ARMY *TM 10-3930-675-23-2 MARINE CORPS TM 11078A-OI/1 VOLUME 2

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4 NSN 3930-01-473-3998 NSN 3930-01-522-7364

*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS 01 OCTOBER 2012 PCN 184 110783 00
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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. FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

EXPLANATION OF SAFETY WARNING ICONS

ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present. May result in death or injury to personnel.

FLYING PARTICLES - Arrows bouncing off face with face shield shows that particles flying through the air will harm face. May result in death or injury to personnel.

HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb. May result in death or injury to personnel.

HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm. May result in death or injury to personnel.

HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique. May result in death or injury to personnel.

HOT AREA - Hand over object radiating heat shows that part is hot and can burn. May result in death or injury to personnel.

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GENERAL SAFETY WARNING DESCRIPTIONS

WARNING

COMPRESSED AIR Compressed air used for cleaning or drying purposes, or for cleaning restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel.

WARNING

ELECTRICAL SYSTEM MAINTENANCE Remove all jewelry, watches, rings, etc. prior to disconnecting cables from batteries or other electrical source. Items can come in contact with battery or electrical source and cause electrical shock. Failure to follow this warning may result in injury or death to personnel.

WARNING

HYDRAULIC SYSTEM DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

WARNING
IR LIGHTS DO NOT look directly at IR source without eye protection and maintain a minimum of 12 inches from energized IR lights to prevent possible eye discomfort or damage.

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GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

LIFTING HEAVY COMPONENTS Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to perform maintenance. DO NOT get under vehicle after it is raised unless it is properly supported with blocks or other suitable cribbing. Failure to observe this warning may result in death or injury to personnel. Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. Improper use of lifting equipment and improper attachment of cables to vehicle can result in serious personnel injury and equipment damage. Observe all standard rules of safety.

WARNING

SLAVE STARTING When slave starting RTCH, use NATO slave cable that DOES NOT have loose or missing insulation. DO NOT proceed if suitable cable is not available. DO NOT use civilian-type jumper cables. EXPLANATION OF HAZARDOUS MATERIALS ICONS

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

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

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

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WARNING SUMMARY - Continued
EXPLANATION OF HAZARDOUS MATERIALS ICONS - Continued

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

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

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.

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HAZARDOUS MATERIALS DESCRIPTIONS

WARNING

BATTERY • Remove all jewelry, such as rings, I.D. tags, rings, bracelets, etc. If jewelry contacts a battery terminal, a direct short will result causing instant heating of jewelry. Failure to follow this warning may result in serious injury or death to personnel. Seek medical attention in the event of an injury. Battery acid (electrolyte) is extremely dangerous. Always wear eye protection and rubber gloves when performing battery checks or inspections. Serious injury to personnel will result if battery acid contacts skin or eyes. Failure to follow this warning may result in injury or death to personnel. Seek medical attention in the event of an injury. DO NOT perform battery system checks or inspections while smoking or near fire, flames, or sparks. Battery gases may explode. Failure to follow this warning may cause serious injury or death to personnel. Seek medical attention in the event of an injury. 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. Failure to follow this warning may cause injury to personnel. Seek medical attention in the event of an injury. a. Eyes. Flush with cold water for no less than 15 minutes and immediately seek medical attention. 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. Immediately seek medical attention. d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia. California Proposition 65 Warning. Battery posts, terminals, and related accessories contain lead and lead components. These chemicals are known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Failure to follow this warning may result in injury or death to personnel. Seek medical attention in the event of an injury.

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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 poisonous gas 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 may result from severe exposure. Seek medical attention in the event of an injury. Carbon monoxide occurs in exhaust fumes of internal combustion engines. 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 RTCH is operated for any purpose. 1. DO NOT operate RTCH engine in enclosed areas. Good ventilation is essential. 2. BE ALERT at all times for exhaust odors. 3. BE ALERT for exhaust poisoning symptoms. They are: • • • Headache Dizziness Drowsiness

• Loss of muscular control 4. 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 cardiovascular pulmonary resuscitation (CPR), if necessary.

• Notify a medic. 5. BE AWARE: The field protective mask for chemical-biological-radiological-nuclear (CBRN) protection will not protect you from carbon monoxide poisoning. 6. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation. 7. Failure to follow this warning may result in injury or death to personnel. 8. Seek medical attention in the event of an injury.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

CBRN EXPOSURE If 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 in the event of an injury.

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

WARNING

CLEANING AGENTS Improper cleaning methods and use of unauthorized cleaning agents can injure personnel and damage equipment. To prevent this, refer to TM 9-247 for further instructions.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

DIESEL FUEL HANDLING • DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. Wear fuel-resistant gloves when handling fuels and promptly wash exposed skin and change fuel-soaked clothing.

WARNING

CLEANING COMPOUND, SOLVENT Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200°F (94°C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately.

WARNING

ETHER COLD START Ether is extremely flammable and explosive. DO NOT perform ether cold start system checks, inspections or maintenance while smoking or near fire, flames or sparks. Failure to follow this warning may cause a fire and explosion, causing serious injury or death to personnel. Avoid breathing cold start system fluid vapors. Wear goggles and fuel-resistant gloves when handling fluid. Failure to follow this warning may result in serious injury or death to personnel.

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher in cab may result in temporary breathing difficulty during and immediately after the discharge event. If at all possible, discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry.

WARNING

HAZARDOUS WASTE DISPOSAL When servicing this vehicle, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-327-3845. Failure to follow this warning may result in death or injury to personnel.

WARNING

PRESSURIZED COOLING SYSTEM • DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to follow this warning may cause serious burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to follow this warning may result in injury.

• •

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WARNING SUMMARY - Continued
HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

R-134A REFRIGERANT • Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Take care to prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if you come in contact with liquid refrigerant. Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with compressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, which could cause personnel injury.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE: This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2 and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December, 2006 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 01 OCTOBER 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 76 AND TOTAL NUMBER OF WORK PACKAGES IS 143 CONSISTING OF THE FOLLOWING: Page/WP No. VOLUME 2 WP Front Cover (6 pages) Warning Summary (10 pages) Title Block Page (2 pages) Table Of Contents (4 pages) How To Use This Manual (4 pages) Chapter 5 Title Page WP 0135 (20 pages) WP 0136 (6 pages) WP 0137 (4 pages) WP 0138 (4 pages) WP 0139 (4 pages) WP 0140 (10 pages) WP 0141 (8 pages) WP 0142 (6 pages) WP 0143 (8 pages) WP 0144 (4 pages) WP 0145 (8 pages) WP 0146 (8 pages) WP 0147 (6 pages) WP 0148 (4 pages) WP 0149 (10 pages) WP 0150 (4 pages) WP 0151 (4 pages) WP 0152 (2 pages) WP 0153 (4 pages) WP 0154 (4 pages) WP 0155 (16 pages) WP 0156 (4 pages) WP 0157 (4 pages) WP 0158 (6 pages) WP 0159 (4 pages) WP 0160 (8 pages) WP 0161 (4 pages) WP 0162 (6 pages) WP 0163 (8 pages) WP 0164 (4 pages) WP 0165 (4 pages) WP 0166 (10 pages) WP 0167 (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 Page/WP No. WP 0168 (6 pages) WP 0169 (4 pages) WP 0170 (2 pages) WP 0171 (4 pages) WP 0172 (4 pages) WP 0173 (6 pages) WP 0174 (4 pages) WP 0175 (6 pages) WP 0176 (12 pages) WP 0177 (10 pages) WP 0178 (2 pages) WP 0179 (24 pages) WP 0180 (4 pages) WP 0181 (4 pages) WP 0182 (4 pages) WP 0183 (4 pages) WP 0184 (4 pages) WP 0185 (4 pages) WP 0186 (8 pages) WP 0187 (6 pages) WP 0188 (4 pages) WP 0189 (2 pages) WP 0190 (10 pages) WP 0191 (8 pages) WP 0192 (2 pages) WP 0193 (4 pages) WP 0194 (14 pages) WP 0195 (6 pages) WP 0196 (16 pages) WP 0197 (6 pages) WP 0198 (4 pages) WP 0199 (8 pages) WP 0200 (4 pages) WP 0201 (4 pages) WP 0202 (2 pages) WP 0203 (2 pages) WP 0204 (4 pages) WP 0205 (6 pages) WP 0206 (6 pages) WP 0207 (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 0208 (2 pages) WP 0209 (8 pages) WP 0210 (10 pages) WP 0211 (4 pages) WP 0212 (20 pages) WP 0213 (8 pages) WP 0214 (8 pages) WP 0215 (4 pages) WP 0216 (4 pages) WP 0217 (6 pages) WP 0218 (10 pages) WP 0219 (2 pages) WP 0220 (2 pages) WP 0221 (2 pages) WP 0222 (2 pages) WP 0223 (2 pages) WP 0224 (2 pages) WP 0225 (2 pages) WP 0226 (2 pages) WP 0227 (6 pages) WP 0228 (44 pages) WP 0229 (4 pages) WP 0230 (4 pages) WP 0231 (8 pages) WP 0232 (4 pages) WP 0233 (4 pages) WP 0234 (6 pages) WP 0235 (8 pages) WP 0236 (8 pages) WP 0237 (4 pages) WP 0238 (4 pages) WP 0239 (4 pages) WP 0240 (4 pages) WP 0241 (4 pages) WP 0242 (4 pages) WP 0243 (14 pages) WP 0244 (2 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 Page/WP No. WP 0245 (8 pages) WP 0246 (4 pages) WP 0247 (4 pages) WP 0248 (6 pages) WP 0249 (2 pages) WP 0250 (4 pages) WP 0251 (4 pages) WP 0252 (16 pages) WP 0253 (4 pages) WP 0254 (4 pages) WP 0255 (6 pages) WP 0256 (8 pages) WP 0257 (10 pages) WP 0258 (18 pages) WP 0259 (16 pages) WP 0260 (14 pages) WP 0261 (6 pages) WP 0262 (4 pages) WP 0263 (20 pages) WP 0264 (8 pages) WP 0265 (2 pages) WP 0266 (4 pages) WP 0267 (20 pages) WP 0268 (10 pages) WP 0269 (2 pages) WP 0270 (4 pages) WP 0271 (6 pages) WP 0272 (62 pages) Chapter 6 Title Page WP 0273 (2 pages) WP 0274 (4 pages) WP 0275 (28 pages) WP 0276 (6 pages) WP 0277 (8 pages) WP 0278 (10 pages) Index (8 pages) Back Cover 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

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*TM 10-3930-675-23-2 ARMY *TM 10-3930-675-23-2 MARINE CORPS TM 11078A-OI/1-2 HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 01 OCTOBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL

ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4 NSN 3930-01-473-3998 NSN 3930-01-522-7364
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring service, should be submitted as follows: (a) Army (A) - 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) website. The Internet address is https://tulsa.tacom.army.mil. 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 website will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. (b) Marine Corps (MC) - Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC may be submitted using either of the following: a. The preferred method of submittal is using https://portal.logcom.usmc.mil/sites/pubs/ URL which will allow direct connection to the LOGCOM SharePoint Pubs site (LOGCOM SharePoint access and CAC required) where the form can be filled out and be submitted to the NAVMC SharePoint database. Problems or questions regarding the NAVMC 10772 program should be reported by calling DSN 567-7628 or DSN 567-5017 (Commercial number is (229) 639-7628 or (229) 639-5017). b. The alternate method of submittal does not require a Common Access Card (CAC) to access the form. Click on http://navalforms.daps.dla.mil/web/public/forms, select the "Keyword Search" button, enter "10772" in the Search Criteria Box. Under "type" click on download page button. Click on PDF icon. Enter user data in the appropriate fields. Must have users contact information block filled with Unit address and telephone number. Click on the 'Envelope' icon in the tool bar. Select "Send Copy” click on "OK". When the PDF document is created, an Outlook Email screen will open with the .PDF as an attachment. On the TO: line type SMB.LOG.Tech.Pubs.fct@usmc.mil. In the body of the email, type any additional information you wish to provide. Click “SEND”. c. A reply will be furnished to you.
*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PCN 184 110783 00

FOR

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TABLE OF CONTENTS
Page No. WP Sequence No. Volume 2 Chapter 5 - MAINTENANCE INSTRUCTIONS TRANSMISSION ASSEMBLY MAINTENANCE.......................................................................................... WP 0135 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. Transmission Sensors Removal........................................................................................... 0135-3 Transmission Hoses Removal.............................................................................................. 0135-4 Transmission Oil Fill Tube Removal..................................................................................... 0135-5 Flywheel Housing Access Cover.......................................................................................... 0135-5 Flywheel-to-Damper Plate Access Cover Removal............................................................. 0135-6 Damper Plates-to-Flywheel Screw Removal........................................................................ 0135-7 Flywheel Housing Screws Removal..................................................................................... 0135-7 Transmission-to-Mounting Bracket Removal....................................................................... 0135-8 Electrical Connectors Removal............................................................................................ 0135-9 Transmission Sensors Installation...................................................................................... 0135-10 Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-12 Flywheel-to-Damper Plate Screw Installation..................................................................... 0135-13 Flywheel Housing Screws Installation................................................................................ 0135-13 Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-14 Flywheel Housing Access Cover Installation...................................................................... 0135-15 Flywheel-to-Damper Plate Access Cover Installation........................................................ 0135-15 Transmission Oil Fill Tube Installation................................................................................ 0135-16 Transmission Hoses Installation......................................................................................... 0135-17 Transmission Electrical Connectors................................................................................... 0135-18

TRANSMISSION CALIBRATION................................................................................................................. WP 0136 Figure 1. Figure 2. Table 1. Table 2. Calibration............................................................................................................................ 0136-2 Calibration............................................................................................................................ 0136-3 Main Transmission Calibration Codes.................................................................................. 0136-4 Sub Transmission Calibration Codes................................................................................... 0136-5

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT.................................. WP 0137 Figure 1. Figure 2. Transmission Assembly Hose and Pipe Location Diagram.................................................. 0137-2 Transmission Hose and Pipe Location................................................................................. 0137-3

TRANSMISSION OIL DIPSTICK HOSE AND PIPE REPLACEMENT........................................................ WP 0138 Figure 1. Transmission Oil Dipstick Hose and Pipe Replacement...................................................... 0138-3

TRANSMISSION TORQUE CONVERTER REPLACEMENT...................................................................... WP 0139 Figure 1. Figure 2. Damper Plates Removal...................................................................................................... 0139-1 Torque Converter Removal.................................................................................................. 0139-3

TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD MAINTENANCE....................................... WP 0140 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Transmission Oil Draining and Filling................................................................................... 0140-3 Transmission Oil Filters Replacement.................................................................................. 0140-5 Transmission Oil Filter Head Replacement.......................................................................... 0140-6 Transmission Oil Filter Head Replacement.......................................................................... 0140-7 Transmission Internal Coarse Oil Filter Removal................................................................. 0140-8 Transmission Internal Coarse Oil Filter Installation............................................................ 0140-10

TRANSMISSION OIL COOLER REPLACEMENT....................................................................................... WP 0141 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Transmission Oil Coolers Removal...................................................................................... 0141-2 Transmission Oil Coolers Removal...................................................................................... 0141-3 Transmission Oil Coolers Removal...................................................................................... 0141-4 Transmission Oil Coolers Removal...................................................................................... 0141-5 Transmission Oil Coolers Installation................................................................................... 0141-6 Transmission Oil Coolers Installation................................................................................... 0141-7 Transmission Oil Coolers Installation................................................................................... 0141-8

TRANSMISSION OIL FILTER HOSES AND OIL COOLER HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0142 Figure 1. Figure 2. Transmission-to-Oil Cooler Hoses Replacement................................................................. 0142-3 Transmission-to-Oil Filter Hose Replacement. .................................................................... 0142-5

FRONT AND REAR PROPELLER SHAFTS REPLACEMENT................................................................... WP 0143

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Propeller Shaft Removal............................................................................................. 0143-2 Front Propeller Shaft Removal. ........................................................................................... 0143-3 Rear Propeller Shaft Removal.............................................................................................. 0143-4 Rear Propeller Shaft Removal.............................................................................................. 0143-5 Rear Propeller Shaft Installation. ......................................................................................... 0143-7

UNIVERSAL JOINT REPLACEMENT......................................................................................................... WP 0144 Figure 1. Propeller Shaft Universal Joint Replacement....................................................................... 0144-3

FRONT AXLE ASSEMBLY REPLACEMENT.............................................................................................. WP 0145 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Axle Removal.............................................................................................................. 0145-2 Front Axle Removal.............................................................................................................. 0145-3 Front Axle Removal.............................................................................................................. 0145-4 Front Axle Removal.............................................................................................................. 0145-5 Front Axle Removal.............................................................................................................. 0145-6 Front Axle Installation........................................................................................................... 0145-7

TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT.................................. WP 0146 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Axle Vent Hose Removal............................................................................................ 0146-2 Front Axle Vent Hose Replacement..................................................................................... 0146-3 Rear Axle Vent Hose Replacement...................................................................................... 0146-4 Rear Axle Vent Hose Replacement...................................................................................... 0146-5 Transmission Vent Hose Replacement................................................................................ 0146-7

REAR AXLE ASSEMBLY MAINTENANCE................................................................................................. WP 0147 Figure 1. Figure 2. Figure 3. Rear Axle Rigging................................................................................................................ 0147-2 Rear Axle Removal.............................................................................................................. 0147-3 Rear Axle Installation........................................................................................................... 0147-5

CAGING AND UNCAGING PARKING BRAKE........................................................................................... WP 0148 Figure 1. Figure 2. Caging Parking Brake.......................................................................................................... 0148-2 Caging Parking Brake.......................................................................................................... 0148-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Caging Parking Brake.......................................................................................................... 0148-3

PARKING BRAKE CYLINDER REPLACEMENT........................................................................................ WP 0149 Figure 1. Figure 2. Figure 3. Figure 4. Parking Brake Cylinder Removal......................................................................................... 0149-3 Parking Brake Cylinder Installation...................................................................................... 0149-5 Parking Brake Rotor Removal.............................................................................................. 0149-7 Parking Brake Bracket Replacement................................................................................... 0149-9

PARKING BRAKE PADS MAINTENANCE.................................................................................................. WP 0150 Figure 1. Parking Brake Pad Replacement. ....................................................................................... 0150-3

PARKING BRAKE CONTROL VALVE REPLACEMENT............................................................................ WP 0151 Figure 1. Figure 2. Figure 3. Parking Brake Control Valve Removal................................................................................. 0151-1 Parking Brake Control Valve Replacement.......................................................................... 0151-3 Parking Brake Control Valve Installation.............................................................................. 0151-4

PARKING BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT.............................. WP 0152 SERVICE BRAKE CONTROL VALVE REPLACEMENT............................................................................. WP 0153 Figure 1. Service Brake Control Valve Replacement.......................................................................... 0153-2

BRAKE ACCUMULATOR REPLACEMENT................................................................................................ WP 0154 Figure 1. Figure 2. Figure 3. Brake Accumulators and Valve Block Replacement............................................................ 0154-2 Brake Accumulators and Valve Block Replacement............................................................ 0154-3 Brake Accumulators and Valve Block Replacement............................................................ 0154-4

BRAKE AND STEERING ACCUMULATOR SERVICE............................................................................... WP 0155 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Brake Accumulator Testing.................................................................................................. 0155-2 Brake Accumulator Testing.................................................................................................. 0155-3 Brake Accumulator Testing.................................................................................................. 0155-4 Brake Accumulator Testing.................................................................................................. 0155-5 Brake Accumulator Testing.................................................................................................. 0155-5 Brake Accumulator Charging............................................................................................... 0155-6 Brake Accumulator Charging............................................................................................... 0155-7

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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. Figure 17. Figure 18. Figure 19. Brake Accumulator Charging............................................................................................... 0155-7 Brake Accumulator Charging............................................................................................... 0155-8 Brake Accumulator Charging............................................................................................... 0155-9 Brake Accumulator Charging............................................................................................... 0155-9 Brake Accumulator Charging............................................................................................. 0155-10 Brake Accumulator Charging............................................................................................. 0155-11 Brake Accumulator Testing................................................................................................ 0155-12 Brake Accumulator Charging............................................................................................. 0155-12 Brake Accumulator Charging............................................................................................. 0155-13 Brake Accumulator Charging............................................................................................. 0155-13 Brake Accumulator Charging............................................................................................. 0155-14 Steering Accumulator Pre-charge Pressure Check............................................................ 0155-15

BRAKE SYSTEM CHARGING VALVE PRESSURE ADJUSTMENT.......................................................... WP 0156 Figure 1. Brake System Charging Valve Pressure Adjustment........................................................... 0156-3

SERVICE BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT............................... WP 0157 Figure 1. Service Brake System Hydraulic Hoses and Fittings Replacement..................................... 0157-3

BRAKE COOLING FILTER AND FILTER HEAD REPLACEMENT............................................................. WP 0158 Figure 1. Figure 2. Figure 3. Brake Cooling Filter Replacement........................................................................................ 0158-2 Brake Cooling Filter Head Removal..................................................................................... 0158-3 Brake Cooling Filter Head Installation.................................................................................. 0158-4

BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT................................................................ WP 0159 Figure 1. Figure 2. Figure 3. Left Lower Panel Removal................................................................................................... 0159-2 Right Lower Panel Removal................................................................................................. 0159-2 Brake Light and Pressure Switch Replacement................................................................... 0159-3

STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE.......................................................... WP 0160 Figure 1. Figure 2. Steering Column Base Removal.......................................................................................... 0160-1 Steering Column Base Removal.......................................................................................... 0160-2

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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. Steering Column Base Removal.......................................................................................... 0160-2 Steering Column Base Disassembly.................................................................................... 0160-3 Steering Column Base Disassembly.................................................................................... 0160-4 Steering Column Base Disassembly.................................................................................... 0160-4 Steering Column Base Assembly......................................................................................... 0160-5 Steering Column Base Installation....................................................................................... 0160-6 Steering Column Base Installation....................................................................................... 0160-6 Steering Column Base Installation....................................................................................... 0160-7

BRAKE INCHING SWITCH REPLACEMENT............................................................................................. WP 0161 Figure 1. Figure 2. Figure 3. Brake Inching Switch Removal............................................................................................. 0161-2 Brake Inching Switch Removal............................................................................................. 0161-3 Brake Inching Switch Installation.......................................................................................... 0161-4

WHEEL ASSEMBLY REPLACEMENT........................................................................................................ WP 0162 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Raise Front Axle................................................................................................................... 0162-2 Raise Front Axle................................................................................................................... 0162-3 Raise Front Axle................................................................................................................... 0162-3 Raise Front Axle................................................................................................................... 0162-4 Wheel and Tire Replacement............................................................................................... 0162-5

BOGIE WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0163 Figure 1. Figure 2. Figure 3. Figure 4. Lower Bogie Wheel.............................................................................................................. 0163-1 Bogie Wheel Replacement................................................................................................... 0163-3 Screw Assembly Removal and Installation.......................................................................... 0163-5 Bogie Wheel Frame Replacement....................................................................................... 0163-7

DOLLY WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0164 Figure 1. Figure 2. Dolly Wheel Disassembly..................................................................................................... 0164-2 Dolly Wheel Assembly.......................................................................................................... 0164-3

STEERING WHEEL REPLACEMENT......................................................................................................... WP 0165

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Steering Wheel Removal...................................................................................................... 0165-1 Steering Wheel Replacement............................................................................................... 0165-2 Steering Wheel Installation................................................................................................... 0165-3

STEERING COLUMN REPLACEMENT...................................................................................................... WP 0166 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Steering Column Removal................................................................................................... 0166-1 Steering Column Removal................................................................................................... 0166-2 Steering Column Removal................................................................................................... 0166-3 Steering Column Removal................................................................................................... 0166-3 Steering Column Removal................................................................................................... 0166-4 Steering Column Removal and Installation.......................................................................... 0166-5 Steering Column Installation................................................................................................ 0166-6 Steering Column Installation................................................................................................ 0166-7 Steering Column Installation................................................................................................ 0166-8 Steering Column Installation................................................................................................ 0166-9

STEERING COLUMN REPAIR.................................................................................................................... WP 0167 Figure 1. Steering Column Disassembly and Assembly...................................................................... 0167-3

STEERING SENSOR REPLACEMENT...................................................................................................... WP 0168 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Steering Column Sensor Removal....................................................................................... 0168-1 Steering Column Sensor Removal....................................................................................... 0168-2 Steering Column Sensor Removal....................................................................................... 0168-3 Steering Column Sensor Installation.................................................................................... 0168-3 Steering Column Sensor Installation.................................................................................... 0168-4 Steering Column Sensor Installation.................................................................................... 0168-5

EMERGENCY STEERING PUMP REPLACEMENT................................................................................... WP 0169 Figure 1. Emergency Steering Pump Replacement............................................................................ 0169-3

STEERING SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT......................................... WP 0170 FRONT AND REAR AXLE STEERING CYLINDERS REPLACEMENT...................................................... WP 0171

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 1. Front and Rear Steering Cylinder Replacement.................................................................. 0171-3

STEERING ACCUMULATOR REPLACEMENT.......................................................................................... WP 0172 Figure 1. Steering Accumulator Replacement..................................................................................... 0172-3

STEERING CONTROL VALVE REPLACEMENT....................................................................................... WP 0173 Figure 1. Figure 2. Steering Control Valve Removal.......................................................................................... 0173-3 Steering Control Valve Removal and Installation................................................................. 0173-5

STEERING CALIBRATION.......................................................................................................................... WP 0174 TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT............................................... WP 0175 Figure 1. Figure 2. Figure 3. Figure 4. Skid Plate Replacement....................................................................................................... 0175-3 Front Access Cover Replacement........................................................................................ 0175-4 Middle Access Cover and Cab Support Replacement......................................................... 0175-5 Rear Access Cover Replacement........................................................................................ 0175-6

BOOM SUPPORT MAINTENANCE............................................................................................................ WP 0176 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Boom Support Removal....................................................................................................... 0176-2 Boom Support Removal....................................................................................................... 0176-3 Boom Support Removal....................................................................................................... 0176-3 Boom Support Removal....................................................................................................... 0176-4 Boom Support Removal....................................................................................................... 0176-5 Boom Support Removal....................................................................................................... 0176-6 Boom Support Installation.................................................................................................... 0176-7 Boom Support Installation.................................................................................................... 0176-8 Boom Support Installation.................................................................................................... 0176-9 Boom Support Installation.................................................................................................... 0176-9 Boom Support Installation.................................................................................................. 0176-10 Boom Support Installation.................................................................................................. 0176-11

FLEXIBLE CONVEYOR MAINTENANCE................................................................................................... WP 0177 Figure 1. Boom Wiring Harness and Cable Removal.......................................................................... 0177-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Boom Wiring Harness and Cable Removal.......................................................................... 0177-3 Boom Wiring Harness and Cable Removal.......................................................................... 0177-3 Hydraulic Hoses Removal.................................................................................................... 0177-4 Conveyor Removal............................................................................................................... 0177-5 Conveyor Installation............................................................................................................ 0177-6 Hydraulic Hoses Installation................................................................................................. 0177-7 Wiring Harness and Cable Installation................................................................................. 0177-7 Wiring Harness and Cable Installation................................................................................. 0177-8 Connect Cable and Wiring Harness..................................................................................... 0177-9

PINTLE HOOK MAINTENANCE.................................................................................................................. WP 0178 Figure 1. Tow Pintle Replacement...................................................................................................... 0178-2

CAB LIFT FRAME MAINTENANCE............................................................................................................ WP 0179 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. Cab Transport Lift System Inspection.................................................................................. 0179-2 Cab Transport Lift System Inspection.................................................................................. 0179-3 Cab Transport Lift System Inspection.................................................................................. 0179-3 Cab Transport Lift System Inspection.................................................................................. 0179-4 Cab Adjustment: Operational Position................................................................................. 0179-5 Cab Adjustment: Operational Position................................................................................. 0179-6 Cab Adjustment: Operational Position................................................................................. 0179-7 Cab Adjustment: Operational Position................................................................................. 0179-7 Cab Adjustment: Operational Position................................................................................. 0179-8 Cab Adjustment: Transport Position..................................................................................... 0179-9 Cab Adjustment: Transport Position................................................................................... 0179-10 Cab Adjustment: Transport Position................................................................................... 0179-11 Cab Adjustment: Transport Position................................................................................... 0179-12 Cab Transport Lift Removal............................................................................................... 0179-13 Cab Transport Lift Removal............................................................................................... 0179-14

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Cab Transport Lift Removal............................................................................................... 0179-15 Cab Transport Lift Installation............................................................................................ 0179-16 Cab Transport Lift Installation............................................................................................ 0179-17 Cab Transport Lift Installation............................................................................................ 0179-18 Cab Transport Lift Structure Removal................................................................................ 0179-19 Cab Transport Lift Structure Removal................................................................................ 0179-20 Cab Transport Lift Structure Removal................................................................................ 0179-21 Cab Transport Lift Structure Installation............................................................................. 0179-22 Cab Transport Lift Structure Installation............................................................................. 0179-23 Cab Transport Lift Structure Installation............................................................................. 0179-24

RIGHT-SIDE STEP ASSEMBLY REPLACEMENT..................................................................................... WP 0180 Figure 1. Right-Side Step Assembly Removal.................................................................................... 0180-2

LEFT-SIDE STAIR ASSEMBLY REPLACEMENT....................................................................................... WP 0181 Figure 1. Figure 2. Figure 3. Left-Side Step Assembly Replacement................................................................................ 0181-1 Left-Side Stair Assembly Removal....................................................................................... 0181-2 Left-Side Stair Assembly Replacement................................................................................ 0181-3

STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT.................................................. WP 0182 Figure 1. Figure 2. Figure 3. Storage Compartment Door Removal.................................................................................. 0182-1 Storage Compartment Door Removal and Installation......................................................... 0182-2 Storage Compartment Door Installation............................................................................... 0182-3

BATTERY AND DOLLY WHEELS STORAGE COMPARTMENT REPLACEMENT................................... WP 0183 Figure 1. Battery and Dolly Wheels Storage Compartment Replacement.......................................... 0183-3

REMOTE HYDRAULIC CONTROL COMPARTMENT REPLACEMENT.................................................... WP 0184 Figure 1. Remote Hydraulic Control Compartment Replacement....................................................... 0184-2

ENGINE COVER MAINTENANCE.............................................................................................................. WP 0185 Figure 1. Figure 2. Engine Cover Removal........................................................................................................ 0185-1 Engine Cover Disassembly.................................................................................................. 0185-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Engine Cover Disassembly.................................................................................................. 0185-2 Engine Cover Disassembly.................................................................................................. 0185-3 Engine Cover Assembly....................................................................................................... 0185-4

CAB DOOR ASSEMBLY MAINTENANCE.................................................................................................. WP 0186 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Cab Door Assembly Removal.............................................................................................. 0186-1 Cab Door Assembly Removal.............................................................................................. 0186-2 Cab Door Disassembly......................................................................................................... 0186-3 Cab Door Disassembly and Assembly................................................................................. 0186-4 Cab Door Installation............................................................................................................ 0186-5 Cab Door Installation............................................................................................................ 0186-6 Cab Door Installation............................................................................................................ 0186-7

CAB DOOR WEATHERSEAL REPLACEMENT.......................................................................................... WP 0187 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cab Door Weatherseal Removal.......................................................................................... 0187-1 Cab Door Weatherseal Removal.......................................................................................... 0187-2 Cab Door Weatherseal Removal.......................................................................................... 0187-3 Cab Door Weatherseal Installation....................................................................................... 0187-4 Cab Door Weatherseal Installation....................................................................................... 0187-5 Cab Door Weatherseal Installation....................................................................................... 0187-5

WINDSHIELD AND WINDOW GLASS REPLACEMENT............................................................................ WP 0188 Figure 1. Figure 2. Window Removal and Installation........................................................................................ 0188-3 Window Removal and Installation........................................................................................ 0188-4

MUDGUARD REPLACEMENT.................................................................................................................... WP 0189 Figure 1. Mudguard Replacement....................................................................................................... 0189-2

FENDER ASSEMBLY REPLACEMENT...................................................................................................... WP 0190 Figure 1. Figure 2. Figure 3. Fender and Fender Bracket Removal (RT 240V1)............................................................... 0190-2 Fender and Fender Bracket Replacement (RT 240V1)........................................................ 0190-3 Front Fender and Fender Bracket Removal (RT 240V1R)................................................... 0190-4

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Front Fender and Fender Bracket Replacement (RT 240V1R)............................................ 0190-5 Rear Fender and Fender Bracket Removal (RT 240V2 and RT 240V3).............................. 0190-6 Rear Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)....................... 0190-7 Front Fender and Fender Bracket Removal (RT 240V2 and RT 240V3)............................. 0190-8 Front Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)...................... 0190-9 Front Bracket Mounting Plate Replacement....................................................................... 0190-10

SEAT ASSEMBLY MAINTENANCE............................................................................................................ WP 0191 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Seat Removal....................................................................................................................... 0191-2 Seat Disassembly................................................................................................................. 0191-3 Seat Disassembly and Assembly......................................................................................... 0191-5 Seat Assembly..................................................................................................................... 0191-7 Seat Installation.................................................................................................................... 0191-8

SEAT BELT REPLACEMENT...................................................................................................................... WP 0192 Figure 1. Seatbelt Replacement.......................................................................................................... 0192-2

REARVIEW MIRRORS REPLACEMENT.................................................................................................... WP 0193 Figure 1. Figure 2. Figure 3. Interior Rearview Mirror Replacement.................................................................................. 0193-1 Exterior Rearview Mirror Removal....................................................................................... 0193-2 Exterior Rearview Mirror Removal and Installation.............................................................. 0193-3

WINDSHIELD WIPER MAINTENANCE...................................................................................................... WP 0194 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Front Windshield Wiper and Motor Removal........................................................................ 0194-2 Front Windshield Wiper and Motor Removal........................................................................ 0194-3 Front Windshield Wiper and Motor Removal........................................................................ 0194-3 Front Windshield Wiper and Motor Installation..................................................................... 0194-4 Front Windshield Wiper and Motor Installation..................................................................... 0194-5 Front Windshield Wiper and Motor Installation..................................................................... 0194-6 Rear Windshield Wiper and Motor Removal........................................................................ 0194-7 Rear Windshield Wiper and Motor Removal........................................................................ 0194-7

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Rear Windshield Wiper and Motor Removal and Installation............................................... 0194-9 Rear Windshield Wiper and Motor Installation..................................................................... 0194-9 Roof Window Windshield Wiper and Motor Removal......................................................... 0194-10 Roof Window Windshield Wiper and Motor Removal......................................................... 0194-11 Roof Window Windshield Wiper and Motor Removal and Installation............................... 0194-12 Roof Window Windshield Wiper and Motor Installation...................................................... 0194-13 Roof Window Windshield Wiper and Motor Installation...................................................... 0194-14

WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT....................................................... WP 0195 Figure 1. Figure 2. Figure 3. Figure 4. Windshield Washer Reservoir Replacement........................................................................ 0195-3 Windshield Washer Pump Removal..................................................................................... 0195-4 Windshield Washer Pump Replacement.............................................................................. 0195-5 Windshield Washer Pump Installation.................................................................................. 0195-6

HEATER HOSES REPLACEMENT............................................................................................................. WP 0196 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. Engine Heater Hoses Removal............................................................................................ 0196-2 Engine Heater Hoses Removal............................................................................................ 0196-3 Engine Heater Hoses Removal............................................................................................ 0196-3 Engine Heater Hoses Removal............................................................................................ 0196-4 Engine Heater Hoses Removal............................................................................................ 0196-5 Engine Heater Hoses Removal............................................................................................ 0196-5 Engine.................................................................................................................................. 0196-6 Engine Heater Hoses Removal............................................................................................ 0196-7 Cab Heater Hoses Removal – RT 240V1 and RT 240V1R.................................................. 0196-8 Cab Heater Hoses Removal – RT 240V2 and RT 240V3 Vehicles...................................... 0196-8 Cab Heater Hoses Removal................................................................................................. 0196-9 Cab Heater Hoses Removal............................................................................................... 0196-10 Cab Heater Hoses Removal............................................................................................... 0196-10 Cab Heater Hoses Removal............................................................................................... 0196-11

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Cab Heater Hoses Installation............................................................................................ 0196-12 Cab Heater Hoses Installation............................................................................................ 0196-13 Cab Heater Hoses Installation............................................................................................ 0196-13 Cab Heater Hoses Installation – RT 240V1 and RT 240V1R Vehicles.............................. 0196-14 Cab Heater Hoses Installation – RT 240V2 and RT 240V3 Vehicles................................. 0196-14

CAB HEATER/AIR CONDITIONING UNIT MAINTENANCE....................................................................... WP 0197 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-2 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-3 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-4 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-5 Cab Heater/Air Conditioning Unit Installation....................................................................... 0197-6

CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT................................ WP 0198 Figure 1. Figure 2. Figure 3. Figure 4. Front Panel Removal............................................................................................................ 0198-1 Cover Removal..................................................................................................................... 0198-2 Blower Motor and Fan Replacement.................................................................................... 0198-3 Blower Motor and Fan Installation........................................................................................ 0198-4

CAB AIR FILTERS REPLACEMENT........................................................................................................... WP 0199 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Grille Removal.............................................................................................................. 0199-2 Cab Side Air Filter Removal................................................................................................. 0199-3 Cab Side Air Filter Installation.............................................................................................. 0199-4 Left Lower Panel Removal – RT 240V1 and RT 240V1R Vehicles Only............................. 0199-5 Cab Interior Air Filter Removal............................................................................................. 0199-5 Cab Interior Air Filter Removal............................................................................................. 0199-6 Left Lower Panel Installation – RT 240V1 and RT 240V1R Vehicles Only.......................... 0199-7 Cab Interior Air Filter Installation.......................................................................................... 0199-8

CAB AUXILIARY FAN REPLACEMENT...................................................................................................... WP 0200 Figure 1. Access Panel Removal........................................................................................................ 0200-1

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 2. Figure 3. Auxiliary Fan Replacement.................................................................................................. 0200-2 Access Cover Installation..................................................................................................... 0200-3

AUTOLUBE SYSTEM MAINTENANCE....................................................................................................... WP 0201 Figure 1. Figure 2. Figure 3. Autolube Tube Replacement................................................................................................ 0201-2 Autolube Pump Replacement............................................................................................... 0201-3 Autolube Distribution Valve Replacement............................................................................ 0201-4

FIRE EXTINGUISHER BRACKET REPLACEMENT................................................................................... WP 0202 Figure 1. Fire Extinguisher Bracket Replacement............................................................................... 0202-1

DATA PLATE REPLACEMENT................................................................................................................... WP 0203 Figure 1. Data Plate Replacement...................................................................................................... 0203-2

RELIEVING HYDRAULIC SYSTEM PRESSURE....................................................................................... WP 0204 Figure 1. Figure 2. Figure 3. Steering Accumulator Evacuation Valve.............................................................................. 0204-2 Steering Accumulator Evacuation Valves............................................................................ 0204-3 Float Control and Emergency Control Valves...................................................................... 0204-3

BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT....................................................... WP 0205 Figure 1. Figure 2. Pump Replacement.............................................................................................................. 0205-3 Pump Installation.................................................................................................................. 0205-5

COOLING FAN HYDRAULIC PUMP REPLACEMENT............................................................................... WP 0206 Figure 1. Figure 2. Pump Removal..................................................................................................................... 0206-3 Pump Installation.................................................................................................................. 0206-5

SERVO CONTROL VALVE REPLACEMENT............................................................................................. WP 0207 Figure 1. Servo Control Valve Replacement....................................................................................... 0207-3

HYDRAULIC SYSTEM COOLING HOSES AND FITTINGS REPLACEMENT........................................... WP 0208 AUXILIARY HYDRAULIC PUMP REPLACEMENT..................................................................................... WP 0209 Figure 1. Figure 2. Figure 3. Cover Removal..................................................................................................................... 0209-2 Hose and Wire Disconnects................................................................................................. 0209-3 Ground Strap and Power Cable Disconnects....................................................................... 0209-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Pump Removal..................................................................................................................... 0209-4 Pump Installation.................................................................................................................. 0209-5 Ground Strap and Power Cable Connections...................................................................... 0209-5 Hose and Wire Connections................................................................................................. 0209-6 Cover Installation.................................................................................................................. 0209-7

TOPHANDLER HYDRAULIC SLEWING MOTORS MAINTENANCE......................................................... WP 0210 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Turning Plate Cover Removal.............................................................................................. 0210-2 Hydraulic Manifold and Hose Removal................................................................................ 0210-3 Hydraulic Manifold and Hose Removal................................................................................ 0210-3 Slewing Motor and Pinion Gear Removal............................................................................ 0210-5 Slewing Motor and Hydraulic Manifold Installation............................................................... 0210-6 Secure Hydraulic Manifold................................................................................................... 0210-7 Hoses and Fittings Installation and Connection................................................................... 0210-8 Protective Cover Installation................................................................................................. 0210-9

SLEWING MOTOR BRAKE REPLACEMENT............................................................................................. WP 0211 Figure 1. Figure 2. Figure 3. Spur Gear Removal.............................................................................................................. 0211-1 Slewing Motor Brake Removal and Replacement................................................................ 0211-3 Slewing Motor Gear Replacement....................................................................................... 0211-4

TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT............................... WP 0212 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Pump Removal..................................................................................................................... 0212-2 Pump Removal..................................................................................................................... 0212-3 Pump Removal..................................................................................................................... 0212-3 Pump Removal..................................................................................................................... 0212-4 Pump Removal..................................................................................................................... 0212-4 Pump Removal..................................................................................................................... 0212-5 Pump Removal..................................................................................................................... 0212-6 Pump Removal..................................................................................................................... 0212-7

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. 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. Pump Removal..................................................................................................................... 0212-7 Pump Removal..................................................................................................................... 0212-8 Pump Removal..................................................................................................................... 0212-9 Pump Installation................................................................................................................ 0212-10 Pump Installation................................................................................................................ 0212-11 Pump Installation................................................................................................................ 0212-11 Pump Installation................................................................................................................ 0212-12 Pump Installation................................................................................................................ 0212-13 Pump Installation................................................................................................................ 0212-14 Pump Installation................................................................................................................ 0212-14 Pump Installation................................................................................................................ 0212-15 Pump Installation................................................................................................................ 0212-16 Pump Installation................................................................................................................ 0212-17 Pump Installation................................................................................................................ 0212-18

TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT.................................................... WP 0213 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-2 Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-3 Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-4 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-5 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-6 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-7

MAIN CONTROL VALVE REPLACEMENT................................................................................................. WP 0214 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Main Control Valve Removal................................................................................................ 0214-2 Main Control Valve Removal................................................................................................ 0214-3 Main Control Valve Removal................................................................................................ 0214-5 Main Control Valve Installation............................................................................................. 0214-6 Main Control Valve Installation............................................................................................. 0214-7

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. BOOM FOLDING CONTROL VALVE REPLACEMENT.............................................................................. WP 0215 Figure 1. Boom Folding Control Valve Replacement.......................................................................... 0215-3

CAB TRANSPORT CONTROL VALVE REPLACEMENT........................................................................... WP 0216 Figure 1. Cab Transport Control Valve Replacement.......................................................................... 0216-3

CONTROL VALVE SOLENOIDS REPLACEMENT..................................................................................... WP 0217 Figure 1. Figure 2. Figure 3. Figure 4. Control Valve Solenoid Replacement – Type A................................................................... 0217-3 Control Valve Solenoid Replacement – Type B................................................................... 0217-4 Control Valve Solenoid Replacement – Type C................................................................... 0217-5 Control Valve Solenoid Replacement – Type D................................................................... 0217-6

BOOM FOLDING CYLINDERS REPLACEMENT....................................................................................... WP 0218 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Boom Folding Cylinder Replacement................................................................................... 0218-3 Boom Folding Cylinder Installation....................................................................................... 0218-4 Boom Folding Cylinder installation....................................................................................... 0218-5 Boom Folding Cylinder Installation....................................................................................... 0218-6 Boom Folding Cylinder Installation....................................................................................... 0218-7 Boom Folding Cylinder Installation....................................................................................... 0218-8

CAB PARKING AND SERVICE BRAKE HYDRAULIC HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0219 MAIN HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................................... WP 0220 HYDRAULIC SERVO SYSTEM HOSES AND FITTINGS REPLACEMENT............................................... WP 0221 HYDRAULIC SYSTEM TEST POINT HOSES AND FITTINGS REPLACEMENT....................................... WP 0222 CAB TRANSPORT HYDRAULIC HOSES AND FITTINGS REPLACEMENT............................................. WP 0223 BOOM HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................................. WP 0224 TOPHANDLER HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................... WP 0225 FORKLIFT KIT HYDRAULIC HOSES AND FITTINGS REPLACEMENT.................................................... WP 0226 HYDRAULIC SYSTEM OIL FILTERS REPLACEMENT.............................................................................. WP 0227 Figure 1. Figure 2. Hydraulic Reservoir Return Oil Filter Removal..................................................................... 0227-2 Reservoir Return Oil Filter Installation.................................................................................. 0227-3

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Figure 4. Hydraulic Reservoir Breather Filter Installation.................................................................... 0227-4 Hydraulic System In-Line Filters and Filter Head Replacement........................................... 0227-5

HYDRAULIC SYSTEM VALVE MAINTENANCE......................................................................................... WP 0228 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. Figure 23. Figure 24. Pump Shut-Off Valve Removal............................................................................................ 0228-3 Shift Valve Removal............................................................................................................. 0228-5 Boom Support/Bogie Supply Valve Removal....................................................................... 0228-6 Boom Support/Bogie Supply Valve Installation.................................................................... 0228-7 Servo Pressure Regulator Valve Removal........................................................................... 0228-9 Bogie/Boom Support Flow Control Valve Removal............................................................ 0228-11 Boom Support Locking Pin Check Valve Removal............................................................ 0228-12 Boom Support Locking Pin Check Valve Installation......................................................... 0228-13 Bogie Pressure Ball Valve Removal................................................................................... 0228-15 Extension Cylinder Over-Center Valve Replacement........................................................ 0228-17 Parking Brake Hold Flow Control Valve Removal.............................................................. 0228-18 Parking Brake Hold Flow Control Valve Installation........................................................... 0228-19 Brake Charging Valve Replacement.................................................................................. 0228-21 Brake Drain Shut-Off Valve Replacement.......................................................................... 0228-23 Brake Circuit Safety Regulating Valve Replacement......................................................... 0228-25 Front Brake Cooling Bypass Valve Replacement.............................................................. 0228-27 Rear Brake Cooling Bypass Valve Replacement............................................................... 0228-29 Cooling Fan Control Valve Removal.................................................................................. 0228-30 Emergency Steering Pressure Balancing Valve Removal................................................. 0228-33 Moderation and Tilt Manifold Valve Removal..................................................................... 0228-34 Tilt Over-Center Valve Removal......................................................................................... 0228-36 Tilt Over-Center Installation................................................................................................ 0228-37 Oscillation Over-Center Valve Installation.......................................................................... 0228-39 Oscillation Float Lock Flow Control Valve Removal........................................................... 0228-40

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 25. Twistlock Double Pilot Operated Check Valve Removal.................................................... 0228-42

LIFT CYLINDER CONTROL VALVE REPLACEMENT............................................................................... WP 0229 Figure 1. Lift Cylinder Control Valve Replacement.............................................................................. 0229-3

TOPHANDLER CONTROL VALVES REPLACEMENT............................................................................... WP 0230 Figure 1. Tophandler Control Valve Replacement.............................................................................. 0230-3

BOOM LIFT CYLINDER REPLACEMENT.................................................................................................. WP 0231 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Boom Lift Cylinder Removal................................................................................................. 0231-2 Boom Lift Cylinder Removal................................................................................................. 0231-3 Boom Lift Cylinder Removal................................................................................................. 0231-4 Boom Lift Cylinder Removal................................................................................................. 0231-5 Boom Lift Cylinder Installation.............................................................................................. 0231-6 Boom Lift Cylinder Installation.............................................................................................. 0231-7 Boom Lift Cylinder Installation.............................................................................................. 0231-7

CAB LIFTING CYLINDER REPLACEMENT................................................................................................ WP 0232 Figure 1. Cab Lifting Cylinder Replacement........................................................................................ 0232-3

CAB SLIDING CYLINDER REPLACEMENT............................................................................................... WP 0233 Figure 1. Cab Sliding Cylinder Replacement....................................................................................... 0233-2

BOGIE WHEEL LIFT CYLINDERS REPLACEMENT.................................................................................. WP 0234 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Cylinders Replacement........................................................................................ 0234-3 Hydraulic Cylinders Replacement........................................................................................ 0234-3 Hydraulic Cylinders Replacement........................................................................................ 0234-4 Hydraulic Cylinders Replacement........................................................................................ 0234-5

BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT............................... WP 0235 Figure 1. Figure 2. Figure 3. Figure 4. Locking Pin Cylinder Removal............................................................................................. 0235-2 Locking Pin Cylinder Removal............................................................................................. 0235-3 Locking Pin Cylinder Removal............................................................................................. 0235-4 Locking Pin Cylinder Installation.......................................................................................... 0235-5

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 5. Figure 6. Locking Pin Cylinder Installation.......................................................................................... 0235-6 Locking Pin Cylinder Installation.......................................................................................... 0235-7

LOCKING PIN BUSHING REPLACEMENT................................................................................................ WP 0236 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Frame Bushings Removal.................................................................................................... 0236-2 Frame Bushings Installation................................................................................................. 0236-3 Boom Support Bushings Removal....................................................................................... 0236-4 Boom Support Bushings Removal....................................................................................... 0236-5 Boom Support Bushings Installation.................................................................................... 0236-6 Boom Support Bushings Installation.................................................................................... 0236-7 Boom Support Bushings Installation.................................................................................... 0236-8

TOPHANDLER TILT CYLINDERS REPLACEMENT.................................................................................. WP 0237 Figure 1. Tophandler Tilt Cylinder Replacement................................................................................. 0237-3

TOPHANDLER SIDESHIFT CYLINDERS REPLACEMENT....................................................................... WP 0238 Figure 1. Tophandler Sideshift Cylinder Replacement........................................................................ 0238-3

TOPHANDLER LEVELING CYLINDERS REPLACEMENT........................................................................ WP 0239 Figure 1. Tophandler Leveling Cylinder Removal............................................................................... 0239-3

TOPHANDLER TWISTLOCK CYLINDERS REPLACEMENT..................................................................... WP 0240 Figure 1. Tophandler Twistlock Cylinder Replacement....................................................................... 0240-3

TOPHANDLER TWISTLOCK REPLACEMENT.......................................................................................... WP 0241 Figure 1. Figure 2. Tophandler Twistlock Removal............................................................................................ 0241-2 Tophandler Twistlock Replacement..................................................................................... 0241-3

DRAINING AND FILLING HYDRAULIC RESERVOIR................................................................................ WP 0242 Figure 1. Figure 2. Draining Hydraulic Reservoir................................................................................................ 0242-2 Filling Hydraulic Reservoir.................................................................................................... 0242-3

HYDRAULIC RESERVOIR MAINTENANCE............................................................................................... WP 0243 Figure 1. Figure 2. Hydraulic Reservoir Removal............................................................................................... 0243-3 Hydraulic Reservoir Removal............................................................................................... 0243-3

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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. Figure 16. Figure 17. Hydraulic Reservoir Removal............................................................................................... 0243-4 Hydraulic Reservoir Removal............................................................................................... 0243-5 Hydraulic Reservoir Removal............................................................................................... 0243-6 Hydraulic Reservoir Removal............................................................................................... 0243-7 Hydraulic Reservoir Removal............................................................................................... 0243-7 Hydraulic Reservoir Removal............................................................................................... 0243-8 Hydraulic Reservoir Installation............................................................................................ 0243-9 Hydraulic Reservoir Installation............................................................................................ 0243-9 Hydraulic Reservoir Installation.......................................................................................... 0243-10 Hydraulic Reservoir Installation.......................................................................................... 0243-10 Hydraulic Reservoir Installation.......................................................................................... 0243-11 Hydraulic Reservoir Installation.......................................................................................... 0243-12 Hydraulic Reservoir Installation.......................................................................................... 0243-13 Hydraulic Reservoir Installation.......................................................................................... 0243-13 Hydraulic Reservoir Installation.......................................................................................... 0243-14

HYDRAULIC RESERVOIR SIGHT GAUGE REPLACEMENT.................................................................... WP 0244 Figure 1. Figure 2. Hydraulic Reservoir Sight Gauge Removal.......................................................................... 0244-1 Hydraulic Reservoir Sight Gauge Installation....................................................................... 0244-2

HYDRAULIC SYSTEM TEST POINT PROCEDURES................................................................................ WP 0245 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic System Test Points.............................................................................................. 0245-2 System Drain Valves............................................................................................................ 0245-3 Steering Accumulator Drain Valve....................................................................................... 0245-4 Engine Driven Pump Test Point........................................................................................... 0245-7

FORKLIFT CYLINDERS REPLACEMENT.................................................................................................. WP 0246 Figure 1. Forklift Cylinder Replacement.............................................................................................. 0246-3

RIFLE MOUNTING BRACKET REPLACEMENT........................................................................................ WP 0247 Figure 1. Rifle Mounting Bracket Removal.......................................................................................... 0247-1

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 2. Figure 3. Rifle Mounting Bracket Replacement................................................................................... 0247-2 Rifle Mounting Bracket Installation....................................................................................... 0247-3

AIR CONDITIONING SYSTEM MAINTENANCE........................................................................................ WP 0248 Figure 1. Figure 2. System Recovery................................................................................................................. 0248-3 Nitrogen Purging.................................................................................................................. 0248-5

AIR CONDITIONER LEAK TEST................................................................................................................ WP 0249 AIR CONDITIONING COMPRESSOR REPLACEMENT............................................................................ WP 0250 Figure 1. Figure 2. Figure 3. Air Conditioner Compressor Removal.................................................................................. 0250-2 Air Conditioner Compressor Replacement........................................................................... 0250-3 Air Conditioner Compressor Installation............................................................................... 0250-4

AIR CONDITIONING COMPRESSOR DRIVE BELTS REPLACEMENT.................................................... WP 0251 Figure 1. Drive Belts Replacement...................................................................................................... 0251-3

AIR CONDITIONER HOSES REPLACEMENT........................................................................................... WP 0252 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. Chassis A/C Hoses Removal............................................................................................... 0252-1 Chassis A/C Hoses Removal and Installation...................................................................... 0252-2 Chassis A/C Hoses Removal Replacement......................................................................... 0252-3 Chassis A/C Hoses Installation............................................................................................ 0252-3 Cab Rear A/C Hose Removal.............................................................................................. 0252-4 Cab Rear A/C Hose Removal.............................................................................................. 0252-5 Cab Rear A/C Hose Replacement....................................................................................... 0252-6 Cab Rear A/C Hose Installation........................................................................................... 0252-7 Cab Interior A/C Hoses Removal......................................................................................... 0252-8 Cab Interior A/C Hoses Removal......................................................................................... 0252-9 Cab Interior A/C Hoses Removal......................................................................................... 0252-9 Cab Interior A/C Hoses Removal....................................................................................... 0252-10 Cab Interior A/C Hoses Removal....................................................................................... 0252-11 Cab Interior A/C Hoses Replacement................................................................................ 0252-12

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 15. Figure 16. Figure 17. Cab Interior A/C Hoses Installation.................................................................................... 0252-13 Cab Interior A/C Hoses Installation.................................................................................... 0252-14 Cab Interior A/C Hoses Installation.................................................................................... 0252-15

AIR CONDITIONER CONDENSER REPLACEMENT................................................................................. WP 0253 Figure 1. Figure 2. Figure 3. Figure 4. Air Conditioner Condenser Removal.................................................................................... 0253-1 Air Conditioner Condenser Removal.................................................................................... 0253-2 Air Conditioner Condenser Replacement............................................................................. 0253-3 Air Conditioner Condenser Installation................................................................................. 0253-4

AIR CONDITIONER RECEIVER/DRYER REPLACEMENT........................................................................ WP 0254 Figure 1. Figure 2. Figure 3. Air Conditioner Receiver/Dryer Removal............................................................................. 0254-1 Air Conditioner Receiver/Dryer Replacement...................................................................... 0254-2 Air Conditioner Receiver/Dryer Installation.......................................................................... 0254-3

AIR CONDITIONER FANS MAINTENANCE............................................................................................... WP 0255 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Condenser Fan Box Cover Removal.................................................................................... 0255-1 Air Conditioner Fan Replacement........................................................................................ 0255-2 Condenser Fan Box Cover................................................................................................... 0255-3 Relays Replacement............................................................................................................ 0255-4 Resistors Replacement........................................................................................................ 0255-5 Condenser Fan Box Cover Installation................................................................................. 0255-6

BOOM ASSEMBLY REPLACEMENT.......................................................................................................... WP 0256 Figure 1. Figure 2. Figure 3. Figure 4. Boom Assembly Removal.................................................................................................... 0256-2 Boom Assembly Removal.................................................................................................... 0256-3 Boom Assembly Installation................................................................................................. 0256-6 Boom Assembly Installation................................................................................................. 0256-7

BOOM AND TOPHANDLER CALIBRATION............................................................................................... WP 0257 Table 1. Figure 1. Range 600-800..................................................................................................................... 0257-2 Boom and Tophandler Calibration........................................................................................ 0257-2

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Table 2. Figure 2. Table 3. Figure 3. Table 4. Figure 4. Table 5. Figure 5. Table 6. Figure 6. Table 7. Figure 7. Table 8. Figure 8. Table 9. Table 10. Range 200-400..................................................................................................................... 0257-2 Boom and Tophandler Calibration........................................................................................ 0257-2 Range 200-400..................................................................................................................... 0257-3 Boom and Tophandler Calibration........................................................................................ 0257-3 Range 600-800..................................................................................................................... 0257-4 Boom and Tophandler Calibration........................................................................................ 0257-4 Range 35-150....................................................................................................................... 0257-5 Boom and Tophandler Calibration........................................................................................ 0257-5 Range 400-550..................................................................................................................... 0257-6 Boom and Tophandler Calibration........................................................................................ 0257-6 Range 500-650..................................................................................................................... 0257-7 Boom and Tophandler Calibration........................................................................................ 0257-7 Range 800-950..................................................................................................................... 0257-8 Boom and Tophandler Calibration........................................................................................ 0257-8 Load Check.......................................................................................................................... 0257-8 Boom Calibration Completed............................................................................................... 0257-9

BOOM ASSEMBLY WEAR PLATES (SLIDE PLATE) REPLACEMENT..................................................... WP 0258 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Boom Wear Plates Locations............................................................................................... 0258-2 Style A Wear Plate Removal................................................................................................ 0258-3 Style A Wear Plate Removal................................................................................................ 0258-4 Style A Wear Plate Installation............................................................................................. 0258-5 Style A Wear Plate Installation............................................................................................. 0258-6 Style B Wear Plate Removal................................................................................................ 0258-7 Style B Wear Plate Removal................................................................................................ 0258-8 Style B Wear Plate Removal................................................................................................ 0258-9 Style B Wear Plate Removal.............................................................................................. 0258-10 Style B Wear Plate Removal.............................................................................................. 0258-11

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Style B Wear Plate Installation........................................................................................... 0258-12 Style B Wear Plate Installation........................................................................................... 0258-13 Style B Wear Plate Installation........................................................................................... 0258-14 Style B Wear Plate Installation........................................................................................... 0258-15 Style B Wear Plate Installation........................................................................................... 0258-16 Style C (RT 240V1 and RT 240V1R) Wear Plate Replacement........................................ 0258-17 Style D (RT 240V2 and RT 240V3 ONLY) Wear Plate Replacement................................ 0258-18

TOPHANDLER REPLACEMENT................................................................................................................ WP 0259 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. Tophandler Removal............................................................................................................ 0259-2 Tophandler Removal............................................................................................................ 0259-3 Tophandler Removal............................................................................................................ 0259-3 Tophandler Removal............................................................................................................ 0259-4 Tophandler Removal............................................................................................................ 0259-5 Tophandler Removal............................................................................................................ 0259-5 Tophandler Removal............................................................................................................ 0259-6 Tophandler Removal............................................................................................................ 0259-6 Tophandler Removal............................................................................................................ 0259-7 Tophandler Removal............................................................................................................ 0259-7 Tophandler Removal............................................................................................................ 0259-8 Tophandler Removal............................................................................................................ 0259-9 Tophandler Removal............................................................................................................ 0259-9 Tophandler Removal.......................................................................................................... 0259-10 Tophandler Installation....................................................................................................... 0259-10 Tophandler Installation....................................................................................................... 0259-11 Tophandler Installation....................................................................................................... 0259-11 Tophandler Installation....................................................................................................... 0259-12 Tophandler Installation....................................................................................................... 0259-13

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 20. Figure 21. Figure 22. Tophandler Installation....................................................................................................... 0259-13 Tophandler Installation....................................................................................................... 0259-14 Tophandler Installation....................................................................................................... 0259-14

SPREADER CHAIN MAINTENANCE.......................................................................................................... WP 0260 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. Access Panels Removal....................................................................................................... 0260-1 Protective Plate Removal..................................................................................................... 0260-2 Sliding Beam Removal from Main Beam.............................................................................. 0260-2 Sliding Beam Reference Mark.............................................................................................. 0260-3 Chain Tensioner Removal.................................................................................................... 0260-3 Locking Plate Removal......................................................................................................... 0260-4 Chain Anchor Access........................................................................................................... 0260-5 Beam and Tensioner Locknut Removal............................................................................... 0260-5 Hydraulic/Electrical Hose Power Track Support Removal................................................... 0260-6 Chain Anchor Removal........................................................................................................ 0260-7 Position Slide Beam............................................................................................................. 0260-8 Assemble Chain Anchor....................................................................................................... 0260-9 Idler Shaft Locking Plate Installation.................................................................................... 0260-9 Chain Adjustment............................................................................................................... 0260-10 Chain Tension Adjustment................................................................................................. 0260-11 Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-12 Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-13

SPREADER 20 AND 40 FOOT ADJUSTMENT.......................................................................................... WP 0261 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Measurement and Adjustment - 20 Ft.................................................................................. 0261-1 Measurement and Adjustment - 20 Ft.................................................................................. 0261-2 Measurement and Adjustment - 20 Ft.................................................................................. 0261-3 Measurement and Adjustment - 20 Ft.................................................................................. 0261-3 Measurement and Adjustment - 40 Ft.................................................................................. 0261-4

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Measurement and Adjustment - 40 Ft.................................................................................. 0261-4 Measurement and Adjustment - 40 Ft.................................................................................. 0261-5 Measurement and Adjustment - 40 Ft.................................................................................. 0261-5

SPREADER MAINTENANCE...................................................................................................................... WP 0262 Figure 1. Figure 2. Hydraulic Motor Replacement.............................................................................................. 0262-2 Gear Installation................................................................................................................... 0262-3

TOPHANDLER WEAR PLATES (SLIDE PLATE) REPLACEMENT............................................................ WP 0263 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. Tophandler Wear Plate Locations........................................................................................ 0263-3 Tophandler Wear Plate Locations........................................................................................ 0263-4 Style A Wear Plate Removal................................................................................................ 0263-5 Style A Wear Plate Replacement......................................................................................... 0263-6 Style B Wear Plate Removal................................................................................................ 0263-7 Style B Wear Plate Removal................................................................................................ 0263-8 Style B Wear Plate Removal................................................................................................ 0263-9 Style B Wear Plate Removal.............................................................................................. 0263-10 Style B Wear Plate Installation........................................................................................... 0263-11 Style B Wear Plate Installation........................................................................................... 0263-12 Style B Wear Plate Installation........................................................................................... 0263-13 Style C Wear Plate Replacement....................................................................................... 0263-15 Style D Wear Plate Replacement....................................................................................... 0263-17 Style E Wear Plate Replacement....................................................................................... 0263-18

TOPHANDLER HYDRAULIC SPREADER MOTOR MAINTENANCE........................................................ WP 0264 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Tophandler Access Panels Removal................................................................................... 0264-2 Tophandler Access Panels Removal................................................................................... 0264-3 Chain Adjuster Measurement and Removal......................................................................... 0264-3 Tophandler Hydraulic Spreader Removal............................................................................ 0264-4 Tophandler Hydraulic Spreader Installation......................................................................... 0264-5

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Chain Adjuster Installation and Measurement...................................................................... 0264-6 Access Panels Installation.................................................................................................... 0264-6 Access Panels Installation.................................................................................................... 0264-7

PREPARATION FOR ARCTIC OPERATION.............................................................................................. WP 0265 Figure 1. Twistlock Cylinder Bypass Valve.......................................................................................... 0265-2

PREPARATION FOR STORAGE OR SHIPMENT...................................................................................... WP 0266 ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS..................................................................... WP 0267 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. Multi-Pin Connector Identifier............................................................................................... 0267-2 Multi-Pin Connector Identifier............................................................................................... 0267-3 Multi-Pin Connector Identifier............................................................................................... 0267-4 Multi-Pin Connector Identifier............................................................................................... 0267-5 Connector Repair................................................................................................................. 0267-6 Connector Repair................................................................................................................. 0267-6 Sealed Connector Repair..................................................................................................... 0267-7 Receptacle Connector Repair.............................................................................................. 0267-8 Waterproof Connector Repair.............................................................................................. 0267-9 Military Connector Repair................................................................................................... 0267-10 Ring Terminal Repair......................................................................................................... 0267-11 Wire Splicing...................................................................................................................... 0267-12 Electrical Ground Points..................................................................................................... 0267-13 Multimeter Usage............................................................................................................... 0267-14 Multimeter Usage............................................................................................................... 0267-15 Multimeter Usage............................................................................................................... 0267-16 Multimeter Usage............................................................................................................... 0267-17 Multimeter Usage............................................................................................................... 0267-18 Relay Inspection and Test.................................................................................................. 0267-19 Solenoid Inspection and Test............................................................................................. 0267-20

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0268 Table 1. Table 2. Table 3. Table 4. Table 5. Boss Type O-rings................................................................................................................ 0268-7 Flat-Face Type O-rings........................................................................................................ 0268-8 O-ring/Retainer Type Fitting Seals....................................................................................... 0268-8 Split Flange Type O-rings..................................................................................................... 0268-8 Hydraulic Hose Torque Chart............................................................................................... 0268-9

ILLUSTRATED LIST OF MANUFACTURED ITEMS................................................................................... WP 0269 Figure 1. Stud, Guide.......................................................................................................................... 0269-1

TORQUE LIMITS......................................................................................................................................... WP 0270 Figure 1. Table 1. Torque Patterns.................................................................................................................... 0270-2 Torque Limits........................................................................................................................ 0270-2

LOAD TESTING PROCEDURE................................................................................................................... WP 0271 Figure 1. Table 1. Figure 2. Figure 3. Figure 4. Table 2. Boom Cylinder Drift Test...................................................................................................... 0271-2 Reference Readings 1.......................................................................................................... 0271-3 Boom Cylinder Drift Test...................................................................................................... 0271-3 Extension Cylinder Drift Test................................................................................................ 0271-4 Extension Cylinder Drift Test................................................................................................ 0271-5 Reference Readings 2.......................................................................................................... 0271-5

SCHEMATICS............................................................................................................................................. WP 0272 Figure 1. Figure 1. Figure 1. Figure 2. Figure 2. Figure 2. Figure 2. Figure 2. ECS Display/CAN-BUS (A34647.0200). (Sheet 1 of 3) ...................................................... 0272-7 ECS Display/CAN-BUS (A34647.0200). (Sheet 2 of 3) ...................................................... 0272-8 ECS Display/CAN-BUS (A34647.0200). (Sheet 3 of 3) ...................................................... 0272-9 ECS Electrical Servo (A34648.0200). (Sheet 1 of 5) ........................................................ 0272-10 ECS Electrical Servo (A34648.0200). (Sheet 2 of 5) ........................................................ 0272-11 ECS Electrical Servo (A34648.0200). (Sheet 3 of 5) ........................................................ 0272-12 ECS Electrical Servo (A34648.0200). (Sheet 4 of 5) ........................................................ 0272-13 ECS Electrical Servo (A34648.0200). (Sheet 5 of 5) ........................................................ 0272-14

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TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 3. Figure 3. Figure 4. Figure 4. Figure 4. Figure 4. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 6. Figure 6. Figure 6. Figure 6. Figure 6. Figure 6. Figure 7. Figure 7. Figure 8. Figure 8. Figure 8. Figure 8. Figure 9. Figure 10. ECS Engine (A34648.0200). (Sheet 1 of 2) ...................................................................... 0272-15 ECS Engine (A34648.0200). (Sheet 2 of 2) ...................................................................... 0272-16 ECS Transmission (A34650.0200). (Sheet 1 of 4) ............................................................ 0272-17 ECS Transmission (A34650.0200). (Sheet 2 of 4) ............................................................ 0272-18 ECS Transmission (A34650.0200). (Sheet 3 of 4) ............................................................ 0272-19 ECS Transmission (A34650.0200). (Sheet 4 of 4) ............................................................ 0272-20 ECS Steering (A34651.0200). (Sheet 1 of 7) .................................................................... 0272-21 ECS Steering (A34651.0200). (Sheet 2 of 7) .................................................................... 0272-22 ECS Steering (A34651.0200). (Sheet 3 of 7) .................................................................... 0272-23 ECS Steering (A34651.0200). (Sheet 4 of 7) .................................................................... 0272-24 ECS Steering (A34651.0200). (Sheet 5 of 7) .................................................................... 0272-25 ECS Steering (A34651.0200). (Sheet 6 of 7) .................................................................... 0272-26 ECS Steering (A34651.0200). (Sheet 7 of 7) .................................................................... 0272-27 ECS Attachment to Tophandler (A34652.0200). (Sheet 1 of 6) ........................................ 0272-28 ECS Attachment to Tophandler (A34652.0200). (Sheet 2 of 6) ........................................ 0272-29 ECS Attachment to Tophandler (A34652.0200). (Sheet 3 of 6) ........................................ 0272-30 ECS Attachment to Tophandler (A34652.0200). (Sheet 4 of 6) ........................................ 0272-31 ECS Attachment to Tophandler (A34652.0200). (Sheet 5 of 6) ........................................ 0272-32 ECS Attachment to Tophandler (A34652.0200). (Sheet 6 of 6) ........................................ 0272-33 Hydraulics (A34654.0200). (Sheet 1 of 2) ......................................................................... 0272-34 Hydraulics (A34654.0200). (Sheet 2 of 2) ......................................................................... 0272-35 Current Supply (A34738.0200). (Sheet 1 of 4) .................................................................. 0272-36 Current Supply (A34738.0200). (Sheet 2 of 4) .................................................................. 0272-37 Current Supply (A34738.0200). (Sheet 3 of 4) .................................................................. 0272-38 Current Supply (A34738.0200). (Sheet 4 of 4) .................................................................. 0272-39 Shifting (A34739.0200). (Sheet 1 of 1) .............................................................................. 0272-40 Sender (A34740.0200). (Sheet 1 of 2) .............................................................................. 0272-41

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TM 10-3930-675-23-2

TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 14. Figure 14. Figure 14. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Sender (A34740.0200). (Sheet 2 of 2) .............................................................................. 0272-42 Wipers (A34741.0200). (Sheet 1 of 1) ............................................................................... 0272-43 AC and Fan (A34742.0200). (Sheet 1 of 1) ....................................................................... 0272-44 Cab (A34743.0200). (Sheet 1 of 1) ................................................................................... 0272-45 Lights (A34744.0200). (Sheet 1 of 5) ................................................................................ 0272-46 Lights (A34744.0200). (Sheet 2 of 5) ................................................................................ 0272-47 Lights (A34744.0200). (Sheet 3 of 5) ................................................................................ 0272-48 Lights (A34744.0200). (Sheet 4 of 5) ................................................................................ 0272-49 Lights (A34744.0200). (Sheet 5 of 5) ................................................................................ 0272-50 Work Lights (A34745.0200). (Sheet 1 of 1) ....................................................................... 0272-51 Auxiliary Pump (A34746.0200). (Sheet 1 of 1) .................................................................. 0272-52 Auto Lubrication (A48665.0100). (Sheet 1 of 1) ................................................................ 0272-53 Information (A34749.0200). (Sheet 1 of 2) ........................................................................ 0272-54 Information (A34749.0200). (Sheet 2 of 2) ........................................................................ 0272-55 Steering System................................................................................................................. 0272-56 Brake System..................................................................................................................... 0272-57 Main System....................................................................................................................... 0272-58 Tophandler System............................................................................................................ 0272-59 Autolube System Tubing Layout........................................................................................ 0272-60 Electrical Symbols.............................................................................................................. 0272-61 Hydraulic Symbols.............................................................................................................. 0272-62

Chapter 6 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0273 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.............................................................. WP 0274 MAINTENANCE ALLOCATION CHART FOR THE RTCH.......................................................................... WP 0275 Table 1. Table 2. Maintenance Allocation Chart (MAC)................................................................................... 0275-1 Tools and Test Equipment................................................................................................. 0275-24

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TM 10-3930-675-23-2

TABLE OF CONTENTS - Continued
Page No. WP Sequence No. Table 3. Remarks............................................................................................................................. 0275-27

EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0276 Table 1. Expendable and Durable List for the RTCH......................................................................... 0276-1

TOOL IDENTIFICATION LIST..................................................................................................................... WP 0277 Table 1. Tool Identification List........................................................................................................... 0277-1

MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0278 Table 1. Index Mandatory Replacement Parts List...................................................................................... 0278-1

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TM 10-3930-675-23-2

HOW TO USE THIS MANUAL

INTRODUCTION 1. This manual is designed to help you perform Field level Maintenance and Troubleshooting on all variants of the RT 240 Rough Terrain Container Handler (RTCH). For model-specific information, see matrix below: RT 240V1 (NSN 3930-01-473-3998) S/N range T34112.0003 to T35112.0373 RT 240V1R (NSN 3930-01-473-3998) S/N range T34112.0003(R) to T35112.0373(R) RT 240V2 (NSN 3930-01-522-7364, and 3930-01-473-3889) S/N range T5112.0401 to T35112.0742 RT 240V3 (NSN 3930-01-522-7364, and 3930-01-473-3889) S/N range S112.00801 to current

NOTE
• • RT 240V2 and V3 models are identical, the only difference between the two models, are the RT 240V3 machines were built in the United States. Any models that have been reset will have one or more "R" stamped at the end of their S/N or the RESET date will be stamped in the Data plate. For model specific information, the configuration name (RT 240V1, RT 240V1R, RT 240V2/3) will be specified in the task title in parentheses (for maintenance tasks) and in the table/errors code title in parentheses (for Troubleshooting procedures). If there is no designation, the task/troubleshooting procedure applies to all models.

2. The Repair Parts and Special Tools List (RPSTL), TM 10-3930-675-24P, is to be used in conjunction with this manual to locate and obtain the repair parts and special tools needed to maintain this equipment. 3. This manual is written in Work Package format: a. Chapters divide the manual into major categories of information (e.g., General Information, Theory of Operation, Troubleshooting Procedures, 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) located on the upper right-hand corner of each page. The Work Package page number (e.g., 0001-1, 0001-2) is located centered at the bottom of each page. c. If a Change Package is issued to this manual, added Work Packages use the 5th and 6th digits of their number to indicate new material. For instance, Work Packages inserted between WP 0001 and WP 0002 are numbered WP 0001 01, WP 0001 02, etc. 4. This manual is published in two volumes: Volume I covers Chapters 1 and 2, Work Packages 0001 through WP 0048 and includes all troubleshooting, Chapter 6: Supporting Information is included in Volumes I and II. Volume II includes Chapters 3 through 6, WP 0049 through WP 0292. 5. Scan through this manual to become familiar with its organization and contents before attempting to maintain the equipment.

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TM 10-3930-675-23-2

HOW TO USE THIS MANUAL - Continued

CONTENTS OF THIS MANUAL 1. A Warning Summary is located at the beginning of each volume of the manual. Become familiar with these warnings before operating or performing troubleshooting or maintenance on the vehicle. 2. A Table of Contents in Volume I lists the contents of Volumes I and II. The Table of Contents in Volume II lists the contents of Volume II only. a. The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA Form 2028 addresses, for the submittal of corrections to the manual. b. 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. The alphabetical Index for each volume lists only those Work Packages found in that volume. 3. Chapter 1, General Information, Equipment Description, and Theory of Operation, provides general information on the manual and the equipment. 4. Chapter 2, Troubleshooting Procedures, contains all applicable troubleshooting and a complete listing of Error Codes resident on the RTCH. 5. a. Before attempting to perform troubleshooting, carefully read the information in WP 0004, Troubleshooting Introduction. It explains how to perform both non-error code and error code-driven troubleshooting. Included at the end of this Work Package are locator diagrams of all electrical and hydraulic components that may be hard to locate. b. The error code reference index in WP 0004 provides a numerical list of error codes. c. The Troubleshooting Symptom Index in WP 0005 is divided into three sections. The first is an “Alphabetical Error Code Symptom Index", the second is a “Numerical Error Code Symptom Index", and the third is a “Non-Error Code Symptom Index". d. The corrective action for certain malfunctions is to notify “SRA". Refer to Table 3 in the Maintenance Allocation Chart (MAC) (Volume 2, WP 0275) for further information about the Specialized Repair Activity for the RTCH. 6. Chapter 3 covers all Maintenance Instructions. In each chapter, work packages are organized in the same Functional Group Code (FGC) sequence as the MAC found in Chapter 6 of both volumes. 7. Chapter 6 includes Supporting Information: References, MAC Introduction, MAC, Expendable and Durable Items List, Load Testing Procedure, and Foldouts of Hydraulic Systems. 8. An alphabetical index completes the manual. FEATURES OF THIS MANUAL 1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid. a. WARNING indicates a hazard which may result in death or serious injury to personnel. 2. b. CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment. c. 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 Work Package in this manual or to another manual. These references indicate where you should look for more complete information. 5. a. If you are told: “Replace engine ECU (WP 0079)", go to the Table of Contents in Volume II of this manual for instructions on replacing the engine ECU. Be sure to read the “Initial Setup" on page 1 of the Work Package, to determine contents of Work Package as well as information regarding tools and equipment, spare parts, and personnel required, etc. b. If you are told: “Check coolant level (TM 10-3930-675-10)", go to TM 10-3930-675-10. Use the Table of Contents or alphabetical Index in TM 10-3930-675-10 to find the procedure.

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HOW TO USE THIS MANUAL - Continued
FEATURES OF THIS MANUAL - Continued 6. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art may be text or numbers, whichever method is easier for the soldier. 7. Numbers located at lower right corner of art (e.g., 350-001; 434-0002) are art control numbers and are used for tracking purposes. Disregard these numbers. 8. Dashed leader lines used in illustrations indicate that called out items are not visible in the view depicted (i.e., they are located within or behind the structure). 9. 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.

NOTE
If at any time you are unsure how to use this manual or you cannot locate the information you need, notify your supervisor.

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CHAPTER 5 MAINTENANCE INSTRUCTIONS

TM 10-3930-675-23-2

0135

FIELD MAINTENANCE TRANSMISSION ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Handle, Sliding-T (WP 0277, Table 1, Item 38) Lifting Device (2,500 lb minimum capacity) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Engine and Transmission (WP 0277, Table 1, Item 68) Sling, Nylon (WP 0277, Table 1, Item 70) Socket, Impact Socket, 3/4" DR, 6PT, Long, 46mm (WP 0277, Table 1, Item 72) Stud, Guide (WP 0269, Figure 1) Wrench, Torque, Click, Ratcheting, 3/4" Drive, 600 lb-ft (WP 0277, Table 1, Item 96) Wrench, Torque, Click, Ratcheting, 3/8" Drive, 75 lb-ft (WP 0277, Table 1, Item 97) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, OE/HDO 10W90 (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealant, Silicone (WP 0276, Table 1, Item 53) Sealing Compound (WP 0276, Table 1, Item 54) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Gasket (WP 0278, Table 1, Item 19) Gasket (WP 0278, Table 1, Item 24) Materials/Parts (cont.) Gasket (WP 0278, Table 1, Item 146) Washer, Lock (WP 0278, Table 1, Item 96) Qty: 12 Personnel Required (3) References TM 10-3930-675-10 Volume 1, WP 0047 Volume 1, WP 0120 WP 0136 WP 0139 WP 0169 Equipment Condition Cab in transport position (TM 10-3930-675-10) Boom raised to maximum angle (TM 10-3930-675-10) Transmission skid plate and access covers removed (WP 0175) Transmission oil drained (WP 0140) Front and rear propeller shafts disconnected (WP 0143) Engine cover removed (WP 0185) Boom and brake system hydraulic pump removed (WP 0205) Tophandler and steering hydraulic pump assembly removed (WP 0212)

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TM 10-3930-675-23-2

0135

WARNING

• Use extreme caution when handling heavy parts. Transmission weighs approximately 1,654 lb (750 kg). Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Improper use of lifting equipment and improper attachment of cable or chains to vehicle can result in serious personnel injury and equipment damage. Observe all standard rules of safety. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
• If engine and/or transmission is not operational and boom must be elevated, auxiliary pump can be used to provide hydraulic power for boom operation. Operate pump for not more than four minutes and allow pump to cool for not less than two minutes. Perform operate and cool cycle as many times as needed to elevate boom. Failure to allow pump to cool may cause damage to pump. • DO NOT begin transmission assembly replacement without first having all required tools and equipment to complete the procedure. This will help in reducing the time boom must remain at maximum elevation. • Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Ensure all hydraulic hoses, lines, fittings, and electrical wiring harnesses and leads are tagged for identification and location prior to disconnection. • When disconnecting hydraulic lines or hoses, position suitable container to catch hydraulic oil retained in lines and hoses. REMOVAL 1. Disconnect electrical wiring connectors from these connections shown on locator diagrams: a. b. c. d. e. Gearbox temperature sensor and gearbox connectors 2WD/4WD valve and output speed sensor connectors 2WD/4WD sensor connector Filter indicator, turbine speed sensor, and internal gear speed sensor connectors Engine speed sensor connector

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TM 10-3930-675-23-2

0135

REMOVAL - Continued
GEARBOX TEMPERATURE SENSOR GEARBOX CONNECTOR

FRONT ENGINE SPEED SENSOR

OUTPUT SPEED SENSOR 2WD/4WD VALVE

FILTER INDICATOR SENSOR 2WD/4WD DRIVE SENSOR

TURBINE SPEED SENSOR

INTERNAL GEAR SPEED SENSOR

RIGHT SIDE

LEFT SIDE

M0889JCH

Figure 1.

Transmission Sensors Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 10-3930-675-23-2

0135

REMOVAL - Continued

NOTE
Ensure all wiring harnesses and connectors are secured away from transmission with temporary tiedowns. 2. 3. Remove and discard all tiedown straps as necessary to remove wiring harnesses from transmission. Disconnect these components: a. b. c. d. 4. Two transmission oil cooler hoses Oil sampling valve hose Breather hose Three oil filter hoses

Install lifting sling between two lifting brackets on transmission assembly. Connect sling to suitable lifting device. Raise lifting device and take up slack in sling.
OIL FILTER HOSES OIL FILTER HOSE

OIL SAMPLING VALVE HOSE

OIL COOLER HOSE LIFTING BRACKETS

OIL COOLER HOSE

BREATHER HOSE

M0890JCH

Figure 2. Transmission Hoses Removal. 5. 6. Remove two screws (Figure 3, Item 1), flange (Figure 3, Item 2), gasket (Figure 3, Item 3), and oil fill tube (Figure 3, Item 4) from transmission assembly. Discard gasket. Remove all screws, washers, nuts, and clamps securing oil fill tube (Figure 3, Item 4) to vehicle. Remove oil fill tube and retain for later installation.

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TM 10-3930-675-23-2

0135

REMOVAL - Continued
1 2

3

4
M0891JCH

Figure 3. Transmission Oil Fill Tube Removal. 7. 8. Disconnect two hydraulic hoses from emergency steering pump (WP 0169) . DO NOT remove pump at this time. Remove four screws (Figure 4, Item 1), access cover (Figure 4, Item 2), and gasket (Figure 4, Item 3) from bottom of flywheel housing (Figure 4, Item 4). Discard gasket.
2 3 4

1

M0892JCH

Figure 4.

Flywheel Housing Access Cover.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 10-3930-675-23-2

0135

REMOVAL - Continued 9. Remove two screws (Figure 5, Item 3), cover (Figure 5, Item 2), and gasket (Figure 5, Item 1) from flywheelto-damper plate mounting screw access.
2

1

3

M0893JCH

Figure 5.

Flywheel-to-Damper Plate Access Cover Removal.

NOTE
Transmission damper plates and torque converter are secured to flywheel with 12 screws. 10. 11. 12. With assistance, bar engine in clockwise direction using accessory drive while observing through access hole. Stop rotation when screw is visible through access hole. Remove screw (Figure 6, Item 1) securing damper plates to flywheel. Repeat Steps 10 and 11 to remove remaining eleven screws (Figure 6, Item 1).

0135-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 10-3930-675-23-2

0135

REMOVAL - Continued

1

M0894JCH

Figure 6. Damper Plates-to-Flywheel Screw Removal. 13. 14. Upon removal of last screw, insert guide stud and secure to damper plate. Remove 12 screws (Figure 7, Item 1) and lockwashers (Figure 7, Item 2) securing transmission to engine flywheel housing (Figure 7, Item 3). Discard lockwashers.

1,2 3

M0895JCH

Figure 7.

Flywheel Housing Screws Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 10-3930-675-23-2

0135

REMOVAL - Continued 15. Remove four screws (Figure 8, Item 1) and washers (Figure 8, Item 2) securing transmission to mounting brackets (Figure 8, Items 3 and 4).
FRONT 3 1,2 4

1,2

1,2 RIGHT SIDE LEFT SIDE
M0896JCH

Figure 8. Transmission-to-Mounting Bracket Removal.

NOTE
Transmission must be moved toward rear, away from engine a minimum of 3 in., while keeping perfect alignment to avoid major damage to the flywheel and to allow damper plate guide stud to clear the flywheel housing. 16. 17. Separate transmission from engine and use nylon sling to ensure damper plates and torque converter remain with transmission. Lift transmission from vehicle and place on temporary cribbing.

NOTE
Perform Steps 18 thru 21 only if a replacement transmission is to be installed. 18. Remove and retain damper plates and torque converter (WP 0139).

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TM 10-3930-675-23-2

0135

REMOVAL - Continued 19. Remove and retain these sensors (Volume 1, WP 0120): a. b. c. d. e. f. 20. 21. Gearbox temperature sensor Output speed sensor Engine speed sensor 2WD/4WD sensor Turbine speed sensor Internal gear speed sensor

Remove fittings for oil filter, oil sampling valve, oil cooler, and breather hoses. Remove emergency steering pump (WP 0169).
GEARBOX TEMPERATURE SENSOR GEARBOX CONNECTOR

FRONT ENGINE SPEED SENSOR

OUTPUT SPEED SENSOR 2WD/4WD VALVE

FILTER INDICATOR SENSOR 2WD/4WD DRIVE SENSOR

TURBINE SPEED SENSOR

INTERNAL GEAR SPEED SENSOR

RIGHT SIDE

LEFT SIDE

M0897JCH

Figure 9. END OF TASK

Electrical Connectors Removal.

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TM 10-3930-675-23-2

0135

INSTALLATION

NOTE
If a replacement transmission is not being installed, proceed to Step 5. 1. 2. 3. Install emergency steering pump (WP 0169). Apply sealant to threads and install fittings for oil filter, oil sampling valve, oil cooler, and breather hoses. Apply sealant to threads and install these sensors (Volume 1, WP 0120): a. b. c. d. e. f. Gearbox temperature sensor Output speed sensor Engine speed sensor 2WD/4WD sensor Turbine speed sensor Internal gear speed sensor
GEARBOX TEMPERATURE SENSOR GEARBOX CONNECTOR

FRONT ENGINE SPEED SENSOR

OUTPUT SPEED SENSOR 2WD/4WD VALVE

FILTER INDICATOR SENSOR 2WD/4WD DRIVE SENSOR

TURBINE SPEED SENSOR

INTERNAL GEAR SPEED SENSOR

RIGHT SIDE

LEFT SIDE

M0898JCH

Figure 10. Transmission Sensors Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 10-3930-675-23-2

0135

INSTALLATION - Continued 4. Install torque converter and damper plates (WP 0139).

WARNING

• Use extreme caution when handling heavy parts. Transmission weighs approximately 1,654 lb (750 kg). Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Improper use of lifting equipment and improper attachment of cable or chains to vehicle can result in serious personnel injury and equipment damage. Observe all standard rules of safety.

NOTE
Ensure transmission and engine mating surfaces are clean and free of old sealant. 5. 6. Install lifting sling between two transmission assembly lifting brackets and connect sling to suitable lifting device. Install nylon sling to hold damper plates and torque converter in place.

NOTE
• Position damper plate guide stud to mate with flywheel housing screw hole. • Ensure guide stud will clear flywheel housing while transmission is lowered. 7. 8. 9. Using suitable lifting device, lift transmission assembly and lower into vehicle. Remove nylon sling holding damper plates and torque converter in place. Apply a coat of silicone sealant to engine and transmission mating surface.

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TM 10-3930-675-23-2

0135

INSTALLATION - Continued

NOTE
Transmission must be moved toward engine, while keeping perfect alignment to avoid damage to the flywheel. It may be necessary to adjust transmission damper plate by hand to align guide stud with mating flywheel screw hole. 10. 11. Position transmission to allow damper plate guide stud to pass through flywheel-to-damper screw hole and flywheel housing access. Install four washers (Figure 11, Item 2) and screws (Figure 11, Item 1) securing transmission to mounting brackets (Figure 11, Items 3 and 4). DO NOT fully tighten screws at this time.
FRONT 3 1,2 4

1,2

1,2 RIGHT SIDE LEFT SIDE
M0899JCH

Figure 11.

Transmission-to-Mounting Bracket Screws Installation.

NOTE
Flywheel and damper plates are secured with 12 screws. Final tightening is done after all screws are installed. 12. 13. 14. 15. Remove guide stud and install screw (Figure 12, Item 1). Tighten screw hand-tight. Bar engine over until next screw hole is visible and install screw (Figure 12, Item 1). Tighten screw hand-tight. Repeat Step 13 for remaining screws until 12 screws are installed securing flywheel-to-damper plate. Bar engine over clockwise and tighten each screw (Figure 12, Item 1) to 48 ft-lb (65 N·m).

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TM 10-3930-675-23-2

0135

INSTALLATION - Continued

1
M0900JCH

Figure 12. 16.

Flywheel-to-Damper Plate Screw Installation.

