembly Assembly............................................................................................. 0123-5 Outrigger Assembly Installation............................................................................................ 0123-6

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. SEAT AND SEAT BELT MAINTENANCE................................................................................................... WP 0124 Figure 1. Figure 2. Figure 3. Figure 4. Seat Belt Removal................................................................................................................ 0124-2 Seat Removal....................................................................................................................... 0124-3 Seat Installation.................................................................................................................... 0124-4 Seat Belt Installation............................................................................................................. 0124-5

WINCH ASSEMBLY MAINTENANCE......................................................................................................... WP 0125 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Winch Removal.................................................................................................................... 0125-2 Winch Disassembly.............................................................................................................. 0125-3 Hydraulic Hose Disassembly................................................................................................ 0125-4 Motor Disassembly............................................................................................................... 0125-4 Brake Clutch and Cylinder Disassembly.............................................................................. 0125-5 Sun Primary Gear Disassembly........................................................................................... 0125-5 Seal and Ball Bearing Disassembly..................................................................................... 0125-6 Primary Planet Carrier Disassembly.................................................................................... 0125-6 Sun Output Gear Disassembly............................................................................................. 0125-7 Output Planet Carrier Disassembly...................................................................................... 0125-7 Snap Ring Disassembly....................................................................................................... 0125-8 Drum Disassembly............................................................................................................... 0125-9 Seal and Bearing Disassembly.......................................................................................... 0125-10 Base Positioning Assembly................................................................................................ 0125-11 Drum Assembly.................................................................................................................. 0125-12 Drum Assembly.................................................................................................................. 0125-13 Bearing Support Assembly................................................................................................. 0125-13 Bearing Support Fasteners Assembly................................................................................ 0125-14 Snap Ring Assembly.......................................................................................................... 0125-15 Sun Output Gear Assembly................................................................................................ 0125-16 Output Planet Carrier Assembly......................................................................................... 0125-16

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Primary Planet Carrier Assembly....................................................................................... 0125-17 Bearing and Seal Assembly............................................................................................... 0125-17 Drum Assembly.................................................................................................................. 0125-18 Sun Primary Gear Assembly.............................................................................................. 0125-18 Brake Cylinder Assembly Assembly................................................................................... 0125-19 Brake Cylinder Assembly Assembly................................................................................... 0125-19 Brake Clutch Assembly Assembly...................................................................................... 0125-20 Motor Installation Assembly............................................................................................... 0125-21 Oil Fill Assembly................................................................................................................. 0125-22 Winch Installation............................................................................................................... 0125-23

WINCH MOTOR MAINTENANCE............................................................................................................... WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Winch Motor Disassembly.................................................................................................... 0126-2 Winch Motor Disassembly.................................................................................................... 0126-2 Winch Motor Disassembly.................................................................................................... 0126-3 Winch Motor Disassembly.................................................................................................... 0126-3 Winch Motor Disassembly.................................................................................................... 0126-4 Winch Motor Disassembly.................................................................................................... 0126-4 Winch Motor Disassembly.................................................................................................... 0126-5 Winch Motor Disassembly.................................................................................................... 0126-5 Winch Motor Disassembly.................................................................................................... 0126-6 Winch Motor Disassembly.................................................................................................... 0126-6 Winch Motor Disassembly.................................................................................................... 0126-7 Winch Motor Disassembly.................................................................................................... 0126-7 Winch Motor Disassembly.................................................................................................... 0126-8 Winch Motor Disassembly.................................................................................................... 0126-8 Winch Motor Disassembly.................................................................................................... 0126-9 Winch Motor Assembly....................................................................................................... 0126-10

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Page No. WP Sequence No. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Winch Motor Assembly....................................................................................................... 0126-10 Winch Motor Assembly....................................................................................................... 0126-11 Winch Motor Assembly....................................................................................................... 0126-11 Winch Motor Assembly....................................................................................................... 0126-12 Winch Motor Assembly....................................................................................................... 0126-12 Winch Motor Assembly....................................................................................................... 0126-13 Winch Motor Assembly....................................................................................................... 0126-13 Winch Motor Assembly....................................................................................................... 0126-14 Winch Motor Assembly....................................................................................................... 0126-14 Winch Motor Assembly....................................................................................................... 0126-15 Winch Motor Assembly....................................................................................................... 0126-15 Winch Motor Assembly....................................................................................................... 0126-16 Winch Motor Assembly....................................................................................................... 0126-16 Winch Motor Assembly....................................................................................................... 0126-17

WINCH BRAKE VALVE MAINTENANCE.................................................................................................... WP 0127 Figure 1. Figure 2. Winch Brake Valve Maintenance......................................................................................... 0127-3 Winch Brake Valve Maintenance......................................................................................... 0127-5

WINCH CONTROL VALVE AND FITTINGS MAINTENANCE.................................................................... WP 0128 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Winch Control Valve Installation........................................................................................... 0128-3 Winch Control Valve Test and Adjustment........................................................................... 0128-4 Winch Control Valve Test and Adjustment........................................................................... 0128-5 Winch Control Valve Test and Adjustment........................................................................... 0128-6 Winch Control Valve Test and Adjustment........................................................................... 0128-7 Winch Control Valve Test and Adjustment........................................................................... 0128-7

VALVE CONTROL, BOOM HOIST, EXTEND, AND WINCH CABLES MAINTENANCE............................ WP 0129 Figure 1. Figure 2. Valve Control Cable Removal.............................................................................................. 0129-2 Valve Control Cable Removal.............................................................................................. 0129-3

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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Valve Control Cable Removal.............................................................................................. 0129-4 Swing and Outrigger Cable Removal................................................................................... 0129-5 Boom Hoist, Extend, and Winch Cable Removal................................................................. 0129-7 Boom Hoist, Extend, and Winch Cable Installation.............................................................. 0129-8 Swing and Outrigger Cable Installation................................................................................ 0129-9 Valve Control Cables Installation....................................................................................... 0129-10 Valve Control Cables Installation....................................................................................... 0129-11 Valve Control Cables Installation....................................................................................... 0129-12 Cables Adjustment............................................................................................................. 0129-13

MIRROR MAINTENANCE........................................................................................................................... WP 0130 Figure 1. Mirror Maintenance.............................................................................................................. 0130-3

WINDSHIELD WIPER ASSEMBLY MAINTENANCE.................................................................................. WP 0131 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Windshield Wiper Removal.................................................................................................. 0131-2 Windshield Wiper Removal.................................................................................................. 0131-3 Windshield Wiper Removal.................................................................................................. 0131-4 Windshield Wiper Removal.................................................................................................. 0131-5 Windshield Wiper Removal and Installation......................................................................... 0131-7 Windshield Wiper Installation............................................................................................... 0131-8 Windshield Wiper Installation............................................................................................... 0131-9 Windshield Wiper Installation............................................................................................. 0131-10 Windshield Wiper Installation............................................................................................. 0131-11

HEATER MAINTENANCE........................................................................................................................... WP 0132 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Heater Removal................................................................................................................... 0132-3 Heater Removal................................................................................................................... 0132-3 Heater Removal................................................................................................................... 0132-4 Heater Removal................................................................................................................... 0132-4 Heater Removal................................................................................................................... 0132-5

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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Heater Removal................................................................................................................... 0132-5 Heater Disassembly............................................................................................................. 0132-6 Heater Disassembly............................................................................................................. 0132-7 Heater Disassembly............................................................................................................. 0132-8 Heater Assembly.................................................................................................................. 0132-9 Heater Assembly................................................................................................................ 0132-10 Heater Installation.............................................................................................................. 0132-10 Heater Installation.............................................................................................................. 0132-11 Heater Installation.............................................................................................................. 0132-11 Heater Installation.............................................................................................................. 0132-12 Heater Installation.............................................................................................................. 0132-12 Heater Installation.............................................................................................................. 0132-13

MARKING DECALS MAINTENANCE.......................................................................................................... WP 0133 MAIN HYDRAULIC PUMP MAINTENANCE................................................................................................ WP 0134 Figure 1. Figure 2. Main Hydraulic Pump Removal............................................................................................ 0134-2 Main Hydraulic Pump Installation......................................................................................... 0134-4

ROTARY MANIFOLD MAINTENANCE....................................................................................................... WP 0135 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Rotary Manifold Removal..................................................................................................... 0135-3 Rotary Manifold Removal..................................................................................................... 0135-4 Rotary Manifold Removal..................................................................................................... 0135-5 Rotary Manifold Removal..................................................................................................... 0135-6 Rotary Manifold Disassembly............................................................................................... 0135-7 Rotary Manifold Assembly.................................................................................................... 0135-9 Rotary Manifold Installation................................................................................................ 0135-10 Rotary Manifold Installation................................................................................................ 0135-11 Rotary Manifold Installation................................................................................................ 0135-12 Rotary Manifold Installation................................................................................................ 0135-13

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Page No. WP Sequence No. Figure 11. Rotary Manifold Installation................................................................................................ 0135-14

OUTRIGGER SOLENOID VALVE MAINTENANCE.................................................................................... WP 0136 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Outrigger Solenoid Valve Removal...................................................................................... 0136-3 Outrigger Solenoid Valve Disassembly................................................................................ 0136-3 Outrigger Solenoid Valve Disassembly................................................................................ 0136-4 Outrigger Solenoid Valve Disassembly................................................................................ 0136-4 Outrigger Solenoid Valve Disassembly................................................................................ 0136-5 Outrigger Solenoid Valve Assembly..................................................................................... 0136-6 Outrigger Solenoid Valve Assembly..................................................................................... 0136-7 Outrigger Solenoid Valve Assembly..................................................................................... 0136-7 Outrigger Solenoid Valve Assembly..................................................................................... 0136-8 Outrigger Solenoid Valve Installation................................................................................... 0136-9

AXLE LOCKOUT VALVE MAINTENANCE.................................................................................................. WP 0137 Figure 1. Figure 2. Figure 3. Axle Lockout Valve Removal................................................................................................ 0137-2 Axle Lockout Valve Installation............................................................................................. 0137-4 Axle Lockout Valve Adjustment............................................................................................ 0137-5

BOOM HOIST, WINCH, AND OUTRIGGER VALVE CONTROLS MAINTENANCE................................... WP 0138 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Boom Hoist, Winch, and Outrigger Valve Controls Removal............................................... 0138-1 Boom Hoist, Winch, and Outrigger Valve Controls Removal............................................... 0138-2 Boom Hoist, Winch, and Outrigger Valve Controls Disassembly......................................... 0138-3 Boom Hoist, Winch, and Outrigger Valve Controls Assembly.............................................. 0138-5 Boom Hoist, Winch, and Outrigger Valve Controls Installation............................................ 0138-6 Boom Hoist, Winch, and Outrigger Valve Controls Installation............................................ 0138-7

SWING/TELESCOPE VALVE CONTROLS MAINTENANCE..................................................................... WP 0139 Figure 1. Figure 2. Figure 3. Swing/Telescope Valve Controls Removal.......................................................................... 0139-2 Swing/Telescope Valve Controls Removal.......................................................................... 0139-3 Swing/Telescope Valve Controls Disassembly.................................................................... 0139-4

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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Swing/Telescope Valve Controls Assembly......................................................................... 0139-5 Swing/Telescope Valve Controls Installation....................................................................... 0139-6 Swing/Telescope Valve Controls Installation....................................................................... 0139-7

UPPER HYDRAULICS LINE MAINTENANCE............................................................................................ WP 0140 Figure 1. Figure 2. Upper Hydraulics Line Removal........................................................................................... 0140-3 Upper Hydraulics Line Installation........................................................................................ 0140-5

LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE.......................................... WP 0141 Figure 1. Figure 2. Lower Boom, Swing, and Winch Hydraulic Lines Removal.................................................. 0141-3 Lower Boom, Swing, and Winch Hydraulic Lines Installation............................................... 0141-5

RETURN AND PRESSURE HYDRAULICS MAINTENANCE..................................................................... WP 0142 Figure 1. Figure 2. Return and Pressure Hydraulics Removal........................................................................... 0142-3 Return and Pressure Hydraulics Installation........................................................................ 0142-4

OUTRIGGER HYDRAULICS MAINTENANCE............................................................................................ WP 0143 Figure 1. Figure 2. Outrigger Hydraulics Removal............................................................................................. 0143-3 Outrigger Hydraulics Installation.......................................................................................... 0143-5

SUCTION HYDRAULICS MAINTENANCE................................................................................................. WP 0144 Figure 1. Figure 2. Suction Hydraulics Removal................................................................................................ 0144-3 Suction Hydraulics Installation............................................................................................. 0144-5

ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE................................................ WP 0145 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-3 Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-4 Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-5 Rotary Manifold Quick Disconnects (Type II) Removal........................................................ 0145-6 Rotary Manifold Quick Disconnects (Type II) Installation..................................................... 0145-7 Rotary Manifold Quick Disconnects (Type II) Installation..................................................... 0145-8 Rotary Manifold Quick Disconnects (Type II) Installation..................................................... 0145-9 Rotary Manifold Quick Disconnects (Type II) Installation................................................... 0145-10

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. HYDRAULIC SYSTEM VALVE BANK MAINTENANCE.............................................................................. WP 0146 Figure 1. Figure 2. Figure 3. Hydraulic System Valve Bank Removal............................................................................... 0146-2 Hydraulic System Valve Bank Installation............................................................................ 0146-3 Hydraulic System Valve Bank Adjustment........................................................................... 0146-5

RELIEF VALVE MAINTENANCE................................................................................................................. WP 0147 Figure 1. Figure 2. Figure 3. Figure 4. Relief Valve Removal........................................................................................................... 0147-2 Relief Valve Installation........................................................................................................ 0147-3 Relief Valve Adjustment....................................................................................................... 0147-4 Relief Valve Adjustment....................................................................................................... 0147-5

RETURN FILTER MAINTENANCE............................................................................................................. WP 0148 Figure 1. Figure 2. Return Filter Removal.......................................................................................................... 0148-3 Return Filter Installation....................................................................................................... 0148-4

BOOM HOIST CYLINDER MAINTENANCE................................................................................................ WP 0149 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Boom Hoist Cylinder Removal............................................................................................. 0149-2 Boom Hoist Cylinder Removal............................................................................................. 0149-3 Boom Hoist Cylinder Disassembly....................................................................................... 0149-4 Boom Hoist Cylinder Disassembly....................................................................................... 0149-4 Boom Hoist Cylinder Disassembly....................................................................................... 0149-5 Boom Hoist Cylinder Disassembly....................................................................................... 0149-6 Boom Hoist Cylinder Disassembly....................................................................................... 0149-7 Boom Hoist Cylinder Disassembly....................................................................................... 0149-8 Boom Hoist Cylinder Assembly............................................................................................ 0149-9 Boom Hoist Cylinder Assembly.......................................................................................... 0149-10 Boom Hoist Cylinder Assembly.......................................................................................... 0149-11 Boom Hoist Cylinder Assembly.......................................................................................... 0149-11 Boom Hoist Cylinder Installation........................................................................................ 0149-13 Boom Hoist Cylinder Installation........................................................................................ 0149-14

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Page No. WP Sequence No. BOOM EXTEND CYLINDER MAINTENANCE............................................................................................ WP 0150 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Boom Extend Cylinder Disassembly.................................................................................... 0150-1 Boom Extend Cylinder Disassembly.................................................................................... 0150-2 Boom Extend Cylinder Disassembly.................................................................................... 0150-3 Boom Extend Cylinder Disassembly.................................................................................... 0150-4 Boom Extend Cylinder Disassembly.................................................................................... 0150-5 Boom Extend Cylinder Disassembly.................................................................................... 0150-6 Boom Extend Cylinder Disassembly.................................................................................... 0150-6 Boom Extend Cylinder Disassembly.................................................................................... 0150-7 Boom Extend Cylinder Disassembly.................................................................................... 0150-7 Boom Extend Cylinder Disassembly.................................................................................... 0150-8 Boom Extend Cylinder Assembly......................................................................................... 0150-9 Boom Extend Cylinder Assembly....................................................................................... 0150-10 Boom Extend Cylinder Assembly....................................................................................... 0150-10 Boom Extend Cylinder Assembly....................................................................................... 0150-11 Boom Extend Cylinder Assembly....................................................................................... 0150-12 Boom Extend Cylinder Assembly....................................................................................... 0150-13 Boom Extend Cylinder Assembly....................................................................................... 0150-14 Boom Extend Cylinder Assembly....................................................................................... 0150-14

OUTRIGGER CYLINDER ASSEMBLY MAINTENANCE............................................................................ WP 0151 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Outrigger Cylinder Removal................................................................................................. 0151-2 Outrigger Cylinder Removal................................................................................................. 0151-3 Outrigger Cylinder Removal................................................................................................. 0151-4 Outrigger Cylinder Disassembly........................................................................................... 0151-5 Outrigger Cylinder Disassembly........................................................................................... 0151-6 Outrigger Cylinder Disassembly........................................................................................... 0151-7 Outrigger Cylinder Disassembly........................................................................................... 0151-7

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Outrigger Cylinder Disassembly........................................................................................... 0151-8 Outrigger Cylinder Assembly................................................................................................ 0151-9 Outrigger Cylinder Assembly.............................................................................................. 0151-10 Outrigger Cylinder Assembly.............................................................................................. 0151-11 Outrigger Cylinder Assembly.............................................................................................. 0151-11 Outrigger Cylinder Assembly.............................................................................................. 0151-12 Outrigger Cylinder Installation............................................................................................ 0151-13 Outrigger Cylinder Installation............................................................................................ 0151-14 Outrigger Cylinder Installation............................................................................................ 0151-15

AXLE LOCKOUT CYLINDER MAINTENANCE........................................................................................... WP 0152 Figure 1. Figure 2. Figure 3. Figure 4. Axle Lockout Cylinder Removal........................................................................................... 0152-3 Axle Lockout Cylinder Removal........................................................................................... 0152-4 Axle Lockout Cylinder Installation........................................................................................ 0152-5 Axle Lockout Cylinder Installation........................................................................................ 0152-6

HYDRAULIC RESERVOIR MAINTENANCE............................................................................................... WP 0153 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Hydraulic Reservoir Removal............................................................................................... 0153-2 Hydraulic Reservoir Removal............................................................................................... 0153-3 Hydraulic Reservoir Removal............................................................................................... 0153-3 Hydraulic Reservoir Removal............................................................................................... 0153-4 Hydraulic Reservoir Installation............................................................................................ 0153-5 Hydraulic Reservoir Installation............................................................................................ 0153-6 Hydraulic Reservoir Installation............................................................................................ 0153-7 Hydraulic Reservoir Installation............................................................................................ 0153-7

BOOM ANGLE INDICATOR MAINTENANCE............................................................................................. WP 0154 Figure 1. Figure 2. Boom Angle Indicator Removal............................................................................................ 0154-2 Boom Angle Indicator Installation......................................................................................... 0154-3

HOOK BLOCK MAINTENANCE.................................................................................................................. WP 0155

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Hook Block Disassembly...................................................................................................... 0155-2 Hook Block Disassembly...................................................................................................... 0155-3 Hook Block Assembly........................................................................................................... 0155-5 Hook Block Assembly........................................................................................................... 0155-6

BOOM ASSEMBLY MAINTENANCE.......................................................................................................... WP 0156 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Boom Assembly Removal.................................................................................................... 0156-2 Boom Assembly Removal.................................................................................................... 0156-3 Boom Assembly Removal.................................................................................................... 0156-4 Boom Assembly Removal.................................................................................................... 0156-5 Boom Assembly Removal.................................................................................................... 0156-6 Boom Assembly Disassembly.............................................................................................. 0156-7 Boom Assembly Disassembly.............................................................................................. 0156-7 Boom Assembly Disassembly.............................................................................................. 0156-8 Boom Assembly Disassembly.............................................................................................. 0156-8 Boom Assembly Disassembly.............................................................................................. 0156-9 Boom Assembly Disassembly............................................................................................ 0156-10 Boom Assembly Disassembly............................................................................................ 0156-11 Boom Assembly Disassembly............................................................................................ 0156-11 Boom Assembly Disassembly............................................................................................ 0156-12 Boom Assembly Disassembly............................................................................................ 0156-12 Boom Assembly Disassembly............................................................................................ 0156-13 Boom Assembly Assembly................................................................................................. 0156-15 Boom Assembly Assembly................................................................................................. 0156-15 Boom Assembly Assembly................................................................................................. 0156-16 Boom Assembly Assembly................................................................................................. 0156-17 Boom Assembly Assembly................................................................................................. 0156-18 Boom Assembly Assembly................................................................................................. 0156-19

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Boom Assembly Assembly................................................................................................. 0156-20 Boom Assembly Assembly................................................................................................. 0156-21 Boom Assembly Assembly................................................................................................. 0156-21 Boom Assembly Assembly................................................................................................. 0156-22 Boom Assembly Assembly................................................................................................. 0156-22 Boom Assembly Installation............................................................................................... 0156-23 Boom Assembly Installation............................................................................................... 0156-24 Boom Assembly Installation............................................................................................... 0156-25 Boom Assembly Installation............................................................................................... 0156-26 Boom Assembly Installation............................................................................................... 0156-27

BOOM WORK LIGHT BRACKET MAINTENANCE..................................................................................... WP 0157 Figure 1. Bracket Maintenance............................................................................................................ 0157-1

UPPERSTRUCTURE MAINTENANCE....................................................................................................... WP 0158 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Upperstructure Removal...................................................................................................... 0158-2 Upperstructure Removal...................................................................................................... 0158-3 Upperstructure Removal...................................................................................................... 0158-5 Swing Bearing Assembly Removal...................................................................................... 0158-6 Swing Bearing Assembly Installation................................................................................... 0158-8 Upperstructure Installation................................................................................................... 0158-9 Upperstructure Installation................................................................................................. 0158-10 Upperstructure Installation................................................................................................. 0158-11 Upperstructure Installation................................................................................................. 0158-12

MAST ASSEMBLY (TYPE II) MAINTENANCE............................................................................................ WP 0159 Figure 1. Mast Assembly Maintenance............................................................................................... 0159-3

SWING MOTOR MAINTENANCE............................................................................................................... WP 0160 Figure 1. Figure 2. Swing Motor Removal.......................................................................................................... 0160-2 Swing Motor Disassembly.................................................................................................... 0160-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Swing Motor Disassembly.................................................................................................... 0160-3 Swing Motor Disassembly.................................................................................................... 0160-4 Swing Motor Disassembly.................................................................................................... 0160-4 Swing Motor Disassembly.................................................................................................... 0160-5 Swing Motor Disassembly.................................................................................................... 0160-5 Swing Motor Disassembly.................................................................................................... 0160-6 Swing Motor Assembly......................................................................................................... 0160-7 Swing Motor Assembly......................................................................................................... 0160-8 Swing Motor Assembly......................................................................................................... 0160-8 Swing Motor Assembly......................................................................................................... 0160-9 Swing Motor Assembly....................................................................................................... 0160-10 Swing Motor Assembly....................................................................................................... 0160-11 Swing Motor Installation..................................................................................................... 0160-12

SWING GEARBOX MAINTENANCE........................................................................................................... WP 0161 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Swing Gearbox Removal...................................................................................................... 0161-2 Swing Gearbox Disassembly............................................................................................... 0161-3 Swing Gearbox Cover Disassembly..................................................................................... 0161-4 Swing Gearbox Bearing Retainer Disassembly................................................................... 0161-4 Swing Gearbox Bearing Retainer Disassembly................................................................... 0161-5 Swing Gearbox Disassembly............................................................................................... 0161-6 Swing Gearbox Disassembly............................................................................................... 0161-7 Swing Gearbox Output Shaft Disassembly.......................................................................... 0161-8 Swing Gearbox Bearing Cups Disassembly......................................................................... 0161-9 Swing Gearbox Vent Plug and Grease Fitting Disassembly................................................ 0161-9 Swing Gearbox Vent Plug and Grease Fitting Assembly................................................... 0161-10 Swing Gearbox Bearing Cups Assembly........................................................................... 0161-11 Swing Gearbox Assembly.................................................................................................. 0161-12

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Swing Gearbox Assembly.................................................................................................. 0161-13 Swing Gearbox Assembly.................................................................................................. 0161-13 Swing Gearbox Assembly.................................................................................................. 0161-14 Swing Gearbox Bearing Retainer Assembly...................................................................... 0161-15 Swing Gearbox Bearing Retainer Assembly...................................................................... 0161-16 Swing Gearbox Cover Assembly........................................................................................ 0161-16 Swing Gearbox Drain Plugs Assembly............................................................................... 0161-17 Swing Gearbox Assembly.................................................................................................. 0161-17 Swing Gearbox Installation................................................................................................. 0161-18

GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0162 GENERAL WIRING HARNESS AND CABLE MAINTENANCE.................................................................. WP 0163 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Electrical Harness Identification........................................................................................... 0163-2 Electrical Harness Identification........................................................................................... 0163-3 Electrical Harness Disassembly........................................................................................... 0163-4 Electrical Harness Disassembly........................................................................................... 0163-5 Electrical Harness Disassembly........................................................................................... 0163-6 Electrical Harness Disassembly........................................................................................... 0163-7 Electrical Harness Disassembly........................................................................................... 0163-8 Electrical Harness Disassembly........................................................................................... 0163-9 Electrical Harness Assembly.............................................................................................. 0163-10 Electrical Harness Assembly.............................................................................................. 0163-11 Electrical Harness Assembly.............................................................................................. 0163-11 Electrical Harness Assembly.............................................................................................. 0163-12 Electrical Harness Assembly.............................................................................................. 0163-13 Electrical Harness Assembly.............................................................................................. 0163-14 Electrical Harness Assembly.............................................................................................. 0163-15 Electrical Harness Assembly.............................................................................................. 0163-16

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 17. Figure 18. Electrical Harness Assembly.............................................................................................. 0163-17 Electrical Harness Assembly.............................................................................................. 0163-18

PREPARATION FOR SHIPMENT AND STORAGE.................................................................................... WP 0164 TORQUE LIMITS......................................................................................................................................... WP 0165 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. English Capscrew Heads. ................................................................................................... 0165-3 English Nut Markings. ......................................................................................................... 0165-3 Metric Fastener Markings..................................................................................................... 0165-4 Fastener Symbol Markings. ................................................................................................. 0165-5 Fastener Indented Markings. ............................................................................................... 0165-6 Metric Capscrew Nomenclature........................................................................................... 0165-6 Engine Fastener Torque Values........................................................................................... 0165-7 Transmission Fastener Torque Values................................................................................ 0165-8 All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values............................................................................................. 0165-10 All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values............................................................................................. 0165-12 Torque Limits for Dry Fasteners......................................................................................... 0165-13 Torque Limits for Wet Fasteners........................................................................................ 0165-14

DIAGRAMS.................................................................................................................................................. WP 0166 Chapter 5 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0167 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.............................................................. WP 0168 MAINTENANCE ALLOCATION CHART (MAC).......................................................................................... WP 0169 Table 1. Table 2. Table 3. Maintenance Allocation Chart (MAC)................................................................................... 0169-1 Tools and Test Equipment................................................................................................. 0169-14 Remarks............................................................................................................................. 0169-14

EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0170 Table 1. Expendable and Durable Items List..................................................................................... 0170-1

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. TOOL IDENTIFICATION LIST..................................................................................................................... WP 0171 Table 1. Tool Identification List........................................................................................................... 0171-1

MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0172 Table 1. Foldout Figures FO-1. FO-2. FO-3. FO-4. Index Vehicle Electrical Schematic............................................................................................................. FP-1 Electrical System Identification......................................................................................................... FP-3 MSD/ICE Electrical Schematic......................................................................................................... FP-5 Hydraulic System Schematic............................................................................................................ FP-7 Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton........................ 0172-1

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HOW TO USE THIS MANUAL

INTRODUCTION 1. This manual contains maintenance procedures for the 7 1/2 Ton Crane. 2. This manual is written in work package format: a. Chapters divide the manual into major categories of information (e.g., General Information, Troubleshooting, PMCS, Maintenance Instructions, and Supporting Information). b. Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001, 0002, etc.) located on the upper right-hand corner of each page. The work package page number (e.g., 0001-1, 0001-2, etc.) is located centered at the bottom of each page. c. Read through this manual to become familiar with its organization and contents before attempting to maintain the equipment.

CONTENTS OF THIS MANUAL 1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before maintaining the equipment. 2. A Table of Contents, located in the front of the manual, lists all chapters and work packages in the publication. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual. 3. Chapter 1, General Information, Equipment Description, and Theory of Operation provides general information about the equipment, identifies the major components and systems, and describes how the components and systems work. 4. Chapter 2, Troubleshooting Procedures, describes troubleshooting procedures to locate and correct malfunctions of the equipment. 5. Chapter 3, PMCS covers field level PMCS. 6. Chapter 4 covers maintenance of the major systems on the crane, including (but not limited to) transmission, fuel system, and electrical. 7. Chapter 5, Supporting Information, contains the following: References, Maintenance Allocation Chart (MAC), Expendable and Durable Items List, Tool Identification List, and Foldouts. 8. An alphabetical Index is located at the back of this manual.

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HOW TO USE THIS MANUAL - Continued

FEATURES OF THIS MANUAL 1. This manual contains information on maintaining the crane. 2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid. WARNING – indicates a hazard which may result in serious injury or death to personnel. CAUTION – is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment. NOTE – is a statement containing information that will make the procedures easier to perform. 3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis. 4. Within a procedural step, reference may be made to another chapter or work package in this manual or to another manual. These references indicate where you should look for more complete information. a. If you are told: "Valve Covers Maintenance (WP 0035)," go to WP 0035 in this manual for instructions on servicing Valve Covers. b. If you are told: “For complete information on batteries, refer to TB 9-6140-252-13", go to WP 0168, References for complete information on the referenced technical manual. 5. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art are text or numbers. 6. Numbers located at lower right corner of art are art control numbers and are used for tracking purposes only. Disregard these numbers. 7. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual. 8. Location Terms. The terms left, right, front, or rear are used to describe areas of the equipment. These terms indicate location as seen when facing toward front of crane.

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CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

TM 5-3810-305-23

0001

FIELD MAINTENANCE GENERAL INFORMATION

SCOPE 1. Type of Manual. This manual is for use in performing troubleshooting and maintenance on the 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light. 2. Equipment Name and Model Number. 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light, Type I NSN 3810-01-165-0646 and Type II NSN 3810-01-165-0647. 3. Purpose of Equipment. 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light is a wheel-mounted, selfcontained, two-wheel/four-wheel drive, two-wheel/four-wheel steering crane. It is used to lift heavy equipment, parts, and building supplies throughout a 360 degree rotation at various radii. It can travel over primary or secondary roads in various climates and military conditions worldwide. 7 1/2 Ton Crane design meets all applicable requirements of OSHA, EPA, PCSA Std. #4, ANSI B30.5 and the specified SAE Standards. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for equipment and maintenance will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS). REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light needs improvement, let us kno w. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance. All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https ://www.pdrep.csd.disa.mil/. If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the address/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

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0001

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE When the tactical situation requires that Army materiel be abandoned, refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use. PREPARATION FOR STORAGE OR SHIPMENT Refer to Preparation for Shipment and Storage (WP 0164) to perform preparation for storage or shipment tasks. NOMENCLATURE CROSS-REFERENCE LIST Nomenclature cross-references used in this manual include the following: Common Name 7 1/2 Ton Crane Type I 7 1/2 Ton Crane Type II Official Nomenclature 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light Type I NSN 3810-01-165-0646 7 1/2 Ton Crane Rough Terrain, Hydraulic, Light Type II NSN 3810-01-165-0647

LIST OF ABBREVIATIONS/ACRONYMS Abbreviation/Acronym ANSI BO C CAGEC CARC CCA cm CPC DCA EDIL EIR EPA F FGC FO ft-lb GP IAW I.D. in-lb IPS IWRC kg km kPa kph kW L lb(s) m MAC MIs mm N•m N Name American National Standards Institute Blackout Celsius Commercial and Government Entity Code Chemical Agent Resistant Coating Cold Cranking Amps Centimeter Corrosion Prevention and Control Diagnostic Connector Assembly Expendable and Durable Items List Equipment Improvement Recommendations Environmental Protection Agency Fahrenheit Functional Group Code Fold Out Foot Pound General Purpose In Accordance With Inner Diameter Inch Pound Improved Plow Steel Independent Wire Rope Core Kilogram Kilometer Kilopascal Kilometers per Hour Kilowatt Liter Pound(s) Meter Maintenance Allocation Chart Modification Instructions Millimeter Newton Meter Neutral

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TM 5-3810-305-23 LIST OF ABBREVIATIONS/ACRONYMS - Continued Abbreviation/Acronym NSN O.D. OHSA PCSA PM-SKOT PMCS PQDR PR psi qt rpm RPSTL SAE SKO SMR SOP SRA TAMMS TDC TI TIR TK TM TMDE TULSA U/I UOC UUT VID VDC VTM WP XDCR QUALITY OF MATERIAL Name National Stock Number Outer Diameter Occupational Health and Safety Administration Power Crane and Shovel Association Product Manager for Sets, Kits, Outfits and Tools Preventive Maintenance Checks and Services Product Quality Deficiency Report Ply Rating Pounds per Square Inch Quart Revolutions Per Minute Repair Parts and Special Tool List Society of Automotive Engineers Sets, Kits and Outfits Source, Maintenance and Recoverability Standard Operating Procedures Specialized Repair Activity The Army Maintenance Management System Top Dead Center Technical Instruction Total Indicator Reading Transducer Kit Technical Manual Test, Measurement and Diagnostic Equipment TACOM Unique Logistics Support Applications Unit of Issue Usable On Code Unit Under Text Vehicle Identification Volts Direct Current Vehicle Test Meter Work Package Transducer

0001

Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of material requirements are not stated in this manual, the material must meet the requirements for the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment. END OF WORK PACKAGE

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0002

FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES Characteristics The 7 1/2 Ton Crane is a wheel-mounted, self-contained, two-wheel/four-wheel drive, two-wheel/four-wheel steering crane. A diesel engine powers the 7 1/2 Ton Crane, driving through a powershift transmission with tandem pump hydraulic power for operation of the crane, outriggers, fully revolving upperstructure, and steering system. The 7 1/2 Ton Crane design meets all applicable requirements of OSHA, EPA, PCSA Std. #4, ANSI B30.5, and specified SAE Standards. Capabilities The capabilities of the 7 1/2 Ton Crane include: • Lifting. • 15,000 lb (6,804 kg) at up to a 10 ft (3 m) radius throughout 360 degree rotation with outriggers. • 4,000 lb (1,814 kg) at up to a 30 ft (9 m) radius throughout 360 degree rotation with outriggers. • 13,600 lb (6,169 kg) straight over the front on tires, no rotation, without use of outriggers. Travel Speeds. • Up to 22 mph (35 kph) on level, hard surfaces. • Up to 2.5 mph (4.0 kph) carrying a 4,500 lb (2,041 kg) load, with boom extended 20 ft (6.1 m) straight over the front. Rough terrain travel when placed in four-wheel drive. Continuous operation in temperatures up to 120°F (49°C) or altitudes up to 5,000 ft (1,524 m). Fording up to 30 inches (76 cm) of water. Safe to operate in ammunition and petroleum dumps.

• • • •

Features The following are features of the 7 1/2 Ton Crane: • • • Upperstructure. Includes counterweight and hydraulic winch. Boom Attachment. Includes crane boom, boom lift cylinder, and hook block. Carrier. Includes chassis, frame, engine, transmission, swing bearing, planetary axles, outriggers, operator cab, fuel tank, hydraulic reservoir, batteries, and tool compartment.

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

1

2

3

4

5

6

10

9 7 15 14 8 13 12 11 10 9
G0001105

Figure 1. KEY 1 COMPONENT Counterweight

Major Components. DESCRIPTION Located at base of boom; used to stabilize crane during a lift. Located at base of boom; used to raise and lower steel cables. Steel beam that acts as an arm to lift a load. Piston cylinder that extends and retracts to lower and raise boom. Controlled by operator to give audible warning to personnel. Can be reeved three different ways, compensates for different size loads. Used to attach load to cable. Also keeps cable tight when there is no load on it. Includes chassis, frame, engine, transmission, swing bearing, planetary axles, outriggers, operator cab, fuel tank, hydraulic reservoir, batteries, and tool compartment.

2

Hydraulic Winch

3 4

Boom Boom Hoist

5

Forward Horn

6

Cable

7

Hook Block

8

Carrier

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued KEY 9 COMPONENT Tiedown/Sling Points DESCRIPTION Attachment points for overhead lifting device. There is one lift point on each side of front and rear of carrier. Supports that lower from each side to balance and support crane during lifts. Transfers rotary motion of engine and transmission to wheels. Center point of rotation for boom. Stores fuel being used to operate crane. Powerplant for crane. See Equipment Data in this work package for more information. Provide attachment points for towbar.

10

Outrigger

11

Planetary Axle

12 13 14

Swing Bearing Fuel Tank Engine/Transmission

15

Towing Lugs

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

1

1

2 2

4 3
Figure 2. KEY 1 COMPONENT Stop Lights Major Components. DESCRIPTION Red lights that illuminate when the brakes are applied. Lights that illuminate based on position of vehicle light switch. Used for trailer and tow bar hookups. Audible warning that sounds when transmission is in REVERSE and ignition switch is in ON position.
G0002105

2

Rear Composite Lights

3 4

Tow Pintle Backup Alarm

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

1

4 2
G0010105

3
Figure 3. KEY 1 COMPONENT Hydraulic Reservoir

Major Components. DESCRIPTION Stores hydraulic fluid used in vehicle hydraulic systems. Provides protection for two batteries. Provides on-vehicle storage for tools and equipment. Located on each side of operator cab.

2 3

Battery Compartment Tool Compartment

4

Rear View Mirror

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

1

2

3 4 5
Figure 4. KEY 1 COMPONENT Operator Cab

4
Major Components. DESCRIPTION

G0011105

Contains all controls and indicators for operation of crane. One at front of boom and two at back near counterweight. Used when operating in blackout mode. Controlled by vehicle light switch from cab. Controlled by turn signal switch from cab.

2

Work Lights

3 4 5

Blackout (BO) Drivelight Service Drivelights Front Turn Signals

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

EQUIPMENT DATA Engine Type Bore and stroke Displacement Maximum gross horsepower Maximum gross torque Net horsepower Air filter Electrical System Alternator Battery Transmission Type Manufacturer Shift controls Powershift Funk Forward/reverse lever, gear speed (1 through 4) select lever, two-wheel/four-wheel drive select lever (See Gear Range Values (Table 1) for gear ranges.) Four speeds forward and reverse 24V, 40 amp 440 cold cranking amps at 24V Cummins 4B3.9 water-cooled, 4-cycle diesel engine 4.02 x 4.72 inches (102 x 120 mm) 239.3 cu inch (3.92 L) 80 hp (60 kW) at 2,800 rpm 184 ft-lb (249 N•m) at 2,800 rpm 60 hp (47 kW) at 2,800 rpm Dry type

Speeds Torque Converter Type

Single-stage, three-element, free-wheel stator (size 11.75 inch, STR-2 9)

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0002

EQUIPMENT DATA - Continued Wheels Type Size Wheel base Tires Tire inflation pressure Axles Type Reduction Brakes Type Suspension Type Driving modes Oscillating rear axle w/automatic lockout Two-wheel, rear drive (For hard surfaces at high speeds.) Four-wheel drive (For rough terrain.) Steering Type Full fluid linked power steering, w/backup steering pump (Auxiliary pump is ground driven off rotation of wheels and provides steering and braking during power loss. Two-wheel steering Four-wheel steering Crab steering Turning radius Two-wheel: 32 ft 2 inches (9.80 m) Four-wheel: 18 ft 4 inches (5.59 m) Hydraulically boosted, dual system with front-to-rear split Soma, planetary, Model 3 19:61:1 Disc 8.25 x 22.5 inches (210 x 572 mm) 108 inches (274 cm) 12 x 22.5, 14 PR radial 115 psi (793 kPa)

Modes

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0002

EQUIPMENT DATA - Continued Hydraulic System Hydraulic pump drive One tandem hydraulic pump driven off transmission at 0.87 x engine rpm

Steering, brake, and swing circuit Pump 21 gal. (79.5 L) per minute, operating at 2,440 rpm and 2,650 psi (18,272 kPa) 10 gal. (37.8 L) per minute at 2,440 rpm and 2,500 psi (17,238 kPa) 18 gal. (68.1 L) per minute, operating at 2,440 rpm and 2,650 psi (18,272 kPa) 21 gal. (79.5 L) per minute, operating at 2,440 rpm and 2,750 psi (18,961 kPa) Four-spool, two-way valve Single-spool, two-way valve Full-flow system with 100 mesh (140 micron) screen and 10 micron return filter

Priority flow

Winch circuit

Boom hoist, telescope, and outrigger circuit

Hydraulic valve bank Winch valve Oil filtration

Swing System Type Speed Drawbar Continuous pull Pintle Hook Towing capacity 40,000 lb (18,144 kg) 10,000 lb (4,536 kg) Hydraulically powered, worm gear reduction unit 3.08 rpm (no load)

0002-9

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued Outriggers Type Flipper, 7 inches (178 mm) lift on 12 x 22.5, 14 PR (standard tires) 4.5 seconds 4.0 seconds

Extend time per outrigger Retract time per outrigger Outrigger cylinders Bore Stroke Rod Boom Type Maximum length Construction Point sheaves

5.0 inches (127 mm) 17.75 inches (451 mm) 3 inches (76 mm)

Standard, two-section 35.75 ft (10.90 m) All welded, box beam Cast, ductile iron, mounted on non-friction bearings, two-sheave boom head To 21.75 ft (6.63 m) (PCSA Standards) 70,000 psi (483 N/mm2) material

Retraction Base and tip sections Boom Cylinders Boom hoist Bore Stroke Rod Hoist time Down time

8.5 inches (216 mm) 39.3 inches (998 mm) 3 inches (76 mm) 28.5 seconds 25.3 seconds

0002-10

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued Boom extend Bore Stroke Rod Extend time Retract time Winch Maximum line speed (no load) First layer Third layer Drum capacity Rope size 177 ft (53.95 m) per minute 216 ft (65.84 m) per minute 350 ft (107 m), five layers 1/2 inch, 6 x 9 Independent Wire Rope Core (IWRC), Improved Plow Steel (IPS), preformed 8.5 inches (216 mm) 12.25 inches (311 mm) 14.56 inches (370 mm) 4.0 inches (102 mm) 167 inches (4.27 m) 3 inches (76 mm) 27.2 seconds 22.7 seconds

Drum diameter Drum length Flange diameter Boom Mounted Work Platform Total weight of platform and adapter Excluding load Maximum load Counterweight Weight

1,005 lb (456 kg) 600 lb (272 kg)

2,200 lb (998 kg)

0002-11

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued Vehicle Weight Distribution Front Type I Type II Rear Type I Type II Hook Block TOTAL Type I Type II Fluid Capacities Cooling system Fuel Crankcase Hydraulic system Hydraulic oil reservoir Transmission Capacity Refill Axle Hub Differential Swing reduction unit Winch 3 qt (2.8 L) 14 qt (13.2 L) 3 qt (2.8 L) 2 qt (1.9 L) 20.5 qt (19.4 L) 12 qt (11.3 L) 28 qt (26.5 L) 44 gal. (166.5 L) 11 qt (10.4 L) 45 gal. (170.3 L) 23.8 gal. (90.1 L) 22,870 lb (10,374 kg) 24,230 lb (10,991 kg) 12,110 lb (5,493 kg) 12,520 lb (5,679 kg) 345 lb (156 kg) 10,760 lb (4,881 kg) 11,710 lb (5,312 kg)

0002-12

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued Table 1. Gear 1 2 3 4 Maximum Speed 3.3 mph (5.3 kph) 6.2 mph (9.9 kph) 11.4 mph (18.3 kph) 22 mph (35.4 kph) Gear Range Values. Gradeability 99.2% 38.8% 19.1% 9.2%

Maximum Tractive Effort 18,830 lb (8,541 kg) 9,930 lb (4,504 kg) 5,400 lb (2,449 kg) 2,900 lb (1,315 kg)

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued

1 2 3 5 4

6 7 10 11 12 9 8

G0005105

Figure 5. KEY DESCRIPTION

General Dimensions. DIMENSIONS

NOTE
All dimensions assume boom fully retracted and crane equipped with standard tires. 1 2 3 4 5 6 7 8 9 10 11 Overall length Centerline of rotation to boom end Boom end to front of carrier Tail swing radius Centerline of rotation to boom pivot Height of cab Ground clearance to transmission Ground clearance to outrigger box Centerline of rotation to centerline of rear axle Wheelbase 308.16 inches (782 cm) 212 inches (538 cm) 78.5 inches (199 cm) 93 inches (236 cm) 56.5 inches (144 cm) 74 inches (188 cm) 14.4 inches (37 cm) 15 inches (38 cm) 50.9 inches (129 cm) 108 inches (274 cm)

Centerline of front outrigger box to centerline of rear 172 inches (437 cm) outrigger box Overall length of carrier 229.6 inches (583 cm)

12

0002-14

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0002

EQUIPMENT DATA - Continued

1

8

3 6 7
G0006105

5

4

2

Figure 6. KEY 1 2 3 4 5 6 7 8 DESCRIPTION Overall travel width Outrigger extension, below Ground clearance to lowest point of axle Track Width of carrier Effective width of outriggers Overall width over floats Overall height

General Dimensions. DIMENSIONS 72 inches (183 cm) 7.3 inches (19 cm) 14 inches (36 cm) 72 inches (183 cm) 82.3 inches (209 cm) 148.9 inches (378 cm) 163.9 inches (416 cm) 92.5 inches (235 cm)

0002-15

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued

G0007105

Figure 7. Radius from Centerline of Rotation.

0002-16

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued

G0008105

Figure 8.

Crane Working Positions.

NOTE
Working areas are measured in a circular area around centerline of rotation.

G1305105

Figure 9.

Lift Capacity (on Outriggers).

0002-17

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TM 5-3810-305-23

0002

EQUIPMENT DATA - Continued

Figure 10. Lift Capacity (on Tires).

Figure 11. Maximum Permissible Hoist Line Load. END OF WORK PACKAGE

0002-18

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TM 5-3810-305-23

0003

FIELD MAINTENANCE THEORY OF OPERATION

INTRODUCTION 1. The purpose of this work package is to provide a general description of the 7 1/2 Ton Crane and an overall view of its components and their functions. 2. This section explains how the systems and components of the crane work together. A functional description is provided for each major component and system. GENERAL 1. The 7 1/2 Ton Crane is a self-contained vehicle, featuring 7.5 ton maximum lifting capacity, optional fourwheel drive, outriggers for added stability during lifting operations, and three different steering modes: front wheel steering for normal driving, crab steering for diagonal moves, and four-wheel steering for minimumradius turns. 2. Power originates from an in-line, four-cylinder, diesel engine mounted at the rear of the vehicle. The transmission is mounted directly on the engine and is used to turn driveshafts and to power the tandem hydraulic pump. One-half of the tandem hydraulic pump supplies hydraulic pressure to winch, and other half supplies hydraulic pressure to actuate the boom telescope cylinder, boom hoist cylinder, boom swing motor, outrigger cylinders, axle lockout cylinders, and steering controls. It also provides hydraulic assistance for brake system. BOOM The boom is a two-section telescope-type with rotating boom support. Two large-diameter, double-acting hydraulic cylinders telescope and hoist the boom assembly. A hydraulic swing motor and worm gear rotates the upperstructure. The cable and hook block assembly are operated by hydraulic winch. Hydraulic and electrical systems on the upperstructure are connected to the rest of the vehicle by a hydraulic rotary manifold and electrical collector ring. TRANSMISSION 1. The transmission is capable of four-speed shifting in both forward and reverse. Direction and speed are selected through hydraulically actuated multiple-disc clutches. The clutches are power absorbing, allowing shifts under full engine power in both forward and reverse. The clutches are hydraulically controlled and spring released. Hydraulic control makes the clutches self-adjusting. Each clutch is made of friction plates and polished-steel reaction plates. 2. The transmission receives power from the engine through the torque converter. The torque converter is fluid driven, creating a smooth and shock-free drive. Fluid drive also eliminates engine stalling and lugging when vehicle has a heavy load. With light loads, the torque converter can transmit engine power directly to the transmission at most engine speeds with no torque multiplication. This provides variable and automatic speed ratios, reducing need for shifting gears.

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0003

AXLES The front and rear axles have remote breathers to allow operation in up to 30 inches (762 mm) of water. The rear axle has lockout cylinders to provide increased stability during hoisting. Steering for each axle is enhanced by dualacting hydraulic cylinders that are tied together by a single tie rod, which provides smooth, sharp, synchronized turning with minimum alignment and adjustment requirements. The service brakes are shoe-type hydraulic units and are part of the axle. The front axle has a disc brake that can be used either as a parking brake or an emergency brake. Each axle has its own differential. WINCH 1. The winch consists of four basic assemblies: winch base, hydraulic motor and brake valve, brake cylinder and motor support, and drum assembly. The hydraulic motor turns the gears in the drum assembly, working the cable. 2. The winch has a dual braking system: a dynamic brake and a static brake. These two types of brakes work together to control the speed of the drum assembly. The dynamic brake uses hydraulic pressure to operate the brake valve, which controls the flow of hydraulic oil to the hydraulic motor. The static brake consists of multiple friction discs, a brake clutch assembly, and a hydraulic piston and cylinder. The static brake is automatically applied unless it is released by brake valve pilot pressure at a level lower than that required to open the pilot-operated spool valve. 3. Either brake system does not affect the winch during hoisting operations. When the operator's control is placed in neutral, rollers between the cam and outer race wedge to prevent the drum assembly from turning. The brake valve stops oil flow from the hydraulic motor. For lowering a load slowly, the operator can allow only enough oil to release the brake without engaging the hydraulic motor. The hydraulic oil dissipates heat build-up. For faster lowering, the hydraulic pressure is increased by the operator to both release the brake and engage the hydraulic motor. END OF WORK PACKAGE

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CHAPTER 2 TROUBLESHOOTING PROCEDURES

TM 5-3810-305-23 FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX

0004

GENERAL This section provides information for identifying and correcting issues which may develop when operating or maintaining the 7 1/2 Ton Crane. The index lists common symptoms which may occur and refers you to the proper work package for a troubleshooting procedure. This section cannot list all symptoms that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify your Maintenance Supervisor. When troubleshooting a malfunction: 1. Question the operator to obtain any information that might help determine the cause of the problem. Before continuing, ensure that all applicable operator/crew troubleshooting was performed. 2. Locate the symptom or symptoms in the Troubleshooting Index that best describe the issue. If the appropriate symptom is not listed, notify your Maintenance Supervisor. 3. Go to the work package where the troubleshooting procedures for the symptom in question are described. Headings at the top of each page show how each troubleshooting procedure is organized: Symptom, Malfunction, and Corrective Action. 4. Perform each step in the order listed until the symptom is corrected and the item being inspected is operational. Do not perform any maintenance task unless the troubleshooting procedure tells you to do so. EXPLANATION OF HEADINGS The headings in the troubleshooting procedures are defined as follows: 1. SYMPTOM. A visual or operational indication that something is wrong with the crane. 2. MALFUNCTION. Observable fault in component or system. 3. CORRECTIVE ACTION. A procedure to correct the fault. TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom ENGINE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine Cranks but Will Not Start; No Smoke from Exhaust.............................................................. WP 0005 Engine Will Not Start when Cold Start is Used.................................................................................. WP 0005 Engine Hard to Start/Will Not Start; Smoke from Exhaust................................................................ WP 0005 Engine Starts, but Will Not Keep Running......................................................................................... WP 0005 Engine Will Not Crank....................................................................................................................... WP 0005 Engine Surges at Idle........................................................................................................................ WP 0005 Warm Engine Idles Rough................................................................................................................ WP 0005 Engine Misfires.................................................................................................................................. WP 0005 Engine Runs Hot............................................................................................................................... WP 0005 Low Oil Pressure............................................................................................................................... WP 0005 Engine Running Too Cold................................................................................................................. WP 0005 Troubleshooting Procedure

0004-1

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TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 12. 13. 14. 15.

0004

Troubleshooting Procedure

Engine RPM Will Not Reach Rated Speed - No Load....................................................................... WP 0005 Low Power........................................................................................................................................ WP 0005 Excessive Smoke Under Load.......................................................................................................... WP 0005 Fuel Knock........................................................................................................................................ WP 0005

HYDRAULICS 1. 2. Control Lever Sticks or Binds............................................................................................................ WP 0006 No Movement of Hydraulic Function(s)............................................................................................. WP 0006

SWING CIRCUIT 1. 2. 3. 4. Upperstructure Will Not Swing.......................................................................................................... WP 0007 Swing Motion Sluggish...................................................................................................................... WP 0007 Swing Motion Erratic......................................................................................................................... WP 0007 Swing Motor Turns in Wrong Direction.............................................................................................. WP 0007

BOOM HOIST CIRCUIT 1. 2. 3. 4. Boom Hoist Cylinder Inoperative or Erratic....................................................................................... WP 0008 Boom Drops Slightly as Raise Control is Released.......................................................................... WP 0008 Boom Hoist, Extend, and Outrigger Cylinders Inoperative or Erratic................................................................................................................................................ WP 0008 Boom Drifts Down............................................................................................................................. WP 0008

BOOM EXTEND CIRCUIT 1. 2. 3. Boom Extend Function Will Not Operate........................................................................................... WP 0009 Boom Extend Cylinder Extends but Will Not Retract......................................................................... WP 0009 Boom Section Retracts Under Load.................................................................................................. WP 0009

OUTRIGGER CIRCUIT 1. 2. 3. 4. All Outriggers Inoperative.................................................................................................................. WP 0010 Individual Outrigger Inoperative........................................................................................................ WP 0010 Outriggers Will Not Lift Vehicle.......................................................................................................... WP 0010 Outrigger Retracts Under Load......................................................................................................... WP 0010

0004-2

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom STEERING CIRCUIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

0004

Troubleshooting Procedure

Slow Steering, Hard Steering, or Loss of Power Assist.................................................................... WP 0011 Vehicle Wanders - Vehicle Will Not Stay in a Straight Line............................................................... WP 0011 Drift - Vehicle Veers Slowly in One Direction.................................................................................... WP 0011 Slip - Slow Movement of Steering Wheel Fails to Cause Any Movement of Steered Wheels........................................................................................................... WP 0011 Temporary Hard Steering or Hang-up............................................................................................... WP 0011 Erratic Steering................................................................................................................................. WP 0011 “Spongy" or Soft Steering.................................................................................................................. WP 0011 Free Wheeling - Steering Wheel Turns With Slight Resistance but Results in Little or No Steered Wheel Action.............................................................................. WP 0011 Excessive Free Play at Steering Wheel............................................................................................ WP 0011 Steering Unit Locks Up..................................................................................................................... WP 0011 Steering Wheel Oscillates or Turns by Itself..................................................................................... WP 0011 Steered Wheels Turn in Wrong Direction When Operator Activates Steering Wheel.................................................................................................................. WP 0011

PUMPS 1. 2. 3. 4. 5. Failure of Hydraulic Pump(s) to Deliver Fluid.................................................................................... WP 0012 Low or No Pressure in System.......................................................................................................... WP 0012 Pump(s) Making Noise...................................................................................................................... WP 0012 External Oil Leakage Around Hydraulic Pump(s).............................................................................. WP 0012 Breakage of Parts Inside Hydraulic Pump Housing(s)...................................................................... WP 0012

RELIEF VALVES 1. 2. 3. 4. Cannot Get Pressure........................................................................................................................ WP 0013 Erratic Pressure................................................................................................................................ WP 0013 Pressure Setting Not Correct............................................................................................................ WP 0013 Leakage............................................................................................................................................ WP 0013

BRAKES 1. 2. 3. 4. Brakes Slow to Release or Drag....................................................................................................... WP 0014 Brakes Do Not Release..................................................................................................................... WP 0014 Brakes Slow to Apply........................................................................................................................ WP 0014 Insufficient Brakes............................................................................................................................. WP 0014 0004-3

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom

0004

Troubleshooting Procedure

ELECTRICAL SYSTEM 1. 2. 3. 4. 5. Starting Motor Does Not Operate...................................................................................................... WP 0015 Alternator Charging Low or Unsteady............................................................................................... WP 0015 Battery Voltage Low.......................................................................................................................... WP 0015 External Light(s) Not Operating......................................................................................................... WP 0015 Worklights Not Operating.................................................................................................................. WP 0015

ANTI-TWO BLOCK SYSTEM 1. 2. 3. 4. 5. Panel Light and Horn Will Not Come On With Anti-Two Block Counterweight Lifted; Control Disconnects Will Not Engage............................................................ WP 0016 Horn Works but No Light With Anti-Two Block Counterweight Lifted; Control Disconnects Will Not Engage..................................................................................... WP 0016 Light and Horn Are On With Hook Block Not Contacting AntiTwo Block Counterweight; Control Disconnects Will Not Engage..................................................... WP 0016 Light and Horn Are On but Control Disconnects Will Not Disengage......................................................................................................................................... WP 0016 No Light and Horn but Control Disconnects Will Not Engage........................................................... WP 0016

TRANSMISSION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Erratic Transmission Oil Pressure..................................................................................................... WP 0017 Excessive Transmission Oil Pressure at High Speed (RPM)............................................................ WP 0017 Low Transmission Oil Pressure in All Gears..................................................................................... WP 0017 Low Transmission Oil Pressure in One Gear but Alright in Other Gears................................................................................................................................................ WP 0017 Low Converter Pressure................................................................................................................... WP 0017 High Transmission Oil Pressure........................................................................................................ WP 0017 Clutch Selected Pressure Does Not Return to Normal..................................................................... WP 0017 Excessive Noise at Engine Idle......................................................................................................... WP 0017 Excessive Gear Noise at High Speed (RPM).................................................................................... WP 0017 Transmission Oil Blows out of Breather on Top of Transmission...................................................... WP 0017 Transmission Overheating................................................................................................................ WP 0017

AXLE ASSEMBLY 1. Wheels Pull to Right or Left............................................................................................................... WP 0018

0004-4

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 5-3810-305-23 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. 4. 5.

0004

Troubleshooting Procedure

Steering is Erratic.............................................................................................................................. WP 0018 Wheel End Leaks Oil......................................................................................................................... WP 0018 Wheels Noisy When Turned to Right or Left..................................................................................... WP 0018 Excessive Noise in Transfer of Power From Engine to Wheels........................................................ WP 0018

WINCH 1. 2. 3. 4. 5. 6. 7. 8. 9. Winch Will Not Develop Maximum Line Pull..................................................................................... WP 0019 Winch Will Lower but Will Not Raise................................................................................................. WP 0019 Winch Will Not Lower Load or Not Lower Load Smoothly................................................................. WP 0019 Hydraulic Oil Leaks From Vent Plug................................................................................................. WP 0019 The Brake Will Not Hold a Load With the Control Lever in Neutral................................................... WP 0019 Winch Will Not Hoist Rated Load...................................................................................................... WP 0019 Winch Runs Hot................................................................................................................................ WP 0019 Winch “Chatters" While Raising Rated Load..................................................................................... WP 0019 Wire Rope Does Not Spool Smoothly on Drum................................................................................ WP 0019

END OF WORK PACKAGE

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0005

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES ENGINE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0020 WP 0022 WP 0025 WP 0031 WP 0039 WP 0043 WP 0044 WP 0045 WP 0047 WP 0048 References (cont.) WP 0049 WP 0051 WP 0052 WP 0054 WP 0056 WP 0058 WP 0059 WP 0061 WP 0063 WP 0064 WP 0065 WP 0066 WP 0075 WP 0076 WP 0162

TROUBLESHOOTING PROCEDURE SYMPTOM ENGINE CRANKS BUT WILL NOT START; NO SMOKE FROM EXHAUST MALFUNCTION Out of Fuel. CORRECTIVE ACTION Fill tank. MALFUNCTION MSD-ICE Fuel Switch OFF. CORRECTIVE ACTION 1. 2. Turn switch ON (WP 0020). Replace switch (WP 0065).

0005-1

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TM 5-3810-305-23

0005

MALFUNCTION Less Than 22 VDC at Fuel Solenoid. CORRECTIVE ACTION 1. 2. Tighten wire connection on fuel solenoid (WP 0162). Check wire for continuity. Replace if faulty (WP 0162).

MALFUNCTION Fuel Line Plugged. CORRECTIVE ACTION 1. 2. 3. Change fuel filters (WP 0022). Clean out fuel line (WP 0162). Replace fuel line (WP 0048) and (WP 0049).

MALFUNCTION Lift Pump Inoperative. CORRECTIVE ACTION Inspect pump. Replace pump if required (WP 0045). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM ENGINE WILL NOT START WHEN COLD START IS USED MALFUNCTION No Ether Delivered from Cylinder. CORRECTIVE ACTION 1. 2. Check cylinder for tightness and quantity of ether. If empty, replace cylinder (WP 0051).

0005-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00010)

TM 5-3810-305-23

0005

MALFUNCTION Valve Not Dispensing Ether. CORRECTIVE ACTION 1. 2. Disconnect tube at valve and actuate valve. Adjust actuating cable (WP 0051).

MALFUNCTION Obstruction in Tube to Atomizer. CORRECTIVE ACTION Reconnect tube to valve. Actuate valve; if no ether is present, replace tube (WP 0051). MALFUNCTION Obstruction in Atomizer. CORRECTIVE ACTION Remove atomizer. Reconnect tube to atomizer. Actuate valve. If either is not discharged from atomizer, it is clogged. Remove atomizer and clean out or replace (WP 0051). SYMPTOM ENGINE HARD TO START/WILL NOT START; SMOKE FROM EXHAUST MALFUNCTION Cranking Speed Too Low. CORRECTIVE ACTION 1. 2. 3. Tighten battery connection (WP 0076). Service batteries (WP 0076). Replace starting motor (WP 0063).

MALFUNCTION Cold Start Needed. CORRECTIVE ACTION Use cold start device (TM 5-3810-305-10).

0005-3

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TM 5-3810-305-23

0005

MALFUNCTION Engine Starting Under Load. CORRECTIVE ACTION Check for properly positioned valve spools, cables, and levers. Repair or replace as required. SYMPTOM ENGINE STARTS, BUT WILL NOT KEEP RUNNING MALFUNCTION Idle Speed Too Low. CORRECTIVE ACTION Adjust low idle screw (WP 0020). MALFUNCTION Engine Starting Under Load. CORRECTIVE ACTION Check for properly positioned valve spools, cables, and levers. Repair or replace as required. MALFUNCTION Contaminated Fuel. CORRECTIVE ACTION Drain fuel and clean fuel system (TM 5-3810-305-10). MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.

0005-4

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TM 5-3810-305-23

0005

SYMPTOM ENGINE WILL NOT CRANK MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON. MALFUNCTION Transmission Shift Not in Neutral. CORRECTIVE ACTION 1. 2. Shift into neutral. Replace neutral safety switch (WP 0064).

MALFUNCTION Battery Connections Loose. CORRECTIVE ACTION Tighten battery connections (WP 0076). MALFUNCTION Battery Voltage Low. CORRECTIVE ACTION Service batteries (WP 0076). SYMPTOM ENGINE SURGES AT IDLE MALFUNCTION Idle Speed Set Too Low. CORRECTIVE ACTION Adjust low idle screw (WP 0020). MALFUNCTION Air in Fuel System.

0005-5

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TM 5-3810-305-23

0005

CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.

MALFUNCTION Low Fuel Level in Tank. CORRECTIVE ACTION Add fuel (TM 5-3810-305-10). MALFUNCTION Fuel Lines Restricted. CORRECTIVE ACTION 1. 2. Clean out fuel lines. Replace fuel lines (WP 0048) and (WP 0049).

MALFUNCTION Fuel Filters Plugged. CORRECTIVE ACTION Replace fuel filters (WP 0022). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM WARM ENGINE IDLES ROUGH MALFUNCTION Idle Speed Set Too Low. CORRECTIVE ACTION Adjust low idle screw (WP 0020).

0005-6

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TM 5-3810-305-23

0005

MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION Drain fuel and clean system (TM 5-3810-305-10). MALFUNCTION Air Cleaner Element Plugged. CORRECTIVE ACTION 1. 2. Clean air cleaner element (TM 5-3810-305-10). Replace air cleaner element (WP 0022).

MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.

MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044).

0005-7

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TM 5-3810-305-23

0005

MALFUNCTION Valves Incorrectly Adjusted. CORRECTIVE ACTION Adjust valve clearance (WP 0031). SYMPTOM ENGINE MISFIRES MALFUNCTION Fuel Contaminated. CORRECTIVE ACTION Drain fuel and clean system (WP 0047). MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fittings. Replace damaged fuel system components.

MALFUNCTION Fuel Injection Lines Leaking. CORRECTIVE ACTION 1. 2. Tighten connections. Replace lines (WP 0048) and (WP 0049).

MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzle (WP 0043). MALFUNCTION Valves Adjusted Incorrectly. CORRECTIVE ACTION Adjust valve clearance (WP 0031).

0005-8

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TM 5-3810-305-23

0005

SYMPTOM ENGINE RUNS HOT MALFUNCTION Vehicle Overloaded. CORRECTIVE ACTION 1. 2. Reduce load (TM 5-3810-305-10). Use lower gear (TM 5-3810-305-10).

MALFUNCTION Coolant Level Low. CORRECTIVE ACTION 1. 2. Add coolant (TM 5-3810-305-10). Check for leaks and repair.

MALFUNCTION Engine Temperature Gage/Sending Unit Malfunctioning. CORRECTIVE ACTION Replace engine temperature gage/sending unit (WP 0066). MALFUNCTION Fins in Radiator Plugged. CORRECTIVE ACTION Clean out fins (TM 5-3810-305-10). MALFUNCTION Thermostat Inoperative, Incorrect, or Missing. CORRECTIVE ACTION Replace thermostat (WP 0056). MALFUNCTION Collapsed Hose. CORRECTIVE ACTION Replace collapsed hose (WP 0054).

0005-9

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TM 5-3810-305-23

0005

MALFUNCTION Loose Belt on Water Pump and Fan. CORRECTIVE ACTION 1. 2. Check belt for correct size (WP 0059). Replace belt tensioner (WP 0061).

MALFUNCTION Pressure Cap Incorrect/Malfunctioning. CORRECTIVE ACTION Replace cap. MALFUNCTION Water Pump Inoperative. CORRECTIVE ACTION Replace water pump (WP 0058). MALFUNCTION Injection Pump Timing Incorrect or Overfueled. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM LOW OIL PRESSURE MALFUNCTION Oil Level Low. CORRECTIVE ACTION 1. 2. Fill to proper level (TM 5-3810-305-10). Check for leaks and repair.

MALFUNCTION Oil Pressure Gage/Sending Unit Malfunctioning. CORRECTIVE ACTION Replace oil pressure gage/sending unit.

0005-10

03/15/2011 Rel(1.8) root(tswp) wpno(T00010)

TM 5-3810-305-23

0005

MALFUNCTION Engine Oil Diluted or Improper Viscosity. CORRECTIVE ACTION 1. 2. Change engine oil (WP 0022). Check for origin of contamination and repair.

MALFUNCTION Engine Oil Filter Plugged. CORRECTIVE ACTION Change engine oil filter (WP 0022). MALFUNCTION Seal on Engine Oil Suction Tube Inoperative. CORRECTIVE ACTION Replace seal (WP 0039). MALFUNCTION Engine Bearing Worn or Damaged. CORRECTIVE ACTION Replace engine (WP 0025). SYMPTOM ENGINE RUNNING TOO COLD MALFUNCTION Engine Temperature Gage/Sending Unit Malfunctioning. CORRECTIVE ACTION Replace engine temperature gage/sending unit. MALFUNCTION Thermostat Inoperative, Incorrect Temperature Set-Point. CORRECTIVE ACTION Replace thermostat (WP 0056).

0005-11

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TM 5-3810-305-23

0005

SYMPTOM ENGINE RPM WILL NOT REACH RATED SPEED - NO LOAD MALFUNCTION Throttle Linkage Incorrectly Adjusted. CORRECTIVE ACTION Adjust throttle linkage. MALFUNCTION Tachometer Malfunctioning. CORRECTIVE ACTION Replace tachometer (WP 0075). SYMPTOM LOW POWER MALFUNCTION Vehicle Overloaded. CORRECTIVE ACTION 1. 2. Reduce load (TM 5-3810-305-10). Use lower gear (TM 5-3810-305-10).

MALFUNCTION Air Cleaner Element Plugged. CORRECTIVE ACTION 1. 2. Clean air cleaner element (TM 5-3810-305-10). Replace air cleaner element (WP 0022).

MALFUNCTION Fuel Filters Plugged. CORRECTIVE ACTION Replace fuel filters (WP 0022).

0005-12

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TM 5-3810-305-23

0005

MALFUNCTION Poor Quality Fuel. CORRECTIVE ACTION 1. 2. Drain fuel tank (TM 5-3810-305-10). Clean out fuel lines (WP 0162).

MALFUNCTION Throttle Linkage Incorrectly Adjusted. CORRECTIVE ACTION Adjust throttle linkage (WP 0052). MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fitting. Replace damaged fuel system components.

MALFUNCTION Fuel Lines Restricted. CORRECTIVE ACTION 1. 2. Clean out lines (WP 0048) and (WP 0049). Replace lines (WP 0048) and (WP 0049).

MALFUNCTION Fuel Drain Manifold Restricted. CORRECTIVE ACTION 1. 2. Clear restriction. Replace fuel drain manifold (WP 0049).

MALFUNCTION Oil Level High. CORRECTIVE ACTION Drain to proper level (TM 5-3810-305-10).

0005-13

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0005

MALFUNCTION Valves Incorrectly Adjusted. CORRECTIVE ACTION Adjust valve clearance (WP 0031). MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). MALFUNCTION Injection Pump Inoperative. CORRECTIVE ACTION Replace injection pump (WP 0044). SYMPTOM EXCESSIVE SMOKE UNDER LOAD MALFUNCTION Air Cleaner Element Plugged. CORRECTIVE ACTION 1. 2. Clean air cleaner element (TM 5-3810-305-10). Replace air cleaner (WP 0022).

MALFUNCTION Engine Running Too Cold. CORRECTIVE ACTION 1. 2. Warm up engine (TM 5-3810-305-10). Replace thermostat (WP 0056).

MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044).

0005-14

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0005

MALFUNCTION More Than One Seal Washer Under Injector Nozzle. CORRECTIVE ACTION Remove extra washers (WP 0043). MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). MALFUNCTION Injection Pump Overfueled. CORRECTIVE ACTION Replace injection pump (WP 0044). MALFUNCTION Poor Quality Fuel. CORRECTIVE ACTION 1. 2. Drain fuel tank (TM 5-3810-305-10). Clean out fuel lines (WP 0162).

MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fitting. Replace damaged fuel system components.

MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044).

0005-15

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0005

MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). SYMPTOM FUEL KNOCK MALFUNCTION Poor Quality Fuel. CORRECTIVE ACTION 1. 2. Drain fuel tank (TM 5-3810-305-10). Clean out fuel lines (WP 0162).

MALFUNCTION Air in Fuel System. CORRECTIVE ACTION 1. 2. Tighten fuel fitting. Replace damaged fuel system components.

MALFUNCTION Injection Pump Timing Incorrect. CORRECTIVE ACTION Replace injection pump (WP 0044). MALFUNCTION Injector Nozzles Plugged or Inoperative. CORRECTIVE ACTION Replace injector nozzles (WP 0043). END OF WORK PACKAGE

0005-16

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0006

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES HYDRAULICS

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References WP 0012 WP 0013 References (cont.) WP 0019 WP 0129 WP 0138 WP 0139 WP 0146

TROUBLESHOOTING PROCEDURE

NOTE
• “Hydraulic function" is the general term used for any of the following five hydraulically controlled operations on the crane: boom hoist, boom telescope, upperstructure swing, winch, and outriggers. • Before any troubleshooting is attempted, become fully acquainted with the following two basic fundamental facts of a hydraulic system: 1. SPEED - The speed of a hydraulic function is directly related to the system flow. A reduction in speed of a cylinder or motor is caused by an insufficient quantity of oil being delivered to the component. 2. POWER - The power or force of a hydraulic function is related to pressure. • If the differences between speed and power of a hydraulic system is understood, then accurate troubleshooting can be accomplished in a minimum of time. Follow these steps to isolate hydraulic malfunctions: 1. Identify hydraulic functions that are malfunctioning. 2. If one function is malfunctioning, check components unique to that function. 3. If more than one function is malfunctioning, refer to hydraulic schematic. Identify components common to all areas malfunctioning. Check those common components first. 4. Check for proper hydraulic oil level in hydraulic reservoir and for obvious leaks. 5. Check for proper hydraulic pressures before any components are replaced.

0006-1

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0006

SYMPTOM CONTROL LEVER STICKS OR BINDS MALFUNCTION Control Linkage or Cable Sticking. CORRECTIVE ACTION

NOTE
Binding push-pull cables may simply have too tight a bend at some point in their length. Starting from the control valve end, disconnect the components one at a time until the malfunction is located. Then repair or replace that component. MALFUNCTION Valve Spool Sticking. CORRECTIVE ACTION Replace control valve (WP 0138) and (WP 0139). SYMPTOM NO MOVEMENT OF HYDRAULIC FUNCTION(S) MALFUNCTION Valve Spool Does Not Shift Fully. CORRECTIVE ACTION 1. 2. 3. Adjust linkage. Replace faulty linkage (WP 0129). Replace control valve (WP 0138) and (WP 0139).

MALFUNCTION Valve Spool Shifts Fully.

0006-2

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0006

CORRECTIVE ACTION 1. Refer to sections on: a. b. c. 2. Relief Valve Troubleshooting (WP 0013). Winch Troubleshooting (WP 0019). Pump Troubleshooting (WP 0012).

Replace control valve (WP 0146).

END OF WORK PACKAGE

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0007

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES SWING CIRCUIT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0114 References (cont.) WP 0134 WP 0146 WP 0147 WP 0160 WP 0161

TROUBLESHOOTING PROCEDURE SYMPTOM UPPERSTRUCTURE WILL NOT SWING MALFUNCTION Swing Relief Valve Stuck in Open Position. CORRECTIVE ACTION Replace swing relief valve (WP 0147). MALFUNCTION Swing Motor Leaks Internally. CORRECTIVE ACTION 1. 2. Repair swing motor (WP 0160). Replace swing motor (WP 0160).

MALFUNCTION Downstream Blockage. CORRECTIVE ACTION 1. 2. Return additional controls to neutral position. Locate and remove blockage.

0007-1

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0007

MALFUNCTION Swing Valve Spool Damaged. CORRECTIVE ACTION Replace main control valve (WP 0146). MALFUNCTION Mechanical Fault in Swing Reducer Gearbox. CORRECTIVE ACTION 1. 2. Repair swing gearbox (WP 0161). Replace swing gearbox (WP 0161).

MALFUNCTION Mechanical Fault in Swing Bearing. CORRECTIVE ACTION Replace swing bearing (WP 0158). MALFUNCTION Main Hydraulic Pump Faulty. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM SWING MOTION SLUGGISH MALFUNCTION Swing Relief Valve Set Too Low. CORRECTIVE ACTION Adjust swing relief valve (WP 0147). MALFUNCTION Fault in Flow Divider Valve. CORRECTIVE ACTION Replace flow divider (WP 0114).

0007-2

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0007

MALFUNCTION Swing Motor Leaks Internally. CORRECTIVE ACTION 1. 2. Repair swing motor (WP 0160). Replace swing motor (WP 0160).

MALFUNCTION Main Hydraulic Pump Faulty. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). MALFUNCTION Leakage Around Swing Control Valve Spool. CORRECTIVE ACTION Replace main control valve (WP 0146). SYMPTOM SWING MOTION ERRATIC MALFUNCTION Swing Bearing Not Lubricated Properly. CORRECTIVE ACTION Lubricate swing bearing (TM 5-3810-305-10). MALFUNCTION Swing Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust swing relief valve (WP 0147). Replace swing relief valve (WP 0147).

0007-3

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0007

SYMPTOM SWING MOTOR TURNS IN WRONG DIRECTION MALFUNCTION Hose Connections Wrong. CORRECTIVE ACTION Reverse hose connections. MALFUNCTION Swing Motor Assembled Improperly. CORRECTIVE ACTION 1. 2. Repair swing motor (WP 0160). Replace swing motor (WP 0160).

END OF WORK PACKAGE

0007-4

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0008

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES BOOM HOIST CIRCUIT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0067 WP 0134 References (cont.) WP 0135 WP 0138 WP 0145 WP 0146 WP 0147 WP 0149 WP 0162

TROUBLESHOOTING PROCEDURE SYMPTOM BOOM HOIST CYLINDER INOPERATIVE OR ERRATIC MALFUNCTION Load is Too Great. CORRECTIVE ACTION Consult capacity chart for maximum loads and reduce as required (TM 5-3810-305-10). MALFUNCTION Anti-Two Block System Malfunctioning. CORRECTIVE ACTION 1. 2. 3. 4. 5. Ensure proper connection of counterweight. Replace relay in anti-two block panel (WP 0067). Repair open circuits in wiring (WP 0162). Lubricate disconnect assemblies (TM 5-3810-305-10). Replace disconnect assemblies (WP 0145).

MALFUNCTION Boom Hoist Hold Valve Malfunctioning. CORRECTIVE ACTION Replace boom hoist hold valve (WP 0138).

0008-1

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0008

MALFUNCTION Rotary Manifold Leaking Internally. CORRECTIVE ACTION 1. 2. Repair rotary manifold (WP 0135). Replace swing motor (WP 0135).

MALFUNCTION Downstream Blockage. CORRECTIVE ACTION Locate and remove blockage. MALFUNCTION Boom Hoist Cylinder Binding. CORRECTIVE ACTION Replace boom hoist cylinder (WP 0149). SYMPTOM BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED MALFUNCTION Boom Hoist Hold Valve Free Flow Check Not Seating Properly. CORRECTIVE ACTION Replace boom hoist hold valve (WP 0138). SYMPTOM BOOM HOIST, EXTEND, AND OUTRIGGER CYLINDERS INOPERATIVE OR ERRATIC MALFUNCTION Main Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).