Install 12 new lockwashers (Figure 13, Item 3) and screws (Figure 13, Item 2) to secure transmission to flywheel housing (Figure 13, Item 1). Tighten screws to 38 ft-lb (52 N•m).

1,2

3
M0901JCH

Figure 13. Flywheel Housing Screws Installation.

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TM 10-3930-675-23-2

0135

INSTALLATION - Continued 17. Tighten four screws (Figure 14, Item 1) securing transmission to mounting brackets (Figure 14, Items 2 and 3) to 146 ft-lb (198 N•m).
FRONT 3 1,2 4

1,2

1,2 RIGHT SIDE LEFT SIDE
M0902JCH

Figure 14. 18. 19.

Transmission-to-Mounting Bracket Screws Installation.

Remove lifting sling and lifting device. Install new gasket (Figure 15, Item 3) and access cover (Figure 15, Item 2) on bottom of flywheel housing (Figure 15, Item 4) with four screws (Figure 15, Item 1).

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TM 10-3930-675-23-2

0135

INSTALLATION - Continued
2 3 4

1

M0903JCH

Figure 15. Flywheel Housing Access Cover Installation. 20. Install new gasket (Figure 16, Item 1) and cover (Figure 16, Item 2) over flywheel-to-damper plate screw access with two screws (Figure 16, Item 3).
2

1

3

M0904JCH

Figure 16.

Flywheel-to-Damper Plate Access Cover Installation.

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TM 10-3930-675-23-2

0135

INSTALLATION - Continued 21. Install new gasket (Figure 17, Item 3), flange (Figure 17, Item 2), and oil fill tube (Figure 17, Item 4) with two screws (Figure 17, Item 1).
1 2

3

4
M0905JCH

Figure 17. Transmission Oil Fill Tube Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00102)

TM 10-3930-675-23-2

0135

INSTALLATION - Continued 22. 23. 24. Secure oil fill tube to vehicle with screws, nuts, washers, and clamps as needed. Connect two hydraulic hoses to emergency steering pump (WP 0169). Connect these hoses: a. b. c. d. Two transmission oil cooler hoses Oil sampling valve hose Breather hose Three oil filter hoses
OIL FILTER HOSES OIL FILTER HOSE

OIL SAMPLING VALVE HOSE

OIL COOLER HOSE

LIFTING BRACKETS

OIL COOLER HOSE

BREATHER HOSE

M0906JCH

Figure 18.

Transmission Hoses Installation.

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TM 10-3930-675-23-2

0135

INSTALLATION - Continued

NOTE
• Remove temporary tiedowns from electrical harnesses and install wiring harnesses using locator diagrams as a routing guide. • Ensure wiring harnesses are secured after connection to terminal points using new tiedown straps as required. 25. Connect wiring harnesses to these connectors: a. b. c. d. e. Gearbox temperature sensor and gearbox connectors 2WD/4WD sensor connector 2WD/4WD valve and output speed sensor connectors Engine speed sensor connector Filter indicator, turbine speed sensor, and internal gear speed sensor connectors
GEARBOX TEMPERATURE SENSOR GEARBOX CONNECTOR

FRONT ENGINE SPEED SENSOR

OUTPUT SPEED SENSOR 2WD/4WD VALVE

FILTER INDICATOR SENSOR 2WD/4WD DRIVE SENSOR

TURBINE SPEED SENSOR

INTERNAL GEAR SPEED SENSOR

RIGHT SIDE

LEFT SIDE

M0907JCH

Figure 19. Transmission Electrical Connectors. END OF TASK

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0135

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill transmission and check fluid level (LO 10-3930-675-13). Install tophandler and steering hydraulic pump assembly (WP 0212). Install boom and brake system hydraulic pump (WP 0205). Connect front and rear propeller shafts (WP 0143).

NOTE
DO NOT install transmission skid plate at this time. 5. 6. 7. 8. 9. 10. Install transmission access covers (WP 0175). Perform operational check of all systems (TM 10-3930-675-10). Perform transmission calibration (WP 0136). Shut down vehicle (TM 10-3930-675-10) and check for leaks. Install skid plate under transmission (WP 0175). Install engine cover (WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0136

FIELD MAINTENANCE TRANSMISSION CALIBRATION

INITIAL SETUP: References TM 10-3930-675-10

CALIBRATION

NOTE
Calibration procedures and checks must be performed if any of the following maintenance actions have occurred: 1. Transmission ECM replaced or disconnected 2. Transmission oil replaced 3. Repairs or adjustment made to transmission 4. Transmission assembly replaced 1. Access to Calibration Menus. a. b. c. d. e. f. g. h. i. Turn master battery switch to ON position. Turn ignition ON. Place transmission shift control lever in Neutral (N) position. Apply parking brake. Start engine and operate at idle speed. Wait for transmission oil temperature to reach operating range of 131°F to 194°F (55°C to 90°C). Select KALMAR service menu on driver's Electronic Control System (ECS) display screen and press "Enter". Enter calibration program access number "13221". Press right arrow button to locate "CALIBR GEAR BOX" menu, then press "Enter".

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TM 10-3930-675-23-2

0136

CALIBRATION - Continued 2. Transmission Calibration, ECM to Clutch Modulation Cycles. a. b. To initiate calibration process, press "Enter". When calibration process is completed without error, ECS display will show an AEB MAIN CODE of No. 7 (refer to Table 1). Calibration data will be saved within transmission ECM when ignition is turned off. When an error is identified during calibration process, AEB MAIN CODE will show a range of error codes of 0 thru 14 identifying the transmission component under calibration and an AEB SUB CODE range of error codes of 1 thru 8 (refer to Main Codes and Sub Codes in Table 1 and Table 2).

c.

CALIBR GEAR BOX AEB CYCLE NR AEB MAIN CODE AEB SUB CODE

1 (2) 0 0 0

M1740JCH

Figure 1.

Calibration.

0136-2

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TM 10-3930-675-23-2

0136

CALIBRATION - Continued d. When calibration process is completed without error, press "Enter" to return to main menu. ECS display screen should resemble window shown below:

CALIBR GEAR BOX CALIBRA TION OF GEAR BOX DONE

2 (2)

ENTER

M1712JCH

Figure 2.

Calibration.

0136-3

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TM 10-3930-675-23-2

0136

CALIBRATION - Continued

Table 1. Main Transmission Calibration Codes. MAIN CODE 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 COMPONENT BEING CALIBRATED AEB mode not selected AEB mode selected, calibrating K1 AEB mode selected, calibrating K2 AEB mode selected, calibrating K2 AEB mode selected, calibrating K4 AEB mode selected, calibrating KV AEB mode selected, calibrating KR AEB mode selected, calibration finished AEB mode selected, calibration aborted AEB mode selected, calibration aborted while adjusting K1 AEB mode selected, calibration aborted while adjusting K2 AEB mode selected, calibration aborted while adjusting K3 AEB mode selected, calibration aborted while adjusting K4 AEB mode selected, calibration aborted while adjusting KV AEB mode selected, calibration aborted while adjusting KR

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TM 10-3930-675-23-2

0136

CALIBRATION - Continued

Table 2. SUB CODE 1

Sub Transmission Calibration Codes.

COMPONENT BEING CALIBRATED Stop and restart truck if fault code is "0". Repeat calibration procedure. If failure continues, transmission maintenance may be required. Stop and restart truck. Ensure transmission shift control lever is in Neutral (N) position. Repeat calibration procedure Stop and restart truck. Ensure parking brake is applied. Repeat calibration procedure. Stop and restart truck. Test parking brake operation. If parking brake operates properly, repeat calibration procedure. If parking brake is not operating properly, service parking brake. Repeat calibration procedure. Stop and restart truck. Allow transmission to warm to operating temperature. Repeat calibration procedure. Allow transmission oil to cool by idling engine but not operating transmission. When oil temperature has cooled, transmission ECM will resume calibration program. Increase engine RPM. Transmission ECM will resume calibration program when RPM are within a specified range. Decrease engine RPM. Transmission ECM will resume calibration program when RPM are within a specified range.

2

3

4

5

6

7

8

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0137

FIELD MAINTENANCE TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Elbow, Hose (WP 0278, Table 1, Item 148) O-Ring (WP 0278, Table 1, Item 126) Qty: 4 O-Ring (WP 0278, Table 1, Item 149) Qty: 12 Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 150) Qty: O-Ring (WP 0278, Table 1, Item 152) O-Ring (WP 0278, Table 1, Item 158) Qty: References Volume 1, WP 0047 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Transmission access covers removed (WP 0175) 7 8

NOTE
• Hydraulic hoses and pipes are used to interconnect transmission clutches, valve body, and other internal components of transmission. A location diagram is provided to aid in locating and routing hydraulic hoses and pipes. • Four basic types of hydraulic hoses and one type of pipe are used on transmission assembly. An identification chart is provided to aid in identifying type of hose and connections. • The following procedures detail replacement of hoses and pipes.

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TM 10-3930-675-23-2

0137

REMOVAL 1. Refer to location diagram (Figure 1) and find hydraulic hose or pipe to be removed.

C B D A E

M F L

K

G J H
M1707JCH

Figure 1. 2.

Transmission Assembly Hose and Pipe Location Diagram.

Remove and discard tiedown straps, as needed, to release hydraulic hoses.

NOTE
Remove adapter fitting and O-ring seal only if damaged or leaking. 3. 4. 5. Position suitable container to catch hydraulic oil retained in hose or pipe and disconnect hose or pipe from adapter fitting. Remove fluid passage bolt, hose connection, and two O-ring seals from transmission. Discard O-rings. Loosen each of two fitting nuts and remove pipe (Figure 1, Items H, J, K, or L) from transmission.

0137-2

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TM 10-3930-675-23-2

0137

REMOVAL - Continued

M1708JCH

Figure 2. END OF TASK INSTALLATION

Transmission Hose and Pipe Location.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and pipes and applying proper torque. • If adapter fitting and O-ring seal have been removed, perform Steps 1 and 2. If not, proceed to Step 3. 1. 2. 3. 4. 5. 6. 7. Apply lubricating oil to new O-ring seal and install on adapter fitting. Install adapter fitting on transmission. Connect hose to adapter fitting and route hose to opposite end as indicated on location diagram. Apply lubricating oil to two new O-rings. Install hose connection and two O-rings on transmission and secure with fluid passage bolt. Secure hydraulic hose with new tiedown straps as needed. Position pipe (Figure 1, Items H, J, K, or L) on transmission and tighten each of two fitting nuts.

END OF TASK

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0137

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Replace transmission access covers (WP 0175). Return cab to operational position (TM 10-3930-675-10). Check transmission oil level and add as needed (Volume 1, WP 0047). Operate vehicle and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0138

FIELD MAINTENANCE TRANSMISSION OIL DIPSTICK HOSE AND PIPE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Gasket (WP 0278, Table 1, Item 146) Equipment Condition Cab moved to the left, but not lowered (TM 10-3930-675-10) Engine cover removed (WP 0185) Transmission oil drained, if replacing pipe (WP 0140)

NOTE
• Transmission oil dipstick hose and engine oil dipstick hose are at same location. • Transmission oil dipstick is indicated by a data plate with a transmission symbol.

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0138

REMOVAL 1. 2. 3. 4. Remove transmission dipstick (Figure 1, Item 1) from transmission oil dipstick hose (Figure 1, Item 4). Loosen hose clamp (Figure 1, Item 3) and disconnect hose (Figure 1, Item 4) from bracket (Figure 1, Item 2). Remove hose clamp from hose. At other end of hose (Figure 1, Item 4), loosen hose clamp (Figure 1, Item 5) and remove hose from pipe (Figure 1, Item 11). Remove hose clamp from hose. From underneath vehicle, remove locknut (Figure 1, Item 6), two washers (Figure 1, Item 7), screw (Figure 1, Item 10), and clamp (Figure 1, Item 9) from bracket (Figure 1, Item 8). Remove clamp from pipe (Figure 1, Item 11). Discard locknut. Remove screw (Figure 1, Item 16), washer (Figure 1, Item 17), and bracket (Figure 1, Item 8) from transmission (Figure 1, Item 15). Remove two screws (Figure 1, Item 12), pipe (Figure 1, Item 11), retaining plate (Figure 1, Item 13), and two gaskets (Figure 1, Item 14) from transmission (Figure 1, Item 15). Discard gaskets.

5. 6.

END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. Install two new gaskets (Figure 1, Item 14), retaining plate (Figure 1, Item 13), and pipe (Figure 1, Item 11) on transmission (Figure 1, Item 15) with two screws (Figure 1, Item 12). Install bracket (Figure 1, Item 8) on transmission (Figure 1, Item 15) with washer (Figure 1, Item 17) and screw (Figure 1, Item 16). Tighten screw to 38 ft-lb (52 N·m). Position clamp (Figure 1, Item 9) on pipe (Figure 1, Item 11) and install clamp on bracket (Figure 1, Item 8) with screw (Figure 1, Item 10), washer (Figure 1, Item 7), and new locknut (Figure 1, Item 6). From top of vehicle, position hose clamp (Figure 1, Item 3) on transmission oil dipstick hose (Figure 1, Item 4) and install hose on pipe (Figure 1, Item 11). Tighten hose clamp. At other end of hose (Figure 1, Item 4), position hose clamp (Figure 1, Item 3) on hose and connect hose to bracket (Figure 1, Item 2). Tighten hose clamp. Install transmission dipstick (Figure 1, Item 1) on transmission oil dipstick hose (Figure 1, Item 4).

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TM 10-3930-675-23-2

0138

INSTALLATION - Continued

1

2

3

4

5 6 17 7 8 16 15 10 11 14 12 9

13

M1713JCH

Figure 1. END OF TASK

Transmission Oil Dipstick Hose and Pipe Replacement.

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TM 10-3930-675-23-2

0138

FOLLOW-ON MAINTENANCE 1. 2. 3. If drained, fill transmission oil (WP 0140). Install engine cover (WP 0185). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0139

FIELD MAINTENANCE TRANSMISSION TORQUE CONVERTER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics Automotive (WP 0277, Table 1, Item 85) Lifting Device (minimum capacity 300 lbs) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Personnel Required (2) Equipment Condition Transmission assembly removed (WP 0135)

REMOVAL 1. Remove 16 screws (Figure 1, Item 1), washers (Figure 1, Item 2), and three damper plates (Figure 1, Item 3).
3

2 1

M0887JCH

Figure 1.

Damper Plates Removal.

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TM 10-3930-675-23-2

0139

REMOVAL - Continued

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
Torque converter contains oil and is subject to spillage if positioned shaft side down when removed. Ensure spills are cleaned up immediately. 2. 3. Slide torque converter (Figure 2, Item 4) from transmission bell housing (Figure 2, Item 5). Place torque converter (Figure 2, Item 5) with transmission side up on suitable cribbing.

END OF TASK INSTALLATION

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
It is not necessary to add fluid to torque converter before installation to transmission. 1. Position torque converter (Figure 2, Item 4) on input shaft and slide into transmission bell housing (Figure 2, Item 5).

NOTE
Ensure damper plates are not bent or damaged. 2. 3. Install three damper plates (Figure 2, Item 3), 16 washers (Figure 2, Item 2), and screws (Figure 2, Item 1). Rotate damper plates (Figure 2, Item 3) and torque converter (Figure 2, Item 4) by hand to ensure no binding occurs.

0139-2

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TM 10-3930-675-23-2

0139

INSTALLATION - Continued
3 4 5

2 1

M0888JCH

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE Install transmission assembly (WP 0135). END OF TASK END OF WORK PACKAGE

Torque Converter Removal.

0139-3/4 blank

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TM 10-3930-675-23-2

0140

FIELD MAINTENANCE TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Wrench, Torque, Dial, 3/8" In. Drive, 300 lb-in (WP 0277, Table 1, Item 98) Materials/Parts Cleaning Compound, Solvent (WP 0276, Table 1, Item 10) Compound, Gasket Forming, Silicone (WP 0276, Table 1, Item 13) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Sealing Compound (WP 0276, Table 1, Item 54) Filter Element, Fluid (WP 0278, Table 1, Item 130) O-Ring (WP 0278, Table 1, Item 81) Qty: 1 Strainer Element, Sediment (WP 0278, Table 1, Item 145) References TM 10-3930-675-10 WP 0136 WP 0175 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0140-1

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TM 10-3930-675-23-2

0140

TRANSMISSION OIL DRAINING

WARNING

At operating temperature, transmission oil is hot. Allow transmission to cool before draining. Failure to do so could result in injury to personnel.

NOTE
• Transmission capacity is approximately 36 qt (34 L) with filter. • Dispose of old transmission oil in accordance with local policy. 1. 2. Position a suitable container under transmission. Working through opening in transmission skid plate (Figure 1, Item 3), remove plug (Figure 1, Item 1) from transmission (Figure 1, Item 2) and allow oil to drain into container.

END OF TASK TRANSMISSION OIL FILLING 1. 2. 3. Working through opening in transmission skid plate (Figure 1, Item 3), apply pipe sealant to threads of plug (Figure 1, Item 1) and install plug in transmission (Figure 1, Item 2). Fill transmission with oil (TM 10-3930-675-10). Start engine (TM 10-3930-675-10) and check for leaks.

0140-2

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TM 10-3930-675-23-2

0140

TRANSMISSION OIL FILLING - Continued
1 2

3

M0313JCH

Figure 1. Transmission Oil Draining and Filling. END OF TASK

0140-3

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TM 10-3930-675-23-2

0140

TRANSMISSION OIL FILTERS REMOVAL

WARNING

At operating temperature, transmission oil is hot. Allow transmission to cool before performing maintenance on transmission or transmission system components. Failure to do so could result in injury to personnel.

NOTE
Ensure suitable container is placed under oil filters. Filters will contain transmission oil and can spill. 1. 2. 3. Use a strap wrench to loosen oil filter (Figure 2, Item 2). Unscrew oil filter (Figure 2, Item 2) from oil filter head (Figure 2, Item 1) by hand. Discard filter. Repeat Steps 1 and 2 for second oil filter (Figure 2, Item 2).

END OF TASK

0140-4

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0140

TRANSMISSION OIL FILTERS INSTALLATION

NOTE
Ensure oil filter head is clean and free of old oil. 1. 2. Apply a thin coat of lubricating oil to filter seal. Fill new oil filter (Figure 2, Item 2) with clean lubricating oil.

CAUTION
DO NOT overtighten oil filter. Overtightening filter may cause damage to filter or filter head which will result in oil leaks. 3. 4. 5. Install oil filter (Figure 2, Item 2) on oil filter head (Figure 2, Item 1) and hand tighten. Use strap wrench to tighten oil filter (Figure 2, Item 2) an additional 1/2 to 3/4 turn. Repeat Steps 1 thru 4 for second oil filter (Figure 2, Item 2).
1

2

M0314JCH

Figure 2. Transmission Oil Filters Replacement. END OF TASK

0140-5

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TM 10-3930-675-23-2

0140

TRANSMISSION OIL FILTER HEAD REMOVAL

WARNING

At operating temperature, transmission oil is hot. Allow transmission to cool before performing maintenance on transmission or transmission system components. Failure to do so could result in injury to personnel. 1. Remove two oil filters from oil filter head (refer to Transmission Oil Filters Removal in this work package).

NOTE
Tag hoses to ensure correct installation. 2. 3. 4. Disconnect three hoses (Figure 3, Items 5, 9 and 11) from filter head fittings (Figure 3, Item 6). Disconnect connector from oil filter sensor (Figure 3, Item 4). Remove oil filter sensor (Figure 3, Item 8) and O-ring (Figure 3, Item 7) from oil filter head (Figure 3, Item 10). Discard O-ring.
1 2 3,4 5

6

6

1

M0315JCH

Figure 3.

Transmission Oil Filter Head Replacement.

0140-6

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TM 10-3930-675-23-2

0140

TRANSMISSION OIL FILTER HEAD REMOVAL - Continued 5. 6. 7. 8. Remove two screws (Figure 4, Item 4) and washers (Figure 4, Item 3) securing bracket (Figure 4, Item 12) with oil filter head (Figure 4, Item 10) to flywheel housing (Figure 4, Item 2). Remove bracket (Figure 4, Item 12) with oil filter head (Figure 4, Item 10). Remove two screws (Figure 4, Item 1), washers (Figure 4, Item 13), and oil filter head (Figure 4, Item 10) from bracket (Figure 4, Item 12). Remove three fittings (Figure 4, Item 6) from oil filter head (Figure 4, Item 10).

END OF TASK TRANSMISSION OIL FILTER HEAD INSTALLATION 1. 2. Apply pipe sealant to threads of three fittings (Figure 4, Item 6) and install in oil filter head (Figure 4, Item 10). Position bracket (Figure 4, Item 12) on oil filter head (Figure 4, Item 10) and secure with two screws (Figure 4, Item 1) and washers (Figure 4, Item 13).

NOTE
Ensure mounting surface of flywheel housing is clean and free of old gasket forming compound. 3. Apply gasket forming compound to mounting surface on flywheel housing (Figure 4, Item 2) and install bracket (Figure 4, Item 12) with oil filter head (Figure 4, Item 10) on flywheel housing with two screws (Figure 4, Item 4) and washers (Figure 4, Item 3). Install new O-ring (Figure 3, Item 7) and oil filter sensor (Figure 3, Item 8) to oil filter head (Figure 3, Item 10). Connect connector to oil filter sensor (Figure 3, Item 8).
2 1

4. 5.

13 12

3 4 11 6 6 10 7 8 9 5

6

M1714JCH

Figure 4.

Transmission Oil Filter Head Replacement.

0140-7

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TM 10-3930-675-23-2

0140

TRANSMISSION OIL FILTER HEAD INSTALLATION - Continued 6. 7. Connect three hoses (Figure 3, Items 5, 9 and 11) to fittings (Figure 3, Item 6). Install two oil filters to oil filter head (refer to Transmission Oil Filters Installation in this work package).

END OF TASK TRANSMISSION INTERNAL COARSE OIL FILTER REMOVAL 1. 2. Remove transmission skid plate (WP 0175). Drain transmission oil (refer to Transmission Oil Draining in this work package).

CAUTION
Ensure no dirt or oil sludge enters transmission. Failure to comply may cause equipment damage. 3. 4. Remove three screws (Figure 5, Item 1), washers (Figure 5, Item 2), and cover (Figure 5, Item 3). Remove and discard O-ring (Figure 5, Item 5) from cover. Remove internal coarse oil filter (Figure 5, Item 4) from transmission.

3 1 2

4 5
M0317JCH

Figure 5. END OF TASK

Transmission Internal Coarse Oil Filter Removal.

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TM 10-3930-675-23-2

0140

TRANSMISSION INTERNAL COARSE OIL FILTER CLEANING AND INSPECTION

WARNING

• Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200°F (94°C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. Failure to comply may cause injury or death to personnel. • Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel. 1. 2. 3. Use solvent to clean internal coarse oil filter. Clean area of transmission where coarse oil filter cover contacts transmission. Dry internal coarse oil filter with compressed air. Inspect filter for damage. If not damaged, filter may be reused.

END OF TASK

0140-9

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0140

TRANSMISSION INTERNAL COARSE OIL FILTER INSTALLATION 1. 2. 3. 4. 5. Install new O-ring (Figure 6, Item 5) in cover (Figure 6, Item 3). Coat gasket sealing surface of oil filter (Figure 6, Item 4) with lubricating oil and install in transmission. Screw in oil filter (Figure 6, Item 4) by hand until contact with sealing surface is obtained. Tighten by hand an additional 1/3 to 1/2 turn. Install cover (Figure 6, Item 3) with three washers (Figure 6, Item 2) and screws (Figure 6, Item 1). Tighten screws to 203 in-lb (23 N•m). Fill transmission with oil (TM 10-3930-675-10).

3 1 2

4 5
M0317JCH

Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5.

Transmission Internal Coarse Oil Filter Installation.

Check transmission oil level with engine idling in neutral and parking brake applied after engine reaches operating temperature (TM 10-3920-675-10). Add oil as needed. Shut down engine and check transmission oil level (TM 10-3930-675-10). Add oil as necessary to obtain proper level. Perform transmission calibration (WP 0136). Start engine (TM 10-3930-675-10) and check for leaks. Operate vehicle (TM 10-3930-675-10) and check for leaks.

END OF TASK END OF WORK PACKAGE

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0141

FIELD MAINTENANCE TRANSMISSION OIL COOLER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Lubricating Oil, Gear OE/HD (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealing Compound (WP 0276, Table 1, Item 54) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 98) Qty: 4 Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 Equipment Condition Engine cover removed (WP 0185) Radiator splash shield removed (Volume 1, WP 0084) Engine coolant drained (Volume 1, WP 0080)

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0141

REMOVAL

NOTE
• Transmission oil cooler consists of two units interconnected with coolant and hydraulic hoses. The two units are mounted on a common bracket attached to engine flywheel housing. • Coolant may remain in transmission oil coolers even when cooling system has been drained. To aid in removal, drain residual coolant from transmission oil coolers. Ensure suitable container is positioned to catch draining transmission oil from disconnected hoses or components. • Tag hoses for installation. 1. 2. Position suitable container under transmission oil coolers and remove two plugs (Figure 1, Item 4). Loosen hose clamps (Figure 1, Item 2) and disconnect coolant hoses (Figure 1, Items 1 and 3).
3 2

4

2

1

4

M0908JCH

Figure 1. Transmission Oil Coolers Removal.

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TM 10-3930-675-23-2

0141

REMOVAL - Continued 3. 4. Loosen two hose clamps (Figure 2, Item 2) and remove coolant hose (Figure 2, Item 1). Remove eight screws (Figure 2, Item 3), two flanges (Figure 2, Item 4), O-ring seals (Figure 2, Item 5), and disconnect two hoses (Figure 2, Items 10 and 11) from bottom of transmission oil cooler lower unit (Figure 2, Item 9). Discard O-ring seals. Remove eight screws (Figure 2, Item 3), two flanges (Figure 2, Item 4), O-ring seals (Figure 2, Item 5), and disconnect two hoses (Figure 2, Items 6 and 11) from top of transmission oil cooler upper unit (Figure 2, Item 8). Discard O-ring seals. Loosen hose clamp (Figure 2, Item 12) and disconnect water hose (Figure 2, Item 7) from fitting (Figure 2, Item 13). Remove fitting (Figure 2, Item 13) from transmission oil cooler upper unit (Figure 2, Item 8).

5.

6. 7.

2 1

3,4,5

6 3,4,5

7 8 9 3,4,5

10 12,13
Figure 2.

11

M0909JCH

Transmission Oil Coolers Removal.

0141-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00108)

TM 10-3930-675-23-2

0141

REMOVAL - Continued 8. 9. With assistance, loosen two hose clamp bands (Figure 3, Item 2) securing transmission oil cooler lower unit (Figure 3, Item 1) to mounting bracket (Figure 3, Item 4). Remove lower unit from bracket. With assistance, loosen two hose clamp bands (Figure 3, Item 3) securing transmission oil cooler upper unit (Figure 3, Item 5) to mounting bracket (Figure 3, Item 4). Remove upper unit from bracket.
1 2 3 4 3 5

2

M0910JCH

Figure 3. Transmission Oil Coolers Removal.

0141-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00108)

TM 10-3930-675-23-2

0141

REMOVAL - Continued 10. If damaged, remove three screws (Figure 4, Item 1), washers (Figure 4, Item 2), and bracket (Figure 4, Item 4) from flywheel housing (Figure 4, Item 3).
1,2

3 4

M0911JCH

Figure 4. END OF TASK

Transmission Oil Coolers Removal.

0141-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00108)

TM 10-3930-675-23-2

0141

INSTALLATION

NOTE
Ensure hydraulic hose mounting flange surfaces on transmission oil cooler units are clean and free of residue. 1. 2. 3. If removed, install bracket (Figure 4, Item 4) on flywheel housing (Figure 4, Item 3) with three washers (Figure 4, Item 2) and screws (Figure 4, Item 1). With assistance, position transmission oil cooler upper unit (Figure 5, Item 5) on bracket (Figure 5, Item 4) and secure with two hose clamp bands (Figure 5, Item 3). With assistance, position transmission oil cooler lower unit (Figure 5, Item 1) on bracket (Figure 5, Item 4) and secure with two hose clamp bands (Figure 5, Item 2).
2 1 3 4 3 5

2

M0912JCH

Figure 5. Transmission Oil Coolers Installation.

0141-6

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TM 10-3930-675-23-2

0141

INSTALLATION - Continued 4. Install two hoses (Figure 6, Items 6 and 11) on top of transmission oil cooler upper unit (Figure 6, Item 8) with two new O-ring seals (Figure 6, Item 5) and flanges (Figure 6, Item 3). Secure flanges with eight screws (Figure 6, Item 4). Install two hoses (Figure 6, Items 10 and 11) on bottom of transmission oil cooler lower unit (Figure 6, Item 9) with two new O-ring seals (Figure 6, Item 5) and flanges (Figure 6, Item 3). Secure flanges with eight screws (Figure 6, Item 4). Apply pipe sealant to fitting (Figure 6, Item 13) and install fitting in transmission oil cooler upper unit (Figure 6, Item 8). Connect water hose (Figure 6, Item 7) to fitting with hose clamp (Figure 6, Item 12). Install coolant hose (Figure 6, Item 1) and secure with two hose clamps (Figure 6, Item 2).

5.

6. 7.

2 1

3,4,5

6 3,4,5

7 8 9 3,4,5

10 12,13 11
M0913JCH

Figure 6. Transmission Oil Coolers Installation.

0141-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00108)

TM 10-3930-675-23-2

0141

INSTALLATION - Continued 8. 9. 10. Connect coolant hose (Figure 7, Item 3) from water pump and secure with hose clamp (Figure 7, Item 2). Connect coolant hose (Figure 7, Item 1) from radiator and secure with hose clamp (Figure 7, Item 2). Apply pipe sealant and install two plugs (Figure 7, Item 4).
3 2

4

2

1

4

M0914JCH

Figure 7. Transmission Oil Coolers Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Check transmission oil level and add oil as needed (LO 10-3930-675-13). Add coolant (Volume 1, WP 0080). Start engine (TM 10-3930-675-10) and check for leaks. Shut down engine. Install radiator splash shield (Volume 1, WP 0084). Install engine cover (WP 0185).

END OF TASK END OF WORK PACKAGE

0141-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00108)

TM 10-3930-675-23-2

0142

FIELD MAINTENANCE TRANSMISSION OIL FILTER HOSES AND OIL COOLER HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Sealing Compound (WP 0276, Table 1, Item 54) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 98) Qty: 2 References LO 10-3930-675-13 Equipment Condition Cab in transport position (TM 10-3930-675-10) Engine cover removed (WP 0185) Transmission access covers removed (WP 0175)

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TM 10-3930-675-23-2

0142

TRANSMISSION-TO-OIL COOLER HOSES REMOVAL

WARNING

At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury.

NOTE
Tag all transmission hydraulic oil hoses. 1. 2. Trace and tag hose (Figure 1, Item 4) from transmission oil cooler upper unit (Figure 1, Item 8) to transmission (Figure 1, Item 1). Trace and tag hose (Figure 1, Item 2) from transmission oil cooler lower unit (Figure 1, Item 9) to transmission (Figure 1, Item 1).

WARNING
Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. 3. 4. 5. 6. 7. 8. 9. 10. Position suitable container to catch lubricating oil remaining in hoses (Figure 1, Items 2 and 4). Remove four screws (Figure 1, Item 5), flange (Figure 1, Item 6), O-ring seal (Figure 1, Item 7), and disconnect hose (Figure 1, Item 4) from transmission oil cooler upper unit (Figure 1, Item 8). Discard O-ring seal. Disconnect opposite end of hose (Figure 1, Item 4) from transmission adapter fitting (Figure 1, Item 3). Remove hose. If damaged, remove adapter fitting (Figure 1, Item 3) from transmission (Figure 1, Item 1). Remove four screws (Figure 1, Item 5), flange (Figure 1, Item 6), O-ring seal (Figure 1, Item 7), and disconnect hose (Figure 1, Item 2) from transmission oil cooler lower unit (Figure 1, Item 9). Discard O-ring seal. Remove screw (Figure 1, Item 10), washers (Figure 1, Item 11), and hose clamp (Figure 1, Item 12) securing hose (Figure 1, Item 2). Disconnect opposite end of hose (Figure 1, Item 2) from transmission adapter fitting (Figure 1, Item 13). Remove hose. If damaged, remove adapter fitting (Figure 1, Item 13) from transmission (Figure 1, Item 1).

END OF TASK TRANSMISSION-TO-OIL COOLER HOSES INSTALLATION 1. 2. 3. If removed, apply pipe sealant to threads of adapter fitting (Figure 1, Item 13) and install fitting in transmission (Figure 1, Item 1). Connect hose (Figure 1, Item 2) to adapter fitting (Figure 1, Item 13) and route hose to transmission oil cooler lower unit (Figure 1, Item 9). Secure hose (Figure 1, Item 2) to transmission oil cooler lower unit (Figure 1, Item 9) with new O-ring seal (Figure 1, Item 7), flange (Figure 1, Item 6), and four screws (Figure 1, Item 5).

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0142

TRANSMISSION-TO-OIL COOLER HOSES INSTALLATION - Continued 4. 5. 6. 7. Install hose clamp (Figure 1, Item 12), screw (Figure 1, Item 10), and washers (Figure 1, Item 11) on hose (Figure 1, Item 2). If removed, apply pipe sealant to adapter fitting (Figure 1, Item 3) and install fitting in transmission (Figure 1, Item 1). Connect hose (Figure 1, Item 4) to adapter fitting (Figure 1, Item 3) and route hose to transmission oil cooler upper unit (Figure 1, Item 8). Secure hose (Figure 1, Item 4) to transmission oil cooler upper unit (Figure 1, Item 8) with new O-ring seal (Figure 1, Item 7), flange (Figure 1, Item 6), and four screws (Figure 1, Item 5).
2 1 3

13

4

5,6,7

8 9

10,11,12

2

5,6,7
M0309JCH

Figure 1. END OF TASK

Transmission-to-Oil Cooler Hoses Replacement.

0142-3

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TM 10-3930-675-23-2

0142

TRANSMISSION-TO-OIL FILTER HOSES REMOVAL

WARNING

At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury.

NOTE
Tag all transmission hydraulic oil hoses. 1. 2. 3. Trace and tag three hoses (Figure 2, Items 1, 3, and 4) from transmission oil filter head (Figure 2, Item 10) to transmission (Figure 2, Item 6). Cut tiedown straps as needed to release hoses (Figure 2, Items 1, 3, and 4). Remove screw (Figure 2, Item 7), nut (Figure 2, Item 10), washer (Figure 2, Item 9), and two clamps (Figure 2, Item 5) from hoses (Figure 2, Items 1 and 3).

WARNING
Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. 4. Position suitable container to catch lubricating oil contained in hoses (Figure 2, Items 1, 3, and 4).

NOTE
Note hose routing when removing hoses to aid in installation of hoses. 5. 6. 7. Disconnect hoses (Figure 2, Items 1, 3, and 4) from transmission oil filter head (Figure 2, Item 10). Disconnect opposite ends of hoses (Figure 2, Items 1, 3, and 4) from three adapter fittings (Figure 2, Item 2). Remove hoses. If damaged, remove adapter fittings (Figure 2, Item 2) from transmission (Figure 2, Item 6).

END OF TASK TRANSMISSION-TO-OIL FILTER HOSES INSTALLATION 1. 2. 3. 4. If removed, apply pipe sealant to threads of adapter fittings (Figure 2, Item 2) and install fittings in transmission (Figure 2, Item 6). Connect hoses (Figure 2, Items 1, 3, and 4) to three adapter fittings (Figure 2, Item 2). Route hoses (Figure 2, Items 1, 3, and 4) as noted in removal and connect opposite ends of hoses to transmission oil filter head (Figure 2, Item 10). Install two hose clamps (Figure 2, Item 5), screw (Figure 2, Item 7), washer (Figure 2, Item 9), and nut (Figure 2, Item 8) on hoses (Figure 2, Items 1 and 3).

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TM 10-3930-675-23-2

0142

TRANSMISSION-TO-OIL FILTER HOSES INSTALLATION - Continued
2 3 2 2

4 1 5

6

10 5 7,8,9
M0310JCH

Figure 2. Transmission-to-Oil Filter Hose Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Check transmission oil level and add oil as needed (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks. Install transmission access covers (WP 0175). Install engine cover (WP 0185). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0143

FIELD MAINTENANCE FRONT AND REAR PROPELLER SHAFTS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 1/2 In. Drive, 250 ft-lb (WP 0277, Table 1, Item 95) Materials/Parts Cleaning Compound, Solvent (WP 0276, Table 1, Item 10) Materials/Parts (cont.) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 107) Qty: 48 Washer, Lock (WP 0278, Table 1, Item 119) Qty: 48 Personnel Required (2) Equipment Condition Vehicle wheels chocked (TM 10-3930-675-10) Transmission shift lever set to N (TM 10-3930-675-10)

WARNING
Propeller shafts are heavy; they weigh 121 lb (55 kg) each. Support end of propeller shaft as nuts or screws are removed to prevent shaft from falling. Failure to follow this warning may result in serious injury to personnel.

CAUTION
Place witness marks at slip joint and propeller shaft housing to aid in reassembly, in the event propeller shaft becomes separated. Failure to follow this caution may result in excessive vibration in propeller shaft and transmission damage.

NOTE
Note position of propeller shaft on vehicle to aid in installation.

0143-1

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TM 10-3930-675-23-2

0143

FRONT PROPELLER SHAFT REMOVAL

NOTE
Perform the following steps at front of front propeller shaft. 1. 2. Remove 12 locknuts (Figure 1, Item 3) and lockwashers (Figure 1, Item 2) from flange of propeller shaft (Figure 1, Item 4). Discard locknuts and lockwashers. Remove propeller shaft (Figure 1, Item 4) from studs of parking brake disc (Figure 1, Item 1) on front axle (Figure 1, Item 5).
2,3 4

1

5
M0326JCH

Figure 1. Front Propeller Shaft Removal.

NOTE
Perform the following steps at rear of front propeller shaft. 3. 4. Remove 12 screws (Figure 2, Item 2), lockwashers (Figure 2, Item 3), and locknuts (Figure 2, Item 4) from flange of propeller shaft (Figure 2, Item 1). Discard lockwashers and locknuts. Remove propeller shaft (Figure 2, Item 1) from flange of transmission (Figure 2, Item 5) and remove propeller shaft from vehicle.

0143-2

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TM 10-3930-675-23-2

0143

FRONT PROPELLER SHAFT REMOVAL - Continued
1 2,3.4

5

M0327JCH

Figure 2. END OF TASK CLEANING AND INSPECTION

Front Propeller Shaft Removal.

WARNING

DRY CLEANING SOLVENT Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 20°F (94°C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. 1. 2. Clean propeller shaft completely with solvent and brush. Inspect propeller shaft for: a. Smooth, complete universal joint rotation. b. Universal joint clip integrity. c. Absence of dents in shaft. d. Missing weights. Replace propeller shaft or universal joint parts as necessary. Maneuver flange through complete range of motion. Motion should be smooth, with no sticking or rough spots. Replace parts as necessary.

3. 4.

END OF TASK

0143-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 10-3930-675-23-2

0143

FRONT PROPELLER SHAFT INSTALLATION

NOTE
• Perform the following steps at rear of front propeller shaft. • Ensure witness marks are aligned. 1. 2. Position propeller shaft (Figure 2, Item 1) on flange of transmission (Figure 2, Item 5). Install 12 screws (Figure 2, Item 2), new lockwashers (Figure 2, Item 3), and new locknuts (Figure 2, Item 4). Tighten locknuts to 85 ft-lb (115 N•m).

NOTE
Perform the following steps at front of front propeller shaft. 3. 4. Position propeller shaft (Figure 1, Item 4) on studs of parking brake disc (Figure 1, Item 1) on front axle (Figure 1, Item 5). Install 12 new lockwashers (Figure 1, Item 2) and new locknuts (Figure 1, Item 3). Tighten locknuts to 85 ft-lb (115 N•m).

END OF TASK REAR PROPELLER SHAFT REMOVAL

NOTE
Perform the following steps at front of rear propeller shaft. 1. 2. Remove 12 screws (Figure 3, Item 1), lockwashers (Figure 3, Item 2), and locknuts (Figure 3, Item 3) from flange of propeller shaft (Figure 3, Item 4). Discard lockwashers and locknuts. Remove propeller shaft (Figure 3, Item 4) from flange of transmission (Figure 3, Item 5).

4 1,2,3

5
M0328JCH

Figure 3.

Rear Propeller Shaft Removal.

0143-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 10-3930-675-23-2

0143

REAR PROPELLER SHAFT REMOVAL - Continued

NOTE
Perform the following steps at rear of rear propeller shaft. 3. 4. Remove 12 locknuts (Figure 4, Item 2) and lockwashers (Figure 4, Item 3) from flange of propeller shaft (Figure 4, Item 1). Discard locknuts and lockwashers. Remove propeller shaft (Figure 4, Item 1) from studs of parking brake disc (Figure 4, Item 4) on rear axle (Figure 4, Item 5) and remove propeller shaft from vehicle.
1

2,3

4 5

M0329JCH

Figure 4. END OF TASK

Rear Propeller Shaft Removal.

0143-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00110)

TM 10-3930-675-23-2

0143

CLEANING AND INSPECTION

WARNING

DRY CLEANING SOLVENT Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 20°F (94°C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately. 1. 2. Clean propeller shaft completely with solvent and brush. Inspect propeller shaft for: a. Smooth, complete universal joint rotation. b. Universal joint clip integrity. c. Absence of dents in shaft. d. Missing weights. Replace propeller shaft or universal joint parts as necessary. Maneuver flange through complete range of motion. Motion should be smooth, with no sticking or rough spots. Replace parts as necessary.

3.

END OF TASK REAR PROPELLER SHAFT INSTALLATION

NOTE
• Perform the following steps at rear of rear propeller shaft. • Ensure witness marks are aligned. 1. 2. Position propeller shaft (Figure 4, Item 1) on studs of parking brake disc (Figure 4, Item 4) on rear axle (Figure 4, Item 5). Install 12 new lockwashers (Figure 4, Item 3) and new locknuts (Figure 4, Item 2). Tighten locknuts to 85 ft-lb (115 N•m).

NOTE
Perform the following steps at front of rear propeller shaft. 3. 4. Position propeller shaft (Figure 5, Item 1) on flange of transmission (Figure 5, Item 5). Install 12 screws (Figure 5, Item 1), new lockwashers (Figure 5, Item 2), and new locknuts (Figure 5, Item 3). Tighten locknuts to 85 ft-lb (115 N•m).

0143-6

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TM 10-3930-675-23-2

0143

REAR PROPELLER SHAFT INSTALLATION - Continued

4 1,2,3

5
M0330JCH

Figure 5. END OF TASK FOLLOW-On MAINTENANCE

Rear Propeller Shaft Installation.

Set parking brake and remove wheel chocks (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0143-7/8 blank

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TM 10-3930-675-23-2

0144

FIELD MAINTENANCE UNIVERSAL JOINT REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Clamp, C (WP 0277, Table 1, Item 16) Vise, Machinist's, 4 In. (WP 0277, Table 1, Item 87) Materials/Parts Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) References LO 10-3930-675-13 Equipment Condition Propeller shaft removed (WP 0143)

0144-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00111)

TM 10-3930-675-23-2

0144

REMOVAL

NOTE
Universal joint at each end of propeller shaft is replaced the same way. 1. 2. 3. 4. 5. 6. 7. Remove two retaining rings (Figure 1, Item 5) from flanged yoke (Figure 1, Item 4) of propeller shaft. Using C-clamp, push downward on one bearing cap (Figure 1, Item 6) to remove opposite bearing cap from flanged yoke (Figure 1, Item 4). Rotate flanged yoke (Figure 1, Item 4) 180 degrees and push downward on end of tee (Figure 1, Item 7) to remove other bearing cap (Figure 1, Item 6). Remove flanged yoke (Figure 1, Item 4) from tee (Figure 1, Item 7). Remove two retaining rings (Figure 1, Item 3) from yoke (Figure 1, Item 1) of propeller shaft. Using C-clamp, push downward on one bearing cap (Figure 1, Item 2) to remove opposite bearing cap from yoke (Figure 1, Item 1) of propeller shaft. Rotate propeller shaft 180 degrees and press downward on end of tee (Figure 1, Item 7) to remove other bearing cap (Figure 1, Item 2).

NOTE
Note position of tee and grease fitting for installation 8. 9. Remove tee (Figure 1, Item 7) from yoke (Figure 1, Item 1) of propeller shaft. Remove grease fitting (Figure 1, Item 8) from tee (Figure 1, Item 7).

END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Install grease fitting (Figure 1, Item 8) in tee (Figure 1, Item 7). Position tee (Figure 1, Item 7) loosely into yoke (Figure 1, Item 1) of propeller shaft. Install bearing cap (Figure 1, Item 2) into one side of yoke (Figure 1, Item 1) of propeller shaft. Rotate propeller shaft 180 degrees and install other bearing cap (Figure 1, Item 2) in other side of yoke (Figure 1, Item 1). Ensure bearing caps and tee (Figure 1, Item 7) are centered. Install two retaining rings (Figure 1, Item 3) on propeller shaft. Position flange yoke (Figure 1, Item 4) loosely on tee (Figure 1, Item 7). Install bearing cap (Figure 1, Item 6) into one side of flanged yoke (Figure 1, Item 4). Rotate flanged yoke (Figure 1, Item 4) 180 degrees and install other bearing cap (Figure 1, Item 6) in other side of flanged yoke. Ensure bearing caps and tee (Figure 1, Item 7) are centered. Install two retaining rings (Figure 1, Item 5) on flanged yoke (Figure 1, Item 4).

0144-2

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TM 10-3930-675-23-2

0144

INSTALLATION - Continued
2 1 4 3

5 8 7 6
M0332JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Propeller Shaft Universal Joint Replacement.

Lubricate grease fitting (Figure 1, Item 8) (LO 10-3930-675-13). Install propeller shaft (WP 0143).

END OF TASK END OF WORK PACKAGE

0144-3/4 blank

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TM 10-3930-675-23-2

0145

FIELD MAINTENANCE FRONT AXLE ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Jack, Bottle, Hydraulic, Hand, 30 Ton (WP 0277, Table 1, Item 44) Multiplier, Torque (WP 0277, Table 1, Item 53) Pan, Drain (WP 0277, Table 1, Item 54) Socket Set, 3/4 In. Drive, Regular Length, Standard (WP 0277, Table 1, Item 71) Wrench, Torque, Click, Ratcheting, 3/4 In. Drive, 600 ft-lb (WP 0277, Table 1, Item 96) Lifting Device, 10,000-lb Capacity Materials/Parts Washer, Lock (WP 0278, Table 1, Item 123) Qty: 16 Personnel Required (3) References LO 10-3930-675-13 References (cont.) Volume 1, WP 0047 Volume 1, WP 0117 Volume 1, WP 0125 WP 0149 WP 0157 WP 0162 WP 0171 WP 0174 WP 0227 Equipment Condition Vehicle parked on level, hard surface (TM 10-3930-675-10) Rear wheels chocked (TM 10-3930-675-10) Ignition switch and master battery switch in OFF position (TM 10-3930-675-10) Boom raised as required (TM 10-3930-675-10) Brake and steering hydraulic system pressure relieved (WP 0204) Front fender assemblies removed (WP 0190) Front propeller shaft removed (WP 0143)

WARNING

• Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to perform maintenance. DO NOT get under vehicle after it is raised unless it is properly supported with blocks or other suitable cribbing. Failure to observe this warning may result in death or injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • This procedure, as written, uses a Truck, Forklift as a suitable lifting device. Some necessary deviations from these tasks may apply, depending on the suitable lifting device being used. • Truck, Forklift used to replace front axle assembly must have a 10,000-lb capacity to ensure task is performed in a safe manner. Failure to follow this warning may result in death or injury to personnel.

0145-1

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TM 10-3930-675-23-2

0145

REMOVAL

NOTE
Blocking both sides of rear axle will prevent vehicle from tilting when front of vehicle is raised. 1. 2. 3. 4. Block (Figure 1, Item 1) left and right sides of rear axle (Figure 1, Item 2) between axle and axle stops. Place two hydraulic jacks under front axle (Figure 1, Item 3) as shown. Raise jacks to contact bottom of axle and lift. Place wood blocks under front of vehicle frame (Figure 1, Item 4) close to hydraulic jacks. Lower jacks and support frame on wood blocks. Repeat Steps 2 and 3 on opposite side of front axle.

1

2

3

4

M0915JCH

Figure 1. Front Axle Removal.

0145-2

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TM 10-3930-675-23-2

0145

REMOVAL - Continued 5. 6. Drain front axle differential (LO 10-3930-675-13). Remove front wheel and tire assemblies (WP 0162).

NOTE
Axle must be removed with all local connecting lines, fittings, and assorted parts intact. 7. 8. 9. 10. 11. Trace main hydraulic supply and return lines (Figure 2, Item 2) to junction box (Figure 2, Item 4), located above axle center section. Disconnect and cap lines and fittings from junction box. Disconnect breather line (Figure 2, Item 3) from top of axle (Figure 2, Item 1) center section. Remove and cap parking brake hydraulic pressure line (Figure 2, Item 5). Disconnect wheel temperature sensor at connector on left end of axle (Volume 1, WP 0117). Remove steering system wheel sensors (Volume 1, WP 0125). Hang sensors on main frame.
1 2,3 4 2

5

M0916JCH

Figure 2.

Front Axle Removal.

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TM 10-3930-675-23-2

0145

REMOVAL - Continued 12. 13. For vehicles with autolube, disconnect front wheel autolube main supply lines. Using forklift truck, firmly support front axle (Figure 3, Item 2).

NOTE
• Width of fork tines outside-to-outside should be 27 inch (68.6 cm). • Front face of axle should be 3 ft (91.4 cm) away from forklift back plate. 14. Remove eight nuts (Figure 3, Item 3), bolts (Figure 3, Item 4), and sixteen lockwashers (Figure 3, Item 5) to free front axle (Figure 3, Item 2) from vehicle frame (Figure 3, Item 1). Discard lockwashers.
1

2

27

IN

3,4,5

(6

8 .6

CM

)

3 FT

( 91.

4 CM

)

3,4,5
M0917JCH

Figure 3. Front Axle Removal.

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TM 10-3930-675-23-2

0145

REMOVAL - Continued 15. With forklift truck, lower front axle (Figure 4, Item 2) to clear vehicle frame (Figure 4, Item 1) lineup pins and move front axle to work area. Place axle on wood blocks or trestles, next to replacement axle.
1

2

27

IN

(6

8 .6

CM

)

3 FT

( 91.

) 4 CM

M0918JCH

Figure 4.

Front Axle Removal.

0145-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00112)

TM 10-3930-675-23-2

0145

REMOVAL - Continued

NOTE
Using the removed axle as a pattern and the work packages as references, transfer all local connecting lines, fittings, and assorted parts to the new axle. 16. 17. 18. 19. 20. Remove and install front parking brake cylinder (WP 0149). Remove and install front steering cylinders (WP 0171). Remove and install front brake lines and brackets (WP 0157). Remove and install wheel temperature sensors (Volume 1, WP 0117). For vehicles with autolube, remove and install autolube junction boxes (Figure 5, Item 2) and local connecting lines (Figure 5, Item 1) that supply front wheel spindle area components and steering cylinder pivot points.

1

2
Figure 5. Front Axle Removal. END OF TASK INSTALLATION 1. Using forklift truck, lift and move front axle (Figure 6, Item 2) to vehicle.

M0919JCH

NOTE
Two or more bolts inserted through frame from above may be used to help align axle with frame. 2. Align front axle (Figure 6, Item 2) with front of vehicle frame (Figure 6, Item 1). Install axle on frame with eight bolts (Figure 6, Item 4), sixteen new lockwashers (Figure 6, Item 5), and eight nuts (Figure 6, Item 3). Tighten nuts securely to hold axle in place. Final torque will be applied when tires and wheels have been installed and vehicle is sitting on ground. Move forklift truck away from vehicle. Reconnect main hydraulic supply lines to junction box located above axle.

3. 4.

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TM 10-3930-675-23-2

0145

INSTALLATION - Continued 5. 6. Connect breather line to top of axle center section. Replace steering system wheel sensors (Volume 1, WP 0125).

NOTE
For the vehicles with autolube, connect the main supply lines of the autolube that feed the front wheel areas. 7. 8. 9. 10. 11. 12. Install front wheel and tire assemblies (WP 0162). Using two hydraulic jacks under one end of axle, remove wood blocks from under the frame and lower vehicle to the ground. Repeat procedure on the opposite end of axle. Remove blocks from left and right sides of rear axle. Using torque wrench and torque multiplier, tighten eight nuts (Figure 6, Item 3) to 1,733 ft-lb (2,350 N•m). Install front propeller shaft (WP 0143). Install a jumper between pins of the wheel temperature sensor connector, at the connector end attached to the vehicle wiring harness (Volume 1, WP 0117). This will allow filling of the wheel cooling areas and will be removed and the sensor connected using standard method in Step 10 of Follow-On Maintenance below.
1

2

27

IN

3,4,5

(6

8 .6

CM

)

(9 3 FT

M) 1 .4 C

3,4,5
M0920JCH

Figure 6. END OF TASK

Front Axle Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00112)

TM 10-3930-675-23-2

0145

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Install front fender assemblies (WP 0190). Fill front axle differential (Volume 1, WP 0048) and check for leaks. Fill front axle hub ends (Volume 1, WP 0048) and check for leaks. Start engine and bring hydraulic oil temperature to 150°F. Perform steering calibration (WP 0174). Operate machine 100 feet forward and then 100 feet in reverse, 10 times, at a speed of no greater than 5 mph.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 7. 8. 9. 10. 11. Stop the machine and turn the ignition switch and master battery switch to OFF position. Relieve the steering hydraulic system pressure (WP 0204). Remove the jumper between the pins at the wheel temperature sensor connector at the connector end attached to the vehicle wiring harness. Connect the sensor to the wiring harness in the standard manner (Volume 1, WP 0117). Check for leaks and recheck oil levels in axle (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0146

FIELD MAINTENANCE TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Sealing Compound (WP 0276, Table 1, Item 55) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Nut, Self-Locking, Clinch (WP 0278, Table 1, Item 86) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 87) References WP 0175 WP 0185

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0146

FRONT AXLE VENT HOSE REMOVAL 1. 2. 3. 4. Remove engine cover (WP 0185). Remove locknut (Figure 1, Item 1), two washers (Figure 1, Item 2), screw (Figure 1, Item 3), and clamp (Figure 1, Item 6) holding front axle vent (Figure 1, Item 4) to plate (Figure 1, Item 5). Discard locknut. Remove clamp (Figure 1, Item 6) from front axle vent (Figure 1, Item 4). Remove front axle vent (Figure 1, Item 4) from vent hose (Figure 1, Item 7).
1,2,3 4 5

6

7

M0319JCH

Figure 1. 5. 6. 7.

Front Axle Vent Hose Removal.

At top-left of front axle (Figure 2, Item 1), disconnect other end of vent hose (Figure 2, Item 2) from adapter (Figure 2, Item 3). Remove adapter (Figure 2, Item 3) from front axle (Figure 2, Item 1). Remove tiedown straps as necessary and remove front axle vent hose (Figure 2, Item 2) from vehicle. Discard tiedown straps.

END OF TASK

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0146

FRONT AXLE VENT HOSE INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Position front axle vent hose (Figure 2, Item 2) on vehicle Apply sealing compound to threads of adapter (Figure 2, Item 3) and install adapter in front axle (Figure 2, Item 1). Connect end of vent hose (Figure 2, Item 2) to adapter (Figure 2, Item 3). At other end of vent hose (Figure 1, Item 7), install front axle vent (Figure 1, Item 4). Install clamp (Figure 1, Item 6) around front axle vent (Figure 1, Item 4). Install clamp (Figure 1, Item 6) on plate (Figure 1, Item 5) with screw (Figure 1, Item 3), two washers (Figure 1, Item 2), and new locknut (Figure 1, Item 1). Install new tiedown straps. Install engine cover (WP 0185).
1 2 3

M0321JCH

Figure 2. END OF TASK

Front Axle Vent Hose Replacement.

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TM 10-3930-675-23-2

0146

REAR AXLE VENT HOSE REMOVAL 1. 2. 3. Remove screw (Figure 3, Item 3), washer (Figure 3, Item 4), and clamp (Figure 3, Item 1) holding rear axle vent (Figure 3, Item 2) to frame (Figure 3, Item 5) of vehicle. Remove clamp (Figure 3, Item 1) from rear axle vent (Figure 3, Item 2). Remove rear axle vent (Figure 3, Item 2) from vent hose (Figure 3, Item 6).
2 1 3,4

5

6

M0322JCH

Figure 3. Rear Axle Vent Hose Replacement. 4. 5. 6. At top right of rear axle (Figure 4, Item 2), disconnect other end of vent hose (Figure 4, Item 3) from adapter (Figure 4, Item 1). Remove adapter (Figure 4, Item 1) from rear axle (Figure 4, Item 2). Remove tiedown straps as necessary and remove rear axle vent hose (Figure 4, Item 3) from vehicle. Discard tiedown straps.

END OF TASK

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TM 10-3930-675-23-2

0146

REAR AXLE VENT HOSE INSTALLATION 1. 2. 3. 4. 5. 6. 7. Position rear axle vent hose (Figure 4, Item 3) on vehicle. Apply sealing compound to threads of adapter (Figure 4, Item 1) and install adapter in rear axle (Figure 4, Item 2). Connect end of vent hose (Figure 4, Item 3) to adapter (Figure 4, Item 1). At other end of vent hose (Figure 3, Item 6), install rear axle vent (Figure 3, Item 2). Install clamp (Figure 3, Item 1) around rear axle vent (Figure 3, Item 2). Install clamp (Figure 3, Item 1) on frame (Figure 3, Item 5) of vehicle with washer (Figure 3, Item 4) and screw (Figure 3, Item 3). Install new tiedown straps.
2 1

3

M0323JCH

Figure 4. END OF TASK

Rear Axle Vent Hose Replacement.

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TM 10-3930-675-23-2

0146

TRANSMISSION VENT HOSE REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove engine cover (WP 0185). Remove transmission front access cover (WP 0175). Remove locknut (Figure 5, Item 7), two washers (Figure 5, Item 8), screw (Figure 5, Item 9), and clamp (Figure 5, Item 2) holding transmission vent (Figure 5, Item 1) to bracket (Figure 5, Item 6). Discard locknut. Remove clamp (Figure 5, Item 2) from transmission vent (Figure 5, Item 1). Remove transmission vent (Figure 5, Item 1) from vent hose (Figure 5, Item 3). At top of transmission (Figure 5, Item 5), disconnect other end of vent hose (Figure 5, Item 3) from adapter (Figure 5, Item 4). Remove adapter (Figure 5, Item 4) from transmission (Figure 5, Item 5). Remove tiedown strap and remove transmission vent hose (Figure 5, Item 3) from vehicle. Discard tiedown strap.

END OF TASK TRANSMISSION VENT HOSE INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. Position transmission vent hose (Figure 5, Item 3) on vehicle. Apply sealing compound to threads of adapter (Figure 7, Item 4) and install adapter in top of transmission (Figure 5, Item 5). Connect end of vent hose (Figure 5, Item 3) to adapter (Figure 5, Item 4). At other end of vent hose (Figure 5, Item 3), install transmission vent (Figure 5, Item 1). Install clamp (Figure 5, Item 2) around transmission vent (Figure 5, Item 1). Install clamp (Figure 5, Item 2) on bracket (Figure 5, Item 6) with screw (Figure 5, Item 9), two washers (Figure 5, Item 8), and new locknut (Figure 5, Item 7). Install new tiedown strap. Install transmission front access cover (WP 0175). Install engine cover (WP 0185).

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TM 10-3930-675-23-2

0146

TRANSMISSION VENT HOSE INSTALLATION - Continued
1 2 3

7,8,9

6

4

5

M0325JCH

Figure 5. Transmission Vent Hose Replacement. END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00113)

TM 10-3930-675-23-2

0147

FIELD MAINTENANCE REAR AXLE ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Jack, Bottle, Hydraulic, Hand, 30 Ton (WP 0277, Table 1, Item 44) Shackle (WP 0277, Table 1, Item 67) Sling, Eye (WP 0277, Table 1, Item 69) Suitable Lifting Device Materials/Parts Antiseize Compound (WP 0276, Table 1, Item 7) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) O-Ring (WP 0278, Table 1, Item 140) Qty: 2 Personnel Required (3) References LO 10-3930-675-13 WP 0162 References (cont.) WP 0174 WP 0227 Equipment Condition Vehicle parked on level, hard surface (TM 10-3930-675-10) Front wheels chocked (TM 10-3930-675-10) Bogie wheel assembly removed (WP 0163) Cab and boom support in transport position (TM 10-3930-675-10) Rear propeller shaft removed (WP 0143) Rear parking brake cylinder removed (WP 0149) Rear brake hydraulic hoses and fittings removed (WP 0157) Rear steering sensors removed (Volume 1, WP 0125) Rear wheel temperature sensors removed (Volume 1, WP 0117) Rear steering cylinders removed (WP 0171) Rear fender assembles removed (WP 0190)

WARNING

• Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to perform maintenance. DO NOT get under vehicle after it is raised unless it is properly supported with blocks or other suitable cribbing. Failure to observe this warning may result in death or injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 10-3930-675-23-2

0147

REMOVAL 1. 2. 3. Remove two rear wheel and tire assemblies (WP 0162). Place two hydraulic jacks under flat section of vehicle frame in front of rear axle. Raise jacks to contact bottom of frame. Ensure jacks are positioned securely under frame. Using hydraulic jacks under frame, raise frame to 36 In. (94.44 cm) height as indicated in Rear Axle Rigging diagram and remove two hydraulic jacks (WP 0162) from under rear axle.

68 IN. (172.72 CM) STRAP TWO REQUIRED SHACKLE AND PIN TWO REQUIRED

144 IN. (365.76 CM) STRAP TWO REQUIRED

36 IN. (94.44 CM) REAR VEHICLE AXLE FRAME REAR AXLE RIGGING

M0921JCH

Figure 1. 4. 5. 6. 7. 8.

Rear Axle Rigging.

Place wood blocks or trestles under vehicle frame in front of, and close to, hydraulic jacks. Lower jacks and support frame on wood blocks. For vehicles with autolube, remove the autolube junction boxes and local connecting lines that supply the rear wheel spindle area components and steering cylinder pivot points. Assemble rigging on rear axle as shown. Attach rigging to suitable lifting device and support rear axle. At rear of rear axle (Figure 2, Item 8), remove 12 screws (Figure 2, Item 4) and washers (Figure 2, Item 5) holding shaft (Figure 2, Item 6) flange to crossmember (Figure 2, Item 1). At front of rear axle (Figure 2, Item 8), remove 12 screws (Figure 2, Item 12), washers (Figure 2, Item 13), and cover (Figure 2, Item 14). Remove O-ring (Figure 2, Item 9) and grease fitting (Figure 2, Item 10) from cover. Discard O-ring.

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TM 10-3930-675-23-2

0147

REMOVAL - Continued

NOTE
Raise or lower rear axle slightly, as necessary, for ease in shaft removal. 9. Remove shaft (Figure 2, Item 6) holding rear axle (Figure 2, Item 8) to crossmembers (Figure 2, Items 1 and 11). Remove O-ring (Figure 2, Item 2) and grease fitting (Figure 2, Item 3) from shaft flange. Discard O-ring. Lower rear axle (Figure 2, Item 8) to clear frame (Figure 2, Item 7) and move rear axle away from vehicle. Place axle on wood blocks or trestles. Remove rigging.
3 2 5 1 6 7 4

10.

14

8 9 12,13 10 11
M0922JCH

Figure 2. END OF TASK

Rear Axle Removal.

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TM 10-3930-675-23-2

0147

INSTALLATION 1. 2. 3. 4. Assemble rigging on rear axle (Figure 3, Item 8). Refer to Rear Axle Rigging diagram (Figure 1). Attach rigging to suitable lifting device. Position rear axle (Figure 3, Item 8) on vehicle. Apply antiseize compound to shaft (Figure 3, Item 6) bearing surface. Install grease fitting (Figure 3, Item 3) and new O-ring (Figure 3, Item 2) on shaft (Figure 3, Item 6) flange.

NOTE
Adjust position of rear axle slightly to ensure accurate alignment of rear axle with crossmembers. 5. 6. Install shaft (Figure 3, Item 6) through crossmembers (Figure 3, Items 1 and 11) and rear axle (Figure 3, Item 8). At front of rear axle (Figure 3, Item 8), install grease fitting (Figure 3, Item 10) and new O-ring (Figure 3, Item 9) on cover (Figure 3, Item 14). Install cover on crossmember (Figure 3, Item 11) with 12 washers (Figure 3, Item 13) and screws (Figure 3, Item 12). At rear of rear axle (Figure 3, Item 8), install shaft (Figure 3, Item 6) flange on crossmember (Figure 3, Item 1) with 12 washers (Figure 3, Item 5) and screws (Figure 3, Item 4). Install two rear wheel and tire assemblies (WP 0162). Remove rigging from rear axle. Position and raise two hydraulic jacks to support vehicle frame (Figure 3, Item 7) and remove trestles or wood blocks. Lower and remove hydraulic jacks from under frame (Figure 3, Item 7). For vehicles with autolube, install the autolube junction boxes and local connecting lines that supply the rear wheel spindle area components and steering cylinder pivot point.

7. 8. 9. 10. 11. 12.

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TM 10-3930-675-23-2

0147

INSTALLATION - Continued
3 2 5 1 6 7 4

14

8 9 12,13 10 11
M0923JCH

Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Install rear fender assemblies (WP 0190). Install rear steering cylinders (WP 0171).

Rear Axle Installation.

Install rear wheel temperature sensors (Volume 1, WP 0117). Install rear brake lines and brackets (WP 0157). Install rear parking brake cylinder (WP 0149). Install rear propeller shaft (WP 0143). Return cab and boom support to operational position (TM 10-3930-675-10). Install bogie wheel assembly (WP 0163). Apply grease to two grease fittings (Figure 3, Items 3 and 10) (LO 10-3930-675-13). Fill rear axle differential. Check and/or fill hub end of new axle (LO 10-3930-675-13). Remove blocks from front wheels. Install rear steering sensors (Volume 1, WP 0125).

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00114)

TM 10-3930-675-23-2

0147

FOLLOW-ON MAINTENANCE - Continued 13. Install a jumper between pins of the wheel temperature sensor connector, at the connector end attached to the vehicle wiring harness (Volume 1, WP 0117). This will allow filling of the wheel cooling areas and will be removed and the sensor connected in the standard manner later in this work package. Start engine and bring hydraulic oil temperature to 150°F. Perform steering calibration (WP 0174). Operate machine 100 feet forward and then 100 feet in reverse, 10 times, at a speed of no greater than 5 mph.

14. 15. 16.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 17. 18. 19. 20. Stop the machine turn the Ignition Switch and Master Battery Switch to the OFF position. Remove the jumper between pins of the wheel temperature sensor connector, at the end attached to the vehicle wiring harness (Volume 1, WP 0117). Connect the sensor to the wiring harness in the standard manner. Check for leaks and recheck oil levels in axle (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0148

FIELD MAINTENANCE CAGING AND UNCAGING PARKING BRAKE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Equipment Condition Wheels chocked (TM 10-3930-675-10) Equipment Condition (cont.) Parking brake released (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204)

0148-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 10-3930-675-23-2

0148

NOTE
• Caging/uncaging procedures at front and rear parking brake are the same. • In order to tow a disabled RTCH, the following procedure must be performed at front and rear parking brakes to cage/uncage parking brakes. CAGING

NOTE
A strap wrench may be required to remove cover. 1. Remove cover (Figure 1, Item 1).
1

M0334JCH

Figure 1. Caging Parking Brake. 2. Loosen jamnut (Figure 2, Item 2).
1

2

M0335JCH

Figure 2. Caging Parking Brake.

0148-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00115)

TM 10-3930-675-23-2

0148

CAGING - Continued 3. Loosen adjusting screw (Figure 2, Item 1) until brake disk pad (Figure 3, Item 1) moves freely.
1

2

M0336JCH

Figure 3. 4.

Caging Parking Brake.

Hand-tighten jamnut (Figure 2, Item 2). Reinstall cover (Figure 1, Item 1).

END OF TASK UNCAGING 1. 2. 3. 4. Remove cover (Figure 1, Item 1). Loosen jamnut (Figure 2, Item 2). Tighten adjusting screw (Figure 2, Item 1) until brake disk pad (Figure 3, Item 1) contacts rotor (Figure 3, Item 2). Retighten jamnut. With parking brake released in cab, ensure there is a gap between brake disk pad (Figure 3, Item 1) and rotor (Figure 3, Item 2). Loosen jamnut (Figure 2, Item 2). Tighten adjusting screw (Figure 2, Item 1) until contact is made between brake disk pad (Figure 3, Item 1) and rotor (Figure 3, Item 2), then back off adjusting screw 4/5 turn. Gap should be 0.04 to 0.08 inch (1 to 2 mm). Tighten jamnut (Figure 2, Item 2). Install cover (Figure 1, Item 1). Replace O-ring only if damaged. Install cover hand-tight.

5. 6.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Apply parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0148-3/4 blank

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TM 10-3930-675-23-2

0149

FIELD MAINTENANCE PARKING BRAKE CYLINDER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Goggles, Industrial (WP 0277, Table 1, Item 34) Multiplier, Torque (WP 0277, Table 1, Item 53) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Wrench, Torque, Click, Ratcheting, 3/4 In. Drive, 600 ft-lb (WP 0277, Table 1, Item 96) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Rag, Wiping (WP 0276, Table 1, Item 50) Wire, Nonelectrical (WP 0276, Table 1, Item 70) Materials/Parts (cont.) Pin, Cotter (WP 0278, Table 1, Item 124) O-Ring (WP 0278, Table 1, Item 125) Qty: 2 Parts Kit, Seal Replacement (WP 0278, Table 1, Item 129) References LO 10-3930-675-13 WP 0143 Equipment Condition Wheels chocked (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204) Parking brake pads removed (WP 0150)

NOTE
• Maintenance tasks for parking brake cylinder at front axle and rear axle are performed the same way. • After performance of this task, replace hydraulic reservoir return filters after 100 hours of operation (WP 0143).

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TM 10-3930-675-23-2

0149

PARKING BRAKE CYLINDER REMOVAL

NOTE
A strap wrench may be required to remove cover. 1. Remove cover (Figure 1, Item 5) and O-ring (Figure 1, Item 7) from pressure ring (Figure 1, Item 3). Remove and discard O-ring only if damaged.

WARNING

Parking brake is under spring tension. Parts could become loose and fly out suddenly if parking brake is not correctly disassembled. Be sure to follow instructions in step 2 before proceeding to avoid injury to personnel. 2. 3. 4. 5. Loosen nut (Figure 1, Item 4) and remove adjusting screw (Figure 1, Item 6) from adjusting cylinder (Figure 1, Item 8). Position adjusting screw back into adjusting cylinder a few turns. Position cover (Figure 1, Item 5) back onto pressure ring (Figure 1, Item 3) a few turns. Remove cotter pin (Figure 1, Item 13) from one remaining castle nut (Figure 1, Item 12). Discard cotter pin. Remove castle nut (Figure 1, Item 12), bolt (Figure 1, Item 14), and parking brake cylinder (Figure 1, Item 2) from rotor (Figure 1, Item 11) and parking brake bracket (Figure 1, Item 1). Support parking brake cylinder with nonelectrical wire.

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure. 6. Disconnect hydraulic hose (Figure 1, Item 10) from fitting (Figure 1, Item 9) and remove parking brake cylinder (Figure 1, Item 2) from vehicle.

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TM 10-3930-675-23-2

0149

PARKING BRAKE CYLINDER REMOVAL - Continued
1 2

3 4 14 13 12 5 6

7 11 8

9

10

M0924JCH

Figure 1. END OF TASK

Parking Brake Cylinder Removal.

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TM 10-3930-675-23-2

0149

PARKING BRAKE CYLINDER INSTALLATION 1. 2. Support parking brake cylinder (Figure 2, Item 2) on vehicle with nonelectrical wire and connect hydraulic hose (Figure 2, Item 5) to fitting (Figure 2, Item 4). Install parking brake cylinder (Figure 2, Item 2) on rotor (Figure 2, Item 6) and parking brake bracket (Figure 2, Item 1) with one of two bolts (Figure 2, Item 9) and one of two castle nuts (Figure 2, Item 7). Remove nonelectrical wire. Install new cotter pin (Figure 2, Item 8) in one of two castle nuts (Figure 2, Item 7). Install parking brake pads (WP 0150). Start engine (TM 10-3930-675-10) to provide hydraulic pressure.

3. 4. 5.

WARNING

Wear eye protection when opening bleeder valve to avoid eye injury. 6. Open bleeder valve (Figure 2, Item 3) slowly until air and a small quantity of hydraulic oil is expelled. Close bleeder valve.

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TM 10-3930-675-23-2

0149

PARKING BRAKE CYLINDER INSTALLATION - Continued
2

1

3

9 8 7

6

4

5
M0926JCH

Figure 2. END OF TASK

Parking Brake Cylinder Installation.

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TM 10-3930-675-23-2

0149

PARKING BRAKE ROTOR REMOVAL

NOTE
Front and rear parking brake rotors are removed the same way. 1. 2. 3. Remove front or rear propeller shaft (WP 0143). Remove parking brake cylinder (refer to Parking Brake Cylinder Removal in this work package). Remove parking brake rotor (Figure 3, Item 1) from 12 bolts (Figure 3, Item 2).

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TM 10-3930-675-23-2

0149

PARKING BRAKE ROTOR REMOVAL - Continued

1

2

M0927JCH

Figure 3. END OF TASK

Parking Brake Rotor Removal.

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TM 10-3930-675-23-2

0149

PARKING BRAKE ROTOR INSTALLATION

NOTE
Front and rear parking brake rotors are installed the same way. 1. 2. 3. Install parking brake rotor (Figure 4, Item 1) on 12 bolts (Figure 4, Item 7). Install parking brake cylinder (refer to Parking Brake Cylinder Installation). Install front or rear propeller shaft (WP 0143).

END OF TASK PARKING BRAKE BRACKET REMOVAL 1. 2. Remove parking brake rotor (refer to Parking Brake Rotor Removal in this work package). Remove nut (Figure 4, Item 3) and flange (Figure 4, Item 2) from differential shaft (Figure 4, Item 4).

NOTE
Note position of parking brake bracket on axle for installation. 3. 4. Remove 12 screws (Figure 4, Item 5) and parking brake bracket (Figure 4, Item 6) from front or rear axle (Figure 4, Item 1). Remove two O-rings (Figure 4, Item 7) from parking brake bracket (Figure 4, Item 6). Discard O-rings.

END OF TASK PARKING BRAKE BRACKET INSTALLATION 1. 2. 3. 4. Install two new O-rings (Figure 4, Item 7) on parking brake bracket (Figure 4, Item 6). Install parking brake bracket (Figure 4, Item 6) on front or rear axle (Figure 4, Item 1) with 12 screws (Figure 4, Item 5). Install flange (Figure 4, Item 2) on differential shaft (Figure 4, Item 4) with nut (Figure 4, Item 3). Tighten nut to 774 to 811 ft-lb (1,050 to 1,100 N•m). Install parking brake rotor (refer to Parking Brake Rotor Installation in this work package).

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TM 10-3930-675-23-2

0149

PARKING BRAKE BRACKET INSTALLATION - Continued

2 1 3 4

5

6

7

M0928JCH

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Fill brake fluid (LO 10-3930-675-13).

Parking Brake Bracket Replacement.

Start vehicle, build hydraulic pressure, and check for leaks (TM 10-3930-675-10) Apply parking brake, and check for proper operation (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0150

FIELD MAINTENANCE PARKING BRAKE PADS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Materials/Parts (cont.) Pin, Cotter (WP 0278, Table 1, Item 124) Brake Lining Kit (WP 0278, Table 1, Item 128) Equipment Condition Wheels chocked (TM 41-3930-675-10) Parking brake released (TM 10-3930-675-10) Brake system hydraulic pressure relieved (WP 0204)

NOTE
Maintenance of parking brake pads at front and rear parking brake cylinders is performed the same way.

0150-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00117)

TM 10-3930-675-23-2

0150

REMOVAL

NOTE
A strap wrench may be required to remove cover. 1. 2. 3. Remove cover (Figure 1, Item 6) from pressure ring (Figure 1, Item 4). Remove and discard O-ring (Figure 1, Item 8) only if damaged. Loosen jamnut (Figure 1, Item 5) and remove adjusting screw (Figure 1, Item 7) and jamnut from piston (Figure 1, Item 9). Retract adjustment cylinder (Figure 1, Item 2) into piston (Figure 1, Item 9) by prying between adjustment cylinder and one brake pad (Figure 1, Item 10).

NOTE
Only one of two bolts needs to be removed in order to remove brake pads. 4. 5. Remove cotter pin (Figure 1, Item 13) from one of two castle nuts (Figure 1, Item 14). Discard cotter pin. Remove castle nut (Figure 1, Item 14) and bolt (Figure 1, Item 12) from parking brake housing (Figure 1, Item 3) and parking brake bracket (Figure 1, Item 1).

NOTE
One brake pad is held in place by a magnet. 6. Remove two brake pads (Figure 1, Item 10) from parking brake housing (Figure 1, Item 3) and parking brake rotor (Figure 1, Item 11).

END OF TASK CLEANING Clean brake pads with detergent, clear water, and rags. Rinse with clear water and dry surfaces with rags. END OF TASK INSPECTION 1. 2. Check for damage to brake pads. Replace if damaged. Check thickness of brake lining of each brake pad, using a feeler gauge as a basis for comparison. Brake lining must be at least 0.080 inch (2 mm) thick. If brake lining thickness is less than required, discard brake pad.

END OF TASK INSTALLATION

NOTE
One brake pad will be held in place by a magnet. 1. 2. 3. Position two brake pads (Figure 1, Item 10) in parking brake housing (Figure 1, Item 3) and on parking brake rotor (Figure 1, Item 11). Install bolt (Figure 1, Item 12) through parking brake housing (Figure 1, Item 3) and parking brake bracket (Figure 1, Item 1). Install castle nut (Figure 1, Item 14). Install new cotter pin (Figure 1, Item 13) in castle nut (Figure 1, Item 14).

0150-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00117)

TM 10-3930-675-23-2

0150

INSTALLATION - Continued 4. Install adjusting screw (Figure 1, Item 7) partially into piston (Figure 1, Item 9) and install jamnut (Figure 1, Item 5) loosely onto adjusting screw.

END OF TASK ADJUSTMENT

NOTE
Ensure brake accumulator evacuation valves are closed. 1. 2. 3. 4. 5. 6. Start engine (TM 10-3930-675-10) and run approximately 30 seconds to provide hydraulic pressure. Stop engine. Rotate adjusting screw (Figure 1, Item 7) clockwise until both brake pads (Figure 1, Item 10) contact parking brake rotor (Figure 1, Item 11). Back off adjusting screw (Figure 1, Item 7) by rotating screw counterclockwise 4/5th turn. Gap should be 0.04 to 0.08 inch (1 to 2 mm). While holding adjusting screw (Figure 1, Item 7), tighten jamnut (Figure 1, Item 5). If removed, install new O-ring (Figure 1, Item 8) in cover (Figure 1, Item 6). Install cover (Figure 1, Item 6) on pressure ring (Figure 1, Item 4).
1 2 14 13 12 4 5 6 7 3

8 10 11 10 9
M0333JCH

Figure 1. END OF TASK

Parking Brake Pad Replacement.

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TM 10-3930-675-23-2

0150

FOLLOW-ON MAINTENANCE 1. 2. 3. Start vehicle and check for leaks (TM 10-3930-675-10). Apply parking brake, and check for proper operation (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00117)

TM 10-3930-675-23-2

0151

FIELD MAINTENANCE PARKING BRAKE CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Nut, Self-Locking (WP 0278, Table 1, Item 131) Qty: 4 References LO 10-3930-675-13 References (cont.) WP 0227 WP 0268 Equipment Condition Wheels chocked (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

REMOVAL 1. Remove four screws (Figure 1, Item 2) and cover (Figure 1, Item 3) from control valve bracket (Figure 1, Item 1).
1

2

2

2

3

M0337JCH

Figure 1. Parking Brake Control Valve Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 10-3930-675-23-2

0151

REMOVAL - Continued

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag hoses and connectors for installation. 2. 3. 4. 5. 6. Disconnect three hydraulic hoses (Figure 2, Item 6) and remove three fittings (Figure 2, Item 5) from control valve (Figure 2, Item 7). Disconnect two connectors (Figure 2, Item 10) of wiring harness from switch (Figure 2, Item 9). Remove switch (Figure 2, Item 9) from control valve (Figure 2, Item 1). Remove two locknuts (Figure 2, Item 2), washers (Figure 2, Item 3), screws (Figure 2, Item 4), and control valve (Figure 2, Item 1) from control valve bracket (Figure 2, Item 8). Discard locknuts. If control valve bracket (Figure 2, Item 8) is damaged, remove two locknuts (Figure 2, Item 7) and control valve bracket from cab. Discard locknuts.

END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 10-3930-675-23-2

0151

INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. 4. 5. 6. If removed, install control valve bracket (Figure 2, Item 8) on cab with two new locknuts (Figure 2, Item 7). Install control valve (Figure 2, Item 1) on control valve bracket (Figure 2, Item 8) with two screws (Figure 2, Item 4), washers (Figure 2, Item 3), and new locknuts (Figure 2, Item 2). Install switch (Figure 2, Item 9) on control valve (Figure 2, Item 1). Connect two connectors (Figure 2, Item 10) of wiring harness to switch (Figure 2, Item 9). Install three fittings (Figure 2, Item 5) on control valve (Figure 2, Item 1). Connect three hydraulic hoses (Figure 2, Item 6) to fittings (Figure 2, Item 5).

1 2,3,4 5 6 7 10 8

9
M0338JCH

Figure 2.

Parking Brake Control Valve Replacement.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 10-3930-675-23-2

0151

INSTALLATION - Continued 7. 8. Check level of oil in hydraulic reservoir and add oil as needed (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 9. Install cover (Figure 3, Item 3) on control valve bracket (Figure 3, Item 1) with four screws (Figure 3, Item 2).
1

2

2

2

3

M0339JCH

Figure 3. END OF TASK FOLLOW-On MAINTENANCE 1. 2.

Parking Brake Control Valve Installation.

Apply parking brake, and check for proper operation (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00118)

TM 10-3930-675-23-2

0152

FIELD MAINTENANCE PARKING BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 WP 0268 WP 0227 Equipment Condition Wheels chocked (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag hoses and connectors for installation.

0152-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 10-3930-675-23-2

0152

REMOVAL 1. Using illustration, (WP 0272) Figure 20, as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Discard O-ring(s).

END OF TASK INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. Lubricate and install new O-ring(s). Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

END OF TASK FOLLOW-On MAINTENANCE 1. Check oil level in hydraulic reservoir (LO 10-3930-675-13).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 2. 3. 4. Start engine (TM 10-3930-675-10) and check for leaks. Apply parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0152-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00119)

TM 10-3930-675-23-2

0153

FIELD MAINTENANCE SERVICE BRAKE CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 References (cont.) WP 0227 WP 0245 WP 0268 Equipment Condition Wheels chocked (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204) Steering column base and brake pedal disconnected from mounting and moved aside (WP 0160) Brake light switch and pressure sensors removed (WP 0159)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0153-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00120)

TM 10-3930-675-23-2

0153

REMOVAL 1. Loosen fitting nut (Figure 1, Item 2) of each hydraulic hose (Figure 1, Item 1) and disconnect hydraulic hoses.

NOTE
Note position of tee fitting, adapter fittings, and elbow fittings to aid in installation. 2. 3. Remove service brake control valve (Figure 1, Item 5) from floor of cab. Remove tee fitting (Figure 1, Item 3), adapter fittings (Figure 1, Item 6), and elbow fittings (Figure 1, Item 4) from service brake control valve (Figure 1, Item 5).

END OF TASK INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. Install elbow fittings (Figure 1, Item 4), adapter fittings (Figure 1, Item 6), and tee fittings (Figure 1, Item 3) on service brake control valve (Figure 1, Item 5). Position service brake control valve (Figure 1, Item 5) on floor of cab. Connect hydraulic hoses (Figure 1, Item 1) and tighten fitting nuts (Figure 1, Item 2).
1 2 3 1

4

4

6

5

M0340JCH

Figure 1. Service Brake Control Valve Replacement. END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00120)

TM 10-3930-675-23-2

0153

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install brake light switch and pressure sensors (WP 0159). Install steering column base and brake pedal (WP 0160). Check level of oil in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 5. 6. 7. Check pressure at hydraulic system test points (WP 0245). Apply parking brake, and check for proper operation (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0154

FIELD MAINTENANCE BRAKE ACCUMULATOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Wrench, Adjustable, Automotive, 18 in. (WP 0277, Table 1, Item 89) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 77) Qty: 11 Nut, Self-Locking (WP 0278, Table 1, Item 88) Qty: 6 Personnel Required (2) Equipment Condition Brake hydraulic pressure relieved (WP 0204) Master battery switch OFF (TM 10-3930-675-10)

WARNING CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• This procedure covers the right side brake accumulators and valve block. Left side is similar. • Mark or tag hoses to aid installation. • After removing hoses, check O-rings for damage and replace if necessary.

0154-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00251)

TM 10-3930-675-23-2

0154

REMOVAL 1. 2. 3. 4. 5. Close two brake hydraulic relief valves (WP 0204). Disconnect hose (Figure 1, Item 3) from fitting (Figure 1, Item 2). Disconnect hose (Figure 1, Item 4) from fitting (Figure 1, Item 2). Disconnect hose (Figure 1, Item 8) from fitting (Figure 1, Item 9). With assistance, remove 6 bolts (Figure 1, Item 7), 12 washers (Figure 1, Item 6), 6 locknuts (Figure 1, Item 5), 3 accumulators (Figure 1, Item 1), and brake accumulator valve (Figure 1, Item 10) from machine. Discard locknuts.
1 2 3 4

7 6 6

5

10 9 8

1

M1207JCH

Figure 1. Brake Accumulators and Valve Block Replacement. END OF TASK DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Remove fitting (Figure 2, Item 8) from brake accumulator valve (Figure 2, Item 9). If damaged, remove three O-rings (Figure 2, Item 7) from fitting (Figure 2, Item 8). Discard O-rings. Remove fitting (Figure 2, Item 5) from brake accumulator valve (Figure 2, Item 9). If damaged, remove two O-rings (Figure 2, Item 4) from fitting (Figure 2, Item 5). Discard O-rings. Loosen three brake accumulator band clamps (Figure 2, Item 6) on accumulators (Figure 2, Item 1). Remove three brake accumulators (Figure 2, Item 1) from brake accumulator valve (Figure 2, Item 9). Remove three fittings (Figure 2, Item 3) from brake accumulator valve (Figure 2, Item 9).

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0154

DISASSEMBLY - Continued 8. Remove six O-rings (Figure 2, Item 2) from fittings (Figure 2, Item 3). Discard O-rings.

END OF TASK ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. If removed, install six new O-rings (Figure 2, Item 2) on fittings (Figure 2, Item 3). Install three fittings (Figure 2, Item 3) on brake accumulator valve (Figure 2, Item 9). Install three brake accumulators (Figure 2, Item 1) on brake accumulator valve (Figure 2, Item 9). Tighten three brake accumulator band clamps (Figure 2, Item 6) on accumulators (Figure 2, Item 1). If removed, install two new O-rings (Figure 2, Item 4) on fitting (Figure 2, Item 5). Install fitting (Figure 2, Item 5) on brake accumulator valve (Figure 2, Item 9). If removed install three new O-rings (Figure 2, Item 7) on fitting (Figure 2, Item 8). Install fitting (Figure 2, Item 8) on brake accumulator valve (Figure 2, Item 9).

1

2 3 4 5

4 2 6

9

8 7

7

M1206JCH

Figure 2. Brake Accumulators and Valve Block Replacement. END OF TASK

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TM 10-3930-675-23-2

0154

INSTALLATION

NOTE
Install hoses as tagged during removal. 1. 2. 3. 4. 5. With assistance, install brake accumulator valve (Figure 3, Item 10) and 3 accumulators (Figure 3, Item 1) on machine with 6 new locknuts (Figure 3, Item 5), 12 washers (Figure 3, Item 6), and 6 bolts (Figure 3, Item 7). Connect hose (Figure 3, Item 8) to fitting (Figure 3, Item 9). Connect hose (Figure 3, Item 4) to fitting (Figure 3, Item 2). Connect hose (Figure 3, Item 3) to fitting (Figure 3, Item 2). Open two brake hydraulic relief valves (WP 0204).
1 2 3 4

7 6 6

5

10 9 8

1

M1207JCH

Figure 3. Brake Accumulators and Valve Block Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Turn master battery switch to ON position (TM 10-3930-675-10). Start engine and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0155

FIELD MAINTENANCE BRAKE AND STEERING ACCUMULATOR SERVICE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Adapter, 3/8 in. Female to 1/2 in. Male (WP 0277, Table 1, Item 2) Charging and Testing Unit, Nitrogen (WP 0277, Table 1, Item 15) Goggles, Industrial (WP 0277, Table 1, Item 34) Kit, Nitrogen Charging (WP 0277, Table 1, Item 46) Screwdriver Attachment, Hex 3/8 in. (WP 0277, Table 1, Item 64) Materials/Parts Cylinder, Compressed Gas, Nitrogen (WP 0276, Table 1, Item 14) Materials/Parts (cont.) Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Rag, Wiping (WP 0276, Table 1, Item 50) Equipment Condition Accumulators and valve removed (WP 0154) Steering hydraulic system pressure relieved, if checking pre-charge pressure on vehicle steering (WP 0204)

0155-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00121)

TM 10-3930-675-23-2

0155

CHECKING BRAKE ACCUMULATOR PRE-CHARGE PRESSURE

WARNING

• The brake accumulators are under extreme pressure (1300 psi (90 bar)). • Do NOT loosen the plug from the end of the brake accumulator more than 1/4 turn. • If plug is removed from the brake accumulator while under pressure it may result in damage to equipment or injury or death to personnel.

NOTE
Each brake accumulator is checked for pre-charge separately. 1. Remove cap (Figure 1, Item 2) from valve end of brake accumulator (Figure 1, Item 2).
2

1

M1208JCH

Figure 1. Brake Accumulator Testing.

0155-2

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TM 10-3930-675-23-2

0155

CHECKING BRAKE ACCUMULATOR PRE-CHARGE PRESSURE - Continued

CAUTION
To prevent damage to the brake accumulator charging tool, loosen plug 1/8 turn before installing the brake accumulator charging tool. Failure to follow this caution may result in equipment damage. 2. 3. Clean threads (Figure 2, Item 2) and O-ring flat surface (Figure 2, Item 4) of brake accumulator. Loosen plug (Figure 2, Item 3) 1/8 turn on brake accumulator (Figure 2, Item 1).

2 1

3

4

M1209JCH

Figure 2.

Brake Accumulator Testing.

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TM 10-3930-675-23-2

0155

CHECKING BRAKE ACCUMULATOR PRE-CHARGE PRESSURE - Continued

NOTE
Before installing the brake accumulator charging gauge on the brake accumulator, ensure the O-ring (Figure 3, Item 2) is fitted correctly in the groove of the brake accumulator charging gauge. 4. 5. 6. 7. Install brake accumulator charging gauge (Figure 3, Item 1) on brake accumulator (Figure 3, Item 3). Close bleeder valve (Figure 3, Item 5) on brake accumulator charging gauge (Figure 3, Item 1). Open plug (Figure 3, Item 4) on brake accumulator (Figure 3, Item 3) until pressure reading is obtained on brake accumulator charging gauge (Figure 3, Item 1). Pressure should be 1300 psi (90 bar). a. b. 8. 9. 10. If pressure is under 1300 psi (90 bar), perform Brake Accumulator Charging in this work package. If pressure is over 1300 psi (90 bar), bleed off excess pressure using bleeder valve (Figure 3, Item 5) on brake accumulator charging gauge (Figure 3, Item 1).

Close plug (Figure 3, Item 4) on brake accumulator (Figure 3, Item 3). Tighten plug to 221 in-lb (25 N·m). Open bleeder valve (Figure 3, Item 5) on brake accumulator charging gauge (Figure 3, Item 1). Remove brake accumulator charging gauge (Figure 3, Item 1) from brake accumulator (Figure 3, Item 3).

3

1

1

2

4 5
Figure 3. Brake Accumulator Testing.
M1210JCH

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0155

CHECKING BRAKE ACCUMULATOR PRE-CHARGE PRESSURE - Continued 11. 12. Tighten plug (Figure 4, Item 2) on brake accumulator (Figure 4, Item 1) to 266 in-lb (30 N·m). Soak plug (Figure 4, Item 2) with soapy water to check for leaks.
2

1

M1211JCH

Figure 4. 13.

Brake Accumulator Testing.

Install cap (Figure 5, Item 1) on brake accumulator (Figure 5, Item 2).
2

1

M1208JCH

Figure 5. END OF TASK

Brake Accumulator Testing.

0155-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00121)

TM 10-3930-675-23-2

0155

BRAKE ACCUMULATOR CHARGING

WARNING

• The brake accumulators are under extreme pressure (1300 psi (90 bar)). • Do NOT loosen the plug from the end of the brake accumulator more than 1/4 turn. • If plug is removed from the brake accumulator while under pressure it may result in damage to equipment or injury or death to personnel.

NOTE
• New brake accumulators are not shipped charged. Brake accumulators must be charged prior to installation on machine. • Each brake accumulator is charged separately. 1. If needed, install brake accumulator charging kit adapters (Figure 6, Item 1) on nitrogen source.
1 1

M1212JCH

Figure 6.

Brake Accumulator Charging.

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TM 10-3930-675-23-2

0155

BRAKE ACCUMULATOR CHARGING - Continued 2. Install brake accumulator charging kit hose (Figure 7, Item 2) on brake accumulator charging kit adapters (Figure 7, Item 1).
1 2

M1213JCH

Figure 7. 3.

Brake Accumulator Charging.

Install brake accumulator charging kit hose (Figure 8, Item 2) on brake accumulator charging gauge (Figure 8, Item 1).
1 2

M1214JCH

Figure 8.

Brake Accumulator Charging.

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TM 10-3930-675-23-2

0155

BRAKE ACCUMULATOR CHARGING - Continued 4. Remove cap (Figure 9, Item 1) from brake accumulator (Figure 9, Item 2).
2

1

M1208JCH

Figure 9.

Brake Accumulator Charging.

CAUTION
To prevent damage to the brake accumulator charging tool, loosen plug 1/8 turn before installing the brake accumulator charging tool. Failure to follow this caution may result in equipment damage.

NOTE
Clean threads (Figure 10, Item 2) and O-ring flat surface (Figure 10, Item 4) of brake accumulator. 5. Loosen plug (Figure 10, Item 3) 1/8 turn on brake accumulator (Figure 10, Item 1).

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TM 10-3930-675-23-2

0155

BRAKE ACCUMULATOR CHARGING - Continued

2 1

3

4

M1209JCH

Figure 10.

Brake Accumulator Charging.

NOTE
Before installing the brake accumulator charging gauge on the brake accumulator, ensure the O-ring (Figure 11, Item 3) is fitted correctly in the groove of the brake accumulator charging gauge. 6. 7. 8. Install brake accumulator charging gauge (Figure 11, Item 1) on brake accumulator (Figure 11, Item 4). Close bleeder valve (Figure 11, Item 2) on brake accumulator charging gauge (Figure 11, Item 1). Open plug (Figure 11, Item 5) on brake accumulator (Figure 11, Item 4).

4 2 1 1 3

5

M1215JCH

Figure 11.

Brake Accumulator Charging.

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TM 10-3930-675-23-2

0155

BRAKE ACCUMULATOR CHARGING - Continued

NOTE
Open nitrogen source valve slightly until nitrogen flows in to brake accumulator. At intervals, close the nitrogen source valve and read the current pressure. 9. Open valve (Figure 12, Item 1) on nitrogen source to charge brake accumulator (Figure 12, Item 2).

NOTE
Once the pressure of 1300 psi (90 bar) has been reached, close the nitrogen source valve and wait for the temperature to stabilize in the brake accumulator. 10. 11. Charge brake accumulator (Figure 12, Item 2) to 1300 psi (90 bar). Close valve (Figure 12, Item 1) on nitrogen source.

1

2

M1216JCH

Figure 12. Brake Accumulator Charging.

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0155

BRAKE ACCUMULATOR CHARGING - Continued

NOTE
Excessive pressure can be released by opening the bleeder screw on the brake accumulator charging gauge. 12. 13. 14. Close plug (Figure 13, Item 3) on brake accumulator (Figure 13, Item 1). Tighten plug to 221 in-lb (25 N·m). Open bleeder valve (Figure 13, Item 4) on brake accumulator charging gauge (Figure 13, Item 2). Remove brake accumulator charging gauge (Figure 13, Item 2) from brake accumulator (Figure 13, Item 1).

1 2

3

4
Figure 13. Brake Accumulator Charging.

M1217JCH

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0155

BRAKE ACCUMULATOR CHARGING - Continued 15. 16. Tighten plug (Figure 14, Item 2) on brake accumulator (Figure 14, Item 1) to 266 in-lb (30 N·m). Soak plug (Figure 14, Item 2) with soapy water to check for leaks.
2

1

M1211JCH

Figure 14. Brake Accumulator Testing. 17. Install cap (Figure 15, Item 1) on brake accumulator (Figure 15, Item 2).
2

1

M1208JCH

Figure 15. Brake Accumulator Charging.

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0155

BRAKE ACCUMULATOR CHARGING - Continued 18. Remove hose (Figure 16, Item 2) from brake accumulator charging gauge (Figure 16, Item 1).
1 2

M1214JCH

Figure 16. 19.

Brake Accumulator Charging.

Remove hose (Figure 17, Item 2) from adapters (Figure 17, Item 1).
1 2

M1213JCH

Figure 17.

Brake Accumulator Charging.

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0155

BRAKE ACCUMULATOR CHARGING - Continued 20. Remove adapters (Figure 18, Item 1) from nitrogen source.

Figure 18. Brake Accumulator Charging. END OF TASK CHECKING STEERING ACCUMULATOR PRE-CHARGE PRESSURE

NOTE
It may be necessary to remove screws, washers, and brackets securing hoses to release hoses to gain access to valve protector. 1. 2. 3. 4. 5. Remove two screws (Figure 19, Item 2) and valve protector (Figure 19, Item 1) from valve end of steering accumulator (Figure 19, Item 4). Remove cap (Figure 19, Item 5) from valve (Figure 19, Item 3). Connect hose assembly of nitrogen charging kit to valve (Figure 19, Item 3). Slowly open pressure valve. Take pressure reading from low pressure gauge. Pre-charge pressure for steering accumulator must be 1,450 psi (100 bar). If pressure is OK, close pressure regulator valve.

NOTE
If pressure reading on low pressure gauge is less than 1,450 psi (100 bar), perform Steering Accumulator Charging. 6. 7. 8. 9. 10. If pressure reading on low pressure gauge is more than 1,450 psi (100 bar), bleed off excess pressure using bleeder valve, then close pressure regulator valve Disconnect hose assembly of nitrogen charging kit from valve (Figure 19, Item 3). Install cap (Figure 19, Item 5) on valve (Figure 19, Item 3). Perform a soapsud leak check at valve end of steering accumulator (Figure 19, Item 4). Install valve protector (Figure 19, Item 1) on valve end of steering accumulator (Figure 19, Item 4) with two screws (Figure 19, Item 2).

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0155

CHECKING STEERING ACCUMULATOR PRE-CHARGE PRESSURE - Continued
1 2

3

4

5

M0933JCH

Figure 19. END OF TASK

Steering Accumulator Pre-charge Pressure Check.

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0155

STEERING ACCUMULATOR CHARGING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove two screws (Figure 19, Item 2) and valve protector (Figure 19, Item 1) from valve end of steering accumulator (Figure 19, Item 4). Remove cap (Figure 19, Item 5) from valve (Figure 19, Item 3) of steering accumulator (Figure 19, Item 4). Connect hose assembly of nitrogen charging kit to valve (Figure 19, Item 3). Open nitrogen tank valve. Slowly open pressure regulator valve. Charge accumulator with nitrogen until pressure reading on low pressure gauge is 1,450 psi (100 bar). Bleed off excess pressure using bleeder valve, then close pressure regulator valve. Close nitrogen tank valve. Disconnect hose assembly of nitrogen charging kit from valve (Figure 19, Item 3). Install cap (Figure 19, Item 5) on valve (Figure 19, Item 3) of steering accumulator (Figure 19, Item 4). Perform a soapsuds leak check at valve end of steering accumulator (Figure 19, Item 4). Install valve protector (Figure 19, Item 1) on valve end of steering accumulator (Figure 19, Item 4) with two screws (Figure 19, Item 2).

END OF TASK FOLLOW-ON MAINTENANCE Install accumulators and valve block (WP 0227). END OF TASK END OF WORK PACKAGE

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0156

FIELD MAINTENANCE BRAKE SYSTEM CHARGING VALVE PRESSURE ADJUSTMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics Automotive (WP 0277, Table 1, Item 85) Coupling Half, Quick Disconnect (WP 0277, Table 1, Item 19) Gage, Pressure, Dial Indicating (WP 0277, Table 1, Item 28) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Personnel Required (2) References TM 10-3930-675-10 References (cont.) WP 0204 WP 0245 Equipment Condition Parking brake applied (TM 10-3930-675-10)

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0156

ADJUSTMENT, BRAKE CIRCUIT NO. 1 1. 2. 3. 4. Relieve brake system hydraulic pressure by opening evacuation valves, then return valves to CLOSED position (WP 0204). Connect hydraulic pressure test gauge to hydraulic test point no. 1 (WP 0245). Start engine (TM 10-3930-675-10). Test gauge indicator will jump to pre-charged accumulator pressure of 1,305 psi (90 bar), then slowly increase to system pressure. If system pressure reaches 2,900 psi (200 bar), OPEN evacuation valves (WP 0245).

WARNING

While adjusting brake charging valve, DO NOT remove adjusting screw from charging valve assembly. The system is under pressure and failure to follow this warning may result in serious injury to personnel. 5. On brake charging valve (Figure 1, Item 1) (mounted under plate) loosen adjusting screw jamnut (Figure 1, Item 3) and slowly turn adjusting screw (Figure 1, Item 2) until test gauge indicates 1,956 to 2,538 psi (135 to 175 bar). Secure adjusting screw by tightening jamnut (Figure 1, Item 3). Shut down engine. Relieve brake system hydraulic pressure by opening brake system evacuation valves (WP 0204). Disconnect test gauge from hydraulic test point no. 1 (WP 0245). Close brake system evacuation valves (WP 0204).

6. 7. 8. 9.

END OF TASK ADJUSTMENT, BRAKE CIRCUIT NO. 2 1. 2. 3. 4. Relieve brake system hydraulic pressure by opening evacuation valves, then return valves to CLOSED position (WP 0204). Connect hydraulic pressure test gauge to hydraulic test point no. 2 (WP 0245). Start engine (TM 10-3930-675-10). Test gauge indicator will jump to pre-charged accumulator pressure of 1,305 (90 bar), then slowly increase to system pressure. If system pressure reaches 2,900 psi (200 bar), OPEN evacuation valves (WP 0245).

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0156

ADJUSTMENT, BRAKE CIRCUIT NO. 2 - Continued

WARNING

While adjusting brake charging valve, DO NOT remove adjusting screw from charging valve assembly. The system is under pressure and failure to follow this warning may result in serious injury to personnel. 5. On brake charging valve (Figure 1, Item 1) (mounted under plate) loosen adjusting screw jamnut (Figure 1, Item 3) and slowly turn adjusting screw (Figure 1, Item 2) until test gauge indicates 1,956 to 2,538 psi (135 to 175 bar). Secure adjusting screw by tightening jamnut (Figure 1, Item 3). Shut down engine. Relieve brake system hydraulic pressure by opening brake system evacuation valves (WP 0204). Disconnect test gauge from hydraulic test point no. 2 (WP 0245). Close brake system evacuation valves (WP 0204).
1

6. 7. 8. 9.

3

2

M0345JCH

Figure 1. END OF TASK END OF WORK PACKAGE

Brake System Charging Valve Pressure Adjustment.

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0157

FIELD MAINTENANCE SERVICE BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring Qty: (as required) References LO 10-3930-675-13 TM 10-3930-675-24P WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

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0157

REMOVAL 1. Using illustration in this work package and foldout (WP 0272, Figure 20) as guides, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Discard O-ring(s) removed.

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

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0157

INSTALLATION - Continued
4 4 3 3 2 11 2 1 1 3 2 1 2 1 4 1 3 5 6 3 3 Item No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Description Tee Nipple Hydraulic Hose Elbow Adapter Manifold Block Clamp Pipe Screw Brake Hub Front Axle Rear Axle

4 1

3 2 9

3

8 1 3 2 6

10
3 6 3 3 2 7

12

13
M0341JCH

Figure 1. Service Brake System Hydraulic Hoses and Fittings Replacement. END OF TASK

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0157

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks. Apply parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0158

FIELD MAINTENANCE BRAKE COOLING FILTER AND FILTER HEAD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealing Compound, Pipe (WP 0276, Table 1, Item 59) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Filter Element, Fluid (WP 0278, Table 1, Item 116) Qty: 2 References LO 10-3930-675-13 TM 10-3930-675-10 WP 0227 WP 0268 Equipment Condition Wheels chocked (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe filter and surrounding area clean prior to removal. After filter removal, immediately install replacement filter or cover area with a clean rag. Contaminated hydraulic system could cause equipment failure.

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0158

BRAKE COOLING FILTER REMOVAL

NOTE
Two brake cooling filters are installed on vehicle: one at front and one at rear. Both are replaced in a similar manner. Front brake cooling filter is detailed below. 1. 2. Position suitable container to catch hydraulic oil from lines. Use a filter strap wrench to loosen brake cooling filter (Figure 1, Item 1) and remove from filter head (Figure 1, Item 3) by hand. Discard filter

END OF TASK BRAKE COOLING FILTER INSTALLATION

NOTE
Ensure filter head mating surface is clean and free of residue. 1. 2. 3. Apply a coat of lubricating oil to brake cooling filter seal (Figure 1, Item 2) and fill filter with clean lubricating oil. Install new brake cooling filter (Figure 1, Item 1) on filter head (Figure 1, Item 3) and tighten by hand. Use a strap wrench to tighten brake cooling filter (Figure 1, Item 1) an additional 1/2 to 3/4 turn..
1 2 3

M0342JCH

Figure 1. Brake Cooling Filter Replacement. END OF TASK

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0158

BRAKE COOLING FILTER HEAD REMOVAL 1. 2. 3. 4. 5. Remove and discard brake cooling filter (refer to Brake Cooling Filter Removal in this work package). Disconnect two hydraulic hoses (Figure 2, Item 7) from filter head (Figure 2, Item 8). Remove two adapter fittings (Figure 2, Item 6) from filter head (Figure 2, Item 8). Remove two screws (Figure 2, Item 1) and washers (Figure 2, Item 2) securing filter head (Figure 2, Item 8) to mounting bracket (Figure 2, Item 5). If damaged, remove two screws (Figure 2, Item 3), washers (Figure 2, Item 4), and mounting bracket (Figure 2, Item 5) from vehicle.
3,4 5 1,2 6 7 6 7

8

M0343JCH

Figure 2. END OF TASK

Brake Cooling Filter Head Removal.

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0158

BRAKE COOLING FILTER HEAD INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. 5. If mounting bracket (Figure 3, Item 5) was removed, install bracket on vehicle with two washers (Figure 3, Item 4) and screws (Figure 3, Item 3). Position filter head (Figure 3, Item 8) on mounting bracket (Figure 3, Item 5) and secure with two washers (Figure 3, Item 2) and screws (Figure 3, Item 1). Apply pipe sealant to threads of two adapter fittings (Figure 3, Item 6) and install in filter head (Figure 3, Item 8). Connect two hydraulic hoses (Figure 3, Item 7) to filter head (Figure 3, Item 8). Install new brake cooling filter (refer to Brake Cooling Filter Installation in this work package).
3,4 5 1,2 6 7 6 7

8

M0344JCH

Figure 3. Brake Cooling Filter Head Installation. END OF TASK

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0158

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check hydraulic oil level and add oil as needed (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks. Apply parking brake, and check for proper operation (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0159

FIELD MAINTENANCE BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Sealing Compound, Pipe (WP 0276, Table 1, Item 59) Tag, Marker (WP 0276, Table 1, Item 66) Equipment Condition Brake hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

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0159

REMOVAL 1. Remove three screws (Figure 1, Item 1), washers (Figure 1, Item 2), and left lower panel (Figure 1, Item 3).

Figure 1. 2.

Left Lower Panel Removal.

Remove three screws (Figure 2, Item 1), washers (Figure 2, Item 2), and right lower panel (Figure 2, Item 3).

Figure 2. 3. 4. 5.

Right Lower Panel Removal.

Disconnect two connectors (Figure 3, Item 2) of cab wiring harness from each of three switches (Figure 3, Item 1). Remove each of four switches (Figure 3, Item 1) from two fittings (Figure 3, Item 3) of brake control valve (Figure 3, Item 4). Remove two fittings (Figure 3, Item 3) from brake control valve (Figure 3, Item 4).

END OF TASK

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0159

INSTALLATION 1. 2. 3. 4. 5. 6. Apply sealing compound to threads of two fittings (Figure 3, Item 3). Install two fittings (Figure 3, Item 3) on brake control valve (Figure 3, Item 4). Install four switches (Figure 3, Item 1) on two fittings (Figure 3, Item 3). Connect two connectors (Figure 3, Item 2) of cab wiring harness to each of three switches (Figure 3, Item 1). Install right lower panel (Figure 2, Item 3) with three screws (Figure 2, Item 1) and three washers (Figure 2, Item 2). Install left lower panel (Figure 1, Item 3) with three screws (Figure 1, Item 1) and three washers (Figure 1, Item 2).
1 2 1

3 3 1

4

1

M0226JCH

Figure 3. Brake Light and Pressure Switch Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Apply parking brake (TM 10-3930-675-10). Start vehicle and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0160

FIELD MAINTENANCE STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Grease, Electrically Conductive (WP 0276, Table 1, Item 28) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) References Volume 1, WP 0078 WP 0161 Equipment Condition Steering column removed (WP 0166)

REMOVAL 1. 2. Remove six screws (Figure 1, Item 1) and two extension plates (Figure 1, Item 2) from brake pedal (Figure 1, Item 6). Remove five screws (Figure 1, Item 3) and washers (Figure 1, Item 4) to separate steering column base (Figure 1, Item 5) from floor of cab.
1 2

3,4

6

5

M0351JCH

Figure 1.

Steering Column Base Removal.

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0160

REMOVAL - Continued 3. 4. Pull up on steering column base (Figure 2, Item 1) and support in upward position to access brake valve (Figure 2, Item 2) underneath. Remove two screws (Figure 2, Item 3) and separate steering column base (Figure 2, Item 1) from brake valve (Figure 2, Item 2).
1

3

2

M0352JCH

Figure 2.

Steering Column Base Removal.

NOTE
Remove and discard tiedown straps as necessary. 5. 6. 7. Disconnect connector (Figure 3, Item 3) of throttle position sensor (Figure 3, Item 5) from wiring harness (Figure 3, Item 4). Disconnect connector (Figure 3, Item 1) of brake inching switch from wiring harness (Figure 3, Item 2). Remove steering column base (Figure 3, Item 6) from floor of cab.
1 2 3 4

5

6

M0353JCH

Figure 3. END OF TASK

Steering Column Base Removal.

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0160

DISASSEMBLY 1. 2. Remove brake inching switch from brake Brake pedal (WP 0161). Remove throttle position sensor (Volume 1, WP 0078).

WARNING

Spring is under tension. Take care when removing spring. Wear protective eyewear to prevent injury to personnel. 3. Remove two setscrews (Figure 4, Item 4), pivot rod (Figure 4, Item 2), spring (Figure 4, Item 1), and brake pedal (Figure 4, Item 3) from hinges of steering column base (Figure 4, Item 5).

NOTE
Note position of screw and jamnut for ease in assembly. 4. Remove screw (Figure 4, Item 6) and jamnut (Figure 4, Item 7) from steering column base (Figure 4, Item 5).
1 2 3

4

6,7

5

M0354JCH

Figure 4. Steering Column Base Disassembly.

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0160

DISASSEMBLY - Continued 5. Remove two retaining rings (Figure 5, Item 10), shaft (Figure 5, Item 1), and lever (Figure 5, Item 7) from steering column base (Figure 5, Item 9).
1 2 3,4,5 6 7 8

10

9
M0355JCH

Figure 5. Steering Column Base Disassembly. 6. Remove two retaining rings (Figure 6, Item 3), shaft (Figure 6, Item 4), and roller (Figure 6, Item 2) from lever (Figure 6, Item 1).
1

2 4 3
M0356JCH

Figure 6. Steering Column Base Disassembly. 7. 8. Remove two retaining rings (Figure 5, Item 3), shaft (Figure 5, Item 4), and roller (Figure 5, Item 5) from brake pedal (Figure 5, Item 2). Remove two grease fittings (Figure 5, Item 6) from brake pedal (Figure 5, Item 2).

END OF TASK

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0160

ASSEMBLY 1. 2. 3. 4. 5. Install two grease fittings (Figure 5, Item 6) on brake pedal (Figure 5, Item 2). Install roller (Figure 5, Item 5) and shaft (Figure 5, Item 4) on brake pedal (Figure 5, Item 2) with two retaining rings (Figure 5, Item 3). Install roller (Figure 6, Item 2) and shaft (Figure 6, Item 4) on lever (Figure 6, Item 1) with two retaining rings (Figure 6, Item 3). Install lever (Figure 5, Item 7) and shaft (Figure 5, Item 1) on steering column base (Figure 5, Item 9) with two retaining rings (Figure 5, Item 10). Install jamnut (Figure 7, Item 7) and screw (Figure 7, Item 6) on steering column base (Figure 7, Item 5) in position noted during disassembly.

WARNING

Spring must be placed under tension. Take care when installing spring. Wear protective eyewear to prevent injury to personnel. 6. 7. 8. Install brake pedal (Figure 7, Item 3) and spring (Figure 7, Item 1) on steering column base (Figure 7, Item 5) with pivot rod (Figure 7, Item 2) and two setscrews (Figure 7, Item 4). Install throttle position sensor on steering column base (Volume 1, WP 0078). Install brake inching switch on brake pedal (WP 0161).
1 2 3

4

6,7

5

M0357JCH

Figure 7. END OF TASK

Steering Column Base Assembly.

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TM 10-3930-675-23-2

0160

INSTALLATION 1. Position steering column base (Figure 8, Item 6) on floor of cab.

NOTE
• Use electrically conductive grease on connectors before connection is made. • Install new tiedown straps as necessary. 2. 3. Connect connector (Figure 8, Item 1) of brake inching switch to wiring harness (Figure 8, Item 2). Connect connector (Figure 8, Item 3) of throttle position sensor (Figure 8, Item 5) to wiring harness (Figure 8, Item 4).
1 2 3 4

5

6

M0358JCH

Figure 8. Steering Column Base Installation. 4. Install steering column base (Figure 9, Item 1) on brake valve (Figure 9, Item 2) with two screws (Figure 9, Item 3).
1

3

2

M0359JCH

Figure 9. Steering Column Base Installation.

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0160

INSTALLATION - Continued 5. 6. Install steering column base (Figure 10, Item 5) on floor of cab with five washers (Figure 10, Item 4) and screws (Figure 10, Item 3). Install two extension plates (Figure 10, Item 2) on brake pedal (Figure 10, Item 6) with six screws (Figure 10, Item 1).
1 2

3,4

6

5

M0360JCH

Figure 10. END OF TASK FOLLOW-ON MAINTENANCE Install steering column (WP 0166). END OF TASK END OF WORK PACKAGE

Steering Column Base Installation.

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0161

FIELD MAINTENANCE BRAKE INCHING SWITCH REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

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0161

REMOVAL

NOTE
Remove and discard tiedown straps as necessary. 1. Disconnect brake inching switch connector (Figure 1, Item 1) from wiring harness connector (Figure 1, Item 2).

NOTE
Pivot pin is under slight spring tension. 2. Press inward on two pivot pins (Figure 1, Item 5) and remove cover (Figure 1, Item 4) from brake inching switch (Figure 1, Item 3).
2 3 4

1

5

M0221JCH

Figure 1. Brake Inching Switch Removal.

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0161

REMOVAL - Continued 3. 4. Remove two screws (Figure 2, Item 2) and brake inching switch (Figure 2, Item 1) from brake pedal (Figure 2, Item 3). Replace cover (Figure 2, Item 4) on brake inching switch (Figure 2, Item 3).
1

2

3
M0222JCH

Figure 2. END OF TASK

Brake Inching Switch Removal.

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0161

INSTALLATION

NOTE
Install new tiedown straps as necessary. 1. 2. 3. 4. Press inward on two pivot pins (Figure 3, Item 5) and remove cover (Figure 3, Item 4) from brake inching switch (Figure 3, Item 3). Install brake inching switch (Figure 3, Item 3) on brake pedal (Figure 2, Item 3) with two screws (Figure 2, Item 2). Replace cover (Figure 3, Item 4) on brake inching switch (Figure 3, Item 3). Connect brake inching switch connector (Figure 3, Item 1) to wiring harness connector (Figure 3, Item 2).
2 3 4

1

5

M0223JCH

Figure 3. END OF TASK END OF WORK PACKAGE

Brake Inching Switch Installation.

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0162

FIELD MAINTENANCE WHEEL ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Chain Assembly, Single Leg (14 ft Nominal) (WP 0277, Table 1, Item 14) Jack, Bottle, Hydraulic, Hand, 30 Ton Qty: 2 (WP 0277, Table 1, Item 44) Lifting Device (4000 lbs minimum capacity) Tools and Special Tools (cont.) Sling, Nylon (WP 0277, Table 1, Item 70) Wrench Set, Impact Wrench, 3/4 in. Drive (WP 0277, Table 1, Item 93) Wrench, Impact, Pneumatic (WP 0277, Table 1, Item 90) Wrench, Torque, Click, Ratcheting, 3/4 in. Drive, 600 lb-ft (WP 0277, Table 1, Item 96)

WARNING

• Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to perform maintenance. DO NOT get under vehicle after it is raised unless it is properly supported with blocks or other suitable cribbing. Failure to observe this warning may result in death or injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
This procedure as written uses a forklift truck and overhead lifting device as a suitable lifting device. Some necessary deviations from this task may apply, depending on the suitable lifting device being used.

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0162

REMOVAL

NOTE
Step 1 applies to front wheel and tire. Steps 2 and 3 apply to rear wheel and tire. 1. Position two hydraulic jacks on wood blocks under front axle (Figure 1, Item 1). Raise jacks to contact axle.
1

M0934JCH

Figure 1.

Raise Front Axle.

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0162

REMOVAL - Continued 2. Position two hydraulic jacks on wood blocks under rear axle (Figure 2, Item 1). Raise jacks to contact bottom of axle.
1

M0935JCH

Figure 2. 3.

Raise Front Axle.

Insert a block (Figure 3, Item 1) between top of rear axle (Figure 3, Item 2) and axle stop prior to raising jacks.

1

2
M0936JCH

Figure 3.

Raise Front Axle.

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0162

REMOVAL - Continued 4. 5. Using wood blocks, chock tires of wheels NOT being removed. Raise jacks to lift wheel and tire assembly (Figure 4, Item 1) clear of ground. Place wood blocks under front axle (Figure 4, Item 2).
1 2

M0937JCH

Figure 4. 6. 7. 8. 9. 10.

Raise Front Axle.

Using suitable lifting device, support wheel and tire assembly (Figure 5, Item 2). Secure wheel and tire assembly (Figure 5, Item 2) to suitable lifting device with chain assembly. Remove 36 nuts (Figure 5, Item 1) to separate wheel and tire assembly (Figure 5, Item 2) from axle flange (Figure 5, Item 3). Attach nylon sling to wheel and tire assembly (Figure 5, Item 2). Attach nylon sling to suitable overhead lifting device. Remove chain assembly and lift wheel and tire assembly (Figure 5, Item 2) from suitable lifting device.

END OF TASK

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0162

INSTALLATION 1. 2. 3. 4. 5. 6. 7. Attach nylon sling to wheel and tire assembly (Figure 5, Item 2) and attach nylon sling to suitable lifting device. Lift wheel and tire assembly (Figure 5, Item 2) and attach to suitable lifting device. Secure wheel and tire assembly to suitable lifting device with chain assembly. Move wheel and tire assembly (Figure 5, Item 2) to vehicle and install wheel and tire assembly on axle flange (Figure 5, Item 3) with 36 nuts (Figure 5, Item 1). Remove lifting device from vehicle. Remove wood blocks from under axle (Figure 5, Item 4) and lower wheel and tire assembly (Figure 5, Item 2) to ground. Remove hydraulic jacks. Tighten 36 nuts (Figure 5, Item 1) to 479 lb-ft (650 N·m). Remove wood blocks from tires not replaced.
1 2

3 4

M0938JCH

Figure 5. END OF TASK END OF WORK PACKAGE

Wheel and Tire Replacement.

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0163

FIELD MAINTENANCE BOGIE WHEELS AND TIRES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (1,500 lbs. minimum capacity) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Materials/Parts Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 22) Qty: 2 Personnel Required (2) References LO 10-3930-675-13 TM 9-2610-200-14 Equipment Condition Wheels chocked (TM 10-3930-675-10) Cab in transport position (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

BOGIE WHEEL REMOVAL 1. Lower bogie wheels (Figure 1, Item 1) until wheels touch ground (TM 10-3930-675-10).

1

M0939JCH

Figure 1.

Lower Bogie Wheel.

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0163

BOGIE WHEEL REMOVAL - Continued

NOTE
Perform Steps 2 thru 5 for each of two bogie wheels. 2. 3. 4. 5. 6. Remove allen head screw (Figure 2, Item 4) from end of axle shaft (Figure 2, Item 5). Rotate axle shaft (Figure 2, Item 5) 180 degrees and remove axle shaft, bogie wheel (Figure 2, Item 2), and two O-rings (Figure 2, Item 3) from frame (Figure 2, Item 1). Retain O-rings if not damaged. Remove grease fitting (Figure 2, Item 6) from axle shaft (Figure 2, Item 5). Roll bogie wheel (Figure 2, Item 2) away from vehicle. For tire maintenance, refer to TM 9-2610-200-14.

END OF TASK

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0163

BOGIE WHEEL INSTALLATION 1. Roll bogie wheel (Figure 2, Item 2) to vehicle.

NOTE
Perform Steps 2 thru 6 for each of two bogie wheels. 2. 3. 4. 5. 6. Temporarily place one O-ring (Figure 2, Item 3) on each side of bogie wheel (Figure 2, Item 2) hub and position bogie wheel on frame (Figure 2, Item 1). Install grease fitting (Figure 2, Item 6) on end of axle shaft (Figure 2, Item 5). Apply coat of grease to bearing surface of axle shaft (Figure 2, Item 5) and install axle shaft through frame (Figure 2, Item 1) and bogie wheel (Figure 2, Item 2). Rotate axle shaft, as necessary, until fully seated. Rotate axle shaft (Figure 2, Item 5) an additional 180 degrees and install allen head screw (Figure 2, Item 4). Move each of two O-rings (Figure 2, Item 3) over to snap into notch between wheel (Figure 2, Item 2) hub and frame (Figure 2, Item 1).
1 2

3

6

5

4

M0940JCH

Figure 2. END OF TASK

Bogie Wheel Replacement.

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0163

SCREW ASSEMBLY REMOVAL 1. 2. 3. 4. 5. Lower bogie wheels (Figure 3, item 7) (TM 10-3930-675-10). Remove two locknuts (Figure 3, Item 6) and ring (Figure 3, Item 5) from lower end of screw (Figure 3, Item 1). Discard locknuts. Lift screw assembly (Figure 3, Item 1) out of frame (Figure 3, Item 8). Remove bushing (Figure 3, Item 9) Remove swivel lock assembly (Figure 3, Item 2) from screw (Figure 3, Item 1). Remove retaining ring (Figure 3, Item 4) from swivel lock (Figure 3, Item 2) and press out nut (Figure 3, Item 3).

END OF TASK SCREW ASSEMBLY INSTALLATION 1. 2. 3. Press nut (Figure 3, Item 2) into swivel lock (Figure 3, Item 3) and install retaining ring (Figure 3, Item 4). Install swivel lock assembly (Figure 3, Item 3) on screw (Figure 3, Item 1). Position screw assembly (Figure 3, Item 1) on frame (Figure 3, Item 5).

NOTE
After installation of ring and two locknuts, screw must be able to rotate freely in frame. Adjust position of two locknuts as necessary. 4. Install ring (Figure 3, Item 6) and two new locknuts (Figure 3, Item 7) on lower end of screw (Figure 3, Item 1). Tighten one locknut against the other.

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0163

SCREW ASSEMBLY INSTALLATION - Continued
2

1

3 4

9

8

5 6

7

M1702JCH

Figure 3. END OF TASK

Screw Assembly Removal and Installation.

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0163

BOGIE WHEEL FRAME REMOVAL

WARNING

• Bogie wheel frame weighs 940 lbs. • Use a suitable lifting device to lift bogie wheel frame. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that and 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 death or injury to personnel.

NOTE
To remove bogie wheel frame, clearance between ground and vehicle frame at rear of vehicle must be at least 40 in. (100 cm). Position rear of vehicle on ramps or over maintenance location that provides proper clearance. 1. 2. 3. 4. Remove hydraulic cylinders (WP 0234). Remove screw assembly (refer to Screw Assembly Removal in this work package). Lower frame (Figure 4, Item 1) to ground and remove nylon sling. Remove frame (Figure 4, Item 1) from under vehicle.

END OF TASK BOGIE WHEEL FRAME INSTALLATION 1. 2. 3. 4. 5. 6. 7. Position frame (Figure 4, Item 1) under vehicle. Install nylon sling on top of frame (Figure 4, Item 1) and attach nylon sling to overhead lifting device. Raise frame (Figure 4, Item 1) and guide frame into vehicle. Continue to raise frame (Figure 4, Item 1) until frame is positioned in vehicle. Install screw assembly (refer to Screw Assembly Installation in this work package). Install hydraulic cylinders (WP 0234). Remove nylon sling with overhead lifting device from top of frame (Figure 4, Item 1) and position vehicle on level ground.

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0163

BOGIE WHEEL FRAME INSTALLATION - Continued
1 2

3

6

5

4

M0940JCH

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.

Bogie Wheel Frame Replacement.

Lubricate bogie wheels (LO 10-3930-675-13). Apply parking brake, and check for proper operation (TM 10-3930-675-10). Raise bogie wheels (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0164

FIELD MAINTENANCE DOLLY WHEELS AND TIRES MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Rag, Wiping (WP 0276, Table 1, Item 50) O-Ring (WP 0278, Table 1, Item 142) Qty: 2 Personnel Required (2) References TM 9-2610-200-14 Equipment Condition Dolly wheel removed from battery and dolly wheels storage compartment (TM 10-3930-675-10)

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0164

DISASSEMBLY 1. 2. 3. Remove two nuts (Figure 1, Item 5), washers (Figure 1, Item 6), screws (Figure 1, Item 7), and retainer (Figure 1, Item 9) from each end of axle shaft (Figure 1, Item 8). Remove axle shaft (Figure 1, Item 8), wheel (Figure 1, Item 1), and two O-rings (Figure 1, Item 4) from bracket (Figure 1, Item 2). Discard O-rings. Remove grease fitting (Figure 1, Item 3) from hub of wheel (Figure 1, Item 1).

2 1

9

8

5,6,7 4

3
M0346JCH

Figure 1. Dolly Wheel Disassembly. END OF TASK CLEANING AND INSPECTION 1. 2. 3. Clean tire, wheel, axle shaft, bracket, and two mounting pins (Figure 2, Item 2) with detergent and water. Dry with clean rags. Inspect components for excessive corrosion and damage. Replace defective components. For tire maintenance, refer to TM 9-2610-200-14.

END OF TASK

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0164

ASSEMBLY 1. 2. 3. 4. 5. Install grease fitting (Figure 2, Item 4) in hub of wheel (Figure 2, Item 1). Apply a thin coat of grease to two new O-rings (Figure 2, Item 5) and position one O-ring on each side of hub of wheel (Figure 2, Item 1). Apply a thin coat of grease to bearing surface of axle shaft (Figure 2, Item 9) and install axle shaft through bracket (Figure 2, Item 3) and wheel (Figure 2, Item 1). Rotate axle shaft, as necessary, until fully seated. Install retainer (Figure 2, Item 10) on each end of axle shaft (Figure 2, Item 9) with two screws (Figure 2, Item 8), washers (Figure 2, Item 7), and nuts (Figure 2, Item 6). Position each of two O-rings (Figure 2, Item 5) against surface of bracket (Figure 2, Item 3).

2 3 1

10

9

6,7,8 5

4
M0347JCH

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Lubricate dolly wheel (LO 10-3930-675-13).

Dolly Wheel Assembly.

Return dolly wheel to battery and dolly wheel storage compartment (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0165

FIELD MAINTENANCE STEERING WHEEL REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85)

REMOVAL 1. Lift insert (Figure 1, Item 2) from center of steering wheel (Figure 1, Item 1).
1 2

M0348JCH

Figure 1.

Steering Wheel Removal.

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TM 10-3930-675-23-2

0165

REMOVAL - Continued 2. 3. Remove nut (Figure 2, Item 2) and washer (Figure 2, Item 3) from steering shaft (Figure 2, Item 4). Remove steering wheel (Figure 2, Item 1) from steering shaft (Figure 2, Item 4).

END OF TASK INSTALLATION 1. 2. Position steering wheel (Figure 2, Item 1) on steering shaft (Figure 2, Item 4). Install washer (Figure 2, Item 3) and nut (Figure 2, Item 2) on steering shaft (Figure 2, Item 4).
1

2,3

4

M0349JCH

Figure 2. Steering Wheel Replacement.

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TM 10-3930-675-23-2

0165

INSTALLATION - Continued 3. Press insert (Figure 3, Item 2) into center of steering wheel (Figure 3, Item 1).
1 2

M0350JCH

Figure 3. END OF TASK END OF WORK PACKAGE

Steering Wheel Installation.

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TM 10-3930-675-23-2

0166

FIELD MAINTENANCE STEERING COLUMN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Grease, Electrically Conductive (WP 0276, Table 1, Item 28) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Lockwasher (WP 0278, Table 1, Item 3) Locknut (WP 0278, Table 1, Item 1) Qty: 4 Equipment Condition Transmission accessory control levers removed (Volume 1, WP 0095)

REMOVAL 1. Disconnect connector (Figure 1, Item 3) of cable from steering column sensor (Figure 1, Item 1) at lower end of steering column (Figure 1, Item 2).
1 2

3

M0361JCH

Figure 1.

Steering Column Removal.

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TM 10-3930-675-23-2

0166

REMOVAL - Continued

NOTE
Perform Steps 2 and 3 at rear of top plastic housing. 2. Disconnect eight connectors (Figure 2, Item 4) from five switches (Figure 2, Item 1).

NOTE
Remove and discard tiedown straps as necessary. 3. Pull each of eight connectors (Figure 2, Item 4) down through bottom plastic housing (Figure 2, Item 3), rubber bellows (Figure 2, Item 5), and away from steering column (Figure 2, Item 2).
1 2 1

3

5

4

M0362JCH

Figure 2.

Steering Column Removal.

NOTE
Perform Steps 4 thru 7 at front of top plastic housing. 4. 5. 6. 7. At top plastic housing (Figure 3, Item 9) of steering column, disconnect four connectors (Figure 3, Item 2) of steering column wiring harness (Figure 3, Item 10) from rear of ignition switch (Figure 3, Item 1). Disconnect connector (Figure 3, Item 11) of steering column wiring harness (Figure 3, Item 10) from connector (Figure 3, Item 12) of warning buzzer (Figure 3, Item 3). Remove two screws (Figure 3, Item 6) and remove test connector (Figure 3, Item 5). Disconnect ground connector (Figure 3, Item 8) and connector (Figure 3, Item 7) of steering column wiring harness (Figure 3, Item 10) from rear of ECS display screen (Figure 3, Item 4).

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0166

REMOVAL - Continued
1 2 3 4 5 6 7 8 9

12

11

10

M0363JCH

Figure 3. 8. 9.

Steering Column Removal.

Trace one of two ground wires (Figure 4, Item 3) down to transmission indicator light panel (Figure 4, Item 2) at rear of top plastic housing (Figure 4, Item 1). Remove nut (Figure 4, Item 4), lockwasher (Figure 4, Item 5), and ground wire (Figure 4, Item 3) from transmission indicator light panel (Figure 4, Item 2). Discard lockwasher.
1 2 3 4,5

M0364JCH

Figure 4.

Steering Column Removal.

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0166

REMOVAL - Continued 10. 11. 12. Disconnect five connectors (Figure 5, Item 5) of steering column wiring harness (Figure 5, Item 3) from five indicator lights (Figure 5, Item 4). Pull each of 13 connectors at front of top plastic housing (Figure 5, Item 1) down through bottom plastic housing (Figure 5, Item 6), rubber bellows (Figure 5, Item 7), and away from steering column (Figure 5, Item 2). Remove top plastic housing (Figure 5, Item 1) and bottom plastic housing (Figure 5, Item 6) from steering column (Figure 5, Item 2).
1 2 3 4 5

6 7
M0365JCH

Figure 5. 13. 14.

Steering Column Removal.

Remove lever (Figure 6, Item 5), washer (Figure 6, Item 4), bolt (Figure 6, Item 3), and tube (Figure 6, Item 2) from steering column base (Figure 6, Item 9). Remove four locknuts (Figure 6, Item 6), screws (Figure 6, Item 7), eight washers (Figure 6, Item 8), and steering column (Figure 6, Item 1) from steering column base (Figure 6, Item 9). Discard locknuts.

END OF TASK INSTALLATION 1. 2. 3. 4. Install steering column (Figure 6, Item 1) on steering column base (Figure 6, Item 9) with eight washers (Figure 6, Item 8), four screws (Figure 6, Item 7), and new locknuts (Figure 6, Item 6). Install tube (Figure 6, Item 2), bolt (Figure 6, Item 3), washer (Figure 6, Item 4), and lever (Figure 6, Item 5) on steering column base (Figure 6, Item 9). Position bottom plastic housing (Figure 5, Item 6) and top plastic housing (Figure 5, Item 1) on steering column (Figure 5, Item 2). Route each of 13 connectors to steering column (Figure 5, Item 2), through rubber bellows (Figure 5, Item 7), and up through bottom plastic housing (Figure 5, Item 6) to front of top plastic housing (Figure 5, Item 1).

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0166

INSTALLATION - Continued

NOTE
• Perform Steps 5 thru 10 at front of top plastic housing. • Apply electrically conductive grease to connectors before connections are made. 5. Connect five connectors (Figure 5, Item 5) of steering column wiring harness (Figure 5, Item 3) to five indicator lights (Figure 5, Item 4).
2,3 4

5 1

9

6,7,8

M0366JCH

Figure 6. Steering Column Removal and Installation.

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0166

INSTALLATION - Continued 6. Connect ground wire (Figure 7, Item 2) to transmission indicator light panel (Figure 7, Item 1) with lockwasher (Figure 7, Item 4) and nut (Figure 7, Item 3).
1 2 3,4

M0367JCH

Figure 7. Steering Column Installation.

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0166

INSTALLATION - Continued 7. 8. 9. 10. Connect connector (Figure 8, Item 7) and ground connector (Figure 8, Item 8) of steering column wiring harness (Figure 8, Item 10) to rear of ECS display screen (Figure 8, Item 4). Install test connector (Figure 8, Item 5) with two screws (Figure 8, Item 6). Connect connector (Figure 8, Item 11) of steering column wiring harness (Figure 8, Item 10) to connector (Figure 8, Item 12) of warning buzzer (Figure 8, Item 3). Connect four connectors (Figure 8, Item 2) of steering column wiring harness (Figure 8, Item 10) to rear of ignition switch (Figure 8, Item 1).
1 2 3 4 5 6 7 8 9

12

11

10

M0368JCH

Figure 8.

Steering Column Installation.

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0166

INSTALLATION - Continued 11. Position each of eight connectors (Figure 9, Item 4) on steering column (Figure 9, Item 2), through rubber bellows (Figure 9, Item 5), and up through bottom plastic housing (Figure 9, Item 3).

NOTE
• Install new tiedown straps as necessary. • Perform Step 12 at rear of top plastic housing. 12. Connect eight connectors (Figure 9, Item 4) to five switches (Figure 9, Item 1).
1 2 1

3

5

4

M0369JCH

Figure 9. Steering Column Installation.

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0166

INSTALLATION - Continued 13. Connect connector (Figure 10, Item 3) of cable to steering column sensor (Figure 10, Item 1) at lower end of steering column (Figure 10, Item 2).
1 2

3

M0370JCH

Figure 10. END OF TASK FOLLOW-ON MAINTENANCE

Steering Column Installation.

Install transmission accessory control levers (Volume 1, WP 0095). END OF TASK END OF WORK PACKAGE

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0167

FIELD MAINTENANCE STEERING COLUMN REPAIR

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Equipment Condition Steering column removed (WP 0166)

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0167

DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Lift edge of rubber bellows (Figure 1, Item 1) to expose inner end of tiltlever (Figure 1, Item 18). Remove screw (Figure 1, Item 16) to disconnect end of link (Figure 1, Item 15) from tilt lever (Figure 1, Item 18). Remove nut (Figure 1, Item 17), tilt lever (Figure 1, Item 18), and rubber bellows (Figure 1, Item 1) from steering column (Figure 1, Item 9). Remove rubber bellows and bushing (Figure 1, Item 11) from tilt lever. Remove pushnut (Figure 1, Item 14), link (Figure 1, Item 15), connector (Figure 1, Item 12), and spring (Figure 1, Item 13) from steering column (Figure 1, Item 9). Remove two springs (Figure 1, Item 7). Remove three screws (Figure 1, Item 3), plate (Figure 1, Item 2), and pin (Figure 1, Item 4). Remove locking plate (Figure 1, Item 6), pin (Figure 1, Item 5), and spring (Figure 1, Item 8). Remove two halves of bearing (Figure 1, Item 10) from end of steering column (Figure 1, Item 9).

END OF TASK ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Install two halves of bearing (Figure 1, Item 10) to end of steering column (Figure 1, Item 9). Install spring (Figure 1, Item 8), pin (Figure 1, Item 5), and locking plate (Figure 1, Item 6) on steering column (Figure 1, Item 9). Install pin (Figure 1, Item 4) and plate (Figure 1, Item 2) with three screws (Figure 1, Item 3). Install two springs (Figure 1, Item 7). Install spring (Figure 1, Item 13), connector (Figure 1, Item 12), link (Figure 1, Item 15), and pushnut (Figure 1, Item 14). Install bushing (Figure 1, Item 11) on tilt lever (Figure 1, Item 18) and position tilt lever through rubber bellows (Figure 1, Item 1). Install tilt lever (Figure 1, Item 18), with rubber bellows (Figure 1, Item 1), on steering column (Figure 1, Item 9) with nut (Figure 1, Item 17). Connect end of link (Figure 1, Item 15) to tilt lever (Figure 1, Item 18) with screw (Figure 1, Item 16).

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0167

ASSEMBLY - Continued

1 2

3

4 5 6 7

8 18 9 17 10 11 12 16 15 14 13 10
M0945JCH

Figure 1. Steering Column Disassembly and Assembly. END OF TASK FOLLOW-ON MAINTENANCE Install steering column (WP 0166). END OF TASK END OF WORK PACKAGE

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0168

FIELD MAINTENANCE STEERING SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Locknut (WP 0278, Table 1, Item 1) Qty: Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

4

REMOVAL 1. Using steering column tilt/extend lever (Figure 1, Item 2) on right side of steering column (Figure 1, Item 1), extend steering column fully up and out.
1

2

M0372JCH

Figure 1.

Steering Column Sensor Removal.

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0168

REMOVAL - Continued 2. Remove four screws (Figure 2, Item 2) and washers (Figure 2, Item 3) from steering column base (Figure 2, Item 7) and slide steering column (Figure 2, Item 1) away from steering column sensor (Figure 2, Item 4). Slide steering column (Figure 2, Item 1) off to one side and remove paper gasket (Figure 2, Item 7) and metal plate (Figure 2, Item 8) from steering column sensor (Figure 2, Item 6).

3.

1

2,3

4 5,6

M0373JCH

Figure 2. Steering Column Sensor Removal. 4. 5. Remove four locknuts (Figure 3, Item 2), screws (Figure 3, Item 3), and eight washers (Figure 3, Item 4). Discard locknuts. Lift steering column sensor (Figure 3, Item 5) up from steering column base (Figure 3, Item 7) and disconnect cable connector (Figure 3, Item 6) from steering column sensor.

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0168

REMOVAL - Continued
1 2,3,4

7

5 6

M0374JCH

Figure 3. END OF TASK INSTALLATION

Steering Column Sensor Removal.

NOTE
Position flange with TOP mark on steering column sensor facing forward with connector in lowest possible position. 1. 2. 3. Connect cable connector (Figure 4, Item 6) to steering column sensor (Figure 4, Item 5). Position steering column sensor (Figure 4, Item 5) in steering column base (Figure 4, Item 7). Install four screws (Figure 4, Item 3), eight washers (Figure 4, Item 4), and four new locknuts (Figure 4, Item 2).
1 2,3,4

7

5 6

M0375JCH

Figure 4. Steering Column Sensor Installation.

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0168

INSTALLATION - Continued 4. 5. Position metal plate (Figure 5, Item 6), paper gasket (Figure 5, Item 5), and steering column (Figure 5, Item 1) on steering column sensor (Figure 5, Item 4). Install four washers (Figure 5, Item 3) and screws (Figure 5, Item 2) on steering column (Figure 5, Item 1).

1

2,3

4 5,6

M0376JCH

Figure 5. Steering Column Sensor Installation.

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0168

INSTALLATION - Continued 6. Using steering column tilt/extend lever (Figure 6, Item 2), place steering column (Figure 6, Item 1) in operating position.
1

2

M0377JCH

Figure 6. Steering Column Sensor Installation. END OF TASK END OF WORK PACKAGE

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0169

FIELD MAINTENANCE EMERGENCY STEERING PUMP REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Wrench, Adjustable, Automotive, 15 In. (WP 0277, Table 1, Item 88) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealing Compound (WP 0276, Table 1, Item 54) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Gasket (WP 0278, Table 1, Item 84) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Steering hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

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0169

NOTE
• Emergency steering pump is located on lower right rear surface of transmission. • Tag all hydraulic lines. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. 2. 3. 4. Trace supply hose (Figure 1, Item 1) back to hydraulic reservoir. Close ball valve in supply hose at reservoir. Disconnect hose (Figure 1, Item 2) from fitting (Figure 1, Item 3). Disconnect supply hose (Figure 1, Item 1) from fitting (Figure 1, Item 6). Remove four screws (Figure 1, Item 7) and pump (Figure 1, Item 5) from transmission (Figure 1, Item 4).

NOTE
Perform Step 5 to remove fittings from pump, if a new pump is being installed. 5. Remove fittings (Figure 1, Items 3 and 6) from pump (Figure 1, Item 5).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Ensure a light coat of sealant is applied to fitting threads. • Perform Step 1 to install fittings removed from old pump, if a new pump is being installed. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. 5. Install fittings (Figure 1, Items 3 and 6) in pump (Figure 1, Item 5). Install pump (Figure 1, Item 5) on transmission (Figure 1, Item 4) with four screws (Figure 1, Item 7). Connect supply hose (Figure 1, Item 1) to fitting (Figure 1, Item 6). Connect hose (Figure 1, Item 2) to fitting (Figure 1, Item 3). Open ball valve at reservoir for supply hose (Figure 1, Item 1).

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0169

INSTALLATION - Continued

1

2

3

4

5

6

7

M0946JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Emergency Steering Pump Replacement.

Check oil level in hydraulic reservoir (LO 10-3930-675-13). Install new tiedown straps as necessary to support hydraulic hoses.

END OF TASK END OF WORK PACKAGE

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0170

FIELD MAINTENANCE STEERING SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) O-Ring (as required) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 TM 10-3930-675-24P WP 0268 WP 0272 Equipment Condition Parking brake applied (TM 10-3930-675-10) Steering hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

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0170

REMOVAL 1. 2. Close hydraulic reservoir ball valve (WP 0272, Figure 19). Using illustration (WP 0272, Figure 19) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 3. 4. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Discard O-ring(s) removed.

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal. Open hydraulic reservoir ball valve.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10), operate steering, and check for leaks.

END OF TASK END OF WORK PACKAGE

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0171

FIELD MAINTENANCE FRONT AND REAR AXLE STEERING CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Antiseize Compound (WP 0276, Table 1, Item 7) Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Oil, Lubricating Gear, OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 137) O-Ring (WP 0278, Table 1, Item 141) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Parking brake applied (TM 10-3930-675-10) Steering hydraulic system pressure relieved (WP 0204) Hydraulic reservoir ball valve in closed position (WP 0170) Autolube system tubing removed from steering cylinder (if equipped) (WP 0201)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

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0171

NOTE
• Front and rear steering cylinders are replaced in the same manner, but are NOT interchangeable. • Tag all hydraulic lines. REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Disconnect two hydraulic hoses (Figure 1, Item 3) from two elbows (Figure 1, Item 4). Cap/plug both hydraulic hoses (Figure 1, Item 3). Loosen jamnuts (Figure 1, Item 5) and remove two elbows (Figure 1, Item 4). Remove bolt (Figure 1, Item 8) and washer (Figure 1, Item 9). Using a hammer, tap out shaft (Figure 1, Item 1) and remove grease fitting (Figure 1, Item 2). Remove and discard two O-rings (Figure 1, Item 7). Repeat Steps 4 thru 6 for opposite end of cylinder (Figure 1, Item 6). Remove cylinder (Figure 1, Item 6).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. 5. 6. 7. 8. Lubricate two new O-rings (Figure 1, Item 7) with lubricating oil. Apply antiseize compound to shaft (Figure 1, Item 1). Align cylinder (Figure 1, Item 6) end and two O-rings (Figure 1, Item 7) on mounting bracket so shaft (Figure 1, Item 1) can be installed. Tap shaft (Figure 1, Item 1) into place using hammer and install grease fitting (Figure 1, Item 2). Install washer (Figure 1, Item 9) and bolt (Figure 1, Item 8). Repeat Steps 1 thru 5 for opposite end of cylinder (Figure 1, Item 6). Install two elbows (Figure 1, Item 4) and tighten jamnuts (Figure 1, Item 5). Remove cap/plug from two hydraulic hoses (Figure 1, Item 3) and install hoses on two elbows (Figure 1, Item 4).

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0171

INSTALLATION - Continued
1 2 3 4 5

8,9

7

6

M0371JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6.

Front and Rear Steering Cylinder Replacement.

Install autolube system removed to steering cylinder (if equipped) (WP 0201) . Open hydraulic reservoir ball valve (WP 0170). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Lubricate two grease fittings on steering cylinder with GAA (LO 10-3930-675-13). Start engine (TM 10-3930-675-10), check steering operation, and check for leaks. Perform steering calibration (WP 0174).

END OF TASK END OF WORK PACKAGE

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0172

FIELD MAINTENANCE STEERING ACCUMULATOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 4 References LO 10-3930-675-13 WP 0227 WP 0268 WP 0155 Equipment Condition Steering hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

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0172

NOTE
• Steering accumulator is located on inside of left-side frame. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hose. REMOVAL 1. 2. 3. 4. 5. 6. Disconnect hose (Figure 1, Item 4) from fitting (Figure 1, Item 3). Remove two nuts (Figure 1, Item 2) and loosen clamps (Figure 1, Item 5). Remove accumulator (Figure 1, Item 1) from clamps (Figure 1, Item 5). If damaged, remove four locknuts (Figure 1, Item 6), screws (Figure 1, Item 7), and two clamps (Figure 1, Item 5) from welded angle brackets (Figure 1, Item 8). Discard locknuts. If replacing accumulator (Figure 1, Item 1), remove fitting (Figure 1, Item 3) from accumulator. If accumulator (Figure 1, Item 1) is unserviceable, ensure it is drained of nitrogen before disposal (WP 0155).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. If installing a new accumulator (Figure 1, Item 1), install fitting (Figure 1, Item 3) on accumulator. If removed, install two clamps (Figure 1, Item 5) on welded angle brackets (Figure 1, Item 8) with four screws (Figure 1, Item 7) and new locknuts (Figure 1, Item 6). Position accumulator (Figure 1, Item 1) inside clamps (Figure 1, Item 5) and install and tighten two nuts (Figure 1, Item 2). Connect hose (Figure 1, Item 4) to fitting (Figure 1, Item 3).

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0172

INSTALLATION - Continued
1 2 3

4

5

5

8

6,7

M0949JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5.

Steering Accumulator Replacement.

Verify accumulator pre-charge pressure and charge as required (WP 0155). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10), operate steering, and check for leaks. Recheck oil level in hydraulic reservoir (LO 10-3930-675-13). Install new tiedown straps as necessary to support hydraulic hoses.

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0173

FIELD MAINTENANCE STEERING CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (minimum capacity 150 lbs) Sling, Nylon (WP 0277, Table 1, Item 70) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (2) References LO 10-3930-675-13 References (cont.) WP 0227 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Steering hydraulic system pressure relieved (WP 0204) Transmission access covers removed (WP 0175) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

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0173

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Tag all hydraulic lines, fittings, and electrical leads. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. 2. Press in on eight retaining clips (Figure 1, Item 4) and disconnect eight electrical leads (Figure 1, Item 2) from solenoids (Figure 1, Item 1). Disconnect 12 hoses (Figure 1, Item 12) from fittings (Figure 2, Item 9) at control valve (Figure 1, Item 13).

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Steering control valve weighs approximately 100 lb (45 kg). Lifting device must have sufficient capacity to lift control valve. Failure to follow this warning may result in injury to personnel. 3. 4. Wrap a nylon sling around control valve (Figure 1, Item 13) and attach sling to a suitable lifting device. Remove four nuts (Figure 1, Item 7), screws (Figure 1, Item 8), eight washers (Figure 1, Item 9), spacers (Figure 1, Item 5), and control valve (Figure 1, Item 13) with plate (Figure 1, Item 6) from two welded angle brackets (Figure 1, Item 3). Set solenoid valve (Figure 1, Item 11) with bracket (Figure 1, Item 10) aside. Remove four screws and washers and separate control valve (Figure 1, Item 13) from plate (Figure 1, Item 6).

5.

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0173

REMOVAL - Continued
2 3

4 5

1 6 7,8,9 10

11

13

12

M0947JCH

Figure 1.

Steering Control Valve Removal.

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0173

REMOVAL - Continued

NOTE
Perform Step 6 to remove fittings from control valve, if a new control valve is being installed. 6. Remove 12 fittings (Figure 2, Item 9) from control valve (Figure 2, Item 8).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old control valve, if a new control valve is being installed. 1. 2. Install 12 fittings (Figure 2, Item 9) in control valve (Figure 2, Item 8). Install control valve (Figure 2, Item 8) on plate (Figure 2, Item 7) with four washers and screws.

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Steering control valve weighs approximately 100 lb (45 kg). Lifting device must have sufficient capacity to lift control valve. Failure to follow this warning may result in injury to personnel. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227) . 3. With a nylon sling wrapped around control valve (Figure 2, Item 8) and sling supported by a suitable lifting device, position control valve with plate (Figure 2, Item 7) and spacers (Figure 2, Item 5) at two welded angle brackets (Figure 2, Item 6). Position solenoid valve (Figure 1, Item 11) with bracket (Figure 1, Item 10). Install four screws (Figure 2, Item 3), eight washers (Figure 2, Item 4), and four nuts (Figure 2, Item 2). Connect 12 hoses (Figure 2, Item 1) to fittings (Figure 2, Item 9) at control valve (Figure 2, Item 8). Connect eight electrical leads (Figure 1, Item 2) to solenoids (Figure 1, Item 1).

4. 5.

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0173

INSTALLATION - Continued
5 2,3,4 6 7 8

1

9

9

1

M0948JCH

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6.

Steering Control Valve Removal and Installation.

Check oil level in hydraulic reservoir (LO 10-3930-673-13). Start engine (TM 10-3930-675-10), operate steering system, and check for leaks. Recheck oil level in hydraulic reservoir (LO 10-3930-673-13). Install new tiedown straps as necessary to support hydraulic hoses. Install transmission access covers (WP 0175). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0174

FIELD MAINTENANCE STEERING CALIBRATION

INITIAL SETUP: Tools and Special Tools Tape, Measuring (50 ft long) (WP 0277, Table 1, Item 79) References TM 10-3930-675-10

NOTE
• When calibrating the steering system, perform all ten calibration steps in order. DO NOT skip or omit any steps. • RTCH must be parked on level ground with all wheels pointing straight ahead. • RTCH wheels are numbered as follows during calibration procedures: 1. Right front wheel is No. 1 2. Right rear wheel is No. 2 3. Left rear wheel is No. 3 4. Left front wheel is No. 4 CALIBRATION 1. Access to Calibration Menus. a. b. c. d. e. 2. Turn master battery switch to ON position (TM 10-3930-675-10). Turn ignition ON and start engine (TM 10-3930-675-10). Select KALMAR service menu on driver’s Electronic Control System (ECS) display screen and press "Enter". Enter calibration program access number “13221". Press right arrow button to locate “CALIBR STEERING" menu, then press “Enter".

Emergency Steering System Turning Speed Calibration (Menu 1 of 10). a. b. Press value increase “+" or value decrease “-" buttons until a value of “60" is displayed on ECS display screen. When value of “60“ is displayed, press “Enter". ECS display screen should look as shown:
CALIBR STEERING TURNING SPEED FOR BUTTON STEERING 1 (10)

60

c.

Press right arrow button to advance through remaining steering system calibration menus.

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0174

CALIBRATION - Continued 3. Steering System Hydraulic and Electrical Connections Check (Menu 2 of 10). a. b. Pressing value increase “+" button will result in wheel No.1 (RF) moving to the right and an increase of values on ECS display screen. Pressing value decrease “-" button will result in wheel No.1 moving to the left and a decrease of values on ECS display screen. ECS display screen should look as shown:
CALIBR STEERING AXLE 1 ADJUST WHEEL ANGLE 2 (10)

X X

Range 0 +/-5

c. 4.

Press right arrow button to advance thru remaining steering system calibration menus.

Steering Cylinder No. 1 Calibration (Menu 3 of 10). a. Steering cylinders position must be manually checked by measuring cylinder length. Measurement should be taken from center-to-center of cylinder mounting pins. Correct length is 31 5/16 in. (796 mm). If length is incorrect, adjust steering cylinder for wheel No.1 (RF) by pressing increase “+" or decrease “-" buttons. Press “Enter". Recheck steering cylinder position. Correct length should be 31 5/16 in. (796 mm). ECS display screen should look as shown:
CALIBR STEERING AXLE 1 SET WHEEL ANGLE 3 (10)

b. c. d.

0 0

e. 5.

Press right arrow button to advance thru remaining steering system calibration menus.

Steering System Hydraulic and Electrical Connections Check (Menu 4 of 10). a. b. Pressing value increase “+" button will result in wheel No. 2 (RR) moving to the right and an increase of values on ECS display screen. Pressing value decrease “-" button will result in wheel No. 2 moving to the left and a decrease of values on ECS display screen. ECS display screen should look as shown:
CALIBR STEERING AXLE 2 ADJUST WHEEL ANGLE 4 (10)

0 0

Range 0 +/-5

c.

Press right arrow button to advance through remaining steering system calibration menus.

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0174

CALIBRATION - Continued 6. Steering Cylinder No. 2 Calibration (Menu 5 of 10). a. Steering cylinder position must be manually checked by measuring cylinder length. Measurement should be taken from center-to-center of cylinder mounting pins. Correct length is 34 in. (863 mm). If length is incorrect, adjust steering cylinder for wheel No. 2 (RR) by pressing increase “+" or decrease “-" buttons. Press “Enter". Recheck steering cylinder position. Correct length should be 34 in. (863 mm). ECS display screen should look as shown:
CALIBR STEERING AXLE 2 SET WHEEL ANGLE 5 (10)

b. c. d.

0 0

e. 7.

Press right arrow button to advance through remaining steering system calibration menus.

Steering System Hydraulic and Electrical Connections Check (Menu 6 of 10). a. b. Pressing value increase “+" button will result in wheel No. 3 (LR) moving right and an increase of values on ECS display screen. Pressing value decrease “-" button will result in wheel No. 3 moving left and a decrease of values on ECS display screen. ECS display screen should look as shown:
CALIBR STEERING AXLE 3 ADJUST WHEEL ANGLE 6 (10)

0 0

Range 0 +/-5

c. 8.

Press right arrow button to advance through remaining steering system calibration menus.

Steering Cylinder No. 3 Calibration (Menu 7 of 10). a. Steering cylinder position must be manually checked by measuring cylinder length. Measurement should be taken from center-to-center of cylinder mounting pins. Correct length is 34 in. (863 mm). If length is incorrect, adjust steering cylinder for wheel No. 3 (LR) by pressing increase “+" or decrease “-" buttons. Press “Enter". Recheck steering cylinder position. Correct length should be 34 in. (863 mm). ECS display screen should look as shown:
CALIBR STEERING AXLE 3 ADJUST WHEEL ANGLE 7 (10)

b. c. d.

0 0

e.

Press right arrow button to advance through remaining steering system calibration menus.

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0174

CALIBRATION - Continued 9. Steering System Hydraulic and Electrical Connections Check (Menu 8 of 10). a. b. Pressing value increase “+" button will result in wheel No. 4 (LF) moving right and an increase of values on ECS display screen. Pressing value decrease “-" button will result in wheel No. 4 moving left and a decrease of values on ECS display screen. ECS display screen should look as shown:
CALIBR STEERING AXLE 4 ADJUST WHEEL ANGLE 8 (10)

0 0

Range 0 +/-5

c. 10.

Press right arrow button to advance through remaining steering system calibration menus.

Steering Cylinder No. 4 Calibration (Menu 9 of 10). a. Steering cylinder position must be manually checked by measuring cylinder length. Measurement should be taken from center-to-center of cylinder mounting pins. Correct length is 31 5/16 in. (796 mm). If length is incorrect, adjust steering cylinder for wheel No. 4 (LF) by pressing increase “+" or decrease “-" buttons. Press “Enter". Recheck steering cylinder position. Correct length should be 31 5/16 in. (796 mm). ECS display screen should look as shown:
CALIBR STEERING AXLE 4 SET WHEEL ANGLE 9 (10)

b. c. d.

0 0

e. 11.

Press right arrow button to advance to remaining steering system calibration menu.

Calibration of Steering System Completed (Menu 10 of 10). a. b. With all calibration steps complete and corrections or adjustments made, press “Enter" to return to main menu. ECS display screen should look as shown:
CALIBR STEERING 10 (10)

CALIBRATION OF STEERING DONE

ENTER

12.

Turn off engine and restart to save data.

END OF TASK END OF WORK PACKAGE

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0175

FIELD MAINTENANCE TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Jack, Dolly Type, Hydraulic, 10-Ton Capacity (WP 0277, Table 1, Item 45) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 4 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 89) Qty: 16 Washer, Lock (WP 0278, Table 1, Item 120) Qty: 8 Personnel Required (2) References Volume 1, WP 0105 WP 0185 Equipment Condition Wheels chocked (TM 10-3930-675-10) Cab in transport position (TM 10-3930-675-10)

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WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may result in injury to personnel. SKID PLATE REMOVAL 1. 2. 3. Position floor jack under center of skid plate (Figure 1, Item 4). Raise jack until it contacts skid plate. Remove eight locknuts (Figure 1, Item 1), screws (Figure 1, Item 2), and 16 washers (Figure 1, Item 3). Discard locknuts. Lower jack and remove skid plate (Figure 1, Item 4) from skid plate brackets (Figure 1, Item 8).

NOTE
Perform Step 4 for each of two skid plate brackets. 4. Remove two locknuts (Figure 1, Item 5), screws (Figure 1, Item 6), four lockwashers (Figure 1, Item 7), and skid plate bracket (Figure 1, Item 8) from vehicle. Discard lock nuts and lockwashers.

END OF TASK

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0175

SKID PLATE INSTALLATION

NOTE
Perform Step 1 for each of two skid plate brackets. 1. 2. 3. Install skid plate bracket (Figure 1, Item 8) on vehicle with four new lockwashers (Figure 1, Item 7), two screws (Figure 1, Item 6), and new locknuts (Figure 1, Item 5). Using jack, position skid plate (Figure 1, Item 4) on skid plate brackets (Figure 1, Item 8). Install 16 washers (Figure 1, Item 3), eight screws (Figure 1, Item 2), and new locknuts (Figure 1, Item 1).
1,2,3 4 5,6,7

8

M0412JCH

Figure 1. END OF TASK

Skid Plate Replacement.

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0175

FRONT ACCESS COVER REMOVAL 1. 2. Remove engine cover (WP 0185). Remove eight screws (Figure 2, Item 2), washers (Figure 2, Item 3), and front access cover (Figure 2, Item 1) from vehicle.

END OF TASK FRONT ACCESS COVER INSTALLATION 1. 2. Install front access cover (Figure 2, Item 1) on vehicle with eight washers (Figure 2, Item 3) and screws (Figure 2, Item 2). Install engine cover (WP 0185).
1

2,3

M0413JCH

Figure 2. Front Access Cover Replacement. END OF TASK MIDDLE ACCESS COVER AND CAB SUPPORT REMOVAL 1. 2. 3. 4. Remove two screws (Figure 3, Item 2) and washers (Figure 3, Item 3) from middle access cover (Figure 3, Item 1). Remove middle access cover (Figure 3, Item 1) from cab support (Figure 3, Item 4). Remove cab support-mounted cab position proximity switch (Volume 1, WP 0105). Remove four locknuts (Figure 3, Item 10), screws (Figure 3, Item 11), eight washers (Figure 3, Item 12), and cab support (Figure 3, Item 4) from vehicle. Discard locknuts.

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MIDDLE ACCESS COVER AND CAB SUPPORT REMOVAL - Continued 5. Remove four locknuts (Figure 3, Item 5), screws (Figure 3, Item 6), eight washers (Figure 3, Item 7), two angle plates (Figure 3, Item 8), and two shims (Figure 3, Item 9) from cab support (Figure 3, Item 4). Discard locknuts.

END OF TASK MIDDLE ACCESS COVER AND CAB SUPPORT INSTALLATION 1. 2. 3. 4. Install two shims (Figure 3, Item 9) and two angle plates (Figure 3, Item 8) on cab support (Figure 3, Item 4) with eight washers (Figure 3, Item 7), four screws (Figure 3, Item 6), and new locknuts (Figure 3, Item 5). Install cab support (Figure 3, Item 4) on vehicle with eight washers (Figure 3, Item 12), four screws (Figure 3, Item 11), and new locknuts (Figure 3, Item 10). Install cab support-mounted cab position proximity switch (Volume 1, WP 0105). Install middle access cover (Figure 3, Item 1) on cab support (Figure 3, Item 4) with two washers (Figure 3, Item 3) and screws (Figure 3, Item 2).
1 2,3 4

5,6,7,8,9

10,11,12

M0414JCH

Figure 3. END OF TASK

Middle Access Cover and Cab Support Replacement.

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REAR ACCESS COVER REMOVAL Remove four screws (Figure 4, Item 2), washers (Figure 4, Item 3), and rear access cover (Figure 4, Item 1) from vehicle. END OF TASK REAR ACCESS COVER INSTALLATION Install rear access cover (Figure 4, Item 1) on vehicle with four washers (Figure 4, Item 3) and screws (Figure 4, Item 2).
1

2,3

M0415JCH

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Rear Access Cover Replacement.

Return cab to operational position (TM 10-3930-675-10). Apply parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0176

FIELD MAINTENANCE BOOM SUPPORT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Jackscrews (2) (BII, TM 10-3930-675-10) Lifting Device (10-ton minimum capacity) Wood Block, 2 X 4 Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (3) References WP 0190 References (cont.) WP 0201 WP 0227 WP 0235 WP 0236 WP 0257 Equipment Condition Boom assembly removed (WP 0256) Hydraulic system pressure relieved (WP 0204) Parking brake applied (TM 10-3930-675-10) Tophandler removed (WP 0259) Boom locking pin in retracted position (TM 10-3930-675-10) Cab in transport position (TM 10-3930-675-10)

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
• Boom support weighs approximately 8,000 lb (3,632 kg). • Tag and mark hydraulic pipes to ensure proper installation.

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REMOVAL

CAUTION
DO NOT sit or step on hoses or pipes. Failure to comply could cause bending damage. 1. 2. 3. Remove eight bolts (Figure 1, Item 2) and four clamps (Figure 1, Item 1) from rear of boom support (Figure 1, Item 3). Disconnect and cap hoses (Figure 1, Item 5) and pipes (Figure 1, Item 4). Lay along frame, on left and right sides. Bundle wire harness (Figure 1, Item 9) and set aside. Remove sixteen bolts (Figure 1, Item 6), washers (Figure 1, Item 7), and two cover plates (Figure 1, Item 8) from inside of boom support (Figure 1, Item 3).
1 2 3 4 9 2 3 5

6,7

8 1

LEFT BOOM SUPPORT

RIGHT BOOM SUPPORT
M1715JCH

Figure 1. Boom Support Removal.

CAUTION
Wipe clean area around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure. 4. Remove eight bolts (Figure 2, Item 2) and washers (Figure 2, Item 3) from boom support and remove cover (Figure 2, Item 1) from vehicle. Repeat for other side.

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REMOVAL - Continued

1

2,3

M1716JCH

Figure 2.

Boom Support Removal.

NOTE
Tag all hydraulic lines for installation. 5. Place drain pan beneath work area. Remove two hydraulic hoses (Figure 3, Item 1) from check valve (Figure 3, Item 2). Cap hoses and fittings (Figure 3, Item 3).
1

3

2

M1717JCH

Figure 3.

Boom Support Removal.

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REMOVAL - Continued

NOTE
Fold boom support completely (TM 10-3930-675-10). 6. 7. 8. With lifting device, sling boom support assembly, before and after, right and left. Take up slack and lift boom support evenly, imposing a slight strain to allow pivot pins to be removed easily. Remove autolube system from boom support, if required (WP 0201). Remove upper clevis pins (Figure 4, Item 1) from boom folding cylinders (Figure 4, Item 2). Support cylinders with wood blocks.
1 2

2

M1718JCH

Figure 4. Boom Support Removal.

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REMOVAL - Continued 9. 10. Retract folding cylinders by operating boom folding lift/lower lever (TM10-3930-675-10). Remove screw (Figure 5, Item 1) and lockwasher (Figure 5, Item 2) from each boom support pivot pin (Figure 5, Item 3).

NOTE
Clean the threads in pivot pin prior to installing jacking screws from BII. 11. Lubricate two jacking screws (Figure 5, Item 4) with lubricating oil and install one into ear of each pivot pin (Figure 5, Item 3).

NOTE
• To avoid bending pivot pin flanges, turn jacking screws in equally and alternately on both sides of vehicle. It may require two jacking screws to get pivot pins to move initially. • Before removal of pivot pins, remove rear fenders and fender support brackets (WP 0190). This will gain clearance to remove boom pivot pins. 12. Turn jacking screws in, to withdraw each pivot pin until clear of frame. Remove pins and set aside.
1,2 3

4

M1719JCH

Figure 5.

Boom Support Removal.

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0176

REMOVAL - Continued

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

CAUTION
Use caution when lifting boom support assembly, Ensure assembly clears vehicle and does not contact electrical or hydraulic components. Failure to follow this caution may cause damage to support or damage to vehicle.

NOTE
Boom support weighs approximately 8,000 lb (3,632 kg). 13. 14. Ensure all disconnected electrical and hydraulic lines are moved aside and secured. Lift boom support assembly from vehicle and remove. Remove attaching pins (Figure 6, Item 1) and cylinders (Figure 6, Items 3 and 4) with locking pins attached, from removed boom support (Figure 6, Item 2) and set aside for installation on new boom support (WP 0235).

1

2

1 4 3
Figure 6. Boom Support Removal. END OF TASK

M1720JCH

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0176

INSTALLATION

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
Boom support weighs approximately 8,000 lb (3,632 kg). 1. 2. Install boom support locking pins, carriers, and hardware onto new boom support assembly. Install cylinders (Figure 7, Items 3 and 4) with locking pins attached using attaching pins (Figure 7, Item 1) onto new boom support assembly (Figure 7, Item 2) (WP 0256).

1

2

1 4
Figure 7. 3. 4.

M1720JCH

3
Boom Support Installation.

Visually check condition of locking pin bushings in frame. Replace bushings if necessary (WP 0236). Sling boom assembly, before and after, right and left, and lift boom support evenly to allow alignment of boom support assembly pivot holes to frame, while lowering boom support into place.

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INSTALLATION - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during these procedures. Ensure that any lifting device used is in good condition and of suitable load capacity. Stay clear of heavy parts supported only by lifting device. Failure to follow this warning may result in injury or death to personnel. • DO NOT insert hands when checking for bore alignment. The use of a straightedge will assist in aligning parts.

CAUTION
Use caution when lifting boom support to ensure boom support clears vehicle and does not contact electrical or hydraulic components. Failure to follow this caution may cause damage to components or to vehicle.

NOTE
• Alignment of pin bores is critical for pin installation. Observe from inside to ensure proper alignment. • Coat pins and bushings with grease before installation. • Ensure pivot shafts are clean and free of burrs. • When installing pivot pins, slot in pivot pin flange should be aligned with screw hole in frame. 5. When aligned, install pivot pins (Figure 8, Item 3) on each side of boom support through boom support and frame. Secure pivot pins with lockwashers (Figure 8, Item 2) and capscrews (Figure 8, Item 1).
1,2 3

M1722JCH

Figure 8. Boom Support Installation.

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INSTALLATION - Continued 6. Connect two hydraulic hoses (Figure 9, Item 1) to fittings (Figure 9, Item 3) of check valve (Figure 9, Item 2).
1

3

2

M1717JCH

Figure 9. 7. 8.

Boom Support Installation.

Start vehicle and position boom support folding cylinder rods to align bores in rod end with holes in boom support (TM 10-3930-675-10). Install pins (Figure 10, Item 1) in boom support folding cylinders (Figure 10, Item 2).

1

2

M1721JCH

Figure 10.

Boom Support Installation.

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INSTALLATION - Continued 9. 10. 11. 12. Install two cover plates (Figure 11, Item 8) using sixteen washers (Figure 11, Item 7) and bolts (Figure 11, Item 6) on inside of boom support (Figure 11, Item 3). Install hydraulic hoses (Figure 11, Item 5) and pipes (Figure 11, Item 4) on each side of boom support (Figure 11, Item 3). Attach clamps (Figure 11, Item 1) and secure with eight bolts (Figure 11, Item 2). Raise boom support by extending folding cylinders (TM 10-3930-675-10). Install and secure electrical cable (Figure 11, Item 9) on right side of frame.
1 2 3 4 9 2 3 5

6,7

8 1

LEFT BOOM SUPPORT

RIGHT BOOM SUPPORT
M1715JCH

Figure 11. Boom Support Installation. 13. 14. Install autolube system to boom support as required (WP 0201). Using eight bolts (Figure 12, Item 2) and washers (Figure 12, Item 3) install cover (Figure 12, Item 1) to boom support. Repeat for other side.

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0176

INSTALLATION - Continued

1

2,3

M1716JCH

Figure 12. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.

Boom Support Installation.

Install rear fender and fender support brackets (WP 0190). Install boom (WP 0256). Install tophandler (WP 0259). Raise boom support completely (TM 10-3930-675-10).

NOTE
Raise boom to 19 degrees and extend to 110 in. (279.4 cm). During this process, always adjust to above settings and pull center lever on boom folding valve to ensure folding cylinders are fully extended. 5. Align boom support locking pin bushing bores.

CAUTION
After bushing alignment is achieved, lubricate locking pins with GAA grease. Extend locking pins to ensure correct and smooth operation. Not sign inside of remote hydraulic control compartment. If sliding pins bind, damage to vehicle may result. 6. Perform Boom and Tophandler Calibration (WP 0257).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 7. Perform Load Testing Procedure (WP 0271).

END OF TASK END OF WORK PACKAGE

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0177

FIELD MAINTENANCE FLEXIBLE CONVEYOR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Wrench, Adjustable, Automotive, 15 in. (WP 0277, Table 1, Item 88) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HD0 (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Nut, Self-Locking Hexagon (WP 0278, Table 1, Item 88) Qty: 7 Personnel Required (2) References LO 10-3930-675-13 Volume 1, WP 0047 WP 0227 WP 0268 Equipment Condition Boom fully extended (TM 10-3930-675-10) Boom hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

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NOTE
• Tag all hydraulic lines. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses and wiring harnesses. REMOVAL 1. 2. 3. At right rear of boom (Figure 1, Item 4), remove two screws (Figure 1, Item 2) and disconnect boom wiring harness (Figure 1, Item 3), and connector (Figure 1, Item 5) from connector (Figure 1, Item 1). Disconnect cable (Figure 1, Item 6), and connector (Figure 1, Item 7) from connector (Figure 1, Item 8). Remove boom wiring harness (Figure 1, Item 3) and cable (Figure 1, Item 6) from attachment to right side of boom (Figure 1, Item 4).
2 1

3

8

4

7

6

5

M0503JCH

Figure 1. 4.

Boom Wiring Harness and Cable Removal.

At right front of boom (Figure 2, Item 1), remove locknut (Figure 2, Item 3), two washers (Figure 2, Item 4), screw (Figure 2, Item 5), and clamp (Figure 2, Item 6) from conveyer support bracket (Figure 2, Item 2). Discard locknut. Remove clamp (Figure 2, Item 6) from boom wiring harness (Figure 2, Item 7) and cable (Figure 2, Item 8).

5.

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0177

REMOVAL - Continued
1 2 3,4,5 6 7,8

M0504JCH

Figure 2.

Boom Wiring Harness and Cable Removal.

NOTE
Conveyer spacers may be separated to allow connector of boom wiring harness to pass through. 6. At front of box channel (Figure 3, Item 4) on boom extension (Figure 3, Item 2), pull boom wiring harness (Figure 3, Item 1) and cable (Figure 3, Item 3) through conveyer (Figure 3, Item 5) until wiring harness and cable are just clear of conveyer.
1 2 3 4

5

M0505JCH

Figure 3.

Boom Wiring Harness and Cable Removal.

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REMOVAL - Continued 7. 8. 9. Disconnect two hydraulic hoses (Figure 4, Item 2) from two adapters (Figure 4, Item 3). Remove two locknuts (Figure 4, Item 4), screws (Figure 4, Item 5), and lower end of conveyer (Figure 4, Item 1) from conveyer support bracket (Figure 4, Item 6). Discard locknuts. Straighten conveyer. At front of box channel (Figure 3, Item 4) of boom extension (Figure 3, Item 2), pull two hydraulic hoses (Figure 4,Item 2) through conveyer (Figure 4, Item 1) until hoses are just clear of conveyer.
1 2

3

6

4,5

M0506JCH

Figure 4. Hydraulic Hoses Removal.

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0177

REMOVAL - Continued 10. 11. Remove four locknuts (Figure 5, Item 2), eight washers (Figure 5, Item 3), four screws (Figure 5, Item 4), and top end of conveyer (Figure 5, Item 6) from box channel (Figure 5, Item5). Discard locknuts. Remove conveyer (Figure 5, Item 6) from vehicle.
1 2,3,4 5

6

M0507JCH

Figure 5. END OF TASK

Conveyor Removal.

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0177

INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. Position conveyer (Figure 6, Item 6) on vehicle with conveyer straightened. Install top end of conveyer (Figure 6, Item 6) in box channel (Figure 6, Item 5) with four screws (Figure 6, Item 4), eight washers (Figure 6, Item 3), and four new locknuts (Figure 6, Item 2).
1 2,3,4 5

6

M0508JCH

Figure 6. 3. 4. 5.

Conveyor Installation.

Extend two hydraulic hoses (Figure 7, Item 2) out from rear of box channel (Figure 6, Item 5) of boom extension (Figure 6, Item 1) through conveyer (Figure 7, Item 1). Bend conveyer (Figure 7, Item 1) and install lower end of conveyer on conveyer support bracket (Figure 7, Item 6) with two screws (Figure 7, Item 5) and new locknuts (Figure 7, Item 4). Connect two hydraulic hoses (Figure 7, Item 2) to two adapters (Figure 7, Item 3).

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0177

INSTALLATION - Continued
1 2

3

6

4,5

M0509JCH

Figure 7. 6.

Hydraulic Hoses Installation.

Extend boom wiring harness (Figure 8, Item 1) and cable (Figure 8, Item 3) out from rear of box channel (Figure 8, Item4) on boom extension (Figure 8, Item 2) through conveyer (Figure 8, Item 5) toward rear of vehicle.
1 2 3 4

5

M0510JCH

Figure 8.

Wiring Harness and Cable Installation.

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0177

INSTALLATION - Continued 7. 8. At right front of boom (Figure 9, Item 1), position clamp (Figure 9, Item 6) on boom wiring harness (Figure 9, Item7) and cable (Figure 9, Item 8). Install clamp (Figure 9, Item 6) on conveyer support bracket (Figure 9, Item 2) with screw (Figure 9, Item 5), two washers (Figure 9, Item 4), and new locknut (Figure 9, Item 3).
1 2 3,4,5 6 7,8

M0511JCH

Figure 9. 9. 10. 11.

Wiring Harness and Cable Installation.

Using new tiedown straps, install boom wiring harness (Figure 10, Item 3) and cable (Figure 10, Item 6) along right side of boom (Figure 10, Item 4). Connect cable (Figure 10, Item 6), and connector (Figure 10, Item 7) to connector (Figure 10, Item 8). Connect boom wiring harness (Figure 10, Item 3), and connector (Figure 10, Item 5) to connector (Figure 10, Item 1) and install two screws (Figure 10, Item 2).

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0177

INSTALLATION - Continued
2 1

3

8

4

7

6

5

M0512JCH

Figure 10. END OF TASK FOLLOW-ON MAINTENANCE 1.

Connect Cable and Wiring Harness.

Return boom to operational position (TM 10-3930-675-10) and check for leaks.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 2. Add hydraulic oil to reservoir, if necessary (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

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0178

FIELD MAINTENANCE PINTLE HOOK MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Adjustable, Automotive, 15 in. (WP 0277, Table 1, Item 88) Materials/Parts Pin, Cotter (WP 0278, Table 1, Item 159)

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0178

REMOVAL 1. 2. Remove cotter pin (Figure 1, Item 2), nut (Figure 1, Item 1), and washer (Figure 1, Item 3) from threaded shaft of tow pintle (Figure 1, Item 5). Discard cotter pin. Remove tow pintle (Figure 1, Item 5) and washer (Figure 1, Item 4) from rear of vehicle.

END OF TASK INSTALLATION 1. 2. Position washer (Figure 1, Item 4) and tow pintle (Figure 1, Item 5) at rear of vehicle. Install washer (Figure 1, Item 3) on threaded shaft. Install nut (Figure 1, Item 1) on threaded shaft hand-tight, until nut contacts washer (Figure 1, Item 3), then back off nut 1/6 turn. Install new cotter pin (Figure 1, Item 2).
2 1 3

4 5

M1725JCH

Figure 1. END OF TASK END OF WORK PACKAGE

Tow Pintle Replacement.

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0179

FIELD MAINTENANCE CAB LIFT FRAME MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Sling, Nylon (WP 0277, Table 1, Item 70) Tape, Measuring (50 ft long) (WP 0277, Table 1, Item 79) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (WP 0277, Table 1, Item 95) Lifting Device (4,000 lb minimum capacity) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 4 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 89) Qty: 8 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 9 Materials/Parts (cont.) Pin, Cotter (WP 0278, Table 1, Item 39) Qty: Washer, Flat (WP 0278, Table 1, Item 171) Qty: 32 Personnel Required (3) References TM 10-3930-675-10 WP 0175 WP 0183 WP 0184 WP 0223 WP 0232 WP 0233 Equipment Condition Wheels chocked Left-side stair assembly removed (WP 0181) 2

WARNING

DO NOT perform maintenance under cab when it is elevated on the cab transport lift. Fully move the cab to the operational position when the procedure indicates a cab movement. Failure to follow this warning may result in injury or death to personnel.

CAUTION
Always move cab slowly between operational and transport positions to prevent moving receptacles out of position.

NOTE
Thoroughly inspect cab transport system for wear and damage before attempting any adjustment or replacement procedures.