0008-2

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0008

MALFUNCTION Main Hydraulic Pump Faulty. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM BOOM DRIFTS DOWN MALFUNCTION Test Boom Hoist Cylinder. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. With hydraulic oil at a working temperature and boom off to one side, elevate boom to 60 degree angle and suspend a 5-ton (4.54 metric ton) load on a two-part line 1 ft (305 mm) off ground. Shut engine OFF. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect hose from adapter on right side of hold valve. Some hydraulic oil will run out, but will stop. Turn ignition switch ON to energize anti-two block solenoid. Push boom hoist lever to lower position and hold. Boom should hold its position. If boom lowers, and no hydraulic oil comes out of adapter, boom hoist hold valve must be replaced. If boom lowers, and hydraulic oil comes out of adapter, boom hoist cylinder is bypassing and should be replaced (WP 0149).

MALFUNCTION Boom Hoist Hold Valve Not Seating Properly. CORRECTIVE ACTION Replace boom hoist hold valve (WP 0138). MALFUNCTION Boom Hoist Cylinder Bypassing Hydraulic Oil. CORRECTIVE ACTION Replace boom hoist cylinder (WP 0149). END OF WORK PACKAGE

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0009

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES BOOM EXTEND CIRCUIT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 References (cont.) WP 0067 WP 0135 WP 0145 WP 0150 WP 0162

TROUBLESHOOTING PROCEDURE SYMPTOM BOOM EXTEND FUNCTION WILL NOT OPERATE MALFUNCTION Load Too Great. CORRECTIVE ACTION Consult capacity chart for maximum load and reduce load as required (TM 5-3810-305-10). MALFUNCTION Anti-Two Block Malfunctioning. CORRECTIVE ACTION 1. 2. 3. 4. 5. Ensure proper connection of counterweight. Replace relay in anti-two block panel (WP 0067). Repair open circuits in wiring (WP 0162). Lubricate disconnect assemblies (TM 5-3810-305-10). Replace disconnect assemblies (WP 0145).

MALFUNCTION Rotary Manifold Leaking Internally. CORRECTIVE ACTION 1. 2. Repair rotary manifold (WP 0135). Replace rotary manifold (WP 0135).

0009-1

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0009

MALFUNCTION Boom Extend Cylinder Binding. CORRECTIVE ACTION 1. 2. SYMPTOM BOOM EXTEND CYLINDER EXTENDS BUT WILL NOT RETRACT MALFUNCTION Counterbalance Valve Malfunctioning. CORRECTIVE ACTION Replace counterbalance valve (WP 0150). MALFUNCTION Internal Leakage in Boom Extend Cylinder. CORRECTIVE ACTION 1. 2. SYMPTOM BOOM SECTION RETRACTS UNDER LOAD MALFUNCTION Boom Section Retracts Under Load. CORRECTIVE ACTION 1. 2. 3. 4. With boom off to one side and horizontal, extend boom approximately 6 ft (1.83 m). Mark side of the extended section at end of the boom base. Elevate boom to maximum angle and suspend a 5 ton (4.54 metric ton) load on a two-part line 1 ft (305 mm) off ground. With engine shut off, hold or tie boom extend lever in fully extended position for approximately 15 minutes. Return boom extend lever to neutral position. Start engine and lower boom to horizontal. Re-mark extended section as in Step 1. Measure distance between marks. The difference is the leak-down: Leak-down must not exceed 0.75 inch (19.1 mm) in 15 minutes with hydraulic oil at a working temperature. If leak-down exceeds 0.75 inch (19.1 mm) in 15 minutes, perform Step 5. Reseal boom extend cylinder (WP 0150). Replace boom extend cylinder (WP 0150). Repair boom extend cylinder (WP 0150). Replace boom extend cylinder (WP 0150).

0009-2

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0009

CORRECTIVE ACTION - Continued 5. With hydraulic oil at a working temperature, elevate boom to a 60 degree angle and suspend a 5 ton (4.54 metric ton) load on a two-part line 1 ft (305 m) off ground. Extend telescoping section approximately 1/2 of full extension. Shut engine off. Disconnect hose from tube on left side of boom. Extend cylinder at boom base. Some hydraulic oil should run out, but will stop. Pull boom extend lever to the retract position and hold. Boom should hold its position. a. b. If boom retracts and no hydraulic oil comes out of tube, counterbalance valve must be replaced. If boom retracts and hydraulic oil comes out of tube, boom extend cylinder is bypassing and should be replaced (WP 0150).

MALFUNCTION Counterbalance Valve Not Seating Properly. CORRECTIVE ACTION Replace counterbalance valve (WP 0150). MALFUNCTION O-ring Around Counterbalance Valve Damaged. CORRECTIVE ACTION Replace counterbalance valve (WP 0150). MALFUNCTION Boom Extend Cylinder Bypassing. CORRECTIVE ACTION 1. 2. Repair boom extend cylinder (WP 0150). Replace boom extend cylinder (WP 0150).

END OF WORK PACKAGE

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0010

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES OUTRIGGER CIRCUIT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References WP 0134 WP 0136 References (cont.) WP 0138 WP 0146 WP 0147 WP 0151 WP 0162

TROUBLESHOOTING PROCEDURE SYMPTOM ALL OUTRIGGERS INOPERATIVE MALFUNCTION No Electrical Power to Outrigger Valve. CORRECTIVE ACTION Reset circuit breaker (WP 0162). MALFUNCTION Solenoid Valves Connection Loose. CORRECTIVE ACTION Tighten wire harness connection (WP 0162). MALFUNCTION Main Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).

0010-1

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0010

MALFUNCTION Main Hydraulic Pump worn or Damaged. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM INDIVIDUAL OUTRIGGER INOPERATIVE MALFUNCTION Wire Connection at Outrigger Solenoid. CORRECTIVE ACTION Connect wire (WP 0162). MALFUNCTION Valve Loose or Disconnected. CORRECTIVE ACTION Repair wire (WP 0162). MALFUNCTION Individual Outrigger Switch Malfunction. CORRECTIVE ACTION Replace bad outrigger switch (WP 0136). MALFUNCTION Outrigger Solenoid Coil Burned Out. CORRECTIVE ACTION Replace outrigger solenoid coil (WP 0136). MALFUNCTION Outrigger Hold Valve on Outrigger Cylinder Not Operating. CORRECTIVE ACTION 1. 2. Repair outrigger hold valve (WP 0138). Replace outrigger hold valve (WP 0138).

0010-2

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0010

MALFUNCTION Outrigger Cylinder Leaking Internally. CORRECTIVE ACTION 1. 2. Repair outrigger cylinder (WP 0151). Replace outrigger cylinder (WP 0151).

MALFUNCTION Outrigger Solenoid Valve Spool Damaged. CORRECTIVE ACTION Replace outrigger solenoid valve (WP 0136). SYMPTOM OUTRIGGERS WILL NOT LIFT VEHICLE MALFUNCTION Main Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).

MALFUNCTION Outrigger Cylinder Leaking Internally. CORRECTIVE ACTION 1. 2. Repair outrigger cylinder (WP 0151). Replace outrigger cylinder (WP 0151).

0010-3

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0010

SYMPTOM OUTRIGGER RETRACTS UNDER LOAD MALFUNCTION To Determine Malfunction Perform the Following: With Hydraulic Oil at Working Temperature, Start Engine and Set Vehicle on Outriggers. Shut Engine Off. Turn Dipstick Cap 1/4 Turn to Safety Notch to Relieve Pressure. Disconnect Both Hoses from Either Front or Rear Outrigger Cylinders at Tee Located by Outrigger Solenoid Valve. Cap Tee. Some Hydraulic Oil Will Run Out, but Will Stop. Turn Ignition Switch ON to Energize Outrigger Solenoid Valve Switches. Pull Outrigger Control Lever To Raise Position and Hold. Actuate Outrigger Switch Corresponding to Outrigger Cylinder Being Checked. CORRECTIVE ACTION

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. 2. If outrigger cylinder retracts and no hydraulic oil comes out of hose, outrigger hold valve must be replaced/ repaired (WP 0138). If outrigger cylinder retracts and hydraulic oil comes out of hose, outrigger cylinder is bypassing and should be replaced/repaired (WP 0151).

END OF WORK PACKAGE

0010-4

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0011

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES STEERING CIRCUIT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0088 WP 0108 WP 0110 References (cont.) WP 0111 WP 0112 WP 0113 WP 0114 WP 0134 WP 0140 WP 0147

TROUBLESHOOTING PROCEDURE SYMPTOM SLOW STEERING, HARD STEERING, OR LOSS OF POWER ASSIST MALFUNCTION Steer Axle Overloaded. CORRECTIVE ACTION Consult capacity chart for maximum load. Reduce load as required (TM 5-3810-305-10). MALFUNCTION Swing Relief Valve Malfunctioning. CORRECTIVE ACTION 1. 2. Adjust swing relief valve (WP 0147). Replace swing relief valve (WP 0147).

MALFUNCTION Flow Divider Sticking. CORRECTIVE ACTION Replace flow divider (WP 0114).

0011-1

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0011

MALFUNCTION Main Hydraulic Pump Worn or Malfunctioning. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). SYMPTOM VEHICLE WANDERS - VEHICLE WILL NOT STAY IN A STRAIGHT LINE MALFUNCTION Mechanical Linkage Worn. CORRECTIVE ACTION Replace linkage (WP 0140). MALFUNCTION Leaking Fitting on Steering Circuit. CORRECTIVE ACTION 1. 2. Tighten fitting. Replace fitting.

MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leaks in pump suction circuit. MALFUNCTION Steering Cylinder Leaking Internally. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Steering Cylinder Piston Loose. CORRECTIVE ACTION Replace steering cylinder (WP 0112).

0011-2

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0011

SYMPTOM DRIFT - VEHICLE VEERS SLOWLY IN ONE DIRECTION MALFUNCTION Steering Linkage Worn or Damaged. CORRECTIVE ACTION Replace steering linkage (WP 0108). MALFUNCTION Steering Cylinder Leaks Internally. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Steering Selector Valve Leaking. CORRECTIVE ACTION Replace steering selector valve (WP 0113). SYMPTOM SLIP - SLOW MOVEMENT OF STEERING WHEEL FAILS TO CAUSE ANY MOVEMENT OF STEERED WHEELS MALFUNCTION Steering Cylinder Leaking Internally. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Steering Control Unit Worn. CORRECTIVE ACTION Replace steering control unit (WP 0110). MALFUNCTION Main Hydraulic Pump Failure. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134).

0011-3

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0011

MALFUNCTION Transmission Pump Drive Failure. CORRECTIVE ACTION Replace transmission (WP 0088). MALFUNCTION Blockage in Supply or Output Lines to Main Hydraulic Pump. CORRECTIVE ACTION Replace hydraulic hose (WP 0111). MALFUNCTION Thermal Shock. CORRECTIVE ACTION

CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50°F [10°C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM TEMPORARY HARD STEERING OR HANG-UP MALFUNCTION Main Hydraulic Pump Failure. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). MALFUNCTION Transmission Pump Drive Failure. CORRECTIVE ACTION Replace transmission (WP 0088).

0011-4

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0011

MALFUNCTION Blockage in Supply or Output Lines to Main Hydraulic Pump. CORRECTIVE ACTION Replace hydraulic hose (WP 0111). MALFUNCTION Thermal Shock. CORRECTIVE ACTION

CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50°F [10°C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM ERRATIC STEERING MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leak in pump suction circuit. MALFUNCTION Leaking Fitting on Steering Circuit. CORRECTIVE ACTION 1. 2. Tighten fitting. Replace fitting.

MALFUNCTION Hose Pinched. CORRECTIVE ACTION Replace hose (WP 0111).

0011-5

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0011

MALFUNCTION Flow Divider Sticking. CORRECTIVE ACTION Replace flow divider (WP 0114). MALFUNCTION Steering Cylinder Piston Loose. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Thermal Shock. CORRECTIVE ACTION

CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50°F [10°C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM “SPONGY" OR SOFT STEERING MALFUNCTION Air in Hydraulic Steering Circuit. CORRECTIVE ACTION Turn steering wheel repeatedly from full left to full right while sitting still.

0011-6

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0011

SYMPTOM FREE WHEELING - STEERING WHEEL TURNS WITH SLIGHT RESISTANCE BUT RESULTS IN LITTLE OR NO STEERED WHEEL ACTION MALFUNCTION Steering Linkage Malfunctioning. CORRECTIVE ACTION 1. 2. Repair steering linkage (WP 0108). Replace steering linkage (WP 0108).

MALFUNCTION Steering Cylinder Internal Leakage. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Loose Steering Cylinder Piston. CORRECTIVE ACTION Replace steering cylinder (WP 0112). MALFUNCTION Wear in Steering Control Unit. CORRECTIVE ACTION Replace steering control unit (WP 0110). SYMPTOM EXCESSIVE FREE PLAY AT STEERING WHEEL MALFUNCTION Steering Wheel Nut Loose. CORRECTIVE ACTION Tighten steering wheel nut.

0011-7

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0011

MALFUNCTION Steering Column Shaft/Steering Wheel Worn or Damaged. CORRECTIVE ACTION Replace steering control unit/steering wheel (WP 0110). MALFUNCTION Steering Linkage Malfunctioning. CORRECTIVE ACTION 1. 2. Repair steering linkage (WP 0108). Replace steering linkage (WP 0108).

MALFUNCTION Loose Steering Cylinder Piston. CORRECTIVE ACTION Replace steering cylinder (WP 0112). SYMPTOM STEERING UNIT LOCKS UP MALFUNCTION Hydraulic Power Insufficient. CORRECTIVE ACTION Replace steering/swing relief valve and/or flow divider (WP 0114). MALFUNCTION Large Particles in Steering Control Unit. CORRECTIVE ACTION 1. 2. 3. Locate origin of particles and correct. Drain and flush entire hydraulic system. Replace steering control unit (WP 0110).

0011-8

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0011

MALFUNCTION Steering Control Unit Worn. CORRECTIVE ACTION Replace steering control unit (WP 0110). MALFUNCTION Thermal Shock. CORRECTIVE ACTION

CAUTION
Thermal shock is an extremely rare condition caused when hydraulic system is operated for some time without turning steering wheel. Fluid in reservoir and system is hot and steering control unit is relatively cool (more than 50°F [10°C] temperature differential). When steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of steering control unit. The temporary seizure may be followed by total free wheeling. Failure to follow this caution may result in damage to equipment. Replace steering control unit (WP 0110). SYMPTOM STEERING WHEEL OSCILLATES OR TURNS BY ITSELF MALFUNCTION Lines Connected to Wrong Cylinder Ports. CORRECTIVE ACTION Reconnect lines correctly. SYMPTOM STEERED WHEELS TURN IN WRONG DIRECTION WHEN OPERATOR ACTIVATES STEERING WHEEL MALFUNCTION Lines Connected to Wrong Cylinder Ports. CORRECTIVE ACTION Reconnect lines correctly. END OF WORK PACKAGE

0011-9/10 blank

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TM 5-3810-305-23

0012

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES PUMPS

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 References (cont.) WP 0134 WP 0147

TROUBLESHOOTING PROCEDURE SYMPTOM FAILURE OF HYDRAULIC PUMP(S) TO DELIVER FLUID MALFUNCTION Low Hydraulic Oil Level. CORRECTIVE ACTION Add hydraulic oil as required (TM 5-3810-305-10). MALFUNCTION Hydraulic Oil Intake Suction Filter Plugged. CORRECTIVE ACTION Clean hydraulic oil intake suction filter. MALFUNCTION Hydraulic Oil Viscosity Too Heavy to Pick Up Prime. CORRECTIVE ACTION Use lighter viscosity hydraulic oil. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Air Leak in Suction Line, Preventing Priming or Causing Noise and Irregular Action of Control Circuit. CORRECTIVE ACTION Repair leaks.

0012-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00017)

TM 5-3810-305-23

0012

MALFUNCTION Shaft or Parts Broken Inside Hydraulic Pump(s). CORRECTIVE ACTION Replace hydraulic pump(s) (WP 0134). MALFUNCTION Contamination in Pump(s). CORRECTIVE ACTION 1. 2. 3. SYMPTOM LOW OR NO PRESSURE IN SYSTEM MALFUNCTION Engine Rpm Too Low. CORRECTIVE ACTION Adjust low idle rpm. MALFUNCTION Relief Valve Set Too Low. CORRECTIVE ACTION Adjust relief valve setting (WP 0147). MALFUNCTION Hydraulic Oil Leaking. CORRECTIVE ACTION 1. 2. Check hydraulic system for leaks. Repair leaks. Locate origin of contamination and correct. Drain and flush entire hydraulic system. Replace hydraulic pump(s) (WP 0134).

0012-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00017)

TM 5-3810-305-23

0012

MALFUNCTION Hydraulic Oil Viscosity Incorrect. CORRECTIVE ACTION Use proper hydraulic oil. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leak in pump suction circuit. SYMPTOM PUMP(S) MAKING NOISE MALFUNCTION Hydraulic Oil Viscosity Too High. CORRECTIVE ACTION 1. 2. Warm hydraulic oil. Use lower viscosity hydraulic oil. Consult lube chart (TM 5-3810-305-10).

MALFUNCTION Air in Hydraulic System. CORRECTIVE ACTION Repair leak in pump suction circuit. MALFUNCTION Partially Clogged Intake Line, Intake Filter, or Restricted Intake Pipe. CORRECTIVE ACTION Clean out intake filter screen or eliminate restriction. MALFUNCTION Worn or Broken Parts in Hydraulic Pump(s). CORRECTIVE ACTION Replace hydraulic pump(s) (WP 0134).

0012-3

03/15/2011 Rel(1.8) root(tswp) wpno(T00017)

TM 5-3810-305-23

0012

SYMPTOM EXTERNAL OIL LEAKAGE AROUND HYDRAULIC PUMP(S) MALFUNCTION Loose Fitting on Hydraulic Pump(s). CORRECTIVE ACTION Tighten fitting. MALFUNCTION Damaged O-rings at Split Flange Fittings. CORRECTIVE ACTION Replace o-ring seal (WP 0134). MALFUNCTION Damaged O-ring Seals Between Hydraulic Pump(s) Sections. CORRECTIVE ACTION Replace o-ring seal (WP 0134). SYMPTOM BREAKAGE OF PARTS INSIDE HYDRAULIC PUMP HOUSING(S) MALFUNCTION Seizure Due to Lack of Hydraulic Oil. CORRECTIVE ACTION Fill hydraulic reservoir to proper level, clean hydraulic oil filter, and check for restrictions in suction line. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Excessive Pressure Above Maximum Rating. CORRECTIVE ACTION Adjust relief valve maximum setting(s) (WP 0147).

0012-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00017)

TM 5-3810-305-23

0012

MALFUNCTION Solid Matter Being Wedged in Hydraulic Pump(s). CORRECTIVE ACTION 1. 2. 3. Locate origin of contamination and correct. Drain and flush entire hydraulic system. Replace hydraulic pump(s) (WP 0134).

END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(tswp) wpno(T00017)

TM 5-3810-305-23

0013

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES RELIEF VALVES

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References WP 0147

TROUBLESHOOTING PROCEDURE SYMPTOM CANNOT GET PRESSURE MALFUNCTION Poppet Stuck Open or Dirt Under Seat. CORRECTIVE ACTION Replace relief valve (WP 0147). SYMPTOM ERRATIC PRESSURE MALFUNCTION Poppet Seat Damaged. CORRECTIVE ACTION Replace relief valve (WP 0147). SYMPTOM PRESSURE SETTING NOT CORRECT MALFUNCTION Locknut and Adjusting Screw Loose. CORRECTIVE ACTION Adjust relief valve (WP 0147).

0013-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00018)

TM 5-3810-305-23

0013

SYMPTOM LEAKAGE MALFUNCTION Damaged Seats or Worn O-rings. CORRECTIVE ACTION Replace relief valve (WP 0147). END OF WORK PACKAGE

0013-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00018)

TM 5-3810-305-23

0014

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES BRAKES

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 References (cont.) WP 0102 WP 0103 WP 0104 WP 0105 WP 0134

TROUBLESHOOTING PROCEDURE SYMPTOM BRAKES SLOW TO RELEASE OR DRAG MALFUNCTION Brake Pedal Adjustment Improper. CORRECTIVE ACTION Adjust pedal free play. MALFUNCTION Brake-shoe Return Springs Weak or Broken. CORRECTIVE ACTION Replace brake-shoe return springs (WP 0103). MALFUNCTION Automatic Adjuster Improperly Assembled. CORRECTIVE ACTION Replace adjuster (WP 0103). MALFUNCTION Parking Brake Caliper Frozen to Mounting Pins. CORRECTIVE ACTION Free up and coat with grease. Consult lube chart (TM 5-3810-305-10).

0014-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00019)

TM 5-3810-305-23

0014

MALFUNCTION Parking Brake Linkage Improperly Assembled or Adjusted. CORRECTIVE ACTION 1. 2. SYMPTOM BRAKES DO NOT RELEASE MALFUNCTION Brake Pedal Sticking. CORRECTIVE ACTION Lubricate clevis and pivot pin with (TM 5-3810-305-10). MALFUNCTION Brake Pedal Adjustment Improper. CORRECTIVE ACTION Adjust pedal free play. MALFUNCTION Brake Booster Defective. CORRECTIVE ACTION Repair or replace brake booster (WP 0104). SYMPTOM BRAKES SLOW TO APPLY MALFUNCTION Piston in Brake Booster Sticking or Damaged. CORRECTIVE ACTION Repair or replace brake booster (WP 0104). Assemble parking brake linkage properly (WP 0102). Adjust parking brake (WP 0102).

0014-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00019)

TM 5-3810-305-23

0014

MALFUNCTION Low Hydraulic Oil Flow. CORRECTIVE ACTION 1. 2. SYMPTOM INSUFFICIENT BRAKES MALFUNCTION Low Brake Fluid Level. CORRECTIVE ACTION 1. 2. Fill to proper level (TM 5-3810-305-10). Bleed brake system (WP 0103). Increase engine rpm. Replace main hydraulic pump (WP 0134).

MALFUNCTION Improper Brake Pedal Adjustment. CORRECTIVE ACTION Adjust brake pedal. MALFUNCTION Automatic Adjuster(s) Inoperative. CORRECTIVE ACTION Replace automatic adjuster(s) (WP 0103). MALFUNCTION Hydraulic Tubing Loose or Damaged. CORRECTIVE ACTION Tighten or replace hydraulic tubing and fittings (WP 0105). MALFUNCTION Brake Hose/Tube Restricted. CORRECTIVE ACTION Replace brake hose/tube (WP 0105).

0014-3

03/15/2011 Rel(1.8) root(tswp) wpno(T00019)

TM 5-3810-305-23

0014

MALFUNCTION Wheel Cylinders Leaking. CORRECTIVE ACTION Replace wheel cylinder (WP 0103). MALFUNCTION Brake Lining or Drum Condition Poor. CORRECTIVE ACTION 1. 2. Replace brake lining (WP 0103). Replace drum (WP 0103).

MALFUNCTION Parking Brake Pads Worn. CORRECTIVE ACTION 1. 2. Adjust parking brake pad clearance (WP 0102). Replace parking brake pad and adjust (WP 0102).

END OF WORK PACKAGE

0014-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00019)

TM 5-3810-305-23

0015

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES ELECTRICAL SYSTEM

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Multimeter (WP 0171, Table 1, Item 29) Tester, Battery, Electrolyte Solution (WP 0171, Table 1, Item 12) References TM 5-3810-305-10 WP 0059 References (cont.) WP 0061 WP 0062 WP 0063 WP 0064 WP 0070 WP 0076 WP 0162 WP 0166

TROUBLESHOOTING PROCEDURE

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Refer to electrical schematic FO-1 (WP 0166) for aid in troubleshooting electrical system. SYMPTOM STARTING MOTOR DOES NOT OPERATE MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON (TM 5-3810-305-10).

0015-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00020)

TM 5-3810-305-23

0015

MALFUNCTION Transmission Not in Neutral. CORRECTIVE ACTION Place transmission in neutral (TM 5-3810-305-10). MALFUNCTION Defective Neutral Safety Switch. CORRECTIVE ACTION Replace neutral safety switch (WP 0064). MALFUNCTION Battery Weak or Dead. CORRECTIVE ACTION 1. 2. Tighten battery terminals (WP 0076). Charge or replace battery (WP 0076).

MALFUNCTION No Voltage at Starting Motor S Terminal. CORRECTIVE ACTION 1. 2. 3. Reset or replace circuit breaker (WP 0162). Charge or replace battery (WP 0076). Repair open circuits (WP 0162).

MALFUNCTION Damaged or Loose Wiring Between Starter Motor and Batteries. CORRECTIVE ACTION 1. 2. Clean and tighten all connections. Replace wiring as needed.

MALFUNCTION Solenoid, Relay, or Starting Switch Defective. CORRECTIVE ACTION Replace failed component.

0015-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00020)

TM 5-3810-305-23

0015

MALFUNCTION Starter Motor Defective. CORRECTIVE ACTION 1. 2. SYMPTOM ALTERNATOR CHARGING LOW OR UNSTEADY MALFUNCTION Fan Belt Loose or Worn. CORRECTIVE ACTION 1. 2. Replace fan belt (WP 0059). Replace belt tensioner (WP 0061). Replace starter motor (WP 0063). Check pinion gear and flywheel ring gear.

MALFUNCTION Alternator Terminals Loose or Corroded. CORRECTIVE ACTION 1. 2. 3. Tighten alternator terminals (WP 0062). Clean alternator terminals (WP 0062). Replace alternator terminals (WP 0062).

MALFUNCTION Brushes Worn. CORRECTIVE ACTION Replace alternator (WP 0062). MALFUNCTION Circuit Open. CORRECTIVE ACTION 1. 2. Repair wire. Replace alternator (WP 0062).

0015-3

03/15/2011 Rel(1.8) root(tswp) wpno(T00020)

TM 5-3810-305-23

0015

MALFUNCTION Diode Panel Defective. CORRECTIVE ACTION Replace alternator (WP 0062). MALFUNCTION Alternator Defective. CORRECTIVE ACTION Replace alternator (WP 0062). SYMPTOM BATTERY VOLTAGE LOW MALFUNCTION Batteries Weak. CORRECTIVE ACTION 1. 2. Charge batteries (WP 0076). Replace batteries (WP 0076).

MALFUNCTION Battery Electrolyte Level Low. CORRECTIVE ACTION Fill battery cells. MALFUNCTION Battery Cables or Terminals Corroded. CORRECTIVE ACTION Clean battery cables, terminals, and battery posts (WP 0076). MALFUNCTION Alternator Defective. CORRECTIVE ACTION Replace alternator (WP 0062).

0015-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00020)

TM 5-3810-305-23

0015

SYMPTOM EXTERNAL LIGHT(S) NOT OPERATING MALFUNCTION Light Switch OFF or in Blackout Mode. CORRECTIVE ACTION Turn on light switch or correct position (TM 5-3810-305-10). MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. Replace circuit breaker.

MALFUNCTION Connection at Light Fixture Corroded or Loose. CORRECTIVE ACTION 1. 2. 3. Tighten connector. Clean connector (WP 0162). Replace connector (WP 0162).

MALFUNCTION Bulb Burned Out in Light Assembly. CORRECTIVE ACTION Replace bulb. MALFUNCTION Light Switch Defective. CORRECTIVE ACTION Replace light switch.

0015-5

03/15/2011 Rel(1.8) root(tswp) wpno(T00020)

TM 5-3810-305-23

0015

MALFUNCTION Lighting Circuit Shorted. CORRECTIVE ACTION Check for shorts and repair (WP 0162). SYMPTOM WORKLIGHTS NOT OPERATING MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. Replace circuit breaker.

MALFUNCTION Vehicle Lights in Blackout Mode. CORRECTIVE ACTION Switch to correct mode (TM 5-3810-305-10). MALFUNCTION Relay Faulty. CORRECTIVE ACTION Replace relay. MALFUNCTION No Circuit Through Electrical Collector Ring. CORRECTIVE ACTION 1. 2. Repair electrical collector ring (WP 0070). Replace electrical collector ring (WP 0070).

END OF WORK PACKAGE

0015-6

03/15/2011 Rel(1.8) root(tswp) wpno(T00020)

TM 5-3810-305-23

0016

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES ANTI-TWO BLOCK SYSTEM

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Multimeter (WP 0171, Table 1, Item 29) References TM 5-3810-305-10 References (cont.) WP 0067 WP 0070

TROUBLESHOOTING PROCEDURE SYMPTOM PANEL LIGHT AND HORN WILL NOT COME ON WITH ANTI-TWO BLOCK COUNTERWEIGHT LIFTED; CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON (TM 5-3810-305-10). MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. If problem still occurs, replace circuit breaker.

MALFUNCTION Wire Broken. CORRECTIVE ACTION 1. 2. 3. 4. Check voltage in control panel harness between terminals #0 and #37. If voltage is 0, check between ignition post of ignition switch and ground. If 24 VDC available, wire to control panel is bad. Replace wire (WP 0067).

0016-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00021)

TM 5-3810-305-23

0016

SYMPTOM HORN WORKS BUT NO LIGHT WITH ANTI-TWO BLOCK COUNTERWEIGHT LIFTED; CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Light Bulb Burned Out. CORRECTIVE ACTION Replace panel bulb (WP 0067). SYMPTOM LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT CONTACTING ANTI-TWO BLOCK COUNTERWEIGHT; CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Anti-Two Block Counterweight Chain Broken or Hung Up. CORRECTIVE ACTION Ensure counterweight is attached to chain and hanging freely. MALFUNCTION Electrical Cable Broken or Bad Connection. CORRECTIVE ACTION 1. Check all cables for visible damage, then check plug terminals #37 and #38 at control panel and check for continuity. If circuit is open, check wires inside cable reel, wires from reel to anti-two block switch, and anti-two block switch on boom head. If continuity exists, check relay in panel (WP 0067). Replace faulty component.

2.

MALFUNCTION Anti-Two Block Switch Defective. CORRECTIVE ACTION 1. 2. 3. Check for correct mechanical operation. If correct, remove cover and wires from terminals #1 and #2. With arm pulled down there should be a closed circuit between terminals. With arm up, circuit should be open. If all conditions are not met, replace anti-two block switch (WP 0067).

0016-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00021)

TM 5-3810-305-23

0016

MALFUNCTION Relay in Anti-Two Block Panel Defective. CORRECTIVE ACTION 1. 2. 3. Check for 24 VDC between relay pins #30 (hot) and #86 (ground). If voltage is 0, check for voltage between pin #87a and ground. If 24 VDC, replace relay. (With no electrical power to relay, pins #30 and #87a should show continuity.) With 24 VDC to #85 and #86 grounded, there should be continuity between pins #87 and #30.

MALFUNCTION No Circuit Through Electrical Collector Ring. CORRECTIVE ACTION 1. 2. SYMPTOM LIGHT AND HORN ARE ON BUT CONTROL DISCONNECTS WILL NOT DISENGAGE MALFUNCTION Ignition Switch OFF. CORRECTIVE ACTION Turn ignition switch ON (TM 5-3810-305-10). MALFUNCTION Circuit Breaker Tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. If problem still occurs, replace circuit breaker. Replace electrical collector ring (WP 0070). Repair electrical collector ring (WP 0070).

MALFUNCTION Wire Broken. CORRECTIVE ACTION 1. 2. 3. 4. Check voltage in control panel harness between terminals #0 and #37. If voltage is 0, check between ignition post of ignition switch and ground. If 24 VDC available, wire to control panel is bad. Replace wire (WP 0067).

0016-3

03/15/2011 Rel(1.8) root(tswp) wpno(T00021)

TM 5-3810-305-23

0016

SYMPTOM NO LIGHT AND HORN BUT CONTROL DISCONNECTS WILL NOT ENGAGE MALFUNCTION Control Disconnect Defective. CORRECTIVE ACTION 1. Check voltage across disconnect terminals. If 24 VDC, check anti-two block BY-PASS switch in anti-two block panel. If voltage is 0, repair or replace disconnect (check other disconnects for condition). To operate crane, solenoid must have 24 VDC supplied to one side and have a good ground on the other side. Under this condition, the disconnect should act as a solid link. With 24 VDC removed, disconnect should allow free motion of control lever in one direction and operate valve spool in other direction.

2.

MALFUNCTION Anti-Two Block BY-PASS Switch Defective. CORRECTIVE ACTION 1. 2. Check to ensure that anti-two block BY-PASS switch is in the OFF position. Check for 24 VDC in anti-two block panel. If present, replace anti-two block BY-PASS switch or anti-two block panel (WP 0067).

MALFUNCTION Wire Broken or Bad Connection. CORRECTIVE ACTION 1. 2. Check voltage across disconnect terminals. If voltage is 0, check voltage across terminals in the anti-two block panel. If 24 VDC, replace wire. If 24 VDC across disconnect, disconnect is defective.

MALFUNCTION Function Disconnect Defective. CORRECTIVE ACTION 1. 2. Check solenoid for function. Applying 24 VDC to disconnect, solenoid should engage with a distinct snap. If not, solenoid must be replaced. If solenoid engages but disconnect “breaks" under load, replace disconnect.

END OF WORK PACKAGE

0016-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00021)

TM 5-3810-305-23

0017

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES TRANSMISSION

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10

TROUBLESHOOTING PROCEDURE

NOTE
If transmission performance is inadequate, install pressure gage(s) on the transmission control valve and check pressures, also check for the following symptoms. SYMPTOM ERRATIC TRANSMISSION OIL PRESSURE MALFUNCTION Transmission Oil Level Low. CORRECTIVE ACTION Add transmission oil to proper level. Consult lube chart (TM 5-3810-305-10). SYMPTOM EXCESSIVE TRANSMISSION OIL PRESSURE AT HIGH SPEED (RPM) MALFUNCTION Main Regulator Valve Sticking. CORRECTIVE ACTION Check main regulator for contamination and clean orifice. MALFUNCTION Main Regulator Valve Spring Faulty. CORRECTIVE ACTION Replace main regulator valve spring.

0017-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00022)

TM 5-3810-305-23

0017

MALFUNCTION Main Regulator Valve Orifice Plugged. CORRECTIVE ACTION Clean main regulator valve orifice. SYMPTOM LOW TRANSMISSION OIL PRESSURE IN ALL GEARS MALFUNCTION Main Regulator Valve Sticking. CORRECTIVE ACTION Check main regulator valve spring. MALFUNCTION Transmission Oil Pressure Set Too Low. CORRECTIVE ACTION 1. 2. Repair control valve. Replace control valve.

MALFUNCTION Main Regulator Valve Spring Faulty. CORRECTIVE ACTION Replace main regulator valve spring. MALFUNCTION Control Valve Body Cracked. CORRECTIVE ACTION Replace control valve body. MALFUNCTION Charge Pump Defective. CORRECTIVE ACTION Replace charge pump.

0017-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00022)

TM 5-3810-305-23

0017

MALFUNCTION O-ring on Charge Pump Mount Defective. CORRECTIVE ACTION Replace o-ring on charge pump. SYMPTOM LOW TRANSMISSION OIL PRESSURE IN ONE GEAR BUT ALRIGHT IN OTHER GEARS MALFUNCTION Broken Seal Ring on Input End of Clutch Weld Assembly Piston Shaft. CORRECTIVE ACTION Replace seal ring. MALFUNCTION Outer or Inner Piston Seal Not Sealing. CORRECTIVE ACTION Replace piston seals. SYMPTOM LOW CONVERTER PRESSURE MALFUNCTION Converter Bypass Valve Defective. CORRECTIVE ACTION Inspect converter bypass valve and replace if necessary. MALFUNCTION Converter Hub Seal Ring Not Sealing. CORRECTIVE ACTION Replace converter hub seal ring.

0017-3

03/15/2011 Rel(1.8) root(tswp) wpno(T00022)

TM 5-3810-305-23

0017

SYMPTOM HIGH TRANSMISSION OIL PRESSURE MALFUNCTION Hose Bends Too Sharp in Routing. CORRECTIVE ACTION Re-route hoses. MALFUNCTION Hose Defective. CORRECTIVE ACTION Replace hose. MALFUNCTION Hoses Not Connected Correctly. CORRECTIVE ACTION Connect hoses correctly. MALFUNCTION Main Regulator Valve Orifice Plugged. CORRECTIVE ACTION Clean main regulator valve orifice. SYMPTOM CLUTCH SELECTED PRESSURE DOES NOT RETURN TO NORMAL MALFUNCTION Main Regulator Valve Spring Weak. CORRECTIVE ACTION Replace main regulator valve spring.

0017-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00022)

TM 5-3810-305-23

0017

MALFUNCTION Accumulator Spring Too Strong. CORRECTIVE ACTION Replace spring. MALFUNCTION Charge Pump Defective. CORRECTIVE ACTION Replace charge pump. MALFUNCTION Excessive Internal Leakage to Clutch. CORRECTIVE ACTION Replace seals. SYMPTOM EXCESSIVE NOISE AT ENGINE IDLE MALFUNCTION Charge Pump Defective. CORRECTIVE ACTION Replace charge pump. MALFUNCTION Excessive Backlash in Gear Train. CORRECTIVE ACTION Replace bearings and inspect for defective gears. SYMPTOM EXCESSIVE GEAR NOISE AT HIGH SPEED (RPM) MALFUNCTION Main Regulator Valve Orifice Plugged. CORRECTIVE ACTION Clean main regulator valve orifice.

0017-5

03/15/2011 Rel(1.8) root(tswp) wpno(T00022)

TM 5-3810-305-23

0017

SYMPTOM TRANSMISSION OIL BLOWS OUT OF BREATHER ON TOP OF TRANSMISSION MALFUNCTION Converter Seal Ring Broken. CORRECTIVE ACTION Replace converter hub seal ring. SYMPTOM TRANSMISSION OVERHEATING MALFUNCTION Converter Stalling. CORRECTIVE ACTION Shift to lower gear. MALFUNCTION Transmission Oil Level Too High. CORRECTIVE ACTION Drain to proper level. Consult lube chart (TM 5-3810-305-10). MALFUNCTION Engine Overheating. CORRECTIVE ACTION 1. 2. Add engine coolant if required. Clean radiator.

0017-6

03/15/2011 Rel(1.8) root(tswp) wpno(T00022)

TM 5-3810-305-23

0017

MALFUNCTION Transmission Oil Cooler Dirty. CORRECTIVE ACTION Flush and clean transmission oil cooler. MALFUNCTION Transmission Oil Level Low. CORRECTIVE ACTION Add transmission oil. Consult lube chart (TM 5-3810-305-10). END OF WORK PACKAGE

0017-7/8 blank

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TM 5-3810-305-23

0018

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES AXLE ASSEMBLY

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0093 WP 0096 References (cont.) WP 0097 WP 0098 WP 0099 WP 0100 WP 0101 WP 0107 WP 0108

TROUBLESHOOTING PROCEDURE SYMPTOM WHEELS PULL TO RIGHT OR LEFT MALFUNCTION Tires Not Properly Inflated. CORRECTIVE ACTION Inflate tires properly (TM 5-3810-305-10). MALFUNCTION Tires Worn. CORRECTIVE ACTION Check and replace tires (WP 0107). SYMPTOM STEERING IS ERRACTIC MALFUNCTION Tie Rods Out of Adjustment or Worn. CORRECTIVE ACTION Adjust or repair tie rods (WP 0108).

0018-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00023)

TM 5-3810-305-23

0018

MALFUNCTION Tires or Wheels Damaged. CORRECTIVE ACTION Replace wheels or tires (WP 0107). MALFUNCTION Wheel Bearings Worn. CORRECTIVE ACTION Replace wheel bearings (WP 0096). MALFUNCTION Worn Pivot and Spindle Assembly Trunnion Bearings. CORRECTIVE ACTION Replace pivot and spindle assembly trunnion bearings (WP 0097) and (WP 0098). SYMPTOM WHEEL END LEAKS OIL MALFUNCTION Hub Seal Defective. CORRECTIVE ACTION Replace hub seal (WP 0096). MALFUNCTION Wheel End Cover O-ring Defective. CORRECTIVE ACTION Replace wheel end cover o-ring (WP 0096). SYMPTOM WHEELS NOISY WHEN TURNED TO RIGHT OR LEFT MALFUNCTION Air Pressure Low or Unevenly Worn Tires. CORRECTIVE ACTION Replace tires (WP 0107).

0018-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00023)

TM 5-3810-305-23

0018

MALFUNCTION Fluid Level Low in Differential or Wheel End. CORRECTIVE ACTION Service wheel end or differential (WP 0096) and (WP 0100). MALFUNCTION Constant-Velocity Joint Worn. CORRECTIVE ACTION Repair constant-velocity joint (WP 0099). SYMPTOM EXCESSIVE NOISE IN TRANSFER OF POWER FROM ENGINE TO WHEELS MALFUNCTION Driveshaft(s) Defective. CORRECTIVE ACTION 1. 2. Repair driveshaft(s) (WP 0093). Replace driveshaft(s) (WP 0093).

MALFUNCTION Differential Defective. CORRECTIVE ACTION Replace ring and pinion gears (WP 0101). END OF WORK PACKAGE

0018-3/4 blank

03/15/2011 Rel(1.8) root(tswp) wpno(T00023)

TM 5-3810-305-23

0019

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES WINCH

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) References TM 5-3810-305-10 WP 0016 WP 0125 WP 0126 WP 0128 References (cont.) WP 0129 WP 0134 WP 0135 WP 0142 WP 0146 WP 0147 WP 0158 WP 0165

TROUBLESHOOTING PROCEDURE SYMPTOM WINCH WILL NOT DEVELOP MAXIMUM LINE PULL MALFUNCTION Winch Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. Adjust winch relief valve (WP 0147). Replace winch control valve (WP 0128).

MALFUNCTION Winch Relief Valve Sticking. CORRECTIVE ACTION Replace winch control valve (WP 0128). MALFUNCTION Main Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. Adjust main relief valve (WP 0147). Replace main control valve (WP 0146).

0019-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00024)

TM 5-3810-305-23

0019

MALFUNCTION Main Relief Valve Sticking. CORRECTIVE ACTION Replace main control valve (WP 0146). MALFUNCTION Winch Motor Worn or Damaged. CORRECTIVE ACTION 1. 2. Repair winch motor (WP 0126). Replace winch motor (WP 0126).

MALFUNCTION Main Hydraulic Pump Worn or Damaged. CORRECTIVE ACTION Replace main hydraulic pump (WP 0134). MALFUNCTION Rotary Manifold Leaking. CORRECTIVE ACTION 1. 2. SYMPTOM WINCH WILL LOWER BUT WILL NOT RAISE MALFUNCTION Insufficient Parts of Line Being Lifted. CORRECTIVE ACTION Consult capacity chart for maximum loads. Reduce load as required (TM 5-3810-305-10). MALFUNCTION Anti-Two Block System Malfunction. CORRECTIVE ACTION Refer to Anti-Two Block Troubleshooting (WP 0016). Repair rotary manifold (WP 0135). Replace rotary manifold (WP 0135).

0019-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00024)

TM 5-3810-305-23

0019

SYMPTOM WINCH WILL NOT LOWER LOAD OR NOT LOWER LOAD SMOOTHLY MALFUNCTION Plugged or Loose Pilot Orifice. Pilot Orifice is a Small Pipe Plug with a Hole Drilled Through It, Located Behind Pilot Port Fitting on Brake Valve. If It Becomes Plugged, It Will Prevent Pilot Pressure from Opening Brake Valve. If It Becomes Loose, It Will Allow an Unregulated Amount of Oil in to Operate Brake Valve, Which Causes Erratic Brake Valve Operation. CORRECTIVE ACTION Remove pilot hose and fitting brake valve, then use a 5/32 inch allen wrench to remove pilot orifice. Diameter of orifice is approximately 0.020 inch (0.51 mm). Clean and install pilot orifice tightly in brake valve (WP 0127). MALFUNCTION Brake Cylinder Seal Leaking. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125).

MALFUNCTION Brake Discs Damaged. CORRECTIVE ACTION 1. 2. SYMPTOM HYDRAULIC OIL LEAKS FROM VENT PLUG MALFUNCTION Brake Cylinder Seal Defective. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125). Repair winch (WP 0125). Replace winch (WP 0125).

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0019

MALFUNCTION High Hydraulic System Back Pressure. CORRECTIVE ACTION 1. 2. 3. SYMPTOM THE BRAKE WILL NOT HOLD A LOAD WITH THE CONTROL LEVER IN NEUTRAL MALFUNCTION High Hydraulic System Back Pressure. CORRECTIVE ACTION 1. 2. 3. Clean hydraulic return filter. Clean out hydraulic return lines. Replace pinched hydraulic return lines (WP 0142). Clean hydraulic return filter. Clean out hydraulic return lines. Replace pinched hydraulic return lines (WP 0142).

MALFUNCTION Brake Discs Damaged. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125).

MALFUNCTION Brake Clutch Slipping. CORRECTIVE ACTION 1. 2. Repair winch (WP 0125). Replace winch (WP 0125).

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0019

SYMPTOM WINCH WILL NOT HOIST RATED LOAD MALFUNCTION Winch Mounted on an Uneven or Flexible Surface. CORRECTIVE ACTION 1. 2. Inspect upperstructure for cracks or defects (WP 0158). Loosen, then evenly retighten all winch mounting bolts to recommended torque (WP 0165).

MALFUNCTION Winch Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. Adjust winch relief valve (WP 0128). Replace winch control valve (WP 0128).

MALFUNCTION Rigging and Sheaves Not Operating Efficiently. CORRECTIVE ACTION Perform rigging service as recommended (TM 5-3810-305-10). SYMPTOM WINCH RUNS HOT MALFUNCTION Winch Mounted on an Uneven or Flexible Surface. CORRECTIVE ACTION 1. 2. Inspect upperstructure for cracks or defects (WP 0158). Loosen then evenly retighten all winch mounting bolts to recommended torque (WP 0165).

MALFUNCTION Hydraulic Oil Cooler Plugged. CORRECTIVE ACTION Thoroughly clean exterior and flush interior of hydraulic cooler.

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0019

MALFUNCTION Internal Winch Parts Excessively Worn or Damaged. CORRECTIVE ACTION 1. 2. SYMPTOM WINCH "CHATTERS" WHILE RAISING RATED LOAD MALFUNCTION Winch Relief Valve Set Too Low. CORRECTIVE ACTION 1. 2. SYMPTOM WIRE ROPE DOES NOT SPOOL SMOOTHLY ON DRUM MALFUNCTION Rope Damaged or Spooled Without Tension. CORRECTIVE ACTION Consult wire rope section (TM 5-3810-305-10). MALFUNCTION Winch May Have Been Overloaded, Causing Permanent Set in Wire Rope. CORRECTIVE ACTION Replace wire rope (WP 0129). END OF WORK PACKAGE Adjust winch relief valve (WP 0128). Replace winch control valve (WP 0128). Repair winch (WP 0125). Replace winch (WP 0125).

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0020

FIELD MAINTENANCE MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Test Set, Electronic Systems (MSD) (WP 0171, Table 1, Item 7) References TM 9-4910-571-12&P WP 0005 WP 0015 WP 0022 WP 0025 WP 0038 References (cont.) WP 0044 WP 0045 WP 0050 WP 0052 WP 0056 WP 0058 WP 0062 WP 0063 WP 0066 WP 0076 WP 0081

GENERAL To troubleshoot a vehicle problem, the technician can use MSD-ICE VTM (Vehicle Test Meter and transducer). DATA ENTRY TESTS For information regarding Data Entry, Cylinder Entry, and Data Display Tests, refer to TM 9-4910-571-12&P. OFFSET TESTS The MSD-ICE VTM performs a test by setting the TEST SELECT switches to the test number and then pressing the TEST button. For some tests, an offset test is required before the test itself can be performed. This is done by selecting the number of the desired test and holding the TEST button down for several seconds. The offset test nulls characteristic differences in the VTM, test leads, and transducer. It zeros the meter. Once the offset is performed, the VTM automatically corrects for the offset before displaying measured values. The displayed offset value should be checked against limits given in the test procedures. If the displayed value is outside these limits, either the transducer or the test cable is faulty and must be replaced. This is a form of a self-test. Perform the offset test when each transducer is connected. The offset test is performed with the test probe cable in TK mode or the DCA plug connected to the VTM. Ensure that no stimulus is applied to the transducer in TK mode. Test probe cable leads should be shorted together. To perform an offset test, dial the test number into the TEST SELECT switches. Press and hold the TEST button, until the prompting message CAL appears on the display. A few seconds after the TEST button is released, a number will appear. This is the measured offset value associated with the test probe cable or transducer and cable.

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CONTROL TESTS These tests are used to change (or control) the way a vehicle test is displayed, or the way it is run. There are four control tests: 1. 2. 3. 4. 01 Interleave (displays rpm with next test) 02 Minimum Value (displays minimum value for next test) 03 Maximum Value (displays maximum value for next test) 04 Peak to Peak Value (displays peak-to-peak value for next test)

(Note: control tests 01, 02, 03, and 04 specify the action to be taken by the next test only. A subsequent test will reset the control.) Interleave (Test 01) This test alternately measures engine speed and a second parameter, such as fuel pressure or alternator voltage. To initiate interleave, dial 01 into the TEST SELECT switches and press and release the TEST button. The prompting message PASS is the signal to dial in the second test number and again press and release the TEST button. Minimum Value (Test 02) This test displays the minimum value display. Dial 02 into the TEST SELECT switches and press and release the TEST button. The minimum value is displayed and updated whenever a lower minimum value is measured. Entering 02 and the test number again will reset the process and a new minimum value will be displayed. Maximum Value (Test 03) This test displays the maximum value measured during a test. To initiate a maximum value display, dial 03 into the TEST SELECT switches and press and release the TEST button. The prompting message PASS is the signal to dial in the desired test number and again press and release the TEST button. The maximum value is displayed and updated whenever a higher maximum value is measured. Entering 03 and the test number again will reset the process and a new maximum value will be displayed. Peak-to-Peak Value (Test 04) This test displays the peak-to-peak measurement. Dial 04 into the TEST SELECT switches and press the TEST button. The prompting message PASS is the signal to dial in one of the four numbers (82, 89, 90, 67) and press the TEST button. MSD-ICE TESTS

NOTE
When using the MSD-ICE, refer to the manufacturer's operating instructions for use. 1. 2. 3. Verify that engine oil, engine coolant, fuel, and batteries are at proper level. Check fan belt installation. Open VTM/XDCR Kit Assembly, MSD-ICE, remove top tray containing TM 9-4910-571-12&P, Simplified Test Equipment For Internal Combustion Engines, and temporarily set aside. Remove DCA cap from DCA receptacle located in right rear of cab. Remove cable W1 from MSD-ICE kit. Attach cable W1 to DCA receptacle.

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0020

MSD-ICE TESTS - Continued

M0835105

Figure 1. Remove Cap from DCA Receptacle.

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0020

MSD-ICE TESTS - Continued 4. 5. Ensure VTM is off. Attach other end of cable W1 to J1 plug on VIM. Turn VTM ON. Change TEST SELECT switches to read 66. Push TEST button. Change TEST SELECT switches to read 99. Push TEST button. VTM will display a series of numbers and then PASS. If display does not read PASS or C, or an incorrect display appears, refer to TM 9-4910-571-12&P. Change TEST SELECT switches to read 60. Push TEST button. VTM will display VEH. Refer to vehicle test card for vehicle identification (VID) number. Change TEST SELECT switches to read VID number. Push TEST button. VTM will display 28. Change TEST SELECT switches to read 61. Push TEST button. VTM will flash VII number. Change TEST SELECT switches to read 58. Push TEST button. VTM will display CYL. Change TEST SELECT switches to read 04. Push TEST button. Change TEST SELECT switches to read 62. Push TEST button. VTM will flash 04. Change TEST SELECT switches to read 67. Push TEST button. VTM will flash battery voltage. Refer to test card for battery voltage test limits. If battery voltage falls outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Start engine. Operate engine at 1,000 to 1,200 rpm. Change TEST SELECT switches to read 01. Push TEST button. VIM will display PASS. Change TEST SELECT switches to read 67. Push TEST button. VTM will alternately flash battery charge voltage and engine rpm. During this test engine speed must be maintained between 1,000 to 1,200 rpm. Refer to test card for battery charge voltage test limits. If battery charge voltage falls outside test limits, refer to Alternator Charging Low or Unsteady (WP 0015). With engine speed at idle, charge TEST SELECT switches to read 10. Push TEST button. VTM will display engine rpm. Refer to test card for engine rpm idle test limits. If engine rpm falls outside test limits, adjust throttle idle speed, refer to Throttle Control Maintenance, (WP 0052). Accelerate engine to full governed speed, no load. Refer to test card for engine rpm governed speed, no load, test limits. If engine rpm falls outside limits, refer to Engine RPM Will Not Reach Rated Speed (WP 0005). Check vehicle engine oil pressure gage reading. Perform TK engine oil pressure test to verify gage (refer to test card and TM 9-4910-571-12&P). If vehicle engine oil pressure gage readings fall outside test limits but TK test is within limits, replace vehicle engine oil pressure gage, refer to Dash Panel Gages and Switches Maintenance (WP 0066). If TK test falls outside test limits, inspect vehicle for oil leaks and change oil filter, refer to PMCS, Change Engine Oil and Oil Filter (WP 0022). Replace lube oil pump, refer to Lube Oil Pump Maintenance (WP 0038). Check air cleaner filter restriction gage. Maximum reading is 25 inches (635 mm) of water. If reading is above 25 inches of water, service air cleaner, refer to PMCS, Service Air Filter (WP 0022). Shut engine OFF. Wait one minute to allow fuel pressure to bleed off. Change TEST SELECT switches to read 24. Push TEST button until VTM displays CAL, then release button. Refer to test card for fuel supply pressure test offset limit. If CAL reading is high, break fuel supply line at tee to release line pressure and retest. Start engine. Accelerate engine to full governed speed. Push TEST button. VTM will display fuel supply pressure. Refer to test card for fuel supply pressure test limits. If fuel supply pressure falls outside test limits, inspect fuel supply lines for leaks or pinched tubes. Service fuel filters, refer to Fuel Filters and Head Assembly Maintenance (WP 0050). Replace fuel pressure transducer, refer to MSD-ICE Wiring Harness Maintenance (WP 0081). Replace fuel lift pump, refer to Fuel Lift Pump Maintenance (WP 0045). Change TEST SELECT switches to read 26. Push TEST button. Accelerate engine to full governed speed. VTM will display either PASS or FAIL. If VTM displays FAIL, service fuel filters, refer to Fuel Filters Head Assembly Maintenance (WP 0050). With engine at idle, change TEST SELECT switches to read 27. Push TEST button. Refer to test card for fuel solenoid voltage test limits. If fuel solenoid voltage falls outside test limits, check wiring at fuel solenoid, refer to MSD-ICE Wiring Harness Maintenance (WP 0081). If fuel solenoid still falls outside test limits, replace fuel solenoid, refer to Fuel Injection Pump Maintenance (WP 0044).

6.

7.

8.

9.

10.

11. 12.

13.

14.

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0020

MSD-ICE TESTS - Continued 15. Operate engine between 1,000 to 1,200 rpm. Change TEST SELECT switches to read 01. Push TEST button. VTM will display PASS. Change TEST SELECT switches to read 82. Push TEST button. Refer to test card for alternator voltage test limits. If alternator voltage falls outside test limits, replace or repair alternator, refer to Alternator and Mounting Assembly Bracket Maintenance (WP 0062). Engine must be within the normal temperature range. With engine at idle, change TEST SELECT switches to read 12. Push TEST button. When VTM displays CIP, push accelerator pedal to floor and hold until VTM displays power test percent full power value. Return engine to idle. Refer to test card for power test percent full power test limits. Shut engine OFF. Turn fuel switch OFF. Change TEST SELECT switches to read 14. Push TEST button. When VTM displays O, crank engine. Stop cranking engine when VTM displays OFF or E013. If the cranking is incorrect, VTM will display E013. If E013 is displayed, batteries could be discharged, cranking speed could be low, or cranking was interrupted during test. Correct problem and repeat test. After VTM displays OFF, it will display either FAIL or the compression unbalance test value. If FAIL appears, the compression unbalance value is too far unbalanced for VTM to measure. Refer to test card for compression unbalance test limits. If compression unbalance test falls outside test limits, replace engine, refer to Engine Assembly Maintenance (WP 0025). Change TEST SELECT switches to read 72. Push TEST button until VTM displays CAL, then release button. Refer to test card for current first peak test offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display amperage value. Refer to test card for current first peak test limits. If amperage falls outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Start engine. Check vehicle engine temperature gage. Refer to test card for engine temperature test limits. If temperature falls outside test limits, replace thermostat, refer to Thermostat Maintenance (WP 0056). If temperature is still outside test limits, replace water pump, refer to Water Pump Maintenance (WP 0058). Shut engine OFF. Turn fuel switch ON. Change TEST SELECT switches to read 01. Push TEST button. VTM will display PASS. Operate engine between 1,000 to 1,200 rpm. Change TEST SELECT switches to read 84. Push TEST button. Refer to test card for alternator negative cable voltage drop test limits. If voltage falls outside test limits, clean and inspect battery and ground connections. Turn fuel switch OFF. Change TEST SELECT switches to read 80. Push TEST button until VTM displays CAL then release button. Refer to TEST card for starter motor current average offset hits. Push TEST button again. Crank engine. Stop cranking engine. VTM will display amperage value. Refer to test card for starter motor current average test limits. If amperage falls outside test limits, clean and inspect battery, starter, and ground connections. Change TEST SELECT switches to read 73. Push TEST button until VTM displays CAL, then release button. Refer to TEST card for battery internal resistance offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display milliohm value. Refer to test card for battery internal resistance test limits. If milliohms fall outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Change TEST SELECT switches to read 74. Push TEST button until VTM displays CAL, then release button. Refer to TEST card for starter current resistance offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display milliohm value. Refer to test card for starter current resistance test limits. If milliohms fall outside test limits, check starter connections. If test limits are still exceeded, replace or repair starter, refer to Starter Motor Maintenance (WP 0063). Change TEST SELECT switches to read 75. Push TEST button until VTM displays CAL, then release button. Refer to TEST card for battery resistance charge offset limits. Push TEST button again. VTM will display GO. Crank engine. When VTM displays OFF, stop cranking engine. VTM will display milliohm value. Refer to test card for battery resistance charge test limits. If milliohms fall outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076).

16.

17.

18.

19.

20.

21.

22.

23.

24.

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0020

MSD-ICE TESTS - Continued 25. Change TEST SELECT switches to read 70. Push TEST button. Crank engine. VTM will display voltage value while engine is cranking. Stop cranking engine. Refer to test card for starter solenoid voltage test limits. If voltage falls outside test limits, replace or repair starter, refer to Starter Motor Maintenance (WP 0063). Change TEST SELECT switches to read 69. Push TEST button. Crank engine. VTM will display voltage value while engine is cranking. Stop cranking engine. Refer to test card for starter negative cable drop test limits. If voltage falls outside test limits, clean and inspect battery and starter cable connections. Change TEST SELECT switches to read 68. Push TEST button. Crank engine. VTM will display voltage value while engine is cranking. Stop cranking engine. Refer to test card for starter motor voltage test limits. If voltage falls outside test limits, service batteries, refer to Battery Assembly and Cables Maintenance (WP 0076). Turn fuel switch ON. Start engine. Operate vehicle at proper road speeds. Check vehicle transmission temperature gage. Refer to test card for vehicle transmission temperature limits. If temperature reading falls outside limits, service transmission oil filter. Perform TK return fuel pressure test. Refer to test card (TM 9-4910-571-12&P). If pressure value falls outside test limits, inspect fuel return hoses for kinks or damage. Turn ignition switch OFF. Turn VTM OFF. Disconnect cable W1 from DCA receptacle. Disconnect cable W1 from J1 plug on VTM. Stow VTM in case (TM 9-4910-571-12&P).

26.

27.

28.

29. 30.

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0020

MSD-ICE TESTS - Continued

M0836105

Figure 2. END OF WORK PACKAGE

Schematics and Diagrams.

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CHAPTER 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

TM 5-3810-305-23

0021

FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL To ensure that the 7 1/2 Ton Crane is ready for operation at all times, it must be inspected on a regular basis so that defects may be found and corrected before they result in serious damage, equipment failure, or injury to personnel. The PMCS Table in Preventive Maintenance Checks and Services (PMCS) (WP 0022) contains systematic instructions on inspections, adjustments, and corrections to be performed by the operator/crew to keep the equipment in good operating condition and ready for its primary mission. EXPLANATION OF PMCS TABLE ENTRIES 1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E, include the item number for the check/service indicating a fault. Item numbers appear in the order in which you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the procedure column. a. Before procedures must be done immediately before you operate the crane. b. During procedures must be done while you are operating the crane. c. After procedures must be done immediately after you have operated the crane.

d. Weekly procedures must be done once each week. e. Monthly procedures must be done once each month. 3. Location, Item to Check/Service Column. This column provides the location and item to be checked or serviced.

NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. You must observe all WARNINGs to prevent serious injury to yourself and others, and all CAUTIONs to prevent the crane from being damaged. 4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item to Check/Service column to know if the equipment is ready or available for its intended mission. You must perform the procedure at the time stated in the interval column. 5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or reporting equipment failure.

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0021

GENERAL PMCS PROCEDURES 1. Always perform PMCS in the same order so it gets to be a habit. Once you've had some practice, you should be able to spot anything wrong in a hurry. If the crane does not perform as required, refer to the appropriate work package in Troubleshooting Symptom Index (WP 0004). 2. If anything looks wrong and you can’t fix it, write it on forms DA Form 2404 or 5988-E. If you find something seriously wrong, IMMEDIATELY report it to your Maintenance Supervisor. 3. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare everything needed to make all the checks. For example, you will always need a rag, or two. a. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use Solvent Cleaning Compound Type III on all metal surfaces. Use soap and water when you clean rubber, plastic, and painted surfaces. b. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and apply a light coat of lubricating oil. Report it to your Maintenance Supervisor. c. Bolts, Nuts and Screws. Check bolts, nuts, and screws for obvious loose, missing, bent, or broken condition. You cannot try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find one is loose, notify your Maintenance Supervisor.

d. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your Maintenance Supervisor. e. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Reconnect loose connectors. Ensure that wires are in good condition. If any damage or looseness is present, notify your Maintenance Supervisor. f. Hoses and Fluid Lines. Look for wear, damage, and signs of leaks. Check for loose clamps and fittings. Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, notify your Maintenance Supervisor. If something is broken or worn out, notify your Maintenance Supervisor.

g. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your crane. The following are definitions of the types/classes of leakage you need to know to determine the status of the crane. Learn and be familiar with them, and remember: when in doubt, notify your Maintenance Supervisor. Table 1. Leakage Definitions for PMCS. Class I Class II Leakage indicated by wetness or discoloration, but not great enough to form drops. Leakage great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected. Leakage great enough to form drops that fall from the item being checked/inspected.

Class III

END OF WORK PACKAGE

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0022

FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Can, Radiator Filling (WP 0171, Table 1, Item 40) Face Shield, Industrial (WP 0171, Table 1, Item 25) Funnel (WP 0171, Table 1, Item 41) Goggles, Industrial (WP 0171, Table 1, Item 27) Pan, Drain (WP 0171, Table 1, Item 39) Pump, Lubricant (WP 0171, Table 1, Item 42) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Antifreeze, 1 Gallon Bottle (WP 0170, Table 1, Item 2) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Cloth, Abrasive, Crocus (WP 0170, Table 1, Item 12) Qty: 1 Filter Element (WP 0172, Table 1, Item 27) Qty: 1 Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 O-Ring, 441-70N (WP 0172, Table 1, Item 96) Qty: 1 Plug, with O-Ring (WP 0172, Table 1, Item 115) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0031 References (cont.) WP 0050 WP 0059 WP 0103 WP 0114 WP 0122 WP 0125 WP 0128 WP 0132 WP 0144 WP 0148 WP 0156 WP 0158 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Parking brake engaged (TM 5-3810-305-10) Engine shut down (TM 5-3810-305-10) Wheels chocked (TM 5-3810-305-10) Battery disconnect switch in OFF position (TM 5-3810-305-10) Hydraulic system pressure relieved (TM 5-3810-305-10)

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0022

Table 1. Preventive Maintenance Checks and Services (PMCS).
ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

PROCEDURE

WARNING

If vehicle is parked indoors during performance of Preventive Maintenance Checks and Services (PMCS), DO NOT run engine unless exhaust fumes are vented to the outside. Failure to follow this warning may cause injury or death to personnel due to carbon monoxide poisoning.

NOTE
• Review all WARNINGs, CAUTIONs, and NOTEs before performing PMCS on the 7 1/2 Ton Crane. • Unless otherwise indicated, perform all lubrication and preventive maintenance with machine parked on level ground, parking brake engaged, transmission in N (Neutral), work tool lowered to the ground, engine shut down, wheels chocked, battery disconnect switch in OFF position, and hydraulic system pressure relieved (TM 5-3810-305-10). • Perform Operator PMCS prior to or in conjunction with Field PMCS if: 1. There is a delay between daily operation of the machine and Field PMCS. 2. The regular operator is not assisting. 1 Two Week Check or Every 80 to 100 Hours of Service Swing Reducer Oil Level Refer to Boom Maintenance (WP 0156).

2

Check Winch Lubrication Level

a. Remove plug. b. If oil is not visible, fill to level of plug.

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0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

PLUG

M0837105

Figure 1. 3 ThreeMonth Check or Every 250 Hours of Service Service Air Filter

Winch Lubrication Level Access Plug.

NOTE
Test drive machine over varied terrain for at least 15 minutes, until fully warmed up.

a. Loosen clamp (Figure 2, Item 1) on air cleaner (Figure 2, Item 2) from underneath carrier. b. Remove cup (Figure 2, Item 5) and baffle (Figure 2, Item 6). c. Separate cup (Figure 2, Item 5) and baffle (Figure 2, Item 6). d. Remove wingnut (Figure 2, Item 4) and element (Figure 2, Item 3).

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0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

WARNING

Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. e. Clean cup (Figure 2, Item 5) with compressed air. f. Clean element (Figure 2, Item 3) with compressed air. Keep air nozzle perpendicular to element pleats while rotating element. g. Inspect element (Figure 2, Item 3) by placing a bright light inside element. If element has thin spots, pin holes or small ruptures, element must be replaced. h. Install element (Figure 2, Item 3) and wingnut (Figure 2, Item 4) on air filter. i. Install baffle (Figure 2, Item 6) in cup (Figure 2, Item 5). j. Install baffle (Figure 2, Item 6) and cup (Figure 2, Item 5) on bottom of air cleaner (Figure 2, Items 2 and 5). k. Tighten clamp (Figure 2, Item 1).

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0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

1 3

4 6 2 5

M0838105

Figure 2. Air Cleaner Element Maintenance. 4 ThreeMonth Check or Every 250 Hours of Service Change Engine Oil and Oil Filter a. Warm engine oil prior to draining.

b. Place a suitable container under oil filter. c. Using a strap wrench, remove oil filter. d. Place a suitable container under engine oil pan and remove drain plug. Engine holds 10 qt (9.46 L). Drain engine oil. e. Install drain plug, torque to 60 ft-lb (81 N•m) and fill with 10 qt (9.46 L) of engine oil (TM 5-3810-305-10). f. Coat oil filter seal with clean engine oil, fill oil filter with oil, and install hand-tight. Oil filter holds 1 qt (0.95 L). g. Start engine and run for approximately 5 minutes. Check for leaks.

0022-5

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

OIL PAN

OIL FILTER
Figure 3. Engine Oil and Filter Change. 5 Four-Month Drain Fuel Tank Check or of Water and Every 500 Sediment Hours of Service a. Change fuel filter elements (WP 0050).

DRAIN PLUG
M0839105

b. Change hydraulic return line filter (WP 0148).

WARNING

Diesel fuel and other combustible materials are used in operation and maintenance of this equipment. DO NOT smoke or allow open flames in areas where combustible materials are stored or used. Failure to follow this warning may cause injury or death to personnel.

NOTE
Vehicle must be level and not operated for approximately one hour to allow fuel and water to separate. c. Place a suitable container under fuel tank. Fuel tank holds 40 gal. (151.4 L).

0022-6

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE d. Loosen plug located at the bottom of fuel tank and drain until fuel runs clearly and no water remains. e. Install drain plug and refill fuel tank.

DRAIN PLUG

M0840105

Figure 4. Fuel Tank Drain Plug. 6 Four-Month Clean Hydraulic Check or Suction Filter Every 500 Hours of Service a. Suction Filter Removal:

(1) Remove deck plates (WP 0122).

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

0022-7

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE (2) Turn dipstick cap 1/4 turn to safety notch to relieve pressure. (3) Remove plug (Figure 5, Item 2), o-ring (Figure 5, Item 3), eight nuts (Figure 5, Item 1), washers (Figure 5, Item 8), cover (Figure 5, Item 4), and o-ring (Figure 5, Item 5). Discard o-rings. (4) Remove filter (Figure 5, Item 6) and o-ring (Figure 5, Item 7) from reservoir. Discard o-rings. b. Suction Filter Cleaning: Clean all parts (WP 0162). c. Suction Filter Inspection: Inspect all parts (WP 0162). d. Suction Filter Installation: (1) Install new o-ring (Figure 5, Item 7) and filter (Figure 5, Item 6). (2) Install new o-ring (Figure 5, Item 5), cover (Figure 5, Item 4), eight washers (Figure 5, Item 8), nuts (Figure 5, Item 1), new o-ring (Figure 5, Item 3), and plug (Figure 5, Item 2). (3) Close dipstick cap. Operate crane at part throttle to slightly pressurize the reservoir. (4) Bleed out all air by loosening plug (Figure 5, Item 2). Tighten plug. (5) Install deck plates (WP 0122).

0022-8

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

3 1 8 2

4

5

6 7
Figure 5. 7 Four-Month Check or Every 500 Hours of Service Hydraulic Suction Filter Removal.
M0841105

Change a. Warm transmission oil to operating temperature Transmission Oil prior to draining. and Transmission Oil Filter b. Using a strap wrench, remove transmission oil filter. c. Place a suitable container under transmission. Transmission holds 12 qt (11.36 L). d. Remove drain plug located on the bottom of transmission and drain.

NOTE
New or rebuilt transmission will require 20.5 qt (19.40 L) of transmission oil. e. Install drain plug and fill transmission with 12 qt (11.36 L) of transmission oil (TM 5-3810-305-10). f. Coat transmission oil filter seal with clean transmission oil and install hand-tight. Warm transmission oil and check for leaks and proper level.

0022-9

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

OIL FILL

DRAIN PLUG
Figure 6. 8 Transmission Fluid Change.

M0842105

Four-Month Check Antifreeze a. Using an antifreeze tester, test the antifreeze Check or Concentration. concentration for -34°F (-37°C). Every 500 Hours of Service b. Maintain a 50/50 mixture of antifreeze to water (TM 5-3810-305-10).

0022-10

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

RADIATOR CAP

DRAIN PLUG

M0843105

Figure 7. 9 Six-Month Check or Every 500 Hours of Service

Check Antifreeze Concentration.

a. Adjust engine valve lash clearance (WP 0031).

b. Change winch oil (WP 0125). c. Check relief valve pressure settings (WP 0147). Tighten swing bearing bolts (WP 0158). 10 Six-Month Check or Every 500 Hours of Service Check Axle Differential and Hub Oil Levels a. Remove axle hub fill check plug.

b. If oil is not visible, fill to level of fill/check plug (TM 5-3810-305-10). Install fill/check plug.

0022-11

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

AXLE HUB FILL/CHECK PLUG AXLE HUB DRAIN PLUG
Figure 8. Check Axle Differential and Hub Oil Levels. c. Remove fill/check plug. d. If oil is not visible, fill to level of fill/check plug (TM 5-3810-305-10). Install fill/check plug.
M0844105

FILL/CHECK PLUG

DRAIN PLUG
Figure 9. Check Axle Differential and Hub Oil Levels.

M0845105

e. Check brake shoes for wear condition (WP 0103). f. Inspect brake shoes for cracks, scoring, grooves, Brake shoe is less than or wear. If brake shoe is less than 0.177 inch (4.50 mm) 0.177 inch (4.50 mm) thick. thick, or if inspection indicates damage, replace.

0022-12

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO. 11

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

Six-Month Check Fan Hub Check or Bearing for End Every 1,000 Play Hours of Service

WARNING

Never perform fan hub bearing end play check with the engine running. Failure to follow this warning may cause death or injury to personnel. a. Release tension of fan belt (WP 0059). b. Fan should spin freely. Grasp fan blade and alternately push and pull fan to check for end play.

M0846105

Figure 10. 12 Six-Month Check or Every 1000 Hours of Service Change Winch Oil

Check Fan Hub Bearing End Play.

a. Start engine and rotate winch drum to align drain plug (Figure 11, Item 3) and access hole in base.

b. Insert a length of 1 inch (25.4 mm) I.D. pipe and screw into the larger threads of drain hole. c. Position a suitable container under pipe. d. Remove drain plug (Figure 11, Item 3) and oring (Figure 11, Item 4) and drain. Discard o-ring. e. Install drain plug (Figure 11, Item 3) and new oring (Figure 11, Item 4). Remove pipe and oil level plug (Figure 11, Item 1) and o-ring (Figure 11, Item 2). Discard o-ring.

0022-13

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE f. Add approximately 2 qt (1.89 L) of lubricant.

NOTE
Allow time for lubricant to flow through winch and then check that lubricant level is at bottom of oil level plug threads. g. Install oil level plug (Figure 11, Item 1) and new o-ring (Figure 11, Item 2).

1,2

3,4
Figure 11. 13 TwelveDrain and Clean Month Hydraulic Check or Reservoir Every 1,500 Hours of Service Winch Oil Change.

M0847105

a. Warm hydraulic oil to operating temperature prior to draining.

b. Position a suitable container under hydraulic reservoir. Hydraulic reservoir holds 23.8 gal. (90.09 L).

0022-14

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

NOTE
Hydraulic reservoir must be completely drained and flushed to remove any water or sediment. c. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Remove drain plug at bottom of hydraulic reservoir and drain. d. Remove suction filter (WP 0144).

WARNING

Diesel fuel and other combustible materials are used in operation and maintenance of this equipment. DO NOT smoke or allow open flames in areas where combustible materials are stored or used. Failure to follow this warning may cause injury or death to personnel. e. Replace drain plug and fill hydraulic reservoir with 10 gal. (37.9 L) of diesel fuel. Allow fuel to remain in hydraulic reservoir approximately 1 hour to thoroughly clean it. f. Remove drain plug and drain diesel fuel from hydraulic reservoir.

0022-15

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE g. Install drain plug and add 15 gal. (56.8 L) of hydraulic oil (TM 5-3810-305-10).

VENT PLUG

DIPSTICK CAP

DRAIN PLUG
Figure 12. Add Hydraulic Oil.

M0849105

h. Remove drain plug and drain hydraulic oil from reservoir. i. Install drain plug and fill hydraulic reservoir with 23.8 gal. (90.09 L) of hydraulic oil (TM 5-3810-305-10). j. After refilling hydraulic reservoir, it will be necessary to bleed air from system. Open vent plug on suction filter cover and vent until filling is complete. Close vent plug and dipstick cap. Operate crane at part throttle to slightly pressurize hydraulic reservoir. Then bleed out all air by loosening vent plug. Tighten vent plug.

0022-16

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

VENT PLUG

DIPSTICK CAP

DRAIN PLUG
Figure 13. Bleed Air from Hydraulic Reservoir. 14 TwelveDrain and Clean Month Hydraulic Check or Reservoir Every 1,500 to 2,000 Hours of Service a. Remove deck plates (WP 0122).

M0849105

b. Position a suitable container under swing reduction unit. c. Remove drain plugs and fill/check plug to drain oil. d. Install drain plugs. e. Fill with gear oil to level of fill/check plug (TM 5-3810-305-10). f. Install fill/check plug. g. Install deck plates (WP 0122).

0022-17

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

FILL/CHECK PLUG

DRAIN PLUGS
Figure 14. Swing Reduction Unit Oil Change. 15 TwelveDrain and Clean Month Hydraulic Check or Reservoir Every 1,500 to 2,000 Hours of Service a. Position axle hub drain plug at “6 o’clock".

M0850105

b. Position a suitable container under axle hub drain plug. Axle hub holds 3 qt (2.84 L). c. Remove axle hub drain plug and drain oil completely. d. Install axle hub drain plug. e. Remove axle hub fill/check plug. f. Fill axle hub with 3 qt (2.84 L) of oil. Oil level should be level of fill plug. If not, add oil to obtain fill plug level. Install sealing washer and axle hub fill plug. g. Repeat Steps a through f for remaining three axle hubs. h. Position a suitable container under differential housing. Remove drain plug at the bottom of differential housing and drain oil completely.

0022-18

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE i. Install drain plug and remove fill/check plug on top rear of differential. Fill with oil and install fill/check plug (TM 5-3810-305-10).

FILL/CHECK PLUG

DRAIN PLUG
Figure 15. Differential Oil Filter. 16 TwelveChange Engine Month Coolant Check or Every 1,500 to 2,000 Hours of Service

M0845105

WARNING

Cooling system is pressurized. Use extreme caution and proper protection when removing radiator cap after operating temperature is reached. Steam and hot gases will be escaping through the radiator cap; avoid being burned by these escaping gases. When removing cap, loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed. Failure to follow this warning may cause death or injury to personnel. a. Remove radiator cap and drain cooling system by opening drain valve on bottom tank of radiator and removing plug in side of engine coolant inlet. Drain radiator into a suitable container. Radiator holds 28 qt (26.50 L). b. Check for damaged coolant hoses and loose or damaged hose clamps. Replace as required. c. To clean system, flush with clean water. If system shows mineral build-up, scale, rust, or oil, use a heavy-

0022-19

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE duty radiator cleaner and follow manufacturer’s directions.

RADIATOR CAP

DRAIN PLUG

M0843105

Figure 16.

Engine Coolant Change.

d. Replace plug, close drain valve, and refill cooling system with a 50/50 mixture of water and ethylene-glycol type antifreeze. Adequate venting is provided for a fill rate of 32 qt (30.38 L) per minute, so allow time for air to be expelled in order to get a complete fill. e. Install radiator cap and start engine. Check for leaks while running engine for 5 minutes. f. Remove radiator cap, recheck coolant level, and add coolant if necessary.