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0179

CAB TRANSPORT SYSTEM INSPECTION 1. In operational position, inspect rail guides (Figure 1, Item 1) for excessive wear or damage.

CAUTION
Excessive clearance between the tapered part of the cab rollers and the taper of the rail guides can cause binding of cab during cab movement. 2. Move cab to transport position (TM 10-3930-675-10) and check for smooth movement of cab on rail guides (Figure 1, Item 1). Support frame assembly (Figure 1, Item 2) and inspect rail guides for excessive wear or damage. Check cab rollers (Figure 1, Item 4) and locking bars (Figure 1, Item 3) for proper operation, excessive wear, or damage. Replace cab transport system components, as needed (refer to Cab Transport Lift Removal and Installation in this work package). Inspect and replace, as needed, cab sliding cylinder (WP 0233), cab lifting cylinder (WP 0232), and/or hydraulic hoses and fittings (WP 0223). Return cab to operational position (TM 10-3930-675-10) and fully raise cab transport lift. Check cab transport lift for height alignment with cab support frame (Figure 1, Item 2). Visually check alignment of rail guides (Figure 1, Item 1) at tapered edge of rail guides, and alignment between cab transport lift and cab support frame (Figure 1, Item 2).
1 2

3. 4. 5. 6. 7.

M0379JCH

4

3

Figure 1. Cab Transport Lift System Inspection.

NOTE
Each cab lifting cylinder has an adjustable clevis on the rod of cylinder. 8. Check for cab transport lift height alignment. a. If cab transport lift height is not aligned, adjust cab lifting cylinder height (WP 0232). Properly support cab lift transport and remove pin (Figure 2, Item 1) from cylinder clevis (Figure 2, Item 2) to lower cylinder (Figure 2, Item 3). Loosen jamnut (Figure 2, Item 4) below clevis and turn clevis to adjust height alignment of wear plates (Figure 2, Item 5).

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0179

CAB TRANSPORT SYSTEM INSPECTION - Continued

1,2,3,4

5

M0380JCH

Figure 2. Cab Transport Lift System Inspection. b. If cab lift transport and cab support frame (Figure 3, Item 3) are not aligned, check cab lift transport for worn plates (refer to Cab Lift Structure Removal in this work package). Raise cab lift transport and check gap between cab lift transport and cab support frame. Maximum allowable gap is 0.75 in. (19 mm) (Figure 3, Item 2) as shown near top step (Figure 3, Item 1).

9. 10. 11. 12.

Move cab to transport position (TM 10-3930-675-10). Loosen four bolts (Figure 3, Item 4) on cab support frame (Figure 3, Item 3) and make small alignment adjustments. Tighten four cab support frame bolts (Figure 3, Item 4). Move cab back and forth several times to check for proper operation.
1 2 3 4

4

M0381JCH

Figure 3. Cab Transport Lift System Inspection.

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0179

CAB TRANSPORT SYSTEM INSPECTION - Continued 13. 14. Inspect cab pins (Figure 4, Item 1) and receptacles (Figure 4, Item 2) for wear, damage, or rust. Clean pins and lightly lubricate with lubricating oil. Check for missing retaining pins (Figure 4, Item 4) and attachment chains (Figure 4, Item 3).

Figure 4. Cab Transport Lift System Inspection. END OF TASK CAB TRANSPORT SYSTEM ADJUSTMENT

NOTE
• Before performing any adjustment procedures, check clearances and alignment of cab pin receptacles with the cab in both operational and transport positions. Check for pin alignment in the U-shaped receptacles (at right side of cab, front, and rear) and at receptacles on cab left side. • A light source, a mirror, and a stiff wire approximately 3 ft (1 m) long with a 2 in. (5 cm) right angle bend will aid in checking for clearances in hard to reach areas. END OF TASK

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0179

CAB ADJUSTMENT: OPERATIONAL POSITION 1. Remove cab pins (Figure 4, Item 1). Turn auxiliary pump on and move cab fully to operational position. Turn auxiliary pump off (TM 10-3930-675-10).

NOTE
• Tag or mark shims, nuts, and washers to ensure the same order of replacement during installation. • Mark position of receptacle before loosening nuts. • Use one of the cab pins as a guide for aligning the two halves when tightening the bolts. 2. 3. 4. 5. 6. 7. Measure distance (A), between right-side cab wall (Figure 5, Item 1) and hydraulic mounting support frame (Figure 5, Item 2). Starting point measurement should be 4 9/16 ± 1/8 in. (11.6 ± 3.2 cm) as shown. Move cab to transport position (TM 10-3930-675-10). Remove front and rear access cover plates (WP 0175) to access right side cab pin receptacles. Loosen bolts (Figure 5, Item 4), washers (Figure 5, Item 5), and nuts (Figure 5, Item 6) enough to adjust receptacles (Figure 5, Item 3). Tighten bolts enough to allow for adjustment. Slowly move cab back to operational position, stopping at (A) (4 9/16 in. measured position).
1 2 3

4,5

A

M0383JCH

6

Figure 5. Cab Adjustment: Operational Position.

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0179

CAB ADJUSTMENT: OPERATIONAL POSITION - Continued 8. 9. 10. 11. Tap right rear receptacle (Figure 6, Item 2) into place around pin frame (Figure 6, Item 1). Keep U-shaped receptacle slot level and center pin (Figure 6, Item 1) in slot. Raise cab lift transport and move cab to transport position to access adjusted receptacle (Figure 6, Item 2). Tighten receptacle bolts (Figure 6, Item 3) and nuts (Figure 6, Item 4) to 180 ft-lb (244 N•m).

1 2

3

4

M0384JCH

Figure 6. Cab Adjustment: Operational Position. 12. 13. 14. 15. 16. Move cab slowly back to operational position. Operate cab side movement control until right rear pin (Figure 7, Item 1) is seated in receptacle (Figure 7, Item 4) and until cab stops. Tap right front receptacle in place around frame pin (Figure 7, Item 1). Keep U-shaped receptacle slot level and center pin (Figure 7, Item 1) in slot. Raise cab lift transport and move cab to transport position to access adjusted receptacle (Figure 7, Item 4). Tighten two receptacle bolts (3) and nuts (2) to 180 ft-lb (244 N•m). Move cab back and forth several times and check that adjustments of two right receptacles to cab maintain 4-9/16-in. gap. Cab should stop at same position each time, and receptacles should not move when pins are fully seated or until cab stops.

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0179

CAB ADJUSTMENT: OPERATIONAL POSITION - Continued

1

2 4

3
M0385JCH

Figure 7. Cab Adjustment: Operational Position. 17. 18. 19. Move cab to transport position. Remove and discard two nuts (Figure 8, Item 3) and washers (Figure 8, Item 4) on two left, front, and rear receptacles (Figure 8, Item 2). Install two new nuts (Figure 8, Item 3) and washers (Figure 8, Item 4) and tighten bolts (Figure 8, Item 1) just enough to allow for adjustment. Move cab back to operational position and ensure cab is fully seated in right-side receptacles.
1 2 3,4 3,4 2

1

M0386JCH

Figure 8. Cab Adjustment: Operational Position.

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0179

CAB ADJUSTMENT: OPERATIONAL POSITION - Continued 20. Tap left-side receptacles (Figure 9, Item 2) in place to receive cab pins (Figure 9, Item 1). Ensure receptacles (Figure 9, Item 2) are as level as possible and insert pin (Figure 9, Item 1) into hole to center receptacles as closely as possible. Slowly move cab to transport position. Tighten receptacle bolts (Figure 9, Item 4) and nuts (Figure 9, Item 3) to 180 ft-lb (244 N•m). Move cab back and forth several times to check pin alignment and proper operation. Install front and rear access covers (WP 0175).
1 2

21. 22. 23.

3,4

M0387JCH

Figure 9. Cab Adjustment: Operational Position. END OF TASK

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0179

CAB ADJUSTMENT: TRANSPORT POSITION

WARNING

DO NOT perform maintenance under cab when it is elevated on the cab transport lift. Fully move the cab to the operational position when the procedure indicates a cab movement. Failure to follow this warning may result in injury or death to personnel.

CAUTION
• Always move cab slowly between operational and transport positions to prevent moving receptacles out of position. • Damage to the proximity switch can occur if it projects beyond the proximity switch guard.

NOTE
The switch should be located approximately 0.039 in. (1 mm) inside proximity switch guard. 1. 2. Move cab to transport position. Activate cab side movement control right until cab stops. At right rear of cab and at frame, observe clearance between proximity switch guard (Figure 10, Item 1) and vehicle frame. Proximity switch guard should be as close as possible to frame, without applying pressure on it.
1

M0388JCH

Figure 10.

Cab Adjustment: Transport Position.

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0179

CAB ADJUSTMENT: TRANSPORT POSITION - Continued 3. Move cab back to operational position.

NOTE
• Tag or mark shims, nuts, and washers to ensure the same order of replacement during installation. • Mark position of receptacle before loosening nuts. • Use one of the cab pins as a guide when aligning the two receptacle halves when tightening the bolts. 4. 5. 6. Loosen bolts (Figure 11, Item 4) and nuts (Figure 11, Item 1) on front and rear, right-side transport receptacles (Figure 11, Item 3). Remove and discard two nuts (Figure 11, Item 1) and washers (Figure 11, Item 2) from receptacles (Figure 11, Item 3). Install two new nuts (Figure 11, Item 1) and washers (Figure 11, Item 2) and tighten bolts (Figure 11, Item 4) enough to allow for adjustment.
1,2 3 4 1,2 3

4

M0389JCH

Figure 11. Cab Adjustment: Transport Position.

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0179

CAB ADJUSTMENT: TRANSPORT POSITION - Continued 7. 8. 9. 10. 11. 12. 13. Slowly move cab back to transport position and stop just as proximity switch guard (Figure 12, Item 1) touches frame. Ensure proximity switch guard (Figure 12, Item 1) is not binding on frame. Tap right rear transport receptacle (Figure 12, Item 1) in place around frame pin (Figure 12, Item 2). Keep U-shaped receptacle slot level, and center pin in slot. Slowly move cab back to operational position to access adjusted receptacle (Figure 12, Item 1). Tighten receptacle bolts (Figure 12, Item 3) and nuts (Figure 12, Item 4) to 180 ft-lb (244 N•m). Move cab back to transport position. Ensure cab pin (Figure 12, Item 2) is fully seated in frame right front transport receptacle (Figure 12, Item 1) and ensure receptacle does not move. Tap transport receptacle (Figure 12, Item 1) in place around frame pin (Figure 12, Item 2). Keep U-shaped receptacle slot level and center pin in slot. Slowly move cab back to operational position to access adjusted receptacle (Figure 12, Item 1).

NOTE
A stiff wire (approximately 3 ft (0.91 m) long with a 2 in. (5.08 cm) right angle bend may aid in ensuring frame pins are fully seated in right transport receptacles. 14. Tighten receptacle bolts (Figure 12, Item 3) and nuts (Figure 12, Item 4) to 180 ft-lb (244 N•m).
1 2 3,4 1 2

3,4

M0390JCH

Figure 12.

Cab Adjustment: Transport Position.

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0179

CAB ADJUSTMENT: TRANSPORT POSITION - Continued 15. 16. 17. 18. 19. 20. 21. 22. 23. Move cab to operational position. Remove and discard two nuts (Figure 13, Item 1) and washers (Figure 13, Item 2) from receptacles (Figure 13, Item 3). Install two new nuts (Figure 13, Item 1) and washers (Figure 13, Item 2) and tighten bolts enough to allow for adjustment. Move cab back to transport position. Ensure cab is fully seated in right-side transport receptacles (Figure 13, Item 5). Tap left-side transport receptacles (Figure 13, Item 3) in place to receive cab pins (Figure 13, Item 5). Ensure the receptacles are parallel and as level as possible. Insert cab pin (Figure 13, Item 5) in hole to center receptacles (Figure 13, Item 3). Tighten receptacle bolts (Figure 13, Item 4) and nuts (Figure 13, Item 1) to 180 ft-lb (244 N•m). Remove cab pins (Figure 13, Item 5). Move cab back and forth several times to check for proper adjustment and operation.
5 3 4 3 1,2

1,2

4

M0391JCH

Figure 13. Cab Adjustment: Transport Position. END OF TASK

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0179

CAB TRANSPORT LIFT REMOVAL

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have a 2,000 lb (908 kg) capacity to lift cab transport lift. Failure to follow this warning may result in death or injury to personnel. 1. 2. Raise cab transport lift (Figure 14, Item 1) approximately 6 in. (15 cm) to gain clearance to attach nylon sling (TM 10-3930-675-10). Attach nylon sling to cab transport lift (Figure 14, Item 1) and suitable lifting device. Take up slack in nylon sling.
1

M0392JCH

Figure 14.

Cab Transport Lift Removal.

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TM 10-3930-675-23-2

0179

CAB TRANSPORT LIFT REMOVAL - Continued

NOTE
Perform Step 3 at top of each of two cab lifting cylinders. 3. 4. Pry spring clip (Figure 15, Item 1) away from cab lifting cylinder (Figure 15, Item 3) and remove spring clip to disconnect cylinder from cab transport lift (Figure 15, Item 2). With assistance, use lifting device to remove cab transport lift (Figure 15, Item 2) from vehicle.
2

1

3

M0393JCH

Figure 15.

Cab Transport Lift Removal.

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0179

CAB TRANSPORT LIFT REMOVAL - Continued 5. Remove four locknuts (Figure 16, Item 1), screws (Figure 16, Item 2), eight washers (Figure 16, Item 3), two shims (Figure 16, Item 4), and rails (Figure 16, Item 6) from cab transport lift (Figure 16, Item 5). Discard locknuts.
1,2,3 4 5

6

M0394JCH

Figure 16. END OF TASK

Cab Transport Lift Removal.

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0179

CAB TRANSPORT LIFT INSTALLATION 1. Install two shims (Figure 16, Item 4) and rails (Figure 16, Item 6) on cab transport lift (Figure 16, Item 5) with eight washers (Figure 17, Item 3), four screws (Figure 16, Item 2), and new locknuts (Figure 16, Item 1).

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have a 2,000 lb (908 kg) capacity to lift cab transport lift. Failure to follow this warning may result in death or injury to personnel. 2. Attach nylon sling to cab lift support (Figure 17, Item 1) and suitable lifting device. Take up slack in nylon sling.
1

M0395JCH

Figure 17.

Cab Transport Lift Installation.

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0179

CAB TRANSPORT LIFT INSTALLATION - Continued

NOTE
If a slight misalignment of components makes installation difficult, refer to Cab Transport Lift Structure Removal, Step 3 and Cab Transport Lift Structure Installation, Steps 2 and 7 in this work package. 3. Position cab transport lift (Figure 18, Item 1) on vehicle and lower cab transport lift onto cab lifting cylinders (Figure 18, Item 2).
1

2

M0396JCH

Figure 18.

Cab Transport Lift Installation.

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0179

CAB TRANSPORT LIFT INSTALLATION - Continued

NOTE
Perform Step 4 at top of each of two cab lifting cylinders. 4. Connect cab lifting cylinder (Figure 19, Item 3) to cab transport lift (Figure 19, Item 2) and install spring clip (Figure 19, Item 1). Ensure spring clip is fully installed.
2

1

3

M0397JCH

Figure 19. END OF TASK

Cab Transport Lift Installation.

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0179

CAB TRANSPORT LIFT STRUCTURE REMOVAL

NOTE
Perform the following procedure only as required to remove support structure for cab transport lift from frame. 1. 2. 3. Remove remote hydraulic control compartment (WP 0184). Remove battery and dolly wheels storage compartment (WP 0183). With cab transport lift removed, loosen, but DO NOT remove, four screws (Figure 20, Item 1) at each of two transport lift brackets (Figure 20, Item 2).
1

2

M0398JCH

Figure 20.

Cab Transport Lift Structure Removal.

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0179

CAB TRANSPORT LIFT STRUCTURE REMOVAL - Continued 4. 5. Remove four screws (Figure 21, Item 3), washers (Figure 21, Item 4), and plate (Figure 21, Item 2) from bottom of transport lift brackets (Figure 21, Item 1). Remove screw (Figure 21, Item 5), three washers (Figure 21, Item 6), and cotter pin (Figure 21, Item 7) holding bottom of cab lifting cylinders (Figure 21, Item 8) to transport lift brackets (Figure 21, Item 1). Discard cotter pin.

NOTE
Hydraulic hoses are to remain connected to cab lifting cylinders. DO NOT attempt to loosen or remove. 6. Raise lifting cylinders (Figure 21, Item 8) from transport lift brackets (Figure 21, Item 1) and set aside.
1

2

8

3,4

7

5,6

M0399JCH

Figure 21.

Cab Transport Lift Structure Removal.

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0179

CAB TRANSPORT LIFT STRUCTURE REMOVAL - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have a 2,000 lb (908 kg) capacity to lift cab transport lift. Failure to follow this warning may result in death or injury to personnel. 7. With assistance, use a nylon sling and suitable lifting device to remove eight screws (Figure 22, Item 1), 16 washers (Figure 22, Item 2), and two transport lift brackets (Figure 22, Item 7) from vehicle.

NOTE
Perform Step 8 for each transport lift bracket. 8. Remove nine locknuts (Figure 22, Item 3), screws (Figure 22, Item 4), three washers (Figure 22, Item 5), and three wear plates (Figure 22, Item 6). Discard locknuts.
1,2

3,4,5

7

6

M0400JCH

Figure 22. END OF TASK

Cab Transport Lift Structure Removal.

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0179

CAB TRANSPORT LIFT STRUCTURE INSTALLATION

NOTE
Perform Step 1 for each transport lift bracket. 1. Install three wear plates (Figure 22, Item 6) with three washers (Figure 22, Item 5), nine screws (Figure 22, Item 4), and new locknuts (Figure 22, Item 3).

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have a 2,000 lb (908 kg) capacity to lift cab transport lift. Failure to follow this warning may result in death or injury to personnel. 2. With assistance, use a nylon sling and suitable lifting device to install two transport lift brackets (Figure 23, Item 3) on vehicle with 16 washers (Figure 23, Item 2) and eight screws (Figure 23, Item 1). DO NOT fully tighten screws.
1,2

3

M0401JCH

Figure 23. Cab Transport Lift Structure Installation.

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TM 10-3930-675-23-2

0179

CAB TRANSPORT LIFT STRUCTURE INSTALLATION - Continued 3. 4. 5. Place bottom of cab lifting cylinders (Figure 24, Item 1) into transport lift brackets (Figure 24, Item 2). Install each of two cab lifting cylinders (Figure 24, Item 1) on transport lift brackets (Figure 24, Item 2) with new cotter pin (Figure 24, Item 8), three washers (Figure 24, Item 7), and screw (Figure 24, Item 6). Install plate (Figure 24, Item 3) on bottom of transport lift brackets (Figure 24, Item 2) with four washers (Figure 24, Item 5) and screws (Figure 24, Item 4).
1 2

3

4,5

8

6,7

M0402JCH

Figure 24.

Cab Transport Lift Structure Installation.

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TM 10-3930-675-23-2

0179

CAB TRANSPORT LIFT STRUCTURE INSTALLATION - Continued 6. 7. 8. Install cab transport lift (refer to Cab Transport Lift Installation in this work package). Fully tighten four screws (Figure 25, Item 1) on transport lift brackets (Figure 25, Item 2). Install battery and dolly wheels storage compartment (WP 0183) Install remote hydraulic control compartment (WP 0184)

1

2

M0403JCH

Figure 25. Cab Transport Lift Structure Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Install left side stair assembly (WP 0181). Apply parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0180

FIELD MAINTENANCE RIGHT-SIDE STEP ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 87) Qty: 4 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 4

WARNING

Mounting brackets of step are under spring tension. Take care when removing and installing. Wear protective eyewear to prevent injury to personnel.

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0180

REMOVAL 1. 2. 3. 4. Place step (Figure 1, Item 4) in lowered position. Remove two nuts (Figure 1, Item 7), washers (Figure 1, Item 8), and rubber bumpers (Figure 1, Item 6) from step (Figure 1, Item 4). Remove four locknuts (Figure 1, Item 9), washers (Figure 1, Item 10), screws (Figure 1, Item 11), and step (Figure 1, Item 4) from two step supports (Figure 1, Item 5). Discard locknuts. Remove four locknuts (Figure 1, Item 1), eight washers (Figure 1, Item 2), four screws (Figure 1, Item 3), and two step supports (Figure 1, Item 5) from vehicle. Discard locknuts.

END OF TASK INSTALLATION 1. 2. 3. 4. Install two step supports (Figure 1, Item 5) on vehicle with four screws (Figure 1, Item 3), eight washers (Figure 1, Item 2), and four new locknuts (Figure 1, Item 1). Install step (Figure 1, Item 4) on step supports (Figure 1, Item 5) with four screws (Figure 1, Item 11), washers (Figure 1, Item 10), and new locknuts (Figure 1, Item 9). Install two rubber bumpers (Figure 1, Item 6) on step (Figure 1, Item 4) with two washers (Figure 1, Item 8) and nuts (Figure 1, Item 7). Place step (Figure 1, Item 4) in raised position.
1,2,3 4 5

6 7,8 5

9,10,11

M0405JCH

Figure 1. Right-Side Step Assembly Removal. END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0181

FIELD MAINTENANCE LEFT-SIDE STAIR ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 75) Qty: 6 Materials/Parts (cont.) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 4 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 4 Personnel Required (2, if replacing stair assembly) Equipment Condition Wheels chocked (TM 10-3930-675-10)

STEP REPLACEMENT 1. 2. Remove four locknuts (Figure 1, Item 3), screws (Figure 1, Item 4), eight washers (Figure 1, Item 5), and step (Figure 1, Item 1) from stair assembly (Figure 1, Item 2). Discard locknuts. Install step (Figure 1, Item 1) on stair assembly (Figure 1, Item 2) with four screws (Figure 1, Item 4), eight washers (Figure 1, Item 5), and four new locknuts (Figure 1, Item 3).
1 2 3,4,5

M0406JCH

Figure 1. END OF TASK

Left-Side Step Assembly Replacement.

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TM 10-3930-675-23-2

0181

STAIR ASSEMBLY REMOVAL 1. 2. Remove two locknuts (Figure 2, Item 1), screws (Figure 2, Item 2), cable loop (Figure 2, Item 3), and hydraulic hoses (Figure 2, Item 4) from underside of stair assembly (Figure 2, Item 10). Discard locknuts. Remove two locknuts (Figure 2, Item 6), screws (Figure 2, Item 7), washers (Figure 2, Item 8), hose clamps (Figure 2, Item 9), and hydraulic hoses (Figure 2, Item 5) from stair assembly (Figure 2, Item 10). Discard locknuts.
1,2 3 4

10

5 9 6,7,8
M0407JCH

Figure 2. 3.

Left-Side Stair Assembly Removal.

Remove six locknuts (Figure 3, Item 2), screws (Figure 3, Item 3), 12 washers (Figure 3, Item 4), and stair assembly (Figure 3, Item 1) from vehicle. Discard locknuts.

END OF TASK STAIR ASSEMBLY INSTALLATION 1. 2. Install stair assembly (Figure 3, Item 1) on vehicle with six screws (Figure 3, Item 3), 12 washers (Figure 3, Item 4), and six new locknuts (Figure 3, Item 2). Secure hydraulic hoses (Figure 2, Item 5) to underside of stair assembly (Figure 2, Item 10) with two hose clamps (Figure 2, Item 9), washers (Figure 2, Item 8), screws (Figure 2, Item 7), and new locknuts (Figure 2, Item 6). Secure hydraulic hoses (Figure 2, Item 4) to stair assembly (Figure 2, Item 10) with cable loop (Figure 2, Item 3), two screws (Figure 2, Item 2), and new locknuts (Figure 2, Item 1).

3.

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TM 10-3930-675-23-2

0181

STAIR ASSEMBLY INSTALLATION - Continued
1

2,3,4

M0408JCH

Figure 3. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Left-Side Stair Assembly Replacement.

Apply parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0182

FIELD MAINTENANCE STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 87) Qty: 1 Personnel Required (2) References TM 10-3930-675-10

REMOVAL

NOTE
• Perform step 1 to remove each door. • Replace bracket bushings only if damaged. 1. With door (Figure 1, Item 5) unlatched and open, remove four locknuts (Figure 1, Item 1), eight washers (Figure 1, Item 2), four screws (Figure 1, Item 3), two brackets (Figure 1, Item 4), and door from storage compartment (Figure 1, Item 6). Discard locknuts.
1,2,3 4

5

6
M0474JCH

Figure 1. Storage Compartment Door Removal.

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0182

REMOVAL - Continued

NOTE
Perform Steps 2 and 3 to remove each door latch. 2. With door (Figure 2, Item 9) unlatched and open, remove four locknuts (Figure 2, Item 1), washers (Figure 2, Item 2), screws (Figure 2, Item 3), and latch (Figure 2, Item 4) from storage compartment (Figure 2, Item 12). Discard locknuts. Remove two locknuts (Figure 2, Item 6), washers (Figure 2, Item 7), screws (Figure 2, Item 8), and hook (Figure 2, Item 5) from door (Figure 2, Item 9). Discard locknuts.
1,2,3 4 5

3.

12

11

10

9

6,7,8

M0475JCH

Figure 2. Storage Compartment Door Removal and Installation. END OF TASK INSTALLATION

NOTE
Perform Steps 1 and 2 to install each door latch. 1. 2. Install hook (Figure 2, Item 5) on door (Figure 2, Item 9) with two screws (Figure 2, Item 8), washers (Figure 2, Item 7), and new locknuts (Figure 2, Item 6). Install latch (Figure 2, Item 4) on storage compartment (Figure 2, Item 12) with four screws (Figure 2, Item 3), washers (Figure 2, Item 2), and new locknuts (Figure 2, Item 1).

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TM 10-3930-675-23-2

0182

INSTALLATION - Continued

NOTE
Perform Steps 3 and 4 to install each door. 3. Loosely install door (Figure 3, Item 5) on storage compartment (Figure 3, Item 6) with two brackets (Figure 3, Item 4), four screws (Figure 3, Item 3), eight washers (Figure 3, Item 2), and four new locknuts (Figure 3, Item 1). Close door to determine proper position of brackets. Readjust door as required for proper closure. Open door (Figure 3, Item 5) and tighten four locknuts (Figure 3, Item 1).
1,2,3 4

4.

5

6
M0476JCH

Figure 3. 5. 6. 7. 8. Loosen jamnut (Figure 2, Item 11).

Storage Compartment Door Installation.

Rotate turnbuckle (Figure 2, Item 10) until door (Figure 2, Item 9) fits snugly when latched. Tighten jamnut (Figure 2, Item 11). Check storage compartment door for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0183

FIELD MAINTENANCE BATTERY AND DOLLY WHEELS STORAGE COMPARTMENT REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (4,000 lb minimum capacity) Materials/Parts Tag, Marker (WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 17 Personnel Required (3) References Volume 1, WP 0130 Volume 1, WP 0134 Equipment Condition Dolly wheels and ramp removed from storage compartment (TM 10-3930-675-10) Equipment Condition (cont.) Handrail removed (TM 10-3930-675-10) Cab transport lift removed (WP 0179) Batteries removed (Volume 1, WP 0128) Air cleaner removed (Volume 1, WP 0071) Exterior rearview mirror removed (WP 0193) Left-side stair assembly removed (WP 0181) Engine cover removed (WP 0185)

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

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0183

REMOVAL 1. 2. 3. 4. 5. 6. 7. Remove six locknuts (Figure 1, Item 1), screws (Figure 1, Item 2), 12 washers (Figure 1, Item 3), and footstep (Figure 1, Item 4) from top of storage compartment (Figure 1, Item 5). Discard locknuts. Disconnect cables from NATO slave receptacle and master battery switch (Volume 1, WP 0130) and (Volume 1, WP 0134). Remove cables from storage compartment (Figure 1, Item 5) by pulling them out into engine compartment. Position lifting device against side of vehicle supporting weight of storage compartment (Figure 1, Item 5). Remove five locknuts, t10 en washers, and five bolts securing storage compartment (Figure 1, Item 5) to side of frame (Figure 1, Item 6). Discard locknuts. Remove six locknuts (Figure 1, Item 7), 12 washers (Figure 1, Item 8), and six bolts (Figure 1, Item 9) securing top of storage compartment (Figure 1, Item 5) to top of frame (Figure 1, Item 6). Discard locknuts. Remove storage compartment (Figure 1, Item 5) from vehicle frame (Figure 1, Item 6).

END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. Position storage compartment (Figure 1, Item 5) against vehicle frame (Figure 1, Item 6). Install five bolts, 10 washers, and five new locknuts securing storage compartment (Figure 1, Item 5) to side of frame (Figure 1, Item 6). Install six bolts (Figure 1, Item 9), 12 washers (Figure 1, Item 8), and six new locknuts (Figure 1, Item 7) securing top of storage compartment (Figure 1, Item 5) to top of frame (Figure 1, Item 6). Remove lifting device. Feed cables for NATO slave receptacle and master battery switch into storage compartment (Figure 1, Item 5) through opening in back of compartment. Connect cables to NATO slave receptacle and to master battery switch (Volume 1, WP 0130) and (Volume 1, WP 0134). Install footstep (Figure 1, Item 4) to top of storage compartment (Figure 1, Item 5) with 12 washers (Figure 1, Item 3), six screws (Figure 1, Item 2), and new locknuts (Figure 1, Item 1).

0183-2

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TM 10-3930-675-23-2

0183

INSTALLATION - Continued
1,2,3 4 5 6

7,8,9

5

M0477JCH

Figure 1. Battery and Dolly Wheels Storage Compartment Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. Install engine cover (WP 0185). Install left-side stair assembly (WP 0181). Install exterior rearview mirror (WP 0193). Install air cleaner (Volume 1, WP 0071). Install batteries (Volume 1, WP 0128). Install cab transport lift (WP 0179). Install handrail (TM 10-3930-675-10). Stow dolly wheels and ramp in storage compartment (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0183-3/4 blank

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TM 10-3930-675-23-2

0184

FIELD MAINTENANCE REMOTE HYDRAULIC CONTROL COMPARTMENT REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (4,000 lb minimum capacity) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 10 Personnel Required (2) Equipment Condition Cab transport raised (TM 10-3930-675-10) Equipment Condition (cont.) Oil sampling valves removed (Volume 1, WP 0062) Hydraulic system test point fittings removed (WP 0222) Cab transport control valve removed (WP 0216) Boom folding control valve removed (WP 0215) Ball valve (shutoff valve #5) removed (WP 0224) Boom lowering solenoid valve removed (WP 0217) Left-side stair assembly removed (WP 0181) Mudguard removed (WP 0189)

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

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0184

REMOVAL 1. 2. 3. 4. 5. Ensure all hydraulic hoses are removed from compartment (Figure 1, Item 2). Position suitable lifting device against side of vehicle supporting weight of compartment (Figure 1, Item 2). Remove four locknuts, eight washers, and four screws securing compartment (Figure 1, Item 2) to side of frame (Figure 1, Item 1). Discard locknuts. Remove six locknuts (Figure 1, Item 3), 12 washers (Figure 1, Item 4), and six screws (Figure 1, Item 5) securing top of compartment (Figure 1, Item 2) to top of frame (Figure 1, Item 1). Discard locknuts. Remove compartment (Figure 1, Item 2) from vehicle.

END OF TASK INSTALLATION 1. 2. 3. Position compartment (Figure 1, Item 2) against vehicle frame (Figure 1, Item 1). Install four screws, eight washers, and four new locknuts securing compartment (Figure 1, Item 2) to side of frame (Figure 1, Item 1). Install six screws (Figure 1, Item 5), 12 washers (Figure 1, Item 4), and six new locknuts (Figure 1, Item 3) securing top of compartment (Figure 1, Item 2) to top of frame (Figure 1, Item 1). Remove lifting device.
1 2

3,4,5

M0478JCH

Figure 1. Remote Hydraulic Control Compartment Replacement. END OF TASK

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0184

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install mudguard (WP 0189). Install left-side stair assembly (WP 0181). Install boom lowering solenoid valve (WP 0217). Install ball valve (shutoff valve #5) (WP 0224). Install boom folding control valve (WP 0215). Install cab transport control valve (WP 0216). Install hydraulic system test point fittings (WP 0222). Install oil sampling valves (Volume 1, WP 0062). Operate cab lift/lower lever in remote hydraulic control compartment to lower cab transport lift (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0184-3/4 blank

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TM 10-3930-675-23-2

0185

FIELD MAINTENANCE ENGINE COVER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Abrasive Pad (WP 0276, Table 1, Item 1) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 87) Qty: 6 Materials/Parts (cont.) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 3 Gasket (WP 0278, Table 1, Item 160) Qty: 1 Personnel Required (2) References TM 10-3930-675-10

NOTE
For ease in removing engine cover, boom may be raised (TM 10-3930-675-10). REMOVAL 1. 2. 3. Release latch (Figure 1, Item 2) on each side of engine cover (Figure 1, Item 1). Lift rear of engine cover (Figure 1, Item 1) and slide front of engine cover out from front latch. Lift engine cover (Figure 1, Item 1) off vehicle.
1

2

M0450JCH

Figure 1. END OF TASK

Engine Cover Removal.

0185-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00152)

TM 10-3930-675-23-2

0185

DISASSEMBLY

NOTE
Perform Step 1 to remove each of two handles. 1. Remove two locknuts (Figure 2, Item 2), screws (Figure 2, Item 3), washers (Figure 2, Item 4), washers (Figure 2, Item 5), and handle (Figure 2, Item 6) from engine cover (Figure 2, Item 1). Discard locknuts.
1 6 2,3,4,5

M0451JCH

Figure 2. Engine Cover Disassembly.

NOTE
Perform Step 2 to remove each of two latches. 2. Remove four locknuts (Figure 3, Item 2), washers (Figure 3, Item 3), plate (Figure 3, Item 4), four screws (Figure 3, Item 5), and latch (Figure 3, Item 6) from engine cover (Figure 3, Item 1). Discard locknuts.
1 2,3,4,5 6

M0452JCH

Figure 3. Engine Cover Disassembly.

0185-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00152)

TM 10-3930-675-23-2

0185

DISASSEMBLY - Continued

NOTE
Perform Step 3 to remove bracket from front of engine cover. 3. Remove three locknuts (Figure 4, Item 2), washers (Figure 4, Item 3), washers (Figure 4, Item 4), screws (Figure 4, Item 5), and bracket (Figure 4, Item 6) from front of engine cover (Figure 4, Item 1). Discard locknuts.

NOTE
Perform Step 4 to remove weatherseal. 4. Remove weatherseal (Figure 4, Item 7) and cut new weatherseal to same length. Discard old weatherseal.

END OF TASK ASSEMBLY

NOTE
Perform Step 1 to install weatherseal on engine cover. 1. Apply adhesive to new weatherseal (Figure 4, Item 7) and install weatherseal on edges of engine cover (Figure 4, Item 1).

NOTE
Perform Step 2 to install bracket on front of engine cover. 2. Install bracket (Figure 4, Item 6) on front of engine cover (Figure 4, Item 1) with three screws (Figure 4, Item 5), washers (Figure 4, Item 4), washers (Figure 4, Item 3), and new locknuts (Figure 4, Item 2).
1

7

6

2,3,4,5

M0453JCH

Figure 4.

Engine Cover Disassembly.

0185-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00152)

TM 10-3930-675-23-2

0185

ASSEMBLY - Continued

NOTE
Perform Step 3 to install each of two latches. 3. Install plate (Figure 3, Item 4) and latch (Figure 3, Item 6) on engine cover (Figure 3, Item 1) with four washers (Figure 3, Item 3), screws (Figure 3, Item 5), and new locknuts (Figure 3, Item 2).

NOTE
Perform Step 4 to install each of two handles. 4. Install handle (Figure 5, Item 7) on engine cover (Figure 5, Item 1) with two washers (Figure 5, Item 6), washers (Figure 5, Item 5), screws (Figure 5, Item 4), and new locknuts (Figure 5, Item 3).

END OF TASK INSTALLATION 1. 2. With assistance, position engine cover (Figure 5, Item 1) over engine compartment and into front latch. Secure engine cover (Figure 5, Item 1) on each side with latch (Figure 5, Item 2).
1 7 3,4,5,6

2

M0454JCH

Figure 5. Engine Cover Assembly. END OF TASK END OF WORK PACKAGE

0185-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00152)

TM 10-3930-675-23-2

0186

FIELD MAINTENANCE CAB DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Materials/Parts (cont.) Nut, Self-Locking, Clinch (WP 0278, Table 1, Item 86) Qty: 4 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 1 Personnel Required (2) References LO 10-3930-675-13 WP 0188

REMOVAL 1. From inside cab (Figure 1, Item 1), with cab door (Figure 1, Item 5) closed, remove two screws (Figure 1, Item 3), washers (Figure 1, Item 4), and yoke (Figure 1, Item 2) from cab door.
1 2 3,4 5

M0957JCH

Figure 1.

Cab Door Assembly Removal.

0186-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00153)

TM 10-3930-675-23-2

0186

REMOVAL - Continued 2. Remove locknut (Figure 2, Item 5), two washers (Figure 2, Item 4), screw (Figure 2, Item 3), and door holder (Figure 2, Item 1) from cab door (Figure 2, Item 2). Discard locknut.

1

2

3

4

4

5

M0958JCH

Figure 2. Cab Door Assembly Removal. 3. Partially open cab door (Figure 3, Item 1) and, with assistance, remove four screws (Figure 3, Item 3) and cab door from vehicle.

END OF TASK

0186-2

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0186

DISASSEMBLY 1. 2. Remove grease fitting (Figure 3, Item 2) from each of two cab door hinges (Figure 3, Item 4). Remove cab door window glass (WP 0188).

1

2

3

4

M0959JCH

Figure 3.

Cab Door Disassembly.

0186-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00153)

TM 10-3930-675-23-2

0186

DISASSEMBLY - Continued

NOTE
Perform Step 3 for each of two handles. 3. 4. 5. 6. 7. Remove two screws (Figure 4, Item 2), washers (Figure 4, Item 3), and handle (Figure 4, Item 1). Remove four locknuts (Figure 4, Item 5), screws (Figure 4, Item 6), and door lock (Figure 4, Item 4). Discard locknuts. Remove two screws (Figure 4, Item 12) and washers (Figure 4, Item 13) from door panel (Figure 4, Item 7). Remove five screws (Figure 4, Item 8) and door panel (Figure 4, Item 7) from cab door (Figure 4, Item 14). Remove two screws (Figure 4, Item 9), washers (Figure 4, Item 10), and door latch (Figure 4, Item 11).

1

2,3

4

5,6 7

8 9,10,11

12,13

1
Figure 4. END OF TASK

14

M0960JCH

Cab Door Disassembly and Assembly.

0186-4

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TM 10-3930-675-23-2

0186

ASSEMBLY 1. 2. 3. 4. Install door latch (Figure 4, Item 11) on cab door (Figure 4, Item 14) with two washers (Figure 4, Item 10) and screws (Figure 4, Item 9). Install door panel (Figure 4, Item 7) with five screws (Figure 4, Item 8). Install two washers (Figure 4, Item 13) and screws (Figure 4, Item 12) on door panel (Figure 4, Item 7). Install door lock (Figure 4, Item 4) with four screws (Figure 4, Item 6) and new locknuts (Figure 4, Item 5).

NOTE
Perform Step 5 for each of two handles. 5. 6. 7. Install handle (Figure 4, Item 1) with two washers (Figure 4, Item 3) and screws (Figure 4, Item 2). Install cab door window glass (WP 0188). Install grease fitting (Figure 5, Item 2) in each of two cab door hinges (Figure 5, Item 4).

END OF TASK INSTALLATION 1. With assistance, install cab door (Figure 5, Item 1) on vehicle with four screws (Figure 5, Item 3).

1

2

3

4

M0959JCH

Figure 5.

Cab Door Installation.

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TM 10-3930-675-23-2

0186

INSTALLATION - Continued 2. From inside cab, and with cab door (Figure 6, Item 2) closed, install door holder (Figure 6, Item 1) on cab door with screw (Figure 6, Item 3), two washers (Figure 6, Item 4), and new locknut (Figure 6, Item 5).
1 2 3 4

4

5

M0962JCH

Figure 6.

Cab Door Installation.

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TM 10-3930-675-23-2

0186

INSTALLATION - Continued 3. 4. Install yoke (Figure 7, Item 1) with two washers (Figure 7, Item 3) and screws (Figure 7, Item 2). Lubricate cab door hinges (LO 10-3930-675-13).
1 2,3

M0963JCH

Figure 7. END OF TASK END OF WORK PACKAGE

Cab Door Installation.

0186-7/8 blank

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TM 10-3930-675-23-2

0187

FIELD MAINTENANCE CAB DOOR WEATHERSEAL REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Sealing Compound (WP 0276, Table 1, Item 55) Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Materials/Parts (cont.) Rag, Wiping (WP 0276, Table 1, Item 50) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 1 Seal, Plain (WP 0278, Table 1, Item 161) Qty: 1

REMOVAL 1. 2. From inside cab (Figure 1, Item 2), with cab door (Figure 1, Item 6) closed, remove nut (Figure 1, Item 7) and disconnect yoke (Figure 1, Item 3) from cylinder (Figure 1, Item 1). Remove two screws (Figure 1, Item 4), washers (Figure 1, Item 5), and yoke (Figure 1, Item 3) from cab door (Figure 1, Item 6).
1 2 3 4,5

6

7

M0470JCH

Figure 1.

Cab Door Weatherseal Removal.

0187-1

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0187

REMOVAL - Continued 3. 4. Open cab door (Figure 2, Item 2) and secure in opened position. Remove locknut (Figure 2, Item 5), two washers (Figure 2, Item 4), screw (Figure 2, Item 3), and door holder (Figure 2, Item 1) from cab door (Figure 2, Item 2). Discard locknut.
1 2 3 4

4

5

M0471JCH

Figure 2.

Cab Door Weatherseal Removal.

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0187

REMOVAL - Continued 5. 6. 7. Remove three screws (Figure 3, Item 3) and plate (Figure 3, Item 4) from cab floor. Remove cab door weatherseal (Figure 3, Item 2) from cab (Figure 3, Item 1). Discard weatherseal. Clean cab door opening with detergent and water. Dry with clean rags.
1 2 3 4

M0472JCH

Figure 3. END OF TASK

Cab Door Weatherseal Removal.

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0187

INSTALLATION 1. 2. 3. 4. 5. At cab floor, mark center of cab door opening. Start new weatherseal (Figure 4, Item 2) at mark and install weatherseal on cab door opening. Press weatherseal firmly into place. Cut weatherseal (Figure 4, Item 2) to a length that allows ends of weatherseal to come together. Apply sealing compound to ends of weatherseal (Figure 4, Item 2) and press ends together. Allow sealing compound to set. Install plate (Figure 4, Item 4) on cab floor with three screws (Figure 4, Item 3).
1 2 3 4

M0472JCH

Figure 4. 6.

Cab Door Weatherseal Installation.

Install door holder (Figure 5, Item 1) on cab door (Figure 5, Item 2) with screw (Figure 5, Item 3), two washers (Figure 5, Item 4), and new locknut (Figure 5, Item 5).

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0187

INSTALLATION - Continued
1 2 3 4

4

5

M0471JCH

Figure 5. 7. 8.

Cab Door Weatherseal Installation.

From inside cab (Figure 6, Item 2), with cab door (Figure 6, Item 6) closed, install yoke (Figure 6, Item 3) on cab door with two washers (Figure 6, Item 5) and screws (Figure 6, Item 4). Connect yoke (Figure 6, Item 3) to cylinder (Figure 6, Item 1) and install nut (Figure 6, Item 7).
1 2 3 4,5

6

7

M0473JCH

Figure 6. END OF TASK END OF WORK PACKAGE

Cab Door Weatherseal Installation.

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0188

FIELD MAINTENANCE WINDSHIELD AND WINDOW GLASS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Dispenser, Sealant (WP 0277, Table 1, Item 22) Gloves, Welders' (WP 0277, Table 1, Item 33) Materials/Parts Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Rubber Strip (WP 0278, Table 1, Item 162) Qty: 1 Personnel Required (2)

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0188

WARNING

• Handle windshield and window glass with care. Dropping or handling windows roughly may cause window to shatter. Failure to follow this warning may result in injury to personnel. • Wear gloves and face shield when handling windshield and window glass to protect against possible injury. REMOVAL 1. 2. 3. 4. Remove windshield wiper, as applicable (WP 0194). Remove four capnuts (Figure 1, Item 1), washers (Figure 1, Item 2), and brackets (Figure 1, Item 3) from cab (Figure 1, Item 7). Trace locking strip (Figure 1, Item 6) of weatherseal (Figure 1, Item 5) to find where ends of locking strip join together. Pry out one end of locking strip (Figure 1, Item 6) and remove locking strip from weatherseal (Figure 1, Item 5). Starting at one INSIDE corner of window (Figure 1, Item 4), pry up flange of weatherseal (Figure 1, Item 5) while pressing outward on window. Work around entire length of weatherseal (Figure 1, Item 5), as necessary, until window (Figure 1, Item 4) and weatherseal are removed from cab (Figure 1, Item 7). Remove weatherseal (Figure 1, Item 5) from window (Figure 1, Item 4).

5. 6. 7.

END OF TASK INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. Position length of weatherseal (Figure 1, Item 5) on edge of window (Figure 1, Item 4) and cut weatherseal so ends of weatherseal will meet in a straight line. Remove weatherseal. Install weatherseal (Figure 1, Item 5) on window (Figure 1, Item 4) with recess for locking strip (Figure 1, Item 6) facing toward outside of window. Install locking strip (Figure 1, Item 6) on weatherseal (Figure 1, Item 5). Lubricate weatherseal (Figure 1, Item 5) with a solution of detergent and water. Place window (Figure 1, Item 4) with weatherseal (Figure 1, Item 5) to outside of cab (Figure 1, Item 7), with one lower corner of weatherseal installed on flange of cab Work around entire length of weatherseal (Figure 1, Item 5) while gently pressing inward on window until weatherseal is fully installed on cab (Figure 1, Item 7). Install four brackets (Figure 1, Item 3) with four washers (Figure 1, Item 2) and capnuts (Figure 1, Item 1). Install windshield wiper, as applicable (WP 0194).

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0188

INSTALLATION - Continued
1,2 3 4

7

6

5

M0964JCH

Figure 1. END OF TASK

Window Removal and Installation.

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0188

REMOVAL – CAB ROOF WINDOW

WARNING

• Handle windshield and window glass with care. Dropping or handling windows roughly may cause window to shatter. Failure to follow this warning may result in injury to personnel. • Wear gloves and face shield when handling windshield and window glass to protect against possible injury. Cut through gasket forming compound of cab roof window (Figure 2, Item 1) and remove cab roof window from cab (Figure 2, Item 2). END OF TASK INSTALLATION – CAB ROOF WINDOW 1. 2. Apply gasket forming compound to all four edges of cab roof window (Figure 2, Item 1) and top of cab (Figure 2, Item 2). Position cab roof window (Figure 2, Item 1) on cab (Figure 2, Item 2). Reapply gasket forming compound as needed and smooth to a beveled finish.
1 2

M1116JCH

Figure 2. END OF TASK END OF WORK PACKAGE

Window Removal and Installation.

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0189

FIELD MAINTENANCE MUDGUARD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 6 Personnel Required (2)

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0189

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. REPLACEMENT 1. 2. Remove six locknuts (Figure 1, Item 2), 12 washers (Figure 1, Item 3), six screws (Figure 1, Item 4), and mudguard (Figure 1, Item 1) from remote hydraulic control compartment (Figure 1, Item 5). Discard locknuts. Install mudguard (Figure 1, Item 1) on remote hydraulic control compartment (Figure 1, Item 5) with six screws (Figure 1, Item 4), 12 washers (Figure 1, Item 3), and six new locknuts (Figure 1, Item 2).
1 2,3,4

5
M0464JCH

Figure 1. Mudguard Replacement. END OF TASK END OF WORK PACKAGE

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0190

FIELD MAINTENANCE FENDER ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Adhesive (WP 0276, Table 1, Item 2) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 75) Qty: 4 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 12 Materials/Parts (cont.) Washer, Lock (WP 0278, Table 1, Item 121) Qty: 8 Washer, Lock (WP 0278, Table 1, Item 123) Qty: 8 Personnel Required (2) References Volume 1, WP 0125 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering hydraulic system pressure relieved (WP 0204)

WARNING

DO NOT perform this task without first relieving steering hydraulic system pressure. When working in close proximity to wheels and tires, safety dictates that there be no danger of inadvertent movement in wheels and tires. Failure to relieve steering hydraulic system pressure could result in injury to personnel.

NOTE
• All four fenders on the RT 240V1 and the two rear fenders on the RT 240V1R vehicle are replaced the same way. • Two front fenders on the RT 240V1R and all fenders on the RT 240V2, RT 240V3 vehicle are replaced using the procedures shown for those configurations.

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0190

FENDERS AND FENDER BRACKETS REMOVAL (RT 240V1) 1. 2. 3. 4. At front and rear of fender (Figure 1, Item 10), remove six locknuts (Figure 1, Item 11), six screws (Figure 1, Item 12), and 12 washers (Figure 1, Item 13). Discard locknuts. Remove fender (Figure 1, Item 10) from fender support bracket (Figure 1, Item 1). Remove nine screws (Figure 1, Item 2), washers (Figure 1, Item 3), and clamps (Figure 1, Item 4) to release wiring harness (Figure 1, Item 5) from fender support bracket (Figure 1, Item 1). Remove four locknuts (Figure 1, Item 6), four screws (Figure 1, Item 7), eight washers (Figure 1, Item 8), and light bracket (Figure 1, Item 9) from fender support bracket (Figure 1, Item 1). Set light bracket and wiring harness (Figure 1, Item 5) aside. Discard locknuts.
1 2,3,4 5 6,7,8 9

11,12,13

10

M0455JCH

Figure 1. 5.

Fender and Fender Bracket Removal (RT 240V1).

Remove eight screws (Figure 2, Item 2), eight lockwashers (Figure 2, Item 3), and fender support bracket (Figure 2, Item 1) from vehicle. Discard lockwashers.

END OF TASK

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0190

FENDERS AND FENDER BRACKETS INSTALLATION (RT 240V1)

NOTE
Perform Steps 1 thru 3 to install fender support bracket on vehicle. 1. 2. Install fender support bracket (Figure 2, Item 1) on vehicle with eight new lockwashers (Figure 2, Item 3) and screws (Figure 2, Item 2). Install light bracket (Figure 1, Item 9) on fender support bracket (Figure 1, Item 1) with eight washers (Figure 1, Item 8), four screws (Figure 1, Item 7), and new locknuts (Figure 1, Item 6).

NOTE
During installation of the wiring harness, allow a loop in the harness at the base of the fender support bracket to allow the wheel to turn without damaging the harness. 3. Install wiring harness (Figure 1, Item 5) on fender support bracket (Figure 1, Item 1) with nine clamps (Figure 1, Item 4), washers (Figure 1, Item 3), and screws (Figure 1, Item 2).

NOTE
Perform Steps 4 and 5 to install fender on fender support bracket. 4. 5. Position fender (Figure 1, Item 10) on fender support bracket (Figure 1, Item 1). Install fender (Figure 1, Item 10) on fender support bracket (Figure 1, Item 1) with 12 washers (Figure 1, Item 13), six screws (Figure 1, Item 12), and new locknuts (Figure 1, Item 11) at front and rear of fender.
1 2,3

M0456JCH

Figure 2. END OF TASK

Fender and Fender Bracket Replacement (RT 240V1).

0190-3

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0190

FRONT FENDERS AND FENDER BRACKETS REMOVAL (RT 240V1R)

WARNING

DO NOT perform this task without first relieving steering hydraulic system pressure. When working in close proximity to wheels and tires, safety dictates that there be no danger of inadvertent movement in wheels and tires. Failure to relieve steering hydraulic system pressure could result in injury to personnel. 1. 2. 3. At rear of fender, remove six locknuts (Figure 3, Item 5), six screws (Figure 3, Item 6), and 12 washers (Figure 3, Item 7). A t front of fender, remove three locknuts (Figure 3, Item 2), three screws (Figure 3, Item 3), and six washers (Figure 3, Item 4). Remove fender (Figure 3, Item 1) from fender bracket (Figure 3, Item 8).
1 2,3,4

8

5,6,7

M0457JCH

Figure 3. 4. 5.

Front Fender and Fender Bracket Removal (RT 240V1R).

Remove screws, washers, nuts, and clamps securing wiring harness and light brackets to fender support bracket (Figure 4, Item 1). Set light bracket and wiring harness aside. Remove eight screws (Figure 4, Item 2), lockwashers (Figure 4, Item 3), and fender support bracket (Figure 4, Item 1) from vehicle. Discard lockwashers.

END OF TASK

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0190

FRONT FENDERS AND FENDER BRACKETS INSTALLATION (RT 240V1R)

NOTE
Perform Steps 1 and 2 to install fender support bracket on the RT 240V1R vehicle. 1. 2. Install fender support bracket (Figure 4, Item 1) on vehicle with eight new lockwashers (Figure 4, item 3) and screws (Figure 4, Item 2). Install light bracket and wiring harness on fender support bracket (Figure 4, Item 1) with screws, nuts, and washers.

NOTE
Perform Steps 3 and 4 to install the fender on the fender support bracket. 3. 4. 5. Position fender (Figure 3, Item 1) on fender support bracket (Figure 3, Item 8). At front of fender, install three screws (Figure 3, Item 2), nuts (Figure 3, Item 3), and six washers (Figure 3, Item 4). At rear of fender, install six screws (Figure 3, Item 5), nuts (Figure 3, Item 6), and 12 washers (Figure 3, Item 7).
1 2,3

M0458JCH

Figure 4. Front Fender and Fender Bracket Replacement (RT 240V1R). END OF TASK

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0190

REAR FENDERS AND FENDER BRACKETS REMOVAL (RT 240V2 and RT 240V3)

WARNING

DO NOT perform this task without first relieving steering hydraulic system pressure. When working in close proximity to wheels and tires, safety dictates that there be no danger of inadvertent movement in wheels and tires. Failure to relieve steering hydraulic system pressure could result in injury to personnel. 1. 2. At front and rear of fender (Figure 5, Item 10), remove six locknuts (Figure 5, Item 11), six screws (Figure 5, Item 12), and 12 washers (Figure 5, Item 13). Discard locknuts. Remove fender (Figure 5, Item 10) from fender support bracket (Figure 5, Item 1).
1 2,3,4 5 6,7,8 9

11,12,13

10

M0459JCH

Figure 5. Rear Fender and Fender Bracket Removal (RT 240V2 and RT 240V3).

NOTE
Rear fender support brackets can be removed with lights and light brackets attached. 3. 4. Disconnect waterproof connector (Figure 6, Item 4) from inside base of fender support bracket (Figure 6, Item 1). Remove eight screws (Figure 6, Item 2), lockwashers (Figure 6, Item 3), and fender support bracket (Figure 6, Item 1) from vehicle. Discard lockwashers.

END OF TASK

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0190

REAR FENDERS AND FENDER BRACKETS INSTALLATION (RT 240V2 and RT 240V3)

NOTE
Rear fender support brackets can be installed with lights and light brackets attached. 1. 2. 3. 4. Install fender support bracket (Figure 6, item 1) with eight screws (Figure 6, Item 2) and new lockwashers (Figure 6, Item 3). Connect waterproof connector (Figure 6, Item 4) to inside base of fender support bracket (Figure 6, Item 1). Position fender (Figure 5, item 10) on fender support bracket (Figure 5, Item 1). At front and rear of fender (Figure 5, Item 10), install six locknuts (Figure 5, Item 11), screws (Figure 5, Item 12), and 12 washers (Figure 5, Item 13).
1 2,3 4

M0460JCH

Figure 6. Rear Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3). END OF TASK

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0190

FRONT FENDERS AND FENDER BRACKETS REMOVAL (RT 240V2 and RT 240V3) 1. 2. 3. At rear of fender (Figure 7, Item 2), remove six locknuts (Figure 7, Item 3), screws (Figure 7, Item 4), and 12 washers (Figure 7, Item 5). Discard locknuts. At front of fender (Figure 7, Item 2), remove three locknuts (Figure 7, Item 6), screws (Figure 7, Item 7), and six washers (Figure 7, Item 8). Discard locknuts. Remove fender (Figure 7, Item 2) from fender support bracket (Figure 7, Item 1).
1

2 6,7,8

3,4,5
M0461JCH

Figure 7. Front Fender and Fender Bracket Removal (RT 240V2 and RT 240V3).

NOTE
Front fender support brackets can be removed with lights and light brackets attached. 4. 5. Disconnect waterproof connector (Figure 8, item 4) from inside base of fender support bracket (Figure 8, Item 1). Remove eight screws (Figure 8, Item 2), lockwashers (Figure 8, Item 3), and fender support bracket (Figure 8, Item 1) from vehicle. Discard lockwashers.

END OF TASK

0190-8

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TM 10-3930-675-23-2

0190

FRONT FENDERS AND FENDER BRACKETS INSTALLATION (RT 240V2 and RT 240V3)

NOTE
Rear fender support brackets can be installed with lights and light brackets attached. 1. 2. 3. 4. Install fender support bracket (Figure 8, Item 1) with eight screws (Figure 8, Item 2) and new lockwashers (Figure 8, Item 3). Connect waterproof connector (Figure 8, Item 4) to inside base of fender support bracket (Figure 8, Item 1). Position fender (Figure 7, Item 2) on fender support bracket (Figure 7, Item 1). At rear of fender, install six locknuts (Figure 7, Item 3), screws (Figure 7, Item 4), and 12 washers (Figure 7, Item 5). At front fender, install three locknuts (Figure 7, Item 6), screws (Figure 7, Item 7), and six washers (Figure 7, Item 8).
1 2,3 4

M0462JCH

Figure 8. END OF TASK

Front Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3).

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0190

FENDER BRACKET MOUNTING PLATE REMOVAL AND INSTALLATION (ALL VEHICLE CONFIGURATIONS) Fender Bracket Mounting Plates Removal

NOTE
Fenders and fender brackets must be removed prior to removing plates. 1. Perform steps 2 and 3 of Steering System Wheel Sensor Replacement (Volume 1, WP 0125) and set wheel sensor and bracket aside. Remove six front (Figure 9, Item 1) or eight rear (Figure 9, Item 2) socket head capscrews to free fender bracket mounting plate (Figure 9, Item 3) from axle.

2.

Fender Bracket Mounting Plate Installation 1. 2. 3. Clean surface of axle and mounting plate (Figure 9, Item 3) and transfer grease fittings from old plate to new plate. Apply RTV adhesive to bolt circle on axle, and install fender bracket mounting plate (Figure 9, Item 3) and secure with six front (Figure 9, Item 1) or eight rear (Figure 9, Item 2) socket head capscrews. Perform Steps 8 and 9 of Steering System Wheel Sensor Replacement (Volume 1, WP 0125) to install wheel sensor.
1 2 3

M0463JCH

3

Figure 9. Front Bracket Mounting Plate Replacement. END OF TASK END OF WORK PACKAGE

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0191

FIELD MAINTENANCE SEAT ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Drill Set, Twist (WP 0277, Table 1, Item 24) Drill, Electric, Portable, 3/8 inch (WP 0277, Table 1, Item 23) Riveter, Blind, Hand 3/32 in., 1/8 in., 5/32 in., and 3/16 in. diameters (WP 0277, Table 1, Item 63) Materials/Parts Locknut (WP 0278, Table 1, Item 21) Qty: 2 Rivet, Blind (WP 0278, Table 1, Item 156) Qty: 2 Personnel Required (2) Equipment Condition Electronic joystick assembly removed (Volume 1, WP 0101) Seat belt removed (WP 0192) Electronic seat warning buzzer removed (Volume 1, WP 0126)

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0191

REMOVAL 1. 2. Remove four screws (Figure 1, Item 1) holding slide rails (Figure 1, Item 2) to seat cover (Figure 1, Item 6) and seat base (Figure 1, Item 5). Remove seat assembly (Figure 1, Item 3) and four spacers (Figure 1, Item 4) from vehicle.

1

2

3

6

4

5
Figure 1. END OF TASK Seat Removal.

M0466JCH

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0191

DISASSEMBLY 1. 2. 3. Remove 17 plastic rivets (Figure 2, Item 8) and five plastic rivets (Figure 2, Item 2) from bellows (Figure 2, Item 9) to separate bellows from seat assembly (Figure 2, Item 1). Remove four nuts (Figure 2, Item 3), washers (Figure 2, Item 4), screws (Figure 2, Item 5), two slide rails (Figure 2, Item 6), and handle (Figure 2, Item 7). Remove bellows (Figure 2, Item 9).

1

2 9

8 3 4 5 7

6
M0467JCH

Figure 2.

Seat Disassembly.

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0191

DISASSEMBLY - Continued 4. 5. 6. 7. 8. Remove lever (Figure 3, Item 1), washer (Figure 3, Item 19), and washer (Figure 3, Item 2) from joystick mounting bracket (Figure 3, Item 18). Remove screw (Figure 3, Item 3), screw (Figure 3, Item 11), washer (Figure 3, Item 10), and joystick mounting bracket (Figure 3, Item 18). Remove screw (Figure 3, Item 4), screw (Figure 3, Item 5), three screws (Figure 3, Item 6), and armrest bracket (Figure 3, Item 7) with armrest (Figure 3, Item 17). Remove adjustment screw (Figure 3, Item 8) from armrest (Figure 3, Item 17). Remove five knobs (Figure 3, Item 16).

NOTE
Step 9 applies to the RT 240V1 vehicle ONLY. 9. Remove two locknuts (Figure 3, Item 12), screws (Figure 3, Item 14), bushings (Figure 3, Item 13), and shock absorber (Figure 3, Item 15). Discard locknuts.

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0191

DISASSEMBLY - Continued

1

2

7 8 3 4 5 9 6

19 18

17

16

10 11

15

14

13 12
M0468JCH

Figure 3. END OF TASK

Seat Disassembly and Assembly.

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0191

ASSEMBLY

NOTE
Step 1 applies to the RT 240V1 vehicle ONLY. 1. 2. 3. 4. 5. 6. 7. 8. 9. Install shock absorber (Figure 3, Item 15) on bottom of seat assembly (Figure 3, Item 9) with two bushings (Figure 3, Item 13), screws (Figure 3, Item 14), and new locknuts (Figure 3, Item 12). Install five knobs (Figure 3, Item 16). Install adjustment screw (Figure 3, Item 8) in armrest (Figure 3, Item 17). Install armrest bracket (Figure 3, Item 7) with armrest (Figure 3, Item 17), three screws (Figure 3, Item 6), screw (Figure 3, Item 5), and screw (Figure 3, Item 4). Install joystick mounting bracket (Figure 3, Item 18) with washer (Figure 3, Item 10), screw (Figure 3, Item 11), and screw (Figure 3, Item 3). Install washer (Figure 3, Item 2), washer (Figure 3, Item 19), and lever (Figure 3, Item 1) on joystick mounting bracket (Figure 3, Item 18). Position bellows (Figure 4, Item 9) on seat assembly (Figure 4, Item 1). Install handle (Figure 4, Item 7) and two slide rails (Figure 4, Item 6) with four screws (Figure 4, Item 5), washers (Figure 4, Item 4), and nuts (Figure 4, Item 3). Install five plastic rivets (Figure 4, Item 2) and 17 plastic rivets (Figure 4, Item 8) on bellows (Figure 4, Item 9).

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0191

ASSEMBLY - Continued

1

2 9

8 3 4 5 7

6
M0467JCH

Figure 4. END OF TASK

Seat Assembly.

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0191

INSTALLATION 1. 2. Position four spacers (Figure 5, Item 4) and seat assembly (Figure 5, Item 3) in vehicle. Install two slide rails (Figure 5, Item 2) on seat base cover (Figure 5, Item 6) and seat base (Figure 5, Item 5) with four screws (Figure 5, Item 1).
1 2 3

6

4

5

M0469JCH

Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Seat Installation.

Install seat warning buzzer (Volume 1, WP 0126). Install seat belt (WP 0192). Install electronic joystick assembly (Volume 1, WP 0101).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0192

FIELD MAINTENANCE SEAT BELT REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Belt, Vehicular Safety (WP 0278, Table 1, Item 102)

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0192

REMOVAL Remove two screws (Figure 1, Item 3), four washers (Figure 1, Item 4), two fiber washers (Figure 1, Item 5), seat belt retractor (Figure 1, Item 2), and seat belt receptacle (Figure 1, Item 6) from seat assembly (Figure 1, Item 1). END OF TASK INSTALLATION Install seat belt receptacle (Figure 1, Item 6) and seat belt retractor (Figure 1, Item 2) on seat assembly (Figure 1, Item 1) with two fiber washers (Figure 1, Item 5), four washers (Figure 1, Item 4), and two screws (Figure 1, Item 3).

1

6

3 2 4 5 3

5

4
M0465JCH

Figure 1. END OF TASK END OF WORK PACKAGE

Seatbelt Replacement.

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TM 10-3930-675-23-2

0193

FIELD MAINTENANCE REARVIEW MIRRORS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 2 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 2

INTERIOR REARVIEW MIRROR REPLACEMENT 1. 2. Remove screw (Figure 1, Item 1), washer (Figure 1, Item 2), and interior rearview mirror (Figure 1, Item 3) from cab. Install interior rearview mirror (Figure 1, Item 3) in cab with washer (Figure 1, Item 3) and screw (Figure 1, Item 1).
1,2 3

M0479JCH

Figure 1. Interior Rearview Mirror Replacement. END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00160)

TM 10-3930-675-23-2

0193

EXTERIOR REARVIEW MIRROR REMOVAL

NOTE
• Right and left exterior rearview mirrors are removed the same way. • Perform Step 1 to remove exterior rearview mirror from arm. 1. Loosen two screws (Figure 2, Item 1) and remove exterior rearview mirror (Figure 2, Item 5) from arm (Figure 2, Item 3).
1

2

3

M0480JCH

Figure 2. Exterior Rearview Mirror Removal.

NOTE
Perform Steps 2 and 3 to remove arm and mounting bracket from vehicle. 2. 3. Remove two locknuts (Figure 3, Item 2), screws (Figure 3, Item 3), and arm (Figure 3, Item 1) from mounting bracket (Figure 3, Item 7). Discard locknuts. Remove two locknuts (Figure 3, Item 4), four washers (Figure 3, Item 5), two screws (Figure 3, Item 6), and mounting bracket (Figure 3, Item 7) from vehicle. Discard locknuts.

END OF TASK

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0193

EXTERIOR REARVIEW MIRROR INSTALLATION

NOTE
• Right and left exterior rearview mirrors are installed the same way. • Perform Steps 1 and 2 to install mounting bracket and arm on vehicle. 1. 2. Install mounting bracket (Figure 3, Item 7) on vehicle with two screws (Figure 3, Item 6), four washers (Figure 3, Item 5), and two new locknuts (Figure 3, Item 4). Install arm (Figure 3, Item 1) on mounting bracket (Figure 3, Item 7) with two screws (Figure 3, Item 3) and new locknuts (Figure 3, Item 2).

NOTE
Perform Step 3 to install exterior rearview mirror on arm. 3. Install exterior rearview mirror (Figure 3, Item 2) on arm (Figure 3, Item 3) and tighten two screws (Figure 3, Item 1).
1 2,3

4,5,6

7

M0481JCH

Figure 3. Exterior Rearview Mirror Removal and Installation. END OF TASK END OF WORK PACKAGE

0193-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00160)

TM 10-3930-675-23-2

0194

FIELD MAINTENANCE WINDSHIELD WIPER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Screwdriver Attachment Set, Torx (WP 0277, Table 1, Item 65) Materials/Parts Compound, Gasket Forming, Silicone (WP 0276, Table 1, Item 13) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Seal, Plain (WP 0278, Table 1, Item 99) Qty: 2 Materials/Parts (cont.) Pivot Assembly, Windshield Wiper (WP 0278, Table 1, Item 100) Qty: 1 Gasket (WP 0278, Table 1, Item 136) Qty: 1 Personnel Required (2) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed (to replace front windshield wiper and motor) (WP 0185)

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0194

FRONT WINDSHIELD WIPER AND MOTOR REMOVAL

NOTE
To remove wiper blade only, perform Step 1. 1. 2. 3. Remove screw (Figure 1, Item 5) and wiper blade (Figure 1, Item 4) from yoke (Figure 1, Item 9). Release jet and hose (Figure 1, Item 8) from steering arm (Figure 1, Item 7). As required, remove two caps (Figure 1, Item 1), c-clips (Figure 1, Item 2), and washers (Figure 1, Item 3) to separate steering arm (Figure 1, Item 7) and wiper arm (Figure 1, Item 6) from yoke (Figure 1, Item 9).
1,2,3 4

5

6 9

8

7

M0482JCH

Figure 1.

Front Windshield Wiper and Motor Removal.

NOTE
• Perform Step 4 to remove steering arm and wiper arm. • Note position of steering arm and wiper arm prior to removal to ensure correct installation. 4. 5. 6. 7. 8. 9. Lift cover and remove nut (Figure 2, Item 11), lockwasher (Figure 2, Item 12), steering arm (Figure 2, Item 13) and wiper arm (Figure 2, Item 14) from windshield wiper motor shafts (Figure 2, Item 6). Discard lockwasher. Disconnect hose (Figure 2, Item 4) from nipple (Figure 2, Item 2). Remove four cap nuts (Figure 2, Item 3), washers, and cover (Figure 2, Item 5) with windshield wiper motor from panel (Figure 2, Item 10). Remove nipple (Figure 2, Item 2) and grommet (Figure 2, Item 1) from cover (Figure 2, Item 5). Disconnect wiring harness connector (Figure 3, Item 5) from motor connector (Figure 3, Item 6). Remove screw (Figure 3, Item 7) and disconnect ground wire (Figure 3, Item 4) from motor (Figure 3, Item 2).

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0194

FRONT WINDSHIELD WIPER AND MOTOR REMOVAL - Continued 10. Remove two plastic caps (Figure 2, Item 9), nuts (Figure 2, Item 8), and seals (Figure 2, Item 7) and separate cover (Figure 3, Item 8) and windshield wiper motor (Figure 3, Item 2). Discard seals.
1,2 3 4 5 6

14 13 7 8 9

11,12

10

M0483JCH

Figure 2.
1 2

Front Windshield Wiper and Motor Removal.
3 4 5 6

7

8

M0484JCH

Figure 3. END OF TASK

Front Windshield Wiper and Motor Removal.

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0194

FRONT WINDSHIELD WIPER AND MOTOR INSTALLATION

NOTE
To install wiper blade only, perform step 9. 1. Install windshield wiper motor (Figure 4, Item 2) on cover (Figure 4, Item 8) with windshield wiper motor shafts (Figure 5, Item 6) through cover. Install two new seals (Figure 5, Item 7), nuts (Figure 5, Item 8), and plastic caps (Figure 5, Item 9). Connect ground wire (Figure 4, Item 4) to motor (Figure 4, Item 2) with screw (Figure 4, Item 7). Connect wiring harness connector (Figure 4, Item 5) to motor connector (Figure 4, Item 6).
1 2 3 4 5 6

2. 3.

7

8

M0485JCH

Figure 4.

Front Windshield Wiper and Motor Installation.

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0194

FRONT WINDSHIELD WIPER AND MOTOR INSTALLATION - Continued 4. Install grommet (Figure 5, Item 1) and nipple (Figure 5, Item 2) in cover (Figure 5, Item 5). Connect hose (Figure 5, Item 4) to nipple.

NOTE
Ensure all old gasket forming compound has been removed and mounting surfaces are clean. 5. Apply gasket forming compound to panel (Figure 5, Item 10). Install cover (Figure 5, Item 5) with windshield wiper motor on panel with four washers and cap nuts (Figure 5, Item 3).

NOTE
Perform Step 6 to install steering arm and wiper arm. 6. Lift cover and install steering arm (Figure 5, Item 13) and wiper arm (Figure 5, Item 14) on windshield wiper motor shafts (Figure 5, Item 6) with new lockwasher (Figure 5, Item 12) and nut (Figure 5, Item 11). Close cover.
1,2 3 4 5 6

14 13 7 8 9

11,12

10

M0486JCH

Figure 5.

Front Windshield Wiper and Motor Installation.

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0194

FRONT WINDSHIELD WIPER AND MOTOR INSTALLATION - Continued 7. 8. 9. If separated, install wiper arm (Figure 6, Item 6) and steering arm (Figure 6, Item 7) on yoke (Figure 6, Item 9) with two washers (Figure 6, Item 3), C-clips (Figure 6, Item 2), and caps (Figure 6, Item 1). Install hose (Figure 6, Item 8) and jet on steering arm (Figure 6, Item 7). Install wiper blade (Figure 6, Item 4) on yoke (Figure 6, Item 9) with screw (Figure 6, Item 5).
1,2,3 4

5

6 9

8

7

M0487JCH

Figure 6. END OF TASK

Front Windshield Wiper and Motor Installation.

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0194

REAR WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL

NOTE
To remove wiper blade and arm only, perform Steps 3 through 5. 1. Remove two screws (Figure 7, Item 1) and cover (Figure 7, Item 2) from windshield wiper motor (Figure 7, Item 3) inside cab.
1 2

3

M0488JCH

Figure 7. 2.

Rear Windshield Wiper and Motor Removal.

Remove and discard tiedown strap (Figure 8, Item 4). Disconnect wiring harness connector (Figure 8, Item 3) from motor connector (Figure 8, Item 2) attached to windshield wiper motor (Figure 8, Item 1).
1 2 3

4

M0489JCH

Figure 8.

Rear Windshield Wiper and Motor Removal.

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0194

REAR WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL - Continued 3. 4. 5. 6. From outside cab, remove wiper blade (Figure 9, Item 8) from wiper arm (Figure 9, Item 7). Remove hose (Figure 9, Item 9) from wiper arm (Figure 9, Item 7). Lift cover and remove nut (Figure 9, Item 6) and wiper arm (Figure 9, Item 7) from motor shaft (Figure 9, Item 11). Remove plastic cap (Figure 9, Item 10), nut (Figure 9, Item 12), and seal ring from end of motor shaft (Figure 9, Item 11).

CAUTION
Take care when removing windshield wiper motor to avoid damaging windshield. 7. 8. Remove two screws (Figure 9, Item 2), washers (Figure 9, Item 3), seal (Figure 9, Item 4), spacer (Figure 9, Item 5) and windshield wiper motor (Figure 8, Item 1) from cab. Discard seal. If damaged, remove hoses (Figure 9, Item 9) inside and outside cab from fitting (Figure 9, Item 1). Remove fitting and grommet (Figure 9, Item 1) from cab.

END OF TASK REAR WINDOW WINDSHIELD WIPER AND MOTOR INSTALLATION

NOTE
To install wiper blade and arm only, perform Steps 4 and 5. 1. 2. If removed, install grommet (Figure 9, Item 1) and fitting (Figure 9, Item 13) in cab. Connect hoses (Figure 9, Item 9) inside and outside cab to fitting. Position new seal (Figure 9, Item 4), spacer (Figure 9, Item 5) and windshield wiper motor (Figure 8, Item 1) against cab with motor shaft (Figure 9, Item 11) through opening in cab. Install two washers (Figure 9, Item 3) and screws (Figure 9, Item 2). From outside cab, install seal ring, nut (Figure 9, Item 12), and plastic cap (Figure 9, Item 10) on end of motor shaft (Figure 9, Item 11). Install wiper arm (Figure 9, Item 7) on motor shaft (Figure 9, Item 11) with nut (Figure 9, Item 6). Close cover over nut. Secure hose (Figure 9, Item 9) to wiper arm. Install wiper blade (Figure 9, Item 8) on wiper arm (Figure 9, Item 7). Inside cab, connect wiring harness connector (Figure 9, Item 3) to motor connector (Figure 9, Item 2). Secure wires and hoses together with new tiedown strap (Figure 9, Item 4) around windshield wiper motor (Figure 10, Item 3).

3. 4. 5. 6.

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0194

REAR WINDOW WINDSHIELD WIPER AND MOTOR INSTALLATION - Continued
1 2,3,4,5 6 7

8

13

12

11

10

9

M0490JCH

Figure 9. 7.

Rear Windshield Wiper and Motor Removal and Installation.

Install two screws (Figure 10, Item 1) and cover (Figure 10, Item 2) on windshield wiper motor (Figure 10, Item 3).
1 2

3

M0488JCH

Figure 10. END OF TASK

Rear Windshield Wiper and Motor Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00161)

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0194

ROOF WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL

NOTE
• Boom must be raised to allow access to roof window windshield wiper and motor. • To remove wiper blade and arm only, perform Steps 3 through 5. 1. Remove two screws (Figure 11, Item 1) and cover (Figure 11, Item 2) from windshield wiper motor (Figure 11, Item 3) inside cab.
1 2 3

M0491JCH

Figure 11. Roof Window Windshield Wiper and Motor Removal.

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0194

ROOF WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL - Continued 2. Remove and discard tiedown straps (Figure 12, Item 4). Disconnect wiring harness connector (Figure 12, Item 2) from motor connector (Figure 12, Item 3).
1 2 3

4

M0492JCH

Figure 12. Roof Window Windshield Wiper and Motor Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00161)

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0194

ROOF WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL - Continued 3. 4. 5. 6. 7. 8. From outside cab, remove wiper blade (Figure 13, Item 1) from wiper arm (Figure 13, Item 2). Remove hose (Figure 13, Item 14) from wiper arm (Figure 13, Item 2). Lift cover and remove nut (Figure 13, Item 3), lockwasher (Figure 13, Item 4), and wiper arm (Figure 13, Item 2) from motor shaft (Figure 13, Item 8). Discard lockwasher. Remove plastic cap (Figure 13, Item 5), nut (Figure 13, Item 9), and seal ring from end of motor shaft (Figure 13, Item 8). Remove two screws (Figure 13, Item 10), washers (Figure 13, Item 11), seal (Figure 13, Item 12), spacer (Figure 13, Item 13) and windshield wiper motor (Figure 12, Item 1) from roof window. Discard seal. If damaged, remove hoses (Figure 13, Item 14) inside and outside cab from fitting (Figure 13, Item 6). Remove fitting and grommet (Figure 13, Item 7) from roof window.
1

2

3,4 5

6 7

14

10,11 12,13

9

8
M0493JCH

Figure 13. Roof Window Windshield Wiper and Motor Removal and Installation. END OF TASK

0194-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00161)

TM 10-3930-675-23-2

0194

ROOF WINDOW WINDSHIELD WIPER AND MOTOR INSTALLATION

NOTE
To install wiper blade and arm only, perform Steps 4 and 5. 1. 2. If removed, install grommet (Figure 14, Item 7) and fitting (Figure 14, Item 6) in roof window. Connect hoses (Figure 14, Item 14) inside and outside cab to fitting. Position new seal (Figure 14, Item 12), spacer (Figure 14, Item 13) and windshield wiper motor (Figure 13, Item 1) against roof window with motor shaft (Figure 14, Item 8) through opening in roof window. Install two washers (Figure 14, Item 11) and screws (Figure 14, Item 10). From outside cab, install seal ring, nut (Figure 14, Item 9), and plastic cap (Figure 14, Item 5) on end of motor shaft (Figure 14, Item 8). Install wiper arm (Figure 14, Item 2) on motor shaft (Figure 14, Item 8) with new lockwasher (Figure 14, Item 4) and nut (Figure 14, Item 3). Close cover over nut. Secure hose (Figure 14, Item 14) to wiper arm. Install wiper blade (Figure 14, Item 1) on wiper arm (Figure 14, Item 2). Inside cab, connect wiring harness connector (Figure 15, Item 2) to motor connector (Figure 15, Item 3). Secure wires and hoses together with new tiedown straps (Figure 15, Item 4) around windshield wiper motor (Figure 15, Item 1).
1 2 3

3. 4. 5. 6.

4

M0492JCH

Figure 14. Roof Window Windshield Wiper and Motor Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00161)

TM 10-3930-675-23-2

0194

ROOF WINDOW WINDSHIELD WIPER AND MOTOR INSTALLATION - Continued 7. Install cover (Figure 16, Item 2) on windshield wiper motor (Figure 16, Item 3) with two screws (Figure 16, Item 1).
1 2 3

M0491JCH

Figure 15. Roof Window Windshield Wiper and Motor Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. If removed, install engine cover (WP 0185). Turn master battery switch to ON position. Check operation of roof window windshield wiper and windshield wiper washer (TM 10-3930-675-10). Check operation of front windshield wiper and windshield wiper washer (TM 10-3930-675-10). Check operation of rear window windshield wiper and windshield wiper washer (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0194-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00161)

TM 10-3930-675-23-2

0195

FIELD MAINTENANCE WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Screwdriver Attachment Set, Torx (WP 0277, Table 1, Item 65) Materials/Parts Cleaning Compound, Windshield (WP 0276, Table 1, Item 11) Materials/Parts (cont.) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0195-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00162)

TM 10-3930-675-23-2

0195

WINDSHIELD WASHER RESERVOIR REMOVAL 1. Disconnect tube (Figure 1, Item 3) from cap fitting (Figure 1, Item 2).

NOTE
Step 2 applies to RT 240V2 and RT 240V3 vehicles ONLY. 2. 3. 4. Remove washer reservoir cover (Figure 1, Item 5) form bracket (Figure 1, Item 4) and washer reservoir (Figure 1, Item 1). Lift windshield washer reservoir (Figure 1, Item 1) from bracket (Figure 1, Item 4). Remove cap (Figure 1, Item 2) and drain windshield cleaning compound into a suitable container.

NOTE
Perform Step 5 to remove bracket from rear of cab. 5. Remove four screws (Figure 1, Item 6) and bracket (Figure 1, Item 4) from cab.

END OF TASK WINDSHIELD WASHER RESERVOIR INSTALLATION

NOTE
Perform Step 1 to install bracket on rear of cab. 1. 2. 3. 4. Install bracket (Figure 1, Item 4) on cab with four screws (Figure 1, Item 6). Install windshield washer reservoir (Figure 1, Item 1) on bracket (Figure 1, Item 4). Fill windshield washer reservoir (Figure 1, Item 1) with windshield cleaning compound. Install cap (Figure 1, Item 2).

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00162)

TM 10-3930-675-23-2

0195

WINDSHIELD WASHER RESERVOIR INSTALLATION - Continued

NOTE
Step 5 applies to RT 240V2 and RT 240V3 vehicles ONLY. 5. 6. Install washer reservoir cover (Figure 1, Item 5) on bracket (Figure 1, Item 4) and washer reservoir (Figure 1, Item 1). Connect tube (Figure 1, Item 3) to cap fitting (Figure 1, Item 2).
1 2 3

6

5

4

M0494JCH

Figure 1. Windshield Washer Reservoir Replacement. END OF TASK

0195-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00162)

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0195

WINDSHIELD WASHER PUMP REMOVAL 1. 2. Lift and remove left access cover (Figure 2, Item 3) from rear of cab. Disconnect elastic loop (Figure 2, Item 1) from top of circuit breaker/relay box (Figure 2, Item 2). Lift box and tilt box forward to gain access to windshield washer pump behind box.
1

2

3

M0495JCH

Figure 2. Windshield Washer Pump Removal.

0195-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00162)

TM 10-3930-675-23-2

0195

WINDSHIELD WASHER PUMP REMOVAL - Continued 3. Disconnect wiring harness connector (Figure 3, Item 2) from windshield washer pump (Figure 3, Item 3).

NOTE
Note position of tubes for installation. 4. 5. Remove two tiedown straps (Figure 3, Item 5) and disconnect two tubes (Figure 3, Item 6) from windshield washer pump (Figure 3, Item 3). Discard tiedown straps. Remove two screws (Figure 3, Item 1), washers, and windshield washer pump (Figure 3, Item 3) from rear of cab.

END OF TASK WINDSHIELD WASHER PUMP INSTALLATION 1. 2. 3. Install windshield washer pump (Figure 3, Item 3) on rear of cab with two washers and screws (Figure 3, Item 1). Connect two tubes (Figure 3, Item 6) to windshield washer pump (Figure 3, Item 3) and install two new tiedown straps (Figure 3, Item 5). Connect wiring harness connector (Figure 3, Item 2) to windshield washer pump (Figure 3, Item 3).
1 2 3 4

6

5

M0496JCH

Figure 3. Windshield Washer Pump Replacement.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00162)

TM 10-3930-675-23-2

0195

WINDSHIELD WASHER PUMP INSTALLATION - Continued

NOTE
Ensure all circuit breakers remain in ON position while circuit breaker/relay box is secured. 4. 5.
1

Tilt circuit breaker/relay box (Figure 4, Item 2) rearward and connect elastic loop (Figure 4, Item 1) to top of box. Install left access cover (Figure 4, Item 3) on rear of cab.

2

3

M0497JCH

Figure 4. Windshield Washer Pump Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Turn master battery switch to ON position (TM 10-3930-675-10). Check operation of windshield washer pump.

END OF TASK END OF WORK PACKAGE

0195-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00162)

TM 10-3930-675-23-2

0196

FIELD MAINTENANCE HEATER HOSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Antifreeze Ethylene Glycol (WP 0276, Table 1, Item 6) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (2) References TM 10-3930-675-10 WP 0185 Equipment Condition Coolant drained (Volume 1, WP 0080)

0196-1

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TM 10-3930-675-23-2

0196

ENGINE HEATER HOSES REMOVAL

NOTE
• Tag hoses to ensure proper connection on installation. • Perform the following steps to remove heater hoses between engine and rear of cab. • Remove loop clamps and remove and discard tiedown straps as necessary. 1. 2. 3. 4. Remove engine cover (WP 0185). Place cab in transport position (TM 10-3930-675-10). Remove transmission access covers (WP 0175). Remove hose clamp (Figure 1, Item 2) and heater hose (Figure 1, Item 1) from fitting (Figure 1, Item 3) at water pump (Figure 1, Item 4).
1 2 3 4

M0606JCH

Figure 1. 5.

Engine Heater Hoses Removal.

Remove hose clamp (Figure 2, Item 2) and heater hose (Figure 2, Item 1) from fitting (Figure 2, Item 3) at right side of engine (Figure 2, Item 4).

0196-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

ENGINE HEATER HOSES REMOVAL - Continued
1 2 3

4

M0607JCH

Figure 2. 6.

Engine Heater Hoses Removal.

Toward rear of vehicle, remove canvas straps (Figure 3, Item 1) from around heater hoses (Figure 3, Items 2 and 3).
1 2 3

M0608JCH

Figure 3.

Engine Heater Hoses Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

ENGINE HEATER HOSES REMOVAL - Continued 7. 8. At cab interface unit at rear of cab, remove two hose clamps (Figure 4, Item 1) and two heater hoses (Figure 4, Item 3 and 4) from two fittings (Figure 4, Item 2). Remove two heater hoses (Figure 4, Items 3 and 4) from vehicle.
1 2 3 4

M0609JCH

Figure 4. END OF TASK ENGINE HEATER HOSES INSTALLATION

Engine Heater Hoses Removal.

NOTE
Perform the following steps to install heater hoses between engine and rear of cab. 1. 2. Position two heater hoses (Figure 5, Items 3 and 4) on vehicle. At cab interface unit at rear of cab, install two heater hoses (Figure 5, Items 3 and 4) on two fittings (Figure 5, Item 2) with two hose clamps (Figure 5, Item 1).

0196-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

ENGINE HEATER HOSES INSTALLATION - Continued
1 2 3 4

M0610JCH

Figure 5. 3.

Engine Heater Hoses Removal.

Install canvas straps (Figure 6, Item 1) around heater hoses (Figure 6, Items 2 and 3).
1 2 3

M0611JCH

Figure 6.

Engine Heater Hoses Removal.

0196-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

ENGINE HEATER HOSES INSTALLATION - Continued

NOTE
Install loop clamps and new tiedown straps as necessary. 4. Install heater hose (Figure 7, Item 1) on fitting (Figure 7, Item 3) at right side of engine (Figure 7, Item 4) with hose clamp (Figure 7, Item 2).
1 2 3

4

M0612JCH

Figure 7.

Engine.

0196-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

ENGINE HEATER HOSES INSTALLATION - Continued 5. 6. 7. 8. Install heater hose (Figure 8, Item 1) on fitting (Figure 8, Item 3) at water pump (Figure 8, Item 4) with hose clamp (Figure 8, Item 2). Install transmission access covers (WP 0185). Return cab to operational position (TM 10-3930-675-10). Install engine cover (WP 0185).
1 2 3 4

M0613JCH

Figure 8. END OF TASK

Engine Heater Hoses Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

CAB HEATER HOSES REMOVAL

NOTE
Perform the following steps to remove heater hoses between rear of cab and heater. 1. 2. Remove three screws (Figures 9 and 10, Item 1), washers (Figures 9 and 10, Item 2), and left lower panel (Figures 9 and 10, Item 3). Remove three screws (Figures 9 and 10, Item 4), washers (Figures 9 and 10, Item 5), and right lower panel (Figures 9 and 10, Item 6).
1,2 3 4,5 6

M0614JCH

RT240V1 AND RT240V1R VEHICLES

Figure 9. Cab Heater Hoses Removal – RT 240V1 and RT 240V1R.
1,2 3 4,5 6

M0615JCH

RT240V2 AND RT240V3 VEHICLES

Figure 10.

Cab Heater Hoses Removal – RT 240V2 and RT 240V3 Vehicles.

0196-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

CAB HEATER HOSES REMOVAL - Continued 3. 4. Remove three hose clamps (Figure 11, Item 4), heater hose (Figure 11, Item 6), connector (Figure 11, Item 5), and hose (Figure 11, Item 3) from heater and A/C unit (Figure 11, Item 11). Remove five hose clamps (Figure 11, Item 2), heater hose (Figure 11, Item 7), connector (Figure 11, Item 8), hose (Figure 11, Item 9), heat control valve (Figure 11, Item 10), and hose (Figure 11, Item 1) from heater and A/C unit (Figure 11, Item 11).
2 3 4 5 6 7

1

11

2

10

2

9

8

2

M0616JCH

Figure 11.

Cab Heater Hoses Removal.

0196-9

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TM 10-3930-675-23-2

0196

CAB HEATER HOSES REMOVAL - Continued 5. Remove 14 screws (Figure 12, Item 2) and three access covers (Figure 12, Item 1) from right side of cab.
2 1 1 2

1

M0617JCH

Figure 12. Cab Heater Hoses Removal. 6. Lift and remove right access cover (Figure 13, Item 1) and middle access cover (Figure 13, Item 2) from rear of cab.
1

2

M0618JCH

Figure 13. Cab Heater Hoses Removal.

0196-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

CAB HEATER HOSES REMOVAL - Continued 7. Remove two hose clamps (Figure 14, Item 3) and two heater hoses (Figure 14, Items 1 and 4) from two fittings (Figure 14, Item 2).

NOTE
Remove and discard tiedown straps as necessary. 8. Remove two heater hoses (Figure 14, Items 1 and 4) from cab.

END OF TASK CAB HEATER HOSES INSTALLATION

NOTE
Perform the following steps to install heater hoses between rear of cab and heater. 1. 2. Position two heater hoses (Figure 14, Items 1 and 4) in cab. At rear of cab, install two heater hoses (Figure 14, Items 1 and 4) on two fittings (Figure 14, Item 2) with two hose clamps (Figure 14, Item 3).
2

3 1

4

M0619JCH

Figure 14.

Cab Heater Hoses Removal.

0196-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

CAB HEATER HOSES INSTALLATION - Continued 3. Install middle access cover (Figure 15, Item 2) and right access cover (Figure 15, Item 1) in rear of cab.
1

2

M0618JCH

Figure 15. Cab Heater Hoses Installation.

NOTE
Install new tiedown straps as necessary. 4. Install three access covers (Figure 16, Item 1) on right side of cab with 14 screws (Figure 16, Item 2).

0196-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00163)

TM 10-3930-675-23-2

0196

CAB HEATER HOSES INSTALLATION - Continued
2 1 1 2

1

M0620JCH

Figure 16. 5.

Cab Heater Hoses Installation.

Install hose (Figure 17, Item 1), heat control valve (Figure 17, Item 10), hose (Figure 17, Item 9), connector (Figure 17, Item 8), and heater hose (Figure 17, Item 7) on heater and A/C unit (Figure 17, Item 11) with five hose clamps (Figure 17, Item 2). Install hose (Figure 17, Item 3), connector (Figure 17, Item 5), and heater hose (Figure 17, Item 6) on heater and A/C unit (Figure 17, Item 11) with three hose clamps (Figure 17, Item 4).
2 3 4 5 6 7

6.

1

11

2

10

2

9

8

2

M0621JCH

Figure 17.

Cab Heater Hoses Installation.

0196-13

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TM 10-3930-675-23-2

0196

CAB HEATER HOSES INSTALLATION - Continued 7. 8. 9. 10. Fill cooling system (Volume 1, WP 0080). Start engine (TM 10-3930-675-10) and check for leaks. Install right lower panel with three screws and three washers (Figures 18 and 19, Items 4, 5, and 6). Install left lower panel (Figures 18 and 19, Item 3) with three screws (Figures 18 and 19, Item 1) and three washers (Figures 18 and 19, Item 2).
1,2 3 4,5 6

M0622JCH

RT240V1 AND RT240V1R VEHICLES

Figure 18. Cab Heater Hoses Installation – RT 240V1 and RT 240V1R Vehicles.
1,2 3 4,5 6

M0615JCH

RT240V2 AND RT240V3 VEHICLES

Figure 19. Cab Heater Hoses Installation – RT 240V2 and RT 240V3 Vehicles. END OF TASK

0196-14

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0196

FOLLOW-ON MAINTENANCE 1. 2. Fill cooling system (Volume 1, WP 0080). Start engine (TM 10-3930-675-10) and check for leaks.

END OF TASK END OF WORK PACKAGE

0196-15/16 blank

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TM 10-3930-675-23-2

0197

FIELD MAINTENANCE CAB HEATER/AIR CONDITIONING UNIT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Antifreeze Ethylene Glycol (WP 0276, Table 1, Item 6) Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 155) Qty: 3 Personnel Required (2) References Volume 1, WP 0080 References (cont.) Volume 1, WP 0094 WP 0196 WP 0254 Equipment Condition Cab moved to the left, but not lowered (TM 10-3930-675-10) Air cleaner removed (Volume 1, WP 0071) Windshield wiper assembly removed (WP 0194) Refrigerant recovered from A/C system (WP 0248) Coolant drained (Volume 1, WP 0080)

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0197

REMOVAL 1. Remove 14 capnuts (Figure 1, Item 2), washers (Figure 1, Item 3), and front panel (Figure 1, Item 1) from cab.

2,3

1

2,3
M1088JCH

Figure 1. 2. 3.

Cab Heater/Air Conditioning Unit Removal.

Underneath instrument panel, disconnect connectors from A/C control switch, disconnect cable from heater temperature control, and remove A/C temperature control (Volume 1, WP 0094). Disconnect two heater hoses from side of cab heater and A/C unit (WP 0196).

0197-2

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0197

REMOVAL - Continued

CAUTION
Water and dirt can damage refrigerant system. Refrigerant lines should be capped after disconnection to avoid contamination. 4. 5. 6. Loosen two fitting nuts (Figure 2, Item 2) and disconnect two A/C hoses (Figure 2, Item 3 and 4) from expansion valve (Figure 2, Item 1). Loosen four hose clamps and disconnect four flexible ducts from top of cab heater and A/C unit (Figure 2, Item 5). Remove screw and disconnect white ground wire from top corner of cab heater and A/C unit (Figure 2, Item 5).

1

2

3

4

5

M1089JCH

Figure 2.

Cab Heater/Air Conditioning Unit Removal.

0197-3

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0197

REMOVAL - Continued 7. 8. 9. Underneath cab, remove two tiedown straps (Figure 3, Item 2) and drain valves (Figure 3, Item 3). Remove three locknuts (Figure 3, Item 4), washers (Figure 3, Item 5), and grommets (Figure 3, Item 6). Discard locknuts. Remove cab heater and A/C unit (Figure 3, Item 1) from cab.
1 2,3,4,5,6

2,3,4,5,6

M1090JCH

Figure 3. END OF TASK

Cab Heater/Air Conditioning Unit Removal.

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0197

INSTALLATION

NOTE
Ensure white ground wire, windshield wiper wiring harness, and clear plastic tube are accessible. 1. 2. 3. 4. 5. 6. 7. 8. Position cab heater and A/C unit (Figure 3, Item 1) in cab. Underneath cab, install three grommets (Figure 3, Item 6), washers (Figure 3, Item 5), and new locknuts (Figure 3, Item 4). Install two drain valves (Figure 3, Item 3) with two new tiedown straps (Figure 3, Item 2). Connect white ground wire to top corner of cab heater and A/C unit (Figure 4, Item 5) with screw. Connect four flexible ducts to top of cab heater and A/C unit (Figure 4, Item 5) and tighten four hose clamps. Connect two A/C hoses (Figure 4, Items 3 and 4) to expansion valve (Figure 4, Item 1) and tighten two fitting nuts (Figure 4, Item 2). Replace receiver/dryer (WP 0254). Connect two heater hoses (Figure 4, Items 3 and 4) to side of cab heater and A/C unit.

1

2

3

4

5

M1089JCH

Figure 4.

Cab Heater/Air Conditioning Unit Removal.

0197-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00164)

TM 10-3930-675-23-2

0197

INSTALLATION - Continued 9. 10. Underneath instrument panel, install A/C temperature control, connect cable to heater temperature control, and connect connectors to A/C control switch (Volume 1, WP 0094). Install front panel (Figure 5, Item 1) on cab with 14 washers (Figure 5, Item 3) and capnuts (Figure 5, Item 2).

2,3

1

2,3
M1088JCH

Figure 5. Cab Heater/Air Conditioning Unit Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. Add coolant (Volume 1, WP 0080). Install air cleaner (Volume 1, WP 0071). Start engine (TM 10-3930-675-10) and check for coolant leaks. Charge A/C system with refrigerant (WP 0248). Install windshield wiper assembly (WP 0194). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0198

FIELD MAINTENANCE CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (WP 0276, Table 1, Item 66) Equipment Condition Air cleaner removed (Volume 1, WP 0071) Equipment Condition (cont.) Front windshield wiper assembly removed (WP 0194) Cab moved to the left, but not lowered (TM 10-3930-675-10) Master Battery Switch in OFF position (TM 10-3930-675-10)

REMOVAL 1. Remove 14 capnuts (Figure 1, Item 2), washers (Figure 1, Item 3), and front panel (Figure 1, Item 1) from cab.
2,3

1

2,3
M0624JCH

Figure 1.

Front Panel Removal.

0198-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00165)

TM 10-3930-675-23-2

0198

REMOVAL - Continued 2. Remove eight screws (Figure 2, Item 2) and cover (Figure 2, Item 3) from cab heater and A/C unit (Figure 2, Item 1).
1 2

3

M0625JCH

Figure 2. 3. 4. 5.

Cover Removal.

Disconnect three connectors (Figure 3, Item 4) of wiring harness (Figure 3, Item 5) from temperature sensor (Figure 3, Item 9) of blower motor and fan (Figure 3, Item 6). Disconnect two connectors (Figure 3, Item 7) of wiring harness (Figure 3, Item 5) from connector (Figure 3, Item 8) of blower motor and fan (Figure 3, Item 6). Remove two screws (Figure 3, Item 2), washers (Figure 3, Item 3), and blower motor and fan (Figure 3, Item 6) from cab heater and A/C unit (Figure 3, Item 1).

END OF TASK

0198-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00165)

TM 10-3930-675-23-2

0198

INSTALLATION 1. 2. 3. 4. Install blower motor and fan (Figure 3, Item 6) on cab heater and A/C unit (Figure 3, Item 1) with two washers (Figure 3, Item 3) and screws (Figure 3, Item 2). Connect two connectors (Figure 3, Item 7) of wiring harness (Figure 3, Item 5) to connector (Figure 3, Item 8) of blower motor and fan (Figure 3, Item 6). Connect three connectors (Figure 3, Item 4) of wiring harness (Figure 3, Item 5) to temperature sensor (Figure 3, Item 9) of blower motor and fan (Figure 3, Item 6). Install cover (Figure 2, Item 3) on cab heater and A/C unit (Figure 2, Item 1) with eight screws (Figure 2, Item 2).
2,3 1 4 5 6 7 8

9

M0626JCH

Figure 3. Blower Motor and Fan Replacement.

0198-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00165)

TM 10-3930-675-23-2

0198

INSTALLATION - Continued 5. Install front panel (Figure 4, Item 1) on cab with 14 washers (Figure 4, Item 3) and capnuts (Figure 4, Item 2).
2,3

1

2,3
M0627JCH

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Blower Motor and Fan Installation.

Install front windshield wiper assembly (WP 0194). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00165)

TM 10-3930-675-23-2

0199

FIELD MAINTENANCE CAB AIR FILTERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Dispenser, Sealant (WP 0277, Table 1, Item 22) Materials/Parts Compound, Gasket Forming, Silicone (WP 0276, Table 1, Item 13) Materials/Parts (cont.) Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Rag, Wiping (WP 0276, Table 1, Item 50)

WARNING

CBRN EXPOSURE If Chemical, Biological, Radiological 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 in the event of an injury.

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

0199-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB SIDE AIR FILTER REMOVAL 1. Remove four capnuts (Figure 1, Item 1), washers (Figure 1 Item 2), and grille (Figure 1 Item 3) from side of cab.
1,2 3

M0628JCH

Figure 1. 2. 3.

Cab Grille Removal.

Remove filter element (Figure 2, Item 2) from cab heater and A/C housing (Figure 2, Item 1). Using rags, wipe interior of cab heater and A/C housing (Figure 2, Item 1) free of dust and dirt.

END OF TASK

0199-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB SIDE AIR FILTER CLEANING AND INSPECTION

WARNING

Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel. 1. 2. 3. Use compressed air to clean dirt and debris from air filter. As required, a solution of detergent and water may be used to clean air filter. Dry thoroughly with compressed air. Inspect air filter for damage. Replace if damaged.

END OF TASK CAB SIDE AIR FILTER INSTALLATION 1. Install filter element (Figure 2, Item 2) in cab heater and A/C housing (Figure 2, Item 1).

2

1

M0629JCH

Figure 2.

Cab Side Air Filter Removal.

0199-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB SIDE AIR FILTER INSTALLATION - Continued

CAUTION
Take care when installing grille to prevent damaging rubber seal. 2. Apply a thin bead of gasket forming compound to flange of grille (Figure 3, Item 1) and install grille on side of cab with four washers (Figure 3, Item 3) and capnuts (Figure 3, Item 2).
1 2,3 1

M0630JCH

Figure 3. END OF TASK CAB INTERIOR AIR FILTER REMOVAL

Cab Side Air Filter Installation.

NOTE
Step 1 applies to the RT 240V1 and RT 240V1R vehicles ONLY. 1. Remove three screws (Figure 4, Item 1), washers (Figure 4, Item 2), and left lower panel (Figure 4, Item 3).

0199-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB INTERIOR AIR FILTER REMOVAL - Continued
1,2 3

M0631JCH

Figure 4. Left Lower Panel Removal – RT 240V1 and RT 240V1R Vehicles Only.

NOTE
Step 2 applies to RT 240V2 and RT 240V3 vehicles ONLY. 2. Remove two thumbscrews (Figure 5, Item 1), securing retaining panel (Figure 5, Item 2) and remove air filter (Figure 5, Item 3) from panel (Figure 5, Item 4).
1 2 3

4

M0632JCH

Figure 5.

Cab Interior Air Filter Removal.

0199-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB INTERIOR AIR FILTER REMOVAL - Continued 3. Remove two screws (Figure 6, Item 4), bracket (Figure 6, Item 3), and cab interior air filter (Figure 6, Item 2) from cab heater and A/C housing (Figure 6, Item 1).
1 2

3

4

M0633JCH

Figure 6. END OF TASK

Cab Interior Air Filter Removal

CAB INTERIOR AIR FILTER CLEANING AND INSPECTION Refer to Cab Side Air Filter Cleaning and Inspection procedures in this work package. END OF TASK

0199-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB INTERIOR AIR FILTER INSTALLATION 1. Install cab interior air filter (Figure 6, Item 2) and bracket (Figure 6, Item 3) on cab heater and A/C housing (Figure 6, Item 1) with two screws (Figure 6, Item 4).

NOTE
Step 2 applies to the RT 240V1 and RT 240V1R vehicles only. 2. Install left lower panel (Figure 7, Item 3) with three screws (Figure 7, Item 1) and three washers (Figure 7, Item 2).
1,2 3

M0634JCH

Figure 7. Left Lower Panel Installation – RT 240V1 and RT 240V1R Vehicles Only.

0199-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0199

CAB INTERIOR AIR FILTER INSTALLATION - Continued

NOTE
Steps 3 and 4 apply to the RT 240V2 and RT 240V3 vehicles ONLY. 3. 4. Position air filter (Figure 8, Item 3) on panel (Figure 8, Item 4). Install retaining panel (Figure 8, Item 2) and secure with two thumbscrews (Figure 8, Item 1).
1 2 3

4

M0635JCH

Figure 8. END OF TASK END OF WORK PACKAGE

Cab Interior Air Filter Installation.

0199-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00166)

TM 10-3930-675-23-2

0200

FIELD MAINTENANCE CAB AUXILIARY FAN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Equipment Condition Master Battery Switch in OFF position (TM 10-3930-675-10)

REMOVAL 1. Lift and move access panel (Figure 1, Item 1) at rear of cab.
1

M0636JCH

Figure 1.

Access Panel Removal.

0200-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00167)

TM 10-3930-675-23-2

0200

REMOVAL - Continued 2. 3. 4. Disconnect connector (Figure 2, Item 3) of auxiliary fan (Figure 2, Item 2) from cab wiring harness (Figure 2, Item 4). Loosen two hose clamps (Figure 2, Item 6) and disconnect two ducts (Figure 2, Items 1 and 5). Remove three screws and auxiliary fan (Figure 2, Item 2) from cab.

END OF TASK INSTALLATION 1. 2. 3. Install auxiliary fan (Figure 2, Item 2) in cab with three screws. Connect two ducts (Figure 2, Item 1 and 5) and tighten two hose clamps (Figure 2, Item 6). Connect connector (Figure 2, Item 3) of auxiliary fan (Figure 2, Item 4) to cab wiring harness (Figure 2, Item 4).
2 1

6

3

4 5

M0637JCH

Figure 2. Auxiliary Fan Replacement.

0200-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00167)

TM 10-3930-675-23-2

0200

INSTALLATION - Continued 4. Install access panel (Figure 3, Item 1) on rear of cab.
1

M0638JCH

Figure 3. END OF TASK END OF WORK PACKAGE

Access Cover Installation.

0200-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00167)

TM 10-3930-675-23-2

0201

FIELD MAINTENANCE AUTOLUBE SYSTEM MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-ring (WP 0278, Table 1, Item 4) Qty: 9 Materials/Parts (cont.) Nut, Self-Locking (WP 0278, Table 1, Item 87) Qty: 2 Nut, Self-Locking (WP 0278, Table 1, Item 88) Qty: 2 Personnel Required (2) References TM 10-3930-675-10 LO 10-3930-675-13 Volume 1, WP 0129

0201-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00168)

TM 10-3930-675-23-2

0201

AUTOLUBE TUBE REMOVAL 1. Push in quick-disconnect collar (Figure 1, Item 1) to release tube (Figure 1, Item 2).

NOTE
• If removing the tube to identify a “plugged" line, the tube may appear “stiff" when under pressure. • Remove a “plugged" line by loosening quick-disconnect fitting with an open end wrench to relieve any pressure. • Quick-disconnect fittings will not disconnect when under pressure. • It may be necessary to remove distribution valve from its mounting to gain access to the quick-disconnect fittings. 2. Remove tube (Figure 1, Item 2) from quick-disconnect collar (Figure 1, Item 1).

END OF TASK AUTOLUBE TUBE INSTALLATION 1. 2. Install tube (Figure 1, Item 2) into quick-disconnect fitting (Figure 1, Item 1). Pull tubing (Figure 1, Item 2) to ensure tube has locked in place.
1

2

M0409JCH

Figure 1. Autolube Tube Replacement. END OF TASK AUTOLUBE PUMP REMOVAL 1. 2. 3. Remove battery compartment cover (Volume 1, WP 0129) . Remove three tiedown straps (Figure 2, Item 11) and pull pump wiring harness (Figure 2, Item 12) through hole and out of battery compartment (Figure 2, Item 13). Discard tiedown straps. Unplug autolube pump wiring harness connector (Figure 2, Item 2) from wiring harness (Figure 2, Item 1).

0201-2

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TM 10-3930-675-23-2

0201

AUTOLUBE PUMP REMOVAL - Continued 4. 5. 6. 7. Disconnect lubrication supply tube (Figure 2, Item 4) from pressure limiting valve (Figure 2, Item 3). Disconnect lubrication return tube (Figure 2, Item 5) from pump (Figure 2, Item 6). Remove two mounting bolts (Figure 2, Item 7), washers (Figure 2, Item 8), and locknuts (Figure 2, Item 9) from pump (Figure 2, Item 6). Discard locknuts. Remove pump assembly (Figure 2, Item 6) from mounting bracket (Figure 2, Item 10).

END OF TASK AUTOLUBE PUMP INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Install pump assembly (Figure 2, Item 6) on mounting bracket (Figure 2, Item 10). Install two new locknuts (Figure 2, Item 9), washers (Figure 2, Item 8), and mounting bolts (Figure 2, Item 7) on pump (Figure 2, Item 6). Connect lubrication return tube (Figure 2, Item 5) to pump (Figure 2, Item 6). Connect lubrication supply tube (Figure 2, Item 4) to pressure limiting valve (Figure 2, Item 3). Insert pump wiring harness (Figure 2, Item 12) through hole and out of battery compartment (Figure 2, Item 13). Plug wiring harness (Figure 2, Item 1) into autolube pump wiring harness connector (Figure 2, Item 2). Secure pump wiring harness (Figure 2, Item 12) with three new tiedown straps (Figure 2, Item 11). Fill pump reservoir with grease, GAA (TM 10-3930-675-10). Initiate a manual lubrication cycle to ensure system is working properly (LO 10-3930-675-13). Install battery compartment cover (Volume 1, WP 0129).
1 2 3 4 5

13

12

11

7,8,9,10

6

M0410JCH

Figure 2. END OF TASK

Autolube Pump Replacement.

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TM 10-3930-675-23-2

0201

AUTOLUBE DISTRIBUTION VALVE REMOVAL

NOTE
Tag each tube on the distribution valve with the number of the port to which it is connected. 1. 2. 3. Disconnect nine tubes (Figure 3, Item 1) from nine quick-disconnect fittings (Figure 3, Item 2) ( Autolube Tubing Removal in this work package). Remove two mounting bolts (Figure 3, Item 6), locknuts (Figure 3, Item 7), and remove distribution valve (Figure 3, Item 5) from vehicle. Discard locknuts. Remove nine fittings (Figure 3, Item 3) and O-rings (Figure 3, Item 4) from distribution valve (Figure 3, Item 5) and set fittings aside for reuse. Discard O-rings.

END OF TASK AUTOLUBE DISTRIBUTION VALVE INSTALLATION 1. 2. 3. 4. Install nine new O-rings (Figure 3, Item 4) on fittings (Figure 3, Item 3) and install fittings on distribution valve (Figure 3, Item 5). Mount distribution valve (Figure 3, Item 5) on frame and secure with two new locknuts (Figure 3, Item 7) and mounting bolts (Figure 3, Item 6). Connect nine tube (Figure 3, Item 1) to nine quick-disconnect fittings (Figure 3, Item 2) ( Autolube Tubing Installation) in this work package. Initiate a manual lubrication cycle to ensure system is working properly (LO 10-3930-675-13).
1 2

6,7 3,4 5
M0411JCH

Figure 3. Autolube Distribution Valve Replacement. END OF TASK END OF WORK PACKAGE

0201-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00168)

TM 10-3930-675-23-2

0202

FIELD MAINTENANCE FIRE EXTINGUISHER BRACKET REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics Automotive (WP 0277, Table 1, Item 85)

REMOVAL 1. 2. Remove fire extinguisher from fire extinguisher bracket (Figure 1, Item 1). Remove six screws (Figure 1, Item 2), washers (Figure 1, Item 3), and fire extinguisher bracket (Figure 1, Item 1) from cab.

END OF TASK INSTALLATION 1. 2. Install fire extinguisher bracket (Figure 1, Item 1) in cab with six washers (Figure 1, Item 3) and screws (Figure 1, Item 2). Install fire extinguisher on fire extinguisher bracket (Figure 1, Item 1).
1 2,3

M0499JCH

Figure 1. END OF TASK END OF WORK PACKAGE

Fire Extinguisher Bracket Replacement.

0202-1/2 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00169)

TM 10-3930-675-23-2

0203

FIELD MAINTENANCE DATA PLATE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Drill, Electric, Portable, 3/8 in. (WP 0277, Table 1, Item 23) Riveter, Blind, Hand 3/32 in., 1/8 in., 5/32 in., and 3/16 in. diameters (WP 0277, Table 1, Item 63) Materials/Parts Rivets Qty: (as required) References TM 10-3930-675-24P

0203-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00170)

TM 10-3930-675-23-2

0203

REMOVAL

WARNING

Wear eye protection when drilling out rivets. Failure to do so could result in serious eye injury.

CAUTION
Avoid using a twist drill with an excessively large diameter when drilling out rivets. Failure to follow this caution could result in enlarged holes in vehicle, too large for rivet size needed. 1. 2. Drill out four rivets (Figure 1, Item 1) from data plate (Figure 1, Item 2). Discard rivets. Remove data plate (Figure 1, Item 2) from vehicle.

END OF TASK INSTALLATION 1. 2. Position data plate (Figure 1, Item 2) over existing holes in vehicle. Install data plate (Figure 1, Item 2) on vehicle with four new rivets (Figure 1, Item 1). Refer to TM 10-3930-675-24P.
1 2

M0498JCH

Figure 1. END OF TASK END OF WORK PACKAGE

Data Plate Replacement.

0203-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00170)

TM 10-3930-675-23-2

0204

FIELD MAINTENANCE RELIEVING HYDRAULIC SYSTEM PRESSURE

INITIAL SETUP: Tools and Special Tools Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) References TM 10-3930-675-10

GENERAL

WARNING

• DO NOT disconnect o remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. 1. During operation of the RTCH, hydraulic pressure is generated by hydraulic pumps to operate the following: a. b. c. d. e. f. g. 2. 3. Lifting boom Tophandler Service brakes Parking brakes Steering system Bogie wheel assembly hydraulic cylinders Cab movement hydraulic cylinders

Both brake and steering systems have pressurized accumulators that provide adequate stored energy to operate in the event of engine shutdown. In order to safely perform maintenance on all hydraulic systems, hydraulic pressure must first be relieved.

END OF TASK

0204-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00171)

TM 10-3930-675-23-2

0204

RELIEVING HYDRAULIC SYSTEM PRESSURE 1. To relieve hydraulic pressure in ALL systems: a. b. Lower and fully retract boom (TM 10-3930-675-10). Shut down engine (TM 10-3930-675-10).

NOTE
When performing steering or brake hydraulic system maintenance, leave evacuation valves open until maintenance action is completed. then close valves before starting engine to pressurize system. 2. To further release pressure in steering hydraulic system, open steering accumulator evacuation valve (Figure 1, Item 1) behind cab. Allow pressure to release, approximately 15 seconds. It is now safe to perform maintenance on steering system.
1

M0513JCH

Figure 1. Steering Accumulator Evacuation Valve. 3. To further release pressure in brake hydraulic system, open two brake accumulator evacuation valves (Figure 2, Item 1) behind cab. Allow pressure to release, approximately 15 seconds. It is now safe to perform maintenance on brake system.

0204-2

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TM 10-3930-675-23-2

0204

RELIEVING HYDRAULIC SYSTEM PRESSURE - Continued

M0514JCH

1

Figure 2. Steering Accumulator Evacuation Valves.

NOTE
Leave valves open until maintenance action is completed, then close valves before starting engine to pressurize system. 4. To further release pressure in boom hydraulic system (boom extension and lift cylinders, hoses, pipes, and valves), open float control valve (Figure 3, Item 1) and emergency control valve (Figure 3, Item 2) on each locking valve at base of each lift cylinder. Leave valves open until maintenance action is completed, then close valves before starting engine to pressurize system.
1 2

M0515JCH

Figure 3. Float Control and Emergency Control Valves.

0204-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00171)

TM 10-3930-675-23-2

0204

RELIEVING HYDRAULIC SYSTEM PRESSURE - Continued 5. When disconnecting hydraulic lines from boom folding cylinders, additional precautions are required due to residual pressure in lines: a. b. c. Wear eye protection. Place drain pan beneath work area. Have a rag handy and slowly disconnect hydraulic lines.

END OF TASK END OF WORK PACKAGE

0204-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00171)

TM 10-3930-675-23-2

0205

FIELD MAINTENANCE BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (Minimum Capacity 300 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealant, Silicone (WP 0276, Table 1, Item 53) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 47) Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 48) O-Ring (WP 0278, Table 1, Item 103) Personnel Required (2) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Brake hydraulic system pressure relieved WP 0204 Transmission access covers and cab support removed WP 0175

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0205-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00172)

TM 10-3930-675-23-2

0205

NOTE
• Tag all hydraulic lines and fittings. • Remove nylon straps and remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. Trace supply hose (Figure 1, Item 13) under pump (Figure 1, Item 4) back to hydraulic reservoir. Close ball valve in supply hose at reservoir.

NOTE
Witness mark check valve and pump to ensure correct installation. 2. Remove four screws (Figure 1, Item 10), flange (Figure 1, Item 9), pump-to-primary filter hose (Figure 1, Item 11), O-ring (Figure 1, Item 8), and check valve (Figure 1, Item 7) from pump (Figure 1, Item 4). Discard O-ring. Under pump (Figure 1, Item 4), loosen two hose clamps (Figure 1, Item 12) and disconnect supply hose (Figure 1, Item 13) from hose connection (Figure 1, Item 16). Disconnect hose (Figure 1, Item 18) from fitting (Figure 1, Item 19) on underside of pump (Figure 1, Item 4). If required, loosen eight screws (Figure 1, Item 3) and rotate two hydraulic pump assembly hoses (Figure 1, Item 2) aside.

3. 4. 5.

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 resulting in death or injury to personnel. • Boom and brake system hydraulic pump weighs approximately 200 lb (91 kg). Lifting device must have sufficient capacity to lift pump. Failure to follow this warning may result in injury to personnel. 6. 7. Wrap a nylon sling around pump (Figure 1, Item 4) and attach sling to a suitable lifting device. Remove two screws (Figure 1, Item 5) and pump (Figure 1, Item 4) from transmission (Figure 1, Item 6).

NOTE
Perform steps 8 and 9 to remove fittings from pump, if a new pump is being installed. 8. 9. On underside of pump (Figure 1, Item 4), remove fitting (Figure 1, Item 19) from flange (Figure 1, Item 1). Remove four screws (Figure 1, Item 20), flange, and O-ring (Figure 1, Item 21) from pump. Discard O-ring. On underside of pump (Figure 1, Item 4), remove four screws (Figure 1, Item 14), flange (Figure 1, Item 15), hose connection (Figure 1, Item 16), and O-ring (Figure 1, Item 17) from pump. Discard O-ring.

END OF TASK

0205-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00172)

TM 10-3930-675-23-2

0205

INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform steps 1 and 2 to install fittings removed from old pump, if a new pump is being installed. • Lubricate new O-rings with lubricating oil as they are installed. 1. 2. On underside of pump (Figure 1, Item 4), install new O-ring (Figure 1, Item 17) and hose connection (Figure 1, Item 16) with flange (Figure 1, Item 15) and four screws (Figure 1, Item 14). On underside of pump (Figure 1, Item 4), install new O-ring (Figure 1, Item 21) and flange (Figure 1, Item 1) on pump with four screws (Figure 1, Item 20). Install fitting (Figure 1, Item 19) on flange.
2 3 4 5

1

6

7 20,21 8 19 9 10
M0997JCH

18

14,15,16,17

13

12

11

Figure 1.

Pump Replacement.

0205-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00172)

TM 10-3930-675-23-2

0205

INSTALLATION - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 resulting in death or injury to personnel. • Boom and brake system hydraulic pump weighs approximately 200 lb (91 kg). Lifting device must have sufficient capacity to lift pump. Failure to follow this warning may result in injury to personnel.

NOTE
Ensure mating surfaces of pump and transmission are clean and free of old sealant material. 3. 4. 5. 6. With a nylon sling wrapped around pump (Figure 2, Item 4) and sling supported by a suitable lifting device, apply sealant to mating surfaces and install pump on transmission (Figure 2, Item 6) with two screws. Connect hose (Figure 2, Item 18) to fitting (Figure 2, Item 19) on underside of pump (Figure 2, Item 4). Connect supply hose (Figure 2, Item 13) to hose connection (Figure 2, Item 16) and tighten two hose clamps (Figure 2, Item 12). If loosened, reposition two hydraulic pump assembly hoses (Figure 2, Item 2) and tighten eight screws (Figure 2, Item 3).

NOTE
Ensure check valve is installed on pump in accordance with witness marks. 7. 8. 9. Install check valve (Figure 2, Item 7), new O-ring (Figure 2, Item 8), pump-to-primary filter hose (Figure 2, Item 11), and flange (Figure 2, Item 9) with four screws (Figure 2, Item 10). Open ball valve at reservoir for supply hose (Figure 2, Item 13). Install nylon straps and new tiedown straps as necessary to support hydraulic hoses.

0205-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00172)

TM 10-3930-675-23-2

0205

INSTALLATION - Continued
2 3 4 5

1

6

7 20,21 8 19 9 10
M0998JCH

18

14,15,16,17

13

12

11

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE 1.

Pump Installation.

Install transmission access covers and cab support (WP 0175).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 2. 3. 4. 5. Return cab to operational position (TM 10-3930-675-10). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10), operate boom and brakes, and check for leaks. Recheck oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

0205-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00172)

TM 10-3930-675-23-2

0206

FIELD MAINTENANCE COOLING FAN HYDRAULIC PUMP REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Wrench, Torque, Click, Ratcheting, 3/8 Inch Drive, 75 lb-ft (WP 0277, Table 1, Item 97) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealant, Silicone (WP 0276, Table 1, Item 53) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 47) O-Ring (WP 0278, Table 1, Item 48) Personnel Required (Two) References TM-10-3930-675-10 Volume 1, WP 0047 Volume 1, WP 0076 WP 0227 WP 0268 Equipment Condition Engine cover removed (WP 0185) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe are clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0206-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00173)

TM 10-3930-675-23-2

0206

NOTE
Tag hydraulic lines and fittings. REMOVAL 1. 2. 3. Drain and remove fuel filter/water separator (Volume 1, WP 0076). Trace hydraulic hose (Figure 1, Item 2) from hydraulic pump (Figure 1, Item 1) back to reservoir and locate ball valve. close ball valve. Remove canvas straps (Figure 1, Item 3) and remove and discard tiedown straps, as needed, to allow free movement in hydraulic hoses (Figure 1, Item 2 and 4).

NOTE
Position suitable container to catch hydraulic oil retained in hoses. 4. Remove four screws (Figure 1, Item 5), flange (Figure 1, Item 6), O-ring (Figure 1, Item 7), and hydraulic hose (Figure 1, Item 2) from hydraulic pump (Figure 1, Item 1) input port. Discard O-ring.

0206-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00173)

TM 10-3930-675-23-2

0206

REMOVAL - Continued

1

7 6 3 5 5

2

M0999JCH

4

Figure 1.

Pump Removal.

0206-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00173)

TM 10-3930-675-23-2

0206

REMOVAL - Continued 5. Remove four screws (Figure 2, Item 8), flange (Figure 2, Item 7), O-ring (Figure 2, Item 6), and hydraulic hose (Figure 2, Item 2) from hydraulic pump (Figure 2, Item 1) output port. Discard O-ring.

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. 6. 7. Remove two screws (Figure 2, Item 3) and washers (Figure 2, Item 4) securing hydraulic pump (Figure 2, Item 1) to drive adapter (Figure 2, Item 5). Remove hydraulic pump (Figure 2, Item 1) from drive adapter (Figure 2, Item 5).

END OF TASK INSTALLATION

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Ensure mating surfaces on hydraulic pump and drive adapter are clean and free of old sealant material. • Lubricate new O-rings with lubricating oil as they are installed. 1. 2. 3. Apply sealant to mating surfaces and install hydraulic pump (Figure 2, Item 1) in position on drive adapter (Figure 2, Item 5). Install two screws (Figure 2, Item 3) and washers (Figure 2, Item 4). Tighten screws to 35 lb-ft (47 N•m). Install new O-ring (Figure 2, Item 6) and hydraulic hoses (Figure 2, Item 2) on hydraulic pump (Figure 2, Item 1) outlet port with flange (Figure 2, Item 7) and four screws (Figure 2, Item 8).

0206-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00173)

TM 10-3930-675-23-2

0206

INSTALLATION - Continued
1

8 2 7 6

M1000JCH

5

3,4

Figure 2. 4. 5. 6. 7.

Pump Installation.

Install new O-ring (Figure 1, Item 7) and hydraulic hose (Figure 1, Item 2) on hydraulic pump (Figure 1, Item 1) inlet port with flange (Figure 1, Item 6) and four screws (Figure 1, Item 5). Secure hydraulic hoses with canvas straps (Figure 1, Item 3) and new tiedown straps as needed. Install fuel filter/ water separator filter (Volume 1, WP 0076). Open ball valve at reservoir for supply hose.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Check oil level in hydraulic reservoir (Volume 1, WP 0047). Start engine (TM 10-3930-675-10) and check for leaks. Recheck oil level in hydraulic reservoir.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 4. Install engine cover (WP 0227).

END OF TASK END OF WORK PACKAGE

0206-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00173)

TM 10-3930-675-23-2

0207

FIELD MAINTENANCE SERVO CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 References (cont.) WP 0227 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Transmission access covers and cab support removed (WP 0175) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe are clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0207-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00175)

TM 10-3930-675-23-2

0207

NOTE
• Tag all hydraulic lines and electrical leads. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. 2. 3. 4. Press in on four retaining clips (Figure 1, Item 4) and disconnect four electrical leads (Figure 1, Item 3) from solenoids (Figure 1, Item 5). Disconnect two hoses (Figure 1, Item 9) from tee (Figure 1, Item 1). Disconnect seven hoses (Figure 1, Item 2) from fittings (Figure 1, Item 8) at control valve (Figure 1, Item 6). Remove two screws, washers, and control valve (Figure 1, Item 6) from plate (Figure 1, Item 7).

NOTE
Perform step 5 to remove fittings from control valve, if a new control valve is being installed. 5. Remove tee (Figure 1, Item 1) and seven fittings (Figure 1, Item 8) from control valve (Figure 1, Item 6).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform step 1 to install fittings removed from old control valve, if a new control valve is being installed. 1. 2. 3. 4. 5. 6. Install seven fittings (Figure 1, Item 8) and tee (Figure 1, Item 1) on control valve (Figure 1, Item 6). Install control valve (Figure 1, Item 6) on plate (Figure 1, Item 7) with two washers and screws. Connect seven hoses (Figure 1, Item 2) to fittings (Figure 1, Item 8) at control valve (Figure 1, Item 6). Connect two hoses (Figure 1, Item 9) to tee (Figure 1, Item 1). Connect four electrical leads (Figure 1, Item 3) to solenoids (Figure 1, Item 5) and ensure retaining clips (Figure 1, Item 4) are secure. Install new tiedown straps, as necessary, to support hydraulic hoses.

0207-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00175)

TM 10-3930-675-23-2

0207

INSTALLATION - Continued
2 3 4 5 1 6

7 8 9 2

M1009JCH

2

8

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Servo Control Valve Replacement.

Install transmission access covers (WP 0175). Return cab to operational position (TM 10-3930-675-10).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 3. 4. 5. Recheck oil level in hydraulic reservoir (LO 10-3930-675-13). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10), operate systems, and check for leaks.

END OF TASK END OF WORK PACKAGE

0207-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00175)

TM 10-3930-675-23-2

0208

FIELD MAINTENANCE HYDRAULIC SYSTEM COOLING HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, OE/HDO 10 (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (as required) References LO 10-3930-675-13 References (cont.) TM 10-3930-675-24P WP 0227 WP 0268 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204) Radiator assembly top grating (Volume 1, WP 0085) and bottom splash shield removed (Volume 1, WP 0084), if replacing hydraulic cooling fan hoses and fittings (Volume 1, WP 0084) (Volume 1, WP 0085)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0208-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00176)

TM 10-3930-675-23-2

0208

NOTE
• This work package covers replacement of hydraulic hoses and fittings that support the following hydraulic system components: 1. engine-driven hydraulic pump 2. cooling fan 3. front and rear service brake cooling lines • Tag all hydraulic lines. REMOVAL

NOTE
Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. Using appropriate illustration (refer to (WP 0272), FO-4 and FO-5) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown straps. Discard O-ring(s) removed.

END OF TASK INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

END OF TASK FOLLOW-ON MAINTENANCE

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. If removed, install radiator assembly top grating and bottom splash shield (Volume 1, WP 0084) and (Volume 1, WP 0085). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks.

END OF TASK END OF WORK PACKAGE

0208-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00176)

TM 10-3930-675-23-2

0209

FIELD MAINTENANCE AUXILIARY HYDRAULIC PUMP REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, OE/HDO 10 (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Nut, Self-Locking (WP 0278, Table 1, Item 80) Qty: 3 References WP 0227 WP 0268 Equipment Condition Cab moved to the left, but not lowered (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0209-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0209

NOTE
• RT 240V2 and RT 240V3 pump mounted other way. • Cab may not be moved to transport position. • Tag all electrical wires and hydraulic lines and fittings to ensure correct installation. REMOVAL 1. Remove three locknuts (Figure 1, Item 1), bolts (Figure 1, Item 2), washers (Figure 1, Item 3), spacers (Figure 1, Item 4) and cover (Figure 1, Item 5). Discard locknuts.
1,2,3,4 5

M0516JCH

Figure 1. 2. 3. 4. 5.

Cover Removal.

Trace supply hose (Figure 2, Item 5) back to hydraulic reservoir. Close ball valve in supply hose at reservoir. Disconnect supply hose (Figure 2, Item 5) from straight connector (Figure 2, Item 6) on pump (Figure 2, Item 4). Disconnect pressure hose (Figure 2, Item 8) from elbow (Figure 2, Item 7). Peel back rubber boot from terminal post (Figure 2, Item 2). Remove nut (Figure 2, Item 3) and disconnect two black wires (Figure 2, Item 9) and gray wire (Figure 2, Item 1) from terminal post.

0209-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0209

REMOVAL - Continued
2,3 1 4

5

6 9 7

8

M0517JCH

Figure 2. 6. 7. 8.

Hose and Wire Disconnects.

Remove nut (Figure 3, Item 4), lockwasher (Figure 3, Item 5), and disconnect strap (Figure 3, Item 3) and gray wire (Figure 3, Item 6). Disconnect two connectors (Figure 3, Item 2) from solenoid (Figure 3, Item 1). Peel back rubber boot and remove nut (Figure 3, Item 7), lockwasher (Figure 3, Item 8), and disconnect power cable (Figure 3, Item 9) from solenoid (Figure 3, Item 1).
2 1 4,5 3

6

9 7,8
M0518JCH

Figure 3. Ground Strap and Power Cable Disconnects.

0209-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0209

REMOVAL - Continued 9. 10. 11. Remove two bolts (Figure 4, Item 5) and washers (Figure 4, Item 6) from underside of pump (Figure 4, Item 1) and mounting bracket (Figure 4, Item 4). Remove two allen screws (Figure 4, Item 2) from clamp (Figure 4, Item 3). Remove pump (Figure 4, Item 1) and two spacers (Figure 4, Item 7) from mounting bracket (Figure 4, Item 3).

1

2

7

5,6

4

3

M0519JCH

Figure 4.

Pump Removal.

NOTE
Perform step 12 to remove fittings from pump, if a new pump is being installed. 12. Remove straight connector (Figure 2, Item 6) and elbow (Figure 2, Item 7) from pump (Figure 2, Item 4).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform step 1 to install fittings removed from old pump, if a new pump is being installed. 1. 2. 3. 4. Install elbow (Figure 2, Item 7) and straight connector (Figure 2, Item 6) on pump (Figure 2, Item 4). Position two spacers (Figure 5, Item 7) and pump (Figure 5, Item 1) on mounting bracket (Figure 5, Item 4). Loosely install two washers (Figure 5, Item 6) and bolts (Figure 5, Item 5). Secure clamp (Figure 5, Item 3) around pump (Figure 5, Item 1) with two allen screws (Figure 5, Item 2). Fully tighten two bolts (Figure 5, Item 5).

0209-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0209

INSTALLATION - Continued

1

2

7

5,6

4

3

M0520JCH

Figure 5. 5. 6. 7.

Pump Installation.

Connect power cable (Figure 6, Item 9) to solenoid (Figure 6, Item 1) with lockwasher (Figure 6, Item 8) and nut (Figure 6, Item 7). Connect two connectors (Figure 6, Item 2) to solenoid (Figure 6, Item 1). Connect strap (Figure 6, Item 3) and gray wire (Figure 6, Item 6) with lockwasher (Figure 6, Item 5) and nut (Figure 6, Item 4).
2 1 4,5 3

6

9 7,8
M0521JCH

Figure 6. Ground Strap and Power Cable Connections.

0209-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0209

INSTALLATION - Continued 8. 9. 10. 11. Connect two black wires (Figure 7, Item 9) and gray wire (Figure 7, Item 1) to terminal post (Figure 7, Item 2) with nut (Figure 7, Item 3). Cover terminal post with rubber boot. Connect pressure hose (Figure 7, Item 8) to elbow (Figure 7, Item 7). Connect supply hose (Figure 7, Item 5) to straight connector (Figure 7, Item 6). Open ball valve at reservoir for supply hose (Figure 7, Item 5).
2,3 1 4

5

6 9 7

8

M0522JCH

Figure 7. Hose and Wire Connections.

0209-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0209

INSTALLATION - Continued 12. Install cover (Figure 8, Item 5) with three spacers (Figure 8, Item 4), washers (Figure 8, Item 3), bolts (Figure 8, Item 2), and new locknuts (Figure 8, Item 1).
1,2,3,4 5

M0523JCH

Figure 8. END OF TASK FOLLOW-ON MAINTENANCE

Cover Installation.

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Return cab to operational position (TM 10-3930-675-10). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and turn on emergency hydraulic pump (TM 10-3930-674-10). Check for leaks.

END OF TASK END OF WORK PACKAGE

0209-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00177)

TM 10-3930-675-23-2

0210

FIELD MAINTENANCE TOPHANDLER HYDRAULIC SLEWING MOTORS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Wrench, Torque, Click, Ratcheting, 1/2" Drive, 250 ft-lb (WP 0277, Table 1, Item 95) Lifting Device (min. capacity 250 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear 85W/140 (WP 0276, Table 1, Item 44) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Seal, Plain (WP 0278, Table 1, Item 132) Personnel Required (2) References LO 10-3930-675-13 WP 0227 WP 0268 WP 0270 Equipment Condition Boom and tophandler lowered for access (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0210-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

NOTE
Tag all hydraulic lines. REMOVAL 1. Remove ten screws (Figure 1, Item 3) and one of four protection covers (Figure 1, Item 2) from turning plate (Figure 1, Item 1).
1

2 3
M0524JCH

Figure 1. Turning Plate Cover Removal.

NOTE
• To remove slewing motor with hydraulic manifold, perform steps 2 and 3. • To remove slewing motor without hydraulic manifold, proceed to step 4. 2. 3. Remove four socket head screws (Figure 2, Item 1) securing hydraulic manifold (Figure 2, Item 2) with hoses to slewing motor (Figure 2, Item 3). Remove hydraulic manifold (Figure 2, Item 2) with hoses attached from slewing motor (Figure 2, Item 3). Discard O-rings from ends of hoses.

0210-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

REMOVAL - Continued
1 2 3

1

M0525JCH

Figure 2. Hydraulic Manifold and Hose Removal.

NOTE
If removing slewing motor without hydraulic manifold, perform step 4. 4. Remove two hydraulic hoses (Figure 3, Items 1 and 5) and fittings (Figure 3, Items 2 and 4) from slewing motor (Figure 3).
1 2

3

5

4

M0526JCH

Figure 3. Hydraulic Manifold and Hose Removal.

0210-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

REMOVAL - Continued

NOTE
Note orientation of slewing motor for positioning hydraulic connections on installation. 5. Remove ten bolts (Figure 4, Item 3) and washers (Figure 4, Item 4) securing slewing motor (Figure 4, Item 1) to turning plate (Figure 4, Item 2).

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Slewing motor weighs approximately 150 lb (68 kg). Lifting device must have sufficient capacity to lift motor. Failure to follow this warning may result in injury to personnel. 6. With assistance, and using nylon sling and suitable lifting device, remove slewing motor (Figure 4, Item 1) with pinion gear (Figure 4, Item 5) from turning plate (Figure 4, Item 2).

END OF TASK

0210-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

INSTALLATION

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Slewing motor weighs approximately 150 lb (68 kg). Lifting device must have sufficient capacity to lift motor. Failure to follow this warning may result in injury to personnel.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Ensure slewing motor is oriented to allow hoses or hydraulic manifold connections. 1. 2. With assistance, and using nylon sling and suitable lifting device, install slewing motor (Figure 4, Item 1) with pinion gear (Figure 4, Item 5) through turning plate (Figure 4, Item 2) and engage ring gear (Figure 4, Item 6). Install ten bolts (Figure 4, Item 3) and washers (Figure 4, Item 4) to secure slewing motor (Figure 4, Item 1) in place. Tighten bolts in an even pattern in accordance with Torque Limits (WP 0270).
1

2

7,8 6 5 3,4
M0527JCH

Figure 4. Slewing Motor and Pinion Gear Removal.

0210-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

INSTALLATION - Continued

NOTE
• To install slewing motor with hydraulic manifold, perform steps 3 and 4. • To install slewing motor without hydraulic manifold, proceed to step 5. • Ensure O-rings are lubricated with lubricating oil prior to installation. 3. Position new O-rings and hydraulic manifold (Figure 5, Item 1) with hoses attached on slewing motor (Figure 5, Item 2) mating surface.
1 2

M0528JCH

Figure 5.

Slewing Motor and Hydraulic Manifold Installation.

0210-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

INSTALLATION - Continued 4. Install four socket head screws (Figure 6, Item 1) to secure hydraulic manifold (Figure 6, Item 2) to slewing motor (Figure 6, Item 3).
1 2 3

1

M0529JCH

Figure 6.

Secure Hydraulic Manifold.

0210-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

INSTALLATION - Continued

NOTE
If installing slewing motor without hydraulic manifold, perform step 5. 5. Install fittings (Figure 7, Items 2 and 4) and connect two hydraulic hoses (Figure 7, Items 1 and 5) to slewing motor (Figure 7, Item 3).
1 2

3

5

4

M0530JCH

Figure 7. Hoses and Fittings Installation and Connection.

0210-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0210

INSTALLATION - Continued 6. 7. Position protective cover (Figure 8, Item 2) on turning plate (Figure 8, Item 1) with ten screws (Figure 8, Item 3). If a new slewing motor was installed, lubricate motor in accordance with LO 10-3930-675-13.
1

2 3
M0531JCH

Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1.

Protective Cover Installation.

Check oil level in hydraulic reservoir (LO 10-3930-675-13).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 2. 3. Operate tophandler (TM 10-3930-675-10) and check for leaks. Return boom and top handler to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0210-9/10 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00252)

TM 10-3930-675-23-2

0211

FIELD MAINTENANCE SLEWING MOTOR BRAKE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 In. Drive, 300 lb-in (WP 0277, Table 1, Item 98) Personnel Required (2)

NOTE
• Motor can be replaced without removing slewing motor assembly from the tophandler. • Place an index mark on hydraulic motor and slew motor brake to mark location for assembly. HYDRAULIC MOTOR REMOVAL 1. 2. Remove two socket-head capscrews (Figure 1, Item 2), washers (Figure 1, Item 3), and hydraulic motor (Figure 1, Item 1) from slewing motor brake (Figure 1, Item 4). Using two pry-bars, remove spur gear (Figure 1, Item 5) from hydraulic motor (Figure 1, Item 1).
1 2,3 4 5

1

M0992JCH

Figure 1. END OF TASK

Spur Gear Removal.

0211-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00178)

TM 10-3930-675-23-2

0211

HYDRAULIC MOTOR INSTALLATION 1. 2. Align keyway of spur gear (Figure 1, Item 5) to key on hydraulic motor (Figure 1, Item 1) shaft and, using dead blow hammer, drive it into place on shaft. Set hydraulic motor (Figure 1, Item 1) in place and secure it with two socket-head capscrews (Figure 1, Item 2) and two washers (Figure 1, Item 3).

END OF TASK SLEWING MOTOR BRAKE REMOVAL 1. 2. Place an index mark on slewing motor brake (Figure 2, Item 4) and planetary housing (Figure 2, Item 6) to mark location for reassembly. Perform Step 1 of Hydraulic Motor Removal in this work package to remove hydraulic motor.

NOTE
• Only remove hardware that is in the way. • Note which side sight glasses are removed from to aid in installation. 3. 4. 5. 6. Remove fittings, plugs, and sight glasses and loosen allen head screws (Figure 2, Item 5). Remove slewing motor from vehicle. Remove eight allen head screws (Figure 2, Item 5) securing slewing motor brake (Figure 2, Item 4) to planetary gear assembly (Figure 2, Item 6). Separate slewing motor brake (Figure 2, Item 4) from planetary gear assembly (Figure 2, Item 6).

END OF TASK SLEWING MOTOR BRAKE INSTALLATION 1. 2. 3. Transfer index mark from old slewing motor brake (Figure 2, Item 4) to new brake for proper positioning of brake during installation. Align index marks and assemble slewing motor brake (Figure 2, Item 4) on planetary assembly (Figure 2, Item 6). Install eight allen head screws (Figure 2, Item 5) to secure slewing motor brake (Figure 2, Item 4) to planetary assembly (Figure 2, Item 6).

NOTE
Apply teflon tape to threads of fittings. 4. 5. 6. Install fittings, plugs, and sight glasses that were removed. Install slewing motor on vehicle. Perform Step 2 of Hydraulic Motor Installation in this work package.

0211-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00178)

TM 10-3930-675-23-2

0211

SLEWING MOTOR BRAKE INSTALLATION - Continued

1

2,3

4

5

6
M0993JCH

Figure 2. Slewing Motor Brake Removal and Replacement. END OF TASK PLANETARY ASSEMBLY REMOVAL Remove hydraulic motor, slewing motor brake, and slewing motor gear from planetary assembly. END OF TASK PLANETARY ASSEMBLY INSTALLATION Assemble slewing motor gear, slewing motor brake, and hydraulic motor on new planetary assembly. END OF TASK

0211-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00178)

TM 10-3930-675-23-2

0211

SLEWING MOTOR GEAR REMOVAL

NOTE
A removed capscrew can be installed into center hole of retaining plate to aid in plate removal. 1. 2. Remove four capscrews (Figure 3, Item 2) and retaining plate (Figure 3, Item 3) securing slewing motor gear (Figure 3, Item 4) to shaft of planetary assembly (Figure 3, Item 1). Slide gear (Figure 3, Item 4) off splined shaft of planetary assembly (Figure 3, Item 1).

END OF TASK SLEWING MOTOR GEAR INSTALLATION 1. 2. Align splines of gear (Figure 3, Item 4) to shaft splines of planetary assembly (Figure 3, Item 1) and slide gear into place. Position retaining plate (Figure 3, Item 3) and secure with four capscrews (Figure 3, Item 2).

1

2

3

4

M0994JCH

Figure 3. Slewing Motor Gear Replacement. END OF TASK END OF WORK PACKAGE

0211-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00178)

TM 10-3930-675-23-2

0212

FIELD MAINTENANCE TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (min. capacity 100 lbs) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealant, Silicone (WP 0276, Table 1, Item 53) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 13) Qty: 3 O-Ring (WP 0278, Table 1, Item 47) Qty: 7 O-Ring (WP 0278, Table 1, Item 48) O-Ring (WP 0278, Table 1, Item 49) O-Ring (WP 0278, Table 1, Item 76) Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 82) Qty: 2 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 88) Qty: 2 Personnel Required (2) References LO 10-3930-675-13 WP 0227 WP 0213 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Transmission access covers and cab support removed (WP 0175) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

0212-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Remove nylon straps and remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. • Tag all hydraulic lines. REMOVAL 1. 2. 3. 4. 5. Trace two supply hoses (Figure 1, Item 10) under pump (Figure 1, Item 3) back to hydraulic reservoir. Close ball valves in supply hoses at reservoir. Loosen clamp (Figure 1, Item 9) and disconnect supply hose (Figure 1, Item 10) from hose (Figure 1, Item 8). Also loosen two hose clamps and disconnect other supply hose from hose connection. Disconnect hoses (Figure 1, Items 1 and 11) from tee fitting (Figure 1, Item 2). Disconnect hoses (Figure 1, Item 5) from fitting (Figure 1, Item 4). Disconnect hose (Figure 1, Item 7) from fitting (Figure 1, Item 6).
2 1 7 3 4 5 6

11 10 9 8
M0965JCH

Figure 1.

Pump Removal.

NOTE
Scribe mark on connection block, check valve (notice flow direction mark), and pump to ensure correct installation. 6. 7. Remove four screws (Figure 2, Item 8), flange (Figure 2, Item 7), hose (Figure 2, Item 9), and O-ring (Figure 2, Item 6) from connection block (Figure 2, Item 5). Discard O-ring. Remove connection block (Figure 2, Item 5), O-ring (Figure 2, Item 4), check valve (Figure 2, Item 3), and O-ring (Figure 2, Item 2) from pump (Figure 2, Item 1). Discard O-rings.

0212-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued

1

2

3

4

5

6

9
Figure 2. 8. Pump Removal.

8

7

M0966JCH

Disconnect two hoses (Figure 3, Items 3 and 4) from fittings (Figure 3, Items 1 and 2).

1

4

3

2

M0967JCH

Figure 3.

Pump Removal.

0212-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued 9. On underside of pump (Figure 4, Item 3), remove two locknuts (Figure 4, Item 4), washers (Figure 4, Item 5), and screws (Figure 4, Item 6) and release yoke (Figure 4, Item 2) from brace (Figure 4, Item 1). Discard locknuts.
2 3

4,5,6

1

M1118JCH

Figure 4. 10.

Pump Removal.

Disconnect two hoses (Figure 5, Item 3) from fittings (Figure 5, Item 1) at check valves (Figure 5, Item 2).
2 1

3 1

M0968JCH

Figure 5.

Pump Removal.

0212-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued 11. 12. 13. Disconnect two hoses (Figure 6, Item 7) from fittings (Figure 6, Item 8). Disconnect two hoses (Figure 6, Item 10) from tee fitting (Figure 6, Item 9). Disconnect two hoses (Figure 6, Item 6) from tee fitting (Figure 6, Item 5).

NOTE
Scribe mark on check valves (notice flow direction mark), connection block, and pump to ensure correct installation. 14. 15. Remove eight screws (Figure 6, Item 3), two flanges (Figure 6, Item 2), and disconnect two hoses (Figure 6, Item 4) from check valves (Figure 6, Item 12). Remove and discard two O-rings. Remove two check valves (Figure 6, Item 12), connection block (Figure 6, Item 11), and two O-rings from pump (Figure 6, Item 1). Discard O-rings.

1

2

3

4

5 12 6 11 7

8

8 6 7 9

10
Figure 6. Pump Removal.

10

M0969JCH

0212-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. 16. 17. Wrap a nylon sling around pump (Figure 7, Item 3) and attach sling to a suitable lifting device. With assistance, remove four screws (Figure 7, Item 2) and pump (Figure 7, Item 3) from transmission (Figure 7, Item 1).

2 1

3
Figure 7. Pump Removal.

M0970JCH

NOTE
Perform Steps 18 thru 25 to remove fittings from pump, if a new pump is being installed. 18. 19. Remove fittings (Figure 8, Items 3 and 4) from pump (Figure 8, Item 1). On underside of pump (Figure 8, Item 1), remove four screws, flange, hose (Figure 8, Item 2), and O-ring. Discard O-ring.

0212-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued

1

4

2

3
Figure 8. 20. 21. Pump Removal.

M0971JCH

Remove tee fitting (Figure 9, Item 1), fitting (Figure 9, Item 2), and fitting (Figure 9, Item 4) from connection block (Figure 9, Item 3). Remove fitting (Figure 9, Item 6), check valve (Figure 9, Item 5), O-ring, adapter, and seal ring from connection block (Figure 9, Item 3). Discard O-ring.

1

2

3

4

5

6

M0972JCH

Figure 9.

Pump Removal.

0212-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued 22. 23. Remove two fittings (Figure 10, Item 4) from pump (Figure 10, Item 2). Remove two tee fittings (Figure 10, Items 3 and 5) from connection block (Figure 10, Item 1).

2

3 1

4 4

5
M0973JCH

Figure 10.

Pump Removal.

0212-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

REMOVAL - Continued 24. 25. On underside of pump (Figure 11, Item 1), remove two fittings (Figure 11, Item 3), check valves (Figure 11, Item 2), O-rings, nipples, and O-rings. Discard O-rings. On underside of pump (Figure 11, Item 1), remove four screws, flange, hose connection, and O-ring. Discard O-ring.
2 1 3

3

M0974JCH

Figure 11. END OF TASK

Pump Removal.

0212-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION

NOTE
• Refer to (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Steps 1 thru 8 to install fittings removed from old pump, if a new pump is being installed. • Lubricate new O-rings with lubricating oil as they are installed. 1. 2. 3. 4. On underside of pump (Figure 12, Item 2), install new O-ring and hose connection with flange and four screws. On underside of pump (Figure 12, Item 2), install two new O-rings, nipples, new O-rings, check valves (Figure 11, Item 2), and fittings (Figure 11, Item 3). Install two tee fittings (Figure 12, Items 3 and 5) on connection block (Figure 12, Item 1). Install two fittings (Figure 12, Item 4) on pump (Figure 13, Item 3).

2

3 1

4 4

5
M0975JCH

Figure 12.

Pump Installation.

0212-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued 5. 6. 7. Install seal ring, adapter, new O-ring, check valve (Figure 13, Item 6), and fitting (Figure 13, Item 7) on connection block (Figure 13, Item 4). Install fitting (Figure 13, Item 5), fitting (Figure 13, Item 2), and tee fitting (Figure 13, Item 1) on connection block (Figure 13, Item 4). On underside of pump (Figure 13, Item 3), install new O-ring and hose (Figure 13, Item 8) with flange and four screws.
1 2 3 4 5 6 7

8

M0976JCH

Figure 13. 8.

Pump Installation.

Install fittings (Figure 14, Items 2 and 3) on pump (Figure 14, Item 1).

1

3

2
Figure 14. Pump Installation.

M0977JCH

0212-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. 9. 10. Apply sealant to mounting surface of pump (Figure 15, Item 3). With assistance and using a nylon sling, position pump (Figure 15, Item 3) at transmission (Figure 15, Item 1) and install four screws (Figure 15, Item 2).
2 1

3

M0978JCH

Figure 15.

Pump Installation.

0212-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued

NOTE
Ensure connection block and check valves are installed on pump In Accordance With (IAW) scribe marks. 11. Assemble two new O-rings, connection block (Figure 16, Item 12), and two check valves (Figure 16, Item 1) on pump (Figure 16, Item 2). Install two new O-rings and hoses (Figure 16, Item 5) on check valves with two flanges (Figure 16, Item 3) and eight screws (Figure 16, Item 4). Connect two hoses (Figure 16, Item 7) to tee fitting (Figure 16, Item 6). Connect two hoses (Figure 16, Item 11) to tee fitting (Figure 16, Item 10). Connect two hoses (Figure 16, Item 8) to fittings (Figure 16, Item 9).

12. 13. 14.

2

3

4

5

6 1 7 12 8

9

9 7 8 10

11
Figure 16. Pump Installation.

11

M0979JCH

0212-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued 15. Connect two hoses (Figure 17, Item 3) to fittings (Figure 17, Item 1) at check valves (Figure 17, Item 2).
2 1

3 1

M0980JCH

Figure 17. 16.

Pump Installation.

Secure yoke (Figure 18, Item 2) to brace (Figure 18, Item 1) on underside of pump (Figure 18, Item 3) with two screws (Figure 18, Item 6), washers (Figure 18, Item 5), and new locknuts (Figure 18, Item 4).
2 3

4,5,6

1

M0981JCH

Figure 18.

Pump Installation.

0212-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued 17. Connect two hoses (Figure 19, Items 3 and 4) to fittings (Figure 19, Items 2 and 1).

1

4

3

2 (HIDDEN)

M0982JCH

Figure 19.

Pump Installation.

0212-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued

NOTE
Ensure check valve and connection block are installed on pump IAW scribe marks. 18. Assemble new O-ring (Figure 20, Item 2), check valve (Figure 20, Item 3), new O-ring (Figure 20, Item 4), and connection block (Figure 20, Item 5) on pump (Figure 20, Item 1).
2 1 3 4 5

M0983JCH

Figure 20.

Pump Installation.

0212-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued 19. Install new O-ring (Figure 21, Item 2) and hose (Figure 21, Item 5) on connection block (Figure 21, Item 1) with flange (Figure 21, Item 3) and four screws (Figure 21, Item 4).

1

2

5
Figure 21.

4

3

M0984JCH

Pump Installation.

0212-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

INSTALLATION - Continued 20. 21. 22. 23. 24. 25. Connect hose (Figure 22, Item 6) to fitting (Figure 22, Item 5). Connect hose (Figure 22, Item 4) to fitting (Figure 22, Item 3). Connect hoses (Figure 22, Items 1 and 10) to tee fitting (Figure 22, Item 2). Connect supply hose (Figure 22, Item 9) to hose (Figure 22, Item 7) and tighten clamp (Figure 22, Item 8). Also connect other supply hose to hose connection and tighten two hose clamps. Open two ball valves at reservoir for supply hoses (Figure 22, Item 9). Check oil level in hydraulic reservoir (LO 10-3930-675-13).

NOTE
Failure to prime pump assembly may damage pump. 26. 27. Trace and locate return hoses for pump assembly at top of hydraulic reservoir. Disconnect return hoses and fill hoses with hydraulic fluid. Reconnect hoses. Start engine, operate tophandler and steering systems, and check for leaks (TM 10-3930-675-10).
2 1 6 3 4 5

10 9 8 7
M0985JCH

Figure 22. END OF TASK

Pump Installation.

0212-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0212

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Recheck oil level in hydraulic reservoir (LO 10-3930-675-13). If a new tophandler and steering pump assembly was installed, adjust each pump (WP 0213). Install nylon straps and new tiedown straps as necessary to support hydraulic hoses. Install transmission access covers (WP 0175).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 5. Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0212-19/20 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00179)

TM 10-3930-675-23-2

0213

FIELD MAINTENANCE TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Coupling Half, Quick Disconnect (WP 0277, Table 1, Item 19) Gauge, Pressure, Dial Indicating (WP 0277, Table 1, Item 28) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Personnel Required (2) References WP 0245 Equipment Condition Cab moved to the left, but not lowered (TM 10-3930-675-10) Steering hydraulic system pressure relieved (WP 0204) Transmission access covers removed (WP 0175)

0213-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0213

TOPHANDLER PUMP STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT 1. 2. 3. Access maintenance diagnostic menus by entering diagnostic code “12443" into driver’s ECS display panel (TM 10-3930-675-10). Using left/right arrows, locate "DIAG EXTRA FUNCT" menu, then press “Enter". Using left/right arrow, locate "EXTRA FUNCT" screen 2 and press “+" button to turn OFF hydraulic pumps.

TOPHANDLER HYDRAULIC PUMP

TOPHANDLER HYDRAULIC PUMP ADJUSTING VALVE
Figure 1. Tophandler Pump Hydraulic Pressure Adjustment.

M0986JCH

0213-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0213

TOPHANDLER PUMP STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT - Continued 4. 5. Connect hydraulic pressure test gauge to hydraulic test point No. 11 (WP 0245). Remove protective caps (Figure 2, Item 1) and washers (Figure 2, Item 2) from tophandler pump adjusting valves (Figure 2, Item 3).

1,2

3

M0987JCH

Figure 2. Tophandler Pump Hydraulic Pressure Adjustment.

0213-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0213

TOPHANDLER PUMP STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT - Continued 6. 7. Start engine (TM 10-3930-675-10). Note tophandler standby hydraulic pressure on test gauge. Pressure should be 261 psi (18 bar): a. b. If pressure is correct, no adjustment is required. If pressure is not correct, loosen adjusting screw jamnut (Figure 3, Item 1) and turn adjusting screw (Figure 3, Item 3) inward to increase pressure and outward to decrease pressure. Secure adjusting screw with jamnut.

8. 9.

At "EXTRA FUNCT" screen 2, press “-" button to turn ON hydraulic pumps. Note tophandler operating hydraulic pressure on test gauge. Pressure should be 3,045 psi (210 bar): a. b. If pressure is correct, no adjustment is required. If pressure is not correct, loosen adjusting screw jamnut (Figure 3, Item 1) and turn adjusting screw (Figure 3, Item 2) inward to increase pressure and outward to decrease pressure. Secure adjusting screw with jamnut.

10. 11. 12. 13.

Shut down engine (TM 10-3930-675-10). Reinstall washers (Figure 2, Item 2) and protective caps (Figure 2, Item 1) on adjusting screws (Figure 3, Items 2 and 3). Relieve hydraulic system pressure (WP 0204). Disconnect hydraulic test gauge.

1

3

2
M0988JCH

Figure 3. Tophandler Pump Hydraulic Pressure Adjustment. END OF TASK

0213-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0213

STEERING PUMPS NOS. 1 AND 2 STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT

STEERING HYDRAULIC PUMP NO. 2 STEERING HYDRAULIC PUMP NO. 1

STEERING HYDRAULIC PUMP NO. 1 ADJUSTING VALVE

STEERING HYDRAULIC PUMP NO. 2 ADJUSTING VALVE
Figure 4. Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment. 1. 2. 3. 4. 5. 6.

M0989JCH

Access maintenance diagnostic menus by entering diagnostic code “12443" into driver’s ECS display panel (TM 10-3930-675-10). Using left/right arrows, locate "DIAG EXTRA FUNCT" menu, then press “Enter". Using left/right arrow, locate "EXTRA FUNCT" screen 2 and press “+" button to turn OFF hydraulic pumps. Connect hydraulic pressure test gauge to hydraulic test point No. 6 for steering pump No. 1 or test point No. 7 for steering pump No. 2 (WP 0245). Remove protective caps (Figure 2, Item 1) and washers (Figure 2, Item 2) from steering pump adjusting valves (Figure 2, Item 3). Start engine (TM 110-3930-675-10).

0213-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0213

STEERING PUMPS NOS. 1 AND 2 STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT Continued 7. Note steering pump standby hydraulic pressure on test gauge. Pressure should be 261 psi (18 bar). a. b. If pressure is correct, no adjustment is required. If pressure is not correct, loosen adjusting screw jamnut (Figure 5, Item 1) and turn adjusting screw (Figure 5, Item 2 or 3) inward to increase pressure and outward to decrease pressure. Secure adjusting screw with jamnut.

8. 9.

At "EXTRA FUNCT" screen 2, press “-" button to turn ON hydraulic pumps. Note steering pump operating hydraulic pressure on test gauge. Pressure should be 3,045 psi (210 bar). a. b. If pressure is correct, no adjustment is required. If pressure is not correct, loosen adjusting screw jamnut (Figure 5, Item 1) and turn adjusting screw (Figure 5, Item 2) inward to increase pressure and outward to decrease pressure. Secure adjusting screw with jamnut.

1

3

2
M0990JCH

Figure 5. Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment.

0213-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0213

STEERING PUMPS NOS. 1 AND 2 STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT Continued 10. 11. 12. 13. Shut down engine (TM 10-3930-675-10). Reinstall washers (Figure 6, Item 2) and protective caps (Figure 6, Item 1) on adjusting screws (Figure 5, Items 2 and 3). Relieve hydraulic system pressure (WP 0204). Disconnect hydraulic test gauge.

1,2

M0991JCH

Figure 6. Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install transmission access covers (WP 0175). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0213-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00180)

TM 10-3930-675-23-2

0214

FIELD MAINTENANCE MAIN CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (Minimum Capacity 150 lbs) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 47) Qty: 7 Personnel Required (2) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Transmission access covers and cab support removed WP 0175 Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0214-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0214

NOTE
• Main control valve is located on right side of vehicle, on inner surface of frame. • Tag all hydraulic lines. • Remove nylon straps and clamp. Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. 2. Disconnect two hoses (Figure 1, Item 1) from fittings (Figure 1, Item 2) at top of control valve (Figure 1, Item 5). On rearward-facing surface of control valve (Figure 1, Item 5), remove four screws (Figure 1, Item 3) and flange (Figure 1, Item 4) and disconnect hose from control valve. Remove and discard O-ring.
2

1

3
FORWARD

4 1

M1004JCH

5

Figure 1.

Main Control Valve Removal.

0214-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0214

REMOVAL - Continued 3. 4. 5. Disconnect two hoses (Figure 2, Item 5) from fittings (Figure 2, Item 6) on underside of control valve (Figure 2, Item 7). On forward-facing surface of control valve (Figure 2, Item 7), disconnect hose (Figure 2, Item 9) from fitting (Figure 2, Item 8). On left inner surface of control valve (Figure 2, Item 7), disconnect each of six remaining hoses (Figure 2, Item 1) as follows: Remove four screws (Figure 2, Item 2), flange (Figure 2, Item 3), and O-ring (Figure 2, Item 4). Discard O-ring.
1

2 3 4

9

5

6 7 8 VIEW FROM UNDERSIDE

M1005JCH

Figure 2.

Main Control Valve Removal.

0214-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0214

REMOVAL - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Main control valve weighs approximately 100 lb (45 kg). Lifting device must have sufficient capacity to lift control valve. Failure to follow this warning may result in injury to personnel. 6. 7. Wrap a nylon sling around control valve (Figure 3, Item 4) and attach sling to a suitable lifting device. Remove four screws (Figure 3, Item 1), washers (Figure 3, Item 2), and control valve (Figure 3, Item 4) from frame (Figure 3, Item 3) and lower from vehicle.

NOTE
Perform Step 8 to remove fittings from control valve, if a new control valve is being installed. 8. Remove two fittings (Figure 1, Item 2), fittings (Figure 2, Item 6) and fitting (Figure 2, Item 8) from control valve (Figure 3, Item 4).

END OF TASK INSTALLATION

NOTE
• Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). • Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old control valve, if a new control valve is being installed. 1. Install fitting (Figure 2, Item 8), two fittings (Figure 2, Item 6), and fittings (Figure 1, Item 2) on control valve (Figure 3, Item 4).

0214-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0214

INSTALLATION - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Main control valve weighs approximately 100 lb (45 kg). Lifting device must have sufficient capacity to lift control valve. Failure to follow this warning may result in injury to personnel. 2. With a nylon sling wrapped around control valve (Figure 3, Item 4) and sling supported by a suitable lifting device, position control valve against frame (Figure 3, Item 3) and install four washers (Figure 3, Item 2) and screws (Figure 3, Item 1).

1,2

3

4

FORWARD

5
Figure 3. Main Control Valve Removal.

M1006JCH

0214-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0214

INSTALLATION - Continued 3. On left inner surface of control valve (Figure 4, Item 7), connect each of six hoses (Figure 4, Item 1) as follows: Install new O-ring (Figure 4, Item 4) and hose with flange (Figure 4, Item 3) and four screws (Figure 4, Item 2). On forward-facing surface of control valve (Figure 4, Item 7), connect hose (Figure 4, Item 9) to fitting (Figure 4, Item 8). Connect two hoses (Figure 4, Item 5) to fittings (Figure 4, Item 6) on underside of control valve (Figure 4, Item 7).
1

4. 5.

2 3 4

9

5

6 8 7
M1007JCH

VIEW FROM UNDERSIDE

Figure 4. Main Control Valve Installation. 6. 7. 8. On rearward-facing surface of control valve (Figure 5, Item 5), install new O-ring and hose with flange (Figure 5, Item 4) and four screws (Figure 5, Item 3). Connect two hoses (Figure 5, Item 1) to fittings (Figure 5, Item 2) at top of control valve (Figure 5, Item 5). Install nylon straps, clamp, and new tiedown straps as necessary to support hydraulic hoses.

0214-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0214

INSTALLATION - Continued
2

1

3
FORWARD

4 1

M1008JCH

5

Figure 5. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5.

Main Control Valve Installation.

Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine. Raise and lower boom and check for leaks (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13). Install transmission access covers and cab support frame (WP 0175). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0214-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00181)

TM 10-3930-675-23-2

0215

FIELD MAINTENANCE BOOM FOLDING CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0215-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00183)

TM 10-3930-675-23-2

0215

NOTE
• Tag all hydraulic lines. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. 2. Disconnect nine hoses (Figure 1, Item 2) from fittings at control valve (Figure 1, Item 8). Remove four nuts (Figure 1, Item 5), screws (Figure 1, Item 6), washers (Figure 1, Item 7), and control valve (Figure 1, Item 8) from remote hydraulic control components.

NOTE
Perform Step 3 to remove fittings from control valve, if a new control valve is being installed. 3. Remove tee fitting (Figure 1, Item 3), adapter fittings (Figure 1, Item 1), and nipples (Figure 1, Item 4) from control valve (Figure 1, Item 8).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old control valve, if a new control valve is being installed. 1. 2. 3. Install nipples (Figure 1, Item 4), adapter fittings (Figure 1, Item 1), and tee fitting (Figure 1, Item 3) on control valve (Figure 1, Item 8). Install control valve (Figure 1, Item 8) in remote hydraulic control compartment with four washers (Figure 1, Item 7), screws (Figure 1, Item 6), and nuts (Figure 1, Item 5). Connect nine hoses (Figure 1, Item 2) to fittings at control valve (Figure 1, Item 8).

0215-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00183)

TM 10-3930-675-23-2

0215

INSTALLATION - Continued
2 1 2

3,4

5,6,7

8

1

M0568JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Boom Folding Control Valve Replacement.

Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate control valve levers, and check for leaks (TM 10-3930-675-10).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 3. Install new tiedown straps as necessary to support hydraulic hoses.

END OF TASK END OF WORK PACKAGE

0215-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00183)

TM 10-3930-675-23-2

0216

FIELD MAINTENANCE CAB TRANSPORT CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0216-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00184)

TM 10-3930-675-23-2

0216

NOTE
• Tag all hydraulic lines. • Remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. REMOVAL 1. 2. Disconnect nine hoses (Figure 1, Item 1) from fittings at control valve (Figure 1, Item 9). Remove four screws (Figure 1, Item 5), nuts (Figure 1, Item 6), washers (Figure 1, Item 7), and control valve (Figure 1, Item 9) from remote hydraulic control compartment.

NOTE
Perform Step 3 to remove fittings from control valve, if a new control valve is being installed. 3. Remove elbow (Figure 1, Item 3), tee fitting (Figure 1, Item 2), adapter fittings (Figure 1, Item 4), and nipples (Figure 1, Item 8) from control valve (Figure 1, Item 9).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform step 1 to install fittings removed from old control valve, if a new control valve is being installed. 1. 2. 3. Install nipples (Figure 1, Item 8), adapter fittings (Figure 1, Item 4), elbow (Figure 1, Item 3), and tee fitting (Figure 1, Item 2) on control valve (Figure 1, Item 9). Install control valve (Figure 1, Item 9) in remote hydraulic control compartment with four screws (Figure 1, Item 5), nuts (Figure 1, Item 6), and washers (Figure 1, Item 7). Connect nine hoses (Figure 1, Item 1) to fittings at control valve (Figure 1, Item 9).

0216-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00184)

TM 10-3930-675-23-2

0216

INSTALLATION - Continued
1 1 2

9

8

5,6,7

4

3

M0563JCH

Figure 1. Cab Transport Control Valve Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate control valve levers, and check for leaks (TM 10-3930-675-10).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 3. Install new tiedown straps as necessary to support hydraulic hoses.

END OF TASK END OF WORK PACKAGE

0216-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00184)

TM 10-3930-675-23-2

0217

FIELD MAINTENANCE CONTROL VALVE SOLENOIDS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Seal Kit (WP 0278, Table 1, Item 127) Tag, Marker (WP 0276, Table 1, Item 66) Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

NOTE
• There are four basic types of solenoid located on control valves throughout the RTCH. Replacement of each type of solenoid is described in this work package. • Tag connectors to ensure correct installation.

0217-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00185)

TM 10-3930-675-23-2

0217

TYPE A SOLENOID REMOVAL

NOTE
Perform this procedure for each of 12 solenoids to be removed. 1. Press in on retaining clip (Figure 1, Item 6) on side of connector (Figure 1, Item 1) and disconnect tophandler wiring harness connector from solenoid (Figure 1, Item 4).

NOTE
• There are twelve solenoid valves on the tophandler control valve assembly; each has an orifice underneath it. Ten have large orifices and two have small orifices. To aid in installation, note the position of the smaller orifices during removal. • Carefully remove orifice from end of solenoid and retain for use on new solenoid during installation. • If the orifice remains in the valve port during removal, leave it there and install the solenoid valve. 2. 3. Remove two screws (Figure 1, Item 2) and solenoid (Figure 1, Item 4) from control valve (Figure 1, Item 3). Remove O-ring (Figure 1, Item 5) from solenoid (Figure 1, Item 4). Discard O-ring.

END OF TASK

0217-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00185)

TM 10-3930-675-23-2

0217

TYPE A SOLENOID INSTALLATION

NOTE
Perform this procedure for each of the 12 solenoids to be installed. 1. 2. 3. Install new O-ring (Figure 1, Item 5) and original orifice from old solenoid onto solenoid (Figure 1, Item 4). Install solenoid (Figure 1, Item 4) on control valve (Figure 1, Item 3) with two screws (Figure 1, Item 2). Connect tophandler wiring harness connector (Figure 1, Item 1) to solenoid (Figure 1, Item 4).
1 2 3 4 5

6

M0564JCH

Figure 1. Control Valve Solenoid Replacement – Type A. END OF TASK

0217-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00185)

TM 10-3930-675-23-2

0217

TYPE B SOLENOID REMOVAL

NOTE
Perform this procedure for each of two solenoids to be removed. 1. 2. Press in on retaining clip (Figure 2, Item 2) on side of connector (Figure 2, Item 1) and disconnect tophandler wiring harness connector from side of solenoid (Figure 2, Item 4). Remove nut (Figure 2, Item 3) and slide solenoid (Figure 2, Item 4) out of control valve (Figure 2, Item 5).

END OF TASK TYPE B SOLENOID INSTALLATION

NOTE
Perform this procedure for each of two solenoids to be installed. 1. 2. Slide solenoid (Figure 2, Item 4) onto control valve (Figure 2, Item 5) and install nut (Figure 2, Item 3). Connect tophandler wiring harness connector (Figure 2, Item 1) to side of solenoid (Figure 2, Item 4).
1 2 3 4

5

M0565JCH

Figure 2. Control Valve Solenoid Replacement – Type B. END OF TASK

0217-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00185)

TM 10-3930-675-23-2

0217

TYPE C SOLENOID REMOVAL 1. 2. Press in on retaining clip (Figure 3, Item 2) on side of connector (Figure 3, Item 1) and disconnect vehicle wiring harness connector from side of solenoid (Figure 3, Item 4). Remove nut (Figure 3, Item 5) and slide solenoid (Figure 3, Item 4) out of control valve (Figure 3, Item 3).

END OF TASK TYPE C SOLENOID INSTALLATION 1. 2. Slide solenoid (Figure 3, Item 4) onto control valve (Figure 3, Item 3) and install nut (Figure 3, Item 5). Connect vehicle wiring harness connector (Figure 3, Item 1) to side of solenoid (Figure 3, Item 4).
1 2 3

5

4

M0566JCH

Figure 3. Control Valve Solenoid Replacement – Type C. END OF TASK

0217-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00185)

TM 10-3930-675-23-2

0217

TYPE D SOLENOID REMOVAL

NOTE
To remove a back row solenoid the adjacent front row solenoid must first be removed. 1. 2. Press in on retaining clip (Figure 4, Item 4) on top of connector (Figure 4, Item 3) and disconnect connector from solenoid (Figure 4, Item 1). Remove solenoid (Figure 4, Item 1) from control valve (Figure 4, Item 2).

END OF TASK TYPE D SOLENOID INSTALLATION 1. 2. Install solenoid (Figure 4, Item 1) on valve (Figure 4, Item 2) and tighten. Position connector (Figure 4, Item 3) on solenoid (Figure 4, Item 1) and press in on clip (Figure 4, Item 4) to install connector.
1 2

3

4

M0567JCH

Figure 4. Control Valve Solenoid Replacement – Type D. END OF TASK END OF WORK PACKAGE

0217-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00185)

TM 10-3930-675-23-2

0218

FIELD MAINTENANCE BOOM FOLDING CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (min. capacity 200 lbs) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 138) Qty: Personnel Required (2) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Boom hydraulic system pressure relieved (WP 0227) Parking brake applied (TM 10-3930-675-10)

2

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Boom folding cylinder weighs 132 lb (60 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

0218-1

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TM 10-3930-675-23-2

0218

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Boom folding cylinders are replaced in same manner. • Tag all hydraulic lines. • Measure and record overall length of cylinder prior to removal. The recorded measurement will aid in cylinder adjustment procedures after installation. REMOVAL 1. Remove hose clamp (Figure 1, Item 7) from cylinder (Figure 1, Item 8).

WARNING

Wear eye protection and have a rag handy when disconnecting hydraulic lines to boom folding cylinder. Failure to do so may result in eye injury due to residual hydraulic pressure in lines. 2. Disconnect two hydraulic hoses (Figure 1, Item 6) from cylinder (Figure 1, Item 8).

WARNING

Boom folding cylinder weighs 132 lb (60 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel. 3. 4. 5. 6. 7. 8. Attach a nylon sling and suitable lifting device to cylinder (Figure 1, Item 8). At one end of cylinder (Figure 1, Item 8), remove screw (Figure 1, Item 1) and washer (Figure 1, Item 2). Remove pin (Figure 1, Item 3). Remove grease fitting (Figure 1, Item 4) from pin. Remove and discard two O-rings (Figure 1, Item 5) only if damaged. Repeat Steps 4 through 6 for opposite end of cylinder (Figure 1, Item 8). Remove cylinder (Figure 1, Item 8) from vehicle.

END OF TASK

0218-2

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TM 10-3930-675-23-2

0218

INSTALLATION

WARNING

Wear eye protection and have a rag handy when disconnecting hydraulic lines to boom folding cylinder. Failure to do so may result in eye injury due to residual hydraulic pressure in lines.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. 5. 6. 7. 8. Using nylon sling and suitable lifting device, align cylinder (Figure 1, Item 8) to vehicle. Lubricate two O-rings (Figure 1, Item 5) with lubricating oil. Position two O-rings (Figure 1, Item 5) on cylinder (Figure 1, Item 8) end. Install grease fitting (Figure 1, Item 4) on pin (Figure 1, Item 3) and install pin. Install washer (Figure 1, Item 2) and screw (Figure 1, Item 1). Repeat Steps 1 through 5 for opposite end of cylinder (Figure 1, Item 8). Connect two hydraulic hoses (Figure 1, Item 6) to cylinder (Figure 1, Item 8). Install hose clamp (Figure 1, Item 7) on hydraulic hose (Figure 1, Item 6) and cylinder (Figure 1, Item 8).
5 6 1,2,3,4 7

6

8

1,2,3,4

5

M1021JCH

Figure 1. Boom Folding Cylinder Replacement.

0218-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0218

INSTALLATION - Continued Procedure for RT 240V1 and RT 240V1R Vehicles 1. Operate boom folding cylinders to full extended position (TM 10-3930-675-10). Measure overall length of cylinder (Figure 2, Item 1). If measurement is identical to that recorded prior to removal, adjustment may not be required. If measurement is not identical, cylinder adjustment is required.

CAUTION
Prior to making adjustments to boom folding cylinders, boom and tophandler must be installed and boom should be raised to a 19 degree angle and extended to 110 inches (279 cm). Failure to perform this step will result in equipment damage.

NOTE
Ensure boom folding cylinders are operated to the full extended position. This will allow boom support locking pin cylinders to operate freely. 2. If overall length of cylinder (Figure 2, Item 1) is identical to that recorded prior to removal, adjustment may not be required, proceed to Step 5. If measurement is not identical, cylinder adjustment is required. Proceed to next Step. Turn adjusting nut to adjust overall length of cylinder. Tighten two clevis clamping screws. Proper adjustment is achieved when two bushings (Figure 3, Item 1) of folding boom support (Figure 3, Item 2) are in perfect alignment with stationary bushing (Figure 3, Item 3) mounted in frame. Adjust cylinder length by loosening two clevis clamping screws (Figure 2, Item 3) at upper end of cylinder (Figure 2, Item 1). Access cylinder piston rod adjusting nut (Figure 2, Item 2) through opening in boom support.
2 3

3.

4.

1 4

M1022JCH

Figure 2.

Boom Folding Cylinder Installation.

0218-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0218

INSTALLATION - Continued Procedure for RT 240V1 and RT 240V1R Vehicles - Continued 5. Determine proper alignment by placing a straightedge across bushing (Figure 3, Item 1), when boom is in proper position for operating boom support locking pin cylinders (TM 10-3930-675-10) and locking pins (Figure 3, Item 4) are retracted. Operate boom support locking pin cylinders (Figure 3, Item 4) to ensure locking pins will retract and extend properly (TM 10-3930-675-10); if pins do not, repeat Steps 3 and 4. Check oil level in hydraulic reservoir (Volume 1, WP 0047). Lubricate grease fittings (LO 10-3930-675-13).
1 2

6. 7. 8.

VIEW FROM TOP

3

M1023JCH

Figure 3.

Boom Folding Cylinder installation.

0218-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0218

INSTALLATION - Continued

Procedure for RT 240V2 and RT 240V3 Vehicles

CAUTION
Prior to making adjustments to boom support, boom and tophandler must be installed and boom should be raised to 19 degrees and extended to 110 inches (279 cm). Failure to comply will result in equipment damage. 1. Operate boom folding cylinders to full extended position (TM 10-3930-675-10). Folding boom support should contact stop bolts (Figure 4, Item 1) that are positioned on frame, slightly before cylinder is fully extended. If boom does not, adjustment is required. Proceed to next Step.

1

M1024JCH

Figure 4.

Boom Folding Cylinder Installation.

0218-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0218

INSTALLATION - Continued Procedure for RT 240V2 and RT 240V3 Vehicles - Continued 2. Adjust cylinder length by loosening two clevis clamping screws (Figure 5, Item 3) at upper end of cylinder (Figure 5, Item 1). Access cylinder piston rod adjusting nut (Figure 5, Item 2) through opening in boom supports. Turn adjusting nut to adjust overall length of cylinder. Tighten two clevis clamping screws.
1 2

VIEW FROM TOP

3

M1023JCH

Figure 5.

Boom Folding Cylinder Installation.

0218-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0218

INSTALLATION - Continued Procedure for RT 240V2 and RT 240V3 Vehicles - Continued 3. Final adjustment of folding boom support position is achieved with stop bolts (Figure 4, Item 1) positioned on frame adjacent to folding boom support (Figure 6, Item 2). Stop bolts should be adjusted so two bushings (Figure 6, Item 1) of folding boom support (Figure 6, Item 2) are in perfect alignment with stationary bushing (Figure 6, Item 3) mounted in frame. Determine proper alignment by placing a straightedge across bushings (Figure 6, Item 1). When boom is in proper position for operating boom, support locking pin cylinders (TM 10-3930-675-10) and locking pins (Figure 6, Item 14) are retracted. Operate boom support locking pin cylinders (Figure 6, Item 14) to ensure locks will retract and extend properly (TM 10-3930-675-10); if locks do not, repeat Steps 1 through 4. Check oil level in hydraulic reservoir (Volume 1, WP 0047) (LO 10-3930-675-13). Lubricate grease fittings (Volume 1, WP 0047) (LO 10-3930-675-13).
2 3

4.

5. 6. 7.

1 4

M1022JCH

Figure 6. END OF TASK

Boom Folding Cylinder Installation.