0022-20

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

RADIATOR CAP

DRAIN PLUG

M0843105

Figure 17. 17 TwelveCheck Hydraulic Month Pressure Relief Check or Valves Every 1,500 to 2,000 Hours of Service

Engine Coolant Change.

NOTE
Hydraulic system has three separate pressure circuits that have protective adjustable relief valves.

a. Main relief valve - set at 2,750 +/- 50 psi (18,960 +/- 345 kPa) at full flow. Controls outriggers, boom hoist, and boom extend. b. Winch relief valve - set at 2,650 +/- 50 psi (18,270 +/- 345 kPa) at full flow. c. Swing relief valve - set at 2,500 +/- 50 psi (17,240 +/- 345 kPa) at full flow.

0022-21

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

M0851105

Figure 18. 18 TwelveCheck Relief Month Valve Check or Adjustments Every 1,500 to 2,000 Hours of Service

Check Hydraulic Pressure Relief Valves.

Setting hydraulic pressure is an extremely intricate operation and should be performed only after satisfying the following conditions:

a. Warm hydraulic oil to operating temperature. b. Be sure to operate at full governed engine speed as relief valve setting will vary with flow rate. c. Use a good quality 4,000 psi (27,580 kPa) gage equipped with a short pressure hose and 1/4 inch female quick disconnect. Be certain to calibrate pressure gage used. Gage calibration can be lost if gage is subjected to rapidly pulsating pressure for a few seconds. Gage must have a proper snubber to read center of pump pressure ripple or erroneous readings will result.

0022-22

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23 Table 1.
ITEM NO.

0022

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

NOTE
• Relief valves used on this crane have screw-type adjustments. If it is determined that a relief valve is out of adjustment, follow this general adjustment procedure. Install a 4,000 psi (27,579 kPa) gage in the designated test port locations and proceed with pressure check and adjustments. If MSD-ICE is available, this version contains a 5,000 psi (34,474 kPa) pressure transducer. This may be substituted for the 4,000 psi gage referenced for checking the hydraulic circuit pressures. By attaching the 1219-879 adapter between the transducer and the 7091272-18 hose, the transducer’s threaded 1/4-inch pipe connection will adapt to the hose.

4. Remove acorn nut and loosen jam nut. 5. Run engine at full rpm so pump will develop required flow. 6. Operate one plunger of control valve at its extreme position long enough to get a pressure reading on the gage. 7. Turn adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure until desired pressure setting is obtained. 8. Holding adjusting screw, tighten jam nut. Install and tighten acorn nut. 9. Retest to check pressure setting.

NOTE
Results of the above settings will indicate a relatively constant relief valve setting across full engine rpm. 10. Check main relief valve (WP 0147). 11. Check winch relief valve (WP 0128). 12. Check steering/swing control relief valve (WP 0114).

0022-23

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

0022

Table 1.

Preventive Maintenance Checks and Services (PMCS) - Continued.
EQUIPMENT NOT READY/ AVAILABLE IF:

ITEM NO.

INTERVAL

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

M0852105

Figure 19.

Relief Valve Adjustment.

END OF TASK END OF WORK PACKAGE

0022-24

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00027)

TM 5-3810-305-23

CHAPTER 4 MAINTENANCE INSTRUCTIONS

TM 5-3810-305-23

0023

FIELD MAINTENANCE SERVICE UPON RECEIPT

INITIAL SETUP: References TM 5-3810-305-10

0023-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00028)

TM 5-3810-305-23

0023

GENERAL Conduct the following checks BEFORE putting a new 7 1/2 Ton Crane into operation. 1. Engine. Check oil and coolant level and ensure all clamps on air intake system are tight. Ensure all filters are installed. Look for oil leaks around engine. Oil level is to be maintained between ADD and FULL as indicated on dipstick. Transmission. Check transmission oil level dipstick. Oil level is checked with engine running at idle speed, transmission in NEUTRAL, and oil warm (160° to 190°F (71° to 88°C)). Oil should be at FULL line on dipstick. Driveshafts. Visually check connecting capscrews and driveshafts for damage. Examine parking brake disc and brake pack. Check brake function. Axles. Visually check all attaching bolts. Check differentials and hub drives for lubricant levels. Visually check steering cylinders and tie rods for damage. Ensure torque on all wheel nuts is 450 to 500 ft-lb (610 to 678 N•m). Visually check tires for damage and verify air pressure. Swing Gearbox. Check lubricant level in swing gearbox. Overall a. Check fuel in fuel tank. b. Check hydraulic components and fittings for oil leaks. c. Check batteries for electrolyte level and ensure all battery connections are tight and not corroded. d. Check brake fluid in brake reservoir. e. Lubricate the crane according to the lubrication chart in PMCS (TM 5-3810-305-10), up to and including two weeks (80 to 100 hours). f. Start engine and check gages while running at low idle rpm. When engine temperature reaches 190°F (88°C), increase rpm and continue to monitor gages, making sure everything is functioning properly. g. Shut engine OFF. h. If not already on the crane, install cable, hook block, and anti-two block counterweight, according to instructions found in Operation Under Usual Conditions (TM 5-3810-305-10). Perform the following requirements once AFTER indicated hours of service. 8 hours: Torque wheel nuts to 450 to 500 ft-lb (610 to 678 N•m) for two-week period. 20 hours: Drain, change filter, and refill transmission with new fluid. 40 hours: Make initial replacement of hydraulic return line filter. 7. Winch 100 hours: Do the following. a. Drain and change winch lubricant. b. Tighten swing bearing capscrews. Eighteen capscrews in outer race hold upperstructure to bearing. Twenty-two capscrews in inner race hold bearing to carrier. Tighten all 40 capscrews to 722 ft-lb (979 N•m). c. Tighten winch base mounting capscrews to 249 ft-lb (338 N•m). d. Tighten counterweight capscrews to 845 ft-lb (1,146 N•m).

2. 3. 4.

5. 6.

0023-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00028)

TM 5-3810-305-23

0023

M0853105

Figure 1. END OF TASK END OF WORK PACKAGE

Vehicle Check Points.

0023-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00028)

TM 5-3810-305-23

0024

FIELD MAINTENANCE POWER PACK ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Indicator, Dial (WP 0171, Table 1, Item 6) Stand, Maintenance, Automotive Engine (WP 0171, Table 1, Item 11) Suitable Lifting Device 2,700-lb (1,225 kgs) Minimum Capacity Test Set, Electronic Systems (MSD) (WP 0171, Table 1, Item 7) Tester, Valve VAC (WP 0171, Table 1, Item 15) Wrench, Torque, Click, 1/2 Inch Drive (345 N•m) (WP 0171, Table 1, Item 35) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 5 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 127) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 11 Personnel Required (Two) References WP 0078 WP 0086 WP 0162 Equipment Condition Upperstructure and boom rotated to an altitude of 90 degrees to carrier frame (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Sliding engine hood removed (WP 0118) Air cleaner removed (WP 0046) Exhaust system removed (WP 0053) Engine oil drained (WP 0022) Transmission fluid drained (WP 0091) Radiator and oil cooler removed (WP 0054)

0024-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel. REMOVAL Power Pack 1. Remove two bolts (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and exhaust system support bracket (Figure 1, Item 3) from engine (Figure 1, Item 4). Discard lockwashers.

1 2

3

4
Figure 1. Power Pack Removal.

M0058105

0024-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 2. Disconnect all electrical connections from alternator, starter, temperature, and pressure sending units (WP 0078).

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 3. Disconnect two hoses (Figure 2, Items 2 and 4) from charge pump (Figure 2, Item 3) on right hand side of transmission (Figure 2, Item 1). Secure hoses out of way for removal.

1

2

3 4
M0059105

Figure 2.

Power Pack Removal.

0024-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 4. Disconnect two hoses (Figure 3, Items 1 and 2) from main hydraulic pump (Figure 3, Item 3). Secure hoses out of the way for removal.

1

2

3
M0060105

Figure 3. 5.

Power Pack Removal.

Disconnect two hoses (Figure 4, Items 1 and 3) from ground driven steering pump (Figure 4, Item 2). Secure hoses out of the way for removal.

1

2

3

M0061105

Figure 4.

Power Pack Removal.

0024-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 6. Remove two cotter pins (Figure 5, Item 1) to disconnect two control cables (Figure 5, Items 2 and 5) from transmission control valve (Figure 5, Item 6). Loosen two jam nuts (Figure 5, Item 4) on each cable and remove cables from mounting bracket (Figure 5, Item 3). Discard cotter pins.

1

2

3

4 6
Figure 5. Power Pack Removal.

5

M0062105

0024-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 7. 8. Remove nut (Figure 6, Item 1) and ground strap (Figure 6, Item 2) from top of hydraulic hose (Figure 6, Item 3). Secure ground strap out of way for removal. Remove two oil cooler hoses (Figure 6, Items 3 and 4) from left-hand side of transmission (Figure 6, Item 5). Secure hoses out of way for removal.

1

2

5 4

3

M0063105

Figure 6.

Power Pack Removal.

0024-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 9. 10. Disconnect two fuel hoses (Figure 7, Items 3 and 4). Remove nut (Figure 7, Item 1) from injector pump throttle cable (Figure 7, Item 2). Secure injector pump throttle cable out of way for removal.

1

2

3

4

M0064105

Figure 7.

Power Pack Removal.

0024-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 11. 12. Remove two hose clamps (Figure 8, Item 1) from upper radiator hose (Figure 8, Item 3). Disconnect upper radiator hose (Figure 8, Item 3) from engine (Figure 8, Item 4) and radiator (Figure 8, Item 2).

1

2

3 4

M0065105

Figure 8.

Power Pack Removal.

0024-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 13. 14. Remove two hose clamps (Figure 9, Item 2) from lower radiator hose (Figure 9, Item 3). Disconnect lower radiator hose (Figure 9, Item 3) from engine (Figure 9, Item 1) and radiator.

1

2

3
M0066105

Figure 9. 15.

Power Pack Removal.

Remove four bolts (Figure 10, Item 2) from shift bracket (Figure 10, Item 1) and transmission (Figure 10, Item 3).

1

2

3

M0067105

Figure 10.

Power Pack Removal.

0024-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 16. Remove cotter pin (Figure 11, Item 1) and straight pin (Figure 11, Item 2) from transmission shift control (Figure 11, Item 3). Discard cotter pin.

1

2

3
Figure 11. Power Pack Removal. 17.

M0068105

Remove four capscrews (Figure 12, Item 1) and disconnect front driveshaft (Figure 12, Item 2) from transmission (Figure 12, Item 3). Support front driveshaft with suitable support.

1

2

3
Figure 12. Power Pack Removal.

M0069105

0024-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued 18. Remove four capscrews (Figure 13, Item 1) and rear driveshaft (Figure 13, Item 2) from transmission (Figure 13, Item 3).

1

2 3
M0070105

Figure 13.

Power Pack Removal.

0024-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued

NOTE
Engine and transmission assembly is mounted at three points with rubber shock mounts: one at front of engine and two on sides of transmission. 19. Remove two nuts (Figure 14, Item 3), capscrews (Figure 14, Item 1), and spacers (Figure 14, Item 2) from sides of transmission (Figure 14, Item 4).

1

2 3

4
M0207105

Figure 14. Power Pack Removal. 20. Remove capscrew (Figure 15, Item 3), washer (Figure 15, Item 2), and spacer (Figure 15, Item 1) from front of engine (Figure 15, Item 4).

0024-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Power Pack - Continued

4

1

3

2
Figure 15. Power Pack Removal.

M0206105

WARNING

Weight of engine and transmission assembly is approximately 1,800 lb (816 kg). Use adequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

NOTE
• Make sure all brackets, electrical connectors, wiring harnesses, hoses, lines and cables have been disconnected or removed from the engine and transmission assembly prior to removal. • Use more than one person when removing engine and transmission assembly to make sure engine and transmission DO NOT contact vehicle. 21. Attach hoist and chains to front engine lift eye and rear transmission mounts. Gradually hoist engine and transmission assembly up, guiding it slightly forward to clear main hydraulic pump on rear of transmission. Move engine and transmission assembly away from carrier. Lower engine and transmission assembly onto suitable support stand.

22.

END OF TASK

0024-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL Transmission from Engine

NOTE
Engine flywheel is bolted to transmission converter drive plate with 12 capscrews. Access to 12 capscrews is through engine side of flywheel housing. 1. Remove two capscrews (Figure 16, Item 1), cover plate (Figure 16, Item 4) and plug (Figure 16, Item 3) on right-hand side of flywheel housing (Figure 16, Item 2).

1 2 3 4

M0073105

Figure 16.

Transmission from Engine Removal.

0024-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Transmission from Engine - Continued 2. With a barring tool or large screwdriver, rotate flywheel ring gear (Figure 17, Item 1) through plug hole access hole (Figure 17, Item 2) until each capscrew (Figure 17, Item 3) is lined up with access hole (Figure 17, Item 4) and remove 12 capscrews.

1

2

3

4
M0201105

Figure 17.

Transmission from Engine Removal.

0024-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

REMOVAL - Continued Transmission from Engine - Continued

WARNING

Weight of transmission is approximately 1,100 lb (499 kg). Use adequate lifting equipment to lift and support transmission. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. 5. Attach hoist and sling around flywheel housing (Figure 18, Item 3) on transmission (Figure 18, Item 4). With transmission (Figure 18, Item 4) supported, remove 12 capscrews (Figure 18, Item 2) and lockwashers (Figure 18, Item 1) from transmission and flywheel housing (Figure 18, Item 3). Discard lockwashers. Pull transmission (Figure 18, Item 4) straight out of flywheel housing (Figure 18, Item 3) and support it on a suitable work stand.

1

2

3

4

M0202105

Figure 18.

Transmission from Engine Removal.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0024-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Transmission to Engine 1. Examine 12 capscrews (Figure 19, Item 2) for damaged threads. Check flywheel ring gear (Figure 19, Item 1) for condition before attaching transmission (Figure 19, Item 3).

3

1

2

M0203105

Figure 19. 2. 3. 4.

Transmission to Engine Installation.

Using a dial indicator, check engine crankshaft end play. It should be from 0.005 to 0.010 inch (0.13 to 0.25 mm). Crankshaft end play should be the same after attaching the transmission. Install 3/8-24 x 2 1/4 threaded guide stud, with a screwdriver slot in end, into one of the threaded inserts on converter drive plate from engine side. Rotate flywheel until one of the holes in flywheel is aligned with flywheel access hole.

0024-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued Transmission to Engine - Continued

WARNING

Weight of transmission is approximately 1,100 lb (499 kg). Use adequate lifting equipment to lift and support transmission. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. Support and align transmission to flywheel. Align protruding stud from drive plate face with mounting hole in flywheel.

CAUTION
DO NOT force transmission at any time. Forcing transmission into pilot sleeve of flywheel can preload crankshaft and cause engine and transmission damage. 6. 7. Push transmission into engine. Install 12 new lockwashers (Figure 20, Item 1) and capscrews (Figure 20, Item 2) to transmission (Figure 20, Item 4) and flywheel housing (Figure 20, Item 3).

1

2

3

4

M0202105

Figure 20. Transmission to Engine Installation.

0024-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued Transmission to Engine - Continued 8. Check crankshaft end play and compare measurement with what was observed in Step 2. No end play can mean crankshaft has been preloaded. Do not proceed until the reason for preload has been determined and corrected. Remove guide stud. Install 12 capscrews (Figure 21, Item 3) through access hole (Figure 21, Item 4) through flywheel into drive plate. Hand tighten all the way around. Tighten capscrews to 31 +/- 2 ft-lb (42 +/- 3 N•m).

9.

1

2

3

4
M0201105

Figure 21.

Transmission to Engine Installation.

0024-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued Transmission to Engine - Continued 10. Recheck crankshaft end play and compare measurement with what was observed in Step 2. No end play can mean crankshaft has been preloaded. Do not proceed until preload has been determined and corrected. When satisfactory, replace cover plate (Figure 22, Item 2), two capscrews (Figure 22, Item 3), and plug (Figure 22, Item 1). The engine and transmission assembly is ready to return to carrier frame.

11.

3 1 2

M0205105

Figure 22. Transmission to Engine Installation.

END OF TASK

0024-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION Power Pack

WARNING

Weight of engine and transmission assembly is approximately 1,800 lb (816 kg). Use adequate lifting equipment to lift and support engine/transmission assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

NOTE
Use more than one person when installing engine and transmission assembly to make sure engine and transmission DO NOT contact vehicle. When reassembled engine and transmission is ready for installation, check rubber shock mounts for deterioration and distortion. Replace if condition warrants. Examine all connecting components to make sure they are in position to install. 1. 2. Attach hoist and chains to front engine lift eye and rear transmission mounts. Gradually lower engine and transmission assembly down, guiding it into position on carrier. Install spacer (Figure 23, Item 1), washer (Figure 23, Item 2), and capscrew (Figure 23, Item 3) on front of engine (Figure 23, Item 4).

4

1

3

2
Figure 23. Power Pack Installation.

M0206105

0024-21

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 3. Install two spacers (Figure 24, Item 2), capscrews (Figure 24, Item 1), and nuts (Figure 24, Item 3) on sides of transmission (Figure 24, Item 4).

1

2 3

4
M0207105

Figure 24. 4. 5.

Power Pack Installation.

Install rear driveshaft and four capscrews (Figure 25, Item 4) to transmission (Figure 25, Item 3). Tighten capscrews to 50 ft-lb (68 N•m). Connect front driveshaft (Figure 25, Item 2) and install four capscrews (Figure 25, Item 1) to transmission (Figure 25, Item 3). Tighten four capscrews to 50 ft-lb (68 N•m).

1 4 2

2 3 3
Figure 25. Power Pack Installation.
M0208105

0024-22

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 6. Install four bolts (Figure 26, Item 2) to shift bracket (Figure 26, Item 1) and transmission (Figure 26, Item 3).

1

2

3

M0067105

Figure 26. 7.

Power Pack Installation.

Install new cotter pin (Figure 27, Item 1) and straight pin (Figure 27, Item 2) to transmission shift control (Figure 27, Item 3).

1

2

3
Figure 27. Power Pack Installation.

M0068105

0024-23

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 8. 9. Install nut (Figure 28, Item 1) to injector pump throttle cable (Figure 28, Item 2). Connect two fuel hoses (Figure 28, Items 3 and 4).

1

2

3

4

M0064105

Figure 28. 10. 11.

Power Pack Installation.

Connect two oil cooler hoses (Figure 29, Items 3 and 4) to left-hand side of transmission (Figure 29, Item 5). Install nut (Figure 29, Item 1) and ground strap (Figure 29, Item 2) to top of oil cooler hose (Figure 29, Item 3).

1

2

5 4

3

M0063105

Figure 29.

Power Pack Installation.

0024-24

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 12. Using two new cotter pins (Figure 30, Item 1) connect two control cables (Figure 30, Items 2 and 5) to transmission control valve (Figure 30, Item 6). Tighten two jam nuts (Figure 30, Item 4) on each cables to mounting bracket (Figure 30, Item 3). Check and adjust cables (WP 0086).

1

2

3

4 6
Figure 30. 13. Power Pack Installation.

5

M0062105

Connect two hoses (Figure 31, Items 1 and 3) to ground driven steering pump (Figure 31, Item 2).

1

2

3

M0061105

Figure 31.

Power Pack Installation.

0024-25

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 14. Connect two hoses (Figure 32, Items 1 and 2) to main hydraulic pump (Figure 32, Item 3).

1

2

3
M0060105

Figure 32. 15.

Power Pack Installation.

Connect two hoses (Figure 33, Items 2 and 4) to charge pump (Figure 33, Item 3) on top right hand side of transmission (Figure 33, Item 1).

1

2

3 4
M0059105

Figure 33.

Power Pack Installation.

0024-26

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 16. Install two bolts (Figure 34, Item 1), new lockwashers (Figure 34, Item 2), and exhaust system support bracket (Figure 34, Item 3) to engine (Figure 34, Item 4).

1 2

3

4
Figure 34. 17. 18. 19. Power Pack Installation.

M0058105

Connect all electrical connections to alternator, starter, temperature and pressure sending units (WP 0078). Install two hose clamps (Figure 35, Item 1) to upper radiator hose (Figure 35, Item 3). Connect upper radiator hose (Figure 35, Item 3) to engine (Figure 35, Item 4) and radiator (Figure 35, Item 2).

1

2

3 4

M0065105

Figure 35.

Power Pack Installation.

0024-27

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0024

INSTALLATION - Continued 20. 21. Install two hose clamps (Figure 36, Item 2) to lower radiator hose (Figure 36, Item 3). Connect lower radiator hose (Figure 36, Item 3) to engine (Figure 36, Item 1) and radiator.

1

2

3
M0066105

Figure 36. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install radiator and oil cooler (WP 0054). Fill transmission fluid (WP 0091). Fill engine oil (WP 0022). Install exhaust system (WP 0053). Install air cleaner (WP 0046). Install sliding engine hood (WP 0118). Connect battery cables (WP 0076).

Power Pack Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0024-28

03/15/2011 Rel(1.8) root(maintwp) wpno(M00029)

TM 5-3810-305-23

0025

FIELD MAINTENANCE ENGINE ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0039 References (cont.) WP 0040 WP 0049 WP 0059 WP 0060 WP 0061 WP 0062 WP 0063 WP 0162 Equipment Condition Power Pack assembly removed (WP 0024)

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove oil pan and suction tube (WP 0039). Remove oil level gage and tube (WP 0040). Remove starter motor (WP 0063). Remove fan drive belt (WP 0059). Remove cooling fan hub assembly (WP 0060). Remove drive belt tensioner and idler pulley (WP 0061). Remove alternator and mounting bracket (WP 0062). Remove fuel injection tubes (WP 0049).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0025-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00030)

TM 5-3810-305-23

0025

INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install fuel injection tubes (WP 0049). Install alternator and mounting bracket (WP 0062). Install drive belt tensioner and idler pulley (WP 0061). Install cooling fan hub assembly (WP 0060). Install fan drive belt (WP 0059). Install starter motor (WP 0063). Install oil level gage and tube (WP 0040). Install oil pan and suction tube (WP 0039).

END OF TASK FOLLOW-ON MAINTENANCE Install power pack assembly (WP 0024). END OF TASK END OF WORK PACKAGE

0025-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00030)

TM 5-3810-305-23

0026

FIELD MAINTENANCE ENGINE MOUNT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Power pack assembly removed (WP 0024)

REMOVAL Remove four capscrews (Figure 1, Item 1) and engine mount (Figure 1, Item 3) from engine (Figure 1, Item 2).

1

3 2
M0043105

Figure 1. END OF TASK CLEANING

Engine Mount Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0026-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00031)

TM 5-3810-305-23

0026

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Install engine mount (Figure 2, Item 3) and four capscrews (Figure 2, Item 1) to engine (Figure 2, Item 2). Tighten to 57 ft-lb (77 N•m).

1

3 2
M0043105

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install power pack assembly (WP 0024). END OF TASK END OF WORK PACKAGE

Engine Mount Installation.

0026-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00031)

TM 5-3810-305-23

0027

FIELD MAINTENANCE CYLINDER HEAD MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 200-lb (91 kgs) Minimum Capacity Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 145) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Preservative and Break-In (WP 0170, Table 1, Item 45) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Exhaust manifold removed (WP 0042) Fuel injection tubes removed (WP 0049) Valve covers removed (WP 0035) Rocker levers and push rods removed (WP 0031) Manifold cover plate removed (WP 0041)

0027-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00032)

TM 5-3810-305-23

0027

REMOVAL 1. Remove 14 capscrews (Figure 1, Item 1) from cylinder head (Figure 1, Item 2).

WARNING

Weight of the cylinder is approximately 80 lb (36 kg). Use adequate lifting equipment to lift and support cylinder head. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 2. Using a suitable hoist and sling, remove cylinder head (Figure 1, Item 2) from block (Figure 1, Item 3) and place on a suitable work table.

1

2

3
M02101045

Figure 1. 3.

Cylinder Head Removal.

Remove gasket (Figure 2, Item 1) from engine block (Figure 2, Item 2). Discard gasket and all gasket material.

0027-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00032)

TM 5-3810-305-23

0027

REMOVAL - Continued

1

2
Figure 2. END OF TASK CLEANING 1. 2. 3. 4. 5. Clean parts IAW General Maintenance Instructions (WP 0162). Clean carbon from injector nozzle seat with a nylon or brass brush. Wash cylinder head in hot soapy water solution and dry with compressed air. Cylinder Head Removal.

M0211105

Polish gasket surfaces with 400-grit paper. Use an orbital sander or sanding block to maintain a flat surface. Dry parts with compressed air.

END OF TASK INSPECTION 1. Inspect parts IAW General Maintenance Instructions (WP 0162). 2. Inspect all parts for wear, pitting, cracks, or corrosion, and replace if necessary. 3. Inspect cylinder head surface for nicks and erosion. 4. Using a feeler gage and straight edge, check cylinder head for distortion.

Limit Variation: 0.0039 inch (0.099 mm) within 2.00 inch (50.8 mm) diameter area. 0.003 inch (0.08 mm) overall end-to-end or side-to-side.

END OF TASK

0027-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00032)

TM 5-3810-305-23

0027

INSTALLATION

NOTE
Make sure cylinder head and block surfaces are clean and not nicked or gouged. 1. Install new gasket (Figure 3, Item 1) on block (Figure 3, Item 2), aligning gasket with holes on block.

1

2
Figure 3. Cylinder Head Installation.

M0211105

0027-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00032)

TM 5-3810-305-23

0027

INSTALLATION - Continued

WARNING

Weight of the cylinder is approximately 80 lb (36 kg). Use adequate lifting equipment to lift and support cylinder head. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 2. 3. Using a suitable hoist and sling, install cylinder head (Figure 4, Item 2) carefully on block (Figure 4, Item 3), making sure gasket stays in place. Lubricate and install 14 capscrews (Figure 4, Item 1) on cylinder head (Figure 4, Item 2). Tighten 14 capscrews in sequence three separate times. First time, tighten capscrews to 29 ft-lb (39 N•m). Second time, tighten capscrews to 62 ft-lb (84 N•m). Third time, tighten capscrews to 92 ft-lb (125 N•m).

1

2

3
M02101045

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install manifold cover plate (WP 0041).

Cylinder Head Installation.

Install rocker levers and push rods (WP 0031). Install valve covers (WP 0035). Install fuel injection tubes (WP 0049). Install exhaust manifold (WP 0042). Connect battery cables (WP 0076).

0027-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00032)

TM 5-3810-305-23

0027

FOLLOW-ON MAINTENANCE - Continued 7. Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0027-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00032)

TM 5-3810-305-23

0028

FIELD MAINTENANCE CRANKSHAFT PULLEY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Cooling fan removed (WP 0060)

REMOVAL 1. 2. Remove plug (Figure 1, Item 1) located at top right of bell housing and use a suitable prybar wedged between flywheel and bell housing to lock flywheel before removing crankshaft pulley (Figure 1, Item 3). Remove four capscrews (Figure 1, Item 2) and crankshaft pulley (Figure 1, Item 3) from vehicle.

1

2

3

M0010105

Figure 1. END OF TASK

Crankshaft Pulley Removal.

0028-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00033)

TM 5-3810-305-23

0028

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Use a suitable prybar in hole of plug wedged between flywheel and bell housing to lock flywheel before installing crankshaft pulley. Install crankshaft pulley (Figure 2, Item 3) and four capscrews (Figure 2, Item 2) in vehicle. Tighten four capscrews to 44 ft-lb (60 N•m). Install plug (Figure 2, Item 1) in bell housing.

1

2

3

M0010105

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install cooling fan (WP 0060). END OF TASK END OF WORK PACKAGE

Crankshaft Pulley Installation.

0028-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00033)

TM 5-3810-305-23

0029

FIELD MAINTENANCE FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Indicator, Dial (WP 0171, Table 1, Item 6) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Materials/Parts O-Ring (WP 0172, Table 1, Item 76) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Power pack assembly removed (WP 0024)

REMOVAL 1. Remove eight capscrews (Figure 1, Item 1), washers (Figure 1, Item 2), and flywheel (Figure 1, Item 3) from engine.

1

2

3
M0215105

Figure 1.

Flywheel Removal.

0029-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00034)

TM 5-3810-305-23

0029

REMOVAL - Continued 2. Remove eight capscrews (Figure 2, Item 3), flywheel housing (Figure 2, Item 1), and o-ring (Figure 2, Item 2) from engine. Discard o-ring.

1

2

3
Figure 2. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK Flywheel Removal.

M0216105

0029-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00034)

TM 5-3810-305-23

0029

INSTALLATION 1. 2. Install new o-ring (Figure 3, Item 2), flywheel housing (Figure 3, Item 1), and eight capscrews (Figure 3, Item 3). Tighten eight capscrews to 57 ft-lb (77 N•m).

1

2

3
Figure 3. 3. Flywheel Installation.

M0216105

Attaching a dial indicator to crankshaft, measure vertical and horizontal runout of flywheel housing.

M0219105

Figure 4.

Flywheel Installation.

0029-3

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TM 5-3810-305-23

0029

INSTALLATION - Continued

CAUTION
Dial indicator tip must not enter capscrew holes or gage will be damaged.

NOTE
Extension bar for dial indicator must be rigid for an accurate reading. 4. 5. 6. Position dial indicator at 12 o’clock position. Adjust dial until needle points to zero. Slowly rotate crankshaft. Record readings obtained at 3 o’clock, 6 o’clock, and 9 o’clock positions. Continue to rotate crankshaft back to 12 o’clock position. Check dial indicator to make sure needle points to zero. Determine Total Indicator Reading (TIR). EXAMPLE: 12 o’clock = 0.000 inch (0.00 mm) 3 o’clock = +0.003 inch (0.08 mm) 6 o’clock = -0.002 inch (0.05 mm) 9 o’clock = +0.003 inch (0.08 mm) Equals TIR = 0.005 inch (0.13 mm)

M0220105

Figure 5. Flywheel Installation.

0029-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00034)

TM 5-3810-305-23

0029

INSTALLATION - Continued

NOTE
Maximum TIR is determined by diameter of housing bore. Replace housing if out of specification. 7. Specification of bore diameter is 17.625 to 17.630 inches (447.68 to 447.80 mm). TIR maximum is 0.008 inch (0.20 mm).

CAUTION
DO NOT force crankshaft beyond point where bearing clearance has been removed. DO NOT use flywheel housing as a fulcrum. Failure to follow this caution may cause damage to equipment. 8. Determine adjustment for main bearing clearance by raising rear of crankshaft to its upper hit. Use a floormounted support with padded pry bar to raise crankshaft and record reading.

M0221105

Figure 6. 9.

Flywheel Installation.

Calculate bearing clearance adjustment by subtracting one-half of reading obtained in Step 8 from reading obtained at 6 o’clock position. EXAMPLE: Total bearing clearance = +0.003 inch (+0.08 mm) One-half bearing clearance = +0.0016 inch (+0.040 mm) 6 o’clock position reading = +0.008 inch (+0.20 mm) Adjusted 6 o’clock reading = +0.0064 inch (+0.162 mm)

0029-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00034)

TM 5-3810-305-23

0029

INSTALLATION - Continued 10. 11. Lock crankshaft. Install flywheel (Figure 7, Item 3), eight washers (Figure 7, Item 2), and capscrews (Figure 7, Item 1).

1

2

3
M0215105

Figure 7. Flywheel Installation. 12. Tighten eight capscrews in sequence shown in (Figure 8) to 101 ft-lb (137 N•m).

C E

A

H F

G B D

M0222105

Figure 8. Flywheel Installation. END OF TASK

0029-6

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TM 5-3810-305-23

0029

FOLLOW-ON MAINTENANCE 1. 2. 3. Install power pack assembly (WP 0024). Connect battery cables (WP 0076). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0030

FIELD MAINTENANCE REAR CRANKSHAFT SEAL MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Drill-Driver, Battery Operated (WP 0171, Table 1, Item 24) Drill Set, Twist (WP 0171, Table 1, Item 23) Wrench, Torque, Dial, 1/4 Inch Drive, 30 in-lb (WP 0171, Table 1, Item 37) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 83) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Seal (WP 0172, Table 1, Item 150) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 Personnel Required (Two) References WP 0029 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0030-1

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TM 5-3810-305-23

0030

REMOVAL

NOTE
• There are two separate procedures for removing rear seal. One is with flywheel housing installed and one is with flywheel housing removed. • Steps 1 through 3 are for removal of rear seal with flywheel housing installed. • Steps 4 through 7 are for removal of rear seal with flywheel housing removed. 1. 2. Remove flywheel (Figure 1, Item 1) (WP 0029). Drill two holes 180 degrees apart to relieve tension on rear seal (Figure 1, Item 2).

1

2
Figure 1. Rear Seal Removal. 3. Remove rear seal (Figure 2, Item 1) from flywheel housing (Figure 2, Item 2).

M0040105

1 2

M0041105

Figure 2. Rear Seal Removal.

0030-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00035)

TM 5-3810-305-23

0030

REMOVAL - Continued 4. 5. 6. 7. Remove flywheel housing (WP 0029). Remove six capscrews (Figure 3, Item 1), rear cover (Figure 3, Item 2), and gasket (Figure 3, Item 4) from block (Figure 3, Item 3). Discard gasket and remove all gasket material from mounting surfaces. Support rear cover (Figure 3, Item 2) on a suitable work stand. Remove rear seal (Figure 3, Item 5) from rear cover (Figure 3, Item 2).

5
Figure 3. END OF TASK CLEANING

4,3

2

1
M0042105

Rear Seal Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0030-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00035)

TM 5-3810-305-23

0030

INSTALLATION

CAUTION
• Seal lip and sealing surface on crankshaft must be free from all oil residue to prevent seal leaks. Teflon seals must be installed on dry clean surfaces. • Drive rear seal alternately at the 12, 3, 6, and 9 o'clock positions to prevent bending rear cover.

NOTE
• Steps 1 through 4 are for installation of rear seal with flywheel housing removed. • Use a mild soap on inside diameter of rear seal for easier installation. DO NOT use any kind of sealant on rear seal. 1. 2. 3. Using a seal starter ring, install new real seal (Figure 4, Item 5) in rear cover (Figure 4, Item 2). Install new gasket (Figure 4, Item 4), rear cover (Figure 4, Item 2) and six capscrews (Figure 4, Item 1) to block (Figure 4, Item 3). Tighten capscrews to 7 ft-lb (9 N•m). Using a seal driver, drive rear seal (Figure 4, Item 5) until seal driver bottoms.

5

4,3

2

1
M0042105

Figure 4. Rear Seal Installation.

0030-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00035)

TM 5-3810-305-23

0030

INSTALLATION - Continued 4. Install flywheel housing (Figure 5, Item 2) (WP 0029).

CAUTION
Drive rear seal alternately at the 12, 3, 6 and 9 o'clock positions to prevent bending rear cover.

NOTE
• Steps 5 through 7 are for installation of rear seal with flywheel housing installed. • Use a mild soap on inside diameter of rear seal for easier installation. DO NOT use any kind of sealant on rear seal. 5. 6. 7. Using a seal starter, install rear seal (Figure 5, Item 1) on flywheel housing (Figure 5, Item 2). Using a seal driver, drive rear seal (Figure 5, Item 1) on crankshaft until seal driver bottoms. Install flywheel (WP 0029).

1 2

M0041105

Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076).

Rear Seal Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0031

FIELD MAINTENANCE ROCKER LEVERS AND PUSH RODS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper, Micrometer, Outside (WP 0171, Table 1, Item 21) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Tester, Valve Spring (WP 0171, Table 1, Item 14) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Engine, 15W40 Grade (WP 0170, Table 1, Item 36) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0044 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) High-pressure fuel injection lines removed (WP 0048) Valve covers removed (WP 0035)

0031-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00036)

TM 5-3810-305-23

0031

REMOVAL 1. 2. 3. Loosen eight adjusting nuts (Figure 1, Item 2) and rocker adjustment screws (Figure 1, Item 3) to release spring tension from rocker shaft support assemblies (Figure 1, Item 4). Remove four capscrews (Figure 1, Item 5) from four rocker shaft support assemblies (Figure 1, Item 4). Remove four capscrews (Figure 1, Item 1) and four rocker shaft support assemblies (Figure 1, Item 4) from cylinder head.

1 4 3 5

2

M0022105

Figure 1. 4. Remove eight push rods (Figure 2, Item 1).

Cylinder Head Removal.

1

M0023105

Figure 2. END OF TASK

Rocker Lever and Push Rods Removal.

0031-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00036)

TM 5-3810-305-23

0031

DISASSEMBLY

NOTE
• The following is a maintenance instruction for one rocker shaft support assembly. Maintenance instruction for remaining three rocker shaft support assemblies is identical. • Before disassembly of rocker shaft support assemblies, mark on each side of rocker shaft support and rocker levers (I) or (E) for intake or exhaust to aid in assembly. 1. Remove two retaining rings (Figure 3, Item 1), thrust washers (Figure 3, Item 2) and intake and exhaust rocker levers (Figure 3, Item 3) from rocker shaft support assemblies (Figure 3, Item 4).
4

1

2
3 3

2

1
M0024105

Figure 3. Rocker Lever and Push Rods Disassembly.

NOTE
DO NOT disassemble rocker shaft support. They are serviced as an assembly. 2. If inspection shows adjusting nuts (Figure 4, Item 1) and rocker adjusting screws (Figure 4, Item 2) are defective, remove and discard from intake and exhaust rocker levers (Figure 4, Item 3).
1 2

3 3

M0025105

Figure 4. Rocker Lever and Push Rods Disassembly. END OF TASK

0031-3

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TM 5-3810-305-23

0031

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect rocker levers for cracks and wear in bore and contact surface of valve stem.

M0026105

Figure 5. 3.

Rocker Lever and Push Rods Inspection.

Measure diameter of rocker lever bore. Diameter of bore should measure 0.7480 inch (18.999 mm) minimum and 0.7500 inch (19.050 mm) maximum.

M0027105

Figure 6.

Rocker Lever and Push Rods Inspection.

0031-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00036)

TM 5-3810-305-23

0031

INSPECTION - Continued 4. 5. Inspect rocker shaft support assembly for wear on shaft. Measure diameter of shaft. Diameter of shaft should measure 0.7456 inch (18.938 mm) minimum and 0.7470 inch (18.974 mm) maximum. Replace rocker shaft support assembly when shaft measurement is not within minimum/maximum tolerance.

M0028105

Figure 7. END OF TASK ASSEMBLY 1.

Rocker Lever and Push Rods Inspection.

If removed, install rocker adjustment screws (Figure 8, Item 2) and adjusting nuts (Figure 8, Item 1) on intake and exhaust rocker levers (Figure 8, Item 3).
1 2

3 3

M0025105

Figure 8. Rocker Lever and Push Rods Assembly.

0031-5

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TM 5-3810-305-23

0031

ASSEMBLY - Continued

NOTE
Be sure to assemble intake and exhaust rocker levers in the correct location. 2. Lubricate rocker shaft support assemblies (Figure 9, Item 4) with engine oil and install intake and exhaust rocker levers (Figure 9, Item 3), two thrust washers (Figure 9, Item 2), and retaining rings (Figure 9, Item 1).
4

1

2
3 3

2

1
M0024105

Figure 9. Rocker Lever and Push Rods Assembly. END OF TASK INSTALLATION 1. Lubricate with engine oil and install eight push rods (Figure 10, Item 1) in engine.

1

M0023105

Figure 10. Rocker Lever and Push Rods Installation.

0031-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00036)

TM 5-3810-305-23

0031

INSTALLATION - Continued 2. 3. 4. 5. 6. 7. 8. 9. Install four rocker shaft support assemblies (Figure 11, Item 4). Lubricate with engine oil and install four capscrews (Figure 11, Item 1) to cylinder head. Tighten four capscrews to 92 ft-lb (125 N•m). Lubricate with engine oil and install four capscrews (Figure 11, Item 5) to four rocker shaft support assemblies (Figure 11, Item 4). Tighten four capscrews to 18 ft-lb (24 N•m). To set valve clearance, turn rocker adjustment screws (Figure 11, Item 3) in until they touch push rod sockets. Loosen valve adjustment screws one full turn. Timing pin is designed only to locate Top Dead Center (TDC) for cylinder number 1 and not to lock engine. Locate TDC for cylinder number 1 (WP 0044). Disengage timing pin. Valve stem to rocker lever clearances for intake should measure 0.010 inch (0.25 mm); for exhaust 0.020 inch (0.51 mm). To adjust, turn adjusting screw (Figure 11, Item 3) to obtain correct clearance and hold. Tighten adjusting nut (Figure 11, Item 2) to 18 ft-lb (24 N•m).

1 4 3 5

2

M0022105

Figure 11. 10. 11. 12. 13.

Cylinder Head Installation.

Perform valve set procedure with cylinder number 1 at TDC; timing pin will engage. Adjust intake and exhaust valves at cylinder number 1, intake at cylinder 2, and exhaust at cylinder 3. Mark crankshaft and front cover and rotate crankshaft 360 degrees. Timing pin will not engage this time. Adjust exhaust and intake valves at cylinder 4, intake at cylinder 3, and exhaust at cylinder 2.

END OF TASK

0031-7

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TM 5-3810-305-23

0031

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install valve covers (WP 0035). Install high-pressure fuel injection lines (WP 0048). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0031-8

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TM 5-3810-305-23

0032

FIELD MAINTENANCE FRONT GEAR COVER AND GASKET MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 79) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Radiator and oil cooler removed (WP 0054) Drive belt, pulleys, and fan removed (WP 0059)

0032-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00037)

TM 5-3810-305-23

0032

REMOVAL 1. 2. Remove two capscrews (Figure 1, Item 3), washers (Figure 1, Item 4) and tachometer drive (Figure 1, Item 2) from front cover (Figure 1, Item 5). Using a strap wrench, remove access hole cover (Figure 1, Item 1) from front cover (Figure 1, Item 5).

1 2 3 4

5

M0016105

Figure 1.

Tachometer Drive Removal.

0032-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00037)

TM 5-3810-305-23

0032

REMOVAL - Continued 3. 4. 5. Remove 20 capscrews (Figure 2, Item 1), front cover (Figure 2, Item 2), and gasket (Figure 2, Item 3). Discard gasket. Remove all gasket material from mounting surfaces. Remove seal (Figure 2, Item 4) by driving out of front cover (Figure 2, Item 2).

1

2

3 4
M0017105

Figure 2. END OF TASK CLEANING

Front Cover Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0032-3

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TM 5-3810-305-23

0032

INSTALLATION 1. Using clean oil, lubricate front gear train (Figure 3, Item 1).

1
Figure 3. Front Gear Train Installation.

M0018105

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel.

CAUTION
Seal lip and sealing surface on crankshaft must be free from all oil residue to prevent seal leaks. Teflon seals must be installed on dry, clean surfaces.

0032-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00037)

TM 5-3810-305-23

0032

INSTALLATION - Continued 2. 3. 4. 5. 6. 7. Thoroughly clean and dry front seal area of crankshaft. Apply sealant to outside diameter of front seal (Figure 4, Item 4). Install seal (Figure 4, Item 4) in front cover (Figure 4, Item 2). Make sure seal and sealing surface is free of oil residue to prevent leaks. Apply sealant to front cover (Figure 4, Item 2) and gear housing. Install new gasket (Figure 4, Item 3) on gear housing. Install front cover (Figure 4, Item 2) and 20 capscrews (Figure 4, Item 1). Tighten 20 capscrews to 18 ft-lb (24 N•m).

1

2

3 4
M0017105

Figure 4.

Front Cover Installation.

0032-5

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TM 5-3810-305-23

0032

INSTALLATION - Continued 8. Install access hole cover (Figure 5, Item 1), tachometer drive (Figure 5, Item 2), two washers (Figure 5, Item 4), and capscrews (Figure 5, Item 3) in front cover (Figure 5, Item 5). Tighten two capscrews to 7 ft-lb (9.5 N•m).

1 2 3 4

5

M0016105

Figure 5. Tachometer Drive Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install drive belt, pulleys, and fan (WP 0059). Install radiator and oil cooler assembly (WP 0054). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Start vehicle, run at operating temperature, and check for leaks (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0032-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00037)

TM 5-3810-305-23

0033

FIELD MAINTENANCE TIMING PIN ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 O-Ring (WP 0172, Table 1, Item 77) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Cylinder head removed (WP 0027) Front gear cover removed (WP 0032)

REMOVAL 1. 2. Remove two screws (Figure 1, Item 3) from timing pin housing (Figure 1, Item 1). Remove timing pin housing (Figure 1, Item 1) from gear housing (Figure 1, Item 2).

1

3

2

M0019105

Figure 1.

Timing Pin Assembly Removal.

0033-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00038)

TM 5-3810-305-23

0033

REMOVAL - Continued 3. Remove o-ring (Figure 2, Item 1) from timing pin housing (Figure 2, Item 2). Discard o-ring.

1

2

M0020105

Figure 2. END OF TASK CLEANING

Timing Pin Assembly Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0033-2

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TM 5-3810-305-23

0033

INSTALLATION 1. 2. 3. Install new o-ring (Figure 3, Item 3) on timing pin housing (Figure 3, Item 1). Install timing pin housing (Figure 3, Item 1) on gear housing (Figure 3, Item 2). Install two screws (Figure 3, Item 4) to timing pin housing.

1

4

2 3
M0021105

Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install front gear cover (WP 0032). Install cylinder head (WP 0027). Connect battery cables (WP 0076).

Timing Pin Assembly Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0033-3/4 blank

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TM 5-3810-305-23

0034

FIELD MAINTENANCE TAPPET COVER AND GASKET MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper, Micrometer, Outside (WP 0171, Table 1, Item 21) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 46) Qty: 1 Grommet (WP 0172, Table 1, Item 55) Qty: 4 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Fuel filters and head assembly removed (WP 0050) Injection pump removed (WP 0044) Lift pump removed (WP 0045) Manifold cover plate removed (WP 0041)

0034-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00039)

TM 5-3810-305-23

0034

REMOVAL 1. 2. Remove spring hose clamp (Figure 1, Item 4) and hose (Figure 1, Item 5) from tappet cover (Figure 1, Item 3). Remove capscrews (Figure 1, Item 6), four grommets (Figure 1, Item 1), tappet cover (Figure 1, Item 3), and tappet cover gasket (Figure 1, Item 2) from block. Remove all gasket material from mounting surfaces.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel.

NOTE
Tappet cover gasket has an adhesive back. Pull off protective cover on gasket to expose adhesive surface. 1. 2. 3. Install new tappet cover gasket (Figure 1, Item 2) with adhesive side down on tappet cover (Figure 1, Item 3). Apply sealing compound to top of gasket and block. Install tappet cover (Figure 1, Item 3), four grommets (Figure 1, Item 1), and capscrews (Figure 1, Item 6) on block. Tighten capscrews to 18 ft-lb (24 N•m). Install hose (Figure 1, Item 5) and spring hose clamp (Figure 1, Item 4) on tappet cover (Figure 1, Item 3).

0034-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00039)

TM 5-3810-305-23

0034

INSTALLATION - Continued

2 1 6 3

4

5
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install manifold cover plate (WP 0041). Install lift pump (WP 0045). Install injection pump (WP 0044). Install fuel filters and head assembly (WP 0050). Place boom in resting position (TM 5-3810-305-10). Tappet Cover Installation.

M0015105

END OF TASK END OF WORK PACKAGE

0034-3/4 blank

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TM 5-3810-305-23

0035

FIELD MAINTENANCE VALVE COVERS AND GASKET MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 58) Qty: 4 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 75) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Sliding engine hood removed (WP 0118)

REMOVAL Remove four capscrews (Figure 1, Item 2), o-rings (Figure 1, Item 3), valve covers (Figure 1, Item 1), and gaskets (Figure 1, Item 4). Remove all gasket material from mounting surfaces. Discard o-rings and gaskets.

1

2

3

4

M0014105

Figure 1. END OF TASK

Valve Covers Removal.

0035-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00040)

TM 5-3810-305-23

0035

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Install four new gaskets (Figure 2, Item 4), valve covers (Figure 2, Item 1), new o-rings (Figure 2, Item 3), and capscrews (Figure 2, Item 2). Tighten four capscrews to 18 ft-lb (24 N•m).

1

2

3

4

M0014105

Figure 2. Valve Covers Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install sliding engine hood (WP 0118). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0035-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00040)

TM 5-3810-305-23

0036

FIELD MAINTENANCE FRONT CRANKSHAFT SEAL MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Drill-Driver, Battery Operated (WP 0171, Table 1, Item 24) Drill Set, Twist (WP 0171, Table 1, Item 23) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Seal Driver (WP 0171, Table 1, Item 46) Stand, Maintenance, Automotive Engine (WP 0171, Table 1, Item 11) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Seal (WP 0172, Table 1, Item 62) Qty: 1 Sealing Compound, High Pressure (WP 0170, Table 1, Item 64) Qty: 1 References WP 0028 WP 0029 WP 0032 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0036-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00041)

TM 5-3810-305-23

0036

REMOVAL

NOTE
• There are two separate procedures for removing front seal. One is with front cover removed and one is with front cover installed. • Step 1 is for removing front seal with front cover removed. 1. Remove front seal (Figure 1, Item 1) from front cover (Figure 1, Item 2) with front cover removed. Refer to Front Gear Cover and Gasket Maintenance (WP 0032).

NOTE
Steps 2 and 3 are for removal of front seal with front cover installed. 2. 3. 4. Remove crankshaft pulley. Refer to Crankshaft Pulley Maintenance (WP 0028). Drill two holes 180 degrees apart to relieve tension on front seal (Figure 1, Item 1). Remove and discard front seal (Figure 1, Item 1) from front cover (Figure 1, Item 2).

1

2
Figure 1. END OF TASK Front Seal Removal.

M0038105

0036-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00041)

TM 5-3810-305-23

0036

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel.

CAUTION
• Seal lip and sealing surface on crankshaft must be free from all oil residue to prevent seal leaks. • Teflon seals must be installed on dry, clean surfaces.

0036-3

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TM 5-3810-305-23

0036

INSTALLATION - Continued

NOTE
Steps 1 through 3 are the procedures for installation of new front seal with front cover installed. 1. 2. 3. Apply sealing compound to outside diameter of front seal (Figure 2, Item 1). Using a seal starter ring, install new front seal (Figure 2, Item 1) on front cover (Figure 2, Item 2). Install crankshaft pulley. Refer to Crankshaft Pulley Maintenance (WP 0028).

CAUTION
Drive front seal alternately at the 12, 3, 6, and 9 o’clock positions to prevent damage to seal carrier.

NOTE
Steps 4 and 5 are for installation of new front seal with front cover removed. 4. 5. Using a seal driver, install new front seal (Figure 2, Item 1) on front cover (Figure 2, Item 2). Install new front seal (Figure 2, Item 1) in cover (Figure 2, Item 2) with front cover removed. Refer to Front Gear Cover and Gasket Maintenance (WP 0032).

1

2

M0039105

Figure 2. Front Seal Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0036-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00041)

TM 5-3810-305-23

0037

FIELD MAINTENANCE LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Tester, Valve Spring (WP 0171, Table 1, Item 14) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 101) Qty: Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0054 WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Oil filter removed (WP 0022)

1

0037-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

TM 5-3810-305-23

0037

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. Disconnect wires (Figure 1, Items 3 and 4) from oil pressure switch (Figure 1, Item 1) and remove oil pressure switch from engine (Figure 1, Item 2).

1

4

3

2

M0212105

Figure 1. 2.

Lube Oil Cooler Removal.

Remove 14 capscrews (Figure 2, Item 1) and cover (Figure 2, Item 3) from engine (Figure 2, Item 2).

1 2 3

M0213105

Figure 2. 3.

Lube Oil Cooler Removal.

Remove cooler core (Figure 3, Item 3) and cooler core gasket (Figure 3, Item 2) from engine (Figure 3, Item 1) and discard gasket.

0037-2

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TM 5-3810-305-23

0037

REMOVAL - Continued

1

3 2
Figure 3. END OF TASK DISASSEMBLY 1. 2. Remove plug (Figure 4, Item 1), sealing washer (Figure 4, Item 2), spring (Figure 4, Item 3), and pressure regulator plunger (Figure 4, Item 4) from cooler core cover (Figure 4, Item 5). Inspect pressure regulator plunger (Figure 4, Item 4) bore for nicks or scratches. Pressure regulator plunger must move freely in bore. If pressure regulator plunger does not move freely, replace lube oil cooler assembly. Lube Oil Cooler Removal.
M0214105

1

2

3

4

5
M2318105

Figure 4.

Lube Oil Cooler Disassembly.

0037-3

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TM 5-3810-305-23

0037

DISASSEMBLY - Continued 3. Check spring (Figure 5, Item 1). If spring is out of tolerance, replace spring.

1

M2319105

Figure 5. Lube Oil Cooler Disassembly. Table 1. Pressure Regulator Spring Limits. Valve Open Height Load END OF TASK Valve Assembled

1.57 inches (39.9 mm) 1.77 inches (44.9 mm) 20.5 lb (91 N) 13.5 lb (60 N)

0037-4

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TM 5-3810-305-23

0037

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Soak cooler core (Figure 6, Item 1) in cleaning solvent to remove coolant deposits. Back flush oil passages and dry with compressed air. Inspect soldered joints for corrosion or cracks. Pressurize cooler core (Figure 6, Item 1) to 70 psi (483 kPa), submerge in water and check for leaks.

1

M2440105

Figure 6. END OF TASK

Lube Oil Cooler Inspection.

0037-5

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0037

ASSEMBLY Install pressure regulator plunger (Figure 7, Item 4), spring (Figure 7, Item 3), sealing washer (Figure 7, Item 2), and plug (Figure 7, Item 1) on cooler core cover (Figure 7, Item 5). Tighten plug to 74 ft-lb (100 N•m).

1

2

3

4

5
M2318105

Figure 7. Lube Oil Cooler Assembly. END OF TASK INSTALLATION 1. Install new cooler core gasket (Figure 8, Item 2) and cooler core (Figure 8, Item 3) to engine (Figure 8, Item 1).

1

3 2
Figure 8. Lube Oil Cooler Installation.
M0214105

0037-6

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TM 5-3810-305-23

0037

INSTALLATION - Continued 2. Install cover (Figure 9, Item 3) and 14 capscrews (Figure 9, Item 1) to engine (Figure 9, Item 2). Tighten 14 capscrews to 18 ft-lb (24 N•m).

1 2 3

M0213105

Figure 9. 3. 4.

Lube Oil Cooler Installation.

Install oil pressure switch (Figure 10, Item 1) on engine (Figure 10, Item 2). Connect wires (Figure 10, Items 3 and 4) to oil pressure switch (Figure 10, Item 1).

1

4

3

2

M0212105

Figure 10. END OF TASK

Lube Oil Cooler Installation.

0037-7

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TM 5-3810-305-23

0037

FOLLOW-ON MAINTENANCE 1. 2. 3. Install oil filter (WP 0022). Fill with coolant, if required (WP 0054). Connect battery cables (WP 0076).

END OF TASK END OF WORK PACKAGE

0037-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

TM 5-3810-305-23

0038

FIELD MAINTENANCE LUBE OIL PUMP MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Indicator, Dial (WP 0171, Table 1, Item 6) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Fuel, Diesel Run-In Mobil 4Y17 (WP 0170, Table 1, Item 19) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Front gear cover removed (WP 0032)

REMOVAL

NOTE
• Before removing lube oil pump, check backlash of lube oil pump gears. • Hold adjoining gear to keep from moving, when checking backlash. • Lube oil pump gear and idler gear backlash limit is 0.003 to 0.013 inch (0.08 to 0.33 mm). 1. 2. Using dial indicator on tooth of lube oil pump gear (Figure 1, Item 2), check for excessive backlash. Using dial indicator on tooth of idler gear (Figure 1, Item 1), check for excessive backlash.

2

1
M0051105

Figure 1.

Lube Oil Pump Removal.

0038-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

TM 5-3810-305-23

0038

REMOVAL - Continued 3. 4. 5. Remove four capscrews (Figure 2, Item 1) from lube oil pump (Figure 2, Item 2). Remove lube oil pump (Figure 2, Item 2) from engine (Figure 2, Item 3). If backlash exceeds limits, replace lube oil pump (Figure 2, Item 2).

1

3

2
Figure 2. Lube Oil Pump Removal.

M0052105

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0038-2

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0038

INSTALLATION

NOTE
Filling lube oil pump before installing will aid in priming during engine startup. 1. 2. 3. Lubricate lube oil pump (Figure 3, Item 2) with clean engine oil. Install lube oil pump (Figure 3, Item 2) to engine (Figure 3, Item 3). Install four capscrews (Figure 3, Item 1) to lube oil pump (Figure 3, Item 2). Tighten capscrews to 18 ft-lb (24 N•m).

1

3

2
Figure 3. Lube Oil Pump Installation.

M0052105

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install front gear cover (WP 0032). Run engine and check for correct engine operation (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0038-3/4 blank

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TM 5-3810-305-23

0039

FIELD MAINTENANCE OIL PAN AND SUCTION TUBE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 82) Qty: 1 Gasket (WP 0172, Table 1, Item 84) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Engine oil drained (WP 0022) Battery cables disconnected (WP 0076)

0039-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

TM 5-3810-305-23

0039

REMOVAL

NOTE
Engine shown removed in Figure 1 for clarity. 1. Remove 24 capscrews (Figure 1, Item 2), washers (Figure 1, Item 3), and oil pan (Figure 1, Item 1) from engine block (Figure 1, Item 4).

1

2 3

4
M0056105

Figure 1.

Oil Pan and Suction Tube Removal.

0039-2

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TM 5-3810-305-23

0039

REMOVAL - Continued 2. 3. Remove gasket (Figure 2, Item 2) from engine block (Figure 2, Item 1). Discard gasket. Remove all gasket material from mounting surfaces. Remove two capscrews (Figure 2, Item 5), capscrew (Figure 2, Item 3), suction tube (Figure 2, Item 4), and gasket (Figure 2, Item 6) from engine block (Figure 2, Item 1). Discard gasket. Remove all gasket material from mounting surfaces.

1

2

3

6

5
Figure 2.

4
Oil Pan and Suction Tube Removal.

M0057105

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0039-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

TM 5-3810-305-23

0039

INSTALLATION

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel.

NOTE
Engine shown removed in Figure 2 for clarity. 1. 2. Install new gasket (Figure 3, Item 6), suction tube (Figure 3, Item 4), capscrew (Figure 3, Item 3), and two capscrews (Figure 3, Item 5) on engine block (Figure 3, Item 1). Tighten capscrews to 18 ft-lb (24 N•m). Apply sealing compound to fill joints between oil pan rail, gear housing and rear cover.

NOTE
Oil pan gasket has a print-a-seal surface on one side. 3. Apply sealing compound to both sides of new gasket (Figure 3, Item 2) and position it with print-a-seal surface toward engine block (Figure 3, Item 1).

0039-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

TM 5-3810-305-23

0039

INSTALLATION - Continued

1

2

3

6

5
Figure 3.

4
Oil Pan and Suction Tube Installation.

M0057105

0039-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

TM 5-3810-305-23

0039

INSTALLATION - Continued 4. Install oil pan (Figure 4, Item 1), 24 washers (Figure 4, Item 3), and capscrews (Figure 4, Item 2) on engine block (Figure 4, Item 4). Tighten 24 capscrews to 18 ft-lb (24 N•m).

1

2 3

4
M0056105

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Oil Pan and Suction Tube Installation.

Fill engine with clean engine oil (WP 0022). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0039-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

TM 5-3810-305-23

0040

FIELD MAINTENANCE OIL LEVEL GAGE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL 1. Remove dipstick (Figure 1, Item 1) from oil gage tube (Figure 1, Item 2).

1

2
Figure 1. Oil Level Gage Removal.

M0054105

0040-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00045)

TM 5-3810-305-23

0040

REMOVAL - Continued

NOTE
DO NOT remove oil gage tube unless damaged. 2. Remove oil gage tube (Figure 2, Item 2) from block (Figure 2, Item 1) by screwing the oil gage tube counterclockwise.

1

2

M0055105

Figure 2. END OF TASK CLEANING

Oil Level Gage Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0040-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00045)

TM 5-3810-305-23

0040

INSTALLATION

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 1. 2. 3. Apply sealing compound to base of oil gage tube (Figure 3, Item 2). Insert a capscrew into top of oil gage tube (Figure 3, Item 2) and install oil gage tube on block. Remove capscrew. Install dipstick (Figure 3, Item 1) into oil gage tube (Figure 3, Item 2).

1

2
Figure 3. END OF TASK Oil Level Gage Installation.

M0054105

0040-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00045)

TM 5-3810-305-23

0040

FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0040-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00045)

TM 5-3810-305-23

0041

FIELD MAINTENANCE INTAKE MANIFOLD COVER AND GASKET MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Gasket (WP 0172, Table 1, Item 78) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) High-pressure fuel injection lines removed (WP 0048)

REMOVAL Remove eight capscrews (Figure 1, Item 1), cover plate (Figure 1, Item 2), and gasket (Figure 1, Item 3). Discard gasket. Clean all gasket material from mounting surfaces.

1 3

2

M0053105

Figure 1. END OF TASK

Manifold Cover Plate Removal.

0041-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00046)

TM 5-3810-305-23

0041

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
Cover plate must be installed with air inlet on flywheel end. Air inlet must be directly above cold start atomizer inlet. 1. 2. 3. 4. 5. Install new gasket (Figure 2, Item 3) and cover plate (Figure 2, Item 2). Lubricate eight capscrews (Figure 2, Item 1) with threadlock compound and install on cover plate (Figure 2, Item 2). Install high-pressure fuel injection lines (WP 0048). Torque eight capscrews (Figure 2, Item 1) to 18 ft-lb (24 N•m) after high-pressure fuel injection lines are installed. Connect battery cables (WP 0076).

1 3

2

M0053105

Figure 2. Manifold Cover Plate Installation. END OF TASK

0041-2

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TM 5-3810-305-23

0041

FOLLOW-ON MAINTENANCE 1. 2. 3. Install high-pressure fuel injection lines (WP 0048). Battery cables connected (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0041-3/4 blank

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TM 5-3810-305-23

0042

FIELD MAINTENANCE EXHAUST MANIFOLD AND GASKETS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 147) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Exhaust pipe removed (WP 0053)

REMOVAL Remove eight capscrews (Figure 1, Item 1), manifold (Figure 1, Item 3), and four gaskets (Figure 1, Item 2) from engine block (Figure 1, Item 4). Remove all gasket material from mounting surfaces. Discard gasket.

1

2

3

4

M0295105

Figure 1. END OF TASK CLEANING

Exhaust Manifold Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0042-1

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0042

INSTALLATION 1. Install four new gaskets (Figure 2, Item 2), manifold (Figure 2, Item 3), and eight capscrews (Figure 2, Item 1) on engine block (Figure 2, Item 4).

1

2

3

4

M0295105

Figure 2. 2.

Exhaust Manifold Removal.

Torque eight capscrews (Figure 3) to 32 ft-lb (43 N•m) in sequence shown.

8

4

1

5

7

3
Figure 3.

2
Exhaust Manifold Installation.

6

M2301105

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install exhaust pipe (WP 0053). Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Place boom in resting position (TM 5-3810-305-10).

0042-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00047)

TM 5-3810-305-23

0042

FOLLOW-ON MAINTENANCE - Continued 6. Shut down engine (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0042-3/4 blank

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TM 5-3810-305-23

0043

FIELD MAINTENANCE FUEL INJECTOR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Tester, Diesel Fuel Injector Nozzle (WP 0171, Table 1, Item 13) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Antiseize Compound (WP 0170, Table 1, Item 5) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Gasket (WP 0172, Table 1, Item 56) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Exhaust manifold removed (WP 0042) Fuel injection tubes removed (WP 0049) Battery cables disconnected (WP 0076)

REMOVAL

CAUTION
If rust has formed on hold-down nut, the injector nozzle can turn in bore when nut is loosened. This will cause injector locating ball to cut a groove in bore, severely damaging head.

NOTE
If injectors are rusty, soak hold-down nut with a rust-penetrating solvent for a minimum of three minutes and loosen rust by carefully hitting injector body with drift pin.

0043-1

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0043

REMOVAL - Continued 1. Loosen hold-down nut (Figure 1, Item 2) and remove four injector nozzles (Figure 1, Item 3) from cylinder head (Figure 1, Item 1).

2 1 3

M0289105

Figure 1. Injector Nozzles Removal. 2. Remove four injector gaskets (Figure 2, Item 1). Discard gaskets.

1

M0290105

Figure 2. Injector Nozzles Removal. END OF TASK

0043-2

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0043

CLEANING 1. 2. Clean parts IAW General Maintenance Instructions (WP 0162). Dry parts with compressed air.

END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks, or corrosion, and replace if necessary. Inspect oil passages to ensure they are clean and unobstructed. Inspect for corrosion, pitting, and damage. Replace as necessary.

END OF TASK INSTALLATION 1. Apply antiseize compound to threads between injector nozzle hold-down nut and injector body.

NOTE
Protrusion on side of nozzle fits into a notch in head to orient injector. 2. Install four new injector gaskets (Figure 3, Item 1).

1

M0290105

Figure 3. Lube Oil Injector Nozzles Installation.

0043-3

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TM 5-3810-305-23

0043

INSTALLATION - Continued 3. 4. Install four injector nozzles (Figure 4, Item 3) in cylinder head (Figure 4, Item 1). Hold injector body with adjustable wrench and tighten hold-down nut, making sure injector nozzle (Figure 4, Item 3) does not rotate. Torque hold-down nut (Figure 4, Item 2) to 44 ft-lb (60 N•m).

2 1 3

M0289105

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install exhaust manifold (WP 0042). Install fuel injection tubes (WP 0049). Connect battery cables (WP 0076).

Injector Nozzles Installation.

Place boom in resting position (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0043-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00049)

TM 5-3810-305-23

0044

FIELD MAINTENANCE FUEL INJECTION PUMP MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Indicator, Dial (WP 0171, Table 1, Item 6) Puller Set, Mechanical (WP 0171, Table 1, Item 38) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, Dial, 1/4 Inch Drive (30 in-lb) (WP 0171, Table 1, Item 37) Materials/Parts Gasket (WP 0172, Table 1, Item 68) Qty: 1 Locknut (WP 0172, Table 1, Item 63) Qty: 2 Locknut (WP 0172, Table 1, Item 65) Qty: 1 O-Ring (WP 0172, Table 1, Item 64) Qty: 1 O-Ring (WP 0172, Table 1, Item 67) Qty: 1 O-Ring (WP 0172, Table 1, Item 71) Qty: 2 O-Ring (WP 0172, Table 1, Item 72) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Copper (WP 0172, Table 1, Item 66) Qty: 1 Materials/Parts (cont.) Washer, Lock 9/16 Reg (WP 0172, Table 1, Item 54) Qty: 1 Washer, Seal (WP 0172, Table 1, Item 18) Qty: 8 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Front cover removed (WP 0032) Fuel injection tubes removed (WP 0049)

0044-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

REMOVAL

NOTE
• Hold camshaft gear from moving when checking injection pump drive gear backlash. • Gear backlash limit is 0.003 to 0.013 inch (0.08 to 0.33 mm). 1. 2. Use dial indicator on tooth of injection pump drive gear and check for excessive injection pump drive gear backlash. If injection pump drive gear backlash exceeds limit, replace injection pump drive gear and/or camshaft gear.

NOTE
Number 1 cylinder must be at Top Dead Center (TDC) before removing pump. 3. 4. 5. Barring engine, slowly push on engine timing pin (Figure 1, Item 1) until pin engages. Number 1 cylinder is now at TDC. Disengage engine timing pin (Figure 1, Item 1).
1

M0269105

Figure 1.

Injection Pump Removal.

0044-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

REMOVAL - Continued

NOTE
Injection pump driveshaft must be locked before removing injection pump. 6. 7. 8. Loosen injection pump driveshaft lockscrew (Figure 2, Item 2) on fuel injection pump (Figure 2, Item 1). Reposition locked timing seal (Figure 2, Item 3). Tighten injection pump lockscrew (Figure 2, Item 2) to 22 ft-lb (30 N•m).

3

1

2
Figure 2. Injection Pump Removal.

M0270105

NOTE
Hold drive gear steady to prevent locked injection pump from rotating during drive gear removal. 9. Remove drive gear mounting nut (Figure 3, Item 2) and lockwasher (Figure 3, Item 3) from injection pump drive gear (Figure 3, Item 1). Discard lockwasher.
1 2 3

M0271105

Figure 3.

Injection Pump Removal.

0044-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

REMOVAL - Continued 10. 11. Using a puller, remove injection pump drive gear from engine (Figure 4, Item 1). Remove fuel injection pump capscrew (Figure 4, Item 2) from rear bracket (Figure 4, Item 3).

1 2

3
Figure 4. 12. 13. Injection Pump Removal.

M0272105

Align marks (Figure 5, Items 1 and 5) on injection pump mounting flange (Figure 5, Item 2) and gear housing (Figure 5, Item 4). Remove three flange nuts (Figure 5, Item 3) from mounting studs.
1 2

5

4

3

M0273105

Figure 5.

Injection Pump Removal.

0044-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

REMOVAL - Continued 14. 15. Remove injection pump (Figure 6, Item 2) with drive gear key (Figure 6, Item 1) in place from engine (Figure 6, Item 4). Remove gasket (Figure 6, Item 3) from engine (Figure 6, Item 4). Discard gasket.

4

1

2 3
Figure 6. END OF TASK Injection Pump Removal.
M0274105

0044-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY

CAUTION
Rebuild and calibration of pumps must be performed by qualified personnel using the appropriate special equipment. However, there are a number of external repairs that can be performed on injection pump without affecting calibration. Failure to follow this caution may result in damage to equipment.

NOTE
Mark shaft position to housing. 1. Remove driveshaft lockscrew (Figure 7, Item 3) and washer (Figure 7, Item 2) from injection pump (Figure 7, Item 1).

1

3

2
M1508105

Figure 7. Injection Pump Disassembly.

0044-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY - Continued 2. Remove o-ring (Figure 8, Item 2) from driveshaft lockscrew (Figure 8, Item 1). Discard o-ring.

1

2

M1509105

Figure 8. 3. 4.

Injection Pump Disassembly.

Remove four banjo bolts (Figure 9, Item 1), eight copper washers (Figure 9, Item 3) and four fittings (Figure 9, Item 7) from injection pump (Figure 9, Item 2). Discard copper washers. Remove solenoid with plunger (Figure 9, Item 4), spring (Figure 9, Item 6), and o-ring (Figure 9, Item 5) from injection pump (Figure 9, Item 2). Discard o-ring.

1

2

7

5,6 4
Figure 9.

3
M1510105

Injection Pump Disassembly.

0044-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY - Continued 5. 6. Remove orifice bleed fitting (Figure 10, Item 1) and washer (Figure 10, Item 2) from injection pump (Figure 10, Item 5). Remove screw assembly (Figure 10, Item 4) and washer (Figure 10, Item 3) from injection pump (Figure 10, Item 5).

1

2

3 4

5
Figure 10. Injection Pump Disassembly. 7.

M1511105

Remove inlet fitting (Figure 11, Item 1), washer (Figure 11, Item 2), and filter (Figure 11, Item 3) from injection pump (Figure 11, Item 4).

1

2,3

4

M1512105

Figure 11. Injection Pump Disassembly.

0044-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY - Continued 8. Remove locknut (Figure 12, Item 2) and throttle lever kit (Figure 12, Item 1). Discard locknut.

2

1

M1513105

Figure 12. 9.

Injection Pump Disassembly.

Remove locknut (Figure 13, Item 2), washer (Figure 13, Item 3), shutoff lever (Figure 13, Item 4), spring (Figure 13, Item 5), and guide (Figure 13, Item 1) from injection pump. Discard locknut.

2 3 1 4

5

M1514105

Figure 13.

Injection Pump Disassembly.

0044-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY - Continued 10. Remove plug (Figure 14, Item 7) and washer (Figure 14, Item 1) from spring cap (Figure 14, Item 2) on injection pump (Figure 14, Item 4).

WARNING

Remove cap slowly. Cap is under spring tension. Failure to follow this warning may cause injury or death to personnel.

NOTE
Record the number of shims for use in assembly. 11. Remove spring cap (Figure 14, Item 2) and o-ring (Figure 14, Item 3) slowly and remove spring (Figure 14, Item 5) and shims (Figure 14, Item 6). Discard o-ring.

1

2 3

4

5 7 6
Figure 14. Injection Pump Disassembly. 12. Remove pressure end cap (Figure 15, Item 1) and o-ring (Figure 15, Item 2) from timing housing (Figure 15, Item 3). Discard o-ring.
M1515105

0044-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY - Continued

1

2 3

M1516105

Figure 15. 13. 14. 15.

Injection Pump Disassembly.

Remove cap nut (Figure 16, Item 4) and sealing washer (Figure 16, Item 5) from timing housing (Figure 16, Item 8). Remove locating fitting (Figure 16, Item 1), o-rings (Figure 16, Item 2), and ball (Figure 16, Item 3) from timing housing (Figure 16, Item 8). Discard o-rings. Remove timing housing (Figure 16, Item 8) and gasket (Figure 16, Item 7) from injection pump (Figure 16, Item 6). Discard gasket.

1

2

3 4

5 2 6

8

7
Figure 16. Injection Pump Disassembly.

M1517105

0044-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

DISASSEMBLY - Continued

NOTE
Mark position of locknut on idle screw to aid in assembly. 16. 17. 18. Remove screw assembly (Figure 17, Item 4) and washer (Figure 17, Item 5) from injection pump (Figure 17, Item 6). Remove low idle screw (Figure 17, Item 3), washer (Figure 17, Item 2), and locknut (Figure 17, Item 1) from injection pump (Figure 17, Item 6). Discard locknut. Remove return fitting (Figure 17, Item 8) and washer (Figure 17, Item 7) from injection pump (Figure 17, Item 6).

1

2

3 4

8

7

5 6
Figure 17. Injection Pump Disassembly. END OF TASK
M1518105

0044-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. 3. Install return fitting (Figure 18, Item 8) and washer (Figure 18, Item 7) on injection pump (Figure 18, Item 6). Install new locknut (Figure 18, Item 1), washer (Figure 18, Item 2), and idle screw (Figure 18, Item 3). Align marks made during disassembly. Install washer (Figure 18, Item 5) and screw assembly (Figure 18, Item 4) on injection pump (Figure 18, Item 6). Tighten screw assembly to 65 in-lb. (7.3 N•m).

1

2

3 4

8

7

5 6
Figure 18. Injection Pump Assembly.
M1518105

0044-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

ASSEMBLY - Continued 4. 5. 6. 7. Position new gasket (Figure 19, Item 7) and timing housing (Figure 19, Item 8) on injection pump (Figure 19, Item 6). Install ball (Figure 19, Item 3), new o-rings (Figure 19, Item 2), and locating fitting (Figure 19, Item 1) on injection pump (Figure 19, Item 6). Do not tighten locating fitting at this time. Install cap nut (Figure 19, Item 4) and sealing washer (Figure 19, Item 5) onto timing housing (Figure 19, Item 8). Tighten cap nut (Figure 19, Item 4) and locating fitting (Figure 19, Item 1) alternately and evenly until a torque of 22 ft-lb (30 N•m) is obtained on cap nut and a torque of 29 ft-lb (39 N•m) is obtained on locating fitting.

1

2

3 4

5 2 6

8

7
Figure 19. Injection Pump Assembly.

M1517105

0044-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

ASSEMBLY - Continued 8. Install new o-ring (Figure 20, Item 2) and pressure end cap (Figure 20, Item 1) into timing housing (Figure 20, Item 3). Tighten pressure end cap to 17.5 ft-lb (23.7 N•m).

1

2 3

M1516105

Figure 20. 9.

Injection Pump Assembly.

Install spring cap (Figure 21, Item 2), new o-ring (Figure 21, Item 3), spring (Figure 21, Item 5), and shims (Figure 21, Item 6) onto timing housing (Figure 21, Item 4), using the number of shims recorded during disassembly. Tighten spring cap to 17.5 ft-lb (23.7 N•m). Install plug (Figure 21, Item 7) into spring cap (Figure 21, Item 2).

10.

1

2 3

4

5 7 6
Figure 21. Injection Pump Assembly.
M1515105

0044-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

ASSEMBLY - Continued 11. 12. 13. Install guide (Figure 22, Item 1), spring (Figure 22, Item 5), and shutoff lever (Figure 22, Item 4) on injection pump. Position return spring (Figure 22, Item 5) with one end contacting boss on governor cover. Hook free end around shutoff lever (Figure 22, Item 4). Rotate lever clockwise until it engages flats on shutoff shaft. Install washer (Figure 22, Item 3) and new locknut (Figure 22, Item 2). Tighten locknut to 30 in-lb. (3.4 N•m).

2 3 1 4

5

M1514105

Figure 22. Injection Pump Assembly. 14. Install throttle lever kit (Figure 23, Item 1) and new locknut (Figure 23, Item 2). Stop arm in lever kit must slide over flats of shaft. Tighten locknut to 30 in-lb. (3.4 N•m).

2

1

M1513105

Figure 23. Injection Pump Assembly.

0044-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

ASSEMBLY - Continued 15. Install filter (Figure 24, Item 3), washer (Figure 24, Item 2), and inlet fitting (Figure 24, Item 1) on injection pump (Figure 24, Item 4). Tighten inlet fitting to 38 ft-lb (52 N•m).

1

2,3

4

M1512105

Figure 24. 16. 17.

Injection Pump Assembly.

Install washer (Figure 25, Item 2) and orifice bleed fitting (Figure 25, Item 1) on injection pump (Figure 25, Item 5). Tighten orifice bleed fitting to 15 ft-lb (20 N•m). Install washer (Figure 25, Item 4) and screw assembly (Figure 25, Item 3) on injection pump (Figure 25, Item 5). Tighten screw assembly to 40 in-lb. (28 N•m).