0218-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0218

FOLLOW-ON MAINTENANCE 1. 2. 3. Start engine (TM 10-3930-675-10). Check for leaks and proper operation of boom folding cylinders (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (Volume 1, WP 0047) (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

0218-9/10 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00186)

TM 10-3930-675-23-2

0219

FIELD MAINTENANCE CAB PARKING AND SERVICE BRAKE HYDRAULIC HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake OFF (TM 10-3930-675-10) Brake hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0219-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00187)

TM 10-3930-675-23-2

0219

REMOVAL 1. Using illustration, (Figure 20), (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal. Check oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Start engine (TM 10-3930-675-10). Operate brake system (TM 10-3930-675-10). Check for leaks. Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0219-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00187)

TM 10-3930-675-23-2

0220

FIELD MAINTENANCE MAIN HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring Qty: (as required) References LO 10-3930-675-13 WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
• Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure. • If replacing hydraulic line coming from bottom of reservoir, close ball valve at reservoir so reservoir need not be drained. After installation of hydraulic line, be sure to open ball valve to restore hydraulic fluid flow. Failure to do so will damage equipment.

0220-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00188)

TM 10-3930-675-23-2

0220

NOTE
Tag all hydraulic lines. REMOVAL 1. Using illustration, (Figure 21), (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Remove and discard O-rings.

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. Lubricate and install new O-ring(s). Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal. Open any ball valve at hydraulic reservoir that was closed.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10) and check for leaks. Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0220-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00188)

TM 10-3930-675-23-2

0221

FIELD MAINTENANCE HYDRAULIC SERVO SYSTEM HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring Qty: (as required) References LO 10-3930-675-13 TM 10-3930-675-24P WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0221-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00189)

TM 10-3930-675-23-2

0221

REMOVAL 1. Using illustration, (Figure 2), (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Remove and discard O-rings.

END OF TASK INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

END OF TASK FOLLOW-ON MAINTENANCE 1. Check oil level in hydraulic reservoir (LO 10-3930-675-13).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 2. 3. 4. Start engine and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0221-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00189)

TM 10-3930-675-23-2

0222

FIELD MAINTENANCE HYDRAULIC SYSTEM TEST POINT HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0222-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00190)

TM 10-3930-675-23-2

0222

REMOVAL 1. Using illustration, Figures 19, 20, 21 and 22 (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0222-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00190)

TM 10-3930-675-23-2

0223

FIELD MAINTENANCE CAB TRANSPORT HYDRAULIC HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring Qty: (as required) References LO 10-3930-675-13 TM 10-3930-675-24P WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
• Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure. • If replacing hydraulic line coming from bottom of reservoir, close ball valve at reservoir so reservoir need not be drained. After installation of hydraulic line, be sure to open ball valve to restore hydraulic fluid flow. Failure to do so will damage equipment.

0223-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00191)

TM 10-3930-675-23-2

0223

NOTE
Tag all hydraulic lines. REMOVAL 1. Using illustration, (Figure 21), (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Remove and discard O-rings.

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal. Open any ball valve at hydraulic reservoir that was closed.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-13). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0223-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00191)

TM 10-3930-675-23-2

0224

FIELD MAINTENANCE BOOM HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring Qty: (as required) References LO 10-3930-675-13 TM 10-3930-675-24P WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0224-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00192)

TM 10-3930-675-23-2

0224

REMOVAL 1. Using illustration, (Figure 21), (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Remove and discard O-rings.

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-13). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0224-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00192)

TM 10-3930-675-23-2

0225

FIELD MAINTENANCE TOPHANDLER HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring Qty: (as required) References LO 10-3930-675-13 TM 10-3930-675-24P WP 0227 WP 0268 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0225-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00193)

TM 10-3930-675-23-2

0225

REMOVAL 1. Using applicable tophandler hydraulic subsystem illustration, (Figure 22), (WP 0272) as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. 3. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s). Remove and discard O-rings.

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Lubricate and install new O-ring(s). Refer to TM 10-3930-675-24P. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate tophandler, and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

0225-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00193)

TM 10-3930-675-23-2

0226

FIELD MAINTENANCE FORKLIFT KIT HYDRAULIC HOSES AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 WP 0272 WP 0227 WP 0268 Equipment Condition Forklift removed from vehicle (TM 10-3930-675-10)

WARNING

• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0226-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00194)

TM 10-3930-675-23-2

0226

REMOVAL 1. Using illustration, Figure 6 (WP 0272), as a guide, remove damaged hose(s) or fitting(s). Cap or plug openings.

NOTE
Note position of tiedown straps and clamps to aid in installation. 2. Remove tiedown strap(s) and clamp(s) (if applicable). Discard tiedown strap(s).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Remove caps/plugs and install and tighten hose(s) or fitting(s). Install clamp(s) and new tiedown strap(s) (if applicable) in same position as noted during removal. Check oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Install forklift to vehicle (TM 10-3930-675-10). Start engine and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0226-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00194)

TM 10-3930-675-23-2

0227

FIELD MAINTENANCE HYDRAULIC SYSTEM OIL FILTERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Wrench, Oil Filter, Strap (WP 0277, Table 1, Item 91) Wrench, Torque, Click, Ratcheting, 38 Inch Drive, 75 lb-ft (WP 0277, Table 1, Item 97) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Sealing Compound Pipe (WP 0276, Table 1, Item 59) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 5) O-Ring (WP 0278, Table 1, Item 9) Filter Element, Intake Air Cleaner (WP 0278, Table 1, Item 92) Qty: 2 Materials/Parts (cont.) Filter Element, Fluid (WP 0278, Table 1, Item 104) Filter Element, Fluid (WP 0278, Table 1, Item 111) Filter Element, Fluid (WP 0278, Table 1, Item 112) Qty: 2 Filter Element, Fluid (WP 0278, Table 1, Item 115) Qty: 2 O-Ring (WP 0278, Table 1, Item 117) References LO 10-3930-675-13 Volume 1, WP 0119 Equipment Condition Wheels chocked (TM 10-3930-675-10) Steering and brake hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0227-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00195)

TM 10-3930-675-23-2

0227

HYDRAULIC RESERVOIR RETURN OIL FILTER REMOVAL

NOTE
Hydraulic reservoir has two return oil filters. Each is removed the same way. 1. Clean area at top of hydraulic reservoir (Figure 1, Item 2).

WARNING

Plate is under spring tension. Take care when removing final screws. Failure to follow this warning may result in injury to personnel. 2. 3. 4. Remove eight screws (Figure 1, Item 4), washers (Figure 1, Item 5), and plate (Figure 1, Item 1) from top of hydraulic reservoir (Figure 1, Item 2). If damaged, remove O-ring (Figure 1, Item 3) from hydraulic reservoir (Figure 1, Item 2). Discard O-ring. Lift oil filter housing (Figure 2, Item 1) out of hydraulic reservoir (Figure 1, Item 2).
1

2

4,5

3

M0572JCH

Figure 1. Hydraulic Reservoir Return Oil Filter Removal. 5. 6. From bottom of oil filter housing (Figure 2, Item 1), remove screw (Figure 2, Item 5), washer (Figure 2, Item 4), and O-ring (Figure 2, Item 3). Discard O-ring. Remove oil filter insert (Figure 2, Item 2) from oil filter housing (Figure 2, Item 1). Discard oil filter insert.

END OF TASK

0227-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00195)

TM 10-3930-675-23-2

0227

HYDRAULIC RESERVOIR RETURN OIL FILTER INSTALLATION 1. 2. 3. 4. 5. Clean oil filter housing (Figure 2, Item 1). Place new oil filter insert (Figure 2, Item 2) into oil filter housing (Figure 2, Item 1). Install new O-ring (Figure 2, Item 3), washer (Figure 2, Item 4), and screw (Figure 2, Item 5). Position oil filter housing (Figure 2, Item 1) in hydraulic reservoir (Figure 1, Item 2). If removed, install new O-ring (Figure 1, Item 3) on hydraulic reservoir (Figure 1, Item 2).

NOTE
Two of eight washers and screws may first be placed on opposite sides of plate, and tightened evenly, to fit plate to hydraulic reservoir. 6. Install plate (Figure 1, Item 1) on hydraulic reservoir (Figure 1, Item 2) with eight washers (Figure 1, Item 5) and screws (Figure 1, Item 4). Tighten screws to 27 lb-ft (37 N•m).
1 2 3

4

5

M0573JCH

Figure 2. Reservoir Return Oil Filter Installation. END OF TASK

0227-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00195)

TM 10-3930-675-23-2

0227

HYDRAULIC RESERVOIR BREATHER FILTER REMOVAL

NOTE
Hydraulic reservoir has two breather filters. Each breather filter is removed the same way. Using strap wrench, remove breather filter (Figure 3, Item 2) from hydraulic reservoir (Figure 3, Item 1). Discard breather filter. END OF TASK HYDRAULIC RESERVOIR BREATHER FILTER INSTALLATION

NOTE
Breather filter comes with a gasket that is not required for this application. Discard gasket. 1. 2. Apply a thin coat of pipe sealing compound to threads at top of hydraulic reservoir (Figure 3, Item 1). Install new breather filter (Figure 3, Item 2) on hydraulic reservoir (Figure 3, Item 1).
1 2

M0574JCH

Figure 3. END OF TASK

Hydraulic Reservoir Breather Filter Installation.

HYDRAULIC SYSTEM IN-LINE FILTERS AND FILTER HEAD REMOVAL 1. 2. 3. 4. 5. Close appropriate ball valve at hydraulic reservoir. If hydraulic filter has a drain plug (Figure 4, Item 8) at bottom of filter bowl (Figure 4, Item 7), remove drain plug and drain hydraulic fluid into a suitable container. Reinstall drain plug. Remove filter bowl (Figure 4, Item 7) from filter head (Figure 4, Item 1) by rotating filter bowl Counterclockwise (CCW). Remove filter element (Figure 4, Item 6) from filter bowl (Figure 4, Item 7). Discard filter element. Remove O-ring (Figure 4, Item 5) between filter head (Figure 4, Item 1) and filter bowl (Figure 4, Item 7). Discard O-ring.

0227-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00195)

TM 10-3930-675-23-2

0227

HYDRAULIC SYSTEM IN-LINE FILTERS AND FILTER HEAD REMOVAL - Continued

NOTE
Tag hydraulic lines for installation. 6. 7. 8. Disconnect hydraulic hoses and fittings from filter head (Figure 4, Item 1). Remove sensor from filter head (Volume 1, WP 0119). Remove two screws (Figure 4, Item 3), washers (Figure 4, Item 4), and filter head (Figure 4, Item 1) from bracket (Figure 4, Item 2).

END OF TASK HYDRAULIC SYSTEM IN-LINE FILTERS AND FILTER HEAD INSTALLATION 1. 2. 3. Install sensor on filter head (Volume 1, WP 0119). Install filter head (Figure 4, Item 1) on bracket (Figure 4, Item 2) with two washers (Figure 4, Item 4) and screws (Figure 4, Item 3). Connect fittings and hydraulic hoses to filter head (Figure 4, Item 1).

NOTE
New O-ring comes packed with new filter element. 4. 5. 6. 7. 8. Lubricate new O-ring (Figure 4, Item 5) with lubricating oil. Clean filter bowl (Figure 4, Item 7). Insert new filter element (Figure 4, Item 6) in filter bowl (Figure 4, Item 7). Place O-ring (Figure 4, Item 5) between filter head (Figure 4, Item 1) and filter bowl (Figure 4, Item 7) and install filter bowl on filter head by rotating bowl Clockwise (CW). Open any ball valve at hydraulic reservoir that was closed.
1 2 3,4 5 6 1 3,4 5 2

7

7

8

M0575JCH

Figure 4. END OF TASK

Hydraulic System In-Line Filters and Filter Head Replacement.

0227-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00195)

TM 10-3930-675-23-2

0227

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10). Operate vehicle and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0227-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00195)

TM 10-3930-675-23-2

0228

FIELD MAINTENANCE HYDRAULIC SYSTEM VALVE MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Gauge, Pressure, Dial Indicating (WP 0277, Table 1, Item 28) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 11) Qty: 3 Packing with Retainer (WP 0278, Table 1, Item 12) Qty: 2 O-Ring (WP 0278, Table 1, Item 78) Qty: 2 Materials/Parts (cont.) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 4 O-Ring (WP 0278, Table 1, Item 97) Qty: 2 References LO 10-3930-675-13 Volume 1, WP 0084 Volume 1, WP 0085 Volume 1, WP 0122 WP 0175 WP 0227 WP 0245 WP 0268 WP 0270 WP 0272 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • DO NOT stand under the tophandler while performing this procedure; tophandler could lower suddenly, causing injury or death to personnel.

0228-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

CAUTION
• Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting if possible. Contamination of hydraulic system could result in equipment failure. • Replace hydraulic reservoir return filters after 100 hours of operation after opening any part of the hydraulic system (WP 0227).

NOTE
Tag and cap or plug all hydraulic lines and openings. PUMP SHUT-OFF VALVE (611) REMOVAL

NOTE
• Refer to Figure 19, (WP 0272) as a guide to remove hose(s) and/or fitting(s) from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Press in on retaining clip and disconnect electrical leads (Figure 1, Item 10) from two solenoids (Figure 1, Item 11). Remove tiedown straps and clamps (if applicable). Discard tiedown straps. Remove two bolts (Figure 1, Item 7), nuts (Figure 1, Item 8), washers (Figure 1, Item 9), and valves (Figure 1, Items 1 and 5) from mounting plate (Figure 1, Item 6). Move shift valve 6041 (Figure 1, Item 1) aside. Remove two hoses (Figure 1, Item 3) and O-rings (Figure 1, Item 4) from valve (Figure 1, Item 5). Discard O-rings. Remove two fittings (Figure 1, Item 2) from valve (Figure 1, Item 5).

END OF TASK

0228-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

PUMP SHUT-OFF VALVE (611) INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if a new valve is being installed. 1. 2. 3. 4. Install two fittings (Figure 1, Item 2) on valve (Figure 1, Item 5). Lubricate and install two new O-rings (Figure 1, Item 4). Install two hoses (Figure 1, Item 3) on valve (Figure 1, Item 5). Install two valves (Figure 1, Items 1 and 5) on mounting plate (Figure 1, Item 6) with two bolts (Figure 1, Item 7), washers (Figure 1, Item 9), and nuts (Figure 1, Item 8). Tighten bolts to specification (WP 0270). Connect electrical leads (Figure 1, Item 10) to valve solenoid (Figure 1, Item 11). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.
1 2 3,4 5 7,8,9 6

5. 6. 7.

11

10

M1064JCH

Figure 1. END OF TASK

Pump Shut-Off Valve Removal.

0228-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

SHIFT VALVE (6041) REMOVAL

NOTE
• Refer to Figure 21, (WP 0272) as a guide to remove hoses and fittings from the valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Press in on retaining clip and disconnect electrical lead (Figure 2, Item 10) from solenoid (Figure 2, Item 7). Remove tiedown straps and clamps (if applicable). Discard tiedown straps. Remove two bolts (Figure 2, Item 7), nuts (Figure 2, Item 8), washers (Figure 2, Item 9), and valves (Figure 2, Items 1 and 5) from mounting plate (Figure 2, Item 6). Remove three hoses (Figure 2, Item 3) and O-rings (Figure 2, Item 4) from valve (Figure 2, Item 1). Discard O-rings. Remove three fittings (Figure 2, Item 2) and two check valves (Figure 2, Item 12) from valve (Figure 2, Item 1).

END OF TASK SHIFT VALVE (6041) INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if a new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install three fittings (Figure 2, Item 2) and two check valves (Figure 2, Item 12) on valve (Figure 2, Item 1). Lubricate and install three new O-rings (Figure 2, Item 4). Install and tighten three hoses (Figure 2, Item 3) on valve (Figure 2, Item 1). Install valves (Figure 2, Items 5 and 1) on mounting plate (Figure 2, Item 6) with two bolts (Figure 2, Item 7), washers (Figure 2, Item 9), and nuts (Figure 2, Item 8). Tighten (IAW) (IAW) Torque Limits (WP 0270). Connect electrical lead (Figure 2, Item 10) to valve solenoid (Figure 2, Item 12). Install clamps (and new tiedown straps, as needed) in position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.

0228-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

SHIFT VALVE (6041) INSTALLATION - Continued
2 3,4 5 7,8,9 6

1

12

11

10
M1065JCH

Figure 2. END OF TASK

Shift Valve Removal.

0228-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOOM SUPPORT/BOGIE SUPPLY VALVE (6043) REMOVAL

NOTE
• Refer to Figure 21, (WP 0272) as a guide to remove hose(s) and fitting(s) from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Press in on retaining clip and disconnect electrical lead (Figure 3, Item 10) from solenoid (Figure 3, Item 9). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove two bolts (Figure 3, Item 5), nuts (Figure 3, Item 6), washers (Figure 3, Item 7), and valves (Figure 3, Item 8) from mounting plate (Figure 3, Item 1). Remove two hoses (Figure 3, Item 3) and O-rings (Figure 3, Item 4) from valve (Figure 3, Item 8). Discard O-rings. Remove two fittings (Figure 3, Item 2) from valve (Figure 3, Item 8).

1

2

3,4 5,6,7

10

9

8
Figure 3. Boom Support/Bogie Supply Valve Removal. END OF TASK

M1066JCH

0228-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOOM SUPPORT/BOGIE SUPPLY VALVE (6043) INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if a new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install two fittings (Figure 4, Item 2) on valve (Figure 4, Item 8). Lubricate and install two new O-rings (Figure 4, Item 4). Install and tighten two hoses (Figure 4, Item 3) on valve (Figure 4, Item 8). Install valve (Figure 4, Item 8) on mounting plate (Figure 4, Item 1) with two bolts (Figure 4, Item 5), washers (Figure 4, Item 7), and nuts (Figure 4, Item 6). Tighten (IAW) Torque Limits (WP 0270). Connect electrical lead (Figure 4, Item 10) to valve solenoid (Figure 4, Item 9). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.

1

2

3,4 5,6,7

10

9

8
Figure 4. Boom Support/Bogie Supply Valve Installation. END OF TASK

M1066JCH

0228-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

SERVO PRESSURE REGULATOR VALVE REMOVAL 1. 2. Move cab to transport position (TM 10-3930-675-10). Remove rear access cover plate (WP 0175).

NOTE
• Refer to Figure 21, (WP 0272) as a guide to remove hose(s) and/or fitting(s) from valve or component. • Note position of tiedown straps and clamps to aid in installation. 3. 4. 5. 6. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove two bolts (Figure 5, Item 3), nuts (Figure 5, Item 4), washers (Figure 5, Item 5), and valve (Figure 5, Item 2) from mounting plate (Figure 5, Item 1). Remove three hoses (Figure 5, Item 7) and O-rings (Figure 5, Item 8) from valve (Figure 5, Item 2). Discard O-rings. Remove three fittings (Figure 5, Item 6) from valve (Figure 5, Item 2).

END OF TASK SERVO PRESSURE REGULATOR VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if a new valve is being installed. 1. 2. 3. 4. 5. 6. 7. 8. Install three fittings (Figure 5, Item 6) on valve (Figure 5, Item 2). Lubricate and install three new O-rings (Figure 5, Item 8). Install and tighten three hoses (Figure 5, Item 7) on valve (Figure 5, Item 2). Install valve (Figure 5, Item 2) to mounting plate (Figure 5, Item 1) with two bolts (Figure 5, Item 3), washers (Figure 5, Item 5), and nuts (Figure 5, Item 4). Tighten (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed. Install rear access cover plate (WP 0175). Move cab back to operational position (TM 10-3930-675-10).

0228-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

SERVO PRESSURE REGULATOR VALVE INSTALLATION - Continued
1 2 3,4,5

6

7,8
M1068JCH

Figure 5. Servo Pressure Regulator Valve Removal. END OF TASK

0228-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOGIE/BOOM SUPPORT FLOW CONTROL VALVE REMOVAL

NOTE
• Refer to Figure 21, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove 14 hoses (Figure 6, Item 2) and O-rings (Figure 6, Item 3) from valve (Figure 6, Item 1). Discard O-rings. Remove four bolts (Figure 6, Item 7), washers (Figure 6, Item 8), and valve (Figure 6, Item 1) from mounting plate (Figure 6, Item 6). Remove 14 fittings (Figure 6, Item 4) from valve (Figure 6, Item 1).

END OF TASK BOGIE/BOOM SUPPORT FLOW CONTROL VALVE ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove plug (Figure 6, Item 5) and connect hydraulic pressure gauge to port “M" on valve (Figure 6, Item 1). Place cab in transport position (TM 10-3930-675-10). Raise bogie wheel off of locking collar and turn 90 degrees, to UNLOCKED position (TM 10-3930-675-10). Lower bogie wheels to ground (TM 10-3930-675-10). Check bogie wheel tire pressure and adjust to 85 psi (586 kPa), if necessary (TM 10-3930-675-10). Loosen jamnut (Figure 6, Item 9) on valve adjusting screw (Figure 6, Item 10). Turn adjusting screw counterclockwise two turns. Start engine and open bogie pressure valve to apply pressure to valve (Figure 6, Item 1) and bogie wheels (TM 10-3930-675-10). Turn adjusting screw (Figure 6, Item 10) clockwise to increase pressure or counterclockwise to decrease pressure on hydraulic gauge. Adjust pressure to 1,088 psi (7,501.5 kPa) and tighten jamnut (Figure 6, Item 9). Close bogie pressure valve and raise bogie wheels to stowed position. Turn bogie locking collar 90 degrees to LOCKED position. Lower bogie wheels to seat locking collar on stowage flanges (TM 10-3930-675-10). Shut engine down and remove hydraulic gauge from valve (Figure 6, Item 1). Reinstall plug (Figure 6, Item 5) in port “M". Place cab in operational position (TM 10-3930-675-10).

END OF TASK

0228-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOGIE/BOOM SUPPORT FLOW CONTROL VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if a new valve is being installed. 1. 2. 3. 4. 5. 6. Install 14 fittings (Figure 6, Item 4) on valve (Figure 6, Item 1). Lubricate and install 14 new O-rings (Figure 6, Item 3). Install and tighten 14 hoses (Figure 6, Item 2) on valve (Figure 6, Item 1). Install valve (Figure 6, Item 1) on mounting plate (Figure 6, Item 6) with four bolts (Figure 6, Item 7) and washers (Figure 6, Item 8). Tighten (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.
2,3 1 1 4 5

10

9

7,8

6

M1069JCH

Figure 6. Bogie/Boom Support Flow Control Valve Removal. END OF TASK

0228-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOOM SUPPORT LOCKING PIN DOUBLE PILOT OPERATED CHECK VALVE REMOVAL

NOTE
• Refer to Figure 21, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove four hoses (Figure 7, Item 6) and O-rings (Figure 7, Item 4) from valve (Figure 7, Item 5). Discard O-rings. Remove two bolts (Figure 7, Item 1), washers (Figure 7, Item 2), nuts (Figure 7, Item 3), and valve (Figure 7, Item 5) from mounting plate (Figure 7, Item 4). Remove four fittings (Figure 7, Item 8) from valve (Figure 7, Item 5).
1,2,3 4 5

6,7 8 6,7
M1070JCH

Figure 7. END OF TASK

Boom Support Locking Pin Check Valve Removal.

0228-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOOM SUPPORT LOCKING PIN DOUBLE PILOT OPERATED CHECK VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. Install four fittings (Figure 8, Item 8) on valve (Figure 8, Item 5). Lubricate and install four new O-rings (Figure 8, Item 7). Install and tighten four hoses (Figure 8, Item 6) on valve (Figure 8, Item 5). Install valve (Figure 8, Item 5) on mounting plate (Figure 8, Item 4) with two bolts (Figure 8, Item 1), washers (Figure 8, Item 2), and nuts (Figure 8, Item 3). Tighten (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.
1,2,3 4 5

6,7 8 6,7
M1070JCH

Figure 8. Boom Support Locking Pin Check Valve Installation. END OF TASK

0228-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOGIE PRESSURE BALL VALVE REMOVAL

NOTE
• Refer to Figure 21, (WP 0272) as a guide to remove hoses and fittings from valve. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove two bolts (Figure 9, Item 4), nuts (Figure 9, Item 5), washers (Figure 9, Item 6), and valve (Figure 9, Item 3) from mounting plate (Figure 9, Item 7). Remove three hoses (Figure 9, Item 1) and O-rings (Figure 9, Item 2) from valve (Figure 9, Item 3). Discard O-rings. Remove three fittings (Figure 9, Item 8) from valve (Figure 9, Item 3).

END OF TASK BOGIE PRESSURE BALL VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. Install three fittings (Figure 9, Item 8) on valve (Figure 9, Item 3). Lubricate and install three new O-rings (Figure 9, Item 2). Install and tighten three hoses (Figure 9, Item 1) on valve (Figure 9, Item 3). Install valve (Figure 9, Item 3) on mounting plate (Figure 9, Item 7) with two bolts (Figure 9, Item 4), washers (Figure 9, Item 6), and nuts (Figure 9, Item 5). Tighten (IAW) Torque Limits (WP 0270).

0228-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BOGIE PRESSURE BALL VALVE INSTALLATION - Continued

1,2

3

4,5,6

1,2

7 8
M1072JCH

Figure 9. Bogie Pressure Ball Valve Removal. 5. 6. Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.

END OF TASK

0228-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

EXTENSION CYLINDER OVER-CENTER VALVE REMOVAL

NOTE
• Refer to Figure 22, (WP 0272) as a guide to remove hoses and fittings from valve. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. 6. 7. Lower and retract boom fully (TM 10-3930-675-10). Remove cover from rear of boom (Volume 1, WP 0122). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove hose (Figure 10, Item 1) and O-ring (Figure 10, Item 2) from over-center valve (Figure 10, Item 9). Discard O-ring. Remove four screws (Figure 10, Item 3), flange (Figure 10, Item 8), hose (Figure 10, Item 5), and O-ring (Figure 10, Item 6) from over-center valve (Figure 10, Item 9). Discard O-ring. Remove four bolts (Figure 10, Item 7), washers (Figure 10, Item 8), and valve (Figure 10, Item 9) from extension cylinder (Figure 10, Item 10). Remove and discard O-ring. Remove fitting (Figure 10, Item 11) from valve (Figure 10, Item 9).

END OF TASK

0228-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

EXTENSION CYLINDER OVER-CENTER VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. 8. 9. Install fitting (Figure 10, Item 11) on valve (Figure 10, Item 9). Install valve (Figure 10, Item 9) on extension cylinder (Figure 10, Item 10) with four bolts (Figure 10, Item 7) and washers (Figure 10, Item 8). Tighten (IAW) Torque Limits (WP 0270). Lubricate new O-rings (Figure 10, Item 6). Install new O-ring (Figure 10, Item 6), hose (Figure 10, Item 5), and flange (Figure 10, Item 4) on over-center valve (Figure 10, Item 9) with four screws (Figure 10, Item 3). Lubricate new O-ring (Figure 10, Item 2). Install new O-ring (Figure 10, Item 2) and tighten hose (Figure 10, Item 1) on valve (Figure 10, Item 9). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed. Install cover on rear of boom (Volume 1, WP 0122).
1,2 3 4

5,6

7,8 11 9 10
M1073JCH

Figure 10. END OF TASK

Extension Cylinder Over-Center Valve Replacement.

0228-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

PARKING BRAKE HOLD FLOW CONTROL VALVE REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Relieve pressure in both brake circuits by opening both brake drain shut-off valves (WP 0245). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove six hoses (Figure 11, Item 1) and O-rings (Figure 11, Item 2) from valve (Figure 11, Item 8). Discard O-rings. Remove two bolts (Figure 11, Item 4), washers (Figure 11, Item 5), nuts (Figure 11, Item 6), and valve (Figure 11, Item 8) from mounting plate (Figure 11, Item 7). Remove six fittings (Figure 11, Item 3) from valve (Figure 11, Item 8).
1,2

3

4,5,6

8

7

M1074JCH

Figure 11. Parking Brake Hold Flow Control Valve Removal. END OF TASK

0228-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

PARKING BRAKE HOLD FLOW CONTROL VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install six fittings (Figure 12, Item 3) on valve (Figure 12, Item 8). Install valve (Figure 12, Item 8) on mounting plate (Figure 12, Item 7) with two bolts (Figure 12, Item 4), washers (Figure 12, Item 5), and nuts (Figure 12, Item 6). Tighten (IAW) Torque Limits (WP 0270). Lubricate and install six new O-rings (Figure 12, Item 2). Install and tighten six hoses (Figure 12, Item 1) on valve (Figure 12, Item 8). Install clamps and new tiedown straps as needed, in same position as noted during removal. Close both brake drain shut-off valves (WP 0245). At hydraulic reservoir, open any ball valve that may have been closed.
1,2

3

4,5,6

8

7

M1074JCH

Figure 12. Parking Brake Hold Flow Control Valve Installation. END OF TASK

0228-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BRAKE CHARGING VALVE REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Relieve pressure in both brake circuits by opening both brake drain shut-off valves (WP 0245). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove five hoses (Figure 13, Item 2) and O-rings (Figure 13, Item 3) from valve (Figure 13, Item 8). Discard O-rings. Remove two bolts (Figure 13, Item 5), washers (Figure 13, Item 6), nuts (Figure 13, Item 7), and valve (Figure 13, Item 8) from mounting plate (Figure 13, Item 1). Remove five fittings (Figure 13, Item 4) from valve (Figure 13, Item 8).

END OF TASK BRAKE CHARGING VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install five fittings (Figure 13, Item 4) on valve (Figure 13, Item 8). Lubricate and install five new O-rings (Figure 13, Item 3). Install valve (Figure 13, Item 8) on mounting plate (Figure 13, Item 1) with two bolts (Figure 13, Item 5), washers (Figure 13, Item 6), and nuts (Figure 13, Item 7). Tighten (IAW) Torque Limits (WP 0270). Install and tighten five hoses (Figure 13, Item 2) on valve (Figure 13, Item 8). Install clamps and new tiedown straps as needed, in same position as noted during removal. Close both brake drain shut-off valves (WP 0245). At hydraulic reservoir, open any ball valve that may have been closed.

0228-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BRAKE CHARGING VALVE INSTALLATION - Continued

1

2,3 4

8
Figure 13. END OF TASK

5,6,7
Brake Charging Valve Replacement.

M1076JCH

0228-21

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BRAKE DRAIN SHUT-OFF VALVE REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. Relieve pressure in both brake circuits by opening two brake drain shut-off valves (WP 0245).

NOTE
Perform the following steps to remove each of two brake drain shut-off valves. 2. 3. 4. 5. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove three hoses (Figure 14, Item 2) and O-rings (Figure 14, Item 3) from valve (Figure 14, Item 1). Perform step Discard O-rings. Remove valve (Figure 14, Item 1) from mounting plate (Figure 14, Item 5). Remove two fittings (Figure 14, Item 4) from valve (Figure 14, Item 1).

END OF TASK BRAKE DRAIN SHUT-OFF VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Steps 1 thru 5 to install each of two brake drain shut-off valves. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install two fittings (Figure 14, Item 4) on valve (Figure 14, Item 1). Lubricate and install three new O-rings (Figure 14, Item 3). Install and tighten three hoses (Figure 14, Item 2) on valve (Figure 14, Item 1). Install valve (Figure 14, Item 1) on mounting plate (Figure 14, Item 5). Install clamps and new tiedown straps as needed, in same position as noted during removal. Close both brake drain shut-off valves (WP 0245). At hydraulic reservoir, open any ball valve that may have been closed.

0228-22

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BRAKE DRAIN SHUT-OFF VALVE INSTALLATION - Continued
1

2,3

4 2,3 4 5
M1077JCH

Figure 14. Brake Drain Shut-Off Valve Replacement. END OF TASK

0228-23

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BRAKE CIRCUIT SAFETY REGULATING VALVE REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. Relieve pressure in both brake circuits by opening both brake drain shut-off valves (WP 0245).

NOTE
Perform the following steps to remove each of two brake circuit safety regulating valves. 2. 3. 4. 5. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove three hoses (Figure 15, Item 2) and O-rings (Figure 15, Item 3) from valve (Figure 15, Item 5). Discard O-rings. Remove valve (Figure 15, Item 5) from mounting plate (Figure 15, Item 4). Remove three fittings (Figure 15, Item 1) from valve (Figure 15, Item 5).

END OF TASK BRAKE CIRCUIT SAFETY REGULATING VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Steps 1 thru 5 to install each of two brake drain shut-off valves. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install two fittings (Figure 15, Item 1) on valve (Figure 15, Item 5). Lubricate and install three new O-rings (Figure 15, Item 3). Install and tighten three hoses (Figure 15, Item 2) on valve (Figure 15, Item 5). Install valve (Figure 15, Item 5) on mounting plate (Figure 15, Item 4). Install clamps and new tiedown straps as needed, in same position as noted during removal. Close both brake drain shut-off valves (WP 0245). At hydraulic reservoir, open any ball valve that may have been closed.

0228-24

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

BRAKE CIRCUIT SAFETY REGULATING VALVE INSTALLATION - Continued

1 5

2,3

4

2,3

1

2,3

1

M1078JCH

Figure 15. Brake Circuit Safety Regulating Valve Replacement. END OF TASK

0228-25

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

FRONT BRAKE COOLING BYPASS VALVE (6049-1) REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. 6. Remove radiator splash shield (Volume 1, WP 0084). Press in on retaining clip and disconnect electrical lead (Figure 16, Item 7) from solenoid (Figure 16, Item 8). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove three hoses (Figure 16, Item 1) and O-rings (Figure 16, Item 2) from valve (Figure 16, Item 9). Discard O-rings. Remove two bolts (Figure 16, Item 4), washers (Figure 16, Item 5), nuts (Figure 16, Item 6), and valve (Figure 16, Item 9) from mounting plate (Figure 16, Item 10). Remove three fittings (Figure 16, Item 3) from valve (Figure 16, Item 9).

END OF TASK FRONT BRAKE COOLING BYPASS VALVE (6049-1) INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. 8. Install three fittings (Figure 16, Item 3) on valve (Figure 16, Item 9). Lubricate and install three new O-rings (Figure 16, Item 2). Install and tighten three hoses (Figure 16, Item 1) on valve (Figure 16, Item 9). Install valve (Figure 16, Item 9) on mounting plate (Figure 16, Item 10) with two bolts (Figure 16, Item 4), washers (Figure 16, Item 5), and nuts (Figure 16, Item 6). Tighten (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. Connect electrical lead (Figure 16, Item 7) to solenoid (Figure 16, Item 8). At hydraulic reservoir, open any ball valve that may have been closed. Install radiator splash shield (Volume 1, WP 0084).

0228-26

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

FRONT BRAKE COOLING BYPASS VALVE (6049-1) INSTALLATION - Continued
1,2 3 1,2

4,5,6

7 10 9 8
M1079JCH

Figure 16. END OF TASK

Front Brake Cooling Bypass Valve Replacement.

0228-27

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

REAR BRAKE COOLING BYPASS VALVE (6049-2) REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Press in on retaining clip and disconnect electrical lead (Figure 17, Item 9) from solenoid (Figure 17, Item 8). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove three hoses (Figure 17, Item 2) and O-rings (Figure 17, Item 3) from valve (Figure 17, Item 1). Discard O-rings. Remove two bolts (Figure 17, Item 5), washers (Figure 17, Item 6), nuts (Figure 17, Item 7), and valve (Figure 17, Item 1) from mounting plate (Figure 17, Item 10). Remove three fittings (Figure 17, Item 4) from valve (Figure 17, Item 1).

END OF TASK REAR BRAKE COOLING BYPASS VALVE (6049-2) INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install three fittings (Figure 17, Item 4) on valve (Figure 17, Item 1). Lubricate and install three new O-rings (Figure 17, Item 3). Install and tighten three hoses (Figure 17, Item 2) on valve (Figure 17, Item 1). Install valve (Figure 17, Item 1) on mounting plate (Figure 17, Item 10) with two bolts (Figure 17, Item 5), washers (Figure 17, Item 6), and nuts (Figure 17, Item 7). Tighten (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. Connect electrical lead (Figure 17, Item 9) to valve solenoid (Figure 17, Item 8). At hydraulic reservoir, open any ball valve that may have been closed.

0228-28

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

REAR BRAKE COOLING BYPASS VALVE (6049-2) INSTALLATION - Continued

1 2,3

10

4

5,6,7

9 8 4 2,3
M1080JCH

Figure 17. Rear Brake Cooling Bypass Valve Replacement. END OF TASK

0228-29

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

COOLING FAN FLOW CONTROL VALVE (6037) REMOVAL

NOTE
• Refer to Figure 20, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. 6. 7. Remove middle and rear radiator top grating sections (Volume 1, WP 0085). Remove radiator splash shield (Volume 1, WP 0084). Disconnect electrical lead from solenoid harness (Figure 18, Item 8). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove four hoses (Figure 18, Item 2) and O-rings (Figure 18, Item 3) from valve (Figure 18, Item 4). Discard O-rings. Remove two screws (Figure 18, Item 6), washers (Figure 18, Item 7), and valve (Figure 18, Item 4) from mounting plate (Figure 18, Item 5). Remove four fittings (Figure 18, Item 1) from valve (Figure 18, Item 4).
1 2,3

4

5 8 6,7
M1081JCH

Figure 18. Cooling Fan Control Valve Removal. END OF TASK

0228-30

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

COOLING FAN FLOW CONTROL VALVE (6037) INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Install four fittings (Figure 18, Item 1) on valve (Figure 18, Item 4). Lubricate and install four new O-rings (Figure 18, Item 3). Install and tighten four hoses (Figure 18, Item 2) on valve (Figure 18, Item 4). Install valve (Figure 18, Item 4) on mounting plate (Figure 18, Item 5) with two screws (Figure 18, Item 6) and washers (Figure 18, Item 7). Tighten (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. Connect electrical lead to solenoid harness (Figure 18, Item 8). At hydraulic reservoir, open any ball valve that may have been closed. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and check for leaks (TM 10-3930-675-10). With engine running, enter diagnostic menu "EXTRA FUNCTION" 11(13). Use +/- keys to change fan speed to test valve operation (TM 10-3930-675-10). Install middle and rear radiator top grating sections (Volume 1, WP 0085). Install radiator splash shield (Volume 1, WP 0084).

END OF TASK

0228-31

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

EMERGENCY STEERING PRESSURE BALANCING VALVE REMOVAL

NOTE
• Refer to Figure 19, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of 7 tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Remove transmission skid plate (WP 0175). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove four hoses (Figure 19, Item 1) and O-rings (Figure 19, Item 2) from valve (Figure 19, Item 4). Discard O-rings. Remove two bolts (Figure 19, Item 6), washers (Figure 19, Item 7), and valve (Figure 19, Item 4) from mounting plate (Figure 19, Item 8). Remove check valve (Figure 19, Item 5) and four fittings (Figure 19, Item 3) from valve (Figure 19, Item 4).

END OF TASK EMERGENCY STEERING PRESSURE BALANCING VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install four fittings (Figure 19, Item 3) and check valve (Figure 19, Item 5) on valve (Figure 19, Item 4). Lubricate and install four new O-rings (Figure 19, Item 2). Install and tighten four hoses (Figure 19, Item 1) on valve (Figure 19, Item 4). Install valve (Figure 19, Item 4) on mounting plate (Figure 19, Item 8) with two bolts (Figure 19, Item 6) and washers (Figure 19, Item 7). Tighten bolts (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed. Install transmission skid plate (WP 0175).

0228-32

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

EMERGENCY STEERING PRESSURE BALANCING VALVE INSTALLATION - Continued
1,2 3 5 4 3 6,7

8

1,2

M1082JCH

Figure 19. Emergency Steering Pressure Balancing Valve Removal. END OF TASK

0228-33

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

MODERATION AND TILT MANIFOLD VALVE REMOVAL

NOTE
• Refer to Figure 22, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Press in on retaining clip and disconnect two electrical leads (Figure 20, Item 8) from solenoids (Figure 20, Item 9). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove 12 hoses (Figure 20, Item 1) and O-rings (Figure 20, Item 2) from valve (Figure 20, Item 6). Discard O-rings. Remove two bolts (Figure 20, Item 4), washers (Figure 20, Item 5), and valve (Figure 20, Item 6) from mounting plate (Figure 20, Item 7). Remove 12 fittings (Figure 20, Item 3) from valve (Figure 20, Item 6).

3 1,2

4,5

6

7

8

9
Figure 20. Moderation and Tilt Manifold Valve Removal. END OF TASK

M1083JCH

0228-34

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

MODERATION AND TILT MANIFOLD VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install 12 fittings (Figure 20, Item 3) on valve (Figure 20, Item 6). Lubricate and install 12 new O-rings (Figure 20, Item 2). Install and tighten 12 hoses (Figure 20, Item 1) on valve (Figure 20, Item 6). Install valve (Figure 20, Item 6) on mounting plate (Figure 20, Item 7) with two bolts (Figure 20, Item 4) and washers (Figure 20, Item 5). Tighten bolts (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. Connect electrical leads (Figure 20, Item 8) to valve solenoids (Figure 20, Item 9). At hydraulic reservoir, open any ball valve that may have been closed.

END OF TASK

0228-35

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

TILT OVER-CENTER VALVE REMOVAL

NOTE
• Refer to Figure 22, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove four hoses (Figure 21, Item 1) and O-rings (Figure 21, Item 2) from valve (Figure 21, Item 4). Discard O-rings. Remove two bolts (Figure 21, Item 5), washers (Figure 21, Item 6), and valve (Figure 21, Item 4) from mounting plate (Figure 21, Item 7). Remove four fittings (Figure 21, Item 3) from valve (Figure 21, Item 4).

3 1,2

4 5,6 7

M1084JCH

Figure 21. END OF TASK

Tilt Over-Center Valve Removal.

0228-36

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

TILT OVER-CENTER VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. Install four fittings (Figure 22, Item 3) on valve (Figure 22, Item 4). Lubricate and install four new O-rings (Figure 22, Item 2). Install and tighten four hoses (Figure 22, Item 1) on valve (Figure 22, Item 4). Install valve (Figure 22, Item 4) on mounting plate (Figure 22, Item 7) with two bolts (Figure 22, Item 5) and washers (Figure 22, Item 6). Tighten bolts (IAW) Torque Limits (WP 0270).

3 1,2

4 5,6 7

M1084JCH

Figure 22. 5. 6.

Tilt Over-Center Installation.

Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.

END OF TASK

0228-37

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

OSCILLATION OVER-CENTER VALVE REMOVAL

NOTE
• Refer to Figure 22, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove four hoses (Figure 23, Item 5) and O-rings (Figure 23, Item 6) from valve (Figure 23, Item 1). Discard O-rings. Remove two bolts (Figure 23, Item 2), washers (Figure 23, Item 3), and valve (Figure 23, Item 1) from mounting plate (Figure 23, Item 7). Remove four fittings (Figure 23, Item 4) from valve (Figure 23, Item 1).

END OF TASK OSCILLATION OVER-CENTER VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. Install four fittings (Figure 23, Item 4) on valve (Figure 23, Item 1). Lubricate and install four new O-rings (Figure 23, Item 6). Install and tighten four hoses (Figure 23, Item 5) on valve (Figure 23, Item 1). Install valve (Figure 23, Item 1) on mounting plate (Figure 23, Item 7) with two bolts (Figure 23, Item 2) and washers (Figure 23, Item 3). Tighten bolts (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.

0228-38

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

OSCILLATION OVER-CENTER VALVE INSTALLATION - Continued

1

2,3 4

5,6 7

M1085JCH

Figure 23. Oscillation Over-Center Valve Installation. END OF TASK

0228-39

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

OSCILLATION FLOAT LOCK FLOW CONTROL VALVE REMOVAL

NOTE
• Refer to Figure 22, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. 5. Press in on retaining clip and disconnect electrical lead (Figure 24, Item 1) from each of two solenoids (Figure 24, Item 2). Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove five hoses (Figure 24, Item 5) and O-rings (Figure 24, Item 6) from valve (Figure 24, Item 3). Discard O-rings. Remove four bolts (Figure 24, Item 7), washers (Figure 24, Item 8), and valve (Figure 24, Item 3) from mounting plate (Figure 24, Item 9). Remove four fittings (Figure 24, Item 4) from valve (Figure 24, Item 3).

1

2

3

4

5,6

7,8 9
Figure 24. Oscillation Float Lock Flow Control Valve Removal. END OF TASK

M1086JCH

0228-40

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

OSCILLATION FLOAT LOCK FLOW CONTROL VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. 7. Install four fittings (Figure 24, Item 4) on valve (Figure 24, Item 3). Lubricate and install five new O-rings (Figure 24, Item 6). Install and tighten five hoses (Figure 24, Item 5) on valve (Figure 24, Item 3). Install valve (Figure 24, Item 3) on mounting plate (Figure 24, Item 9) with four bolts (Figure 24, Item 7) and washers (Figure 24, Item 8). Tighten bolts (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. Connect electrical lead (Figure 24, Item 1) to each of two valve solenoids (Figure 24, Item 2). At hydraulic reservoir, open any ball valve that may have been closed.

END OF TASK

0228-41

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

TWISTLOCK DOUBLE PILOT OPERATED CHECK VALVE REMOVAL

NOTE
• Refer to Figure 22, (WP 0272) as a guide to remove hoses and fittings from valve or component. • Note position of tiedown straps and clamps to aid in installation. 1. 2. 3. 4. Remove tiedown straps and clamps, as needed. Discard tiedown straps. Remove four hoses (Figure 25, Item 6) and O-rings (Figure 25, Item 7) from valve (Figure 25, Item 2). Discard O-rings. Remove two bolts (Figure 25, Item 3), washers (Figure 25, Item 4), nuts (Figure 25, Item 5), and valve (Figure 25, Item 2) from mounting plate (Figure 25, Item 1). Remove four fittings (Figure 25, Item 8) from valve (Figure 25, Item 2).

1

2

3,4,5

8

6,7

M1087JCH

Figure 25. Twistlock Double Pilot Operated Check Valve Removal. END OF TASK

0228-42

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0228

TWISTLOCK DOUBLE PILOT OPERATED CHECK VALVE INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old valve, if new valve is being installed. 1. 2. 3. 4. 5. 6. Install four fittings (Figure 25, Item 8) on valve (Figure 25, Item 2). Lubricate and install four new O-rings (Figure 25, Item 7). Install and tighten four hoses (Figure 25, Item 6) on valve (Figure 25, Item 2). Install valve (Figure 25, Item 2) on mounting plate (Figure 25, Item 1) with two bolts (Figure 25, Item 3), washers (Figure 25, Item 4), and nuts (Figure 25, Item 5). Tighten bolts (IAW) Torque Limits (WP 0270). Install clamps and new tiedown straps as needed, in same position as noted during removal. At hydraulic reservoir, open any ball valve that may have been closed.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine and check for leaks (TM 10-3930-675-10). Set parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0228-43/44 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00196)

TM 10-3930-675-23-2

0229

FIELD MAINTENANCE LIFT CYLINDER CONTROL VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (min. capacity 100 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) O-Ring (WP 0278, Table 1, Item 47) Qty: 3 O-Ring (WP 0278, Table 1, Item 48) Rag, Wiping (WP 0276, Table 1, Item 50) Personnel Required (Two) References LO 10-3930-675-13 References (cont.) WP 0227 WP 0257 WP 0268 WP 0271 Equipment Condition Tophandler fully lowered and resting on cribbing (TM 10-3930-675-10) Boom hydraulic system pressure relieved (WP 0204) Parking brake applied (TM 10-3930-675-10)

0229-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00197)

TM 10-3930-675-23-2

0229

LIFT CYLINDER CONTROL VALVE REMOVAL

NOTE
• Both valves are replaced in the same manner. • Tag all hydraulic lines 1. 2. 3. 4. 5. Lower boom fully to lowest position (TM 10-3930-675-10). Open emergency lowering and float valves (TM 10-3930-675-10). Disconnect the electrical connectors from the pressure sensors (Figure 1, Item 8), and control valve solenoid (Figure 1, Item 5). Disconnect two smaller hydraulic hoses (Figure 1, Item 7) from the valve (Figure 1, Item 6). Discard O-rings. Remove four screws (Figure 1, Item 1), flange (Figure 1, Item 2), O-ring (Figure 1, Item 3) and hose (Figure 1, Item 4) from the valve (Figure 1, Item 6) for each of the three larger hoses. Discard O-rings.

WARNING

Lift cylinder valve weighs approximately 50 lb (23 kg). Lifting device must have sufficient capacity to lift valve. Failure to follow this warning may result in death or injury to personnel. 6. 7. 8. 9. Attach a nylon sling and suitable lifting device to valve (Figure 1, Item 4). Remove four screws (Figure 1, Item 2) securing valve (Figure 1, Item 4) to cylinder (Figure 1, Item 3). Lift valve (Figure 1, Item 4) from cylinder (Figure 1, Item 3) and place on suitable work surface. Discard O-ring. Remove two fittings (Figure 1, Item 5) for small hydraulic hoses, two pressure sensors (Figure 1, Item 1) and two fittings for pressure sensors (Figure 1, Item 6) from valve (Figure 1, Item 4).

END OF TASK LIFT CYLINDER CONTROL VALVE INSTALLATION

WARNING

Lift cylinder valve weighs approximately 50 lb (23 kg). Lifting device must have sufficient capacity to lift valve. Failure to follow this warning may result in death or injury to personnel.

NOTE
• Vehicle has two valves. Make sure valves are identical • Lubricate new O-rings with lubricating oil. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. Install two fittings (Figure 1, Item 5) for small hydraulic hoses, two fittings for pressure sensors

0229-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00197)

TM 10-3930-675-23-2

0229

LIFT CYLINDER CONTROL VALVE INSTALLATION - Continued (Figure 1, Item 6) and pressure sensors (Figure 1, Item 1) onto valve (Figure 1, Item 4). 2. 3. 4. 5. 6. 7. 8. Attach a nylon sling and suitable lifting device to valve (Figure 1, Item 4). Install new O-ring on cylinder (Figure 1, Item 3) and lift valve (Figure 1, Item 4) onto cylinder. Install four screws (Figure 1, Item 2) securing valve (Figure 1, Item 4) to cylinder (Figure 1, Item 3). Install four screws (Figure 1, Item 1), flange (Figure 1, Item 2), new O-ring (Figure 1, Item 3), and hose (Figure 1, Item 4) to the valve (Figure 1, Item 6) for each of the three larger hoses. Install new O-rings and connect two smaller hydraulic hoses (Figure 1, Item 7) to the valve (Figure 1, Item 6). Reconnect the electrical connectors on the pressure sensors (Figure 1, Item 8) and valve solenoid (Figure 1, Item 5). Close emergency lowering and float valves (TM 10-3930-675-10).
1,2,3,4

8 5

7

RT 240V2 AND RT 240V3

6

RT 240V1 AND RT 240V1R
M1018JCH

Figure 1. END OF TASK

Lift Cylinder Control Valve Replacement.

0229-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00197)

TM 10-3930-675-23-2

0229

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Check oil level in hydraulic reservoir (LO 10-393-675-13). Start engine, operate lift cylinders, and check for leaks (TM 10-3930-675-10). Check oil level in hydraulic reservoir (LO 10-393-675-13). Perform Boom and Tophandler Calibration (WP 0257). Perform Load Testing Procedure (WP 0271).

END OF TASK END OF WORK PACKAGE

0229-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00197)

TM 10-3930-675-23-2

0230

FIELD MAINTENANCE TOPHANDLER CONTROL VALVES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Lifting Device (min. capacity 250 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 131) Qty: 4 Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (Two) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Cab and boom in transport position (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Master battery switch in OFF position (TM-10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0230-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00199)

TM 10-3930-675-23-2

0230

NOTE
• Tag all electrical leads and hydraulic lines. • Remove and discard tiedown straps as necessary to gain free movement in electrical leads and hydraulic hoses. REMOVAL 1. 2. Press in on retaining clips (Figure 1, Item 8) and disconnect electrical leads (Figure 1, Item 7) from solenoids (Figure 1, Item 6). Secure electrical leads away from control valve (Figure 1, Item 5). Disconnect hydraulic hoses (Figure 1, Item 9) from fittings (Figure 1, Item 10) at control valve (Figure 1, Item 5). Secure all hydraulic hoses away from control valve.

WARNING

Use extreme caution when handling heavy parts. Tophandler weighs approximately 150 lb (68 kg). Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. 3. With assistance, remove four screws (Figure 1, Item 12) and washers (Figure 1, Item 13) securing mounting plate (Figure 1, Item 11) with control valve (Figure 1, Item 5) to tophandler (Figure 1, Item 1). Remove control valve to work bench. Remove four screws (Figure 1, Item 2), washers (Figure 1, Item 3), locknuts (Figure 1, Item 4), and mounting plate (Figure 1, Item 11) from control valve (Figure 1, Item 5). Discard locknuts.

4.

NOTE
Perform Step 5 to remove fittings from control valve, if a new control valve is being installed. 5. Remove fittings (Figure 1, Item 10) from control valve (Figure 1, Item 5).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Step 1 to install fittings removed from old control valve, if a new control valve is being installed. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. Install fittings (Figure 1, Item 10) on control valve (Figure 1, Item 5).

0230-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00199)

TM 10-3930-675-23-2

0230

INSTALLATION - Continued

WARNING

Use extreme caution when handling heavy parts. Tophandler weighs approximately 150 lb (68 kg). Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. 2. 3. 4. 5. 6. 7. 8. Position mounting plate (Figure 1, Item 11) on control valve (Figure 1, Item 5) and secure with four screws (Figure 1, Item 2), washers (Figure 1, Item 3), and new locknuts (Figure 1, Item 4). With assistance, position control valve (Figure 1, Item 4) against tophandler (Figure 1, Item 1) and secure with four washers (Figure 1, Item 13) and screws (Figure 1, Item 12). Connect electrical leads (Figure 1, Item 7) to solenoids (Figure 1, Item 6). Connect hydraulic hoses (Figure 1, Item 9) to fittings (Figure 1, Item 10) at control valve (Figure 1, Item 5). Install new tiedown straps, as necessary, to support electrical leads (Figure 1, Item 7) and hydraulic hoses (Figure 1, Item 9). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate tophandler, and check for leaks (TM 10-3930-675-10).
5 2,3,4 6 7,8

9 1 9

12,13

M1010JCH

11

10

Figure 1. END OF TASK

Tophandler Control Valve Replacement.

0230-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00199)

TM 10-3930-675-23-2

0230

FOLLOW-ON MAINTENANCE 1. 2. 3. Return cab and boom support to operational position (TM 10-3930-675-10). Check operation of tophandler (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

0230-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00199)

TM 10-3930-675-23-2

0231

FIELD MAINTENANCE BOOM LIFT CYLINDER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (min. capacity 1,350 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Oil, Lubricating, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) O-Ring (WP 0278, Table 1, Item 47) Washer, Lock (WP 0278, Table 1, Item 74) Washer, Lock (WP 0278, Table 1, Item 118) Personnel Required (Two) References LO 10-3930-675-13 WP 0227 WP 0268 WP 0271 Equipment Condition Tophandler fully lowered and resting on cribbing (TM-10-3930-675-10) Boom hydraulic system pressure relieved (WP 0204) Parking brake applied (TM-10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting 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 death or injury to personnel. • Boom lift cylinder weighs 886 lb (402 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow his warning may result in death or injury to personnel.

0231-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Boom lift cylinders are replaced in the same manner. BOOM LIFT CYLINDER REMOVAL 1. 2. Open emergency lowering and float valves (TM 10-3930-675-10). Place a drain pan under cylinder (Figure 1, Item 3) to catch any spillage. Remove four screws (Figure 1, Item 2) securing valve (Figure 1, Item 1) to cylinder. Set valve aside. Discard O-ring.
2 1

3

M1011JCH

Figure 1. Boom Lift Cylinder Removal.

0231-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

BOOM LIFT CYLINDER REMOVAL - Continued 3. Remove four screws (Figure 2, Item 3), flange (Figure 2, Item 1), O-ring (Figure 2, Item 2), and hose (Figure 2, Item 4) from cylinder (Figure 2, Item 5). Discard O-ring.
1,2 3

5

4

M1012JCH

Figure 2.

Boom Lift Cylinder Removal.

0231-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

BOOM LIFT CYLINDER REMOVAL - Continued

WARNING

Boom lift cylinder weighs approximately 886 lb (402 kg). Lifting device must have sufficient capacity to lift control valve. Failure to follow this warning may result in death or injury to personnel. 4. 5. 6. Attach a nylon sling and suitable lifting device to cylinder (Figure 3, Item 1). At frame end of cylinder (Figure 3, Item 1), remove screw (Figure 3, Item 4) and lockwasher (Figure 3, Item 3). Discard lockwasher. Using two jackscrews (Figure 3, Item 5), remove pin (Figure 3, Item 2).
1

2

5

4

3

M1013JCH

Figure 3. Boom Lift Cylinder Removal.

NOTE
Ensure sling is positioned so cylinder is balanced and will not tilt when removed from vehicle. 7. 8. 9. 10. Raise cylinder (Figure 4, Item 4) until parallel with ground. At boom end of cylinder (Figure 4, Item 4), remove nut (Figure 3, Item 2), lockwasher (Figure 3, Item 1), and washer (Figure 3, Item 5). Discard lockwasher. Remove end of cylinder (Figure 4, Item 4) from welded shaft (Figure 4, Item 3) on boom. Lower cylinder (Figure 4, Item 4) to ground.

END OF TASK

0231-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

BOOM LIFT CYLINDER INSTALLATION

WARNING

Boom lift cylinder weighs approximately 886 lb (402 kg). Lifting device must have sufficient capacity to lift control valve. Failure to follow this warning may result in death or injury to personnel.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. Using nylon sling and lifting device, raise cylinder (Figure 4, Item 4) parallel to ground and position on slide boom end of cylinder on welded shaft (Figure 4, Item 3). Slide end of cylinder (Figure 4, Item 4) onto welded shaft (Figure 4, Item 3). Install washer (Figure 4, Item 5), new lockwasher (Figure 4, Item 1), and nut (Figure 4, Item 2). Bend tabs on lockwasher. Lower frame end of cylinder (Figure 4, Item 4) to mounting bracket on vehicle body (Figure 4, Item 1).
1 2

5 3

4

M1014JCH

Figure 4.

Boom Lift Cylinder Removal.

0231-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

BOOM LIFT CYLINDER INSTALLATION - Continued

NOTE
• Ensure pin is clean and free of burrs. • When installing pin, slot in pin for retaining screw must be aligned with screw hole in mounting bracket. 5. 6. Install pin (Figure 5, Item 2) in cylinder (Figure 5, Item 1). Install new lockwasher (Figure 5, Item 3) and screw (Figure 5, Item 4).
1

2

4

3

M1015JCH

Figure 5. 7.

Boom Lift Cylinder Installation.

Remove sling and lifting device from cylinder (Figure 6, Item 5).

NOTE
Lubricate new O-rings with lubricating oil. 8. Install new O-ring (Figure 6, Item 2) and hose (Figure 6, Item 4) on cylinder (Figure 6, Item 5) with flange (Figure 6, Item 1) and four screws (Figure 6, Item 3).

0231-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

BOOM LIFT CYLINDER INSTALLATION - Continued
1,2 3

5

4

M1016JCH

Figure 6. 9. 10.

Boom Lift Cylinder Installation.

Position new O-ring and valve (Figure 7, Item 1) and secure to cylinder (Figure 7, Item 3) with four screws (Figure 7, Item 2). Close emergency lowering and float valves.
2 1

3

M1017JCH

Figure 7.

Boom Lift Cylinder Installation.

0231-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0231

BOOM LIFT CYLINDER INSTALLATION - Continued 11. Check oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Start engine, operate lift cylinders, and check for leaks (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13). Perform load testing procedure (WP 0271).

END OF TASK END OF WORK PACKAGE

0231-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00202)

TM 10-3930-675-23-2

0232

FIELD MAINTENANCE CAB LIFTING CYLINDER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 6) Qty: 2 Pin, Cotter (WP 0278, Table 1, Item 39) Qty: 2 Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 WP 0204 WP 0223 WP 0227 WP 0268 Equipment Condition Parking brake applied (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0232-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00203)

TM 10-3930-675-23-2

0232

NOTE
• Each cab lifting cylinder is replaced in the same manner. • Tag all hydraulic lines. • Remove ladder from area of step, as necessary. REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Raise cab lifting cylinders to fully raised position (TM 10-3930-675-10). Place wood cribbing under cab transport lift (Figure 1, Item 3) to hold cab transport lift in raised position. Relieve hydraulic system pressure (WP 0204). Close hydraulic reservoir ball valve (WP 0223). Disconnect two hydraulic hoses (Figure 1, Item 9) from cylinder (Figure 1, Item 4). Cap/plug both hydraulic hoses. Remove and discard O-rings. Remove pin (Figure 1, Item 2) from top of cylinder (Figure 1, Item 4). Remove screw (Figure 1, Item 7), washer (Figure 1, Item 6), and cotter pin (Figure 1, Item 5) from bottom of cylinder (Figure 1, Item 4). Discard cotter pin. Lift cab transport lift (Figure 1, Item 3) to remove cylinder (Figure 1, Item 4) from mounting brackets (Figure 1, Items 1 and 8).

END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. Lift cab transport lift (Figure 1, Item 3) and align cylinder (Figure 1, Item 4) to mounting brackets (Figure 1, Items 1 and 8). Install new cotter pin (Figure 1, Item 5), washer (Figure 1, Item 6), and screw (Figure 1, Item 7) on bottom of cylinder (Figure 1, Item 4). Apply a thin coat of grease to pin (Figure 1, Item 2). Install pin in top of cylinder (Figure 1, Item 4).

NOTE
Ensure new O-rings are lubricated with lubricating oil before installation. 4. 5. 6. 7. Remove cap/plug from two hydraulic hoses (Figure 1, Item 9), install two new O-rings, and connect hoses to cylinder (Figure 1, Item 4). Start engine (TM 10-3930-675-10). Remove wood cribbing from cab transport lift (Figure 1, Item 3). Open hydraulic reservoir ball valve (WP 0223).

0232-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00203)

TM 10-3930-675-23-2

0232

INSTALLATION - Continued
1 2

3

4 9 5

8

6 7
M0569JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Cab Lifting Cylinder Replacement.

Check for leaks and proper operation of cab lifting cylinder. Shut down engine (TM 10-3930-675-10). Check oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

0232-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00203)

TM 10-3930-675-23-2

0233

FIELD MAINTENANCE CAB SLIDING CYLINDER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (2) References LO 10-3930-675-13 WP 0227 WP 0268 Equipment Condition Parking brake applied (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Hydraulic reservoir ball valve closed (WP 0223)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag all hydraulic lines.

0233-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00204)

TM 10-3930-675-23-2

0233

REMOVAL 1. 2. 3. 4. 5. Disconnect two hydraulic hoses (Figure 1, Item 3) from cylinder (Figure 1, Item 8). Cap or plug all openings. At end of cylinder (Figure 1, Item 8), remove pin (Figure 1, Item 1). At opposite end of cylinder (Figure 1, Item 8), remove screw (Figure 1, Item 7), washer (Figure 1, Item 4), and shaft (Figure 1, Item 6). Remove cylinder (Figure 1, Item 8) from mounting brackets (Figure 1, Items 5 and 9). Remove two fittings (Figure 1, Item 2) from cylinder (Figure 1, Item 8).

END OF TASK INSTALLATION

NOTE
• Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). • Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. 4. 5. 6. 7. Install two fittings (Figure 1, Item 2) on cylinder (Figure 1, Item 8). Align end of cylinder (Figure 1, Item 8) to mounting bracket (Figure 1, Item 5) so shaft (Figure 1, Item 6) can be installed. Apply a thin coat of grease to shaft (Figure 1, Item 6) and install cylinder (Figure 1, Item 8) with shaft. Install washer (Figure 1, Item 4) and screw (Figure 1, Item 7). Apply a thin coat of grease to pin (Figure 1, Item 1). At opposite end of cylinder (Figure 1, Item 8), align cylinder to mounting bracket (Figure 1, Item 9) and install pin (Figure 1, Item 1). Remove cap/plugs and connect two hydraulic hoses (Figure 1, Item 3) to cylinder (Figure 1, Item 8).
1 2 3 3 4

8

M0570JCH

9

8

7

6

5

Figure 1. END OF TASK

Cab Sliding Cylinder Replacement.

0233-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00204)

TM 10-3930-675-23-2

0233

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Open hydraulic reservoir ball valve (WP 0223). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10). Check for leaks and proper operation of cab sliding cylinder (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0233-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00204)

TM 10-3930-675-23-2

0234

FIELD MAINTENANCE BOGIE WHEEL LIFT CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (Minimum Capacity 200 lbs) Materials/Parts O-Ring (WP 0278, Table 1, Item 138) Qty: O-Ring (WP 0278, Table 1, Item 139) Qty: References LO 10-3930-675-13 References (cont.) WP 0163 TM 10-3930-675-10 Equipment Condition Bogie Wheels (WP 0163)

2 2

0234-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00205)

TM 10-3930-675-23-2

0234

HYDRAULIC CYLINDERS REMOVAL

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connectors prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
Tag hydraulic lines for installation. 1. Remove bogie wheels (WP 0163).

NOTE
If bogie wheel frame is to be removed from vehicle after hydraulic cylinders are removed, support bogie wheel frame with nylon sling and overhead lifting device instead of wood blocks. 2. 3. Support frame (Figure 1, Item 5) with wood blocks. Disconnect hydraulic hoses from each of two hydraulic cylinders (Figure 1, Item 4).

0234-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00205)

TM 10-3930-675-23-2

0234

HYDRAULIC CYLINDERS REMOVAL - Continued
2 1 3 4 5 1

6 9

6

7

8

7

M0941JCH

Figure 1.

Hydraulic Cylinders Replacement.

NOTE
Perform Steps 4 thru 6 at top end of each hydraulic cylinder. 4. 5. 6. Remove screw (Figure 2, Item 7) and washer (Figure 2, Item 6) from end of upper pin (Figure 2, Item 1). Remove upper pin (Figure 2, Item 1), two washers (Figure 2, Item 3), and O-rings (Figure 2, Item 4) from vehicle frame (Figure 2, Item 2). Retain O-rings if not damaged. Remove grease fitting (Figure 2, Item 5) from upper pin (Figure 2, Item 1).
1 2 3 4

5

6

7

M0942JCH

Figure 2.

Hydraulic Cylinders Replacement.

0234-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00205)

TM 10-3930-675-23-2

0234

HYDRAULIC CYLINDERS REMOVAL - Continued

NOTE
Perform Steps 7 and 8 at bottom end of each hydraulic cylinder. 7. 8. Remove screw (Figure 3, Item 2) ad washer (Figure 3, Item 3) from end of lower pin (Figure 3, Item 9). Remove lower pin (Figure 3, Item 9), two washers (Figure 3, Item 6), and O-rings (Figure 3, Item 7) from frame (Figure 3, Item 5) and hydraulic cylinders (Figure 3, Item 4). Remove hydraulic cylinder. Retain O-rings if not damaged. Remove grease fittings (Figure 3, Item 8) from frame (Figure 3, Item 5) as necessary.

9.

END OF TASK HYDRAULIC CYLINDERS INSTALLATION 1. 2. If removed, install grease fitting (Figure 3, Item 8) on frame (Figure 3, Item 5). Position two hydraulic cylinders (Figure 3, Item 4) on vehicle.

NOTE
Perform Steps 3 and 4 at lower end of each hydraulic cylinder. 3. 4. Install two O-rings (Figure 3, Item 7), washers (Figure 3, Item 6), and hydraulic cylinder (Figure 3, Item 4) on frame (Figure 3, Item 5) and install lower pin (Figure 3, Item 9). Install washer (Figure 3, Item 3) and screw (Figure 3, Item 2) on end of lower pin (Figure 3, Item 9).
2 1 3 4 5 1

6 9

6

7

8

7

M0941JCH

Figure 3.

Hydraulic Cylinders Replacement.

0234-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00205)

TM 10-3930-675-23-2

0234

HYDRAULIC CYLINDERS INSTALLATION - Continued

NOTE
Perform Steps 5 thru 7 at upper end of each hydraulic cylinder. 5. 6. 7. 8. Install grease fitting (Figure 4, Item 5) on upper pin (Figure 4, Item 1). Install two O-rings (Figure 4, Item 4), washers (Figure 4, Item 3) and hydraulic cylinder (Figure 4, Item 4) on vehicle frame (Figure 4, Item 2) and install upper pin (Figure 4, Item 1). Install washer (Figure 4, Item 6) and screw (Figure 4, Item 7) on end of upper pin (Figure 4, Item 1). Connect hydraulic hoses to each of two hydraulic cylinders (Figure 4, Item 4)

NOTE
Remove wood blocks, or nylon sling and overhead lifting device, as bogie wheels are installed.
1 2 3 4

5

6

7

M0942JCH

Figure 4. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4.

Hydraulic Cylinders Replacement.

Install bogie wheels (Figure 1, Item 1) (WP 0163). Apply grease to grease fittings (LO 10-3930-675-13). Check level of oil in hydraulic reservoir (LO 10-3930-675-13). Raise bogie wheels (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0234-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00205)

TM 10-3930-675-23-2

0235

FIELD MAINTENANCE BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Pliers Set, Retaining Ring (WP 0277, Table 1, Item 56) Sling, Nylon (WP 0277, Table 1, Item 70) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 7) Qty: 2 Materials/Parts (cont.) Ring, Retaining (WP 0278, Table 1, Item 73) Qty: 2 Ring, Retaining (WP 0278, Table 1, Item 170) Qty: 2 Personnel Required (2) References LO 10-3930-675-13 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Boom locking pins in retracted position (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Parking brake applied (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0235-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0235

NOTE
• Both boom locking pin cylinders are replaced in the same manner. • Tag all hydraulic lines. LOCKING PIN CYLINDER REMOVAL 1. 2. Place a drain pan under cylinder (Figure 1, Item 4) to catch any spillage. Disconnect two hydraulic hoses (Figure 1, Item 1) from check valve mounted on one cylinder. Remove two retaining rings (Figure 1, Item 2) and pin (Figure 1, Item 3) that secure cylinder (Figure 1, Item 4) to vehicle. Discard retaining rings.
1 1 2,3

4

M1027JCH

Figure 1. Locking Pin Cylinder Removal.

0235-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0235

LOCKING PIN CYLINDER REMOVAL - Continued 3. 4. Loosen hose clamp (Figure 2, Item 2) and slide rubber bellows (Figure 2, Item 1) from bellows retaining plate (Figure 2, Item 4) to expose end of cylinder (Figure 2, Item 3) connected to locking pin (Figure 2, Item 5). Remove and discard two retaining rings (Figure 2, Item 6).
1 2 3

4

M1028JCH

6

5

Figure 2.

Locking Pin Cylinder Removal.

0235-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0235

LOCKING PIN CYLINDER REMOVAL - Continued 5. 6. 7. Pivot and rotate cylinder (Figure 3, Item 13) to access retaining ring (Figure 3, Item 2). Remove retaining ring (Figure 3, Item 2) and pin (Figure 3, Item 4). Discard retaining ring. Loosen clamp (Figure 3, Item 9) and remove rubber bellows (Figure 3, Item 7), retaining plate (Figure 3, Item 1), two adapter fittings (Figure 3, Item 10), check valve (Figure 3, Item 11), two O-rings (Figure 3, Item 12), clamp (Figure 3, Item 9), two bolts (Figure 3, Item 14), nuts (Figure 3, Item 15), and four washers (Figure 3, Item 16) from cylinder (Figure 3, Item 13). Retain for installation.

END OF TASK LOCKING PIN REMOVAL

WARNING
Locking pin weighs 85 lb (39 kg). Care should be taken in handling to prevent injury to personnel. 1. 2. 3. Loosen clamp (Figure 3, Item 5) securing rubber bellows (Figure 3, Item 7) to locking pin carrier assembly (Figure 3, Item 6) and remove bellows. Slide locking pin (Figure 3, Item 3) out of locking pin carrier assembly (Figure 3, Item 6). Remove eight socket head screws (Figure 3, Item 8) and locking pin carrier assembly (Figure 3, Item 6).
1 2 3 4

14,15,16

5

13

6 7 8

M1029JCH

10,11,12

9

Figure 3. Locking Pin Cylinder Removal. END OF TASK

0235-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0235

LOCKING PIN INSTALLATION

WARNING
Locking pin weighs 85 lb (39 kg). Care should be taken in handling to prevent injury to personnel. 1. 2. 3. Install locking pin carrier assembly (Figure 4, Item 6) and eight socket head screws (Figure 4, Item 8). Install locking pin (Figure 4, Item 3) and slide into locking pin carrier assembly (Figure 4, Item 6), leaving hole for cylinder pin exposed. Slide rubber bellows (Figure 4, Item 7) into place and secure with clamp (Figure 4, Item 5).

END OF TASK LOCKING PIN CYLINDER INSTALLATION 1. 2. 3. Install two adapter fittings (Figure 4, Item 10) on cylinder (Figure 4, Item 13). Install bellows retaining plate (Figure 4, Item 1) and clamp (Figure 4, Item 9) on cylinder (Figure 4, Item 13). Install four washers (Figure 4, Item 16), two nuts (Figure 4, Item 15), bolts (Figure 4, Item 14), clamp (Figure 4, Item 9), check valve (Figure 4, Item 11), and rubber bellows (Figure 4, Item 7) on cylinder (Figure 4, Item 13). Tighten clamp Insert cylinder (Figure 4, Item 13) into locking pin (Figure 4, Item 3) and secure with pin (Figure 4, Item 4) and new retaining ring (Figure 4, Item 2).
1 2 3 4

4.

14,15,16

5

13

6 7 8

M1029JCH

10,11,12

9

Figure 4.

Locking Pin Cylinder Installation.

0235-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0235

LOCKING PIN CYLINDER INSTALLATION - Continued 5. 6. Rotate and pivot cylinder (Figure 5, Item 3) and insert new retaining rings (Figure 5, Item 6). Slide rubber bellows (Figure 5, Item 1) over retaining plate (Figure 5, Item 4) and secure with clamp (Figure 5, Item 2) to cover end of cylinder (Figure 5, Item 3) connected to locking pin (Figure 5, Item 5).
1 2 3

4

M1028JCH

6

5

Figure 5.

Locking Pin Cylinder Installation.

0235-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0235

LOCKING PIN CYLINDER INSTALLATION - Continued 7. Position cylinder (Figure 6, Item 4) on vehicle mounting and secure with pin (Figure 6, Item 3) and two new retaining rings (Figure 6, Item 2).

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 8. 9. Connect two hydraulic hoses (Figure 6, Item 1) to cylinder (Figure 6, Item 4). Check oil level in hydraulic reservoir (LO 10-3930-675-13).
1 1 2,3

4

M1027JCH

Figure 6. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Locking Pin Cylinder Installation.

Start engine, extend and retract boom support locking pins, and check for leaks (TM 10-3930-675-10). Perform operational check of boom locking pins (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0235-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00206)

TM 10-3930-675-23-2

0236

FIELD MAINTENANCE LOCKING PIN BUSHING REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Bushing, Driver (WP 0277, Table 1, Item 11) Wrench, Torque, Click, Ratcheting, 1/2 Inch Drive, 250 lb-ft (WP 0277, Table 1, Item 95) Materials/Parts Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Rag, Wiping (WP 0276, Table 1, Item 50) Sealing Compound, Pipe (WP 0276, Table 1, Item 59) Parts Kit, Bearing Replacement, ME (WP 0278, Table 1, Item 16) Qty: 1 Materials/Parts (cont.) Parts Kit, Bearing Replacement, ME (WP 0278, Table 1, Item 17) Qty: 1 Bearing, Sleeve (WP 0278, Table 1, Item 85) Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 WP 0176 WP 0235 Equipment Condition Cab in transport position (TM 10-3930-675-10) Boom support in transport position (TM 10-3930-675-10)

FRAME BUSHINGS REMOVAL

WARNING

Work will be performed around the exhaust pipe and muffler. To prevent injury, allow the exhaust system to cool before starting this procedure.

CAUTION
• Take care not to scar or damage the bushing bore in the frame. • If bushing is damaged, collapse it with common tools.

0236-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00207)

TM 10-3930-675-23-2

0236

FRAME BUSHINGS REMOVAL - Continued Remove two bushings (Figure 1, Item 1) from frame (Figure 1, Item 2). Discard damaged bushings.

2

1

M0950JCH

Figure 1. Frame Bushings Removal. END OF TASK 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. Failure to do so may result in injury or death to personnel. • Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury to personnel. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. 1. 2. 3. Clean bushing bore of old sealing compound and smooth any scratches. Clean bore with oil free solvent. Dry with compressed air.

END OF TASK FRAME BUSHINGS INSTALLATION

NOTE
Bushings are installed from both the inside and outside of the frame.

0236-2

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TM 10-3930-675-23-2

0236

FRAME BUSHINGS INSTALLATION - Continued 1. 2. 3. Lightly coat outside of new bushings (Figure 2, Item 1) and bushing bore in frame (Figure 2, Item 2) with sealing compound. Place one new bushing (Figure 2, Item 1) on installation tool (Figure 2, Item 3) and center in frame bushing bore and lightly tap tool to get bushing started and centered. With bushing aligned, hold pressure on installation tool (Figure 2, Item 3) and press against bushing while it is being driven/hammered into bore until tool bottoms out against frame.

CAUTION
When installing the second bushing, drive it in only until it contacts the first bushing in the center of the frame. Do not drive it in until the bushing driver seats against the frame. Failure to follow this caution may cause distortion of bushings and binding of locking pin. This could cause the locking pin not to move or the bushing to be pushed out of the bore.

NOTE
Ensure that seams of the bushings are not aligned with each other. 4. 5. Install second bushing (Figure 2, Item 1) from opposite side of frame (Figure 2, Item 2). Drive in until it makes contact with first bushing. Clean inside of bushings (Figure 2, Item 1) of excess sealing compound that may have seeped through holes in bushings.

NOTE
Allow sealing compound to cure for 24 hours before the locking pins are extended into bushings. 6. 7. Apply a thin coat of GAA to locking pins and bushings. Return boom and cab to operational position (TM 10-3930-675-10).

1

2

3
Figure 2. END OF TASK Frame Bushings Installation.

M0951JCH

0236-3

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TM 10-3930-675-23-2

0236

BOOM SUPPORT BUSHINGS REMOVAL

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may result in injury to personnel.

NOTE
• Locking pin weighs 65 lb (29 kg). • Locking pin support weighs 35 lb (16 kg). 1. 2. 3. If removing inside bushings only, locking pin and locking pin support must first be removed (WP 0235). If removing outside bushings only, the outside cover must be removed and locking pins must be retracted (WP 0176). Remove eight capscrews (Figure 3, Item 1) and outside cover Figure 3, Item 2).

1

2
M0952JCH

Figure 3. Boom Support Bushings Removal. 4. 5. 6. 7. Remove large clamp (Figure 4, Item 4) from protection bellows (Figure 4, Item 3) on cylinder end of locking pin (Figure 4, Item 1) of inside boom support (Figure 4, Item 7). Slide bellows (Figure 4, Item 3) toward boom support (Figure 4, Item 8) to expose locking pin (Figure 4, Item 1). Remove upper snap ring (Figure 4, Item 2) from locking pin (Figure 4, Item 1). Tap pin on end using hammer and drift pin to push it through and out of locking pin (Figure 4, Item 1).

NOTE
Do not disconnect hoses or other end of cylinder. 8. Rotate disconnected cylinder end away from locking pin (Figure 4, Item 1).

0236-4

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TM 10-3930-675-23-2

0236

BOOM SUPPORT BUSHINGS REMOVAL - Continued 9. 10. 11. Remove locking pin (Figure 4, Item 1) from locking pin support (Figure 4, Item 8) and place in a protected area. Remove eight flat socket head capscrews (Figure 4, Item 5) from locking pin support (Figure 4, Item 8). Remove retaining ring (Figure 4, Item 6) and locking pin support (Figure 4, Item 8) and set aside.

1

2

3

4

5

6

7 8
Figure 4. Boom Support Bushings Removal.
M0953JCH

NOTE
• Support weighs 35 lb (16 kg). • Take care not to scar or damage bushing bore in the boom support. • If bushing is damaged, it may be collapsed and removed with common tools. 12. Clean bushing bore in the boom support IAW Cleaning in this work package.

END OF TASK

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TM 10-3930-675-23-2

0236

BOOM SUPPORT BUSHINGS INSTALLATION

NOTE
Bushings must be installed from the outside of the boom support towards the center of the support legs. 1. 2. 3. Lightly coat outside of new bushings (Figure 5, Item 1) and bushing bore in boom support (Figure 5, Item 2) with sealing compound. Place one new bushing (Figure 5, Item 1) on installation tool (Figure 5, Item 3) and center in boom support bushing bore. Lightly tap tool to get started and centered. With bushing (Figure 5, Item 1) aligned, hold pressure on installation tool (Figure 5, Item 3) and press against bushing while it is being driven/hammered into bore until tool bottoms out against boom support.

NOTE
• Ensure that seams of the bushings are not aligned with each other. • Allow sealing compound to cure for 24 hours before the locking pins are extended into bushings. 4. 5. Install second bushing (Figure 5, Item 1) from opposite side of boom support (Figure 5, Item 2). Drive bushing in until the tool bottoms out against boom support. Clean inside of bushings (Figure 5, Item 1) of excess sealing compound that may have seeped through holes in bushings.

1

2

3
Figure 5. 6. 7. 8. Boom Support Bushings Installation.

M0954JCH

Install locking pin support (Figure 6, Item 7) and retaining ring (Figure 6, Item 6) on vehicle. Install eight flat socket head capscrews (Figure 6, Item 5) in retaining ring (Figure 6, Item 6). Install locking pin (Figure 6, Item 1) into locking pin support (Figure 6, Item 7).

0236-6

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TM 10-3930-675-23-2

0236

BOOM SUPPORT BUSHINGS INSTALLATION - Continued

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may result in injury to personnel.

NOTE
• Locking pin weighs 65 lb (29 kg). • Locking pin support weighs 35 lb (16 kg). 9. 10. 11. 12. 13. Position locking pin (Figure 6, Item 1) on cylinder end. Tap locking pin (Figure 6, Item 1) into place using hammer and drift pin. Install upper snap ring (Figure 6, Item 2) on locking pin (Figure 6, Item 1). Slide protection bellows (Figure 6, Item 3) over locking pin (Figure 6, Item 1). Install large clamp (Figure 6, Item 4) on protection bellows (Figure 6, Item 3) on cylinder end of locking pin (Figure 6, Item 1).
1 2 3 4

5

6

7

M0955JCH

Figure 6.

Boom Support Bushings Installation.

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TM 10-3930-675-23-2

0236

BOOM SUPPORT BUSHINGS INSTALLATION - Continued 14. Install eight capscrews (Figure 7, Item 1) and outside cover (Figure 7, Item 2).

1

2
M0956JCH

Figure 7. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Boom Support Bushings Installation.

Apply a thin coat of GAA to locking pins and bushings (LO 10-3930-675-13). Adjust boom support-to-frame alignment (WP 0235). Return boom and cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0237

FIELD MAINTENANCE TOPHANDLER TILT CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (Minimum Capacity 200 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Washer, Lock (WP 0278, Table 1, Item 119) Qty: 2 Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 WP 0227 WP 0268 Equipment Condition Tophandler fully lowered and resting on cribbing (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Parking brake applied (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Tophandler tilt cylinder weighs 115 lb (52 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

0237-1

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TM 10-3930-675-23-2

0237

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Tophandler tilt cylinders are replaced in the same manner. • Tag all hydraulic lines. REMOVAL 1. Place a drain pan under cylinder (Figure 1, Item 4) to catch any spillage. Disconnect two hydraulic hoses (Figure 1, Item 8) from cylinder.

WARNING

Tophandler tilt cylinder weighs 115 lb (52 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel. 2. 3. 4. 5. 6. 7. 8. 9. Attach a nylon sling and suitable lifting device to cylinder (Figure 1, Item 4). At lower end of cylinder (Figure 1, Item 4), remove screw (Figure 1, Item 5) and lockwasher (Figure 1, Item 6). Discard lockwasher. Remove pin (Figure 1, Item 7). Raise cylinder (Figure 1, Item 4) to free lower end of cylinder from tophandler. Ensure sling is positioned so cylinder will not tilt when removed. At upper end of cylinder (Figure 1, Item 4), remove screw (Figure 1, Item 2) and lockwasher (Figure 1, Item 3). Discard lockwasher. Remove pin (Figure 1, Item 1). Remove upper end of cylinder (Figure 1, Item 4) from boom. Lower cylinder (Figure 1, Item 4) to ground.

END OF TASK

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0237

INSTALLATION

WARNING

Tophandler tilt cylinder weighs 115 lb (52 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Coat pins with grease before installation. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. 3. 4. 5. 6. 7. 8. Using nylon sling and lifting device, position cylinder (Figure 1, Item 4) so upper end of cylinder can be attached to boom. Install upper end of cylinder (Figure 1, Item 4) on boom with pin (Figure 1, Item 1). Install new lockwasher (Figure 1, Item 3) and screw (Figure 1, Item 2). Lower end of cylinder (Figure 1, Item 4) to tophandler. Install pin (Figure 1, Item 7). Install new lockwasher (Figure 1, Item 6) and screw (Figure 1, Item 5). Remove sling and lifting device from cylinder (Figure 1, Item 4). Connect two hydraulic hoses (Figure 1, Item 8) to cylinder (Figure 1, Item 4).
1 2,3 4

8

5,6

7

M1033JCH

Figure 1. Tophandler Tilt Cylinder Replacement. END OF TASK

0237-3

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TM 10-3930-675-23-2

0237

FOLLOW-ON MAINTENANCE 1. 2. 3. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate tilt cylinders, and check for leaks (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0238

FIELD MAINTENANCE TOPHANDLER SIDESHIFT CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Pliers Set, Retaining Ring (WP 0277, Table 1, Item 56) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (Minimum Capacity 300 lbs) Materials/Parts Cap Set, Protective Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Materials/Parts (cont.) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 WP 0227 WP 0268 Equipment Condition Tophandler fully lowered and resting on cribbing (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204) Parking brake applied (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. • Tophandler sideshift cylinder weighs 211 lbs (96 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

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TM 10-3930-675-23-2

0238

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Tophandler sideshift cylinders should be fully retracted to aid in replacement. • Tophandler sideshift cylinders are replaced in the same manner. • Tag all hydraulic lines. REMOVAL 1. 2. Remove three hose clamps (Figure 1, Item 5) from hydraulic hoses (Figure 1, Item 4) and cylinder (Figure 1, Item 6). Place a container under cylinder (Figure 1, Item 6) to catch any spillage. Disconnect two hydraulic hoses (Figure 1, Item 4) from cylinder

WARNING

Tophandler sideshift cylinder weighs 211 lb (96 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel. 3. 4. 5. 6. Attach nylon sling to cylinder (Figure 1, Item 6) and attach sling to suitable lifting device. Remove lockring (Figure 1, Item 1), spacer ring (Figure 1, Item 2), and pin (Figure 1, Item 3). Repeat step 4 at opposite end of cylinder (Figure 1, Item 6). Remove cylinder (Figure 1, Item 6) from tophandler (Figure 1, Item 7).

END OF TASK INSTALLATION

WARNING

Tophandler sideshift cylinder weighs 211 lb (96 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227).

0238-2

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TM 10-3930-675-23-2

0238

INSTALLATION - Continued 1. 2. 3. 4. 5. Using suitable lifting device and nylon sling attached to cylinder (Figure 1, Item 6), align cylinder to tophandler (Figure 1, Item 7). Install pin (Figure 1, Item 3), spacer ring (Figure 1, Item 2), and lockring (Figure 1, Item 1). Repeat step 2 at opposite end of cylinder (Figure 1, Item 6). Connect two hydraulic hoses (Figure 1, Item 4) to cylinder (Figure 1, Item 6). Install three hose clamps (Figure 1, Item 5) on hydraulic hoses (Figure 1, Item 4) and cylinder (Figure 1, Item 6).
4 5 4

1,2,3 1,2

M1034JCH

7

6

3

Figure 1. Tophandler Sideshift Cylinder Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate sideshift cylinders, and check for leaks (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0239

FIELD MAINTENANCE TOPHANDLER LEVELING CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Pliers Set, Retaining Ring (WP 0277, Table 1, Item 56) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (min. capacity 150 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Materials/Parts (cont.) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 WP 0268 Equipment Condition Tophandler fully lowered and resting on cribbing (TM 103930-675-10) Hydraulic system pressure relieved (WP 0204) Parking brake applied (TM 103930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Tophandler leveling cylinder weighs 97 lb (44 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

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TM 10-3930-675-23-2

0239

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• All tophandler leveling cylinders are replaced in the same manner. • Tag all hydraulic lines. REMOVAL 1. 2. Remove hose clamp (Figure 1, Item 5) from hydraulic hose (Figure 1, Item 2) and cylinder (Figure 1, Item 4). Place a drain pan under cylinder (Figure 1, Item 4) to catch any spillage. Disconnect two hydraulic hoses (Figure 1, Item 2) from cylinder.

WARNING

Tophandler leveling cylinder weighs 97 lb (44 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel. 3. 4. 5. 6. Attach nylon sling to cylinder (Figure 1, Item 4) and attach sling to suitable lifting device. Remove lockring (Figure 1, Item 3) and pin (Figure 1, Item 1). Repeat step 4 at opposite end of cylinder (Figure 1, Item 4). Remove cylinder (Figure 1, Item 4) from the tophandler.

END OF TASK INSTALLATION

WARNING

Tophandler leveling cylinder weighs 97 lb (44 kg). Lifting device must have sufficient capacity to lift cylinder. Failure to follow this warning may result in death or injury to personnel.

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. 2. Using suitable lifting device and nylon sling, align cylinder (Figure 1, Item 1) to tophandler. Install pin (Figure 1, Item 1) and lockring (Figure 1, Item 3).

0239-2

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TM 10-3930-675-23-2

0239

INSTALLATION - Continued 3. 4. 5. Repeat step 2 at opposite end of cylinder (Figure 1, Item 4). Connect two hydraulic hoses (Figure 1, Item 2) to cylinder (Figure 1, Item 4). Install hose clamp (Figure 1, Item 5) on hydraulic hose (Figure 1, Item 2) and cylinder (Figure 1, Item 4).