1

2

3 4

5
Figure 25. Injection Pump Assembly.

M1511105

0044-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

ASSEMBLY - Continued 18. 19. Install new o-ring (Figure 26, Item 6), spring (Figure 26, Item 5), and solenoid with plunger (Figure 26, Item 4) in injection pump (Figure 26, Item 2). Tighten solenoid to 11 ft-lb. (15 N•m). Install four fittings (Figure 26, Item 7), eight new copper washers (Figure 26, Item 3), and four banjo bolts (Figure 26, Item 1) on injection pump (Figure 26, Item 2). Tighten four banjo bolts to 23 ft-lb (31 N•m).

1

2

7

5,6 4

3
M1510105

Figure 26. Injection Pump Assembly. 20. Install new o-ring (Figure 27, Item 2) on driveshaft lockscrew (Figure 27, Item 1).

1

2

M1509105

Figure 27. Injection Pump Assembly.

0044-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

ASSEMBLY - Continued 21. Position shaft as marked during disassembly, and install washer (Figure 28, Item 2) and lockscrew (Figure 28, Item 3) into injection pump (Figure 28, Item 1) to lock.

1

3

2
M1508105

Figure 28. END OF TASK INSTALLATION

Injection Pump Assembly.

NOTE
Number 1 cylinder must be at Top Dead Center (TDC) before installing injection pump. 1. Barring engine slowly, push in engine timing pin (Figure 29, Item 1) until pin engages.
1

M0269105

Figure 29.

Injection Pump Installation.

0044-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

INSTALLATION - Continued 2. 3. 4. 5. Number 1 cylinder is now at TDC. Disengage engine timing pin. Install new gasket (Figure 30, Item 3) on engine (Figure 30, Item 4). Install timed and locked injection pump (Figure 30, Item 2) with drive gear key (Figure 30, Item 1) on engine (Figure 30, Item 4).

4

1

2 3
Figure 30. 6. Injection Pump Installation.
M0274105

Install three flange nuts (Figure 31, Item 1) finger tight on mounting studs.

1

M0287105

Figure 31.

Injection Pump Installation.

0044-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

INSTALLATION - Continued 7. 8. 9. Install injection pump drive gear (Figure 32, Item 1) onto driveshaft, aligning keyway in injection pump drive gear with key in shaft and aligning mark on injection pump drive gear with timing mark on camshaft gear. Install new lockwasher (Figure 32, Item 3) and drive gear mounting nut (Figure 32, Item 2) on injection pump drive gear (Figure 32, Item 1). Tighten nut to 11 to 15 ft-lb (15 to 20 N•m).
1 2 3

M0271105

Figure 32. 10. 11.

Injection Pump Installation.

When installing previously removed injection pump, align matchmarks. When new or rebuilt injection pump is installed, align injection pump mounting flange (Figure 33, Item 1) mark to gear housing (Figure 33, Item 2) mark.
1

2

M0288105

Figure 33.

Injection Pump Installation.

0044-21

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0044

INSTALLATION - Continued 12. Install fuel injection pump capscrew (Figure 34, Item 2) on fuel injection pump (Figure 34, Item 1) to rear bracket (Figure 34, Item 3).

1 2

3
Figure 34. 13. 14. 15. 16. 17. Injection Pump Installation.

M0272105

Tighten three flange nuts to 18 ft-lb (24 N•m). Tighten rear bracket capscrew to 18 ft-lb (24 N•m). Loosen injection pump driveshaft lockscrew. Reposition locked timing seal to unlocked position. Tighten injection pump driveshaft lockscrew to 7 ft-lb (10 N•m).

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install fuel injection tubes (WP 0049). Install front cover (WP 0032). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0044-22

03/15/2011 Rel(1.8) root(maintwp) wpno(M00050)

TM 5-3810-305-23

0045

FIELD MAINTENANCE FUEL LIFT PUMP MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Gasket (WP 0172, Table 1, Item 85) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10)

0045-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 5-3810-305-23

0045

REMOVAL 1. 2. Disconnect fittings (Figure 1, Items 1 and 2) from lift pump (Figure 1, Item 4). Remove two capscrews (Figure 1, Item 3), lift pump (Figure 1, Item 4), and gasket (Figure 1, Item 5) from engine (Figure 1, Item 6). Remove all gasket material from mounting surfaces. Discard gasket.

1

2

6

5

4
Figure 1. END OF TASK CLEANING 1. 2.

3
Lift Pump Removal.

M0291105

Clean parts IAW General Maintenance Instructions (WP 0162). Clean parts and surfaces with solvent cleaning compound.

END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect camshaft lever and return spring for wear. Inspect diaphragm by blocking fuel inlet line with finger and operating priming lever. A properly operating pump will have suction that will not bleed down until finger is removed from inlet.

END OF TASK

0045-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 5-3810-305-23

0045

INSTALLATION 1. 2. Install new gasket (Figure 2, Item 5), lift pump (Figure 2, Item 4), and two capscrews (Figure 2, Item 3) to engine (Figure 2, Item 6). Tighten two capscrews to 18 ft-lb (24 N•m). Connect fittings (Figure 2, Items 1 and 2) to lift pump (Figure 2, Item 4).

1

2

6

5

4
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

3
Lift Pump Installation.

M0291105

0045-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 5-3810-305-23

0046

FIELD MAINTENANCE AIR CLEANER ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock M4 (WP 0172, Table 1, Item 168) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0051 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Hood support removed (WP 0120)

0046-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00052)

TM 5-3810-305-23

0046

REMOVAL

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. 3. Remove cold start cylinder, if so equipped (WP 0051). Loosen four clamps (Figure 1, Item 4). Remove elbows (Figure 1, Items 1 and 3), four clamps (Figure 1, Item 4), and tube (Figure 1, Item 2) from vehicle.

1

2

3 4

M0001105

Figure 1. Air Cleaner Removal.

0046-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00052)

TM 5-3810-305-23

0046

REMOVAL - Continued 4. 5. 6. Remove two screws (Figure 2, Item 3) and nuts (Figure 2, Item 1) to loosen two mounting bands (Figure 2, Item 2). Remove air cleaner (Figure 2, Item 4) from vehicle. Remove two nuts (Figure 2, Item 8) and capscrews (Figure 2, Item 7) to disconnect bracket (Figure 2, Item 6) from bracket (Figure 2, Item 5).

1

2
3 8
7

4

6

5
M0002105

Figure 2.

Air Cleaner Removal.

0046-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00052)

TM 5-3810-305-23

0046

REMOVAL - Continued 7. 8. 9. 10. Remove four nuts (Figure 3, Item 8), lockwashers (Figure 3, Item 9), capscrews (Figure 3, Item 7), and two mounting bands (Figure 3, Item 6) from bracket (Figure 3, Item 3). Discard lockwashers. Remove two nuts (Figure 3, Item 10), capscrews (Figure 3, Item 2), and bracket (Figure 3, Item 11) from vehicle. Remove two capscrews (Figure 3, Item 4), washers (Figure 3, Item 5), and bracket (Figure 3, Item 3) from vehicle. Remove two nuts (Figure 3, Item 1), lockwashers (Figure 3, Item 14), vehicle screws (Figure 3, Item 13), and restriction indicator (Figure 3, Item 12) from hood support. Discard lockwashers.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. Install restriction indicator (Figure 3, Item 12), two vehicle screws (Figure 3, Item 13), new lockwashers (Figure 3, Item 14), and nuts (Figure 3, Item 1) on hood support. Install bracket (Figure 3, Item 3), two washers (Figure 4, Item 5), and capscrews (Figure 3, Item 4) on vehicle. Install bracket (Figure 3, Item 11), two capscrews (Figure 3, Item 2), and nuts (Figure 3, Item 10) on vehicle. Install two mounting bands (Figure 3, Item 6), four capscrews (Figure 3, Item 7), new lockwashers (Figure 3, Item 9), and nuts (Figure 3, Item 8) to bracket (Figure 3, Item 3).

0046-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00052)

TM 5-3810-305-23

0046

INSTALLATION - Continued

2 1 11 10 9 14 8 7 6 13 12
M0003105

3

4

5

Figure 3. 5. 6.

Air Cleaner Maintenance.

Install two capscrews (Figure 4, Item 7) and nuts (Figure 5, Item 8) to connect bracket (Figure 4, Item 6) on bracket (Figure 5, Item 5). Install air cleaner (Figure 4, Item 4) and tighten two mounting bands (Figure 4, Item 2) by installing two nuts (Figure 5, Item 1) and screws (Figure 4, Item 3).

1

2
3 8
7

4

6

5
M0002105

Figure 4.

Air Cleaner Installation.

0046-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00052)

TM 5-3810-305-23

0046

INSTALLATION - Continued 7. 8. 9. Install tube (Figure 5, Item 2), four clamps (Figure 6, Item 4), and elbows (Figure 5, Items 1 and 3). Tighten four clamps (Figure 5, Item 4). Install cold start cylinder, if so equipped (WP 0051).

1

2

3 4

M0001105

Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install hood support (WP 0120).

Air Cleaner Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0046-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00052)

TM 5-3810-305-23

0047

FIELD MAINTENANCE FUEL TANK MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Gasket (WP 0172, Table 1, Item 2) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 1) Qty: 5 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL 1. 2. Remove drain plug (Figure 1, Item 5) and drain fuel tank (Figure 1, Item 1). Remove four nuts (Figure 1, Item 3), washers (Figure 1, Item 4), capscrews (Figure 1, Item 2), and bracket (Figure 1, Item 6) from fuel tank (Figure 1, Item 1).

1 2

6 3 4

5
Figure 1. Fuel Tank Removal.

M0265105

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TM 5-3810-305-23

0047

REMOVAL - Continued

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 3. Disconnect fuel lines (Figure 2, Items 1 and 3) from fuel tank (Figure 2, Item 7).

NOTE
Tag all wire assemblies before disconnecting to aid installation. Remove tags following maintenance. 4. 5. Remove nut (Figure 2, Item 10), lockwasher (Figure 2, Item 11), screw (Figure 2, Item 8), lockwasher (Figure 2, Item 9), and disconnect sending unit harness (Figure 2, Item 2). Discard lockwashers. Remove four nuts (Figure 2, Item 4), washers (Figure 2, Item 5), two straps (Figure 2, Item 6), and fuel tank (Figure 2, Item 7) from vehicle.

1 10,11 2

3 8,9 4 5 7

6
Figure 2. Fuel Tank Removal. END OF TASK DISASSEMBLY 1. 2.

M0266105

Remove elbows (Figure 3, Items 1 and 3), bushing (Figure 3, Item 2), and check valve (Figure 3, Item 4) from fuel tank. Remove five machine screws (Figure 3, Item 6), lockwashers (Figure 3, Item 7), sending unit (Figure 3, Item 5) and gasket from fuel tank. Discard lockwashers and gasket.

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0047

DISASSEMBLY - Continued

1 2 6,7 3 4

5
M0267105

Figure 3. 3. 4.

Fuel Tank Disassembly.

Unscrew cap (Figure 4, Item 1) and remove fill screen (Figure 4, Item 2) from fuel tank. Unhook chain (Figure 4, Item 3) at clip (Figure 4, Item 4) and remove cap from fuel tank.

2 1

4
Figure 4. END OF TASK

3
Fuel Tank Disassembly.

M0268105

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0047

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. Hook chain (Figure 5, Item 3) on clip (Figure 5, Item 4). Install fill screen (Figure 5, Item 2) and cap (Figure 5, Item 1) on fuel tank.

2 1

4
Figure 5.

3
Fuel Tank Assembly.

M0268105

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0047

ASSEMBLY - Continued 3. 4. Install sending unit (Figure 6, Item 5), new gasket, four new lockwashers (Figure 6, Item 7), and machine screws (Figure 6, Item 6) on fuel tank. Install check valve (Figure 6, Item 4), bushing (Figure 6, Item 2), and elbows (Figure 6, Items 1 and 3).

1 2 6,7 3 4

5
M0267105

Figure 6. END OF TASK

Fuel Tank Assembly.

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0047

INSTALLATION 1. 2. 3. 4. Position fuel tank (Figure 7, Item 7) and install two straps (Figure 7, Item 6), four washers (Figure 7, Item 5), and nuts (Figure 7, Item 4). Install screw (Figure 7, Item 8) and new lockwasher (Figure 7, Item 9). Position ground wire and install lockwasher and screw. Connect sending unit harness (Figure 7, Item 2) and install new lockwasher (Figure 7, Item 11) and nut (Figure 7, Item 10) on fuel tank (Figure 7, Item 7). Connect fuel lines (Figure 7, Items 1 and 3) on fuel tank (Figure 7, Item 7).

1 10,11 2

3 8,9 4 5 7

6
Figure 7. Fuel Tank Installation.

M0266105

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0047

INSTALLATION - Continued 5. 6. Install bracket (Figure 8, Item 6), four capscrews (Figure 8, Item 2), washers (Figure 8, Item 4), and nuts (Figure 8, Item 3). Install drain plug (Figure 8, Item 5) and fill fuel tank (Figure 8, Item 1).

1 2

6 3 4

5
Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Fuel Tank Installation.

M0265105

END OF TASK END OF WORK PACKAGE

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0048

FIELD MAINTENANCE FUEL LINES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Strap, Tiedown, Electrical Component (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine hood removed (WP 0118)

REMOVAL

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. 1. Disconnect fuel lines (Figure 1, Items 1 and 3) at elbows (Figure 1, Item 2) on top of fuel tank (Figure 1, Item 4).

1

2

3

2

4

M0260105

Figure 1.

Fuel Lines Removal.

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0048

REMOVAL - Continued 2. Remove two nuts (Figure 2, Item 1), washers (Figure 2, Item 3), clamps (Figure 2, Items 2 and 4), and tiedown strap (Figure 2, Item 5) from fuel lines. Discard tiedown strap.

1

2

3 5
Figure 2. 3. 4.

4
M0261105

Fuel Lines Removal.

Remove fuel line (Figure 3, Item 2) from fuel lift pump (Figure 3, Item 1). Remove clamp (Figure 3, Item 3) from fuel line (Figure 3, Item 5) and fuel return line (Figure 3, Item 4).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Install clamp (Figure 3, Item 3) to fuel line (Figure 3, Item 5) and fuel return line (Figure 3, Item 4). Install fuel line (Figure 3, Item 2) to fuel lift pump (Figure 3, Item 1).

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0048

INSTALLATION - Continued

1 2

3 4

5
M0263105

Figure 3. 3.

Fuel Lines Installation.

Install two nuts (Figure 4, Item 1), washers (Figure 4, Item 3), clamps (Figure 4, Items 4 and 2), and new tiedown strap (Figure 4, Item 5) to fuel lines.

1

2

3 5
Figure 4.

4
M0261105

Fuel Lines Installation.

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INSTALLATION - Continued 4. Connect fuel lines (Figure 5, Items 1 and 3) to elbows (Figure 5, Item 2) on top of fuel tank (Figure 5, Item 4).

1

2

3

2

4

M0260105

Figure 5. Fuel Lines Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine hood (WP 0118). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0049

FIELD MAINTENANCE FUEL INJECTION TUBES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting (WP 0171, Table 1, Item 36) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Seal, Banjo (WP 0172, Table 1, Item 60) Qty: 4 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Seal (WP 0172, Table 1, Item 18) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Throttle cable disconnected (WP 0052) 1

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0049

REMOVAL High-Pressure Tubes

NOTE
• Before removal of fuel injection tubes, have suitable container available. • Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. Remove four capscrews (Figure 1, Item 1) and tube clamps (Figure 1, Item 2) from high-pressure tubes (Figure 1, Items 3, 4, 5, and 6) from injection pump (Figure 1, Item 7).

2 1

3

4

5

7

6
Figure 1. High-Pressure Tubes Removal.

M0252105

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0049

REMOVAL - Continued High-Pressure Tubes - Continued

NOTE
Mark on four tags, No. 1 cylinder through No. 4 cylinder, to aid in installation. 2. Disconnect four high-pressure tubes (Figure 2, Items 1, 2, 3, and 4) from four injectors (Figure 2, Item 5). Make sure marked tags match proper cylinders.

2 1

3

4

5

M0253105

Figure 2.

High-Pressure Tubes Removal.

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TM 5-3810-305-23

0049

REMOVAL - Continued High-Pressure Tubes - Continued

CAUTION
Use a wrench on injection pump delivery valves when removing high-pressure tubes to prevent damage to injection pump delivery valves. 3. 4. Remove No. 3 cylinder high-pressure tube (Figure 3, Item 3) and No. 4 cylinder high-pressure tube (Figure 3, Item 2) from injection pump (Figure 3, Item 5). Remove No. 1 cylinder high-pressure tube (Figure 3, Item 4) and No. 2 cylinder high-pressure tube (Figure 3, Item 1) from injection pump (Figure 3, Item 5).

1

2

5 3

4
Figure 3. High-Pressure Tubes Removal.

M0254105

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0049

REMOVAL - Continued

Low-Pressure Tubes

NOTE
• Before removal of fuel injection tubes, have suitable container available. • Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. Disconnect two fuel pressure sender hoses (Figure 4, Items 6 and 7) from banjo fittings (Figure 4, Items 3 and 5). Remove two banjo screws (Figure 4, Items 8 and 9) and four copper seals (Figure 4, Items 2 and 4) from engine (Figure 4, Item 1). Discard four copper seals.

1

2

3

4

5

6

9

8
Figure 4.

7
Low-Pressure Tubes Removal.

M0255105

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TM 5-3810-305-23

0049

REMOVAL - Continued Low-Pressure Tubes - Continued

CAUTION
Use a wrench on lift pump connection while removing low-pressure tube to prevent damage to lift pump connection. 3. Loosen nut (Figure 5, Item 1) and remove low-pressure tube (Figure 5, Item 2) from lift pump (Figure 5, Item 3).

1

2

3

M0256105

Figure 5. Low-Pressure Tubes Removal.

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0049

REMOVAL - Continued Low-Pressure Tubes - Continued 4. 5. Loosen two nuts (Figure 6, Items 2 and 5) and remove low-pressure tube (Figure 6, Item 4) from injection pump (Figure 6, Item 6) and tee fitting (Figure 6, Item 3). Loosen nut (Figure 6, Item 7) and remove low-pressure tube assembly (Figure 6, Item 1) from injection pump (Figure 6, Item 6).

1

2

3

4 7

6
Figure 6.

5
M0257105

Low-Pressure Tubes Removal.

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0049

REMOVAL - Continued

Fuel Drain Tubes

NOTE
• Before removal of fuel injection tubes, have suitable container available. • Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. Remove four banjo connector screws (Figure 7, Item 3) and banjo connector seals (Figure 7, Item 2) from injectors (Figure 7, Item 1). Discard four banjo connector seals.
1

2

3

M0258105

Figure 7. Fuel Drain Tubes Removal.

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0049

REMOVAL - Continued Fuel Drain Tubes - Continued 2. 3. Remove fuel manifold tube (Figure 8, Item 3) from male union tee (Figure 8, Item 4). Remove two capscrews (Figure 8, Item 6) from engine (Figure 8, Item 2).

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel. 4. Remove fuel drain hose (Figure 8, Item 1) from rubber hose (Figure 8, Item 5) and injection pump (Figure 8, Item 7). Remove fuel drain hose from vehicle.

1

2

3

4

7 6
Figure 8. END OF TASK

5

M0259105

Fuel Drain Tubes Removal.

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TM 5-3810-305-23

0049

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Fuel Drain Tubes 1. 2. 3. Install fuel drain tube (Figure 9, Item 1) to rubber hose (Figure 9, Item 5) and injection pump (Figure 9, Item 7). Install two capscrews (Figure 9, Item 6) to engine (Figure 9, Item 2). Tighten two capscrews to 18 ft-lb (24 N•m). Install fuel manifold tube (Figure 9, Item 3) to male union tee (Figure 9, Item 4).

1

2

3

4

7 6
Figure 9.

5

M0259105

Fuel Drain Tubes Installation.

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0049

INSTALLATION - Continued Fuel Drain Tubes - Continued 4. Install four new banjo connector seals (Figure 10, Item 2) and banjo connector screws (Figure 10, Item 3) to injectors (Figure 10, Item 1). Tighten four banjo connector screws to 6.5 ft-lb (8.8 N•m).
1

2

3

M0258105

Figure 10.

Fuel Drain Tubes Installation.

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TM 5-3810-305-23

0049

INSTALLATION - Continued

Low-Pressure Tubes

CAUTION
Make sure injection pump connection is held securely when tightening low-pressure tubes. Failure to follow this caution may result in damage to equipment. 1. 2. Install low-pressure tube assembly (Figure 11, Item 1) to injection pump (Figure 11, Item 6) and tighten nut (Figure 11, Item 7). Install low-pressure tube (Figure 11, Item 4) to injection pump (Figure 11, Item 6) and tee fitting (Figure 11, Item 3) and tighten two nuts (Figure 11, Items 2 and 5).

1

2

3

4 7

6

5
M0257105

Figure 11. Low-Pressure Tubes Installation.

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0049

INSTALLATION - Continued Low-Pressure Tubes - Continued

CAUTION
Make sure lift pump connection is held securely when tightening low-pressure tubes. Failure to follow this caution may result in damage to equipment. 3. Install low-pressure tube (Figure 12, Item 2) to lift pump (Figure 12, Item 3) and tighten nut (Figure 12, Item 1).

1

2

3

M0256105

Figure 12.

Low-Pressure Tubes Installation.

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0049

INSTALLATION - Continued Low-Pressure Tubes - Continued 4. 5. Install four new copper seals (Figure 13, Items 1 and 3), two banjo fittings (Figure 13, Items 2 and 4), and two banjo screws (Figure 13, Items 7 and 8) to filter head. Tighten two banjo fittings to 18 ft-lb (24 N•m). Connect two fuel pressure sender hoses (Figure 13, Items 5 and 6) to banjo fittings (Figure 13, Items 7 and 8).

1

2

3

4

5

8

7

6

M0262105

Figure 13. Low-Pressure Tubes Installation.

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TM 5-3810-305-23

0049

INSTALLATION - Continued

High-Pressure Tubes

CAUTION
Make sure injection pump connections are held securely when tightening high-pressure tubes. Failure to follow this caution may result in damage to equipment.

NOTE
Make sure high-pressure lines are correct for engine. Check part number tag on tubes. 1. Connect four high-pressure tubes (Figure 14, Items 1, 2, 3, and 4) to four injectors (Figure 14, Item 5). Make sure marked tags match proper cylinders.

2 1

3

4

5

M0253105

Figure 14.

High-Pressure Tubes Installation.

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TM 5-3810-305-23

0049

INSTALLATION - Continued High-Pressure Tubes - Continued 2. 3. 4. Connect No. 3 cylinder high-pressure tube (Figure 15, Item 5) and No. 4 cylinder high-pressure tube (Figure 15, Item 4) to injection pump (Figure 15, Item 7). Connect No. 1 cylinder high-pressure tube (Figure 15, Item 6) and No. 2 cylinder high-pressure tube (Figure 15, Item 3) to injection pump (Figure 15, Item 7). Install four capscrews (Figure 15, Item 1) and tube clamps (Figure 15, Item 2) to high-pressure tubes.

2 1

3

4

5

7

6
Figure 15. High-Pressure Tubes Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect throttle cable (WP 0052). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

M0252105

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0050

FIELD MAINTENANCE FUEL FILTER HEAD ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Oil Filter, Strap (WP 0171, Table 1, Item 32) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Lubricating Oil, Preservative and Break-In (WP 0170, Table 1, Item 45) Qty: 1 O-Ring (WP 0172, Table 1, Item 70) Qty: 1 Materials/Parts (cont.) Packing, Preformed (WP 0172, Table 1, Item 69) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Fuel injection tubes disconnected (WP 0049)

REMOVAL 1. Remove secondary fuel filter (Figure 1, Item 3) and primary fuel filter (Figure 1, Item 2) from fuel filter head (Figure 1, Item 1).

1 2

3
Figure 1. Fuel Filters and Head Assembly Removal.

M0246105

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TM 5-3810-305-23

0050

REMOVAL - Continued 2. Remove preformed packing (Figure 2, Item 1), hexagon nut (Figure 2, Item 2), fuel filter head (Figure 2, Item 4), and o-ring (Figure 2, Item 3). Discard o-ring and preformed packing.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install new o-ring (Figure 2, Item 3), fuel filter head (Figure 2, Item 4), new preformed packing (Figure 2, Item 1), and hexagon nut (Figure 2, Item 2) to engine. Tighten hexagon nut to 24 ft-lb (33 N•m).

1

2

3

4

M0247105

Figure 2. Fuel Filters and Head Assembly Maintenance.

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0050

INSTALLATION - Continued 2. 3. Fill fuel filters with clean fuel and lubricate seal with clean oil. Install primary fuel filter (Figure 3, Item 2) and secondary fuel filter (Figure 3, Item 3) to fuel filter head (Figure 3, Item 1).

1 2

3
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect fuel injection tubes (WP 0049). Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Shut down engine (TM 5-3081-305-10). Place boom in resting position (TM 5-3810-305-10). Fuel Filters and Head Assembly Installation.

M0246105

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0051

FIELD MAINTENANCE COLD START DEVICE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He M6 (WP 0172, Table 1, Item 138) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL 1. 2. 3. 4. 5. 6. Remove cold start cylinder, if equipped. Loosen screw (Figure 1, Item 9) securing cable end. Remove screw (Figure 1, Item 10), clamp (Figure 1, Item 2), and disconnect cable (Figure 1, Item 1). Disconnect tube fitting (Figure 1, Item 8) from elbow (Figure 1, Item 7). Remove elbow (Figure 1, Item 7) from valve (Figure 1, Item 3). Remove two nuts (Figure 1, Item 6), bracket (Figure 1, Item 5), valve (Figure 1, Item 3), and two capscrews (Figure 1, Item 4).

1

2

3

4

5 10 9
Figure 1.

6 8 7
M0248105

Cold Start Device Removal.

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TM 5-3810-305-23

0051

REMOVAL - Continued 7. Remove tube (Figure 2, Item 3) and fitting (Figure 2, Item 2) from cylinder head (Figure 2, Item 1).

1

2

3

M0249105

Figure 2. Cold Start Device Removal. 8. 9. Remove two nuts (Figure 3, Item 8), capscrews (Figure 3, Item 7), and bracket (Figure 3, Item 6) from vehicle. Remove two nuts (Figure 3, Item 1), capscrews (Figure 3, Item 3), bracket (Figure 3, Item 2), and clamp (Figure 3, Item 4) from vehicle.

1

2
3 8
7

4

6

5
M0002105

Figure 3. Cold Start Device Removal.

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0051

REMOVAL - Continued 10. Remove knob (Figure 4, Item 1), locknut (Figure 4, Item 3), washer (Figure 4, Item 4), and cable (Figure 4, Item 2) from vehicle. Discard locknut.

1

4
Figure 4. END OF TASK CLEANING

3

2
Cold Start Device Removal.

M0251105

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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0051

INSTALLATION 1. 2. Install cable by positioning through opening on back wall of operator's compartment and through opening on instrument panel. Install washer (Figure 5, Item 4), new locknut (Figure 5, Item 3), and knob (Figure 5, Item 1) to cable (Figure 5, Item 2).

1

4

3

2

M0251105

Figure 5. Cold Start Device Installation. 3. 4. Install clamp (Figure 6, Item 4), bracket (Figure 6, Item 2), two capscrews (Figure 6, Item 3), and nuts (Figure 6, Item 1) on vehicle. Install bracket (Figure 6, Item 6), two capscrews (Figure 6, Item 7), and nuts (Figure 6, Item 8) on vehicle.

1

2
3 8
7

4

6

5
M0002105

Figure 6. Cold Start Device Installation.

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0051

INSTALLATION - Continued

NOTE
Atomizer opening at end of fitting must point straight up when installed in cylinder head. 5. Install fitting (Figure 7, Item 2) and tube (Figure 7, Item 3) to cylinder head (Figure 7, Item 1).

1

2

3

M0249105

Figure 7.

Cold Start Device Installation.

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TM 5-3810-305-23

0051

INSTALLATION - Continued 6. 7. 8. Install valve (Figure 8, Item 3), bracket (Figure 8, Item 5), two capscrews (Figure 8, Item 4), and nuts (Figure 8, Item 6) to bracket. Install elbow (Figure 8, Item 7) to valve (Figure 8, Item 3). Connect tube fitting (Figure 8, Item 8) to elbow (Figure 8, Item 7).

NOTE
Cable knob inside cab must be down when connecting cable to valve. 9. 10. 11. 12. Insert cable end into lever opening on valve (Figure 8, Item 3). Install clamp (Figure 8, Item 2) and screw (Figure 8, Item 10) to secure cable (Figure 8, Item 1). Position lever on valve to up position until just before lever springs back. Tighten screw (Figure 8, Item 9) to secure cable end (Figure 8, Item 1). Check that valve lever can perform full operating stroke.

1

2

3

4

5 10 9 8 7 6
M0248105

Figure 8. Cold Start Device Installation. 13. Install cold start cylinder, if equipped.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0051-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

TM 5-3810-305-23

0052

FIELD MAINTENANCE THROTTLE CONTROL MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter (WP 0172, Table 1, Item 154) Qty: 2 Pin, Spring (WP 0172, Table 1, Item 152) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Strap, Tiedown, Electrical Component (WP 0170, Table 1, Item 71) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 4 References WP 0054 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

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TM 5-3810-305-23

0052

REMOVAL 1. 2. 3. 4. Slide open engine cover. Remove nut (Figure 1, Item 11) and disconnect throttle cable (Figure 1, Item 1) from fuel injection pump (Figure 1, Item 12). Remove two nuts (Figure 1, Item 8), washers (Figure 1, Item 6), capscrews (Figure 1, Item 4), clamp (Figure 1, Item 3), and shim (Figure 1, Item 5) from throttle cable (Figure 1, Item 1). Remove two nuts (Figure 1, Item 10), lockwashers (Figure 1, Item 9), capscrews (Figure 1, Item 7), and bracket (Figure 1, Item 2) from vehicle. Discard lockwashers.

3 1 2

4

12 11 5 10 9 8 7 6
M0539105

Figure 1. Throttle Control Removal. 5. Cut and discard tiedown straps (Figure 2, Item 1) as required.

1

M0540105

Figure 2. Throttle Control Removal.

0052-2

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TM 5-3810-305-23

0052

REMOVAL - Continued 6. Remove nut (Figure 3, Item 2), washer (Figure 3, Item 3), clamp (Figure 3, Item 1) and detach throttle cable (Figure 3, Item 4) from vehicle.

2 1 3

4
Figure 3. 7. Throttle Control Removal.

M0541105

Remove two nuts (Figure 4, Item 5), washers (Figure 4, Item 4), lockwashers (Figure 4, Item 3), cover (Figure 4, Item 1), and washers (Figure 4, Item 2) from vehicle. Discard lockwashers.

1

5 4 3

2

M0542105

Figure 4.

Throttle Control Removal.

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TM 5-3810-305-23

0052

REMOVAL - Continued 8. Remove cotter pin (Figure 5, Item 5) and pin (Figure 5, Item 4) from end yoke (Figure 5, Item 3) and bell crank (Figure 5, Item 6). Discard cotter pin.

NOTE
DO NOT remove end yoke from throttle cable unless necessary. If removal is necessary, mark distance from end of cable prior to removal. 9. 10. 11. 12. 13. 14. 15. 16. Loosen nut (Figure 5, Item 2), if necessary, to remove end yoke (Figure 5, Item 3). Loosen nut (Figure 5, Item 22) and disconnect throttle cable (Figure 5, Item 1) from weldment. Pull throttle cable through opening in cab. Remove spring (Figure 5, Item 7) from hook (Figure 5, Item 10) and yoke (Figure 5, Item 3). Remove nut (Figure 5, Item 8), lockwasher (Figure 5, Item 9), and hook (Figure 5, Item 10). Discard lockwasher. Remove two nuts (Figure 5, Item 13), washers (Figure 5, Item 12), and capscrews (Figure 5, Item 11). Remove two nuts (Figure 5, Item 20), washers (Figure 5, Item 19), capscrews (Figure 5, Item 16), bell crank (Figure 5, Item 6), and pedal (Figure 5, Item 21) as an assembly. Remove bearing unit (Figure 5, Item 14) from pedal (Figure 5, Item 21). Remove two roll pins (Figure 5, Item 15), pedal (Figure 5, Item 21), bracket (Figure 5, Item 17), and bushing (Figure 5, Item 16) from bell crank (Figure 5, Item 6). Discard roll pins.

1 21 22

2

3

4 5 6

7

20 19 18 17 16 14 15 12 13 11 8 10 9
M0544105

Figure 5. Throttle Control Removal.

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TM 5-3810-305-23

0052

REMOVAL - Continued 17. Loosen nut (Figure 6, Item 1) and remove capscrew (Figure 6, Item 2) and nut, only if necessary.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install nut (Figure 6, Item 1) and capscrew (Figure 6, Item 2) and tighten nut to secure, if removed.

2 1

M0545105

Figure 6.

Throttle Control Maintenance.

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TM 5-3810-305-23

0052

INSTALLATION - Continued 2. 3. 4. 5. 6. 7. 8. 9. 10. Install pedal (Figure 7, Item 21), bushing (Figure 7, Item 16), bracket (Figure 7, Item 17), and two new roll pins (Figure 7, Item 15) on bell crank (Figure 7, Item 6). Install bearing unit (Figure 7, Item 14) on pedal (Figure 5, Item 21). Install bell crank (Figure 7, Item 6) and pedal (Figure 8, Item 21) as an assembly and secure with two capscrews (Figure 8, Item 16), washers (Figure 7, Item 19), and nuts (Figure 7, Item 20). Install two capscrews (Figure 7, Item 11), washers (Figure 7, Item 12), and nuts (Figure 7, Item 13). Install hook (Figure 7, Item 10), new lockwasher (Figure 7, Item 9) and nut (Figure 7, Item 8). Install spring (Figure 7, Item 7) on yoke (Figure 7, Item 3) and hook (Figure 7, Item 10). Install throttle cable (Figure 7, Item 1) and push through opening in cab. Position throttle cable in weldment and tighten nut (Figure 7, Item 22). Install end yoke (Figure 7, Item 3), if removed, and secure with nut (Figure 7, Item 2). Install to distance as marked. Install pin (Figure 7, Item 4) and new cotter pin (Figure 7, Item 5) to attach bell crank (Figure 7, Item 6) and end yoke (Figure 7, Item 3).

1 21 22

2

3

4 5 6

7

20 19 18 17 16

14 15

12 13 11

8 10 9
M0544105

Figure 7. Throttle Control Installation.

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TM 5-3810-305-23

0052

INSTALLATION - Continued 11. Install two washers (Figure 8, Item 2), cover (Figure 8, Item 1), two new lockwashers (Figure 8, Item 3), washers (Figure 8, Item 4), and nuts (Figure 8, Item 5).

1

5 4 3

2

M0542105

Figure 8. 12.

Throttle Control Installation.

Install clamp (Figure 9, Item 3), washer (Figure 9, Item 2), and nut (Figure 9, Item 1) on vehicle.

Figure 9.

Throttle Control Installation.

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TM 5-3810-305-23

0052

INSTALLATION - Continued 13. Install new tiedown straps (Figure 10, Item 1) as required.

1

M0540105

Figure 10. Throttle Control Installation.

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TM 5-3810-305-23

0052

INSTALLATION - Continued 14. 15. Install bracket (Figure 11, Item 2), two capscrews (Figure 11, Item 7), new lockwashers (Figure 11, Item 9), and nuts (Figure 11, Item 10) on throttle cable (Figure 11, Item 1). Install shim (Figure 11, Item 5), clamp (Figure 11, Item 3), two capscrews (Figure 11, Item 4), washers (Figure 11, Item 6), and nuts (Figure 11, Item 8) to secure throttle cable (Figure 11, Item 1) to bracket (Figure 12, Item 2). Connect throttle cable (Figure 12, Item 1) to fuel injection pump (Figure 12, Item 12). Install nut (Figure 12, Item 11). Check throttle cable adjustment.

16. 17.

3 1 2

4

12 11 5 10 9 8 7 6
M0539105

Figure 11. END OF TASK

Throttle Control Installation.

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TM 5-3810-305-23

0052

ADJUSTMENT

NOTE
Throttle control adjustment will require two people to make the adjustment. 1. 2. Release nut (Figure 12, Item 2) on stop capscrew (Figure 12, Item 3) and screw all the way in. Adjust cable (Figure 12, Item 1) and linkage so that engine injection pump lever has full stop to stop travel. If full travel is not obtained, jam nuts on pedal end of cable conduit on cable end fittings must be adjusted to increase travel. Check cable (Figure 12, Item 1) to ensure that threads on cable ends are not entering wiper seals on ends of cable conduit. If one does, ball joint and yoke on cable ends must be readjusted to move threads on cable core further away from that wiper seal. Adjust pedal stop capscrew (Figure 12, Item 3) on floor of cab by loosening the nut (Figure 12, Item 2) and screwing capscrew in or out. Pedal should rest against stop capscrew (Figure 12, Item 3) just as arm on fuel injection pump touches high idle stop. Hold capscrew (Figure 12, Item 3) in position and tighten nut (Figure 12, Item 2). Check cable (Figure 12, Item 1) for free travel. If adjustment of low idle is required, loosen nut (Figure 12, Item 4) and turn capscrew (Figure 12, Item 5) to obtain required rpm. Tighten nut. Slide engine cover closed.

3.

4. 5. 6. 7. 8. 9.

1 2 5 3

4
M0547105

Figure 12. END OF TASK

Throttle Control Adjustment.

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TM 5-3810-305-23

0052

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0053

FIELD MAINTENANCE EXHAUST SYSTEM ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 148) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 14) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Engine hood support removed (WP 0118)

REMOVAL 1. Remove four nuts (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and capscrews (Figure 1, Item 5) from bracket (Figure 1, Item 1). Discard lockwashers.

1

2 3 5
Figure 1.

4

M0292105

Exhaust System Removal.

0053-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00059)

TM 5-3810-305-23

0053

REMOVAL - Continued 2. 3. 4. 5. Remove four capscrews (Figure 2, Item 2) and exhaust tube (Figure 2, Item 3) from exhaust manifold (Figure 2, Item 5). Remove gasket (Figure 2, Item 4) from exhaust manifold (Figure 2, Item 5). Remove all gasket material from mounting surfaces. Discard gasket. Remove complete exhaust system from vehicle. Remove two nuts (Figure 2, Item 7), capscrews (Figure 2, Item 6), and clamp (Figure 2, Item 8) from muffler (Figure 2, Item 1) and exhaust tube (Figure 2, Item 3).

1

2

3

4

5

8 7 6

M0293105

Figure 2. Exhaust System Removal.

0053-2

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TM 5-3810-305-23

0053

REMOVAL - Continued 6. Remove two nuts (Figure 3, Item 1), lockwashers (Figure 3, Item 2), clamp (Figure 3, Item 3), and exhaust tube (Figure 3, Item 5) from end of muffler (Figure 3, Item 4). Discard lockwashers.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install exhaust tube (Figure 3, Item 5) to end of muffler (Figure 3, Item 4) with clamp (Figure 3, Item 3), two new lockwashers (Figure 3, Item 2), and nuts (Figure 3, Item 1). Do not tighten at this time.

1,2

3

4

5

M0294105

Figure 3.

Exhaust System Maintenance.

0053-3

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TM 5-3810-305-23

0053

INSTALLATION - Continued 2. 3. 4. Install exhaust tube (Figure 4, Item 3) to muffler (Figure 4, Item 1) with clamp (Figure 4, Item 8), two capscrews (Figure 4, Item 6), and nuts (Figure 4, Item 7). Position complete exhaust system on vehicle. Install new gasket (Figure 4, Item 4) between exhaust manifold (Figure 4, Item 5) and exhaust tube (Figure 4, Item 3). Secure with four capscrews (Figure 4, Item 2). Torque capscrews to 32 ft-lb (43 N•m).

1

2

3

4

5

8 7
Figure 4.

6
Exhaust System Installation.

M0293105

0053-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00059)

TM 5-3810-305-23

0053

INSTALLATION - Continued 5. Install four capscrews (Figure 5, Item 5), washers (Figure 5, Item 4), new lockwashers (Figure 5, Item 3), and nuts (Figure 5, Item 2) to bracket (Figure 5, Item 1).

1

2 3 5
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install engine hood support (WP 0118). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).

4

M0292105

Exhaust System Installation.

END OF TASK END OF WORK PACKAGE

0053-5/6 blank

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TM 5-3810-305-23

0054

FIELD MAINTENANCE RADIATOR AND OIL COOLER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Antifreeze (WP 0170, Table 1, Item 2) Qty: 1 Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 1/4 Inch (WP 0172, Table 1, Item 110) Qty: 8 References WP 0162 Equipment Condition Upperstructure rotated 90 degrees out of the way (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine sliding hood removed (WP 0118) Drive belt removed (WP 0059) Alternator removed (WP 0062)

0054-1

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TM 5-3810-305-23

0054

REMOVAL

WARNING

Cooling system is pressurized. Use extreme caution and proper protection when removing radiator cap after operating temperature is reached. Steam and hot gases will be escaping through the radiator cap; avoid being burned by these escaping gases. When removing cap, loosen it slowly to the left, then pause a moment. Continue to turn cap until it can be removed. Failure to follow this warning may cause death or injury to personnel. 1. 2. 3. Position drain pan (28 qt [26.50 L] minimum capacity). Remove radiator cap (Figure 1, Item 1) and open drain valve (Figure 1, Item 2). Allow coolant to drain.

1

2

M0074105

Figure 1.

Radiator and Oil Cooler Removal.

0054-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

REMOVAL - Continued

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 4. Turn dipstick cap 1/4 turn to safety notch.

NOTE
• Tag all hose and tube assemblies before disconnecting to aid in installation. • Cap and plug all hoses, tubes, and ports to reduce fluid leakage and system contamination. • Remove caps, plugs, and tags prior to installation. 5. Disconnect hose (Figure 2, Item 1) and hose (Figure 2, Item 3) on front of oil cooler (Figure 2, Item 2).

2

3 1
M0075105

Figure 2.

Radiator and Oil Cooler Removal.

0054-3

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TM 5-3810-305-23

0054

REMOVAL - Continued 6. Remove two clamps (Figure 3, Item 1), upper hose (Figure 3, Item 2), two clamps (Figure 3, Item 3), and lower hose (Figure 3, Item 4) from radiator and engine.

1

3

2

4

3

1
Figure 3. Radiator and Oil Cooler Removal.

M0076105

0054-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

REMOVAL - Continued 7. 8. Remove overflow hose (Figure 4, Item 1) from clips on shroud (Figure 4, Item 2). Remove eight capscrews (Figure 4, Item 5), lockwashers (Figure 4, Item 4), and washers (Figure 4, Item 3) from shroud (Figure 4, Item 2). Remove and support shroud on engine. Discard lockwashers.

1

2

3,4,5

M0079105

Figure 4.

Radiator and Oil Cooler Removal.

0054-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

REMOVAL - Continued 9. 10. Remove two capscrews (Figure 5, Item 4) that attach rod ends (Figure 5, Item 5) on each side of radiator. Remove two nuts (Figure 5, Item 1), spacers (Figure 5, Item 2), and rod assembly (Figure 5, Item 3).

5 4

3

2 1
Figure 5. Radiator and Oil Cooler Removal.

M0080105

0054-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

REMOVAL - Continued 11. Remove two mounts (Figure 6, Item 6), retainers (Figure 6, Item 5), nuts (Figure 6, Item 4), studs (Figure 6, Item 3), and nuts (Figure 6, Item 2) from rod ends (Figure 6, Item 1).

Figure 6. 12.

Radiator and Oil Cooler Removal.

Remove two nuts (Figure 7, Item 2) and spacers (Figure 7, Item 1) from studs on bottom of radiator under frame.

2

1
Figure 7. Radiator and Oil Cooler Removal.

M0082105

0054-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

REMOVAL - Continued

WARNING

Weight of radiator and oil cooler assembly is approximately 300 lb (136 kg). Use adequate lifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury to death to personnel. 13. 14. Install two capscrews (Figure 8, Item 2) in radiator and oil cooler assembly (Figure 8, Item 1). Attach suitable sling to two capscrews (Figure 8, Item 2) and using lifting device, carefully lift radiator and oil cooler assembly (Figure 8, Item 1) upward and away from frame.

1

2

M0083105

Figure 8.

Radiator and Oil Cooler Removal.

0054-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

REMOVAL - Continued 15. Remove shroud (Figure 9, Item 1) and two mounts (Figure 9, Item 2) from engine and frame.

1

2

M0084105

Figure 9. END OF TASK

Radiator and Oil Cooler Removal.

0054-9

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TM 5-3810-305-23

0054

DISASSEMBLY 1. Position radiator on suitable work surface and remove two capscrews (Figure 10, Item 6), drain valve (Figure 10, Item 5), eight capscrews (Figure 10, Item 8), washers (Figure 10, Item 9), brackets (Figure 10, Items 3 and 7), and oil cooler (Figure 10, Item 1) from radiator. Remove plug (Figure 10, Item 4) and overflow tube (Figure 10, Item 2), if necessary, for repair of radiator.

2.

END OF TASK CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Clean radiator interior and exterior with water and dry with compressed air. Cap oil cooler ports to prevent contamination. Clean exterior with water and dry with compressed air. Clean all other parts.

END OF TASK INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect hoses for deterioration. Inspect radiator for leaks in seams and tubes. Inspect all other parts.

END OF TASK ASSEMBLY 1. 2. If removed, install overflow tube (Figure 10, Item 2) and plug (Figure 10, Item 4) from radiator. Install oil cooler (Figure 10, Item 1), brackets (Figure 10, Items 3 and 7), eight washers (Figure 10, Item 9), capscrews (Figure 10, Item 8), drain valve (Figure 10, Item 5), and two capscrews (Figure 10, Item 6) to radiator.

0054-10

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TM 5-3810-305-23

0054

ASSEMBLY - Continued

2 3 1

9

4 8 7 6 5
Figure 10. END OF TASK Radiator and Air Cooler Assembly.
M0085105

0054-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

INSTALLATION 1. Support shroud (Figure 11, Item 1) on engine and install two mounts (Figure 11, Item 2) on frame.

1

2

M0084105

Figure 11. Radiator and Air Cooler Installation.

0054-12

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TM 5-3810-305-23

0054

INSTALLATION - Continued

WARNING

Weight of radiator and oil cooler assembly is approximately 300 lb (136 kg). Use adequate lifting device to lift and support radiator and oil cooler. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury to death to personnel. 2. 3. Using suitable hoist and sling, attach sling to two capscrews (Figure 12, Item 1) and carefully position radiator and cooler assembly (Figure 12, Item 2) in frame. Remove sling and two capscrews (Figure 12, Item 2) from radiator and oil cooler assembly (Figure 12, Item 1).

1

2

M0083105

Figure 12.

Radiator and Air Cooler Installation.

0054-13

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TM 5-3810-305-23

0054

INSTALLATION - Continued 4. Install two spacers (Figure 13, Item 1) and nuts (Figure 14, Item 2) to studs on bottom of radiator.

2

1
Figure 13. Radiator and Air Cooler Installation.

M0082105

5.

Install nut (Figure 14, Item 4), retainer (Figure 14, Item 5), and mounts (Figure 14, Item 6) on one end of stud (Figure 15, Item 3), and nut (Figure 14, Item 2), and rod end (Figure 14, Item 1) on other end of stud.

Figure 14. Radiator and Air Cooler Installation.

0054-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

INSTALLATION - Continued 6. 7. Install rod assembly (Figure 15, Item 3) and secure with two spacers (Figure 15, Item 2) and nuts (Figure 15, Item 1). Secure two rod ends (Figure 15, Item 5) to radiator with capscrews (Figure 15, Item 4).

5 4

3

2 1
Figure 15. Radiator and Air Cooler Installation.

M0080105

0054-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00060)

TM 5-3810-305-23

0054

INSTALLATION - Continued 8. 9. Install shroud (Figure 17, Item 2), eight washers (Figure 17, Item 3), new lockwashers (Figure 17, Item 4), and capscrews (Figure 17, Item 5) to radiator. Install overflow hose (Figure 17, Item 1) to clips on shroud.

1

2

3,4,5

M0079105

Figure 16. Radiator and Air Cooler Installation.

0054-16

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TM 5-3810-305-23

0054

INSTALLATION - Continued 10. 11. Install lower hose (Figure 17, Item 4) and secure with two clamps (Figure 17, Item 3). Install upper hose (Figure 17, Item 2) and secure with two clamps (Figure 17, Item 1).

1

3

2

4

3

1
Figure 17. 12. Radiator and Air Cooler Installation.

M0076105

Connect hose (Figure 18, Item 3) and hose (Figure 18, Item 1) to front of oil cooler (Figure 18, Item 2).

2

3 1
M0075105

Figure 18.

Radiator and Air Cooler Installation.

0054-17

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TM 5-3810-305-23

0054

INSTALLATION - Continued 13. 14. 15. 16. 17. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Close dipstick cap. Close drain valve (Figure 19, Item 2). Fill radiator with recommended antifreeze solution to proper level. Install radiator cap (Figure 19, Item 1).

1

2

M0074105

Figure 19. Radiator and Air Cooler Installation. END OF TASK

0054-18

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TM 5-3810-305-23

0054

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install alternator (WP 0062). Install drive belt (WP 0059). Install engine sliding hood (WP 0118). Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Check for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0054-19/20 blank

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TM 5-3810-305-23

0055

FIELD MAINTENANCE DEFROSTER FAN MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 3 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

0055-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

TM 5-3810-305-23

0055

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. 1. 2. 3. Disconnect wire assembly (Figure 1, Item 4). Remove three bolts (Figure 1, Item 1) and lockwashers (Figure 1, Item 2) from defroster fan assembly (Figure 1, Item 3). Discard lockwashers. Remove defroster fan assembly (Figure 1, Item 3) from vehicle.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
Install wire as tagged during removal. 1. 2. 3. Install defroster fan assembly (Figure 1, Item 3) on vehicle. Install three new lockwashers (Figure 1, Item 2) and bolts (Figure 1, Item 1) on defroster fan assembly (Figure 1, Item 3). Connect wire assembly (Figure 1, Item 4).

0055-2

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0055

INSTALLATION - Continued

1,2

3

4
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Defroster Fan Maintenance.

M0527105

END OF TASK END OF WORK PACKAGE

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0056

FIELD MAINTENANCE THERMOSTAT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 149) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Thermostat, Flow Con (WP 0172, Table 1, Item 81) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Coolant drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Drive belt removed (WP 0059) Alternator removed (WP 0062) Upper radiator hose removed (WP 0054)

0056-1

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0056

REMOVAL 1. Remove three capscrews (Figure 1, Item 3), thermostat housing (Figure 1, Item 2), gasket (Figure 1, Item 4), and lifting bracket (Figure 1, Item 1) from engine (Figure 1, Item 5). Remove remaining gasket material from engine. Discard gasket.

1

2 3

4 5

M0296105

Figure 1. Thermostat Removal. 2. Remove thermostat (Figure 2, Item 2) from thermostat housing (Figure 2, Item 1). Discard thermostat.

1 2

M0297105

Figure 2. Thermostat Removal. END OF TASK

0056-2

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0056

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Make sure vent notch is open and free from corrosion.

END OF TASK INSTALLATION 1. Install new thermostat (Figure 3, Item 1) in thermostat housing (Figure 3, Item 2) aligning tang up with notch.

2 1

M0298105

Figure 3.

Thermostat Installation.

0056-3

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0056

INSTALLATION - Continued 2. Install lifting bracket (Figure 4, Item 1), new gasket (Figure 4, Item 4), thermostat housing (Figure 4, Item 2), and three capscrews (Figure 4, Item 3). Tighten three capscrews to 18 ft-lb (24 N•m).

1

2 3

4 5

M0296105

Figure 4. Thermostat Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install upper radiator hose (WP 0054). Install alternator (WP 0062). Install drive belt (WP 0059). Connect battery cables (WP 0076). Fill radiator with coolant (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Inspect for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0057

FIELD MAINTENANCE WATER INLET CONNECTION MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Packing, Preformed (WP 0172, Table 1, Item 57) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom is horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Coolant drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Drive belt removed (WP 0059) Alternator removed (WP 0062) Lower radiator hose removed (WP 0054)

0057-1

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0057

REMOVAL Remove three capscrews (Figure 1, Item 1), water inlet connection (Figure 1, Item 2), and o-ring (Figure 1, Item 3) from engine. Discard o-ring.

1

2

3
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK Water Inlet Connection Removal.

M0299105

0057-2

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0057

INSTALLATION Install new o-ring (Figure 2, Item 3), water inlet connection (Figure 2, Item 2), and three capscrews (Figure 2, Item 1).

1

2

3
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install lower radiator hose (WP 0054). Install alternator (WP 0062). Install drive belt (WP 0059). Connect battery cables (WP 0076). Fill radiator with coolant (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Check for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10). Water Inlet Connection Installation.

M0299105

END OF TASK END OF WORK PACKAGE

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0058

FIELD MAINTENANCE WATER PUMP MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts O-Ring (WP 0172, Table 1, Item 59) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Coolant drained (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Drive belt removed (WP 0059)

REMOVAL 1. 2. Remove two capscrews (Figure 1, Item 2), and water pump (Figure 1, Item 3) from engine. Remove o-ring (Figure 1, Item 1) from groove on inside of water pump (Figure 1, Item 3). Discard o-ring.

1 2

3
Figure 1. END OF TASK Water Pump Removal.

M0300105

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0058

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect impeller blades for wear or corrosion. Inspect for free rotation of water pump. Check weep hole (Figure 2, Item 1) for evidence of a leaky seal. If seal is bad, replace water pump (Figure 2, Item 2)

1 2

M0354105

Figure 2. END OF TASK

Water Pump Inspection.

0058-2

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0058

INSTALLATION 1. 2. Install new o-ring (Figure 3, Item 1) in groove on water pump (Figure 3, Item 3). Install water pump (Figure 3, Item 3) and two capscrews (Figure 3, Item 2) on engine. Tighten two capscrews to 18 ft-lb (24 N•m).

1 2

3
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. Install drive belt (WP 0059). Connect battery cables (WP 0076). Fill with coolant (TM 5-3810-305-10). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Check for leaks. Place boom in resting position (TM 5-3810-305-10). Shut down engine (TM 5-3810-305-10). Water Pump Installation.

M0300105

END OF TASK END OF WORK PACKAGE

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0059

FIELD MAINTENANCE FAN DRIVE BELT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Sliding engine hood removed (WP 0118)

0059-1

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TM 5-3810-305-23

0059

REMOVAL

WARNING

• Keep hands out of path of spring-loaded tensioner. • Keep fingers from between belt and pulley. • Failure to follow these warnings may cause serious injury if tensioner slips. 1. 2. Use square hole in belt tensioner (Figure 1, Item 2) to rotate belt tensioner clockwise to release tension on fan drive belt (Figure 1, Item 1). Remove fan drive belt (Figure 1, Item 1) from vehicle.

2 1

M0007105_1

Figure 1. END OF TASK

Fan Drive Belt Removal.

0059-2

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TM 5-3810-305-23

0059

INSTALLATION 1. 2. Use square hole in belt tensioner (Figure 2, Item 2) and rotate belt tensioner clockwise to permit installation of fan drive belt (Figure 2, Item 1). Install fan drive belt (Figure 2, Item 1) around pulleys and under belt tensioner (Figure 2, Item 2).

2 1

M0007105_1

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install sliding engine hood (WP 0118).

Fan Drive Belt Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0060

FIELD MAINTENANCE COOLING FAN AND HUB ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Fixture, Arbor Press (WP 0171, Table 1, Item 1) Vise (WP 0171, Table 1, Item 44) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Grease, Molybdenum (WP 0170, Table 1, Item 27) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Solvent Cleaning Compound Type III (WP 0170, Table 1, Item 9) Qty: 1 Washer, Lock M8 (WP 0172, Table 1, Item 126) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Drive belt tensioner and idler removed (hub assembly only) (WP 0061)

REMOVAL 1. Remove four capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 1), and fan (Figure 1, Item 3) from vehicle. Discard lockwashers.

1

2

3
M0007105_2

Figure 1.

Cooling Fan Removal.

0060-1

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TM 5-3810-305-23

0060

REMOVAL - Continued 2. Remove spacer (Figure 2, Item 1) and fan pulley (Figure 2, Item 2) from vehicle.

1

2
M0008105

Figure 2. 3.

Fan Pulley Removal.

Remove four capscrews (Figure 3, Item 1) and hub assembly (Figure 3, Item 2) from vehicle.

1

2

M0009105

Figure 3. END OF TASK

Fan Drive Removal.

0060-2

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0060

DISASSEMBLY 1. Secure hub assembly in suitable vise. Remove center bolt (Figure 4, Item 1) and washer (Figure 4, Item 2) from fan hub.

1

2
M0011105

Figure 4.

Hub Assembly Disassembly.

NOTE
Approximately 6 tons (5.44 metric tons) of pressure are required for the following step. 2. Press roller bearing (Figure 5, Item 1) out of hub housing.

1

M0012105

Figure 5. END OF TASK

Roller Bearing Disassembly.

0060-3

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TM 5-3810-305-23

0060

CLEANING 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean roller bearing for leakage of lubricant and make sure hub rotates freely. Clean all other parts IAW General Maintenance Instructions (WP 0162).

END OF TASK INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect roller bearing for leakage of lubricant and make sure hub rotates freely. Inspect all other parts IAW General Maintenance Instructions (WP 0162).

END OF TASK ASSEMBLY 1. Pack roller bearing (Figure 6, Item 1) with grease. Press roller bearing into fan hub housing, flush with front of housing.

1

M0012105

Figure 6.

Roller Bearing Assembly.

0060-4

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TM 5-3810-305-23

0060

ASSEMBLY - Continued 2. Install washer (Figure 7, Item 2) and center bolt (Figure 7, Item 1) in hub assembly. Tighten center bolt to 57 ft-lb (77 N•m).

1

2
M0011105

Figure 7. END OF TASK INSTALLATION 1.

Hub Assembly Assembly.

Install hub assembly (Figure 8, Item 2) on vehicle with four capscrews (Figure 8, Item 1). Tighten four capscrews to 18 ft-lb (24 N•m).

1

2

M0009105

Figure 8.

Fan Drive Installation.

0060-5

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TM 5-3810-305-23

0060

INSTALLATION - Continued 2. Install fan pulley (Figure 9, Item 1) and spacer (Figure 9, Item 2) on vehicle.

1

2
M0008105

Figure 9. Fan Pulley Installation. 3. Install fan (Figure 10, Item 3) on vehicle with four new lockwashers (Figure 10, Item 1), and capscrews (Figure 10, Item 2). Tighten capscrews to 18 ft-lb (24 N•m).

1

2

3
M0007105_2

Figure 10. Cooling Fan Installation. END OF TASK

0060-6

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0060

FOLLOW-ON MAINTENANCE 1. 2. Install drive belt tensioner and idler (WP 0061). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0061

FIELD MAINTENANCE DRIVE BELT TENSIONER AND IDLER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) References WP 0162 Equipment Condition Fan drive belt removed (WP 0059)

0061-1

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0061

REMOVAL

WARNING

• Keep hands out of path of spring-loaded tensioner. • Keep fingers from between belt and pulley. • Failure to follow these warnings may cause serious injury if tensioner slips. Remove capscrew (Figure 1, Item 2) and drive belt tensioner (Figure 1, Item 1) from engine.

1

2

M0007105_3

Figure 1. END OF TASK CLEANING

Drive Belt Tensioner Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0061-2

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0061

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION Install belt tensioner (Figure 2, Item 1) and capscrew (Figure 2, Item 2) with idler pulley hanging directly below capscrew. Tighten capscrew to 32 ft-lb (43 N•m).

1

2

M0007105_3

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install fan drive belt (WP 0059). END OF TASK END OF WORK PACKAGE

Drive Belt Tensioner Installation.

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0062

FIELD MAINTENANCE ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Fan drive belt removed (WP 0059)

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid installation. Remove tags following maintenance. 1. 2. Disconnect wires (Figure 1, Items 1 and 2) from alternator (Figure 1, Item 5). Remove two capscrews (Figure 1, Item 4) and brace (Figure 1, Item 3) from lower end of alternator (Figure 1, Item 5).

2 1 5

4

3

M0102105

Figure 1. Alternator and Mounting Bracket Assembly Removal.

0062-1

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0062

REMOVAL - Continued 3. 4. Remove mounting capscrew (Figure 2, Item 1), alternator (Figure 2, Item 5), and spacer (Figure 2, Item 4) from support (Figure 2, Item 3). Remove three capscrews (Figure 2, Item 2) and support (Figure 2, Item 3) from engine.

1

2 3 4

5
M0103105

Figure 2. Alternator and Mounting Bracket Assembly Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0062-2

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0062

INSTALLATION 1. 2. Install support (Figure 3, Item 3) and three capscrews (Figure 3, Item 2) on engine. Install spacer (Figure 3, Item 4), alternator (Figure 3, Item 5) and mounting capscrew (Figure 3, Item 1) on support (Figure 3, Item 3). Do not tighten capscrew at this time.

1

2 3 4

5
M0103105

Figure 3. Alternator and Mounting Bracket Assembly Installation. 3. 4. 5. Install brace (Figure 4, Item 3) and two capscrews (Figure 4, Item 4) at lower end of alternator (Figure 4, Item 5). Tighten two capscrews to 18 ft-lb (24 N•m). Tighten mounting capscrew (Figure 3, Item 1) to 32 ft-lb (43 N•m). Connect wires (Figure 4, Items 1 and 2) to alternator (Figure 4, Item 5).

2 1 5

4

3

M0102105

Figure 4. Alternator and Mounting Bracket Assembly Installation. END OF TASK

0062-3

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0062

FOLLOW-ON MAINTENANCE 1. 2. 3. Install fan drive belt (WP 0076). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0062-4

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TM 5-3810-305-23

0063

FIELD MAINTENANCE STARTER MOTOR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL

NOTE
Tag and identify all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect cables and wires from starting motor solenoid (Figure 1, Item 2). Remove three capscrews (Figure 1, Item 4), clip (Figure 1, Item 1) and starting motor (Figure 1, Item 3) from engine.

1

2

3 4
Figure 1. END OF TASK Starter Motor Removal.
M0115105

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TM 5-3810-305-23

0063

CLEANING

WARNING

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT directed compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Position starting motor (Figure 2, Item 3) on engine and install clip (Figure 2, Item 1) and three capscrews (Figure 2, Item 4). Tighten capscrews to 32 ft-lb (43 N•m). Connect wires and cables to starting motor solenoid (Figure 2, Item 2).

1

2

3 4
Figure 2. END OF TASK Starter Motor Assembly.
M0115105

0063-2

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TM 5-3810-305-23

0063

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Check starter operation. Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0064

FIELD MAINTENANCE NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Equipment Condition (cont.) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122)

0064-1

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TM 5-3810-305-23

0064

REMOVAL 1. 2. 3. 4. Remove two wires (Figure 1, Items 3 and 6) from neutral safety switch (Figure 1, Item 2). Remove two wires (Figure 1, Items 4 and 5) from reverse warning switch (Figure 1, Item 1). Remove neutral safety switch (Figure 1, Item 2) from transmission. Remove reverse warning switch (Figure 1, Item 1) from transmission.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. Install reverse warning switch (Figure 1, Item 1). Install neutral safety switch (Figure 1, Item 2). Connect wires (Figure 1, Items 4 and 5) to reverse warning switch (Figure 1, Item 1). Connect wires (Figure 1, Items 3 and 6) to neutral safety switch (Figure 1, Item 2).

2

1

6

5

4 3

M2100105

Figure 1. Warning Switches Maintenance. END OF TASK

0064-2

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TM 5-3810-305-23

0064

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (WP 0122). Connect battery cables (WP 0076). Check neutral safety switch and backup reverse warning switch operation (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0064-3/4 blank

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TM 5-3810-305-23

0065

FIELD MAINTENANCE FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine hood removed (WP 0118)

0065-1

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TM 5-3810-305-23

0065

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid installation. Remove tags following maintenance. 1. Disconnect pressure switch wire (Figure 1, Item 5) and transducer wire (Figure 1, Item 17) from transducer (Figure 1, Item 4).

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs and tags following maintenance. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect two hose fittings (Figure 1, Items 10 and 18) from elbow adapters (Figure 1, Items 9 and 19) on transducer (Figure 1, Item 4). Disconnect hose fitting (Figure 1, Item 16) from elbow adapter (Figure 1, Item 13) and remove hose (Figure 1, Item 11) from vehicle. Disconnect hose fitting (Figure 1, Item 14) from straight adapter (Figure 1, Item 15) and remove hose (Figure 1, Item 12) from vehicle. Remove two nuts (Figure 1, Item 20), capscrews (Figure 1, Item 3), clamps (Figure 1, Item 7), and transducer (Figure 1, Item 4) from plate (Figure 1, Item 2). Remove two elbow adapters (Figure 1, Items 9 and 19) from transducer (Figure 1, Item 4). Remove pressure switch (Figure 1, Item 6) from tee adapter (Figure 1, Item 8). Remove tee adapter (Figure 1, Item 8) from transducer (Figure 1, Item 4). Remove two capscrews (Figure 1, Item 1) and plate (Figure 1, Item 2) from vehicle.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00071)

TM 5-3810-305-23

0065

INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Install plate (Figure 1, Item 2) and two capscrews (Figure 1, Item 1) on vehicle. Install tee adapter (Figure 1, Item 8) on transducer (Figure 1, Item 4). Install pressure switch (Figure 1, Item 6) on tee adapter (Figure 1, Item 8). Install two elbow adapters (Figure 1, Items 19 and 9) on transducer (Figure 1, Item 4). Install two nuts (Figure 1, Item 20), capscrews (Figure 2, Item 3), clamps (Figure 1, Item 7), and transducer (Figure 1, Item 4) to plate (Figure 1, Item 2). Install hose (Figure 1, Item 12) to vehicle and connect hose fitting (Figure 1, Item 14) to straight adapter (Figure 1, Item 15). Install hose (Figure 1, Item 11) to vehicle and connect hose fitting (Figure 1, Item 16) to elbow adapter (Figure 1, Item 13). Connect two hose fittings (Figure 1, Items 18 and 10) to elbow adapters (Figure 1, Items 9 and 19) on transducer (Figure 2, Item 4). Connect pressure switch wire (Figure 1, Item 5) and transducer wire (Figure 1, Item 17) to transducer.

2 1

3

4

5

6

7

8

9

10

11 12 19 18 17 16

20

15

14

13

M0264105

Figure 1. Fuel Pressure Switch and Transducer Installation. END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00071)

TM 5-3810-305-23

0065

FOLLOW-ON MAINTENANCE 1. 2. 3. Install engine hood (WP 0118). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0066

FIELD MAINTENANCE DASH PANEL GAGES AND SWITCHES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking He M6 (WP 0172, Table 1, Item 138) Qty: 1 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 6 References WP 0015 References (cont.) WP 0068 WP 0124 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

CAUTION
When removing dash, care must be used to avoid damage to electrical wires attached to back of gages.

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0066

REMOVAL - Continued

Dash Panel 1. 2. 3. 4. 5. Remove six bolts (Figure 1, Item 1), six lockwashers (Figure 1, Item 2) and washers (Figure 1, Item 3) from dash panel (Figure 1, Item 7). Discard lockwashers. Loosen jam nut (Figure 1, Item 5) and remove cold start knob (Figure 1, Item 4) from dash panel (Figure 1, Item 7). Remove jam nut (Figure 1, Item 5) and cable locknut (Figure 1, Item 6). Pull cold start cable out of dash panel (Figure 1, Item 7). Discard locknut. Disconnect two plastic cannon-style electrical connectors under right-hand corner of dash panel (Figure 1, Item 7). Remove screw (Figure 1, Item 9) from turn signal switch mounting band to release ground wire and clamp (Figure 1, Item 8), and remove dash panel (Figure 1, Item 7) assembly to a work bench for further disassembly.

2 1,2,3 3

4

6 5 7 9 8
M0500105

Figure 1. Dash Panel Removal.

NOTE
Tag wires to aid installation. 6. 7. 8. 9. 10. 11. 12. 13. 14. Disconnect wires (Figure 2, Item 9) from back of gage and light. Remove two nuts (Figure 2, Item 15), washers (Figure 2, Item 14), and bracket (Figure 2, Item 13) from dash panel (Figure 2, Item 1). Pull gage (Figure 2, Item 8) out of dash panel (Figure 2, Item 1). Remove light bulb assembly (Figure 2, Item 12) from gage (Figure 2, Item 8). Remove filter (Figure 2, Item 11) from light bulb (Figure 2, Item 12). Push down and twist light bulb (Figure 2, Item 12) to remove from socket (Figure 2, Item 10). If necessary, use same procedure to remove remaining five gages. Disconnect two wires (Figure 2, Item 7) and remove nut (Figure 2, Item 2) and internal tooth washer (Figure 2, Item 3) from dash panel (Figure 2, Item 1). Pull light socket (Figure 2, Item 6) through dash panel (Figure 2, Item 1).

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0066

REMOVAL - Continued Dash Panel - Continued 15. 16. Unscrew cover (Figure 2, Item 5), remove filter, and push and turn light bulb (Figure 2, Item 4) to remove from socket (Figure 2, Item 6). Follow same procedure to remove remaining two dash lights, if necessary.

1

2,3,4,5

6

7

8 9

15

14 13 12 11 10
M0501105

Figure 2. 17. 18.

Dash Panel Removal.

Hold socket (Figure 3, Item 2) and remove nut (Figure 3, Item 1). Pull socket through back of dash panel (Figure 3, Item 5) and remove washer (Figure 3, Item 3). Unscrew red lens cap and pull bulb (Figure 3, Item 4) from back of lens cap.

2 1

3

4 5

M0502105

Figure 3.

Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued Dash Panel - Continued 19. Push out through rear of dash panel (Figure 4, Item 1).

NOTE
Tag wires to aid installation. 20. 21. 22. Disconnect wires (Figure 4, Item 2) from back of horn button (Figure 4, Item 4). Loosen nut (Figure 4, Item 3) on back of horn button (Figure 4, Item 4) and unscrew rubber cover (Figure 4, Item 5). Push out through rear of dash panel (Figure 4, Item 1).

5 4 3 2

1
M0503105

Figure 4. Dash Panel Removal.

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0066

REMOVAL - Continued Dash Panel - Continued

NOTE
Tag wires to aid installation. 23. 24. Unscrew plastic retaining nut (Figure 5, Item 3) and push speedometer alarm (Figure 5, Item 2) through dash panel (Figure 5, Item 5). Disconnect wires (Figure 5, Item 1) from speedometer (Figure 5, Item 4).
2,3 2,3 (HIDDE4 ) N

4
5

1 1

M0504105

Figure 5.

Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued

Side Sloping Dash Panel

NOTE
It is not necessary to remove side sloping panel to remove switches. Tag wires to aid installation. 1. 2. 3. Remove screw (Figure 6, Item 2) from knob (Figure 6, Item 3). Pull knob off ignition switch (Figure 6, Item 1) and remove nut (Figure 6, Item 4). Pull ignition switch (Figure 6, Item 1) through back of sloping dash panel (Figure 6, Item 6). Disconnect wires (Figure 6, Item 5) from switch (Figure 6, Item 1).

2 1 3,4,5

6
M0505105

Figure 6.

Side Sloping Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued Side Sloping Dash Panel - Continued 4. 5. Pull knob (Figure 7, Item 5) up, remove nut (Figure 7, Item 4), washer (Figure 7, Item 3), and push switch (Figure 7, Item 6) through sloping dash panel (Figure 7, Item 1). Disconnect wires (Figure 7, Item 2) from wiper switch (Figure 7, Item 6).

1

6 5,4,3,2
M0506105

Figure 7.

Side Sloping Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued Side Sloping Dash Panel - Continued

NOTE
Tag wires to aid installation. 6. 7. 8. Pull switch up through sloping dash panel (Figure 8, Item 4). Disconnect wires (Figure 8, Item 3) from worklight (Figure 8, Item 1) and outrigger switches (Figure 8, Item 2). Follow same procedure to remove remaining outrigger switches and worklights, if necessary.

1,2,3

4

M0507105

Figure 8.

Side Sloping Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued Side Sloping Dash Panel - Continued

NOTE
Tag wires to aid installation. 9. 10. 11. 12. 13. Remove three screws (Figure 9, Item 4), three levers (Figure 9, Item 5), and four screws (Figure 9, Item 1). Push switch (Figure 9, Item 2) down through sloping dash panel (Figure 9, Item 6). Disconnect wires (Figure 9, Item 3) from master light switch (Figure 9, Item 2). Disconnect wires (Figure 9, Item 8) from back of start button (Figure 9, Item 7). Loosen nut (Figure 9, Item 9) on back of start button (Figure 9, Item 7) and unscrew rubber cover (Figure 9, Item 10). Push start button (Figure 9, Item 7) out through rear of sloping dash panel (Figure 9, Item 6).

7,8,9,10

6

1

2,3

4
5

M0508105

Figure 9.

Side Sloping Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued Side Sloping Dash Panel - Continued 14. Remove two nuts (Figure 10, Item 1), capscrew (Figure 10, Item 2), and side sloping dash panel (Figure 10, Item 3) from vehicle.

1 2

1

3

M0509105

Figure 10. Side Sloping Dash Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued

Circuit Breaker Panel

NOTE
Tag wires to aid installation. 1. 2. 3. 4. Remove four capscrews (Figure 11, Item 4) and washers (Figure 11, Item 3) from circuit breaker panel (Figure 11, Item 1). Lift circuit breaker panel (Figure 11, Item 1) up and out of frame. Remove retaining nut (Figure 11, Item 5) and push circuit breaker (Figure 11, Item 2) through circuit breaker panel (Figure 11, Item 1). Disconnect wires (Figure 11, Item 6) from circuit breakers. If necessary, remove nine remaining circuit breakers using the same procedure.

1 2 3 4

5 6
M0510105

Figure 11.

Circuit Breaker Panel Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued

Tachometer and Turn Signal

NOTE
Tag wires to aid installation. 1. 2. 3. 4. Remove two screws (Figure 12, Item 5) and lockwashers (Figure 12, Item 6) from case (Figure 12, Item 3). Slide case down wires (Figure 12, Item 4). Discard lockwashers. Disconnect wires (Figure 12, Item 4) from tachometer (Figure 12, Item 2). Disconnect wires (Figure 12, Item 7) from turn signal (Figure 12, Item 1). Remove two retaining screws and turn signal (Figure 12, Item 1) from vehicle.

2 1

3,4

7

6

5
M0511105

Figure 12. Tachometer and Turn Signal Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued

Right Console 1. 2. 3. 4. 5. 6. 7. 8. Remove seat (WP 0124). Remove two capscrews, nuts (Figure 13, Item 1), and washers (Figure 13, Item 2) from cover (Figure 13, Item 18). Remove four nuts (Figure 13, Item 14) and washers (Figure 13, Item 13) from cover (Figure 13, Item 18). Remove three nuts (Figure 13, Item 11), capscrews (Figure 13, Item 9), and washers (Figure 13, Item 10) from cover (Figure 13, Item 18). Remove two capscrews (Figure 13, Item 17), lockwasher (Figure 13, Item 16), washers (Figure 13, Item 15), and cover (Figure 13, Item 18) from vehicle. Discard lockwashers. Remove four capscrews (Figure 13, Item 6) and lockwashers (Figure 13, Item 7). Lay circuit breaker panel (Figure 13, Item 8) against back cab wall. Discard lockwashers. Remove two capscrews (Figure 13, Item 3), lockwasher (Figure 13, Item 4), and washer (Figure 13, Item 5) from vehicle. Discard lockwashers. Lift right console (Figure 13, Item 12) and rotate 1/4 turn to allow access to shift control linkage.

6,7 3,4,5 1,2

8 9,10 11

18

12

15,16,17
Figure 13.

13,14
M0512105

Right Console Removal.

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TM 5-3810-305-23

0066

REMOVAL - Continued Right Console - Continued 9. 10. Remove six nuts (Figure 14, Item 2), lockwashers (Figure 14, Item 3), and capscrews (Figure 14, Item 1). Discard lockwashers. Remove three clamps (Figure 14, Item 4) and shims (Figure 14, Item 5).

NOTE
Tag cable terminals and record holes in shifter to aid in assembly. 11. Remove three cotter pins (Figure 14, Item 7) and pins (Figure 14, Item 8) from cable terminal (Figure 14, Item 6). Discard cotter pins.

1

2,3 4 5

8 7 8 7 6 7 8 6
Figure 14. Right Console Removal.
M0513105

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TM 5-3810-305-23

0066

REMOVAL - Continued Right Console - Continued 12. 13. Remove four capscrews (Figure 15, Item 6), lockwashers (Figure 15, Item 5), washer (Figure 15, Item 4), and spacer (Figure 15, Item 3) and remove shifter (Figure 15, Item 1). Discard lockwashers. Remove vehicle bubble level (Figure 15, Item 2), if necessary (WP 0068).

1

2

3

4,5,6
M0514105

Figure 15. END OF TASK CLEAN

Right Console Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0066-15

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TM 5-3810-305-23

0066

INSTALLATION Tachometer and Turn Signal 1. 2. 3. 4. 5. Position turn signal (Figure 16, Item 1) on stud and connect wires (Figure 16, Item 6). Install two retaining screws (Figure 16, Item 6) in turn signal strap and turn signal (Figure 16, Item 1). Position and tighten. Install case on wires (Figure 16, Item 3) and connect wires to tachometer (Figure 16, Item 2). Slide case up wires and install tachometer (Figure 16, Item 2) in case. Position tachometer (Figure 16, Item 2) on dash and install two new lockwashers (Figure 16, Item 5) and screws (Figure 16, Item 4).

2 1

3,4

6

5

4
M0515105

Figure 16. Tachometer and Turn Signal Installation.

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0066

INSTALLATION - Continued

Circuit Breaker Panel

NOTE
Install wires as tagged during removal. 1. 2. 3. 4. Connect wires (Figure 17, Item 6) to circuit breaker (Figure 17, Item 2). Push circuit breaker (Figure 17, Item 2) up through circuit breaker panel (Figure 17, Item 1) and install retaining nut (Figure 17, Item 5). Use same procedure to install remaining nine circuit breakers. Position circuit breaker panel and install four washers (Figure 17, Item 3) and capscrews (Figure 17, Item 4).

1 2 3 4

5 6
M0510105

Figure 17.

Circuit Breaker Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued

Side Sloping Dash Panel 1. Install slide sloping dash panel (Figure 18, Item 3), two capscrews (Figure 18, Item 2), and nuts (Figure 18, Item 1) on vehicle.

1 2

1

3

M0509105

Figure 18. Side Sloping Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued Side Sloping Dash Panel - Continued

NOTE
Install wires as tagged during removal. 2. 3. 4. 5. 6. 7. Push start button (Figure 19, Item 7) in through rear of sloping dash panel (Figure 19, Item 6). Connect wires (Figure 19, Item 8) to back of start button (Figure 19, Item 7). Screw rubber cover (Figure 19, Item 10) on back of start button (Figure 19, Item 7) and tighten nut (Figure 19, Item 9). Connect wires (Figure 19, Item 3) to master light switch (Figure 19, Item 2). Push master light switch (Figure 19, Item 2) up through panel and install four screws (Figure 19, Item 1). Install three levers (Figure 19, Item 5) on master light switch (Figure 19, Item 2) and install three screws (Figure 19, Item 4) in levers.

7,8,9,10

6

1

2,3

4
5

M0508105

Figure 19.

Side Sloping Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued Side Sloping Dash Panel - Continued

NOTE
Install wires as tagged during removal. 8. 9. Pull wires (Figure 20, Item 3) up through sloping dash panel (Figure 20, Item 4) and install on worklight or outrigger switches (Figure 20, Item 1). Push switch down through dash panel. Use same procedure to install remaining two outrigger switches (Figure 20, Item 2).

1,2,3

4

M0507105

Figure 20. Side Sloping Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued Side Sloping Dash Panel - Continued

NOTE
Install wires as tagged during removal. 10. 11. Connect wires (Figure 21, Item 2) to wiper switch (Figure 21, Item 6) and remove tags. Push switch through sloping dash panel (Figure 21, Item 1). Install washer (Figure 21, Item 3), nut (Figure 21, Item 4), and knob (Figure 21, Item 5). Tighten nut.

1

6 5,4,3,2
M0506105

Figure 21.

Side Sloping Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued Side Sloping Dash Panel - Continued

NOTE
Install wires as tagged during removal. 12. 13. Push ignition switch (Figure 22, Item 1) in through back of sloping dash panel (Figure 22, Item 6). Install nut (Figure 22, Item 4), knob (Figure 22, Item 3), and screw (Figure 22, Item 2). Connect wires (Figure 22, Item 5) to ignition switch (Figure 22, Item 1).

2 1 3,4,5

6
M0505105

Figure 22. Side Sloping Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued

Dash Panel

NOTE
Install wires as tagged during removal. 1. 2. Push speedometer alarm (Figure 23, Item 2) through dash panel (Figure 23, Item 5) and install plastic retaining nut (Figure 23, Item 3) on front of speedometer alarm. Install wires (Figure 23, Item 1) speedometer (Figure 23, Item 4).
2,3 2,3 (HIDDE4 ) N

4
5

1 1

M0504105

Figure 23.

Dash Panel Installation.

NOTE
Install wires as tagged during removal. 3. 4. Connect wires (Figure 24, Item 2) on horn button. Install nut (Figure 24, Item 3) on horn button (Figure 24, Item 4), push horn button through dash panel (Figure 24, Item 1) and install rubber covers (Figure 24, Item 5). Tighten nut.

5 4 3 2

1
M0503105

Figure 24.

Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued Dash Panel - Continued 5. 6. Install axle centering light bulb (Figure 25, Item 4) in red lens cap and install in socket (Figure 25, Item 2). Install washer (Figure 25, Item 3) and push socket (Figure 25, Item 2) through dash panel (Figure 25, Item 5). Install nut (Figure 25, Item 1).

2 1

3

4 5

M0502105

Figure 25. Dash Panel Installation.

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TM 5-3810-305-23

0066

INSTALLATION - Continued Dash Panel - Continued

NOTE
Install wires as tagged during removal. 7. 8. Installation of three dash lights: Install light bulb (Figure 26, Item 4) and filter in socket. Connect wires (Figure 26, Item 7) and push socket (Figure 26, Item 6) through dash panel (Figure 26, Item 1) and install internal tooth washer (Figure 26, Item 3) and nut (Figure 26, Item 2). Install cover (Figure 26, Item 5). Use same procedure to install remaining two dash lights. Install light bulb (Figure 26, Item 12) and filter (Figure 26, Item 11) in socket (Figure 26, Item 10). Push gage (Figure 26, Item 8) through dash panel (Figure 26, Item 1). Install bracket (Figure 26, Item 13), two washers (Figure 26, Item 14) and nuts (Figure 26, Item 15). Connect wires (Figure 26, Item 9) on gage (Figure 26, Item 8).

9. 10. 11. 12.

1

2,3,4,5

6

7

8 9

15

14 13 12 11 10
M0501105

Figure 26.

Dash Panel Installation.

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0066

INSTALLATION - Continued Dash Panel - Continued

NOTE
Install wires as tagged during removal. 13. 14. 15. 16. 17. Carefully lift and position dash (Figure 27, Item 7) over mounting holes and install screw (Figure 27, Item 9) to turn signal switch mounting band and secure clamp and ground wire (Figure 27, Item 8). Connect two plastic cannon-style electrical connectors under-hand corner of dash panel (Figure 27, Item 7). Position cold start cable in dash panel (Figure 27, Item 7). Install new cable locknut (Figure 27, Item 6), cold start knob (Figure 27, Item 4), and jam nut (Figure 27, Item 5). Install six washers (Figure 27, Item 3), new lockwashers (Figure 27, Item 2), and six bolts (Figure 27, Item 1). Test speedometer alarm (WP 0015).

2 1,2,3 3

4

6 5 7 9 8
M0500105

Figure 27. Dash Panel Installation.

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0066

INSTALLATION - Continued

Right Console 1. 2. 3. Install vehicle bubble level, if removed (WP 0068). Install shifter (Figure 28, Item 1) in right console (Figure 28, Item 2) with four spacers (Figure 28, Item 3), washers (Figure 28, Item 4), new lockwashers (Figure 28, Item 5), and capscrews (Figure 28, Item 6). Position right console (Figure 28, Item 2) in cab to allow access to shift control linkage.

1

2

3

4,5,6
M0514105

Figure 28.

Right Console Installation.

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0066

INSTALLATION - Continued Right Console - Continued 4. 5. Position cable terminal (Figure 29, Item 6) as recorded during disassembly and install three pins (Figure 29, Item 8) and new cotter pins (Figure 29, Item 7). Install three shims (Figure 29, Item 5), clamps (Figure 29, Item 4), six capscrews (Figure 29, Item 1), new lockwashers (Figure 29, Item 3), and nuts (Figure 29, Item 2).

1

2,3 4 5

8 7 8 7 6 7 8 6
Figure 29. Right Console Installation.
M0513105

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0066

INSTALLATION - Continued Right Console - Continued 6. 7. 8. Rotate right console (Figure 30, Item 12) 1/4 turn and position it in cab. Install two washers (Figure 30, Item 5), new lockwasher (Figure 30, Item 4), and capscrew (Figure 30, Item 3) on dash (Figure 30, Item 12). Install but DO NOT TIGHTEN washers (Figure 30, Item 2), capscrews and nuts (Figure 30, Item 1), cover (Figure 30, Item 18), washers (Figure 30, Item 15), new lockwashers (Figure 30, Item 16), capscrews (Figure 30, Item 17), three washers (Figure 30, Item 10), capscrews (Figure 30, Item 9), nuts (Figure 30, Item 11), four washers (Figure 30, Item 13) and nuts (Figure 30, Item 14). Tighten capscrews and nuts (Figure 30, Item 1), capscrews (Figure 30, Item 17), capscrews (Figure 30, Item 9), and nuts (Figure 30, Item 14). Install circuit breaker panel (Figure 30, Item 8), four new lockwashers (Figure 30, Item 7), and capscrews (Figure 30, Item 6). If circuit breaker panel was completely removed, refer to Circuit Breaker Panel in this work package. Install seat (WP 0124).

9. 10.

11.

6,7 3,4,5 1,2

8 9,10 11

18

12

15,16,17
Figure 30. END OF TASK

13,14
M0512105

Right Console Installation.

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0066

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect battery cables (WP 0076). Run engine until normal operating temperature is reached (TM 5-3810-305-10). Raise all outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Shut down engine (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0067

FIELD MAINTENANCE ANTI-TWO BLOCK CONTROL PANEL MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Soldering Gun (WP 0171, Table 1, Item 31) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Battery cables disconnected (WP 0076)

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance.

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0067

REMOVAL 1. 2. 3. Remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and tubes (Figure 1, Item 3) from control panel (Figure 1, Item 13). Disconnect plug (Figure 1, Item 11) from connector in cab at rear of control panel (Figure 1, Item 13). Remove control panel (Figure 1, Item 13) from vehicle.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove two bolts and disconnect two wires from BY-PASS toggle switch (Figure 1, Item 5). Remove nut, washers, and BY-PASS toggle switch (Figure 1, Item 5) from control panel (Figure 1, Item 13). Disconnect five wires from relay (Figure 1, Item 6). Remove relay from control panel (Figure 1, Item 13). Disconnect two wires from HORN (Figure 1, Item 12). Remove plastic nut and HORN (Figure 1, Item 12) from control panel (Figure 1, Item 13). Disconnect two wires from TEST switch (Figure 1, Item 10). Remove nut, washer, and TEST switch (Figure 1, Item 10) from control panel (Figure 1, Item 4). Disconnect two wires from HORN switch (Figure 1, Item 4). Remove HORN switch (Figure 1, Item 4) by pressing in on spring clips while pushing HORN switch out.

NOTE
DO NOT unsolder connections unless necessary. 10. Remove nut, washer, and WARNING light (Figure 1, Item 14) from control panel (Figure 1, Item 13).

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0067

DISASSEMBLY - Continued

1

2 3 14

4

5 6 7 8

13 12 10 11

9
M0089105

Figure 1. END OF TASK

Control Panel Maintenance.

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0067

ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install WARNING light (Figure 2, Item 14), washer, and nut to control panel (Figure 2, Item 13). Install HORN switch (Figure 2, Item 4) by pushing HORN switch in hole until spring clips lock. Connect two wires to HORN switch (Figure 2, Item 4). Install TEST switch (Figure 2, Item 10), washer, and nut to control panel (Figure 2, Item 13). Connect two wires to TEST switch (Figure 2, Item 10). Install HORN (Figure 2, Item 12) and plastic nut on control panel (Figure 2, Item 13). Connect two wires to HORN (Figure 2, Item 12). Connect five wires to relay (Figure 2, Item 6). Install BY-PASS toggle switch (Figure 2, Item 5), washers, and nut to control panel (Figure 2, Item 13). Connect two wires to BY-PASS toggle switch (Figure 2, Item 5) with two bolts.

END OF TASK INSTALLATION 1. 2. 3. Connect plug (Figure 2, Item 11) on rear of control panel (Figure 2, Item 13) to connector in cab. Install four tubes (Figure 2, Item 3), washers (Figure 2, Item 2), and bolts (Figure 2, Item 1) to control panel (Figure 2, Item 13). Install control panel (Figure 2, Item 13) to vehicle.

1

2 3 14

4

5 6 7 8

13 12 10 11

9
M0089105

Figure 2. Control Panel Maintenance. END OF TASK

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0067

FOLLOW-ON MAINTENANCE Connect battery cables (WP 0076). END OF TASK END OF WORK PACKAGE

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0068

FIELD MAINTENANCE VEHICLE BUBBLE LEVEL MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 3 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Equipment Condition (cont.) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122) Battery cables disconnected (WP 0076)

REMOVAL Remove three screws (Figure 1, Item 2), lockwashers (Figure 1, Item 3), six nuts (Figure 1, Item 4), and vehicle bubble level (Figure 1, Item 1) from vehicle. Discard lockwashers.

1

4

3

2
M0565105

Figure 1. END OF TASK

Vehicle Bubble Level Removal.

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0068

INSTALLATION

NOTE
Installation of vehicle bubble level is critical to the proper operation of vehicle and must be installed properly. 1. 2. 3. 4. 5. 6. 7. 8. 9. Lower outrigger pads and raise tires off ground. Clean machined surface of frame around swing pinion. Place a vehicle bubble level (Figure 2, Item 1) on the machined surface of frame next to swing pinion. By raising or lowering outrigger pads, level the frame in both side-to-side and front-to-rear directions. Install three screws (Figure 2, Item 2) in vehicle bubble level (Figure 2, Item 1). Install two nuts (Figure 2, Item 4) then one new lockwasher (Figure 2, Item 3) on each screw (Figure 2, Item 2). Tighten two nuts on each screw up to vehicle bubble level (Figure 2, Item 1). Position machined vehicle bubble level (Figure 2, Item 1) and start screws (Figure 2, Item 2) in mounting holes. Adjust three screws (Figure 2, Item 2) until bubble in vehicle bubble level (Figure 2, Item 1) is centered in center circle. Hold screws (Figure 2, Item 2) in place and tighten bottom nut (Figure 2, Item 4) and lockwasher (Figure 2, Item 3) down against panel. Recheck vehicle bubble level on frame and vehicle bubble level (Figure 2, Item 1).

1

4

3

2
M0565105

Figure 2. END OF TASK

Vehicle Bubble Level Installation.

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0068

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Raise all outriggers (TM 5-3810-305-10). Install deck plates (WP 0122). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0069

FIELD MAINTENANCE HORN MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect electrical wires (Figure 1, Item 5) from horn (Figure 1, Item 4). Remove locknut (Figure 1, Item 1), washer (Figure 1, Item 3), and horn (Figure 1, Item 4) from stud (Figure 1, Item 2). Discard locknut.

1,2,3

4

5
Figure 1. END OF TASK Horn Removal.

M0124105

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0069

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Install horn (Figure 2, Item 4), washer (Figure 2, Item 3), and new locknut (Figure 2, Item 1) on stud (Figure 2, Item 2). Connect electrical wires (Figure 2, Item 5) to horn (Figure 2, Item 4).

1,2,3

4

5
Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Horn Installation.

M0124105

END OF TASK END OF WORK PACKAGE

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0070

FIELD MAINTENANCE ELECTRICAL COLLECTOR RING MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, Dial, 1/4 Inch Drive, 30 in-lb (WP 0171, Table 1, Item 37) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Tape, Pressure Sensitive Adhesive - Clear (WP 0170, Table 1, Item 69) Qty: 1 References WP 0162 Equipment Condition Boom to 15 degree position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) 1

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

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0070

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. 3. Disconnect four knife connectors (Figure 1, Item 5) from under carrier at bottom of rotary manifold (Figure 1, Item 4). Disconnect four knife connectors (Figure 1, Item 2) from inside upperstructure near top of collector ring (Figure 1, Item 6). Remove two nuts (Figure 1, Item 1) and washers (Figure 1, Item 3) from cover (Figure 1, Item 7) of collector ring (Figure 1, Item 6). Remove cover.

1 7 6

2

3 4

5
M0128105

Figure 1. Electrical Collector Ring Removal.

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0070

REMOVAL - Continued 4. Remove cap nut (Figure 2, Item 1), nylon washer (Figure 2, Item 6), nylon plate (Figure 2, Item 5), capscrew (Figure 2, Item 3), and washer (Figure 2, Item 2) from cover (Figure 2, Item 4).

2 1 3 6

4 5
Figure 2. Electrical Collector Ring Removal.
M0129105

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0070

REMOVAL - Continued 5. Loosen three setscrews (Figure 3, Item 11) on bottom of collector ring core (Figure 3, Item 12). Lift collector ring base (Figure 3, Item 8) and brush assemblies (Figure 3, Item 7) off as an assembly from mounting column (Figure 3, Item 9). Remove setscrews, if necessary. Remove two of four set collars (Figure 3, Item 1), bearing (Figure 3, Item 4), and remaining two set collars from two studs (Figure 3, Item 3). Push upon lower harness (Figure 3, Item 13) to create slack. Slide collector ring core (Figure 3, Item 12) to one side and remove collector ring core from brush assemblies (Figure 3, Item 7). Remove lower harness (Figure 3, Item 13) from collector ring core (Figure 3, Item 12).

6. 7. 8.

NOTE
Record number of nylon shims used when removing brush assemblies. Also note position of color coded wires when removing brush assemblies. 9. 10. 11. 12. 13. Remove nylon shim(s) (Figure 3, Item 15) and four brush assemblies (Figure 3, Item 7) from two studs (Figure 3, Item 3). Remove four springs (Figure 3, Item 2) from brush assemblies (Figure 3, Item 7). Remove upper harness (Figure 3, Item 5) from brush assemblies (Figure 3, Item 7). Loosen two nuts (Figure 3, Item 6) and remove two studs (Figure 3, Item 3), washers (Figure 3, Item 14), and nuts from collector ring base (Figure 3, Item 8). Remove bearing (Figure 3, Item 10) from collector ring base (Figure 3, Item 8).

1 15 14

2

3 4 5

6 13 12 11 10 9 8 7
M0130105

Figure 3. Electrical Collector Ring Removal.

0070-4

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0070

REMOVAL - Continued 14. 15. Remove three capscrews (Figure 4, Item 3) and mounting column (Figure 4, Item 4) from rotary manifold (Figure 4, Item 5). Remove two capscrews (Figure 4, Item 1), washers (Figure 4, Item 6), and bracket (Figure 4, Item 2) from rotary manifold (Figure 4, Item 5).

3

4 1 2

5

6

M0131105

Figure 4. END OF TASK CLEANING

Electrical Collector Ring Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0070-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 5-3810-305-23

0070

INSTALLATION 1. 2. Install bracket (Figure 5, Item 2), two washers (Figure 5, Item 6), and capscrews (Figure 5, Item 1) on rotary manifold (Figure 5, Item 5). Install mounting column (Figure 5, Item 4) and three capscrews (Figure 5, Item 3).

3

4 1 2

5

6

M0131105

Figure 5.

Electrical Collector Ring Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 5-3810-305-23

0070

INSTALLATION - Continued 3. 4. 5. 6. Install bearing (Figure 6, Item 10) in collector ring base (Figure 6, Item 8). Install two nuts (Figure 6, Item 6) and washers (Figure 6, Item 14) on two studs (Figure 6, Item 3). Install studs in collector ring base (Figure 6, Item 8). Secure two nuts. Connect upper harness (Figure 6, Item 5) to brush assemblies (Figure 6, Item 7). Install four springs (Figure 6, Item 2) in four brush assemblies (Figure 6, Item 7).

NOTE
Use number of nylon shims recorded in removal for assembling collector ring core. Also, use the placement of color coded wires noted during removal for assembling collector ring core. 7. 8. 9. Install nylon shim(s) (Figure 6, Item 15) and four brush assembly (Figure 6, Item 7) on two studs (Figure 6, Item 3). Connect lower harness (Figure 6, Item 13) to collector ring core (Figure 6, Item 12). Install lower harness (Figure 6, Item 13) and collector ring core (Figure 6, Item 12) through collector ring base (Figure 6, Item 8). Slide collector ring core into brush assemblies (Figure 6, Item 7). Make sure brush assemblies are on correct ring. Install two of four set collars (Figure 6, Item 1), bearing (Figure 6, Item 4), and remaining two set collars on studs (Figure 6, Item 3). Install three setscrews (Figure 6, Item 11), if removed. Install collector ring core (Figure 6, Item 12) and collector ring base (Figure 6, Item 8) as an assembly on mounting column (Figure 6, Item 9). Align hole in collector ring base with bracket (Figure 6, Item 2) on rotary manifold (Figure 5, Item 5). Tighten three setscrews to 45 to 55 in-lb (5.1 to 6.2 N•m).

10. 11.

1 15 14

2

3 4 5

6 13
Figure 6.

12

11 10

9 8

7
M0130105

Electrical Collector Ring Installation.

0070-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 5-3810-305-23

0070

INSTALLATION - Continued 12. Install washer (Figure 7, Item 2), capscrew (Figure 7, Item 3), nylon plate (Figure 7, Item 5), nylon washer (Figure 7, Item 6), and cap nut (Figure 7, Item 1) on cover (Figure 7, Item 4).

2 1 3 6

4 5
Figure 7. Electrical Collector Ring Installation.
M0129105

0070-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 5-3810-305-23

0070

INSTALLATION - Continued 13. Install cover (Figure 8, Item 7). Make sure upper harness grommet fits in slot on side of cover. Install two washers (Figure 8, Item 3) and nuts (Figure 8, Item 1).

CAUTION
Secure harness so that it does not drop down around electrical collector ring. Damage to harness may result. 14. 15. Connect four knife connectors (Figure 8, Item 2) inside upperstructure. Protect connectors with shrink tubing or electrical tape. Secure harnesses together with tiedown straps. Connect four knife connectors (Figure 8, Item 5) to connector ring (Figure 8, Item 6) under carrier near rotary manifold (Figure 8, Item 4). Protect connectors with shrink tubing or electrical tape. Secure harnesses together with electrical tiedown straps.

1 7 6

2

3 4

5
M0128105

Figure 8. END OF TASK

Electrical Collector Ring Installation.

0070-9

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TM 5-3810-305-23

0070

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0071

FIELD MAINTENANCE REAR LIGHTS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 14) Qty: 4 Washer, Lock Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

1

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

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0071

REMOVAL

NOTE
• Tag and identify wires to aid in installation. • Following steps apply to both left and right hand rear light assemblies. 1. 2. 3. Disconnect electrical connectors (Figure 1, Item 7). Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), ground wire (Figure 1, Item 6), rear turn signal (Figure 1, Item 2), and washer (Figure 1, Item 3) from mounting bracket (Figure 1, Item 1). Discard lockwasher. Remove two bolts (Figure 1, Item 8), lockwashers (Figure 1, Item 9), ground wires (Figure 1, Item 10), and rear taillight (Figure 1, Item 12) from mounting bracket (Figure 1, Item 11). Discard lockwashers.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
Install wires as tagged during removal. 1. 2. 3. Install rear taillight (Figure 1, Item 12), two ground wires (Figure 1, Item 10), new lockwashers (Figure 1, Item 9), and bolts (Figure 1, Item 8) on mounting bracket (Figure 1, Item 11). Install washer (Figure 1, Item 3), rear turn signal (Figure 1, Item 2), ground wire (Figure 1, Item 6), new lockwasher (Figure 1, Item 5), and nut (Figure 1, Item 4) on mounting bracket (Figure 1, Item 1). Connect electrical connectors (Figure 1, Item 7).

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0071

INSTALLATION - Continued

2

3

1

4,5,6

7 12

11

8,9,10
M0151105

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076).

Rear Lights Maintenance.

Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0072

FIELD MAINTENANCE FRONT LIGHTS AND BRACKETS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 8 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

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0072

REMOVAL Left Front Lights and Bracket

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Tag all wires and electrical connectors to aid in installation. 1. 2. 3. 4. 5. 6. Disconnect electrical connectors (Figure 1, Items 7, 15 and 16) from blackout lamp (Figure 1, Item 3), headlight (Figure 1, Item 19), and turn signal (Figure 1, Item 2). Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), ground wire (Figure 1, Item 6), and blackout lamp (Figure 1, Item 3) from bracket (Figure 1, Item 18). Discard lockwasher. Remove nut (Figure 1, Item 8), lockwasher (Figure 1, Item 9), ground wire (Figure 1, Item 10), turn signal (Figure 1, Item 2), and washer (Figure 1, Item 1) from bracket (Figure 1, Item 18). Discard lockwasher. Remove nut (Figure 1, Item 22) and lockwasher (Figure 1, Item 21) from headlight (Figure 1, Item 19) base. Discard lockwasher. Remove headlight (Figure 1, Item 19) and washer (Figure 1, Item 20) from bracket (Figure 1, Item 18). Remove four nuts (Figure 1, Item 11), lockwashers (Figure 1, Item 12), capscrews (Figure 1, Item 13), and left front bracket (Figure 1, Item 18) from vehicle. Discard lockwashers.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect grommet (Figure 1, Item 14) and rubber bumper (Figure 1, Item 17) IAW General Maintenance Instructions (WP 0162). If damaged, replace.

END OF TASK

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0072

INSTALLATION Left Front Lights and Bracket

NOTE
Install all wires and electrical connectors as tagged during removal. 1. 2. 3. 4. 5. Install left front bracket (Figure 1, Item 18), four capscrews (Figure 1, Item 15), new lockwashers (Figure 1, Item 12), and nuts (Figure 1, Item 11) on vehicle. Install washer (Figure 1, Item 20), headlight (Figure 1, Item 19), new lockwasher (Figure 1, Item 21), and nut (Figure 1, Item 22) on bracket (Figure 1, Item 18). Install washer (Figure 1, Item 1), turn signal (Figure 1, Item 2), ground wire (Figure 1, Item 10), new lockwasher (Figure 1, Item 9), and nut (Figure 1, Item 8) on bracket (Figure 1, Item 18). Install blackout lamp (Figure 1, Item 3), ground wire (Figure 1, Item 6), new lockwasher (Figure 1, Item 5), and nut (Figure 1, Item 4) on bracket (Figure 1, Item 18). Connect electrical connectors (Figure 1, Items 7, 15, and 16) on blackout lamp (Figure 1, Item 3), headlight (Figure 1, Item 19), and turn signal (Figure 1, Item 2).

2 1

3

4,5,6

7

8,9,10 11,12,13

14

15 16 18 17

21,22

20

19

M0149105

Figure 1.

Left Front Lights and Bracket Installation.

END OF TASK

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0072

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK REMOVAL Right Front Lights and Bracket

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Tag and identify all wires and electrical connectors to aid in installation. 1. 2. 3. 4. 5. Disconnect electrical connectors (Figure 2, Items 7 and 10) from headlight (Figure 2, Item 16) and turn signal (Figure 2, Item 2). Remove nut (Figure 2, Item 4), lockwasher (Figure 2, Item 5), ground wire (Figure 2, Item 6), turn signal (Figure 2, Item 2), and washer (Figure 2, Item 3) from right front bracket (Figure 2, Item 1). Discard lockwasher. Remove nut (Figure 2, Item 11) and lockwasher (Figure 2, Item 12) from headlight (Figure 2, Item 16) base. Discard lockwasher. Remove headlight (Figure 2, Item 16) and washer (Figure 2, Item 9) from right front bracket (Figure 2, Item 1). Remove four nuts (Figure 2, Item 13), lockwashers (Figure 2, Item 14), capscrews (Figure 2, Item 15), and right front bracket (Figure 2, Item 1) from vehicle. Discard lockwashers.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect grommet and rubber bumper IAW General Maintenance Instructions (WP 0162). If damaged, replace.

END OF TASK

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0072

INSTALLATION Right Front Lights and Bracket 1. 2. 3. Install right front bracket (Figure 2, Item 1), four capscrews (Figure 2, Item 15), new lockwashers (Figure 2, Item 14), and nuts (Figure 2, Item 13) on vehicles. Install washer (Figure 2, Item 9), headlight (Figure 2, Item 16), new lockwasher (Figure 2, Item 12), and nut (Figure 2, Item 11) on right front bracket (Figure 2, Item 1). Install washer (Figure 2, Item 3), turn signal (Figure 2, Item 2), ground wire (Figure 2, Item 6), new lockwasher (Figure 2, Item 5), and nut (Figure 2, Item 4) on right front bracket (Figure 2, Item 1).

NOTE
Install all wires and electrical connectors as tagged during removal. 4. Connect electrical connectors (Figure 2, Items 7 and 10) on turn signal (Figure 2, Item 2) and headlight (Figure 2, Item 16).

2

3

4,5,6 7

1

16 10 11,12 13,14,15
M0150105

8 9

Figure 2. Right Front Lights and Bracket Installation.

END OF TASK

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0072

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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0073

FIELD MAINTENANCE WORK LIGHTS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

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0073

WARNING

Wear protective equipment while heating and handling bearing cone. Failure to follow this warning may cause injury or death to personnel. REMOVAL

NOTE
• The following is a maintenance procedure for one work light. Maintenance procedure for remaining two work lights is identical. • Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect two wires (Figure 1, Item 3) from work light (Figure 1, Item 1). Remove nut (Figure 1, Item 4), lockwasher (Figure 1, Item 5), and work light (Figure 1, Item 1) from boom (Figure 1, Item 2). Discard lockwasher.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
Install wires as tagged during removal. 1. 2. Install work light (Figure 1, Item 1), new lockwasher (Figure 1, Item 5), and nut (Figure 1, Item 4) to boom (Figure 1, Item 2). Connect two wires (Figure 1, Item 3) to work light (Figure 1, Item 1).

0073-2

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TM 5-3810-305-23

0073

INSTALLATION - Continued

1

2

4,5
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

3
Work Lights Maintenance.

M0126105

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0074

FIELD MAINTENANCE AXLE CENTERING LIGHT SWITCH ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 53) Qty: 2 Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 2 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

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TM 5-3810-305-23

0074

REMOVAL

NOTE
Tag and identify all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. Disconnect cam switch electrical lead (Figure 1, Item 1).

1

M0152105

Figure 1. Axle Centering Light Switch Assembly Removal. 2. 3. 4. 5. 6. 7. 8. 9. Remove two capscrews (Figure 2, Item 6), locknuts (Figure 2, Item 7), and washers (Figure 2, Item 8) from cam switch (Figure 2, Item 5). Discard locknuts. Remove switch (Figure 2, Item 5) from vehicle. Remove jam nut (Figure 2, Item 3) and washer (Figure 2, Item 1) from plate (Figure 2, Item 4). Remove two locknuts (Figure 2, Item 9), washers (Figure 2, Item 10), capscrews (Figure 2, Item 13), washers (Figure 2, Item 12), block (Figure 2, Item 11), and rod (Figure 2, Item 14) from vehicle. Discard locknuts. Remove rod (Figure 2, Item 14) from block (Figure 2, Item 11). Loosen jam nut (Figure 2, Item 15) and remove rod (Figure 2, Item 14) from rod end (Figure 2, Item 16). Remove jam nut (Figure 2, Item 15) from rod (Figure 2, Item 14). Remove two capscrews (Figure 2, Item 2) and plate (Figure 2, Item 4) from vehicle.

0074-2

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TM 5-3810-305-23

0074

REMOVAL - Continued

2

3 4 5

6 7,8

9

10 11

1

16

12

13 15 14
Figure 2. Axle Centering Light Switch Assembly Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
M0153105

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TM 5-3810-305-23

0074

INSTALLATION 1. 2. 3. 4. 5. 6. 7. Install plate (Figure 3, Item 4) and two capscrews (Figure 3, Item 2) on vehicle. Install jam nut (Figure 3, Item 15) on rod (Figure 3, Item 14). Install rod (Figure 3, Item 14) into rod end (Figure 3, Item 16). Install rod (Figure 3, Item 14) into the large diameter hole side of block (Figure 3, Item 11). Install block (Figure 3, Item 11) with rod (Figure 3, Item 14), two washers (Figure 3, Item 12), capscrews (Figure 3, Item 13), washers (Figure 3, Item 10), and new locknuts (Figure 3, Item 9) on vehicle. Install rod end (Figure 3, Item 16), washer (Figure 3, Item 1) and jam nut (Figure 3, Item 3) on plate (Figure 3, Item 4). Install switch (Figure 3, Item 5), two capscrews (Figure 3, Item 6), washers (Figure 3, Item 8) and locknuts (Figure 3, Item 7) on vehicle.

2

3 4 5

6 7,8

9

10 11

1

16

12

13 15
Figure 3.

14
Axle Centering Light Switch Assembly Installation.

M0153105

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TM 5-3810-305-23

0074

INSTALLATION - Continued 8. 9. Connect battery cables (WP 0076). Connect cam switch electrical lead (Figure 4, Item 1).

1

M0152105

Figure 4. END OF TASK

Axle Centering Light Switch Assembly Installation.

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TM 5-3810-305-23

0074

ADJUSTMENT 1. 2. 3. 4. 5. 6. Rear wheels must be parallel to carrier frame when making any adjustments. Loosen jam nut (Figure 5, Item 2) on rod (Figure 5, Item 4). Thread rod (Figure 5, Item 4) in or out of rod end (Figure 5, Item 1) until cam switch is in the center of groove on rod. Tighten jam nut (Figure 5, Item 2) against rod end (Figure 5, Item 1). Loosen two capscrews (Figure 5, Item 3). Slide cam switch until roller is centered in groove and just rests on rod (Figure 5, Item 4). Tighten two capscrews. Red indicator light should be on while rear axle is being turned right or left. Light should be off when axle is centered.

1 2

3

4
Figure 5. Axle Centering Light Switch Assembly Adjustment. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

M0154105

END OF TASK END OF WORK PACKAGE

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0075

FIELD MAINTENANCE TACHOMETER ADJUSTMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Gasket (WP 0172, Table 1, Item 61) Qty: 1 O-Ring (WP 0172, Table 1, Item 80) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL 1. 2. Remove male connector (Figure 1, Item 3) of tachometer sensor (Figure 1, Item 2) from female connector (Figure 1, Item 4) of vehicle wiring harness (Figure 1, Item 5). Loosen nut (Figure 1, Item 6) and remove tachometer sensor (Figure 1, Item 2) from tachometer drive (Figure 1, Item 1).

1 2 6 3 4 5
M2106105

Figure 1. Tachometer Wiring Harness Removal.

0075-1

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TM 5-3810-305-23

0075

REMOVAL - Continued 3. 4. 5. 6. Remove two screws (Figure 2, Item 1) and two flatwashers (Figure 2, Item 2) securing tachometer drive (Figure 2, Item 8). Remove tachometer drive (Figure 2, Item 8), o-ring (Figure 2, Item 7), cover (Figure 2, Item 3) and gasket (Figure 2, Item 4) from engine as an assembly. Discard gasket. If necessary, remove hub (Figure 2, Item 6) from shaft (Figure 2, Item 5). If necessary, remove tachometer drive (Figure 2, Item 8) and o-ring (Figure 2, Item 7) from cover (Figure 2, Item 3). Discard o-ring.

4 2 1 5 6 7 8
M2107105

3

Figure 2. END OF TASK CLEANING

Tachometer Drive Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0075-2

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TM 5-3810-305-23

0075

INSTALLATION 1. 2. 3. 4. If removed, install hub (Figure 3, Item 6) onto shaft (Figure 3, Item 5). If removed, install drive (Figure 3, Item 8) and new o-ring (Figure 3, Item 7) to cover (Figure 3, Item 3). Position new gasket (Figure 3, Item 4) on cover (Figure 3, Item 3). Install new gasket (Figure 3, Item 4), cover (Figure 3, Item 3), new o-ring (Figure 3, Item 7) and tachometer drive (Figure 3, Item 8) to engine as an assembly, and secure with two flatwashers (Figure 3, Item 2) and screws (Figure 3, Item 1).

4 2 1 5 6 7 8
M2107105

3

Figure 3.

Tachometer Drive Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00081)

TM 5-3810-305-23

0075

INSTALLATION - Continued 5. 6. 7. Insert tachometer sensor (Figure 4, Item 2) into tachometer drive (Figure 4, Item 1). Hand-tighten nut (Figure 4, Item 6) on tachometer sensor (Figure 4, Item 2) and then further tighten nut 1/4 to 1/2 additional turn. Insert male connector (Figure 4, Item 3) of tachometer sensor (Figure 4, Item 2) into female connector (Figure 4, Item 4) of vehicle wiring harness (Figure 4, Item 5).

1 2 6 3 4 5
M2106105

Figure 4. Tachometer Wiring Harness Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Connect battery cables (WP 0076). Verify correct tachometer operation (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0076

FIELD MAINTENANCE BATTERY ASSEMBLY AND CABLES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Battery Kit, Service (WP 0171, Table 1, Item 43) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 2 O-Ring Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Soda, Baking (WP 0170, Table 1, Item 67) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 8) Qty: 2 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 92) Qty: 4 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 129) Qty: 1 References TB 9-6140-252-13 TM 5-3810-305-10 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10)

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TM 5-3810-305-23

0076

REMOVAL

WARNING

BATTERIES • Battery gases can explode. DO NOT smoke or allow sparks or open flames near batteries. Wear safety glasses or goggles when checking the batteries. • To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury or death to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Seek medical attention in the event of an injury. a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia. • Failure to follow these warnings may cause injury or death to personnel. 1. Open battery compartment cover (TM 5-3810-305-10).

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 2. Disconnect ground cable (Figure 1, Item 6) from battery (Figure 1, Item 9). Discard lockwasher.

0076-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00082)

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0076

REMOVAL - Continued 3. 4. 5. 6. 7. Disconnect black wire from ground cable (Figure 1, Item 6). Disconnect positive cable (Figure 1, Item 2) from battery (Figure 1, Item 3). Discard lockwasher. Disconnect two white wires and cable (Figure 1, Item 1) from cable (Figure 1, Item 2). Remove jump cable (Figure 1, Item 4) from batteries (Figure 1, Items 3 and 9). Discard lockwasher. Remove four nuts (Figure 1, Item 8), washers (Figure 1, Item 7), and two battery clamps (Figure 1, Item 5) from vehicle.

1

3 2

4

9 8

7 5 6
Figure 1. Battery and Cables Assembly Removal.
M0091105

0076-3

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TM 5-3810-305-23

0076

REMOVAL - Continued 8. 9. 10. 11. Remove capscrew (Figure 2, Item 2) and lockwasher (Figure 2, Item 3), and disconnect cable (Figure 2, Item 4) from slave receptacle (Figure 2, Item 1). Discard lockwasher. Remove capscrew (Figure 2, Item 2) and lockwasher (Figure 2, Item 3), and disconnect cable (Figure 2, Item 9) from slave receptacle (Figure 2, Item 1). Discard lockwasher. Remove batteries (Figure 2, Items 5 and 6) from battery compartment. Remove four bolts (Figure 2, Item 7) and o-rings (Figure 2, Item 8) from battery compartment. Discard o-rings.

1

7 2,3 4 5 6

8

2,3 9

M0092105

Figure 2. Battery and Cables Assembly Removal.

0076-4

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TM 5-3810-305-23

0076

REMOVAL - Continued 12. 13. Remove capscrew (Figure 3, Item 2) and lockwasher (Figure 3, Item 3), and disconnect cables (Figure 3, Items 5 and 6) from shunt (Figure 3, Item 4). Discard lockwasher. Remove capscrews (Figure 3, Item 2) and lockwasher (Figure 3, Item 3), and disconnect cable (Figure 3, Item 1) from shunt (Figure 3, Item 4). Discard lockwasher.

1

2,3

4

2,3

5

6

M0093105

Figure 3.

Battery and Cables Assembly Removal.

0076-5

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TM 5-3810-305-23

0076

REMOVAL - Continued 14. 15. 16. 17. 18. 19. Remove bolt (Figure 4, Item 5) and lockwasher (Figure 4, Item 6), and disconnect cables (Figure 4, Items 7 and 10). Discard lockwasher. Cut and remove all tiedown straps securing cables (Figure 4, Items 1 and 7). Discard tiedown straps. Remove nut (Figure 4, Items 2 and 3) securing cable (Figure 4, Item 1) to starting motor. Disconnect cable (Figure 4, Items 1 and 4). Install nut (Figure 4, Item 2) and washer (Figure 4, Item 3) on starting motor (Figure 4, Item 4). Follow cable (Figure 4, Item 10) down to frame and remove nut (Figure 4, Item 9), washer (Figure 4, Item 8), and cable. Remove cables (Figure 4, Items 1 and 7) from vehicle.

1

2,3,4

5,6

10 9,8

7

M0094105

Figure 4. Battery and Cables Assembly Removal.

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TM 5-3810-305-23

0076

REMOVAL - Continued 20. Remove two locknuts (Figure 5, Item 2), two washers (Figure 5, Item 1), and four clamps (Figure 5, Item 3). Discard locknuts.

1,2

3
M0095105

1,2
Figure 5. 21. Battery and Cables Assembly Removal.

Remove grommet (Figure 6, Item 1) and flexible trim (Figure 6, Item 2).

1

2

M0096105

Figure 6.

Battery and Cables Assembly Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00082)

TM 5-3810-305-23

0076

REMOVAL - Continued 22. 23. 24. Remove two screws (Figure 7, Item 1) and lockwashers (Figure 7, Item 2), and disconnect red and blue wires from shunt (Figure 7, Item 3). Discard lockwashers. Remove two nuts (Figure 7, Item 4), lockwashers (Figure 7, Item 5), bolts (Figure 7, Item 6), and shunt (Figure 7, Item 3) from battery box. Discard lockwashers. Remove four nuts (Figure 7, Item 7), lockwashers (Figure 7, Item 8), bolts (Figure 7, Item 9), and slave receptacle (Figure 7, Item 10) from battery box. Discard lockwashers.

1,2 3

4,5,6

10

7,8,9
M0097105

Figure 7. Battery and Cables Assembly Removal. END OF TASK CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Clean cable terminals with a solution of baking soda and water. Rinse with clean water and wire brush. Clean batteries with a solution of baking soda and water. Rinse with clean water. Clean negative and positive terminal posts with a wire brush. Clean all other parts.

END OF TASK

0076-8

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TM 5-3810-305-23

0076

INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect battery cables for broken, cracked, or deteriorated insulation. Inspect battery cable terminal for corroded or damaged condition. Inspect battery case for signs of cracks or electrolyte leakage. Ensure terminal posts are solid. Replace battery cables that have broken wires or damaged insulation. If battery is to be charged, observe all safety precautions. Charge batteries (refer to TB 9-6140-252-13). Inspect all other parts.

END OF TASK INSTALLATION 1. 2. 3. Install slave receptacle (Figure 8, Item 10), four bolts (Figure 8, Item 9), new lockwashers (Figure 8, Item 8), and nuts (Figure 8, Item 7) on battery box. Install shunt (Figure 8, Item 3), two bolts (Figure 8, Item 6), new lockwashers (Figure 8, Item 5), and nuts (Figure 8, Item 4) on battery box. Connect blue and red wires to shunt (Figure 8, Item 3) and install two new lockwashers (Figure 8, Item 2) and screws (Figure 8, Item 1) on shunt.

1,2 3

4,5,6

10

7,8,9
M0097105

Figure 8. Battery and Cables Assembly Installation.

0076-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00082)

TM 5-3810-305-23

0076

INSTALLATION - Continued 4. 5. Install flexible trim (Figure 9, Item 2) and grommet (Figure 9, Item 1) on battery box. Route cables (Figure 9, Items 3 and 4) through flexible trim (Figure 9, Item 2) and grommet (Figure 9, Item 1).

1

2

3 4

M0099105

Figure 9. Battery and Cables Assembly Installation.

0076-10

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TM 5-3810-305-23

0076

INSTALLATION - Continued 6. 7. 8. 9. Connect cable (Figure 10, Item 1) to starting motor (Figure 10, Item 4) and install nut (Figure 10, Item 2) and washer (Figure 10, Item 3). Install cable (Figure 10, Item 10), washer (Figure 10, Item 8), and nut (Figure 10, Item 9). Connect cable (Figure 10, Items 7 and 10) and install new lockwasher (Figure 10, Item 5) and bolt (Figure 10, Item 6). Install new tiedown straps as needed.

1

2,3,4

5,6

10 9,8
Figure 10.

7
Battery and Cables Assembly Installation.

M0094105

0076-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00082)

TM 5-3810-305-23

0076

INSTALLATION - Continued 10. 11. 12. 13. 14. 15. Connect cable (Figure 11, Item 1) to shunt (Figure 11, Item 4) and install lockwasher (Figure 11, Item 3) and capscrew (Figure 11, Item 2). Install four bolts (Figure 11, Item 12) and new o-rings (Figure 11, Item 13). Install batteries (Figure 11, Items 10 and 11) into battery compartment. Install cables (Figure 11, Items 5 and 14), lockwasher (Figure 11, Item 3), and capscrew (Figure 11, Item 2) to shunt (Figure 11, Item 4). Connect cable (Figure 11, Item 14) and install two lockwashers (Figure 11, Item 8) and capscrew (Figure 11, Item 7) to slave receptacle (Figure 11, Item 6). Connect cable (Figure 11, Item 9) and install two lockwashers (Figure 11, Item 8) and capscrew (Figure 11, Item 7) to slave receptacle (Figure 11, Item 6).

4 1 2,3 2,3 5

6

7,8 9

10

11

12

13

14

8,9

14
Figure 11. Battery and Cables Assembly Installation.

M0100105

0076-12

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TM 5-3810-305-23

0076

INSTALLATION - Continued 16. 17. Install two battery clamps (Figure 12, Item 2), four washers (Figure 12, Item 4), and locknuts (Figure 12, Item 5). Connect black wire to ground cable (Figure 12, Item 3) and connect ground cable to battery (Figure 12, Item 1).

1

5

4 2 3
Figure 12. Battery and Cables Assembly Installation.
M0101105

0076-13

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TM 5-3810-305-23

0076

INSTALLATION - Continued 18. Install four clamps (Figure 13, Item 3), two washers (Figure 13, Item 1), and two new locknuts (Figure 13, Item 2).

1,2

3
M0095105

1,2
Figure 13. Battery and Cables Assembly Installation.

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TM 5-3810-305-23

0076

INSTALLATION - Continued 19. 20. 21. Install jumper cable (Figure 14, Item 3) to batteries (Figure 14, Items 4 and 5). Connect cable (Figure 14, Item 1) and two white wires to cable (Figure 14, Item 2). Install cable (Figure 14, Item 2) to battery (Figure 14, Item 5).

1

2

5

4

3
M0090105

Figure 14. END OF TASK FOLLOW-ON MAINTENANCE

Battery and Cables Assembly Installation.

Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

0076-15/16 blank

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TM 5-3810-305-23

0077

FIELD MAINTENANCE BATTERY BOX AND TOOLBOX WITH COVERS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Nut, Self-Locking, He M6 (WP 0172, Table 1, Item 138) Qty: 3 Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 8 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Batteries removed (WP 0076)

REMOVAL 1. 2. 3. 4. Remove four locknuts (Figure 1, Item 5), washers (Figure 1, Item 6), and capscrews (Figure 1, Item 7) from battery cover (Figure 1, Item 8). Discard locknuts. Remove battery cover (Figure 1, Item 8) from vehicle. Remove four locknuts (Figure 1, Item 2), washers (Figure 1, Item 3), and capscrews (Figure 1, Item 4) from toolbox cover (Figure 1, Item 1). Discard locknuts. Remove toolbox cover (Figure 1, Item 1) from toolbox (Figure 1, Item 9).

1

2,3 4

5,6

9 7

8
Figure 1. Battery Box and Toolbox Cover Removal.

M1250105

0077-1

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TM 5-3810-305-23

0077

REMOVAL - Continued 5. 6. Remove three locknuts (Figure 2, Item 5), capscrews (Figure 2, Item 6), and hand pump (Figure 2, Item 7) from inside of toolbox (Figure 2, Item 2). Discard locknuts. Remove all tools and spare parts from toolbox (Figure 2, Item 2).

WARNING

Weight of toolbox is approximately 180 lb (82 kg). Use adequate lifting equipment to support toolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. Support toolbox (Figure 2, Item 2) with suitable blocking or a floor jack. Remove six capscrews (Figure 2, Item 3), washers (Figure 2, Item 4), and toolbox (Figure 2, Item 2) from vehicle (Figure 2, Item 1).

2 1

3

4 7 6

5
M1251105

Figure 2. Battery Box and Toolbox Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0077-2

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TM 5-3810-305-23

0077

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

WARNING

Weight of toolbox is approximately 180 lb (82 kg). Use adequate lifting equipment to support toolbox. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. 4. Support toolbox (Figure 3, Item 2) in suitable blocking or floor jack. Install toolbox (Figure 3, Item 2), six washers (Figure 3, Item 4) and capscrews (Figure 3, Item 3) on vehicle (Figure 3, Item 1). Install all tools and spare parts removed earlier from toolbox (Figure 3, Item 2). Using three capscrews (Figure 3, Item 6) and new locknuts (Figure 3, Item 5) secure hand pump (Figure 3, Item 7) to inside of toolbox (Figure 3, Item 2).

2 1

3

4 7 6

5
M1251105

Figure 3.

Battery Box and Toolbox Installation.

0077-3

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0077

INSTALLATION - Continued 5. 6. 7. 8. Install toolbox cover (Figure 4, Item 1) on vehicle (Figure 4, Item 9). Install four capscrews (Figure 4, Item 4), washers (Figure 4, Item 3), and new locknuts (Figure 4, Item 2) on toolbox cover (Figure 4, Item 1). Install battery cover (Figure 4, Item 8) on vehicle. Install four capscrews (Figure 4, Item 7), washers (Figure 4, Item 6), and new locknuts (Figure 4, Item 5) on battery cover (Figure 4, Item 8).

1

2,3 4

5,6

9 7

8
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install batteries (WP 0076). Place boom in resting position (TM 5-3810-305-10). Battery Box and Toolbox Cover Installation.

M1250105

END OF TASK END OF WORK PACKAGE

0077-4

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TM 5-3810-305-23

0078

FIELD MAINTENANCE MAIN ENGINE WIRING HARNESS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 8 Materials/Parts (cont.) Washer, Lock M8 (WP 0172, Table 1, Item 126) Qty: 26 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance.

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TM 5-3810-305-23

0078

REMOVAL 1. Disconnect main engine wiring harness (Figure 1, Item 12) from shunt (Figure 1, Item 21), hydraulic valve bank (Figure 1, Item 6), winch valve (Figure 1, Item 10), fuel shutoff toggle switch (Figure 1, Item 8), front outrigger solenoid valve (Figure 1, Item 9), collector ring (Figure 1, Item 5), fuel sender (Figure 1, Item 13), transmission temperature sender (Figure 1, Item 4), axle centering light switch (Figure 1, Item 14), oil pressure sender (Figure 1, Item 17), backup alarm (Figure 1, Item 19), rear outrigger solenoid valve (Figure 1, Item 3), water temperature sender (Figure 1, Item 20), alternator (Figure 1, Item 2), starting motor solenoid and starting motor relay (Figure 1, Item 1), speedometer sender (Figure 1, Item 7), taillights (Figure 1, Item 16), fuel solenoid (Figure 1, Item 18), and turn signals (Figure 1, Item 15). Remove main engine wiring harness mounting clamps (Figure 1, Item 11), lockwashers and tiedown straps. Discard tiedown straps and lockwashers. Remove main engine wiring harness (Figure 1, Item 12).

2. 3.

1

2 3

19 18

20 21 4 5 6 7 8

17

16

15 14 13 12 11 10 9
M0164105

Figure 1. END OF TASK CLEANING

Main Engine Wiring Harness Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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0078

INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Repair wire harness, if necessary.

END OF TASK INSTALLATION 1. 2. Position main engine wiring harness (Figure 2, Item 12) in vehicle. Connect main engine wiring harness (Figure 2, Item 12) at shunt (Figure 2, Item 21), hydraulic valve bank (Figure 2, Item 6), winch valve (Figure 2, Item 10), fuel shutoff toggle switch (Figure 2, Item 8), front outrigger solenoid valve (Figure 2, Item 9), collector ring (Figure 2, Item 5), fuel sender (Figure 2, Item 13), transmission temperature sender (Figure 2, Item 4), axle centering light switch (Figure 2, Item 14), oil pressure sender (Figure 2, Item 17), backup alarm (Figure 2, Item 19), rear outrigger solenoid valve (Figure 2, Item 3), water temperature sender (Figure 2, Item 20), alternator (Figure 2, Item 2), starting motor solenoid and starting motor relay (Figure 2, Item 1), speedometer sender (Figure 2, Item 7), taillights (Figure 2, Item 16), fuel solenoid (Figure 2, Item 18), and turn signals (Figure 2, Item 15). Install new tiedown straps, new lockwashers, and clamps to secure main engine wiring harness.

3.

1

2 3

19 18

20 21 4 5 6 7 8

17

16

15 14 13 12 11 10 9
M0164105

Figure 2. END OF TASK

Main Engine Wiring Harness Installation.

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0078

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for normal operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0079

FIELD MAINTENANCE CAB MAIN HARNESS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Tool Kit, Auto Fuel and Electrical System (WP 0171, Table 1, Item 16) Materials/Parts Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Circuit breaker panel and wire assemblies disconnected (WP 0066) Side sloping dash panel and wire assemblies disconnected (WP 0066) Dash panel and wire assemblies disconnected (WP 0066)

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0079

REMOVAL

NOTE
Tag and identify all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. 3. Disconnect wire harness plugs from receptacles on back wall of cab. Remove two clamps (Figure 1, Item 14) and wire (Figure 1, Item 15) from heater and circuit breaker. Disconnect cab main harness from cab floor ground (Figure 1, Item 12), circuit breaker (Figure 1, Item 11), sloping dash panel (Figure 1, Item 10), horn (Figure 1, Item 7), defroster fan (Figure 1, Item 5), brakelight switch (Figure 1, Item 6), wiper motor (Figure 1, Item 2), turn signal switch (Figure 1, Item 17), speedometer (Figure 1, Item 3), headlights (Figure 1, Item 1), and speedometer alarm (Figure 1, Item 4). Remove cab main harness mounting clamps (Figure 1, Item 13), capscrews (Figure 1, Item 8), nuts (Figure 1, Item 9), and tiedown straps (Figure 1, Item 16). Discard tiedown straps. Remove cab main harness from cab.

4. 5.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Repair cab main harness, if necessary.

END OF TASK

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0079

INSTALLATION 1. 2. 3. Position cab main harness in cab. Install new tiedown straps (Figure 1, Item 16), nuts (Figure 1, Item 9), capscrews (Figure 1, Item 8), and cab main harness mounting clamps (Figure 1, Item 13) to secure cab main harness. Connect cab main harness to cab floor ground (Figure 1, Item 12), circuit breaker (Figure 1, Item 11), sloping dash panel (Figure 1, Item 10), horn (Figure 1, Item 7), defroster fan (Figure 1, Item 5), brakelight switch (Figure 1, Item 6), wiper motor (Figure 1, Item 2), turn signal switch (Figure 1, Item 17), speedometer (Figure 1, Item 3), headlights (Figure 1, Item 1), and speedometer alarm (Figure 1, Item 4). Install wire (Figure 1, Item 15) and two clamps (Figure 1, Item 14) to heater and circuit breaker.

4.

1

2

3 4 7

5 6

17

8

16 10 13 11 12 9

15

14
Figure 1. Cab Main Harness Maintenance.

M0127105

END OF TASK

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0079

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect dash panel and wire assemblies (WP 0066). Connect side sloping dash panel and wire assemblies (WP 0066). Connect circuit breaker panel and wire assemblies (WP 0066). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0080

FIELD MAINTENANCE BACKUP ALARM MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 93) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

1

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

TM 5-3810-305-23

0080

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Disconnect electrical connections (Figure 1, Item 1). Remove two nuts (Figure 1, Item 2), two washers (Figure 1, Item 3), lockwashers (Figure 1, Item 4), and backup alarm (Figure 1, Item 6) from mounting studs (Figure 1, Item 5). Discard lockwashers.

1

2,3,4

5

6
M0125105

Figure 1. Back Up Alarm Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0080-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

TM 5-3810-305-23

0080

INSTALLATION 1. 2. Install backup alarm (Figure 2, Item 6), two new lockwashers (Figure 2, Item 4), washers (Figure 2, Item 3), and two nuts (Figure 2, Item 2) on mounting studs (Figure 2, Item 5). Discard lockwashers. Connect electrical connections (Figure 2, Item 1).

1

2,3,4

5

6
M0125105

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076).

Back Up Alarm Installation.

Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0080-3/4 blank

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TM 5-3810-305-23

0081

FIELD MAINTENANCE MSD-ICE WIRING HARNESS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. Disconnect main MSD-ICE harness (Figure 1, Item 10) from resistor module (Figure 1, Item 8), tachometer sender (Figure 1, Item 12), fuel pressure transducer (Figure 1, Item 2), alternator (Figure 1, Item 3), starting motor solenoid (Figure 1, Item 5), fuel differential pressure switch (Figure 1, Item 1), shunt (Figure 1, Item 6) batteries (Figure 1, Item 7), starting motor (Figure 1, Item 4), and fuel solenoid (Figure 1, Item 11). Remove main MSD-ICE harness mounting clamps (Figure 1, Item 9) and hardware from main MSD-ICE harness (Figure 1, Item 10). Remove MSD-ICE harness (Figure 1, Item 10) from vehicle.

2. 3.

1

2 3

12

5

4 6 7

11 10
Figure 1. END OF TASK

9

M0163105

8

Main MSD-ICE Harness Removal.

0081-1

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TM 5-3810-305-23

0081

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. Position main MSD-ICE harness (Figure 2, Item 10) in vehicle. Connect main MSD-ICE harness (Figure 2, Item 10) resistor module (Figure 2, Item 8), tachometer sender (Figure 2, Item 12), fuel pressure transducer (Figure 2, Item 2), alternator (Figure 2, Item 3), starter solenoid (Figure 2, Item 5), fuel pressure differential switch (Figure 2, Item 1), shunt (Figure 2, Item 6), batteries (Figure 2, Item 7), starting motor (Figure 2, Item 4), and fuel solenoid (Figure 2, Item 11). Install DCA and resistor module connectors on rear wall of cab. Install clamps (Figure 2, Item 9) and hardware to secure main MSD-ICE wire harness (Figure 2, Item 10).

3. 4.

1

2 3

12

5

4 6 7

11 10 9
M0163105

8

Figure 2. Main MSD-ICE Harness Installation. END OF TASK

0081-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00087)

TM 5-3810-305-23

0081

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for normal operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0082

FIELD MAINTENANCE BOOM WIRING HARNESS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 129) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 165) Qty: 2 Personnel Required (Two) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

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TM 5-3810-305-23

0082

REMOVAL

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Lift and turn latch (Figure 1, Item 2) on counterweight (Figure 1, Item 1). Split and remove counterweight (Figure 1, Item 1) from around cable (Figure 1, Item 3).

2

1

2

1

3 3
Figure 1. Boom Wiring Harness Removal.
M0165105

0082-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

REMOVAL - Continued 3. 4. 5. Remove threaded pin from clevis (Figure 2, Item 5). Unlatch lock (Figure 2, Item 2) and disconnect electrical connector (Figure 2, Item 1). Remove pin (Figure 2, Item 3) and switch (Figure 2, Item 4) from mounting bracket (Figure 2, Item 6).

1

2

3

4

5

6
Figure 2. Boom Wiring Harness Removal.

M0166105

0082-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

REMOVAL - Continued

CAUTION
Anti-two block switch is serviced only as a complete assembly. DO NOT discard or lose any parts. Failure to follow this caution may result in damage to equipment.

NOTE
Tag wires and note routing to aid in installation. 6. 7. Remove four screws (Figure 3, Item 1) and cover (Figure 3, Item 2) from switch (Figure 3, Item 4). Disconnect wiring harness (Figure 3, Item 3) from switch (Figure 3, Item 4).

1 4

3 2
M0167105

Figure 3. Boom Wiring Harness Removal.

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TM 5-3810-305-23

0082

REMOVAL - Continued

WARNING

DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness may result in serious injury or death if it hits personnel. 8. 9. Remove four screws (Figure 4, Item 1) and connector (Figure 4, Item 2). Remove cable (Figure 4, Item 4) from strain relief tube (Figure 4, Item 3). Slowly allow cable reel to take up cable.

1

2

3

4

M0168105

Figure 4.

Boom Wiring Harness Removal.

0082-5

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TM 5-3810-305-23

0082

REMOVAL - Continued 10. 11. Remove two capscrews (Figure 5, Item 6), lockwashers (Figure 5, Item 7), and roller bracket (Figure 5, Item 5) from boom. Discard lockwashers. Remove nut (Figure 5, Item 4), roller (Figure 5, Item 3), washer (Figure 5, Item 2), and shoulder screw (Figure 5, Item 1) from roller bracket (Figure 5, Item 5). Repeat for other roller.

2 3 1 7 4

5 6
Figure 5. Boom Wiring Harness Removal.

M0169105

0082-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

REMOVAL - Continued

NOTE
Boom must be raised to highest position to aid in removing wire harness clamps. 12. 13. 14. 15. 16. 17. Connect battery cables (WP 0076). Start engine. Raise boom to highest position (TM 5-3810-305-10). Remove two nuts (Figure 6, Item 1), washers (Figure 6, Item 2), and clamps (Figure 6, Item 3) from vehicle. Install two washers (Figure 6, Item 2) and nuts (Figure 6, Item 1). Remove nut (Figure 6, Item 7), washer (Figure 6, Item 8), and clamp (Figure 6, Item 9) from vehicle. Remove nut (Figure 6, Item 4), washer (Figure 6, Item 5), and clamp (Figure 6, Item 6) from vehicle.

1,2,3

4,5,6

7,8,9 1,2,3
Figure 6. Boom Wiring Harness Removal.
M0170105

0082-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

REMOVAL - Continued 18. 19. 20. 21. Hold anti-two block BY-PASS switch and lower boom. Shut engine OFF. Disconnect battery cables (WP 0076). Disconnect two worklight wires (Figure 7, Item 4) from each of the three worklights (Figure 7, Item 1). Remove three nuts (Figure 7, Item 3), washers (Figure 7, Item 2), worklights (Figure 7, Item 1), and spacers (Figure 7, Item 5) from vehicle.

1

2

3

5 4
Figure 7. Boom Wiring Harness Removal.
M0171105

0082-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

REMOVAL - Continued

NOTE
Tag wires and note routing to aid in installation. 22. 23. Disconnect wire harness (Figure 8, Item 3) from wire harnesses (Figure 8, Items 1 and 2). Remove nut (Figure 8, Item 6), washer (Figure 8, Item 5), and clamp (Figure 8, Item 4) from vehicle.

1

2

3 5,6
Figure 8.

4

M0172105

Boom Wiring Harness Removal.

NOTE
Tag wires and note routing to aid in installation. 24. 25. Disconnect wire harness (Figure 9, Item 1) from collector ring wire harness (Figure 9, Item 2). Remove wire harness (Figure 9, Item 1) from vehicle.

1

2

M0173105

Figure 9. END OF TASK

Boom Wiring Harness Removal.

0082-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
Install wiring harness as tagged during removal. 1. Install wiring harness (Figure 10, Item 1) to collector ring wiring harness (Figure 10, Item 2).

1

2

M0173105

Figure 10. Boom Wiring Harness Installation.

0082-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

INSTALLATION - Continued

NOTE
Install wiring harness as tagged during removal. 2. 3. Install clamp (Figure 11, Item 4), washer (Figure 11, Item 5), and nut (Figure 11, Item 6) on vehicle. Connect wiring harnesses (Figure 11, Items 1 and 2) to wiring harness (Figure 11, Item 3).

1

2

3 5,6
Figure 11. 4. 5.

4

M0172105

Boom Wiring Harness Installation.

Install three spacers (Figure 12, Item 5) worklights (Figure 12, Item 1), washers (Figure 12, Item 2), and nuts (Figure 12, Item 3). Connect two worklight wires (Figure 12, Item 4) to each of three worklights (Figure 12, Item 1).

1

2

3

5 4
Figure 12. Boom Wiring Harness Installation.
M0171105

0082-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

INSTALLATION - Continued

NOTE
Boom must be raised to highest position to aid in installing wire harness clamps. 6. 7. 8. 9. 10. 11. Connect battery cables (WP 0076). Start engine. Raise boom to highest position. Install clamp (Figure 13, Item 6), washer (Figure 13, Item 5), and nut (Figure 13, Item 4) on vehicle. Install clamp (Figure 13, Item 8), washer (Figure 13, Item 7), and nut (Figure 13, Item 9) on vehicle. Remove two nuts (Figure 12, Item 1) and washers (Figure 12, Item 2). Install two clamps (Figure 12, Item 3), washers (Figure 12, Item 2), and nuts (Figure 12, Item 1) on vehicle.

1,2,3

4,5,6

7,8,9 1,2,3
Figure 13. Boom Wiring Harness Installation.
M0170105

0082-12

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TM 5-3810-305-23

0082

INSTALLATION - Continued

WARNING

DO NOT release cord as cable reel will pull harness rapidly. Rapidly moving harness may result in serious injury or death if it hits personnel. 12. 13. 14. 15. Hold anti-two block BY-PASS switch and lower boom. Shut engine OFF. Disconnect battery cables (WP 0076). Install shoulder screw (Figure 14, Item 1), washer (Figure 14, Item 2), roller (Figure 14, Item 3), and nut (Figure 14, Item 4) on roller bracket (Figure 14, Item 5). Repeat for other roller. Install roller bracket (Figure 14, Item 5), two new lockwashers (Figure 14, Item 7), and capscrews (Figure 14, Item 6) on boom.

2 3 1 7 4

5 6
Figure 14. Boom Wiring Harness Installation.

M0169105

0082-13

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TM 5-3810-305-23

0082

INSTALLATION - Continued 16. 17. Install cable (Figure 15, Item 4) into strain relief tube (Figure 15, Item 3). Install connector (Figure 15, Item 2) and four screws (Figure 15, Item 1) on boom.

1

2

3

4

M0168105

Figure 15. Boom Wiring Harness Installation.

CAUTION
Anti-two block switch is serviced only as a complete assembly. DO NOT discard or lose any parts. Failure to follow this caution may result in damage to equipment.

NOTE
Install wire harness as tagged during removal. 18. 19. Connect wiring harness (Figure 16, Item 3) on switch (Figure16, Item 4). Install cover (Figure 16, Item 2) and four screws (Figure 16, Item 1) on switch (Figure 16, Item 4).

1 4

3 2
M0167105

Figure 16. Boom Wiring Harness Installation.

0082-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0082

INSTALLATION - Continued 20. 21. 22. Install switch (Figure 17, Item 4) on mounting bracket (Figure 17, Item 6) with secure pin (Figure 17, Item 3). Connect electrical connector (Figure 17, Item 1). Secure with lock (Figure 17, Item 2). Install threaded pin on clevis (Figure 17, Item 5).

1

2

3

4

5

6
Figure 17. 23. 24. Boom Wiring Harness Installation.

M0166105

Close counterweight (Figure 18, Item 1) around cable (Figure 18, Item 3). Turn and lower latch (Figure 18, Item 2) on counterweight (Figure 18, Item 1).

2

1

2

1

3 3
Figure 18. END OF TASK Boom Wiring Harness Installation.
M0165105

0082-15

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TM 5-3810-305-23

0082

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0082-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 5-3810-305-23

0083

FIELD MAINTENANCE MSD-ICE DCA CONNECTOR/RESISTOR MODULE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Battery cables disconnected (WP 0076) Deck plates removed (TM 5-3810-305-10) (WP 0122)

0083-1

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TM 5-3810-305-23

0083

REMOVAL

NOTE
Tag and identify all wires and wiring harnesses to aid in installation. 1. 2. 3. Remove MSD-ICE cap (Figure 1, Item 3), four nuts (Figure 1, Item 6), ground wires (Figure 1, Item 5), screws (Figure 1, Item 4), and MSD-ICE diagnostic connector (Figure 1, Item 7) from inside rear cab wall. Remove resistor cap (Figure 1, Item 1), four nuts (Figure 1, Item 8), screws (Figure 1, Item 2), and resistor module (Figure 1, Item 9) from inside rear cab wall. Remove nut (Figure 1, Item 11), washer (Figure 1, Item 12), and fuel toggle switch (Figure 1, Item 10) from inside rear cab wall.

1

2

3

4

6

7

8

9

5

10 11,12
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK MSD-ICE DCA Connector Resistor/Module Removal.
M0155105

0083-2

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TM 5-3810-305-23

0083

INSTALLATION

NOTE
Install all wires and wiring harnesses as tagged during removal. 1. 2. 3. Install fuel toggle switch (Figure 2, Item 10), washer (Figure 2, Item 12), and nut (Figure 2, Item 11) on inside rear cab wall. Install resistor module (Figure 2, Item 9), four screws (Figure 2, Item 2), resistor cap (Figure 2, Item 1), and nuts (Figure 2, Item 8) to inside rear cab wall. Install MSD-ICE diagnostic connector (Figure 2, Item 7), four screws (Figure 2, Item 4), ground wires (Figure 2, Item 5), nuts (Figure 2, Item 6), plug and MSD-ICE cap (Figure 2, Item 3) to inside rear cab wall.

1

2

3

4

6

7

8

9

5

10 11,12
Figure 2. MSD-ICE DCA Connector Resistor/Module Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (WP 0122). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.
M0155105

END OF TASK END OF WORK PACKAGE

0083-3/4 blank

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TM 5-3810-305-23

0084

FIELD MAINTENANCE TRANSMISSION DIPSTICK TUBE ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122) Transmission fluid drained (WP 0091)

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TM 5-3810-305-23

0084

REMOVAL 1. 2. 3. Remove cap screw (Figure 1, Item 1) and clamp (Figure 1, Item 6) from top rear of transmission (Figure 1, Item 2). From the bottom of vehicle, remove tubing nut (Figure 1, Item 4) and remove dipstick tube (Figure 1, Item 5) from elbow (Figure 1, Item 3). Remove elbow (Figure 1, Item 3) from transmission (Figure 1, Item 2).

1 2 6

5 4

3
M2105105

Figure 1. Transmission Dipstick Tube Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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INSTALLATION 1. 2. 3. Install elbow (Figure 2, Item 3) on transmission (Figure2, Item 2). From the bottom of vehicle, install dipstick tube (Figure 2, Item 5) and install tubing nut (Figure 2, Item 4) on elbow (Figure 2, Item 3). Install clamp (Figure 2, Item 6) and cap screw (Figure 2, Item 1) on the top rear of transmission (Figure 2, Item 2).

1 2 6

5 4

3
M2105105

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Fill transmission fluid (WP 0091). Install deck plates (WP 0122). Connect battery cables (WP 0076).

Transmission Dipstick Tube Installation.

Place boom in resting position (TM 5-3810-305-10). Check proper operation.

END OF TASK END OF WORK PACKAGE

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0085

FIELD MAINTENANCE TRANSMISSION SHIFT CONTROLS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 117) Qty: 2 Washer, Split (WP 0172, Table 1, Item 116) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Right console panel removed (WP 0066) Battery cables disconnected (WP 0076)

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0085

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove four capscrews (Figure 1, Item 22) and split washers (Figure 1, Item 23) from side housing (Figure 1, Item 8). Discard split washers. Remove two capscrews (Figure 1, Item 25) and lockwashers (Figure 1, Item 7) from side housing (Figure 1, Item 8). Discard lockwashers. Remove two side housings (Figure 1, Items 8 and 9) and extruded spacers (Figure 1, Item 19) from control assembly. Remove two access caps (Figure 1, Item 26) and decals (Figure 1, Item 24) from side housing (Figure 1, Item 8). Remove three ball knobs (Figure 1, Item 4) from shift levers (Figure 1, Items 1, 3, and 5). Remove gate plate (Figure 1, Item 27) from control assembly. Remove position strips (Figure 1, Items 28, 29, and 30) from gate plate (Figure 1, Item 27). Remove two retaining rings (Figure 1, Item 10) and spacers (Figure 1, Item 11) from actuator assembly (Figure 1, Item 21). Remove three time actuator assemblies (Figure 1, Item 21) and two spacers (Figure 1, Item 18) from shaft (Figure 1, Item 20).

NOTE
The following step covers removal for one actuator assembly; removal of remaining actuators is similar. 10. 11. 12. 13. Drive pin spring (Figure 1, Item 17) from actuator assembly (Figure 1, Item 21) and remove shift lever (Figure 1, Item 5). Remove lever detent (Figure 1, Item 6) from actuator assembly (Figure 1, Item 21). Straighten ends of torsion springs (Figure 1, Items 2 and 13) extending through actuator assembly (Figure 1, Item 21). Remove torsion springs (Figure 1, Items 2 and 13) and torsion spring shaft (Figure 1, Item 12) from actuator assembly (Figure 1, Item 21). Remove torsion springs (Figure 1, Items 2 and 13) from torsion spring shaft (Figure 1, Item 12). Remove balls (Figure 1, Item 16), springs (Figure 1, Item 15), and slugs (Figure 1, Item 14) from center actuator assembly (Figure 1, Item 21).

14.

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0085

REMOVAL - Continued

4 5 4 30 29 28 27 1 3 2

6 7

8

9

11

10

12 13

18 26 8 7 25 24 23
Figure 1. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

16 17

15

14

11

21 19 20

22

M0548105

Transmission Shift Controls Removal.

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0085

INSTALLATION

NOTE
Steps 1, 2, and 3 explain installation for one lever; installation of remaining levers is the same. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Install lever detent (Figure 2, Item 6) on shift lever (Figure 2, Item 5). Position shift lever (Figure 2, Item 5) in actuator assembly (Figure 2, Item 21). Install pin spring (Figure 2, Item 17) in actuator assembly (Figure 2, Item 21). Install ball (Figure 2, Item 16), spring (Figure 2, Item 15), and slug (Figure 2, Item 14). Repeat for opposite side of center actuator assembly (Figure 2, Item 21). Install torsion springs (Figure 2, Items 2 and 13) on torsion spring shaft (Figure 2, Item 12). Insert spring ends through mounting holes on actuator assembly (Figure 2, Item 21) and bend over to secure. Install shaft (Figure 2, Item 20), two spacers (Figure 2, Item 18), and three actuator assemblies (Figure 2, Item 21). Install two spacers (Figure 2, Item 11) on each end of shaft (Figure 2, Item 20) and secure each end of shaft (Figure 2, Item 20) with retaining ring (Figure 2, Item 10). Install gate plate (Figure 2, Item 27) on control assembly. Install position strips (Figure 2, Items 28, 29, and 30) on gate plate (Figure 2, Item 27). Install three ball knobs (Figure 2, Item 4) on levers (Figure 2, Items 1, 3, and 5). Install two side housings (Figure 2, Items 8 and 9) and extruded spacers (Figure 2, Item 19). Secure two side housings (Figure 2, Items 9 and 8) with two capscrews (Figure 2, Item 25) and new lockwashers (Figure 2, Item 7). Secure two extruded spacers (Figure 2, Item 19) with four capscrews (Figure 2, Item 22) and new split washers (Figure 2, Item 23). Install two access caps (Figure 2, Item 26) and decals (Figure 2, Item 24).

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0085

INSTALLATION - Continued

4 5 4 30 29 28 27 1 3 2

6 7

8

9

11

10

12 13

18 26 8 7 25 24 23 20 22 11 21 17

16

15

14

19
M0548105

Figure 2. Transmission Shift Controls Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install right console panel (WP 0066). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0086

FIELD MAINTENANCE TRANSMISSION CABLES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking He (WP 0172, Table 1, Item 139) Qty: 2 Nut, Self-Locking He 1/4F (WP 0172, Table 1, Item 102) Qty: 2 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 3 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 167) Qty: 3 Washer, Split (WP 0172, Table 1, Item 116) Qty: 5 Personnel Required (Two) References TM 9-254 WP 0162 Equipment Condition Main battery switch in OFF position (TM 5-3810-305-10) Right console panel removed (WP 0066)

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0086

REMOVAL 1. 2. 3. 4. Remove five nuts (Figure 1, Item 13), lockwashers (Figure 1, Item 12), screws (Figure 1, Item 11), two clamps (Figure 1, Item 14), and shims (Figure 1, Item 9) from lever shim (Figure 1, Item 15). Discard lockwashers. Remove lever shim (Figure 1, Item 15). Remove three nuts (Figure 1, Item 4), lockwashers (Figure 1, Item 5), screws (Figure 1, Item 6), clamp (Figure 1, Item 7), and shim (Figure 1, Item 8) from lever shim (Figure 1, Item 10). Discard lockwashers. Remove left hanger (Figure 1, Item 3) and right hanger (Figure 1, Item 16).

NOTE
Tag all wiring assemblies before disconnecting to aid in installation. Remove tags following maintenance. 5. Release three jam nuts (Figure 1, Item 2) and remove two cable terminals (Figure 1, Item 17) and cable terminal (Figure 1, Item 1).

1

2

3

4

5

6 8

7

15 14

9

10

17 16
Figure 1.

13

11 12
M2115105

Transmission Cable Removal.

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0086

REMOVAL - Continued 6. 7. Remove two grommets (Figure 2, Item 4) and grommet (Figure 2, Item 3) from rear cab panel. Push two cables (Figure 2, Item 2) and cable (Figure 2, Item 1) through rear cab panel.

1

3 2 4 4

M2116105

Figure 2. 8.

Transmission Cable Removal.

Remove nut (Figure 3, Item 6), washer (Figure 3, Item 5), washer (Figure 3, Item 4), and clamp (Figure 3, Item 3) from two cables (Figure 3, Item 1). Cut and remove three wire ties (Figure 3, Item 2) from two cables. Remove two locknuts (Figure 3, Item 9), washers (Figure 3, Item 8), clamps (Figure 3, Item 11), and washers (Figure 3, Item 7) from cable (Figure 3, Item 10). Discard locknuts. Near center of vehicle, cut and remove wire tie (Figure 3, Item 2) from cable (Figure 3, Item 10).

9. 10.

2 1 11

3,4,5,6

7

8 9 10

M2117105

Figure 3.

Transmission Cable Removal.

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0086

REMOVAL - Continued 11. Remove two cotter pints (Figure 4, Item 1) and pivots (Figure 4, Item 3) from side transmission shift controls. Remove two pivots (Figure 4, Item 3) from end of cables (Figure 4, Item 3). Discard cotter pins.

1

2

3
M2118105

Figure 4. 12. 13. 14.

Transmission Cable Removal.

Remove cotter pin (Figure 5, Item 3) and pin (Figure 5, Item 4) from clevis (Figure 5, Item 10) through cut out in bracket (Figure 5, Item 2). Discard cotter pin. Remove two screws (Figure 5, Item 8) locknuts (Figure 5, Item 7), and clamp (Figure 5, Item 6) from bracket (Figure 5, Item 1). Discard locknuts. Remove clevis (Figure 5, Item 10) from end of cable by loosening jam nut (Figure 5, Item 5) and unscrewing clevis (Figure 5, Item 10). Remove cable (Figure 5, Item 9) from vehicle.

2 1 3 10 8 9 4

5 7
Figure 5.

6
M2119105

Transmission Cable Removal.