1 2 3

5

4 1

3
M1035JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Tophandler Leveling Cylinder Removal.

Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine (TM 10-3930-675-10), operate sideshifting cylinders, and check for leaks. Recheck oil level in hydraulic reservoir (LO 10-3930-675-13).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0240

FIELD MAINTENANCE TOPHANDLER TWISTLOCK CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) References LO 10-3930-675-13 References (cont.) TM 10-3930-675-10 Volume 1, WP 0104 WP 0227 WP 0268 Equipment Condition Parking brake applied (TM 103930-675-10) Tophandler tilted, to assist in capturing hydraulic (TM 103930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0240-1

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0240

NOTE
• Tophandler twistlock cylinders are replaced in the same manner. • Note direction of cylinder during removal to aid in installation. • Tag all hydraulic lines. REMOVAL

NOTE
A container may be placed under drain opening on underside of spreader beam, inbound from twistlock, to catch draining hydraulic fluid. 1. 2. 3. 4. Loosen fitting nuts (Figure 1, Item 6) and disconnect two tees (Figure 1, Item 8) from fittings (Figure 1, Item 4). Cap/plug hydraulic openings. At each end of cylinder (Figure 1, Item 5), remove retaining pin (Figure 1, Item 1), spacer (Figure 1, Item 2), and shaft (Figure 1, Item 3). Remove cylinder (Figure 1, Item 5) from mounting bracket (Figure 1, Item 9) and link (Figure 1, Item 7). Remove two fittings (Figure 1, Item 4) from cylinder (Figure 1, Item 5).

END OF TASK INSTALLATION

NOTE
• Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). • Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. 4. 5. Install two fittings (Figure 1, Item 4) on cylinder (Figure 1, Item 5). Align cylinder (Figure 1, Item 5) to mounting bracket (Figure 1, Item 9) and link (Figure 1, Item 7). At each end of cylinder (Figure 1, Item 5), install shaft (Figure 1, Item 3), spacer (Figure 1, Item 2), and retaining pin (Figure 1, Item 1). Remove cap/plug from hydraulic openings and connect two tees (Figure 1, Item 8) to fittings (Figure 1, Item 4). Tighten two fitting nuts (Figure 1, Item 6). Adjust proximity switches (Volume 1, WP 0104).

0240-2

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TM 10-3930-675-23-2

0240

INSTALLATION - Continued
1,2,3 4 5 6 5 2 1

9

6

8

4

3

7

M0571JCH

Figure 1. Tophandler Twistlock Cylinder Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Check oil level in hydraulic reservoir (LO 10-3930-675-13). Start engine, operate twistlock cylinders, and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0241

FIELD MAINTENANCE TOPHANDLER TWISTLOCK REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pliers Set, Retaining Ring (WP 0277, Table 1, Item 56) Wrench Set, Socket (1 in. drive) (WP 0277, Table 1, Item 94) Wrench, Adjustable, Automotive, 15 Inch (WP 0277, Table 1, Item 88) Wrench, Torque, Click, Ratcheting, 3/4 Inch Drive, 600 lb-ft (WP 0277, Table 1, Item 96) Materials/Parts Washer, Lock (WP 0278, Table 1, Item 122) Materials/Parts (cont.) Washer, Lock (WP 0278, Table 1, Item 168) Qty: 2 Pin, Straight, Headless (WP 0278, Table 1, Item 133) Qty: 2 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 134) Personnel Required (2) References Volume 1, WP 0104

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TM 10-3930-675-23-2

0241

REMOVAL 1. 2. Remove cotter pin (Figure 1, Item 6), retaining ring (Figure 1, Item 7), and shaft (Figure 1, Item 2) from end bracket (Figure 1, Item 1) of twistlock link (Figure 1, Item 5). Discard cotter pin. Loosen locknut (Figure 1, Item 3) and nut (Figure 1, Item 4).
2 1 7 3 4 5

6

M1044JCH

Figure 1. 3.

Tophandler Twistlock Removal.

Remove twistlock link (Figure 2, Item 6) assembly from tophandler.

NOTE
Note position and location of each of two end brackets for installation. 4. 5. 6. 7. 8. Remove end bracket (Figure 2, Item 1) and nut (Figure 2, Item 5) from twistlock link (Figure 2, Item 6). Remove locknut (Figure 2, Item 4) and lockwasher set (Figure 2, Item 3) from lifting pin (Figure 2, Item 10). Discard locknut and lockwasher set. Remove key (Figure 2, Item 15), lever (Figure 2, Item 16), bearing (Figure 2, Item 13), lifting pin (Figure 2, Item 10), and washer (Figure 2, Item 12) from tophandler. Remove guide pin (Figure 2, Item 11) from lifting pin (Figure 2, Item 10). Remove two nuts (Figure 2, Item 7), bar (Figure 2, Item 9), and spring (Figure 2, Item 8) from tophandler.

END OF TASK

0241-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00212)

TM 10-3930-675-23-2

0241

INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Install spring (Figure 2, Item 8) and bar (Figure 2, Item 9) on tophandler with two nuts (Figure 2, Item 7). Install guide pin (Figure 2, Item 11) on lifting pin (Figure 2, Item 10). Install washer (Figure 2, Item 12), lifting pin (Figure 2, Item 10), bearing (Figure 2, Item 13), lever (Figure 2, Item 16), and key (Figure 2, Item 15) on tophandler. Loosely install new lockwasher set (Figure 2, Item 3) and new locknut (Figure 2, Item 4) on lifting pin (Figure 2, Item 10). Install nut (Figure 2, Item 5) and end bracket (Figure 2, Item 1) on twistlock link (Figure 2, Item 6). Position twistlock link (Figure 2, Item 6) assembly on tophandler. Tighten nut (Figure 2, Item 5). Tighten locknut (Figure 2, Item 4) to 221 lb-ft (300 N•m). Install shaft (Figure 2, Item 2) and retaining ring (Figure 2, Item 17) on end bracket (Figure 2, Item 1) of twistlock link (Figure 2, Item 6) with new cotter pin (Figure 2, Item 14). Ensure bar (Figure 2, Item 9) is adjusted so its vertical movement aligns with proximity switch. Adjust proximity switch (Volume 1, WP 0104).
2 3 1 17 16 15 14 13 8 12 9 7 4 5 6

11

10

M1045JCH

Figure 2. END OF TASK END OF WORK PACKAGE

Tophandler Twistlock Replacement.

0241-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00212)

TM 10-3930-675-23-2

0242

FIELD MAINTENANCE DRAINING AND FILLING HYDRAULIC RESERVOIR

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Installer, Cup Plug (WP 0277, Table 1, Item 42) Pan, Drain (WP 0277, Table 1, Item 54) Tool, Hydraulic Reservoir (TM 10-3930-675-10, Basic Issue Items) Materials/Parts Lubricating Oil, Engine (WP 0276, Table 1, Item 37) Materials/Parts (cont.) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) References LO 10-3930-675-13 WP 0158 WP 0227 Equipment Condition Boom fully lowered and retracted (TM 10-3930-675-10) Hydraulic system pressure relieved (WP 0204)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0242-1

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TM 10-3930-675-23-2

0242

DRAINING

NOTE
Hydraulic reservoir capacity is 180 gal. (680 L). 1. 2. 3. Place a suitable container under drain plug (Figure 1, Item 1). Remove drain plug (Figure 1, Item 1) and drain hydraulic fluid into container. Dispose of oil in accordance with standard operating procedures (SOP). Reinstall drain plug (Figure 1, Item 1).

1

M0576JCH

Figure 1. Draining Hydraulic Reservoir. END OF TASK

0242-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00213)

TM 10-3930-675-23-2

0242

FILLING 1. 2. 3. 4. 5. 6. Fill hydraulic reservoir by removing plug (Figure 2, Item 1) in top of reservoir. Refer to Lubrication Order (LO 10-39-30-675-13) for correct lubricating oil to be used per expected temperature ranges. Replace all hydraulic system filters (WP 0158) and (WP 0227). Start engine and bring up to operating temperature (TM 10-3930-675-10). Operate joystick and cycle steering and brake system to circulate hydraulic fluid throughout system. Check for leaks (TM 10-3930-675-10). Shut down engine. Wait 3 to 4 minutes after engine shutdown, then check oil level in hydraulic reservoir. Level should be visible in sight gauge (Figure 2, Item 2). As required, add hydraulic fluid through plug (Figure 2, Item 1) opening on top of hydraulic reservoir.
1

2

M0577JCH

Figure 2. END OF TASK END OF WORK PACKAGE

Filling Hydraulic Reservoir.

0242-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00213)

TM 10-3930-675-23-2

0243

FIELD MAINTENANCE HYDRAULIC RESERVOIR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Lifting Device, 2,000-lb Minimum Capacity Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 47) Qty: 11 O-Ring (WP 0278, Table 1, Item 48) Qty: 2 O-Ring (WP 0278, Table 1, Item 49) Qty: 2 O-Ring (WP 0278, Table 1, Item 72) Qty: 2 Personnel Required (2) References Volume 1, WP 0124 References (cont.) WP 0227 WP 0242 WP 0268 Equipment Condition Cab in transport position (TM 10-3930-675-10) Transmission access covers removed (WP 0175) Exhaust muffler removed (Volume 1, WP 0079) Fuel tank removed (Volume 1, WP 0074) Radiator splash shield removed (Volume 1, WP 0084) Hydraulic system pressure relieved (WP 0204) Hydraulic reservoir drained (WP 0242) Master battery switch in OFF position (TM 10-3930-675-10) Hydraulic reservoir pressure sensor removed (Volume 1, WP 0124)

0243-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have sufficient capacity to lift reservoir. Use a lifting device with a 2,000-lb minimum capacity to remove reservoir. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Remove nylon straps and remove and discard tiedown straps as necessary to gain free movement in hydraulic hoses. • Tag all hydraulic lines. REMOVAL 1. 2. 3. Disconnect connector (Figure 1, Item 2) from wiring harness connector. Close five ball valves (Figure 1, Item 1) at bottom of reservoir (Figure 1, Item 4). Place drain pan beneath work area. At five ball valves (Figure 1, Item 1), remove four screws (Figure 1, Item 7), flange (Figure 1, Item 6), and disconnect hose (Figure 1, Item 8) or pipe (Figure 1, Item 5) from ball valve. Remove and discard O-ring.

0243-2

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TM 10-3930-675-23-2

0243

REMOVAL - Continued
4 2 3

1

5

8 6 7 1 7

M1047JCH

6

Figure 1. 4.

Hydraulic Reservoir Removal.

Close ball valve (Figure 2, Item 1) and disconnect hose (Figure 2, Item 2) from ball valve.

M1048JCH

2

1

Figure 2.

Hydraulic Reservoir Removal.

0243-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

REMOVAL - Continued

NOTE
If vehicle is equipped with arctic heater, perform Steps 5 thru 7. If vehicle is not equipped with arctic heater, proceed to Step 8. 5. 6. 7. 8. Remove two screws (Figure 3, Item 1), washers (Figure 3, Item 2) and arctic heater electrical and fuel lines (Figure 3, Item 5) with support from hydraulic reservoir (Figure 3, Item 9). Remove screw (Figure 3, Item 15) and hose clamp (Figure 3, Item 16). Cut and discard tiedown straps as necessary. Position arctic heater electrical and fuel lines (Figure 3, Item 5) away from hydraulic reservoir (Figure 3, Item 9). Place drain pan beneath work area. At top left side of reservoir (Figure 3, Item 9), disconnect hydraulic oil return hoses as follows: a. b. 9. Remove four screws (Figure 3, Item 6), flange (Figure 3, Item 7), and O-ring (Figure 3, Item 8) to disconnect each of five hoses (Figure 3, Item 12). Discard O-rings. Disconnect ten remaining hoses (Figure 3, Item 11) from fittings (Figure 3, Item 10) at reservoir.

Remove four screws (Figure 3, Item 3), flange (Figure 3, Item 4), and sensor (Figure 3, Item 13) with electrical lead (Figure 3, Item 14) from hydraulic reservoir (Figure 3, Item 9).
1,2 3 4 5 6 7,8 9 10 11 16

15

10

10
M1049JCH

11

11

14 13

12

12

Figure 3. Hydraulic Reservoir Removal.

0243-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

REMOVAL - Continued 10. Place drain pan beneath work area. At top front of reservoir (Figure 4, Item 7), remove three hydraulic hoses as follows: a. b. Remove four screws (Figure 4, Item 2), flange (Figure 4, Item 3), O-ring (Figure 4, Item 4), and hose (Figure 4, Item 8). Discard O-ring. Disconnect two hoses (Figure 4, Items 9 and 10) from adapter fittings (Figure 4, Item 1).
1 2 3,4 5,6

M1050JCH

10

9

8

7

Figure 4.

Hydraulic Reservoir Removal.

0243-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

REMOVAL - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have sufficient capacity to lift reservoir. Use a lifting device with a 2,000-lb minimum capacity to remove reservoir. Failure to follow this warning may result in injury to personnel.

NOTE
Ensure suitable lifting device is positioned and supporting the reservoir prior to removing attaching hardware. 11. Remove six screws (Figure 4, Item 5) and washers (Figure 4, Item 6) securing hydraulic reservoir (Figure 4, Item 7) to frame.

NOTE
Perform Steps 12 thru 15 to remove fittings and ball valves from reservoir, if a new reservoir is being installed. 12. Remove 10 fittings (Figure 5, Item 2) from top left side of reservoir (Figure 5, Item 1).
1 2

2

2
M1051JCH

Figure 5. Hydraulic Reservoir Removal.

0243-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

REMOVAL - Continued 13. Remove two adapter fittings (Figure 6, Item 1) from top front of reservoir (Figure 6, Item 2).
1

M1052JCH

2

Figure 6. 14.

Hydraulic Reservoir Removal.

Remove ball valve (Figure 7, Item 3) and fitting (Figure 7, Item 2) from reservoir (Figure 7, Item 1).

1

M1053JCH

3

2

Figure 7.

Hydraulic Reservoir Removal.

0243-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

REMOVAL - Continued 15. Remove each remaining ball valve (Figure 8, Item 1) from reservoir (Figure 8, Item 2) as follows: a. b. Remove four screws (Figure 8, Item 3), flange (Figure 8, Item 4), and ball valve (Figure 8, Item 1). Remove and discard O-ring (Figure 8, Item 5).
1 2

M1054JCH

4,5

3

4,5

3

1

Figure 8. Hydraulic Reservoir Removal. END OF TASK INSTALLATION

NOTE
• Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Perform Steps 1 thru 4 to install fittings removed from old reservoir, if a new reservoir is being installed. • Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 1. Install each of five ball valves (Figure 9, Item 1) at bottom of reservoir (Figure 9, Item 2) as follows: a. b. Lubricate new O-ring (Figure 9, Item 5). Install new O-ring (Figure 9, Item 5) and ball valve (Figure 9, Item 1) with flange (Figure 9, Item 4) and four screws (Figure 9, Item 3).

0243-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

INSTALLATION - Continued
1 2

M1054JCH

4,5

3

4,5

3

1

Figure 9. 2.

Hydraulic Reservoir Installation.

Install fitting (Figure 10, Item 2) and ball valve (Figure 10, Item 3) at bottom of reservoir (Figure 10, Item 1).

1

M1053JCH

3

2

Figure 10.

Hydraulic Reservoir Installation.

0243-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

INSTALLATION - Continued 3. Install two adapter fittings (Figure 11, Item 1) on top front of reservoir (Figure 11, Item 2).
1

M1052JCH

2

Figure 11. Hydraulic Reservoir Installation. 4. Install 10 fittings (Figure 12, Item 2) on top left side of reservoir (Figure 12, Item 1).
1 2

2

2
M1051JCH

Figure 12. Hydraulic Reservoir Installation.

0243-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

INSTALLATION - Continued

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Lifting device must have sufficient capacity to lift reservoir. Use a lifting device with a 2,000-lb minimum capacity to remove reservoir. Failure to follow this warning may result in injury to personnel. 5. 6. Using lifting device, position reservoir (Figure 13, Item 7) and secure to frame with six washers (Figure 13, Item 6) and screws (Figure 13, Item 5). At top front of hydraulic reservoir (Figure 13, Item 7), install three hydraulic hoses as follows: a. b. Lubricate new O-ring (Figure 13, Item 4). Install new O-ring and hose (Figure 13, Item 8) with flange (Figure 13, Item 3) and four screws (Figure 13, Item 2). Connect two hoses (Figure 13, Items 9 and 10) to two adapter fittings (Figure 13, Item 1).
1 2 3,4 5,6

M1050JCH

10

9

8

7

Figure 13.

Hydraulic Reservoir Installation.

0243-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

INSTALLATION - Continued

NOTE
If vehicle is equipped with arctic heater, perform Steps 7 and 8. If vehicle is not equipped with arctic heater, proceed to Step 9. 7. 8. 9. 10. Position arctic heater electrical and fuel lines (Figure 14, Item 5) with support on hydraulic reservoir (Figure 14, Item 9) and secure with two screws (Figure 14, Item 1) and washers (Figure 14, Item 2). Install screw (Figure 14, Item 15) and hose clamp (Figure 14, Item 16). Install new tiedown straps as necessary. Install sensor (Figure 14, Item 13) with electrical lead (Figure 14, Item 14) and flange (Figure 14, Item 4) with four screws (Figure 14, Item 3). At top of reservoir (Figure 14, Item 9), connect hydraulic oil return hoses as follows: a. b. Connect ten hoses (Figure 14, Item 11) to fittings (Figure 14, Item 10). Lubricate new O-ring (Figure 14, Item 8). Install each of five hoses (Figure 14, Item 12) with new O-ring, flange (Figure 14, Item 7), and four screws (Figure 14, Item 6).
1,2 3 4 5 6 7,8 9 10 11 16

15

10

10
M1049JCH

11

11

14 13

12

12

Figure 14. Hydraulic Reservoir Installation. 11. At bottom of reservoir (Figure 15, Item 1), connect hose (Figure 15, Item 3) to ball valve (Figure 15, Item 2).

0243-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

INSTALLATION - Continued
1

M1061JCH

3

2

Figure 15. 12.

Hydraulic Reservoir Installation.

At each of five ball valves (Figure 16, Item 1), lubricate new O-ring. Install hose (Figure 16, Item 8) or pipe (Figure 16, Item 5) on ball valve with new O-ring, flange (Figure 16, Item 6), and four screws (Figure 16, Item 7). Connect connector (Figure 16, Item 2) to wiring harness connector (Figure 16, Item 3).
2 3 4

13.

1

5

8 6 7 1 7

6

M1062JCH

Figure 16. 14. 15.

Hydraulic Reservoir Installation.

Install hydraulic reservoir pressure sensor (Volume 1, WP 0124). Fill hydraulic reservoir (WP 0242).

0243-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0243

INSTALLATION - Continued 16. Open five ball valves (Figure 17, Item 1) and ball valve (Figure 17, Item 3) at bottom of reservoir (Figure 17, Item 2).
1 2

M1063JCH

3

Figure 17. Hydraulic Reservoir Installation. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. Install fuel tank (Volume 1, WP 0074). Install nylon straps and new tiedown straps as necessary to support electrical leads and hydraulic hoses. Install exhaust muffler (Volume 1, WP 0079). Start engine and check for leaks (TM 10-3930-675-10). Perform operational check of all hydraulic systems (TM 10-3930-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13). Install transmission access covers (WP 0175). Install radiator splash shield (Volume 1, WP 0084). Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0243-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00214)

TM 10-3930-675-23-2

0244

FIELD MAINTENANCE HYDRAULIC RESERVOIR SIGHT GAUGE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Equipment Condition Boom elevated to maximum height (TM 10-3930-675-10

NOTE
New sight gauge comes with new O-rings and new rubber seals. REMOVAL 1. 2. Remove two fluid passage bolts (Figure 1, Item 1) and O-rings (Figure 1, Item 2) from hydraulic reservoir sight gauge (Figure 1, Item 4). Discard O-rings. Remove sight gauge (Figure 1, Item 4) and two rubber seals (Figure 1, Item 3) from side of hydraulic reservoir (Figure 1, Item 5). Discard rubber seals.
1,2,3

4

5
M0578JCH

Figure 1. END OF TASK

Hydraulic Reservoir Sight Gauge Removal.

0244-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00215)

TM 10-3930-675-23-2

0244

INSTALLATION 1. 2. Position two new rubber seals (Figure 2, Item 3) and sight gauge (Figure 2, Item 4) on side of hydraulic reservoir (Figure 2, Item 5). Install two new O-rings (Figure 2, Item 2) and fluid passage bolts (Figure 2, Item 1) on sight gauge (Figure 2, Item 4).
1,2,3

4

5
M0579JCH

Figure 2. END OF TASK FOLLOW-ON MAINTENANCE

Hydraulic Reservoir Sight Gauge Installation.

Fully lower boom and check for leaks (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0244-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00215)

TM 10-3930-675-23-2

0245

FIELD MAINTENANCE HYDRAULIC SYSTEM TEST POINT PROCEDURES

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Coupling Half, Quick Disconnect (WP 0277, Table 1, Item 19) Gage, Pressure, Multiple Dial Indicating (WP 0277, Table 1, Item 29) Pan, Drain (WP 0277, Table 1, Item 54) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Personnel Required (2) References WP 0185 Equipment Condition Parking brake applied (TM 10-3930-675-10) Engine shut down (TM 10-3930-675-10) Wheels chocked (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0245-1

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TM 10-3930-675-23-2

0245

GENERAL This work package describes how to use each of 11 test points (Figure 1, Item 1) located inside the remote hydraulic control compartment and the one test point on the engine driven pump to check hydraulic pressure in various systems/circuits on the vehicle.

1

M0580JCH

Figure 1. Hydraulic System Test Points. TEST POINT NO. 1: BRAKE ACCUMULATOR No. 1

NOTE
Test point No. 1 provides a means to check brake charging valve opening pressure and accumulator pre-charge nitrogen pressure within brake circuit No. 1. 1. 2. 3. 4. 5. 6. Open both brake system drain valves (Figure 2, Item 1) slowly until pressure is completely drained. Connect hydraulic test gauge to test point No. 1. Close both valves (Figure 2, Item 1). Start engine (TM 10-3930-675-10). Pressure will jump to pre-charged nitrogen pressure in accumulators; 1,230 to 1,300 psi (85 to 90 bar). Pressure will then build to 2,540 to 2,610 psi (175 to 180 bar). Pump brake pedal (TM 10-3930-675-10). Pressure will slowly drop to 2,000 psi (140 bar) and back to 2,540 to 2,610 (175 to 180 bar) when brake system recharges. Shut engine off (TM 10-3930-675-10). Open both brake system valves slowly and note point at which pressure drops off completely. Drop-off point is pre-charged nitrogen pressure in accumulators; 1,230 to 1,300 psi (85 to 90 bar).

0245-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00216)

TM 10-3930-675-23-2

0245

TEST POINT NO. 1: BRAKE ACCUMULATOR No. 1 - Continued 7. Disconnect hydraulic test gauge from test point No. 1. Close both valves (Figure 2, Item 1).

END OF TASK TEST POINT NO. 2: BRAKE ACCUMULATOR No. 2

NOTE
Test point No. 2 provides a means to check brake charging valve opening pressure and accumulator pre-charge nitrogen pressure within brake circuit No. 2. 1. 2. 3. 4. 5. 6. Open both brake system drain valves (Figure 2, Item 1) slowly until pressure is completely drained. Connect hydraulic test gauge with adapter to test point No. 2. Close both valves (Figure 2, Item 1). Start engine (TM 10-3930-675-10). Pressure will jump to pre-charged nitrogen pressure in accumulators; 1,230 to 1,300 psi (85 to 90 bar). Pressure will then build to 2,540 to 2,610 psi (175 to 180 bar). Pump brake pedal (TM 10-3930-675-10). Pressure will slowly drop to 2,000 psi (140 bar) and back to 2,540 to 2,610 (175 to 180 bar) when brake system recharges. Shut engine off (TM 10-3930-675-10). Open both brake system valves slowly and note point at which pressure drops off completely. Drop-off point is pre-charged nitrogen pressure in accumulators; 1,230 to 1,300 psi (85 to 90 bar). Disconnect hydraulic test gauge from test point No. 2. Close both valves (Figure 2, Item 1).

7.

1

M0581JCH

Figure 2. END OF TASK

System Drain Valves.

0245-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00216)

TM 10-3930-675-23-2

0245

TEST POINT NO. 3: STEERING SYSTEM MAIN VALVE 1. Open steering accumulator drain valve (Figure 3, Item 1) slowly until pressure is drained completely. Close valve.

1

M0582JCH

Figure 3. Steering Accumulator Drain Valve.

NOTE
Test point No. 3 provides a means to check the steering system main valve operating pressure. 2. 3. 4. 5. Connect hydraulic test gauge with adapter to test point No. 3. Start engine. Pressure will be 260 psi (18 bar). After 5 seconds, pressure will jump to 3,045 psi (210 bar). Shut engine off. Open steering accumulator drain valve (Figure 3, Item 1) slowly until pressure is drained completely. Close valve. Disconnect hydraulic test gauge from test point No. 3.

END OF TASK TEST POINT NO. 4: BRAKE CIRCUIT No. 2

NOTE
Test point No. 4 provides a means to check brake circuit No. 2 operating pressures. 1. 2. 3. 4. 5. 6. 7. Chock vehicle wheels. Release parking brake. Connect hydraulic test gauge to test point No. 4. Start engine. Apply parking brake. Pressure will jump to 1,100 psi (75 bar). Press brake pedal. Pressure will jump to 1,450 psi (100 bar). Release brake pedal. Release parking brake. Disconnect hydraulic test gauge from test point No. 4.

0245-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00216)

TM 10-3930-675-23-2

0245

TEST POINT NO. 4: BRAKE CIRCUIT No. 2 - Continued 8. Apply parking brake.

END OF TASK TEST POINT NO. 5: BRAKE CIRCUIT No. 1

NOTE
Test point No. 5 provides a means to check brake circuit No. 1 operating pressures. 1. 2. 3. Connect hydraulic test gauge to test point No. 5. Start engine. Press brake pedal. Pressure will jump to 1,450 psi (100 bar). Shut engine off. Release brake pedal. Disconnect hydraulic test gauge from test point No. 5.

END OF TASK TEST POINT NO 6: STEERING PUMP No. 1

NOTE
Test point No. 6 provides a means to check steering pump No. 1 operating pressures. 1. 2. 3. Connect hydraulic test gauge to test point No. 6. Start engine. Pressure will be 260 psi (18 bar). After 5 seconds, pressure will jump to 3,045 psi (210 bar). Shut engine off. Disconnect hydraulic test gauge from test point No. 6.

END OF TASK TEST POINT NO 7: STEERING PUMP No. 2

NOTE
Test point No. 7 provides a means to check steering pump No. 2 operating pressures. 1. 2. 3. Connect hydraulic test gauge to test point No. 7. Start engine. Pressure will be 260 psi (18 bar). After 5 seconds pressure will jump to 3,045 psi (210 bar). Shut down engine. Disconnect hydraulic test gauge from test point No. 7.

END OF TASK TEST POINT NO 8: BOOM LIFT/EXTEND MAIN VALVE

NOTE
Test point No. 8 provides a means to check boom lift and extend main valve operating pressure. 1. 2. 3. 4. Connect hydraulic test gauge to test point No. 8. Start engine. Press throttle and hold at 1,500 RPM. Fully retract boom and hold. Pressure will build to 3,480 psi (240 bar). Release joystick. Release throttle. Shut engine off.

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TM 10-3930-675-23-2

0245

TEST POINT NO 8: BOOM LIFT/EXTEND MAIN VALVE - Continued 5. Disconnect hydraulic test gauge from test point No. 8.

END OF TASK TEST POINT NO. 9: SERVO SYSTEM

NOTE
Test point No. 9 provides a means to check the servo system operating pressure. 1. 2. 3. 4. Connect hydraulic test gauge to test point No. 9. Start engine. Pressure will be 435 psi (30 bar). Shut engine off. Turn ignition on. Exercise joystick. Turn ignition off. Disconnect hydraulic test gauge from test point No. 9.

END OF TASK TEST POINT NO. 10: CAB LIFT MAIN VALVE

NOTE
Test point No. 10 provides a means to check the cab lift operating pressure. 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove handrail from mounted position. Connect hydraulic test gauge to test point No. 10. Turn ignition on, but DO NOT start engine. Turn on auxiliary pump. Raise cab transport lift and hold. Pressure will build to 1,595 psi (110 bar). Lower cab transport lift. Turn auxiliary pump off. Turn ignition off. Reinstall handrail. Disconnect hydraulic test gauge from test point No. 10.

END OF TASK TEST POINT NO. 11: TOPHANDLER/BOOM FOLDING SYSTEMS

NOTE
Test point No. 11 provides a means to check tophandler and boom folding system operating pressure. 1. 2. 3. Connect hydraulic test gauge to test point No. 11. Start engine. Pressure will be 260 psi (18 bar). After 5 seconds, pressure will jump to 3,045 psi (210 bar). Shut engine off. Disconnect hydraulic test gauge from test point No. 11.

END OF TASK

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TM 10-3930-675-23-2

0245

TEST POINT NO. 12: ENGINE DRIVEN PUMP/FAN HYDRAULIC SYSTEM

WARNING
The engine will be operated at full throttle during the test: DO NOT stand or sit around the front of the engine while performing this test. Keep hands and objects away from the engine drive belts. Failure to follow this warning may result in serious injury to personnel.

CAUTION
The engine should be at operating temperature before performing this test. Operating a cold engine at full throttle may result in premature wear or damage to the engine.

NOTE
Test point No. 12 provides a means to check the engine driven pump pressure and the fan hydraulic system operation and pressure. 1. 2. Remove engine cover to access engine driven pump located at left front of engine (WP 0185). Locate test point (Figure 4, Item 1) on engine driven pump discharge port. Clean test point and connect hydraulic test gauge.

1

M0583JCH

Figure 4. 3. 4. 5. 6. 7. 8. 9. 10. Start engine.

Engine Driven Pump Test Point.

Enter diagnostic menu "EXTRA FUNCT" Screen "11 (13)". Use plus and minus keys to increase fan speed to 100%. Press the accelerator pedal fully and bring engine to full throttle. Pressure will increase to 2,600 to 2,700 psi (180 to 186 bar). Release accelerator pedal. Shut down engine after 30 seconds. Disconnect hydraulic test gauge from test point (Figure 4, Item 1). Reinstall engine cover (WP 0185).

END OF TASK

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TM 10-3930-675-23-2

0245

FOLLOW-ON MAINTENANCE 1. 2. Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

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0246

FIELD MAINTENANCE FORKLIFT CYLINDERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Pan, Drain (WP 0277, Table 1, Item 54) Sling, Nylon (WP 0277, Table 1, Item 70) Lifting Device (min. capacity 100 lbs) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Materials/Parts (cont.) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Personnel Required (2) References LO 10-3930-675-13 WP 0268 Equipment Condition Forklift removed from tophandler (TM 10-3930-675-10)

WARNING

• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to do so could result in injury. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

NOTE
• Forklift cylinders are replaced in the same manner. • Tag all hydraulic lines.

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0246

REMOVAL 1. 2. 3. 4. 5. Loosen nylon strap (Figure 1, Item 10) and using a drain pan to catch any spillage, disconnect two hydraulic hoses (Figure 1, Item 2) from adapter fittings (Figure 1, Item 1). Remove two adapter fittings (Figure 1, Item 1) from cylinder (Figure 1, Item 9). At one end of cylinder (Figure 1, Item 9), remove screw (Figure 1, Item 4), spring washer (Figure 1, Item 5), and pin (Figure 1, Item 6). If damaged, remove two retaining rings (Figure 1, Item 7) and guide bearing (Figure 1, Item 8). Repeat Steps 3 and 4 for opposite end of cylinder (Figure 1, Item 9).

WARNING

Forklift cylinder weighs 60 lbs. Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device 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 death or injury to personnel. 6. Remove cylinder (Figure 1, Item 9) from forklift frame (Figure 1, Item 3).

END OF TASK

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0246

INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. 2. 3. 4. 5. If removed, install guide bearing (Figure 1, Item 8) and two retaining rings (Figure 1, Item 7). Position cylinder (Figure 1, Item 9) on forklift frame (Figure 1, Item 3) and install pin (Figure 1, Item 6). Install spring washer (Figure 1, Item 5) and screw (Figure 1, Item 4). Repeat Steps 1 thru 3 for opposite end of cylinder (Figure 1, Item 9). Install two adapter fittings (Figure 1, Item 1) on cylinder (Figure 1, Item 9).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 6. Connect two hydraulic hoses (Figure 1, Item 2) to cylinder (Figure 1, Item 9). Tighten nylon strap (Figure 1, Item 10).
1 2 3 2 4,5 6

7,8

M1046JCH

10

9

Figure 1. END OF TASK

Forklift Cylinder Replacement.

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TM 10-3930-675-23-2

0246

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. Install forklift to tophandler (TM 10-3930-675-10). Check oil level in hydraulic reservoir (LO 10-3930-675-13). Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). Start engine, operate forklift cylinders, and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0247

FIELD MAINTENANCE RIFLE MOUNTING BRACKET REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85)

REMOVAL 1. Remove two screws (Figure 1, Item 2), washers (Figure 1, Item 3), latch assembly (Figure 1, Item 1), and bracket (Figure 1, Item 4) from side of cab.
1 2,3

4

M0500JCH

Figure 1.

Rifle Mounting Bracket Removal.

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TM 10-3930-675-23-2

0247

REMOVAL - Continued 2. Remove screw (Figure 2, Item 2) and bracket (Figure 2, Item 1) from floor of cab.
1

2

M0501JCH

Figure 2. END OF TASK

Rifle Mounting Bracket Replacement.

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TM 10-3930-675-23-2

0247

INSTALLATION 1. 2. Install bracket (Figure 2, Item 1) on floor of cab with screw (Figure 2, Item 2). Install bracket (Figure 3, Item 4) and latch assembly (Figure 3, Item 1) on side of cab with two washers (Figure 3, Item 3) and screws (Figure 3, Item 2).
1 2,3

4

M0502JCH

Figure 3. END OF TASK END OF WORK PACKAGE

Rifle Mounting Bracket Installation.

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TM 10-3930-675-23-2

0248

FIELD MAINTENANCE AIR CONDITIONING SYSTEM MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Puller, Attachment, Mechanical (WP 0277, Table 1, Item 58) Reclaimer, Refrigerant (WP 0277, Table 1, Item 62) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Lubricating Oil, Refrigerant Compressor, Synthetic (WP 0276, Table 1, Item 46) Tetrafluoroethane Technical Refrigerant, R-134a (WP 0276, Table 1, Item 68) Personnel Required 91C (1) Maintainer (1) References TM 10-3930-675-10 WP 0254 WP 0250 WP 0249 Equipment Condition Engine cover removed (WP 0185)

WARNING

• Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Take care to prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if you come in contact with liquid refrigerant. • Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with compressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, which could cause personnel injury or death.

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0248

RECOVERY 1. 2. Remove caps from suction valve (Figure 1, Item 5) and discharge valve (Figure 1, Item 6) on A/C compressor (Figure 1, Item 7). Wearing protective goggles and non-leather gloves, attach recovery/recycling station's hoses to valves (Figure 1, Items 5 and 6).

NOTE
Push down firmly on hose connectors until a clicking sound is heard. This will ensure coupler is locked. a. b. c. d. 3. Ensure recovery/recycling station's valves are closed. Connect red hose to discharge valve (Figure 1, Item 6). Connect blue hose to suction valve (Figure 1, Item 5). Turn knob clockwise on each coupler to open valves (Figure 1, Items 5 and 6).

Follow recovery/recycling manufacturer's instructions and recover all refrigerant from system.

NOTE
• Always comply with all local regulations regarding refrigerant disposal. You may be subject to substantial penalties for improper disposal. • Anytime A/C system refrigerant is evacuated, replace receiver/dryer. 4. Replace receiver/dryer (WP 0254).

NOTE
If system is contaminated with moisture, compressor oil must be replaced with clean oil. If system is heavily contaminated with desiccant or grit, replace compressor and expansion valve. 5. Replace A/C compressor (WP 0250).

END OF TASK EVACUATING/RECYCLING

NOTE
System must have been recovered and compressor filled with correct amount of refrigerant oil. Replace receiver/dryer if system is opened. 1. Wearing protective goggles and rubber gloves, attach recovery/recycling station's hoses to valves.

NOTE
Push down firmly on hose connectors until a clicking sound is heard. This will ensure coupler is locked. a. b. c. d. Ensure recovery/recycling station's valves are closed. Connect red hose to discharge valve (Figure 1, Item 6). Connect blue hose to suction valve (Figure 1, Item 5). Turn knob clockwise on each coupler to open valves (Figure 1, Items 5 and 6).

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TM 10-3930-675-23-2

0248

EVACUATING/RECYCLING - Continued 2. Follow recovery/recycling manufacturer's instructions and evacuate/recycle refrigerant system.

2 1

3 4

8

5 6 7
M1092JCH

Figure 1. END OF TASK

System Recovery.

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TM 10-3930-675-23-2

0248

PURGING

NOTE
Dry nitrogen gas is recommended for purging. A pressure regulator is required to regulate between 0 to 200 psi (0 to 1,379 kPa). Commercial cylinders of nitrogen contain pressures in excess of 2,000 psi (13,780 kPa); this pressure must be reduced to 200 psi (1,379 kPa) for purging. 1. 2. 3. 4. 5. 6. 7. Recover system refrigerant (refer to Recovery in this work package). Disconnect both ends of line or part being purged. Tightly cap rest of system. Ensure valves (Figure 2, Items 1, 2, and 6) are closed. Connect supply line valve (Figure 2, Item 6) to outlet end of part or line. Connect drain line (Figure 2, Item 4) to inlet end of part or line. Place outlet of drain line into a recycling system container. Adjust nitrogen bottle regulator (Figure 2, Item 3) to 200 psi (1,379 kPa). Open nitrogen bottle control valve (Figure 2, Item 2) and purging control valve (Figure 2, Item 1). Then, slowly open supply line valve (Figure 2, Item 6). Check drain line (Figure 2, Item 4) for gas flow. Let nitrogen flow at 200 psi (1,379 kPa) for 1 to 2 minutes. If part or line was very wet, allow it to flow until there is no trace of refrigerant oil or solid bits of dirt or grit flowing from drain tube. Close nitrogen bottle control valve (Figure 2, Item 2) and purging control valve (Figure 2, Item 1) first, then close supply line valve (Figure 2, Item 6). Disconnect supply line valve (Figure 2, Item 6) and drain line (Figure 2, Item 4). Tightly cap both ends of part or line.

8. 9. 10.

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TM 10-3930-675-23-2

0248

PURGING - Continued
2 1 3 4 5 6

8

6

4 7
M1093JCH

Figure 2. END OF TASK FLUSHING 1. 2. 3. 4. 5.

Nitrogen Purging.

Recover refrigerant system (refer to Recovery in this work package). Disconnect both ends of part or line being flushed. Tightly cap lines to rest of system. Heat R-134a refrigerant in a dial-a-charge or pressurize refrigerant in accordance with manufacturer's instructions provided with refrigerant reclaimer. Connect dial-a-charge outlet hose to outlet side of system (this will ensure R-134a will flow in reverse direction of normal flow). Connect a line from inlet side of system to recovery/recycling station.

NOTE
If system is extremely contaminated, install a receiver/dryer inline as a pre-filter for recovery/ recycling station. 6. Turn on recovery/recycling station and open outlet valve for dial-a-charge. Allow about 2 lb (1 kg) of R-134a to flow through system.

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TM 10-3930-675-23-2

0248

FLUSHING - Continued 7. 8. 9. 10. Close supply line valve and wait for recovery station to shut off. Disconnect supply line and drain line from dial-a-charge and recovery station. Connect lines to nitrogen bottle. Purge system and check collection bottle for contaminants. Repeat process if needed. Disconnect lines from part and tightly cap both ends of part.

END OF TASK CHARGING

NOTE
Before charging, system must be recovered and evacuated with recovery and recycling station connected to service and discharge port connections 1. 2. Check the tag on the left side of the RTCH frame just below the cab to obtain the correct weight of the 134a charge. The charge weight is normally 3.75 lb (1.7 kg). Obtain enough refrigerant to fully charge the system. Ensure the recovery/recycling unit is connected properly and charge the system according to the manufacturer's instructions.

CAUTION
Some recovery, recycling, and recharging systems have the capability to charge system through the high pressure side of the system. Always follow the manufacturer's instructions or damage to the compressor may result. 3. Start engine and run at 1,500 RPM. Set cab A/C controls at maximum cooling and fan speed; refrigerant compressor must engage.

NOTE
If refrigerant is slow to enter system because of low outside temperatures, vaporization can be quickened by placing refrigerant tank in a tub of warm water, no warmer than 125°F (52°C). 4. Shut down engine and recovery/recycle unit. Disconnect recovery/recycle unit as per the manufacturer/ instructions.

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. Leak test A/C system (WP 0249). Check operation of A/C system (TM 10-3630-675-10). Install engine cover (WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0249

FIELD MAINTENANCE AIR CONDITIONER LEAK TEST

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Leak Detector, Refrigerant Gas (WP 0277, Table 1, Item 50)

INSPECTION

WARNING

• Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Take care to prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if you come in contact with liquid refrigerant. • Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with compressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, which could cause personnel injury or death.

NOTE
• Refrigerant is odorless. As a result, all of it may leak away and not be noticed until system stops cooling. All vehicle refrigerant systems lose some refrigerant depending on the condition of the system. Higher loss rates signal a need to locate and repair leaks. • Leaks are most often found at the compressor hose connections and at various fittings and joints in the system. If unapproved replacement hoses are installed, refrigerant can be lost through hose permeation. 1. 2. Visually inspect refrigerant system for A/C lubricant leakage and corrosion and damage to lines, hoses, and other components. Visually inspect lowest points of fittings, hoses, and lines for indications of lubricant leakage.

END OF TASK TEST Use a leak detector in accordance with manufacturer’s instruction manual and check for refrigerant leakage at hose connections, fittings, and in areas where leakage might occur. If leaks are indicated, repair or replace parts necessary. END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0250

FIELD MAINTENANCE AIR CONDITIONING COMPRESSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 80) Qty: 2 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 70) Qty: 2 References WP 0254 Equipment Condition A/C system refrigerant recovered (WP 0248)

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TM 10-3930-675-23-2

0250

REMOVAL

NOTE
Remove and discard tiedown strap as necessary. 1. 2. 3. 4. Disconnect A/C compressor (Figure 1, Item 3) connector (Figure 1, Item 2) from engine wiring harness (Figure 1, Item 1). Loosen locknuts (Figure 1, Items 4 and 9). Loosen two jamnuts (Figure 1, Item 5) and rotate support rod (Figure 1, Item 6) to allow slack in two belts (Figure 1, Item 8). Remove two belts (Figure 1, Item 8) from A/C compressor (Figure 1, Item 3) and pulley (Figure 1, Item 7).

1 9 2 8

3

4

5

7

M1094JCH

6
Figure 1. Air Conditioner Compressor Removal. 5. Remove locknut (Figure 2, Item 10) and screw (Figure 2, Item 12) from support rod (Figure 2, Item 9) and yoke (Figure 2, Item 11). Discard locknut.

CAUTION
Water and dirt can damage refrigerant system. Refrigerant lines should be capped after disconnection to avoid contamination 6. 7. Loosen two fitting nuts (Figure 2, Item 5) and disconnect two A/C hoses (Figure 2, Item 6) from A/C compressor (Figure 2, Item 13). Remove locknut (Figure 2, Item 1), bolt (Figure 2, Item 4), two washers (Figure 2, Item 2), and A/C compressor (Figure 2, Item 13) from bracket (Figure 2, Item 3). Discard locknut.

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TM 10-3930-675-23-2

0250

REMOVAL - Continued

NOTE
Perform step 8 to remove bracket from engine. 8. Remove four screws (Figure 2, Item 7), washers (Figure 2, Item 8), and bracket (Figure 2, Item 3) from left front of engine.

END OF TASK INSTALLATION

NOTE
Perform step 1 to install bracket on engine. 1. 2. 3. 4. 5. 6. 7. Install bracket (Figure 2, Item 3) on left front of engine with four washers (Figure 2, Item 8) and screws (Figure 2, Item 7). Install A/C compressor (Figure 2, Item 13) on bracket (Figure 2, Item 3) with two washers (Figure 2, Item 2), bolt (Figure 2, Item 4), and new locknut (Figure 2, Item 1). DO NOT fully tighten locknut. Connect two A/C hoses (Figure 2, Item 6) to A/C compressor (Figure 2, Item 13) and tighten two fitting nuts (Figure 2, Item 5). Position two belts (Figure 1, Item 8) on A/C compressor (Figure 1, Item 3) and pulley (Figure 1, Item 7). Install support rod (Figure 2, Item 9) and yoke (Figure 2, Item 11) on A/C compressor (Figure 2, Item 13) with screw (Figure 2, Item 12) and new locknut (Figure 2, Item 10). DO NOT fully tighten locknut. Rotate support rod (Figure 1, Item 6) until belts (Figure 1, Item 8) can be depressed no more than 1/2 in. (12.7 mm) at center of belts. Tighten two jamnuts (Figure 1, Item 5). Tighten locknuts (Figure 1, Items 4 and 9).
1 2 3 4 5

6 13

12

11 10

9

7,8

M1094_1JCH

Figure 2. Air Conditioner Compressor Replacement.

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TM 10-3930-675-23-2

0250

INSTALLATION - Continued

NOTE
Install new tiedown strap as necessary. 8. Connect A/C compressor (Figure 3, Item 3) and connector (Figure 3, Item 2) to engine wiring harness (Figure 3, Item 1).

1 9 2 8

3

4

5

7

M1094JCH

6
Figure 3. END OF TASK FOLLOW-ON MAINTENANCE Air Conditioner Compressor Installation.

NOTE
Any time A/C system refrigerant is evacuated, replace receiver/dryer. 1. 2. Replace receiver/dryer (WP 0254). Charge A/C system (WP 0248).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0251

FIELD MAINTENANCE AIR CONDITIONING COMPRESSOR DRIVE BELTS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Equipment Condition Engine cover removed (WP 0185) Master battery switch in OFF position (TM 10-3930-675-10)

0251-1

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TM 10-3930-675-23-2

0251

REMOVAL 1. 2. 3. Loosen screw (Figure 1, Item 2), nut (Figure 1, Item 3), and washer (Figure 1, Item 4) securing A/C compressor (Figure 1, Item 5) to mounting bracket (Figure 1, Item 1). Loosen two adjusting jamnuts (Figure 1, Item 7) on belt tension adjusting rod (Figure 1, Item 8). Remove drive belts (Figure 1, Item 10) from accessory drive pulley (Figure 1, Item 9) and A/C compressor pulley (Figure 1, Item 6).

END OF TASK INSTALLATION

NOTE
If drive belts are worn, cracked, frayed, or dry rotted, belts must be replaced. 1. 2. 3. 4. 5. Install drive belts (Figure 1, Item 10) around accessory drive pulley (Figure 1, Item 9) and A/C compressor pulley (Figure 1, Item 6). Tighten belt tension adjusting rod (Figure 1, Item 8) until drive belts (Figure 1, Item 10) can be depressed no more than ½-in. (12.7 mm) at center of belts. Tighten two adjusting jamnuts (Figure 1, Item 7) on belt tension adjusting rod (Figure 1, Item 8). Tighten screw (Figure 1, Item 2), washer (Figure 1, Item 4), and nut (Figure 1, Item 3) securing A/C compressor (Figure 1, Item 5) to mounting bracket (Figure 1, Item 1). Recheck tension of drive belts (Figure 1, Item 10) to ensure not more than ½-in. (12.7 mm) depression at center of belts.

0251-2

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TM 10-3930-675-23-2

0251

INSTALLATION - Continued
1 2,3,4 5

6

7 10 8 9 7

M0639JCH

Figure 1. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3.

Drive Belts Replacement.

Turn master battery switch to ON position (TM 10-3930-675-10). Operate engine (TM 10-3930-675-10) for ten minutes. Shut down, recheck, and adjust tension as needed. Install engine cover (WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0252

FIELD MAINTENANCE AIR CONDITIONER HOSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) O-Ring (WP 0278, Table 1, Item 110) Qty: 4 Materials/Parts (cont.) O-Ring (WP 0278, Table 1, Item 108) Qty: O-Ring (WP 0278, Table 1, Item 109) References WP 0175 WP 0254 Equipment Condition A/C system refrigerant recovered (WP 0248) 4

CHASSIS A/C HOSES REMOVAL 1. Remove transmission access cover (WP 0175).

CAUTION
Water and dirt can damage refrigerant system. Refrigerant lines and compressor should be capped after disconnection to avoid contamination. 2. Loosen two fitting nuts (Figure 1, Item 2) and disconnect two A/C hoses (Figure 1, Items 3 and 4) from A/C compressor (Figure 1, Item 1).

1

2

3

4

M1095JCH

Figure 1.

Chassis A/C Hoses Removal.

0252-1

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TM 10-3930-675-23-2

0252

CHASSIS A/C HOSES REMOVAL - Continued

CAUTION
Use two wrenches when loosening fitting nut to avoid twisting condenser tube.

NOTE
Remove nylon straps and remove and discard tiedown straps as necessary. 3. Behind cab, loosen fitting nut (Figure 2, Item 2) and disconnect A/C hose (Figure 2, Item 1) from condenser (Figure 2, Item 3) at condenser fan box (Figure 2, Item 4).
1 2 3 4

M1096JCH

Figure 2. Chassis A/C Hoses Removal and Installation. 4. 5. Loosen fitting nut (Figure 3, Item 2) and disconnect A/C hose (Figure 3, Item 3) from fitting (Figure 3, Item 1) at cab interface at rear of cab. Remove two A/C hoses from vehicle.

END OF TASK CHASSIS A/C HOSES INSTALLATION 1. 2. Position two A/C hoses on vehicle. Connect A/C hose (Figure 3, Item 3) to fitting (Figure 3, Item 1) at cab interface at rear of cab and tighten fitting nut (Figure 3, Item 2).

CAUTION
Use two wrenches when tightening fitting nut to avoid twisting condenser tube. 3. Connect A/C hose (Figure 2, Item 1) to condenser (Figure 2, Item 3) at condenser fan box (Figure 2, Item 4) and tighten fitting nut (Figure 2, Item 2).

0252-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CHASSIS A/C HOSES INSTALLATION - Continued
1 2 3

M1097JCH

Figure 3. Chassis A/C Hoses Removal Replacement. 4. Toward front of vehicle, connect two A/C hoses (Figure 4, Items 3 and 4) to A/C compressor (Figure 4, Item 1) and tighten two fitting nuts (Figure 4, Item 2).

1

2

3

4

M1095JCH

Figure 4. 5.

Chassis A/C Hoses Installation.

Install transmission access covers (WP 0175).

END OF TASK

0252-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB REAR A/C HOSE REMOVAL

NOTE
Perform the following steps for short A/C hose at outside rear of cab. 1. Remove ten screws (Figure 5, Item 2) and separate cover (Figure 5, Item 3) assembly from condenser fan box (Figure 5, Item 1).

1

2

3

M1098JCH

Figure 5. Cab Rear A/C Hose Removal.

0252-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB REAR A/C HOSE REMOVAL - Continued

CAUTION
Water and dirt can damage refrigerant system. Refrigerant lines should be capped after disconnection to avoid contamination. 2. Loosen fitting nut (Figure 6, Item 3) and disconnect A/C hose (Figure 6, Item 2) from receiver/dryer (Figure 6, Item 1).

3

2

1

M1099JCH

Figure 6.

Cab Rear A/C Hose Removal.

0252-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB REAR A/C HOSE REMOVAL - Continued

NOTE
Remove and discard tiedown straps as necessary. 3. 4. Loosen fitting nut (Figure 7, Item 2) and disconnect other end of A/C hose (Figure 7, Item 3) from fitting (Figure 7, Item 1) at cab interface at rear of cab. Remove A/C hose (Figure 7, Item 3) from rear of cab.
1 2 3

M1100JCH

Figure 7. Cab Rear A/C Hose Replacement. END OF TASK

0252-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB REAR A/C HOSE INSTALLATION 1. 2. 3. 4. 5. Position A/C hose (Figure 7, Item 3) at rear of cab. Connect A/C hose (Figure 7, Item 3) to fitting (Figure 7, Item 1) at cab interface at rear of cab and tighten fitting nut (Figure 7, Item 2). Replace receiver/dryer (WP 0254). Connect other end of A/C hose (Figure 6, Item 2) to receiver/dryer (Figure 6, Item 1) and tighten fitting nut (Figure 6, Item 3). Close cover (Figure 8, Item 2) assembly and install ten screws (Figure 8, Item 1).

1

2

M1101JCH

Figure 8. END OF TASK

Cab Rear A/C Hose Installation.

0252-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES REMOVAL

NOTE
Perform the following steps to remove A/C hoses between cab heater and A/C unit and rear of cab. 1. Remove four screws (Figure 9, Item 1), washers (Figure 9, Item 2), and lower panel (Figure 9, Item 3) from cab.
1,2 3

M1102JCH

Figure 9. Cab Interior A/C Hoses Removal.

CAUTION
Water and dirt can damage refrigerant system. Refrigerant lines should be capped after disconnection to avoid contamination 2. Loosen two fitting nuts (Figure 10, Item 2) and disconnect two A/C hoses (Figure 10, Items 3 and 4) from expansion valve (Figure 10, Item 1).

0252-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES REMOVAL - Continued

1

2

3

4

M1103JCH

Figure 10. 3.

Cab Interior A/C Hoses Removal.

Remove fourteen screws (Figure 11, Item 2) and three access covers (Figure 11, Item 1) from right side of cab.
1

2

1

2

M1104JCH

Figure 11.

Cab Interior A/C Hoses Removal.

0252-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES REMOVAL - Continued 4. Lift and remove right access cover (Figure 12, Item 1) and middle access cover (Figure 12, Item 2) from rear of cab.

1

2

M1105JCH

Figure 12. Cab Interior A/C Hoses Removal.

0252-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES REMOVAL - Continued 5. 6. At cab interface behind cab, loosen two fitting nuts (Figure 13, Items 2 and 3) and disconnect two A/C hoses (Figure 13, Items 4 and 5) from two fittings (Figure 13, Items 6 and 7). Remove two jamnuts (Figure 13, Item 1) and push two fittings (Figure 13, Items 6 and 7) into cab.
1 2 3 4 5

7

6

1

M1106JCH

Figure 13.

Cab Interior A/C Hoses Removal.

0252-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES REMOVAL - Continued 7. 8. At inside rear of cab, loosen two fitting nuts (Figure 14, Item 3) and disconnect two A/C hoses (Figure 14, Items 4 and 5) from two fittings (Figure 14, Items 1 and 2). Set fittings aside. Remove two A/C hoses (Figure 14, Items 4 and 5) from cab.

1,2

3

4

5

M1107JCH

Figure 14. Cab Interior A/C Hoses Replacement. END OF TASK

0252-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES INSTALLATION 1. 2. 3. 4. 5. 6. Position two A/C hoses (Figure 14, Items 4 and 5) in cab. At inside rear of cab, connect two A/C hoses (Figure 14, Items 4 and 5) to two fittings (Figure 14, Items 1 and 2) and tighten two fitting nuts (Figure 14, Item 3). Push two fittings (Figure 14, Items 1 and 2), with two A/C hoses (Figure 14, Items 4 and 5) attached, out of cab. Install two jamnuts (Figure 13, Item 1) and connect two A/C hoses (Figure 13, Items 2 and 3) to two fittings (Figure 13, Items 4 and 5) and tighten two fitting nuts (Figure 13, Items 7 and 6). Install middle access cover (Figure 12, Item 2) and right access cover (Figure 12, Item 1) in rear of cab. Install three access covers (Figure 15, Item 1) on right side of cab with 14 screws (Figure 15, Item 2)
1

2

1

2

M1104JCH

Figure 15.

Cab Interior A/C Hoses Installation.

0252-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES INSTALLATION - Continued 7. Connect two A/C hoses (Figure 16, Items 3 and 4) to expansion valve (Figure 16, Item 1) and tighten two fitting nuts (Figure 16, Item 2).

1,2

3

4

5

M1107JCH

Figure 16.

Cab Interior A/C Hoses Installation.

0252-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0252

CAB INTERIOR A/C HOSES INSTALLATION - Continued 8. Install lower panel (Figure 17, Item 3) to cab with four washers (Figure 17, Item 2) and screws (Figure 17, Item 1).
1,2 3

M1108JCH

Figure 17. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Replace receiver/dryer (WP 0254). Charge A/C system (WP 0248).

Cab Interior A/C Hoses Installation.

END OF TASK END OF WORK PACKAGE

0252-15/16 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00226)

TM 10-3930-675-23-2

0253

FIELD MAINTENANCE AIR CONDITIONER CONDENSER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Washer, Lock (WP 0278, Table 1, Item 118) Qty: 4 References WP 0248 WP 0254

REMOVAL 1. 2. Recover A/C system refrigerant (WP 0248). Remove ten screws (Figure 1, Item 2) and separate cover (Figure 1, Item 3) assembly from condenser fan box (Figure 1, Item 1).
1 2 3

M1109JCH

Figure 1. Air Conditioner Condenser Removal.

0253-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00227)

TM 10-3930-675-23-2

0253

REMOVAL - Continued

CAUTION
• Water and dirt can damage refrigerant system. Refrigerant lines should be capped after disconnection to avoid contamination. • Use two wrenches when loosening fitting nut to avoid twisting condenser tube. 3. From outside condenser fan box (Figure 2, Item 4), loosen fitting nut (Figure 2, Item 2) and disconnect A/C hose (Figure 2, Item 1) from condenser (Figure 2, Item 3).
1 2 3 4

M1110JCH

Figure 2. Air Conditioner Condenser Removal. 4. 5. 6. From inside condenser fan box (Figure 3, Item 1), loosen fitting nut (Figure 3, Item 4) and disconnect tube (Figure 3, Item 5) from receiver/dryer (Figure 3, Item 8). Remove pressure switch (Figure 3, Item 7) from condenser (Figure 3, Item 6). Remove four screws (Figure 3, Item 2), lockwashers (Figure 3, Item 3), and condenser (Figure 3, Item 6) from condenser fan box (Figure 3, Item 1). Discard lockwashers.

NOTE
Any time A/C system refrigerant is evacuated, replace receiver/dryer. 7. Remove receiver/dryer (Figure 3, Item 8) (WP 0254).

END OF TASK

0253-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00227)

TM 10-3930-675-23-2

0253

INSTALLATION 1. 2. 3. 4. 5. 6. Install receiver/dryer (Figure 3, Item 8) (WP 0254). Install condenser (Figure 3, Item 6) in condenser fan box (Figure 3, Item 1) with four screws (Figure 3, Item 2) and new lockwashers (Figure 3, Item 3). Install pressure switch (Figure 3, Item 7). Connect tube (Figure 3, Item 5) to receiver/dryer (Figure 3, Item 8) and tighten fitting nut (Figure 3, Item 4). Outside condenser fan box (Figure 2, Item 4), connect A/C hose (Figure 2, Item 1) to condenser (Figure 2, Item 3) and tighten fitting nut (Figure 2, Item 2). Charge A/C system (WP 0248).
1 2,3 4 5 6

8

7

M1111JCH

Figure 3. Air Conditioner Condenser Replacement.

0253-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00227)

TM 10-3930-675-23-2

0253

INSTALLATION - Continued 7. Close cover (Figure 4, Item 2) assembly and install ten screws (Figure 4, Item 1).
1 2

M1112JCH

Figure 4. Air Conditioner Condenser Installation. END OF TASK END OF WORK PACKAGE

0253-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00227)

TM 10-3930-675-23-2

0254

FIELD MAINTENANCE AIR CONDITIONER RECEIVER/DRYER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) References WP 0248

REMOVAL 1. 2. Recover A/C system refrigerant (WP 0248). Remove ten screws (Figure 1, Item 2) and separate cover (Figure 1, Item 3) assembly from condenser fan box (Figure 1, Item 1).
1 2 3

M1113JCH

Figure 1. Air Conditioner Receiver/Dryer Removal.

0254-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00228)

TM 10-3930-675-23-2

0254

REMOVAL - Continued

CAUTION
Water and dirt can damage refrigerant system. Refrigerant lines and open ports should be capped after disconnection to avoid contamination. 3. 4. 5. From inside condenser fan box (Figure 2, Item 1), loosen fitting nut (Figure 2, Item 8) and disconnect A/C hose (Figure 2, Item 7) from receiver/dryer (Figure 2, Item 5). Loosen fitting nut (Figure 2, Item 2) to disconnect tube (Figure 2, Item 3) from receiver/dryer (Figure 2, Item 5). Remove two clamps (Figure 2, Item 4) and receiver/dryer (Figure 2, Item 5) from bracket (Figure 2, Item 6).
1 2 3

8

7

6

5

4
M1114JCH

Figure 2. END OF TASK

Air Conditioner Receiver/Dryer Replacement.

0254-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00228)

TM 10-3930-675-23-2

0254

INSTALLATION 1. 2. 3. 4. 5. Install receiver/dryer (Figure 2, Item 5) on bracket (Figure 2, Item 6) with two clamps (Figure 2, Item 4). Do not fully tighten clamps. Connect tube (Figure 2, Item 3) to receiver/dryer (Figure 2, Item 5) and tighten fitting nut (Figure 2, Item 2). Connect A/C hose (Figure 2, Item 7) to receiver/dryer (Figure 2, Item 5) and tighten fitting nut (Figure 2, Item 8). Tighten two clamps (Figure 2, Item 4). Charge A/C system (WP 0248). Close cover (Figure 3, Item 2) assembly and install ten screws (Figure 3, Item 1).
1

2

M1115JCH

Figure 3. Air Conditioner Receiver/Dryer Installation. END OF TASK END OF WORK PACKAGE

0254-3/4 blank

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TM 10-3930-675-23-2

0255

FIELD MAINTENANCE AIR CONDITIONER FANS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Materials/Parts (cont.) Nut, Self-Locking, Clinch (WP 0278, Table 1, Item 86) Qty: 6 Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 87) Qty: 8 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

AIR CONDITIONER FANS REMOVAL 1. Remove ten screws (Figure 1, Item 2) to free cover assembly (Figure 1, Item 3) from condenser fan box (Figure 1, Item 1).
1 2

3

M0641JCH

Figure 1. Condenser Fan Box Cover Removal.

0255-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00229)

TM 10-3930-675-23-2

0255

AIR CONDITIONER FANS REMOVAL - Continued

NOTE
• Perform steps 2 and 3 for each of two air conditioner fans. • Tag connectors for installation. • Remove tiedown straps as necessary. 2. 3. Disconnect air conditioner fan (Figure 2, Item 4) connector (Figure 2, Item 6) from fan wiring harness (Figure 2, Item 7). Remove four locknuts (Figure 2, Item 1), eight washers (Figure 2, Item 2), four screws (Figure 2, Item 3), and air conditioner fan (Figure 2, Item 4) from cover (Figure 2, Item 5). Discard locknuts.

END OF TASK AIR CONDITIONER FANS INSTALLATION

NOTE
Perform steps 1 and 2 for each of two air conditioner fans. 1. 2. Install air conditioner fan (Figure 2, Item 4) on cover (Figure 2, Item 5) with four screws (Figure 2, Item 3), eight washers (Figure 2, Item 2), and four new locknuts (Figure 2, Item 1). Connect connector (Figure 2, Item 6) of air conditioner fan (Figure 2, Item 4) to fan wiring harness (Figure 2, Item 7). Install new tiedown straps.
5 1,2,3 4 6

7

M0642JCH

Figure 2.

Air Conditioner Fan Replacement.

0255-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00229)

TM 10-3930-675-23-2

0255

AIR CONDITIONER FANS INSTALLATION - Continued 3. Position cover (Figure 3, Item 3) assembly on condenser fan box (Figure 3, Item 1) and install ten screws (Figure 3, Item 2).

END OF TASK RELAYS AND RESISTORS REMOVAL 1. Remove ten screws (Figure 3, Item 2) to free cover assembly (Figure 3, Item 3) from condenser fan box (Figure 3, Item 1).
1 2

3

M0643JCH

Figure 3.

Condenser Fan Box Cover.

0255-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00229)

TM 10-3930-675-23-2

0255

RELAYS AND RESISTORS REMOVAL - Continued

NOTE
Perform steps 2 and 3 to remove two fan relays. 2. 3. Remove two relays (Figure 4, Item 2) from terminal blocks (Figure 4, Item 6) of fan wiring harness (Figure 4, Item 7). Remove two locknuts (Figure 4, Item 3), washers (Figure 4, Item 4), screws (Figure 4, Item 5), and terminal blocks (Figure 4, Item 6) from cover (Figure 4, Item 1). Discard locknuts.
1 2 3,4,5

6

7

M0644JCH

Figure 4. Relays Replacement. 4. 5. Disconnect two connectors (Figure 5, Item 6) of fan wiring harness (Figure 5, Item 7) from resistor (Figure 5, Item 5). Remove two locknuts (Figure 5, Item 2), washers (Figure 5, Item 3), screws (Figure 5, Item 4), and resistor (Figure 5, Item 5) from cover (Figure 5, Item 1). Discard locknuts.

END OF TASK

0255-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00229)

TM 10-3930-675-23-2

0255

RELAYS AND RESISTORS INSTALLATION

NOTE
Perform steps 1 and 2 to install each of two resistors. 1. 2. Install resistor (Figure 5, Item 5) on cover (Figure 5, Item 1) with two screws (Figure 5, Item 4), washers (Figure 5, Item 3), and new locknuts (Figure 5, Item 2). Connect two connectors (Figure 5, Item 6) of fan wiring harness (Figure 5, Item 7) to resistor (Figure 5, Item 5).

NOTE
Perform steps 3 and 4 to install two fan relays. 3. 4. Install terminal blocks (Figure 4, Item 6) of fan wiring harness (Figure 4, Item 7) on cover (Figure 4, Item 1) with two screws (Figure 4, Item 5), washers (Figure 4, Item 4), and new locknuts (Figure 4, Item 3). Install two relays (Figure 4, Item 2) on terminal blocks (Figure 4, Item 6).
1 2,3,4 5 6 7

M0645JCH

Figure 5.

Resistors Replacement.

0255-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00229)

TM 10-3930-675-23-2

0255

RELAYS AND RESISTORS INSTALLATION - Continued 5. Install cover (Figure 6, Item 3) assembly on condenser fan box (Figure 6, Item 1) and install ten screws (Figure 6, Item 2).
1 2

3

M0646JCH

Figure 6. END OF TASK END OF WORK PACKAGE

Condenser Fan Box Cover Installation.

0255-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00229)

TM 10-3930-675-23-2

0256

FIELD MAINTENANCE BOOM ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (WP 0277, Table 1, Item 66) Sling, Engine and Transmission (WP 0277, Table 1, Item 68) Wrench, Adjustable, Automotive, 15 Inch (WP 0277, Table 1, Item 88) Lifting Device (30,000 lbs minimum capacity) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Tag, Marker (WP 0276, Table 1, Item 66) Washer, Lock (WP 0278, Table 1, Item 118) Personnel Required (3) References Volume 1, WP 0097 References (cont.) Volume 1, WP 0098 Volume 1, WP 0107 Volume 1, WP 0110 Volume 1, WP 0115 Volume 1, WP 0121 Volume 1, WP 0122 Volume 1, WP 0123 WP 0177 WP 0204 WP 0208 WP 0220 WP 0224 WP 0227 WP 0231 WP 0237 WP 0257 WP 0268 WP 0271 WP 0278 Equipment Condition RTCH parked on level ground (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Wheels chocked (TM 10-3930-675-10) Tophandler removed (WP 0259)

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

NOTE
Boom assembly weighs 20,486 lb (9,300 kg).

0256-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00230)

TM 10-3930-675-23-2

0256

REMOVAL 1. Fully retract boom (TM 10-3930-675-10) and relieve hydraulic system pressure (WP 0204).

NOTE
Use a jeweler’s screwdriver to disconnect electrical leads from boom junction box. 2. 3. 4. 5. 6. 7. Remove boom angle sensor (Volume 1, WP 0121). Remove boom extension sensor (Volume 1, WP 0122). Remove sensor cable from attachment to boom assembly (Figure 1, Item 8) and from boom junction box (Figure 1, Item 7). Discard tiedown straps removed. Disconnect electrical leads of wiring harness (Figure 1, Item 6) from boom junction box (Figure 1, Item 7). Disconnect boom wiring harnesses (Figure 1, Item 5) from two connectors (Figure 1, Item 4). Remove wiring harnesses (Figure 1, Items 2 and 6) from attachment to boom assembly (Figure 1, Item 8). Discard tiedown straps removed. Place a drain pan under hydraulic hoses (Figure 1, Item 1) to catch any spillage. Disconnect hydraulic hoses from hydraulic pipes (WP 0224). Remove hydraulic hoses from attachment to boom assembly (Figure 1, Item 8).
2 1 3 4

5 8

7
M1036JCH

6

4

Figure 1. Boom Assembly Removal.

0256-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00230)

TM 10-3930-675-23-2

0256

REMOVAL - Continued 8. Place a drain pan to catch any spillage, disconnect hydraulic hoses from extension cylinder (WP 0220).

NOTE
With boom fully retracted, boom assembly’s center of gravity is 142 in. (360.6 cm), as measured forward from center of pivot shaft that attaches boom assembly to boom support. 9. 10. 11. 12. Sling boom assembly, using two suitable lifting devices. Attach slings to lifting eyes at each end of boom assembly (Figure 2, Item 1). Take up slack in slings. Remove lift cylinders from boom assembly (Figure 2, Item 1) and rest cylinders on blocks of wood on frame (WP 0231). Remove screw (Figure 2, Item 4) and lockwasher (Figure 2, Item 5) from each side of boom support (Figure 2, Item 2). Discard lockwashers. Lubricate two jackscrews with lubricating oil and install into ear of each pivot shaft (Figure 2, Item 3).

CAUTION
To avoid binding pivot shaft, screw in jackscrews equally and alternately. 13. Screw in jackscrews approximately 8 in. (20.3 cm) to withdraw each pivot shaft (Figure 2, Item 3) until boom assembly (Figure 2, Item 1) is free of boom support (Figure 2, Item 2).

1

M1037JCH

4,5

3

2

Figure 2.

Boom Assembly Removal.

0256-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00230)

TM 10-3930-675-23-2

0256

REMOVAL - Continued

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

CAUTION
Use caution when lifting boom assembly. Ensure boom assembly clears vehicle and does not contact electrical or hydraulic components. Failure to follow this caution may cause damage to components on boom assembly or damage to vehicle. 14. 15. Ensure all disconnected electrical and hydraulic lines are secured away. Lift boom assembly (Figure 2, Item 1) from vehicle and remove. Place boom assembly on suitable cribbing as required. As required, remove these components from boom assembly (Figure 2, Item 1) to be installed on replacement boom assembly: a. b. c. d. e. f. g. h. Work lights (Volume 1, WP 0110) and IR lights (Volume 1, WP 0115). Boom wiring harnesses (Volume 1, WP 0107). Boom junction box (Volume 1, WP 0098). Hydraulic hoses, pipes, and fittings (WP 0220). Boom-to-boom extension flexible conveyor (WP 0177). Tophandler tilt cylinders (WP 0237). Tophandler junction box with twistlock indicator lights (Volume 1, WP 0097). Tophandler angle sensor (Volume 1, WP 0123).

END OF TASK

0256-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00230)

TM 10-3930-675-23-2

0256

INSTALLATION

NOTE
Refer to General Maintenance Instructions (WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 1. If removed, install these components on replacement boom assembly (Figure 3, Item 1). a. b. c. d. e. f. g. h. Work lights (Volume 1, WP 0110) and IR lights (Volume 1, WP 0115). Boom wiring harnesses (Volume 1, WP 0107). Boom junction box (Volume 1, WP 0098). Hydraulic hoses, pipes, and fittings (WP 0220). Boom-to-boom extension flexible conveyer (WP 0177). Tophandler tilt cylinders (WP 0237). Tophandler junction box with twistlock indicator lights (Volume 1, WP 0097). Tophandler angle sensor (Volume 1, WP 0123).

NOTE
With boom fully retracted, boom assembly’s center of gravity is 142 in. (360.6 cm), as measured forward from center of pivot shaft that attaches boom assembly to boom support. 2. Sling boom assembly, using two suitable lifting devices. Attach slings to lifting eyes at each end of boom assembly (Figure 3, Item 1). Take up slack in slings.

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel.

CAUTION
Use caution when lifting boom assembly. Ensure boom assembly clears vehicle and does not contact electrical or hydraulic components. Failure to follow this caution may cause damage to components on boom assembly or damage to vehicle. 3. Lift boom assembly and position at vehicle.

0256-5

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TM 10-3930-675-23-2

0256

INSTALLATION - Continued 4. Lower boom assembly (Figure 3, Item 1) and position into boom support (Figure 3, Item 2), while aligning pivot shaft holes in boom assembly with holes in boom support.

NOTE
• Ensure pivot shafts are clean and free of burrs. • When installing pivot shafts, slot in pivot shaft for retaining screw must be aligned with screw hole in boom assembly. • Covers may be removed to aid in alignment of pivot shafts. 5. Install pivot shaft (Figure 3, Item 3) on each side of boom support (Figure 3, Item 2). Secure with new lockwasher (Figure 3, Item 5) and screw (Figure 3, Item 4).

1

M1037JCH

4,5

3

2

Figure 3. 6. 7. 8. 9. 10. 11.

Boom Assembly Installation.

Connect lift cylinders to boom assembly (WP 0231). Remove lifting devices from boom assembly (Figure 4, Item 1). Connect hydraulic hoses to extension cylinder (WP 0208). Connect hydraulic hoses (Figure 4, Item 1) to hydraulic pipes (Figure 4, Item 3) (WP 0268). Secure hydraulic hoses to boom assembly (Figure 4, Item 8). Secure wiring harnesses (Figure 4, Items 2 and 6) to boom assembly (Figure 4, Item 8) with new tiedown straps. Connect boom wiring harnesses (Figure 4, Item 5) to two connectors (Figure 4, Item 4).

NOTE
Use a jeweler’s screwdriver to connect electrical leads to boom junction box. 12. Connect electrical leads of wiring harnesses (Figure 4, Item 6) to boom junction box (Figure 4, Item 7).

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TM 10-3930-675-23-2

0256

INSTALLATION - Continued 13. 14. 15. Install boom extension sensor (Volume 1, WP 0122). Connect sensor cable to boom junction box (Figure 4, Item 7) and secure cable to boom assembly (Figure 4, Item 8) with new tiedown straps. Install boom angle sensor (Volume 1, WP 0121). Lubricate pivot shafts (LO 10-3930-675-13).
2 1 3 4

5 8

7
M1036JCH

6

4

Figure 4. END OF TASK

Boom Assembly Installation.

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TM 10-3930-675-23-2

0256

FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Install tophandler (WP 0259). Check the oil level in hydraulic reservoir (LO 10-3930-675-13). Perform Boom and Tophandler Calibration (WP 0257). Check operation of boom assembly and tophandler (TM 10-2920-675-10). Recheck oil level in hydraulic reservoir (LO 10-3930-675-13).

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 6. 7. 8. Perform Load Testing Procedure (WP 0271). Set parking brake (TM 10-3930-675-10). Remove wheel chocks.

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-2

0257

FIELD MAINTENANCE BOOM AND TOPHANDLER CALIBRATION

INITIAL SETUP: References TM 10-3930-675-10

NOTE
• RTCH must be parked on level ground with all wheels pointing straight ahead. • When calibrating the boom and tophandler, perform all ten calibration steps in order. DO NOT skip or omit any steps. CALIBRATION 1. Access to Calibration Menus. a. b. c. Turn master battery switch to ON position (TM 10-3930-675-10). Turn ignition switch ON and start vehicle (TM 10-3930-675-10). Select Kalmar service menu on driver’s Electronic Control System (ECS) display screen and press “Enter".

NOTE
If boom or tophandler angle sensors have been removed or are being replaced, steps d thru f must be performed prior to calibration. d. e. Ensure boom and tophandler are level with ground. Enter diagnostic menus, select DIAG SERVO menu, and scroll down to display 7 (13). Note angle sensor voltage reading. Enter diagnostic menus, select DIAG ATTACHMENT menu, and scroll down to display 2 (16). Note tophandler angle sensor voltage reading. Loosen setscrew securing angle sensor lever to shaft. Rotate sensor shaft until voltage reading is between 7V and 8V (boom angle sensor) or 4V (tophandler angle sensor). Retighten setscrew and recheck voltage reading. Enter calibration program access number “13221". Press right arrow button to locate “CALIBR SERVO" menu, then press “Enter".

f.

g. h.

0257-1

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 2. Boom Calibration, Boom Angle, Lowered Position (Menu 1 of 10). a. b. c. Boom fully lowered, fully retracted, and tophandler level with ground. Allow ECS display to stabilize, then press “Enter". ECS display screen should look as shown in Table 1. Table 1. CALIBR SERVO LOWER MINIMUM BOOM ANGLE Range 600-800. 1 (10) XXX XXX

M1040JCH

Figure 1. Boom and Tophandler Calibration. d. 3. Press right arrow button to advance through remaining calibration menus.

Boom Calibration, Tophandler Tilt Position (Menu 2 of 10). a. b. c. Boom fully lowered, fully retracted, and tophandler level with the ground. Allow ECS display to stabilize, then press “Enter". ECS display screen should look as shown in Table 2. Table 2. CALIBR SERVO LOWER MINIMUM TILT ANGEL Range 200-400. 2 (10) XXX XXX

M1040JCH

Figure 2. Boom and Tophandler Calibration. d. Press right arrow button to advance through remaining calibration menus.

0257-2

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 4. Boom Calibration, Boom Angle, Raised Position (Menu 3 of 10). a. b. c. Raise boom to maximum height, fully retracted, and with tophandler level with ground. Allow ECS display to stabilize, then press “Enter". ECS display screen should look as shown in Table 3. Table 3. CALIBR SERVO LIFT MAXIMUM BOOM ANGEL Range 200-400. 3 (10) XXX XXX

M1040JCH

Figure 3. d.

Boom and Tophandler Calibration.

Press right arrow button to advance through remaining calibration menus.

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 5. Boom Calibration, Tophandler Tilt Angle (Boom in Raised Position) (Menu 4 of 10). a. b. c. Raise boom to maximum height, fully retracted, and tophandler level with ground. Allow ECS display to stabilize, then press “Enter". ECS display screen should look as shown in Table 4. Table 4. CALIBR SERVO LIFT MAXIMUM TILT ANGEL Range 600-800. 4 (10) XXX XXX

M1041JCH

Figure 4. Boom and Tophandler Calibration. d. Press right arrow button to advance through remaining calibration menus.

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 6. Boom Calibration, Retracted Position (Menu 5 of 10). a. b. c. Raise boom to maximum height, fully retracted, and tophandler level with ground. Allow ECS display to stabilize, then press “Enter". ECS display screen should look as shown in Table 5. Table 5. CALIBR SERVO BOOM MIN EXTENSION Range 35-150. 5 (10) XXX XXX

M1041JCH

Figure 5. d.

Boom and Tophandler Calibration.

Press right arrow button to advance through remaining calibration menus.

0257-5

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 7. Boom Calibration, Extended Position (Menu 6 of 10). a. b. c. Raise boom to maximum height, fully extended, and tophandler level with ground. Allow ECS display to stabilize, then press “Enter". ECS display screen should look as shown in Table 6. Table 6. CALIBR SERVO BOOM MIN EXTENSION Range 400-550. 6 (10) XXX XXX

M1042JCH

Figure 6. Boom and Tophandler Calibration. d. Press right arrow button to advance through remaining calibration menus.

0257-6

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 8. Boom Calibration, Boom Cylinders (Retracted) (Menu 7 of 10). a. b. c. d. Boom fully lowered, fully retracted, and tophandler level with ground. Raise boom 1/4-in. (0.64 cm) to pressurize boom cylinders, then release joystick. DO NOT reposition or move joystick again until procedure is completed. The last movement of the boom must be “UP." Allow system and ECS display to stabilize (10 to 20 seconds), then press “Enter". ECS display screen should look as shown in Table 7. Table 7. CALIBR SERVO INIT BY MIN LOAD LE XXX XXX Range 500-650. 7 (10) RIXXX XXX

M1040JCH

Figure 7. e.

Boom and Tophandler Calibration.

Press right arrow button to advance through remaining calibration menus.

0257-7

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 9. Boom Calibration, Boom Cylinders (Extended) (Menu 8 of 10). a. b. c. d. Boom fully lowered, fully extended, and tophandler level with ground. Raise boom 1/4-in. (0.64 cm) to pressurize lift cylinders, then release joystick. DO NOT reposition or move joystick again until procedure is completed. The last movement of the boom must be “UP." Allow system and ECS display to stabilize (10 to 20 seconds), then press “Enter". ECS display screen should look as shown in Table 8. Table 8. CALIBR SERVO INIT BY MIN LOAD LE XXX XXX Range 800-950. 8 (10) RIXXX XXX

M1043JCH

Figure 8. Boom and Tophandler Calibration. e. 10. Press right arrow button to advance through remaining calibration menus

Boom Calibration, Load Check (Menu 9 of 10). a. b. c. d. e. Boom fully retracted and raise 1 in. (2.5 cm). Check ECS display. Actual Load should read “0-100" kg. Raise and extend boom 6-12 in. Actual Load reading should return to “0-100" kg after stabilizing. Tilt tophandler out 2-4 degrees. Actual Load reading should return to “0-100" kg after stabilizing. ECS display screen should look as shown in Table 9. Table 9. CALIBR SERVO ALLOWED LOAD ACTUAL LOAD L-LC f. Load Check. 9 (10) Kg Kg M

Press right arrow button to advance to remaining calibration menu.

0257-8

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TM 10-3930-675-23-2

0257

CALIBRATION - Continued 11. Boom Calibration Completed (Menu 10 of 10). a. b. c. With all calibration steps completed and corrections or adjustments made, press “Enter" to return to main menu. ECS display screen should look as shown. Turn off engine, wait 1 minute, and restart to save data. Table 10. Boom Calibration Completed. 10 (10) DONE

CALIBR SERVO CALIBRATION OF EL SERVO 12. Boom Calibration Verification a. b. c.

Operate twistlocks while activating override switch to the locked position (TM 10-3930-675-10). Raise and extend the boom 60-72 in. and check for weights to settle to 0 lb. If weight does not settle to 0 lb within 10 to 20 seconds after repositioning boom, repeat calibration procedure.

END OF TASK END OF WORK PACKAGE

0257-9/10 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00231)

TM 10-3930-675-23-2

0258

FIELD MAINTENANCE BOOM ASSEMBLY WEAR PLATES (SLIDE PLATE) REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 Inch Drive, 75 lb-ft (WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Washer, Lock (WP 0278, Table 1, Item 118) Qty: 6 Personnel Required (2) References Volume 1, WP 0122 WP 0270 Equipment Condition Boom and tophandler loaded in transport position (TM 10-3930-675-10)

NOTE
After initial 100 hours of RTCH operation, torque of boom assembly wear plates must be checked.

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TM 10-3930-675-23-2

0258

GENERAL 1. 2. 3. 4. 5. 6. 7. Wear plates are used on the boom assembly between sliding components as opposed to using lubrication grease and grease fittings. Spacer blocks and spacers are used with boom wear plates and need to be replaced to maintain proper spacing between boom sliding assemblies. Wear plates are inspected at semi-annual intervals and must be maintained in good working order for the boom assembly to function properly. There are three styles of wear plates used on the boom assembly: A, B, and C. One wear plate for each style is replaced in this work package. Appropriate notes and access procedures are included for removal and replacement of each style wear plate as applicable. The fixed boom uses four style A wear plates at the front. The extending boom uses four style A wear plates at the rear. An illustration is provided below to aid in identifying location and style of each wear plate.
A

B C AND D

B

A

REAR

B FRONT

M0419JCH

Figure 1. END OF TASK

Boom Wear Plates Locations.

0258-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE A WEAR PLATE REMOVAL

NOTE
• Replace style A wear plates one at a time to maintain distance relationship. • Rear wear plate is illustrated. 1. 2. 3. Retract boom to access rear wear plates (TM 10-3930-675-10). Remove boom access cover (Volume 1, WP 0122). Remove six screws (Figure 2, Item 1), lockwashers (Figure 2, Item 2), and cover plate (Figure 2, Item 3). Discard lockwashers.
1 2 1 2

3

2

1

2

1

M0420JCH

Figure 2.

Style A Wear Plate Removal.

0258-3

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TM 10-3930-675-23-2

0258

STYLE A WEAR PLATE REMOVAL - Continued

NOTE
Ensure spacers are tagged or marked for location. Spacers must be reinstalled in same location to maintain boom spacing. 4. 5. Remove spacers (Figure 3, Item 1) and wear plate (Figure 3, Item 2). Measure wear plate thickness. Measurement must be a minimum of 1 in. (25.4 cm). If wear plate is not as specified, replace wear plate.
1 2

M0421JCH

Figure 3. Style A Wear Plate Removal. END OF TASK

0258-4

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TM 10-3930-675-23-2

0258

STYLE A WEAR PLATE INSTALLATION 1. Install wear plate (Figure 4, Item 2) and spacers (Figure 4, Item 1) as noted in removal.
1

2

M0422JCH

Figure 4.

Style A Wear Plate Installation.

0258-5

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TM 10-3930-675-23-2

0258

STYLE A WEAR PLATE INSTALLATION - Continued 2. Install cover (Figure 5, Item 1) with six screws (Figure 5, Item 5) and new lockwashers (Figure 5, Item 4).

NOTE
Spacing between extending boom (Figure 5, Item 2) and fixed boom (Figure 5, Item 3) should be as even as possible. Add or remove spacers as necessary to maintain even spacing. 3. 4. 5. 6. Check spacing between wear plate and contact surface. Spacing must be 0.078 in. (1.98 mm). If not within specifications, remove cover and add or subtract spacers to adjust wear plate spacing. Tighten all screws in accordance with Torque Limits (WP 0270). Perform operational check of boom assembly (TM 10-3930-675-10). Install boom access cover (Volume 1, WP 0122).
1 2

3

5

4

M0423JCH

Figure 5. Style A Wear Plate Installation. END OF TASK

0258-6

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TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE REMOVAL 1. 2. Measure thickness of wear plate. Measurement should be not less than 9/16 in. (14.29 mm). If wear plate is not as specified, replace wear plate. To remove style B wear plates from fixed boom lower front location:

NOTE
Extend boom and support tophandler on cribbing to relieve weight on lower front wear plates. a. Remove two screws (Figure 6, Item 3), lockwashers (Figure 6, Item 2), and lock plate (Figure 6, Item 1). Discard lockwashers.

1

3

2

M0424JCH

Figure 6.

Style B Wear Plate Removal.

0258-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE REMOVAL - Continued b. c. Remove three screws (Figure 7, Item 3) and washers (Figure 7, Item 4) securing wear plate (Figure 7, Item 5). Remove shims (Figure 7, Item 6) and wear plate (Figure 7, Item 5) from extending boom (Figure 7, Item 1) and fixed boom (Figure 7, Item 2).
1 2

5,6

3,4

M0425JCH

Figure 7. Style B Wear Plate Removal.

0258-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE REMOVAL - Continued 3. To remove style B wear plates from extending boom upper rear location:

NOTE
Retract boom and support tophandler on cribbing to relieve weight on upper rear wear plates. a. Remove two screws (Figure 8, Item 3), lockwashers (Figure 8, Item 1), and lock plate (Figure 8, Item 2) from fixed boom (Figure 8, Item 5) and extending boom (Figure 8, Item 4). Discard lockwashers.
1 2

5

4

3

M0426JCH

Figure 8.

Style B Wear Plate Removal.

0258-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE REMOVAL - Continued b. Remove three screws (Figure 9, Item 1) and washers (Figure 9, Item 2) securing wear plate.
1,2

M0427JCH

Figure 9. Style B Wear Plate Removal.

0258-10

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TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE REMOVAL - Continued c. Remove shims (Figure 10, Item 4) and wear plate (Figure 10, Item 2) from between extending boom (Figure 10, Item 3) and fixed boom (Figure 10, Item 1).
1 2

3

4

M0428JCH

Figure 10. END OF TASK

Style B Wear Plate Removal.

0258-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE INSTALLATION 1. To install style B wear plates on fixed boom lower front location:

NOTE
Extend boom (Figure 11, Item 1) and support tophandler on cribbing to relieve weight on lower front wear plates. a. b. Install shims (Figure 11, Item 6) and wear plate (Figure 11, Item 5) and align holes in wear plate with holes in bottom of fixed boom (Figure 11, Item 2). Install and tighten three screws (Figure 11, Item 3) and washers (Figure 11, Item 4) in accordance with Torque Limits (WP 0270).
1 2

5,6

3,4

M0429JCH

Figure 11. Style B Wear Plate Installation.

0258-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE INSTALLATION - Continued c. d. e. Install lock plate (Figure 12, Item 1), two new lockwashers (Figure 12, Item 2), and screws (Figure 12, Item 3). Tighten screws (Figure 12, Item 3) in accordance with Torque Limits (WP 0270). Perform operational check of boom assembly (TM 10-3930-675-10).

1

3

2

M0430JCH

Figure 12.

Style B Wear Plate Installation.

0258-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE INSTALLATION - Continued 2. To install style B wear plates on extending boom upper rear location:

NOTE
Retract boom and support tophandler on cribbing to relieve weight on rear wear plates. a. Install shims (Figure 13, Item 4) and wear plate (Figure 13, Item 2) between extending boom (Figure 13, Item 3) and fixed boom (Figure 13, Item 1) and align holes in wear plate with holes in top of extending boom (Figure 13, Item 3).
1 2

3

4

M0431JCH

Figure 13. Style B Wear Plate Installation.

0258-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE INSTALLATION - Continued b. Install and tighten three screws (Figure 14, Item 1) and washers (Figure 14, Item 2) in accordance with Torque Limits (WP 0270).
1,2

M0432JCH

Figure 14.

Style B Wear Plate Installation.

0258-15

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TM 10-3930-675-23-2

0258

STYLE B WEAR PLATE INSTALLATION - Continued c. d. e. Install lock plate (Figure 15, Item 3), two new lockwashers (Figure 15, Item 2), and screws (Figure 15, Item 4) between fixed boom (Figure 15, Item 1) and extending boom (Figure 15, Item 5). Tighten screws (Figure 15, Item 4) in accordance with Torque Limits (WP 0270). Perform operational check of boom assembly (TM 10-3930-675-10).
1 2 3

5

4

M0433JCH

Figure 15. Style B Wear Plate Installation. END OF TASK

0258-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE C (RT 240V1 and RT 240V1R) WEAR PLATE REMOVAL

NOTE
Extend boom, if necessary, and allow tophandler to hang unsupported. 1. 2. Remove two screws (Figure 16, Item 3) and washers (Figure 16, Item 4) securing each of two spacer plates (Figure 16, Item 5). Slide spacer plate (Figure 16, Item 5) from between fixed boom (Figure 16, Item 2) and extending boom (Figure 16, Item 1).