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TM 5-3810-305-23

0086

REMOVAL - Continued 15. 16. 17. 18. Loosen two jam nuts (Figure 6, Item 3) on each cable (Figure 6, Item 1). Disconnect two cables (Figure 6, Item 1) from bulkhead bracket on side of transmission. Remove two cables (Figure 6, Item 1) from vehicle. Remove four nuts (Figure 6, Item 3) and washers (Figure 6, Item 2) from two cables (Figure 6, Item 1).

2,3 1

2,3
M2120105

Figure 6. END OF TASK CLEANING

Transmission Cable Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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0086

INSTALLATION Transmission Cable

1. 2. 3. 4.

Install jam nut (Figure 7, Item 5) and clevis (Figure 7, Item 10) on cable (Figure 7, Item 9) and tighten jam nut (Figure 7, Item 5) against clevis. Position clamp (Figure 7, Item 6) over cable on bracket (Figure 7, Item 1). Install two screws (Figure 7, Item 8) and locknuts (Figure 7, Item 7) on bracket (Figure 7, Item 1). Position clevis (Figure 7, Item 10) on lever (Figure 7, Item 2) and install pin (Figure 7, Item 4) and new cotter pin (Figure 7, Item 3) through cut out in bracket.

2 1 3 10 8 9 4

5 7
Figure 7.

6
M2119105

Transmission Cable Installation.

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TM 5-3810-305-23

0086

INSTALLATION - Continued 5. 6. Install nut (Figure 8, Item 3), two washers (Figure 8, Item 2) and nut on each cable (Figure 8, Item 1). Position two cables (Figure 8, Item 1) in bulkhead bracket on side of transmission. Tighten two jam nuts (Figure 8, Item 3) to secure each cable.

2,3 1

2,3
M2120105

Figure 8. 7.

Transmission Cable Installation.

Install two pivots (Figure 9, Item 3) on cables (Figure 9, Item 2). Install two pivots in valve body on side of transmission and install two cotter pins (Figure 9, Item 1) in pivots.

1

2

3
M2118105

Figure 9.

Transmission Cable Installation.

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0086

INSTALLATION - Continued 8. 9. Install three grommets (Figure 10, Items 3 and 4) in rear cab panel. Push two cables (Figure 10, Item 2) and cable (Figure 10, Item 1) through grommets (Figure 10, Items 3 and 4) in rear of cab panel.

1

3 2 4 4

M2116105

Figure 10. Transmission Cable Installation. 10. 11. 12. Install three jam nuts (Figure 11, Item 2) on cables (Figure 10, Items 1 and 2). Install two cable terminals (Figure 11, Item 16) on cables (Figure 10, Item 2) and cable terminal (Figure 11, Item 1) on cable (Figure 10, Item 1). Install three screws (Figure 11, Item 6), lockwashers (Figure 11, Item 5), nuts (Figure 11, Item 4), clamp (Figure 11, Item 7), shim (Figure 11, Item 8) on lever shim (Figure 11, Item 10) with left hanger (Figure 11, Item 3) and right hanger (Figure 11, Item 15). Install five screws (Figure 11, Item 11), new lockwashers (Figure 11, Item 12), nuts (Figure 11, Item 13), two clamps (Figure 11, Item 14), and two shims (Figure 11, Item 9) on lever shim (Figure 11, Item 17) with right hanger (Figure 11, Item 15) and left hanger (Figure 11, Item 3).

13.

1

2

3

4

5

6 8

7

15 14

9

10

17 16

13

11 12
M2115105

Figure 11. Transmission Cable Installation.

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TM 5-3810-305-23

0086

INSTALLATION - Continued 14. 15. 16. Near center of vehicle install tie wrap (Figure 12, Item 2) on cable (Figure 12, Item 10) to secure cable to vehicle. Install two clamps (Figure 12, Item 11), flatwashers (Figure 12, Item 7), washers (Figure 12, Item 8) and locknuts (Figure 12, Item 9) on cable (Figure 12, Item 10). Install clamp (Figure 12, Item 3), washers (Figure 12, Items 4 and 5), nut (Figure 12, Item 6) to secure two cables (Figure 12, Item 1) under vehicle. Install three tie wraps (Figure 12, Item 2) on cables to secure cables to bottom of vehicle.

2 1 11

3,4,5,6

7

8 9 10

M2117105

Figure 12. END OF TASK ADJUSTMENT Two-Wheel Four-Wheel Cable

Transmission Cable Installation.

1. 2. 3. 4. 5. 6. 7. 8.

Put lever in cab into two-wheel drive position. Pull shaft spool on transmission to full out position. Clamp cable to bracket aligning groove in cable with groove in clamp. Thread yoke jam nut all the way onto rod end. Thread yoke onto rod end and adjust to insert pin. Check lever in cab for full movement from stop to stop. Adjust yoke if lever is not centered between stops. Tighten jam nut on yoke. Insert cotter pin into pin. Check cables (Figure 12, Item 10) and (Figure 12, Item 1) for freedom of movement.

END OF TASK

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0086

FOLLOW-ON MAINTENANCE Install right console panel (WP 0066). END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0087

FIELD MAINTENANCE TRANSMISSION CONTROLS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking He 1/4F (WP 0172, Table 1, Item 102) Qty: 2 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 167) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122)

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0087

REMOVAL 1. 2. 3. 4. 5. Disconnect battery cables (WP 0076). Remove cotter pin (Figure 1, Item 15) and pin (Figure 1, Item 4) from clevis assembly (Figure 1, Item 10) through the cut-out in bracket (Figure 1, Item 3). Discard cotter pin. Remove two screws (Figure 1, Item 9), locknuts (Figure 1, Item 5), and clamp (Figure 1, Item 8) from bracket (Figure 1, Item 3). Discard locknuts. Remove cotter pin (Figure 1, Item 18), pin (Figure 1, Item 20), and two straps (Figure 1, Item 19) from transmission. Discard cotter pin. Remove four capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 1), and bracket (Figure 1, Item 3). Discard lockwashers.

END OF TASK DISASSEMBLY 1. 2. Remove two snaprings (Figure 1, Item 16), pin (Figure 1, Item 17), two spacers (Figure 1, Item 12), and lever (Figure 1, Item 13). Remove cotter pin (Figure 1, Item 14), pin (Figure 1, Item 11), and two straps (Figure 1, Item 19). Discard cotter pin.
1 2 3 4 19 20 5

18 14 17 16

16 15 12 12 13

6 11 10 8 9
M2140105

7

Figure 1. Transmission Controls Maintenance. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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0087

ASSEMBLY 1. 2. 3. Position one strap (Figure 2, Item 19) on each side of lever (Figure 2, Item 13) and install pin (Figure 2, Item 11) and new cotter pin (Figure 2, Item 14). Install two spacers (Figure 2, Item 12) on each side of lever (Figure 2, Item 13) and install pin (Figure 2, Item 17) in bracket (Figure 2, Item 3). Install two snaprings (Figure 2, Item 16) on each end of pin (Figure 2, Item 17).

END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. Position bracket (Figure 2, Item 3) over mounting holes in frame and install four new lockwashers (Figure 2, Item 1) and capscrews (Figure 2, Item 2). Install pin (Figure 2, Item 20) through two straps (Figure 2, Item 19) and install new cotter pin (Figure 2, Item 18). Position clamp (Figure 2, Item 8) over cable on bracket (Figure 2, Item 3) and install two screws (Figure 2, Item 9) and new locknuts (Figure 2, Item 5). Position clevis (Figure 2, Item 10) on lever (Figure 2, Item 13) and install pin (Figure 2, Item 4) and new cotter pin (Figure 2, Item 15). Check control for freedom of movement. Connect battery cables (WP 0076).
1 2 3 4 19 20 5

18 14 17 16

16 15 12 12 13

6 11 10 8 9
M2140105

7

Figure 2. Transmission Controls Maintenance. END OF TASK

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0087

ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove cotter pin (Figure 3, Item 14) and pin (Figure 3, Item 11). Put lever in cab into two-wheel drive position. Pull shaft spool on transmission to full out position. Thread jam nut (Figure 3, Item 6) all the way onto rod end (Figure 3, Item 7). Thread clevis (Figure 3, Item 10) either up or down rod end (Figure 3, Item 7) to adjust. Position clevis (Figure 3, Item 10) on lever (Figure 3, Item 13). Install pin (Figure 3, Item 11) and new cotter pin (Figure 3, Item 14) through lever (Figure 3, Item 13) and clevis (Figure 3, Item 10). Check lever in cab for full movement from stop to stop. Repeat Steps 1 through 7 if not adjusted correctly. Tighten jam nut (Figure 3, Item 6) to clevis (Figure 3, Item 10).
1 2 3 4 19 20 5

18 14 17 16

16 15 12 12 13

6 11 10 8 9
M2140105

7

Figure 3. Transmission Controls Maintenance. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install deck plates (WP 0122). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Outriggers raised and unextended (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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0088

FIELD MAINTENANCE TRANSMISSION ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) References TM 5 3810-305-10 References (cont.) WP 0089 WP 0109 WP 0134 WP 0162 Equipment Condition Power pack removed (WP 0024)

REMOVAL 1. 2. 3. Remove main hydraulic pump from transmission (WP 0134). Remove charge pump from transmission (WP 0089). Remove ground driven steering pump from transmission (WP 0109).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Install ground driven steering pump to transmission (WP 0109). Install charge pump to transmission (WP 0089). Install main hydraulic pump to transmission (WP 0134).

END OF TASK

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0088

FOLLOW-ON MAINTENANCE 1. 2. Install power pack to vehicle (WP 0024). Check transmission for proper operation (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0089

FIELD MAINTENANCE CHARGE PUMP MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 141) Qty: 4 References TM 9-254 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Equipment Condition (cont.) Battery cables disconnected (WP 0076) Deck plates removed (WP 0122)

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TM 5-3810-305-23

0089

REMOVAL 1. 2. 3. Disconnect hoses (Figure 1, Items 5 and 6) from charge pump (Figure 1, Item 1) on right side of transmission main case (Figure 1, Item 4). Position hoses aside. Remove four cap screws (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from charge pump (Figure 1, Item 1). Discard lockwashers. Remove charge pump (Figure 1, Item 1) from transmission main case (Figure 1, Item 4).

3 2 1

4 6 5

M2104105

Figure 1. Charge Pump Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0089-2

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0089

INSTALLATION 1. 2. 3. 4. Install charge pump (Figure 2, Item 1) on transmission main case (Figure 2, Item 4). Install four new lockwashers (Figure 2, Item 3) and capscrews (Figure 2, Item 2) on charge pump. Position hoses (Figure 2, Items 5 and 6) on charge pump (Figure 2, Item 1). Connect hoses (Figure 2, Items 5 and 6) to charge pump (Figure 2, Item 1) on top right side of transmission main case (Figure 2, Item 4).

3 2 1

4 6 5

M2104105

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install deck plates (WP 0122). Connect battery cables (WP 0076).

Charge Pump Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0089-3/4 blank

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TM 5-3810-305-23

0090

FIELD MAINTENANCE CONTROL VALVE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gage, Pressure, Dial Indicating (WP 0171, Table 1, Item 3) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Tester, Valve Spring (WP 0171, Table 1, Item 14) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket, Valve Body (WP 0172, Table 1, Item 88) Qty: 1 Materials/Parts (cont.) Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 89) Qty: 3 Packing, Preformed (WP 0172, Table 1, Item 86) Qty: 1 Seal, Plain (WP 0172, Table 1, Item 17) Qty: 2 Solvent, Cleaning Compound Type III (WP 0170, Table 1, Item 9) Qty: 1 References WP 0140 Equipment Condition Battery cables disconnected (WP 0076) Control valve linkages and hoses removed (WP 0140)

0090-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

DISASSEMBLY

CAUTION
Care must be taken not to lose two detent springs and balls when handling control valve. Failure to follow this caution may result in damage to equipment.

NOTE
Record bore location of balls, springs, and rollers to aid installation. 1. 2. Remove two detent springs (Figure 1, Item 3) and balls (Figure 1, Item 4) from control valve (Figure 1, Item 1). Remove rolled needle (Figure 1, Item 5) and roller (Figure 1, Item 2).

1 5

2

3

4

3

4
M0223105

Figure 1. Control Valve Disassembly.

0090-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

DISASSEMBLY - Continued

NOTE
Flat surface shown as TOP of control valve will be referred to as "top" for this maintenance procedure. Disassembly is started from bottom bore. 3. 4. 5. Remove neutral safety switch (Figure 2, Item 3). Remove reverse warning switch (Figure 2, Item 5) and elbow (Figure 2, Item 4). Remove four pipe plugs (Figure 2, Item 2) from valve body (Figure 2, Item 1).

TOP 1 2

3

4 5
Figure 2. Control Valve Disassembly.
M0224105_1

0090-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

DISASSEMBLY - Continued 6. Remove plug (Figure 3, Item 2) and o-ring (Figure 3, Item 1) from control valve. Discard o-ring.

TOP

1 2
Figure 3. Control Valve Disassembly.
M0225105

0090-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

DISASSEMBLY - Continued

CAUTION
Use care when handling parts. DO NOT scratch the vehicle surface of stems. Failure to follow this caution may cause damage to equipment. 7. 8. Remove plug (Figure 4, Item 5), o-ring (Figure 4, Item 4), seal (Figure 4, Item 6), and stem (Figure 4, Item 7). Discard o-ring and seal. Remove forward/reverse stem (Figure 4, Item 2) and seal (Figure 4, Item 3) from control valve (Figure 4, Item 1). Discard seal.

1

2

3 4 5 6

7

M0226105

Figure 4.

Control Valve Disassembly.

0090-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

DISASSEMBLY - Continued 9. Remove plug (Figure 5, Item 3) and o-ring (Figure 5, Item 2) from control valve (Figure 5, Item 1). Discard o-ring.

TOP

1

2

3
M0227105

Figure 5. Control Valve Disassembly. 10. 11. 12. Remove regulator spool (Figure 6, Item 3) from control valve (Figure 6, Item 1). Remove shim (Figure 6, Item 2) from regulator spool (Figure 6, Item 3). Remove orifice plate (Figure 6, Item 4) and snapring (Figure 6, Item 5) from regulator spool (Figure 6, Item 3).

1 TOP

2 3 4 5

M0228105

Figure 6. Control Valve Disassembly.

0090-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

DISASSEMBLY - Continued 13. Remove dump valve plug (Figure 7, Item 4), o-ring (Figure 7, Item 5), dump valve spring (Figure 7, Item 3), and dump valve (Figure 7, Item 2) from control valve (Figure 7, Item 1). Discard o-ring.

1

2 3 5 4
Figure 7. 14. Control Valve Disassembly.
M0229105

Remove accumulator piston (Figure 8, Item 4), accumulator spring (Figure 8, Item 3), and washer (Figure 8, Item 2) from control valve (Figure 8, Item 1).

TOP

1

2 3 4
Figure 8. END OF TASK Control Valve Disassembly.
M0230105

0090-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

CLEANING

WARNING

• Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. • Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. • Fire extinguishers should be placed nearby when using solvent cleaning compound. • Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. • Eye shields must be worn when cleaning with a wire brush. • Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. • Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound. Dry parts with compressed air.

END OF TASK

0090-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks, or corrosion, and replace if necessary. Inspect opening in orifice plate. Inside diameter should be 0.02 inch (0.5 mm) and outside diameter should be 0.550 to 0.555 inch (13.97 to 14.10 mm). Inspect flatness of valve body. Inspect dump valve and valve spool for scratches, gouges, and wear. Inspect dump valve and valve spool for freedom of movement in valve body. Inspect all parts for cracks and flaking. Inspect all parts for warpage, wear, scratches, and gouges. Inspect sealing surfaces for any scratches and score marks.

WARNING

Safety glasses or face protection must be used when working with compressed air. Failure to follow this warning may result in serious injury to personnel. 10. 11. 12. Use compressed air to clean and inspect oil passages for leakage. Soak all parts in transmission oil prior to installing. Measure detent springs. Spring specifications should be as follows: LOAD 0 lb (0 kg) 7.00 lb (3.18 kg) 11.00 lb (4.99 kg) SPRING HEIGHT 0.97 inch (24.6 mm) 0.75 inch (19.1 mm) 0.625 inch (15.88 mm)

END OF TASK

0090-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

ASSEMBLY 1. 2. 3. Install shim (Figure 9, Item 2) on regulator spool (Figure 9, Item 3). Install snapring (Figure 9, Item 5) and orifice plate (Figure 9, Item 4) on regulator spool (Figure 9, Item 3). Install regulator spool (Figure 9, Item 3) in control valve (Figure 9, Item 1).

1 TOP

2 3 4 5

M0228105

Figure 9. Control Valve Assembly. 4. 5. Install new o-ring (Figure 10, Item 2) on plug (Figure 10, Item 3). Install plug (Figure 10, Item 3) in control valve (Figure 10, Item 1).

TOP

1

2

3
M0231105

Figure 10.

Control Valve Assembly.

0090-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

ASSEMBLY - Continued 6. 7. 8. 9. 10. Install new seal (Figure 11, Item 3) in control valve (Figure 11, Item 1). Install new seal (Figure 11, Item 6) and o-ring (Figure 11, Item 4) on plug (Figure 11, Item 5). Install forward/reverse stem (Figure 11, Item 2) in control valve (Figure 11, Item 1). Install stem (Figure 11, Item 7) in control valve (Figure 11, Item 1). Install plug (Figure 11, Item 5) in control valve (Figure 11, Item 1).

1

2

3 4 5 6

7

M0226105

Figure 11.

Control Valve Assembly.

0090-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

ASSEMBLY - Continued 11. Install washer (Figure 12, Item 2), accumulator spring (Figure 12, Item 3) and accumulator piston (Figure 12, Item 4) in control valve (Figure 12, Item 1).

TOP

1

2 3 4
Figure 12. Control Valve Assembly.
M0230105

NOTE
Depress accumulator piston and accumulator spring in order to install roller in back side of valve body. 12. Install rolled needle (Figure 13, Item 2) and roller (Figure 13, Item 3) in back side of control valve (Figure 13, Item 1).

TOP 1 2

3

M0232105

Figure 13.

Control Valve Assembly.

0090-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

ASSEMBLY - Continued 13. 14. Install new o-ring (Figure 14, Item 5) on dump valve plug (Figure 14, Item 4). Install dump valve (Figure 14, Item 2), dump valve spring (Figure 14, Item 3), and dump valve plug (Figure 14, Item 4) in control valve (Figure 14, Item 1).

1

2 3 5 4
Figure 14. 15. 16. Control Valve Assembly.
M0229105

Install pipe plugs (Figure 15, Item 2) on control valve (Figure 15, Item 1). Install elbow (Figure 15, Item 4), reverse warning switch (Figure 15, Item 5), and neutral safety switch (Figure 15, Item 3) in control valve.

TOP 1 2

3

4 5
Figure 15. Control Valve Assembly.
M0224105_1

0090-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

ASSEMBLY - Continued 17. 18. 19. 20. Install two balls (Figure 16, Item 4) and detent springs (Figure 16, Item 3) in back side of control valve (Figure 16, Item 1). Ensure rolled needle (Figure 16, Item 5) and roller (Figure 16, Item 2) are properly seated. Install control valve linkages and hoses (WP 0139). Connect battery cables (WP 0076).

1 5

2

3

4

3

4
M0223105

Figure 16. END OF TASK PRESSURE CHECKS

Control Valve Assembly.

NOTE
Pressure checks must be made with transmission oil temperature at 160°F to 190°F (71°C to 88°C). Pressure Regulator Test 1. 2. 3. Install 200 psi (1,379 kPa) gage in port (Figure 17, Item 5). Position forward-neutral-reverse shift lever in neutral and 1-2-3-4 shift lever in 1. Start engine and operate at approximately 2,000 rpm while reading pressure indicated on gage. Pressure must be 155 to 180 psi (1,069 to 1,241 kPa). If pressure is within this range, proceed to Clutch Pressure Test. If pressure is not within this range, proceed to Step 4. Shut engine OFF. Remove plug (Figure 17, Item 4), o-ring (Figure 17, Item 3), regulator spool (Figure 17, Item 2) and shims (Figure 17, Item 1). Discard o-ring. Check o-ring for nicks or damage and regulator spool (Figure 17, Item 2) to ensure that it works freely in valve body. Add or remove shims (Figure 17, Item 1) to increase or decrease pressure.

4. 5. 6. 7.

0090-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 5-3810-305-23

0090

PRESSURE CHECKS - Continued Pressure Regulator Test - Continued 8. 9. 10. Install shims (Figure 17, Item 1), regulator spool (Figure 17, Item 2), o-ring (Figure 17, Item 3), and plug (Figure 17, Item 4). Repeat Step 3. If required pressure range cannot be reached through shimming, replacement of charge pump may be required.

1

2

3

4

5

M0233105

Figure 17. Clutch Pressure Test 1. 2. 3. 4. 5. 6. 7.

Control Valve Assembly.

Record pressure indicated on gage with engine idling. Repeat Step 1 for 2nd, 3rd and 4th gears. Apply brakes, shift forward-neutral-reverse lever to forward position, and record pressure. Shift to reverse and record pressure. Return shift lever to neutral and shut engine OFF. Pressures recorded in Steps 1 through 4 must not vary more than 10 psi (69 kPa). If pressures vary more than this, clutch packs must be rebuilt. Remove gage from port.

END OF TASK FOLLOW-ON MAINTENANCE Check for proper operation. END OF TASK END OF WORK PACKAGE

0090-15/16 blank

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TM 5-3810-305-23

0091

FIELD MAINTENANCE TRANSMISSION OIL AND FILTER ELEMENT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Wrench, Oil Filter, Strap (WP 0171, Table 1, Item 32) Materials/Parts Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References TM 9-254 WP 0162 Equipment Condition Transmission oil at operating temperature (TM 5-3810-305-10)

0091-1

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TM 5-3810-305-23

0091

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel. REMOVAL 1. 2. Place a suitable container under oil filter (Figure 1, Item 2). Remove oil filter (Figure 1, Item 2) from filter base (Figure 1, Item 1).

1

2

M0243105

Figure 1. Transmission Oil and Filter Element Removal.

0091-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 5-3810-305-23

0091

REMOVAL - Continued 3. 4. Place a suitable container under transmission (Figure 2, Item 1) and remove drain plug (Figure 2, Item 2). Drain transmission oil from transmission (Figure 2, Item 1).

1

2

M0244105

Figure 2. Transmission Oil and Filter Element Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0091-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 5-3810-305-23

0091

INSTALLATION

NOTE
New or rebuilt transmission will require 20.5 qt (19.40 L) of transmission oil. 1. 2. 3. Install drain plug (Figure 2, Item 2) into transmission (Figure 2, Item 1). Coat oil filter (Figure 3, Item 2) seal with clean transmission oil and fill oil filter with new transmission oil. Install oil filter (Figure 3, Item 2) onto filter base (Figure 3, Item 1) and hand tighten.

1

2

M0243105

Figure 3.

Transmission Oil and Filter Element Installation.

0091-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 5-3810-305-23

0091

INSTALLATION - Continued 4. 5. 6. 7. Remove transmission fill plug (Figure 4, Item 2) from transmission (Figure 4, Item 3) and fill with 12 qt (11.36 L) of transmission oil. Install transmission fill plug (Figure 4, Item 2) into transmission (Figure 4, Item 3). Check for proper fill level with dipstick (Figure 4, Item 1). Repeat Steps 4 through 6 if not at proper level.

1

2

3

M0245105

Figure 4. END OF TASK END OF WORK PACKAGE

Transmission Oil and Filter Element Installation.

0091-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 5-3810-305-23

0092

FIELD MAINTENANCE PUMP ADAPTER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 87) Qty: 1 O-Ring (WP 0172, Table 1, Item 143) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock 1/2 Inch Reg (WP 0172, Table 1, Item 142) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Main hydraulic pump removed (WP 0134)

0092-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 5-3810-305-23

0092

REMOVAL 1. 2. Remove four bolts (Figure 1, Item 3) and lockwashers (Figure 1, Item 4). Discard lockwashers. Remove pump adapter (Figure 1, Item 2) from transmission (Figure 1, Item 1).

1

2 3,4

M0375105

Figure 1. Pump Adapter Removal. END OF TASK

0092-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 5-3810-305-23

0092

CLEANING

WARNING

• Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. • Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. • Fire extinguishers should be placed nearby when using solvent cleaning compound. • Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. • Eye shields must be worn when cleaning with a wire brush. • Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. • Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound. Soak all parts in lubricating oil prior to installation.

END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect all parts for wear, pitting, cracks or corrosion, and replace if necessary.

END OF TASK

0092-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 5-3810-305-23

0092

INSTALLATION 1. 2. Install pump adapter (Figure 2, Item 2) on transmission (Figure 2, Item 1). Install four bolts (Figure 2, Item 3) and new lockwashers (Figure 2, Item 4).

1

2 3,4

M0375105

Figure 2. Pump Adapter Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install main hydraulic pump (WP 0134). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0092-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 5-3810-305-23

0093

FIELD MAINTENANCE FRONT AND REAR DRIVESHAFT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

REMOVAL Front Driveshaft 1. 2. Support front end of driveshaft assembly (Figure 1, Item 1) with jack stand. Remove four capscrews (Figure 1, Item 3) from front spider bearing assembly (Figure 1, Item 2).

2

1

3
M0187105

Figure 1.

Front Driveshaft Removal.

0093-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

REMOVAL - Continued Front Driveshaft - Continued 3. 4. 5. Support rear end of driveshaft assembly (Figure 2, Item 2) with jack stand. Remove four capscrews (Figure 2, Item 3) from rear spider bearing assembly (Figure 2, Item 1). Lower driveshaft assembly (Figure 2, Item 2) and remove from under vehicle.

1

2

3
Figure 2. Front Driveshaft Removal.

M0188105

END OF TASK DISASSEMBLY Front Driveshaft 1. 2. Remove four capscrews (Figure 3, Item 4) and rear spider bearing assembly (Figure 3, Item 3) from tube assembly (Figure 3, Item 2). Remove grease fitting (Figure 3, Item 1) from rear spider bearing assembly (Figure 3, Item 3).

1

4 3
Figure 3.

2
Front Driveshaft Disassembly.

M0189105

0093-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

DISASSEMBLY - Continued Front Driveshaft - Continued 3. 4. 5. 6. 7. 8. Remove four capscrews (Figure 4, Item 8) and front spider bearing assembly (Figure 4, Item 7) from yoke assembly (Figure 4, Item 5). Remove two grease fittings (Figure 4, Item 6) from yoke assembly (Figure 4, Item 5). Loosen dust cap (Figure 4, Item 2). Separate slip yoke assembly (Figure 4, Item 5) from tube assembly (Figure 4, Item 1). Remove washer (Figure 4, Item 3), felt washer (Figure 4, Item 4), and washer (Figure 4, Item 3) from tube assembly (Figure 4, Item 1). Remove dust cap (Figure 4, Item 2) from tube assembly (Figure 4, Item 1).

6 1 2 3 4 5

7

8 3
Figure 4. Front Driveshaft Disassembly.
M0190105

END OF TASK CLEANING Front Driveshaft Clean parts IAW General Maintenance Instructions (WP 0162).

END OF TASK INSPECTION Front Driveshaft Inspect parts IAW General Maintenance Instructions (WP 0162).

END OF TASK

0093-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

ASSEMBLY Front Driveshaft 1. 2. 3. 4. 5. 6. Install dust cap (Figure 5, Item 2) on tube assembly (Figure 5, Item 1). Install split washer (Figure 5, Item 3), felt washer (Figure 5, Item 4), and split washer (Figure 5, Item 3) on tube assembly (Figure 5, Item 1). Install tube assembly (Figure 5, Item 1) into slip yoke assembly (Figure 5, Item 5). Tighten dust cap (Figure 5, Item 2). Install two grease fittings (Figure 5, Item 6) on yoke (Figure 5, Item 5). Install front spider bearing assembly (Figure 5, Item 7) and four capscrews (Figure 5, Item 8) to yoke assembly (Figure 5, Item 5).

6 1 2 3 4 5

7

8 3
Figure 5. Front Driveshaft Assembly. 7. 8. 9. Install grease fitting (Figure 6, Item 1) on rear spider bearing assembly (Figure 6, Item 3). Install rear spider bearing assembly (Figure 6, Item 3) and four capscrews (Figure 6, Item 4) to tube assembly (Figure 6, Item 2). Tighten eight capscrews (Figure 6, Item 4 and Figure 4, Item 8) to 50 ft-lb (68 N•m).
M0190105

1

4 3 2
Figure 6. Front Driveshaft Assembly.
M0189105

END OF TASK

0093-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

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0093

INSTALLATION Front Driveshaft 1. 2. Position driveshaft assembly (Figure 7, Item 2). Install four capscrews (Figure 7, Item 3) in rear spider bearing assembly (Figure 7, Item 1).

1

2

3
Figure 7. 3. 4. 5. 6. Front Driveshaft Installation.

M0188105

Position front end of driveshaft assembly (Figure 8, Item 1). Install four capscrews (Figure 8, Item 3) in front spider bearing assembly (Figure 8, Item 2). Tighten eight capscrews (Figure 8, Item 3) to 50 ft-lb (68 N•m). Check for proper operation.

2

1

3
M0187105

Figure 8.

Front Driveshaft Installation.

0093-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

INSTALLATION - Continued

END OF TASK REMOVAL Rear Driveshaft 1. 2. 3. Remove four capscrews (Figure 9, Item 1) from front spider bearing assembly (Figure 9, Item 2). Remove four capscrews (Figure 9, Item 4) from rear spider bearing assembly (Figure 9, Item 5). Lower driveshaft assembly (Figure 9, Item 3) and remove from under vehicle.

1 2

5
Figure 9.

4

3

M0199105

Rear Driveshaft Removal.

END OF TASK DISASSEMBLY Rear Driveshaft 1. 2. 3. 4. 5. 6. 7. Remove four capscrews (Figure 10, Item 1) and front spider bearing assembly (Figure 10, Item 2) from stub yoke (Figure 10, Item 7). Remove four capscrews (Figure 10, Item 1) and rear spider bearing assembly (Figure 10, Item 8) from slip yoke assembly (Figure 10, Item 4). Unscrew dust cap (Figure 10, Item 5). Separate slip yoke assembly (Figure 10, Item 4) from stub yoke (Figure 10, Item 7). Remove washer (Figure 10, Item 6), felt washer (Figure 10, Item 9), and washer (Figure 10, Item 6) from stub yoke assembly (Figure 10, Item 7). Remove dust cap (Figure 10, Item 5) from stub yoke assembly (Figure 10, Item 7). Remove three grease fittings (Figure 10, Item 3) from front spider bearing assembly (Figure 10, Item 2), rear spider bearing assembly (Figure 10, Item 8), and slip yoke assembly (Figure 10, Item 4).

0093-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

DISASSEMBLY - Continued Rear Driveshaft - Continued

2 1 3

4 5 9 6 3 7

8 1
Figure 10.

3
Rear Driveshaft Disassembly.

M0200105

END OF TASK CLEANING Rear Driveshaft Clean parts IAW General Maintenance Instructions (WP 0162).

END OF TASK INSPECTION Rear Driveshaft Inspect parts IAW General Maintenance Instructions (WP 0162).

END OF TASK

0093-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

ASSEMBLY Rear Driveshaft 1. 2. 3. 4. 5. 6. 7. 8. Install three grease fittings (Figure 11, Item 3). Install dust cap (Figure 11, Item 5) on stub yoke assembly (Figure 11, Item 7). Install split washer (Figure 11, Item 6), felt washer (Figure 11, Item 10), and split washer (Figure 11, Item 1) on stub yoke assembly (Figure 11, Item 7). Install stub yoke (Figure 11, Item 7) into slip yoke assembly (Figure 11, Item 3). Tighten dust cap (Figure 11, Item 5). Install rear spider bearing assembly (Figure 11, Item 9) and four capscrews (Figure 11, Item 1) on yoke assembly (Figure 11, Item 4). Install front spider bearing assembly (Figure 11, Item 2) and four capscrews (Figure 11, Item 1) on stub yoke (Figure 11, Item 7). Tighten eight capscrews (Figure 11, Item 1) to 50 ft-lb (68 N•m).

2 1 3

4 5 9 6 3 7

8 1 3
Figure 11. Rear Driveshaft Assembly.
M0200105

END OF TASK

0093-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00103)

TM 5-3810-305-23

0093

INSTALLATION Rear Driveshaft 1. 2. 3. 4. Position driveshaft assembly (Figure 12, Item 3) under vehicle. Install four capscrews (Figure 12, Item 4) in rear spider bearing assembly (Figure 12, Item 5). Install four capscrews (Figure 12, Item 1) in front spider bearing assembly (Figure 12, Item 2). Tighten eight capscrews (Figure 12, Items 1 and 4) to 50 ft-lb (68 N•m).

1 2

5
Figure 12.

4

3

M0199105

Rear Driveshaft Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0093-9/10 blank

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TM 5-3810-305-23

0094

FIELD MAINTENANCE FRONT AXLE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Gage, Depth, Dial Indicating (WP 0171, Table 1, Item 2) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Materials/Parts Pin, Cotter (WP 0172, Table 1, Item 156) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References TM 5-3810-305-10 WP 0076 WP 0103 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Tire and wheel assemblies removed (WP 0107)

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0094

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. Disconnect and cap all hydraulic lines to steering cylinders, brake lines, and breather hose.

WARNING

Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. Remove two cotter pins (Figure 1, Item 3), washers (Figure 1, Item 4), pins (Figure 1, Item 2), and parking brake assembly (Figure 1, Item 10) from front axle (Figure 1, Item 6). Discard two cotter pins. Let parking brake assembly (Figure 1, Item 10) hang by cable (Figure 1, Item 5).

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel. 5. Disconnect battery negative ground cable (WP 0076).

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 6. Disconnect two wires from speedometer sensor unit.

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0094

REMOVAL - Continued 7. 8. 9. 10. 11. Using floor jack, support front driveshaft (Figure 1, Item 12). Remove four capscrews (Figure 1, Item 1) to disconnect front axle (Figure 1, Item 6) from front driveshaft spider bearing (Figure 1, Item 11). Using hydraulic floor jacks, support front axle (Figure 1, Item 6). Remove eight nuts (Figure 1, Item 7), washers (Figure 1, Item 8), and capscrews (Figure 1, Item 9). Remove front axle (Figure 1, Item 6) from under vehicle.

2 1

3 4 5

6

7

8

12

11 3 2 4 10

9
M0198105

Figure 1. END OF TASK

Front Axle Removal.

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0094

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

CAUTION
Copper sealing washers are not reusable. If a previously tightened connection containing copper sealing washer(s) is loosened, the washer(s) must be replaced before retightening. Failure to follow this caution may result in damage to equipment. 1. Transfer steering cylinders, brake connections, vent hose adapter, and other attaching components to new axle before installing on vehicle.

WARNING

Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. 4. 5. Raise front axle (Figure 2, Item 6) in position under vehicle. Install eight capscrews (Figure 2, Item 9), washers (Figure 2, Item 8), and nuts (Figure 2, Item 7). Tighten eight capscrews to 500 ft-lb (678 N•m). Install four capscrews (Figure 2, Item 1) to connect front axle (Figure 2, Item 6) to front driveshaft spider bearing (Figure 2, Item 11). Tighten capscrews to 50 ft-lb (68 N•m). Position parking brake assembly (Figure 2, Item 10) and cable (Figure 2, Item 5) on front axle (Figure 2, Item 6) and install two pins (Figure 2, Item 2), washers (Figure 2, Item 4), and new cotter pins (Figure 2, Item 3).

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0094

INSTALLATION - Continued

2 1

3 4 5

6

7

8

12

11 3 2 4 10

9
M0198105

Figure 2.

Front Axle Installation.

CAUTION
Speedometer sensor wires must be connected as tagged for speedometer to work properly. Failure to follow this caution may result in damage to equipment. 6. 7. 8. Connect two wires to speedometer sensor unit. Connect all hydraulic lines to breather hose, brake lines, and steering cylinders. Close dipstick cap.

END OF TASK

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TM 5-3810-305-23

0094

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Bleed front brake system (WP 0103). Be sure outer hub drives and center axle differential have been serviced with lubricant (TM 5-3810-305-10). Install tire and wheel assemblies (WP 0107). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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0095

FIELD MAINTENANCE FRONT DIFFERENTIAL ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Grease, General Purpose, Lithium Base (WP 0170, Table 1, Item 25) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealing Compound, Silicone (WP 0170, Table 1, Item 62) Qty: 1 Sealing Compound, Thread Locking (WP 0170, Table 1, Item 65) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Front axle removed (WP 0094) Constant-velocity joint removed (WP 0099) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Tire and wheel assemblies removed (WP 0107)

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0095

REMOVAL

WARNING

Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

CAUTION
Differential assembly may be removed with axle attached to vehicle, but this is not recommended. If differential assembly is removed with axle installed, use extreme care in positioning and hoisting differential assembly. Failure to follow this caution may result in damage to equipment.

NOTE
Removal of differential assembly from axle or axle from vehicle is not required for pinion seal replacement. 1. Position axle with pinion flange on differential assembly (Figure 1, Item 3) in an upward direction.

WARNING

Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. Using an overhead hoist, attach a suitable lifting fixture to input yoke and disc (Figure 1, Item 2). To ease alignment at installation, matchmark differential assembly (Figure 1, Item 3) and axle housing.

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0095

REMOVAL - Continued

WARNING

Heating differential mounting bolts to a temperature of 300°F (149°C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may cause injury or death to personnel. 4. 5. Unstake and loosen pinion nut (Figure 1, Item 1) to aid in disassembly. Remove 10 differential mounting bolts (Figure 1, Item 4) and washers (Figure 1, Item 5) securing differential assembly (Figure 1, Item 3) to axle housing.

NOTE
A tap with a soft-faced mallet may be required to break seal between differential assembly and axle housing. 6. Apply pressure to hoist and lift differential assembly (Figure 1, Item 3) from axle housing approximately 1 inch (25 mm). Rotate differential assembly 90 degrees to align ring gear with clearance cutouts in axle housing and remove from housing.

1 2

4,5
Figure 1.

3
Front Differential Removal.

M0301105

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0095

REMOVAL - Continued

CAUTION
DO NOT interchange bearings, pinions, or input yoke from other axles. Preload is factory set. Failure to follow this caution may result in damage to equipment. 7. 8. 9. Remove pinion nut (Figure 2, Item 1), input yoke (Figure 2, Item 2), and dust shield (Figure 2, Item 8). Discard pinion nut. Remove trunnion (Figure 2, Item 4) and spacer (Figure 2, Item 3), if necessary. Remove input yoke seal (Figure 2, Item 5).

1 8

2

3

4

7

5 6
Figure 2. Front Differential Removal. END OF TASK CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Remove sealant IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound IAW General Maintenance Instructions (WP 0162). Dry parts with compressed air.
M0315105

END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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0095

INSTALLATION

WARNING

Wear protective equipment while heating and handling spacer. Failure to follow this warning may result in serious injury to personnel. 1. 2. 3. Lubricate and install new input yoke seal (Figure 3, Item 5) flush. Heat spacer (Figure 3, Item 3) to approximately 350°F (176°C). Install spacer (Figure 3, Item 3) and trunnion (Figure 3, Item 4). Install input yoke (Figure 3, Item 2), dust shield (Figure 3, Item 8) and new pinion nut (Figure 3, Item 1). Tighten pinion nut (Figure 3, Item 1) to 405 to 433 ft-lb (549 to 587 N•m). Stake pinion nut (Figure 3, Item 1) in two locations 180 degrees apart.

1 8

2

3

4

7

5 6
Figure 3. Front Differential Installation.
M0315105

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0095

INSTALLATION - Continued 4. If differential was disassembled, file off washer face of bolts (Figure 4, Item 1) flush with machined surface of bearing cap (Figure 4, Item 2).

1

2

M0316105

Figure 4. Front Differential Installation.

WARNING

• Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. • Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. • Failure to follow these warnings may result in serious injury or death to personnel. 5. 6. 7. Install a suitable fixture to input yoke and disc (Figure 5, Item 1) and suspend differential assembly (Figure 5, Item 2) over axle housing opening. Spread a bead of silicone sealant around differential assembly opening. Lower differential assembly (Figure 5, Item 2) into axle housing to approximately 1 inch (25 mm) from seating.

NOTE
Differential assembly must be rotated to align with axle shafts and matchmarks made during removal.

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0095

INSTALLATION - Continued 8. 9. 10. 11. Lower and tap differential assembly (Figure 5, Item 2) with a mallet to seat in axle housing. Remove lifting fixture. Apply thread sealant to 10 differential mounting bolts (Figure 5, Item 3) and install with washers (Figure 5, Item 4). Tighten bolts (Figure 5, Item 3) to 58 ft-lb (79 N•m).

1

2

3,4
Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Fill differential assembly with oil (TM 5-3810-305-10). Install front axle assembly (WP 0094). Install constant-velocity joints (WP 0099). Install tire and wheel assemblies (WP 0107). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Front Differential Installation.

M0302105

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0096

FIELD MAINTENANCE PLANETARY WHEEL END MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gage, Depth, Dial Indicating (WP 0171, Table 1, Item 2) Gloves, Leather (WP 0171, Table 1, Item 5) Socket, Wrench, Face Spanner (WP 0171, Table 1, Item 10) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Gasket (WP 0172, Table 1, Item 24) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 O-Ring (WP 0172, Table 1, Item 111) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 25) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Tire and wheel assemblies removed (WP 0107) Battery cables disconnected (WP 0076)

REMOVAL

WARNING

• Weight of brake drum is approximately 81 lb (37 kg). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. • The brake linings contain asbestos. Wear a protective breather respirator when performing maintenance on the break assembly and brake drum. • Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. • DO NOT use compressed air to dry the brake assembly. Let it air dry. • Failure to follow these warnings may cause injury or death to personnel.

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TM 5-3810-305-23

0096

REMOVAL - Continued

NOTE
Jacking bolts may be required to remove brake drum. There is no difference in the maintenance procedures for front and rear planetary wheel ends. 1. 2. 3. Remove three assembly screws (Figure 1, Item 3) and brake drum (Figure 1, Item 2) from wheel hub (Figure 1, Item 1). Position a suitable container to accept oil from wheel end. Rotate wheel hub (Figure 1, Item 1) so that drain plug (Figure 1, Item 4) is at 6 o’clock position. Remove drain plug.

1 2 3

4
M0308105

Figure 1. Planetary Wheel End Removal.

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TM 5-3810-305-23

0096

REMOVAL - Continued 4. 5. 6. Remove fill plug and washer (Figure 2, Item 5) and eight bolts (Figure 2, Item 4) from wheel end cover (Figure 2, Item 3). Remove wheel end cover (Figure 2, Item 3), thrust plug (Figure 2, Item 6), and o-ring (Figure 2, Item 2) from wheel hub (Figure 2, Item 1) as an assembly. A punch and hammer may be required for this. Remove four sector plates (Figure 2, Item 7).

NOTE
DO NOT remove thrust plug from wheel end cover unless replacement is required. 7. Remove o-ring (Figure 2, Item 2) and, if necessary, thrust plug (Figure 2, Item 6) from wheel end cover (Figure 2, Item 3). Discard o-ring.
1

2

3
4 7 6 5
M0309105

Figure 2.

Planetary Wheel End Removal.

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0096

REMOVAL - Continued 8. 9. Remove planetary gear carrier assembly (Figure 3, Item 4) from wheel hub (Figure 3, Item 1) by pulling outward. Remove sun gear (Figure 3, Item 3) and coupler (Figure 3, Item 2).
1

2 3 4

M0310105

Figure 3. Planetary Wheel End Removal.

NOTE
It may be necessary to strike ring gear carrier assembly with a soft-faced mallet to jar centering cone loose before removing. Outer hub bearing assembly comes off when ring gear carrier assembly is removed. 10. Straighten tab on lockwasher (Figure 4, Item 1). Remove spindle nut (Figure 4, Item 2), lockwasher, and centering cone (Figure 4, Item 3). Discard lockwasher.

1

2

3
M0311105

Figure 4. Planetary Wheel End Removal.

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0096

REMOVAL - Continued

WARNING

Weight of hub and studs is approximately 79 lb (36 kg). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 11. Remove ring gear carrier assembly (Figure 5, Item 2) and hub (Figure 5, Item 1) from vehicle.
1

2

M0312105

Figure 5. END OF TASK DISASSEMBLY

Planetary Wheel End Removal.

NOTE
If there are no visible signs of damage, bearing assemblies or oil seal and runner should not be removed. 1. Remove bearing cone (Figure 6, Item 1), if necessary, from ring gear carrier assembly (Figure 6, Item 2).

1

2
Figure 6. Planetary Wheel End Disassembly.

M0313105

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TM 5-3810-305-23

0096

DISASSEMBLY - Continued

NOTE
Hub seal runner remains on pivot and spindle when hub assembly is removed. 2. Remove hub seal runner (Figure 7, Item 1), hub seal (Figure 7, Item 2), and bearing cone (Figure 7, Item 3) from hub (Figure 7, Item 5).

NOTE
Remove hub seal runner only if inspection proves necessary. 3. If hub seal runner (Figure 7, Item 1) is damaged, remove 15 bolts which attach brake assembly to pivot and spindle assembly, and remove brake assembly.

WARNING

Wear protective equipment while heating and handling seal runner. Failure to follow this warning may cause serious injury to personnel. 4. 5. 6. Remove hub seal runner (Figure 7, Item 1), if necessary. Apply moderate heat and use pry bar to remove seal. Discard seal. Remove 10 studs (Figure 7, Item 7), if necessary, from hub (Figure 7, Item 5). Remove two bearing cups (Figure 7, Items 4 and 6) from hub (Figure 7, Item 5) if inspection proves necessary.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. 3. 4. 5. 6. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect ring gear carrier assembly for deformed or scored teeth. Inspect wheel hub and studs for damage. Check inner portion of hub for damaged teeth, rough spots on bearing surface, or cracks. Inspect studs for deformed shanks or damaged threads. Inspect all parts for wear, pitting, cracks, or corrosion. Replace if necessary.

END OF TASK

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0096

ASSEMBLY

WARNING

Wear protective equipment while heating and handling seal runner. Failure to follow this warning may cause serious injury to personnel.

NOTE
Hub seal must be installed in the hub concentric and perpendicular to the axis. 1. 2. 3. 4. 5. 6. Heat hub seal runner (Figure 7, Item 1), if removed, to approximately 176°F (80°C). Install and secure with threadlock compound. If removed, install brake assembly and 15 bolts, which attach the brakes to pivot and spindle assembly. If removed, install two bearing cups (Figure 7, Items 4 and 6). If removed, install bearing cone (Figure 7, Item 3) in hub (Figure 7, Item 5). Install hub seal (Figure 7, Item 3) into hub (Figure 8, Item 5) against shoulder. If removed, install 10 studs (Figure 7, Item 7) to hub (Figure 7, Item 5).

1 2 3 4 5 6

7
M0314105

Figure 7.

Planetary Wheel End Maintenance.

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TM 5-3810-305-23

0096

ASSEMBLY - Continued 7. If removed, heat bearing cone (Figure 8, Item 1) to approximately 176°F (80°C) and install on ring gear carrier (Figure 9, Item 2).

1

2
Figure 8. Planetary Wheel End Assembly. END OF TASK INSTALLATION

M0313105

CAUTION
All parts must be cleaned before installation to prevent damage to gears. 1. Apply grease to hub seal lips and to hub seal runner.

WARNING

Weight of hub and studs is approximately 79 lb (36 kg). Use adequate lifting equipment to lift and support hub and studs. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in injury or death to personnel. 2. 3. Position hub (Figure 9, Item 1) onto pivot and spindle. Install ring gear carrier assembly (Figure 9, Item 2).

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TM 5-3810-305-23

0096

INSTALLATION - Continued
1

2

M0312105

Figure 9. 4.

Planetary Wheel End Installation.

Install centering cone (Figure 10, Item 3), new lockwasher (Figure 10, Item 1), and spindle nut (Figure 10, Item 2). Tighten spindle nut according to procedures in Steps a, b, and c below: a. b. c. Tighten spindle nut (Figure 10, Item 2) while rotating hub to correctly position all components (bearings and spindle cone). Tighten spindle nut to 258 to 295 ft-lb (350 to 400 N•m). Apply 15.8 lb (70 N) tangential force to wheel stud. Adjust spindle nut (Figure 10, Item 2) by loosening until rotation of hub is obtained. Secure spindle nut (Figure 10, Item 2) by bending tab on lockwasher (Figure 10, Item 1).

1

2

3
M0311105

Figure 10.

Planetary Wheel End Installation.

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0096

INSTALLATION - Continued 5. 6. Install coupler (Figure 11, Item 2) and sun gear (Figure 12, Item 3) to wheel hub (Figure 11, Item 1). Install planetary carrier assembly (Figure 11, Item 4).
1

2 3 4

M0310105

Figure 11. 7. 8. 9. 10. 11.

Planetary Wheel End Installation.

Install four sector plates (Figure 12, Item 7) onto wheel hub (Figure 12, Item 1). Lubricate new o-ring (Figure 12, Item 2) and install onto wheel end cover (Figure 12, Item 3). If removed, install thrust plug (Figure 12, Item 6) into wheel end cover. Install wheel end cover (Figure 12, Item 3) with eight bolts (Figure 12, Item 4) and tighten to 58 ft-lb (79 N•m). Install washer and fill plug (Figure 12, Item 5) on wheel end cover (Figure 12, Item 3).
1

2

3
4 7 6 5
M0309105

Figure 12.

Planetary Wheel End Installation.

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TM 5-3810-305-23

0096

INSTALLATION - Continued 12. Install drain plug (Figure 14, Item 4) on wheel hub (Figure 14, Item 1).

WARNING

Weight of brake drum is approximately 81 lb (37 kg). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel. 13. Install brake drum (Figure 13, Item 2) and three assembly screws (Figure 13, Item 3) on wheel hub (Figure 13, Item 1). Tighten screws to 14 to 18 ft-lb (19 to 24 N•m).

1 2 3

4
M0308105

Figure 13. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5.

Planetary Wheel End Installation.

Install tire and wheel assemblies (WP 0107). Fill with oil (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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0097

FIELD MAINTENANCE PIVOT AND SPINDLE ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 100-lb (46 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Trunnion Seal (WP 0172, Table 1, Item 23) Qty: 2 Personnel Required (Two) References WP 0096 WP 0103 WP 0108 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Tires and wheels removed (WP 0107)

REMOVAL

NOTE
There is no difference in the maintenance procedures for front and rear pivot and spindle assemblies. 1. Remove tie rod assembly, if necessary (WP 0108).

NOTE
It is not necessary to remove planetary wheel end or brake assembly from pivot and spindle assembly to remove constant-velocity joint or differential assembly. 2. Remove planetary wheel end (WP 0096).

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all parts. Remove caps, plugs, and tags following maintenance. 3. 4. Disconnect and cap brake lines, if necessary. Remove brake assembly (WP 0103).

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0097

REMOVAL - Continued

WARNING

Weight of pivot and spindle assembly is approximately 69 lb (30 kg). Use adequate lifting equipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. 6. 7. Position hoist above pivot and spindle assembly (Figure 1, Item 3). Support pivot and spindle assembly with sling. Remove eight bolts (Figure 1, Item 1), pivot cap (Figure 1, Item 2), and tie rod lever (Figure 1, Item 4) from spindle assembly (Figure 1, Item 3). Remove and measure shim packs (Figure 1, Item 5) from spindle assembly (Figure 1, Item 3). Record measurements and locations of shims.

1

2

5 3

5 4 1

M0303105

Figure 1.

Pivot and Spindle Assembly Removal.

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0097

REMOVAL - Continued 8. 9. 10. 11. Remove and tag trunnions (Figure 2, Item 1) from spindle assembly (Figure 2, Item 5). Remove upper and lower bearings (Figure 2, Item 4) from trunnions (Figure 2, Item 1), if necessary. Pull pivot and spindle assembly (Figure 2, Item 5) horizontally outward from spindle assembly. If necessary, pull out bearing cups (Figure 2, Item 3).

NOTE
Pivot and spindle assembly consists of a thrust ring on splined end, a shaft bushing on other end, and pivot and spindle. 12. 13. 14. If necessary, remove thrust ring (Figure 2, Item 6) and shaft bushing (Figure 2, Item 8) from pivot and spindle assembly (Figure 2, Item 5). Remove and discard trunnion seals (Figure 2, Item 2) from spindle assembly (Figure 2, Item 5). Remove mid-shaft (Figure 2, Item 7) from spindle assembly (Figure 2, Item 5).

1 2 3 4 5

8

5

6

4 4 2 3 1
M0304105

7

Figure 2. END OF TASK

Pivot and Spindle Assembly Removal.

0097-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00107)

TM 5-3810-305-23

0097

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
If bearings, trunnions, main housing, or pivot spindle have not been replaced, use shim pack thickness recorded during removal in this work package, and go to Step 2. 1. Perform the following steps to determine required lower shimming:

NOTE
Lower shims to ensure alignment of pivot, axle housing sphere, and axle shaft. a. b. c. d. e. Read pivot dimension X (distance from lower machined surface to center of pivot) on lower face of pivot and spindle assembly. Measure height of trunnion hearing assembly and call it Y. Read axle housing measurement Z (distance from bearing cup seat to center line of axle housing) as stamped in bottom of lower trunnion cavity. To calculate thickness of required lower shim, substitute dimensions in the following equation: Lower shim = X - (Y+ Z).

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00107)

TM 5-3810-305-23

0097

INSTALLATION - Continued

Z X AXLE HOUSING MEASUREMENT-Z Y

PIVOT DIMENSION-X
Figure 3. Pivot and Spindle Assembly Installation.

M0305105

0097-5

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TM 5-3810-305-23

0097

INSTALLATION - Continued

WARNING

Weight of housing assembly is approximately 631 lb (286 kg). Use adequate lifting equipment to lift and support housing assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

NOTE
Place axle housing with input yoke in an upward direction. This will ease installation of trunnion/bearing assemblies. 2. Install mid-shaft (Figure 4, Item 2) in pivot and spindle assembly (Figure 4, Item 1).

1

2
M0306105

Figure 4. Pivot and Spindle Assembly Installation. 3. 4. If removed, install thrust ring (Figure 5, Item 6) in splined end and shaft bushing (Figure 5, Item 7) on spindle assembly (Figure 5, Item 5). Grease center bore of pivot and spindle assembly (Figure 5, Item 5).

NOTE
If bearing cups were removed, install them at this time using a bearing installing tool. Apply grease to trunnion bore in axle housing. 5. 6. Pack trunnion bearings (Figure 5, Item 4) with grease. Install new trunnion seals (Figure 5, Item 2) and bearing cups (Figure 5, Item 3) onto trunnions (Figure 5, Item 1).

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TM 5-3810-305-23

0097

INSTALLATION - Continued

WARNING

Weight of pivot and spindle assembly is approximately 69 lb (30 kg). Use adequate lifting equipment to lift and support pivot and spindle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. 9. Install pivot and spindle assembly (Figure 5, Item 5) onto axle housing. Lubricate trunnion bores in pivot and spindle assembly (Figure 5, Item 5). Insert trunnions (Figure 5, Item 1) into axle housing through pivot and spindle assembly (Figure 5, Item 5).

1 2 3 4 7 5

6 4 4 3 2 1
M0307105

Figure 5. Pivot and Spindle Assembly Installation.

0097-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00107)

TM 5-3810-305-23

0097

INSTALLATION - Continued

NOTE
Ensure correct shim packs are with trunnion and bearing assemblies. 10. Install lower shim packs (Figure 6, Item 5).

CAUTION
DO NOT tighten bolts at this time. Damage to axle could result. 11. Install tie rod lever (Figure 6, Item 4) and four bolts (Figure 6, Item 1) to pivot and spindle assembly (Figure 6, Item 3).

NOTE
If axle housing, pivot and spindle assembly, or trunnion assemblies have been replaced, shimming must be checked and a preload check must be made. If not, go to Step 13. 12. Perform the following procedures to determine the required upper shimming: a. b. Install all shims (Figure 6, Item 5) supplied in shim kit. Install pivot cap (Figure 6, Item 2) and bolts (Figure 6, Item 1). Tighten bolts in diagonal pattern to 30 ft-lb (41 N•m), then retighten them in the same pattern, increasing the torque in 2 ft-lb (2.7 N•m) increments until all have been tightened to 35 ft-lb (47 N•m). Move pivot cup (Figure 6, Item 2) through 5 to 10 complete turns to seat bearing. Using the procedure from Step b, re-tighten bolts (Figure 6, Item 1) to 35 ft-lb (47 N•m). Using a feeler gage, measure the gap between pivot and spindle assembly (Figure 6, Item 3) and pivot cap (Figure 6, Item 2) on all four sides. The average of the gaps is the amount to be subtracted from shim kit to obtain upper shim pack (Figure 6, Item 5). Remove bolts (Figure 6, Item 1), pivot cap (Figure 6, Item 2), and shim (Figure 6, Item 5).

c. d. e. f. g. 13. 14. 15. 16.

Install shim pack (Figure 6, Item 5) onto upper trunnion/bearing assembly. Apply grease to bore of pivot cap (Figure 6, Item 2) and snug pivot cap to pivot and spindle assembly (Figure 6, Item 3) with bolts (Figure 6, Item 1). Tighten all bolts (Figure 6, Item 1) to 542 ft-lb (735 N•m). Install pivot and spindle assembly (Figure 6, Item 3).

0097-8

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TM 5-3810-305-23

0097

INSTALLATION - Continued

1

2

5 3

5 4 1

M0303105

Figure 6. Pivot and Spindle Assembly Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install tires and wheels (WP 0107). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0098

FIELD MAINTENANCE PIVOT BEARINGS (TYPE II) MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Puller Set, Mechanical (WP 0171, Table 1, Item 38) Wrench, Torque, 1/2 Inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Materials/Parts Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 242 (WP 0170, Table 1, Item 56) Qty: 1 References WP 0162 Equipment Condition Perform sectionalization of equipment (TM 5-3810-305-10)

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TM 5-3810-305-23

0098

REMOVAL

NOTE
Do not disassemble unless pivot is not turning freely. 1. 2. 3. 4. Remove two capscrews (Figure 1, Item 1), washers (Figure 1, Item 2), cap (Figure 1, Item 3), and shims (Figure 1, Item 4) from housing assembly (Figure 1, Item 7). Using a bearing puller, remove housing assembly (Figure 1, Item 7) from frame spud (Figure 1, Item 8). Remove cone (Figure 1, Item 5) and two cups (Figure 1, Item 6) from housing assembly (Figure 1, Item 7). Remove cone (Figure 1, Item 5) from spud (Figure 1, Item 8).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

CAUTION
There is a limit to which gaging material will compress, thus resulting in a false measurement. If 0.12 inch (3.0 mm) material crushes to below 0.05 inch (1.3 mm), remeasure using 0.06 inch (1.5 mm) material.

NOTE
If using new parts, before installing cap and capscrews, place one piece of either 0.12 inch(3.0 mm) or 0.06 inch x 2.00 inch (1.5 x 50.8 mm) gaging material across end of spud. Install cap and capscrews and evenly torque until no end play is felt in bearing, and slight resistance is felt in bearing rotation. Remove capscrew, cap and gaging material. Measure, using a micrometer, to find proper shim pack equal to or up to 0.002 inch (0.05 mm) thicker than measurement. 1. 2. 3. 4. 5. 6. 7. Pack bearings with grease. Install two cups (Figure 1, Item 5) and one cone (Figure 2, Item 6) into housing assembly (Figure 1, Item 7). Install housing assembly (Figure 1, Item 7) onto spud (Figure 1, Item 8). Install one cone (Figure 1, Item 6) onto spud (Figure 2, Item 8). Apply sealant compound on threads of two capscrews (Figure 1, Item 1). Install shims (Figure 1, Item 4), cap (Figure 1, Item 3), two washers (Figure 1, Item 2), and capscrews (Figure 1, Item 1) to housing assembly (Figure 1, Item 7). Tighten two capscrews (Figure 1, Item 1) to 74 ft-lb (100 N•m).

0098-2

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TM 5-3810-305-23

0098

INSTALLATION - Continued

1 2 3 4 5

6

7 5 6

8

M2300105

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE

Pivot Bearings (Type II) Installation.

Perform sectionalization of equipment (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

0098-3/4 blank

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TM 5-3810-305-23 FIELD MAINTENANCE CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE

0099

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, 1/2 inch Drive Ratcheting, 250 ftlb (WP 0171, Table 1, Item 33) Materials/Parts Grease, Automotive and Artillery Qty: 1 (WP 0170, Table 1, Item 20) Grease, Ball and Roller Bearing Qty: 1 (WP 0170, Table 1, Item 31) Parts Kit, Steering Qty: 1 (WP 0172, Table 1, Item 22) Materials/Parts (cont.) Rag, Wiping Qty: 1 (WP 0170, Table 1, Item 52) Sealing Compound, Silicone Qty: 1 (WP 0170, Table 1, Item 62) References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Pivot and spindle assembly removed (WP 0097)

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00109)

TM 5-3810-305-23

0099

REMOVAL

NOTE
• • 1. 2. There is no difference in the maintenance procedures for front and rear constantvelocity joint and axleshaft. Pivot and spindle assembly must be removed to remove constant-velocity joint and shaft assembly.

Remove nut (Figure 1, Item 7) and seal assembly (Figure 1, Item 8) from bowl (Figure 1, Item 3). Remove face seal (Figure 1, Item 6) and o-ring (Figure 1, Item 4) from bowl (Figure 1, Item 3). Discard o-ring.

CAUTION
If a slide hammer or pry bar is used, extreme care must be exercised to prevent damage to bowl.

NOTE
It may be necessary to use a pry bar or slide hammer and ring to remove bowl. 3. Remove bowl (Figure 1, Item 3), guide bushing (Figure 1, Item 2), and o-ring (Figure 1, Item 1) from axle housing (Figure 1, Item 5). Discard o-ring.

8 1 7 6 5 4 3 2
M0195105

Figure 1. 4. 5.

Constant-Velocity Joint and Axle Shaft Removal.

Remove constant-velocity joint (Figure 2, Item 2) and axle shaft (Figure 2, Item 4) from axle housing (Figure 2, Item 3). Remove oil baffle (Figure 2, Item 1) only if there is visible damage.

0099-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00109)

TM 5-3810-305-23 REMOVAL - Continued

0099

1

4 3
Figure 2.

2
Constant-Velocity Joint and Axle Shaft Removal.

M0196105

NOTE
Left and right axle shafts are different lengths. It may be necessary to place axle shaft into a soft-faced vise to separate it from constant-velocity joint. Once it is secure in the vise, use a brass drift to remove joint from shaft. A “C" ring mounted on the shaft will compress into a groove to slip through joint. It will expand when shaft is out of joint. 6. Separate axle shaft (Figure 3, Item 1) from constant-velocity joint (Figure 3, Item 2).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

CAUTION
All parts must be clean before installation to prevent damage to constant-velocity joint.

0099-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00109)

TM 5-3810-305-23 INSTALLATION - Continued

0099

NOTE
Make sure axle shaft has a “C" ring installed in the groove before assembling constantvelocity joint and shaft. “C" ring will be compressed as it goes through joint and will expand to hold assembly when compression is released. 1. Insert end of axle shaft (Figure 3, Item 1) into constant-velocity joint (Figure 3, Item 2).

1 2

M0197105

Figure 3. 2. 3. 4.

Constant-Velocity Joint and Axle Shaft Maintenance.

Lubricate constant-velocity joint (Figure 4, Item 2) and inner surface of axle housing (Figure 4, Item 3). Install oil baffle (Figure 4, Item 1), if removed. Insert axle shaft (Figure 4, Item 4) and constant-velocity joint (Figure 4, Item 2) into axle housing (Figure 4, Item 3).

1

4 3
Figure 4.

2

M0196105

Constant-Velocity Joint and Axle Shaft Installation.

0099-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00109)

TM 5-3810-305-23 INSTALLATION - Continued 5. 6.

0099

Place guide bushing (Figure 5, Item 2) over small end of bowl (Figure 5, Item 3) and push to large portion of bowl. Lubricate new o-ring (Figure 5, Item 4) and face seal (Figure 5, Item 6) with ball and roller bearing grease and install on bowl (Figure 5, Item 3).

NOTE
Make sure o-ring is on rear of guide bushing. 7. Lubricate with ball and roller bearing grease and install new o-ring (Figure 5, Item 1), guide bushing (Figure 5, Item 2), bowl (Figure 6, Item 3), new o-ring (Figure 5, Item 4), and face seal (Figure 6, Item 6) as an assembly into axle housing (Figure 5, Item 5). Using ball and roller bearing grease, lubricate seal assembly (Figure 5, Item 8) and install on bowl. Fill free intervals between parts with grease.

8.

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 9. 10. Apply a bead of silicone sealant around threaded portion of nut (Figure 5, Item 7). Install nut (Figure 5, Item 7). Turn nut in counterclockwise direction to engage the leading thread. Tighten nut in clockwise direction to 100 ft-lb (136 N•m).

0099-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00109)

TM 5-3810-305-23 INSTALLATION - Continued

0099

8 1 7 6 5 4 3 2
M0195105

Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Constant-Velocity Joint and Axle Shaft Installation.

Install pivot and spindle assembly (WP 0097). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00109)

TM 5-3810-305-23

0100

FIELD MAINTENANCE REAR AXLE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References WP 0074 References (cont.) WP 0103 WP 0152 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Tire and wheel assemblies removed (WP 0107) Tie rod assembly removed (WP 0108) Steering cylinder removed (WP 0112)

0100-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 5-3810-305-23

0100

REMOVAL 1. 2. Use outriggers or jack to raise tires off ground. Support frame with jack stands.

NOTE
Tag all wire assemblies for disconnecting to aid in installation. 3. Disconnect axle centering indicator electrical wire (WP 0074).

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 4. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. 5. 6. 7. 8. 9. 10. Disconnect and cap all hydraulic lines to steering cylinders, brake lines, and breather hose. Disconnect and remove rear axle lockout cylinders retaining pins (WP 0152). Remove four capscrews (Figure 1, Item 2) to disconnect rear axle (Figure 1, Item 6) from rear driveshaft spider bearing assembly (Figure 1, Item 3). Using hydraulic floor jacks, support rear axle (Figure 1, Item 6). Matchmark two caps (Figure 1, Item 5) and bushings (Figure 1, Item 4). Remove eight capscrews (Figure 1, Item 7), washers (Figure 1, Item 8), two caps (Figure 1, Item 5), and grease fitting (Figure 1, Item 1).

0100-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 5-3810-305-23

0100

REMOVAL - Continued

1

8 7 6 5 4 3 2
M0318105

Figure 1. END OF TASK CLEANING

Rear Axle Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0100-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 5-3810-305-23

0100

INSTALLATION

CAUTION
Copper sealing washers are not reusable. If a previously tightened connection containing copper sealing washer(s) is loosened, washer(s) must be replaced before retightening. Failure to follow this procedure may result in damage to equipment. 1. Transfer steering cylinders, brake connections, vent hose adapter and other attaching components to new axle before installing on vehicle.

WARNING

Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. 4. 5. 6. 7. 8. 9. 10. Apply threadlock compound to the outside diameter of bushing (Figure 2, Item 4) and install. Raise rear axle (Figure 2, Item 6) in position under vehicle. Install grease fittings (Figure 2, Item 1), capscrews (Figure 2, Item 5), eight washers (Figure 2, Item 8), and capscrews (Figure 2, Item 7). Tighten eight capscrews (Figure 2, Item 5) to 100 ft-lb (136 N•m). Install four capscrews (Figure 2, Item 2) to connect rear axle (Figure 2, Item 6) to driveshaft spider bearing assembly (Figure 2, Item 3). Install lockout cylinder retaining pins (WP 0152). Connect all brake lines, breather hose and hydraulic lines. Connect axle centering indicator electrical wire (WP 0074). Bleed rear brake system (WP 0103). Ensure outer hub drives and center axle differential have been serviced with lubricant, and bushings (Figure 2, Item 4) greased.

0100-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 5-3810-305-23

0100

INSTALLATION - Continued

1

8 7 6 5 4 3 2
M0318105

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install steering cylinder (WP 0112). Install tie rod assembly (WP 0108). Install tire and wheel assemblies (WP 0107). Close dipstick cap.

Rear Axle Installation.

Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0101

FIELD MAINTENANCE REAR DIFFERENTIAL ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Leather (WP 0171, Table 1, Item 5) Indicator, Dial (WP 0171, Table 1, Item 6) Suitable Lifting Device, 5,000-lb (2,268 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 lbft (WP 0171, Table 1, Item 34) Materials/Parts Gasket (WP 0172, Table 1, Item 112) Qty: 1 Nut (WP 0172, Table 1, Item 21) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Personnel Required (Two) References WP 0095 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Oil from differential removed (TM 5-3810-305-10) Tires and wheels removed (WP 0107) Constant-velocity joint removed (WP 0099) Rear axle removed (WP 0100)

0101-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0101

REMOVAL

WARNING

Weight of axle assembly is approximately 1,323 lb (600 kg). Use adequate lifting equipment to lift and support axle assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

CAUTION
Differential assembly may be removed with axle attached to vehicle, but this is not recommended. If differential assembly is removed with axle installed, be careful when positioning and hoisting differential assembly. Failure to follow this caution may result in damage to equipment.

NOTE
Removal of differential assembly from axle or axle from vehicle is not required for pinion seal replacement. 1. Position axle with pinion flange on differential assembly (Figure 1, Item 7) in an upward direction.

WARNING

Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. 3. Using an overhead hoist, attach a suitable lifting fixture to input yoke (Figure 1, Item 2) and disc. To ease alignment at installation, matchmark differential assembly (Figure 1, Item 7) and axle housing.

WARNING

Heating differential mounting bolts to a temperature of 300°F (149°C) may be required to break down thread sealing compound. Wear protective equipment while heating and handling differential mounting bolts. Failure to follow this warning may cause injury or death to personnel. 4. Unstake and loosen pinion nut (Figure 1, Item 1) to aid in disassembly of differential assembly (Figure 1, Item 7).

0101-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0101

REMOVAL - Continued 5. Remove 10 differential mounting bolts (Figure 1, Item 6) and washers securing differential assembly (Figure 1, Item 7) to axle housing.

NOTE
A tap with a soft-faced mallet may be required to break seal between differential assembly and axle housing. 6. Apply pressure to hoist and lift differential assembly (Figure 1, Item 7) from axle housing approximately 1 inch (25 mm). Rotate differential 90 degrees to align ring gear with clearance cutouts in axle housing and remove from housing.

CAUTION
DO NOT interchange bearings, pinions, or input yoke from other axles. Preload is factory set. Failure to follow this caution may result in damage to equipment. 7. 8. 9. Remove pinion nut (Figure 1, Item 1), input yoke (Figure 1, Item 2), and dust shield (Figure 1, Item 8). Discard pinion nut. Remove trunnion (Figure 1, Item 4) and spacer (Figure 1, Item 3), if necessary. Remove input yoke seal (Figure 1, Item 5).

1 8

2

3

4

7

5 6
Figure 1. END OF TASK Rear Differential Assembly Removal.
M0315105

0101-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0101

CLEANING 1. 2. 3. 4. Clean parts IAW General Maintenance Instructions (WP 0162). Remove sealant IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound IAW General Maintenance Instructions (WP 0162). Dry parts with compressed air.

END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

WARNING

Wear protective equipment while heating and handling spacer. Failure to follow this warning may result in serious injury to personnel. 1. 2. Lubricate and install new input yoke seal (Figure 2, Item 5) flush. Heat spacer (Figure 2, Item 3) to approximately 350°F (176°C). Install spacer and trunnion (Figure 2, Item 4).

0101-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0101

INSTALLATION - Continued 3. Install input yoke (Figure 2, Item 2), dust shield (Figure 2, Item 8) and new pinion nut (Figure 2, Item 1). Tighten pinion nut to 405 to 433 ft-lb (549 to 587 N•m). Stake pinion nut in two locations 180 degrees apart.

1 8

2

3

4

7

5 6
Figure 2. 4. Rear Differential Assembly Installation.
M0315105

If differential was disassembled, file off washer face of bolts (Figure 3, Item 1) flush with machined surface of bearing cap (Figure 3, Item 2).

1

2

M0316105

Figure 3.

Rear Differential Assembly Installation.

0101-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0101

INSTALLATION - Continued

WARNING

• Weight of differential assembly is approximately 120 lb (54 kg). Use adequate lifting equipment to lift and support differential assembly. DO NOT lift over personnel or let personnel walk underneath suspended load. • Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. • Failure to follow these warnings may result in serious injury or death to personnel. 5. 6. 7. Install a suitable lifting fixture to input yoke (Figure 4, Item 3) and disc and suspend differential assembly (Figure 4, Item 5) over axle housing opening. Spread a bead of silicone sealant around differential assembly opening. Lower differential assembly (Figure 4, Item 5) into axle housing to approximately 1 inch (25 mm) from seating.

NOTE
Differential assembly must be rotated to align with axle shafts and marks made during removal. 8. 9. 10. 11. Lower and tap differential assembly (Figure 4, Item 5) with a mallet to seat in axle housing. Remove lifting fixture. Apply threadlock compound to 10 mounting bolts (Figure 3, Item 4) and install to secure differential assembly (Figure 4, Item 5) to axle housing. Tighten 10 mounting bolts (Figure 4, Item 4) to 58 ft-lb (79 N•m).

0101-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0101

INSTALLATION - Continued

1

2

3

5

4
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install rear axle (WP 0100). Fill differential assembly with oil (TM 5-3810-305-10). Install constant-velocity joints (WP 0099). Install tire and wheel assemblies (WP 0107). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Rear Differential Assembly Installation.

M0317105

END OF TASK END OF WORK PACKAGE

0101-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 5-3810-305-23

0102

FIELD MAINTENANCE PARKING BRAKE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Pin, Cotter 3/32X1 Inch (WP 0172, Table 1, Item 122) Qty: 1 Pin, Cotter 3X30 (WP 0172, Table 1, Item 156) Qty: 4 Pin, Cotter (WP 0172, Table 1, Item 158) Qty: 1 Grease, Automotive and Artillery (WP 0170, Table 1, Item 20) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Washer, Lock 3/8 Inch (WP 0172, Table 1, Item 12) Qty: 2 Materials/Parts (cont.) Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 16) Qty: 4 Washer, Split (WP 0172, Table 1, Item 95) Qty: 6 References WP 0076 WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Constant-velocity joint removed (WP 0099) Battery cables disconnected (WP 0076)

0102-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

REMOVAL 1. 2. 3. 4. Remove cotter pin (Figure 1, Item 2) and pin (Figure 1, Item 1) from caliper assembly (Figure 1, Item 3). Discard cotter pin. Remove yoke (Figure 1, Item 13), nut (Figure 1, Item 11), lockwasher (Figure 1, Item 12), and spring (Figure 1, Item 10) from end of cable (Figure 1, Item 7). Discard lockwasher. Remove two nuts (Figure 1, Item 5), lockwashers (Figure 1, Item 4), capscrews (Figure 1, Item 9), and clamp (Figure 1, Item 8) from cable (Figure 1, Item 7). Discard lockwashers. Remove cable (Figure 1, Item 7) from bracket (Figure 1, Item 6).

2 1 13 12 11 10 4 5 6 9 8

3

7

M0528105

Figure 1. Parking Brake Removal. 5. 6. Remove four cotter pins (Figure 2, Item 2), washers (Figure 2, Item 3), and two mounting pins (Figure 2, Item 1) from caliper assembly (Figure 2, Item 4) on front axle. Discard cotter pins. Remove caliper assembly (Figure 2, Item 4) from front axle for further disassembly.

2 1

3

4

3
M0534105

Figure 2. Parking Brake Removal.

0102-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

REMOVAL - Continued

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 7. 8. Disconnect wiring harness on sensor (Figure 3, Item 3). Remove jam nut (Figure 3, Item 1) and sensor (Figure 3, Item 3) from bracket (Figure 3, Item 2).

1

2 3

M0530105

Figure 3. 9.

Parking Brake Removal.

Remove four locknuts (Figure 4, Item 3), washers (Figure 4, Item 2), washers (Figure 4, Item 1), and clamps (Figure 4, Item 4) to release cable (Figure 4, Item 5) from vehicle frame. Discard locknuts.

1 5

2 3 4

M0531105

Figure 4.

Parking Brake Removal.

0102-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

REMOVAL - Continued 10. Remove two nuts (Figure 5, Item 3), lockwashers (Figure 5, Item 4), capscrews (Figure 5, Item 9), spacer (Figure 5, Item 2), clamp (Figure 5, Item 12), and two spacers (Figure 5, Item 13) from cable (Figure 5, Item 1) mounted to lever (Figure 5, Item 6). Discard lockwashers. Remove cotter pin (Figure 5, Item 5) and pin (Figure 5, Item 7) to release cable (Figure 5, Item 1) from lever (Figure 5, Item 6). Discard cotter pin. Remove cable (Figure 5, Item 1) by pulling out of cab. Remove four nuts (Figure 5, Item 11) and lockwashers (Figure 5, Item 10) from rear of cab. Discard lockwashers. Remove four capscrews (Figure 5, Item 8) inside cab to remove lever (Figure 5, Item 6).

11. 12. 13. 14.

2 1

3 4 5 6

13 12 11 10 9 8 7
M0532105

Figure 5. Parking Brake Removal. END OF TASK DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Remove cotter pin (Figure 6, Item 13), castle nut (Figure 6, Item 12), and washer (Figure 6, Item 14) from stud in cam side casting (Figure 6, Item 5). Discard cotter pin. Remove operating cam (Figure 6, Item 11) from stud in cam side casting (Figure 6, Item 5). Remove two springs (Figure 6, Item 4) and spring (Figure 6, Item 7) from side casting (Figure 6, Item 5) and carrier casting (Figure 6, Item 6). Remove two pad holder assemblies (Figure 6, Item 8) from side casting (Figure 6, Item 5) and carrier casting (Figure 6, Item 6). Remove two bolts (Figure 6, Item 1), washers (Figure 6, Item 2), and bracket (Figure 6, Item 3) from side casting (Figure 6, Item 5). Remove bolt (Figure 6, Item 15) and washer (Figure 6, Item 9) to separate cam side casting (Figure 6, Item 5) and carrier casting (Figure 6, Item 6). Remove two push pins (Figure 6, Item 10) from cam side casting (Figure 6, Item 5).

0102-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

DISASSEMBLY - Continued

6

7

5 3 2 1 8 14 13 12
Figure 6. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

4

15 10 11 9

4

M0533105

Parking Brake Disassembly.

0102-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

ASSEMBLY

NOTE
• Lightly lubricate all moving parts except friction plates. • Stamped on the back of each pad holder is a code number. The first or first and second numbers specify the friction material type. The new friction pad material must be the same as the pads being replaced. 1. 2. 3. 4. 5. 6. 7. Position two pad holder assemblies (Figure 7, Item 8) on cam side casting (Figure 7, Item 5) and carrier casting (Figure 7, Item 6). Install two springs (Figure 7, Item 4) and spring (Figure 7, Item 7) holding pad holder assemblies (Figure 7, Item 8) in place. Position cam side casting (Figure 7, Item 5) and carrier casting (Figure 7, Item 6) together. Install washer (Figure 7, Item 9) and bolt (Figure 7, Item 15). Tighten bolt to 32 ft-lb (43 N•m). Install bracket (Figure 7, Item 3) with two washers (Figure 7, Item 2) and bolts (Figure 7, Item 1). Tighten bolts to 32 ft-lb (43 N•m). Install two push pins (Figure 7, Item 10) in cam side casting (Figure 7, Item 5). Install operating cam (Figure 7, Item 11) on stud in cam side casting (Figure 7, Item 5). Install washer (Figure 7, Item 14) and castle nut (Figure 7, Item 12) on stud in cam side casting (Figure 7, Item 5). Do not install cotter pin (Figure 7, Item 13) at this time. See Installation, Step 14 in this work package. All sliding parts must move freely.

8.

6

7

5 3 2 1 8 14 13 12 11
M0533105

4

15 10 9

4

Figure 7. Parking Brake Assembly. END OF TASK

0102-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

INSTALLATION 1. 2. 3. 4. Install four capscrews (Figure 8, Item 8), new lockwashers (Figure 8, Item 10), and nuts (Figure 8, Item 11) securing lever (Figure 8, Item 6) to rear of cab. Push cable (Figure 8, Item 1) through rear of cab. Install pin (Figure 8, Item 7) and new cotter pin (Figure 8, Item 5), attaching end of cable (Figure 8, Item 1) to lever (Figure 8, Item 6). Install two spacers (Figure 8, Item 13), clamp (Figure 8, Item 12), spacer (Figure 8, Item 2), two capscrews (Figure 8, Item 9), new lockwashers (Figure 8, Item 4), nuts (Figure 8, Item 3) and mounting cable (Figure 8, Item 1) to lever (Figure 8, Item 6).

2 1

3 4 5 6

13 12 11 10 9 8 7
M0532105

Figure 8. 5.

Parking Brake Installation.

Install four clamps (Figure 9, Item 4), washers (Figure 9, Item 1), new lockwashers (Figure 9, Item 2), and nuts (Figure 9, Item 3) to secure cable (Figure 9, Item 5) to vehicle frame.

1 5

2 3 4

M0531105

Figure 9.

Parking Brake Installation.

0102-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

INSTALLATION - Continued 6. 7. Install sensor (Figure 10, Item 3) on bracket (Figure 10, Item 2) with jam nut (Figure 10, Item 1). Adjust sensor. Connect wiring harness to sensor (Figure 10, Item 3). Note tag from removal.

1

2 3

M0530105

Figure 10. Parking Brake Installation. 8. 9. Position caliper assembly (Figure 11, Item 4) on front axle. Apply grease to two mounting pins (Figure 11, Item 1). Install mounting pins, four washers (Figure 11, Item 3), and new cotter pins (Figure 11, Item 2), securing caliper assembly (Figure 11, Item 4) to front axle.

2 1

3

4

3
M0534105

Figure 11. Parking Brake Installation. 10. 11. 12. 13. Install clamp (Figure 12, Item 8), two capscrews (Figure 12, Item 9), new lockwashers (Figure 12, Item 4), and nuts (Figure 12, Item 5) to secure cable (Figure 12, Item 7) to bracket (Figure 12, Item 6). Install spring (Figure 12, Item 10), new lockwasher (Figure 12, Item 12), nut (Figure 12, Item 11), and yoke (Figure 12, Item 13) on end of cable (Figure 12, Item 7). Install pin (Figure 12, Item 1) and new cotter pin (Figure 12, Item 2) in caliper assembly (Figure 12, Item 3). Check cable (Figure 12, Item 7) for correct adjustment and ease of movement.

0102-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

INSTALLATION - Continued

2 1 13 12 11 10 4 5 6 9 8

3

7

M0528105

Figure 12. 14. 15.

Parking Brake Installation.

With lever in cab in UP position, pins (Figure 13, Item 2) should rest in bottom of groove in cam (Figure 13, Item 3). Adjust two pad holder assemblies (Figure 13, Item 1) clearance to 0.010 to 0.020 inch (0.25 to 0.51 mm) by turning castle nut (Figure 13, Item 4) in or out until proper clearance has been obtained. Install new cotter pin (Figure 13, Item 5).

1

2 5 4
Figure 13. Parking Brake Installation.

3
M0535105

0102-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0102

INSTALLATION - Continued 16. 17. 18. 19. Additional adjustment can be made on lever. Turn lever handle right to tighten cable, or left to loosen cable. Loosen jam nut (Figure 14, Item 1) on sensor (Figure 14, Item 2). Using a feeler gage, adjust sensor so the gap between sensor and parking brake disc measures 0.025 to 0.040 inch (0.64 to 1.02 mm). Tighten jam nut. Inspect actuator linkage for adequate freedom of movement for positive brake operation. Fill and bleed brake system (WP 0103).

1

2

M0536105

Figure 14. Parking Brake Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Connect battery cables (WP 0076). Install constant-velocity joints (WP 0099). Raise and retract outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0102-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 5-3810-305-23

0103

FIELD MAINTENANCE BRAKE ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, 3/4 Inch Drive Ratcheting, 600 ftlb (WP 0171, Table 1, Item 34) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive, 75 ft-lb (WP 0171, Table 1, Item 36) Materials/Parts Brake Fluid, Automotive (WP 0170, Table 1, Item 6) Qty: 1 Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealant, Loctite 222 (WP 0170, Table 1, Item 55) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Planetary wheel end removed (WP 0096) Battery cables disconnected (WP 0076)

WARNING

• The brake linings contain asbestos. Wear protective breather respirator when performing maintenance on the brake assembly and brake drum. • Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. • DO NOT use compressed air to dry the brake assembly. Let it air dry. • Failure to follow these warning may cause injury to death to personnel.

0103-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

REMOVAL

CAUTION
When brake linings have worn down to a thickness of 0.177 inch (4.50 mm) they must be replaced. Failure to follow this caution may result in damage to brake drum.

NOTE
• Replacement of parts other than brake drum, brake shoes, springs, banjo fitting, bleeder screw, or automatic adjuster will require disassembly of planetary wheel end. • Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. 2. 3. Disconnect and cap brake lines. Remove bolt (Figure 1, Item 4) from spring retainer plate (Figure 1, Item 3) and relieve tension on springs (Figure 1, Item 1). Remove bolt (Figure 1, Item 2), spring retainer plate (Figure 1, Item 3), springs (Figure 1, Item 1), spring retainer (Figure 1, Item 7), spring (Figure 1, Item 9), lockplate (Figure 1, Item 8), brake shoes (Figure 1, Item 5), and spring (Figure 1, Item 10) from wheel (Figure 1, Item 6).

2 1

3 4 5

6

7 8 10 9
Figure 1. Brake Assembly Removal. 4. 5. 6. Unscrew bolt (Figure 2, Item 5) from rear of automatic adjuster (Figure 2, Item 3). Remove automatic adjuster (Figure 2, Item 3) from brake spider assembly (Figure 2, Item 1). Remove 15 bolts (Figure 2, Item 2), brake spider assembly (Figure 2, Item 1), bolt (Figure 2, Item 5), and two washers from wheel (Figure 2, Item 4).
M0191105

0103-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

REMOVAL - Continued

1

2

5 4
Figure 2. 7. 8.

3
Brake Assembly Removal.

M0192105

Remove banjo fitting assembly (Figure 3, Item 5), six bolts and washers (Figure 3, Item 3), and dust shield (Figure 3, Item 1) from brake spider assembly (Figure 3, Item 6). Remove two bolts (Figure 3, Item 4) and wheel cylinder (Figure 3, Item 2) from brake spider assembly (Figure 3, Item 6).

2 1 3

5 6

4

M0193105

Figure 3. END OF TASK CLEANING

Brake Assembly Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0103-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

INSPECTION 1. Inspect parts IAW General Maintenance Instructions (WP 0162).

WARNING

• The brake linings contain asbestos. Wear protective breather respirator when performing maintenance on the brake assembly and brake drum. • Care must be taken when cleaning the brake assembly. Clean the assembly as a whole by using a solution of hot soapy water. Go over the assembly three times or enough to be sure it is completely clean to prevent the asbestos fibers from being released into the air and circulated in the maintenance area. • DO NOT use compressed air to dry the brake assembly. Let it air dry. • Failure to follow these warning may cause injury to death to personnel. 2. Inspect all parts for wear, pitting, cracks, or corrosion and replace if necessary.

END OF TASK INSTALLATION 1. Install wheel cylinder (Figure 4, Item 2) and two bolts (Figure 4, Item 4) on brake spider assembly (Figure 4, Item 6).

CAUTION
Copper sealing washers are not reusable. If previously tightened connection containing copper sealing washer(s) is loosened, washer(s) must be replaced before retightening. Failure to follow this caution may result in damage to equipment. 2. Install dust shield (Figure 4, Item 1), six bolts and washers (Figure 4, Item 3), and banjo fitting assembly (Figure 4, Item 5) on brake spider assembly (Figure 4, Item 6). Do not tighten until brake lines have been connected.

0103-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

INSTALLATION - Continued

2 1 3

5 6

4

M0193105

Figure 4. 3. 4.

Brake Assembly Installation.

Install automatic adjuster (Figure 5, Item 3), two washers (Figure 5, Item 4), and bolt (Figure 5, Item 5) on brake spider assembly (Figure 5, Item 1) roughly centered. Hand tighten only. Apply threadlock compound to bolt (Figure 5, Item 2) threads. Install brake spider assembly (Figure 5, Item 1) and 15 bolts onto wheel. Tighten bolts to 252 ft-lb (342 N•m).

1

2

5 4
Figure 5.

3
Brake Assembly Installation.

M0192105

0103-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

INSTALLATION - Continued

NOTE
Clearance between adjusting plate and star wheel is set at 0.070 inch (1.78 mm) per side. Brake adjuster is designed to work with a total of 0.140 inch (3.56 mm). The maximum clearance on one side is 0.080 inch (2.03 mm). Replace adjuster if clearance is outside specified range. 5. Turn adjustment screws (Figure 6, Item 1) until distance between slots is 4.00 inch (101.6 mm) and both slots have the same distance (Figure 6, Item 2) to star wheel on each side. By following this procedure, brake shoes will be properly centered.

1

2 4.00 IN. (101.6 MM)

2
M0194105

Figure 6. 6.

Brake Assembly Installation.

Install brake shoes (Figure 7, Item 5), lockplate (Figure 7, Item 8), springs (Figure 7, Item 9), spring retainers (Figure 7, Item 7), spring (Figure 7, Item 10), springs (Figure 7, Item 1), spring retainer plate (Figure 7, Item 3), and bolt (Figure 7, Item 2) on wheel (Figure 7, Item 6). Using spring retainer plate, tension springs (Figure 7, Item 1) and install bolt (Figure 7, Item 4). Tighten bolts (Figure 7, Items 2 and 4) to 18 ft-lb (24 N•m). After brake shoes (Figure 7, Item 5) have been installed, check diameter of brake. Diameter must be 0.010 to 0.020 inch (0.25 to 0.51 mm) less than inside diameter of brake drum.

7.

0103-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

INSTALLATION - Continued

2 1

3 4 5

6

7 8 10
Figure 7. 8. 9. 10.

9
Brake Assembly Installation.

M0191105

Loosen bolt (Figure 8, Item 5) to allow automatic adjuster (Figure 8, Item 3) to move back and forth. Using a feeler gage through the inspection holes, center the brake assembly so there is an equal amount of clearance at each side. With brake centered, tighten bolt (Figure 8, Item 5) to 60 ft-lb (82 N•m).

1

2

5 4
Figure 8.

3
Brake Assembly Installation.

M0192105

0103-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0103

INSTALLATION - Continued 11. 12. Check clearance between brake and drum. Clearance should be between 0.010 to 0.020 inch (0.25 to 0.51 mm). If necessary, adjust clearance by turning star wheels with a brake adjusting tool through openings provided in dust shield.

END OF TASK BRAKE BLEEDING

CAUTION
• Never reuse fluid that has been drained from the system. • Be sure a high level of fluid is maintained in reservoir during and after the entire bleeding process. • Use only hydraulic brake fluid MIL-B-46176. • Make sure master cylinder is mounted securely, all fittings are tight, and reservoir is full with proper fluid. • DO NOT depress pedal and connect pressure bleeder into reservoir adapter. Recommended bleeding pressure is 30 psi (207 kPa) maximum. • Failure to follow these cautions may result in damage to equipment. 1. 2. 3. 4. 5. Open wheel cylinder bleeder screw furthest from master cylinder. Most of air contained in system will escape by this route. Close bleeder screw. Continue to next furthest bleeder screw. At each point when air bubbles disappear, close bleeder screw. Open bleeder screw at master cylinder. Actuate cylinder to remove any residual air. Tighten bleeder screw before permitting pedal to return. Remove pressure bleeder. Actuate pedal several times. If pedal is spongy, check for system leaks and repeat bleeding process.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install planetary wheel end (WP 0096). Connect battery cables (WP 0076). Place boom in resting position (TM 9-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0103-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 5-3810-305-23

0104

FIELD MAINTENANCE BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Cotter Pin 1/8X1 Inch (WP 0172, Table 1, Item 118) Qty: 1 Lubricating Oil, Hydraulic (WP 0170, Table 1, Item 42) Qty: 1 Parts Kit, Hydraulic (WP 0172, Table 1, Item 4) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock (WP 0172, Table 1, Item 47) Qty: 3 Materials/Parts (cont.) Washer, Lock 7/16 (WP 0172, Table 1, Item 166) Qty: 4 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0146 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Lower dash panel removed (WP 0066)

0104-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. 2. 3. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Position oil drain pan under master cylinder and brake booster valve (Figure 1, Item 2). Remove brake relief valve (WP 0146).

WARNING

• When servicing equipment, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, or Chemical Agent Resistant Coating (CARC) paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. • Wear protective eye covering. • Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit. • Failure to follow these warnings may result in injury or death to personnel.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 4. Disconnect two brake lines (Figure 1, Item 5) and hoses (Figure 1, Items 1 and 2) from brake master cylinder (Figure 1, Item 3). Drain fluid from system into container and discard.

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

0104-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

REMOVAL - Continued

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 5. 6. Disconnect two brake light wires (Figure 1, Item 7) from brake light switch (Figure 1, Item 6) on master cylinder (Figure 1, Item 3). Remove brake light switch (Figure 1, Item 6) and elbow (Figure 1, Item 4) from master cylinder (Figure 1, Item 3).

2 1

7 4 6
Figure 1. 7.

3 5
M0488105

Brake Booster Valve/Master Cylinder Removal.

Remove four capscrews (Figure 2, Item 2) and lockwashers (Figure 2, Item 1). Lower steering assembly so that steering wheel rests on instrument panel. Discard lockwashers.

2
Figure 2.

1
M0489105

Brake Booster Valve/Master Cylinder Removal.

0104-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

REMOVAL - Continued 8. 9. Remove cotter pin (Figure 3, Item 21) from pin on yoke (Figure 3, Item 18). Discard cotter pin. Remove pin (Figure 3, Item 17) from yoke (Figure 3, Item 18) connecting brake booster valve to brake pedal (Figure 3, Item 8).

NOTE
Brake pedal stop bracket will be removed along with brake booster mounting brackets. 10. 11. Remove four capscrews (Figure 3, Item 6) and lockwashers (Figure 3, Item 7) holding brake booster valve and pedal stop bracket to mounting bracket (Figure 3, Item 27). Discard lockwashers. Lower and remove brake booster valve from under dash.

NOTE
Before removing yoke, measure and retain distance between locking nuts to aid in assembly. 12. 13. Remove yoke (Figure 3, Item 18) and push rod (Figure 3, Item 5) by loosening jam nuts (Figure 3, Item 28) and unscrewing from brake booster valve, if required. Remove two elbows (Figure 3, Item 26) and o-rings (Figure 3, Item 25) from master cylinder. Discard o-rings.

2 1

3 4 5 6 7 8

13 9 12 11 10 34 32 31 33 17 14 15 16

28

18

19 20

27

30 23 22 29 25 26 24 21

M0490105

Figure 3. END OF TASK

Brake Booster Valve/Master Cylinder Removal.

0104-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

DISASSEMBLY 1. 2. Mark across ends of brake booster valve (Figure 4, Item 2) and master cylinder (Figure 4, Item 1) where they attach. Remove three capscrews (Figure 4, Item 4) and lockwashers (Figure 4, Item 3) from master cylinder (Figure 4, Item 1). Separate booster valve (Figure 4, Item 2) and master cylinder. Discard lockwashers.

1

2

4

3

M0491105

Figure 4. Brake Booster Valve/Master Cylinder Disassembly.

NOTE
Drain fluid from booster assembly before disassembling. 3. Remove push rod (Figure 5, Item 1) and boot (Figure 5, Item 2) from brake booster valve (Figure 5, Item 3). Discard boot.

1

2 3
Figure 5. Brake Booster Valve Disassembly.
M0492105

0104-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

DISASSEMBLY - Continued 4. 5. 6. Loosen end plug (Figure 6, Item 4) with spanner wrench and remove piston assembly (Figure 6, Item 5) from brake booster valve (Figure 6, Item 3) housing. Remove spring (Figure 6, Item 2) and retainer (Figure 6, Item 1) from internal assembly. Remove end plug (Figure 6, Item 4) from piston assembly (Figure 6, Item 5).

1

2

5 4
Figure 6. 7. 8.

3
Brake Booster Disassembly.

M0493105

Remove o-ring (Figure 7, Item 2) from end plug (Figure 7, Item 1). Discard o-ring. Remove cup (Figure 7, Item 3) and back-up ring (Figure 7, Item 4) from bore of end plug (Figure 7, Item 1).

CAUTION
Care should be taken when removing piston ring. Failure to follow this caution may result in damage to equipment.

NOTE
Record position of piston from piston assembly to aid in assembly. 9. Remove piston assembly (Figure 7, Item 7) from piston (Figure 7, Item 5) and remove piston ring (Figure 7, Item 6) from piston. Discard piston ring.

3,4 2 1 5 6 7

M0494105

Figure 7.

Brake Booster Disassembly.

0104-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

DISASSEMBLY - Continued 10. Remove retaining ring (Figure 8, Item 1) from piston assembly (Figure 8, Item 6). Retaining ring is under tension of spring (Figure 8, Item 5).

CAUTION
Care should be taken so as not to scratch bore of piston when removing cup and back-up ring. Failure to follow this caution may result in damage to equipment. 11. 12. 13. Remove piston (Figure 8, Item 2) from piston assembly (Figure 8, Item 6). Remove cup (Figure 8, Item 3) and back-up ring (Figure 8, Item 4) from bore of piston (Figure 8, Item 2). Remove spring (Figure 8, Item 5) from piston assembly.

3 1 2

4

5

6

M0495105

Figure 8.

Brake Booster Disassembly.

CAUTION
Care should be taken so as not to scratch housing bore when removing cup and back-up ring. Failure to follow this caution may result in damage to equipment. 14. Remove cup (Figure 9, Item 2) and back-up ring (Figure 9, Item 3) from brake booster valve housing (Figure 9, Item 1).

1 2

3

M0496105

Figure 9.

Brake Booster Disassembly.

0104-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

DISASSEMBLY - Continued 15. Remove plug (Figure 10, Item 6) and o-ring (Figure 10, Item 5) from plug. Discard o-ring.

NOTE
Record number of shims when removed. 16. Remove spring (Figure 10, Item 4), shims (Figure 10, Item 3), and piston (Figure 10, Item 2) from brake booster valve housing (Figure 10, Item 1).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY

CAUTION
Use only clean hydraulic oil to lubricate. Failure to follow this caution may result in damage to equipment. 1. 2. 3. Lubricate all parts with hydraulic oil before assembling. Install piston (Figure 10, Item 2) and shims (Figure 10, Item 3) as recorded, and spring (Figure 10, Item 4) in brake booster valve housing (Figure 10, Item 1). Piston must be free to move in housing. Install new o-ring (Figure 10, Item 5) and plug (Figure 10, Item 6).

3 1 2

4

5

6

M0497105

Figure 10.

Brake Booster Maintenance.

0104-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

ASSEMBLY - Continued

CAUTION
Two lips of U-cup must point toward inside of brake booster. Use care to avoid nicking or scratching seal lips. 4. Install back-up ring (Figure 11, Item 3) and cup (Figure 11, Item 2) and in brake booster valve housing (Figure 11, Item 1).

1 2

3

M0496105

Figure 11. 5.

Brake Booster Assembly.

Install spring (Figure 12, Item 5) on piston assembly (Figure 12, Item 6).

NOTE
Two lips of U-cup must be away from piston. Use care to avoid nicking or scratching seal lips. 6. 7. 8. Install back-up ring (Figure 12, Item 4) and cup (Figure 12, Item 3) in piston (Figure 12, Item 2). Do not mar piston bore. Install piston (Figure 12, Item 2) over spring (Figure 12, Item 5) and piston assembly (Figure 12, Item 6). Install retaining ring (Figure 12, Item 1) on piston assembly (Figure 12, Item 6).

3 1 2

4

5

6

M0495105

Figure 12.

Brake Booster Assembly.

0104-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

ASSEMBLY - Continued

CAUTION
DO NOT allow the piston seal to “twist" in the seal groove. The piston seal can be made pliable to aid in installation by soaking in approximately 300°F (149°C) oil. Failure to follow this caution may result in damage to equipment. 9. 10. 11. 12. 13. Install new piston ring (Figure 13, Item 6) on piston (Figure 13, Item 5). Caution should be taken when installing piston ring (Figure 13, Item 6). Install piston assembly (Figure 13, Item 7) on piston assembly (Figure 13, Item 5). Note direction of piston (Figure 13, Item 6) as recorded during disassembly. Install back-up ring (Figure 13, Item 4) and cup (Figure 13, Item 3) in bore of end plug (Figure 13, Item 1). Install new o-ring (Figure 13, Item 2) on end plug (Figure 13, Item 1). Install end plug (Figure 13, Item 1) on piston assembly.

3,4 2 1 5 6 7

M0494105

Figure 13. Brake Booster Assembly. 14. 15. Install retainer (Figure 14, Item 1) and spring (Figure 14, Item 2) over piston assembly (Figure 14, Item 5). Install piston assembly (Figure 14, Item 5) into brake booster valve housing bore (Figure 14, Item 3). Use a spanner wrench to tighten end plug (Figure 13, Item 4).

1

2

5 4

3

M0493105

Figure 14. Brake Booster Assembly.

0104-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

ASSEMBLY - Continued 16. Install new boot (Figure 15, Item 2) and push rod (Figure 15, Item 1) into booster valve housing (Figure 15, Item 3).

1

2 3
Figure 15. 17. Brake Booster Assembly.
M0492105

Align marks on brake booster valve (Figure 16, Item 2) and master cylinder (Figure 16, Item 1). Install three new lockwashers (Figure 16, Item 3) and capscrews (Figure 16, Item 4).

1

2

4

3

M0491105

Figure 16. Master Cylinder/Brake Booster Assembly. END OF TASK

0104-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

INSTALLATION

NOTE
If yoke was disassembled, use measurement taken in disassembly to assemble yoke to rod. 1. 2. 3. 4. 5. 6. Install two new o-rings (Figure 17, Item 25) and elbows (Figure 17, Item 26) to master cylinder. Install yoke (Figure 17, Item 18), push rod (Figure 17, Item 5), and tighten jam nuts (Figure 17, Item 28). Position brake booster valve, master cylinder, and brake pedal stop bracket under dash on mounting bracket (Figure 17, Item 27). Install four new lockwashers (Figure 17, Item 7) and capscrews (Figure 17, Item 6). Attach yoke (Figure 17, Item 18) to brake pedal (Figure 17, Item 8) using pin (Figure 18, Item 17). Install new cotter pin (Figure 17, Item 21) in pin (Figure 17, Item 17).

2 1

3 4 5 6 7 8

13 9 12 11 10 34 32 31 33 17 14 15 16

28

18

19 20

27

30 23 22 29 25 26 24 21

M0490105

Figure 17. Master Cylinder Installation. 7. Install four new lockwashers (Figure 18, Item 1) and capscrews (Figure 18, Item 2) in steering wheel pump.

0104-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

INSTALLATION - Continued

2

1
M0489105

Figure 18. 8. 9. 10. 11. 12.

Master Cylinder Installation.

Connect hoses (Figure 19, Items 1 and 2) and two brake lines (Figure 19, Item 5) to master cylinder (Figure 19, Item 3). Install elbow (Figure 19, Item 4) and brake light switch (Figure 19, Item 6) to master cylinder (Figure 19, Item 3). Install two brake light wires (Figure 19, Item 7) to brake light switch (Figure 19, Item 6) on master cylinder (Figure 19, Item 3). Install brake relief valve (WP 0146). Fill and bleed brake system (WP 0103).

2 1

7 4 6 5

3
M0488105

Figure 19. Brake Booster Valve/Master Cylinder Installation.. END OF TASK

0104-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0104

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install lower dash panel (WP 0110). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0104-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 5-3810-305-23

0105

FIELD MAINTENANCE HYDRAULIC BRAKE LINES AND FITTINGS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 37) Qty: 4 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 7 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 2 References WP 0103 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0105-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Wipe area clean around all connections to be opened during removal. Cap lines and hoses. Plug openings after removing lines. Contamination of system could result in premature failure.

NOTE
Tag hoses prior to removal to ensure correct installation. 1. 2. 3. 4. Disconnect hoses (Figure 1, Items 7 and 11) from master cylinder reservoir (Figure 1, Items 1 and 6). Disconnect hoses (Figure 1, Items 7 and 11) from master cylinder (Figure 1, Item 8). Disconnect tubes (Figure 1, Items 9 and 10) from master cylinder (Figure 1, Item 8). Remove two capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), nuts (Figure 1, Item 5), and master cylinder reservoir (Figure 1, Items 1 and 6) from vehicle. Discard lockwashers.

0105-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued

2,3,4,5 1 6

11 7 10

8 9

M0326105

Figure 1.

Hydraulic Brake Lines and Fittings Removal.

0105-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued 5. 6. 7. 8. Disconnect tube (Figure 2, Items 2 and 4) from coupling (Figure 2, Item 3). Disconnect tube (Figure 2, Items 1 and 9) from coupling (Figure 2, Item 10). Remove tube (Figure 2, Items 1 and 2) from vehicle. Remove capscrew (Figure 2, Item 5), nut (Figure 2, Item 6), washer (Figure 2, Item 7), and clamp (Figure 2, Item 8).

1

2

3 4

5,6,7,8

9

10
Figure 2. Hydraulic Brake Lines and Fittings Removal.

M0327105

0105-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Disconnect tube (Figure 3, Item 7) from reducer (Figure 3, Item 8). Remove tube (Figure 3, Item 7) from vehicle. Disconnect reducer (Figure 3, Item 8) from tee (Figure 3, Item 9). Disconnect tube (Figure 3, Item 10) from tee (Figure 3, Item 9). Disconnect tube (Figure 3, Item 11) from tee (Figure 3, Item 9). Disconnect tube (Figure 3, Item 3) from coupling (Figure 3, Item 2). Disconnect tube (Figure 3, Item 1) from coupling (Figure 3, Item 2). Remove nut (Figure 3, Item 4), washer (Figure 3, Item 5), and clamp (Figure 3, Item 6) from tube (Figure 3, Item 3). Remove tube (Figure 3, Item 3) from vehicle. Remove nut (Figure 3, Item 14), washer (Figure 3, Item 13), and clamp (Figure 3, Item 12) from tube (Figure 3, Item 1).

1

2

3

4,5,6

3

7

12, 13, 14

11
Figure 3.

11

10

9

8
M0335105

Hydraulic Brake Lines and Fittings Removal.

0105-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued

NOTE
Steps 19 and 20 are removal procedures for one outer axle area. The removal procedures for the other three outer axle areas are identical. 19. 20. Remove capscrew (Figure 4, Item 4), bracket (Figure 4, Item 3), spring (Figure 4, Item 2), and clamp (Figure 4, Item 1) from vehicle. Disconnect hose (Figure 4, Item 6) from axle (Figure 4, Item 5).

1

2

3

4

6 5
Figure 4. 21. 22. 23. 24. 25. 26. 27. 28. Hydraulic Brake Lines and Fittings Removal.
M0329105

Remove nut (Figure 5, Item 1), washer (Figure 5, Item 2), and clamp (Figure 5, Item 3) from tube (Figure 5, Item 6). Disconnect tube (Figure 5, Item 5) from coupling (Figure 5, Item 4). Remove tube (Figure 5, Item 5) from vehicle. Disconnect tube (Figure 5, Item 6) from coupling (Figure 5, Item 4). Disconnect tube (Figure 5, Item 6) from coupling (Figure 5, Item 11). Remove nut (Figure 5, Item 7), washer (Figure 5, Item 8), and clamp (Figure 5, Item 9) from tube (Figure 5, Item 6). Remove tube (Figure 5, Item 6) from vehicle. Disconnect hose (Figure 5, Item 10) from coupling (Figure 5, Item 11).

0105-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued

1,2,3

6 4 5

7,8,9

6

10

11
M0330105

Figure 5. 29. 30. 31. 32.

Hydraulic Brake Lines and Fittings Removal.

Disconnect hose (Figure 6, Item 1) from tee (Figure 6, Item 2). Disconnect tubes (Figure 6, Items 3 and 7) from tee (Figure 6, Item 2). Remove capscrew (Figure 6, Item 6), washer (Figure 6, Item 5), and nut (Figure 6, Item 4). Remove tee (Figure 6, Item 2) from vehicle.

1

2 3

7
Figure 6.

4,5,6
M0331105

Hydraulic Brake Lines and Fittings Removal.

0105-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued 33. 34. 35. 36. Disconnect left rear hose (Figure 7, Item 1) from coupler (Figure 7, Item 2). Remove hose from vehicle. Disconnect left rear tube (Figure 7, Item 3) from coupler (Figure 7, Item 2). Remove tube from vehicle. Disconnect right rear hose (Figure 7, Item 6) from coupler (Figure 7, Item 5). Remove hose from vehicle. Disconnect right rear tube (Figure 7, Item 4) from coupler (Figure 7, Item 5). Remove tube from vehicle.

1

2

3

4

5

6
M0332105

Figure 7. 37. 38. 39. 40.

Hydraulic Brake Lines and Fittings Removal.

Disconnect left front hose (Figure 8, Item 4) from coupler (Figure 8, Item 3). Remove hose from vehicle. Disconnect left front tube (Figure 8, Item 2) from coupler (Figure 8, Item 3). Remove tube from vehicle. Disconnect right front hose (Figure 8, Item 1) from coupler (Figure 8, Item 6). Remove hose from vehicle. Disconnect right front tube (Figure 8, Item 5) from coupler (Figure 8, Item 6). Remove tube from vehicle.

0105-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

REMOVAL - Continued

Figure 8. END OF TASK CLEANING

Hydraulic Brake Lines and Fittings Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0105-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION 1. 2. 3. 4. Install right front tube (Figure 9, Item 5) on vehicle and connect to coupler (Figure 9, Item 6). Install right front hose (Figure 9, Item 1) and connect to coupler (Figure 9, Item 6). Install left front tube (Figure 9, Item 2) on vehicle and connect to coupler (Figure 9, Item 3). Install left front hose (Figure 9, Item 4) and connect to coupler (Figure 9, Item 3).

Figure 9.

Hydraulic Brake Lines and Fittings Installation.

0105-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION - Continued 5. 6. 7. 8. Install right rear tube (Figure 10, Item 4) on vehicle and connect to coupler (Figure 10, Item 5). Install right rear hose (Figure 10, Item 6) and connect to coupler (Figure 10, Item 5). Install left rear tube (Figure 10, Item 3) on vehicle and connect to coupler (Figure 10, Item 2). Install left rear hose (Figure 10, Item 1) and connect to coupler (Figure 10, Item 2).

1

2

3

4

5

6
M0332105

Figure 10. Hydraulic Brake Lines and Fittings Installation.

0105-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION - Continued 9. 10. 11. 12. Place tee (Figure 11, Item 2) on vehicle. Install nut (Figure 11, Item 4), washer (Figure 11, Item 5), and capscrew (Figure 11, Item 6). Connect tube (Figure 11, Items 3 and 7) to tee (Figure 11, Item 2). Connect hose (Figure 11, Item 1) to tee (Figure 11, Item 2).

1

2 3

7

4,5,6
M0331105

Figure 11. Hydraulic Brake Lines and Fittings Installation. 13. 14. 15. 16. 17. 18. 19. 20. Connect hose (Figure 12, Item 10) to coupling (Figure 12, Item 11). Install tube (Figure 12, Item 6) on vehicle. Connect tube (Figure 12, Item 6) to coupling (Figure 12, Item 11). Install clamp (Figure 12, Item 9), washer (Figure 12, Item 8), and nut (Figure 12, Item 7) on tube (Figure 12, Item 6). Connect tube (Figure 12, Item 6) to coupling (Figure 12, Item 4). Install tube (Figure 12, Item 5) on vehicle. Connect tube (Figure 12, Item 5) to coupling (Figure 12, Item 4). Install clamp (Figure 12, Item 3), washer (Figure 12, Item 2), and nut (Figure 12, Item 1) on tube (Figure 12, Item 6).

0105-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION - Continued

1,2,3

6 4 5

7,8,9

6

10

11
M0330105

Figure 12. Hydraulic Brake Lines and Fittings Installation. 21. 22. Install capscrew (Figure 13, Item 4), bracket (Figure 13, Item 3), spring (Figure 13, Item 2), and clamp (Figure 13, Item 1). Connect hose (Figure 13, Item 6) to axle (Figure 13, Item 5).

1

2

3

4

6 5
Figure 13. Hydraulic Brake Lines and Fittings Installation.
M0329105

0105-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION - Continued 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. Install nut (Figure 14, Item 14), washer (Figure 14, Item 13), and clamp (Figure 14, Item 12) on tube (Figure 14, Item 1). Install tube (Figure 14, Item 3) on vehicle. Install nut (Figure 14, Item 4), washer (Figure 14, Item 5), and clamp (Figure 14, Item 6) on tube (Figure 14, Item 3). Connect tube (Figure 14, Item 1) to coupling (Figure 14, Item 2). Connect tube (Figure 14, Item 3) to coupling (Figure 14, Item 2). Connect tube (Figure 14, Item 11) to tee (Figure 14, Item 9). Connect tube (Figure 14, Item 10) to tee (Figure 14, Item 9). Connect reducer (Figure 14, Item 8) to tee (Figure 14, Item 9). Install tube (Figure 14, Item 7) on vehicle. Connect tube (Figure 14, Item 7) to reducer (Figure 14, Item 8).

1

2

3

4,5,6

3

7

12, 13, 14

11

11

10

9

8
M0335105

Figure 14. Hydraulic Brake Lines and Fittings Installation.

0105-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION - Continued 33. 34. 35. 36. Install clamp (Figure 15, Item 8), washer (Figure 15, Item 7), nut (Figure 15, Item 6), and capscrew (Figure 15, Item 5). Install tube (Figure 15, Items 1 and 2) on vehicle. Connect tube (Figure 15, Items 2 and 4) to coupling (Figure 15, Item 3). Connect tube (Figure 15, Items 1 and 9) to coupling (Figure 15, Item 10).

1

2

3 4

5,6,7,8

9

10
Figure 15. Hydraulic Brake Lines and Fittings Installation.

M0327105

0105-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

INSTALLATION - Continued 37. 38. 39. 40. 41. Install nuts (Figure 16, Item 5), washers (Figure 16, Item 4), new lockwashers (Figure 16, Item 3), and two capscrews (Figure 16, Item 2) to master cylinder reservoir (Figure 16, Items 1 and 6) on vehicle. Connect hoses (Figure 16, Items 7 and 11) to master cylinder reservoir (Figure 16, Items 1 and 6). Connect hoses (Figure 16, Items 7 and 11) to master cylinder (Figure 16, Item 8). Connect tubes (Figure 16, Items 9 and 10) to master cylinder (Figure 16, Item 8). Bleed brakes (WP 0103).

2,3,4,5 1 6

11 7 10

8 9

M0326105

Figure 16. Hydraulic Brake Lines and Fittings Installation. END OF TASK

0105-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0105

FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0105-17/18 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00116)

TM 5-3810-305-23

0106

FIELD MAINTENANCE BRAKE PEDAL AND LINKAGE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Jelly, Petroleum (WP 0170, Table 1, Item 32) Qty: 1 Nut, Self-Locking, He 3/4 Inch (WP 0172, Table 1, Item 10) Qty: 1 Pin, Cotter 1/8X1 Inch (WP 0172, Table 1, Item 118) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 49) Qty: 4 Materials/Parts (cont.) Washer, Lock 7/16 (WP 0172, Table 1, Item 166) Qty: 4 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Outriggers lowered and fully extended (TM 5-3810-305-10) Lower dash panel removed (WP 0110) Battery cables disconnected (WP 0076)

REMOVAL 1. Remove four capscrews (Figure 1, Item 3) and lockwashers (Figure 1, Item 2) from steering assembly (Figure 1, Item 1). Discard lockwashers.

1 3 2
M0498105

Figure 1.

Brake Pedal and Linkage Removal.

0106-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 5-3810-305-23

0106

REMOVAL - Continued 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove cotter pin (Figure 2, Item 10) and pin (Figure 2, Item 8) from booster valve (Figure 2, Item 9). Discard cotter pin. Remove locknut (Figure 2, Item 19), bushing (Figure 2, Item 20), washer (Figure 2, Item 21), and bolt (Figure 2, Item 3) from bracket (Figure 2, Item 11). Discard locknut. Remove pedal (Figure 2, Item 2), bushing (Figure 2, Item 1), and rubber pedal (Figure 2, Item 14) as an assembly from bracket (Figure 2, Item 11). Remove bushing (Figure 2, Item 1) from pedal (Figure 2, Item 2), if necessary. Remove rubber pedal (Figure 2, Item 14) from pedal (Figure 2, Item 2). Remove four capscrews (Figure 2, Item 17) and lockwashers (Figure 2, Item 16) from booster valve (Figure 2, Item 9). Discard lockwashers. Remove bracket (Figure 2, Item 12), capscrew (Figure 2, Item 15), nut (Figure 2, Item 13), bumper (Figure 2, Item 18), and screw (Figure 2, Item 4) from bracket (Figure 2, Item 11) as an assembly. Remove screw (Figure 2, Item 4), bumper (Figure 2, Item 18), nut (Figure 2, Item 13), and capscrew (Figure 2, Item 15) from bracket (Figure 2, Item 12). Remove four nuts (Figure 2, Item 7), lockwashers (Figure 2, Item 6), capscrews (Figure 2, Item 5), and bracket (Figure 2, Item 11). Discard lockwashers.

1 2 21 3 4 19 20 5 6 7 17 16 15 11 10 8 9

18

14
Figure 2. END OF TASK CLEANING

13

12

M0499105

Brake Pedal and Linkage Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0106-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 5-3810-305-23

0106

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Install bracket (Figure 3, Item 11), four capscrews (Figure 3, Item 5), new lockwashers (Figure 3, Item 6), and nuts (Figure 3, Item 7). Install capscrew (Figure 3, Item 15) and nut (Figure 3, Item 13) to bracket (Figure 3, Item 12). Install bumper (Figure 3, Item 18) and screw (Figure 3, Item 4) to capscrew (Figure 3, Item 15). Position bracket (Figure 3, Item 12) on bracket (Figure 3, Item 11). Install four new lockwashers (Figure 3, Item 16) and capscrews (Figure 3, Item 17) through bracket (Figure 3, Item 11) into booster valve (Figure 3, Item 9). Heat rubber pedal (Figure 3, Item 14) in hot water and install on pedal (Figure 3, Item 2). Install bushing (Figure 3, Item 1), if removed. Position pedal (Figure 3, Item 2) against bracket (Figure 3, Item 11). Apply a coat of petroleum jelly on bolt (Figure 3, Item 3). Install shoulder bolt (Figure 3, Item 3), washer (Figure 3, Item 21), bushing (Figure 3, Item 20) to new locknut (Figure 3, Item 19) and install. Position booster valve clevis to pedal (Figure 3, Item 2). Install pin (Figure 3, Item 8) and new cotter pin (Figure 3, Item 10) in booster valve (Figure 3, Item 9).

1 2 21 3 4 19 20 5 6 7 17 16 15 11 10 8 9

18

14
Figure 3.

13

12

M0499105

Brake Pedal and Linkage Installation.

0106-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 5-3810-305-23

0106

INSTALLATION - Continued 13. Install four new lockwashers (Figure 4, Item 2) and capscrews (Figure 4, Item 3) in steering assembly (Figure 4, Item 1).

1 3 2
M0498105

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Connect battery cables (WP 0076). Install lower dash panel (WP 0066).

Brake Pedal and Linkage Installation.

Raise and retract outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0106-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 5-3810-305-23

0107

FIELD MAINTENANCE TIRES AND WHEELS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) 10 Ton Jack Stand (WP 0171, Table 1, Item 19) Materials/Parts Lubricant, Tire and Rim (WP 0170, Table 1, Item 33) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0103 WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

WARNING

• Never reinflate a tire that has been run flat or seriously underinflated without removing and checking for tire tube or rim damage. • Never exceed 3 psi (21 kPa) inflation prior to placing tire and wheel assembly into inflation safety cage or mounting on a tire change machine that has a positive lockdown device. • Always inflate tires that are mounted on rims with demountable side ring flanges or lock rings in an inflation safety cage. • When inflating tires in an inflation cage, always use extension are hose and pneumatic tire inflator-gage. • Improperly seated side ring flanges or lock rings may fly off during inflation. Never attempt to seat a side ring flange or lock ring during inflation or after inflation. • Never inflate tires over 40 psi (276 kPa) to seat tire beads. If beads do not seat, deflate, demount, and check the tire/rim match. Mount and lubricate according to instructions. • When inflating tires mounted on the vehicle, all personnel must remain a minimum of 10 ft (3.1 m) away from tire and not in possible path of lock ring or rim flange. Should they fly off, serious injury or death may result. • Failure to follow these warnings may cause injury or death to personnel.

0107-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 5-3810-305-23

0107

REMOVAL 1. 2. 3. 4. Use outriggers or jack to raise affected tire off ground. Support frame with jack stands. Remove 10 lug nuts (Figure 1, Item 1) from tire and wheel assembly (Figure 1, Item 3). Remove tire and wheel assembly (Figure 1, Item 3) from axle hub (Figure 1, Item 2).

2

1

3
M0181105

Figure 1. Tires and Wheels Removal. END OF TASK DISASSEMBLY

WARNING

When deflating tires, always ensure tire is completely deflated before removing from rim. Failure to follow this warning may result in serious injury or death to personnel. 1. 2. 3. Remove valve stem cap (Figure 2, Item 1) and completely deflate tire (Figure 2, Item 3). Dismount deflated tire (Figure 2, Item 3) from wheel using tire irons. Discard tire. Remove valve stem (Figure 2, Item 2). Discard valve stem.

0107-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 5-3810-305-23

0107

DISASSEMBLY - Continued

3

2 1

M0182105

Figure 2. END OF TASK CLEANING

Tires and Wheels Disassembly.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION 1. 2. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect valve stem for wear, cracks or leaks. Discard if worn or leaking.

END OF TASK

0107-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 5-3810-305-23

0107

ASSEMBLY

WARNING

• When inflating tires, always ensure tires are properly seated. Improperly seated tires can burst with explosive force. • DO NOT mix one type of wheel with a different type of tire. Improper seating of these components can cause tire and wheel to fly apart with explosive force. • Failure to follow these warnings may result in serious injury or death to personnel. 1. 2. 3. 4. 5. Install new valve stem (Figure 3, Item 2). Apply lubricant to both beads of tire and wheel rim. Position wheel flat on floor with valve stem (Figure 3, Item 2) up. Place tire and wheel assembly (Figure 3, Item 3) into safety cage. Inflate tire. Recommended tire pressure for the 12.00 x 22.5, 14 PR tire is 115 psi (793 kPa).

3

2 1

M0182105

Figure 3. Tires and Wheels Assembly. 6. Install valve stem cap (Figure 4, Item 1).

0107-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 5-3810-305-23

0107

ASSEMBLY - Continued

1
M0184105

Figure 4. END OF TASK INSTALLATION

Tires and Wheels Assembly.

NOTE
• DO NOT lubricate lug nuts. • Tire tread is directional. Refer to travel direction arrow on sidewall of tire. 1. Install inflated tire and wheel assembly (Figure 5, Item 3) on axle hub (Figure 5, Item 2). Install 10 lug nuts (Figure 5, Item 1) on hub studs on the tire and wheel assembly.

2

1

3
M0181105

Figure 5.

Tires and Wheels Installation.

0107-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 5-3810-305-23

0107

INSTALLATION - Continued 2. 3. 4. 5. Tighten 10 lug nuts (Figure 6, Item 1) to 450 to 500 ft-lb (610 to 678 N•m) in sequence. Remove jack stands. Raise outriggers or remove jack. Recheck after 8 hours of operation.

1

M0185105

Figure 6. Tires and Wheels Installation. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

0107-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 5-3810-305-23

0108

FIELD MAINTENANCE TIE ROD ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Wrench, Torque, 1/2 Inch Drive Ratcheting (250 ftlb) (WP 0171, Table 1, Item 33) Wrench, Torque, Click, Ratcheting 3/8 Inch Drive (75 ft-lb) (WP 0171, Table 1, Item 36) Materials/Parts Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 Materials/Parts (cont.) Pin, Cotter 6.3 X 56MM (WP 0172, Table 1, Item 159) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

0108-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00120)

TM 5-3810-305-23

0108

REMOVAL

NOTE
The following is a maintenance procedure for rear tie rod. The maintenance procedure for front tie rod is identical. 1. 2. Measure and record distance between two tie rod ends (Figure 1, Item 6) to aid in installation. Loosen clamp assemblies (Figure 1, Item 7).

NOTE
Remove tie rod ends only if necessary. 3. 4. 5. 6. 7. 8. 9. Remove cotter pins (Figure 1, Item 3) from tie rod ends (Figure 1, Item 6). Discard cotter pins. Remove tie rod end nuts (Figure 1, Item 2) from tie rod ends (Figure 1, Item 6). Separate tie rod ends (Figure 1, Item 6) from tie rod levers (Figure 1, Item 4). Remove dust shields (Figure 1, Item 5) from tie rod levers (Figure 1, Item 4). Unscrew tie rod ends (Figure 1, Item 6) from tie rod (Figure 1, Item 8). Remove clamp assemblies (Figure 1, Item 7) from tie rod (Figure 1, Item 8). Remove grease fittings (Figure 1, Item 1) from tie rod ends (Figure 1, Item 6).

1

8 7

2 6 5 4 3
M0186105

Figure 1. Tie Rod Assembly Removal. END OF TASK CLEANING 1. 2. Clean parts IAW General Maintenance Instructions (WP 0162). Clean parts and surfaces with cleaning compound solvent.

END OF TASK

0108-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00120)

TM 5-3810-305-23

0108

INSPECTION 1. 2. 3. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect dust shields (Figure 1, Item 5) for wear, tears, and deformation. Inspect all parts for wear, pitting, cracks, or corrosion. Replace if necessary.

END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install grease fittings (Figure 2, Item 1) on tie rod ends (Figure 2, Item 6). Slide clamp assemblies (Figure 2, Item 7) onto tie rod (Figure 2, Item 8). Screw tie rod ends (Figure 2, Item 6) onto tie rod (Figure 2, Item 8), using measurement recorded in removal. Install dust shields (Figure 2, Item 5) on tie rod levers (Figure 2, Item 4). Install tie rod ends (Figure 2, Item 6) into tie rod levers (Figure 2, Item 4). Install tie rod end nuts (Figure 2, Item 2) on to tie rod ends (Figure 2, Item 6). Tighten tie rod end nuts to 180 ft-lb (244 N•m) and advance to next castellation. Install new cotter pins (Figure 2, Item 3) on tie rod ends (Figure 2, Item 6). Secure clamp assemblies (Figure 2, Item 7).

1

8 7
Figure 2. END OF TASK

2 6 5 4 3
M0186105

Tie Rod Assembly Installation.

0108-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00120)

TM 5-3810-305-23

0108

ADJUSTMENT 1. 2. 3. Position wheels straight ahead. Loosen clamp assemblies. Measure distance between outside edges of tread shoulders at axle height on front side of tires. Repeat measurement on back side of tires. When adjustment is correct, back side measurement will be 0.125 to 0.250 inch (3.18 to 6.35 mm) greater than front side measurement. Turn tie rod (Figure 3, Item 8) until measurements fall within tolerance found in Step 3. Tighten clamp assembly to 33 ft-lb (45 N•m). Perform Steps 1 through 5 for other axle, if necessary. Check for proper operation.

4. 5. 6. 7.

1

8 7
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE

2 6 5 4 3
M0186105

Tie Rod Assembly Adjustment.

Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

0108-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00120)

TM 5-3810-305-23

0109

FIELD MAINTENANCE GROUND DRIVEN STEERING PUMP MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Face Shield, Industrial (WP 0171, Table 1, Item 25) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Wrench, Torque, Click Ratcheting 3/8 Inch Drive (75 ft-lb) (WP 0171, Table 1, Item 36) Materials/Parts Adhesive, 1 Pint Can (WP 0170, Table 1, Item 1) Qty: 1 Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Cleaning Compound, Solvent, Type III (WP 0170, Table 1, Item 9) Qty: 1 O-Ring (WP 0172, Table 1, Item 163) Qty: 1 Parts Kit, Seal Repl (WP 0172, Table 1, Item 26) Qty: 1 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 515 (WP 0170, Table 1, Item 58) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 7/16 Inch Regular (WP 0172, Table 1, Item 51) Qty: 4 References Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Engine hood removed (WP 0120) Hydraulic reservoir drained (WP 0153)

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel.

0109-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

REMOVAL

NOTE
• Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. • Use a suitable container to catch hydraulic oil when hoses are removed from pump. 1. 2. 3. 4. 5. 6. Loosen clamp (Figure 1, Item 7) and remove hose (Figure 1, Item 6) from adapter (Figure 1, Item 10). Remove four capscrews (Figure 1, Item 8) and lockwashers (Figure 1, Item 9) from pump (Figure 1, Item 12). Discard lockwashers. Remove adapter (Figure 1, Item 10) and o-ring (Figure 1, Item 11) from pump (Figure 1, Item 12). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 2). Remove two capscrews (Figure 1, Item 4) and washers (Figure 1, Item 5) from pump (Figure 1, Item 12). Remove pump (Figure 1, Item 12) from transmission (Figure 1, Item 3).

1 12

2

3

11 10 8,9 4,5

7 6
M0437105

Figure 1. END OF TASK DISASSEMBLY

Ground Driven Steering Pump Removal.

NOTE
Matchmark pump sections before disassembly. 1. Remove elbow (Figure 2, Item 4) and o-ring (Figure 2, Item 3). Discard o-ring.

0109-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

DISASSEMBLY - Continued 2. 3. Remove four capscrews (Figure 2, Item 5) and washers (Figure 2, Item 6) from pump. Separate rear flange plate (Figure 2, Item 1) from gear plate (Figure 2, Item 2).

1

2

7

5,6 3

4

M0438105

Figure 2. Ground Driven Steering Pump Disassembly. 4. Remove o-ring (Figure 3, Item 4), back-up ring (Figure 3, Item 3), and o-ring (Figure 3, Item 2) from rear flange plate (Figure 3, Item 1). Discard o-rings and back-up rings.

1

4

3

2
M0439105

Figure 3. Ground Driven Steering Pump Disassembly.

0109-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

DISASSEMBLY - Continued 5. Remove thrust plate (Figure 4, Item 2) from gear plate (Figure 4, Item 1).

1

2

M0440105

Figure 4. Ground Driven Steering Pump Disassembly. 6. Remove idler gear (Figure 5, Item 2) and drive gear (Figure 5, Item 3) from gear plate (Figure 5, Item 1).

1

2 3

M0441105

Figure 5. Ground Driven Steering Pump Disassembly.

NOTE
Matchmark position of thrust plate before removal.

0109-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

DISASSEMBLY - Continued 7. 8. 9. Separate gear plate (Figure 6, Item 1) from front flange plate (Figure 6, Item 4). Remove thrust plate (Figure 6, Item 3). Remove eight dowel pins (Figure 6, Item 2) from gear plate (Figure 6, Item 1).

1 2 4

3

M0442105

Figure 6. Ground Driven Steering Pump Disassembly. 10. Remove o-ring (Figure 7, Item 2), back-up ring (Figure 7, Item 4), and o-ring (Figure 7, Item 3) from front flange plate (Figure 7, Item 1). Discard o-rings and back-up ring.

2 1 3 4

M0443105

Figure 7. Ground Driven Steering Pump Disassembly.

0109-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

DISASSEMBLY - Continued 11. Remove plug (Figure 8, Item 5), seal (Figure 8, Item 1), snapring (Figure 8, Item 2), and seal (Figure 8, Item 3) from front flange plate (Figure 8, Item 4). Discard seals.

1 2 3

5

4
Figure 8. Ground Driven Steering Pump Disassembly. END OF TASK

M0444105

0109-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

CLEANING

WARNING

• Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. • Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment. • Fire extinguishers should be placed nearby when using solvent cleaning compound. • Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities' procedures. • Eye shields must be worn when cleaning with a wire brush. • Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. User must wear protective goggles or face shield. • Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Clean parts IAW General Maintenance Instructions (WP 0162). Clean all parts and surfaces with solvent cleaning compound. Dry parts with compressed air.

END OF TASK INSPECTION 1. 2. 3. 4. 5. 6. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect wear plates. A smooth wear pattern on the plate face mat is slightly heavier on the inlet side is normal. If surface is severely scored or discolored, plate must be replaced. Inspect gears. Check journals and faces of each gear. They must be smooth and free from nicks or burrs. If any surfaces are discolored, gear must be replaced. Inspect bearing. Bearing interior should be smooth. A light contact pattern is normal. If severe wear or roughness is apparent, the part that bearing is housed in must be replaced. Bearing cannot be replaced. Gear plate pockets should be free from any large grooves around the inside diameter. A gear wipe pattern on this diameter on inlet side is normal and necessary for proper pump operation. Inspect all other parts.

END OF TASK

0109-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

ASSEMBLY 1. Install new seal (Figure 9, Item 3), snapring (Figure 9, Item 2), new seal (Figure 9, Item 1), and plug (Figure 9, Item 5) on front flange plate (Figure 9, Item 4).

1 2 3

5

4
Figure 9. Ground Driven Steering Pump Assembly. 2.

M0444105

Install new o-ring (Figure 10, Item 3), back-up ring (Figure 10, Item 4), and new o-ring (Figure 10, Item 2) in front flange plate (Figure 10, Item 1).

0109-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

ASSEMBLY - Continued

2 1 3 4

M0443105

Figure 10. Ground Driven Steering Pump Assembly. 3. 4. 5. Install eight dowel pins (Figure 11, Item 3) in gear plate (Figure 11, Item 2). Align matchmarks and install gear plate (Figure 11, Item 2) on cover plate (Figure 11, Item 1). Align matchmarks and install thrust plate (Figure 11, Item 4).

1 2 4

3

M0442105

Figure 11. Ground Driven Steering Pump Assembly.

0109-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

ASSEMBLY - Continued 6. Install drive gear (Figure 12, Item 3) and idler gear (Figure 12, Item 2) in gear plate (Figure 12, Item 1).

1

2 3

M0441105

Figure 12. Ground Driven Steering Pump Assembly. 7. Align matchmarks and install thrust plate (Figure 13, Item 1) in gear plate (Figure 13, Item 2).

1

2

M0440105

Figure 13. Ground Driven Steering Pump Assembly.

0109-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

ASSEMBLY - Continued 8. Install new o-ring (Figure 14, Item 2), back-up ring (Figure 14, Item 3), and o-ring (Figure 14, Item 4) in rear flange plate (Figure 14, Item 1).

1

4

3

2
M0439105

Figure 14. Ground Driven Steering Pump Assembly.

0109-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

ASSEMBLY - Continued 9. 10. 11. 12. Align matchmarks and install rear flange plate (Figure 15, Item 7) on gear plate (Figure 15, Item 1). Install four washers (Figure 15, Item 6) and capscrews (Figure 15, Item 5) on pump. Torque capscrews to 35 ft-lb (47 N•m). Install new o-ring (Figure 15, Item 3) and elbow (Figure 15, Item 4). Coat splines of pump (Figure 15, Item 2) with antiseize thread compound.

1

2

7

5,6 3

4

M0438105

Figure 15. Ground Driven Steering Pump Assembly. END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. Apply threadlock compound to pump mounting flange. Apply threadlock compound to two capscrews (Figure 16, Item 4). Position pump (Figure 16, Item 12) on transmission (Figure 16, Item 3) and install two new lockwashers (Figure 16, Item 5) and capscrews (Figure 16, Item 4). Install hose (Figure 16, Item 1) on elbow (Figure 16, Item 2). Install new o-ring (Figure 16, Item 11) on adapter (Figure 16, Item 10). Position adapter (Figure 16, Item 10) on pump (Figure 16, Item 12) and install four new lockwashers (Figure 16, Item 9) and capscrews (Figure 16, Item 8). Install hose (Figure 16, Item 6) on adapter (Figure 16, Item 10) and tighten clamp (Figure 16, Item 7).

0109-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0109

INSTALLATION - Continued

1 12

2

3

11 10 8,9 4,5

7 6
M0437105

Figure 16. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill hydraulic reservoir (WP 0153). Connect battery cables (WP 0076). Install engine hood (WP 0120).

Ground Driven Steering Pump Installation.

Place boom in resting position (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0109-13/14 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00122)

TM 5-3810-305-23

0110

FIELD MAINTENANCE STEERING CONTROL UNIT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Fixture, Arbor Press (WP 0171, Table 1, Item 1) Materials/Parts Cap Set, Protective, Dust And Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Parts Kit, Steering (WP 0172, Table 1, Item 19) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 129) Qty: 4 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Lower dash panel removed (WP 0066) 1

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

0110-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00123)

TM 5-3810-305-23

0110

REMOVAL

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all port. Remove all caps, plugs, and tags following maintenance. 1. 2. 3. 4. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Remove steering wheel cap (Figure 1, Item 1), nut (Figure 1, Item 2), and steering wheel (Figure 1, Item 3) from control unit (Figure 1, Item 7). Disconnect five hoses (Figure 1, Item 6) from control unit (Figure 1, Item 7). Remove four capscrews (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and control unit (Figure 1, Item 7) from under dash. Discard lockwashers.

1 2 3

7 6 5

4
M0406105

Figure 1. Steering Control Removal. END OF TASK DISASSEMBLY 1. 2. Remove dirt seal (Figure 2, Item 1) from control unit (Figure 2, Item 3). Discard dirt seal. Remove retaining ring (Figure 2, Item 2) from control unit (Figure 2, Item 3).

NOTE
Remove seal package using one of the two following methods. 3. If control unit (Figure 2, Item 3) has not been removed from vehicle and five hoses (Figure 2, Item 4) have not been disconnected, with engine running, rotate shaft of control unit in counterclockwise direction to pressurize control unit and force seal package (Figure 2, Item 5) out. Discard seal package.

0110-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00123)

TM 5-3810-305-23

0110

DISASSEMBLY - Continued

WARNING

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT directed compressed air against human skin. Failure to follow this warning may result in injury. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, personnel must wear protective goggles or face shield. 4. If control unit (Figure 2, Item 3) has been removed from vehicle, plug three of four ports in control unit and attach air hose to remaining port. With air pressure, force seal package (Figure 2, Item 5) out. Discard seal package.

1 5

2

1 2

5

3 3 4

M0407105

Figure 2. END OF TASK CLEANING

Steering Control Disassembly.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0110-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00123)

TM 5-3810-305-23

0110

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY

CAUTION
Keep new seal package free of particles of lint, felt, and dirt. Failure to follow this caution can cause new seal package to leak, damaging equipment.

NOTE
Clean input shaft of control unit and upper cover seal bore to remove particles of dirt, felt and lint with a clean, lint-free rag. 1. 2. 3. 4. 5. 6. 7. Cover control unit (Figure 3, Item 3) shaft with cellophane tape to protect new seal package (Figure 3, Item 5). Lubricate new seal package (Figure 3, Item 5) with hydraulic oil and install and control unit (Figure 3, Item 3) shaft lip side first. Remove cellophane tape. Install new seal package (Figure 3, Item 5) with small end first on control unit (Figure 3, Item 3) shaft. Using deep-well socket push new seal package (Figure 3, Item 5) washer down into upper cover of control unit (Figure 3, Item 3). Install retaining ring (Figure 3, Item 2) on control unit (Figure 3, Item 3) shaft and push down into upper groove in control unit cover. Install new dirt seal (Figure 3, Item 1) on control unit (Figure 3, Item 3) shaft and press down into control unit upper cover.

0110-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00123)

TM 5-3810-305-23

0110

ASSEMBLY - Continued

1 5

2

1 2

5

3 3 4

M0407105

Figure 3. END OF TASK

Steering Control Assembly.

0110-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00123)

TM 5-3810-305-23

0110

INSTALLATION 1. 2. 3. 4. 5. Position control unit (Figure 4, Item 7) under dash and align mounting holes. Install four new lockwashers (Figure 4, Item 4) and capscrews (Figure 4, Item 5). Connect five hoses (Figure 4, Item 6) on control unit (Figure 4, Item 7). Install steering wheel (Figure 4, Item 3), nut (Figure 4, Item 2), and cap (Figure 4, Item 1) on control unit (Figure 4, Item 7). Close dipstick cap.

1 2 3

7 6
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install lower dash panel (WP 0110).

4 5
Steering Control Installation.
M0406105

Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0110-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00123)

TM 5-3810-305-23

0111

FIELD MAINTENANCE STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 19 O-Ring (WP 0172, Table 1, Item 49) Qty: 12 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 49) Qty: 8 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0111-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00124)

TM 5-3810-305-23

0111

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove all caps, plugs and tags following maintenance. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect hose (Figure 1, Item 21) from steering valve and tee (Figure 1, Item 23). Disconnect hose (Figure 1, Item 20) from steering valve and elbow (Figure 1, Item 17). Remove five clamps (Figure 1, Item 8) and clamp (Figure 1, Item 4). Remove hose (Figure 1, Item 12) from elbow (Figure 1, Item 17) and tee (Figure 1, Item 24). Remove tiedown straps (Figure 1, Item 10) as required, six clamps (Figure 1, Item 8), and four clamps (Figure 1, Item 4). Discard tiedown straps. Remove hose (Figure 1, Item 25) from adapter (Figure 1, Item 19) and tee (Figure 1, Item 24). Remove tiedown straps (Figure 1, Item 10), four clamps (Figure 1, Item 4), and three clamps (Figure 1, Item 8). Discard tiedown straps. Remove hose (Figure 1, Item 11) from tee (Figure 1, Item 23) and adapter (Figure 1, Item 19). Remove two clamps (Figure 1, Item 8). Remove hose (Figure 1, Item 3) from elbow (Figure 1, Item 2) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 24) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove two clamps (Figure 1, Item 22). Remove hose (Figure 1, Item 25) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 24) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 25) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23). Remove hose (Figure 1, Item 1) from elbow (Figure 1, Item 3) and tee (Figure 1, Item 23).

0111-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00124)

TM 5-3810-305-23

0111

REMOVAL - Continued

3 8 23 1 3 23 24 1 2 2 3
2

14 13 5 6 7 8 4 11 9 10 2 3 1 2 12 4 8 25 4
1

4 24 2

23 24

2

15 16 17 2 17 15 16 18
2

2

12 2 21 2

24 2 3 2 2 3 2

23

22 8 20

18

19

M0413105

Figure 1. Steering System Hydraulic Hoses Removal. END OF TASK

0111-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00124)

TM 5-3810-305-23

0111

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Install hose (Figure 2, Item 1) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 25) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hoses (Figure 2, Item 24) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 1) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 1) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 25) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 24) on elbow (Figure 2, Item 3) and tee (Figure 2, Item 23). Install two clamps (Figure 2, Item 22). Install hose (Figure 2, Item 3) on elbow (Figure 2, Item 2) and tee (Figure 2, Item 23). Install hose (Figure 2, Item 11) on tee (Figure 2, Item 23) and adapter (Figure 2, Item 19). Install two clamps (Figure 2, Item 8). Install hose (Figure 2, Item 25) on tee (Figure 2, Item 24) and adapter (Figure 2, Item 19). Install three clamps (Figure 2, Item 8), four clamps (Figure 2, Item 4), and new tiedown straps (Figure 2, Item 10). Install hose (Figure 2, Item 12) on elbow (Figure 2, Item 17) and tee (Figure 2, Item 24). Install six clamps (Figure 2, Item 8), four clamps (Figure 2, Item 4), and new tiedown straps (Figure 2, Item 10) as required. Install hose (Figure 2, Item 20) on tee (Figure 2, Item 17) and steering valve. Install hose (Figure 2, Item 21) on tee (Figure 2, Item 23) and steering valve. Install clamp (Figure 2, Item 4) and five clamps (Figure 2, Item 8). Close dipstick cap.

0111-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00124)

TM 5-3810-305-23

0111

INSTALLATION - Continued

3 8 23 1 3 23 24 1 2 2 3
2

14 13 5 6 7 8 4 11 9 10 2 3 1 2 12 4 8 25 4
1

4 24 2

23 24

2

15 16 17 2 17 15 16 18
2

2

12 2 21 2

24 2 3 2 2 3 2

23

22 8 20

18

19

M0413105

Figure 2. Steering System Hydraulic Hoses Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Check for leaks. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0111-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00124)

TM 5-3810-305-23

0112

FIELD MAINTENANCE STEERING CYLINDERS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Sealant Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0112-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00125)

TM 5-3810-305-23

0112

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

NOTE
The following is a maintenance procedure for one steering cylinder assembly. The maintenance procedure for the remaining three steering cylinders is identical. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. 5. 6. Disconnect two hydraulic lines (Figure 1, Item 6) from elbows (Figure 1, Item 4). Remove two elbows (Figure 1, Item 4) and o-rings (Figure 1, Item 5) from steering cylinder assembly (Figure 1, Item 8). Discard o-rings. Remove two capscrews (Figure 1, Item 3) and washers (Figure 1, Item 2) from steering cylinder assembly (Figure 1, Item 8). Drive out two pins (Figure 1, Item 1) from steering cylinder assembly (Figure 1, Item 8). Remove four washers (Figure 1, Item 7) and steering cylinder (Figure 1, Item 8) from vehicle.

0112-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00125)

TM 5-3810-305-23

0112

REMOVAL - Continued

6 4 1 2,3 4 5 5 1

2,3

7

7

8 7
Figure 1. Steering Cylinders Removal.
M0459105

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0112-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00125)

TM 5-3810-305-23

0112

INSTALLATION 1. 2. 3. 4. 5. 6. Install steering cylinder (Figure 2, Item 8) and four washers (Figure 2, Item 7) on vehicle. Install two pins (Figure 2, Item 1) on steering cylinder assembly (Figure 2, Item 8). Install two washers (Figure 2, Item 2) and capscrews (Figure 2, Item 3) on steering cylinder assembly (Figure 2, Item 8). Install two new o-rings (Figure 2, Item 5) and elbows (Figure 2, Item 4) on steering cylinder assembly (Figure 2, Item 8). Connect two hydraulic lines (Figure 2, Item 6) to elbows (Figure 2, Item 4). Close dipstick cap.

6 4 1 2,3 4 5 5 1

2,3

7

7

8 7
Figure 2. Steering Cylinders Installation.
M0459105

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0112-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00125)

TM 5-3810-305-23

0113

FIELD MAINTENANCE STEERING SELECTOR VALVE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 44) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Strap, Tiedown Electrical Components (WP 0170, Table 1, Item 71) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock 5/16 Inch Regular (WP 0172, Table 1, Item 49) Qty: 4 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0113-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0113

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.

NOTE
Matchmark knob and vehicle body, noting position of arrow. 2. Remove setscrew (Figure 1, Item 1) and knob (Figure 1, Item 4) from vehicle.

NOTE
Matchmark cap and underside of vehicle. 3. Remove four capscrews (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from vehicle. Discard lockwashers.

0113-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0113

REMOVAL - Continued

1

4

2

3
M0408105

Figure 1.

Steering Selector Valve Removal.

0113-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0113

REMOVAL - Continued

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel.

NOTE
• Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. • A container will be necessary to catch hydraulic oil remaining in hose and tube assemblies after disconnecting. 4. 5. 6. From underside of vehicle, disconnect hoses (Figure 2, Items 1, 3, 5, and 6) from steering selector valve (Figure 2, Item 8). Remove steering selector valve (Figure 2, Item 8) from vehicle. Remove two elbows (Figure 2, Item 7), adapters (Figure 2, Item 4), and four o-rings (Figure 2, Item 2) from steering selector valve (Figure 2, Item 8). Discard o-rings.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0113-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0113

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Install four new o-rings (Figure 3, Item 2), two adapters (Figure 3, Item 4), and elbows (Figure 3, Item 7) on steering selector valve (Figure 3, Item 8). Install valve (Figure 3, Item 8) aligning matchmark on cap with matchmark on underside of vehicle. Connect hoses (Figure 3, Items 1, 3, 5, and 6) to elbows (Figure 3, Item 7) and adapters (Figure 3, Item 4).

1

2

3

4

5

7
Figure 2.

8

7

6

M0409105

Steering Selector Valve Installation.

0113-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0113

INSTALLATION - Continued 4. From inside cab, install four new lockwashers (Figure 4, Item 3) and capscrews (Figure 4, Item 2) on vehicle.

NOTE
Align matchmark on knob with matchmark on vehicle body. 5. 6. Install knob (Figure 4, Item 4) and setscrew (Figure 4, Item 1) on vehicle. Close dipstick cap.

1

4

2

3
M0408105

Figure 3. END OF TASK

Steering Selector Valve Installation.

0113-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0113

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0113-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00126)

TM 5-3810-305-23

0114

FIELD MAINTENANCE FLOW DIVIDER AND STEERING VALVE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Fuel, Diesel, DF-1 Grade, Winter (WP 0170, Table 1, Item 13) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 28) Qty: 1 O-Ring (WP 0172, Table 1, Item 120) Qty: 4 O-Ring (WP 0172, Table 1, Item 146) Qty: 2 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: Washer, Lock (WP 0172, Table 1, Item 93) Qty: 2 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Deck plates removed (TM 5-3810-305-10) Battery cables disconnected (WP 0076) 1

0114-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00127)

TM 5-3810-305-23

0114

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. 5. 6. 7. 8. 9. Disconnect hoses (Figure 1, Item 7) from flow divider (Figure 1, Item 1) and steering valve (Figure 1, Item 12). Remove two nuts (Figure 1, Item 13), lockwashers (Figure 1, Item 14), and capscrews (Figure 1, Item 6) from steering valve (Figure 1, Item 12). Discard lockwashers. Remove flow divider (Figure 1, Item 1) and steering valve (Figure 1, Item 12) as a unit from its frame location. Remove flow divider (Figure 1, Item 1) from adapter (Figure 1, Item 4). Remove adapter (Figure 1, Item 4) and two o-rings (Figure 1, Item 5) from steering valve (Figure 1, Item 12). Discard o-rings. Remove two elbows (Figure 1, Item 10) and o-rings (Figure 1, Item 11) from steering valve (Figure 1, Item 12). Discard o-rings. Remove adapter (Figure 1, Item 8) and o-ring (Figure 1, Item 9) from steering valve (Figure 1, Item 12). Discard o-ring. Remove elbow (Figure 1, Item 2), o-ring (Figure 1, Item 3), adapter (Figure 1, Item 8), and o-ring (Figure 1, Item 15) from flow divider (Figure 1, Item 1). Discard o-rings.

0114-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00127)

TM 5-3810-305-23

0114

REMOVAL - Continued

8,15

1

2,3

4 5 14 6 13

7

10,11

7

12

10,11

8,9

M0324105

Figure 1. Flow Divider and Steering Valve Removal. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0114-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00127)

TM 5-3810-305-23

0114

INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Install new o-ring (Figure 2, Item 15) and adapter (Figure 2, Item 8) on flow divider (Figure 2, Item 1). Install new o-ring (Figure 2, Item 3) and elbow (Figure 2, Item 2) on flow divider (Figure 2, Item 1). Install adapter (Figure 2, Item 8) and new o-ring (Figure 2, Item 9) on flow divider (Figure 2, Item 1). Install two elbows (Figure 2, Item 10) and new o-rings (Figure 2, Item 11) on flow divider (Figure 2, Item 1). Install two new o-rings (Figure 2, Item 5) and adapter (Figure 2, Item 4). Install flow divider (Figure 2, Item 1) onto steering valve (Figure 2, Item 12). Install flow divider (Figure 2, Item 1) and steering valve (Figure 2, Item 12) as a unit in the frame. Install two capscrews (Figure 2, Item 6), new lockwashers (Figure 2, Item 14), and nuts (Figure 2, Item 13) on steering valve (Figure 2, Item 12). Check hydraulic oil level. Fill to proper level, if necessary (TM 5-3810-305-10). Close dipstick cap.

8,15

1

2,3

4 5 14 6 13

7

10,11

7

12

10,11

8,9

M0324105

Figure 2. Flow Divider and Steering Valve Installation. END OF TASK

0114-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00127)

TM 5-3810-305-23

0114

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install deck plate (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0114-5/6 blank

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TM 5-3810-305-23

0115

FIELD MAINTENANCE HOOK BLOCK TIEBACK MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Shop Equipment, Welding (WP 0171, Table 1, Item 9) Grinder (WP 0171, Table 1, Item 45) Materials/Parts Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (91W) (91L) Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

WARNING

• Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. • Wear protective eye covering. Serious injury to personnel may result from flying metal fragments. • Wear protective gloves when handling hot parts. • Failure to follow these warnings may result in injury or death to personnel.

0115-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00128)

TM 5-3810-305-23

0115

REMOVAL 1. 2. 3. Burn off hook block tieback approximately 0.25 inch (6.4 mm) from surface of mounting plate. Grind mounting plate smooth. Ensure all carbon residue from air arc has been removed by grinding.

M0593105

Figure 1. Hook Block Tieback Removal. END OF TASK

0115-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00128)

TM 5-3810-305-23

0115

INSTALLATION

WARNING

• Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. • Wear protective eye covering. Serious injury to personnel may result from flying metal fragments. • Wear protective gloves when handling hot parts. • Failure to follow these warnings may result in injury or death to personnel. 1. 2. 3. Position hook block tieback on mounting plate as shown. Tack weld in place. Weld in place with 0.25 inch (6.4 mm) fillet weld and groove weld as shown. Use the following American Welding Society procedures: • • • SMAW (Shielded Metal Arc Welding) - Use AWS E7018 or El 1018 electrode. GMAW (Gas Metal Arc Welding) - Use AWS E70T-1 Flux Core electrode or E70S-3, E70S-6 Type Solid electrode. FCAW (Flux Core Arc Welding) - Use AWS E70T-1 Flux Core electrode or E70S-3, E70S-6 Type Solid electrode.

M0593105

Figure 2. END OF TASK

Hook Block Tieback Installation.

0115-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00128)

TM 5-3810-305-23

0115

FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

0115-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00128)

TM 5-3810-305-23

0116

FIELD MAINTENANCE PINTLE HOOK MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter 1/4 X 3 (WP 0172, Table 1, Item 160) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Equipment Condition (cont.) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Grille guard removed (WP 0118) Battery cables disconnected (WP 0076)

0116-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00129)

TM 5-3810-305-23

0116

REMOVAL 1. 2. 3. Remove cotter pin (Figure 1, Item 1) from nut (Figure 1, Item 2). Discard cotter pin. Remove nut (Figure 1, Item 2) and bushing (Figure 1, Item 3) from pintle hook (Figure 1, Item 5). Remove pintle hook (Figure 1, Item 5) from vehicle.

END OF TASK DISASSEMBLY Remove three grease fittings (Figure 1, Item 4) from pintle hook (Figure 1, Item 5). END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY Install three grease fittings (Figure 1, Item 4) onto pintle hook (Figure 1, Item 5). END OF TASK INSTALLATION 1. 2. 3. Install pintle hook (Figure 1, Item 5) onto vehicle. Install bushing (Figure 1, Item 3) and nut (Figure 1, Item 2) onto pintle hook (Figure 1, Item 5). Install new cotter pin (Figure 1, Item 1) onto nut (Figure 1, Item 2).

0116-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00129)

TM 5-3810-305-23

0116

INSTALLATION - Continued

2 3 1

4

4 5
M0594105

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install grille guard (WP 0118).

Pintle Hook Maintenance.

Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0116-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00129)

TM 5-3810-305-23

0117

FIELD MAINTENANCE CAB DOOR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Locknut Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 11) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock 3/8 Inch (WP 0172, Table 1, Item 12) Qty: 4 Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 1 Materials/Parts (cont.) Washer, Lock M8 (WP 0172, Table 1, Item 126) Qty: 2 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 4 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

0117-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00130)

TM 5-3810-305-23

0117

REMOVAL 1. Open door (Figure 1, Item 3) and lift door off of pins on hinges (Figure 1, Item 4).