END OF TASK STYLE C (RT 240V1 and RT 240V1R) WEAR PLATE INSTALLATION 1. 2. Install each of two spacer plates (Figure 16, Item 5) from between fixed boom (Figure 16, Item 2) and extending boom (Figure 16, Item 1). Align holes in wear plate with holes in top of fixed boom. Install and tighten two screws (Figure 16, Item 3) and washers (Figure 16, Item 4) in accordance with Torque Limits (WP 0270).
1 2

3,4

5

M0434JCH

Figure 16. Style C (RT 240V1 and RT 240V1R) Wear Plate Replacement. END OF TASK

0258-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00232)

TM 10-3930-675-23-2

0258

STYLE D (RT 240V2 and RT 240V3 ONLY) WEAR PLATE REMOVAL 1. 2. Remove four capscrews (Figure 17, Item 1) and washers (Figure 17, Item 2) from slide plate (Figure 17, Item 3) and retainer (Figure 17, Item 4). Slide retainer (Figure 17, Item 4) and slide plate (Figure 17, Item 3) out from between inner boom (Figure 17, Item 5) and outer boom (Figure 17, Item 6).

END OF TASK STYLE D (RT 240V2 and RT 240V3 ONLY) WEAR PLATE INSTALLATION 1. 2. Slide retainer (Figure 17, Item 4) and slide plate (Figure 17, Item 3) in place and align holes in retainer with holes in outer boom (Figure 17, Item 6). Install four capscrews (Figure 17, Item 1) and washers (Figure 17, Item 2) on retainer (Figure 17, Item 4) and slide plate (Figure 17, Item 3).
1,2

6

5 3,4
M0435JCH

Figure 17. Style D (RT 240V2 and RT 240V3 ONLY) Wear Plate Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1. 2. Boom and top handler in operational position (TM 10-3930-675-10). Perform operational check of boom assembly (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0258-18

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TM 10-3930-675-23-2

0259

FIELD MAINTENANCE TOPHANDLER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Jackscrew (2) (TM 10-3930-675-10, Basic Issue Items) Materials/Parts Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27) Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Tag, Marker (WP 0276, Table 1, Item 66) Materials/Parts (cont.) Washer, Lock (WP 0278, Table 1, Item 118) Qty: 2 Washer, Lock (WP 0278, Table 1, Item 119) Qty: 2 Personnel Required (3) References TM 10-3930-675-10 Volume 1, WP 0123 WP 0257 WP 0271

CAUTION
• DO NOT extend the boom support locking pins into the frame with the tophandler removed from the boom. • Damage to boom support and frame slide bearings can occur if the boom support locking pins are extended or retracted into the operational/locked position when the tophandler is removed from the boom.

NOTE
• This procedure, as written, uses a trailer to place the tophandler at the correct height in order to avoid putting RTCH in transport modes (TM 10-3930-675-10). Some necessary deviations from this task may apply, depending on the availability of a trailer that is at least 50 in. (127 cm) high. • The tophandler can be removed onto a trailer at least 50 in. (127 cm) high without placing the boom in the transport position. If trailer is unavailable, place RTCH in transport mode (TM 10-3930-675-10) to remove top handler.

0259-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL 1. 2. 3. Position RTCH directly behind trailer on which tophandler is to be placed. Side shift tophandler right 6 to 8 in. (15.2 to 20.3 cm) from center position. Extend boom to 110 in. (279.4 cm). Raise boom to 19 degrees (TM 10-3930-675-10). Place cribbing on deck of trailer so twistlocks will not touch trailer deck when tophandler spreader beams (Figure 1, Item 1) are placed on cribbing.

1

M0584JCH

Figure 1. Tophandler Removal. 4. 5. Drive RTCH as close as possible to back of trailer. Apply parking brake (TM 10-3930-675-10). Place boom in transport position (TM 10-3930-675-10): a. b. c. d. e. f. g. h. i. Remove boom support locking pin retaining pins. Move cab to transport position. Ensure boom is at 19 degrees and extended to 110 in. (279.4 cm). Pull center (tall) lever to raise boom support fully. Retract boom support locking pins. Fully lower boom support to lowest position. Lower boom until bottom of tophandler is 5 to 6 ft (152.4 to 182.9 cm) off ground. Rotate tophandler clockwise to longitudinal position. Raise boom high enough to clear trailer height.

CAUTION
Damage to boom support and frame slide bearings can occur if the boom support locking pins are extended or retracted into the operational/locked position when the tophandler is removed from the boom.

0259-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued 6. Lower tophandler onto cribbing on deck of trailer until oscillation/leveling cylinders are fully collapsed (TM 10-3930-675-10). Raise boom just enough to start lifting collapsed center section 0.04 in. (1 mm) or less off center wear pads (Figure 2, Item 1).

1

M0585JCH

Figure 2.

Tophandler Removal.

WARNING
DO NOT fully relax the boom pressure on the tophandler. Serious injury or damage can occur from boom movement during pivot shaft removal. 7. Shut down RTCH engine (TM 10-3930-675-10).

NOTE
DO NOT disconnect tophandler angle sensor from junction box. 8. Remove tophandler angle sensor/bracket (Figure 3, Item 1) and cable clamps from their mounting, move aside and secure to boom, (Volume 1, WP 0123). Reinstall mounting hardware to prevent loss.

1

M0586JCH

Figure 3.

Tophandler Removal.

0259-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued

NOTE
DO NOT disconnect tilt cylinder hydraulic hoses when disconnecting tilt cylinders from tophandler. 9. Disconnect each tilt cylinder from tophandler (Figure 4, Item 1): a. b. c. Remove bolt (Figure 4, Item 2) and lockwasher (Figure 4, Item 3). Retain lockwasher. Install bolt into threaded hole (Figure 4, Item 4) in pin, and screw in to withdraw pin. After disconnecting tilt cylinders, reinstall pin, bolt, and lockwasher in cylinder end for stowage.
1 2,3

4
M0587JCH

Figure 4. Tophandler Removal. 10. 11. Operate tilt cylinders to fully retract right tilt cylinder (Figure 5, Item 1) and fully extend left tilt cylinder (Figure 5, Item 2) (TM 10-3930-675-10). Rest right tilt cylinder (Figure 5, Item 1) on tilt cylinder support bolt and secure. Secure left tilt cylinder (Figure 5, Item 2) to boom by wrapping cargo strap around boom.

0259-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued
1 2

M0588JCH

Figure 5.

Tophandler Removal.

CAUTION
Ensure electrical connectors are clear and secured to avoid damaging connectors.

NOTE
Tag electrical connectors to ensure correct installation. 12. Disconnect four electrical connectors (Figure 6, Item 2) from bottom of tophandler junction box (Figure 6, Item 1) and secure.
1

2

M0589JCH

Figure 6.

Tophandler Removal.

0259-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued

CAUTION
• Wipe clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure. • Ensure hydraulic hoses are clear and secure to avoid damaging hoses. 13. Disconnect six hydraulic hose quick disconnect fittings (Figure 7, Item 2) from top of tophandler (Figure 7, Item 1). Cap/plug all hydraulic connections. Lift hoses up and over slewing motors and secure to boom.
1

2

M0590JCH

Figure 7. Tophandler Removal. 14. Remove bolt and lockwasher (Figure 8, Item 2) from each pivot shaft (Figure 8, Item 1). Retain lockwashers.
1

2

M0591JCH

Figure 8. Tophandler Removal. 15. Lubricate two jackscrews (Figure 9, Item 2) (from Basic Issue Items) with lubricating oil and install into threaded holes of pivot shaft (Figure 9, Item 1).

0259-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued
1

2

M0592JCH

Figure 9.

Tophandler Removal.

CAUTION
• Use caution when removing the last part of the pivot shaft from the boom. The boom may drop or lift slightly when the pivot shaft is released. • The pivot shafts are extremely heavy. DO NOT withdraw them all the way out.

NOTE
To avoid binding pivot shaft, screw in jackscrews equally and alternately. 16. Screw in jackscrews (Figure 10, Item 3) approximately 8 in. (20.3 cm) to completely withdraw each pivot shaft (Figure 10, Item 2) until boom (Figure 10, Item 1) is free of tophandler (Figure 10, Item 4).
1 2 3 2

4
M0593JCH

Figure 10.

Tophandler Removal.

0259-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued

NOTE
Because tophandler junction box is disconnected from RTCH electrical system, error codes will appear on driver’s ECS display screen when boom is operated. These error codes will include numbers 245 to 265 as well as others. To continue operation, reset driver’s display and use override button on right side of joystick housing (TM 10-3930-675-10). 17. Operate boom (Figure 11, Item 1) while pressing override switch to lift boom clear of tophandler (Figure 11, Item 2) (TM 10-3930-675-10).

1

2

M0594JCH

Figure 11. Tophandler Removal. 18. Back RTCH away from trailer.

CAUTION
• The boom support must be lowered to its lowest position before installing boom rest, transport. • Damage will occur to the equipment if the boom is fully lowered when the tophandler is removed from the boom and the boom support is lowered to its lowest position. 19. Install boom rest, transport (Figure 12, Item 1): a. b. c. Fully retract boom (TM 10-3030-675-10). Remove boom rest, transport (Figure 12, Item 1) from stowed position (rear of RTCH). Install the boom rest, transport (Figure 12, Item 1) on boom (Figure 12, Item 2).

0259-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued

1

2

M0595JCH

Figure 12. d.

Tophandler Removal.

Lower boom until boom rest, transport (Figure 13, Item 1) is resting on RTCH frame (Figure 13, Item 2).

1

2
M0596JCH

Figure 13.

Tophandler Removal.

0259-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

REMOVAL - Continued 20. 21. Tie down tophandler to trailer IAW shipping data plate on RTCH (TM 10-3930-675-10). Reinstall tophandler mounting hardware (pivot shafts, lockwashers, and bolts) (Figure 14, Item 1) to provide secure stowage of items while tophandler (Figure 14, Item 2) is in transit.
1

2

M0597JCH

Figure 14. Tophandler Removal. END OF TASK INSTALLATION 1. Remove tiedowns from tophandler and trailer.

NOTE
It is crucial that RTCH and trailer be in alignment. If time is not taken to ensure accurate alignment, installation of tophandler to boom will be very difficult because pivot shafts will bind while being installed. 2. 3. Position RTCH 10 to 15 ft (3.0 to 4.6 m) directly behind trailer, so that tophandler and RTCH boom are aligned. Raise boom off boom rest, transport (Figure 15, Item 1). Remove boom rest, transport and stow (rear of RTCH).
1

M0598JCH

Figure 15.

Tophandler Installation.

0259-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

INSTALLATION - Continued

CAUTION
Damage will occur to the equipment if the boom is fully lowered when the tophandler is removed from the boom and the boom support is lowered to its lowest position. 4. Remove tophandler mounting hardware (pivot shafts, lockwashers, and bolts) (Figure 16, Item 1). Discard lockwashers if new lockwashers are available.
1

M0599JCH

Figure 16.

Tophandler Installation.

NOTE
• Because tophandler junction box is disconnected from RTCH electrical system, error codes will appear on driver’s ECS display screen when boom is operated. These error codes will include numbers 245 to 265 as well as others. To continue operation, reset driver’s display and use override button on right side of joystick housing (TM 10-3930-675-10). • If alignment of boom to tophandler does not look OK, reposition RTCH and ensure accurate alignment before proceeding. 5. 6. Raise boom high enough to clear tophandler. Extend boom to 120 in. (304.8 cm). Using a ground guide, slowly drive RTCH toward trailer until boom is over tophandler Lower boom (Figure 17, Item 1) and position boom into tophandler (Figure 17, Item 2), while aligning pivot shaft holes in boom with holes in tophandler.
1

2

M0600JCH

Figure 17.

Tophandler Installation.

0259-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

INSTALLATION - Continued

CAUTION
Never hammer directly on the pivot shaft flanges. Always use a wooden block or damage will occur to the pivot shaft.

NOTE
• Ensure pivot shafts are clean. • When installing pivot shafts, slots in pivot shaft for retaining bolt must be aligned with bolt hole in tophandler. • Remove the lockwashers from the retaining bolt and place on one of the jackscrews. Insert the jackscrew through the slot and into the retaining screw bolt hole. Use the jackscrew to draw the pivot shaft into the boom. It may be necessary to tap on the pivot shaft with a 4x4 block and hammer to aid in installation. Make sure the lockwashers are reinstalled back onto the retaining bolt before installation. • It may be necessary to connect the hydraulic hoses and use tophandler controls to aid in boom-to-tophandler positioning. • Turning the steering wheel while in crab steering will move the boom side to side for minor alignment adjustments. Boom movement is the opposite of steering wheel movement. 7. Install pivot shaft (Figure 18, Item 1) on each side of tophandler. Secure with new lockwasher and bolt.
1

M0601JCH

Figure 18.

Tophandler Installation.

NOTE
Install the hose with the large female quick disconnect fitting first. It will be necessary to bleed off the residual oil in the hose by rocking it back and forth on the male fitting before the fitting will connect. Use plenty of rags to catch the bled off oil. 8. Remove caps/plugs and connect six hydraulic hose quick disconnect fittings (Figure 19, Item 1) to top of tophandler.

0259-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

INSTALLATION - Continued
1

M0602JCH

Figure 19. 9.

Tophandler Installation.

Connect four electrical connectors (Figure 20, Item 2) to bottom of tophandler junction box (Figure 20, Item 1).

1

2

M0603JCH

Figure 20.

Tophandler Installation.

0259-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

INSTALLATION - Continued 10. 11. 12. Remove cargo straps from tilt cylinders (Figure 21, Item 1) and remove pin, bolt, and lockwasher from cylinder ends. Operate tilt cylinders to align tilt cylinder ends (Figure 21, Item 1) with mounting holes in tophandler (TM 10-3930-675-10). Install pin at end of each tilt cylinder (Figure 21, Item 1). Secure with new lockwasher and bolt.

1

M0604JCH

Figure 21. 13.

Tophandler Installation.

Install tophandler angle sensor/bracket (Figure 22, Item 1) (Volume 1, WP 0123).
1

M0605JCH

Figure 22.

Tophandler Installation.

0259-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0259

INSTALLATION - Continued 14. 15. Raise boom and tophandler off trailer and back RTCH away from trailer. Place boom back into operational position (TM 10-3930-675-10): a. b. c. d. e. f. g. h. i. 16. Extend the boom to 110 in. (279.4 cm). Rotate tophandler 90 degrees counterclockwise to operational position. Raise boom and tophandler 12 to 13 ft (3.7 to 4.0 m) off the ground. Retract locking pins fully. Raise boom support fully. Check boom angle and readjust to 19 degrees. Extend boom support locking pins. Return cab to operational position (TM 10-3930-675-10). Install boom support locking pin retaining pins.

Perform boom and tophandler calibration (WP 0257).

END OF TASK CERTIFICATION OF INSPECTION 1. 2. If tophandler was replaced with a new or rebuilt unit, perform Load Testing Procedure (WP 0271) for certification. A tophandler that was removed and reinstalled from one RTCH does not have to be re-certified.

END OF TASK END OF WORK PACKAGE

0259-15/16 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00233)

TM 10-3930-675-23-2

0260

FIELD MAINTENANCE SPREADER CHAIN MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Sling, Nylon (WP 0277, Table 1, Item 70) Tie Down, Cargo, Vehicle (WP 0277, Table 1, Item 82) Lifting Device (4,000 lbs. minimum capacity) Materials/Parts Nut, Self-Locking Hexagon (WP 0278, Table 1, Item 87) Qty: 4 Materials/Parts (cont.) Nut, Self-Locking Hexagon (WP 0278, Table 1, Item 90) Qty: 2 Pin, Cotter (WP 0278, Table 1, Item 169) Qty: 2 Personnel Required (3) Equipment Condition Parking brake applied (TM 10-3930-675-10) Tophandler in normal operating position (TM 10-3930-675-10)

NOTE
• Tophandler spreader chain replacement procedure is to be performed due to a broken or worn chain. For broken chain, the tophandler spreader function will be inoperative and the spreader sections could be spread at any position. The procedure described for removal is for a completely closed tophandler. Read through the steps to determine the best starting point as per the tophandler spread position. For worn chain, the tophandler spreader motor can be used to spread tophandler to required positions. • This procedure, as written, uses a truck, forklift as a suitable lifting device. Some necessary deviations from these tasks may apply, depending on the suitable lifting device being used. REMOVAL 1. Remove ten capscrews (Figure 1, Item 1), washers (Figure 1, Item 2), and two access panels (Figure 1, Items 3 and 4) from each side of tophandler main beam (Figure 1, Item 5).
1,2 3 4 5

M0540JCH

Figure 1.

Access Panels Removal.

0260-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

REMOVAL - Continued 2. Remove four capscrews (Figure 2, Item 2), washers (Figure 2, Item 3), and protection plate (Figure 2, Item 1) from motor side of tophandler.
1

2,3

2,3

M0541JCH

Figure 2. Protective Plate Removal.

NOTE
If chain is broken, a suitable lifting device must be used to move sliding beams to facilitate this procedure. Position the beams as necessary to access and perform each step. 3. Position a suitable lifting device under tophandler tee and attach a sling around beam and suitable lifting device, to allow sliding beam (Figure 3, Item 2) to be pulled out of main beam (Figure 3, Item 1).
1

2

M0542JCH

Figure 3. 4. 5.

Sliding Beam Removal from Main Beam.

Pull sliding beam (Figure 5, Item 3) out until chain tensioner (Figure 5, Item 4), which attaches to chain end being replaced, is positioned in access hole of main beam (Figure 5, Item 2). Remove locknut (Figure 5, Item 1), which secures tensioner to beam. Discard locknut.

0260-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

REMOVAL - Continued 6. Place a mark (Figure 4, Item A) on sliding beam at end of main beam for reference during installation process.

A

M0543JCH

Figure 4. 7.

Sliding Beam Reference Mark.

Remove cotter pin (Figure 5, Item 7), washer (Figure 5, Item 8), pin (Figure 5, Item 5), and tensioner (Figure 5, Item 4) from chain (Figure 5, Item 6). Discard cotter pin.
1 2 3 4 5

6

M0544JCH

7,8

Figure 5.

Chain Tensioner Removal.

0260-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

REMOVAL - Continued 8. At idler gear (Figure 6, Item 3), remove two capscrews (Figure 6, Item 2) and locking plate (Figure 6, Item 6). Use a punch and hammer to move idler shaft (Figure 6, Item 1), from lower end, up through idler gear and remove it to free idler gear, bearing (Figure 6, Item 4), and spacer (Figure 6, Item 5).
1

2

6

3,4,5

M0545JCH

Figure 6. Locking Plate Removal.

CAUTION
Step 9 will keep the loose chain from bunching up between the main and sliding beams as the sliding beam moves outward. Lack of tension on the chain could cause the beams to bind and prevent the sliding beam from moving. 9. Thread loose end of chain (Figure 7, Item 3) through opening vacated by idler gear, and out of end of main beam (Figure 7, Item 1), along wall of sliding beam (Figure 7, Item 4) until full length of chain is positioned against sliding beam wall. Attach a vehicle cargo tiedown to spreader chain, and to end beam tee, and apply tension to chain (Figure 7, Item 3), to allow chain to move with sliding beam (Figure 7, Item 4), while it is being slid out to access chain anchor (Figure 7, Item 2) attached to inside of beam.

10.

0260-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

REMOVAL - Continued
1

2 3

4

M0546JCH

Figure 7.

Chain Anchor Access.

NOTE
Step 11 is performed to remove the tensioner. This will allow the sliding beam being pulled out for chain replacement to move without disturbing the other sliding beam. It is not necessary to remove the tensioner from the spreader chains on both ends unless both chain are being replaced. 11. At other end of tophandler, measure and record distance (B) from mounting flange (Figure 14, Item 3) to center of pin (Figure 14, Item 2) for correct positioning during reassembly. Remove locknut (Figure 14, Item 4) from beam and tensioner (Figure 14, Item 1).
2 3 4 5

1

6

M0547JCH

7,8

Figure 8. Beam and Tensioner Locknut Removal.

0260-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

REMOVAL - Continued 12. 13. 14. Return to end of tophandler where chain is being replaced and slowly pull sliding beam out of main beam until it reaches 40-ft stop block (Figure 10, Item 3). Remove four capscrews (Figure 9, Item 1) and washers (Figure 9, Item 2) from hydraulic/electrical hose power track support (Figure 9, Item 3), allow support to hang loose. Remove four socket head capscrews (Figure 9, Item 5), washers (Figure 9, Item 6), and locknuts (Figure 9, Item 7), from other end of hydraulic hose/electric power track (Figure 9, Item 4) to allow enough slack to continue to slide beam outward. Discard locknuts.
1,2 3 4 5,6 7

M0548JCH

Figure 9. Hydraulic/Electrical Hose Power Track Support Removal.

0260-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

REMOVAL - Continued 15. Mark position (C) of 40-ft stop block (Figure 10, Item 3) for repositioning during reassembly. Remove four capscrews (Figure 10, Item 1), washers (Figure 10, Item 2), and stop block and slowly pull sliding beam out another 2.5 ft (76.2 cm) to access chain anchor (Figure 10, Item 4). Remove cotter pin (Figure 10, Item 7), washer (Figure 10, Item 8), and pin (Figure 10, Item 5) from chain (Figure 10, Item 6). Discard cotter pin.
1,2 3 4 5 6

16.

7,8

M0549JCH

Figure 10. END OF TASK

Chain Anchor Removal.

0260-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

INSTALLATION 1. 2. 3. 4. 5. 6. Install new chain (Figure 12, Item 6) on chain anchor (Figure 12, Item 4) with pin (Figure 12, Item 5), washer (Figure 12, Item 8), and new cotter pin (Figure 12, Item 7). Attach ratchet strap to spreader chain (Figure 12, Item 6) and end beam tee, and apply tension to keep spreader chain tight, while sliding beam is being pushed back into main beam about 30 in. (76.2 cm). Install 40-ft stop block (Figure 12, Item 3), four screws (Figure 12, Item 1), and four washers (Figure 12, Item 2). Position stop block on mark (C) made during removal and tighten bolts. Install four socket head capscrews (Figure 9, Item 5), washers (Figure 9, Item 6), and new locknuts (Figure 9, Item 7) on other end of hydraulic hose/electric power track (Figure 9, Item 4). Install four capscrews (Figure 9, Item 1) and washers (Figure 9, Item 2) on hydraulic/electrical hose power track support (Figure 9, Item 3) and vehicle. Using suitable lifting device, slowly slide beam into main beam until it is positioned at mark (Figure 11, Item A), on wall of sliding beam at main beam, made during removal.

A

M0543JCH

Figure 11.

Position Slide Beam.

0260-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

INSTALLATION - Continued
1,2 3 4 5 6

7,8

M0550JCH

Figure 12. 7. 8.

Assemble Chain Anchor.

Remove ratchet strap from spreader chain and thread spreader chain through idler gear opening. Install idler gear (Figure 13, Item 3), bearing (Figure 13, Item 4), spacer (Figure 13, Item 5), and shaft (Figure 13, Item 1) with two capscrews (Figure 13, Item 2) and idler shaft locking plate (Figure 13, Item 6).
1

2

6

3,4,5

M0551JCH

Figure 13.

Idler Shaft Locking Plate Installation.

0260-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

INSTALLATION - Continued 9. Position chain tensioner (Figure 14, Item 1) on spreader chain (Figure 14, Item 5) and install pin (Figure 14, Item 2), washer (Figure 14, Item 7), and new cotter pin (Figure 14, Item 6) to secure tensioner to spreader chain. Position spreader chain (Figure 14, Item 5) around idler gear (and spreader motor gear if that end is being replaced) and slide threaded end of tensioner (Figure 14, Item 1) through flange (Figure 14, Item 3) and install locknut (Figure 14, Item 4). At opposite end of tophandler, install tensioner (Figure 14, Item 1) with new locknut (Figure 14, Item 4). Tighten to position (B) marked during removal. At end of tophandler where chain is being replaced, tighten locknut (Figure 14, Item 4) until spreader chain (Figure 14, Item 5) is tight and slack is removed.
1 2 3

10.

11. 12.

5

M0552JCH

6,7

4

Figure 14. END OF TASK CHAIN TENSION MEASUREMENT 1. 2. 3. 4. 5.

Chain Adjustment.

Open tophandler spreader to 40-ft position and observe spreader has bottomed out on stop blocks. Measurement is to be made at third access hole closest to middle of tophandler. Place tape measure against back wall of tophandler middle section perpendicular to chain. Apply force of approximately 50 to 60 lb (250 N) against chain (Figure 15, Item 1). Measure deflection of chain. Deflection should be a minimum of 3/4 in. (20 mm) to a maximum of 1-1/2 in. (40 mm). Measure tension of both chains.

END OF TASK

0260-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

CHAIN TENSION ADJUSTMENT

NOTE
• Both chains must be equally adjusted during adjustment procedure. • DO NOT adjust more than 1 turn (1/8 in. (2 mm)) of the adjustment nut at a time without rechecking chain tension. Operating tophandler spreader with excessive tension on chain may result in damage to equipment. 1. 2. 3. 4. If chains (Figure 15, Item 1) require adjustment, operate tophandler spreader towards 20-ft position, stopping to allow access to chain adjuster. Loosen jamnut (Figure 15, Item 3). Loosen or tighten locking nut (Figure 15, Item 2) to decrease or increase tension. Reposition tophandler spreader and recheck tension measurement. Adjust as needed. Tighten jamnut (Figure 15, Item 3) when correct tension is obtained.
1 2 3

M0553JCH

Figure 15. END OF TASK

Chain Tension Adjustment.

0260-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

CHAIN ADJUSTER VERTICAL ADJUSTMENT (RT 240V1 and RT 240V1R ONLY) 1. 2. 3. Close tophandler spreader to 20-ft position. Check angle of pull on chain (Figure 16, Item 1) in relation to spreader motor sprocket. If chain is pulling upward, adjust vertical adjustment on chain adjuster (Figure 16, Item 2) down until pull is straight.

NOTE
Chain has vertical adjustment in only one direction. It may be necessary to reconfigure the chain adjuster as follows to gain adjustment in the other direction. 1. Loosen and remove chain adjuster (Figure 6, Item 2) from mounting flange. Mark adjustment position before removing. 2. Remove vertical adjustment bolt. 3. Separate two parts and rotate adjusting screw side. 4. Reassemble two parts and install bolt, nut, and washers. 5. Install the chain adjuster back onto mounting at original position. 4. If chain is pulling downward, adjust vertical adjustment on chain adjuster up until the pull is straight.
1 2

M0554JCH

Figure 16.

Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).

0260-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00234)

TM 10-3930-675-23-2

0260

CHAIN ADJUSTER VERTICAL ADJUSTMENT (RT 240V1 and RT 240V1R ONLY) - Continued
SLOT IN CHAIN TENSIONER FOR VERTICAL ADJUSTMENT

M0555JCH

Figure 17. Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only). END OF TASK FOLLOW-ON MAINTENANCE Operate tophandler spreader function several times and observe chain tension. Make adjustments as needed (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0260-13/14 blank

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TM 10-3930-675-23-2

0261

FIELD MAINTENANCE SPREADER 20 AND 40 FOOT ADJUSTMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Tape, Measuring (50 ft long) (WP 0277, Table 1, Item 79) Materials/Parts Antifreeze Ethylene Glycol (WP 0276, Table 1, Item 6) Rag, Wiping (WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (WP 0276, Table 1, Item 63) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Washer, Flat (WP 0278, Table 1, Item 94) Qty: as required Personnel Required (2) References WP 0260 TM 10-3930-675-10 Equipment Condition Wheels chocked (TM 10-3930-675-10) Parking brake applied (TM 10-3930-675-10) Tophandler in normal operating position (TM 10-3930-675-10)

MEASUREMENT AND ADJUSTMENT - 20 FT 1. 2. 3. Check tophandler chain tension and adjust if necessary (WP 0260). Operate tophandler spreader to 20-ft position (TM 10-3930-675-10). Ensure stop blocks (Figure 1, Item 1) are bottomed out on both ends of spreader sections (Figure 1, Item 2).
1

2

M0556JCH

Figure 1.

Measurement and Adjustment - 20 Ft.

0261-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00235)

TM 10-3930-675-23-2

0261

MEASUREMENT AND ADJUSTMENT - 20 FT - Continued

NOTE
Twistlocks can be moved side to side in any horizontal position, by hand, to position them in middle of cutout. 4. Use override switch to operate twistlocks (Figure 2, Item 2) to locked position. Green light on boom will be lit (TM 10-3930-675-10).

NOTE
When twistlocks are in the locked position, spreader function is deactivated. 5. Ensure twistlocks (Figure 2, Item 2) are in middle of cutout position in bottom of spreader section (Figure 2, Item 1).

1

2

M0557JCH

Figure 2.

Measurement and Adjustment - 20 Ft.

NOTE
Measurement should be 230 7/16 in. ± 1/8 in. (5,853 mm ± 3 mm). 6. Measure from inside flat edge of one twistlock (Figure 2, Item 2) to other twistlock outer flat edge.

0261-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00235)

TM 10-3930-675-23-2

0261

MEASUREMENT AND ADJUSTMENT - 20 FT - Continued

M0558JCH

Figure 3.

Measurement and Adjustment - 20 Ft.

CAUTION
DO NOT remove washers on left side (spreader motor side) bolt stop. Removing washers from left-side stop bolt will cause damage to spreader motor when operated.

NOTE
Remove or add one washer at a time, then recheck measurement. 7. 8. If measurement is not within limits, extend spreader section, add or remove washers (Figure 4, Item 2) at 20-ft position bolt stop (Figure 4, Item 1) on right side only. Recheck chain tension and adjust if necessary (WP 0260).
1

2

M0556JCH

Figure 4. 9.

Measurement and Adjustment - 20 Ft.

Use override switch to operate twistlocks to unlocked position. Red light on boom will be lit (TM 10-3930-675-10).

END OF TASK

0261-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00235)

TM 10-3930-675-23-2

0261

MEASUREMENT AND ADJUSTMENT - 40 FT 1. 2. 3. Check tophandler chain tension and adjust if necessary (WP 0260). Operate tophandler spreader to 40-ft position (TM 10-3930-675-10). Ensure stop blocks (Figure 5, Item 2) are bottomed out on both spreader sections (Figure 5, Item 1).

2 1

M0559JCH

Figure 5. 4.

Measurement and Adjustment - 40 Ft.

Use override switch to operate twistlocks (Figure 6, Item 2) to locked position (TM 10-3930-675-10).

NOTE
When twistlocks are in locked position, spreader function is deactivated. 5. Ensure twistlocks (Figure 6, Item 2) are in middle position of cutout in bottom of spreader section (Figure 6, Item 1).

1

2

M0560JCH

Figure 6.

Measurement and Adjustment - 40 Ft.

0261-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00235)

TM 10-3930-675-23-2

0261

MEASUREMENT AND ADJUSTMENT - 40 FT - Continued

NOTE
Measurement should be 471 7/8 in. ± 1/8 in. (11,985 mm ± 3 mm). 6. Measure from inside flat edge of one twistlock (Figure 6, Item 2) to other twistlock outer flat edge.

3

M0561JCH

Figure 7. 7.

Measurement and Adjustment - 40 Ft.

If measurement is not within limits, adjust stop block (Figure 8, Item 1) at each end of spreader section.

NOTE
DO NOT adjust more than one turn at a time on adjusting nuts before rechecking measurement and chain tension. 8. Recheck chain tension and adjust if necessary (WP 0260).
1

M0562JCH

Figure 8.

Measurement and Adjustment - 40 Ft.

0261-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00235)

TM 10-3930-675-23-2

0261

MEASUREMENT AND ADJUSTMENT - 40 FT - Continued 9. Use override switch to operate twistlocks to unlocked position. Red light on boom will be lit (TM 10-3930-675-10).

END OF TASK FOLLOW-ON MAINTENANCE 1. 2. 3. 4. 5. Operate tophandler spreader to 20-ft and 40-ft positions (TM 10-3930-675-10). Recheck 20-ft and 40-ft measurements. Recheck chain tension (WP 0260). Set parking brake (TM 10-3930-675-10). Remove wheel chocks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0261-6

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TM 10-3930-675-23-2

0262

FIELD MAINTENANCE SPREADER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts O-Ring (WP 0278, Table 1, Item 135) Personnel Required (2) Equipment Condition Tophandler hydraulic spreader motor removed (WP 0264)

NOTE
Place an index mark across hydraulic motor and spreader assembly to mark location for assembly.

0262-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00236)

TM 10-3930-675-23-2

0262

HYDRAULIC MOTOR REMOVAL 1. 2. 3. Remove two socket-head capscrews (Figure 1, Item 2) and washers (Figure 1, Item 3). Lift hydraulic motor (Figure 1, Item 1) from spreader assembly (Figure 1, Item 5). Remove and discard O-ring (Figure 1, Item 6). Use two pry-bars to remove drive gear (Figure 1, Item 4) from shaft of hydraulic motor (Figure 1, Item 1).
1 2,3

4 6

1

M0995JCH

5

Figure 1. END OF TASK HYDRAULIC MOTOR INSTALLATION 1. 2. 3.

Hydraulic Motor Replacement.

Align keyway in drive gear (Figure 1, Item 4) with key in shaft of hydraulic motor (Figure 1, Item 1) and drive key into place with a dead blow hammer. Install new O-ring (Figure 1, Item 6). Position hydraulic motor (Figure 1, Item 1) on spreader assembly (Figure 1, Item 5) and secure in place with two socket-head capscrews (Figure 1, Item 2) and washers (Figure 1, Item 3).

END OF TASK GEAR REMOVAL 1. 2. Remove four capscrews (Figure 2, Item 2), washers (Figure 2, Item 3), and retaining plate (Figure 2, Item 4). Slide gear (Figure 2, Item 5) off of splined shaft of spreader assembly (Figure 2, Item 1).

END OF TASK

0262-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00236)

TM 10-3930-675-23-2

0262

GEAR INSTALLATION 1. 2. Align gear (Figure 2, Item 5) with splined shaft of spreader assembly (Figure 2, Item 1) and slide gear onto shaft. Install retaining plate (Figure 2, Item 4) with four capscrews (Figure 2, Item 2) and washers (Figure 2, Item 3).
1 2,3

4

5

M0996JCH

Figure 2. END OF TASK PLANETARY ASSEMBLY REMOVAL 1. 2.

Gear Installation.

Perform Step 1 of Hydraulic Motor Removal (in this work package). Perform Gear Removal procedure (in this work package).

END OF TASK PLANETARY ASSEMBLY INSTALLATION 1. 2. Perform Gear Installation procedure (in this work package). Perform Hydraulic Motor Installation procedure (in this work package).

END OF TASK FOLLOW-ON MAINTENANCE Install top handler spreader motor. END OF TASK END OF WORK PACKAGE

0262-3/4 blank

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TM 10-3930-675-23-2

0263

FIELD MAINTENANCE TOPHANDLER WEAR PLATES (SLIDE PLATE) REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (WP 0276, Table 1, Item 50) Personnel Required (Two) References WP 0270 Equipment Condition Boom and tophandler lowered to transport position (TM 10-3930-675-10)

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TM 10-3930-675-23-2

0263

GENERAL

NOTE
DO NOT lubricate wear plates. 1. 2. 3. 4. 5. Wear plates are used on the tophandler between sliding components as opposed to lubrication grease and grease fittings. Wear plates are inspected at semi-annual intervals and must be maintained in good working order for the tophandler to function properly. There are five styles of wear plates: A, B, C, D, and E. Replacement of one wear plate of each style is described in this work package. Appropriate notes and access procedures are included for removal and replacement of each style wear plate, as applicable. Spacer blocks and shims may be used with wear plates and need to be replaced to maintain proper spacing between tophandler assemblies.

0263-2

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TM 10-3930-675-23-2

0263

GENERAL - Continued

STYLE A STYLE B STYLE B STYLE B

STYLE B

STYLE E (HIDDEN)

STYLE C

STYLE C (HIDDEN)

STYLE E

STYLE B WEAR PLATE LOCATOR DIAGRAM

STYLE B
M0436JCH

Figure 1.

Tophandler Wear Plate Locations.

0263-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

GENERAL - Continued 6. Illustrations are provided in Figure 2 to aid in identifying the location of each style wear plate.
STYLE B STYLE D

STYLE B

STYLE E

STYLE C WEAR PLATE LOCATOR DIAGRAM

M0437JCH

Figure 2. Tophandler Wear Plate Locations. END OF TASK

0263-4

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TM 10-3930-675-23-2

0263

STYLE A WEAR PLATE REMOVAL

NOTE
• Replace style A wear plates one at a time to maintain distance relationship. • Replace style A wear plates as a set. 1. Remove six screws (Figure 3, Item 1), washers (Figure 3, Item 2), and cover plate (Figure 3, Item 3) from sideshift carriage frame (Figure 3, Item 4).
1,2

3

4 1,2

M0438JCH

Figure 3.

Style A Wear Plate Removal.

NOTE
If shims are used, note number of shims used. 2. 3. Remove shims (Figure 4, Item 1) and wear plate (Figure 4, Item 2). Measure wear plate thickness. Measurement MUST be a minimum of 1 in. (25.4 mm). If wear plate is not as specified, replace wear plate.

END OF TASK

0263-5

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TM 10-3930-675-23-2

0263

STYLE A WEAR PLATE INSTALLATION 1. Measure thickness of shims (Figure 4, Item 2) removed from wear plate location. Shim measurement MUST NOT exceed 0.25 in. (6.4 mm). Remove shims as necessary so as not to exceed requirement.

NOTE
Total thickness of wear plate and shims for style A location must not exceed 1.25 in. (31.8 mm). 2. 3. Install wear plate (Figure 4, Item 1) and shims (Figure 4, Item 2) as needed in sideshift carriage frame (Figure 3, Item 4). Position cover (Figure 4, Item 3) and secure in place with six screws (Figure 3, Item 1) and washers (Figure 3, Item 2). Tighten screws in accordance with Torque Limits (WP 0270).
1 2 2

3
M0439JCH

Figure 4. Style A Wear Plate Replacement. END OF TASK FOLLOW-ON MAINTENANCE Perform operational check of tophandler (TM 10-3930-675-10). END OF TASK

0263-6

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TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE REMOVAL

NOTE
• Style B wear plates use the same hardware. For removal procedures, refer to Step 1 below. • Access procedures and requirements for each location are different. Refer to Steps 2 and 3 for specific access procedures. 1. To remove a style B wear plate mounted on sideshift carriage frame: a. Remove four screws (Figure 5, Item 2) and washers (Figure 5, Item 3) securing mounting plate (Figure 5, Item 4), backing plate (Figure 5, Item 5), and frame (Figure 5, Item 7) to sideshift carriage frame (Figure 5, Item 1). Remove screw (Figure 5, Item 8) and washer (Figure 5, Item 9) securing wear plate (Figure 5, Item 6).
1

b.

2,3

4,5,6,7 8,9

2,3

M0440JCH

Figure 5.

Style B Wear Plate Removal.

0263-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE REMOVAL - Continued c. d. e. Remove spacer (Figure 6, Item 3), spacer (Figure 6, Item 4), frame (Figure 6, Item 2), and wear plate (Figure 6, Item 1). Measure thickness of wear plate (Figure 6, Item 1). Measurement must not be less than 0.5 in. (13 mm). If measurement is more than 0.5 in. (12.7 mm), but less than 1 in. (25.4 mm), add backing plates (Figure 6, Item 4) as needed.
1

2

4

3
M0441JCH

Figure 6. Style B Wear Plate Removal.

0263-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE REMOVAL - Continued 2. To access a style B wear plate mounted on sideshift carriage horizontal frame: a. b. Remove lower right screw (Figure 7, Item 1), nut (Figure 7, Item 2), and washer (Figure 7, Item 3). Perform procedures in Step 1 to remove wear plate.

1,2,3

M0442JCH

Figure 7.

Style B Wear Plate Removal.

0263-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE REMOVAL - Continued 3. To access a style B wear plate on sideshift beam interior:

NOTE
Internal beam wear plates may use a spacer block in some mounting locations. Ensure spacer block is retained and replaced. a. Remove ten screws (Figure 8, Item 1), washers (Figure 8, Item 2), and two access panels (Figure 8, Items 3 and 4) from side of each extending beam.
1,2 3 4

M0443JCH

Figure 8. Style B Wear Plate Removal. b. c. d. With assistance, extend or retract beams to expose internal-mounted style B wear plates (TM 10-3930-675-10). Position tophandler beams on cribbing to aid in relieving weight from load-bearing wear plates. Perform procedures in Step 1 to remove wear plate, frame, backing plate, and mounting plate.

END OF TASK

0263-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE INSTALLATION 1. To install a style B wear plate mounted on sideshift carriage frame: a. b. c. d. Position wear plate (Figure 9, Item 6), frame (Figure 9, Item 7), spacer (Figure 9, Item 5), and spacer (Figure 9, Item 4) on sideshift carriage frame (Figure 9, Item 1). Align and install screw (Figure 9, Item 8) and washer (Figure 9, Item 9) to secure wear plate (Figure 9, Item 6) in position on sideshift carriage frame (Figure 9, Item 1). Hand-tighten screw. Align holes in mounting plate (Figure 9, Item 4) with sideshift carriage frame (Figure 9, Item 1) and install four screws (Figure 9, Item 2) and washers (Figure 9, Item 3). Tighten all screws in accordance with Torque Limits (WP 0270).
1

2,3

4,5,6,7 8,9

2,3

M0444JCH

Figure 9.

Style B Wear Plate Installation.

0263-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE INSTALLATION - Continued 2. To install a style B wear plate mounted on sideshift carriage horizontal frame: a. b. Perform procedures in Step 1. Install lower right screw (Figure 10, Item 1), washer (Figure 10, Item 2), and nut (Figure 10, Item 3), which were removed for access. Tighten screw in accordance with Torque Limits (WP 0270).

1,2,3

M0445JCH

Figure 10. Style B Wear Plate Installation.

0263-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE B WEAR PLATE INSTALLATION - Continued 3. To install a style B wear plate on sideshift beam interior:

NOTE
Ensure spacer blocks are replaced with sideshift beam internal wear plates where used. a. b. Perform procedures in Step 1. Position two access panels (Figure 11, Items 3 and 4). Install and tighten 10 screws (Figure 11, Item 1) and washers (Figure 11, Item 2).
1,2 3 4

M0446JCH

Figure 11. END OF TASK FOLLOW-ON MAINTENANCE

Style B Wear Plate Installation.

Perform operational check of tophandler (TM-10-3930-675-10). END OF TASK

0263-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE C WEAR PLATE REMOVAL

NOTE
• If measurement of wear plate is less 0.5 in. (12.7 mm), perform this procedure to replace wear plate. • To prevent shifting of sideshift carriage, wear plates should be replaced in sets one at a time. 1. 2. 3. 4. With assistance, position sideshift carriage (Figure 12, Item 2) on cribbing to relieve weight on wear plates (Figure 12, Item 9). Remove two screws (Figure 12, Item 6), washers (Figure12, Item 7), and nuts (Figure 12, Item 8) securing lock plate (Figure 12, Item 3) in position. Remove lock plate and retain for installation. Through access hole in frame bottom, remove screw (Figure 12, Item 4) and washer (Figure 12, Item 5) securing wear plate (Figure 12, Item 9) to sideshift carriage frame (Figure 12, Item 1). Slide wear plate (Figure 12, Item 9) from position on sideshift carriage frame (Figure 12, Item 1).

END OF TASK

0263-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE C WEAR PLATE INSTALLATION 1. 2. 3. Position wear plate (Figure 12, Item 9) on sideshift carriage frame (Figure 12, Item 1) and install screw (Figure 12, Item 4) and washer (Figure 12, Item 5) through access hole in frame bottom. Install lock plate (Figure 12, Item 3) with two screws (Figure 12, Item 6), washers (Figure 12, Item 7), and nuts (Figure 12, Item 8). Tighten all screws in accordance with Torque Limits (WP 0270).
1 2

9

3 6,7,8

4,5

M0447JCH

Figure 12. END OF TASK FOLLOW-ON MAINTENANCE

Style C Wear Plate Replacement.

Perform operational check of tophandler (TM 10-3930-675-10). END OF TASK

0263-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE D WEAR PLATE REMOVAL

NOTE
• If measurement of wear plate is less 0.5 in. (12.7 mm), perform this procedure to replace wear plate. • Note location of beveled edge on wear plate. Ensure wear plate is oriented with beveled edge in same position for installation. 1. 2. 3. Position sliding beam to access wear plate (Figure 13, Item 1) and remove two screws (Figure 13, Item 6) and lock plate (Figure 13, Item 3). Through access hole in extending beam, remove two screws (Figure 13, Item 4) and washers (Figure 13, Item 5) securing wear plate (Figure 13, Item 1) and shims (Figure 13, Item 2). Slide two wear plates (Figure 13, Item 1) and shims (Figure 13, Item 2) from extending beam location.

END OF TASK STYLE D WEAR PLATE INSTALLATION

NOTE
Ensure wear plates are oriented with beveled edge the same as note in removal. 1. 2. Position two wear plates (Figure 13, Item 1) on extending beam. Install two screws (Figure 13, Item 4) and washers (Figure 13, Item 5) through access hole in extending beam to secure wear plates (Figure 13, Item 1).

0263-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE D WEAR PLATE INSTALLATION - Continued 3. 4. 5. Position lock plate (Figure 13, Item 3) on extending beam. Install two screws (Figure 13, Item 6) to secure lock plate (Figure 13, Item 3). Tighten all screws in accordance with Torque Limits (WP 0270).
2 1 3 1

2

6

4,5

M0448JCH

Figure 13. END OF TASK FOLLOW-ON MAINTENANCE

Style D Wear Plate Replacement.

Perform operational check of tophandler (TM-10-3930-675-10). END OF TASK

0263-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

STYLE E WEAR PLATE REMOVAL

NOTE
If measurement of wear plate is less 0.5 in. (12.7 mm), perform this procedure to replace wear plate. 1. 2. 3. Position sliding beam on cribbing to relieve weight on wear plate (Figure 14, Item 1) in sideshift carriage (Figure 14, Item 5). Through access hole in bottom of sideshift carriage (Figure 14, Item 5), remove two screws (Figure 14, Item 3) and washers (Figure 14, Item 4) from lock plate (Figure 14, Item 2). Slide wear plate (Figure 14, Item 1) and lock plate (Figure 14, Item 2) from sideshift carriage (Figure 14, Item 5).

END OF TASK STYLE E WEAR PLATE INSTALLATION 1. 2. 3. Position wear plate (Figure 14, Item 1) with lock plate (Figure 14, Item 2) on sideshift carriage (Figure 14, Item 5). Align lock plate (Figure 14, Item 2) holes with holes in sideshift carriage (Figure 14, Item 5). Install two screws (Figure 14, Item 3) and washers (Figure 14, Item 5) to secure wear plate (Figure 14, Item 1). Tighten screws in accordance with Torque Limits (WP 0270).
1,2

5

3,4

M0449JCH

Figure 14. END OF TASK

Style E Wear Plate Replacement.

0263-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0263

FOLLOW-ON MAINTENANCE Perform operational check of tophandler (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0263-19/20 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00237)

TM 10-3930-675-23-2

0264

FIELD MAINTENANCE TOPHANDLER HYDRAULIC SPREADER MOTOR MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Lifting Device (225 lb minimum capacity) Sling, Nylon (WP 0277, Table 1, Item 70) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 lb-ft (WP 0277, Table 1, Item 95) Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Nut, Self-Locking, Hexagon (WP 0278, Table 1, Item 75) Qty: 7 Rag, Wiping (WP 0276, Table 1, Item 50) Seal, Plain (WP 0278, Table 1, Item 132) Qty: 2 Personnel Required (2) References LO 10-3930-675-13 WP 0204 WP 0227 WP 0270 Equipment Condition Boom and tophandler lowered for access (TM 10-3930-675-10)

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

CAUTION
Wipe area clean around all hydraulic connections prior to disconnecting. Cap or plug all openings after disconnecting. Contamination of hydraulic system could result in equipment failure.

0264-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00238)

TM 10-3930-675-23-2

0264

REMOVAL 1. 2. Remove ten screws (Figure 1, Item 1), washers (Figure 1, Item 2), and two access panels (Figure 1, Items 5 and 6) from side of tophandler carriage. Position tophandler expanding beams (Figure 1, Item 3) to access chain adjuster (Figure 1, Item 4).
1,2

6

5

3

4
M0532JCH

Figure 1. 3. 4.

Tophandler Access Panels Removal.

Relieve hydraulic system pressure (WP 0204). Remove seven locknuts (Figure 2, Item 1), washers (Figure 2, Item 2), screws (Figure 2, Item 3), and protective cover (Figure 2, Item 4) from tophandler. Set protective cover aside. Discard locknuts.

0264-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00238)

TM 10-3930-675-23-2

0264

REMOVAL - Continued
1,2,3 4

M0533JCH

Figure 2.

Tophandler Access Panels Removal.

NOTE
Prior to removal or disconnection of drive chain, measure and record adjuster rod length as shown in location diagram to ensure proper chain adjustment on installation. 5. 6. Measure and record (Figure 3, Item 3) chain adjuster (Figure 3, Item 2) as shown below. Loosen chain adjuster jamnuts (Figure 3, Item 1).
1 2

3
M0534JCH

Figure 3.

Chain Adjuster Measurement and Removal.

0264-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00238)

TM 10-3930-675-23-2

0264

REMOVAL - Continued 7. 8. Remove chain (Figure 4, Item 6) from drive sprocket (Figure 4, Item 5). Remove four socket head screws (Figure 4, Item 4), hydraulic manifold (Figure 4, Item 2) with hoses, and O-rings (Figure 4, Item 3) from spreader motor (Figure 4, Item 1). Discard O-rings.

NOTE
Note direction of screws securing spreader motor to mounting weldment for installation. 9. Remove ten screws (Figure 4, Item 7), washers (Figure 4, Item 9), and nuts (Figure 4, Item 10) securing spreader motor (Figure 4, Item 1) to mounting weldment (Figure 4, Item 8).

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Spreader motor weighs approximately 150 lb (68 kg). Lifting device must have sufficient capacity to lift motor. Failure to follow this warning may result in injury to personnel.

NOTE
Note orientation of spreader motor to allow connection of hydraulic manifold on installation. 10. Using suitable lifting device, nylon sling, and with assistance, remove spreader motor (Figure 4, Item 1) from mounting weldment (Figure 4, Item 8).
1 2,3 4

9,10 8

7

6

5

M0535JCH

Figure 4. END OF TASK

Tophandler Hydraulic Spreader Removal.

0264-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00238)

TM 10-3930-675-23-2

0264

INSTALLATION

WARNING

• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that 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 death or injury to personnel. • Spreader motor weighs approximately 150 lb (68 kg). Lifting device must have sufficient capacity to lift motor. Failure to follow this warning may result in injury to personnel.

NOTE
Ensure spreader motor is oriented to allow connection of hydraulic manifold. 1. Using suitable lifting device, nylon sling, and with assistance, install spreader motor (Figure 5, Item 1) on mounting weldment (Figure 5, Item 8).

NOTE
Ensure screws are installed from bottom up as noted in removal. 2. Install ten screws (Figure 5, Item 7), washers (Figure 5, Item 9), and nuts (Figure 5, Item 10) to secure spreader motor (Figure 5, Item 1). Tighten screws in an even pattern in accordance with (WP 0270).

NOTE
Ensure O-rings are lubricated with lubricating oil prior to installation. 3. 4. Position hydraulic manifold (Figure 5, Item 2) with hoses and new O-rings (Figure 5, Item 3) on spreader motor (Figure 5, Item 1) and secure with four socket head screws (Figure 5, Item 4). Position chain (Figure 5, Item 6) on drive sprocket (Figure 5, Item 5).
1 2,3 4

9,10 8

7

6

5

M0536JCH

Figure 5. Tophandler Hydraulic Spreader Installation.

0264-5

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TM 10-3930-675-23-2

0264

INSTALLATION - Continued 5. 6. Measure chain adjuster (Figure 6, Item 2) and compare reading to measurement recorded during removal. Adjust jamnuts (Figure 6, Item 1) on chain adjuster to obtain recorded reading (Figure 6, Item 3).
1 2

3
M0537JCH

Figure 6. 7. 8. 9. 10. 11.

Chain Adjuster Installation and Measurement.

If a new spreader motor was installed, lubricate motor in accordance with (LO 10-3930-675-13). Check oil level in hydraulic reservoir (LO 10 3930-675-13). Operate tophandler spreader motor and check for leaks (TM 10-3930-675-10). Recheck chain adjuster (Figure 7, Item 3) measurement and adjust jamnuts as required. Install access panels (Figure 7, Item 4 and 5) to side of tophandler carriage with ten washers (Figure 7, Item 2) and screws (Figure 7, Item 1).
1,2

5

4

3
M0538JCH

Figure 7. Access Panels Installation.

0264-6

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TM 10-3930-675-23-2

0264

INSTALLATION - Continued

NOTE
Replace hydraulic reservoir return filters after 100 hours of operation (WP 0227). 12. Install protective cover (Figure 8, Item 4) on tophandler with seven screws (Figure 8, Item 3), washers (Figure 8, Item 2) and new locknuts (Figure 8, Item 1).
1,2,3 4

M0539JCH

Figure 8. END OF TASK FOLLOW-ON MAINTENANCE 1. 2.

Access Panels Installation.

Check oil level in hydraulic reservoir (LO 10 3930-675-13). Return boom and top handler to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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0265

FIELD MAINTENANCE PREPARATION FOR ARCTIC OPERATION

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Materials/Parts Diesel Fuel, DF-1 Grade (WP 0276, Table 1, Item 18) Oil, Lubricating, Engine OEA (WP 0276, Table 1, Item 37) References TB 750-651 References (cont.) TM 10-3930-675-10 Volume 1, WP 0059 Volume 1, WP 0092 WP 0140 WP 0158 WP 0195 WP 0227 WP 0204 WP 0251

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0265

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Drain engine oil and replace with OEA oil. Replace engine oil filter (Volume 1, WP 0059). Drain transmission oil and replace with OEA oil. Replace transmission oil filters (WP 0140). Drain hydraulic reservoir oil and replace with OEA oil (WP 0204). Replace all hydraulic (steering, brake, and boom) system filters (WP 0227) and (WP 0158). Check engine coolant to ensure safe operation at temperature range down to -50°F (-46°C) (TB 750-651). Drain fuel tank. Refill with arctic grade diesel fuel (TM 10-3930-675-10). Inspect engine drive belts for signs of cracking. Replace belts as required (Volume 1, WP 0092) and (WP 0251). Drain windshield washer fluid (WP 0195). Start vehicle and allow engine to reach operating temperature (TM 10-3930-675-10). Open both left- and right-side twistlock cylinder bypass valves on tophandler.

M1701JCH

CLOSED POSITION

OPEN POSITION

Figure 1. Twistlock Cylinder Bypass Valve. 11. 12. Operate twistlocks at least five times, while activating override switch, to circulate hydraulic oil within twistlock cylinders (TM 10-3930-675-10). Close both left- and right-side twistlock cylinder bypass valves.

FOLLOW-ON MAINTENANCE Perform operational check of all vehicle systems (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

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0266

FIELD MAINTENANCE PREPARATION FOR STORAGE OR SHIPMENT

INITIAL SETUP: Materials/Parts Lubricating Oil, Gear OE/HDO (WP 0276, Table 1, Item 45) Rag, Wiping (WP 0276, Table 1, Item 50) Turbine Fuel, Aviation, JP-8 Grade (WP 0276, Table 1, Item 69) References TB 750-651 References (cont.) Volume 1, WP 0092 Volume 1, WP 0093 Volume 1, WP 0128 WP 0185 WP 0204 WP 0251

NOTE
Short-term storage is storage for two weeks or less. Long-term storage is storage for more than two weeks. PREPARATION FOR SHORT-TERM STORAGE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Thoroughly clean vehicle. Perform Operator Preventive Maintenance Checks and Services (PMCS) (TM 10-3930-675-10). Fill fuel tank completely to prevent condensation from forming (TM 10-3930-675-10). Store vehicle indoors in a dry, protected area with boom fully lowered and retracted (TM 10-3930-675-10). When moderate temperatures are expected, leave batteries in place. If extreme cold is expected, remove batteries (Volume 1, WP 0128) and store in a protected area. Check engine coolant to ensure coolant has correct mixture for expected temperatures (TB 750-651). Seal all openings in engine, including air intake, exhaust outlet, and crankcase breather tube. Close cab rear window and door. Ensure engine cover is installed and latched (WP 0185). Ensure master battery switch is in OFF position (TM 10-3930-675-10). Relieve hydraulic system pressure. Be sure to close evacuation valves after pressure is relieved (WP 0204). Fill in Form DD 1397 completely and attach to a conspicuous part of vehicle.

END OF TASK PREPARATION FOR RETURN TO SERVICE FROM SHORT-TERM STORAGE 1. 2. 3. Remove seals from all engine openings, including air intake, exhaust outlet, and crankcase breather tube. If removed, install batteries (Volume 1, WP 0128). Check oil and hydraulic fluid levels in engine crankcase, transmission, axle differentials, wheel hub ends, hydraulic reservoir, and tophandler slewing and spreader motors (LO 10-3930-675-13).

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0266

PREPARATION FOR RETURN TO SERVICE FROM SHORT-TERM STORAGE - Continued 4. 5. 6. 7. 8. Check coolant level in radiator expansion tank (TM 10-3930-675-10). Start engine (TM 10-3930-675-10) and idle engine 3 to 5 minutes to allow it to warm up. Verify all indicator and warning lights operate properly on driver’s ECS display screen. Ensure fuel tank is full (TM 10-3930-675-10). Drive vehicle without a load and check engine, transmission, brakes, steering, and electrical accessories for proper operation (TM 10-3930-675-10). Check operation of boom and tophandler (TM 10-3930-675-10).

END OF TASK PREPARATION FOR LONG-TERM STORAGE 1. 2. 3. 4. 5. 6. Perform Operator PMCS (TM 10-3930-675-10). Perform Semi-annual PMCS (Volume 1, WP 0048). Schedule next PMCS. Thoroughly clean vehicle. Inspect vehicle for corrosion. Use touch-up paint where necessary to prevent rust. Store vehicle indoors in a dry, protected area with boom fully lowered and retracted and with tophandler resting on cribbing or other suitable supporting device. Exercise joystick through all positions after engine shutdown to relieve any pressure in hydraulic circuits (TM 10-3930-675-10). Coat all exposed hydraulic cylinder rods with Grease, Automotive and Artillery, GAA (WP 0276, Table 1, Item 27)to protect polished surfaces.

7.

NOTE
If vehicle has accumulated very low mileage since its last scheduled lubrication service, DO NOT drain and refill transmission and axles; skip Step 8. 8. 9. 10. 11. Drain and refill transmission and axles with new oil (LO 10-3930-675-13). Drain engine crankcase and refill with recommended oil (LO 10-3930-675-13). Completely drain fuel tank. Mix a solution of diesel fuel and flushing oil per instructions supplied with flushing oil. Pour mixture into fuel tank. Run engine for at least 10 minutes on this solution. Before shutting down engine, treat upper cylinders by spraying recommended engine oil into air intake for about two minutes. Open throttle momentarily, shut engine down, and continue spraying oil into air intake until engine comes to a stop. Check engine coolant to ensure coolant has correct mixture for expected temperatures (TB 750-651). Seal all openings in engine, including air intake, exhaust outlet, and crankcase breather tube. Loosen or remove alternator drive belt and A/C compressor drive belts (Volume 1, WP 0092) and (WP 0251). Ensure master battery switch is in OFF position (TM 10-3930-675-10). Remove batteries (Volume 1, WP 0128). Clean batteries and ensure they are fully charged. Refer to Battery Maintenance (Volume 1, WP 0128). Completely drain fuel tank. Close cab rear window and door.

12. 13. 14. 15. 16. 17. 18.

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0266

PREPARATION FOR LONG-TERM STORAGE - Continued 19. 20. 21. 22. Ensure engine cover is installed and latched (WP 0185). Place blocking under axles to remove weight from tires. Relieve hydraulic system pressure. Be sure to close evacuation valves after pressure is relieved (WP 0204). Fill in Form DD 1397 completely and attach to a conspicuous part of vehicle.

END OF TASK PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Ensure tires are inflated to 85 psi (586 kPa). Remove blocking from under axles. Remove GAA grease from exposed hydraulic cylinder rods. Wipe rods clean with a rag dipped in oil. Fill fuel tank with fuel (TM 10-3930-675-10). Check oil and hydraulic fluid levels in engine crankcase, transmission, axle differentials, wheel hub ends, hydraulic reservoir, and tophandler slewing and spreader motors (LO 10-3930-675-13). Check coolant level in radiator expansion tank (TM 10-3930-675-10). Install fully charged batteries (Volume 1, WP 0128). Tighten or install alternator drive belt and A/C compressor drive belts (Volume 1, WP 0092) and (WP 0251). Remove seals from all engine openings, including air intake, exhaust outlet, and crankcase breather tube. Start engine (TM 10-3930-675-10). Idle engine 3 to 5 minutes to allow it to warm up. Verify all indicator and warning lights operate properly on driver’s ECS display screen. Drive vehicle without a load and check engine, transmission, brakes, steering, and electrical accessories for proper operation (TM 10-3930-675-10). Check operation of boom and tophandler (TM 10-3930-675-10).

END OF TASK

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0266

PREPARATION FOR SHIPMENT 1. Follow instructions in TM 10-3930-675-10 to prepare vehicle for these transport modes: Highway Transport on M1000 Trailer • Rail Transport • Marine Transport • Air Transport • Ensure RTCH transmission control lever is in Neutral (N) and parking brake is applied (TM 10-3930-675-10). Ensure RTCH wheels are securely blocked and adequate tiedowns are used. For rail and marine transport, seal all openings in engine, including air intake, exhaust outlet, and crankcase breather tube. Check engine coolant to ensure coolant has correct mixture for expected temperatures (TB 750-651).

2. 3. 4. 5.

WARNING
Check travel route for overpass and bridge clearances. If clearances are not adequate, an accident causing injury or death to personnel or damage to equipment could result. 6. For highway transport, check state and local laws governing weight, width, and length of load.

END OF TASK END OF WORK PACKAGE

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0267

FIELD MAINTENANCE ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (WP 0277, Table 1, Item 85) Tool Kit, Automotive Fuel and Electrical System Repair (WP 0277, Table 1, Item 83) Adapter Set, Cable Breakout (WP 0277, Table 1, Item 3) Heat Gun, Electric (WP 0277, Table 1, Item 39) Multimeter (WP 0277, Table 1, Item 52) Materials/Parts Cloth, Abrasive, Emery, Fine (WP 0276, Table 1, Item 12) Materials/Parts (cont.) Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Grease, Electrically Conductive (WP 0276, Table 1, Item 28) Insulation Sleeving, Electrical (WP 0276, Table 1, Item 29) Tag, Marker (WP 0276, Table 1, Item 66) References WP 0272

CAUTION
Splicing is prohibited on any wire within the RTCH electronic CAN-BUS system. Refer to system diagrams (WP 0272).

NOTE
Use electrically conductive grease on unprotected (exposed to weather) electrical connectors before connections are made.

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0267

MULTIPLE- PIN CONNECTOR IDENTIFICATION DIAGRAMS

15 PIN AMP CONNECTOR (MOUNTED SIDE) FEMALE PINS

15 PIN AMP CONNECTOR (LOOSE CABLE SIDE) MALE PINS

9 PIN AMP CONNECTOR (MOUNTED SIDE) FEMALE PINS

9 PIN AMP CONNECTOR (LOOSE CABLE SIDE) MALE PINS

M0280JCH

Figure 1.

Multi-Pin Connector Identifier.

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0267

MULTIPLE- PIN CONNECTOR IDENTIFICATION DIAGRAMS - Continued

M0281JCH

Figure 2.

Multi-Pin Connector Identifier.

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TM 10-3930-675-23-2

0267

MULTIPLE- PIN CONNECTOR IDENTIFICATION DIAGRAMS - Continued

Connectors 790-2, 791-2, 791-3

Connectors 790-1, 791-1
M0282JCH

Figure 3.

Multi-Pin Connector Identifier.

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TM 10-3930-675-23-2

0267

MULTIPLE- PIN CONNECTOR IDENTIFICATION DIAGRAMS - Continued

M0283JCH

Figure 4. END OF TASK

Multi-Pin Connector Identifier.

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0267

CONNECTOR REPAIR

NOTE
• Perform the following Steps for each wire of connector. • Tag wires for installation. 1. 2. 3. Using pin removal tool, position tool over pin (Figure 5, Item 1) and push inward to retract two barbs of pin. Remove wire (Figure 5, Item 3), with pin (Figure 5, Item 1) attached, from rear of connector (Figure 5, Item 2). If defective, remove pin (Figure 5, Item 1) from wire (Figure 5, Item 3) by cutting through wire just behind pin.

3 2

1

M0284JCH

Figure 5. 4. 5.

Connector Repair.

Using wire stripping tool, strip insulation off wire (Figure 6, Item 1) to expose proper length of metal strands (Figure 6, Item 4). Using crimping tool, securely crimp tabs (Figure 6, Item 3) of pin (Figure 6, Item 5) over metal strands (Figure 6, Item 4) of wire (Figure 6, Item 1).

NOTE
The other two tabs of pin may need to be crimped slightly in order to enter connector. 6. Using crimping tool, crimp tabs (Figure 6, Item 2) at rear of pin (Figure 6, Item 5) over insulation of wire (Figure 6, Item 1).
1 2 3 4 5

M0285JCH

Figure 6.

Connector Repair.

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TM 10-3930-675-23-2

0267

CONNECTOR REPAIR - Continued 7. Push pin (Figure 6, Item 1) into rear of connector (Figure 6, Item 2) until fully seated.

END OF TASK SEALED CONNECTOR REPAIR 1. Open hinged cover (Figure 7, Item 8) of connector (Figure 7, Item 7) for access to rear of connector.

NOTE
• Perform Steps 2 thru 9 for each wire of connector. • Tag wires for installation. 2. 3. 4. 5. 6. 7. 8. 9. 10. Using pin removal tool, position tool over pin (Figure 7, Item 6) and push inward to retract two barbs of pin. Remove wire (Figure 7, Item 1), with pin (Figure 7, Item 6) and seal (Figure 7, Item 3) attached, from rear of connector (Figure 7, Item 7). If defective, remove pin (Figure 7, Item 6) and seal (Figure 7, Item 3) from wire (Figure 7, Item 1) by cutting through wire just behind seal. Position new seal (Figure 7, Item 3) on wire (Figure 7, Item 1). Using wire stripping tool, strip insulation off wire (Figure 7, Item 1) to expose 1/8-in. (3-mm) length of metal strands (Figure 7, Item 8). Using crimping tool, securely crimp tabs (Figure 7, Item 5) of pin (Figure 7, Item 6) over metal strands (Figure 7, Item 2) of wire (Figure 7, Item 1). Slide seal (Figure 7, Item 3) next to pin (Figure 7, Item 6) and crimp tabs (Figure 7, Item 4) of pin over end of seal. Push pin (Figure 7, Item 6) into rear of connector (Figure 7, Item 7) until fully seated. Close hinged cover (Figure 7, Item 8) of connector (Figure 7, Item 7).
1 2 3 4 5 6 7

8
M0286JCH

Figure 7. END OF TASK

Sealed Connector Repair.

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TM 10-3930-675-23-2

0267

RECEPTACLE CONNECTOR REPAIR 1. 2. 3. 4. Using removal tool, insert tool into front of connector (Figure 8, Item 1) and depress locking tab of receptacle (Figure 8, Item 6). Push wire (Figure 8, Item 2), with receptacle (Figure 8, Item 6) attached, through front of connector (Figure 8, Item 1). If defective, remove receptacle (Figure 8, Item 6) from wire (Figure 8, Item 2) by cutting through wire just behind receptacle. Slide connector (Figure 8, Item 1) back on wire (Figure 8, Item 2).
1 2 3 4

5

6

M0287JCH

Figure 8. Receptacle Connector Repair. 5. 6. 7. 8. Using wire stripping tool, strip insulation off wire (Figure 8, Item 2) to expose 1/4-in. (6-mm) length of metal strands (Figure 8, Item 3). Using crimping tool, securely crimp tabs (Figure 8, Item 5) of receptacle (Figure 8, Item 6) over metal strands (Figure 8, Item 3). Using crimping tool, crimp tabs (Figure 8, Item 4) of receptacle (Figure 8, Item 6) over insulation of wire (Figure 8, Item 2). Slide connector (Figure 8, Item 1) forward over receptacle (Figure 8, Item 6) until locking tab of receptacle snaps into place.

END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00241)

TM 10-3930-675-23-2

0267

WATERPROOF CONNECTOR REPAIR 1. 2. Remove end cover (Figure 9, Item 7) and gasket (Figure 9, Item 6) from front of connector (Figure 9, Item 5). Remove seal (Figure 9, Item 1) from rear of connector (Figure 9, Item 5) and slide seal back on wire (Figure 9, Item 2).

NOTE
• Perform Steps 3 thru 9 for each wire of connector. • Tag wires for installation. 3. 4. 5. 6. 7. 8. 9. 10. 11. Using pin removal tool, insert tool into front of connector (Figure 9, Item 5) and depress locking tab of connector. Remove wire (Figure 9, Item 2) with pin (Figure 9, Item 4) from rear of connector (Figure 9, Item 5). If defective, remove pin (Figure 9, Item 4) from wire (Figure 9, Item 2) by cutting through wire just behind pin. Using wire stripping tool, strip insulation off wire (Figure 9, Item 2) to expose 1/4-in. (6-mm) length of metal strands (Figure 9, Item 3). Insert metal strands (Figure 9, Item 3) of wire (Figure 9, Item 2) fully into rear of pin (Figure 9, Item 4). Using crimping tool, securely crimp pin (Figure 9, Item 4) to metal strands (Figure 9, Item 3) of wire (Figure 9, Item 2). Push pin (Figure 9, Item 4) into rear of connector (Figure 9, Item 5) until fully seated. Install seal (Figure 9, Item 1) on rear of connector (Figure 9, Item 5). Install gasket (Figure 9, Item 6) and end cover (Figure 9, Item 7) on front of connector (Figure 9, Item 5).
1 2 3 4 7 5

6

M0288JCH

Figure 9. END OF TASK

Waterproof Connector Repair.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00241)

TM 10-3930-675-23-2

0267

MILITARY CONNECTOR REPAIR 1. 2. 3. 4. 5. 6. 7. Slide shell (Figure 10, Item 1) back on wire (Figure 10, Item 2) to expose sleeve (Figure 10, Item 5). Remove sleeve (Figure 10, Item 5) from terminal (Figure 10, Item 4) by pulling sleeve forward. If defective, remove terminal (Figure 10, Item 4) from wire (Figure 10, Item 2) by cutting through wire just behind terminal. Using wire stripping tool, strip insulation off wire (Figure 10, Item 2) to expose length of metal strands (Figure 10, Item 3) equal to depth of terminal (Figure 10, Item 4). Using crimping tool, securely crimp terminal (Figure 10, Item 4) to metal strands (Figure 10, Item 3) of wire (Figure 10, Item 2). Install sleeve (Figure 10, Item 5) on terminal (Figure 10, Item 4) by pushing sleeve over front of terminal until fully seated. Slide shell (Figure 10, Item 1) up wire (Figure 10, Item 2) and over sleeve (Figure 10, Item 5).
5 4 1 2 3

M0289JCH

Figure 10. Military Connector Repair. END OF TASK

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TM 10-3930-675-23-2

0267

RING TERMINAL REPAIR 1. 2. 3. 4. 5. 6. 7. 8. Remove ring terminal (Figure 11, Item 6) from wire (Figure 11, Item 2) by cutting through wire just behind heat shrink tubing (Figure 11, Item 1). Cut heat shrink tubing (Figure 11, Item 1) to length sufficient to cover tabs (Figure 11, Items 4 and 5) of ring terminal (Figure 11, Item 6) and ¼-in. (6-mm) of wire (Figure 11, Item 2). Slide heat shrink tubing (Figure 11, Item 1) back on wire (Figure 11, Item 2). Using wire stripping tool, strip insulation off wire (Figure 11, Item 2) to expose proper length of metal strands (Figure 11, Item 3). Using crimping tool, securely crimp tabs (Figure 11, Item 5) of ring terminal (Figure 11, Item 6) over metal strands (Figure 11, Item 3). Using crimping tool, crimp tabs (Figure 11, Item 4) of ring terminal (Figure 11, Item 6) over insulation of wire (Figure 11, Item 2). Slide heat shrink tubing (Figure 11, Item 1) over tabs (Figure 11, Items 4 and 5) of ring terminal (Figure 11, Item 6). Using heater gun, apply heat to heat shrink tubing (Figure 11, Item 1) until tubing snugly conforms to ring terminal (Figure 11, Item 6) and insulation of wire (Figure 11, Item 2).
4 1 2 3 5 6

M0290JCH

Figure 11. END OF TASK

Ring Terminal Repair.

0267-11

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TM 10-3930-675-23-2

0267

SPLICING WIRES

NOTE
The selection of crimping tool and type of splice connectors is optional. High quality splice connectors can be expected to last the life of the vehicle. Splicing of CAN-BUS wires is prohibited. 1. 2. Inspect each end of wire (Figure 12, Item 5). Trim insulation and metal strands (Figure 12, Item 2) of wire back, as necessary, to ensure integrity of wire. Using wire stripping tool, strip each end of wire (Figure 12, Item 5) to expose length of metal strands (Figure 12, Item 4) to suit type of splice connector (Figure 12, Item 3) used.

NOTE
Perform Steps 3 and 4 at each end of splice connector. 3. 4. Insert metal strands (Figure 12, Item 4) of wire (Figure 12, Item 5) fully into splice connector (Figure 12, Item 3). Using crimping tool, securely crimp splice connector (Figure 12, Item 3) to metal strands (Figure 12, Item 4) of wire (Figure 12, Item 1).
3 1 2 4 5

M0291JCH

Figure 12. END OF TASK

Wire Splicing

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TM 10-3930-675-23-2

0267

ELECTRICAL GROUND POINTS Many electrical problems are the result of poor ground connections. Ensure ground connections are good by performing the following steps.

WARNING

Although master battery switch must be ON to test electrical circuit voltage, turn master battery switch to OFF position before performing resistance tests or replacing parts. Failure to follow this warning may result in injury to personnel and damage to parts or equipment. a. b. c. d. e. Remove screw, lockwasher, nut, etc., connecting ground wire terminal to vehicle ground point If necessary, clean mounting hardware, wire terminal, and ground point with detergent and a scrub brush. Remove any rust or corrosion from ground point with a wire brush and abrasive cloth. Replace defective mounting hardware and wire terminal as necessary. Install wire terminal to ground point with screw, lockwasher, nut, etc., and tighten securely.

M0292JCH

Figure 13. END OF TASK

Electrical Ground Points.

0267-13

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TM 10-3930-675-23-2

0267

MULTIMETER USAGE 1. General. A Digital Multimeter, is used to troubleshoot the electrical system of the vehicle. The multimeter’s Ohms scale is used to test for continuity, shorts, and resistance and the voltmeter scale is used to test voltage levels at any point in the electrical system. Continuity Tests. Continuity tests are performed to check for breaks in a circuit (such as a fuse, switch, light bulb, or electrical cable).

2.

NOTE
If digital readout will not zero properly, replace batteries and repeat zeroing procedure. If digital readout will not zero after batteries have been replaced, notify your supervisor. a. Zero the Multimeter (1) (2) (3) (4) Set multimeter ON/OFF switch to ON position. Set the meter to the OHMS FUNCTION. Set to the LOWEST OHMS scale if it is not an auto ranging type meter. Touch black and red probes together and check for a zero or less one ohm reading on digital readout.

M0293JCH

Figure 14.

Multimeter Usage.

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TM 10-3930-675-23-2

0267

MULTIMETER USAGE - Continued

CAUTION
Before performing a continuity test, always turn master battery switch to OFF position and disconnect circuit to be tested. Failure to follow this caution may damage multimeter. b. Testing for Continuity. (1) (2) (3) Zero multimeter. Connect black and red probes from both terminals to circuit being tested. Read digital readout and interpret results as follows: (a) (b) If digital readout indicates 0 (zero) or less than ten ohms; the circuit has continuity. If digital readout indicates no or high (>100k ohms) resistance; the circuit is open.

TESTING AN ELECTRICAL CABLE

TESTING A BULB

TESTING A SWITCH
M0294JCH

Figure 15.

Multimeter Usage.

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TM 10-3930-675-23-2

0267

MULTIMETER USAGE - Continued

CAUTION
Before performing a continuity test, always turn master battery switch to OFF position and disconnect circuit to be tested. Failure to follow this caution may damage multimeter. c. Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be connected have metal-to metal contact with each other. A short also occurs when a circuit that should not touch ground has metal-to-metal contact with ground. (1) (2) (3) Zero multimeter Connect black probe to one circuit and red probe to either a ground or another circuit. Read digital readout and interpret results as follows: (a) (b) (c) If digital readout indicates 0 (zero) or less than 10 ohms, circuits are shorted or circuit is grounded if testing to ground. If digital readout does not indicate a reading or is greater than 100k ohms, circuits are not shorted. If digital readout jumps or flickers, circuits are shorted or grounded intermittently.

M0295JCH

Figure 16.

Multimeter Usage.

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TM 10-3930-675-23-2

0267

MULTIMETER USAGE - Continued

CAUTION
Before performing a continuity test, always turn master battery switch to OFF position and disconnect circuit to be tested. Failure to follow this caution may damage multimeter. d. Testing for Resistance. Allowable resistance readings depend on circuit being tested. Refer to the particular section dealing with that circuit or component for allowable readings. (1) (2) (3) (4) (5) Zero multimeter. Set the meter to the OHMS FUNCTION. Set to the LOWEST OHMS scale if it is not an auto ranging type meter. Connect black and red probes across circuit to be tested. Read digital readout and interpret results as circuit resistance. (a) If digital readout does not indicate a reading, set to the next higher resistance scale.

NOTE
A component such as a relay or solenoid coil should have a measurable resistance value. If the value is not known there may be other components available on the vehicle to make a value comparison. (b) Different components will have different resistance values.

Figure 17. 3. Measuring DC Voltage. a. b.

Multimeter Usage.

Set multimeter ON/OFF switch to ON position. Set the meter to the DC VOLTS FUNCTION.

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TM 10-3930-675-23-2

0267

MULTIMETER USAGE - Continued c. d. Select the VOLTAGE setting for voltage range higher than Volts to be measured. Connect red probe to positive (+) side of circuit and black probe to negative (-) side of circuit.

NOTE
Always check for voltage through the dedicated ground of the circuit if not directly grounded to the vehicle chassis. A false voltage may be read if only checking to vehicle ground. e. Read digital readout and interpret results as DC voltage in circuit being tested.

M0297JCH

Figure 18. END OF TASK

Multimeter Usage.

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TM 10-3930-675-23-2

0267

RELAY OR SOLENOID INSPECTION AND TEST 1. Inspecting Relays or Solenoids. a. b. 2. Check for bent or damaged pins. Check for burned or damaged relay case.

Testing Relays.

NOTE
When testing relays, refer to the circuit diagram printed or stamped on relay case or the electrical diagram designation for the specific relay. a. b. Using a multimeter, check for a measurable resistance across relay coil. Using a multimeter, check open or closed contacts between the relay terminals.

CAUTION
There are 20 small five terminal relays on the RTCH that control various functions. These relays contain a diode across the relay coil. The diode makes the relays “polarized". If the positive and negative voltage coil inputs are switched, as when testing the relay, the diode will short out. All relays should be regarded as terminal 86 as positive and terminal 85 as negative. The resistance between terminal 85 and 86 should be 290-350 ohms. c. Activate relay to check contact operation.

M0298JCH

Figure 19.

Relay Inspection and Test.

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TM 10-3930-675-23-2

0267

RELAY OR SOLENOID INSPECTION AND TEST - Continued 3. Testing Solenoids.

NOTE
Solenoids do not always have a circuit diagram printed or stamped on its case. Refer to the electrical diagram designation for the specific solenoid. Usually the larger terminals on the solenoid will be the contacts and the smaller terminals will be the solenoid coil. a. b. c. Using a multimeter, check for a measurable resistance across relay coil. Using a multimeter, check open or closed contacts between the relay terminals. Activate relay to check contact operation.

M0299JCH

Figure 20. Solenoid Inspection and Test. END OF TASK END OF WORK PACKAGE

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FIELD MAINTENANCE GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP: Tools and Special Tools Crowfoot Attachment Set (WP 0277, Table 1, Item 20) Scrub Brush Materials/Parts Cleaning Compound, Solvent Type III (WP 0276, Table 1, Item 10) Cap Set, Protective, Dust and Moisture Seal (WP 0276, Table 1, Item 9) Detergent General Purpose Liquid (WP 0276, Table 1, Item 15) Lubricating Oil, Gear 80W/90 (WP 0276, Table 1, Item 42) Rag, Wiping (WP 0276, Table 1, Item 50) Materials/Parts (cont.) Tag, Marker (WP 0276, Table 1, Item 66) Tape, Duct (WP 0276, Table 1, Item 67) References FM 5-20 LO 10-3930-675-13 TM 9-214 TM 9-237 TM 9-247 TM 43-0139 TM 43-0209 Volume 1, WP 0096 Volume 1, WP 0097 Volume 1, WP 0100 WP 0276

1.

These general maintenance instructions contain general shop practices and specific methods which you must be familiar with to properly maintain the RTCH. You should read and understand these practices and methods before performing any Field Maintenance procedures. Before beginning a task, find out how much repair, modification or replacement is needed to fix the equipment. Sometimes the reason for equipment failure can be seen right away and complete teardown is not necessary. Disassemble equipment only as far as necessary to repair or replace damaged parts. In some cases, a part may be damaged during removal. If the part appears to be good, and other parts behind it are not defective, leave it in place and continue with the procedure. Here are a few simple rules: a. b. c. DO NOT remove dowel pins or studs unless loose, bent, broken, or otherwise damaged. DO NOT remove bearings or bushings unless damaged. If you need to remove them to access parts behind, carefully pull out bearings and bushings. Replace all gaskets, lockwashers, locknuts, seals, cotter pins, and O-rings.

2.

3.

4.

All tags and forms attached to the equipment must be checked to learn the reason for removal of equipment from service. Modification Work Orders (MWOs) and Technical Bulletins (TBs) must also be checked for equipment changes and updates.

END OF TASK

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WORK SAFETY

WARNING

• DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. • Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. 1. 2. Before beginning a procedure, think about the safety risks and hazards to yourself and to others. Wear protective gear such as safety goggles or lenses, safety shoes, rubber apron, or gloves. Before beginning a procedure, ensure the following conditions have been observed, unless otherwise specified: a. b. c. d. e. f. 3. 4. 5. 6. 7. Vehicle must be parked on level ground with parking brake applied or wheels chocked. Transmission must be in N (Neutral). Engine must be off. Master battery switch must be in OFF position. Components must be at operating temperature to be tested. Components which are hot at operating temperatures (i.e., cooling, exhaust, and hydraulic systems) must cool down before they are removed.

DO NOT disconnect any hydraulic line or fitting without first relieving pressure in hydraulic lines. Follow instructions in Relieving Hydraulic System Pressure (WP 0204) to safely relieve pressure. Immediately clean up spilled fluids to avoid slipping. When lifting heavy parts, have someone help you. Ensure lifting equipment or jack is working properly, meets weight requirement of part being lifted, and is securely fastened to part. Always use power tools carefully. Observe all WARNINGS and CAUTIONS.

END OF TASK

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CLEANING INSTRUCTIONS

WARNING

Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment. To prevent this, refer to TM 9-247 for further instructions. 1. General. Cleaning instructions will be the same for the majority of parts and components which make up the RTCH. The following applies to all cleaning operations: a. b. c. 2. Clean all parts before inspection, after repair, and before assembly. Keep hands free of grease which can collect dust, dirt, and grit. After cleaning, all parts should be covered or wrapped to protect them from dust and dirt. Parts that are subject to rust should be lightly oiled after cleaning.

Castings, Forgings, and Vehicle Metal Parts. a. b. Clean inner and outer surfaces with detergent and dry with clean rag. Remove grease and accumulated deposits with a scrub brush.

WARNING

Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel. c. Clear all threaded holes with compressed air to remove dirt and cleaning fluids.

CAUTION
DO NOT wash oil seals, electrical cables, and flexible hoses with cleaning compound, solvent or mineral spirits. Serious damage or destruction of material will result. 3. 4. Oil Seals, Electrical Cables, and Flexible Hoses. Wash oil seals, electrical cables, and flexible hoses with a solution of detergent and water, and wipe dry with a clean rag. Bearings. Clean bearings in accordance with TM 9-214.

END OF TASK PRESERVATION OF PARTS Unpainted metal parts that will not be installed immediately after cleaning may be covered with a thin coat of oil. END OF TASK

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PAINTING 1. 2. On painted areas where paint has been removed, paint in accordance with procedures outlined in TM 43-0139 and TB 43-0209. For camouflage painting instructions, refer to FM 5-20.

END OF TASK INSPECTION INSTRUCTIONS

NOTE
All damaged areas should be marked for repair or replacement. 1. 2. All components and parts must be carefully checked to determine if they are serviceable for use, can be repaired or must be scrapped. Inspect drilled and tapped (threaded) holes for the following: a. b. 3. Wear, distortion, cracks, and any other damage in or around holes. Threaded areas for wear, distortion (stretching), and evidence of cross-threading.

Inspect metal lines, flexible lines or hoses, and metal fittings and connectors for the following: a. b. c. Metal lines for sharp kinks, cracks, bad bends, and dents. Flexible lines or hoses for fraying, evidence of leakage, and loose metal fittings or connectors. Metal fittings and connectors for thread damage and worn or rounded hex heads.

4.

Inspect castings, forgings, and vehicle metal parts for the following: a. b. Vehicle surfaces for nicks, burrs, raised metal wear, and other damage. Inner and outer surfaces for breaks and cracks.

5.

Inspect bearings in accordance with TM 9-214.

END OF TASK DISASSEMBLY AND ASSEMBLY INSTRUCTIONS 1. 2. 3. 4. 5. 6. Keep major components together whenever possible and practical. Tag hoses, electrical wires, cables, and harnesses to identify them and aid during installation. Keep related parts together for identification purposes. Temporarily install attaching hardware such as screws, bolts, washers, and nuts to prevent loss. Only disassemble to the point of the problem. Ensure parts are clean and lubricated before assembly.

END OF TASK

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REPAIR INSTRUCTIONS

CAUTION
Before welding, the following components must be disconnected to avoid damage to electronic components: 1. Hydraulic servo system ECU - computer no. 790 (Volume 1, WP 0100). 2. Tophandler ECU - computer no. 791 (Volume 1, WP 0097). 3. Steering system ECU - computer no. 792 (Volume 1, WP 0100). 4. Transmission ECU - computer no. 793 (Volume 1, WP 0100). 5. Engine ECU - computer no. 794 (Volume 1, WP 0100). 6. Electronic Control System (ECS) display screen - computer no. 795 (Volume 1, WP 0096). 1. Repair castings, forgings, and vehicle parts using the following instructions: a. b. c. d. Repair minor cracked castings or forgings in accordance with TM 9-237. Repair minor damage to vehicle surfaces with an abrasive cloth dipped in detergent. Replace any deeply nicked vehicle surface that could affect the assembly operation. Repair minor damage to threaded capscrew holes with thread tap of same size to prevent cutting oversize.

NOTE
Refer to Lubrication Order (LO 10-3930-675-13) for detailed, illustrated instructions on proper lubrication. 2. After repair, thoroughly clean all parts to prevent dirt, metal chips or other foreign material from entering any working parts. Some general practices to remember: a. b. c. d. Use the correct lubricant. Keep lubricants clean. Clean all fittings prior to lubrication. Lubricate clean disassembled and new parts to prevent rust.

END OF TASK APPLICATION OF ADHESIVES AND SEALING COMPOUNDS 1. 2. General. Adhesives are recommended in some tasks to ensure and strengthen seals. Sealing compounds are used to seal parts against moisture. The following information describes their correct use and application. Adhesive. Adhesive provides a seal against leakage and a resistance to loosening when used in the assembly of threaded, slip-fitted, or press-fitting parts. Always use the grade of adhesive specified and never use adhesive when other retaining means are provided, such as lockwires, lockwashers, lockplates, and fasteners. Sealing Compound. a. b. c. Anytime a seal is broken, the part must be thoroughly cleaned to remove any remaining sealing compound and dirt. Thoroughly clean surface before applying sealing compound. When applying sealing compound, ensure the area is completely covered. Press sealing compound into and around parts as necessary.

3.

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APPLICATION OF ADHESIVES AND SEALING COMPOUNDS - Continued d. Refer to manufacturer’s instructions for time needed to set sealing compound.

END OF TASK STANDARD TOOL REQUIREMENTS 1. The following are general practices regarding the use of tools: a. b. c. d. e. f. 2. Always use the proper tool kit and tools for the procedure being performed. Ensure tools are clean and lubricated to reduce wear and prevent rust. Keep track of tools. DO NOT be careless with them. Return tools to toolbox when finished with repair or maintenance. Return toolboxes and tools to tool storage when not in use. Inventory tools before and after each use.

Some maintenance tasks may require special or fabricated tools. The “Initial Setup" of the procedure will specify any special or fabricated tools needed to perform that procedure. Use these special tools only for the maintenance procedures for which they are designed or called out. If you are unfamiliar with a required tool, see your supervisor.

END OF TASK TAGGING WIRES AND HOSES 1. Use marker tag to identify all electrical wires, fuel, oil, coolant, and hydraulic lines, and any other parts which may be hard to identify or replace later. Fasten tags to parts during removal by wrapping wire fasteners around or through parts and twisting ends together. Position tags to be out of the way during cleaning, inspection, and repair. Mark tags with a pencil, pen, or marker. Whenever possible, identify electrical wires with the number of the terminal or wire to which it connects. If no markings can be found, tag both wires or wire and terminal, and use the same identifying mark for both. If you cannot tag a wire because it must fit through a small hole or you cannot reach it, write down the description of the wire and the point to which it connects or draw a simple diagram on paper. Be sure to write down enough information so you will be able to properly connect the wires during assembly. If you need to identify a loose wire, look for an identifying number near end of the wire, stamped on a permanent metal tag. Compare the number to wire numbers on the appropriate electrical schematic. Identify fuel, oil, coolant, and hydraulic lines when you are taking off more than one line at the same time. Mark tags with points to which lines and hoses must be connected. If it is not obvious which end of a line goes where, tag each end of the line. Identify and tag other parts as required by name and installed location.

2.

3.

4.

END OF TASK

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LINES AND PORTS To keep dirt from contaminat