NOTE
Top and bottom hinges are removed using the same procedure outlined in Step 2. 2. Remove two nuts (Figure 1, Item 7), washers (Figure 1, Item 6), lockwashers (Figure 1, Item 2), capscrews (Figure 1, Item 1), hinges (Figure 1, Item 4), and spacer plate (Figure 1, Item 5) from doorway. Discard lockwashers.

1 7 7 2 6 5 4 1 4 6

2

5

3

4
Figure 1. Cab Door Removal.

M0574105

0117-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00130)

TM 5-3810-305-23

0117

REMOVAL - Continued 3. 4. Drive out roll pin (Figure 2, Item 3) from inside handle (Figure 2, Item 5). Remove inside handle (Figure 2, Item 5), four screws (Figure 2, Item 2), inside latch (Figure 2, Item 1), and spacer plate (Figure 2, Item 6) from door (Figure 2, Item 4).

3 2 1 4

6 5
Figure 2. 5. Cab Door Removal.
M0575105

Remove two screws (Figure 3, Item 1) and outside handle (Figure 3, Item 3) from door (Figure 3, Item 2).

1

2

3
M0576105

Figure 3.

Cab Door Removal.

0117-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00130)

TM 5-3810-305-23

0117

REMOVAL - Continued 6. Remove two capscrews (Figure 4, Item 5), lockwashers (Figure 4, Item 4), washers (Figure 4, Item 3), striker (Figure 4, Item 2), and spacer plate (Figure 4, Item 1) from cab. Discard lockwashers.

1 2

3

4

5
Figure 4. Cab Door Removal.

M0577105

NOTE
It may be necessary to cut or peel back insulation on door to gain access to nut securing door latch. 7. Remove four nuts (Figure 5, Item 2), four lockwashers (Figure 5, Item 3) screws (Figure 5, Item 4), and door latch (Figure 5, Item 5) from door (Figure 5, Item 1).

2,3 1 4

5

M0578105

Figure 5.

Cab Door Removal.

0117-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00130)

TM 5-3810-305-23

0117

REMOVAL - Continued 8. 9. 10. Remove four nuts (Figure 6, Item 8), washers (Figure 6, Item 7), screws (Figure 6, Item 6), and door latch plate (Figure 6, Item 5) from bracket (Figure 6, Item 2). Remove nut (Figure 6, Item 3) and bumper (Figure 6, Item 4) from bracket (Figure 6, Item 2). Remove two locknuts (Figure 6, Item 11), washers (Figure 6, Item 10), bolts (Figure 6, Item 9), plate (Figure 6, Item 1), and bracket (Figure 6, Item 2) from cab. Discard locknuts.

1 11 10

2 3

9 8 7
Figure 6. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

6

5

4
M0579105

Cab Door Removal.

0117-5

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TM 5-3810-305-23

0117

INSTALLATION 1. 2. 3. Install bracket (Figure 7, Item 2), plate (Figure 7, Item 1), two bolts (Figure 7, Item 9), washers (Figure 7, Item 10), and locknuts (Figure 7, Item 11) on cab. Install bumper (Figure 7, Item 4) and nut (Figure 7, Item 3) on bracket (Figure 7, Item 2). Install door latch plate (Figure 7, Item 5), four screws (Figure 7, Item 6), washers (Figure 7, Item 7), and nuts (Figure 7, Item 8) on bracket (Figure 7, Item 2).

1 11 10

2 3

9 8 7
Figure 7. 4.

6

5

4
M0579105

Cab Door Installation.

Install door latch (Figure 8, Item 5), four screws (Figure 8, Item 4), lockwashers (Figure 8, Item 3), and nuts (Figure 8, Item 2) on door (Figure 8, Item 1).

2,3 1 4

5

M0578105

Figure 8.

Cab Door Installation.

0117-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00130)

TM 5-3810-305-23

0117

INSTALLATION - Continued 5. Install spacer plate (Figure 9, Item 1), striker (Figure 9, Item 2), two washers (Figure 9, Item 3), new lockwashers (Figure 9, Item 4), and capscrews (Figure 9, Item 5) on cab.

1 2

3

4

5
Figure 9. 6. Cab Door Installation.

M0577105

Install outside handle (Figure 10, Item 3) and two screws (Figure 10, Item 1) on door (Figure 10, Item 2).

1

2

3
M0576105

Figure 10.

Cab Door Installation.

0117-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00130)

TM 5-3810-305-23

0117

INSTALLATION - Continued 7. 8. Install spacer plate (Figure 11, Item 6), inside latch (Figure 11, Item 1), four screws (Figure 11, Item 2), and inside handle (Figure 11, Item 5) on door (Figure 11, Item 4). Install roll pin (Figure 11, Item 3) to secure inside handle (Figure 11, Item 5).

3 2 1 4

6 5
Figure 11. Cab Door Installation. 9. 10. Install spacer plate (Figure 12, Item 5), hinges (Figure 12, Item 4), two capscrews (Figure 11, Item 1), new lockwashers (Figure 11, Item 2), washers (Figure 11, Item 6), and nuts (Figure 11, Item 7) on doorway. Lift door (Figure 12, Item 3) over pins on hinges (Figure 12, Item 4) and align hinges. Lower door (Figure 11, Item 1) onto hinge pins.
M0575105

0117-8

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TM 5-3810-305-23

0117

INSTALLATION - Continued

1 7 7 2 6 5 4 1 4 6

2

5

3

4
Figure 12. END OF TASK FOLLOW-ON MAINTENANCE Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE Cab Door Installation.

M0574105

0117-9/10 blank

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TM 5-3810-305-23

0118

FIELD MAINTENANCE ENGINE HOOD AND GRILLE GUARD MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He M10 (WP 0172, Table 1, Item 132) Qty: 2 Nut, Self-Locking (WP 0172, Table 1, Item 137) Qty: 4 Nut, Self-Locking (WP 0172, Table 1, Item 140) Qty: 2 Materials/Parts (cont.) Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock M16 (WP 0172, Table 1, Item 130) Qty: 2 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

0118-1

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TM 5-3810-305-23

0118

REMOVAL Grille Guard 1. Remove two locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), washers (Figure 1, Item 3), bosses (Figure 1, Item 4), washers (Figure 1, Item 11), and capscrews (Figure 1, Item 10) from grille guard (Figure 1, Item 9). Remove two locknuts (Figure 1, Item 8), washers (Figure 1, Item 7), grille guard (Figure 1, Item 9), and two bosses (Figure 1, Item 6) from engine hood (Figure 1, Item 5).

2.

4 5 1,2,3

11

6 10 9 8
Figure 1. Grille Guard Removal.

7
M0582105

0118-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00131)

TM 5-3810-305-23

0118

REMOVAL - Continued

Engine Hood 1. 2. 3. 4. 5. 6. Disconnect engine hood (Figure 2, Item 2) by unlatching lower latches (Figure 2, Item 6). Pull engine hood (Figure 2, Item 2) approximately half way out. Push inward on side of engine hood (Figure 2, Item 2) just above cam follower (Figure 2, Item 4) and lift engine hood to position cam follower on top of guide rail (Figure 2, Item 5). Repeat for other cam follower (Figure 2, Item 4) and lift engine hood (Figure 2, Item 2) up and off frame. Remove four capscrews (Figure 2, Item 3) and two lower latches (Figure 2, Item 6) from guide rail (Figure 2, Item 5). Remove four screws (Figure 2, Item 1) and two blocks (Figure 2, Item 7) from vehicle.

2

4 1 3

5

7

6
M0583105

Figure 2. END OF TASK

Engine Hood Removal.

0118-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00131)

TM 5-3810-305-23

0118

DISASSEMBLY 1. 2. 3. 4. Remove four locknuts (Figure 3, Item 6), washers (Figure 3, Item 5), capscrews (Figure 3, Item 4), and two upper latches (Figure 3, Item 3) from engine hood (Figure 3, Item 1). Discard locknuts. Remove two cam followers (Figure 3, Item 7) and lockwashers (Figure 3, Item 8) from engine hood (Figure 3, Item 1). Discard lockwashers. Remove two grease fittings (Figure 3, Item 9) from engine hood (Figure 3, Item 1). Remove reflective tape (Figure 3, Item 2) and two reflective tapes (Figure 3, Item 10) from engine hood(Figure 3, Item 1).

1 2

3 4 10

9 8 7 6 5
M0584105

Figure 3. Engine Hood Disassembly. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0118-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00131)

TM 5-3810-305-23

0118

ASSEMBLY 1. 2. 3. 4. Install two reflective tapes (Figure 4, Item 10) and reflective tape (Figure 4, Item 2) on engine hood (Figure 4, Item 1). Install two grease fittings (Figure 4, Item 9) on engine hood (Figure 4, Item 1). Install two new lockwashers (Figure 4, Item 8) and cam followers (Figure 4, Item 7) on engine hood (Figure 4, Item 1). Install two upper latches (Figure 4, Item 3), four capscrews (Figure 4, Item 4), washers (Figure 4, Item 5), and new locknuts (Figure 4, Item 6) on engine hood (Figure 4, Item 1).

1 2

3 4 10

9 8 7
Figure 4. END OF TASK

6

5

M0584105

Engine Hood Assembly.

0118-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00131)

TM 5-3810-305-23

0118

INSTALLATION Engine Hood 1. 2. 3. 4. 5. Install two blocks (Figure 5, Item 7) and four screws (Figure 5, Item 1) on vehicle. Install two lower latches (Figure 5, Item 6) and four capscrews (Figure 5, Item 3) on guide rail (Figure 5, Item 5). Position engine hood (Figure 5, Item 2) onto top of guide rails (Figure 5, Item 5) past hood on radiator. Push inward on side of engine hood (Figure 5, Item 2) just above cam follower (Figure 5, Item 4) and position cam follower under guide rails (Figure 5, Item 5). Push engine hood (Figure 5, Item 2) back and latch in place with lower latches (Figure 5, Item 6).

2

4 1 3

5

7

6
M0583105

Figure 5.

Engine Hood Installation.

0118-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00131)

TM 5-3810-305-23

0118

INSTALLATION - Continued

Grille Guard 1. 2. 3. 4. Install two bosses (Figure 6, Item 6) and grille guards (Figure 6, Item 9) on engine hood (Figure 6, Item 5). Install two washers (Figure 6, Item 7) and new locknuts (Figure 6, Item 8). Install two capscrews (Figure 6, Item 10), washers (Figure 6, Item 11), grille guard (Figure 6, Item 9), and two bosses (Figure 6, Item 6). Install two washers (Figure 6, Item 3), washers (Figure 6, Item 2), and new locknuts (Figure 6, Item 1).

4 5 1,2,3

11

6 10 9 8
Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Grille Guard Installation.

7
M0582105

END OF TASK END OF WORK PACKAGE

0118-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00131)

TM 5-3810-305-23

0119

FIELD MAINTENANCE CAB ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Adhesive (WP 0170, Table 1, Item 1) Qty: 1 Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 18 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Silicone (WP 0170, Table 1, Item 62) Qty: 1 Seal, Non-Metallic (WP 0172, Table 1, Item 106) Qty: 2 Seal, Non-Metallic (WP 0172, Table 1, Item 107) Qty: 1 Seal, Non-Metallic (WP 0172, Table 1, Item 108) Qty: 2 Materials/Parts (cont.) Washer, Lock M5 (WP 0172, Table 1, Item 92) Qty: 4 Weather Stripping (WP 0172, Table 1, Item 169) Qty: 1 Personnel Required (Two) References WP 0066 WP 0079 WP 0148 WP 0162 Equipment Condition Vehicle parked on level ground Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Cab door removed (WP 0117) Windshield wiper removed (WP 0131) Mirrors removed (WP 0130) Defroster fan removed (WP 0055) Seat removed (WP 0124) Seat belt removed (WP 0124)

0119-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

REMOVAL 1. 2. Remove two nuts (Figure 1, Item 1), capscrews (Figure 1, Item 8), and clamps (Figure 1, Item 7) releasing defroster fan harness (Figure 1, Item 6) from cab (Figure 1, Item 2). Remove 18 locknuts (Figure 1, Item 3) and washers (Figure 1, Item 4) from cab (Figure 1, Item 2). Discard locknuts.

WARNING

Weight of cab is approximately 250 lb (113 kg). Use adequate lifting equipment to lift and support cab. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 3. 4. 5. Attach hoist with sling through door and window openings in cab (Figure 1, Item 2). Using hoist and sling, lift cab (Figure 1, Item 2) off of frame. Remove seals (Figure 1, Item 5). Discard seals.

1

2

8 7 7 4 8 7 6 5
M0587105

3

Figure 1. Cab Assembly Removal.

0119-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

REMOVAL - Continued 6. Remove fire extinguisher (Figure 2, Item 3), four capscrews (Figure 2, Item 5), lockwashers (Figure 2, Item 4), and bracket (Figure 2, Item 1) from cab (Figure 2, Item 2). Discard lockwashers.

1

2

5

4 3
M0588105

Figure 2.

Fire Extinguisher Removal.

0119-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

REMOVAL - Continued

NOTE
Floormats are held in place with adhesive and should not be removed unless inspection indicates replacement is necessary. 7. 8. 9. Inspect floormats (WP 0162). If necessary, remove two wingnuts (Figure 3, Item 4), washers (Figure 3, Item 3), and floormat (Figure 3, Item 5) from cab (Figure 3, Item 1). Remove all adhesive from cab floor. Remove floormats (Figure 3, Items 2 and 6), if replacement is necessary from cab floor.

1 2

3 6

4

5

M0589105

Figure 3.

Floormats Removal.

NOTE
Insulation pads are held in place with adhesive and should not be removed unless inspection indicates replacement is necessary. 10. 11. 12. 13. Inspect insulation pads (WP 0162). If left front or right side insulation pad replacement is necessary, remove cab main harness (WP 0079). If lower right insulation pad replacement is necessary, remove panel (WP 0066). If necessary, remove eight insulation pads. Remove all adhesive from cab wall.

END OF TASK

0119-4

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TM 5-3810-305-23

0119

DISASSEMBLY

NOTE
DO NOT remove glass panels or weather strips unless inspection indicates replacement is necessary. 1. 2. 3. Inspect glass panels and weather strip (WP 0162). Remove glass panels (Figure 4, Items 1, 4, and 5) from cab (Figure 4, Item 3). Remove weather strips (Figure 4, Item 2). Discard weather strips.

1

1 2 3

2 4 5

2 4 2 5 2

2

M0590105

Figure 4. END OF TASK

Cab Assembly Disassembly.

0119-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. 2. Apply a bead of silicone sealant in both cab (Figure 5, Item 3) and glass channels of weather strips (Figure 5, Item 2). Install glass panels (Figure 5, Item 5).

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 3. Apply a bead of silicone sealant in window frame channel of weather strips (Figure 5, Item 2) for glass panels (Figure 5, Item 1).

0119-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

ASSEMBLY - Continued 4. 5. 6. Install glass panels (Figure 5, Item 1). Install new weather strips (Figure 5, Item 2). Install remaining glass panels (Figure 5, Item 4) in weather strips (Figure 5, Item 2). Seal joints with silicone sealant, as required.

1

1 2 3

2 4 5

2 4 2 5 2

2

M0590105

Figure 5. END OF TASK

Cab Assembly Assembly.

0119-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

INSTALLATION

WARNING

ADHESIVES AND SEALANTS Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 1. 2. 3. 4. If removed, apply adhesive to cab walls and install eight insulation pads. If removed, install right console panel (WP 0066). If removed, install cab main harness (WP 0079). If removed, install floormats (Figure 6, Items 1 and 5). Apply adhesive to mating surfaces and install floormat (Figure 6, Item 4), two washers (Figure 6, Item 2), and wingnuts (Figure 6, Item 3) to cab floor.

1 2

3 6

4

5

M0589105

Figure 6. Floormats Installation.

0119-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

INSTALLATION - Continued 5. Install bracket (Figure 7, Item 1), four new lockwashers (Figure 7, Item 3), capscrews (Figure 7, Item 4), and fire extinguisher (Figure 7, Item 2).

1

2

5

4 3
M0588105

Figure 7.

Fire Extinguisher Installation.

0119-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

INSTALLATION - Continued 6. If removed, install new seals (Figure 8, Item 5). Seal ends of seals together with silicone sealant.

WARNING

Weight of cab is approximately 250 lb (113 kg). Use adequate lifting equipment to lift and support cab. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 7. 8. 9. Using a hoist with sling through door and window openings, position cab (Figure 8, Item 2) mounting holes over studs in frame and install cab to vehicle. Secure defroster fan harness (Figure 8, Item 6) to cab (Figure 8, Item 2) with two clamps (Figure 8, Item 7), capscrews (Figure 8, Item 8), and nuts (Figure 8, Item 1). Install 18 washers (Figure 8, Item 4) and new locknuts (Figure 8, Item 3) to cab (Figure 8, Item 2).

1

2

8 7 7 4 8 7 6 5
M0587105

3

Figure 8. Cab Assembly Installation. END OF TASK

0119-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00132)

TM 5-3810-305-23

0119

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install seat (WP 0124). Install seat belts (WP 0124). Install defroster fan (WP 0055). Install mirrors (WP 0130). Install windshield wiper (WP 0131). Install cab door (WP 0117). Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0119-11/12 blank

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TM 5-3810-305-23

0120

FIELD MAINTENANCE HOOD SUPPORT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 6 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Lock M4 (WP 0172, Table 1, Item 168) Qty: 2 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Vehicle parked on level ground (TM 5-3810-305-10)

0120-1

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TM 5-3810-305-23

0120

REMOVAL 1. 2. 3. 4. 5. Start engine. Rotate boom to right side of carrier. Shut engine OFF. Remove nut (Figure 1, Item 13), capscrew (Figure 1, Item 4), plate (Figure 1, Item 1), spacer (Figure 1, Item 3), and two clamps (Figure 1, Item 2) from hoses (Figure 1, Items 11 and 12). Remove two nuts (Figure 1, Item 6) and U-bolt (Figure 1, Item 7) from hood support. Loosen nut (Figure 1, Item 10) on T-bolt clamp (Figure 1, Item 9). Remove T-bolt clamp, 90 degree elbow (Figure 1, Item 8), and stack cap (Figure 1, Item 5) as an assembly from vehicle. Disconnect restriction indicator hose (Figure 1, Item 15) from restriction indicator (Figure 1, Item 14).

1 12 13

2 3 4 5

6 11 14 15 7

8 10

9

M0581105

Figure 1.

Hood Support Removal.

0120-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00133)

TM 5-3810-305-23

0120

REMOVAL - Continued 6. Remove six locknuts (Figure 2, Item 2), washers (Figure 2, Item 3), and hood support (Figure 2, Item 1) from frame. Discard locknuts.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. Install hood support (Figure 2, Item 1), six washers (Figure 2, Item 3), and locknuts (Figure 2, Item 2) on frame.

1 2 3 2 3

M2312105

Figure 2.

Hood Support Installation.

0120-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00133)

TM 5-3810-305-23

0120

INSTALLATION - Continued 2. 3. 4. 5. Connect restriction indicator hose (Figure 3, Item 15) to restriction indicator (Figure 3, Item 14). Install stack cap (Figure 3, Item 5), 90 degree elbow (Figure 3, Item 8), and T-bolt clamp (Figure 3, Item 9) as an assembly and tighten nut (Figure 3, Item 10) on T-bolt clamp. Install U-bolt (Figure 3, Item 7) and two new locknuts (Figure 3, Item 6) on hood support. Install two clamps (Figure 3, Item 2), spacer (Figure 3, Item 3), plate (Figure 3, Item 1), capscrew (Figure 3, Item 4), and nut (Figure 3, Item 13) on hoses (Figure 3, Items 11 and 12).

1 12 13

2 3 4 5

6 11 14 15 7

8 10

9

M0581105

Figure 3. END OF TASK

Hood Support Installation.

0120-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00133)

TM 5-3810-305-23

0120

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Start engine (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Shut down engine (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0120-5/6 blank

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TM 5-3810-305-23

0121

FIELD MAINTENANCE FENDERS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device 150-lb (69 kgs) Minimum Capacity Materials/Parts Nut, Self-Locking (WP 0172, Table 1, Item 131) Qty: 24 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

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TM 5-3810-305-23

0121

REMOVAL

NOTE
The following is a maintenance procedure for one fender. The maintenance procedure for the remaining fenders is identical. 1. Remove six locknuts (Figure 1, Items 2 and 5) and washers (Figure 1, Items 3 and 4) from studs on frame. Discard locknuts.

WARNING

Weight of fender is approximately 99 lb (45 kg). Use adequate lifting equipment to support fender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 2. Remove fender (Figure 1, Item 1) from frame.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0121-2

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TM 5-3810-305-23

0121

INSTALLATION

WARNING

Weight of fender is approximately 99 lb (45 kg). Use adequate lifting equipment to support fender. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. Install fender (Figure 1, Item 1) on frame. Install six washers (Figure 1, Items 3 and 4) and new locknuts (Figure 1, Items 2 and 5) to studs on frame.

1

1 2 3

4

5
Figure 1. END OF TASK FOLLOW-ON MAINTENANCE Return upper structure and boom rotated to resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE Fender Maintenance.

M0641105

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0122

FIELD MAINTENANCE DECK PLATES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 3 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground Boom in horizontal position and fully retracted (TM 5-3810-305-10)

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0122

REMOVAL

WARNING

Weight of brake drum is approximately 81 lb (37 kg). Use adequate lifting equipment to lift and support brake drum. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may result in serious injury or death to personnel. 1. 2. 3. Remove five capscrews (Figure 1, Item 6), washers (Figure 1, Item 5), deck plate (Figure 1, Item 4), and five clips (Figure 1, Item 7) from vehicle. Remove three locknuts (Figure 1, Item 8), four washers (Figure 1, Item 3), and capscrew (Figure 1, Item 2) from pinion cover (Figure 1, Item 1). Discard locknuts. Remove pinion cover (Figure 1, Item 1) from vehicle.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION 1. 2. 3. Position pinion cover (Figure 1, Item 1) on vehicle. Install four washer (Figure 1, Item 3), capscrew (Figure 1, Item 2), and three new locknuts (Figure 1, Item 8) on pinion cover (Figure 1, Item 1). Install five clips (Figure 1, Item 7), deck plate (Figure 1, Item 4), five washers (Figure 1, Item 5), and capscrews (Figure 1, Item 6) on vehicle.

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0122

INSTALLATION - Continued

VIEWED FROM TOP 1 2 2

1

3 3 5 3 8

4 6 5

8 7

6 7
M0642105

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE

Deck Plates Maintenance.

Place boom in resting position (TM 5-3810-305-10). END OF TASK END OF WORK PACKAGE

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0123

FIELD MAINTENANCE OUTRIGGER ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Caliper, Micrometer, Outside (WP 0171, Table 1, Item 21) Caliper Set, Micrometer, Inside (WP 0171, Table 1, Item 22) Fixture, Arbor Press (WP 0171, Table 1, Item 1) Gloves, Rubber (WP 0171, Table 1, Item 26) Goggles, Industrial (WP 0171, Table 1, Item 27) Suitable Lifting Device, 500-lb (227 kgs) Minimum Capacity Materials/Parts Bearing Sleeve (WP 0172, Table 1, Item 109) Qty: 16 Nitrogen, Liquid, Industrial Grade (WP 0170, Table 1, Item 49) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Sealing Compound, Loctite 271 (WP 0170, Table 1, Item 57) Qty: 1 Materials/Parts (cont.) Washer, Lock M16 (WP 0172, Table 1, Item 130) Qty: 8 Washer, Lock M25 (WP 0172, Table 1, Item 7) Qty: 4 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

0123-1

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0123

REMOVAL 1. Fully extend and lower all outriggers without putting any pressure on outrigger pads (TM 5-3810-305-10).

WARNING

Weight of beam is approximately 129 lb (59 kg). Use adequate lifting equipment to lift and support beam. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

NOTE
The following is a maintenance procedure for one outrigger assembly. The maintenance procedure for the remaining outrigger assemblies is identical. 2. 3. 4. 5. 6. 7. Support cylinder and beam (Figure 1, Item 1) with suitable lifting device. Remove pin (Figure 1, Item 3) from pin (Figure 1, Item 2). Remove pin (Figure 1, Item 2) from beam (Figure 1, Item 1). Remove capscrew (Figure 1, Item 7), lockwasher (Figure 1, Item 6), and rod end (Figure 1, Item 9). Discard lockwasher. Remove pin (Figure 1, Item 8) from beam (Figure 1, Item 1). Remove beam (Figure 1, Item 1) from frame.

0123-2

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0123

REMOVAL - Continued

3 2 1 14 13

4 5 8 6 10 5 3 2 5 10 13 1 14
M0585105

7

6

9

9 8 10 12 11 12 11

7

Figure 1. END OF TASK DISASSEMBLY 1. 2. 3.

Outrigger Assembly Removal.

Remove nut (Figure 1, Item 14), washer (Figure 1, Item 13), bolt (Figure 1, Item 12), and pad (Figure 1, Item 11) from beam (Figure 1, Item 1). Remove two grease fittings (Figure 1, Item 4) and two grease fittings (Figure 1, Item 5) from beam (Figure 1, Item 1). Using a press, remove four bushings (Figure 1, Item 10) from beam (Figure 1, Item 1).

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0123-3

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0123

INSPECTION 1. 2. 3. 4. 5. Inspect parts IAW General Maintenance Instructions (WP 0162). Inspect beam bushings. Maximum I.D. is 2.03 inch (51.64 mm). If I.D. is greater than limit, replace bushings. Inspect outrigger beam pins. Minimum O.D. is 1.964 inch (49.89 mm). If O.D. is less than limit, replace pins. Inspect pad pivot bolt. Minimum O.D. is 1.230 inch (31.24 mm). If O.D. is less than limit, replace bolt. Inspect pivot bolt bushing. Maximum I.D. is 1.275 inch (32.39 mm). If I.D. is greater than limit, replace outrigger beam.

END OF TASK ASSEMBLY

WARNING

Liquid nitrogen is extremely cold, having a temperature of -320°F (-195°C). Wear protective gloves that will not absorb liquid nitrogen. Excess liquid nitrogen must be disposed of promptly since liquid nitrogen will condense oxygen from the atmosphere. The mixture of liquid nitrogen and liquid oxygen is a powerful oxidizer and may react violently with easily oxidizable substances. Failure to follow this warning may cause injury or death to personnel.

NOTE
Cool bushings to -320°F (-195°C) submerging bushings in liquid nitrogen. 1. 2. 3. Submerge four bushings (Figure 3, Item 10), in liquid nitrogen to cool them. Apply threadlock sealant to outrigger bushing beam bore. Using a press, install four chilled bushings (Figure 3, Item 10) in beam (Figure 3, Item 1). Stake beam as indicated in Figure 2.

PUNCH 3 PLACES AROUND BUSHINGS BUSHING OUTRIGGER

OUTSIDE ONLY BOTH SIDES OF BEAM
Figure 2. Outrigger Assembly Assembly.

M0586105

0123-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00138)

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0123

ASSEMBLY - Continued 4. 5. Install two grease fittings (Figure 3, Item 5) and two grease fittings (Figure 3, Item 4) in beam (Figure 3, Item 1). Install pad (Figure 3, Item 11), bolt (Figure 3, Item 12), washer (Figure 3, Item 13), and nut (Figure 3, Item 14) in beam (Figure 3, Item 1).

3 2 1 14 13

4 5 8 6 10 5 3 2 5 10 13 1 14
M0585105

7

6

9

9 8 10 12 11 12 11

7

Figure 3. END OF TASK

Outrigger Assembly Assembly.

0123-5

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TM 5-3810-305-23

0123

INSTALLATION

WARNING

Weight of beam is approximately 129 lb (59 kg). Use adequate lifting equipment to lift and support beam. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. 4. 5. Install beam (Figure 4, Item 1) in frame, aligning holes in beam with holes in frame. Support with lifting device. Install pin (Figure 4, Item 8) into beam (Figure 4, Item 1). Install rod end (Figure 4, Item 9), new lockwasher (Figure 4, Item 6), and capscrew (Figure 4, Item 7). Install pin (Figure 4, Item 2) into beam (Figure 4, Item 1) and cylinder rod eye. Install new pin flush with rod end on cylinder. Remove lifting device supporting beam (Figure 4, Item 1) and cylinder.

3 2 1 14 13

4 5 8 6 10 5 3 2 5 10 13 1 14
M0585105

7

6

9

9 8 10 12 11 12 11

7

Figure 4. Outrigger Assembly Installation. END OF TASK

0123-6

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0123

FOLLOW-ON MAINTENANCE 1. 2. 3. Raise all outriggers (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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0124

FIELD MAINTENANCE SEAT AND SEAT BELT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Nut, Self-Locking, He (WP 0172, Table 1, Item 139) Qty: 4 Nut, Self-Locking, He M12 (WP 0172, Table 1, Item 133) Qty: 2 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

0124-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00140)

TM 5-3810-305-23

0124

REMOVAL Seat Belt 1. 2. Tilt seat (Figure 1, Item 2). Remove two locknuts (Figure 1, Item 3), washers (Figure 1, Item 6), and capscrews (Figure 1, Item 5) from seat belt halves (Figure 1, Items 1 and 4). Discard locknuts.. Remove two seat belt halves (Figure 1, Items 1 and 4) from seat bracket (Figure 1, Item 7).

1

2

3 4 7

5 6
Figure 1. Seat Belt Removal.
M0638105

0124-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00140)

TM 5-3810-305-23

0124

REMOVAL - Continued

Seat 1. 2. 3. 4. Tilt seat (Figure 2, Item 1), remove capscrews (Figure 2, Item 6) and washers (Figure 2, Item 3) from slide assembly (Figure 2, Item 2). Remove seat (Figure 2, Item 1) from vehicle. Remove four locknuts (Figure 2, Item 4) and washers (Figure 2, Item 3) from under cab. Remove four capscrews (Figure 2, Item 5) from inside cab on slide assembly. Discard locknuts. Remove slide assembly (Figure 2, Item 2) from inside of cab.

1

3 6 5 3 4
M0639105

2

Figure 2. END OF TASK CLEANING

Seat Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0124-3

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0124

INSTALLATION Seat 1. 2. 3. 4. Install slide assembly (Figure 3, Item 2) inside of cab with four capscrews (Figure 3, Item 5). Install four washers (Figure 3, Item 3) and new locknuts (Figure 3, Item 4) under cab. Install seat (Figure 3, Item 1) in vehicle. Tilt seat (Figure 3, Item 1), and install on slide assembly (Figure 2, Item 2) with four capscrews (Figure 3, Item 6) and washers (Figure 3, Item 3).

1

3 6 5 3 4
M0639105

2

Figure 3.

Seat Installation.

0124-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00140)

TM 5-3810-305-23

0124

INSTALLATION - Continued

Seat Belt 1. 2. 3. Position two seat belt halves (Figure 4, Items 1 and 4) into slide assembly (Figure 4, Item 7). Install two locknuts (Figure 4, Item 3), washers (Figure 4, Item 6), capscrews (Figure 4, Item 5), into seat belt halves (Figure 4, Items 1 and 4). Tilt seat (Figure 4, Item 2) into upright position.

1

2

3 4 7

5 6
Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Seat Belt Installation.
M0638105

END OF TASK END OF WORK PACKAGE

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0125

FIELD MAINTENANCE WINCH ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Suitable Lifting Device, 2,000-lb (907 kgs) Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade 1 (WP 0170, Table 1, Item 42) Qty: 1 Nut, Self-Locking, He M16 (WP 0172, Table 1, Item 6) Qty: 4 Parts Kit, Seal Repl (WP 0172, Table 1, Item 105) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 9) Qty: 12 Washer, Lock 3/8 Reg (WP 0172, Table 1, Item 41) Qty: 6 Personnel Required (Two) References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10) Drum cable removed (TM 5-3810-305-10) Battery cables disconnected (WP 0076)

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel.

0125-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

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0125

REMOVAL 1. Turn dipstick cap 1/4 turn to safety notch to relieve pressure.

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 2. 3. 4. Disconnect two hydraulic hoses (Figure 1, Item 5) from two elbows (Figure 1, Item 6). Remove two elbows (Figure 1, Item 6) from brake valve assembly (Figure 1, Item 7). Remove four locknuts (Figure 1, Item 3), washers (Figure 1, Item 2), and capscrews (Figure 1, Item 1) from winch base (Figure 1, Item 4). Discard locknuts.

WARNING

Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. Attach hoist and sling to winch base (Figure 1, Item 4) and remove from vehicle. Lower onto flat surface.

2,3 1

4 5

6

7

M0648105

Figure 1. END OF TASK

Winch Removal.

0125-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY

CAUTION
Work should be done in a clean, dust-free area. Cleanliness is of the utmost importance when servicing hydraulic equipment. Failure to follow this caution may result in damage to equipment.

NOTE
It may be necessary to insert a bar into anchor pocket and manually rotate drum in the direction to hoist a load until drain holes are aligned. 1. Remove drain plug (Figure 2, Item 3) and o-ring (Figure 2, Item 4) from winch (Figure 2, Item 2). O-ring is part of plug. If o-ring is damaged replace plug.

NOTE
DO NOT remove relief valve unless inspection indicates replacement is necessary. 2. 3. Inspect relief valve (WP 0162). Remove relief valve (Figure 2, Item 1) from winch (Figure 2, Item 2), if inspection proves necessary.

WARNING

Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 4. Remove oil level plug (Figure 2, Item 5), o-ring (Figure 2, Item 6), and stand winch on bearing support end. O-ring is part of plug. If o-ring is damaged replace plug.

1

2

6 3,4 5

M0649105

Figure 2.

Winch Disassembly.

0125-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

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0125

DISASSEMBLY - Continued 5. Disconnect hydraulic hose (Figure 3, Item 1) from winch (Figure 3, Item 2).

1

2

M0650105

Figure 3. Hydraulic Hose Disassembly. 6. Remove two capscrews (Figure 4, Item 2), lockwashers (Figure 4, Item 3), motor (Figure 4, Item 1), and o-ring (Figure 4, Item 4) from motor support (Figure 4, Item 5). Discard o-ring and lockwashers.

1

5
Figure 4.

4

2,3

M0651105

Motor Disassembly.

CAUTION
Avoid damaging sealing or bearing surfaces while removing brake cylinder assembly. Failure to follow this caution may result in damage to equipment. 7. 8. Remove brake clutch assembly (Figure 5, Item 1) from motor support. Remove six capscrews (Figure 5, Item 2) and lockwashers (Figure 5, Item 3), and brake cylinder assembly (Figure 5, Item 5) from winch (Figure 5, Item 4). Discard lockwashers.

0125-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY - Continued

1 2,3

4 5
M0652105

Figure 5. 9.

Brake Clutch and Cylinder Disassembly.

Remove sun primary gear (Figure 6, Item 1) snapring (Figure 6, Item 5), drum closure (Figure 6, Item 3), and o-ring (Figure 6, Item 4) from drum (Figure 6, Item 2). Discard o-ring.

1 5

2

3 4
Figure 6. Sun Primary Gear Disassembly.
M0635105

0125-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY - Continued 10. Remove seal (Figure 7, Item 1) and ball bearing (Figure 7, Item 2) from inside of drum closure (Figure 7, Item 3). Discard seal.

2 1

3
M0654105

Figure 7. Seal and Ball Bearing Disassembly. 11. Remove thrust ring (Figure 8, Item 1) and primary planet carrier (Figure 8, Item 2) from drum (Figure 8, Item 3).

1

2

3

M0655105

Figure 8. Primary Planet Carrier Disassembly.

0125-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY - Continued 12. Remove thrust washer (Figure 9, Item 1) and sun output gear (Figure 9, Item 2) from output planet carrier (Figure 9, Item 3).

1

2

3

M0656105

Figure 9. 13.

Sun Output Gear Disassembly.

Remove output planet carrier (Figure 10, Item 1) from drum (Figure 10, Item 2).

1

2
M0657105

Figure 10.

Output Planet Carrier Disassembly.

0125-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY - Continued

WARNING

Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 14. Remove snapring (Figure 11, Item 2) from bearing support (Figure 11, Item 1) and stand winch on motor end with bearing support up.

1 2

M0658105

Figure 11.

Snap Ring Disassembly.

0125-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY - Continued

CAUTION
Use care when removing drum. Failure to follow this warning may result in damage to sealing or bearing surfaces. 15. 16. Remove six capscrews (Figure 12, Item 1), six lockwashers (Figure 12, Item 2), and bearing support (Figure 12, Item 3) from drum (Figure 12, Item 4). Discard lockwashers. Remove drum (Figure 12, Item 4) from base (Figure 12, Item 5).

3 1,2

4

5

M0659105

Figure 12.

Drum Disassembly.

0125-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

DISASSEMBLY - Continued 17. Remove seal (Figure 13, Item 1) and bearing (Figure 13, Item 2) from support end of drum (Figure 13, Item 3). Discard seal.

1

2

3

M0660105

Figure 13. Seal and Bearing Disassembly. END OF TASK

0125-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY 1. Place base (Figure 14, Item 1) on side with bearing support end up.

1

M0661105

Figure 14.

Base Positioning Assembly.

0125-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued

NOTE
Lubricate all o-rings and oil seals with lubricating oil, prior to installation. Use a sealing compound on outside surface of oil seals and a light coat of thread sealing compound on pipe threads. Avoid getting thread compound inside parts or passages which conduct lubricating oil. 2. 3. 4. Install bearing (Figure 15, Item 4) and new seal (Figure 15, Item 3) in drum (Figure 15, Item 5). Install new seal (Figure 15, Item 3) with spring side of seal away from bearing, and press into drum (Figure 15, Item 5). Install o-ring (Figure 15, Item 2) and drain plug (Figure 15, Item 1) securely in drum (Figure 15, Item 5).

3,4 5 1,2

M0662105

Figure 15.

Drum Assembly.

WARNING

Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 5. Install drum (Figure 16, Item 1) into opening of base (Figure 16, Item 2).

0125-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued

1

2

M0663105

Figure 16. 6. 7. 8.

Drum Assembly.

Install relief valve (Figure 17, Item 1) on bearing support (Figure 17, Item 2), if removed. Lubricate bearing support (Figure 17, Item 2) with lubricating oil. Install bearing support (Figure 17, Item 2) on base (Figure 17, Item 4) in drum (Figure 17, Item 3).

1

2

3

4

M0664105

Figure 17.

Bearing Support Assembly.

0125-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued

CAUTION
Be sure relief valve is located above the horizontal centerline for the intended application. Oil leakage may occur if vent is positioned incorrectly. 9. Install six new lockwashers (Figure 18, Item 2) and capscrews (Figure 18, Item 1) on bearing support (Figure 18, Item 3).

3 1,2

M0665105

Figure 18.

Bearing Support Fasteners Assembly.

WARNING

Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel.

CAUTION
Snapring will keep output planet carrier correctly positioned in winch. Gear train damage may occur if snapring is omitted. 10. Stand winch on bearing support end and install snapring (Figure 19, Item 2) in bearing support (Figure 19, Item 1).

0125-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued

1 2

M0666105

Figure 19.

Snap Ring Assembly.

0125-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued 11. Install sun output gear (Figure 20, Item 1) and thrust washer (Figure 20, Item 2) into output planet carrier (Figure 20, Item 3).

1

2

3

M0667105

Figure 20. 12.

Sun Output Gear Assembly.

Install output planet carrier (Figure 21, Item 2) into drum (Figure 21, Item 3) while meshing planet gears with ring gear and planet carrier with bearing support (Figure 21, Item 1).

1

2

3
Figure 21. Output Planet Carrier Assembly.

M0668105

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TM 5-3810-305-23

0125

ASSEMBLY - Continued 13. 14. Install thrust ring (Figure 22, Item 2) on primary planet carrier (Figure 22, Item 1). Install primary planet carrier (Figure 22, Item 1) into drum (Figure 22, Item 3) while meshing planet gears with ring gear and planet carrier with output gear.

1

2

3
Figure 22. 15. Primary Planet Carrier Assembly.

M0669105

Install bearing (Figure 23, Item 2) and new seal (Figure 23, Item 1) in drum closure (Figure 23, Item 3). Install new seal with spring side of seal away from bearing.

1,2 3

M0670105

Figure 23.

Bearing and Seal Assembly.

0125-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued 16. 17. 18. Install new o-ring (Figure 24, Item 3) in drum (Figure 24, Item 1). Lubricate new o-ring (Figure 24, Item 3) and drum (Figure 24, Item 1) opening with lubricating oil. Install drum closure (Figure 24, Item 4) and snapring (Figure 24, Item 2) into drum (Figure 24, Item 1).

1

2

3

4

M0671105

Figure 24. 19.

Drum Assembly.

Install sun primary gear (Figure 25, Item 2) into primary planet carrier (Figure 25, Item 1) while meshing sun primary gear with planet gears.

2 1

M0672105

Figure 25.

Sun Primary Gear Assembly.

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TM 5-3810-305-23

0125

ASSEMBLY - Continued 20. 21. Apply lubricating oil to new seal and bearing surfaces of brake cylinder assembly (Figure 26, Item 1). Install brake cylinder assembly (Figure 26, Item 1) into base (Figure 26, Item 3) and drum (Figure 26, Item 2).

1 2

3

M0673105

Figure 26. 22.

Brake Cylinder Assembly Assembly.

Install six new lockwashers (Figure 27, Item 2) and capscrews (Figure 27, Item 1) on brake cylinder assembly (Figure 27, Item 3).

1,2

3

M0674105

Figure 27.

Brake Cylinder Assembly Assembly.

0125-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued

CAUTION
Be certain snapring is seated in groove in splined bore of cam. Snapring will keep brake clutch assembly correctly positioned in center of friction brake pack. Binding of brake or brake failure may occur if snapring is omitted.

NOTE
• When installed correctly, cam should turn freely in opposite direction drum turns to pull wire rope in. An easy way to check rotation is to hold outer race in one hand, and rotate cam. • If brake discs are misaligned, preventing installation of clutch, use a hand pump to apply 750 to 1,000 psi (5,171 to 6,895 kPa) to brake release port adapter. Brake discs will move freely with brake released, permitting alignment of discs, brake clutch and sun primary gear. 23. Install brake clutch assembly (Figure 28, Item 1) into drum (Figure 28, Item 2).

1

2
Figure 28. Brake Clutch Assembly Assembly.

M0675105

0125-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued 24. 25. 26. 27. 28. Lubricate new o-ring (Figure 29, Item 1) with lubricating oil. Install new o-ring (Figure 29, Item 1) on pilot of motor (Figure 29, Item 6). Install motor, engaging motor shaft with brake clutch cam and lower motor into drum. Install two new lockwashers (Figure 29, Item 4) and capscrews (Figure 29, Item 3). Connect hose (Figure 29, Item 2) to winch (Figure 29, Item 5).

2 1 3,4

6

5
M0676105

Figure 29.

Motor Installation Assembly.

0125-21

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

ASSEMBLY - Continued 29. 30. 31. Check all capscrews and fittings to make certain they have been tightened correctly. Refill winch assembly with lubricating oil. Install o-ring (Figure 30, Item 2) and oil level plug (Figure 30, Item 1) on winch (Figure 30, Item 3).

1,2

3

M0677105

Figure 30. END OF TASK INSTALLATION

Oil Fill Assembly.

WARNING

Weight of winch is approximately 300 lb (136 kg). Use adequate lifting equipment to lift and support winch. DO NOT lift over personnel or let personnel walk underneath suspended load. Failure to follow this warning may cause injury or death to personnel. 1. 2. 3. 4. 5. Attach hoist and sling to winch base (Figure 31, Item 4) and install on vehicle. Install four capscrews (Figure 31, Item 1) washers (Figure 31, Item 2) and new locknuts (Figure 31, Item 3) to secure winch base (Figure 31, Item 4). Install two elbows (Figure 31, Item 6) on brake valve assembly (Figure 31, Item 7). Connect two hydraulic hoses (Figure 31, Item 5) to brake valve assembly (Figure 31, Item 7). Close dipstick cap.

0125-22

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0125

INSTALLATION - Continued

2,3 1

4 5

6

7

M0678105

Figure 31. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Connect battery cables (WP 0076). Install cable on drum (TM 5-3810-305-10).

Winch Installation.

Run engine until normal operating temperature is reached (TM 5-3810-305-10). Place boom in resting position (TM 5-3810-305-10). Check for proper operation. Shut down engine (TM 5-3810-305-10).

END OF TASK END OF WORK PACKAGE

0125-23/24 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00141)

TM 5-3810-305-23

0126

FIELD MAINTENANCE WINCH MOTOR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Pan, Drain (WP 0171, Table 1, Item 39) Materials/Parts Adapter (WP 0172, Table 1, Item 39) Qty: 1 Adapter (WP 0172, Table 1, Item 45) Qty: 1 Cap Set, Protective Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 Elbow (WP 0172, Table 1, Item 36) Qty: 2 O-Ring (WP 0172, Table 1, Item 38) Qty: 2 Parts Kit, Seal Repl (WP 0172, Table 1, Item 73) Qty: 1 Materials/Parts (cont.) Plug (WP 0172, Table 1, Item 115) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Tee (WP 0172, Table 1, Item 40) Qty: 1 References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Winch removed (WP 0125)

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel.

0126-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 1. Disconnect hose (Figure 1, Item 1) and elbow with o-ring from winch brake valve assembly (Figure 1, Item 2). Discard elbow with o-ring.

1

2
Figure 1. 2. Winch Motor Disassembly.

M0623105

Remove two hoses (Figure 2, Item 3) and tee with o-ring (Figure 2, Item 2) from motor (Figure 2, Item 1). Discard tee with o-ring.

1

2 3
Figure 2. Winch Motor Disassembly.
M0624105

0126-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 3. 4. Disconnect hose (Figure 3, Item 1) and elbow with o-ring from winch brake valve assembly (Figure 3, Item 3). Discard elbow with o-ring. Remove hose (Figure 3, Item 1) from motor (Figure 3, Item 2).

2 1

3
Figure 3. Winch Motor Disassembly.

M0625105

NOTE
Matchmark brake valve assembly and winch motor gear housing prior to disassembly. 5. Remove four allen screws (Figure 4, Item 3), winch brake valve assembly (Figure 4, Item 2), and o-ring (Figure 4, Item 1) from motor (Figure 4, Item 4). Discard o-ring.

1

2 3

4
Figure 4. Winch Motor Disassembly.

M0626105

0126-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 6. Remove four allen screws (Figure 5, Item 1), split flange adapter (Figure 5, Item 2), and o-ring (Figure 5, Item 4) from motor (Figure 5, Item 3). Discard o-ring.

1 2 3

4
M0627105

Figure 5. 7.

Winch Motor Disassembly.

Remove seal (Figure 6, Item 1) from split flange adapter (Figure 6, Item 2). Discard seal.

1

2
M0628105

Figure 6.

Winch Motor Disassembly.

0126-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 8. Remove drain plug and o-ring (Figure 7, Item 3) to drain hydraulic oil. Discard plug and o-ring.

NOTE
Matchmark gear housing to shaft end cover and port end cover 9. Remove four capscrews (Figure 7, Item 1) and washers (Figure 7, Item 2).

2 1 3

M0629105

Figure 7. 10.

Winch Motor Disassembly.

Remove shaft end cover (Figure 8, Item 1) from motor (Figure 8, Item 2).

1 2

M0630105

Figure 8.

Winch Motor Disassembly.

0126-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 11. 12. 13. Remove six pocket seals (Figure 9, Item 3) and gasket seal (Figure 9, Item 2) from gear housing (Figure 9, Item 4). Discard pocket seals and gasket seals. Remove port end cover (Figure 9, Item 1) from gear housing (Figure 9, Item 4). Remove remaining six pocket seals (Figure 9, Item 3) and gasket seal (Figure 9, Item 2) from gear housing (Figure 9, Item 4). Discard pocket seals and gasket seals.

1 2 3

4

2 3

M0631105

Figure 9.

Winch Motor Disassembly.

NOTE
Matchmark thrust plates to gear housing. 14. 15. Remove two thrust plates (Figure 10, Item 1) by tapping on shafts (Figure 10, Item 3) to unseat thrust plates. Remove two shafts (Figure 10, Item 3) from gear housing (Figure 10, Item 2).

1

2

3

1
M0632105

Figure 10. Winch Motor Disassembly. 16. Inspect four dowel pins (WP 0162).

0126-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 17. Remove four dowel pins (Figure 11, Item 1) from port end cover (Figure 11, Item 2), if inspection proves necessary.

2

1

M0633105

Figure 11. 18. 19.

Winch Motor Disassembly.

Remove two bearings (Figure 12, Item 1) and ring seal (Figure 12, Item 4) from port end cover (Figure 12, Item 2). Remove adapter with o-ring (Figure 12, Item 3) from port end cover (Figure 12, Item 2). Discard adapter with o-ring.

1 2

3 4
M0634105

Figure 12.

Winch Motor Disassembly.

0126-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 20. Remove two bearings (Figure 13, Item 1) and ring seal (Figure 13, Item 3) from shaft end cover(Figure 13, Item 2).

1

3

2

M0635105

Figure 13. Winch Motor Disassembly. 21. Remove two check assemblies (Figure 14, Item 1) and adapter with o-ring (Figure 14, Item 2). Discard adapter with o-ring.

1

2
Figure 14. Winch Motor Disassembly.

M0636105

0126-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

DISASSEMBLY - Continued 22. Remove snapring (Figure 15, Item 5), spacer (Figure 15, Item 4), seal retainer (Figure 15, Item 3), and lip seal (Figure 15, Item 1) from shaft end cover (Figure 15, Item 2). Discard lip seal.

2 1

3 4 5
Figure 15. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK
M0637105

Winch Motor Disassembly.

0126-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY 1. Install snapring (Figure 16, Item 5), spacer (Figure 16, Item 4), seal retainer (Figure 16, Item 3), and new lip seal (Figure 16, Item 1) onto shaft end cover (Figure 16, Item 2).

2 1

3 4 5
M0637105

Figure 16. Winch Motor Assembly. 2. Install two check assemblies (Figure 17, Item 1) and adapter with o-ring (Figure 17, Item 2).

1

2
Figure 17. Winch Motor Assembly.

M0636105

0126-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 3. Install new ring seal (Figure 18, Item 3) and two bearings (Figure 18, Item 1) in shaft end cover (Figure 18, Item 2).

1

3

2

M0635105

Figure 18. 4. 5.

Winch Motor Assembly.

Install new adapter and o-ring (Figure 19, Item 3) in port end cover (Figure 19, Item 2). Install new ring seals (Figure 19, Item 4) and two bearings (Figure 19, Item 1) in port end cover (Figure 19, Item 2).

1 2

3 4
M0634105

Figure 19.

Winch Motor Assembly.

0126-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 6. Install four dowel pins (Figure 20, Item 1) in port end cover (Figure 20, Item 2), if removed.

2

1

M0633105

Figure 20. Winch Motor Assembly. 7. 8. Install thrust plate (Figure 21, Item 1) as matchmarked in gear housing (Figure 21, Item 2). Thrust plate is installed flush with gear housing. Install two shafts (Figure 21, Item 3) in gear housing (Figure 21, Item 2).

1

2

3

1
M0632105

Figure 21. Winch Motor Assembly.

0126-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 9. 10. 11. 12. Install new gasket seal (Figure 22, Item 2) and six new pocket seals (Figure 22, Item 3) in gear housing (Figure 22, Item 4). Install port end cover (Figure 22, Item 1) on gear housing (Figure 22, Item 4) as matchmarked during disassembly. Install remaining thrust plate (Figure 22, Item 4) as matchmarked in gear housing (Figure 22, Item 4). Thrust plate is installed flush with gear housing. Install new gasket seal (Figure 22, Item 2) and remaining six new pocket seals (Figure 22, Item 3) in gear housing (Figure 21, Item 4).

1 2 3

4

2 3

M0631105

Figure 22. 13.

Winch Motor Assembly.

Install shaft end cover (Figure 23, Item 1) as matchmarked on motor (Figure 23, Item 2).

1 2

M0630105

Figure 23.

Winch Motor Assembly.

0126-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 14. Install four washers (Figure 24, Item 2), capscrews (Figure 24, Item 1), new o-ring and drain plug (Figure 24, Item 3) to motor (Figure 24, Item 2).

2 1 3

M0629105

Figure 24. Winch Motor Assembly. 15. Install new seal (Figure 25, Item 1) onto split flange adapter (Figure 25, Item 2).

1

2
M0628105

Figure 25. Winch Motor Assembly.

0126-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 16. Install new o-ring (Figure 26, Item 4) and split flange adapter (Figure 26, Item 2) on motor (Figure 26, Item 3) with four allen screws (Figure 26, Item 1).

1 2 3

4
M0627105

Figure 26. 17.

Winch Motor Assembly.

Install new o-ring (Figure 27, Item 1), winch brake valve assembly (Figure 27, Item 2), and four allen screws (Figure 27, Item 3) on motor (Figure 27, Item 4).

1

2 3

4
Figure 27. Winch Motor Assembly.

M0626105

0126-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 18. Install hose (Figure 28, Item 1) with new elbow and o-ring on motor (Figure 28, Item 2) and winch brake valve assembly (Figure 28, Item 3).

2 1

3
Figure 28. Winch Motor Assembly. 19.

M0645105

Install new tee with o-ring (Figure 29, Item 2) and two hoses (Figure 29, Item 3) on motor (Figure 29, Item 1).

1

2 3
Figure 29. Winch Motor Assembly.
M0646105

0126-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0126

ASSEMBLY - Continued 20. Connect hose (Figure 30, Item 1) and new elbow with o-ring to winch brake valve assembly (Figure 30, Item 2).

1

2
Figure 30. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076). Install winch (WP 0125). Check for proper operation. Winch Motor Assembly.

M0647105

END OF TASK END OF WORK PACKAGE

0126-17/18 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00143)

TM 5-3810-305-23

0127

FIELD MAINTENANCE WINCH BRAKE VALVE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Elbow (WP 0172, Table 1, Item 36) Qty: 2 Lubricating Oil, Hydraulic MIL-L-2104 OE, 10 Grade (WP 0170, Table 1, Item 42) Qty: 1 O-Ring (WP 0172, Table 1, Item 29) Qty: 1 O-Ring (WP 0172, Table 1, Item 30) Qty: 1 O-Ring (WP 0172, Table 1, Item 31) Qty: 1 O-Ring (WP 0172, Table 1, Item 32) Qty: 1 O-Ring (WP 0172, Table 1, Item 33) Qty: 1 Materials/Parts (cont.) O-Ring (WP 0172, Table 1, Item 34) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Personnel Required (Two) References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Winch disassembled (WP 0125) Separate winch valve from winch motor (WP 0127)

0127-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00142)

TM 5-3810-305-23

0127

REMOVAL

NOTE
Elbows come with o-rings installed. 1. 2. 3. 4. 5. 6. 7. 8. Remove elbow (Figure 1, Item 11), o-ring (Figure 1, Item 10), ball (Figure 1, Item 9), and spring (Figure 1, Item 8) from housing (Figure 1, Item 23). Discard elbow and o-ring. Remove elbow (Figure 1, Item 14), o-ring (Figure 1, Item 13), and pilot orifice (Figure 1, Item 12) from housing (Figure 1, Item 23). Discard elbow and o-ring. Remove spring retainer (Figure 1, Item 4), o-ring (Figure 1, Item 5), and spring (Figure 1, Item 6) from housing (Figure 1, Item 23). Discard o-ring. Remove cap plug (Figure 1, Item 18), damper piston (Figure 1, Item 7), and spool (Figure 1, Item 15) as a unit from housing (Figure 1, Item 23). Remove back-up ring (Figure 1, Item 17) and o-ring (Figure 1, Item 16) from spool (Figure 1, Item 15). Discard o-ring. Separate damper piston (Figure 1, Item 7) from spool (Figure 1, Item 15). Remove back-up ring (Figure 1, Item 2) and o-ring (Figure 1, Item 3) from damper piston (Figure 1, Item 7). Discard o-ring. Remove spring retainer (Figure 1, Item 19), o-ring (Figure 1, Item 20), spring (Figure 1, Item 21), check valve poppet (Figure 1, Item 22), and plug (Figure 1, Item 1) from housing (Figure 1, Item 23). Discard o-ring.

0127-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00142)

TM 5-3810-305-23

0127

REMOVAL - Continued

4

5 6 7 1 2 3 9 8 13,14 12 10,11

23

22 15 21 20 17 8 19 18
M0622105

16

Figure 1. END OF TASK CLEANING

Winch Brake Valve Maintenance.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0127-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00142)

TM 5-3810-305-23

0127

INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSTALLATION

NOTE
Coat all parts with clean lubricating oil prior to assembly. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install plug (Figure 2, Item 1), check valve poppet (Figure 2, Item 22), spring (Figure 2, Item 21), new o-ring (Figure 2, Item 20), and spring retainer (Figure 2, Item 19) in housing (Figure 2, Item 23). Install new o-ring (Figure 2, Item 3) and back-up ring (Figure 2, Item 2) on damper piston (Figure 2, Item 7). Install damper piston (Figure 2, Item 7) into spool (Figure 2, Item 15). Install new o-ring (Figure 2, Item 16) and back-up ring (Figure 2, Item 17) on spool (Figure 2, Item 15). Install spool (Figure 2, Item 15) and damper piston (Figure 2, Item 7) as a unit in housing (Figure 2, Item 23). Center unit in housing while installing. Install cap plug (Figure 2, Item 18) in housing (Figure 2, Item 23). Install spring (Figure 2, Item 6), new o-ring (Figure 2, Item 5), and spring retainer (Figure 2, Item 4) in housing (Figure 2, Item 23). Install pilot orifice (Figure 2, Item 12), new elbow with o-ring (Figure 2, Item 14) in housing (Figure 2, Item 23). Install spring (Figure 2, Item 8), ball (Figure 2, Item 9), new elbow with o-ring (Figure 2, Item 11) in housing (Figure 2, Item 23). Ball should rest on spring. Install brake clutch assembly.

0127-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00142)

TM 5-3810-305-23

0127

INSTALLATION - Continued

4

5 6 7 1 2 3 9 8 13,14 12 10,11

23

22 15 21 20 17 8 19 18
M0622105

16

Figure 2. END OF TASK

Winch Brake Valve Maintenance.

0127-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00142)

TM 5-3810-305-23

0127

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Assemble winch (WP 0125). Install winch valve to winch motor (WP 0126). Connect battery (WP 0076). Check for proper operation.

END OF TASK END OF WORK PACKAGE

0127-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00142)

TM 5-3810-305-23

0128

FIELD MAINTENANCE WINCH CONTROL VALVE AND FITTINGS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Gage, Pressure, Dial Indicating (WP 0171, Table 1, Item 3) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0170, Table 1, Item 7) Qty: 1 O-Ring (WP 0172, Table 1, Item 120) Qty: 18 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Materials/Parts (cont.) Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 3 References WP 0076 WP 0129 WP 0145 WP 0162 Equipment Condition Deck plates removed (WP 0122)

0128-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00144)

TM 5-3810-305-23

0128

REMOVAL

WARNING

Never disconnect hydraulic lines or fittings before venting pressure. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Failure to follow this warning may cause death or injury to personnel. 1. 2. Turn dipstick cap 1/4 turn to safety notch to relieve pressure. Disconnect battery cables (WP 0076). Disconnect winch control cable (WP 0129).

NOTE
Tag all hose and tube assemblies before disconnecting to aid in installation. Cap and plug all ports. Remove caps, plugs, and tags following maintenance. 3. 4. 5. Disconnect all attaching hoses (Figure 1, Item 1), fittings and o-rings (Figure 1, Item 2) from winch control valve (Figure 1, Item 3). Discard o-rings. Remove three nuts (Figure 1, Item 4) and lockwashers (Figure 1, Item 5) from winch control valve (Figure 1, Item 3). Discard lockwashers. Remove winch control valve (Figure 1, Item 3) and three washers (Figure 1, Item 6) from frame location.

END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

0128-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00144)

TM 5-3810-305-23

0128

INSTALLATION 1. 2. 3. Install three washers (Figure 1, Item 6) and winch control valve (Figure 1, Item 3) on frame. Install three new lockwashers (Figure 1, Item 5) and nuts (Figure 1, Item 4). Connect all hoses (Figure 1, Item 1), fittings and new o-rings (Figure 1, Item 2) to winch control valve (Figure 1, Item 3).

1

2

3

2 4 2

3 1 1 2 6 2 2 1 2 5 4 2 1 2
M0478105

4,5,6

2

Figure 1.

Winch Control Valve Installation.

0128-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00144)

TM 5-3810-305-23

0128

INSTALLATION - Continued 4. Connect winch control cable (WP 0129).

WARNING

• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. • Wear protective eye covering. • Avoid sudden movement of vehicle. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Failure to follow these warnings may result in injury or death to personnel. 5. 6. Close dipstick cap. Connect battery cables (WP 0076). Start engine (TM 5-3810-305-10) and operate winch control lever. Make sure components operate correctly. Check for leaks. Check hydraulic oil level. Fill to proper level as necessary (TM 5-3810-305-10).

END OF TASK ADJUSTMENT 1. Disconnect brake release hose (Figure 2, Item 1) attached to winch motor, lower port and cap tee before checking pressure. Vent hose to atmosphere.

1

M0479105

Figure 2.

Winch Control Valve Test and Adjustment.

0128-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00144)

TM 5-3810-305-23

0128

ADJUSTMENT - Continued 2. Remove dust cap (Figure 3, Item 1) from test port located on inlet end of main control valve.

1

M0480105

Figure 3.

Winch Control Valve Test and Adjustment.

0128-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00144)

TM 5-3810-305-23

0128

ADJUSTMENT - Continued 3. 4. Install a 0 to 4,000 psi (0 to 27,580 kPa) gage equipped with short pressure hose and 1/4 inch female quick disconnect. Remove acorn nut (Figure 4, Item 1) from relief on winch valve.

WARNING

Keep all personnel away from winch and hook block area. Failure to follow this warning may result in death or serious injury to personnel. 5. Run engine at full rpm, operate winch lever in lowering mode and hold long enough to get a pressure reading.

NOTE
Winch control valve is set at 2,650 (+50, -0) psi (18,272 [+345, -0] kPa). 6. 7. Hold adjusting screw (Figure 4, Item 3) and loosen jam nut (Figure 4, Item 2). Turn adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure, until desired pressure setting is obtained. Hold adjusting screw (Figure 4, Item 3) and tighten jam nut (Figure 4, Item 2). Install and tighten acorn nut (Figure 4, Item 1).

2 1

3

M0481105

Figure 4.

Winch Control Valve Test and Adjustment.

0128-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00144)

TM 5-3810-305-23

0128

ADJUSTMENT - Continued 8. Remove pressure gage from test port and install dust cap (Figure 5, Item 1).

1

M0482105

Figure 5. 9.

Winch Control Valve Test and Adjustment.

Remove cap from tee and connect brake release hose (Figure 7, Item 1).

1

M0483105

Figure 6. END OF TASK

Winch Control Valve Test and Adjustment.

0128-7

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0128

FOLLOW-ON MAINTENANCE 1. 2. Install deck plates (WP 0122). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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0129

FIELD MAINTENANCE VALVE CONTROL, BOOM HOIST, EXTEND, AND WINCH CABLES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Pin, Cotter (WP 0172, Table 1, Item 155) Qty: 3 Pin, Cotter (WP 0172, Table 1, Item 156) Qty: 4 Pin, Cotter (WP 0172, Table 1, Item 157) Qty: 1 Nut, Self-Locking (WP 0172, Table 1, Item 139) Qty: 4 Washer, Lock (WP 0172, Table 1, Item 93) Qty: 6 Materials/Parts (cont.) Washer, Lock M10 (WP 0172, Table 1, Item 129) Qty: 8 Washer, Split M8 (WP 0172, Table 1, Item 95) Qty: 4 References WP 0162 Equipment Condition Boom in horizontal position and fully retracted (TM 5-3810-305-10) Battery cables disconnected (WP 0076) Outriggers lowered and fully retracted (TM 5-3810-305-10) Deck plates removed (WP 0122)

WARNING

Ensure to tag all cables and valve body properly before disconnecting. Failure to follow this warning may result in injury or death to personnel.

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0129

REMOVAL Control Valve Cable

NOTE
The following is a procedure for removal of one operator's end of valve control cable. The procedure for removal of the operator's end of the remaining valve control cables is identical. 1. Remove six capscrews (Figure 1, Item 2), lockwashers (Figure 1, Item 1), and front dash panel (Figure 1, Item 3) from vehicle. Discard lockwashers.

1 2 3

M0558105

Figure 1. Valve Control Cable Removal.

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0129

REMOVAL - Continued Control Valve Cable - Continued 2. 3. 4. 5. Remove cotter pin (Figure 2, Item 7), pin (Figure 2, Item 2), and yoke (Figure 2, Item 3) from lever assembly (Figure 2, Item 1). Discard cotter pin. Remove jam nut (Figure 2, Item 4) and remove yoke (Figure 2, Item 3) from vehicle. Loosen locking nuts (Figure 2, Item 5) and pull cable (Figure 2, Item 9) from bracket (Figure 2, Item 8). Remove two locking nuts (Figure 2, Item 5) and washers (Figure 2, Item 6) from cable (Figure 2, Item 9).

3 4 2 5 1 8 7 6 9
M0559105

Figure 2.

Valve Control Cable Removal.

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0129

REMOVAL - Continued Control Valve Cable - Continued 6. 7. 8. 9. 10. 11. Remove two nuts (Figure 3, Item 2), lockwashers (Figure 3, Item 3), and capscrews (Figure 3, Item 4) from bracket (Figure 3, Item 5). Discard lockwashers. Remove two locknuts (Figure 3, Item 1) and washers (Figure 3, Items 8 and 9) from clamps (Figure 3, Items 7 and 10). Discard locknuts. Spread two clamps (Figure 3, Items 7 and 10) apart and remove cable (Figure 3, Item 6) from vehicle. Remove two locknuts (Figure 3, Item 11) and washers (Figure 3, Items 8 and 9) from two clamps (Figure 3, Item 12). Discard locknuts. Spread two clamps (Figure 3, Item 12) apart and remove cable (Figure 3, Item 6). Pull cable through operator's cab access hole.

1 2, 3, 4 5

9 8 7

6

8 12 9 11

10

M0560105

Figure 3. Valve Control Cable Removal.

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0129

REMOVAL - Continued

Swing And Outrigger Cable

NOTE
The valve end of boom hoist, extend and winch cables are different from outrigger and swing cable. The end of each cable group must be removed using the correct procedure. 1. 2. 3. 4. 5. Remove cotter pin (Figure 4, Item 2) and pin (Figure 4, Item 10) from clevis (Figure 4, Item 9). Discard cotter pin. Remove two jam nuts (Figure 4, Item 1) and clevis (Figure 4, Item 9). Loosen two locking nuts (Figure 4, Item 3) and pull cable from bracket. Remove two locking nuts (Figure 4, Item 5) and washers (Figure 4, Items 6 and 8) from clamps (Figure 4, Item 7). Carefully pull cable (Figure 4, Item 4) out of vehicle.

1

2 1

10 9 3 4

5 6 7 8
Figure 4. Swing and Outrigger Cable Removal.
M0561105

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0129

REMOVAL - Continued

Boom Hoist, Extend, And Winch Cable 1. Remove cotter pin (Figure 5, Item 2) and pin (Figure 5, Item 9) from clevis (Figure 5, Item 3). Discard cotter pin.

NOTE
• Clevis is not removed from disconnect assembly on winch cable. Disconnect assembly and clevis are removed as an unit. • Use Steps 3, 4, 5, and 6 for winch cable removal. 2. Remove capscrew (Figure 5, Item 1) and clevis (Figure 5, Item 3) from disconnect assembly (Figure 5, Item 8).

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 3. 4. 5. 6. 7. Disconnect two wires from disconnect assembly (Figure 5, Item 8). Loosen jam nut (Figure 5, Item 10) and remove disconnect assembly (Figure 5, Item 8) from vehicle. Remove jam nut (Figure 5, Item 10) from cable (Figure 5, Item 5). Loosen two locking nuts (Figure 5, Item 4) and lift cable assembly (Figure 5, Item 5) from bracket (Figure 5, Item 6). Remove locking nuts and washers (Figure 5, Item 7) from cable. Remove cable (Figure 5, Item 5) from carrier.

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0129

REMOVAL - Continued Boom Hoist, Extend, And Winch Cable - Continued

1 9 8 10

2 3

4 7 5 6

2 10 7 9 8
M0562105

Figure 5. END OF TASK CLEANING

Boom Hoist, Extend, and Winch Cable Removal.

Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK

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0129

INSTALLATION Boom Hoist, Extend, And Winch Cable

NOTE
Before tightening jam nut, see adjustment procedure. 1. 2. 3. 4. 5. 6. 7. Install clevis (Figure 6, Item 3) and capscrew (Figure 6, Item 1) on end of disconnect assembly (Figure 6, Item 8), telescope and boom hoist cable only. Install jam nut (Figure 6, Item 10) and disconnect assembly (Figure 6, Item 8) on cable end. Tighten jam nut securing disconnect assembly (Figure 6, Item 8) on cable end. Connect two wires on disconnect assembly (Figure 6, Item 8). Note tag from removal. Position cable (Figure 6, Item 5) in place and install pin (Figure 6, Item 9) and new cotter pin (Figure 6, Item 2) on clevis (Figure 6, Item 3). Install washers (Figure 6, Item 7) and new locking nuts (Figure 6, Item 4) on cable (Figure 6, Item 5). Tighten two new locking nuts (Figure 6, Item 4) securing cable (Figure 6, Item 5) in bracket (Figure 6, Item 6). Check cable (Figure 6, Item 5) operation for correct adjustment and movement.

1 9 8 10

2 3

4 7 5 6

2 10 7 9 8
M0562105

Figure 6. Boom Hoist, Extend, and Winch Cable Installation.

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0129

INSTALLATION - Continued Swing And Outrigger Cable

NOTE
The valve end of boom hoist, extend and winch cables are different from outrigger and swing cable. The end of each cable group must be installed using the correct procedure. 1. 2. 3. 4. 5. Carefully position cable (Figure 7, Item 4) in place on vehicle. Install two clamps (Figure 7, Item 7), washers (Figure 7, Items 6 and 8), and locking nuts (Figure 7, Item 5) on cable. Tighten two locking nuts (Figure 7, Item 3) to hold cable in place on bracket. Install two jam nuts (Figure 7, Item 1) and clevis (Figure 7, Item 9) on end of cable. Thread two jam nuts and clevis to full threaded engagement. Tighten rear jam nut to lock clevis in place. Position cable (Figure 7, Item 4) in place and install pin (Figure 7, Item 10) and cotter pin (Figure 7, Item 2).

1

2 1

10 9 3 4

5 6 7 8
Figure 7. Swing and Outrigger Cable Installation.
M0561105

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0129

INSTALLATION - Continued

Valve Control Cables

NOTE
The following is a procedure for installation of the operator's end of one valve control cable. The procedure for installation of the operator's end of the remaining valve control cables is identical. 1. 2. 3. 4. Pull cable (Figure 8, Item 8) through access hole in rear cab panel. Install two locking nuts (Figure 8, Item 5) and washers (Figure 8, Item 6) on cable (Figure 8, Item 8). Install jam nut (Figure 8, Item 4) and yoke (Figure 8, Item 3) on cable (Figure 8, Item 8). Install yoke (Figure 8, Item 3), pin (Figure 8, Item 2), and new cotter pin (Figure 8, Item 7) on lever assembly (Figure 5, Item 1).

3 4 2 5 1 7 6 8
M0563105

Figure 8. Valve Control Cables Installation.

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0129

INSTALLATION - Continued Valve Control Cables - Continued 5. 6. 7. 8. Install bracket (Figure 9, Item 5) with two capscrews (Figure 9, Item 4), new lockwashers (Figure 9, Item 3) and nuts (Figure 9, Item 2). Tighten locking nuts (Figure 9, Item 2) and washers (Figure 9, Item 3) on bracket (Figure 9, Item 8). Position cable (Figure 9, Item 9) through clamps (Figure 9, Item 12) and install washer (Figure 9, Items 8 and 9), and locknuts (Figure 9, Item 11). Position cable (Figure 9, Item 6) through clamps (Figure 9, Items 7 and 10) and install washers (Figure 9, Items 8 and 9) and two new locknuts (Figure 9, Item 1).

1 2, 3, 4 5

9 8 7

6

8 12
Figure 9.

10 9 11
M0560105

Valve Control Cables Installation.

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0129

INSTALLATION - Continued Valve Control Cables - Continued 9. Install front panel (Figure 10, Item 3) with six new lockwashers (Figure 10, Item 1) and capscrews (Figure 10, Item 2).

1 2 3

M0558105

Figure 10. Valve Control Cables Installation. END OF TASK ADJUSTMENT 1. Adjustment on hoist, winch, and telescope cables are made by installing disconnect assemblies (Figure 11, Item 3) until they bottom on cable ends. Turn out two turns and tighten jam nuts (Figure 11, Item 2). Adjustment for hoist winch and telescope levers are made with electrical power disconnected. Push levers to full forward position (full rearward for winch). Adjust yoke (Figure 11, Item 1) so that no movement to valve bank piston is made. Reposition locking nuts on cable if further adjustment is necessary. Return levers to neutral position. Adjust yoke (Figure 11, Item 1) on remaining levers in alignment with hoist and telescope levers. Tighten jam nuts on all five cables for operator's safety.

2.

3. 4.

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0129

ADJUSTMENT - Continued

1 3 2

M0564105

Figure 11. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Connect battery cables (WP 0076). Install deck plates (WP 0122).

Cables Adjustment.

Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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TM 5-3810-305-23

0130

FIELD MAINTENANCE MIRROR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Locknut (WP 0172, Table 1, Item 151) Qty: 4 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Washer, Split M8 (WP 0172, Table 1, Item 95) Qty: 4 References WP 0162 Equipment Condition Vehicle parked on level ground (TM 5-3810-305-10) Boom in horizontal position and fully retracted (TM 5-3810-305-10)

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0130

REMOVAL

NOTE
The following is a maintenance procedure for left mirror. The maintenance procedure for right mirror is identical. Remove two nuts (Figure 1, Item 9), lockwashers (Figure 1, Item 8), capscrews (Figure 1, Item 1), and mirror (Figure 1, Item 10) from vehicle. Discard lockwashers. END OF TASK DISASSEMBLY Remove two nuts (Figure 1, Item 5), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), and brackets (Figure 1, Items 7 and 11) from mirror (Figure 1, Item 10). Discard lockwashers. END OF TASK CLEANING Clean parts IAW General Maintenance Instructions (WP 0162). END OF TASK INSPECTION Inspect parts IAW General Maintenance Instructions (WP 0162). END OF TASK ASSEMBLY Install two brackets (Figure 1, Items 7 and 11), washers (Figure 1, Item 4), new lockwashers (Figure 1, Item 3), and nuts (Figure 1, Item 5) on mirror (Figure 1, Item 10). END OF TASK INSTALLATION Install mirror (Figure 1, Item 10), two capscrews (Figure 1, Item 1), new lockwashers (Figure 1, Item 8), and nuts (Figure 1, Item 9) on vehicle.

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0130

INSTALLATION - Continued

2 1 3 4 5

11 10

6 2 3 4 8 9 1 5 7 6

8 9
M0572105

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Connect battery cables (WP 0076).

Mirror Maintenance.

Place boom in resting position (TM 5-3810-305-10). Check for proper operation.

END OF TASK END OF WORK PACKAGE

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0131

FIELD MAINTENANCE WINDSHIELD WIPER ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0171, Table 1, Item 17) Materials/Parts Gasket (WP 0172, Table 1, Item 144) Qty: 1 Locknut (WP 0172, Table 1, Item 151) Qty: 1 Rag, Wiping (WP 0170, Table 1, Item 52) Qty: 1 Tag, Marker (WP 0170, Table 1, Item 68) Qty: 1 Materials/Parts (cont.) Washer, Lock (WP 0172, Table 1, Item 13) Qty: 2 Washer, Lock (WP 0172, Table 1, Item 173) Qty: 1 References WP 0162 Equipment Condition Battery cables disconnected (WP 0076) Lower dash panel removed (WP 0066)

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0131

REMOVAL

WARNING

Remove jewelry and disconnect battery negative ground cable before performing maintenance on this equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE
Tag all wire assemblies before disconnecting to aid in installation. Remove tags following maintenance. 1. 2. Remove screw (Figure 1, Item 1), clamp (Figure 1, Item 4), and wire (Figure 1, Item 5) from wiper motor (Figure 1, Item 3). Disconnect electrical connector (Figure 1, Item 2) from wiper motor (Figure 1, Item 3).

1

2

3

5

4
Figure 1. Windshield Wiper Removal.

M0566105

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0131

REMOVAL - Continued 3. Remove two nuts (Figure 2, Items 1 and 3), lockwashers (Figure 2, Items 2 and 4), and wiper arm (Figure 2, Item 6) from adapter (Figure 2, Item 5). Discard lockwashers.

1

2

3

4

5

6
Figure 2. Windshield Wiper Removal.

M0567105

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0131

REMOVAL - Continued 4. Remove knurled driver nut (Figure 3, Item 1) and plastic insert (Figure 3, Item 2) from adapter (Figure 3, Item 3).

1

2

3

M0568105

Figure 3. Windshield Wiper Removal.

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0131

REMOVAL - Continued 5. 6. Remove rubber cap (Figure 4, Item 1), nut (Figure 4, Item 2), and two washers (Figure 4, Items 3 and 8) from adapter (Figure 4, Item 4). Remove two capscrews (Figure 4, Item 5), washers (Figure 4, Item 6), adapter (Figure 4, Item 4), and gasket (Figure 4, Item 7) from vehicle. Discard gasket.

1

2

3

4

8
Figure 4.

7

5,6

M0569105

Windshield Wiper Removal.

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0131

REMOVAL - Continued 7. 8. 9. 10. 11. Remove nut (Figure 5, Item 2) and washer (Figure 5, Item 3) from pivot shaft (Figure 5, Item 7) on wiper motor (Figure 5, Item 6). Remove pivot shaft link (Figure 5, Item 4) from pivot shaft (Figure 5, Item 7). Remove three bolts (Figure 5, Item 5) from bracket (Figure 5, Item 1) and wiper motor (Figure 5, Item 6). Remove wiper motor (Figure 5, Item 6) from vehicle. Remove bracket (Figure 5, Item 1) from vehi